Atch_5_Rev_Section_48_13_13.09_26.pdf

Main Unit Bearings W912EF18R0024 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.09 26

FURNISH GENERATOR GUIDE BEARING SHOES (LOWER GRANITE UNITS 4-6, LITTLE GOOSE

UNITS 4-6, AND LOWER MONUMENTAL UNITS 4-6)

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.1.1 Description of Work

1.1.2 Description of Generator Guide Bearings

1.2 REFERENCES

1.3 SUBMITTALS

1.4 FINAL INSPECTION AND ACCEPTANCE

1.5 WARRANTY

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

2.1.2 Steel Plates

2.1.3 Tool Steel

2.1.4 Bolts/Capscrews

2.2 BABBITTING MATERIALS

PART 3 EXECUTION

3.1 GENERAL INFORMATION

3.1.1 RESERVED

3.1.2 Duplication of Bearings from Government-furnished Samples

3.1.3 Drawings

3.2 FINAL INSPECTION AND ACCEPTANCE

3.3 PACKAGING, MARKING, AND SHIPMENT

3.3.1 Packaging

3.3.2 Marking

3.3.3 Shipment of Existing Governement Sample

3.4 BEARING COMPONENT FABRICATION

3.4.1 Fabrication Process

3.4.2 Weld Repair

3.5 BABBITTING

3.5.1 General Requirements

3.5.2 Babbitting Process

3.5.3 Babbitt Repair

3.6 FINISHING

3.6.1 General

3.6.2 Finishing Segments

3.7 INSPECTION

3.7.1 General

3.7.2 Notification

3.7.3 Instrument Calibrations

3.7.4 Preliminary Inspections

3.7.5 Final Inspections

3.8 NONDESTRUCTIVE TESTING (NDT)

3.8.1 General

3.8.2 Independent Party NDT Report

SECTION 48 13 13.09 26 - Page 1 g4edddca Line g4edddca Line

3.9 NONDESTRUCTIVE TESTING OF BASE METAL

3.10 NONDESTRUCTIVE TESTING OF BABBITT

3.10.1 General

3.10.2 Babbitt Liquid Penetrant (PT) Testing

3.10.3 Acceptance Standards

3.10.4 Babbitt Bond Acceptance

-- End of Section Table of Contents --

SECTION 48 13 13.09 26 - Page 2

SECTION 48 13 13.09 26

FURNISH GENERATOR GUIDE BEARING SHOES (LOWER GRANITE UNITS 4-6, LITTLE GOOSE

UNITS 4-6, AND LOWER MONUMENTAL UNITS 4-6)

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.1.1 Description of Work

This section covers the requirements for furnishing one (1) set of upper guide bearing shoes and appurtenances and one (1) set of lower guide bearing shoes and appurtenances for Lower Granite Units 4-6 (Washington), one (1) set of upper guide bearing shoes and appurtenances and one (1) set of lower guide bearing shoes and appurtenances for Little Goose Powerhouse Units 4-6 (Washington), as well as one (1) set of upper guide bearing shoes and appurtenances and one (1) set of lower guide shoes and appurtenances for Lower Monumental Powerhouse Units 4-6 (Washington) with all necessary parts.

The generator guide bearing components for Lower Granite units 4-6, Little Goose units 4-6, and Lower Monumental units 4-6 are identical to existing bearings currently stored at Little Goose. The furnished generator guide bearings shall duplicate the existing generator guide bearings, unless otherwise noted in this section.

1.1.2 Description of Generator Guide Bearings

a. Original detailed manufacturing drawings are not available for the Lower Granite Units 4-6, Little Goose Units 4-6, and Lower Monumental Units 4-6 upper and lower generator guide bearings. The Lower Granite Units 4-6, Little Goose Units 4-6, and Lower Monumental Units 4-6 upper and lower generator guide bearings were originally manufactured by GE.

The bearings currently stored at Little Goose will be made available in order for the Contractor to duplicate the product design within fifteen

(15) days of NTP. These bearings include the jack screw inserts.

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.

