Attachment_1_-_PWS_18116_Replace_DFAC_Boilers.pdf

PERFORMANCE WORK STATEMENT

(PWS)

FOR

REPLACE BOILERS AT IN DFAC

WO#18116

BUILDING 115

CIVIL ENGINEERING 496 ABS/CEORM

(21 March 2018)

PERFORMANCE WORK STATEMENT (PWS)

TABLE OF CONTENTS

SECTION PAGE

1. DESCRIPTION OF SERVICES 5

2. SERVICES SUMMARY 6

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES 6

4. GENERAL INFORMATION 6/8

5. APPENDICES 9-19

DESCRIPTION OF SERVICES. The contractor shall provide all management, tools, supplies, equipment and labor needed to replace existing Omnivap 2.0, manufactured by Vulcano Sadeca, N1 and N2 boilers at the mechanical room of Building 115, Dining Facility.

1.1. Description of Work.

The work will consist of:

- Replace existing two boilers and auxiliary devices in accordance with appendix A.

- All the auxiliary devices of the boilers will be replaced in accordance with technical specification, except those that are specifically indicated below:

Optical levels of existing boilers will remain.

DN25/40 safety valves will remain.

- Replace existing water softener by a twin configuration electronic unit made with 2 resin bottles 125 each. Including:

9000 SXT Automatic control.

2 resin bottles made of polyester/fiber, interior in P.E. food grade with a volume 188 liters.

250 liters cationic exchange resin, food grade.

Brine tank equipped with suction system.

Connection between bottles and internal elements.

- In addition to the aforementioned Regulations, the fulfillment of this contract must comply with the requirements of the Air Force Instruction (AFI) 32-10168 Heating Systems and Unfired Pressure Vessels (1 Oct 1998).

Submit boilers final documents (certificates), including As-built, plans, specific documentation referring to spare parts lists and maintenance and operation manuals for each element of the installation.

1.2. Special Requirements.

All boiler work must be performed by personnel homologated and/or approved to perform this type of work by the manufacturer of the boilers. Before carrying out any activity, the contractor shall submit the documents proving these circumstances. The contractor shall not be authorized to perform any work until such documents are approved by the Contracting Officer.

1.3. Final Cleaning.

Final cleaning of installations affected by this contract.

1.4. Period of Performance.

The period of performance for this contract is one hundred and twenty (120) days of field work. The contractor will provide its deadline with its proposal. The replacement of the boilers will be carried out sequentially, to minimize the impact on the operation of the buildings supplied by the boilers. No work will be started in boiler N.2 until boiler N.1 is finished, tested, and certified.

The items mentioned and the list of main tasks do not limit in any way the responsibility of the contractor to perform all work required by the contract to provide a complete and operational installation.

2. SERVICES SUMMARY.

Performance Objective SOW Performance Threshold Activities. Par 1.1 100%

3. GOVERNMENT FURNISHED PROPERTY AND SERVICES.

3.1. Use of Base Utilities: Base utilities are available to the Contactor at no additional expense to the Contractor. The following utilities shall be available from the existing Base utility connections in reasonable quantities:

a. Electricity 120/208 volts, 60 Hz.

b. Water.

All of the equipment, materials and labor required to accomplish the aforementioned items stipulated shall be supplied by the Contractor, as part of this contract.

4. GENERAL INFORMATION.

4.1. Security Requirements. The contractor will request installation access through 496

ABS/CE.

4.2. Physical Security. The contractor shall be responsible for safeguarding all government property provided for contractor use. At the close of each work period, government facilities, property, and materials shall be secured.

4.3. Hours of Operation.

4.3.1. Normal Hours of Operation. The contractor shall perform the services required under this contract during the following hours: Monday to Friday, 08:00-17:00. The contractor may work, with prior approval of the Contracting Officer, extended hours to ensure timely completion of work at no additional cost to the Government.

