W912P520Q0053 SOW_TSpecs.pdf

SCOPE OF WORK (SOW)

KENTUCKY LOCK

GEAR / MOTOR SHAFT AND COUPLING ALIGNMENT

PROJECT

GRAND RIVERS, KENTUCKY

July 28, 2020

Table of Contents Background Information

Action Proposed

Existing Site Conditions

Work Plans

Accident Prevention Plan (APP)

Activities Work Plan (AWP) and Schedule

Quality Control Plan

Submittals

Qualifications

Product Data

Installation and Alignment Procedure

Coupling Inspection Report

Gearbox Inspection Report

Post Alignment Report

Operation Condition Assessment (OCA) Reports

Final Review

General

Pay Estimates

Progress Reports

Release of Claims

Period of Performance (PoP)

Site Visit

Site Accessibility

Project Duration and Deliverable Schedule

Deliverable Schedule

Safety

COVID-19

Security

AT Level I Training

Access and General Protection/Security Policy and Procedures

Pre-screen candidates using E-Verify Program

References

Appendix A: USACE Accident Prevention Plan Checklist

Appendix B: Quality Control Plan Guide

Appendix C: Plans and Specifications

SCOPE OF WORK (SOW)

KENTUCKY LOCK

GEAR/MOTOR SHAFT AND COUPLING ALIGNMENT PROJECT

Grand Rivers, Kentucky

28 JULY 2020

Background Information

Kentucky Lock is a high lift navigation lock located at mile 22.4 on the Tennessee River in Grand Rivers, Kentucky. Kentucky Lock is the most utilized Navigation Lock in the U.S. and the busiest in the Nashville District. Per year, the machinery is cycled in excess of 5,000 to 6,000 times, creating wear and tear on instrumental parts of the required equipment needed to operate the lock.

Figure 1 – Project Location at Kentucky Lock & Dam

Action Proposed

The contractor shall provide all necessary labor, material, and equipment necessary to disassemble, inspect, grease, reinstall, and realign the couplings for the miter gate machinery, culvert valve machinery, and tow haulage machinery. Option 1 and 2 are available for replacement of couplings, if needed. There are 25 total couplings that need to be examined.

Where couplings are found to be in poor condition, the contractor shall replace them in the same outline, size, and construction shown on the drawings. Submit the replacement couplings for Government approval.

Option 1: Small Coupling Replacement (Each) This option will be awarded for the replacement of smaller couplings (i.e. for motor shaft and/or tow haulage). It may be awarded up to 9 times.

Option 2: Large Coupling Replacement (Each) This option will be awarded for the replacement of larger couplings (i.e. for gearbox). It may be awarded up to 16 times.

Visually inspect, measure, and align all gearboxes in the miter gate (4 machinery assemblies), culvert valves (4 machinery assemblies), and tow haulage (1 machinery assembly) machinery through inspection ports. Inspect the entire gearbox to ensure there are no oil leaks. Examine the inspection port cover and determine whether all bolts are tight and the cover is properly sealed.

Clean the inspection port cover and surrounding area, and do not contaminate the gearbox interior while removing the cover. Visually inspect the condition of the gear teeth. Cover the inspection port and tighten all bolts to the proper torque. The shaft alignment shall have maximum tolerances corresponding to the shaft RPM. Reference Table 1 Maximum Tolerances below.

Table 1: Maximum Tolerances

When shimming is required, use stainless steel shim stock.

The Contractor is required to use all applicable Federal and industry standards and quality equipment and parts to achieve work. All required adjustments to machinery shall be made using industry standards and tolerances with shims and other spacing devices manufactured to meet quality standards

Existing Site Conditions

The following drawings are provided in Appendix C:

Miter Gate Machinery

a) 64W255 - Upper and Lower Gate Operating Machinery Arrangement

b) 64W258 - Upper and Lower Gate Operating Machinery Sector, Pinion and Misc

c) 64W262 - Upper and Lower Gate Operating Machinery Base Sheet 1

d) 64W263 - Upper and Lower Gate Operating Machinery Base Sheet 2

e) FI-10993-1 - High Speed Reducer

f) D412185 - Low Speed Reducer

Culvert Valve Machinery

a) 64W282 - Segmental Valve Operating Machinery Drive Assembly

b) 64N284 - Segmental Valve Operating Machinery Misc. Machinery Parts

c) 64N288 - Segmental Valve Operating Machinery Base Sheet 1

d) 64N289 - Segmental Valve Operating Machinery Base Sheet 2

e) FI-11005-6 - Segmental Valve High Speed Reducer

f) FI-11008-0 - Segmental Valve Low Speed Reducer

Tow Haulage Machinery

a) 2030145AP - Drum Winch Shop Drawing

b) Electric Motor Drawing - Weg 50 HP, 1800 RPM

c) Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 1

d) Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 2

e) Brevini S-Series epicyclic Gear Unit Model No. SC6004MP Detail 3

The following photographs depict the existing work area:

Figure 1: Miter Gate Machinery Motor and High Speed Gearbox

Figure 2: Miter Gate Machinery Arrangement

Figure 3: Miter Gate Machinery Low Speed Gearbox

Figure 4: Culvert Valve Machinery Arrangement 1

Figure 5: Culvert Valve Machinery Arrangement 2

Figure 6: Culvert Valve Machinery Motor and High Speed Gearbox

Figure 7: Tow Haulage Machinery

Figure 8: Tow Haulage Machinery Motor and Planetary Gearbox

Work Plans

Prior to any site work commencing, the Contractor shall prepare and submit to the Government, an Accident Prevention Plan, an Activities Work Plan, and a Quality Control Plan. The SSHO, CQC Systems Manager and the Superintendent may be same person and have a Competency Experience Level 1. Competency Experience Level 1 includes:

- A minimum of 3 years safety work on similar project.