ASME INTERNATIONAL (ASME)

ASME BPVC SEC VIII (2015) Section VIII Division 1 Rules for Construction of Pressure Vessels

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A307 (2014) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A354 (2011) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

SECTION 48 13 13.09 26 - Page 3

ASTM A516/A516M (2010; R2015) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

ASTM A681 (2008; R2015) Standard Specification for Tool Steels Alloy

ASTM B23 (2000; R 2014) Standard Specification for White Metal Bearing Alloys (known Commercially as "Babbitt Metal")

ASTM E165 (2012) Standard Test Method for Liquid Penetrant Examination

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 2011) Structural Welding Code - Steel

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J429 (2014) Mechanical and Material Requirements for Externally Threaded Fasteners

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. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Generator Guide Bearing Shoes G, HDC Submit at least 30 calendar days prior to commencing work, paragraph 3.1.3.

SD-03 Product Data

Inspection Sketches and Check Sheets Submit at least 30 calendar days prior to their use, paragraph 3.7.4.

As-received Inspection Findings Submit at least 30 calendar days prior to commencing work, paragraph 3.1.2.

Material Certification Report; G, HDC Submit at least 14 calendar days prior to using the material, paragraph 2.1.1

Rust Resisting Compound Submit at least 30 calendar days prior to use, paragraph 3.3.1.

SD-04 Samples

Samples of Materials; G, HDC

SECTION 48 13 13.09 26 - Page 4

Submit within 14 days of request, paragraph 2.1.1.

SD-06 Test Reports

Pre-Babbitt Inspection Report; G, HDC Submit at least 14 calendar days prior to babbitting, paragraph 3.7.4.

Preliminary Inspection Report; G, HDC Submit at least 14 calendar days prior to final inspection of the finished components paragraph 3.7.4.

Final Inspection Report; G, HDC Submit within 7 calendar days of completing the work and a copy shall be placed inside the packaging for shipment, paragraph 3.7.5.

SD-07 Certificates

Laboratory Qualifications Submit at least 30 calendar days prior to use of the babbitt paragraph 2.2.

Notice of Inspection; I, HDC Submit at least 7 calendar days prior to inspections, paragraph 3.1.

SD-08 Manufacturer's Instructions

Generator Guide Bearing Dimensional Inspection Procedures; G, HDC Submit at least 30 calendar days prior to commencing work, paragraph 3.1.2.

Generator Guide Bearing Fabrication Procedure; G, HDC Submit at least 30 calendar days before starting the fabrication process, paragraph 3.4.1.

Weld Repair Procedure; G, HDC Submit at least 14 calendar days prior to performing the repairs, paragraph 3.4.2.

Tinning and Babbitting Procedure; G, HDC Submit at least 30 calendar days prior to commencing the babbitting work, paragraph 3.5.1.

Babbitt Repair Procedure; G, HDC Submit at least 14 calendar days in advance of repairs as part of the repair procedure, paragraph 3.5.3.

1.4 FINAL INSPECTION AND ACCEPTANCE

Final inspection and acceptance for full compliance with the specifications will be made by the Government upon delivery to the project. Any materials or workmanship not complying with the provisions of these specifications will be cause for rejection. Corrections shall be made at the expense of the Contractor and are subject to approval. Tests may be repeated at the project site to ensure that materials and workmanship conform to contract requirements. Tests will be at the Contractor's expense if the refurbished components do not meet contract requirements.

SECTION 48 13 13.09 26 - Page 5

1.5 WARRANTY

Warranty provisions of these specifications shall apply, except that notwithstanding inspection and acceptance, the finished components shall be warranted to conform to these specifications for one year after receipt and acceptance at delivery site.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 General

a. The classification and grade of material incorporated in the work shall be in accordance with the specifications designated herein, unless otherwise accepted in writing. All materials shall meet or exceed the standards as specified herein. When two or more of these standards apply, the most stringent standard shall be used. All materials, parts, and components supplied shall be new and unused and of the best available kind and quality. Workmanship shall be of the highest grade and in accordance with the best modern standard practice. Samples of materials shall be made available within 14 days of request.

b. An independent Material Certification Report shall be submitted prior to use of the material to verify conformance with these specifications.

2.1.2 Steel Plates

Steel plates shall conform to ASTM A516/A516M-S1, Grade 70, fully annealed and vacuum degassed, in accordance with supplementary requirement S1.

Alternate methods and material may be submitted for Government approval.

