Performance_Work_Statement.pdf

HYDRAULIC CYLINDER REPAIRS

U.S. ARMY CORPS OF ENGINEERS

BLACKWATER DAM

WEBSTER, NH

Scope of Work

March 2018

A. General

1. Scope – The work of this project includes the following: secure gates; drain and dispose hydraulic fluid, remove operating cylinders, ship to machine shop; hone bore and replace piston rings; return cylinder to the dam and re-install with new annealed copper cylinder gaskets, new piston rod and rod extension packings, and all new bolts and nuts; re-fill with new hydraulic fluid; test gate operation for each gate; adjust packings, and repair any leaks resulting from work of this contract. The contract covers four hydraulic gates, with an optional fifth and a second option for a sixth. The four gates to be repaired will be service gate 1, emergency gate 1, emergency gate 2 and service gate 3.

The first option will be to repair emergency gate 3 and the second option will be to repair service gate 2.

2. Location – The Black Water Dam Office is located at 43 White Plains Rd., Webster, NH 03303.

The Blackwater Gatehouse is located on White Plains Rd., Webster, NH.

3. Site Visit – Contact the Technical Point of Contact Tia Mercer at the Franklin Falls field Project Office at 978-318-8323 or Tia.M.Mercer@usace.army.mil to arrange a site visit.

4. Schedule – Work to be accomplished as soon as possible. Work shall be performed Monday through Friday 7:00 AM to 4:00 PM unless otherwise approved by the Technical Point of Contact.

No work shall be done on weekends or Government holidays.

5. Safety – The contractor will comply with all pertinent provisions of the latest edition of the U.S.

Army Corps of Engineers Safety and Health Requirements COE EM 385-1-1. A copy of COE EM 385-1-1 is available for reference at the project office or may be ordered from Superintendent of Documents, P O Box 371954 Pittsburgh, PA 15250-7954 (Tel: 202 783-3238). In addition, the manual may be viewed at the following link http://www.usace.army.mil/SafetyandOccupationalHealth/SafetyandHealthRequirementsManual.asp

x. The contractor shall also comply with all OSHA work safety standards. The project staff can and will order the cessation of work at any time should the safety of employees and visitors become jeopardized.

The following is a list of additional site specific safety requirements:

a. Cranes/Load Handling Equipment (LHE)

General: All load handling and crane operations are required to be completed in accordance with EM 385-1-1, Section 16. These requirements are applicable to load handling equipment (LHE) to include cranes, derricks, hoists and power-operated equipment that can be used to raise, lower and/or horizontally move a suspended load. This includes excavators, forklifts, and other equipment when used with rigging.

mailto:Tia.M.Mercer@usace.army.mil http://www.usace.army.mil/SafetyandOccupationalHealth/SafetyandHealthRequirementsManual.aspx http://www.usace.army.mil/SafetyandOccupationalHealth/SafetyandHealthRequirementsManual.aspx

There is an existing 2 Ton chainfall in the gatehouse of Blackwater Dam. The contractor may utilize this LHE if he/she chooses, as long as the following items have met:

i. The load is rigged by a Qualified Rigger (see Section E below)

ii. The operator is familiar with the LHE manufacturer’s safe operating procedures and limitations.

iii. A lift plan has been completed and accepted (See Sections B and C below).

iv. The chainfall has been inspected and is in good operating conditions.

Submittals: A Standard Lift Plan is required to be submitted and approved by the GDA prior to any lifting operations. USACE will provide a non-mandatory, fillable template plan. However, the contractor is permitted to submit their own plan, at a minimum it must include the items listed in EM 385-1-1, Section 16.A.03.

Critical Lifts: A Critical Lift Plan (Form 16-3, or equivalent, in accordance with 16.H.02.d) is required for lifts involving the characteristics listed in EM 385-1-1, 16.H.01.

Crane-LHE Standard and Critical Lift Plan.pd Crane Operators: Crane Operators must meet the requirements of EM 385-1-1, Section 16.B. Prior to the start of crane activities, documentation of operator certifications, qualifications and designations must be submitted to the GDA for review. (See EM 385-1-1, Section 16.C.05 - 16.C.07 for specific information and exemptions on Class II cranes.)

i. The onsite LHE is designated as a chainfall and is exempt from operator qualification and certification requirements. Still, the person in charge of operating the chainfall must be familiar with the manufacturer’s safe operating procedures and the LHE’s limitations.

