Specification_Drawings_-Automatic_Greasing_System.pdf

Specification for Automatic Greasing Systems for

Elephant Butte Power Plant Wicket Gate

Table of Contents

I. BACKGROUND

II. SCOPE

III. DRAWINGS

IV. DESCRIPTION OF TURBINES

V. EB AUTOMATIC GREASING SYSTEM SUPPLY REQUIREMENTS

1. MECHANICAL SUPPLY

2. ELECTRICAL SUPPLY

3. CONTROLS SUPPLY

VI. DESIGN REQUIREMENTS

VII. ALTERNATIVE DESIGN

1. OVERALL DESIGN ALTERNATIVE

2. INDIVIDUAL COMPONENT ALTERNATIVE DESIGNS

VIII. INFORMATION

1. WARRANTY

2. OPERATION AND MAINTENANCE INFORMATION

IX. REQUIRED SUBMITTALS AFTER AWARD

X. AS-BUILT DRAWINGS AND DATA

XI. EB AUTOMATIC GREASING SYSTEM INSTALLATION REQUIREMENTS

1. SYSTEM INSTALL REQUIREMENTS

XII. COMMISSIONING PLAN

XIII. PROJECT CONDITIONS

XIV. SAFETY AND HEALTH

1. REFERENCES

2. SAFETY AND HEALTH REQUIREMENTS

XV. QUALITY ASSURANCE

XVI. REQUIRED QUOTE SUBMITTALS

XVII. PHOTOS OF PROJECT AREA

I. BACKGROUND

The Bureau of Reclamation - Elephant Butte Field Division (EBFD) Powerplant was constructed in 1939 and is located at 4696 Hwy 51, Truth or Consequences, New Mexico. EBFD has a need for an automatic greasing system with install for three hydropower generation units. The original greasing system was planned, designed, and specified for the original construction of the powerplant, then installed, and then removed throughout the past. The present grease system consists of an air-operated grease pump connected to a common header running to each turbine pit.

II. SCOPE

Furnishing, installing and testing three (3) new turbine wicket gate dual-line automatic greasing systems with 110 points per unit for a total of 330 greasing points. Each unit has greasing points separated into two distinct greasing requirements, one set of points provide grease for underwater and will be set to a once-weekly greasing frequency, and the rest will be set to a once-monthly frequency. The electrical power required for the installation will need to be supplied from an existing electrical panel by the installer. The installation schedule of the new greasing systems will be restricted to EBFD’s maintenance season dates of October 15 through February 15.

III. DRAWINGS

Drawings included in this specification are for information only to show features of existing powerplants, layouts of a different previous greasing system, electrical panel locations, and desired installation locations for the new automatic greasing system equipment.

Drawings of the Contractor installed system shall be delivered to EBFD prior to final payment.

These drawings shall include Installation Layout, Electrical Schematic, Electrical Wiring, Control Logic and Wiring, and drawings of all installed equipment. The drawings shall be delivered in electronic “.dwg” file format to the Contracting Officer.

IV. DESCRIPTION OF TURBINES

Each of the three turbines in the Elephant Butte Powerplant is a vertical-shaft, single-runner, Francis type. The turbines are rated at 11,500 horsepower with a head of 140 feet. Each turbine is controlled by two oil-actuated servomotors connected by an inside gate ring, linkage, and connecting rods to 16 wicket gates. The general arrangement of the powerplant at the turbine level, which shows the relative location of the turbines and auxiliary equipment, is shown on

Drawings No. 24-D-174, 24-D-176, and 24-D-177.

The two distinct greasing schedules are currently on a weekly and monthly basis and are segregated by bearing location, underwater or above water line.

The turbines only run a few months out of the year, so the ability to disable the greasing system will be critical during maintenance seasons.

V. EB AUTOMATIC GREASING SYSTEM SUPPLY REQUIREMENTS

1. MECHANICAL SUPPLY

The Contractor shall furnish and install three (3) automatic greasing systems for all three wicket gates assemblies complete with all required control systems, supply lines, connectors, and any required accessories. The system supplied shall be capable of supplying grease to the underwater set of grease points. The controls systems shall be compatible with the controls supply and electrical supplies and shall meet the design specifications in the next section, Design

Requirements.

