Attachment_1_-_SOW_Repair_and_Refurbish_AFTF_29_Dec_16.pdf

STATEMENT OF WORK

FOR

REPAIR AND REFURBISHMENT

OF

AIRCRAFT FIRE TRAINING FACILITY

AT

SHAW AIR FORCE BASE

SOUTH CAROLINA

(Revision 1) 29 Dec 2016

STATEMENT OF WORK

FOR

INSPECTION, MAINTENANCE AND REPAIR

OF THE

AIRCRAFT FIRE TRAINING FACILITY

1. DESCRIPTION OF SERVICES. The contractor shall provide all supplies, materials, tools, equipment, and qualified labor necessary to repair, refurbish, and test the Aircraft Fire Training Facility (AFTF) at Shaw Air Force Base, South Carolina in a manner that will ensure its serviceability and prevent deterioration in operational effectiveness. As a minimum the contractor shall have the following licenses/certifications: Licensed Electrician, Hold a Certified Propane Installer Card, licensed by Propane Education & Research Council (PERC) and have a licensed Mechanical Engineer with specialization of NFPA 1403 as part of contracting company.

1.1 REPAIR, REFURBISHMENT AND TESTING SERVICES. The contractor shall Repair, Refurbish and Test all items stated below. Items provided shall at a minimum, comply with the standards set forth in T.O 35E1-2-13-1, 25 June 2013 Edition.

1.1.1 Remove all propane connections which are corroded, uncovered or have damaged fittings in the pit and transition box. Cut back piping to structurally sound material. Add stainless steel couplings or transition fittings by way of threading or welding. Add as needed flex or rigid stainless steel to complete connections. Replace all flex connections using stainless steel terminations in transition box, provide corrosion control at control tower. Test and repair all leaks in plumbing and valves, blow piping system for any loose debris, reconnect and test for leaks. Wrap all exposed iron piping per standard using rubberized or thrush mesh pipe tape mastics. Troubleshoot air leak in mainline and repair, replace all air gauges with stainless oil filled gauges. Written 1 year warranty upon completion/acceptance of all work performed.

1.1.2 Remove all 15 coax valves, disassemble and replace. Install new stainless steel spline connection bolts during reassembly. Ensure piping connections have been refurbished under SoW 1.1.1. Re-assemble coax valve in place. Install new stainless steel air adaptors and flex air connections, ensure air piping has been cut back to good piping. Test for leaks and repair as needed. Install new stainless steel burner support piping with 2 inch shield and burners from each coax valve to fire scene. Written 1 year warranty upon completion/acceptance of all work performed.

1.1.3 Remove all igniter wire, conduit, J-boxes from pit and transformer panel and dispose of material. Install 2-3” high-density polyethylene/el (HDPE/EL) chase conduits from transformer panel to transition vault at pit. Install 18 plus one spare (empty for ground wires) 1/22” hermetically sealed HDPE/EL conduits cellular raceways one from each transformer to each ignitor housing. Install 7 ground igniter housings. (left front, debris, left rear, right front, right wing, right rear and spill fire scene). Install 2-#8 solid bare ground wires in spare HDPE conduit, bond at transformer panel per NEC 70. Bond at transition vault per NEC 70 using a Blackburn submersible grounding connector USB350-12. Bond each pipe in vault. Install along the side of each cellular raceway igniter cable a single #12 green ground wire. Install memcon sealoff fittings on igniter housings and 1220mil shrink tubes on all other terminations. Supply and install by welding or drill and tapping as needed full face igniter housing cover plates and bolts.

(this will require site fabrication of existing housing which requires replacement of missing bolts, broken bolts, missing plates, etc.) Install permanent welded water jacket ¾” fill fittings and 2” drain and flush fitting with stainless steel control valves at water jackets ( cockpit, pax, cargo, apu, wheelwell, hightail, outboard engine, inboard engine). Re-plumb water jacket plumbing, cut back bad corroded piping to good solid structure and refit with new stainless steel fittings as needed. Flush water jackets, weld back on the inspection plates cut out by others to ensure a solid non leaking water jacket. Test all transformers, replace any transformer testing below 9700v at load. (test at igniter should be within 5600-7400v) Written 1 year warranty upon completion/acceptance of all work performed. Provide all materials and labor.

