Attachment A - FP PH1 Unwatering Pump Replacement PWS 04_2025.pdf

PERFORMANCE WORK STATEMENT (PWS)

Fort Peck Power Plant 1 Unwatering Pump Replacement

April 2025

1.0 General Information.

1.1 Background: The powerplant 1 unwatering pump-motor assemblies have reached the end of their service life and require replacement for reliable future service. Both pumps are Fairbanks-Morse SN: PL494, 12-inch 3000

GPM 2 stage vertical turbine pumps with a dynamic head rating of 36.5ft. The pumping unit is direct driven by a high thrust, U.S. Electrical Motors motor manufactured by Emerson Electric. The motor is a 460-volt, 3-phase, 60-hertz, 50- horsepower, 1760-rpm, squirrel-cage type motor.

The pump inlet is located at EL. 2005.0’ and motor is located at EL. 2050.0’. There are existing lifting points above the pumps that have not been rated or load tested. If the contractor chooses to use the existing lifting points, the structural capacity shall be analyzed by a registered professional engineer in addition to being load tested. New rated lifting points may be installed by the contractor with COR approval. Other methods of removal such as portable A Frame hoists or other suitable equipment may also be used as deemed appropriate by the contractor.

The components requiring replacement are indicated on the reference drawings 5576.1-0-15, MFP78-87E521, and “MFP78-87E521 Annotated”. MFP78-87E521 depicts the current location and orientation of the unwatering pumps. 5576.1-0-15 shows the location of the pumps prior to the 1977 upgrade and relocation of the pump motors to El. 2050’. The reference drawings are “For Information Only” and indicates the general layout of the existing pump components.

1.2 Scope of Work. This is a non-personal supply purchase with incidental services to remove and dispose of the existing two (2) 3000 GPM unwatering pump assemblies and automatic greasing system and to supply, install, and commission two (2) new complete dual or single stage turbine unwatering pump assemblies (including piping) with motors, one (1) automatic greasing system (connected to both pumps) for the new pump assemblies

(including electronic controls for the grease system), and the system components at Fort Peck Power Plant 1 listed in Section 5.

The existing pipe hangers may be reused for the new pump system. However, if the new pump system requires additional supports/hangers, the new hangers must meet the requirements in Section 5.

The existing pumps and piping system is coated in lead-based paint (LBP). Any lead-based paint work or removal must adhere to the requirements in EM-385-1-1 and local reporting requirements. In addition, comply with applicable OSHA requirements in 29 CFR 1926.62 and applicable US EPA requirements for waste disposal.

Where project activities will disturb or remove paint, ensure that workers are protected from any exposure to airborne lead particulate and that no loose paint contaminates the environment. Collect any lead-containing paint waste generated when paint is disturbed for proper disposal in accordance with applicable regulations and in coordination with the Ft. Peck project environmental POC.

The existing flange gaskets in the pump system have been tested and do not contain asbestos.

The government shall not exercise any supervision or control over the contract service providers performing the services herein. Such contract service providers shall be accountable solely to the contractor who, in turn is responsible to the government.

1.3 Period of Performance. The work must be completed 240 days after the date of contract award.

1.3.1 No Onsite Work Window. During the maintenance outage for the main generating units in powerplant 1, the existing unwatering pumps must remain intact and functional. This window is as follows: 9 MAR 2026-23

MAY 2026.

1.4 Contractor Personnel

1.4.1 The contractor shall perform all work, under this contract, using his or her own forces except as provided in

Paragraph 1.4.2 Subcontracting. Employees who perform this work shall be qualified persons on the contractor’s own payroll. The Contractor’s employee must have company identification on their person, while on Federal property.

1.4.2 Subcontracting. The contractor shall not subcontract any work without written approval of the Contracting

Officer. Compliance with the provisions of this contract by subcontractors shall be the responsibility of the

1.5 Quality Control

1.5.1 The contractor shall designate, in writing, an employee who shall serve as the contact for matters involving quality and performance or nonperformance of the required work stated in this PWS. The employee(s) shall be qualified and fully competent with full authority to act for, and on behalf of, the contractor as necessary to ensure that the required work is performed in accordance with the standards contained herein. The contractor shall furnish the above written designation to the Contracting Officer Representative (COR) no later than the first day of work. The contractor shall include the name(s), address(s), and telephone number(s) of the responsible individual(s).

