TechSpec_Amend-0001.pdf

Lower Mon. Navlock Downstream Gate Hoist Machinery Upgrade W912EF-15-R-0048 Amend-0001

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 78 23.00 28

OPERATION AND MAINTENANCE DATA

PART 1 GENERAL

1.1 SUBMITTALS

1.2 SUBMISSION OF OPERATION AND MAINTENANCE DATA

1.2.1 Package Quality

1.2.2 Package Content, Types and Number of Copies

1.2.3 Changes to Submittals

1.2.4 Electronic Copies

1.3 LIST AND SCHEDULE OF O&M DATA PACKAGE ITEMS

1.3.1 O&M Data Package 1

1.3.2 O&M Data Package 2

1.3.3 O&M Data Package 3

1.3.4 O&M Data Package 4

1.3.5 O&M Data Package 5

1.3.6 Controls O&M Data Packages

1.4 O&M DATA PACKAGES FOR MAJOR EQUIPMENT

1.5 DEFINITIONS OF O&M DATA PACKAGE ITEMS

1.5.1 Operating Instructions

1.5.1.1 Safety Precautions

1.5.1.2 Operator Prestart

1.5.1.3 Startup, Shutdown, and Post-Shutdown Procedures

1.5.1.4 Normal Operations

1.5.1.5 Emergency Operations

1.5.1.6 Operator Service Requirements

1.5.1.7 Environmental Conditions

1.5.2 Preventive Maintenance

1.5.2.1 Lubrication Data

1.5.2.2 Consumables

1.5.2.3 Preventive Maintenance Plan and Schedule

1.5.3 Corrective Maintenance (Repair)

1.5.3.1 Troubleshooting Guides and Diagnostic Techniques

1.5.3.2 Wiring Diagrams and Control Diagrams

1.5.3.3 Maintenance and Repair Procedures

1.5.3.4 Removal and Replacement Instructions

1.5.4 Corrective Maintenance Work-Hours

1.5.5 Appendices

1.5.5.1 Product Submittal Data

1.5.5.2 Manufacturer's Instructions

1.5.5.3 O&M Submittal Data

1.5.5.4 Parts Identification

1.5.5.5 Spare Parts and Supply Lists

1.5.5.6 Warranty Information

1.5.5.7 Personnel Training Requirements

1.5.5.8 Testing Equipment and Special Tool Information

1.5.5.9 Testing and Performance Data

1.5.5.10 Contractor Information

SECTION 01 78 23.00 28

G4EDHCMP

Line

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION (Not Used)

-- End of Section Table of Contents --

SECTION 01 78 23.00 28

SECTION 01 78 23.00 28

OPERATION AND MAINTENANCE DATA

PART 1 GENERAL

1.1 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES.

SD-10 Operation and Maintenance Data

Preliminary O&M Manuals and Parts Catalogs for Data Packages (1)

(2) (3) (4) (5); G C

Draft O&M Manuals and Parts Catalogs for Data Packages (1) (2) (3)

(4) (5); G C

SD-11 Closeout Submittals

Final O&M Manuals and Parts Catalogs for Data Packages (1) (2) (3)

(4) (5); G C

1.2 SUBMISSION OF OPERATION AND MAINTENANCE DATA

Submit Operation and Maintenance (O&M) Data specifically applicable to this contract and a complete and concise depiction of the provided equipment, product, or system, stressing and enhancing the importance of system interactions, troubleshooting, and long-term preventative maintenance and operation. Compile and prepare a preliminary version, a draft version and a final version of the aggregate O&M data, including clarifying and updating the original sequences of operation to as-built conditions.

Organize and present information based on the O&M Data Package called out in the individual technical specifications and in sufficient detail to clearly explain O&M requirements at the system, equipment, component, and subassembly level. Include an index preceeding each submittal. Submit in accordance with this SECTION, SECTION 01 78 00.00 28 CLOSEOUT SUBMITTALS (only for SD-11 submittals) and SECTION 01 33 00 SUBMITTAL PROCEDURES.

1.2.1 Package Quality

Documents must be fully legible. Poor quality copies and material with hole punches obliterating the text or drawings will not be accepted.

