Amend-0002 Tech Specs W912EF21B0013.pdf

Lower Monumental Unit 2 Turbine Hub Seal Repairs W912EF21B0013 Amendment - 002

PROJECT TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

00 01 15.00 28 LIST OF DRAWINGS

DIVISION 01 - 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 16.00 28 SMALL PROJECT CONSTRUCTION PROGRESS SCHEDULES

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 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

DIVISION 05 - METALS

05 05 33.20 26 NON-DESTRUCTIVE TESTING

DIVISION 48 - ELECTRICAL POWER GENERATION

48 13 13.04 26 EXISTING TURBINE COMPONENT, REFURBISHMENT AND REPLACEMENT

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PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 11 01.00 28

SUPPLEMENTARY REQUIREMENTS

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 FIELD VERIFICATION OF SITE CONDITIONS

1.4 DEFINITIONS

1.5 PROJECT SCHEDULE

1.6 REGULAR CLEANUP AND DEBRIS DISPOSAL

1.7 GOVERNMENT-FURNISHED PROPERTY

1.8 GOVERNMENT ISSUED ITEMS

1.9 EQUIPMENT LIST

1.10 TESTING OF EQUIPMENT

1.11 DISPOSITION OF REMOVED MATERIALS AND EQUIPMENT

1.12 PROTECTION AND RESTORATION OF EXISTING FACILITIES

1.13 PRE-CONSTRUCTION ON-SITE INSPECTION

1.14 PROTECTION OF POWERHOUSE FLOORS

1.15 AIR PURITY CONTROL IN THE POWERHOUSE

1.16 DISCONNECTED OIL LINES

1.17 PROJECT SUPERINTENDENT

1.18 KEY PERSONNEL SUBSTITUTION

1.19 POST AWARD MEETINGS

1.19.1 Pre-Work/Pre-Construction

1.19.2 Pre-Construction

1.19.2.1 Minutes

1.19.3 RMS Orientation Meeting

1.20 WEEKLY PRODUCTION MEETINGS

1.20.1 Minutes

1.21 ADDITIONAL MEETINGS

1.22 PARTNERING

1.22.1 General

PART 2 PRODUCTS (NOT APPLICABLE)

PART 3 EXECUTION (NOT APPLICABLE)

ATTACHMENTS:

Weekly Meeting Agenda

-- End of Section Table of Contents --

SECTION 01 11 01.00 28 Page 1 g4ecctgh

Amendment-002 - Paragraph: 1.11

SECTION 01 11 01.00 28 Page 2

SECTION 01 11 01.00 28

SUPPLEMENTARY REQUIREMENTS

PART 1 GENERAL

The work covered by this section of the specifications consists of work common to more than one section of these TECHNICAL SPECIFICATIONS.

1.1 REFERENCES

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

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

Comply with the current edition and all changes posted on the web as of the effective date of this solicitation.

1.2 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-01 Preconstruction Submittals

Project Schedule ; G, C

Property Management Plan ; G, C

Equipment List ; I, C

Pre-Construction On-Site Inspection report ; I, C

Air Purity Control Program ; I, C

Project Superintendent ; I, C

SD-07 Certificates

Key Personnel Substitution ; G, C

SD-11 Closeout Submittals

Government Issued Items ; G, C

1.3 FIELD VERIFICATION OF SITE CONDITIONS

Field verify all elevations, dimensions, and coordinates of existing features indicated on the contract drawings that affect new construction.

SECTION 01 11 01.00 28 Page 3

Any deviations shall be updated as per SECTION 01 78 00.00 28 , CLOSEOUT SUBMITTALS, paragraphs WORKING AS-BUILT DRAWINGS.

1.4 DEFINITIONS

a. Qualified Person.

As defined in EM 385-1-1 ; "DEFINITIONS", unless otherwise specified.

b. F.O.B.

An abbreviation for free on board, which means that a vendor or consignor will deliver goods on a railroad car, truck, vessel, or other conveyance without any expense to the purchaser or consignee.

1.5 PROJECT SCHEDULE

a. Furnish a cost loaded schedule for the complete project in accordance with Clause 52.236-15 Schedules for Construction Contracts within 15 days after receipt of Notice to Proceed.

b. Email an electronic copy of the schedule, in the original format the schedule was developed in (e.g. .xer, .xls., .mpp, etc.), to the Contracting Officer's Representative (COR). See SECTION 01 33 00 SUBMITTAL PROCEDURES paragraph "Electronic Copies" for email address.

1.6 REGULAR CLEANUP AND DEBRIS DISPOSAL

With the exception of materials specifically indicated or specified to be salvaged for reuse in construction, or turned over to the Government, all wastes and demolished materials shall become the property of the Contractor and shall be removed from the job site daily in accordance with Federal, State, and local regulations. The Contractor shall furnish waste containers. All small waste containers provided by the contractor shall be emptied daily, large bin containers shall be emptied when full or once a week.

1.7 GOVERNMENT-FURNISHED PROPERTY

Submit a Property Management Plan in accordance with FAR Clause 52.245-1 Government Property.

1.8 GOVERNMENT ISSUED ITEMS

Return to the Government all items issued to the Contractor from the Government, including but not limited to the following: keys, ID and security badges, radios, pagers, and excess/unused Government Furnished Property/Equipment . Submit documentation signed by the Contractor and Contracting Officer indicating items have been returned or fully accounted for. Format of submittal will be discussed and agreed upon at the Pre-Work Meeting.

