W9127N24R0001 TRGR Draft 100 Percent Specifications 3.pdf

JDTRGR24 - OIL FREE JDTRGR24OILFREE

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.05 26

DISASSEMBLY AND REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR UNITS FOR

STANDALONE REWIND (OPTIONAL)

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.1.1 Unit Description

1.1.2 Work Required

1.1.3 Supervision

1.1.4 Unit Access

1.1.5 Unclassified Asbestos Containing Material (ACM)

1.1.6 Contractor Supplied Special Equipment, Tools, Scaffolding

1.1.7 Turbine Maintenance Platform

1.1.8 Access to Contractor's Reports

1.1.9 Government Activity Durations

1.2 REFERENCES

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 GENERAL

2.2 FASTENERS

2.3 INSULATION

2.4 MISCELLANEOUS CONSUMABLES

PART 3 EXECUTION

3.1 GENERAL

3.2 LAYDOWN CRITERIA FOR DISASSEMBLED COMPONENTS

3.2.1 Floor Design Loads

3.2.2 Rotor Assembly

3.2.3 Definition of Top-Heavy Items

3.2.4 Lateral Restraint Design

3.2.5 Blocking

3.2.6 Additional Protection of the Powerhouse

3.3 PRE-DISASSEMBLY WATERED OPERATIONAL TESTING

3.3.1 General

3.3.2 Steady State Testing

3.3.3 Load Rejection Testing

3.3.4 Synchronous Condensing Testing

3.3.5 Steady State and Load Rejection Measurements

3.3.6 Predisassembly Watered Operational Testing Report

3.4 PRE-DISASSEMBLY MEASUREMENTS

3.4.1 Pre-Disassembly Measurements Procedures

3.4.2 Measurements That Do Not Require A Free-Hanging Shaft

3.4.3 Measurements That Require A Free-Hanging Shaft

3.4.3.1 General

3.4.3.2 Unit Preparation for Alignment Measurements

3.4.3.3 Pre-Disassembly Alignment Requirements

3.4.3.4 Pre-Disassembly Insulation Resistance Test

3.4.3.5 Pre-Disassembly Measurement/Inspection Report

3.5 DISASSEMBLY

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3.5.1 General

3.5.2 Disassembly Procedure

3.6 CLEANING, AS-FOUND INSPECTIONS, REPORTS, RECOMMENDATIONS,

REFURBISHMENT, REPAIR

3.6.1 General

3.6.2 Cleaning, Inspection and Recommendations

3.6.3 Repair

3.6.4 Laser Measurements of As-Found Rotor and Refurbished Rotor and

Stator

3.7 DISPOSAL OF DISCONTINUED EQUIPMENT

3.8 COMPONENT REPLACEMENT

3.8.1 Fasteners

3.8.2 Electrical Insulation

3.9 REASSEMBLY

3.9.1 General

3.9.2 Reassembly Procedure

3.9.3 Miscellaneous Parts

3.9.4 Tapped Holes

3.9.5 Lifting Eyes

3.9.6 Piping

3.9.7 Electrical

3.9.8 Painting

3.9.9 Locking Mechanisms

3.9.10 Major Connections

3.9.11 Nameplate

3.9.12 Reassembly Insulation Resistance Test

3.9.13 Reassembly Unit Alignment

3.9.14 Reassembly Measurements

3.9.15 Adjustments

3.9.16 Reassembly Measurement Report

3.9.17 Systems Tests

3.10 UNIT TESTING AND COMMISSIONING

3.10.1 General

3.10.2 Commissioning Agent

3.10.3 Testing and Commissioning Plan

3.10.4 Operational Testing

3.10.5 ROTOR BALANCING (OPTIONAL)

-- End of Section Table of Contents --

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SECTION 48 13 13.05 26

DISASSEMBLY AND REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR UNITS FOR

STANDALONE REWIND (OPTIONAL)

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.1.1 Unit Description

a. The existing John Day turbines and generators are described in Section 01 33 16.11 26, HYDRAULIC TURBINE DESIGN. The redesigned turbine assemblies will result from the iterative design process described in Section 01 33 16.10 26, HYDRAULIC DESIGN PROCESS.

b. The generators for Units 1-16 were designed and manufactured by the General Electric Company. The generator designs have a suspended type bearing arrangement and a spring bed type thrust bearing.

c. The requirements for a full disassembly, reassembly, and commissioning are contained in Section 48 13 13.02 26 DISASSEMBLY AND

REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR UNITS.

1.1.2 Work Required

a. The work governed by this Section includes the disassembly/reassembly of up to four units for the optional rewind-only work. Perform the rewind work as outlined in Section 48 13 16.00 26 REWIND OF HYDRAULIC-TURBINE DRIVEN GENERATORS and abide by all other relevant sections for the optional rewind-only work.

b. A maximum of four generating units will have the option of having a standalone rewind. This option can be exercised by the Government before or after the turbine site work.

c. The work includes the following:

(1) Pre-disassembly inspections, tests and measurements

(2) Pre-disassembly shaft straightness and runout inspections

(3) Partial disassembly of the turbine generator unit, including the removal of all interferences

(4) Establishing a centerline for the reassembled unit

(5) Cleaning and inspection of the disassembled components

(6) Recommendations for repairs, replacements, and refurbishment

(7) Supplying any auxiliary mechanical and electrical equipment necessary to perform the work under this Contract

(8) Reassembly of the turbine generator unit, including the reinstallation of all interferences

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d. The Contractor's work must not cause the existing generating unit's electrical or mechanical characteristics to be altered or degraded in any way, unless specified herein or otherwise approved.