1.5.2 The Contracting Officer reserves the right to disapprove any individual whom he considers incompetent to perform the work required. The Contracting Officer will provide a written notice of any disapproval to the

1.6 Quality Assurance. The government will ensure that the contractor is performing the services required by this PWS in an acceptable manner.

1.6.1 The government has the right to inspect all services called for by the contract, to the extent practicable at all times and places during the term of the contract.

1.6.2 If any of the work does not conform to contract requirements, the government may require the contractor to re-perform the work in conformity with contract requirements and at no increase cost to the Government.

1.7 The contractor shall take all measures to prevent or mitigate damage to government facilities or any associated equipment during the execution of this project. The contractor will held be liable for any cost incurred by the government replace/repair damaged government facilities or associated equipment.

1.8 Hours of Operation. The contractor will have access to the facility for work during the hours of 0700-1700

Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. Bridge crane support from Government is unavailable on Fridays without special request by the contractor 48 hours prior to the need of crane.

The following Federal legal holidays are observed by this installation:

New Year’s Day 1 January

Martin Luther King’s Birthday Third Monday in January

President’s Day Third Monday in February

Memorial Day Last Monday in May

Juneteenth 19 June

Independence Day 4 July

Labor Day First Monday in September

Columbus Day Second Monday in October

Veterans Day 11 November

Thanksgiving Day Fourth Thursday in November

Christmas Day 25 December

1.9 Kick-off Meeting. Prior to commencing any activities, the COR will schedule a Kickoff Meeting with the contractor. The meeting shall establish methods of communication, set clear expectations, discuss the work requirements, scheduling, submittal process, and review of the Activity Hazard Analysis (AHA), and Abbreviated

Accident Prevention Plan (AAP). The Contractor will be responsible to schedule periodic meetings to ensure all milestones are being met according to the agreed upon schedule. At least one (1) week prior to commencing work, the Contractor shall coordinate their proposed work schedule with the COR.

1.9. Submittals. Prior to commencement of the work, the Contractor will submit the following documents to the

COR for review and approval. Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for Contractor Quality Control approval. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following electronically to the Contracting Officer Representative (COR):

a. Activity Hazard Analysis (AHA)

b. Abbreviated Accident Prevention Plan (APP)

c. List of who will perform work on this contract

d. Proof of Insurance for Contractors and Subcontractors

e. Confined Space Entry Plan

f. Manufacturer's Catalog Data; G

g. Pump Performance Curve; G

h. Spare Parts List; G

i. Special Tools; G

j. Wet-Pit Sump Pumps; G

k. Operation And Maintenance Manual; G

l. Hydrostatic Leak; G

m. Static Heads; G

n. Pump Flow Capacity; G

o. Initial Site Visit Report; G

p. Refurbishment Plan and Procedure Submittal; G

q. Final Test Reports; G

r. Bench Test Data

s. Manufacturer's Certification of Bearing Life

t. Manufacturer's Installation Instructions

u. Vibration Specifications

Additional submittal details are listed in Section 5. All submittals requiring Government approval will have a minimum of 14 calendars days for review unless otherwise stated.

1.10 Standards and Regulations. The Contractor shall perform to the standards in the contract and comply with all Local, State, and Federal Regulations during the services performed. The Contractor is responsible for ascertaining the extent to which these regulations affect the operations resulting from this contract. The

Contractor shall comply will all applicable regulations. Applicable regulations include, but are not limited to the following:

a. Engineering Manual (EM) 385-1-1 (USACE – Safety and Health Requirements Manual), dated March 2024

b. Occupational Safety and Health Standards (29 CFR 1910)

c. ASME B31.3 Process Piping

d. NFPA 70 (2023)

e. ABMA 9(2015) Load Ratings and Fatigue Life for Ball Bearings

f. ABMA 11(2014) Load Ratings and Fatigue Life for Roller Bearings

g. ASTM A53/A53M (2022) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless

h. ASTM A276/A276M (2023) Standard Specification for Stainless Steel Bars and Shapes

i. ASTM A105/A105M (2021) Standard Specification for Carbon Steel Forgings for Piping Applications

j. ASTM A193/A193M (2023) Standard Specification for Alloy-Steel and Stainless-Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

k. ASTM A194/A194M (2023) Standard Specification for Carbon Steel, Alloy Steel, and Stainless-Steel

Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

l. ASTM F844(2019) Standard Specification for Washers, Steel, Plain (Flat), Unhardened for General Use

m. HI ANSI/HI 11.6(2016) Rotodynamic Submersible Pumps for Hydraulic Performance, Hydrostatic

