ASHE 14-1000 SOW ENG.docx

29 June 2009

TECHNICAL SPECIFICATIONS

PROJECT ASHE 14-1000

CONSTRUCT GEOTHERMAL PLANT AT FITNESS CENTER, FACILITY N. 1405

AREA F, AVIANO AIR BASE, ITALY

1. PROJECT SCOPE

The Contractor shall furnish all personnel, equipment, material, transportation, supervision and any other necessary item and service to design and construct a new Heat Pump Geothermal Plant to provide hot sanitary water and chilled water for the air conditioning of the Fitness Center, Facility N. 1405, during the summer season.

Work items include but are not limited to the following:

a. Construction of a new masonry facility to be used as mechanical room, approximate dimensions mt 6 x 7.

b. Furnishing and installation of 2 each geothermal heat pumps comple of inertial storage tanks, pumps, accessories for the conneciton to the exisitng boiler room.

c. Furnishing and installation of geothermal probes and associated connection pipelines.

d. All steel pipelines shall have adequate insulation and shall be covered with embossed aluminum sheet.

e. The exisiting boiler room has a water softener that shall be maintained operational and, if necessary, modified based on the new requirements.

f. Furnishing and installation of Man-Machine Interface in the new mechanical room to operate and monitor all the components, including also a Personal Computer and a graphic/synoptic interface monitor. The PC rack shall be of adequate size to house PC, UPS, modem, electrical feeding line, interface relays and terminal blocks.

g. Furnishing and installation of the necessary equipment for Ethernet connection.

h. Main feeding line from the existing MDP to the new mechanical room, new electrical distribution panel, secondary electrical lines, lighting system and service outelts.

i. Fire detection system in the new mechanical room with optic/thermal detectors connected to the existing main fire panel, including panel reprogramming.

j. Setting into operation and start-up of the new system.

k. Work includes two (2) years of maintenance for system optimization and training of base maintenance personnel.

l. On-site training for base maintenance personnel during the start-up.

2. GENERAL REQUIREMENTS

a. The contractor shall furnish with the offer all the necessary documents to prove competence and experience in the design and construction of geothermal plants, also by submitting his own brochures as well as a list of the works already accomplished.

3. WORK SITE CONDITIONS

a. The Contractor is permitted to use reasonable quantities of available electricity and water at the work site. The Contractor shall alter characteristics and shall observe conservation practices at all times. All connections shall be the responsibility of the Contractor, including restorations to initial conditions.

b. Interruption of utilities. Utilities shall not be interrupted until approval is received from the Contracting Officer. Any such need shall be requested in writing by the Contractor at least 10 days in advance of the needed interruption. Requests for utility interruption shall indicate the type of utility to be interrupted, the type of operation requiring the interruption, date and duration. To the maximum extent possible interruption shall be scheduled on week ends or U.S. holidays in order to minimize impact to base activities.

c. Authorized work hours and days. Performance of work hereunder shall be from Monday through Friday excluding holidays from 07.30 to 18.30 hours. Work during week ends or holidays may be requested by the Contractor with a minimum of 10 days advance notice, however the Contracting Officer has the right to deny such request if reasons requiring week end and holiday work are not valid or for security or other necessities.

d. Toilet facilities in the vicinity of the work site shall be available for Contractor use. The Contractor shall use facilities in a manner to maintain their state of cleanliness and hygiene.

e. If welding is to be performed the Contractor shall ensure a welding permit is obtained from the Aviano Air Base Fire Department prior to performing welding operations.

f. The Contractor shall not use base refuse containers to discard debris. All construction debris shall be discarded by the Contractor off base at authorized sites according to category of debris/refuse in strict observance of all host country laws, decrees and local regulations in force.

g. The Contractor shall be responsible for ensuring all personnel engaged in the performance of this contract observe all host country laws concerning safety and in particular Italian laws 626 and 528.

h. The Contractor shall perform no digging until receipt of a completely coordinated AF form 103 from the Contracting Officer.

i. The Contractor shall perform no digging until receipt of a completely coordinated AF form 103 from the Contracting Officer. Digging permit will not be issued for the entire contract at one time. Contractor shall submit request for digging permit 15 days prior to excavating in each area segment. Contractor shall clearly mark proposed digging and excavation route with white paint or chalk prior to Government marking.