1.1.3 Supervision

Provide site personnel as required by Section 01 10 10.00 25 CONTRACTOR'S OPERATIONS AND REQUIREMENTS, familiar with the type of work and equipment involved, to direct the disassembly, repair, and reassembly of the units as specified. The on-site agent(s) and work supervisor(s) must be fluent in both the spoken and written English language. Perform all work on the units via skilled craftsmen familiar with the type of work and the equipment involved.

1.1.4 Unit Access

a. The Government will secure the units for safe access. See Section 01 10 10.00 25, CONTRACTOR'S OPERATIONS AND REQUIREMENTS for access, additional information, and requirements. Personnel must not enter a unit until a unit clearance is issued by the Government verifying that all safe clearance steps are complete.

b. The Government will dewater the units and maintain the unwatered condition until the completion of the respective units work. Anticipate leakage past the bulkheads, headgates, stoplogs and other sources and take measures for prevention, care, diversion and removal of water away from work areas.

c. The Government will open the personnel entry doors to the draft tubes and scroll cases. Once opened, barricade or close the access ways unless manned or otherwise approved.

d. The Government will drain the necessary hydraulic and lube oil systems. The Contractor must be responsible for cleaning, flushing, handling, and removing all residual oil from the units necessary to perform work under these specifications.

e. At the completion of refurbishment, the Government will refill all hydraulic and lube oil systems.

f. At the completion of refurbishment, the Government will close all personnel entry doors and water the unit.

1.1.5 Unclassified Asbestos Containing Material (ACM)

Asbestos abatement will be performed by the Government under a separate Contract. Notify the Contracting Officer immediately when suspect ACM is found. For additional details see Contract Clause 52.211-10 COMMENCEMENT, PROSECUTION, AND COMPLETION OF WORK. Suspected asbestos containing materials are:

a. Wire insulation

b. Pipe insulation

c. Wiring box to slip ring area

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e. Turbine runner gasket between cone and hub

f. Gaskets and pipe insulation on the vacuum breaker and valves

g. Generator heater wiring

1.1.6 Contractor Supplied Special Equipment, Tools, Scaffolding

a. Government furnished equipment available for the Contractor's use is listed in Section 01 11 00.00 25, SUMMARY OF WORK. Supply all additional equipment necessary for disassembly/reassembly; including tools, wrenches, lifting/handling devices, scaffolding, platforms, pedestals, etc. This also includes turbine platforms required as part of reassembly, measurements, and commissioning and any platforms or scaffolding required for removing and installing the stator winding.

b. Turn over Contractor supplied specialty built equipment (defined as equipment that is not available "off the shelf" for purchase or rent) necessary for Government performed maintenance or future disassembly/reassembly to the Government at the completion of the Contract. Transfer the equipment to the Government in Contractor-provided steel or sturdy wood boxes labeled with the boxes content. Equipment turned over to the Government must conform with Occupational Safety and Health Administration (OSHA) and EM 385-1-1 requirements. Submit drawings and design calculations.

c. The use of Government furnished equipment under loads (weights, forces, torques) in excess of those under which the equipment would have been used in the original assembly must be subject to Government approval of a Contractor provided stress analysis prepared according to the requirements of Section 48 13 13.01 26, PROTOTYPE TURBINE DESIGN

AND SUPPLY.

1.1.7 Turbine Maintenance Platform

Usage requirements of the existing turbine maintenance platform are located in Section 01 10 10.00 25, CONTRACTOR'S OPERATIONS AND REQUIREMENTS and Section 01 11 00.00 25, SUMMARY OF WORK.

1.1.8 Access to Contractor's Reports

a. Make all measured and recorded data available for review and copying by the Government immediately after the data has been initially recorded. Submit reports as required in the "Submittals" paragraph of Section 01 33 00, SUBMITTAL PROCEDURES.

b. Whenever written records of examinations, measurements, tests, checks, etc. are required, keep a copy of each in a separate file in the Contractor's field office for access and examination by the Government. Keep copies of records that are required for submittal as well as those not requiring submittal.

1.1.9 Government Activity Durations

A list of typical Government activities and durations that relate to disassembly/reassembly can be found in Section 01 10 10.00 25, CONTRACTOR'S

OPERATIONS AND REQUIREMENTS.

