Rev_SOW_BearingCoolingCoil_1.pdf

Spring Creek Power Plant Bearing Oil Cooler Assembly

BUREAU OF RECLAMATION

NORTHERN CALIFORNIA AREA OFFICE

STATEMENT OF WORK

FOR

SPRING CREEK POWER PLANT

HYDRO-ELECTRIC GENERATOR

THRUST BEARING

OIL COOLER REPLACEMENT

SEPTEMBER 2025

SPRING CREEK POWER PLANT

HYDRO-ELECTRIC GENERATOR THRUST BEARING

OIL COOLER REPLACEMENT

Contents

PART 1 GENERAL

1.01 BACKGROUND

1.02 SCOPE

1.03 OBJECTIVE

1.04 TYPE OF CONTRACT

1.05 MEASUREMENT AND PAYMENT

1.06 ADMINISTRATIVE REQUIREMENTS

1.07 DELIVERY

1.08 DESCRIPTION OF EXISTING EQUIPMENT

1.09 REFERENCE DRAWINGS

1.10 REFERENCE STANDARDS

1.11 PERFORMANCE REQUIREMENTS

1.12 QUALIFICATIONS

PART 2 TECHNICAL REQUIREMENTS

2.01 BEARING OIL COOLER

2.02 HYDROSTATIC TESTING

PART 3 DELIVERABLES

APPENDIX A

EXISTING BEARING OIL COOLER PHOTOGRAPHS

PART 1 GENERAL

1.01 BACKGROUND

A. There are four oil coolers located in the thrust bearing sump of a 75 MW hydroelectric generator supplied by Allis-Chalmers in 1964. The coolers are original and have developed leaks due to age and have reached the end of their useful life.

1.02 SCOPE

A. The scope of this contract includes all the work necessary to provide modern replacement coolers that meet or exceed the operating characteristics of the original heat exchangers.

The government will dispose of all the existing coolers once the new coolers are received.

1.03 OBJECTIVE

A. The objective of this contract is to furnish the government with modern replacement thrust bearing coolers as drop-in replacement units.

1.04 TYPE OF CONTRACT

A. Firm fixed price.

1.05 MEASUREMENT AND PAYMENT

A. Payment: Lump sum price.

1. Includes ten each oil coolers, manufacturer drawings, inspection and testing reports, and all shipping costs.

1.06 ADMINISTRATIVE REQUIREMENTS

A. Administration of this contract shall be by the Contracting Officer’s Representative (COR) appointed by the Contracting Officer.

1. Supplier communication and coordination of work shall be through the

Contracting Officer’s Representative.

2. The Supplier shall perform the work as defined under Part 2 Technical Requirements.

3. Supplier should provide a point of contact: name, title, telephone number and email address.

B. Required Documentation

1. Post Award Documentation

a. Calculations for obtaining thermal loading and determination of cooler capacity and performance

b. Assembly drawing

c. Material List

d. Dimensions, weight, and lifting points

e. Hydrostatic test report

f. Installation procedures

g. Recommended Flowrate per inlet water temperature.

h. Repair and maintenance procedures

i. Parts list

C. Warranty Information

1.07 DELIVERY

A. All equipment shall be packaged and shipped in a manner to prevent damage during loading, transporting, unloading, and storing.

B. The Supplier shall ship the first four coolers completed separately from the remaining six for onsite form and fit verification. The remaining six shall be shipped after this verification has been completed.

C. The Supplier shall include all shipping costs in the pricing.

D. The Supplier is to coordinate with the government COR for all shipping and delivery details.

Shipping Address:

ATTN: James Friday Bureau of Reclamation-MP-NCAO Shasta Maintenance Center 16349 Shasta Dam Blvd.

Shasta Lake, CA 96019

1.08 DESCRIPTION OF EXISTING EQUIPMENT

A. Operating Conditions

1. The thrust bearing coolers are immersed in approximately 600 gallons of ISO 68 turbine oil. The coolers are necessary to remove the heat generated by the combined operation of the adjustable shoe thrust bearing and generator upper guide bearing.

