W912P820B0063_Wilkinson Canal Pump Station TECH Service.pdf.pdf

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RATING PAGE OF PAGES

7. ISSUED BY

(Date)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

Previous Edition is Unusable 33-134 STANDARD FORM 33 (REV. 9-97)

Prescribed by GSA FAR (48 CFR) 53.214(c)

1 82

(If other than Item 7)

15A. NAME 16. NAME AND TITLE OF PERSON AUTHORIZED TO

AND

ADDRESS SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

15B. TELEPHONE NO (Include area code) 17. SIGNATURE15C. CHECK IF REMITTANCE ADDRESS

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

W912P8 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and 1 copies for furnishing the supplies or services in the Schedule will be received at the place specified in Item 8, or if handcarried, in the depository located in

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and

Virtual Bid Opening conditions contained in this solicitation.

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

SHERMEKA L SHOWERS

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 5

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT

PACKAGING AND MARKING

6 - 21 J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

23 X K REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror) 24 - 34 M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the price set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to the SOLICITATION for offerors and related documents numbered and dated):

FACILITY

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period

SOLICITATION, OFFER AND AWARD

X

(X) SEC. DESCRIPTION (X) SEC. DESCRIPTION PAGE(S)

PART I - THE SCHEDULE

26. NAME OF CONTRACTING OFFICER (Type or print) 27. UNITED STATES OF AMERICA 28. AWARD DATE

EMAIL:TEL: (Signature of Contracting Officer)

CODE CODE

B. TELEPHONE (Include area code) C. E-MAIL ADDRESS

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL AND OPEN COMPETITION:

10 U.S.C. 2304(c)( ) 41 U.S.C. 253(c)( ) (4 copies unless otherwise specified)

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

24. ADMINISTERED BY (If other than Item 7) CODE 25. PAYMENT WILL BE MADE BY CODE

PART IV - REPRESENTATIO NS AND INSTRUCTIO NS

PART III - LIST O F DO CUMENTS, EXHIBITS AND O THER ATTACHMENTS

35 - 61

PART II - CO NTRACT CLAUSES

USACE, CONTRACTING DIVISION

ATTN: CEMVN-CT, ROOM 172

7400 LEAKE AVE.

NEW ORLEANS LA 70118-3651

FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

21 Dec 2020

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

W912P820B0063

BID BOND

(See instructions on reverse)

OMB Control Number: 9000-0045 Expiration Date: 8/31/2022

PRINCIPAL (Legal name and business address) TYPE OF ORGANIZATION ("X" one)

STATE OF INCORPORATION

SURETY(IES) (Name and business address)

PERCENT

OF BID

PRICE

PENAL SUM OF BOND

AMOUNT NOT TO EXCEED

MILLION(S) THOUSAND(S) HUNDRED(S) CENTS

BID IDENTIFICATION

BID DATE INVITATION NUMBER

PRINCIPAL

SIGNATURE(S)

NAME(S) &

TITLE(S)

(Typed)

1.

1. 2.

2.

3.

3.

(Seal) (Seal) (Seal) Corporate Seal

INDIVIDUAL SURETY(IES)

SIGNATURE(S)

NAME(S)

(Typed)

1.

1.

2.

2.

(Seal) (Seal)

CORPORATE SURETY(IES)

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NAME &

ADDRESS

STATE OF INCORPORATION LIABILITY LIMIT ($)

SIGNATURE(S)

NAME(S) &

TITLE(S)

(Typed)

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1.

2.

2. Corporate Seal

AUTHORIZED FOR LOCAL REPRODUCTION

Previous edition is NOT usable

STANDARD FORM 24 (REV. 8/2016)

Prescribed by GSA - FAR (48 CFR) 53.228(a)

FOR (Construction, Supplies or Services)

OBLIGATION:

We, the Principal and Surety(ies) are firmly bound to the United States of America (hereinafter called the Government) in the above penal sum. For payment of the penal sum, we bind ourselves, our heirs, executors, administrators, and successors, jointly and severally. However, where the Sureties are corporations acting as co-sureties, we, the Sureties, bind ourselves in such sum "jointly and severally" as well as "severally" only for the purpose of allowing a joint action or actions against any or all of us. For all other purposes, each Surety binds itself, jointly and severally with the Principal, for the payment of the sum shown opposite the name of the Surety. If no limit of liability is indicated, the limit of liability is the full amount of the penal sum.

CONDITIONS:

The Principal has submitted the bid identified above.

THEREFORE:

The above obligation is void if the Principal - (a) upon acceptance by the Government of the bid identified above, within the period specified therein for acceptance (sixty (60) days if no period is specified), executes the further contractual documents and gives the bond(s) required by the terms of the bid as accepted within the time specified (ten (10) days if no period is specified) after receipt of the forms by the principal; or (b) in the event of failure to execute such further contractual documents and give such bonds, pays the Government for any cost of procuring the work which exceeds the amount of the bid.

Each Surety executing this instrument agrees that its obligation is not impaired by any extension(s) of the time for acceptance of the bid that the Principal may grant to the Government.

Notice to the surety(ies) of extension(s) is waived. However, waiver of the notice applies only to extensions aggregating not more than sixty (60) calendar days in addition to the period originally allowed for acceptance of the bid.

