W912P522R0003 RTA TSpecs.pdf

CUI

CUI

Nashville District

OLD HICKORY POWERHOUSE

TURBINE-GENERATOR REHABILITATION

(Units 1-3)

Old Hickory Powerhouse Cumberland River Sumner County, Tennessee

Solicitation Number: W912P5-22-R-0003 Contract Number: W912P5-22-C-XXXX

Technical Specifications

-Certified Final - RTA

March 30, 2022

Turbine-Generator Rehabilitation Old Hickory Power Plant Section PROJECT Page 1 Sumner County, TN

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 11 10.00 SUMMARY OF WORK

01 22 00.00 MEASUREMENT AND PAYMENT

01 30 00 GENERAL REQUIREMENTS & SITE OPERATIONS

01 32 01 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS

01 35 50 SITE SECURITY AND AT/OPSEC PROCEDURES

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 00.00 QUALITY CONTROL

01 45 00.15 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 50 00 TEMPORARY CONSTRUCTION FACILITIES AND CONTROLS

01 57 19 TEMPORARY ENVIRONMENTAL CONTROLS

01 78 00 CLOSEOUT SUBMITTALS

01 78 23 OPERATION AND MAINTENANCE DATA

01 91 00.00 UNIT COMMISSIONING

01 95 00 FORMS AND ATTACHMENTS

DIVISION 02 - EXISTING CONDITIONS

02 82 01 ASBESTOS COORDINATION

02 83 00 LEAD ABATEMENT, REMOVAL, & DISPOSAL

DIVISION 03 - CONCRETE

03 30 53.00 CAST-IN-PLACE CONCRETE AND FOUNDATIONS

03 60 00.01 CONCRETE DEMOLITION, REPAIR OF CONCRETE SURFACES, AND

MINOR EQUIPMENT FOUNDATIONS

03 60 00.02 STATOR FOUNDATION REPAIR

03 64 23.00 DISCHARGE RING AND DRAFT TUBE EPOXY INJECTION AND GROUTING

DIVISION 05 - METALS

05 05 23.20 WELDING

05 05 33.20 NON-DESTRUCTIVE TESTING

05 50 03.20 METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS

PROVISIONS

DIVISION 09 - FINISHES

09 97 02.23 PAINTING

DIVISION 13 - SPECIAL CONSTRUCTION

13 48 00.00 SEISMIC RESTRAINT FOR MECHANICAL AND ELECTRICAL EQUIPMENT

DIVISION 25 - INTEGRATED AUTOMATION

25 05 11.00 CYBERSECURITY

DIVISION 26 - ELECTRICAL

26 05 00.00 BASIC ELECTRICAL MATERIALS AND METHODS FOR MAJOR UNIT

REHABILITATION

26 05 13.00 MEDIUM-VOLTAGE CABLE

26 05 19.00 INSULATED WIRE AND CABLE

PROJECT TABLE OF CONTENTS Page 1

OLD TG

Section PROJECT Page 2 Sumner County, TN

26 05 26.00 GROUNDING

26 11 15.00 HIGH RESISTANCE GROUNDING SYSTEM (HRG)- MEDIUM VOLTAGE

DIVISION 40 - PROCESS INTERCONNECTIONS

40 05 13.00 PIPING AND EQUIPMENT

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 67 13.12 FLUSHING AND CLEANING OF LUBRICATING OIL SYSTEMS

DIVISION 48 - ELECTRICAL POWER GENERATION

48 06 15.00 TURBINE OIL

48 13 13.00 HYDRAULIC TURBINE MODEL TESTING

48 13 13.01 HYDRAULIC TURBINE

48 13 13.02 DISASSEMBLY AND REASSEMBLY OF HYDRAULIC TURBINE-GENERATOR

UNITS

48 13 13.03 GENERATOR THRUST BEARING HIGH PRESSURE LIFT SYSTEM

48 13 13.04 EXISTING TURBINE COMPONENT REFURBISHMENT AND REPLACEMENT

48 13 13.06 THRUST BEARING INSPECTION AND REFURBISHMENT

48 13 13.07 GUIDE BEARING INSPECTION & REFURBISHMENT

48 13 13.09 DISCHARGE RING OVERLAY

48 13 13.11 MISCELLANEOUS PARTS, MATERIALS, AND SERVICES

48 13 13.25 GENERATOR BRAKE SYSTEM REFURBISHMENT

48 13 13.26 TURBINE GUIDE BEARING LUBRICATION SYSTEM AND TURBINE SUMP

PUMPS REHABILITATION

48 13 16.00 REWIND OF HYDRAULIC-TURBINE DRIVEN GENERATORS

48 13 16.01 MACHINE CONDITION MONITORING OF HYDRAULIC TURBINE

GENERATOR UNIT

48 13 16.03 GENERATOR THRUST BEARING HIGH PRESSURE LIFT PUMP SYSTEM

(ELECTRICAL)

48 70 01.00 NERC COMPLIANCE FOR HYDROGENERATORS

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PROJECT TABLE OF CONTENTS Page 2

Section 01 11 10.00 Page 1 Sumner County, TN

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 11 10.00

SUMMARY OF WORK

PART 1 GENERAL

1.1 SUMMARY

1.1.1 WORK COVERED BY CONTRACT DOCUMENTS

1.2 Project Description

1.3 WORK CONSTRAINTS

PART 2 PRODUCTS

PART 3 EXECUTION

-- End of Section Table of Contents --

SECTION 01 11 10.00 Page 1

Section 01 11 10.00 Page 2 Sumner County, TN

SECTION 01 11 10.00

SUMMARY OF WORK

PART 1 GENERAL

1.1 SUMMARY

1.1.1 WORK COVERED BY CONTRACT DOCUMENTS

The Old Hickory powerhouse is located on the Cumberland River in Tennessee, northeast of Nashville. There are four main turbine generating units at the Old Hickory Powerhouse. This specification includes the requirements for all equipment, labor, materials, and work necessary to design, manufacture and install Kaplan turbines, rewind the existing generators, and refurbish associated equipment and components for three base units and one optional unit at Old Hickory.The replacement runners shall be designed using both Computational Fluid Dynamics (CFD) and a physical performance (scale) model.