1.2.2 Package Content, Types and Number of Copies

Data package content shall be as shown in the paragraph titled "List and Schedule of O&M Data Package Items." Comply with the data package requirements specified in paragraph O&M DATA PACKAGES FOR MAJOR EQUIPMENT, including the content of the packages and addressing each product, component, and system designated for data package submission, except as follows. Commissioned items without a specified data package requirement in the individual technical sections shall use Data Package 3. Different Data Package items are required for each O&M Data Submittal. These items are detailed in the tables under paragraph SCHEDULE OF OPERATIONS AND MAINTENANCE DATA PACKAGES in this SECTION. O&M Data types are defined as follows:

a. Preliminary O&M Data - Shall cover the equipment required to be included in the O&M manuals as specified in the technical sections.

Submit four (4) Preliminary O&M Manuals and Parts Catalogs for each type and class of equipment, a minimum of 60 calendar days prior to commencement of on-site construction.

b. Draft O&M Data - Shall cover the equipment required to be included in the O&M manuals as specified in the technical sections. Submit four

(4) Draft O&M Manuals and Parts Catalogs for each type and class of equipment, not later than 14 calendar days after final commissioning.

The Contracting Officer will return two (2) draft copies of the data either "APPROVED" or "RETURNED FOR CORRECTION." Resubmit corrected and additional data as directed by the Contracting Officer.

c. Final O&M Data - A minimum of 14 calendar days after final approval of all draft O&M Manuals, submit five (5) Final O&M Manuals and Parts Catalogs for approval, for each type and class of equipment. If the final O&M Manuals are "RETURNED FOR CORRECTION," four (4) of the five

(5) sets of manuals will be returned to the Contractor with all submitted final binders. The final submittal, after corrections, shall consist of five (5) copies of the approved O&M Manuals. If final O&M Manuals are "APPROVED," the Government will retain all five (5) copies and return a signed ENG Form 4025 to the Contractor.

1.2.3 Changes to Submittals

Manufacturer-originated changes or revisions to submitted data shall be furnished by the Contractor if a component of an item is so affected subsequent to acceptance of the O&M Data. Changes, additions, or revisions required by the Contracting Officer for final acceptance of submitted data, shall be submitted by the Contractor within 30 calendar days of the notification of this change requirement.

1.2.4 Electronic Copies

Provide electronic copies of the O&M material in the form of a CD-ROM.

Submit the CDs with the hard copies of the O&M Manuals (Preliminary, Draft and Final). The documents placed on the CDs shall be in either Adobe Acrobat PDF or Microsoft Office formats. Label all CD-ROMs with the following information:

1. Name of project.

2. Contract number.

3. Name and address of Contractor.

4. Specific item or materials covered by the manual.

5. Date of submittal.

Set up an index of all O&M information linked to the location named in the index. The documents (electronic files) placed on the CD-ROM shall meet the following criteria:

1. Be an exact duplicate of the Approved Final hard copy O&M Manual.

2. Comprehensive Maintenance Table shall be provided in "Read Only" and Microsoft Excel format.

3. Be in the latest PDF version of Adobe Acrobat.

4. All documents must be configured to be searchable using a key word when the file is opened by a user.

5. All documents must be "Read Only.

6. Page numbering, indexing and the marking out of irrelevant parts shall be consistent with the hard copies of the O&M Manuals and ARE required for the documents.

1.3 LIST AND SCHEDULE OF O&M DATA PACKAGE ITEMS

Furnish the O&M data packages specified in individual technical sections.

For definition of Data Package information requirements see paragraph DEFINITIONS OF O&M DATA PACKAGE ITEMS. The aggregate list of Data Package Items is as follows:

a. Safety precautions

b. Cleaning recommendations

c. Maintenance and repair procedures

d. Warranty information

e. Contractor information

f. Spare parts and supply list

g. Normal operations

h. Environmental conditions

i. Lubrication data

j. Preventive maintenance plan and schedule

k. Removal and replacement instructions

l. Parts identification

m. Operator prestart

n. Startup, shutdown, and post-shutdown procedures

o. Emergency operations

p. Troubleshooting guides and diagnostic techniques

q. Wiring diagrams and control diagrams

r. Product submittal data

s. O&M submittal data

t. Testing equipment and special tool information

u. Testing and performance data

v. Operator service requirements

w. Corrective maintenance man-hours

x. Personnel training requirements

y. Manufacturer's instructions

1.3.1 O&M Data Package 1

Furnish the following items for each O&M Data Package 1 submittal:

