PWS B304 Boiler 3 vessel integrity NEW.docx

Performance Work Statement Project Title: B304 Boiler 3 Vessel integrity Inspection NextGen Work Task #: WT 14158299

1. Objectives:

The scope of work is to remove the jacketing and insulation from around Boiler #, clean the vessel surface, and perform NDT/NDE to verify and certify the structural integrity of the boiler vessel. Afterwards, if the structural integrity is satisfactory; the boiler shall be re-tubed and the insulation and jacketing is to be replaced and the boiler put back in service with a full pressure test, combustion check and tuning, and operational and safety inspections. The Contractor shall provide a proposal for the work split into two portions in accordance with this conditional scenario.

2. Existing Conditions:

The existing boiler is a Superior Seminole brand high pressure 150 hp steam boiler, model number 6-X-750, NB# 14249, rated for 150 psi at 5175 lbs/hr. The relief valve has leaked sporadically in the past and for a prolonged period in recent months, resulting in corrosion along the top and bottom of the boiler and the rotting away of the protective jacketing. Leakage has been noted at the internal portion of several tubes after recently finding leak-by to the fire-side. Several boiler tubes have already been re-rolled to repair noted leakage on prior occasions, so rolling again for repair is not an option. Replacing the tubes is required.

3. Requirements

· The Contractor shall disconnect all piping, electrical connections, controls, and ancillary equipment that prohibits the removal of the boiler jacketing/insulation and inspection of the vessel surface.

· The Contractor shall remove the jacketing, cutting away the corroded portions and salvaging the remaining pieces for re-use.

· The Contractor shall remove and dispose of all boiler surface insulation. The Contractor shall clean the boiler vessel surface (exterior and interior) via industry-standard methods of all loose and adhered corrosion, scale, and debris as required for the NDT/NDE inspection.

· The contractor shall perform NDT/NDE along all areas of the boiler surface affected by corrosion, to include a representative grid or sample of points in each location, in order to prove and provide a record of structural integrity. The Contractor shall notify the Government within 24 hours of the structural integrity results.

· If the structural integrity is satisfactory, the Contractor shall proceed with steps A-F outlined below. If the structural integrity is not satisfactory, the Contractor shall consult with the Government for modification to the contract or cessation of work. If steps A-F are not performed, the Government shall incur no cost for steps and Contractor shall forfeit the portion of cost proposed for these actions. The Contractor shall still leave the salvaged jacketing in the Government’s possession in this case.

· A - The Contractor shall flame cut and remove all tubes in the boiler. The Contractor shall clean the boiler internals of all loose scale and debris, and any non-loose scale or debris that interferes with installation of new tubes. The Contractor shall prepare the tube sheet for the new tubes. The Contractor shall furnish and install all new tubes for the boiler. The tubes shall be like-for-like per manufacturers’ recommendations.

· B - The Contractor shall ensure that all installation is NBIC and ASME certified as required. The Contractor shall provide for an NBIC internal and external examination, followed by a hydrostatic test to prove satisfactory installation of the new tubes. The Contractor shall also provide a satisfactory operational test of the tube installation, including boil-out as needed, and provide for repair or replacement of any tube installation if deemed required per inspection.

· C - The Contractor shall install new insulation around the boiler per manufacturers recommendations and industry standards. The Contractor shall reinstall the salvaged jacketing.

· D - The Contractor shall reconnect all piping, electrical and controls connections, and ancillary equipment that was removed for the project.

· E - The Contractor shall ensure that all installation is NBIC and ASME certified as required.

· F - Contractor shall also conduct satisfactory operational tests of the boiler after reconnecting all piping, electrical, and control connections. Operational tests shall include a combustion check and tuning as well as a full check of the safeties and a CSD-1 and certified BC operational inspection. The Contractor shall provide a written report of these results.

· The Contractor shall abide by all hot work permit requirements per Offutt AFB process.

· The Contractor shall provide at least a 1-year warranty on all labor and new materials.

· The Contractor shall clean up and dispose of all removed equipment and project waste from the replacements, as well as any trash generated from the work. Refuse shall be disposed of off-Base in accordance with Offutt AFB Environmental Special Conditions section 01 57 19.

The contractor shall furnish all material, labor, transportation, equipment, tools, services, expertise, supervision, and incidentals required to fulfill the requirements of this contract. No alterations, additions, or deletions shall be made unless by prior approval of the government Project Manager and the government Procuring Contract Officer (PCO). The work shall conform to the most current applicable State, AFI, ETL, NFPA, ASME, NBIC, and Unified Facility Criteria Standards. Work shall be completed in a neat, substantial, and competent manner. All personnel shall abide by all industry safety standards, such as OSHA, and the Contractor shall provide all required PPE. The contractor shall perform quality assurance activities that conform to the quality assurance processes outlined in International organization of Standards (ISO) 9001, Quality Management Systems. The Contractor shall use PWS requirements.

The Contractor shall coordinate with the Government for needed system operation to allow the work and subsequent testing on the boiler. The Contractor shall provide their own lock-out-tag-outs as needed.