2. ELECTRICAL SUPPLY

The Contractor shall supply the electrical cabling required to supply 230VAC to each of the new automatic greasing systems, required electrical breakers, electrical disconnect at each greasing system, and properly rated electrical power cabling, breakers, and electrical connection accessories. The electrical supply shall meet the requirements of the automatic greasing system’s electrical needs. The electrical system supply shall be compatible with the mechanical supply and controls supplies and shall meet the design specifications in the next section, Design

Requirements.

3. CONTROLS SUPPLY

The Contractor shall supply the control system for the automatic greasing system according to the design specifications and the needs of the installation. The controls supply shall be able to support greasing on a frequency of once-weekly for one set of bearings, and to the rest on a once-monthly frequency. The controls systems shall be compatible with the mechanical supply and electrical supplies and shall meet the design specifications in the next section, Design

Requirements.

VI. DESIGN REQUIREMENTS

i. Lubrication Points

A. The contractor shall be responsible to replace the lubrication points, as necessary, to ensure that the new system fits the existing grease points.

B. The number of lubrication points and type and size of connections are shown on Drawing

No. 24-508-1119.

C. The total number of lubrication points is 110 per unit, for 330 total points for all three units.

D. The underwater lubrication points are 32 per unit, for 96 total underwater lubrication points for all three units.

E. Tap size is ¼, per drawing 24-508-1119.

F. 1 tap per bearing

ii. Grease A. The new greasing system shall be compatible with VSG brand ‘Green’ Wicket Gate

Grease, Canoil Canada, Ltd. This is the grease currently in use at EBFD powerplant because of its biodegradable properties.

B. The Contractor shall supply and apply first fill of all new automatic greasing system grease reservoirs with the same grease.

iii. Lubricating System, General The contractor shall provide equipment with the following specifications:

A. Electrical control equipment required for the automatic operation of the system with

Auto-Hand-Off function modes at minimum.

B. The Contractor shall work onsite with staff to calibrate and ensure that the greasing system is set optimally for minimizing waste of grease through the bearings.

a. Programming of the Control Equipment to meet the greasing requirements of the bearings weekly and monthly equivalence to current manual greasing practices.

The Contractor shall work with EBFD craft mechanic and COR to ensure the control system is tuned so that equipment is being greased sufficiently and not excessively.

b. The contractor shall receive written approval from the COR that the control system is providing adequate lubrication for each unit (see Commissioning Plan).

C. Terminal strip with output signal indications of:

a. Alarm signal outputs for malfunctions of the system,

b. Run/Stop status output for each manifold system,

c. Power status of each system

D. Greasing fittings that fit existing grease points, E. Grease station consisting of pump, reservoir, and motor, F. Mounting hardware for installation of grease station, control equipment, grease line installations, and auxiliary equipment.

G. Manually operated shutoff valves on each generator system capable of isolating pressures for the safe maintenance of each unit’s greasing system, H. Manually operated power disconnectscapable of isolating electrical energy for the safe maintenance of the greasing system, I. Check valves to ensure backflow is not allowed in the system, J. Lubricant measuring or indication for the proper control of flow and volume of grease, K. Indication of flow and volume of grease for each system

L. Any special piping fittings needed to connect the furnished equipment and to any existing equipment being utilized.

M. Any piping and flexible hose required for the system installation

N. Any special pipe fittings such as tee blocks, swivels, or manifold blocks

iv. Functional requirements A. All functions necessary for the operation of the system shall be performed automatically.

B. Shutoff valves shall be provided in the supply lines entering a turbine pit to permit isolating that turbine from the system during extended shutdown periods or for maintenance. A shutoff valve terminates the existing header in each turbine pit. The shutoff valve shall be manually operated.

