75D301-18-Q-68676_Statement_of_Work-Specs_FINAL-REVISED_7-27-18.pdf

Specification Mine Fan Replacement SRCM - 75D301-18-Q-68676

Centers for Disease Control and Prevention (CDC)

National Institute for Occupational Safety and Health (NIOSH)

Safety Research Coal Mine (SRCM) Fan Installation

Statement of Work-Revised 07-26-2018

1.0 SCOPE

The project includes the supply and installation of a mine ventilation fan system and related components at the CDC/NIOSH/Safety Research Coal Mine (SRCM) facility in Pittsburgh, PA.

The work shall consist of purchasing, installing and placing into satisfactory operation all mechanical and electrical equipment, erecting all structures including the fan, metal duct work, electrical cables, a building to house the motor and electrical controls, excavation, furnishing all foundations and floor slabs required, erection of all ductwork and horns to discharge vertically, airlock to provide access to fan ductwork on mine pressure side, explosion doors, noise suppression, suitable connection to the existing facility power system and controls to monitor all system functions.

1.1. Work shall include, but is not necessarily limited to, supplying the fan system, providing all engineering design, furnishing all layout, supplies and materials, furnishing all labor, superintendence, tools, controls, and equipment, and performing all work necessary to complete the installation to the satisfaction of and subject to the approval of the NIOSH project manager. The work must result in a fully functional mine ventilation fan connected to the SRCM.

1.2. The existing fan shaft is a concrete lined; approximately 20 ft. deep, 6 foot by 10 foot rectangle opening. The motor driving the fan is rated 10 hp, 13.5, Amps, 440 Volts.

Actual operating values measured on 07/26/18 were 7.0 Amps, 488 Volts.

1.3. The current operating point of the existing fan is 33,000 cubic feet per minute at 0.9” of water gauge. We expect the mine resistance to stay the same or possibly decrease as there are no plans to advance the mine in the future.

The existing fan is placed within a structure that contains three distinct parts: a) the 90° shaft top compartment, the fan compartment, and the 90° exhaust elbow The 90° shaft compartment is rectangular in shape and allows the air moving vertically through the shaft to turn 90° and enter the circular fan. The 90° rectangular exhaust elbow compartment allows the air exiting the fan to turn vertically and enter the atmosphere. The picture titled “Mine Portal and Fan” shows the location of the tubing for the fan water gauge chart recorder. The inlet to the tubing is at the junction of the rectangular exhaust elbow and the circular fan compartments. The circular fan compartment is approximately 54” in diameter.

1.4. There are facility drawings showing both topographic and utility information available. These would be made available after a non-disclosure agreement is signed and transferred in a secure format. Government facility maps and building plans are considered Controlled Unclassified Information (CUI) that have restrictions from public release.

1.5. Basic elevation data as could be derived from publically available information such as that seen on “Google Earth” would entail; The roadway elevation at the Safety Mine portal is approximately 1017 feet in elevation and the elevation at the mine fan base location is approximately 1039 feet in elevation.

2.0 GENERAL REQUIREMENTS

2.1 The contractor will supply the fan system and all required components. The fan system will be delivered to SCRM. It shall be the responsibility of the contractor to off load and protect before erection.

2.2 The available on-site work week will be Monday through Friday from 6:30am to 6:00 pm.

2.3 The work shall also consist of removing the existing fan and associated structure. The contractor shall be responsible for removing all scrap from the site. The existing mine fan shall be left in operation until the new fan and structure is ready for final connection to the shaft. The contractor shall state the estimated amount of time the mine will be without ventilation in the proposal.

2.4 The contractor shall supply the electrical control building with its components. The motor shall be located in the control building and directly connected to the fan with a drive shaft. The contractor shall be responsible to off load and protect components before installation.

2.5 The contractor shall supply the electric motor (designed to operate from a variable speed drive), motor disconnect switch, variable frequency drive with reversing contactor and motor starter disconnect switch for the fan along with the coupling components and have them delivered to the SRCM. The contractor shall be responsible to off load the units and protect before installation.

