Complete Steam Generator Project-SOW.pdf

DRAFT

SOW NEW STEAM GENERATOR INSTALLATION AT

AREA 1-42 STATEMENT OF WORK

JULY TBDTH, 2024 REV 2

UNITED STATES AIR FORCE RESEARCH LABORATORY

(AFRL)

Statement of Work for

NEW STEAM GENERATOR INSTALLATION AT AREA 1-42

TABLE OF CONTENTS

1. INTRODUCTION 4

2. BACKGROUND 6

3. REFERENCE DOCUMENTS 7

4. SCOPE OF WORK 8

4.1 WORK PLATFORMS FOR PROPANE VESSELS 9

4.2 INSTALL DELUGE SYSTEM FOR PROPANE VESSELS 10

4.3 INSTALL LIGHTING AND POWER DISTRIBUTION AT PROPANE

STORAGE AREA 10

4.4 INSTALL PROPANE DISTRIBUTION PIPING 10

4.5 DESIGN, FABRICATION AND INSTALLATION OF NEW STEAM

GENERATOR 11

4.6 INSTALL FILL WATER PIPING FOR STEAM GENERATOR 12

4.7 INSTALL WATER DRAIN PIPING FOR STEAM GENERATOR 12

4.8 INSTALL POWER DISTRIBUTION FOR STEAM GENERATOR 12

4.9 INSTALL VENT LINES 13

5. TECHNICAL REQUIREMENTS 13

5.1 GENERAL REQUIREMENTS 13

5.2 ENVIRONMENTAL AND NATURAL PHENOMENA CONDITIONS 13

5.3 CERTIFIED MATERIAL TEST REPORTS 14

5.4 HYDROSTATIC TESTING OF PRESSURE BOUNDARY PIPING

SYSTEMS 14

6. WELDING 15

7. INSPECTION AND EXAMINATION 17

8. CLEANING 18

9. DRAWINGS AND CALCULATIONS 18

10. DELIVERABLES 19

11. PROJECT PLAN AND SCHEDULE 20

12. SAFETY 22

13. QUALITY CONTROL 23

14. SECURITY 23

15. HOLD POINTS 24

16. PROPOSAL 24

17. AVAILABILITY OF UTILITIES AND WORK SPACE 25

18. OTHER 26

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 PROCESS 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. INTRODUCTION

The United States Air Force Research Laboratory (AFRL), Edwards Air Force Base, 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. The scope of work for this project will generally include the following tasks:

Note: A separate Statement of Work (SOW) to include the installation of the foundation for the propane storage area, demolition of the existing propane storage area, rigging, transport and placement of existing propane storage vessels on new foundations, foundation for the new steam generator, installation of pre-fab trenches and other miscellaneous civil work has been prepared and titled

STATEMENT OF WORK FOR CONCRETE AND CIVIL WORK IN SUPPORT OF

NEW STEAM GENERATOR INSTALLATION. The work identified in this document requiring the installation of the foundations, demolition, movement of the propane vessels and other grading and related civil work will be performed by others and is NOT part of the scope of the scope of work and tasks outlined herein.

• INSTALL NEW PIPING, ELECTRICAL, LIGHTING, PLATFORMS,

DELUGE WATER AND OTHER SYSTEMS AT NEW PROPANE

STORAGE AREA—THIS WILL INCLUDE RELOCATING AND

INSTALLING THE SALVAGED VAPORIZER

• FABRICATE AND INSTALL NEW STEAM GENERATOR (REFERENCE

SEPARATE STATEMENT OF WORK FOR AREA 1-42 STEAM

GENERATOR)

• INSTALL NEW PIPING SYSTEMS FOR STEAM GENERATOR

• INSTALL NEW ELECTRICAL AND OTHER SYSTEMS FOR STEAM

GENERATOR

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 infrastructure and systems required for the first, single steam generator. The Contracting Officer 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 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 Contracting Officer 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 Contracting Officer immediately.

Procurement, fabrication and associated inspection, testing, transport and installation of the new steam generator is a substantial task included as part of this Statement of Work. Because of the complexity and magnitude of the new equipment, a separate document STATEMENT OF WORK FOR AREA 1-42 STEAM GENERATOR has been developed to describe in detail the scope and technical requirements for the steam generator. This document and the associated scope of work are incorporated herein by reference. This SOW and the SOW for the Steam Generator need to be worked and referenced TOGETHER to fully describe the entire scope of this project.

The new steam generator will replace an aging steam generation system in use at AREA 1-42 that includes large spherical saturated water 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. The existing system will largely be left intact and mothballed for potential future use.

For the purposes of this Statement of Work (SOW) the term Contractor shall apply to the vendor who will perform the work identified herein. The term Contracting Officer shall apply to the US Air Force or it’s designated representative.

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

This is a fixed price, lump sum contract. The steam generator and foundations, piping, electrical and other work described herein shall be FOB, AFRL, Edwards AFB, California.

