A.07.24_Amendment_0005_W912EF-17-R-0006_w_Specs.pdf

W68SBV63270594

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

See the summary of changes for Amendment 0005

The proposal response date remains unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 3

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

16C. DATE SIGNED

BY 23-Aug-2017

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-17-R-0006

X 9B. DATED (SEE ITEM 11)

30-Jun-2017

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

23-Aug-2017

CODE

WALLA WALLA DISTRICT,COE-G4P

CONTRACTING DIVISION

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-17-R-0006

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

AMENDMENT 0005

Summary of Changes for amendment 0005

Specifications:

00 01 00.00 28 LIST OF DRAWINGS

Updated subpart 1.3; added FIO-049 drawing

42 13 19.01 26 THRUST BEARING OIL COOLERS

Updated 1.3 Submittals

SD-02 Shop Drawings, reduced calendar days to 60 days SD-05 Design Data submittal requirement deleted.

48 13 13.06 26 GENERATOR THRUST BEARING INSPECTION AND OPTIONAL REFURBISHMENT

Attachments Thrust Runner Tolerance Sheets and Thrust Collar Dimensions provided

48 13 16.01 26 GENERATOR STATOR, ROTOR, AND UPPER BEARING BRACKET REPAIR AND

TESTING

Updated subpart 3.3.2.1 C Drawings:

Added FIO drawing FIO-049, 118” (12X) NON-KI THR SHOE SET

(End of Summary of Changes)

This page intentionally left blank

Little Goose Unit 5 Rotor Spider Repair W912EF-17-R-0006 amend 0005

PROJECT TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

00 01 15.00 28 LIST OF DRAWINGS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 00.00 28 SUMMARY OF WORK

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 26 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 54 19.10 28 CRANES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

01 91 00.00 28 SYSTEMS TESTING AND COMMISSIONING

DIVISION 02 - EXISTING CONDITIONS

02 83 33.12 28 LEAD BASED PAINT (LBP) REMOVAL AND DISPOSAL

DIVISION 05 - METALS

05 05 23.13 26 NON-DESTRUCTIVE EXAMINATION

05 05 23.16 26 WELDING

05 50 04.00 26 METALS: MISCELLANEOUS, STANDARD ARTICLES, SHOP FABRICATED

ITEMS

DIVISION 09 - FINISHES

09 90 00.00 26 PAINTING

DIVISION 40 - PROCESS INTERCONNECTIONS

40 05 13.96 26 THRUST BEARING OIL COOLERS - WELDING

DIVISION 42 - PROCESS HEATING, COOLING, AND DRYING EQUIPMENT

42 13 19.01 26 THRUST BEARING OIL COOLERS

DIVISION 48 - ELECTRICAL POWER GENERATION

48 13 13.02 26 DISASSEMBLY, REASSEMBLY, AND STARTUP OF HYDRAULIC TURBINE

GENERATOR UNIT

48 13 13.06 26 GENERATOR THRUST BEARING INSPECTION AND OPTIONAL

REFURBISHMENT

48 13 13.07 26 GUIDE BEARING INSPECTION & OPTIONAL REFURBISHMENT

PROJECT TABLE OF CONTENTS Page 1

48 13 16.01 26 GENERATOR STATOR, ROTOR, AND UPPER BEARING BRACKET REPAIR

AND TESTING

48 13 16.03 26 MACHINE CONDITION MONITORING SYSTEM

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

1.2 CONTRACT DRAWINGS

1.3 FOR INFORMATION ONLY DRAWINGS (FIO)

-- End of Section Table of Contents --

DOCUMENT 00 01 15.00 28

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

This section lists the drawings for the project pursuant to contract clause "DFARS 252.236-7001, Contract Drawings, Maps and Specifications."

1.2 CONTRACT DRAWINGS

Contract drawings are as follows:

FILE NUMBER SHEET

NUMBER

DESCRIPTION Revision Number

Date

GENERAL

LGP-1.38-0/1 G-001 SITE PLAN AND LOCATION MAPS

LGP-1.38-0/2 G-002 DRAWING INDEX SHEET

LGP-1.38-0/3 G-003 CONTRACTOR'S WORK TRAILERS

AND OFFICES

LGP-1.38-0/4 G-004 CONTRACTOR WORK AREA

MECHANICAL

LGP-1.38-3-0/1 M-101 GENERATOR ROTOR SPIDER -

GENERAL

LGP-1.38-3-0/2 M-301 GENERATOR ROTOR SPIDER -

SECTIONS & DETAILS

LGP-1.38-3-0/3 M-302 UPPER BEARING BRACKETS

LGP-1.38-3-0/4 M-303 ARM - UPPER BEARING BRACKET

SECTORS 1 & 2

LGP-1.38-3-0/5 M-304 ARM - UPPER BEARING BRACKET

SECTORS 3 & 4

LGP-1.38-3-0/6 M-305 ARM - UPPER BEARING BRACKET

SECTORS 5 & 6

LGP-1.38-3-0/7 M-306 ARM - UPPER BEARING BRACKET

SECTORS 7 & 8

LGP-1.38-3-0/8 M-307 ARM - UPPER BEARING BRACKET

SECTORS 9 & 10

LGP-1.38-3-0/9 M-308 ARM - UPPER BEARING BRACKET

SECTORS 11 & 12

Microstation V8 is the only CAD system used by Walla Walla District.