2.6 The contractor shall be responsible for all required design of the motor/control, electrical controls, water gauge monitoring and fan monitoring controls, power supply upgrade and connection to the existing facility power system, footings and buildings. Supply and install monitoring of the motor (current, voltage, power, stator & bearing temperature and bearing vibration), fan (water gauge and fan chart) and fan bearings (vibration and temperature).

2.7 The contractor shall be responsible for electrical/control installation with checkout, startup, and testing.

2.8 The contractor shall be responsible for all proper footing designs and soil testing to properly design for adequate static and dynamic loading.

2.9 Provide four 3/4 inch threaded Tee- plugged holes in ductwork approximately one foot from fan blades and accessible with pitot tube to enable manual survey of air quantity and pressure of fan.

2.10 Fan ductwork shall be installed as per MSHA guidelines with 15 foot offset from edge of ventilation shaft, with MSHA acceptable explosion doors.

2.11 The contractor shall identify any desired government supplied equipment. It shall be the responsibility of the contractor to inspect such equipment and certify that it is acceptable for the intended use.

3.0 WORK BY CONTRACTOR

NIOSH will provide general hazard training. The contractor is responsible for providing all additional training required to ensure the safety of the workers and the work site. The contractor shall furnish all supervision, labor, materials, tools, and equipment necessary to do the following work:

3.1 Supply, install, and make fully operational the mine fan complete with electric motor. The contractor will supply all structural steel, all piping, wiring, foundations, etc. necessary to put fan into operation.

3.2 The Contractor shall coordinate with the NIOSH Project Officer/COR the need for any traffic or area access restrictions necessary to perform the project functions. The Contractor shall obey all facility traffic and parking requirements when off-loading material and staging construction vehicles. The Contractor shall be responsible to provide appropriate safety signage, barricades and traffic control as necessary for performance of this project.

3.3 The fan system shall be installed per manufacturer’s instructions. All fan components shall be inspected prior to assembly. The contractor will make arrangements necessary for the coupling alignment to be checked, vibration checked and any other startup inspection to be performed by a representative from the fan company they purchased the fan from at the time of installation.

3.3.1 The contractor shall perform all fabrication work required and supply miscellaneous materials, guards for couplings, jack shaft and floating shaft, and steel shims and shim stock for the ventilating fan steel. The contractor shall furnish all new erection bolts, nuts, washers, sealers, and painting (desert tan or other acceptable environmental color) in erecting the fan system.

3.4 The maximum size of the fan building is determined by the available area above the SRCM portal. A Columbia Gas transmission line is located just to the east of the existing mine fan. Any building structure will have to be positioned outside the utility easement right of way (25 feet to centerline) of that pipeline. Since there are employees working in Building #44 and Building #50, the maximum fan noise inside Building #44 and Building #50 is expected to be less than 60 dbA.

The contractor shall include the calculated noise levels in the proposal.

3.5 Grade all excess material from the foundation excavations as directed and restore disturbed areas of the project caused by the work.

3.6 Design, furnish, and erect a building to house designated electric controls and motor drive.

Erection of the building shall house all electrical power, controls, monitoring, motor and include complete insulation, lighting, heating, cooling, ventilation, utility supports, foundations, and floor slabs. The contractor shall construct the control house to meet the following specifications:

3.6.1.1 Roof and wall sheeting shall be 24 gauge minimum.

3.6.1.2 Mandoor shall be 3 ft. X 7 ft. X 1¾” insulated metal, complete with frame, hinges, threshold, and hasp for owner supplied pad lock.

3.6.1.3 One (1) rollup door 9'-4" wide x 8’-0” or 10'-0" high, 22 gauge, galvanized steel door for inside mounting and chain operation, if required based on all internal components size and removal.

3.6.1.4 Insulation for buildings shall have a minimum specification of 3" thick, 0.6 density fiberglass roll insulation with white vinyl reinforced polyester with two (2) 3" tabs.