- 30-hour OSHA construction safety class or equivalent within last 3 years.

- Competent person training as needed.

Accident Prevention Plan (APP) The Contractor will develop an Accident Prevention Plan (APP) for this project. The APP shall include a description of the project and the anticipated work, as well as an Activity Hazard Analysis for specific tasks of this project. Copies of personnel training certifications need to be submitted with this APP.

See Attachment B for an example of the APP checklist to assist with preparation.

NOTE: Field activities shall NOT begin until final APP is approved by CELRN.

Activities Work Plan (AWP) and Schedule The Contractor shall prepare and submit a simple Activities Work Plan (AWP). The work plan shall address the Contractor's approach for achieving the project objectives and present a proposed work schedule and bill of materials.

The Contractor shall submit for approval a schedule of all work to be performed. The schedule shall detail time required for submittals, approvals, material purchases, inspection, and realignment. The lock will be on a schedule outage for the realignment process. The Contractor must submit a 6 week notice prior to starting work on the miter gate machinery and tow haulage machinery to schedule a lock outage for the navigation industry. When work is performed on the culvert valve machinery, the lock will be operating with either one filling or one emptying valve, so this will give the lock ample time to notify any authorities necessary.

The work plan should identify all predicted need for temporary lock closures. Lock closures shall be avoided if possible. Any need for temporary lock closures shall be limited to a 4 hour closure window, no more than one time per day. Any need to temporarily shut down the lock shall be coordinated with the Lockmaster.

Quality Control Plan The Contractor shall submit a QCP after Notice to Proceed. Any testing that will be required shall be submitted as part of the QCP. All testing equipment shall be calibrated and the calibration certifications submitted as part of the QCP.

Submittals Any required submittals may be delivered in electronic (PDF) format.

If the contractor provides any electronic media, electronic files, data etc. to the government they must ensure it is free of any viruses, e.g. Trojan horses, botnet, worms, spyware, adware, rootkits, or any other malicious software that could be harmful or of a destructive nature to government computer systems.

Qualifications A statement certifying that the contractor possesses the capability to perform the work of similar scope and quality shall be submitted with the contractors quote. The statement shall include examples of similar work performed within the past 36 months. List of qualifications shall be submitted with the contractor's bid prior to award.

Product Data Submit product data for couplings.

Installation and Alignment Procedure Provide installation and alignment procedures for the equipment to be furnished.

Coupling Inspection Report A gearbox inspection report shall include sufficient detail in words, photographs, or other methods to fully describe the condition of all couplings inspected. There shall be a report for each set of machinery couplings (Ex: Landside Filling Valve Machinery Couplings).

The reports shall include a section discussing recommended work. The report shall include a section detailing suggested materials and equipment to be maintained at the worksite for ideal maintenance/operation of the equipment.

Gearbox Inspection Report A gearbox inspection report shall include sufficient detail in words, photographs, or other methods to fully describe the condition of all gearboxes inspected. There shall be a report for each set of machinery (four miter gate machinery assemblies, four culvert valve machinery assemblies, and one tow haulage machinery assembly). The reports shall include a section discussing recommended work. The report shall include a section detailing suggested materials and equipment to be maintained at the worksite for ideal maintenance/operation of the equipment.

Post Alignment Report The contractor shall submit the post alignment reports for approval. There shall be a total of 9 post alignment reports, one for each miter gate machinery assembly, one for each culvert valve machinery assembly, and one for the lock tow haulage assembly. At a minimum, the report shall include the alignment tolerances for offset and angularity of each component that is realigned. If it is not necessary to realign a group of machinery, then the report shall include the existing offset and angularity values measured for each component.

This report shall contain sections detailing site conditions and photographs (areas measured for alignment), survey methods, narrative overview of the work performed, pre-alignment baseline findings of misalignments including tolerances (if any), and post-alignment adjusted findings of realignments including tolerances (if any), and any equipment installed including photos, product/manufacturing information, etc.

NOTE: During the execution of this contract, the Contractor may discover damage or deficiencies in the areas near, but not directly associated with, the project work area. The contractor shall notify the GOV in writing, documenting with pictures where practicable, any unusual findings related to the condition of equipment that fall outside of the scope of this effort. This may include but is not limited to physical damage, warping, bad bearings or gears, etc.

Operation Condition Assessment (OCA) Reports The Contractor shall submit Operational Condition Assessments (OCA) Report for each piece of equipment in the project.

Final Review A final review shall be conducted between the contractor and a GOV representative prior to acceptance of work. Any deficiencies identified must be corrected by the contractor prior to final acceptance.

General

Method of Preparing the Proposal

This shall be a firm fixed-price Contract. The agreed price shall constitute full compensation by the GOV to the Contractor for work performed under this contract. The Contractor shall prepare their proposal for negotiation with the USACE based on work tasks as presented in this SOW.

