B.08 - W912DR23B0001.pdf

PROJECT TITLE: Jennings Randolph Lake Backup Hydraulic System

LOCATION OF PERFORMANCE: Jennings Randolph Lake, West Virginia

MAGNITUDE OF CONSTRUCTION: Betw een $500,000 and $1,000,000

SOCIOECONOMIC: This procurement is Full and Open Competition

NAICS CODE: 238990 All Other Specialty Trade Contractors w ith a size standard of $16,500,000.00

X

CHARLES M. BOSWELL

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

10. THE GOVERNMENT REQUIRES PERFORMANCE OF THE WORK DESCRIBED IN THESE DOCUMENTS

NEGOTIATED

28-Oct-2022

(RFP)

(IFB)

CALL:

B. TELEPHONE NO. (Include area code) (NO COLLECT CALLS)

See Item 7

2. TYPE OF SOLICITATION

SEALED BID

3. DATE ISSUED

9. FOR INFORMATION A. NAME

SOLICITATION

NSN 7540-01-155-3212 1442-101 STANDARD FORM 1442 (REV. 4-85)

Prescribed by GSA FAR (48 CFR) 53.236-1(e)

11. The Contractor shall begin performance w ithin _______10 calendar days and complete it w ithin ________120 calendar days after receiving aw ard, X notice to proceed. This performance period is X mandatory, negotiable. (See _________________________52.211-10

12 A. THE CONTRACTOR MUST FURNISH ANY REQUIRED PERFORMANCE AND PAYMENT BONDS?

(If "YES," indicate within how many calendar days after award in Item 12B.)

X YES NO

13. ADDITIONAL SOLICITATION REQUIREMENTS:

A. Sealed offers in original and __________1 copies to perform the w ork required are due at the place specif ied in Item 8 by ___________ local time ______________30 Nov 2022 (date). If this is a sealed bid solicitation, offers must be publicly opened at that time.

shall be marked to show the offeror's name and address, the solicitation number, and the date and time offers are due.

B. An offer guarantee X is, is not required.

C. All offers are subject to the (1) w ork requirements, and (2) other provisions and clauses incorporated in the solicitation in full text or by reference.

D. Offers providing less than _______60 calendar days for Government acceptance after the date offers are due w ill not be considered and w ill be rejected.

SOLICITATION, OFFER,

AND AWARD

(Construction, Alteration, or Repair)

1. SOLICITATION NO.

IMPORTANT - The "offer" section on the reverse must be fully completed by offeror.

4. CONTRACT NO.

7. ISSUED BY CODE

USACE, BALTIMORE, RSFO

300 SENTINEL DRIVE, STE 400

ANNAPOLIS JUNCTION MD 20701-0548

W912DR

PAGE OF PAGES

1 OF

CODE

(Title, identifying no., date):

12B. CALENDAR DAYS

12:00 PM (hour) Sealed envelopes containing offers

5. REQUISITION/PURCHASE REQUEST NO. 6. PROJECT NO.

8. ADDRESS OFFER TO (If Other Than Item 7)

FAX:TEL: 410-854-0700 TEL: FAX:

W912DR23B0001 63

20B. SIGNATURE

(REV. 4-85)STANDARD FORM 1442 BACK

TO SIGN

NSN 7540-01-155-3212

SOLICITATION, OFFER, AND AWARD (Continued) (Construction, Alteration, or Repair)

CODE FACILITY CODE

17. The offeror agrees to perform the w ork required at the prices specif ied below in strict accordance w ith the terms of this solicitation, if this offer is accepted by the Government in w riting w ithin ________ calendar days after the date offers are due.

the minimum requirements stated in Item 13D. Failure to insert any number means the offeror accepts the minimum in Item 13D.)

AMOUNTS SEE SCHEDULE OF PRICES

18. The offeror agrees to furnish any required performance and payment bonds.

19. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments to the solicitation -- give number and date of each)

AMENDMENT NO.

DATE

20A. NAME AND TITLE OF PERSON AUTHORIZED TO SIGN

OFFER (Type or print)

AWARD (To be completed by Government)

21. ITEMS ACCEPTED:

22. AMOUNT 23. ACCOUNTING AND APPROPRIATION DATA

24. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

(4 copies unless otherwise specified)

CODE

(Insert any number equal to or greater than

20C. OFFER DATE

25. OTHER THAN FULL AND OPEN COMPETITION PURSUANT TO

10 U.S.C. 2304(c) 41 U.S.C. 253(c)

CODE27. PAYMENT WILL BE MADE BY:26. ADMINISTERED BY

(Include ZIP Code)14. NAME AND ADDRESS OF OFFEROR 15. TELEPHONE NO. (Include area code)

See Item 14

(Include only if different than Item 14)16. REMITTANCE ADDRESS

30B. SIGNATURE

29. AWARD (Contractor is not required to sign this document.)

document and return _______ copies to issuing office.) Contractor agrees Your of f er on this solicitation, is hereby accepted as to the items listed. This award con-to f urnish and deliv er all items or perf orm all work, requisitions identif ied summates the contract, which consists of (a) the Gov ernment solicitation and on this f orm and any continuation sheets f or the consideration stated in this y our of f er, and (b) this contract award. No f urther contractual document is contract. The rights and obligations of the parties to this contract shall be necessary .

gov erned by (a) this contract award, (b) the solicitation, and (c) the clauses, representations, certif ications, and specif ications or incorporated by ref er-ence in or attached to this contract.

