Attachment - 1_Statement of Work.pdf

Area 1-42 Steam Generator Statement of Work March 13, 2025

UNITED STATES AIR FORCE RESEARCH LABORATORY (AFRL)

Statement of Work for

AREA 1-42

STEAM GENERATOR

TABLE OF CONTENTS

1. Introduction

2. Background

3. Reference Documents

4. Scope of Work

4.1. Design and Engineering

4.2. Procurement of Materials, Parts, & Equipment for Fabrication

4.3. Fabrication of Steam Generator at AFRL Staging Area

4.4. Transport and Placement of Steam Generator

4.5. Final Installation of Generator and Periphery Systems, Piping, Insulation, Blowers, and other

Parts and Equipment

4.6. Final Acceptance Testing and Training

5. Technical Requirements

5.1. General Requirements

5.2. Steam Generations Requirements

5.3. Steam Vessel

5.4. Nozzles and Manway

5.5. Water Heating System

5.5.1. Burner Gas Train Supply

5.5.2. Burner

5.5.3. Burner Blower

5.5.4. Fire Tube

5.5.5. Burner Exhaust Stack

5.6. Steam Vessel Support Saddles

5.7. Pressure Relief Valves

5.8. Vessel Insulation

5.9. External Stairs and Maintenance Platforms

5.10. External Piping and Components

5.11. Instrumentation and Controls

5.12. Stamping and Nameplates

5.13. Environmental and Natural Pehoneman Conditions

5.14. Analysis for Lifting and Transport of Steam Generator

6. Staging of Steam Generator at AFRL for Fabrication and Transport to Area 1-42

7. Welding

8. Inspection and Examination

9. Testing in Accordance with ASME B&PVC Section I

10. Cleaning

11. Drawings and Calculations

12. Operations and Maintenance Manual

13. Deliverables

14. Project Plan and Schedule

15. Safety

16. Quality Control

17. Security

18. Hold Points

19. Proposal

20. Other

Appendix 1 – “SOW NEW STEAM GENERATOR INSTALLATION AT AREA 1-42”

ACRONYMS

AFRL AIR FORCE RESEARCH LABORATORY

AI AUTHORIZED INSPECTOR

AISC AMERICAN INSTITUTE OF STEEL CONSTRUCTION

ANSI AMERICAN NATIONAL STANDARDS INSTITUTE

ASCE AMERICAN SOCIETY OF CIVIL ENGINEERS

ASME AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASNT AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING

ASTM AMERICAN SOCIETY OF TESTING AND MATERIALS

AWS AMERICAN WELDING SOCIETY

BEP BOILER EXTERNAL PIPING

B&PVC BOILER AND PRESSURE VESSEL CODE

CMTR CERTIFIED MATERIAL TEST REPORT

FCAW FLUX CORE ARC WELDING

FOB FREE ON BOARD

GMAW GAS METAL ARC WELDING

GTAW GAS TUNGSTEN ARC WELDING

IBC INTERNATIONAL BUILDING CODE

MAWP MAXIUM ALLOWABLE WORKING PRESSURE

NFPA NATIONAL FIRE PROTECTION ASSOCIATION

NOx NITROGEN OXIDES

O&M OPERATIONAL AND MAINTENANCE

OSHA OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

PWHT POST WELD HEAT TREATMENT

PP POWER PIPING

PRV PRESSURE RELIEF VALVE OR PRESSURE REDUCING VALVE

PSV PRESSURE SAFETY VALVE

P&ID PIPING AND INSTRUMENTATION DIAGRAM

PQR PROCEDURE QUALIFICATION RECORDS

ROV REMOTE OPERATED VALVES

SAW SHIELDED ARC WELDING

SMAW SHIELDED METAL ARC WELDING

SOW STATEMENT OF WORK

SS STAINLESS STEEL

WPS WELDING PROCEDURE SPECIFICATION

WQR WELDER QUALIFICATION RECORD

1. INRODUCTION

The United States Air Force Research Laboratory (AFRL), Edwards Air Force Base (AFB), California, requires the design, fabrication, testing, inspection and installation of one (1) new steam generator to be installed at the Area 1-42 Steam Plant.

NOTE: This Statement of Work (SOW) addresses the design, fabrication, transport, testing, installation and related work for one (1) new steam generator.

This SOW is an integral part of a larger project identified in the document

STATEMENT OF WORK NEW STEAM GENERATOR INSTALLATION AT AREA 1-42

which includes the propane system, connecting piping systems to the steam generator and other related work. This SOW will be included for reference. the Contractor shall be required to provide dimensions and plans for interfaces as called out in the rest of the document below in order to facilitate the remainder of the larger project to integrate the Steam Generator.

NOTE: A third and separate SOW has been developed to address concrete and civil work, titled STATEMENT OF WORK FOR CONCRETE AND CIVIL WORK IN SUPPORT OF NEW STEAM GENERATOR INSTALLATION. This SOW is mentioned here for reference and context about the scope of the overall project. The Contractor shall be required to provide dimensions of the Steam Generator as specified in Section 5.2.4 in order to allow concrete and civil work to commence and will be required before delivery, installation, inspection, and acceptance testing can begin.

