TECHSPECS_17-R-0006_amd0001_14Jul17.pdf

Little Goose Unit 5 Rotor Spider Repair W912EF-17-R-0006 amend 0001

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 01 - GENERAL REQUIREMENTS

SECTION 01 22 00.00 26

MEASUREMENT AND PAYMENT

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 MEASUREMENT

1.2.1 Per Job Payment Items

1.2.2 Unit Price Payment Items

1.2.3 Not to Exceed (NTE) Items

1.2.4 Retainage of Payment

1.3 BASE BID ITEMS

1.3.1 CLIN 0001 Mobilization and Demobilization

1.3.2 CLIN 0002 Pre-Disassembly Operational Testing, Alignment

Checks, and Unit Disassembly

1.3.3 CLIN 0003 Unit Reassembly, Alignment and Post-Assembly

Operational Testing

1.3.4 CLIN 0004 Thrust Bearing Inspection - Phase 1, and High

Pressure Lift System Component Replacement

1.3.5 CLIN 0005 Refurbish One Turbine Guide Bearing Including

Babbitting and Machining

1.3.6 CLIN 0006 Generator Guide Bearing Site Inspection (including spares)

1.3.7 CLIN 0007 Weld Repair, Contouring, and Strengthening - Rotor

Spider and Upper Bearing Bracket

1.3.8 CLIN 0008 NDE Verification and Report - Rotor Spider and

Upper Bearing Bracket

1.3.9 CLIN 0009 FEA Analysis and Verification of Rotor Modifications

1.3.10 CLIN 0010 Generator Inspection, Testing, and Cleaning

1.3.11 CLIN 0011 Install and Test Machine Condition Monitoring

System

1.3.12 CLIN 0012 Supply and Install Thrust Bearing Cooler Assembly

1.4 OPTIONAL BID ITEMS

1.4.1 CLIN 0013 Thrust Bearing Inspection - Phase 2 (Optional)

1.4.2 CLIN 0014 Refurbish One Set of Thrust Bearing Shoes Including

Babbitting and Machining (Optional)

1.4.3 CLIN 0015 Refurbish One Set of Upper Generator Guide Bearing

Shoes Including Babbitting and Machining (Optional)

1.4.4 CLIN 0016 Refurbish One Set of Lower Generator Guide Bearing

Shoes Including Babbitting and Machining (Optional)

1.4.5 CLIN 0017 Refurbish Generator Thrust Bearing Runner and

Collar (OPTIONAL)

1.4.5.1 CLIN 0017AA Stoning of Thrust Bearing Runner Running

Surface

1.4.5.2 CLIN 0017AB Machining of Thrust Bearing Runner Running

Surface.

1.4.5.3 CLIN 0017AC Machining of Thrust Bearing Runner Backside and Running Surface.

1.4.5.4 CLIN 0017AD Refurbishment of Thrust Runner Split Line

1.4.5.5 CLIN 0017AE Refurbishment of Thrust Bearing Runner and

Collar

1.4.6 CLIN 0018 Additional Welding

1.4.7 CLIN 0019 Additional NDE

SECTION 01 22 00.00 26

1.4.8 CLIN 0020 Inspection and Installation of Spare Shaft Sleeve

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION - NOT USED

-- End of Section Table of Contents --

SECTION 01 22 00.00 26

MEASUREMENT AND PAYMENT

PART 1 GENERAL

1.1 GENERAL INFORMATION

In each instance, the contract price for an item constitutes full compensation for furnishing all labor, equipment, and materials, and for performing all operations required to complete the work included in the item as herein specified, or as otherwise approved. Notwithstanding the omission of mention of any incident or incidental work, the contract price and payment also constitutes full compensation for all work incident or incidental to completion of the item, unless such work is otherwise specifically mentioned for separate payment under another Contract Line Item Number (CLIN).

1.2 MEASUREMENT

1.2.1 Per Job Payment Items

Payment items for the work of this contract for which per job payments will be made are listed in the BID SCHEDULE and described below. Include all costs for items of work not specifically mentioned to be included in a particular per job payment item, in the listed item most closely associated with the work involved. The per job price and payment made for each item listed will constitute full compensation for furnishing all plant, labor, materials, and equipment; performing all associated Contractor quality control, environmental protection, commissioning, preparation of working as-built drawing redlines, O&M manuals, tests and reports, meeting safety requirements; and for performing all work required for which separate payment is not otherwise provided.

