Attach-1-SOW.pdf

STATEMENT OF WORK

TO

21-022 REPAIR WELLS BATCH 1

AT

MONTE VISTA NATIONAL WILDLIFE REFUGE

I. GENERAL CONDITIONS

A. The Contractor shall provide all material, equipment, and labor required to install and/or repair water wells and all appetences outlined in Section VIII.

B. The Contractor shall be responsible for installing all materials described in Section

VIII.

C. The Contractor shall have all certificates and licenses required by law for the execution of the work, and shall comply with all Federal, State, or local laws, ordinances, rules, regulations, and codes relating to performance of the work.

D. Typical working hours are 7:30 am to 4:00 pm Monday through Friday. Any work that deviates from this schedule or during a holiday requires Contracting Officer approval. These times can be negotiable during the pre-construction meeting.

E. Any conflict or overlap of Colorado Department of Environmental Quality, EPA, OSHA, and other applicable Federal, State, and local regulations, the Contractor shall follow the most stringent provision.

F. Safety

1. The Contractor shall assume full responsibility and liability for compliance with all applicable Federal, State, and local regulations pertaining to the protection of workers, visitors to the site, and persons occupying areas adjacent to the site, including the provisions of 29CFR1910 and 29CFR1926 of the Code of Federal Regulations. The Contractor shall hold harmless the

Government for failure to comply with any applicable safety or health regulations on the part of himself, his employees, or his subcontractors.

2. Every Contractor employee shall be responsible for complying with applicable safety requirements, wearing prescribed safety equipment, and preventing avoidable accidents and property damage.

3. The Contractor shall provide and maintain a basic first aid kit for use of the workers. The kit shall contain first aid supplies in type and quantity commensurate with type and size of project and the work force, with items necessary for first aid treatment of all injuries. The Contractor shall advise all workers of the location of first aid supplies.

4. The Contractor shall post the telephone numbers of nearest hospital, ambulance service, and fire station in a conspicuous location. The

Contractor shall advise all workers of the location of telephone numbers.

Communication devices shall be made available and be ready at the work site to alert others in case of emergencies.

5. The Contractor shall provide at least one nonfreezing type fire extinguisher in each field office, workshop, work site, and storage shed at the work site. These fire extinguishers shall be placed in locations readily accessible by workers.

II. WORK SITE CONDITIONS

A. The site of the work is at Monte Vista National Wildlife Refuge.

B. The Contractor is responsible for following all federal, state, and local laws.

C. Environmental Litigation

1. Time lost due to work stoppage because of failure of the Contractor to comply with these requirements may not be the subject of a claim for extension of time or for costs or damages.

D. Fossils and Cultural Materials:

1. Should the Contractor discover any fossils or cultural materials during construction operations, such objects shall become the property of the

Government. The Contractor shall cease construction operations in the area of the "find," and immediately notify the station manager of such discovery.

Construction operations may proceed in other areas not affected by this clause. Care shall be exercised by the Contractor not to damage or collect fossils or cultural materials uncovered during excavation operations.

2. Failure to comply with this requirement may be considered a violation of the

Archeological Resources Protection Act of 1979 as amended. Destruction of historic and prehistoric sites and/or unauthorized collection of cultural materials can result in criminal and/or civil penalties. Penalties can include fines, prison sentences, and/or confiscation of equipment.

III. TEMPORARY FACILITIES AND CONTROLS

A. Temporary Utilities

1. The site does not have access to electricity, sanitary sewer, or drinking water.

The Contractor shall supply a porta-john.

2. The Contractor shall be responsible for the daily removal and disposal of all debris from demolition and construction activities.

B. Site access and equipment storage areas

1. All Contractor operations (including storage of materials) upon

Government premises shall be confined to areas authorized or approved by the Refuge Manager, or her designee.

2. The Contractor shall restore all work and storage areas and areas disturbed by construction to their original condition, or as approved by the Refuge

Manager, or her designee, upon completion of the work

3. The Contractor shall observe all laws and regulations of the local, county, and State authorities in the use of all public roads and highways for the transportation of materials and equipment in connection with work on the project.

4. The Contractor shall observe all overhead obstructions such as bridges, cables, ect. The Contractor shall repair damage to roads, highways, overhead obstructions, and similar items, resulting from operations performed in connection with this project.

C. Protection and Restoration:

1. The Contractor shall protect all structures and vegetation during the progress of the work and remove all debris and unused materials from the site.

2. Upon completion of the work, the Contractor shall restore, at their expense, all vegetation to its original condition, including the replacement any facility or landscaping which has been damaged.

3. The Contractor shall limit removal of any vegetation to that which interferes with the construction, and shall seed any disturbed soil with native grass. The Contractor shall obtain the seed mix from the Refuge Manager.

D. Traffic Regulation

1. If traffic regulation is required at the jobsite, the Contractor shall provide, erect, and maintain all necessary barricades, suitable and sufficient flasher lights, flagmen, danger signals and signs, and shall take all necessary precautions for the protection of the work and the safety of the public.

