PWS-BEP_WWPP_Performance_Work_Statement.pdf

1.0 BACKGROUND

The Bureau of Engraving & Printing’s (BEP) Facility is a component of the United

States Department of the Treasury that designs, engraves, and prints U.S. currency banknotes and other U.S. security products. U.S. currency banknote manufacturing occurs at BEP’s District of Columbia Facility (DCF) located in Washington, DC. BEP’s primary customer is the Federal Reserve Board (FRB). As part of the manufacturing process various industrial wastewater streams are generated as well as storm water streams. These waste streams must be either pretreated through the BEP Wastewater

Pretreatment Plant (WWPP) in order to comply with environmental regulations that allow for their discharge into the sanitary sewer or must be otherwise managed in compliance with applicable regulations.

1.1 Objective

The Bureau of Engraving & Printing’s (BEP) Facility located in

Washington, DC contains an Industrial Wastewater Pretreatment Plant

(WWPP). BEP’s objective is to procure contractor services to manage, operate, maintain supplies and perform maintenance and provide engineering support for the Wastewater and Storm Water Programs. The

WWPP requires services to support the BEP on a 24/7 basis. The WWPP currently consists of three (3) systems: (1) Wiping Solution Wastewater

Pretreatment Plant (WSWPP), (2) Plating Wastewater Pretreatment Plant

(PWPP) and (3) Grease Trap Wastewater Pretreatment Plant (GTWPP).

The WWPP includes an on-site lab and a materials storage area. Refer to

Attachments 2, 3, and 4 for descriptions of the three (3) existing systems as well as Attachment 9 and 10 for listings of the equipment that are part of the existing WSWPP and PWPP, respectively.

In FY 2015, BEP is installing a Wiping Solution Recycling Plant that contains three (3) separate, yet interrelated systems: (1) Wiping Solution

Recycling Plant (WSRP), (2) Wiping Solution make-up/Manufacturing

Plant (WSMMP), (3) Wiping Solution Wastewater Pretreatment Plant

(WSWPP). The new WSWPP will replace the current WSWPP. The current

PWPP may be replaced during the performance period. Refer to

Attachments 5 and 6 for descriptions of the three (3) new systems. In addition to all of these full systems, additional small systems are currently being researched that will be included in scope of this requirement. These processes will be limited to elementary neutralization.

1.2 References

The Contractor shall comply with and perform all Services associated with the contract in accordance with any and all applicable Regulations/

Publications/ Codes. The Contractor is solely responsible for ensuring it is complying with and performing in accordance with any such amendments, supplements to such Regulations/ Publications/ Codes as well as any and all superseding documents issued or enacted during the life of the contract. The following is a listing of applicable Regulations/ Publications/ Codes governing the management, operation, supply, maintenance, and engineering of the BEP Plant. This list is not all inclusive.

REGULATION/

PUBLICATION

ORGANIZATION/

FEDERAL/STATE/LOCAL

AGENCY

WEBSITE/ LOCATION

Federal, State, Local and Organizational Regulations/ Publications/ Codes

All applicable regulations as prescribed under 29 CFR

1910.

Occupational Safety and Health

Standards (OSHA), Department of Labor http://www.osha.gov/

Applicable Standards and codes, including the National Electric Code

(NEC) codes.

National Fire Protection

Agency (NFPA) http://www.nfpa.org/

Applicable standards related to safety and health and ANSI/ASQC Q91-1987

Quality Systems Model for Quality

Assurance in Design/Development, Production, Installation, and Servicing.

American National Standards

Institute (ANSI) http://www.ansi.org/

All applicable Washington D.C.

regulations related to air, solid waste and water quality.

District of Columbia, Office of

Documents and Administrative

Issuance.

http://ddoe.dc.gov/service/r egulations-and-legislative-affairs http://www.osha.gov/ http://www.nfpa.org/ http://www.ansi.org/ http://ddoe.dc.gov/service/regulations-and-legislative-affairs http://ddoe.dc.gov/service/regulations-and-legislative-affairs http://ddoe.dc.gov/service/regulations-and-legislative-affairs

All applicable regulations, including but not limited to;

40 CFR 110 Discharge of Oil

40 CFR 112 Oil Pollution Prevention

40 CFR 122 and 123

40 CFR 136

40 CFR 141 through 143

40 CFR 260 through 268

40 CFR 273 Standards for Universal

Waste Management

40 CFR 279 Standards for the

Management of Used Oil

40 CFR 300 and 302 Releases to the

Environment

40 CFR 370 Hazardous Chemical

Reporting: Community Right-to-

Know

40 CFR 372 Toxic Chemical Release

Reporting: Community Right-to-

Know

40 CFR 403 General Pretreatment

Regulations for Existing and New

Sources of Pollution

40 CFR 433.15 Pretreatment

Standards for Existing Sources

NPDES Multi-Sector General Permit for Storm Water Discharges

Associated With Industrial Activities

NPDES General Permit for

Discharges from Construction

Activities

United States Environmental

Protection Agency (EPA) http://www.epa.gov/

49 CFR 171-180 United States Department of

Transportation (DOT) http://www.dot.gov/

BEP’s Wastewater Discharge

Permit

DC Water (DCWASA) Attachment 1

BEP Regulations/ Publications/ Codes

BEP’s WWPP Wiping Solution

Wastewater Pretreatment Plant

(WSWPP) Process Description

BEP Attachment 2

BEP’s WWPP Chemical Treatment

Process Plating Wastewater

Pretreatment Plant (PWPP) Process

Description

BEP Attachment 3

BEP’s WWPP Chemical Treatment

Process Grease Trap Wastewater

Pretreatment Plant (GTWPP) Process

Description

BEP Attachment 4 http://www.epa.gov/ http://www.dot.gov/

BEP’s WWPP Chemical Treatment

Process Wiping Solution Recycling

Plant (WSRP)/ Wiping Solution make-up/Manufacturing Plant (WSMMP)

