W912BV20R0037 AM05 - Tenkiller BFV.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

TENKILLER FERRY DAM POWERSHOUSE BUTTERFLY VALVE REFURBISHMENT

1. Amendment 0005 is issued to replace the follow ing sections, see "Summary of Changes." RFP due date has been extended 29 April 2021 at 2:00 PM CST.

2. All other terms and conditions remain unchanged by this amendment.

3. The point of contact for this action is Shaw n Brady at shaw n.brady@usace.army.mil.

1. CONTRACT ID CODE PAGE OF PAGES

1 3

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 21-Apr-2021

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street , County, State and Zip Code) X W912BV20R0037

X 9B. DATED (SEE ITEM 11)

01-Feb-2021

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

20-Apr-2021

CODE

CONTRACTING DIV

US ARMY CORPS OF ENGINEERS, TULSA DISTRICT

2488 E. 81ST STREET

TULSA OK 74137-4290

W912BV 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912BV20R0037

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION 00 01 10 - TABLE OF CONTENTS

The following have been deleted:

SECTION 00 11 00 - SF 1442 AND CLIN SCHEDULE

The required response date/time has changed from 22-Apr-2021 02:00 PM to 29-Apr-2021 02:00 PM.

The following have been added by full text:

SUMMARY OF CHANGES

AMENDMENT #0005

SOLICITATION NO.

W912BV20R0037 TENKILLER FERRY

DAM POWERSHOUSE BUTTERFLY

VALVE REFURBISHMENT SEQUOYAH

COUNTY, OKLAHOMA

Standard Form (SF) 30, Block 14 (continuation):

Revise the proposal documents as follows:

SPECIFICATIONS

Delete previously issued sections and replace with the corresponding sections in their entirety:

00 22 11

DRAWINGS

Delete previously issued sheet/s and replace with the corresponding sheets/s in its/their entirety:

N/A

OTHER

1. A photo showing the staging area location is hereby added as a part of

W912BV20R0037

the solicitation.

2. Information transcribed from a 6 May 1965 memo that contains additional information regarding the valve body seal replacement performed by the project is hereby added as a part of the solicitation.

3. Lead test results are hereby added as a part of the solicitation.

END OF SUMMARY OF CHANGES – AMENDMENT 0005

(End of Summary of Changes)

SECTION 22 00 00.00 26

BUTTERFLY VALVE, MECHANICAL EQUIPMENT AND PIPING

PART 1 GENERAL

1.1 GENERAL INFORMATION

a. The work covered by this Section of the specifications consists of refurbishment and replacement of existing equipment as specified and shown, and detailed requirements for the design, modification, installation, and testing of existing and new equipment and systems, as specified and as shown. This includes but is not limited to the list below:

(1) Refurbishment of Two, 180 inch Diameter, Penstock Butterfly Valves (PBV):

(a) Removal of Metal Body Seal and Replacement with a Hartman Elastomeric Seal with Mechanical Retention System;

(b) Removal and Replacement of Metal Disk Seal;

(c) Refurbishment of Valve Disk Surface;

(d) Refurbishment of Valve Body Internal Surface;

(e) Refurbishment of Valve Body External Surfaces;

(f) Refurbishment of (AM#5)Exposed Upper Valve Stem Surfaces and Adjustment of Thrust Bearing.(AM#5)Valve Stem Seals and Bearings;

(e) Removal and Replacement of Air/Vacuum Release Valve Assembly, Including Manual Gate Valve;

(g) And, Two Spares of Body Seal System.

(2) Two New Complete PBV and Operator Grease Lubrication Systems

(3) Refurbishment of Two PBV Operators:

(a) Removal and Replacement of PBV Operator Gearbox and Motor Coupling;

(b) Removal and Replacement of PBV Operator Controls;

(c) Removal and Replacement of PBV Operator Drive Motor/Brake;

(d) Refurbishment of PBV Manual Locking Device;

(e) Refurbishment of PBV Quarter Sector Gear.

(4) Refurbishment of Two PBV Bypass Systems:

(a) Removal and Replacement of Limitorque Motorized Gate Valve;

(b) Refurbishment of Bypass System Piping;

(c) Removal and Replacement of Complete Pressure Monitoring System;

(d) Removal and Replacement of System Controls;

b. Design and installation shall be in accordance with the provisions of these specifications, complete and fully operational, in direct correlation with the other section of this contract.