Qualified Riggers (QRs): Employers must designate in writing which employees are QRs and the specific rigging tasks for which they are qualified. All QR’s must meet the requirements listed in EM 385-1-1, Section 15.B.01.

Signal Person: A signal person is required to be utilized onsite when the operator cannot maintain a full view of the load and the load travel paths at all times the load is rigged to the equipment. A signal person must meet the qualifications listed in EM 385-1-1, Section 16.B.06.

b. Confined Space:

For contractor activities, NAE has designated the wet well as a permit-required confined space. However, contractors who perform work within this space are allowed to re-classify the space to non-permit required following the procedures outlined in OSHA's Permit-Required Confined Space Regulation, 29 CFR

1910.146 and EM 385-1-1, Section 34.

c. Spill Control:

The Contractor shall comply with all Federal, State, and local hazardous waste regulations. Work shall conform with 40 CFR 280-SUBPART E.

The Contractor shall develop and submit a comprehensive Spill and Discharge Control plan. This plan shall provide contingency measures for potential spills and discharges of hazardous material both on site, and from trucks handling off-site transportation.

The Contractor shall provide methods, means, and facilities required to prevent contamination of soil, water, atmosphere, uncontaminated structures, equipment, or material by the discharge of wastes from spills due to Contractor’s operations.

The Contractor shall provide equipment and personnel to perform emergency measures required to contain any spillages, and to collect and remove spilled materials or materials that become contaminated due to spillage. This collected spill material shall be properly disposed of at the Contractor’s expense. The contractor shall provide equipment and personnel to perform decontamination measures that may be required to remove spillage from previously uncontaminated structures, equipment, or material. Decontamination residues must be properly disposed of at the Contractor’s expense.

The Contractor shall provide, as a minimum, the following equipment to be kept on site at all times during site work activities: 1. Sand, or other noncombustible absorbent, 2. Drums (55 gallon, U.S. DOT 17-E or 17-H.), 3. Shovels.

If a spill occurs, the following actions shall be taken by the contractor.

1. Notify the Technical Point of Contact immediately.

2. Take immediate measures to control and contain the spill within the site boundaries in accordance with the approved Spill and Discharge Control Plan.

3. Report the spill and take corrective actions as required in 40 CFR 280-

SUBPART E.

4. Notify the New Hampshire Department of Environmental Resources, Water

Supply and Pollution Control Division as required in New Hampshire Code of Administrative Rules ENV-WS 412.

5. Prepare a written follow up and submit to the Technical Point of Contact no later than 7 days after the initial report. The written report shall be in narrative form and shall include the following as a minimum:

a. Description of the material spilled including identity and quantity.

b. Reportability of spill and when and to whom is was reported.

c. Exact time and date of spill and description of area involved.

d. Site map with location of spill marked and distance from any receiving waters.

e. Cause of incident and equipment and personnel involved.

f. Injuries or property damage.

g. Duration and quantity of discharge.

h. Description of containment procedures initiated, and cleanup procedures employed or planned.

i. Summary of all the Contractor communications regarding the spill.

Decontamination procedures may be required after cleanup to eliminate traces of the substance spilled or reduce it to an acceptable level as determined by the Technical Point of Contact. Complete cleanup may require removal of contamination soils. Personnel decontamination should include showers and cleansing or disposing of clothing and equipment. All contaminated materials including solvents, cloth, soil, and construction materials that cannot be decontaminated shall be properly containerized, labeled, and disposed of off-site as soon as possible in accordance with all Federal, State and local regulations.

6. Pre-Work Conference – Prior to the start of any work, the Technical Point of Contact will schedule and conduct a “Pre-work Conference”. The Contractor’s Project Manager and Quality Control Personnel will attend this meeting. This conference will be held at the time and location agreeable to the government and contractor. No work may be performed under this contract prior to this conference. The purpose of the conference is to enable the Technical Point of Contact to outline the procedures that will be followed by the Government in its administration of the contract, and to discuss the performance that will be expected from the Contractor. This conference will allow the Contractor an opportunity to ask questions about the Government’s administration and inspection of contract work or obtain other pertinent information that might be required. At the Pre-work conference the contractor shall provide the Technical Point of Contact the name of the project superintendent with a telephone number for project coordination.

