Draft Turbine Performance 48 13 13.01 26.pdf

John Day Turbine Runner Replacement and Generator Rewind JDATRGR

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.01 26

PROTOTYPE TURBINE DESIGN AND SUPPLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 EXISTING TURBINE

1.3 REHABILITATED TURBINE ASSEMBLY

1.4 REFERENCES

1.5 SUBMITTALS

1.6 DESIGN STRESS REQUIREMENTS

1.6.1 Normal Operating Conditions

1.6.2 Allowable Stresses Under Normal Operating Conditions

1.6.3 Higher Allowable Stresses

1.6.4 Stress and Fatigue Analysis

1.7 ROTATING PARTS ANALYSIS

1.8 THRUST BEARING STRUCTURAL ANALYSIS (Optional)

1.9 PROTOTYPE BLADE OPERATING MECHANISM ANALYSIS

1.10 PROTOTYPE WICKET GATE OPERATING MECHANISM ANALYSIS

1.11 CAVITATION DAMAGE

1.11.1 Cavitation Damage Guarantee

1.11.2 Cavitation Repair

1.12 GEOMETRIC UNIFORMITY AND SIMILARITY

1.12.1 General

1.12.2 Allowable Tolerances

1.12.3 Methodology for Assuring Geometric Similarity

1.12.4 Government Witnessing of Measurements

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT GENERAL

2.2 STEEL AND STAINLESS STEEL CASTINGS

2.2.1 General

2.2.2 Materials

2.2.3 Inspection

2.2.4 Repair of Castings

2.2.5 Final Casting Inspection

2.3 STEEL MATERIALS

2.3.1 Steel Plate Structural

2.3.2 Steel Plate for Low Stress (Non-Structural) Components

2.3.3 Steel Forgings

2.4 STAINLESS STEEL MATERIALS

2.4.1 Handling and Working of Stainless Steel Materials

2.4.2 Martensitic Materials

2.4.3 Austenitic Materials

2.4.4 Turbine Shaft Sleeve Materials

2.4.5 Adjustable Blade Runner Blade Actuating Mechanism Materials

2.4.6 Adjustable Blade Runner Operating Rod Material

2.5 BRONZE AND BRASS MATERIALS

2.6 PIPE AND TUBE

2.6.1 Steel Pipe

2.6.2 Brass Pipe

2.6.3 Copper Pipe

SECTION 48 13 13.01 26 Page 1

2.6.4 Copper Tube

2.6.5 Pipe Threads

2.7 FASTENERS

2.7.1 General

2.7.2 Threads

2.7.3 Bolts

2.7.4 Nuts

2.7.5 Cap and Set Screws

2.7.6 Machine Screws and Nuts

2.7.7 Washers

2.7.8 Corrosion-Resisting Steel Bolts

2.7.9 Corrosion-Resisting Steel Nuts

2.7.10 Brass Bolts and Nuts

2.7.11 Bronze Bolts and Nuts

2.7.12 Head Cover Fasteners

2.7.13 Locking Mechanisms

2.8 MATING SURFACE PACKINGS, O-RING, SEALS, GASKETS, AND SEALANT

2.9 SELF-LUBRICATING BEARING MATERIAL

2.9.1 Acceptable Materials General

2.9.2 Acceptable Self-Lubricating Materials

2.9.3 Acceptable Self-Lubricating Materials for Adjustable Blade Hubs

2.10 STAINLESS STEEL MATING MATERIALS FOR SELF-LUBRICATING BEARINGS

2.10.1 General

2.10.2 Requirements for Wicket Gate Operating Mechanism Pins

2.10.3 Requirements for Blade Operating Mechanism Pins

2.10.4 Requirements for Stainless Plate

2.10.5 Requirements for Weld Overlay

2.10.6 Requirements for Sleeves

2.11 OIL IN WATER DETECTION SYSTEM

2.11.1 Sensor

2.11.2 Transmitter

2.12 WATER IN OIL DETECTION SYSTEM

PART 3 EXECUTION

3.1 DISCHARGE RING DIAMETERS

3.1.1 Adjustable Blade Discharge Ring Diameters

3.1.2 Fixed Blade Discharge Ring Diameters

3.2 INFORMATIONAL REQUIREMENTS

3.2.1 Drawings, Data, Calculations

3.2.2 Installation Instructions/Drawings

3.2.3 Manufacturing Plan and Schedule

3.3 MAJOR COMPONENT FINAL INSPECTIONS

3.4 MEASUREMENTS

3.5 TURBINE RUNNERS

3.5.1 General

3.5.2 Runner Stress and Fatigue Analysis

3.5.3 Runner Hub

3.5.4 Runner Hub Coupling Surface

3.5.5 Runner/Shaft Coupling Fasteners

3.5.6 Runner Discharge Cone

3.5.7 Runner Materials

3.5.8 Surface Finish

3.5.9 Runner Blade-To-Discharge Ring and Blade-To-Hub

Contour/Clearance

3.5.10 Runner Blade Numbering

3.5.11 Runner Mechanical Balance

3.5.12 Runner Blade Maintenance Templates

3.5.13 Finished Runner Shop Inspection

SECTION 48 13 13.01 26 Page 2

3.5.14 Runner Field Assembly

3.6 ADJUSTABLE BLADE TURBINE RUNNERS

3.6.1 Adjustable Blade Runner General

3.6.2 Adjustable Blade Runner Material Combinations and Construction

Techniques

3.6.3 Adjustable Blade Runner Blade Actuating Mechanism

3.6.4 Adjustable Blade Runner Operating Rod

3.6.5 Adjustable Blade Runner Improved and Redundant Sealing

3.6.6 Adjustable Blade Trunnion Seals

3.6.7 Adjustable Blade Runner Drain Valve

3.6.8 Adjustable Blade Angle Marking

3.7 FIXED BLADE TURBINE RUNNERS

3.7.1 Fixed Blade Runner General

3.7.2 Fixed Blade Runner Construction

3.7.3 Fixed Blade Runners Having Removable Blades

3.7.4 Fixed Blade Runners Having Individual Blade-Hub Segments

3.8 TURBINE NAMEPLATE

3.9 SHAFTING AND BLADE SERVOMOTOR FOR UNITS RECEIVING ADJUSTABLE BLADE

RUNNERS

3.9.1 General

