Amend 0003.pdf

W68SBV81690561

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

The solicitation is amended as show n on the attached pages. Generator Temperatures and Emergency Shutdow n files are provided for information only.

MAIN UNIT STATOR WINDING REPLACEMENT, MCNARY DAM

1. CONTRACT ID CODE PAGE OF PAGES

J

FAR (48 CFR) 53.243

1 18

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

16C. DATE SIGNED

BY 11-Jun-2009

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 W912EF-09-R-0018

X 9B. DATED (SEE ITEM 11)

28-Apr-2009

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

11-Jun-2009

CODE

USAED, WALLA WALLA CONTRACTING DIVISION

PHYLLIS L. BUERSTATTE

201 NORTH 3RD AVE.

WALLA WALLA WA 99362-1876

W912EF 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912EF-09-R-0018

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

The following items are applicable to this modification:

AMENDMENT 0003

A. The due date for receipt of proposals remains unchanged. Proposals are due no later than July 10, 2009 at 2:00 pm, local time.

B. Offerors must acknowledge receipt of this amendment. See Block No. 11 of Standard Form 30 for methods of acknowledging solicitation amendments.

C. The following changes are made:

1. Section 48 13 16.00 26 Generator Rewind, paragraph 2.4.8 Quantity – paragraph modified to read, "Sufficient bars to make up two (2) complete windings per year shall be supplied, for a total of ten (10) complete windings. In addition, the Contractor shall provide five (5) production run bars from each of the two (2) winding production runs each year for a total of fifty (50) production run bars, plus any which may be added due to failure, for the accelerated life testing specified in paragraph ACCELERATED LIFE TESTS. Bars subjected to accelerated life testing shall not be used in any of the newly constructed windings. See paragraph 2.11.2 Stator Bars and Supplies for the spare bar quantity."

2. Section 48 13 16.00 26 Generator Rewind, paragraph 2.13.1 Stator Core (Optional), General – added two new sentences to end of paragraph.

3. Section 48 13 16.00 26 Generator Rewind, paragraph 3.11.2 Interlaminar Insulation Test Procedure – modified 2nd and 3rd sentences to read, "The Contractor shall provide power for the loop test. A Government's power source will not be available for this test."

4. Section 48 13 16.00 26 Generator Rewind, paragraph 3.27.2, item a. Verification Tests – in 2nd sentence, changed 84,736 kVA to 84,737 kVA.

5. In response to inquiry #2535160, GeneratorTemperatures.pdf has been provided For Information Only.

6. In response to inquiry #2539074, OM_Emergency_Shutdown.pdf has been provided For Information Only.

7. Sheet G-002 – added FIO-211A, FIO-211B and FIO-211C drawings to index.

8. FIO-211A, FIO-211B and FIO-211C – new sheets added to set.

9. Clause 52.211-10 COMMENCEMENT, PROSECUTION, AND COMPLETION OF WORK (APR 1984), item c(4) – modified sentence to read, "The Contractor shall complete final cleanup and demobilization by not later than 15 calendar days after completion of work for each unit outage yearly (every two (2) units)."

10. Clause 252.236-7001 CONTRACT DRAWINGS, MAPS, AND SPECIFICATIONS (AUG 2000) – added FIO-211A, FIO-211B and FIO-211C to drawing list.

11. Section 00800, PERFORMANCE & PAYMENT BONDS, is amended to change “10 calendar days” to “21 calendar days.”

SUMMARY OF CHANGES

SECTION 00010 - SOLICITATION CONTRACT FORM

The performance payment bonds calendar days has increased by 11 from 10 to 21.

SECTION 00700 - CONTRACT CLAUSES

The following have been modified:

52.211-10 COMMENCEMENT, PROSECUTION, AND COMPLETION OF WORK (APR 1984)

The Contractor shall be required to (a) commence work under this contract within 14 calendar days after the date the Contractor receives the notice to proceed, (b) prosecute the work diligently, and (c) complete the entire work ready for use not later than the dates listed below:

(1) The Contractor shall complete all work for the 10 main unit generator rewinds, 2 per year, by not later than 31 December 2014. All work for each 2 main units shall be completed by the respective end date of each year listed below. The Contractor is required to demobilize at the end of each period noted below.

i. First work window: Main Units 2 and 7 will be available 1 July 2010 through 31 December 2010.

ii. Second work window: Main Units 1 and 4 will be available 1 July 2011 through 31 December 2011.

iii. Third work window: Main Units 3 and 8 will be available 1 July 2012 through 31 December 2012.

iv. Fourth work window: Main Units 9 and 10 will be available 1 July 2013 through 31 December 2013.

v. Fifth work window: Main Units 11 and 12 will be available 1 July 2014 through 31 December 2014.

(2) The First Year of the bid schedule will commence within 10 calendar days after receipt of Notice to Proceed. The Second Year period shall commence no earlier than 15 October 2010; the Third Year no earlier than 15 October 2011; the Fourth Year no earlier than 15 October 2012; the Fifth Year no earlier than 15 October 2013.

(3) The Contractor shall complete final submission of O&M manuals and all spare parts within 30 calendar days after completion of the first unit outage (first two (2) units). If any changes are required to the O&M manuals in subsequent years, they shall be re-submitted with the changed material incorporated. The Contractor shall complete final submission of working “as-built” contract drawings (see Section 01 11 01.00 28) and final approved versions of Contractor prepared drawings (see Section 01 33 00) by not later than 30 calendar days after completion of work in (1) above.

(4) The Contractor shall complete final cleanup and demobilization by not later than 15 calendar days after completion of work for each unit outage yearly (every two (2) units).

(End of clause)

252.236-7001 CONTRACT DRAWINGS AND SPECIFICATIONS (AUG 2000)

(a) The Government will provide to the Contractor, without charge, one set of contract drawings and specifications, except publications incorporated into the technical provisions by reference, in electronic or paper media as chosen by the Contracting Officer.

(b) The Contractor shall--

(1) Check all drawings furnished immediately upon receipt;

(2) Compare all drawings and verify the figures before laying out the work;

(3) Promptly notify the Contracting Officer of any discrepancies;

(4) Be responsible for any errors that might have been avoided by complying with this paragraph (b); and

(5) Reproduce and print contract drawings and specifications as needed.

(c) In general--

(1) Large-scale drawings shall govern small-scale drawings; and

(2) The Contractor shall follow figures marked on drawings in preference to scale measurements.

(d) Omissions from the drawings or specifications or the misdescription of details of work that are manifestly necessary to carry out the intent of the drawings and specifications, or that are customarily performed, shall not relieve the Contractor from performing such omitted or misdescribed details of the work. The Contractor shall perform such details as if fully and correctly set forth and described in the drawings and specifications.