2.1.3 Tool Steel

The jack screw inserts, to be fastened on the outer diameter of each shoe, shall be fabricated from a tool steel with physical properties at least equal to those required by ASTM A681, Type D, unless otherwise approved.

2.1.4 Bolts/Capscrews

Carbon steel bolts/capscrews shall meet the requirements of ASTM A307, ASTM A354, or SAE J429, unless otherwise approved.

2.2 BABBITTING MATERIALS

a. The Babbitt metal shall be new material conforming to ASTM B23 Alloy 2.

b. The tin used for tinning shall be 99 percent pure.

c. Use of reclaimed metal will not be acceptable.

d. An independent laboratory shall be used to analyze each sample taken at the time the Babbitt is poured, paragraph 3.5.2.a. Laboratory

SECTION 48 13 13.09 26 - Page 6

Qualifications of this laboratory shall be submitted prior to use of the Babbitt.

PART 3 EXECUTION

3.1 GENERAL INFORMATION

The Contractor shall fabricate, inspect, test, prepare for shipment, package, and ship six total sets of generator guide bearing shoes, with jack screw inserts. The new shoes shall be furnished in accordance with the Government-accepted drawing provided by the Contractor, paragraph 3.1.3, and as specified in these specifications, unless otherwise accepted. These specifications shall take precedence over the FIO drawings, unless otherwise accepted. The following deviation from previous design shall be made to all sets of furnished guide shoes:

a. A textured surface or record finish shall be machined into the inner cylindrical surface of the steel bearing shoes (surface onto which the Babbitt will be poured), such that the Babbitt has a surface to which it can bond. Dovetails shall not be used on any set of the new bearings. The final Babbitt thickness shall not exceed the maximum thickness that was applied to the original shoes bewteen the steel ID bore and the Babbitt ID bore.

b. Notify the Government with a Notice of Inspection at least 7 calendar days prior to all shop guide bearing inspections. Any inspection may be witnessed by the Government at its discretion.

3.1.1 RESERVED

3.1.2 Duplication of Bearings from Government-furnished Samples

a. The Government will make available the existing Little Goose Units 4-6 bearings with jack screw inserts, identical to Lower Granite and Lower Monumental's Units 4-6 bearings within fifteen (15) days from NTP.

After the Conractor removes the Cosmoline and cleans the provided sample shoes, the Contractor shall measure the sample shoe sets and determine the original design dimensions, using averaging, other statistical methods, or analysis as necessary. Using the measurements taken, the Contractor shall fabricate, inspect, prepare for shipment, package and ship six complete sets of guide bearings and appurtenances, as described above. Submit the Generator Guide Bearing Dimensional Inspection Procedures at least 30 calendar days prior to the start of fabrication.

b. Record all sample shoe measurement data on Contractor-furnished inspection sheets. The As-received Inspection Findings shall be submitted. The COR shall be immediately notified, within 24 hours, when finding any damaged or defective component and the Contractor shall follow up this notice with a written notice within 5 days.

c. Take all measurements with calibrated instruments accurate to the nearest 0.001 inch unless otherwise indicated. Furnish calibration certification for all equipment with the report of findings.

d. As-received Inspection. The Contractor shall submit a Notice of Inspection. As-received Inspection shall be witnessed by the Government, unless otherwise accepted. In all cases, the guide bearing

SECTION 48 13 13.09 26 - Page 7 shoes shall be arranged to allow taking all measurements necessary to determine the original design dimensions, per paragraph 3.1.2.a.

3.1.3 Drawings

For each unique set of guide bearing shoes, a shop drawing(s) of the Generator Guide Bearing Shoes associated with the work specified herein shall be submitted and approved prior to commencing work. For the Lower Granite Units 4-6, Little Goose Units 4-6, and Lower Monumental Units 4-6 upper and lower generator guide bearing shoes and jack screw inserts, the drawings shall reflect the features and dimensions of the existing bearings as measured by the Contractor.

3.2 FINAL INSPECTION AND ACCEPTANCE

a. Final inspection and acceptance for full compliance with the specifications will be made by the Government upon delivery to the project site. Tests may be repeated at the project site to ensure that materials and workmanship conform to the specifications. Tests will be at the Contractor's expense if the components do not meet contract requirements. The Contractor will be notified in writing of acceptance.