The existing turbines are five-bladed Kaplan type turbines manufactured by Baldwin-Lima-Hamilton. They were designed for a maximum output of 45,000 hp, but have been operated at 35,000 hp to accommodate the existing generator nameplate of 31,250 kVA at a power factor of 0.8.

The Contractor shall also be required to rehabilitate Units 1-3 by replacement of the generator stator core and stator winding; and re-insulation and testing of the field winding. The new stator winding shall be rated at 45,000 kVA at a power factor of 0.9 with a temperature rise limited to 83 degrees C above a 40 degree C ambient temperature. This rehabilitation shall be concurrent with the supply and installation of the turbines.

The stationary components and rotational components of Old Hickory Units 1-3 are out of concentricity by as much as 1/4" due to historical powerhouse movement. Realignment scope includes investigation of cyclical seasonal powerhouse movement that may affect the concentricity of the discharge ring to other embedded components on the magnitude of 0.040" to 0.060". Realignment scope includes two intermediate stationary alignment checks to confirm realignment about a reference centerline.

As it is known that there is asbestos present, then after the Contractor completes blocking of the rotor on the erection pedestal and installation of the stator work platform to make safe for access, the Government will utilize a separate asbestos abatement Contractor to clean and remove dust from affected surfaces (including but not limited to the stator core, coil assembly, rotor spider, rotor poles, brake pads). Allow a period of up to 30 calendars days for abatement and cleaning of surfaces. During this time, the Contractor will not have access into the abatement areas. After completion of cleaning, the Contractor will resume completion of work required by this Contract.

The following list is a general summary of the required and optional work for each unit and is not all-inclusive.

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Section 01 11 10.00 Page 3 Sumner County, TN

SITE WORK AND STRUCTURAL

a. Perform all work required to comply with the site operations, environmental protection, and safety and health provisions.

b. Perform all work required for painting including lead-based paint removal and disposal.

c. Perform all work required for miscellaneous welding, machinist, electrician, and other skilled craftsman hire.

TURBINE and MECHANICAL

a. Design and construct a hydraulic model. Testing shall take place at a laboratory conforming to SECTION 48 13 13.00 and shall include the new runner with new wicket gate design.Following notification by the Government, ship model f.o.b. destination to the Government.

b. Design, manufacture, prepare, and load for shipment, deliver f.o.b. destination, and unload the Kaplan turbine runner and appurtenances. The runner design will be chosen by the Government following all model testing.

c. Disassemble generating unit by removing rotating and stationary components and related interferences. The generator spider shall be removed from the generator shaft, which has an integral thrust collar.

d. Perform alignment investigations, including pre-disassembly alignment checks and two stationary alignment checks, and provide recommendations.

e. Correct alignment problems, including optionally moving the stator core, leveling the thrust bracket, and refurbishing the discharge ring, with allowable placement of the reference center up to 1/4" from the existing discharge ring center. Confirm the results of alignment corrections with a post-reassembly alignment check.

f. Inspect and either refurbish or replace, based on the specifications of this contract, miscellaneous turbine and generator mechanical components and piping including but not limited to: wicket gate shear pins, turbine shaft packing box and gland, wicket gate packing boxes and glands, servomotor, runner coupling bolts, and other components as specified.

g. Disassemble, inspect, and refurbish the wicket gate servos and the operating ring.

h. Inspect and test the generator air and thrust bearing coolers Eddy current testing required for thrust bearing coolers.

i. Replace bronze bushings with new bronze bushings. Provide one spare set of bronze bushings with machining stock intact.

j. Replace the automatic greasing systems, grease lines and related equipment.

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Section 01 11 10.00 Page 4 Sumner County, TN

k. Perform draft tube liner inspection.

l. Refurbish turbine and generator guide bearings and generator thrust bearings as directed.

m. Ship off-site, inspect, and perform clean-up machining of the turbine shaft and intermediate shaft.

n. Provide high pressure lift systems pump, motor, piping to each shoe, and pressure gauges, and inspect refurbish all shoes.

o. Supply and install RTDs for each bearing shoe for the thrust and generator guide bearings and replace the capillary tube system with RTDs and pressure instrumentation.

p. Inspect and clean turbine pit cooling and packing water piping.

q. Reassemble generating unit with a new turbine runner and appurtenances and other rehabilitated and replacement components.

r. Clean turbine pit, generator, and work or storage areas used by the Contractor..

s. Perform complete alignment of the turbine/generator unit.

t. Perform pre and post operational tests on the generating unit.

u. Install machine condition monitoring system.

v. Provide new turbine oil and clean oil tanks and lines.

w. Replace turbine oil piping.

x. Replace turbine guide bearing lubrication system and piping.

y. Replace turbine pit sump pump system and piping.

z. Mobilization and demobilization.

aa. Provide miscellaneous mechanical spare parts.

ab. Provide new wicket gates.

ac. Refurbish blade servomotor.

ad. Refurbish oil head.

ae. Refurbish generator brakes and supply one new brake/ jack assembly.

af. Replace drainage and scroll case cooling water intake grates.

ag. Replace draft tube access ladder.

ah. Preform cleaning and testing of CO2 system.

ai. Prefomr inspection of generator brake ring.

