A06_SOW_7_June_2019.pdf

Scope of Work – Revision June 7th 2019

Tainter Gate Gear Box Oil Replacement at LD2, LD4, and LD5

U.S. Army Corps of Engineers, St. Paul District

1. Contractor shall provide all plant, labor, and equipment necessary to service and replace oil in tainter gate gear boxes at Lock and Dams (LD) 2, 4, and 5 in the St. Paul District. Replacement oil and flushing fluid is Government furnished and will be provided by the US Army Corps of Engineers as early as August 1st 2019, but not later than September 1st, 2019. The supplied oil is Schaeffer 167 Fully Synthetic Gear Oil ISO 220. The oil safety data sheet is included in Appendix C. The oil and flushing fluid will be delivered and stored at a Government location in Fountain City, WI near Lock and Dam 5a. Reference paragraph 2f for additional information. Contractor may move oil between sites but must comply with state and Federal hazmat transportation regulations. Gear boxes are accessible from access covers on top of the dam bridge on LD4 and LD5, and from the service-bridge spanning the dam at LD2. These facilities are located along the Upper Mississippi River between Hastings, MN and Minneiska, MN. Vendors will be afforded one site-visit prior to bid. Vendors will meet at the site with Government POCs on the date determined at the time of solicitation.

a. Safety – Contractor shall be responsible for following all applicable local, state, and federal safety laws and regulations as well as special provisions found in USACE EM 385-1-1 Safety and Health Requirements Manual, ER 385-1-92 Safety and Occupational Health Requirements for Environmental Cleanup Projects, and USACE Fall Protection Program Guide, dated 01 April 2012. Contractor shall submit the Safety Plan for Government approval prior to commencing work. For inquiries or questions on safety considerations, Contractor may contact the contracting officer who will appropriately direct any and all inquiries.

b. Uniform – All contractor personnel shall wear an appropriate work uniform consisting of full length trousers, steel toe (or equivalent) safety shoes, and at a minimum a short-sleeved shirt. Personal Protective Equipment (PPE) such as hard hat, work gloves, hearing protection, and eye protection shall be worn as required.

2. Service Operations shall consist of draining, cleaning and replacing oil inside all tainter gate gear boxes, utilizing gravity-feed or pumps to evacuate and fill gearboxes. For cleaning/flushing operations of gear boxes with the provided flushing fluid, refer to Appendix B. Contractor shall be responsible for all aspects of spill prevention, draining gear box systems, collection of used oil and flushing fluid, and all aspects of oil disposal to ensure safe disposal of all used/waste oil, flushing fluid, and all associated containers for the oil and flushing fluid. If Contractor utilizes pumping operations for oil replacement, Contractor shall include a catalog cut or informative publication showing make and model of apparatus, and methodology of use in the final report. Lock and Dam personnel have had success utilizing a two-pump configuration, one drain pump and one fill pump, to change oil at other sites. This configuration eliminates the need to reconfigure pump setups and swap components. Contractor shall provide additional empty drums as needed as Government will not provide empty oil containers. Electrical power is available as follows. There is no compressed air available.

LD2 - has 700' dam, (6) 480V receptacles on dam - one on each end the other (4) spaced evenly, approx.

150' between each

LD4 - has (23) 480V receptacles approx.. 43' between each, one by each Tainter gate control and one on Pier house 6

LD5 - has (27) 480V receptacles approx. 43' between each

a. Locations for servicing work are located on the Upper Mississippi River near the following cities - LD2: Hastings, MN; LD4: Alma, WI; LD5: Minneiska, MN.

b. Spill Prevention: Contractor shall be responsible for all aspects of spill prevention and mitigation, and adhere to all state and federal regulations regarding handling and disposal. Contractor shall report all spills to appropriate environmental hazards and management organization as addressed in the Spill Plan submittal, as well as to the USACE St. Paul Environmental section. See Section 9, Submittals for information on required submissions. For inquiries or questions on environmental considerations, Contractor may contact the contracting officer who will appropriately direct any and all inquiries.

Contractor shall submit the Spill Plan for Government approval prior to commencing work.

c. Gear Box Information is listed below. There are three unique gear box configurations that require servicing; the equipment at LD4 and LD5 is a mechanically identical Type 3 gearbox configuration, while the machinery at LD2 varies between three gear boxes:

i. Type 1: Philadelphia Helical Gear Reducer Size 3609 Type BLT, Ratio 130:1, estimated 10.5 gal each from original manufacturer publication – ISO Viscosity Grade 220

ii. Type 2: Philadelphia Size 9HB3, estimated 12 gal each from original manufacturer publication – ISO Viscosity Grade 220

iii. Type 3: Dual-box configuration:

1) Harnischfeger Corp Type 2 Double Reduction, Ratio 25.59:1 enclosed speed reducer, 1 gal each – ISO Viscosity Grade 220