2. Roads closed to traffic shall be protected by effective barricades on which shall be placed acceptable warning signs.

a. All barricades and obstructions shall be illuminated at night and all lights shall be kept burning from sunset until sunrise.

3. Install appropriate traffic signs at crossroads and approaches to site as needed to direct all affected traffic. Specific sign and barricade requirements are detailed in ANSI D61, "Manual on Uniform Traffic Control Devices."

E. Delivery and Storage: Material shall be delivered to the site in a dry and undamaged condition and stored out of contact with the ground. Materials shall be covered with weather tight covering and kept dry. Storage accommodations shall provide good air circulation and protection from surface staining, when appropriate.

IV. MEANS AND METHODS

A. Means and methods of construction shall be such as the Contractor or subcontractors may choose; subject, however, to the Contracting Officer's right to reject means and methods proposed which:

1. Constitute a hazard to the work, persons, or property.

2. Will not produce finished work according to the terms of the contract.

3. Are contrary to specified means or methods included in the contract.

B. The right to reject means and methods of the Contractor or subcontractor shall not be construed or interpreted as acceptance of control of means and methods by the

Contracting Officer.

C. The Contracting Officer's approval of means and methods or failure to exercise right to reject means and methods shall not relieve the Contractor of the obligation to complete the work required by the contract.

D. Total responsibility for control of all means and methods lies with the Contractor for all work.

E. Final Inspection

1. The Contractor shall request a final inspection in writing at least ten (10) days prior to the anticipated date of completion. If, as the anticipated date of completion approaches and it becomes apparent that the date will not be met, the Contractor shall inform the Contracting Officer at the earliest possible moment, but in any case not later than 2 business days prior to the anticipated completion date.

2. Work will not be considered READY FOR FINAL INSPECTION until all the work has been completed and the Contractor has certified that all items are properly operating and in strict compliance with all contract terms and conditions.

3. The Contractor and/or his project supervisor shall be at the job site during the final inspection.

F. Final Cleanup: The Contractor shall clean the site and remove from the site all construction debris.

G. Final Payment: The Contractor shall submit the following prior to final payment:

evidence of completion, guarantees, warranties, O&M manual, certificates, certified payrolls, and as-builts.

V. CONTRACTOR QUALIFICATIONS

A. The Contractor and all subcontractors shall have all Federal, State, and local licenses, and/or certifications, etc., necessary to perform work in Rio Grande

County, Colorado. All licenses and/or certificates must be current from start to finish of the project.

VI. SUBMITTALS

A. The Contractor shall provide copies of all required permits, clearance, and licenses obtained to perform this work to the Contracting Office.

B. If alternatives to the means and materials described in these specifications are offered, the submittal must contain a written description of the proposed means and materials comparing all features, options, and codes (if any), in detail. A detailed explanation of why the proposed alternative should be accepted must also be submitted.

D. The Contractor shall submit manufacturer's warranties, guarantees, and certificates for all installed equipment listed on the Project Submittal List.

E. Timing of Submittals/Unapproved Work: As specified above, the Contractor shall submit all deliverables, copies of all required permits, and all product data sheets to the Contracting Officer for review. These submittals must be approved PRIOR to the installation of any purchased or fabricated components. THE PURCHASE AND/OR

INSTALLATION OF ANY UNAPPROVED COMPONENTS SHALL BE AT THE CONTRACTOR’S

RISK. Contract performance time shall not be extended due to delays caused either directly or indirectly by the purchase and/or installation of unapproved components.

F. All items in Section VIII shall be submitted for approval.

G. The attached submittal form shall be used.

VII. PERFORMANCE

A. The pump, piping, and all other materials shall be installed according to the manufacturer’s instructions.

B. The pump shall be protected against freezing conditions during installation.

C. The Contractor shall coordinate the construction start date with the Contracting

Officer. The project shall be completed and available for use within 120 calendar days from the date the Notice to Proceed (NTP) is issued. Additional time will be allowed, if needed, to obtain permits and lead times for materials. Construction will not continue on Saturdays, Sundays, or Federal Government holidays without prior permission of the Contracting Officer.

D. During the performance period of the contract, the Contractor shall be available for conference calls as needed with the Contracting Officer, the Contracting Officer’s

Representative (COR), and the Government On-Site Inspector to discuss project progress and/or problems.

E. The Contractor shall obtain all permits and licenses, pay all fees and taxes, and give the notices necessary to perform the services of the contract. The Contractor shall submit all permits and licenses, and receipts for all fees and taxes paid.

F. The Contractor shall be liable for damages to roads, utilities, structures, and property, due to any act, omission, neglect, or misconduct during the period of performance of the services of this contract, unless the Government provided that portion of work that directly damaged one of these items.

G. The Contractor is responsible for completing the job to the specifications outlined in this document. The presence of an inspection does not preclude the Contractor from following this document and the specifications outlined.

VIII. PROJECT REQUIREMENTS

A. Any removal of materials not outlined in this project shall be placed in a condition the same, or better, prior to the start of the project.

B. All materials and workmanship shall have a one-year warranty of work.

C. All estimated quantities can be found in the bid schedule and/or reports.

D. All materials that are replaced or removed is the property of the Contractor. If

USFWS wants any parts, the contract will be modified to incorporate the change in the contract.