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Section 01 11 10.00 Page 5 Sumner County, TN

aj. Provide and install new hydraulic jacking system.

ELECTRICAL

a. Design, manufacture, and perform voltage endurance testing on 4 prototype coils. Design, manufacture, and perform thermal cycle testing on 5 prototype coils.

b. Design, manufacture, shop test, prepare and load for shipment, deliver f.o.b. destination, and unload three complete sets of stator coils and all accessories specified herein.

c. Furnish new stator cores.

e. Inspect and clean the rotors.

f. Refurbish the rotor field poles.

g. Refurbish the field leads.

h. Install and test new stator windings and accessories specified herein.

i. Remove existing and install and test new stator cores.

j. Furnish generator and miscellaneous electrical spare parts..

k. Perform generator special field tests (single unit only).

l. Perform start-up, commissioning, and testing of the generator.

m. Perform electrical equipment/wiring removal and installation including replacement of cable, wiring, miscellaneous relays, and RTDs within the air housing, turbine pit, and associated with all bearings as required.

n. Remove and dispose of generator neutral circuit breakers and reactors on Units 1-3

o. Furnish and Install High Resistance Grounding System for Units 1-3 in the existing neutral circuit breaker cabinets.

p. Perform factory and field acceptance testing on all the new High Resistance Grounding systems.

1.2 Project Description

The work shall be located at the Old Hickory powerhouse, located on the Cumberland River in Tennessee, as shown on contract drawing G-001.

1.3 WORK CONSTRAINTS

a. The turbine runner, stator coils, and stator core laminations for a specific unit shall be finished, inspected, and available for delivery prior to taking that unit out of service for rehabilitation.

b. The final height of the new wicket gates for each unit shall be determined based upon a consideration of as-found dimensions and the

SECTION 01 11 10.00 Page 5

Section 01 11 10.00 Page 6 Sumner County, TN extent of machining performed to the stay ring's upper flange, machining performed on the outer head cover mounting flange, and skim cuts to the outer head cover and bottom ring facing plates.

c. Detailed work constraints are listed in Section 01 30 00.

PART 2 PRODUCTS

Not used.

PART 3 EXECUTION

Not used.

-- End of Section --

SECTION 01 11 10.00 Page 6

Section 01 22 00.00 Page 1 Sumner County, TN

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 22 00

MEASUREMENT AND PAYMENT

08/15

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 Services of Miscellaneous Hire Items for Government Directed

Work

1.2.4 Miscellaneous Welding

1.2.5 Miscellaneous Parts and Materials

1.2.6 Reference Sections

1.3 PAYMENT

1.3.1 Non-Unit Specific Base Bid Items

1.3.2 Non-Unit Specific Optional Bid Items

1.3.3 Unit 1 Base Bid Items

1.3.4 Unit 1 Optional Bid Items

1.3.5 Unit 2 Base Bid Items

1.3.6 Unit 2 Optional Bid Items

1.3.7 Unit 3 Base Bid Items

1.3.8 Unit 3 Optional Bid Items

1.3.9 Unit 4 Base Bid Items

1.3.10 Unit 4 Primary Optional Bid Items

1.3.11 Unit 4 Secondary Optional Bid Items

1.3.12 Excess Work Options

PART 2 PRODUCTS

PART 3 EXECUTION

-- End of Section Table of Contents --

SECTION 01 22 00.00 Page 1

Section 01 22 00.00 Page 2 Sumner County, TN

SECTION 01 22 00

MEASUREMENT AND PAYMENT

08/15

PART 1 GENERAL

1.1 GENERAL INFORMATION

In each instance, the contract price for an item will constitute full compensation as specified, as shown, or as otherwise approved. The contract price and payment will also constitute full compensation for all work incidental to completion of the item, unless such work is otherwise specifically mentioned for separate payment under another item. In the event any work is required by the specification sections or by the drawings and not specifically mentioned in the measurement and payment paragraphs, separate or direct payment will not be made, and all costs thereof are incidental to, and included in, the contract prices and payment for all items listed in the bid schedule.

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 bid schedule 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 bid 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 Services of Miscellaneous Hire Items for Government Directed Work

Machinist hire, electrician hire, welding services, painter hire, other skilled craftsman hire, general laborer hire, liquid penetrant method, magnetic particle method, ultrasonic method, radiographic method, and thermal spraying measurement of time will be units of man-hours, with a man-hour defined as one person working as directed for a period of 60 minutes. To qualify as services of miscellaneous hire, the directed work will be additional to that necessary to comply with specifications

SECTION 01 22 00.00 Page 2

Section 01 22 00.00 Page 3 Sumner County, TN requirements. Time will be computed by rounding off to the next higher one-half (1/2) hour. No separate measurement for supervision, helper labor, overhead and/or other markups will be made as they are incidental to the service being furnished.

1.2.4 Miscellaneous Welding

Miscellaneous welding will be measured as the number of pounds of welding rod or wire placed. When directed to perform welding under this item, the welding rod or wire for the work shall be weighed in the presence of a Government Inspector. Upon completion of the work, the rod studs and unused rods or wire shall be weighed in the presence of a Government Inspector and the difference in weight between the rods or wire issued and the stubs and rods or wire returned will be the amount for payment. If the number of studs plus the unused rods does not equal the number of rods issued, the weight of one rod will be deducted for each rod unaccounted for.