Pressure, Mechanical, and Electrical Acceptance Tests

n. HI M100(2009) HI Pump Standards Set

o. ISO 1940-1(2003; R 2008) Mechanical Vibration - Balance Quality Requirements for Rotors in a

Constant (Rigid) State - Part 1: Specification and Verification of Balance Tolerances

p. ISO 2858(1975) End Suction Centrifugal Pump (Rating 16 Bar) Designation Nominal Duty Point and Dimensions - International Restrictions

q. ISO 5199(2002) Technical Specifications for Centrifugal Pumps, Class II

r. NEMA 250(2020) Enclosures for Electrical Equipment (1000 Volts Maximum)

s. NEMA MG 1(2021) Motors and Generators

t. MSS SP-44(2019) Steel Pipeline Flanges

u. MSS SP-58(2018) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

v. MSS SP-128 (2012) Ductile Iron Gate Valves

w. ASME B31.1(2022) Power Piping

x. ASME BPVC SEC IX (2017; Errata 2018) BPVC Section IX-Welding, Brazing and Fusing Qualifications

y. ASME B16.5(2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

z. ASME B16.21(2021) Nonmetallic Flat Gaskets for Pipe Flanges

1.10.1 Activity Hazard Analysis (AHA). The contractor shall prepare the AHA in accordance with Paragraph 1-6.

Note: Contractors and other individual employer’s typically use Job Safety Analyses (JSAs), Job Hazard Analyses

(JHAs), or similar Risk Management assessment tools. The government considers equivalent to, and acceptable substitutes for, the USACE’s AHA provided the data collected is the same as that required by the AHA, commensurate with the type of services the contractor is performing.

1.10.2 Abbreviated Accident Prevention Plan (APP). EM 385-1-1 in its entirety may be too complex for the type of work performed under these contracts; contractors may reference Appendix A, for abbreviated Accident

Prevention Plan (APP). The contractor shall only need to submit items in Appendix A that are pertinent to the contract. The contractor shall use a qualified person to prepare the site-specific abbreviated Accident Prevention

Plan (APP). The contractor shall prepare the APP in accordance with the format and requirements of the EM 385-1-

1 and supplemented herein. The contractor shall sign and submit the APP for approval prior to the start of work onsite.

1.11 Physical Security and Access Control Requirements

1.11.1 All contract personnel requiring physical access to a federal installation or facility shall comply with the access control procedures of that location. Contract personnel requiring unescorted access, to meet contract performance requirements on a DoD installation in the United States, shall be vetted by the installation/facility

Provost Marshal/Directorate of Emergency Services/Security Office using the National Crime Information

Center-Interstate Identification Index (commonly referred to as “NCIC-III”) and Terrorist Screening Database

(commonly referred to as “TSDB”). Contract personnel shall comply with all personal identity verification requirements specified in installation/facility policies and procedure. Contract personnel who do not meet requirements for unescorted access to U.S. Army Corps of Engineers (USACE) facilities shall coordinate escorted access with the Government representative, as needed. Contract personnel who receive keys, access cards, or lock combinations that provide access to government-owned property shall comply with key and lock control procedures of the Requiring Activity (RA).

The contractor shall be responsible for safeguarding all government facilities, property, and materials provided for contractor use. The contractor shall secure at all times all government facilities, property, and materials.

Specific security conditions may change based on threats to national defense and based on the risk of specific facilities to these threats. The contractor shall abide by these changing conditions at all times, as applicable.

1.11.2 Key Control. The contractor shall ensure all keys issued by the Government are not lost, stolen, duplicated, or used by unauthorized persons.

1.11.2.1 The Contractor shall immediately report to the COR any occurrences of lost or stolen keys.

1.11.2.2 In the event keys, other than master keys, are lost or stolen, the contractor may be required, upon written direction of the COR, to re-key or replace the affected lock or locks without cost to the Government. The

Government may, however, at its option, replace the affected lock or locks or perform re-keying and deduct the cost of such from the payment due the contractor. If a master key is lost or stolen, the Government may need to replace all locks and keys for that system. The Government will deduct the total cost to replace the locks and keys from the contractor’s invoice.

1.11.2.3 The contractor shall prohibit the use of keys issued by the government by any persons other than the contractor’s employees. The contractor shall not facilitate access of secured areas to persons other than contractor personnel or subcontractors engaged in performance of contract work requirements.

