Statement of Work - Technical Specs - Cordell Hull Thrust Bearing Shoes .pdf

Nashville District

CORDELL HULL POWER PLANT

THRUST BEARING SHOES

Cumberland River Basin

Carthage, Tennessee

Technical Specifications

July 9, 2021

THIS PAGE INTENTIONALLY LEFT BLANK

FOR DUPLEX PRINTING

Thrust Bearing Shoes Cordell Hull Power Plant

SECTION 48 13 13.06 Page 1

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.06

GENERATOR THRUST BEARING SHOES

PART 1 GENERAL

1.1 GENERAL SCOPE

1.2 SYSTEM DESCRIPTION

1.3 REFERENCES

1.4 SUBMITTAL REQUIREMENTS

1.4.1 General

1.4.2 Scheduling

1.4.3 Submittal Delivery

1.4.4 Review Notations

1.5 SUBMITTALS

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Point of Delivery

1.6.2 Delivery Schedule

1.7 WARRANTY

1.8 PAYMENT

1.9 WITHHOLDING OF PAYMENT

1.10 STAMPS

1.11 PROJECT SITE SECURITY

1.11.1 Access and General Protection/Security Policy and Procedures

1.11.2 Background Investigation Requirements

1.11.3 Required Escorts

1.11.4 Pre-Screening Employee Candidates

PART 2 PRODUCTS

2.1 THRUST BEARING SHOES

2.1.1 Babbitting Materials

2.1.2 Material and Workmanship

2.1.3 ISO Certification

PART 3 EXECUTION

3.1 DISASSEMBLY

3.2 SHIPPING

3.3 REFURBISHMENT OF THRUST BEARING SHOES

3.3.1 General

3.3.2 General Refurbishment Requirements

3.3.3 Refurbishment Including Babbitting

3.3.4 Thrust Shoe Finished Inspection and Final Report

3.4 BABBITT BOND NDT

3.4.1 General

3.4.2 NDT Procedure and Requirements

3.4.3 UT Inspectors Qualifications

3.4.3.1 Examination of Babbitt Bonding

3.4.3.2 Technician(s)

3.4.4 Equipment

3.4.5 Procedure

3.4.6 Liquid Penetrant (PT) Testing

SECTION 48 13 13.06 Page 2

3.4.7 Acceptance Standards

3.4.8 NDT Inspection Report

3.4.9 Babbitt Repairs

3.4.10 Babbitt Bond Acceptance

3.5 INSTALLATION

3.6 THRUST BEARING SHOE DISASSEMBLY TESTS

3.7 ACCEPTANCE

3.7.1 Thrust Bearing Shoe Acceptance

ATTACHMENTS:

Submittal Register

ENG Form 4025-R

Inspection Sheets

Tolerance Sheets

-- End of Section Table of Contents --

SECTION 48 13 13.06 Page 3

PART 1 GENERAL

1.1 GENERAL SCOPE

SECTION 48 13 13.06

GENERATOR THRUST BEARING SHOES

The Contractor shall refurbish the thrust bearing shoes for Unit 3 for

Cordell Hull Power Plant. The Contractor shall arrange round-trip pickup and delivery of the thrust bearing shoes. Period of performance of this contract shall not exceed 60 calendar days from date of award.

1.2 SYSTEM DESCRIPTION

The thrust bearing consists of 10 steel-backed babbitt segments or shoes.

For the purposes of this Specification, one "set" consists of 10 shoes.

The babbitt is of a tin base. Dimensions, fits, and estimated weights are based on original design criteria and/or calculations, thus are provided for information only. The Contractor shall verify all provided dimensions, properties, and features in the solicitation documents.

1.3 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 V (2011) BPVC Section V-Nondestructive

Examination

ASTM INTERNATIONAL (ASTM)

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

Commercially as "Babbitt Metal")

ASTM E114 (2015) Standard Practice for Ultrasonic

Pulse-Echo Straight-Beam Contact Testing

ASTM E165/E165M (2012) Standard Practice for Liquid

Penetrant Examination for General Industry

SECTION 48 13 13.06 Page 4

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2016) Recommended Practice for Personnel Qualification and Certification in

Nondestructive Testing

1.4 SUBMITTAL REQUIREMENTS

1.4.1 General

The Government may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections.

Submittals requiring Government approval are to be scheduled and made prior to the acquisition of the material or equipment covered thereby.

All submittals will go through the Contracting Officer's

Representative(COR), as directed. The COR may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections.

Units of weights and measures used on all submittals are to be the same as those used in the contract drawings.

Each submittal is to be complete and in sufficient detail to allow ready determination of compliance with contract requirements.

The Contractor and the Designer of Record, if applicable, shall check, approve, stamp, sign, and date all items prior to submittal submission indicating action taken. Proposed deviations from the contract requirements are to be clearly identified. Include within submittals items such as: Contractor's, manufacturer's, or fabricator's drawings;

descriptive literature including (but not limited to) catalog cuts, diagrams, operating charts or curves; test reports; test cylinders;

samples; O&M manuals (including parts list); certifications; warranties;

and other such required submittals.

Submittals requiring Government approval are to be scheduled and made prior to the acquisition of the material or equipment covered thereby.

Work cannot proceed without approval of submittals requiring government approval.

Submittals will be evaluated based on only their compliance with requirements set forth in the contract documents. It is the Contractor's responsibility to ensure compliance before submission. The Government reserves the right to reject submittals not in compliance with contract documents. The Contractor will bear all of the cost from rejected submittals due to non-compliance.