1.2 REFERENCES

The publications listed below form a part of this specification to the

Amendment #5 - Reissued in Entirety

TENKILLER LAKE BUTTERFLY VALVE REFURB FY20

Solicitation W912BV20R0037

TNKLRBTRFLYFY20

extent referenced. The publications are referred to in the text and on the drawings by basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B16.5 (2009) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ANSI/AGMA 6001 (2019) Design and Selection of Components for Enclosed Gear Drives

ANSI/AGMA 6013-A06 (2006) Standard for Industrial Enclosed Gear Drives

ANSI/AGMA 6022-C93 (2014) Design Manual for Cylindrical Wormgearing

ANSI/AGMA 6034-B92 (2016) Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

ANSI/AWWA C507-11 (2011) Ball Valves, 6 In. Through 60 In.

(150mm Through 1,500 mm)

ANSI/NFPA T2.13.1 (2007) Recommended Practice – Hydraulic Fluid Power – Use Of Fire Resistant Fluids In Industrial Systems

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B16.1 (2015) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

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

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2010) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ANSI Y32.10 (1967; R 1999) Graphic Symbols for Fluid Power Diagrams

ASTM INTERNATIONAL (ASTM)

ASTM A193/A193M (2014) Standard Specification for Alloy-Steel and Stainless Steel Bolting

Amendment #5 - Reissued in Entirety

Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2013) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A269/A269M (2015a) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM B88 (2016) Standard Specification for Seamless Copper Water Tube

ASTM D1744 (2013) Standard Test Method for Determination of Water in Liquid Petroleum

ASTM D3184 (2011) Standard Practice for Rubber - Evaluation of NR (Natural Rubber)

ASTM D3192 (2014) Standard Test Methods for Carbon Black Evaluation in NR (Natural Rubber)

ASTM D4057 (2012) Standard Practice for Manual Sampling of Petroleum and Petroleum Products

ASTM D6304 (2007) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASTM F844 (2007a; R 2013) Washers, Steel, Plain (Flat), Unhardened for General Use

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4406 (1999) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-25 (2013) Standard Marking System for Valves, Fittings, Flanges and Unions

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-25 (2013) Standard Marking System for Valves, Fittings, Flanges and Unions

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J514 (2012) Hydraulic Tube Fittings

Amendment #5 - Reissued in Entirety

1.3 Submittals

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. The following shall be submitted in accordance with Section 01 33 00, SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Butterfly Valve Refurbishment Plan and Procedure; G HDC

Submit within 90 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing of components a complete plan and procedure for the refurbishment of the two existing 180 inch diameter Penstock Butterfly Valves, and removal and installation of associated systems.

Plan and Procedure for Refurbishing the PBV Operators; G HDC

Submit within 90 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing.

Plan and Procedure for Refurbishing the PBV Bypass System; G HDC

Submit within 90 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing.

New PBV Operator Gearbox Final Inspection and Factory Test Procedure; G, HDC

Submit at least 60 days prior to any Factory Testing of the Gearbox, the factory test procedure for the two PBV operator gearboxes.

Refurbished Penstock Butterfly Valve Systems Field Testing Procedure; G, HDC

Submit at least 60 days prior to any onsite construction, a complete set of Field Testing Procedure for the two Refurbished Penstock Butterfly Valve.

Grease Lubrication System Field Testing Procedure; G, HDC

Submit at least 45 days prior to any construction, a complete set of Field Testing Procedure for the New Penstock Butterfly Valve Grease Lubrication System.

SD-02 Shop Drawings

Butterfly Valve Detailed Refurbishment Drawings; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing, submit together with the new Butterfly Valve Design.

Grease Lubrication System Schematics, Component Detailed Drawings

Amendment #5 - Reissued in Entirety and Installation Drawings; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing;

submit together with new Component/System/Routing Design.

New PBV Valve Operator Gearbox Components and Assembly Detailed Drawings; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction or manufacturing.

PBV Operator System Schematics, Component Detailed Drawings and Installation Drawings; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing;

submit together with System Refurbishment Plan.

PBV Bypass System Schematics, Component Detailed Drawings and Installation Drawings; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing;

submit together with System Refurbishment Plan.

SD-03 Product Data

Manufacturers Data, General Equipment; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing;

submit together with each System/Component Design.

Butterfly Valve Body Seal Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the New Butterfly Valve Seal Design.

Butterfly Valve Disk Seal Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the New Butterfly Valve Seal Design.

Butterfly Valve Body Internal Coating Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Butterfly Valve Refurbishment Plan and Procedure.

Butterfly Valve Body External Coating Product Data; G, HDC

Amendment #5 - Reissued in Entirety

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Butterfly Valve Refurbishment Plan and Procedure.

Butterfly Valve Disk Filler Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Butterfly Valve Refurbishment Plan and Procedure.

Butterfly Valve Disk External Coating Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Butterfly Valve Refurbishment Plan and Procedure.