1.12 Payment

1.12.1 The government will make payment upon completion of all work, after the government has inspected and accepted the work, and the government has reviewed, approved, and processed the contractor’s invoice. The contractor shall submit the invoice to the COR and/or any other person that has been designated in the contract to receive the invoice.

2.0 Definitions. The following definitions and descriptions apply wherever the word(s) or phrase(s) is/are stated in this PWS:

Contracting Officer’s Representative (COR): means an individual designated an authorized in writing by the Contracting Officer to perform specific technical or administrative functions.

Requiring Activity (RA): responsible for integrating Antiterrorism (AT) and Operations Security

(OPSEC) considerations into contract requirements packages

Performance Requirements Summary (PRS): The PRS shows contract requirements, the component requirements related to each contract requirement, the price of each work requirement as a percentage of the associated contract requirement (Fixed Price Contracts), the standard of performance, and the acceptable level of performance (ALP) for each work requirement.

3.0 Government Furnished Items and Services

3.1 Services. The Government will provide crane support with the Powerplant 1 bridge crane to assist with the movement of equipment to the heavy equipment room. The Contractor must request Government crane assistance

48 hours prior to need. The Contractor must provide rigging and riggers for loads/equipment to be moved by the

Government. The Government will inspect rigging prior to movement.

3.2 Facilities. The Government will not provide bathroom facilities or office space. The Contractor must provide their own portable toilets for the duration of the onsite work.

3.3 Utilities. The Government will provide access to 120V or 240V electrical power for tools.

3.4 Equipment. None

3.5 Materials. None

4.0 Contractor Furnished Items and Responsibilities

4.1 General. The Contractor shall furnish all supplies, equipment, facilities, and services required to perform work under this contract that are not listed under Section 3 of this PWS.

4.2 Equipment. Contractor will provide all equipment required in the performance of the work.

5.0 Specific Tasks

The replacement pump assembly requirements are detailed below:

5.1 Delivery, Storage, and Handling

Inspect the pump for damage or other distress when received at the project site. Store the pump and associated equipment indoors as recommended by the pump manufacturer, protected from construction or weather hazards at the project site. Before installation, provide adequate short-term storage for the pump and equipment in a covered, dry, and ventilated location. Follow the manufacturer's instructions for extended storage.

5.2 Products

Provide a pump and motor with vibration levels conforming to ISO 1940-1, unless otherwise noted. Ensure that motor vibration levels conform to NEMA MG 1, Motors and Generators, Part 7, unless otherwise noted.

5.3 System Description

Submit manufacturer's catalog data for sump pumps showing the sump pump size, type, and efficiency rating along with performance data, including pump performance curve, indicating brake horsepower, head, flow rate, and NPSH (net positive suction head). Also include equipment foundation data and equipment data. Manufacturer catalogue data must also be submitted for the non-pump equipment listed in paragraph 5.4. Provide manufacturer's installation instructions and vibration specifications.

5.4 Equipment

5.4.1 Wet-Pit Sump Pumps

Provide a pump with continuous duty conditions.

Construct and furnish pumps in accordance with the applicable requirements of HI M100 standards and those specified herein.

Include with the duplex pump unit two individual, vertical, submerged, volute, centrifugal pumps mounted below a cover plate; vertical, flexible-connected, solid-shaft motors; motor and bearing support housing attached to the cover plate; pump support and shaft housing pipes; discharge pipes; and automatic controls. Design the installation of the unit to permit removal of one pump assembly without disturbing the operation of the other.

Ensure that requirements for each material designation are in accordance with the applicable definition listed in the centrifugal pump section of HI M100 standards. Ensure that materials for components and accessories not covered by these definitions are as specified herein.

Avoid contact between dissimilar metals. Where such contact cannot be avoided, protect joints between dissimilar metals against galvanic corrosion by plating, organic-insulation coatings, gaskets, or other suitable means. Bench test data must be submitted for each pump in accordance with HI 11.6.

5.4.2 Pump Selection

Parallel pump operation is required during emergency plant conditions, select pumps with characteristics specifically suited for the service, without unstable operation.

Provide a self-priming pump unit that delivers, at rated speed, not less than the specified 3000 gallons per minute against the specified or indicated discharge head while the liquid level is not more than 45.5 foot above the datum elevation of the pump. The dynamic head of the existing pumps are 36.5 ft. Use the level of the entrance eye of the impeller as the datum elevation. Include, in the calculations of the discharge head, both the friction head of the system piping external to the pump unit and the static head measured from a point of reference on the sump to the highest point in the system. Base ratings on pumping clear, fresh water at a temperature of 40 degrees F.

