SPECIFICATIONS AND REQUIREMENTS Vibration Data Collection and Analysis/Laser Alignment 1.

SCOPE: The purpose of this Bid is to establish a Contract to furnish all labor, equipment, hardware, software, testing, tools, transportation, and materials necessary to collect data, provide vibration analysis, interpretation services, and reports, on a monthly basis, for an estimated 700 individual data points, and provide laser alignment and/or balancing, as needed, at various locations for Broward County Water and Wastewater Services.

2.

QUALIFICATIONS AND CERTIFICATES 2.1. All work to be performed by a certified Vibration Analyst, Category II at a minimum, as certified by the Vibration Institute. 2.2. Contractor must have adequate organization, facilities, equipment, and personnel to ensure prompt and efficient service to County. 2.3. Contractor shall have a minimum of five (5) years’ experience performing industrial vibration analysis (e.g. power plant or treatment plant) and demonstrate experience with industrial machines over 400 HP.

3.

QUALITY CONTROL 3.1. Contractor must provide competent workers, qualified to perform vibration analysis according to industry established procedures, set-up instruments, and maintain a database of results, with a minimum of 18 months experience on the job and certified as Vibration Analyst, Category II at a minimum, by the Vibration Institute. 3.2. Contractor shall perform services without spillage and contamination of the surrounding environment. 3.3. Contractor shall perform services without making any modifications to the rotating equipment that may render equipment’s warranty void; this includes, but is not limited to drilling holes and attaching fixtures. Any modification to equipment shall be previously approved by County and shall not affect existing warranty conditions and terms. 3.4. Contractor shall, upon service completion, put rotating equipment back in its original state of operation and ascertain that they are functional. Contractor shall refrain from leaving objects such as tools, testing equipment and machine parts that may render the rotating equipment dysfunctional or become a safety hazard. 3.5. If unsafe conditions are found anywhere in the rotating equipment and/or rotating equipment has exceeded safe rated domain of vibrations, Contractor shall notify County, in writing, immediately and make recommendations to return the equipment to manufacturer’s recommended operating standards.

4.

DELIVERABLES 4.1. For each day Contractor is on-site performing monthly service, Contractor must complete and submit a Daily Work Log form, incorporated herein as “Attachment A-1”. The Daily Work Log form is to be signed by County’s designee accompanying Contractor on-site at each facility visited on that day. The forms are to be submitted to Water and Wastewater Services Engineering Division within 24 hours of completion of service and monthly with invoice for payment. 4.2. For each day Contractor is on-site to do laser alignment and/or balancing, Contractor must

 

complete and submit a Daily Service Report form, incorporated herein as “Attachment A-2”. The Daily Service Report form is to be signed by County’s designee accompanying Contractor on-site at each facility visited on that day. The forms are to be submitted to Water and Wastewater Services Engineering Division within 24 hours of completion of service and monthly with invoice for payment. 4.3. Contractor must provide analysis report of all data by the first week of the succeeding month. County expects Contractor to complete all monthly data collection within the first 10 calendar days of the month. 4.4. Contractor should coordinate with County and submit a data collection schedule for County’s approval. 4.5. Contractor’s monthly reports will show a summary of the equipment inspected with corresponding list of data points completed, problems found, and recommendations for further investigation and/or repair. Contractor shall be prepared to suggest changes to the testing schedule and maintenance requirements of rotating equipment based on test results and experience in similar projects. 4.6. Contractor shall submit to County with monthly report, 15 to 20 equipment data sheet and schematic diagram, so at the end of the first year, County has received data sheets and schematics on all its equipment. Contractor shall provide revised schematics when equipment is replaced and/or at County’s request. 4.6.1. Data sheet shall include date, asset number, equipment type, equipment process, speed, drive information, bearing type and manufacturer, gear information, pump or fan capacity, generator size, and location. 4.6.2. Diagram schematic shall include bearing, gear and sensor locations and orientation, and overall dimensions. 4.7. Contractor must provide, within five (5) calendar days of agreement award: 4.7.1. Manufacturer’s specification sheets of proposed vibration data collection equipment and software for County’s approval. 4.7.2. Proof of annual calibration on Contractor’s data collection equipment to be utilized at County’s facilities. Proof of annual calibration shall be submitted every year that agreement is renewed. 4.7.3. Example of an analysis report and data interpretation as specified under Section 6 of this document. 4.7.4. Proof of Vibration Analyst Certification - Category II at a minimum, issued by the Vibration Institute, for employees assigned to do the work specified in this agreement. 4.7.5. Proof that equipment and instrumentation utilized by the Contractor in hazardous environments are certified intrinsically safe. 5.

