SOW JDF Fish Pump Design_2026_updated.docx

JDA Fish Pumps Emergency Repair Project South Fish Ladder Units 1 and 2 Interim Bearing Repair

General:

The bearings on the fish turbine pump 2 are in a progressive failure state. Efforts have been implemented by Project personnel to provide a temporary repair which has a lifespan of 6 – 12 months. A more reliable repair is needed. Additionally there is significant wear on the ring/pinion gears and excessive wear on the gearbox roller bearings, with the bull gear/idler gear also showing signs of spalling. This led to an outsider inspector recommended that unit 2 not be operated.

Based on the observed conditions, the scope of this project is to replace the bearings and gearbox, and repair the shaft and impeller for pump 2 at John Day Dam.

Statement of Work:

Rehabilitate John Day South fish turbine gearboxes and restore pumps to full operational capacity for 2. This will include removing and replacing damaged bearings and the gearbox. The pump shaft will be re-balanced to meet manufacturer spec and partially replaced to support the replacement of the bearings and sleeves.

Prior work on fish pump No.3 included replacement of the lower pump shaft, true-up machining of the upper pump shaft, true-up machining of the upper and lower bearing mounting flanges and spigot bores on the cover plate and diffuser, and true-up machining of the diffuser extension cone. The upper and lower bearings were fitted with greaseless bearing liners and the shafts existing stainless bearing journals were replaced with spares originally manufactured by Worthington Pump. Work will be replicated for pump No.2 as listed above.

The work to be performed under this contract includes the following tasks:

1. Provision of the labor, plant, equipment, and materials to procure, deliver, and install one right-angle drive fishwater pump gearbox to John Day Dam.

2. Provision of labor, equipment, and materials to replace the shafts, bearings, and bearing brackets on the pump.

a. Replacement of lower pump shaft

b. True-up machining of upper pump shaft.

c. True-up machining of upper and lower bearing mounting flanges and spigot bores on the cover plate and diffuser.

d. True-up machining of the diffuser extension cone.

e. The upper and lower bearings are to be fitted with greaseless bearing liners

f. The shafts existing stainless bearing journals shall be replaced.

3. Provide new Operation and Maintenance manuals, general layout drawings, for the replaced gearbox.

4. Provide gearbox lube system spare parts (one each complete).

5. The contract includes requirements for the following: Provide gear design calculations and gearbox detail drawings.

6. The work consists of off-site steel and composite fabrication as part of the new gearbox fabrication and new pump-shaft machining, on-site installation of mechanical components, on-site installation of new pump shaft, bearings and bearing brackets, and other items defined in the Contract Documents.

The general work sequence to accomplish the above contracted tasks is as follows:

1. Remove input shaft coupling guard.

2. Disconnect the input and output shaft of the gearbox.

3. Ensure pump shaft is supported while it’s disconnected from gearbox.

4. Remove all the oil lube piping from gearbox.

5. Remove old gearbox from site.

6. Lower pump into the draft tube and properly support.

7. Disconnect pump shaft from pump at key connection

8. Hoist out shaft assembly cutting lower pump shaft and sleeves as required.

9. Complete all machining and replacement work for bearings and sleeves and true shaft components including new lower shaft installation

10. Reinstall pump assembly.

11. Install new gearbox.

12. Reconnect input and output shafts

13. Install coupling guard

14. Align pump system by aligning turbine with gearbox and aligning gearbox with pump. Alignment must be done to manufacturer specs.

15. Balance the entire system.

16. Perform a pre-test inspection and ensure gearbox meets all design requirements.

17. Perform final test prior to returning pump to project.

The general project path of work is as follows:

1. Submittals for new pump shafts, gear box, and bearings are submitted

2. New components are ordered after submittals are approved.

3. Contractor mobilizes on site.

4. Contractor removes Unit 2 Gearbox, shaft and bearings.

5. Contractor installs new shaft and bearings

6. Contractor installs new Unit 2 gearbox.

7. Contractor tests completed install.

8. Contractor demobilizes.

Schedule – PRELIMINARY & PROJECTED This preliminary schedule will change however, it is anticipated that the Contractor will have the following work windows to shut down the Units to perform the on-site Work:

· Unit No. 2: 1 DEC 2026 – 26 NOV 2027