E. All specific materials listed in the reports are considered or equal.

F. Well #1

1. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates G.A to G.E. Additionally the well shall have the following completed:

a. Electrical components mentioned in the report.

b. The pump head loss of the new piping and piping system should be considered when sizing a motor and pump.

c. Provide new pump and motor that pumps a maximum rate of 1,500 GPM with the total head of the system. Refer to the attached report for recommended

d. No timeline limitation of construction.

G. Well #5

1. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates A-1 to G, not A. Additionally the well shall have the following completed:

a. The pump head loss of the new piping and piping system should be considered when sizing a motor and pump.

b. Provide new pump and motor that pumps a maximum rate of 2,200 GPM with the total head of the system. Refer to the attached report for the recommended rate of pumping, if any.

c. No timeline limitation of construction.

H. Well #11

1. The work shall be completed by April 1st.

2. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates A to D. Additionally the well shall have the following completed:

a. Abandon existing line to reservoir by severing the connection to the new connection. The new connection shall be a mechanical joint fitting with a thrust block. The mechanical joint fitting shall be a tee with the third opening pointing towards the abandoned line. The tee end shall have a mechanical joint cap. The new line shall have a check valve located near the tee.

b. The pump head loss of the new piping and piping system should be considered when sizing a motor and pump. The demand of the center pivot shall also be considered.

c. Provide new pump and motor that pumps a maximum rate of 1,800 GPM with the total head of the system. Refer to the attached report for the recommended rate of pumping, if any.

d. The well can be worked on between the months of October to end of

March.

I. Well #51

1. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates A to D. Additionally the well shall have the following completed:

a. Provide new pump and motor that pumps a maximum rate of 2,320 GPM with the total head of the system. Refer to the attached report for the recommended rate of pumping, if any.

b. Item D shall be the new pump option.

c. Electrical components mentioned in the report.

d. No timeline limitation of construction.

J. Well #56

1. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates B to D. Additionally the well shall have the following completed:

a. Provide new pump and motor that pumps a maximum rate of 2,200 GPM with the total head of the system. Refer to the attached report for the recommended rate of pumping, if any.

b. The system requires a new electrical box, but the system does not require a VFD.

c. Well needs to be completed first

K. Well #61

1. The Contractor shall provide a product that aligns with the Ecodynamics Inc

Well Inspection and Evaluation Report. This includes all items in section

Cost Estimates A to H. Additionally the well shall have the following completed:

a. Provide new pump and motor that pumps a maximum rate of 2,000 GPM with the total head of the system. Refer to the attached report for the recommended rate of pumping, if any.

b. The casing shall be lined and grouted to prevent future erosion.

c. No timeline limitation of construction.

L. All well discharge pipes shall be verified for regulations, if the system is modified.

IX. POINTS OF CONTACT

A. Refuge Manager

1. Suzanne Beauchaine (719-588-3473)

B. Contracting Officer Representative / Technical Representative

1. Michael Wandersee (303-236-4479)

END OF STATEMENT OF WORK

5492 EAST US HWY 160 – Monte Vista, Co 81144 – Phone 719-852-2662 - License 1488

Page 1of 7

Well Inspection and Evaluation Report

Report Date: 10-14-2020

Monte Vista Wildlife Refuge

Well # 1 – Permit # 283-R

Well Construction Year: 1954

A. General Overview:

The 30 HP GE motor on this well was not running and numerous mouse nests were found inside the housing and the connection box.

The discharge plumbing of this well is very long and heavy and no flexible connection is installed between the pump head and the pipe.

The gate valve of the free flow plumbing was found stuck in a half open position

It appears that pulling of a pump from a well is always filled with surprises: This pump was recently modified from its original type into an oil lube (enclosed line shaft) version by re-using the existing open line shaft column pipe. The difference between both types is simply the overall length. 120 inch or 240 inch butt to butt surface on oil lube type column and 119.25 inch on water lube. That is to allow the centralizing bearing (spider) of the water lube type column to be “sandwiched” between the precisely machined butt surfaces of the column ends. It is important to understand that in both types the designation butt thread refers to this method of sealing between column sections. This is done by the two machined surfaces threaded tightly together and in contrast to the taper threads of a standard pipe fitting which seals at the threaded area. Butt threads are easier to dis-assemble and guarantee precise alignment of the pump column for the line shaft (power transmitting rotating shaft hate to be misaligned) and the guarantee the same stick-up of the shafting of the bowl assembly all the way up to the discharge. Many may believe – and unfortunately among them licensed pump installers – that pump work consists of screwing together big pipes with heavy equipment. In reality it is precision machinery and small errors are often multiplied in magnitude up the column assembly.

C. Electrical:

The electrical system is in good condition and in conformity with the codes. Only a damaged conduit section from the ground surface to the motor connection box must be replaced.

All electrical components within the pump panel are in good, almost new condition and the wire seizes are corresponding to the HP seize of the driver. This electrical service has been installed not too long ago.

Longer motor leads will have to be installed depending on the new motor.

