Attachment 0001 - Statement of Work.pdf

Service Contract DeGray Lake Dam Intake Tower Bulkheads

Non-Destructive Weld Testing

SCOPE OF WORK

August 31st, 2021

Scope of Work DeGray Lake Dam, Intake Tower - Bulkheads

Table of Contents

1 General

1.0 Background

1.1 Overview of Requirements

1.2 Dates of Work

1.3 Location

2 SUBMITTALS

2.1 Bid Submittal,

2.2 Required Security Training (see section 8, NLT 14 days after award)

2.3 Work Plan,

2.4 Job Hazard Analysis:

2.5 Raw electronic data:

2.6 Final Report:

3 SAFETY AND ACCESS

3.1 Safety

3.2 Access

3.3 Job Hazard Analysis (JHA)

4 DETAILED INSPECTION REQUIREMENTS

4.1 Operator Certification and Minimum Experience

4.2 Equipment

4.3 UT examination with Alternative Techniques

4.4 Testing

4.5 Testing Plan

Scan Plan

Calibration Plan

Data Collection Plan

4.6 Field Testing Plan

4.7 Evaluation Plan

4.8 Data Evaluation

4.9 Data Quality

4.10 Reporting

4.11 Oversight

5 Equipment, Procedure, and Technician Validation for UT

6 USACE Technical Points of Contact:

7 References:

8 ANTITERRORISM/OPERATIONS SECURITY REQUIREMENTS

8.1 AT Level 1 Training:

8.2 Access and General Protection/Security Policy and Procedures:

8.3 Access to DOD facility or installation:

8.4 Suspicious Activity Reporting Training (iWATCH):

8.5 Escort in areas with classified/sensitive areas:

8.6 Pre-screen candidates using E-Verify Program:

Attachment #1 – Project Location & Photos

Attachment #2 - Bulkhead Drawing

Attachment #3 - Blow-up Weld Photos and Identifications

Attachment #4 – Quantity of Welds Requiring Testing

Attachment #5 – Example Data Evaluation Forms

(Phase 1)

(Phase 2) Advanced UT

Attachment #6 – Example -Welded Samples for Validation Testing

Attachment #7 – Example - "Validation Reporting Form”

Attachment #8 – Example -"Validation Test Report”

1 General

1.0 Background

There are (4) bulkheads required for maintenance of components at the DeGray Lake Dam Intake Tower. The bulkheads are classified as fracture critical, meaning failure of 1 weld at any location on the fracture critical component, the skin plate in this case, could cause the entire structure to fail. Prior to any future maintenance activity, the bulkheads must have weld inspection documentation to be certified safe for personnel to work behind. This includes quality verification of critical weld connections to ensure they meet current weld acceptance criteria or are fit for service. See Attachment #1 for project location and photos. A construction drawing of the gate is shown on Attachment #2.

1.1 Overview of Requirements

The goal of this inspection is to inspect and test all tension weld joints identified on Attachment #3. Ultrasonic testing (UT) of the Complete Joint Penetration (CJP) welds and magnetic particle (MT) testing of the fillet welds is required.

Some welds may not meet visual code requirements and the base metals may not comply with AWS D1.5. The MT and UT testing is still required and shall be considered an "engineering directed inspection". The total linear footage of welds is given in Attachment #4.

CJP welds:

Testing of 100% of the CJP welds identified shall be completed without removal of the paint and conducted in two phases:

Phase 1: Use conventional UT to test each weld and evaluate to AWS D1.5, Inspection Clause using UT Acceptance-Rejection Criteria for Tensile Stress (Table 8.4).

Phase 2: Test welds found to be rejectable under Phase 1 to quantify defects using other “advanced” or “alternative” NDT methods and equipment.

Fillet welds:

Magnetic particle testing shall be completed on 100% of the fillet welds identified in accordance with AWS D1.5, Inspection Clause. Paint will be removed prior to inspection.

1.2 Dates of Work

The inspections are required to be completed no later than May 2022. The anticipated inspection start date is October 11th. The exact dates of the inspection is dependent upon when removal of the paint along the fillet welds is completed. Contractor will be given a minimum of 14 days advanced notice of the required inspection date. This will be coordinated with the USACE technical POC. Workdays may consist of up to (10) hour work days, on site, maximum.

1.3 Location

DeGray Lake Dam Intake Tower, Clark County, Arkansas

GPS Coordinates:

Longitude: 93°06'38.05"W Latitude: 34°12'51.91"N

2 SUBMITTALS

Deliver all submittals by email in pdf format.

