Barkley Turbine Generator Rehabilitation Project

The Nashville District U.S. Army Corps of Engineers (USACE) anticipates soliciting a requirement for a firm fixed-price construction contract to rehabilitate four (4) turbine generators at Barkley Power Plant, Kuttawa, KY. The estimated magnitude of this project is between $25,000,000 and $100,000,000.

Summary of work for the Barkley Turbine Generator Rehab Project:

1. The overall goal of this project is to increase the generator maximum output from 41.52 MW to 46.5 MW. This will be accomplished by rewinding units 2, 3, and 4. Unit 1 was rewound in September 2011 and will require some generator work. All the mechanical system to support this new load will have to be assessed and refurbished. While the units are down for rehabilitation there will be some efforts to upgrade or replace systems associated with the turbine generators.

2. General Project: The term of the project is estimated for six (6) years and eight (8) months which includes model testing, fabrication and installation of each unit.

3. Electrical Work: The electrical work will primarily include the stator winding, core laminations, rotor poles, and model verification. The stator is expected to be upgraded to epoxy mica insulation. This will allow for better thermal performance. The core will be designed with continuously stacked cores for more physical strength.

4. Turbine Work: Majority of the turbine work will be focused around head covers, wicket gates, turbine shaft, runner, bearings, operating ring, servomotors, and facing plates. Four (4) new runners will be installed with the implementation of a static oil head. A special item in this contract will be producing a display from one existing runner. The wicket gates will be refurbished and some spares will be fabricated. All turbine bearings will be inspected and converted to a straight fit. The rest of the turbine equipment will be inspected and/or replaced to include but not limited to stay ring, stay vane, vacuum breaker, discharge ring, winter-kennedy and heat taps, head covers, bottom ring, and facing plates.

5. Mechanical Work: During the rehab all the mechanical support systems will be inspected or upgraded. This will include but not limited to brake ring, brake cylinders, thrust bearing coolers, float switches, digital relays, oil cleaning skid, governor temperature readout, lift system replacement, surface air cooler replacement, rotor spider inspection, guide bearing pumps, unwater valve, vacuum breakers, wicket gate lubrication system, and rotating exciter will be removed.

The contractor will be required to provide all plant, labor and materials to construct these features.

Due to the social distancing guidelines put forth by the Centers for Diease Control and Prevention (CDC) because of the COVID-19 situation, two site visits will be held for this project. The first site visit will be held virtually via teleconeference and is tentatively scheduled for Friday, May 22, 2020. The second site visit will allow contractors to visit the Barkley Power Plant physically and is tentatively scheduled for Thursday, June 18, 2020 to Friday, June 19, 2020. Please note that contractors will be limited to the number of company representatives that will be allowed to participate in the physical site visit. Additional information in regards to the site visits will be contained in the solicitations.

Questions regarding this project should be addressed to Contract Specialist Kristal Jones via e-mail at Kristal.R.Jones@usace.army.mil.