1.2.5 Miscellaneous Parts and Materials

Miscellaneous parts and materials will be paid on a per Job basis. Each job shall constitute $1.00. Payment under the CLIN is paid at the Contractor's cost of procuring the miscellaneous parts and materials, including all indirect markups and excluding profit. If the Government contemplates authorizing the use of this Item, the Contractor shall submit the proposed costs and supporting documentation (i.e. vendor quotes, shipping costs, etc.) to the Government for review. The Government will authorize the agreed upon items in writing, and the Contractor will be reimbursed for the actual cost of these items. The total cost of items covered shall not exceed the amount shown on the bid schedule.

1.2.6 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

Contract line items designated 'Optional' will not be subject to adjustments under, "Variation in Estimated Quantities."

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

1.3.1 Non-Unit Specific Base Bid Items

Item No. 0001 Mobilization

Mobilization will be paid for as a job under Item No. 0001.

Mobilization will be considered complete when the Contractor has the equipment and manpower oniste and ready to begin unit disassembly.

Reference is made to DFAR Clause 252.236-7004.

Item No. 0002 Furnish Special Tools, Equipment, and Scaffolding

Payment for furnshing special tools, equipment, and scaffolding will be measured for payment as a job under Item No. 0002. "Special" is defined as that which is not available "off the shelf" for purchase or rent. Payment shall include but not be limited to labor, material, and

SECTION 01 22 00.00 Page 3

Section 01 22 00.00 Page 4 Sumner County, TN equipment required to transport on site special tools and scaffolding and includes erection and labor; complete, as specified and approved.

Item No. 0003 Drain and Dispose of Dirty Oil from Tanks and Piping

Payment for draining, cleaning, and flushing of the oil dilivery system will be made as a job under Item No. 0003. Payment shall include labor, material, and equipment required to drain existing lube oil from the supply and return headers, unit distribution and drain lines using jumpers, clean the clean lubrication oil (CLO), dirty lubrication oil (DLO), and portable tanks, flush the system, and provide a test report, as specified and approved

Item No. 0004 Supply Clean Oil for Tank and Piping

Payment for the new compatible turbine oil for the supply tanks will be made on a gallon basis under Item No. 0004. Payment shall be in accordance with the specifications.

Item No. 0005 Provide Miscellaneous Mechanical and Electrical Spare Parts

Payment for furnishing spare RTDs and relays will be measured for payment as a job under Item No. 0005. Payment shall be full compensation for all work required for furnishing of all spare parts to include but not be limited to RTDs and relays, terminal blocks, valves, and other specified spared parts not covered under other CLINs;

complete, as specified and approved.

Item No. 0006 Manufacture Prototype Test Coils and Perform Voltage Endurance and Thermal Cycling Tests

Payment for furnishing of prototype coils for voltage endurance and thermal cycle testing, perform testing, and provide reports will be made on a job basis under Item No. 0006. Payment shall include all labor, materials and equipment required as described in the specifications.

Item No. 0007 Furnish Generator Spare Parts

Payment for the furnishing of spare parts will be made on a job basis under Item No. 0007. Payment shall include all labor, materials and equipment required for provision of spare generator parts as described in the specifications.

Item No. 0008 Perform Generator Special Field Tests

Payment for performing generator special field tests will be made on a job basis under Item No. 0008. Payment shall include all labor, materials and equipment required for performing a special field test as described in the specifications.

Item No. 0009 Furnish Two Assembled Spare Pole Assemblies with Universal Connections

Payment for furnishing of two assembled spare poles with universal connections will be made on a job basis under Item No. 0009. Payment shall include all labor, materials and equipment required for the furnishing of two spare assembled spare pole assemblies with universal connections as described in the specifications.

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Section 01 22 00.00 Page 5 Sumner County, TN

Item No. 0010 Engineering and Installation of Outdoor Display Runner and Sign

Payment for the turbine runner display will be made on a job basis under Item No. 0010. Payment shall include all labor, materials and equipment required for the engineering, design, fabrication of stand, concrete foundation, erection of stand, transportation of runner, installation of runner on stand and painting operations as described in the specifications.

Item No. 0011 Generator Thrust Bearing Runner Phase 1 Inspection, Spare

Payment for the inspection of the generator thrust bearing will be made on a job basis under Item No. 0130. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 0012 Ship and Refurbish Thrust Bearing Shoes, Including Babbitting, Backside Machining, Spare

Payment for the shipment and refurbishment of one set of thrust bearing shoes, including babbitting, machining, spacers, and backside machining will be made on a job basis under Item No. 0012. Payment shall include all labor, materials and equipment required for the shipment and refurbishment of the thrust bearing shoes as described in the specifications.

Item No. 0013 Furnish Turbine Model

Payment for one complete Kaplan model test, including testing, reporting, and delivery will be made on a job basis under Item No.

0013. Payment shall include labor, material, and equipment in accordance with the specifications. This includes delivery of the model components to the Powerhouse after testing is finished; One model test per project.

Item No. 0014 Inspect Turbine Guide Bearing, Spare

Payment for the site inspection of the spare turbine guide bearing will be made as a job under Item No. 0014. Payment shall include all labor, material, and equipment to perform inspections of the spare turbine guide bearing in accordance with the specifications.

Item No. 0015 Asbestos Coordination

Payment for the coordination between the Contractor, Government, and Government-employed asbestos abatement contractor will be made as a job under Item No. 0015. Payment shall include all labor, material, and equipment to coordinate with and provide support for the Government and asbestos abatement contractor in accordance with the specifications.

The Contractor will not be handling uncontained asbestos.

