Old Hickory Turbine Generator Rehabilitation

Contract Award Date: Feb 02, 2023 Contract Award Number: W912P523C0002 Task/Delivery Order Number: Contractor Awarded Unique Entity ID: Contractor Awarded Name: Andritz Hydro Corp. Contractor Awarded Address: Charlotte, NC 282621289 USA Base and All Options Value (Total Contract Value): $101574900.68 The Nashville District U.S. Army Corps of Engineers (USACE) is soliciting for a firm fixed-price construction contract to rehabilitate turbine generator units at Old Hickory Power Plant, Hendersonville, TN. The estimated magnitude of this project is between $25,000,000 and $100,000,000. Summary of work for the Old Hickory Turbine Generator Rehab Project: The overall goal of this project is to increase generator maximum output to 45 MW. This will be accomplished by rewinding units 1, 2, and 3 and replacing turbines runner for the same units. Unit 4's generator was rewound in 2021, but the turbine runner was not replaced. All the mechanical system to support this new load will have to be assessed and refurbished. While the units are down for rehabilitation there will be some efforts to upgrade or replace systems associated with the turbine generators. General Project: The term of the project is estimated at two (2) years of model testing, design, and fabrication for the first unit. Followed by an additional eighteen (18) months of installation per base unit. Electrical Work: The primary electrical scope of work is to accomplish the rewind and restack of the generator stators on Units 1, 2, and 3 to 45,000 kVA, with a 0.9 power factor at 13.8 kV. The electrical work includes, but is not limited to replacing the stator winding, replacing core laminations, reinsulating rotor poles, and model verification. Other major electrical scope items for Units 1, 2 and 3 include but are not limited to the installation of a machine condition monitoring system, refurbishment of rotor field poles and field leads, replacement of cable, wiring, relays, and RTDs, and furnishing and installing new high resistance grounding systems. The scope of work for each unit will culminate with testing and commissioning. Turbine Work: The primary mechanical scope of work is the replacement of the Kaplan turbine runners of Units 1, 2, and 3 to an increased rated output of 61,600 hp at 54 feet of net head, along with replacement of the wicket gates. Turbine runner and wicket gate replacement for Unit 4 will be at the option of the Government. The existing turbine runners are 264-in diameter, 5-bladed Kaplan runners rated at 35,000 hp at a net head of 45 feet. Other turbine work will be focused around stay ring, bottom ring, headcovers, turbine shaft, bearings, operating ring, servomotors, and facing plates. A special item in this contract will be producing a display from the existing runner. Old Hickory's powerhouse has experienced historical movement that has rendered the stator core eccentric to the discharge ring by as much as one-quarter inch on some units. Refurbishment of the discharge rings by machining and weld overlay is a feature of work that shall accomplish cavitation repair and the re-establishment of concentric unit alignment. Mechanical Work: During the rehab all the mechanical support systems will be inspected, refurbished, or upgraded. This will include but not limited to brake ring, brake cylinders, thrust bearing coolers, float switches, digital relays, turbine guide bearing lubrication system, high pressure lift system addition, vacuum breakers, and wicket gate lubrication system, and rotating exciter will be removed. The contractor will be required to provide all plant, labor and materials to construct these features. An organized site visit is scheduled for Thursday, May 5, 2022 at 9:00 a.m. Central Time. See FAR 52.236-27 Site Visit (Construction) (FEB 1995) - Alternate I for additional details. Vendors interested in attending the site visit MUST fill out the site visit request forms (FN Pre-bid or Site Visit Request Form or US Citizen Pre-bid or Site Visit Request Form provided as separate attachments to this notice) and submit them to Kristal Jones via e-mail at Kristal.R.Jones@usace.army.mil. Site visit request forms must be submitted for each individual company representative who will be in attendance at the site visit. Foreign nationals submitting a site visit request form must have the form and its associated documentation sent to Kristal Jones at the aforementioned e-mail address at least 2 weeks prior to the site visit. U.S. citizens submitting a site visit request form must have the form sent to Kristal Jones at the aforementioned e-mail address at least 5 business days prior to the site visit. Failure to submit the site visit request forms in a timely manner will result in interested participants not being able to gain access to the areas that will be shown during the site visit. The Question and Answer period for this project is now open. Technical inquiries and questions relating to proposal procedures or bonds must be submitted through ProjNet at https://www.ProjNet.org. See Section 00 21 00 - Instructions, paragraph 1.10, POC for Communication/Questions of the solicitation for additional details and instructions on how to access the website. 28 April 2022: This solicitation notice is being amended to change attachments from controlled/restricted to unrestricted. 2 May 2022: This solicitation notice is being amended to remove an attachment. *The value for this project is based on a financial range. The value is listed as the highest possible cost from the range provided by a stakeholder or official project document.

