PBS_with_Tech_Specs.pdf

PERFORMANCE BASED SCOPE (PBS)

OAHE THRUST BEARING REFURBISHMENT

PART 1

GENERAL INFORMATION

1. GENERAL: This is a non-personal services agreement to provide services to refurbish two sets of Oahe Powerhouse generator thrust bearing shoes, package for shipment, and shipment between the project and the Contractor’s refurbishment workshop. One set will be completed and returned prior to the second set being shipped within 30 days after receiving the first refurbished set. The Government shall not exercise any supervision or control over the agreement service providers performing the services herein. Such service providers shall be accountable solely to the Contractor who, in turn is responsible to the Government.

1.1 Description of Services/Introduction: The contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to perform the refurbishment of the thrust bearing shoes as defined in this Performance Based Scope except for those items specified as government furnished property and services. The contractor shall perform to the standards in this agreement and the technical specifications attached.

1.2 Background: The refurbishment services will be accomplished at the Contractor’s site. The Contractor must ensure they can perform to USACE specifications by providing references and/or samples of work upon request.

1.3 Objectives:

Refurbish the thrust bearing shoes according to specifications.

Package the shoes according to the specifications.

Ship the shoes from the Government facility to the Contractor facility and back to the Government. Two shipments will be required.

1.4 Scope: The refurbishment of the thrust bearing shoes shall be performed as specified in Technical Sections: 48 13 13.05 26 (Generator Thrust Bearing Refurbishment) and 05 05 23.20 26 (Welding), Tolerance Sheets, and Shoe Dimension Sheet.

1.4.1. Estimate Quantity of Work: The U.S. Army Corps of Engineers, Omaha District, Oahe Project has two sets (each set is fourteen sections) of thrust bearing shoes to be refurbished.

1.4.2. Starting Date: Work is to begin within 15 days of written notice by the USACE and delivered back to the Oahe Project within 150 days, unless a mutually agreed upon start and completion date is approved by the COR. The first set is to be refurbished and returned to the Oahe Project within 45 days. The second set will then be prepared for shipment by USACE within 30 days of receiving the first refurbished set.

1.5 Period of Performance: The period of performance shall be for 150 days.

1.6 General Information

1.6.1 Quality Control: The contractor shall develop and maintain an effective quality control program (QCP) to ensure services are performed in accordance with this Performance Based Scope. The contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. The contractor’s quality control program is the means by which he assures himself that his work complies with the requirement of the agreement. The contractor’s quality control program shall be submitted with the contractor’s quote for evaluation (if evaluation factors are used and not based on low price). Three copies of a comprehensive written QCP shall be submitted to the Contracting Officers Representative within five (5) working days of award and when any changes are made. The contractor shall receive the Contracting Officer’s acceptance in writing of any proposed change to his QCP system.

1.6.2 Quality Assurance: The Government shall evaluate the contractor’s performance under this agreement in accordance with the Quality Assurance Surveillance Plan. This plan is primarily focused on what the Government must do to ensure that the contractor has performed in accordance with the performance standards. It defines how the performance standards will be applied, the frequency of surveillance, and the minimum acceptable defect rate(s).

1.6.3 Recognized Holidays: The Contractor is not required to work on the following recognized Federal holidays:

New Year’s Day Labor Day Martin Luther King Jr.’s Birthday Columbus Day President’s Day Veteran’s Day Memorial Day Thanksgiving Day Independence Day Christmas Day

1.6.4 Hours of Operation: The contractor is responsible to be available, between the hours of 8:00 a.m. to 5:00 p.m. CST Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. The Contractor must at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PBS. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

1.6.5 Place of Performance: The work to be performed under this agreement will be performed at the Contractor’s service facility.

1.6.6 Type of Agreement: The government will award a firm fixed priced Contract.

1.6.7 Security Requirements: 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 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 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 individual facility or installation change, the Government may require changes in Contractor security matters or processes. No background checks are required for this contract.

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.

1.6.7.1 PHYSICAL Security: The contractor shall be responsible for safeguarding all government information, materials, and property provided to the contractor.

1.6.8 Special Qualifications: The Contractor must pre-screen Candidates using the E-verify Program (http://www.dhs.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 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.

1.6.9 Key Personnel: The following personnel are considered key personnel by the government: Ms. Kris Cleveland, Chief Technical Support. The contractor shall provide a contract manager who shall be responsible for the performance of the work. The name of this person and an alternate, who shall act for the contractor when the manager is absent, shall be designated in writing to the contracting officer. The contract manager or alternate shall have full authority to act for the contractor on all matters relating to daily operation of this agreement. The COR or alternate shall be available between 8:00 a.m.

to 5:00 p.m. CST Monday thru Friday except Federal holidays or when the government facility is closed for administrative reasons.

1.6.10 Data Rights: The Government has unlimited rights to all documents/material produced under this agreement. All documents and materials, to include the source codes of any software, produced under this agreement shall be Government owned and are the property of the Government with all rights and privileges of ownership/copyright belonging exclusively to the Government. These documents and materials may not be used or sold by the contractor without written permission from the Contracting Officer.

All materials supplied to the Government shall be the sole property of the Government and may not be used for any other purpose. This right does not abrogate any other Government rights.