WITNESS:

The Principal and Surety(ies) executed this bid bond and affixed their seals on the above date.

DATE BOND EXECUTED (Must not be later than bid opening date)

Paperwork Reduction Act Statement - This information collection meets the requirements of 44 USC § 3507, as amended by section 2 of the Paperwork Reduction Act of 1995. You do not need to answer these questions unless we display a valid Office of Management and Budget (OMB) control number. The OMB control number for this collection is 9000-0045. We estimate that it will take 1 hour to read the instructions, gather the facts, and answer the questions. Send only comments relating to our time estimate, including suggestions for reducing this burden, or any other aspects of this collection of information to: General Services Administration, Regulatory Secretariat Division (M1V1CB), 1800 F Street, NW, Washington, DC 20405.

JOINT VENTURE

OTHER (Specify)

PARTNERSHIPINDIVIDUAL

CORPORATION

INSTRUCTIONS

1. This form is authorized for use when a bid guaranty is required. Any deviation from this form will require the written approval of the Administrator of General Services.

2. Insert the full legal name and business address of the Principal in the space designated "Principal" on the face of the form. An authorized person shall sign the bond. Any person signing in a representative capacity (e.g., an attorney-in-fact) must furnish evidence of authority if that representative is not a member of the firm, partnership, or joint venture, or an officer of the corporation involved.

3. The bond may express penal sum as a percentage of the bid price. In these cases, the bond may state a maximum dollar limitation (e.g., 20% of the bid price but the amount not to exceed dollars).

4. (a) Corporations executing the bond as sureties must appear on the Department of the Treasury's list of approved sureties and must act within the limitations listed therein. The value put into the LIABILITY LIMIT block is the penal sum (i.e., the face value) of the bond, unless a co-surety arrangement is proposed.

(b) When multiple corporate sureties are involved, their names and addresses shall appear in the spaces (Surety A, Surety B, etc.) headed "CORPORATE SURETY(IES)." In the space designated "SURETY(IES)" on the face of the form, insert only the letter identifier corresponding to each of the sureties. Moreover, when co-surety arrangements exist, the parties may allocate their respective limitations of liability under the bond, provided that the sum total of their liability equals 100% of the bond penal sum.

(c) When individual sureties are involved, a completed Affidavit of Individual Surety (Standard Form 28) for each individual surety, shall accompany the bond.

The Government may require the surety to furnish additional substantiating information concerning its financial capability.

5. Corporations executing the bond shall affix their corporate seals. Individuals shall execute the bond opposite the word "Corporate Seal"; and shall affix an adhesive seal if executed in Maine, New Hampshire, or any other jurisdiction requiring adhesive seals.

6. Type the name and title of each person signing this bond in the space provided.

7. In its application to negotiated contracts, the terms "bid" and "bidder" shall include "proposal" and "offeror."

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TITLE(S)

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Corporate Seal

LIABILITY LIMIT ($)STATE OF INCORPORATION

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Corporate Seal

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STANDARD FORM 24 (REV. 8/2016) BACK

SECTION B-SCHEDULE OF PRICES

Item No.

Supplies/Services Quantity Unit Unit Price

Amount

0001 New Speed Reducers (Right Angle Gearboxes) - Supply

1 JOB

0002 Mobilization/Demobilization 1 JOB 0003 F.S.I. Barriers - Supply 2 EA

0004 Dewatering Pump Station Intake

• Trash Screen Removal & Re-installation

• Divers

• F.S.I. Barrier Installation &

Removal

• Sump Pumps

• Materials

1 JOB

0005 Pump Unit #2 & #3 Final Repairs

• Pump Column Removal

• Transport

• Inspection

• New Speed Reducer Pedestals

• New Solid Shafts

• New Bearings

• Materials

• Shop Testing & Alignment

• Transport

• Installation

• Electrical Work

• Engine Pedestal Repairs

• Alignment Work

• Materials

• Pump Monitoring & Controls Repair

Work

• Diesel Engines #2 & #3 Oil

Changes w/ Oil Sample Analysis

• Pump Test & Vibration Reading

• Training

1 JOB

0006 Pump Unit #2 Inspection Report and Findings

1 JOB

0007 Pump Unit #1 & #4 Final Repairs

• Pump Column Removal

• Transport

• Inspection

• New Speed Reducer Pedestals

• New Solid Shafts

• New Bearings

• Materials

• Shop Testing & Alignment

1 JOB

• Transport

• Installation

• Electrical Work

• Engine Pedestal Repairs

• Alignment Work

• Materials

• Pump Monitoring & Controls Repair

Work

• Diesel Engines #1 & #4 Oil

Changes w/ Oil Sample Analysis

• Pump Test & Vibration Reading

• Training

0008 Spare Parts 1 JOB 0009 Material Disposal 1 JOB 0010 Final Report & As Built Drawings

• Shop Inspection Reports & Findings

• Alignment & Installation Tolerance Verifications

• Engine & Speed Reducer Bolt Torque Values

• Pump Test & Vibration Reports

1 JOB

Total Amount:_________________________

Section C - Descriptions and Specifications

PERFORMANCE WORK STATEMENT

Performance Work Statement Wilkinson Pump Station Technical Services

Plaquemines Parish, Louisiana

1. Basic Data and Support. The Contractor shall inspect, disassemble, remove, repair, reconfigure, re-install, and re-align the pump units for Wilkinson Canal Pump Station (WCPS), Plaquemines Parish, Louisiana.