The intent of this project is for the Contractor to perform all work required to install piping, mechanical, platforms, electrical and related items at the new propane storage area, and provide and install one (1) safe, complete, fully functional and operable steam generator, and required support systems, 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 Contracting Officer has assigned a tag number to the steam generator, the propane vessels and other system components. These tag numbers shall be used by the Contractor to reference the tag items 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” ID carbon steel spherical vessels used to store heated, saturated water. A system including a process heater that heats oil and a shell and tube heat exchanger 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. Two (2) propane storage vessels are used to supply fuel to the process heaters.

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 operate 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 a number of 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. A photo of the steam plant is shown in Figure 1.

FIGURE 1—AERIAL VIEW OF AFRL AREA 1-42 STEAM PLANT

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 substantial 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 a new large capacity steam generator.

3. REFERENCE DOCUMENTS

The following documents are referenced throughout the SOW:

REFERENCE DOCUMENTS FOR NEW STEAM GENERATOR

INSTALLATION AT AREA 1-42

DOCUMENT NUMBER DOCUMENT TITLE

202236360 NEW STEAM GENERATORS KEY MAP AND DRAWING

INDEX

202236361 NEW STEAM GENERATORS SITE PLAN

202236362 NEW STEAM GENERATORS SURVEY CONTROL DRAWING

202236363 NEW STEAM GENERATORS EQUIPMENT AND PIPING

LAYOUT

202236364 NEW STEAM GENERATORS FABRICATION AREA SITE

PLAN

202236368 NEW WORK PLATFORMS FOR PROPANE STORAGE

202236371 NEW STEAM GENERATORS P&ID

202236372 NEW PROPANE P&ID

202236373 NEW PROPANE LIQUID FILL PIPING LAYOUT AND

FABRICATION DETAILS

202236374 PROPANE TANK WATER DELUGE P&ID

202236375 NEW PROPANE LIQUID SUPPLY PIPING LAYOUT AND

FABRICATION DETAILS

202236376 STEAM GENERATOR AND PIPING CONCEPTUAL

INSULATION PLAN

202236377 NEW WATER FILL PIPING PLAN AND DETAILS

202236378 NEW DRAIN PIPING PLAN AND DETAILS

202236379 NEW PROPANE STORAGE WATER DELUGE PIPING

PLANS AND DETAILS

202236381 STEAM GENERATOR RIGGING AND TRANSPORT PLAN

202236382 NEW PROPANE VAPOR FILL PIPING LAYOUT AND

FABRICATION DETAILS

202236383 ELECTRICAL DISTRIBUTION, LIGHTING, ONE LINE

DIAGRAM FOR PROPANE STORAGE AREA

202236384 ELECTRICAL DISTRIBUTION, LIGHTING, ONE LINE

DIAGRAM FOR STEAM GENERATORS

STATEMENT OF WORK FOR AREA 1-42 STEAM

GENERATORS

STATEMENT OF WORK FOR CONCRETE AND CIVIL WORK

IN SUPPORT OF NEW STEAM GENERATOR

INSTALLATION (INCLUDED FOR REFERENCE ONLY)

COMPONENT DATA SHEETS

Technical Documents and Standards

-AISC Manual of Steel Construction

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

-ASNT SNT-TC-1A Personnel Qualification and Certification in Non Destructive Testing

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

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

-ASME B&PVC Section V Nondestructive Examination

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

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

-ASME B31.1 Power Piping

-AWS D1.1 Structural Welding Code

-IBC International Building Code

-NFPA 13 Standard for the Installation of Sprinkler Systems

-NFPA 15 Standard for Water Spray Fixed Systems for Fire Protection

-NFPA 54 National Fuel Gas Code

-NFPA 58 Liquefied Petroleum Gas Code

4. SCOPE OF WORK

In general, the scope of work for this project includes the Contractor providing the necessary resources to perform all work as described herein to furnish and install one (1) complete and ready to operate steam generator.

The Contractor shall provide all materials, labor, supervision, tools, consumables, equipment, forms, incidental materials, vehicles, freight, utilities, subcontracts, testing equipment and materials and any other resources required to provide a full and complete installation and furnish all identified training, manuals, documentation, records, spare parts and ALL other deliverables as identified herein.

All equipment, piping and other items shall be installed to the lines, grades and dimensions as shown on the drawings. The Contractor shall be responsible to obtain careful measurements and verify correct placement of all installed equipment, piping, platforms, conduit and any other items as shown on the drawings.

The following are the major sub tasks associated with this project.

Note: As explained above a separate Statement of Work (SOW) to include the installation of the foundation for the propane storage area, demolition of the existing propane storage area, rigging, transport and placement of existing propane storage vessels on new foundations, foundation for the new steam generator, installation of pre-fab trenches and other miscellaneous civil work has been prepared and titled STATEMENT OF WORK FOR CONCRETE AND CIVIL WORK IN SUPPORT OF NEW STEAM GENERATOR INSTALLATION. The work identified in this document requiring the installation of the foundations, demolition, movement of the propane vessels and other grading and related civil work will be performed by others and is NOT part of the scope of the scope of work and tasks outlined herein. Much of the work described herein will need to be properly interfaced with the foundations and other work performed by others.