The date of this notification is the starting date of the warranty period.

b. Any materials or workmanship not complying with the provisions of these specifications will not be accepted. Corrections shall be made at the expense of the Contractor.

3.3 PACKAGING, MARKING, AND SHIPMENT

3.3.1 Packaging

a. The bearing shoes shall not be prepared for shipment until they have been inspected by the Government, unless such inspection is waived in writing by the Government. Packaging shall be provided by the Contractor at the Contractor's expense. Packaging shall prevent deterioration and damages due to the hazards of shipping, storage, handling, and processing. Each shoe segment shall be packed within an individual compartment in the packing crate for shipment. The packaging shall be for long-term storage and include coating all components with an accepted rust preventative substance as specified below. The method of packing shall be suitable for handling with a crane and lift truck.

All packaging shall be designed such that it can be handled, moved and loaded with a fork lift. All packaging materials used shall become the property of the Government. The Contractor shall prepare and load the bearing components for shipment in such a manner as to protect them from damage in transit and shall be responsible for and make good any and all damage until they are delivered to the Government at the specified delivery point.

b. After satisfactory inspection, all surfaces shall be coated with a protective filming agent which is suitable to withstand shipping and long-term storage of at least 10 years. Submit product data for the Rust Resisting Compound chosen by the Contractor prior to use. All holes, inlets and outlets shall be cleaned and covered to exclude dirt, water, etc.

SECTION 48 13 13.09 26 - Page 8

3.3.2 Marking

The Contractor shall stamp their name, contract date, unit family designation (i.e. U4-6) and the Government contract number on a non-Babbitted side of each bearing segment, along with a shoe identification number. The packaging shall be clearly labeled with the return address and package contents.

3.3.3 Shipment of Existing Governement Sample

The sample components that are provided by the Government shall be prepared and packaged for shipment from the Little Goose Powerhouse. The Contractor shall provide packaging as outlined in the paragraph "Packaging," above, and prepared with identification as outlined in the paragraph "Marking," above. After completion of the dimensional analysis of the existing bearings, the inspected samples shall also be treated with the same protective filming agent as approved for the new shoes and shipped back to Little Goose Powerhouse.

3.4 BEARING COMPONENT FABRICATION

The requirements governing the fabrication of generator guide bearing shoes apply to six complete sets of shoes. Informational drawings provided herein do not supersede information provided in the specification. The dimensions, geometrical features, and miscellaneous feature requirements shown on the drawings, submitted by the Contractor and approved by the Government, shall be duplicated, unless otherwise accepted. With exception to the parameters listed in the paragraph titled "General Information," these features shall be included in the drawings.

3.4.1 Fabrication Process

The Contractor shall fabricate the generator guide bearing shoes using steel plate. See paragraph "Steel Plates" for material requirements, and in accordance with SECTION 05 05 23.20 26.

a. Submit a detailed Generator Guide Bearing Fabrication Procedure at least 10 calendar days prior to fabrication, including a detailed step-by-step babbitting procedure. Do not perform any work until receiving written approval from the Government.

b. Submit a proposed schedule (dates and times) for all phases of the shoes' fabrication prior to the beginning of the work. Update and revise the schedule as required. The Government will use this schedule for witnessing refurbishment processes and will notify the Contractor as to which process will be witnessed. The Government is especially interested in witnessing shoe preparation prior to Babbitt pouring and Babbitt pouring, and inspections.

3.4.2 Weld Repair

A Weld Repair Procedure for base metal repairs shall be submitted for approval and welding shall not take place without prior written approval. A Weld Repair Procedure shall include welder qualifications and shall be in accordance with Section 4, Part C of AWS D1.1/D1.1M and Specification

SECTION 05 05 23.20 26.

SECTION 48 13 13.09 26 - Page 9

3.5 BABBITTING

3.5.1 General Requirements

a. The Contractor shall submit a detailed step-by-step Tinning and Babbitting Procedure. The Contractor shall not perform any babbitting until written approval of the procedure is received from the Government.

b. Babbitt shall be applied using the static cast method. NDT reports of castings or weldments in fabricated components shall be received and approved prior to babbitting.

3.5.2 Babbitting Process

The Contractor shall babbitt the guide bearing shoes as specified below.

