Heat_Plant_PWS_26Apr17.pdf

Performance Work Statement

For

Heat Plant Operation and Maintenance Services

509 Civil Engineering Sq.

Whiteman AFB, MO

24 February 2017

Table of Contents

1.0 Introduction

2.0 Operations

3.0 Maintenance Services

4.0 Maintenance Reports and Records

5.0 Parts, Materials, and Equipment

6.0 Management and Administrative Support

7.0 Service Delivery Summary

8.0 Government Furnished Property and Services

9.0 Contractor Personnel

10.0 Contractor Training

11.0 Quality Control

12.0 General Guidelines

13.0 Contractor Furnished Items and Services

Appendix A Workload Estimates

Appendix B1 Government Furnished Items

Appendix B2 Government Furnished Facilities

Appendix B3 Government Owned Equipment

Appendix B4 Government Furnished/Equipment

Appendix C Applicable Publications and Forms

Attachment 1 General Requirements

SCOPE OF WORK

1. Introduction.

1.1. General Information. Unless otherwise specified in this Performance Work Statement (PWS) the contractor shall provide all supervision, personnel, equipment, tools, transportation, materials/supplies, and other items and services necessary to safely operate, maintain, and repair the Government-owned Central Heat Plant (CHP) and the entire steam and condensate distribution system at Whiteman Air Force Base (AFB), Missouri. The terms Central Steam Plant (CSP) and CHP may be interchanged throughout this document and refer to the same facility. The contractor shall be responsible for operating and maintaining the plant in the most efficient manner possible with emphasis on energy savings. (Note: the CHP and the steam and condensate distribution are considered as one unit in the operation and maintenance of this contract).

1.2. Continuity of Service. To ensure continuity of essential services, the successful bidder shall be prepared to fully commence all work on the start date of this contract. Government employees will not be available to train, guide, direct, and/or specifically orient any contractor employee except as identified in Section 10.3.

2. Operations.

2.1. Plant Operations. The CHP has five (5) water tube boilers capable of producing 200,000 MBTU per hour. Plant operation is 24 hours per day 365/366 days per year. The CHP supplies steam to 61 buildings through a steam and condensate return system approximately 7 miles. Boilers #1, #2 and #3 are 35,000lbs/HR English boilers built in 2004, Boiler #4 is 35,000lbs/HR Nebraska Boiler built in 1985, and boiler #5 is a 60,000lbs/HR Nebraska boiler built in 1989. Heat plant steam production is nominally at 125 psi at 353 degrees Fahrenheit. The boilers primary fuel is gas with back up of diesel fuel oil #2. Operation of the plant includes the safe start-up, monitor, control, and shutdown of equipment for the efficient, economical, and environmental compliant production and distribution of steam and condensate, meeting the thermal demands and availability requirements of the Government at the lowest costs. Operation and maintenance of the CHP includes all inspections and maintenance of all primary and ancillary heat plant equipment, systems, and subsystems including those used in the maintenance of these systems.

2.1.1. The CHP is operated and maintained via Emerson’s DeltaV instrumentation and control computer system. DeltaV is a unique building automation system specifically configured to control the equipment in the CHP. The system operates boilers, monitors boilers, maintains boiler efficiently, and controls boiler start-up/shut down. The system also controls and monitors key support equipment. The DeltaV system has the capability to remotely monitor and control the CHP. A DeltaV remote terminal is in operation at the Whiteman’s water treatment plant.

Remote monitoring and control allows the CHP to be operated with only one (1) DeltaV qualified instrumentation and control boiler operator/stationary engineer at the CHP provided the alternate/remote operating system at the water treatment plant in operating. This enables one person manning per eight (8) hour shift during normal workdays and up to twelve (12) hour shifts on weekends and holidays. If one (1) operator is utilized the contractor shall still be required to perform all maintenance IAW this PWS. The remote monitor and control capability enables shut down of the system in the event of an emergency. Geographically remote monitoring and operation is currently reserved for Government personnel only and is the responsibility of the 509th Civil Engineer Squadron (CES). Should remote monitoring be lost the contractor shall be responsible to have two (2) fully qualified boiler operators/stationary engineers operating the heat plant until the system is repaired and remote monitoring is restored.

2.1.2. The CHP has the capability to monitor certain portions of the steam distribution system to include steam pit sump pumps through the “CEVLAN” (METASYS) system. The contractor will monitor the CEVLAN system and take appropriate action to correct or repair steam plant or distribution system equipment not operating properly. The contractor shall be responsible to ensure the pump stations are properly transmitting their status to the CEVLAN. The contractor shall troubleshoot and repair the CEVLAN. The contractor is not responsible for communication lines.

2.1.3. The contractor shall be responsible for all equipment within the plant, primary and ancillary equipment and systems. Key equipment includes but is not limited to the following:

1. Five (5) water tube boilers and associated equipment

2. All DeltaV system components (hardware, software, controllers, wiring, sensors, transmitters, accessories, etc.),

3. Production and control

4. Control room Automatic Transfer Switch power distribution

5. Control room battery backup (UPS)

6. Feed water pumps

7. Condensate pumps

8. Tanks

9. Economizers

10. Pumping, piping, and valves

11. Emission equipment

12. Water treatment equipment: Water softeners and Reverse Osmosis systems

13. Fuel supply gas and oil

14. Plant effluent equipment

15. Air compressors

16. Wall heaters and louvers

2.2. Steam Production: The contractor shall be responsible for the operation, maintenance, and repair of the entire CSP, to include the steam and condensate system, as identified in Appendix B1, Government Furnished Items.