D. Well Components:

Discharge Head: When this pump was converted from open into closed line shaft type a tube tension box was installed by bonding with epoxy glue. Replacement of the head will be less expensive than any attempt of removal of this tension box and the rusted in tight top column section.

Pump Column: 10 inch Butt Thread open line shaft type sections were combined with 10 ft.

enclosed line shaft assemblies. (Please refer to the general discussion above for further details) The total column setting as pulled from the well: 105 feet = 10 sections of 10 feet and a 5 ft. top column. The pump column has considerable pitting but may be re-used with a life expectancy of +- 10 years remaining. Butt seal spacers will be required between column butt surfaces if it is desired to keep the enclosed line shaft design. Conversion back to open line shaft with 4 upper centralizing bearings in Vesconite (limited dry run) will be the best and least expensive way to re-install this pump.

Inner Column: Inner column assemblies are in good condition and can be re-used if it is decided to re-install the pump as enclosed line shaft type.

Some water was found inside the oil tubes instead of oil which was lost into the well.

(For further technical details please refer to our pull sheet)

Bowl Assembly: We dis-assembled the 2 stage bowl and found it in fair and serviceable condition.

We could not find a data plate and were unable to positively identify type and manufacturer.

According to the pump test the bowl has a total dynamic head of +- 60 feet at 1100 GPM. Some galvanic corrosion and pitting may result from stray voltage being transmitted through the motor ground lead and should be checked for between ground wire and well casing when re-installing the pump.

Driver:

The motor is a 30 HP older style General Electric hollow shaft type.

Amperage reading could not be taken as the motor was inoperative due to extensive mouse damage and the pump test was completed with a combustion engine. By running the numbers from the pump test based upon a 53 feet pumping water level, 100 feet of column and a flow rate of 1200 GPM the total horsepower requirements for this pump can be calculated at 23.86 and a 30 HP motor is sufficient for this pump at 7500 feet of elevation. As an alternative the 40 HP motor from well # 51 can be used as it will be available.

The conduit of the motor leads was pulled out from the connection box.

E. Well Casing Evaluation:

The slider of the (obsolete) free flow discharge is half open and some rodents had built a nest inside the pipe on the side of the well casing.

The upper 16” diameter casing section reaches down to

141.6 feet and appears in fair condition with some metallic corrosion. The water in this section is stagnant and cloudy and the oil on top of the water being slowly decomposed by bacteria and algae has certainly contributed to this.

The intersection of upper and lower casings is well sealed with no indication of circulation of water between aquifers to be detected.

Perforations are mostly open and are confirmed from 220 feet to the well bottom.

The well bottom or fill level was found at 392 feet from the well seal plate and just shy of 8 feet from the records.

Please watch the video for further details.

In general it may be stated that this well is in a fair shape and still has a lot of service life remaining. With the static level now at 32 feet we should not expect it to free-flow again and this additional piping is obsolete and should be removed and the hole in the casing properly welded closed to protect the ground water.

F. Recommended Action:

With my following recommendations I will outline the technically correct solutions as well as justifiable cost saving “short cuts” if options are available. My recommendations will therefore make the difference by using the terms “must” or “should”.

Well Casing:

An adequately sized well seal plate must be installed on top of the casing to support the discharge head. The free flow discharge plumbing should be removed and the connection flange at the casing capped.

Pump Repair:

With a shallow static water level of 32 feet this pump should be designed as an open line-shaft pump (water lube) with the 4 upper line shaft bearings in Vesconite with (limited) dry run capabilities. Open line shaft conversion will allow re-installing most of the 9’ 11 ¾” column sections with recommended 1 3/16 stainless steel shafting and new centralizing spiders. It will eliminate the needs for drip oil and solve the shaft corrosion problem.

The discharge head should be replaced rather than investing labor for recovery attempts (only if open line shaft is installed). I always recommend the installation of a mechanical seal instead of a packing box as they eliminate maintenance which is often neglected and results in water spraying into the foot bearing of the motor. A 5 feet top column section with a special shaft must be installed in order to provide proper guidance for the top shafting. The special shaft starts inside the 5 ft. top column and reaches through the 2 ft. head nipple and stretch tube into the discharge head.

The bill of material includes:

New High Quality Flowise Discharge Head New Head Nipple 24” New Top Column 10” x 48.25” x 0.28 Wall Water Lube New Special Shaft, SS 416 and new Head Shaft New Bowl Column 10” x 48.25” x 0.28 Wall Water Lube 9 new SS 416 shafting 3/16 x 10 ft.

1 new SS 416 shafting 3/16 x 5 ft.

4 new spiders SS 304 10x2 with Vesconite Bearing (limited dry run) 7 new spiders standard Bearing (below static water level) New John Crane Series 5600 mechanical seal with new discharge bearing

C.) Well Head repairs: including:

Removal of the defective gate valve and free flow discharge plumbing.

Installation of a new ¾” thick well seal plate matching the discharge head base flange

D.) New Discharge Assembly as follows:

Dimensioned to match the flow meter requirements and to discharge into the existing structure

Fabricated adjustable steel support with large ½” footplate below the ground surface “Bump” at the discharge end to allow full pipe for the flow meter.

