Attach-2_13864-14-002__C-Plant_Refrigeration_Sys_SOW.pdf

13864-14-002 NOT SENSITIVE

SPEC NO. 13864-14-002

29 May 2014

STATEMENT OF WORK

FOR

C-PLANT RC12.1, RC12.2, AND RC22.1 REFRIGERATION SYSTEMS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

IRA-1244

ATTACHMENT #2

ATTACHMENT #2

Table of Contents-1

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.2. Non-Government Documents

3. REQUIREMENTS

3.1. General

3.2. Verification and Acceptance

3.3. Submittals

Appendix A – Submittal Procedure

Appendix B – Job Conditions at AEDC

Appendix C – RC12.1, RC12.2, and RC22.1 Interfaces

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1. SCOPE

1.1 The Contractor shall provide up to three refrigeration systems to Arnold Engineering Development Complex (AEDC) at Arnold Air Force Base, Tennessee. This includes delivery and installation of refrigeration units with a 22-foot evaporator shell for each refrigeration unit, the RC12.1, RC12.2, and RC22.1 refrigeration systems. The scope of work includes chiller package, charge of refrigerant and oil, controls and control connections, chilled brine connections, condenser water connections, auxiliary water connections, starters, electrical power connections, and all other equipment required to provide a fully functional chiller. Each refrigeration unit shall include an option to provide a portable refrigerant machine and tank sized for 14,000 pounds of R134A refrigerant. Refrigeration systems shall be designed, fabricated, inspected, tested, delivered, installed, and tested as a fully functional system in accordance with this Statement of Work and Specification 13864-14-001 for use in the C-Plant Airside Building 929. Demolition of the existing refrigeration systems will be performed by the Government and is not included in the scope of work.

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1. Specification Number 13864-14-001 Specification for C-Plant RC12.1, RC12.2, and RC22.1 Refrigeration Systems.

2.1.2. AEDC Safety, Health, and Environmental Standards latest version, available at http://www.aerospacetestingalliance.com/en/vendors/-site-work/safety-standards (applicable only to work performed on-site e.g. warranty work):

A. A2 Mishap Investigation and Reporting.

B. A5 Hazard Abatement Program.

C. A6 with Supplement User and Subcontractor Safety (AEDC Outside Contractor Safety Program).

D. A8 Environmental Impact Analysis Process.

E. A9 Hazard Communication.

F. A10 Job Safety Analysis.

G. B1 Master Work Permit.

H. B2 Lockout/Tagout – LOTO.

I. B3 Control of Hazardous Areas Using Safety Signs, Tags, and Barricades.

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J. B5 Confined Spaces.

K. C2 Contaminated Equipment.

L. D5 with Annex Hoisting Devices (AEDC Hoisting and Rigging Handbook).

M. D6 Aerial Work Platforms.

N. D7 Grinding Wheels.

O. D8 Portable Power Tools.

P. D10 Scaffolds.

Q. E9 Wastewater Discharge Management.

R. E18 Managing Wastes Containing Chemical or Petroleum Products.

S. F2 Personal Protection Equipment (PPE).

T. F5 Hazardous Noise and Hearing Conservation.

2.1.3. AEDC Engineering Standard:

A. AEDC-ENGR-STD-T-2 AEDC Standard Pressure Piping, 2012.

2.1.4. Air Force Federal Acquisition Regulation:

A. AFFARS 2.101 Definitions of Words and Terms.

B. AFFARS 233.401 Use of Recovered Materials Definition.

C. AFFARS 52.223-9 Estimate of Percentage of Recovered Material Content for EPA-Designated Items.

D. AFFARS 5352.223-9000 Elimination of Use of Class I Ozone Depleting Substances (ODS).

2.1.5. Code of Federal Regulations (CFR):

A. 7 CFR 2902 Subpart B Guidelines for Designating Biobased Products for Federal Procurement, Designated Items, 2013.

B. 29 CFR 1926.1101 Asbestos, 2013.

C. 40 CFR 261 Identification and Listing of Hazardous Waste, 2013.

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D. 40 CFR 370 EPA Hazardous Chemical Reporting and Community Right to Know Requirement, 2013.