30A. NAME AND TITLE OF CONTRACTOR OR PERSON AUTHORIZED 31A. NAME OF CONTRACTING OFFICER (Type or print)

30C. DATE

(Type or print)

TEL: EMAIL:

31B. UNITED STATES OF AMERICA 31C. AWARD DATE

BY

CONTRACTING OFFICER WILL COMPLETE ITEM 28 OR 29 AS APPLICABLE

(Contractor is required to sign this28. NEGOTIATED AGREEMENT

(M ust be fully completed by offeror)OFFER

W912DR23B0001

Section 00 10 00 - Solicitation

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Each Provide One Hydraulic Power Unit

FFP

Manufacture Hydraulic Power Unit per "A.02 - Jennings Randolph Backup Hydraulic System Specs" FOB: Destination

PSC CD: J043

NET AMT

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0002 1 Job Installation

FFP

Installation of Hydraulic Power Unit w/ associated concrete and electrical work needed.

FOB: Destination

PSC CD: J043

NET AMT

BID SCHEDULE

SUBTOTAL FOR CLIN 0001

SUBTOTAL FOR CLIN 0002

TOTAL PROPOSED PRICE FOR ALL LINE ITEMS

SCOPE OF WORK

SCOPE OF WORK

General: Jennings Randolph Lake is located on the border of West Virginia in Mineral County and Maryland in Garrett County and is on the North branch of the Potomac River approximately eight miles upstream of Bloomington MD.

Background: The US Army Corps of Engineers (USACE) at Jennings Randolph Lake have a hydraulic power unit on the elevation level 1289 of the intake tower that provides hydraulic power to two service gate cylinder, two emergency gate cylinders and two low flow gate cylinders inside the intake tower. Due to past tower flooding concerns, it has been determined that the site requires an auxiliary hydraulic power unit to be installed on elevation level 1337 and incorporated into the existing system inside the dam intake tower.

Objective: The Contractor will provide and install one hydraulic power unit (HPU) on the 1337 elevation level of the intake tower and incorporate the unit both hydraulically and electrically to the existing HPU system. The HPU will conform to the specifications laid out in the Task Requirements section of the document as well as the companion drawings.

Task Requirements: The Contractor must 1) design and fabricate as well as 2) install a HPU for the Jennings Randolph lake project on site, incorporating the new system into the existing unit on site. Project installation should be scheduled for November 1, 2021 to February 28, 2022 for minimum environmental impact. See appendix for all required fabrication standards and tests to complete the project.

Design and Fabrication of Hydraulic Components: The HPU being provided must be designed to operate as shown in the attached hydraulic circuit and be comprised of the following hydraulic components:

Tank Reservoir: The HPU must include an oil reservoir of stainless-steel construction that is 1,000 gallons capacity with an active volume of approximately 350 gallons. Provide a bolt-on mounting base to allow the motor-driven hydraulic pumps, associated valves, electronic control panels, and accessories to be mounted on top of the reservoir. Provide a baffle between the intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid. Due to the strength of the concrete floors withing the intake tower, the max operating weight of the unit to be less than 14,000 LBS spread over minimum 5 foot width. Shape and slope the reservoir bottom to facilitate emptying and cleaning. Equip the reservoir with a drain with shut-off ball valve. Both the intake and return pipes should extend be down to a distance of 1-1/2 pipe diameters above the tank bottom. Provide each side of the reservoir with a cleanout opening of not less than 400 square inches clearance with a bolted, gasketed cover. All components (i.e. pumps/motors, valves) will be mounted on top of the reservoir and the entire unit must be able to fit down a 120” x 120” shaft. The top of the tank shall not exceed 48” from the floor for easy reach access to mounted components. Lift points are to be incorporated on the reservoir to allow to move the entire unit without disassembly of any component. Finish the welded joints of the reservoir smooth and free from irregularities. Do not grind welds to an extent that weakens the reservoir. External of tank and all components to be painted according to approved manufacturer standards and requirements in this document. The tank must be designed to include the following subcomponents:

a) Immersion Heater: an immersion heater with a watt density not to exceed 11 watt per square inch and total heating output to be 3KW, 480V, 3 phase. The immersion heater to be of stainless-steel construction. Immersion heat to include built in adjustable thermostat set to maintain hydraulic oil temperature at 60 degrees F.

b) Oil Float Switch: Provide HPU with a dual float switch with flanged switches and install inside a pipe to eliminate surge effects. The switches to have a narrow differential and be rated for 13 amps at 120 volts. Set separate normally open switches to close when oil level rises above 900 gallons or drops below the recommended level as designed by the manufacturer and observed during operational tests. Provide a NEMA 4x junction box.

c) Hydraulic Oil High Temperature Switch: Provide a thermostat to sense the oil temperature in the tank and close its contacts when the temperature exceeds 125 degrees F as indicated. The thermostat to be of the bulb and capillary type and provide with a protective well which extends into the tank. The temperature adjustment range to be 50 to 300 degrees F with plus or minus 2 degree F differential switch. Fit the switch with an external calibrated adjustment knob. The thermostat to be rated for 15 amps at 120 volts. Provide weatherproof junction box.

d) Air Breather: Provide the reservoir with an air breather which removes dirt and moisture from the incoming air. The incoming air to first pass through a desiccant bed to remove the moisture, and then pass through a filter to eliminate the solid contaminants before entering the reservoir. Outgoing air to pass directly to the atmosphere through a check valve. Breather to also provide visual indication of the desiccant and filter condition.

e) Oil Level Sight Gauge: Provide the reservoir with an oil level sight gauge to be able to visually see the level of the hydraulic oil inside the tank. This oil level gauge should show the tank volume in the “full” position through the “low oil” position.