3.9.2 New Blade Servomotor Shaft

3.9.3 New Lower Turbine Shaft

3.9.4 Coupling Fasteners

3.9.5 Blade Servomotor Piston, Piston Cap and Fasteners, and Piston

Rings

3.9.6 Blade Operating Rod Guide Bushings

3.9.7 Oil and Water Basin at the Blade Servomotor

3.10 MODIFICATION USING THERMAL PROCESSES

3.11 DISCHARGE RING AND DRAFT TUBE LINER TRANSITION

3.11.1 General

3.11.2 Materials

3.11.3 Discharge Ring Insert for Adjustable Blade Design

3.11.4 Permanent Discharge Ring Section

3.11.5 Replacement Embedded Discharge Ring Section

3.11.6 Permanent Draft Tube Liner Transition Section

3.11.7 Replacement Embedded Draft Tube Liner Transition Section

3.12 BOTTOM RING

3.13 REPLACEMENT HEAD COVERS (OPTIONAL)

3.13.1 General

3.13.2 Replacement Inner Head Cover (Optional)

3.13.3 Replacement Outer Head Cover (Optional)

3.14 TURBINE MAIN SHAFT SEAL AND OIL SUMP

3.15 STAY VANE MODIFICATION COMPONENTS

3.15.1 General

3.15.2 Leading and Trailing Edge Stay Vane Extensions

3.15.3 Stay Vane Modification Components for Alternative Methods

3.16 REPLACEMENT WICKET GATES

3.16.1 General

3.16.2 Material Requirements

3.16.3 Stress Analysis

3.16.4 Requirements for Hydraulic Surfaces (Excluding Vertical

Contact Surfaces and End Faces)

3.16.5 Requirements for Gate Stems

3.16.6 Gate End Faces

3.16.7 Vertical Contacting Surfaces

3.16.8 Wicket Gate Drawings

3.17 TURBINE COMPONENT PIPING

3.18 TURBINE ELECTRICAL WIRING AND EQUIPMENT

3.19 SPARE PARTS

SECTION 48 13 13.01 26 Page 3

3.20 LIFTING AND HANDLING

3.21 OPERATION AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 48 13 13.01 26 Page 4

SECTION 48 13 13.01 26

PROTOTYPE TURBINE DESIGN AND SUPPLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

a. This specification Section contains requirements governing the design and supply of prototype adjustable and fixed blade runners and additional turbine components and assemblies required by the hydraulic turbine designs. Unless otherwise specified, requirements in this Section apply to both adjustable and fixed blade turbines. Requirements governing the refurbishment/modification of existing turbine components and the supply of replacement components not related to the hydraulic design are contained in Section 48 13 13.04 26, EXISTING TURBINE COMPONENT REFURBISHMENT AND REPLACEMENT. Generating unit assembly and disassembly requirements are contained in Section 48 13 13.02 26, DISASSEMBLY AND REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR UNITS.

b. Complete the Discharge Ring Diameter Analyses and begin prototype design for specific components during the first hydraulic design iteration for both adjustable and fixed blade design in accordance with Section 01 33 16.11 26, HYDRAULIC TURBINE DESIGN.

c. Evaluate existing turbine components and systems as to their suitability for use with the adjustable and fixed blade turbine hydraulic design.

1.2 EXISTING TURBINE

The existing John Day turbines are described in Section 01 33 16.11 26

HYDRAULIC TURBINE DESIGN.

1.3 REHABILITATED TURBINE ASSEMBLY

a. The adjustable and fixed blade turbines must interface with existing mechanical, structural, and electrical components to produce a satisfactory operating generating unit. The turbines must not cause the existing generating unit's mechanical, structural, or electrical characteristics to be degraded in any way, unless otherwise specified herein or as approved. Refer to Section 48 13 13.02 26, DISASSEMBLY AND REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR UNITS for testing required to establish existing unit operational characteristics.

b. Evaluate components and structures affected by the Contractor's work, including component replacement or modification, to determine if they are adequate for the intended turbine operation. Any modification or equipment replacements to make these affected components useful and safe must be at the Contractor's expense.

c. The specification Section paragraphs, except for those which specify requirements for spare parts, special tools/equipment, lifting/handling devices, and manuals, prescribe the minimum requirements for one turbine. However, the requirements also apply to all turbines included under the Contract. Similar parts of the turbines must be of the same materials and workmanship and must be interchangeable.

SECTION 48 13 13.01 26 Page 5

d. Design Contractor supplied components for entrance into John Day Powerhouse through the 14 feet wide by 18 feet high assembly bay door.