Contract drawings created on CAD in Microstation V8 will be available in electronic form for use by the Contractor. No For Information Only drawings are available on CAD. The Contractor assumes all risks associated in using electronic CAD 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 CAD drawing. If contract modifications are issued, the associated electronic CAD drawings will not be available to the Contractor. Electronic copies of CAD drawings are only available in Bentley MicroStation format. The Government will provide the files on CD

ROM.

1.3 FOR INFORMATION ONLY DRAWINGS (FIO)

These FIO drawings are included with the drawings for information. The Government does not warrant the accuracy of the FIO drawings. The Government recommends that the Contractor verify the accuracy of FIO drawings.

FIO drawings are as follows:

FILE NUMBER SHEET

NUMBER

DESCRIPTION Revision Number

Date

1123AWF1 FIO-001 64.5 DIA. BEARING SHELL ELEVS

1123AWG1 FIO-002 64.5 DIA. BEARING SHELL PLAN

1123AWJ1 FIO-003 64.5 DIA. BEARING SHELL ELEV

112F291 SHEET 1 FIO-004 OUTLINE OF GENERATOR ELEV

112F291 SHEET 2 FIO-005 OUTLINE OF GENERATOR PLAN

112F292 FIO-006 MAIN & NEUTRAL LEAD TERMINATIONS

114F413 FIO-007 GENERATOR ASSEMBLY SECTION

122C8382 FIO-008 LIFTING DEVICE FOR GEN. SHAFT ONLY

135D5130 FIO-009 LIFTING DIAGRAM FOR ROTOR & GEN. SHAFT

135D5131 FIO-010 LIFTING DIAGRAM FOR MAJOR GEN. PARTS

135D5293 FIO-011 UPPER BEARING BRACKET HUB

135D5295 FIO-012 UPPER BEARING BRACKET ARM

135D5324 FIO-013 STATOR BAR WINDING

FILE NUMBER SHEET

NUMBER

DESCRIPTION Revision Number

Date

135D5327 FIO-014 SHIPPING WEIGHTS & DIMENSIONS/SECTIONS

135D5471 FIO-015 LIFTING DEVICE FOR UPPER BEARING

BRACKET

167C7704 FIO-016 THRUST BEARING 45x118

167C825 FIO-017 ADAPTER FOR ROTOR ERECTION SOLEPLATE

3743ANA2 FIO-018 PACKING BOX

3821UN5 FIO-019 PACKING GLAND FOLLOWER

4034OE1 FIO-020 TURBINE GUIDE BEARING OIL BASIN

SECTION

4062ANZ FIO-021 TURBINE SHAFT SUPPORT

437HA170A FIO-022 MAINTENANCE PROCEDURE

437HA170B FIO-023 MAINTENANCE PROCEDURE

437HA170E FIO-024 MAINTENANCE PROCEDURE

437HA170H FIO-025 MAINTENANCE PROCEDURE

437HA170K FIO-026 MAINTENANCE PROCEDURE

43910 (AS-BUILT) FIO-027 52" DIA TURBINE SHAFT

4460OTI FIO-028 DISTRIBUTER SECTION 312 IN. 6XARH

TURBINE

4834AQT1 FIO-029 COOLING WATER, MAIN BRG, & PACKING

BOX DETAILS

544E6062 FIO-030 STATOR CONNECTIONS

554E588 FIO-031 STATOR BAR DIAGRAM

554E6061 FIO-032 STATOR CONNECTIONS INTERNAL

554E641A FIO-033 OIL AND WATER PIPING TO BEARINGS

5852-IU-1 FIO-034 SLEEVE FOR 52" DIAMETER SHAFT

75-133-10 FIO-035 PIPING TERMINATIONS

75-133-58 FIO-036 OIL COOLER OUTLINE DRAWING

135D5481 FIO-037 HIGH PRESSURE LIFT SYSTEM

135D5481 FIO-038 HIGH PRESSURE LIFT SYSTEM - PARTS

LIST A

FILE NUMBER SHEET

NUMBER

DESCRIPTION Revision Number

Date

135D5481 FIO-039 HIGH PRESSURE LIFT SYSTEM - PARTS

LIST B

70-12675 FIO-040 (12)-118" OD x 45" ID x 2.340" THICK

SEGMENTED THRUST SHOES

10-205-000-04 FIO-041 ROTOR POLE DIMENSIONS

LGP-1-4-2/62 FIO-042 POWERHOUSE GENERATOR BAYS -

REINFORCEMENT INTAKE BASE SLAB-PIER

DOWELS

LGP-1-4-3/1 FIO-043 POWERHOUSE ERECTION BAY - CONCRETE

OUTLINE TRANSVERSE SECTION THRU SUMPS

LGP-1-4-3/3 FIO-044 POWERHOUSE ERECTION BAY - CONCRETE

OUTLINE LONGITUDINAL SECTION

LGP-1-4-3/10 FIO-045 POWERHOUSE ERECTION BAY-CONCRETE

OUTLINE PLAN - EL. 542

LGP-1-4-3/11 FIO-046 POWERHOUSE ERECTION BAY - CONCRETE

OUTLINE PLAN - EL. 558

LGP-1-4-3/96 FIO-047 POWERHOUSE ERECTION BAY -

REINFORCEMENT PLAN - FLOOR EL. 558 -

SHEET 1

LGP-1-4-3/97 FIO-048 POWERHOUSE ERECTION BAY -

REINFORCEMENT PLAN - FLOOR EL. 558 -

SHEET 2

16-00027-5-1 FIO-049 118" (12X) NON-KI THR SHOE SET

-- End of Document --

DOCUMENT 00 01 15.00 28

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SECTION TABLE OF CONTENTS

DIVISION 42 - PROCESS HEATING, COOLING, AND DRYING EQUIPMENT

SECTION 42 13 19.01 26

THRUST BEARING OIL COOLERS

PART 1 GENERAL

1.1 SUMMARY OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Verification of Dimensions

1.4.2 Product Data

1.4.3 Drawings

1.5 PROTECTION OF WORK

1.5.1 Protection of Pipe, Coolers, and Related Materials

1.5.2 Protection of Existing Work

1.6 DISSIMILAR METALS

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Materials

2.1.2 Standard Products

2.1.3 Finned Tube Supplier Qualifications

2.2 BOLTS, NUTS, AND WASHERS

2.3 NAMEPLATES

2.4 THRUST BEARING COOLERS