Preliminary O&M Data Items

Draft O&M Data Items

Final O&M Data Items a, b, c a, b, c, f a, b, c, d, e, f

1.3.2 O&M Data Package 2

Furnish the following items for each O&M Data Package 2 submittal:

Preliminary O&M Data Items

Draft O&M Data Items

Final O&M Data Items a, b, c, g, i, j a, b, c, f, g, h, i, j, a, b, c, d, e, f, g, h, i j

1.3.3 O&M Data Package 3

Furnish the following items for each O&M Data Package 3 submittal:

Preliminary O&M Data Items

Draft O&M Data Items

Final O&M Data Items a, b, c, g, i, j, m, n, o, p, q, s a, b, c, f, g, h, i, j, k, l, m, n, o, p, q, r, s, t, u a, b, c, d, e, f, g, h, i, j, k, l, m, n, o, p, q, r, s, t, u, y

1.3.4 O&M Data Package 4

Furnish the following items for each O&M Data Package 4 submittal:

Preliminary O&M Data Items

Draft O&M Data Items

Final O&M Data Items a, b, c, g, i, j, m, n, o, p, q, s, v, w, x a, b, c, f, g, h, i, j, k, l, m, n, o, p, q, r, s, t, u, v, w, x a, b, c, d, e, f, g, h, i, j, k, l, m, n, o, p, q, r, s, t, u, v, w, x,

1.3.5 O&M Data Package 5

Furnish the following items for each O&M Data Package 5 submittal:

Preliminary O&M Data Items

Draft O&M Data Items

Final O&M Data Items a, c, g, j, m, n, p, q, s, y a, c, f, g, h, j, k, l, m, n, p, q, r, s, t, y a, c, d, e, f, g, h, j, k, l, m, n, o, p, q, r, s, t, u, y

1.3.6 Controls O&M Data Packages

Include Data Package 5 and the following items in the Final O&M Manual Data submittal for control systems:

a. Narrative description on how to perform and apply all functions, features, modes, and other operations, including unoccupied operation, seasonal changeover, manual operation, and alarms. Include detailed technical manual for programming and customizing control loops and algorithms.

b. Full as-built sequence of operations.

c. List of all error codes and complete step-by-step instructions to clear all error codes.

d. Copies of all checkout tests and calibrations performed by the Contractor. Does not include Commissioning Test results. See Section 01 91 00.00 28 SYSTEMS TESTING AND COMMISSIONING for Commissioning test requirements.

e. Full print out of all schedules and set points after testing and acceptance of the system. Include final settings, alignments, balances, etc. of all equipment impacted by work on this project.

f. Full as-built print out of software program.

g. Electronic copy on disk or CD of the entire program for all work under this contract.

1.4 O&M DATA PACKAGES FOR MAJOR EQUIPMENT

Refer to the following table to determine which Data Package is required for each type of major equipment and which submittals are required for that Data Package. For each O&M Data submittal required, submit all items in the corresponding Data Package table in paragraph LIST AND SCHEDULE OF O&M DATA PACKAGE ITEMS above. For example, Variable Frequency Drives (VFDs) require Data Package 5, so the Preliminary O&M Data submittal for the VFDs would require items a, c, g, j, m, n, p, q, s, y based on the Data Package 5 table above. For equipment that does not require a Preliminary O&M Data Package, submit only the manufacturer's standard O&M Manual(s).

O&M DATA PACKAGES TABLE FOR MAJOR EQUIPMENT

EQUIPMENT DATA PACKAGE PRELIMINARY

O&M DATA

DRAFT O&M DATA FINAL O&M

DATA

Variable Frequency Drives (VFDs)

5 YES YES YES

Hoist Drive Motors

5 YES YES YES

SECTION 01 78 23.00 28

EQUIPMENT DATA PACKAGE PRELIMINARY

O&M DATA

DRAFT O&M DATA FINAL O&M

DATA

Brakes 3 YES YES YES

Load Cells 5 YES YES YES

Programmable Logic Controller

(PLC)

5 YES YES YES

PLC Central Processor Unit (CPU)