1.4 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B1.1 (2019) Unified Inch Screw Thread (UN and UNR Thread Form)

ANSI B1.20.1 (2018) Pipe Threads, General Purpose

ANSI B18.2.1 (1990) Square and Hex Bolts and Screws (Inch Series) Including Hex Cap Screws and Lag Screws

ANSI B18.2.2 (2012) Square and Hex Nuts

ANSI B18.3 (2012) Socket Cap Shoulder, and Set Screws (Inch Series) Including Dimensions of Hexagon and Spline and Keys to Match

ANSI B18.6.2 (2020) Slotted Head Cap Screws, Square Head Set Screws, and Slotted Headless Set Screws

ANSI B18.6.3 (2013) Machine Screws and Machine Screw Nuts

ANSI B18.22.1 (2009) Plain Washers (R 1990)

ASTM INTERNATIONAL (ASTM)

ASTM A27/A27M (2020) Standard Specification for Steel Castings, Carbon, for General Application

ASTM A48/A48M (2003; R 2021) Standard Specification for Gray Iron Castings

ASTM A53/A53M (2022) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A148/A148M (2020; E 2020) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A176 (1999; R 2004) Stainless and Heat-Resisting Chromium Steel Plate, Sheet, and Strip

ASTM A182/A182M (2023) Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe

SECTION 48 13 13.01 26 Page 6

Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193/A193M (2023) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2023) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A216/A216M (2021) Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service

ASTM A240/A240M (2023) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A283/A283M (2013) Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates

ASTM A285/A285M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-Tensile Strength

ASTM A307 (2021) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

ASTM A350/A350M (2023) Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components

ASTM A380/A380M (2017) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A434 (2006) Standard Specification for Steel Bars, Alloy, Hot-Wrought or Cold-Finished, Quenched and Tempered

ASTM A487/A487M (2021) Standard Specification for Steel Castings Suitable for Pressure Service

ASTM A479/A479M (2023a) Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels

ASTM A516/A516M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate-and Lower-Temperature Service

ASTM A564/A564M (2019) Standard Specification for

SECTION 48 13 13.01 26 Page 7

Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A609/A609M (2012; R 2018) Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof

ASTM A668/A668M (2023) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM A693 (2013) Standard Specification for Precipitation-Hardening Stainless and Heat-Resisting Steel Plate, Sheet, and Strip

ASTM A705/A705M (2023) Standard Specification for Age-Hardening Stainless Steel Forgings

ASTM A743/A743M (2021) Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application

ASTM A747/A747M (2004) Standard Specification for Steel Castings, Stainless, Precipitation Hardening

ASTM A781/A781M (2004) Standard Specification for Castings, Steel and Alloy, Common Requirements, for General Industrial Use

ASTM B22 (2002) Bronze Castings for Bridges and Turntables

ASTM B42 (2020) Standard Specification for Seamless Copper Pipe, Standard Sizes

ASTM B43 (2020) Standard Specification for Seamless Red Brass Pipe, Standard Sizes

ASTM B88 (2022) Standard Specification for Seamless Copper Water Tube

ASTM B98/B98M (2013) Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes

ASTM B171/B171M (2012) Standard Specification for Copper-Alloy Plate and Sheet for Pressure Vessels, Condensers and Heat Exchangers

ASTM B271/B271M (2015) Standard Specification for Copper-Base Alloy Centrifugal Castings

ASTM B584 (2022) Standard Specification for Copper Alloy Sand Castings for General Applications

SECTION 48 13 13.01 26 Page 8

ASTM D1193-06 (2018) Standard Specification for Reagent Water

AMERICAN WELDING SOCIETY (AWS)

AWS A5.4/A5.4M (2012; R 2022) Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding

AWS A5.7/A5.7M (R2017) Specification for Copper and Copper - Alloy Bare Welding Rods and Electrodes

AWS A5.9/A5.9M (2022) Welding Consumables-Wire Electrodes, Strip Electrodes, Wires, and Rods for Arc Welding of Stainless and Heat Resisting Steels- Classification

AWS A5.22/A5.22M (2012) Specification for Stainless Steel Flux Cored and Metal Cored Welding Electrodes and Rods

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPVC SEC VIII (2010) Boiler and Pressure Vessel Codes:

Section VIII Rules for Construction of Pressure Vessel

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60193 (2019) Hydraulic Turbines, Storage Pumps and Pump Turbines - Model Acceptance Tests

IEC 60609 (1978) Cavitation Pitting Evaluation in Hydraulic Turbines, Storage Pumps and Pump-Turbines First Edition

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 810 (2015) Hydraulic Turbine and Generator Shaft Couplings and Shaft Runout Tolerances

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 21940-11 (2016) Mechanical vibration -- Rotor balancing -- Part 11: Procedures and Tolerances for Rotors with Rigid Behavior

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2024) Safety -- Safety and Health Requirements Manual

Comply with the current edition and all changes posted on the web as of the effective date of this solicitation.

SECTION 48 13 13.01 26 Page 9

NATIONAL ASSOCIATION OF ARCHITECTURAL METAL MANUFACTURERS (NAAMM)

NAAMM MBG 532 (2019) Heavy Duty Metal Bar Grating Manual

1.5 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. An "A" designation identifies separate submittals are required for each main unit.

Submit the following in accordance with Section 01 33 00, SUBMITTAL

PROCEDURES.