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1.2 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.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1095 (2012) Guide for Installation of Vertical Generators and Generator/Motors for Hydroelectric Applications

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI S1.4 (2014) Specifications for Sound Level Meters

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2022) Nuts for General Applications:

Machine Screw Nuts, and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.21.1 (2009; R 2016) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers (Inch Series)

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM F436 (2011) Hardened Steel Washers

CEATI INTERNATIONAL, INC. (CEATI)

CEATI T122700-0381 (2015) Hydroelectric Turbine Generator Units - Guide for Erection Tolerances and Shaft System Alignment

UNITED STATES BUREAU OF RECLAMATION (USBR)

USBR FIST 2-1 (2016) Alignment of Vertical Shaft Hydro Units

USBR FIST 2-2 (2016) Field Balancing Large Rotating Machinery

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety -- Safety and Health Requirements Manual

Comply with the current edition and all changes posted on the web as of

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1.3 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-01 Preconstruction Submittals

Pre-Disassembly Operational Testing Plan; G

Laydown Plan; G

Pre-Disassembly Measurement/Inspection Report; G, A

Reassembly Measurement/Inspection Report; G, A

Disassembly Procedure; G

Pre-Disassembly Measurement Procedure; G

Reassembly Procedure; G

Unit Testing and Commissioning Plan Supplemental Information; G

Unit Alignment Procedure

SD-02 Shop Drawings

Drawings And Design Calculations

SD-05 Design Data

Notification of Damaged or Unserviceable Item

SD-06 Test Reports

Pre-Disassembly Watered Operational Testing Report; G, A

Stationary Alignment Report and Recommendations;G, A

As-Found Inspection And Repair Recommendations Report; G, A

Mechanical Equipment and Systems Test Report; G, A

Post-Refurbishment Operational Testing Report; G, A

Disassembled As-Found Rotor And Refurbished Rotor And Stator Measurement Report

Stress Analysis

SD-08 Manufacturer's Instructions

Procedures for Repair of Defects; G

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PART 2 PRODUCTS

2.1 GENERAL

All products and materials must conform to the applicable requirements of these specifications. Substitution or deviations in materials specified must not be made except on specific prior written approval.

2.2 FASTENERS

Threaded bolts and studs must conform to the requirements ASME B18.2.1, SAE J429 Grade 2 or higher. Threaded nuts must conform to ASME B18.2.2. Lock and plain washers must conform respectively to ASME B18.21.1, ASTM F436 Type 1. Bolts, nuts, studs, and washers in contact with galvanized surfaces must also be galvanized. Galvanized coatings must conform to ASTM A123/A123M.

2.3 INSULATION

Replace insulation removed during the disassembly process in kind.

2.4 MISCELLANEOUS CONSUMABLES

Replace all gaskets, seals, and miscellaneous consumables in kind.

PART 3 EXECUTION

3.1 GENERAL

The following applies to all work covered by this specification Section:

a. Notify the Government in writing of any items which appear to be damaged or unserviceable to allow maximum lead time for procurement of replacement parts. Provide the Notification of Damaged or Unserviceable Item within three workdays of the Contractor becoming aware of the discrepancy. Replace all items that are damaged due to the fault or negligence of the Contractor, as determined by the Government.

b. All electrical disassembly and reassembly work must be performed by electricians according to Section 26 05 00.00 26, BASIC ELECTRICAL

MATERIALS AND METHODS.

c. Install all Government furnished equipment as directed.

3.2 LAYDOWN CRITERIA FOR DISASSEMBLED COMPONENTS

a. Submit a Laydown Plan depicting the planned location of all major new and existing components 45 calendar days prior to the date of the first units outage. Include proposed locations of all major components capable of exceeding the floor loading limits or restricting access to, from, or within the Powerhouse. Also include cribbing/blocking details, restraint details, anticipated floor loading for each component, and note differences between adjustable and fixed units. The Laydown Plan must detail movements over time in order to properly sequence work.

Also include staging movements necessary to assemble new components shipped to site as part of this effort. Include the necessary

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b. Place major components only in Government-approved locations. For additional information, see Section 01 10 10.00 25, CONTRACTOR'S

OPERATIONS AND REQUIREMENTS.

(1) Storage and work areas available for Contractor usage outside of the Powerhouse are shown on drawing G-007.

(2) Storage and work areas available for Contractor usage inside of the Powerhouse are shown on drawing G-011.

c. Maintain clear paths for Project personnel including a contiguous six foot forklift path on the downstream side of the generators and offset from the downstream wall (an example is shown on drawing G-011), a minimum six foot path around the switchboards of each generating unit, clear paths through doorways, and egress paths shown on drawing G-011.

d. Store bearings in an approved location and immediately cover and protect them after disassembly.

3.2.1 Floor Design Loads

Maintain floor loading requirements as specified in Section 01 10 10.00 25, CONTRACTOR'S OPERATIONS AND REQUIREMENTS.

3.2.2 Rotor Assembly

Place and secure the rotor and generator shaft on the existing rotor pedestals.

3.2.3 Definition of Top-Heavy Items

Consider a component top-heavy if its base is less than twice the vertical distance to its center of mass. The rotor assembly is considered a top-heavy component when not installed on the rotor support stand.