1.2.2 Unit Price Payment Items

Payment items for the work under this contract on which the contract unit price payments will be made are listed in the BID SCHEDULE and described below. The unit price and payment made for each item listed will constitute full compensation for furnishing all plant, labor, materials, and equipment; performing all associated Contractor quality control, environmental protection, commissioning, preparation of working as-built drawing redlines, O&M manuals, tests and reports, meeting safety requirements; and for performing all work required for each of the unit price items.

1.2.3 Not to Exceed (NTE) Items

The quantity shown in OPTIONAL CLINs 0019 and 0020 are "not to exceed" quantities. Payment includes the actual quantity of the line item ordered and accepted, if any, and will not exceed the quantity shown, as directed by the CO. When so directed by the COR, the Contractor shall furnish materials and labor under CLINs 0019 and 00201 Not to Exceed the amount shown on the bid schedule.

1.2.4 Retainage of Payment

Retainage in the amount of 10% of original contract award amount will be withheld until the final submittals, listed below, have been approved by the Government. The 10% retainage for final submittals will not be held until such time as the Contractor has earned 90% of the original contract value. See SECTION 01 78 00.00 28 "CLOSEOUT SUBNMITTALS" for additional information

1. Final Operation and Maintenance Manauls and Parts Catalogs.

2. Final Approved Versions of Contractor Prepared Drawings.

3. As-built contract drawings nad FIO drawings.

4. Return of Government Issued Items.

1.3 BASE BID ITEMS

1.3.1 CLIN 0001 Mobilization and Demobilization

Payment for site mobilization and demobilization to perform the site work specified herein will be made on a per job basis under CLIN 0001 at a rate of 60 percent for mobilization and 40 percent for demobilization. This bid item covers mobilization to the project site and work preparatory to commencing the pre-disassembly operational and alignment checks to perform the work and the demobilization from the project site to cleanup and restore the site to original condition in accordance with the specificationsas well as for payment and performance bonds.

Mobilization will be considered complete after all of the Contractor's equipment and site personnel have arrived and equipment has been set up to accomplish the work.

Demobilization will be considered complete when the Contractor has removed all construction equipment, cleaned the area, and restored the work area to as-found, pre-contract conditions, unless otherwise approved. Payment includes labor, material, and equipment required for mobilization in accordance with the specifications.

1.3.2 CLIN 0002 Pre-Disassembly Operational Testing, Alignment Checks, and Unit Disassembly

Payment for pre-disassembly operational testing and alignment checks will be made on a per job basis under CLIN 0002. Payment includes labor, material, and equipment required to perform investigations, pre-disassembly operational testing, alignment checks, and unit disassembly in accordance with the specifications. For more information, see Section 48 13 13.02 26

1.3.3 CLIN 0003 Unit Reassembly, Alignment and Post-Assembly Operational Testing

Payment for generating unit reassembly and alignment will be made on a per job basis under CLIN 0003. Payment includes labor, material, and equipment required to reassemble the generating units, alignment, and post-assembly operation testing in accordance with Section 48 13 13.02 26.

1.3.4 CLIN 0004 Thrust Bearing Inspection - Phase 1, and High Pressure Lift System Component Replacement

Payment for thrust bearing inspection (Phase 1) will be made on a per job basis under CLIN 0004. Payment includes all labor, material, and equipment required to inspect the thrust bearing shoes, collar, and runner (rotating ring) in accordance with Section 48 13 13.06 26.

1.3.5 CLIN 0005 Refurbish One Turbine Guide Bearing Including Babbitting and Machining

Payment for refurbishing one turbine guide bearing, including babbitting and machining, skim cutting the split faces, and refurbishing the OD fits, will be made on a per job basis under CLIN 0005. Payment includes labor, material, shipping, and equipment as required in accordance with Section 48 13 13.07 26.

1.3.6 CLIN 0006 Generator Guide Bearing Site Inspection (including spares)

Payment for upper and lower generator guide bearing inspections, including spare sets for both upper and lower, will be made on a per set (or EACH) basis under CLIN 0006. Payment includes all labor, material, and equipment required to inspect the upper and lower generator guide bearing sets (and spares) in accordance with Section 48 13 13.07 26.