SD-02 Shop Drawings

Drawings, Data, and Calculations; G

Additional Drawings, Design Data, and Calculations; G

SD-05 Design Data

Deviations in Material Specifications; G

Bottom Ring Evaluation Report; G

SD-06 Test Reports

Stress Analysis Reports; G

Rotating Parts Analysis Reports; G

Thrust Bearing Structural Analysis Reports; G

Prototype Blade Operating Mechanism Analysis Report; G

Prototype Wicket Gate Operating Mechanism Analysis Reports; G

Contractor's Internal Quality, NDT, and Dimensional Inspection Reports; G

Preliminary Runner Inspection Report; G, A

Final Runner Shop Inspection Report; G, A

Component Final Inspection Reports; G, A

Preliminary Casting Inspection Report; G, A

Final Casting Inspection Reports; G, A

Final Forging Inspection Report; G, A

Filled Water Quality Report G, A

SD-07 Certificates

Major Defect Notifications; G

Self-Lubricating Bearing Certification; G

SECTION 48 13 13.01 26 Page 10

Notification of Final Casting Inspection; A

Notification of Final Forging Inspection; A

Notification of Repeat Final Casting NDT Inspection; A

Notice of Finished Runner Inspection; A

SD-08 Manufacturer's Instructions

Method and Procedure for Determining the Volume of Cavitation Damage; G

Cavitation Repair Plan; G

Homology Checking Procedure; G

Material Defect Repair Procedures; G

Installation Instructions/Drawings; G

Runner Assembly Instructions/Drawings; G

Manufacturing Plan and Schedule; G

1.6 DESIGN STRESS REQUIREMENTS

1.6.1 Normal Operating Conditions

For the determination of stresses, the following is considered normal operating conditions:

a. Operation at 93 to 107 feet of head at power outputs between the minimum and maximum values defined in Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN Table 1 for adjustable blade turbine designs and Table 2 for fixed blade designs.

b. Governor pressure of 550 psi.

1.6.2 Allowable Stresses Under Normal Operating Conditions

a. The allowable stresses (S) in tension and compression for parts of the turbine under normal operating conditions are the values listed below:

(1) Cast iron: 2,000 psi tension and 10,000 psi compression.

(2) Carbon steel, stainless-steel, & other ductile materials: 20 percent of ultimate strength or 33 percent of yield strength, whichever is more limiting.

(3) Major connections: Preload fasteners used in major connections to 60 percent of the materials yield strength, unless the Contractor provides calculations that demonstrate otherwise.

(4) Self-lubricating bushings and bearing plate: 20 percent of ultimate strength or 33 percent of yield strength, whichever is more limiting.

SECTION 48 13 13.01 26 Page 11

(5) Bearings, bushings, and bearing plate made from ASTM B271/B271M, UNS No. 93700: 3,500 psi.

(6) Bearings, bushings, and bearing plate made from ASTM B271/B271M, UNS No. 93200: 5,400 psi.

(7) Bearings, bushings, and bearing plate made from Contractor selected bronze: 20 percent of ultimate strength or 33 percent of yield strength, whichever is more limiting.

b. The unit stress for ductile materials is defined as the combined stress calculated for a triaxial stress state using the three principal stresses. Calculate the combined stress using the distortion-energy (von Mises-Hencky) theory.

c. Use appropriate safety factors throughout the design, especially in the design of all parts subject to alternating stresses or shock.

d. For the adjustable blade turbine runner hub blade actuating mechanism components, the maximum design pressure on self-lubricating bushings and bearing plates, as defined by the force divided by the area (projected area for a bushing- bushing diameter multiplied by the contact length), must not exceed 6,000 psi for the blade trunnion bushings and 7,400 psi for all other components. The maximum design pressure must be calculated based on the force applied to each component associated with the maximum blade torque required to change the blade angle.

1.6.3 Higher Allowable Stresses

Higher allowable stresses (1.5*S) than those permitted above, but not exceeding two thirds of the yield strength, will be permitted for the following parts and conditions:

a. For all affected parts of the turbine when operating at maximum runaway speed under conditions of maximum head with the wicket gates at the maximum runaway position and no load on the generator.

b. For all affected parts of the turbine during assembly/disassembly.

c. For wicket gates, gate stems, and gate operating mechanism at the breaking point of the shear pin.

d. For major fasteners.

e. For load rejection from the maximum turbine output defined in Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN Table 1 for adjustable blade turbine designs and Table 2 for fixed blade designs, at 107 feet head with the wicket gates timed to move a full closing stroke in nine seconds, as originally designed.

1.6.4 Stress and Fatigue Analysis

Perform stress analyses and submit Stress Analysis Reports for all Contractor supplied components. Include nominal and maximum stresses and deformations in the results.

a. For adjustable blade turbine runners, stay ring/vane assemblies, SECTION 48 13 13.01 26 Page 12 wicket gates, discharge rings, and head covers (optional), submit stress analysis reports 120 calendar days following the date of shipments of the first adjustable blade hydraulic design iteration model runner from the Contractor's performance model testing laboratory to ERDC.

b. For fixed blade turbine runners, stay ring/vane assemblies, wicket gates, discharge rings, and head covers (optional), submit stress analysis reports 120 calendar days following the date of shipment of the first fixed blade hydraulic design iteration model runner from the Contractor's performance model testing laboratory to ERDC.

c. Resubmit stress analysis reports for subsequent iteration runners, stay ring/vane assemblies, wicket gates, discharge rings and head covers (optional) 120 calendar days following the date of shipment of that iterations model runner from the performance model testing laboratory to ERDC.

d. Update stress analysis reports submitted during the iterative hydraulic design process to reflect the final component prototype designs and resubmit within 120 calendar days following the date of release for manufacturing of the adjustable or fixed blade turbines.

e. For other components, submit stress analysis reports 120 calendar days following the date of release for manufacturing of the adjustable or fixed blade turbines.

f. Unless required otherwise for a particular component, perform stress analyses for all "normal operating conditions" defined above and assembly/disassembly. For the final designs from which prototypes will be constructed, perform additional calculations at 109 feet head.

g. For all calculations include a list of significant assumptions made, a list of all codes and standards referenced, and free body diagrams or sketches for each load case.

h. Perform stress analyses using Finite Element Analysis (FEA). The finite element mesh must have sufficient resolution so as to identify regions of localized high stress. When FEA data is submitted it must be accompanied by quality and plausibility checks such as reaction load, mesh convergence, and mesh/discretization error determination. Note any modeled deviations from prototype design with an explanation for why deviation is acceptable. All calculations and FEA must be stamped and signed by a registered professional engineer of any state within the U.S or other Contracting Officer approved location.

i. Where appropriate, evaluate stresses using guidance set forth in ASME BPVC SEC VIII Division 2. Use the specified stress limits (S) set forth in Paragraphs ALLOWABLE STRESSES UNDER NORMAL OPERATING CONDITIONS and HIGHER ALLOWABLE STRESSES for establishing allowable primary general membrane stress across solid section (Pm). Use 1.5*S for allowable primary local membrane plus primary bending (Pl + Pb).