a. The Contractor shall provide a qualified technician and calibrated equipment to inspect, disassemble, remove, repair, reconfigure, re-install, and re-align the pump unit components of the four (4) pumps at New Orleans to Venice, Non-Federal (NOV-NF-W) WCPS as directed by the Contracting Officer Representative (COR).

b. The technician shall check in with the Government Inspector each time he/she reports to the site.

c. The following attachments shall be used to supplement the performance work statement:

a. Attachment 1_Selected NOV-NF-W-05b Reference Specs.pdf

b. Attachment 2_Selected NOV-NF-W-05b As-built Drawings.pdf

c. Attachment 3_Government supplied drawings.pdf

2. Contract Requirements. The Contractor shall provide all labor, materials, equipment, machine shop facilities, tools, transportation, and supervision to inspect, disassemble, remove, repair, reconfigure, re-install, and re-align the Moving Waters Industries (M.W.I.) NWC60 Vertical Pump Assemblies located at the WCPS as follows:

2.1 Submittals:

The Contractor shall submit all new items and materials to be used in the proceedings of this contract or as specified herein. The Contractor shall carefully control his procurement operations to ensure that each individual submittal is approved by the Contracting Officer’s Representative and/or the Technical Manager before procurement of submitted item(s). Submittals shall include items such as: Contractor's, manufacturer's, or fabricator's drawings; descriptive literature including (but not limited

to) catalog cuts, crane lift plan, diagrams, dewatering plan, impeller two-plane balancing technique, operating charts or curves; test reports; samples; O&M manuals (including parts list); certifications; warranties; and other such required submittals. The Contractor shall submit their intended submittal list for approval before commencement of work.

2.2 Order of Work:

Mobilization of the NOV-NF-W-05b.1.b contract shall require previous approval by a representative of Construction Division (Resident Engineer, Project Engineer, or Quality Assurance/Quality Control Inspector) and/or the Technical Manager. The order of work for the repairs to the pump units at WCPS shall start with the repairs of Pump Unit #2 and Pump Unit #3 and finish with Pump Unit #4 and Pump Unit #1. The Contractor shall document by photographs and/or video the existing conditions in the areas in and around the pump station where they intend to work and submit them to the Government.

The Contractor shall submit their schedule for accomplishing this work within the calendar days allotted in paragraph 6 before commencement of work.

2.3 Pump Unit Repairs:

The repairs to the pump units at WCPS involve the ordering of new speed reducers for the four (4) pumps at WCPS, fabrication and installation of the formed suction intake (FSI) barrier, the removal of the pump column, disassembly of the pump column, inspection, measurement, and recording of the dimensions, tolerances, and any deviations of the pump shaft and speed reducer components, the fabrication of solid stainless steel pump shafts (head, upper, and lower) to couple to the output shaft of the new speed reducers, assemble the new pump shafts with the existing impeller and compare against measured length of the old pump shaft assembly, reassembly of the pump column with new speed reducer and compare against measured length of the old pump column and speed reducer assembly, factory testing of re-assembled pump column, transport components to site, installation of components onsite, align the speed reducer to pump shaft, align the diesel engine to the speed reducer, couple shafts together, and 4 hour operational test with vibrational monitoring . The Contractor shall provide a detailed final report within four (4) weeks of completion of all final repairs. The details of the course of work are contained herein.

2.3.1 New Speed Reducers (Right Angle Gearboxes):

As part of the repair work for the pump units at WCPS, four (4) new, unused speed reducers shall be purchased to replace the four (4) existing speed reducers. The speed reducers shall be designed and manufactured by a firm that is regularly engaged in the manufacture of speed reducers of the type utilized for these installations. The speed reducers shall be configured as best as possible in order to maintain the existing elevations and locations so as to not cause undo modification and/or relocation of other equipment and auxiliaries. Speed reducers and all auxiliaries shall be compatible with the existing pump unit components and provided by a company that has consistently provided speed reducers and all auxiliaries for pump unit components for over 50 years.

Speed reducers and all auxiliaries shall be submitted for approval. Submit complete computations, design loads, and catalog data. The speed reducers shall display the certified manufacturer's ANSI/AGMA insignia as evidence of conformance to these standards. The nameplate shall bear the manufacturer's name, model designation, serial number, unit rating, application factor, reduction ratio, and other applicable information. The housing shall be enclosed to limit dust, dirt, and water intrusion and rated for a harsh marine environment. The speed reducers shall be single reduction spiral bevel gear type equipped with thrust bearings to make the speed reducers suitable for use with a vertical impeller pump. All gears shall be manufactured to AGMA Quality 13 or better as outlined in AGMA Standards. Gear teeth shall be carburized and hardened to 58 to 63 Rockwell C and shall be hard finished after completion of heat treatment. No flame hardening of the gear teeth is permissible. Final surface finish of the gear teeth shall be 32 micro inch RMS or better. Gear reducer efficiency for single reduction spiral bevel speed reducers shall be a minimum of 98.5%.

