SOLICITATION NOTICE
J -- GENERATOR THRUST BEARING SHOE REFURBISHMENT - CHIEF JOSEPH DAM BRIDGEPORT, WA
- Notice Date
- 4/19/2012
- Notice Type
- Combined Synopsis/Solicitation
- NAICS
- 332710
— Machine Shops
- Contracting Office
- USACE District, Seattle, ATTN: CENWS-CT, PO Box 3755, Seattle, WA 98124-3755
- ZIP Code
- 98124-3755
- Solicitation Number
- W912DW-Q-0082
- Response Due
- 4/27/2012
- Archive Date
- 6/26/2012
- Point of Contact
- Darrell S. Resendez, 2067646691
- E-Mail Address
-
USACE District, Seattle
(darrell.s.resendez@usace.army.mil)
- Small Business Set-Aside
- Total Small Business
- Description
- This is a combined synopsis/solicitation for commercial items prepared in accordance with the format in Subpart 12.6, as supplemented with additional information included in this notice. This announcement constitutes the only solicitation; proposals are being requested and a written solicitation will not be issued. PART 1 GENERAL 1.1GENERAL INFORMATION 1.1.1Description of Work This specification governs the refurbishment of a set of Chief Joseph Dam General Electric generator thrust bearing shoes. Shipping round trip FOB Chief Joseph Dam shall be included in the bid price. The Chief Joseph thrust bearing shoes shall be refurbished and be back on site at the project within 90 days of notice to proceed. 1.1.2Description of the Chief Joseph Spare Thrust Bearing Set. a. The original manufacturer's drawings are not available for the thrust bearing shoes. Drawing 167C6773 illustrates the general arrangement of the thrust shoes to the thrust runner and Alstom Hydro Drawing 2-55311-001 details the finished bearing specifications. b. The set of thrust bearing shoes consists of 14 shoes which are annular wedges with 18" wide at the outer radius and 12-5/8" at the inner radius (not cord length). The length down the side from the inner to the outer radius is 15-1/4". The overall height of the bearing is 2-1/4" (including the Babbitt) with the Babbitt being a 1/4" thick at the thinnest and 3/8" thick to the bottom of the dove tails. The shoe material is thought to be ASTM A 36 steel. Each shoe, with Babbitt, is estimated at 150 lbs. each, or 2100 lbs. for the entire set. The shoes rest on a spring bed for support. The thrust shoes are ported for a high pressure lift system and an instrument hole. Two shoes of the set have one each extra instrument hole. All dimensions and features of the shoes to be refurbished shall be independently measured on each subject set. c. Dimensions and estimated weights are based on current reference drawings, design criteria and/or calculations. The Government does not warrant or guarantee that these values are accurate. 1.2REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT) ASNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing ASTM INTERNATIONAL (ASTM) ASTM A 36 (1992) Structural Steel ASTM B 23 (2000) White Metal Bearing Alloys ASTM E 114 (2001) Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method ASTM E 165 (2002) Liquid Penetrant Inspection Method 1.3SUBMITTALS Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. SD-01 Preconstruction Submittals Schedule for Thrust Shoe Refurbishment; G Submit 10 calendar days following Notice to Proceed. "Paragraph 3.2.1.e, General Requirements" SD-03 Product Data Certified Chemical Analysis Of the Babbitt And Tin; G Submit 10 calendar days prior to tinning. "Paragraph 2.1.d, BABBITTING MATERIALS" SD-04 Samples Samples of Materials; G Submit within 10 days of request. "Paragraph 2.2, MATERIAL AND WORKMANSHIP" SD-07 Certificates Proof of ISO 9000 Certification or Equivalence; G Submit 7 calendar days prior to shipment from the project. "Paragraph 2.3, ISO CERTIFICATION" NDT Personnel/Laboratory Qualifications; G Submit 10 calendar days prior to tinning of shoes. "Paragraph 3.3.2, UT Inspectors Qualifications" Notice of Thrust Shoes Finished Inspections; Submit 7 calendar days in advance of shoe inspections, "Paragraph 3.2.4.c, Thrust Shoes Final Inspection and Report". SD-08 Manufacturer's Instructions Thrust Shoe Refurbishment Procedure; G Submit 10 calendar days in advance of repairs. "Paragraph 3.2.1.d, General Requirements" SD-09 Manufacturer's Field Reports Thrust Shoes As-Found Inspection and Report; G Submit 5 calendar days following inspections. "Paragraph 3.2.1.c General Requirements" Thrust Shoes Final Report; G Submit 5 calendar days following inspections, inspection approval required prior to shipment. "Paragraph 3.2.4.f, Thrust Shoes Final Inspection and Report" 1.4FINAL INSPECTION AND ACCEPTANCE Final inspection and acceptance for full compliance with the Specifications will be made by the Government upon delivery to the project. Any materials or workmanship not complying with the provisions of these specifications will be cause for rejection. Corrections shall be made at the expense of the Contractor, and are subject to approval. Tests may be repeated at the project site to ensure that materials and workmanship conform to contract requirements. Additional tests will be at the Contractor's expense if the refurbished components do not meet contract requirements. 