5 YES YES YES

Input/Output (I/O) Modules

5 YES YES YES

Power Supply Modules

5 YES YES YES

Absolute Encoders

5 YES YES YES

Human Machine Interfaces

(HMI)

5 YES YES YES

Media Converting

5 YES YES YES

Position Encoders

5 YES YES YES

Control Panels 5 YES YES YES

3.5-Ton Overhead Maintenance Cranes

3 YES YES YES

Gearboxes 3 YES YES YES

Pinion bearings

3 YES YES YES

Sheave bearings

3 YES YES YES

Pinion Shafts 3 YES YES YES

Pinion Gears 3 YES YES YES

Couplings 3 YES YES YES

1.5 DEFINITIONS OF O&M DATA PACKAGE ITEMS

1.5.1 Operating Instructions

Include specific instructions, procedures, and illustrations for the following phases of operation for the installed model and features of each system:

1.5.1.1 Safety Precautions

List personnel hazards and equipment or product safety precautions for all operating conditions.

1.5.1.2 Operator Prestart

Include procedures required to install, set up, and prepare each system for use.

1.5.1.3 Startup, Shutdown, and Post-Shutdown Procedures

Provide narrative description for Startup, Shutdown and Post-shutdown operating procedures including the control sequence for each procedure.

1.5.1.4 Normal Operations

Provide narrative description of Normal Operating Procedures. Include Control Diagrams with data to explain operation and control of systems and specific equipment. Include functional descriptions of operating parts.

1.5.1.5 Emergency Operations

Include Emergency Procedures for equipment malfunctions to permit a short period of continued operation or to shut down the equipment to prevent further damage to systems and equipment. Include Emergency Shutdown Instructions for fire, explosion, spills, or other foreseeable contingencies. Provide guidance and procedures for emergency operation of all utility systems including required valve positions, valve locations and zones or portions of systems controlled.

1.5.1.6 Operator Service Requirements

Include instructions for services to be performed by the operator such as lubrication, adjustment, inspection, and recording gage readings.

1.5.1.7 Environmental Conditions

Include a list of Environmental Conditions (temperature, humidity, and other relevant data) that are best suited for the operation of each product, component or system. Describe conditions under which the item equipment should not be allowed to run.

1.5.2 Preventive Maintenance

Include the following information for preventive and scheduled maintenance to minimize corrective maintenance and repair for the installed model and features of each system. Include potential environmental and indoor air quality impacts of recommended maintenance procedures and materials.

1.5.2.1 Lubrication Data

Include preventative maintenance lubrication data, in addition to instructions for lubrication provided under paragraph titled "Operator Service Requirements":

a. A table showing recommended lubricants for specific temperature ranges and applications.

b. Charts with a schematic diagram of the equipment showing lubrication points, recommended types and grades of lubricants, and capacities.

c. A Lubrication Schedule showing service interval frequency.

d. Where the Contractor or the supplier has installed a lubricant or oil prior to shipment to the project, the "Brand Name" as well as the specification shall be indicated.

1.5.2.2 Consumables

Provide a list of all consumable (grease, oil, filters, etc.) products used in equipment provided under this contract. Where the Contractor has installed a consumable product prior to Government acceptance, provide the "Brand Name" as well as the specification for each product. Include the following information:

a. Manufacturer's name and contact information.

b. Manufacturer's model number, part number, and serial number as applicable.

c. Current sources/vendors with contact information.

d. Current prices for each consumable.

1.5.2.3 Preventive Maintenance Plan and Schedule

Include manufacturer's schedule for routine preventive maintenance, inspections, tests and adjustments required to ensure proper and economical operation and to minimize corrective maintenance. Provide manufacturer's projection of preventive maintenance work-hours on a daily, weekly, monthly, and annual basis including craft requirements by type of craft.

For periodic calibrations, provide manufacturer's specified frequency and procedures for each separate operation.

1.5.3 Corrective Maintenance (Repair)

Include manufacturer's recommended procedures and instructions for correcting problems and making repairs..

1.5.3.1 Troubleshooting Guides and Diagnostic Techniques

Include step-by-step procedures to promptly isolate the cause of typical malfunctions. Describe clearly why the checkout is performed and what conditions are to be sought. Identify tests or inspections and test equipment required to determine whether parts and equipment may be reused or require replacement.