(AM#5)

Butterfly Valve Stem Seals and Bearings Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Butterfly Valve Refurbishment Plan and Procedure.(AM#5)

Grease Lubrication System Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing;

submit together with New Grease Lubrication System Design.

New Lubrication Grease Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the New Grease Lubrication System Design.

PBV Operator Refurbishment Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Plan and Procedure for Refurbishment of the PBV Operator.

New PBV Operator Gearbox Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Plan and Procedure for Refurbishment of the PBV Operator.

PBV Operator Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or

Amendment #5 - Reissued in Entirety refurbishment of the butterfly valves; submit together with the Plan and Procedure for Refurbishment of the PBV Operator.

New Gearbox Oil Product Data; G, HDC

Submit at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves.

Bypass System Product Data; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction mobilization or refurbishment of the butterfly valves; submit together with the Plan and Procedure for Refurbishment of the Bypass System.

SD-05 Design Data

Butterfly Valve Seal System Design; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 45 days prior to any construction or manufacturing of an components for the New Penstock Butterfly Valves Sealing System.

Grease Lubrication System Design; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing a complete System Design for the New Penstock Butterfly Valve Grease Lubrication System including distribution manifolds, and related system routing for both Penstock Butterfly Valves.

New PBV Operator Gearbox Design; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing a complete design for the New PBV Operator Gearbox Design including mounting and interface details.

PBV Operator System Design; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing a complete detailing of the overall PBV Operator System Design, detailing the interface of new and existing system components.

PBV Bypass System Design; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed and at least 30 days prior to any construction or manufacturing a complete detailing of the both the bypass system and differential pressure system design for the PBV Bypass System Design including related system routing for both units.

Design Calculations and Documentation; G, HDC

Submit within 75 calendar days after receiving Notice to Proceed

Amendment #5 - Reissued in Entirety and at least 30 days prior to any construction or manufacturing, submit together with each System/Component Design.

Spare Parts; G HDC

Submit at least 30 days prior to demobilization, a complete list of spare parts for the Refurbished Penstock Butterfly Valves.

SD-06 Test Reports

Butterfly Valve Disk and Body Surface NDE Test Report for Unit 1;

G, HDC

Submit within 7 days of performing the examination of the existing valve disk and body to identify areas of repair a complete Report of the Examination Results and Repair Approach for Unit 1's Penstock Butterfly Valves.

Butterfly Valve Disk and Body Surface NDE Test Report for Unit 2;

G, HDC

Submit within 7 days of performing the examination of the existing valve disk and body to identify areas of repair a complete Report of the Examination Results and Repair Approach for Unit 2's Penstock Butterfly Valves.

Refurbished Penstock Butterfly Valve Systems Field Testing Report;

G, HDC

Submit within 14 days of performing the Refurbished Penstock Butterfly Valve Field Testing, a complete Report of the Field Test Results for both Refurbished Penstock Butterfly Valves.

Grease Lubrication System Field Test Report; G, HDC

Submit within 14 days of completing the New Penstock Butterfly Valve Grease Lubrication System Field Test, a complete Report of the Field Test Results for the New Penstock Butterfly Valve Grease Lubrication System.

New PBV Operator Gearbox Final Inspection and Factory Test Report;

G, HDC

Submit within 14 days of performing the Factory Testing, a complete Report of the Factory Test Results for both PBV operator gearboxes.

New Gearbox Supply Oil Cleanliness Sampling Test Results; G, HDC

Submit within 14 days after samples are taken.

Gearbox Oil Final Test Results; G, HDC

Submit within 14 days after samples are taken.

New Grease Lubrication System Cleaning and Flushing Test Results;

Amendment #5 - Reissued in Entirety

G, HDC

Submit within seven days of completion of the cleaning and flushing.

Existing PBV Operator Gear Contact

Submit within 14 days after test.

New PBV Operator Gear Contact

Submit within 14 days after test.

SD-07 Certificates

Inspection and Test Notification; G, HDC

Notifications of date and location of all inspections and tests. Submit at least 21 days prior to the inspection or test within the United States and 60 days prior to the inspection or test outside of the United States.

Materials and Equipment Certificates; G, HDC

Proof of compliance to codes and standards; at least 30 calendar days prior to use.

Valve Disk Seal Material Certificates; G, HDC

Proof of compliance to codes and standards; at least 30 calendar days prior to use.

Valve Body Seal Material Certificates; G, HDC

Proof of compliance to codes and standards; at least 30 calendar days prior to use.

SD-10 Operation and Maintenance Data

Training Manuals; G, SWT

Submit at least 21 days prior to scheduled class

Draft Operation and Maintenance Manual for Refurbished Penstock Butterfly Valve Systems; G, HDC

Submit at least 45 calendar days prior to system testing and onsite training session.