Electric Motor: The HPU must include two electric motors. The electric motors are to be TEFC, 40 HP, 1200 RPM, 480V, 3 phase, 60hz, 364T Frame 1.15 SF, NEMA B, normal starting torque, Class B insulation, continuous 65 deg C ambient, Fungus protection, tropical insulation and 120V, 100W winding heaters.

Hydraulic Pump: The HPU must include two hydraulic pumps driven by the electric motors. Each pump must be a positive displacement, vane type fixed displacement pump with 25 GPM nominal flow at 2500 psi. Maximum rotational speed must be no greater than 1200 rpm. Equip the pumps with safety guards for all exposed rotation parts. Pumps are to include flange style Code 61 fittings for the suction and pressure ports.

Relief Valve: Each pump must have installed, as shown on the hydraulic circuit, a pilot operated relief valve.

Each valve body must be of close grain alloy cast iron or forged steel. Each relief valve must have a pressure range of 1500-3000 psi and be set according to the hydraulic circuit. Each valve must be rated for full pump flow. Each relief valve must include ability to unload pump during start up. This is accomplished using a solenoid operated vent valve shown on the schematic. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Pressure Gauge: Pressure gauges must be installed as shown on the hydraulic circuit. Each gauge must have a 0- 3000 psi range. Each gauge must also include a pressure snubber to prevent damage to the gauge from pressure spikes. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Pressure Filter: The pressure filter must be installed in accordance to the hydraulic circuit. The housing must be constructed of cast iron or steel. Locate the filter so they can be changed without removal of hydraulic system components. The filter must be equipped with a color coated visual indicator dirt alarm and a bypass check set to 25 psi. The filter must have a minimum capacity of 50 GPM at a pressure drop not exceeding 10 psi. The filter element must be a spin-on style and have a rating of 25 microns absolute unless a smaller mesh is recommended by the manufacturer of the component with the highest cleanliness requirement. Elements to be compatible with existing filter elements on existing HPU which are Schroeder brand KM25 elements. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Return Filter: The return in-line filter must be installed in accordance to the hydraulic circuit. The housing must be constructed of cast iron or steel. Locate the filter so they can be changed without removal of hydraulic system components. The filter must be equipped with a color coated visual indicator dirt alarm and a bypass check set to 25 psi. The filter must have a minimum capacity of 50 GPM at a pressure drop not exceeding 10 psi. The filter element must be a spin-on style and have a rating of 25 microns absolute unless a smaller mesh is recommended by the manufacturer of the component with the highest cleanliness requirement. Elements to be compatible with existing filter elements on existing HPU which are Schroeder brand KM25 elements. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Control Valve: A total of six directional control valves are required for the HPU. Each control valve must be a 3-position 4-way double solenoid spring centered, closed center control valve. The control valve shall be of cast iron or steel construction with an operating pressure of 3,000 psi. The control valve must be subplate mounted.

Each valve must be rated for a minimum of 50 GPM flow. Directional control valves are to include manual overrides. Supply power for the valve with an input of 120 VAC. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Direct Acting Sequence Valve: A total of six direct acting sequence valves to be installed per the circuit. The valve must be direct operated, externally drained and adjustable for operating per the design parameters. Valves are to be subplate mounted and cast iron or steel construction. 4 valves are to have a pressure range of 125-500 psi and 2 valves are to have a pressure range of 75-250 psi. Permit free flow in the reverse direction. The valves are to be set to the pressure described on the hydraulic circuit. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Pressure Reducing Valve: The HPU must include two pressure reducing valve. The valve must be a pilot operated pressure reducing valve. Each valve body must be of close grain alloy cast iron or forged steel. Each reducing valve must have a pressure range of 1000-3000 psi and be set at 1,800 psi. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Flow Control Valve: The HPU must include two pressure compensated flow control valves. The valves must be of steel or cast-iron construction, subplate mounted flow control valves. Maximum operating pressure rating is 3,000 psi and provide adjustable flow from 0 to 30 GPM set to GPM listed on circuit. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Check Valve: The HPU to include ball or poppet style check valves as indicated on the hydraulic circuit. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Ball Valve: Ball valves must be in-line mounted, lever operated, ball type valves. Ball valves to match line size and have a maximum allowable working pressure of 3000 psi. Valves to be specifically designed and rated for hydraulic system applications and have a removable operating lever. Ports to be designed for SAE O-Ring fittings sized for designed flow.

Controller: The HPU must include electrical controls housed in a NEMA 4X single or dual door enclosure as specified in the electrical drawings. The controller must be bolted to the HPU unit. The controller shall be manufactured and tested by a company with an active UL 508A certification.