1.5.3.2 Wiring Diagrams and Control Diagrams

Wiring diagrams and control diagrams shall be point-to-point drawings of wiring and control circuits including factory-field interfaces. Provide a complete and accurate depiction of the actual job specific wiring and control work. On diagrams, number electrical and electronic wiring and pneumatic control tubing and the terminals for each type, identically to actual installation configuration and numbering.

1.5.3.3 Maintenance and Repair Procedures

Include instructions and a list of tools required to repair or restore the product or equipment to proper condition or operating standards. Include recommended clearances, bolt torques, pressure settings, etc.

1.5.3.4 Removal and Replacement Instructions

Include step-by-step procedures and a list required tools and supplies for removal, replacement, disassembly, and assembly of components, assemblies, subassemblies, accessories, and attachments. Provide tolerances, dimensions, settings and adjustments required. Instructions shall include a combination of text and illustrations.

1.5.4 Corrective Maintenance Work-Hours

Include manufacturer's projection of corrective maintenance work-hours including requirements by type of craft. Corrective maintenance that requires completion or participation of the equipment manufacturer shall be identified and tabulated separately.

1.5.5 Appendices

Provide information required below and information not specified in the preceding paragraphs but pertinent to the maintenance or operation of the product or equipment. Include the following:

1.5.5.1 Product Submittal Data

Provide a copy of all SD-03 Product Data submittals required in the applicable technical sections.

1.5.5.2 Manufacturer's Instructions

Provide a copy of all SD-08 Manufacturer's Instructions submittals required in the applicable technical sections.

1.5.5.3 O&M Submittal Data

Provide a copy of all SD-10 Operation and Maintenance Data submittals required in the applicable technical sections.

1.5.5.4 Parts Identification

a. Provide identification and coverage for all parts of each component, assembly, subassembly, and accessory of the end items subject to replacement. Parts identification lists shall contain the following information:

1. Special hardware requirements, such as requirement to use high-strength bolts and nuts.

2. Identification of all parts by manufacturer's make, model, serial number, and National Stock Number (NSN).

3. Manufacturer's name, address, phone number, and website where parts can be ordered to allow reordering without further identification.

4. Current sources\vendor names for the parts, their respective addresses and telephone numbers.

5. Purchase price, where applicable.

6. Current replacement costs for each part.

7. Clear and legible illustrations, drawings, and exploded views to enable easy identification of the items. When illustrations omit the part numbers and description, both the illustrations and separate listing shall show the index, reference, or key number that will cross-reference the illustrated part to the listed part.

8. Cross referencing of Manufacturer's reference numbers with Contractor's reference numbers and shop drawings where applicable.

b. Parts shown in the listings shall be grouped by components, assemblies, and subassemblies in accordance with the manufacturer's standard practice. Parts data may cover more than one model or series of equipment, components, assemblies, subassemblies, attachments, or accessories, such as typically shown in a master parts catalog.

Include all information in an Excel Spreadsheet as part of the electronic copy of the "Operation And Maintenance Manuals And Parts Catalogs".

1.5.5.5 Spare Parts and Supply Lists

a. When specified, include lists of spare parts and supplies required for maintenance and repair to ensure continued service or operation without unreasonable delays. Special consideration is required for facilities at remote locations. Identify spare parts and supplies that have a long lead-time to obtain.

b. All spare parts lists, for both recommended spare parts and those provided under this contract, shall contain the information identified in paragraph "Parts Identification". Include all information in an Excel Spreadsheet as part of the electronic copy of the "Operation And Maintenance Manuals And Parts Catalogs".

c. Supply/Parts Lists shall also include the following:

1. Full description and nomenclature of each part.

2. Required number of each part for equipment operation.

3. Recommended list of spare parts to be stocked at the Project.

4. Actual spare parts supplied under this contract.

5. Serial numbers of spare parts received from the Contractor.

1.5.5.6 Warranty Information

List and explain the various warranties and clearly identify the servicing and technical precautions prescribed by the manufacturers or contract documents in order to keep warranties in force. Include warranty information for primary components such as the compressor of air conditioning system.

1.5.5.7 Personnel Training Requirements

Provide information available from the manufacturers that is needed for use in training designated personnel to properly operate and maintain the equipment and systems.