Thrust bearings shall be designed to resist up thrust during pump startup or shutdown load as described herein and in subsection 33 45 00.00 10 (Attachment 1). All bearings incorporated within the speed reducer are of the anti-friction type with an AGMA minimum rated life expectancy (L-10) of 100,000 hours. The speed reducers shall be able to withstand all specified operating conditions in subsection 33 45 00.00 10 (Attachment 1) without damage. A backstop shall be provided to prevent reverse rotation of the pump. The gear speed reducers shall conform to the requirements of ANSI/AGMA 6013 or ANSI/AGMA 6123 as applicable. The speed reducers shall be designed to exceed the maximum input power times an application factor for durability purposes. The 1.75 application factor shall be used for this project. Obtain the operating conditions from the pump and prime mover suppliers. Operating conditions which shall be considered include (as a minimum): maximum input power, motor or engine speed, speed reducers ratio, maximum pump reverse overspeed, low-speed shaft downward thrust including weight, low-speed shaft momentary upward thrust during startup or shutdown (if applicable), high-speed shaft direction of rotation, low-speed shaft direction of rotation, overhung load, motor stall torque, or maximum engine overload torque transmitted through the clutch, and reverse torque load on the backstop. The speed reducers shall be designed to withstand backstop failure and maximum pump reverse runaway speed for a period of 30 minutes. Dynamic analysis of the pump, speed reducers, and motor (engine) assembly shall be performed by the speed reducer manufacturer. The speed reducer manufacturer shall coordinate with the pump manufacturer in performing the dynamic analysis. The speed reducer manufacturer shall make any design modifications to the speed reducers which are necessary to avoid resonances in the system. A torsional or lateral natural frequency within 25 percent of normal operating speed of any shaft or gear mesh frequency is unacceptable. The pump shaft shall be designed so that it passes through concentrically through the speed reducer shaft allowing finite impeller elevation adjustment. The speed reducers input shaft shall be connected to the motor by one flexible coupling and one torsional coupling and an intermediate shaft. Ensure compatibility and fit of the speed reducer high- and low-speed shafts with that of the pump and prime mover. The inboard pinion shaft shall be supported by straddle mounted bearings to aid in negating transference of deflections/misalignments throughout the entire pump unit assembly. The inboard pinion shaft shall not be supported by overhung bearings. Before assembly, each gear and shaft assembly shall be dynamically balanced.

Other requirements shall be in accordance with specification section 33 45 00.00 10 Speed Reducers for Storm Water Pumps (Attachment 1).

2.3.1.a New Speed Reducer Pedestals:

The pedestal for the speed reducer shall incorporate the dimensions of the new speed reducer while maintaining the elevations of the existing pump unit. The output shaft of the diesel engine is at EL. 15.83 (NAVD 88 (2004.65)). The input shaft of the speed reducer is at EL. 16.00 (NAVD 88 (2004.65)). Verify with field measurements before manufacture of the new pedestal. The old pedestal section of the pump column shall be removed, and the new pedestal section of the pump column shall be bolted in its place.

Other requirements shall be in accordance with specification section 33 45 00.00 10 Speed Reducers for Storm Water Pumps (Attachment 1).

2.3.1.b Auxiliary Heat Exchanger Unit:

The auxiliary heat exchanger shall be an oil-to-air type floor mounted heat exchanger with size based upon a maximum ambient temperature of 100 degrees F. Heat exchanger tubes and fins shall be copper or copper alloy.

Working pressure shall exceed the oil pump working pressure. The auxiliary heat exchanger shall withstand a test pressure of 150 percent of the design pressure held for a period of 4 hours during which time the heat exchanger shall be checked for leakage. Any leakage shall be cause for rejection. The oil-to-air heat exchanger system shall include a fan, motor, and controls for maintaining the specified oil temperature. The auxiliary heat exchanger shall have an instrumented bypass to avoid cooling temperatures below 40 degrees F. Power to each heat exchanger shall be provided from the existing 120/208V panels. The circuits shall be run in RGS conduits. The conductors shall be copper, with type THHN/THWN insulation. Any junction boxes used shall be of NEMA 4X stainless steel. Auxiliary heat exchanger units and auxiliaries shall be compatible with the existing pump unit components and provided by a company that has consistently provided auxiliary heat exchanger units and all auxiliaries for pump unit components for over five years. Auxiliary heat exchanger units and all auxiliaries shall be submitted for approval.

2.3.1.c Shop Testing Submit a shop test report fully documenting the test. In addition to or as part of the Contractor's normal shop testing procedure, the reducer shall be tested at rated speed, no load to check for potential problems which shall be eliminated prior to field testing. Gear contact patterns, sound level, lubrication and cooling, and all other operational characteristics shall be checked. The sound pressure level of the speed reducer and prime mover used in the shop test shall not exceed 85 dBA measured at 3 feet from the equipment. Sound shall be measured in accordance with ANSI/AGMA 6025. Provide any preventative measures to control background noise. Notify the Contracting Officer 2 weeks prior to performing the shop test. Shop testing results shall be submitted for approval.

