Final_Dyess PWS version N

FILE NO: FD2060-12-31449

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 1

PERFORMANCE-BASED WORK STATEMENT

FOR

EMERGENCY HUSH HOUSE REPAIRS

Version N 04 Aug 2012

FD2060-12-31449

NOMENCLATURE: A/F32 T-9 NOISE SUPPRESSOR/HUSH HOUSE,

MODEL: A/F32T-9

LOCATION:

DYESS AFB, S/N 1010 AND 05009

NSN: 4920-01-082-1095

Prepared by:

Michael Randel

WR-ALC/GRVEC

Warner Robins Air Logistics Center (WR-ALC)

The marking requirements of DoDD 5230.24 do not apply to this document.

No data/documents incorporated by reference are export controlled.

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 2

PERFORMANCE- BASED WORK STATEMENT

EMERGENCY HUSH HOUSE REPAIRS, DYESS AFB

1.0 DESCRIPTION OF SERVICES:

The purpose of this Performance-based Work Statement (PWS) is to perform emergency repairs to the T-9 Hush Houses at Dyess AFB. Currently, several components of the Hush Houses are inoperable or do not function as originally designed. One of the Hush Houses (S/N 05009) is Not Mission Capable (NMC.) Inoperable components within the Hush Houses are a definite operational concern, since the Hush Houses cannot be properly and safely used without fully functioning components. The benefit of repairing the Hush Houses and components is to maintain operational testing capability for both installed and uninstalled aircraft engines, as well as safety of the personnel within the Hush House. Maintaining operational capability directly impacts the mission capable rate for the aircraft, and increases aircraft uptime. This effort will be considered a s uccess if the Hush Houses are repaired in accordance with the provided requirements for the T-9 Hush Houses.

2.0 SERVICES SUMMARY

Objective PWS paragraph Performance Threshold

Inspect and repair all components listed within the PWS in order to provide fully functional Hush Houses with all repaired components operating as originally designed and repaired in accordance with the standard Hush House configuration.

PWS sections 4.1-4.2

The Government will reject the workmanship or installation quality of the repaired components if one or more major flaws or two or more minor flaws are discovered by Government personnel during final inspections. A major flaw is defined as any inoperable components or systems repaired, or systems/components not repaired in accordance with the standard configuration. A minor flaw is defined as functional and operable systems not fully meeting the standard configuration, as defined by the Hush House drawing package. All major and minor flaws identified during the Government’s final inspection shall be corrected within 7 days of Government disapproval.

Submit CDRL items listed in PWS on t ime, within the period of performance, and complete

PWS section 4.3

No more than two rejections of data (final report, monthly status reports, repair evaluations, and engineering change proposals (ECPs) by Government personnel.

No more than two late submissions of monthly status reports by Contractor.

Rejected data shall be corrected and resubmitted within 7 d ays of Government disapproval. The Government will reject the

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 3 submitted data if two or more technical flaws or five or more minor flaws are found within the submitted documents. A technical flaw is defined as format not in accordance with the provided CDRLs, or does not provide all technical content in accordance with the PWS. A minor flaw is defined as typographical errors.

3.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES

The Government shall provide all inventoried drawings and Technical Orders associated with the design and use of the Hush Houses. A Technical Order list, as well as a l ist of applicable drawings, is provided in the Appendix (section 5.0) of this PWS. The drawings provided by the Government may not be all-inclusive and provide all necessary details required for successful completion of this PWS. The Contractor shall be responsible for determining and executing all inspections, and data gathering necessary, in order to obtain all information required for successful completion of this effort.

The Government shall provide access to the sites and/or passes for crews onto all locations listed within this PWS. The Government shall provide any necessary aircraft or engines for Hush House operation so that the Contractor can properly locate and functionally test the installed equipment.

Upon contract award, the Government shall provide a Work Load Agreement stating the points of contact (POCs) at each location listed within this PWS, all facilities to be provided, badge requirements, etc.

3.1 REPORTING LOSS OF GOVERNMENT PROPERTY

A. Definitions. As used in this clause –

1. “Government property” is defined in the clause at FAR 52.245-1, Government

Property.

2. “Loss of Government property” means unintended, unforeseen, or accidental loss, damage, or destruction of Government property that reduces the Government’s expected economic benefits of the property. Loss of Government property does not include purposeful destructive testing, obsolescence, normal wear and tear, or manufacturing defects. Loss of Government property includes, but is not limited to—

(1) Items that cannot be found after a reasonable search;

(2) Theft;

(3) Damage resulting in unexpected harm to property requiring repair to restore the item to usable condition; or

(4) Destruction resulting from incidents that render the item useless for its intended purpose or beyond economical repair.

3. “Unit acquisition cost” means—

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 4

(1) For Government-furnished property, the dollar value assigned by the Government and identified in the contract; and

(2) For Contractor-acquired property, the cost derived from the Contractor’s records that reflect consistently applied, generally acceptable accounting principles.

B. Reporting loss of Government property.

1. The Contractor shall use the Defense Contract Management Agency (DCMA) eTools software application for reporting loss of Government property. Reporting value shall be at unit acquisition cost. The eTools “LTDD of Government Property” toolset can be accessed from the DCMA home page External Web Access Management application at http://www.dcma.mil/aboutetools.cfm.

2. Unless otherwise provided for in this contract, the requirements of paragraph (b)(1) of this clause do not apply to normal and reasonable inventory adjustments, i.e., losses of low-risk consumable material such as common hardware, as agreed to by the Contractor and the Government Property Administrator. Such losses are typically a product of normal process variation. The Contractor shall ensure that its property management system provides adequate management control measures, e.g., statistical process controls, as a means of managing such variation.