Pay Estimates Requests for payments and requests for retainage refunds shall be submitted to the COR. The preferred method of submission is electronic in PDF format. Pay estimates shall be submitted to the COR for review and processing with USACE Millington, TN finance center.

Progress Reports Progress reports should be submitted with each invoice (preferred monthly) as justification for the amount of payment requested and address the period of performance covered by the invoice. The progress report shall include a narrative summary of activities completed, estimated percentage complete (for individual tasks and overall project), project schedule evaluation, any deviation from schedule, and any problems and recommended solutions. The Contractor shall submit monthly invoices for completed work only; payments will not be made in advance. Pay Estimates should be submitted directly to the COR.

Release of Claims A Release of Claims shall accompany the final invoice. The Release of Claims shall be signed by a contractor company employee with signatory and contract-binding authority, include the final Contract amount, and include a statement similar to the following: “The undersigned company under Contract No. xxxx, between the United States of America and said contractor for services at ____, ____ (Location), hereby releases the United States, its officers, agents, and employees from any and all claims arising under or by virtue of said contract or any modification or change thereof except with respect to those claims, if any, listed below:”

Period of Performance (PoP) The Contract PoP shall be 120 days from Notice to Proceed.

Site Visit A site visit can be organized, if needed, for this Invitation for Bids.

Site Accessibility The contractor shall coordinate all site work with the USACE Site Superintendent (or the designated GOV representative) to minimize disruption of normal operating activities. All work shall be at conducted at the address below:

Kentucky Navigation Lock 265 Kentucky Lock Road Grand Rivers, Kentucky 42045

Work shall be performed between the hours of 06:00 to 16:00 Central Time, Monday through Thursday. No work will be permitted on Friday, weekends, or Federal holidays. Any work outside these hours shall be submitted for approval.

NOTE: Contractor shall coordinate site work at least two days (48 hours) in advance with the contact listed below.

Name: Mr. Chris Marshall Position: WKY Maintenance Engineer Organization: USACE, Nashville District Office Phone: (270) 362-4236 E-Mail: Christopher.J.Marshall@usace.army.mil

Name: Ms. Peyton S. Abernathy Position: COR Organization: USACE, Nashville District Office Phone: 615-736-5363 E-Mail: Peyton.S.Abernathy@usace.army.mil mailto:Peyton.S.Abernathy@usace.army.mil

Name: Mr. Caleb Skinner Position: KY Lockmaster Organization: USACE, Nashville District Office Phone: (270) 508-1319 E-Mail: John.C.Skinner@usace.army.mil

Project Duration and Deliverable Schedule

Lock closures shall be avoided if possible. Any need for temporary lock closures shall be limited to a 4 hour closure window, no more than one time per day. Any need to temporarily shut down the lock shall be coordinated with the Lockmaster.

Deliverable Schedule The following schedule is estimated for this project to be accomplished:

Activity Time Frame APP, AWP, QCP Draft – no later than 14 days after NTP

Final – no later than 14 days after Receipt of USACE Comments (USACE Comments submitted within 14 days of receipt of Draft documents)

Field Work (30 days duration max.) Completed within 100 days after NTP Project Report Within 10 days after field work completion Contract PoP Completion 120 days after NTP

Safety

While working on Government equipment contractor will adhere to safety standards

EM 385-1-1.

COVID-19

Contractors should take precautions to avoid the spread of COVID-19. Contractors should be aware of moving parts while working in the machinery pits. Radio communications shall be maintained between the Lock Operator and the Contractor while personnel are in the machinery pits.

USACE Mechanics (Lockout/Tagout) are onsite from 0600 – 1630, Monday through Thursday.

As the site is a construction area, hard hats and vest shall be worn at all times. Any need to temporarily shut down the lock shall be coordinated with the Lockmaster.

mailto:John.C.Skinner@usace.army.mil

Security

AT Level I Training All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes

Access and General Protection/Security Policy and Procedures All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, controlled access areas, or require network access, shall complete AT Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. Upon request, the contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer (if a COR is not assigned), within 5 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website:

http://jko.jten.mil/courses/atl1/launch.html; or it can be provided by the RA ATO in presentation form which will be documented via memorandum.

Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

Since the work is being done within a controlled area but is expected to last less than six months, the investigation requirements fall under Category B1 for US Citizens and Category C for Foreign Nationals. Contract employees will need to be supervised/ escorted by a Corps employee while within the restricted area. In the event it is determined the contract will extend beyond six months, the contractor will need to comply with the requirements in Category B2 for US Citizens. Guidance and forms for the requirements are available on the Nashville District Public Website:

https://www.lrn.usace.army.mil/Business-With-Us/Contract-Security-Requirements/.

Because the work is being performed in a restricted area, there are restrictions on use of persons either imprisoned or previously convicted of a felony. The Contractor shall not employ in the performance of this contract any person undergoing a sentence of imprisonment imposed by any court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American

Samoa, Guam, or the U.S. Virgin Islands, or the US Federal Government. The Contractor shall not employ in the performance of this contract any person who has been convicted of a felony imposed by any court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American Samoa, Guam, the U.S. Virgin Islands, or the US Federal Government.

Pre-screen candidates using E-Verify Program The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of GOV issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than three (3) business days after the initial contract award.

