Wolf Creek Turbine Generator Rehab

REQUEST FOR INFORMATION 

 The Government is issuing this Request for Information for market research purposes. This is not a solicitation. No reimbursement will be made for any costs associated with providing information in response to this survey.  

 This survey is for market research purposes only.  Only contractors capable of performing this type of work should respond to this Request for Information.  

 Requirement  

The U.S. Army Corps of Engineers (USACE), Nashville District, anticipates a requirement for a firm fixed-price construction contract to rehabilitate the turbine generator units at Wolf Creek Powerhouse in Jamestown, Kentucky.  The estimated magnitude of this project is between $100,000,000 and $250,000,000.

A partial rehabilitation of one of the units at Wolf Creek has recently concluded with an operational unit and may be fully rehabilitated under this contract with replacement of key components.  Upon completion, the Project will significantly increase effectiveness, efficiency, and reliability of the hydrogenating units at Wolf Creek Powerhouse.  This significant restoration and increase in critical mission factors of the units is the main driver for the Project.  The power produced is an economic benefit to the surrounding community since it is provided to local utilities at the minimum possible cost. The rehabilitation effort at Wolf Creek is an extension of the larger decades-long hydropower rehabilitation effort throughout the Cumberland River System.

The Contractor will be responsible for the following activities/items under the proposed contract*:   

 This specification includes the requirements for all equipment, labor, materials, and work necessary to design, manufacture and install Francis turbines, improve dissolved oxygen levels, rewind the existing generators Units 1-3 and Unit 5, and refurbish associated equipment and components for all Units 1-6. The runner shall be designed using both Computational Fluid Dynamics (CFD) and a physical performance (scale) model. The latest design and proven technologies shall be applied to develop aerating capability for the replacement turbines.

The existing generators will be rewound concurrent with the supply and installation of the turbines.

Asbestos abatement shall be performed by others. Abatement is needed in the stator windings, rotor cleaning, brake pad dust, etc. The Government will perform a survey of the asbestos and provide this to the Contractor. The Contractor should plan on not being able to work on each unit for a period of 6 to 8 weeks while asbestos abatement is being performed.

The following list is a general summary of the required and optional work for each unit and is not all-inclusive.

General Project: The time allotted for design and manufacturing of replacement components for the first unit is estimated to be no more than thirty seven (37) months in duration. The time allotted for unit outage is estimated to be no more than twenty-four (24) months in duration for the first unit and eighteen (18) months for the second unit and follow on units, including all incidental related work.

Turbine and Mechanical

a. Design and construct a hydraulic model.

b. Design, manufacture, prepare and load for shipment, deliver F.O.B. destination, and unload the Francis turbine runner and appurtenances.

c. Disassemble generating unit by removing rotating and stationary components and related interferences such as the generator rotor from shaft.

d. Perform alignment investigations and provide recommendations.

e. Inspect and refurbish, or replace miscellaneous turbine and generator mechanical components and piping including but not limited to: brake cylinders, oil jacking pump, brake rings (optional), wicket gate shear pins, runner wearing rings, and gland, wicket gate packing boxes and glands, seals, runner coupling bolts, and other components as specified.

f. Disassemble and inspect and refurbish the wicket gate servomotors. Inspect and refurbish the operating ring (bull ring).

g. Replace greased bushings and rehabilitate or replace (using plates, weldments, or sleeves). Work must include line boring of the bottom ring and head cover bushing housings and bushings.

h. Provide an aeration system for the turbine, including piping and controls.

i. Provide new head covers.

j. Provide new wicket gates

k. Refurbish turbine and generator guide bearings and generator thrust bearings as directed. Provide detailed dimensional drawing for thrust shoes. Fabricate a new turbine guide bearing.

l. Supply new turbine oil. (21,000 Gallons)

m. Supply and install RTDs replacements for each bearing, including the addition of one RTD per shoe for the thrust bearings.

n. Replace cooling and packing water piping 1 ½ inch and smaller for steel piping or 3 inch and smaller for copper and stainless steel piping.

o. Reassemble generating unit with a new turbine runner and appurtenances and other rehabilitated and replacement components.

p. Clean turbine pit, generator, and work or storage areas used by the Contractor. Dispose of (recycle) grease, etc.

q. Perform complete alignment of the turbine/generator unit.

r. Perform pre and post operational tests on the generating unit.

s. Perform aeration testing on units.

t. Perform flushing and cleaning of oil piping.

u. Provide new Turbine Maintenance Platform (TMP)

Electrical

a. Design, manufacture, and perform voltage endurance testing on 4 prototype coils. Design, manufacture, and perform thermal cycle testing on 4 prototype coils.

b. Design, manufacture, shop test, prepare and load for shipment, deliver f.o.b. destination, and unload four complete sets of stator coils and all accessories specified herein for Units 1, 2, 3, and 5.

c. Supply and install stator winding and accessories.

d. Supply and install new stator core and accessories.

e. Inspect, clean and test stator winding and core for Units 4 and 6.

f. Refurbish all 408 rotor field poles.

g. Reinsulate the rotor field leads.

h. Inspect the collector rings, brushes, and brush holders.

i. Replace or refurbish collector ring, brushes, and/or brush holders (OPTIONAL).

j. Furnish spare parts.

k. Perform generator special field tests.

l. Perform start-up, commissioning, and testing of the generator.

m. Perform miscellaneous electrical equipment/wiring removal and installation including replacement of cable, wiring, miscellaneous relays, and RTDs as required and directed.

n. Replace existing 2500-amp metal-enclosed bus generator leads.with new 3500-amp 15.5kV segregated-phase bus complete with cable transition enclosures and taps to station service equipment, exciters, and instrumentation cubicles.

o. Perform model validation testing.

p. Replace existing 15kV 1000kcmil cables and 18-inch cable tray with new 1250kcmil 15kV MV-105 cable and 22-inch cable tray between the generator metal-enclosed bus and the switchyard bus.

q. Replace existing generator neutral breakers and reactors with high-resistance grounding units and disconnect switch.

r. Remove the existing main exciter components including field poles (iron and coil), brush rigging (commutator), and fans.