1.9 EQUIPMENT LIST

Furnish a complete list of all equipment to be used on the Project 30 calendar days prior to commencement of on-site work. Submit a revised list in the event of change of equipment. Lists shall include rented equipment as well as lease-purchase or sale-leaseback equipment. The

SECTION 01 11 01.00 28 Page 4 initial list and the revised lists shall indicate dates equipment is assigned to or removed from the Project and adequate identification or description of each item of equipment including manufacturer's name (abbreviated), model number, manufacturer's serial number, year of manufacture, and Contractor's assigned serial or record number.

1.10 TESTING OF EQUIPMENT

Before any machinery or mechanized equipment is put to use on the job, it shall be inspected and tested by a qualified person and determined to be in safe operating condition. Cranes or derricks shall be tested by the Contractor or a qualified testing agency in accordance with EM 385-1-1 .

Equipment shall be large enough to safely handle proposed picks or tasks without exceeding the crane rating established by these tests.

1.11 DISPOSITION OF REMOVED MATERIALS AND EQUIPMENT

a. All blade followers and related parts shall be removed and turned over to the government. Remove in a manner to avoid damage and move to an onsite location, as coordinated with the KO. The Government has removed the blade followers for the Contractor to facilitate required contractual inspections.

b. Unless otherwise specified in other sections of these Specifications, all existing equipment removed and not reinstalled shall become the property of the Contractor, removed from the Project site, and disposed of in a legal manner. Materials that cannot be removed daily may be temporarily stored on-site at an approved area.

Salvaged materials shall not be sold on the Project site.

1.12 PROTECTION AND RESTORATION OF EXISTING FACILITIES

Reference FAR 52.236-9 Protection of Existing Vegetation, Structures, Equipment, Utilities, and Improvements (Apr 1984).

1.13 PRE-CONSTRUCTION ON-SITE INSPECTION

Prepare a Pre-Construction On-Site Inspection Report of existing conditions, prior to start of on-site work, with the Contracting Officer (KO). Document existing site conditions prior to Construction by digital photographs, and/or videos along with descriptive narrative report to the KO within five (5) calendar days after completion.

1.14 PROTECTION OF POWERHOUSE FLOORS

a. Care shall be taken to prevent damage to all floors and curbs within the Powerhouse. Protection shall include a continuous layer of oil-impervious kraft paper over the existing floor surface with joints of the kraft paper joined with an appropriate tape. In addition, tongue and groove 3/4-inch-thick Oriented Strand Board (OSB) plywood shall be installed over the craft paper at all work and storage areas. Plywood joints shall be fastened to ensure edges of plywood sheets are, and remain, flush with each other and do not pose a tripping hazard during execution of this work. Minimum nominal 2"x4" wood shall be installed along existing curb features within the contractor work areas and along perimeters of the work areas. Wood used for curb protection shall be secured in place without anchoring into the existing floors or curbs.

SECTION 01 11 01.00 28 Page 5 g4ecctgh

Amendment-002 - Paragraph: 1.11

b. Pipe trenches shall remain accessible even if covered. All designations relating to fire protection equipment that get covered shall be marked on the temporary floor covering. Provide additional blocking and wood supports when required. Also suitably protect other surfaces of work. Damage to floors or curbs caused by the Contractor's operations shall be repaired at no additional cost to Government. Repairs shall match the surrounding area in material type, color, texture, and surface finish and are subject to approval.

Work in the powerhouse shall not start until floor and curb protection is in place.

1.15 AIR PURITY CONTROL IN THE POWERHOUSE

Take all necessary precautions to maximize the control, and prevention, of all dust and fumes created by operations under this contract from escaping into the Powerhouse. To the maximum extent possible, all dust and dirt shall be removed by vacuum cleaning. At least 30 working days prior to commencement of work in the Powerhouse, submit for approval, in writing, a proposed Air Purity Control Program . Air Purity Control Program shall include, but not necessarily be limited to, the following:

(1) Adequate isolation and ventilation of air arcing, welding, burning, and grinding operations.

(2) Provision of exhaust ducts that shall discharge outside the Powerhouse structure where mechanical ventilation is used.

(3) Controlled operation of power driven tools.

(4) Furnishing and removing of oiled sawdust or other dust preventatives in areas that cannot be properly rendered free from excessive dusting by vacuum cleaning or other methods.

(5) Vacuum cleaning of spaces within the work areas where dust accumulates.

(6) Air-, electrical-, or battery-driven equipment may be used inside the Powerhouse.

(7) Internal-combustion engine powered equipment will not be permitted to operate inside the Powerhouse unless exhausted to the exterior except for short periods of time (not to exceed 15 minutes in a two

(2) hour window) to unload materials and equipment.

Depending upon the Contractor's plant, equipment, and methods of operation, additional provisions for satisfactory air purity control will be required and shall be included in the proposed Air Purity Control Program.

1.16 DISCONNECTED OIL LINES

Anytime an oil line is disconnected by the Contractor due to work performed under this contract it shall be the Contractors responsibility to cap the line. Oil line cap shall be rated at 125 percent of the pressure in the line. Contractor shall notify the KO that an oil line has been disconnected, and then document by KO witness that the disconnected oil line has been sealed to ensure no transfer of oil or water from or into the sealed line.

SECTION 01 11 01.00 28 Page 6

1.17 PROJECT SUPERINTENDENT

The Contractor's Project Superintendent shall be on the worksite during performance of work on this contract. The Project Superintendent is required on the worksite, at all times work is being performed, until work on this contract is completed and accepted. Assign a competent superintendent as per FAR Clause 52.236-6 "Superintendence by the Contractor". Submit Superintendent name and contact information prior to start of on-site construction.