Process Description - NEW

BEP Attachment 5

BEP’s WWPP Wiping Solution

Wastewater Pretreatment Plant

(WSWPP) Process Description - NEW

BEP Attachment 6

BEP Environment, Health, and Safety

Requirement for Construction and

Services

BEP Attachment 8

Wage Determination DOL Attachment 11

BEP Environment, Health, and Safety

Policy 75.00 (4.2).

BEP

Provided to the successful contractor after award.

BEP’s Quality Management System

Manual

BEP Provided to the successful contractor after award

BEP’s Environmental Management

System Manual

BEP Provided to the successful contractor after award

BEP Operational Control –

Management of Hazardous Waste 75D-

03.0-04

BEP Provided to the successful contractor after award

BEP’s SPCC Plan 75D-02.0-01 BEP Provided to the successful contractor after award

BEP's Emergency Action & Fire

Prevention Plan 75D-04.0-01

BEP Provided to the successful contractor after award

Escort Procedure:

BEP Security Manual 71-00, Chapter

BEP Provided to the successful contractor after award

The Contractor shall notify in writing the Contracting Officer (hereinafter

“CO”) and Contracting Officer Representative (hereinafter “COR”) of any change to an applicable Regulation/ Publication/ Codes and any impact it may have on the contract price. Before implementing any change that will result in a decrease or no change in the contract price, the Contractor shall submit to the CO a proposal no later than fifteen (15) calendar days following receipt of the notification of the change by the Contractor. The

Contractor shall implement those changes that result in a decrease or no change in the contract price as directed by the CO. Before implementing any change that will result in an increase in the contract price, the

Contractor shall submit to the CO a proposal no later than fifteen (15) calendar days following receipt of the notification of the change by the

Contractor. The Government and the Contractor shall then negotiate the change into the contract under the terms and provisions of the contract.

1.3 Acronyms and Definitions

The terms set forth below shall have the following meanings throughout this document:

1.3.1 "BEP” or “Bureau" means the Bureau of Engraving and Printing, U.S. Department of the Treasury.

1.3.2 "Contractor personnel” means all Contractor employees, including subcontractor employees, or any other person(s) acting for or on behalf of the Contractor to perform the Services as specified herein.

1.3.3 “Chemical Process” means a process by which a chemical is manufactured or a process that is inherently chemical in nature such as manufacturing processes that require the physical management of chemical usages in the process and require associated quality control techniques to maintain the process. Examples of chemical processes would be substrate coating operations, painting operations, pharmaceutical operations, water treatment operations, etc.

Specifically excluded from this definition is the process of the use of chemicals in boiler treatment or the process of the use of chemicals in cooling tower treatment or chiller facilities.

1.3.4 “Double shift” means two (2) times the normal time period of the contractor’s single shift. If the Contractor’s normal shift is 12 hours, a double shift is 24 hours consecutively. If the Contractor’s normal shift is 8 hours, a double shift is 16 hours consecutively.

1.3.5 "Facilities and/or Facility" means BEP's District of Columbia facility (hereinafter “DCF”), including the Plant, and any changes or improvements thereto, located at 301 14 th

Street, S.W., Washington, DC 20228-0001.

1.3.6 “Immediate or Immediately” means within fifteen (15) minutes, unless otherwise specified.

1.3.7 “Janitorial Supplies” means any and all supplies that may be used by personnel to keep the Plant and the personnel clean. Examples of janitorial supplies include, but are not limited to: paper towels, toilet paper, any bathroom supplies, hand soaps, sanitizers, mops, mop buckets, brooms, dust pans, and components, any floor mats sent for periodic cleaning service, trash bags, etc.

1.3.8 "Key Personnel" means Contractor personnel or positions who/which are considered vital to the performance of the Contract.

Those roles that are considered to be Key are the Plant Manager, Assistant Plant Manager, Maintenance Manager, On-site Daily

Support Engineer, Maintenance Technician, Supervisor and

Operator.

1.3.9 "Materials" means the consumables (e.g. chemicals [lab reagents, support, and process]), supplies (e.g. spare and repair parts and components) and other necessary materials (e.g. equipment, lubricants and containers) used to perform these services.

1.3.10 "Maintenance” includes work to repair and maintain as well as installation of process improvements. This includes work undertaken to prevent damage to equipment, a system or component thereof that otherwise would be more costly to completely overhaul or replace, to maintain Plant equipment and systems in a specified condition, or to restore equipment, systems or components to initial or usable condition by overcoming the effects of breakdowns, wear and tear, damage or deterioration, or work to correct an inoperable, broken, damaged, or worn system or component to a condition such that it operates in the manner in which it was intended or is restored to its "as built" condition and may consist of refurbishing and replacing systems or components as necessary in order to ensure reliable, long-term and safe and efficient operation of the Plant.