1.5WARRANTY Warranty provisions of these Specifications shall apply, except that notwithstanding inspection and acceptance, the finished shoes shall be warranted to conform to these specifications for three years after receipt and acceptance at delivery site. PART 2 PRODUCTS 2.1 BABBITTING MATERIALS a. The Babbitt metal shall be new material conforming to ASTM B 23 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 certified 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. 2.2 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. 2.3 ISO CERTIFICATION The workshop where the thrust bearing 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 within 7 calendar days prior to shipment from the project. PART 3 EXECUTION 3.1 SHIPPING a. The Government will visually inspect each thrust shoe condition, prior to shipment from the site. Any existing damage will be recorded by the Government prior to shipment. Note that the babbitt on these shoes have been is damaged. b. The Government will package the thrust shoes in a proper shipping container at the project and prepare them for shipment. The Government will load the bearing onto the Contractor provided truck. If the Contractor damages the packaging, they shall repair or replace packaging to original condition. The shoes are in 14 separate crates. c. The Contractor shall provide round trip shipment between the project and the contractor refurbishment facility. Pickup and delivery shall be between the hours of 0730 and 1530, Monday thru Thursday. d. Prior to return shipment, coat components with a suitable preservative. e. The Contractor shall preserve the Government supplied shipping containers and shall properly re-pack the bearing to prevent damage during shipment. The Contractor shall assume full responsibility for any damage occurring during shipment. f. The Government will unload the bearing from the Contractor provided truck, after return shipment. 3.2 REFURBISHMENT OF THRUST BEARING SHOES 3.2.1 General Requirements The general refurbishment requirements of the thrust bearing are listed below with the specific requirements described in paragraph 3.2.2 below: a. Upon receipt of the shoes at the refurbishment workshop, measure the shoe thickness at a minimum of three locations per shoe (near the shoe ID, center and OD) in undamaged locations. Also, measure inside outside shoe radii, hole locations and sizes including thread features, oil lift port details, edge fillet radii, keyways, and other relevant features. c. Parts a. shall be compiled into a thrust shoes as-found inspection and report and be submitted within 5 calendar days following the inspection. d. The Contractor shall submit a detailed thrust shoe refurbishment procedure a minimum of 10 calendar days prior to commencing the refurbishment work, including a detailed step-by-step babbitting procedure. The shoes are to be machined and/or ground to the original or as measured existing thickness (combined shoe and Babbitt thickness). The Contractor shall not perform any work until receiving written approval from the Government. e. A proposed schedule for thrust shoe refurbishment, i.e. dates shall be submitted for all phases of the shoes' refurbishment a maximum of 10 calendar days following the notice to proceed. 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 process will be witnessed. The Government is especially interested in the final shop inspection. f. All of the shoes shall be machined at the same time in one setup on a machining table or plate. The runout and flatness tolerances for the plate or table, as listed in the tolerances sheets at the end of this section, shall apply at each setup. g. The rotation of the machining table shall be in the direction opposite to the direction of rotation of the generator. The generator rotates counter-clockwise. h. The requirements for the refurbished shoes (flatness, runout, thickness and surface finish) are listed on the tolerance sheets at the end of this section and attached reference drawing 2-55311-001. i. Finish dimensions and runout checks shall be made while the shoes are still on the machining table. j. All high-pressure lift pockets, bronze inserts, and grooves that existed on the original shoes shall be produced. k. All non-babbitted surfaces (including the shoe's I.D., O.D. and sides) and holes shall be thoroughly cleaned without the removal of metal, unless approved in writing. l. All options shall include appropriate finished inspections and the preparation of a report according to these specifications. Following the completion of the work, the Contractor shall protect the shoes from damage and corrosion with appropriate coatings and packaging for possible long term storage in a temperature controlled environment. 