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13 April 2023

Blue Marsh Dam

Emergency Generator for Bernville Protective Works Pump Station

Design/Build Acquisition

The U.S. Army Corps of Engineers, Philadelphia District, intends to award a firm fixed contract to Design/Build contract acquisition to Install an Emergency Generator at the Bernville, PA Protective Works Pump Station. The work is located at the Bernville Protective Works in Bernville, PA. The Protective Works is located on the south side of the town along Northkill Creek, to the west of the intersection of Bernville Road and Garfield Road.

Contract work consists of: The work includes design and construction of an emergency generator system and replacement of the Motor Control Center (MCC) for the Bernville Protective Works. Demolition and modifications of the existing electrical system and site features are required. The scope of this effort includes design, construction, and commissioning of the emergency generator system (generator, day tank, diesel fuel storage tank, fuel transfer system, load bank, motor control center with ATS/ATO) and incidental related work.

The NAICS Code for this project is 236220. The NAICS Code for this project is 236220 Commercial and Industrial Building and the small business size standard is $39.5 Million. Estimated cost range of the project is $1 - $5 Million dollars. This project will be advertised as a 100% small business set-aside.

Solicitation. Solicitation No. W912BU23R0011 will be issued on or about 28 April 2023. Proposal will be due on 28 May 2023 at 5:00 p.m. Payment and Performance Bonding will be required after award but before Notice to Proceed. The contract period of performance is 365 days after receipt of Award/Notice to Proceed.

Solicitation documents, plans and specifications will only be available via the SAM.gov homepage located at https://www.SAM.gov/. Registration for plans and specifications should be made via SAM Internet homepage and hard copies will not be available. No written or fax requests will be accepted. It is the contractor’s responsibility to monitor SAM for any amendments. The solicitation will contain FAR 52.222-38 Compliance with Veterans’ Reporting Requirements, therefore contractors who have received a Federal Contract of $100,000.00 or greater, except as waived, must have submitted the preceding fiscal year Federal Contractor Veterans’ Employment Report (VETS-100 and/or VETS-100A Report) to be eligible for an award. If you have any questions or concerns regarding VETS-100 or VETS[1]100A reports please contact VETS-100 customer support at 1-866-237-0275 or via email at VETS100-customersupport@dol.gov. The solicitation will contain FAR provision 52.204-7; therefore a bidder must be registered in the System for Award Management (SAM) database prior to award. Davis Bacon rates will be applicable to the construction. Affirmative action to insure equal employment opportunity is applicable to the resulting contract.

Questions regarding this notice should be directed to Baisy.J.Lanzo@usace.army.mil

Contract work includes:

The work includes design and construction of an emergency generator system and replacement of the Motor Control Center (MCC) for the Bernville Protective Works. Demolition and modifications of the existing electrical system and site features are required. The scope of this effort includes design, construction, and commissioning of the emergency generator system (generator, day tank, diesel fuel storage tank, fuel transfer system, load bank, motor control center with ATS/ATO) and incidental related work.

A diesel-powered emergency generator is required to power storm water pumping operations at the Bernville Protective Works in the event of public utility power failure. The loads generally consist of startup and running transient current demands of the six 250 Horsepower (HP) storm water pumps, dewatering (sump) pumps, controls, general loads (lighting, ventilation, convenience receptacles, etc.), as well as other operational motor loads. The existing MCC has surpassed its life expectancy and is to be replaced. The new MCC is to also include an Automatic Transfer Switch (ATS) or Automatic Throwover (ATO) transfer scheme.

Design and construct an emergency generator, day tank, load bank, and fuel storage system to provide 100 percent emergency generator backup power for a 72-hour period and a MCC with an ATS/ATO. The emergency generator system shall be sized to power the entire Bernville Protective Works. The transition from Utility to Emergency power shall be via an ATS/ATO located within the MCC. Equipment shall be Service Entrance rated and Life Safety rated in accordance with Unified Facilities Criteria (UFC) and National Fire Protection Association (NFPA) standards and requirements. Provide an above ground diesel fuel storage tank with fuel transfer system to meet the emergency generator runtime requirements. MCC specifications and features shall match existing MCC as a minimum.

The emergency generator system is to provide 60 Hz, 480/277V, 3-phase power, be diesel powered, and provide power at 100 percent load for 72 hours. The system is to be designed considering the startup procedures of the facility.

The emergency generator system shall be designed, furnished, constructed, and installed in accordance with UFC and NFPA requirements and standards. Power rating category shall be defined as Emergency Power in accordance with UFC 3-540-01, which can deliver power in the event of utility outage or test for up to 200 hours of operation per year. The required electrical performance shall be Class G2, as defined in UFC 3-540-01 and ISO 8528. ATS/ATO is to be configured for open transition transfer scheme. Design and construct a permanent load bank for commissioning and maintaining the emergency generator system.