1.3.7 CLIN 0007 Weld Repair, Contouring, and Strengthening - Rotor Spider and Upper Bearing Bracket

Payment for weld repair, contouring, and strengthening for both the rotor spider and the upper bearing bracket will be made on a per job basis under CLIN 0007. Payment includes all labor, material, and equipment required to perform weld repairs, contouring, and strengthening in accordance with the drawings, and Section 48 13 16.01 26

1.3.8 CLIN 0008 NDE Verification and Report - Rotor Spider and Upper Bearing Bracket

Payment for NDE verification and report for both the rotor spider and the upper bearing bracket will be made on a per job basis under CLIN 0008.

Payment includes all labor, material, and equipment required to perform NDE verification and report in accordance with Section 48 13 16.01 26

1.3.9 CLIN 0009 FEA Analysis and Verification of Rotor Modifications

Payment for rotor repair will be made on a per job basis under CLIN 0009.

Payment includes all labor, material, and equipment required to perform FEA analysis and verification of rotor modifications in accordance with Section 48 13 16.01 26

1.3.10 CLIN 0010 Generator Inspection, Testing, and Cleaning

Payment for generator inspection, testing, and cleaning will be made on a per job basis under CLIN 0010. Generator work includes insulation resistance and polarization index test on stator winding before disassembly, insulation resistance and polarization index test on rotor, AC pole drop test on field winding, clean rotor, inspect rotor, high-potential withstand test, clean stator winding and core, inspect stator winding, check wedge tightness, inspect stator core, ramped voltage test on stator winding, AC high potential test on stator winding, and insulation resistance test and final AC high potential test on stator winding after reassembly in accordance with Section 48 13 16.01 26.

1.3.11 CLIN 0011 Install and Test Machine Condition Monitoring System

Payment for installing and testing machine condition monitoring system will be made on a per job basis under CLIN 0011. Payment includes all labor, material, and equipment required to perform installation and testing in accordance with Section 48 13 16.03 26

1.3.12 CLIN 0012 Supply and Install Thrust Bearing Cooler Assembly

Payment for supply and installation of thrust bearing coolers, thrust bearing RTDs, high pressure lift hoses, and high pressure lift check valves will be made on a per job basis under CLIN 0012. Payment includes all labor, material, shipping, and equipment required to perform installation and testing in accordance with Section 42 13 19.01 26.

1.4 OPTIONAL BID ITEMS

1.4.1 CLIN 0013 Thrust Bearing Inspection - Phase 2 (Optional)

At the option of the Government, payment for complete thrust bearing shoe sets, collar, and runner (rotating ring) inspection - Phase 2 will be made on a per job basis under CLIN 0013. This work includes. Payment includes labor, material, and equipment as required in accordance with Section 48 13 13.06 26.

1.4.2 CLIN 0014 Refurbish One Set of Thrust Bearing Shoes Including Babbitting and Machining (Optional)

At the option of the Government, payment for refurbishing all thrust bearing shoes for one unit will be made on a per job basis under CLIN 0014. Payment includes labor, material, shipping and equipment as required in accordance with Section 48 13 13.06 26.

1.4.3 CLIN 0015 Refurbish One Set of Upper Generator Guide Bearing Shoes Including Babbitting and Machining (Optional)

At the option of the Government, payment for refurbishing one set of upper generator guide bearing shoes, including babbitting and machining, will be made on a per job basis under CLIN 0015. Payment includes labor, material, shipping, and equipment as required in accordance with Section 48 13 13.07 26.

1.4.4 CLIN 0016 Refurbish One Set of Lower Generator Guide Bearing Shoes Including Babbitting and Machining (Optional)

At the option of the Government, payment for refurbishing one set of lower generator guide bearing shoes, including babbitting and machining, will be made on a per job basis under CLIN 0016. Payment includes labor, material, and equipment as required in accordance with Section 48 13 13.07 26.

1.4.5 CLIN 0017 Refurbish Generator Thrust Bearing Runner and Collar

(OPTIONAL)

1.4.5.1 CLIN 0017AA Stoning of Thrust Bearing Runner Running Surface

At the option of the Government, payment for stoning the running surface

SECTION 01 22 00.00 26

G4EDDMTJ

Line of the thrust runner, while assembled to the collar, will be made on a per job basis under CLIN 0017AA. Payment includes labor, material, and equipment as required in accordance with Section 48 13 13.06 26.