2.3.2 Formed Suction Intake (FSI) Barrier:

In order to facilitate the removal of the pump column, a watertight barrier must be designed and installed at each FSI opening prior to removing any part of the pump assembly. This barrier must resist full hydrostatic head of water at El. 0.0 (NAVD88 2004.65). The sill is at El. -14.5 (NAVD88 2004.65). The trash screen may be temporarily removed to place the barrier but must be replaced to the original position and all debris must be removed from the area between the FSI opening and the trash screen prior to operation of any pump. There are no established contracting options to pay for dive inspections during the bid process, the standard contract changes clause will be utilized to account for any differing site conditions found. The watertight barrier must be designed by a Professional Engineer with experience in this area. If divers are utilized for any of these tasks, proper safety and dive plans shall be submitted for review and approval by the Technical Manager prior to any work being performed. Dive Inspections occurring before project mobilization approval shall be requested from a representative of Construction Division (Resident Engineer, Project Engineer, or Quality Assurance/Quality Control Inspector). Refer to structural drawings S-301 and S-501 for dimensions and spacing (Attachment 2). The approved FSI Barriers shall be incorporated into a Dewatering Plan and submitted for approval. The Dewatering Plan shall demonstrate the ability maintain low water levels within the pump station sump area and to possibly lower the water levels within the pump station intake in order to facilitate in the FSI Barrier installation. The FSI Barriers shall be turned over to Plaquemines Parish Drainage Department before project completion.

Other requirements shall be in accordance with specification sections 05 50 03.00 12 Metalwork Fabrication, Machine Work, and Miscellaneous Provisions and 05 50 13 Miscellaneous Metal Fabrications (Attachment 1).

2.3.3 Pump Shaft Removal and Inspection:

The Contractor shall disassemble and remove the pump column for inspection at their shop, inspect for wear, and prepare a written report indicating the needed repairs. The written report shall be emailed immediately for verification by the COR and TM before proceeding further with repair work. Existing Pump Shafts – Three (3) each Shafts, flange boss fits, and keyways shall be inspected per each other as finding of American Standard Fit of Class LT-1. Shaft and flanges shall be checked for run out in an engine lathe with a written report on each shaft of findings. Shaft flanges and studs shall be inspected for wear and a written report shall indicate the needed repairs for each.

Document the alignment and torque values, showing that they are in conformance with industry standards and tolerances specified in specification section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1) for the components of each pump unit. For Pump Unit #2, extra care and attentiveness shall be exercised during the disassembly, removal, inspection, and reporting so as to properly diagnose why Pump Unit #2 does not have the capability to properly adjust the impeller height in a manner similar to the other three (3) pump units.

2.3.4 New Solid Pump Shafts:

New solid shafts and bearings shall be manufactured corresponding to the output shaft of the new speed reducers. Upper Bearing/Packing Box Bearing: Contractor shall furnish a new bearing (Material: ASTM B505 ALLOY ‘932’). Contractor shall machine finish bearing (bronze) for bearing housing per the Government supplied drawings (Attachment 3). Contractor shall verify the OD of the bearing prior to machining the new bearing. All finishes shall be 64 RMS. Install bearing in housing in pump. Middle Bearing/Pump Shaft Bearing: Contractor shall furnish a new bearing (Material: ASTM B505 ALLOY ‘932’). Contractor shall machine finish bearing (bronze) for bearing housing per the Government supplied drawings (Attachment 3). Contractor shall verify the OD of the bearing prior to machining the new bearing. All finishes shall be 64 RMS.

Install bearing in housing in pump. Lower Bearing/Throttle Bearing: Contractor shall furnish a new bearing (Material: ASTM B505 ALLOY ‘932’). Contractor shall machine finish bearing (bronze) for bearing housing per the Government supplied drawings (Attachment 3). Contractor shall verify the OD of the bearing prior to machining the new bearing. All finishes shall be 64 RMS. Install bearing in housing in pump. All bearings and all auxiliaries shall be compatible with the existing pump components and provided by a company that has consistently provided bearings and all auxiliaries for pump components for over five years. All bearings and all auxiliaries shall be submitted for approval. Line Shaft Assembled: The Contractor shall assemble the complete solid line shaft and install the impeller and spinner impeller in their shop. The solid line shaft can be blocked or placed in a machine lathe to be checked for straightness. The Contractor shall check the solid line shaft by way of optical alignment and check at 360 degrees to each side in the full length. The Contractor shall submit a written report on the results to the Government. The Government quality assurance representative shall witness this check. Balance impeller by the two-plane balancing technique. Impeller shall be balanced at rated operating speed. Check balance at 110 percent of balance speed and make needed corrections. Amount of allowable unbalance shall be in accordance with grade G6.3 of ASA S2.19. Weights needed to obtain required level of balance shall be securely fastened to inside cavity of impeller hub. In no case will portions of the impeller be removed or weights be added to outside of hub, vanes, or water passages. Submit balancing procedure to Contracting Officer for approval at least four weeks prior to date of balancing. Each finished impeller shall be weighed and weight stamped on the bottom of hub. Weight shall be accurate to 0.5 percent of the total weight of impeller.

Weighing and balancing shall be witnessed by Contracting Officer. A written report shall indicate findings on each piece. The Contractor shall furnish to the Government up to date certifications of the calibration of the machine being used to balance the parts and the operator’s certification.

