8_axle_Railcar RFI SOW Final_Dec_14_2020.pdf

Draft Statement of Work

8-Axle Railcar Prototype for Transportation of Spent Nuclear Fuel and High-Level Radioactive Waste.1

1. Introduction/Background

Under the Nuclear Waste Policy Act of 1982, as amended, the U.S. Department of Energy (DOE) is responsible for disposal of spent nuclear fuel (SNF) and high-level radioactive waste (HLW), including their associated transportation. DOE anticipates that rail will be the primary mode used for the transport of SNF and HLW due to the size and weight of the SNF containers (known as “casks”), which are certified by the U.S. Nuclear Regulatory Commission (NRC). The NRC has approved transport cask designs supplied by various manufacturers. The casks are typically steel cylinders that are either welded or bolted closed. The steel cylinder provides leak-tight confinement of the SNF.

The transportation casks that could be used by DOE to transport SNF weigh approximately 80–210 tons.

The Association of American Railroads Standard S-2043 (AAR S-2043), Performance Specification for Trains Used to Carry High-Level Radioactive Material, is the technical standard railcars must

1 Association of American Railroads AAR S-2043 standard uses the terminology, High-level radioactive material (HLRM) to refer to Spent Nuclear Fuel (SNF) and High-Level Radioactive Waste (HLW). Legal statutes applicable to DOE activities define and use the terms SNF and HLW. Therefore, for the purpose of this RFI, SNF and HLW are synonymous with HLRM.

meet to transport SNF and HLW in compliance with AAR’s interchange standards. DOE intends to use AAR S-2043-compliant railcars to transport SNF and HLW casks in the future. DOE has previously fabricated two prototype buffer railcars, one prototype rail escort vehicle, and one 12-axle cask-carrying railcar (known as the Atlas railcar project). These prototypes are currently undergoing testing to confirm they meet the AAR S-2043 standard. This Statement of Work (SOW) focuses on the fabrication and testing of one 8-axle cask-carrying railcar only.

AAR interchange rules require use of railcars that comply with AAR standards. The objective of AAR S-2043 is to provide a cask/railcar/train system that supports safe transportation of SNF casks in the railroad operating environment and allows timetable speeds with no restrictions on meets or passes. Also, AAR free/unrestricted interchange is desired to avoid the need for a special agreement by all railroads concerned for railcar handling between participating railroads. There are no AAR S-2043-compliant railcars available for DOE to lease for its transport needs;

therefore, new railcars will be required to transport SNF and HLW on the U.S. rail network at standard commerce rail speeds. The purpose of this SOW is to fabricate a prototype 8-axle cask-carrying railcar (henceforth referred to as the “Fortis railcar”), to conduct railcar testing required by AAR S-2043, and to receive railcar approval from AAR’s Equipment Engineering Committee (EEC). The AAR EEC-approved2 design for the Fortis railcar will be provided to the contractor by DOE, along with the associated documentation needed for fabrication and testing.

Currently, a DOE contractor has completed the preliminary design of an 8-axle railcar prototype.

The approval for the fabrication of the prototype from the AAR EEC is anticipated before the end of the first quarter of fiscal year 2021. It is this existing prototype design that will be fabricated and then tested. This work is being executed in two phases, with Phase 2 exploring two options for the execution of work scope. Phase 1 is the prototype design, which will be completed at that time of this procurement. Phase 2 includes the fabrication of the railcar as well as options for the execution of the railcar testing working scope. Phase 2, Option 1 proposes the fabrication and testing work be split into two different contracts, allowing bidders to pursue one or both parts. Phase 2, Option 2 proposes the work be completed under a single contract. Part of the goal of this SOW is to determine the pros and cons of dividing this work scope into two contracts.

Each Fortis railcar will carry only one SNF transport cask at a time. DOE estimates that each Fortis railcar will be used in shipments between 5 and 10 times per year. The lifetime of a Fortis railcar is assumed to be 50 years.

DOE may decide to issue a separate contract for prototype railcar fabrication (Option 1a) and a subsequent separate contract for the testing of the fabricated prototype Fortis railcar (Option 1b), or DOE may combine the fabrication and testing tasks into one contract (Option 2).

