Construction Contract: McNary Governors, Exciters, Powerhouse Upgrade
The work is located at the McNary Dam located in Umatilla County near Umatilla, Oregon.
The work consists of the following major elements:
McNary Main Unit Generator Details:
McNary Generator units 1-12 were manufactured by the General Electric Company and commissioned between 1953 and 1956. McNary Generator units 13 and 14 were manufactured by the English Electric Company and commissioned in 1956. The three-phase, salient pole, vertical, synchronous generators have the following characteristics and ratings:
Units: 1-12 13-14
Manufacturer: General Electric English Electric
Rating (kVA) 73,684 73,684
Power Factor: 0.95 0.95
Overload Capability (%): 115 115
Voltage (V): 13,800 13,800
Speed (rpm) 85.7 85.7
Digital Governor Upgrades:
Upgrade digital governors on all 14 hydropower main generator units at the McNary Dam hydroelectric power plant. All 14 main units are Kaplan type with adjustable turbine blades.
There are two families of hydropower units at McNary powerhouse, both utilizing adjustable turbine blades. All 14 units have original governors with proportional, integral, and derivative (PID) control for both the gate and blade servomotors. The governors control unit speed by operating wicket gates through a combination of hydraulic, mechanical and electrical means. The governors control blade pitch by adjusting blade angle through a combination of hydraulic, mechanical, and electrical means. Unit governor speed reference is generated by a permanent magnet generator (PMG) or by a speed signal generator (SSG).
Digital governor equipment has already been procured and shall be provided under this contract as Government Furnished Equipment (GFE) for contractor installation. Installation plans and specifications will contain prescriptive and performance requirements for the installation and testing of GFE digital governor equipment and will include detailed wiring on a representative number of units. The Contractor will perform the removal of the existing governor components and the installation of the new GFE digital governors. Main units one through four will utilize Allis-Chalmer governor retrofit kits manufactured by American Governor and main units five through fourteen will utilize Woodward governor retrofit kits manufactured by American Governor.
Digital Governor - General Work:
As part of the digital governor installation work, a front panel of the actuator cabinet will be removed and replaced with a new governor cabinet with a GFE Human Machine Interface (HMI). Two additional GFE HMI's will be installed in the control room and will be capable of controlling seven units each.
As part of the digital governor upgrade, the new digital governor controller will replace the hardwired relay logic for automatic unit start/stop sequencing. The start sequence will bring the unit to speed-no-load, and the stop sequence will shutdown the unit after the breaker has been opened. The governor will include automatic, semiautomatic, and manual starting.
Upon completion of all demolition work within the governor actuator cabinets, the interior surfaces will be stripped and repainted. The interior surfaces of the governor actuator cabinets are painted with toxic metals based paint that includes barium, chromium, lead, and mercury.
Digital Governor - Mechanical Work, each unit:
The existing distributing valves, servomotors, and pump drive motors will remain. All gate and blade distributing valves will be cleaned, inspected and rebuilt using existing components or new internal parts as needed. New gaskets, seals and O-rings will be installed and the valves will be reassembled to OEM specifications. Existing servomotors and pump drive motors of the governor systems require no rework or refurbishment.
The work includes installation of a new GFE Electro-Hydraulic Interface (EHI) module which includes a manifold block, gate and blade proportional valves, duplex oil filters with clogged oil filter switch contacts, and emergency shutdown valve, a Linear Variable Differential Transducer (LVDT) on the servomotor and blade distributing valves for position feedback to the proportional valves, new hydraulic tubing, isolation maintenance valves (padlock capable), and redundant Magnetostrictive Linear Displacement Transducers (MLDTs) for blade and wicket gate position. No rework or refurbishment of existing gate lock solenoid valves will be required.
The Contractor will be required to provide detailed shop drawings for the interconnections of all new and existing GFE and Contractor provided parts and accessories.
The governor control column and all mechanical linkages associated with it, including the mechanical pilot valves for the gate and blade will be removed. All speed adjustment, gate limit and gate position equipment will be removed. The existing Lead, Lag, Alarm and Shut Down governor oil pressure switches shall be relocated in the cabinet as necessary to facilitate the installation of the new digital governor cabinet. The existing duplex strainers for the gate and blade pilot valves will be removed.
GFE LVDTs will be installed to monitor each unit's gate and blade distributing spool valves' position to provide intermediate feedback (relay restoring). The existing feedback system, consisting of cables, pulleys, weights, and etc., will be removed along with the associated mounting hardware, piping, and conduit. All unused cable ports in the governor actuator cabinet will be closed with a threaded metal cap with o-ring.