Revised Draft Operation and Maintenance Manual for Refurbished Penstock Butterfly Valve Systems; G, HDC

Submit at within 14 calendar days of completion of onsite training session.

SD-11 Closeout Submittals

Amendment #5 - Reissued in Entirety

Final Operation and Maintenance Manual for Refurbished Penstock Butterfly Valve Systems; G HDC

O&M Manual with details for all systems associated with, modified, removed, tested, and installed for this Contract shall be submitted within 14 calendar days following approval of the Revised Draft Operation and Maintenance Manual for Refurbished Penstock Butterfly Valve Systems submittal.

As-Constructed Drawings; G HDC

As-Constructed drawings for all systems associated with, modified, removed, and installed for this Contract shall be submitted within 30 calendar days following installation.

1.4 GENERAL REQUIREMENTS

1.4.1 Verification of Dimensions

The Contractor shall become familiar with details of the work, verify dimensions in the field, and advise the Contracting Officer (CO) of any discrepancy before performing any work. The Contractor shall correct the design and installation to remedy any discrepancies to the satisfaction of the Government.

1.4.2 Equipment

All equipment shall be properly installed, completely interconnected, and placed in working order. Where two or more items of the same type of equipment are required, they shall be the product of the same manufacturer.

1.4.3 Protection of Existing Work

Before beginning any dismantling, drilling, cutting, removal, or other modification of existing work, precautions shall be taken to ensure against damage to the existing work. Any damage to such work shall be repaired or replaced as directed by the CO at the Contractor's expense.

1.4.4 Coordination

System components shall be installed in the most direct and workmanlike manner so that interference between other piping, ducts, and conduit, mechanical, electrical and structural features will be avoided. Previously installed work shall be examined prior to developing layout and installation plans for piping, valves, ducting, and accessories to determine that installation can be made without interference with other work. In case interference does develop, the Government will decide which work shall be relocated regardless of which work was first installed. The rerouting shall be made without additional cost to the Government.

Structural portions of the Powerhouse shall not be cut or weakened to install any accessories.

1.5 SYSTEM DESCRIPTION

This Section of the specifications consists of requirements for the design, refurbishment, and testing of the Refurbished Penstock Butterfly Valves, new Grease Lubrication System, Refurbishment of PBV Operators, and

Amendment #5 - Reissued in Entirety

Refurbishment of the PBV Bypass System.

1.6 SYSTEM/ROUTING DESIGNS

a. The Contractor shall be responsible for compliance of the Refurbished Penstock Butterfly Valves, new Grease Lubrication System, Refurbishment of PBV Operators, and Refurbishment of the PBV Bypass System with the requirements of the other Contract Sections, as well as each of the installed systems with applicable codes and standards, industry standard practice, and performance requirements of this Contract. Mechanical components and systems shall be reviewed by a mechanical engineer, and the other systems by their respective disciplines.

b. The Contractor shall submit for approval complete Butterfly Valve Seal System Design, Grease Lubrication System Design, New PBV Operator Gearbox Design, PBV Operator System Design, and PBV Bypass System Design that shall detail how each will meet all of the requirements within this specification and other applicable sections of this contract.

c. Product Data, to be submitted with each system and component design:

(1) Manufacturers Data, General Equipment submittal is to include, but not be limited to the Manufacturer's Catalog Data for each new or modified piece of equipment proposed for use in any system that is not addressed by a separate, system specific data submittal.

Data shall indicate the name of the manufacturer of each item of equipment, with data highlighted to indicate model, size, options, etc. proposed for installation. Any non-applicable data shall be clearly annotated as not applicable. In addition, a complete equipment list, which includes equipment description, model number and quantity, shall be provided; submit together with each System/Routing Design.

(2) The product data for the Refurbishment of the Penstock Butterfly Valves shall indicate the name of the manufacturer, with data highlighted to indicate type, construction, class, and size and materials for body and bonnet, seating surfaces, stem, and trim. The manufacturer's Catalog Data must be submitted for any standard catalog component used in this system. Any non-applicable data shall be clearly annotated as not applicable.

