RFP_1100_MMH3038_MWDBE_PAC_v1.pdf
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- Solicitation number
- RFP 1100 MMH3038
- Issued by
- Texas
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RFP 1100 MMH3038: Gas Turbine 7FA & Steam Turbine D-11 Parts, Maintenance, Services & Monitoring
This Request for Proposal (RFP) issued by the City of Austin Purchasing Office on behalf of Austin Energy seeks a contractor to perform planned, corrective, predictive, and preventative maintenance on the Sand Hill Energy Center Unit 5 Combined Cycle plant. The scope encompasses maintenance services for a General Electric 7FA+e gas turbine (Serial No. 298259), GE 7FH2 generator, and GE D-11 steam turbine (Serial No. 270T607), along with associated control systems, excitation systems, and auxiliary equipment. The contract requires semi-annual borescope inspections during planned outages, a Hot Gas Path Inspection tentatively scheduled for November 2029 at approximately 24,000 fired hours, and a Major Inspection tentatively scheduled for February 2033 at approximately 48,000 fired hours. The initial contract term is three years with two optional three-year renewal periods. The contractor must provide project management, field technical leadership, craft supervision, labor, parts supply and reconditioning, optional remote monitoring services, and 24/7 customer support with an assigned Customer Service Manager. All planned maintenance work must follow OEM specifications and comply with General Electric GER-3620 standards for parts life expectancy.
Pricing shall be based on factored fired hours calculated according to applicable GER standards, with quarterly payments distributed over the initial nine-year contract period (three years initial term plus two optional three-year extensions). The contractor must submit proposals for quarterly planned maintenance payments, optional quarterly payments for remote monitoring services, time and materials labor rates, markup rates on procured services and parts, and pricing for optional spare parts listed in the contract attachments. The contract includes comprehensive warranty provisions covering parts for 24,000 fired hours or until contract termination and rotor components for the contract term plus extensions with a minimum recommended life of 144,000 fired hours. All warranty work must be performed on an expedited seven-day-per-week, 24-hour-per-day basis. The contractor bears responsibility for all costs associated with early part replacement, fallout coverage, refurbishment of Austin Energy-owned parts returned within 120 days, and compliance with emissions requirements and air permit limits (NOx: 5.0 ppmvd, CO: 17.5 ppmvd, VOC: 5.2 ppmvd, NH3: 10.0 ppmvd). Detailed outage schedules must be submitted 90 days in advance in Microsoft Project format, and comprehensive reports including inspection results, dimensions, NDE testing results, and performance data must be provided within 30 days of each outage.
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CITY OF AUSTIN
PURCHASING OFFICE
SCOPE OF WORK
RFP 1100 MMH3038
GAS TURBINE 7FA & STEAM TURBINE D-11
PARTS, MAINTENANCE, SERVICES & MONITORING
SECTION 1: PURPOSE AND BACKGROUND
SECTION 2: CONTRACT SCOPE
SECTION 3: CONTRACT COVERAGE
SECTION 4: CONTRACT SCHEDULE
SECTION 5: GENERAL
SECTION 6: ASSUMPTIONS
SECTION 7: CONTRACT PRICING
SECTION 8: WARRANTY
SECTION 9: TERM OF CONTRACT
SECTION 10: DESIGNATION OF KEY PERSONNEL
SECTION 11: DELIVERY LOCATION
SECTION 12: INVOICE REQUIREMENTS
SECTION 1: PURPOSE AND BACKGROUND
Austin Energy (AE) is the nation’s eighth-largest publicly owned electric utility, serving over 437 square miles across Austin, Travis County, and portions of Williamson County. AE’s mission is to deliver clean, affordable, reliable energy and excellent customer service.
Contractor shall perform planned, corrective maintenance, predictive maintenance, preventative maintenance, and minor upgrades on the Sand Hill Energy Center Unit 5 Combined Cycle plant for Austin Energy. Definitions for each of the services are provided in the chart below summarizing the Contract requirements per piece of equipment included.
a) Service Definitions
i. Definitions for each of the services are provided in the chart below summarizing the contract requirements per piece of equipment included.
ii. Replace Systems
1) Any replacement system Austin Energy may purchase.
iii. Preventative maintenance
1) Preventative maintenance includes scheduled maintenance or planned maintenance, which is scheduled in advance according to a pre-determined schedule.
2) Payment for these services is incorporated into the quarterly payments.
3) Warranty Work is included in this category as there is no charge for this work.
iv. Unplanned Maintenance
1) Unplanned Maintenance includes without limitation all parts, on-site and shop repairs, support services, labor, supervision, planning and technical services necessary to implement unplanned maintenance.
Scheduled preventative/ planned maintenance
(Note 2) and any warranty work
Unplanned Maintenance
(Note 3) (Unscheduled
Maintenance on an as needed basis)
Parts as necessary
Optional Remote
Monitoring
Upgrades
Testing
GE 7FA+e Combustion
Turbine yes
GE 7FH2 Generator (CT)
GE D-11 Steam Turbine
GE 7FH2 Generator (ST)
Mark VI Control System for gas turbine (Note 1)
Mark VI Control System for steam turbine (Note 1)
EX2100 Generator Excitation System (CT)
(ST)
Load Commutate
Inverter (LCI)
TILS related to Planned
Maintenance
TILs unrelated to
Planned Maintenance
Cimplicity HMI
2) Covered Units for Planned Maintenance and Unplanned Maintenance:
a) General Electric 7FA+e (PG7241) Gas Turbine (GT)
i) Serial Number: 298259
ii) Entered Long Term Service Agreement (LTSA) in August 2011 with Power Systems
Manufacturing (PSM).
