Attachment 27

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CORROSION MONITORING OF SULFURIC ACID STORAGE TANK (T-12) AND

ASSOCIATED FEED AND FILL PIPING

PROJECT DESCRIPTION: This requirement is for the design and implementation of an annual corrosion monitoring program for the sulfuric acid storage tank and associated feed and fill piping.

(a) General

The sulfuric acid storage tank and associated stainless steel fill and feed piping is comprised of a 10-foot diameter, 18-foot tall 10,000-gallon lined carbon steel tank which stores 93% sulfuric acid (66° Baume’) used in the wastewater pretreatment plant (WWPP) located at the Department of the Treasury’s Bureau of Engraving and Printing (BEP), 301 14th Street SW, Washington, DC facility. This acid storage tank has a 90-mil Halar liner installed on the interior of the tank to provide added corrosion protection. The tank is contained within a 9-foot tall, 12-foot wide and 13-foot long spill containment tank.

This requirement is to retain NACE certified corrosion specialist personnel (labor) with appropriate thickness testing equipment and materials necessary to design, implement, and perform a one-year corrosion monitoring program having methods, processes and procedures sufficient to produce highly reliable and legally defensible calculated estimates of the remaining lifespan of the acid tank, tank feed and fill piping and associated fittings in the BEP’s Wastewater Pretreatment Plant (WWPP).

(b) Code and Regulatory Requirements

The labor performed under this requirement must conform to all applicable codes and regulations. Some of the applicable codes are, but not limited to:

(1) 29 CFR 1910.146 – Permit-Required Confined Spaces

(2) 29 CFR 1910.133 – Eye/Face Protection

(3) NACE RP024-94 – Design, Fabrication and Inspection of Tanks for the Storage of Concentrated Sulfuric Acid and Oleum at Ambient Temperatures

(4) API – 570 – Inspection, Repair Alteration, and Rerating of In-Service Piping Systems

(5) API – 575 – Guidelines and Methods for Inspection of Existing

Atmospheric and Low-Pressure Storage Tanks

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(6) 29 CFR Subpart Q – Welding, Cutting and Brazing

(7) API – 653 – Tank Inspection, Repair, Alteration, and Reconstruction

(8) NACE RPO 391 – Materials for the Handling and Storage of Concentrated (90 to 100%) Sulfuric Acid at Ambient Temperatures

(9) District of Columbia Municipal Regulations (DCMR) Title 20 Environment

(c) Work Requirements

The Contractor will be required to provide detailed information addressing the specified requirements: all technical specifications, detailed methodology as applicable, for the following sections concerning the acid storage and delivery system corrosion monitoring program:

Section (c) (3) – Preparation of the Corrosion Monitoring Program Plan

Section (c) (4) – Semi-Annual Corrosion Monitoring of Acid Tank Fill and Feed Piping

Section (c) (5) – Annual Inspection of the Sulfuric Acid Storage Tank

All expenses related to fulfilling this requirement are to be included in the annual procurement. The Contractor will provide the COR information on all material and labor cost estimates for all of the sections to include an itemized list of all cost items, including all subcontractor work and materials, as applicable. All submittals will be reviewed by the COR for technical completeness to ensure responsiveness to the detailed requirements including best engineering and cost solutions with emphasis on regard to worker safety, environmental compliance, and adherence to project schedule.

The acid tank, containment pit and underside of the acid storage tank are each considered permit-required confined spaces; all personnel must have confined space training. For all portions of the project, the Contractor will develop and submit a comprehensive Safety and Health plan for approval by the COR, prior to project start, in order to ensure that proper safety procedures are followed at all times during this project.

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(1) General Requirements

a. The Contractor will be responsible for all decontamination, materials management, transportation, and installation and dismantling of all equipment necessary for their use with thickness measurements of the acid storage tank and feed and fill piping and fittings of the acid distribution system at the BEP.

This includes, but is not limited to: lighting, test equipment, support equipment, and miscellaneous personnel protective equipment and any other miscellaneous equipment. All equipment must be in good and safe working order and meet applicable OSHA standards.

b. The Contractor will prepare permits as needed for the confined space entry and submit it to the BEP Office of Environment, Health and Safety (OEHS) for approval a week before the confined space entry. The Contractor will follow required confined space entry protocol for work that is performed in the acid containment pit and all other permit required spaces. The Contractor will provide all necessary personnel and monitoring for the confined space entries. Copies of the monitoring records will be provided to the COR within 24 hours after completion of each confined space entry.

c. The work period for the semi-annual acid feed and fill piping measurements will normally consist of eight hour days from 8:00 AM to 5:00 PM, Monday through Friday.

d. The work period for the annual acid tank inspection will be on non-production Saturday and/or Sunday and will consist of eight hours from 8:00 AM to 5:00 PM. Transfer of contents and decontamination should be accomplished the day before testing. Longer days may be permitted, but must be scheduled three days in advance.

e. The Contractor will ensure prompt and appropriate attendance during all scheduled work days and times to ensure proper completion of this project;

this is a specific requirement to meet currency production schedules and security requirements.

f. The Contractor will perform all work in a safe manner in accordance with the existing standards of the Occupational Safety and Health Act (OSHA) of 1970; more specifically, general industry standards, 29 CFR 1910 and 29 CFR 1926, latest editions, and any standards newly published during the term of this Contract.

g. Additionally, all work performed must be performed in accordance with all applicable Regulations, Directives, and Procedures; both internal to BEP and external to BEP.

