W912DW22R0001-0005.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

The purpose of this Amendment 0005 is to revise paragraph 3.4 in Section 48 13 16.00 26.

1. CONTRACT ID CODE PAGE OF PAGES

1 2

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

16C. DATE SIGNED

BY 04-Mar-2022

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 W912DW22R0001

X 9B. DATED (SEE ITEM 11)

14-Dec-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 is extended, X 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

03-Mar-2022

CODE

USA ENGINEER DISTRICT, SEATTLE

ATTN: CENWS-CT

4735 EAST MARGINAL WAY SOUTH, BLDG. 1202

SEATTLE WA 98134-2388

W912DW 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

CJD SS Primary Components

AMENDMENT

SECTION 48 13 16.00 26

REWIND OF HYDRAULIC-TURBINE DRIVEN GENERATORS

PART 1 GENERAL

1.1 GENERAL INFORMATION

This Section covers the work listed below as a minimum for two station service generators at Chief Joseph Lock and Dam. The Contractor may perform the work in this specification on site or at an approved offsite facility in accordance with approved submittals.

a. Supply, install, and test two stator windings, including removing the old stator windings. The stator windings may contain asbestos materials.

b. Supply, install, and test two stator cores, including removing the old stator cores.

c. Optional Work: Re-insulate two sets of rotor field poles. The rotor field poles may contain asbestos materials.

d. Remove existing, supply, install, and test new auxiliary equipment including unit current transformers, surge arresters and capacitor, and unit heaters .

e. Refurbish the collector rings for each generator.

f. Perform a visual inspection of the rotor spider for each generator.

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 basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A 343 (2014) Standard Test Method for Alternating-Current Magnetic Properties of Materials at Power Frequencies using Wattmeter-Ammeter-Voltmeter Method and 25-cm Epstein Test Frame

ASTM A 717 (2012) Standard Test Method for Surface Insulation Resistivity of Single-Strip Specimens

ASTM A 720 (2002; R 2016) Standard Test Method for Ductility of Nonoriented Electrical Steel

AMERICAN WELDING SOCIETY (AWS)

AWS A5.8/A5.8M (2012) Specification for Filler Metals for Brazing and Braze Welding

SECTION 48 13 16.00 26 Page 1

AWS D1.1/D1.1M (2020) Structural Welding Code - Steel

CEATI INTERNATIONAL (CEATI)

CEATI T052700 0329 (2008) Hydroelectric Turbine-Generator Units Guide for Erection Tolerances and Shaft System Alignment

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 43 (2013) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

IEEE 56 (2016) Guide for Insulation Maintenance of Electric Machines

IEEE 95 (2002; R 2012) Recommended Practice for Insulation Testing of Large AC Rotating Machinery with High Direct Voltage

IEEE 115 (2019) Guide for Test Procedures for Synchronous Machines Including Acceptance and Performance Testing and Procedures and Parameter Determination for Dynamic Analysis

IEEE 286 (2000; R 2012) Recommended Practice for Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation

IEEE 522 (2004; R 2009) Guide for Testing Turn Insulation of Form-Wound Stator Coils for Alternating Electric Machines

IEEE 1043 (1996; R 2009) Recommended Practice for Voltage-Endurance Testing of Form-Wound Bars and Coils

IEEE 1434 (2014) Guide for the Measurement of Partial Discharges in AC Electric Machinery

IEEE 1553 (2002; R 2007) Standard for Voltage-Endurance Testing of Form-Wound Coils and Bars for Hydrogenerators

IEEE 1799 (2012) Recommended Practice for Quality Control Testing of External Discharges on Stator Coils, Bars, and Windings

IEEE C50.12 (2005; R 2010) Standard for Salient Pole 50 HZ and 60 Hz Synchronous Generators and Generation/Motors for Hydraulic Turbine Applications Rated 5 MVA and above

IEEE C57.13 (2008; INT 2009) Standard Requirements for Instrument Transformers

IEEE C57.13.1 (2006; R 2012) Guide for Field Testing of Relaying Current Transformers

SECTION 48 13 16.00 26 Page 2

IEEE C62.21 (2003; R2009; Errata 2006; Corr 1 2008) Guide for the Application of Surge Voltage Protective Equipment on AC Rotating Machinery 1000 V and Greater

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA FI 1 (2004) Manufactured Electrical Mica

NEMA LI 1 (1998; R 2011) Industrial Laminating Thermosetting Products

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017) National Electrical Code

Occupational Safety and Health Act (OSHA)

54 CFR 2920 (1970) Williams Steiger Occupational Safety and Health Act

1.3 SUBMITTALS

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

submittals having an "I" are for information only. Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 , SUBMITTAL PROCEDURES.

SD-01 Preconstruction Submittals ;

Within 60 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Stator Winding Warranty Details ; I

Stator Coil Facility ; G

Stator Coil Voltage Endurance Test Facility ; G

Stator Design Review Meeting ; I

Lamination Manufacturing Facility ; G

SD-02 Shop Drawings

Include a parts list in shop drawings as appropriate.