1.18 KEY PERSONNEL SUBSTITUTION

If the Contractor plans on replacing any Key personnel (Project Superintendent, CQC System Manager, or CQC staff Members) they must have the approval of the Contracting Officer. Personnel shall possess the qualifications that meet or exceed those stated in this contract for the position of the individual they are replacing. Submit qualifications of new personnel at least 15 calendar days in advance of date of replacement.

1.19 POST AWARD MEETINGS

1.19.1 Pre-Work/Pre-Construction

A combined Pre-Work/Pre-Construction Meeting will be held within fifteen

(15) calendar days after receipt of Notice to Proceed. Attend the Pre-Work/ Pre-Construction Meeting. Senior level members of the Contractor's staff and the Contractor's Project Superintendent and QC system manager shall attend this meeting. The Government will lead the first portion of the meeting and take the meeting minutes. The Government will discuss the overall contract requirements.

1.19.2 Pre-Construction

For the Pre-Construction part of the meeting, the Project Superintendent shall lead the meeting and discuss the Contractor's plan on executing the work at the Project site, schedule, required clearances and timeframe for clearances, and plan for implementing safety and quality control. The Government will have key members from the Project staff to discuss environmental and clearance issues for the Project.

1.19.2.1 Minutes

Contractor is responsible for taking the meeting minutes for this portion of the meeting and shall send them electronically within 48 hours after the meeting to the Government's Contracting Officer, Project Engineer, Quality Assurance Representative, and Resident Engineer.

1.19.3 RMS Orientation Meeting

a. An RMS (Resident Management System) Orientation Meeting will be held within fifteen (15) calendar days after receipt of Notice to Proceed. See SECTION 01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM) for additional information. Orientation meeting will be at District Headquarters, and may occur in conjunction with, but not at the same time as, the Pre-Work Meeting. Coordinate meeting date and time with the Contracting Officer a minimum of seven

(7) calendar days prior to the meeting.

b. At a minimum, the Contractor's RMS-CM Administrator and QC system

SECTION 01 11 01.00 28 Page 7 manager shall attend the RMS Orientation Meeting. A Government Representative will lead the orientation. Anticipate the following at the meeting:

1. Allow for a maximum four (4) hour duration.

2. Cover the following topics, at a minimum, in RMS Contractor Mode (CM):

i. Contractor use of RMS (CM) system.

ii. Contractor Data.

iii. Quality Control Reports.

iv. Submittals.

v. RFI's.

vi. Payment.

3. Receive a follow-up handout/guide for reference on the above items.

c. Contractor employees shall bring a computer with Wi-Fi capability (to gain access to the Internet), with RMS pre-loaded.

d. The RMS Orientation Meeting is required for Contractors with no prior RMS experience. The RMS Orientation Meeting, is optional, but may be requested, for all other Contractors.

1.20 WEEKLY PRODUCTION MEETINGS

During all fabrication and onsite construction work, hold a weekly production meeting to brief the Government on the status of the project.

a. Use the attached "Weekly Meeting Agenda" and discuss all elements of this agenda.

b. Provide a three (3) week 'look ahead'.

1. Describe all planned construction activities, on-site and off-site over the next three (3) weeks.

2. ENSURE these activities align to the overall construction SCHEDULE submitted under PROJECT SCHEDULE.

3. RECORD any changes to the Project Schedule AND INCLUDE IN the next scheduled update.

c. Key members of the Contractor's staff including the Quality Control System Manager and the SITE SAFETY AND HEALTH OFFICER shall attend.

d. The Quality Control System Manager shall discuss all QC aspects outlined in SECTION 01 45 04.00 28 CONTRACTOR QUALITY CONTROL.

e. The Government reserves the right to require any person from the Contractor's staff such as the Project Manager, Engineer, Scheduler or Key Subcontractor Personnel to attend the meeting.

SECTION 01 11 01.00 28 Page 8

Photos of on site construction activities and progress shall be provided to the Government for unrestricted use by the Government.

a. Photos shall be submitted at the end of each work week.

b. Furnish digital photographs, Utilize JPEG file format for all photograph and image files.

c. Provide full-color photos with photo resolution of not less than 4 megapixels and not more than 12 megapixels.showing the sequence and progress of work.

d. Take a minimum of 20 digital photographs each week throughout the entire project.

e. Submit weekly two sets of digital photographs, each set on a separate compact disc (CD)or data versatile disc (DVD).

Ensure that the photographs are digitally dated. Log shall be furnished for each photograph that records the following information:

a. Photograph number (the specific format should be tied to the filename of the electronic photograph)

b. Date the photograph was taken;

c. A brief description of the location, what the photograph depicts, and the orientation of the view.

1.20.1 Minutes

The Contractor shall be responsible for taking the meeting minutes and shall send them electronically within 24 hours of the meeting to the Government's Project Engineer, Quality Assurance Representative, and Resident Engineer.

1.21 ADDITIONAL MEETINGS

Record the minutes of all meetings, including all conference calls, that occur between the Contractor and Government. Send minutes electronically within 24 hours of the meeting to the Contracting Officer for concurrence.

E-mail subject line shall include project name and meeting topic.

1.22 PARTNERING

1.22.1 General

The Government intends to encourage the foundation of a cohesive partnership with the Contractor and its subcontractors by informally partnering this contract. This partnership will be structured to draw on the strengths of each organization to identify and achieve reciprocal goals. The objectives are effective and efficient contract performance with the intent to achieve a safe completion of the work - within budget, on schedule, and in accordance with plans and specifications. This partnership would be bilateral in makeup and participation will be totally voluntary.