The plant shall be operated to meet Whiteman AFB industrial and heating steam load requirements (pressure and mass flow rate), uninterrupted and continuous, 24 hours a day, 7 days a week, 365/366 days a year. The CHP must produce steam at a nominal rate of 125 psi at 353 degrees Fahrenheit to maintain all facilities.

2.2.1. Plant Operation Includes: Operation of the DeltaV instrumentation and computer controlled building automation system, boilers, associated pumps and fans, plant water make-up systems, steam and condensate distribution system, emissions controls, plant effluent equipment, Reverse Osmosis (R.O.) system, associated equipment, deaerator, fuel storage and handling, plant instrumentation, controls and associated systems, waste heat recovery equipment, emergency backup equipment, and water treatment equipment.

2.2.1.1. Operating procedures and instructions shall be provided by the contractor for all primary and ancillary systems with the CHP and distribution system. This includes, but not limited to, boilers, controls and associated equipment, DeltaV, piping, pumping, emission control, water treatment, fuel storage and handling equipment, and condenser and heat exchangers. These procedures and instruction shall be submitted to the Contracting Officer (CO) and Contracting Officer Representative (COR) for approval thirty (30) calendar days after award. The approved procedures shall be instituted upon commencement of contract operations. The contractor shall update and implement revised procedures for operation, maintenance, and repair on a continuing basis as required at no additional cost to the Government.

2.2.1.2. The contractor shall operate at least one (1) boiler monthly on oil to verify system operation, check for leaks, and maintain compliance with Air Force Instructions (AFI) listed in Appendix C. A 30 minute run, at operational pressure, will satisfy this requirement. This run shall be documented in the daily log.

2.2.2. The contractor shall be required to maintain fuel storage facilities at Buildings 140 and 141 (i.e. valves, lines, exterior oil float monitoring gauges, receiving oil deliveries, transferring oil from tanker truck to oil tank, pumping oil into tanks, transferring oil from tank to tank). The contractor shall maintain daily record keeping of oil quantity and inform the COR when oil needs to be ordered for each tank to maintain operation limits set by the Government. The Government will conduct tank custodian training for all contractor employees IAW Section 10.3.

2.2.3. Emergency Back-Up Generators. The emergency back-up diesel generator supplying electricity to the CHP is located at Building 140. The generator will be maintained and repaired by the Government, to include fueling. Contractor’s employees, working in plant, shall be trained by the Government to operate back-up emergency generators IAW Section 10.3. If commercial electrical power is lost the generator should start automatically. The contractor shall ensure the emergency generator has started automatically. If the generator fails to start automatically, the contractor will start it manually and transfer power. Should a generator start or fail to start, the contractor shall notify 509th CES during normal duty hours (0700-1600) or the Emergency Response Center after normal duty hours. Contact phone numbers will be provided to the contractor after award of contract.

Note:

1. Natural gas is supplied by Missouri Gas and Energy (MGE) to Whiteman’s CHP Bldg. 140 and is contracted on an interruptible basis. When an interruption in service occurs, MGE issues a two (2) hour curtailment notice to CHP contract manager, allowing time to switch the boilers from natural gas to oil operation. For the duration of this contract, it shall be the contractor’s responsibility to: act as MGE’s point-of-contact for receiving curtailment notices, switching boilers between primary and secondary fuel sources as necessary, provide forecasted demands for both primary and secondary fuels sources, notify both the COR and CO about fuel source curtailment notices and provide a written summary estimating the impacts (if any) that the curtailment will have on the contractor’s end users, verify primary and secondary fuel source meter readings, before and after a switch over, and verify and certify all invoices from fuel suppliers. The contractor will be responsible for any fines or cost increases imposed by MGE for not meeting gas curtailment notice to switch to secondary fuel source.

2.3. Shutting Off Steam or Condensate. The contractor shall be responsible to shut off steam and/or condensate when directed by the Government. There are three (3) types of steam/condensate shut down requirements.

1. Scheduled shut down: The Government will give the contactor a minimum of a three (3) day notice prior to shut down to allow for scheduling. Normally this shutdown will occur at a designated steam pit.

2. Emergency Government directed shut down: The Government discovers an emergency or urgent need to shut down the system. Should the Government direct a shutdown at the CHP an “immediate” shutdown shall be accomplished. Should the shutdown be at a steam pit the contractor has two (2) hours to shut down the system and respond per Section 3. Should this situation occur, Emergency Service and Temporary Repair, Section 3.2.1, shall be performed after the shutdown.

3. The contractor detects a critical or emergency situation and determines the system needs to be shut down immediately to eliminate life or serious injury hazard to personnel, prevent loss or damage to Government property. Should this situation occur, Emergency Service and Temporary Repair, Section 3.2.1, shall be performed after the shutdown.