1.5.5.8 Testing Equipment and Special Tool Information

Include information on test equipment required to perform specified tests and on special tools needed for the operation, maintenance, and repair of components.

1.5.5.9 Testing and Performance Data

Include completed prefunctional checklists, functional performance test forms, and monitoring reports. Include recommended schedule for retesting and blank test forms.

1.5.5.10 Contractor Information

Provide a list that includes the name, address, and telephone number of the General Contractor and each Subcontractor who installed the product or equipment, or system. For each item, also provide the name address and telephone number of the manufacturer's representative and service organization that can provide replacements most convenient to the project site. Provide the name, address, and telephone number of the product, equipment, and system manufacturers.

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION (Not Used)

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SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

SECTION 01 91 00.00 28

SYSTEMS TESTING AND COMMISSIONING

PART 1 GENERAL

1.1 DESCRIPTION

1.2 REFERENCED PUBLICATIONS

1.3 ROLES AND RESPONSIBILITIES

1.3.1 Construction Test Phase

1.3.2 Pre-Operational Test Phase

1.3.3 Operational Test Phase

1.4 SUBMITTALS

1.5 GENERAL REQUIREMENTS

1.5.1 Equipment Commissioning Testing Plan and Schedule

1.5.2 Government Commissioning and Testing Plan

1.5.3 Equipment Commissioning Testing Report

1.6 QUALIFICATIONS

1.6.1 Contractor's Commissioning Agent

1.6.2 Equipment Manufacturer's Commissioning Services

1.7 GENERAL RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT

1.8 RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT DURING

CONTRACTOR'S COMMISSIONING

1.9 RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT DURING

GOVERNMENT'S COMMISSIONING

1.10 COMMISSIONING SUPPORT

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION

3.1 FIELD TESTING

3.2 COMMISSIONING AND TESTING TABLE

3.3 FINAL GOVERNMENT COMMISSIONING AND TESTING

ATTACHMENTS:

Commissioning List Narrative

-- End of Section Table of Contents --

SECTION 01 91 00.00 28

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SECTION 01 91 00.00 28

SYSTEMS TESTING AND COMMISSIONING

PART 1 GENERAL

1.1 DESCRIPTION

This SECTION covers the testing and commissioning of mechanical, electrical and control equipment installed under this contract. Commissioning will be a collaborative effort between the Government and the Contractor.

Satisfactory completion of all commissioning activities will be a condition for turnover of the gate hoist machinery from the Contractor to the Government.

The work under this contract alters and interfaces with numerous systems within an operating Navigation Lock. Therefore, final acceptance of installed equipment shall consist of: the commissioning of the installed work and the verification of the overall Government system.

The Contractor has lead responsibility for the commissioning of the installed work and the Government has lead responsibility for the verification of the overall Government system.

Furnish labor and material to accomplish and complete the testing and commissioning as specified herein.

1.2 REFERENCED PUBLICATIONS

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 Safety and Health Requirements Manual

The Contractor shall be responsible for complying with the current edition and all changes posted on the web as of the effective date of this solicitation.

1.3 ROLES AND RESPONSIBILITIES

During commissioning, the Government and the Contractor will each have roles and responsibilities which will be phase dependent as follows:

1.3.1 Construction Test Phase

During the Construction Test Phase, the Contractor will have the lead role and shall perform all contract required inspections and tests. The Government will perform contract administration and quality assurance for commissioning activities during this phase.

1.3.2 Pre-Operational Test Phase

During the Pre-Operational Test Phase, the Contractor will have the lead role and will be responsible for coordination and performance of commissioning activities. Perform commissioning activities and provide support for the Government verification and learning activities during this phase. The Government will perform contract administration and quality assurance for commissioning activities during this phase.