1.6.11 Organizational Conflict of Interest: Contractor and subcontractor personnel performing work under this agreement may receive, have access to, or participate in the development of proprietary or source selection information (e.g., cost or pricing information, budget information or analyses, specifications or work statements, etc.) or perform evaluation services which may create a current or subsequent Organizational Conflict of Interests (OCI) as defined in FAR Subpart 9.5. The Contractor shall notify the Contracting Officer immediately whenever it becomes aware that such access or participation may result in any actual or potential OCI and shall promptly submit a plan to the Contracting Officer to avoid or mitigate any such OCI. The Contractor’s mitigation plan will be determined to be acceptable solely at the discretion of the Contracting Officer and in the event the Contracting Officer unilaterally determines that any such OCI cannot be satisfactorily avoided or mitigated, the Contracting Officer may affect other remedies as he or she deems necessary, including prohibiting the Contractor from participation in subsequent contracted requirements which may be affected by the OCI.

ATTACHMENTS

Attachment A- Shoe Dimension Sheet

Attachment B-Tolerance Sheets

PART 2

DEFINITIONS & ACRONYMS

2. DEFINITIONS AND ACRONYMS:

2.1. DEFINITIONS:

2.1.1. CONTRACTOR: A supplier or vendor awarded a contract to provide specific supplies or service to the government. The term used in this contract refers to the prime.

2.1.2. CONTRACTING OFFICER: A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the Government. Note: The only individual who can legally bind the Government.

2.1.3. CONTRACTING OFFICER'S REPRESENTATIVE (COR): An employee of the U.S. Government appointed by the contracting officer to administer the contract. Such appointment shall be in writing and shall state the scope of authority and limitations.

This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the agreement, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the agreement.

2.1.4. DEFECTIVE SERVICE: A service output that does not meet the standard of performance associated with the Performance Work Statement.

2.1.5. DELIVERABLE: Anything that can be physically or electronically delivered, but may include non-manufactured things such as meeting minutes or reports.

2.1.6. KEY PERSONNEL: Contractor personnel that are evaluated in a source selection process and that may be required to be used in the performance of a agreement by the Key Personnel listed in the PWS. When key personnel are used as an evaluation factor in best value procurement, an offer can be rejected if it does not have a firm commitment from the persons that are listed in the proposal.

2.1.7. PHYSICAL SECURITY: Actions that prevent the loss or damage of Government property.

2.1.8. QUALITY ASSURANCE: The government procedures to verify that services being performed by the Contractor are performed according to acceptable standards.

2.1.9. QUALITY ASSURANCE SURVEILLANCE PLAN (QASP): An organized written document specifying the surveillance methodology to be used for surveillance of contractor performance.

2.1.10. QUALITY CONTROL: All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet agreement requirements.

2.1.11. SUBCONTRACTOR: One that enters into a contract with a prime contractor.

The Government does not have privity of contract with the subcontractor.

2.1.12. WORK DAY: The number of hours per day the Contractor provides services in accordance with the agreement.

2.1.12. WORK WEEK: Monday through Friday, unless specified otherwise.

2.2. ACRONYMS:

ACOR Alternate Contracting Officer's Representative AFARS Army Federal Acquisition Regulation Supplement AR Army Regulation CCE Contracting Center of Excellence CFR Code of Federal Regulations CONUS Continental United States (excludes Alaska and Hawaii) COR Contracting Officer Representative COTR Contracting Officer's Technical Representative COTS Commercial-Off-the-Shelf DA Department of the Army DD250 Department of Defense Form 250 (Receiving Report) DD254 Department of Defense Contract Security Requirement List DFARS Defense Federal Acquisition Regulation Supplement DMDC Defense Manpower Data Center DOD Department of Defense FAR Federal Acquisition Regulation HIPAA Health Insurance Portability and Accountability Act of 1996 KO Contracting Officer OCI Organizational Conflict of Interest OCONUS Outside Continental United States (includes Alaska and Hawaii) ODC Other Direct Costs PIPO Phase In/Phase Out POC Point of Contact PRS Performance Requirements Summary PWS Performance Work Statement QA Quality Assurance QAP Quality Assurance Program QASP Quality Assurance Surveillance Plan QC Quality Control QCP Quality Control Program TE Technical Exhibit

PART 3

GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

3. GOVERNMENT FURNISHED ITEMS AND SERVICES:

3.1. Services: The Government will provide two sets of thrust bearing shoes (each set is fourteen sections) to be refurbished according to the specifications at the Contractor’s facility.

3.2 Facilities: Not applicable.

3.3 Utilities: Not applicable.

3.4 Equipment: Not applicable.

3.5 Materials: Not applicable.

PART 4

CONTRACTOR FURNISHED ITEMS AND SERVICES

4. CONTRACTOR FURNISHED ITEMS AND RESPONSIBILITIES:

4.1 General: The Contractor shall furnish all software, supplies, equipment, facilities and services required to perform work under this agreement that are not listed under Section 3 of this PBS.

4.2 Secret Facility Clearance: Not applicable.

4.3. Materials: The Contractor shall furnish materials, supplies, and equipment necessary to meet the requirements under this PBS.

4.4. Equipment: The Contractor shall furnish everything necessary to meet the requirements under this PBS.

PART 5

SPECIFIC TASKS

5. Specific Tasks:

5.1. Basic Services: The contractor shall provide services to refurbish two complete sets of thrust bearing shoes, package the bearing for shipment, and provide pickup and return shipping between Oahe Project and the Contractor’s facility. The bearing sets shall be in two different shipments separated by a period of 30 days to allow the government to install the first set and prepare the second set for shipment to the Contractor’s facility.

The Contractor is responsible for all shipping fees.