Flexicraft UltraSpool 10” flanged expansion joint installed between a fabricated hinge style steel guidance assembly.

E.) New 30 HP General Electric Prime Efficiency Hollow shaft motor: or installation of your 40 HP motor ex well # 51 at no additional cost.

Page 1of 7

Report Date: 10-22-2020

Monte Vista Wildlife Refuge

Well # 5 – Permit # 0444-R

Well Construction Year: 1955

Well #5 has been built in 1955. Pumping equipment may have been installed a few years later but appears to be mostly the original components. The discharge plumbing was found unsupported on the far end and no device is installed to keep the pipe filled for accurate meter reading.

The motor on this well is an older Newman 25 HP with a Full Load Amperage of 33 Amps. I measured 28.4/30.2/25.8 on the different phases during operation.

The bowl assembly, an unidentified type is designed for high capacity around 2200 GPM which was the recorded production rate at the beginning. There is no question that this pump must be entirely re-designed to adjust for the measured draw-down and pumping rate.

B. Pump Test:

With a stabilized draw down of 15 feet at a pumping rate of 1026 GPM and resulting in a pumping water level of 45.5 feet this a strong well. With the original motor installed we could not increase the pump speed in order to establish a better overview of the well’s capabilities but we should be able to pump 1500 GPM from an acceptable pumping level around 60 feet.

The pump panel is old but operational

Replacement is recommended.

Discharge Head: In re-buildable condition.

Pump Column:

10” open line shaft type column assemblies: The walls are thinned by normal corrosion over the long service life and should not be re-installed. The centralizing spiders are vintage style with wood bearings that are worn. The shafting is carbon steel in economically unsalvageable condition.

Additional column setting is necessary.

Bowl Assembly:

This appears to be the original bowl installed into this well. We could not identify manufacturer and type. The impeller by shape and size points towards the original capabilities of this well and with one single stage cannot meet the new head requirements of today’s lowered pumping levels. This bowl will have to be replaced by a multi stage bowl meeting the new design criteria. (see recommendations below)

Driver:

The motor on this well is an old Newman 25 HP, going back to the times of initial pump installation.

A new motor must be installed meeting the horse power requirements of the additional TDH (Total Dynamic Head) for the new bowl assembly.

Discharge Plumbing:

The pump discharge plumbing must be replaced and re-designed in order to maintain a full pipe for the flow meter. Considering the required length of the discharge plumbing an elastomer element with articulated guide must be installed between the discharge head and the discharge assembly.

The upper casing is 16” in diameter and reaches down to 134 feet and is followed by a 10 ¾” lower casing section to the measured bottom of 444 feet. Perforations are starting 217 feet downhole within the lower casing section and appear to be regular mill slot with a slot width of + - ¼”.

The step down to the 10 10” lower section was measured at 134 feet, about 11 feet above the 145 feet of the driller’s report. The lower section is not centered in the 16” upper casing but leans against one side. The wide crescent shaped annulus is well sealed and debris have accumulated and partially solidified on that platform. (This is what misled me during the camera inspection where I had to interrupt and pull the camera back out in order to reset the centralizer down to 6 inches diameter from initially 10”)

The picture below shows the crescent shaped platform with the arrow pointing to the overhanging and partially consolidated debris. Unable to penetrate at first I was afraid that this was a breach of the casing which is not the case.

Electrical:

The old Well Guard pump panel is in poor condition and can be replaced by the VFD pump controller installed next to it. A less expensive option will be the replacement by a new pump control panel.

Pump Repair:

The bowl assembly must be replaced by a type with a higher capacity. The column assemblies are obsolete by age and normal wear and must be replaced.

The motor must be replaced by a 40 HP to meet the proposed pump design of a 1500 GPM discharge rate.

The pumping water level of 60 feet @ 1500 GPM is an estimation based on the single point data received by the pump test.

4 new spiders SS 304 10x2 with Vesconite Bearing (limited dry run)

F.) New Motor GE Premium Efficiency 40 HP:

F.) New Discharge Assembly as follows:

Fabricated adjustable steel support with large ½” footplate below the ground surface “Bump” at the discharge end to allow full pipe for the flow meter.

Page 1of 6

Report Date: 10-07-2020

Monte Vista Wildlife Refuge

Well # 11 – Permit # 11863-F

Well Construction Year: 1967

The pump on well #11 is an open line shaft type not appropriate for the 85 ft. static water level of this well!

The centralizing bearings, mostly in the upper column sections are deteriorating fast even if pre-lubrication by pouring down water before start is done. The well depth is documented with 475 feet in the construction report and measured 465 feet. During start-up the pump shaft is vibrating excessively with intense rattling noise. The discharge bearing of the head is worn. The discharge plumbing is excessive in weight and the head was leaning forward through the weight of the heavy and poorly supported pipe. The camera inspection showed evidence of oxygen concentration cell activity (a variant of severe galvanic corrosion) that may have impacted and weakened the casing significantly.

Remarks regarding this field system: Well # 11 is used for irrigation purposes on a field circle with center pivot. The way this system is designed represents the worst economical approach there is.