5.4.3 Pump Casing

Provide cast-iron pump casing. Provide a volute and discharge nozzle of the pump casing cast as one piece.

Construct the casing with a bolted plate to permit inspection and removal of the impeller. Ensure that the casing can withstand a hydrostatic pressure of not less than 1-1/2 times the design shutoff head of the pump.

5.4.4 Impeller

Provide a ASTM A276/A276M 304, or 316 corrosion-resistant steel, enclosed, with vanes on the back shroud.

Refer to paragraph BEARINGS AND LUBRICATION for additional requirements. Ensure that the impeller is dynamically balanced.

5.4.5 Twelve Inch Inlet and Pipeline Strainers

Protect the sump intake with a large cast-iron, slotted intake basket strainer with an effective free area sufficient to prevent cavitation and degradation of efficiency. Ensure that the strainer has a free area of at least four times the cross-sectional area of the suction casing. The strainers must have Class 150 flange connections. Strainer locations are shown on Drawings MFP78-87E521 Annotated.

5.4.6 Pump Shaft

Construct the pump shaft of ground and polished AISI Type 304 or 316 corrosion-resistant steel with hardened wearing surfaces at intermediate shaft-bearing locations. Hardened surfaces may be overlays of 500 Brinell, Deloro Stellite, Wall Colmonoy, or similar proprietary metals, or plasma-spray-applied ceramic materials of not less than 900 Brinell hardness. Provide one (1) shaft bearing for every five feet of elevation minimum.

5.4.7 Bearings and Lubrication

Furnish one or more antifriction ball or roller bearings in the motor and bearing support housing above the cover plate surface, with full provision for the mechanical and hydraulic radial and thrust loads imposed. Provide sealed and grease-lubricated bearings that have an L-10 rating of at least 80,000 hours in accordance with ABMA

9 or ABMA11. Ensure that the shop drawings bear the manufacturer's certification of bearing life. Provide bearings manufactured from vacuum-processed or degassed-alloy steels.

Provide sleeve-type intermediate shaft bearings. Ensure that the center distance between any two bearings on the shaft does not exceed 4-1/2 feet for pumps operating between 1,700 and 1,800 revolutions per minute (rpm) or five (5) feet for pumps operating at 1,200 rpm or less. Provide a sleeve bearing at least two times the shaft diameter and locate the bearing near the lower extremity of the shaft.

Provide heavy-duty bronze or bronze-backed, babbitt-lined sleeve bearings. Provide appropriate nonferrous piping and fittings to permit individual lubrication of the intermediate and lower bearings from above the sump cover plate. Provide a means to prevent the pumped fluid from entering the lower bearing. Include a suitable seal or a system wherein a partial vacuum developed below the bearing by the impeller rotation induces a positive flow of lubricant into the bearing. Fit bearings with a centralized grease lubricator that is electrically operated from a single point.

5.4.8 Rigid Couplings

Connect the pump shaft to the motor shaft through a keyed or non-keyed vertical rigid coupling.

5.4.9 Support Pipe

Provide a wrought-iron or steel support pipe concentric with the pump shaft that connects the pump to the sump cover plate. Provide support pipe flanges that are machined and doweled to ensure proper alignment of the pump and shaft whenever the pipe is disassembled and reassembled in the field.

5.4.10 Discharge Pipes

Furnish discharge pipes running from the pump discharge outlets to the sump cover plate as an integral part of the pump unit. Arrange the discharge pipe to preclude discharge piping beyond the pump assembly from imposing loads that could cause shaft misalignment. Provide black steel or wrought-iron pipe, with wall thickness not less than that specified in ASTM A53/A53M for Schedule 40 pipe. All pipe flanges connections must be ASME

B16.5 Class 150 flanges. All welded flange connections must conform to ASME B31.1.

5.4.11 Dresser Couplings

Replace-in-kind two (2) 12-inch dresser couplings as shown on reference drawing MFP78-87E521 Annotated.

5.4.12 Swing Check Valves

Replace-in-kind two (2) 12-inch swing check valves as shown on reference drawing MFP78-87E521 Annotated.

5.4.13 Plug Valve and Reducing Elbow

Replace-in-kind one (1) 12-inch plug valve, operating rod, and Schedule 40 carbon steel 14" to 12" reducing elbow with ASME B16.5 Class 150 flanges as shown on reference drawing MFP78-87E521 Annotated. The valve operator rod is to be reused on the new valve.