In addition, description of component location and any associated code numbers, design ratings including temperatures and pressures, shall be included. For materials include information that details the supplier's information, material properties, and testing results. The product data for this refurbishment includes:

(a) Butterfly Valve Body Seal Product Data

(b) Butterfly Valve Disk Seal Product Data

(c) Butterfly Valve Body Internal Coating Product Data

(d) Butterfly Valve Body External Coating Product Data

(e) Butterfly Valve Disk Filler Product Data

Amendment #5 - Reissued in Entirety

(f) Butterfly Valve Disk External Coating Product Data

(AM#5)(g) Butterfly Valve Stem Seals and Bearings Product Data

(AM#5)

(3) Grease Lubrication System Product Data shall indicate the name of the manufacturer, with data highlighted to indicate type, construction, class, size and materials. The manufacturer's Catalog Data must be submitted for any standard catalog component used in this system. Any non-applicable data shall be clearly annotated as not applicable. Include a description of component location and any associated code numbers, design ratings including temperatures and pressures, shall be included. Provide the New Lubrication Grease Product Data that details the supplier's information, material properties, and testing results.

(4) PBV Operator Refurbishment Product Data shall be submitted.

Indicate the name of the manufacturer, with data highlighted to indicate type, construction, class, size and materials. The manufacturer's Catalog Data must be submitted for any standard catalog component used in this system. Any non-applicable data shall be clearly annotated as not applicable. Include a description of component location and any associated code numbers, design ratings including temperatures and pressures, shall be included. In addition provide as separate submittals:

(a) PBV Operator Product Data shall detail each supplier's information, material properties, and testing results for any provided components. New PBV Operator Gearbox Product Data shall to include the same detail for the gearbox but be separate from this material.

(b) New Gearbox Oil Product Data shall detail the supplier's information, material properties, and testing results. Include a description of any associated code numbers.

(5) Bypass System Product Data shall include all provided components, and indicate the name of the manufacturer, with data highlighted to indicate type, construction, class, size and materials. The manufacturer's Catalog Data must be submitted for any standard catalog component used in this system. Any non-applicable data shall be clearly annotated as not applicable.

Include a description of component location and any associated code numbers, design ratings including temperatures and pressures, shall be included.

1.7 Butterfly Valve Design Parameters

The refurbishment of the two existing butterfly valves shall be such that the resulting body seal, disk, and disk seal are able to perform without failure under the principal design parameters for the penstock butterfly valves, which are as follows:

a. Designed to fully close the valves in not less than five minutes without exceeding the design stresses under 181 feet head and 2300 cfs

Amendment #5 - Reissued in Entirety of water flow condition.

b. Design for a functional body seal life of 30 years or more, in an operating condition of 2300 cfs water flow condition.

c. Zero external leakage under any operating condition up to 181 feet of head, with the valve fully open, fully closed or in any transition position.

d. When fully closed against a static head up to 181 feet the valve internal leakage shall not exceed twenty gallons per minute, with no leakage concentrated in one location along the circumference of the disk, excluding the upper stem and lower stem areas.

e. The disk shall be properly streamlined and of such thickness and shape that the flow of water through the valve will be disturbed as little as possible.

f. Valve internal and external coatings with a design life 30 years or more.

1.8 DESIGN DRAWINGS

1.8.1 General

The system/routing drawings, detailed drawings, system schematics, and installation drawings shall be submitted in both hardcopy and electronic (Microstation) format and submitted with the System Design. All shall clearly differentiate between new, refurbished, and existing components.

The drawings shall be submitted for CO approval as Butterfly Valve Detailed Refurbishment Drawings, Grease Lubrication System Schematics, Component Detailed Drawings and Installation Drawings, PBV Operator System Schematics, Component Detailed Drawings and Installation Drawings, New PBV Valve Operator Gearbox Components and Assembly Detailed Drawings, and PBV Bypass System Schematics, Component Detailed Drawings and Installation Drawings. Design calculations and documentation for each item shall be submitted at the same time as the drawings and schematics.

1.8.2 System Schematics and Drawings

Overall system schematics shall include the following:

a. System schematics shall include schematic piping, hoses and other component layouts symbolically indicating, using standard system symbols, all system piping, and other components, including their sizes, materials, heights, spacing, and locations. Both new and refurbished components shall be shown on the schematic with any interfaces to existing equipment noted. All set point and size parameters shall be indicated for each component. Component support types and locations, anchor points versus sliding supports, flex joints, and seismic supports shall also be shown. Include proposed pertinent installation details. Required capacities and system pressures as well as direction of system flow or motion shall be indicated. Each drawing shall include a legend of symbols and bill of materials (BOM). BOM to include name of component, component drawing number or reference drawing, and part number.

Amendment #5 - Reissued in Entirety

b. System Installation Drawings shall include the plan, isometric, and section views of all system equipment. Installation Drawings shall include outline drawings in section views of all of the components which make up the system/routing designs, including piping, pipe fittings, valves, pipe supports, ducting, and all other equipment as applicable required to fasten a complete and working system. Loadings and the type and kinds of frames, brackets, or other supports as necessary shall be indicated. Materials, dimensions and sizes shall be indicated. Any associated structure or other components shall be indicated to show location and integration. A minimum of one section view shall be submitted per area.

