SOW_draft_1.docx

Statement of Work Folsom Powerplant Unit 2 Thrust Bearing Shoes and Turbine Guide Bearing Repair

1.0 General

A. This is a non-personal services contract to repair twelve (12) thrust bearing shoes and one (1) turbine guide bearing (TGB) for the Central California Area Office of the California Great Basin Region, Bureau of Reclamation.

B. The Government shall not exercise any supervision or control over the contract service providers performing the services. Such contract service providers shall be accountable solely to the Contractor who, in turn is responsible to the Government.

2.0 Background

A. The thrust bearing on Unit 2 at Folsom Powerplant failed in July of 2022. The thrust bearing shoes were removed and inspected. The thrust shoe babbitt was found displaced due to the failure and requires repair to restore the babbitt surface. The shoes also require modifications to match the new High-Pressure Lubrication (HPL) system modification already done to three (3) sets of twelve (12) thrust shoes for Folsom Powerplant units. The new thrust shoe design was created by Kingsbury, Inc. and their manufacturing was performed by Kingsbury Repair and Service Division in Yuba City, CA.

B. The TGB was also removed in July 2022, inspected, and requires final machining to match the other existing TGBs installed in the Folsom Powerplant generators.

3.0 Principal Items of Work

A. Inspect, re-babbitt, and modify twelve (12) thrust bearing shoes for the new HPL system.

B. Inspect and machine one (1) TGB per specifications.

1. Additional services for re-babbitting TGB as needed.

4.0 Administrative Requirements

A. Contractor Furnished Items and Services:

1. The Contractor shall provide all equipment, supplies, management, supervision, personnel, and transportation except as specified herein as Government-Furnished, necessary to assure that all services are in accordance with the contract and all applicable laws and regulations.

2. The Contractor shall ensure all work uses quality workmanship that meets current industry performance standards and standards specified in this Statement of Work (SOW).

B. Government Furnished Property, Equipment, and Services:

1. One (1) set of TGB clamp rings will be provided. The clamp rings will be pre-installed on the TGB and must remain in place for measurements, and machining. The clamp rings should be returned separate from the machined TGB to the Government after completion of work.

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

1. Contractor communication and coordination of work shall be through the COR.

2. The COR may hold Government on-site inspections at points listed in Section 6.0, Specific Tasks.

a) Notify the COR within 5 working days before an inspection point is to occur.

3. The Contractor shall perform the work as defined under Section 6.0, Specific Tasks.

a) Additional work, as may be required and resulting from deficiencies identified by the post application testing, can only be performed upon written authorization by the Contracting Officer (CO) with a contract modification.

b) The only person that has the authority to modify the terms of the contract or request work for which compensation will be provided is a CO

i) If the Contractor receives a request from Government personnel directing or requesting work that the contractor believes is not within the terms of the SOW or the contract, then the Contractor must notify the CO of the request.

c) Contract modifications are subject to the terms contained within these contract documents unless otherwise stated.

4. Contractor shall provide a point of contact: name, title, telephone number and email address during normal working hours for the government to schedule work under this contract.

D. Period of Performance

1. The overall period of performance for the purchase order is 120 days after Contract Award and receipt of parts.

E. Place of Performance

1. The Government will deliver and pick-up the equipment to / from the Contractor’s location at:

Kingsbury Repair and Services Division, West 209 Burns Drive Yuba City CA 95991

2. All work will be performed at the Contractor’s facility.

F. Safety

1. Contractor shall perform the work in accordance with the applicable State and Federal OSHA standards.

5.0 Reference Standards

A. American Society of the International Association for Testing Materials (ASTM).

1. ASTM B23 - Standard Specification for White Metal Bearing Alloys (Known Commercially as “Babbitt Metal”) B. American Society of Mechanical Engineers (ASME).

1. ASME B46.1-2019 - Surface Texture Surface Roughness, Waviness and Lay C. American Society for Nondestructive Testing (ASNT).

1. ASNT SNT-TC-1A-2021 - Qualification of Nondestructive Testing Personnel

6.0 Specific Tasks

A. Thrust Bearing Shoes

1. Remove old Babbitt material.

2. As-found inspection.

a) Perform visual inspection and non-destructive testing of base material for defects. Submit inspection report to the Government.

i) Report should include at minimum surface conditions, and visual inspections.

ii) If other work, not currently specified in the SOW, for the thrust shoes is found necessary from the inspection, it will be handled through a bilateral modification to the contract. Pause work and contact the Government for the modification.