4.1 Work Platform for Propane Vessels

The Contractor shall prepare shop drawings, fabricate and install in the field the work platform between the two (2) vessels at the new propane storage area as shown on Drawing No. 202236368. The Contractor shall arrange to provide all materials, detailed shop drawings, perform all painting, fabrication, cutting, welding and field installation of the work platforms.

The Contractor shall obtain field measurements after the propane vessels are set in place to finalize fabrication dimensions of the work platform to ensure proper fit up and clearances. Likewise, the Contractor may consider incorporating into his design allowances to obtain field measurements and make final adjustments when installing the work platform at the site.

4.2 Install Deluge System for Propane Vessels

As shown on Drawing No. 202236374 the Contractor shall provide all materials for and install the deluge piping for the new propane storage area. The Contractor shall be responsible to connect into the Contracting Officer’s existing underground piping connection point (the tie in point shall be located by the Contracting Officer).

All excavation, backfilling, compaction, installation of the vault, piping, pipe wrapping, components, structural supports, welding, testing, painting and any other work required for a complete and operable system shall be performed by the Contractor.

The Contracting Officer shall install all power wiring and controls to the new deluge system Remote Operated Valve (ROV).

After all installation and pressure testing of the deluge system is complete the Contractor shall coordinate with the Contracting Officer to perform an operational test of the deluge system to verify correct operation. This test shall be jointly witnessed by the Contractor and Contracting Officer. The Contractor shall prepare a brief test plan and record the results of the subject test.

4.3 Install Lighting and Power Distribution at Propane Storage Area

As shown on Drawing No. 202236383 the Contractor is responsible to provide all materials and perform all installation for lighting and electrical power distribution at the new propane storage area. This will include providing and installing all conduit, boxes, panels, light fixtures, switches, receptacles, supports, wiring and cables and any other items required for a full and complete installation.

The Contractor shall be responsible to connect to the Motor Control Center (MCC) as shown on the drawing and route conduit, wiring/cables to the propane storage area. The Contractor shall connect all wiring and cables to the identified equipment, fixtures and receptacles. All testing of installed systems shall be performed to verify correct operation.

4.4 Install Propane Distribution Piping

Propane distribution piping shall be provided and installed by the Contractor as shown on Drawing Nos. 202236373, 202236375 and 202236382. Also reference the Propane P&ID Drawing No. 202236372. This will generally include all propane piping from the propane storage vessels to the burner gas train supplies at the steam generator. A branch line from the propane distribution piping will also be routed to the existing propane piping that supply the process heaters. The Contractor shall provide all piping, fittings, components, pipe supports, instruments, and any other materials or items called out on the drawing for a complete installation. The Contractor shall perform all measuring, fitting, cutting, welding, threading, installation, inspection and testing required to install a complete and functional propane distribution system. The Contracting Officer shall install any wiring for power or controls to instruments, valves or similar components.

As shown on the Drawing No. 202236382, the Contractor shall be responsible to remove and reinstall in the new location, the propane vaporizer. Installation shall include properly orienting and installing new anchors to secure this equipment.

Any control or instrument wiring required for operation of the vaporizer shall be provided by the Contracting Officer. Likewise, the Contractor is responsible to install the salvaged propane transfer pump as shown on the drawings. The Contractor shall salvage the local push button control box for the pump, mount the controller and provide wiring to the controller for operation of the pump.

The Contractor shall obtain cut sheets, drawings, O&M Manuals and other vendor documentation for all components (e.g. valves, ROVs, filters, pressure regulators, gages) as shown on the drawings.

Note that as shown on the drawings, branch lines for supply to the future steam generators are required to be installed and blinded off.

4.5 Design, Fabrication and Installation of New Steam Generator

The scope of work and technical details for this task is identified separately in the document STATEMENT OF WORK FOR AREA 1-42 STEAM GENERATOR.

Reference is made here as providing the steam generator is an integral part of this Statement of Work. For reference, key tasks to be performed to furnish the steam generator include (this is ONLY a brief synopsis—read the referenced document for a full and complete description of the scope and technical requirements):

• Design of the steam generator

• Design of the boiler external piping

• Preparation of a separate area at AFRL to be used for staging and fabrication of the steam generator

• Rigging, lifting, transport and placement of the steam generator from the staging area to the permanent location on the new foundations at Area 1- 42 (includes providing, setting, aligning and leveling of base plates for the steam generator as shown on the drawings)

• Installation of boiler external piping to connect to the facility piping (also provided by the Contractor and described herein). Note that for the main steam outlet the Contractor shall design, fabricate and install all piping designated as boiler external piping AND additional piping to connect to the existing facility steam header

• Install insulation on steam generator and boiler external piping

• Provide for training of Contractor personnel to operate the steam generator

• Perform field testing of the steam generator to verify they are ready for service

• Provide all deliverables including reports, drawings, calculations, records or inspection and testing, spare parts and other items as specified in the referenced SOW

4.6 Install Fill Water Piping for Steam Generator

Fill water piping for the steam generator is shown on Drawing No. 202236377.

