McNary Intake Gates and Isophase Bus Systems

Please note, the solicitation is posted to this notice. A separate soliciation notice will not be posted. Construction Contract: McNary Intake Gates and Isophase Bus Systems The work is located at the McNary Dam located in Umatilla County near Umatilla, Oregon. The work consists of the following major elements: SPECIFIC REQUIREMENTS FOR INTAKE GATES SYSTEM: Background Information: The 14 main generating units (MU) and 2 station service units (SSU) at McNary utilize hydraulically operated intake gates. Each main unit has three intake gates and each station service unit has one gate. There is also one spare gate that normally resides in the gate repair pit. All gates are interchangeable between operating positions between main units/station service units. All gates utilize the same overall operating and control systems. Each intake gate is supported in its operating position by a support beam which rests on retractable dogs that are installed on the intake gate slot. The intake gates are connected to the support beams through two hydraulic cylinders. Flexible hoses connect the hydraulic cylinders to the hydraulic system which is located in a gallery within the dam. Each unit is controlled by a manually operated control console that integrates the distribution manifold and valving for controlling the gates. The 16 manual control consoles are connected to supply and return headers that run the length of the powerhouse. Pressurized oil is supplied by a single HPU that is connected to the supply header and there are 4 hydraulic oil storage tanks connected to the return header. Summary of Work: The work covered by this contract for the intake gate portion includes the following: Rehabilitate 45 intake gates including work to replace the seals, seal bars, seal hardware, replace anodes, and perform touch up painting. Inspect sealing bar surfaces for 44 intake gate slots. Provide 90 new hydraulic cylinders for 45 intake gates. Provide two additional cylinder assemblies that will be placed into long term storage as spares. Provide 45 new support beams for 45 intake gates. 5. Provide a new hydraulic power unit, including new motor starters, breakers, and other electrical and control components. 6.. Provide new high and low pressure hydraulic fluid header piping system 7. Provide new flexible hose assemblies for 44 intake gate slots. 8. Provide 14 new main unit control consoles and 2 station service unit control consoles, inclusive of all new electrical and control components. 9. Replace the accumulator tanks located at the control console for each unit. Add one additional accumulator tank per unit to provide back-up mechanical energy storage. 10.Provide approximately 26,000 gallons of new hydraulic fluid 11.Rehabilitate the existing oil storage tanks and transfer piping. 12. Rehabilitate the existing gate position indicating system. 13. Inspect and rehabilitate gate dog system, including replacing components, for 44 intake gate slots. 14. Add emergency gate closure switches to the control room main unit switchboards. 15. Provide cable and conduit for system power, controls and annunciation. 16. Remove and dispose of existing: Intake gate seals, seal bars, anodes, and hardware 90 hydraulic cylinders 45 support beams Hydraulic power unit High and low pressure headers Flexible hose assemblies for 44 intake gate slots 14 main unit control consoles and 2 station service unit control consoles Approximately 26,000 gallons of hydraulic fluid. Electrical and control equipment associated with the above items 17. Provide as-built drawings, operations manual, training, and operations and maintenance manual, and spare parts as specified. SPECIFIC REQUIREMENTS FOR ISO PHASE SYSTEM: Background Information: Each of the 14 generating units at McNary powerhouse are currently rated 74MVA. The generators send power at 13.8kV (medium-voltage) to the generator step-up (GSU) transformer banks through the isolated-phase bus, or isophase bus, via the main unit circuit breakers inside the powerhouse. The existing indoor three-phase runs of isophase bus from the generators to EL. 346.0 is rated 4,000A. In the EL. 333.0 gallery, the three-phase configuration changes to single-phase configurations in what is called the delta bus. The existing single-phase runs of 2,500A isophase bus runs up through the transformer deck using transition bushings, and becomes outdoor 2,500A isophase bus to each single-phase transformer in the GSU transformer bank. The GSU transformers send 115kV and 230kV power (high voltage) through 2 tubular aluminum bus to steel latticework takeoff towers. From the towers, power is delivered through aerial conductors (Lines 1 through 6) to the BPA switchyard. The work covered by this contract for the isophase bus systems portion includes the following: Replace existing 15kV 4,000 amp copper isophase bus including in-line current transformers and 2,500 amp copper delta isophase bus with new 15kV aluminum isophase bus rated 5,000 amp including in-line current transformers and new aluminum delta isophase rated 3,000 amp from the main unit generator barrels