Atch 1_PWS_24 April 2024.pdf

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Performance Work Statement For

Belt Filter Press Control Panel Replacement Dated 24 April 2024

1. Requirement

1.1. Scope. Whiteman Air Force Base Wastewater Treatment Plant is requesting proposals for the removal of the existing Belt Filter Press Control Panel in addition to the fabrication and installation of a new Belt Filter Press Control Panel. The existing control panel was manufactured in 1991. Most of the existing components are no longer manufactured making maintenance difficult. Contractors are required to replicate the existing functionality of the control panel with modern components and perform functional upgrades as outlined below.

1.2. Functional Upgrades.

1.2.1. Enclosure shall be 304 Stainless Steel Field Terminal Box with three-point latching mechanism.

1.2.2. Provide three phase monitor and prevent all motors from operating during a three-phase fault.

1.2.3. Remove speed control and feedback for Sludge Pump 1 and 2. The speed for these pumps will be controlled and monitored from the existing power control room. Start and Stop control will still be controlled by the Belt Filter Press Control Panel.

1.2.4. Remove all polymer control. This will be controlled from the existing polymer control panel. (Speed and Start/Stop control)

1.2.5. Provide Mixer Motor control circuit.

• Provide single phase 208VAC motor control with electronic overloads for existing added mixer.

• Troubleshoot wiring to ensure functionality of control panel

• Include Hand OFF Auto selector switch.

• Include red run pilot light.

• Include green stop pilot light.

1.3. Existing Schematics.

1.3.1. Please see the attached Belt Filter Control Panel schematics dated 08-26-1991 for design reference.

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2. Qualifications

2.1.1. Contractors including electricians, technicians, programmers, and system integrators shall have completed a minimum of 2-3 similarly complex projects; proven capability to the skills necessary to remove the existing panel in addition to fabricate, install, and troubleshoot the new panel.

3. Contractor Responsibilities

3.1. Task 1 Removal of Existing Panel

3.1.1. Removal and disposal of existing panel from the government installation shall be the responsibility of the Contractor. The Government will disconnect power to the existing panel. Contractor will disconnect all power and control wiring including conduits.

Contractor will unbolt and remove existing panel without causing damage to other processes or facility components. All panel components will be disposed of and not reused.

3.2. Task 2 Fabrication of New Panel Specifications

3.2.1. General Requirements

3.2.1.1. New Belt Filter Press Control Panel SHALL NOT reuse old control panel components.

3.2.1.2. Enclosures

• Main Enclosure. Shall be a 304 stainless-steel free-standing enclosure with stainless feet. Must include three-point latching hardware on each door, stainless feet, right hand flange mount disconnect, and be a minimum size of 60” high, 60” wide, and 12” deep. Subpanel shall be white powder coated steel. Finished enclosure shall maintain a Type 4X rating. All entries shall use field installed conduit sealing fittings that utilize a poured sealing compound.

• Field Terminal Box. A field terminal box shall be provided and installed over the existing through slab conduits. The enclosure shall be a minimum of 24” high, 30” wide and 10” deep. Provide with aluminum subpanel. Installation to the Main Enclosure shall use conduit sealing fittings that utilize a poured sealing compound. Provide a minimum of two spare conduit sealing fittings installed and poured between the Field Terminal Box and Main Enclosure. All conduit sealing fittings between the Field Terminal Box and Main Enclosure shall be the same trade size.

3.2.1.3. Overcurrent Protection

• Main Breaker: The Belt Filter Control Panel shall be provided with an Allen- Bradley or equivalent flange mounted Type 4X handle mechanism and a 60A main breaker.

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• Control Breaker: All control breakers shall be Allen-Bradley or equivalent Din Rail mount. Fuses will not be accepted.

• Motor Protection: All motors shall have a breaker. Fuses will not be accepted.

3.2.1.4. Phase Monitor.

• Add a three-phase monitor to the control panel.

• Phase monitor shall be rated for 190VAC to 500VAC and be manufactured by Macromatic or equivalent. Shall include dial adjustment knobs for; unbalance, voltage line to line, undervoltage trip %, trip delay, restart delay and protect against; phase reversal, phase loss, phase unbalance, overvoltage, and undervoltage.

• Provide one white push-to-test pilot light to indicate three phase power is OK. When pushed the light shall be off.

3.2.1.5. Motor Control.

• The control panel will include NEMA or equivalent starters for the following motors.

They will include electronic adjustable overloads. All motor starters shall be of the same series.

• Hydraulic Pump (Three Phase, 1-1/2HP, 5.3FLA @ 208VAC)

• Wash Pump #1 (Three Phase, 5HP, 13.3FLA @ 200VAC)

• Wash Pump #2 (Three Phase 5HP, 13.8FLA @ 208VAC)

• Mixer (Single Phase, 1/2HP, 4.4 FLA @ 208-230VAC)

• Belt Drive Motor

• Three Phase, 2HP, 7.0 FLA @ 208VAC

• Provide an Allen-Bradley Power Flex 525 for the Belt Drive.

• “CF1” Cooling Fan is not required for the VFD.

3.2.1.6. Pilot Devices. Selector switches and pilot lights shall be 30.5mm corrosion resistant, Allen-Bradley 800H or equivalent. Control panel shall use the same series for all types of pilot devices. Pilot Lights shall be push-to-test LED and match the existing Belt Filter Press Control Panel layout.

