SOW_Final.pdf

Council Bluff Day Use Area Lagoon Effluent Lift Station Pumping System Replacement - 2017

SECTION C – SPECIFICATIONS

COUNCIL BLUFF DAY USE AREA LAGOON EFFLUENT

LIFT STATION PUMPING SYSTEM REPLACEMENT – 2017

Latitude N 37-44-11.6 (37.7365)

Longitude W 90-54-45 (-90.9125)

MARK TWAIN NATIONAL FOREST

WASHINGTON COUNTY, MISSOURI

STATEMENT OF WORK, PROJECT LOCATION AND PERIOD OF PERFORMANCE:

1. DESCRIPTION OF WORK

The project consists of installing a new duplex lift station pumping system at the Council Bluff Day Use Area Lagoon system. Work will include pumping out the current effluent lift station, removal of the current duplex pump system including all rails, floats, pumps, wiring, junction box, control panel and piping to just past the current check valves, power washing the inside of the lift station, furnishing and installing a new duplex pump system including floats, hangers, 2” discharge piping with unions, check valves and rail systems, installing a new control panel and junction box on top of the concrete lift station using slotted strutted rail channel, furnishing and installing a new davit crane on the concrete lift station and performing all necessary operational checks to ensure the system is working properly. It is required that the Contractor provide and install a safe, secure, complete, turn-key, operational, leak free effluent lift station system of the highest quality of workmanship. All materials and equipment shall be new and from the same manufacturer, unless indicated otherwise. All removed materials shall become the property of the Contractor and shall be properly disposed of off of Government property unless otherwise indicated.

Contractor shall pay Davis-Bacon prevailing wages for Washington County for all work performed on site.

Contractor is required to obtain all necessary permits and include those costs in the bid price. Contractor shall contact 1-800-DIGRITE prior to any excavating to verify the location or absence of any buried utilities.

If the Contractor desires to provide different materials and equipment than specified, the Contractor must submit 5 WORKING DAYS PRIOR TO THE BID DUE DATE all necessary documentation, with a side-by-side comparison of the material and equipment specified and Contractor proposed, demonstrating the Contractor proposed material and equipment is equal or superior. Failure to do so will void the Contractor’s proposed material and equipment and the Contractor will be required to provide the specified materials and equipment.

2. PROJECT LOCATION

Access to the project is as follows: From St. Louis, MO, take Highway 30 West to Affton, then take Highway 21 south to Potosi and then take Highway P south and west to Highway C. Turn right and then turn left on Highway DD. Travel approximately 7 miles on Highway DD to the recreation area which is signed. The lagoon area is behind a series of locked gates. Bidders must contact Forest Service Facilities Engineer Amy Crews at 573-341-7438 to obtain entry. It is highly recommended bidders visit the site to inspect the project.

3. PERIOD OF PERFORMANCE

The waste water system must remain in operation on weekends, between Friday 6:00 AM and Monday 6:00 AM, due to peak use by the public, unless otherwise approved by the COR.

CONSTRUCTION SPECIFICATIONS, MATERIALS, SEQUENCING AND PLAN OF WORK:

This plan of work includes all of the major work elements in the general order of accomplishment. Minor additional incidental work may be necessary to complete this project. It shall be the responsibility of the contractor to identify all work elements and bid the project accordingly. If any missing elements or deviations are discovered, please bring to the attention of the Contracting Officer (CO) prior to submitting the bid package. Bids will be considered all-inclusive for the work described and no extra payment will be awarded unless substantial differing site conditions are discovered.

Contractor shall comply with the latest NEC, IPC and IBC codes. No Permits are required for this project.

ALL WORK PERFORMED INSIDE THE LIFT STATION IS A PERMIT REQUIRED CONFINED

SPACE. ALL PERSONNEL ENTERING THE TANK SHALL BE CURRENTLY CONFINED SPACE

CERTIFIED AND WILL FOLLOW ALL OSHA 29 CFR 1910 REGULATIONS. COPIES OF ALL

PERMITS, AIR QUALITY CHECKS, ETC. WILL BE PROVIDED TO THE COR PRIOR TO FINAL

PAYMENT. FAILURE OF THE CONTRACTOR TO FULLY COMPLY WITH OSHA CONFINED

SPACE REGULATIONS WILL RESULT IN THE FOREST SERVICE CONTRACTING OFFICER’S

REPRESENTATIVE (COR) OR INSPECTOR SHUTTING DOWN THE CONTRACTOR’S

OPERATIONS UNTIL FULL COMPLIANCE IS ACHIEVED. NO CLAIM AGAINST THE

GOVERNMENT FOR COMPENSATION WILL BE ALLOWED.

1. MOBILIZATION

Mobilization shall include Contractor getting all equipment and personnel to the site to do the work, insurance, bonds if needed, permits, and other costs of similar nature.

