ATTACH 1 FA5209-10-T-0258 PWS 23 Sep solt.doc

ATTACHMENT 1

Solicitation # FA5209-10-T-0258

DEPARTMENT OF THE ARMY

UNITED STATES ARMY GARRISON, JAPAN

DIRECTORATE OF PUBLIC WORKS

UNIT 45006 APO AP 96343-5006

PERFORMANCE-BASED WORK STATEMENT (PWS)

FOR

MAINTENANCE AND REPAIR

OF

REFUSE INCINERATOR PLANT

EQUIPMENT AND SYSTEMS

AT BLDG No. 1024-1, CAMP ZAMA

CAMP ZAMA

23 Sep 2010 (FEWR No.JF-10020-0J) The attached Performance-based Work Statement is being provided IAW Section 801, 10 USC 2330. Any contract or task order resulting from this request is to be acquired using performance-based principles.

TABLE OF CONTENTS

SECTION 1

Description of Services/General Information

3 - 12

SECTION 2

Services Summary

SECTION 3

Government Furnished Property and Services

13 - 14

SECTION 4

Appendices

14 - 44

1. Estimated Workload Data

14 - 15

2. Minimum Required Maintenance Items for Annual Overhaul

16 – 18

3. Equipment List for Refuse Incinerator Plant

19 – 44

SECTION 1

DESCRIPTION OF SERVICES/GENERAL INFORMATION

1. DESCRIPTION OF SERVICES. The Contractor shall provide all labor, equipment, transportation, tools, materials, supervision, and other items and services necessary to perform maintenance and repair of refuse incinerator plant, Bldg No. 1024-1 at Camp Zama by providing contractor-furnished materials. The Contractor shall perform: (a) Routine maintenance and inspection that includes minor repair (Para 1.1.), (b) Annual overhaul work (Para 1.2.), and (c) Unscheduled work (Para 1.3.) in accordance with the plant manufacturer’s standard, the requirements of this Performance-based Work Statement (PWS), and acceptable commercial practice to assure continuous refuse burning operation of subject refuse incinerator. Estimated workload data is in Appendix 1, minimum required annual overhaul maintenance items are in Appendix 2, and the equipment list for the refuse incinerator plant is in Appendix 3.

1.1. ROUTINE MAINTENANCE AND INSPECTION.

1.1.1. The Contractor shall perform periodic inspection and maintenance services required to preserve all plant equipment items including but not limited to those listed in Appendix 3, to maintain incinerator systems and equipment. Such work is described in maintenance manuals published by each equipment manufacturer. The manufacturer’s maintenance manual and instructions are available for the Contractor to review at the incinerator plant. Any minor repair and replacement of the refuse incinerator plant equipment and systems not exceeding ¥500,000 for the total labor cost per occurrence shall be performed within the scope of this paragraph, “Routine Maintenance and Inspection”. Examples of routine maintenance include, but are not limited to inspections, lubrication, adjustments, measurement of insulation resistance for electrical circuits, replacement of worn out electrical magnetic contacts, and replacement of expired parts. A workload estimate for minor repairs/replacements not to exceed ¥500,000 is located at Appendix 1. Required materials for this paragraph shall be furnished by the Contractor in accordance with para 1.6.1. below.

1.1.2. Annual Maintenance Schedule. The Contractor shall conduct preliminary studies of plant equipment and provide an annual schedule for routine maintenance, inspection, and annual overhaul services, detailing the dates the Contractor will perform the services listed in paragraphs 1.1 and 1.2 (including sub-paragraphs) of this PWS to Quality Assurance Personnel (QAP) for approval, prior to performing services. The routine maintenance schedule shall show the order in which the Contractor proposes to perform services, the dates on which the Contractor will start a work element, the scheduled dates for completion, and the number of man-hours needed for each work element. The schedule will be used by the QAP to schedule surveillance of the Contractor’s work. The contractor shall prepare and submit the routine maintenance schedule for the first year performance period and each option year no later than 15 calendar days prior to the performance start date. The “days” in this PWS shall read “calendar days” unless otherwise specified.

1.1.3. Monthly Requirements

1.1.3.1. Crane System. Monthly inspections and maintenance in addition to annual inspection and maintenance of the crane system shall be conducted by the Contractor IAW Article 34 and 35 of Crane Safety Regulation issued by Ministry of Health, Labor and Welfare (厚生労働省のクレーン等安全規則). Inspection reports shall be submitted within 15 calendar days after inspection.

1.1.3.2. Ash monitoring. The Contractor shall conduct monthly analysis of residual ash and treated fly ash. The results shall be submitted to the QAP within 20 calendar days after measurements.

1.1.4. Quarterly Requirements

1.1.4.1. The Contractor shall also conduct quarterly analysis for quality of extracted refuse, IAW the Waste Management and Public Cleansing Law, Paragraph 8-3 (廃棄物の処理及び清掃に関する法律、第8条の3) and the results shall be submitted within 20 calendar days after measurements.

1.1.5. Semiannually Requirements

1.1.5.1. Cleaning. The Contractor shall conduct cleaning and inspection of all equipment and systems in the plant in May and November of each year (two times a year). This cleaning service shall include, but not be limited to, the inside of furnaces, gas cooling chambers, air pre-heaters, gas cooling towers, bag filtration chambers and induced draft fans. The Contractor shall also maintain the markings on piping equipment and provide touch-up painting on plant equipment as required. The Contractor shall match existing paint in both type and color when accomplishing touch-up painting.