The Fortis railcar must comply with AAR’s Manual of Standards and Recommended Practices, 2 Throughout this document, “AAR conditional approval” or “AAR approval” means approval by the AAR EEC of compliance with the AAR S-2043 standard.

including AAR S-2043. A copy of these standards can be obtained for a fee of approximately $2,500 from the AAR website (https://aarpublications.com/manual-of-standards-and-recommended-practices.html) or by contacting the AAR at 877-999-8824 (or direct line 719-584-0538) to obtain a copy of these standards and to verify the latest version of these standards.

It is anticipated that the train consist for transporting SNF or HLW will be comprised of two locomotives, two buffer railcars, cask-carrying railcars, and one escort railcar. This contract’s SOW only includes activities to fabricate and/or test the previously designed AAR S-2043-compliant Fortis prototype cask-carrying railcar, pending the option for Phase 2.

DOE does not plan to develop any new locomotives and expects the railcars to be transportable by standard locomotives.

DOE anticipates that this work scope will include the following:

• 8-axle Fortis railcar prototype fabrication

• single-railcar testing (AAR S-2043, Section 5)

• multi-railcar testing (AAR S-2043, Section 6, DOE will supply buffer and escort railcars)

• test reports (AAR S-2043, Section 7)

• post-test analysis (AAR S-2043, Section 8)

• a final report (AAR S-2043, Section 9)

• submission of testing results to the AAR EEC

• receipt of the AAR EEC’s conditional approval for the Fortis railcar.

2. Statement of Work

The contractor(s) shall perform the options described in this SOW, as authorized in writing by DOE, for fabrication and testing of a prototype Fortis railcar. As stated, this procurement is being considered as a combined effort (fabrication and testing of the Fortis railcar prototype), or two separate efforts, related to (1a) the fabrication of the prototype, and (1b) the subsequent testing of the fabricated prototype railcar.

Previous work has resulted in approved build-to-print drawings that can be used to competitively fabricate the Fortis railcar prototype, and will be provided to the contractor by DOE, along with the associated documentation needed for fabrication. DOE will take ownership of the deliverables resulting from this contract.

Deliverables provided under this contract shall be performed in accordance with AAR’s Manual of Standards and Recommended Practices (including AAR S-2043) and any other applicable standards. This SOW begins with the AAR EEC-approved prototype design. This provides that a conceptual design as well as an AAR EEC-approved Preliminary Design Submittal is available for all bidders. Some details about this railcar design are as follows:

https://aarpublications.com/manual-of-standards-and-recommended-practices.html https://aarpublications.com/manual-of-standards-and-recommended-practices.html

• The loaded cask railcar clearances fit within AAR Plate E so that the Fortis railcar can be used in limited interchange service. The requirements for Plate E are contained in AAR Standards S-2026, S-2027, and S-2030. These standards are referenced in AAR S-2043, Section 4.7.9.1.

• The transportation casks rest on cradles, or “skids,” on top of the railcar deck. Cradles and test weights for prototype testing will be supplied by DOE.

• Some casks will already be horizontal when they are placed on the cradle. Other casks will be positioned on the cradle vertically, and then rotated to a horizontal position to rest on the cradle. This vertical-to-horizontal operation may be performed on top of the railcar.

• Therefore, the cask-carrying railcar is required to support the weight of a cask in a vertical position during loading and unloading operations.

• The cradle will be tall enough and open-ended so that the impact limiters can be attached to a cask after the cask is secured to the cradle. The impact limiters will clear the cask-carrying railcar deck by at least three inches.

• The impact limiters may be attached to the cask after the cask is loaded on the railcar, so the railcar deck must accommodate this operation.

The associated rough order of magnitude estimate should include the following, as appropriate (along with supporting rationale/basis of estimates):

• Option 1a – Prototype Fabrication

– Only prototype fabrication per AAR requirements, or

• Option 1b – Prototype Testing

• Prototype AAR single-railcar and multi-railcar testing and AAR EEC conditional approval, or

• Option 2 – Prototype Fabrication and Testing

– prototype fabrication per AAR requirements, prototype AAR single-railcar and multi-railcar testing, and AAR EEC approval.

Further descriptions of the fabrication and project phases, as well as the work scope options, is provided below.

2.1 Phase 1: Fortis Prototype Design (Completed)

A preliminary design of an 8-axle cask railcar, as described in Section 4.0 of AAR S-2043 has been developed, and the design contractor has received notification from the AAR EEC to “proceed with the test phase,” as stated in Paragraph 3.2.1 of AAR S-2043. Additionally, the preliminary design includes all deliverables necessary to have a prototype cask railcar produced by a third party.