1.4.5.2 CLIN 0017AB Machining of Thrust Bearing Runner Running Surface.

Payment for machining of the thrust runner running surface will be made on a per job basis under Item No. 0017AB at the option of the Government. Payment shall include shipping, labor, material,and equipment required to resurface running surface only of the thrust bearing runner in accordance with Section 48 13 13.06 26.

1.4.5.3 CLIN 0017AC Machining of Thrust Bearing Runner Backside and Running Surface.

Payment for thrust runner resurfacing of backside and running surface will be made on a per job basis under Item No. 0017AC at the option of the Government. Payment shall include shipping, labor, material, and equipment required to resurface backside and running surface of the thrust bearing runner in accordance with Section 48 13 13.06 26.

1.4.5.4 CLIN 0017AD Refurbishment of Thrust Runner Split Line

Payment for refurbishing the thrust runner running split line will be made on a per job basis under Item No. 0017AD at the option of the Government. Payment shall include labor, material, and equipment required to refurbish the split faces of the thrust bearing runner, furnish and install new split line keys, and furnish and install new fasteners in accordance with Section 48 13 13.06 26.

1.4.5.5 CLIN 0017AE Refurbishment of Thrust Bearing Runner and Collar

Payment for refurbishing the thrust collar will be made on a lump sum basis under Item No. 0017AE at the option of the Government. Payment shall include shipping of the collar, machining of the collar mounting face, labor, material, and equipment required to refurbish the thrust bearing collar in accordance with Section 48 13 13.06 26.

1.4.6 CLIN 0018 Additional Welding

At the option of the Government, payment for additional welding will be measured as the total number of cubic inches (900 Cu. In.) completed under CLIN 0018, not to exceed the quantity shown. Payment includes full compensation for performing all preparation for welding, preheat, welding, overwelding as necessary, and finish grinding as required to complete all work required under this contract.

1.4.7 CLIN 0019 Additional NDE

At the option of the Government, payment for additional Non-Destructive Examination (NDE) will be measured as the total number of cubic inches (900 Cu. In)completed under CLIN 0019 not to exceed the quantity shown.

Payment includes full compensation for performing all preparation for testing, interpretation of test results, and clean up as required to complete all work required under this contract.

SECTION 01 22 00.00 26

1.4.8 CLIN 0020 Inspection and Installation of Spare Shaft Sleeve

At the option of the Government, payment for the inspection and installation of the spare shaft sleeve will be made on a per job basis.

Payment includes full compensation labor, material, and equipment required to perform shaft sleeve spare work as described in Section 48 13 13.02 26.

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION - NOT USED -- End of Section --

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 16.03 26

MACHINE CONDITION MONITORING SYSTEM

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 AIR GAP SENSOR AND SHAFT VIBRATION MONITORING SYSTEM

2.1.1 General

2.1.2 Air Gap Sensors

2.1.3 Shaft Vibration Sensor

2.1.4 Key Phasor Probe (Synchro)

2.1.5 Processing Unit

2.1.6 Alarm Relay Extension Panel

2.1.7 Controller and Diagnostic Software

PART 3 EXECUTION

3.1 OPERATION AND MAINTENANCE DATA

-- End of Section Table of Contents --

SECTION 48 13 16.03 26

SECTION 48 13 16.03 26

MACHINE CONDITION MONITORING SYSTEM

PART 1 GENERAL

1.1 SUMMARY

This section covers the supply, installation, and testing of a machine condition monitoring system as described herein. The system will consist primarily of air gap sensors, shaft vibration sensors, processing unit, laptop, and analysis software for one hydroelectric generator.