Normally submittals for information only will not be returned. Approval by the COR is not required on information only submittals, but submission is still required. The Government reserves the right to require the

Contractor to resubmit any item found not to comply with the contract.

This stipulation: does not relieve the Contractor from the obligation to furnish material conforming to the plans and specifications; will not prevent the COR from requiring removal and replacement of nonconforming material incorporated in the work; and does not relieve the Contractor of the requirement to furnish samples for testing by the Government

SECTION 48 13 13.06 Page 5 laboratory or for check testing by the Government in those instances where the technical specifications so prescribe.

1.4.2 Scheduling

Allow 14 calendar days, unless otherwise noted under heading SUBMITTALS, from date of submission for COR to review and return Government approval required submittals.

Allow 14 calendar days from date of submission for COR to review For

Information Only (FIO) submittals.

Schedule and submit concurrently submittals covering component items forming a system or items that are interrelated. Include certifications to be submitted with the pertinent drawings at the same time. No delay damages or time extensions will be allowed for time lost in late submittals.

a. Coordinate scheduling, sequencing, preparing and processing of submittals with performance of work so that work will not be delayed by submittal processing. Allow for potential resubmittal of requirements.

b. Submittals called for by the contract documents will be listed on the register. If a submittal is called for but does not pertain to the contract work, the Contractor is to include the submittal in the register and annotate it "N/A" with a brief explanation. Approval by the COR does not relieve the Contractor of supplying submittals required by the contract documents but which have been omitted from the register or marked

"N/A."

c. Re-submit register and annotate monthly by the Contractor with actual submission and approval dates. When all items on the register have been fully approved, no further re-submittal is required.

d. Carefully control procurement operations to ensure that each individual submittal is made on or before the Contractor scheduled submittal date shown on the approved "Submittal Register."

1.4.3 Submittal Delivery

Use transmittal form ENG Form 4025-R for submitting both Government approved and information only submittals in accordance with the instructions on the reverse side of the form. Properly complete this form by filling out all the heading blank spaces and identifying each item submitted. Exercise special care to ensure proper listing of the specification paragraph and sheet number of the contract drawings pertinent to the data submitted for each item. Each submittal will have an updated submittal register attached.

Provide submittals in electronic format, with the exception of material samples required for SD-04 Samples items. Compile the submittal file as a single, complete document, to include the Transmittal Form described within. Name the electronic submittal file specifically according to its contents, coordinate the file naming convention with the COR. Electronic files must be of sufficient quality that all information is legible. Use PDF as the electronic format, unless otherwise specified or directed by the COR. Generate PDF files from original documents with bookmarks so that the text included in the PDF file is both searchable and can be copied. If documents are scanned, Optical Character Resolution (OCR) routines are

SECTION 48 13 13.06 Page 6 required. Index and bookmark files exceeding 30 pages to allow efficient navigation of the file. When required, the electronic file must include a valid electronic signature, or scan of a signature.

E-mail electronic submittal documents fewer than 10MB to an e-mail address as directed by the COR. E-mail only one (1) submittal per e-mail, unless otherwise directed by the COR. Provide electronic documents over 10MB on an optical disc, or through an electronic file sharing system such as the

DOD SAFE Web Application located at the following website:

https://safe.apps.mil/

1.4.4 Review Notations

Submittals will be returned to the Contractor with the following notations:

a. Submittals marked "approved" or "accepted" authorize the Contractor to proceed with the work covered.

b. Submittals marked "approved as noted" "or approved except as noted, resubmittal not required," authorize the Contractor to proceed with the work covered provided he takes no exception to the corrections.

c. Submittals marked "not approved" or "disapproved," or "revise and resubmit," indicate noncompliance with the contract requirements or design concept, or that submittal is incomplete. Resubmit with appropriate changes. No work shall proceed for this item until resubmittal is approved.

d. Submittals marked "not reviewed" will indicate submittal has been previously reviewed and approved, is not required, does not have evidence of being reviewed and approved by Contractor, or is not complete. A submittal marked "not reviewed" will be returned with an explanation of the reason it is not reviewed. Resubmit submittals returned for lack of review by Contractor or for being incomplete, with appropriate action, coordination, or change.

1.5 SUBMITTALS

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

submittals not having a "G" designation are for information only.

SD-01 Preconstruction Submittals

Thrust Bearing Shoe Refurbishment Procedure; G

Submit within 14 calendar days of contract award notice and at least 14 days prior to planned start of work. Allow 14 days for the COR to review this particular submittal. Work shall not proceed without COR approval of the Refurbishment Procedure.

Schedule For Thrust Bearing Shoe Refurbishment

Submit initial schedule within 14 calendar days of award notice and at least 14 days prior to refurbishment. Schedule will be updated weekly and as required. Coordinate with the Government for schedule regarding when thrust bearing shoes can be picked up. The schedule shall track the entire project. The Contractor shall provide weekly project updates and shall include updated schedules as needed. The project schedule shall not extend https://safe.apps.mil/

SECTION 48 13 13.06 Page 7 beyond the period of performance for the contract.

SD-02 Shop Drawings

Thrust Bearing Shoes Shop Drawings; G

Submit within 14 calendar days of contract award notice and at least 14 days prior to planned start of work. Work shall not proceed without COR approval of Shop Drawings. Workshop certification shall be submitted as part of shop drawings. Any and all computations performed shall be provided with the shop drawings. One (1) set of shop drawings in PDF format and one (1) set in .dgn or .dwg format shall be submitted for approval prior to refurbishment.

SD-04 Samples

Samples Of Materials

Submit within 10 calendar days of request.