3.2.4 Lateral Restraint Design

If a component must be placed in a top-heavy configuration, as defined above, design a restraint system to prevent tipping with a factor of safety against tipping of one to three. The lateral design load must be 0.1 g or 10 percent of the weight of the component and must be applied in the most adverse horizontal direction. Embedment and anchorage design must be subject to Government approval. Submit for Government approval, as part of the laydown plan, the design and supporting calculations stamped by a registered professional structural engineer.

3.2.5 Blocking

Supply all cribbing, blocking, etc. Components not required to have designed supports may be blocked up according to the Contractor's preference, provided the load is properly distributed for the floor load limit. Blocking must be no greater than two feet in height unless otherwise approved. Blocking must not damage existing tile and terrazzo floors.

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3.2.6 Additional Protection of the Powerhouse

Provide protection of existing architectural features as part of the laydown plan in accordance with Section 01 10 10.00 25, CONTRACTOR'S

OPERATIONS AND REQUIREMENTS.

3.3 PRE-DISASSEMBLY WATERED OPERATIONAL TESTING

3.3.1 General

a. Conduct an operational test of each unit to document the operating characteristics of the generating unit. The intent of testing is to develop a baseline criteria for the reassembly process. Use tests and instrumentation such that the tests can be duplicated after the unit is reassembled. Conduct the same tests after reassembly and the test results must be no worse than the as-found test results.

b. To the extent practicable, existing installed instruments, e.g.

forebay and tailwater recorders, digital governor output, watt-hour meter, cooling water flow meters and thermometers, etc. may be used.

Provide all additional equipment and instrumentation as well as all necessary personnel.

c. Submit a Pre-Disassembly Operational Testing Plan 45 calendar days prior to date scheduled for arrival of Contractor's personnel for the first units test. Include a description of the tests to be conducted, the instrumentation to be used, the requested Government involvement, a schedule and a request for unit availability.

d. Coordinate all investigations with the Government and have them witnessed by the Government.

e. Make all measured and recorded data available for review or copying by the Government immediately following the completion of the investigations.

f. As a minimum, conduct steady state testing and load rejections.

Perform the testing at whatever head is available at the time of the testing.

3.3.2 Steady State Testing

Conduct testing at a minimum of the following wicket gate positions:

speed-no-load unexcited, speed-no-load excited, 30, 40, 50, 60, 70, 80, 90, and 100 percent wicket gate opening (limited to rated load on the generator or rated turbine output). Record gate and blade position for each test.

Include measurements for at least five minutes in each condition, after the unit has stabilized in each condition for two minutes. Note that some units will have the runner blades fixed and may not be capable of stable operation. Coordinate the steady state testing with the Government to avoid unsatisfactory operating conditions.

3.3.3 Load Rejection Testing

Perform load rejection testing at approximately 25 percent, 50 percent, 75 percent, and full load conditions. Measure and plot spiral case pressure using one of the piezometer taps, draft tube liner pressure, shaft speed, wicket gate position, and blade, all versus time, with the initiation of load rejection indicated. Check the shaft speed increase prior to moving to

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3.3.4 Synchronous Condensing Testing

Conduct shaft runout and vibration testing in synchronous condensing mode on Units 11, 12, 13, and 14. Also record all relevant measurements to match the requirements in paragraph STEADY STATE AND LOAD REJECTION MEASUREMENTS during synchronous condensing.

3.3.5 Steady State and Load Rejection Measurements

At a minimum, take the following measurements during steady state and load rejection testing:

a. Shaft Runout

(1) Install two proximity probes on the shaft, 90 degrees apart, near each guide bearing.

(2) Measurements must be recorded in decimal inches (thousandths) peak-to-peak and RMS. Analysis must be capable of performing a Fast Fourier Transform (FFT).

b. Vibration

Measurements must be accurate to 0.001 in/s/s with a minimum sampling rate of 1000 Hz. There must be three axis accelerometers mounted on the thrust bearing bracket near the guide bearing, on the head cover, and near the turbine guide bearing. Results must be shown in a amplitude versus time as well as in an FFT.

Calibration certificates for these devices must be submitted in the Pre-Disassembly Operational Testing Procedure.

c. Generator Output

Generator output must be recorded as reported by existing Powerhouse devices or the Contractor may use their own calibrated power transducers installed in the PT and CT circuits prior to unit startup.

d. Key Phasor

Use a key phasor to determine the angular position of the unit.

Determine shaft speed during load rejection testing.

e. Wicket Gate Opening.

(1) Measure wicket gate opening (servo stroke) using the digital governor readout.

(2) The percent gate indicated by the turbine pit must also be recorded.

f. Temperature Readings

Turbine, generator guide, and thrust bearing temperatures must be recorded.

g. Pressure and Head

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Pressure measurements must be taken accurate to the nearest one psi with a minimum sampling rate of 1000 Hz. Measurements should be reported with both peak-to-peak values as well as 95 percent confidence intervals. Elevation measurements must be taken accurate to the nearest 0.5 feet. The following must be measured for each test condition:

(1) Forebay elevation

(2) Tailwater elevation

(3) Head cover pressure gauge reading (if available)

(4) Inlet pressure fluctuations

(5) Draft tube pressure fluctuations

h. Unit Rotational Speed (during load rejections).

i. Sound levels using an electroacoustics sound level measuring device in accordance with ANSI S1.4.

