A.01.30_SWF-RDW_transformer_remanufacture_PWS_with_edits_05_09_2019.pdf

PERFORMANCE WORK STATEMENT (PWS)

R.D. WILLIS GENERATOR STEP-UP TRANSFORMER REMANUFACTURE

B.A. STEINHAGEN LAKE, JASPER COUNTY, TX

1. PROJECT BACKGROUND

R.D. Willis hydroelectric facility is built on the Town Bluff, or Dam “B”, structure at the

South end of B.A. Steinhagen Lake in Jasper County, Texas. The existing 8,900 kVA, 25kV Grd Y / 4,160V Delta R.D. Willis main generator step-up transformer, which also provided station service power, is failed on the high voltage A-phase and diesel is currently being used to power the station service loads. The U.S. Army Corps of Engineers: Fort Worth District intends issue a turn-key contract to remanufacture the existing transformer.

GENERAL: This is a non-personal services contract to provide the remanufacturing of existing 8,900 kVA, 25kV Grd Y / 4,160V Delta, R.D. Willis main generator step-up transformer and services. The Government shall not exercise any supervision or control over the contract service providers performing the services herein. Such contract service providers shall be accountable solely to the Contractor who, in turn is responsible to the Government:

1. Disconnection, rigging and movement to truck, and shipment of the existing transformer from the R.D. Willis hydroelectric facility to the remanufacturing facility.

2. Contractor shall comply with EM 385-1-1 and OPSEC requirements.

3. Remanufacturing of the transformer to include:

• Engineering services to determine remanufacturing requirements

• Three new low voltage coils

• Three new high voltage coils

• New gaskets

• New tank paint

• New external accessories –

• Bushings will be reused

• Nitrogen regulator will be reused

• All connections and processing

• Testing

4. Return shipment to the R.D. Willis hydroelectric facility, offload, placement, reconnection, and testing ready for service

5. Warranty period of 1 year after energizing at the facility to include all leaks, gassing above IEEE Condition 1 rates, and paint.

STATEMENT OF WORK:

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2. BID SCHEDULE

BID ITEMS UNITS QTY.

UNIT

PRICE TOTAL

0001: Transformer

Remanufacturing:

Disconnection, rigging, transportation to and offloading at the remanufacturing facility;

remanufacture; and transportation to and offloading at the R.D.

Willis facility, placement in operating location, testing for return to service, and completion of all external connections

JOB 1

TOTAL PRICE OF ALL BID ITEMS

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3. MEASUREMENT AND PAYMENT

To meet the requirements of this statement of work, the Contractor shall perform the following in accordance with the bid items listed above:

0001: Transformer Remanufacture: Payment for this item shall be made on a JOB basis to include all temporary protection, materials, tools, labor, and pre-work submittals required to perform all requirements of this Statement of Work at the RD Willis facility for removal

(disconnect the transformer power and control connections, remove the transformer from the vault location, load onto transport truck, transport to and offload at the remanufacturing facility), remanufacture, and reinstallation of the transformer (load onto transport truck, transport to the R.D. Willis facility, unload from the from the transport truck into the final vault location, reconnect all power and control wiring, test all connections, and test the transformer to certify ready for service) and additional work required to remove all temporary features, repair any damage to the facility, and make the installation ready for operation.

4. DETAILED REQUIREMENTS FOR SERVICES

A. Nameplate Information

A nameplate photo is included as an attachment to this scope of work. Key information is included here for bidding purposes.

Transformer Ratings:

Delta Star Serial No. Z490003

3 phase, 60 Hz, 2500 Grd Y / 14434 – 4160 Volts

6,675 / 8,900 kW, class OA / FA cooling

5.6% impedance

150 kV HV BIL

75 kV LV BIL

+3 / -1 @ 2.5% de-energized tap changer

Weights:

13,858 Un-tanking weight, lbs.

9,248 Tank and fittings, lbs.

864 Oil quantity, gallons

29,500 Complete oil-filled weight, lbs.

B. Transportation

The transformer may be transported oil-filled and fully assembled.