The Phase 1 deliverables from the prototype design will be shared with the Phase 2 contractor(s) as follows:

• Preliminary Design Submittal, conforming to Section 4.7 of AAR S-2043, as approved by the AAR EEC.

• Computer modeling/simulation input and output files for the structural analyses, nonstructural static analyses, and dynamic analyses.

• A copy of the AAR EEC notification to “proceed with the test phase,” along with any supporting documentation from the AAR EEC.

• A complete set of technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.) of the prototype design.

• A complete list of all required components that will be required to fabricate the prototype cask railcar, including the sources of supply. Custom-built components must be annotated as such, and if required, the contractor will provide drawings or specifications necessary to manufacture the items. An inspection plan suitable for use by a third party to verify that the fabrication and assembly of the cask railcar systems meets the design specifications.

• Cost and schedule estimate for the single cask railcar testing phase.

• Cost estimate and schedule for a future production run of 120 cask railcars.

• Operations and maintenance (O&M) information (including cost and operations downtime) for operation of a railcar during a typical lifespan, including attention given in the design to reliability, maintainability, and quality assurance requirements.

Publicly available information regarding SNF transportation casks is provided in Attachment A. If additional information is required, the contractor shall be responsible for the execution of any non-disclosure agreement with cask vendors to obtain any required detailed design information about the NRC-certified or soon to be NRC-certified transportation casks.

2.2 Phase 2, Option 1a: Fortis Railcar Prototype Fabrication, per AAR Requirements (no testing)

Upon receiving written authorization from the Contracting Officer, the contractor shall fabricate one Fortis railcar in accordance with the approved by the AAR EEC Prototype Design (to be provided by DOE). Fabrication must be performed by an AAR-certified railcar builder. Upon completion, the contractor shall be responsible for transporting the fabricated Fortis railcar from its point of fabrication to the location where the testing will occur.

The contractor shall fabricate the Fortis railcar addressing the requirements to receive the AAR EEC’s conditional approval.

For the initial fabrication the contractor shall deliver the following:

• Prototype Fortis railcar build that meets the provided AAR EEC approved design specifications.

• Delivery to test site.

• An arranged inspection day/visit for the AAR EEC to see the railcar.

• A minimal demonstration that the Fortis railcar (loaded) can mate with all existing other AAR S-2043 railcars (available at the test site) and move at slow speed (5 mph) within a consist through the test site special trackwork.

• A set of as-built drawings and inspection reports, including weld inspections for all components, depicting the final configuration of the Fortis railcar.

• A list (bill of material) of all procured parts necessary to complete assembly of the Fortis railcar, including cut sheets, part numbers, specifications, vendors, etc.

• All O&M manuals, including preventative maintenance information, necessary for the long-term use of the Fortis railcar system.

• A complete set of technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.)

• O&M information, including attention given in the design to reliability, maintainability, and quality assurance requirements

• A copy of all approval records issued by the AAR EEC.

• A copy of all Federal Railroad Administration (FRA) approval records.

The fabrication contractor (Option 1a) shall remain available after prototype fabrication, either through a separate contracting mechanism or as a contract line-item number (CLIN), in the event modifications to the Fortis railcar are required based on single-railcar or multi-railcar testing. If during railcar testing, fabrication defects are identified, the fabrication contractor will be responsible for immediate remediation.

During single-railcar and multi-railcar testing of the Fortis prototype railcar, the fabrication contractor (Option 1a) shall provide:

– A complete set of updated technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.), if revisions are applicable after either single-railcar or multi-railcar testing.

– A complete list of all railcar adjustments and modifications that were required during single-railcar and multi-railcar testing, including the sources of any new components.

Custom-built components shall be annotated as such, and if required, the contractor will provide the drawings or specifications necessary to manufacture the items, if revisions are applicable after either single-railcar or multi-railcar testing.

– Revised O&M information, including attention given in the design to reliability, maintainability, and quality assurance requirements, if revisions are applicable after either single-railcar or multi-railcar testing.

– A complete set of as-built drawings and inspection reports depicting the final configuration of the cask railcar and buffer railcar.

In addition to the actual prototype Fortis railcar, the fabrication contractor (Option 1a) shall provide the Contracting Officer Representative (COR) one electronic copy of all other deliverables.

