A02. PWS.pdf

Chain of Rocks Pump Station – Pump Replacement Granite City, Illinois

SECTION 1 - GENERAL

1.1. Scope of Work. The pump station pumps are in need of replacement. Work is anticipated to be accomplished with traditional equipment. The work includes three main components:

1.1.1. Removal, Installation and Testing of Pumps. The work provided for herein consists of providing all plant, labor, materials, and equipment required for removing existing MWI model SEMC30, 400HP pumps, and providing and installing three new pumps. New pumps shall be Flygt Model LL3602/866, 3 phase, 480V, 10 poles, with 355 hp motor. The existing pump tubes are 48” outer diameter, ASTM A36 steel and will accommodate the new pumps. Alterations to the pump tube flange may be necessary to ensure a tight seal between the pump and pump tube. These alterations could include cutting and welding. Upon installation of the new pumps, each of the pumps shall be field tested.

1.1.1.1. Refer to Section 7 DESCRIPTION OF WORK for further details of the work required for the removal, reinstallation and testing of pumps.

1.1.2. Electrical. The work provided for herein consists of providing all plant, labor, materials, and equipment required for the following:

1.1.2.1. Disconnecting all sets of existing pump motor feeder cables and pump monitoring control cables for three existing 400hp, 480V submersible pump motors.

1.1.2.2. Removal of three submersible pump motors including all associated feeder cables and pump monitoring control cables up to the termination in existing motor junction boxes.

1.1.2.3. Installation of three new 355hp, 480V submersible pump motors, as described in paragraph 1.1.1 and elsewhere herein. Installation of all new sets of pump motor feeder cables as recommended by pump manufacturer. New sets of motor feeder cables shall be routed in existing conduit and terminated in existing motor junction boxes on existing terminal blocks.

1.1.2.4. Evaluation of existing pump motor branch circuits and controls for each new motor. Contractor shall make any necessary changes to existing motor branch circuits and controls as required per NFPA 70 and as recommended by pump manufacturer to accommodate new pump motors. Existing motor branch circuits consist of but are not limited to: feeder circuit breaker, solid state reduced voltage (SSRV) starter, power factor correction capacitors (PFCC), 120VAC control circuitry, and programmable logic controller

(PLC).

1.1.2.5. Replacement of three existing Pump Protection Panels with three new manufacturer specific pump protection panels including all ancillary devices including but not limited to: control wiring, pushbutton devices, pilot lights, electronic displays, and labels. New pump protection panels shall be integrated with existing PLC control system and motor control circuits to retain existing operating parameters.

1.1.2.6. Refer to Section 7 DESCRIPTION OF WORK for further details of electrical work required.

1.1.3. Intake Testing. Provide complete performance model testing of the pump intake systems. Use the model testing to confirm the configuration of the intake systems, including the proposed intake conduit, hydraulic losses to the pump, the position of the pump in the intake bay, and to confirm the selection of the pump. The Contracting Officer will witness the final tests confirming the geometry for the intake conduit. Furnish the Contracting Officer with not less than 14 days written notice of the time and location for the final tests.

1.1.3.1. Refer to Section 7 DESCRIPTION OF WORK for further details of the sump design model study work required.

1.2. Omissions. This scope of work may duplicate or not cover all specified activities, steps, and/or procedures required to accomplish work. In case of omission, the normal industry standards, practices, specifications and/or guidelines shall prevail. In no instance shall omission be a reason to perform inferior work, produce a less than acceptable product or service, or refuse to perform an intended activity.

1.3. Contracting Officer. The term "Contracting Officer" shall mean the person executing this contract on behalf of the Government, and any other officer or civilian employee who is properly designated Contracting Officer; and the term shall include, except as otherwise provided in this contract, the authorized representative of a Contracting Officer acting within the limits of their authority.

1.4. Schedule. The Contractor shall schedule all work associated with removal and reinstallation of pumps to be performed Monday through Friday, 7:00 a.m. – 5:00 p.m., unless otherwise specified herein, or as specifically approved in advance by the Contracting Officer. The Contractor shall coordinate with the Authorized Representative of the Contracting Officer to schedule all work.

1.5. Work Period. All work & order and coordination of work including, but not limited to removal, installation of new pumps, assessment, inspection, testing, submission of submittals and reports, must be performed and completed within 270 calendar days from date of Contract Award. Each pump replacement shall be completed within 30 consecutive days. Contractor will ensure two pumps remain operational for the duration of the work period.

1.6. Required Insurance:

1.6.1. Insurance-Work on a Government Installation. As required by the contract clause entitled “Insurance- Work on a Government Installation”, the Contractor shall, furnish to the Contracting Officer, prior to the commencement of work, a certificate or written statement as evidence of the minimum insurance listed below.

The Contractor shall procure and maintain such types and amounts of insurance during the entire period of his performance under this contract. The Contractor shall assure that the certificate or written statement is in accordance with required wording indicated in paragraph 1.6.2 or the aforementioned Contract Clause.