Impeller shaft shall be stainless steel and intermediate shaft(s) shall be same material as impeller shaft. The Contractor shall design shafting so that any necessary vertical adjustment of impeller can be made from operating room floor without interfering with shaft alignment. Also provide for removal of impeller from below without disassembly of pump above impeller bowl. Design shafts for two different design cases. The first uses a factor of safety of 5 based on ultimate tensile strength of shaft material and rated horsepower of engine. The second uses 75 percent of the yield strength of shaft material and maximum horsepower of engine. Pump and gear reducer shafts and pump shaft sections shall be coupled together using rigid flanged coupling capable of transmitting the forces and torques involved. Coupling halves shall be bolted together and shall be maintained concentric with each other, by means of a rabbet fit, to within

0.002 inch. Shaft coupling nut, if used, shall be retained by fitted bolts, and all tolerances specified for the coupling shall apply. Finish machine the flange and bore in one setup to ensure that flange of coupling shall be true to the bore. Flange shall be perpendicular to the bore, and parallel to the opposite end and mating flanges to within

0.002 inch. Flange shall be concentric to centerline of shaft to within 0.002 inch. Pump shaft sections shall be joined with sleeve-type couplings capable of taking rotation in either direction. Threads, except on fasteners, shall not be employed in construction of sleeve-type couplings. Couplings, including keys and fasteners, shall be constructed of stainless-steel materials. The finished shaft assembly shall be concentric about shaft centerline to within 0.004 inch. Shop assemble couplings and pump shaft and inspect for compliance with contract requirements. After inspection, matchmark parts, including fitted bolts, to their mating pieces. Finish the shaft journal at all guide bearing and packing gland locations to at least 32 RMS and finish shaft at seal journal locations to 16 RMS. The Contractor has the option to install replaceable stainless-steel one-piece sleeves at each bearing, packing gland and seal locations with the finishes stated above. Securely fasten sleeves to shaft to prevent movement. Keys and fasteners, if used, shall be made from corrosion resisting steel; fastening by adhesive or welding is not acceptable. The surface hardness at the seal locations shall be as recommended by the seal manufacturer. A circumferential line shall be inscribed or etched on shaft above stuffing box and an adjustable pointer shall be provided and mounted opposite this line in order to indicate a change in the vertical position of shaft and to permit realignment after gear reducer removal. Provide shaft enclosure to cover intermediate shaft and coupling. It shall be rigid enough to be self-supporting. The Contractor shall design enclosure to be watertight and for easy assembly and disassembly in the field.

Enclosing tubes constructed with screw type joints and using tension in the tube to hold alignment, shall be constructed to prohibit tension tube from unscrewing when packing gland adjustments are made. On oil-lubricated pumps, the enclosing tube below lowest bearing and above oil seals shall be fitted with an oil/water drain line to the outside of the pump. The drain line shall have a check valve outside of the pump to preclude entrance of sump water.

Other requirements shall be in accordance with specification section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type.

2.3.4.a Torsional Analysis The Contractor shall analyze the system for harmful torsional natural frequencies using mass elastic information provided by pump and gear drive manufacturers.

The Contractor shall re-assemble pump unit with a new torsional damper. The torsional damper shall be capable of withstanding natural frequencies that occur within 25 percent above or below normal operating speed. The torsional damper and all auxiliaries shall be compatible with the existing pump unit components and provided by a company that has consistently provided torsional dampers and all auxiliaries for pump unit components for over five years. Torsional dampers and all auxiliaries shall be submitted for approval.

Other requirements shall be in accordance with specification section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1).

2.3.4.b Guide Bearings The Contractor shall provide pump with sleeve-type bearings designed for oil lubrication. Bearing shall have a bronze lining in contact with shaft journal and shall be replaceable type. Arrange bearing liner for maximum distribution of oil for lubrication of journal surface. Bearings shall have a surface finish of 32 micro inches RMS or better to match journal finish. Since pumped water may contain some fine sand and silt in suspension, give special attention to the design and selection of bearing parts, especially seal rings, to preclude entrance of foreign material between bearing and journal due to differential water pressure.

Other requirements shall be in accordance with specification section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1).

2.3.4.c Bearing Heat Sensors The Contractor shall fit impeller shaft bearings with temperature-sensing elements, inserted in bearings to within 1/8 inch of shaft. These temperature-sensing elements shall be provided with temperature readouts mounted on engine instrument board or at a central location as shown. Provide visual and audible alarm system to warn of bearing overheating. Support leads and protect from water and mechanical damage. Terminate leads outside of pump casing in a waterproof connection head and cap until final connections are made in the field. The connection head shall be rated watertight to 25 psi. Lead protection shall consist of pipes fastened to pump with brackets using bolts and nuts to permit their removal and shall be constructed with enough unions to be completely disassembled. Leads passing through pump water passage in pump shall either be contained in a guide vane or be protected by Schedule 120 pipe.

Protection pipe shall be removable if connected to shaft-enclosing tube. Install bearing heat sensors as shown in Figure 2 at end of section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type. Run leads and wiring to a junction box located on baseplate. Provide terminal strip in junction box for connection of wiring to temperature readouts. Waterproof connect heads, bearing heat sensors, temperature sensing elements, and all auxiliaries shall be compatible with the existing pump components and provided by a company that has consistently provided Waterproof connect heads, bearing heat sensors, temperature sensing elements, and all auxiliaries for pump components for over five years. Waterproof connect heads, bearing heat sensors, temperature sensing elements, and all auxiliaries shall be submitted for approval.