3. The Contractor shall report losses of Government property outside normal process variation, e.g., losses due to—

(1) Theft;

(2) Inadequate storage;

(3) Lack of physical security; or

(4) “Acts of God.”

4. This reporting requirement does not change any liability provisions or other reporting requirements that may exist under this contract.

4.0 GENERAL INFORMATION

The standard Hush House configuration and original design for all of the Hush Houses covered in this PWS are defined by the Hush House drawing package – top level 8753080 (T-9) and all applicable sub drawings.

4.1.1 Air Dryer: This unit is not equipped with the standard compressed air dryer (see TO 33D4-6-692-4, pp 2-363 and 2-364.) The Contractor shall install an air dryer as described in the TO and relevant drawings to bring this unit within full compliance.

4.2.1 Augmentor Studs: Several studs in the augmentor panels are missing or broken. The Contractor shall replace all missing hardware in the augmentor tube. N ew hardware shall be

Section 4.1 is applicable to Dyess AFB (Serial Number 1010) T-9

Section 4.2 is applicable to BOTH Dyess AFB (Serial Number 1010 and 05009) T-9s http://www.dcma.mil/aboutetools.cfm�

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 5 identical in form, fit, function, material, and installation to the existing hardware in the augmentor.

Figure 1. Example of missing stud

4.2.2 Personnel Doors: The hardware on the personnel doors is worn. The contractor shall repair or replace all components necessary, including door hinges, door closure/fastening hardware, door seals, and the entire door if necessary, to ensure the personnel doors operate correctly. The Contractor shall align the repaired doors for free and smooth operation in both opening and closing actions.

4.2.3 Fuel System: The above-ground fuel storage tanks do not meet current EPA regulations and require replacement. On both units, the fuel pump and motor (see TO 33D7-50-885-4, pp 2- 275, p/n 1424M27G01) require replacement. The fuel tank control motor on uni t 1010 i s inoperable (see picture.) The core fuel flow indicator on unit 5009 is inoperable.

Figure 2. Broken fuel tank control motor

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 6

The Contractor shall replace the above ground storage tanks, fuel pumps, and fuel pump motors.

All other components shall be repaired or replaced as necessary to ensure that the fuel system is fully operational and in compliance with all relevant regulations (including EPA 40 C FR part 112). All electronic components shall be compliant with NEMA Class I, Division II requirements. A Testing and Acceptance plan detailing the methods and procedures for verifying correct operation of the repaired fuel system including the new fuel tank (see CDRL A007) shall be submitted to WR-ALC. Upon completion of installation, a report shall be submitted to WR-ALC detailing all work performed; test results and data; and operation, maintenance, and inspection instructions if different from those already described in the Technical Orders (see CDRL A008.) A 1 (one) year parts and labor warranty shall be provided covering all replacements and repair work performed by the Contractor in addition to any manufacturer’s warranty provided. All repairs and replacements shall maintain equivalent form, fit, and function to the existing fuel system where possible; if any changes to form, fit, or function are required, the Contractor shall follow the procedures in Sections 4.3.5 and 4.3.6. An attachment is provided describing testing and acceptance requirements for a similar above-ground storage tank replacement; this attachment is an example and is provided for reference only.

4.3.1 CAVAF Reporting: The contractor shall report using the Commercial Asset Visibility (CAVAF). ( CDRL A001, Data Item Description, DI-MGMT-81634B). T he contractor shall provide data related to the tasks and efforts conducted for each repairable unit. If CAVAF training is required, send an email to: 406scms.cav.af.ar@robins.af.mil. The contractor shall conduct production reporting on a daily or as transactions occur basis. T he contractor shall obtain a valid DoD PKI certificate to log into CAVAF. Each user shall be required to have an Identity Certificate only; an encryption certificate is not required.

4.3.2 Repair Evaluation: After contract award and before the initiation of any repairs, the Contractor shall investigate each of the Hush Houses to be repaired and submit to the Hush House Program Office and Contracting Officer a ‘Repairable Item Inspection Report’ for each Hush House within 30 days after contract award. ( If required in order to complete and submit the report, the Contractor may travel to the Hush House to be repaired) W ithin the report submitted to the Government, the Contractor shall include, at a minimum, a complete analysis of the failure and repairs required and a complete list of the components to be repairs/replaced/refurbished. No repairs shall commence until this report is approved by the Government. [CDRL A002, Repairable Item Inspection Report, DI-ILSS-80386]

4.3.3 Monthly Status Reports: The Contractor shall prepare and submit a monthly status report compiling the status of the contract. These reports shall include a status summary of all work accomplished-to-date, all program activities for the period and shall provide a forecast of work to be accomplished during the upcoming month, all work outstanding, and a schedule of all deliverables. The contractor shall identify actions being taken to correct all schedule deficiencies.