The steam generator will be used to replace an aging steam generation system in use at AREA 1-42 that includes large spherical saturated steam storage vessels, heat exchangers, process heaters, pumps, supply and return piping and other hardware to generate and provide the required mass quantity of steam at specified pressure and temperature.

NOTE: The Air Force is planning to install a total of three (3) identical steam generators starting with the single generator described herein and the other two (2) steam generators will be installed as part of the overall system in the future. This scope of work includes ONLY the first, single steam generator. The Government has made a good faith effort to update all relative project documents to address the inclusion of ONLY the single steam generator and clearly identify the other two (2) steam generators are intended for installation in the future but are NOT included as part of the current scope of work. Likewise, the Government has endeavored to identify interface points on piping, platforms, conduit and other systems where connections to provide service to the future steam generators will be required. If the Contractor identifies ANY scope, interfaces or other items that are not clear as to the intent of what is to be included in the current scope of work and what is intended future installation, the

Contractor shall bring this to the attention of the Government immediately.

For the purposes of this SOW the term Contractor shall apply to the vendor who will perform the work identified herein. The term Government shall apply to the Contracting Officer, Program Manager, or Government Technical Team.

For any contradiction between this SOW and the documents referenced herein, this SOW shall take precedence.

The anticipated contract type is a firm fixed price contract. The Steam Generator shall be Free on Board, AFRL, Edwards AFB, California.

The intent of this project is for the Contractor to provide the Government one (1) safe, complete, fully functional and operable steam generator to be used to supply saturated steam for the AFRL Area 1-42 Steam Plant as described herein.

As shown on the referenced drawings the Government has assigned tag numbers to the steam generator. This tag number shall be used by the Contractor to reference the steam generator on documents, drawings, records, spare parts and wherever a unique identifying tag number is required.

2. BACKGROUND

The current steam plant is comprised of nine (9) ~19’-0” Inner Diameter (ID) carbon steel spherical vessels used to store heated, saturated water. The system includes a process heater that heats oil, and a shell and tube heat exchanger used to heat water to high temperatures. The heated oil is on the shell side of the exchanger and water on the tube side. Supply and return piping is used to circulate feed water through the system to the storage vessels.

The current system includes three “strings”. Each string includes three large storage vessels, one process heater, one heat exchanger, one circulation pump and associated piping. The overall system is designed so one, two or three strings can be operated in parallel.

The purpose of the described steam plant is to allow high temperature saturated water to continuously flash to high pressure saturated steam. The steam is then used to drive a two-stage ejector system which is connected to several test cells. The first stage ejector is horizontal, followed by a condenser and the second stage vertical ejector which exhausts to the atmosphere. The low pressure generated by the ejectors is used to simulate high altitude atmospheric pressure for testing of rocket motors and other hardware. There are three ejector systems which can be operated simultaneously for maximum vacuum and flow rate for large engines or singularly for reduced flow and pressure for smaller engines. The steam system is designed such that three spheres can operate each ejector system, or all 9 spheres can operate a single ejector system for an extended duration test.

While providing functionality and a reasonably high level of reliability, the current system requires significant and constant maintenance in terms of vessel inspection and repairs, replacement of heat exchanger tube bundles, repairs of heat exchanger shells, inspection and maintenance of the process heaters, inspection, maintenance, repair and replacement of piping systems and components.

The current system was built in ~1966 and has been in periodic use since that time, but as mentioned above has required considerable inspection, repair and at times replacement of major equipment, parts and systems.

Because of the age of the current system and need for on-going maintenance and monitoring, the Air Force is seeking to replace the current system with new large capacity steam generators. Figure 1 indicates an aerial view of the AFRL Area 1- 42 Steam Plant.

FIGURE 1 – AREIAL VIEW OF THE AFRL AREA 1-42 STEAM PLANT

3. REFERENCE DOCUMENTS

REFERENCE DOCUMENTS FOR NEW TEAM GENERATORS AT AREA 1-42

DOCUMENT NUMBER NEW STEAM GENERATORS EQUIPMENT AND PIPING

LAYOUT

202236363 NEW STEAM GENERATORS FABRICATION AREA SITE PLAN

202236364 NEW STEAM GENERATOR FOUNDATIONS

202236367 NEW STEAM GENERATORS P&ID

202236371 NEW PROPANE P&ID

202236372 STEAM GENERATOR AND PIPING CONCEPTUAL

INSULATION PLAN

202236376 STEAM GENERATOR RIGGING AND TRANSPORT PLAN

STATEMENT OF WORK FOR CONCRETE AND CIV8IL WORK IN

SUPPORT OF NEW STEAM GENERATOR INSTALLATION

(INCLUDED IN ANNEX)

Various COMPONENT DATA SHEETS

3.1. Technical documents and Standards

The following are documents to be referenced in the execution of the work:

3.1.1. AISC Manual of Steel Construction

3.1.2. ASCE 7 Minimum Design Loads and Associated Criteria for Buildings and Other Structures

3.1.3. ASME Boiler and Pressure Vessel Code (B&PVC) Section I Rules for Construction of Power Boilers

3.1.4. ASME B&PVC Section II, Material, Part A, Part B, Part C, Part D

3.1.5. ASME B&PVC Section V Nondestructive Examination

3.1.6. (NDE)

3.1.7. ASME B&PVC Section VIII Rules for Construction of Pressure Vessels

3.1.8. ASME B&PVC Section IX Welding, Brazing and Fusing Qualifications

3.1.9. ASME B31.1 Power Piping

3.1.10. ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers

3.1.11. AWS D1.1 Structural Welding Code

3.1.12. IBC International Building Code

3.1.13. NFPA 54 National Fuel Gas Code

4. SCOPE OF WORK

In general, the scope of work for this task includes the Contractor providing the resources to furnish one complete, installed, and ready to operate steam generator as described herein.