2. REMOVALS OF EXISTING LIFT STATION EQUIPMENT

Forest Service and Contractor shall ensure both lagoon outlet valves are closed so no effluent may enter the lift station. The Contractor shall pump all effluent and accumulated sludge in the lift station back into the center of the lagoon. Contractor shall remove the current duplex pump system including all rails, floats, hangers, pumps, wiring, junction box, control panel and piping to just past the current check valves. Chain used to lift pumps and FS pad locks are to remain FS property. The float hanger bracket may be reused in this contract but will be repositioned as further explained in these specifications.

Inside view of lift station. Lift station is approximately 12’3” deep from bottom of floor to top of slab, 8’ wide inside wall width and 11’ length inside wall width. There is a 7’-9” tall concrete separator wall in the lift station that separates it into 2 sections which will require 2 separate entries into the lift station. Picture shows duplex pump system rails, floats and 2” PVC pipe to remove to just past the check valves shown with arrow (check valves to be removed and replaced with new check valves).

Another view of the interior of the lift station showing the concrete separator wall.

There is no equipment to be removed from the non-pump side of the lift station.

3. CLEANING OF LIFT STATION

After all required existing equipment is removed from the lift station, the Contractor shall pressure wash all interior surfaces of the lift station and remove all debris from the lift station floor. This includes both chambers in the lift station. Overall interior of lift station is approximately 12’-3” deep from bottom of floor to top of slab, 8’ wide inside wall width and 11’ length inside wall width. There is a 7’-9” tall concrete separator wall in the lift station that separates it into 2 sections.

4. FURNISH AND INSTALL RAIL SYSTEMS, FLOATS & PUMPS

After lift station cleaning is completed, Contractor shall install 2 each FE Myers rail systems, model SRA- 150, ¾” diameter stainless steel rails and stainless steel top rail support brackets. Rails shall be installed plumb and follow manufacturer’s installation directions. Each rail system shall include a stainless steel intermediate guide bracket installed at the midpoint that securely attaches to the lift station wall, not to the vertical discharge pipe.

Contractor shall furnish and install 2 each galvanized steel chain packages FE Myers CP-75. These chain packages are 10’ long. The Contractor shall reuse portions of the existing stainless steel chain removed from the lift station to lengthen the new chains so there is at least 5 feet of chain extending above the lift station. FS will provide padlocks as needed to secure the chain.

Contractor shall furnish and install all new 2” Sch 80 PVC piping to replace what was removed. This shall include reducer, vertical pipe, 90 degree elbow, union, check valve and any other pipe fitting needed for each pump. All piping shall be installed vertically and horizontal plumb using proper solvents or threaded connections.

The Contractor may reuse the removed existing float hanger to hang the floats. The float hanger shall be securely hung, using appropriate concrete anchors, near the pump hatch opening such that the floats can be easily reached without entering the lift station for readjustment yet will not interfere with pump operation, removal or reinstallation.

Side view inside lift station showing corroded junction box, float hanger, and associated wiring to be removed.

Contractor furnished and installed floats shall be mercury free level float switches made of durable polypropylene material construction. Floats shall be solid propylene foam interior that is leak-proof, shock-proof and impact resistant and made specifically for sewage and wastewater applications. There shall be 4 each normally open float switches positioned for pumps off, lead pump on, lag pump on and high water alarm. There shall be 1 each normally closed float switch positioned for redundant pumps off-low water alarm. All floats shall be labeled at the float hanger bracket. Float elevations shall be set as follows:

o Redundant pumps off-low water alarm = level with the top of the pumps o Pumps off = 4” above the top of the pumps o Lead pump on = 19” above the top of the pumps o Lag pump on = 22” above the top of the pumps o High water alarm on = 25” above the top of the pumps

Contractor shall furnish and install 2 each FE Myers P102D effluent pumps on the rail systems and connect power chords to the junction box and control panel. Junction box is NOT to be located in the lift station but will be located at the control panel. Contractor to verify pumps are properly lubricated and seat correctly on the rail systems.

Float and pump wires are to exit the side of the lift station in conduit so as no trip or tangle hazard is present. Conduit to lift station connection shall be waterproof. Contractor shall ensure all float cords and pump power cords are long enough to reach the junction box at the control panel so no splices are required.

Two copies of all product documentation, warranty, literature, O&M plans, etc. for the rail system, floats and pumps shall be provided to the COR.