The Bernville Protective Works is currently on a ratchet billing program and the large storm water pumps when activated can cause the electric utility bills to increase substantially over the course of 6 months before returning to normal. The design is to investigate and if applicable implement energy reducing technologies to help lower the large spike in demand as the storm water pumps currently have across the line starters. Investigations shall consider and research the use of soft start technologies or variable frequency drives for example. The storm water pumps are original to the facility and implementing energy reduction technologies requires research to ensure the storm water pumps are not damaged over time due to those technologies being implemented.

Locate the emergency generator system on the site in such a way that facilitate ease of access and future maintenance requirements. The proposed location is outside of the existing fenced in area of the parking lot. Installation of the emergency generator or other equipment within the parking lot is prohibited due to the storm water discharge piping from the protective works to the levee being located underneath. Install fence around the exterior equipment with a sufficient clear-zone around the equipment to facilitate future maintenance requirements and to be in accordance with national standards and manufacturer requirements. The emergency generator, other equipment, and equipment pads shall not be located within 15 feet of the existing levee toe.

For bidding purposes, an initial analysis for a 60Hz, 480/277V, 3 phase, diesel emergency generator sized the emergency generator to be 1,500 kilo-watt (kW). During design, complete a load analysis and confirm equipment and load sizes, as well as operational constraints to size and design the emergency generator system. In accordance with UFC 3-540-01 a commercially available generator sizing software provided by a generator manufacturer to determine the required rating must be utilized for the design.

Submit calculations for sizing of the emergency generator, fuel system, load bank, MCC, and ATS/ATO. MCC/ATS/ATO is to be service entrance rated. This ATS/ATO shall provide automatic control of power sources (Utility and Emergency) to the Protective Works. The equipment shall be able to be operated in automatic or manual mode. The ATS/ATO shall be installed in the MCC.

The emergency generator shall be complete and totally functional, with all necessary ancillary equipment to include air filtration; starting system; generator controls, protection, and isolation; instrumentation; lubrication; fuel system; integral fuel storage; cooling system; and engine exhaust system at a minimum. The emergency generator shall consist of one engine, one generator, and one exciter, mounted, assembled, and aligned on one base; and all other necessary ancillary equipment which may be mounted separately. Emergency generator components shall be environmentally suitable for the location and shall be the manufacturer's standard product offered in catalogs for commercial or industrial use.

1. Emergency generator shall have a weather resistant, sound attenuated aluminum enclosure with OSHA compliant access. Doors shall be lockable and enclosure shall provide adequate access to components requiring maintenance in accordance with NFPA 70, OSHA, and manufacturer requirements. Instruments, control, and battery system shall be mounted within the enclosure and powered from the facility. Sound attenuation levels shall be in compliance with UFC 3-540-01 and OSHA 29 CFR 1910.95. The emergency generator shall be a complete package, assembled and tested from the factory before being delivered to site.

1. To meet the requirement for a 72-hour run time, the diesel fuel storage tank capacity exceeds 1,100 gallons and tanks over that size are regulated by the Pennsylvania Department of Environmental Protection (PADEP). This requires coordination and compliance with the PADEP Storage Tank Program requirements which includes, but not limited to, registration of the diesel fuel storage tank and requirements for PADEP certified storage tank installers. Comply with and execute the project in accordance with PADEP requirements, complete the required PADEP Storage Tank Program Documentation and submit to PADEP for review and approval. Once approval from PADEP is received, submit the approved registration and other approvals to the COR for review and approval.

1. Diesel fuel storage tank shall be a double wall secondary containment type, constructed of corrosion resistant steel, listed and labeled, conforming to the requirements of NFPA 30 and NFPA 37 and have the following features. Locate the diesel fuel storage tank and ancillary equipment to allow easy refueling operations.

1. Design and construct a fuel transfer system to transfer fuel from the above ground diesel fuel storage tank to the emergency generator day tank. The fuel transfer system must have duplex diesel fuel transfer pumps. Fuel transfer system must have fuel line filters, anti-siphon valves (provide an anti-siphon valve at the highest point in the fuel piping system as a minimum), foot valves, automatic safety shutoff valves, check valves, and manual shutoff valves.

Other work that the contractor shall design and construct includes: site specific geotechnical data to develop foundations, materials, earthwork, and other geotechnical related design and construction elements as well as a survey of the site; provide reinforced concrete foundations for the emergency generator, load bank, above ground diesel fuel storage tank, and for other equipment as needed; provide fence around the emergency generator and ancillary equipment for security purposes per requirements in the specification; provide an access road from the existing road to the fenced in area if the fence gate is located twenty feet or more from the existing road; and due to the proposed location of the equipment and existing drainage features, a grading and drainage plan shall be included in the design.

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