Synopsis_JDA Fish Pump 25R00007.pdf

JDA Fish Pumps Emergency Repair Project South Fish Ladder

Units 1 and 2 Interim Bearing Repair

General:

The bearings on Units 1 and 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.

The scope of this project is to provide long-term repairs to the bearings and gearboxes on Pump units 1 and 2 at John Day Dam, including brand-name utilization of parts and service labor by Philadelphia Gear (a Timken company). To accomplish this scope of work, a spare gearbox will also be rebuilt be on-site mobilization begins. Any General Contractor offering on this work will have to demonstrate an in-place agreement with Philadelphia Gear to utilize them as a subcontractor providing parts and services for the off-site rebuild of the three gearboxes that will be rebuilt within the scope of this project.

Design statement:

Generate specifications and informational drawings to rehabilitate John Day South fish turbine gearboxes and restore pumps to full operational capacity for Units 1 and 2. This will include removing and replacing damaged bearings and other failed components as needed. The entire pump system will be realigned to meet manufacturer specs. The gearbox refurbishment will be staggered to minimize pump downtime and begin with the spare gearbox. The newly refurbished spare gearbox will be installed into pump No.2. The work will then be repeated until the pump No.1 gearbox is refurbished and becomes the new spare gearbox.

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 propeller itself had its blade tips built up with weld and re-machined a proper clearance (nominally 1/8" radial clearance) to the pit liner. In addition, the propeller center bores were true-up machined for proper fit (0.004-0.006" clearance) to the new lower shaft. 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.1 and pump No.2. Work on pump No.2 will be performed first, during gearbox removal. The work will then be repeated for pump No.1.

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

1. Provision of the labor, plant, equipment, and materials to transport, disassemble, inspect, design, refurbish and upgrade, reassemble, and test three fishwater pump right angle drive gearboxes from John Day Dam. This includes:

a. Fish Pump No.1 Gearbox

b. Fish Pump No.2 Gearbox

c. Spare Gearbox

d. The Contractor shall package, load, and ship the spare gearbox to their facility no later than 14 calendar days after the contract award date. The Contractor shall schedule the loading date and time with John Day Dam project personnel. Further guidance on shipping will be provided in the contract. The destination will be determined by Philadelphia Gear, the brand name supply of parts and services for the gearbox rebuilds.

e. Schedule for sequential replacement of Pump No.2 Gearbox with the Spare Gearbox and then Pump No.1 Gearbox with the rebuilt Pump No.2 Gearbox will then be submitted by the contractor.

f. Pump No.1 original gearbox shall then be rebuilt as the new spare.

2. Provision of labor, equipment, and materials to replace the shafts, bearings, and bearing brackets on the Pump 1 and Pump 2.

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, and spare parts for the refurbished and upgraded gearboxes.

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 gear-box rebuilds, on-site installation of mechanical components, including a rebuilt turbine gearbox to be furnished by the Government, 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. Take as found measurements and readings.

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

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

5. Remove all the oil lube piping from gearbox.

6. Tear down gearbox.

7. Clean and inspect components.

8. Record all the findings during part inspection

9. Replace damaged gearbox components.

10. Clean and inspect entire gearbox prior to reassembly.

11. Reassemble gearbox.

12. Perform checks on gearbox internal components, such as tooth contact, backlash, bearing settings and lubrication system.

13. Replace input and output shaft bushings

14. Reconnect input and output shafts

15. Install coupling guard

16. Align pump system by aligning turbine with gearbox and aligning gearbox with pump.

Alignment must be done to manufacturer specs.

17. Balance the entire system.

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

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

The general project path of work is as follows:

1. Ship out spare gearbox for rebuild (work begins immediately without the need for submittals to be approved in advance).

2. Spare gearbox is rebuilt.

3. Submittals for new pump shafts and bearings are submitted

4. New pump shafts and bearings are ordered after submittals are approved.

5. Spare gearbox is shipped back to ODJ site.

6. Contractor mobilizes on site.

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

8. Contractor ships Unit 2 Gearbox for rebuild.

9. Contractor installs new shaft and bearings

10. Contractor installs Spare Gearbox as new Unit 2 Gearbox.

11. Contractor tests completed install.

12. Contractor demobilizes.

13. ODJ staff deconstructs break room to clear space for contractor operations.

14. Contractor ships rebuilt old Unit 2 Gearbox back to ODJ site.

15. Contractor remobilizes.

16. Contractor removes Unit 1 gearbox, pump shaft and bearings.

17. Contractor ships Unit 1 gearbox for rebuilding into spare gearbox.

18. Contractor installs new pump shaft and bearings.

19. Contractor installs old Unit 2 Gearbox as new Unit 1 Gearbox.

20. Contractor tests completed install.

21. Old Unit 1 Gearbox is shipped back to ODJ site after rebuild to be stored as new Spare

Gearbox.

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: 9 JAN 2026 – 5 May 2026

• Unit No. 1: 31 AUG 2026 – 24 DEC 2026