3. Plug existing HPL oil port on the face of each shoe.

4. Installation of new Babbitt material.

a) ASTM B23 Grade 2 Babbitt material. Provide Babbitt material certificate of analysis.

b) Percentage of total Babbitt area un-bonded needs to be less than one percent using Ultrasonic Thickness (UT) measurements.

i) Inspection shall be completed by qualified person in nondestructive testing.

c) Porosity – Pinholes .015” and less will be acceptable if they are spaced 1/8” away from one another and no more than five in one square inch.

d) Any cracks, laps or other liner indications are not allowed.

5. Modify for the new HPL system per drawing specifications.

a) Supply and install hydraulic valves and fittings internal to each shoe to use with the new HPL system.

6. Final Inspection.

a) Notify the COR for on-site witnessing and self-spot checks of the measurements.

b) Submit report to the Government.

i) Report should include at minimum final dimensions, surface conditions, and UT inspection results.

7. Package and box for long term storage.

B. Turbine Guide Bearing

1. Incoming Inspection.

a) Unbox, clean, and perform incoming inspection. Submit inspection report to the Government.

i) Report should include at minimum dimensions, surface conditions, and visual inspections.

b) Measure as-found conditions.

i) Notify the COR for on-site witnessing and self-spot checks of the measurements.

ii) Four (4) evenly spaced inside micrometer inner diameter measurements (every 45 degrees).

iii) Radial runout measurements shall be taken at four (4) elevations of the bore.

iv) Axial runout measurement on the bolt flange machined surface.

v) Determine if as-found measurements of the Babbitt bore are acceptable deviations from cylindrical; nominal diameter plus tolerance of 0.0015-inches.

vi) Submit as-found measurements to the Government.

c) If other work, not currently specified in the SOW, for the TGB is found necessary from the inspection and measurements, it will be handled through a bilateral modification to the contract. Pause work and contact the Government for the modification.

2. Part setup and fixturing:

a) The TGB will be shipped with provided clamp rings pre-installed to the target height. The clamp rings mimic the tapered fit installation of the TGB.

i) All modifications must be made while clamp rings are in place.

ii) Verify heights of installed clamp rings from the machined bottom surface of the TGB flange.

b) Chuck jaws, axial hold down clamps, and jacks shall be used as necessary to hold rigid the dimensional relationships during machining. See Figure 3 for example of proper setup.

i) Notify the COR for on-site inspection and approval of the setup before proceeding with machining.

c) Consider thermal expansion of the bearing between the machined location and installed location for machining dimensional accuracy.

i) The ambient temperature of the shop at the vicinity of the bearing shall be submitted to the government in the final report.

ii) Ambient temperature of the installed location is 60 degrees Fahrenheit.

3. Flange clamping bolts and alignment pins, see Figure 4.

a) Through-drill the flange clamping (pinch) bolt holes for slip fit of similarly sized commercially off the shelf Grade 8 bolt and nut with washers.

b) Spot face for proper fit of commercially off the shelf washers on both sides of the flange surface.

c) Machine tapered alignment pins and holes located parallel and adjacent to the clamping bolts. Ream for final fit and install alignment pins prior to final Babbitt machining.

4. Machine TGB babbitt per drawing specifications.

a) Inside diameter (bore).

b) Oil grooves and chamfering.

c) The final machined babbitt axis shall be concentric to the TGB outside diameter tapers. The TGB bore shall be perpendicular to the machined bottom surface of the TGB flange.

d) The finished machining surface shall meet a 32 micro-inch rating (ANSI B46.1-2019).

5. Spot face the top bolt flange surface to 3" diameter over the four (4) each 1-1/4" jack bolt holes, see Figure 5.

a) The spot face shall be parallel to the bottom machined surface of the bearing flange.

b) The depth of spot face cutting shall be the minimum depth required to achieve 90% spot face parallelism with the bottom surface of the flange.

6. Drill for the six witness holes on the TGB flange for measuring with a depth gage to match the other three (3) modified TGBs at the Folsom Powerplant, see Figure 7.

7. Machine one threaded RTD port on one bearing shell using the provided RTD for proper fit.

a) Final port location to be identified by the COR, see Figures 6 and 7.

i) The drilling will be located on the top surface, inside of the highest raised oil dam of the assembled TGB, adjacent to the Babbitt on the “downstream” cast steel bearing shell half, adjacent to the existing capillary tube temperature bulb. It will initially drill through the bearing shell but be angled from vertical such that it allows the RTD to touch Babbitt material without penetrating the Babbitt inside diameter.