1.8.3 Component Detailed Drawings

Provide component detailed drawings, including fabrication details for all mechanical and structural parts or components, except those which are of standard manufacture. The drawings shall show complete details of materials, tolerances, machined surface finishes, connections, any applicable instructions for paint, applicable instructions for installation, and proposed welding sequences which differentiate shop welds and field welds. PBV operator gearbox detailed component drawings for all gearbox components shall be included in the New PBV Valve Operator Gearbox Components and Assembly Detailed Drawings and referenced in the PBV Operator System Schematics, Component Detailed Drawings and Installation Drawings.

1.8.4 Shop Drawings

Detailed shop drawings shall include fabrication, shop assembly, delivery, and field installation drawings. Any component part of fabricated items omitted shall be detailed on the shop drawings. If departures from the Contract drawings are deemed necessary by the Contractor, submit details of such departures, including changes in related portions of the project and reasons therefore, with the shop drawings.

1.8.5 Butterfly Valve Detailed Refurbishment Drawings

The Butterfly Valve Detailed Refurbishment Drawings shall detail how the existing components will be refurbished. The drawing shall detail the modifications, rework, and final state of all the components involved in the refurbishment. They shall clearly identify locations and amount of material to be added and removed. Drawing submittal shall include formal approval from the new valve seal system designer with a signed letter identifying the drawings reviewed and approved, the drawings being provided directly from the seal designer, or other government approved method.

1.8.6 PBV Operator Refurbishment Drawings

The PBV Operator System Schematics, Component Detailed Drawings and Installation Drawings shall detail the new components, how the existing components will be refurbished, and how each will interface. The drawing shall detail the modifications, rework, and final state of all the components involved in the refurbishment. They shall clearly identify what is to be added and removed.

1.8.7 PBV Bypass System Refurbishment Drawings

The PBV Bypass System Schematics, Component Detailed Drawings and

Amendment #5 - Reissued in Entirety

Installation Drawings shall detail the new components, how the existing components will be refurbished, and how each will interface. The drawing shall detail the modifications, rework, and final state of all the components involved in the refurbishment. They shall clearly identify what is to be added and removed.

1.9 Design Calculations and Documentation

Submit the Design Calculations and Documentation for each system to be refurbished, replaced and serviced showing how the equipment and/or approach adheres to the design requirements of these specifications and the operating conditions for which it will experience in conjunction with any existing equipment.

PART 2 PRODUCTS

2.1 GENERAL EQUIPMENT REQUIREMENTS

2.1.1 Standard Products

a. Materials and equipment shall conform to the drawings and these specifications. Submit materials and equipment certificates of compliance, where materials or equipment are specified to comply with requirements of Hydroelectric Power Plants, ASME, ASHRAE or other standards organizations. The label or listing of the specified agency will be acceptable evidence. In lieu of the label or listing, a written certificate may be submitted from an approved, nationally recognized testing organization equipped to perform such services, stating that the items have been tested and conform to the requirements and testing methods of the specified agency.

b. Materials and equipment shall be the products of manufacturers regularly engaged in the manufacture of such products. Items of equipment shall essentially duplicate equipment that has been in satisfactory use at least two years prior to bid opening. Materials differing in minor respect from that specified may be proposed, provided such differences are clearly stated. Any materials required which are not covered in the piping material schedule, on the drawings, or these specifications shall conform to applicable specifications. In cases where material is not covered by one of the listed specification groups, the Contractor shall furnish the highest commercial grade of material or product available. Particular attention shall be given to the marking of valves to indicate body and trim material and pressure rating.

c. Where items are referred to hereinafter as "similar and equal to" a particular manufacturer's product, such references have been made merely as a convenient method of indicating the type of material or equipment required, with no intention of asserting superiority thereof. The standard product of any reputable manufacturer regularly engaged in the commercial production of the type and quality of material or equipment referred to will not be excluded on the basis of minor differences, provided essential requirements of the specifications relative to materials, capacity, certification, and performance are met. In accordance with paragraph SUBMITTALS, furnish for approval, performance capacities and other pertinent information concerning the manufacturer's "equal to" standard products intended for incorporation in the work. "Equal to" standard products installed or

Amendment #5 - Reissued in Entirety used without such approval shall be at the risk of subsequent rejection. The exceptions to these statements are the Hartman mechanical seal design, Philadelphia Gear operator equipment, and Limitorque motorized gate valve, which are all not to be substituted.

2.1.2 Nameplates

Major components of equipment shall have the manufacturer's name, address, type or style, model or serial number, voltage and current rating and catalog number on a metal plate permanently affixed to the equipment.