SECTION 01 11 01.00 28 Page 9

PART 2 PRODUCTS (NOT APPLICABLE)

PART 3 EXECUTION (NOT APPLICABLE)

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SECTION 01 11 01.00 28 Page 10

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 Job Measurement Items

1.2.2 Unit Price Measurement Items

1.2.3 Reference Sections

1.3 PAYMENT

PART 2 PRODUCTS (NOT APPLICABLE)

PART 3 EXECUTION (NOT APPLICABLE)

-- End of Section Table of Contents --

SECTION 01 22 00.00 26 Page 1 g4ecctgh

Amendment-002 - Paragraph: 1.3

SECTION 01 22 00.00 26 Page 2

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 shall constitute full compensation for furnishing all parts, labor, equipment, and materials, as well as 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 shall also constitute 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 bid item.

1.2 MEASUREMENT

1.2.1 Job Measurement Items

Measurement items for the work of this contract for which contract lump sum payments will be made are listed in the SECTION B and described below. All costs for items of work, which are not specifically mentioned to be included in a particular lump sum or unit price measurement item, shall be included in the listed lump sum item most closely associated with the work involved. The lump sum price for each item listed shall constitute full compensation for furnishing all plant, labor, materials, and equipment, and performing any associated Contractor quality control, environmental protection, meeting safety requirements, tests and reports, and for performing all work required for which separate payment is not otherwise provided.

1.2.2 Unit Price Measurement Items

Measurement items for the work of this contract on which the contract unit price payments will be made are listed in the PRICING SCHEDULE and described below. The unit price for each item listed shall constitute full compensation for furnishing all plant, labor, materials, and equipment, and performing any associated Contractor quality control, environmental protection, meeting safety requirements, tests and reports, and for performing all work required for each of the unit price items.

1.2.3 Reference Sections

Sections referenced at the end of each Bid Item listing are included for reference only and do not necessarily include all the detailed information required for the completion of the work described in the bid item.

1.3 PAYMENT

Payment for all work specified, shown or incidental to complete the work will be made as follows:

Required Work

SECTION 01 22 00.00 26 Page 3

Item 0001 - Partial Disassembly and Reassembly

Payment for the Partial Disassembly and Reassembly of the turbine needed to complete the work will be made on a job basis under Item 0001. This includes the removal and reassembly of half the turbine guide bearing housing, packing box, top plate, nut guard, and any auxiliary mechanical or electrical equipment (pumps, RTDs, etc).

Payment also includes the coupling and installation of the turbine guide bearing halves, which is currently split and removed from the unit.

Item 0002 - Design, Fabrication, and Installation of Sealing Ring

Payment for the Design, Fabrication, and Installation of the Sealing Ring will be made on a job basis under Item 0002. Payment shall include all labor, material, and equipment required to design, fabricate, and install a sealing ring at the location connecting the turbine shaft flange to the turbine hub. Payment also includes detailed design drawings, o-rings, sealants, and any consumables.

Item 0003 - Welded Caps for Coupling Bolts

Payment for fabricating and installing the Welded Caps for Coupling Bolts will be made on a job basis under Item 0003. Payment shall include labor, material, and equipment required to fabricate and weld 30 caps. Payment for pressure testing will be made under Item 0011.

Additionally, payment includes the labor and equipment required to pressure test the caps.

Item 0004 - Stainless Steel Tubing Installation

Payment for the Stainless Steel Tubing Installation routed to the unwatering piping will be made on a job basis under Item 0004. Payment shall include complete design, labor, material, and equipment required to install stainless tubing from jacking bolt holes to existing unwatering piping and providing a check valve, in accordance with specifications. Additionally, payment includes the submitted drawing.

Item 0005 - Furnishing Shaft Packing

Payment for Furnishing Shaft Packing will be made on a per foot length basis under Item 0005. Payment shall include purchasing the shaft packing and delivery to the powerhouse.

Item 0006 - T&M: Provide Skilled Liquid Penetrant Testing (PT)

Payment for all Penetrant Testing (PT) will be made on an hourly basis under Item 0006. This CLIN is intended for additional work as required based on as-found conditions. Payment shall include labor, material, and equipment as required , as well as a report of findings.

in accordance with specifications.

Item 0007 - T&M: Provide Skilled Millwright Hire

Payment for Millwright Hire will be made on a per hour basis under Item 0007. This CLIN is intended for additional work as required based on as-found conditions. Payment shall include labor, material, and equipment as required in accordance with specifications. It is anticipated that this item will be used for surface preparation of the

SECTION 01 22 00.00 26 Page 4 g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0003" g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0006" g4ecctgh

Amendment-002 - Paragraph: 1.3 "Item 0007" turbine shaft flange, as estimated with 24 hours. If any other millwright labor is anticipated, this item may be used.

Item 0008 - T&M: Provide Skilled Welding Hire

Payment for Welding Hire will be made on an hourly basis under Item 0008. Payment for welding of the caps on the coupling bolts as well as the welding of the nut guard during reassembly will be made under Item 0008. This CLIN is intended for additional work as required based on as-found conditions. Payment shall include labor and equipment as required. THis line item is for welder hire and appropraite equipment for welding. Payment shall include labor and equipment as required in accordance with specifications. The payment for consumables required for welding will be made under Item 0009.

Item 0009 - T&M: Welding Consumables

Payment for Welding Consumables as required will be made on a per pound (lb) basis under Item No. 0009. This CLIN is intended for additional work as required based on as-found conditions. Payment shall include the materials as required in accordance with specifications. Payment shall include only the cost of only the consumables needed for welding. Payment for welding hours and equipment will be made under Item 0008.