C. All components shall be designed to withstand the maximum pressure output of the pump.

D. Flexible lengths of piping shall be required to ensure that constant movement of the wicket gate, shaft, and collar assembly does not negatively impact the greasing system function, connections, or components.

v. Control Timing A. The control system shall provide fully automatic control of greasing timing. The timing devices shall permit adjustment of the interval between lubrication of bearings as follows:

i. Bearings subject to water pressure, once a week frequency, with variation of at least ± 3 days.

ii. All other bearings, once a month frequency, with variation of at least ± 7 days.

vi. Control Interface B. A 3-way selector switch, with Hand-Off-Automatic selector and a method for manual activation in Hand mode, shall also be provided to permit manual operation of the system for each of the groups of bearings listed above, and for deenergizing the entire system with the Off selector.

C. Indicating lights shall be provided to show that the system for each group of bearings is operating, and to indicate abnormal conditions in the system, including failure of the grease pumping unit to deliver grease and for over-pressure in the system, which will send an alarm signal, for each unit. Snap action contacts shall be provided for remote indicating lights or annunciators which will be furnished by others.

vii. Components D. The control equipment shall be enclosed in a NEMA rated cabinet suitable for surface mounting, with the indicating lights, selector switch, and pushbuttons mounted on the door of the cabinet. All control circuits shall be 115 volts, single phase, 60 Hz. The remote alarm circuit will operate on 125 volts direct current. All wiring within the cabinet shall be completed by the contractor and shall be terminated at terminal blocks with marking strips and correspond to the wiring drawings provided by the contractor.

E. AII contactors, relays, transformers, control switches, pushbutton stations, limit switches, and other electrical accessories and equipment shall meet the requirements of the

"National Electrical Code" and shall be in accordance with the latest applicable American

National Standards of the American National Standards Institute. All conduit and all wiring, except wiring for external annunciation upon system alarm for overpressure, selector switch position, and other status, will be furnished by the Contractor.

viii. Connections to existing electrical panels A. The contractor shall be responsible to install the new breakers required for the new automatic greasing systems to existing EBFD electrical panels distribution system.

B. The contractor shall provide materials and labor for the electrical cabling runs from the breaker to the new automatic greasing systems. The runs will be from the Control room

AC panel through wire trays, contractor provided conduit when wiring must leave the existing wire trays, and to each individual unit’s location, see Drawings: 24-D-174_002-

InstallNotes, 24-D-00176_01_02- InstallNotes, 24-D-00177_01_02- InstallNotes, 24-D-

1412- InstallNotes.

C. Connection to the new automatic greasing system design shall also include a manually operated power disconnect capable of isolating electrical energy for the safe maintenance of the greasing system so that a maintenance person can use OSHA approved lockout equipment on the disconnect.

D. Electrical designs shall be according to NEC70E, NFPA, IEEE and all applicable local and state electrical codes.

VII. ALTERNATIVE DESIGN

1. OVERALL DESIGN ALTERNATIVE

A. This specification is for three (3) independent automatic greasing systems. If the

Contractor’s proposed design proposes a different design of greasing system that still meets the dual frequency requirement, grease compatibility, control specifications, other functional requirements, and other pertinent specifications outlined in this document, then the Contractor shall provide evidence of cost savings to the Government for this proposed design. The evidence shall be in the form of a cost comparison and comparative analysis of both design types meeting functional requirements, the independent unit design and the alternative design option.

2. INDIVIDUAL COMPONENT ALTERNATIVE DESIGNS

B. If the Contractor proposes a different design of individual components to the components described in this specification, the Contractor shall provide written explanation of how the design meets or exceeds the performance of the existing specified component design it replaces. This provision is included to allow for alternative or new technologies and designs to be included in this specification. The comparison for any design will be made to the functional and technical specifications written in this document.

VIII. INFORMATION

1. WARRANTY

A. Contractor shall provide manufacturer warranty information on supplied materials and equipment.

B. Contractor shall provide information on warranty for installation labor.

2. OPERATION AND MAINTENANCE INFORMATION

A. Contractor shall provide maintenance information on proper maintenance of the automatic greasing equipment. This is to include procedure on the refilling of greasing supply tank

B. and a manufacturer spare parts list to include manufacturer part numbers.

IX. REQUIRED SUBMITTALS AFTER AWARD

Table 1. Required Submittals

Number Description Date Due Delivered to

1 Schedule, including Outage requests for each unit, Delivery, and Installation

14 days after award Contracting Officer and COR via email

2 Parts List, Lead Times, and

Availability

30 days after award Contracting Officer and COR via email

3 Drawing of Layout of grease systems, controls, piping, and mounting points

30 days prior to installation

Contracting Officer and COR via email

4 Commissioning Plan 14 Days prior to installation

Commissioning.