This segment of fill water piping shall be routed from where it connects to the Contracting Officers facility piping (shown on the drawings) to where it connects to the boiler external water fill piping (also shown on the drawing) included as part of the steam generator.

Provide all materials as called out on drawing. Install piping, supports, perform all inspection and testing.

Note that as shown on the drawings, branch lines for supply to the future steam generators are required to be installed and blinded off.

4.7 Install Water Drain Piping for Steam Generator

Drain system piping for the steam generator shall be provided and installed by the Contractor as shown on Drawing No. 202236378. This segment of drain piping connects to the boiler external drain piping from the steam generator and is routed to a drain trench as shown on the drawing. Note that this segment of drain piping will interface with and connect to the drain line from the main steam header, located between the two (2) shut off valves and shown on the drawings.

The Contractor shall provide all materials and perform installation of the piping and supports, perform all testing and inspection as called for on the drawing.

Note that as shown on the drawings, branch lines for supply to the future steam generators are required to be installed and blinded off.

4.8 Install Power Distribution for Steam Generator

Provide and install all conduit, fittings, wiring and cables, boxes, panels, and any other electrical items as shown on Drawing No. 202236384. Route conduit and wiring to provide power to steam generator blower, valve motors and any other equipment or items requiring power.

The Contractor shall be responsible to connect to the Motor Control Center (MCC) as shown on the drawing and route wiring/cables to the steam generator. The Contractor shall connect all wiring and cables to the identified equipment and fixtures. All testing of installed systems shall be performed to verify correct operation.

Note that as shown on the drawings, branch connections for supply of power to the future steam generators are required to be installed and capped off. Also, the lighting and receptacles shown on the drawing will not be installed at this time.

4.9 Install Vent Line

As shown on drawing 202236363 provide the new vent line, from the steam generator. This line will route vertically from the steam generator. As shown on the drawing, a weather cap shall be installed on the vent line to prevent water from entering the pipe.

Note also the vent line will need to interface with a ROV to be close coupled to the 3” vent nozzle on the steam generator (this valve will be designated as “PP” piping in accordance with ASME B&PVC Section I requirements). The vent line downstream of the ROV shall be designed and installed in accordance with ASME B31.1 Power Piping Code. The Contractor shall design the vent line so as to exhaust the steam a minimum of 8 feet above the work platform walking/working surface and design any supports needed for structural adequacy.

5 Technical Requirements

5.1 General Requirements

In general most technical requirements for the tasks identified herein are included on the referenced drawings and specifications. Supplemental and general technical requirements are included in this Section.

5.2 Environmental and Natural Phenomena Conditions

The steam generator will be installed outdoors at the AFRL, Edwards Air Force Base, California. The following are relevant environmental conditions:

Altitude for the Project: 3150 ft

Mean Barometric Pressure: 26.7 in Hg

Outdoor Ambient Temperature Range: +0 to 120°F Humidity: 0 to 100% plus condensation

Outdoor Conditions: High Desert Environment--Wind, blowing sand and dust.

Wind Design Conditions (IBC 2018) Minimum wind speed 115 mph Importance Factor 1.0 Wind Exposure D

Seismic Design Requirements (IBC 2018) Ss 0.821 S1 0.329

SDS 0.657

Importance Factor 1.0

Snow Load (IBC 2018) Minimum Ground Snow Load 5 psf

5.3 Certified Material Test Reports

All pressure boundary materials used in the fabrication of the piping systems included in this SOW 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. The Contractor’s Quality Control Plan shall address transfer of heat numbers and traceability for individual pieces and parts that are cut or altered.

5.4 Hydrostatic Testing of Pressure Boundary Piping Systems

Hydrostatic testing of all pressure boundary piping systems shall be performed as required by ASME B31.1 Power Piping Code. All provisions for testing including temperature of test media, test pressure, hold times, calibrated test gages and other requirements shall be met by the Contractor.

The Contractor shall prepare a hydrostatic test plan to be used as a basis for testing of the pressure boundary piping systems . This plan shall be submitted to the Contracting Officer for review and approval prior to use. This plan shall include a schematic indicating the boundaries of the piping to be tested—including interface and connection points with equipment and boiler external piping, test pressure, temperature requirements, location of the test gage, location and installation of temporary hardware including blinds, gaskets, bolting, tubes, pipes, pumps, location of high point bleed and low point drains, plans for filling and draining the steam vessels, inspections to be performed during pressure testing and any other key information required to support this test. Execution of the hydrotest shall use a checklist type format to verify completion.

Water used for hydrotesting of stainless steel piping shall be de-mineralized, deionized or chemically treated to limit chloride content to no more than 10ppm.