SECTION 01 91 00.00 28

1.3.3 Operational Test Phase

During the Operational Test Phase, the Government will have the lead role and will be responsible for coordination, performance and oversight of commissioning activities. Perform commissioning activities and provide support for the Government commissioning activities during this phase.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Equipment Commissioning Testing Plan and Schedule; G EL

Commissioning Agent's Qualifications; G EL

SD-06 Test Reports

Field Test Reports; G EL

Equipment Commissioning Testing Report; G EL

1.5 GENERAL REQUIREMENTS

1.5.1 Equipment Commissioning Testing Plan and Schedule

Submit, at least 60 calendar days prior to the start of on-site work, the proposed step-by-step Equipment Commissioning Testing Plan and Schedule, hereinafter also referred to throughout these specifications as the "Commissioning Plan". This plan and schedule is in addition to the Project Schedule requirements of SECTION 01 32 01.00 28 PROJECT SCHEDULE.

The Commissioning Plan shall include those activities and requirements listed in all specification sections in this contract and this SECTION, the items described as Contractor Responsibilities in the "Commissioning List Narrative" attached at the end of this SECTION, as well as those required by equipment manufacturer instructions. The Commissioning Plan shall include a detailed sequential list of activities and duration of each activity. The Commissioning Plan shall be updated and furnished with the monthly project schedule submittals. No on-site work shall commence until the Commissioning Plan has been "Approved" or "Approved Except as Noted".

1.5.2 Government Commissioning and Testing Plan

The Government will provide its step-by-step Commissioning and Testing Plan at least 10 calendar days prior to the start of Government commissioning activities. The plan will include a detailed sequential list of activities and duration of each activity. An overview of the Government Commissioning Plan is contained in the "Commissioning List Narrative" attached at the end of this SECTION.

1.5.3 Equipment Commissioning Testing Report

Submit, upon completion of the testing of any equipment, a report that includes the completed Equipment Commissioning Testing Plan and Schedule and all tests performed during commissioning. The report shall include a copy of all original forms used during commissioning.

1.6 QUALIFICATIONS

1.6.1 Contractor's Commissioning Agent

Furnish a Commissioning Agent with a minimum of five (5) years experience in preparing commissioning plans and performing commissioning and testing of electrical, mechanical and control equipment of comparable physical size and complexity in an industrial facility. The Commissioning Agent may be a subcontractor. The Commissioning Agent shall coordinated directly with the Prime Contractor's on-site management to ensure overall compliance with the contract and the approved Commissioning Plan. The Commissioning Agent's qualifications shall be submitted in résumé format for approval 90 calendar days prior to commencement of on-site construction.

1.6.2 Equipment Manufacturer's Commissioning Services

Furnish manufacturer certified personnel to perform start-up, testing, and commissioning for all new equipment and systems.

1.7 GENERAL RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT

The responsibilities of the Contractor's Commissioning Agent shall include, but not be limited to:

a. Coordinate with subcontractors to provide the Equipment Removal, Installation, and Testing Plan and Schedule, and provide scheduled progress updates.

b. Attend scheduled commissioning coordination meetings including the Red Zone meeting (as defined in SECTION 01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS), to discuss, coordinate and schedule commissioning activities.

c. Prepare and submit detailed inspection and test plans required by the contract technical specifications and oversight of the Contractor's commissioning activities, including subcontractor activities for all commissioning phases.

d. Provide on-site oversight of commissioning tests and inspections for installed or modified equipment during the Test Phases.

e. Provide technical commissioning support for Government-led commissioning activities during the Operational Test Phase.

f. Coordinate the availability of required craftworkers during Pre-Operational and Operational Test Phases.

1.8 RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT DURING

CONTRACTOR'S COMMISSIONING

The responsibilities of the Contractor's Commissioning Agent during the Contractor's Commissioning shall include, but not be limited to:

a. Coordinate with subcontractors equipment manufacturers, provide Equipment Removal, Installation, and Testing Plans and Schedules, and provide scheduled progress updates.

b. Represent the Contractor by attending commissioning coordination meetings.

c. Certify and submit results of all required Quality Control Reports.

1.9 RESPONSIBILITIES OF CONTRACTOR'S COMMISSIONING AGENT DURING

GOVERNMENT'S COMMISSIONING

The responsibilities of the Contractor's Commissioning Agent during the Government's Commissioning shall include, but not be limited to:

a. Represent the Contractor by attending commissioning coordination meetings.

b. Coordinate the availability of fully qualified craftsmen for commissioning support to assist during system commissioning for both the Contractor's commissioning and testing requirements, as well as all of the Government's commissioning and testing requirements.

