SOLICITATION NOTICE
99 -- LOCK 5A MITER GATE AND TAINTER VALVE MECHANICAL PARTS
- Notice Date
- 7/24/2014
- Notice Type
- Combined Synopsis/Solicitation
- NAICS
- 333613
— Mechanical Power Transmission Equipment Manufacturing
- Contracting Office
- USACE District, St. Paul, Contracting Division CEMVP-CT, 180 East Fifth Street, St. Paul, MN 55101-1678
- ZIP Code
- 55101-1678
- Solicitation Number
- W912ES-14-T-0098
- Response Due
- 8/1/2014
- Archive Date
- 9/22/2014
- Point of Contact
- Jesse Onkka, 6512905444
- E-Mail Address
-
USACE District, St. Paul
(jesse.l.onkka@usace.army.mil)
- Small Business Set-Aside
- Total Small Business
- Description
- 1. GENERAL. Furnish parts and quantities as specified in the following table and in Paragraph 2.4.Drawings of these parts are included at the end of this specification section. 1.1 Applicable Publications. The latest issue of the publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. 1.2.1 American National Standards Institute (ANSI) B1.1(2003) Unified Screw Threads B46.1(2002) Surface Finish 1.2.2 American Society for Testing and Materials (ASTM) A 325(2006) High Strength Bolts for Structural Steel Joints. A 564(2004) Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes B 22(2002) Bronze Castings for Bridges and Turntables. B 148(2003) Aluminum-Bronze Sand Castings. B 271(2011) Standard Specification for Copper-Base Alloy Centrifugal Castings D 149(2013) Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies D 570(2010) Standard Test Method for Water Absorption of Plastics D 695(2010) Standard Test Method for Compressive Properties of Rigid Plastics D 1002(2010) Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal) D 2240(2010) Standard Test Method for Rubber Property- Durometer Hardness D 3846(2008) Standard Test Method for In-Plane Shear Strength of Reinforced Plastics 2.3 Society of Automotive Engineers (SAE). J429(1999) Mechanical and Material Requirements For Externally Threaded Fasteners. 2.4 U.S.Army Corps Engineer Research and Development Center (ERDC) CERL TR 99/104(1999) Greaseless Bushings for Hydropower Applications: Program, Testing, and Results 1.3 SUBMITTALS Shop drawings and material certifications shall be submitted electronically via email to both the Government contracting officer representative and also to the Government technical point of contact. The Government technical point of contact is: DEPARTMENT OF THE ARMY St. Paul District, Corps of Engineers 180 5th Street East Saint Paul, Minnesota 55101-1638 CEMVP-EC-D, M.Klika (651)290-5575 mark.s.klika@usace.army.mil Government review turnaround time will be within five (5) calendar days from the date of receipt by the Contracting Officer. The Contractor will be notified by the Contracting Officer of the results of the review, and also of final approval. Any work performed prior to notification of approval shall be at the Contractor's own risk. 1.3.1 Shop drawings. The contractor shall submit shop drawings to the Government for all items furnished under this contract. Shop drawings may be copies of Government-furnished drawings, with markups to describe any/all proposed changes from the specified condition. Drawing markups shall include dimensions, tolerances, weld callouts, surface finishes, materials, tests and heat treatments. Furnish catalog cuts for standard products to indicate model numbers and salient characteristics of the part. Catalog cuts shall be furnished for fasteners to include fastener specification, size, and manufacturer. 1.3.2 Material Certifications. The Contractor shall submit dated copies of all purchase orders. The purchase orders shall identify the UNS alloy designation and the ASTM specification (as applicable) of all metal alloys to be used for each item. Purchase orders shall indicate the quantities and weights of each piece. All purchase orders shall be dated after the date of contract award. All purchase orders shall be accompanied with a listing of what parts are to be fabricated from the raw materials described. 1.3.3 Self-Lubricating Bearing Submittals. Submit self-lubricated material bonding adhesive data, pre-qualification data, Material Certifications, and installation instructions as specified in Paragraphs 2.5, 2.6, 2.7, 2.8, and 2.9. 2.0 PRODUCTS 2.1 TOLERANCES AND SURFACE FINISHES Where tolerances are not called out, dimensions shall be within (+/-)0.05 inch of the stated dimension. Surface finishes shall be in accordance with ANSI B46.1. All surfaces, machine finished or otherwise, shall be described on the shop drawings by symbols which conform to ANSI B46.1. Journal surfaces that will mate to bushings (pin outer diameters, bores, etc.) shall be finished to 16 micro inches or smoother. Roughness specified in the maximum value and any lesser degree will be satisfactory unless otherwise called for on the drawings. Compliance with specified surface shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens, in accordance with the provisions of ANSI B46.1. 2.2 GREASE GROOVES All bushing grease grooves shall be machine cut to the depth, width and layout as indicated on the drawings with radii or deburring to all sharp edges. Submit for approval the machine tool method used to produce the grease grooves. 2.3 PINS After heat treatment of the surface hardness to Brinnell Hardness Number range 350-400, polish the pin outside diameter to remove surface oxides. Anchor bar pins 21/10-P1 are not heat treated because they will be final machined by others not under this contract. 