Dworshak Unit 4

THIS IS A SOURCES SOUGHT ANNOUNCEMENT ONLY. This notice does not constitute a commitment by the Government. All information in response to this announcement is voluntary, and the Government will not pay for information requested nor will it compensate any respondent for any cost incurred in developing information provided to the Government. As part of its market research the US Army Corps of Engineers (USACE), is issuing this sources sought to seek out interested firms capable of completing one or all aspects of the work defined below. The Government may use the responses to this sources sought for information and planning purposes. Responses are requested regardless of business size. Estimated magnitude of construction will be included in future market research after an acquisition strategy is determined. Further market research (including a site visit) will be conducted once an acquisition strategy is determined. 1. Project Summary The U.S. Army Corps of Engineers (USACE), Walla Walla District intends to expand the generation capability of the Dworshak Dam Powerhouse by installing a fourth generating unit (Main Unit 4) and associated powerhouse structure extension. Dworshak Dam is located on the Clearwater River in Ahsahka, ID, approximately 50 miles east of Lewiston, ID. The Government intends to accomplish this work through one or multiple, firm fixed-price procurements with a proposed work breakdown and general scopes as follows: a. Civil/Structural - Preparation of site, construction of powerhouse and tailrace substructure, and erection of functional building envelope for powerhouse extension. b. Generator Step-Up Transformer - Supply contract for the procurement and delivery of three single-phase oil filled transformers with an approximate rating of 13.8 Delta - 500/288.68 GrdY kV at 100,000 kVA each. c. Turbine-Generator - Design, supply, installation and commissioning of a hydroelectric generator with an approximate rating of 250-300MW. d. Balance of Plant - Auxiliary mechanical and electrical systems to support power generation and powerhouse operations. e. Hydraulic Steel Structures - Supply of standalone steel structures such as gates, bulkheads and trash racks. 2. Existing Conditions Construction of the existing powerhouse and installation of its three units completed in 1973. Allowing for updates in technology and operation, Main Unit 4 is generally considered to analogous to Main Unit 3, and they will operate concurrently. At 259MW, Main Unit 3 is currently the largest installed unit and provides approximately 56% of plant capacity. Main Unit 3 is a 192-inch diameter turbine runner and rotates at 128.6 rpm; the rated head is 560 ft. Owing to its size, Main Unit 3 is also most important environmentally, providing temperature and total dissolved gas control for downstream flows. The original Dworshak design anticipated six units at full build-out. Bays 4-6 are currently empty down to bedrock (skeleton bays) with intake structure, penstocks embedded in the intake, and some of the discharge structure already constructed. 3. Project-Specific Constraints and Challenges a. The Government intends to generally extend the configuration and design of the existing powerhouse for Main Unit 4. b. Operations activities in the existing powerhouse will continue throughout the construction phase of all the work related to the addition of Main Unit 4. Contractor operations will generally not be allowed to disrupt Government operations and personnel. c. Disruption of the power generating capacity of existing units will not be allowed except during specific defined times when the units are normally not used. These periods will be referred to as - outages. d. Some areas of work will involve extensions of existing powerhouse systems. The window to do this associated work may have work windows corresponding to outages that have very limited flexibility for extensions or changes. e. The project work site has very limited room for contractor operations and staging of equipment. Remote sites, either Government- or Contractor-provided, will likely be needed for work crew parking, equipment staging, office trailers and tool storage. Access to the powerhouse is currently through a single road which has minimal turnaround and parking spaces. f. Transportation and delivery routes for large or heavy equipment may be limited by the capacity of bridges and other public transportation infrastructure. g. The community in the vicinity of the project area has limited capacity to accommodate a surging construction workforce. Available land for temporary housing, project offices, and life support areas is constrained by the mountainous terrain, rivers, and federal, tribal, and other land ownership and usage agreements. h. The work will occur adjacent to, over, or in water. Environmental controls will be critical to avoid oil spills and other impacts. i. There may be multiple prime contractors with the various proposed procurements. Contractors will need to coordinate between other contractors and with the Government. 4. Scope Description a. Civil/Structural 1) Design (potentially contractor-provided, as under design-build) a) Draft tube & spiral case modifications: Design and oversight of modifications to the existing draft tube and construction of a new spiral case. b) Penstock extension: Design and installation of a new penstock extension between the existing penstock and the spiral case to be provided, including foundation and support structures. c) Powerhouse superstructure: Design and construction of a new powerhouse superstructure, including foundations, walls, roof, and crane support. d) Transformer yard & diesel generator area: Site preparation, foundation design, and construction of a new transformer yard and diesel generator area, including fire protection and oil containment systems. e) Structural steel design: Design of steel structures other than embedded turbine-generator components. f) (Reinforced) Concrete design: Design of reinforced concrete foundations, retaining walls, mass concrete placements, powerhouse superstructure. g) Drainage design: Civil drainage design for site runoff and dewatering systems. 