References

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

Item Description Yes No N/A

1. Signature sheet

a. Includes the name, signature, and title of the Plan Preparer (Qualified person, i.e. corporate safety staff person, QC )

b. Includes the name, signature, and title of the Plan Approver (e.g. owner, company president, regional vice president ) (HTRW activities require approval of a Certified Industrial Hygienist, a Certified Safety Professional may approve the plan for operations involving UST removal where contaminants are known to be petroleum, oils, or lubricants).

c. Includes the name(s), signature(s), and title(s) for Plan Concurrence (provide concurrence of other applicable corporate and project personnel (contractor)) (e.g. Chief of Operations, Corporate Chief of Safety, Corporate Industrial Hygienist, project manager or superintendent, project safety professional, project

QC. )

2. Background information

a. Includes the Contractor Name.

b. Includes the Contract Number.

c. Includes the Project Name.

d. Includes the Brief Project Description.

e. Includes the Location of the Project (map).

f. Includes the Contractor Accident Experience (Copy of OSHA

g. Includes the Listing of Phases of Work and Hazardous Activities Requiring an Activity Hazard Analyses (AHA).

3. Statement of Safety and Health Policy. Includes a copy of the corporate safety policy. (In addition to the corporate policy statement, a copy of the corporate safety program may provide a portion of the information required by the accident prevention

4. Responsibilities and Lines of Authorities

a. Includes the identification and job responsibilities of personnel responsible for safety - at both corporate and project level – including their resumes.

b. Includes the lines of authority.

CESO Form A-02 Sep 13

Remarks (Any NO or N/A item)

Form A-02 U.S. Army Corps of Engineers

Accident Prevention Plan Checklist

Date of Inspection

Location (Plant or Facility) Contract Number

Contractor Name Project Name

Inspector Name (Print) Inspector Signature

This checklist serves as a guide only, it does not replace or eliminate the need to comply with the requirements set forth in Engineering Manual 385-1-1, Safety and Health Requirements Manual, dated XX Sept 2014. The references included in this checklist correspond to the applicable sections of EM 385-1-1.

5. Training

a. Includes the list of subjects to be discussed with employees at safety indoctrination.

b. Includes the list of mandatory training and certifications applicable to this project (e.g., explosive actuated tools, confined space entry, crane operator, diver, vehicle operator, HAZWOPER training and certification, PPE ) and any requirements for periodic retraining / recertification.

c. Includes the identity requirements for emergency response training.

d. Includes the outline requirements (who attends, when given, who will conduct, etc. ) for supervisory and employee safety

6. Safety and Health Inspections

a. Includes the name(s) of individual(s) responsible for conducting safety inspections. (e.g., PM, safety professional, QC, supervisors, employees )

b. Includes proof of inspector's training / qualifications.

c. Indicates when inspections will be conducted.

d. Furnished sample forms upon which inspections will be recorded.

e. Indicates deficiency tracking system and follow-up procedures.

f. Includes the names of competent and / or qualified person(s) and proof of competency / qualification to meet specific OSHA competent / qualified person(s) requirements.

g. Includes any external inspections / certifications which may be required. (e.g., US Coast Guard )

7. Safety and Health Expectations, Incentive Programs, and Compliance

a. Includes the company's written safety program goals, objectives, and accident experience goals.

b. Includes a brief description of the company's safety incentive programs (if any ).

c. Includes the policies and procedures regarding noncompliance with safety requirements (to include disciplinary actions for violation of safety requirements).

d. Includes the written company procedures for holding managers and supervisors accountable for safety.

8. Mishap Reporting

a. The plan identifies how, when, and who shall complete the Exposure data (man-hours worked).

b. The plan identifies how, when, and who shall complete mishap investigations, reports, and logs.

c. The plan identifies how, when, and who shall make immediate notification of major mishaps.

CESO Form A-02 Sep 13

Remarks (Any NO or N/A item)

Form A-02 U.S. Army Corps of Engineers

Accident Prevention Plan Checklist (cont’d)

Date of Inspection

9. Plans (Programs, Procedures) required by the Safety Manual

a. Fatigue Management Plan (01.A.20)

b. Emergency response plans:

(1) Procedures & Test (01.E.01)

(2) Spill Plans (01.E.01, 06.A.02)

(3) Fire Fighting Plan (01.E.01; 19.A)

(4) Posting of Emergency Telephone Numbers (01.E.05)

(5) Man overboard/abandon ship (19.A.04)

(6) Medical Support. Outline on-site medical support and off-site medical arrangements including rescue and medical duties for those employees who are to perform them, and the name(s) of on-site Contractor personnel trained in first aid and CPR. A minimum of two employees shall be certified in CPR and first-aid per shift/site (Section 03.A; 03.D)

c. Plan for prevention of alcohol and drug abuse (01.C.02)

d. Site Sanitation Plan (Section 02.B)

e. Medical Support Plan, (03.A.01; 03.A.06; 03.D)

f. Bloodborne Pathogen Plan (03.A.05)

g. Exposure Control Plan (03.A.05)

h. Site Layout Plan (04.A)

i. Access/Haul road Plan (04.B)

j. Hearing Conservation Program (05.C)

k. Respiratory Protection Plan (05.G)

l. Health Hazard Control Program (06.A)

m. Process Safety Management Plan (06.B.04)

n. Lead Abatement Plan (06.C & Specs)

o. Asbestos Abatement Plan (06.C & Specs)

p. Radiation Safety Program (06.F)

q. Abrasive Blasting Plan (06.I)

r. Heat/Cold Stress Monitoring Plan (06.J)

s. Indoor Air Quality Management Plan (06.L)

t. Mole Remediation Plan (06.L.04)

u. Chromium (VI) Exposure Evaluation (06.M)

v. Crystalline Silica Assessment (06.N)

w. Lighting Evaluation (07.A)

x. Lighting Plan for Night Operations (07.A.09) CESO Form A-02 Sep 13

Form A-02 U.S. Army Corps of Engineers

Accident Prevention Plan Checklist (cont’d)

