DRAFT_SOW_Truman_Power_Plant_for_the_fabrication_of_Main_Shaft_and_Stub_Shafts_Studs_Units_1-5_July_2018_Update.pdf

SCOPE OF WORK

Harry S. Truman Power Plant

Fabrication of Main Shaft and Stub Shaft Studs

1. Description. Contractor shall manufacture components as specified herein and as indicated on the drawings. Contractor shall perform non-destructive testing on components as specified herein. Work shall also include all packaging and shipping required for delivery of all completed components to Harry S. Truman Power Plant.

2. Applicable Publications.

2.1 American Society for Testing and Materials (ASTM) Publications:

A29/A29M-16 General Requirements for Steel Bars, Carbon and Alloy, Hot Wrought

A434-06 Steel Bars, Alloy, Hot-Wrought or Cold Finished, Quenched and

Tempered

A576-90b Steel Bars, Carbon, Hot-Wrought, Special Quality

E709-15 Standard Guide for Magnetic Particle Testing

E114-15 Standard Practice for Ultrasonic Pulse-echo Straight-Beam Contact

Magnetic Testing

2.2 American National Standards Institute (ANSI) Specifications:

B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

B1.2 Gages and Gaging For Unified Inch Screw Threads

B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)

Y14.5 Dimensioning and Tolerancing

2.3 Department of Defense Specification:

DOD-P-16232F 7 Nov 78; Phosphate Coatings, Heavy, Manganese, or Zinc Base (For

Ferrous Metals)

2.4 American Society for Nondestructive Testing

ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and Certification of

Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

3. Contractor shall fabricate the following turbine components in the quantities listed:

A. Provide 95 stub shaft studs per drawing. Material shall be SAE or AISI grade 4140 or

4142 or 4145, Class BC meeting the requirements of ASTM A434. Tensile strength shall be 110,000 p.s.i. (minimum) and yield strength shall be 85,000 p.s.i. (minimum).

Elongation in 2 inches shall be 16% (minimum). Reduction of area shall be 45%

(minimum). Brinell hardness shall be in the range of 320 (+/- 20 points). Threads shall be ROLLED type as indicated on the drawings.

B. Provide 65 main shaft studs per drawing. Material shall be SAE or AISI grade 4140 or

4142 or 4145, Class BC meeting the requirements of ASTM A434. Tensile strength shall be 110,000 p.s.i. (minimum) and yield strength shall be 85,000 p.s.i. (minimum).

Elongation in 2 inches shall be 16% (minimum). Reduction of area shall be 45%

(minimum). Brinell hardness shall be in the range of 320 (+/- 20 points). Threads may be

MACHINED or ROLLED type as indicated on the drawings.

4. Contractor shall procure the following turbine components in the quantities listed:

A. Provide 95 Superbolt MT-02986 supernuts. Each supernut shall contain (1) B-08785 nut,

(1) W-07310 washer, (14) JB-1089 jackbolts, (1) CP-01667 O-ring, (1) CP-01668 O-ring, and (14) CP-01665 jackbolt plugs.

B. Provide 65 Superbolt MT-02986 supernuts. Each supernut shall contain (1) B-08709 nut,

(1) W-07280 washer, (16) JB-1089 jackbolts, (1) CP-01663 O-ring, (1) CP-01664 O-ring, and (16) CP-01665 jackbolt plugs.

C. Provide 17 pint sized containers of Superbolt JL-M lubricant.

5. Threads. All threads shall comply with requirements in ANSI B1.1 as applicable. The threads for the stub shaft studs shall be ROLLED type as indicated on the drawings. The threads for the main shaft studs shall be MACHINED or ROLLED type as indicated on the drawings.

6. Machining. The contractor shall machine all items as indicated and all dimensions shall be within the tolerance indicated. Finish shall be as shown on the drawings and finish roughness specified is the maximum value acceptable. Flaws due to machining or handling, such as scratches, ridges, holes, peaks, or cracks, may render the part unsuitable for its intended purpose and may be cause for rejection.

7. Non-destructive Testing: All studs shall be machined to the “blank” size before the threads are rolled. Once the blanking operation for the threaded ends and the main body of each stud has been completed, each stud (at the three diameters) shall be inspected per ASTM E114-15 for subsurface (from outside diameter to a maximum depth of 3/8”) discontinuities. Ninety per cent

(90%) of each “blanked” or main body surface area shall be inspected. Any discontinuity greater than 1/16” in length (in any direction) and less than 3/8” below the outside diameter, will be cause for rejection of the stud. After completion of all machine work, including thread rolling, the threaded areas will be re-inspected per ASTM E 709. Any stud with a crack or discontinuity found during this phase of the inspection will be unsuitable for use and rejected at the contractor’s expense. The contractor shall prepare and submit to the government, inspection reports for both the “before” and “after” thread rolling process.

Nondestructive testing (NDT) personnel shall be qualified in accordance with a nationally recognized NDT personnel qualification practice or standard such as ANSI/ASNT CP-189, SNT-

TC-1A, NAS-410, or a similar document. The person performing the testing shall submit his/her certificate (for the nationally recognized NDT personnel qualification) with the NDT test reports.

8. Manganese Phosphate Coating for New Studs: Each stud shall be coated in accordance with DOD-P-16232F, Type M, Class 2. Coating thickness shall be between 0.0005-inch and

0.001-inch. The Contractor shall provide written manganese phosphate coating thickness certification reports.

9. Quality Control. Workmanship shall be of the highest grade in accordance with the best modern practices to conform to the specifications for the work being performed. The contractor shall be responsible for quality control to ensure all parts meet requirements of this contract.