All changes from previous reports shall be highlighted and explained. T he contractor shall report any problems requiring immediate action by the government using the most expeditious

Section 4.3 is applicable to all Hush Houses within this PWS mailto:406scms.cav.af.ar@robins.af.mil�

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 7 means (telecon, e-mail, or letter) and shall document the problem in the monthly report. The Contractor shall provide, within the monthly status reports, a listing of the repairs required, all components to be repaired or replaced, as well as a listing of all Hush House drawings applicable to performing the repairs. [CDRL A003, Status Report, DI-MGMT-80368A]

4.3.4 Final Report: The Contractor shall prepare and submit a final report detailing the repairs performed at each location. This shall include a summary of all work accomplished, statement and record as to the satisfactory inspection and testing of all work, and recommendations for any future repair, repair-to-the-latest-configuration, or other corrective actions not addressed under this effort. [CDRL A004, Contract Summary Report, DI-ADMN-80447A]

4.3.5 Engineering Changes: The Contractor shall not change, alter, or modify any Noise Suppressor components and shall not install any components that differ in form, fit, function, or material from the original or current configurations without the approval of WR-ALC through an ECP (ECP). [CDRL A005, Engineering Change Proposal (ECP,) DI-CMAN-80639C]

4.3.6 Notice of revision (NOR): The Contractor shall submit a Notice of Revision (NOR) with each ECP for Government approval and coordination prior to altering, revising, or otherwise changing any feature of the items involved within the scope of this contract. [CDRL A006, Notice of Revision (NOR,) DI-CMAN-80642C]

4.3.7 Test Plan: A maximum of 60 days after contract award, the Contractor shall submit to WR-ALC a test plan for this effort, illustrating in detail the tests needed in order to meet the requirements of section 4.2.3 of this PWS. T he Contractor shall not perform any acceptance testing until the test plan has been approved by WR-ALC. T he Government shall have the ability to add, change, or delete tests in order to meet the requirements of this PWS. [CDRL A007, Test Procedure, DI-NDTI-80603A]

4.3.8 Test/Inspection Report: A maximum of 30 da ys after completion of testing, the Contractor shall write and submit a final report documenting the data collected from all tests, an analysis of the data, and details of the modifications or other changes made to the Hush House in support of section 4.2.3 of this PWS. The report shall include in detail all tests performed and all data. This test report shall also include a summary of all work accomplished, as well as a written statement and record as to the satisfactory inspection and testing of all work. The Contractor shall conduct an out briefing with on-site personnel from the Air Force and address proper maintenance and operation of repaired and/or modified systems to prevent future damage.

Within the test/inspection report, the Contractor shall provide all inspection and maintenance requirements of the Hush House modifications to include step-by-step procedures, inspection intervals, and illustrations of the modified components for inclusion within the Hush House Tech Data. [CDRL A008, Test/Inspection Report, DI-ADMN-80809B]

4.3.9 GIDEP: The Contractor shall participate in the Government-Industry Data Exchange Program (GIDEP) in accordance with GIDEP Operations Manual S0300-BT-PRO-010, Government-Industry Data Exchange Program, November 1994. T he Contractor shall be required to submit all appropriate data to GIDEP, as it is generated, in accordance with the CDRLs of this contract. P art, component, material, equipment or manufacturing process

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 8 deficiencies (actual or potential) shall be reported to GIDEP. The Contractor shall maintain a record of the status and disposition of all Alert/Safe-Alert reports in accordance with the CDRLs.

The Contractor shall screen each Alert/Safe-Alert report received from GIDEP to determine if the device or process for which the Alert/Safe Alert report is issued is used in the repair/manufacture of the item(s) covered by this contract and take appropriate action. Upon the determination that an Alert/Safe-Alert report has implications for the item(s) being repaired/manufactured, a response shall be submitted informing the specified organizations in accordance with the CDRLs. Sub-Contractors to the prime shall be notified of reports associated with the devices, components or processes supplied by the sub-Contractor to the prime. GIDEP Alert/Safe-Alert Report, (CDRL A009, DI-QCIC-80125B), GIDEP Alert Response, CDRL

A010, DI-QCIC-80126B).

4.3.10 Non-Standard Configurations: The Contractor shall not install any non-standard equipment or materials during the execution of this contract without the expressed written approval of the cognizant engineer in WR-ALC/GRVEC or the Program Manager in WR- ALC/GRVCB through the Contracting Officer.

4.3.11 Essential Services: In accordance with DoDI 1100.22, and Procedures for Determining Workforce Mix, 12 Apr 10, the Functional Commander/Functional Director has determined, in writing, that this effort is not considered mission critical and will not continue in the event of a crisis.

4.3.12 Inspection of Services: Inspection clauses are applicable.

4.3.13 Green Procurement Program: GPP is a mandatory federal acquisition program that focuses on the purchase and use of environmentally preferable products and services. The prime contractor is responsible for ensuring that all subcontractors comply with this requirement.

4.3.14 Security Requirements: The Contractor will not require access to classified information in performance of the contract.

1. General: Actual knowledge of, generation, or production of classified information is not required for performance of the contract. Cleared personnel are required to perform this service because security measures which are in force do not preclude access to classified information.

2. Operations Security (OPSEC): Contractor personnel will participate in the OPSEC program locally administered by the AF activity.

3. Employee Clearances: Contractor employees that need access to Government owned Automated Information Systems (AIS) will require the minimum of a Favorable National Agency Check (NAC). Submit a Standard Form 85P (fingerprint cards if available) to the Security Team for processing.

4. Security Incidents and Violations: The contractor will immediately notify the wing security team of any actual security violation, security incident, or of any indication of a potential unauthorized disclosure or compromise of classified or sensitive but unclassified information.

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 9

5. Security Education: All full-time contractor employees occupying physical space on Robins AFB, will comply with the Security Education and Awareness program. The program consists of four components: initial training, annual refresher training, and periodic tailored training.

4.3.15 Coordination of Base Access: The Contractor shall inform the local base personnel at least 7 days in advance of ANY site visit to enable the base personnel to verify availability and prepare for Contractor visit, evaluation, or repair work.