2.4.1 Design of New Thrust Bearing Coolers

2.4.2 Cooler Frame

2.4.3 Gaskets

2.4.4 Cooling Water

2.4.5 Oil Flow

2.5 ASSOCIATED PIPING

2.5.1 Piping

2.5.2 Gate Valve

2.5.3 Flow Meter

2.6 PIPE JOINT MATERIALS

2.6.1 Flange Gaskets

2.6.2 Brazing Material

2.6.3 Brazing Flux

2.6.4 Flanged Fittings

2.7 PIPE HANGERS AND SUPPORTS

2.8 PIPE INSULATION

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 Fabrication General

3.1.2 Welding

3.2 PIPING

3.2.1 Di-electric Connections

3.3 EXISTING COOLER REMOVAL

SECTION 42 13 19.01 26

3.4 SHOP ASSEMBLY

3.5 INSTALLATION

3.6 SHOP PRESSURE TEST

3.6.1 Shop Pressure Test Plan

3.6.2 Shop Pressure Test Report

3.7 ASSOCIATED PIPING FLUSHING AND PRESSURE TEST

3.7.1 Flushing

3.7.2 Pressure Testing

3.7.3 Pipe Pressure Test Plan

3.7.4 Pipe Pressure Test Report

3.8 FIELD PRESSURE TEST

3.8.1 Field Pressure Test Plan

3.8.2 Field Pressure Test Report

3.9 OPERATIONAL TEST

3.10 OPERATION AND MAINTENANCE (O&M) DATA

-- End of Section Table of Contents --

SECTION 42 13 19.01 26

THRUST BEARING OIL COOLERS

PART 1 GENERAL

1.1 SUMMARY OF WORK

This section governs the removal of existing, as well as provision and installation of new thrust bearing oil coolers and associated piping for Unit 5. It is of General Electric design, and the original manufacturer's drawing is included in the FIO set.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B88 (2009) Standard Specification for Seamless Copper Water Tube

ASTM C534/C534M (2011) Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form

ASTM E84 (2012a) Standard Test Method for Surface Burning Characteristics of Building Materials

ASTM F2329 (2013) Zinc Coating, Hot-Dip, Requirements for Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners

AMERICAN WELDING SOCIETY (AWS)

AWS A5.8/A5.8M (2011) Specification for Filler Metals for Brazing and Braze Welding

ASME INTERNATIONAL (ASME)

ASME B16.21 (2011) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B16.22 (2001; R 2010) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ASME B16.24 (2011) Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes 150, 300, 600, 900, 1500, and 2500

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-80 (2008) Bronze Gate, Globe, Angle and Check Valves

UNDERWRITERS LABORATORIES (UL)

UL 723 (2008; Reprint Sep 2010) Test for Surface Burning Characteristics of Building Materials

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Drawings; G, HDC

Submit 60 calendar days following the date of formal written authorization to proceed for coolers, paragraph "Drawings"

SD-03 Product Data

Descriptive Literature and Specifications; G, HDC

Submit with drawings showing the component, or with piping layout drawings containing the component, paragraph "Product Data"

SD-06 Test Reports

Shop Pressure Test Report; G, HDC

Submit within 7 calendar days of performing testing, paragraph "Shop Pressure Test Report"

Field Pressure Test Report; G, HDC

Submit within 7 calendar days of performing testing, paragraph "Field Pressure Test Report"

Pipe Pressure Test Report; G, HDC

SECTION 42 13 19.01 26

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Submit within 7 calendar days of performing testing, paragraph "Field Pressure Test Report"

Operational Test Report; G, HDC

Submit within 30 calendar days of performing testing, paragraph "Operational Test"

SD-07 Certificates

Finned Tube Supplier Qualifications; G, HDC

Submit 140 calendar days following the date of formal written authorization to proceed for coolers, paragraph "Finned Tube Supplier Qualifications"

Shop Pressure Test Notification; I, HDC

Submit a minimum of 30 calendar days prior to the date scheduled for the test, paragraph "Shop Pressure Test"

SD-08 Manufacturer's Instructions

Shop Pressure Test Plan; G, HDC

Submit 30 calendar days prior to testing, paragraph "Shop Pressure Test Plan"

Field Pressure Test Plan; G, HDC

Submit 30 calendar days prior to testing, paragraph "Field Pressure Test Plan"

Pipe Pressure Test Plan; G, HDC

Submit 30 calendar days prior to testing, paragraph "Pipe Pressure Test Plan"

1.4 QUALITY ASSURANCE

1.4.1 Verification of Dimensions

Become familiar with details of the work and advise the Contracting Officer of any discrepancy before performing any work. The new coolers are interfacing with existing equipment and must fit in the existing thrust tub.