130 Length, inches

94 Width, inches

134.75 Height, inches

29,500 Complete oil-filled weight, lbs.

B.A. STEINHAGEN LAKE, JASPER COUNTY, TX

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C. Rigging

The transformer is in a 3-sided containment vault with clear access to the front after removing a chain-link fence. A small non-removable curb spans the front of the vault. A permissible loading diagram is included as an attachment to this scope of work. The transformer sits on top of the powerhouse structure, and loading must be strictly observed to prevent structural failure. A lifting / loading plan will be required indicating all trucks, cribbing, cranes, outriggers, and loading prior to work. This plan must be approved before removal can proceed. Note: No outriggers within the service bridge span or hatch.

D. Background Information

The transformer failed in service during a severe weather event in the area. All indications are of a failure in the A-phase high voltage coil or lead structure. All available data regarding the failure is provided in an attachment to this work statement. An inspection of the interior has not been performed. Dissolved gas-in-oil analysis supports arcing event under oil at greater than 700 degrees C. Oil analysis is available upon request.

E. Arrival Inspection

Perform all inspections and tests necessary to determine any deviations from the scope proposed in this document. Notify the Government immediately of any deviations. Upon un-tanking, document with photographs indicating the failure location, arc strikes to the tank wall, and other incident impacts of the in-service failure.

F. Remanufacturing: Active Assembly

Disassemble the top yoke and remove the existing transformer windings. Inspect the transformer core iron for suitability of re-use. Remanufacture new high voltage and low voltage coils of new copper and insulation with materials suitable for a 65 degree C temperature rise transformer rating. Incidental to this is all blocking, leads, spacers, and insulators required to land the remanufactured coils on the core assembly, clamped in place for short circuit strength and reconnected as a complete active assembly rated per the original nameplate.

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G. Bill of Materials

The bill of materials below is for external components. Items numbers correspond with H.K.

Porter Inc. drawing 346142, included as an attachment to this PWS.

No. Item Quantity Requirement

1 HV BUSHING, 25 KV 3

re-use existing, replaced 2016; replace gasket

2 LV BUSHING, 8.7 KV 3

re-use existing, replaced 2016; replace gasket

RADIATORS WITH SHUT-OFF

VALVES AND DRAIN AND VENT

PROVISIONS (DEMOUNTABLE, 5

TOTAL)

Replace 10 butterfly valves, 5 drains, 5 vents, and all gaskets. Inspect, leak-test, repair if necessary, and repaint radiators

BOLTED MANHOLE COVER,

APPROX 12x28 1 Replace gasket

LIFTING EYES FOR LIFTING

COVER ONLY

4 inspect, re-paint with tank

JUNCTION BOX FOR INTERNAL

C.T. LEADS WIRED TO CONTROL

CABINET

1 inspect, replace as-needed

PRESSURE RELIEF DEVICE W/

AUTOMATIC OPERATION AND

SIGNAL FOR INDICATION,

MANUAL RESET WITH ALARM

CONTACTS

replace with new, replace wiring to control cabinet termination

CONTROL CABINET WITH

PRIVISIONS FOR LOCKING,

BOLTED TO THE TANK WALL

1 no work required

3 INCH FLANGED CONNECTION

FOR VACUUM PUMP

1 replace blind flange and gasket

CORE GROUND TO COVER ACCESS

THRU ITEM 4

1 inspect, replace as-needed

ONE INCH DRAIN VALVE AND

FILTER PRESS CONNECTION WITH

3/8 SAMPLING DEVICE

1 replace, new blind flange and gasket

ONE INCH UPPER FILTER PRESS

CONNECTIONS

1 replace, new blind flange and gasket

TRANSFORMER TANK WITH

BOLTED ON COVER

1 inspect, re-paint, ANSI no. 70 grey

TRANSFORMER BASE WITH

PROVSION FOR ROLLING IN

EITHER DIRECTION

1 inspect, re-paint, ANSI no. 70 grey

LIFTING LUGS FOR LIFTING

TRANSFORMER COMPLETE WITH

LIQUID

4 inspect, re-paint with tank

SUDDEN PRESSURE RELAY WITH

CONTACTS WIRED TO ITEM 8

replace with new, replace wiring to control cabinet termination

B.A. STEINHAGEN LAKE, JASPER COUNTY, TX

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HV TAP CHANGER FOR

DEENERGIZED OPERATION,

WHEEL TYPE W/ PROVISION FOR

PADLOCKING

inspect assembly, re-grease, replace springs, replace rollers as-needed

18 STAINLESS STEEL NAMEPLATE 1

add adjacent nameplate for remanufacturing of HV and LV windings, indicating facility name, location, and month / year