5.4.14 Automatic Grease System

Replace-in-kind the existing Farval greasing system with a new automatic greasing system, reservoir, metering blocks, electronic controller, fittings, and stainless-steel lines required for all of the new pump system bearings.

The existing grease system uses a 1/3HP single phase 115/230V motor.

5.4.15 Flowmeter

The Contractor must provide one flowmeter per pump with readout installed between 3-5ft above the heavy equipment room floor (El 2050ft).

All parts must meet or exceed the pressure classification of the pipe system it is installed in. Flowmeter accuracy must be plus or minus 1.0% flowrate or better. Wetted material parts must be 300 series stainless steel. The flowmeter must include a 4-20 ma output. Meter shall be a combined meter/transmitter unit. ASME B16.5 class

150 flanges, carbon steel. Polyurethane liner. NEMA 4X Watertight enclosure. SST electrodes and grounding rings. Flow Rate:0-3000 gpm for 12" flow meters(minimum). Flow Velocity: 0-10 ft/sec. 120 VAC/130 VDC power supply. Reliability: Magnetic flow meter shall have a Mean Time Between Failures Reliability (MTBF) rating of 25 years minimum per MIL-HDBK-217F. Flow meter shall be capable of withstanding no water in the sensing portion while powered up with no degradation to the unit. Mount-Anywhere technology preferred.

Flowmeter shall have remote display capable of indicating flow rate in gpm and flow velocity in ft/sec along with totalized flow in gallons.

5.4.16 Sump Inlet Gate Valve

Provide one (1) twelve-inch class 150 gate valve identified as "Relocated 12-inch valve" in Section 2 on drawing

MFP78-87E521. The new valves must conform to MSS SP 128 and attach to the existing operating shaft. New U-joints in this valve's operating shaft must also be provided. The new U-joints must be greaseable via grease fitting. The operating shaft is to be reused.

5.4.17 Painting

Treat and paint equipment in accordance with the manufacturer's standard practice for the specified duty. Carbon steel piping components must be coated with corrosion resistant materials. Coatings and finishes must be 100 percent holiday free. All carbon steel fasteners must be coated following final joint tensioning.

All non-corrosion free material must be painted by the manufacturer and rust free. Any components not painted by the manufacturer must be painted with the following paint system:

System No. 23-A-Z

Items to be coated with this system: All other equipment furnished under this Contract, other than items which come with factory coating.

Surface Prep 1st Coat 2nd Coat 3rd Coat

White metal blast cleaning SSPC Paint 40 Type II SSPC Paint 41 SSPC Paint 38

Finish Color: Gray

Clean surfaces to be painted before applying paint or surface treatments. Remove deposits of grease or oil in accordance with SSPC SP 1, prior to mechanical cleaning. The finished coating must be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Damaged areas of paint on such metalwork must be cleaned and touched up without delay. Prior to field coating phase of work, submit an accident prevention plan in accordance with the requirements of Section

01 of EM 385-1-1, including, but not limited to, each of the topic areas listed in Appendix A therein and the specified requirements. Develop each topic in a concise manner to include management and operational aspects.

Submit a ventilation assessment plan complying with all applicable safety standards to the Government for review.

5.4.18 Flanged Connections and Flanged Fittings

The internal diameter bores of flanges and flanged fittings must be the same as that of the associated pipe. Use slip- on welding flanges on pipe and welding neck flanges on fittings. Flanges and flanged fittings must be forged steel, ASTM A105/A105M, per the requirements of ASME B16.5 or MSS SP-44, Class 150 with a flat face. Wall thickness of flanges must be equal to, or exceed that of the pipeline that it is installed in. For tie-in to existing flanges, field check existing flanges for non-standard bolt hole configurations and design as required to assure new pipe and flange mate properly.

5.4.19 Flange Gaskets

Provide flange gaskets made from fiber, plastic, or other synthetic material suitable for the pressure and service and meeting the requirements of ASME B16.5. Nonmetallic gaskets must conform to ASME B16.21. Use electrically isolative flange gasket kits on any connection between dissimilar metals.

5.4.20 Bolts, Nuts, and Washers

Steel bolts and nuts shall conform to ASTM A193/A193M, Grade B7 or B16, with ASTM A194/A194M, Grade

8 nuts. Flat washers shall conform to ASTM F844 for bolted connections where washer is in direct contact with carbon steel surface of one component. All non-stainless fasteners must be painted after final torque is achieved.