Within 60 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Cross-Sectional View of Stator Coils ; G

Exterior Dimensions of Stator Coils ; G

Winding Diagram ; G

Stator Coil Connection ; G

SECTION 48 13 16.00 26 Page 3

Connection Details ; G

Winding Bracing Configuration ; G

Circuit Ring Configuration and Dimensions ; G

Surge Rings ; G

Surge Arrester and Capacitor Catalog Cuts ; G

Main and Neutral Lead Details ; G

Main and Neutral Lead Arrangement ; G

Nameplate ; G

Stator Core Laminations ; G

Stator Core Vent Duct Spacers ; G

Stator Core Completed Assembly ; G

Core Keybars ; G

Stator Core Clamping System ; G

Wiring Diagrams ; I

Within 60 calendar days after the Government has exercised the option to refurbish the rotor poles:

Rotor Pole Assembly and Details (Optional) ; G

Rotor Pole Connections Assembly and Details ; (Optional) G

SD-03 Product Data

Within 60 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Stator Coil Insulation System ; G

Within 90 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

RTDs, RTD Extension Cable, and terminal block Catalog Cuts ; G

Stator Assembly Materials and Dimensions ; G

Current Transformer Catalog Cut ; G

Within 120 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Spring Type Washers Loading ; G

Brushes and Holders ; G

SECTION 48 13 16.00 26 Page 4

Heater ; G

SD-05 Design Data

Within 90 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Wedging System Deflection Characteristics ; G

DC I²R Copper Losses Design Calculations ; G

Stray Load Losses Design Calculations ; G

Maximum Temperature Rise ; G

Temperature Rise Calculations ; G

Within 60 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Core Losses Design Calculations ; G

SD-06 Test Reports

Within 30 calendar days after the completion of the test:

Coil Test Record ; G

Current Transformer Routine Test Report ; I

Prototype Coil Voltage Endurance Test Report ; G

Production Run Coil Voltage Endurance Test Report ; G

Dissection and Examination Report ; G

Coil Factory Test Report ; G

Spring Type Filler Material Test Report ; G

RTD Test Report ; I

Lamination Test Report ; G

Rotor Pole Factory Test Report ; (Optional) G

Field Winding Final Test Report ; G

Rotor Spider Inspection Report ; G

SD-08 Manufacturer's Instructions

Within 60 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Voltage Endurance Test Methods ; G

Coil Factory Test Procedure ; G

SECTION 48 13 16.00 26 Page 5

Stator Winding Installation Procedure ; G

Interlaminar Insulation Test Procedure ; G

Initial Acceptance Test Procedures ; G

Final Acceptance Test Procedures ; G

Generator Special Field Tests Procedure ; G

Lamination Test Procedure ; G

Stator Core Keybars Installation Procedure ; G

Collector Ring Refurbishment Procedure ; G HDC

Within 60 calendar days after the Government has exercised the option to refurbish the rotor poles:

Rotor Pole Removal and Reinstallation Procedure ; (Optional) G

Pole Transportation Procedure ; (Optional) G

Field Coil Reinsulation Procedure and Materials ; (Optional) G

Field Leads Replacement Procedure ; (Optional) G

SD-09 Manufacturer's Field Reports

Within 30 calendar days after the completion of the inspection or test:

Stator Frame Inspection Report ; G

Stator Core Final Check Report ; G

Interlaminar Insulation Test Report ; G

Stator Winding Final Inspection Report ; G

Winding Installation Test Report ; G

Rotor Inspection Report ; G

Initial Acceptance Test Report ; G

Final Acceptance Test Report ; G

Generator Special Field Test Report ; G

SD-10 Operation and Maintenance Data

Within 120 calendar days after receipt of written notice to proceed (NTP) with the rewinds:

Spare Parts List ; I

Within 30 calendar days after completion of the first generator commissioning:

SECTION 48 13 16.00 26 Page 6

Generator Operations and Maintenance Manual ; G

1.4 EXISTING GENERATOR INFORMATION

1.4.1 Unit Identification and Nameplate

The Chief Joseph Station Service Units are water cooled, vertical hydro-generators, manufactured by Elliott Company and installed in 1954.

Generator ratings, as defined by the nameplate stamping information, are as follows.

3,000 kVA 2,400 kW

0.8 Power Factor

4,160 V 416 Amps 3-phase 60 Hz

514 RPM

60 deg. C Stator rise 80 deg. C Rotor rise

1.4.2 Test Report Data

The following information is from the field test report. The original field test data is attached at the end of this section for the Contractor's information.

(b) Losses in Kilowatts (kW).

Losses at rated voltage and power factor.

Percent Load 25 50 75 100

Frict. & Wind. Loss 18.72 18.72 18.72 18.72

Core Loss 19.6 19.6 19.6 19.6

Armature DC I²R Loss (75°C)

1.28 5.14 14.28 20.55

Field I²R Loss (75°C) 6.86 10.05 13.54 16.38

Stray -Load Loss 0.9 1.9 3.5 5.8

TOTAL LOSSES 47.36 55.41 69.64 81.05

1.4.3 Description of Generator

The generators are designed for wye-connection of the stator windings with each phase consisting of seven parallel paths. The stator core has a bore diameter of approximately 61 inches, and a height of approximately 21 inches. Each unit has 14 rotor poles.

1.4.4 Failure History

Station Service Unit SS01 is currently out of service following a stator winding failure in May 2020. An apparent A-phase turn-to-turn fault led to A to B phase fault after re-energization with significant smoke and debris noted. Damage to the lower end winding area includes several coils, clamping fingers between slots 96 and 97, and a rotor to stator rub.