(1) Third Hot Gas Path Inspection---May 2023
(a) 127,578 Fired Hours
(b) 503 Fired Starts
(c) 1087 Factor Fired Starts
(2) Third Major Inspection---planned for February 2026
(a) 147,978 Fired Hours---estimate
(b) 826 Fired Starts---estimate
(c) 1150 Factored Fired Starts---estimate
(3) Fourth Major Inspection---Planned for 2033
(a) 195,578 Fired Hours---estimate
(b) 1210 Fired Starts---estimate
iii) Other major maintenance performed during existing Contract
(1) Upgraded compressor with PSM parts in May 2012
(a) S0-S17 and EGV’s
(b) R0-R17
iv) PSM NOx Autotune System installed November 2014
v) Mark VI Control System
(1) Austin Energy reserves the right to upgrade or change the control system during the Contract including third party non-OEM vendors
vi) Single fuel – natural gas
vii) The engine has a Donaldson self-cleaning air inlet filter system with an evaporator cooler
(1) GE Model List Item Number: A040
(2) Erection Definitions Part Number: 378A7296
viii) The engine has the Online Water Wash Gen II upgrade in May 2009
ix) Air permit limits:
(1) NOx: 5.0 ppmvd
(2) CO: 17.5 ppmvd
(3) VOC: 5.2 ppmvd
(4) NH3: 10.0 ppmvd
b) General Electric 7FH2 Generator
i) Serial Number: 337X863
c) General Electric D-11 Steam Turbine (ST)
i) Serial Number: 270T607
(1) HP/RHT turbine damage after startup from first major Spring 2011
(2) HP/RHT rotor removal and shop balance Spring 2013
(3) RHT balance weights liberated, remove HP/RHT rotor repair damage Spring 2014
(4) Minor Inspection performed Fall 2017
(5) Major Inspection performed Fall 2021
d) General Electric 7FH2 Generator
i) Serial Number: 290T607
ii) March 2014 Installed End Winding Stability system that includes epoxy-injected rope, straining blocks and or epoxy-saturated felt padding to provide ample support.
SECTION 2: CONTRACT SCOPE
1) Gas Turbine and Steam Turbine with associated generator scope included the following services:
a) Perform planned maintenance on the gas turbine and steam turbine tentatively to start November
2026 for the term of this contract.
i) Perform semi-annual borescope inspections during planned outages scheduled at times requested by Austin Energy.
ii) Tentatively scheduled for November 2029, perform a Hot Gas Path Inspection (HGPI) and associated Generator Minor Inspection at 24,000 total fired hours (± 1,500 fired hours) or 900 factored fired starts whichever comes first after last completed Major Inspection. Perform a Steam Turbine Major Inspection and associated Generator Major Inspection.
iii) Tentatively scheduled for February 2033, perform a Gas Turbine Major Inspection (MI) and associated Generator Major Inspection at 48,000 fired hours (± 2,500 fired hours) or 2,400 factored fired starts whichever comes first after last completed Major Inspection. Perform a Steam Turbine Minor Inspection and associated Generator Minor Inspection.
iv) The planned maintenance shall include project management, field technical lead, craft supervision, craft labor, subcontracting services, and all tooling required to perform this work scope.
v) To the extent an OEM Technical Information Letter(s) (TIL) have any effect on the planned maintenance interval, or the life of any part used in planned maintenance, perform all replacements of parts, repair (both field and shop), labor supervision, planning and technical services to comply with the provisions of any required or recommended TIL issued for the covered units.
vi) TILs not covered under planned maintenance will be covered under unplanned maintenance.
b) Unplanned maintenance on the gas turbine, steam turbine, both generators, the Gas Turbine and the Steam Turbine Mark vi+e control systems, the LCI, Cimplicity HMI (Human Machine Interface), and both the GT and ST exciters for the term of this contract to include, without limitation, all replacement parts, repairs (both field and shop), support services, labor, supervision, planning, and technical services to implement unplanned maintenance.
i) The definition of unplanned maintenance for this contract is maintenance that is performed which is not included in the work scope defined in Attachment 2 or warranty work.
ii) Unplanned maintenance will be quoted to Austin Energy on an as needed basis by either time/materials, firm fixed quote, or both based on the rates proposed for each in this proposal.
iii) Austin Energy reserves the right to use other vendors for unplanned maintenance as deemed appropriate.
iv) The Contractor will provide updated prices lists as required by the terms and conditions of the agreed upon Contract.
v) Should the Contractor open any covered unit for the purpose of performing unplanned maintenance and then performs planned maintenance, the “in and out” work, including all costs associated with the disassembly and reassembly necessary for access to perform the unplanned maintenance, shall be part of planned maintenance.
vi) Contractor shall commence unplanned maintenance as soon as practical, but in any event, within twenty-four (24) hours after receiving notice from Austin Energy of the condition requiring such unplanned maintenance and the release to commence work. Contractor shall proceed diligently to complete such unplanned maintenance.
vii) Contractor shall give notice to Austin Energy immediately upon discovery of any condition requiring unplanned maintenance or warranting planned maintenance outside of the expected schedule for such planned maintenance. Contractor shall consult with Austin Energy in determining the root cause and contributing factors of any event or events giving rise to any need for unplanned maintenance any reduction in performance or increase in emissions.
c) Provide parts for unplanned work for the gas turbine, steam turbine, generators, control system, excitation system, power system stabilizer, and LCI.
i) Parts for unplanned maintenance will be priced based on the most current price list submitted by Contractor, the price proposed by the Contractor for specific part if it is included in the parts sheet of the Contract (Attachment 6) or the adjusted amount at the time of purchase, whichever is less.
d) Provide and recondition Contract Parts
i) Recondition all Austin Energy owned spare parts removed during the 2026 Major Inspection and cover any fallout (those parts which, after inspection, are deemed to be worn or damaged to the point that refurbishment is not economically justified or possible).
ii) Replace all Austin Energy owned spare parts which reach the end of life per this work scope at the Hot Gas Path Inspection 2029.
iii) The Contractor will provide parts with equal or greater life expectancy per the latest revision of GER 3620 directive (or its successor) on total parts life for the parts which are replaced.
iv) Contract parts which reach the end of life will be replaced with new parts. New parts shall meet or exceed the design life expectancy and performance of parts installed in machine at the start of the contract (FFH, FFS, repairs, inspection interval, and replacement interval) i.e.