1.6.2. Workmen’s Compensation. Amounts required by applicable jurisdictional statutes.

1.6.3. Employer’s Liability Insurance. -- $100,000.

1.6.4. Comprehensive General Liability Insurance. – (No property damage liability insurance is required) Bodily Injury -- $500,000 per occurrence

1.6.5. Comprehensive Automobile Insurance.

Bodily Injury -- $200,000 each person $500,000 each accident

Certificate of Insurance should be submitted to the following address:

Department of the Army St. Louis District Corps of Engineers Rivers Project Office ATTN: Justin Elmore 301 Riverlands Way West Alton, MO 63386

1.7. References. All referenced publications shall be the most current version, edition, standard, or latest revision unless otherwise stated. The publications and standards listed below will be referred to only by the basic designation, and shall form a part of this specification to the extent indicated by the references thereto:

1.7.1. Acoustical Society of America (ASA).

ASA S2.19 Mechanical Vibration – Balance Quality Requirements of Rigid Rotors, Part 1L

Determination of Permissible Residual Unbalance

1.7.2. American Society of Mechanical Engineers (ASME).

B 4.1 Preferred Limits and Fits for Cylindrical Parts

B 46.1 Surface Texture (Surface Roughness, Waviness, and Lay)

BPV IX Boiler and Pressure Vessel Code;

Section IX, Qualifications for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators

1.7.3. American Society for Testing and Materials (ASTM).

A 27 Steel Castings, Carbon, for General Application

A 36 Carbon Structural Steel

A 48M Gray Iron Castings (Metric)

A 108 Steel Bars, Carbon, Cold Finished, Standard Quality

A 276 Stainless Steel Bars and Shapes

A 285 Pressure Vessel Plates, Carbon Steel, Low- and

Intermediate-Tensile Strength

A 297 Steel Casting, Iron-Chromium and Iron-Chromium-Nickel, Heat Resistant, for General Application

A 312 Seamless and Welded Austenitic Stainless

Steel Pipes A 488 Steel Castings, Welding, Qualifications of

Procedures and Personnel

A 516 Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

A 572 High-Strength Low-Alloy Columbium-Vanadium

Structural Steel

A 576 Steel Bars, Carbon, Hot-Wrought, Special Quality

A 668 Steel Forgings, Carbon and Alloy, for General Industrial Use

B 148 Aluminum-Bronze Sand Castings

B 584 Copper Alloy Sand Castings for General

Applications

D 2000 Rubber Products in Automotive Applications

1.7.4. American Welding Society (AWS).

D 1.1 Structural Welding Code Steel

D 11.2 Guide for Welding Iron Castings

1.7.5. American Water Works Association (AWWA).

C200 Steel Water Pipe - 6 In. and Larger

C203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines - Enamel and Tape - Hot Applied

C207 Steel Pipe Flanges for Waterworks Service -

Sizes 4 In. Through 144 In.

C208 Dimensions for Fabricated Steel Water Pipe Fittings

1.7.6. Hydraulic Institute (HI).

1.1 – 1.2 (2014) Rotodynamic Centrifugal Pumps for Nomenclature and Definitions

1.3 (2013) Rotodynamic (Centrifugal) Pumps for Design

1.4 (2014) Centrifugal Installation, Operation, and Maintenance

2.1 – 2.2 (2014) Rotodynamic Vertical Pumps for Nomenclature and Definitions

2.3 (2013) Rotodynamic (Vertical) Pumps for Design and Application

2.4 (2014) Rotodynamic (Vertical) Pumps for Manuals Describing Installation, Operation and Maintenance

9.1 - 9.5 (2015) Pumps - General Guidelines

9.6.4 (2016) Rotodynamic Pumps for Vibration Measurements and Allowable

Values

9.8 (2018) Pump Intake Design Standard

14.1 – 14.2 (2019) Rotodynamic Pumps for Nomenclature and Definitions

14.6 (2016) Rotodynamic Pumps for Hydraulic Performance Acceptance Tests

1.7.7. The International Society of Automation Control (ISA).

RP2.1 Manometer Tables

1.7.8. National Electrical Manufacturer's Association (NEMA).

MG 1 Motors and Generators WC 70 Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy

WC 70 Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy

1.7.9. National Fire Protection Association (NFPA).

NFPA 70 National Electrical Code

1.7.10. Steel Structures Painting Council (SSPC)

SSPC Paint 33 Coal Tar Mastic, Cold-Applied

SSPC SP 3 Power Tool Cleaning

1.8. Reference Publications. These specifications, standards and descriptions are not available from Government sources. They may be obtained from the publishers listed below:

Acoustical Society of America (ASA) Suite 300 1305 Walt Whitman Road Melville, NY 11747-4300 www.acousticalsociety.org

American National Standards Institute (ANSI) 11 West 42ND Street New York, NY 10036 www.ansi.org

American Society of Testing and Materials (ASTM) 100 Barr Harbor Drive West Conshohocken, PA 19428 www.astm.org

American Water Works Association (AWWA) 666 West Quincy Denver, CO 80235 www.awwa.org

American Welding Society (AWS) 8669 NW 36 Street, # 130 Miami, Fl. 33166-6672 www.aws.org

American Society of Mechanical Engineers (ASME) ASME International Three Park Avenue New York, NY 10016-5990 www.asme.org

Hydraulic Institute (HI) 300 Interpace Parkway Bldg. A, 3rd Floor Parsippany, NJ 07054 www.pumps.org http://www.acousticalsociety.org/ http://www.ansi.org/ http://www.astm.org/ http://www.awwa.org/ http://www.aws.org/ http://www.asme.org/ http://www.pumps.org/

The International Society of Automation (ISA) 67 T.W. Alexander Drive PO Box 12277 Research Triangle Park, NC 27709 www.isa.org

National Electrical Manufacturers Association (NEMA) VP, Technical Services: Alvin Scolnik 1300 North 17th Street, Suite 1752 Rosslyn, VA 22209 www.nema.org

National Fire Protection Association (NFPA) 1 Batterymarch Park Quincy, Massachusetts

USA 02169-7471

www.nfpa.org

Steel Structures Painting Council (SSPC) 800 Trumbull Dr.