Date of Inspection

Based on a risk assessment of contracted activities and on mandatory OSHA compliance programs, the Contractor shall address all applicable occupational risks and compliance plans. Using the EM 385-1-1 as a guide, plans may include but not be limited to:

Remarks (Any NO or N/A item)

9. Plans (Programs, Procedures) continued.

y. Traffic Control Plan (08.C.05)

z. Fire Prevention Plan (09.A.01)

aa. Wild Land Fire Management Plan (09.L)

bb. Arc Flash Hazard Analysis (11.B)

cc. Assured Equipment Grounding Control Program (AEGCP), (11.D.05, App D)

dd. Hazardous Energy Control Plan, (12.A.01)

ee. Standard Pre-Lift Plan (LHE) (16.A.03, 16.L.15)

ff. Critical Lift Plan – LHE (16.H)

gg. Naval Architectural Analysis (16.L)

hh. Contingency Plan for Severe Weather (19.A.03)

ii. Man Overboard/Abandon Ship (19.A.04)

jj. Float Plan (19.F.04)

kk. Fall Protection Program, (21.D);

ll. Demolition/Renovation Plan (to include engineering survey), (23.A.02)

mm. Rope Access Program, (24.H.02)

nn. Excavation/Trenching Plan, (25.A.01)

oo. Underground construction fire prevention and protection Plan, (26.D.01)

pp. Compressed Air Plan, (26.I.01)

qq. Formwork and Shoring Erection and Removal plan, (27.C)

rr. PreCast Concrete Plan, (27.D) ss Lift. slab plans, (27.E)

tt. Masonry Bracing Plan, (27.F.01)

uu. Steel Erection Plan, (28.B)

vv. Explosives Safety Site Plan (ESSP) (29.A)

ww. Blasting Plan, (29.A; 26.J)

xx. Underwater Dive Operations Plan, (30.A.14, 16, )

yy. Tree Felling/Maintenance Program, (31.A)

zz. Aircraft/Airfield Construction Safety & Phasing Plan, (32.A.02) aaa. Site Safety and Health Plan (HTRW), (33.B) bbb. Confined Space Entry Program, (34.A.06, 07)

10. Risk Management Processes. Detailed project-specific hazards shall be identified and controls provided via Activity Hazard CESO Form A-02 Sep 13

Form A-02 U.S. Army Corps of Engineers

Accident Prevention Plan Checklist (cont’d)

Date of Inspection

Based on a risk assessment of contracted activities and on mandatory OSHA compliance programs, the Contractor shall address all applicable occupational risks and compliance plans. Using the EM 385-1-1 as a guide, plans may include but not be limited to:

Remarks (Any NO or N/A item)

Other Remarks:

CESO Form A-02 Sep 13

Appendix B: Quality Control Plan Guide

1. Master File. Certify that a master file (record File) has been established. Give project name, location, file number, control and access details. The Corps will provide the Master File number and maintain the file; the Contractor will be responsible for providing pertinent information (QCP, critical correspondence, review documentation) to keep the file up to date.

2. Scope of Work. Define the task. Designate project team. Assign responsibilities. Address budget and schedule. Discuss CRUCIAL project parameters.

3. Specify the review process. Designate the review team, checking of comps, verification of CRUCIAL project parameters, review by specialists, supervisory review, use of interim reviews.

4. Use of checklists. Identify applicable references and guidance. Discuss project checklists, environmental checklist, others. Show copies.

5. Coordination. Tell who is in the coordination loop. Who needs to know your results? Whose input do you need? How does the Corps fit in? Describe provisions for estimating, specifications, and printing (where applicable).

6. Analyze CRUCIAL project features. Describe what must not be allowed to go wrong and what steps will be taken to be sure it doesn’t.

7. Site visits. Describe how site visits will be used. Detail frequency, coordination, use of photos, field data. Identify any special equipment needed for site visits.