However, work performed under Maintenance shall be classified as follows:

1.3.10.1 “Preventive/Predictive Maintenance”

Preventive/Predictive maintenance is maintenance that is routinely scheduled and performed prior to the failure of equipment.

1.3.10.2 "Non-Routine Maintenance” Non-routine maintenance is unscheduled maintenance performed to correct items, which do not adversely affect production or jeopardize compliance with Regulations/ Publications/ Codes, specifically the Discharge Permit or constitute immediate danger to people, property or the environment, but if left unrepaired would result in failure of equipment, systems and/or other issues.

1.3.10.3 "Emergency Maintenance” Emergency maintenance is unscheduled maintenance performed to correct failures, which constitute an immediate danger to people, property, the environment or impact production or jeopardize compliance with compliance with Regulations/ Publications/ Codes, specifically the Discharge Permit.

1.3.11 "Monitoring and Testing” Monitoring and Testing is performed to provide reasonable assurance that Plant equipment is functioning as designed and that the equipment functions properly under both normal and emergency conditions so that adequate treatment is provided to meet Regulations/ Publications requirements.

1.3.12 "Normal Operating Hours" means twenty four (24) hours a day, seven (7) days a week, three hundred sixty-five (365) days a year, including all Federal Holidays and BEP’s Shutdown Period. The

BEP’s Shutdown Period typically occurs between December 25th and January 1st of each year. The COR will notify the Contractor of any change to the schedule.

1.3.13 “Oxidation-Reduction Potential or ORP” means tendency of a chemical species to acquire electrons and thereby be reduced. ORP is expressed in millivolts or mV.

1.3.14 “Permit” means BEP’s Wastewater Discharge permit and future revisions. Refer to Attachment 1 of this document for a copy of the current Permit.

1.3.15 “Personal Protective Equipment or PPE” means any type of device, material or equipment that is used to protect an individual from environmental or occupational harm that may be present due to conditions of normal operation or abnormal operation. Examples of these include but are not limited to: safety shoes, safety glasses, gloves, hearing protection, hard hats, protective suits, lotions or creams, etc.

1.3.16 “pH” means the negative log of the hydrogen ion concentration of an aqueous material expressed in Standard Units or S.U..

1.3.17 "Plant" means BEP's Industrial Wastewater Pretreatment Plant located at the BEP Washington, DC Facility and any changes, replacement or improvements thereto. The Plant currently consists of three (3) systems: (1) Wiping Solution Wastewater Pretreatment

Plant (hereinafter “WSWPP”), (2) Plating Wastewater Pretreatment

Plant (hereinafter “PWPP”) and (3) Grease Trap Wastewater

Pretreatment Plant (hereinafter “GTWPP”). In addition, the Plant includes an on-site lab and Materials storage area. When the new systems are installed as noted herein, they become part of the Plant as well.

1.3.18 “Plant shutdown or Plant stoppage” occurs when the Plant is out of operation due to a mechanical, electrical or operational failure, lack of treatment chemicals, or inadequate volume in the treatment tanks. Plant shutdown or Plant stoppage does not occur when the plant is intentionally shut off by the Government because the BEP is not in operation or resulting from a planned shutdown/ stoppage that does not affect BEP operations.

1.3.19 “Regulations/ Publications/ Codes” means any and all applicable

Federal, State, Local and Organizational laws, regulations, codes, ordinances and conditions (i.e. public and occupational health, safety, and environmental protection, pretreatment regulations, etc.)

as well as any and all BEP policies, procedures, guidelines and requirements that govern the management, maintenance and operation of the Plant. A listing of applicable Regulations/

Publications/ Codes is provided in Section 1.2 of this document.

1.3.20 “Repair or Repairs” means emergency repairs and minor repairs that are performed (1) in the event that any component or part, including equipment of the Plant should fail or not perform in accordance with Regulations/ Publications and/or equipment specifications, (2) by knowledgeable, trained, certified and experienced personnel utilizing proper equipment and tools and (3) to provide reliable, long-term and safe and efficient operation of the

Plant. Repairs are classified as follows:

1.3.20.1 “Emergency Repairs”: Emergency repairs are required to correct failures which constitute an immediate danger to workers, property, and impact production or jeopardize the

Plant’s compliance with Regulations/ Publications, specifically the Permit. The Contractor shall assess the situation, immediately (within 15 minutes of becoming aware of the issue) notify the COR or designee and provide a plan of action, and once approved, proceed with completing such repairs in a safe and expeditious manner.

1.3.20.2 “Repairs”: Repairs are required to correct failures which do not adversely affect production or constitute immediate danger to workers, property, and impact production or jeopardize the Plant’s compliance with Regulations/ Publications, specifically the Permit. The Contractor shall assess the situation, notify the COR or designee and provide a plan of action within twenty-four (24) hours of being alerted or becoming aware of failure or situation, and once approved, proceed with completing the repair in a safe and expeditious manner.

1.3.21 “SCADA” Supervisory Control and Data Acquisition software and associated hardware. This is also referred to as Human-Machine

Interface software or HMI. This is the equipment control software used for operational control in most of the Plant systems.

1.3.22 “Maximo” A BEP provided enterprise asset management application software through which asset lifecycle maintenance is performed. All materials, supplies and spare parts are managed through the storeroom function and all maintenance activities including PMs, calibrations, monitoring and measuring activities are managed through the service request and work order system.