1.1.5.2. Dioxins Analysis of Ash. The Contractor shall conduct semiannual analysis of residual ash and treated fly ash to quantify dioxins in accordance with Japan Environmental Governing Standards (JEGS). The testing laboratory that conducts tests for dioxins shall possess a license for the Measurement Certification Business for Concentration of Dioxins in residual ash and treated fly ash issued under the Specified Measurement Laboratory Accreditation Program (特定計量証明事業者認定‐焼却灰その他の燃え殻及びばいじん中のダイオキシン類濃度の計量証明事業) based on the Measurement Law of Japan. The results shall be submitted to the QAP within 20 calendar days after measurements.

1.1.6. Annual Requirements

1.1.6.1. The Contractor shall conduct an annual inspection called the “Precision Inspection (精密機能検査) over the function of all equipment and systems of the refuse incinerator plant” in May of each year, IAW Enforcement Regulation of the Waste Management and Public Cleansing Law, paragraph 5 (廃棄物の処理及び清掃に関する法律施行規則、第５条), and the manufacturer’s recommendations, before annual overhaul work will be accomplished in November of each year. The precision inspection report shall be completed by competent engineers under direct supervision of the Contractor and submitted to the QAP within 20 calendar days. This report should include at minimum, 1) an evaluation of the inspection studies, 2) the annual overhaul work schedule as planned in November (see para 1.2) including material information as required for the overhaul work, 3) the Contractor’s technical recommendations/advice for annual overhaul, through coordination with the QAP. The work schedule shall show the order in which the Contractor proposes to perform the services, the dates on which the Contractor will start a work element, the scheduled dates for completion, the number of man-hours needed for each work element, annual inspection results, and necessary sketches/photos. The Contractor shall submit three (3) bilingual copies of the schedule to the QAP (two copies) and the Contracting Officer (KO) (one copy). The schedule will be used to inspect and evaluate work by the QAP.

1.2. ANNUAL OVERHAUL WORK.

1.2.1. Annual overhaul work shall cover major repairs and restorations required by annual inspection. The Contractor shall plan and execute annual overhaul work and routine maintenance work to keep all equipment and systems under this contract in their designed conditions. The Contractor shall perform annual overhaul work on all incinerator plant equipment and system components per an approved schedule to be submitted by the Contractor, including, but not limited to, the work elements listed in Appendix 2. The overhaul work shall be conducted in November of each year. The Contractor, therefore, shall submit the work schedule 10 calendar days in advance and obtain an approval from the QAP prior to the actual work to be conducted in November (the annual overhaul work schedule is referenced to para 1.1.6.1 above). The Contractor shall furnish all required materials to be accomplished an annual overhaul work in accordance with para 1.6.1. below.

1.2.2. The Contractor shall accomplish the annual overhaul work in accordance with the approved work schedule. This service should be programmed and performed one furnace at a time. One furnace shall remain operational at all times. For any services requiring plant operation stoppage, the Contractor shall keep the plant operational for the maximum amount of time possible.

1.2.3. Overhaul Work Reports. The report for annual overhaul work conducted shall be prepared by the Contractor per piece of equipment in Appendix 3 and submitted to the QAP within 30 calendar days after the date of actual performance. Such reports shall contain the following information, at a minimum:

(1) Date Work Started

(2) Who performed the service

(3) Equipment Item Checklist

(4) Description of Services performed with used material information (name, model, type, quantity and cost)

(5) Drawings/sketches for specified service areas

(6) Pictures/ photographs such as deteriorated parts, replacement of new parts, etc.

(7) Test Data Results

(8) Recommendation for effective maintenance and operation

(9) Work Completion Date

(10) Cost break-down for each service provided, per equipment item

(11) Signature of Contractor Representative

1.3. UNSCHEDULED WORK (Other than Minor Repair and Replacement).

1.3.1. Unscheduled work is not included in the monthly unit price of the contract under para 1.1 Routine Maintenance and Inspection. When the KO determines any repair/replacement work beyond the scope of para 1.1 Routine Maintenance & Inspection (i.e. exceeding the ¥500,000 limitation of the total labor cost per occurrence), and para 1.2 Annual Overhaul Work, of the PWS, necessary to maintain the Government refuse incinerator plant in an operable condition, price of such work will be negotiated in terms of the materials and labor between the Contractor and the KO based on the hourly rates set forth in the contract, on a case by case basis as required, and included in a Supplemental Agreement to the contract. The funds for individual unscheduled work will be obligated on a separate purchase request and modification will be issued. When the KO directs any repair work within the scope of this unscheduled work, the Contractor shall submit a detailed cost breakdown to support the individual cost elements of labor and material cost estimation other than the Contractor’s stock materials, as well as providing information and instruction on the work scope and the desired period of time for completion of the work.

1.3.2. Unscheduled Work Document. The Contractor shall prepare and maintain Unscheduled Work Documents. Each unscheduled work requirement must be represented on a separate document, which shall include the following information:

(1) Control number.

(2) Date and Time the request was received and work began.

(3) Location of the unscheduled work requirement.

(4) Description of the unscheduled work requirement

After completion of the unscheduled work, the following information is to be added to the working copy of the unscheduled work document:

(5) Description of cause of malfunction and defective parts.

(6) Photographs showing deficiencies.

(7) Date and Time Completed.

(8) Signature of Contractor representative.

A copy of the complete unscheduled work document shall be submitted to the KO or the QAP within 10 calendar days after completion of the unscheduled work.

1.4. RECORDS KEEPING. The Contractor shall prepare and maintain checklists as cumulative maintenance records for each piece of equipment. The record shall include a routine maintenance and inspection report, overhaul work report, unscheduled work document, any document for repair work, and any other data necessary for maintenance of the system. The record shall be updated as work is performed. The record shall be made available to the Government in digital format and hard copy for examination and reproduction to the KO and/or QAP within five (5) working days after completion/termination of each contract/option period.