Upon completion of all deliverables, the fabrication contractor shall brief DOE on all the activities conducted during this Phase 2, Option 1a (Fortis railcar prototype fabrication and approval by the AAR EEC). It is anticipated that this briefing will occur in Washington, D.C., after receipt of conditional fabrication approval by the AAR EEC. The schedule for this briefing will be coordinated through the COR.

2.3 Phase 2: Option 1b Fortis Railcar Prototype Single-railcar and Multi-railcar Testing and

Conditional Approval by the AAR EEC

Upon receipt of written authorization from the Contracting Officer, the railcar testing contractor shall begin the single-railcar tests on the Fortis prototype railcar, as described in Section 5 of AAR S-2043. During the testing process, the railcar testing contractor shall document and perform any required design changes (if necessary) and shall fabricate or acquire any required new pieces (if any) in order to obtain the AAR EEC’s conditional approval of the single Fortis railcar and its design.

This will also include scope outlined in AAR S-2043, Section 7 (Test Reports), Section 8 (Post-Test Analyses), and Section 9 (Final Report).

Upon the completion and conditional approval of the single-railcar testing, and upon written authorization from the DOE Contracting Officer, the railcar testing contractor shall begin the multi-railcar testing as documented in Section 6 of AAR S-2043. This will also include scope outlined in AAR S-2043, Section 7 (Test Reports), Section 8 (Post-Test Analyses), and Section 9 (Final Report).

The testing will require test cradles and test weight (simulated cask and/or ballast) as required by the AAR for testing. This equipment will be furnished by DOE from the Atlas railcar project. In addition, instrumented wheel sets (IWSs) will be needed for testing. Considering the need for spares, it is recommended that the successful bidder provide six IWSs to accomplish the single-car and multi-car tests.

The railcar testing contractor (Option 1b) shall test the Fortis railcar as necessary to receive the AAR EEC’s conditional approval.

If AAR EEC conditional approval requires modifications to the Fortis prototype, the fabrication contractor (Option 1a) shall provide a cost and schedule estimate to make those changes as directed by DOE.

The railcar testing contractor (Option 1b) shall deliver the following:

• Single-railcar Testing

– A copy of all approval records issued by the AAR EEC.

– Copies of all test reports required by AAR standards.

– Single-railcar tests and test report, including an independent third-party review report.

– Supporting report of any further finite element analysis and/or multibody dynamics modeling.

– All documents and a letter to AAR EEC stating the Fortis railcar has passed single-railcar testing and is ready for multi-railcar testing.

• Multi-railcar Testing

– A multi-railcar testing test plan, schedule, and test procedures (for information).

– A multi-railcar test report, including an independent third-party review report.

– Computer modeling/simulation input and output files for any dynamic analyses that are revised during the multi-railcar testing phase.

– Post-Test Analysis (Section 8) and Final Report (multi-railcar testing portion) (Section 9).

– A complete list of all railcar adjustments and modifications that were required during single-railcar and multi-railcar testing, including the sources of any new components.

Custom-built components shall be annotated as such, and if required, the contractor will provide the drawings or specifications necessary to manufacture the items (if revisions are applicable after either single-railcar or multi-railcar testing).

– A complete set of as-built drawings and inspection reports depicting the final configuration of the cask railcar and buffer railcar.

– A description of any problems with the escort railcar and suggested design modifications to allow this railcar to meet the consist requirements of AAR S-2043.

– AAR EEC conditional approval for the assembled consist (consisting of buffer, cask, and escort railcars).

In addition to the actual prototype Fortis railcar, the contractor shall provide the COR one electronic copy of all other deliverables.

Upon completion of all single-railcar and multi-railcar testing on the Fortis railcar and receipt of approval from the AAR EEC, DOE shall work with the railcar testing contractor (Option 1b) to identify an appropriate location for the storage of the Fortis railcar.

If the storage location is to be at a Government-owned facility, DOE will take possession of the prototype Fortis railcar once it is delivered to the Government-owned facility. If the storage location is at a non-Government site, the contractor will store the Fortis railcar, as directed by the Contracting Officer and COR. Contractor storage will be accomplished using a fixed monthly price to store the railcar, in accordance with Section B of this contract.

Upon completion of all deliverables, the contractor shall brief DOE on all the activities of Phase 2, Option 1b (Single-car and multi-car testing and conditional approval by the AAR EEC). It is anticipated that this briefing will occur in Washington, D.C., after conditional approval by the AAR EEC. The schedule for this briefing will be coordinated through the COR.