1.4.2 Product Data

Submit complete, Descriptive Literature and Specifications for each manufactured product used in the coolers. Include original, legible, manufacturer's cut sheets and data sheets that clearly indicate physical construction, operation, mechanical and structural characteristics, and associated hardware, as applicable. For data sheets with extraneous data, clearly indicate which data applies by crossing out other models, or circling or highlighting the correct options. Product data must clearly show conformance with these Specifications, including, but not limited to:

product manufacturers' declarations of conformance to applicable technical standards. Submit product data concurrent with the shop drawings.

1.4.3 Drawings

Drawings of Contractor supplied components (coolers, valves, etc) including drawings showing installation and piping details shall be submitted. The drawings shall show the complete fabrication, assembly, and installation details of the coolers. Show detail views, with appropriate tolerances and material callouts for all fabricated parts.

Include a bill of materials or parts list on the drawings.

1.5 PROTECTION OF WORK

1.5.1 Protection of Pipe, Coolers, and Related Materials

Handle coolers to prevent damages including, but not limited to, dents and scratches. Tightly cover openings on cooler flanges with caps or plugs during shipping to prevent entry of foreign material. Protect coolers against dirt, water, and chemical or mechanical damage.

1.5.2 Protection of Existing Work

Before beginning any dismantling, drilling, cutting, removal, or other modification of existing work, take precautions to ensure against damage to the existing systems or structures. Repair any damage to such existing systems or structures.

1.6 DISSIMILAR METALS

Electrically isolate all dissimilar metals from one another, including bolts, nuts and washers. The isolation must prevent electrical current flow between adjacent parts. The material of the isolation means must be suited for the service and atmosphere it is placed in. Clearly show on the shop drawings how dissimilar metals are isolated.

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Materials

Materials and equipment must conform to the requirements of these specifications. When materials and equipment are specified to be replaced in kind, at minimum they must be of equal design as existing equipment being replaced, unless specified otherwise.

Any materials required which are not covered in the drawings or these specifications must conform to applicable specifications. In cases where material is not covered by one of the listed specification groups, furnish the highest commercial grade of material or product available.

2.1.2 Standard Products

Provide materials and equipment that are the standard products of manufacturers regularly engaged in the manufacture of such products.

Items of equipment provided must essentially duplicate equipment that has been in satisfactory use at least 2 years prior to bid opening.

2.1.3 Finned Tube Supplier Qualifications

The supplier of the finned tubes must have been in the business of producing finned tubes as specified herein for at least 2 years prior to bid opening. During that time, the finned tube supplier must have produced finned tubing for similar submerged oil types of coolers for hydroelectric generating units that are specified in this section.

Submit the qualifications and resume of the finned tube supplier. The finned tube supplier qualifications submittal shall include examples and references for coolers that have been successfully installed.

2.2 BOLTS, NUTS, AND WASHERS

Provide bolts, nuts, and washers per SECTION: 05 50 04.20 26 METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS. Provide bolts, nuts, and washers used on piping systems per SECTION: 40 05 13.96 26

PIPING AND EQUIPMENT.

Unless specified otherwise, bolts, nuts and washers that are in contact with, or joining stainless steel parts must be made from stainless steel.

Carbon steel bolts, nuts and washers must be hot-dip galvanized in accordance with ASTM F2329.

2.3 NAMEPLATES

Provide a nameplate for each cooler that is permanently affixed to the cooler. Make the nameplates from corrosion and oil resistant material.

Emboss or engrave the letters on to the nameplates. Nameplates must contain the following information, at a minimum:

a. Manufacturer name, address, and phone number;

b. Serial Number;

c. Model Number;

d. Manufacture date;

e. Maximum allowable working pressure, at temperature;

f. Weight, empty;

g. Weight, full of water;

2.4 THRUST BEARING COOLERS

2.4.1 Design of New Thrust Bearing Coolers

Fabricate the new thrust bearing oil coolers in accordance with the details shown on the reference drawing.

The new coolers must fit in the existing thrust tubs. The only modifications to the thrust hubs that are allowed are for mounting of the cooler frames and connections to the cooling water supply and drain lines.

2.4.2 Cooler Frame

Make the cooler frame from carbon steel. The frame must support the weight of the full coolers. Design the frames to utilize the existing mounting points in the thrust tubs as much as possible.

2.4.3 Gaskets

Make gaskets out of rubber that is compatible with the fluids it will be exposed to (i.e. oil resistant). Acceptable materials include, but are not limited to, neoprene, buna-n, or viton.

2.4.4 Cooling Water

All available cooling water is from a gravity supply. Use the existing thrust tub penetrations for the cooling water supply and drain. Provide flanged connections to connect the coolers to the piping.

2.4.5 Oil Flow

All oil flow and movement within the tub is due to the spinning action of the thrust bearing. Addition of power circulators or other forced circulation devices to increase oil flow is not allowed.

2.5 ASSOCIATED PIPING

2.5.1 Piping

Piping shall be seamless copper tubing conforming to ASTM B88, type K solder joint. Fittings shall be wrought copper solder joint conforming to ASME B16.22 . Flange gaskets shall be fiber, plastic, or other synthetic material suitable for the service. Flanges shall conform to ASME B16.24 , Class 150.

2.5.2 Gate Valve

Gate valves shall be MSS SP-80 , class 150 or higher and shall be suitable for river water application.

2.5.3 Flow Meter

The existing flow meter and orifice flanges are to be reused. Install new pipe to flow meter and verify proper operation of meter.

