J.01_SOW-Tainter_Gate_1&2_Repairs.pdf

SCOPE OF WORK FOR PERFORMING REPAIRS TO

TAINTER GATES NO 1 & 2 AND ASSOCIATED STRUCTURES

AT AMISTAD DAM

I. GENERAL REQUIREMENTS

1. General Scope:

The vendor is required to perform inspection, maintenance, repairs and testing of civil, mechanical & electrical facilities and the hoist system/ hoist platforms of Tainter Gates number 1 and 2 (the Work); all in accordance with Article V “Scope of Work”.

2. Project Location:

The USIBWC Amistad Office is located at 670 Texas Spur 349, Del Rio, Texas 78840; about 15 miles from downtown Del Rio. The Dam is a couple of miles from the office. The work shall be performed at three levels of inspection galleries under the bridge deck.

The work is located completely within the United States, but is directly adjacent to the international border with Mexico. The international border is clearly identified at the centerline of the dam. Any excursions into Mexico subject the Contractor to Mexican laws.

II. AMISTAD DAM

1. Amistad Dam, constructed and completed in 1969 by the United States (U.S.)

and Mexico pursuant to the Water Treaty of 1944, is located on the Rio Grande 12 miles northwest of Del Rio, Texas, 574 river miles above the mouth of the Rio Grande, and 1 river mile below confluence of the Devils River.

2. The dam is used for flood control, water conservation, hydroelectric power, and recreation. The dam is operated and maintained by the International Boundary and Water Commission (IBWC); an international body composed of the United States Section and the Mexican Section.

3. The reservoir, per 1992 survey data, has 405,000 acre-feet of surcharge storage, 1,744,000 acre-feet of flood control storage, and 3,151,000 acre-feet of silt and conservation storage. U.S. and Mexico’s power plants were constructed and completed in 1983 and 1987, respectively. Average annual

U.S. generation is about 161,000,000 kilowatt hours.

III. GENERAL PROVISIONS:

Contractor:

1. All the work shall be performed by a professional contractor(s) with experience in structural, mechanical and electrical works on dams or similar facilities. The Contractor and each of his subcontractors (if any) shall individually have a minimum of five (5) years of experience in their respective fields on identical or similar projects and shall submit a list of clients and their respective contact information for reference.

2. A structural/ mechanical Contractor shall subcontract the electrical part of the SOW to an experienced Electrical Contractor. Alternatively, an Electrical Contractor shall subcontract the structural/ mechanical part of the SOW to a contractor with proven experience in structural and/ or mechanical work.

3. The work shall be carried out by experienced professional crew properly trained in this type of work. The Contractor shall maintain adequate staffing level to complete the works within the Contract period.

4. The Contractor shall designate and assign an experienced on-site representative to be present during all on site activities. The Contractor on-site representative shall have a minimum three-year experience in identical or similar projects.

5. The Contractor shall provide all labor, equipment, materials, supplies, and incidentals to complete the project as identified under this SOW. All material used shall be new and conform to standard construction industry specifications and means and methods of construction.

6. The Contractor shall have access to electric power from a location near Tainter Gates number 1 and 2.

7. The Contractor may have access to the limited restroom facilities at the dam.

However, other sanitary facilities or trash disposal shall be provided by the Contractor at no additional cost.

8. The Contractor is deemed to have field verified the existing conditions prior to submitting his proposal and prior to commencement of the work.

9. The Contractor shall be responsible for all safety and quality control features required for work of this nature.

10. The Contractor shall be fully responsible for repairs or replacement of all damages to existing conditions resulting from work under this contract

Government Representatives:

1. The USIBWC’s representatives for this Contract are the Contracting Officer (CO) and the Contracting Officer’s Representative (COR).

2. The Contracting Officer (CO) is responsible for the Contract, including its terms and conditions. The CO is authorized to enter into and administer the Contract, change or terminate the Contract, and make determinations and findings relating to the Contract.

3. The CO shall notify the Contractor in writing of the COR appointment and the limits of the COR authority.

4. The COR is the USIBWC’s representative in direct daily contact with the Contractor. The COR is the Contractor’s initial Point Of Contact (POC) with USIBWC during the performance of this Contract.

Report, drawings and photographs:

The following report, drawings and photographs are provided to the Contractor for reference. The documents shall be available at a File Transfer Protocol (FTP) site set up by the USIBWC:

1. Amistad Electrical Evaluation Report.

2. Chapter 9 of Amistad Dam O&M Manual “Tainter Gates and Hoists”.

3.