2.1.6. Occupational Safety and Health Act:

A. FED OSHA 2001 Occupational Safety and Health Act of 1970.

2.1.7. US Army Corp of Engineers:

A. USACE EM 385-1-1 Safety and Health Requirements Manual, 2008.

2.2. Non-Government Documents:

2.2.1. Air-Conditioning, Heating, and Refrigeration Institute:

A. AHRI 550/590-11 Performance Rating Of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle.

B. AHRI 575-08 Method of Measuring Machinery Sound Within an Equipment Space Price.

C. AHRI 740-98 Refrigerant Recover/Recycling Equipment.

2.2.2. American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc:

A. ASHRAE 15 & 34-13 Safety Standard for Refrigeration Systems.

B. ASHRAE-30-95 Methods of Testing Liquid-Chilling Packages.

C. ASHRAE 90.1-13 Energy Standard for Buildings Except Low- Rise Residential Buildings.

2.2.3. ASME International (BPVC):

A. ASME B16.5-13 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard.

B. ASME B31.3-12 Process Piping.

C. ASME B31.5-13 Refrigeration Piping and Heat Transfer Components.

D. ASME SEC VIII-1-13 (BPVC) Rules for Construction of Pressure Vessels.

E. ASME SEC IX-13 (BPVC) Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and

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Welding and Brazing Operators Welding and Brazing Qualifications.

2.2.4. The Institute of Electrical and Electronics Engineers, Inc.:

A. IEEE C37.2-08 Electrical Power System Device Function Numbers, Acronyms, and Contact Designations.

2.2.5. National Electrical Manufacturers Association:

A. NEMA MG 1-11 Motors and Generators.

2.2.6. National Fire Protection Association:

A. NFPA 70-14 National Electrical Code (NEC).

2.2.7. Underwriters Laboratories, Inc.

A. UL 508-13 Industrial Control Equipment.

B. UL 1995-11 Heating and Cooling Equipment.

3. REQUIREMENTS

3.1. General:

3.1.1. Refrigeration systems shall be designed, fabricated, inspected, tested, and shipped to Arnold AFB in accordance with Specification Number 13864-14- 0001 for C-Plant RC12.1, RC12.2, and RC22.1 Refrigeration Systems.

3.1.2. Maximum floor loading capacity when entering the building (8 inch concrete slab at south roll-up door) is 36 kips. Submit a plan demonstrating the floor capacity will not be exceeded prior to unloading chillers in the building.

3.1.3. The refrigeration equipment will be located on the main floor of Building 929, with a basement below. The floor is concrete and beam construction with a design capacity of 500 pounds per square foot. The Contractor shall be responsible for providing calculations to demonstrate that equipment transferred into the building will not overload the floor. Access to Building 929 is through a 20-foot wide by 18-foot height overhead door on the south side of the building.

3.2. Installation:

3.2.1. Contractor and all subcontractor personnel shall comply with Appendix B - Job Conditions requirements at Arnold AFB.

3.2.2. Installation Plan: Submit a detailed installation plan including transport vehicles to be used, structural analysis of floor, and the crane lift plan.

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3.2.3. Piping Material:

A. All pressure piping shall conform to AEDC-ENGR-STD-T-2.

B. Design, installation, and testing shall be per ASME 31.5 and ASME 31.3.

C. All carbon steel components shall be painted per the manufacturer’s instructions. All carbon steel piping to be insulated shall be painted and leak checked prior to insulating.

D. Piping and components that are subjected to sweating shall be insulated as specified by the chiller manufacturer.

E. Design shall incorporate block and bleed valves for the major system components to allow maintenance on one of the chillers without affecting the operation of other chillers. Major components include compressors, evaporators, condensers, and transfer to storage system. AEDC shall provide isolation valves for the brine and water.

3.2.4. Connect piping to interfaces depicted in Appendix C.

3.2.5. Provide vibration isolation for equipment installation.

3.2.6. Piping shall be designed and installed to prevent vibration. Dampers and snubbers may be used.

3.2.7. Install the following minimum piping accessories on evaporator chilled brine piping connections.

A. On inlet:

A. Thermometer well for temperature transmitter.

B. Thermometer well and thermometer.

C. Pressure gage with double block and bleed valves.

D. Additional shut-off valve if AEDC valve does not meet chiller functional requirements.

B. On outlet:

1. Thermometer well and thermometer.

2. Flexible pipe connector.

3. Pressure gage.

4. Additional shut-off or balancing valve, whichever best suits the system design if AEDC valve does not meet chiller function requirements.