Contracting Officer and COR via email

5 Commission Results for each unit, total of three (3)

7 days after each

Unit Commissioning

Contracting Officer/

COR via email

6 Warranty 14 days after commissioning and acceptance

Contracting Officer and COR via email

7 Operation and Maintenance information

14 days after commissioning.

Contracting Officer and COR via email

8 As-built drawings in .dwg digital file format

14 days after commissioning.

Contracting Officer and COR via email

Final payment will not be made until all submittals are accepted and approved by CO.

X. AS-BUILT DRAWINGS AND DATA

A. Provide Drawings of Automatic Greasing Systems (in *.dwg digital file format) with separate drawings for each of the Units, including electrical and mechanical systems of as built and installed systems within 14 days of installation and acceptance.

B. A listing of all alarm points shall be provided to EBFD at commissioning.

XI. EB AUTOMATIC GREASING SYSTEM INSTALLATION REQUIREMENTS

1. SYSTEM INSTALL REQUIREMENTS

i. LAYOUT A. The distribution piping of the greasing system shall allow walkway space for maintenance access and egress around the turbine pit. Space is limited for the installation of any equipment in the turbine pit, so EBFD has identified a location outside of the turbine pit for a reservoir and pump/motor unit to be installed, while the piping travels down into the turbine pit through deck plate access, shown in drawings: 24-D-174_002-

InstallNotes, 24-D-00176_01_02- InstallNotes, 24-D-00177_01_02- InstallNotes, 24-D-

1412- InstallNotes. Once the piping reaches the turbine pit, the Contractor shall determine the best way to install and mount the piping into the turbine pit.

B. Tubing and piping shall not inhibit the walkway inside of the turbine pits. Egress in the pit is limited, so we don’t want additional trip hazards from the new automatic greasing system.

C. For piping to be installed against the wall of the turbine pit, some modification may be required on existing deck plate mounts. Any modification of existing structures shall be approved by the COR and follow EBFD Hazardous Energy Control Program and

Operational Change Management Program requirements for any modification work being performed.

ii. INSTALLATION PERMITS A. EBFD has local safety programs and permits to ensure the safety of personnel, the public, and equipment. All permits required will be issued locally. Installation Permits that may be required, depending on the type of work to be performed, are: Drilling Permits, Clearance Permits, Special Work Permits, Hot Work Permits, and Hazardous Energy

Work Permits.

a. Drill Permits are required for any drilling into concrete within the Dam, in any place and at any depth. They are obtainable from the Electrical Engineer at EBFD and must be requested at least one (1) business day prior to start of work.

b. Clearance Permits may be required under the Hazardous Energy Control Program depending on the work being performed. For example, the electrical installation may require a clearance for installing new breakers to power the automatic greasing system controls. The Clearance Permit can be obtained from the

Operation Control Room at EBFD and requires minimum of 1 week from submittal prior to performing work. Training on when a clearance is required and how to request a clearance will be given to the Contractor Representative on the

Facility Hazardous Energy Control Program, the COR can assist in this process.

c. Special Work Permits will be provided by EBFD operations for any contractor work under a Clearance Permit.

d. Hot Work Permits may be required for activities such as welding, grinding, or other spark inducing work outside of hot work purpose-built stations.

e. Hazardous Energy Permits may be required if a hazardous energy source cannot be mitigated, and work must be performed. These must follow approval process by the EBFD Field Division Manager and Operations.

iii. OUTAGES A. Installation shall take place during the maintenance season, between the dates of October

15 and February 15, the following year. The Contractor shall submit a proposed outage schedule to the Government for approval prior to commencing work. The contractor's outage schedule should coincide with the Government’s maintenance schedule as much as possible.

B. The Contractor will be allowed 21 days maximum for each turbine generating unit for installation and testing of the greasing systems.