2.1 Bid Submittal, Include the below items with bid/proposal. Any bids not including all items may not be accepted.

1. Cost quote:

A. Base Contract (inspection of identified welds)

B. Hourly rates (in case additional welds are identified in the field requiring inspection.)

2. Statement of understanding of the specified work.

3. Names of potential technicians to be assigned to the specified work.

4. Technician resumes and work history on jobs with similar complexity and equipment.

5. ASNT CP-189 Certifications for Technicians

2.2 Required Security Training (see section 8, NLT 14 days after award)

1. AT Level 1 Training (within 14 days)

2. iWATCH Training (within 14 days)

2.3 Work Plan, Within 10 business days after the notice to proceed (NTP) provide:

1. Equipment to be used for this project.

2. How the equipment will be used to accomplish the testing and evaluation.

3. Testing plan (including scan, calibration, and data collection plans).

4. Field Testing Plan

2.4 Job Hazard Analysis:

No less than seven (7) days prior to the inspection provide a preliminary job hazard analysis, see paragraph “Job Hazard Analysis”. Updates may be required in the field. Provide the final signed JHA as an appendix to the final report.

2.5 Raw electronic data:

Submit all raw electronic data for each joint tested under Phase 2, in an organized manner, specific to each gate, with an identifier that matches indications noted in the report, and in the order that the inspections occurred.

2.6 Final Report:

Create an individual report specific to each bulkhead that was tested. The report should describe all procedures and processes used to conduct testing, evaluate results, and summarize the results for both Phases. Include all test results in accordance with the evaluation plan. Each report shall be specific to the bulkhead that was tested, and clearly identify deficiency geographic locations on the gate.

Submit the final report within five (5) business days after the inspection is completed. The government will have five (5) business days to review the final report and provide comments. The contractor will have five (5) business days to respond to all comments and resubmit.

3 SAFETY AND ACCESS

3.1 Safety

All work activity and equipment used by the contractor must meet or exceed OSHA and ANSI requirements, and be in accordance with the Corps of Engineers Manual EM 385-1-1, entitled Safety and Health Requirements Manual, dated 30 November 2014.

3.2 Access

The bulkheads are stored in slots where they hang beneath the operating platform. Multi-level scaffolding will be setup in place prior to the inspection. Only two sets of scaffolding will be available at any one time, or rather only 2 gates can be inspected simultaneously. Fall protection will be required when working on the scaffolding. The contractor is responsible for providing their own fall protection harness and lanyard meeting EM 385-1-1 for each personnel on site.

3.3 Job Hazard Analysis (JHA)

The Contractor shall coordinate with the USACE technical POC to develop and provide the JHA and host a pre-work safety briefing before inspection work commences. A preliminary JHA shall be developed to the extent possible with information available prior to the inspection and shall be submitted to the USACE as a draft no less than seven (7) days prior to the inspection. The JHA shall be completed on site by the Contractor with USACE and facility POC input, reviewed and signed by all applicable parties at the pre-work safety briefing prior to the inspection. Prior to conducting any inspection work before each shift, the

Contractor shall hold documented safety meetings and provide Job Hazard Analysis forms.

4 DETAILED INSPECTION REQUIREMENTS

4.1 Operator Certification and Minimum Experience

Provide only certified equipment operators. Operators should be certified in accordance with ASNT CP-189 and have a minimum of two (2) years of experience in flaw sizing with the equipment, or similar equipment being used.

Provide resumes for each operator to include a copy of certificate and history of testing experience using the equipment, or similar, to be used on the job.

4.2 Equipment

1. Conventional MT for evaluating the fillet welds.

2. UT equipment for evaluating CJP welds under Phase 1 testing.

3. Any equipment deemed necessary for “advanced or alternative” Phase 2 testing to accurately quantify defects (in 3-dimensions) including conventional UT, Phased Array Ultrasonic Testing (PAUT) Advanced PAUT capable of Full Matrix Capture (FMC)/Total Focus Method (TFM), or Time of Flight Diffraction (TOFD) or a combination of these methods.

Hardware must be capable of displaying data at the same rate as it is captured and of storing the full data set unprocessed for future evaluation.

Software must be capable of capturing results electronically, accurately characterizing, quantifying, and locating all defects. For Phase 2 testing, characterize discontinuities in terms of type: cracks, planer, or volumetric;

also, ensure flaws are detailed in 3 dimensions: length, depth, and width.

The raw electronic data file for each joint tested shall be submitted along with the final report, specific for each gate.

The Work Plan and Final Report shall include a description of the type of equipment.