Pittsburgh, PA 15205

USA

https://www.sspc.org/

Underwriters Laboratories Inc.

333 Pfingsten Road Northbrook, IL 60062-2096 www.ul.com

SECTION 2 – SAFETY

2.1. Safety. The Contractor shall perform all work in accordance with safety requirements set forth in Corps of Engineers' Manual, EM 385-1-1, entitled "Safety and Health Requirements Manual", updated 30 NOV 2014 copies online at https://intranet.usace.army.mil/mvd/mvs/soh/Documents/EM%20385-1-1/EM_385-1- 1%20(as%20of%2011-30-2014).pdf The contractor shall be responsible for complying with the current edition and all changes posted on the web.

2.2. Equipment/Materials. All equipment and materials may be inspected by the Government. Any equipment and material found not in conformity with the safety manual shall be removed from Government property immediately.

Any unsafe work and/or actions will be stopped immediately. The Contracting Officer may require the Contractor to immediately remove from the work site any employee, of the Contractor, who endangers persons or property.

Notification shall be by telephone or in person and shall be confirmed in writing as soon as possible. No such removal, however, shall reduce the Contractor's obligation to perform all work required under this contract.

2.3. Safety Exposure Report. At the end of the job, the Contractor shall submit, in writing, a safety exposure report.

This report shall include (1) the total employee hours worked by employees during the performance of this job, and

(2) detailed descriptions of any accidents or injuries sustained on the project by their employees, including copies of documents for claims under Workman’s Compensation.

2.4. Accident Reporting. An accident constitutes an incident or act involving the Contractor which may or may not have caused obvious damage to persons or property. All accidents shall be reported to the COR or their representative within 24 hours of the occurrence. All serious accidents (those resulting in death or injury requiring medical attention) shall be reported immediately.

http://www.isa.org/ http://www.nema.org/ http://www.nfpa.org/ http://www.sspc.org/ http://www.sspc.org/ http://www.ul.com/

2.5. Accident Prevention Plan. The Contractor shall refer to Contract Clause FAR 52.236-13 entitled, "Accident Prevention". Within 14 calendar days after receipt of contract award, and prior to start of work, the original and one copy of the Accident Prevention Plan shall be submitted to the Contracting Officer or authorized representative for review. A checklist has been included at the end of this section to aid the Contractor in preparing the Accident Prevention Plan. The APP form A-01 may be used to insure each area of required information has been provided.

The Contractor shall not commence physical work at the site until the program has been reviewed and found acceptable by the Contracting Officer, or an authorized representative. At the Contracting Officer's discretion, the Contractor may submit its Activity Hazard Analysis only for the first phase of services provided that it is accompanied by an outline of the remaining phases of services. All remaining phases shall be submitted and accepted prior to the beginning of work in each phase. Also refer to Section 1 of EM 385-1-1.

Accident Prevention Plan – Checklist. See EM 385-1-1 30 NOV 2014 Appendix A, Paragraph 3.k.

2.5.1. Title, signature, and phone number of the plan preparer.

2.5.2. Background Information to include:

2.5.2.1. Contractor;

2.5.2.2. Contract number;

2.5.2.3. Project name;

2.5.2.4. Brief project description,

2.5.2.5. Description of work to be performed, and

2.5.2.6. Location of work being performed, to include a map.

2.5.3. Statement of Safety and Health Policy detailing their commitment to providing a safe and healthful workplace for all employees.

2.5.4. Responsibilities and Lines of Authorities – to include a statement of the employer’s ultimate responsibility for the implementation of his SOH program; Identification and accountability of personnel responsible for safety at all levels to include designated site safety and health officer (SSHO) and associated qualifications. The District SOHO will be asked to review the qualifications for acceptance.

2.5.5. Training - new hire SOH orientation training at the time of initial hire of each new employee and any periodic retraining/recertification requirements.

2.5.6. Procedures for job site inspections - assignment of responsibilities and frequency.

2.5.7. Procedures for reporting man-hours worked and reporting and investigating any mishaps required by Section 01.D.

2.5.8. Emergency Planning. Employees working alone shall be provided an effective means of emergency communication. This may be cellular phone, two-way radio or other acceptable means. The selected means of communication must be readily available and must be in working condition.

2.5.9. Drinking Water provisions, toilet and washing facilities.

2.5.10. First Aid and CPR training (at least two employees on each shift shall be qualified/certified to administer first aid and CPR) and provision of first aid kits (types/size).

2.5.11. Personal Protective Equipment (PPE).

2.5.11.1. Work Clothing - Minimum Requirements. Employees shall wear clothing suitable for the weather however minimum requirements for work shall be short-sleeve shirt, long pants (excessively long or baggy pants are prohibited) and leather work shoes. If analysis determines that safety-toed (or other protective) footwear is necessary they shall be worn.