Item 0010 - T&M: Provide Skilled Painting (Labor Only)

Payment for painting the sealing ring and coupling bolt welded caps will be made on a per-square foot basis under Item 0010 and is for labor and painter equ pi ip ment only (brushes, rags, etc.). Estimated area of paint is 30 square feet. Only paint and primer will be furnished by the Government.

Item 0011 - Final Testing

Payment for Final Testing will be made on a per job basis under Item 0011. Payment shall include labor, material, and equipment for penetrant testing of all welds performed by the Contractor during disassembly, completion of work, and reassembly. Payment shall also include final to test the pressure testing and repairs in all locations (welded caps, seal ring, blade seals, runner cone gasket). Penetrant testing will be made separately under Item 0006.

Optional Work

Item 0012 - Installion of Blade Seals (OPTION)

Payment for installing blade seals will be made on a job basis under Item 0012. Payment shall include the installation of government-furnished turbine blade seals and followers (seal rings).

Item 0013 - Installation of Runner Cone Gasket (OPTION)

Payment for installing the runner cone gasket will be made on a job basis under Item 0013. Payment shall include the installation of the government-furnished runner cone gasket.

Item 0014 - Hub to Runner Cone Seal Weld (OPTION)

SECTION 01 22 00.00 26 Page 5

Lower Monumental Unit 2 Turbine Hub Seal Repairs W912EF21B0013 Amendment - 002 g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0007" g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0008" g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0009" g4ecctgh Line Amendment-002 - Paragraph: 1.3 "Item 0010" g4ecctgh

Amendment-002 - Paragraph: 1.3 "Item 0011"

Payment for the Hub to Runner Cone Seal Weld will be made on a job basis under Item 0014. Payment shall include all labor and materials needed for the seal weld of the turbine hub to runner cone connectionto be completed.

PART 2 PRODUCTS (NOT APPLICABLE)

PART 3 EXECUTION (NOT APPLICABLE)

SECTION 01 22 00.00 26 Page 6

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.04 26

EXISTING TURBINE COMPONENT, REFURBISHMENT AND REPLACEMENT

PART 1 GENERAL

1.1 SCOPE

1.2 CURRENT UNIT STATUS

1.3 GENERAL REQUIREMENTS

1.4 REFERENCES

1.5 SUBMITTALS

PART 2 PRODUCTS

2.1 MATERIALS

2.2 SHAFT SEALING RING

2.3 WELDED CAPS ON COUPLING BOLTS

2.4 STAINLESS STEEL TUBING

2.5 MAIN SHAFT PACKING

2.6 FASTENERS

PART 3 EXECUTION

3.1 CLEANING AND AS-FOUND INSPECTIONS

3.1.1 General Requirements

3.1.2 Cleaning

3.1.3 As-Found Inspections

3.2 DISASSEMBLY

3.2.1 General

3.2.2 Disassembly Procedure

3.2.3 Disassembly Procedure Notes

3.3 INSTALLATION OF METAL SEALING RING

3.3.1 Requirements of Shaft Sealing Ring Installation

3.4 SEAL WELD SHAFT-TO-HUB COUPLING BOLT CAPS

3.4.1 Penetrant Testing

3.5 INSTALLATION OF OIL VENT TUBING

3.6 INSTALLATION OF BLADE SEALS (OPTIONAL)

3.7 INSTALLATION OF RUNNER CONE GASKET (OPTIONAL)

3.8 SEAL WELD RUNNER CONE TO HUB (OPTIONAL)

3.9 FINAL INSPECTIONS

3.9.1 Hold Points

3.9.2 Pressure Test

3.10 ACCESSORIES

3.10.1 Auxiliary Mechanical and Electrical Equipment

3.10.2 Painting

3.10.3 Packing, O-Ring, Gaskets

3.10.4 Locking Mechanisms

3.10.5 Dowel Pins

3.10.6 Tapped Holes

3.11 SURFACE CLEANUP

3.12 REASSEMBLY

3.12.1 Reassembly Procedure

ATTACHMENTS:

SECTION 48 13 13.04 26 Page 1 g4ecctgh Line Amendment-002 - Paragraph: 3.2.1(d) g4ecctgh Line Amendment-002 - Paragraph: 3.7 g4ecctgh

Amendment-002 - Paragraph: 3.12

"Blade Seal Installation Guidance"

-- End of Section Table of Contents --

SECTION 48 13 13.04 26 Page 2

SECTION 48 13 13.04 26

EXISTING TURBINE COMPONENT, REFURBISHMENT AND REPLACEMENT

PART 1 GENERAL

1.1 SCOPE

This Section details the work required. The Contractor shall complete this work as specified herein or as directed in writing. The following articles and paragraphs, prescribe the minimum requirements.

1.2 CURRENT UNIT STATUS

The unit will be nearly fully-assembled upon Contractor arrival. All of the work will be contained in the turbine pit and water passage. The unit will be unwatered with the turbine maintenance platform installed. The oil is removed from the turbine runner. The turbine guide bearing is already removed, but disassembly work is required as described herein. After completion of repairs, the turbine guide bearing is to be installed by the contractor. The blade followers (BLH 43901 Items 1-4 Seal Ring) have already been removed from the turbine hub.

Hazardous energy sources will be isolated and rendered inoperative before work is started on the equipment. All work around the unit should be done in accordance with Lower Monumental's safe clearance procedures as specified in Section 01 35 29.10 28 .