8. Quality indicators. Tell what you will use to monitor budget, schedule, technical quality, and responsiveness.

Solicitation No. W38XDD01953365

US Army Corps Of Engineers Nashville District

MACHINERY INSPECTION AND

REALIGNMENT

Kentucky Lock Tennessee River

Livingston County, Kentucky

Technical Specifications

RTA – Certified Final

August 2020

KYL Machinery Inspection and Realignment Kentucky Lock W38XDD01953365 Livingston County, Kentucky

PROJECT TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.10 MACHINERY INSPECTION AND REALIGNMENT

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PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.10

MACHINERY INSPECTION AND REALIGNMENT

PART 1 GENERAL

1.1 SCOPE

1.1.1 Inspection

1.1.2 Realignment

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Inspection

1.2.1.1 Payment

1.2.1.2 Unit of Measure

1.2.2 Alignment

1.2.2.1 Payment

1.2.2.2 Unit of Measure

1.2.3 Option 1 - Small Coupling Replacement

1.2.3.1 Unit of Measure

1.2.4 Option 2 - Large Coupling Replacement

1.2.4.1 Unit of Measure

1.3 REFERENCES

1.4 SUBMITTALS

1.4.1 Submittals Requiring Approval

1.4.2 Submittals for Information Only

1.5 APPLICABLE DRAWINGS

1.5.1 Miter Gate Machinery

1.5.2 Culvert Valve Machinery

1.5.3 Tow Haulage Machinery

1.6 PRE-BID SITE VISIT

1.6.1 Uncertain Measurements

1.7 QUALIFICATIONS

1.8 COORDINATION WITH OTHER CONTRACTORS

1.9 PERIOD OF PERFORMANCE

1.9.1 Schedule

1.10 SITE WORK

1.10.1 General

1.10.2 Machinery Conditions

1.10.3 COVID-19 Precautions

1.11 SAFETY

1.12 SECURITY

1.12.1 Background Investigations

1.12.2 Convict Labor

1.12.3 Escorting

1.12.4 E-verify

1.12.5 Reports of Crime

1.13 CONDUCT OF CONTRACT EMPLOYEES

PART 2 PRODUCTS

2.1 COUPLINGS

PART 3 EXECUTION

SECTION 35 01 41.10 Page 1

3.1 QUALITY CONTROL

3.1.1 Inspection Procedures

3.1.2 Field Measurements

3.1.3 Machinery Lifts

3.2 TESTS, INSPECTION AND VERIFICATION

3.2.1 Coupling Inspection

3.2.2 Gearbox Inspection

3.2.3 Coupling Inspection Report

3.2.4 Gearbox Inspection Report

3.2.5 Post Alignment Reports

3.3 PROTECTION OF PROPERTY

3.3.1 Existing Equipment

3.3.2 Damage or Loss of Contractor's Supplies and Property

3.4 POINT OF CONTACT

3.5 ATTACHMENTS

-- End of Section Table of Contents --

SECTION 35 01 41.10 Page 2

35 01 41.10

MACHINERY INSPECTION AND REALIGNMENT

PART 1 GENERAL

1.1 SCOPE

1.1.1 Inspection

The contractor shall provide all necessary labor, material, and equipment necessary to inspect the following items: the couplings for the miter gate machinery, culvert valve machinery, and tow haulage machinery. The contractor shall also inspect all gearboxes through the inspection ports.

a. Couplings: couplings of the miter gate machinery, culvert valve machinery and tow haulage unit shall be completely disassembled and removed from the shaft for cleaning and inspection. The coupling that exits the motor and connects to the high speed gearbox, and the two couplings that connect the high speed gear box to the low speed gear box shall be inspected. See paragraphs 3.2.1 "Coupling Inspection" for more information. If a coupling is found to be damaged and requiring replacement. The contractor will reassemble the machinery with a spare coupling provided by the Government. The contractor must confirm if the coupling will properly fit the shafts. The contractor will then submit a reference for a new coupling to the government for approval to replace the spare coupling. Upon government approval, the contractor will purchase and then replace the spare coupling with the new coupling. If a spare coupling is not availabe, the Contractor shall reassemble the machinery with the damaged coupling if possible and then go through the submittal process. Only reassemble the machinery with a damaged coupling if a spare coupling is not available. Inform the COR prior to this action for approval.

b. Gearboxes: all low speed gearboxes and high speed gearboxes of miter gate machinery and culvert valve machinery shall be inspected through the inspection ports. Planetary gearbox of the tow haulage will also visually inspected. See paragraph 3.2.2 "Gearbox Inspection" for more information on the work to be included for the inspection. The scope of work does not require disassembling of the gearboxes for inspection.

c. Inspection reports: Provide inspection reports that will include the conditions of the couplings and gearboxes. See paragraph 3.2.3 "Coupling Inspection Report" and paragraph 3.2.4 "Gearbox Inspection Report" for more information on what should be included in the reports.

1.1.2 Realignment

The shafts where the couplings are inspected shall be realigned within the maximum tolerances in Table 1. Realignment shall be performed after the couplings are fully inspected and reinstalled. The lock personnel can aid in any necessary machinery lifts in order to align the machinery properly.

This shall be confirmed during the pre-bid site visit.

The shaft alignment shall have maximum tolerances corresponding to the

SECTION 35 01 41.10 Page 3 shaft rpm. Reference Table 1 Maximum Tolerances.

Shaft Speed (RPM) Angularity (mils/inch) (0.001/1")

Offset (mils) (0.001")

0 - 600 1.5/1" 5.0

600 - 900 1.0/1" 3.5

900 - 1200 0.7/1" 3.0

1200 - 1800 0.5/1" 2.5

Contractor shall provide post alignment reports at the completion of the project. The post alignment reports shall include at a minimum the new offset alignment (mils) and angular alignment (mils/in) and the procedure to address the misalignment issue.

1.2 PRICE AND PAYMENT PROCEDURES

1.2.1 Inspection

1.2.1.1 Payment

Payment shall be made for costs associated with the inspection as indicated in the paragraph "SCOPE" which include inspection of the couplings, inspection of the gearboxes, and inspection reports. Mobilization, demobilization, bond payment, clean up, etc. shall be incidental to this payment.