2) Construction (based on either government- or contractor-provided design) a) Site preparation & demolition: Controlled demolition of existing structures (transformer bridge), excavation, dewatering, and site preparation activities. b) Penstock extension installation: Installation of the penstock extension, including connections to existing structures. c) Retaining wall construction: Construction of retaining walls and powerhouse walls d) Drainage system installation: Installation of civil drainage systems for site runoff and dewatering. e) Foundation construction: Construction of foundations for the powerhouse superstructure, transformer yard, diesel generator area, and penstock extension. f) Powerhouse concrete work: Placement of reinforced concrete for foundations, walls, mass concrete (draft tube, spiral case), and other structural elements. g) Structural steel erection: Erection and installation of structural steel components (penstock, spiral case liners, powerhouse superstructure). h) Draft tube & spiral case installation: Installation of steel draft tube liners and spiral case components. i) Removal of toro-spherical bulkhead: This blocks the penstock for Main Unit 4. j) Powerhouse Superstructure: Construct generator pedestal, powerhouse walls and galleries, powerhouse roof, powerhouse end wall. k) Building systems: All high-bay lighting, HVAC and ducting, convenience and user lighting, doors, surface finishes, hand/guard railings, access controls, and fire alarm, control, and suppression systems that are not power-train equipment-specific. b. Three Generator Step-Up (GSU) Transformers 1) 13.8 Delta - 500/288.68 GrdY kV at 100,000 kVA each 2) Core or shell form construction 3) BIL: H winding 1,425 kV; X winding 110 kV 4) Nitrogen blanketed 5) ODAF or OFAF cooling 6) Maximum shipping weight of 315,000 lbs 7) One, three-phase transformer is acceptable if it can meet the shipping weight restriction for movement across the powerhouse facility. c. Turbine-Generator 1) Turbine a) A minimum of 346,000 hp at 560 ft of head. Final size, dimensions, and rotational speed not determined. b) Existing Unit 3 has a flanged split runner design to accommodate shipping c) CA6NM Stainless Steel d) Coordination will be required with the construction of the powerhouse extension. Specifically, the extension from the existing penstock through the existing skeleton draft tube (from approximately Section 11 of the Unit 3 draft tube) will be coordinated with the Civil/Structural Construction. e) A model test will be required 2) Generator a) Roebel Bar construction b) Totally Enclosed, Water-Air Cooled (TEWAC) construction c) Radial-free stator frame hold down design d) Intended winding design life of 45 years e) Wedge design pole to rim interface f) Continuously stacked core d. Balance of Plant Procurement includes design, supply, installation, and/or commissioning of various mechanical and electrical systems (referred to here as - balance of plant equipment) that support the operation of the newly installed hydroelectric turbine-generator unit. Potential equipment or systems of equipment that may be covered by this effort include, but are not limited to: 1) Direct current (DC) Power distribution systems [125Vdc class], including extension of existing systems, and preferred AC systems using an inverter powered by the station DC battery. 2) High voltage alternating current (AC) 500kVac class power distribution systems, including taps, bus work, disconnect switches, and interconnections between the transformer high voltage bushings and existing overhead 500 kVac transmission line. 3) Medium voltage alternating current (AC) 15kVac class power distribution systems including isolated phase bus from the generator terminals to the main unit circuit breaker, isolation points, taps, disconnect switches, and main unit circuit breaker, and isolated phase bus from the breaker to the transformer low voltage winding. 4) Low voltage alternating current (AC) 600 Vac and under power distribution systems including extension of existing station service systems, new motor control centers, and lighting circuits 5) Generator control, metering, and annunciation switchboard 6) Generator, transformer, and bus protective relays 7) Integration of new equipment with existing plant SCADA system 8) Generator fire protection system (high pressure CO2 system using bottles). 9) Turbine-Generator unit governor systems including digital controllers and hydraulic systems with a pressure rating of 350 psi or greater 10) Generator excitation system; full inverting potential source static rectifier exciter 11) Plant raw water distribution systems 12) Plant compressed air systems including 100 psi shop air and 350 psi or greater governor air. 13) Installation of government-furnished (via separate contract) generator step-up (GSU) transformer including mounting, containment and water-deluge-type fire protection system. 14) Extension of existing powerhouse drainage and unwatering systems. 15) Heating, ventilating and air-conditioning systems for the powerhouse and auxiliary conditioned spaces. e. Hydraulic Steel Structures 1) New Trash Racks. Fabrication, delivery, and installation of new trash racks. (At this time, designer is assumed to be USACE.) 