1.5. CONTRACTOR FURNISHED STOCK MATERIALS.

1.5.1. The Contractor is responsible for developing and maintaining adequate level of stock materials. The stock materials shall be purchased and furnished by the Contractor to be used under this contract. All stock materials shall be procured and reimbursed to the Contractor in accordance with paragraph 1.6.1. below.

1.5.1.1. Inventory Record. The Contractor and the QA Personnel shall conduct a quarterly joint inventory for the stock materials. The Contractor shall create and maintain the stock material inventory record, which reflects the material description, unit cost, and transaction history and current balance on hand. All stock materials shall be procured and reimbursed to the Contractor in accordance with paragraph 1.6.1. below.

1.6. GOVERNMENT REIMBURSEMENT FOR MATERIALS.

1.6.1. All materials procured under this contract required to sustain continuous operable conditions and maintenance/repair of the Government owned incinerator in support of CLIN x001 and x002, shall be reimbursed under CLIN x003.

1.6.1.1. This paragraph refers to the Government reimbursement for materials furnished by the Contractor under CLIN x003, thus labor hours to repair and replace parts shall be included in Routine Maintenance and Inspection services under CLIN x001 that includes the minor repair service and Annual Overhaul Works under CLIN x002. The Contractor shall procure all items as required, competitively and at the best market prices obtainable in line with the urgency of delivery requirement. The Contractor shall maintain documented proof of competition from at least three (3) sources on all purchases exceeding the yen equivalent of $3,000, and the QA personnel will review the documents each time submitted by the Contractor and obtain approval from the CO prior to the purchase of any item exceeding the stated limitation.

1.6.2. The Contractor shall procure all materials competitively and at the best market prices. In case competition cannot be obtained, the Contractor is required to submit a proof of non-availability of competition. Any discounts and rebates on materials as obtained by the Contractor shall be credited to the Government.

1.6.3. All the materials thus procured shall be reimbursed at the net purchase cost on a monthly basis by the Government. The Contractor's invoice shall include a listing of all the materials procured by material description, quantity, unit, total purchase costs, original copy of each delivery ticket, sales slip or other documentation of proof that the material was procured at the best market price.

1.6.4. The materials, parts, and supplies purchased shall be of equal or greater quality than the materials to be replaced. Replacement materials shall be standard products from manufacturers regularly engaged in the production of such materials, parts, and supplies.

1.6.5. Each purchased material shall be inspected and accepted by the QA Personnel upon delivery and title thereto shall transfer to the Government upon acceptance.

1.6.6. Material Approval. Substitute materials required to perform repairs or replacement shall be approved by the KO through QA Personnel’s technical review on AF Form 3000, Material Approval Submittal.

1.6.7. Delivery and Storage of Materials. All materials delivered and placed in storage shall be protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants by the Contractor.

1.7. CONTRACTOR MANPOWER REPORTING. The office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) operates and maintains a secure Army data collection site where the Contractor will report ALL Contractor manpower (including subcontractor manpower) required for performance of this contract. The Contractor is required to completely fill in all the information in the format using the following web address: https://contractormanpower.army.pentagon.mil. The required information includes: (1) Contracting Office, Contracting Officer, Contracting Officer’s Technical Representative; (2) Contract number, including task and delivery order number; (3) Beginning and ending dates covered by reporting period; (4) Contractor name, address, phone number, e-mail address, identity of Contractor employee entering data; (5) Estimated direct labor hours (including sub-contractors); (6) Estimated direct labor dollars paid this reporting period (including sub-contractors); (7) Total payments (including sub-contractors); (8) Predominant Federal Service Code (FSC) reflecting services provided by Contractor (and separate predominant FSC for each sub-contractor if different); (9) Estimated data collection cost; (10) Organizational title associated with the Unit Identification Code (UIC) for the Army Requiring Activity (the Army Requiring Activity is responsible for providing the Contractor with its UIC for the purposes of reporting this information); (11) Locations where Contractor and sub-contractors perform the work (specified by zip code in the United States and nearest city, country, when in an overseas location, using standardized nomenclature provided on website); (12) Presence of deployment or contingency contract language; and (13) Number of Contractor and sub-contractor employees deployed in theater this reporting period (by country). As part of its submission, the Contractor will also provide the estimated total cost (if any) incurred to comply with this reporting requirement. Reporting period will be the period of performance not to exceed 12 months ending 30 September of each Government fiscal year and must be reported by 31 October of each calendar year. The Contractors may use a direct XML data transfer to the database server or fill in the fields on the website. The XML direct transfer is a format for transferring files from a Contractor’s systems to the secure web site without the need for separate data entries for each required data element at the website. The specific formats for the XML direct transfer may be downloaded from the website.

1.8. GENERAL INFORMATION.

1.8.1. Contractor Qualifications. The Contractor must have a certification of Specification Construction Industry Permission （特定建設業許可）of Incinerator Plant Engineering Work (清掃施設工事業) and Plumbing Engineering Work (管工事業) issued by the Governor of metropolis or prefectures (都道府県知事), or Ministry of Land, Infrastructure, Transport and Tourism (国土交通省).

1.8.2. Contract Manager. The Contractor shall provide a contract manager who shall be responsible for the work. The name of this person, and an alternate(s) who shall act for the Contractor when the manager is absent, shall be designated in writing to the KO.

1.8.2.1. The contract manager or alternate shall have full authority to act for the Contractor on all matters relating to this contract.