Item No. 0016 Discharge Ring Cementitious Grouting

Measurement for Discharge Ring Cementitious Grouting will be made on a per job basis under Line Item No. 0016. Payment includes labor, material, equipment, and transportation required to develop design, methods of execution, and to execute Discharge Ring Cementitious Grouting . Assume 50 cubic feet per Unit for 3 units with a total of

SECTION 01 22 00.00 Page 5

Section 01 22 00.00 Page 6 Sumner County, TN

150 cubic feet for the job. For additional information see SECTION 03 64 23.00.

Item No. 0017 Discharge Ring Epoxy Injection Grouting

Measurement for Discharge Ring Epoxy Injection Grouting will be made on a per job basis under Line Item No. 0017. Payment includes labor, material, equipment, and transportation required to develop design, methods of execution, and to execute Discharge Ring Epoxy Injection Grouting. Assume 5 cubic feet per Unit for 3 units with a total of 15 cubic feet for the job. For additional information see SECTION 03 64 23.00.

Item No. 0018 Provide Preliminary Cam Plate

Payment for provision of a preliminary cam plate for the first unit rehabilitated will be made on a job basis under Item No. 0018. Payment shall include al labor, materials, and equipment required for the design, fabrication, and installation of the preliminary cam plate as desribed in the specifications.

Item No. 0019 Conduct Index Test

Payment for an index test and associated report will be made on a job basis under Item No. 0019. Payment shall include all labor, materials, and equipment required to carry out the test and compile and submit a test report as described in the specifications.

Item No. 0020 Demobilization

Demobilization will be paid for as a job under Item No. 0020.

Demobilization will be considered complete when the Contractor has removed all construction equipment, cleaned the area and restored the work area to "as found" pre-contract conditions, unless otherwise approved. Reference is made to DFAR Clause 252.236-7004.

Item No. 0021 Supply Turbine, Make up Oil

Payment for the new compatible turbine oil to supplement the volumes supplied under the unit-specific CLINs will be made on a gallon basis under Item No. 0021. Payment shall by in accordance with the specifications.

1.3.2 Non-Unit Specific Optional Bid Items

Item No. 0200 Shipment and Refurbishment of Thrust Bearing Runner Including Resurfacing Running Face, Resurfacing Backside, Split Face Work, Furnishing Keys and Split Bolts/ Hardware, Spare (OPTIONAL)

Payment for shipment and refurbishment of the thrust bearing runner including resurfacing of the running face, resurfacing of the backside, split face work, furnishing of keys and split bolts/hardware will be made on a job basis under Item No. 0200. Payment shall include all labor, materials and equipment required for the shipment and refurbishment of the thrust bearing runner as described in the specifications. Exercise of this option will be coordinated with the exercise of an option to ship a generator shaft, as the thrust runner machining must occur with the runner mounted to a shaft.

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Section 01 22 00.00 Page 7 Sumner County, TN

Item No. 0201 Furnish Mandrel and Clamps for Shaft Sleeve (OPTIONAL)

Payment for Item No. 0201 shall be paid for as a complete Job. Payment shall include, labor, material, and equipment required to furnish a mandrel and clamps for fabrication of the sleeve and installation of the sleeve in accordance with the specifications.

Item No. 0202 RefurbishTurbine Guide Bearing, Spare (OPTIONAL)

Payment for the inspection, shipment, and refurbishment of the spare turbine guide bearing, including babbitting an machining will be made on a job basis under Item No. 0202. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 0203 Furnish Set of Wicket Gate Shear Pins, Spare (OPTIONAL)

Payment for furnishing one set (24) shear pins for Unit 1 will be paid for as a job under Item No. 0203. Payment shall include labor, material, and equipment required to design, fabricate, ship, and install a set of shear pins ins accordance with the specifications.

Item No. 0204 Furnish New Blade Servomotor Piston Rod (OPTIONAL)

Payment for the furnishing a new blade servomotor piston rod will be paid for as a job uner Item No. 0204. Payment shall include, but not be limited to, labor, material, and equipment required to design, fabricate, ship, and install a new blade servomotor piston rod in accordance with the specifications.

Item No. 0205 Stator Foundation: Low-Pressure Epoxy Adhesive Grout Injection (OPTIONAL)

Measurement for Low-Pressure Epoxy Adhesive Grout Injection will be made on a per linear foot basis under Line Item No. 0205. Estimated between 0 ft and 75 ft per Unit and up to 3 units for a maximum of 225 linear feet for the job. Payment includes labor, material, equipment, and transportation required to complete repairs as specified. For additional information see SECTION 03 60 00.02.

Item No. 0206 Stator Foundation: Shallow-Face Grout & Concrete Damage Repair (OPTIONAL)

Measurement for Stator Foundation Shallow-Face Grout & Concrete Damage Repair will be made on a per cubic foot basis under Line Item No.

0206. Estmated between 0 and 1 cubic feet per Unit and up to 3 units for a maximum of 3 cubic feet for the job. Payment includes labor, material, equipment, and transportation required to complete repairs as specified. For additional information see SECTION 03 60 00.02.

Item No. 0207 Discharge Ring Cementitious Grouting (OPTIONAL)

Measurement for Discharge Ring Cementitious Grouting will be made on a per cubic foot basis under Line Item No. 0207. Estmated between 0 and 10 cubic feet per Unit and up to 3 units for a maximum of 30 cubic feet for the job. Payment includes labor, material, equipment, and transportation required to complete repairs as specified. For additional information see SECTION 03 64 23.00.

