Old Hickory Turbine Generator Rehabilitation

The Government is issuing this Sources Sought Notice to determine a competitive basis. This is not a solicitation. No reimbursement will be made for any costs associated with providing information in response to this survey. This questionnaire is for market research purposes only. Only contractors capable of performing this type of work should respond to this Notice.RequirementThe Nashville District U.S. Army Corps of Engineers (USACE) anticipates soliciting a requirement 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.*Please note that this description is subject to change.The anticipated NAICS code is 237990, Other Heavy and Civil Engineering Construction, with a small business size standard of $39.5 million.SurveyThe Government is issuing this Notice to determine a competitive basis. This is not a solicitation and the items listed herein are subject to change or eliminated from the requirement. This questionnaire is for market research purposes only. Only contractors capable of performing this  type of work should respond to this Sources Sought Notice.Responses to this survey are to be submitted by Tuesday, December 28, 2021 at 4:00 p.m. Central Time. Please send by email to Contract Specialist Kristal Jones at Kristal.R.Jones@usace.army.mil.1.   Name of your firm:2.   CAGE:3.   Point of Contact, Phone number and e-mail address:4.   Please provide responses to the following:a)   Provide a minimum of (3) projects completed within the last (14) years*, or (2) projects completed in the last (14) years* and (1) project that is currently substantially complete*, that were self-performed as a prime or sub-contractor, that demonstrate design, scale model testing, and fabrication of new turbine runners with a minimum blade diameter of 175 inches for units rated at 25-65 MW.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii) Prime Contractor or – Sub-Contractor:iv) Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)       General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii) Prime Contractor or – Sub-Contractor:iv) Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project: Third Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii) Prime Contractor or – Sub-Contractor:iv) Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi) General Description of project:b)   Provide a minimum of (3) projects completed within the last (10) years*, or (2) project completed in the last (10) years* and (1) project that is currently substantially complete*, that were self-performed as a prime or sub-contractor, that demonstrate design, scale model testing, and fabrication of new turbine runners with a minimum blade diameter of 175 inches for units rated at 25-65 MW.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:ii)   Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Third Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:c)   Provide a minimum of (2) projects completed within the last (5) years*, or (1) project completed in the last (5) years* and (1) project that is currently substantially complete*, that were self-performed as a prime or sub-contractor, that demonstrate design, scale model testing, and fabrication of new turbine runners with a minimum blade diameter of 175 inches for units rated at 25-65 MW.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:d)   Provide a minimum of (3) projects completed within the last (10) years*, or (2) project completed in the last (10) years* and (1) project that is currently substantially complete*,              that were self-performed as a prime or sub-contractor, that demonstrate disassembly and reassembly of a  Kaplan turbine generator unit with a minimum blade diameter of 175 inches.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Third Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:e)   Provide a minimum of (3) projects completed within the last (10) years*, or (2) project completed in the last (10) years* and (1) project that is currently substantially complete*, that were self-performed as a prime or sub-contractor, that demonstrate experience design, manufacture, installation, and testing of a complete winding and at least a portion of stator core for units rated at 25-65 MW.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Third Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project: f)    Provide a minimum of (2) projects completed within the last (5) years*, or (1) project completed in the last (5) years* and (1) project that is currently substantially complete*, that were self-performed as a prime or sub-contractor, that demonstrate experience design, manufacture, installation, and testing of a complete winding and at least a portion of stator core for units rated at 25-65 MW.      First Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:Second Project Name: i)    Contract Number (if applicable):ii)   Year Completed:iii)  Prime Contractor or – Sub-Contractor:iv)  Type and percentage of work self-performed (based on contract value):v)   Dollar Amount:vi)  General Description of project:g)   At least one of the submitted projects must have been completed within the last (5) years with a contract value of at least $30 million.*Define “substantially complete” as at least 50% complete.*Define “10 years” as 10 years from the date this notice is posted. 5.   Are you a Small Business classified under the above NAICS code? If so, do you fall into a sub-category (e.g. HubZone, 8(a), SDVOSB, WOSB, etc.)?6.   If your company is a small business concern, per FAR 52.219-14, at least 25 percent of the cost of contract performance incurred for personnel shall be expended for employees of the concern. Can your firm be expected to do this, given your current employee situation? (Please respond yes or no.)7.   What is your organization’s bonding capacity?8.   Would you be interested in submitting a proposal for this work if it were solicited?9.   Please provide any additional information you feel is necessary:Interested contractors must also provide a response to the Project Labor Agreement (PLA) survey attached in the Attachments section of this Notice titled “Updated PLA OLD T-G” and submit it along with their response to this Notice by the aforementioned date and time.12/14/2021: Sources Sought Notice is amended to extend the response due date from 28 December 2021 to 14 January 2022. Also, interested contractors must provide a response to additional survey questions attached in the Attachments section of this Notice entitled "General Market Research Questions" and submit it along with their response to this Notice by the revised due date and time.