1.8.2.2. The contract manager or alternate shall be available during normal duty hours, and be available within 3 hours during non-duty hours to meet on the installation with QAP to discuss emergencies. The contract manager shall provide an emergency contact number for other than normal duty hours.

1.8.2.3. The contract manager or alternate shall be proficient in English and have a good understanding of the requirements pertaining to this contract for interpretation and implementation of directives, written and oral, issued in English by the KO or QAP. If the contract manager or alternate do not meet this requirement, the Contractor shall provide a translator for them.

1.8.2.4. The contract manager or the job site supervisor of the Contractor shall be a certified Supervising Engineer （監理技術者）as required by paragraph 26-2 of The Construction Law （建設業法第２６条２項）.

1.8.3. Contractor Employees. The Contractor is required to provide employees who have experience in incinerator plant brick repair work and possess the following listed certificates/licenses in accordance with Japanese laws, jurisdictional regulations, and the manufacture’s maintenance manuals. The Contractor shall submit a list with the employee’s name and license/certificate title, and documentation of license/certificate with the date obtained and validated. The required licenses/certificates shall be current and updated when changes occur. The Contactor shall submit all required certificates/licenses to the QAP prior to the performance start date.

1. Chief Electric Engineer, Class 3 (第３種電気主任技術者)

2. Hazardous Material Handler, Otsu Group 4 (危険物取扱者 乙種4種)

3. Individual being trained exclusively for Operation, Inspection, and Demolition Works at Refuse

Incinerator Plant IAW para 34 thru 36 of Article 36 of Ordinance of Labor Safety and Hygiene (労働安全衛生規則第36条第34～36号の規定に基づき廃棄物焼却施設内における運転、点検等作業及び解体作業に関する特別教育修了者).

4. Supervisor of Anoxic Area Work (酸素欠乏危険作業主任者)

5. Crane Inspector (クレーン検査官)

6. Forklift Operator or Small-sized Special Motor Vehicle Operator such as Payloader**

(フォークリフト運転手或いはペイローダー等小型特殊免許取得者)

7. A Certified Measurer（計量士） **Note: Licensed Forklift Operator or Small-Sized Special Motor Vehicle Operator, such as payloader, is required to be at the worksite only when the operation of such equipment is necessary during the course of performing these services.

1.8.3.1. Removal of Contractor’s Employees. The Contractor shall utilize only experienced, responsible and capable employees in the performance of this contract. The KO may require that the Contractor remove from the Government job any of his/her employees who endanger persons or property, or whose continued employment under this contract is inconsistent with the interests of military security.

1.8.3.2. Third Country Nationals (TCN). The Security Forces on each base control entry to the base. Under certain circumstances, the TCN might be denied entry. It is the Contractor’s responsibility to coordinate with Security Forces at each base when there is a question about particular circumstances.

1.8.3.3. U.S. Government or Master Labor Contract Employees. The Contractor shall not hire employees of the U.S. Government and/or Master Labor Contract employees in violation of the Procurement Integrity Act (see FAR Section 3.104). Further, the Contractor shall not employ any Department of Defense employee, either military or civilian, unless such person seeks and receives approval in accordance with Department of Defense 5500.7-R, Joint Ethics Regulation.

1.8.3.4. Military Personnel. Contractor is cautioned that off-duty active duty military personnel hired under this contract may be subject to permanent change of station (PCS), change in duty hours, or deployment. Military Reservists and National Guard members may be subject to recall to active duty. Abrupt absence of these personnel could adversely affect the Contractor’s ability to perform, however, their absence at any time shall not constitute an excuse for non-performance under this contract.

1.8.3.5. Roster. The Contractor shall provide a complete roster of all personnel (including contract manager and alternate contract manager) to the QAP prior to the start of performance. The roster must include employee’s name, address, telephone number and certificate/license, and documentation of the certificate/license with the date obtained and validated. The Contractor shall maintain a current listing of employees, providing updates as changes occur.

1.8.4. Quality Control. The Contractor shall develop and maintain a quality control program for management, operation and maintenance of the refuse incinerator plant in accordance with commonly accepted commercial practices. The Contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective services. At a minimum, the Contractor shall develop quality control procedures addressing the areas identified in paragraph 2, Service Summary.

1.8.5. Quality Assurance. The Government will evaluate the Contractor’s performance in accordance with the Performance Plan (PP) by appointing QAP to monitor performance to ensure services are received.”

1.8.6. Government Remedies. The KO shall follow FAR 52.212-4, Contract Terms and Conditions-Commercial Items, for the Contractor’s failure to perform satisfactory services or failure to correct non-conforming services.

1.8.7. Mobilization and Phase-In Period. In the event other than the incumbent Contractor is the successful offeror, a period of 30 calendar days is deemed sufficient for the new Contractor to mobilize, phase-in and complete preparations prior to the start of contract performance on the date specified in the contract. All offerors are cautioned to be fully aware of the above and consider the stated phase-in time in their planning and the pricing of their proposals. Mobilization and phase-in costs are not reimbursable under this contract.

1.8.8. AVAILABILITY OF FACILITY.

1.8.8.1. Hours of Service. The Contractor’s personnel will perform scheduled work on weekdays, Monday through Friday (exclusive of the U.S. Federal and other designated holidays listed below), during normal duty hours, 0800 - 1600 hours, unless prior arrangements have been made with the QAP.