Division 02 -	Existing Conditions, Subsurface Investigation.
Division 03 -	Concrete, Concrete Forming and Accessories, Concrete Reinforcing, Cast-in-Place Concrete, Structural Concrete, High-Performance Structural Concrete, Concrete Finishing, Specialty Placed Concrete, Precast Structural Concrete, Precast Concrete Specialties.
Division 04 -	Masonry, Unit Masonry, Concrete Form Masonry Units.
Division 05 -	Metals, Structural Metal Framing, Metal Fabrications.
Division 06 -	Wood, Plastics, and Composites, Rough Carpentry.
Division 07 -	Thermal and Moisture Protection, Dampproofing and Waterproofing, Thermal Protection, Weather Barriers.
Division 08 -	Openings, Doors and Frames, Specialty Doors and Frames, Access Doors and Panels, Coiling Doors and Grilles, Windows, Hardware, Glazing.
Division 09 -	Finishes, Plaster and Gypsum Board, Ceilings, Flooring, Painting and Coating.
Division 10 -	Specialties, Compartments and Cubicles, Toilet, Bath, and Laundry Accessories, Safety Specialties, Emergency Aid Specialties, Fire Protection Specialties, Exterior Specialties, Security Mirrors and Domes.
Division 11 -	Equipment, Parking Control Equipment, Loading Dock Equipment, Security Equipment.
Division 13 -	Special Construction, Radiation Protection, Special Instrumentation, Seismic Instrumentation.
Division 21 -	Fire Suppression.
Division 22 -	Plumbing, Instrumentation and Control for Plumbing, Plumbing Piping, Plumbing Equipment, Plumbing Fixtures.
Division 23 -	Heating, Ventilating, and Air Conditioning (HVAC), Instrumentation and Control for HVAC, HVAC Air Distribution.
Division 26 -	Electrical, Instrumentation and Control for Electrical Systems, Power Distribution Units, Lighting, Interior Lighting, Emergency Lighting, Exit Signs, Special Purpose Lighting, Exterior Lighting.
Division 27 -	Communications, Structured Cabling, Data Communications, Voice Communications, Audio-Video Communications.
Division 28 -	Electronic Safety and Security, Electronic Access Control and Intrusion Detection, Electronic Surveillance, Video Surveillance, Electronic Personal Protection Systems, Electronic Detection and Alarm, Fire Detection and Alarm, Radiation Detection and Alarm, Fuel-Oil Detection and Alarm.
Division 31 -	Earthwork, Grading, Earthwork Methods, Soil Treatment, Soil Stabilization.
Division 32 -	Exterior Improvements, Bases, Ballasts, and Paving, Flexible Paving, Rigid Paving, Curbs, Gutters, Sidewalks, and Driveways, Fences and Gates, Planting, Turf and Grasses.
Division 33 -	Utilities, Water Utilities, Sanitary Sewerage Utilities, Storm Drainage Utilities, Fuel Distribution Utilities, Electrical Utilities, Electrical Utility Transmission and Distribution, Utility Substations, Utility Transformers, High-Voltage Switchgear and Protection Devices, Medium-Voltage Utility Switchgear and Protection Devices, Communications Utilities.
Division 41 -	Material Processing and Handling Equipment, Conveyors, Cranes and Hoists.
Division 46 -	Water and Wastewater Equipment.
Division 48 -	Electrical Power Generation, Common Work Results for Electrical Power Generation, Instrumentation and Control for Electrical Power Generation, Electrical Power Generation Equipment, Electrical Power Generation Testing.