Lettering on nameplates shall be machine engraved on steel plate or metal stamped with a black background. Plates shall be mounted in a location easily visible without use of a mirror or removal of any components.

2.2 PENSTOCK BUTTERFLY VALVES

2.2.1 Purpose

The purpose of the penstock butterfly valves includes the shutoff of the flow of water to the turbines to relieve the pressure on the turbine wicket gates when they are closed, for emergency shut-off of the water to the turbine in case of failure of the normal speed regulating equipment, for shut-off of the turbine to permit maintenance of the turbine wicket gates, and to allow isolation of one unit for maintenance while allowing full operation of the other unit.

2.2.2 General Butterfly Valve Requirements

The two existing penstock butterfly valves are 180 inches in diameter; see reference drawings for more detailed information. They were built in 1952 by Newport News Shipbuilding and Drydock Company and manufactured to be identical, but length in service could have resulted in alteration of some dimensions. The two butterfly valves are each actuated by their own, dedicated valve operator system. Each valve operator system consists of a five horsepower, 440-volt, three-phase, 60 hertz, 1,725 rpm, induction motor manufactured by Westinghouse that drives a rack and pinion through a double reduction worm gear speed reducer manufactured by Philadelphia Gear. It is equipped with a spring-set solenoid brake on an extension of the rotor. A hand wheel is fitted to the motor shaft for manual operation of the valve.

2.2.3 New Mechanically Retained Elastomeric Valve Body Seal

The mechanically retained elastomeric valve body seal shall be of the Hartman Circlok retrofit design that is able to operate in the design conditions detailed above without loss of retention or sealing capability.

The new body seals shall be a system that consists of a mechanical retention portion and a main flexible seal portion. The flexible seal portion shall be made of compression molded natural rubber per ASTM D3192 and ASTM D3184, that is radius molded with hot vulcanized joint. Ethylene propylene diene monomer (M-class) rubber (EDM) or other type of synthetic rubber are not acceptable. Submit Valve Body Seal Material Certificates.

The mechanical retention portion of the seal design shall utilize the existing seal grooves and old metal seals adjustment bolt holes for retention. The design shall not require additional holes in the valve body for proper retention.

2.2.4 New Metal Disk Seal

Amendment #5 - Reissued in Entirety

The new metal seals for the penstock butterfly valve disks shall be a forged ring of NITRONIC 60, UNS S21800 in ASTM A193/A193M. Valve Disk Seal Material Certificates shall be submitted to the government to review.

NITRONIC 60 hardware is to be used for the attachment of the new seal to the disk. The attachment should utilize the existing seal's attachment points in the disk where possible. If it is necessary to modify the existing disk seal attachment holes or add new holes in the disk for the attachment, such an approach must be formally approved by the government before any modification occurs with either valve disk. The attachment approach is to be formally addressed in the butterfly valve seal system design and the associated product data, drawings, and calculations submittals.

2.2.5 New Valve Stem Seals and Bearings(AM#5)Not Used

The new upper valve stem seals and bearing shall be equivalent to current Garlock Chevron Packing, utilizing the same packing grooves. The bearings shall be the same material or approved equal to the existing thrust bearing and thrust plate. Dimensions of the new components shall be compared to the existing components and the results submitted to the government.Not Used(AM#5)

2.2.6 Valve Disk Filler

If a filler material is to be used to address minor disk surface material loss, then the material shall be compatible with the disk material and coating system. Submit the planned use and product data of the filler material as part of the Butterfly Valve Refurbishment Plan and Procedure.

2.2.7 Valve Disk Coating

The coating used for refurbishment of the valve disk surface shall be in accordance with the requirements of this contract including Section 09 97 02.00 26 for coal tar epoxy..

2.2.8 New Air-Vacuum Release Valve Assembly

a. Provide new air-vacuum release valve assembly rated for a minimum 150 psig, with a manually operated 8 inch diameter wedge gate valve for isolation. Orientation of the gate valve shall allow manual operation from the current structural platform above the penstock pipe. On top of the manual valve, install the new automatic air and vacuum release valve, which shall be an approved equal to the existing "CLA-VAL Corporation" model 358-AV. The valve shall automatically operate to release the air trapped above the turbine wicket gates when the PBV is closed and the by-pass is opened to fill the spiral case, and to automatically close as soon as this air is exhausted. The valve shall also automatically operate to allow air to enter the spiral case when the butterfly valve has been closed and the spiral case is being dewatered. All working parts of the air and vacuum valves shall be made of stainless steel or bronze and floats shall be stainless steel.

The valves shall be designed for a minimum hydrostatic pressure of 150 psig.

b. Inlets shall be flanged and comply with ASME B16.1 for 150 pound class rating and connect with the existing flange of the PBV.