1.1.4 Cut and refit as needed twin “I” beams on the troop ramp, weld on 42” extensions to each “I” beam. Add 36” of 2.5” bar grate creating a no more then 3/12 ramp. Refit hinges on low wing door, refit hinges on cargo door and provide swing latch closures. Provide Written 1 year warranty upon completion/acceptance of all work performed. Provide all material and labor required.

1.1.5 Remove deformed upper wing and engines and dispose of said material. Supply and install new upper wing and engines (T-1 boiler plate with fabricated round leading edges).

Supply new inboard and outboard engine with front and rear turbine fins. Twin support columns with built in stainless steel igniter housings and engine water mister and bath fill cellular raceway entrance seal offs. 1inch stainless steel igniter mounting plates with champion igniters and spray shields, stainless steel water adjusting valves, all attachment points to be new stainless steel.

New stainless steel burner and swirl piping. Written 1 year warranty upon completion/acceptance of all work performed. Provide all material and labor.

1.1.6 Supply and install new mechanical HPRV on quade stack on LP vessel. Supply and install new HPRV’s at fill vessel stations. Remove, test and recertify HPRV’s at control tower.

Remove old shut off valve and supply and install fail safe “snappy joe” propane fuel valve at control tower. Inspect internal valves, replace packing seals. Remove old rusted air cans on internal valves and dispose of. Replace with new fail safe cans with heat plugs. Refit all airlines to vessel ensuring no leaks and proper mounted estop and function at vessel per National Fire Protection Association 58 (NFPA). Provide all material and labor Written 1 year warranty upon completion/acceptance of all work performed.

1.1.7 Provide corrosion control to all electrical panels

1.1.8 Supply and install new G/R 10 HP 600 GPM submersible pump and required accessories for installation new wiring, new stainless steel starter and new fittings and Test. Clean pond while empty, inspect and repair liner, as needed. Provide written 1 year warranty an all work performed and provide all material and labor.

1.1.9 Supply Aquashade pond/water treatment—8 gallons equivalent to 1 year supply

1.1.10 Re-fit/ jack into place high tail engine. Provide and install steel plate “rudder” in between “H” beam support, weld to mock up, engine and “H” beam supports. Provide and install steel plate cross support inside mock up under engine, weld to mock up to remove deflection. Re-fit/re-weld as needed “H” beam supports. Provide all new water jackets relocated to rear of mockup. Provide Written 1 year warranty upon completion/acceptance of all work performed.

Provide all materials and labor.

1.1.11 Remove all supports and elevated sprinkler piping from top of mockup. Provide and install new stainless steel riser, header and sprinkler drops mounted no more then 2 inches from top of mock up and off set from the flame impingement/cut outs on top of mock up. Supply (5) 1” drops and 1” 120 degree stainless steel full jet spray heads per T.O. 35E1-2-13-1. Provide Written 1 year warranty upon completion/acceptance of all work performed. Provide all materials and labor.

1.1.12 Provide written certification for mock up.

2.0 COMPLIANCE

2.1 Environmental Controls. The contractor shall be knowledgeable of and comply with all applicable Federal, State, and local laws, regulations, and requirements regarding environmental protection. The contractor shall ensure policies and procedures are established that protect the health and safety of employees and the community and minimize/eliminate the risk of environmental pollution.

2.2 Notification of Environmental Spills. If the contractor spills or releases any hazardous substance into the environment, the contractor shall immediately report the incident to the QA, base fire department, and base civil engineering. The contractor shall be liable for containment and environmental clean up of the spill or release of such substance.