2.5.11.2. Eye and Face Protection. Eye and face protection shall be worn as determined by an analysis of the operations being performed, however, all involved in chainsaw use, chipping, stump grinding, pruning operations, grass mowing, weedeating and blowing operations shall be provided safety eyewear (Z87.1) as a minimum.

2.5.11.3. Hearing Protection. Hearing protection must be worn by all those exposed to high noise activities (to include grass mowing and trimming, chainsaw operations, tree chipping, stump grinding and pruning).

2.5.11.4. High Visibility Apparel shall comply with ANSI/ISEA 107, Class 2 requirements at a minimum and shall be worn by all workers exposed to vehicular or equipment traffic.

2.5.11.5. Protective Leg chaps shall be worn by all chainsaw operators.

2.5.11.6. Gloves of the proper type shall be worn by persons involved in activities that expose the hands to cuts, abrasions, punctures, burns and chemical irritants.

2.5.11.7. If work is being performed around water and drowning is a hazard, PFDs must be provided and worn as appropriate.

2.5.12. Machine Guards and safety devices. Power tools/equipment must have appropriate guards and safety devices in place and operational.

2.5.13. Hazardous Substances. When any hazardous substances are procured, used, stored or disposed, a Hazard Communication Program must be in place and MSDSs (SDSs) shall be available at the worksite.

Employees shall have received training in hazardous substances being used. When the eyes or body of any person may be exposed to corrosives, irritants or toxic chemicals, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within 10 seconds of the worksite.

2.5.14. Traffic control shall be accomplished in accordance with DOT’s MUTCD.

2.5.15. Control of Hazardous Energy (Lockout/Tagout). Before an employee performs any servicing or maintenance on any equipment where the unexpected energizing or startup of the equipment could occur, procedures must be in place to ensure adequate control of this energy. > See Section 12.

2.5.16. High hazard activities should not be encountered on these types of jobs. If they are (i.e., driving/operating equipment on slopes, working from/in boats, etc), a determination shall be made by the KO and local SOH Office as to whether an abbreviated APP is applicable. If so, they shall be fully addressed in the APP. AHAs are required on work activities which include high hazard activities.

2.6. Activity Hazard Analysis (AHA).

2.6.1. Format and Submittal. The Activity Hazard Analysis (AHA) format shall be in accordance with USACE EM 385-1-1. Submit the AHA to the COR for review following award and prior to the post award conference. Format subsequent AHAs as amendments to the APP. The analysis should be used during daily inspections to ensure the implementation and effectiveness of the activities safety and health controls.

2.6.2. Reviewing. The AHA list will be reviewed periodically and updated as necessary when procedures, scheduling or hazards change.

2.6.3. Relevance. The activity hazard analyses shall be developed for activities being performed. The AHAs will be developed by the contractor, supplier or subcontractor and provided to the prime contractor for submittal to the COR.

2.6.4. Emergency Medical Treatment. Contractors will arrange for their own emergency medical treatment.

Government has no responsibility to provide emergency medical treatment.

SECTION 3 - SECURITY

3.1. Suspicious Activity Reporting Training. The contractor and all associated sub-contractors shall receive a brief/training (provided by the COR) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

3.2. Pre-screen employees using E-Verify Program. The Contractor must pre-screen Employees using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Employee has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Employees must be provided to the COR no later than 3 business days after the initial contract award.

SECTION 4 - ENVIRONMENTAL PROTECTION

4.1. Scope. This section covers prevention of environmental pollution and damage as result of activities under this contract. This section is in addition to those measures set forth in other sections of these specifications. For the purpose of this specification, environmental pollution and damage are defined as the presence of chemical, physical, or biological elements or agents which adversely affect human health or welfare, unfavorably alter ecological balances of importance to human life; affect other species of importance to man; or degrade the utility of the environment or aesthetically, cultural and/or historical purposes. The control of environmental pollution and damage requires consideration of air, water, and land and includes management of visual esthetics, noise, solid waste, radiant energy and radioactive materials, as well as their pollutants.

4.2. Quality Control.

4.2.1. General. The contractor shall establish and maintain quality control for environmental protection operations to assure compliance with contract requirements and maintain detailed records of quality control.

4.2.2. Reporting. One copy of these records and tests, as well as records of corrective action taken, shall be furnished to the Government daily when work covered by this section is being performed.

4.3. Permits and Licenses. The Contractor shall obtain and comply with all required permits and licenses. Copies of all applications, permits and licenses obtained from Federal, State and local governing bodies pursuant to this contract shall be submitted to the Contracting Officer. (1) Permit or license and the location of solid waste disposal areas.

4.4. Protection of Environmental Resources. The environmental resources within the project boundaries and those affected outside the limits of permanent work under this contract shall be protected during the entire period of each task order work period. Environmental protection shall be as stated in the following subparagraphs.

http://www.uscis.gov/e-verify)

4.5. Protection of Land Resources. The Contractor shall not remove, cut, deface, injure or destroy land resources including trees, shrubs, vines, grasses, topsoil, and landforms without special permission from the Contracting Officer.

4.6. Disposal of Solid Wastes. Solid Wastes shall be placed in containers, which are emptied on a regular schedule.

All handling and disposal shall be conducted to prevent contamination. The Contractor shall transport all solid wastes off Government property and dispose of them in compliance with Federal, State and local requirements for solid waste disposal.