4.3.16. Over and Above (O&A): During the performance of the contract, additional work (i.e.

over and above work) may be discovered which is not explicitly outlined in the PWS. If over and above work is necessary to obtain an operable Hush House which functions properly and safely with fully functioning components, it should be detailed within the RIIR report for the Government's review. If the RIIR has already been submitted and over and above work is discovered, an addendum to the RIIR can be submitted to detail the over and above work identified. The submission of over and above work does not obligate the Government to authorize this work. After approval of the RIIR, the Government will request a quotation to perform over and above work along with details to support the quotation in relation to the over and above work. After receipt, evaluation and negotiation of the contractor’s quotation, a supplemental agreement will be issued to establish the firm fixed price for the over and above work. The price so established shall be evidenced by modification by the PCO. Actual performance of over and above work shall commence only once a modification has been issued.

4.3.17 Safety and Health

4.3.17.1 Government Safety and Health Regulations: The Contractor shall comply with Occupational Safety and Health Act (OSHA) [Public Law 91-596 as amended by Public Law 101-552] and OSHA Standard 29 Code of Federal Regulations (CFR), Part 1910, Occupational Safety and Health Standards. The Contractor shall comply with DoD Directive 4715.1E, Environmental, Safety, and Occupational Health (ESOH). The Contractor shall comply with AFI 91-301, Air Force Occupational and Environmental Safety, Fire Protection, and Health (AFOSH) Program.

4.3.17.2 Safety and Health Plan/Program: Within ten business days after contract (basic or order, as applicable) award, the Contractor shall submit a Safety and Health Plan for review and acceptance by the Government Safety Office (78 ABW/SEG). The Contractor shall establish and maintain a Safety and Health Program in accordance with the requirements listed in the contract (basic or order, as applicable) Appendix C, Industrial Safety Requirements, and the Safety and Health Plan.

[CDRL A011, DI-ENVR-81375, Environmental Health and Safety Plan]

4.3.17.3 Mishap Incidence: There shall be no Class A and/or B mishaps. There shall be no more than two Class C mishaps per contract/order year.

4.3.17.4 Mishap Notification/Investigation: The Contractor shall notify the Government Safety Office (478-926-6271) within four cumulative business hours of an employee injury

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 10 resulting from performance of the contract/order or a mishap involving Government property provided under the contract/order. The Contractor shall provide a written report within 24 cumulative business hours of mishap incidence. There shall be no more than one late mishap notification per contract/order year. If requested by the Government, the Contractor shall immediately secure the mishap scene and/or damaged property and impound pertinent records until released by the investigating Safety Office. If the Government investigates the mishap, the Contractor and subcontractors shall cooperate fully and assist the Government personnel until the investigation is completed.

(CDRL A012, DI-SAFT-81563, Accident/Incident Report)

5.0 APPENDICES

5.1 Air Force Technical Orders (TOs): The following documents are applicable to this PWS to the extent specified herein.

Tech Order Description Applicable 33D7-50-885-1 Operation and Maintenance Instructions, Intermediate Test Cell Adapter Kit, A/F32T-9 Test Stand Mounting Adapter Kit, Fuel System Adapter Kit

Entire Technical Order is applicable.

33D7-50-885-4 Illustrated Parts Breakdown, Intermediate Test Cell Adapter Kit, A/F32T-9 Test Stand Mounting Adapter Kit, Fuel System Adapter Kit

33D4-6-692-1 Operation and Maintenance Instructions, Enclosed Noise Suppressor System Aircraft/Engine (Hush House), A/F32T-9

33D4-6-692-4 Illustrated Parts Breakdown, Enclosed Noise Suppressor System Aircraft/Engine (Hush House), A/F32T-9

33D4-6-737-1 Operation and Maintenance Instructions, A/M32T-9 Noise Suppressor Control Room

5.2 Air Force Drawings: The following drawings are applicable to the repair of the Hush Houses. N ote, the drawing list provided below may not be all-inclusive and provide every drawing required for the Hush House repairs. A dditional drawings may be available and provided by the Government.

Section 4.1.1 Air dryer, T.O. 33D4-6-692-4, pp 2-363, 2-364 Section 4.2.1 Augmentor studs, 8753055 Section 4.2.2 Personnel doors, 8866501, 8866543 Section 4.2.3 8866703 – Fuel System Installation

8866940 – Electrical Installation Fuel System 8866928 – Fuel Tank And Valve Assembly, JP-4

PREPARED BY: Michael Randel, WR-ALC/GRVEC, DSN 472-1804 11

T.O. 33D4-6-737-1 Figure F1 Fuel Flow Diagram, paragraph 3- 4.13 T.O. 33D4-6-737-1 Figure 1-5 Pg 1-9 T.O. 33D4-6-737-1 Pg 1-6.2 and 1-7 T.O. 33D4-6-737-1 Paragraph 3-4.13

5.3 Packaging Specifications: (entire specifications are applicable)

MIL-STD-2073-1D, DATED 10 MAY 02, STANDARD PRACTICE FOR MILITARY

PACKAGING

MIL-STD-129P (4), DATED 19 S EP 07, M ILITARY MARKING FOR SHIPMENT

AND STORAGE

Ellsworth Air Force Base, SD Building 1500

T-9 Test Cell Tank August 2009

7500 Gallon Aboveground Single Wall UL-142 JP-8 Tank

PART 1--GENERAL

1.1 SCOPE OF SECTION

A. This section describes requirements for providing the equipment, labor and materials necessary to furnish and install a petroleum storage tank system utilizing an aboveground steel tank.