2.3 SAFETY. Liquid propane used in the facility is potentially explosive. Personnel shall practice proper grounding procedures in accordance with the National Electrical Code (NEC).

Personnel working with or near high voltage equipment should be familiar with modern methods of resuscitation. Personnel shall wear appropriate protective clothing and be aware of emergency procedures to perform emergency shutdown and start-up.

2.4 Safety Requirements and Reports: The Contractor shall perform work in a safe manner as required by OSHA Safety and Health Requirements and applicable Department of Labor, Department of Defense and Air Force safety standards. The Contractor shall provide a verbal report to the CO as soon as possible following an occurrence of damage to Government property or an accident resulting in death, injury, occupational disease, or adverse environmental impact.

Provide a completed copy of the required Accident Investigation Report to the CO within five (5) calendar days of each occurrence. The Accident Investigation Report shall be prepared and submitted IAW AFI 91-204.

2.5 Mishaps: In the event of an accident/mishap, the Contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence until released by the accident/mishap investigative authority through the CO.

2.6 Investigations: If the Government elects to conduct an investigation of the accident/mishap, the Contractor shall cooperate fully and assist Government personnel in the conduct of investigation until the investigation is completed.

2.7 Confined Space Program: IAW AFI 91-203 paragraph 23.8, the Air Force is required to inform Contractors of Confined Spaces and known hazards associated with them. This includes the following:

2.7.1 Notify the Contractor that work will be performed in a permit-required confined space and ensure the information is included in the Performance Work Statement (PWS) or equivalent contracting tool.

2.7.2 Ensure the Fire Chief coordinates on the confined space entry contract and either approves or disapproves the use of the rescue team supplied by the installation Fire Emergency Services Flight.

2.7.3 Brief the Contractor on the contents of the space and known hazards that make the space permit-required and any precautions and procedures that have been implemented by the organization to protect Air Force workers.

2.7.4 The Contractor shall provide the CO an after-action brief providing information regarding hazards encountered or created in the space(s) and report any unsafe act or procedure performed.

3.1. GENERAL INFORMATION:

3.2. HOURS OF OPERATION. All non-emergency work shall be accomplished during the normal duty hours of 0730 through 1630, Monday through Friday, excluding US Government holidays.

3.2.1. Base Closure: The Government will notify the contractor of anticipated closure of the facility due to inclement weather or any other authorized closure. In the event of an unplanned closure of the facility the contractor will be notified using the contact information provided. Work scheduled but not accomplished because of base closure, will be accomplished as soon as possible after reopening the base

3.3. Shaw AFB recognizes the following holidays:

New Year’s Day 1 January Martin Luther King’s Birthday Third Monday in January President’s Day Third Monday in February Memorial Day Last Monday in May Independence Day 4 July Labor Day First Monday in September Columbus Day Second Monday in October Veterans Day 11 November Thanksgiving Day Fourth Thursday in November Christmas Day 25 December

NOTE: Any of the above holidays falling on a Saturday will be observed on the proceeding Friday. Holidays falling on a Sunday will be observed on the following Monday.

4.1. SECURITY REQUIREMENTS FOR UNCLASSIFIED CONTRACTS

4.2. Listing of Employees. The contractor shall maintain a current listing of employees. The list shall include the employee's name, social security number and type of investigation if contract work involves unescorted entry to Air Force restricted areas or other sensitive areas designated by the installation commander. The list shall be provided to the Program Manager and sponsoring agencies Security Manager. An updated listing shall be provided when an employee's status or information changes.

4.3. Security Training. The contractor ensures all contractor employees receive initial and recurring security education training from the sponsoring agencies security manager. Training must be conducted IAW DODM 5200.01, Volume 3, Information Security Program, and AFI 31- 401, "Information Security Program Management". Contractor personnel who work in Air Force controlled/restricted areas must be trained IAW AFI 31- 101, The Air Force Installation Security Program.

4.4. Pass and Identification Items. The contractor shall ensure the pass and identification items required for contract performance are obtained for employees.