2.4 Phase 2: Option 2 Fortis Railcar Prototype Fabrication, Testing and Conditional

Approval by the AAR EEC

Upon receipt of written authorization from the Contracting Officer, the contractor shall fabricate one Fortis railcar in accordance with the approved by the AAR EEC prototype design (to be provided by DOE). Fabrication must be performed by an AAR-certified railcar builder.

Upon completion of the fabrication, and with written authorization from the Contracting Officer, the contractor shall perform the AAR S-2043, Section 5, single-railcar and multi-railcar tests. During the testing process, the contractor shall document and perform any required design changes (if necessary) and shall fabricate or acquire any required new pieces (if any) in order to obtain the AAR EEC’s conditional approval of the single Fortis railcar and its design.

The contractor shall be responsible for transporting the fabricated Fortis railcar from its point of fabrication to the location where the testing will occur.

The testing will require test cradles and test weight (simulated cask and/or ballast) as required by the AAR for testing. This equipment will be furnished by DOE from the Atlas railcar project. In addition, IWSs will be needed for testing. Considering the need for spares, it is recommended that the successful bidder provide six IWSs to accomplish the single-car and multi-car tests.

The contractor shall fabricate and test the Fortis railcar as necessary to receive the AAR EEC’s conditional approval.

The contractor shall deliver the following:

• Railcar Fabrication

– Prototype Fortis railcar build.

– Delivery to test site.

– An arranged inspection day/visit of AAR EEC to see the railcar.

– A minimal demonstration that the Fortis railcar (loaded) can mate with all existing other AAR S-2043 railcars (available at the test site) and move at slow speed (5 mph) within a consist through the test site special trackwork.

– A set of as-built drawings and inspection reports depicting the final configuration of the cask railcar.

– A list (bill of material) of all procured parts necessary to complete assembly of the Fortis railcar including cut sheets, part numbers, specifications, vendors, etc.

– All O&M manuals, including preventative maintenance information, necessary for the long-term use of the Fortis railcar system.

– A complete set of technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.)

– O&M information, including attention given in the design to reliability, maintainability, and quality assurance requirements

– A copy of all approval records issued by the AAR EEC.

– A copy of all FRA approval records.

• Single-railcar Testing

– A copy of all approval records issued by the AAR EEC.

– Copies of all test reports required by AAR standards.

– Single-railcar tests and test report, including an independent third-party review report.

– Supporting report of any further finite element analysis and/or multibody dynamics modeling.

– All documents and a letter to the AAR EEC stating the Fortis railcar has passed single-railcar testing and is ready for multi-railcar testing.

– A complete set of updated technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.) if revisions are applicable after either single-railcar or multi-railcar testing.

– Revised Operation and Maintenance (O&M) information, including attention given in the design to reliability, maintainability, and quality assurance requirements, if revisions are applicable after single-railcar testing.

• Multi-railcar Testing

– A multi-railcar testing test plan, schedule, and test procedures (for information).

– A multi-railcar test report, including an independent third-party review report.

– Computer modeling/simulation input and output files for any dynamic analyses that are revised during the multi-railcar testing phase.

– Post-Test Analysis (Section 8) and Final Report (multi-railcar testing portion) (Section 9).

– A complete set of updated technical specifications and procedures for all special processes needed to complete fabrication and assembly (i.e., welding, heat treatment, etc.) if revisions are applicable after either single-railcar or multi-railcar testing.

– A complete list of all railcar adjustments and modifications that were required during single-railcar and multi-railcar testing, including the sources of any new components.

Custom-built components shall be annotated as such, and, if required, the contractor will provide the drawings or specifications necessary to manufacture the items (if revisions are applicable after either single-railcar or multi-railcar testing).

– Revised O&M information, including attention given in the design to reliability, maintainability, and quality assurance requirements, if revisions are applicable after either single-railcar or multi-railcar testing.

– A complete set of as-built drawings and inspection reports depicting the final configuration of the cask railcar and buffer railcar.

– A description of any problems with the escort railcar and suggested design modifications to allow this railcar to meet the consist requirements of AAR S-2043.

– AAR EEC conditional approval for the assembled consist (consisting of buffer, cask, and escort railcars).

In addition to the actual prototype Fortis railcar, the contractor shall provide the COR one electronic copy of all deliverables.