PART 6

APPLICABLE PUBLICATIONS

6. Publications (Current Editions):

6.1. The Contractor must abide by all applicable regulations, publications, manuals, and local policies and procedures, including:

6.1.1 Federal Records Act of 1950, as amended, Subchapter B of 36 Code of Federal Regulations Chapter XII

6.1.2 Freedom of Information Act, exemptions 5 U.S.C. § 552(b)(1)-(9);

http://www.gpoaccess.gov/cfr/index.html

TABLE 1

THRUST BEARING COMPONENTS

Location In Unit Below Rotor Number Of Shoes 14 Shoe (Nominal) Measurement# OD (optional) 100 1 ID (optional) 70 2 Overall Thickness 2.5 in. 3 Babbitt Thickness 7/16 in. 4

Circumferential Chord Segment Length (Outside) 17 ¾ in 5

Circumferential Chord Segment Length (Inside) 12 ½ in. 6

Shoe Radial Segment Length 14 7/8 in 7

#7

#6

#5

#2

#1

#4

TOLERANCES FOR STATIONARY THRUST BEARING SHOE SEGMENTS MACHINED ALL AT

ONE TIME

1. CIRCUMFERNTIAL RUNOUT

A DIAL INDICATOR SHALL BE MOUNTED IN THE HEAD OF THE MACHINE TOOL WITH

THE STEM OF THE INDICATOR RESTING ON AN INDIVIDUAL SHOE’S BABBITTED

SURFACE. THE MACHINE TABLE SHALL THEN BE SLOWLY ROTATED AND READINGS

TAKEN WHEN THE STEM IS ON EACH INDIVIDUAL SHOE. VARIATIONS ON AN

INDIVIDUAL SHOE AND AMONG THE SET OF SHOES SHALL NOT BE MORE THAN 0.0005

INCHES OVER ONE COMPLETE REVOLUTION OF THE TABLE. THIS CHECK SHALL BE

MADE NEAR THE I.D., CENTER, AND O.D. OF THE SHOES.

2. DISH FLATNESS

INDIVIDUAL SHOES SHALL BE CHECKED FOR FLATNESS USING APPROVED METHOD. THE

BABBITTED SURFACE SHALL BE FLAT OR CONCAVE WITH THE MAXIMUM LOW SPOT IN

THE CENTER OF THE SHOE. THE LOW SPOT SHALL NOT EXCEED 0.0015 INCHES. THIS

LOW SPOT SHALL NOT INCLUDE OIL HOLES, THREADED HOLES, OR OIL GROOVES OR

POCKETS. A BABBITTED SURFACE THAT IS CONVEX (OUTER EDGE OF SHOE LOWER

THAN CENTER PORTION OF SHOE) IS UNACCEPTABLE AND WILL BEREJECTED.

3. FLATNESS OF BACKSIDE

THE FLATNESS OF THE BACKSIDE SHALL BE MEASURED FOR FLATNESS USING

APPROVED METHOD AND SHALL BE FLAT WITHIN 0.001 INCHES. A MINIMUM OF 4

MEASUREMENTS ALONG EACH EDGE (1 INCH IN FROM EDGE) AND 2 DIAGONAL

MEASUREMENTS FROM THE I.D. TO O.D. CORNERS SHALL BE TAKEN.

4. VARIATION IN THICKNESS

THE VARIATION IN OVERALL SHOE/BABBITT THICKNESS SHALL NOT EXCEED 0.001

INCHES OVER THE ENTIRE SURFACE OF AN INDIVIDUAL SHOE WHEN MEASURED ON ANY

CIRCLE CONCENTRIC WITH THE BORE. A MINIMUM OF 3 EVENLY SPACED MEASUREMENT

PER SHOE SHALL BE TAKEN ON 3 CIRCLES CONCENTRIC WITH THE BORE, I.E., NEAR

THE I.D., CENTER, AND O.D.SEE SKETCH BELOW:

5. SURFACE FINISH

THE BABBITTED SURFACE AND BACKSIDE OF THE SHOES SHALL HAVE A FINISHED

SURFACE OF 16 AND 63 MICROINCHES OR BETTER, RESPECTIVELY. THE FINISH

SHALL BE MEASURED USING A PROFILOMETER, OR AS APPROVED.

TOLERANCES FOR STATIONARY THRUST BEARING SHOE SEGMENTS MACHINED

SEPARATELY

1. DISH FLATNESS

INDIVIDUAL SHOES SHALL BE MEASURED FOR FLATNESS USING THE SAME GRANITE

TABLE IN CONJUNCTION WITH THE SAME COORDINATE MEASURING MACHINE, HEIGHT

GAUGE, OR OTHER APPROVED METHOD. ALL MEASURING DEVICES SHALL BE ACCURATE

TO 0.0001 INCHES. THE BABBITTED SURFACE SHALL BE FLAT OR CONCAVE WITH THE

MAXIMUM LOW SPOT IN THE CENTER OF THE SHOE. THE LOW SPOT SHALL NOT EXCEED

THE AMOUNT INDICATED BELOW. THIS LOW SPOT SHALL NOT INCLUDE OIL HOLES,

THREADED HOLES, OR OIL GROOVES OR POCKETS. A BABBITTED SURFACE THAT IS

CONVEX (OUTER EDGE OF SHOE LOWER THAN CENTER PORTION OF SHOE) IS

UNACCEPTABLE AND WILL BE REJECTED. A MINIMUM OF 7 SWEEP MEASUREMENTS PER

SHOE SHALL BE TAKEN: 3 EVENLY SPACED MEASUREMENTS ON 3 CIRCLES CONCENTRIC

WITH THE BORE, I.E., NEAR THE I.D.,CENTER, AND O.D., 2 ALONG THE LEADING

EDGE AND TRAILING EDGE OF THE SHOE, AND 2 FROM THE OPPOSITE CORNERS, SEE

SKETCHES BELOW FORDIRECTION AND TOLERANCES:

2. FLATNESS OF BACKSIDE

THE FLATNESS OF THE BACKSIDE SHALL BE MEASURED FOR FLATNESS USING

APPROVED METHOD AND SHALL BE FLAT WITHIN 0.001 INCHES. A MINIMUM OF 4

MEASUREMENTS ALONG EACH EDGE (1 INCH IN FROM EDGE) AND 2 DIAGONAL

MEASUREMENTS FROM THE I.D. TO O.D. CORNERS SHALL BE TAKEN.