SECTION 48 13 16.00 26 Page 7

Failure report available upon request.

1.4.5 Inspection by Contractor

Coordinate the inspection schedule and access requirements with the Contracting Officer (CO). The Contractor is responsible for obtaining and verifying dimensions and other information, including information contained in this specification, that may be required to design replacement stator windings and stator core laminations and clamping system. Take measurements on the generator as necessary to ensure that coils and materials supplied under this contract will meet all contract requirements. The Contractor is responsible for developing the necessary information required for design. Bring any discrepancies between information given in this document and information developed to the attention of the Government before proceeding.

1.5 WARRANTY

The warranty period for the complete installed windings is to be five (5) years after the successful completion of tests and acceptance. The Contractor is responsible for repairing or replacing any component failing to perform its function as specified and documented at no additional cost to the Government within the five (5) year period. Respond to the Government and perform an assessment of the failure within four (4) weeks of the incident. Include disassembly and reassembly sufficient to make repairs, repair to any surrounding generator equipment as a result of the failure, and any necessary testing to confirm the efficacy of the repair.

Replace any spare parts used during the repair in kind within one year of the completion of the repair. Submit for approval the Stator Winding Warranty Details , to include duration of warranty coverage and items and labor covered by the warranty.

1.6 DELIVERY AND HANDLING

If the Contractor chooses to rewind the stator winding and restack the stator core in the factory, each generator shall be disassembled for shipment to and from the Contractor's facility. All small parts or elements shall be boxed. The skid mounting and boxing shall be done in a manner which will prevent damage or distortion to the stator frame during loading, shipment, unloading, indoor storage, and subsequent handling.

Weatherproof covers shall be provided to protect the generator components during shipment. Ship all generator components in an enclosed trailer truck. Any eyebolts, special slings, strongbox, or other devices used in loading the equipment at the Contractor's facility shall be furnished for unloading and handling at the destination.

PART 2 PRODUCTS

2.1 MATERIALS

Conform all materials to the applicable specifications and standards listed and to the additional requirements specified herein. Obtain approval for the intended purpose of any materials required for the work, but not covered by the specifications, prior to the material incorporation. Reference to any equipment, article, or catalog number within this specification is to establish a standard of quality and not intended to limit competition.

SECTION 48 13 16.00 26 Page 8

2.2 WINDING RATING AND INSULATION CLASS

Supply a stator winding rated for continuous operation at 3,000 kVA at 4,160 volts. Provide stator coils and winding installation materials capable of operation at Class F temperature limits as defined in IEEE C50.12 . Design and provide a stator winding such that the winding temperature rise does not exceed 75°C above a cooler discharge air temperature of 40°C, when operated at rated load.

2.3 NAMEPLATE

Submit for approval the nameplate drawing. Include details on material, dimensions, and arrangement of information on the drawing. Make the nameplate s of cast, stamped or etched brass or stainless steel similar in size and thickness to the original nameplates. Include the following information on the nameplates:

(a) Winding manufacturer's name

(b) Rated kVA

(c) Power factor

(d) Stator current

(e) Stator temperature rise

(f) Date of rewind

(g) Rated kV

(h) Insulation class

2.4 STATOR COILS

2.4.1 General

Incorporate modern practice in design, material, and workmanship for the stator coils manufactured under this specification. Design coils to be the hard, multi-turn type with minimized eddy current loss. Use annealed copper, free from splinters, flaws, rough spots, or short radius bends for the strands. Transposition of the strands shall be made internal to the coils. Round all finished outside edges of each coil with a minimum radius of 1/16 inch. For the narrow side of the slot portion of each stator coil, provide a flat bearing surface of at least 3/8 inch. Do not cut or tailor any coil leads for any particular slot; design each coil for use in any slot. Submit the following for approval:

(a) Stator Coil Facility . The name, address and qualification of the stator coil facility.

(b) Cross-Sectional View of Stator Coils . A cross-sectional view of the stator coil in a stator slot, describing the stranding arrangement, strand dimensions, copper cross-sectional area, strand and turn insulation details (including insulating material types and thicknesses), slot fillers, wedging details, and partial discharge suppressive treatments. Include groundwall insulation materials and thickness on the drawing.

SECTION 48 13 16.00 26 Page 9

(c) Exterior Dimensions of Stator Coils . Include bending radii, dimensions of slot paint and grading tape on the drawing.

(d) Winding Diagram . A drawing that shows the three phases in different colors and RTD locations. Include a tabular listing of the winding showing the progression from line end to neutral end for all parallels with the diagram.

(e) Stator Coil Insulation System . A description of the stator coil insulation system, including processes and materials employed to meet specification requirements. Include data sheets for materials used in the coil construction.

(f) Stator Coil Connection . Drawings to show the coil external connections, pole group jumpers, and connections to circuit ring.

(g) DC I²R Copper Losses Design Calculations . Detailed design calculations demonstrating how the stator DC I²R (copper) losses are determined at 75°C. Illustrate with the calculations the composition of the various portions of winding circuit resistance, including number of coils in series, parallel connections, end connections, circuit rings, etc.

(h) Stray Load Losses Design Calculations . Detailed calculations showing how the stray load loss is determined.

(i) Maximum Temperature Rise . Maximum temperature rise of the winding above 40°C ambient at rated load, voltage, and power factor.