Upon completion of all single-railcar testing and multi-railcar testing on the Fortis railcar and receipt of conditional approval from the AAR EEC, DOE shall work with the contractor to identify an appropriate location for the storage of the Fortis railcar.

If the storage location is to be at a Government-owned facility, DOE will take possession of the prototype Fortis railcar once it is delivered to the Government-owned facility. If the storage location is at a non-Government site, the contractor will store the Fortis railcar, as directed by the Contracting Officer and COR. Contractor storage will be accomplished using a fixed monthly price to store the railcar, in accordance with Section B of this contract.

Upon completion of all deliverables, the contractor shall brief DOE on all the activities of this phase.

It is anticipated that this briefing will occur in Washington, D.C. after receipt of conditional approval by the AAR EEC. The schedule for this briefing will be coordinated through the COR.

2.5 Delivery Location

See Sections 2.2, 2.3, and 2.4 above regarding delivery location(s).

2.6 Meetings, Reports, and Reviews

Kickoff Meeting

The contractor will attend a team kickoff meeting in Washington, D.C., to discuss project scope, schedule, and budget and to explain the contractor’s approach to Phase 2. This meeting will be scheduled within three weeks of the contract award. The contractor’s main point of contact for this contract should attend this meeting, and the contractor may bring one or two additional key personnel. The contractor will be expected to lay out the work to be done under the contract with particular emphasis on the method and timing for executing the tasks to be conducted during Phase 2, of work scope awarded.

Progress Review Meetings

The contractor and COR will participate in progress review meetings via teleconference, as needed or directed by the COR, to address potential issues in a timely manner and to facilitate moving forward on the SOW. These calls will start four weeks after the kickoff meeting and may continue for the duration of the contract, although the timing and frequency may be changed at the discretion of the COR. During these meetings, the contractor may present project technical progress, cost, and schedule status for each phase executed. The contractor shall identify existing or anticipated problem areas for each task (including impacts) and discuss corrective actions reporting on progress toward task closure. For cost estimating purposes, assume that these progress review teleconferences will occur monthly. Any issues regarding contract terms and conditions, or that impact the cost, schedule, or performance of the contract, should involve the Contract Specialist and/or Contracting Officer.

Status Reports

On a monthly basis, the contractor will submit a brief written status report on a form provided by the DOE COR. The status report shall be issued in coordination with the progress review teleconferences. The status report shall include, but be not limited to, the following information:

• Project manager’s narrative highlights and status assessment regarding technical progress for the executed phase.

• Schedule and cost input that provides cost/schedule data for measuring performance.

Progress and any changes in the latest revised estimate shall be included in the cost performance report with variance explanations. All of the contractor’s detailed budget information (staff hours and dollars) shall be available for review by the DOE COR, as required.

• Issues/concerns (cost, schedule, technical), recommended resolution, and progress toward resolution.

Deliverables Reviews

DOE has not yet decided to fabricate the proposed fleet of railcars. This large-scale fabrication, if such a decision is made, will be performed under a separate contract. DOE will own the rights to the design modifications produced under this contract and previous contracts (prototype design) and will use them in an unrestricted manner.

Deliverables requiring a review by DOE shall be submitted to the DOE for review and comment on or before the contract deliverable due date. DOE will normally submit comments to the contractor on contract deliverables no later than two weeks after each due date and normally approximately two weeks after each design review, whichever is later.

All reports shall be prepared in accordance with the DOE Office of Nuclear Energy Nuclear Fuel Cycle and Supply Chain (NFCSC) Quality Assurance Program Document, Revision 6, dated 10/07/2019. The Quality Rigor Level shall be (QRL-3). The Fuel Cycle Technologies (FCT) Document Cover Sheet shall be attached to each report.

3. Required Skills/Expertise

Option 1a and Option 2 – The contractor shall be an AAR-certified freight railcar manufacturer (or have on their team an AAR-certified freight railcar manufacturer) and have demonstrated experience with the design, fabrication, and AAR approval of custom-made heavy-duty railcars. The contractor shall provide all necessary expertise, equipment, and facilities necessary to fully execute the SOW.

AAR approval according to the standard for quality assurance (M-1003) is also a requirement.

Welding must comply with the requirements of American Welding Society (AWS) D15.1.

Option 1b and Option 2 – The contractor shall have an AAR-certified testing facility (or have an AAR-certified testing facility as part of their team).

4. Security Considerations

No security clearances will be needed for this contract.