24K Combustion parts will be replaced with 24K or better Combustion parts.
v) All Contract parts will be refurbished or reconditioned to allow the component to reach the engine operating intervals, maintain engine performance, emissions requirements, and component full life.
vi) New parts shall be OEM parts or OEM equivalent parts. For OEM equivalent parts the Contractor shall provide the following information to Austin Energy at least calendar 90-day prior for pre-approval before installation:
(1) Company that manufactures the parts
(2) Experience manufacturing 7FA+e parts
(a) How many parts in service
(b) Hours in service
(c) Failure rate
(d) How long has manufacturer been making parts
(e) Any improvement or modifications from original part
(f) Compatibility to OEM parts and differences
(g) Certification that no deviation from OEM component materials, manufacturing, or dimensions (i.e. installed turbine nozzles throat area) shall prevent gas turbine from meeting ISO performance parameters and component longevity
(h) Verify the parts are the most current configuration
(i) Repair history of NON-OEM parts and qualified repair vendor for those parts
vii) All parts installed shall be guaranteed by the Contractor to meet or exceed 7FA.03 ISO performance in all operation conditions, including:
(1) Megawatt output
(2) Heat rate
(3) Emission
viii) If it is determined that an installed part is preventing the engines’ ability to meet ISO performance criteria the Contractor shall replace that part including labor at their cost.
ix) Installed parts shall not degrade or impair the engines’ ability to meet air emissions permit requirements. If it is determined that an installed part is preventing the engines’ ability to meet air emissions permit requirement, the Contractor shall replace the part with a part that restores the ability to comply with air emission permit requirements solely at its cost including labor and any consumable and/or support equipment necessary (i.e. lubricants, gaskets, crane, scaffolding, etc.).
e) Supply parts during Hot Gas Inspection (HGPI) and Major Inspection (MI)
i) The contractor shall maintain a stock of Contract parts listed in section 3 paragraph 3 of this scope of work (all combustion and hot gas path parts) which can be made available to Austin Energy for emergent maintenance within one week of request. A different schedule may be approved by the Austin Energy Project Manager. Contractor shall also use and refurbish (as applicable) Austin Energy owned spare parts as shown in the table below.
ii) Contractor shall have all parts identified in the table below available during the HGPI and MI.
iii) Parts shall be inspected during planned maintenance and borescope inspections to ensure that they are able to run the full interval.
iv) Only parts which meet the OEM criteria to continue service to the next planned maintenance inspection will be kept in service.
v) Parts that fail inspection will be replaced with parts that are new or have an equivalent remaining life as the parts are removed (i.e. if the 2nd stage shrouds shall be replaced in the HGPI they shall be evaluated for replacement in the MI with new parts depending on whether new or used parts were install in the HGPI). If parts are replaced earlier than in the table below the Contractor will adjust parts maintenance interval based on OEM guidelines. If a part which is due for inspection during the MI requires replacement the Contractor will cover this at no additional cost.
vi) Parts evaluation will be based on an engineering assessment agreeable to both the Contractor and Austin Energy. This assessment will include the operation profile of the turbine, history of parts condition in the unit, applicable engineering tests, and good engineering judgement.
vii) Under no circumstances will a part that exceeds OEM service life guidelines be left in service.
Table 1 – Parts to be installed at Scheduled Planned Outages
Hot Gas Path Inspection (HGPI) Major Inspection (MI) Combustion Liners (replace with repaired parts that have been in service one HGPI interval or new parts)
Combustion Liners (replace with either repaired parts removed during HGPI or parts with equivalent service or new)
Liner Caps (replace with repaired parts that have been in service one HGPI interval or new parts)
Liner Caps (replace with either repaired parts removed during HGPI or parts with equivalent service or new)
Transition Pieces (replace with repaired parts that have been in service one HGPI interval or new parts)
Transition Pieces (replace with either repaired parts removed during HGPI or parts with equivalent service or new)
Fuel Nozzles (replace with repaired parts that have been in service one HGPI interval or new parts)
Fuel Nozzles (replace with either repaired parts removed during HGPI or parts with equivalent service or new)
Combustion Flow sleeves (Inspect & Repair) Combustion Flow sleeve (inspect and repair) Crossfire Tubes (replace--new) Crossfire Tubes (replace--new) Crossfire Tube Retaining Clips (replace-new) Crossfire Tube Retaining Clips (replace--new) 1st Stage Shrouds (replace – with new part)) 1st Stage Shrouds (replace with repaired parts that have been in service one HGPI interval or new part)
1st Stage Nozzles (replace with either repaired parts removed during MI or parts with equivalent service or new)
1st Stage Nozzles (replace with repaired parts that have been in service one HGPI interval or new part)
1st Stage Buckets (replace – with new part) 1st Stage Buckets (replace with repaired parts that have been in service one HGPI interval or new part)
2nd Stage Shroud Blocks (replace with either repaired parts removed during MI or parts with equivalent service or new)
2nd Stage Shroud Blocks (replace with repaired parts that have been in service one HGPI interval or new part)
2nd Stage Nozzles (replace with either repaired parts removed during MI or parts with equivalent service or new)
2nd Stage Nozzles (replace with repaired parts that have been in service one HGPI interval or new part)
2nd Stage Buckets (replace with either repaired parts removed during MI or parts with equivalent service or new)
2nd Stage Buckets (replace with repaired parts that have been in service one HGPI interval or new part)
3rd Stage Shroud Blocks (replace with either repaired parts removed during MI or parts with equivalent service or new)
3rd Stage Shroud (replace with repaired parts that have been in service one HGPI interval or new part)
3rd Stage Nozzles (replace with either repaired parts removed during MI or parts with equivalent service or new)
3rd Stage Nozzles (replace with repaired parts that have been in service one HGPI interval or new part)
3rd Stage Buckets (replace – with new part) 3rd Stage Buckets (replace with repaired parts that have been in service one HGPI interval or new part)
f) Dry Low NOx (DLN) Combustor Tuning
i) The Contractor shall have the capability to provide DLN tuning for NOX and CO.