All fabrication, inspection, NDE and other related work shall be verified complete prior to performing hydrostatic testing. All welding of any type on the pressure boundary of the piping systems shall be completed, inspected and verified acceptable prior to testing.

The Contractor shall provide all necessary temporary hardware for hydrotesting including, but not limited to, blinds, gaskets, bolting, tubes, piping, gages, valves, PSVs, pumps, and any other equipment or items required to conduct the test. A copy of the completed hydrotest documentation shall be provided to the Contracting Officer.

6 Welding

Welding of Pressure Boundary Piping Systems

All welding of piping pressure boundaries shall be performed in accordance with ASME B31.1 Power Piping Code and ASME B&PVC Code Section IX Welding and Brazing Qualifications, latest editions with addenda.

All welding shall be performed using the gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), flux core arc welding (FCAW), gas metal arc welding (GMAW) or shielded arc welding (SAW) methods. Either manual, semi-automatic or automatic methods may be used. Welding methods shall provide gas purging when required. Absolutely no sugaring will be allowed. A clean, smooth textured final internal surface will be required. Other welding processes may be proposed for use by the Contractor but shall be approved prior to use by the Contracting Officer.

Welding of pressure boundary systems and components will be primarily carbon steel to carbon steel welds as shown on the drawings.

The Contractor shall have a written Quality Control Plan as required by ASME B31.1 Power Piping Code which addresses topics such as, but not limited to, records of Welder Qualification Tests, tracking method to identify which welders are currently qualified for specific procedures, storage and control of filler metals, fluxes, and gases, weld repair procedures, preparation of weld maps, and similar topics. The Contractor shall provide a copy of his Quality Control Plan to the Contracting Officer for his review and approval.

Prior to the start of any welding the Contractor shall submit copies of ALL Procedure Qualification Records (PQRs) and Weld Procedure Specifications (WPS’) for all welding of pressure boundary parts to the Contracting Officer for review and approval prior to use. The Contractor shall specifically identify which PQRs and WPS’ will be used to weld which systems, parts and components.

The Contractor shall carefully maintain records and a log of all personnel performing pressure boundary welds. The log shall include, at a minimum, the name of the welder, the welding process(es) they are qualified to weld to, key qualification variables such as thickness of material and position. Additionally the Contractor shall maintain a welder continuity log to document and verify dates that welders have used welding processes they are qualified for to ensure they meet ASME B&PVC Section IX requirements.

It is advisable that the Contractor issue each welder a card noting the process(es) they are qualified for, key variables and other relative information.

As may be required by ASME B31.1 Power Piping Code, materials and parts of pressure boundary systems shall be preheated and post-weld heat treated (PWHT). Preheating of parts and joints in preparation for welding shall be noted on the WPS. Any parts requiring post-weld heat treatment shall be specifically identified by the Contractor and a detailed plan developed for performing PWHT.

Welding of Non-Pressure Boundary Items

Welding of non-pressure boundary items such as pipe supports and work platforms shall be performed in accordance with AWS D1.1 Structural Welding Code.

It is anticipated the Contractor will primarily use shielded metal arc welding (SMAW), flux core arc welding (FCAW), gas metal arc welding (GMAW) or shielded arc welding (SAW) methods. Either manual, semi-automatic or automatic methods may be used. Welding methods shall provide gas purging when required.

Other welding processes may be proposed for use by the Contractor, but shall be approved prior to use by the Contracting Officer.

Welding of non-pressure boundary systems and components will be primarily carbon steel to carbon steel welds as shown on the drawings.

The Contractor shall have a written Quality Control Plan for performing non pressure boundary welds in accordance with AWS D1.1. The Quality Control Plan shall addresses topics such as, but not limited to, records of Welder Qualification Tests, tracking method to identify which welders are currently qualified for specific procedures, storage and control of filler metals, fluxes, and gases, weld repair procedures, preparation of weld maps, and similar topics. The Contractor shall provide a copy of this Quality Control Plan to the Contracting Officer for his review and approval.

Prior to the start of any welding the Contractor shall submit copies of ALL Procedure Qualification Records (PQRs) and Weld Procedure Specifications (WPS’) for all welding of non-pressure boundary parts to the Contracting Officer for review and approval prior to use. The Contractor shall specifically identify which PQRs and WPS’ will be used to weld which systems, parts and components.

The Contractor shall carefully maintain records and a log of all his personnel performing non-pressure boundary welds. The log shall include, at a minimum, the name of the welder, the welding process(es) they are qualified to weld to, key qualification variables such as thickness of material and position. Additionally the Contractor shall maintain a welder continuity log to document and verify dates that welders have used welding processes they are qualified for to ensure they meet AWS D1.1 requirements.

It is advisable that the Contractor issue each welder a card noting the process(es) they are qualified for, key variables and other relative information.