Secondary and peak stresses must be evaluated using methodology outlined in ASME BPVC SEC VIII Division 2 and these specifications.

Stress classification lines (SCLs) must be clearly shown on three-dimensional models and tables/graphs of linearized stress results along each SCL must be provided.

j. For components subject to dynamic loading where alternating stresses

SECTION 48 13 13.01 26 Page 13 are present at local structural or material discontinuities, perform fatigue analysis to evaluate cumulative fatigue damage. Requirements for different materials are as follows:

(1) Non-stainless steel components: Use the fatigue curve shown in Figure 3-F.2 in ASME BPVC SEC VIII Division 2, Annex 3-F. Total cumulative damage must be less than 100 percent.

(2) Stainless steel components (excluding 17-4 PH): Use the fatigue curve shown in Figure 3-F.2 in ASME BPVC SEC VIII Division 2, Annex 3-F. Total cumulative damage must be less than 100 percent.

(3) For 17-4 PH stainless steel components, use the fatigue curve derived from Government corrosion induced fatigue testing of 17-4 PH with 32 Ra surface finish in demineralized water in accordance with ASTM D1193-06 Type IV: Cycles to Failure = 6.87106×10^9 * (Euler's Number) ^ (-0.0283565 * Stress Amplitude). Equation given in MPa. Test data is in Attachment A26 and report can be made available by the Government upon request. Use the coefficients of friction found in Paragraph PROTOTYPE BLADE OPERATING MECHANISM ANALYSIS. Total cumulative damage must be less than 90 percent.

k. Assume the following operation and load cycles for fatigue analysis:

(1) Five million blade regulation adjustments (due to governor adjustments). Assume blade regulations happen at the point of maximum hydraulic thrust across the operating range.

(2) 200,000 load variations (10 MW load change or greater). Assume half of the load variations happen from at the point of maximum hydraulic thrust -10 MW to maximum hydraulic thrust and half of the load variations happen from maximum hydraulic thrust -10 MW to maximum hydraulic thrust -20 MW.

(3) 9,000 start/stop cycles. Assume cycles to and from peak efficiency at gross head with maximum hydraulic thrust.

(4) 100 load rejections.

(5) One runaway event (under worst case condition).

l. Include in the design calculations for steel components that will be embedded in concrete, those for the steel component itself and for the attachment to the concrete, including embedment and anchorage, needed to securely install the metallic component. For steel design, comply with the more restrictive provisions of AISC 325 Manual of Steel Construction or the stress limitations provided in this specification, whichever is more restrictive.

1.7 ROTATING PARTS ANALYSIS

Prepare prototype Rotating Parts Analysis Reports for prototype turbines beginning at the first iteration adjustable and first iteration fixed blade hydraulic designs. Update and resubmit each analysis for each subsequent iteration hydraulic design and for the final designs from which the prototypes are constructed. The analyses must describe the changes to the units vibration and critical speed characteristics. The reports must address (for rated unit speed up to maximum runaway speed) the forcing

SECTION 48 13 13.01 26 Page 14 frequencies, critical speeds, and natural periods of vibration of the combined replacement runner, shafts, and generator parts in bending and in torsion. The reports must be based on calculations using data associated with the existing equipment, the Contractor supplied equipment, and the collaborative developed hydraulic designs. Include investigations of the following in the analyses:

a. Possible sources of forcing frequencies (including but not confined to rated unit speed through maximum runaway speed) including the following sources:

(1) Turbine (runner) type.

(2) Number of turbine runner blades and blade position.

(3) Number of turbine wicket gate and stay vanes.

(4) The redesigned hydraulic components.

(5) Power system natural frequency.

(6) Rheingans vortex phenomenon.

(7) Unit speed.

(8) von Karman trailing edge vortices.

b. Torsional natural frequency including:

(1) No WK² (WR²) contribution by water.

(2) WK² (WR²) contribution of 50 percent of hub water capacity.

c. Flexural natural frequencies assuming both rigid and flexible bearings.

d. Torsional and flexural effects for all normal operating conditions as defined in Paragraph DESIGN STRESS REQUIREMENTS and at the maximum runaway speed determined from performance model testing. For the final designs from which prototypes will be constructed, perform additional calculations at 109 feet head.

e. A stress analysis in the event that forcing frequencies are within 20 percent of the natural frequencies.

f. Shaft deflections including the resulting reduction in blade tip clearance.

g. Submit rotating parts analysis report for adjustable blade turbines 120 calendar days following the date of shipment of the first adjustable blade hydraulic iteration model runner from the Contractor's performance model testing laboratory to ERDC.

h. Submit rotating parts analysis report for fixed blade turbines 120 calendar days following the date of shipment of the first fixed blade hydraulic iteration model runner from the Contractor's performance model testing laboratory to ERDC.

i. Resubmit rotating parts analysis report for each subsequent design

SECTION 48 13 13.01 26 Page 15 iteration 120 calendar days following the date of shipment of that iterations model runner from the performance model testing laboratory to ERDC.

j. Update calculations provided initially during the iterative hydraulic design process to reflect the final adjustable and fixed blade prototype designs and resubmit 120 calendar days following the date of release for manufacturing of the adjustable or fixed blade turbines.