The babbitting process includes pouring new babbitt and babbitt machining, including the provision of oil supply grooves and other details.

a. A sample of the tin and babbitt shall be taken and marked for identification at the time the tin and babbitt are poured. A sample shall be taken for each heat. NDT reports of weld repairs in fabricated components shall be received and accepted prior to babbitting. An independent testing laboratory shall analyze each babbitt sample with the results linked to individual heats and the results shall be submitted in the Preliminary Inspection Report, paragraph "Preliminary Inspection".

b. The Contractor shall prepare the bearing shoes for babbitting according to the accepted procedure. The base metal surface shall be cleaned by machining or shot blasting and shall not be touched prior to tinning. Special care shall be taken to protect all holes and surfaces of the bearing shoes not receiving babbitt. Precautions shall be taken to minimize distortion during babbitting.

c. The babbitt shall be applied using a static cast process. The babbitt shall be poured at a high temperature. The form and bearing shell thickness shall be pre-heated. Cold checks will not be acceptable. Precautions shall be taken to minimize bearing distortion during babbitting.

d. Machine the oil supply grooves, radii, and other details as shown on the approved drawings prior to performing final NDT testing of the babbitt.

3.5.3 Babbitt Repair

If repairs are required to the babbitt surface or to the babbitt-to-backing material interface, a Babbitt Repair Procedure shall be submitted, if not already submitted as part of the rebabbitting procedure. Puddling will be acceptable for small areas on the surface, and to correct a localized lack of bond between the babbitt and backing material; however, the total lack of bond repaired by puddling shall not exceed 5% of the total babbitted surface.

3.6 FINISHING

3.6.1 General

The bearing segments' dimensions, shape, features, finishes, including all

SECTION 48 13 13.09 26 - Page 10 lubrication grooves, miscellaneous openings, threaded holes, and pockets, tolerances, etc. needed for proper operation of the bearing segments shall duplicate those shown on the approved drawings, unless specified or directed otherwise. Round or break all sharp edges.

3.6.2 Finishing Segments

c. The requirements for the new shoes are as follows:

(1) Babbitt Inner Diameter: Nominal + 0.000 to 0.004 inch. The nominal diameter of the Lower Granite, Little Goose, and Lower Monumental shoes shall be as found during the Contractor's inpsection of Government-provided samples.

(2) Thickness at bearing disk, leading edge and trailing edge (measurements made according to subparagraph c above): Nominal +/-

0.005 inch.

(3) Babbitt surface runout: Maximum 0.002 inch. Applies for all shoes over one revolution of the machining table over any and all elevations.

(4) Surface finish: Maximum 32 microinch, free of chatter and abnormal tool marks.

(5) Machined Jack Screw Insert Recess: The vertical centerline of the machined backside jack screw contact surface shall be parallel to the babbitted surface within +/- 0.005 inches.

f. Make finish dimensions and runout checks while the shoes are still on the machining table.

g. Produce oil supply grooves, radii at the shoe edges, and other details existing on the original shoes or as shown on the drawings,.

h. Thoroughly clean all non-babbitted surfaces and holes.

i. All options include appropriate final inspections and the preparation of a report according to paragraph INSPECTION OF FINISHED

GUIDE BEARING SHOES/FINAL REPORT.

j. Following the completion of the work, protect the shoes from damage and corrosion with appropriate coatings and packaging.

3.7 INSPECTION

3.7.1 General

The Government reserves the right to inspect any or all phases of the work described in these specifications. The Government reserves the right to perform supplemental non-destructive examinations as deemed necessary when the soundness of any material or weldment is in doubt. The cost of such inspection will be borne by the Government. Any repairs and re-examination of repairs shall be performed by the Contractor, at no additional cost to the Government.

3.7.2 Notification

The Contractor shall submit an Notice of Inspection and all inspections may

SECTION 48 13 13.09 26 - Page 11 be witnessed by the Government at its discretion.

3.7.3 Instrument Calibrations

All measurements taken shall be made with instruments calibrated to the nearest 0.0005 inch, without interpolation, unless otherwise stated herein or accepted. Dimensions shown on the drawing with 4 decimal places shall be made with instruments calibrated to the nearest 0.0001 inch. Instruments shall have been calibrated within 90 calendar days before measurements are taken. Submit an instrument calibration report with the Final Inspection Report, listing all instruments used, date of latest calibration, and accuracy.