4.3 UT examination with Alternative Techniques

For Alternative UT techniques, the use of AWS D1.1, Annex O, “UT Examination of Welds by Alternative Techniques” is mandatory unless otherwise noted herein. This is needed to obtain the required accuracy in discontinuity sizes. This requires the procedure to be validated or proven and documented. All (15) items listed in part 3 of Annex O must be documented. Only section O11, section O12, and Table 1 are not applicable since the acceptance and rejection criteria are already given in this scope of work.

4.4 Testing

Provide testing services, including all equipment and operators to conduct testing on all welds identified in Attachment #3 and others that may be identified in the field.

Record the test data obtained and evaluate the data to the acceptance criteria listed in Phase 1. Where acceptance criteria are not met, proceed to Phase 2, characterize and quantify (length, depth, and width) any embedded or surface discontinuities. The testing must be capable of detecting typical discontinuities encountered in welded steel members to include cracks, lack of fusion, lack of penetration, slag inclusions, and porosity. Develop a Testing Plan that ensures full coverage of the weld metal, heat affected zone (HAZ), and adjacent base metal for each connection tested. Calibrate all equipment, in accordance with the testing plan, prior to each day of testing, at a minimum.

4.5 Testing Plan

The testing plan consists of a scan plan, a calibration plan, and a data collection plan. Each of these are essential in achieving accurate data collection and evaluation. Develop a testing plan for each connection to be tested. Note that a base plan with minor modifications for each connection may suffice.

Scan Plan Describe in detail how all areas within the member, weld metal, heat affected zone, and adjacent base metal, will be covered with ultrasound signals and what procedures will be used to ensure these signals are adequate in detecting any discontinuities that may reside within the connection. Plan shall require rastering, multiline offset, and scanning each joint from all four (4) sides. Expect uneven surfaces (due to weld reinforcement or other causes) and include in the procedures how to compensate for uneven surfaces (e.g., Adaptive TFM). Include all parameters that will be used to ensure accurate detection of discontinuities including ranges of probe arrays, aperture sizes, frequencies, and probe configurations (Pulse Echo, Pitch - Catch, or other), scan speeds, and sampling rates. Explain how focal laws, focal length, near field depths, beam spread, attenuation, dead zones, noise, and other ultrasonic testing parameters can impact accuracy of detection and how the procedures will account for these parameters to ensure accurate detection.

Calibration Plan Describe in detail how calibration of the equipment will be accomplished and when the equipment will be calibrated. At a minimum, equipment will be calibrated daily. Calibration material must have equivalent sound characteristics of the material being tested. Reflectors should be located within the calibration block at locations where typical discontinuities in the connections to be tested would be expected. Include calibration procedures for painted members.

Fabrication of a calibration block or use of a side drill hole at a location on the actual gate will be required for calibration. If a calibration block is utilized by the contractor, it shall be from metal with equivalent sound characteristics and equivalent paint system (vinyl). An ample quantity of similar vinyl (5-EZ) paint can be provided by the government, if desired.

Note existing gate material is ASTM A36. If a side drill hole on the gate is desired, the engineer will designate an acceptable location. The government will drill a 1/16” diameter hole in the flange edge at the approved location, using an assembly to ensure the hole is square, as desired, in 2 planes.

Data Collection Plan Describe in detail how data will be collected and how data quality will be assured throughout the testing. Include procedures and equipment to monitor data collection as it is captured and how data will be stored for future evaluation. Describe how the data will be protected from corruption, loss, or other maladies, including data backup or redundancy of data collection. Indicate how locations of all discontinuity indications will be tracked in three dimensions (encoding or other methods). Define the sampling size or resolution and explain why this is sufficient.

Data must provide the length, height, and depth. Use a permanent reference point on the member. For example, use specific edge and centerline to locate the beginning of the discontinuity. Note that for evaluation purposes, location and extents of a discontinuity or groups of discontinuities, are essential.

4.6 Field Testing Plan

Develop this to show how field testing will be implemented in the field for the Testing Plan. Include sequence of testing and how connections will be accessed. Describe how the Testing Plan will be validated during testing to identify any needed adjustments and describe the process for making those adjustments.

4.7 Evaluation Plan

Evaluation for this work means accurately characterizing, quantifying, and locating discontinuities. The resolution of the data collected should be the maximum allowed while achieving efficiency in data collection and processing.

The accuracy of the data collected holds precedence over the speed of data collection and processing. Describe the procedures that will be used to evaluate all detected discontinuities. Verify adequate resolution is captured when following the testing procedures proposed. Define a threshold limit where indications are not of sufficient magnitude to warrant detection, when interpretation of the results provides meaningless data. Identify evaluation software and describe how it will be used for evaluation.

4.8 Data Evaluation

Data evaluation consists of validating the quality of data collected and evaluating the testing results as described in requirement Testing Plan.