4.3.2. Recognized Holidays. The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving Day and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

4.4. Conservation of Utilities. The contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions which prevent the waste of utilities which include the following:

4.4.1. Lights shall be used only in areas where and when work is actually being performed.

4.4.2. Mechanical equipment controls for heating, ventilation, and air conditioning systems shall not be adjusted by the contractor or by contractor employees unless authorized.

4.4.3. Water faucets or valves shall be turned off after the required use has been accomplished.

4.4.4. Government telephones shall be used only for official government business.

4.5. Records. The contractor shall be responsible for creating, maintaining, and disposing of only those government required records that are specifically cited in this PWS.

4.6. Environmental Controls:

4.6.1. Compliance with Laws and Regulations. The contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the Contracting Officer pursuant to notice requirements and negotiate a modification to the contract.

4.6.2. Notification of Environmental Spills. If the contractor spills or releases any substance contained in 40 CFR 302 into the environment, the contractor or its agent shall immediately report the incident to Moron AB Fire Dept at 117. The liability for the spill or release of such substances rests solely with the contractor and its agent.

4.6.3. Material Storage and Use. The contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes hazardous materials.

4.7. Government Observations. Government personnel, other than contracting officers (COs) and quality assurance personnel (QAPs), may from time-to-time, with CO coordination, observe contractor operations. However, these personnel may not interfere with contractor performance or make any changes to the contract.

4.8. Safety Requirements. In performing work under this contract, the contractor shall:

4.8.1. Conform to the safety requirements contained in the contract for all activities related to the accomplishment of the work.

4.8.2. Take such additional immediate precautions as the contracting officer may reasonably require for safety and mishap prevention purposes.

4.8.3. Develop and provide at the start of the orientation period or the start of the first operational performance period (if there is no orientation period) a safety plan for the protection of government facilities and property and to provide a safe work environment for contractor personnel.

4.8.4. Provide protection to government property to prevent damage during the period of time the property is under the control or in possession of the contractor.

4.8.5. Include a clause in all subcontracts to require subcontractors to comply with the safety provisions of this contract as applicable.

4.8.6. Record and report promptly (within one hour) to the contracting officer or designated government representative (GR), all available facts relating to each instance of damage to government property or injury to either contractor or government personnel.

4.8.7. In the event of an accident/mishap, 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 contracting officer.

4.8.8. 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.

4.8.9. Include a clause in each applicable subcontract requiring the subcontractor's cooperation and assistance in accident reporting and investigation.

4.9. Special Qualifications. The Contractor shall submit any commercial certifications and a reference of past performance on similar works performance to the existing as a means to verify experience in this field of work.

4.10. Continuation of Essential DOD Contractor Services During Crisis IAW DoDI 3020.37.

IAW AFI 63-124, para 2.7.1, and DODI 3020.37 this requirement is not considered mission essential.

4.11. Contract Restriction: In accordance with the Agreement of Defense and Cooperation between the Kingdom of Spain and the United States of America, any contract resulting from this notice/solicitation can only be entered into with companies authorized to carry out these activities in Spain under Spanish law. Companies must meet the requirements established by Spanish legislation for execution of Government works. In addition, in accordance with the Office of Defense Cooperation Policy Directive 400- 5 "(4) Spanish material, labor, and equipment must be used if permitted by the requirements of the contract specifications."

APPENDIX A

THECNICAL

SPECIFICATION

STEAM BOILER

OMNIVAP

TYPE 2.0

INDEX

1. GENERAL DESCRIPTION

1.1 Design and performance.

1.2 Materials.

1.3 Quality records.

2. TECHNICAL DATA

3. ESPECIFICATION

3.1 Pressure body.

3.2 Gas boxes, frame and exterior finish.

3.3 Valves and accessories.

3.4 Combustion equipment.

3.5 Water supply equipment.

3.6 Control equipment and level regulation.

3.7 Pressure control and regulation equipment.

3.8 Electrical control devices.

3.9 Electrical installation.

3.10 Interconnection pipes.

4. ASSEMBLY AND INSTALLATION

5. LIMITS OF SUPPLY

6. EQUIPMENTS BRAND NAMES

7. COMMISIONING

8. DIMENSIONS

1. GENERAL DESCRIPTION

Piro-tubular boiler "OMNIVAP" with internal pressurized furnace, totally heat-insulated, guaranteeing a perfect thermal insulation, mounted on skids, built with laminated profiles and covered with fluted sheet, which allows the assembly on it all control, regulation and control devices and that causes, due to its support surface, a reduction in the pressures transmission to floors and slabs.