1.2.1.2 Unit of Measure

Job.

1.2.2 Alignment

1.2.2.1 Payment

Payment shall be made for costs associated with the realignment of the stated machinery shafts and the post alignment reports as indicated in the paragraph "SCOPE".

1.2.2.2 Unit of Measure

Job.

1.2.3 Option 1 - Small Coupling Replacement

Payment shall be made for costs associated with the replacement of the small couplings that connect the motor to the high speed gear box or the epicyclic gearbox. There are a total of 9 small couplings.

1.2.3.1 Unit of Measure

Each.

SECTION 35 01 41.10 Page 4

1.2.4 Option 2 - Large Coupling Replacement

Payment shall be made for costs associated with the replacement of the two large couplings that connect the high speed gear box to the low speed gearbox. There are a total of 16 large couplings.

1.2.4.1 Unit of Measure

Each.

1.3 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

1.4.1 Submittals Requiring Approval

Submittals requiring approval shall be submitted per the following procedure: Each submission by the Contractor shall be accompanied by a letter of transmittal containing a list of the items submitted, giving titles and numbers as applicable. Transmittals shall be addressed to the person designated by the Contracting Officer. All submittals shall be provided via email unless otherwise requested or approved. Decisions on these submittals, either approval or disapproval, will be given by the Government's Representative within 15 calendar days (30 calendar days for shop drawings). Each item submitted with "Approved," "Approved Except as Noted," or "Returned for Correction." The notations "Approved" and "Approved Except as Noted" authorize the Contractor to proceed with the work covered by such drawings, subject to the corrections, if any, indicated thereon or described in the letter of the transmittal. When the submittal has been "Returned for Correction", the Contractor shall make the necessary revisions and shall resubmit for approval in the same routine as before. Every revision made during the life of the contract shall be shown by the number, date, and subject in a revision block and a notation shall be made in the drawing margin to permit rapid location of the revision. The time consumed by the Contractor in submitting and obtaining approval of submittals shall be included in the time allowed for completion of the contract.

1.4.2 Submittals for Information Only

Submittals not requiring government approval shall be submitted for information only.

SD-01 Preconstruction Submittals

SECTION 35 01 41.10 Page 5

Qualifications; G, ECD-E Please submit the qualifications along with the Contractor's bid prior to award.

Schedule; G, ECD-E

Inspection Procedures; G, ECD-E

SD-03 Product Data

Couplings; G, ECD-E

SD-06 Test Reports

Coupling Inspection Report; G, ECD-E

Gearbox Inspection Report; G, ECD-E

Post Alignment Reports ; G, ECD-E

1.5 APPLICABLE DRAWINGS

1.5.1 Miter Gate Machinery

a. 64W255 - Upper and Lower Gate Operating Machinery Arrangement

b. 64W258 - Upper and Lower Gate Operating Machinery Sector, Pinion and Misc

c. 64W262 - Upper and Lower Gate Operating Machinery Base Sheet 1

d. 64W263 - Upper and Lower Gate Operating Machinery Base Sheet 2

e. FI-11000-00 - High Speed Reducer

f. D412185 - Low Speed Reducer

1.5.2 Culvert Valve Machinery

a. 64W282 - Segmental Valve Operating Machinery Drive Assembly

b. 64N284 - Segmental Valve Operating Machinery Misc. Machinery Parts

c. 64N288 - Segmental Valve Operating Machinery Base Sheet 1

d. 64N289 - Segmental Valve Operating Machinery Base Sheet 2

e. FI-11005-6 - Segmental Valve High Speed Reducer

f. FI-11008-0 - Segmental Valve Low Speed Reducer

1.5.3 Tow Haulage Machinery

a. 2030145AP - Drum Winch Shop Drawing

1.6 PRE-BID SITE VISIT

The pre-bid site visit is recommended to verify the equipment prior to placing the bid. This will provide important information of what is required to perform the work. However, it is not required to bid on this job.

1.6.1 Uncertain Measurements

The Downstream River Miter Gate High Speed Gearbox is different from the other three gate high speed gearboxes. The shaft size is similar to the other three; however the contractor will visually observe the size of the output shafts during the pre-bid site visit, and confirm the dimensions

SECTION 35 01 41.10 Page 6 during the inspection and realignment process. Where measurements are unknown, the contractor shall make a note of them during the pre-bid site visit, and confirm the dimensions during the work to be performed.

1.7 QUALIFICATIONS

A statement certifying that the contractor possesses the capability to perform the work of similar scope and quality shall be submitted with the contractors quote. The statement shall include examples of similar work performed within the past 36 months. List of qualifications shall be submitted with the contractor's bid prior to award.

1.8 COORDINATION WITH OTHER CONTRACTORS

Coordination with other Contractors in the area will be required. The Contractor has primary responsibility to initiate the coordination and communication in a timely manner with the Contracting Officer's Representative to schedule activities and minimize or eliminate conflicts.

The Contracting Officer's Representative may determine that the Contractor should communicate directly with others. The COR shall be timely informed of all communications or actively involved in the communications.