Measurements shall be taken by experienced operators with instruments that have been certified and recently calibrated. Certification of calibration shall be submitted for the Contracting

Officer's Representative to review. Measurement of machine surfaces shall be accurate to the nearest 0.001 (one-thousandth) of an inch. Those items not conforming to the material requirements or measurements indicated will be rejected at the contractor's expense and the associated shipping charges, if any, shall be borne by the contractor. The Contracting Officer reserves the right to inspect and witness the work at any time and witness any or all inspections or measurements.

10. Required Submittals. The Contractor shall allow seven (7) days in the schedule for the

Government's review and approval. Government approval is required for submittals with a "G" designation; submittals not 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. After award, the contractor shall submit the following to the Government for approval in accordance with Section 01 33 00 SUBMITTAL PROCEDURES Contractor shall submit the following for approval:

10.1 SD-03 Product Data; G, DO. Mechanical properties and chemical composition of the main shaft stud and stub shaft stud, washer, and Superbolt supernut material. These shall be provided prior to manufacturing the studs, washers and hex nuts.

10.2 Certificates; G. Manganese phosphate coating thickness certifications.

10.3 Inspection Schedule; G, DO. Fifteen (15) Day Notice for Inspection of all items in accordance with paragraph: 14. Shipping.

10.4 Test Reports; G, DO. Non-destructive (UT and MT) inspection reports for all studs (before and after thread rolling process). Include NDT personnel certification.

10.5 Quality Assurance Report, G, DO. This report shall be submitted and approved prior to shipment of any parts.

10.6 Trial Fitting Schedule, G, DO. Fifteen (15) Day Notice for Trial Fitting of all items in accordance with paragraph: 17. Trial Fitting of Studs and Supernuts

11. Quality Assurance Report. This report shall indicate actual dimensions of each new part, surface finishes and other data as noted herein. For studs (i.e. rolled threads) and nuts (i.e. cut threads) the threads shall conform to their applicable standard.

At a minimum, the data sheets that make up the Quality Assurance Report shall include the following:

a) Micrometer readings (at three places) for each “blanked” area on each end of each stud before threads have been rolled (to the nearest 0.001”).

b) Micrometer readings (at three places) for each “body” (i.e. middle portion of stud) area on each stud (to the nearest 0.001”).

c) Contractor shall set up three dial indicators (one for each area where threads will be rolled and for the body) for checking the total run-out (to the nearest 0.001”) for each stud.

Readings will be taken at 0, 90, 180 and 270 degrees rotation. Each of the three dial indicators will then be moved approximately 2 inches (as a set) and the run-out checked as outlined above.

Each of the three dial indicators will then be moved approximately 2 inches (as a set) again and the run-out checked as outlined above. There will be a total of three “sets” of run-out readings for each stud.

d) Each stud shall have a “unique” identifier (numbers/letters) stamped on one of the flats of the hex at the top of the stud. This identifier shall be noted on each data sheet for each stud.

Possible identifiers could be M1, M2, etc. for the main shaft studs and S1, S2, etc. for the stub shaft studs.

e) The overall length of each stud (to the nearest 1/64”) shall be noted on the data sheet.

f) The surface finish for the “blanked” and body areas for each stud shall be noted on the data sheet.

12. Protection of Machined Surfaces. Machined surfaces shall be covered with a moisture resistant coating (light oil is preferred, not cosmoline), crated and covered for corrosion protection.

13. Points of Contact.

The point of contact for work in this contract at the powerhouse is:

Rich Chiles (OFH-TP)

Power Plant Superintendent

29564 Powerhouse Road

Warsaw, Mo. 65355

Phone Number: 816-389-3806

The point of contact for technical questions concerning mechanical items for this work is:

Greg Wright (OFH-T-P)

Mechanical Engineer

Phone Number: 816-389-3304

14. Shipping. The contractor shall provide a minimum of fifteen (15) working days advance notice to the Contracting Officer's Representative for inspection of all items prior to shipment.

All parts shall be shipped to the Harry S. Truman Power Plant near Warsaw, Missouri at the contractor's expense. The Contractor shall properly package and secure all items to protect them from damage during shipping and delivery. Damaged items shall be replaced at the expense of the Contractor. The items shall be shipped to:

Truman Power Plant

15. Powerhouse Delivery. The government will provide a crane operator to unload all items with the Power Plant bridge crane if necessary (provided the parts are on a flatbed truck). The contractor shall disconnect all rigging, packing, and connections prior to the government unloading all items and materials. The contractor shall give two (2) days advance notice to the

Power Plant prior to delivery. The crane operator will be available between 0700 and 1500 hours, Monday through Thursday, excluding government holidays. All shipments and deliveries shall be coordinated within this time frame. No delivery and/or unloading shall commence later than 1400 hours. Other method of unloading available is by forklift (maximum capacity is 5000 pounds).

16. Gaging of Threads on Studs and Supernuts. The Government will gage the threads with

Government-owned Johnson Gages to determine pitch and functional diameters. Final acceptance will not be given until all studs and supernuts pass the gaging test. Those studs and supernuts found to have threads that are not within the tolerance/allowance for specified/indicated class will be rejected at the contractor's expense.

17. Trial Fitting of Studs and Supernuts. After completion of all machining and coating operations, the contractor shall trial fit all studs and supernuts to check for proper thread engagement on both ends of the studs. A Government Quality Assurance Representative may witness any trial fitting. Any stud that exhibits tight spots or other difficulty engaging shall be rejected at the contractor’s expense.

18. Completion of the Work. One set of main shaft studs (10 studs), one set of stub shaft studs

(15 studs), one set of main shaft supernuts (10 supernuts), and one set of stub shaft supernuts (15 supernuts) shall be complete, including delivery to the power plant, within 90 calendar days from date of award. All work for the base contract including delivery to the Power Plant, shall be completed within 210 calendar days from date of award.