Although Maximo is a BEP wide application, the Plant will utilize a separate subset of the system that is not visible to the rest of BEP on a generalized basis.

1.3.23 "Services" means the Contractor providing throughout the performance of the contract any and all labor and resources such as, but not limited to; Management, Operations, Engineering, Maintenance, Sampling and Testing, Monitoring, Measuring, Repairs, Process improvements, Transportation as well as any Tools and Equipment and Materials furnished by or utilized by the

Contractor in the performance of this effort for the safe, clean, orderly, efficient and successful operation, management and maintenance during Normal Operating Hours the BEP Plant.

1.3.24 “Tools and Equipment” means the tools and equipment furnished by the Contractor to perform the Services. For example, the

Contractor is to identify and provide its personnel with the necessary respiratory and Personnel Protective Equipment (hereinafter “PPE”) as required by OSHA regulations. The Contractor is responsible for identifying the Tools and Equipment needed to perform these

Services.

2.0 SCOPE

The Contractor shall perform any and all Services necessary for the safe, neat, clean, orderly, efficient and successful management, operation, maintenance, and engineering during Normal Operating Hours of the BEP’s Industrial Wastewater Pretreatment Plant

(hereinafter “Plant”) which includes small ancillary treatment systems, existing and installed, during the performance of this contract located in Washington, DC in addition to assigned Storm water activities.

The Government’s objectives are to obtain Services of exceptional value that afford it the opportunity to continuously improve, reduce costs and develop effective and efficient means to manage, operate, and maintain the Plant. Therefore, the Contractor shall implement the necessary controls, plans, processes, etc. to ensure such value. The contractor shall ensure that prudent engineering and operating practices are utilized at all times; with prudent engineering and operating practices meaning the practices, methods, and acts that at a particular time, in the exercise of reasonable judgment in light of the facts known or that should have been known at the time a decision was made, would be expected to accomplish the desired result in a manner consistent with law, regulation, reliability, safety, environmental protection, and the written recommendations of the equipment manufacturers. The Government will continue to implement improvements to the Plant throughout the duration of this effort and future efforts; thus it is expected that the Contractor is able to continuously tailor their controls, plans, processes, etc. to the needs of the BEP. The Contractor is expected to perform in accordance with the contract and performance requirements contained herein and in the attachments. The separation of the Contractor’s responsibility and BEP’s responsibility is the point at which a given utility (electricity, air, water, wastewater, and IT supplies) is provided to the equipment in the Plant. Once the utility is attached to the Plant equipment, the remainder of the responsibility belongs to the Contractor and is as such, then governed by the requirements prescribed herein.

2.1 Contract Line Item Number (CLIN) Structure and Definitions:

The Contract Line Items (CLINs) are defined as follows:

2.1.1 CLIN 001: Firm Fixed Price (FFP) - Phase-in and Training.

Description: This CLIN will provide for all of the labor and expenses associated with Phase-in for the existing Plant and training on the new systems. (Ref. Sections 3.25., 5.2., 5.12.1).

2.1.2 CLIN 002 (and subsequent options if exercised): Firm Fixed

Price (FFP) - Operation and Maintenance Labor.

Description: This CLIN will provide for all of the labor for

Management, Operations, Daily On-site Engineering and

Maintenance of the new plant and the remaining equipment along with the equipment that will go away ( the current Wiping Solution

Wastewater Pretreatment Plant) while the new equipment is being brought up on line. Examples of the labor requirements included in this CLIN would be operating the systems, labor for managing parts and supplies in Maximo, identifying new spare parts requirements for the new equipment, setting up and maintaining Maximo for the

Plant, cleaning all equipment in the plants, calibrating probes, changing malfunctioning probes, performing all maintenance on all of the plant equipment, recording data, collecting samples for operational control and performing operational control testing, collecting compliance samples, sending compliance samples to the lab, and preparing deliverables. The scope of this CLIN will also include labor to install process improvements associated with the new equipment where the improvements fall clearly in line with the required capabilities of the maintenance personnel, such as installing system equivalent pumps, tanks and control equipment as well as decontaminating and removing obsolete equipment as applicable.

(Ref. Sections 3.4.3., 3.5., 3.25., 4.10.)

2.1.3 CLIN 003 (and subsequent options if exercised): FFP - Parts and Supplies and Ancillary Services.

Description: This CLIN provides for all parts, supplies, and ancillary services for the current systems that will remain (PWPP, GTWPP) and the supplies and ancillary services for the systems that remain which will be used on the new systems (WSWPP, WSRP, WSMMP) and are currently used excluding process or treatment chemicals used in the current and new equipment which would be covered by a separate CLIN. This CLIN includes current lubricants, plant deodorizers, and laboratory supplies and chemicals. This CLIN also includes the ancillary services that are normally performed by outside sub-contractors. Ancillary Services include the following:

outside laboratory analysis, process control equipment and scale calibrations, confined space meter calibrations and service, laboratory equipment calibrations, SCBA tank testing and service, outfall flow measurement (only in FY 2017) and corrosion monitoring for sulfuric acid storage and piping. (Ref. Sections

3.3.3., 3.22., 3.27., 3.28., 3.29., 3.32.1., 3.36.)

2.1.4 CLIN 004 (and subsequent options if exercised): FFP - Process

Chemicals.