As may be required by AWS D1.1, materials and parts of non-pressure boundary systems shall be preheated and post-weld heat treated (PWHT). Preheating of parts and joints in preparation for welding shall be noted on the WPS. Any parts requiring post-weld heat treatment shall be specifically identified by the Contractor and a detailed plan developed for performing PWHT.

7 Inspection and Examination

All inspection and examination of pressure boundary welds shall be performed in accordance with the requirements of ASME B31.1 Power Piping Code and ASME B&PVC Section V Nondestructive Examination latest editions and addenda.

All inspection and examination of non-pressure boundary welds, i.e. structural or other welds, shall be in accordance with the requirements of AWS D1.1 Structural Welding Code.

All pressure boundary materials shall be tested with a Positive Material Identification process to verify the material is the same as shown on the CMTR. A written procedure shall be used to perform and record this testing activity.

All pressure boundary and non-pressure boundary welds shall be 100% visually inspected in accordance with ASME B31.1 Power Piping Code and ASME B&PVC Section V for pressure boundary welds and AWS D1.1 for non-pressure boundary welds and the results of the inspection recorded.

One Hundred (100) % of all pressure boundary welds on each piping system shall be volumetrically examined in accordance with ASME B31.1 Power Piping Code and ASME B&PVC Section V.

One Hundred (100) % of all pressure boundary fillet welds shall be examined using liquid penetrant (LP) examination in accordance with ASME B31.1 Power Piping Code and ASME B&PVC Section V.

All personnel performing nondestructive testing shall be certified in accordance with American Society for Non-Destructive Testing ASNT SNT-TC-1A, Qualification of NDT Personnel. Upon request the Contractor shall provide his written procedures for performing radiography, phased array testing, visual inspection, liquid penetrant inspection or any other non-destructive testing procedure that the Contractor may employ as part of the inspection and examination of the steam generator.

8 Cleaning

The interior wetted perimeter of all pressure boundary systems shall be cleaned so there are no visible indications of dirt, grease, markings, weld spatter, mill scale or other foreign material.

Any unpainted external surfaces of pressure boundary systems shall be cleaned so there are no visible indications of dirt, grease, markings, weld spatter, mill scale or other foreign material.

Some minor indications of rust is allowable on the exterior surfaces of pressure boundary systems.

The Contractor shall take particular care to inspect and ensure no tools, rags, cuttings, weld rods or other foreign materials are left inside of pressure boundary piping systems.

9 Drawings and Calculations

In general the Contracting Officer has performed engineering and prepared drawings for the work described in this SOW.

Any other shop drawings, cut sheets, vendor data or similar information that the Contractor obtains in support of the work described herein shall be provided to the Contracting Officer.

The Contractor shall maintain “red-lines” throughout fabrication, installation, testing, and inspection for all Contracting Officer provided engineering drawings.

At the conclusion of the project one complete set of paper copy red lined drawings shall be provided to the Contracting Officer. Red lines shall be made in a neat, clear and legible manner. An electronic set of red lined drawings shall also be created by the Contractor and submitted to the Contracting Officer.

All drawings, except red lines, and related documents shall be submitted to the Contracting Officer electronically.

10 Deliverables

The following is a summary of the deliverables to be provided by the Contractor:

1) One (1) completely designed, fabricated, installed, inspected, tested, insulated and ready for operation steam generator as described in the document Statement of Work for Area 1-42 Steam Generator

2) As described in the document Statement of Work for Area 1-42 Steam Generator all boiler external piping.

3) As described in the document Statement of Work for Area 1-42 Steam Generator all documentation, code packages, drawings, records and any other information as noted in the referenced SOW.

4) As described in the document Statement of Work for Area 1-42 Steam Generator provide all spare parts for equipment, components and all other items as noted in the SOW.

5) Provide and install all piping, components, electrical, burner exhaust stack, PRV discharge lines and all other permanent items as shown on the drawings and described in this SOW.

6) One (1) sets of recommended spare parts for all valves, instruments, components or similar items provided by the Contractor

7) Shop drawings for the work platform between the propane vessels.

8) Cut sheets, catalog data, O&M Manuals, drawings and other similar information for all components provided by the Contractor.

9) Procedure Qualification Records for all weld procedures used during the fabrication of pressure boundary and non-pressure boundary systems

10) Weld Procedure Specifications used during the fabrication of pressure boundary and non-pressure boundary systems 13)Reader sheets for volumetric examination of circumferential V groove butt welds 14)Results of liquid penetrant testing 15)Results of visual inspection of welds 16)Results of Positive Material Identification examinations of pressure boundary materials 17)Weld maps

18) Records of any repairs 19)Certified Material Test Reports for all pressure boundary materials

21) Results of pressure testing 22)Paper copy of red lined as-built drawings for all piping systems and any other in scope items.

23) Electronic set of red lined as built drawings for all piping systems and any other in scope items.