3.2.2 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. The refurbishment shall return the shoes to the dimensional tolerances listed in the tolerances sheets at the end of this section and attached reference drawing 2-55311-001. a. A sample of the babbitt shall be taken and marked for identification at the time that the babbitt is poured. A sample of material shall be taken for each heat; e.g. if more than one shoe is poured simultaneously, only one sample is required. An independent testing 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. c. After removing existing babbit and tinning, round the top edges of each dovetailed slot by machining or grinding a 1/32 radius if required based on as found measurements. d. Machine or shot blast, including dovetail grooves, 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. e. 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. f. The shoes shall be machined and/or ground to the original or as measured existing thickness (combined shoe and babbitt thickness), unless otherwise approved. The Contractor's refurbishment procedure shall list any additional thickness of Babbitt to be added to the shoes. If the Government notifies in writing execution of the optional activity of machining the backside of the set of shoes, it shall be finished prior to finishing the Babbitt running surface. g. Machine/and or grind the poured Babbitt layer to achieve the tolerances (flatness, runout, thickness and surface finish) listed on the tolerance sheets at the end of this section and attached reference drawing 2-55311-001. Provide oil supply grooves, radius edges and other details identical to that found for the existing shoes and attached reference drawing 2-55311-001. h. Perform NDT of the babbitt bond according to Paragraph "BABBITT BOND NDT". i. Additional requirements are listed under Paragraph 3.2.1 above. 3.2.3 Machine Shoe Backside (Optional) If the Government notifies in writing execution of the optional activity of machining the backside of the set of thrust shoes, the contractor shall include the procedures as part of the Thrust Shoe Refurbishment Procedure submittal. The backside of the shoes shall be machined and/or ground as required to remove spring indentations and to achieve the tolerances (flatness, runout, thickness and surface finish) listed on the tolerance sheets 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. No more than 0.020 inches shall be removed from the surface or from the entire thickness of the shoes, unless otherwise approved in writing. Additional requirements are listed under Paragraph 3.2.1 above. 3.2.4 Thrust Shoes Final Inspection and Report a. The finished thrust shoes shall be inspected while on the machining turntable for the purpose of verifying the requirements (flatness, runout, thickness and surface finish) listed in the tolerance sheets at the end of this section and attached reference drawing 2-55311-001. b. The Contractor shall notify the Government 7 calendar days in advance of all inspections in the form of a submittal Notice of Thrust Shoes Finished Inspections, and all inspections may be witnessed by the Government at its discretion. c. 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 at the Governments request. d. 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. e. A thrust shoes final inspection report documenting the refurbishment including the results of the Babbitt bonding NDT shall be submitted prior to shipment and shipment shall not be made until authorized by the Government. 3.3 BABBITT BOND NON-DESTRUCTIVE EXAMINATION (NDT) This paragraph shall be performed for the thrust shoes that have been rebabbitted. 3.3.1 General The babbitt to base metal bond 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 babbitted area shall be inspected. UT examination shall be performed in accordance with the applicable portions of ASTM E 114 or of Article 5 of the ASME BPVC V. The UT procedure which is to be used shall be submitted for approval. The Government at its discretion my witness any and all inspections. 