(1) Manual tuning may be performed at the discretion of Austin Energy at a cost quoted by the Contractor utilizing Contractor rates.
g) Customer Support
i) A Customer Service Manager will be assigned as the primary point to contact to support plant operations, parts, field service, and maintenance for the duration of this Contract. The Contractor will designate an alternate Customer Service Manager to ensure continuous support should the assigned Customer Service Manager be temporarily unavailable.
ii) The assignment of a Customer Service Manager shall be subject to Austin Energy approval, which shall not be unreasonably withheld. Austin Energy shall be entitled at any time, acting reasonably, to require Contractor to promptly remove and designate a new Customer Service Manager. Any such new Customer Service Manager shall be subject to Austin Energy’s approval, not to be unreasonably withheld.
iii) The assigned Customer Service Manager will be available on call 24/7 basis to facilitate unplanned maintenance, operational issues, and parts requirements.
iv) The Customer Service Manager assigned will be on site or available within four hours notification from Austin Energy during the HGPI, MI, and during any unplanned repairs performed by the Contractor.
v) The Customer Service Manager assigned shall be experienced with the support of an operational plant and fully understand the requirements of performing planned and unplanned maintenance of the specified equipment.
vi) The Customer Service Manager assigned shall provide technical support and technical advice as required to support unit operation.
(1) The Customer Service Manager shall advise Austin Energy of all TIL’s and other service bulletins in a timely manner.
h) Remote Monitoring
i) Vendor will replicate functionality of existing IPSec Tunnel through AE Corporate network to reach Sand Hill Plant Controls Network Firewall.
ii) Vendor equipment needed to collect GE Controls data will be located at the Sand Hill Engineering/Server room. Vendor will own and maintain equipment.
iii) Vendor is responsible for keeping their equipment up to date with OS patches and anti-virus updates.
iv) Vendor equipment shall be complaint with the latest NERC standards. Vendor is responsible for ensuring any changes within the NERC standards are incorporated into their equipment on the Austin Energy site.
v) Austin Energy will approve list of data, collection method, and monitoring method that vendor will use.
vi) All communications from GE controls network to the vendor equipment will pass through Sand Hill Plant Controls Network firewall.
vii) All communications sent to remote monitoring site from vendor equipment will pass through Sand Hill Plant Controls Network firewall.
viii) Any changes to remote monitoring network will have to be approved by Sand Hill Control LAN administrator.
ix) The Contractor shall provide remote monitoring of critical parameter for both the 7FA+e gas turbine and the D-11 steam turbine.
x) The monitoring shall be performed on a 24/7 basis.
xi) The Contractor shall maintain staffing 24/7 at the remote monitoring facility to assist the plant with troubleshooting problems.
xii) The Contractor shall provide a monthly operation report of all key parameters monitored. This report shall highlight any issues and unit problems with recommendations for correction.
xiii) The Remote Monitoring Facility shall immediately notify Austin Energy of any critical conditions or parameters which may lead imminent failure of covered equipment.
xiv) This service will be provided for the life of the contract including any contract amendments after the completion of the MI.
xv) All data collected is for the purpose of supporting this contract and not to be distributed outside the Remote Monitoring Division of the contract or any other companies. All data collected shall be considered confidential information of the project. At conclusion of the contract, all data collected by Contractor shall be destroyed or deleted.
i) Spare Parts
i) Contractor shall provide parts and refurbishment pricing as part of the contract as an option for Austin Energy to purchase additional parts during the term of the contract. This pricing shall be provided in Attachment 6.
ii) Parts shall be either OEM or non-OEM but shall be compatible with all parts in the engine at the conclusion of the Major Planned Outage without degradation of the performance or the emissions of the engine.
iii) The Contractor shall have the capability to provide all parts listed in Attachment 6
iv) Refurbish Austin Energy owned spare parts at start of contract. Austin Energy reserves the right to refurbish all, some, or none of the Austin Energy owned parts at the start of this contract.
v) Optional pricing may be given for contract parts to be supplies from parts pool program.
Pricing and details shall be submitted with Schedule 0600.
SECTION 3: CONTRACT COVERAGE
This Contract will cover the work scope to disassemble, inspect, replace, refurbish, reassemble, and startup the Sand Hill Combined Cycle Units:
1) The following auxiliary equipment will be included in the contract as noted below:
a) Accessory Module (draining oil reservoir, cleaning oil reservoir, and inspecting AC Oil Pumps)
b) Gas Fuel Skid
c) Packaged Electrical Control Cab
d) Hydraulic Power Unit
e) Seal Oil Control Skid
f) LCI
g) AVR/PSS (EX2100)
h) Lube Oil Coolers
2) The following services and parts will be included in planned maintenance:
a) All planned borescope inspections (listed in this work scope) during the contract.
b) During the gas turbine HGPI – replace the inlet guide vane bushings, and rack/pinion gears and adjust as necessary.
i) Perform Generator Minor Inspection as referenced in Attachment 2.
c) During the Gas Turbine MI
i) Evaluate (eddy current) the condition of all compressor air foils and advise Austin Energy of estimated remaining useful life.
ii) Evaluate (eddy current) the condition of all compressor stator vanes and advise Austin
Energy of estimated remaining useful life.
d) During the Gas Turbine MI – replace the inlet guide vane bushings, and rack/pinion gears and adjust as necessary.
i) Perform Generator Major Inspection as referenced in Attachment 2.
e) Perform the Steam Turbine (ST) Major and Minor Inspections referenced in Attachment 3.
i) Perform Generator Major and Minor inspection referenced in Attachment 3.
