Statement of Work_1.pdf

STATEMENT OF WORK

TRINITY UNIT 2 SERVOMOTOR REHABILITATION

PART 1 GENERAL

1.01 BACKGROUND

The Northern California Area Office (NCAO) has a requirement to refurbish two servomotors located at the Trinity Powerhouse located approximately 35 miles northwest of Redding, California in Trinity County.

1.02 OBJECTIVE

The contractor shall complete all work necessary to refurbish the two servomotors, meeting or exceeding the operating characteristics of the original servomotors.

1.03 TYPE OF CONTRACT

The contract will be firm fixed price.

1.04 MEASUREMENT AND PAYMENT

Lump sum payment will be made on acceptance of repair work by the Contracting Officer’s Representative (COR).

1.05 TRANSPORTATION

A. The contractor shall ensure that all materials, products and components required for the execution of the work, regardless of origin, be: properly handled to prevent damage; cared for while in storage; and adequately protected while in transit to their intermediate and final destination. When applicable, follow manufacturer’s instructions for the storage, handling and transportation of materials. Items received by the Government that appear to be damaged due to improper handling, storage or transportation are to be replaced at Contractor’s expense.

B. The contractor shall include all shipping and handling costs in their price. The contractor will contract the COR at least one week prior to delivery to arrange a delivery date and time. The servomotors will be shipped together to minimize shipping costs.

C. SHIPPING ADDRESS:

Northern California Area Office Bureau of Reclamation 16349 Shasta Dam Blvd Shasta Lake, CA 96019

ATTN: Ryan Hennigan Phone: 530-247-8606 Email: rhennigan@usbr.gov

*PLEASE NOTE: If award is made to a contractor located within 200 miles of Shasta, California, then Reclamation will be responsible for delivery of the servomotors to the contractor’s facility and back to Reclamation.

1.06 DESCRIPTION OF EQUIPMENT

Two servomotors. Original servomotor stroke: 11.0 inches. Original servomotor stroke: 11.0 inches. Working oil pressure: 270 psi to 300 psi.

1.07 REFERENCE STANDARDS

American Society of Mechanical Engineers (ASME)

ASME B 4.1 Preferred Limits and Fits for Cylindrical Parts ASME BPVC-V Boiler and Pressure Vessel Code - Section V -

Nondestructive Examination ASME BPVC-IX Boiler and Pressure Vessel Code – Section IX –

Welding and Brazing Qualifications ASTM International (ASTM)

ASTM A 159 Standard Specification for Automotive Gray Iron Castings

ASTM B 271 Copper-Base Alloy Centrifugal Casting

International Organization of Standards (ISO) ISO 68 Hydraulic Oil

1.08 QUALIFICATIONS

The contractor shall specialize in manufacturing or repairing products specified in this section. The contractor shall certify compliance with all applicable standards.

PART 2 TECHNICAL REQUIREMENTS

2.01 ITEMS

The contractor shall provide new piston rings, bushing, seals, and packing.

2.02 MATERIALS

a. Packing: Chevron Garlock 431, or equal.

b. Piston Ring: Cast Iron, step seal cut, ASTM A 159, G3000.

c. Piston Rod Bushing: ASTM B 271, UNC C93200.

d. Oil type: ISO 68 Hydraulic Oil.

PART 3 EXECUTION

3.01 REFURBISHMENT

A. See OEM Drawing Nos.:

1. R651/128 Sheets 1 and 2 – Arrangement of W.G. Servomotor

2. R651/2763 – Servo Cylinders

3. R652/2763 – Wicket Gate Servo Piston

4. 416-MD-35-103 – Servomotor End Cover Details

5. 416-MD-35-106 – Servo Bearing Housing Plan

6. 416-MD-35-107 – Wicket Gate Servo Piston

B. Cylinder (Drawing Nos. R.652/2763):

1. Clean and inspect for discrepancies with drawings tolerances.

2. Machine to remove piston ring wear.

a. Bore cylinder to 2 foot 4.000 inches ±0.003 inches

b. Hone cylinder bore to obtain final finish

C. Piston (Drawing No. 416-MD-35-107):

1. Clean and inspect for discrepancies with drawing tolerances.

2. Inspect piston bore, if out of tolerance, machine to insert sleeve using same material with interference fit. Finish as per drawing to 125 micro-inch.

3. Clean and inspect grooves for piston rings.

a. If out of tolerance, machine to restore square shoulders and finish as per OEM drawings with COR approval.

4. Fit piston with three new piston rings (Item 9), oversize rings as may be required.

D. New Internal Piston Rod Bushings (Drawing No. R651/128):

1. Install new aluminum bronze piston rod bushings.

a. Fit and finish to be to OEM drawing requirements, unless otherwise specified.

E. New Piston Rings (Drawing No. 416-MD-35-107):

1. Appropriately sized for the final machined cylinder diameter.

2. Suited for bidirectional sealing, flow and intermittent movement.

3. Surface finish 16 micro-inches, or better.

4. Install so the ring joints are equally offset circumferentially.

3.02 SERVOMOTOR ASSEMBLY

A. Reassemble with new gaskets, hardware, plugs, fittings, and globe valves.

3.03 SHOP TESTING

A. Hydrostatic test as noted on OEM Drawing No. R652/2763 using pre-heated ISO 68

Hydraulic Oil.

B. Record all pressures, time duration, and leakage point and rates for the servomotor testing.

C. Leak test:

1. Pressurize to 450 psi.

a. Maintain pressure long enough to calculate an accurate flowrate through the piston rings.

b. Perform on servomotors in both open and closed positions.

1) Piston and rod fully extended and retracted.

2. Internal leakage:

a. Record the internal leakage.

3. External leakage:

a. No leakage is allowed.

b. Verify there is no leakage through the packing, head gasket, plug, check valve and any other ports or mating surfaces on the servomotor.

D. Stroke:

1. Measure the full available servomotor stroke; piston movement from fully open to fully closed positions.

2. Record position of stroke limiter.

E. Servomotor Operational Check:

1. Open and close under normal operating pressure of 300 psi, repeat for 10 operations.

Observe and document operation of piston travel, operation of cushioning valves, check for leaks, adjust packing follower as necessary.

PART 3 WARRANTY

All materials and workmanship shall be warranted for a period of one year from completion of work.

PART 4 PLACE OF PERFORMANCE

All work shall be performed at the contractor’s facility.