2.6 PIPE JOINT MATERIALS

2.6.1 Flange Gaskets

Flange Gaskets: Gaskets shall be made of non-asbestos material in accordance with ASME B16.21 . Gaskets shall be flat, 1/16 inch thick, and contain Aramid fibers bonded with Styrene Butadiene Rubber (SBR) or Nitro Butadiene Rubber (NBR). Gaskets shall be the full face or self centering flat ring type.

2.6.2 Brazing Material

Brazing Material: Brazing material shall conform to AWS A5.8/A5.8M , BCuP-5.

2.6.3 Brazing Flux

Brazing Flux: Flux shall be in paste or liquid form appropriate for use with brazing material. Flux shall be as follows: lead-free; have a 100 percent flushable residue; contain slightly acidic reagents; contain potassium borides; and contain fluorides.

2.6.4 Flanged Fittings

Flanged fittings including, but not limited to, flanges, bolts, nuts and bolt patterns shall be in accordance with ASME B16.5 class 150 and shall have the manufacturer's trademark.

2.7 PIPE HANGERS AND SUPPORTS

Pipe hangers, inserts, and supports shall conform to MSS SP-58

2.8 PIPE INSULATION

Pipe insulation shall be flexible elastomeric cellular complying with ASTM C534/C534M, Grade 1, Type I. Pipe insulation shall be at least 1 inch thick. Insulation must have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E84. Flame spread, and smoke developed indexes, shall be determined by ASTM E84 or UL 723 .

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 Fabrication General

Fabricate one (1) thrust bearing cooler assembly for Unit 5

3.1.2 Welding

Perform welding of pipe for the thrust bearing cooler assemblies per

40 05 13.96 26 WELDING, PIPING.

3.2 PIPING

The supply and return copper tubing between the thrust bearing coolers and the main steel headers shall be removed and replaced with new copper tubing. New gasket material shall be provided for the flange connections . Di-electric unions shall be installed between the copper piping and the steel supply and return headers.

3.2.1 Di-electric Connections

a. Any connections between dissimilar metals shall be made with di-electric unions or insulated flanges.

b. Insulated flange connections (typically for pipe 3 inches and larger) shall prevent electrical current flow between the adjacent flanges. The insulation parts shall include flange gasket, bolt sleeves, and washers. Special flanges shall be provided if necessary.

All parts shall be suitable for the required operating pressure, temperature,and fluid.

c. Dielectric unions (typically for pipe 3 inches and smaller) shall be made of two dissimilar metals that will isolate any current flow between the union and the ends shall match the materials and connection type of the new or existing piping or equipment.

3.3 EXISTING COOLER REMOVAL

Remove the existing internal thrust bearing oil coolers. This includes, but is not limited to, plate heat exchangers, pumps, motors, valving, piping, supports, instrumentation, controls, and other electrical equipment. Dispose of the existing coolers and equipment in a manner that complies with all National and Local regulations.

3.4 SHOP ASSEMBLY

Fully assemble the thrust bearing oil coolers at the fabricator's shop before shipping. Ship coolers fully assembled. Repair any damage, such as bent fins, before shipping the coolers. Prepare and package the coolers for shipping in a way that prevents the coolers from being damaged in transit. Package the spare cooler assemblies in packaging designed for long term storage.

3.5 INSTALLATION

Install the cooler assembly into the thrust tubs to result in a cooler assembly having the same functionality that existed prior to unit refurbishment. Connect the coolers to the new supply and return piping.

Provide new hardware and gaskets at all connections.

Protect the new coolers and existing construction from damage during installation. Repair any such damage at no additional cost to the Government.

3.6 SHOP PRESSURE TEST

Pressure test each cooler section before shipping the coolers to the job site. The Government will witness the test. Submit a shop pressure test notification to the Government. Provide all equipment, materials, and personnel required to complete the pressure tests. During the test, orient and support the coolers in the same manner that they will be installed in.

The test must be a static pressure test, using water as the test medium.

Use a test pressure of 150% the operating pressure. Use a test period of a minimum of one hour. The criteria for a successful test is: zero drop in pressure and zero leaks. Any drop in pressure or leak from the cooler will result in a failed test. If a leak is discovered during testing, repair the leak and re-perform the test in full.

3.6.1 Shop Pressure Test Plan

Submit a Shop Pressure Test Plan that includes the following elements at a minimum:

a. Date and planned location test will take place;

b. Name and contact information for Contractor point of contact that will be conducting the test;

c. Make, model, serial number, and up-to-date calibration certificates for each instrument to be used in the test;

d. Drawings or sketches that show the support fixtures and how the coolers will be connected to the pressure supply;

e. A detailed, step-by-step, repeatable testing procedure;

f. A blank copy of the form that certifies a successfully completed test.

3.6.2 Shop Pressure Test Report

Submit a Shop Pressure Test Report that includes the following elements at a minimum:

a. Date and location test took place;

b. Identify the type and quantity of coolers tested that are covered by the report;

c. Certification of successful test completion for each cooler tested;

d. If a leak was discovered during the test, note the location of the leak and the measures taken to fix it.

3.7 ASSOCIATED PIPING FLUSHING AND PRESSURE TEST

3.7.1 Flushing

After installation the new supply and return copper tubing between the thrust bearing coolers and the main steel headers shall be flushed to remove accumulated construction debris and other foreign matter before connection to the thrust bearing coolers are made. The piping shall be flushed until all foreign matter is removed from the pipeline. The flushing fluid shall be water.

Provide all hoses, temporary pipes, and other items as required to properly dispose of flushing water without damage to adjacent properties. The minimum flushing velocity shall be 2.5 fps. Cone strainers shall be installed in the flushing connections of attached equipment and left in place until cleaning is completed. Remove strainers and accumulated debris after cleaning is completed.