1.10 COMMISSIONING SUPPORT

Provide commissioning support during all test phases. Commissioning support shall be as follows:

a. Commissioning Agent: During the Pre-Operational Test Phase and the Operational Test Phase, the Contractor's Commissioning Agent shall be present to witness the Government's commissioning activities and to participate in troubleshooting and issue resolution as it relates to the equipment being commissioned. The Commissioning Agent shall coordinate directly with the Prime Contractor to adjust and/or make changes to equipment installed or modified by the Contractor during the installation.

b. Craftworkers: During the Pre-Operational Test Phase and Operational Test Phase, the Contractor shall provide skilled craftworkers to support the Government's commissioning activities.

Craftworkers shall be appropriate trades and skill level required for the particular commissioning tests to be performed and will be under the supervision of the Commissioning Agent. Craftworkers will only be required to make adjustments or changes to Contractor-installed equipment when a need is identified during performance of the Government's commissioning activities.

PART 2 PRODUCTS (Not Used)

PART 3 EXECUTION

3.1 FIELD TESTING

a. During the construction and installation of all equipment specified under this contract, perform the necessary inspections to ensure that the installations are in accordance with manufacturer's instructions and the contract documents.

b. Detailed testing shall be performed on all installed equipment as specified in the technical specification sections of this contract to ensure that operation and performance conform to contract documents.

All tests will be witnessed by the Contracting Officer. Notify the Government not less than 30 calendar days prior to starting any test.

All Field Test Reports shall be submitted prior to the commissioning tests.

c. The following data shall be recorded and submitted for all tests:

(1) Description of test;

(2) Description of equipment tested;

(3) Calibration information to include a list of each instrument used during testing, stating calibration requirements by the instrument manufacturer and the calibration history of the instrument. The calibration history shall include dates calibrated and calibration procedures used.

(4) Description of operation of all affected system components.

3.2 COMMISSIONING AND TESTING TABLE

The following table includes commissioning and testing activities that shall be performed on all equipment installed under this contract.

The list contains, but is not limited to the following:

COMMISSIONING AND TESTING TABLE

EQUIPMENT/

SECTION

GOVERNMENT

WITNESS

FACTORY

TESTING

Variable Frequency Drives (VFDs)

26 29 23.00 28

NO

Hoist Drive AC Motors

35 01 43.00 28

NO

Brakes

35 01 43.00 28

NO

Load Cells

35 01 43.00 28

NO

Process Control Panels

40 95 13.00 28

YES

Fiber Optic Tests

40 95 13.00 28

NO

Absolute Encoders

40 94 43.01 28

NO

3.5-Ton Overhead Maintenance Cranes

41 22 13.17 28

NO

EQUIPMENT/

SECTION

GOVERNMENT

WITNESS

FACTORY

TESTING

Pressure Transducers contract drawings

NO

Couplings

35 01 43.00 28

NO

Pillow Block Bearings

35 01 43.00 28

NO

Sheave Bearings

35 01 43.00 28

NO

Pinion Shafts

35 01 43.00 28

NO

Pinion Gears

35 01 43.00 28

NO

Wire Rope Tensioning

35 01 43.00 28

NO

Limit Switch and Position Indication Settings

35 01 43.00 28

NO

Open Spur Gear Alignment

35 01 43.00 28

NO

Shaft Alignments

35 01 43.00 28

NO

Dynamic Balancing of Machinery

35 01 43.00 28

NO

Downstream Gate 1 contract drawings

NO

Tainter Valves 1-4 contract drawings

NO

This Testing and Commissioning table is not intended to be all inclusive, but is intended to be used as a guide in developing Testing and Commissioning Plans to be submitted as per this contract. Responsible for including Testing and Commissioning Plans for all equipment installed under this contract and to include other plans as prescribed by equipment manufacturers or by the Government.

3.3 FINAL GOVERNMENT COMMISSIONING AND TESTING

After the Contractor has completed all testing and commissioning required under these specifications, the Government will conduct an overall verification of the completed system's installation. Participate in these activities by reviewing and becoming familiar with the Government final commissioning plan, and by participating in the final commissioning process. The Government Final Commissioning activities are estimated to be performed over seven (7) consecutive, calendar days (12 hours per day) for a total of 84 hours.

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SECTION 01 91 00.00 28

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