5. Environmental, Safety, and Health (ES&H) Considerations

There will be no special ES&H requirements or considerations. During the phases that contain fabrication of a railcar unit, if authorized, the contractor shall fabricate the prototype in a facility of the contractor’s choosing (subject to AAR requirements).

6. Period of Performance

Option 1a – The period of performance for fabrication and delivery of the 8-axle Fortis prototype railcar at the testing location for this contract will be 18 months from date of award.

Option 1b – The period of performance for single-railcar and multi-car testing and AAR conditional approval for this contract will be 3 years from date of receipt of the prototype railcar.

Option 2 – The period of performance for fabrication and delivery of the 8-axle Fortis prototype railcar at the testing location and for single-railcar and multi-car testing and AAR conditional approval for this contract will be 4.5 years from date of award.

7. Travel/Work Location

The work location shall be at the discretion of the contractor. Periodic travel to DOE Headquarters in Washington, D.C., will be required to present program status and participate in program reviews.

For costing purposes, assume one such trip for the initial kickoff meeting and two additional trips each year during the execution of the work scope in this SOW. In addition, assume two meetings during the fabrication phase at the fabricator’s location as well as two meetings each year at the testing location during the testing phase.

Attachment A – Transport Cask Characteristics

Nominal Characteristics of Spent Nuclear Fuel Transportation Casks

Manufacturer and Model

Length without Impact

Limiters (in.)

Length with Impact

Limiters (in.)

Diameter without Impact

Limiters (in.)

Diameter with

Impact Limiters

(in.)

Empty Weight with

Impact Limiters (lb)

Loaded Weight with

Impact Limiters (lb)

NAC International

NAC-STC 193.0 273.7 99.0 128.0 188,767–

194,560

241,664– 254,589

NAC-UMS

UTC

209.3 273.3 92.9 124.0 178,798 248,373– 255,022

MAGNATRAN 214.0 322 110 128 208,000 312,000

Holtec International

HI-STAR 100 203.25 307.5 96.0 128.0 179,710 272,622–

279,893

HI-STAR HB 128.0 230.8a 96.0 128.0a --b 187,200

HI-STAR 180 174.37 285.04 106.30 128.0 < 308,647 308,647

HI-STAR 60 158.94 274.37 75.75 128.0a <164,000 164,000

HI-STAR 190

SL

214.4688 339.5625 106.5e 128 282,746 369,049– 382,746f

HI-STAR 190

XL

236.9688 362.0625 106.5e 128 304,369 Up to 420,769

Areva Transnuclear

MP187 201.5 308.0 92.5 126.75 190,200 265,100–

271,300

MP197 208.0 281.25 91.5 122.00 176,710 265,100

MP197HB 210.25 271.25 97.75 126.00 179,000 303,600

TN32Bc 184.0 261.0a 97.75 144.0a --d 263,000a

TN-40 183.75 261.0 99.52 144.00 --d 271,500

TN40HT 183.75 260.9 101.0 144.0 --d 242,343

TN-68 197.25 271.00 98.00 144.00 <272,000 272,000

Energy Solutions

TS125 210.4 342.4 94.2 143.5 196,118 285,000

Manufacturer and Model

Length without Impact

Limiters (in.)

Length with Impact

Limiters (in.)

Diameter without Impact

Limiters (in.)

Diameter with

Impact Limiters

(in.)

Empty Weight with

Impact Limiters (lb)

Loaded Weight with

Impact Limiters (lb)

Source: Design and Prototype Fabrication of Railcars for Transport of High-Level Radioactive Materials, Phase 2: Preliminary Design, Table 2-1, Contract DE-NE0008390

a. Estimated

b. HI-STAR HB transportation casks are already loaded so they would not be shipped empty.

c. This is the TN-32B that DOE plans to use in the High Burnup Dry Storage Cask Research and Development Project, and ship from North Anna Nuclear Power Plant. The TN-32B does not currently have a transport certificate of compliance. The dimensions and weight with impact limiters for the TN-32B are estimated.

d. TN-40 transportation casks are authorized for single-use shipments and would not be shipped empty. TN-32B and TN40HT transportation casks are also assumed to be authorized for single-use shipments and would not be shipped empty on an AAR S-2043 cask railcar.

e. The diameter is of cask body and does not include trunnions.

f. Weights do not include the weights of any MPC spacers that may be required.

3. Required Skills/Expertise