Performance_Work_Statement.pdf

Performance Work Statement San Dimas Pump Lab’s Well Rehabilitation

Section 1: General Specifications

A. Introduction: The National Technology & Development Program (NTDP), San Dimas Technology & Development Center (SDTDC) has a need to procure services to repair its Pump Lab Well system located at 444 E. Bonita Avenue, San Dimas, CA 91773-3101.

B. Background: The SDTDC tests portable and truck-mounted pumps for drafting capability at various heights. Using an automated pneumatically controlled system, well height is controlled by pumping water from two (2), 30-feet deep wells to an above ground reservoir, controlling the return flow with a pneumatic pinch valve (Figure 2 and 3). The control system depends on a pneumatic pinch valve that is leaking air and can no longer provide a controlled stable well height (Image 13).

An evaluation of the plumbing used by the automated pneumatically controlled system in the wells was commissioned and the findings and recommendations are listed below in Section 1., D.

C. Operations of the wells: A submersible pump moves water from the east well (pump side) to the reservoir. A return line with a pneumatic pinch valve controls the flow from the reservoir to the west well (return side). The two wells are equal depth and are connected by a cross-over pipe, located at the bottom of the wells.

A pneumatic system provides pressurized air to the control system. On the interior wall adjacent to the wells is the well height control, a Programmable Logic Controller Touch Screen (PLC).

The user enters the required well height and starts the submersible pump; water is pushed from the east well into the reservoir. An ultrasonic level sensor located at the bottom of the well will sense and report the current well height to the PLC. The PLC adjusts the pressure to the pneumatic pinch valve as it compares both the setpoint and current height until setpoint height is reached.

The pneumatic pinch valve will open when pressure is lost. The water will seek an equilibrium between the reservoir and the wells.

D. Findings and recommendations during an evaluation of the wells

A thorough, confined space inspection and assessment of the Pump Lab Wet Well Piping, Check Valve, Pinch Valve and Pump was performed on Wednesday December 12, 2018.

The following findings and recommended actions are presented for your review:

1. The 10” Pneumatic Pinch Valve on the end of the water return pipeline in the bottom of the West section of the Wet Well is not-serviceable. The continuous air leak indicates this pinch valve’s sleeve has been compromised. This 10” valve needs to be replaced.

2. Recommend the I/P controller on the 10” Pneumatic Pinch Valve be resized for higher compressed air flow input and venting versus the ¼” NPT model currently on the system.

This is a suggestion and not necessarily required. The response of the pinch valve would be shortened with this change.

3. The 10” Wafer Swing Check Valve located on the upper section of the water return pipeline of the West Wet Well is corroded and frozen in place restricting gravity water flow into the Wet Well. This Check Valve needs to be replaced with a Stainless Steel model. New pipe spool(s) may be required to fit it properly.

4. All steel flange bolts throughout the system in both Wet Wells are heavily corroded.

Some are broken. All flange bolts must be removed and replaced with stainless steel replacements.

5. The pump discharge 4” PVC piping spool flanged to a cast iron elbow near the upper area of the East Wet Well leading to the outside Water Holding Tank does not have the correct flange bolt pattern. The cast iron flange is a 4-bolt pattern and the PVC flange is an 8-bolt pattern. This flange joint leaks water when the pump is operating. New flanges or additional bolt holes are needed in the cast iron flange.

6. The pump discharge piping immediately off the submerged pump is comprised of multiple fittings, hose and clamps. The hose is partially collapsed restricting the pump’s discharge capacity. All fittings and hose should be removed and replaced with the proper pipe and fittings to improve pump performance and piping life span.

SECTION 2: SCOPE

A. Place of Performance: San Dimas Technology & Development Center, 444 E. Bonita Avenue, San Dimas, CA 91773-3101

B. Period of Performance: All work shall be completed between September 2, 2019 through October 7, 2019, a total of 45 calendar days.

C. Work Hours: All work shall be performed during normal business hours between 8:00 am to 4:00 pm, Monday through Thursday with the exception of Federal Holidays (see below for holiday schedule).

Any work performed outside of this timeframe shall be approved by the Contracting Officer’s Representative (COR) prior to start.

D. Federal Holidays Observed: Labor Day, Columbus Day, Veteran’s Day, Thanksgiving Day, New Year’s Day, Martin Luther King Day, President's Day, Memorial Day, Independence Day, Christmas Day, and any other day specifically designated by the President of the United States.

E. Contractor Requirements: The contractor shall provide all labor, transportation, equipment, material, and expertise necessary to accomplish the following task:

1. The contractor shall be current in all necessary certifications required to work in confined spaces per industry standards.