Evaluate all data collected and report discontinuity type, size, and location in a table similar to one shown in Attachment #5A for (Phase 1). When Phase 2 testing is required more detail is required to identify the location along the member and size of the discontinuity in “3-dimensions” so that evaluation can be made to determine if the member is fit for service, per a structural analysis.

4.9 Data Quality

The contractor is responsible for obtaining quality data for each joint tested. The contractor will ensure data is of sufficient quality before leaving the test site or will return to collect additional data. Sufficient quality is defined as sufficient to identify embedded discontinuities within a reasonable degree of accuracy.

4.10 Reporting

Create a report that describes all procedures and processes used to conduct testing and evaluate results. Include all test results in accordance with the evaluation plan. Each report shall be specific to the bulkhead that was tested and shall include a photograph of any joints with defects not meeting the acceptance criteria. The photograph shall capture the joint number and location of the defect. Also, the geographic locations and sizes of discontinuities on the gate shall be clearly reported.

4.11 Oversight

The Government will maintain oversight of all inspection and evaluation activities. This means Government personnel will be present during these activities and will have the option to witness all inspection procedures and evaluation processes as they occur. The contractor will accommodate Government personnel to facilitate witnessing.

5 Equipment, Procedure, and Technician Validation for UT The validation and adequacy of testing equipment, procedures, and technician shall be verified by testing samples with welded connections similar to that shown in Attachment #6 with included discontinuities. Validation is required to be performed at the project site on the first day, prior to the start of work. This validation is similar to the AWS D1.8, Annex F Technician Qualification; however, it has been modified to fit the requirements of this work. There will be up to 7 samples and a minimum of 20 discontinuities. The location, types, and sizes of the discontinuities have been confirmed by independent sources with specialized experience in flaw sizing and construction. The validation will be used to screen out technicians who perform unacceptably per the evaluation criteria outlined in this SOW. The contractor may provide multiple technicians to ensure that at least one technician can demonstrate use of equipment, ability to follow the written procedure, and size the flaws within required tolerances. The testing shall be performed independently by technicians and open discussion of the flaws in various samples between technicians is not allowed.

Validation will be based on sizing accuracy and will be witnessed and confirmed by the government’s representative, engineer, and the values will be checked by a second government representative for accuracy. The validation will be based on these tolerances:

Tolerances Length (in) 0.8 between -0.4

Depth (in) 0.25 between -0.25

Reported length values for flaws greater than 1/2" long must overlap along the actual length of the flaw to be considered a “detected flaw”. Flaws less than or equal to 1/2" long must have a start/stop location within 1/2" of the actual start/stop locations. If any one variable is outside of the required tolerances that flaw is considered not detected. If a flaw does not exist but is reported this shall be considered a false indication, F.

The rate of flaws detected, D, is equal to # of detected flaws / total flaws. The rate of false indications, F, is equal to # of false indications / total flaws. The UT technician rating, R, is equal to ½ (1+D-F) *100. To be validated the following must all be achieved:

1. An overall rating R of 80% or higher

2. A detection rating D of 70% or higher

3. A false indication rating F of 15% or less

In Attachment #7 there is an example “Validation Reporting Form” that each technician will need to independently fill out for each sample tested during the validation testing process. To avoid confusion the technician shall clearly designate which faces the measurements were taken from. Additional, pages will be provided for each sample with dimensions of the plate and joint configuration. After the completed validation reporting forms are provided to the engineer, validation test results will be provided to the technicians on the same day by the close of business.

It is expected that the validation test will take between 4 and up to 6 hours to be completed, but no longer than 9 hours.

In Attachment #8 there is a “Validation Test Report” with hypothetical data and calculations provided for example. Information regarding the exact discontinuity sizes and locations in the test specimens will remain confidential since the samples may be used again for later validation tests. Therefore, the flaw sizes will be omitted or greyed out on the final “Validation Test Report”, and the report will not look the same, since thisthe confidential information will be omitted.

6 USACE Technical Points of Contact:

Primary: Ronnie Morrow, Ronnie.L.Morrow@usace.army.mil Phone: (Office) 601-631-5575 (Cell) 601-629-8075

Alternate: Jack Hinton Jack.Hinton@usace.army.mil Phone: (Office) 601-631-5923 (Cell) 601-529-5271

7 References:

1. AASHTO/AWS D1.5 Bridge Welding Code, 2020.

2. AASHTO/AWS D1.1 Structural Welding Code, 2020.

3. AWS D1.8 Structural Welding Code - Seismic Supplement, 2016.

4. EM 385-1-1, Safety And Health Requirements, 2014.

8 ANTITERRORISM/OPERATIONS SECURITY REQUIREMENTS

8.1 AT Level 1 Training:

All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, controlled access areas, or require network access, shall complete AT Level I awareness training within 14 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. Upon request, the contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the, COR or to the contracting officer (if a COR is not assigned), within 5 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website:

http://jko.jten.mil/courses/atl1/launch.html; or it can be provided by the RA ATO in presentation form which will be documented via memorandum.