There are six (6) major tasks associated with supplying the steam generator. They include:

4.1. Design and Engineering

The Contractor shall be responsible to perform all engineering, design, analyses, sizing, modeling, preparation of drawings, calculations, and related work to provide for a safe, complete, fully functional, and operable steam generator. All design and related technical tasks shall be based on the requirements in ASME B&PVC Section I Power Boilers latest edition and as further identified herein. Unless specified otherwise all prepared design, analysis, and related documents shall be presented to the Government for review and approval at Design Reviews as specified in Section 4.1.9.

The following are disciplines for which the Contractor shall prepare the necessary technical documents to describe the overall configuration, performance, capacities, fabrication, materials, welding and other related tasks to produce the steam generator. These identified disciplines and tasks may not be all inclusive and the Contractor may need to supplement these with additional work tasks

4.1.1. Process Engineering - Develop a set of P&IDs to describe the overall capacities, expected performance, sizes, flow rates, temperatures, instruments, process components such as Remote Operated Valves (ROVs), Pressure Safety Valves (PSVs), Regulators, Filters, Flow Meters and other similar hardware. The P&IDs shall be prepared in a schematic format to represent the overall process design and function of the steam generator. Reference Drawing No. 202236371 which indicates a conceptual P&ID to be used as a basis for development of the final P&IDs for the steam generator.

4.1.2. Layout and General Arrangement - Prepare detailed drawings to indicate the overall layout, arrangement and configuration of the steam generator. This drawing will include overall envelope and other critical dimensions, will show key parts of the steam generator to include the saturated water vessel, burner, fire tube arrangement, man ways, nozzles and piping connections, all instrumentation and connection points on the steam generator, structural support saddles, external blower for the burner, burner exhaust stack, external access ladder and platform and in general all primary parts that comprise the steam generator proper. As noted below separate drawings will be required for connecting piping, insulation and other items. Reference Drawing No. 202236363 which indicates a conceptual layout and general arrangement for the steam generator and its connecting components.

These drawings shall be presented to the Government no later than 3 weeks after contract award to allow for planning of the civil engineering and concrete work to be done at Area 1-42. Other drawings may be requesting by the Government if needed for this civil engineering work.

4.1.3. Steam Generator Fabrication Drawings – the contractor shall prepare a detailed set of fabrication drawings for use by shop and field personnel to fabricate the new steam generator. This will include roll out drawings indicating the placement, fit up and welding of plates for the main saturated water vessel, details of all penetrations and nozzles, details for the installation of the burner assembly, fire tube, burner exhaust, structural saddles, details for external stairs and access platform, fabrication and installation of vessel heads and all other pertinent details necessary to identify materials, cut and fit all parts, segments, sub-assemblies and pieces to produce a safe and complete steam generator.

As described in section 6.0, it is anticipated the steam generator will be assembled on site at AFRL at a designated staging area. It will then be lifted, placed on a heavy transport, and set into final position at AFRL Area 1-42. As the Contractor determines, they may need to develop “phased” drawings indicating the required sequencing and other key details for fabrication of the steam generator. If the Contractor develops such drawings these shall be provided as part of the fabrication drawing package.

4.1.4. External Piping – The Contractor shall prepare drawings and perform analyses for several segments of external piping to connect from the steam generator to the Government’s designed facility piping systems.

Interface/connection points where Contractor provided steam generator external piping and Government designed systems will interface as shown on drawings provided in this bid package. Reference Drawing No. 202236363 showing the overall routing and interfaces of external piping. Design will include all piping, pipe supports, valves, instruments, ports, drains, insulation and any other required parts and segments to provide for a complete piping system. Note that as shown on the drawing, interface points are identified for piping systems, some as a blinded flange connection, to allow for connection to piping for the installation of the future steam generators

4.1.5. Steam Generator Insulation Details - The Contractor shall prepare drawings showing details for extent of installation and details for installation of insulation over the steam generator for retention of heat and personnel protection. To enable visual inspection and NDE measurement of the steam generator and external piping, the Contractor shall design inspection ports that will include removable “plugs”. These plugs will be approximately 3” to 4” in diameter and shall be weatherproof. The Contractor shall determine the need for any insulation, anchors, clips, or pins that may need to be installed on the surfaces of the items to be insulated to ensure proper anchorage and placement of insulation. The number and location of the plugs are dependent on the final design and shall be presented and approved by the Government at Design Reviews as specified in section 4.1.9.