Electrical Coordination: The Contractor shall design the electrical coordination of the new feeder in conjunction with the Controller’s power circuits. The Contractor shall provide design coordination documentation for approval prior to manufacturing or installation.

Paint:

Shop prime and coat all exposed exterior surfaces of assemblies and equipment except stainless steel, synthetic rubber, and plastic with manufacturer’s standard finish for specified service conditions. Insofar as is practicable, apply the complete coating system to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion. Paint shop assembled equipment prior to any storage or shipment. Do not paint aluminum, stainless steel, non-ferrous surfaces, or machined surfaces requiring field assembly, except as approved. Paint standard manufactured equipment, such as motors, pumps, hydraulic cylinders, valves, in accordance with the manufacturer's standard practice for high humidity service, subject to approval. Repair chips, scratches, and other damage to shop- applied painted surfaces in the field.

Field Installation of HPU:

The Contractor shall provide a detailed schedule for installation. The Contractor must leave operational one service gate, one emergency gate, and one low flow gate operational during field installation. Outages shall not exceed 48 hours in duration. The Contractor will be responsible for proper installation and incorporation of the auxiliary HPU with the existing unit on the 1289 elevation level. Locate the new HPU on 1337 elevation level as shown on drawing MY-101 in approximate location. Install new hydraulic tubing along the wall of the tower and down through the existing square opening in the floor. These tubes will then be ran along the ceiling and down the wall to the existing unit where they will be connected to existing lines approximately as shown on the image attached to drawing MY-101. Tubing must be seamless, stainless steel tubing used for hydraulic circuits in accordance with ASTM A269 Grade TP 304 and of the sizes indicated on the drawing. All tubing to be rated for a working pressure of 2,500 psi with a factor of safety of 4 against bursting pressure in accordance with ASME B31.1 this includes any necessary derating of tube due to tubing bending. Contractor to submit minimum bend radius and related compliance calculations. Provide flareless type tube fittings with SAE straight threads and Buna N O-Ring seals. Each fitting to hold the tubing with a chucking action and provide a firm flat grip on the tubing without penetration of the tubing wall. Fittings not to twist the tubing during assembly. Each fitting connection to be capable of no less than 30 connect-disconnect-reconnect cycles without galling, leaking, or any other damage. Provide all tube fittings without special adaptors or custom-designed assemblies. Hydraulic tubing must be flushed after connecting the lines to ensure no contamination exists. The Contractor must develop a plan for proper installation and have it approved by COR. See appendix for all required testing and standards to complete the project.

Existing HPU on 1289 elevation level will need to be modified in order to incorporate the new system. In accordance with MY-501, there will be a need for two additional penetrations in the existing oil reservoir. The new penetrations are to be made in the top of the existing tank. The tapping of the existing tank for the new ports should be done with the hydraulic tank drained and a method of catching the metal shaving in place.

After draining and completing work on the existing HPU the existing hydraulic system must be cleaned and flushed and the system refilled with hydraulic oil per appendix. A detailed plan as to how this work will be performed is to be submitted by Contractor. One will be for an oil float switch and one will be for a suction line for the transfer pump. The oil float switch will be the same type as specified for the new tank and wired into the existing control panels. The Contractor will wire the float switch into the existing control panel to shut down the local pumps as well as turn on an independent indicator light for either “high level” or “low level” and if either light is activated, send a signal to the remote unit to fire the system fault light. A transfer pump system will be installed on the existing HPU level in order to provide a system to transfer oil from one level to the other level in the event of a high oil alarm. The schematic of the transfer pump is shown on MY-

501. The transfer pump system must be controlled from 1337 level and power to ran down to the transfer system on the 1289 level.

Transfer Pump System: System will include the following components.

Hydraulic Pump: A hydraulic pump driven by the electric motor. The pump must be a positive displacement, gear type fixed displacement pump with a minimum 5 GPM nominal flow at 2500 psi. Maximum rotational speed must be no greater than 1200 rpm. Equip the pump with safety guards for all exposed rotation parts.

Pumps are to include flange style Code 61 fittings for the suction and pressure ports.

Electric Motor: A electric motor is required that will drive the transfer gear pump. The electric motor will be a

0.75 HP, 1200rpm, 1 phase, 60hz, 240V motor coupled to the gear pump.

Control Valve: A control valve is required for the transfer pump system. The control valve must be a 2-way control valve that is a solenoid open, spring return closed spool. The control valve shall be of cast iron or steel construction with an operating pressure of 3,000 psi. The control valve must be subplate mounted. Each valve must be rated for an adjustable flow rate of 0-10 GPM flow. Supply power for the valve with an input of 120 VAC. Ports to be designed for SAE O- Ring fittings sized for designed flow.

Additionally, the electrical control systems must be built and incorporated into the existing tower systems as described on E-100 thru E-104.

Power Distribution: The contractor shall install a 480V 3 phase power circuit to the auxiliary HPU from Panel 1P. The contractor shall provide and install a 200A, 25kA, LSI breaker. The breaker shall be the same manufacturer as the panelboard. The contractor shall run a 2/0 XHHW-2 feeder with a 1/0 ground conductor from Panel 1P to the auxiliary HPU at 1337 elevation. The feeder shall be ran in 2” galvanized rigid metal conduit its entire length. Install appropriate expansion joints an all runs 25’ or greater. Fittings, hardware and Unistrut shall match the conduit’s galvanized steel. All electrical work shall be in accordance with NFPA 70. Final locations to be determined by the COR.