(j) Temperature Rise Calculations . Calculated stator winding temperature rise as indicated by embedded temperature detectors and calculated stator winding hot spot temperature at rated load, voltage, and power factor. Correlate the relationship between the operating "hot spot" temperature of the stator coils and the temperature measured by RTD demonstrated by direct measurement or recognized methods of calibration to special factory tests on a basically similar machine.

2.4.2 Coil Design

2.4.2.1 Conductor Strand Insulation

Make strands continuous (splice free) within the entire mean turn length of each coil . Insulate strands with continuous filament glass, dacron-glass fibers, or mica tape, bonded to the copper with a suitable bonding agent. Size and arrange conductor strands to minimize eddy and circulating current losses.

2.4.2.2 Turn Insulation

Insulate each turn with multiple layers of mica tape in combination with suitable backing materials. Turn insulation may be applied to individual strands in lieu of dedicated turn insulation or alternative methods for insulating turns as approved.

2.4.2.3 Ground Insulation

Provide ground insulation that consists of multiple overlapped layers of mica tapes applied continuously throughout the entire length of the coil for equal thickness. Meet the requirements of NEMA FI 1 , Table 5-4 or Table 5-6 for the mica tape. Use mica tapes constructed with a glass or

SECTION 48 13 16.00 26 Page 10 polyester fabric backing material. Apply a suitable protective covering tape over the ground insulation mica tape.

2.4.2.4 Coil Consolidation

Bond the slot and end winding portions of the assembled strands into a homogenous structure of controlled size using heat and pressure. Use strand bonding resins with properties and characteristics to prevent bond failure due to the mechanical, thermal, and chemical effects associated with thermal cycling while operating within the Class F temperature limits for which the winding is to be designed.

2.4.3 Coil Manufacturing Methods

2.4.3.1 Vacuum Pressure Impregnation (VPI)

After drying treatments, completely fill the coil insulation with a solventless epoxy resin using a vacuum pressure impregnation process.

After impregnation, cure the coil insulation system by the application of heat and pressure to the slot and end winding portions of the coils. Size slot portions to closely controlled dimensions and restrain end portions with suitable pressure devices to ensure a well-compacted insulation structure. No internal voids, as determined by the COIL DISSECTIONS in paragraph 3.4, are allowed in the insulation between the copper strands and the outer edge of the stator coils in the slot portion of the stator coils, including those coils subjected to the Voltage Endurance tests as described in paragraph 3.3, VOLTAGE ENDURANCE TESTS. Global VPI is not acceptable.

2.4.3.2 Resin Rich Tapes

Resin rich, B stage, or loaded tapes may be used in lieu of the resin impregnation process. Cure the coil insulation system by the application of heat and pressure to the slot and end winding portions of the coils.

Size slot portions to closely controlled dimensions and restrain end portions with suitable pressure devices to ensure a well-compacted insulation structure. No internal voids, as determined by the COIL DISSECTIONS in paragraph 3.4, are allowed in the insulation between the copper strands and the outer edge of the stator coils in the slot portion of the stator coils, including those subjected to the Voltage Endurance tests as described in paragraph 3.3, VOLTAGE ENDURANCE TESTS.

2.4.4 Finish and Partial Discharge Suppression Treatment

Treat slot portions of the stator coils, and a suitable distance beyond, with a semiconductive compound capable of giving positive electrical contact between the treated portions of the coil surface and the entire length of the core slot walls. Design this semiconductive treatment to eliminate surface discharge (corona) between the coil and slot surfaces and between top and bottom coil sides.

2.4.5 Graded Suppression Treatment

Apply a voltage grading semiconductive tape to the stator coil surface extending outward from the semiconductive treatment. Apply the voltage grading semiconductive tape to be of a length and resistivity to limit coil surface voltage gradients to levels well below corona onset levels under normal operating voltage stresses at normal operating temperatures.

Leave the voltage grading semiconductive treatment exposed and accessible

SECTION 48 13 16.00 26 Page 11 for inspection and possible repair. During a black-out test, as described in paragraph 3.24(d), Blackout Test, no visible corona is allowed to be produced by the winding. Treat coil surfaces beyond the discharge suppressive treatments with a finish capable of resisting exposure to dampness, oil vapors, Contractor-recommended cleaning solvents, or other materials to which the winding may be exposed during operating life.

2.4.6 Coil Test Record

Give each coil a unique identification. Keep a permanent Coil test record for each coil, whether the coil is included in the finished winding or not. Include the results of all coil tests and the slot number where each coil has been installed in this record.

2.4.7 Prototype Coils

Use entire coils for prototype stator coils, complete with all armor tapes and stress control materials applied. Omit materials normally bonded to the coil that are used to secure the coil in the slot. Manufacture prototype coils to be identical to those manufactured under paragraph 2.4, STATOR COILS.

2.4.8 Quantity

(a) Prototype Coils. Prior to manufacturing the production run coils, manufacture at least four stator coils for voltage endurance testing.

Do not manufacture the production run coils before the prototype coils are tested and dissected and the test report is approved.

(b) Production Run Coils. Following the approval of the prototype coil testing and dissection, provide 6 production run coils, plus any additional coils which may be required due to failure, for the Voltage Endurance testing specified in paragraph 3.3, VOLTAGE ENDURANCE TESTS.

