CONTACTS 
0201 - Dep Natrl Rscrs & Consvn           406 444 6699 fax 6721
020101 - Mr. Walt Anderson; Hydro Power Section Supervisor
020102 - Engineering Division

SUBJECTS
Voith Contrct
Speed Increaser
Review with State Pending
Claim Notices

0506 -    ..
0507 - Summary/Objective
0508 -
050801 - Walt explained in some detail understandings DNRC has developed
050802 - so far about defects that have showed up in the speed increaser
050803 - equipment installed by Voith at the plant.  The main problem seems to
050804 - be out of spec resonance causing accelerated gear deterioriation,
050805 - relative to expected product life, plus the vibration is shaking the
050806 - plant so violently that it may be damaging foundations and every
050807 - component in the plant, along with plant management and crews.
050808 -
050809 - Tudor reported a "noise" problem in its final report reviewed on
050810 - 911005. ref SDS 1 3088
050811 -
050812 -    Walt drew some sketches and showed photographs that indicate the
050813 -    nature of the problem and impact on the plant.
050814 -
050815 - DNRC has an expert who has given an opinion that "scuffing" has
050816 - occurred to the gear teeth that render the gear box defective, even
050817 - though it is being run.  The "scuffing" was discovered through
050818 - examination by advanced video technology.  There is some question as
050819 - to the method of designing and testing the gear teeth.  Walt mentioned
050820 - two methods for evaluating the adequacy of the design, one being
050821 - German which DNRC's expert feels is less accurate.
050822 -
050823 -
050824 -    Collateral Damage
050825 -    Notice to Voith DNRC Surety
050826 -
050827 -    I asked Walt if there is possibility of collateral damage to the
050828 -    plant if the speed increaser fails while being run, and whether
050829 -    DNRC's insurance carrier has been notified of this matter?
050830 -
050831 -    Actually, consideration should be given to notifying Voith that
050832 -    DNRC is running the speed increaser to mitigate the damages for
050833 -    which Voith is in the first instance liable, and that in the event
050834 -    of collateral damage, DNRC will hold Voith liable, unless Voith
050835 -    gives DNRC notice that it should not run the plant.
050836 -
050837 -       [On 911011 reviewed issue with DNRC. ref SDS 2 2066]
050838 -
050839 -       [On 911015 evidence of collateral damage. ref SDS 3 0499]
050840 -
050841 -       [On 911021 notified DNRC counsel to notify Voith and surety
050842 -       about liability for collateral damage to the plant, including
050843 -       lost revenue. ref SDS 4 0001]
050844 -
050845 -       [On 911021 report Voith recommends plant be run at half
050846 -       capacity. ref SDS 4 0001]
050847 -
050848 -       [On 911022 no evidence in the record that Voith has recommended
050849 -       or instructed anything about plant operations. ref SDS 5 0001]
050850 -
050851 -       [On 911022 Voith notified of vibration problem. ref SDS 5 9499]
050852 -
050853 -       [On 911022 Voith recognized liability for noise problem caused
050854 -       by trying a new idea with a bad design. ref SDS 6 3088]
050855 -
050856 -       [On 911025 expert confirmed Voith's design defective.
050857 -       ref SDS 7 9499]
050858 -
050859 -       [On 911026 bolting was defective in 2 ways. ref SDS 8 0001]
050860 -
050861 -       [On 911027 no plans and specs showing bolting for speed
050862 -       increaser. ref SDS 9 0001
050863 -
050864 -
050865 - Walt seems to have a very good grasp of the engineering on this
050866 - matter.
050867 -
050868 - A report should be prepared setting out the elements that show there
050869 - is a problem and that it is Voith's responsibility.  This report will
050870 - disclose gaps in the evidence, and permit planning for developing
050871 - information to fill the evidentiary gaps.
050872 -
050873 - Walt gave me a copy of a letter he issued today that requests Voith to
050874 - submit calculations on its design for evaluation by DNRC and its
050875 - experts.
050876 -
050877 -
050878 -
050879 -
0509 -