The boiler, unless otherwise indicated, is delivered forming a mono block assembly, which facilitates its installation, requiring only electrical connections to electrical panelboard terminals, supply of liquid fuels to the burner, connection to the funnel and the purges connections to the networks of evacuation. The constructive characteristics, manufacturing controls, performances, etc., are following described.

The OMNIVAP boiler, object of this technical specification, is in accordance with the current regulations for pressure vessels and the ITC MIE-AP1.

The boiler shall be approved by the Ministry of Industry and homologation code and date shall be submitted by the manufacturer prior to installation.

1.1. DESIGN AND PERFORMANCE

The design and construction of the boiler will be carried out in accordance with the TRD CODE, standard UNE 9.300, Regulation of Pressure Appliances and ITC-MIE-AP1.

Regardless of the regulatory inspections of the Ministry of Industry, the Collaborating Organization of the Administration and/or other inspection entities, the construction is supervised in all its different phases by manufacturer Quality Assurance Department, carrying out the ultrasonic inspection of the welds, distension heat treatment in the elements that require it, as well as partial and total hydraulic tests.

1.2. MATERIALS

As is mandatory in the boilers construction, the materials used in the construction of the generator respond to the special quality required for high temperature work. The quality of the materials will be supported in any case by factory certificates reflecting mechanical characteristics and chemical composition and subject to reception controls by the manufacturer Quality Assurance Department.

Quality of materials:

Metal sheets: DIN-H-11, DIN-17155 or equivalent.

Tubes: St 35.8.1, DIN-17175 or equivalent.

1.3. QUALITY RECORDS

Once the manufacturing has been completed, the manufacturer Quality Department will prepare the appropriate quality file, including the following documentation:

Certificates of materials quality.

Welding processes used approval.

Qualification of the welders involved in manufacturing.

Tests result, controls and inspections

2. TECHNICAL DATA

Boiler model OMNIVAP-2.0 Steam class Saturated Steam production 2000 Kg/h Stamped pressure 4 Kg/cm² Normal working pressure 3.5 Kg/cm² Test pressure 6 Kg/cm² Max. Temperature of steam design 151 °C Feeding water temperature 60 °C Exterior air temperature 20 °C Smoke circuits overpressure 75 mm c.a.

Fuel consumption: diesel 132 Kg/h Performance 89 ± 1 % Heating surface 36.29 m²

Water volume (content) 2.28 m³ Total volume (including steam chamber) 2.77 m³

Category according to regulation C Electric voltage 208/3/60 Hz Transport weight, approximately 3.90 Tm Operation weight, approximately 6.67 Tm

Layout and general dimensions in accordance with the attached sketch.

3. ESPECIFICATION

3.1. PRESSURE BODY

The "OMNIVAP" boiler is a smoke generator, mono block, with three passes of gases, two in the furnace and one in tubes that incorporates in its project special characteristics that give it great efficiency in any working condition with low fuel consumption costs and maintenance.

Basically the boiler consists of:

- An outer envelope, constituted by ferrules of laminated steel, joined to the extreme bottoms, duly braced by means of brackets.

- On the water and steam side, a manhole is incorporated that allows access to the interior of the boiler.

- A tubular oven, easily accessible through the front door without the need to disassemble the burner.

- A front door that allows access to the tubular group for cleaning and entertainment and two registers located on the back for control of areas not accessible from the aforementioned registers.

- A set of smoke tubes, arranged in one step, of the proper diameter to achieve optimal heat transmission. The tubes will be drawn steel, without welding and will be joined to the tubular plates by welding.