2) Harnischfeger P&H Corp Type 3 Triple Reduction, Ratio 66.2:1 enclosed speed reducer, 84 gal each – ISO Viscosity Grade 220

d. Distribution of gear box types and number of systems requiring servicing is listed below:

i. LD2: 19 x Tainter Gate Gear Boxes, Types 1-3 distributed as follows, total volume 800 gal of ISO 220:

1) Gates 1-5, 8, 10, 11: Type 1

2) Gates 6, 7, 9: Type 2

3) Gates 12-19: Type 3

ii. LD4: 22 x Tainter Gate Gear Boxes, all Type 3 configuration. Estimated total 1,870 gal of ISO 220.

iii. LD5: 28 x Tainter Gate Gear Boxes, all Type 3 configuration. Estimated total 2,380 gal of ISO 220.

e. System flushing requirements. Gear boxes shall be flushed with Government furnished flushing fluid in accordance with Safety Data Sheet (SDS) and published flushing procedures by Schaeffer Lubrication (see references Appendix A and B). The Government will operate the gearboxes after flushing.

f. Oil delivery. Oil and flushing fluid required for the execution of this contract will arrive as early as August 1st 2019, but not later than September 1st, 2019. The Government will retain responsibility for procurement of oil. The oil and flushing fluid will be delivered to the warehouse at Lock and Dam 5a, W679 Highway 35, Fountain City, WI 54629-7214 and will be secured by the Government. Contractor shall pick up all fluids from this location, and shall sign out oil and flushing fluid on a Government form to be provided by the Government or Contracting Officer’s Representative. Contractor shall provide all methods of moving and transporting oil, to include forklift, load lifting/hauling equipment, and vehicles as needed. Government will not load or transport barrels to work sites. The oil is provided in 55 gallon drums and the flushing fluid in five gallon buckets.

3. Contractor shall provide a qualified Quality Control (QC) Inspector to conduct QC throughout duration of work and compile results following completion of work. QC shall address the general condition of the gear boxes and all externally visible components to include input drive and output shafts, seals, fill and drain ports, and outer gear box casing. The QC inspection shall include a visual inspection of the internal components of the gear box, as accessible from the access cover mounted on the top of the gear box, to include observed condition of the gears and any issues or contaminants present within the gear boxes.

The Contractor shall notify the Government of any observed deficiencies or issues with the gear boxes.

Government will be responsible to provide Quality Assurance (QA) checks.

4. Personnel Requirements. Servicing teams shall be led by a qualified team leader. The team leader shall be present for the duration of on-site work. If the team leader must leave the site, inspection and servicing activities shall cease until he/she returns.

a. Servicing/Maintenance Team Leader – Shall have a minimum of five years of experience in leading servicing and/or maintenance teams. Reference paragraph 9e of this scope of work for what is required to demonstrate experience.

b. Quality Control Inspector: QC and team leader shall be familiar with applicable AGMA publications on Gear lubrication, and operation and lubrication of enclosed gearing systems. Inspection personnel shall have experience with ANSI/AGMA 1010-E95 as pertains to gear wear modes, as well as other applicable ANSI/AGMA publications. (AGMA 9005-E02)

5. Work Locations/Contact Information (see attached drawings and appendices):

Location Lockmaster Grid/Address/Phone

Lock and Dam 2 1350 Dam Road, Hastings, Minnesota 55033-1145

15TWK1036256285

651.437.3150

Lock and Dam 4 420 North Main Street, Alma, Wisconsin 54610-4421

15TWK8618608674

608.685.4421

Lock and Dam 5 12554 Highway 61, Minneiska, Minnesota 55959-9756

15TWJ9493590344

507.689.2101

Note: Grid coordinates are given in MGRS/NGRS. This system is compatible with Google Earth and most GPS receivers.

6. Coordination. Contractors shall be responsible for coordinating with the lockmasters at least seven calendar days prior to servicing gearboxes in order to coordinate for lock and dam personnel to close or prepare specified gates for maintenance. Service work shall be done between 7:30 AM and 4:00 PM, Monday – Friday. No work shall be done on Federal holidays. Contractor may elect to use tenting or enclosures if needed during duration of work, for example during winter months to keep oil warm and viscous. Use of tenting or enclosures must be approved by lockmaster at each site. Site visits following contract award are permitted but the Contractor shall coordinate with site lockmasters not later than seven days in advance of proposed site visit. Contractor personnel shall be escorted by lock staff if required by site lockmaster.

a. Accessibility at each site.

i. LD2 Access to the dam is limited and marine plant is required for this work. Dam shall be accessed from the upstream side. Marine plant and marine crane shall be Contractor provided for lifting oil drums on and off the dam. The Government will close gates as necessary to allow Contractor access next to dam on the upstream side. Contractor Personnel shall enter the site from the west side of the river and near the control building, due to the railroad running along the east side of the dam.

