DRAFT_PWS_Pump_Bearing_Repairs_1.pdf

PERFORMANCE WORK STATEMENT (PWS)

FOU Pump 2, 4, 5 and 6 Repair and Commissioning

1.0 BACKGROUND

A. Folsom Pumping Plant, located in Folsom, California, function is to provide water to the surrounding area, including the city of Folsom, city of Roseville, and the San Juan water district. Currently Folsom Pumping Plant has seven (7) pumps, and it is critical to have all pumps available to maintain reliable water supply to surrounding cities. Currently four pumps are out of service, and two are showing signs of failure. This PWS is specific to the inspect, repair, and commission pumps 2, 4, 5 and 6.

B. Pump specifications:

Pump No. Pump 2 Pump 4 Pump 5 Pump 6

Model 16_LAS_2 Volute

20_LAS_2

Volute

20_LAS_2

Volute

I-R/30ALV

Serial No. 1414439 1414442 1414441 05533222

Driver HP 250 400 400 800

RPM 1200 900 900 514

Total Dynamic Head

100ft 82ft 82ft 60 ft

GPM

(CFS)

9,000 (20 CFS) 17,500 (39 CFS) 17,500 (39 CFS) 33,660 (75 CFS)

2.0 SCOPE

A. This contract is to inspect, replace bearings, provide spare parts, and commission four (4)

Horizontal Between-Bearings Split Case Centrifugal Pumps for the Central California Area Office (CCAO) of the California Great Basin Region, Bureau of Reclamation

(BOR).

B. Requirements

1. Measure, supply, and install discharge and suction pipe flanges for each pump while pump is removed from service.

2. De-couple, remove, and transport pump 2 and pump 4 for in-house machine shop inspections. Replace pump 2 and pump 4 thrust and line bearings.

3. Install, align, and commission pumps 2 and 4.

4. De-couple, remove, and transport pump 5 for in-house machine shop inspections.

Replace pump 5 thrust and line bearings.

5. Install, align, and commission pump 5.

6. De-couple, remove, and transport pump 6 for in-house machine shop inspections.

Replace pump 6 thrust and line bearings.

7. Install, align, and commission pump 6.

8. Provide CCAO with new spare wear rings and spare bearings for pumps 2, 4, 5, and 6.

9. One year warranty on all parts and labor from date of delivery.

3.0 Place of Performance

A. All pumps are located at the following address:

US Bureau of Reclamation Central California Area Office Folsom Pumping Plant Attn: Jarad George 7794 Folsom Dam Road Folsom, CA 95630

4.0 Period of Performance

A. Pump 2 and pump 4 inspection, bearing replacement, and commissioning must be completed within 28 days after request from government representative.

B. Pump 5 inspection, bearing replacement, and commissioning is performed and completed within 28 days after section 4.0 A is complete.

C. Pump 6 inspection, bearing replacement, and commissioning is performed and completed within 28 days after section 4.0 B is complete.

D. All warranty claims must be completed within 35 days of CCAO notifying the contractor.

E. Period of performance for all other tasks will be 180 days after request from government representative.

5.0 Administrative Requirements

A. Definitions

1. The follow acronyms, terms, and wording will be used throughout this Performance Work Statement.

• CO – Contracting Officer

• COR – Contracting Officers Representative

• CCAO – Central California Area Office

• Contractor – Prime Contractor awarded contract

• CGB – California Great Basin Regional Office B. Contractor Furnished Items and Services:

2. The Contractor shall provide all equipment, supplies, management, supervision, personnel, and transportation except as specified herein as Government-Furnished, necessary to assure that all services are in accordance with the contract and all applicable laws and regulations.

3. The Contractor shall ensure all work uses quality workmanship that meets current industry performance standards and standards specified in this Performance Work Statement (PWS).

C. Government Furnished Property, Equipment, and Services

The Bureau of Reclamation will provide the following:

• Provide access and required site safety orientation, if required.

• Provide material lifting/handling equipment, if required.

• Provide clear access to the pump.

• Provide electrical power (120v / 480v) as necessary.

• Provide plant compressed air (up to 50 CFM at 90 psi) as necessary.

