F1M3E2BOILERS_SOW_Rev_1_021317.pdf

Statement of Work Boiler System Repairs

Joint Base Charleston, South Carolina 13 February 2017

Boiler #1 (Building 515 Hurst Boiler)

The contractor shall provide all labor, equipment, supplies, material and coordination required to remove defective boiler tubes and install new boiler tubes in Boiler #1 Hurst Boiler Model# 53X350-100W, Serial# D51750-100-1 at Building 515. All work shall adhere to guidelines specified in applicable regulations and codes. All gas piping work shall be accomplished to meet NFPA 54: National Fuel Code.

• Contractor shall conduct a HAZMAT survey to the presence or absence of suspect asbestos containing material (ACM), lead based paint, mercury, and PCBs Contractor shall submit an official report with the findings prior to any demolition or any other type of work that may disturb hazardous materials.

• Contractor shall thoroughly remove defective tubes, clean, inspect, and prepare tube sheets for the installation of necessary new tubes on Hurst Model # 53X350-100W, Serial #D51750- 100-1 boiler.

• Contractor shall repair crack located at Boiler #1 cone.

• Dye penetrant inspection (PT) is required.

• Contractor will be responsible to ensure all work be inspected by a NBIC certified inspector.

• All tubes installed must have R1 router repair certification.

• All cracks must be ground out and 100% penetration repairs made. Any distortion of the tube hole to be repaired after full penetration weld repair per ASME HW600 & HW610. SA 178A 2.5” boiler tubes .105 wall thickness per ASME HF204.

• Hydrostatic testing must hold for 60 minutes without leaks per ASME HLW505.1 & 505.2

• Contractor must open and inspect boiler internally.

• Contractor shall perform tube cleaning of all boiler tubes.

• Contractor must inspect all safety controls for boiler to include low water cut out control and replace any defective controls.

• Contractor shall install a drip-leg in the existing gas supply piping in accordance with

National Gas Piping code.

• Contractor must install NEW gas isolation valve which meets current Gas Code in order to access valve at floor level.

• Contractor must install boiler return water mixing valve on boiler return water piping.

• Refractory turn around and rear doors refractory must be repaired with Corbond© or Gref©

Patch plastic refractory patching material. The door, baffle, turnaround all to be coated with Sairset© upon completion.

• After repairs the burner must be set to manufacturer’s specifications.

• The contractor shall ensure performance of the boiler and submit results.

• Replace boiler door existing steel nuts with brass nuts.

• A required, state-approved combustion report must be provided for boiler.

• Contractor shall perform a post-repair adjustment to burners during peak (full load) operating season.

Boiler #2 (Building 515 Hurst Boiler)

The contractor shall provide all labor, equipment, supplies, material and coordination required to remove defective boiler tubes and install new boiler tubes in Boiler #2 Hurst Boiler Model# 53X350-100W, Serial# D51750-100-2 at Building 515. All work shall adhere to guidelines specified in applicable regulations and codes. All gas piping work shall be accomplished to meet NFPA 54: National Fuel Code.

• Contractor shall conduct a HAZMAT survey to identify the presence or absence of suspect asbestos containing material (ACM), lead based paint, mercury, and PCBs. Contractor shall sample and test for asbestos and lead based paint. Sampling shall be representative in nature.

Contractor shall submit an official report with the findings prior to any demolition or any other type work that may disturb hazardous materials.

• Contractor shall thoroughly remove defective tubes, clean, inspect, and prepare tube sheets for the installation of necessary new tubes on Hurst Model # 53X350-100W, Serial #D51750- 100-2 boiler.

• Dye penetrant inspection (PT) is required.

• Contractor will be responsible to ensure all work be inspected by a NBIC certified inspector.

• All tubes installed must have R1 router repair certification.

• All cracks must be ground out and 100% penetration repairs made. Any distortion of the tube hole to be repaired after full penetration weld repair per ASME HW600 & HW610. SA 178A 2.5” boiler tubes .105 wall thickness per ASME HF204.

• Hydrostatic testing must hold for 60 minutes without leaks per ASME HLW505.1 & 505.2

• Contractor must open and inspect boiler internally.

• Contractor shall perform tube cleaning of all boiler tubes.

• Contractor must inspect all safety controls for boiler to include low water cut out control and replace any defective controls.

• Contractor shall install a drip-leg in the existing gas supply piping in accordance with

National Gas Piping code.

• Contractor must install NEW gas isolation valve which meets current Gas Code in order to access valve at floor level.

• Contractor must remove existing defective 8” butterfly valve and replace with new 8”

Butterfly valve in Boiler Piping.