1.8 THRUST BEARING STRUCTURAL ANALYSIS (Optional)

a. If the calculations submitted as part of the model testing report (see Section 01 33 16.13 26, PERFORMANCE MODEL TESTING) for third or subsequent iteration adjustable or fixed blade designs show the existing General Electric thrust bearing capacity to be exceeded, perform a prototype thrust bearing analysis for the bearing design.

General Electric thrust bearing capacities are provided in Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN. Thrust bearing structural analyses must examine each load bearing component (thrust collar, thrust collar retaining ring, thrust runner, thrust shoes, thrust bearing springs, spring base, thrust bearing bracket, etc.) including the calculation of component stresses and deflections using FEA. The analyses must additionally determine shaft and bearing bracket vertical displacement. The analyses must provide a recommendation regarding each component's adequacy for usage with the replacement runner and existing/replacement rotating components. Include thrust bearing component modification and replacement recommendations.

b. Update the structural analysis for General Electric bearing designs for fourth and subsequent adjustable and fixed blade iteration designs in the case that the model test determined prototype axial thrust plus rotating component weight exceeds existing thrust bearing capacities.

c. Submit Thrust Bearing Structural Analysis Reports 120 calendar days following the exercise of the option to proceed with the analysis, provided during the third or subsequent adjustable and fixed hydraulic design iterations.

d. Resubmit thrust bearing structural analysis for subsequent adjustable and fixed blade design iterations, if required based on model testing axial thrust results, 120 calendar days following the date of shipment of that iterations model runner from the performance model testing laboratory to ERDC.

e. Results from a previous thrust bearing study completed by GENMAT will be provided after Contract award.

1.9 PROTOTYPE BLADE OPERATING MECHANISM ANALYSIS

a. For the adjustable blade prototype turbine, the required blade force (torque) and blade range of motion will be achieved through hub mechanism design. The design must not require any changes to the existing governor oil system except for the oil head piping.

b. Perform a prototype blade operating mechanism analysis for a prototype turbine following the first iteration adjustable blade hydraulic design. Update the analysis for each subsequent hydraulic iteration adjustable blade design. The inputs to the analysis must

SECTION 48 13 13.01 26 Page 16 include the model test determined prototype hydraulic blade torque and the blade rotational range. Coordinate the analysis with the stress analysis of replacement runner hub blade operating mechanism components performed under Paragraph RUNNER STRESS ANALYSIS.

c. Calculate stresses in the components that transmit torque to the runner blades according to the requirements defined in Paragraph DESIGN STRESS REQUIREMENTS. Perform the analysis using a static and dynamic coefficient of friction of 0.11 for KAron V, 0.09 for TXM-M, and TBD for Devatex 522. Governor pressures are those defined for the existing turbine in Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN.

d. Ensure the existing components planned for reuse and the new components provided by the Contractor are adequate for the full range of blade rotation established as part of the model testing (see Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN). Limit total off cam over travel to one degree of blade rotation, 0.5 degrees flat and 0.5 degrees steep, unless otherwise approved.

e. Submit a Prototype Blade Operating Mechanism Analysis Report 120 calendar days following the date of shipment of the first adjustable blade hydraulic iteration model runner from the Contractor's performance model testing laboratory to ERDC. Resubmit for each subsequent adjustable blade design iteration 120 calendar days following the date of shipment of that iterations model runner from the performance model testing laboratory to ERDC. Update the calculations provided initially during the iterative hydraulic design process to reflect the final prototype design and resubmit 120 calendar days following the date of release to manufacture the adjustable blade turbines. The reports must include stresses and ranges of motion for existing components planned for reuse and new components and provide recommendations regarding existing component adequacy. Coordinate reports with the replacement runner stress analysis required under Paragraph RUNNER STRESS ANALYSIS. Include existing component modification and replacement recommendations.

1.10 PROTOTYPE WICKET GATE OPERATING MECHANISM ANALYSIS

a. In the rehabilitated prototype turbines, the force required to operate the replacement wicket gates and the gate range of motion will be achieved using existing prototype components. The design must not require any changes to the existing governor oil system.

b. Submit Prototype Wicket Gate Operating Mechanism Analysis Reports for prototype turbines having the third iteration adjustable blade hydraulic design and the third iteration fixed blade hydraulic design.

Update the adjustable and fixed blade analyses for each subsequent iteration adjustable and fixed blade hydraulic design and the final designs from which prototypes will be constructed. The inputs to each analysis must include the model test determined prototype hydraulic wicket gate torque and the gate rotational range. Each analysis must examine existing wicket gate operating mechanism components planned for reuse including the servomotors (cylinders and pistons), connecting rods, operating ring, gate links, gate levers, gate stops, etc.

c. Calculate stresses in existing components that transmit torque to the wicket gates and that are planned for reuse according to requirements defined in Paragraph DESIGN STRESS REQUIREMENTS above.