3.7.2 Pressure Testing

After installation the new supply and return copper tubing between the thrust bearing coolers and the main steel headers shall be pressure tested before connection to the thrust bearing coolers are made.The test fluid shall be water. the Contractor shall provide all personnel, pressure sources, test fluids, instrumentation, and any other items needed to successfully complete testing.

The test pressure shall be 1.5 times the operating pressure. The test pressure shall be maintained continuously for 60 minutes minimum and for such additional time as necessary to conduct examinations for leakage. All joints and connections shall be examined for leakage. The piping system, exclusive of possible localized instances at valve packing, shall show no visual evidence of leaking. The criteria for a successful test is zero leaks. Any leak that is discovered will result in a failed test. If a leak is discovered during testing, repair the leak and re-perform the test in full

3.7.3 Pipe Pressure Test Plan

Submit a Pipe Pressure Test Plan that includes the following elements at a minimum:

a. Date test will take place;

b. Name and contact information for Contractor point of contact that will be conducting the test;

c. Make, model, serial number, and up-to-date calibration certificates for any instrument to be used in the test;

d. A detailed, step-by-step, repeatable testing procedure;

e. A blank copy of the form that certifies a successfully completed test.

f. Method for disposal of pressure test water.

3.7.4 Pipe Pressure Test Report

Submit a Pipe Pressure Test Report that includes the following elements at a minimum:

a. Date test took place;

b. Certification of successful test completion for each cooler tested;

c. If a leak was discovered during the test, note the location of the leak and the measures taken to fix it.

3.8 FIELD PRESSURE TEST

Pressure test the coolers after they have been installed on-site. Perform the test before the thrust tub has been filled with oil and before the unit has been reassembled to a point where the coolers are not accessible. The Government will witness the test. Provide all equipment, materials, and personnel required to complete the pressure tests.

Perform the pressure test using the cooling water supply at normal operating conditions: flow rate and pressure. Use a test period of a minimum of one hour. The criteria for a successful test is zero leaks.

Any leak from the cooler or the connection to the supply piping will result in a failed test. If a leak is discovered during testing, repair the leak and re-perform the test in full.

3.8.1 Field Pressure Test Plan

Submit a Field Pressure Test Plan that includes the following elements at a minimum:

a. Date test will take place;

b. Name and contact information for Contractor point of contact that will be conducting the test;

c. Make, model, serial number, and up-to-date calibration certificates for any instrument to be used in the test;

d. A detailed, step-by-step, repeatable testing procedure;

e. A blank copy of the form that certifies a successfully completed test.

f. Method for disposal of pressure test water.

3.8.2 Field Pressure Test Report

Submit a Field Pressure Test Report that includes the following elements at a minimum:

a. Date test took place;

b. Certification of successful test completion for each cooler tested;

c. If a leak was discovered during the test, note the location of the leak and the measures taken to fix it.

3.9 OPERATIONAL TEST

Perform an operational test during the unit operational tests described in Section 48 13 13.02 26once the unit has been fully reassembled and is returned to service. The purpose of the operational test is to verify satisfactory performance of the new coolers.

Perform the test after the unit has been brought online to 100% rated output and temperatures of the bearings and generator have reached steady state conditions.

Submit an Operational Test Report that verifies that the new coolers meet the specifications. Include in the report a narrative that explains the process to collect the data as well as an evaluation of the results.

3.10 OPERATION AND MAINTENANCE (O&M) DATA

In addition to the standard requirements for operation and maintenance data submittals, include the following in the Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA, required O&M data:

a. All SD-05 calculation packages

b. All SD-06 test reports

-- End of Section --

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 16.01 26

GENERATOR STATOR, ROTOR, AND UPPER BEARING BRACKET REPAIR AND TESTING

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 GENERATOR

1.4.1 General Information

1.4.2 Description of Unit Condition

1.5 VERIFICATION OF DIMENSIONS

PART 2 PRODUCTS

2.1 MATERIALS

2.2 Equipment for Supporting the Weight of the Rotor Rim and Poles

PART 3 EXECUTION

3.1 GENERAL

3.2 INSTALLATION SUPERVISOR

3.3 GENERATOR WORK

3.3.1 General

3.3.2 Preparation for Work

3.3.2.1 Procedure for Supporting the Weight of Rotor Rim and Poles

3.3.3 Cleaning and Inspection

3.3.3.1 Stator Frame

3.3.3.2 Stator Winding

3.3.3.3 Rotor

3.3.4 Testing

3.3.4.1 Stator Winding

3.3.4.2 Rotor

3.4 ROTOR STRESS ANALYSIS

3.5 REPAIR WELDING

3.5.1 Rotor Spider Repairs

3.5.2 Upper Bearing Bracket Repairs

3.5.3 Weld Repair Verification

3.6 STRENGTHENING OF ROTOR SPIDER

-- End of Section Table of Contents --

SECTION 48 13 16.01 26

SECTION 48 13 16.01 26

GENERATOR STATOR, ROTOR, AND UPPER BEARING BRACKET REPAIR AND TESTING

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This section covers the repair to the Unit 5 generator at Little Goose Lock & Dam. The Section covers the following work:

(1) Inspect the stator; inspect and test the rotor;

(2) Conduct a Finite Element Analysis (FEA) of the generator rotor spider (including Government proposed strengthening);

(3) Perform weld repair of cracks in the rotor spider arms and upper bearing bracket;

(4) Strengthen the generator rotor spider.