B. Requirements include furnishing and installing all equipment and accessories necessary to make complete systems for the storage and supply of JP-8 to the T-9

Test Cell at Ellsworth AFB.

1.2 RELATED SECTIONS

A. All material and installation sections relating to site preparation, painting, concrete and other related work not specified herein are covered by owner’s standard specification.

1.3 DEFINITIONS

A. AGREEMENT consists of the conditions of the contract between the Owner and the Contractor, including referenced specifications, drawings and related documents.

B. AUTHORITY HAVING JURISDICTION is the local fire marshal (28 CES/CEF) having statutory jurisdiction over the project.

C. CONSTRUCTION DOCUMENTS consist of the general and supplemental conditions, specifications, drawings, and any addenda issued prior to bidding.

D. CONTRACTOR is the person, firm, or corporation with whom Owner has entered into the Agreement.

E. FURNISH means the Contractor shall supply the item specified, at the job site, unloaded, and secured against damage, vandalism or theft.

F. FRP is an abbreviation for fiberglass reinforced plastic.

G. INSTALL means the Contractor shall perform all work required to place the equipment specified in operation, including installation, testing, calibration, and start-up.

H. INTERSTITIAL refers to the space between primary and secondary containment of tanks as well as piping.

I. LEAK MODE TESTING refers to testing the integrity of the tanks and in accordance with the test device manufacturer's instructions and U.S. EPA

Technical Standards.

J. LIQUID TIGHT means prevention of the release of product from contained spaces into the surrounding soil and the prevention of infiltration of ground or surface water into a contained space.

K. OWNER is the person or entity identified as such in the Agreement.

L. PRODUCT means the liquid stored and dispensed from the tank.

M. PROVIDE means the Contractor shall Furnish and Install the equipment specified, and perform all work necessary to provide a complete and functional code-compliant system.

N. SPOIL means all material removed by demolition or excavating.

O. STI is the Steel Tank Institute 570 Oakwood Drive, Lake Zurich, IL. 60047 (847)

438-8265

P. SUBSTANTIAL COMPLETION is the stage in the progress of the Work when the Work or designated portion thereof is sufficiently completed in accordance with the Contract Documents for the Owner to utilize the Work for its intended use.

Q. WORK means all materials, equipment, construction and services required by the

Contract, whether completed or partially completed.

1.4 GENERAL REQUIREMENTS

A. Unless otherwise specified, equipment furnished under this section shall be fabricated and installed in compliance with the instructions of the manufacturer.

B. The Contractor shall ensure that all equipment, accessories and installation materials comply with the specification and that adequate provision is made in the tank design and fabrication for mounting the specified system equipment and accessories.

C. The Contractor is solely responsible for construction means, methods, techniques, sequences and procedures and for safety precautions and programs.

D. The contractor shall provide all labor, equipment and material required to provide a complete and functional system.

E. To avoid delays in construction, the Contractor shall ensure that all components of the system are available at the time of installation.

F. The Contractor shall coordinate his work with other work being performed at the construction site and minimize interference with the Owner's normal activities which may continue during construction.

G. The Contractor shall obtain necessary permits, arrange for inspections and obtain approval of the appropriate Authority Having Jurisdiction over the work described.

1.5 STANDARDS

A. The manufacture and installation of aboveground storage tank systems described in this section shall adhere to the following standards and regulatory requirements:

1. Standard for Steel Aboveground Tanks for Flammable and Combustible

Liquids, Standard UL 142; Control Equipment for Use With Flammable

Liquid Dispensing Devices, UL 1238; Pipe Connectors for Flammable and

Combustible Liquids and LP-Gas, UL 567; Powered-operated Dispensing

Devices for Petroleum Products, UL 87; Valves for Flammable Fluids, UL

842; UL Listed Non-Metal Pipe, UL 971; Underwriters Laboratories Inc., 333

Pfingsten Road, Northbrook, Illinois 60062. (847) 272-8800.

2. Recommended Practices for Installation of Aboveground Storage Systems for

Motor Vehicle Fueling, PEI/RP200; Petroleum Equipment Institute, P.O. Box

2380, Tulsa, OK 74101.

3. Protected Aboveground Tanks For Motor Vehicle Fuel Dispensing Stations

Outside Buildings, Article 79, Uniform Fire Code, 2000, International Fire

Code Institute, 5360 Workman Mill Road, Whittier, California 90601-2298.

4. Control of External Corrosion of Submerged Metallic Piping Systems, NACE

Recommended Practice RP0169, ; External Cathodic Protection of On-Grade

Metallic Storage Tank Bottoms, NACE Recommended Practice RP0193-93, NACE International, P.O. Box 218340, Houston, TX 77213.

5. Standard for Aboveground Tanks with Integral Secondary Containment, F-

921®; Shop Fabricated Stationary Aboveground Storage Tanks for

Flammable, Combustible Liquids - Installation Instructions, R912-00;

Recommended Practice for Corrosion Protection of Underground Piping

Networks Associated with Liquid Storage and Dispensing Systems, R892;

Recommended Practice for External Corrosion Control of Shop Fabricated

Aboveground Tank Floors, R893-98; Standard for Inspection of In-Service

Shop Fabricated Aboveground Tanks for Storage of Combustible and

Flammable Liquids, SP-001-00, Steel Tank Institute, 570 Oakwood Road, Lake Zurich, IL 60047 (847) 438-8265.