C. Operation of EBFD equipment and systems by Contractor personnel is not permitted.

D. Contractor safety representative will be responsible for Contractor personnel locking and tagging of equipment in compliance with EBFD Safety Procedures. (See Safety & Health for training requirement)

iv. EXISTING EQUIPMENT AND INSTALLATION Existing equipment includes the manual greasing system piped into all three turbine pits from a single pneumatic pressurized 55-gallon grease drum adjacent to the dam-facing wall of the powerplant. Any existing equipment shall be left in place except where the existing equipment inhibits the installation of the new system, then the Contractor shall meet with the COR to find a solution for the installation. When an agreement cannot be met or if the solution requires a

Change Order, the Government and its Contracting Officer, CO, shall decide the best course of action benefitting the Government.

v. AESTHETICS The priority of the installation is safety and accessibility over aesthetics. However, the aesthetic of the installation shall be considered by the Contractor. The Contractor shall ensure a clean-looking installation. When multiple hoses and lines are run parallel to each other, the contractor shall ensure that they are evenly spaced and parallel. When possible, the installation of the greasing hose runs, connectors, and mounting hardware shall run parallel to circumference of the shift collar and be laid out in a clean, evenly spaced method.

vi. CLEANUP A. The Contractor shall ensure that the workplace is free of excess waste and material before the end of each workday. Walkways, equipment panels, and other government owned equipment shall not be inhibited by the storage or placement of Contract materials and tools.

B. The Contractor shall ensure that all waste and unused materials are removed from the worksite after Installation and Commissioning.

XII. COMMISSIONING PLAN

A. The Contractor shall work onsite with staff to calibrate and ensure that the greasing system is set optimally for minimizing waste of grease through the bearings.

B. The Contractor shall develop a commissioning plan to fully test the automatic greasing system’s greasing capabilities to grease on two separate sets of frequencies (once-weekly and once-monthly) and to demonstrate that effective isolation of greasing system lines can be accomplished with the included valves and control system.

XIII. PROJECT CONDITIONS

A. Normal work hours are Monday through Thursday, except federal holidays, 7:30 a.m. to

4:00 p.m. If the Contractor plans to work outside the regular schedule work hours, a request must be made to the COR for approval 72 hours in advance.

B. The Government has electricity at 120 VAC available for Contractors use. No charge will be made for power obtained from this Government source.

C. The Contractor is responsible to provide any additional needed generators, transmission lines, and distributing power to points of use for additional voltage requirements.

D. Non-potable water is available on-site at no charge to the contractor. The Contractor is responsible to provide any needed equipment to convey the water to needed site.

E. A running-water restroom is available for Contractor use at the EB worksite.

F. No housing for Contractor personnel will be permitted on EB worksite.

G. The contractor shall be responsible for all clean up and for disposal of waste materials or rubbish from transportation and installation of the greasing supply and installation.

H. Contractor cannot dispose of project waste in Reclamation dumpster.

I. The disposal of waste materials and rubbish shall be in accordance with this paragraph and all applicable Federal, State, and local regulations, standards, codes, and laws.

J. The requirements contained in the Reclamation Safety and Health Standards (RSHS, 2024 Edition, see Safety and Health section for references) are applicable to clean up and to dispose waste materials and rubbish. If there is a conflict between the requirements contained in this paragraph, the RSHS, and other Federal, State, or local regulations, standards, codes, and laws, the more stringent requirements shall prevail.

K. Any damage caused to the existing site or equipment due to Contractor’s use of premises or installation of the greasing systems shall be repaired by the Contractor, at the expense of the Contractor, to the existing condition prior to damage. This includes roads, walls, buildings, fences, gates, nearby equipment, and existing powerplant equipment.

XIV. SAFETY AND HEALTH

1. REFERENCES

A. RSHS (Reclamation Safety and Health Standards), 2024 Edition.

a. Available online at: www.usbr.gov/safety/rshs/index.html

B. Hazardous Energy Control Program, FIST 1-1 (Facilities Instructions, Standards, and

Techniques), EBFD Facility Edition.

a. Available from EBFD upon request after award.