1.8.8.2. Legal American Holidays and Other Designated Holidays.

American Holidays

1 January New Year’s Day

3rd Monday in January Martin Luther King Jr.’s Birthday

3rd Monday in February President’s Day

Last Monday in May Memorial Day

4th of July* Independence Day

1st Monday in September Labor Day

2nd Monday in October Columbus Day

11 November* Veterans Day

4th Thursday in November Thanksgiving Day

25 December* Christmas Day

Other Designated Holidays

2 & 3 January New Year’s Days

29, 30 & 31 December Year End Days

*Holidays falling on a Saturday will be observed on the preceding Friday, Holidays falling on a Sunday will be observed on the following Monday.

1.8.9. SECURITY SAFETY REQUIREMENTS.

1.8.9.1. Installation Base Passes. The U.S. Government will issue all required Installation/Base Passes and Controlled Area Badges to contractor personnel at no cost to the contractor. Vehicle insurance certificate are required to obtain Base Passes and must cover the automobile liability insurance in the types and minimum amounts of (a) Bodily Injury - ¥30,000,000 per person per occurrence, in addition to the Japanese Compulsory Insurance (JCI), and (b) Property Damage - ¥3,000,000 per occurrence. The prime Contractor shall be responsible for all passes issued to his/her own or subcontractor’s employees under this contract. The Contractor shall return all applicable passes upon termination of employment or completion of this contract to the Japanese Pass Section, and a certificate of receipt shall be obtained.

NOTE: Contractor personnel are required to comply with U.S. Army Regulation 190-5 http://www.apd.army.mil/USAPA PUB pubrange P.asp for personnel pass requirements. Contractors are also required to comply with U.S. Army Garrison Japan Regulation 190-13 http://intranet.zama.army.mil/CmdStaff/usagj/cmdgrp/doc/reg190-13.pdf for vehicle pass requirements. These regulations are available for the selected Contractor’s review upon personnel and/or vehicle pass issuance.

1.8.9.2. Security Requirements. Contractor shall ensure each employee obtains required pass and identification items for access to Camp Zama. These items are issued by the Security Forces Pass and Registration Section, located in Building 235. Contractor and employees shall return identification cards to Security Forces within 24 hours of termination or completion of this contract. All other Government identification for terminated employees shall be returned to the KO within 24 hours of termination.

1.8.9.3. Reports of Damages, Destruction, Injury, or Death

(a) The Contractor shall report all incidents of damage or destruction to property, or personal injury or death to any person, arising out of and during the performance of this contract. For the purposes of this clause, the term “property” includes equipment, freight, or property of any type, whether Government owned or not. The term “Contractor” includes the Contractor, its agents, servants or employees.

(b) The Contractor shall submit these reports to the KO through the QAP as follows:

(1) A preliminary report shall be made as soon as practicable after the time the incident occurs. Report may be either verbal or facsimile.

(2) A complete written report shall be submitted within 96 hours after occurrence of the incident. A copy of this report shall be furnished to the QAP.

1.8.9.4. Security Danger Warning, Accident Prevention, Fire Prevention and Fire Protection Requirements. The Contractor shall comply with all pertinent requirements of the U.S. Army and USAG-J Fire Protection and Safety Regulations or Japanese Law, whichever is more stringent, to insure compliance by all subcontractors.

1.8.9.5. The Contractor shall not commence work at the job site until an Accident Prevention Plan and a Job Hazard Analysis are submitted for review and approved by the KO. The Contractor is responsible for reviewing section 1 of EM 385-1-1, the US Army Corps of Engineers’ Safety and Health Requirements Manual, which will be provided at time of contract award.

1.8.9.6. The Contractor shall provide warning signs and barricades around the job site while the equipment and/or systems are being serviced. The Contractor shall control all personnel desiring access into job site areas when work is in progress.

1.8.9.7. Hazardous Materials. All hazardous materials must be contained and stored in the appropriate storage containers and/or cabinets. The Contractor shall immediately report spills or releases of hazardous materials to the KO and QAP. The Contractor shall be liable for containment and environmental clean-up of spill or release of such substance. The Contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. The Contractor shall comply with environmental and hazardous materials storage and handling requirements and maintain current Material Safety Data Sheets (MSDS).

1.8.9.8. Environmental and Hazardous Material Handling. The Contractor shall comply with municipal environmental laws to protect the health and safety of employees/residents and minimize or eliminate environmental pollution.

1.8.9.9. Confined Space Entry. The inside of UST is assigned as the confined space. The Contractor shall comply with section34 of EM 385-1-1, the US Army Corps of Engineers’ Safety and Health Requirements Manual, (http://140.194.76.129/publications/eng-manuals/em385-1-1/2008_English/toc.html). The Contractor shall provide equipment (and equipment maintenance procedures) to be used for confined space entry. Equipment shall include the following at a minimum:

(1) Atmospheric testing and monitoring equipment to assure safe entry;

(2) Ventilation equipment to assure maintenance of safe entry conditions;

(3) Communication equipment for entry;

(4) Personal Protective Equipment (PPE) necessary in the event that engineering controls and work practices do not adequately protect entrants;

(5) Lighting equipment for entry;

(6) Barriers and shields to keep unauthorized entrants out of the confined spaces during entry;

(7) Ladders or other equipment necessary for entrant access and egress;

(8) Rescue and emergency equipment needed to remove entrants in the event of an emergency;

(9) Any other equipment necessary for safe entry into or rescue from confined spaces;

1.8.10. Cleanliness. The Contractor is responsible for cleanliness of the service areas in the plant, immediately adjacent to the plants, toilet, shop and office spaces used. This includes, but is not limited to, washing, sweeping, dusting and other janitorial services necessary to maintain the area in a clean and sanitary condition. The Contractor shall furnish such supplies as required.