3.7.4 Preliminary Inspections

Submit Inspection Sketches and Check Sheets prior to their use. Perform the following inspections and submit the preliminary reports prior to the final inspection.

a. Guide Bearing Segments Pre-Babbitt Inspections. Measurements, checks, and NDT tests shall be performed by the Contractor and recorded on Contractor furnished inspection drawings and check sheets. Perform visual (VT) and either liquid penetrant (PT) or magnetic particle (MT) inspection over the entire surface of each guide shoe prior to babbitting, include final UT weld inspections. Measure surface finishes and dimensions. Map defect size and locations. The Contractor shall submit a Pre-Babbitt Inspection Report of findings and shall not proceed with babbitting until the report is approved by the Government.

b. Guide Bearing Segments Post-Babbitt Inspections. Dimensional measurements, checks, and NDT tests shall be performed by the Contractor and recorded on Contractor-furnished Inspection Sketches and Check Sheets that capture all bearing component dimensions, shapes, features, finishes, grooves, miscellaneous openings, threaded holes, plugs, inserts, keys, pockets, tolerances, fasteners, etc. and capture NDT findings. The finished guide bearing segments shall be inspected while on the machining device with the two halves bolted together. The following inspections shall be included:

(1) Measure the babbitt bore diameter at three elevations: top, middle, and bottom. If machined in one setup using a boring mill, measure the diameter for each shoe between the opposing shoe while all shoes are setup on the turntable. If each shoe is machined separately, measure at least 10 points per elevation using a coordinate measuring machine (CMM) and analyze the data to determine the diameter of each shoe at each elevation. Another alternative is to make a template machined to the design diameter of the shoes that can be placed up against the babbitted surface and feeler gages can be used to measure deviation from the template at each elevation. Utilize feeler gage data to calculate the diameter of each shoe at each elevation. Templates shall be turned over to the Government after completion of work. Templates shall be shipped to the dam at the same time as the bearings, but in separate containers.

(2) Measure the total indicated runout (TIR) at three elevations:

top, middle, and bottom. If machined in one setup using a boring

SECTION 48 13 13.09 26 - Page 12 mill, take the TIR measurements with the shoes set up on the machining turntable in a circular ring. If each shoe is machined separately, use the CMM measurements from (1) above to calculate the TIR at each elevation, or use template and feeler gage data to calculate TIR.

(3) Measure the thickness for each shoe at the bearing pivot disk

(4) Measure and record the Babbitt surface finish, and the surface finish for any other machined surfaces.

c. Preliminary Inspection Report. The Contractor shall submit a combined Preliminary Inspection Report, comprised of the following:

- Generator Guide Bearing Shoes Post-Babbitt Inspections, paragraph "Preliminary Inspection," part b., above.

- Independent Party NDT Report, paragraph "Independent Party NDT Report"

- Independent laboratory tin and babbitt sampling report, paragraph "Babbitting Process"

Measurements, drawings, check sheets, and NDT examinations shall all be included.

3.7.5 Final Inspections

Perform the following during the final inspection and submit the final report following completion of these inspections.

a. Final Inspections and Measurements. The Contractor shall submit a Notice of Inspection. Final inspections shall be witnessed by the Government, unless otherwise accepted. In all cases, the guide bearing shoes shall be arranged to allow taking all measurements, and witnessing of nondestructive examination of the babbitt at the same time, unless otherwise accepted. The Contractor shall wait for written release from the COR for shipment.

b. Final Inspection Report. The Contractor shall submit a Final Inspection Report including everything required in the Preliminary Inspection Report and all final witnessed measurements, inspections, babbitt analysis, instrument calibration report, and miscellaneous checks, recorded on the accepted Inspection Sketches and Check Sheets.

The final report shall be accepted prior to shipment of the bearings, unless directed otherwise. A copy of the final report shall be placed inside the packaging for shipment.

3.8 NONDESTRUCTIVE TESTING (NDT)

3.8.1 General

Material shall be subject to inspection to determine conformance with the requirements of ASME BPVC SEC VIII and provisions stated elsewhere in the specifications and SECTION 05 05 33.20 26. An adequate inspection system shall be maintained as part of the Contractor's Quality Control Program and is subject to approval. All welds and nondestructive testing shall be conducted by a Contractor's inspector (CWI).