C. OSHA (Occupational Safety and Health Administration

a. 29 CFR Part 1910, 1926 available online at: www.osha.gov

2. SAFETY AND HEALTH REQUIREMENTS

A. The Contractor shall take proper safety and health precautions to protect the workers, Government employees, the public and the property of others.

B. The Contractor shall provide a designated Contractor Safety Representative. This person may also serve dual roles as an installation laborer or supervisor but will be the http://www.usbr.gov/safety/rshs/index.html http://www.osha.gov/

Contractor point of contact for safety procedures, including stop-work, clearance placement and removal, and any other safety concerns.

C. For Lockout/Tagout procedures, the Contractor Safety Representative shall receive training on EBFD Hazardous Energy Control procedures. The Contractor Safety

Representative shall be responsible for ensuring the proper compliance, use, and application of lockout procedures amongst Contractor Personnel. EBFD Operations personnel will be available to guide Contractor personnel with proper procedure.

D. The Contractor shall perform safe work procedures in accordance with RSHS Section

1.10

E. The Contractor shall include use of personal protective equipment in accordance with

RSHS Section 1.07

F. The Contractor must develop job hazardous analysis for the installation of the greasing system

G. The Contractor must report any accidents that happen on the jobsite and on EBFD property in accordance with RSHS Section 1.22.

H. The Contractor shall be responsible for ensuring that all contractor personnel and subcontractors comply with the requirements set forth in this specification and all regulatory standards.

I. The Contractor shall comply with all federal, state, and local laws and standards.

XV. QUALITY ASSURANCE

A. The Contractor shall install new greasing system in compliance with, and ensuring subcontractor’s compliance with:

a. Applicable Federal, State, and local laws, orders, regulations, and Water Quality

Standards concerning control and abatement of water pollution; and terms and conditions of applicable manufacturer installation specifications.

b. If conflict occurs between Federal, State, and local laws, regulations, and requirements, the most stringent shall apply.

B. Contractor Violations

a. If noncompliance should occur, immediately (verbally) report noncompliance to the Contracting Officer. Submit specific information within 2 days.

b. Consistent violations of applicable Federal, State, or local laws, orders, regulations, or Water Quality Standards may result in Contracting Officer stopping all site activity until compliance is ensured.

c. Contractor shall not be entitled to extension of time, claim for damage, or additional compensation by reason of such a work stoppage.

d. Corrective measures required to bring safety processes, installation of the greasing system, or performance of systems into compliance shall be at

Contractor’s expense.

XVI. REQUIRED QUOTE SUBMITTALS

Include cost in prices offered in the schedule for other items of work.

Table 2. Required Quote Submittals

Number Description Detail

1 Itemized supply parts List and Prices

Include cut sheets of all supplied equipment and installation materials.

2 Installation and Administration

Prices

Include itemized labor, including

Contractor safety representative and laborers, other personnel, etc.

3 Supply and Delivery Schedule Include lead times for supplied equipment and any equipment on backorder

4 Installation plan and Schedule Include layout design, install, and test estimated duration

5 Warranty Information Include warranty information for

Parts and Installation Labor

Warranty, if any

6 Previous Experience Requirement -

Five (5) wicket gate greasing systems installs

Minimum five (5) Wicket Gate

Greasing systems installation experience. Include Customer phone contacts for each system installed.

XVII. PHOTOS OF PROJECT AREA

Reference photos of installation area. Space is limited in each turbine pit.

Partial view of Unit 2 turbine pit with greasing points.

Closeup of the wicket gate bearing cover and greasing points, from top to bottom: (2) grease points on link; (1) upper wicket gate bearing grease point; (1) underwater packing grease point (lower left); (1) lower wicket gate bearing grease point (bottom).

Left image: (Top to bottom) (1) gray bracket grease point for sleeve, (1) gray link grease point,

(1) shift collar grease point, wicket gate assembly at bottom.

Right image: side view of other grey sleeve and link grease points.

Manual Greasing line, equipment (top, hanging) and black feed line (right)

Existing Manual Greasing Inlet line (pink), shutoff valve, and black grease hose to stay in place.