  

*Please note that this description is subject to change. 

The anticipated NAICS code is 237990 (Other Heavy Civil Engineering Construction, size standard of $45 million) 

Survey 

The 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 survey is for market research purposes only. Only contractors capable of performing this type of work should respond to this Request for Information. 

Your response to this survey is requested by 1:00 PM Central Time, June 26, 2026. Please send by email to Alison Abernathy at Alison.T.Abernathy@usace.army.mil

Please provide your candid response to the questions below. Your response at this time is non-binding and does not preclude your firm from making changes to an opinion between these sources-sought and any future solicitations related to this work:

1. Name of your firm: 

2. CAGE: 

3. Point of Contact, Phone number and EMAIL address: 

4. Please provide responses to the following: 

1) List three (3) projects completed within ten (10) years of the date of this notice that demonstrates experience, as a prime contractor or subcontractor, constructing gantry cranes with capacities exceeding 100 tons. 

(a)  Project Name: 

Contract Number (if applicable):  

Year Completed: 

Prime Contractor or Sub-Contractor: 

Type and percentage of work self-performed (based on contract value): 

Dollar Amount:  

General Description of project: 

(b)  Project Name: 

Contract Number (if applicable):  

Year Completed: 

Prime Contractor or Sub-Contractor: 

Type and percentage of work self-performed (based on contract value): 

Dollar Amount:  

General Description of project: 

(c)  Project Name: 

Contract Number (if applicable):  

Year Completed: 

Prime Contractor or Sub-Contractor: 

Type and percentage of work self-performed (based on contract value): 

Dollar Amount:  

General Description of project: 

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. For this requirement, what percentage of this work would you subcontract (reference RFO 52.219-14, Limitations on Subcontracting, Class Deviation 2026-O0038)?   

7. Do you plan to subcontract to only small businesses? 

8. If the answer to question 7 is “yes”, are these small businesses with a sub-category (e.g. e.g. HubZone, 8(a), SDVOSB, WOSB, etc.)  

9. What is your bonding capacity per contract? 

10.  What is your aggregate bonding capacity per contract? 

  

11. If this requirement is advertised, do you anticipate submitting a proposal? 

12. Assuming a firm fixed-price solicitation, would your firm submit a bid on a turbine and/or generator contract for Wolf Creek under the following scenerios: 

1.  Full Turbine/Generator Replacement: Design, supply, and install six turbine runners and four generator stator windings? If not, would your firm consider bidding on a full turbine/generator replacement for less than six units? If yes, how many?
2. Full Turbine Replacement with Windings Provided as Government Furnished Equipment (GFE): Design, supply, and install six turbine runners and install (only) four generator stator windings provided as GFE? If not, would your firm consider bidding on a full turbine replacement with GFE windings less than six units? If yes, how many?
3. Full Turbine Supply with Partial Installation: Design and supply six turbine runners and install one? The remaining five installations would be completed by a separate contractor with technical consultation from your firm.
4. Generator Stator Winding and Core Supply and Partial Installation: Design and supply four sets of generator stator windings and cores and install one unit’s worth?

13. Would the inclusion of an index-based EPA clause covering both labor and materials, with no cap, change your answer(s) to any of the options under Question #1? Are there specific indices that need to be included to make the package more attractive to your firm?

14. Would your firm be willing to install turbine runners, head covers, wicket gates, and miscellaneous components designed and supplied by another vendor?

15. Would the inclusion of a Project Labor Agreement requirement, between Contractor and Union, make a solicitation unbiddable by your firm?

16. Would the inclusion of a Cybersecurity Maturity Model Certification (CMMC) Level 1 or 2 Self Certification make a solicitation unbiddable by your firm?

17. For any of the scenarios under Question #1, would your firm be unable to comply with Buy American Act? If your firm is unable, explain why.

18. Are there major components required for this project that may require exceptions under the Buy American Act?

If so, identify: specific components, country of origin, lead times, domestic alternatives (if any).

19. What other factors, if any, would preclude your firm from submitting a proposal for any of the scenarios under Question #1?

20. The Government is considering a longer advertising period for solicitation. How long does industry recommend for a project of this scope?

21. Would your firm be willing to serve as prime contractor if installation were performed through a subcontractor team member selected by your firm?

22. Is your firm willing to provide a system-level warranty for turbine-generator rehabilitation if installation is subcontracted to a qualified installation partner?

23. What commodities or components should be considered for escalation adjustment (e.g., copper, steel, specialty forgings, controls, imported generator components)?

24. What contract duration would your firm consider commercially reasonable for a project of this size and complexity?

25. What pre-award information or Government-furnished data (e.g., inspections, scans, existing condition assessments, OEM reports) would significantly reduce contingency pricing?

26. Please provide any additional information you feel is necessary: