A04 SOW Three Thermic Syphons.pdf

United States Department of the Interior

NATIONAL PARK SERVICE

Facility Management Program

150 S. Washington Ave.

Scranton, Pa. 18503

Scope of Work Boston & Maine #3713

New Firebox Thermic Syphons

Steamtown National Historic Site

150 S. Washington Ave.

Scranton, Pa. 18503

Prepared by:

Bruce Mowbray

Preservation Specialist COR

Steamtown N.H.S.

May 25, 2020

Part I: General Information:

Steamtown NHS, located in Scranton, PA, serves approximately 100,000 visitors annually and several visitor use areas. The park normally offers mainline, round trip excursions of various length for the visitor so they can see, feel, and smell what it is like to have a live steam locomotive experience. Presently, Steamtown National Historic Site has no operational mainline locomotives due to mandatory FRA regulations regarding steam locomotive safety requirements and inspections. The restoration of the Boston and Maine #3713 shall offer the park an opportunity to preserve an American steam locomotive while providing a visitor experience of riding behind an operational steam locomotive in mainline excursion service.

Introduction:

This portion of the Boston and Maine locomotive #3713 restoration shall provide the manufacture of 3 (three) new Nicholson thermic syphons for the firebox. The project shall follow copies of historic drawings and documents used in the original manufacture of the locomotive as well as satisfying current Federal Railroad Administration (FRA) safety regulations, American

Welding Society (AWS) standards, and the National Board Inspection Code (NBIC), where applicable. The following statement of work (SOW) is to address the manufacture of 3 new thermic syphons for the Boston and Maine #3713 firebox.

Background:

The firebox of a steam locomotive is where fuel, coal in this case, is burned to produce heat and generate steam to power the locomotive. The thermic syphon is an addition to the firebox structure that improves the efficiency of the firebox by increasing the surface area on which the heat from the fire impinges. The syphon also improves the circulation within the boiler by taking the water from the coldest area of the pressure vessel and running it through the firebox and up to the hottest area of the boiler, directly above the firebox, by convection and a syphoning effect.

Objectives:

Construct 3 (three) new syphons – one center, one left hand, and one right hand, following copies of the original Lima Locomotive Works drawings, Locomotive Firebox Company drawings, and a patent document with directions on fabrication of syphons on a press brake machine, using the original syphons for dimensional reference. Manufacture methods must satisfy NBIC welding procedures and NBIC welder qualifications for boilers and pressure vessels

Description:

The three original syphons have been removed from the firebox and were inspected for defects.

Many cracks, poor weld joints, areas of burned metal, and highly corroded areas were found, and it was decided that it would be safer to build three new syphons. Also, a brand-new firebox was constructed and to put these old, questionable syphons into a new firebox would not be a wise choice due to the difficulty of replacing them should they fail in service.

The three syphons for #3713 locomotive shall be constructed of 3/8” thick, pressure vessel quality (PVQ) steel sheet. Alloy ASTM A516 grade 55. Each syphon shall be formed from one sheet of steel using a press brake along with some hot forming. The seams shall all be Shielded

Metal Arc Welded (SMAW) to form a steam tight joint using the welding procedure listed in the attached welding procedure document for boilers and pressure vessels. Once formed, the flat surfaces shall be “stayed” together using threaded steel stay bolts. This keeps the unsupported flat surfaces from pushing apart. This project does not require the application of the stay bolts.

However, if cross holes are necessary for the manufacturing process, undersize holes can be drilled in the locations where a stay bolt would otherwise be applied.

Part II: Work Requirements

Syphon Manufacture

New syphons for the Boston and Maine #3713 shall be produced following copies of the original

Lima Locomotive Works boiler drawings, Locomotive Firebox Company Drawings, a patent document containing information on syphon fabrication using a press brake, and for reference, the original syphons that were removed from the firebox. The work shall satisfy ASME standards for boiler and pressure vessel welding. The contractor shall provide all equipment, materials, correspondence, supplies, staging, labor, travel (except as otherwise specified in the

Contract) to construct 3 (three) new thermic syphons for the Boston and Maine #3713.

