OTV_23Z2AK9_SOW_Boiler2-3_10262023_FA_Approved.pdf

STATEMENT OF WORK (SOW)

REPAIR BOILERS 2 & 3

B&F PROJECT 23Z2AL9: EMG Repair Boilers 1, 2 & 3

FCI OTISVILLE

OTISVILLE, NEW YORK

October 26, 2023

PREPARED BY: AARON M. CHURCHILL

FACILITIES MANAGER

FCI OTISVILLE

NERO APPROVAL:

FACILITIES ADMINISTRATOR: _______________________ DATE: ____________

MICHAEL C. BOND

INSTITUTION APPROVAL:

FACILITY MANAGER: _______________________ DATE: ____________

A. CHURCHILL

PART 1. ‐ GENERAL

1.01. PROJECT DESCRIPTION

A. Contractor shall supply all labor, equipment, tools and materials to repair Boiler #2, Cleaver‐Brooks boiler having a model number: CB‐100‐200 and serial number: L65065, hereinafter referred to as Boiler 2 and Boiler #3, Cleaver‐Brooks boiler having a model number: CB‐100‐200 and serial number: L65066 hereinafter referred to as Boiler 3 for the Federal Bureau of Prisons, hereinafter referred to as FBOP.

B. Work shall be performed within the Powerhouse Boiler Room at the Federal Correctional

Institution Otisville, hereinafter referred to as FCIO located at Two Mile Drive, Otisville, New York 10963.

C. Repairs to Boiler 2 and Boiler 3 by welding can be made only by a Contractor holding an

ASME “R” stamp, in accordance with Chapter III of the National Board Inspection Code.

D. Boiler 2 and Boiler 3 Current Conditions:

1. Boiler 2 current conditions are as follows to include but not limited to:

a. Boiler is not currently in service.

b. Front and rear doors of boiler are open.

c. Boiler tubes showing signs of corrosion and fatigue with one or more tubes having failed.

d. Front intermediate door insulation has failed.

e. Minimum of two (2) threaded studs attached to boiler flange ring have failed.

f. Rear davit hinge bearings have failed.

2. Boiler 3 current conditions are as follows to include but not limited to:

a. Boiler is not currently in service.

b. Front and rear doors of boiler are open.

c. Boiler tubes showing signs of corrosion and fatigue with one or more tubes having failed.

d. Furnace extension has been removed.

(1) Furnace throat tile have been removed from furnace extension.

(2) Furnace liner tile have been removed.

e. Minimum of two (2) threaded studs attached to boiler flange ring have failed.

f. Minimum of one crack at front of boiler where tube sheet meets furnace tube.

g. Rear davit hinge bearings have failed.

1.02. GOVERNING STANDARDS/REFERENCES

A. Installation of materials necessary to accomplish the work specified herein shall comply with the latest revisions of the applicable federal, state and local codes and governing standards and/or references concerning repairs to pressure vessels to include but not limited to the following:

1. National Board Inspection Code (NBIC)

1.03. WORK SCHEDULE

A. Contractor will agree to perform all work between Monday and Friday between the hours of 6:00 a.m. and 4:00 p.m.

1.04. SUBMITTALS

A. Contractor shall submit the following documents within ten (10) working days of Contract

Award.

1. Manufacturer’s cut sheets for all products with model numbers indicated for materials to be furnished.

2. Safety Data Sheets (SDSs) on all materials and substances that will be furnished by Contractor in the completion of work. In the event that any material and/or substance is not approved, it shall be the responsibility of the Contractor to locate and submit on an alternative material and/or substance.

B. FBOP will approve Contractor submittals within five (5) working days of receiving submittal.

1.05. PAYMENTS:

A. Contractor will invoice FBOP upon completion of work. FBOP to process Invoice within thirty (30) days.

B. Contractor invoice to include the following:

1. Contractor Name

2. Contractor Address

3. Contract Number

4. Invoice Date

5. Description of work performed.

6. Name, title, phone number, email address and mailing address of a person to notify in the event of a defective invoice.