4.4.1. Computer Network Access. Contractor employees requiring initial issuance of a Common Access Card (CAC), Access to Restricted Areas, Use of Government

Automated Information Systems/Networks, Child Care positions, or designated Positions of Trust shall complete submission of a National Agency Check with Inquiries (NACI) to the Office of Personnel Management (OPM), or a DoD-determined equivalent investigation. When required, the government will submit NACI investigations to OPM at no cost to the contractor.

4.4.2. Background Checks. All contractor employees not falling into one of the categories listed in the preceding paragraph shall submit to a criminal background check accomplished by Shaw Air Force Base Security Forces prior to the employee being issued base access credentials. Failure to submit requested Contractor Listing of Employees as indicated can result in denial or delay of issuing base access credentials. Processing criminal background checks takes, at a minimum, 7-10 days from time of submission.

4.5. Retrieving Identification Media. The contractor is responsible for retrieving all government-issued identification media from employees who depart for any reason before the contract expires; e.g. terminated for cause, retirement, etc. The contractor shall return retrieved items to the Security Forces Pass and Registration Office.

4.6. Traffic Laws. The contractor and its employees shall comply with base traffic regulations.

4.7. Weapons, Firearms, and Ammunition. Contractor employees are prohibited from possessing weapons, firearms, or ammunition, on themselves or within their contractor-owned vehicle or privately-owned vehicle while on Shaw Air Force Base.

4.8. For Official Use Only (FOUO). The contractor shall comply with DoD 5400-7-R, Chapter 4, DoD Freedom of Information Act (FOIA) Program, requirements. This regulation sets policy and procedures for the disclosure of records to the public and for marking, handling, transmitting, and safeguarding FOUO material.

4.9. Reporting Requirements. Contractor personnel shall report to an appropriate authority any information or circumstances of which they are aware may pose a threat to the security of DOD personnel, contractor personnel, resources, and classified or unclassified defense information.

Contractor employees shall be briefed by their immediate supervisor upon initial on-base assignment.

4.10. Physical Security. The contractor shall be responsible for safeguarding all government property and controlled forms provided for contractor use. At the end of each work period, all government facilities, equipment, and materials shall be secured.

4.11. Controlled/Restricted Areas. The contractor shall implement local base procedures for entry to Air Force controlled/restricted areas where contractor personnel will work. An AF Form 2586, Unescorted Entry Authorization Certificate, must be completed and signed by the sponsoring agencies Security Manager before a Restricted Area Badge will be issued. Contractor employees must have a completed National Agency Check with written inquiries (NACI) investigation before receiving a Restricted Area Badge.

4.12. Key Control. The contractor shall establish and implement methods of making sure all keys issued to the contractor by the Government are not lost or misplaced and are not used by unauthorized persons. The contractor shall not duplicate any keys issued by the government.

4.12.1. The contractor shall immediately report to the Contracting Officer (COR) or Program Manager any occurrences of lost or duplicated keys.

4.12.2. In the event keys, other than master keys, are lost or duplicated, the contractor may be required, upon written direction of the Contracting Office, to re-key or replace the affected lock or locks without cost to the government. The government may, however, at its option, replace the affected lock or locks or perform re-keying and deduct the cost of such from the monthly payment due the contractor. In the event a master key is lost or duplicated, all locks and keys for that system shall be replaced by the government and the total cost deducted from the monthly payment due the contractor.

4.12.3. The contractor shall prohibit the use of keys, issued by the government, by any persons other than the contractor’s employees and the opening of locked areas by contractor employees to permit entrance of persons other than contractor employees engaged in performance of contract work requirements in those areas.

4.13. Photography Restrictions: No one is authorized to take any pictures or video recordings of Air Force operational aircraft or restricted areas without the approval of 20 FW/CVN regardless of location while on Shaw AFB. This includes, but is not limited to, photographs taken from personal electronic devices such as blackberries, iPADs, iPODs, cell phones, or any other devices with digital recording capabilities.