3.2.1.7. Control Relays shall be 4 Pole, Double Pole, 120VAC, Allen-Bradley or equivalent with general purpose silver contacts. Shall include a push-to-test function and LED indicator light.

3.2.1.8. Timers shall be 120VAC, Allen-Bradley 700-HR or equivalent. Shall include a front mounted dial and selectable ranges.

3.2.1.9. Terminals shall be Allen-Bradley or equivalent, IEC, finger safe, screw type with a minimum width of 0.24”. Terminals shall be labeled according to Section 05, by a computer-based system, on both sides. Hand drawn terminal labels will not be accepted or allowed.

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3.2.1.10. Control Power Transformer. Provide control power transformer with a maximum size of 750VA, single phase 208VAC to 120VAC. With the exception of analog control signals all control circuits shall be 120VAC.

3.2.1.11. Control Panel Labels. Provide labels for all pilot devices on the control panel doors. Labels cannot be attached with fasteners through the door. Labels may be attached with adhesive or be held on by the pilot device(s) as long as the label does not interfere with the type 4X rating of the enclosure. All Wires must be labeled with a computer-based marking system at each end of the wire and be labeled according to Section 3.2.2 Schematics. Hand drawn wire labels will not be accepted.

3.2.2. Schematics Requirements

• Tabloid (11” x 17”)

• Shall be generated in a CAD program. (Text based ASCII schematics will not be accepted.)

• Shall utilize rung numbers:

• The rung numbers shall determine the device name.

• The rung number shall determine the wire and terminal number.

• Relays coils shall include rung cross-references to corresponding contacts.

• Provide a minimum of two hard copies of As-Built Schematics in the Belt

Filter Press Control Panel.

• As-Builts must be approved by the Government’s technical expert prior to acceptance

• Provide digital pdf copy.

• Provide digital CAD drawing(s) in an AutoCAD format.

3.3. Task 3 Installation

3.3.1. Installation shall begin following fabrication and must occur and be completed within

30 days of existing panel removal.

3.4. Task 4 Troubleshooting

3.4.1. All functions performed by the panel shall be included in troubleshooting and must be successfully resolved within 30 days of existing panel removal. Troubleshooting will occur on the entire panel. All functions performed by the panel must be checked.

4. Project Closeout and Documentation Requirements

4.1. Provide two physical Operation and Maintenance Manuals that shall include the following at a minimum:

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• Component list with quantities used, part numbers, description, supplier, and contact information.

• As-Built Schematics.

• Product Data Sheets.

• Signed certification of panel functionality from Contractor.

4.2. Spares. Upon completion of installation and troubleshooting, the Contractor shall provide the following spare parts:

• One Three Phase monitor with base.

• Two Relays and Bases of each type used.

• One Timing Relay and Base of each type used.

• One of each type of momentary push button used.

• One of each type of rotary switch used.

• Three switches of each type of contact block used.

• One of each type of Pilot Light used.

• Three replacement pilot light LEDs of each type used.

4.3. Warranties

4.3.1. Proposal shall include one year warranty for all services, parts and labor provided, and a two-year warranty for all components, that shall start after final documentation approval.

5. Government Responsibilities

5.1. Smoking Areas. While on WAFB, smoking is only permitted in designated smoking areas. Contact the building facility manager and/or Government representative for areas where smoking is permitted.

6. General Information

6.1. Document Formats. Documents, plans, reports, etc., will be provided electronically using Microsoft Office products to the CO/CA and Government Task Lead (GTL). Exception is forms already in Adobe Acrobat PDF format. Errors shall be corrected within two business days of notification. All forms and reports shall be kept on site and readily available for the duration of the contract then turned over to CO/CA and GTL.

6.2. Travel and Transportation. The Contractor is responsible for mobilization of personnel and equipment to and from all individual facilities including all shipping, delivery of materials, loading and offloading of materials, tools, and necessary equipment, including storage, to perform the required activities to accomplish the PWS.

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6.3. PoP. The Period of Performance (PoP) shall be 6 months from the signing of the award.

All removal, fabrication, installation, and troubleshooting shall occur within the PoP.

6.4. Hours of Service. The Contractor shall provide core service between the hours of 0730- 1630 on Monday through Friday. During normal duty hours, Contractor point of contracts (POC) is the Government Task Lead (GTL).

6.5. Identification of Contractor Employees. All Contractor personnel attending meetings, answering Government telephones, and working in other situations where their Contractor status is not obvious to third parties are required to identify themselves as such to avoid creating an impression that they are Government employees. The Contractor shall ensure that all documents or reports produced by Contractor personnel are suitably marked as Contractor products or that Contractor participation is appropriately disclosed. The Contractor’s status as a “Contractor” shall be predominantly displayed in all correspondence types (to include signature blocks on e-mail) and dealings with Government or non-Government entities.

6.6. Contractor Required Identification. All Contractor personnel shall be required to obtain and wear badges or Contractor specific clothing, etc., in the performance of this contract. The badges or clothing shall have the company name, employee name, and the word “Contractor” displayed prominently and in a visible location.

7. Attachments

7.1. Existing Schematics

END OF PERFORMANCE WORK STATEMENT