6. Flammable and Combustible Liquids Code, NFPA 30, 2008, National Fire

Protection Association, 1 Batterymarch Park, Quincy, Massachusetts 02269-

9101.

7. Automotive and Marine Service Station Code, NFPA 30A, 2008, National

Fire Protection Association, 1 Batterymarch Park, Quincy, Massachusetts

02269-9101.

8. National Electric Code, NFPA 70, 2008, National Fire Protection Association, 1 Batterymarch Park, Quincy, Massachusetts 02269-9101.

9. Occupational Safety and Health Standards, particularly Flammable and

Combustible Liquids, 29CFR 1910.106, Personal Protective Equipment

29CFR 1910 Subpart I, Excavations 29CFR 1926.650 Subpart P, U. S.

Department of Labor, Occupational Safety and Health Administration

(OSHA), Washington, D.C.

10. Clean Water Act and Oil Pollution Act of 1990, Spill Prevention, Control and

Countermeasure (SPCC) Plans, 40 CFR 112, 113 and 114.

11. Uniform Building Code, International Conference of Building Officials, 5360

Workman Mill Road, Whittier, California 90601-2298.

12. Applicable state and local regulations and ordinances

B. In case of differences between building codes, state laws, local ordinances, utility company regulations, and contract documents, the most stringent shall govern.

C. The codes and standards listed are the latest as of this publication. Codes and standards are continuously updated. The Contractor shall confirm the construction standard edition enforced by the authority having jurisdiction.

1.6 SUBMITTALS

A. The Contractor shall provide three (3) sets of shop drawings of the following system components for approval before commencing construction.

1. Shop drawings of the tank(s) by the tank manufacturer.

2. Assembly and installation drawings.

B. The Contractor shall provide product data sheets and descriptive material for major components to be provided.

1. Tank coatings.

2. Pumps, valves and fittings.

3. Piping, venting equipment, leak detection equipment, and overfill prevention equipment.

4. All other system accessories.

C. Submittals shall be delivered to the owner’s Engineer within 10 days of notice to proceed. The Engineer shall review the drawings and return them to the

Contractor approved, or with appropriate comments, within 28 days of receipt.

1.7 CONSTRUCTION DOCUMENTATION

A. At contract close-out, the Contractor shall provide three (3) sets of the following installation instructions:

1. Tank

2. Pumps, dispensers, valves and fittings

B. The Contractor shall provide three (3) sets of manufacturers' system component operation and maintenance manual instructions.

C. The Contractor shall provide record ("as-built") drawings and photographs of the following:

1. All tank system components.

2. The completed tank system in place.

D. The Contractor shall provide copies of all testing and inspection reports to the

Owner prior to substantial completion.

1.8 GUARANTEES, WARRANTIES AND INSURANCE

A. The Contractor shall provide the insurance as required by owner.

B. The Contractor shall provide the guarantees/warranties as required by owner.

END OF SECTION

PART 2--PRODUCTS

2.1 ABOVEGROUND STORAGE TANK

A. The storage tank shall be UL142 aboveground tank for the storage of petroleum product at or near atmospheric pressure. Contractor to provide:

(1) 7500 gallon capacity (nominal) Horizontal Cylindrical tank for JP-8 storage. (exact dimensions and weights vary between manufacturers; verify with manufacturer.)

1. A legible embossed metal UL 142 label shall be affixed to the side of the aboveground storage tank(s).

2. Steel outer wall of the tank shall have white finish coating to prolong weather resistance and to further reduce maintenance needs.

3. The storage tank and supports shall be delivered as a complete UL listed unit.

4. The storage tank and supports shall meet all Uniform Building Code and/or applicable local code requirements.

B. Tank shall be designed for stationary use aboveground.

C. Provide an external ladder/safety platform/catwalk to allow access to top of tank for filling and maintenance that complies with all applicable OSHA standards and building codes.

2.2 VENTING REQUIREMENTS

A. Provide one (1) normal atmospheric or pressure/vacuum vent for the tank.

1. Vent shall discharge upward or laterally and be protected from intrusion of rain.

2. Vents for tanks shall terminate at least 12 feet above ground level and be located at least five feet from building openings.

3. Vent installation shall comply with applicable sections of the fire and mechanical codes, including, but not limited to, NFPA 30A (2-4.5.e), NFPA 30 (2-3.5), or UFC (7902.1.10) and all applicable local codes.

B. Provide one (1) emergency vent for the primary tank.

1. Vent size shall be determined by the tank configuration, the primary tank capacity, and the product stored.

2. Emergency venting shall comply with provisions of NFPA 30A (2-4.5), NFPA 30 (2-3.6), or UFC (7902.2.6) (Article 79 5.3), UL 142 and all applicable local codes.

3. Vents shall be located as close to the center of the tank as possible.

2.3 TANK FILLING AND OVERFILL PREVENTION COMPONENTS

A. For tank with top fill assembly, provide one (1) lockable tight fill cap, adapter, fill pipe, and drop tube per tank

1. The bottom of the fill drop tube shall be cut at a 45 degree angle with the open end facing the long dimension of the tank.

2. Terminate drop tube six inches from the bottom of the tank.

3. Comply with provisions of NFPA 30 (2-4.6.3 & 2-4.6.4) or UFC Article

79 (5.6).

B. Provide a spill container with cover and lockable hasp to contain product spills from the fill hose. Spill containment shall comply with UFC Article 79 (5.7).