PAYMENTS 5.1. The cost of service (bid lines 1 through 3) shall be inclusive of all expenses such as labor, equipment, hardware, software, testing, tools, transportation, materials, and consumables. No travel or per diem expenses shall be billed separately. 5.2. Payments will be made in arrears, after receipt and approval of proper invoices and supporting documentation.

 

6.

CODES AND STANDARDS 6.1. International Organization for Standardization (ISO) ISO standards relating to machinery vibration monitoring and analysis as guided by Technical Committee TC108, Mechanical vibration and shock, specifically Standards for Evaluation of Vibration Severity ISO 7919 series and ISO 10816 series, ISO 9001for Quality Management, and ISO 10012 for Measurement Management Systems. 6.2. American National Standards Institute (ANSI) ANSI standards relating to vibration analysis and measurements, specifically ANSI/HI 9.6.4 for Centrifugal and Vertical Pumps – Vibration Measurements and Allowable Values 6.3. United States Military Standards (MIL) MIL standards relating to vibration analysis and measurements, specifically MIL-STD-810 for Environmental Test Methods 6.4. Institute of Electrical and Electronics Engineers (IEEE) IEEE standards relating to vibration analysis and measurements, including transducers, inertial sensors, and associated electronic gadgetry 6.5. American Society for Testing and Materials (ASTM) ASTM standards relating to vibration analysis and measurements, and associated equipment 6.6. Vibration Institute Standards and Recommendations

7.

DATABASE CREATION, PROGRAM IMPLEMENTATION, BASELINE SURVEY 7.1. Database creation and program implementation for Water and Wastewater Services that meet specifications and program requirements described in Section “Specifications and Requirements,” including all labor, equipment, hardware, software, testing, tools, transportation, materials, and consumables necessary to implement the program. 7.2. Contractor shall inspect the facilities, collect data, and perform vibration analysis and interpretation services on estimated 150 pieces of equipment and utilize this data and manufacturer’s test results or recommendations to prepare baseline information for the equipment. 7.3 Contractor shall provide diagnostic report, as specified in Section 8.4, on the initial vibration analysis and interpretation services being utilized to prepare baseline information for equipment.

8.

MONTHLY DATA COLLECTION, VIBRATION ANALYSIS AND INTERPRETATION SERVICES, AND REPORTS 8.1. Data Collection and Recording 8.1.1. Vibration analysis shall be performed on list of machinery provided each month by the County. County estimates 700 individual data points per month to be collected from various locations within Broward County. 8.1.2. Contractor shall submit to County with monthly report, 15 to 20 equipment data sheet and schematic diagram, so at the end of the first year, County has received data sheets and schematics on all its equipment. Contractor shall provide revised schematics when equipment is replaced and/or at County’s request.

 

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Data sheet shall include date, asset number, equipment type, equipment process, speed, drive information, bearing type and manufacturer, gear information, pump or fan capacity, generator size, and location.

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Diagram schematic shall include bearing, gear and sensor locations and orientation, and overall dimensions.