The furnace situation allows an important volume of water to be available below and above it, eliminating dead zones and ensuring a rapid circulation of water in the boiler.

The completely refrigerated combustion chamber design, built with steel sheet, practically eliminates the refractory, eliminating the costly maintenance work, with stops for this concept.

At the same time the radiation losses of the generator are reduced to a negligible amount and therefore the thermal performance of the unit is increased.

The quality of the steam is ensured in any load regime by means of a special arrangement of the main outlet of the steam with which a practically unitary result is achieved.

3.2. GAS BOXES, FRAMES AND EXTERIOR FINISH

GAS BOXES

The boiler includes:

- A front door to establish the change of direction of the gases and at the same time provided for the coupling of the combustion equipment, being pivoting to allow access to the tubular plate and facilitate the periodic cleaning of the tubes. It includes the refractory material of first quality, necessary for the conformation of the chamber of ignition and the establishment of the flame of the burner, as well as the insulating material in the front to minimize the losses by radiation.

- A fume box to receive the gases from the boiler, built with steel sheet and including two covers for access to the tubes. It is designed to support the chimney suitable for the exhaust of combustion gases.

FRAME

- The body of the boiler will be anchored on a support base, built with sheet metal and laminated profiles, to support the complete unit and facilitate transport and installation at the work site.

EXTERIOR FINISH

- The enclosure of the boiler is thermally insulated, based on high quality mineral wool, protected with external lining in stainless steel plate AISl-304.

- The exterior surfaces that do not require thermal insulation are protected by a layer of anti-rust primer paint and an anti-heat paint layer

3.3. VALVES AND ACCESSORIES

A complete set of valves and accessories, for steam, water and purges, comprising:

VALVES:

1 Main steam outlet shut-off valve PN16 DN125.

1 Aeration shut-off valve PN16 DN15.

1 Boiler and purge interconnection shut-off valve PN16 DN50.

1 Spring safety valve PN16 DN40.

1 Purge valve PN16 DN50.

1 Pressure collector purge punch valve.

2 Working pressure switches punch valves.

ACCESSORIES:

1 Level indicator, box, with reflector glass and top and bottom taps with purge.

1 Pressure gauge for steam pressure, with three-way tap with check flange.

3.4. COMBUSTION EQUIPMENT

A burner for combustion of modulating regulation diesel.

Burner equipped with:

- Automatic ignition device using electrodes and ignition transformer.

- Photo resistant cell for flame detection.

- Combustion air fan.

- Fuel pump.

- Carrier-atomizer bar.

- Atomizer.

- Air regulation flap

- Electric drive motor

The burner is mounted on the front of the boiler, and its combustion head protected by a refractory cement crown highly resistant to temperature.

3.5. WATER SUPPLY EQUIPMENT

The water feeding equipment will be used and the following new elements will be assembled:

3 Shut-off valves for incoming line 3 Check valves for incoming line 2 Glycerin manometers with siphon and purge tap

3.6. CONTROL EQUIPMENT AND LEVEL REGULATION

The equipment for regulation and control of water level in the boiler, comprising:

1 Water supply regulator, depending on the level in boiler, to maintain this between limits previously established. The regulating system incorporates water pump electronic control relay, receiving signal from stainless steel electrodes.

The regulator's function is to start and stop the electric water pump automatically, according to boiler fluctuations level.

1 Level limiter, for low level safety control, consisting of an electronic relay and stainless steel signal electrode.

This limiter has the mission to block the burner when for any reason the water level falls below previously established limit, connecting at the same time an acoustic alarm.

1 Second level limiter, for control of the minimum safety level, composed of electronic relay and signal electrode. These devices, like the limiter indicated above, are mounted directly on the body of the boiler and its function is the burner blockage and alarm by minimum level if for any reason the first of the described controls did not act.