3.6.1.5 The electrical power components (motor, starter and switchgear) shall be isolated from the miner accessible monitoring displays (temperature, vibration and water gauge).

3.6.1.6 The heating and cooling systems shall provide for a temperature range suitable for all components installed in the building.

3.6.1.7 No wood framing for support or boxing of the unit or ductwork shall be allowed.

3.6.1.8 The building shall be adequately sized by current industry standards.

3.6.1.9 Adequate lighting shall be provided inside and outside the building.

3.7 Reinforced Concrete Work

3.7.1 All concrete shall have a minimum compressive strength of 4000 PSI at 28 days or greater if needed based on design. Foundation and caisson designs shall be certified by a professional engineer to meet the manufacturer’s loading requirements. A geotechnical-subsurface exploration report to be provided by the contractor after contract award.

3.8 Electrical

3.8.1 Procurement

It is the responsibility of the contractor to provide all electrical and control material for this project.

3.8.2 Incoming Power

Substation 216 shown in Attachment 4 includes three single phase 100 kVA transformers. The secondary voltage is 480 VAC. If the contractor chooses to supply power to the fan from this substation, the contractor will have to run underground conduit and cable from the substation to the motor starter and will have to provide and install proper switchgear in the substation to provide proper protection for the cable.

Since other loads are supplied from this substation, NIOSH facilities has established a 100 hp maximum for a fan powered from Substation 216.

Pad 213 shown in Attachment 4 is the other option. The equipment sitting on this pad has been out of service and will be scrapped. If the contractor chooses to supply power to the fan from this pad, the contractor will have to run underground conduit and cable from Substation 2 to the pad. The contractor will have to provide and install a properly protected ANSI/IEEE “pad-mounted” transformer on the pad and then run conduit and cable to the motor starter.

3.8.3 All electrical work must comply with the current edition of the National Electrical Code and federal mining regulations. A MSHA certified electrician shall inspect the completed work and certify that it complies with the National Electrical Code and federal mining regulations.

3.8.4 The contractor shall supply the electric motor (designed to operate from a variable speed drive), motor disconnect switch, variable frequency drive with reversing contactor and motor starter disconnect switch for the fan along with the coupling components and have them delivered to the SRCM. The contractor shall be responsible to off load the units and protect before installation.

3.8.5 The contractor shall be responsible for all required design of the motor/control, electrical controls, water gauge monitoring and fan monitoring controls, power supply upgrade and connection to the existing facility power system, footings and buildings. Supply and install monitoring of the motor (current, voltage, power, stator & bearing temperature and bearing vibration), fan (water gauge and fan chart) and fan bearings (vibration and temperature). An insulated cable assembly with ground such as quadruplex, GGC or similar cable may be acceptable for the connection to the facility power system.

3.8.6 Supply and install remote control of the fan motor (on-off and speed) and remote monitoring system in the mine foreman’s office Building # 50.

3.8.7 The source substation frame ground wire will be solidly connected to the building ground ring, all ground rods, building steel, fan ducts, fans, and all electrical equipment frames.

3.8.8 Water Gauge System

The fan water gauge will be measured inside the fan house by tapping into the fan duct with a ½” ID insulated copper line. The copper line will connect to a 4" x 36" baffled steel damper. The copper line will be routed to prevent water traps, and will drain into the damper. The damper will have a drain valve located in the bottom. The damper shall be mounted to the wall of the fan house. Heat tape shall be installed on the section of water gauge line exposed to the outside. The heat tape shall have thermostatic controls. A 0- 5" range U-Tube manometer (or larger, if needed) will be ported from the damper, along with a Bristol Water Gauge Recorder (or equivalent).

The U-Tube will be filled with red unity oil. The dP transmitter will have an LCD display for local readout of the water gauge, and 4-20 mADC output.

The water gauge measurement equipment will be mounted on a steel backplate whose legs are anchored into the floor. Each device shall include a shutoff valve and a test valve to open to atmosphere.