3. VARIATION IN THICKNESS

THE VARIATION IN OVERALL SHOE/BABBITT THICKNESS SHALL NOT EXCEED 0.001

INCHES OVER THE ENTIRE SURFACE OF AN INDIVIDUAL SHOE AND THE ENTIRE SET

OF SHOES WHEN MEASURED ON ANY CIRCLE CONCENTRIC WITH THE BORE. A MINIMUM

OF 3 EVENLY SPACED MEASUREMENT PER SHOE SHALL BE TAKEN ON 3 CIRCLES

CONCENTRIC WITH THE BORE, I.E., NEAR THE I.D., CENTER, AND O.D. SEE

SKETCH BELOW:

4. SURFACE FINISH

THE BABBITTED SURFACE AND BACKSIDE OF THE SHOES SHALL HAVE A FINISHED

SURFACE OF 16 AND 63 MICROINCHES OR BETTER, RESPECTIVELY. THE FINISH

SHALL BE MEASURED USING A PROFILOMETER, OR AS APPROVED.

0.0005 INCHES 0.0015 INCHES 0.0015 INCHES

*****TOLERANCES FOR BASE PLATE*****

1. BASE PLATE SURFACE.

A. CIRCUMFERENTIAL RUNOUT.

A DIAL INDICATOR SHALL BE MOUNTED IN THE MACHINING HEAD WITH THE STEM OF

THE INDICATOR RESTING ON THE RUNNING FACE, BACKSIDE OF THE BASE PLATE.

THE BASE PLATE SHALL BE SLOWLY ROTATED AND THE READINGS OBSERVED.

VARIATIONS SHALL NOT BE MORE THAN 0.0003 INCHES OVER ONE COMPLETE

REVOLUTION OF THE RUNNER OR BASE PLATE. THIS CHECK SHALL BE MADE NEAR THE

I.D., CENTER, AND O.D. OF THEFACE WIDTH.

B. RADIAL FLATNESS.

A RADIAL CHECK, BY LAYING A STRAIGHT EDGE ACROSS THE RUNNING AND BACKSIDE

FACES OF THE BASE PLATE SURFACE, SHALL BE MADE TO VERIFY THE FLATNESS,

SEE FIGURE 1. THE FACES AND SURFACE SHALL BE TRUE WITHIN 0.0005 INCHES

WHEN CHECKED IN THIS MANNER. ALTERNATE MEASURING METHODS SHALL BE

SUBMITTED FOR APPROVAL.

C. DISH FLATNESS.

TO CHECK FOR DISH FLATNESS, LAY A STRAIGHT EDGE ALONG A CHORD LINE ON THE

BASE PLATE SURFACE, SEE FIGURE 2. THE FACES AND SURFACE SHALL BE FLAT

WITHIN 0.0015 INCHES. A CONCAVE SHAPE IS ACCEPTABLE, I.E. WITH THE LOW

POINT TOWARD THE CENTER. A CONVEX SHAPE (O.D. SURFACE EDGE IS LOWER THAN

I.D. SURFACE EDGE) IS NOT ACCEPTABLE AND WILL BE REJECTED.

∗ BASE PLATE REFERS TO EITHER A SEPARATE PLATE OR THE BORING MILL’S

MACHINING TABLE.

SECTION 48 13 13.05 26

GENERATOR THRUST BEARING REFURBISHMENT

07/08

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.1.1 Description of Work

This Section governs the refurbishment of the Oahe Powerhouse generator thrust bearing shoes, packaging for shipment and shipment between the project and the Contractor's refurbishment workshop.

1.1.2 Description of Thrust Bearing

The stationary portion of the bearing consists of 14 steel-backed babbitt segments or shoes which are each supported on pre-compressed springs. The overall shoe thickness is 2.5 inches including a dove tailed Babbitt layer of approximately 7/16 inch above the dove tail. The babbitt is of a lead base. Additionally stationary components consist of the high-pressure lift system, cooling water coils and electrical insulation.

General information follows in Table 1.

TABLE 1

THRUST BEARING COMPONENTS

Location In Unit Below Rotor Number Of Shoes 14 Shoe (Nominal) OD 100 in.

ID 70 in.

Overall Thickness 2.5 in.

Babbitt Thickness 7/16 in.

Circumferential Chord Segment Length (Outside) 17 ¾ in.

Circumferential Chord Segment Length (Inside) 12 1/2 in.

Shoe Radial Segment Length 14 7/8 in.

Dimensions, fits and estimated weights are based on original design drawings, design criteria and/or calculations. The Government does not warrant or guarantee that these values are accurate.

1.2 REFERENCES

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPC, SECTION V Non-destructive Examination

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM B 23 (2000) White Metal Bearing Alloys

ASTM E 114 (2001) Standard Practice for Ultrasonic Pulse-Echo Straight-Beam

Examination by the Contact Method

ASTM E 165 (2002) Liquid Penetrant Inspection Method

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 (2004) Structural Welding Code - Steel

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. These submittals will be required after date of award.

SD-01 Pre-Construction Schedules

Schedule For Shoe Refurbishment;

Submit 10 calendar days in advance of refurbishment," Paragraph 3.2.1.d, General Requirements".