3.3.6 Predisassembly Watered Operational Testing Report

Submit test data in a Pre-Disassembly Watered Operational Testing Report for each unit 60 calendar days following the completion of testing. Note any abnormal or excessive vibrations, runouts, or noise levels in the report.

3.4 PRE-DISASSEMBLY MEASUREMENTS

The purpose of the pre-disassembly measurements are to establish a baseline of unit existing conditions, facilitate refurbishment decisions, and ease reassembly. Disassembly will not be permitted until the pre-disassembly measurements report has been approved by the Government. Pre-disassembly measurements are broken up between measurements that require a free-hanging shaft and measurements that do not require a free-hanging shaft.

3.4.1 Pre-Disassembly Measurements Procedures

Submit the Pre-Disassembly Measurement Procedure 30 calendar days prior to measurements. Address the methodology of all measurements including both those requiring a free-hanging shaft and those that do not, which are discussed below. Include the following in the Pre-Disassembly Measurement Procedure:

a. Any time the shaft is rotated or moved laterally, energize the thrust bearing high pressure oil injection pump to establish an oil film between the thrust bearing and the thrust runner.

b. Measurements must be taken and recorded in accordance with CEATI T122700-0381 Part III. All relevant requirements of this publication must be followed even if they are not specifically listed in this specification Section.

c. A step-by-step discussion of the measurements to be taken, including identification and discussion of any potential disassembly necessary to take measurements (e.g. air housing shroud removal for air gap

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e. Measuring devices proposed to be used, including accuracy. Note that unit alignment measurement devices are subject to Government approval based on details provided.

f. The number of measurements proposed to be taken. Note that the minimum number of measurements are specified in following paragraphs.

g. If the unit must be reconfigured (e.g. rotated), the original orientation and enough information to determine the reconfigured orientation. For example, "the unit originally was oriented with Pole 1 facing upstream. It will be rotated 30 degrees in a clockwise manner when viewed in plan.". Lack of detail in descriptions will be grounds for submittal disapproval.

h. Special attention should be given to bearing clearance measurements that need to be taken prior to obtaining a free hanging shaft as well as identifying which items may require disassembly in order to obtain a free hanging shaft (turbine guide bearing, packing box, etc.).

i. Additional and specific measurement requirements are detailed in paragraphs MEASUREMENTS THAT DO NOT REQUIRE A FREE-HANGING SHAFT and

MEASUREMENTS THAT REQUIRE A FREE-HANGING SHAFT.

j. Any additional measurements the Contractor deems necessary to ensure the unit is acceptable upon reassembly.

k. Methodology for completing the stationary alignment post-disassembly; see USBR FIST 2-1. Include measurement tools and their accuracy. If a laser is to be used, include mapping of monument locations and number of laser setups needed. Note that monument locations need to be accessible in a semi-disassembled state. In as much as possible, validate laser measurements with mechanical measuring devices, such as hard micrometers accurate to 0.001 inches. Include laser validation locations in methodology. If a plumb wire is to be used, include all processes to determine verticality and level.

3.4.2 Measurements That Do Not Require A Free-Hanging Shaft

Pre-disassembly measurements that do not require a free-hanging shaft must not be taken until the Government has approved the Pre-Disassembly Watered Operational Testing Report and the Pre-Disassembly Measurement Procedure.

a. Turbine Guide Bearing Clearance

Take clearance measurements accurate to 0.001 inches in the minimum of four locations (US, DS, N, S). All measurements should be in one condition (i.e. no shaft rotation).

b. Generator Lower And Upper Guide Bearing Clearances

Take clearance measurements accurate to 0.001 inches at all pads.

All measurements should be in one condition (i.e. no shaft rotation).

c. Bearing Brackets Positions

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Take radial and elevation positions of the upper and lower brackets (US, DS, N, S); or alternatively verify the existence of dowels for the radial positions and save and match mark shims, blocks, etc. for the elevations.

d. Unit Rise

Measure the rise of the unit to its highest position without causing contact of any components using the generator jacks. Leave enough generator upper guide bearing segments in place while the rotor is raised and lowered to assure a vertical lift.

e. High Pressure Vertical Lift Distance and Timing

Measure the vertical lift of the high pressure oil injection system in four quadrants with devices accurate to 0.001 inches.

Also measure the time in seconds from engagement to lift being achieved.

f. Generator Shaft

Using dial indicators or proximity probes accurate to 0.001 inches, take runout measurements in a minimum of two locations, 90 degrees apart, on each collector ring. In addition, take measurements on two elevations on the shaft with one elevation being as close as possible to generator guide bearing. The other shaft measurement elevation should be a minimum of 48 inches different than the first. In all elevations, the devices located 90 degrees apart should align as one looks in plan. For example, one of the devices would be oriented towards the Upstream and one towards the North, such that four devices are on the same plane although in different elevations. In all, there should be a minimum of eight measuring devices.

g. Generator Brake Ring Runout

Measure the generator brake ring runout accurate to 0.001 inches.