Remote Control Wiring: The contractor shall run all control circuits from the auxiliary HPU to the existing Remote Station on the second level. All conductors shall be #10 XHHW-2 and installed in 2” galvanized rigid metal conduit its entire length. Install appropriate expansion joints an all runs 25’ or greater. Fittings, hardware and Unistrut shall match the conduit’s galvanized steel. All electrical work shall be in accordance with NFPA 70. Final locations to be determined by the COR.

Electrical Testing:

1. Insulation Testing – Provide testing procedures with pass/fail criteria and results collection for performing comprehensive insulation testing on the HPU controller, power feeder and control wiring.

2. Factory Testing

a. Electrical/Controls Functionality – Provide testing procedures with pass/fail criteria and results collection to verify proper operation of all controller functions.

b. Factory Acceptance Testing – Provide the COR with at least 3 weeks notice to perform Factory Acceptance testing prior to equipment shipping. The contractor shall prepare a demonstration to prove functionality of the system and all its components.

For Factory Acceptance Testing provide testing procedures with pass/fail criteria and results collection to verify proper operation of all controller functions upon testing date notice.

Testing would be limited to one working day.

3. Field Testing

a. Electrical/Controls Functionality – Provide testing procedures with pass/fail criteria and results collection to verify proper operation of all controller functions.

Appendix

The following information has been adapted from UFGS 35 05 40.14 10 and is to be used as the standards for all fabrication, assembly, testing and installation.

1 SHOP ASSEMBLY

A. General - Shop Assembly

Completely assemble the hydraulic power unit in the shop. Upon satisfactory completion and verification of the shop assembly and testing, preliminary acceptance will be made by the Government and parts/components may be shipped to site.

B. Protection During Assembly

During HPU assembly securely cover all openings to avoid the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of piping, tubing, and ports of the components.

C. Cleaning and Protection During Assembly

During assembly, ensure all components are free of abrasives, dirt, metal chips and other foreign materials. Clean components as needed to remove foreign materials. Securely cover openings to prevent recontamination.

D. Flushing

After completing assembly, flush each HPU. Use the same hydraulic fluid for flushing as approved for the final filling. Filter oil using a 10 µm filter. Perform flushing until the contamination level is [18/16/13] in accordance with ISO 4406. Take three 500 milliliter samples at approved locations in accordance with ISO 4021. Perform particle counting on each sample in accordance with ISO 11500 or ISO 4407 by an approved independent test laboratory.

Water content of each sample to be below 200 ppm. Reclean if any sample does not comply with the permissible contamination limits and reinspect. Submit shop oil testing reports.

2 SHOP TESTING

A. General - Shop Testing

Perform the shop testing listed in the following paragraphs. Provide all personnel, tools, hydraulic fluid as a well as temporary piping, hoses, oil reservoirs, wiring, and other appurtenances and accessories as needed to complete testing. The designated Government Witness must be present for the entirety of each test unless previously waived in writing.

B. Notification of Shop Testing

Provide notification to the Government [14] days prior to the planned start of testing. Include in the notification an identification of what equipment is being tested.

C. Hydraulic Power Unit Tests

Perform a shop test on the hydraulic power unit. Provide all temporary oil, piping, hoses, oil reservoirs, wiring, and other appurtenances and accessories as needed.

During testing the temperature of oil during test not to be more than 125 degrees F. If at any time during any of the testing a deficiency is found or failure occurs, immediately stop the test, correct the issue, and restart that portion of the test from the start. The shop test must consist of the following operations and tests:

1) Perform a hydrostatic test of all piping on the HPU. Use a test pressure of 3000 psi for 30 minutes. Check all joints for leakage. Any leakage found is cause for rejection and a failed test.

2) Perform a hydrostatic test of the storage tank. Use the specified hydraulic fluid as the test fluid. Use a test pressure of 3 psi for 30 minutes. Check all joints and seals for leakage.

Any leakage found is cause for rejection and a failed test.

3) Perform a functionality and controls test. During the test:

1. Verify the correct function of each switch, indicating light, and, outputs/alarms.

2. Verify the correct function of each measurement instrument and device.

3. Verify the correct function and operation of each valve and valve operator.

4) Perform an operational test of the HPU consisting of the following:

1. Operate each pump individually for 15 minutes at the specified operating pressure and flow rate 2,500 psi and 25 GPM. Measure pressure, flow rate, motor voltage, and motor amperage using calibrated instrumentation and data collection equipment. Collect a data at a minimum of 10 samples per second.

2. Operate all pumps simultaneously for 15 minutes at the specified operating pressure. Measure pressure, flow rate, motor voltage, and motor amperage using calibrated instrumentation and data collection equipment. Collect a data at a minimum of 10 samples per second.

3. Test the function of each unloader circuit. Record the pressure at which the unloading valve opens and closes. Record flow rate through the unloading circuit with calibrated instrumentation. Collect a data at a minimum of 10 samples per second.

5) Test the function of each pressure relief valve. Record the pressure at which the pressure relief valve opens and closes. Perform the test 3 times.