Tasks:

• Contractor shall fabricate new syphons following the copies of the original drawings, patent documents, and original syphons (for reference)

• Contractor shall determine perimeter shape of syphons based on drawings, original syphons, and bending allowances.

• Contractor shall provide all material certification and traceability documents for all materials used in the manufacture of the syphons.

• Contractor shall provide x-ray examination of all unsupported welded joints and forward original films to Steamtown NHS.

Applicable Documents:

• Contractor shall obtain copy of ASME part PW “Requirement for Boilers Fabricated By

Welding”.

• Contractor shall obtain a copy of ASME part PG “General Requirements for All Methods of Manufacture”.

• Contractor shall obtain a copy of ASME part PL “Locomotive Boilers”

• Contractor shall supply Boiler Welding Procedure that meets or exceeds ASME standards for boiler pressure vessel welding

Part III: Supporting Information

Place of performance: Contractors facility

Contractor Shall:

• Have six (6) months after contract award to complete the project.

• Supply progress reports including photos and dialog of work being performed.

• Expect at least 2 on site visits by Steamtown NHS representatives during the period of performance for quality assurance purposes.

• The Contractor shall notify the Contracting Officer’s Representative 5 business days prior to the proposed Government Acceptance inspection date. The contractor, lead technician (if applicable) and the Contracting Officer’s Representative shall be in attendance during all acceptance inspections

Steamtown NHS will:

• Ship original syphons to contractor’s facility after award.

• Provide special dies for forming arch brick support seat if required.

Final payment will not be made until completed syphons are inspected (along with x-ray films) and accepted by a qualified Steamtown NHS representative.

A site visit to Steamtown NHS is recommended to assess, evaluate, and estimate the scope of work and complexity of this project. Contractor shall be responsible to verify all field measurements for the amounts, size, and quantities of materials and tools required to complete the project.

Part IV: Warranty

Contractor shall guarantee all workmanship for a minimum period of one year from date of final acceptance.

All defective material and workmanship disclosed as the result of the acceptance inspection given herein shall be corrected at no cost to the Government. After all deficiencies have been corrected, a Letter of Acceptance will be issued. If only designated portions have been inspected, a letter of partial acceptance will be issued for that portion of the work. However, payment will be withheld until a Letter of Acceptance is issued.

Part V: Delivery

Contractor shall be responsible for delivery of the new and original syphons to Scranton.

Steamtown National Historic Site.

150 South Washington Ave.

Scranton, PA 18503

Locomotive Shop

Part VI: Instructions to Offerors

Contractor shall break down price quote and submit for requirements as follows:

1. 3 (three) syphons complete

2. Shipping to Steamtown NHS

Successful offeror must register in the System for Award Management database https://www.sam.gov/portal/SAM/# prior to award.

https://www.sam.gov/portal/SAM/

Part VII. Submittals: Submittals and Approval Procedures

• All submittals shall be transmitted using National Park Service DCC-1(CS), dated 11/95.

o No action will be taken on a submittal item unless accompanied by the transmittal form

(included at the end of this section).

• All submittals that pertain to products to be installed by the Contractor should go directly to the

Contracting Officers Technical Representative. (Bruce Mowbray) of Steamtown, National

Historic Site, for review.

• Contractor shall submit enough copies for his/her needs plus three copies to Steamtown National

Historic Site.

• Contractor shall forward submittals at least 30 working days before need of approval.

• Approved Equals; for each item proposed as an “approved equal,” submit supporting data, including:

o Drawings and samples as appropriate.

o Comparison of the characteristics of the proposed item with that specified.

o Changes required in other elements of the work because of the substitution.

o Name, address, and telephone number of vendor.

o Manufacture’s literature regarding installation, operation, and maintenance, including schematics for electrical systems, and parts lists.

o Describe availability of maintenance service, and state source of replacement materials.