1.3 GENERAL REQUIREMENTS

a. Requirements governing the disassembly and modification of existing turbine components and the supply of associated replacement components are contained in this Specification SECTION.

b. In the event that Contractor proposed modifications impact other systems or components, the Contractor shall modify or replace said systems or components in such a manner as to maintain the function or functionality which existed prior to commencing the refurbishment.

c. All items which are replaced or no longer used as a result of these refurbishments or replacements shall be placed in a single location, as directed by the on site Government Quality Assurance Representative (GQAR).

1.4 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.

The Contractor shall be responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation.

ASTM INTERNATIONAL (ASTM)

ASTM A285/A285M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and

SECTION 48 13 13.04 26 Page 3

Intermediate-Tensile Strength

ASTM A516/A516M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate-and Lower-Temperature Service

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020) Structural Welding Code - Steel

1.5 SUBMITTALS

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

submittals having an "I" designation are for information only. A 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-01 Preconstruction Submittals

Shaft Sealing Ring Drawing ; G, HDC Submit 15 calendar days prior to fabrication.

Coupling Bolt Welded Cap Drawing ; G, HDC Submit 15 calendar days prior to fabrication.

Procedure for Welded Caps on Coupling Bolts ; G, HDC Submit 15 calendar days prior to commencing fabrication and installation.

Disassembly Procedure ; G, HDC Submit at least 15 calendar days prior to site mobilization.

Oil Vent Tubing Schematic ; G, HDC Submit at least 60 calendar days prior to commencing installation.

Materials List ; G, HDC Submit at least 15 calendar days prior to fabrication.

Runner Cone to Hub seal Weld Procedure ; G, HDC Submit at least 15 calendar days prior to seal welding.

SD-05 Design Data

Pressure Test Procedure ; G, HDC Submit at least 15 calendar days prior to testing.

Deviations In Material Specifications ; G, HDC A minimum of 15 calendar days prior to use of alternative materials.

Notification of Pressure Test ; G, HDC Submit at least 7 calendar days prior to pressure test of tubing.

Reassembly Procedure ; G, HDC Submit at least 30 calendar days before reassembly

Notification of Reassembly ; G, HDC Submit at least 7 days prior to reassembly

SECTION 48 13 13.04 26 Page 4

Runner Cone Gasket Installation Procedure ; G, HDC Submit at least 21 days prior to gasket installation work.

Blade Seal Installation Procedure ; G, HDC Submit at least 21 days prior to gasket installation work.

SD-06 Test Reports

Welded Caps PT Report ; G, HDC

Pressure Test Record ; G, HDC Submit within 7 calendar days of the completion of the pressure test .

SD-07 Certificates

Notification of Hold Point Inspection ; G, HDC Submit 72 hours prior to inspection; reference paragraph "Hold Points".

PART 2 PRODUCTS

2.1 MATERIALS

Submit Materials List for proposed materials to be used in design with available material certifications. Materials listed should include, but are not limited to, the materials used in the shaft sealing ring, the sealing ring sealant, sealing ring gaskets, welded caps, unwatering piping, and welding materials. Submit proposed Deviations in Material Specifications whenever a change in materials from the original design or these specifications is desired by the Contractor.

2.2 SHAFT SEALING RING

A two-part sealing ring complete with a gasket is to be used from material conforming to ASTM A285/A285M , ASTM A516/A516M , or approved deviation as described in paragraph "Materials". Reference the contract drawing package (M-101, M-102, and M-901). The intent is to fabricate and install a shaft sealing ring, as designed by the Contractor, to secure around the turbine shaft with a flanged connection. Segmenting of the shaft sealing ring will be required for assembly around the shafting in place. The shaft sealing ring is to have a void where it interfaces with the shaft and hub. This void is to be filled with a RTV sealant to fill the groove area, as recommended by the Contractor. The shaft sealing ring is to be designed with injection ports for the RTV sealant. Gaskets are required on the shaft surface (vertical) and on the turbine hub surface (horizontal).

Submit a fully dimensioned Shaft Sealing Ring Drawing for approval to include at a minimum the following:

a. Method of joining split flange(s) and securing sealing ring in place;

b. RTV sealant to be used at shaft OD and turbine hub (reference M-101);

c. Material composition;

Alternate sealing systems can be submitted for review. The formed-in-place (FIP) gasket may either be an anaerobic adhesives or room temperature vulcanizing silicone, as recommended by the Contractor.

SECTION 48 13 13.04 26 Page 5

2.3 WELDED CAPS ON COUPLING BOLTS

a. Provide 30 coupling bolt caps and weld in place. Two caps will require modification to accommodate existing unwatering piping, see drawing M-901.

b. The coupling bolt nuts are shown on drawing R-022 (Item 3 on BLH drawing 43912). However, for sizing cap length and ID, field verification of nut dimensions and coupling bolt protrusion is required. Cap length should be sized to ensure runner hub cover plate can be re-installed without interference, see 3.2.3 below. Submit Coupling Bolt Welded Cap Drawing for approval, prior to completing work.

c. Caps shall be welded to turbine shaft flange in accordance with approved procedure.

2.4 STAINLESS STEEL TUBING

Supply 3/8 inch stainless steel tubing, a check valve, and all required National Pipe Thread (NPT) taps for complete installation as described by these specifications and contract drawings. The tubing is shown on M-102 and will have three connections into the top of the turbine shaft flange.

Three NPT connections, 120 degrees apart, are to be installed into the existing jack bolt holes. Each of these connections are to be routed to the existing unwatering piping at this location. A check valve will be used at the junction of the unwatering pipe such that backflow through the tubing and the jacking bolts will not be possible.