SD-06 Test Reports

Chemical Analysis Of the Babbitt And Tin

Submit at least 14 days prior to tinning. Submit one for the set.

Thrust Bearing Shoe Disassembly Tests

Submit within 5 calendar days following tests. Submit one for the set.

Pre-Shipping Damage Inspection Report; G

Submitted prior to shipment from the project. Submit one for

Thrust Bearing Shoe Finished Inspection Report; G

Submit within 5 calendar days following inspections and prior to shipment. Submit one for the set.

SD-07 Certificates

Proof of ISO 9000 certification or equivalence

Submit with shop drawings.

NDT Personnel/Laboratory Qualifications

Submit at least 14 days prior to performing any NDT. Submit one for each NDT Personnel/Laboratory used.

Notice Of Thrust Shoe Finished Inspection

Submit at least 14 days prior to inspections. Submit one for

SECTION 48 13 13.06 Page 8

1.6 DELIVERY, STORAGE, AND HANDLING

Materials and equipment delivered and placed in storage shall be protected from the weather, humidity and temperature variations, dirt and dust, other contaminants, and physical damage. Equipment shall be shipped as completely assembled and wired as feasible so as to require a minimum of installation work. Any device which cannot withstand the hazards of shipment when mounted in place on the equipment shall be carefully packed and shipped separately. These pieces shall be marked and fully identified so they can be readily mounted and connected. All finished painted surfaces and metal work shall be wrapped suitably or otherwise protected from damage during shipment. The full set of shoes for one unit (10 shoes) shall be carefully packaged for long-term protection and storage and shall be clearly marked.

1.6.1 Point of Delivery

The Contractor shall coordinate shipping through Wesley Butler (Wesley.T.Butler@usace.army.mil; 615-735-0123). Phone contact shall take place Monday through Thursday during normal business hours (0800-1400) unless otherwise directed by the point of contact (POC).

150 Corps Ln

Carthage, Tennessee 37030

1.6.2 Delivery Schedule

The Contractor shall have 60 calendar days from pickup of a set of thrust bearing shoes to deliver the contract-compliant set of shoes to the project site. The Contractor shall allow for an adequate amount of time for relevant submittals to be reviewed as described in Paragraph SUBMITTAL

REQUIREMENTS. The Contractor shall coordinate with the Government regarding delivery date.

1.7 WARRANTY

The equipment to be furnished under this section shall be warranted to be free from defects in materials, design and workmanship for a period of one year from delivery date of each set, or the contracted period of any extended warranty agreed upon by the Contractor and the Government, after successful completion and acceptance of the job. Any component failing to perform its function as specified and documented shall be repaired or replaced by the Contractor at no additional cost to the Government.

1.8 PAYMENT

The Contractor shall receive one (1) payment for work performed on a per thrust bearing shoe set basis.

Each shoe needs to be contract-compliant for the entire set to be contract-compliant. Therefore, no partial payment will be made for a set

SECTION 48 13 13.06 Page 9 containing any noncompliant shoes until all shoes in that set are contract-compliant.

1.9 WITHHOLDING OF PAYMENT

No payment for materials or services incorporated in the work will be made if all required Government approvals have not been obtained. No payment will be made for any materials or services incorporated into the work for any conformance review submittals or information only submittals found to contain errors or deviations from the Solicitation or Accepted Proposal.

1.10 STAMPS

Stamps used by the Contractor on the submittal data to certify that the submittal meets contract requirements is to include:

a. Firm Name

b. Checkbox corresponding to "Approved"

c. Checkbox corresponding to "Approved with corrections as noted on submittal data and/or attached sheets"

d. Signature of approving official (Electronic or Scanned are Acceptable for electronic delivery).

e. Title of approving official

f. Date Signed

For design-build construction, both the Contractor Quality Control System

Manager and the Designer of Record are to stamp and sign to certify that the submittal meets contract requirements.

SECTION 48 13 13.06 Page 10

1.11 PROJECT SITE SECURITY

1.11.1 Access and General Protection/Security Policy and Procedures

All contractors and all associated sub-contractors shall comply with applicable District and local security policies and procedures (provided by the Government representative). The contractor shall provide any/all requested information required for background checks, background investigations and/or to meet installation/facility access requirements to be accomplished by the District Security Office. Refer to the next paragraph for current background investigation requirements. Contractor workforce must comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the

Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information

Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

1.11.2 Background Investigation Requirements

Since the work to be performed by the Contractor on-site is for 10 days or less the contractors must comply with site visit request requirements, there is an initial background screening. Please visit http://www.lrn.usace.army.mil/Business-With-Us/Contract-Security-Requirements/

However, Contractor(s) who only arrive on-site to pick up or drop off

(i.e. truck driver) are there specifically to provide a delivery and/or supply service, there are no investigation requirements. However, Contractor(s) will be escorted at all times inside the restricted area.

1.11.3 Required Escorts

All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

http://www.lrn.usace.army.mil/Business-With-Us/Contract-Security-Requirements/

SECTION 48 13 13.06 Page 11

1.11.4 Pre-Screening Employee Candidates

The Contractor must pre-screen potential employees to work on this contract using the E-verify Program (http:www.uscis.gov/e-verify) website to meet the established eligibility requirements. The Contractor must ensure that the employee has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible contract employees must be provided to the COR no later than 3 business days after the initial contract award.

PART 2 PRODUCTS

2.1 THRUST BEARING SHOES

2.1.1 Babbiting 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. The Contractor shall submit a Chemical Analysis of the Babbitt and

Tin material prepared by an independent testing laboratory prior to performing any tinning. The laboratory shall not be associated with the Contractor in any way.