2.3.1. If steam was shut off due to an emergency that the contractor detected the contractor shall immediately notify the COR and 509th CES Heating, Ventilation, and Air Conditioning

(HVAC) section. During non-duty hours, contact customer service and leave a message for the

COR.

2.3.2. The contractor shall immediately evaluate the situation causing the emergency shut down and repair per Section 3.2.1, Emergency Service and Temporary Repair. If a repair cannot be performed at that time due to parts, they will be ordered and repair scheduled when parts arrive.

The contractor shall turn on steam and/or condensate after repairs are complete. The HVAC section will be notified when steam is being turned on. This allows for HVAC to verify mechanical room status when steam is restored. When steam or condensate is turned “off” or “on” a log entry shall be made in the daily log specifying time and location by pit.

2.4. Operation Procedures. The contractor shall be fully capable to operate and maintain complete control of the CHP on the start date of the contract. The contractor shall maintain complete control of the plant operation through the preparation and use of written operating procedures and instructions. These procedures shall be prepared by the contractor to comply with the manufacturer’s instructions and recommendations, industry standards, and Federal, State, and Local codes. Copies shall be turned in to the CO and COR ten (10) workdays before the “Notice to proceed date”. New and/or updated procedures for new and/or modified equipment shall be submitted within thirty (30) days of equipment being placed in operation. All operators/stationary engineers shall be fully proficient in these procedures before being assigned duties as the plant operator. At a minimum, these written procedures and instructions shall include:

1. Detailed operating and maintenance instructions for each piece of equipment. To include but not limited to: operation of the DeltaV system, boilers, pumps, fans, burners, dampers, auto blow down system, transmitters, probes, air compressors, and water treatment system.

2. Detailed sequence of start-up (to include both hot and cold boiler start-up) and shut down procedures remote (from DeltaV system) and local (at boiler).

3. Observation and adjustments to be made during operation.

4. Frequency of the observation and adjustments, and who shall perform each task.

5. Plant equipment operating schedule.

6. Water treatment plan.

7. Systems maintenance and inspection schedule.

8. Emergency procedures for production/distribution disruptions.

9. Safety/accident to include chemical contamination procedures.

10. Equipment overhaul and inspection procedures.

11. Procedures to comply with base environmental requirements and permits.

12. Detailed operating procedures that maximize plant energy and efficiency by optimizing equipment efficiencies with load.

13. Emergency shutdown, both local and remote, procedures for boilers.

14. Boiler casualty control procedures for high water, low water, flareback, boiler explosion, etc.

15. Wet and dry boiler lay-up procedures.

16. Pressure vessel inspection procedures.

17. Boiler minimum and maximum load testing procedures.

18. Procedures for switching to alternate (s) fuel. (See note1)

19. Procedures for maintaining fuel storage facilities. (See note 2).

20. Asbestos abatement and disposal procedures.

21. Chemical spill procedures.

22. Firing oil on high-pressure air or high-pressure steam atomization.

23. Transmitter-gauge calibration procedures (including loop command control systems).

24. Lock Out/Tag Out procedures.

25. Confined space entry/permit procedures.

26. Reverse Osmosis (RO) System operation and cleaning procedures.

27. Emergency procedures to recover plant from “Operational Emergencies” (Section 12.8.);

unexpected pressure drops.

28. Fuel Dyke pumping and environment requirements.

2.4.1. Administrative Deliverables. Contractor schedules, reports, annual plans and programs:

2.4.1.1. Monthly: The contractor shall provide the 509th CES COR with electronic monthly schedules due five (5) calendar days before the end of the preceding month.

1. Which boiler(s) are scheduled to be in operation and dates they will be in operation also include boiler operating on diesel fuel. Diesel fuel operation will be on normal work days between the hours of 0700 and 1600.

2. Steam Pit inspection/cleaning schedule detailing the days, hours, and which pits will be cleaned.

3. Preventive maintenance schedule detailing the equipment and the dates scheduled.

4. Corrective Maintenance schedule detailing the equipment and the dates scheduled.

Note: The contractor shall submit schedules, forms, and reports electronically to the COR.

Errors shall be corrected within one (1) calendar day of being notified by the COR. All forms and reports shall be kept on site and readily available for the duration of the contract then returned to CO and/or COR.

2.4.1.2. Monthly Reports: The contractor shall provide the 509th CES COR with electronic monthly reports due five (5) calendar days after start of month. These reports include:

1. Air Force (AF) Form 1458, Daily Steam Plant Operation Log

2. AF Form 1464, Monthly Steam Boiler Operating Log

3. NOX reports

4. Fuel Oil Daily tanks readings

5. Periodic Maintenance

6. Corrective Maintenance

7. DeltaV Log

2.4.1.2.1. The contractor shall make available to the COR all logs, to include daily logs, upon request.

2.4.1.3. The contractor shall maintain a Daily Operations and Maintenance Log available 24 hours to the Government. The Daily Operations and Maintenance log book shall contain at a minimum:

a. All personnel working: operators, mangers/supervisors, technicians

b. Entries shall identify shift date and time

c. All pertinent issues affecting the plant; operations and maintenance

d. Condensate return temperatures every four (4) hours

e. Loss of steam plant pressure, start time of drop, start time of recovery, time to full recovery, bottom pressure drop, all actions taken to recover

f. Blow down of equipment

g. Cycling of equipment

h. Maintenance procedures

i. Plant Visitors

2.4.1.4. Annual Work Plan. The contractor shall prepare an annual maintenance plan that provides an overall approach to ensure scheduled maintenance activities are accomplished in a manner that will keep the CHP and distribution system in fully operational condition. The plan shall describe how and when the tasks listed in this PWS shall be accomplished. A copy of the plan shall be submitted to the COR and/or CO by the contractor thirty (30) calendar days after contract start date, and annually thereafter. The COR and/or CO may require changes to the contractor’s maintenance plan at any time during the life of the contract.