4.6.1. Removal of Materials and Rubbish. The Contractor shall remove from the site of work, before final payment is made, all his equipment and unused materials provided by him, any waste materials and rubbish resulting from the operations performed herein. The methods and locations of disposal of materials, wastes, effluents, trash, garbage, oil, grease, chemicals, etc., within the right-of-way limits shall be such that harmful debris will not enter project lands, lakes, ditches, rivers, canals, waterways, or reservoirs. The contractor shall dispose of all oil and refrigerant in accordance with EPA guidelines, local codes, permits, and ordinances as required.

4.7. Protection of Water Resources. The Contractor shall keep activities under surveillance, management and control to avoid pollution of surface and ground waters.

4.8. Protection of Air Resources. The Contractor shall keep activities under surveillance, management and control to minimize pollution of air resources. All activities, equipment processes, and work operated or performed by the Contractor in accomplishing the specified activities shall be in strict accordance with the State of Missouri and/or the State of Illinois and all federal emission and performance laws and standards.

4.9. Protection of Fish and Wildlife. The Contractor shall keep activities under surveillance, management and control to minimize interference with, disturbance to, and damage of fish and wildlife.

4.10. Protection of Historical, Archaeological, and Cultural Resources. The preservation and recovery of existing historical, archaeological and cultural resources within the Contractor's work area will be so designated by the Contracting Officer and precautions shall be taken to preserve all such resources as they existed at the time they were identified to the Contractor. Any item that may have historical or archaeological value discovered by the Contractor shall be left undisturbed and the Contracting Officer shall be immediately notified of such discovery.

4.11. Protection of Sound Intrusion. The Contractor shall keep activities under surveillance and control to minimize damage to the environment by noise.

4.12. Protection of Government Facilities and Structures. The Contractor shall be responsible for restoring any Government facilities or structures damaged as a result of his operations. Reasonable care shall be used to avoid damage. Any such damage shall be repaired or the items replaced as directed by the Contracting Officer at no cost to the Government. If the Contractor does not make such repair or replacement, the cost thereof will be deducted from payments to be made to him. The Contractor shall advise the Contracting Officer of any damage to the facilities due to vandalism or other causes on the day he first notices such damage.

4.13. Payment. No separate payment or direct payment will be made for the cost of the work covered under this section and all costs in connection therewith shall be included in other items for which payment is provided.

SECTION 5 - GOVERNMENT FURNISHED PROPERTY AND SERVICES

5.1. General. The Government will supply to the Contractor, for use only in connection with this contract, the below described equipment and materials at times necessary for the use by the Contractor to provide the necessary work described herein. The Contractor will receive Government-furnished materials at the Chain of Rocks Pump Station [2865A Old Rock Rd, Granite City, IL. 62040].

5.2. Keys. The Government will furnish the necessary keys for access to the work site. NOTE: DUPLICATION OF GOVERNMENT-FURNISHED KEYS IS NOT PERMITTED. The Contractor shall immediately report the loss of keys to the Contracting Officer. In the event that a Government-furnished key is lost, the Contractor is responsible for reimbursement of all costs incurred by the Government for replacement of lock systems throughout the project which are affected by the lost key. Contractor costs shall include, but not be limited to, Government labor, replacement lock costs, replacement key costs, tumbler reworking and all contracted labor costs required to replace lock systems. All lock systems required to be replaced will be equal quality to lock systems presently in place. The Government will determine the specific replacement lock system.

5.3. Utilities. Electricity can be obtained by the Contractor from sources within the work areas or from other pre-approved Government sources.

SECTION 6 - CONTRACTOR FURNISHED PROPERTY/MATERIALS/EQUIPMENT

6.1. General. All Contractor-furnished equipment and materials used in the performance of this contract shall be of suitable size and type and/or quality for the intended use. Unless otherwise stated, the Contractor shall furnish and maintain all sufficient equipment, materials, and supplies suitable to perform the work. All equipment shall be maintained in safe operating condition in accordance with Section 2 - SAFETY.

6.2. Equipment Storage. All items shall be removed from the work site as soon as possible after the completion of the work described herein. The Contractor will not be allowed to store equipment, supplies, and property on Government property except for storage areas as approved in advance by the Contracting Officer. If approval is given for storage, the Contracting Officer will specify designated location(s), and the Government assumes no responsibility for the safety or security of the items.

6.3. Materials Delivery and Storage. Materials shall be delivered to the site in a dry and undamaged condition and stored out of contact with the ground at a location approved by the Contracting Officer. Materials may be stored at the work site during continuous working days if notification is given to the Contracting Officer in advance. The Government assumes no responsibility for the safety or security of materials left on Government property.

6.4. Materials to be furnished by the Contractor. Except as otherwise provided herein, the Contractor shall furnish all materials necessary to perform the work described herein, including, but not limited to; pumps, lids and hatches, lifting chains, guide rail systems, cable holder, pump tube alterations, and other related materials.