4. DESIGN REQIREMENTS

a. PERFORMANCE SCHEDULE

Performance schedule authorized is 240 (TWO- HUNDRED and FORTY) calendar days after Notice to Proceed (NTP) of which the first 90 (NINETY) calendar days shall be exclusively for design and site survey and the following 150 (ONE-HUNDRED AND FIFTY) calendar days shall be for construction as described in Table 1.

Table 1

[CD]

PROGRESSION

[CD]

NTP = Notice to Proceed CD = Calendar Days

b. SUBMITTALS

· All submittals shall be in dual language: Italian and English.

· A transmittal sheet must accompany the media containing the information included on the external labels, total number of volumes being delivered, and a list of file names and file descriptions on each volume. The transmittal sheet must also include instructions for reading, restoring, or transferring the files from the media, and certification that all delivery media is free of known computer viruses.

· Prepare typed documents on compact disk (CD) read only memory (ROM) media in “Microsoft© Office 2007” and “Adobe Acrobat 7.0” or latest editions. Prepare A4 (210 x 297 mm) size documents.

· Prepare computer aided design (CAD) drawings on compact disk (CD) read only memory (ROM) media in an AutoCAD Release 2007 "DWG" file format and “Adobe Acrobat 7.0”. Prepare drawings in A2 size.

· Unless otherwise specified in the Statement of Work, each delivery of documents is subject to review and approval by the Contracting Officer.

· Submittal include copies of the minutes of all review comments, items discussed, Contractor answers to Government review comments, discussions, conclusions, agreements, etc.

· A copy of the preferred title sheet and title can be provided in both digital and hard copy upon request.

· When available, the Government will furnish “as built” or construction drawings pertinent to the facilities involved. Such drawings, however, are not warranted to show presently existing conditions at the site. Contractor therefore, shall verify in the field all data shown on such drawings as necessary for accomplishment of this work and shall obtain all other data as required to insure the complete and proper design of the project.

· The Contractor is encouraged to prepare and submit with the design documents appropriate connection, fabrication, layout, and product specific drawings.

· The Contractor is encouraged to produce design submittals that are more like shop drawing submittals so that after final design approval, submittals are minimized.

Submittal requiements are as follows:

b.1 Site Survey and Pre-Final Design (35% DESIGN). Include Site Survey report, half-size drawings, specifications and manufacturer's data sheets.

b.2 Final Design (100% DESIGN). Incorporate comments on 35% design, design analysis and calculations and submit original design documents.

b.3 Format of Design Documents Prepare, organize, and present design drawings in accordance with ISO-UNI Standards in a manner considered standard industry practice, except as modified herein. Design drawings shall be complete, accurate, and explicit enough to show compliance with requirements and to permit construction. Prepare computer aided design (CAD) drawings on compact disk (CD) read only memory (ROM) media in an AutoCAD Release 2007 "DWG" file format. Prepare A1size drawings. Each drawing shall bear the seal and signature of the registered architect or professional engineer who prepared the design for the specific technical field. Drawings shall be geospatially referenced using real world coordinates WGS-1984 UTM 33N. The Technical Support Section will provide an AutoCAD drawing that is geospatially referenced for the contractor to use as a background.

b.4 Drawings required As a minimum, prepare design drawings to incorporate the types of drawings needed by each design discipline and in the detail required by the specification sections furnished with the SOW.

b.5 Copies of Design Documents Provide copies of the design documents for review as follows:

· 4 hard copies of drawings;

· 4 hard copies of specifications and manufacturer's data sheets;

· 3 hard copies of design analysis;

· 3 hard copies of calculations;

· 3 CDs with the entire submittal.

c.

DESIGN STANDARDS

447 dated 06 December 1991;

(8) Italian Ministerial Decree dated 14 January 2008 Technical Norms for Constructions in Seismic Areas

(9) Other applicable Italian national and regional laws.

