Attachment 1. Statement of Work.pdf

Statement of Work (SOW)

Project: Bldg. 154 - Boiler #3 Refractory Repair

GENERAL INFORMATION

1.0 Scope of Work: The requirement is for boiler #3 firebox refractory, mud drum refractory and repair of the firebox manway. The new refractory must match the existing dimensions once the work has been completed. The dimensions must not change to remain in compliance with our air quality permit from the Iowa Department of Natural Resources. Asbestos abatement is necessary. As such, asbestos testing was performed (see attachment). The mud drum access opening on both ends of Boiler #3 are approximately 16” diameter manway opening with an inside cavity of 28” diameter (inside) and tapering from 12” depth on the outside to 6” in the center in depth. The friable material on both ends of the mud drum needs appropriate abatement and encapsulation. An option for reinsulating with ceramic blanket insulation is included.

2.0 Background: The United State Department of Agriculture, USDA, Agriculture Research Service, ARS, located in Ames, Iowa has a requirement for boiler #3 to repair the firebox refractory inside the firebox to include front burner wall, rear target wall, two view port locations, mud drum connection manway repair and any other necessary repairs.

CONTRACTOR REQUIREMENTS

3.0 Technical Requirements/Tasks:

BASE:

The manway access opening into the fire box at the rear of the boiler is approximately 15”W X 19”H with an 18”W X 22”H cover fastened by eighteen ½” studs. The firebox manway frame has warped and bowed inward restricting access.

The metal frame that holds the access plate in place needs to be repaired including the ½” studs.

The mud drum access is approximately 16” diameter on both ends with a 20” diameter covers fastened by twelve ½” studs equally spaced. The mud drum access areas on the outside of the boiler need the loose refractory that contains friable asbestos that needs to be properly abated and sealed with an encapsulant that is rated for up to 500 Degrees F.

Asbestos abatement is necessary. As such, asbestos testing was performed (see attachments). The mud drum access opening on both ends of Boiler #3 has friable material identified and needs appropriate abatement and encapsulation, along with

Iowa DNR notification with a copy provided to USDA. The contractor is responsible for covering any Iowa DNR fees, if required.

The work needs to be completed within 180 days of date of award due to steam requirements on the site. Drawings and photos to support the repair are attached for reference. The 2025 boiler #3 inspection by Tom Hidreth Company is also included for reference. No drawings for the boiler are available. Drawings for the work location, building 154 floor plan, boiler photos, asbestos testing, and specifications are attached.

Access to adjacent Boiler #2 needs to be maintained and Boiler #2 needs to stay in operation during abatement and repairs.

The refractory inside the firebox has loose areas with minor cracks that need the loose material removed and patched. Contractor shall prepare the firebox for refractory removal and installation. This will include the removal and reinstallation of the firebox manway access door, mud drum, and steam drum access openings to complete the repairs. Once the preparation is completed the contractor shall remove the existing loose refractory and temperature resistant insulation transport off site and dispose of it properly. After the refractory and insulation have been removed, the contractor shall check the metal walls for any heat damage and notify COR of any damage. Any damage found shall be repaired as needed by the contractor.

Contractor shall apply new refractory rated for 3000F to the interior of firebox.

Contractor shall complete the installation of the refractory so that it conforms to standards as called out in the specifications attached.

The contractor shall then restore the work area to pre-work conditions.

Contractor shall provide portable toilet facilities and dumpsters as needed to complete the work.

OPTION #1:

Replace insulation in (4) four equally sized manway opening for both ends of the mud drum and steam drum on the boiler with new ceramic blanket insulation that has end plugs that are removable for maintenance. The mud drum access opening on both ends of Boiler #3 are approximately 16” diameter manway opening with an inside cavity of 28” diameter (inside) and tapering from 12” depth on the outside to 6” in the center in depth. The top steam drum openings on both ends of the boiler are the same dimensions as the mud drum. The steam drum accesses have no remaining visible insulation.

4.0 Government Furnished: The Government shall Lock Out Tag Out boiler #3 by isolating all energy sources to boiler #3 including electric, gas, fuel oil, air, steam, steam condensate, feed water and hydraulic energy. Contractor shall Lock Out Tag Out all sources of energy to boiler #3 in addition to the USDA. The Government shall furnish water for cleaning and preparation work, 208V 3 phase 60 Amp.

NEMA 14-60R 3P4W power outlet for welder, two 120V-20 amp receptacles for electrical power.

5.0 Deliverables / Schedule:

Performance Requirements

Required Services

Performance Objective Performance Requirement

Asbestos Abatement Plan

Contractor to submit detailed plan to COR.

Submit a detailed plan for asbestos mitigation and containment including abatement worker certifications to the COR for review at least 10 days prior to starting any on-site project activities.