8.1.3. Contractor shall submit monthly data collected to County in digital format (software specific format as well as Excel or Access) 8.1.4. Contractor shall use measurement point routes already in place 8.1.5. Equipment consists mostly of pumps and motors 75 HP and higher 8.1.6. Contractor to provide portable multi-channel digital data collector 8.1.7. Contractor shall utilize a data acquisition system that is able to initiate data collection using a barcode system, where the barcode is placed at a specific data collection location allowing for data to be correctly correlated to the machinery. The barcode specifically identifies the measurement location to the data collector and ensures measurement data are assigned correctly regardless of the order in which the data is collected. 8.1.8. Each single speed machine shall be tested at rated speed and load. Variable speed machines shall be tested at a minimum of three speeds. Critical speeds shall be determined, recorded, and avoided if necessary. Groups of machines shall be tested under identical conditions, if possible, to permit comparative analysis. Actual test conditions shall be reported. Vibration levels, generally, shall be integrated and reported in velocity units. 8.1.9. Contractor shall collect Tri-axial Spectral Data; Axial (A), tangential (T), and radial (R), oriented with respect to the equipment/machinery shafting axis, vibration (velocity decibels or inches per second) measurements shall be taken at appropriate locations on each piece of equipment using tri-axial accelerometers. The number and exact position of the transducers shall be selected by the Contractor, based upon his or her knowledge of and familiarity with the type of equipment and expertise in vibration analysis, and approved by the County. 8.1.10. Measurements to be taken:

 

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Acceleration

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Velocity

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Speed profiling plots

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Nyquist plots

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Startup/cost down FFT waterfall plots

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Amplitude vs. RPM

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Time synchronous waveforms

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Time synchronous FFTs

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Speed

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Phase (1x – 99x)

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AdB, VdB

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AC/DC voltage

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Thrust or axial position

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Temperature

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G spike energy (GSE)

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Displacement

8.2. Equipment and Instrumentation 8.2.1. Contractor shall provide industry leading equipment and instrumentation for vibration analysis that is acceptable to the County 8.2.2. The equipment shall be portable multi-channel digital data collector 8.2.3. Data acquisition equipment shall be compatible with the vibration monitoring equipment. The equipment shall also be capable of a sufficient variety of data acquisition rates so as to match the ranges of rotational speeds encountered and minimize data adjustment during normalization. The equipment shall be capable of acquiring data from three-axis self-aligning transducers plus one tachometer channel at two frequency ranges. The capability to select a variety of frequency ranges up to ten kilohertz shall be included. Data records shall be sufficient to hold at least six hundred 400-line or 800-line spectral plots. As required, filtering and filter control adjustment capability shall be provided and be appropriate for the frequency ranges of the spectral data. 8.2.4. All Contractor provided equipment and instrumentation shall be capable of operation without degradation at temperatures of 40˚ to 120˚ F and non-condensing relative humidity of 0% to 95%, inclusive. 8.2.5. All equipment and instrumentation utilized by the Contractor in hazardous environments shall be certified intrinsically safe. 8.2.6. All equipment and instrumentation shall be calibrated every year. The Contractor shall ensure that adequate spare parts are carried so as not to cause service to be delayed or aborted because of equipment/instrumentation breakdown. 8.3. Software, Vibration Analysis, and Interpretation Services 8.3.1. Contractor shall provide industry leading software for vibration analysis that is acceptable to the County 8.3.2. Reports must be available from the software: 

Reports must include machines overdue for testing, missed on route, above alarm, requiring action, and a general report listing the status of all machines. The report must optionally be able to show the summary status of the machine or the status of each point on the machine. The report must optionally allow the user to select data from individual machines, an area of the facility/plant, a route, a class of machine, or to view the status of the entire database. The severity of the status should be color coded.

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The results of diagnostic tests, note codes, measurement test dates, and user entered notes must be logged to a long term “history” file such that these events can be reviewed at any time in the future. As a minimum, it must be possible to review the entire history of a nominated machine, and it must be possible to list the machines which have experienced a selected event.

8.3.3. Must provide early and accurate diagnosis of the following: imbalance, misalignment, developing bearing and gear faults, etc. This would include analysis of bearing