5.4.21 Pipe Support

Pipe supports must conform to the requirements of MSS SP-58. Where pipe supports contact bare piping or in-line devices, provide supports of compatible material so that neither will have a deteriorating action on the other.

Provide auxiliary steel where the support of piping systems and equipment is required between building structural elements. Light gauge and structural steel shapes must conform to the requirements of ASTM A36/A36M. The

Contractor has the option to use pre-engineered support systems. However, a mixture of support system manufacturers products is not permitted.

All hanger types are per Figure A1 of MSS SP-58

a. Prohibited Types: Support Types 5, 12, and 26 are not permitted to be used.

b. C-Clamps: Only Type 19 and Type 23 C-clamps are permitted. Use manufacturer furnished locknuts and retaining devices. Field fabricated C-clamps or retaining devices are not acceptable.

c. Hangers: All hanger types, except those listed above are acceptable. Type 24 may only be used on trapeze hanger systems or on fabricated frames.

d. Horizontal Pipe Supports: Space horizontal pipe supports as specified in MSS SP-58 and install a support not over one (1) foot from the pipe fitting joint.

5.5 Execution

5.5.1 Pump Installation

Install equipment in accordance with manufacturer's recommendations. The modification and installation of systems and components including all seals, piping, valves, fittings and related accessories shall be per the approved installation procedures. Material and equipment installed shall be suitable for the pressures, flows, and temperatures encountered. Installation shall be in accordance with the manufacturer's written instructions and under the direction of the erection engineer or manufacturer's representative. The new pump system (valves, flanges, and joints) must be free of external water leaks after commissioning.

During the pump replacement, when the existing unwatering pumps are no longer operational, the Contractor will be responsible for maintaining a sump water level below El. 2018 at all hours of the day and have an available continuous pump capacity totaling 3000 GPM until the commissioning of the new unwatering pumps is accepted by the Government. Lower sump water levels may be required for the Contractor to perform the pump removal and installation. Only one of the Government's sump drainage pumps will be operational during the unwatering pump replacement to assist with managing water levels in the sump. The Government will always maintain control of the permanent drainage sump pumps. The water from the sump by the Contractor's temporary pumps may be discharge into the tailrace from the tailrace deck under the Contractor's State of Montana discharge permit.

The lower portion of the pumps are in the Powerplant 1 sump. The sump is a confined space and proper safety precautions must be followed by the Contractor personnel. At least 30 days prior to mobilization, the Contractor must submit a confined space entry plan in accordance with EM-385-1-1 Section 34.

5.5.2 Post Award Site Visit

The Contractor must conduct an initial site visit after contract award but prior to mobilization. The Contractor must measure and verify the existing equipment's location and dimensions. An Initial Site Visit Report must be submitted to the Government 14 calendar days following the end of the site visit. The site visit report must include the following information: existing component, type, location and dimensions relative to the sump floor.

Reference drawing "MFP78-87E521 Annotated" shows a general layout of the existing equipment.

5.5.3 Overhead Lifting Points/Device

The Contractor must provide equipment/means of removing the existing pump equipment/components. The lifting points directly above the current pumps may be used if the Contractor's licensed structural engineer certified the lifting points. The powerplant bridge crane will be operated by the Government at the request of the Contractor.

Bridge crane support must be coordinated with the Government two business days in advance of Contractor need.

5.5.4 Welding

Perform fabrication and welding in accordance with ASME B31.1. All mandatory appendices will be considered part of ASME B31.1 and therefore apply. The non-mandatory appendices and commentary will be used as guides and supplementary information unless otherwise specified for the interpretation and application of ASME B31.1.

Unless otherwise specified, the choice of welding process is the responsibility of the Contractor. Partial penetration welds are not permissible.

5.5.5 Removal of Existing Equipment

a. The existing equipment identified in the contract reference drawings, including but not limited to the two unwatering pumps systems, existing farval system must be removed by the Contractor. All equipment not specified to be salvaged shall become the property of the Contractor, removed from the Project site, and disposed of in a legal manner. Materials that cannot be removed daily may be temporarily stored on-site at an approved area.

Salvaged materials shall not be sold on the project site.

b. The Contractor must submit a Refurbishment Plan and Procedure. This submittal must include an existing equipment removal procedure, detailing the sequence and procedures for removing the pumps and components to be removed or affected by the removal of the pump system. Procedures are to include but not be limited to a detailing of:

(1) Items to be removed.