4.1.6. Steam Generator Rigging, Transport, and Placement - The Contractor shall prepare drawings to address rigging, lifting, transport and placement of the steam generator from the either the Contractor’s proposed facilities, or the AFRL Fabrication Staging Area if used, to the new and permanent location at AFRL Area 1-42 Steam Plant. Drawings shall indicate layouts for the steam generator, positions of cranes and transport vehicles, transport route, rigging hardware and arrangements. The Contractor may use as a basis rigging drawings prepared by the Government and included as part of this bid package. Reference AFRL Drawing No. 202236381 which indicates conceptual layouts for lifting and placement of the steam generator and the transportation route. Rigging, Transport, and placement drawings shall be presented to the Government for review and approval.

4.1.7. Steam Generator Staging Area - If the Contractor proposes to conduct assembly of the Steam Generator as per section 4.3, the Contractor shall prepare a layout of the proposed arrangement for storage of materials, fabrication of the steam generator, traffic and equipment flow through the staging area, offices and temporary buildings/trailers, fenced off areas, equipment storage and routing of utilities. Any grading, excavation, trenching or similar activity that disturbs the ground in the staging area shall be clearly identified on the drawing and will include an estimate as to how much soil will be required to be moved or otherwise disturbed. Reference AFRL Drawing No. 202236364 which indicates the area designated for use by the Contractor for staging of the steam generator and identifies specific use areas. These drawings, analysis or other documents shall be presented to the Government at the 30% Design Review.

4.1.8. Instrumentation and Controls - The Contractor shall be responsible to develop an overall control scheme for operation of the steam generator. This scheme shall account for normal start up, normal operation and normal shut down of the steam generator. It shall also address emergency and anomalous conditions that could occur with operation of the steam generator. The Contractor shall provide this scheme to the Government in the 60% Design Review.

4.1.8.1. The Contractor shall be responsible to identify the need for, select and design for the installation of all individual instruments including, but not limited to, sight glasses, thermocouples, pressure and temperature gauges, pressure and temperature transducers, level indicators and monitors, NOx emission monitors and alarms and any other identified instruments required to affect the overall normal operation and emergency shut down of the steam generator.

4.1.8.2. Whichever manufacturer the Contractor selects for the steam generator burner, the unit will require a burner management panel. This panel will be expected, to manage and control overall operation of the steam generator, control burner gas shut off, valve controls, adjust and control air/gas ratio for combustion, monitor UV flame detection and perform numerous other control, alarm and shut off functions. As part of the overall scheme for management and control of the steam generator the Contractor shall select a burner management panel that shall be designed and integrated to provide for safe control of and the overall operation of the steam generator.

This panel will be required to be operated locally at the steam generator and wired and connected to the Governments site control system so the steam generator can be monitored and operated remotely from the Area 1-42 Blockhouse/control room.

4.1.8.3. All instruments and controls provided by the Contractor shall interface with the Governments Allen Bradley Control Logix PLC with a 4-20 mA signal for sending setpoints and receiving process variables and other data. All thermocouples shall be Type K.

4.1.8.4. The Contractor shall select and integrate into the overall design a sight glass located near the control panel on the steam generator. The sight glass shall be of sufficient size to allow for field personnel to determine through visual inspection the level of fluid in the steam vessel. The sight glass shall be fabricated from stainless steel and shall be rated for all service conditions. The sight glass shall also be capable of being integrated into the overall steam generator control system so the level of fluid in the steam vessel can be indicated and read remotely at the Government’s site control facilities.

This reading shall also be able to interface with the Government’s Allen Bradley system as stated in the paragraph above. Note that any piping connecting to the sight glass shall be designed, fabricated and installed to meet the requirements of ASME B&PVC Section I and ASME B31.1 Power Piping requirements. The sight glass shall be provided with necessary block valves, drains and other components to allow for the removal and maintenance of the sight glass as may be required. The Contractor shall provide all monitoring and emergency shut down and alarm systems as required by ASME B&PVC Section I. These systems shall specifically be identified in the overall design and shall state the ASME B&PVC Section I requirement they address. All systems, instruments or other hardware required by ASME B&PVC Section I shall be fully integrated with the overall control systems and shall be identified on the local control panel and shall be able to be integrated into the Government’s site control system.

4.1.9. Design Reviews - As an integral part of the engineering and design effort the Contractor shall arrange for and host three (3) design reviews. Reviews shall be held when the design task is approximately 30% complete, 60% complete and 95% complete. Design reviews shall focus on how the design meets stated SOW and ASME B&PVC Section I requirements.

4.1.9.1. The 30% Design Review shall be conducted at the Contractor’s facilities. The Contractor shall arrange for this review. They shall provide the Government a minimum of three (3) weeks-notice in advance of the review to allow for scheduling of travel and coordination of personnel schedules for the review team. The Contractor shall make their own arrangements to have the proper personnel present to answer the Government’s questions and present the design. The review team for this Design Review shall consist of the Contractor’s design team including relevant engineers and technicians, as well as any project managers. The Contractor shall present all developed documentation and analysis for review to the Government and their designated team. The Contractor shall take notes, document action items, and publish these to all design review participants.