Care must be taken to ensure the measurement device must accommodate the brake segments split line gaps.

3.4.3 Measurements That Require A Free-Hanging Shaft

3.4.3.1 General

Do not take pre-disassembly alignment measurements until the Government has approved the Pre-Disassembly Watered Operational Testing Report and the Pre-Disassembly Alignment Measurement Procedure.

3.4.3.2 Unit Preparation for Alignment Measurements

a. Remove any interferences which impede having a free-hanging shaft or impede measuring surfaces for alignment measurement purposes. Include removal of the turbine guide bearing and packing box. Note that any parts to be disassembled for alignment purposes must be identified in the Pre-Disassembly Measurement Procedure. Notify the Government COR should additional disassembly of components not identified in the Pre-Disassembly Measurement Procedure. Resubmission of the procedures may be necessary.

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b. Note any existing match marks. Where needed, make new match marks visible after cleaning and painting.

c. Lock the shaft in position by adjusting four shoe segments of the generator guide bearing closest to the thrust bearing at 90 degree spacing. The shoes should just touch the shaft.

3.4.3.3 Pre-Disassembly Alignment Requirements

Incorporate the following in the pre-disassembly alignment procedure:

a. Concentricity/Circularity Measurements:

(1) Take concentricity/circularity measurements accurate to 0.001 inch by measuring clearance measurements of the following locations:

(a) Stator

(b) Rotor

(c) Guide Bearing Housings

(2) In order to determine stator circularity, measure a constant point on the rotor as the unit is rotated. Take a minimum of 24 measurements equally spaced apart. Similarly, measure the blade tip clearances from a constant point on one blade as the unit is rotated.

(3) In order to determine the rotor concentricity and circularity, measure every other pole from a constant location from the stator as the rotor is rotated by hand.

(4) Take a minimum of eight diameters from the shafting to each guide bearing housings to determine their circularity.

b. Verticality Measurements.

(1) Take measurements in order to determine the verticality of the stator and rotor by completing the concentricity/circularity measurements at both the top and the bottom of the air gap.

(2) Take measurements to ascertain shaft verticality with a device/methodology capable of determining verticality to 0.00001 in/in. Shaft measurement methodology must be submitted for approval as part of the Pre-Disassembly Alignment Procedure.

c. Shaft Straightness Measurements.

Take measurements to determine the degree of shaft straightness.

Measurements need to be able to determine differences in shafting such that issues like coupling offset and dogleg can be determined. In order to ascertain shaft straightness, ample measurements/devices must be utilized to determine the angle at which each shaft is at throughout rotation. Methodology must be submitted for approval as part of the Pre-Disassembly Alignment Procedure. Shaft straightness and shaft verticality measurements may be taken simultaneously, if approved in the Pre-Disassembly

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d. Runout Measurements.

Take shaft runout measurements with a minimum of two measurement devices accurate to 0.001 inches located 90 degrees apart at each guide bearing location. Take the measurements at the same time as taking the shaft straightness and verticality measurements and record the location of the measurement devices.

e. Rotor-to-Stator Relative Elevation Measurements.

Take measurements accurate to 0.001 inches on every other pole to determine the relative elevation difference between the rotor and the stator. Note that the measurements must be taken off of toleranced surfaces.

f. Shafting Journal Diameters at Guide Bearings

Using a pi tape accurate to 0.001 inches, take measurements of the shaft journal diameters at each guide bearing location.

g. Semi-Permanent Monuments

At all pertinent elevations install monuments at 90 degree increments; US, DS, N and S. Tie these monuments to monuments required for laser alignment. Take measurements accurate to 0.001 inch from each monument to the shafting. Monuments must be located in areas accessible when the unit is disassembled.

h. Generator Guide Bearing Clearances

(1) Determine the existing position of the shaft by setting two dial indicators or proximity probes at 90 degrees apart on the shaft immediately below the guide bearing shoes and zero. Push the shaft against the bearing at each dial indicator position and record the existing clearances.

(2) Ensure that the shaft is hanging free at the turbine guide bearing housing and packing box.

i. At the discretion of the Contractor, a "stationary alignment" may additionally be performed. A stationary alignment would occur following the removal of the existing turbine runner and would involve the reinstallation of stationary components including the head covers and the generator thrust bearing bracket. A plumb line would then be suspended from the top of the thrust bearing bracket through the discharge ring. The center of the stationary components is then determined based on measurements from the stationary components to the plumb line. If a stationary alignment is performed, submit a Stationary Alignment Report and Recommendations for each unit 30 calendar days following the completion of the stationary alignment.

