MP Gear Box SOW 2021.doc

US Army Corps of Engineers

St. Louis District

Gear Box Rehabilitation/Repair Rivers Project Office

St. Louis District Melvin Price Locks and Dam

SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

May 2021

BID SCHEDULE

MELVIN PRICE LOCKS AND DAM

Inspect, Rehabilitate, Repair

UOM

Cost

1. Gear Box 1

EA

2. Gear Box 2

3. Gear Box 3

4. Gear Box 4

5. Gear Box 5

6. Gear Box 6

7. Gear Box 7

8. Gear Box 8

9. Gear Box 9

10. Spare Gear Box

11. Spare Gear Box

12. Technician Hourly Rate

HR

13. Unknown Repair

JA

TBD

SCOPE OF WORK:

The Contractor is to furnish all labor, equipment, freight, materials, supplies and incidentals to inspect, rehabilitate/repair and/or remove and reinstall 9 Model 900 A gear boxes currently in use and 2 spare Model 900 A at Melvin Price Locks and Dam. The contractor shall follow all Standard Operating Procedures (SOP) for all work associated with rehabilitation/repairs on gear boxes. Rehabilitation/repairs shall include, but not limited to, the disassembly and inspection of all electrical and mechanical parts; steam cleaning of all parts; strip, rewind, dip, and new bake stator; installation of new bearings, balancing of rotor; reassembly of gear boxes, test run of gear boxes on full voltage and total repaint of gear boxes. All reusable torque transmitting components shall be Magnetic Particle inspected to ensure they do not show any indications of operational distress and will continue to operate with long term reliability.

REQUIREMENTS:

1.0 General. The contractor shall inspect, rehabilitate, repair Model 900A gear boxes in accordance with Philadelphia Gear Company original design manufacture specifications.

2.0 Removal/Reinstallation of gear box. The contractor will be responsible for removal and reinstallation of each gear box. A new spare gear box will be installed in place of gear box 1. Once gear box 1 has been rehabilitated it will then be installed in place of gear box 2 and continue until all 9 are rehabilitated. Only one gear box can be rehabilitated at a time. Dam operating system shall remain operational at all times except during removal and installation of the gear box.

3.0 Inspection process of gear box. All gear boxes will be inspected per IAW Philadelphia Gear Company SOP to include but not be limited to the following:

· The contractor shall take digital photographs to document the “As-Received” condition of the gear box both exterior and interior.

· The exterior of the gear box shall be thoroughly cleaned as necessary in preparation for visual inspection.

· The gear box shall be thoroughly disassembled.

· All external and internal components shall be removed as required for inspection.

· All internal and external components to be inspected shall be thoroughly cleaned.

· The contractor shall take digital photographs of all damaged areas.

· If a repair other than what is considered part of a basic rebuild is deemed necessary the contractor shall notify the Government before making the repair and the cost shall be negotiated.

4.0 Housing and Covers. The contractor shall clean, sand blast and prime the interior and exterior of the gear box housing and covers. The contractor shall replace all components that were identified in the inspection of all gear box cover studs and inspection covers.

5.0 Bearings. The contractor shall replace all bearings to restore the unit’s efficiency and reliability. All bearings shall be precision rolling element assemblies per the original drive configuration. Bearing capacities shall match the AGMA and AFBMA rating methods originally employed.

6.0 Gears and Shafts. The contractor shall replace all worn shafts, worn gears and LS shafts in each gear box. Gear capacities shall match the AGMA and AFBMA rating methods originally employed.

7.0 Seals, Shims, Gaskets and O Rings. The contractor shall replace all seals, shims, gaskets and O rings in each gear box. The contractor shall replace all oil-level gauges, breathers, thermometers and gate valves. All locating plugs, pins, nuts, bolts and washers shall also be replaced.

8.0 Performance Testing. The contractor shall provide standard mechanical no-load, full-speed, mechanical spin-test for a minimum of ninety (90) minutes. Operating temperature, sound, vibration, oil pressure and flow levels will be recorded on all rehabilitated gear boxes.

9.0 Painting. The contractor shall paint each unit with a high quality, high-solids “Slate Blue” epoxy finish. A rust-preventative that provides six months of protection shall first be applied prior to painting the exterior of the gear boxes.

10.0 Performance Period: The period of performance for this contract shall be for five (5) years commencing from the date of award. Each gear box shall be completed no later than 6 months from removal to installation.

11.0 Submittals. Certificate; GA. The contractor shall provide a 5 year warranty on new enclosed drives, a 3 year warranty on overhauled drives and a OEM parts 1 year warranty on onsite technical services for government approval.

12.0 Submittal Performance Testing; FIO. The contractor shall provide upon completion of rehabilitation of each gear box the standard mechanical no-load, full-speed, mechanical spin-test results for each gear box.

13.0 Submittal Paint; GA. The contractor shall provide color chart for government approval.

14.0 Safety. The Contractor shall perform all work in accordance with safety requirements set forth in U.S. Army Corps of Engineers Safety Manual, EM 385-1-1 entitled, "Safety and Occupational Health” manual, 2008. Copies of which are available at http://www.usace.army.mil/CESO/Pages/EM385-1-1,2008NEW!.aspx.

15.0 Contract Area. The contract area will be at Melvin Price Locks and Dam, #1 Lock and Dam Way, East Alton, IL 62024 in Madison County, Illinois.