C. Contractor shall submit a completed National Board Form R‐1 for all boiler weld repairs with Contractor invoice.

PART 2. ‐ PRODUCTS

2.01. BOILER MATERIALS

A. Contractor shall furnish all materials to repair Boiler 2 and Boiler 3 to include but not limited to the following:

1. Boiler tubes. Furnish the following boiler tubes for Boiler 2 and Boiler 3:

a. (108) 2‐1/2 inch Outside Diameter (OD) 12‐gauge by 169‐1/2‐inch long

SA178A / ASTM A178 Grade A low carbon steel electric resistance welded boiler tubes. Boiler tubes shall have a minimum thickness of 0.105‐inch, original Cleaver‐Brooks specification.

2. Intermediate front door insulation kit. Furnish the following intermediate front door insulation kit for Boiler 2:

a. (15) square feet ‐ Bulk insulation, blanket 1‐1/2 inch thick, 2400 degrees

Fahrenheit, 8 pound.

b. (65) Pin, welding #10 Gauge by 4‐inch‐long stainless steel.

c. (65) Clip, welding stainless steel

d. (90) ounces of rigidizer, coating cement

e. (12) ounces of adhesive

f. (1) gasket, tape 1/8 inch by 2 inches by 59‐1/2 inches long

g. (35) square feet of screen stainless steel

3. Boiler flange ring and machine studs. Furnish the following boiler flange ring and machine studs for Boiler 2 and Boiler 3:

a. Boiler flange ring.

b. (8) Stud, machine, 1/2 inch – 13 inch by 2‐1/8 inches long.

c. (8) Standard 1/2‐inch washer.

d. (8) Hex nut, ½‐inch brass

4. Original Equipment Manufacturer (OEM) refractory brick and furnace tile.

Furnish the following OEM refractory brick and furnace tile for Boiler 2 and Boiler

3:

a. (16) Refractory brick, dry oven

b. (17) Furnace tile

5. OEM rear davit bearings, pin, washers, and spacers for Boiler 2.

6. OEM fire and waterside gaskets for Boiler 2 and Boiler 3.

EXECUTION

2.02. FBOP RESPONSIBILITIES

A. FBOP will be responsible to:

1. Furnish hose bib water with a supply of untreated fresh water.

2. Supply electrical circuit(s) with sufficient voltage and amperage for Contractor tools and equipment.

3. Open front and rear doors of Boiler 2 and Boiler 3. Drain each boiler prior to

Contractor arrival.

4. Maintain clear pathway in front of Boiler 2 and Boiler 3 for Contractor to remove existing tubes and install new tubes.

2.03. CONTRACTOR RESPONSIBILITIES

A. General Requirements:

1. All Contractor personnel that will be working onsite shall be required to comply with FBOP personnel identity verification procedures of Homeland Security

Presidential Directive‐12 (HSPD‐12).

2. Contractor shall clean work area and remove all debris from Powerhouse and place in FCIO dumpsters.

B. Contractor shall perform the following work with regard to Boiler 2 and Boiler 3 in accordance with Cleaver‐Brooks instructions and/or specifications:

1. Replace boiler tubes ‐ Boiler 2 and Boiler 3.

a. Remove all boiler tubes.

(1) Waterside of boiler shall be opened to include all handholes and manhole upon removing all boiler tubes. Waterside of boiler to be flushed to remove all scale, deposits, and debris from boiler.

b. Install boiler tubes.

(1) Entrance pass tube ends over rear tube sheet shall be rolled, seal welded if necessary. Tube ends shall be ground down to correct projection and re‐rolled.

(2) Exit pass tube ends shall be rolled, flared, and beaded over front tube sheet.

2. Replace boiler flange ring and machine studs ‐ Boiler 2 and Boiler 3

3. Perform weld repair at front of boiler where tube sheet meets furnace tube –

Boiler 3

4. Replace OEM refractory brick and furnace tile ‐ Boiler 2 and Boiler 3.

5. Replace intermediate front door insulation ‐ Boiler 2.

6. Replace OEM rear davit bearings, pin, washers, and spacers ‐ Boiler 2.

7. Fill each boiler with fresh water and perform hydrostatic test to verify integrity of the boiler work completed ‐ Boiler 2 and Boiler 3.

a. Hydrostatic test must hold 50 Pounds per Square Inch (PSI).

8. Properly gasket, seal and close front and rear doors ‐ Boiler 2 and Boiler 3.

END OF SECTION