Amend_0004 _15-R-0044.pdf

W68SBV50771656

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 solicitation is amended to incorporate the changes stated in the attached Summary of Changes.

The proposal due date is unchanged as a result of this amendment. Proposals must be received no later than 4:00pm, Pacif ic, on 10 November 2015.

ICE HARBOR DAM REWINDS AND TURBINE RUNNER REPLACEMENTS

1. CONTRACT ID CODE PAGE OF PAGES

J 1 6

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

16C. DATE SIGNED

BY 26-Oct-2015

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-15-R-0044

X 9B. DATED (SEE ITEM 11)

01-Sep-2015

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

26-Oct-2015

CODE

USAED, WALLA WALLA - CONTRACTING DIV.

PHYLLIS L. BUERSTATTE

201 N. THIRD AVENUE

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-15-R-0044

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

Summary of changes for Amendment 0004

Ice Harbor Turbine Installation and Rewind Units 1 – 3

1. Revised the following Specification:

SECTION 48 13 16.00 26 REWIND OF HYDRAULIC-TURBINE DRIVEN

ALTERNATING CURRENT GENERATOR

• Revised the following paragraphs

3.4 COIL TESTS AT FACTORY f. Stator Coil Dimension Check

3.13.1 General

3.18 TESTS DURING WINDING INSTALLATION

3.22.1 Rotor Pole Removal

Removed 3.22.2 Rotor Pole Cleaning Added 3.22.2 Pole Asbestos Handling and Transportation

3.22.3 Rotor Pole Reinsulation

2. Revised or added the Contract Provisions and Clauses as stated below.

The following have been added by full text:

AMENDMENT 0004

SECTION 00100 - BIDDING SCHEDULE/INSTRUCTIONS TO BIDDERS

The following have been added by reference:

52.204-16 Commercial and Government Entity Code Reporting JUL 2015 52.204-17 Ownership or Control of Offeror NOV 2014

SECTION 00600 - REPRESENTATIONS & CERTIFICATIONS

The following included by full text have been revised:

252.204-7004 ALTERNATE A, SYSTEM FOR AWARD MANAGEMENT (FEB 2014)

(a) Definitions. As used in this provision—

“System for Award Management (SAM) database” means the primary Government repository for contractor information required for the conduct of business with the Government.

“Commercial and Government Entity (CAGE) code” means—

(1) A code assigned by the Defense Logistics Information Service (DLIS) to identify a commercial or Government entity; or

(2) A code assigned by a member of the North Atlantic Treaty Organization that DLIS records and maintains in the CAGE master file. This type of code is known as an “NCAGE code.”

“Data Universal Numbering System (DUNS) number” means the 9-digit number assigned by Dun and Bradstreet, Inc. (D&B) to identify unique business entities.

“Data Universal Numbering System +4 (DUNS+4) number” means the DUNS number assigned by D&B plus a 4-character suffix that may be assigned by a business concern. (D&B has no affiliation with this 4-character suffix.) This 4-character suffix may be assigned at the discretion of the business concern to establish additional SAM records for identifying alternative Electronic Funds Transfer (EFT) accounts (see FAR 32.11) for the same parent concern.

“Registered in the System for Award Management (SAM) database” means that—

(1) The contractor has entered all mandatory information, including the DUNS number or the DUNS+4 number, and Contractor and Government Entity (CAGE) code into the SAM database; and

(2) The contractor has completed the Core Data, Assertions, Representations and Certifications, and Points of Contact sections of the registration in the SAM database;

(3) The Government has validated all mandatory data fields, to include validation of the Taxpayer Identification Number (TIN) with the Internal Revenue Service (IRS). The Contractor will be required to provide consent for TIN validation to the Government as part of the SAM registration process; and

(4) The Government has marked the record “Active.”

(b) (1) By submission of an offer, the offeror acknowledges the requirement that a prospective awardee shall be registered in the SAM database prior to award, during performance, and through final payment of any contract, basic agreement, basic ordering agreement, or blanket purchasing agreement resulting from this solicitation.

(2) The offeror shall enter, in the block with its name and address on the cover page of its offer, the annotation “DUNS” or “DUNS+4” followed by the DUNS or DUNS+4 number that identifies the offeror’s name and address exactly as stated in the offer. The DUNS number will be used by the Contracting Officer to verify that the offeror is registered in the SAM database.

(c) If the offeror does not have a DUNS number, it should contact Dun and Bradstreet directly to obtain one.

(1) An offeror may obtain a DUNS number—

(i) Via the internet at http://fedgov.dnb.com/webform or if the offeror does not have internet access, it may call Dun and Bradstreet at 1-866-705-5711 if located within the United States; or

(ii) If located outside the United States, by contacting the local Dun and Bradstreet office. The offeror should indicate that it is an offeror for a U.S. Government contract when contacting the local Dun and Bradstreet office.

(2) The offeror should be prepared to provide the following information:

(i) Company legal business name.

(ii) Tradestyle, doing business, or other name by which your entity is commonly recognized.

http://fedgov.dnb.com/webform

(iii) Company physical street address, city, state and Zip Code.

