FP BFV Industry Day Presentation.pdf

WELCOME

FORT PECK DAM

POWERHOUSE #2 BUTTERFLY

VALVE REHABILITATION

INDUSTRY DAY

SOLICITATION: W9128F23R0009

17 NOV 2022 / 11:00 MST

To join the meeting:

https://usace1.webex.com/meet/ronald.s.beyer

Conference line: 1-844-800-2712 (Toll-Free)

1-669-234-1177 (US)

Access Code: 199 032 3791 https://usace1.webex.com/meet/ronald.s.beyer

INTRODUCTIONS

USACE, Omaha District Office Ron Beyer Project Manager Robin Puskar Program Manager Dan Monahan Contracting Officer Lynne Reed Contract Specialist Mo Al Soufi Mechanical Engineer

Fort Peck Dale Pugh Maintenance and Operations Manager Tom Grant Mechanical Engineer Mike Bratz Senior Power Plant Mechanic Irene Whitmer Electrical Engineer

Missouri River Construction Office

Tom Westenburg Resident Engineer

Hydroelectric Design Center (HDC), Portland

Dan Lundy Mechanical Engineer

Kwadwo Amankwa-Poku Electrical Engineer

Sean Kim Structural Engineer

AGENDA – NOV 17, 2022

1100 – 1105 Introductions / Project Overview

1105 – 1110 Contracting Briefing / Rules of Engagement

1110 – 1130 Statement of Work / Project Specs

1130 – 1200 Project Site Specifics

1200 – 1230 Q&A

PROJECT OVERVIEW

Objective is to reduce internal bypass leakage on Units 4 and 5 valve discs and address component end of life and system reliability

1) Refurbish the eighteen (18) foot spiral case butterfly valve in Units 4 and 5

2) Manufacture and install new Hydraulic Power Units (HPUs) and related equipment in Units 4 and 5

3) Optional Items

• Ultrasonic testing of Tunnel 2, and the Units 4 and 5 penstock

• Penstock External Paint System Repairs

• Butterfly Valve Weld Repairs as needed

RULES OF ENGAGEMENT

DAN MONAHAN, CONTRACTING OFFICER

• No side bars or independent conversations between contractors and government personnel.

• No discussions relating to other Corps acquisitions.

• No corporate denigration or sabotage will be tolerated.

• Hold all questions until the designated question and answer session.

• The Government will address general questions during this briefing. Specific questions must be entered into ProjNet via the published Bidder Inquiry Key.

• There will be a site visit opportunity once the solicitation is posted.

PROJECTED PROJECT SCHEDULE

Pre-solicitation Late Dec 2022

Advertise Period Jan-Feb 2023 (30-day advertisement period)

Contractor Site Visit TBD (posted with solicitation)

Award Mar/Apr 2023

Penstock Outage

Start 16 September 2024

End 24 January 2025 (130 calendar days)

CONTRACT AND EVALUATION INFORMATION

Contract Information

• Contract Type: Firm Fixed Price Construction

• Solicitation Type: Request for Proposal (RFP)

• Contract Magnitude: $1M-$5M

• Period of Performance: NTP (Est. April 2023) – Jan 2025 (Note: onsite work must be completed by 24Jan2025)

Evaluation Factors

• Factor 1 Past Performance (most important)

• Factor 2 Technical Approach (second most important)

• Factor 3 Personnel Qualifications and Experience (equal to factor 2)

• Factor 4 Small Business Participation (significantly less important than factors 1-3)

• Factor 5 Price (Least important factor. All evaluation factors other than price, when combined, are considered significantly more important than Price.)

PROJNET AND CONTACT INFORMATION

ProjNet

• Used for Contractor(s) to submitted questions

• Website: https://www.projnet.org

• Virtual Industry Day Bidder Inquiry Key: E3BCGG-7ABR3E

• Questions need to be submitted before 4 pm Mountain Standard Time, 20 NOV 2022

Contract Specialist Contact Information

Lynne Reed

• Email: Lynne.D.Reed@usace.army.mil

• Phone: 402-995-2039

9File Name

STATEMENT OF WORK

AND

PROJECT SPECS

HYDROELECTRIC DESIGN CENTER

DAN LUNDY, MECHANICAL ENGINEER

Functional Areas

• Mechanical Scope of Work

• Butterfly Valves

• Hydraulic Power Systems

• Scroll Case and Tunnel Drain Valves

• Other

»Tunnel 2, Unit 4, and Unit 5 Penstock Ultrasonic Testing (optional)

»Penstock Paint Repairs - 10 Locations (optional)

• Electrical Scope of Work

• Electrical Equipment for Hydraulic Power Systems

• Electrical Equipment for Motor Operated Bypass Valves, and Misc.

