Attachment 1 - Statement of Work - DDSP Boiler Repairs.pdf

Statement of Work: Boiler Repair, Obstruction Clearing, and Calibration

1. Introduction This Statement of Work (SOW) outlines the requirements for boiler repairs, obstruction clearing, and control calibration at The Defense Logistics Agency at Susquehanna. The work is divided into three (3) Contract Line-Item Numbers (CLINs).

CLIN 0001: Replacement of one (1) ruptured waterwall tube, one (1) previously repaired tube adjacent to the ruptured tube, and associated membrane sections within Nebraska Boiler C8 (NB#4529, Boiler #2).

Nebraska, model number: NS-E-64-250, serial number: CP-4088 CLIN 0002: Clearing of obstructions from the boiler header and associated tubes of Boiler #2.

Nebraska, model number: NS-E-64-250, serial number: CP-4088

CLIN 0003: Calibration of the boiler controls for all three (3) boilers.

The contractor shall provide all labor, materials, equipment, and supervision necessary to safely and effectively complete all CLINs as detailed below.

2. Scope of Work

CLIN 0001: Ruptured and Adjacent Waterwall Tube Replacement - Boiler #2 The Contractor shall perform the following tasks to replace the ruptured tube section and the previously repaired adjacent tube section in Boiler #2.

2.1. Site Assessment and Preparation:

2.1.1. Conduct a pre-job site visit to visually inspect the damaged tube, the previously repaired adjacent tube, and the surrounding area.

2.1.2. Verify the exact location of the rupture and the adjacent tube requiring replacement.

2.1.3. Identify and document any obstructions or access challenges.

2.1.4. Review and adhere to all plant safety regulations, including LOTO procedures and confined space entry requirements.

2.1.5. Coordinate with boiler plant operators to ensure the boiler is properly shut down, cooled, and isolated.

2.1.6. Prepare the work area by erecting scaffolding, removing insulation as needed, and establishing proper ventilation.

2.2. Removal of Tubes and Membrane:

2.2.1. Precisely measure and document the dimensions of the existing tube sections to be replaced.

2.2.2. Carefully cut and remove the damaged section of the waterwall tube, the previously repaired adjacent tube, and the connecting membrane.

2.2.3. Grind and prepare the existing tube ends for welding to ensure a clean, beveled surface.

2.2.4. Properly dispose of the removed tubes and membrane sections per regulations.

2.3. Fabrication and Installation of Replacement Tubes and Membrane:

2.3.1. Fabricate replacement tubes and membrane sections matching the original specifications and meeting ASME Boiler and Pressure Vessel Code requirements.

2.3.2. Position and weld the replacement components into place using qualified welders and approved procedures.

2.3.3. Perform visual inspection of all welds.

2.4. Post-Weld Treatment and Inspection:

2.4.1. Perform post-weld heat treatment (PWHT) on the welded joints, if required.

2.4.2. Provide all Non-Destructive Examination (NDE) reports to the plant for review and approval.

2.5. Hydrostatic Testing:

2.5.1. Coordinate with plant operators to hydrostatically test the repairs at the required pressure for a minimum of 30 minutes.

2.5.2. If leaks are detected, repair the welds and re-perform the test until no leaks are present.

2.5.3. Document the final hydrostatic test results.

2.6. Cleanup and Demobilization:

2.6.1. Remove all scaffolding, tools, and debris from the work area and restore any removed insulation.

2.6.2. Demobilize from the site upon completion of CLIN 0001 work.

CLIN 0002: Obstruction Clearing - Boiler #2 The Contractor shall inspect and clear the boiler header and associated tubes of Boiler #2 to ensure there are no blockages.

2.7. Inspection and Clearing:

2.7.1. Conduct a borescope inspection of the boiler header and accessible tubes to identify any obstructions, scale, or debris.

2.7.2. If obstructions are found, remove them using approved mechanical methods (e.g., brushing, snaking) or a localized chemical flush.

2.7.3. All chemical usage must be pre-approved by the plant and handled in accordance with environmental regulations.

2.7.4. Perform a post-cleaning inspection to verify that all obstructions have been cleared.

2.7.5. Document the findings of the inspection and the methods used for clearing.

CLIN 0003: Boiler Controls Calibration The Contractor shall inspect, test, and calibrate the primary control and safety devices for all three (3) boilers.

2.8. Control System Calibration:

2.8.1. Inspect all primary boiler control and safety devices, including but not limited to, pressure sensors, temperature sensors, level switches, fuel-air ratio controllers, and flame scanners.

2.8.2. Calibrate all analog and digital control instruments against certified, traceable standards.

2.8.3. Verify and document the operational setpoints and trip points of all safety interlocks, including low-water cutoff, high-pressure limit, and high/low gas pressure switches.

2.8.4. Perform functional tests to ensure the control system responds correctly to simulated plant conditions and that the boiler executes a safe shutdown upon a trip condition.

2.8.5. Document all "as-found" and "as-left" calibration data for each device.

2.8.6. Provide a final calibration certificate for each boiler upon completion.

3. Materials The Contractor shall provide all materials necessary to complete the work for all CLINs, including but not limited to:

Replacement tubes and membrane sections (SA-192 Carbon Steel, A36 Carbon Steel, or equivalent)

Welding consumables, grinding wheels, and cutting discs Scaffolding and insulation materials Hydrostatic testing equipment and PPE Borescope or other inspection equipment Certified calibration instruments and testing equipment for boiler controls

4. Personnel Qualifications The Contractor shall employ qualified personnel for all tasks, including:

Certified welders with experience in boiler tubes.

Supervisors with experience in boiler repair.

Certified instrumentation and control technicians with experience in boiler control systems.

5. Safety The Contractor shall be responsible for ensuring the safety of all personnel and shall comply with all applicable OSHA regulations and plant safety procedures. A pre-job safety briefing shall be conducted for all work.

6. Schedule The Contractor shall complete all work within 60 days of receiving a purchase order and shall provide a detailed schedule of activities for all three CLINs.

7. Deliverables The Contractor shall provide the following deliverables:

Detailed schedule of activities Material certifications Welding Procedure Specifications (WPS) and welder qualification records NDE reports Hydrostatic test report for CLIN 0001 Inspection and obstruction clearing report for CLIN 0002 Boiler controls calibration report with "as-found" and "as-left" data for CLIN 0003

8. Warranty The Contractor shall warrant all workmanship and materials for a period of 1 year from the date of completion.

9. Owner Furnished Information/Assistance

9.1. Plant operators will assist with the testing of all repairs and controls.

9.2. Plant operators will assist with filling and draining the boiler for hydro testing.

9.3. The plant will provide potable water for hydro testing and flushing.