2.5 MAIN SHAFT PACKING

Supply and deliver six (6) lengths of Style 102SC AKII Blackjack packing, suited for use in hydroelectric turbines as specified herein. The packing shall be one (1) inch square, 15-1/2 foot long lengths, industrial style, densely braided fiber packing made from 100% GFO material (a composition of tetrafluroethylene (TFE) and graphite fiber yarn). The packing shall utilize multi-cord silicone rubber o-ring cords within the braided packing and be suitable for surface speeds up to 4200 fpm, pressures up to 2000 psi, and temperatures of 500 degrees Fahrenheit. The packing shall be designed that it naturally squares itself around the shaft. Braided packing that forms a wedge-shape (keystone) when formed around a shaft will not be accepted.

Deliver to the site at least seven (7) days prior to reassembly. The Contractor shall be responsible for packing and shipping the packing in a manner that will ensure all pieces are undamaged and complete upon arrival to the Project.

2.6 FASTENERS

Supply replacement fasteners for the top plate. Fasteners 0.75-inch in diameter and larger shall conform to ASTM A193/A193M type B7, and nuts shall conform to ASTM A194/A194M grade 7.

Replace all other fasteners removed with the same material, grade, temper, size, shape, etc. as the original, unless otherwise approved or directed.

Threaded bolts and studs shall conform to the requirements ASME B18.2.1.

Threaded nuts shall conform to ASME B18.2.2. Lock and plain washers shall

SECTION 48 13 13.04 26 Page 6 conform to ASME B18.21.1. Bolts, nuts, studs, and washers in contact with galvanized surfaces shall also be galvanized. Galvanized coatings shall conform to ASTM A123/A123M.

PART 3 EXECUTION

3.1 CLEANING AND AS-FOUND INSPECTIONS

3.1.1 General Requirements

It is the intent of this work that all disassembled components will be cleaned and reused. Cleaning, inspections, recommendations for repair or replacement (if necessary) shall be considered incidental to the work and separate payment shall not be made.

3.1.2 Cleaning

Components and assemblies that shall be reused shall be cleaned of all rust, scale, oil, scum, grease and foreign matter. The Contractor shall then inspect the physical condition of each component, submit an inspection report and submit recommendations for corrective action prior to performing any refurbishment.

3.1.3 As-Found Inspections

a. All components shall be visually examined (inspected) for surface condition (wear, physical damage, cracks, cavitation, etc.). If the Contractor considers any of the components not suitable for reuse, notify the Government immediately.

b. Each component shall be examined within 5 calendar days of its removal from the unit, unless specified differently elsewhere and for each component, submitted, and the Government may witness any inspection at its discretion.

3.2 DISASSEMBLY

3.2.1 General

a. The preparation of the work area will require partial disassembly, limited to within the turbine pit. During disassembly the contractor shall clearly identify all of the parts, noting the match marks and making new match marks where needed. Match marks shall be visible after cleaning and painting.

b. Disassembly of the unit shall include disassembly of all related parts required for the specified work.

c. All opened oil pipes, including those removed, shall be capped by covering the end with plastic, and then securely taping the plastic in place such that no foreign material can enter.

d. For the storage of components, surfaces shall be protected from damage by utilizing wood softeners or equivalent. All components disassembled , with the exception of the turbine guide bearing housing, are to be stored within the turbine pit on the erection bay floor . Coordinate with the GQAR if there are any concerns about where to store components after disassembly.

SECTION 48 13 13.04 26 Page 7 g4ecctgh

Amendment-002 - Paragraph: 3.2.1(d)

3.2.2 Disassembly Procedure

a. The Contactor shall submit a proposed Disassembly Procedure .

Disassembly of the unit is to follow the approved work schedule and disassembly.

b. The procedure shall describe the methods, including rigging, to be used to remove all components, including, but not limited to the turbine guide bearing housing, packing box, top plate, and nut guard. Specific details for each component to be disassembled are provided in the following paragraphs. All removed components, with the exception of the turbine guide bearing housing, are to be taken to the erection bay floor to be refurbished by the Government. After refurbishment by the Government, it's the Contractor's responsibility to return components to turbine pit for reassembly.

3.2.3 Disassembly Procedure Notes

Access to bolting flange will be made with inner headcover left in place.

The nut guard (identified as cover plate, piece 4 on BLH drawing 43892) will need to be cut and removed near the OD for accessing bolting flange.

The following steps are to be detailed in the submitted Disassembly Procedure.

a. Prior to removal of turbine guide bearing housing half (see BLH drawing 43848), the oil sump (guide bearing oil catcher on BLH drawing 43851) will need to be lowered from the turbine guide bearing housing. Remove one half of the turbine guide bearing housing. After removal of turbine guide bearing housing half, the oil sump will need to be split and removed.

b. Remove the packing box assembly (see detail on BLH drawing 43853), top plate, and other interferences (e.g. sump pump, piping, packing box walkway, etc.) to gain access to the work area.

c. Cut the nut guard, referred to as runner hub cover plate on BLH drawing 43892, near the OD such that it can be welded back after repairs are made.

All welds, welders, and consumables must follow requirements in

AWS D1.1/D1.1M .

d. Unbolt the ID of the cover plate halves and remove.

3.3 INSTALLATION OF METAL SEALING RING

The surface condition of the turbine shaft and turbine hub in this location is not known until this work has begun and the nut guard has been cut out, as described above. It is expected that after disassembly, surface preparation will take place to clean up the surface for the remaining work. At a minimum, area should be cleaned to remove surface corrosion and paint to provide suitable surface for sealing. Wire brush, or similar, is acceptable. However, the use of grinding wheels is prohibited. Assume a maximum of 24 labor hours to prepare the surface for sealing ring. If significant additional surface preparation is required, prior to performing work, notify the Contracting officer as per FAR 52.236-2 Differing Site Conditions for prompt investigation.