The Contractor shall troubleshoot and re-calibrate the Pump Protection Panel for each pump unit and all the associated meters, modules, relays, sensors, and transmitters to return the system back to the intended functionality.

Other requirements shall be in accordance with specification section 22 10 00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1).

2.3.5 Alignment: Gearbox to Impeller

The pump shall be assembled at the Contractor's plant to assure proper fitting and alignment of all parts. Tolerances shall not exceed those specified in section 22 10

00.00 10 Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1) or shown on the Government supplied drawings (Attachment 3). Rotating elements shall be checked for binding. The suction bell, impeller housing, diffuser, and the discharge elbow shall be properly match marked and have their centerlines clearly marked on the outside of all flanges to facilitate erection and alignment in the field. Notify the Contracting Officer sufficiently in advance to permit a representative of the Contracting Officer and/or the Technical Manager to inspect and witness the pump assembly. All parts disassembled for shipment shall be matchmarked.

The pump shall be re-installed onsite. The pump sole plate shall be installed and aligned per the manufacturer's instructions. The sole plate shall be supported and leveled on jack bolts (no shim packs). The grout for use in grouting under the pump sole plate shall be an epoxy grout which is an expansive, non-shrink, low exothermic epoxy system, mixed and applied according to the manufacturer's directions. The manufacturer of the expansive, non-shrink, low exothermic epoxy grout shall have offered expansive, non-shrink, low exothermic epoxy grout products for engine, pump column, and other large equipment grout pads and setting for over five years. The presence of a manufacturer's representative during the pouring of the epoxy, as well as, the use of rigid non-absorbing formwork and a head box is mandatory. The surface of the formwork in contact with the epoxy grout shall be covered with a layer of paste wax to facilitate removal. Clearance between the head box/motor support sole plate and the concrete surface shall be per the manufacturer's recommendation. The concrete surface to be in contact with the epoxy grout shall be chipped to present a slightly rough surface and the laitance removed. The surface shall then be cleaned of all dust, moisture and oil. A 2-inch diameter by 1/2-inch-thick stainless-steel disk, with full radiused edges shall be placed under each jack bolt for them to bear on. A thin layer of leveling grout shall be placed under the disks. Plastic vent tubes, sized and spaced per manufacturer's recommendation, shall be placed under the sole plate to vent air during grouting and prevent voids in the epoxy. All metal edges and corners in contact with the epoxy grout shall be radiused to a minimum 1/2-inch radius in order to prevent stress risers in the epoxy grout. The annular space between the anchor bolts and the sleeve shall be filled with expanding urethane foam. The threads of both the anchor bolts and jack bolts in contact with the grout shall be covered with paste wax and a layer of duct tape. After all alignment tolerances are met, the anchor bolts shall be snugged to prevent movement during the pour. The epoxy grout shall not be allowed to extend above the bottom edge of the sole plate. After the epoxy grout has fully cured, within 24 to 48 hours after pouring, the jack bolts shall be removed, and the anchor bolts torqued to the torque levels specified by the pump manufacturer. The threaded jack bolt holes shall be coated with grease and the jack bolts cleaned of the paste wax and duct tape then reinserted and secured in position with a lock nut to within 1/4 inch of the bottom of the hole. After grouting, edges shall be chipped and patched to present a smooth finish.

Vertical Pumps, Axial-Flow and Mixed-Flow Impeller-Type (Attachment 1).

2.3.6 Alignment: Diesel Engine to Speed Reducer (Right Angle Gearbox) The Contractor shall re-assemble pump unit with a new torsional damper and align the diesel engine and right-angle gearbox according to the tolerance of the Cardan shaft,

0.0007 inch per inch, connecting the two pieces of equipment in the vertical and horizontal planes. This shall include the use of allowable undersized bolts in securing the diesel engine base and the gearbox. The Contractor shall submit the allowable undersized bolts, plan, and other materials required before proceeding forward. If needed, the grout pad for the diesel engine base shall be reconfigured using a non-shrink epoxy grout. The engine shall be set and aligned using jack bolts and non-shrink epoxy grout - no shim stacks will be allowed. The grout to be used under the engine's sole plate shall be an epoxy grout which is an expansive, non-shrink, low exothermic epoxy system, mixed and applied according to the manufacturer's directions. The manufacturer of the expansive, non-shrink, low exothermic epoxy grout shall have offered expansive, non-shrink, low exothermic epoxy grout products for engine, pump column, and other large equipment grout pads and setting for over five years. The presence of a manufacturer's representative during the pouring of the epoxy as well as the use of rigid non-absorbing formwork and a head box are mandatory. The surface of the formwork in contact with the epoxy grout shall be covered with a layer of paste wax to facilitate removal. Clearance between the head box and the sole plate, as well as the clearance between the concrete surface and the bottom surfaces of the sole plate shall be per manufacturer's recommendation. The concrete surface to be in contact with the epoxy grout shall be chipped to present a slightly rough surface and the laitance removed. The surface shall then be cleaned of all dust, moisture and oil. A thin layer of leveling grout shall be placed under the metal discs that the jack bolts bear on. A 2-inch diameter by 1/2-inch-thick stainless-steel disk, with full radiused edges shall be placed under each jack bolt. Plastic vent tubes, sized and spaced per manufacturer’s recommendation, shall be placed under the sole plate to vent air during grouting and prevent voids in the epoxy. All metal edges and corners in contact with the epoxy grout shall be radiused to a minimum 1/2-inch radius in order to prevent stress risers in the epoxy grout. The annular space between the anchor bolts and their sleeves shall be filled with expanding urethane foam. The threads of both the anchor bolts and jack bolts in contact with the grout shall be covered with paste wax and a layer of duct tape. After all alignment tolerances are met, the anchor bolts shall be snugged to prevent movement during the pour. The epoxy grout shall not be allowed to extend above the bottom edge of the sole plate. After the epoxy grout has fully cured, within 24 to 48 hours after pouring, the jack bolts shall be removed, and the anchor bolts torqued to the torque levels specified by the pump manufacturer. The threaded jack bolt holes shall be coated with grease and the jack bolts cleaned of the paste wax and duct tape then reinserted and secured in position with a lock nut to within ¼ inch of the bottom of the hole. After grouting, edges shall be chipped and patched to present a smooth finish.