Here is why:

A well pump with a design point efficiency of 84% @ 2000 GPM operates at an efficiency of merely 60% to lift water up from a pumping water level of 100 feet at a pump rate of 1065 GPM! The water is pumped through a pipeline open discharge into a large reservoir which is poorly sealed causing considerable losses of pumped ground water through evaporation and seepage. From the reservoir the remaining water is picked up by a close coupled can pump (in poor condition) and pressurized for the requirements of the sprinkler system.

The way this Field System should be designed:

A pipeline extension should be installed from the end of the existing field pipeline to the well head.

(Red line on the diagram above). The worn can booster pump can then be eliminated and a new pump installed into the well providing sufficient dynamic head to pressurize the center pivot. That way every gallon of ground water that is pumped will end up on the crop.

We performed a pump test according to the job requirements with the original equipment installed at a constant discharge rate of 1065 GPM. The static water level was measured at

85.5 feet below the well seal plate. The pumping level stabilized very rapidly (common behavior of the San Luis Valley deep wells) and the draw down at the above pump rate stabilized at 14.04 feet. For details please refer to the attached printout of the data records. This is a very strong well and should be pumped at a rate of 950 GPM.

During the pump test I recorded an amperage draw on the motor leads of 78.5/77.8/70.3 Amps with a voltage of 475/466/471 between phases. The motor, a 60 HP GE Value-Line has a FLA of 76 Amps. The motor was running hot as can be expected when running a load higher than manufacturer’s FLA at an elevation where for cooling reasons the motor output should be derated by 5% according to manufacturer’s instructions.

The electrical system is in fair condition and in conformity with the codes. The motor leads will have to be replaced by a larger wire gauge in order to satisfy the higher amperage draw of this pump and the higher horse power motor that will be required.

All electrical components within the pump panel are in acceptable condition.

The pump control panel is an older WellGuard, size SF4100 designed for motors 40-100 HP at 480 Volt but it appears that a larger fuse holder has been retrofitted. The fuses are FRS-200 (200 Apms) other particles.

Bolt heads from the bowl assembly eroded away by galvanic reaction.

Problems were encountered during the pulling of the upper sections of the pump column as the threads rusted together firmly. We proceeded to split the couplers in order to save the column pipes which are in good condition. I recommended re-using these column sections in well # 50

The line shaft consists of 1 3/16 carbon steel shafting with bonded on stainless steel race sleeves for the centralizing bearings. All neoprene bearing inserts are showing advanced wear with those above the static water level being the worst with tear marks. (See picture) With a static water level of 85 feet this should be an enclosed oil lube type pump!

Bowl Assembly:

The Goulds 12DHMC bowl is not suitable by design point to the pumping requirements of this well.

Driver: The motor is a 60 HP Value Line General Electric type running above manufacturer’s full load amperage.

The lower 12.75” well casing, starting at 116 feet is covered with barnacles to an extent that I had to pull out the camera in order to set the centralizers to six inches in diameter. With the low oxygen content of the water there should be hardly any metallic corrosion.

The upper 16” diameter casing section is in fair condition with quite some rust. The annulus space at the transition of the casing is open to a point that the pressure transducer penetrated this area by a few feet and I had pain to get it pulled out again. I could not see evidence of heavy circulation between aquifers and with a pumping level of a few feet only above this annulus the differential pressure during pumping cannot be very high. I will not push therefore for an expensive attempt of re-grouting this annulus but support of the well head through railing as described for well #50 should be considered.

Please watch the video for further depiction of the situation at the intersection of the casings. In general it may be stated that this well has lost a lot of service life but should still have potential left if treated and pumped responsively.

Same as for my recommendations on other well reports I will use the keywords of “must” or “should”.

The thin ¼ inch well seal plate must be replaced to allow safe support for the pump.

A railing system should be installed in order to support the weight of the upper casing and the pump as there is high possibility of a sliding down of the upper casing as it has been experienced on your well #3 and #50. Incidentally this could result in considerable damages to pump and discharge plumbing

Pump Repair:

There is no choice and this pump must be replaced with a new pump meeting well data requirements and field system efficiency considerations. I must strongly recommend the use of a VFD pump controller allowing a very smooth start and stop of the pump and a pre-charge time for the filling of the sprinkler pipe in order to avoid excessive stress on a well casing that has lost a lot of its structural strength. Treating this well “right” will be key point in the extension of its future service potential.

The pump discharge plumbing must be replaced and re-designed in order to maintain a full pipe for the flow meter and the connection to the pipeline extension as shown on the diagram on top of this report.

G. Cost Estimates:

A.) New Pump and motor: including:

New Discharge Head with new Tube Tension Assembly New Head Shaft New Special Shaft New 8” column pipe 7 x 20’ + 2 x 5’ + 2’; total column setting 152 feet New 2 x 1 3/16 Tube and Shaft assemblies: 7 x 20’ + 2 x 5’ New Bowl assembly for 1000 GPM @ 215 feet TDH New Cone Strainer New Oil Pot New 75 HP General Electric Premium Efficiency Motor New Motor Leads Installation and adjustment

B.) Railing of the Well Head including:

Excavation around the well head and placement of 2 each 15 ft. W8#31 wide flange beams. (coated with asphaltic paint for rust protection)

Installation of a ½” support plate welded to the well head and the beams

C.) VFD Pump Controller:

Installation of a YASKAWA 75 HP IQ P1000 Intelligent pump controller on galvanized steel structure with concrete footings. Pressure Transducer installed on pump discharge.