Description: This CLIN provides for all process and treatment chemicals used to recycle the used wiping solution, make-up new wiping solution, treat the non-recycled wiping solution, and treat the plating wastewater. A listing of materials and their annual usage estimates are provided in Attachment 22. (Ref. Section 3.3.3.)

2.1.5 CLIN 005 (and subsequent options if exercised): Not To Exceed

(NTE), and unfunded $ - Emergency Repair Parts and Service;

New Equipment Spare Parts; and Process Improvement Parts

Description: This CLIN provides for emergency repair parts and service where the prime Contractor does not have the specialized skills or equipment to perform emergency repairs, an example might be welding on a stainless steel tank to fix a leak, another example would be if something happened to the SCADA software and IT could not fix the problem. This would also include spare parts for the new equipment that are not presently known; for example the new equipment has pumps. These pumps will require periodic maintenance. The maintenance will require unknown parts in order to rebuild the pump so that it may be placed back into service. The contractor is required to identify the spare parts for the new equipment and set up the information in WWPP Maximo system and provide the information to BEP. As a quotation is provided for the list of new equipment spare parts, a new requisition would need to be written so that the parts would be charged for under this CLIN.

As the new system parts are identified, in time they will be added to

Section 2.1.3. Finally this CLIN will provide the parts needed for process improvements. As noted in Section 2.1.2, the prime contractor will already be required to provide installation labor for process improvements. (Ref. Sections 3.3.1., 3.25., 3.31., 3.28.)

2.1.6 CLIN 006 (and subsequent options if exercised): NTE, and unfunded $ - Process Improvements Engineering.

Description: This CLIN provides for the engineering labor to develop process improvements. The Contractor may suggest

Process Improvements and submit a quotation, or the government can request the Contractor to provide a quotation for a Process

Improvement. These would be in terms of a Task Order (TO) or a

Delivery Order (DO). It is important to understand that any equipment, part, or supply needed for a Process Improvement would be covered under Section 2.1.5 type description and the installation labor would already be covered under the Section 2.1.2 type description. If the Process Improvement is decided to go forward with, a requisition would be written to cover the cost for the engineering labor here and the parts under Section 2.1.5. It should be also understood that only 1 or 2 Process Improvement projects would be undertaken in a year, after the new equipment warranty is out on the equipment. Therefore there would be no Process

Improvements requiring engineering in the base period. (Ref.

Sections 3.5., 3.25., 3.34., 4.10.)

3.0 Contractor Responsibilities:

The Contractor shall be responsible for, but not limited to:

3.1 General: Managing, operating, and maintaining the Plant in a neat, clean, orderly, efficient and professional fashion during Normal

Operating Hours, to include furnishing required supplies and equipment in performance of this contract.

3.1.1 Fines and Penalties: The Contractor shall assume full responsibility and liability for compliance with all applicable regulations pertaining to the health and safety of personnel, security, and environmental management within the Contractor’s control during the execution of work, and shall hold the BEP harmless for any action on its part or that of its employees or subcontractors including but not limited to illness, injury, death or fines. If the Contractor fails to operate the Plant in compliance with the BEP Discharge

Permit or any applicable regulation and any fines or penalties are assessed against the BEP, the Contractor shall reimburse the BEP the amount of these fines and penalties and the cost of any legal defense against them.

3.1.1.1 Plant Shutdown: The Contractor shall fully recognize that the services covered by this contract are vital to BEP's mission;

that continuation of the services shall be maintained at the utmost proficiency without interruption since the operation, management and maintenance of the Plant is vital to the

BEP's mission. If the Contractor fails to maintain the Plant in 100% operational status and/or in compliance with the

Regulations/Publications/Codes, except when such conditions are beyond the control of the Contractor (e.g.

acts of God, civil unrest, labor disputes, military events) or when directed by the BEP, resulting in shutdowns/stoppages and/or fines or penalties being levied against the BEP, the BEP will assess damages and pass that amount onto the Contractor for reimbursement. These damages will be determined by and based upon the amount of down-time, the number of presses affected, and any direct support to the affected area(s) as well as the actual amount of any the fine(s) and/or penalty(ies) levied against the BEP. Current BEP labor rates will be used where applicable and other costs will be based upon actual costs.

Example: $1,000.00 fines or penalties were assessed, one

(1) hour down-time, affecting one (1) press with direct support being Plate Printer at $50.40/hr and a Foreman at

$71.47/hr and production cost of $500.00. Therefore, the amount that would be assessed against the Contractor would be as follows:

Information:

Penalties/ Fines = $1,000.00

Plate Printer $50.40/hr x One (1) hour = $50.40

Foreman $71.47/hr x One (1) hour = $71.47

Production cost $500.00 x One (1) hour = $500.00

Formula

$1,000.00 + ($500.00 +$50.40 + $71.47) = $1,621.87 (Total amount of

Damages to be assessed against the Contractor.)

3.1.2

House Keeping: This includes keeping waste to a minimum as well as keeping the Plant work area free of all foreign materials. Control cabinets are not to be used for storage and all maintenance items

(tools, excess parts, used parts, waste materials, etc.) are to be placed in their proper location at the end of the operations or maintenance event.

3.1.3

Odor Control: The Contractor shall ensure that no malodorous odors escape from the plant. There are processes internal to the plant, which periodically generates malodorous odors. These odors must be controlled inside of the plant before they exit the plant by the use of odor control agents.