(iv) Company mailing address, city, state and Zip Code (if separate from physical).

(v) Company telephone number.

(vi) Date the company was started.

(vii) Number of employees at your location.

(viii) Chief executive officer/key manager.

(ix) Line of business (industry).

(x) Company Headquarters name and address (reporting relationship within your entity).

(d) If the Offeror does not become registered in the SAM database in the time prescribed by the Contracting Officer, the Contracting Officer will proceed to award to the next otherwise successful registered Offeror.

(e) Processing time, which normally takes 48 hours, should be taken into consideration when registering. Offerors who are not registered should consider applying for registration immediately upon receipt of this solicitation.

(f) Offerors may obtain information on registration at https://www.acquisition.gov.

(End of Provision)

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 10 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 timeframes listed below.

(1) The work shall commence at Unit 2 (fixed blade runner with stator rewind) followed by Unit 3 (adjustable blade runner with stator rewind) followed by Optional Unit 1 (adjustable blade runner with stator rewind). No two units may be out of service at the same time unless allowed by the Contracting Officer. Each unit must be completely operational, commissioned and ready for operation prior to taking another unit out of service.

i. The Contractor shall include 15 calendar days in the schedule for the Government to dewater and prepare each unit for work to start. This time includes initial asbestos abatement pre-cleaning of the generator area (by others).

https://www.acquisition.gov/

ii. When disassembling the generator, the Contractor shall place the rotor on the existing rotor pedestal and provide a dust containment structure over and around the rotor. The structure shall be adequate for the abatement of asbestos (by others) and containment of any dust as a result of the abatement effort. The Contractor shall provide a safe working platform for all work conducted on the stator, including asbestos abatement and lead based paint removal (by others). The Contractor shall include an additional 28 calendar days in the schedule for asbestos abatement of the stator and rotor. During this time frame the Contractor shall allow for unimpeded access to the rotor and stator for asbestos abatement. The Contractor can proceed with other work in the powerhouse but will not be allowed to work in the generator/turbine pit areas that are subjected to the asbestos abatement operations. Actual time may vary depending on the extent of the abatements as required. Asbestos abatement will be performed under a separate contract by others.

iii. Upon completion and acceptance of work on the first unit (Unit 2), the Government requires 5 calendar days to perform the pre-operational test phase. Operational testing performed by the Government will require 5 additional calendar days, which will include Commissioning Support provided by the Contractor, prior to returning the unit to service. See Section 01 32 01.00 28 PROJECT SCHEDULE: paragraph Mandatory Tasks; sub paragraph q for additional information.

Upon completion of commissioning, the Government will require an additional 15 calendar days to dewater and prepare the second unit for work to start. This time includes initial asbestos abatement pre-cleaning of the generator (by others)

iv. Upon completion and acceptance of work on the Second unit, the Government requires 5 calendar days to perform pre-operational test phase. Operational testing phase performed by the Government will require 5 additional calendar days, which will include Commissioning Support provided by the Contractor, prior to returning this unit to service. Upon completion of the commissioning, the Government will require an additional 15 calendar days to dewater and prepare the third unit for work to start. This time includes initial asbestos abatement pre-cleaning of the generator (by others).

v. Upon completion and acceptance of work on the Third unit, the Government requires 5 calendar days to perform pre-operational test phase. Operational testing phase performed by the Government will require 5 additional calendar days, which will include Commissioning Support provided by the Contractor, prior to returning this unit to service. Upon completion of commissioning, the Government will require an additional 10 calendar days to return to Unit 2 to dewater and prepare to complete the stator core rewind

(2) The Contractor shall complete final cleanup and demobilization by not later than 15 calendar days after completion of work in (1) above.

(3) The Contractor shall complete final submission of, working “as-built” contract drawings and final approved versions of Contractor prepared drawings (see Section 01 78 00.00 28) by not later than 30 calendar days after completion of work in (1) above.

(4) The timeframes to complete the work will be based on the accepted proposed schedule as awarded, but shall not exceed a total of 1000 calendar days for Units 2 and Unit 3, and an additional 450 calendar days for Optional Unit 1, from notice to proceed to completion of final demobilization, unless otherwise agreed by the Contracting Officer.

(End of clause)

52.236-1 PERFORMANCE OF WORK BY THE CONTRACTOR (APR 1984)

The Contractor shall perform on the site, and with its own organization, work equivalent to at least FIFTY percent of the total amount of work to be performed under the contract. This percentage may be reduced by a supplemental agreement to this contract if, during performing the work, the Contractor requests a reduction and the Contracting Officer determines that the reduction would be to the advantage of the Government.