D.) Pipeline extension:

Installation of 520 feet of 10” PVC buried pipeline Connection to existing field pipeline Installation of well head connection riser with vacuum relief valve, pressure relief valve and all required plumbing components.

We performed a pump test according to the job requirements with the original equipment installed at a constant discharge rate of 2065 GPM. The static water level was determined at 25.5 feet below well seal plate. The pumping level stabilized very rapidly (common behavior of the San Luis Valley deep wells) and the draw down at that pump rate was stabilized 17.5 feet. The 5 minute recovery was swift with a level of 27.8 feet, just 2.3 feet shy of the static water level. For details please refer to the attached printout of the data records. This is a very strong well.

During the pump test I recorded an amperage draw on the motor leads of 57/58/54 Amps with a voltage of 457/454/447 between phases. The motor, a 40 HP GE Value-Line has a FLA of 48.5 Amps. The motor was running very hot as can be expected when running a nearly 60 HP load!

The electrical system is in fair condition and in conformity with the codes. A damaged conduit section from the ground surface into the pump panel needs attention and the conduit for the motor leads must be replaced. The motor leads will have to be replaced by a larger wire gauge in order to satisfy the higher amperage draw of this pump.

All electrical components within the pump panel are in acceptable condition.

The pump control panel is an older WellGuard, size SF4100 designed for motors 40-100 HP at 480 Volt.

One of the installed fuses has no markings and should be replaced.

Discharge Head: In poor condition and cast iron bearing adapter broken. (picture here above)

Pump Column: 10 inch Butt Thread type column pipe in 9 ft. 11.25” sections (open line shaft type.)

Total column setting as pulled from the well: 90 feet = 8 sections of 10, a bowl column 5’ and a top column 5’.

The thin ¼ inch well seal plate must be replaced to allow safe support for the pump. The casing must be extended by +- 1 foot in order to comply with the Colorado Water Well Construction Rules.

The open discharge gate must be repaired or better and less expensive the entire discharge plumbing removed and a blind flange with gasket bolted to the flange in the casing.

Pump Repair:

With a shallow static water level of 25 feet this pump is properly designed as an open line shaft type. The top section should be re-designed with an additional guidance bearing by installing a 2 ft.

head nipple and a special shaft reaching from the bottom of the 5 ft. top column into the discharge head. This is our standard design for maximum shaft guidance in the upper column section and extends the service life of the discharge bearing. This design allows also installing a motor with different frame size if required without partially pulling the pump head.

The discharge head is in poor condition and to re-use it a new bearing box will have to be fabricated and the top column separated from the severely rusted threads. I am recommending the replacement of the head as it will be the economically better way to go. Same as for the my recommendation under the open line shaft option for well # 50 I am recommending the use of a mechanical seal instead of the service intensive and always leaking packing box.

The Simmons SM14M single stage bowl assembly is in good condition and can be re-installed after servicing as planned.

The 40 Hp. motor must be replaced by a 60 Hp. Unit and the motor leads replaced as required by wire size. You can use the motor from Well # 11

The conduit section of the motor leads from the ground into the connection box must be replaced.

The conduit section with the incoming electric service wires into the pump panel must be repaired.

The pump discharge plumbing must be replaced and re-designed in order to maintain a full pipe for the flow meter. Considering the required length of the discharge plumbing an elastomer element with articulated guide must be installed between the discharge head and the discharge assembly.

(See image below depicting our standard design option – meter not shown)

G. Cost Estimates:

A.) Additionally to our Bid Price of for service and re-installation of the pump the sum for the required and recommended replacement parts is , adding up to a total repair cost of

The additional bill of material includes:

New High Quality Flowise Discharge Head 10x10 New Head Nipple 24” New Special Shaft and Head Shaft 9 new Column Couplers 10” Butt 4 new spiders SS 304 10x2 with Vesconite Bearing (limited dry run) New John Crane Series 5600 mechanical seal with new discharge bearing

B.) Well Head:

Removal of the defective gate valve and free flow discharge plumbing.

Extension of the casing by 12 inches

C.) New Discharge Assembly as follows:

Fabricated adjustable steel support with large ½” footplate below the ground surface “Bump” at the discharge end to allow full pipe for the flow meter.