3.4.3.4 Pre-Disassembly Insulation Resistance Test

a. Components above the generator rotor that make contact directly or indirectly with the shafting are insulated from the supporting structure to eliminate the possibility of stray currents. Locations having electrical insulation include the thrust bearing base to tub, SECTION 48 13 13.05 26 Page 16

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b. Test the resistance of electrical insulating material that will be disturbed during the disassembly while the unit has a free hanging shaft. Test according to IEEE 1095 Paragraph 10.9 using a 500 VDC insulation tester. Additionally, individually check the resistance of individual layers of double insulation (two layers with a metallic compound between), the resistance from shafting to high point, from bearing bracket to high point, and from shafting to bearing bracket.

Prior to testing, clean exposed portions of the insulation with rags and solvent to remove carbon dust and contaminants.

c. Visually inspect all accessible insulation following disassembly.

d. Define all tests in the Disassembly Procedure as required in paragraph DISASSEMBLY. Include results in the disassembly measurement/inspection report, including a recommendation regarding the insulations suitability for reuse.

3.4.3.5 Pre-Disassembly Measurement/Inspection Report

The purpose of the measurements and analysis is to determine a reference centerline for the unit about which turbine and generator components must be installed, identify any unanticipated adjustments, and to identify the level of effort needed to refurbish/replace specific components. Submit a Pre-Disassembly Measurement/Inspection Report 30 calendar days following measurements. Include or identify the following:

a. All raw and processed measurements.

b. The as-found center of the stator and the center of the turbine guide bearing and the components' position relative to each other.

c. The proposed reference centerline about which the turbine and generator components must be positioned. Include the turbine and generator monument measurements that define the centerline. Describe all adjustments to existing or replacement turbine and generator components to achieve alignment of the unit (turbine and generator) along the reference centerline within the tolerances specified for the reassembly in paragraph REASSEMBLY UNIT ALIGNMENT.

d. The rotor-to-stator air gap, including the average, the minimum, and the maximum air gap. Report results at both the top and bottom of the rotor/stator. Include recommendations for reassembly.

e. The average elevation of the existing stator and the average elevation of the existing rotor. Additionally report the maximum misalignment between any rotor pole and the stator core. If the difference is greater than 25 percent of the nominal air gap, provide recommendations for bringing the averages to within 25 percent of the air gap. The analysis will account for the deflection of the thrust bearing support structure and the final weight of rotating parts and hydraulic thrust of the new turbines.

f. Existing shafting runouts, straightness and verticality, including a comparison to the requirements for the reassembled unit as contained in paragraph REASSEMBLY UNIT ALIGNMENT. Define all adjustments to existing

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g. Rotor circularity and best center with respect to the axis of rotation, and a comparison with the tolerances listed in CEATI T122700-0381 Part III.

h. Stator circularity and verticality.

i. The results of the insulation resistance test.

3.5 DISASSEMBLY

3.5.1 General

a. Do not commence disassembly of the unit until Government approval has been provided for the Pre-Disassembly Measurement/Inspection Report and the Disassembly Procedure.

b. Disassembly of the unit must include the disassembly of all related parts necessary for the specified replacement, rehabilitation, refurbishment and modification.

c. Store disassembled components in Government approved locations; see paragraph LAYDOWN CRITERIA FOR DISASSEMBLED COMPONENTS

d. During disassembly, identify all of the generator and turbine parts, noting the match marks and making new match marks where needed. Match marks must be visible after cleaning and painting.

e. Use only lint free rags.

f. Jacking screws and hydraulic jacks must be used where provisions are made to separate bolted surfaces; except for head covers, which must be separated using the center hole jacking system specified herein. Use of the crane for breaking connections is prohibited.

g. Slugging wrenches must not be used, unless requested by the Contractor and approved by the Government in the Disassembly Procedure.

Requests must specify components on which the slugging wrenches are to be used. See paragraph DISASSEMBLY PROCEDURE for more submittal requirements.

h. Heat must not be applied in the vicinity of the thrust bearing runner or stationary segments during any part of the work without approval. Should there be any interference fits necessitating heating of parts, a Request and Procedure to Apply Heat must be submitted and approved before applying heat. See paragraph DISASSEMBLY PROCEDURE for more submittal requirements.

3.5.2 Disassembly Procedure

Submit a detailed step-by-step Disassembly Procedure for Government approval 45 calendar days prior to the date of the first units outage, including references to drawings and photos, as applicable. Note differences for units which will have adjustable or fixed blade turbines. A lack of detail will be grounds for submittal rejection. Include separate paragraphs for each component with specific instructions, including prerequisites. Include in the Disassembly Procedure the following items:

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a. All paragraph DISASSEMBLY activities and requirements, including those for insulation resistance tests, alignment checks, and unwatered tests and measurements, in the Disassembly Procedure.

b. Detailed thrust collar removal procedures, including the method of heating, temperatures, jacking/lifting, etc.

c. A center hole jacking system for shaft separation, shaft closure, breaking of the head cover to stay ring connection, and intermediate head cover to outer head cover. The jacks must function in unison for transferring the weight of the turbine rotating parts from the coupling bolts to the runner / shafting support bracket and back again during reinstallation.

d. Describe the methodology for documenting the reference centerline about which the replacement discharge ring will be installed. Include separate methodology for documenting the reference centerline about the replacement discharge ring for fixed blade and adjustable blade units.