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.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

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

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME BPVC SEC VIII D2 (2010) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 2-Alternative Rules

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

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

Generator Inspection and Cleaning Procedure; G, HDC Within 15 calendar days of receipt of written Notice to Proceed.

Generator Test Procedures; G, HDC Within 15 calendar days of receipt of written Notice to Proceed.

Procedure for Weld Repair of Rotor; G, HDC Within 30 calendar days of completed generator inspection.

Procedure for Weld Repair of Upper Bearing Bracket; G, HDC Within 30 calendar days of completed generator inspection.

Procedure for Strengthening the Rotor; G, HDC Within 30 calendar days of completed generator inspection

Procedure for Supporting the Weight of Rotor Rim and Poles; G, HDC Within 45 calendar days of completed generator inspection.

SD-03 Product Data

Equipment for Supporting the Weight of the Rotor Rim and Poles; G, HDC

In conjunction with "Procedure for Supporting the Weight of Rotor Rim and Poles"

SD-05 Design Data

Rotor Stress Analysis; G, HDC Within 9 weeks after Notice to Proceed.

Rotor Stiffener Design; G, HDC

SD-06 Test Reports

Test Reports; G, HDC Within 5 calendar days after the inspection.

Rotor Spider Material Properties; G, HDC

Upper Bearing Bracket Material Properties; G, HDC

1.4 GENERATOR

1.4.1 General Information

Little Goose Unit 5 was manufactured by General Electric and brought on line in 1978. It is a vertical, salient pole, air-cooled (with air water heat exchangers) generator rated as follows:

142,105 kVA with 115% overload capability

0.95 power factor

13.8 kV 3-phase 60 Hz 90 rpm 80 poles 732 slots in stator 37'-10.25" rotor diameter with 12 arms 0.645" nominal air gap

5,945 A full load current 785 A rated excitation current 375 Vdc rated excitation voltage

1.4.2 Description of Unit Condition

Within the past decade, cracks have been observed in the rotor spider and upper bearing bracket of Little Goose Unit 5. Additionally, the unit has exhibited a high level of vibration, which likely contributed to the cracked in the upper bearing bracket. The symptoms can be improved by correcting bearing shoe clearances, performing some level of unit alignment, repairing and strengthening the rotor spider, and repairing the upper bearing bracket. The generator field winding, stator winding, and stator core are in good condition. The stator was rewedged with ripple in 2002.

1.5 VERIFICATION OF DIMENSIONS

The Contractor shall be responsible for obtaining and verifying dimensions and other information, including information contained in this specification that may be required for implementation of the contract repair. Discrepancies between information given in this document and information developed by the Contractor 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. The Contractor may use any equipment, material, or article, which in the judgment of the Contracting Officer, is equal to that named.

2.2 Equipment for Supporting the Weight of the Rotor Rim and Poles

Lifting equipment may be either of the hydraulic or acme screw jack. If the equipment is hydraulically controlled, supply all hydraulic pressure hoses, jacks, fittings, manifold, and hydraulic power unit. Hydraulic lifting equipment shall only be used to achieve the lift, and cribbing shall be used to firmly support the load at the desired level of lift during all welding and NDE operations. Screw jacks, however, may be used for both lifting and holding operations, provided that calculations show capacity of the jack design to hold the load, with a factor of safety of 2 on the proposed jack's rated holding load.

If hydraulic equipment is used, the jacks shall have near-equal length hydraulic hoses with appropriate provisions to ensure the jacks are equally and simultaneously loaded. Pressure gauges shall be mounted at each jack to monitor pressure during jacking operations.

PART 3 EXECUTION

3.1 GENERAL

The following items are required for implementation of the repair to Unit 5 and are specific to this section of the contract.

3.2 INSTALLATION SUPERVISOR

The representative of the Contractor who is technically qualified to supervise the repair and other specified work shall be present at the work site during the entire job. This representative shall report immediately in writing to the Contracting Officer any work not in accordance with the contract specifications, approved repair procedures, industry practice or any special conditions which may result in an unsatisfactory work.

3.3 GENERATOR WORK

3.3.1 General

Prior to commencement of any work on the stator and rotor, submit for approval the Generator Inspection and Cleaning Procedure and Generator Test Procedures. In the procedures, cover all portions of the generator work including cleaning of stator and rotor, inspection of stator and rotor, testing of stator and rotor, and disposal of trash resulting from the cleaning activities. Following completion of an inspection, submit for approval an findings in the inspection report; include any discovered issues that require repair and recommend repairs.

3.3.2 Preparation for Work

Once the rotor is removed from the stator housing, place the rotor on the rotor erection pedestal identified on drawing G-004.

3.3.2.1 Procedure for Supporting the Weight of Rotor Rim and Poles

At a minimum for this procedure, provided a description (and any helpful or necessary diagrams or drawings) of the method for supporting the weight of the rotor rim during welding repair. Ensure the chosen methodology fully supports the weight of the rim, but does not lift above the spider arms' neutral stress axis, such that the spider arms experience minimal to zero stress due to self-weight, pole weight, or rim weight. This is to be done without the removal of rim keys, and while the rim is still attached to the spider. Use the FEA model required in 48 13 16.01 26 to validate and demonstrate effectiveness of the support plan in minimizing stresses due to self-weight. Include the following details:

A. Any necessary cribbing or blocking plans in order to ensure that the generator shaft weight is fully supported, and is not exerting stress on the rotor spider during the repairs.

B. Provisions to measure the amount of lift on the arms, provisions to show zero lift at the hub (directly above the rotor erection pedestal). Rotor shall not be firmly bolted to pedestal.