(e) The work shall conform to the specifications and the contract drawings identified on the following index of drawings:

MCNARY MAIN UNIT STATOR WINDING REPLACEMENTS

FILE NUMBER SHEET

NUMBER TITLE REVISION

NUMBER DATE

MDP-5.21-0-0/1 G-001 PROJECT SITE PLAN, LOCATION AND VICINITY

MAPS

MDP-5.21-0-0/2 G-002 INDEX OF DRAWINGS SHEET 1

MDP-5.21-0-0/3 G-003 INDEX OF DRAWINGS SHEET 2

NUMBER TITLE REVISION

NUMBER DATE

MDP-5.21-0-0/4 G-004 INDEX OF DRAWINGS SHEET 3

MDP-5.21-0-0/5 G-101 CONTRACTOR STAGING AREA PLAN EL. 287

MDP-5.21-0-0/6 G-901 PHOTO SHEET 1

MDP-5.21-0-0/7 G-902 PHOTO SHEET 2

MDP-5.21-0-0/8 G-903 PHOTO SHEET 3

FOR INFORMATION ONLY

W-9678851 FIO-001 OUTLINE - HYDRAULIC TURBINE DRIVEN

GENERATOR

528E235 FIO-002 ASSEMBLY - TURBINE DRIVEN GENERATOR

T-5138836 FIO-003 ASSEMBLY OF PARTS ON SHAFT AND

COLLECTOR CONNECTION ON THE SHAFT

528E502 FIO-004 ROTOR CONNECTIONS

181C865 FIO-005 LIFTING DEVICE FOR UPPER BEARING

BRACKET

528E433 FIO-006 LOWER BEARING BRACKET

528E513 FIO-007 RUNNER FOR THRUST BEARING

163D882 FIO-008 LOWER GUIDE BEARING COOLER PIPING

V-5387750 FIO-009 DOWEL PIN

V-9686746 FIO-010 BEARING ADJUSTING SCREW

528E527 FIO-011 STATIONARY SEGMENTS 128 X 4L

538E245 FIO-012 STAIRWAY RAILING

NUMBER TITLE REVISION

NUMBER DATE

528E266 FIO-013 COVER PLATES

528E384 FIO-014 LIFTING DEVICE

528E507 FIO-015 PIPING PLAN FOR ODD UNITS

528E524 FIO-016 WRENCH BOARD

528E291 FIO-017 GRILLE FOR MAIN AND NEUTRAL LEADS

163D162 FIO-018 CO2 FIRE EXT. PIPING UNITS 4,6,8

551E169A FIO-019 AIR COOLER PIPING UNITS 1-11 SHEET 1

551E169B FIO-020 AIR COOLER PIPING UNITS 1-11 SHEET 2

528E515 FIO-021 HIGH PRESSURE PIPING

185C815 FIO-022 3" WATER RETURN TERMINATIONS ODD AND

EVEN UNITS

528E211A FIO-023 COVER PLATES AND HOUSING 1 OF 2

528E211B FIO-024 COVER PLATES AND HOUSING 2 OF 2

T-9677624 FIO-025 PIPING DIAGRAM

528E520 FIO-026 PIPING PLAN EVEN UNITS

529E386A FIO-027

INSTRUMENTS AND ACCESSORIES CONDUIT

AND CONNECTIONS, EVEN UNITS SHEET 1 OF

529E386B FIO-028

INSTRUMENTS AND ACCESSORIES CONDUIT

AND CONNECTIONS, EVEN UNITS SHEET 2 OF

529E385A FIO-029 INSTRUMENTS AND ACCESSORIES CONDUIT

AND CONNECTIONS, ODD UNITS SHEET 1 OF 2

529E385B FIO-030 INSTRUMENTS AND ACCESSORIES CONDUIT

AND CONNECTIONS, ODD UNITS SHEET 2 OF 2

NUMBER TITLE REVISION

NUMBER DATE

529E389 FIO-031 TEST CONNECTIONS AND INSTRUMENTS IN

THRUST GUIDE BEARINGS

T-9745118 FIO-032 ERECTION SOLE PLATE

T-5139650 FIO-033 BRAKE AND JACK PIPING

P-9735462 FIO-034 LIFTING DEVICE FOR GENERATOR SHAFT

528E275 FIO-035 ARRANGEMENT OF MAIN & NEUTRAL LEADS,

EVEN UNITS

W-9749724 FIO-036 ARRANGEMENT OF MAIN & NEUTRAL LEADS,

ODD UNITS

528E238 FIO-037 STATOR CONNECTIONS

161D375 FIO-038 R.T.D. & ACCESSORIES, EVEN UNITS.

T-5139623 FIO-039 R.T.D. & ACCESSORIES, ODD UNITS.

T-9745562 FIO-040 STATOR COIL DIAGRAM

161D300 FIO-041 ASSEMBLY OF CONNECTIONS

181C696 FIO-042 DIAGRAM OF CONNECTIONS

T-5138791 FIO-043 SPARE GENERATOR WINDING UNWOUND

STATOR

162D559 FIO-044 TERNINAL BOX

163D882 FIO-045 LOWER GUIDE BRG - COOLER PIPING

181C913 FIO-046 OUTLINE - BARTON FLOWMETER 211

252A150 FIO-047 8"GE FLOW METER

252A152 FIO-048 3"GE FLOW METER

NUMBER TITLE REVISION

NUMBER DATE

528E240A FIO-049

INSTRUMENTS AND ACCESSORIES - CONDUIT

AND CONNECTIONS - (ODD UNITS) SHEET 1

OF 2

528E240B FIO-050

INSTRUMENTS AND ACCESSORIES - CONDUIT

AND CONNECTIONS - (ODD UNITS) SHEET 2

OF 2

529E389 FIO-051 TEST CONNECTIONS AND INSTRUMENTS IN

THRUST AND GUIDE BEARINGS (ODD UNITS)

529E390 FIO-052 TEST CONNECTIONS AND INSTRUMENTS IN

THRUST AND GUIDE BEARINGS (EVEN UNITS)

P-9730747 FIO-053 SCHEMATIC PIPING PLAN FOR SURFACE AIR

COOLERS

P-9732493 FIO-054 SURFACE AIR COOLERS

SPARE FIO-055 SPARE

SPARE FIO-056 SPARE

528E215 FIO-057 TEST CONNECTIONS & INSTRUMENTS IN

THRUST & GUIDE BEARINGS

M-9716607 FIO-058 THERMOMETER

P-5124882 FIO-059 BEZEL & MOUNTING

P-9730740 FIO-060 THERMOMETER

528E280_2 FIO-061 INSTRUMENTS & ASSESSORIES - CONDUIT &

CONNECTIONS

528E286_1 FIO-061A INSTRUMENTS & ASSESSORIES - CONDUIT &

CONNECTIONS - EVEN NUMBER UNITS

528E290 FIO-061B TEST CONNECTIONS AND INSTRUMENTS IN

THRUST AND GUIDE BEARINGS

528E213 FIO-061C BRAKE & JACK - 12 3/4 " X 33 1/2 "