Do not use or provide as spares coils subjected to Voltage Endurance testing in the final winding. Provide sufficient coils to make up 2 complete windings. Also supply the spare coils listed in paragraph

2.15, SPARE PARTS.

If the manufacturing of the first and second set of coils is separated by more than 2 months, provide another set of 6 production run coils, plus any additional coils which may be required due to failure, for the Voltage Endurance testing.

2.5 RESISTANCE TEMPERATURE DETECTORS (RTDs)

Supply for installation in the stator winding of each unit twelve (12) 4-wire resistance temperature detectors (RTDs) suitable for operation in a Class F insulation system. Provide 100 ohm platinum RTDs (±0.12% at 0°C) with a TCR of 0.00385 ohm/ohm/°C. Supply RTDs with a semiconductive coating on the body. Supply and locate RTDs in accordance with clause 7.3 of IEEE C50.12 . Replace existing RTD extension wires to the generator terminal cabinet with new extension wires. Provide new RTD terminal blocks as required to replace existing RTDs and accomodate new RTDs. Use No. 16 AWG tinned stranded copper, four-conductor cable immune to electrical noise for RTD extension wires. Use oil and water resistant cable with an overall metallic armor for mechanical protection. Polyvinyl chloride (PVC) will not be allowed. RTD leads will be solder-spliced to the RTD extension wires outside the stator slot. Do not use mechanically

SECTION 48 13 16.00 26 Page 12 spliced leads. Splices are not allowed within the slot portion. Submit RTDs, RTD Extension Cable, and terminal block Catalog Cuts .

2.6 NOT USED

2.7 FILLERS, WEDGES, TIES, AND BLOCKING MATERIAL

2.7.1 General

Provide materials suitable for use in conjunction with a Class F winding insulation system for use in the stator slots, such as fillers, wedges, ties and blocking.

2.7.2 Stator Assembly Materials and Dimensions

Submit for approval a description of materials used for the assembly of the stator coil s in the generator core. Include all end-bracing and blocking materials, wedging, filler, and brazing materials. Include drawings detailing the dimensions of all wedges and fillers used in the stator.

2.7.3 Side Packing

Systems using a non-spring-type filler inserted in the slot after inserting the coil are not acceptable. Use one of the following side packing systems:

(a) Apply a semiconductive silicone rubber compound to the sides of the coil and cure before insertion. Form an interference fit between the silicone rubber and the sides of the slot.

(b) Apply a semiconductive coil wrapper in conjunction with conducting putty continuously applied throughout the length of the slot.

(c) Drive a semiconductive ripple spring between one side of the coil and the slot to form an interference fit. Submit the acceptable semiconductive ripple spring deflection.

2.7.4 Center and Bottom Filler

Fabricate center and bottom fillers from semiconductive materials. Provide semiconductive material impregnated throughout and not coated on top of an insulating backing. Provide a center filler between the two coil sides in a slot sized to prevent interference between the top and bottom coils in the straight part extension. Install RTDs in place of the center filler.

RTD location shall be determined per IEEE C50.12 . Use bottom filler between the bottom coil side, or furthest from the center of the bore, and the bottom of the slot.

2.7.5 Spring-Type Filler Material

Install spring-type filler material between the top filler and the wedge.

2.7.6 Wedges and Top Filler

Manufacture slot wedges from NEMA LI 1 Grade G11 material with a cross-sectional shape to match the groove shape of the stator laminations and provide a snug, sliding fit when placed in position in the slot.

Include a wedge cutback at the cooling air passages designed to enhance

SECTION 48 13 16.00 26 Page 13 the air flow. Furnish top fillers of various thicknesses to ensure acceptable radial wedging pressures. Furnish a top filler of at least

0.020 inch for use against the coil. Provide a locking system for restricting the possible axial movement of the wedges. Furnish one check wedges per slot, located in the center of the slot. Design check wedges with no less than five (5) holes to measure spring-type filler deflection. Upon completion of the wedging, all wedges along the length of the slot must be independently tight in the slot.

2.7.7 Two-Part Wedges

If using a two-part wedging system, assemble the wedges and slides using a master slide to select the correct slide thickness. Provide slide lengths that neither project above the top of the wedge nor touch the wedge below.

Install all wedges so that all slides are driven from above.

2.7.8 Wedging System Deflection Characteristics

Submit the wedging deflection characteristics for approval including:

(a) Initial deflection of slot wedging spring-type filler and radial pressure applied to the stator coils in slot portions.

(b) Minimum acceptable deflection of the slot wedging spring-type filler after extended operation and the radial pressure applied to the stator coil at the minimum acceptable deflection.

(c) Calculations to show that the radial pressure wedging system forces will exceed the non-fault condition forces throughout the life of the winding. Calculate forces at rated load, voltage, power factor and at worst fault condition.

2.7.9 End Winding Bracing and Blocking Material

End winding bracing material consists of resin-impregnated conforming materials, blocks, and glass twine. Use Dacron felt thoroughly impregnated with resin for conforming material between the coils. Use glass-based blocks when the space cannot be filled with the conforming material. Saturate all ties with resin during and after installation.