GFE redundant MLDTs will be installed and affixed to an aluminum channel mounted on the servo motor #1 using a combination of a U-bolt mount and cantilever bracket. The existing feedback system consisting of cables, pulleys, sheaves, and weights, along with the associated mounting hardware and piping, will be removed from the governor cabinet up to the point of connection with the new blade angle feedback assembly. The new blade angle feedback assembly will be supported by a combination of a U-bolt support on the existing blade angle oil line and a support backed mounted to the bridge. The MLDT conduit will be routed from the assembly up to the existing SSG/PMG junction box, and then will be routed to the governor cabinet.
Permanent magnetic generators shall have existing rotor and stator windings removed. Speed signal generators shall have existing pickup sensors removed. Each PMG and SSG will retain one existing mechanical overspeed switch and each will receive two new proximity probes providing speed reference and creep detection.
Digital Governor - Electrical Work, each unit:
For all units, the following components (along with wiring) located on the front of the governor control cubicle will be either removed or relocated: 3D CAM EStop Switch, 3D CAM HMI, Analog Governor, Blade Position Indicator, Dashpot By-Pass Control, Gate Limit Control Knob, Gate Limit - Gate Position Indicator, Generator Air Brake Control Switch & Indicating Light, Generator Air Brake Pressure Gauge (Duplex), Nitrogen Shutdown Indicating Lamp, Speed Droop Control, Speed Droop Indicator, Speed Indicator/Tachometer Speed Level Control/Speed Adjustment Control Knob, Speed Level Indicator/Speed Adjustment Indicator, System Pressure/Governor Oil Pressure Gauge, Transfer Valve Control/Gov. Transfer Control Switch & Indicating Lights, Transfer Valve Position Indicator.
The existing interface to the Generic Data Acquisition and Control System (GDACS) and Station Control Console (SCC) will be retained. Redundant Zero Velocity Pickup (ZVPU) proximity probes installed at the PMG and SSG gear teeth shall serve as creep detection and speed signal. The primary speed signal will be from a new frequency transducer connected to the Unit's potential transformer (PT). GFE digital governor cabinet with Programmable Logic Controller (PLC), power supplies, interposing relays (controlled by the PLC output modules), and associated equipment will be installed, along with all necessary components, wiring, and conduit.
A fiber optic cable will be routed in rigid metal conduit from each generator unit to a new network switch located in the control room. Any fiber optic junction boxes or patch panels will have a lockable cover. A GFE free standing touch screen governor HMI will be installed in the control room at the operator's desk. Copper Ethernet will be routed from the new network switch to the operator desk HMI.
As part of the control circuit changes, several devices/relays and associated wiring located within panels of the unit switchboard and actuator cabinet will be removed and their functions will be incorporated into the new digital governor.
Governor Mechanical System – Mechanical Work, each unit:
The governor system is composed of a compressed air system, air receiver tanks, oil accumulator tanks, oil sumps, oil pumps, valves, piping, pressure sensors, oil level sensors and filters.
For all units, include replacement of all 4 inch diameter and smaller governor air and governor oil piping. Inspect, clean and refurbish governor oil piping greater than 4 inch diameter. Cleaning shall be done by a “pigging” or swabbing method. Include removal of wicket gate emergency closure piping
For units 1-4 only, the governor oil pumps will be replaced.
Modernizing the air compressor changes requires inspection of 30 accumulator tanks and replacement of all three governor air compressors.
Main Unit Exciter Replacement:
Upgrade exciters on all 14 hydropower main generator units at the McNary Dam hydroelectric power plant. The existing excitation system for the main generator units at McNary Dam is of the analog static type and was manufactured by General Electric Company and installed circa 1987. The new contractor-furnished excitation system will be of the digital static type. The functionality will be similar to that of the existing system but using modern technology.
The new contractor-furnished exciter equipment will be installed in the same location as the existing equipment. The new contractor-furnished excitation system will be sized to accommodate the future generating unit uprate of 100 MVA and 0.95 power factor. The field current requirement will increase for the future generator rating. A preliminary estimate of field current is 1300 Adc for units 1-12, 1600 Adc for unit 13, and 1400 Adc for unit 14.