5845-PT-1 FIO-062 TURBINE SHAFT

SPARE FIO-063 SPARE

NUMBER TITLE REVISION

NUMBER DATE

SPARE FIO-064 SPARE

4460-FM-1 FIO-065 DISTRIBUTOR SECTION

4414-AV-1 FIO-066 OIL SUPPLY PIPING

4845-I-2 FIO-067 OIL HEAD PLATFORM

4845-J-1 FIO-068 RAILING & LADDER OIL HEAD PLATFORM

5114-E-2 FIO-069 OIL HEAD ARRANGEMENT UNITS 1-12

5114-J-5 FIO-070 ARRANGEMENT FOR P.M.G. DRIVE UNITS 1-12

4303-FZ-1 FIO-071 10" OIL SUPPLY HEAD ASSEMBLY

4303-FV-1 FIO-072 OIL SUPPLY HEAD TOP

4345-BU-1 FIO-073 OIL HEAD SUPPORT WITH OIL BASIN

5114-A-1 FIO-074 VERTICAL KAPLAN TURBINE

5350-0-1 FIO-075 PRESSURE EQUALIZER TANK ASSEMBLY

5350-AE-2 FIO-076 MOTOR & PUMP BRACKET

5350-AF-1 FIO-077 PUMP, MOTOR, & PIPING ARRANGEMENT

PRESSURE EQUALIZER TANK

5350-R-1 FIO-078 PRESSURE EQUALIZER TANK AND DETAILS

5350-S-1 FIO-079 COLLECTOR RING & BRUSH HOLD

5842-CT-3 FIO-080 COUPLING BOLT

4680-FR-1 FIO-081 WRENCH BOARD

NUMBER TITLE REVISION

NUMBER DATE

5842-CS-3 FIO-082 COUPLING BOLT

3743-QI-1 FIO-083 46.25 DIA. PACKING BOX

4065-CZ-5 FIO-084 LIFTING DEVICE FOR OIL PIPES

5295-T-1 FIO-085 RUNNER SUPPORT

1123-UK-1 FIO-086 44.5 IN. DIA BABBITED BEARING AND PACKING

BOX ASSEMBLY

1123-UQ-1 FIO-087 44.5 INCH BABBITED BEARING, WELD AND

MACHINE

1123-UX-1 FIO-088 COVER AND OIL BAFFLES OR 44.5 INCH

BEARING

1310-FB-1 FIO-089 24 X 36 MANDOOR, DRAFT TUBE LINER

2507-BH-1 FIO-090 LUBRICATING PUMPS AND PIPING FOR MAIN

BEARING

2507-BH-1.1 FIO-091 LUBRICATING PUMPS AND PIPING FOR MAIN

BEARING (CORPS DRAWING)