SECTION 48 13 13.09 26 - Page 13

3.8.2 Independent Party NDT Report

A certified written report shall be prepared by the independent NDT party and submitted with the Preliminary Inspection Report, paragraph 3.7.4.c, and Final Inspection Report, paragraph 3.7.5.b. The NDT report shall, at a minimum, include the following: (1) VI, UT, and PT procedures, (2) equipment, (3) mapping of un-bonded areas and interpretation, specifically addressing babbitt-to-metal bonding and percentage of un-bonded surface area, (4) description of surface and subsurface discontinuity size and locations, and their accumulated total surface areas relative to the babbitted surface area, and (5) the presence of cracks.

3.9 NONDESTRUCTIVE TESTING OF BASE METAL

Perform visual (VT) and liquid penetrant (PT) inspection over the entire surface of each guide bearing prior to babbitting in accordance with SECTION 05 05 33.20 26. All surfaces shall be examined using the liquid penetrant (PT) method. This shall be done using a solvent-removable visible dye and shall be in accordance with ASTM E165.

3.10 NONDESTRUCTIVE TESTING OF BABBITT

3.10.1 General

The metallurgical bonding of the babbitt shall be examined using the Ultrasonic Test Method (UT) and Liquid Penetrant Method (PT) of non-destructive testing by an independent party's UT inspector in accordance with SECTION 05 05 33.20 26. A visual inspection (VT) shall also be completed according to SECTION 05 05 33.20 26.

3.10.2 Babbitt Liquid Penetrant (PT) Testing

After the ultrasonic testing is completed, all exposed babbitt to backing material bond lines shall be examined using the liquid penetrant (PT) method. This shall be done using a solvent-removable visible dye and shall be in accordance with ASTM E165. The purpose of the PT bond line examination is to define the babbitt to backing material bond at edges, which the UT examination may not reveal.

3.10.3 Acceptance Standards

Babbitt bond acceptance criteria is defined below as a function of zones:

a. Perimeter and Holes. Zone defined as bond surface area within 1 inch from any edge or hole having an exposed bond line. The maximum dimension of any individual unbonded area shall be less than 1/2 inch, with acceptable unbonded areas located no closer than two inches apart.

The total unbonded area in the perimeter zone shall be no larger than 5% of the total zonal area as examined by the UT method.

b. Corners. Zone defined as bond surface area within 1 inch from any corner having an exposed bond line. Corners shall have no unbonded areas as examined by the UT method.

c. Remainder of Shoe. Zone defined as bond surface area other than perimeters, holes and corners. The maximum area for any individual unbonded area shall be less than 1 sq. inch or 3 percent of the total zonal area, whichever is less. Acceptable unbonded areas shall be located no closer than 2 inches apart. The total unbonded area shall

SECTION 48 13 13.09 26 - Page 14 be no larger than 5 percent of the total zonal area as examined by the UT method.

d. Bond Lines. Defined as exposed lines at the babbitt to base metal interface. PT indications of lack of bond totaling over 10 percent of the length of a particular edge shall be unacceptable. Any PT detected lack of bond over 3/4 inch in length shall be re-examined by the UT method, using a 0.250 diameter transducer. Unbonded areas extending more than 1/8 inch away from an edge shall be unacceptable.

e. Additional Requirements. Visual (VT) acceptance standards. The babbitt surface shall have no holes greater than 1/32". Holes of less than 1/32" shall be acceptable if they are spaced at least 1/8" apart and no more than five per sqaure inch. The exposed bond line shall have no visible disbonding.

3.10.4 Babbitt Bond Acceptance

If a bearing's babbitt bond does not meet the acceptance criteria as laid out above, it shall be repaired or completely rebabbitted and retested at the Contractor's expense until the bond is acceptable in accordance with the specifications.

-- End of Section --

SECTION 48 13 13.09 26 - Page 15

1.1.3 Work

3.1.5 Liquid Penetrant Inspection PT

2.2 FABRICATED METAL ITEMS

3.5 WELDING

2.2 BABBITTING MATERIALS

3.11 TOLERANCES FOR STATIONARY THRUST BEARING SHOE SEGMENTS

2.2 BABBITTING MATERIALS

2.2 BABBITTING MATERIALS

2.2 BABBITTING MATERIALS