2.4.1.5. Deficiency Inspection Program. A deficiency inspection program shall be established and implemented by the contractor in order to identify and project system deficiencies and determine the physical condition of system components. Inspections shall be conducted annually and inspector shall possess at least a Craftsman rating in their respected trades. The COR and/or CO reserves the right to have Government representatives present during contractor inspections, or to make separate inspections in order to determine the accuracy and completeness of the contractor’s control inspections. A complete deficiency inspection plan shall be submitted to the COR and/or CO for approval within thirty (30) calendar days after contract award. Yearly deficiency listings and condition reports based upon inspection findings shall be submitted annually to the COR and/or CO to support system evaluation. Records and files documenting the deficiency inspection program shall be maintained up to date, accurate, and available for the CO/COR review during all normal working hours.

2.4.1.5.1. These deficiency listings and condition reports shall be submitted NLT 31 July of each year.

2.5. Operational Efficiency.

2.5.1. Steam/Heat Plant Boilers. The contractor shall be responsible of operating the heat plant at a minimum thermal efficiency equal to the plant efficiency. Thermal efficiencies shall be calculated as shown on AF Form 1458, Daily Steam Plant Operation Log, for steam plants.

Operating boilers at their high end provides for better efficiency as a result additional boilers should not be put on line until load demand has reached at least 85% of rated load unless waived by COR.

2.5.2. Boilers Automatic Blow Down System. The plant is equipped with an automatic boiler blow down system designed to blow down each boiler automatically. The contractor shall utilize this system to the maximum extent possible to minimize make up water usage, maximize plant and energy efficiency, and prevent boiler sludge build up.

2.6. Water Treatment.

2.6.1. Water Test and Treatment. The contractor shall operate and maintain all water treatment equipment affecting steam plant and all distribution systems. (Note: The steam distribution system at Whiteman AFB, Missouri has approximately seven (7) miles of steam and condensate lines requiring proper Amines chemical to cathodically protect the entire system. The use of a blend of the following three (3) amines chemicals is required: Morpholine, which is effective for short runs of 800 feet or less, Diethlaminoethanol (DEAE), which is more effective for runs of up to one (1) mile and Cyclohexylamine, which is effective for runs over one (1) mile is required. The contractor shall submit a water treatment program within thirty (30) days after contract award for approval by the CO and COR. The treatment program shall meet the requirements of AFI 32-1054, Corrosion Control. Testing and treatment for the CHP shall be performed by qualified boiler water and corrosion control tester and include pretreatment of make-up, treatment of boilers, boiler feed water, and condensate return. The contractor shall collect samples, at the plant, for testing and perform tests necessary to maintain water treatment records at least once per shift day. One (1) daily collection of samples and testing of water shall be during the peak steam usage hours of 0600hrs and 1200hrs.

2.6.2. To determine the proper PH levels and the neutralization of carbon dioxide in the condensate return line, the contractor shall take water samples each shift. These samples shall be tested and added to the monthly water report AF Form 1459, Water Treatment Operating Log for Steam and Hot Water Boilers. The COR or CO will reserve the right to witness the tests. If it is determined that the boiler or condensate water chemicals are out of specified set limits, the contractor must provide immediate corrective actions to maintain the proper chemical limits of the boiler or condensate water, then notify the COR of the corrective taken. The contractor shall develop control charts for chemical treatment and take necessary action to maintain a stable water treatment program. The contractor shall monitor and/or measure feed water conductivity and boiler conductivity and determine cycles to ensure boiler is operating no less than 75X feed water conductivity. The Government reserves the right to test the water either by a Government representative or an independent chemical company.

2.6.3. The contractor shall provide all chemicals including reagents, water softener salt, equipment cleaning chemicals, and all testing equipment necessary to run a water treatment program at no additional cost to the Government. The contractor shall submit for Government approval the chemical supply company selected to supply chemicals prior to use. The contractor shall complete and submit for approval by the COR copies of the AF Form 1459, Water Treatment Operating Log for Steam and Hot Water Boilers, NLT the seventh day of the following month. Errors shall be corrected within one (1) calendar day of being notified by the COR. Records shall be maintained of chemical quantities used and control charts. Other records shall be maintained as required by AFI 32-1054, Corrosion Control; Federal, State, and Local regulations.

2.6.4. The CHP plant utilizes a water softener and Reverse Osmosis Systems. The contractor shall operate, maintain, repair, clean and perform periodic maintenance IAW manufactures’ recommendations for these systems.