(End of clause)

The following included by reference have been revised:

52.203-13 Contractor Code of Business Ethics and Conduct APR 2010 52.204-10 Reporting Executive Compensation and First-Tier

Subcontract Awards

JUL 2013

52.209-6 Protecting the Government's Interest When Subcontracting With Contractors Debarred, Suspended, or Proposed for Debarment

AUG 2013

52.219-9 Alt II Small Business Subcontracting Plan (OCT 2014) Alternate II OCT 2001 52.222-35 Equal Opportunity for Veterans JUL 2014 52.222-36 Equal Opportunity for Workers with Disabilities JUL 2014 52.222-37 Employment Reports on Veterans JUL 2014 52.222-40 Notification of Employee Rights Under the National Labor

Relations Act

DEC 2010

52.222-54 Employment Eligibility Verification AUG 2013 52.223-3 Hazardous Material Identification And Material Safety Data JAN 1997 52.232-40 Providing Accelerated Payments to Small Business

Subcontractors

DEC 2013

52.244-6 Subcontracts for Commercial Items APR 2015 52.248-3 Value Engineering-Construction OCT 2010 252.203-7004 Display of Fraud Hotline Poster(s) JAN 2015 252.204-7012 Safeguarding of Unclassified Controlled Technical

Information

AUG 2015

252.209-7004 Subcontracting With Firms That Are Owned or Controlled By The Government of a Country that is a State Sponsor of Terrorism

DEC 2014

252.223-7006 Prohibition On Storage, Treatment, and Disposal of Toxic or Hazardous Materials

SEP 2014

252.225-7012 Preference For Certain Domestic Commodities FEB 2013 252.244-7000 Subcontracts for Commercial Items JUN 2013 252.244-7001 Contractor Purchasing System Administration MAY 2014 252.247-7023 Transportation of Supplies by Sea APR 2014

(End of Summary of Changes)

Ice Harbor Turbine Installation and Rewind Units 1 - 3 W912EF-15-R-0044 Amend-0004