The 30% review will focus on developing advanced concepts for the steam generator to include size, key dimensions, material selection, preliminary sizing calculations, meeting steam production requirements, and key systems and components such as the burner, fire tube, exhaust stack, external piping, control system and instrumentation. All key safety systems shall be identified and concepts for each selected. Upon conclusion of the 30% review, The Contractor shall not proceed until given Authority to Proceed by the Government. The Government will send, in writing, this approval.

4.1.9.2. The 60% review shall take place via virtual meeting (i.e. Microsoft Teams). This review shall advance previously approved concepts for the steam generators. All basic calculations, analysis, material selection and other key engineering functions should be complete or nearly completed to a point where final design can proceed. Safety systems shall be well developed and selected designs shall clearly demonstrate meeting ASME B&PVC

Section I requirements. Upon conclusion of the 60% review, The Contractor shall not proceed until given Authority to Proceed by the Government. The Government will send, in writing, this approval

4.1.9.3. The 95% Design Review shall be conducted at the Government’s facilities. The Contractor shall arrange for this review. They shall provide the Government a minimum of three (3) weeks’ notice in advance of the review to allow for scheduling of travel and coordination of schedules for the review team. The Contractor shall make their own arrangements for travel to the Government’s site and shall submit necessary personnel information to the Government for security and site access purposes. The review team shall consist of the Contractor’s design team including relevant engineers and technicians, as well as any project managers. The Contractor shall present all developed documentation and analysis for review by the Government and their designated review team.

The 95% review will feature completed design drawings, all supporting calculations and analyses and a complete review of how the design meets all stated requirements. It is anticipated only minor comments will be made during the final design review. The Government will make comments on the design and the Contractor shall incorporate any changes into the final design before proceeding to procurements of materials and fabrication of the Steam Generator and associated parts or components. Once all changes have been made by the Contractor, and the Government is satisfied that all issues have been addressed, the Government will send, in writing, Authority to Proceed with fabrication. The Contractor shall send the final design package to the Government for their records.

4.2. Procurement of Materials, Parts, and Equipment for Fabrication

4.2.1. The Contractor shall generally be responsible to specify, procure, receive, store and make arrangements for use of all materials, equipment, parts, spare parts, sub-assemblies, subcontracted services and any other material items required for a complete and operable steam generator as identified herein. The Contractor shall prepare a final list of procurements and deliver this to the Government at the 95% Design Review. The Government will concur and give Authority to Proceed with procurements after all Design Review actions have finished

4.2.2. The Contractor shall also be responsible to acquire all spare parts as identified herein. These spare parts shall be clearly identified, labeled, organized and ready for transfer to the Government at the conclusion of the project. Upon final acceptance testing of the Steam Generator, the Contractor shall deliver all spare parts to the Governments facilities. These parts will be delivered to the Government via the deliverables in this SOW, via a form DD-250, or other methods as necessary.

4.3. Fabrication of Steam Generator at AFRL Staging Area - Note: Section 4.3 may be only partially applicable based on the Contractor’s bid and need for the staging area. If the Contractor makes use of the AFRL Staging Area for some or all the work, they shall follow the requirements laid out in this section

4.3.1. The Contractor shall be responsible to perform all necessary fabrication of the steam generator to produce a safe, complete and fully operational equipment item.

4.3.2. Because of the magnitude of the steam generator and size constraints associated with transportation, it is anticipated that assembly of the unit will occur at a staging area at AFRL, outside of Area 1-42. A possible example of this staging area is shown on Drawing No. 202236364 but may be subject to change pending AFRL mission needs. There is adequate space for storage of materials, fuel storage, areas for work and assembly of the steam generator and as may be required sub- assemblies, adequate space for equipment including cranes, trucks, forklifts, welding equipment and other items. There is adequate space for site offices, secure storage areas and like facilities. No temporary fencing around the entire perimeter of the designated area is permitted. No modifications to any permanent structures or Government infrastructure are permitted. The Contractor may install fencing to protect and secure small areas for material, tools, equipment or other storage and similar purposes. The Contractor shall identify an area for the collection of refuse and materials to be recycled and shall likewise arrange for the proper removal and disposal of all refuse and recycled materials. The Contractor shall arrange for adequate sanitary facilities for personnel at the staging area. The Contractor shall also arrange for drinking water for their personnel at the staging area.

There is also electrical power and non-potable water available. The Government will not make available any phone or internet service. For emergency services and communication with AFRL Site Operations, The Government will provide alternate communication methods and hardware. The Contractor will need to determine if phone or internet services are required and available through third party carriers at the staging area. AFRL has two working cell carriers that may be able to provide this service.

4.3.3. While on the AFRL rocket site and while performing any work, personnel shall follow all site safety regulations, including listening for and responding to site-wide announcements, drills, shelter-in-place orders, or other real-world or simulated events. Prior to starting any hot-work or other dangerous operations, the Contractor shall submit emergency shutdown procedures to the Government in writing. The Contractor is responsible for their own mishap accountability and handling but shall report any mishaps or incidents to the Government

4.3.4. A secondary spill containment system for each fuel storage tank shall be required. The Contractor shall describe the method for secondary containment to the Government in advance of use. Installation of fuel tanks, dispensing systems and containment shall be reviewed and approved by the Government in advance of installation and use.