The following existing excitation system equipment will be removed:
• Excitation cubicle line up (Regulator, Rectifier, AC Breaker, Rectifier (note that units 1-12 have two rectifier bridges, while units 13 and 14 have three)
• Excitation transformer
• DC Bus transition box
• High Voltage Fuses / Holders / and CTs / Connecting Bus
• Speed Relay / Speed Sensor / Speed Relay Power Supply
• Associated Wiring
The following existing excitation system equipment will be replaced:
• DC Bus. The existing bus is rated at 1665 Adc.
• Cable tray carrying cables from main generator unit control boards (S-Board) to exciter
• Cable tray carrying cables from exciter transformer to exciter
Generator switchboards will be modified by the contractor to remove the balance meter and dc voltage adjust switch. The new contractor-furnished excitation equipment will have an auto tracking feature which makes the balance meter unnecessary. Furthermore, the new contractor-furnished excitation equipment will make use of the ac voltage adjust for voltage raise and lower commands to both the automatic and manual voltage regulators. The resulting openings in the switchboards will be covered with plates and painted to match. The ac voltage adjust and regulator transfer switches will be replaced with contractor-furnished equipment.
Control room switchboard modifications will be required. The dc voltage adjust switch and lights will be removed from each unit's control board. The ac voltage adjust switches will be replaced with contractor-furnished equipment.
The contractor will be required to perform generator brush rigging modifications will be required. The brush rigging will be modified to add brush holders in preparation of the additional brushes that will be needed to carry the additional field current required for the future uprated generating units.
The components comprising the generator bus tap will be replaced with contractor-furnished equipment. These components are housed in the High Voltage Fuse Compartment which is located atop the surge protection equipment and the exciter transformer. The components include, conductors, fuses/holders, and current transformers. The housing for these components will also be replaced.
Provide and Install new 125VDC distribution panels for each S-board.
Protective relaying will be replaced and upgraded with the S-board upgrades.
Provide manual synchronization equipment for each unit.
Exciter and Governor Controls Network Upgrades:
Provide, assemble and install a new main unit fiber optic communication control cabinet at each main unit pair. Cabinets shall include contractor provided and installed racks, patch panels and GFE network equipment.
Provide and install conduit and patch panels in the actuator cabinet and Sboard to connect to the new control cabinets. Provide, install and connect new conduit and pull boxes to connect new exciter cabinet and s-boards to the new fiber optic communication control cabinets.
Provide, install and connect new conduit, pull boxes and patch panels to interconnect new main unit fiber optic communication control cabinets. Provide, assemble and install new main unit fiber optic communication control cabinet in the power house communication room. Cabinet shall include contractor provided and installed rack, patch panels and GFE network equipment.
Provide, install and connect new conduit, pull boxes and patch panels to interconnect new main unit fiber optic communication control cabinets at main unit #1 and #14 to the unit fiber optic communication control cabinet in the power house communication room.
Install and connect GFE touch screen HMIs, power supplies, and communication modules in the control room SC-board.
Provide, install and connect new conduit, pull boxes and patch panels to connect new control room fiber optic communication control cabinet to the SC board.
Perform OTDR and Power Attenuation testing on fiber optic cables while on the reels, after installation but before termination, and after termination.
Install, test, terminate and connect fiber optic cables as shown in the plans.
Provide, install and connect auxiliary equipment in the communication cabinets as shown in the plans.
Digital Exciter and Governor Upgrades - General Contract Requirements:
The contract requires completion of all work within coordinated on-site installation work windows covering a period of approximately 730 calendar days. Work must be completed within the specified work window in order to return the power plant back to service in accordance with a coordinated power generation system outage plan. The Contractor must be able to staff (supervision and labor) and provide on-site physical plant to support potential multiple daily work shifts and 7-day work weeks to meet the requirements of the construction schedule constraints.
Two hydropower units shall be upgraded at a time and shall be completed within a sixteen to twenty week work window, for each pair of units. Work on subsequent units shall not commence until the previous pair of units has been successfully returned to service. Unit testing and commissioning support is required after each digital upgrade is completed. The prime contractor will be required to provide authorized commissioning engineers from the Exciter and Governor manufacturers during the on-site testing and commissioning activities for each Main Unit.
TIME FOR COMPLETION: The work shall be completed not later than 22 January 2025
Performance and payment bonds will be required. 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. The proposal due date will be contained in the solicitation and any solicitation amendments that may be issued.
The solicitation is to be competed as Unrestricted. The small business size standard for NAICS Code 238210, Electrical Contractors and Other Wiring Installation Contractors is no more than $16,500,000 in average annual receipts.
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