C. As indicated on the contract drawing, the deck is designed to support a 1000 PSF uniform load. Concentrated loads exceeding 1000 PSF require government approval. Provide structural deck loading calculations to demonstrate that the structure will not be overloaded

SECTION 48 13 16.01 26

by the planned support methodology. Cribbing will not be permitted to load hatch covers. Analyze the deck using ACI 318 (2014), assume a concrete strength of 3000 psi, and a reinforcement strength of 40ksi.

See the provided concrete outline and reinforcement for information only (FIO) drawings for additional analysis information.

D. Calculations and diagrams to demonstrate capabilities of the hydraulic or screw jacking system to support the load of the rim and pole weights. If hydraulic jacks are proposed, include a system design shematic, indicating all pressure gauges, check valves, and hose type (length, rating, and material).

3.3.3 Cleaning and Inspection

The Contractor shall perform inspections on the accessible areas of the stator frame, clamping system, stator core, stator winding,and rotor in accordance with approved procedure. Report condition, problems to be corrected, and recommendations for correcting problems. Following inspections, the generator shall be cleaned. Materials and products for cleaning shall be identified in the procedure. Include Upper Bearing Bracket inspection in this effort, to be included in the Generator Inspection and Cleaning Procedure

3.3.3.1 Stator Frame

The stator frame shall be inspected and cleaned. The stator sole plate area, and radial dowels shall be examined for general condition and for evidence of abnormal movement. Stator hold-down bolt torques shall be checked to ensure that excessive torque does not constrain normal stator radial expansion and contraction. The Contractor shall include methods for releasing and checking torque and allowable torque values in the generator inspection procedures.

3.3.3.2 Stator Winding

Begin cleaning at the top of the winding, dry wipe and HEPA vacuum all end turns and bus work down to the top of the core. Wipe and HEPA vacuum the face of the core and back iron. Dry wipe and HEPA vacuum the bottom end turns of the windings up to core. Following the cleaning, the inspection shall include the following items, which shall be outlined in the submitted procedure.

a. Wedging System Inspection. The deflection of the spring-type filler material shall be measured at each check wedge and recorded.

b. Lashing and Blocking. The winding lashing and blocking shall be inspected for damage due to excessive vibration and distortion under stresses.

Include recommended corrective actions in the inspection report.

3.3.3.3 Rotor

The Contractor shall follow the approved procedure for inspecting and cleaning the rotor. For cleaning, a shroud shall be placed around the rotor to contain dust. Begin at the top of the rotor, dry wipe and HEPA vacuum all exposed surfaces. Cleaning solvents can then be used to remove the remaining dust. Following cleaning, the inspection shall include all mechanical components, such as the rotor spider, rotor rim, rim keys, SECTION 48 13 16.01 26 brake plate, pole keys, keeper plates, fan blades, etc., in addition to the field windings and connectors. Include recommended corrective actions in the inspection report.

3.3.4 Testing

Testing shall be performed in accordance with the approved Generator Test Procedures. All tests shall be performed twice; before and after cleaning and repairs. Test Reports shall be submitted for all tests. Electrical tests shall include those identified in paragraphs "Stator Winding" and "Rotor" below. Major equipment for testing shall be identified in the procedures for which they will be used.

3.3.4.1 Stator Winding

The following stator winding tests shall be performed in accordance with the approved procedure:

a. Stator Winding Resistance Measurements. Accurate stator winding resistance measurements shall be made on each phase of the stator winding. Within one hour of these measurements, accurate temperature measurements shall be made from each of the stator winding embedded temperature detector readings. The average of the temperature detector readings shall be considered to be the stator ambient temperature at the time of the stator winding resistance measurements and shall be used to calculate the stator winding resistance at 75°C.

b. Insulation Resistance and PI Tests. Insulation Resistance and Polarization Index Tests shall be made on each phase of the stator as described in IEEE 43 , with the exceptions noted below, in accordance with the approved Test Procedures. In all cases, the phases not under test shall be solidly grounded. Tests shall be made at 10,000 Vdc.

Winding insulation resistance at one minute shall be not less than 100 megohms, corrected to 40°C. If it is greater than 1,000 megohms, corrected to 40°C, the test need not continue. If it is less than 1,000 megohms, corrected to 40°C, the testing shall continue for 10 minutes and the polarization index (PI) shall be calculated. If PI is not greater than 2, it should be brought to the attention of the Government.

3.3.4.2 Rotor

The following field winding tests shall be performed in accordance with the approved procedure:

a. Insulation Resistance. Insulation resistance shall be measured between winding and ground at 500 Vdc. The test shall be run for 10 minutes. The insulation resistance readings and Polarization Index (PI) shall be recorded and submitted.

b. Voltage Drop Test. An AC voltage shall be applied across the first and last field pole of the rotor and the voltage appearing across each coil measured and recorded. The proposed test voltage and allowable pole voltage drop variations shall be included in the test procedure.

3.4 ROTOR STRESS ANALYSIS

Submit analysis in the form of a technical report for approval. Outline required modifications to the rotor spider. Simulate the incorporation of the recommended stiffening modifications to the rotor spider. The report shall contain a final analysis comparing the Simulated Analysis Points (below) to the final proposed condition to incorporate and proposed modifications (stress relief cutouts or strengthening stiffeners). The analysis provided by the Contractor will be the basis for the detailed design of the final repair, in order to ensure satisfactory operation of Unit 5 once the repairs are completed.

a. Prior to commencement of any repair work on the generator rotor, the contractor will conduct a rotor stress analysis and receive…