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 16.00 26

REWIND OF HYDRAULIC-TURBINE DRIVEN ALTERNATING CURRENT GENERATOR

PART 1 GENERAL

1.1 GENERAL

1.2 REFERENCES

1.3 SUBMITTALS

1.4 EXISTING GENERATOR INFORMATION

1.4.1 Unit Identification and Nameplate

1.4.2 Description of Generator

1.4.3 Test Report Data

1.4.4 Existing Damage to the Generators

1.4.5 Inspection By Contractor

PART 2 PRODUCTS

2.1 MATERIALS

2.2 PROTOTYPE STATOR COILS

2.3 WINDING RATING AND INSULATION CLASS

2.4 STATOR COILS

2.4.1 General

2.4.2 Conductor Strands

2.4.3 Turns

2.4.4 Ground Insulation

2.4.5 Drying

2.4.6 Resin Impregnation and Curing

2.4.7 Alternate Construction

2.4.8 Finish and Partial Discharge (Corona) Suppression Treatments

2.4.9 Graded Suppression Treatment

2.4.10 Coil Identification and Record

2.4.11 Quantity

2.5 RESISTANCE TEMPERATURE DETECTORS (RTDs)

2.6 CIRCUIT RINGS

2.6.1 General

2.6.2 Electrical Configuration

2.6.3 Physical Construction

2.6.4 Insulation

2.6.5 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

2.7.7 End Winding Bracing and Blocking Material

2.8 STATOR LAMINATION DIE

2.9 STATOR LAMINATIONS

2.10 VENT DUCT SPACERS

2.11 STATOR CORE CLAMPING SYSTEM

SECTION 48 13 16.00 26

2.12 PARTIAL DISCHARGE ANALYSIS SYSTEM

2.12.1 General

2.12.2 Coupling Capacitors

2.12.2.1 General

2.12.2.2 Rating

2.12.2.3 Construction

2.12.3 Leads

2.12.4 Termination Panel

2.13 NAMEPLATE

2.14 SPARE PARTS

2.14.1 General

2.14.2 Stator Coils and Supplies

2.14.3 RTDs and RTD cable

2.14.4 Laminations

2.14.5 Stator Core Vent Duct Spacers

2.14.6 Packaging and Storage

2.15 ROTOR POLE REFURBISHMENT (OPTIONAL)

2.15.1 Insulating Materials

2.15.2 Field Coil Insulation

2.15.3 Pole Body Insulation

2.15.4 Sealant

2.15.5 Insulating Collars

2.15.6 Interpole Connectors

2.15.7 Amortisseur Connectors

2.15.8 Pole Keys

PART 3 EXECUTION

3.1 GENERAL TESTING REQUIREMENTS

3.2 ACCELERATED LIFE TESTS

3.2.1 Test Procedure

3.2.2 Accelerated Life Test of Prototype Coils

3.2.3 Accelerated Life Test of Production Run Coils

3.3 THERMAL CYCLING TEST

3.4 COIL TESTS AT FACTORY

3.5 SPRING TYPE FILLER MATERIAL TEST

3.6 RESISTANCE TEMPERATURE DETECTOR (RTD) TESTS AT FACTORY

3.7 STATOR CORE PUNCHING TESTS

3.8 GENERATOR DISASSEMBLY

3.9 GENERATOR WORK PLATFORM

3.10 REMOVAL OF EXISTING WINDING

3.11 STATOR CORE CLEANING AND INSPECTION

3.12 MINOR STATOR CORE IRON REPAIR

3.12.1 General

3.12.2 Minor Stator Core Iron Repair Methods

3.13 STATOR CORE INTERLAMINAR INSULATION TEST

3.13.1 General

3.13.2 Interlaminar Insulation Test

3.14 APPLICATION OF EPOXY

3.15 APPLICATION OF VARNISH

3.16 STATOR CORE REPLACEMENT (OPTIONAL)

3.16.1 General

3.16.2 Unstack Stator Core

3.16.3 Stator Inspection

3.16.4 Center and Round Stator

3.16.5 Restack Stator Core Laminations

3.16.6 Final Check

3.16.7 Interlaminar Insulation Test

3.16.8 Application of Epoxy

SECTION 48 13 16.00 26

G4EDDRJR

Line

G4EDDRJR

Line

3.16.9 Application of Varnish

3.17 INSTALLATION OF STATOR WINDING

3.18 TESTS DURING WINDING INSTALLATION

3.19 PARTIAL DISCHARGE ANALYSIS (PDA) SYSTEM INSTALLATION

3.19.1 General

3.19.2 Coupling Capacitors

3.19.3 Leads

3.19.4 Termination

3.20 PARTIAL DISCHARGE ANALYSIS (PDA) SYSTEM TESTS

3.20.1 General

3.20.2 Test Equipment

3.20.3 PDA Tests

3.20.4 PDA Test Report

3.21 ROTOR CLEANING, INSPECTING AND TESTING

3.21.1 Initial Testing of Rotor Parts

3.21.2 Cleaning of Rotor Parts

3.21.3 Inspection of Rotor Parts

3.21.4 Final Testing of Rotor Parts

3.21.5 Rotor Field Lead Insulation

3.21.6 Rotor Varnish

3.22 ROTOR POLE REFURBISHMENT (OPTIONAL)

3.22.1 Rotor Pole Removal

3.22.2 Pole Asbestos Handling and Transportation

3.22.3 Rotor Pole Reinsulation

3.22.4 Factory Tests

3.22.5 Reinstallation of Rotor Poles

3.22.6 Field Tests

3.22.7 Pole Connections

3.22.8 Final Field Tests

3.23 INITIAL WINDING ACCEPTANCE TESTS

3.24 GENERATOR REASSEMBLY

3.25 GENERATOR DRY-OUT

3.26 FINAL WINDING ACCEPTANCE TESTS

3.27 GENERATOR SPECIAL FIELD TESTS

3.27.1 General

3.27.2 Verification Tests

3.27.3 Determination Tests

ATTACHMENTS:

Attachment A

-- End of Section Table of Contents --

SECTION 48 13 16.00 26

G4EDDRJR

Line

SECTION 48 13 16.00 26

REWIND OF HYDRAULIC-TURBINE DRIVEN

ALTERNATING CURRENT GENERATOR

PART 1 GENERAL

1.1 GENERAL

This section covers supplying one complete stator core; supplying three complete stator windings with accessories; installing and testing two stator windings and accessories; and supplying spare parts. All associated testing is included. At the option of the Government, work would include installing and testing one stator winding and accessories, installing and testing one stator core; supplying one or two additional stator cores, installing one or two stator cores, and refurbishing all rotor poles for the Ice Harbor Generator Units 1, 2, and 3.

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; R2011) Standard Test Method for Ductility of Nonoriented Electrical Steel

ASTM D 1868 (2013) Standard Test Method for Detection and Measurement of Partial Discharge (Corona) Pulses in Evaluation of Insulation Systems

AMERICAN WELDING SOCIETY, INC. (AWS)

AWS A5.8 (2012) Specification for Filler Metals for

Brazing and Braze Welding

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 (1976; R1991 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.

IEEE 95 (2002; R2007) Recommended Practice for Insulation Testing of Large AC Rotating Machinery with High Direct Voltage

IEEE 115 (2009) Guide for Test Procedures for Synchronous Machines: Part I Acceptance and Performance Testing; Part II Test Procedures and Parameter Determination for Dynamic Analysis

IEEE 286 (2000; R2012) Recommended Practice for Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation

IEEE 1043 (1996; R2009) Recommended Practice for Voltage-Endurance Testing of Form-Wound Bars and Coils

IEEE 1310 (2012) Recommended Practice for Thermal Cycle Testing of Form-Wound Stator Bars and Coils for Large Rotating Machines

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA FI 1 (2004) Manufactured Electrical Mica

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

1.3 SUBMITTALS

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

When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

SD-01 Preconstruction Submittals

Within 60 calendar days after date of receipt of written notice to proceed:

Stator Coil Insulation System; G HDC

Stator Coil Facility; G HDC

Stator Coil Factory Test Methods; G HDC

Prototype Coil Accelerated Life Test Facility; G HDC

Production Coil Accelerated Life Test Facility; G HDC

Accelerated Life Test Method; G HDC

Prototype Coil Thermal Cycling Test Facility; G HDC

Thermal Cycling Test Method; G HDC

Lamination Facility; G HDC

Lamination Fabrication Procedure; G HDC

Lamination Factory Test Methods; G HDC

Within 30 calendar days after the Government exercises the option to refurbish the rotor poles:

Rotor Pole Insulating Materials; G HDC

Interpole Connectors; G HDC

Within 90 calendar days after date of receipt of written notice to proceed:

Stator Assembly Materials; G HDC

DC I²R Copper Losses; G HDC

Stray Load Losses; G HDC

Temperature Rise; G HDC

Wedging Deflection Characteristics; G HDC

Catalog Cuts for the RTDs and RTD Cables; G HDC

Catalog Cuts for the Neutral Current Transformers; G HDC

Within 120 calendar days after date of receipt of written notice to proceed:

Part List; G HDC

Spare Parts List; G HDC

Stator Winding Removal Procedure; G HDC

Stator Core Cleaning and Inspection Procedure; G HDC

Interlaminar Insulation Test Procedure; G HDC

Stator Winding Installation Procedure; G HDC

Main and Neutral Lead Insulation Procedure; G HDC

Stator Core Repairing Procedure; G HDC

Rotor Cleaning, Inspecting and Testing Procedure; G HDC

Testing During Winding Installation Procedure; G HDC

Initial Winding Acceptance Test Procedure; G HDC

Final Winding Acceptance Test Procedure; G HDC

Generator Special Field Tests Procedure; G HDC

Within 30 calendar days after the Government exercises the option to restack the stator core:

Stator Core Removal Procedure; G HDC

Stator Core Stacking Procedure; G HDC

Within 30 calendar days after the Government exercises the option to refurbish the rotor poles:

Rotor Pole Removal Procedure; G HDC

Rotor Pole Reinsulation Procedure; G HDC

Rotor Pole Reinstallation Procedure; G HDC

Rotor Pole Factory Test Procedure; G HDC

Rotor Pole Field Test Procedure; G HDC

SD-02 Shop Drawings

Note: Shop drawings shall include a parts list as appropriate.

Within 60 calendar days after date of receipt of written notice to proceed:

Cross-Sectional View of the Stator Coil; G HDC

Exterior Dimensions of the Stator Coil; G HDC

Dimensions and Details of the Wedges and Fillers; G HDC

Winding Diagram; G HDC

Bracing Configuration for the Winding; G HDC

Circuit Ring Configuration and Dimensions; G HDC

Details of the Connections; G HDC

Details of the Main and Neutral Leads; G HDC

RTD Terminal Box; G HDC

RTD Installation Drawing; G HDC

Nameplate Drawing; G HDC

Lamination Die Drawing; G HDC

Vent Duct Spacer Drawing; G HDC

Lamination Drawing; G HDC; G HDC

Completed Stator Core Detail Drawing; G HDC

Stator Core Clamping System Drawing; G HDC

Partial Discharge Analysis (PDA) System; G HDC

Within 30 calendar days after the Government exercises the option to refurbish the rotor poles:

Rotor Pole Assembly Drawings; G HDC

SD-06 Test Reports

Within 7 calendar days after the completion of testing and/or inspection:

Prototype Coil Accelerated Life Test Report; G HDC

Prototype Coil Thermal Cycling Test Report; G HDC

Production Coil Accelerated Life Test Report; G HDC

Coil Factory Test Report; G HDC

Spring Type Filler Material Test Report; G HDC

Resistance Temperature Detector Test Report; G HDC

Lamination Factory Test Report; G HDC

Interlaminar Insulation Test Report; G HDC

Test During Winding Installation Report; G HDC

Partial Discharge Analysis System Test Report; G HDC

Amortisseur Inspection Report, G HDC

Rotor Inspection Report; G HDC

Rotor Test Report; G HDC

Rotor Pole Factory Test Report; G HDC

Rotor Pole Field Test Report; G HDC

Initial Winding Acceptance Test Report; G HDC

Final Winding Acceptance Test Report; G HDC

Generator Special Field Test Report; G HDC

Coil Test Record; G HDC

Condition of the Die Report; G HDC

Stator Core Final Check Report; G HDC

Preliminary Coil Inspection Report; G HDC

Stator Inspection Report; G HDC

Stator Winding Final Inspection Report; G HDC

Stator Core Inspection Report; G HDC

1.4 EXISTING GENERATOR INFORMATION

1.4.1 Unit Identification and Nameplate

Ice Harbor Units 1, 2 and 3 are air-cooled, vertical hydro-generators, manufactured by the General Electric Company. The units were brought on line between 1961 and 1962. Generator ratings, as defined by the nameplate stamping information are as follows:

94,737 kVA

0.95 Power Factor

13,800 V 3-phase 60 Hz

90 RPM

115 percent overload capability

1.4.2 Description of Generator

The stator core is 64 1/8 inches high and has 630 slots. The stator winding is wye connected, and consists of 630 four-turn form wound coils with 10 parallel paths per phase and 21 multi-turn coils per parallel. It is rated for NEMA Class B temperature rise when operated at rated kVA.

1.4.3 Test Report Data

The following information is from the original GE Field Test Report. Copy of the original GE Field Test Report is included as Attachment A to this

Section.

a. Operating Temperature in Degrees Centigrade, at rated kVA, voltage, and power factor.