3.3.2 UT Inspectors Qualifications 3.3.2.1 Examination of the Babbitt Bonding An examination of the babbitt bonding shall be performed by an approved independent testing laboratory that is regularly engaged in nondestructive testing, or it may be performed using Contractor personnel. For examinations performed by Contractor personnel offsite, a representative from an approved independent testing laboratory shall be present during the examination to witness and certify the results. For examinations performed by Contractor personnel on Government property, the Government may request the presence of an independent laboratory at its discretion. 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 for approval as part of NDT Personnel/Laboratory Qualifications. 3.3.2.2 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-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 for approval as part of NDT Personnel/Laboratory Qualifications. The inspector shall locate bonded and unbonded areas on the "Reference Blocks" in the presence of the Government's quality assurance representative. 3.3.3 Equipment 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 unbounded areas shall be defined in the UT procedure. (3) Reference blocks shall be kept available for frequent reference during actual testing. 3.3.4 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. 3.3.5 Liquid Penetrant (PT) Testing a. After the ultrasonic testing is completed 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 E 165. Lack of bond indications greater than inches in length shall be marked on the bearing shoes and mapped on inspection reports or documented in photos. b. The surface area of the babbitt, including oil grooves, shall be PT examined for cracks and any and all indicated cracks recorded on inspection sheets or documented in photos. 3.3.6 Acceptance Standards Babbitt bond acceptance criteria are defined below as a function of zones and the bearing backing material: a. Perimeter & 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 2 inches apart. The total unbonded area shall be no larger than 5 percent of the total zonal area. b. Corners. Zone defined as bond surface area within 1 inch from any corner having an exposed bond line. Corners shall have no unbounded 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. PT indications of lack of bond totaling over 10 percent of the length of a particular edge shall be unacceptable. Any PT detected lack of bond over 3/4 inch in length shall be re-examined by the UT method, using a 0.250 inch diameter transducer. Unbonded areas extending more than 1/8 inch away from an edge shall be unacceptable. e. Remainder of Pad. 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 sq. inch or 3 percent of the total zonal area, whichever is less. Acceptable unbonded areas shall be located no closer than 2 inches apart. The total unbounded area shall be no larger than 5 percent of the total zonal area. 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. 3.3.7 NDT Inspection Report A babbitt bond NDT inspection report shall be submitted as part of the shoes final report. If the NDT is performed or witnessed by an independent laboratory, the laboratory shall provide a certified written 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 for the zone. PT results shall include a mapping of the indications at the bond lines or photos. The report shall also address porosity and any cracking that is found. 3.3.8 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 lack of bond between the babbitt and backing material, however, the total lack of bond repaired by puddling shall not exceed 10% of the total babbitted surface. 3.3.9 Babbitt Bond Acceptance If a bearing'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 level of defects are acceptable in accordance with these specifications. 4. DELIVERY AND SHIPMENT The Contract price shall include shipping FOB to Chief Joseph Dam. The thrust bearing weight is approximately 2100 lbs without shipping crates. The bearings shall be properly packaged and protected to protect them from moisture, corrosion, or dirt buildup during shipping. All surfaces subject to corrosion shall be preserved in cosmoline or approved equal. Items that arrive in poor condition will not be accepted for final payment. US Army Corps of Engineers, Chief Joseph Dam ATT: James Boag HWY 17 & Pearl Hill Road Bridgeport, WA 98813-1120 Point of Contact for this action is: Darrell S. Resendez Contract Specialist Voice: 206-764-6691 Fax: 206-764-6817 Email: darrell.s.resendez@usace.army.mil
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- Place of Performance
- Address: USACE District, Seattle ATTN: CENWS-CT, PO Box 3755 Seattle WA
- Zip Code: 98124-3755
- Zip Code: 98124-3755
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