2.8 CIRCUIT RINGS AND STATOR CONNECTIONS

2.8.1 General

Provide new circuit rings, complete with all necessary connections and circuit ring support system. Insulate the circuit rings for 5kV. Provide drawings of the Connection Details including coil-to-coil connections, jumper connections, connections from coils to circuit rings, details of connections from the circuit rings to the main and neutral leads, Winding Bracing Configuration , and Circuit Ring Configuration and Dimensions .

2.8.2 Electrical Configuration

Design the stator windings to be wye-connected, with each phase of the stator winding consisting of multi-turn coils with neutral leads and the common main lead brought out within the generator housing at their existing location.

SECTION 48 13 16.00 26 Page 14

2.8.3 Physical Construction

Design the circuit rings for installation in the same general location as the existing equipment. Do not use more than six pieces to make up each circuit ring.

2.9 SURGE RINGS

Provide upper and lower stainless steel surge rings and mounting assemblies. Submit for approval drawings of the surge rings including dimensions, materials, and assembly. Insulate surge rings for 5kV and ground each at one location.

2.10 MAIN AND NEUTRAL LEADS

Replace the main and neutral leads using a similar design on both units.

Silver surface all bolted connections and make connections using Belleville spring-type washers with stainless steel fasteners, or approved equal. Submit calculations to demonstrate the adequacy of the Spring Type Washers Loading . Design and supply main and neutral lead supports to firmly maintain the connections in place. Provide Main and Neutral Lead Details and Main and Neutral Lead Arrangement drawings.

2.11 NOT USED

2.12 STATOR CORE MATERIALS

2.12.1 Stator Core Laminations

Provide a new stator core for each unit. Provide drawings of the Stator Core Laminations and Stator Core Vent Duct Spacers including dimensions, materials and tolerances. Submit an assembly drawing of the Stator Core Completed Assembly , including dimensions and tolerances, for the completed stator core.

(a) Furnish the required number of new laminations to completely stack the new stator cores, continuously without splits. Make the laminations from high-grade non-aging silicon steel. Submit for approval Core Losses Design Calculations based upon design factors including, but not limited to, the proposed lamination steel and stacking factor.

The new core losses shall be no worse than the original core losses.

Make the steel thickness no greater than the original steel. Coat each lamination on both sides with an insulating varnish or other suitable material to minimize eddy current losses.

(b) Furnish the required number of new stator vent duct spacers to completely stack the new stator cores.

Submit for approval the name, address and qualifications for the proposed Lamination Manufacturing Facility .

2.12.2 Not Used

2.12.3 Stator Keybars

Furnish new keybars for both furnished stator cores. Furnish detailed drawings of the Core Keybars , including materials and dimensions and stator frame modifications if applicable. Submit the Stator Core Keybars Installation Procedure .

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2.12.4 Stator Clamping System

Furnish a new stator clamping system for both furnished cores. Include flanges and fingers, tightening nuts and through bolts in new clamping systems. Do not use cast iron for flanges. Weld fingers to the flanges.

If the clamping system design includes through bolts that are welded or attached to the frame, do not make the weld or attachment until the bolts have been properly torqued. Provide detailed drawings of the Stator Core Clamping System , including materials, dimensions and torque values of the new clamping system, and stator frame modifications, if applicable.

2.13 GENERATOR AUXILIARY EQUIPMENT

2.13.1 Neutral Current Transformers

For each generator, replace the existing Westinghouse type CT-5 style number 1263062A current transformers (CTs) with new ones of similar style and ratings. Provide three (3) 5 kV CTs with 600:5 ratios for use in the differential protection scheme. Provide CTs with an accuracy rating of existing CTs and a BIL rating of 60 kV. Comply with IEEE C57.13 Part 6 for CTs. Submit a Current Transformer Catalog Cut for approval include accuarcy determination methodology. Install in accordance with paragraph, Current Transformer Installation.

2.13.2 Line Current Transformers

For each generator, replace the existing Westinghouse type CT-5 style 1304451 current transformers with new ones of similar style and ratings.

Provide three (3) 5 kV CTs with 600:5//5 ratios having double secondaries, that is, two independent secondary windings for use in metering circuits.

Provide CTs with an accuracy rating of existing CTs and a BIL rating of 60 kV. Comply with IEEE C57.13 Part 6 for CTs. Submit a Current Transformer Catalog Cut for approval include accuracy determination methodology.

Install in accordance with paragraph, Current Transformer Installation.

2.13.3 Brushes and Brush Holders

Provide new carbon brushes and new constant pressure type brush holders mounted to the existing brush rigging. The brush holders shall be staggered and shall be of the constant pressure type. Brush arrangement shall be made to minimize the possibility of a short circuit. Submit drawings of the brushes and holders for approval. Install in accordance with paragraph, Brushes and Brush Holders Installation. In addition, provide a shaft grounding brush, holder, and bracket assembly to be installed below the rotor and provide drawings. Recommend the number of collector ring brushes to install. Provide a basis for the recommendation, include anaysis of current density for selected collector ring and shaft grounding brush. Include these items in the brushes and holders submittal.

2.13.4 Heaters

Replace existing heaters with new heaters, see Elliott Company drawing E-5062-89. Provide new space heaters with thermostat control, rated for 3-phase operation at 480 Vac for a total of 3 kW. Provide all new wiring.

Provide heater catalog cuts, include thermostat controls and wiring in submittal. Install in accordance with paragraph, Heater Installation.