The following is a general list of items for discussion during this Pre-work Conference:

a. Authority of the Technical Point of Contact.

b. Contractor’s Safety Program (including sub-contractors).

c. Activity Hazard Analysis (Submitted & accepted prior to start of work on site)

d. Contractor’s Equipment

e. Correspondence, Communication and Administrative Procedures.

f. Contractor Utilities.

g. Invoice and payment.

7. Permits – The Contractor shall, without additional expense to the Government, be responsible for obtaining any necessary licenses, permits, and letters of certification. The Contractor shall comply with any applicable Federal, State, County, and Municipal laws, codes, and regulations in connection with the performance of the work specified under this contract.

8. Security – The contractor will comply with all established security policies at Blackwater Dam.

Due to periods of heightened security that may affect the access to the areas covered under this contract, the Government reserves the right to close any property or portion of property and reschedule and/or cancel any subsequent service. The Contractor shall be given at least 24 hour notice of any such closure.

9. Contractor Conduct – Alcohol and firearms are prohibited on project grounds. Contractor and employees must comply with CFR 36 Rules and Regulations.

10. Payment – After final inspection and acceptance by the Government, the Contractor must submit an invoice to the Technical Point of Contact. The invoice shall include the invoice date, contract number, dates of service, description of work, quantities, and total amount due per line item.

All invoice may be mailed to:

U.S. Army Corps of Engineers Franklin Falls Dam 46 Granite Dr Franklin, NH 03235

Or Emailed to Tia.M.Mercer@usace.army.mil mailto:Geoffrey.Steuerwald@usace.army.mil

B. Technical Requirements: General Requirements:

1. Summary – There are six flood control gates located in the spillway of the dam. (See reference drawings 1 & 2). Each gate is operated by an 18-inch diameter by 6-1/2-foot long hydraulic cylinder. For this contract four gates (service gate 1, emergency gate 1, emergency gate 2, and service gate 3), with an optional fifth gate (emergency gate 3) and possibly a sixth (service gate 2), will be serviced.

There are three flood control conduits through the spillway. Each conduit contains two gates in series; an emergency gate upstream, and a service gate downstream. Work shall be done on the operating cylinder for four of the gates, with an option for a fifth. Cylinders were manufactured by Phillips and Davies and are approximately 75 years old.

Work on all gate cylinders shall be done with gates in the closed position. Only one conduit (both emergency and service gate) can be work on at a time. The four gates in conduits not being work on shall remain operational at all times. (See sketch 1.)

Prior to beginning the work, temporarily seal floor drains in spillway with drain blocker matting to prevent accidental release of hydraulic fluid from work area. Remove and dispose of matting only after testing is complete and work has been accepted by the Technical Point of Contact.

Before removing hydraulic cylinder isolate the control valve for the gates and ascertain that hydraulic fluid was not leaking through the control valve.

Close shut-off valves, drain hydraulic fluid from cylinder and dispose of off-site. Remove cylinder from dam using previously approved written procedure and transport to machine shop for repair. At a minimum, complete disassembly, detailed inspection of all components, replace piston rings with new and polish bore so as to eliminate leakage of hydraulic fluid are the piston.

(See reference drawings 3 & 4 for details of cylinder construction.)

Machine lockdown plate.

Install pipe thread sealant and o-ring on piston rod to try to prevent leaking of hydraulic fluid through middle of piston to top chamber of piston prior to reassembly.

Transport cylinder back to dam and reinstall according to pre-approved written procedure.

Provide new oil side packings for gate stem and stem extension. Packings shall be garlock style 435 V-rings with style 260 rockhard adaptors or approved equal.

Provide two new annealed copper gaskets; one for each end of the cylinder.

Provide (44) all new 1-1/4” N.C. x 5-1/2” machine bolts and hex nuts of ASTM A325 steel, conforming to ASME b18.2.1. Tighten bolts with torque wrench to industry recommended values for the bolt material and in a bolt pattern approved in advance by the Technical Point of Contact.

Tighten bolts in 50 Ft-Lb increments.

Replace all hydraulic fluid in the reservoir tank and piping with new oil meeting the same specs.

New fluid shall be compatible with existing fluid in case of residual oil and shall be filtered to 10 microns before adding to the reservoir. Old hydraulic fluid will be disposed of offsite by the contractor.