4. Drawing No. 18,107 Spillway ‐ Bridge Typical Span – Plan and Elevation.

5. Drawing No. 18,192 Spillway ‐ Tainter Gates – Hoist Machinery Layout Details I.

6. Drawing No. 18,193 Spillway ‐ Tainter Gates ‐ Hoist Machinery Layout Details II.

7. Drawing No. 18,194 Spillway ‐ Tainter Gates – Hoist Machinery Layout Details III.

8. Drawing No. 18,195 Spillway ‐ Tainter Gates ‐ Hoist Machinery Layout Details IV.

9. Drawing No. 18,199 Spillway ‐ Tainter Gates – Measuring Device General

Arrangement.

10. Drawing No. 18,204 Spillway – Tainter Gates – Hoist Machinery Bases Detail II.

11. Drawing No. 18,205 Spillway – Tainter Gates – Hoist Machinery Bases Detail III.

12. Drawing No. 18,208 Spillway – Tainter Gates – Platforms – Plans and Details.

13. Drawing No. 18,247 Spillway – Tainter Gates – Miscellaneous Metals – Spillway

Bridge Railing Details.

14. Drawing No. 18,298 Spillway – Tainter Gates Control.

15. Drawing No. 18,299 Spillway – Tainter Gates Details.

16. Photo No. 6: Tainter Gates No. 1, 2 bent shaft.

17. Photo No. 7: Broken Frame.

18. Photo No. 8: Damaged Components on Tainter Gate No. 2 Drive.

19. Photo No. 9: Damaged Piping on Gearbox.

20. Photo No. 10: Damaged walkway plates.

21. Photo No. 11: Bent shaft on Gate No. 2.

22. Photo No. 12: Roadway Railing.

Standards and Codes:

The work under this contract shall be performed in accordance with the latest ANSI, OSHA NEC, NESC, and NFPA and other applicable industry standards including, but not limited to, the following:

2. ANSI A10.32 Fall Protection Systems for Construction and Demolition.

3. OSHA 3146 ‐ Fall Protection regulation.

4. The latest governing NEC, NESC, and NFPA Standards.

5. Corps of Engineers Manual EM 385‐1‐1 Safety and Health Requirements

Facility Operations:

1. There may be agency employees and/ or contractors working at the Dam. The contractor shall coordinate his activities with other stakeholders on site so that he does not impede their activities.

2. The Contractor shall coordinate all on site activities so as not to interfere with the regular daily function of the facilities.

3. The Contractor shall confine all operations, storage of material and employees' parking within designated areas as approved by the COR.

4. The Contractor is responsible for any damage caused by his activities and/or employees to existing facilities including paving and curbs, and shall repair such damage to the satisfaction of the COR.

Submittals:

The Contractor shall submit the following documents during the term of the contract:

1. Work schedule: The work schedule shall be submitted at or before the “Pre- Commencement Meeting”. The schedule shall show the main activities, their durations, schedule of values and the Critical Path.

2. A safety plan in accordance with OSHA and industry standards including but not limited to OSHA Fall Protection regulation OSHA 3146. The plan shall be submitted at or before the pre-commencement meeting. The safety plan shall be accepted by the USIBWC before commencement of work. Notwithstanding acceptance of the safety plan by USIBWC, the contractor remains solely responsible for safety during the performance of the work under this contract.

3. The resume for an on-site representative with at least three-year experience in identical or similar projects.

4. Weekly reports charting the work progress against the agreed schedule as well as a weekly record of safety measures. The report for each week shall be due on the first working day of the following week.

5. Technical specifications of all material to be incorporated in the contract prior to procurement. The Contractor shall submit all manufacturer literature, specifications, samples and certifications and obtain USIBWC approval before purchasing any item for applying to or incorporation into the work.

6. Written summary report and as built drawings providing a complete record of the completed works.

The USIBWC shall approve, accept or otherwise respond to each submittal from the contractor within five (5) working days.

Pre-commencement Meeting and Coordination with others:

1. The Contractor shall be available for pre-commencement meeting with the COR within one week of receiving the COR appointment letter. The meeting shall be initiated and coordinated by the COR.

2. The Contractor shall present at or before the meeting one hard copy and one electronic copy of his work schedule. The schedule shall account for all stages of the Contract including approvals by USIBWC and activities on site.

3. The contractor shall submit, at or before the meeting, a safety plan in accordance with OSHA and industry standards for review acceptance by USIBWC before commencement of the work on site. Acceptance of the safety plan by USIBWC shall not relieve the contractor of any part of its sole responsibility for safety under this contract.

4. The Contractor shall provide at or before the pre-commencement meeting the resume for an on-site representative with at least three-year experience in identical or similar projects.