Mechanical Scope of Work:

(1) Refurbishment of two (2) 216-inch diameter penstock BFVs, performed simultaneously.

• valve disc seal;

• stainless-steel overlay body seat;

• valve internal surfaces (LBP abatement, blast, and recoating);

– Inspect butterfly valve welds;

– Repair butterfly valve welds (OPTION);

Removal and replacement of:

• upper stub shaft (trunnion) bearing and seals;

• lower stub shaft (trunnion) bearing and seals, and thrust bearing assemblies;

– Adjust and align disc leaf seals (contact bluing check);

Mechanical Scope of Work:

(2) Two new complete Penstock BFV grease lubrication systems, including:

Removal and replacement of:

• grease lines;

• grease lubrication components and supporting systems;

Mechanical Scope of Work

(3) Refurbishment of two Penstock BFV bypass systems, including:

Removal and replacement of:

– Limitorque motor operated gate valve with manual handle;

– bypass system piping;

– absolute pressure switch,

– system controls;

Install new manually operated isolation gate valve; and new equalizing line pressure monitoring system;

(4) Refurbishment of two spiral case drain valves:

Removal and replacement of:

• manual gate valve with new manual operated gate valve;

• insulation;

• limit switch;

(5) Refurbishment of tunnel drain valve:

Removal and replacement of:

• one manual gate valve (current location, as shown);

• piping and insulation;

• heating cable and thermostat;

(6) Provide new second manual operated gate valve located as shown;

(7) New maintenance platforms, ladders and guardrails for each BFV;

(8) Modify access hatch for each BFV;

(9) Furnish spare parts, including two sets of bronze metal disc seals.

Hydraulic Scope of Work

• The work specified includes, but is not limited to, all appurtenances required for a complete, fully functional installed hydraulic power system.

• The new BFV operators, HPUs, and associated systems must be identical and interchangeable.

(1) Design and provide two BFV operators (quarter-turn hydraulic cylinder actuators) with integral mechanical locking device:

–Remove existing BFV operator and associated plumbing;

–Install new BFV operator with integral mechanical locking device, and new plumbing;

Hydraulic Scope of Work

(2) Design and provide two BFV HPUs with controls and offline oil filtration system:

•Remove existing BFV HPU and associated plumbing;

• Install new BFV HPU and associated plumbing;

Electrical Scope of Work

Supply and installation of:

(1) New motor actuators for the penstock fill bypass valves and remote operators, remote open/close indicators and control systems, one each for Unit 4 and Unit 5;

(2) Limit switches and wiring for new manually operated spiral case drain valves one each for Unit 4 and Unit 5;

Electrical Scope of Work

(3) Supply and installation of new wall mounted 480VAC panels which contain a disconnect switch, motor starter and control power transformer as follows:

• 2-480VAC panel (BVQ) for the HPU pump motors for each unit:

•BVQ1 - 480VAC panel for HPU pump 1

•BVQ2 - 480VAC panel for HPU pump 2

• Two (2) - oil filtration system 480VAC panels (FSQ), one for each unit's HPU

• Two (2) - 480VAC panel (VP), one for each bypass valve motor actuator

(4) Supply and installation of new heat tape and thermostat for the tunnel drain valve

20File Name

PROJECT SITE

SPECIFICS

FORT PECK PROJECT BRIEF

DAN LUNDY AND TOM GRANT

CONTRACTOR STAGING & WORK AREAS (SHEET G-401 & MD201)

CONTRACTOR STAGING & WORK AREAS (SHEET MD201)

EL 2070.0 SURGE TANK STRUCTURE

EL 2052.0 BFV CORRIDOR

EL 2023.5 BUTTERFLY VALVE ROOM

CONTRACTOR STAGING & WORK AREAS

TUNNEL #2 PENSTOCKS 4 & 5

BIFURCATION

CONTRACTOR STAGING AND WORK AREAS (SH MD101)

SURGE TANK STRUCTURE, EL 2070.00

Office

Trailer

10T MONORAIL HOIST

SURGE TANK

STRUCTURE

BFV ACCESS

HATCHES

CONTRACTOR STAGING AND WORK AREAS (SH MD102)

BUTTERFLY VALVE CORRIDOR, EL 2052.00

BFV ACCESS

HATCHES

CONTRACTOR STAGING AND WORK AREAS (SH MD102)