SECTION 7 – DESCRIPTION OF WORK

7.1. General. The pump station pumps are in need of replacement. Work is anticipated to be accomplished with traditional equipment. The work includes three main components:

7.1.1. Removal, Installation and Testing of Pumps. The work provided for herein consists of providing all plant, labor, materials, and equipment required for removing existing MWI model SEMC30, 400HP pumps, and providing and installing three new pumps. New pumps shall be Flygt Model LL3602/866, 3 phase, 480V, 10 poles, with 355 hp motor. The existing pump tubes are 48” outer diameter, ASTM A36 steel and will accommodate the new pumps. Alterations to the pump tube flange may be necessary to ensure a tight seal between the pump and pump tube. These alterations could include cutting and welding. If any alteration such as cutting or welding is to be made to the pump tube, see paragraph 7.1.1.1 for the painting schedule requirement.

Any additional material added to the pump tube shall be the same material as the existing pump tube. All welding shall be in accordance with AWS D1.1 and completed per requirements with the pump manufacturer. It is the Contractor’s responsibility to maintain the water level in the sump to maintain water levels at an elevation that allows for them to accomplish all work in the sump during construction. The intake sluice gates shall be closed prior to the commencement of all work. The Contractor shall have a sump pump on standby in the event of leakage to occur from the sluice gate seals. The Contractor shall ensure that the sump is clear of any debris and/or tools prior to operational testing of the pump and rewatering of the sump after all work is complete.

7.1.1.1. Paint Schedule. The following painting schedule shall be adhered to if any alteration is to be made to the pump tube. Prior to painting the metal shall be cleaned SSPC SP 3.

7.1.1.1.1. System No. 7. Touch-up work of pump tube after welding has been done.

SURFACE

PREPARATION 1st Coat 2nd Coat 3rd Coat

SSPC SP 3 SSPC Paint 33 SSPC Paint 33 SSPC Paint 33

7.1.1.2. Performance Requirements.

7.1.1.2.1 The maximum level of vibration of the assembled pumping unit shall not be greater than 5.3 mm/s (0.21 in/s) as specified in Hydraulics Institute standard 9.6.4.

7.1.1.2.2. The pump shall be capable of operating without instability over the required range of head.

The pump/motor combination shall be non-overloading over the entire length of the pump station curve from shutoff to runout.

7.1.1.3. Bio-based Requirement. The United States Department of Agriculture (USDA) designates certain biobased products for federal procurement and specifies minimum biobased content levels for those products. Any designated product that is being offered or supplied under this contract shall meet USDA BioPreferred’s minimum biobased content level. Visit the BioPreferred web site for the complete list of designated products and the associated minimum biobased content level requirements.

7.1.1.4. Capabilities

7.1.1.4.1. Discharge not less than 23,200 gal/min against a total design head corresponding to a static head of 33.0 ft. with a water surface in the sump at Elevation 406.5.

7.1.1.4.2. Discharge not less than 14,700 gal/min against a total head corresponding to a static head of

39.25 feet with water surface in the sump at Elevation 406.5.

7.1.1.4.3. Discharge not less than 27,000 gal/min against a total head corresponding to a static head of

20.5 feet with water surface in the sump at Elevation 405.0.

7.1.2. Electrical. The work provided for herein consists of reconnecting the electrical leads to each of the pump motors to the existing power source. Contractor shall provide all expertise, plant, labor, materials, and equipment required for the evaluation and work described hereunder:

7.1.2.1. Disconnection of all sets of existing pump motor feeder cables for three existing 400hp, 460V submersible pump motors. Each pump is currently fed by six 350 MCM conductors with two 350 MCM ground conductors.

7.1.2.2. Removal of three submersible pump motors and all associated feeder cables up to the termination in respective motor junction box. Motor junction boxes are located directly adjacent to each pump.

7.1.2.3. Installation of three new submersible pump motors, as described in paragraph 7.1.1 and elsewhere herein, and all sets of associated motor feeder cables. Contractor shall determine appropriate conductor sizing based on motor specifications and as required by NFPA 70 and pump manufacturer’s recommendations. New sets of motor feeder cables shall be routed in existing conduit and terminated in existing motor junction boxes on existing terminal blocks. Contractor shall be responsible for verifying existing conduit, junction boxes, and power terminal blocks are adequate and sized appropriately per NFPA

70. Contractor responsible for phase rotation testing and ensuring new motors are installed/operating properly.

7.1.2.4. Evaluation of existing pump motor branch circuits and controls for each new motor. Contractor shall make any necessary changes to existing motor branch circuits and controls as required per NFPA 70 and as recommended by pump manufacturer to accommodate new pump motors. Existing motor branch circuits consist of but are not limited to:

7.1.2.4.1. Feeder Circuit Breaker: The pump feeders are currently protected by EATON Catalog No.

HND312T33W circuit breakers with an 800A frame rating and an 800A trip rating. Contractor shall verify existing breakers can be set to trip at an appropriate amperage based on pump motor specifications and relevant electrical codes or provide new properly-sized circuit breakers based thereon.

7.1.2.4.2. Solid State Reduced Voltage Starter (SSRV): The three submersible pumps are each equipped with an EATON IT SG11 Catalog No. S811V65P3S soft starter with external 120VAC control circuitry. The soft starter is controlled via the PLC. Contractor shall verify current soft starters are compatible with new pumps, as well as associated feeder circuitry based on electrical specifications stated in this contract, relevant codes, and manufacturer’s requirements for existing equipment. If current soft starter is not appropriate for new pumps and associated feeder circuitry, contractor shall provide new soft starter with functionalities greater than or equal to those of the current soft starter.