Permanently installed cranes are not available at LD2. Contractor shall provide a method of staging and transporting new and used/waste oil and flushing fluid on and off the dam utilizing marine plant.

ii. LD4 Access to the dam can be accomplished from both the east and west sides of the dam or by marine plant and marine crane. The East side is only accessible for personnel access and requires walking across the miter gates and auxiliary lock. The gravel service road on the west side of the dam is able to support large utility vehicle traffic, however use of large trailers may be limited due to limited maneuverability area. Permanently installed cranes are not available at LD4 and Contractor shall provide means for lifting oil drums on and off the dam. Contractor shall provide staging location and a method of transporting new and used/waste oil and flushing fluid on and off the dam.

iii. LD5 Access to the dam can be accomplished from both the east and west sides of the dam or by marine plant and marine crane. The West side is only accessible for personnel access and requires walking across the miter gates and auxiliary lock. The gravel service road on the east side of the dam is able to support large utility vehicle traffic, however use of large trailers may be limited due to limited maneuverability area. Permanently installed cranes are not available at LD5 and Contractor shall provide means for lifting oil drums on and off the dam Contractor shall provide a staging area and method of transporting new and used/waste oil and flushing fluid on and off the dam.

7. Reporting. A separate final report shall be created for each of the three sites. Reports shall be submitted in .pdf format. Reports shall consist of a cover page, table of contents, executive summary, photos, fluids consumption report, and servicing/inspection reports. The individual gear boxes shall be given descriptive names as needed to identify any addressed or remaining deficiencies that might affect future operation of machinery. The fluids consumption report shall detail fluids used for each gear box unit per lock and dam site, as well as unused oil returned to the Government.

8. Schedule. Contractor shall complete all field work within 365 calendar days after contract award. The draft report shall be provided for review no later than 30 calendar days following the completion of field work. The Government will provide comments no later than 15 calendar days after receipt of the draft report. The Contractor shall submit the final report with Government comments incorporated no later than 14 calendar days from receipt of Government’s comments.

9. Submittals. All submittals shall be in a .pdf electronic format. All personnel certifications, Spill Plans, Risk Mitigation and safety plans, timeline, oil disposal plan, and equipment description shall be submitted no later than 30 calendar days prior to the start of the first service.

a. Spill Prevention Plan: Contractor shall provide a spill prevention plan that includes a “contingency plan meeting the provisions of 40 CFR part 109 as well as a written commitment of manpower, equipment and materials required to expeditiously control and remove any quantity of oil discharged that may be harmful” (MVP Oil Spill Contingency Plan and Checklist.) Plan shall include all aspects of spill prevention and primary and secondary containment, information on splash guards to be used during servicing operations, and information on personnel protective gear to be used.

b. Safety Plan and Risk Mitigation by site: Contractor shall provide a safety plan specific to each site that meets the requirements of OSHA and the Army Corps of Engineers Safety Manual (EM 385-1-1) as well as all federal, state, and local rules and regulations. The safety plan shall address all safety issues applicable to this contract. Any fall protection equipment shall be inspected by a competent person as defined in EM 385-1-1 and shall be suitable for the work being performed. All personnel expected to wear the equipment shall be properly trained by a competent instructor. Documentation of training shall be provided as part of the plan. The Contractor shall adhere to all requirements of the plan. All equipment is accessible via hatches on top of the dam and ladders are built into the structure to climb down onto walkways.

c. Operating Procedures Plan: Contractor shall provide a plan documenting the standard operating procedures to be used when conducting servicing on enclosed gear drive units.

d. Oil Disposal Plan: Contractor shall be responsible for disposal of all used/waste oil and flushing fluid, as well as remaining empty drums and barrels taken from existing gear boxes. Plan should be brief and provide method of removal of waste oil products from Government site.

e. QC Inspector and Servicing Team Leader Resumes: Contractor shall submit resumes for the QC inspector and servicing team leader documenting five years of relevant experience each. Included in the resumes shall be a short bio that supports experience and qualifications appropriate to this Scope of Work.

f. Timeline: Contractor shall submit timeline in electronic .pdf format detailing the following dates:

mobilization for field work, projected start date and time on site for each site, demobilization, and draft/final report submittals.

g. Draft Reports: Contractor shall submit draft reports in electronic .pdf format in accordance with paragraph 8, Schedule.

h. Final Reports: Contractor shall submit draft reports in electronic .pdf format in accordance with paragraph 8, Schedule.

10. Reference Drawings and appendices. Sample reference drawings, shop drawings, site photographs, hydrographs, and applicable references are attached to this Scope of Work.

a. Appendix D Lock and Dam 2 site overview and gear box drawings

b. Appendix E Lock and Dam 4 site overview and gear box drawings

c. Appendix F Lock and Dam 5 site overview and gear box drawings

d. Appendix G Additional gear box pictures and information

e. Appendix H Hydrographs and adverse weather days for LD2, 4, and 5

11. Technical Points of Contact. Technical questions regarding this Scope of Work shall be directed in e-mail format to David Seidel at David.A.Seidel@usace.army.mil, MAJ Bryson Rossol at Bryson.R.Rossol@usace.army.mil,.