2.4 FASTENERS Furnish fasteners as specified in the following table: Each bolt shall be furnished with two flat washers and one nylon insert hex lock nut unless otherwise noted. All fasteners including nuts and washers shall be SAE Grade 8 with yellow zinc finish unless noted. Flathead fasteners shall have 82-degree included angle or as approved. All bolts specified to be furnished with two flat washers and hex nuts shall be furnished preassembled loose with 2 flat washers and one hex nut per bolt. All fasteners shall be furnished in 5-gallon steel pails sealed with reusable lids with contents clearly marked on the exterior. All parts of a given specification shall be furnished packaged together and not randomly mixed with other specified parts. 2.5 SELF-LUBRICATED COMPOSITE BEARINGS The bearings shall be self-lubricating plain bearings, designed to operate without additional lubricant for the life of the product. The bearing solid lubricant shall not contain graphite, molybdenum disulfide, or any other materials that promotes electrolysis in sea water. Self-lubricated materials shall be approved for use in outdoors unprotected marine environments by the material manufacturer. Self-lubricated materials shall have water absorption of less than 0.1 percent by weight as tested per ASTM D 570. All surfaces of the self-lubricated components that come into contact with the mating running surfaces shall have a minimum dielectric strength of 200V/mm as tested per ASTM D 149. The bearing solid lubricant shall meet the following two qualifiers: QUALIFIER 1-The self-lubricating material shall have been tested and approved under CERL 99/104 quote mark Greaseless Bushings for Hydropower Applications: Program, Testing, and Results quote mark by Powertech Labs Inc., 12388-88th Ave., Surrey, B.C., Canada V3W 7R7 or by an equivalent independent testing firm (see paragraph 2.5 of the Statement of Work). Provide copy of test report and evaluation. QUALIFIER 2-The bearing lubricant shall have been successfully used in at least five outdoors applications similar to this application for at least 2 years. Provide locations, description of specified loads, and point of contact for each reference application. Point of contact information shall include at least: full name, phone number, and e-mail address. 2.6 SELF-LUBRICATED MATERIALS Manufacturers load capacity ratings shall be based on the projected bearing area (width x diameter). The self-lubricating bearings shall have a dynamic load capacity of at least 6 ksi (41 MPa) for surface speeds up to 10 fpm (.05 m/s). The static and dynamic coefficients of friction shall not exceed 0.10 when subjected to loads up to 6 ksi. Self lubricated materials shall have a temperature operating range of -40 to 150 degrees F. 2.6.1 Fabric Reinforced Resin (FRR) Self-Lubricated Materials Fabric reinforced resin self-lubricated materials shall be made from catalyzed isopthalic polyester or vinylester resin reinforced with polyester or a combination of polyester and polytetrafluoroethylene (PTFE) fabric. FRR materials shall have a minimum shear strength of 12,000 psi as tested per ASTM D 3846. 2.6.2 Sprayed Thermoset Resin Coatings Sprayed thermoset resin coating shall be a minimum of 0.020 inch thick after final machining and shall have a dynamic coefficient of friction that is less than or equal to 0.08 dry and 0.10 water-lubricated for a bearing pressure load of 2 ksi at surface speed 90 fpm. The ultimate compressive strength of the self-lubricating material shall be a minimum of 50 ksi. 2.6.3 Plugged Bronze Self-Lubricated Materials Plugged bronze bearings shall consist of supporting metal fabricated from ASTM B271 UNS C95500 aluminum-bronze with a symmetrical array of circular recesses machined perpendicular to the bearing surface at the bearing inside diameter sliding interface. The pattern of circular recesses shall have a net cross-sectional area not less than 30% of the total bearing surface, and shall extend to within 0.25 inches (6.4 mm) of the chamfers at each end of the bearings. Each circular recess shall be at least 0.25-inches (6.4 mm) deep. The surface finish of the bearing shall not exceed 63 microinches (1.6 micrometers) as measured in accordance with ANSI Standard B46.1. Each recess shall be each filled with the manufacturers recommended solid lubricant. The solid lubricant shall consist of PTFE solids and binders capable of long-term exposure to flowing water. The lubricant shall not contain graphite, molybdenum disulfide, or any other ingredients that tend to promote electrolytic or chemical action. The solid lubricant shall be integrally molded and compressed into the recesses provided for containment, with an additional coating 0.040 inches (1 mm) thick (+/-) 10% applied to 100% of the bearing inside diameter surface area. The lubricant shall be free from detrimental pits, pinholes and any other imperfections that will impair the performance or capacity of the selflubricating bearings. The lubricant shall have a Type D Durometer hardness of at least 80 when tested in accordance with ASTM D2240. 