4.3.5. Any grading, leveling, soil conditioning or other site improvements in preparation for mobilization to the staging area shall be the responsibility of the Contractor.

4.3.6. Upon demobilization from the staging area the Contractor shall remove ALL equipment, tools, excess materials, trailers, refuse or any other items in possession of the Contractor to restore the area to the as found condition prior to mobilization. Regrading of the area prior to mobilization to restore original ground contours is not required.

4.4. Transport and Placement of the Steam Generator

4.4.1. The Contractor is responsible to perform the lifting, placement on a heavy transport, transporting and final placement of the steam generator at Area 1-42.

Reference Drawing No. 202236381 which indicates conceptual layouts and arrangements for lifting of the steam generator at the staging area, transport and final placement at Area 1-42. When all fabrication work is complete the Contractor shall arrange for lifting and transport equipment to mobilize at the AFRL staging area. The steam generator shall be lifted and placed on a heavy transport for delivery to AFRL Area 1-42. Once placed and secured on the transport, the steam generator shall be transported to Area 1-42, positioned and readied for placement. The Contractor shall have arranged for a crane at Area 1- 42 to lift the steam generator from the transport and place in final position on the foundation

Note: The Contractor shall evaluate if it is advantageous to arrange for multiple cranes (i.e. one located at the staging area and one located at Area 1-42 Steam Plant simultaneously) rather than a single crane that would require multiple assemblies, break downs, and transport between the sites for moving the steam generator. The Contractor is responsible for selecting the best suited arrangement for their plan to execute the project.

4.4.2. In addition to the drawings described herein (involving illustration of the rigging, lifting, handling, transport, and final placement of the steam generators), the Contractor shall also prepare a written Rigging, Lifting, and Transport Plan.

This plan shall outline in detail the Contractors approach to accomplish this phase of the work. The plan shall include the listings of intended equipment to be used; rigging hardware; calculations demonstrating safety factors for all key elements of the lifting including, but not limited to, crane capacity based on pick radii, equipment capacities, rigging hardware capacities; and other key lift and transport items. The plan, referencing the Contractor’s prepared drawings, shall also include a description of the route planned for transport, and evaluation and inspections to verify adequate clearances during all phases of transport. The plan shall consider the use of plates, mats, and other equipment to ensure stable support for cranes during lifting operations. The Contractor’s plan shall be complete and thorough to ensure safety and effective lifting, transport, and placement of the steam generator. The Riggin, Lifting, and Transport Plan shall be submitted to, reviewed, and approved by the Government prior to performing and lifting, rigging, and transport work.

Note: The foundation for the new Steam Generator is shown on drawing 202236367. The foundation will be installed by the Government. The Steam Generator bill be transported, rigged, lifted, and set in place on the foundation by the Contractor as part of the scope of the overall task

4.4.3. In preparation for placement of the steam generator into its final position on the foundation, the Contractor shall furnish and install all bearing plates, slide plates, shims and grouting, and torquing of anchor bolt nuts as specified on the steam generator equipment and piping layout, Drawing No. 202236363. Bearing and slide plates shall be placed level and to the precise elevations called out on the drawings and shall be fully supported with shims. Anchor bolt nuts shall be torqued as called out on the foundation drawings to ensure the Steam Generator is secure. Final grouting shall not occur until at least after all piping and other external connections are made to the steam generator. The Contractor shall use care to ensure the pattern of the anchor bolt holes on the bearing and slide plats and steam generator base plates matches the placement of the embedded anchor bolts in the foundation. It is recommended the Contractor use templates and other precision methods to ensure proper alignment and tolerancing between the vessel base plates, slide and bearing plates, and anchor bolts.

4.4.4. If the Contractor must procure or custom fabricate any rigging hardware, spreader beams, slings, shackles, or other hardware for the planned rigging and lifting of the steam generator, these items shall become the property of the Government at the conclusion of the project and shall be inventoried and formally transferred to the Government.

4.4.5. Preparing the area for location of the crane as shown on Drawing No.

202236381 includes importing, placing, compacting structural fill, and generally readying the area where the crane will be located to the east of the steam generator foundation. The Contractor shall perform all preparatory work as shown on the drawing to ensure a complete, stable and safe location for the crane. All materials, equipment, labor, and other resources to place and compact the fill area shall be provided by the Contractor

4.5. Final Installation of Generator and Periphery Systems, Piping, Insulation, Blowers, and other Parts and Equipment.

Once the steam generator has been set into final position on the foundation, the Contractor shall be responsible to connect and install all other equipment and systems associated with the steam generator. This includes, but is not limited to, designing, furnishing, installing, inspecting and testing all boiler external piping systems (to be PP stamped), the burner blower, the external stairs and access platform, PSVs, instruments, control panels and systems, safety systems and any other items that connect and interface with the steam generator. Boiler external piping systems provided by the Contractor shall be properly interfaced and connected to Government provided facility piping systems.

Once all other systems, piping, instruments, and external connections are made, the steam generator shall be insulated as specified and called out for in Section 5.8. The extent of the insulation to be installed is shown on Drawing No. 202236376. In general, insulation shall be installed over the entire shell, nozzles, the man way, and any other areas of the steam generator that present a potential heat leak path and/or personnel safety hazard. As noted on the insulation drawing, removeable insulation blankets for valves and flanges shall be provided and installed by the Contractor.