3) Contract Parts:
a) The following are considered contract parts (replace on schedule per this work scope, replace based on condition assessment, or replace on failure):
b) Combustion Hardware (24K parts)
i) Fuel Nozzle Assembly
ii) Combustor Cap Assembly
iii) Combustion Liner
iv) Transition Piece Assembly
v) Flow Sleeves
vi) Crossfire Tubes
vii) Crossfire Tube Clips
c) Hot Gas Path Hardware
i) 1st through 3rd Stage Shroud Blocks
ii) 1st through 3rd Stage Nozzles
iii) 1st through 3rd Stage Buckets
d) Consumables
i) All consumables (gaskets, hardware, lubricants, sealants, never-seize, rags, etc.) required to perform the work scope listed in this contract.
(1) HGPI
(2) MI
(3) Borescope Inspections
4) Optional Parts (purchased as required at Austin Energy’s discretion):
a) Compressor Hardware
i) Compressor Stator Vanes 0-EGV’s as individual rows with stator rings as required.
ii) Compressor Rotating Blades Rows 0-17. R0 blades must be water wash compliant and allow normal inspection intervals.
iii) Inlet Guide Vanes
iv) Rotor through bolts and hardware
5) Other Parts (Inspect Only)
a) The following parts and systems of the covered units are considered non-contract parts and are list as inspection only.
b) Gas Turbine (GT)
i) Inlet bell mouth, Compressor Cases, Turbine Case, Exhaust Casings, and Shells (including internal casings)
ii) Bearings and oil/air seals
iii) Inlet and Exhaust Expansion Joints
iv) Turbine Disks
c) Generator
i) Bearings
ii) Hydrogen Seals
iii) Rotor
iv) Gland Casings
v) Stator and Windings
vi) Turbine/Collector End Inner and Outer End Shields, Oil Deflectors, Fan Blades, and
Hydrogen Coolers
vii) Seal Oil and Hydrogen System
viii) Collector Ring Assembly
ix) Bearing oil/air seals
x) Flux Density Probe
6) Parts installed at GT Major Inspection
a) Table 2 lists the parts to be installed at the major inspection.
Table 2 – Parts that were installed at last Major Inspection (March 2026) – Parts installed at Start of New Contract
Set Part Status Fired
Hours/Factored Fired Starts
Repairs
#1 Fuel nozzle assembly
Installed (new) 0/0 0
#1 Cap Assembly Installed (new) 0/0 0 #1 Transition Pieces Installed (new) 0/0 0
#1 Combustion Liners Installed (new) 0/0 0 NA 1st Stage Shrouds Installed (new) 0/0 0
(see note below) #1 1st Stage Nozzles Installed (new) 0/0 0
NA 1st Stage Buckets Installed (new) 0/0 0
NA 2nd Stage Shrouds Installed (new) 0/0 0 NA 2nd Stage Nozzles Remained in Service 27,500/158 * 0
NA 2nd Stage Buckets Remained in Service 27,500/158 * 0 NA 3rd Stage Shrouds Remained in Service 27,500/158 * 0 NA 3rd Stage Nozzles Remained in Service 27,500/158 * 0 NA 3rd Stage Buckets Installed (new) 0/0 0
*Estimate fired hours and fired starts for these parts
SECTION 4: CONTRACT SCHEDULE
1) Table 3 provides a preliminary schedule that will apply assuming the unit runs 6,800 hours per year.
a) A HGPI estimated in November 2029 at 24,000 ±1,500 factored fired hours from the last MI, and a
MI estimated in February 2033 at 48,000 ± 2,500 factored fired hours from the last MI.
b) If the operational profile of the unit changes during the term of the contract, the contract shall be converted from hours based to start based. Proposers should include with their proposal a method to accomplish this for consideration by Austin Energy. This should include the method to convert is as well as a metric or algorithm to determine when to shift from fired hours based to fired starts based.
The proposed method shall address and be based on the OEM recommendations concerning starts and hours criteria as detailed in the latest revision of the General Electric publication of
GER-3620.
Table 3 – Preliminary Schedule
Date Gas Turbine Task Steam Turbine Task November 2026 Borescope Inspection Borescope L-0 blade tips March 2027 Borescope Inspection November 2027 Borescope Inspection Borescope L-0 blade tips March 2028 Borescope Inspection November 2028 Borescope Inspection Borescope L-0 blade tips March 2029 Borescope Inspection November 2029 Hot Gas Path Inspection (HGPI) Major Inspection March 2030 Borescope Inspection November 2030 Borescope Inspection Borescope L-0 blade tips March 2031 Borescope Inspection November 2031 Borescope Inspection Borescope L-0 blade tips March 2032 Borescope Inspection November 2032 Borescope Inspection Borescope L-0 blade tips
February 2033 Major Inspection (MI) Minor Inspection
November 2033 Borescope Inspection or remaining planned maintenance (if first Contract extension is exercised)
Borescope L-0 blade tips
March 2034 Borescope Inspection or remaining planned maintenance (if first Contract extension is exercised)
Borescope L-0 blade tips
November 2034 Borescope Inspection or remaining planned maintenance (if second Contract extension is exercised)
Borescope L-0 blade tips
March 2035 Borescope Inspection or remaining planned maintenance (if second Contract extension is exercised)
Borescope L-0 blade tips
Note: Planned maintenance ac�vi�es may be shi�ed, as required, to execute maintenance at Contract specified fired hours or fired starts.