 

frequencies, simple gear frequencies, epicyclic gear frequencies, belt frequencies, motor frequencies, etc. 8.3.4. Manage the definition, acquisition, review, communication, and reporting of vibration and process data with an intuitive/productive user interface 8.3.5. Must provide 4-channel route collection, real-time analysis and event monitoring with supporting 4-channel plotting and report formats. 8.3.6. Must organize data by sites, which are the following: District 1, District 2, District 4, and Master Lift Stations. 8.3.7. Must define test-point specific alarm levels. 8.3.8. Each test point must have the following definitions: waveform, fast fourier transform, envelope, and direct current levels. 8.3.9. Must print and annotate all data. All analysis must give detailed explanation of problem source and correction needed. 8.3.10. Must define machine-specific failure frequency characteristics and attach pictures. 8.3.11. Must maintain routes and template already developed. 8.3.12. Must analyze vibration measurements in three mutually perpendicular axes at two frequency ranges. Must provide measurements, such as shaft vibration or other data display modes such as orbits, cascades, envelope data that are used in the assessment of machinery health. 8.3.13. Must identify both parallel and angular misalignment. 8.4. Reports 8.4.1. Contractor shall prepare a report, the format and content of which shall be mutually agreed to between the Contractor and County. For guidance purposes, this report shall include the following: a complete description of the vibration equipment and instrumentation used; a list of the equipment, machinery, and systems surveyed; the quantitative data/results obtained in the prescribed format including identification of each anomaly; and the qualitative analysis and fault diagnosis of each anomaly and corrections/actions considered necessary. 8.4.2. Each anomaly shall be classified as to the priority for remedial action; mandatory, important, or desirable. The County and Contractor shall agree to the specific measurement criteria (limits/ranges of vibration and relevant frequencies) for each class. 8.4.3. Spectral data – copies of all exception spectra (i.e., those in excess of threshold), along with an overall level trend chart for each exception spectrum. Must be plotted adjacent to the exception spectrum. 8.4.4. Max-peak id tables – a table of the five or more maximum peak values and overall levels in all exception spectra and must be plotted adjacent to the exception spectrum. The table units shall include mils (thousands of an inch), inches per second, g’s (acceleration due to gravity), and the corresponding frequency of each peak in units of Hertz and cycles per minute, or spike energy analysis. 8.4.5. Trend reports – must provide trend data for each of three inputs using stored spectra (including trends of 1x rpm, and 2x rpm, low, and high bands) and trends of any given spectral frequency components. 8.4.6. Additional data – must provide where appropriate, cascade/waterfall plots, orbital

 

displays, time traces, envelope data, etc. 8.4.7. Report must be in graph form and state in laymen’s terms possible problems and solutions for each equipment. 8.4.8. Must display spectra, waveforms, cascades, trends, envelopes. 8.4.9. Computerized analysis report – the computer must be able to produce and analyze all spectra for machine faults based on narrowband (discrete peak) percent changes from previous and/or baseline spectra, alarm band exceptions, and narrowband peak and overall level exceptions. The computer shall be capable of receiving user input regarding fault symptoms (including spectral frequency component, predominant plane of vibration, proximity of symptom to coupling, etc.) and weighting thereof, to improve diagnostic power and institutionalize knowledge of Water and Wastewater Operations Division rotating asset behavior. 8.4.10. Must provide real time display of rpm, amplitude, phase data for two channels simultaneously, relative weight location, and a graphical display indicating data stability. 8.4.11. Must be able to provide the following reports upon request from Water and Wastewater Services: Diagnostic report, magnitude exception reports band exception reports, spectrum exception reports, custom report, interactive report, integrated plots in report 8.4.12. Must plot the measurements taken in the following format:

 

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trend

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averaged trend

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trend projection

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spectrum

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spectrum map

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data overlay of spectrum and trend data

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time waveform

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images as data (i.e. infrared images)

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frequency trend

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polar plot of magnitude/phase

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x versus y plot

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spectrum difference/ratio

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active-x object support

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interactive plot controls including rubber band zoom; grids; auto scaling; linear, log, or decibel y scaling; linear or log x scaling; and multiple cursor types

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spectrum plot access to bearing database

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hertz, CPM, or orders scaling

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integration and differentiation of spectrum

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band trend

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spectrum/band alarm

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spectrum/narrow band alarms

8.4.13. Must provide the following Alarm/Alert features in report when requested: 

Alarms per measurement

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Eleven levels of alarm severity – user configurable

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Magnitude alarms based on constant, category constant, in window, statistical, statistical indicator, peak, baseline, percentage change, or rate of change

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Sorting of data based on alarm severity

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Multidimensional/state based statistical alarms

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Spectrum alarms enveloped at a constant bandwidth or percentage bandwidth

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Spectrum alarms based on peak, statistical, statistical indicator, baseline, or constant

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Band alarms based on category constant, in window, peak, statistical, statistical indicator, baseline, percent change, or rate of change.