2) New Draft Tube Bulkheads (Optional). Fabrication to EM 1110-2-2107 requirements, delivery, and installation of new draft tube bulkheads (At this time, designer is assumed to be USACE.) 3) New Intake Headgate (Optional). Fabrication to EM 1110-2-2107 requirements, delivery, and installation of new intake headgates (At this time, designer is assumed to be USACE. 5. Questions for Industry a. General 1) What in your opinion is the optimal packaging of this scope and corresponding number of government-issued contracts 2) Given the answer to Question #1 above, what portions of work or contracts would contractor-provided design (ex. design-build) be preferred? 3) Does anything in this project scope discourage you from bidding? 4) Does anything in this project scope as written increase pricing uncertainty? 5) What factors other than scope would incentivize you to bid on this work? 6) Are there any market conditions or industry practices that you feel the Government needs to be aware of? 7) If bidding as a prime, what features of work or percentage of the project scope would you self-perform? b. Schedule and Workforce 1) Given the limited scope above, what is the approximate estimated duration for this project scope, inclusive of both design and construction elements? 2) Are there recommended scope items (above) that should be phased? 3) What would be the estimated maximum size of work crew needed to accomplish the work? 4) If workforce accommodations in the project area are insufficient and Lewiston does not provide viable options, what lodging and other facilities would the contractor anticipate needing to provide to practically accomplish this effort? c. Logistics 1) Are there shipping considerations the Government should be aware of? For example, is another flanged, split runner anticipated? d. Balance Of Plant 1) Would you recommend any of the systems or equipment identified in the proposed balance of plant effort be combined into one of the other proposed efforts for this project? 2) Are there any specific systems or equipment not identified in this notice that you would recommend including under this effort rather than one of the other proposed efforts for this project? 3) If the procurement required the balance of plant contractor to interface and coordinate with the turbine-generator contractor during commissioning activities of the new turbine-generator unit, would there be any objections, provided the limits and requirements of coordination for each party were clearly defined? 4) The Government intends to lead the commissioning, energizing, and systems integration startup processes. The various subcontractors and suppliers would each be responsible for their area of installation, procedures for energizing, and any tuning. Is this proposed process acceptable or would contractor(s) prefer it was assigned to a specific prime contractor. 6. Submission Instructions Responses to this Sources Sought notice must be submitted electronically (via email) with SUBJECT: Sources Sought - W912EF25RSS27. Please email to Jani Long, Contracting Officer, at contact@example.gov and Cyndi Jacobsen, Contracting Specialist at contact@example.gov before 2:00 pm Pacific time on 12 June 2025. Interested parties responses to this Sources Sought shall include the following information: a. Firm's name, address, point of contact, phone number, e-mail address, CAGE and Unique Entity ID. b. Firm's business category and size: Large Business (include summary of small business participation metrics), Small Business, Small Disadvantaged Businesses to include 8(a) firms, Historically Underutilized Business Zones (HUBZone), Woman-Owned Small Business (WOSB) to include Economically Disadvantaged Women-Owned Small Business (EDWOSB), Service-Disabled Veteran-Owned Small business (SDVOSB) and at the subcontracting level, Veteran Owned Small Business (VOSB). c. An explanation of the prime firm's capabilities, special qualifications/certifications and equipment and describe the work to be self-performed as it pertains to the proposed work outlined in the Project Scope. d. A description of work that has been performed by the prime firm that is similar to scope described in Paragraph 1 and was completed under similar constraints and challenges listed under Paragraph 2. e. Project Examples (for Joint Ventures, please include projects completed by the Joint Venture if available): - Provide up to five (5), (List the critical elements required) project examples. These project examples must be similar in size, scope and complexity to the work described in this notice, with a description of each project (to include pertinent qualitative and quantitative information about featured scope elements), and include the following: Project Title Contract Number Contract award date Customer name, phone number and email address Prime or Subcontractor Initial contract dollar value Final contract dollar value Initial contract completion date Final contract completion date The Government may verify information in CPARS or PPIRS. f. Firm's Joint Venture information if applicable - existing and potential. g. Firm's Bonding Capability in the form of a letter from Surety. h. Firm's interest and the likelihood in bidding on a potential solicitation related to the scope described above, if advertised. i. Responses to the government's questions in paragraph 5 and any other information the Firm feels the government needs to be aware of. 7. Disclaimer and Important Notes a. All interested firms must be registered in the System for Award Management (SAM) at https://www.sam.gov to have size status considered. You must remain current for the duration of the source selection process to be eligible for award of a Government contract. 8. Attachments a. See Dworshak Unit 4 Figure Book