SOW 21Q0017-rev a.pdf

SCOPE OF WORK

Bernville Levee Pump Overhaul PR&C No.: W25PHS10751608

INTENT

The intent of this scope of work is to remove, overhaul and reinstall one mixed flow storm water pump and its associated automatic greaser at the Bernville Protective Works (BPW) in Bernville, Pennsylvania. The pump to be removed and overhauled is Pump #6, however, if conditions change, a different pump may be substituted. The six existing pumps have serial numbers 76BT1573-G30 thru 76BT1578-G30. The automatic greaser is manufactured by FARVAL, Model FS05-0093-003.

REFERENCE DRAWINGS

1) Patterson Pump Dwg D-4142-3; Bernville Protective Works, 26x30 Type SAFV Pump

2) Parts and Material List for Type SAFV Pump

REFERENCE MANUAL

Patterson Pump – Operation &Maintenance Manual for Short Coupled Vertical Turbine

Pumps

HISTORY

The Bernville Protective Works consist of six Patterson Pump 26 x 30 SAFV Vertical

Turbine Pumps, Model No. 26X30SAFV, with a design capacity of 22,400 GPM, and 33’ TDH.

Each pump is driven by a 250-hp, 460V, 3PH General Electric motor.

The automatic greaser is manufactured by FARVAL, Model FS05-0093-003. The automatic greaser is interlocked with its associated pump via a relay within the storm water pump motor control panel.

SAFETY AND HEALTH

The contractor shall provide all necessary PPE to the personnel working in/around the Bernville Protective Works. All contractor employees are required to always wear face masks while working in/around the Bernville Protective Works facility. All contractor employees shall be required to have their temperatures taken prior to being allowed on the premises.

Any contractor employee who has symptoms of COVID-19 or has a temperature of 100F or above, will not be allowed in/around the premises.

All work performed by the Contractor shall be in accordance with USACE EM 385-1-1, Safety and Health Requirements Manual, Nov 2014. The electronic version can be downloaded from https://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_ 385-1-1.pdf.

Coordinate with the Government personnel at BPW, and the COR for access to the facility, security, and safety discussions and concerns.

NOTE – Access to BPW shall be coordinated 24 hours in advance.

Coordinate with the Government personnel at BPW, and the COR, and ensure the electrical systems are disconnected, secured, and properly tagged-out prior to any work. The contractor shall supply the appropriate hasps so that the Government can install their own locks/tags in addition to the contractor.

NOTE – Deenergizing and reenergizing of the aforementioned electrical systems shall be coordinated 24 hours in advance.

Operation of any equipment at BPW will be done by Government personnel, and coordinated with the COR.

GOVERNMENT FURNISHED MATERIAL

Automatic Greaser grease.

SCOPE OF WORK

The contractor shall provide all necessary labor, material, non-personal services, mobile crane, rigging, parts, tools, staging, transportation, material and equipment, to perform and complete the work in accordance with the following specifications. The Government will provide access to the facility.

All CHECKPOINTS are considered stopping points until all requirements of the CHECKPOINT have been satisfied in writing. Written documentation of the CHECKPOINT shall be submitted to the COR within 24 hours of the CHECKPOINT having been completed.

NOTE – The contractor has total control of the performance and scheduling of the work listed herein. The contractor does not have to perform the work in the exact order listed, however it is responsibility of the contractor to ensure that all work is completed.

https://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1.pdf

1. Patterson Vertical Turbine Pump

The contractor shall lockout and tag-out (LOTO) the pump and associated automatic greasing system. LOTO of the pump to be removed shall be accomplished such that the remaining five pumps will remain functional and operational.

CHECKPOINT – Once the pump being repaired has been LOTO’d, an operational bump test will be performed on the remaining five pumps in the presence of the COR.

Disconnect the 30” OD discharge elbow at the Style 38 Dresser Coupling, in the upper level of the channel, below the concrete floor.

Disconnect all electrical (power and control) connections from the pump motor and secure all exposed wiring. Mark each leg of the wiring to ensure identical installation upon reinstallation of motor.