1. Fill pipe spill container shall have a capacity of not less than five gallons.

2. Provide a means for returning collected product to the storage tank.

C. Provide overfill prevention equipment which complies with the requirements of

NFPA 30A (2-4.6.1) and which incorporates the following features:

1. An audible alarm which will sound when the product level in the tank has reached 90% of tank capacity.

2. The overfill prevention equipment shall be rated to accept the fill flow rate and pressure.

D. The Contractor shall provide a means for determining the liquid level in tank which is visible to the delivery operator, in accordance with NFPA 30A (2-4.6.1) or UFC Article 79 (5.5).

2.4 MONITORING AND GAUGING SYSTEM

A. Provide one (1) mechanical tank liquid level sight gauge per tank.

B. Provide an audible weather-proof alarm horn tied into the overfill monitoring system, which will be programmed to alarm as the tank contents reach a predetermined level, dictated by applicable codes. Alarm must be located so that the person filling the tank can hear the alarm and halt the tank filling procedure.

Provide all associated conduit and wiring tied into the monitoring system.

2.5 PIPING (As Applicable)

A. Aboveground piping shall be Schedule 40 steel pipe with standard (ANSI 150#) nodular iron fittings.

1. Exposed piping shall be protected from exposure to outdoor conditions.

2. Low melting point materials may be not be used aboveground.

2.6 VALVES, FITTINGS AND FLEXIBLE CONNECTORS

A. Provide a fire impact valve or shear section on product pipe beneath each dispenser and/or at any tank penetration potentially below liquid level.

C. Provide a steel or nodular iron block valve to allow the tank and piping to be isolated and secured.

D. Provide an anti-siphon device in the product piping at the tank which will prevent the flow of liquid from the tank unless the suction pump is operating, in accordance with NFPA 30A (2-4.6.2 and 2-4.6.3); UFC Article 79 (6.4); BOCA

(F-3207.5.6). Anti-siphoning may be met by installation of an electric solenoid valve. A solenoid valve used in conjunction with an under pump vacuum operated valve meets this requirement.

E. Provide a pressure relief valve in each segment of blocked piping which will relieve excessive pressure resulting from thermal expansion and return any excess product to the tank.

2.7 Fuel assembly shall consist of top mounted withdrawal tube with all valves, and components necessary to connect into fuel system in accordance with applicable national and local fire and building codes.

PART 3--EXECUTION

3.1 GENERAL

A. Familiarity with the Site.

1. Contractor shall familiarize himself with the location of all public utility facilities and structures that may be found in the vicinity of the construction.

2. The Contractor shall conduct his operation to avoid damage to the utilities or structures. Should any damage occur due to the Contractor's operations, repairs shall be made at the Contractor's expense in a manner acceptable to the Owner.

3. The Contractor is responsible for meeting all the requirements established by the agencies for utility work, as well as work affecting utilities and other government agencies.

3.2 TANK HANDLING, STORAGE AND INSTALLATION

A. Tanks shall be handled, lifted, stored and secured in accordance with the manufacturer's instructions.

B. Unload with equipment having sufficient lifting capacity to avoid damage to the tank. Securely store the tank at the job site.

C. The tank and associated equipment shall be installed in accordance with the fire safety codes, regulations, standards and manufacturers instructions including:

1. Federal, state and local fire safety, occupational health and environmental regulations.

2. Steel Tank Institute installation instructions for F921® aboveground tanks (Publication No. R001-00, Installation and Testing Instructions for

F921® Aboveground Storage Tanks).

3. The installation instructions of other system component manufacturers.

4. The Construction Documents and associated Drawings.

5. Recommended Practices for Installation of Aboveground Storage Systems for Motor Vehicle Fueling, PEI/RP 200, Petroleum Equipment Institute.

D. Advise the Owner of any shipping or handling damage encountered.

E. No modifications shall be made to any tank without the prior written approval of the manufacturer and the Engineer. This includes any welding on tank shells, adding penetrations in the tank structure, or repairing damage which might affect the integrity of the inner or outer tank.

3.3 CORROSION PROTECTION

A. Any portion of the fueling system in contact with the soil shall be protected from corrosion in accordance with sound engineering practice and in accordance with

NFPA 30A (2-4.8).

B. Protect aboveground piping and equipment from corrosion by painting or wrapping it with a coating which is compatible with the product stored and the conditions of the exposure.

3.4 EQUIPMENT INSTALLATION

A. Pipe installation. (As Applicable)

1. Maintain at least 1/8 inch slope in all pipe back to the tanks to prevent traps as prescribed in the standards.

2. Provide at least two secondary pipe diameter clearance between parallel piping runs. Separate crossed piping by at least four-inches.

3.5 ELECTRICAL

A. Installation shall be in accordance with manufacturers' installation instructions and shall conform to state and local electrical codes with special attention to compliance with requirements for work in classified areas.

B. Provide explosion-proof electrical junction boxes, conduit and sealoffs specified in Article 500-514 of the National Electrical Code as required.

C. Contractor shall provide wiring and seal-offs for all conduit.

3.6 TESTING

A. The Contractor is responsible for testing all installed systems for liquid tightness and proper operation, including:

1. Pre-installation inspection of all materials.

2. Product, containment and vent piping during construction.

3. Containment sump integrity, as required.

4. System tightness test after all work, including paving, is completed and before the system is placed in service.

5. Post installation inspection and testing eleven months after substantial completion of all work and approval of the Owner.

B. Test each component of the system for calibration, tightness and proper operation in accordance with the instructions of the component manufacturer.