4.13.1. Any Contractor requiring pictures or videotape of Shaw's airfield to support their contract must request and possess written authorization prior to entering the airfield area.

4.13.2. Written authorization letters to photograph or video of the flightline must be signed by one of the following: 20 Maintenance Group Commander or Deputy; Aircraft Maintenance Squadron Commander; a Fighter Squadron Top 3, Director of Operations, or Commander; 20 Operations Group Commander or Deputy; 20 Operations Support Squadron Commander or Director of Operations; or 20 FW/CVN.

APPENDIX A

System Particulars

1. This theory of operation is based on the generic design. The Aircraft Fire Training Facility (AFTF) consists of an aircraft mock-up, burn area, control stand, liquid propane fuel system, cathodic protection system and water conservation pond.

2. The aircraft mock-up, located in the burn area, is constructed of non-coated/unpainted carbon steel. It is approximately 72 feet long, 25 feet high at tip of tail, with a wingspan of 72 feet. The mock-up is configured with three simulated aircraft engines, two on the right wing and one located on the vertical stabilizer. Each engine contains one burner assembly and two ignitors.

The wiring to the engine ignitors is enclosed in a protective water jacket that protects it from possible failure due to extreme heat. Water injection is located in both wing engines and at some sites in the tail engine. The wing engines also have dams installed to simulate a flowing fuel type fire. Wheel well and auxiliary power unit fires are simulated on the right side of the fuselage adjacent to the inboard engine. In the interior of the mock-up, ignitors and burners are installed to simulate flight deck, passenger compartment, and cargo box fires. A water sprinkler system is installed in the top of the mock-up to cool and washout the mock-up. An expansion joint is located midway on the fuselage to allow for expansion and contraction during the training.

Cutout panels are located on the left and right aft sides of the fuselage. These 36 inches x 84 inches replaceable panels are constructed of .031 inch thick sheet metal. The panels are used to simulate emergency entrance into an aircraft. Two steel hinged doors are located at the forward left and left amid ships.

3. The burn area is 100 feet in diameter. It is recessed and lined with one 80-mil thick high-density polyethylene (HDPE) liner. The liner is sandwiched between 6 inch thick layers of sand and then covered by a layer of geotextile fabric and then an 18 inch layer of compacted aggregate crushed stone.

4. There are seven ignitors and burners installed in the burn area to simulate six exterior ground fires and one running fuel fire with pool fire on the outboard engine. The ground fires are located on the left and right sides of the forward fuselage, between the right wing engines, under the left wing, and on the left and right sides of the aft fuselage. The weir is used to maintain the proper water level in the burn area. Opening the burn area drain valve allows all the water in the burn area to drain to the water conservation pond.

5. Located on the control stand are the valves, solenoids, and switches used to control the propane flow and ignitors during training events. Turning off the master/emergency switch located on the control stand will turn off power to all ignitors and close the internal valve located on the propane tank via the pneumatic control system, if applicable. The propane piping, water piping, and electrical conduits from the control stand to the burn area are located in an underground HDPE lined trench.

6. The liquid propane system supplies fuel for training exercises. Propane is supplied from 10,000 gallon-WC (water capacity) tank to the various burners in the burn area through a series of pipes and valves.

7. A propane pump may be installed to obtain adequate pressure, if applicable. A corresponding valve located on the control stand, controls propane flow to each individual burner. Safety features of the propane system are provided to stop the flow of fuel to the burners, and will include a pneumatic or manual control system, and an emergency shut-off valve located on the control stand. Pressure relief valves are installed on the piping as required by NFPA Standard

58. Cathodic protection system is used to protect below ground piping from corrosion through sacrificial anodes inside the trench from the control stand to the burn area.

8. The water conservation pond is a 72 feet by 72 feet square area and 9 feet deep. It is lined with 80 mil thick HDPE. Unlike the burn area, the liner is not covered. A pump located in the pond is used to supply necessary water for the training area.