Temperature of air into generator (discharge side of cooler) 40.1 Stator Winding Temperature Rise 42.4

b. Losses in Kilowatts:

(1) Losses at 13.8 kV and 0.95 power factor:

Percent Load 25 50 75 100 115 Friction and Windage Loss 450 450 450 450 450 Core Loss 368 368 368 368 368 Stray-Load Loss 12.5 45 97 167 218 Armature DC I²R Loss (75 C) 22.5 90 202.5 360 476

Field I²R Loss (75 C) 100.5 129 173 235 294

TOTAL LOSSES 953.5 1082 1290.5 1580 1806

(2) Losses at 13.8 KV and 1.0 power factor:

Percent Load 25 50 75 100 115 Friction and Windage Loss 450 450 450 450 450 Core Loss 368 368 368 368 368 Stray-Load Loss 12.5 45 97 167 218 Armature DC I²R Loss (75 C) 22.5 90 202.5 360 476

Field I²R Loss (75 C) 87 100 120 152 177

TOTAL LOSSES 940 1053 1237.5 1497 1689

c. Resistance Values at 25 degrees C:

Stator resistance (line to ground) 0.00643 ohms Rotor resistance 0.29 ohms

1.4.4 Existing Damage to the Generators

On September 3, 1967, a short between A and C phases caused a failure in coils number 60 and 61 in unit 3 stator winding. The damaged coils were cut-out and bypassed from the circuit without removing the rotor or any rotor poles. The unit was returned to service without operating limitation. On July 7, 2014, a ground fault in B phase caused a failure in coil number 316 in unit 3 stator winding. The damaged coil was removed from the winding and jumpered. The stator core has sustained minor damage. No operating limitation was established for the repaired generator.

1.4.5 Inspection By Contractor

The Government will make the generator available at the Contractor's request to permit the Contractor to inspect and obtain dimensions required to design the stator winding and core replacement. The inspection schedule shall be coordinated with the Contracting Officer (KO) and Ice Harbor Project personnel. The generator rotor will not be removed for this inspection. The Contractor shall be responsible for obtaining and verifying dimensions and other information, including information contained in this specification, that may be required to design a replacement stator winding and stator core. 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 coil is available at the powerhouse for measurement by the Contractor. However, the Government will not assume any responsibility for the accuracy of the dimensions of the coil. 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 Government 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. Submit for approval a part 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.

2.2 PROTOTYPE STATOR COILS

Prior to manufacture of the stator winding, four prototype coils, plus any additional coils which may be required because of failures, shall be manufactured for accelerated life testing. In addition, four prototype coils, plus additional coils required as control temperature coils shall be manufactured for thermal cycle testing. The prototype coils shall be identical to those manufactured under paragraph 2.4, and they shall have passed all the factory tests specified in paragraph 3.4 and a report submitted for approval prior to the accelerated life and thermal cycling tests. The accelerated life testing procedure shall be as stated in paragraph 3.2.1. The thermal cycling test procedure shall be as stated in paragraph 3.3.

2.3 WINDING RATING AND INSULATION CLASS

The new stator winding shall be rated at 121,000 kVA at a 0.95 power factor. The stator coil and winding 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. The combined I2R (R corrected to 75 degrees C) and stray load losses of the new winding at 108,948 kVA, 13.8 kV, and 0.95 power factor shall not exceed the combined I2R (R corrected to 75 degrees C) and stray load losses of the existing winding at 108,948 kVA, 13.8 kV, and 0.95 power factor.

2.4 STATOR COILS

2.4.1 General

The stator coils to be supplied under this specification shall incorporate modern practice in design, material, and workmanship. Coils shall be of the hard, multi-turn type designed to minimize eddy current loss. The strands shall be annealed copper, free from splinters, flaws, rough spots, or short radius bends. All finished outside edges of each coil shall be rounded with a minimum radius of 1/16 inch. The narrow side of the slot portion of each stator coil shall have a flat bearing surface of at least

3/8 inch. Coil leads shall not be cut or tailored for any particular slot and shall be designed for use in any slot. Submit for approval the following:

Stator Coil Facility

The name, address, and qualification of the stator coil facility.

Cross Sectional View of the Stator Coil A cross-sectional view of the stator coils in a stator slot, describing the stranding arrangement, strand dimensions, copper cross-sectional area, strand and turn, and ground insulation details including insulating material types and thicknesses, slot fillers, RTD position in the slot, wedging details, and partial discharge suppressive treatments.

Exterior Dimensions of the Stator Coil Drawing shall include bending radii, dimensions of slot paint and grading paint.

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

Stator Coil Insulation System A description of the stator coil insulation system, including processes and materials employed to meet specification requirements.

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

Stray Load Losses

Detailed calculations showing how the stray load loss is determined.

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

2.4.2 Conductor Strands

Strands shall be continuous (splice free) within the entire mean turn length of each coil 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 Turns

The slot and end winding portion of the assembled strands shall be bonded into a homogenous structure of controlled size using heat and pressure.