5. Following the pre-commencement meeting, the COR shall issue the “Notice To Proceed” starting at least seven calendar days after the pre-commencement Meeting date.

Contractors Access at USIBWC Field Office:

1. The working hours shall be from 07:30 AM to 04:30 PM Monday through Friday except for Federal Holidays. The Contractor, and his subcontractors shall only work onsite during these hours.

2. USIBWC facilities are closed during all Federal Holidays.

3. Access to the work site is through a port of entry controlled by the Custom and Border Security. Workers crossing through the port of entry need to have proper documentation for reentry to the United States.

4. The port of entry is open from 10:00 a.m. to 6:00 p.m. If the Contractor requires to begin work prior to the port of entry opening, this must be coordinated with the Amistad Dam Area Operations Manager. Contractor personnel can be allowed onto the project site prior to 10:00 am, but they must wait for the Port of Entry to open before leaving the project site.

5. Compressed air is not available at the dam. The contractor shall provide any compressed air that is required during the performance of this contract.

6. Field office telephones and restroom facilities are not available to the Contractor’s employees. However, the contractor may have access to the limited restroom facilities at the dam. Beyond that, the Contractor shall make alternative arrangements before commencement of site operations.

7. Security is a major concern at this location which is adjacent to the international boundary. The Contractor is responsible for securing the work site, equipment, and materials from vandalism and theft.

IV. BACKGROUND:

Gate No. 2 is one of sixteen 50 feet by 50 feet Tainter Gates designed for spillway releases.

The background to the required inspection, maintenance and repair of Tainter Gates number 1 and 2 under this contract is as follows:

In April 2015, a Grove TM 9120 Crane tipped onto its side and damaged the gate hoist assembly for Tainter Gate #2.

A visual inspection indicates that an oil feed line is bent and may have to be replaced. Also, the drive shaft from Gate #2 Gate Hoist to the Gate #2 Bull Gear (located on the Gate #3 Gate Hoist Platform, 50 feet away) is bent and must be repaired or replaced.

The hand rail and catwalk around Gate #2 hoist platform are missing; apparently, they were sheared off by the tipping crane and fell in the river. Currently there is no fall protection on Gate# 2 hoist platform.

The Limit Switch housing was broken during the crane incident and the Limit Switch and screw drive appear to have been damaged.

A spare Limit Switch housing, switches, and screw drive are available on site from decommissioned penstock gates hoists (penstock #4); and may be suitable to use for Tainter Gate No. 2.

Gate number 1 drive shaft support frame and support bearing have been impacted by the incident. They are to be inspected and repaired.

During subsequent attempts to remove the crane, a fire broke out damaging wiring in an electrical pull box, located in front of the Tainter Gate #2 platform.

Replacement of wiring and cables damaged by the fire IS NOT part of this project.

The USACE conducted an inspection during September 2015 and provided recommendations for the electrical repairs. The report is summarized as “Amistad Electrical Evaluation Report.”

V. SCOPE OF WORK:

A. Structural and Mechanical Scope of work

The Contractor shall repair and/ or replace structural and mechanical equipment in accordance with the detailed requirements listed below.

Gate 1 Area: The contractor shall provide all equipment necessary to gain access to and repair/replace damaged Gate #1 equipment and structural items listed below:

Repair rotating drive shaft support frame. See Miscellaneous Metals Spillway Bridge

Railings drawing 18,247 Remove, clean, inspect and re-install shaft support Bearing Remove and straighten 2 1/4” Rotating shaft between couplings.

Replace drive side parallel gear box oil line

Gate 2 Area: The contractor shall Repair and/ or replace all damaged and/ or broken off structures and restore the Tainter Gates hoist platform to its original state The Contractor shall provide all equipment necessary to gain access to and repair/replace damaged Gate #2 equipment and structural items listed below:

Replace per original drawings walkway grating and frame on drive side of gate #2.

See Spillway-Tainter Gates Hoist Machinery Bases Detail II drawing 18,204, Spillway-Tainter Gates Hoist Machinery Bases Detail III drawing 18,205, and Spillway-Tainter Gates Platform drawing 18,208

Replace hand railing around new walkway grating (approximately 20 feet). See Miscellaneous Metals Spillway Bridge Railings drawing 18,247

Replace four (4) damaged walkway plates.