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2.13.5 Surge Arresters and Surge Capacitors

For each generator, provide three 3 kV rms duty cycle surge arresters and one three phase capacitor. Provide surge arresters of the zinc-oxide type with a maximum continuous operating voltage rating (line-to-ground) no less than 2.55 kV rms. Supply surge arresters suitable for surge protection of 3-phase generators at rated kVA, voltage, and power factor, at 60 Hz and for operation with the generator neutrals solidly grounded.

If provided, supply porcelain surge arresters with a pressure relief diaphragm designed to protect the porcelain from excessive internal pressure. Provide surge arresters which are rated and have passed a high-current impulse design test minimum of 65,000 A rms. Do not install surge arresters subjected to the 65,000 A rms design test. Conform to applicable requirements of IEEE C62.21 for surge arresters. Provide 0.5 microFarad per pole and PCB free capacitors. Submit the Surge Arrester and Capacitor Catalog Cuts for approval. Install in accordance with paragraph, Surge Arresters and Surge Capacitors Installation.

2.14 MATERIALS FOR FIELD WINDING REFURBISHMENT (OPTIONAL)

2.14.1 General

Reinsulation of rotor field poles is optional work, do not proceed without written authorization.

2.14.2 Reinsulation of Rotor Field Poles

Use materials suitable for operation in a generator with Class F insulation to reinsulate the field coils (ground insulation and turn insulation). Make the turn insulation of two layers of insulating paper, bonded in place with brush on epoxy resin or B-stage insulating paper. Support proposals for alternative insulations with data sheets demonstrating equivalence or superiority of specified materials. Use materials suitable for operation in a generator at Class F limits for pole collars. Fabricate collars fabricated from single sheets such that the collars have no joints. Suitably brace field coils against the pole iron.

Seal any gaps left between pole collars and the pole body and field coils to prevent foreign material ingress. Submit drawings of the Rotor Pole Assembly and Details . The insulating paper shall have the following characteristics:

a. Dielectric Strength (V/mil): 460 to 680

b. Full Wave Impulse V/mil): 1000 to 1250

c. Dielectric Constant at 60 Hz: 1.6 to 3.7

d. Dissipation Factor at 60 Hz: 4 to 7

Mechanical Properties

a. Typical Thickness (mm): 0.05 to 0.076

b. Basic Weight (b/m2): 41 to 839

c. Density (g/cc): 0.72 to 1.08

d. Tensile Strength (N/cm): 43 to 816

SECTION 48 13 16.00 26 Page 17

e. Elongation (%): 10 to 21

f. Elmendorf Tear, Machine Direction (N): 0.8 to 14.3

g. Initial Tear Strength, Machine Direction (N): 11 to 233

h. Shrinkage at 300 degree C, Machine Direction (%): 1.8 to 0

i. Maintain 300V/mil dielectric strength for several hours at 400 degrees C

2.14.3 Interpole Connectors

Furnish new interpole connectors as necessary on reinsulated field poles.

Fabricate the connections to match the original design in order to connect to the existing rotor poles. Submit drawings of the Rotor Pole Connections Assembly and Details including materials, dimensions and details.

2.14.4 Tapered Mounting Keys

Supply new tapered mounting keys for the installation of the rotor poles on the rotor rim. Comprise the tapered mounting key sets of one stationary key and one drive key of a sufficient length, thickness and taper to secure the rotor poles to the rotor rim.

2.14.5 Interpole Blocking

Provide new interpole blocking, insulation, and mounting hardware.

Materials shall be in-kind replacement or as approved.

2.15 SPARE PARTS

2.15.1 General

Ship all spare parts to Chief Joseph when the feature of work with which the spare parts are associated begins on site. Submit a Spare Parts List .

Match the part numbers in the spare parts list to the part numbers given on all submitted drawings.

2.15.2 Packaging and Storage

Provide suitable packing for long term storage of all spare parts. The windings shall be packed for indoor storage, protected from water, humidity, and tight sealed. The windings shall be stored within the powerhouse. Provide long term storage instructions for all spare parts, including temperature and humidity requirements for the storage area.

2.15.3 Coils and Supplies

Supply a set of 14 spare coils, along with all non-deteriorating parts necessary for their installation, packing, and wedging. Make all spare coils interchangeable with and of the same material and workmanship as those used in the installed winding.

2.15.4 RTDs

Provide a set of two spare RTDs and RTD extension cable, identical to those provided under paragraph, RESISTANCE TEMPERATURE DETECTORS (RTDs).

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2.15.5 Laminations

Supply a set of ten (10) spare laminations. Make these laminations identical to those specified in paragraph 2.12.1, Stator Core Laminations.

2.15.6 Stator Core Vent Duct Laminations

Supply a set of two (2) spare stator core vent duct laminations. Make these laminations identical to those specified in paragraph 2.12.1, Stator Core Laminations.

2.16 OPERATIONS AND MAINTENANCE MANUAL

In addition to meeting the requirements for Operations and Maintenance manuals elsewhere in this specification, include the following information in the submitted Generator Operations and Maintenance Manual :

(a) Operational considerations regarding abnormal operation, temperature ranges, etc.

