Amendment 6 and Docs.pdf

Combined Synopsis/Solicitation

AMENDMENT #6

Contracts Branch (fc)

Action Code: Combined Synopsis/Solicitation

Date: Aug 8, 2023

NACIS Code: 811310

Class Code: Z

Subject: Overhaul of Bernville Pumps (Extending Response Date)

Solicitation No.: W912BU23R0014-Bernville Pumps Overhaul

Set-Aside Code: Small Business

Response Date: 23 August 2023

Place of Performance: Bernville Protective Works, Bernville, PA

Description of Work:

This Amendment #6 is to advise that the amended response date of 9 June 2023, has changed and the new response date is 23 August 2023 with all proposals due by 2PM. All proposals are to be sent to Frederick Conway, Email: frederick.conway@usace.army.mil.

The last date to submit questions regarding this project is by the close of business on 16

August 2023.

This attachment contains answers to Requests For Information (RFIs) and a revised Statement

Of Work (SOW).

All other Terms and Conditions remain unchanged.

Robert Hutcheon

Contracting Officer

SCOPE OF WORK

Overhaul of Five Bernville Levee Pumps

PR&C No.: W25PHS21403054

INTENT

The intent of this scope of work is to remove, overhaul, and reinstall five mixed flow storm water pumps and their associated automatic greasers at the Bernville Protective Works (BPW) in Bernville, Pennsylvania. The pumps and greasers that are to be removed, overhauled, and reinstalled are #1, #2, #3, #4 and #5. Pump #6 and its greaser were previously removed and overhauled. The pumps and automatic greasers are to be removed, repaired and reinstalled one at a time in sequential order, with the second pump and greaser removed after successful installation and testing of the first pump and greaser, and so forth.

It is also the intent of this scope of work to replace the lower motor (guide) bearing on all six pump motors, with an option to replace up to six upper bearings on all six pump motors.

REFERENCE DRAWINGS

Patterson Pump Dwg D-4142-3; Bernville Protective Works, 26x30 Type SAFV Pump Parts and Material List for Type SAFV Pump

REFERENCE MANUAL

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

GOVERNMENT-FURNISHED MATERIAL

Upper Motor Bearings – 6 Lower Motor Bearings – 6

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.

Pump #6 was previously overhauled in May 2022. The five pumps to be overhauled have serial numbers 76BT1573-G30, and 76BT1575-G30 thru 76BT1578-G30.

The automatic greaser for the pumps are 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.

The motors are General Electric, Model No. 5K6328XC402A, Serial Nos. MMJ1215023-5028.

SAFETY AND HEALTH

The contractor shall provide all necessary PPE to the personnel working in/around the Bernville Protective Works. Safety shoes, hardhats and protective eyewear must be worn at all times when working at the BPW.

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 locked-out/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 – to be provided at greaser reinstallation

SCOPE OF WORK

The contractor shall provide all necessary labor, material, 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.

For each of the five pumps and greasers, the contactor shall accomplish the following work:

The pumps and greasers that are to be removed, overhauled, and reinstalled are #1, #2, #3, #4 and #5. The pumps and automatic greasers are to be removed one at a time in sequential order, with the second pump and greaser removed after successful installation and testing of the first pump and greaser, and so forth.

NOTE – Successful installation and testing of the pump and greaser will be determined by the COR. The COR will then direct the contractor to proceed with work on the next pump.

1. Patterson Vertical Turbine Pump

The contractor shall lockout and tag-out (LOTO) the designated pump and associated automatic greasing system. LOTO of the designated pump to be removed shall be accomplished such that the remaining five pumps will remain functional and operational. Functionality can be accomplished by installing wiring jumpers or re-programming.

CHECKPOINT – Once the designated pump has been LOTO’d, perform an operational bump test on the remaining five pumps in the presence of the COR to ensure operational readiness. Once this bump test is successful, the contractor shall begin the process of removing the pump.

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

NOTE – The contractor shall secure the mating pipe where it penetrates the wall so that the pipe does not move when the elbow is disconnected. This bracing shall remain in place until the pump assembly is returned.

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 the motor.

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

Each 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. Extra labor and force may be required since this coupling has not been removed in over 10 years. The contractor has the option to cut the motor coupling and machine a new one for reinstallation. Care shall be taken not to scar or damage the motor and pump shafts.

Unbolt the motor from the motor foundation and 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. Bolt the motor to the motor pallet, and store in a location within the building as directed by the COR, that will not interfere with daily operations of the facility. The pallet shall be constructed to facilitate replacement of the lower motor bearing.

Unbolt the suction umbrella from the pump prior to lifting the pump since it will not fit thru the floor opening in the installed position.

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.

Open the rooftop access doors, and 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.

Rig and securely shore the pump onto a transport vehicle and transport the pump to the contractor’s facility. The contractor may elect to use the repair facility location at the OEM.

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/from the repair facility.

Once delivered to the repair facility, the contractor shall disassemble, clean, and inspect the pump.

Inspection shall include visual inspection, measurements, and NDT testing.