7.1.2.4.3. Power Factor Correction Capacitors (PFCC): The power factor of the existing pumps is corrected by an appropriate configuration of capacitor banks, connected to the motor feeders though fuses and activated while the motor is running at full-speed. The power factor correction unit used in each feeder circuit is an EATON Catalog No. 16043PMURF. Contractor shall verify existing PFCC are adequate to operate on new motor circuits and provide any necessary modifications to PFCC.

7.1.2.4.4. 120VAC control circuitry: Each motor starter has associated control circuitry consisting of control relays, time delay relays, selector switches, pushbuttons, and indicating lights. This circuitry runs on 120VAC power. The transformer supplying this power is an EATON Catalog No.

C0350E2AFB. Contractor shall verify that this existing control circuitry is compatible with all related motor control elements and that complete functionality is preserved between the existing pumps and new pumps specified in this contract. Contractor shall replace any control circuitry incompatible with the new pumps or pump operating equipment per relevant codes and standards.

7.1.2.4.5. Programmable Logic Controller (PLC): The programmable Logic Controller operates on an Allen-Bradley CompactLogix platform and consists of a 1769-L32E processor, 1769-PB2 power supply, 1769-IQ32 discrete input modules, 1769-IF16C analog input module, and a 1769-OB32 relay output module. All equipment modified or installed by the contractor pursuant to this contract shall be compatible with the existing PLC. Contractor shall verify that all current communication and logic capabilities between the PLC and connected equipment are maintained through all equipment alterations and replacements described in this contract.

7.1.2.4.6. Pump Protection Panels. Replacement of each existing Pump Protection Panels with new pump protection panels including all ancillary devices including but not limited to: control wiring, pushbutton devices, pilot lights, electronic displays, and labels. Each pump is currently monitored by a Pump Protection Panel by MWI. Contractor shall provide Pump Protection Panels recommended by pump manufacturer to be used with submersible pump motors described in paragraph 7.1.1. Power to Pump Protection Panel shall be sourced from existing circuit in lighting panel LP1. Contractor shall use existing 20A circuit breaker if possible, based on relevant electrical codes and standards. If a larger circuit breaker is required, it shall be provided by the Contractor. Contractor shall integrate new pump protection panels with existing PLC control system and motor control circuits to retain existing operating capabilities including but not limited to: alarms, sensors, inputs, outputs, communication, and logic. Contractor shall ensure that operating logic and alarm conditions are functionally identical between the old and new Pump Protection Panels based on manufacturer requirements.

7.1.3 Intake Testing. Provide complete performance model testing of the pump intake systems. Use the model testing to confirm the configuration of the intake systems, including the proposed intake conduit, hydraulic losses to the pump, the position of the pump in the intake bay, and to confirm the selection of the pump. The Contracting Officer will witness the final tests confirming the geometry for the intake conduit. Furnish the Contracting Officer with not less than 14 days written notice of the time and location for the final tests.

7.1.3.1. Qualifications. Perform the modeling work in a hydraulic laboratory located within the United States where this type of work has been performed for a period of at least ten years. The individual in responsible charge of the modeling work must be a registered professional engineer in the U.S. state where the model testing will be performed with at least ten years' experience in pump and intake modeling work for similar projects. The engineer must seal and sign all reports and data documents generated as a part of the test work prior to submitting them.

7.1.3.2. Intake Model Setup and Objective. The model intake setup must be of the intake system, custom designed for this installation and suitable for operation at atmospheric pressure for observation of the intake basin performance. The intake model must be suitable for use with a model pump. Use clean and clear water for the test to allow proper observation. The temperature of the water during any test cannot exceed 85 degrees F. For the FSI, provide a setup to determine flow patterns in the suction basin approaching the intake, along with losses to the pump. Provide further tests to identify flow patterns in the intake itself and approach patterns at the entrance to the pump. In the intake model, include all items in the intake path.

7.1.3.3. Intake Model Tests. The objective of the modeling work is to define the performance of the proposed pumping unit and to confirm the geometry to be used for the pump intake. The model must have a model-to-prototype Froude number ratio of 1, based upon the pump impeller diameter. Arrange the model in the same relative orientation as the prototype structure and include the bay configuration and screening system. Perform all testing with the same model. Intake Tests: For the intake geometry shown on the drawings, use the model setup to determine flow characteristics in the suction basin intake bay and at the entrance to the FSI at all specified operating conditions. In addition, use the model to determine the effect of the intake system on pump operating characteristics. Use a siphon generated by a separate pump to examine flow characteristics in the intake bay using Froude relationships to model intake operation in the first set of tests. Use second test to develop information on the effect of the intake on pump operation. Use these values to forecast the performance of the pump-intake conduit combination.

Alternate Intake Geometry: If an intake geometry differing from that indicated is proposed, or other modifications such as baffling, test the proposed intake and/or modifications to demonstrate its suitability for use in the project. For that reason, design the laboratory setup specifically to monitor free and sub-surface vortices, swirl and pre-rotation approaching the pump impeller, flow separation at hydraulic surfaces in the intake conduit and at the hydraulic surfaces approaching the pump impeller, and axial velocity distribution at the entrance to the impeller.