6) Operate each pump as lead pump and test the lag functionality of the remaining pumps. Manually jumper, actuate, or otherwise trigger the required devices to initiate lag pumps starting.

D. Draining of Fluid Upon successful completion of flushing and testing operation, drain the flushing fluid from the equipment.

E. Shop Testing Plan and Procedures

Prepare and submit a shop testing plan and procedure prior to the start of testing. Shop testing activities are not allowed until the testing plan is approved. Submit the testing plan a minimum of

[30] days prior to the start of testing. Include the following elements, as a minimum, in the testing plan:

1) Address of testing location and contact information for the designated point of contact.

2) A step-by-step, repeatable procedure for each test to be performed, including but not limited the tests detailed above.

3) Diagrams or drawings of test setups showing orientation of equipment during testing and installation of instrumentation.

4) List of instrumentation that will be used to take measurements.

5) Sample data collection sheets, clearly identifying what is to be recorded, to what accuracy, and the planned outcome (such as value range, threshold, or condition).

F. Shop Testing Report:

1) After completion of each test or group of tests, submit a test report. Include the following elements, as a minimum, in the testing plan:

G. Date(s) testing occurred

H. Identification of which equipment was tested

I. Completed data collection sheets.

J. Provide records of all adjustments and final settings for all hydraulic components in the system.

This includes pump flow rates, operating times, relief settings, sequence valve adjustments, operating pressures at both the hydraulic power units and cylinder manifolds, flow level adjustments, and other parameters.

K. Post-processed output from any data collection equipment

L. Identification of a successful test. If any test stoppages or failures occurred, identify them and the measures taken to correct the deficiencies.

M. Current, non-expired calibration certificates for all instrumentation and measurement devices used during testing.

3 SHIPPING, HANDLING, DELIVERY, AND STORAGE

A. Packaging: Do not prepare the hydraulic power systems for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer, unless inspection has been waived in writing. Ship each hydraulic power system or subassembly completely assembled as feasible. [Any separate delivery of components must be coordinated by the Contractor and noted in a submittal.] The subassemblies are defined as the following:

1) Hydraulic power units.

2) Piping assemblies.

3) Control consoles.

Provide all subassemblies and spare equipment and parts with adequate protective pads, supports, and blocking, and securely restrained to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, will be the Contractor's responsibility; replace or repair without any cost to the Government. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY" or "SPARE PARTS ONLY." Place a packing list, listing the contents of each container, in a moisture-proof envelope and securely fasten to the outside of the container.

Standard commercial packaging in accordance with ASTM D3951 will be acceptable except where a different method or standard of packaging is specified.

B. Shipping, Preservation, and Storage: Packing, crating, cradles, and other packing materials necessary to ensure safe shipment are the responsibility of the Contractor and become the property of the Government upon delivery of the equipment. Adequately protect machined surfaces from corrosion and physical damage. Protect equipment delivered and placed in storage from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

C. Manufacturer Preparation Before Shipment: After cleaning and prior to shipment, flush each hydraulic power unit. Fill the hydraulic tank with hydraulic fluid as specified and actuate the oil filtration system with a 25 µm element in the filter. Circulate the fluid and change filters as become clogged. After flushing of the fluid in the tank is complete, install a by-pass loop with filter on the pressure and tank lines of the unit and the run pumps alternately until the returning oil meets the requirement for system cleanliness. Tank to be drained prior to shipment.

4 ON-SITE INSTALLATION

Install the equipment specified and as shown to complete the hydraulic power systems for operation of the gate cylinders. Install hydraulic components in accordance with the manufacturer's written instructions and under the direction of the erection engineer or manufacturer's representative. Install complete units or assemblies without disassembly. Provide necessary supports for all appurtenances, pumps, motors, and other equipment or components as indicated. Anchor floor- mounted equipment to concrete pads by anchor bolts or expansion anchors as shown. Submit an Installation Plan and Procedures.

A. Erection Engineer

Obtain the services of an experienced erection engineer who is regularly employed by the hydraulic cylinder/power unit manufacturer to supervise the installation, start-up, adjustment and operation, and testing of the equipment provided. The erection engineer to furnish a signed statement stating that the final installation and start-up of the hydraulic power system has been inspected, witnessed, and complies fully with the manufacturer's warranty requirements. Following completion of the work the erecting engineer to instruct the Contracting Officer in the operation and maintenance of the system. These field instructions to cover all items contained in the bound instructions. Do not conduct instruction until Operation and Maintenance Manuals are approved.

B. Filling And Bleeding The System

With all hydraulic equipment installed and all cleaning and flushing complete filling of the system may begin. The cleanliness of the oil used to fill the system in accordance with the requirements for system cleanliness. Open the by-pass ball valves at the cylinders. Fill each hydraulic power unit and pump oil into the system through a 25 µm filter and keep adding oil as long as the level continues to drop. Cease pumping when the oil level no longer drops. Install by-pass piping and repeat the procedure to fill the drain/siphon line. Take care to expel as much air as possible from the piping and cylinders during the initial filling.