After work on the cylinder has been completed, run service and emergency gates through two complete cycles to assure that the system is functioning correctly and that there is no leakage from any of the remade joints. All operational tests will be done in coordination with the Technical Point of Contact. New packings shall be adjusted until leakage is reduced to the minimum required for proper operation. Contractor shall repair and retest at his or her expense any joints which fail the test. If required, top off the hydraulic fluid reservoir again upon satisfactory completion of testing. Consult with Technical Point of Contact prior to each and every gate operation.

Provide new red brass safety stud for service and emergency gates. Recommend contractor remove safety stud and cap assembly from an adjacent gate to use as a pattern. After new stud is fabricated, install new stud assembly on service and emergency gates, and replace “borrowed” stud assembly on adjacent gate. Manufacturer information on safety stud will be provided to the Technical Point of Contact. Four (4) spare safety studs will be provided and left at the project site.

1. Unit Description- The cylinders are mounted on the top of flood control gates located in gate chambers within the spillway of the dam. The cylinders and gates were manufactured by Phillips and Davies and are approximately 75 years old.

Work shall be done with the affected flood control gates in the closed position. All four gates in the two remaining conduits shall remain operational. Operation of the flood control gates within their normal range of motion to allow testing of completed work shall be coordinated with the Technical Point of Contact and a project staff member. Project staff approval shall be obtained in advance for all gate movements and settings.

In the event that it becomes necessary to operate the reservoir for flood control purposes, the contractor will be given a minimum of 12 hours advance notice. Upon such notification, the contractor shall suspend construction operations, and take such other actions and perform such additional work as directed by the Technical Point of Contact to prepare the dam for flood control operations.

2. Clean Up and Waste Disposal – The contractor shall keep the work area free from accumulation of waste materials. Any and all disturbed areas resulting from contractor activities shall be restored by the contractor to the satisfaction of the Technical Point of Contact.

3. Environmental Protection –Contractor will take necessary steps to ensure all federal, state, and local environmental regulatory requirements are met.

4. Government Resources – The contractor may use the existing restroom facilities at Blackwater Dam office but may also want to provide accommodations as staff will be in field often and facility will not be available. The government will supply any electricity and water necessary for the project work from points of existing outlets. The contractor shall carefully conserve the use of electricity and water provided. The contractor shall supply his own means of communication (telephone).

5. Omissions – This contract may not cover all specified activities, steps, and procedures required to supply the contract product. In case of omission, the normal industry, state, or federal standards, practices, specifications, and/or guides shall prevail. In no instance shall an omission be reason to produce less than an acceptable product.

6. Quality Assurance – The contractor is responsible for the quality control of the contract work.

The government has the right to inspect and test all items called for by the contract, to the extent practicable at all times and at all places during the term of the contract.

7. Receiving and Storing Materials – The Corps of Engineers will provide a storage area and parking for contractor personnel. The contractor is responsible for protecting any stored material until it is placed in service. The contractor is responsible for receiving and unloading of delivered goods. Government employees will not receive material for supplies for the contractor and will not be responsible for damage to the contractor’s equipment or materials.

8. Requests for information – Requests concerning the work of this project should be directed to the Technical Point of Tia Mercer at Franklin Falls Field Office 978-318-8323 or Tia.M.Mercer@usace.army.mil.

9. Submittals – Although the Government technically reviews submissions required by this scope of work, it is emphasized that the Contractor’s work must be prosecuted using proper internal controls and review procedures. The documents identified below must be prepared in accordance with the applicable standards, submitted for review and accepted by the Government prior to the commencement of any field activities.

• Activity Hazard Analysis – Prior to the Start of Field Work

• Detailed Work Plan – The work plan shall cover the Contractor’s detailed step-by-step procedure for removal and re-installation of the hydraulic cylinder.

• Manufacturer’s cut sheets for all new and replaced materials.

• Warranty information

• Lift Plan, if necessary

• Operational Test Results – Provided at the completion of the field work and prior to payment.

Service Requirements

1. General

a. Equipment – It is the contractor’s responsibility to furnish and supply his/ her personnel with the proper safety harnesses and clamps in the performance of inspection and maintenance.

b. Workmanship – The contractor shall establish and maintain a quality control system to assure compliance with the contract requirements.

C. Fall Protection – Fall protection shall be the contractor’s responsibility.

d. Inspection Certificate: The Contractor shall provide a signed certificate rendering the elevators in a safe operating condition by qualified Technician.

mailto:Tia.M.Mercer@usace.army.mil