1 Horn for signaling of acoustic alarm by low level, which will be activated by any of the two limiters mentioned.

3.7. PRESSURE CONTROL AND REGULATION EQUIPMENT

The steam pressure regulation and control equipment is composed of:

1 1st flame pressure switch for connection or disconnection burner 1st flame solenoid valve.

1 2nd flame pressure switch for the connection or disconnection burner 2nd flame solenoid valve.

1 Safety pressure switch, for disconnection and blocking of combustion equipment, with optical alarm, in the event that the vapor pressure exceeds a previously established limit and if for any circumstance the previous disconnection pressure switches do not act.

3.8. ELECTRICAL CONTROL DEVICES

Electrical panelboard, consisting of a cabinet built in steel sheet, containing:

- Main switch, Main fuses, input contactor, contactors, control and protection relays from the various motors, auxiliary relays, burner programmer relay, signaling lamps and alarms, acoustic signaling alarm horn. Control timer of 120 minutes.

- Including wiring in steel pipe between electrical panelboard, burner, regulation and control elements.

3.9. ELECTRICAL INSTALLATION

The complete electrical installation for the interconnection of different elements, such as:

combustion equipment motors, feeding equipment, level and pressure controls, etc. with the electric control panel.

The materials to be used in the installation are selected according to the working conditions they have to support according to the following specifications:

- Rigid steel pipe special for electrical connections.

- Flexible special steel pipe for electrical connections.

- Aluminum casting junction boxes, incorporating waterproof seal or steamproof seal.

- Cable glands in all connection points, with neoprene seals, unalterable over time.

- Electrical conductors especially suitable for this type of work, with special silicone insulation, for service at high temperatures and high resistance to aging.

3.10. INTERCONNECTION PIPES

The complete system of water pipes, purges, fuel and steam, integrated on the boiler and necessary for the connection of the different elements, as reflected below:

- Water pipe, from the supply of the feed equipment to the boiler water inlet.

- Steam manifold for connecting the pressure gauge and automatic level and pressure controls.

- Boiler purge pipe with two purge points in lower part of boiler ferrule.

4. ASSEMBLY AND INSTALLATION

Assembly and installation of boilers in Building 115 and consisting of:

4.1. Removal the boiler, replacing existing connections, remove old boiler and remove it outside the limits of the base.

4.2. Connection of the new boiler, including:

- Transport the boiler to Morón de la Frontera (Seville).

- Unload and locate at final location.

- Connection of the main steam outlet, aeration, evacuation, safety valve, boiler purge, optical indicator purge, safety valve, all with flanged joints and connections with stainless steel nuts.

- Adapt the flue gas outlet from the boiler to the existing chimney with a steel plate duct, heat-insulated with glass wool and finished in stainless steel sheet.

- Connect the existing supply pumps to the new boiler, placing new shut-off and check valves.

- Start-up and regulation.

4.3. Once finished and tested the first boiler will proceed to replace the second boiler following the same steps made in the boiler replaced.

5. SUPPLY LIMITS

MAIN STEAM

Steam main valve output pipe.

Safety valve discharge pipe.

Aeration valve exhaust pipe.

WATER SUPPLY

Boiler water inlet flange.

FUELS

Boiler front area connection, burner filter.

PURGES

Boiler connection points.

POWER SUPPLY

Main connection to the control and operation panelboard.

FUMES

Rear gas box horizontal smoke outlet and chimney connection duct.

6. BRAND NAMES

The brands, or equal approved, of the main equipment accepted for this boiler are the following:

- Safety valves: ARI

- Shut-off valves: IMO

- Check valves: GESTRA

- Level indicators: KLINGER

- Pressures gauges: WIKA

- Levels controls: APER

- Pressure switches: SAUTER

- Combustion equipment: TEKENER

- Automatic salt purge: GESTRA

- Sample cooler: GESTRA

7. COMMISIONING

As part of the boiler commissioning process, and once the entire installation is completed, a type C inspection will be carried out in accordance with Royal Decree 2060/2008 by means an authorized OCA agency.

8. DIMENSIONS.

Attached are the dimensions of the boiler used in this contract.