1.8.11. Disposal of Materials. All debris and unserviceable materials generated under this contract such as industrial waste, non-recyclable materials and equipment/material not listed on hand-receipts shall be disposed off-base by the Contractor in accordance with the laws of Japan. Hand receipt items require turn-in action by the Contractor when the listed items have to be replaced.

1.8.12. Warranty. The Contractor shall provide the Government with their commercial warranty. The Government shall receive the same warranty service as the Contractor’s most favored customers. If the services fail to be performed or otherwise fail due to workmanship or materials, the Contractor shall correct the affected area(s) at no additional cost to the U.S. Government.

1.8.13. Responsibility for Damages. Any damages caused to U.S. Government property during the course of performing this contract shall be restored, replaced and/or repaired to its original condition at no additional cost to the U.S. Government.

1.8.14. Conservation of Utilities. The Contractor shall instruct employees in utility conservation practices. The Contractor shall be responsible for operating under conditions, which preclude the waste of utilities. The Contractor shall comply with additional energy policies upon notification by the KO.

SECTION 2

2. SERVICES SUMMARY.

SECTION 3

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES.

3.1. GOVERNMENT FURNISHED FACILITIES, EQUIPMENT AND MATERIALS.

3.1.1. Government Furnished Facilities.

3.1.1.1. Toilet, Shop, and Office Spaces. For the performance of routine maintenance, inspection, and service work under this contract, the Government will furnish existing toilet, shop and office spaces in the refuse incinerator plant, Bldg No. 1024-1, Camp Zama for joint use. For the performance of overhaul and unscheduled work, the Contractor shall provide and maintain a temporary field office and lavatories at an approved space of the job site prior to beginning overhaul or unscheduled work. The Contractor shall coordinate with the QAP and submit in writing for the Government’s approval, the location and size of field office, and request utility connections prior to performance.

3.1.2. Government Furnished Materials (GFM).

3.1.2.1. Materials. The Government will reimburse all required materials to be accomplished paragraph 1.1 and 1.2 in accordance with paragraph 1.6.

3.1.3. Government Furnished Tools and Equipment. None

3.2. OTHER GOVERNMENT-FURNISHED ITEMS.

3.2.1. Utilities. The Government shall furnish available water and electricity, without cost to the Contractor. All temporary installations and connections made by the Contractor shall comply with Army Regulations (AR) 420-1 and applicable building codes, and shall be subject to periodic inspection by the QAP.

3.2.2. Maintenance Manuals, and As-Built Drawings. The manufacturer’s maintenance manual, instructions and as-built drawings are available to the Contractor for review at the incinerator plant. Any other information and/or technologies of this refuse incinerator plant (constructed by HITACHI ZOSEN Co., Ltd.) shall be obtained from the manufacturer by the Contractor.

3.2.3. Security Forces and Fire Protection. Upon request for assistance, the following units will provide services on installations as necessary:

Emergency Telephone for Fire, Ambulance, and the Military Police:

Telephone 911 When the Contractor uses the above services, the contract manager shall immediately report the details to the QAP. The detailed reporting requirements are specified paragraph 1.8.10.3 above.

3.2.4. Emergency Medical. In the event of a medical emergency, accident, or injury involving Contractor personnel during performance of duties under this contract, services will be rendered in order to save life, limb or to stabilize for transportation to a local medical treatment facility. The Contractor shall reimburse the Government for the emergency medical services at the prescribed rate. The Contractor shall submit the report in accordance with paragraph 1.8.10.3 above.

SECTION 4

4. APPENDICES.

1. Estimated Workload Data.

2. Minimum Required Maintenance Items for Annual Overhaul Work

3. Equipment List for Refuse Incinerator Plant Appendix 1. Estimated Workload Data.

Man Hour

Unscheduled Work

Exceeding ¥500,000

Minor repair/replacement workload estimate within the routine maintenance work identified at paragraph 1.1 of the PWS (labor cost not exceeding ¥500,000/task). This information is based on historical data.

for Repair Approximately

Cost for Task

Replace parts for atomizer compressor

Replace Air-pre-heater dust conveyor

Replace parts for bag filter compressor

Replace lime and reagent compressor

Replace parts for of injection blower

Replace parts of HCL analyzer

Replace parts for Nox analyzer

Historical data for Unscheduled Work

Appendix 2. Minimum Required Maintenance Items for Annual Overhaul Work.

4.2.1. Inspect and overhaul (as required) the refuse crane (including the replacement of wire ropes).

4.2.2. Calibrate and overhaul the truck scale and weight recorder.

4.2.3. Measure thickness of the water jacket’s steel plates on the refuse hoppers and repair if necessary. Overhaul (as required) hydraulic cylinders of refuse hopper gates.

4.2.4. Repair heat resistant refractory mortar on refuse feeders. Adjust and overhaul (as required) hydraulic cylinders of refuse feeding systems.

4.2.5. Replace adjustable bolts for fire grates. Measure and adjust clearance of fire grates and side plates in furnaces. Adjust and overhaul (as required) hydraulic cylinders of movable grate systems.

4.2.6. Overhaul (as required) and repair after burning systems in furnaces. Replace and/or repair heat resistant refractory mortar, fire bricks and fire grates. Adjust and overhaul (as required) hydraulic cylinders of after burning systems.

4.2.7. Overhaul (as required) the hydraulic oil pressure generating power unit and replace hydraulic oil in it. Check and repair hydraulic oil distribution pipes and hoses.