2.1.2 Material and Workmanship

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 submitted upon request.

2.1.3 ISO Certification

The workshop where the thrust bearing shoes will be refurbished shall be

ISO 9000 certified or equivalent as approved by the Government. Proof of

ISO 9000 Certification or Equivalence shall be submitted to the Government with the shop drawing submittal.

PART 3 EXECUTION

3.1 DISASSEMBLY

Removal of the thrust bearing shoes shall be performed by the Government.

3.2 SHIPPING

The following general requirements apply to the thrust bearing shoes that are http://www.uscis.gov/e-verify)

SECTION 48 13 13.06 Page 12 being shipped:

a. The Contractor shall visually inspect the components' condition prior to shipment from the site in addition to measurements. Any existing damage shall be recorded and submitted as a Pre-Shipping

Damage Inspection Report prior to shipment. All damage shall be witnessed and "signed off" by the Government.

b. All components shall be prepared for shipment in a manner to protect them from damage. The Contractor shall be responsible for making-good any and all damage resulting from improper preparation, inspection, or shipping at no additional cost to the Government.

c. Prior to shipment, coat components with a suitable preservative.

d. The Contractor shall provide packaging services as required, packaging materials for shipment, and transportation roundtrip for each individual shoe or each set of thrust shoes between the project and the refurbishment workshop. New shipping boxes shall be provided as necessary to assure delivery of the thrust shoes in satisfactory, undamaged condition. Each shoe shall be packaged in a separate box that shall be suitable for handling with a lift truck.

e. The crates and all packaging shall become the property of the

Government.

f. Components shall be shipped in a way that protects from the environment. See Paragraph DELIVERY, STORAGE, AND HANDLING. Prior to shipping cover all inlets and outlets to exclude dirt, water, etc.

3.3 REFURBISHMENT OF THRUST BEARING SHOES

3.3.1 General

The thrust bearing shoes are described in the paragraph SYSTEM DESCRIPTION. The requirements governing the refurbishment of thrust bearing shoes shall apply to individual shoes or to an entire set of shoes. The Contractor shall be responsible for making-good any and all damage resulting from improper preparation, inspection, or refurbishment at no additional cost to the Government.

3.3.2 General Refurbishment Requirements

General requirements that apply for all thrust shoe refurbishment options are listed below:

a. Measure the shoe thickness at a minimum of three locations per

SECTION 48 13 13.06 Page 13 shoe: in the center of the shoe, in a machined location near the shoe

ID and in a machined location near the shoe OD, in undamaged locations. The results of the measurements and measurement locations shall be submitted to the Government prior to the beginning of any refurbishment as part of the Contractor's detailed refurbishment procedure. These measurements are in addition to the shoe measurements and inspections which were performed in the field prior to removal from the site under paragraph 3.2.a.

b. The Contractor shall submit a detailed Thrust Bearing Shoe

Refurbishment Procedure including a detailed step-by-step babbitting procedure. The thickness measurements taken in Paragraph a above, shall be included as well as the proposed thickness for the refurbished shoes. The Government's intention is that the shoes be machined and/or ground to the original or as measured existing thickness (combined shoe and babbitt thickness) plus the thickness removed from the runner and thrust collar (if applicable). The

Contractor shall not perform any work until receiving written approval from the Government.

c. A Schedule for Thrust Bearing Shoe Refurbishment, i.e. dates, shall be submitted for all phases of the shoes' refurbishment prior to beginning of the work. The schedule shall be updated and revised as required. The Government will use this schedule for witnessing refurbishment processes and will notify the Contractor as to which processes will be witnessed. See Paragraph Delivery Schedule

Requirements.

d. The requirements for the refurbished shoes (flatness, runout, thickness and surface finish) are listed on the Inspection Sheets provided at the end of this section.

e. Finish dimensions and runout checks shall be made while the shoes are still on the machining table or by an approved method.

f. All non-babbitted surfaces (including the shoe's ID, OD and sides) and holes shall be thoroughly cleaned without the removal of metal, unless approved in writing.

g. All options shall include appropriate finished inspections and the preparation of a report as specified in Paragraph "Thrust Shoe

Finished Inspection and Final Report".

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

3.3.3 Refurbishment Including Babbitting

The Contractor shall refurbish the thrust bearing shoes as specified below. Refurbish means removing the existing babbitt, pouring new babbitt, babbitt machining including the provision of oil supply grooves and other detail, and machining the shoe backside. The refurbishment shall return the shoes to the dimensional tolerances listed in the tolerances sheets provided at the end of this section.

a. A sample of the babbitt shall be taken and marked for identification at the time that the babbitt is poured. A sample shall be taken for each heat; i.e. if more that one shoe is poured simultaneously, only one sample is required. An independent testing

SECTION 48 13 13.06 Page 14 laboratory shall analyze each sample, unless otherwise approved, with the results linked to individual shoes and included in the final report.

b. The Contractor shall prepare the shoes for babbitting according to the procedure approved by the Government. Remove the existing babbitt and tinning material. Machine or shot blast, including dovetail grooves if applicable, and proceed immediately with tinning. Special care shall be taken to protect all holes and surfaces of the shoes not receiving babbitt. Precautions shall be taken to minimize shoe distortion during babbitting.

c. The babbitt shall be poured at a high temperature. The form and shoe shall be pre-heated. The pouring shall be continuous. Cold checks will not be acceptable.

d. The shoes shall be machined and/or ground to the original thickness or the as-measured existing thickness (combined shoe and babbitt thickness) plus the thickness removed from the runner and thrust collar (if applicable), unless otherwise approved. The Contractor's refurbishment procedure shall list any additional thickness of babbitt to be added to the shoes. The shoe backside shall be finished prior to finishing the babbitt running surface.