The construction of the Lock Addition will be ongoing for the life of this contract. The Contractor shall not impact the progress of the Lock Addition contract. Special attention is required to ensure that all activities, especially those involving work with and around lifting equipment, meet the requirements for safety as directed in EM 385-1-1.

1.9 PERIOD OF PERFORMANCE

Period of performance is 120 calendar days after the contract is awarded.

1.9.1 Schedule

The Contractor shall submit for approval a schedule of all work to be performed. The schedule shall detail time required for submittals, approvals, material purchases, inspection, and realignment. The lock will be on a scheduled outage for the realignment process. Contractor must submit a 6 week notice prior to starting work on the culvert valve, miter gate, and tow haulage machinery to schedule a lock outage for the navigation industry. When work is performed on the culvert valve machinery, the lock will be operating with either one filling or one emptying valve, so this will give the lock ample time to notify any authorities necessary.

When work is being performed on the other machinery, one, four-hour outage per day will be acceptable. Any outage shall not exceed this four hour time frame. The contractor shall be responsible for performing the requested work within this time period.

1.10 SITE WORK

1.10.1 General

While working on Government equipment contractor will adhere to safety standards EM 385-1-1. All coordination while on site shall be conducted through the lock master and his staff. Working hours shall be Monday-Thursday from 0600hrs-1600hrs except for federal holidays. Any work outside these hours shall be submitted for approval.

SECTION 35 01 41.10 Page 7

1.10.2 Machinery Conditions

The machinery being worked on will be in the closed position for the duration of the inspection and realignment procedure and will not be moved or returned to service until the contractor has completed the realignment of the machinery. The contractor shall notify the COR upon completion.

1.10.3 COVID-19 Precautions

Contractors shall take precautions to avoid the spread of COVID-19. Social distance where possible. The contractor shall adhere to any precautions described by the COR.

1.11 SAFETY

The contractor must adhere to safety requirements in EM 385-1-1. The contractor shall closely coordinate with the lock master to conduct the work safely in accordance with Nashville District Operations safe work procedures.

1.12 SECURITY

Security requirements are based on the assumption that the Contractor will be onsite working less than 60 calendar days. In the event the Contractor is required to work onsite for a longer period of time, contact the Project Representative for the purpose of adjusting these requirements.

All contractor and associated sub-contractor employees shall comply with all applicable project and local security policies and procedures (provided by the district representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by the District Security Management Office. Contractor workforce must comply with all personal identity verification requirements (FAR Clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

1.12.1 Background Investigations

Since the work is being done within a controlled area but is expected to last less than six months, the investigation requirements fall under Category B1 for US Citizens and Category C for Foreign Nationals. Contract employees will need to be supervised/ escorted by a Corps employee while within the restricted area. In the event it is determined the contract will extend beyond six months, the contractor will need to comply with the requirements in Category B2 for US Citizens. Guidance and forms for the requirements are available on the Nashville District Public Website:

http://www.lrn.usace.army.mil/BusinessWithUs/ContractSecurityRequirements.aspx

1.12.2 Convict Labor

Because the work is being performed in a restricted area, there are restrictions on use of persons either imprisoned or previously convicted of a felony. The Contractor shall not employ in the performance of this contract any person undergoing a sentence of imprisonment imposed by any

SECTION 35 01 41.10 Page 8 court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American Samoa, Guam, or the U.S. Virgin Islands, or the US Federal Government. The Contractor shall not employ in the performance of this contract any person who has been convicted of a felony imposed by any court of a State, the District of Columbia, Puerto Rico, the Northern Mariana Islands, American Samoa, Guam, the U.S. Virgin Islands, or the US Federal Government.t

1.12.3 Escorting

All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

1.12.4 E-verify

The Contractor must pre-screen potential employees to work on this contract using the E-verify Program (http:www.uscis.gov/e-verify) website to meet the established eligibility requirements. The Contractor must ensure that the employee has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible contract employees must be provided to the COR no later than 3 business days after the initial contract award.

1.12.5 Reports of Crime

Please ensure ALL reports of theft, suspected theft, vandalism, or ANY crime of Government OR Contractor property, OR crime against/by Contractor personnel is forwarded to the District Security Office. This information is critical for threat and risk assessments and may assist in obtaining funds for additional security measures.

1.13 CONDUCT OF CONTRACT EMPLOYEES

All contract employees and subcontractors shall conduct themselves in a proper manner at all times. No alcoholic or intoxicating beverages or substances or illegal drugs or controlled substances not prescribed by a physician shall be possessed, consumed, or be under the influence of any such substance while on Government property.

The Contractor shall remove from the site any individual whose continued employment is deemed by the appointed receiving agent to be contrary to the public interest or inconsistent with the best interests of the U.S. Army Corps of Engineers.

The Contracting Officer or the appointed receiving agent will require the Contractor to immediately remove from the work site anyone who is incompetent or who endangers persons or property or whose physical or mental condition is such that it would impair the employee's ability to satisfactorily perform the work. Notification to the Contractor will be made in writing if time and circumstances permit. Otherwise, notification will be verbal and will be confirmed in writing as soon as possible. No such removal, however, will reduce the Contractor's obligation to perform all work required under this contract and immediate replacement shall be made as required.

SECTION 35 01 41.10 Page 9

PART 2 PRODUCTS

2.1 COUPLINGS

Where couplings are found to be in poor condition, the contractor shall replace them in the same outline, size, and construction…