1.2 REFERENCES

API 670(2000; R 2010) American Petroleum Institute (API) Machinery Protection Systems - Fourth Edition

1.3 SUBMITTALS

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

Submittals having a "FIO" 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", unless otherwise indicated below:

SD-03 Product Data Within 90 calendar days after date of receipt of written notice of award:

Detailed Description of Complete System; G, HDC

Air Gap Sensors; G, HDC

Shaft Vibration Sensors; G, HDC

Software and PC specifications; G, HDC

SD-10 Operation and Maintenance Data Within 30 calendar days after date of delivery of the equipment:

Operation and Maintenance Manuals; G; HDC

PART 2 PRODUCTS

2.1 AIR GAP SENSOR AND SHAFT VIBRATION MONITORING SYSTEM

2.1.1 General

A complete on-line vibration monitoring system for air gap sensor, shaft vibration sensors, data collection, and trending shall be provided. The monitoring system will be permanently mounted in the generator with a remotely located (outside the generator barrel), permanently mounted processing unit. Manufacturer's software shall run on a PC computer and provide capability for trending and analysis of all data inputs synchronized to a common base signal. The system shall be complete with all necessary sensors, wiring, connections, processing units, laptop, and software.

Furnish a laptop computer loaded with the Manufacturer's software. The system shall be of a proven design for use in a hydroelectric generator.

Submit Detailed Description of Complete System, to include all speciffic product data listed in SD-03.

2.1.2 Air Gap Sensors

Provide nine (9) flat, non-contact, passive capacitive sensors to monitor the generator air gap. Sensors shall be designed to monitor the air gap under all operating conditions from generator standstill up to machine over-speed condition. Sensor output shall be 4-20 mA. Capacitive-type sensor shall be resistant to magnetic field, dust, oil, carbon particles, and vibration. Sensors shall be stator-mounted, with eight (8) near the top of the rim and equally spaced around the rim, and one (1) near the bottom of the rim at a matching location to one of the top sensors.

Rotor-mounted sensors are not acceptable. The sensors shall not block more than two ventilation holes on the stator wall. Sensors shall be suitable for mounting air gap up to 0.5". Accuracy shall be at least 97% and repeatability shall be at least 99.7%. Sensors shall be complete with probes, power supplies, extension cables, and linearization modules.

2.1.3 Shaft Vibration Sensor

Six non-contact proximity probes to monitor shaft deflection shall be provided for each unit. This includes one pair each for the upper guide bearing, lower guide and turbine guide bearings. All probes, special cables, signal conditioning (oscillator/demodulators), power supplies, mounts, and special cables shall be provided. The proximity probes and related equipment shall be API 670 compliant.

2.1.4 Key Phasor Probe (Synchro)

The key phasor probe shall be optical or proximity type, suitable for use without modifying the generator/turbine shaft. The signal shall be compatible with the keyphasor input of the processing unit. All power supplies, mounts and targets shall be provided.

2.1.5 Processing Unit

The processing unit shall be designed for use with the provided air gap sensors, proximity probes and keyphasor. Sufficient processing units shall be supplied to accommodate all data inputs. Each processing unit shall accept up to 16 air gap sensors, 1 keyphasor, 8 shaft vibration sensors, 4-20 mA signals, 0-10 V signals, or any combination thereof. The system shall be suitable for operation at rotational speeds as low as 10 rpm.

2.1.6 Alarm Relay Extension Panel

Each vibration monitoring system shall include an alarm relay extension panel with at least four NO / NC dry contacts for "alert" and "danger" levels as set in the monitoring software.

SECTION 48 13 16.03 26

2.1.7 Controller and Diagnostic Software

A portable laptop computer, interface cables and software for use in interfacing with all generator vibration monitoring systems shall be provided. The software shall have the following features:

(1) Background automatic acquisition of data for trending at user-defined intervals Password protection to prevent unauthorized access.

(2) Remote monitoring and configuration via the plant or corporate network.

(3) Fast and easy export utility: data to spreadsheet, measurement to disk.

(4) Simultaneous display of multiple parameters for data/event correlation.

(5) Trend plots of all static and dynamic values.

(6) Air gap plots of rotor and stator

(7) Fast Fourier Transform Spectrum plots of vibration and other parameter for analysis.

(8) Orbit graphs of the rotor shaft path inside each guide bearing referenced to the actual rotor position.

PART 3 EXECUTION

3.1 OPERATION AND MAINTENANCE DATA

The Operation and Maintenance Manuals shall be submitted in accordance with SECTION 01 30 60.00 25. The manual shall include detail instructions and drawings for the installation of the equipment furnished under this contract.

-- End of Section --