e. The backside of the shoes shall be machined and/or ground as required to enable the machining of the babbitted surface to achieve the tolerances listed on the Tolerance Sheets provided at the end of this section. The machining of the backside shall be performed prior to the machining of the babbitted face. Material removal shall be uniform over the shoe backside and consistent from shoe to shoe.

f. Machine and/or grind the poured babbitt layer to achieve the tolerances (flatness, runout, thickness, and surface finish) listed on the tolerance sheets provided at the end of this section. Provide oil supply grooves, radius edges, and other details identical to that found for the existing shoes.

g. Perform Non-Destructive Testing (NDT) of the babbitt bond according to paragraph "BABBIT BOND NDT".

h. Additional requirements are listed under paragraph "General Refurbishment Requirements" above.

3.3.4 Thrust Shoe Finished Inspection and Final Report

The inspection shall be performed as follows:

a. The finished thrust shoes shall be inspected for the purpose of verifying the requirements (flatness, runout, thickness, and surface finish) listed in the tolerance sheets provided at the end of this section.

b. The inspection shall include the NDT of the babbitt-to-shoe bond, as specified in Paragraph "BABBIT BOND NDT".

c. The Contractor shall furnish a Notice of Thrust Shoe Finished

Inspection to the Government in advance of all inspections and all inspections may be witnessed by the Government at its discretion.

SECTION 48 13 13.06 Page 15

d. All measurements shall be taken with calibrated instruments to the nearest 0.001 inch, unless otherwise indicated. Calibration certification for all equipment shall be furnished with the report of findings.

e. All data shall be recorded on the Contractor-supplied inspection sheets which shall be provided to the Government inspector prior to departure from the Contractor's facilities. Sample inspection sheets applicable for some of the required inspections are contained at the end of this section.

f. A Thrust Bearing Shoe Finished Inspection Report documenting the refurbishment including the results of the finished inspection measurements and of the babbitt bonding NDT shall be submitted prior to shipment and shipment shall not be made until authorized by the

Government.

3.4 BABBITT BOND NDT

3.4.1 General

This paragraph contains both NDT processes and acceptance criteria. The intent is that the acceptance criteria should only be applied to refurbished shoes and should not be used in non-final inspections. The

NDT performed during non-final inspections is not to assess the acceptability of the babbitting work, but rather to provide the Government with information to aid in the evaluation of the shoes existing condition. The acceptance criteria for final inspections of refurbished shoes is contained in Paragraph "Acceptance Standards".

3.4.2 NDT Procedure and Requirements

The metallurgical bonding of the babbitt to the thrust bearing shoes shall be examined using the Ultrasonic Test (UT) and Liquid Penetrant (PT) method of nondestructive testing. The Pulse-Echo Method of UT inspection shall be employed. Examination shall be made from the babbitt side and

100 percent of the babbitt area shall be inspected. UT examination shall be performed in accordance with the applicable portions of ASTM E114 and of Article 5 of the ASME BPVC SEC V. The UT procedure which is to be used shall be submitted for approval. The Government at its discretion may witness any inspections.

3.4.3 UT Inspectors Qualifications

3.4.3.1 Examination of Babbitt Bonding

An examination to determine the integrity of the babbitt-to-base metal bond, and to detect porosity and babbitt cracking, shall be performed by an approved independent testing laboratory which is regularly engaged in nondestructive testing, or it may be performed using Contractor personnel. If the examination is performed by Contractor personnel, the

Government may require that a representative from an approved independent testing laboratory be present during the examination to witness and certify the results. The laboratory shall be a member in good standing of the American Council of Independent Laboratories (ACIL). The laboratory shall be mutually agreeable between the Government and the Contractor.

Prior to the performance of any tests, the laboratory name, location and qualifications shall be submitted as part of the NDT Personnel/Laboratory

Qualifications submittal.

SECTION 48 13 13.06 Page 16

3.4.3.2 Technician(s)

Technician(s) performing the inspection shall be certified in accordance with the American Society for Nondestructive Testing (ASNT). The inspector who is performing the UT inspection or who is acting as a representative from an independent testing lab shall, as a minimum, be NDT: ASNT SNT-TC-1A level 2 qualified, with a minimum of 3 years experience at Level 2 in the last 5 years. Prior to the performance of any tests, the inspector's qualifications shall be submitted as part of the NDT Personnel/Laboratory Qualifications submittal. The inspector shall locate bonded and unbonded areas on the "Reference Blocks" in the presence of the Government's quality assurance representative.

3.4.4 Equipment

The following equipment shall be used:

a. Search Unit.

(1) All testing of the babbitt bond shall be performed with a

2.25 MHz or 5 MHz longitudinal wave crystal.

(2) Transducer diameter shall be between 0.25 inch and 1 inch.

(3) Transducer gloves or delay lines shall be made of Lucite or other materials with similar sonic properties.

b. Couplants used for testing shall be either lightweight oil or glycerin, the viscosity of which is no more than SAE 30 oil.

c. Reference Blocks.

(1) A reference block shall consist of a soundly babbitted steel block with a scanning surface and babbitt thickness representative of the shoes being tested. The block shall be used to set the sensitivity of the instrument. A reference block with artificially unbonded areas shall be provided for comparison of indications for areas showing bond and lack of bond.

(2) Test sensitivity shall be such that the babbitt-to-base material interface is readily identified on the CRT. Details of sensitivity calibration and determination of bonded and unbonded areas shall be defined in the UT procedure.