3.3.1 Requirements of Shaft Sealing Ring Installation

a. All injection ports are to be plugged prior to pressure testing.

SECTION 48 13 13.04 26 Page 8

b. Upon completion, the installation will be inspected by the Government.

3.4 SEAL WELD SHAFT-TO-HUB COUPLING BOLT CAPS

The thirty (30) coupling nut and studs protruding from turbine shaft are to be covered with welded caps. All welds, welders, and consumables must follow requirements in AWS D1.1/D1.1M . Note that the two coupling bolts that are nearest to the existing unwatering piping will need to have a reduction in diameter at the top of the welded cap, due to this interference of components. A photo of these caps, with an arrowhead pointing to the two differing caps, is provided in M-901 (Detail G-15).

Submit for approval the Procedure for Welded Caps on Coupling Bolts to include the following at a minimum:

a. Welder certifications and welding procedure specifications (WPS);

b. Materials and dimensions for welded caps;

3.4.1 Penetrant Testing

Upon completion of the welding, penetrant testing (PT) is to be performed by a third-party Non Destructive Examination (NDE) company on 100% of completed welds, including any welds to fabricate the caps. NDE requirements are detailed in 05 05 33.20 26 . Rejectable defects are to be repaired at no additional cost to the Government. Submit the Welded Caps PT Report to the Government before completing final pressure testing, described below.

3.5 INSTALLATION OF OIL VENT TUBING

Oil that leaks between the turbine hub and turbine shaft will be routed out the current unwatering piping system, located near the turbine shaft to hub flange. There are three 1.5-inch diameter jacking bolt holes with 8-UN threads located on the top of the turbine shaft flange 120 degrees apart. New NPT taps will be installed for 3/8-inch stainless steel tubing.

A check valve will be included to prevent any backflow into the flange face. Piping from the jacking bolt holes will be installed and routed to an existing unwatering piping location and into the static oil at the bottom of the runner. Prior to completion of work, the piping will be pressure tested to verify no leaks are present, with GQAR oversight.

NPT reducers (3 total) are to be installed in the jacking bolt holes and welded in place. Secure the fitting to piping or stainless steel tubing such that leaks in the shaft coupling flange will be vented to the hub static oil. Tubing will be secured in place every 18" of arc length by welding tubing holders to the turbine shaft (see M-901). The use of the existing unwatering piping is expected, but include a check valve such that the unwatering pipe can still be used to empty the runner hub. Submit Oil Vent Tubing Schematic for approval of the intended piping locations, to assure the piping is routed such that it is entering the static oil in the hub.

3.6 INSTALLATION OF BLADE SEALS (OPTIONAL)

The blade seals are government furnished equipment that will be installed by the contractor if optional work is elected. A "Blade Seal Installation Guidance" attachment can be found at the end of this section. The attachment is a drawing for the seals to be installed, and manufacturer fitting procedures that need to be followed. Use this attached information

SECTION 48 13 13.04 26 Page 9 to draft and submit for approval the Blade Seal Installation Procedure , detailing at a minimum the following:

a. Removal of existing seals on all six runner blades. Blade followers (BLH 43901 Items 1-4 Seal Ring) do not require disassembly as they are already removed;

b. Cleaning and preparation of the blade seal packing area, including hold point for inspection by Government;

c. Installation of the government-furnished blade seals, to manufacturer's recommendations;

d. Reassembly of government-furnished blade seal followers;

e. General description of process and quality control.

3.7 INSTALLATION OF RUNNER CONE GASKET (OPTIONAL)

The runner cone gasket and runner cone studs are government furnished equipment. The runner cone gasket is Garlock 3760 with a thickness of 1/16". If optional work is elected by Government, the runner cone gasket is to be installed by the contractor. Submit for approval, the Runner Cone Gasket Installation Procedure detailing at a minimum, the following:

a. Installation and calculations for welded lugs on runner hub and cone (for lowering of the cone in-place);

b. Removal of bolt access panels (18 total), approximately 8 x 14 x

0.25 inches in size. Procedure will include the rewelding of these panels after the work is complete. Include the proposed welding procedure (WPS).

c. Cleaning and preparation of gasket surface;

d. Proposed torque sequence, including torque calculation;

e. General description of process and quality control.

3.8 SEAL WELD RUNNER CONE TO HUB (OPTIONAL)

Weld a band of simliar steel to the runner hub and runner cone connection.

The band will be approximately 1.5 inches wide, and fully cover the circumference at this connection. Seal welds will be used on the top and bottom of the band, as specified in the procedure required below.

If this option is exercised, the Contractor is to submit for approval a Runner Cone to Hub Seal Weld Procedure . The procedure will include a material certificate for the band, welding procedure specification (WPS), and welder certifications, showing qualifications for the desired welding technique.

3.9 FINAL INSPECTIONS

The Government will perform a final inspection of the completed work, prior to reinstallation of the nut guard. It is expected that this can occur at the time of the test described in paragraph "Pressure Test."

SECTION 48 13 13.04 26 Page 10 g4ecctgh

Amendment-002 - Paragraph: 3.7

3.9.1 Hold Points

At the following stages of the work, the Government requires inspection.

These are considered hold points and the contractor is not to continue work until the Government has agreed work can continue. A Notification of Hold Point Inspection is required 72 hours prior to the inspection.