While disassembled, the contractor shall complete the following on each pump:

1. Repair the suction bell and apply an epoxy coating such as Belzona on the corroded areas.

2. Balance the impeller to within a dynamic balancing tolerance of 4 W/N or better.

3. Fabricate and install four new bronze bushings and a new shaft coupling (if required)

4. Blast the disassembled parts and components for NDT inspection.

5. Replace the grease tubes with new 316 stainless-steel grease tubes and fittings.

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 additional required repairs and parts replacement. Any additional repairs found necessary will be performed under a Contract Modification.

NOTE – Any use of non-OEM parts shall be approved by the COR in advance via Condition Report.

Upon completion of all repairs and replacement of parts, prime and paint all parts, reassemble the pump, check clearances, thrust and rotation. Provide these readings to the COR via Condition Report and document that they are in accordance with OEM requirements. The pump shall be reassembled with new stainless-steel fittings and hardware.

Upon final assembly, prepare and paint the pump and required components. Prior to transport, 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, and rig and install the pump in the original orientation.

Upon reinstallation of the pump and pump base structure onto the angle iron embedded in the concrete, install a new ¼” thick Garlock gasket all around as shown on the reference drawing.

Torque hardware as required for this application.

Bolt the suction umbrella to the pump after reinstalling the pump on the concrete base since it will not fit thru the floor opening in the installed position.

Furnish and install new lower bearings on the motors for Pumps # 1-5 and furnish and install new lower bearing on the motor for Pump # 6.

NOTE – The contractor will need to decouple the pump from the motor on Pump #6 to replace the lower bearing on the motor. Upon completion of the bearing replacement, recouple the pump to the motor.

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.

After repairs to the automatic greaser, 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.

The contractor shall also perform the same work to the Sump Pump greaser, which is Farval Part No. J010-1501-10. The Sump Pump greaser unit shall be removed and repaired in coordination with the removal and repair of the first storm water pump and greaser.

3. Upper Motor Bearing Replacement (OPTION)

The contractor shall quote to replace the upper bearing on the pump motor with GFM, up to all six motors. The contractor shall furnish and install any gaskets, seals and O-rings compromised by the removal and replacement of the bearing. Price per motor.

4. Acceptance and Verification

Testing of the overhauled pumps, greaser units and motor assemblies will occur in the field once reinstalled in the presence of the COR.

Field test each pump and motor under field conditions. Establish field operating pump characteristics and compare to original certified pump curves from the OEM.

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.

Once successful testing is accomplished and verified by the COR, the COR will direct the contractor to begin removal of the next pump for overhaul.

PERIOD OF PERFORMANCE

The contract work is expected to begin on/about 1 September 2023. The contractor shall order required parts after NTP. Physical work on the pumps cannot start until after 1 November 2023, and all work shall be completed by 30 April 2024. All work listed above shall be completed within this time frame unless extended by a Contract Modification. Completion shall be for overhaul of all five storm water pumps and greasers, one sump pump greaser, installed and ready for use, and replacement of all six motor lower bearings.

PLACE OF PERFORMANCE

Pumps are 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). The repair facility used to rebuild these pumps shall have the capabilities and testing equipment to rebuild and test this type and style of pump.

These pumps were manufactured and installed 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 capability to fabricate the required replacement parts. All parts will have to be supplied by the OEM unless stated otherwise herein.

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.

After review the Q & A amendment that was up loaded a couple days ago we still have a few questions.

I believe there is still some major confusion on the replacement of the lower bearings. (Pump or Electric Motor) We just want to make sure we are including all you require in the revised bid.

1. Can you please confirm finally, whether they are talking about the lower bearings of the pump (suction bowel bearing. #9 on the drawing)

2. Or is it the lower bearings of the electric motors.

It is very unusual to replace just one of the bearings on an electric motor. We cannot warranty replacing just the lower motor bearings nor would any other company. The upper bearings would need to be replaced as well. The Specs and scope of work are very misleading. The below information was taken directly from the bid W912BU23R0014:

Please Confirm:

It is the intent of this scope of work to replace the lower motor bearing on all six pump motors, including furnishing and installing new lower bearings on the motors for Pumps # 1-5 and furnishing and installing new lower bearing on the motor for Pump # 6. Are we to replace the upper motoring bearing to? It is very unusual to replace just one of the bearings on an electric motor. We cannot warranty replacing just the lower motor bearings nor would any other company. The upper bearings would need to be replaced as well. The Specs and scope of work are very misleading.

Please Confirm:

is this still a part of the scope? Unbolt the motor from the motor foundation and 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. Bolt the motor to the motor pallet, and store in a location within the building as directed by the COR, that will not interfere with daily operations of the facility.

(Does not talk about lower motor bearing replacement.)

Please Confirm:

Bid Schedule W912BU23R0014 has a line item only for- #6 Replace Lower Bearing Pump# 6 FFP

Answers to questions above provided below:

Use of the non-OEM part for the pumps are acceptable, as long as all fabricated parts meet the required specs.

The greasers have to be rebuilt or replaced with OEM parts.

What we have found so far on the pumps is that only minor parts - couplings, bushings - have had to be replaced.

The greasers are much more complicated than the pumps and given that we have no detailed manufacturing drawings for these parts, we have to use OEM.