3. Maintenance Services.

3.1. Summary: The contractor shall perform to the standards in this contract. The contractor shall repair all equipment and items identified in the PWS identified as a contractor responsibility regardless of the cause of the damage or whomever may have caused the damage. The contractor shall provide all supervision, personnel, equipment, tools, transportation, chemicals, materials/supplies, and other items and services necessary to perform the operation, maintenance, and repair of the Government-owned CHP, steam and condensate distribution system, as described in the technical exhibits. The work shall include operation, maintenance and repair of boilers and associated equipment, plant control and monitoring systems, the entire DeltaV system (hardware and software) and all associated maintenance and repairs, report preparation, laboratory analysis, and other services as specified IAW this PWS at Whiteman AFB, Missouri. Should any portion of the DeltaV system, computers, hardware, or software etc., require repair only qualified employees shall do the repair. Should the contractor elect to subcontract out the repair only authorized Emerson representatives are allowed to repair DeltaV equipment and associated components. At no time will DeltaV equipment be repaired by any other repair companies (i.e. Office Depot, Best Buy, etc.).

3.1.1. CM within the specified time limits of:

1. Emergency (2 hours)

2. Urgent (8 hours)

3. Routine (10 days)

The COR will determine if the CM is Emergency, Urgent, or Routine.

3.1.2. Distribution system includes but is not limited to: pits, pumps, pump control stations and data transmission equipment within the control box, hardware, mechanical equipment, valves, steam traps, and piping, expansion joints, expansion loops, insulation, braces, and other related services (lifting is required). Work shall also include all maintenance types (Section 3.2).

3.1.3. A data base shall be developed and maintained identifying all parts and equipment repaired and/or replaced with information identified in Section 2.4. A separate DeltaV log with updates, changes, calibrations, adjustments, and repairs specific to the DeltaV system shall be developed and maintained. All logs and data bases are subject to inspection and approval by the COR and shall be provided when requested.

3.1.4. All lubricants, paints, degreasers, filters, belts, fittings, indicator lights bulbs, and fasteners are to be ordered by the contractor as part of preventive/recurring maintenance. The contractor shall replace or repair items not functioning properly or needing repair on a cost reimbursable basis IAW Section 5.1.

3.1.5. The contractor shall be responsible for all plumbing/piping requirements in the plant and distribution system, except toilets, sinks, showers, floor drains and backflow devices.

3.1.6. As Built Drawings. The contractor shall provide AsBuilt drawings to the COR and/or CO of any work performed by contractor personnel, which causes changes to the plant layout, piping or equipment design. This includes equipment modifications, equipment upgrades, or replacing parts with different part numbers. Copies of approved as-builts shall be maintained in the CHP.

3.1.7. The contractor is advised that the CHP may contain asbestos products throughout the plant.

3.1.8. Compliance with OSHA, and other applicable laws and regulations for the protection of employees is exclusively the obligation of the contractor.

3.2. Maintenance Types: Emergency Service and Temporary Repair, Preventive Maintenance (PM), Corrective Maintenance (CM).

3.2.1. Emergency Service and Temporary Repair. For purposes of this specification, an emergency situation is defined as any condition that requires immediate action to eliminate life or serious injury hazard to personnel, prevent loss or damage to Government property, or restore essential services. Emergency services may become necessary to accomplish certain maintenance, repair, and new service connections. Temporary repairs shall be accomplished using methods to avoid service disruptions, where possible, or to minimize system downtime, if full corrective maintenance cannot be performed at the time. These repairs shall be at no additional cost to the Government. Temporary repairs shall be coordinated and approved by the COR and/or CO. The COR and/or CO shall be notified of all temporary repair conditions and schedule the job for corrective maintenance. The contractor shall notify the COR and/or CO as soon as possible with notification time not to exceed one (1) hour after contractor identifies the emergency situation. If the COR/or CO cannot be contacted within the one (1) hour requirement, 509th CES customer service or Fire Department (non-duty hours) shall be notified.

The contractor shall then brief the COR/CO when available.

3.2.2. PM Program. The contractor shall develop and maintain a PM schedule (reference Section 2.4.1.1.) for all primary and ancillary equipment included in this contract based in part, on the procedures contained in the manufacturers’ technical literature. The manufacture’s PM requirements and/or recommendations for PM shall be included in the PM program. See Appendix B3 for a list of equipment requiring PM and Appendix A for a breakdown of required tasks. The PM plan and schedule shall be submitted to the CO and COR for approval within thirty (30) calendar days of contract award. The contractor shall perform PM according to the Government approved schedule at the intervals recommended by the manufacturer.

3.2.2.1. The PM program shall include all equipment to include: rotating equipment (examples: pumps, motors, air compressors, etc.), DeltaV, heat exchange equipment, verify operation of boiler alarm and cutouts, and plant steam heat distribution systems. The preventive maintenance program for rotating equipment shall be accomplished, at routine intervals during the year according to manufacturers’ recommendations. The result shall be used to identify the correct alignment, balance, and bearing problems to enable implementation of repairs prior to equipment failure. The PM program for heat exchange equipment shall be accomplished, at a minimum , either visual inspection of heat transfer surfaces monthly or as required by the COR and/or CO, trend analysis of pressure drop and heat transfer across heat transfer equipment to determine fouling and equipment efficiencies.