3.8.9 Vibration Monitoring System

The contractor shall furnish and install IRD or equivalent vibration monitoring equipment.

3.8.10 Telemetry and Communications

The contractor will supply and install a Phonetics Sensa phone Express II telephone dialer unit (or equivalent). Selectable contacts will trigger the Alarm/Status messages in the Sensa phone (or equivalent) so that CDC/NIOSH can integrate into the site phone system if desired to contact others on site should fan be in alarm stage.

The building housing the electrical power, controls, monitoring, and motor shall include the pressure monitoring (7 day paper fan chart recorder) vibration, temperature and electrical monitoring as specified in 3.8.5. An audible and visual alarm shall be mounted on the outside of the building.

The mine foreman’s office, Building # 50, shall include (3.8.6) a 24 hour paper fan chart recorder and all of the vibration, temperature and electrical monitoring displays discussed above. The connection from the fan building to the mine foreman’s office shall be contractor supplied fiber or copper. In addition the mine foreman’ office shall include the capability of starting, stopping, changing speed and reversing the fan motor. There shall also be a means of silencing the audible and visual alarm.

The Phonetics Sensa phone Express II telephone dialer unit (or equivalent) shall be suitable for connection to a fiber telephone system. CDC/NIOSH will integrate the dialer into the site telephone system.

3.8.11 Transformer Pads

If needed, the contractor is responsible for the installation of the concrete pads outside the electric fan house. If needed, the contractor is responsible for purchase and installation of the new transformers.

3.8.12 Power Meter

The contractor is also responsible for the purchase and installation of the power meter specified in Attachment 2.

3.8.13 Testing and Commissioning

It is the responsibility of the contractor to test and make operational all electrical, monitoring, and control systems will be thoroughly tested by the contractor to assure that everything works properly as a system. Commissioning responsibility will be up to the time that the fan goes “on line”, with final acceptance by CDC/NIOSH at that time.

3.8.14 Approval

This fan installation is subject to inspection and approval by CDC/NIOSH project manager, facilities, and CDC/NIOSH Pittsburgh Mining Research Division (PMRD) designated personnel. The contractor will be called upon to be present during inspections by these groups and stand ready to make corrections. The installation shall be installed in accordance with MSHA and PA Bureau of Mine Safety standards unless otherwise approved by project manager. Implicit in this requirement is that all work will be performed in a workmanlike manner and in such a way that will comply with all applicable codes. The contractor will submit documentation within their proposal to designate variances from codes mandated by law. The contractor will also document alternative options for correction of any variance to install in accordance with codes mandated by law for approval for this installation.

4.0 FAN PERFORMANCE

4.1 The contractor shall specify the operating performance for the completely assembled fan connected to the SRCM. The expectation is that a fan will be chosen by the contractor that, with various blade settings and speed settings, will provide approximately 15,000 cfm to 100,000 cfm. CDC/NIOSH expects that the motor will be rated at approximately 100 hp. It is important to note that the fan chart (Attachment 1) is for reference only and the contractor is expected to select an appropriate fan.

Contractor shall estimate performance of fan in reverse (blowing) mode; there is no expectation of same volume being achieved in both forward and reverse directions.

5.0 ADDITIONAL FAN SYSTEM EQUIPMENT

5.1 Contractor will provide a line item quote to supply a silencer to be installed in line with the discharge of the fan and required to meet discharge decibel noise levels for South Park Township noise regulations applicable to this operation:

No operation or activity shall cause or create noise in excess of the sound levels prescribed below. There are exceptions such as construction activity. The noise shall be measured on an “A-weighted” scale of a sound pressure level meter which conforms to the standards prescribed by ANSI, Specifications for Sound Level Meters. The NIOSH facility is zoned Business Park and is surrounded by Residential. Where two or more zoning districts in which different noise levels are prescribed share a common boundary, the most restrictive noise level standards shall govern. Therefore, the Residential noise levels are applicable to this site.