Strand bonding resins shall have properties and characteristics to prevent bond failure due to the mechanical, thermal, and chemical effects associated with thermal cycling while operating with the class F temperature limits for which multiple layers of mica tape in combination with suitable backing materials.

2.4.4 Ground Insulation

Ground insulation shall consist of multiple overlapped layers of mica tapes applied continuously and of equal thickness throughout the entire length of the coil. The tape shall meet the requirements of NEMA FI 1. 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.

2.4.5 Drying

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

2.4.6 Resin Impregnation and Curing

After drying treatments, the coil insulation shall be completely filled with a solventless epoxy resin using a vacuum pressure or mechanical impregnation process. After impregnation, the coil insulation system shall be cured by the application of heat and pressure to the slot and end winding portions of the coils. 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.

2.4.7 Alternate Construction

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

2.4.8 Finish and Partial Discharge (Corona) Suppression Treatments

Slot portions of the stator coils, and a suitable distance beyond, shall be treated with a semiconducting compound capable of giving positive electrical contact between the treated portions of the coil surface and the entire length of the core slot walls. This semiconducting treatment shall be designed to eliminate corona discharges between coil and slot surfaces and between top and bottom coil sides.

2.4.9 Graded Suppression Treatment

A voltage grading semiconducting tape shall be applied to a suitable portion of the stator coil surface extending outward from the semiconducting treatment. This voltage grading semiconducting tape shall be of a length and resistivity to limit coil surface voltage gradients to levels well below surface discharge (corona) onset levels under normal operating voltage stresses. The semiconducting treatment shall be exposed and accessible for inspection and possible repair. The winding shall exhibit no visible corona during a black-out test at 10 kV as described in paragraph 3.23(d). Coil surfaces beyond the discharge suppressive treatments shall be treated 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 its operating life.

2.4.10 Coil Identification and Record

Each coil shall be given a unique identification. A permanent coil test record for each coil shall be kept, whether the coil is included in the finished winding or not. The record shall include the results of all coil tests. Include the slot number where each coil has been installed in this record.

2.4.11 Quantity

Sufficient coils to make up three complete windings shall be provided. In addition, 6 production run coils, plus any additional ones which may be required because of failure, shall be supplied for the accelerated life testing specified in paragraph 3.2. Coils subjected to accelerated life testing shall not be used in the final winding. The spare coils listed in paragraph 2.14.2 shall also be supplied.

2.5 RESISTANCE TEMPERATURE DETECTORS (RTDs)

Twenty four 3-wire resistance temperature detectors (RTDs), of 100 ohms platinum , ±0.12% at 0 degrees C having a temperature coefficient of resistance of 0.00385 ohm/ohm/degree C shall be provided in the stator winding. The RTD body shall have a semiconductive coating. The detectors and their location shall be in accordance with paragraph 7.3 of IEEE C50.12.

All existing RTD cables shall be replaced with insulated cable designed to withstand a Class F temperature rise. RTD cable shall be No. 16 AWG tinned stranded copper, three-conductor cable. The cable shall be oil and water resistant and have an overall metallic armor for mechanical protection.

The RTD cable insulation shall not be polyvinyl chloride (PVC). RTD leads may be solder-spliced to the RTD cable wires outside the slot.

Mechanically spliced leads shall not be used. Splices within the slot portion will not be allowed. Provide a terminal box with all necessary hardware for wiring all RTDs for installation next to the existing terminal box housing the existing RTDs. Submit for approval catalog cuts for the RTDs and RTD cables and RTD terminal box that shows the construction type, location, and arrangement of the terminations within the box.

2.6 CIRCUIT RINGS

2.6.1 General

New circuit rings, complete with all necessary connections, taps, adapters, braces, supports, and materials for making the necessary main and neutral connections between the winding, the terminals of the phase buses, and the terminals of the neutral current transformer bus assembly shall be provided. Submit for approval the following:

Circuit Ring Configuration and Dimensions

Details of the Main and Neutral Leads

Details of the Connections This shall include connections from coils to circuit rings and from circuit rings to main and neutral leads.

2.6.2 Electrical Configuration

The stator winding shall be wye-connected. Each phase of the stator winding shall consist of multi-turn coils, with the circuits per phase connected to give two parallel paths, as nearly equal as feasible, with neutral leads and the common main lead brought out within the generator housing at an approved location. The individual coils in each of the two parallel paths which are connected to the circuit rings, shall be connected in locations such that the differential protection of the winding will not be adversely affected by circulating currents between the parallel paths caused by misalignment of the rotor with respect to the stator. False tripping of differential relays due to circulating currents shall be considered an adverse effect. Readjustment of relay restraint settings to correct such a condition will not be permitted.

2.6.3 Physical Construction

The circuit rings, supports, and connecting leads shall be designed for installation in the same general location as the existing equipment, without alteration of the air baffling system or modification of structural parts. Each circuit ring shall be made up of not more than twelve pieces.

All factory joints shall be brazed in accordance with the requirements of

AWS A5.8.

2.6.4 Insulation

The circuit rings and connections shall be insulated for 15 kV with full

Class F insulation, or better, composed of mica or glass tapes.

