Attachment (1) - Statment of Work (SOW).docx

Statement of Work (SOW) for 45 Ton Reverberatory Furnace Reline For the Naval Foundry and Propeller Center Scope of Work This specification is for the services of a contractor to reline the 45 ton Reverberatory furnace. The furnace is located in the NFPC Foundry, Building 20 low bay side at the Norfolk naval shipyard detachment Philadelphia.

Conditions:

1. The Norfolk Naval Shipyard Detachment Philadelphia will supply Crane Service for the project (within reason i.e. if contractor needs crane and shop is in the middle of a lift, contractor may have to wait 15-30minutes. Scheduling lifts beforehand will greatly reduce any conflicts).

2. The Norfolk Naval Shipyard Detachment Philadelphia will supply an air, electric and water supply for the contractor to tap into during the project.

3. The Norfolk Naval Shipyard Detachment will provide a dumpster for disposal of the debris. It is the contractors’ responsibility to place debris from the project into the dumpster and clean the work site when finished.

4. The contractor will provide all the material required to reline the furnace.

5. The contractor shall be familiar with the installation and relining of gas fired furnaces of this capacity. The contractor shall provide satisfactory evidence of having installed such linings.

6. The work will be performed Monday through Friday 0730 to 1600 hours. The Norfolk Naval Shipyard Detachment will be notified three working days prior to the start of work. The point of contact at Philadelphia is Jean Clotaire, Equipment Engineering, Bldg. #712, phone 215.897.2485

7. The Contractor will be responsible for obtaining the required security passes/badges to work in building 20 of the Norfolk Naval Shipyard Detachment Requirements:

1. Replace existing brick lining inside the furnace at the following locations; Charging wall, Burner wall, flue wall, tap wall, and all cast iron Bungs. Exercise care not to cause damage to any other area outside of the above listed items to be removed.

2. Remove all debris as a result of the brick removal and place in dumpsters provided by the government. The NFPC foundry personnel will be responsible for removing the floor debris in the furnace prior to the contractor starting work.

3. Brick material types to be used at the specified locations are as outlined;

· Charging wall, Burner wall, Flue wall, and Tap wall – 80% Alumina with super duty back up brick and a ceramic insulating board material. Roof and shelve areas will be 70% Alumina brick

4. The Contractor will be required to provide Product safety sheets for all materials to be used for the furnace project to the Government. The contractor will provide documentation from the Brick/Refractory supplier stating that a Bake out/Sinter procedure will be or will not be required prior to the startup operation of the furnace. If a Bake out/Sinter procedure is recommended by the material supplier, then the full procedure is to be provided to the Government.

5. The Contractor will provide the Government with a complete set of “as built” drawings that depict all materials used and where they were installed including wall anchor details.

North Wall (Tap Side) Remove all brick from the Tap Side wall to the shell of the furnace. Clean shell of all debris and install a ceramic insulating board. The approximate dimensions of the interior wall are 4’ h x 12’ w. The new brick wall, with a thickness of about 13”, will include 80% alumina hot face brick (approximately 306 pieces at 9” x 4-1/2” x 3”), 40% super duty backup brick (approximately 612 pieces at 13-1/2x 4-1/2 x 3”), high alumina mortar and insulating board material. The wall is to be anchored to the shell with a combination of properly rated metal wall anchors and physical brick ties using the 80% alumina brick.

South Wall (Charge Side) Remove all brick from the Charge Side wall to the shell of the furnace. Clean shell of all debris and install a ceramic insulating board. The approximate dimensions of the interior wall are 4’ h x 12’ w. The new brick wall, with a thickness of about 13”, will include 80% alumina hot face brick (approximately 306 pieces at 9” x 4-1/2” x 3”), a 40% super duty backup brick (approximately 612 pieces at 13-1/2x 4-1/2 x 3”), high alumina mortar and insulating board material. The wall is to be anchored to the shell with a combination of properly rated metal wall anchors and physical brick ties using the 80% alumina brick. The two arched walls will also need to be rebricked with 80% alumina material. Make both arch openings the same size if possible.

East Wall and Arched Roof (Flue Side) Remove all brick from the Flue Side wall and arched roof to the shell of the furnace. Clean shell of all debris and install a ceramic insulating board. The approximate dimensions of the interior walls are 4’ in height with the flue opening being 4’ long and the two angled side walls being 5’ long. The new brick wall, with a thickness of about 13”, will include 80% alumina hot face brick (approximately 306 pieces at 9” x 4-1/2” x 3”), a 40% super duty backup brick (approximately 612 pieces at 13-1/2x 4-1/2 x 3”), high alumina mortar and insulating board material. The wall is to be anchored to the shell with a combination of properly rated metal wall anchors and physical brick ties using the 80% alumina brick. Reconstruct the roof with 9” 70% alumina wedge cut firebrick (approximately 102 pieces of 9 x 4-1/2 x 2-1/2” and 306 pieces of 1 x wedge). Establish a point of reference to ensure new roof installation terminates in the exact location of existing. Reconstruct shelf area to its original dimensions at 1.5’ tall using 70% alumina firebrick (approximately 458 pieces of 9 x 4-1/2 x 2-1/2”).

West Wall, Shelf, and Arched Roof (Burner Side) Remove all brick from the Tap Side wall to the shell of the furnace. Clean shell of all debris and install a ceramic insulating board. The approximate dimensions of the interior wall are 4’ h x 12’ w. The new brick wall, with a thickness of about 13”, will include 80% alumina hot face brick (approximately 357 pieces at 9” x 4-1/2” x 3”), a 40% super duty backup brick (approximately 714 pieces at 13-1/2x 4-1/2 x 3”), high alumina mortar and insulating board material. The wall is to be anchored to the shell with a combination of properly rated metal wall anchors and physical brick ties using the 80% alumina brick. Reconstruct the burner side roof with 9” 70% alumina firebrick (approximately 102 pieces of 9 x 4-1/2 x 2-1/2” and 306 pieces of 1 x wedge). Establish a point of reference to ensure new roof installation terminates in the exact location of existing. Reconstruct shelf area to its original dimensions using 70% alumina firebrick (approximately 458 pieces of 9 x 4-1/2 x 2-1/2”).

Roof Bungs Remove all brick from the Roof Bungs to the cast iron shell. Clean the shell of all debris and install new brick. The new brick will be 70% alumina firebrick. Establish a reference point to ensure that the roof instillation terminates in the exact location of existing.

· 5 Cast iron Roof Bungs (approximately 12’ x 3’) reline with approximately 408 pieces of 9 x 4-1/2 x 2-1/2” 70% alumina firebrick (approximately 245 pieces of 1 x wedge and approximately 163 pieces of 9” straights per Bung)

· 2 Cast iron Roof Bungs (approximately 12’ x 1’) reline with approximately 153 pieces of 9 x 4-1/2 x 2-1/2” 70% alumina firebrick (approximately 92 pieces of 1 x wedge and approximately 61 pieces of 9” straights per Bung) Upon completion of installation, contractor will confirm that all roof bungs are able to be properly aligned. NFPC personnel will provide support with this task.