7.1.3.3.1. The intake conduit and pump inlet must contain several clear windows and similar appurtenances and adequate lighting at all critical areas to allow visual determination of the presence of vortices, turbulence, and other defects. Make provisions to insert dye at intervals in the intake conduit and at the entrance to the impeller during operation of the test. Reynolds and Weber numbers for all model runs must be greater than 30,000 and 120, respectively. The manufacturer must develop scale factors for velocity, flow, and time for use in evaluation of model results. Scale factors are subject to review by the Contracting Officer. In addition to model runs at all specified operating conditions, conduct no fewer than five runs at 1.5 times Froude-scaled flows after final geometrics for the intake conduit and intake bays have been established, keeping the submergences at the geometrically scaled values. Track and document circulation contributing to development of vortices.

7.1.3.3.2. Determine vortex formation in the model every 15 seconds extending over a period of 10 minutes. Classify vortices in accordance with the strength classification system in HI ANSI/HI 9.8 for both surface and subsurface vortices, using dye wand injection to assist in classification. The manufacturer must provide both photographic and video documentation of vortex formation. Direct particular attention to subsurface vortex formation at the intake conduit entrance and on intake conduit surfaces leading to the impeller entrance.

7.1.3.3.3. Provide a swirl meter or other satisfactory device to determine liquid rotation (swirl) at the entrance to the impeller. Obtain swirl readings at intervals of 20 seconds for a period of not less than 10 minutes after the model has achieved steady-state operation at any specified operating condition.

Swirl angle is defined by the relationship:

swirl angle = (1/tan) ((pi*d*n)/u)

Where:

u = average axial velocity at the swirl meter.

d = diameter of the conduit at the swirl meter.

n = revolutions/second at the swirl meter.

7.1.3.3.4. Also record the head loss from just upstream of the FSI to the throat of one model pump for a minimum of 10 flow rates after the model Euler number is determined to be constant and at least one point (near the middle of the data) must be within 2 percent of the scaled rated flow of the pump.

Measure head loss with a differential manometer or differential stilling basin. Install a minimum of four pressure taps around the pump throat measurement point and joined to form an average pressure reading. Calculate a dimensionless head loss coefficient for the formed inlet that includes the entrance loss into the formed inlet.

7.1.3.3.5. Determine the velocity profile in the channel cross section approaching the intake and performing the velocity traverses on perpendicular axes at the intake throat, just upstream from the impeller. Velocity measurement instruments must be capable of an accuracy of plus or minus 2 percent.

7.1.3.3.6. Use the following as criteria for acceptance of the proposed design:

(1) Free surface and sub-surface vortices entering the pump intake must be less severe than Type 1, as defined in HI ANSI/HI 9.8, unless dye core vortices appear for less than 10 percent of the time or only for pump operating conditions that are expected to be infrequent, such as the listed maximum or minimum operating conditions.

(2) Swirl angles, both maximum and average, indicated by swirl meter readings, must be less than 5 degrees. Swirl angles as great as 7 degrees will be accepted if occurring less than 10 percent of the time or for operating conditions that are expected to be infrequent, such as the listed maximum or minimum operating conditions.

(3) Velocities at points of equal radii at the throat of the intake conduit must be within 10 percent of each other.

(4) Determine NPSHR on the basis of a one percent reduction of efficiency.

(5) Time-varying velocity fluctuation (turbulence) levels as defined by a standard deviation over average velocity at a point within the pump throat must be less than 10 percent.

7.1.3.3.7. Unless otherwise specified, conform accuracy of all measurements to the levels established in HI ANSI/HI 14.6.

Recommendations from the Model Test

If the results of the intake model testing indicate that any features of the design are deficient, report this to the Contracting Officer in writing immediately. If the intake modeler has recommendation for improving the flows in the pumps, provide them in the Intake Model Test Report. Flag these as important information that requires the Contracting Officer's immediate attention. Note all recommendations considered major changes, provide any minor recommended changes to the intake as variations in the shop drawings.

7.2. Payment

7.2.1. Line Item 0001 “Pump #1 Removal, Installation and Testing of New Pump #1” Payment for Removal, Installation and Testing of New Pump #1 shall be made at the per Job Price for bid item, “Pump #1 Removal, Installation and Testing of New Pump #1”, which such price and payment shall constitute full compensation for providing all labor, plant, equipment, materials, supplies, supervision, and incidentals required for removal of existing pump, supply of new pump, installation and testing of Pump #1 and evaluation of electrical equipment associated with pump operation, disconnection, removal, and alteration as necessary for existing equipment, and installation of new pump operating equipment, completion of associated work, and submission of reports in accordance with the contract specifications.

7.2.2. Line Item 0002 “Pump #2 Removal, Installation and Testing of New Pump #2” Payment for Removal, Installation and Testing of New Pump #2 shall be made at the per Job Price for bid item, “Pump #2 Removal, Installation, and Testing of New Pump #2”, which such price and payment shall constitute full compensation for providing all labor, plant, equipment, materials, supplies, supervision, and incidentals required for removal of existing pump, supply of new pump, installation and testing of Pump #2 and evaluation of electrical equipment associated with pump operation, disconnection, removal, and alteration as necessary for existing equipment, and installation of new pump operating equipment, completion of associated work, and submission of reports in

7.2.3. Line Item 0003 “Pump #3 Removal, Installation and Testing of New Pump #3” Payment for Removal,…