8.4.14. Diagnostic features must be capable of the following:

9.

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User input and storage of diagnostic frequency items

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Frequency calculation methods, constants, multiplication, division, ratios, addition, subtraction, harmonics, sidebands, belts, gearbox, planetary gearbox, bearings, or motors

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Bearing database containing bearings from multiple manufacturers including Barden, Cooper, FAG, Fafnir, Gamet, Link-Belt, MRC, NTN, SKF, Timken, and Torrington.

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Speed references from manual entry, setup RPM, measured RPM, current RPM stored with spectrum, or RPM extracted from spectrum

ON-SITE SERVICE FOR LASER ALIGNMENT AND/OR BALANCING 9.1. On site work for Laser Alignment and/or Balancing, as needed and requested by County 9.2. Hourly rate shall be inclusive of all expenses such as equipment, labor, travel, and consumables. No travel or per diem expenses shall be billed separately. 9.3. Work to be done during normal business hours, Monday through Friday, 7:30 am – 4:00 pm, excluding holidays. Maximum response time will not exceed 3 calendar days/72 hours.

10. NEW TECHNOLOGY Contractor shall advise County of any technology which would enhance vibration monitoring or analysis of the rotating equipment at Water and Wastewater Services’ facilities 11. SAFETY 11.1. Contractor shall provide protection for all persons including but not limited to its employees and employees of other contractors or subcontractors; members of the public; and employees, agents, and representatives of the County and regulatory agencies that may be on or around the work. 11.2. Contractor is responsible for providing all Personal Protective Equipment (PPE) at

 

Contractor’s cost. 11.3. Contractor shall provide protection for all public and private property including but not limited to structures, pipes, and utilities, above and below ground. 11.4. Contractor shall comply with all applicable federal, state, and local laws, ordinances, rules and regulations, and lawful orders of all authorities having jurisdiction for the safety of persons and protection of property. 11.5. Contractor shall comply with all applicable safety program and training required and provided by the County. 11.6. Security Badge Identification System: The Contractor shall have a security badge identification system for its employees working in and around Broward County facilities to maintain a level of security necessary to protect the public and Contractor, Engineer and County employees. All workers, including day laborers and subcontractor employees shall be issued an identification badge by the contractor. The identification badges shall be worn visibly by workers at all times. All lost or stolen identification badges shall be reported to the County immediately. 11.6.1. The identification badges shall be made of plastic or laminated plastic material. All text shall be typewritten or printed by computer. The badges shall include the following information: First Line:

The words Contractor (or Visitor for vendors, etc.) shall be printed in all caps across the top of the badge

Second Line: The name of the Contractor Third Line:

The name and phone number (preferably a cell phone number) of the Contractor’s on site manager or superintendent for the project

Fourth Line:

A shortened name for the project (e.g. Vibration Analysis)

Fifth Line:

A unique badge control number for each badge (defined below)

11.6.2. A set of badge control numbers shall be established by the Contractor. A unique control number shall be permanently assigned to each worker on site. The list of worker names and his or her assigned control number shall be kept by the Contractor and provided to the County. A revised list shall be transmitted to the County through the Project Manager as new workers and control numbers are added. 11.6.3. The Contractor shall also manufacture a limited number of Visitor badges for their vendors or other site visitors. The Visitor badges shall be identical to the badges specified above except that they shall be issued and retrieved daily by the Contractor. The Contractor shall keep a daily log of the people, dates, and times that Visitor badges have been issued and the corresponding badge control number. All Visitor badges shall be accounted for at the end of each day. 11.7. Broward County reserves the right to direct the removal of an employee for misconduct, security reasons, or any overt evidence of nonperformance. All contractor personnel having access to Broward County Water and Wastewater Services facilities are subject to a criminal background investigation (state of domicile) at Contractor’s cost, if County deems necessary. Criminal background investigation must be performed upon demand by County, and results provided to the County within 5 calendar days after request.