NOTE – For crane and rigging purposes, the motor has a weight of approximately 3,600 pounds.

The pump has a weight of approximately 9,500 pounds. The length of the pump from the motor mount base to the suction umbrella is approximately 20 feet. The diameter of the suction umbrella is 6’-6”. The height of the BPW building is approximately 15 feet.

Decouple the motor shaft from the pump shaft at the threaded coupling.

NOTE – Extra labor and force may be required since this coupling has not been removed in over 10 years.

Unbolt the motor from the motor foundation. rig and store the motor in the vertical position (to prevent the motor lube oil reservoir from spilling out), on a contractor furnished/constructed motor pallet. Secure the motor to the motor pallet, and store in a location within the building that will not interfere with daily operations of the facility.

Unbolt the 6’- 6” x 6’- 6” pump base structure that is bolted to the floor with 8 concrete anchored bolts. Care shall be taken to not damage these bolts.

Remove by crane, the pump with base structure from the building thru the double door rooftop opening.

NOTE – While the pump is removed, the expose floor opening shall be protected from personnel falling in as required in EM-385-1-1, Section 21 - Fall Protection.

Load the pump onto a transport vehicle and transport the pump to an authorized Patterson

Pump repair facility. As a suggested source, the regional authorized Patterson Pump office is Sherwood-Logan and Associates in Langhorne, PA., whose repair facility is in Toccoa, GA. All costs associated with the loading and offloading the pump shall be included herein.

NOTE – The suction umbrella of the pump is not a load bearing component. It shall not be used to support the load of the pump, especially during transit to the repair facility.

While the pump and motor are removed, calibrate the existing panel gages and instrumentation for this pump.

Disassemble, clean, and inspect the pump. Inspection shall include visual inspection, measurements, and NDT testing.

Provide a Condition Report to the COR of inspection and findings. Record all critical component dimensions including bore diameters, and impeller clearance and balancing. This report shall include a recommendation of required repairs and parts replacement. Any additional repairs found necessary will be performed under a Contract Modification.

Upon completion of all repairs and replacement of parts, reassemble the pump, test the pump to OEM requirements and provide test results to the COR. Upon final assembly, prepare and paint the pump and required components. Seal all inlet and outlet connections with plastic or wooden materials. Assembled and completed unit shall be ready for installation upon delivery at

BPW.

Transport the pump to BPW in Bernville, PA. Install the pump in the original orientation.

Upon reinstallation of the pump and pump base structure onto the angle iron embedded in the concrete, furnish and install a new ¼” thick lead gasket all around as shown on the reference drawing. Torque hardware as required for this application.

NOTE – Prior to connection with the pump, the electric motor shall be checked for rotation. Make electrical connections and jog the motor momentarily to check rotation. The motor must rotate counterclockwise when looking down from top end of motor.

Rig and mount the motor onto the motor foundation. Install the shaft coupling and connect the motor shaft to the pump shaft.

Clean and prepare the ends of the discharge elbow of the pump and the existing pipe and furnish and install a new Style 38 Dresser coupling.

Install the automatic greaser and connect all wiring and grease tubes. Fill the grease holding tank with GFM grease and use the Manual setting on the control panel to test and grease the bearings.

Restore all other removals.

2. Farval Automatic Greaser

Disconnect all electrical (power and control) connections from the automatic greaser system and secure all exposed wiring.

Disconnect the seven 3/8” grease tube lines from the grease pump to the deck penetrations and side of the discharge elbow. Clean and remove all internal grease from the grease tubes and prove to COR prior to reinstallation. Reconnect upon verification of cleanliness.

Remove grease pump assembly prior to removal of pump.

Jumper electric system controls and test and verify grease pump operates as scheduled according to the setting on the F5AT automatic timer. Provide Condition Report of any issues observed. Any repairs will be handled via a Contract Modification.

CHECKPOINT – COR to witness greaser operation.

Upon satisfactory repairs, reinstall and reconnect the automatic grease pump, wiring, and grease tubing.