SECTION 5: GENERAL
1) Outage Schedules and Staffing
a) Detailed outage inspection schedules will be developed and provided to Austin Energy at least 90 days prior to the start of the inspection for review and pre-approval.
i) Inspection schedules shall be provided in Microsoft Project files.
b) Inspection shall meet the minimum time criteria as noted in section 5.2.
c) Contractor shall supply the following personnel with appropriate experience to complete the outage work scope:
i) Project Manager
ii) Field Engineer/Technical Direction
iii) Supervision
iv) Labor
d) Inspections shall be staffed to meet the outage timeline required by this work scope.
e) During the outage the Project Manager shall provide daily briefings to Austin Energy personnel concerting the status of this project. Topics covered by these daily briefings shall include, but no limited to:
i) Progress made since the last briefing
ii) Discovery of any usual or unforeseen conditions.
iii) Any emergent unplanned work which may be necessary
iv) One-and-three-day look-ahead at project work to be performed
v) Status of the delivery of any necessary parts, tools, equipment, or specialists
vi) Any test, inspections, and significant measurements conducted since the last daily briefing and any results (if available)
vii) Tests, inspections, and significant measurements scheduled to be conducted in the next three day including any QA/QC Hold or Witness points
viii) Any Safety or Environment incidents or close calls which occurred or were discovered since the last daily briefing
2) Inspection Durations
a) Annual Borescope Inspection shall be completed in 3 calendar days.
b) Hot Gas Path Inspection (HGPI) shall be completed in 12 calendar days.
c) Major Inspection (MI) shall be completed with the timeframe proposed by the Contractor and pre-approved by Austin Energy.
d) Unplanned maintenance that is not contracted prior to the start of the outage shall have a completion day agreed upon in writing by both Austin Energy and the Contractor. Unplanned work is work that is NOT defined in Attachment 2 or is warranty work.
e) The start and stop dates for the planned worked is detailed in Attachment 2.
f) The Contractor shall provide an updated schedule which includes unplanned work within twenty-four (24) hours of identification of said unplanned work.
g) The Contractor will be liable for delays associated with their planned work scope (Attachment 3), the agreed upon schedule for unplanned work, or warranty work, excepting delays from Force Majeure events.
3) Division of Responsibility and Maintenance Work Scope
a) A division of responsibility between Austin Energy and the Contractor is specified in Attachment 1.
b) The maintenance work scope is detailed in Attachment 2 and 3.
4) Part Reconditioning Schedule
a) Contractor shall recondition parts removed during scheduled outages within 120 days of completion of the outage to ensure spare parts are available for unplanned events, if Contractor opts to utilize parts removed during the HGPI for installation of the MI.
b) Contractor shall have set of contract parts as shown in Attachment 6 available at all times for unplanned events and on site within 48 hours of notification from Austin Energy for unplanned maintenance (excluding compressor rotor wheels and turbine disks).
c) Austin Energy owned parts shall be repaired and returned to site within 120 days of completion of the HGPI or any other unplanned event.
5) Reports
a) The Contractor shall provide an electronic copy of the report following each planned outage and for any unplanned work performed within 30 days.
b) The report at a minimum shall contain:
i) A detailed description of work performed.
ii) A list of all contract parts removed and installed including serial number and visual inspection results.
iii) The reports shall denote the nozzle position in which the combustion hardware was installed.
iv) Contract parts installed shall have the following information:
(1) Total Factored Fired Starts
(2) Total Factored Fired Hours
(3) Number of Repairs
v) Total fired hours on the unit
vi) Fired hours on the unit since the last inspection
vii) Total factored fired starts on unit (if monitoring option is implemented by Austin Energy)
viii) Factored fired starts on unit (if monitoring option is implemented by Austin Energy)
ix) High quality images of critical components
x) Alignment data
xi) All critical dimensions including but not limited to, as found and final balance weights, and other adjustments made.
xii) Bearing inspection and test results
xiii) Generator inspection and test results
xiv) NDE test results
xv) Critical disassembly and assembly clearances and their specifications that define those clearances for compliance.
xvi) Outage and start time and completion
xvii) Pre and post engine performance parameters from DCS
xviii) Documentation showing any safety or environmental issues during the outage.
xix) Bucket serial numbers with moment weight charts
c) Contractor shall provide Emissions Compliance Testing results conducted during DLN tuning within 15 business days.
6) Quality Management Program
a) Contractor shall prepare a Quality Management Program in accordance with OEM standards for review, comment, and acceptance by Austin Energy.
b) As part of the Quality Management Program, the Contractor shall prepare a comprehensive inspection and test plant (ITP) for each planned maintenance and unplanned maintenance event inclusive of all previously agreed to Witness (W) and Hold (H) points. The designated Austin Energy representative shall be notified one day prior to each Witness Point and two days prior to each Hold Point. Austin Energy may elect to have a Third-Party Inspector (TPI), provided that such inspectors shall not be direct competitors of Contractor or its affiliates and provided that such inspectors first execute a confidentiality agreement with terms substantially similar to those set forth herein, conduct the surveillance or waive the Witness Point, but must be present for the Hold Point. Irrespective of Austin Energy presence, in all cases the Contractor shall record the results of the activities on the appropriate data sheet or form, with illustrations such as a sketch or digital image, then confirmed by signature and date.
c) Contractor will submit the ITP Matrix organized chronologically within each major system in a similar form and content as provided in Table 4, which provides a few illustrative examples:
Table 4 – Sample Format for ITP Matrix
ITP Inspection Activity Verification Point Contractor TPI AE
Combustion Turbine and Ancillary Equipment Evaporative cooler media orientation H W W Evaporative cooler drift eliminator orientation H W W Initial Alignment H W W Cold Alignment H W H Final / Hot Alignment H W H DLN Tuning; Emissions Monitoring results H W W DLN Tuning; Set-points H W W
Steam Turbine and Ancillary Equipment Rotor Float Check H H H Installing the Gib Keys H W W Shell Arm Loading Check (a.k.a. Horn Drop Test) H H H Initial Alignment H W W Cold Alignment H W H Final / Hot Alignment H H H
Generator and Electrical Stator Helium Leak Check; pressure decay H H H Helium Leak Check; detection sensor readings H H W Meggerohmeter Test H H H Relay Functional Tests H H H
General Material Certifications per Heat Number H H H Positive Material Identification (PMI) H H H Replacement Part Serial Number Reading / Recordation H H H Hydrostatic Pressure Test H H H In-service Testing H H H
7) Other
a) Austin Energy reserves the right to inspect/observe work and participate in the outage work scope development.
b) Austin Energy reserves the right to provide additional testing (electrical and NDT) from a third-party vendor at Austin Energy’s cost as required.