(b) Safety precautions

(c) Parts list of provided and installed parts, including quantities, details, and model numbers as relevant

(d) Spare parts list including quantities, details, and model numbers as relevant

(e) Maintenance information, including but not limited to:

(1) Frequency and techniques for cleaning and testing equipment

(2) Procedures for adjustment, repair, and replacement of materials and equipment, as well as relevant materials, clearances, and tolerances

(3) Procedure to replace coils

(4) Procedure to insulate pole group connections, series connections, and main leads

(5) Instructions to dry the rotor field poles and stator windings

(6) Procedure for half-coil splice repairs

(f) Address, telephone number, and website (if available) for the manufacturers' service organization

(g) Technical Data Section, including but not limited to:

(1) Generator Nameplate Data

(2) Details of work performed (stator winding, core, field winding, interpole connectors, etc.)

(h) Test reports (Final Acceptance and Special Field Test Reports)

(i) Final submitted and approved drawings

SECTION 48 13 16.00 26 Page 19

PART 3 EXECUTION

3.1 STATOR DESIGN REVIEW MEETING

3.1.1 General

Within 150 day after notice to proceed, conduct a stator design review meeting at a location approved by the Government. Notify the Government of the date, the location, the duration, the persons in attendance, and the proposed agenda for the stator design review meeting at least 30 calendar days (60 if location is outside of the United States) in advance of the meeting. Prepare a stator design report for the meeting, and provide hard copies for the Government personnel in attendance. The intent of the design review meeting is to:

(a) Meet with the contractor. If the contractor is not the manufacturer of the windings, then arrange for manufacturer personnel to also be in attendance.

(b) Discuss the technical specifications that deal specifically with stator winding and core manufacturing, testing, shipment, and ancillary systems associated with a rewind and core replacement.

(c) Perform a design review with key design personnel for the stator winding and core replacement.

3.1.2 Requirements

The purpose of the design review meeting is to help assure that the key elements of the stator winding and core specification requirements are understood, and to describe the stator winding and core manufacturing and design features. Be prepared to discuss the following elements:

(a) Nameplate data and ratings.

(b) Preliminary drawings.

(c) Winding diagram and dimensions.

(d) Winding information, including:

(1) Insulation type

(2) Turns

(3) Coils

(e) Core information, including:

(1) Material

(2) Acceptable burr height

(3) Clamping system

(4) Stacking method

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(f) Loss calculations.

(g) Results of stator inspection.

(h) Other materials and systems, including:

(1) Wedging, bracing, and blocking

(2) Other proposed accessories

3.2 GENERAL TESTING REQUIREMENTS

Subject equipment supplied under this contract to the manufacturer routine factory and field tests. Perform additional tests as specified. The Contracting Officer's Representative (COR) will witness all tests unless waived in writing. Do not ship equipment until it has been approved for shipment by the COR. Only test Contractor-furnished equipment unless otherwise directed in this specification. Perform tests in accordance with the applicable requirements of IEEE C50.12 and IEEE 115 , in addition to those specified elsewhere. The waiver of any test or witnessing of a test does not relieve the Contractor of the responsibility of complying with these specifications. Furnish all necessary test equipment, instrument transformers, temporary installations, and personnel.

Calibrate all test equipment prior to performing the specified test or group of tests. Notify the COR in writing 30 calendar days (60 calendar days if testing is outside of the United States) in advance of tests.

Inform the COR of all final tests and measurements, to include final tests and measurements performed at Chief Joseph Powerhouse.

3.3 VOLTAGE ENDURANCE TESTS

3.3.1 Test Procedure

Submit for approval the Voltage Endurance Test Methods . Include an outline and description of the test methods and equipment to be employed including all required test values. For the test, subject the specified coils to a 60 Hz test voltage of 9 kV rms, at a steady-state surface temperature of 90°C, continuously until breakdown or the test termination time of 400 hours, whichever is first. Perform the test in accordance with IEEE 1043 and IEEE 1553 . Failure of the stress grading system of the coil will not be considered a failure under this test. In this event, repair the stress grading and continue the test. Do not use any of the coils subjected to the voltage endurance tests in the stator winding or supply as spares.

3.3.2 Voltage Endurance Test of Prototype Coils

Perform voltage endurance tests on prototype coils. Have the test performed by an independent testing laboratory. Submit for approval the name, address and qualifications of the proposed Stator Coil Voltage Endurance Test Facility . During the test, no failure may occur before 200 hours. If a failure occurs between 200 and 400 hours, test two additional coils; no further failures may occur before 400 hours. Redesign of the coils or of the manufacturing process is required (subject to approval), in the event of failure to pass the voltage endurance test. Retest redesigned coils in accordance with this paragraph. At the completion of the testing, submit for approval Prototype Coil Voltage Endurance Test Report . Production of stator coils may not begin until the prototype coils have passed voltage endurance testing and the prototype coil test report

SECTION 48 13 16.00 26 Page 21 has been approved. Coils manufactured prior to the date of approval of the prototype coils voltage endurance test may be rejected. Dissect coils in accordance with paragraph 3.4, COIL DISSECTIONS.

3.3.3 Voltage Endurance Test of Production Run Coils

Perform voltage endurance tests on coils chosen by the Government at random from the production run. Perform the test at the Contractor's facilities or at an approved independent testing laboratory. If a failure occurs in any of the coils between 200 and 400 hours, two more coils will be picked at random from the production run and subjected to the test. If any further failures occur, or if any failures occur before 200 hours, stop the production, determine the cause of failure, and report to the Government.