• A request for approval constitutes a representation that Contractor:

o Has investigated the proposed item and determined that it is equal or superior in all respects to that specified.

o Will provide the same warranties for the proposed item as for the item specified.

o Has determined that the proposed item is compatible with interfacing items.

o Will coordinate the instillation of an approved item and make changes required in other elements of the work because of the substitution.

o Waives all claims for additional expenses that may be incurred as a result of the substitution.

• Coordinate all submittals and review them for legibility, accuracy, completeness, and compliance with contract requirements.

o Forward submittals that are related to or affect one another as a package to facilitate coordinated review.

o Each transmittal shall contain data specific to that individual submittal

• Submittal Identification:

o Contractor Officer will provide a project identification stamp which shall be applied by the Contractor. Identification shall include the park package number, project title, contract number, and transmittal number.

o All sets of shop drawings, manufacture’s catalog sheets, samples, and other documents submitted to the Contracting Officer must have the identification information stamped on the submittal.

o Identification information shall be applied to the bottom right margin on each page.

o Identification information on samples shall be applied to the most readily visible area on the sample or on tags attached to the sample.

• Submittal Numbering:

o Number each submittal consecutively.

o For re-submittals use the original submittal number, plus a letter suffix beginning with A.

o Additional re-submittals of the same item shall contain the original number with the next consecutive letter.

• Contracting Officer’s Review:

o Submittals will be returned disapproved without technical review if identification information is missing, not filled in, or if placed on back of submittal; an incorrect number or format of submittals is provided; the transmittal form is incorrectly filled out; submittals are not coordinated; or do not show evidence of Contractor’s approval.

TRANSMITTAL - NATIONAL PARK SERVICE

Transmittal No.:

Sheet: 1 of:

Park:

Project:

Contract No.:

Pkg. No.:

Date:

Contractor:

Subcontractor/Supplier:

NPS ACTION

Specification

Section No.

Description of Item

(Size, Type, Name, Manufacturer, Use, Etc.)

Contractor Signature

Recommended by

Title, Date

Title

Date I hereby certify that this submittal has been reviewed for accuracy, completeness, and compliance with contract requirements (FAR 52.236-21)

Review Comments

Action By

Date

Contracting Officer’s Representative

Approval of this submittal is subject to the provisions of the contract drawings and specifications. This action is for general concurrence only and the Government is not responsible for errors or omission.

SUBMITTAL LOG DATES: From contractor [__________], To reviewer [__________], From reviewer [__________], To Contractor [__________]

Distribution: ( ) Contractor ( ) DSC File ( ) COR ( ) A/E ( ) DSC Interim ( ) COR Interim ( ) Contractor Interim CM-16Rev. 4/00 (Formerly DSC-

1(CS)

TRANSMITTAL CONTINUATION - NATIONAL PARK SERVICE

Transmittal No.:

Sheet: 1 of:

Park:

Project:

Contract No.:

Pkg. No.:

Date:

Contractor:

Subcontractor/Supplier:

NPS ACTION

Specification

Section No.

Description of Item

(Size, Type, Name, Manufacturer, Use, Etc.)

Review Comments

CM-16 Rev. 4/00 (Formerly DSC-1(CS)

Points of contact:

Contracting officer:

Email:

Contracting Officers Representative:

Bruce Mowbray

Preservation Specialist for National Park Service

Steamtown National Historic Site

150 south Washington Ave

Scranton, PA 18503

Phone: (570) 650-1316

Fax: (570) 340-5310

Email: Bruce_Mowbray@nps.gov mailto:Bruce_Mowbray@nps.gov

ATTACHMENTS:

Photos of original syphons

Copy of Lima Locomotive Works drawings

Copies of Locomotive Firebox Company Patent drawings

Copy of syphon patent document showing the making of syphons