SD-03 Product Data

Certified Chemical Analysis Of the Babbitt And Tin;

Submit 7 calendar days prior to tinning," Paragraph 2.1.d, Babbitting Materials".

Proof of ISO 9000 certification or equivalence;

Submit 7 calendar days prior to shipment from the project, "Paragraph 2.3, ISO Certification".

Pre-Shipping Damage Inspection; G

Prior to shipment from the project," Paragraph 3.1.1.a, Shipping General".

NDT Personnel/Laboratory Qualifications;

Submit 10 calendar days prior to performing any NDT, " Paragraph 3.3.2.1,Examination of the Babbitt Bonding".

SD-04 Samples

Samples Of Materials;

Submit within 10 days of request, PART 2," Paragraph 2.2, Materials and Workmanship".

SD-06 Test Reports

Thrust Shoe Finished Inspection Report; G Submit 5 calendar days following inspections and prior to shipment," Paragraph 3.2.3.f, Notice of Thrust Shoe Finished Inspection/Final Report".

SD-07 Certificates

Notice Of Thrust Shoe Finished Inspections;

Submit 7 calendar days in advance of inspections," Paragraph 3.2.3.c, Notice of Thrust Shoe Finished Inspection/Final Report".

Notification Of Welding Repair;

Submit 7 calendar days in advance of welding," Paragraph 3.4.2, Repair of Thrust Bearing Components".

SD-08 Manufacturer's Instructions

Thrust Shoe Refurbishment Procedure; G Submit 10 calendar days in advance of repairs," Paragraph 3.2.1.c, General Requirements".

1.4 FINAL INSPECTION AND ACCEPTANCE

Final inspection and acceptance for full compliance with the Specifications will be made by the Government upon delivery to the project. Any materials or workmanship not complying with the provisions of these specifications will be cause for rejection. Corrections shall be made at the expense of the Contractor, and are subject to approval. Tests may be repeated at the project site to ensure that materials and workmanship conform to contract requirements. Tests will be at the Contractor's expense if the refurbished components do not meet contract requirements.

1.5 WARRANTY

Warranty provisions of these Specifications shall apply, except that notwithstanding inspection and acceptance, the shoes shall be warranted to conform to these specifications for three years after receipt and acceptance at delivery site or 8000 hours of unit operation after installation, whichever comes first.

PART 2 PRODUCTS

2.1 BABBITTING MATERIALS

a. The babbitt metal shall be new material conforming to ASTM B 23 Alloy 2.

b. The tin used for tinning shall be 99 percent pure.

c. Use of reclaimed metal will not be acceptable.

d. The Contractor shall submit a certified chemical analysis of the babbitt and tin material prepared by an independent testing laboratory prior to performing any tinning. The laboratory shall not be associated with the Contractor in any way.

2.2 MATERIAL AND WORKMANSHIP

All materials, parts, and components supplied shall be new and unused and of the best available kind and quality. Workmanship shall be of the highest grade and in accordance with the best modern standard practice. Samples of materials shall be submitted upon request.

2.3 ISO CERTIFICATION

The workshop where the guide bearing will be refurbished shall be ISO 9000 certified or equivalent as approved by the government. Proof of ISO 9000 certification or equivalence shall be submitted to the Government within 7 calendar days prior to shipment from the project.

PART 3 EXECUTION

3.1 SHIPPING

3.1.1 Shipping General

The following general requirements apply to the bearing shoes.

a. The Government will prepare and package the thrust bearing shoes for shipment from the Oahe Powerplant. The Government will provide all necessary forklift service at the Oahe Powerplant for loading and unloading.

b. The Contractor may visually inspect the components condition prior to shipment from the site.

Any existing damage shall be recorded, witnessed and "signed off" by the Government, and submit a pre-shipping damage inspection prior to shipment.

c. All components shall be prepared for shipment in a manner to protect them from damage and the Contractor shall be responsible for and make good at no extra cost to the Government damage resulting from improper preparation, as well as for damage occurring during inspection, shipping or refurbishment.

d. Prior to shipment, coat components with a suitable preservative.

e. If steel banding is used it shall have adequate protection so that it does not harm the shoes.

f. The crates and all packaging shall become the property of the Government.

3.1.2 Shipment of Thrust Bearing Shoes

a. Prior to shipping cover all inlets and outlets to exclude dirt, water, etc.

b. The Contractor shall provide packaging as required, package for shipment and provide transportation roundtrip for individual shoes or one set of thrust shoes between the project and the refurbishment workshop. The bearing shoes shall be shipped as a complete set, do not split the shipment into individual shoes.

c. The existing shipping boxes may be used by the contractor. If new shipping boxes are to be used, they shall be provided as necessary to assure delivery of the thrust shoes in satisfactory, undamaged condition. Each shoe shall be packaged in a separate box that shall be suitable for handling with a lift truck.

d. The Contractor shall provide round trip shipment between the project and the contractor refurbishment facility. Pick up and delivery shall be between the hours of 0730 and 1730, Monday thru Thursday. Non regular work hours may be coordinated with the Project in advance.

The Contractor shall coordinate with the Project regarding all equipment delivery. The Government shall be notified at least 5 working days in advance of each delivery date of this equipment.

e. General shipping requirements are listed in Paragraph 3.1.1.

3.2 REFURBISHMENT OF THRUST BEARING SHOES

The thrust bearing shoes are described in Paragraph 1.1.2.

The requirements governing the refurbishment of thrust bearing shoes shall apply to an entire set of shoes.

For the purposes of this Specification, one "set" consists of 14 shoes.