2. The cooler was originally designed for 9-degrees Celsius cooling water.

3. The flowrate through the coolers is adjustable using throttle valves on the outlet piping attached directly to the coolers. The inlet header supplying the bearing housing is 2” Nominal Pipe Size (NPS) with a water pressure of 25 psi. The outlet header from the bearing housing is 2.5” NPS.

B. Original Cooler Details:

1. The original coolers have copper manifolds and steel tube support plates (See reference drawings and photographs).

1.09 REFERENCE DRAWINGS

A. Manufacturer’s Drawings: Allis-Chalmers

1. N/A (Upon award of the contract, two spare coolers are available to reference for reverse engineering purposes. All packaging and shipping of the spare coolers to and from the contractor’s facility shall be the responsibility of the contractor.)

B. Government Drawings

1. No. 416-214-5513 Spring Creek Power Plant Turbine Oil Cooler Layout and Views

2. No. 416-214-5514 Spring Creek Power Plant Turbine Oil Cooler Details

1.10 REFERENCE STANDARDS

A. The purpose of including reference standards is to ensure that the supplied replacement cooler is manufactured in accordance with modern materials and standards. This is not intended to be an all-inclusive list. The government will perform a final inspection of the supplied cooler and reserves the right to reject the cooler or negotiate a lower price should the inspection disclose that modern materials and manufacturing processes in accordance with applicable standards were not used.

B. American Society of Mechanical Engineers (ASME)

1. ASME BPVC VIII Boiler and Pressure Vessel Code - Section VIII, Division I

- Rules for the Construction of Pressure Vessels

2. ASME BPVC IX Boiler and Pressure Vessel Code - Section IX - Welding and Brazing Qualifications

3. ASME B16.18 Cast Copper Alloy Solder Joint Pressure Fittings

4. ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges

C. American Society for Testing and Materials (ASTM) International

1. ASTM A307 Carbon Steel Bolts, Studs, and Threaded Rod

2. ASTM A563 Carbon and Alloy Steel Nuts

3. ASTM A653 Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

4. ASTM A924 General Requirements for Steel Sheet, Metallic-Coated by the Hot- Dip Process

5. ASTM B32 Standard Specification for Solder Metal

6. ASTM B88 Seamless Copper Water Tube

7. ASTM B111 Copper and Copper-Alloy Seamless Condenser Tubes and Ferrule

Stock

8. ASTM B171 Copper-Alloy Plate and Sheet for Pressure Vessels, Condensers, and Heat Exchangers

9. ASTM B828 Standard Practice for Making Capillary Joints by Soldering of

Copper and Copper Alloy Tube and Fittings (2016)

D. Tubular Exchanger Manufacturer’s Association

1. TEMA Standards for the Tubular Exchanger Manufacturer’s Association

E. Copper Development Association Incorporated

1. Guide Specification for Copper and Copper Alloy Building Piping Systems

1.11 PERFORMANCE REQUIREMENTS

A. The new bearing oil cooler shall perform to the same characteristics as the original cooler. Below are typical operating characteristics of the existing cooler.

1. Temperatures:

a. Cooling water from reservoir water has a temperature range from 7 to 18 degrees Celsius.

b. Operating temperature of the thrust bearings ranges from 50 to 55 degrees Celsius, with an upper temperature limit of 100 degrees Celsius.

c. Operating temperature of the thrust bearing oil varies from 25 to 50 degrees Celsius.

2. Pressures:

a. Actual thrust bearing cooling water pressures vary from 15-40 psi.

3. Cooling Water Flow:

a. The flow rate through the coolers is adjustable using throttle valves on the downstream pipe connection to the coolers. Both the inlet and outlet connections to the coolers are 3/4” NPS. The inlet header supplying the bearing housing is 2” NPS; The outlet header from the bearing housing is

2.5” NPS.

1.12 QUALIFICATIONS

A. Designer:

1. Licensed/Registered/Chartered Professional Engineer experienced in heat exchanger design of this type. The design shall be reviewed by a state Licensed/Registered Professional Engineer in an applicable specialty in the State of California.

2. The designer shall be authorized and certified by the manufacturer of the equipment being furnished to determine the requirements for cooling equipment.