Asbestos Abatement Notification

Contractor shall notify Iowa DNR prior to starting any abatement.

The contractor is responsible for meeting Iowa DNR Asbestos Notification Of Demolition And Renovation requirements. Provide owner copy of notification at the time submitted.

Asbestos Abatement

Asbestos removal and encapsulation on both mud drum access openings.

Remove loose asbestos containing material inside both ends of the mud drum access manways. Encapsulate stable material and provide air sampling and methods that meet Iowa DNR requirements. Provide copies of documentation to COR.

Asbestos Encapsulant

Contractor to submit with Asbestos Abatement Plan.

Submit product details with the temperature rating of the encapsulant that is a minimum of 500 degrees Fahrenheit.

Welder Certification

Contractor shall submit Welder Certification

Submit Welder Certification that meets the weld positioning required and ASTM Pressure Vessel welding requirements.

Repair of firebox manway

Contractor shall remove damaged metal frame and surrounding metal as required to provide rebuilt a minimum of 15”W X 19”H inside dimension manway.

Verify the new manway is a minimum of 15”W X 19”H inside dimension and the ½” metal studs have been repaired to resecure the cover. The refractory blocks are stacked in place with ceramic insulation plug in place prior to replacing cover and securing with all fasteners.

Removal of existing refractory

Contractor will remove any loose or damaged refractory inside the firebox and the mud drum access outside the boiler.

Old refractory material will be removed from the building and disposed of properly.

Fire box manway access shall be removable fire brick and removable ceramic insulation, covers reinstalled and secured with all fasteners.

Damage to exterior shell

Contractor will check exterior shell of the boiler for heat damage.

Any damage to the exterior shell of the combustion chamber will be reported to the COR. Contractor shall repair the damage via approved methods then repaint with close match high temperature paint.

Refractory material

Contractor will supply material capable of withstanding 3000F

All material specifications will be submitted by Contractor to be approved by COR prior to starting the work to verify temperature requirements are met.

Firebox Dimensions

Contractor will repair firebox of boiler #3 so that it conforms to the present dimensions.

The firebox of boiler #3 dimensions will conform to the existing dimensions so that boiler #3 still meets the standards outlined in our Air Quality Permit from the Iowa Department of Natural Resources.

Safety The contractor is responsible for contractor personnel’s safety and is required to abide by all applicable OSHA, Local State and Federal Safety Laws and regulations.

All required safety equipment, safety glasses and steel toed boots will be donned while on USDA property.

Hard Hat, face shield and dust masks must be added during demolition of existing refractory. Contractor shall submit their safety plan to the COR.

Security The contractor shall provide names of contractor employees to the COR to provide security guards to verify employees requesting access to the site.

Contractor personnel shall sign in and sign out every time they enter and exit the facility. Contractor personnel shall present a valid photo government-issued REAL ID every time they enter the site.

Contractor personnel shall be supplied with an NCAH badge and vehicle badge that must be always displayed while on site. Contractor personnel shall return the NCAH badges every time they leave the secure facility.

6.0 Safety: The contractor is responsible for contractor personnel safety and is required to abide by all applicable OSHA, Local State and Federal safety laws and regulations.

7.0 Travel: The contractor is responsible for all mobilization/demobilization to and from the site.

8.0 Security Requirements: The names of contractor employees will be given to the guard desk to verify employees requesting access to the site. Contractor personnel shall sign in and sign out every time they enter or exit the facility. Contractor personnel shall present a valid photo of the government issued ID every time they enter the site. Contractor personnel shall be supplied with a NCAH badge and vehicle badge that must be always displayed while on site. Contractor personnel shall return the NCAH badges every time they leave the secure facility. Contractor personnel shall always be escorted while within the secure areas of the NCAH facility.

9.0 Place of Performance: The Work is located at the National Center for Animal Health in Ames Iowa. Boiler #3 is located on the ground level of Building 154. The front access into building 154 has a 12’W X 13’H overhead door, rear access near possible laydown area to be coordinated with COR has a set of double doors 5’-10”W X 6’-10” H behind boiler #3.

10.0 Period of Performance: The work shall be completed within 180 days after award of the contract.

11.0 Evaluation Factors: The contractor shall deliver fully repaired firebox. The repaired firebox chamber shall match the original dimensions as required by the IDNR air quality permit. The new refractory repairs shall withstand 3000 F and the internal dimensions of the chamber shall be the same dimensions as the original refractory. The manway opening shall be repaired with a minimum inside dimension of 15”W X 19”H with refractory placed in the opening and cover reinstalled and secured. The refractory shall be encapsulated after asbestos abatement inside both ends of the mud drum access openings.

If Option #1 is accepted the mud drum and steam drum access opening shall be reinsulated with removable and reusable ceramic blanket insulation plugs and the access covers reinstalled and secured.

END