• Contractor must install boiler return water mixing valve on boiler return water piping.

Contractor shall install a thermostatic mixing valve which provides variable temperature settings. The valve should be installed where return water enters the boiler

• Contractor shall pressure test air separator tank to 1.5% of operating pressure.

• Refractory turn around and rear doors refractory must be repaired with Corbond© or Gref©

Patch plastic refractory patching material. The door, baffle, turnaround all to be coated with Sairset© upon completion.

• After repairs the burner must be set to manufacturer’s specifications.

• A required, state-approved combustion report must be provided for each unit.

• Replace boiler door existing steel nuts with brass nuts.

Boiler #3 (Building 515 Sellers Boiler)

The contractor shall provide all labor, equipment, supplies, material and coordination required to inspect and repair Sellers Boiler Model# BT-32-1000, S/N 11810 that produces hot water to wash aircraft at Building 515. All work shall adhere to guidelines specified in applicable regulations and codes. All work shall be accomplished to meet NFPA 54:National Fuel Gas Code. Contractor shall schedule and complete Boiler #3 repairs as priority. Repairs of Boilers #1, #2, and #4 may be executed concurrent to Boiler #3 repairs.

• Contractor shall conduct a HAZMAT survey to identify the presence or absence of suspect asbestos containing material (ACM), lead based paint, mercury, and PCB S Contractor shall sample and test for asbestos and lead based paint. Sampling shall be representative in nature.

Contractor shall submit an official report with the findings prior to any demolition or any other type work that may disturb hazardous materials.

• Sellers Boiler Model# BT-32-1000, S/N 11810 that produces hot water to wash aircraft needs to have gas piping modified to allow access to service the boiler.

• Contractor must install isolation valve and spool-piece gas piping. (located at floor level) and drip leg in piping.

• Contractor must insure isolation valve in vertical pipe run is accessible at floor level.

• Contractor must modify the cold water supply piping to allow for opening of the boiler front door.

• Contractor must relocate (1) ½” conduit & wiring as necessary to allow for opening of the boiler front door.

• Diaphragm valve vent located in overhead must be installed in accordance with Gas Vent

Code NFP54.

• Burners for boiler must be tuned in accordance with manufacturer’s specification.

• Combustion will be set to manufacturer’s specifications.

• Boilers must have final performance inspection performed by a National Board Certified boiler inspector to ensure the safety and integrity of boilers’ operation.

• A required, state-approved combustion report must be provided.

• Tear Down & Quote - The boiler is currently non-operational. Contractor must inspect and determine required repairs to bring the boiler to operational status. The contractor shall submit a report identifying all repair actions necessary to bring the boiler to operational status. The report shall be submitted to the government for review and approval. The report shall include a detail of all labor hours (per repair action) and detail all material required to include material prices (per repair action). Labor will be at the rates submitted by the contractor in their proposal. The level of effort to perform the inspection and prepare the report shall be compensated through CLIN 0003 of the contractors proposal. Any subsequent repairs will be executed through modification.

Boiler #4 (Building 700 Burnham Boiler)

The contractor shall provide all labor, equipment, supplies, material and coordination required to remove defective boiler tubes and install new boiler tubes in Burnham 5W-350-50-6-PF Boiler, Serial# 68133 at Building 700. All work shall adhere to guidelines specified in applicable regulations and codes.

• The Contractor shall remove and install 22 boiler tubes using SA178A tube material 2.5” x .105 thickness.

• Repairs are to be performed under the provision of Section IV of the International Pressure Vessel Code.

• Dye penetrant test (PT) is required

• All work must be inspected by a NBIC certified inspector.

• All tubes installed must have R1 router repair certification.

• All cracks must be ground out and 100% penetration repairs made. Any distortion of the tube hole to be repaired after full penetration weld repair per ASME HW600 & HW610. SA 178A 2.5” boiler tubes .105 wall thickness per ASME HF204.

• Hydrostatic testing must hold for 60 minutes without leaks per ASME HLW505.1 & 505.2

• The boiler must receive a hydrostatic pressure test upon completion. A state approved combustion report is required for each unit.

• A state approved combustion report must be submitted via AF 3000.

• The Powerflame© BCC7-6-30HTD Burner shall be outfitted with a new air inlet box.

• The subject burner will be upgraded with Honeywell© control links model 7999 or approved equal for more optimum air to fuel ratio adjustments.

• This project is to include a fully documented combustion tune-up with snapshots of the complete air & fuel curves for record keeping purposes.

• The burner combustion and efficiency will be recorded and documented using a state approved form.

• Contractor shall hydrostatically test the existing expansion tank and provide results via submittal (AF 3000).