JA Brand Name - 20R0037 Final Version_Redacted.pdf

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Brand Name Justification and Approval (J&A) for Other Than Full and Open Competition

Program/Equipment: Tenkiller Ferry Powerhouse Penstock Butterfly Valve Refurbishment

Assigned Control Number: SWT-21-0006.

Authority: FAR 6.302-1, Only One Responsible Source and No Other Supplies or Sources Will Satisfy Agency Requirements.

Amount: $ (brand name portion of the acquisition only)

Prepared by:

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Brand Name Justification and Approval (J&A) for Other Than Full and Open Competition

1. Agency/Contracting Activity: U.S. Department of Army, Corps of Engineers

Tulsa District, Contracting Division Tulsa, OK 74137

2. Description of Action: IAW FAR 6.302-1(c)(B) approval is being requested for a portion of the construction contract to provide the retrofit replacement of the penstock butterfly valve’s metal valve body seals with Hartman Valve Corporation Circlok Seal system, designed and manufactured by Hartman Valve Corporation, with the two 180 inch diameter penstock butterfly valve remaining in the fully installed condition at the powerhouse and provide the replacement of each existing penstock butterfly valve operator’s Philadelphia Gear gearbox with an equivalent Philadelphia Gear Model DUT Worm Drive gearbox. Use of the Hartman Valve Circlok seal system and the Philadelphia Gear gearboxes are essential to the Government’s requirements.

Nature: New Requirement Follow-on Requirement

Mod to Existing Purchase Order/Contract Number

Pricing: Firm-Fixed Price Time & Materials Cost

Funds: OMA Other Funds: CIVIL

Name of Proposed Suppliers:

Hartman Valve Corp.

Philadelphia Gear Timken Gears & Services, Inc

Street Address: 700 Capac Ct. 10830 Train Ct

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City, State, Zip: Saint Louis, MO, 63125-5201 Houston, TX 77041 Phone: (480) 844-2884 (610) 662-9591

4. Description of Services or Supplies: The total value of the proposed brand name portion for this action is $ . This acquisition is an FY21 programming action and will be funded with Civil Construction funds. This action includes one option to Abatement of Lead Paint. The contract duration is 300 calendar days.

5. Justification: Both penstock butterfly valve bodies are permanently connected to penstock and scroll case extension by rivets, requiring any valve refurbishment to occur with the valve remaining in place. Previous replacement of the metal body seal has not resulted in acceptable performance, and has led to a progressing degradation of sealing capability, requiring a new, alternate seal system approach. The Hartman Valve Corporation Circlok seal retrofit is a mechanically retained, elastomeric seal system that can be installed with the valve remaining in place. Hartman Valve Corporation seal retrofit has been successfully installed in following similar operating conditions: fifteen 168” and two 120” valves at Hoover Dam, two 100” valves at Anderson Ranch, one 78” valve at Dutch Flat, two 123” valves at San Gabriel Dam, one 96” valve at San Gabriel Dam, one 53” valve at San Gabriel Dam, one 90”inch valve at Narrows 1, and one 204” valve at Merwin Dam. “Successfully installed” being the installation of the new seal system and its exposure to unit’s full operating conditions without damage to the installation, failure of its retention system, or impact to its sealing capability. Anderson Valley and Hoover Dam inspections of units operating 10 plus years have shown fully functional elastomeric seals. Most major valve companies either require full removal of the penstock valve for replacement of the seal system or recommend full replacement of the valve

The primary operating configuration for these valves are in the open position with water flowing through to the turbine. These valves at Tenkiller Ferry Powerhouse can see between 13 and 14 ft/sec water velocity for which the valve body seal must remain retained. Conventional elastomeric sealing systems are unable to withstand the velocities and will result in loss of seal retention. Both with the examples previously stated and in controlled testing, Hartman Valve Corporation has shown their seal system is successfully installed, remaining retrained and with full sealing capability. No other seal system has been identified by USACE as being both available and with proven history of successful installation with the valve in-place and exposed to the operating conditions presented at Tenkiller Ferry.

The Philadelphia Gear two-stage worm gear gearbox is a component of the existing penstock butterfly valve operator system. It translates the speed and torque from the drive motor to the sector gear connected on the valve stem, which then translates to the rotational force and speed of the valve disk. The gearbox is supported by connection on the existing valve housing, and output pinion mounts for direct engagement of the sector gear. The arrangement does not allow for an off-the-shelf gearbox. A replacement gearbox must provide the same output torque and speed, with equivalent load distribution on the

For Official Use Only Page 4 of 6 sector gear, while having its profile fit within the limitations of the sector gear engagement and valve mounting. In the procurement of the original penstock butterfly valves and their operating systems, the government only received envelope drawings and bill of material drawings for the Philadelphia Gear gearbox. In order to provide a new gearbox to the existing gearbox design, both an existing would need to be reverse engineered and unique manufacturing and assembly details generated, or one would have access to the original detailed plans and procedures. Reverse engineering would require the full dismantling of a gearbox, and potentially destructive testing of its components.