GROUND PAD WITH (2) 1/2-13

TAPPED HOLES (2 TOTAL)

2 no work required

20 PRESSURE VACUUM GAUGE 1 replace with new

LIQUID LEVEL GUAGE WITH

ALARM CONTACTS (LOW LEVEL

AND HIGH LEVEL ALARMS)

replace with new, replace wiring to control cabinet termination

DIAL TYPE THERMOMETER WITH

ALARM CONTACTS (REMOTE

DIAL: 10-120 C RANGE

replace with new, replace wiring to control cabinet termination

HV LIGHTING ARRESTER (18KV)

STATION CLASS

3 no work required

WINDING TEMPERATURE

INDICATOR WITH CONTACTS

(REMOTE DIAL)

replace with new, replace wiring to control cabinet termination

HV NEUTRAL COVER MOUNTED

CURRENT TRANSFORMER,

EXTERNAL TYPE, 10:5

replace with new, replace wiring to control cabinet termination

26 FANS - 25 INCH 1/2 HP 4

replace with new (Krenz-vent or equivalent), replace wiring to control cabinet termination

HV BCT 300/5 C50 (2 PER PHASE 6

TOTAL)

replace with new, replace wiring to control cabinet termination

* 28

HV COVER MOUNTED POTENTIAL

TRANSFORMER (3 TOTAL)

3 remove and store at site; reinstall

H0 GROUNDING PROVISIONS 1/4 X

2 COPPER BUS TO ITEM 19

1 inspect hardware and replace as-needed

30 TWO INCH FLANGED GATE VALVE 1 replace, new blind flange and gasket

HV NEUTRAL BUSHING, 15 KV, 600

AMPS

re-use existing, replaced 2016; replace gasket

PORTERAIRE NITROGEN GAS

REGULATING SYSTEM WITH

PURGING VALVE

inspect for leaks, replace components or seals as-needed

OIL LEVEL MARKINGS - 20, 25, & 95

DEG C PERMANENT WELD LINES

1 no work required

* REMOVE FOR SHIPMENT

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H. Testing – Factory

Test the transformer to affirm success of remanufacturing and suitability for return to service prior to shipment from the factory per IEEE and NETA requirements for class of equipment. Government representation for witness testing at the Factory’s final testing is required. Contractor to provide government minimum of 10 working day notice prior to factory test date.

I. Testing – after installation

After offloading from the transportation truck to the final operation location, test the transformer to ensure no damage from transportation and certify for operation per IEEE and

NETA requirements for class of equipment.

J. Installation

Reconnect all external control and power connections. Working with Government personnel, verify that all functions are operating correctly and providing signals to Government equipment in the powerhouse.

K. Warranty

The warranty period shall be for 1 year following 48 hours of successful energized operation after installation. In addition to the active assembly, the warranty shall include all leaks, paint systems, and any gassing conditions beyond Condition 1 defined in IEEE C57.104.

B.A. STEINHAGEN LAKE, JASPER COUNTY, TX

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5. DELIVERABLES

All deliverable products and documents shall be the property of USACE. Submit one paper copy of all non-electronic files. Deliverables for this scope of work are as follows:

A. Schedule. Provide a schedule within 7 calendar days after notice to proceed. The schedule shall specifically note where USACE support is needed onsite. The Schedule shall also include major and minor work elements and stages of the work.

B. Per USACE EM 385-1-1 Section 01.A12 Accident Prevention Plan (APP) shall be submitted and accepted by GDA prior to initiation of any work activity, The APP shall be submitted with in Ten (10) calendar day of NTP.