The project shall be also in compliance with Aviano Air Base Master Specifications, dated November 2005 available at the Engineering Office (31CES/CEPM) during normal duty hours.

6. SITE SURVEY REPORT

The Contractor shall perform site surveys and all other investigations needed to clearly determine the existing site conditions and to perform drawings to be used for the survey report and project design. Contractor shall make all needed contacts and coordination with the Base Agencies to clearly determine all work requirements to be included in the project design, to develop the facility floor plan and to identify and size all equipment and materials to be installed in order to fulfill the project scope and the related defined work requirements. The Contractor shall prepare a “Survey Report” containing the project scope and requirements; list of all applicable US Air Force and Italian laws, norms and local regulations; descriptions of survey’s findings including lists of contacted Persons and Base Agencies; discussions, evaluations and evaluations results; recommendations including descriptive lists of works to be performed and preliminarily sized equipment/materials to be installed in order to fulfill the project scope and requirements; problems to be solved.

7. SPECIFICATIONS AND MANUFACTURER'S DATA SHEETS

The Contractor is encouraged to make final product and material selections during the design phase. Submit manufacturer's data sheets for materials, equipment, fixtures, devices, and systems that will be provided, clearly marked to indicate the exact item(s) to be included in the construction.

The Contractor is encouraged to prepare construction specifications only for materials, products, or installation instructions that cannot be adequately described with manufacturer's data sheets.

8. DESIGN ANALYSES

Prepare design analyses consisting of a basis of design and calculations for each design discipline. The design analyses shall be a presentation of facts to demonstrate the concept of the project is fully understood and the design is based on sound engineering principles. The design analyses for each discipline shall include:

a. A basis of design consisting of:

1. An introductory description of the project concept which addresses the salient points of the design;

2. An orderly and comprehensive documentation of criteria and rationale for system selection; and

3. The identification of any necessary licenses and permits that are anticipated to be required as a part of the design and/or construction process.

4.

b. Calculations as needed to support the design and their format:

The design analyses for each design discipline shall include a cover page indicating the project title and location, contract number, table of contents, and tabbed separations for quick reference. Each design analyses shall be prepared on A4 size (210 x 297 mm) or Letter (8.5 x 11 inch) size white paper and be bound in separate volumes for each design discipline. Multiple volumes for individual disciplines, appropriately numbered, may be provided when needed. Organize as follows:

a. Civil;

b. Structural;

c. Mechanical - Plumbing;

d. Electrical

e. Fire Protection.

9. CALCULATIONS

Calculations for each design discipline shall include a cover page, a table of contents, a summary of criteria, the project title and location, and contract number. Calculation pages shall be legible. Cite criteria from which calculations, rationale, and formulas are extracted by publication number, title, edition and page number. The cover page of calculations shall also include the names of the persons originating and checking the calculations. The person checking the calculations shall be a registered professional engineer other than the originator. In addition, the signature and seal of the designer responsible for the work shall be placed on the cover page of the calculations for the respective design discipline.

Computer printouts, if used, shall be identified similar to the calculations and may be referenced as an appendix or attachment to the design analyses. Identify the computer program name, source, and version. Schematic models used for computer input shall also be provided.

10. MATERIAL SUBMITTAL

Materials and other items listed in AF Form 66 shall be submitted as required by the time schedule indicated, for the approval by the Contracting Officer in accordance with clause entitled “Materials and Workmanship”.

The number of copies will be as required on AF Form 66.

The Government will review, approve and/or disapprove material submittals within 10 working days.

11. CLOSEOUT DOCUMENTATION

After construction has been completed, provide “As built” drawings:

a. Two (2) CD-ROM disks with conformed set of the Design drawings which incorporates as-built construction;

b. Three (3) A2-size drawings from the updated CAD CD-ROM disk.

12. DECLARATION OF COMPLIANCE

Contractor shall provide declaration of compliance for all mechanical and electrical systems in accordance with D.M. No.37 22/01/2008.

13. TESTING CERTIFICATES AND REPORTS

Provide Three (3) copies of Testing Certificates and Reports of all structural, mechanical, electrical and telecommunication systems. All related certificates shall be done, stamped and signed by Official Testers registered in their own Boards. The Contractor shall submit a three-name list of official testers in which the Government will choose one.

14. O&M MANUALS

Provide Two (2) copies of use, maintenance, repair and safety manuals of the equipment in accordance with the norms in force.

15. WARRANTY POC AND MAINTENANCE SCHEDULE

Contractor shall provide a Point of Contact with Name, Address, Telephone and Fax number, email address, etc. for all warranty related matters and for the 2-year maintenance schedule included in this contract.

16. NEW WORK ITEMS – ARCHITECTURAL, STRUCTURAL AND CIVIL REQUIREMENTS

a. Provide any necessary architectural, structural and civil work for the construction of a new masonry facility to be used as a mechanical room. Item includes masonry works, curtain walls, restoration to original conditions, etc.

b. 6X7 m approximate layout dimensions.

c. Masonry structure.

d. Pitched roof with clay tiles like the exisiting ones.

e. Adequate thermal insulation.

f. Front access double door, 2m-wide, like the exisiting.

g. Flashings and downspouts like the exisiting.

h. Internal and external painting like the existing.

17. NEW WORK ITEMS – ELECTRICAL REQUIREMENTS

a. Dedicated feeding line from Fitness Center Main Distribution Panel (MDP).

b. MDP and electrical lines. The Main Distribution Panel shall consist of the following: 1 (one) IP55 metal enclosure of adequate size, 1 (one) main circuit breaker of adequte capacity, 2(two) adjustable ground fault circuit interrupters to protect heat pumps feeding lines, 4 (four) adjustable ground fault circuit interrupters to protect circulation pumps feeding lines, 4 (four) double throw switches for twin pumps commutation, 4 (four) thermal overload cutoffs for pump motors, 2 (two) spare 2P16A thermal magnetic switches, 1 (one) 3-phase electrical power analyzer complete with current transformers (TA), data recording system. Electrical feeding lines shall consist of fire-resistant cables of adequate size and flexible conduits and shall include the MDP secondary feeding lines, plant equipment secondary feeding lines.

c. Internal lighting system of the mechanical room with 4 (four) 2x36W,IP 55 fluorescent lighting fixtures.

d. External lighting with 25W IP55 compact fluorescent light .

e. 220V 16A shuko/bipasso IP55 service outlet.

f. 2 (two) rate of rise fire detectors connected to the existing FAP on a dedicated zone.

18. NEW WORK ITEMS – MECHANICAL REQUIREMENTS

a. The new geothermal plant shall support the Fitness Center that is open 24 hours a day.

b. The above-mentioned plant shall guarantee hot sanitary water supply as well as summer cooling.

c. Heating in winter is guaranteed by a natural gas boiler that shall be maintained operational as at is now and feed the existing AHUs; in any case the new geothermal plant shall be presetted for a future connection with the above said AHUs.

d. We estimated peaks of 300 showers/day (about 16,000 Lt daily)

e. The exisiting boiler plant consists of:

· One boiler only for heating with 314 KW net capacity.

· One boiler only for hot sanitary water with 167 KW net capacity.

· One water softner.

· One chiller unit for summer cooling with 320 KW cooling capacity.

f. The following specifications have been prepared by 31 CES/CEPM for the Fitness Center Geothermal Plant. These specifications are to be consisdered as a guideline only. Therefore, they are indicative and not binding.

1) Furnishing and installation of a geothermal plant consisting of the following:

-2 each geothermal heat pumps AQUA MAGIS RM 2170 or equal approved, each one consisting of the following components:

- Galvanized steel self-bearing structure and panels, epoxy-polyester coated, RAL9018 color code

- 2 each SCROLL hermetic compressors by primary manufacturer, to guarantee high efficiency and low noise, working with refrigerant gas R407c, provided with rubber antivibrating at the base of the compressor and thermal amperometric protection.