3.2.8. Insulate evaporator and cold surfaces per the manufacturer’s recommendation.

3.2.9. Install the following minimum piping accessories on condenser water piping connections.

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A. On inlet:

1. Thermometer well for temperature controller.

2. Thermometer well and thermometer.

3. Nipple and flow switch.

4. Flexible pipe connector.

5. Pressure gage.

6. Additional shut-off valve if AEDC valve does not meet chiller functional requirements.

B. On outlet:

1. Thermometer well and thermometer.

2. Flexible pipe connector.

3. Pressure gage.

4. Water flow control valve to allow unit to maintain functional condensing pressure for the various water flow, temperature and pressure variations.

3.2.10. Arrange piping for easy dismantling to permit tube cleaning.

3.2.11. Install piping from chiller rupture disc to outdoors per ASHRAE 15 and 34.

3.2.12. Provide chiller accessories for field mounting.

3.2.13. The compressor and motor shall be fitted with vertical lifting points.

3.2.14. Provide electrical devices for field mounting.

3.2.15. Install control wiring between chiller control panel and field mounted control devices.

3.2.16. Provide for connection of electrical wiring between starter and chiller control panel and auxiliaries.

3.2.17. Maintenance access: Provide OSHA compliant platforms and ladders to access the units for operations and routine maintenance.

3.2.18. Refrigeration systems shall be installed within defined footprint (see Drawing 3 20-A56 in Appendix C). The footprint dimensions shall not exceed (L) 34 feet- 6 inches, (W) 32 feet, and (H) 30 feet.

3.2.19. Provide refrigerant sampling stations and make them accessible from the floor.

3.3. Verification and Acceptance:

3.3.1. Conform to ASME SEC VIII-1, ASHRAE 15 and 34, and ASHRAE 30 for construction and testing of chillers.

3.3.2. Provide inspection and testing of completed chiller at manufacturer’s facility.

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3.3.3. The Government reserves the right to inspect the chiller and witness factory inspections and test at manufacturer’s factory prior to packaging for shipment.

Notify the Government at least 14 days before testing and packaging is scheduled.

3.3.4. Provide testing and analysis of package chillers.

3.3.5. Conform to UL 1995 code for construction of chillers and furnish UL label.

3.3.6. Demonstrate chiller functionality after on-site commissioning. Demonstrate the chiller controls and reaches exiting brine temperatures over partial to full load operation. Functional testing shall include both air-off and air-on functional tests.

3.3.7. Acceptance: The Government will accept the refrigeration systems upon satisfactory completion of the installation and function testing by the Contractor.

3.4. Submittals: The Contractor shall submit all documentation in accordance with Appendix A – Submittal Procedure. A summary table of required submittals is listed at the end of this section.

3.4.1. General Arrangement Drawings:

A. Drawings/Manual: Indicate components, assembly, dimensions, weights and loads, required clearances, and location and size of field connections.

Indicate equipment, piping and connections, valves, strainers, and any other components required for complete system:

1. Final assembly design drawings.

2. Bills of material, details, and assembly information.

3. Manufacturer's Installation Instructions: Submit assembly, support details, connection requirements, and include start-up instructions.

B. Product Data: Submit rated capacities, specialties and accessories, electrical requirements and wiring diagrams.

C. Design Data: Indicate energy input versus cooling load output from 25 to 100 percent of full load at condenser water conditions of 80 deg. F, 100 psig.

D. Test Procedures: Provide pressure test and chiller performance test procedures.

E. Test Results Reports:

1. Weld examinations

2. Start-up report

3. Leak tests

4. Pressure tests

5. Field performance tests.

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F. Manufacturer's Certificate: Certify products meet or exceed specified requirements including components not produced by manufacturer.