24)Provide for use during hydrotesting all temporary piping, blinds, tubes, bolting, gaskets, pumps, gages and any other equipment or parts required to perform the required hydrotesting of the piping systems

25) As may be required a PWHT Plan for any pressure boundary systems

26) Hydrostatic Test Plan and results of all hydrostatic testing of piping systems

27) Safety Plan

28) Quality Control Manual

29) Steam Generator Water Treatment Recommendations

30) Project Plan and Schedule

31) Test Plan and recorded results of field test to demonstrate correct operation of deluge piping at new propane storage area

One paper copy of the above documents shall be provided in a binder and shall be indexed and well organized for reference.

Three sets of complete electronic copies of all documents and related information shall be provided to the Contracting Officer.

11 Project Plan and Schedule

The Contractor shall prepare a detailed project plan that shall be used as a basis for the overall planning, management and execution of this project. The Contractor is at liberty to structure and arrange the Project Plan, but in general it shall address in sufficient detail all key aspects of the project as noted in this SOW. It is recommended the Contractor first prepare an outline identifying key sections of his Project Plan and submit the same to the Contracting Officer for concurrence prior to proceeding with detailed development of the document. NOTE: A Project Plan and Schedule are identified as required in the document SOW for Area 1-42 Steam Generator. The Contractor may elect to combine the Project Plan for execution of the work identified in this SOW with the work in the separate SOW for the steam generator.

As part of the Project Plan the Contractor shall also develop a detailed project schedule. The project schedule format may be selected by the Contractor but should clearly define line item activities and interdependencies between discreet tasks. The detailed schedule is estimated to include 75 to 100 separate line items—but the level of detail of the schedule shall be determined by the Contractor.

A high level milestone schedule follows that should be used for guidance by the Contractor in preparation of the detailed project schedule.

The following is the project milestone schedule. All durations are After Receipt of Order (ARO). This schedule is notional and assumes the Contractor will mobilize to the site one time to perform the tasks identified in this SOW in preparation for final installation of the steam generator. As shown in the document SOW for Area

1-42 Steam Generator, transport and placement of the steam generator is not scheduled to occur until 62 weeks into the project. It is assumed the Contractor will mobilize to the site ~30 weeks in advance of transport and delivery of the steam generator to complete the work identified herein in preparation for final placement and installation of the steam generator.

This schedule and the schedule included in the SOW for Area 1-42 Steam Generator should be worked together and carefully coordinated to ensure the execution of the project is optimized and performed effectively.

PROJECT SCHEDULE FOR INSTALLATION OF FOUNDATIONS, PIPING,

STRUCTURES AND PERFORM OTHER WORK IN SUPPORT OF NEW STEAM

GENERATOR AT AREA 1-42

TASK DURATION

PRE AWARD KICK OFF MEETING AT CONTRACTORS

FACILITIES

5-10 DAYS PRIOR

TO AWARD OF

CONTRACT

SUBMIT PROJECT PLAN AND PROJECT SCHEDULE 3 WEEKS

INITIATE PROCUREMENT OF MATERIALS 4 WEEKS

SUBMIT PQRS AND WPS’ FOR REVIEW AND

APPROVAL (2)

4 WEEKS

OBTAIN ALL MATERIALS, PERFORM ALL SHOP

FABRICATION IN PREPARATION TO MOBILIZE

41 WEEKS

MOBILIZE TO AREA 1-42 IN PREPARATION TO

START WORK AT SITE

42 WEEKS

INSTALL ALL PIPING, PERFORM ALL OTHER WORK

IN PREPARATION OF INSTALLATION OF STEAM

GENERATOR (1)

61 WEEKS

ALL FIELD WORK COMPLETED 77 WEEKS

SUBMIT ALL OTHER PROJECT DOCUMENTATION,

AS BUILT DRAWINGS, NDE RECORDS ANY OTHER

IDENTIFIED DELIVERABLES

81 WEEKS

TRANSFER ALL SPARE PARTS TO AFRL 81 WEEKS

PROJECT COMPLETE 81 WEEKS

(1) Assumes all foundation, civil work will be completed by another Contractor by this time in preparation for transport and placement of the steam generator

(2) The Contracting Officer shall review and approve the identified weld documentation in advance of any welding commencing

12 Safety

Prior to starting work at the AFRL all Contractor personnel who will be working on site are required to attend an approximate 2 hour orientation meeting. This meeting will cover a variety of safety related topics related to the safe execution of work at the AFRL. Details of when and where this meeting will be held will be provided by the Contracting Officer. All Contractor personnel shall also participate in a brief daily morning safety and coordination meeting to be conducted by the Contracting Officer. The Contracting Officer shall ensure that appropriate Contractor personnel and AFRL Area 1-42 management personnel are notified of this daily meeting and attend as required.

At a minimum all personnel working at AFRL shall wear proper protective clothing, hardhats, steel toed shoes, safety glasses, and gloves. When personnel are working in and around the designated work areas, they should be aware of and watch for poisonous snakes, spiders, scorpions, and other stinging and biting insects. The Contractor shall determine if ANY other PPE or other special protective clothing or equipment is required for performing the tasks described herein and provide the same.