4.6. Final Acceptance Testing and Training

4.6.1. Once the Steam Generator has been fully installed at Area 1-42 the Contractor shall work closely with the Government to conduct a series of final acceptance tests. These tests will be designed to demonstrate the steam generator operates safely, is fully functional and meets the Government’s performance requirements. The Contractor shall first develop a Final Acceptance Testing Plan. This document will form the basis for all final inspections, testing and acceptance of the Steam Generator, culminating in the equipment being ready for operation and use by the Government.

4.6.2. An integral part of the Final Acceptance Testing Plan shall be training of Government personnel. The Contractor shall develop a comprehensive, rigorous and specific training program that he shall use to train Government personnel in the safe operation of the steam generator. Training shall include “classroom” training, simulation training as may be deemed necessary and field training and actual operation of the steam generator. The Contractor shall be responsible to structure the training to educate personnel in a gradual and thorough manner to all aspects of safe operation of the steam generator. The Contractor shall issue all Government personnel a certification at the conclusion of the training verifying the individual has successfully completed the required Contractor sponsored training program.

4.6.3. Besides basic, safe operation of the steam generator, the Contractor shall also focus the training program on upset and anomalous conditions that can be expected to occur during operation of the steam generator and how operations personnel react for safe shutdown, or other actions, that may be required.

4.6.4. The Contractor shall outline the contractor’s training plan and length of time required for training of Government personnel in the proposal. The Contractor shall also recommend the number of Government personnel to be trained for operation of the Steam Generator.

4.6.5. The Contractor is responsible to develop and present a field Final Acceptance Testing Plan for the steam generator. Final Acceptance Testing shall include, at a minimum, the following elements:

4.6.5.1. Safety pre-check of the steam generator conducted prior to each use, with a focus on systems for the safe shut down of the steam generator

4.6.5.2. Perform any simulated testing of safety systems to verify safe shut down of steam generator

4.6.5.3. Perform any other simulated operation of the steam generator in preparation for actual operation.

4.6.5.4. Start-up and operation of the steam generator to produce a quantity of saturated steam. The initial quantity of saturated steam to be produced may be a fraction of the amount specified for and anticipated for normal operation of the system. (i.e., the quantity of saturated steam produced may be graduated through several tests until the full specified volume, ~60% of the total volume of the vessel, is achieved).

4.6.5.5. Once a quantity of saturated steam is produced in the steam generator, it shall be released through the steam piping and ducting system of the Area 1-42 Steam Plant to verify proper overall operation of the system

4.6.5.6. Identify any post operation inspection, checks, and/or tests required to ensure the steam generator is left in a condition fit for the next use.

4.6.6. At the conclusion of the field testing the Contractor and Government shall plan to enter the steam generator and make a joint careful visual inspection and assessment of the condition of the interior surfaces. Photographs, notes and a report on observations and findings shall be prepared by the Contractor and included as part of the results of the Final Acceptance Testing.

4.6.7. Development of the Final Acceptance Testing Plan is anticipated to be worked with the Government as field testing of the steam generator will require close coordination and dependence on other facility steam plant systems under the control of the Government

4.6.8. The overall structure, development and approach of the Final Acceptance Plan should consider the use of a step-by-step checklist type format for testing activities. The Final Acceptance Testing Plan shall identify all key personnel including Contractor and Government personnel who will be involved in the Final Acceptance Testing. Each person shall be assigned a title and their specific function and responsibilities relative to the testing shall be clearly identified.

4.6.9. The Contractor shall plan on several “dry runs” with all personnel to help ensure familiarity and safe operation of the steam generator during actual testing.

The Final Acceptance Testing Plan shall identify clear parameters and metrics defining success thresholds for each test. These shall be carefully monitored and documented during actual testing. Actual measured and observed results shall be noted and compared with predicted results to verify success or the need to make adjustments and alterations in the testing plans.

4.6.10. The Government shall have final approval of all personnel laid out in the Acceptance Test Plan and their titles and responsibilities.

4.6.11. Copies of completed testing checklists, results, notes, observations, alterations, adjustments, and any retesting shall be provided to the Government at the conclusion of each planned field test, in both hard copy and digital format (i.e., both the actual as-completed document and a digital scan of it).

5. Technical Requirements

5.1. General Requirements

5.1.1. The steam generator shall be designed, fabricated, tested, inspected and stamped in accordance with the requirements of the ASME B&PVC Section I, Rules for Construction of Power Boilers, Latest Edition. The steam generator shall be stamped with an ASME B&PVC Section I “ASME” and “S” Certification mark as noted in PG-105 of ASME B&PVC Section I. The Contractor shall be authorized by ASME to perform the identified code construction and shall have the appropriate “S” stamp.

5.1.2. The steam generator shall be a fire tube type boiler and shall meet all requirements for the same. The Government has done a preliminary analysis to refine the requirements for the dimensions, working pressures, and operating parameters. These specifications are laid out within section 5. The bidder may propose alternate dimensions for the Steam Generator as long as they maintain the specified volume, quality of steam, and heat/reheat time specified in this section. The contractor’s proposed Steam Generator and associated piping and infrastructure must also fit within the proposed dimensions of Area 1-42 as laid out in the Reference Documents in Section 3 of this SOW.