Determine the ability of the existing wicket gate servomotors to

SECTION 48 13 13.01 26 Page 17 operate against the hydraulic gate torque and wicket gate operating mechanism frictional forces over the full range of motion. Perform the analysis using friction factors developed in consultation with the Government. Governor pressures are those defined for the existing turbine in Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN.

d. If model testing shows that gate rotation exceeds the 50 degrees (see BLH drawing 43831) available for the existing turbine (see Section 01 33 16.11 26 HYDRAULIC TURBINE DESIGN), determine the adequacy of the existing components planned for reuse at the increased range of travel in the Prototype Gate Operating Mechanism Analysis.

e. The reports must include stresses and ranges of motion for existing components planned for reuse and provide recommendations regarding existing component adequacy. Include component modification and replacement recommendations.

f. Submit prototype wicket gate operating mechanism analysis report for adjustable blade turbines 120 calendar days following the date of shipment of the third adjustable blade hydraulic design iteration model runner from the Contractor's performance model testing laboratory to

ERDC.

g. Submit prototype wicket gate operating mechanism analysis report for fixed blade turbines 120 calendar days following the date of shipment of the third fixed blade hydraulic design iteration model runner from the Contractor's performance model testing laboratory to ERDC.

h. Resubmit prototype wicket gate operating mechanism analysis report for each subsequent design iteration 120 calendar days following the date of shipment of that iterations model runner from the performance model testing laboratory to ERDC.

i. Update calculations provided initially during the iterative hydraulic design process to reflect final adjustable of fixed blade prototype design and resubmit 120 calendar days following the date of release for manufacturing of the adjustable or fixed blade turbines.

1.11 CAVITATION DAMAGE

1.11.1 Cavitation Damage Guarantee

a. The guaranteed cavitation free turbine operating range is provided by the Contractor as specified in Section 01 33 16.11 26 HYDRAULIC

TURBINE DESIGN.

b. Warrant/guarantee the replacement runners against excessive pitting due to cavitation according to Contract Clause 52.246-21 Warranty of Construction. In addition to new hydraulic surface components, any refurbished component's hydraulic surface profile changed by the Contractor must be similarly warranted against excessive pitting. The Contactor is not responsible for existing damage.

c. The Contractor's guarantee of the turbine against pitting due to cavitation must be based on operation for not more than ten percent of the operating time during the guarantee period at loads less than the minimum horsepower and for not more than five percent of the operating time during the guarantee period at loads greater than the maximum horsepower as specified in the Contractor's cavitation guarantee. At no

SECTION 48 13 13.01 26 Page 18 time will the turbine be operated more than two percent above the maximum power limit of the cavitation guarantee. Operation will be with trash racks installed and with fish screens installed or removed.

d. Prior to the expiration of the two-year guarantee period, the Contractor and Government will jointly inspect and measure any cavitation damage, unless waived in writing. The Government will notify the Contractor a minimum of 28 days in advance of the inspection date.

If excessive pitting occurs, the Contractor must immediately, unless otherwise approved, repair all cavitation damaged areas, and reshape and resurface the cavitated areas and adjacent areas by grinding, polishing, building up by welding, or other approved means, to remedy the cause insofar as possible. Propose and implement corrective action to mitigate future damage. Repairs must be at the expense of the Contractor. Upon completion of the repairs, the cavitation guarantee will be renewed for an additional two calendar years. The cavitation guarantee will be renewed a maximum of one time, resulting in a maximum of two Contractor-cavitation repairs.

e. Excessive pitting caused by cavitation and corrosion is defined as the removal of 0.000006D^2 pounds of metal per operating hour (D is the runner reference diameter in feet) or the removal of metal to a depth exceeding 1/8 inch in an area of 2 square inches or greater. Erosion or damage caused by suspended matter in the water, or corrosion that may occur at the boundary of corrosion-resistant material and adjacent mild steel material, is not intended to be covered by the Contractor's guarantee.

f. The amount of damage will be determined by evaluating the volume of material needed to restore the area to its original undamaged surface shape and multiplying this volume by the density of the damaged material. The depth, area, and volume of metal lost will be determined as set forth in Section 10 of IEC 60609, except that English Units of measurement will be used, unless otherwise specified herein, and no measuring inaccuracy will be considered. The Government and Contractor will jointly outline the areas of damage. The Contractor must then make sketches on transparent material which depict the areas and give each area an identification. Submit a Method and Procedure for Determining the Volume of Cavitation Damage in conformance with the IEC Publication within 21 calendar days from the date of the Government's request. Use a digital planimeter to determine area, unless otherwise approved. Area may be determined from a sketch replica of the area or by using the planimeter on the actual water passage surface. Submit the Contractor's volume estimate(s) and calculations of metal loss for approval. The Government will witness the taking of measurements for the determination of the excavated volume, unless otherwise indicated in writing. Determine the weight of metal loss by multiplying the volume

(V) by the density of the material damaged. Other methods of determining metal loss may be submitted for consideration and approval.

1.11.2 Cavitation Repair

a. Submit the Cavitation Repair Plan for review and approval within 28 calendar days from the date of the Government's request. The plan must include a repair procedure and an estimate of the number of days required for the repair. All repair work must be coordinated with and will be witnessed by the Government unless otherwise waived in writing.

Make suitable template checks, vent measurements, and other dimensional checks to demonstrate to the Government that the proper hydraulic

SECTION 48 13 13.01 26 Page 19 shapes and profiles of the runner and water passage elements are maintained or changed to mitigate cavitation damage.

b. For each turbine inspection and for any repairs, the Government will dewater the turbine and will install and remove the working platform under the runner. In addition, the Government will provide electrical power and compressed air at no charge to the Contractor from existing locations, in quantities and amounts commensurate with system capacities.

c. Templates previously furnished by the Contractor will be made available. If the surface contours are changed and the existing templates or data are no longer representative of the surface, new templates must be furnished at Contractor's expense to the Government at the site and must be of the same construction as the existing templates.

d. Provide the services of a qualified engineer/individual for turbine inspection and repairs to review the extent of pitting and ensure proper repair and remedial work is undertaken.