- 1 each dry expansion heat exchanger on the internal side of the plant consisiting of AISI 316 stainless steel brazed plates, with closed-cell, high thickness, anti-condensation insulation. Heat exchanger shall be provided with threaded connections for connection to the mechanical system

- 1 each dry expansion heat exchanger on the external side of the plant consisiting of AISI 316 stainless steel brazed plates, with closed-cell, high thickness, anti-condensation insulation. Heat exchanger shall be provided with threaded connections for connection to the mechanical system

- 1 each dry expansion total heat recuperator consisiting of AISI 316 stainless steel brazed plates, with closed-cell, high thickness, anti-condensation insulation. Heat exchanger shall be provided with threaded connections for connection to the mechanical system

- 2 each refrigeration circuits made of copper tubes, jointed by heavy brazing with silver alloy and including: - dehydrating strainer capable to capture any impurity in the refrigeration circuit, - liquid and humidity indicator, - thermostatic valve to modulate gas flow based on cooling demand - pressure relief safety switch on both high and low pressure circuits – inversion valve of the refrigeration cycle – check valves on the pressure outlets to charge and discharge the ref Supervision rigeration gas and, if necessary, connection of pressure gauges. The low pressure circuit shall have a closed-cell, high thickness, anti-condensation insulation.

- electrical panel installed on the equipment, fully wired inside a steel box per IEC norms, provided with terminal board for conneciton of each external component. The power circuit shall be 400 V/3ph/50Hz and shall include: Themomagnetic protection for the compressor – Main disconnect switch and door safety switch.

2) Supervision system:

The supervision system shall be PLC type, provided with multiline display to allow reading of the operation paramenters and shall have icons for the immediate evaluation of the operation condition.

The supervision system performs the following diagnosis of the following parameters: setting, adjustment and display of the fluid temperature and of the relative set points, anti-freezing safety device and activaiton of associated heating resistors, compressor timing, buzzer and manual alarm reset, remote on/off digital input, remote summer/winter digital input, remote alarm signaling, compressor and pump working hour, coded alarm description, main alarm icons, pemanent alarm memory with the last 50 alarms report, automatic restart in case of power failure, summer/winter set-point, pump operation based on demand, serial port for supervison Ethernet interface, optional electronic board for system communication with MODBUS® electrical standard RS485, installation of an Ethernet board for direct connection to the web server resident in the PLC allowing to supervise and modify all the parameters and to update the software form a remote location.

Included shall be the control system of the two units in Master Slave mode that will be capable to supervise the two units on the total 4 steps as they were a single unit. This system shall be also capable to supervise the sanitary water pumps and the different output set point of each unit based on demand and priority.

The supervision system shall be provided with Anti-Legionella cycle and historical report.

The system shall also recall and activate the exisiting heating and domestic hot water boilers in case the demand is not satisfied by the heat pumps or if it is not economically convenient. Once fuel and electrical energy costs are input, an algorithm will calculate the most economically convenient option and decide which is the best modality between the traditional boilers or the geothermal.

Compressors type : Scroll -cooling-heating Water temperature °C 12 / 7 - 40 / 45 Water temperature “sgv” side °C 28 / 34 - 0/ -3 Geothermal probe glycole 25%

Compressor nominal power consumption kW 40,6- 48,4

Internal side

Geothermal probe side Underground heating exchange kW 208 – 125

Heat recuperation

Heat recuperation capacity kW 200 Brazed plate heat exchangers 1

Auxiliary electrical data V/ph/hz 230/1/50

Dimensions

3) 1 each inertial storage tank (puffer) capacity 2000 lt, in galvanized steel, cathodic protection, insulation made 100 mm-thick polyurethane, complete of stainless steel coil for pre-heating with a heating exchane surface equal to 4,6 SqMt.

4) 1 each twin circulation electric pumps for the refrigeration circuit, sigle pump capacity: 16,4 l/s, head as per claculation, including check valve and ball valves.