3380-AAW-4 FIO-092 BUSHING IN CYLINDER HEAD

3380-BAA-4 FIO-093 LINK, PUSH-PULL ROD AND STEP BEARING

BUSHING

3380-BAN-4 FIO-094 BUSHING, STYLE D

3380-CAQ-5 FIO-095 PISTON ROD BUSHING

3380-CAR-3 FIO-096 BUSHING

3743-QH-2 FIO-097 46.25 INCH PACKING GLAND

3743-QI-1 FIO-098 46.25 INCH PACKING BOX

3859-FC-3 FIO-099 WEARING RING FOR 46.25 INCH SHAFT

NUMBER TITLE REVISION

NUMBER DATE

3995-IF-1 FIO-100 PIT LINER ELEVATION

3995-IG-1 FIO-101 PIT LINER PLAN

3997-BN-2 FIO-102 OIL DEFLECTOR

3997-BO-5 FIO-103 OIL DEFLECTOR

4034-FJ-1 FIO-104 OIL BASIN

4034-FL-1 FIO-105 OIL BASIN AT BLADE SERVOMOTOR

4034-FM-1 FIO-106 TANK GUARD

4034-FO-2 FIO-107 TANK GUARD EXTENSION

4034-FP-1 FIO-108 SERVOMOTOR GUARD

4034-FQ-2 FIO-109 DISCHARGE PIPING FROM OIL BASIN PUMP

4034-GY-1 FIO-110 OIL BASIN AT BLADE SERVOMOTOR

4065-DF-2 FIO-111 LIFTING DEVICES FOR BLADE SERVOMOTOR

AND SHAFT WITH OPERATION ROD

4086-A1-2 FIO-112 NAME PLATE

4296-BN12-2 FIO-113 OIL FILLING VALVE

4296-BN8-1 FIO-114 GUIDE BEARING

4301-HO-1 FIO-115 80 INCH DIA. SERVO MOTOR

4301-HS-1 FIO-116 80 INCH BLADE OPERATING SERVOMOTOR

ASSEMBLY

4301-JG-1 FIO-117 80 INCH DIA. BLADE OPERATING

SERVOMOTOR ASSEMBLY

NUMBER TITLE REVISION

NUMBER DATE

4301-JH-2 FIO-118 DRAIN PIPING DETAILS FOR 80 INCH

SERVOMOTOR

4302-CT-1 FIO-119 OPERATING ROD

4303-FU-1 FIO-120 10 INCH OIL SUPPLY HEAD

4303-FW-1 FIO-121 HANDHOLE COVER FOR OIL SUPPLY HEAD

TOP

4303-GU-5 FIO-122 BYPASS DETAILS FOR 10" OIL HEAD

4343-CL-2 FIO-123 CAMS

4343-CQ-1 FIO-124 CAMS

4343-CS-2 FIO-125 CAM ASSEMBLY FOR MCNARY UNITS 9 TO 14

4345-BW-1 FIO-126 HANDHOLE COVER, OIL HEAD SUPPORT

4345-CJ-1 FIO-127 OIL HEAD SUPPORT WITH OIL BASIN

4435-BI-3 FIO-128 BLADE POSITION INDICATOR

4490-GY-1 FIO-129 DETAIL OF RH GATE OPERATING CYLINDER

4490-GZ-1 FIO-130 DETAIL OF LH GATE OPERATING CYLINDER

4490-HA-2 FIO-131 GATE OPERATING CYLINDER HEAD

4490-HB-3 FIO-132 24 INCH DIA. PISTON

4490-HE-3 FIO-133 CAP

4490-HF-3 FIO-134 CHECK VALVE

4490-HG-3 FIO-135 VALVE GUIDE

NUMBER TITLE REVISION

NUMBER DATE

4490-HI-3 FIO-136 PACKING GLAND

4490-HK-5 FIO-137 LOCK RING FOR GATE OPERATING CYLINDER

4490-HN-3 FIO-138 SLEEVE

4490-HO-5 FIO-139 OPERATING NUT & RETAINER FOR

SERVOMOTOR GATE LIMIT DEVICE

4490-HP-2 FIO-140 FORK END

4490-HQ-5 FIO-141 FORK END

4490-HU-5 FIO-142 PISTON ROD, RIGHT HAND, FOR GATE

OPERATING CYLINDER

4490-HV-5 FIO-143 PISTON ROD, LEFT HAND, FOR GATE

OPERATING CYLINDER

4490-HX-2 FIO-144 DETAILS FOR SERVOMOTOR GATE LIMIT

DEVICE

4490-HY-5 FIO-145 CONNECTING ROD FOR GATE OPERATING

CYLINDERS

4490-HZ-1 FIO-146 GENERAL ARRANGEMENT OF GATE

OPERATING CYLINDERS

4490-JA-5 FIO-147 OPERATING GEARS FOR SERVOMOTOR GATE

LIMIT DEVICE

4490-JB-2 FIO-148 LIMIT SWITCH BRACKET FOR RH GATE

OPERATING CYLINDER

4490-JC-1 FIO-149 ASSEMBLY FOR GATE LIMIT MECHANISM

4555-BN-4 FIO-150 PACKING RING

4570-BQ-1 FIO-151 WIRING DIAGRAM FOR TURBINE BEARING OIL

PUMPS

4585-P-5 FIO-152 H RING FOR 46.25 IN. DIA. SHAFT

4782-GQ-3 FIO-153 LIFT TACKLE FOR GATES

NUMBER TITLE REVISION

NUMBER DATE

4803-A-2 FIO-154 DRAIN VALVE ASSEMBLY FOR BLADE RUNNER

HUBS

4803-C-5 FIO-155 FILLING VALVE

4845-G-1 FIO-156 PLATFORM AND STAIRWAY IN TURBINE PIT

4845-H-5 FIO-157 ARRANGEMENT OF PLATFORMS AND

STAIRWAYS IN TURBINE PIT

4845-L-5 FIO-158 ANGLES TO SUPPORT GRATING FLOOR IN

TURBINE PIT

4845-R-1 FIO-159 RAILING AND LADDER, OIL HEAD PLATFORM

5112-G-1 FIO-160 FOUNDATION LAYOUT

5114-B-1 FIO-161

PLAN VIEW KAPLAN TURBINE - VERTICAL

SETTING - DIRECTLY CONNECTED TO

GENERATOR

5114-C-1 FIO-162 ARRANGEMENT OF TURBINE PIT

5114-D-1 FIO-163 LIFTING ARRANGEMENT FOR RUNNER,

SHAFT, HEAD COVER, ETC.

5114-H-5 FIO-164 PROPOSED CONNECTION FOR STAIRWAY

AND RAIL TO GRATING FLOOR IN PIT

5114-I-2 FIO-165 PROPOSED RUNNER ASSEMBLY

ARRANGEMENT

5114-M-1 FIO-166 ARRANGEMENT OF SUMP PUMPS FOR HEAD

COVER DRAIN

5114-N-1 FIO-167 PIPING ARRANGEMENT OF SUMP PUMP,

DRAINS AND PACKING BOX

5114-O-1 FIO-168 PIPING DETAIL FOR HEAD COVER SUMP

PUMPS AND DRAINS

5114-P-2 FIO-169 SUMP PUMP FOR HEAD COVER DRAIN

5114-S-5 FIO-170 PRESSURE REGULATOR ON 0.25 IN. BYPASS

ON BLADE ANGLE RELAY VALVE

5121-C-2 FIO-171 COVER AND FRAME FOR BEARING OIL PIPING

AND ROTASIGHT

NUMBER TITLE REVISION

NUMBER DATE

5350-AD-1 FIO-172 PRESSURE EQUALIZER TANK ASSEMBLY

5842-CP-3 FIO-173 COUPLING STUD/BOLT

5843-Q-1 FIO-174 WALKWAY IN TURBINE PIT

5843-T-1 FIO-175 GUARD SUPPORT AND WALKWAY

5843-X-1 FIO-176 WALKWAY IN TURBINE PIT

5845-PX-1 FIO-177 INTERMEDIATE SHAFT

5859-N-1 FIO-178 80" PISTON CAP, PIPE HEAD AND PIPE GLAND

E100-1 FIO-179 GEN. THRUST BEARING OIL COOLER

ASSEMBLY

E100-2 FIO-180 GEN. THRUST BEARING OIL COOLER DETAILS

MDP-2.2-2-0/2 FIO-181 KEY PLAN SHEET 1

MDP-1-0-0/5 FIO-182 MAIN UNITS PLAN AND SECTION

MDP-1-0-8/1 FIO-183 MAIN GENERATOR - CLEARANCE LIMITING

OVERALL DIMENSIONS

MDP-1-3-1/4 FIO-184 GENERATOR ROTOR LIFTING FACILITIES

MDP-1-3-9/4 FIO-185 PIPING ARRANGEMENT OF CO2 SYSTEM

MDP-9-3-12/3 FIO-186 OIL SPRAY COLLECTION PAN

MDP-2.2-6-

2A8/15 FIO-187 SLIP RING AREA LIGHTING

MDP-1.2-5-0/2 FIO-188 GENERATOR WALKWAY UNITS 1-12

MDP-1.21-3-9/6 FIO-189 UNITS 1-12 THRUST BEARING COOLER

ASSEMBLY

NUMBER TITLE REVISION

NUMBER DATE

MDP-1.21-3-9/8 FIO-190 UNITS 1-12 THRUST BEARINGS OIL COOLER

DETAILS

940 FIO-191 REVISE AND RELOCATE THRUST BEARING OIL

LEVEL SWITCH

867 FIO-192 THRUST HOUSING AND UPPER BEARING

BRACKET GASKET

828 - 1 OF 3 FIO-193 HIGH PRESSURE OIL PUMP ASSEMBLY

DETAILS

828 - 2 OF 3 FIO-194 HIGH PRESSURE OIL PUMP PIPING

ARRANGEMENT

828 - 3 OF 3 FIO-195 HIGH PRESSURE OIL PUMP ELECTRICAL

DETAILS

BDP-5.46-3-

10/1 FIO-196 CENTER HOLE JACK SYSTEM

MDP-5.21-3-

10/1 FIO-197 TURBINE SHAFT SLEEVE

MDP-2.2-6-

8A11/1 FIO-198 THERMOMETER CAPILLARY TUBING

INSTALLATION DETAILS

MDP-3-6-

9A31/1 FIO-199 MAIN UNIT ANNUNCIATOR SCHEMATIC

DIAGRAM

MDP-3-6-

9A31/3 FIO-200 WIRING DIAGRAM & DETAILS MAIN UNIT

ANNUNCIATOR CENTRALIZED CONTROL

MDP-2.2-6-

9E4/2 FIO-201 SWITCHBOARD S1 AND GOVERNOR

CABINETS

MDP-2.2-6-

9E24/1 FIO-202 UNITS 1 & 2 CONTROL SCHEMATIC DIAGRAM

MDP-2.2-6-

9E24/1 FIO-203 UNITS 1 THRU 8 CONTROL SCHEMATIC

DIAGRAM, SHT. 1

MDP-2.2-6-

9E24/2 FIO-204 UNITS 1-14 AUXILIARY CONTROL SCHEM.

DIAG.

MDP-2.2-6-

9G24/3 FIO-205 MAIN UNITS 5-14 CONTROL SCHEMATIC

DIAGRAM

MDP-3.2-6-

9A9/1 FIO-206 RTD TEMPERATURE TRANSMITTER

CONNECTIONS SWBDS. S0 & S1 THRU S7

MDP-1.2-6-

9E31/6 FIO-207 UNITS 1 & 2 ANNUNCIATION & TEMP. DET.