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h. The work area must be kept clean and orderly. The Contractor will furnish all required personal protective equipment for his personnel. The Contractor will immediately notify the COR of any accident/incident involving injury or occupational illness or damage to Government property that occurs within the BEP, followed by a formal notification using the BEP accident/incident reporting procedures. The BEP will have the right to investigate all claims of unsafe or unhealthful working conditions and report any finding associated with the Contractor's performance on working conditions to the BEP’s Contracting Officer's Representative (COR) for appropriate action.

(2) Site Visit

a. A site visit for subcontractors may be recommended, if applicable for this corrosion monitoring project. All contractors will be invited to make a group appointment to survey the site. The site survey will be scheduled, in advance, through the WWPP COR of the BEP. To enter the site, visiting contractors may obtain temporary visitor badges. Individual(s) full name (as it appears on their driver’s license) and company name will be required at least 24 hours prior to the site visit. Onsite, photo identification will be required to obtain the temporary visitor badges.

b. The purpose of the site visit is to: survey the acid tank and associated feed and fill piping in the WWPP and assess the areas and containment pit to aid in the determination of sizing, procedures, and equipment needs and accessibility.

c. Drawings cannot be removed from the BEP without special permission. The BEP has an onsite digital camera and can provide photographs through e-mail if requested. The photos will have to pass the BEP security screening before being e-mailed.

d. All BEP equipment ratings and sizing measurements are to be noted onsite during the site survey, and should be on a separate paper. This segment of the project should be performed prior to submission of any design documentation.

(3) Preparation of the Corrosion Monitoring Program

The objective of this task is to design (prepare) a draft corrosion monitoring plan to satisfy the annual acid storage tank internal and external investigation and the semi-annual fill and feed piping evaluation requirements. The contractor will develop external inspection and RBI data collection forms, specific to the BEP, to address API 653 and NACE RP0294-94 recommended inspection practices and

Page 5 of 7 Pages to establish thickness monitoring locations specific to the acid tank. The Contractor will be allowed access to review existing history of equipment and review pertinent records and historical monitoring reports. The draft plan will be prepared and presented to the COR. A final implementation plan will be prepared and provided by the Contractor based on comments received from the

COR.

a. Deliverables

The Contractor will submit a report covering all items under Section (c) (3) a.

unless otherwise noted, in electronic PDF or MS Word format, as applicable with an additional requirement for three (3) printed copies documenting the recommended monitoring program and findings including the following items:

1. A printed 24’ x 36” site diagram – and an electronic copy in the latest version of Auto CAD – showing the location of recommended thickness reading locations for the storage tank and associated fill and feed piping.

2. Recommended testing intervals for the tank and associated fill and feed piping if greater frequency is recommended than currently required. Other wise the current required frequency should be noted as sufficient.

3. Applicable qualifications of all project personnel including professional registration and/or certification status must be provided.

4. Recommended corrosion calculation method(s) sufficient to produce highly reliable and legally defensible estimates of the remaining lifespan of critical acid storage, tank feed and fill piping and fittings locations must be provided.

5. The program must be reviewed and stamped by a NACE Certified

Corrosion Specialist and/or PE.

(4) Semi-Annual Corrosion Monitoring of Acid Tank Fill and Feed Piping

The Contractor will perform one testing of the sulfuric acid piping, semi-annually

– in accordance with the submitted and BEP approved program specified in Section (c) (3).

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The Contractor will provide a detailed report covering all items required under Section (c) (4) in electronic PDF or MS Word format, as applicable with an additional requirement for three (3) hard copies documenting the test results and comparison with previous forecast of pipe life of components.

1. The report will compare corrosion rates at specific sampling locations with the previous results and provide conclusions and recommendations for continued safe operation of said feed and fill piping runs.

2. The Contractor will submit the Corrosion Monitoring Report to the COR within 45 calendar days after testing is completed.

3. This report must have been reviewed and stamped by a NACE Certified Corrosion Specialist and/or P.E. before submittal.

(5) Annual Inspection of the Sulfuric Acid Storage Tank

The Contractor will perform an annual internal and external inspection of the sulfuric acid storage tank T-12, in accordance with the submitted and BEP approved program specified in Section (c) (3). The Contractor will visually inspect the inside and outside of the tank and take photos, using a BEP provided digital camera, as required to document areas in need of remedial attention.

1. Any area that shows degradation and/or corrosion must be photographed and the Contractor will provide a detailed report covering all items required under number 4.5.1 in electronic PDF file format with an additional requirement for three (3) hard copies documenting the findings and recommendations provided to WWPP Management within 30 calendar days after the inspection of the tank.

2. This task must be reviewed and stamped by a NACE Certified Corrosion Specialist and/or PE.

(6) Design Documents

a. Submittal Requirements

The below listed items must be included with the submittal:

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1. Outline of Health and Safety Plan for each phase

2. Itemized Cost Estimate for each phase to show labor and materials

3. General schedule and period of time required for each phase

4. The COR must approve the design documents before any work is performed in the WWPP.

(7) Safety Requirements

The BEP OEHS will issue burn permits for any welding that is required during any phase of the project. All personnel are required to wear personnel protective equipment, as defined by OSHA in 29 CFR 1910.133, within the pretreatment plants when burning, cutting, and/or welding is performed.

To perform work at the BEP, all personnel are required to wear safety glasses and safety shoes along with any other PPE given the nature of the work involved within the plant areas.

For the permit-required confined space entry, Contractor personnel are required to adhere to all the permit requirements, be confined space certified, and provide documentation proving said certification status.

(d) Contractor Qualifications

(1) Contractor must possess a valid and appropriate API and/or NACE certifications for lead engineer and measurement technician(s) appropriate for acid corrosion monitoring, inspection, assessment and design projects.

(2) Contractor must have a valid registered NACE Corrosion Specialist or a licensed Professional Engineer review and certify all required final reports.