3. Acceptance and Verification

Testing of the overhauled pump and motor assembly will occur at BPW once reinstalled in the presence of the COR. The pump and motor assembly shall be operated and tested in accordance with OEM requirements.

Successful operation of the Pump and Motor assembly at BPW constitutes Final

Acceptance of the work listed herein.

Use the existing calibrated instrumentation during field testing. The general method outlined in ANSI/HI Pump Standards will be used as a guide for all procedures.

PERIOD OF PERFORMANCE

The contract work is expected to begin on/about 15 October 2021. All work listed above shall be completed within 180 calendar days after award of contract, unless extended by a Contract Modification.

SITE VISIT

A Bernville Protective Works site visit for interested contractors is scheduled for 22 June 2021, at 1000 at Bernville Levee at the intersection of Garfield Road and Bernville Road in Bernville, PA. (Coordinates: 40.428810, -76.112491). Coordinate with Josh Dinko at (610) 377- 0332 or Daniel Kelly at (215) 200-2340 to confirm site visit and for access to the facility.

PLACE OF PERFORMANCE

Pump is located at Bernville Protective Works:

Department of the Army U.S. Army Corps of Engineers, Philadelphia District Bernville Protective Works Intersection of Garfield Road and Bernville Road Bernville, PA. 19506

ORIGINAL EQUIPMENT MANUFACTURER (OEM)

Patterson Pump in Toccoa, GA is the Original Equipment Manufacturer (OEM). This repair facility has the capabilities and testing equipment to rebuild and test this type and style of pump. The repair facility will verify every design and performance specification of this Patterson pump, including cavitation testing, vibration testing, and model testing. This Patterson pump requires a large pump hydraulic testing area because of its significant size, which is available at this location.

This test facility also features a comprehensive range of testing equipment to ensure both mechanical and hydraulic performance. With this onsite capacity, this pump can be tested for a wide variety of simulated field conditions. Then, from the assembled test data, Patterson Pumps will generate values of pump capacity, head, horsepower and efficiency. Patterson's modern test facility in Toccoa, GA offers a complete closed-loop system for this testing.

Since this pump was installed in 1977 and has not been overhauled in over 45 years, it is expected that many internal parts will have to be newly machined or cast. There are no “on-the-shelf” or commercial parts available for rebuilding the pump. As the OEM, Patterson Pump owns the proprietary rights to the required drawings and has the machinists, computer-controlled machining equipment, and vertical turning centers and lathes to fabricate and machine the required replacement parts.

The contractor may use their own designated pump repair facility, however all repair parts shall be OEM.

CONTRACTOR SUBMITTALS

The contractor shall be required to submit five separate documents within 14 calendar days of Notice To Proceed (NTP) for government approval prior to mobilization of any equipment. The five separate documents are as follows: Work Plan, Health and Safety Plan, Accident Prevention Plan, Quality Control Plan, and Critical Lift Plan, as detailed below.

1. Work Plan.

The Work Plan shall be prepared and implemented by the Contractor as part of its project work. The Work Plan shall apply to all tasks/activities and products required by this contract.

The Work Plan shall be submitted in a report format, and approved by the Contracting Officer’s Representative (COR) before field activities can commence. The Contractor shall provide one electronic copy of the Draft Final Work Plan to COR who will then state what changes must be made or accept the draft as a final. The project specific work plan shall include, at a minimum:

a. Detailed project schedule through the entire period of performance.

b. Procedures for maintain equipment during period of performance.

c. Plan for completing and submitting all reports in a timely manner.