c) All machine alignment and part clearances shall meet OEM specifications.
d) For planned work scope all costs associated with proper alignment and clearances are considered part of the planned work and shall be borne solely by the Contractor.
e) Austin Energy reserves the right to provide the Contractor with QAQC hold points during both planned and unplanned outage work. This includes both on site (field service) and off site (shop work).
f) Austin Energy reserves the right to visit the Contractors facility to monitor work on Austin Energy equipment.
g) Austin Energy reserves the right to appoint an Owners Representative to observe work both for field service work and shop work.
h) No modifications or changes will be made to the covered units without prior written approval of Austin Energy.
i) Austin Energy will be provided reasonable access to Contractors records and reports concerning the Facility and all work done under the LTSA both on and off-site.
j) Contractor employees and Contractor subcontractors will complete individual training, as specified by Austin Energy, concerning site policies and compliance.
k) Contractor shall be responsible for providing secure storage for Contractor’s tools and equipment.
l) Contractor shall inform Austin Energy on any improved part, component, or service procedure of which the Contractor becomes aware as it may apply to any planned or unplanned maintenance.
Austin Energy shall be afforded the option of incorporating any or all such improvements into the work.
m) In the event any condition occurs that, in the judgement of Austin Energy, warrants either planned or unplanned maintenance, Contractor shall perform such work regardless of whether a dispute exists as to whether such work constitutes planned maintenance or unplanned maintenance, and the existence of any dispute shall not excuse Contractor from performing such work, provided however, all disputes will be resolved in accordance the agreed upon provisions of the contract.
SECTION 6: ASSUMPTIONS
1) Parts Removal and End-of-Life
a) All parts in the machine at the beginning of this contract are the property of Austin Energy.
b) Contract parts removed from the gas turbine during the 2029 Hot Gas Path Inspection (HGPI):
i) Parts scheduled in be removed during HGPI or a MI are shown in Table 5. Parts determined to be at end-of-life shall be removed and replaced by new parts. Parts removed for refurbishment shall be replaced with either new parts or refurbished parts which have an equivalent or longer remaining expected service life.
(1) These parts shall be refurbished to OEM criteria. The cost to refurbish these parts will be included in the quarterly contract payments. The Contractor shall cover the full cost, including labor, or any fallout with parts with equivalent remaining life or new parts.
(2) The Contractor shall provide a repair report for each refurbished part detailing repairs made and critical dimensions.
(3) Critical dimensions shall include throat opening for all three stages of turbine nozzles.
(4) The Contractor may elect to refurbish existing non-OEM parts or provide equivalent new or refurbished parts. Austin Energy reserves the right to alter the election made by the Contractor.
(5) Parts removed from the turbine for end of life shall become the property of the Contractor and provide a credited value (invoice off-set) to Austin Energy of half of their fair market value. Contractor shall provide Austin Energy with an estimated value of any parts removed due to end of life.
ii) Parts that are removed from the gas turbine which are NOT end of life (whether refurbished for the MI or not) shall remain the property of Austin Energy.
c) Parts refurbishment by the Contractor that will be installed during the MI shall be returned to Austin Energy within 120 days of completion of the HGPI unless otherwise agreed to in writing with Austin Energy.
d) Contract parts removed the gas turbine during the 2033 Major Inspection (MI):
i) Parts removed during the MI which still have remaining life will be considered the property of
Austin Energy. Note: Parts removed during MI that have remaining life will not be refurbished.
ii) Parts removed the MI which are considered end of life shall become property of the
Contractor.
iii) All parts installed the gas turbine during the MI shall be considered the property of Austin
Energy.
Table 5 – Parts Scheduled for Removal During Inspection
Part HGPI MI Fuel Nozzles Remove---Recondition Remove---24K or end of life Liner Cap Remove---Recondition Remove---24K or end of life Combustion Liners Remove---Recondition Remove---24K or end of life Transition Pieces Remove---Recondition Remove---24K or end of life Flow sleeve Remove---Inspect, repair, and reinstall
Remove---Inspect, repair, and reinstall
Crossfire Tubes Remove—End of life Remove---End of life Crossfire Tube Retaining Clips
Remove---End of life Remove---End of life
1st Stage Shroud Blocks Remove---Recondition Remove—24K or end of life
1st Stage Nozzles Remove---Recondition Remove---Recondition 1st Stage Buckets Remove—Recondition Remove—24K or end of life.
2nd Stage Shroud Blocks Remove---Recondition Remove---Recondition 2nd Stage Nozzles Remove—End of life Remove---Recondition
2nd Stage Buckets Remove--–Recondition Remove---Recondition 3rd Stage Shroud Block Remove---Recondition Remove----Recondition 3rd Stage Nozzles Remove---Recondition Remove---Recondition 3rd Stage Buckets Remove---Recondition Remove---24K or end of life
SECTION 7: CONTRACT PRICING
1) Pricing for Contract shall be based on the following:
a) Contract Parts
i) New Parts – parts provided within the Contract Part Table as new are replacement parts for contract parts that have reached their end of life. The new parts shall be OEM or OEM equivalent and shall have the same or better life expectancy (FFH, FFS, and total repairs) of the parts which are replaced. Title of parts installed in the machine shall transfer to Austin Energy.
ii) Parts removed in which are NOT at end of life shall be replaced with either new or repaired parts that have an equivalent or longer remaining life. Title of all parts installed in the machine shall transfer to Austin Energy.
iii) The Contractor shall cover the entire cost of early replacement (i.e. if the part requires replacement prior to the schedule in the table above) of contract parts which are removed during the HGPI from the machine and refurbish/replace these parts for use in the MI as part of this contract.
iv) The Contractor shall cover the entire cost of early replacement (i.e. if the part requires replacement prior to the schedule in the table above) of contract parts which are removed during the Major Inspection. Parts which are removed early during the MI shall be placed with parts with an equivalent or longer life expectancy. Title of parts installed the machine shall transfer to Austin Energy; title of parts removed from the machine for refurbishment shall transfer to the Contractor.
b) Reconditioning of Austin Energy Owned Parts
i) Recondition Austin Energy owned parts which are NOT at end of life (per the most recent version of the OEM GER 3620 standard or its successor) that are removed during the HGPI.
ii) The Contractor shall cover fallout and replace parts which cannot be repaired with parts with an equivalent or better remaining life and performance.
iii) Austin Energy owned parts which reach end of life (per the parts table in this section of the specification) at the HGPI shall be replaced with new parts. The new parts shall have at least the equivalent expected life of existing Austin Energy parts (i.e. 24K Combustion Hardware).
iv) Austin Energy owned parts (Combustion Hardware) shall be reconditioned and returned to Sand Hill Energy Center within 120 calendar days of the end of the HGPI.
