Webbers SWT Project Managers Brief 28 Oct 10.pptxCD

Slide 1: 

Webbers Falls Major Rehab

Slide 2: 

Purpose: Familiarize the Project Manager Workshop Members on the Webbers Falls Major Rehab Project. Briefing Topics: Background Project Cost and Scope Challenges / Successes Sub Agreements Unit 3 Schedule PDT & Partnering with SWL Project Specific Items

Slide 3: 

Run of river plant that produces 69 MW from three inclined axis units. The project was started in 1965 and the units were placed in service in 1973. Average annual energy from the powerhouse is 213,000 MWH. Project Purpose – Navigation and Hydropower. Background

Slide 4: 

Background - cont Cut View of the Powerhouse

Slide 5: 

Webbers Falls powerhouse unscheduled major breakdowns: 4/80-2/83 - cracked main shaft – Unit 1 6/80-9/83 - cracked main shaft – Unit 2 1/81-12/84 - cracked main shaft – Unit 3 5/96-12/99 - speed increaser gear – Unit 1 7/04 – Present - cracked main shaft – Unit 3 Background – cont

Background - contTurbine Shaft Failures : 

Background - contTurbine Shaft Failures Crack

Slide 7: 

Major Rehabilitation Evaluation Report approved for Plan “D” in July 2001. Plan “D” - Replaces the turbine runners, rewinding the generators and performing other technological improvements. 2 MW per unit (8.5%) increase by up-rating. Webbers Falls Turbine Replacement included as a contract option under the Ozark contract. $5 Million savings (2001) by combining Webbers Falls and Ozark turbine replacement under one contract. Background - cont

Slide 8: 

New Runner Design

Slide 9: 

One “Supply” contract, two separate contract numbers, two P2 projects, two project managers. Ozark – 5 units, Awarded – May 2005; Scheduled Completion Date – Feb 2014; Current Contract Amount $89.9M (appropriated funds). Webbers Falls - 3 units, Awarded – Feb 2008, Scheduled Completion Date – Jul 2012; Current Contract Amount $41.3M (customer funds). Background - Turbine Contract

Slide 10: 

Working at an operating powerhouse. Successful revision of the MOA between the US Army, Southwestern Power Administration and Jonesboro, Ark. Design build, performance based, supply contract. Schedule Development. Project Challenges and Successes

Slide 11: 

Project meetings with the customers and SWPA. Establishing a Joint Resident Office to manage construction at both sites. Proper Staffing. HDC involvement in design, shop drawing review, inspection and construction. Utilizing Mobile District for cathodic protection design. Project Challenges and Successes – cont

Slide 12: 

Total Cost Breakdown 2010 Current Cost Est. - $72.7M Turbine Rehab Cont. - 55.3 Generator Rewind Cont - 6.0 Intake/Draft Tube Cranes – 4.0* Rehab Two Bridge Cranes – 2.6 Misc. Electrical Mech. - 4.0** New 13.8KV Breakers - 0.8* Total - $72.7M *ARRA Funded **Partial ARRA Funded Cost include S&A and Contingency

Slide 13: 

Project Funding Project was originally 100% funded through customer funding using the Jonesboro MOA. In FY09 ARRA funds were received. ARRA funds were used for, gantry cranes, breakers, cables and distribution panels. To date customer funds in the amount of $67.9M have been provided for this project.

Slide 14: 

Sub agreement S127 Unit 3 Turbine for $19.5M signed 15 August 2007. Sub agreement S131 Unit 2 Turbine for $17.9M signed 11 January 2008. Sub agreement S135 Unit 1 Turbine for $17.9M signed 21 April 2008. Turbine – Sub Agreements

Slide 15: 

Total Contingencies - $7.93M Vs. Est. Escalation - $6.08

Slide 16: 

Additional Sub Agreements SW00431-S138 – Rewind Generators Units 1,2 & 3 = $6.0M Solicitation in Progress SW00431-S092- Rehab Bridge Cranes - $2.62M Contract Complete SW00431-S088- 13.8KV Circuit Breakers - $320K Ongoing $787K funded through ARRA SW00431-S137- Intake Gate, Bulkhead and Misc. Electrical - $4M Awarded $518K funded through ARRA

Slide 17: 

Turbine Runner 3 Schedule Runner Manufacturing – Complete Shaft Manufacturing - Complete Wicket Gate Manufacturing - Complete Disassembly – Complete Reassembly – Jun 10 - Jan 11 Testing & Acceptance – Feb 11 – Mar 11

Runner and Lower ShaftStress Analysis : 

Runner and Lower ShaftStress Analysis Shaft is failing from fatigue due to alternating stresses. New design will increase fatigue life by reducing stresses. Shaft diameter is increasing from 46 inches to 63 inches at runner end. Shaft wall thickness will decrease from 6.5 inches to 5.3 inches. Stress is reduced, weight stays the same, and buoyancy force increases.

Project Delivery TeamOzark/Webbers Falls Turbine Rehab Project : 

Project Delivery TeamOzark/Webbers Falls Turbine Rehab Project Design - Hydroelectric Design Center, Portland District Construction Management - Ozark/Webbers Falls Joint Resident Office, Tulsa and Little Rock Districts Consulting - Cathodic Protection Center of Expertise, Mobile District Project Management – Little Rock and Tulsa Districts Contracting – Little Rock District Contractor – Andritz Hydro

Ozark/Webbers Falls Joint Resident Office : 

Ozark/Webbers Falls Joint Resident Office Formalized by MOU between the two Districts, Oct 2009 Provide consistent contract administration and safety management Little Rock District Project Engineer and staff at Ozark Tulsa District Project Engineer and staff at Webbers Falls Tulsa District Resident Engineer oversees both sites Tulsa District Safety Office oversees both sites

Slide 21: 

SWT/SWL Cooperation: Joint district contractor partnering sessions Joint QA overseas inspection service contract Joint input on turbine component submittals Lessons Learned (SWT personnel on site at SWL) Contractor work plans Modifications Turbine component lifts Project Management Regional Partnering with SWL

Overseas QA Inspection : 

Overseas QA Inspection Hydro Consulting and Maintenance Services and Q-TECHNA inspection agencies for runner and blades in Slovenia. Bureau Veritas for inspection of wicket gates and shafts in South Korea.

Overseas Manufacturing : 

Overseas Manufacturing Runner hub and blades are being manufactured in Ljublijana, Slovenia by Litostroj Steel. Lower main shaft, stub shaft, and wicket gates are being manufactured Pusan, South Korea by Hochang Machinery. Runner is being assembled in Toronto, Canada.

Intermediate Shaft Removal(37 tons) : 

Intermediate Shaft Removal(37 tons)

Runner Disassembly : 

Runner Disassembly

Runner Blades : 

Runner Blades

Runner Hub : 

Runner Hub

Slide 28: 

New Runner Design

Boring Bar & Wear Band : 

Boring Bar & Wear Band

Slide 30: 

Stub Shaft Hochang Ltd. (S. Korea)

Slide 31: 

Lower Main Shaft

Lower Main Shaft : 

Lower Main Shaft

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Questions