SCHEM. WIRING

NUMBER TITLE REVISION

NUMBER DATE

MDP-5.34-6-

1E21/2 FIO-208 CQ11 ONE LINE DIAGRAM

SKET161A FIO-209 POWERHOUSE - ELEC. PLANT ONE LINE

DIAGRAM, SHEET A

SKET161B FIO-210 POWERHOUSE - ELEC. PLANT ONE LINE

DIAGRAM, SHEET B

MDP-5.34-0-0/1 FIO-211 SQO/SU BOARD REPLACEMENT INDEX

MDP-1-3-4/23

FIO-211A TRASH RACKS – MAIN AND STATION SERVICE

UNITS

MDP-1-0-0/2 FIO-211B TRANSVERSE SECTION AT UNIT 1 – TYPICAL

FOR ALL MAIN UNITS

MDP-1.42-6-

9E21/1 FIO-211C T1, T2, T4 & T6 – MAIN ONE LINE DIAGRAM

M119275D FIO-212 CLAMP (BILL OF MATERIAL)

M119275D FIO-213 CLAMP

M119274B FIO-214 MANDREL (BILL OF MATERIAL)

M119274D FIO-215 MANDREL

(End of drawing list)

(End of Clause)

Contract drawings created on CADD will be available in electronic form for use by the Contractor. No For Information Only drawings are available on CADD. The Contractor assumes all risks associated in using electronic CADD drawings. The contract drawings shall govern if there are any discrepancies between the electronic copy and the contract drawing. The Contractor shall promptly notify the Contracting Officer of any discrepancies. The Government will not be responsible to correct the electronic CADD drawing. If contract modifications are issued, the associated electronic CADD drawings will not be available to the Contractor. Electronic copies of CADD drawings are only available in Bentley MicroStation format. The Government will provide the files on CD ROM. If the Contractor requires different media, such as floppy disks, the Contractor shall be responsible for all conversions required for their use and associated conversion inaccuracies.

SECTION 00800 - SPECIAL CONTRACT REQUIREMENTS

The following have been modified:

PERFORMANCE & PAYMENT BONDS

If the successful offeror, upon acceptance of its proposal by the Government within the period specified for acceptance, fails to execute all contractual documents or furnish executed performance and payment bonds within 21 calendar days after receipt of the contract award forms by the offeror, the Contracting Officer may terminate the contract for default.

(End of Summary of Changes)

McNary Main Unit Stator Winding Replacements W912EF-09-R-0018

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 16.00 26

GENERATOR REWIND

PART 1 GENERAL

1.1 GENERAL

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DRAWINGS

1.4.1 Drawing Index

1.4.2 Bill of Materials

1.5 EXISTING GENERATOR INFORMATION

1.5.1 Unit Identification and Nameplate

1.5.2 Existing Damage to the Generators

1.5.3 Inspection By Contractor

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Parts List

2.1.2 Winding Delivery and Storage

2.2 PROTOTYPE STATOR BARS

2.3 WINDING RATING AND INSULATION CLASS

2.4 NEW STATOR BARS

2.4.1 General

2.4.2 Conductor Strands

2.4.3 Ground Insulation

2.4.3.1 General

2.4.3.2 Drying

2.4.3.3 Resin Impregnation and Curing

2.4.3.4 Alternate Construction

2.4.4 Finish and Partial Discharge (Corona) Suppression Treatments

2.4.5 Graded Suppression Treatment

2.4.6 Testing

2.4.7 Bar Identification and Record

2.4.8 Quantity

2.5 RESISTANCE TEMPERATURE DETECTORS (RTD'S)

2.6 NEW CIRCUIT RINGS

2.6.1 General

2.6.2 Design Drawings

2.6.3 Electrical Configuration

2.6.4 Physical Construction

2.6.5 Insulation

2.6.6 Neutral Current Transformers

2.7 FILLERS, WEDGES, TIES, AND BLOCKING MATERIAL

2.7.1 General

2.7.2 Side Packing

2.7.3 Center Filler and Bottom Filler

2.7.4 Spring-Type Filler Material

2.7.5 Wedges and Top Fillers

2.7.6 Two-Part Wedges

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2.7.7 End Winding Bracing and Blocking Material