Item No. 0208 Discharge Ring Epoxy Injection Grouting (OPTIONAL)

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Section 01 22 00.00 Page 8 Sumner County, TN

Measurement for Discharge Ring Epoxy Injection Grouting will be made on a per cubic foot basis under Line Item No. 0208. Estmated between 0 and 5 cubic feet per Unit and up to 3 units for a maximum of 15 cubic feet for the job. Payment includes labor, material, equipment, and transportation required to complete repairs as specified. For additional information see SECTION 03 64 23.00.

Item No. 0209 Provide Spare Wicket Gates (OPTIONAL)

Payment for the design, manufacture, and shipment of two (2) new stainless steel wicket gates will be paid for on a job basis under Item No. 0209. Payment shall include but not be limited to labor, materials, and equipment to design, manufacture, ship, and install new stainless steel wicket gates in accordance with the Contractor's approved drawings and in accordance with the specifications.

Item No. 0210 Perform GENMAT Study (OPTIONAL)

Payment for conducting a GENMAT study will be paid for on a job basis under Item No. 02010. Payment shall include but not be limited to the labor necessary to coordinate and analyze the capacity of the thrust bearing via a GENMAT study in accordance with the specifications.

1.3.3 Unit 1 Base Bid Items

Item No. 1000 Disassemble Hydraulic Turbine/Generator Unit and Inspect Components, Unit 1

Payment for the disassembly and inspection of the turbine-generator unit will be made on a job basis under Item No. 1000. Payment shall include labor, material, and equipment required to disassemble on Kaplan hydrogenerating unit in accordance with the specifications.

Item No. 1001 Reassemble Hydraulic Turbine/Generator Unit and Inspect Components, Unit 1

Payment for the reassembly of the turbine-generator unit will be made on a job basis under Item No. 1001. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1002 Pre-Disassembly Measurements and Tests, Unit 1

Payment for the investigation of the unit operation will be made on a job basis under Item No. 1002. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1003 Operational Testing After Reassembly of Generating Unit, Unit 1

Payment for the reassembled operational testing will be made on a job basis under Item No. 1003. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1004 Determine Unit Centerline with Benchmarks, Unit 1

Payment for centerline determination will be paid for as a Job on for Unit 1 under Item No. 1004. Payment shall include, labor, material, and equipment required to reassemble some components of the generating unit

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Section 01 22 00.00 Page 9 Sumner County, TN after disassembly and determine the concentricity of major components around the turbine guide bearing housing center in accordance with the Contractors approved procedure, and in accordance with the specifications. The new centerline shall be submitted and approved and benchmarks shall be shall be mounted or located.

Item No. 1005 Painting, System No. 5-E-Z, Unit 1

Payment for painting components specified for paint system no. 5-E-Z on Unit 1 will be made on a job basis under Item No. 1005. Payment shall include all labor, materials and equipment required for the painting operations as described in the specifications.

Item No. 1006 Painting, System No. 18, Unit 1

Payment for painting components specified for paint system no. 18 on Unit 1 will be made on a job basis under Item No. 1006. Payment shall include all labor, materials and equipment required for the painting operations as described in the specifications.

Item No. 1007 Painting, System No. 21-A-Z, Unit 1

Payment for painting components specified for paint system no. 21-A-Z on Unit 1 will be made on a job basis under Item No. 1007. Payment shall include all labor, materials and equipment required for the painting operations as described in the specifications.

Item No. 1008 Painting, System No. 23-C-Z, Unit 1

Payment for painting components specified for paint system no. 23-C-Z on Unit 1 will be made on a job basis under Item No. 1008. Payment shall include all labor, materials and equipment required for the painting operations as described in the specifications.

Item No. 1009 Painting, Non-system-specific, Unit 1

Payment for painting components with paint systems other than system 5-E-Z, 18, 12-A-Z, or 23-C-Z will be made on a job basis under Item No.

1009. Payment shall include all labor, materials and equipment required for the painting operations as described in the specifications.

Item No. 1010 On-site Lead-Based Paint Removal and Disposal, Unit 1

Payment for Lead Based Paint Sampling, Removal, and Disposal from Unit 1 will be made on a job basis under Item No. 1010. Payment shall by in accordance with the specifications.

Item No. 1011 Clean and Visually Inspect Oil and Water Piping, Unit 1

Payment for cleaning and visual inspection of oil and water piping for Unit 1 will be made on a job basis under Item No. 1011. Payment shall include labor, material, and equipment required to perform cleaning, and inspection in accordance with the specifications.

Item No. 1012 Supply Turbine Oil, Unit 1

Payment for the new compatible turbine oil for Unit 1 will be made on a gallon basis under Item No. 1012. Payment shall by in accordance with the specifications.

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Section 01 22 00.00 Page 10 Sumner County, TN

Item No. 1013 Drain, Clean, and Flush System, Unit 1

Payment for draining, cleaning, and flushing of Unit 1 will be made as a per unit under Item No. 1013. Payment shall include labor, material, and equipment required to drain existing lube oil from the unit's supply and return lines, clean and flush the system, and provide a test report.

Unit 1 Mechanical Work

Item No. 1020 Design, Manufacture, Test and Deliver 61,600 hp Kaplan Runner Assembly, Unit 1

Payment for one complete Kaplan blade runner, including testing and delivery, will be made on a job basis under Item No. 1020. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1021 Inspect and Ship Turbine Shaft to and from Contractor's Shop, Unit 1

Payment for shipment of the turbine shaft to and from the Contractor's shop will be made on a job basis under Item No. 1021. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1022 Inspect Generator Shaft, Unit 1

Payment for the onsite inspection of the of the generator shaft will be made on a job basis under Item No. 1022. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1023 Inspect and Ship Intermediate Shaft to and from Contractor's Shop, Unit 1

Payment for shipment of the intermediate shaft to and from the Contractor's shop will be made on a job basis under Item No. 1023.

Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1024 Provide New Oil Head Bushings, Unit 1

Payment for providing new oil head bushings will be made a on a job basis under Item No. 1024. Payment shall include labor, materials, and equipment to provide new oil head bushings in accordance with the specifications.

Item No. 1025 Refurbish Oil Head, Unit 1

Payment for refurbishing the oil head will be paid as a complete job under Item No. 1025. Payment shall include, but not be limited to labor, material, and equipment required to as a minimum refurbish the oil head, to measure and record diameters and other pertinent information inside the oil head, to provide a set of supports on which to store oil head pipes, to provide a set of rollers on which to check pipe straightness, to replace oil head bushings, to provide a set of master plugs and ring gages for each oil head threaded connection as shown on the drawings and in accordance with the specifications.

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Section 01 22 00.00 Page 11 Sumner County, TN

Item No. 1026 Machine Turbine Shaft Flange Face as Needed for New Runner Hub and Boring for New Coupling Bolts, Unit 1.

Payment for machining of the turbine shaft flange face as needed for the new runner, and boring for new coupling bolts will be made on a job basis under Item No. 1026. This item also includes new fasteners for the runner to turbine shaft joint and machining of redundant o-ring grooves for advanced sealing. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1027 Turbine Shaft Skim Cut, Unit 1

Payment for machining the turbine shaft above, below, and underneath the shaft sleeve will be paid for as a complete job under Item No.

1027. Payment shall include labor, materials, and equipment to machine

0.010 inch from the turbine shaft below the shaft sleeve in accordance with the specifications.

Item No. 1028 Inspect, Ship, and Refurbish Upper Generator Guide Bearing Pads, Unit 1

Payment for the inspection, shipment, and refurbishment of the upper generator guide bearing pad set, including babbitting and machining, will be made on a job basis under Item No. 1028. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1029 Inspect, Ship, and Refurbish Lower Generator Guide Bearing Pads, Unit 1

Payment for the inspection, shipment, and refurbishment of the lower generator guide bearing pad set, including babbitting and machining, will be made on a job basis under Item No. 1029. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1030 Inspect, Ship, and Refurbish Turbine Guide Bearing, Unit 1

Payment for the inspection, shipment, and refurbishment of the turbine guide bearing, including babbitting and machining will be made on a job basis under Item No. 1030. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1031 Inspect, Ship, and Refurbish Turbine Guide Bearing Housing, Unit 1

Payment for the inspection, shipment, and refurbishment of the turbine guide bearing housing, including machining, will be made on a job basis under Item No. 1031. Payment shall include labor, material, and equipment in accordance with the specifications.

Item No. 1032 Generator Thrust Bearing Runner Phase 1 and Phase 2 Inspection, Unit 1

Payment for the inspection of the generator thrust bearing runner will be made on a job basis under Item No. 1032. Payment shall include labor, material, and equipmen in accordance with the specifications.

Item No. 1033 Inspect and Refurbish Air Valve Assembly, Unit 1

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Section 01 22 00.00 Page 12 Sumner County, TN

Payment for inspection and refurbishment of the air valave assembly will be made on a job basis under Item No. 1033. Payment shall include, labor, material, and equipment required to refurbish the turbine vacuum and check valve including but not be limited to inspection, refurbishment of mating surfaces, replacement of greased bushings in kind, replacing packing, o-rings gaskets, additional refurbishments as required and perform leakage tests as shown on the drawings and in accordance with the specifications.

Item No. 1034 Inspect and Refurbish Wicket Gate Servomotors, Unit 1

Payment for the refurbishment of the wicket gate servomotors (2 per unit) will be made on a job basis under Item No. 1034. Payment shall include labor, material, and equipment required to clean, inspect, and refurbish the wicket gate servomotors, including but not limited to disassembly, shipment, cleaning, preapartion of suface for and replacement of packing, boring and honing of cylinders, refurbishment of mating surfaces, replacement of rings and bushings, reassembly and testing, and providing miscellaneous components as shown on the drawings and in accordance with the specifications.

Item No. 1035 Provide New Stainless Steel Wicket Gates, Unit 1

Payment for the design, manufacture, and shipment of new stainless steel wicket gates will be paid for on a job basis under Item No.

1035. Payment shall include but not be limited to labor, materials, and equipment to design, manufacture, ship, and install new stainless steel wicket gates in accordance with the Contractor's approved drawings and in accordance with the specifications.

Item No. 1036 Provide New Greased Bushings/Bearing Plate for Wicket Gate Linkage, Operating Mechanism, and Gate Stems, Unit 1

Payment for providing a set of new bronze bushings/bearing plate for wicket gate linkage, operating mechanism, and gate stem will be paid for as a job under Item No. 1036. Payment shall include, but not be limited to labor, material, and equipment required to provide one set of bushings in accordance with the specifications.

Item No. 1037 Inspection of Blade Servo Piston and Cylinder, Piston Rod and Piston Cap

Payment for the inspection of the blade servo piston and cylinder, piston rod, and piston cap will be paid for as a job under Item No.

1037. Payment shall include but not be limited to labor, materials, and equipment for a thorough visual inspection and NDT of the blade operating components and furnish a report in accordance with the specifications.

Item No. 1038 Provide Blade Servomotor Piston Rings

Payment for providing new blade servomotor piston rings will be paid for as a job, inclusive of the three rings associated with a single blade servomotor piston, under Item No. 1038. Payment shall include but not be limited to labor, materials, and equipment to provide the rings as specified and required.