(2) Temporary arrangement or storage of items.

(3) Special containment and disposal procedures.

(4) Extraction and lifting plans

(5) Sump water level management plan

5.5.6 Alignment

Before attempting alignment, demonstrate that the pump does not have any load/force imposed by the piping system. Minimum alignment values (below) are for pump and driver at normal running temperatures.

Compensate values for thermal growth. Correct limited movement of the pump or driver (commonly known as bolt-bound) to ensure alignment capability. Ensure that hold down bolts are not undercut to perform adjustment.

Ensure that shims are commercially die-cut, without seams or folds, and are made of corrosion-resistant stainless steel. Do not use more than four shims at any single point. For units with drive motors over 10 hp, install alignment jack bolts.

Pump and driver may have an intermediate shaft, spacer, or spool piece (sometimes called a jackshaft) Based on the motor's nominal operating speed, align the pump and driver to the following minimum specifications:

Speed (RPM) close-coupled offset(mils) close-coupled angle(mils/in) spool piece angle (mils/in

@ coupling pt.)

600 6.0 2.0 3.0

900 5.0 1.5 2.0

1200 4.0 1.0 1.5

1800 3.0 0.5 1.0

3600 1.5 0.4 0.5

7200 1.0 0.3 0.4

Provide final alignment settings as part of the final test data.

5.5.7 Field Quality Control

a. Vibration Analyzer

Use a Fast Fourier Transform (FFT) analyzer to measure vibration levels. Provide an FFT analyzer with the following characteristics: a dynamic range greater than 90 dB; a minimum of 400-line resolution; a frequency response range of 5 Hz to 10 kHz (300 to 600,000 cpm); the capacity to perform ensemble averaging; the capability to use a Hanning window; auto ranging frequency amplitude; a minimum amplitude accuracy over the selected frequency range of plus or minus 20 percent or plus or minus 1.5 dB.

Use a stud-mounted accelerometer, a mass-to-structure ratio below 1/100, and sound disk (or finished surface) with the FFT analyzer to collect data. Ensure that the mass of the accelerometer and its mounting has minimal influence on the frequency response of the system over the selected measurement range. The FFT analyzer and accelerometers must be within calibration date at time of use, with calibration certificates.

Vibration levels must be evaluated against the acceptance criteria specified in paragraph 3.2.2. Provide in the

Final Test Report, spectral plots and time-domain data to identify dominant frequencies.

b. Pump Acceptance

Ensure that vibration analysis verifies pump conformance to specifications. Ensure that vibration levels are not more than 0.075 in/sec at one (1) time run speed and at pump frequency, and 0.04 in/sec at other multiples of run speed.

Perform tests, including hydrostatic leak checking of piping and operation of equipment, in accordance with the manufacturer's instructions.

Operate pumps against static heads indicated and verify pump flow capacity.

Provide final test reports to the Contracting Officer. Provide reports with a cover letter/sheet clearly marked with the System name, Date, and the words "Final Test Reports".

5.5.8 Closeout Activities

Submit one (1) electronic copy of the manufacturer' complete spare parts list, showing all parts, spare parts, and bulletins for pumps. Clearly show all details and parts, and adequately describe parts or furnish proper identification marks.

Furnish one (1) set of all special tools necessary to completely assemble, disassemble, or maintain the pumps.

"Special tools" refers to oversized or specially dimensioned tools, special attachments or fixtures, or any similar items.

5.5.9 Operation and Maintenance Manuals

Furnish complete sets of instructions containing the manufacturer's operation and maintenance instructions for the new unwatering pumps and components in a single integrated Operation and Maintenance Manual to the

Contracting Officer. Provide a draft version of the manual to the government prior to the field testing to revise the manual with the lessons learned from those events. The Final Operation and Maintenance Manual must not be submitted until a Draft Operation and Maintenance Manual (with lessons learned and Government review comments incorporated) has been approved.

5.5.10 Motor and Wiring Requirements:

Size motors to meet the operating requirements for the new unwatering pumps. Motor sizing, motor protection and wiring must meet NFPA 70 requirements. Current motor protection and wiring is sized for the existing 50hp motor. New motors are not to exceed 50 hp rating. New motor product data must be submitted no later than 180 days prior to Contractor mobilization onsite.

6.0 Attachment Drawings:

- MFP78-87E521 Annotated

- 5576.1-0-15

- MFP78-87E521

- MFP78-87E522

- FP17-70-127

- FP17-70-128