8. Repair the 29/32-inch threaded holes for the two (2) 3/4-inch oil supply ports in the sides of the bearing housing. The thread pitch on the oil supply port in National Pipe Thread (NTP).

9. Final Inspection

a) After machining is complete, take another set of measurements in the same manner as required for the as-found measurements.

b) Submit inspection report to the Government and refer to as the “machined measurements”.

c) Notify the COR for on-site witnessing and self-spot checks of the measurements.

10. Package and box for long term storage.

7.0 Documentation

A. The Contractor shall provide the following documentation to the Government.

1. Thrust bearing shoes as-found inspection report.

2. Certificate of analysis for Babbitt material

3. Thrust bearing shoes final inspection report

4. TGB initial inspection report and as-found measurements.

5. TGB final inspection report.

6. Dimension mapping information for TGB measurements.

a) All radial and axial runout measurements shall be indexed by 8 evenly spaced locations around the part’s axis of rotation.

b) The number Bore runout measurements elevations shall be sufficient to determine the axial direction of the bore.

7. As-built drawings.

a) The Contractor shall provide the Government with as-built drawings for the TGB and thrust bearing shoes for all critical dimensions.

i) Drawings shall be in .DWG format compatible with AutoCAD, version 2018

8. Warranty

a) All materials and work shall be warranted by the Contractor for a period of one year after received by the Government.

B. Government supplied information.

1. The Government will provide electronic versions (PDF file format) of available reference drawing related to the thrust bearing shoes and turbine guide bearing.

2. The Contractor shall verify all dimensions provided in the drawings to assure accuracy of final machining.

3. See Section 10.0 - Attachment/Technical Exhibit List for list of Government provided drawings.

8.0 Contacts

A. Central California Area Office (CCAO) Attn: Janell Vincent US Bureau of Reclamation 7794 Folsom Dam Rd.

Folsom, CA 95630

9.0 Quality Assurance and Surveillance Plan

A. The period of performance begins when the Contractor receives the Contract Award and the Government-Furnished equipment.

1. The Contractor has 120 days to complete the re-babbitting, machining, of the thrust shoes.

a) The Contractor has 90 days to complete the machining and re-babbitting (if needed) of the TGB.

b) The Contractor will coordinate with the Government to schedule shop visits at mutually agreed upon time windows.

B. The Quality Assurance Surveillance Plan (QASP) is intended to establish guideline that shall be used to evaluate what level of success/completion the Contractor has achieved in executing the work as defined in the SOW. The absence of a QASP for any contract requirement, however, shall not detract from its enforceability or limit the rights or remedies of the Government under any other provision of the contract in determining the quality of the Contractor performance.

10.0 Attachment/Technical Exhibit List

A. Performance Requirements Summary (PRS) and Quality Assurance Surveillance Plan (QASP).

1. Government required documentation

2. Acceptance testing

3. Performance of minor maintenance and adjustments

1.Responsiveness a.) To required documentation.

b.) To technical requirements.

No more than two (2) issues with responsiveness for documentation and technical requirements.

2.Timeliness -

Contractor executes each task or activity within the agreed upon timeframe.

All tasks and activities shall be 100% complete within the agreed upon timeframe. The Contractor may work with the COR if the timeframe becomes an issue.

3.Quality of Work -

Contractor performed each task or activity with a clear understanding of the requirements. Workmanship was free of defects.

No more than two (2) defects that the Government finds outside of the Contractor QC process.

4.Completeness -

Contractor executes each activity in the SOW to completion.

All SOW activities shall be 100% complete.

COR to provide surveillance, track Contractor progress and performance, discuss findings and follow-up as necessary.

B. Government Provided Drawings.

C. List of Photos.

Figure 8, View of final machined TGB.

Photos Folsom Powerplant Unit 2 Thrust Bearing Shoes and Turbine Guide Bearing Repair

Figure 1, Thrust bearing shoes as assembled on the Folsom Units.

Figure 2, Unit 2 TGB, arrow showing notch on oil dam that signifies upstream.

Figure 3, Example of four-point chuck fixture setup for machining the TGB.

Figure 4, Final placement of clamping bolt and tapered alignment pin on the other three TGBs at Folsom Powerplant.

Figure 5, Arrows showing two of the four jacking bolt holes that require spot facing.

Figure 6, Arrow showing existing capillary tube temperature bulb port.

Figure 7, New threaded RTD port shown (smaller drill bit) adjacent to existing capillary tube temperature bulb port. Witness holes shown on same surface.

Figure 8, View of final machined TGB.

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