2.8 PARTIAL DISCHARGE ANALYSIS (PDA) SYSTEM

2.8.1 Coupling Capacitors

2.8.1.1 General

2.8.1.2 Rating

2.8.1.3 Construction

2.8.2 Leads

2.8.3 Termination Panel

2.8.4 Analyzer

2.9 SURGE ARRESTERS

2.9.1 Surge Arresters

2.9.2 Zinc-Oxide Type

2.10 WIRE FOR LIGHTING INSIDE THE GENERATOR AIR HOUSING

2.11 SPARE PARTS

2.11.1 General

2.11.2 Stator Bars and Supplies

2.11.3 RTD's

2.11.4 Neutral Current Transformers (CT's)

2.11.5 AC High Voltage Resonant Test Set

2.12 NEW NAMEPLATE

2.13 STATOR CORE (OPTIONAL)

2.13.1 General

2.13.2 New Stator Core Laminations

2.13.3 New Vent Duct Spacers

2.13.4 Stator Core Clamping System

2.13.5 Lamination Die

2.13.6 Lamination Packaging

PART 3 EXECUTION

3.1 GENERAL TESTING REQUIREMENTS

3.2 ACCELERATED LIFE TESTS

3.2.1 Test Procedure

3.2.2 Prototype Bars

3.2.3 Production Run Bars

3.3 BAR TESTS AT FACTORY

3.4 SPRING TYPE FILLER MATERIAL TEST

3.5 RESISTANCE TEMPERATURE DETECTOR (RTD) TESTS AT FACTORY

3.6 STATOR CORE PUNCHING TESTS (OPTIONAL)

3.7 GENERATOR DISASSEMBLY

3.8 REMOVAL OF EXISTING WINDING

3.9 STATOR CORE INSPECTION AND CLEANING

3.10 MINOR STATOR CORE IRON REPAIR

3.10.1 General

3.10.2 Minor Stator Core Iron Repair Methods

3.11 STATOR CORE INTERLAMINAR INSULATION TEST

3.11.1 General

3.11.2 Interlaminar Insulation Test Procedure

3.12 APPLICATION OF EPOXY

3.13 APPLICATION OF VARNISH

3.14 POST INSULATOR CLEANING AND INSPECTION

3.15 INSTALLATION OF NEW STATOR WINDING

3.16 TESTS DURING WINDING INSTALLATION

3.17 PARTIAL DISCHARGE ANALYSIS (PDA) SYSTEM INSTALLATION

3.17.1 Coupling Capacitors

3.17.2 Leads

3.17.3 Termination

3.18 PARTIAL DISCHARGE ANALYSIS (PDA) SYSTEM TESTS

3.18.1 General

SECTION 48 13 16.00 26

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3.18.2 Test Equipment

3.18.3 PDA System Tests

3.18.4 PDA System Test Report

3.19 SURGE ARRESTERS

3.20 ROTOR WORK

3.20.1 Initial Rotor Test

3.20.2 Rotor Cleaning and Inspection

3.20.3 Final Rotor Tests

3.20.3.1 Post-cleaning Insulation Resistance Test

3.20.3.2 Pole Drop Test

3.20.3.3 High Potential Test

3.20.4 Rotor Varnish

3.20.5 Rotor Field Lead Re-insulation

3.21 INITIAL ACCEPTANCE TESTS

3.22 GENERATOR REASSEMBLY

3.23 GENERATOR DRY-OUT

3.24 FINAL ACCEPTANCE TESTS

3.25 SURGE ARRESTER TESTS

3.25.1 General

3.25.2 Design Tests

3.25.3 Conformance Tests

3.25.4 Failure to Meet Tests or Specified Characteristics

3.26 WIRING TEST

3.27 GENERATOR SPECIAL FIELD TESTS

3.27.1 General

3.27.2 Verification Tests

3.28 RE-STACKING STATOR CORE USING GOVERNMENT-FURNISHED SPARE CORE

(OPTIONAL)

3.28.1 General

3.28.2 Un-stack Stator Core

3.28.3 Inspection

3.28.4 Center and Round Stator

3.28.5 Re-stack Stator Iron

3.28.6 Final Check

3.28.7 Clamping and Locking System

3.28.8 Stator Core Interlaminar Insulation Test

3.29 CURRENT TRANSFORMER TEST

3.30 WARRANTY

-- End of Section Table of Contents --

SECTION 48 13 16.00 26

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SECTION 48 13 16.00 26

GENERATOR REWIND

PART 1 GENERAL

1.1 GENERAL

This SECTION covers the technical specifications for supplying ten (10) new stator windings, including the bars, circuit rings, blocking, winding materials, all accessories specified herein, and spare parts. Work includes removing the old windings from the stator of ten (10) main units, preparing the stators of ten (10) units for rewinding, and installing the new stator windings and accessories in these ten (10) units. It also covers inspecting, cleaning, testing, and painting the rotors of these ten

(10) units. In addition, the Contractor shall furnish and install new wires for the lighting inside the generator housing. At the option of the Government, work would include un-stacking one stator core, re-stacking it with Government-furnished stator laminations, and furnishing one new spare core. Windings provided are for Units 1-4 and 7-12 only.

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 (2003) 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 (2006) Standard Test Method for Surface Insulation Resistivity of Single-Strip Specimens

ASTM A 720 (2002; R 2007) Standard Test Method for Ductility of Nonoriented Electrical Steel

ASTM D 1868 (2007) Standard Test Method for Detection and Measurement of Partial Discharge (Corona) Pulses in Evaluation of Insulation Systems

AMERICAN WELDING SOCIETY (AWS)

AWS A5.8/A5.8M (2004; Errata 2004) Specification for Filler Metals for Brazing and Braze Welding

CEA TECHNOLOGIES INC. (CEATI)

CEATI 000 G 1977 (1998) Hydroelectric Turbine Generator Units - Guide for Erection Tolerances on

Shaft System Alignment

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 43 (2000; R2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

IEEE 56 (1976; R 1991 Withdrawn) Guide for Insulation Maintenance of Large Alternating-Current Rotating Machinery Note: The requirements of IEEE 56 are part of this specification even though the standard is no longer in publication. The Contractor shall obtain a historical copy of the standard for use.

IEEE 95 (2002; R 2007) Recommended Practice for Insulation Testing of Large AC Rotating Machinery with High Direct Voltage

IEEE 115 (1995; R 2002) Guide: Test Procedure for Synchronous Machines

IEEE 286 (2000; R 2006) Recommended Practice for Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation

IEEE 1043 (1996; R 2003) Recommended Practice for Voltage-Endurance Testing of Form-Wound Bars and Coils

IEEE C50.12 (2005) Salient-Pole 50 Hz and 60 Hz Synchronous Generators and Generator/Motors for Hydraulic Turbine Applications Rated 5 MVA and Above

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

IEEE C62.11 (2005) Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA LI 1 (1998) Industrial Laminated Thermosetting Products

NEMA LA 1 (1992; R 1999) Surge Arresters

NEMA WC 70 (1999; Errata 2001) Non-Shielded Power Cables Rated 2000 Volts or less for the Distribution of Electrical Energy

1.3 SUBMITTALS

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

submittals not having 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. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Within 60 calendar days after date of receipt of written Notice To Proceed:

Bar Insulation System; G HDC A description of the bar insulation system, including processes and materials employed to meet specification requirements.

Factory Test Methods; G HDC An outline and description of the test methods and equipment to be employed in the factory test for the stator bars including all required test values.

Facility Information; G HDC The name and address of the facilities proposed to perform the accelerated life testing of the prototype bars and the production run bars.

Design Information on Surge Arresters; G HDC The design report of identical surge arresters of previous contracts.

Within 90 calendar days after date of receipt of written Notice To Proceed:

DC I²R Copper Losses; G HDC Detailed design calculations illustrating how the stator DC I²R (copper) losses are determined at 75 degrees C. Calculations shall illustrate the composition of the various portions of winding circuit resistance, including number of bars in series and parallel connections, end connections, circuit rings, etc.

Stray Load Losses; G HDC Detailed calculations showing how the stray load loss is determined.

Temperature Rise; G HDC Maximum temperature rise of the new winding above 40 degrees C ambient at rated load, voltage, and power factor.

Wedging Deflection Characteristics; G HDC The wedging deflection characteristics shall include the following:

a. Initial deflection of slot wedging spring-type filler and radial pressure applied to 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 stator bar at the minimum acceptable deflection.

c. Method for verifying spring type filler material at the three quarter points of the slot.

d. Calculations to show that the radial pressure wedging system forces will exceed the non-fault-condition forces throughout the life of the winding. Forces shall be calculated at rated load, voltage, power factor, and at worst fault condition.

Stator Assembly Materials; G HDC A description of the materials for the assembly of the stator bars into the generator. This includes all wedging, filler, and brazing materials.

Main Lead Blocking Materials and Dimensions; G HDC A description of the materials including dimensions for the main lead blocking.

Catalog cut for the Resistance Temperature Detectors (RTD's)

Wire and Cable Manufacturing Data

Within 120 calendar days after date of receipt of written Notice To Proceed:

Parts List; G HDC

Spare Parts List; G HDC

Procedures for Removal of the Existing Stator Winding; G HDC

Procedure for Cleaning and Inspecting the Stator Core; G HDC

Procedure for Repairing the Stator Core; G HDC

Installation Procedure; G HDC The procedure shall include sufficient detail for the Government inspectors to determine if work is being performed in accordance with the manufacturer's and contract's requirements. The procedure shall include a description of the brazing methods for winding connections and the quality control checks to be used in those operations. The procedure shall also include calculations of the loading of the spring-type washers.