2.6.5 Neutral Current Transformers

Three new neutral current transformers (CTs) with a rating of 2500:5 for use in the differential protection scheme shall be supplied and installed.

The neutral current transformers are part of the generator split-phase differential relaying protection scheme, which is to be retained. The accuracy of the new CTs shall be C400 or greater. Submit for approval catalog cuts for the neutral current transformers.

2.7 FILLERS, WEDGES, TIES, AND BLOCKING MATERIAL

2.7.1 General

All material in the slot or used in bracing the winding shall be of an approved Class F, or higher, insulation. Submit for approval the following:

Stator Assembly Materials A description of the materials for the assembly of the stator coils into the generator. This shall include all wedging, filler, brazing materials, and end-winding bracing and blocking materials.

Wedging Deflection Characteristics

a. Initial deflection (including tolerance) 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 coil 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.

Dimensions and Details of the Wedges and Fillers

Details shall include wedge tightness criteria.

Bracing Configuration for the Winding

2.7.2 Side Packing

One of the following side packing systems shall be used. No systems will be approved which require non-spring-type side filler to be inserted in the slot after the coil has been inserted:

a. A semiconducting silicone rubber compound shall be applied to the sides of the coils and cured before coil insertion. The silicone rubber shall form an interference fit with the sides of the slot.

b. A semiconductive coil wrapper used in conjunction with conducting putty shall be continuously applied throughout the length of the slot.

The coil shall be inserted into the slot before the putty has cured.

c. A ripple spring shall be driven between one side of the coil and the slot to form an interference fit. Acceptable deflection of the spring shall be submitted.

d. Other approved systems.

2.7.3 Center Filler and Bottom Filler

All center filler and bottom filler shall be fabricated from semiconducting material. The semiconducting material shall be impregnated throughout and shall not be coated on top of an insulating backing. A center filler between the two coil sides in a slot shall be provided of such a thickness as to prevent interference between the coils in the straight part extension. RTDs shall be installed in place of the center filler in specified slots. A bottom filler shall be used between the bottom coil side (furthermost from the bore) and the bottom of the slot.

2.7.4 Spring-Type Filler Material

Spring-type filler material, or other approved follow-up, shall be installed between the front filler and the wedge.

2.7.5 Wedges and Top Fillers

Stator slot wedges shall be manufactured from NEMA LI 1, Grade G11 material. The slot wedge cross sectional shape shall match the wedge groove shape of the stator laminations. Wedge width shall result in a snug, sliding fit in the stator core wedge groove prior to driving over top fillers. Oversized or undersized wedges may be necessary for the wedges in the stator core splits. Top fillers shall be furnished in a variety of thicknesses to ensure that a proper combination is available to produce a satisfactory radial wedging pressure. In all cases a filler of at least

0.020 inches thickness must be installed between the stator bar and spring filler. The base filler strip against the coil shall consist of one or two strips spanning the entire length of the core slot section. Three special check wedges shall be provided per slot. The check wedges shall have five or more holes for checking the spring-type filler deflection. The initial deflection shall be recorded and furnished to the Contracting Officer. The check wedges shall be located at the quarter points of each slot. End wedges shall be secured in place to prevent axial movement or migration of slot wedges or wedge fillers. Wedges shall be furnished with cutbacks at the cooling air passages. These cutbacks shall be designed to enhance the airflow.

2.7.6 Two-Part Wedges

If two-part wedges are used, the wedges and slides shall be assembled using a master slide to select the slide of correct thickness. The slide shall neither project above the top of the wedge nor touch the wedge below. All wedges shall be installed so that all slides are driven from above. A locking system for restricting the possible vertical movement of the wedges shall be provided.

2.7.7 End Winding Bracing and Blocking Material

End winding bracing material shall be Class F and shall include resin-impregnated conforming material, blocks, and glass twine. The conforming material shall be Dacron felt and shall be impregnated thoroughly with resin before use between the coils. The blocks shall be glass-based and shall be used when the space cannot be filled with resin-impregnated Dacron felt. After installation the ties are to be saturated with the resin.

2.8 STATOR LAMINATION DIE

The Contractor shall furnish a new die for the new laminations. The die shall be of the straight cut type, suitable for punching all of the laminations for the work. The die shall be turned over to the Government at the conclusion of the contract. The die shall be sharpened and packaged in a clearly labeled box prior to being returned to the Government. Submit for approval the following:

Lamination Die Drawing

Drawing shall include dimensions, dimensional tolerances, materials, method of securing die set to the press, identification of fasteners, and operating instructions.

Condition of the Die Report The report shall include the number of sharpenings the die can withstand and the number of laminations that can be punched between sharpenings.

2.9 STATOR LAMINATIONS

Furnish the required number of stator core laminations to completely stack one stator core. The laminations shall be made from high-grade nonaging silicon steel. The loss index shall not be worse than the original laminations. The new core loss shall not exceed the existing core loss at

108,948 kVA, 13.8 kV, and 0.95 power factor. As needed after punching, deburr each lamination and coat with an insulating varnish to minimize eddy current…