• Wash up / toilet / break facilities.

• Material staging areas.

• Trash disposal area.

D. Administration of this contract shall be by the Contracting Officer’s Representative (COR) appointed by the Government.

1. Contractor communication and coordination of work shall be through the COR.

2. The COR may hold Government on-site inspections at points listed in Section 7.0 Specific Tasks and Section 11.0 Quality Assurance and Surveillance Plan.

a) Notify the COR within 5 working days before an inspection point is to occur.

3. The Contractor shall perform the work as defined under Section 7.0, Specific Tasks.

a) Additional work, as may be required and resulting from deficiencies identified by the post application testing, can only be performed upon written authorization by the Contracting Officer (CO) with a contract modification.

b) The only person that has the authority to modify the terms of the contract or request work for which compensation will be provided is a CO.

i) If the Contractor receives a request from Government personnel directing or requesting work that the contractor believes is not within the terms of the PWS or the contract, then the Contractor must notify the CO of the request.

c) Contract modifications are subject to the terms contained within these contract documents unless otherwise stated.

4. Contractor shall provide a point of contact: name, title, telephone number and email address during normal working hours for the government to schedule work under this contract.

E. Contract requirements

1. Experience reburnishing similar size or larger horizontal, between-bearings, double suction, centrifugal pumps or is the OEM.

2. Identify the OEM or equivalent inboard and outboard bearings for the pump, specifications on the bearings, a vendor that will supply the bearings, the cost for replacement bearings, and the estimated lead time for the bearings by the vendor.

3. Contractor must have an in-house machine shop for restoring pumps. If a contractor wishes to use a subcontractor the subcontractor must be identified, GSA registered, and have an in-house machine shop for restoring pumps.

4. Contractor and all subcontractors must be within a 200 mile radius unless they are the

OEM.

F. Safety

1. Contractor shall perform the work in accordance with the applicable State and Federal OSHA standards.

6.0 Reference Standards

A. International Organization for Standardization (ISO) and American Petroleum Institute

(API).

1. ISO 13709 / API 610 - Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

a) API Standard 610 is the identical national adoption of ISO 13709.

B. Worthington 2120-E1E – OEM Instructions for Installation, Operation, and maintenance and List of Parts L Pumps Types L, LA, and LC Pumps 24”and Under

7.0 Specific Tasks

7.01 Blind flanges

A. Prior to starting work the contractor must identify and supply appropriate blind flanges for the suction and discharge valves for pumps 2, 4, 5, and 6.

7.02 Pump 2 and Pump 4

A. Pump removal

1. Contractor is responsible for safely decoupling from motor, frame, and piping. Once the pumps dresser couplings are removed the contractor shall install blind flanges onto the suction and discharge valves to isolate any potential water flow.

a) Please note, there may be lead pain inside the pipelines leading and following the pump. Use proper safe procedures to remove paint if necessary.

2. The contractor will be advised to take pre-pump removal measurements and photos to ensure proper pump install later.

3. Contractor will be responsible for loading and transporting pump to and from the contractor’s machine shop.

B. Perform pump inspection.

1. Disassemble horizontal pump, remove cooling lines, removing bearing cover, and pump cover.

2. Inspect bearings, cooling lines and water jackets, packing, sleeves, wear rings, and impeller.

a) Photograph and record inspection in inspection report.

3. Identify possible reason for outboard bearing overheating.

4. Provide inspection report to COR within 5 business days after inspection. Include all recommendations statements of work and estimated repair cost.

5. Before continuing with pump repair, COR must give approval to continue work.

C. Replace line and thrust bearings

1. Supply line bearings, thrust bearings, and hardware.

a) Contractor will be responsible to identify correct inboard (line) bearings, outboard (thrust) bearings, and appropriate hardware such as but not limited to grease seals, retaining collars, water shields, gaskets, set screws, bearing nut, and spacer collars for each pump. COR must approve identified bearings, quantity, and hardware.

2. Contractor will be responsible to install correct inboard (line) and outboard (thrust) bearings and necessary hardware.

3. Replace bearing that meet OEM specifications or API 610 section 5.10.1 and 8.2 standards.

a) Record bearing manufacture, model, and drawings in final report.