Procedure for Re-insulating the Main Leads; G HDC

Procedure for Cleaning, Inspecting and Testing the Rotor; G HDC Test procedure shall contain acceptance/rejection criteria.

Procedure for Insulating the Rotor Field Leads; G HDC

Interlaminar Insulation Test Procedure; G HDC Technical details of the interlaminar insulation test including power requirements.

Final Acceptance Test Procedures; G HDC An outline and description of the test methods and equipment to be employed in the field tests for the completed winding.

Generator Special Field Tests Procedure; G HDC An outline and description of the test methods and equipment to be employed in the special field tests for the completed winding.

The procedure shall include the following:

(1) Setup, including sketches of connections

(2) Step-by-step procedure of each test

(3) Responsible party for each step of each test

(4) Testing schedule, including setup and teardown

Surge Arrester Maintenance and Testing Manual; G HDC

If the Government exercises the option to re-stack the stator core and purchase one (1) new core, the following shall be submitted within 60 calendar days after date of receipt of written notice to the option being exercised:

Lamination Fabrication Procedure; G HDC Stator lamination fabrication procedure including production tolerances. Information on the varnish insulation shall also be included.

Lamination Test Procedure; G HDC An outline and description of the test methods and equipment to be employed in the Epstein test, Franklin test, and Ductility test for the stator core laminations, including all required test values and acceptance criteria.

Stator Core Stacking Procedures; G HDC Detailed procedures for stacking the stator core including stacking tolerances.

SD-02 Shop Drawings

Within 60 calendar days after date of receipt of written Notice To Proceed:

Cross-Sectional View of the Proposed Stator Bars; G HDC A cross-sectional view of the proposed stator bars in a stator slot, describing the stranding arrangement, strand dimensions, copper cross-sectional area, strand insulation details (including insulating material types and thicknesses), slot fillers, wedging details, and partial discharge suppressive treatments. Drawing shall also include groundwall insulation materials and thickness.

Exterior Dimensions of the Stator Bars; G HDC Drawing shall include bending radii, dimensions of slot paint and grading paint.

Dimensions and Details of the Wedges and Fillers; G HDC

Bracing Configuration for the Winding; G HDC

Circuit Ring Configuration and Dimensions; G HDC

Details of the Connections; G HDC This shall include connection from bars to circuit rings and from circuit rings to main and neutral leads.

Details of the Main and Neutral Leads; G HDC

Winding Diagram; G HDC A drawing that shows three phases in different colors and showing partial discharge analysis (PDA) and RTD location.

Partial Discharge Analysis (PDA) System; G HDC

Details of the PDA system and installation, including coupling capacitor details, coupling capacitor location and mounting, termination panel details, termination panel location, and coaxial cable routing and mounting.

Nameplate; G HDC Dimensions, material, and arrangement of information on the new nameplate.

Dummy Stator Core; G HDC

Surge Arrester Drawing and Catalog Cut; G HDC The drawing shall include materials and dimensions.

If the Government exercises the option to re-stack the stator core and purchase one (1) new core, the following shall be submitted within 60 calendar days after date of receipt of written notice to the option being exercised:

Stator Core Lamination Die Drawings shall include dimensions, dimensional tolerances, materials, method of securing die set to the press, identification of fasteners, and operating instructions.

Vent Duct Spacer Detail Drawing; G HDC Dimensions, materials, and tolerances of vent duct spacers.

Lamination Drawing Dimensions, materials, and tolerances of stator laminations.

Completed Stator Core Detail Drawing; G HDC Dimensions and tolerances for the completed stator core.

Stator Core Clamping System Drawing; G HDC

SD-06 Test Reports Except as noted, test reports shall be submitted within 30 calendar days after the completion of testing.

Winding Temperature and Moisture Report Submit monthly if off-site, long-term storage is required.

Paragraph WINDING DELIVERY AND STORAGE.

Prototype Bar Test Report; G HDC

Production Run Bar Test Report; G HDC

Spring Test Report or Catalog Cut; G HDC

RTD Factory Test Report

Factory Bar Test Report; G HDC

Bar Test Record; G HDC

Stator Core Inspection Report; G HDC

Stator Frame Measurements Report

Stator Core Installation Measurements Report

Clamping & Locking System Torque Measurements Report

Interlaminar Insulation Test Report; G HDC The report shall include thermal couple readings, setup photos, infrared photos of hot spots, and repair recommendations if hot spots are found.

Report of Tests During Winding Installation; G HDC

Partial Discharge Analysis System Test Report

Initial Acceptance Test Report; G HDC

Final Acceptance Test Report; G HDC

Generator Special Field Test Report; G HDC

Varnish Resistance Measurements Report

Post Insulator Inspection Report

Rotor Cleaning and Inspection Report; G HDC The report shall include any unusual conditions, any problems that need to corrected, any recommendations for correcting the problems, and an estimate of labor, materials, and time required to correct the condition.

Rotor Test Report; G HDC

Preliminary Bar Inspection Report

Bar Packing Report

Stator Winding Final Inspection Report

Stator Core Final Check Report; G HDC

Current Transformer Test Report; G HDC

Surge Arrester Conformance and Design Test Report; G HDC

Conductor Insulation Resistance, Conductor Continuity and Labeling, and Circuit Functionality Test Reports; G HDC Within 14 calendar days following the completion of testing and prior to startup testing.

Lamination Test Report; G HDC (If the Government exercises the option to re-stack the stator core and purchase one (1) new core.)

1.4 DRAWINGS

1.4.1 Drawing Index

Include a comprehensive index of shop drawings for each drawing set submitted. The index shall be part of the accompanying drawing set, having a title block, border, and sheet number compatible with the drawing set.

1.4.2 Bill of Materials

Include a comprehensive bill of materials (schedule of equipment) for each shop drawing set submitted. The schedule shall be part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. The schedule shall provide a cross reference between manufacturer data and shop drawings, regardless of whether the product data is submitted at the same time as the shop drawing set. The schedule shall include the total quantity, manufacturer, part number, and location of each item of equipment supplied. For complete assemblies, provide the serial numbers of each assembly, and a sub-schedule of replaceable components within the assembly.

1.5 EXISTING GENERATOR INFORMATION

1.5.1 Unit Identification and Nameplate

Main Units 1 through 12 generators were manufactured by General Electric Company and were commissioned between November 1953 and April 1956. They are salient pole, air-cooled (via air-water heat exchangers) machines rated as follows:

73,684 KVA

0.95 PF

13.8 KV

85.7 rpm

The generator is rated to operate continuous at 115 percent.

The stator winding configuration is six (6) circuit wye. The winding is composed of 522 three-turn asphalt-mica coils and it is rated for NEMA Class B temperature rise when operated at rated kVA.