Corrective actions shall be taken prior to exceeding manufacturers’ limits or design standards.

3.2.2.2. PM programs for CHP and distribution systems (reference Section 3.2.8) shall be developed. The contractor shall be responsible for all steam and condensate line and boiler repairs, insulation repairs, patches, removal, firebrick installation and repair, and proper disposal needed to perform work under this contract. The contractor shall be responsible for corrosion control on boilers, boiler equipment, boiler support equipment and assemblies, and piping. The contractor shall abide by all Federal, State, and Local regulations dealing with asbestos, tremolite, anthophyllite and actinolite work. Records of all maintenance performed and dates performed shall be maintained.

3.2.2.3. Periodic maintenance shall include the calibration of all plant transmitters, instrumentation and control set points according to the manufacturers’ recommended frequency and the ABMA Standards, heat output meters shall be calibrated at a minimum once annually. The contractor shall maintain records of before and after calibration settings, equipment used to perform calibration, date of calibration and personnel performing the calibration. In addition to normal yearly and periodic calibration, the contractor shall recalibrate any gauge or instrument, which is suspected of being in error beyond manufacturer accuracy. The Government reserves the right to check the calibration of plant metering and instrumentation at any time. When maintenance tasks indicate that repair of specific equipment is needed to prevent further damage or unscheduled outages, the contractor shall initiate the appropriate action to complete repairs.

3.2.2.4. Calibrations may be contracted out with COR approval of subcontractor and at no expense to the Government.

3.2.2.5. PM Work. The contractor shall be responsible for performing PM on all CHP equipment. These requirements are identified by the manufacturer and AFIs listed in Appendix C. The Government is required to periodically monitor PM so the contractor should make every effort to schedule PM during normal work hours (0700-1600 M-F). PM shall include, but not limited to, all work identified in Appendix A.

Key PM Requirements also Include:

1. The DeltaV system to include hardware and software updates

2. Corrosion control on equipment

3. Boiler overhaul during shutdown for annual inspections (see Section 3.2.3 for more details)

4. Rotating equipment requirements

5. Air compressors

6. Water treatment equipment

7. Valve operation (control, safety, PRV, etc.)/ Operate valve

PM Schedule: The contractor shall submit to the Government a PM schedule NLT that 5 days before the preceding month. This schedule shall encompass the following:

1. The maintenance to be accomplished and the date and shift of that scheduled maintenance.

2. The part requiring the maintenance to include part and serial numbers if part has part or serial numbers.

3. The PM schedule shall contain a detailed listing of the manufacture’s maintenance cycles and work required for each piece of equipment. Examples: change oil every 2000 hours or annually, lubricate bearings every 200 hours, clean pump inlet monthly.

4. If PM work is not being accomplished by a regular contractor employee (i.e. sub contracted out), the subcontractors company name and individuals names shall be included.

5. The PM schedule shall be submitted to the COR for approval identifying all work and the dates of scheduled PM work for the following month. Once approved by the COR and/or CO, the PM program and schedule shall be carefully executed by the contractor.

Any proposed changes to approved schedules shall be submitted for approval and changes shall be approved prior to being implemented. The contractor shall correct all equipment deficiencies identified during PM work subject to the limits specified in Section 2.4., Corrective maintenance (CM). When possible, equipment deficiencies detected during PM work shall be corrected prior to departing job site.

3.2.2.6. PM Work also Includes: periodic operation and inspection of idle equipment, purchasing of supplies other than fuel, preservation cleaning, lubrication, and adjustment of plant equipment.

3.2.2.7. The areas around all equipment shall be kept clean at all times. All components shall be checked hourly for overheating of electrical drives and bearing housings, excessive vibrations and unusual noises. Any findings and corrective actions or adjustments will be logged on AF Form 1458, Daily Steam Plant Operation Log. Minor repairs, tightening loose fittings/nuts/bolts/screws, tightening loose electrical connections, and the reinstallation on handles and knobs shall be included as part of preventive/recurring maintenance. All electrical work shall be in compliance with NFPA-70, National Electrical Code, and NFPA- 70B, Electrical Equipment Maintenance.

3.2.2.8. The contractor shall be responsible for the entire DeltaV system to include:

operation, calibration, diagnostics, hardware, software, software updates, maintenance, tuning, and software programming for all portions of the system to include, but not limited to, software, drives, computers, monitors, wiring, controllers, I/O cards, loops, transmitters, actuators, switches, and calibration of the control system and the boilers. The contractor shall be responsible to perform all required software and hardware updates as recommended by the manufacturer (Emerson and Experitec) and the Government. The Government will only reimburse for parts to include the software. All required labor to configure, upgrade, calibrate and the expertise required to install software, calibrate system, or replace parts are the contractor’s responsibility and considered part of normal operation and maintenance of the heat plant. Should any portion of the DeltaV system, computers, hardware, or software etc., require repair only qualified employees shall do the repair. Should the contractor elect to subcontract out the repair only authorized Emerson representatives are allowed to repair DeltaV equipment. At no time will DeltaV equipment be repaired by any other repair companies (i.e. Office Depot, Best Buy, etc.).