(1) The Contractor may elect to refurbish existing non-OEM parts or provide equivalent new or refurbished parts.
(2) Parts that are removed from the gas turbine which are NOT end of life (whether refurbished for the MI or not) shall remain the property of Austin Energy.
(3) The parts shall be packaged for long term storage in a warehouse without climate control.
(4) Part repairs required due to inadequate packaging shall be the responsibility of the
Contractor.
(5) Part repairs required due to any damage incurred during shipping shall be the responsibility of the Contractor. The Contractor shall service, replace, and/or repair any damaged parts, as necessary.
c) The Contractor shall perform all DLN tuning required to satisfy the Austin Energy specified emissions requirements. These requirements may include Austin Energy Specified operational margin relative to the permitted limits.
d) The contractor shall provide all technical support, consulting, analysis, and advice concerning the specified scope of work at no additional cost. Any specific limitations on the Customer Support provided shall be specified by the Contractor for approval by Austin Energy as part of the acceptance of this agreement.
e) The Contractor shall detail their capability for Remote Monitoring and Diagnostics (M&D) and identify the price for their services over the duration of this agreement. Any communication requirements to support the M&D service proposed shall be the responsibility and at the sole cost of the Contractor. The specific approach for communication recommendation from their remote condition assessment to Austin Energy shall be detailed, including any responsibly for Austin Energy to provide feedback on the recommendation provided.
2) The Contract price shall be based on factored fired hours (FFH). FFH will be calculated as specified by the GER that is applicable at the time that the contract is signed or by the current logic in the DCS/Turbine Governor. The amount payable will be in the form of quarterly payments for the initial 3-year contract term. If Austin Energy opts to perform additional services above the planned work scope, the pricing for these shall be in addition to the quarterly payments.
a) The term of the contract is 3 years term with two additional 3 years assume 6,800 fired hours per year.
b) The contract will be paid in quarterly installments with the first payment due during the first month of the calendar quarter in which the contract is signed. There after the quarterly payments are due in the third month of each calendar quarter. All quarterly payments for the planned contract work scope shall be completed seven-years after the contract is signed.
c) There shall be two additional 3 years periods contract extension options.
(1) Austin Energy reserves the right to execute one or both extensions if contract planned maintenance is not completed during the original 3-year contract term or coverage is required for unplanned maintenance.
d) After the MI is executed the scope of the contract will be for warranty and unplanned work only.
e) The Contractor shall specify the following pricing:
i) Quarterly payment for planned GT and ST maintenance paid over first nine -years of contract.
Reference Attachment 4 and 5.
ii) Optional quarterly payment (if any) for three -year contract extensions.
iii) Optional quarterly payment for remote monitoring for entire term of contract including any optional contract extensions.
iv) Pricing for parts listed in Attachment 6.
v) Provide time and materials labor pricing.
vi) Provide markup on services and parts procured by Contractor.
f) The Contractor shall submit a proposal for a method to “true up” the contract if the contract shall be converted from Factored Fired Hours basis to a Factor Fired Starts basis.
g) If the contract is terminated for Contractor’s default prior to execution of the MI the Contractor and Austin Energy shall agree to the following:
i) Contract terminated early (prior to execution of MI)
(1) All remaining contract payments will be cancelled.
(2) Payments made for parts and services not delivered shall be returned to Austin Energy.
(3) Austin Energy shall have the option to offset any amounts due to Austin Energy against outstanding invoices.
SECTION 8: WARRANTY
Parts delivered during the term of this contract shall be free from defects in material, workmanship, and title. Non-OEM parts supplied by Contractor shall be equivalent in design capabilities to OEM parts.
Services performed during the term of this contract shall be performed in a competent diligent manner.
Parts delivered during the term of this contract shall be free from defects in design, measured by the standards applied and general use at the time of the manufacture of the parts.
Contractor shall provide a full warranty on any parts that do not provide their expected service life. The full warranty shall cover both the cost of the covered parts and the costs of installation and labor. This warranty shall be effective as follows:
After installation for the parts in the covered unit, for a period of 24K (24,000) fired hours.
Warranty on an 7FA rotor (compressor disks, turbine wheels, spacers, through bolts, and other rotor hardware) if applicable shall be for the period of the term of this contract and for any extensions or renewals with a minimum recommended life of 144K (144,000) fired hours.
Contractor shall cover the cost of both removal and installation of contract parts if they fail to reach the expected design outage intervals.
All warranty work shall be done in a 7 day a week/24 hour a day expedited basis to return the equipment to operation status.
The Contractor shall provide a full warranty on any services that do not support operation to the expected maintenance intervals. The full warranty shall cover both the cost of the covered labor and any parts required to correct the unsatisfactory service provided. This warranty shall be effective as follows:
After performance of the services, for a period of either 24K (24,000) fired hours or one year after termination of close out of this contract (including one or both contract extension if executed), whichever comes first.
All warranty work shall be done in a 7 day a week/24 hour a day expedited basis to return the equipment to operational status.
Parts replaced during term of the contract or during a warranty period shall be replaced with new parts that are with expected service life and performance or better of the replaced part.
Any new parts supplied by Contractor (either when…
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