The following information is from the GE Field Test Report No. 174477:

a. Operating Temperature Degrees Celsius (C) at rated load and power factor:

Maximum Stator Winding by RTD 83.0 Temperature of air entering generator 41.9 (discharge side of cooler) Stator Winding temperature rise 41.1

b. Losses in Kilowatts:

(1) Load of (at 13.8 kV and 0.95 power factor):

18,421 36,842 55,263 73,684 84,737 kVA kVA kVA kVA KVA 25% 50% 75% 100% 115% rated rated rated rated rated

Friction and Windage Loss 460 460 460 460 460 Core Loss 570 571 572 573 575 Stray-Load Loss 7 18 39 79 111 Armature DC I²R Loss (75 C) 14 56 126 224 296 Field I²R Loss (75 C) 216 249 290 347 385

TOTAL LOSSES* 1267 1354 1487 1683 1827

*Does not include exciter losses.

(2) Load of (at 13.8 KV and 1.0 power factor):

18,421 36,842 55,263 73,684 84,737 KVA kVA kVA kVA kVA 25% 50% 75% 100% 115% Rated rated rated rated rated

Friction and Windage Loss 460 460 460 460 460 Core Loss 570 571 572 573 575 Stray-Load Loss 7 18 39 79 111 Armature DC I²R Loss (75 C) 14 56 126 224 296 Field I²R Loss (75 C) 196 207 224 249 268

TOTAL LOSSES* 1247 1312 1421 1585 1710

*Does not include exciter losses.

c. Resistance Values:

Armature resistance (line-to-line) at 75 degrees C is 0.01572 ohm.

Rotor resistance at 75 degrees C is 0.3470 ohm.

1.5.2 Existing Damage to the Generators

Main Unit 2 experienced a coil failure in 1996. The failed coil was cut out and the unit was returned to service with no restriction on operations. Main Unit 7 experienced a coil failure in 2006. The failed coil was removed from the winding. The unit was returned to service in a de-rated condition. Extent of stator core damage is unknown in both failures.

1.5.3 Inspection By Contractor

The Government will make one (1) generator available at the Contractor's request to permit the Contractor to inspect the generator and obtain dimensions required to design the winding replacement. The maximum duration of the unit outage for the the inspection and measurements is two

(2) weeks. The inspection schedule shall be coordinated with the Contracting Officer. The Contractor shall give the Government 30 calendar days of advance notice. The Contractor shall be responsible for obtaining and verifying dimensions and other information, including information contained in this SPECIFICATION, which may be required to design a replacement stator winding. Measurements shall be made on the generator as necessary to ensure that all materials supplied under this contract will meet all contract requirements. A spare bar and a spare lamination are available at the Powerhouse for measurement by the Contractor. However, the Government will not assume any responsibilities for the accuracies of the dimensions of the bar or lamination. The Contractor shall be responsible for developing the necessary information required for design.

Any discrepancies between information given in this document and information developed shall be brought to the attention of the Contracting Officer before proceeding.

PART 2 PRODUCTS

2.1 MATERIALS

All materials shall conform to the applicable specifications and standards listed and to the additional requirements specified herein. Any materials required in the work, but not covered by the specifications, shall be approved for the purpose intended prior to their incorporation. Reference to any equipment, article, or catalog number shall be regarded as establishing a standard of quality and shall not be construed as limiting competition. The Contractor may use any equipment, material, or article that in the judgment of the Contracting Officer is equal to that named.

2.1.1 Parts List

The Contractor shall submit for approval a parts list that includes all materials to be furnished in this contract. Each entry on the parts list shall be individually designated with a part number that is keyed to the applicable shop drawing.

2.1.2 Winding Delivery and Storage

The Contractor shall not deliver more than two (2) windings at a time. The Contractor shall not deliver the windings until they are ready to rewind.

The windings shall be stored within the Powerhouse. If off-site storage for the windings is required, the Contractor shall provide the storage at no additional cost to the Government. The storage shall be suitable for long-term storage and be furnished with heat and ventilation. Once a month, the Contractor shall check the temperature and moisture on the winding while they are being stored and submit a Winding Temperature and Moisture Report.

2.2 PROTOTYPE STATOR BARS

Prior to manufacture of the stator winding, eight (8) prototype bars, plus any additional bars which may be required because of failures, shall be manufactured for accelerated life testing. The bars shall be identical to those manufactured under paragraph NEW STATOR BARS, and they shall have passed all the factory tests specified in paragraph BAR TESTS AT FACTORY.

The testing procedure shall be as stated in paragraph TEST PROCEDURE.

2.3 WINDING RATING AND INSULATION CLASS

The new stator winding shall be rated at 100,000 kVA and 0.95 power factor. The stator bars and winding installation materials shall be capable of operation at Class F temperature limits as defined in IEEE C50.12.

The stator winding temperature rise shall not exceed 75 degrees C above a cooler discharge air temperature at 40 degrees C, when operated at rated load.

2.4 NEW STATOR BARS

2.4.1 General

The new stator bars to be supplied under this SPECIFICATION shall incorporate modern practice in design, material, and workmanship. Bars shall be of the hard, single-turn type with Roebel transposition. The strands shall be annealed copper, free from splinters, flaws, rough spots, or short radius bends. All finished outside edges of each bar shall be rounded with a minimum radius of 1/16-inch. The narrow side of the slot portion of each stator bar shall have a flat bearing surface of at least 3/8-inch. Bar leads shall not be cut or tailored for any particular slot and shall be designed for use in any slot. The Contractor shall submit for approval the following:

a. Cross sectional view of the proposed stator bars;

b. Exterior dimensions of the stator bars;

c. Bar insulation system;

d. Winding diagram.

2.4.2 Conductor Strands

Strands shall be continuous (splice-free) within the entire mean turn length of each bar and shall be insulated with continuous filament glass or Dacron-glass fibers, or mica tape, bonded to the copper with a suitable bonding agent. Conductor strands shall be sized and arranged to minimize eddy and circulating current losses.

2.4.3 Ground Insulation

2.4.3.1 General

Ground insulation shall consist of multiple overlapped layers of mica splitting and/or mica flake tapes applied continuously and of equal thickness throughout the entire length of the bar. The mica splitting tape, if used, shall consist of large white mica splittings, NEMA Grade C or better. All mica tapes shall be constructed with a glass or polyester fabric backing material. A suitable protective covering tape shall be applied over the ground insulation mica tape.

2.4.3.2 Drying

After the application of all insulation, the bars shall be given appropriate drying treatments to remove absorbed or trapped moisture and gases from the insulation system.

2.4.3.3 Resin Impregnation and Curing

After drying treatments, the bar insulation shall be completely filled with a solventless epoxy resin using a vacuum pressure or mechanical impregnation process. After impregnation, the bar insulation system shall be cured by the application of heat and pressure to the slot and end winding portions of the bars. Slot portions shall be sized to closely controlled dimensions and end portions shall be restrained with suitable pressure devices to assure a well-compacted insulation structure. The insulation in the slot portion and under the grading paint shall be free of internal voids visible, when dissected, to the naked eye.

2.4.3.4 Alternate Construction

B stage or loaded tapes may be used in lieu of the resin impregnation process described in paragraph RESIN IMPREGNATION AND…