3.1.4

Roll – up Doors: All roll-up doors must be kept closed unless transferring materials or equipment. The doors must be closed within 15 minutes of using the door, unless the doors are being used by the Office of Security. If a separate government contractor is causing the doors to be opened periodically, it is still the responsibility of the Plant Contractor to ensure that the doors are opened and closed as prescribed herein.

3.1.5

Maintenance of Plant Documentation: The Contractor will update

Plant documentation (all associated documents, forms, and electronic drawings) as changes in equipment, materials, and processes occur or as directed by the COR. The documentation must be updated after changes are completed so that the documentation is updated to the final level of the change. The updated document must be sent to the COR for review and approval within 15 calendar days of the completion of the change. The changes in the documentation will be highlighted so as to be easily recognizable with new or additional information in light blue and obsolete information struck through. Once the changes are approved by the COR, the

Contractor will remove the obsolete information, leaving the highlighted information until the next change. A change record will be maintained for each document in accordance with standard ISO document control methodologies and BEP policies.

3.2 Workforce and Personnel:

3.2.1

The Contractor shall hire, train, administer, manage and supervise the workforce necessary to perform the Services.

3.2.1.1

Under no circumstances shall any contract employee be hired to fulfill the requirements of the position for which they have applied that they do not already meet the requirements for the position unless otherwise noted. The BEP Plant is not to be a training facility. A contractor employee should only need to become familiarized with the work prescribed herein for which they will be performing and require the training as prescribed herein.

3.2.1.2

If after hiring a contract employee, the Contractor finds that the employee does not or cannot fulfill the requirement for the positions for which they were hired, the Contractor must remove the contractor employee from this contract and will be required to replace the removed contractor employee at the Contractor’s full expense.

3.2.1.3

The Contractor is required to have a system by which they evaluate all contract employees to ensure that they are performing to the expected level of the position for which they are employed as prescribed herein.

3.2.1.4

If the COR observes a contract employee that appears to not be performing to the required level of performance as prescribed herein, that action will be brought to the attention of the appropriate level of management of the Contractor for corrective action as appropriate. The Contracting Officer reserves the right to remove personnel from this contract if they do not meet the qualifications and/or performance of the required position.

3.2.2

The Contractor shall maintain satisfactory standards of personnel competency, conduct, appearance, and integrity and shall be responsible for taking such disciplinary action with respect to their personnel as necessary.

3.2.3

Ensuring there is sufficient personnel to perform Services at all times throughout the performance of the contract.

3.2.3.1

Sufficient personnel means the Contractor has an adequate number of capable, knowledgeable, trained and experienced and qualified individuals at all times to perform the Services as specified herein throughout the performance of this effort. The contractor must maintain a minimum of two (2) individuals on-site at all times, with one (1) individual being a Supervisor or equivalent, Plant Manager or Assistant Plant Manager. In addition, because of safety issues, at no time shall the Contractor allow any individual to be on duty for greater than 1.5 shifts without being sent off-site for rest. Under no circumstances will any contractor be allowed to sleep, nap, or rest between shifts on

BEP premises. Under no circumstances shall the Contractor ever be allowed to have an individual work a “double” shift.

3.2.3.2

The COR or CO may authorize an exception to the above minimum two (2) individual requirement for special circumstances that may arise during the performance of the contract, such exceptions if authorized, shall be granted only for a limited period of time and shall not release or hold harmless the

Contractor from its responsibility of performing these Services in accordance with the contract. The Contractor shall provide a written request no less than seventy-two (72) hours in advance of requesting such an exception.

3.2.3.3

Personnel that have been hired to fulfill roles under Section

4.10.1 are strictly prohibited from performing in a role listed under Section 4.10.2 as back-up, in excess of sixteen (16) hours within any seven (7) calendars day period, whether individually or as a group. Specifically, when any personnel hired under

Section 4.10.1 fill-in for a person that may be out (such as covering their shift), for any reason, fulfilling a role listed under

Section 4.10.2 for 16 hours, no other person from the group of personnel hired under Section 4.10.1 may fill-in for a person or persons hired under Section 4.10.2 again until 7 calendar days have passed.

3.2.4

The Contractor shall develop and establish an Emergency Operation

Plan as outlined in Section 8.1.11 below. The plan purpose is for providing any additional support or coverage needed to respond to emergency conditions, instances requiring additional expertise (e.g.

welding, specialized engineering, etc.) or instances of personnel illness, vacation and training.

3.3 Materials:

The Contractor shall be responsible for evaluating, testing, recommending, scheduling, maintaining, inventorying, tracking, supplying and stocking any and all materials necessary to perform the Services. All materials must be obtained in conformance with

Attachments 12 and 13. All current WWPP materials are required to be managed in Maximo within 4 months of award of the contract.

This time period may only be extended if there are technical issues with the use of Maximo. Inadequate training is not a technical issue.

An extension will not be granted for non-technical issues. In any case, monthly implementation progress reports will be required to be submitted to the COR as part of the Monthly Status Report (See

Section 8.1.18). An adequate inventory of materials shall be readily available and warehoused within the Plant in order to perform the

Services. Additional materials (process or treatment chemicals only) may be stored and warehoused at the BEP’s Landover Warehouse in order to provide a means for quick replenishment of on hand stock.