3.2.3. Boiler Overhaul. Maintenance and repair work on the heat generation system and direct support ancillary equipment, which cannot be performed during normal operation, shall be accomplished as an overhaul item. All maintenance and repairs shall be performed IAW ASME Boiler and Pressure Vessel Code. All repairs shall be fully warranted against defects due to material or workmanship.

3.2.3.1. The contractor shall coordinate the annual overhaul with performance of inspections and witness the tests that are required while the unit is open. During the annual overhaul an internal and external inspection of all units will be conducted by a certified boiler inspector at Government expense. The contractor shall prepare and submit and overhaul schedule indicating the date, time, and duration of work for approval by the COR and/or CO thirty

(30) calendar days prior to the proposed work. No steam outages shall be allowed for boiler overhaul. Any vessel deficiency found shall be reported to the COR or CO immediately.

Work affecting the structure or pressure integrity of any pressure vessel shall be performed by an individual holding the appropriate ASME code stamp at no additional cost to the Government. Completed work shall be inspected prior to the affected equipment being returned to operation. Weld repairs and operations shall be reported to the National Board of Boiler and Pressure Vessel Inspectors on Form R-1, Report of Welded Repair or Alteration. (Note: The contractor shall be responsible for all steam line boiler insulation repairs, patches, removal, and proper disposal needed to perform work under this contract.

The contractor is advised that the CSP may contain asbestos throughout the plant. The contractor shall abide by all Federal, State, and Local regulations dealing with asbestos, tremolite, anthophyllite, and actinolite).

3.2.4. Boiler and Pressure Vessel Inspection. Each high pressure steam boiler and unfired pressure vessel assigned to the contractor shall be inspected IAW AFI 32-1068, Heated Systems and Unfired Pressure Vessels (Section 3.5.5). See Appendix B3 for a list of boilers and unfired pressure vessels. The Government will schedule and pay for annual boiler inspections. The contractor shall be responsible for preparing each piece of equipment for inspection, operation of equipment as required during inspection, hydrostatic pressure testing during inspection and placing each unit back in service for full operational needs for the base. Inspections are currently accomplished through an Air Force central boiler inspection contract. These inspections will normally be performed during the summer months when the load requirements are at a minimum.

3.2.4.1. The Government will schedule type A-B-C boiler inspections with the designated Air Force boiler contract to keep all boilers current under inspection requirements. If rescheduling is caused by the contractor, the contractor shall cover additional expenses. The contractor shall ensure that a boiler found in an unsafe condition shall not be fired until the contractor corrects all deficiencies and the boiler has passed all inspections.

3.2.4.2. The contractor shall post one (1) copy of the latest inspection report of each piece of equipment requiring inspection under a transparent protective cover in a conspicuous location in the plant (bulletin board). Any inspection recommendations/remarks made by the boiler inspector indicating a piece of equipment needs repair or is unsafe to operate shall immediately be reported to the COR and/or CO. The inspection procedures of AFI 32- 1068, Heated Systems and Unfired Pressure Vessels, (Section 3.5.5), shall be followed. The contractor is responsible for initiating and tracking repairs recommended on AF Form 1222, Boiler Inspection Report. Recommended repairs shall be accomplished as soon as possible with completion NLT during annual overhaul unless otherwise approved by COR and/or CO. Corrective actions required (provided they were not caused by the contractors actions or inactions) shall be corrected by the contractor and will be reimbursed by the Government for parts and materials per the Bid Schedule line item for Reimbursable Parts and Materials.

All repairs of pressure components of boilers, unfired pressure vessels and safety pressure relief devices for pressure vessels shall be performed by an organization holding the appropriate ASME code stamp. Repair status shall be reported monthly to the COR and/or

CO.

3.2.5. PM Reports. No later than the fifth working day of each month during the term of the contract, the contractor shall submit to the COR details of all PM work and inspections completed during the previous month, a list of schedule work or inspections which were not accomplished, and a description of any CM requirements noted during the previous month’s inspection but not accomplished. The work details shall include but not limited to: dates, description of problem, repair actions, parts replaced, and as-builts if system was modified. Any changes to the PM Schedule will be noted.

3.2.6. Corrective Maintenance (CM). CM is maintenance and repair work that is required to return a system or component to proper operating condition. CM may be required on a routine basis (operator maintenance) or as a result of a PM inspection. CM shall be performed as required during the course of routine operations or as an emergency repair. The contractor shall provide corrective maintenance and repair services required to return a system and/or equipment in this contract and all related support items to their proper operating condition.

Emergency service/repairs are required CM repairs needed to prevent damage to equipment and will meet the requirements of Section 3.2. It includes maintenance and repair work that is 200 man-hours or less in labor. The contractor’s liability under the firm fixed portion of the contract shall be limited to 200 man hours per CM action. Maintenance and repair work exceeding 200 man-hours will be negotiated with the Government. CM actions with an estimated labor effort greater than 200 man-hours will be executed by supplemental agreement to the contract, or awarded under a separate contract by the Government. Labor hour requirements for work over 200 hours will be based on, at the Government’s discretion, Government and Administrative costs guides, R.S. MEANS Cost Estimating Guides or three competitive quotes from commercial vendors. Should the work required exceed the 200 man-hour limit, the entire job will require neogotiation for a supplemental agreement, or the entire job will be awarded under a separate contract by the Government. Direct materials costs will be based on the actual direct cost of the material. The Government retains the right to obtain additional quotes.