4. Replace bearing retaining collars and bearing nut as needed.

a) Record retaining collars and bearing nut used in final report.

D. Replace packing

1. Record packing manufacture, type, and quantity in final report.

E. Pump Assembly

1. Final inspection

a) Verify and measure impeller position to volute.

b) Measure clearances between wear rings.

c) Measure shaft runout.

d) Install bearing housing and record element lift.

e) Photograph and record all final measurements and checks on final report.

2. Deburr and clean gasket mating surfaces.

3. Replace gasket.

a) Gasket should be cut from one piece of the same material and thickness so that it will compress to the same original thickness.

b) Gasket material should be garlock or similar.

c) Gasket should be glued in place with quick gasket glue or equivalent.

d) Record gasket type and thickness in final report.

4. Install casing gasket and top half of case to specification (50/75/100 percent)

a) Record torque values in final report.

5. Replace coupling onto pump shaft.

a) Replace coupling rubber seals.

6. Ensure all piping, valves, and coupling for priming, draining, bearing cooling water (if applicable), and seal water piping are free of foreign material and working properly.

a) Replace all plumbing piping, valves, and couplings as needed.

7. Check if discharge and intake pressure gauges are working properly.

a) Replace pressure gauges as needed with similar.

F. Pump Install

1. Contractor will be responsible for loading and transporting pump from the contractor’s machine shop to CCAO’s pumping plant.

2. Contractor is responsible for safely coupling from motor, frame, and piping.

3. Contractor shall replace the suction and discharge dresser couplings seals.

4. Contractor shall notify the COR give CCAO ample time to wire each motor and perform a bump test prior to coupling pump to motor.

G. Coupling alignment

1. Align pump motor with pump using laser alignment.

2. Record procedures and as-left alignment specifications in final report.

H. Commissioning

1. Verify all fittings are torqued, bearings greased, coupling greased.

2. Support pump startup and observe pump start up and heat run.

3. Record commissioning in final report.

7.03 Pump 5

Repeat section 7.02 for pump 5 after pump 2 and pump 4 are returned to service or approved by COR to proceed.

7.04 Pump 6

Repeat section 7.03 for pump 6 after pump 5 has been returned to service or approved by COR to proceed.

Contractor shall replace the pump coupling key.

7.05 Spare replacement Supply

A. Supply replacement line bearings, thrust bearings, and hardware for pumps 2, 4, 5, and 6.

1. Record replacement bearings specifications in final report.

B. Supply replacement wear rings for pumps 2, 4, 5, and 6 that meet OEM specs.

1. Provide as-build drawings and wear tolerances in final report.

8.0 Deliverables

A. Blind flanges.

B. Pumps 2, 4, 5, and 6 inspected and bearings replaced.

C. Replacement thrust bearings, line bearings, hardware, and wear rings for pump 2, 4, 5, and 6.

D. Pump final report.

E. Itemized part replacement, including part specifications, model number, serial number, manufacture, and cost.

F. Pump 2, 4, 5, and 6’s OEM documents drawings including tolerances, clearances, parts list, installation, operation, maintenance, repair, original as-built drawing, and any other document that are pertinent to the installation, operation, maintenance, and repair of the pump.

G. Warranty

1. All materials and work shall be warranted by the Contractor for a period of one year after received by the Government.

9.0 Government supplied information.

A. See Section 13.0 Attachment/Technical Exhibit List for list of Government provided material.

10.0 Contacts

Central California Area Office (CCAO) Attn: Jarad George US Bureau of Reclamation 7794 Folsom Dam Rd.

Folsom, CA 95630

11.0 Quality Assurance and Surveillance Plan

A. If requested by the Government, manufacturing, processing, testing and inspection operations affecting the equipment or material shall be subject to surveillance by Government or Government's Contracting Officer’s Representative (COR).

B. All deviations from this specification must be documented and referred to Government for disposition.

C. Contractor shall furnish the following documents for the Government's records:

1. A Quality assurance plan that describes the contractor’s methods of assuring that items and services, including subcontracted items and services, comply with this specification. The quality assurance plan shall be submitted at least 14 days before the project begins.