5.1.3. The Contractor shall provide a Manufacturer’s Data report Form, Form P- 2, for the steam generator. All required documentation, including, but not limited to, calculations, welding certifications, non-destructive testing (NDE) records, Certified Material Test Reports (CMTRs), pressure testing, Master Data Report Form and all other documentation as required by ASME B&PVC Section I for the design, fabrication, welding, inspection, NDE, testing and any other activities shall be furnished as part of the code package for the steam generator.

5.1.4. The steam generator shall be meet the requirements of ASME B&PVC Section I, Part PG General Requirements for all Methods of Construction, Part PW Requirements for Boiler Fabricated by Welding, PFT Requirements for Fire Tube Boilers. The Contractor shall determine, depending on the specific design and methods selected to design and fabricate the steam generator, other parts and appendices of ASME B&PVC Section I that are applicable to the scope of this project.

5.1.5. All pressure boundary materials used in the fabrication of the steam generator shall be provided with Certified Material Test Reports (CMTRs) as required in ASME B&PVC Section II. All pressure boundary materials shall be clearly stamped or otherwise marked with the corresponding heat number from the CMTR. Any requirements for marking or stamping plates or other pressure boundary materials identified in ASME B&PVC Section I that are in addition to any marking or identification of materials noted in ASME B&PVC Section II shall be met. The Contractor’s Quality Control Plan shall address transfer of heat numbers and traceability for individual pieces and parts that are cut or altered.

5.2. Steam Generation Requirements

5.2.1. Perform an engineering analysis that ensures there is 110 lbm/sec of dry steam (or good quality steam) for 12 min and 115 psia at the ejectors. This will include a pressure drop analysis from the boiler to ejectors to include pressure losses from dynamic flow and piping/component losses to be presented at the 60% design review. In addition, a heat transfer analysis within the boilers and from the boilers to the ejectors will be performed to ensure even heating and good quality steam at the ejectors

See Drawing No. 202236371 for a conceptual P&ID of the steam generator and the over steam supply system

5.2.2. The Maximum Allowable Working Pressure (MAWP) of the steam generator is 600 psig. The maximum temperature of the steam within the steam generator is 500⁰F. The steam generator shall be designed to provide 110 lbm/sec of saturated steam for a minimum of 12 minutes for a total of 79,200 lbs of steam. Steam pressure within the steam generator shall initially be ~600 psig and when released from the steam generator will be controlled at 100 psig at the point of application. Pressure within the steam generator at the conclusion of a 12-minute run shall be a minimum of 100 psig.

5.2.3. Following a 12-minute steam run, the water in the steam generator shall be able to be reheated until the pressure within the steam generator is ~600 psig without the addition of any make-up water. This shall occur for a minimum of 3 times before any make up water is to be added to the steam generator.

Heating/Reheating from 100 psig to 600 psig shall be done over a period of no more than 20 hours. It is expected the subsequent steam runs will be shorter in duration than 12 minutes, as saturated water is removed from the system for each steam run. The above requirements will mean the fire tube must remain submerged below the waterline in the vessel during all reheating operations.

5.2.4. The estimated size of the new steam generator main water storage vessel is 15’ diameter X 60’ length for the straight cylinder and an additional length of ~7.5’ for each head (assuming spherical heads), for a total length of ~75’. The bidder may propose alternate dimensions as long as they maintain all other specifications including volume, quality of steam, and heat/reheat time. The total volume of the water storage vessel is ~12,369 CF or 92,500 gallons. For normal operation of the steam generator, it is assumed the vessels will be filled to approximately 60% of capacity (55,500 gallons) to produce the specified 110 lb/sec of steam for 12 minutes. The Contractor shall verify the required quantity of steam can be produced with the steam generators filled to the specified capacity

5.2.5. Feed water is anticipated to be provided to the steam generator at ambient temperature, 40 GPM and ~600 psig. For design purposes, the Contractor shall perform calculations for the required heating of the feed water based on the described conditions.

5.3. Steam Vessel

5.3.1. As noted above the estimated size and dimensions for the new steam vessel will be an outside diameter of 15’-0” by 60’-0” (cylinder only) and the vessel heads at an approximate length of 7.5’-0” each (assuming hemispherical heads) for an overall length of 75’-0”. These dimensions provide for an approximate volume of 12,369 CF or ~92,500 gallons. The bidder may propose alternate dimensions as noted in section 5.1.

5.3.2. Fabrication of the cylindrical portion of the steam vessel shall be accomplished using rolled sections of plate. It is assumed hemispherical heads will be preferred for the design of the vessel, but the Contractor may select another type of head if that is advantageous to the design and fabrication of the vessel. Vessel heads shall be designed in accordance with the requirements of ASME B&PVC Section I.

5.3.3. The steam vessel shall be fabricated from carbon steel. It is recommended the Contractor use SA516-70 as the primary material. Other materials may be used so long as they are ASME listed materials and approved for use with the fabrication of ASME B&PVC Section I steam generators.

5.3.4. The size and arrangement of rolled plates and weld joints, thickness of materials and…