3.3.1

Some materials will not be the responsibility of the Contractor until the preparations for the start-up of the new recycling plant begins.

These materials are those utilized in the new plant but not utilized in the current Plant. The Contractor will be responsible for coordinating the materials that change in preparation of the new plant start-up. Those new materials associated with the new equipment must all be completely managed in Maximo within 4 months of the start-up of the new equipment. The new equipment spare parts shall be developed and purchased by the Contractor.

(Ref. Section 2.1.5).

3.3.2

The inventory of chemicals should be maintained in sufficient quantity, yet still produce ample turns per year (a minimum of four

(4) are recommended) to ensure fresh chemicals except for safety stock materials. An exception to this recommendation would only be for materials that are purchased in truck load quantities. A treatment system being shut down because there is no treatment or process chemicals means the chemicals are not being maintained in sufficient quantities.

3.3.3

The Contractor shall utilize only materials recommended by the original equipment manufacturer or the BEP for maintenance, repair and/or other such purposes. Attachments 14 through 19 provide specifications for the chemicals currently being used by BEP. Some chemicals however will not become the responsibility of the

Contractor until implementation of the Wiping Solution Recycling

Plant (Attachment 19). In addition, Attachments 20 and 21 provide specifications for the containers currently being used. Materials may be substituted, added or subtracted only if advanced approval is provided in writing by the COR. Attachment 22 provides a listing of process and treatment chemical estimated usages based on past annual usage amounts and projected annual amounts for the new systems when they come on line (Ref. Section 2.1.4). The

Contractor is responsible for procurement, use and inventory management of these materials as prescribed herein. The BEP already has contracts in place for the purchase of 50% Sodium

Hydroxide and 50% Sodium Sulfated Castor Oil. As such, the

Contractor will not be responsible for the procurement of these two materials, however will be responsible for inventory management and providing information to the COR such that these materials may be shipped in to the BEP in a manner that will support the operation of the BEP when the wiping solution recycling plant comes on line in accordance with the materials management methods prescribed herein. The specifications for these two materials (Attachment 18 and 19) are provided for information for the operation of the Plant and any required on site testing of the raw materials or external testing as needed, which is the responsibility of the Contractor.

Attachment 23 is a listing of spare parts and other materials with annual past usage amounts for the current systems (Ref. Section

2.1.3).

3.3.4

Some Materials (chemicals only) may need to be delivered to BEP’s

Landover Warehouse prior to delivery for use in the Plant. The

Contractor shall provide a three (3) business day advance notice for scheduling and coordinating the transfer of Materials from the

Landover Warehouse to the Plant. Additionally, the Contractor shall copy the COR on all requests for materials from the Landover

Warehouse.

3.3.4.1 BEP’s Landover Warehouse Information:

Items needing to be delivered to the BEP Landover Warehouse shall be delivered to the following address:

U. S. Department of the Treasury

Bureau of Engraving and Printing

3201 Pennsy Drive, Landover, MD 20785

Receiving hours for deliveries is 7:30 a.m. to 2:30 p.m., local time, Monday through Friday, excluding U.S.

Government holidays and BEP Year-End-Shutdown (which normally occurs between December 24 and January 1).

The Contractor shall call the Landover Warehouse appointment line at (202) 874-0874 at least at least twenty-four (24) hours in advance to schedule deliveries. The appointment line is staffed from 7:00 am to 3:00 pm

Monday through Friday. The following information must be provided:

- Name of supplier/manufacturer

- Contact Person with phone number

- Contract/Purchase Order Number

- Total number of cartons or pallets

- Total weight

- Date and Time of Delivery

3.3.4.2

All safety stock materials stored at the Landover Warehouse must be used at least on an annual basis in order to ensure their freshness and the integrity of the storage container.

3.3.4.3

The Contractor shall submit a list of safety stock materials for approval by the COR within 60 calendar days after contract award and update the list for approval by the COR within 15 calendar days of a change, either addition or subtraction that is proposed and approved by the COR.

3.3.5

Changes in materials levels that may impact the operation of the

Plant shall, with no exception, be brought to the attention of the

COR immediately.

3.4 Repairs and Maintenance:

The Contractor shall perform any and all necessary management, repairs, maintenance and other such tasks and duties required to ensure that the

Plant systems, equipment, components and parts are functioning as designed and that they are functioning properly under both normal and emergency conditions so that Plant systems are maintaining treatment at adequate levels and meet Regulation/ Publications/Code requirements throughout the performance of the contract.

3.4.1

The Contractor shall be responsible for the management of all equipment (assets), spare parts, and materials through the BEP provided enterprise asset management application Maximo.

3.4.2

The Contractor shall be responsible for learning and utilizing

Maximo accurately to the fullest extent possible up to and including requesting changes in the system, by submitting the written request to the COR which must include justification and desired outcomes to better utilize the system for the purpose of efficient operation of the Plant.

3.4.2.1

The Contractor will be given a list of Maximo training companies through which detailed training for Maximo, that will not be provided by BEP or reimbursed, may be obtained, if needed to fulfill the requirements herein. Training that will not be provided by BEP will be the sole responsibility of the

Contractor.

3.4.2.2

The training for the maintenance technician personnel and operators completing the work orders will be provided by BEP.

Any additional, re-training, or update training will be the sole responsibility of the Contractor and is non-reimbursable.