8.2 Access and General Protection/Security Policy and Procedures:

All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative).

The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office.

Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

8.3 Access to DOD facility or installation:

Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

8.4 Suspicious Activity Reporting Training (iWATCH):

The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 14 calendar days of contract award and within 3 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

8.5 Escort in areas with classified/sensitive areas:

Contractor will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas. The contractor will coordinate with the COR and/or the facility security office for access when required. (Use when security clearances are not required, i.e. facility repair or construction). Proposed language: "All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas."

8.6 Pre-screen candidates using E-Verify Program:

The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than 3 business days after the initial contract award.

----End of Scope---

Scope Attachments Included:

1. Project Location and Photo(s)

2. Bulkhead Drawing

3. Blow-up Weld Identification Views

4. Quantity of Welds Requiring Testing

5. Example - Data Evaluation Forms

6. Example – Welded Samples for Validation Testing

7. Example - Validation Reporting Form

8. Example - Validation Test Report

Attachment #1 – Project Location & Photos

Mailing Address: GPS Coordinates:

DeGray Lake Dam Longitude: 93°06'38.05"W 848 Channel Road Latitude: 34°12'51.91"N Arkadelphia, AR 71923

Photo 1: Bulkhead Overview (Tension Side)

Photo 2: Bulkhead Overview (Compression Side)

Attachment #2 - Bulkhead Drawing

Weld Identification Drawing

Attachment #3 - Blow-up Weld Photos and Identifications

Welds on Skin Plate, Downstream Side, Picture #1

Close-up of Splice Welds, Detail - #1

Welds on Top of Gate Picture #2

Welds on Upstream Side, Picture #3

Weld at Bottom of Gate, Top Face, Picture #4

Weld at Bottom of Gate, Bottom Face, Picture #5

Blow up views of Welds -Identification - #1

Attachment #4 – Quantity of Welds Requiring Testing

Weld Length, Size and Type

Fillet Length, ft CJP Length, ft

1A Fillet weld around lifting plates on top of gates. 1/4" Fillet all around.

5.6 ‐

1B

Weld of vertical lifting plate/stiffeners, below the top web.

Attached drawings do not show this weld being in place; but it is a

1/4" fillet weld.

18.0

Weld of horizontal plates (web of beams) to skin plate. Fillet welds are 1/4" and 5/16".

450.0 ‐

Fillet weld of vertical stiffener plate to skin plate above and below splice location. Weld size 1/4"

17.0 ‐

Fillet weld of middle vertical stiffener along centerline of bulkhead.

Weld size 5/16".

47.0 ‐

5A & 5B Fillet weld around release valve. 2.0 ‐

6 Horizontal splice welds in skin plate (3 ea gate). ‐ 67.5

7A Weld of top horizontal web plate to skin plate at the top of gate.

Weld size is a 1/4" fillet weld.

22.5

7B Weld of top horizontal web plate to skin plate at the top of gate.

Weld size is a 5/16" fillet weld.

22.5

8A Weld of bottom horizontal web plate to skin plate at the bottom of gate. Top weld is a 5/16" fillet weld. Bottom weld is a flush bevel.

22.5

8B Weld of bottom horizontal web plate to skin plate at the bottom of gate. Top weld is a 5/16" fillet weld. Bottom weld is a flush bevel.

22.5

630 68

TOTAL QUANTITY FOR ALL 4 GATES

Weld No.

Total Length of Welds for each gate:

Length of Welds

*Note: "A" is used to denote exterior welds and "B" is used to denote welds on the interior bays.

Location of Weld

2518 270

Attachment #5 – Example Data Evaluation Forms

Example Data Evaluation Form (Phase 1)

Example Data Evaluation Form- (Phase 2) Advanced UT

Attachment #6 – Example -Welded Samples for Validation Testing

Example Sample No. 1

Example Sample No. 2

Attachment #7 – Example - "Validation Reporting Form”

See section 5 for discussion of Equipment, Procedure, and Technician Validation Requirements

Example - Validation Reporting Form:

(to be submitted by each technician during validation testing, 1 for each sample, copies to be provided to technician by the government for the validation)

Attachment #8 – Example - "Validation Test Report”

See section 5 for discussion of Equipment, Procedure, and Technician Validation Requirements