(3) Reference blocks shall be kept available for frequent reference during actual testing.

3.4.5 Procedure

The entire babbitt surface of each shoe segment shall be scanned, overlapping scan paths by at least 20 percent of the effective transducer width. Scanning rates shall not exceed 3 inches per second. Unbonded babbitt areas will result in an increase in the size of the reflection or indications of multiple reflections at the interface of the babbitt and base metal. Babbitted areas located over anchoring dovetail grooves will be excluded from UT inspection. All unbonded babbitted areas shall be carefully scanned to determine their size and configuration. The outside edges of all unbonded areas shall be marked on the surface of the babbitt and recorded on inspection sheets.

SECTION 48 13 13.06 Page 17

3.4.6 Liquid Penetrant (PT) Testing

The following test shall be performed:

a. All exposed babbitt to backing material bond lines, including dovetails if applicable, shall be examined with the liquid penetrant (PT) method. This shall be done using a solvent-removable visible dye. 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. The PT method that the Contractor proposes to use shall be submitted for approval and shall be in accordance with

ASTM E165/E165M. Lack of bond indications greater than 3/4 inches in length shall be marked on the shoes and mapped on inspection sheets or documented in photos.

b. The surface area of the babbitt, including oil grooves, shall be PT examined for cracks and porosity. Any and all indications shall be recorded on inspection sheets or documented in photos.

3.4.7 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.

(1) For steel backed shoes the total unbonded area shall be no larger than 5 percent of the total zonal area.

(2) For cast iron backed shoes the total unbonded area shall be no larger than 15 percent.

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.

c. Dovetails. Zone defined as the entire surface area over a dovetail. Dovetails are exempt from UT examination.

d. Bond Lines. Defined as exposed lines at the babbitt to base metal interface.

(1) For steel backed shoes, 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 0.25 inch diameter transducer. Unbonded areas extending more than 1/8 inch away from an edge shall be unacceptable.

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

(1) For steel backed shoes the total unbonded area shall be no larger than 5 percent of the total zonal area.

SECTION 48 13 13.06 Page 18

f. Additional Requirements. The babbitt surface shall have no visible porosity, blow holes, shrinkage or cracks. The exposed bond line shall have no visible disbonding.

3.4.8 NDT Inspection Report

A written report from the independent laboratory, whether they perform or witness the testing, shall be submitted as part of the final report. The report shall include a complete description of the UT procedures used, equipment used, a mapping of the areas tested, shoe number, and interpretation of results. The report shall specifically address areas of lack of bond between the babbitt and the shoe and their accumulated total surface area relative to the area allowed area for the zone. PT results shall include a mapping of indications at the bond lines or photos. The report shall also address porosity, cracking and other surface defects.

3.4.9 Babbitt Repairs

If repairs are required to the babbitt surface or to the babbitt-to-backing material interface a 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 10 percent of the total babbitted surface.

3.4.10 Babbitt Bond Acceptance

If a shoe's babbitt bond does not meet the above acceptance criteria it shall be repaired or completely rebabbitted and retested at the

Contractor's expense until the bond is acceptable in accordance with these specifications.

3.5 INSTALLATION

Installation of the refurbished thrust bearing shoes shall be performed by the Government. The Contractor shall coordinate with the Government regarding schedule of installation and disassembly to ensure minimization of unit downtime.

3.6 THRUST BEARING SHOE DISASSEMBLY TESTS

The following tests shall be performed upon disassembly:

a. Visual Inspection. All surfaces of each shoe shall be visually inspected. Areas of damage or defects shall be mapped and recorded.

Record babbitt and backside surface finish. See Inspection Sheet 5.

b. Backside Flatness. The flatness of the backside shall be checked as described on Inspection Sheet No. 14.

c. Backside Spring Loading Location. On the backside of a shoe spring marks are sometimes visible. These marks shall be examined and a record made of evidence of non-uniform spring loading and spring movement. See Inspection Sheet No. 15.

d. Spring Mounting Surface. The surface on which the thrust bearing springs sit shall be examined. Record all spring marks, evidence of non-uniform spring loading, spring movement, damage, or any other evidence of deviations from original plans.

SECTION 48 13 13.06 Page 19

3.7 ACCEPTANCE

3.7.1 Thrust Bearing Shoe 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. Disassembly of the next unit will not begin until delivered shoes are accepted. Corrections shall be made at the expense of the Contractor and are subject to Government approval. Tests may be repeated by the Contractor 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.

-- End of Section --

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 1 OF 2 PAGES

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION

Cordell Hull Thrust Bearing Shoe Refurbishment

CONTRACTOR

A C

T I V

I T

Y

O N

R A N

S M I

T T

L

S P E

DESCRIPTION

ITEM SUBMITTED

R

A G # R

A

H

G

V

C T

L A O S R

S I A F / I E

C A R T E

I V O W N R

CONTRACTOR:

SCHEDULE DATES

CONTRAC T OR

ACTION

APPROVING AUTHORITY

MAILED

TO

CONTR/

DATE RCD

FRM APPR

AUTH

REMARKS

SUBMIT

APPRO V A L

NEEDED

BY

MATERI A L

T I

D

DATE

OF

DATE FWD

TO APPR

AUTH/

FROM

CONTR

TO OTHER

REVIEWER

FROM OTH

T I

ACTION

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

48 13 13.06 SD-01 Preconstruction Submittals

Thrust Bearing Shoe 3.3.2 G

Refurbishment Procedure

Schedule For Thrust Bearing 3.3.2

Shoe Refurbishment

SD-02 Shop Drawings

Thrust Bearing Shoes Shop 3.3.4 G

Drawings

SD-04 Samples

Samples Of Materials 2.1.2

SD-06 Test Reports

Chemical Analysis Of the Babbitt 2.1.1

And Tin

Thrust Bearing Shoe 3.6

Disassembly Tests

Pre-Shipping Damage Inspection 3.2 G

Report

Thrust Bearing Shoe Finished 3.3.5 G

Inspection Report

SD-07 Certificates

Proof of ISO 9000 certification or 2.1.3 equivalence

NDT Personnel/Laboratory 3.4.3.1

Qualifications

NDT Personnel/Laboratory 3.4.3.2

Qualifications

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 2 OF 2 PAGES

SUBMITTAL REGISTER

CONTRACT NO.