to the GSU transformer banks. All bus must be able to pass through existing floor openings. The GSU transformer banks must be partially moved out of their vaults, requiring temporary removal of the radiators, then reinstalled, moved back in place and tested under supervision of an approved field engineer to facilitate isophase bus replacement. Replace seven existing 15kV 3-phase synchronizing potential transformer cubicles with potential transformers with fourteen new 15kV 3-phase synchronizing potential transformer cubicles with potential transformers, complete with wiring. Replace the existing 230kV tubular aluminum bus segments that are cracked at Lines 1 through 4 with new reconfiguration, including slip fittings. Replace seven existing manual group-operated disconnect switches and six manually-operated ground switches with seven new motorized group-operated disconnect switches (MOD's) equipped with surge resistors and seven manual ground switches, including Kirk key interlocks, electrical interlocks, and GDACS status indications. The first six sets of switches are 230kV, the seventh set of switches is 115kV. The first five 230kV disconnect/ground switches have larger than standard phase spacing requiring each phase to be mounted separately. Provide 480 volt - 240/120 volt step-down transformers and 120 volt load centers (mini-power centers) at existing 480 volt motor control centers (MCC's) to provide power and control for the new MOD's. Provide new 2-pole 480 volt breakers in the MCC's to power the step-down transformers. Presume a new bucket will be required, field verify and match existing. Provide new wire and cable connections to existing pistol grip control switches with red and green position indication lights for the seven new MOD switches, both locally at each S board and in the Control Room on the SC board. The pistol grip control switches will be supplied and installed by others but not wired. Replace the 115kV and 230kV surge arresters on the deck behind the GSU transformers. Perform field acceptance testing and commissioning of the seven transformer banks and all new installed equipment. Provide as-built drawings, operations manual, training, and operations and maintenance manual, and spare parts as specified. Optional draining of an entire transformer tank in the event of a radiator isolating valve failing while draining the radiators for transformer movement. The work covered by this contract will be subject to the following work area and schedule restrictions: The period of performance is estimated from December 2021 to May 2030 Overall schedule adherence will be critical as this work will require main generating unit outages which must be minimized to avoid lost generation. Work windows (unit outage windows) will be approximately 6 months out of each year. Two generating units (3 intake gates each) will be taken out of service at a time during each outage window. Work on the isophase systems and the intake gates for the two units will occur simultaneously. Work requiring a unit outage will not be allowed outside the specified unit outage windows. The first unit outage window is currently scheduled to occur in 2023 with the last outage window in 2029. Work that doesn't require a main unit outage (e.g. overall hydraulic system, overall control system, intake gates for station service units, spare intake gate) may be performed outside of the 6-month unit outage windows. Portions of the work for both the isophase systems and the intake gates will occur in the same general areas on the intake deck, Scheduling and coordination for access in this area will be essential. Rehabilitation of the intake gates will occur on-site in the gate repair pit (which can accommodate a single gate at a time). The Government will perform all required physical moves of intake gates/bulkheads/fish screens facilitate the intake gate rehabilitations. All work is expected to be completed in early 2030. Performance and payment bonds will be required for the entire effort but may be permitted to be on per unit, - rolling basis. . The magnitude of the project is estimated to be between $25,000,000 and $100,000,000. Sustainability requirements will be contained in the solicitation and resulting contract. The source selection process will be conducted as a best value trade-off, as defined in FAR Part 15.101-1. The resulting contract will be Fixed Price. One or more of the items under this acquisition is subject to the World Trade Organization Government Procurement Agreement and Free Trade Agreements. Solicitation documents for the Request for Proposal No. W912EF21R0015 will be posted to the Beta.sam.gov website on or about June 2021 under this notice titled presolicitaion notice. The proposal due date will be contained in the solicitation and any solicitation amendments that may be used. The solicitation is to be competed as unrestricted. The small business size standard for NAICS Code 237990, Other Heavy and Civil Engineering Construction, and the associated small business size standard is $39.5 MIL in average annual receipts. 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