1.12 GEOMETRIC UNIFORMITY AND SIMILARITY

1.12.1 General

The prototype runners and additional Contractor-supplied hydraulic components must be geometrically similar to that of the tested and accepted performance models representing the final hydraulic designs.

1.12.2 Allowable Tolerances

The tolerances for the hydraulic surfaces of the Contractor-furnished components must be as follows:

a. Prototype uniformity and similarity tolerances must be one half of the values given in IEC 60193 Table 2.2.2.1.7.

b. As a minimum, waviness criteria for surfaces in contact with water must not exceed one-half of the values set forth in IEC 60193, Section 2.2.3, unless otherwise approved.

c. Runner surface roughness must not exceed 3.2 micro-meters (125 micro-inch) at any location in the water passageway.

d. Additional tolerances for specific component are listed in paragraphs governing the supply of the component.

1.12.3 Methodology for Assuring Geometric Similarity

a. If it can be demonstrated, to the Government's satisfaction, that the as-tested model runner is within the dimensional tolerances stipulated in these specifications, use the model design file as the dimensional basis of design for the manufacture of the prototype.

Modify the design file in the areas where the runner is not within tolerance, such that the design file matches the measured as-tested model runner.

b. Measure complex machined shapes (runner blade profiles, for example) using templates and either a coordinate measuring machine or laser

SECTION 48 13 13.01 26 Page 20 tracker. Employ not less than six templates at the leading edge and six templates at the blade trailing edge, approximately equally spaced between the runner hub and the blade periphery. The templates may be the same set supplied to the Government under Paragraph RUNNER BLADE MAINTENANCE TEMPLATES. Any templates that are used in the manufacture or assembly of components must be available for use by the Government when checking homology. When a coordinate measuring device is used to verify similarity, procedures describing the method of comparison and criteria for acceptance must be as approved. Account for the accuracy and tolerances of each device when confirming that the prototype is homologous to the basis of design.

c. Prior to performing any manufacturing, prepare a detailed Homology Checking Procedure for each hydraulic component within 150 calendar days following the date of release for manufacturing of the adjustable or fixed blade turbines. The procedure must define the procedure, tools, methods of measurement, and tolerances to be used for assuring and checking the geometric similarity of prototype components with the basis of design.

1.12.4 Government Witnessing of Measurements

As part of the finished runner shop inspection (see requirements in PART 3) the Government will witness measurements of the finished assembled prototype runners, including the runner blades, for the purpose of verifying geometric similarity and uniformity. Provide access to all data and procedures that are necessary to confirm that geometric similarity and uniformity has been achieved.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT GENERAL

a. Material requirements for specific components are specified in paragraphs governing the component. Where utilized, the specific requirements supercede the general requirements listed in PART 2.

b. The classification and grade of material incorporated in the work must be in accordance with the specifications designated herein, unless otherwise approved in writing. All materials must meet or exceed the standards as specified. When two or more of these standards apply, the most stringent standard must be used.

c. The Contractor may propose equipment, material, or articles that in the Contractor's opinion is equal or superior to that required. In this case prepare a Deviations in Material Specifications, no later than 90 calendar days prior to commencing fabrication of the particular component. Identify the proposed equipment, material, or article, the alternate standards, a detailed comparison with the specified standard, and the reasons it should be accepted. The final decision will reside with the Government. If accepted by the Government, there will be no monetary/price adjustment or compensation to the Contractor. Equipment, materials, and articles used without written approval will be at the risk of subsequent rejection.

d. Reference to any equipment, article, or catalog number must be regarded as establishing a standard of quality and must not be construed as limiting competition.

SECTION 48 13 13.01 26 Page 21

e. Where such material or construction is herein specified, this must be considered the minimum acceptable. With the exception of existing components specified for reuse with or without modification/refurbishment, all materials incorporated in the final work must be new and unused. Any materials required in the work not covered by specifications must be of the most suitable grade for the purpose intended. Reference to any equipment, article, or catalog number must be regarded as establishing a standard of quality and must not be construed as limiting competition.

f. For castings, coupons and coupon testing results are required under Paragraph STEEL AND STAINLESS STEEL CASTINGS below. Coupons and coupon mechanical testing results (tensile strength, yield strength, elongation, reduction in area, impact, hardness and bend tests) are required for wrought materials on Government request.

g. Prepare Contractor's Internal Quality, NDT, and Dimensional Inspection Reports for each component and submit within 14 calendar days of performing the inspection.

h. Hazardous materials, such as asbestos or mercury, must not be utilized.

i. The Government will have the option of inspecting Contractor-supplied equipment at any phase of the manufacturing process. Do not ship from the Contractor's shop any major piece of prototype equipment until it has been inspected by the Government, unless waived by the Government.

2.2 STEEL AND STAINLESS STEEL CASTINGS

The following subparagraphs apply to all steel castings, including corrosion-resistant steel castings, except where superceded for specific components.

2.2.1 General

Castings must not be warped or otherwise distorted. The structure of the castings must be homogeneous and free from excessive inclusions. An excessive segregation of impurities or alloys at critical points in a casting will be cause for its rejection.

2.2.2 Materials

a. Except as required otherwise for specific components, all steel castings must conform to ASTM A27/A27M Grade 70-40, ASTM A148/A148M Grade 80-40, or ASTM A216/A216M Grade WCC.

b. For the turbine runner, carbon steel must conform to ASTM A216/A216M Grade WCC castings, or ASTM A516/A516M Grade 60 plate.

c. Except as required otherwise for specific components, all corrosion-resisting steel castings to ASTM A743/A743M Class CA6NM.