TITLE AND LOCATION

Cordell Hull Thrust Bearing Shoe Refurbishment

CONTRACTOR

T I V

I

Y

R A N

S M I

T T

L

DESCRIPTION

ITEM SUBMITTED

R

A G # R

A

H

G

V

C T

L A O S R

S I A F / I E

C A R T E

I V O W N R

CONTRACTOR:

SCHEDULE DATES

CONTRAC T OR

APPROVING AUTHORITY

MAILED

TO

CONTR/

FRM APPR

AUTH

REMARKS

SUBMIT

APPRO V A L

MATERI A L

T I

TO APPR

AUTH/

FROM

CONTR

TO OTHER

FROM OTH

T I

ACTION

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

48 13 13.06 Notice of Thrust Shoe

Finished Inspection 3.3.5

SUBMITTAL FORM,Jan 96 PREVIOUS EDITION IS OBSOLETE PAGE 3 OF 2 PAGES

INSPECTION SHEET 5

VISUAL CONDITION

CONTRACT NO.

PLANT UNIT

INSPECTOR

DATE PAGE NO.

CLEAN AND IDENTIFY SHOE SEGMENTS

RECORD VISUAL CONDITIONS OF EACH SEGMENT. CHECK FOR GOUGES,

SCRATCHES ETC. EXAMINE BOTH BABBITT AND STEEL SURFACES. INDICATE ON

DRAWINGS AREAS OF DAMAGE.

SEGMENT NO.

INSPECTION SHEET 14

BACKSIDE FLATNESS

CONTRACT NO.

PLANT UNIT

INSPECTOR

DATE PAGE NO.

THE FLATNESS OF THE BACKSIDE SHALL BE MEASURED ACCURATE TO THE

NEAREST 0.0001 INCHES.

RECORD LOCATION OF MEASUREMENTS ON DRAWINGS

INSPECTION SHEET 15

SPRING LOAD LOCATION

OR PIVOT LOCATION

CONTRACT NO.

PLANT UNIT

INSPECTOR

DATE PAGE NO.

INSPECTION SHEET 16

BABBIT SURFACE

CONTACT AREA

CONTRACT NO.

PLANT UNIT

INSPECTOR

DATE PAGE NO.

DETERMINE PERCENT CONTACT AREA FOR THE BABBITT SIDE OF

THE SHOE AND RECORD. MAP THE CONTACT AREA.

INSPECTION SHEET 17

U.T. INSPECTION

CONTRACT NO.

PLANT UNIT

INSPECTOR

DATE PAGE NO.

TOLERANCES FOR STATIONARY THRUST BEARING SHOE SEGMENTS

ENTIRE SET MACHINED SIMULTANEOUSLY IN ONE SETUP

1. CIRCUMFERNTIAL RUNOUT

A DIAL INDICATOR ACCURATE TO 0.0001 INCHES SHALL BE MOUNTED IN THE

HEAD OF THE MACHINE TOOL WITH THE STEM OF THE INDICATOR RESTING ON

AN INDIVIDUAL SHOE’S BABBITTED SURFACE. THE MACHINE TABLE SHALL

THEN BE SLOWLY ROTATED AND READINGS TAKEN WHEN THE STEM IS ON EACH

INDIVIDUAL SHOE. VARIATIONS ON AN INDIVIDUAL SHOE AND AMONG THE

SET OF SHOES SHALL NOT BE MORE THAN 0.0005 INCHES OVER ONE

COMPLETE REVOLUTION OF THE TABLE. THIS CHECK SHALL BE MADE NEAR

THE I.D., CENTER, AND O.D. OF THE SHOES.

2. DISH FLATNESS

INDIVIDUAL SHOES SHALL BE CHECKED FOR FLATNESS USING A PLANEKATOR

CALIBRATED TO 0.0001 INCHES. THE BABBITTED SURFACE SHALL BE FLAT

OR CONCAVE WITH THE MAXIMUM LOW SPOT IN THE CENTER OF THE SHOE.

THE LOW SPOT SHALL NOT EXCEED 0.0015 INCHES. THIS LOW SPOT SHALL

NOT INCLUDE OIL HOLES, THREADED HOLES, OR OIL GROOVES OR POCKETS.

A BABBITTED SURFACE THAT IS CONVEX (OUTER EDGE OF SHOE LOWER THAN

CENTER PORTION OF SHOE) IS UNACCEPTABLE AND WILL BE REJECTED.

3. FLATNESS OF BACKSIDE

THE BACKSIDE SHALL BE MEASURED FOR FLATNESS USING

APPROVED METHOD AND SHALL BE FLAT WITHIN 0.001 INCHES. A MINIMUM

OF 4 MEASUREMENTS ALONG EACH EDGE (1 INCH IN FROM EDGE) AND 2

DIAGONAL MEASUREMENTS FROM THE I.D. TO O.D. CORNERS SHALL BE

TAKEN.