5) 1 each twin circulation electric pumps for the geothermal vertical probes, sigle pump capacity: 20,0 l/s, head as per claculation, including check valve and ball valves.

6) 1 each hot sanitary water supply kit consisting of the following:

- heat exchanger made of insulated stainless steel plates, designed based on hot water demand, complete of ball valves, thermometers, drain valve and any necessary accessories;

- twin pump unit on the primary circuit, each pump capacity: 19,2 l/s, head based on design calculations, complete of check valve and interception ball valve;

- twin pump unit on the secondary circuit, capacity and head based on design calculations, complete of check valve and interception ball valve;

- hot water storage tank, stainless steel, 3000 litri capacity, anodic protection, insulated with 100 mm-thick polyurethane, equipped with 7,5 kW antilegionella resistor, complete of ball valves, thermometers, drain valve and any accessories.

- thermostatric mixing 3-way valve with servomotor, themometric probes, thermometer.

7) Steel pipelines and installation accessories, including brackets and guys, safety valves, membrane expansion tanks, capacity based on design calculations, manifolds, ball interception valves, automatic air bleeders, check valves, connection to the main water supply with strainers, water make-up. Item icludes design calculation of the pipelines and plant layout.

8) Start-up of the geothermal plant performed by qualified technicians.

9) Furnishing and installation of geothermal probes, consisting of the following:

-36 each vertical geothermal probes for a total length of 3600 m. Holes will be drilled into soil of any nature and consistency. Installation of geothermal probes, double U Ø 32 PN 16 PE 100 with pipes up to plane of site, pressure injection of bentonite mixture from the bottom to the top of the probe.

Item shall include:

- transportation of all the necessary equipment and of the waste material;

- installation and removal of drilling equipment for each probe location;

- Flow dynamic test to obtain H/Q curve of each probe. In case of anomalous data flow tests shall be performed on each branch of the probe.

- pressure tightness test;

- Soil stratigraphy report at the end of the work;

10) Performance of GRT (Ground Response Test), for the following:

- equivalent thermal conductivity of the soil;

- equivalent thermal resistance of the well (probe and filling compound)

- undisturbed soil temperature.

Flow rate measurement with 1,5% precision sensor control Probe circuit measurement with thermometers (precision 0, 01°C).

Digital data recording every 60 sec, for 72 hours of the following values:

- date and time of every single recording;

- volumetric capacity;

- supply temperature;

- return temperature;

- ambient air temperature;

- electrical voltage of each single phase;

- electrical current of each single phase;

- frequency;

- Phase angle V-I;

- Determination of the flow resistance curve of the probe.

- Technical report with measured parameters and calculated values.

- Performance of dynamic simulations to determine the minimum necessary probe number and of the probe location plan. Max. temperature of the fluid during the summer shall be < 35 °C.

11) Geothermal probes connection system to the heating plant. The network shall be designed by the contractor and shall consist of HD PN16 polyethylene pipelines, with adequate diameters. It shall have the following characteristics and accessories:

- Interception valves for each probe;

- Precision balancing valves for each probe;

- Pressure outlets to measure flow resistance for each probe;

- Measurements and/or thermal expansion absorption devices;

- Stainless steel or polyethylene manifolds complete of anticondense insulation.

- Circuits balancing including flow dynamic test.

- Circuits refill with glycol-water mixture.

12) Excavations, masonry work, backfilling and restorations, consisting in the following:

- trench excavations into soil of any nature and consistency, including weed removal, grading of vertical wall and of the bottom, removal of excavated material and transportation to authorized dumping site as per Italian regulations.

- furnishing and installation of prefabricated concrete pits or cast in place, to house manifolds including frame and cover suitable for heavy traffic.

- backfill with 15cm-thick sand bedding, 20cm-thick sand layer above the pipeline, backfill completion with compacted excavated material.

- restoration of the excavated area to original conditions.

PART IV – ATTACHMENTS

Attachment No.1 – Project Location Attachemnt No.2 – Existing Mechanical Room LayOut Attachment No.3 – AF Form 66

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ASHE 14-1000

31CES/CEPM