C. Testing shall be documented by the Contractor and witnessed by the Engineer.

1. Record the date and time of the test, the name of the tester and his affiliation with the project, and the names of each individual witnessing the test.

2. Record the test method, duration and results.

3. Provide a record of the testing to the Owner at the time of system start-up.

D. Testing shall be witnessed by the Owner.

1. The Owner shall witness tank delivery and setting in place, anchoring, piping backfilling, piping tests, final precision testing and system start-up.

2. The Owner shall indicate approval of all testing witnessed in writing.

E. Tests shall be performed in conformance with the manufacturers' instructions, state laws and the quoted industry standards, particularly PEI/RP200 and

PEI/RP100.

1. If a conflict exists between the test protocols, the most stringent test shall be performed.

2. Any conflict which affects manufacturers' warranties must be resolved before beginning construction.

3. The Contractor shall document all tests in writing, signed by the individuals who performed and witnessed the test.

F. The Contractor shall demonstrate the operation of all systems to the Owner at the time of the final start-up test.

1. Provide one day of instruction on the proper operation and maintenance of all components.

2. Demonstrations shall include, but are not limited to, pump operation, monitoring and gauging systems, fuel filter replacement and leak detection.

3.7 TESTING THE PRIMARY TANK

A. Air pressure testing of the tank shall be conducted on-site, in the presence of the

Engineer, before placing the tank in service.

B. Refer to Publication STI-SP001 for complete procedural details.

C. Other integrity tests may be required by the local authority having jurisdiction.

3.8 TESTING PRODUCT, CONTAINMENT AND VENT PIPING

A. Test product and vent piping in accordance with manufacturer's instructions and quoted industry standards, particularly PEI/RP-100.

B. Maintain minimum 10 psig pressure on all piping during backfilling and paving operations.

C. Tightness test the piping at 50 psig before it is buried or connected to the tank.

Soap and examine all connections for leakage.

D. Tightness test the secondary containment piping with 10 psig before it is buried or connected to the tank. Soap and examine all connections for leakage.

3.9 TEST DOCUMENTATION AND REPORTING

A. The Contractor shall document all testing and provide copies to the Owner and authorities having jurisdiction. Test records shall include:

1. Date and time of test.

2. Name of tester.

3. Names of any inspectors present.

4. Test procedure followed.

5. Test results.

B. Provide documentation for all testing with contract close-out documentation to the

Owner.

C. The Contractor shall ensure that future testing is not impaired. The Contractor may be requested to demonstrate the tests as a part of the final approval process.

1. Inspection of tank interstices.

2. Periodic hydrostatic testing of containment sump. Caution: Piping which has contained flammable or combustible liquids may not be air tested under any circumstances. (NFPA 30)

The fuel system includes a fuel supply tank, fuel pump and filter unit, fuel flow measurement module, and a fuel pressure regulating and shutoff valve assembly. The fuel tank assembly consists of an aluminum tank that has a 7500-gallon capacity which is adequate to support full afterburner operation of the F101 for 30 minutes. The tank has two spring-loaded shutoff valves mounted in the bottom. One valve, which is for filling and calibration, includes a pipe adapter with a single point refueling valve and a calibration port. The other valve is complete with a fuel outlet pipe flange for connection to the fuel pump inlet. Other tank accessories include a manhole cover, vent, fuel level float, fuel level sight glass, and fuel level transmitter. The fuel pump is a centrifugal-type pump that is driven by a 20 HP electric motor and has a capacity of 380 GPM at

85 psig. This high capacity pump used in conjunction with system accumulators to ensure adequate fuel supply during acceleration test of the F101 engine. The fuel filter is a 10-micron high capacity filter that is mounted directly downstream of the pump and protects the engine under test. The fuel measurement assembly system incorporates three turbine meters complete with control valves to measure fuel flow rate. The range of the three elements is from 180 PPH to

100,000 PPH. The fuel FILE NO: WR/4920/08- PREPARED BY: David Tribble, WR-ALC/GRVEC, DSN 472-1737 22 pressure regulator and shutoff valve assembly interfaces with the fuel flow piping in the T9 pass-through and the engine supply hose. This assembly includes a 15-gallon accumulator and interface connections to the engine preservation oil system. Fuel pressure is regulated by two valves operating in parallel-one valve provides regulation at low flow rates while the other regulates pressure at high flow rates. Pressure adjustments provide regulation over a range of 25 to 60 psig. The fuel accumulator pipe adaptation assembly at the exterior wall has provisions for interfacing with the GEF101 fuel accumulator furnished by the Air Force. This accumulator has sufficient capacity to operate an F101 engine for several minutes in the event of a fuel pump malfunction. References included, but are not limited to, T.O 33D4-6-737-1 Figure F1 Fuel Flow

Diagram, paragraph 3-4.13 Installation; T.O 33D4-6-737-1 Figure 1-5 Pg 1-9; T.O 33D4-6-737-1

Pg 1-6.2 and 1-7; T.O 33D4-6-728-1 Pg 4-23 for current Fuel Flow Chassis; and drawings

8866703 – Fuel System Installation, 8866940 – Electrical Installation Fuel System, 8866928 –

Fuel Tank And Valve Assembly, JP-4.

4.3.6 Notice of revision (NOR): The Contractor shall submit a Notice of Revision (NOR) with each ECP for Government approval and coordination prior to altering, revising, or otherwise changing any feature of the items involved within the scope of this contract. [CDRL A006, Notice of Revision (NOR,) DI-CMAN-80642C]