Include the location of turbine and generator tram points. The methodology must be such that the centerline can be determined following the removal of turbine and generator rotating and stationary components.

e. Identify the use of Government Furnished Equipment identified in Section 01 11 00.00 25, SUMMARY OF WORK to facilitate the coordination of the equipment needed at each step.

f. Describe the alignment tools to be used (laser, optical, electronic level, plumb line, etc.), including a usage history, a written description of the proposed procedure, equipment description, and accuracy.

g. During disassembly identify all of the generator and turbine parts, noting the match marks and making new match marks where needed. Match marks must be visible after cleaning and painting.

h. Cap all opened oil pipes by covering the end with plastic, and then duct taping the plastic in place. Prior to capping, visually inspect the inside of each pipe, and ensure that there are no obstructions or debris present. Remove any foreign matter found.

i. Protect all component-mating surfaces and flanges from damage by utilizing wood softeners or equivalent.

j. Protect all tapped holes in components that will be reused from damage during disassembly, temporary storage, and reassembly.

k. Worksheets for recording all measurements.

l. Disassemble turbine and generator assemblies and components as necessary to perform the Contract specified disposal, inspection, measurement, replacement, refurbishment, rehabilitation and modifications.

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3.6 CLEANING, AS-FOUND INSPECTIONS, REPORTS, RECOMMENDATIONS,

REFURBISHMENT, REPAIR

3.6.1 General

a. This paragraph's requirements apply to turbine and generator components and assemblies that will be reused and for which refurbishment requirements are not listed elsewhere. The work will be considered incidental to the unit disassembly and reassembly, and separate payment will not be made.

b. Requirements for the majority of the rewind work are contained in Section 48 13 16.00 26 REWIND OF HYDRAULIC-TURBINE DRIVEN GENERATORS.

c. Requirements for inspection and refurbishment of thrust bearings are contained in Section 48 13 13.06 26, GENERATOR THRUST BEARING INSPECTION AND REFURBISHMENT. Guide bearing inspection and refurbishment requirements are contained in Section 48 13 13.07 26, GUIDE BEARING INSPECTION AND REFURBISHMENT.

3.6.2 Cleaning, Inspection and Recommendations

a. Clean all components and assemblies that are to be reused. Remove all rust, scale, oil, scum, grease and foreign matter.

b. Visually examine (inspect) all components for surface condition (wear, physical damage, cracks, etc.) and measure for dimensional acceptability. Record on Contractor provided inspection sheets.

c. Examine each component within 30 calendar days of its removal from the unit, unless specified differently elsewhere.

d. Notify the Government Quality Assurance Representative (GQAR) of the date and time of all inspections and who will witness the inspection unless waived in writing.

e. Submit an As-Found Inspection And Repair Recommendations Report for each component/system within ten calendar days of the completion of the component's inspection. Include in each report inspection results with applicable drawings of items inspected, measurements with a comparison to design dimensions, a visual inspection report documenting surface conditions, an evaluation of the components ability to function satisfactorily and recommendations for repair or replacement.

f. Based on the results of the examinations and the recommendations, the Government may direct the Contractor to perform additional inspection using LP, MT or UT, which would be paid for under the appropriate CLIN rate schedule item.

g. Provide all packing, O-rings, seals and gaskets between mating surfaces that are exposed to liquids for all replacement or refurbished items. For mating surfaces that are exposed to liquids, and that do not have the ability to accept the aforementioned items, use sealant.

h. Manually remove any burrs, sharp edges, nicks, gouges, minor worn areas, scuff marks, minor pitting or corrosion. Repair items disassembled by removal of weldments by an approved welding method prior to reassembly.

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j. Remove replacement component rust preventative coatings according to coating manufacturers' recommendations.

3.6.3 Repair

a. After review of the Contractor's inspection reports and recommendations, the Government will direct the Contractor in writing how to proceed with the repair. Repairs, which are specifically directed in writing, may require labor, parts and materials that can only be determined after disassembly and inspection. Such repairs will be paid for under the most appropriate CLIN schedule item.

b. Prepare and submit Procedures For Repair of Defects seven calendar days prior to commencing with repair. Crack repair cannot proceed prior to Government approval of the Procedure For Repair of Defects. Make the repair procedure for pre-existing cracks to eliminate their occurrence in the future. Address the prevention of future cracks, if applicable, in the repair procedure. Repairs, procedures and submittals must conform to Section 05 50 03.01 26, STRUCTURAL METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS and Section 05 50 03.02 26, PRESSURIZED METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS

PROVISIONS.

3.6.4 Laser Measurements of As-Found Rotor and Refurbished Rotor and Stator

After disassembly and before the rotor is reinstalled, a laser measurement tool must be used to measure both the rotor and the stator and then the air gap, rotor and stator concentricity, circularity, and elevation calculated from the measurements. This data must be correlated to the reference center/best center line. A minimum of three locations, top, middle, and bottom must be used on each pole. An equal number of measurements must be taken on the stator core. The data must include minimum, maximum, and averages of the data provide.