3.2.1 General Requirements

The refurbishment of the shoes will be done by rebabbitting followed by machining. General requirements that apply for all thrust shoe refurbishment are listed below:

a. Upon receipt of the shoes at the refurbishment workshop, measure the shoe thickness at a minimum of three locations per shoe (near the shoe ID, center and OD) in undamaged locations.

The results of the measurements and measurement locations shall be submitted to the Government prior to the beginning of any refurbishment as part of the Contractor's detailed refurbishment procedure.

b. A scaled drawing(s) of an average thrust shoe shall be created from the measurements outlined in Part "a" and according to the specification requirements. The drawing shall show all features and shall be in sufficient scope and detail to permit fabrication of an identical thrust shoe (minus imperfections and wear). The tolerances for decimals shall be to the nearest 0.001 inch and for fractions to the nearest 1/64 inch. The drawing shall meet the drawing standards and the requirements for submittal as listed in these Specifications.

c. The Contractor shall submit a detailed thrust shoe refurbishment procedure a minimum of 10 calendar days prior to commencing the refurbishment work, including a detailed step-by-step babbitting procedure and the scaled drawing created according to paragraph "b" above. The thickness measurements taken in part "a" above shall be included as well as the proposed thickness for the refurbished shoes. The Government's intention is that the shoes be machined to the original or as measured existing thickness (combined shoe and babbitt thickness). The Contractor shall not perform any work until receiving written approval from the Government.

d. A schedule for shoe refurbishment, i.e. dates and times, shall be submitted for all phases of the shoes' refurbishment a minimum of 10 calendar days in advance of the beginning of the work.

The schedule shall be updated and revised as required. The Government will use this schedule for witnessing refurbishment processes and will notify the Contractor as to which process will be witnessed. The Government is especially interested in witnessing shoe preparation prior to Babbitt pouring, and final inspections.

e. The shoes shall be machined at the same time in one setup on a machining table or plate, or separately. Regardless of which of the two machining set-ups is utilized the shoe requirements shall be as stated in part h, and the tolerances for the machining plate or table, as listed in the tolerances sheets at the end of this section, shall apply at each setup.

f. The rotation of the machining table shall be in the direction opposite to the direction of rotation of the generator.

g. The requirements for the refurbished shoes (flatness, runout, thickness and surface finish) are listed on the tolerance sheets at the end of this section.

h. If the set of shoes are machined all at one time in one setup on a machining table or plate the finish dimensions and runout checks shall be made while the entire set of shoes are still on the machining table, unless an alternative method is submitted and approved by the government.

i. All high-pressure lift pockets and copper inserts that existed on the original shoes shall be reproduced.

j. All non-babbitted surfaces (including the shoe's I.D., O.D. and sides) and holes shall be thoroughly cleaned without the removal of metal, unless approved in writing.

k. All options shall include appropriate finished inspections and the preparation of a report according to Paragraph 3.2.3.

Following the completion of the work, the Contractor shall protect the shoes from damage and corrosion with appropriate coatings and packaging.

3.2.2 Refurbishment Including Babbitting

The Contractor shall refurbish the thrust bearing shoes as specified below. Refurbish means removing the existing babbitt, pouring new babbitt, babbitt machining including other detail, and machining the shoe backside. The refurbishment shall return the shoes to the dimensional tolerances listed in the tolerances sheets at the end of this section.

a. A sample of the babbitt shall be taken and marked for identification at the time that the babbitt is poured. A sample shall be taken for each heat; e.g. if more than one shoe is poured simultaneously, only one sample is required. An independent testing laboratory shall analyze each sample, unless otherwise approved, with the results linked to individual shoes and included in the final report.

b. The Contractor shall prepare the shoes for babbitting according to the procedure approved by the Government.

c. After removing existing babbitt and tinning, break or grind a 1/32 chamfer along the top edges of each dovetailed slot and remove all burrs.

d. Machine or shot blast, including dovetail grooves, and proceed immediately with tinning.

Special care shall be taken to protect all holes and surfaces of the shoes not receiving babbitt.

Precautions shall be taken to minimize shoe distortion during babbitting.

e. The babbitt shall be poured at a high temperature. The form and shoe shall be pre-heated. The pouring shall be continuous. Cold checks will not be acceptable.

f. The shoes shall be machined and/or ground to the original or as measured existing thickness (combined shoe and babbitt thickness), unless otherwise approved. The Contractor's refurbishment procedure shall list any additional thickness of Babbitt to be added to the shoes. The shoe backside shall be finished prior to finishing the Babbitt running surface.

g. The backside of the shoes shall be machined and / or ground as required to remove spring indentations and to achieve the tolerances (flatness, runout, thickness and surface finish) listed on the tolerance sheets at the end of this section. Material removal shall be uniform over the shoe backside and consistent from shoe to shoe.

h. Machine / and or grind the poured Babbitt layer to achieve the tolerances (flatness, runout, thickness and surface finish) listed on the tolerance sheets at the end of this section. Provide radius edges and other details identical to that found for the existing shoes.

i. Perform NDT of the babbitt bond according to Paragraph 3.3.

j. Additional requirements are listed under Paragraph 3.2.1 above.

3.2.3 Notice of Thrust Shoe Finished Inspection / Final Report

a. The finished thrust shoes shall be inspected while on the machining turntable for the purpose of verifying the requirements (flatness, runout, thickness and surface finish) listed in the tolerance sheets at the end of this section.

b. For shoes that have been rebabbitted, the inspection shall include the Paragraph 3.3 NDT of the Babbitt to shoe bond.

c. The Contractor shall notify the Government 7 calendar days in advance of all inspections and all inspections may be witnessed by the Government at its discretion.

d. All measurements shall be taken with calibrated instruments to the nearest 0.001 inch, unless otherwise indicated. Calibration certification for all equipment shall be furnished with the report of findings.

e. All data shall be recorded on the Contractor supplied inspection sheets which shall be provided to the Government inspector prior to departure from the Contractor's facilities. Sample inspection sheets applicable for some of the required inspections are contained at the end of the section.

f. A thrust shoe finished inspection report and measurement report documenting the refurbishment including the results of the Babbitt bonding NDT (for rebabbitted shoes) shall be submitted prior to shipment and shipment shall not be made until authorized by the Government.

3.3 BABBITT BOND NDT

The paragraph 3.3 NDT shall be performed as part of the paragraph 3.2.2 refurbishment.

3.3.1 General

The metallurgical bonding of the babbitt to the thrust bearing shoes shall be examined using the Ultrasonic Test (UT) and Liquid Penetrant (PT) method of nondestructive testing.

The Pulse-Echo Method of UT inspection shall be employed. Examination shall be made from the babbitt side and 100 percent of the babbitted area shall be inspected. UT examination shall be performed in accordance with the applicable portions of ASTM E 114 or of Article 5 of the ASME BPC, SECTION V.

The UT procedure which is to be used shall be submitted for approval. The Government at its discretion may witness any and all inspections.

3.3.2 UT Inspector's Qualifications

3.3.2.1 Examination of the Babbitt Bonding

An examination of the babbitt bonding, and for porosity and cracking shall be performed by an approved independent testing laboratory, which is regularly engaged in nondestructive testing, or it may be performed using Contractor personnel. If the examination is performed by Contractor personnel, a representative from an approved independent testing laboratory shall be present during the examination to witness and certify the results. The laboratory shall be a member in good standing of the American Council of Independent Laboratories (ACIL). The laboratory shall be mutually agreeable between the Government and the Contractor. Prior to the performance of any tests, the laboratory name and qualifications, location and inspector/witness certification data shall be submitted as part of NDT Personnel/Laboratory Qualifications.

3.3.2.2 Technician(s)

Technician(s) performing the inspection shall be certified in accordance with the American Society for Nondestructive Testing (ASNT). The inspector who is performing the UT inspection or who is acting as a representative from an independent testing lab shall, as a minimum, be NDT:ASNT-TC-1A level 2 qualified, with a minimum of 3 years experience at Level 2 in the last 5 years. The inspector shall locate bonded and unbonded areas on the "Reference Blocks" in the presence of the Government's quality assurance representative.

3.3.3 Equipment

a. Search unit.

(1) All testing of the babbitt bond shall be performed with a 2.25 MHz or 5 MHz longitudinal wave crystal.

(2) Transducer diameter shall be between 0.25 inch and 1 inch.

(3) Transducer gloves or delay lines shall be made of Lucite or other materials with similar sonic properties.

b. Couplants used for testing shall be either lightweight oil or glycerin, the viscosity of which is no more than SAE 30 oil.

c. Reference Blocks.

(1) A reference block shall consist of a soundly babbitted steel block with a scanning surface and babbitt thickness representative of the shoes being tested. The block shall be used to set the sensitivity of the instrument. A reference block with artificially unbonded areas shall be provided for comparison of indications for areas showing bond and lack of bond.

(2) Test sensitivity shall be such that the babbitt-to-base material interface is readily identified on the CRT. Details of sensitivity calibration and determination of bonded and unbonded areas shall be defined in the UT procedure.

(3) Reference blocks shall be kept available for frequent reference during actual testing.

3.3.4 Procedure

The entire babbitt surface of each shoe segment shall be scanned, overlapping scan paths by at least 20 percent of the effective transducer width. Scanning rates shall not exceed 3 inches per second. Unbonded babbitt areas will result in an increase in the size of the reflection or indications of multiple reflections at the interface of the babbitt and base metal. Babbitted areas located over anchoring dovetail grooves will be excluded from UT inspection.

All unbonded babbitted areas shall be carefully scanned to determine their size and configuration. The outside edges of all unbonded areas shall be marked on the surface of the Babbitt and recorded on inspection sheets.

3.3.5 Liquid Penetrant (PT) Testing

a. After the ultrasonic testing is completed all exposed babbitt to backing material bond lines, including dovetails, shall be examined with the liquid penetrant (PT) method. This shall be done using a solvent-removable visible dye. The purpose of the PT bond line examination is to define the babbitt to backing material bond at edges, which the UT examination may not reveal. The PT method that the Contractor proposes to use shall be submitted for approval and shall be in accordance with ASTM E 165.

b. Lack of bond indications greater than 3/4 inches in length shall be marked on the shoes and mapped on inspection sheets or documented in photos.

3.3.6 Acceptance Standards

Babbitt bond acceptance criteria is defined below as a function of zones:

a. Perimeter & Holes. Zone defined as bond surface area within 1 inch from any edge or hole having an exposed bond line. The maximum dimension of any individual unbonded area shall be less than 1/2 inch, with acceptable unbonded areas located no closer than two inches apart.

(1) For steel backed shoes the total unbonded area shall be no larger than 5 percent of the total zonal area.

b. Corners. Zone defined as bond surface area within 1 inch from any corner having an exposed bond line. Corners shall have no unbonded areas.

c. Dovetails. Zone defined as the entire surface area over a dovetail. Dovetails are exempt from UT examination.

d. Bond Lines. Defined as exposed lines at the babbitt to base metal interface.

(1) For steel backed shoes, PT indications of lack of bond totaling over 10 percent of the length of a particular edge shall be unacceptable. Any PT detected lack of bond over 3/4 inch in length shall be re-examined by the UT method, using a 0.250 diameter transducer.