Since a spare gearbox is not available, the reverse engineering would need to be performed on one of the two installed and operating gearboxes. Philadelphia Gear has confirmed that still have in-house the original detailed component and assembly plans for the existing gearboxes and would be able to directly utilize them to produce equivalent replacements.

6. Failure to Limit Impacts:

Valve Seal Retrofit.

The Hartman Valve Corporation Circlok in-place seal replacement has been the only domestic elastomeric seal retrofit solution shown to have success with high flow velocities experienced in Tenkiller Ferry’s penstock. The use of another system that has not been shown to have the same level of success as the Hartman’s seal system greatly increases the risk/likelihood of immediate or near term failure of the seal system during unit operation and results in significant impact recovery of operation for the units.

In the event of an inherent failure of new seal system, the valve would not be operable as an emergency closure device for the main unit, or used for unit isolation for maintenance until sealing capability was restored. In the event of a runaway turbine, lack of emergency closure would result in catastrophic physical damage to the plant and high likelihood of loss of life. Retrofit of the valves with any new elastomeric seal system requires the permanent removal of the existing metal valve body seal. If a new seal system were to fail and be inherently flawed, returning the seal system to a metal to metal seal or replacing the full valve assembly would be only main recovery approaches available. Depending on the modifications made to the valve assembly for the seal retrofit design, there may be irreversible conditions for the penstock butterfly valve that would not allow for the return to the metal to metal seal system, and only fully replacement would remain as the only viable recovery option.

A 180-inch penstock butterfly valves is not an off-the-shelf item and would require, in addition to acquisition time, time to design, manufacture and install, all of which would be in excess of a year in order to procure a replacement. Due to the current valves being permanently connected to the penstock and scroll case extension, a replacement of a valve would require the cutting of both. The existing, embedded penstock would have to be retrofitted with a flanged collar, to the same or higher rating of that of the penstock. Such a modification carries great risk due to the complexities of the in-place welding and fit of the new collar with existing, partially embedded material from the early 1960’s. Failure to

For Official Use Only Page 5 of 6 properly install the new flange would result in the in ability to operate the powerhouse for an extensive period of time since the modification is irreversible, and solutions would only increase in complexity, risk, and cost.

Valve Operator’s Replacement Gearbox.

Philadelphia Gear was the original designer and manufacturer, and has the original, detailed manufacturing plans for the existing valve operator gearbox, for which the government is not in possession. Use of another supplier to provide a replacement for this part of the valve operator system could result in conditions ranging from gearbox fit issues to immediate or premature failure of the valve operators assembly, presenting long-term risk to penstock valve operation as an emergency closure system and isolation system for maintenance. If the replacement gearbox does not properly fit and function within existing penstock butterfly valve operator system, components would be subjected to conditions that could result in irreversible damage. An incorrect loading condition of the gearbox to the sector gear connected to the valve operating stem could damage the gear or improperly load the valve stem bearings, requiring replacement of these custom components. Replacement of the valve stem bearings would require the complex process of suspending in place the 180 inch vertical steel valve disk assembly while the upper and lower bearing housings and bearings are removed and replaced with new, custom components. Incorrect loading from the gearbox could also result in the penstock butterfly valve over traveling or having excessive closure forces that could permanently damage the seal system, requiring either restart of the seal system replacement, or full replacement of the penstock butterfly valve (risks and impacts detailed above). This would also potentially result in loss of emergency closure ability. In the event of a runaway turbine, loss of emergency closure would result in catastrophic physical damage to the plant and a high likelihood of life.

7. Authority: The statutory authority permitting Brand Name Justification and Approval (J&A) for Other Than Full and Open competition for Hartman Valve Corp to provide elastomeric valve seals and Philadelphia Gear to provide the valve operator gearboxes is contained in 10 U.S.C. 2304 (c)(1), as implemented by FAR 6.302-1 and DFARS 206.302-1, only one responsible source and no other supplies or sources will satisfy agency requirements.

8. Efforts to Obtain Competition: Not applicable. Hartman Valve Corp is the only domestic elastomeric seal, and Philadelphia Gear is the original designer and manufacturer of the gearboxes and has the original detailed manufacturing plans for the existing valve operator box, for which government is not in possession.

9. Market Research: Market research was not conducted for elastomeric seal and Valve

Operator’s Replacement Gearbox due to need for the requirement to conform to the existing; however, market research was done by searching the SBA Dynamic Small Business Search website for NAICS code: 237990 – Other Heavy and Civil Engineering Construction and there were no other sources capable of satisfying the agency’s

For Official Use Only Page 6 of 6 requirements and determined there are no items are available to satisfy the agency’s needs.

10. Other Factors: N/A

10. Contracting Officer Certification:

I certify that this justification is accurate and complete to the best of my knowledge and belief.