Utilize piping vents and drains as much as possible to expel air from the system. Each power circuit pipe for the gate cylinder to have this procedure performed to fill the respective piping. Actuate cylinders by shifting spool on the four-way valve back and forth and bleeding air from ports provided on cylinders. Continue procedure for all hydraulic power units until all cylinders have been bled. Ball valves in tank lines may be closed during bleeding to prevent introduction of air into tank lines. After all the cylinders for the machinery have been filled and bled of air, fill the hydraulic power unit tanks with oil approved by site and COR. Submit oil recommendations prior to field installation. The oil level with the gate cylinders in their normal operating positions should be approximately 500 gallons. The system, once filled, to be bled of air, operated, and periodically bled during the first week of operation to remove any air entrained in the system.

C. Used Hydraulic Oil

Contractor is responsible for the containment, transfer, removal, and disposal of all used hydraulic oil. Used hydraulic oil includes any oil in existing components being removed or refurbished, and any generated used oil from flushing, draining, or bleeding activities as identified in this section.

Containment, transfer, removal, and disposal procedures for the used oil must be detailed in the applicable removal and installation procedures.

D. Power Piping and Hoses

The general arrangement of the hydraulic piping and hoses is as indicated. Any changes to the arrangement necessary to facilitate the installation and proper functioning of the system may be made subject to the approval of the Contracting Officer. Arrange the piping such as to close and open the gate cylinders when the valve spools are positioned as indicated.

E. Piping Installation

Install the system complete including all necessary valves, fittings, and pipe accessories. All joints to be tight and successfully pass the test as specified. Submit details of pipe supports and anchors not indicated. Adequately support all lines at intervals not greater than 10 feet or as otherwise indicated. All anchor bolts and pipe supports are to be of stainless-steel construction. Install hangers and supports using machine bolts and masonry anchors caulked in drilled holes in the masonry or by using machine bolts and expansion shields. Power piping must not be used to support other equipment. Other equipment can use the same standoff or hanger mounting point as one to support the piping, but the pipe itself must not provide the support of the equipment's load. Spacers and guides can be used if no load is transferred. Ream and remove burrs from all cut ends of pipe.

Remove metal particles from the reaming operations and thoroughly clean ends of pipe before proceeding with the work. Tightly plug all piping at all times except when work is being performed on a pipe. Clean the pipe sleeves, recesses and trenches of all debris and thoroughly wash with a high pressure stream of water before any piping is installed. Drilling, chipping, or grinding of concrete in close proximity of any piping being installed is not permitted. Repeat washing out of the sleeves, recesses and trenches from time to time as necessary. Store valves in a clean, dry place and protect against moisture. Do not install valves in the system prior to 4 months before the system is to be filled with hydraulic oil. Install pipes passing through masonry in pipe sleeves as indicated.

Mitering of joints for elbows and notching of straight runs of pipe for tees is not permitted.

F. Support of Valves with Manual Operators

Valves that operate through a manual operator (such as a handwheel or handlever) connecting to hydraulic tubing must have a hanger or support on each side of the valve within 1 inch of the connection. Such valves include block, ball and needle valves. The hangers or supports must translate the load from the use of the manual operator away from the connection of the valve and tubing. Valves used with hydraulic piping larger than 2 inches in diameter may not require this additional support if the manual operator can be used without induction detrimental induction of forces into the assembly.

G. Support of Cartridge Components

Components, such as filters, that require the periodic removal and installation of housings and cartridges, must not be supported by hydraulic tubing. The component's manifold or housing must be directly supported so that the forces used to perform the periodic removal and installation of the housing or cartridge element is not translated into its connection with the hydraulic tubing or piping.

H. Identification of Piping, Hoses, and Valves

Identify all pipe, tubing, valves, fittings, as required, and hydraulic power equipment, located within the trenches, machine rooms, and machinery recesses. Use No. 20 gauge brass tags for tagging, with the proper identification symbol stamped into the metal. Use piping symbols as indicated and stamp with 19 mm or 3/4-inch high lettering. Attach tags to piping and valving by means of No. 12 gauge copper wire. Install pipe markers at intervals of no greater than 5 m or 15 feet, except as approved.

1) Provide a numerical identification tag on each valve, coded such that no other valve in a connected hydraulic power system has the same number. Provide each power circuit valve with an additional tag, which indicates the valve's function.

2) Provide manifold-mounted valves with port identification markings on a part of the valve body that remains in view after mounting.

3) Identify all other valves at the port location, on the connecting piping.

4) Identify manifold assemblies with a tag indicating the manifold's function and the identity of the machine operated.

5) Identify all ball, bleed, and globe valves with a "normally closed" or "normally open" legend.

6) Identify all gauge mounts and pressure transducer mounts with numerical tags, as well as any working or instruction tags required for safe operation.

7) Provide a warning tag and an instruction tag, or tags as required, at each return filter assembly to indicate the safe, approved procedures for cartridge replacement and by-pass operation.

5 CLEANING AND FLUSHING

During assembly, securely cover all openings to avoid the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of piping, tubing, and ports of the components. Use the same hydraulic fluid for flushing as approved for final filling. Include a detailed description of the equipment, materials, hydraulic fluid, temperatures, and duration of each phase of the flushing in the submitted procedures. Clean the system of particles so that the contamination level is below [18/16/13] in accordance with ISO 4406. Take three 500 milliliter samples at approved locations in accordance with ISO 4021. Perform particle counting on each sample in accordance with ISO 11500 or ISO 4407 by an approved independent test laboratory.