D.) New 60 HP General Electric Prime Efficiency Hollow shaft motor including new larger seized motor leads and conduit from control panel to motor: or installation of the GE Value Line 60hp motor from Well #11 with new motor leads and conduit:

when moving the transducer up and down and reached a bottom with +-84 feet when taking into account the lead weight string below the transducer. That means the transducer penetrated a wide open annulus between both casings, of at least 27 feet in depth! The red arrow on the image above shows the upper edge of the lower casing section. It is highly possible that a subterranean cave has formed over the years around this well from around 50 feet down to 84 feet. Since the annulus is probably too small to penetrate with the camera it will be hard to visually confirm but we do have precedents in this area:

The picture on the left was taken after we broke the top of an underground “dome” that had formed closer to the surface than I am expecting it for well #61. This well is located on the Hersink property about 2 miles away from the well # 61 location.

After just pump testing well #56 (+- 1 mile to the west of 61) of which we know that it has a shifted/separated casing I was amazed of the almost unbelievable specific yield of that well. The pump data show a very slow and regular decrease in draw-down as if we would be pumping from an underground lake. Incidentally the reasons for both, separated casing and abnormally strong production capabilities often have the same cause: cavity formation. – We may have 2 of them…

The pumping rate started out with 1220 GPM which left me with only 5.5 feet above my downhole transducer. I throttled the flow down to 1100 GPM to keep sufficient reserve for additional drawdown during pumping level stabilization. Initial draw-down with the start of the pump was 16 feet and stabilized with 18 feet in a slow and constant manner as if we were pumping out of a big pond. Recovery occurred fast and slowed with the last foot below static level. The very strength of this well may be connected an subterranean cavity that has formed over time, eventually with a system of underground streams towards this cavity as we had witnessed at the Hersink field.

The pump panel, a newer style 200 Amp WellGuard is in mint condition. With some evidence of electro chemical corrosion on pump and well casing in this low oxygen well water it will be recommended to check for stray voltage between motor ground lead and the well casing.

Driver:

The motor is a 60 HP older GE motor and very noisy in the bearings. Full load amperage of the motor is 74 and amperage draw was measured 59.2/65.5/65.5. Replacement of this motor by a new premium efficiency model and installation of an appropriate bowl assembly will reduce electricity consumption significantly on this well.

Discharge Plumbing:

The open discharge plumbing is too short to allow required dimensions for flow meter installation and some minor structural changes of the ditch must be considered.

The upper casing portion is 20” pipe and reaches down to 56 feet welded together with multiple pieces. Corrosion advanced and structural strength may be impacted. First perforations appear at 23 feet downhole, well above today’s static water level of 57.5 feet. Cascading waters are resulting.

This upper section clearly needs insertion of a liner of plank pipe.

The annulus between lower casing and upper casing is deep and wide open as explained here above. Close attention and further investigation required.

The below images are both providing straight view onto a well open perforation, the first one at 80 feet, roughly where my transducer was located and the second one at 84 feet, just below the bottom of where I could lower the transducer. The background on picture 1 is black which means there is no borehole wall visible and we are looking into an empty space. The second picture shows mostly sands and fine gravel where we should see larger gravel from the filter pack. Incidentally water must be flowing from whatever cavity we have there into the well during operation of the pump.

In the lower part of the 12 inch casing large deposits are becoming suddenly predominant and debris from the disintegrated cone strainer are suspended on these barnacles. The casing ends at 201 feet and open borehole reaches down to 217 feet.

An adequately sized well seal plate must be installed on top of the casing to support the discharge head and the casing must be extended by 10 inches in compliance with Colorado Well Construction Rules in order to prevent ground water contamination during severe rain storms.

Since this upper casing has lost a lot of its structural strength and to eliminate all perforations above the static level I do recommend inserting a 16” casing into the 20” upper casing which may reach down to 84 feet or deeper depending on the seize of the cavity that has formed. I will have to do some further investigation into this issue and it should be resolved before decisions are made regarding the production equipment of this well. Depending on the size of the cavity well performance may decrease and risks and possibilities must be evaluated and discussed.

Pump Repair:

The bowl assembly will have to be replaced by a type with an appropriate design for flow and head requirements

The motor must be replaced as parts i.e. bearings for these vintage motors are very hard to find.

Horsepower adjustment may be required.

The discharge head must be replaced and the pump re-installed with new shafting. All centralizing bearings above static level should be Vesconite (limited dry run) type in order to eliminate pre-lubrication with water before pump start (which is always forgotten about).

The pump discharge plumbing must be replaced and re-designed in order to maintain a full pipe for the flow meter. Considering the required length of the discharge plumbing an elastomer element with articulated guide must be installed between the discharge head and the discharge assembly.

(see image below depicting our standard design option – meter not shown) In order to do that the discharge structure in the ditch must be re-located to allow for the necessary discharge length.

Cost Estimates:

The following figures should allow for budgeting and decision making. Please note that the items below will be additional to the reinstallation cost as per our bid item # 61 for the amount of and all figures are preliminary at this point in time because we don’t know the full extends of the cavity formation that we discovered during the camera inspection. Insertion of a liner into the upper casing part may be required for stabilization of the upper 20inch casing and for closing some of the perforated area above 84 feet. I have added all these items in order to allow for final budgeting but under any circumstances can they be considered final or required.

A.) VFD Pump Controller:

Installation of a YASKAWA 50 HP IQ P1000 Intelligent pump controller on galvanized steel structure with concrete footings.

B.) Replacement FW10ZC…