2. Supply Gantry or other suitable means to facilitate work on pipe.

3. Supply all necessary rescue equipment.

4. Perform continuous testing air quality in confined space.

5. Remove all debris from bottom of well.

6. Replacement Pneumatic Pinch Valve shall be equal to Red Valve Type A Pinch Valve.

7. Successfully perform Test Procedures.

8. Perform the work described in Pumpside and Returnside.

F. Pumpside and Returnside Well: The contractor shall provide all labor, transportation, equipment, material, and expertise necessary to accomplish the following tasks:

1. Pumpside (East) Well

Remove/inspect/repair or replace 4" PVC as necessary Remove and replace connection between pump discharge and 4"PVC as necessary Replace or adapt from 4" 8 bolt PVC to 4 bolt Ductile Iron Flange Remove/inspect/repair or replace wall brackets as necessary

*Reference: Images 1-7& Findings 4, 5, 6

2. Returnside (West) Well Remove/inspect/repair or replace:

o Vertical mounted 10” ductile iron pipe, o Bolts and nuts, o Braces as necessary to facilitate replacement of butterfly valve and pinch valve o Remove rust and gasket from flanges as necessary

Document the current position of the existing butterfly valve.

Butterfly Valve o Remove and replace butterfly valve.

o Mount butterfly locking valve handle at surface.

o Mount connecting link

Remove and replace pinch valve.

Remove/inspect/repair or replace pinch valve airtank as necessary.

Remove/inspect/repair or replace wall brackets as necessary.

* Reference: Images 8-11 & Findings 1,2,3 and, 4

SECTION 3 - TEST PROCEDURES

A. Contractor Requirements: The contractor shall provide all labor, transportation, equipment, material, and expertise necessary to accomplish the following testing tasks:

B. Valves:

Figure 1. Schematic for pneumatic system lever valves and Controller located adjacent to the wells.

Valve 1 – Valve to pneumatic supply air

Valve 2 – Inlet to Controller Valve 3 – Outlet to Controller Valve 4 – Bypass pipe

Close Pinch Valve - Bypass mode:

Valves 4 is open, Valves 2 and 3 are closed.

Open Pinch Valve - Bleed down pressure:

Valve 1 is closed Valve 3 and 4 are open

Submersible camera such as a GoPro in an underwater housing to view and record live conditions during the Pinch Valve leak test.

Begin Test with no water in the wells or the reservoir.

C. Controller:

1. Turn on PLC and use touch screen to show well height.

2. Place in manual mode – screen is on for well height information.

D. Pneumatic system:

1. Place pneumatic system in bypass mode. Open valves 1 and 4.

2. Between the pneumatic outlet and pneumatic pinch valve, spray soapy water on all pneumatic connection, tubing bends, pinch valve air canister, pinch valve connections and at rubber to metal interfaces on the pinch valve.

a. Bubbling:

i. If bubbling occurs repair.

ii. When no bubbling is observed continue test.

E. Returnside Test:

1. Verify butterfly valve is open.

2. Close Pinch valve.

3. Observe floor and bottom of Pinch Valve for leaks.

a. Leaks

i. If leaks occurs stop test and determine cause

ii. If no leaks occur, continue test.

4. Add water to reservoir.

a. Fill reservoir with water to approximately 1 foot inside reservoir.

b. Make frequent checks for water flowing into the bottom of well?

i. If there is flow into well,

1. Stop filling reservoir

2. Document pressure shown on 0-100 psi gage.

3. Check the pneumatic system for leaks

4. Valve is not sealing, determine cause and fix.

ii. If there is no flow into the wells, continue test.

5. Open pinch valve

6. Continue to allow water to flow and fill wells to just above the pump motor.

7. Close Pinch Valve

8. Well should stop filling, check for bubbles:

a. Pinch valve air canister

b. Pneumatic connections that are submerged

c. Exposed pneumatic pinch valve seals

9. Open Pinch Valve

F. Pumpside Test:

1. Open reservoir valve to discharge into reservoir spray system

2. Water level should be just above pump motor.

3. Start pump.

4. When water has drained too just above the pump, stop the pump.

5. While pump is operating, check pumpside plumbing:

a. Check flanges for leaks

b. Use submersible camera to view connection between pump and discharge line, check for leaks.

6. If no leaks are found, fill reservoir with water until well height is about 20 feet.

7. Start pump, Close pinch valve.

a. Observe if wells begin to drain, indicates normal operation

b. Stop when water level is just above the top of the pump motor.

8. Bleed pneumatic pressure down until water begins to fill the wells.

9. Document pressure.

10. Open Pinch Valve until reservoir and wells are in equilibrium.

11. Conclude Test

G. Schematic of Wells and images – attached (pumpside pictures.doc):

Figure 2. Layout of Reservoir and Wells.

Figure 3. Schematic of Wells with index of images listed below

Pump Side Image 1. View looking down from top of wells to pumphead.

Image 2. View looking up from bottom of well at lower flanged PVC pipe.

Image 3. View of connection between pump and vertical PVC.

Image 4. View of connection between pump and vertical PVC.

Image 5. View of connection between rubber hose and vertical PVC.

Image 6. Close up view of connection between rubber hose and vertical PVC.

Image 7. Close up view of pumphead.

Returnside Image 8. View of flanges and butterfly valve Image 9. Closeup view of flanges and butterfly valve Image 10. View of upper corroded bracket.

Image 11. View of lower corroded bracket.

Image 12. View of Corroded bottom of Red Valve Pinch Valve with single stand bolt

Detail of Red Valve Image 13. Air bubbles are streaming from the bottom of the pinch valve Image 14. Pinch Valve and Pneumatic tank.

Image 15. Pneumatic airline to the Red Valve.

Image 16. View from opposite side of Red Valve.