Unbonded areas extending more than 1/8 inch away from an edge shall be unacceptable.

e. Remainder of Shoe. Zone defined as bond surface area other than perimeters, holes, corners and dovetails. The maximum area for any individual unbonded area shall be less than 1 sq. inch or 3 percent of the total zonal area, whichever is less. Acceptable unbonded areas shall be located no closer than 2 inches apart.

(1) For steel backed shoes the total unbonded area shall be no larger than 5 percent of the total zonal area.

f. Additional Requirements. The babbitt surface shall have no visible porosity, blow holes, shrinkage or cracks. The exposed bond line shall have no visible disbonding.

3.3.7 NDT Inspection Report

A certified written report from the independent laboratory, whether they perform or witness the testing, shall be submitted as part of the Paragraph 3.2.5 final report. The report shall include a complete description of the UT procedures used, equipment used, a mapping of the areas tested, shoe number, and interpretation of results. The report shall specifically address areas of lack of bond between the babbitt and the shoe and their accumulated total surface area relative to the area allowed area for the zone. PT results shall include a mapping of indications at the bond lines or photos. The report shall also address porosity, cracking and other surface defects.

3.3.8 Babbitt Repairs

If repairs are required to the babbitt surface or to the babbitt to backing material interface a repair procedure shall be submitted, if not already submitted as part of the rebabbitting procedure. Puddling will be acceptable for small areas on the surface, and to correct a localized lack of bond between the babbitt and backing material, however, the total lack of bond repaired by puddling shall not exceed 10% of the total babbitted surface.

3.3.9 Babbitt Bond Acceptance

If a shoe's babbitt bond does not meet the above acceptance criteria it shall be repaired or completely rebabbitted and retested at the Contractor's expense until the bond is acceptable in accordance with these specifications.

3.4 WELDING REPAIR OF THRUST BEARING COMPONENTS

3.4.1 General

After removal of babbitt and tinning, the shoes shall be visually inspected for any preexisting defects or void on the steel backed shoes. If directed in writing by the Government, any preexisting defect or void found on the babbitt side of the steel backed shoes shall be repaired as specified below. This repair is distinct from the refurbishment described elsewhere in this section and would be paid for by modification to the contract.

3.4.2 Repair of Thrust Bearing Components

The Government shall be notified of all recommended repairs, and written approval provided by the Government prior to any repairs being performed. Defective metal shall be removed by grinding, unless otherwise approved. The surfaces shall be thoroughly cleaned before welding and inspected visually and by the dye penetrant method. The resulting cavities shall be rewelded in compliance with Article 6.6 of AWS D1.1. The Contractor shall submit a Notification Of Welding Repair for approval before repairs are made.

3.4.3 Welding Procedure

Welding shall be performed in accordance with SECTION 05 05 23.20 26, unless otherwise stated herein or approved. The qualification of welders shall be in accordance with SECTION 05 05 23.20 26.

Paragraph 3.4 welds shall be examined by non-destructive methods (visual, ultrasonic, magnetic or dye penetrant) as specified in SECTION 05 05 23.20 26.

3.4.4 Stress Relieving

Any stress relieving following welding or stress relieving to relieve existing turbine bearing distortions would be paid for under the most appropriate miscellaneous time and materials CLIN by modification to the contract.

(THRUST BEARING REFURBISHMENT TOLERANCES FOLLOW)

SECTION 05 05 23.20 26

WELDING

07/08

PART 1 GENERAL

1.1 GENERAL INFORMATION

This section covers welding. Deviations from applicable codes, approved procedures, and approved detail drawings will not be permitted without prior written approval. Materials or components with welds made off the site will not be accepted if the welding does not conform to the requirements of this specification, unless otherwise specified. Procedures shall be developed by the Contractor for welding all metals included in the work.

Welding shall not be started until welding procedures, welders, and welding operators have been qualified. References to the Code or, Section II, Section VIII or Section IX of the Code refer to the ASME Boiler and Pressure Vessel Code. Weldments not governed by the Code shall be governed by appropriate portions of the American Welding Society's publications.

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.

ASME INTERNATIONAL (ASME)

ASME BPVC (2004) Boiler and Pressure Vessel Codes

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (1998) Standard Symbols for Welding, Brazing and

Nondestructive Examination

AWS B2.1 (2000) Welding Procedure and Performance

Qualification

AWS QC1 (1996) AWS Certification of Welding Inspectors

AWS D1.1/D1.1M (2004) Structural Welding Code - Steel

U.S. ARMY CORPS OF ENGINEERS (USACE)

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

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. These submittals will be required after date of award.

SD-06 Test Reports

Reports of Physical Tests of Specimens Welded in the Qualification Tests; G Within 14 calendar days of request by the Government.

Stress-Relief Time-Temperature Charts; G

SD-07 Certificates

Qualification of Welder(s); G

Witness Additional Operator Qualification Tests

Provide notice 48 hours prior to the performance of qualification testing

Certification of Welding Inspectors; G

SD-08 Manufacturer's Instructions

Welding Procedures, Specifications and Reports of Test Results; G

1.4 QUALIFICATION OF WELDER(S)

Welding operators, welders, and tack welders, shall be qualified and, as necessary, requalified for the particular type of work to be done. Qualification shall be in accordance with one of the following codes: (1) Section 4, Part C, of AWS D1.1/D1.1M, or (2) Section IX of the Boiler and Pressure Vessel Code, or (3) AWS B2.1 (for cladding), whichever is most applicable to the work being performed. The record of qualification shall be approved. The Contractor shall certify by name the welders and welding operators so qualified including the date of qualification code, and the procedures under which qualified. Certification and testing of welders and operators shall be performed by an independent testing company.