5. FURNISH & INSTALL CONTROL PANEL AND JUNCTION BOX

Bid item shall include all installation and incidental costs. Contractor shall furnish and install a new NEMA 4X duplex control panel by FE Meyers with the following features:

o Terminals for the pump power cords o Thermal magnetic pump branch circuit breakers o Separate circuit breaker for the control and alarm circuit o IEC rated starter and ambient compensated class 10 overload relays o H-O-A switches and green pump running lights mounted inside the enclosure o Duplex diversified alternator o Automatic reset pump motor heat sensor circuit o 24 hour timer programmable controller system – due to site usage restrictions, this system can only pump during the time frame midnight to 6 AM. The system should run only one pump at a time each day. Dose is 750+/- gallons. Pump rate should be around 33 gpm and run for around 23 minutes.

o ABZ – Alarm buzzer – PUSH TO TEST switch mounted inside the enclosure and PUSH TO SILENCE switch mounted on the enclosure side o ACH – 50 watt anti-condensation heater and thermostat o ANL – Alarm light on panel (This is standard on the NEMA 4X panel).

o CCD – Cycle counter for each pump mounted inside the enclosure with pump # label o CO – 120 V, 15 amp, GFI, duplex convenience outlet o ETMD – Elapsed time meter for each pump mounted inside the enclosure with pump # label o HWTA - High water alarm activation and dry contact activation with push to test switch o LS1 – Lightening arrestor(single phase) o LWTA – Low water alarm activation, dry contact activation, and redundant pumps off.

o N4XFRB – NEMA 4x Fiberglass enclosure o SDF – Aluminum swing dead front inner door. Does not include main circuit breaker or disconnect.

o SFD – Seal fail indication for each pump mounted inside the enclosure

Junction box shall be NEMA 4X fiberglass enclosure. Contractor shall furnish and install a NEMA 4X, hinged cover, gray fiberglass junction box sized 10” x 8” x 6”. All wires in the junction box shall be clearly labeled as to their operation (which float, which pump, etc.).

Control panel and junction box shall be installed where indicated in the below picture. This will require the Contractor to extend the existing power supply wires. Existing wires are #10 AWG copper. Contractor shall comply with the current NEC for all wiring and installations. All wiring shall be in metal or PVC conduit (floats, pumps, power supply, etc.) when it is located outside of the lift station. Conduit shall be buried alongside the lift station until it needs to rise up to the junction box. Multiple conduit runs may be used if Contractor chooses.

6. FURNISH & INSTALL DAVIT CRANE

Contractor shall furnish and install a Thern Ensign Series 1200 pound max capacity portable davit crane, product number 5PA10G-M1 (galvanized) with a M4312PB-K spur gear hand winch. Base shall be a Thern Ensign Series 1000 pedestal base, product number 5BP10G (galvanized) with anchor bolt kit product number AN62A-6. Note – concrete must be 6” thick to use these anchors. As-built drawings show the thickness of the lift station top slab to be 6”. Contractor shall field verify prior to drilling anchor holes.

Cable shall be Thern product number WA25-60NS (galvanized, 60 feet long). Contractor shall demonstrate the davit crane through its full motion of movement and use it to remove and reinstall both pumps with FS personnel present. This demonstration can be done during the pressure test and system operation, but it must be done at the beginning of the tests, not after the pumps have been put through their operation. Two copies of all product documentation, warranty, literature, O&M plans, etc. for the davit crane shall be provided to the COR.

Contractor to install new duplex pump control box and junction box in the location indicated with the panel door facing the direction of the arrow. The control panel shall be mounted above the junction panel on a frame securely placed and attached on top of the lift station. The frame shall consist of electrogalvanized slotted strutted channel 1-5/8” wide.

The best configuration of the frame shall be determined by the Contractor once the orientation, control panel and junction panel are on site. Top of control panel shall be no higher than 5’ above the top of the lift station.

7. PRESSURE TEST AND SYSTEM OPERATION

After all connections are made, the Contractor shall perform a pressure test and system operation, in the presence of the COR. The test shall show there are no leaks with the new piping and pump systems installed by the Contractor under full pump operating pressure. Each float shall be operated to show they operate as designed. The system operation shall clearly show the pumps automatically alternate, lead and lag pumps will both operate at the same time, all hour meters and event counters work, the timer is set correctly, alarm sounds, all operating lights work, the condensation heater works and the convenience outlet works properly including the GFCI.

8. SITE CLEANUP AND CONTRACT CLOSEOUT AFTER SUCCESSFUL PRESSURE TEST AND

SYSTEM OPERATION

Contractor shall remove all construction debris from the site and properly dispose of off of Government property. The top of the lift station, adjoining chlorine tablet chamber, new control panel, junction box, supporting frame and davit shall be clean and free of debris, soil, etc. All excavation for conduit shall be raked smooth. Seeding is not required.

Contractor shall ensure two copies of all product literature is provided to the COR. This includes, but is not limited to, pump, control panel and davit manuals, product info on floats, rail system, chain packages, brackets, hangers, slotted strutted channel and junction box, copies of Confined Space Entry permits and any obtained permits.

Proposed location of davit base. Davit shall be installed to fully utilize the reach and height of the davit so one person can easily lift out and reset the new effluent pumps in the rail systems. COR shall determine the final location of the davit installation with input from the lagoon operator.