The Contractor is responsible to provide all necessary safety equipment that shall be in good working order.

Hot work permits are required for all cutting and welding activities. The Contractor shall coordinate with the Contracting Officer a minimum of 24 hours in advance of when hot work is anticipated to be performed to acquire the necessary permit.

As necessary the Contractor shall barricade his work areas to keep non-Contractor personnel out of the work areas as required.

Normal work hours at the AFRL are 7:00am to 4:30pm M-Th and 7:00am to 3:30pm F. If the Contractor plans to work other than these hours he shall notify the Contracting Officer a minimum of 48 hours in advance so the Contracting Officer can arrange for safety and technical oversight of the work.

Contractor shall perform all work described herein in a safe manner to protect all personnel.

Any accident, incident, or similar anomaly shall be reported immediately to the Contracting Officer.

The Contractor shall have a site specific Safety Plan for performing all work on site at AFRL. A copy of this plan shall be made available to the Contracting Officer early on in the project for his review and approval prior to the Contractor mobilizing on site and performing any activity.

13 Quality Control

The Contractor shall, at a minimum, have a written Quality Control System identifying his quality control procedures and methods and plans for controlling performing, and verifying the work. The Quality Control System shall be based on the requirements of the ASME B&PVC, Section VIII Div. 1, Mandatory Appendix 10, which specifies quality parameters to be addressed in the document. The Contractor shall provide a copy of his company Quality Control Manual that will be used as a basis for all work associated with the work identified in the SOW.

Additionally the Contractor shall address project quality control as a part of his project plan. A written, detailed description of how all aspects of the work including, but not limited to, requirements definition, design and engineering, material procurement and control, welding, fabrication, document control, configuration management, training of project personnel, managing work flow, NDE, testing, and other pertinent aspects related to quality shall be addressed.

The Contractor shall identify an individual within his organization as the designated Quality Control Manager who is responsible for quality oversight of the work.

14 Security

All Contractor personnel coming on site shall be US Citizens. Contractor personnel coming on site who will be working full time at AFRL will be required to obtain a Temporary (“T”) Badge to allow for unescorted access to the site. All other Contractor personnel who will not be working full time on site, such as delivery truck drivers, will need to be escorted by the Contracting Officer while on site. The Contractor shall coordinate with the Contracting Officer in advance of when the Contractor will be on site so the Contracting Officer can ensure 1) proper “T” badges are available for Contractor full time personnel, and 2) personnel are available for escorting support. “T” badges must be returned to the AFRL guard gate daily prior to exiting the site. The Contractor shall provide a list of all personnel working on site who will require “T” badges a minimum of one week in advance prior to coming on site.

In addition to a “T” badge the Contractor’s personnel are required to obtain on a daily basis a Restricted Area Badge to enter and perform work at Area 1-42 Steam

Plant. Restricted Area Badges will be made available to Contractor personnel each day at the Area 1-42 Blockhouse. These Restricted Area Badges must be returned to the Area 1-42 Blockhouse at the conclusion of work each day.

Note: Edwards Air Force Base strictly enforces all traffic laws, and the Contractor shall be particularly cognizant of posted speed limits, and the requirement to wear a seat belt at all times in a moving vehicle.

No photographic equipment is allowed at AFRL. If the Contractor requires photography during the on-site work, he shall advise the Contracting Officer who can arrange for photographs to be obtained, reviewed and cleared by the base photographer.

15 Hold Points

In general, during the period when the Contractor is on site at AFRL the Contracting Officer will be in daily contact with the Contractor. Contact will include discussions concerning schedule and status of the project, issues and planned resolutions, action items, material status, work activities and related topics. The Contracting Officer will also have periodically inspection personnel, engineers, management, and technicians and supervisors visiting the work areas to observe and inspect the work in progress.

Communication about current and planned work activities are anticipated to occur on a nearly daily basis and Contracting Officer personnel will coordinate with the Contractor concerning any planned activities to be witnessed, inspected, checked or verified as work progresses.

For planning purposes there are only several firm hold points identified in advance of work commencing in the field. They are notification and witnessing of ASME B31.1 Power Piping Code required pressure testing of piping systems, pouring of the concrete foundations, transport and placement of the propane vessels and testing to demonstrate proper operation of the propane deluge system. For all these tasks the Contractor shall notify the Contracting Officer a minimum of two

(2) working days in advance of when the task is planned to be performed.

16 Proposal

The Contractor shall prepare a written proposal describing his approach and plans to fulfill the necessary requirements to provide the work identified in this SOW. In general the proposal should provide a sufficient level of information and detail to allow the Contracting Officer to evaluate the Contractor’s experience and capability relative to furnishing the foundations, piping, steam generator and all other required work and resources. The proposal shall include, at a minimum, the following information:

-Qualifications to perform the identified work including a financial disclosure statement demonstrating his financial ability to accomplish the work -Brief explanation of his approach to accomplish the…