3.2.6.1. CM may be required on any/all equipment or system in the CHP unless specifically identified in this PWS as not a contractor responsibility. CM includes but not limited to rebuilding: air compressors, pumps, valves, etc., to return the component or system to an operational status.

3.2.7. Distribution System Maintenance. The contractor is responsible for repairing or replacing all components in the steam and condensate distribution system through preventive and corrective maintenance. The contractor shall be responsible for all piping up to and including where the piping meets the inside of the building wall to include the seal at/in the wall.

The seal must be functional to prevent steam, from leaks, from entering the building. All maintenance shall be in accordance with the ASME Code and the manufacturer’s recommendations. The distribution is approximately seven (7) miles long of both steam pipes and return condensate pipes running parallel to each other. Pipe lines are primarily in trenches below concrete lids of different sizes and weights. This includes going under roads and parking lots. Some piping is above ground and some is direct buried. Access to 98% of distribution system main components (except piping) is through steam pit lids and manholes. A few components (i.e. valves) are only accessible through hand held covers and concrete lids. A few drains are only accessible through concrete lid removal. Approximately one-third (1/3) of the distribution system is located within the restricted area and requires a restricted area badge for entry (Section 9.3.1).

3.2.7.1. Most of the steam distribution system is located below concrete sidewalk lids of different sizes weighing several hundred pounds and require mechanical lifting devices for removal for repairs. The contractor shall provide the equipment and operator(s) necessary to remove lids to gain access to piping and trenches at no additional cost to the Government.

This equipment may include but not limited to, forklifts, skid loaders, or front end loaders, or digging equipment. Repaired piping and components will be pressure tested and then re-insulated before lids are replaced. The contractor shall re-seal all lids after repair is complete and before replacing. The work area shall be returned to its previous condition. 509th CES approval is required prior to start of dig, through the submission and acceptance of appropriate forms. The contractor must have this completed and approved form in his/her possession prior to starting work. Dirt or pavement must be returned to the original condition. The contractor will supply all material, equipment, and labor for the entire operation. Any and all steam pit maintenance shall be fully documented and at a minimum will include: parts removed, replaced, repaired, and/or adjusted and a complete report will be provided to the Government within five (5) working days. All materials will be approved by the COR.

3.2.7.1.1. The contractor shall replace/install insulation on all piping when repaired, replaced or when needed.

3.2.7.1.2. Distribution system piping may require welding. All welding operations require a burn permit which the contractor will obtain from the base Fire Department.

3.2.7.1.3. The contractor shall develop, implement, and maintain a confined space training program. This program must be OSHA and Base Safety approved. A copy of the confined space program must be submitted to Base Safety annually. The contractor shall, at no additional cost to the Government, supply all confined space resources, equipment, and required training needed to enter the steam trenches, pits, and utilidor.

3.2.7.1.4. Distribution system parts are paid through reimbursable CLIN(s).

3.2.8. PM of the distribution system.

3.2.8.1. Visual inspections of all steam pits, valves, sumps pits, above ground and below ground lines and related equipment shall be conducted. A visual inspection shall be performed at least once during each shift at least eight (8) hours apart. The visual inspection may be accomplished during shift change. If a twelve (12) hour shift is utilized on the weekend the inspection may be done at the twelve (12) hour shift change. Visual inspection may need to be performed more often during adverse weather such as heavy rain. The contractor shall verify that water in the pits is at a minimum below the piping. Steam coming from pits or trenches shall be investigated to determine source. If water is high and the pit pump is inoperable or does not have an installed pump the contractor shall pump water out of the pit. The source of the leak shall be determined. The contractor shall make repairs to the pump immediately or as soon as parts become available.

3.2.8.2. Quarterly cleaning and inspection of all pits is required. Contractor should be aware that some lifting will be required doing steam pit cleaning. The contractor shall verify there are no steam or condensate leaks, inspect the structural integrity of the pit and lids, blow down and verify the operation of all traps, ensure valves operate, ensure entire pit is free of debris and clean. Dirt, mud, and other debris will need to be removed and disposed of. The Government will identify the location on base. Ensure sump pump(s) are operational, floats operate as intended, control box components are functioning as intended and is clean, proper status is being sent from the control panel to Metasys, and cabinet door is water tight and valves. If discrepancies are discovered they shall be noted and corrected at that time unless parts need to be ordered.

3.2.8.3. CM of the distribution system.

3.2.8.3.1. Manholes, Steam Pits, Trenches, Direct Buried Conduit, Above Ground Piping, and the Utilidor. The contractor shall make repairs when identified. The contractor shall be responsible for the inspection, maintenance, and repair of everything within the steam pits and trenches to include the following:

All piping Pipe insulation and jacketing Pipe anchors and supports Steam traps, valves, flanges, etc.

Expansion joints, etc.

Sump pumps and assemblies Pump control panels: all parts/equipment within the control panel to include pump operation and Components used to transmit pump and station status to Metasys Guide rail systems…