C. Proposed Site Work Plan - Removal. Provide a written plan of onsite work including deck loading for movement of the transformer and transport truck and personnel information for security clearance.

SAFE CLEARANCE PROCEDURES:

A Safe Clearance System, as stated in EM 385-1-1, and EM 385-1-31 and the power plant

Safe Clearance procedure, is used by project personnel to insure continuity of service and safety to personnel and equipment. Any work performed which requires taking project operating equipment out of service will be done only after a formal clearance is obtained by the Government with a seven calendar day notice. After the Government clearance tags and locks have been placed on the equipment, the Contractor shall place his own clearance tag and lock on the equipment. Safe Clearance procedures shall not be violated by Contractor personnel, and any violations will be grounds for requesting the removal of the offender(s). A copy of the Safe Clearance Procedure program will be supplied to the Contractor upon request.

D. Receiving Inspection. Provide a written report receiving inspection report of test results, external physical inspections, and internal physical inspections of the transformer. Note any deviations from expected condition that may affect the scope of remanufacturing.

E. Test results - factory. Provide a written report of all test results from the remanufacturing facility. Where digital files, such as with Doble test systems, are available, provide the digital file on a compact disc.

F. Proposed Site Work Plan - Install. Provide a written plan of onsite work including deck loading for movement of the transformer and transport truck and personnel information for security clearance.

G. Test Results - field. Provide a written report of all test results to the USACE within 3 days after completion of tests. Where digital files, such as with Doble test systems, are available, provide the digital file on a compact disc.

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6. SCHEDULE

All services under this agreement shall be completed NLT 360 days after award. Specific milestones are as follows:

MILESTONE COMPLETION DATE

Award

Schedule 7 calendar days after Award

Pre-Work Conference /Site visit 14 days after Award

Proposed Site Work Plan - Removal 14 calendar days prior to work

Receiving Inspection 5 calendar days after inspection

Test Results - Factory 3 calendar days following testing

Test Factory- Prior to shipment [ Government witness Test] 10 work days prior to test [notification required.]

Proposed Site Work Plan - Install 14 calendar days prior to work

Test Results - field 3 calendar days following testing

Job Completion

7. COORDINATION

Coordinate delivery scheduling, offloading location, and site access with the R.D. Willis

Project POC. Make every effort to resolve issues in a timely manner before they become a problem.

Project Manager. The Contractor shall appoint a project manager (PM) to serve as a single point-of-contact (POC) and liaison between USACE and the Contractor. Upon signed agreement, the Contractor shall immediately advise the R.D. Willis Project POC of the individual so designated. The PM shall be responsible for the coordination of all work performed for this contract and may be the site supervisor overseeing the work.

PLANT AND EQUIPMENT IDENTIFICATION. The contractor shall identify major plant and equipment and keep the Superintendent informed of what is on site.

TRASH. All refuse generated by the contractor shall be removed by contractor.

DAMAGED EQUIPMENT OR ABNORMAL CONDITIONS. The Government shall be informed immediately upon finding any damaged equipment or other abnormal conditions.

The failure or abnormality shall not be disturbed until witnessed by the Powerhouse

Superintendent. Prior to proceeding further with work on the unit, the Contractor, Owner, and the Government shall agree in writing as to the responsibility for the damage or abnormality.

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Government Project Personnel Working Hours. The scheduled working hours of the

Project staff at the R.D. Willis power plant are Mondays through Fridays from 7:30 a.m. until

5:00 p.m. Saturdays, Sundays and Federal Holidays are non-work days. All Project support required by the Contractor shall be scheduled during the Project staff working hours.

Contractor's Working Hours. The allowable Contractor's working hours shall be the same as that for the Government project personnel, unless otherwise specifically approved. The schedule of work hours, shifts and days of the week shall be coordinated with the Powerhouse

Superintendent. Notification of any proposed changes of the schedule of regular work hours, overtime work hours, and shifts of work crews and personnel at the site shall be coordinated with the Powerhouse Superintendent.