BFV ACCESS

HATCHES

FREIGHT

ELEVATOR

CONTRACTOR STAGING AND WORK AREAS

18 FT (216 INCHES)

BUTTERFLY VALVE

EL 2023.50

EL 2023.50

NORTH EXTERIOR

IMAGES OF

18 FT (216 INCHES)

SOUTH EXTERIOR

18 FT (216 INCHES)

UPSTREAM UNDERSIDE

EXTERIOR IMAGE OF

18 FT (216 INCHES)

DOWNSTREAM

UNDERSIDE EXTERIOR

IMAGES OF

18 FT (216 INCHES)

TOPSIDE EXTERIOR

18 FT (216 INCHES)

INTERIOR IMAGE OF

BUTTERFLY VALVE

INTERNAL LEAKAGE

GOVERNMENT SEAL

ADJUSTMENT U4: 2006

UNIT 4 UNIT 5

CLOSE-UP OF VALVE DISC BRONZE SEAL

CLOSE-UP OF VALVE DISC BRONZE SEAL

STAINLESS STEEL

OVERLAY BODY

SEAT AND

INTERNAL

SURFACES

WISCO DWG H-4070

STAINLESS STEEL

OVERLAY BODY

SEAT AND

INTERNAL

SURFACES

WISCO DWG H-4070

WELDS

WISCO DWG H-4075

(UPSTREAM SIDE)

(DOWNSTREAM

SIDE)

(DOWNSTREAM

SIDE)

UPPER AND LOWER

STUB SHAFT

(TRUNNION)

BEARINGS

UPPER STUB

SHAFT (TRUNNION)

BEARING

LOWER STUB

SHAFT (TRUNNION)

BEARING & THRUST

BEARING

EXISTING GREASE LUBRICATION SYSTEM

(UNIT 4 SHOW, UNIT 5 SIMILAR)

EXISTING GREASE LUBRICATION SYSTEM

(UNIT 4 SHOW, UNIT 5 SIMILAR)

EXISTING BFV BYPASS SYSTEMS

EXISTING BFV BYPASS SYSTEMS

BYPASS VALVE & PIPING, & ABSOLUTE

PRESSURE SWITCH

EXISTING

LIMITORQUE GATE

VALVE – BYPASS

VALVE OPERATOR

BFV POSITION

INDICATOR

BFV ACCESS

HATCH

MAINTENANCE

ACCESS HATCH

EXISTING BFV HPU

BYPASS VALVE

CONTROLS &

INDICATION

BFV CONTROLS &

INDICATION

BYPASS VALVE

CONTROLS

BFV CONTROLS

EXISTING SPIRAL CASE DRAIN VALVES

EXISTING TUNNEL DRAIN VALVES

EXISTING MAINTENANCE LADDERS & PLATFORMS

EXISTING BFV MAINTENANCE ACCESS HATCH

HYDRAULIC POWER SYSTEMS

BFV OPERATOR

HYDRAULIC POWER SYSTEMS

BFV HPU

TUNNEL #2, UNIT 4 & 5 PENSTOCK ULTRASONIC TESTING

AND PAINT REPAIR LOCATIONS (S-101)

TUNNEL #2, UNIT 4 & 5 PENSTOCK ULTRASONIC TESTING

AND PAINT REPAIR LOCATIONS (S-101)

UNIT CONTROL SWITCHBOARD &

MCC’S ON TURBINE FLOOR,

EL. 2049.00 (E-101 & E-201)

ELECTRICAL WORK

MCC4 DC

DIST. PANEL

INSTRUMENT CONTROL BOARD,

CONTROL ROOM (E-202)

ELECTRICAL WORK

MOTOR ACTUATORS

FOR BYPASS VALVE

OPERATORS, W/

REMOTE

OPEN/CLOSE

INDICATORS &

CONTROLS

SUPPLY/INSTALL

NEW LIMIT

SWITCHES FOR

SPIRAL CASE DRAIN

(SH M-420)

SUPPLY/INSTALL

NEW LIMIT

SWITCHES FOR BFV

POSITION

INDICATOR

(SH M-420 &

M-601)

WALL MOUNTED

480VAC PANELS

W/ DISCONNECT

SWITCHES, MOTOR

STARTER, &

CONTROL POWER

TRANSFORMER

FOR:

HPU PUMPS 1 & 2

OIL FILT. SYST.

BYPASS VALVE

MOT. ACTUATOR

(SH E-101)

NEW HEAT TAPE

AND THERMOSTAT

FOR TUNNEL DRAIN

VALVE

(SH M-430)

POST-INDUSTRY DAY

Q & A