2.7 SELF LUBRICATED COMPOSITE BEARING PRE-QUALIFICATION TEST a. In addition to the self-lubricated material requirements stated above, bearing materials shall have been tested by Powertech Labs Inc., B.C., Canada and received a rating of 350 or above for both the wet and dry testing according to the test procedure outlined in CERL Technical Report 99/104, quote mark Greaseless Bearings for Hydropower Application: Program Testing and Results quote mark. In lieu of the Powertech test results published in CERL 99/104, the manufacturer may also submit test results from an equivalent independent testing firm. The methods and procedures of the testing shall be similar to the Powertech test in 99/104. All test results shall be public information. The independent testing shall include a standardized rating system similar to CERL 99/104. The Government reserves the right to deny use of bearing materials that meet the criteria above but have suffered in-service operating problems. b. Obtain and submit Material Certifications from the material manufacturer stating that the chemical formulations, manufacturing processes and overall structure of the materials supplied are identical to those of the bearings tested and judged to be acceptable by the Corps of Engineers under the test procedure outlined in CERL Technical Report 99/104, quote mark Greaseless Bearings for Hydropower Application: Program Testing and Results. 2.8 SELF-LUBRICATED COMPOSITE BEARING MATERIAL BONDING ADHESIVE The bearing manufacturer may recommend that a bonding adhesive be used to hold the bearings in place. If bonding adhesive is recommended, the contractor shall furnish a sufficient quantity of this bonding adhesive to install all of the self-lubricating composite bearings furnished under this contract. Self-lubricated material bonding adhesives shall be approved by the adhesive manufacturer for use in submerged and marine environments, and for use with the existing trunnion bores. Self-lubricated material bonding adhesives, after reaching full cure, shall have a minimum compressive strength of 7,500 psi as tested per ASTM D 695, and a minimum tensile lap shear strength of 4,000 psi as tested per ASTM D 1002. Bonding adhesive shall be approved for service in the temperature range of -40 to 150 degrees F by the adhesive manufacturer. Submit bonding adhesive literature to demonstrate the minimum requirements listed above. 2.9 SELF-LUBRICATED COMPOSITE BEARING INSTALLATION PROCEDURES The contractor is responsible to design and submit for approval the method to prevent relative motion at the bearing outside diameter interface. The contractor shall determine the proper bearing outside diameter dimensions, tolerances, and surface condition for this application. Provide complete procedures and consumables for press-fit and/or bonded installation as recommended by the bearing manufacturer. Include recommended tolerances dimensions, surface finishes, solvents, cleaners, adhesives and ambient condition requirements. Provide detailed fabrication drawings of recommended bearing press tools and fixtures. Provide video documentary of bearing installation using the same sequential installation procedures as required for this application. 2.10 O-RINGS FOR PINTLES Furnish O-rings Buna-Nitrile A70 Durometer hardness, 14.0-inch ID, 15.0-inch OD, cross-section circular diameter 0.5-inch. Furnish each O-ring as a pre-assembled spliced and bonded continuous loop. Cut the splice plane 45-degrees to axial, and use cyanoacrylate glue (super glue) as the bonding agent 3.0 EXECUTION 3.1 QUALITY CONTROL The Contractor shall establish and maintain a quality control system to assure compliance with the contract requirements and shall maintain records of all quality control operations covered by these specifications. 3.2 INSPECTION. At the discretion of the Contracting Officer, an inspection may be conducted in the Contractor's facility prior to shipment by a government representative to determine conformance with the specifications. The Contractor shall notify the Contracting Officer 4 calendar days in advance of the date the items will be ready for inspection. If the inspection and/or testing reveal any defect or unapproved deviation from the requirements of the contract which would make it unfit for proper performance, the Contractor will be required to satisfactorily remedy such conditions, at no additional cost to the Government. 3.2.1 Measurement Instruments. The Contractor shall have at the inspection pre-shipment site suitable micrometers, calipers, and similar precision equipment as required to allow the Government's inspector to verify all dimensions with tolerances (diameters) and surface finishes of Contractor-furnished components. 3.3 PACKAGING AND MARKING. Parts shall be packaged and shipped fully enclosed in weatherproof shipping crate boxes with forklift skids, packing lists, and removable and reusable covers. Parts will be accounted upon delivery. Crates shall be externally marked with 2-inch tall block lettering to include the contract number and the following text: quote mark LOCK 5A MECHANICAL PARTS. quote mark 3.5 DELIVERY DUE DATES. All of the Contractor-furnished components shall be delivered on or before 1 October 2014. 3.6 SHIPMENT. The bid price shall include the cost of transportation and unloading the destination site. Shipment shall be prepaid and made at the Contractor's expense. The Government will not unload parts from the Contractor's delivery truck at the below listed destination. All other shipping and handling costs to be borne by the Contractor. Shipment destination address and shipping point of contact is: US ARMY CORPS OF ENGINEERS 431 North Shore Drive P.O. Box 397 Fountain City WI 54629-0397 ATTENTION: Scott Uhl Office: 651-290-5987 Cell: 612-508-3156 The Contractor shall notify the point of contact of the shipment at least 4 days before the scheduled delivery date. Delivery shall be between the hours of 7:00 AM and 3:00 PM Monday through Friday, except on Government holidays.
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