Replace limit switch. See Tainter Gate Control Drawing 18,298 Repair Rotating drive shaft support frame. See Miscellaneous Metals Spillway

Bridge Railings drawing 18,247 Remove, inspect, clean and replace shaft support bearing

Remove and straighten first section of 2 1/4” rotating shaft between couplings Replace approximately 20 feet of steel protective fence in front of gate #2 operating machinery Replace approximately 42 feet of road railing to match existing. See Spillway–Bridge

Typical Span drawing 18,107 and Miscellaneous Metals Spillway Bridge Railings drawing 18,247

B. Electrical Scope of Work:

The objective is to replace the damaged electrical and control conductors and equipment between Tainter Gates one (1) and three (3), thereby restoring functionality to the currently inoperable facilities. The Contractor shall replace electrical and control cable, motor control panel, related equipment and related ducts and conduits as described in the Amistad Electrical Evaluation Report. The Contractor shall:

Replace electrical feed to gate control panel box. See Tainter Gate and Details drawing 18,299.

Replace electrical control panel box and equipment inside the box. The control panel operates the gate. See Tainter Gate and Details drawing 18,299

Reinstall electrical lighting on new hand railing Reinstall roadway lighting pedestal and connect roadway lighting

Replacement of the wiring and cable damaged by the fire will be carried out by others;

and is not part of this project.

In case of conflict, the description given in the Amistad Electrical Evaluation Report shall supersede other descriptions in this SOW; except that, notwithstanding any statement to the contrary, operational testing shall be conducted on both Gates No. 1 and 2.

All equipment, materials, connections, splices and subsequent insulation covering connections, shall meet current NEC, NESC, and NFPA standards.

C. Material Supplied by USIBWC:

1. The limit switch at Penstock No. 4, complete with its housing, switches and screw drive and any other related part, is available for the contractor to use as a replacement to the damaged limit switch at Tainter Gate# 2. However, the Contractor shall be entirely responsible for removing the limit switch and related parts from Penstock# 4, testing and installing it at Tainter Gate# 2.

2. If the Contractor determined that the limit switch at Penstock# 4 cannot be used as a replacement to the one at Tainter Gate# 2, the Contractor shall procure a suitable alternative Limit switch and submit the purchase documents to the agency for reimbursement.

D. Testing and Commissioning:

1. Upon completion of the works, the Contractor shall conduct an operational test of each of gate (Gates# 1 & 2) as described in Chapter 9 of the Amistad Dam Operation and Maintenance Manual.

2. For each Gate, the testing stated here shall be as described on 9.1 (e) “Operation from Controls at the Gate”; and shall be limited to raising the gate to the first stop position, keeping the gate at that position for sixty seconds and then lowering the Gate to the Closed position.

3. During each operational test the Contractor shall measure the current draw of the motor and compare it to the manufacturer’s nameplate data to ensure that it is within tolerance. If the current is too high, the contractor shall trouble shoot, diagnose and rectify as needed.

4. The tests shall be witnessed by USIBWC Amistad Dam employees and/ or USIBWC third party representatives.

5. A copy of the said Chapter entitled “Tainter Gates and Hoists” is included as part of this Scope of Work.

E. Safety:

I. Safety is a major concern for this contract. The Contractor shall place emphasis on safety procedures for conducting the work at Gates# 1 and 2. The Contractor shall:

1. Provide all equipment necessary to access all parts of the Tainter Gates

Hoist Platform. Fall protection is a major concern

2. Develop a detailed Safety Plan that meets or exceeds the requirements of

OSHA Standards and ANSI standards for fall protection. Review and discuss the safety plan with the USIBWC Staff and third party representative and reach consensus.

3. Prepare a daily safety report recording all safety related features of the work for the day including how the safety plan was implemented and any incidents or near miss.

4. Meet, each day before proceeding to the work site at Tainter Gates number 1 and 2 with the USIBWC staff and third party representative (USACE) and review the work plan and safety features of the work for that day.

VI. NON-DISCLOSURE

All aspects of this work are considered property of the Government. No release of any information or opinion related to this work is permitted by the Contractor or the Contractor Employees or agents without written authorization of the United States Section, International Boundary and Water Commission.

VII. SCHEDULE:

Delivery period shall be One Hundred Fifty (150) calendar days from the “Notice to proceed.

VIII. PRICING:

The work as required in accordance with this scope shall be provided at a Firm Fixed Price (FFP). The contractor is deemed to have allowed for all costs, including all material, labor overhead and incidental costs of performing the works except the cost of the following material items:

The 2 ¼” shaft: If it is determined that the shaft is to be replaced; then either the USIBWC shall provide a replacement shaft or the cost of a replacement shaft shall be reimbursed to the contractor against actual receipts.

The limit switch: The USIBWC shall provide a replacement limit switch from Penstock No. 4, or the cost of a replacement limit switch shall be reimbursed to the contractor against actual receipts.

IX. PAYMENTS

The Contractor shall submit monthly invoices requesting progress payments.

END