3.4.3

The Contractor shall be responsible for but not limited to:

developing job plans, identifying work assets and safety plans, labor requirements including costs, materials requirements, services, and tools for all service requests and scheduling of work orders.

3.4.4

The Contractor shall be responsible for transferring the data in the current asset maintenance management system (Antero) into the

Maximo system by whatever means necessary in accordance with

BEP policy.

3.4.5

The Contractor is required to complete the transition to the Maximo system from the current asset maintenance management system, including asset management within Six (6) months of contract award for the current existing Plant. This time period may only be extended if there are technical issues with the use of Maximo.

Inadequate training and or insufficient personnel are not technical issues. An extension will not be granted for non-technical issues. In any case, monthly implementation progress reports will be required to be submitted to the COR as part of the Monthly Status Report

(See Section 8.1.18).

3.4.6

The Contractor is required to coordinate with BEP personnel to correctly identify, tag, log and expand/associate as needed (Parent –

Child relationships), the new recycling equipment under the direction of the COR in the Maximo system within 6 months of the new equipment start-up. Inadequate training and or insufficient personnel are not technical issues. An extension will not be granted for non-technical issues. In any case, monthly implementation progress reports will be required to be submitted to the COR as part of the Monthly Status Report (See Section 8.1.18). A skeletal system will be provided from the equipment installation contractor. The

Contractor will be required to keep the system up to date with any and all changes in the Plant throughout performance of this contract.

3.5 On-site Daily Support Engineering:

Performing any and all necessary engineering tasks and duties required to ensure that the Plant’s systems, equipment, components and parts are functioning as designed and that they are functioning properly under both normal and emergency conditions so that Plant systems are maintaining treatment at required levels and meeting Regulations/Publications/Codes requirements continuously throughout Normal Operating Hours. This On-site Daily Support Engineering function is separate from the Process

Improvements Engineering as noted under Section 3.33. Examples of tasks and duties include but are not limited to; analysis or studies, cost control, identifying and seeking efficiencies, verifying and ensuring compliance with Regulations/Publications/Codes, developing, reviewing, maintaining and providing specifications, designs or drawings, developing and/or reviewing plans, policies and procedures, planning and forecasting, development and implementation of the new recycling system for wiping solution generated from press operations or associated sludge, conducting tests, experiments, reviewing and inspecting the Plant, and supporting the implementation of Maximo as needed. Determinations as to the classification of engineering being performed or needed will be made by the COR if there is a question. Materials management is not an engineering function and is prohibited from being done by the engineer under this CLIN. See note below. Additionally the person fulfilling this role must have the ability and knowledge to be able to back-up

Programmable Logic Controller (PLC) programs and be able to reload

PLC programs for all Plant PLCs. This is considered rudimentary PLC work. This person is not required to have extensive PLC programming knowledge, only rudimentary knowledge and capabilities. NOTE: Labor for this On-site Daily Engineering function is included in the operation, maintenance and engineering CLINs (Ref. Section 2.1.2) and is not covered by Section 3.33 which has a separate CLIN (Ref. Section 2.1.6).

The following is a brief listing of the projects that currently need to have on-site engineering work completed in order to be implemented in the plant. The On-site Daily Engineer is strictly prohibited from performing work on Process Improvements. Their work may be used by another engineer on Process Improvements, but they may not engineer a Process

Improvement, because their labor is already included in Section 2.1.2.

3.5.1 Valve Tagging and ANSI Pipe Labeling.

The valves and pipes throughout the plant shall be tagged and labeled in order to facilitate the efficient operation and documentation of the Plant. A system must be engineered, developed and implemented to facilitate this project and maintain the system and associated documentation as changes occur.

3.5.2 Filter Cloth Cleaning.

The WSWPP filter cloths are currently cleaned by power washing.

Develop and engineer a process that will allow for the safe and efficient cleaning of the filter clothes in place, without removing them from the filter presses. The project will involve the identification and testing of various cleaning materials and subsequent physical changes to the equipment and process changes.

3.5.3 HMI Software Upgrade.

The contractor will be responsible for engineering upgrading the

HMI software to correct obsolete screens, add screens to the system for equipment not currently covered, and improve collection and management of the data from the Plant. This work will include working with BEP IT and their contractor.

3.5.4 GTWPP.

The GTWPP currently must have the front two basket strainers cleaned on a daily basis to prevent solids build-up from blocking the flow through the system. The Contractor will be responsible for developing a method/process change/ to eliminate or automate the daily cleaning requirement.

3.5.5 Sulfuric Acid Drum Filling Station.

There is a requirement for procurement and storage of 93% Sulfuric

Acid in 55 gallon drums in the Landover Warehouse to be used as a safety stock supply in instances where there are extended delays in bulk shipments of Sulfuric Acid to the Plant. In the event that 93%

Sulfuric Acid cannot be procured in the drums that meet the material specification to fulfill this safety stock storage requirement, a system needs to be engineered, developed and implemented that will allow for the filling of drums from the bulk tank in a safe manner and those drums may be properly labeled and transported to Landover

Warehouse for storage to meet the safety stock supply requirements.

3.5.6 50% Sodium Hydroxide Drum Filling Station.

There is a requirement to be able to safely provide the BEP Shops with small amounts of 50% Sodium Hydroxide in order for the shops personnel to make up a cleaning solution to flush and…