4.2.8. Repair heat resistant refractory mortar and firebrick walls and ceiling in the furnaces, gas cooling chambers, gas cooling towers and bag filter chambers by replacement. Required replacement of heat resistant refractory mortar and firebricks in the furnace areas are listed in 4.2.6 above. Required replacement of heat resistant refractory mortar in the gas cooling chamber and tower areas are approximately 50m². These replacement areas shall be adjusted by the result of the inspection performed every May.

4.2.9. Replace all gaskets of manholes on ash shooting ducts from the furnace to the under stoker ash conveyor. Repair rusted shooting ducts if necessary.

4.2.10. Overhaul (as required) and repair catch up burners and secondary burning burners. Overhaul (as required) fuel oil transfer pumps and inspect/repair distribution pipes from the fuel oil storage tank to burners.

4.2.11. Check and replace the water spray nozzles for gas cooling systems on gas cooling chambers.

4.2.12. Replace all gaskets on the gas cooling chambers.

4.2.13. Check the steel casings, structures and heat insulations with metal covers and repair it if necessary.

4.2.14. Overhaul (as required), adjust and repair the rotary scraping system and rotary valves for the collection of fly ash located at the bottom of gas cooling chambers.

4.2.15. Overhaul boost up water pumps for the water spray on gas cooling chambers.

4.2.16. Check water distribution pipes for water spray and repair them if necessary.

4.2.17. Check and adjust the coil of air pre-heaters and repair if necessary. Replace all gaskets of manholes on air pre-heaters. Check the steel casings, structures and heat insulations with metal covers and repair if necessary.

4.2.18. Check and replace the water spray nozzles for gas cooling systems on gas cooling towers.

4.2.19. Replace all gaskets on the gas cooling towers.

4.2.20. Check the steel casings, structures and heat insulations with metal covers and repair it if necessary.

4.2.21. Overhaul (as required), adjust and repair the fly ash scraping system and rotary valves located at the bottom of gas cooling towers.

4.2.22. Check and replace electric heaters on the gas cooling towers.

4.2.23. Overhaul (as required) and repair 3 each air compressors and associated systems for gas cooling towers.

4.2.24. Overhaul (as required) boost up water pumps for the water spray on gas cooling towers.

4.2.25. Adjust the tension of bag filters. Replace bag filters if it has un-repairable damages or is beyond its usable period.

5.2.26. Replace all gaskets on the bag filter casings.

4.2.27. Overhaul (as required), adjust and repair the fly ash scraping system and rotary valves located at the bottom of the bag filtering chambers.

4.2.28. Check and replace electric heaters on the bag filtering chambers.

4.2.29. Overhaul (as required) and repair 2 each air compressors and associated systems for bag filter systems.

4.2.30. Overhaul (as required) slaked lime storage and constant volume feeding systems (storage silo, valve, blower pomp, feeding hose, etc.).

4.2.31. Overhaul (as required) activated carbon storage and constant volume feeding systems (storage silo, valve, blower pomp, feeding hose, etc.).

4.2.32. Overhaul (as required) urea storage and injection systems (tanks, pumps, concentration control system, etc.).

4.2.33. Overhaul (as required), measure and adjust vibration and balance of forced draft fans. Repair or Replace them if necessary.

4.2.34. Check smoke gas ducts and air ducts and repair them if necessary.

4.2.35. Overhaul (as required), measure and adjust vibration and balance of induced draft fans. Repair or replace them if necessary.

4.2.36. Measure thickness of the steel plates for ash conveyor casings (Under stoker ash conveyor No.1 & 2, Main ash conveyor No.1 & 2) and repair them if necessary.

4.2.37. Adjust tension of conveyor chains and overhaul (as required) driving units of conveyors.

4.2.38. Make repair of ash bunkers. Overhaul (as required) auxiliary equipments of ash bunker such as hydraulic oil cylinders and knock out vibrators.

4.2.39. Check steel casings and heat insulation with metal covering of fly ash transferring conveyors.

4.2.40. Adjust tension of fly ash conveyor belt and overhaul (as required) driving units of fly ash conveyors. Repair or replace them if necessary.

4.2.41. Measure electric resistance of the purge air heater for fly ash conveyors and replace it if necessary. Calibrate the temperature controller of the purge air and overhaul (as required) the purge air supply systems.

4.2.42. Overhaul (as required) the fly ash stabilization systems (chelate injection system, fly ash constant feeding system, mixes and kneads machine, controller, etc.). Repair or replace them if necessary.

4.2.43. Check and clean the elevated water tank and repair it if necessary. Overhaul (as required) boost up pumps for the elevated water tank.

4.2.44. Overhaul (as required) the cooling tower and boost up pumps for equipment cooling.

4.2.45. Overhaul (as required) the refuse drainage water transfer pump and clean up the receiving tank of the drainage water.

4.2.46. Overhaul (as required) the refuse drainage water spray systems (spray pumps, nozzles, piping, etc.)

4.2.47. Check, clean-up and repair various waste water receiving tanks (ash drainage water receiving tanks, domestic waste water receiving tank, treated refuse drainage water receiving tank, fly ash stabilizer drainage water receiving tank). Overhaul (as required) submergible transfer pumps in them. Check the water surface level control systems for them and repair them if necessary. Repair or replace them if necessary.

4.2.48. Check and calibrate all electrical instruments in the plant such as central controllers, monitors, cameras, analyzers, inverters, etc. Repair or replace them if necessary.

Appendix 3. EQUIPMENT LIST FOR REFUSE INCINERATOR PLANT:

BLDG No. 1024-1,CAMP ZAMA

Manufacturer: Hitachi Zosen Co., Ltd.