Water content of each sample to be below 200 ppm. Reclean if any sample does not comply with the permissible contamination limits and reinspect. When flushing is completed, drain the system and then fill with the specified hydraulic fluid introduced through a 10 micron filter.

A. Flushing Piping/Tubing

Flush all new hydraulic piping/tubing before installation of the hydraulic power unit, cylinders, and manifolds. Install by-pass loops of piping in place of cylinders, manifolds and the power units.

Circulate hydraulic fluid through each and every pipe unit until returning oil meets the requirement for system cleanliness. Sequence flushing so that all piping/tubing is flushed in both directions.

The flow capacity of the flushing system to produce aminimum velocity of 15 feet per second in all piping/tubing. Provide means to verify the flow during the flushing operation. Additionally, the flushing equipment must also be capable of heating the oil to a minimum of 140 degrees F.

B. Flushing Manifolds and Hoses

After cleaning and prior to installation, flush each valve manifold, pipe manifold, and hose by circulating hydraulic fluid through all ports until the returning fluid meets the requirement for system cleanliness.

6 FIELD TESTS AND INSPECTIONS

A. General Requirements - Field Testing

The following requirements apply to all testing activities:

1) Notify the Contracting Officer at least 14 calendar days before any field testing is to be conducted.

2) Conduct testing in the presence of the Contracting Officer unless waived in writing.

3) Conduct testing under the direction of the erection engineer or manufacturer's representative.

4) Constantly monitor details of all operations for signs of impending trouble or leakage and make corrections as necessary to prevent damage to the equipment.

5) Immediately correct any deficiency or maladjustment disclosed by the tests and repeat the test until satisfactory results are obtained. No subsequent tests will be permitted until all preceding tests have been completed satisfactorily.

6) No subsequent tests will be permitted until all preceding tests have been completed satisfactorily.

B. Field Pressure Testing

1) Pressure Testing Requirements Perform a hydrostatic pressure test for all new installed piping and equipment. Pressure testing may be split up into distinct and separate portions as determined by the Contractor.

Perform the pressure testing in accordance with the following requirements:

1. Use the hydraulic fluid specified in this SECTION as the test fluid.

2. Use a test pressure of 2,500 psi.

3. Perform each test for a minimum of [1 hour] and additional time as needed to verify no leakage.

4. Inspect all joints, seals, packing, valves, and other areas that are possible leak points. Carefully examine welded, flanged, flared, and threaded connections and wipe for leakage, also inspect lines for evidence of deflection caused by inadequate anchorage.

5. The criteria for a successful test is zero leaks, zero drop in pressure, and no deflection of piping or equipment.

6. Take means to protect other portions of the system not being tested from becoming inadvertently pressurized during testing.

(2) Field Pressure Testing Plan Prepare and submit a pressure testing plan a minimum of [30] days prior to the start of testing.

The plan must be approved prior to the start of testing. Include the following elements, at a minimum, in the plan:

1. A step-by-step, repeatable procedure for performing the pressure testing.

Address how challenging to reach portions of the equipment will be accessed for inspection during the test. Address installation details of temporary instruments and measuring devices.

2. List of equipment and instrumentation to be used during the test.

3. Spill protection, controls and counter measures plan to address plans and response to any leaking oil.

4. Sample data recording sheets.

(3) Field Pressure Testing Report

For each pressure test performed, submit a test report. Include the following elements, at a minimum, in the report:

1. Date(s) testing took place

2. Identification of the equipment or systems of equipment tested and covered by the test report.

3. Completed data recording sheets with the results from testing.

4. Short narrative or statement confirming successful completion of the test.

5. If issues were discovered during testing and any testing had to be repeated, provide a narrative describing the issues and the measures taken to correct the issues.

6. Current, non-expired calibration certificates for all instrumentation and

C. Field Functional Testing

1) HPU Functional Testing Requirements Perform the following functional tests and inspections for the HPU:

1. Inspect the hydraulic reservoir to ensure that the fluid is at the proper level.

2. Start the hydraulic pumps from all control stations.

3. Pumps:

a. Inspect the pumps for proper operation and discharge pressure.

b. Verify proper operation of the pump controls.

c. Read and record the discharge pressure and flow.

d. Monitor and record, using data collection equipment, the motor voltage and amperage during all motor operations.

4. Adjust the pressure relief valves to limit the system pressure to the specified value. Record the set pressure and valve adjuster setting.

5. Adjust the unloading valves to unload the pumps to the reservoir. During initial system startup and when a function is not being performed.

Measure and record unloader settings, actuating pressure and flow rate during unloader operation.

2) Control Console Functional Testing Requirements For each control console:

1. Verify the correct operation of each devices on the control console, including but not limited to: manual shut-off valves, manual control valves, manual flow control valves, solenoid operated valves, check valves, pressure gauges, etc.

2. Test all automated control systems and devices.

3) Field Functional Testing Plan

Prepare and submit a functional testing plan. Submit plan a minimum of [45 days] prior to the start of testing. Plan must be approved by the Government prior to the start of testing.

Include the following elements in the plan at a minimum:

1. A step-by-step, repeatable procedure for performing the functional testing.

The procedure must individually address testing of the controls and control consoles and the HPU.

2. List of equipment and instrumentation to be used during the test.

3. Spill protection, controls and counter measures plan to address…