B. Manufacturer:

1. Company specializing in manufacturing products specified with a minimum of three years documented experience.

2. Certified in ASME BPVC Section VIII Division 1 fabrication processes.

3. Recognized by the Tubular Exchanger Manufacturer’s Association for the design and manufacturing of tubular exchangers.

PART 2 TECHNICAL REQUIREMENTS

2.01 BEARING OIL COOLER

A. Cooler materials shall be suitable for immersion in ISO 68 turbine oil and with freshwater flowing through the coils.

B. Dimensions:

1. Dimensions shall match the original Bearing Oil Cooler dimensions. Clocking of the input and output flange connections shall align with the original cooler orientations. Drawing 416-214-5513 can be used as a reference however the contractor is responsible for designing the bearing oil coolers so that they fit into the locations of the existing bearing oil coolers hard piped system without any system piping modifications. After award of the contract, two spare original coolers will be made accessible to the contractor to utilize for form and fit dimensions. The following are mandatory design requirements that the coolers shall incorporate:

a. Flange Interface Connections: 3/4” Nominal Pipe Size Flat Face Slip-On

Class 150 Flanges made from Cu/Ni 90/10 material.

b. All hardware shall be standard units. Metric units shall not be used.

c. Tube diameter and fin spacing dimensions shall be left to the supplier to determine the optimum efficiency.

C. Coolers shall be designed, built and certified to ASME BPVC Section VIII and stamped with an ASME Code "U" stamp.

D. Coolers shall comply with TEMA Class C - General Commercial Applications for design, fabrication and testing.

E. Cooler design shall be heavy-duty, industrial type suitable for both continuous and cyclic duty operation.

F. Cooler shall have a maximum allowable working pressure of not less than 100 psi.

G. Material for Cooler tubes shall be C70600 (90/10 Copper-Nickel).

H. Each cooler shall incorporate an extruded aluminum fin-tube design. Original cooler fins are 0.049-inches thick, spaced 8 fins per inch.

I. Cooler shall have a rigid frame, be self-contained and designed for lifting and handling as a complete assembly.

J. Cooler tubes shall be supported to prevent sagging and vibration at the generator natural frequency, or the harmonics or sub-harmonics thereof.

K. Design cooler to allow for thermal expansion and contraction without causing leakage or excessive stress within flanged connections or mounting points.

L. Cooler shall have lifting eyes for installation and removal.

M. The contractor shall provide preliminary design drawings to the government for review and approval prior to the production of any coolers. The preliminary design shall be reviewed by a Licensed/Registered Professional Engineer in an applicable specialty in the State of California prior to submitting it for review by the government.

2.02 HYDROSTATIC TESTING

A. Prior to the hydrostatic test, the contractor shall perform the following tasks on all ten coolers:

1. Check all soldered and brazed connections and perform non-destructive testing

(NDT) on them.

2. Check to ensure all tubes and inner components are free of slag or any other foreign material.

3. Finding from these tasks shall be provided to the government.

B. Testing shall be done in accordance with Section VIII Division 1 of the ASME Boiler and Pressure Vessel Codes:

1. Test shall be at 1.5 times the maximum allowable working pressure.

2. Pressure shall be held for a minimum of 120 minutes.

3. A successful hydrostatic test shall result in no loss of pressure.

4. Following the application of the hydrostatic test pressure, an inspection shall be made of all joints and connections. The contractor shall provide a condition-found report describing the results for all ten coolers.

PART 3 DELIVERABLES

3.01 POST AWARD

A. Preliminary design Drawings are due within 45 days after award of contract.

B. The first four coolers shall be delivered 14 weeks after design approval; the remaining six coolers shall be delivered 8-weeks after the form and fit of the first four coolers have been verified onsite.

C. Installation and Operating Guidelines shall be provided to the government within a week of shipping the first four coolers.

D. Copies of all relevant Test Reports and Quality Control Documentation shall be provided to the government within a week after shipping the first four coolers and within a week after shipping the remaining six coolers.

E. As-built drawings shall be provided to the government within four weeks after the form and fit of the first four coolers has been verified.

APPENDIX A

EXISTING BEARING OIL COOLER PHOTOGRAPHS

Recent photographs of the existing coolers.