2. Health and Safety Plan.

The Contractor will be responsible for providing appropriate on-site management and supervision to accomplish work tasks and comply with the US Army Corps of Engineers Safety and Health Requirements Manual, EM 385-1-1.

a. EM 385-1-1 and its changes are available at:

https://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-

1.pdf.

b. The Contractor shall be responsible for complying with the current edition and all changes posted on the web. Equipment and operators must be onsite and ready to work no later than the date specified in the notice to proceed unless otherwise specified within the contract.

c. The Contractor shall submit a project specific health and safety plan (HASP) for review and approval prior to initiation of any fieldwork. The final HASP shall include all review comments and Contractor’s responses. The HASP will comply with OSHA, EM 385- 1-1 (current version) and any other federal, state or local requirements. The HASP will detail personnel training and responsibilities, project equipment, necessary personal protective equipment, medical surveillance, and other applicable procedures and protocols for maintaining complete project safety. Any action required protecting the surrounding environment, community and other third parties (e.g. visitors) will be discussed. The Contractor shall ensure that his/her personnel are not only aware of, but also comply with the safety requirements. Adherence to the plan and protection of the environment is the responsibility of the Contractor.

d. Draft Final HASP shall be submitted electronically in a report format to COR and approved by COR before field activities are authorized to commence. Upon approval from COR, the Contractor shall provide the Final HASP for the project records.

3. Accident Prevention Plan.

The contractor shall submit a project specific Accident Prevention Plan. It is expected that the Accident Prevention Plan will require the Contractor to immediately notify COR and designated US government safety officer of all accidents or incidents involving employee use of or damage or injury to facilities, equipment, or personnel. The Accident Prevention Plan Checklist is located on in Appendix A, Form A-02, of EM 385-1-1.

4. Contractor Quality Control Plan.

The Contractor shall be responsible for contract performance quality control. To facilitate this effort, the Contractor shall establish an inspection system acceptable to the Government.

The Contractor shall provide a Quality Control Plan (QCP) which addresses methods for meeting the requirements of this task order. The complete QCP shall be submitted to COR in accordance with the delivery schedule. Contractor shall revise the QCP at no additional cost to the Government as directed by the Contracting Officer.

a. Contract shall submit a work history of successfully completing five (5) pump overhauls of equal design, which are in satisfactory operation for at least five (5) years. List of projects must be provided with the vendor’s bid.

The contractor shall develop and maintain an effective quality control program to ensure services are performed in accordance with this scope of work. The contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. The contractor’s quality control program is the means by which he assures himself that his work complies with the requirement of the contract. The Contractor shall be responsible for contract performance quality control. To facilitate this effort, the Contractor shall establish an inspection system acceptable to the Government. The Contractor shall provide a Quality Control Plan (QCP) which addresses methods for meeting the requirements of this contract. The complete QCP shall be submitted to COR. The Contractor shall revise the QCP at no additional cost to the Government if required by the Contracting Officer. The Contractor shall conduct weekly on-site meetings (as required) with the Government QA representative to discuss work activities, milestones and any other pertinent issues and provide meeting minutes of said meetings within 3 days of each meeting. The QCP plan shall include a concise daily report that a minimum discusses personnel and equipment on site, significant issues, working status of each piece of equipment, weather, and all other pertinent information.

b. The Government will provide onsite quality assurance during the Contractors ongoing work performance as required. Government verification of services shall not constitute acceptance nor replace the contractor inspection or in any way relieve the contractor of any responsibility to take all actions necessary to assure highest quality of service rendered.

c. Final Acceptance. Prior to contract completion, the COR will perform a final inspection of the contract area to ensure that the contractor has complied with all contract requirements. The results of that inspection will be documented by the COR for the contract file.

5. Critical Lift Plan

Provide a Critical Lift Plan as required by EM 385-1-1, Section 16.H.01, using Form 16-

3. In addition, Critical Lift Plans are required for the following:

a. When working around energized power lines where the work will get closer than the minimum clearance distance in EM 385-1-1 Table 16-1.

b. For lifts with anticipated binding conditions.

c. Critical lifts require detailed planning and additional or unusual safety precautions.

Develop and submit a CLP to the COR 5 calendar days prior to critical lift for removal of the pump, and another CLP for reinstallation of the pump. Comply with load testing requirements in accordance with EM 385-1-1, Section 16.F.03.

BIDDING

The Contractor shall submit one quote for the work listed above:

QTY UNIT AMOUNT

1 Job $________________

NET AMOUNT: $_________________________