2.3 NEW PENSTOCK BUTTERFLY VALVE GREASE LUBRICATION SYSTEM

Amendment #5 - Reissued in Entirety

The two existing grease lubrication systems of the two penstock butterfly valves shall be fully replaced. The new system shall include for each of the two systems a New Butterfly Valve Lubrication Pump, Distribution Manifolds (Metering Valves), System Routing (Piping, Hoses and Fittings), and any additional components needed to provide the necessary lubrication grease to the existing butterfly valves and operator bearings. The new stainless steel tubing and distribution manifolds or metering valves with adjustable orifices to field adjust flow rates of grease to provide necessary lubrication to meet both the Contractor's design and the manufacturers' recommendations shall be made possible without special tools. The pump and metering valve assembly shall be mounted on its own painted steel plate panel, located next to the PBV controls, and mounted to the existing walkway structure in accordance with SECTION 13 48 00.00 26.

2.3.1 Grease Pumps

The New Penstock Grease Lubrication System Pump shall be sized for proper distribution of grease through the routing, with additional margin. The additional margin shall be such that not one adjustable orifice in each distribution manifold shall need to be over 75% open to provide the proper identified amount of grease. The pumps shall be a hand actuated Larval Model DA 6 Series or equivalent shall be provided for each of the two butterfly valves..

2.3.2 Strainers

Grease strainers shall be located in an area of easy access and shall be rated for a minimum of twice system pressure. Contractor shall determine the pressure and flow rating of the strainers to be compatible with his design.

2.3.3 Gauges

2.3.3.1 Pressure Gauges

Pressure gauges shall conform to ASME B40.100, have a black enameled metal case, a 4-1/2 inch dial, and a stainless steel Bourdon tube. The scale range of the gauge shall be approximately 150 percent of the maximum pressure of the line in which installed. Gauges shall be the safety type with solid fronts and blowout backs. Each gauge shall be provided with a pressure snubber. Gauge mounting shall be readable while working the pump hand lever. Gauges and gauge lines shall be bottom tapped in horizontal pressure lines.

2.3.4 Valves

Valves and manifolds shall have a minimum pressure rating of 1.5 times the system pressure unless stated otherwise. Valves shall have SAE straight thread ends and Buna N O-rings with tube fittings. Valves shall be specifically designed and rated for grease system applications. Unless otherwise stated, valve shall be marked per MSS SP-25.

2.3.4.1 Ball Valves

Ball valves shall be made of stainless steel and designed for use with the lubricant. The valves shall have replaceable seats and be repairable without disturbing the connections. Valves shall be in accordance with

Amendment #5 - Reissued in Entirety

ANSI/AWWA C507-11.

2.3.4.2 Needle Valves

Needle valves shall be made of stainless steel and designed for fine flow regulation. The stem sealing O-rings shall be Buna N.

2.3.4.3 Metering Valves

A metering or measuring valve shall be provided for each bearing. It shall be fully hydraulic in its operation, requiring no internal springs or check valves. The valve for any given lubricated device shall have sufficient capacity to deliver a maximum quantity of lubricant needed in accordance with the bearing manufacturer, each time the measuring valve is discharged with the valve adjusted to no more than 75% open. Valves shall be a Dualine DD series or similar. Stainless steel indicator pins with an aluminum or steel manifold. Grease orifices shall be adjustable with an Allen wrench or other common tool.

2.3.4.4 Pressure Relief Valves

Pressure relief valves shall be adjustable with a body designed for a set pressure to protect the system. The flow capacity shall be determined by the Contractor.

2.3.4.5 Supply Spring Loaded Check Valves

Supply spring loaded check valves shall be of stainless steel construction and shall be the ball or poppet type with a body designed for high shock and system service.

2.3.4.6 Return Spring Loaded Check Valves

Return spring loaded check valves shall be of stainless steel construction and shall be the ball or poppet type with a body designed for the applicable conditions generated by the lubrication pump.

2.3.5 Grease Lubrication Routing

All Grease Lubrication routing shall be tubing and designed for the system working pressure. A check valve shall be provided in each lubricating line of the valve bearings to prevent the entrance of water into the respective measuring valves.

2.3.5.1 Tubing

Tubing shall be seamless stainless steel tubing conforming to ASTM A269/A269M. The wall thickness shall be selected to provide a safety factor of 6 based on the manufacturer's ratings for burst strength.

2.3.5.2 Tube Fittings

Tube fittings shall be made of stainless steel and be the flareless type or 37-degree JIC flare type with SAE straight threads and Buna N O-ring seals. The fittings shall conform to SAE J514.