After the alignment and vibrational values are met, the base flange for the gearbox shall be “doweled-in” to the mating flange of the gearbox stand in order to firmly secure and maintain the proper alignment position.

Install the speed reducer and ensure all features and systems are operational. The speed reducer shall be installed under the supervision of the speed reducer manufacturer's representative. The speed reducer shall be designed for ease of handling and installation. All necessary lifting devices, attachments, and special tools required for maintenance shall be provided by the Contractor. Submit an Operation and Maintenance Manual which provides detailed startup and operating procedures, lubrication instructions, installation and alignment procedures, routine maintenance requirements and procedures, complete detailed procedures for disassembly and assembly of the reducer, parts list for all parts detailed, assembly drawings of the reducer showing all parts, suppliers for all parts, settings and adjustment for protective devices, and a list of all tools, handling devices, and spare parts furnished.

Field test the speed reducer at rated speed and load to demonstrate that reducer operation, lubrication, cooling, and instrumentation meet contract requirements. The duration of the testing shall be enough to develop verifiable gear contact patterns. Gear contact patterns shall be inspected and shown to the Contracting Officer and Technical Manager. The gear contact patterns shall be submitted for approval. Spiral bevel gears shall have a central toe contact pattern with contact of 50 percent of face width at full load. Gear contact patterns shall be photographed and included as part of the field test report. The report shall document all data collected for load and speed measurement, lubrication, oil temperature and flow, ambient temperature, cooling water temperature and flow, gear contact patterns, and any other data required to show compliance with specifications.

Align driver with speed reducer to obtain parallel and angular alignment within Cardan shaft manufacturer's specifications. Misalignment should be as close to zero as possible for maximum life and smoothest operation. Use only the correct tools and procedures specified by manufacturer when aligning the gear drive and driver. Excessive noise and vibration in a new speed reducer is almost always an indication of misalignment or poor installation. Proper installation includes alignment of the engine, speed reducer, and pump. Positive alignment must be maintained. Recheck alignment at regular intervals after starting the operation of the system and correct if settling or drifting has occurred.

The Diesel Engine PTO Shaft IS 2" lower than the Gear Drive Shaft to produce an operating angle in the Drive Shaft of approximately 2° or 0.00025 inch per inch in the vertical direction. The existing torsional dampers shall be shipped to the below address for post operational analysis. Care and caution should be exercised during removal to preserve and keep the torsional damper intact for post operational analysis. Reich Kupplungen will need prior notification before shipment of the torsional dampers. POC information is also listed below.

Reich Kupplungen Reich USA Corporation

300 NJ-17

Mahwah, NJ 07430

Mauricio Alvarez Regional Sales Manager Reich USA Corporation Office Phone: (201) 684-9400 extension 304.

Other requirements shall be in accordance with specification section 41 65 10.00 10 Diesel Fueled Engine Pump Drives (Attachment 1).

2.3.7 Testing: Wet Tests

The Contractor shall obtain oil samples for analysis before draining, cleaning, and replacing the diesel engine oil (72 quarts of the manufacturer’s diesel engine oil either 10W-30 or 15W-40, according to the diesel engine make and model, and the manufacturer’s oil filters after successful re-alignment of each pump unit. Record and report diesel engine run hours for future reference. Oil samples shall be shipped to Louisiana Machinery, LLC, SOS Services Laboratory, 3799 W. Airline Hwy., Reserve, LA 70084-0536, (985) 536-0495, www.louisianamachinery.com, for analysis. Each pump unit shall be given a test under load, at or near normal operating conditions with the vibration levels measured and recorded not exceeding the "Good" range in the ISO 10816 “Machinery Vibration Severity Chart”, for at least 4 hours or as directed by the Contracting Officer; the test will be witnessed by the Government. Provide all supplies and equipment required to conduct the test. During the pump test, and under normal operating speed, the speed reducer shall be checked for vibration in the vertical and two mutually perpendicular radial planes using an instrument that produces printed results.

The Contractor shall submit the vibration meter and its most recent calibration certificate for approval.