Sanitation Facilities. The nearest bathroom facilities are offsite at Sandy Creek Park.

USACE POCs

ASSIGNMENT PERSONNEL PHONE EMAIL

R.D. Willis Project POC Tom Webb (409) 384-5292 thomas.r.webb@usace.army.mil

Invoices POC

8. R.D. WILLIS POWERHOUSE COORDINATION AND ACCESS

R.D. Willis is a remote unmanned powerhouse West of Jasper, TX accessed via County

Road 154. The approximate location is shown on the map below. Personnel and equipment accessing the powerhouse will be escorted by USACE Personnel to the site.

mailto:thomas.r.webb@usace.army.mil

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Coordinate access with:

Tom Webb

Superintendent

Piney Woods Hydropower Business Line Manager

Sam Rayburn / RD Willis Power Plants

(409) 384-5292 or (409) 384-9368

Thomas.r.webb@usace.army.mil

OPSEC REQUIREMENTS:

AT Level I Training. This provision/contract text is for contractor employees with an area of performance within an Army controlled installation, facility or area. Proposed language:

"All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, controlled access areas, or require network access, shall complete AT

Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. Upon request, the contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer (if a COR is not assigned), within 5 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website:

http://jko.jten.mil/courses/atl1/launch.html; or it can be provided by the RA ATO in presentation form which will be documented via memorandum."

Access and General Protection/Security Policy and Procedures. This standard language text is for contractor employees with an area of performance within an Army controlled installation, facility or area. Proposed language: "All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office.

Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by

DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes."

mailto:Thomas.r.webb@usace.army.mil

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For contractors who do not require CAC, but require access to a DoD facility or installation. Proposed language: Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime

Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening

Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures

(provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

Suspicious Activity Reporting Training (e.g. iWATCH, CorpsWatch, or See Something, Say Something). This standard language is for contractor employees with an area of performance within an Army controlled installation, facility or area. Proposed language:

"The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training."

Will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas. The contractor will coordinate with the

COR and/or the facility security office for access when required. (Use when security clearances are not required, i.e. facility repair or construction). Proposed language: "All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas."

(FOR CLASSIFIED CONTRACTS ONLY) Contractor Company to obtain a Facility

Clearance and individual clearances at the appropriate level. Proposed language: "The

Prime Contractor Company must have a Facility Clearance (FCL) at the appropriate level

(IAW the NISPOM DOD 5220.22-M and AR 380-49) prior to the start of the contract awarded period of performance. Contractor personnel performing work under this contract must have the required security clearance, per AR 380-67, at the appropriate level at the start of the period of performance. Security Clearances and FCL requirements are required to be maintained for the life of the contract IAW the DD Form 254 attached to the contract. If no

FCL, the supporting Government Contracting Activity will sponsor the prime contract company in obtaining the FCL."

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Pre-screen candidates using E-Verify Program. Proposed language: "The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than 3 business days after the initial contract award." *When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility Verification, with the designated Government representative. This Form will be provided to the Contracting

Officer and shall become part of the official contract file.

REFERENCES. All work shall comply with the requirements of these publications. The publications are referenced to in the text by basic definition only.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

EM 385-1-31The Control of Hazardous Energy

UNIFIED FACILITIES GUIDE SPECIFICATIONS (UFGS)

UFGS 01 57 19 Temporary Environmental Controls

U.S. DEPARTMENT OF THE ARMY (DA)

ARMY REGULATION (AR) DA AR 200-1 Environmental Protection and Enhancement

9. ATTACHMENTS

1. Map – Regional

2. Map – Local

3. Map – Satellite view of facility

4. Drawing – Plan – El 85.0 – powerhouse deck loading limits

5. Drawing – El 85.0 – powerhouse deck

6. Drawing – GSU vault and tower

7. Drawing – 346142 – Transformer outline and assembly

8. Drawing – 345150 – Transformer wiring diagram

9. Drawing – Transformer LV terminal cover box

10. Photo – El 85.0 Back of vault

11. Photo – El 85.0 Access area

12. Photo – El. 85.0 Front of vault