Item No. 1039 Provide Blade Servomotor Piston Rod Bushing

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Section 01 22 00.00 Page 13 Sumner County, TN

Payment for providing a new blade operating rod bushing will be paid for as a complete job under Item No. 1039. Payment shall include but not be limited to labor, materials, and equipment to provide the fings as specified and required.

Item No. 1040 Provide Multi-jackbolt Tensioning Nuts for Blade Piston Rod

Payment for providing new multi-jackbolt tensioning nuts for the blade piston rod shall be paid for as a complete job under Item No. 1040.

Payment shall include but not be limited to labor, materials, and equipment to Provide multi-jackbolt tensioning nuts for both ends of the piston rod in accordance with the specifications.

Item No. 1041 Wicket Gate Operating Mechanism Refurbishment, Unit 1

Payment for the refurbishment of the wicket gate operating mechanism (links and levers) will be made on a job basis under Item No. 1041.

Payment shall include labor, material, and equipment required to clean, inspect, refurbish, and paint the wicket gate operating mechanism in accordance with the specifications.

Item No. 1042 Provide a Pneumatic Shear Pin Detection System with Alarms, Unit 1

Payment for a pneumatic shear pin detection system for Unit 1 will be paid for as a job under Item No. 1042. Payment shall include labor, material, and equipment required to design, fabricate, ship, and install a new pneumatic detection system in accordance with the specifications.

Item No. 1043 Provide One Set of Shear Pins, Unit 1

Payment for providing one set (24) shear pins for Unit 1 will be paid for as a job under Item No. 1043. Payment shall include labor, material, and equipment required to design, fabricate, ship, and install a set of shear pins ins accordance with the specifications.

Item No. 1044 Stay Ring Inspection, Unit 1

Payment for stay ring inspection will be paid for as a complete job under Item No. 1044. Payment shall include labor, material, and equipment required to perform stay ring inspection including visual and liquid penetrant or magnetic particle techniques in accordance with the specifications.

Item No. 1045 Inspect, Ship, and Refurbish Outer Head Cover, Unit 1

Payment for outer head cover and facing plate inspection and refurbishment for Unit 1 will be paid for as a job under Item No.

1045. Payment shall include but not be limited to labor, material, and equipment required to inspect the outer head cover and report findings, refurbishment of gate stem packing boxes, machining of flanges, and installation of wicket gate stem bushings in accordance with the specifications. Refer to optional items for any work to the facing plates.

Item No. 1046 Inspect, Ship, and Refurbish Intermediate Head Cover, Unit 1

Payment for intermediate head cover inspection and refurbishment for

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Section 01 22 00.00 Page 14 Sumner County, TN

Unit 1 will be paid for as a job under Item No. 1046. Payment shall include but not be limited to labor, material, and equipment required to inspect the intermediate head cover and report findings, machining of flanges, and installation of operating thrust bearing plate and guide surfaces in accordance with the specifications.

Item No. 1047 Inspect, Ship, and Refurbish Inner Head Cover, Unit 1

Payment for inner head cover inspection and refurbishment for Unit 1 will be paid for as a job under Item No. 1047. Payment shall include but not be limited to labor, material, and equipment required to inspect the inner head cover and report findings, machining of flanges, and installation of operating thrust bearing plate and guide surfaces in accordance with the specifications.

Item No. 1048 Not Used

Item No. 1049 Bottom Ring (Top of Discharge Ring) and Facing Plate Inspection and Refurbishment, Unit 1

Payment for bottom ring refurbishment will be paid for as a job under Item No. 1049. Payment shall include labor, material, and equipment required to refurbish the bottom ring, including inspection and report of findings and installation of the bronze bushings in accordance with the specifications.

Item No. 1050 Operating Ring Refurbishment, Unit 1

Payment for the operating ring refurbishment will be paid for as a job under Item No. 1050. Payment shall include labor, material, and equipment required to refurbish the operating ring. The work shall include but not be limited to machining the steel running surfaces on the operating ring, refurbishing the bushing bores, and installing the new bronze bushings in accordance with the specifications.

Item No. 1051 Line Bore Wicket Gate Stem Bushing Housings, Unit 1

Payment for line boring the bottom ring's wicket gate stem bushing housings will be paid as a job under Item No. 1051. Payment shall include labor, material, and equipment required to line bore the 24 bottom gate stem bushing housings, utilizing the upper gate stem housings of the outer head cover as a guide in accordance with the specifications. (Refer to machining of the upper gate stem housings under the scope of outer head cover refurbishment.)

Item No. 1052 Provide New Packing Box, Gland, and Lantern, Unit 1

Payment for the provision of a new packing box, gland, and lantern ring will be made on a job basis under Item No. 1052. Payment shall include labor, material, and equipment required to provide one new complete packing box including lantern rings and gland in accordance with the specifications.

Item No. 1053 Provide Shaft Sleeve, Unit 1

Payment for the provision of a new shaft sleeve will be made on a job basis under Item No. 1053. Payment shall include labor, material, and equipment required to provide one turbine shaft sleeve and mounting hardware in accordance with the specifications.

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Section 01 22 00.00 Page 15 Sumner County, TN

Item No. 1054 Discharge Ring Anchorage, Unit 1

Reinforcing steel bar anchors installed in the discharge ring will be measured for payment as the number of anchors satisfactorily installed.

Payment will be made at the contract unit price per anchor for Item 1054, 'First 288 Anchors Installed.' This price and payment shall be full…