I. Refuse Receiving and Feeding System.

1. Refuse weighing scale.

a. Type:

Load cell with scale beam.

b. Quantity:

1 each

c. Capacity:

Maximum, 20 ton, minimum scale 20 Kg.

d. Size:

2.7 m (W) x 6.5 m (L)

e. Indication:

Digital.

f. Measuring method:

Card insertion, push button stamping and folding paper.

2. Refuse crane.

Glove bucket, electric traveling crane.

1 each.

c. Load:

Hoisting load: 2.3 ton, standard 0.6 ton.

d. Electric motor:

Trucking:

1.5 KW

Traveling:

0.75 KW x 2 ea

Hoisting:

7.5 KW

Bucketing:

7.5 KW

e. Electric supply:

Flexible cable, curtain hanger.

f. Operation:

Remote control from central control room.

3. Bulk combustion refuse shearing crusher.

Hydraulic oil shearing shredder.

1 ton/hr (shearing force: Max. 80 ton).

d. Bed size:

1.1 m (W) x 2.5 m (L) x 0.7 m (D)

4. Crusher driving unit.

Hydraulic oil pump self-contained.

c. Component:

Hydraulic oil pump, Oil reservoir, Relief valve, Strainer, Check valve self-contained.

22 KW

II.

Combustion System.

1. Refuse hopper.

Steel plate welded slope (with cooling water jacket).

2 each.

Approx. 8 M³ (usable 4.6 M³).

Opening, 2.8 m x 3.45 m

e. Hopper gate:

Hydraulic Oil Cylinder Driving (350mm stroke)

2. Refuse feeder.

Hydraulic oil pusher.

c. Size:

1.44 m (W) x 1.12 m (L).

d. Driving method:

Hydraulic oil with combination use of grate driving.

e. Speed control:

Central remote control. (8 – 12 m/h)

f. Stroke:

250 mm (Max 400 mm)

3. Combustion equipment.

3-1. Grate.

Burning grate: Vibrating and step down grate.

After burning device:

Damper grate.

Burning grate:

1.44 m (W) x 3.6 m (L)

After burning:

1.44 m (W) x 0.9 m (L)

d. Grate burning rate:

151.3 Kg/m²/hr

e. Driving method:

Hydraulic oil

f. Speed control:

Central remote control.

3-2. Grate driving unit.

3-2-1. Hydraulic oil machine.

Hydraulic oil pump self-contained.

Hydraulic oil pump, Oil reservoir, Relief valve, Strainer and Check valve self – contained.

3-2-2. Driving device.

Hydraulic oil.

Constructed by cylinder and connecting rod.

4. Furnace.

4-1. Furnace frame and casing.

Self – standing, Steel frame and plate covering.

c. Combustion chamber:

21.7 m³

d. Heating value:

125,500 Kcal/m²/hr

4-2. Under grate hopper and manhole.

Steel plate welded pyramid.

c. Main material:

Rolled steel for general structure.

4-3. Ash hauling duct.

Heat resistant steel plate welded rectangular

(with cooling water jacket).

c. Main material:

4-4. Bricking.

Flat ceiling.

c. Material:

Location 1st layer 2nd layer 3rd layer

Furnace wall

SK34

B-1

Insulation board

Furnace ceiling #34 Caster

#10 Caster

Grate wall

After burning wall

Grate down-step

B-1

5. Auxiliary burning system.

5-1. Oil burner (For Start Up Burning)

Rotary oil burner.

56 lit/hr.

d. Fuel:

Diesel.

e. Operation:

Start: Manual switch and automatic ignition.

Oil adjustment:

Manual.

Ignition:

Propane gas.

5-2. Oil burner (For Secondary Burning)

Gun type oil burner.

60 lit/hr.

d. Fuel:

Diesel.

e. Operation:

Start: Manual switch and automatic ignition.

Oil adjustment:

Ignition:

Propane gas.

5-3. Oil tank.

a. Type:

Steel plate welded vertical – round.

b. Quantity:

1 each.

c. Capacity:

490 lit.

5-4. Oil pump.

Gear pump.

c. Delivery capacity:

300 lit/hr, Total head: 20m, Outlet: 12mm

0.2 KW

III. Flue Gas Cooling System.

1. Flue gas cooling chamber.

Self – standing steel frame and plate covering round.

17.5 m³

d. Evaporative heating load: 414 MJ/m³·h (max) say 99,000 kcal/m³·h

e. Treated gas volume:

7,800 Nm³/hr (max)

f. Inlet gas temperature:

880 – 950 degree C

g. Outlet gas temperature

(at outlet of air-preheater) under 200 degree C

h. Interior material:

Location 1st layer 2nd layer 3rd layer Upper: WPC100 castable (150mm) Super Board (50mm) Super Board (75mm)

Lower: WPC100 castable (100mm) Insulation Board (75mm)

2. Dust removal system.

Rotary type.

c. r.p.m.:

0.87 r.p.m.

d. Driven motor:

0.4 kw x 400 v x 50 Hz

e. Cyclo drive gear:

CWVM05-4175DA-2065

3. Spray nozzle.

Spray amount controllable type.

12 each. (6 each of nozzle per chamber).

c. Spray water capacity:

0.8 – 8.0 liter/min

d. Spray pressure:

2 MPa

e. Sprayed water form degree:

60°, 110° - 120°

4. Spray water pressurized pump.

Multi-stage turbine pump.

3 each (include one stand-by).

4.2 m³/hr, Total head: 2.16MPa(220m), Outlet: 40mm

d. Driven Motor:

200 V x 2 P x 11 kw

IV

Flue Gas Treatment System.

1. Bag filtration type dust…