Business Park: At no point on or beyond the boundary of any lot within these districts shall the exterior noise level resulting from any use or activity located on such lot exceed a maximum of sixty (60) dBA.

Residential: At no point beyond the boundary of any lot within these districts shall the exterior noise level resulting from any use or activity located on such lot exceed a maximum of fifty-five (55) dBA.

Since there are employees working in Building #44 and Building #50, the maximum fan noise inside Building #44 and Building #50 is expected to be less than 60 dbA. The contractor shall include the calculated noise levels in the proposal.

5.2 Provide recommend spare parts lists.

5.3 Furnish “as built” drawing of installation including structural, electrical, and general layout in both paper and electronic format.

5.4 Furnish list of contacts regarding equipment and components, owner’s manuals, and service manuals. Owner’s manuals, and service manuals shall be provided in both paper and electronic format.

6.0 ENGINEERING SPECIFICATIONS

6.1 Fan System

6.1.1 The sequence of erection of the entire fan system shall be in accordance with the fan manufacturer erection instructions.

6.1.2 Installation shall be in accordance with the location, lines, elevations, and details as shown on the specification and manufacturers supplied equipment drawings.

6.1.3 Specify approximate weight of the heaviest fan component to be installed.

6.1.4 After all fan steel has been erected, shimmed, and securely bolted and before any grouting is performed, Contractor shall bring the drive train for fan to final alignment and level. The goal for such alignment shall be 0.00 inch vertically and horizontally as measured by a dial indicator and as acceptable to industry standards. This work shall also include initial cleaning of all main fan bearings, examination of the bearings for endplay and foreign particles, flushing of the bearing feed lines and filling with oil. If needed, remote greasing lines installed and serviced.

7.0 OTHER REQUIREMENTS

7.1 The contractor shall comply with all site entry and exit requirements.

7.2 The contractor shall provide acceptable employee provided information as require by site/government security.

7.3 The contractor shall comply with all government site and facilities requirements for the

CDC/NIOSH Facility.

8.0 CONTRACTOR’S TURN-KEY PROPOSAL

8.1 The contractor shall complete a summary and detailed cost/business proposal per Clause E.3B for the project including specified option(s). The cost/business proposal shall include the total price of installation including option(s) for the turnkey installation.

8.2 The contractor shall provide an estimated time to complete in days per Clause C.5.

8.3 In addition to the requirements of Clause E.3B, the contractor shall break down at a minimum their cost/business proposal in accordance with the items listed below with the understanding that the total shall be a firm lump sum price.

NOTE: All unit rates shall be inclusive of all costs, including but not limited to labor, materials, equipment (including operating and maintenance costs), payroll burdens, fringes and benefits, and overhead and profit.

Description Quantity Units Unit Price Total

1. Supply fan system 1 LS

2. Installation of electrical power and control systems for fan

1 LS

3. Install fan and associated ductwork 1 LS

4. Fan house (including all lighting and monitoring)

1 LS

5. Fan house heating and cooling system

1 LS

6. Connection of the electrical power for the fan to the existing facility power system

1 LS

7. Footing and Foundations for Complete Installation

1 LS

8. Other (Specify Detail)for Installation 1 LS

9 Reversing variable frequency motor controller

1 LS

10 Optional remote monitoring and control LS

10. Total Lump Sum

Attachment 1 (General Information Relating to Fan Performance):

Attachment 2 (Power Meter):

Attachment 3 (Single Line Substation Diagram):

Attachment 4 (Photographs):

Building 44 and Substation 216 (1)

Building 44 and Substation 216 (2)

Existing Pad 213 and Fan

Mine Fan (1)

Mine Fan (2)

Mine Fan (3)

Mine Portal and Fan

Additional photographs taken at site visit:

Current setup in mine office with 24 hour fan charts

Existing Pad 213

Current Mine Fan

Pad 213 as seen from the fan location

Concrete on top the shaft

Concrete on top the shaft

Concrete on top the shaft and base of the current fan structure