4. VARIATION IN THICKNESS (SPRING BED DESIGNS)

ALL INDIVIDUAL SHOE THICKNESS MEASUREMENTS SHALL BE WITHIN 0.001

INCHES. A MINIMUM OF 9 EVENLY SPACED MEASUREMENT PER SHOE SHALL

BE TAKEN AS SHOWN BELOW, ON 3 CIRCLES CONCENTRIC WITH THE BORE,

I.E., NEAR THE I.D., CENTER, AND O.D. OF THE SHOES.

THE VARIATION OF EACH SHOE TO THE AVERAGE SHOE THICKNESS SHALL NOT

EXCEED 0.0015 INCHES. A MINIMUM OF 9 EVENLY SPACED MEASUREMENT

PER SHOE SHALL BE TAKEN AS SHOWN BELOW, ON 3 CIRCLES CONCENTRIC

WITH THE BORE, I.E., NEAR THE I.D., CENTER, AND O.D. OF THE SHOES.

5. SURFACE FINISH (SPRING BED DESIGNS)

THE BABBITTED SURFACE AND BACKSIDE OF THE SHOES SHALL HAVE A

FINISHED SURFACE OF 16 AND 63 MICROINCHES OR BETTER, RESPECTIVELY.

THE FINISH SHALL BE MEASURED USING A PROFILOMETER, OR AS APPROVED.

TOLERANCES FOR STATIONARY THRUST BEARING SHOE SEGMENTS

SHOES MACHINED SEPARATELY

1. DISH FLATNESS

INDIVIDUAL SHOES SHALL BE MEASURED FOR FLATNESS USING THE SAME

GRANITE TABLE IN CONJUNCTION WITH A PLANEKATOR CALIBRATED TO

0.0001 INCHES. THE GRANITE TABLE SHALL BE CERTIFIED BY ITS

SUPPLIER AS FLAT TO WITHIN 0.0005 INCH. ALL MEASURING DEVICES

SHALL BE ACCURATE TO 0.0001 INCHES. THE BABBITTED SURFACE SHALL

BE FLAT OR CONCAVE WITH THE MAXIMUM LOW SPOT IN THE CENTER OF THE

SHOE. THE LOW SPOT SHALL NOT EXCEED THE AMOUNT INDICATED BELOW.

THIS LOW SPOT SHALL NOT INCLUDE OIL HOLES, THREADED HOLES, OR OIL

GROOVES OR POCKETS. A BABBITTED SURFACE THAT IS CONVEX (OUTER

EDGE OF SHOE LOWER THAN CENTER PORTION OF SHOE) IS UNACCEPTABLE

AND WILL BE REJECTED.

A MINIMUM OF 7 SWEEP MEASUREMENTS PER SHOE SHALL BE TAKEN: 3

EVENLY SPACED MEASUREMENTS ON 3 CIRCLES CONCENTRIC WITH THE BORE,

I.E., NEAR THE I.D., CENTER, AND O.D., 2 ALONG THE LEADING EDGE

AND TRAILING EDGE OF THE SHOE, AND 2 FROM THE OPPOSITE CORNERS.

SEE SKETCHES BELOW FOR DIRECTION AND TOLERANCES:

0.0005 INCHES 0.0015 INCHES 0.0015 INCHES

PRIOR TO PERFORMING EACH SWEEP, ZERO THE MEASURING DEVICE USING

THE SAME LOCATION IN THE CENTER OF THE SHOE. REPORT LOW SPOTS AS

A NEGATIVE READING AND HIGH SPOTS AS POSITIVE.

2. FLATNESS OF BACKSIDE

THE BACKSIDE SHALL BE MEASURED FOR FLATNESS USING A PLANEKATOR

CALIBRATED TO 0.0001 INCHES AND SHALL BE FLAT WITHIN 0.001 INCHES.

A MINIMUM OF 4 MEASUREMENTS ALONG EACH EDGE (1 INCH IN FROM EDGE)

AND 2 DIAGONAL MEASUREMENTS FROM THE I.D. TO O.D. CORNERS SHALL BE

TAKEN.

3. VARIATION IN THICKNESS (SPRING BED DESIGNS)

ALL INDIVIDUAL SHOE THICKNESS MEASUREMENTS SHALL BE WITHIN 0.001

INCHES. A MINIMUM OF 9 EVENLY SPACED MEASUREMENT PER SHOE SHALL

BE TAKEN AS SHOWN BELOW, ON 3 CIRCLES CONCENTRIC WITH THE BORE,

I.E., NEAR THE I.D., CENTER, AND O.D. OF THE SHOES.

THE VARIATION OF EACH SHOE TO THE AVERAGE SHOE THICKNESS SHALL NOT

EXCEED 0.0015 INCHES. A MINIMUM OF 9 EVENLY SPACED MEASUREMENT

PER SHOE SHALL BE TAKEN AS SHOWN BELOW, ON 3 CIRCLES CONCENTRIC

WITH THE BORE, I.E., NEAR THE I.D., CENTER, AND O.D. OF THE SHOES.

4. SURFACE FINISH (SPRING BED DESIGNS)

THE BABBITTED SURFACE AND BACKSIDE OF THE SHOES SHALL HAVE A

FINISHED SURFACE OF 16 AND 63 MICROINCHES OR BETTER, RESPECTIVELY.

THE FINISH SHALL BE MEASURED USING A PROFILOMETER, OR AS APPROVED.

Note: Invoices are to be mailed to Valerie Wolfe at:

71 Corps Lane

Carthage, TN 37030

Valerie can be reached at (615)735-1034.