2. Certificate of Compliance, stating the following: "All work provided by contractor under this specification complies with all requirements of this specification and accepted deviations."

3. Documents identifying deviations and their acceptance.

D. The Quality Assurance Surveillance Plan (QASP) is intended to establish guideline that shall be used to evaluate what level of success/completion the Contractor has achieved in executing the work as defined in the PWS. The absence of a QASP for any contract requirement, however, shall not detract from its enforceability or limit the rights or remedies of the Government under any other provision of the contract in determining the quality of the Contractor performance.

12.0 Performance Requirements Summary (PRS)

Performance Requirement Acceptable Quality Level Method of Surveillance

1. Government required documentation

2. Acceptance testing

3. Performance of minor maintenance and adjustments

4. As otherwise stated in the PWS

Each activity/task shall be evaluated for:

1. Responsiveness

a. To required documentation.

b. To technical requirements.

No more than two (2) issues with responsiveness for documentation and technical requirements.

2.Timeliness

1. Contractor executes each task or activity within the agreed upon timeframe.

2. All tasks and activities shall be

100% complete within the agreed upon timeframe. The Contractor may work with the COR if the timeframe becomes an issue.

3.Quality of Work

Contractor performed each task or activity with a clear understanding of the requirements.

Workmanship was free of defects.

No more than two (2) defects that the

Government finds outside of the Contractor QC process.

4.Completeness -

Contractor executes each activity in the PWS to completion.

All PWS activities shall be 100% complete.

COR to provide surveillance, track Contractor progress and performance, discuss findings and follow-up as necessary.

13.0 Quality Assurance Surveillance Plan (QASP)

TASK

DESCRIPTION

WHAT

WHO

WHEN

WHERE

METHOD

7.01 Blind flange

measurements Pumping Plant valves

COR,

Gov.

Rep.

Prior to pump removal

CCAO Observe measurements and psi ratings

7.02 A.

Pump removal and secure for transport

Pump 2 &

COR,

Gov.

Rep.

On-site pick-up

CCAO Sign pick-up inventory record

7.02 B.

As-found inspection

Pump 2 &

COR,

Gov.

Rep.

Disassemble pump completely

Contractor’s Machine Shop

Reviewing as-found documents

7.02 F-H

Witnessing of pump install, alignment, and commissioning

Pump 2 &

COR,

Gov.

Rep.

Pump install CCAO Witness installs and alignment measurements

7.03 A.

Pump removal and secure for transport

Pump 5 COR, Gov.

Rep.

On-site pick-up

CCAO Sign pick-up inventory record

7.03 B.

As-found inspection

Pump 5 COR, Gov.

Rep.

Disassemble pump completely

Contractor’s Machine Shop

Reviewing as-found documents

7.03 F-H

Witnessing of pump install, alignment, and commissioning

Pump 5 COR, Gov.

Rep.

Pump install CCAO Witness installs and alignment measurements

7.04 A.

Pump removal and secure for transport

Pump 6 COR, Gov.

Rep.

On-site pick-up

CCAO Sign pick-up inventory record

7.04 B.

As-found inspection

Pump 6 COR, Gov.

Rep.

Disassemble pump completely

Contractor’s Machine Shop

Reviewing as-found documents

7.04 F-H

Witnessing of pump install, alignment, and commissioning

Pump 6 COR, Gov.

Rep.

Pump install CCAO Witness installs and alignment measurements

14.0 Attachment/Technical Exhibit List

A. Government Provided Documents.

1. Worthington 2120-E1E – OEM Instructions for Installation, Operation, and maintenance and List of Parts L Pumps Types L, LA, and LC Pumps 24”and Under

2. Drawings:

Sheet No.

Drawing No. Drawing Title

1 NA NA

B. List of Photos

Figure 1 – USBR CCAO Folsom Pumping plant.

Figure 2 – Pump 2 inside pumping plant.

Figure 3 – Pump 2 thrust bearing housing and label.

Figure 4 – Pump 4 thrust bearing housing and label.

Figure 5 – Pump 6 thrust bearing housing and label.