RECOVERY--The Government shall be issuing a Request for Proposal (W912DQ-10-R-1001, replacing W91DQ-09-R-1015) on or about 19 October 2009 with an expecting closing date of 19 November 2009, for a Firm-Fixed Price Service Contract for repair of Kaplan blades. Stockton Power Plant is located in Stockton, MO and has a single turbine-generator unit. The turbine is an adjustable 6 blade Kaplan unit, with a runner diameter of 280 inches. In February 2009, one of broke off. The position of the beachmarks indicate that this failure initiated from the top, inside (pressure, hub side) corner of the blade at the downstream cutout.
The weight of a runner blade for this unit is 22,000 pounds. The estimated weight of the broken blade section is 14,000 pounds. The blade section has been located in the bottom of the draft tube. The Contractor shall provide all labor, materials, incidentals, and equipment to perform the work required to repair Blade.
1. Part I:
a. Take samples of the blade and perform a chemical analysis. The blade is thought to be carbon steel with estimated carbon content is of 0.30%.
b. Define the weld geometry for preparation of the double bevel weld of the of the broken blade segment.
c. Be responsible for having the blade prepared for welding, including all weld grooves and bevels. It is assumed that the weld prep will be performed on the blade prior to it being re-inserted in the draft tube.
d. Define the weld procedures (subject to COE approval).
e. Award a dive contract to reposition the blade section into the draft tube, resting it on the floor of the draft tube at the elbow transition.
2. Part II:
a. Fix the 5 good blades and the broken blade section to the runner hub with blocks.
b. Create templates of the proper blade shape that will be representative of the surface profile of one of the five good blades.
c. Measure and determine the average entrance and exit blade vents of the five good blades.
d. Weld tabs to the headcover and drop plumb lines to the top of one of the good runner blades. Six plumb lines will be used to establish absolute blade position.
e. The high lift system will be used to allow rotation of the unit so plumb lines are positioned above the broken blade. The position of the broken blade must be identical to the good blade from which the plumb lines were set.
f. Gouge out and weld repair the vertical crack on the trailing edge of the broken blade stub. Use NDT either PT or MT to verify that the crack has been completely removed before weld repair is initiated.
g. Use chain falls, jacks, etc. to lift the broken blade segment from the bottom of the draft tube into position so it can be welded onto the stub/trunnion section still in the runner hub.
h. Install the Government furnished draft tube work platform and reinforce the existing platform or fabricate a new platform if needed to facilitate work (subject to COE approval).
i. Weld the two blade sections together while monitoring blade conformation with plumb lines, templates and vent measurements and hub to blade and blade to discharge ring clearances.
j. Maintain the original blade shape until welding is complete.
k. Complete PT of the blade cutouts on the other 5 runner blades and perform weld repair on identified cracks (subject to COE approval).
l. Remove any temporary tabs, lifting lugs, blade blocks and other brackets, tooling, etc. that were welded to the headcover, turbine runner, blade, or draft tube. Grind flush and restore the surfaces to their original contour.
m. Perform final measurements on the repaired blade.
The NAICS code is 811310 Commercial and Industrial Machinery and Equipment Repair and Maintenance. Solicitation shall be posted on or about 1 September 2009 with an estimated closing date of 1 October 2009. All questions about this project shall be forwarded to Andre D. Vasseur, Contract Specialist, E-mail address is firstname.lastname@example.org or phone 816-389-3435.
Set-aside code: N/A
Place of performance:
US Army Engineer District, Kansas City ATTN: CENWK-CT, 700 Federal Building 60l East 12th Street Kansas City MO
Contact: Andre D. Vasseur, 816-389-3435
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Email: US Army Engineer District, Kansas City (email@example.com)
Updated on 2009/10/05