G. Weld procedures and welder qualifications.

H. Provide all special tool(s) required to perform maintenance.

I. Warranty: The Contractor shall submit warranty for materials and labor.

Submit a 2 year manufacturer warranty to include coverage for compressor, compressor motor, compressor controls, motor soft starter, evaporator, condenser, complete chiller package as manufactured and delivered to site, and assembled on site, including materials and labor.

Warranty (or manufacturer’s standard warranty) for each refrigeration system shall commence upon each system’s acceptance by Government.

J. Two paper copies and 1 electronic copy of Operation and Maintenance manuals.

1. Operational instructions – start up, monitoring, stopping, including a trouble-shooting guide.

2. Maintenance instructions.

3. Spare Parts lists.

4. As-Built drawings (AutoCAD 2005 or later version and PDF format).

3.4.2. Manufacturing Plan and Schedule with Milestones: At a minimum the plan and schedule shall include:

A. Performance calculations and analysis delivery date.

B. Design completion date.

C. Fabrication/assembly completion date.

D. Factory test date.

E. Arrival at AEDC date.

F. Installation completion date

G. Onsite functional test date.

3.4.3. Engineering Analysis and Calculations for the Refrigeration System:

A. Refrigeration system performance estimates which shall include methods and calculations used to determine such estimates.

3.4.4. Manufacturer's Field Support and Training:

A. After acceptance of unit, furnish support of factory trained representative for minimum 30 days to leak test, pressure test, evacuate, dehydrate, Page-9 charge, leak check, start-up, calibrate controls, and instruct Government on operation and maintenance.

B. Training: The Contractor shall provide separate operations and maintenance training. Each shall consist of in-class and hands-on sessions lasting a maximum of 4 hours each (8 hours total). Each shall be taught twice, once to first shift personnel from 0700 to 1500 hours and once to second shift personnel from 1500 to 2300 hours.

C. Training manuals.

D. Furnish initial charge of refrigerant and oil plus 10 percent.

3.4.5. Submittal Table:

Table 1 - Required Submittal List

No. Section Reference Submittal Description Due

1 3.2.2 Installation and crane lift plan 10 days after contract award

2 3.4.1.A Drawings and manuals 14 days prior to design review

3 3.4.1.B Product data 14 days prior to design review

4 3.4.1.C Design data 14 days prior to design review

5 3.4.1.D Test procedures 14 days prior to testing

6 3.4.1.E.1 Weld examinations 14 days after test completion

7 3.4.1.E.2 Start-up report 14 days after test completion

8 3.4.1.E.3 Leak tests 14 days after test completion

9 3.4.1.E.4 Pressure Tests 14 days after test completion

10 3.4.1.E.5 Field performance test 14 days after test completion

11 3.4.1.F Manufacturer’s certification 14 days after test completion

12 3.4.1.G Weld procedures and welder qualifications

14 days prior to field installation

13 3.4.1.H Special maintenance tool(s) 14 days after commissioning

14 3.4.1.I Warranty 14 days after commissioning

15 3.4.1.J Operation and maintenance manuals 14 days prior to unit commissioning

16 3.4.2 Manufacturing plan and schedule 10 days after contract award

17 3.4.3 Engineering analysis and calculations 14 days prior to design review

18 3.4.4 Manufacturer’s field services and training

14 days prior to unit commissioning

19 3.4.4.C Training manuals 14 days prior to unit commissioning

20 Appendix A 1.2.B Summarized submittal list 10 days after contract award

21 Appendix B 1.3.C Outage request 2 weeks prior to outage

22 Appendix B 1.3.N Proposed scaffolding Before beginning work

23 Appendix B 1.4.B Existing conditions report which could be construed as damage resulting from work

Before beginning work

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No. Section Reference Submittal Description Due

24 Appendix B 1.5.A Safety and health plan 10 days after contract award

25 Appendix B 1.6.A Form GC-1785 Prior to disposal

26 Appendix B 1.9.A.2 Percentage of recovered material content

Before final inspection

27 Appendix B 1.11.A Disallowed products locations Before final inspection

28 Appendix B 1.12.A Asbestos locations Before final inspection

29 Appendix B 1.13.A Forms GC-565 and GC-1337 Before final inspection

30 Appendix B 1.14.A.1.a Hazardous material info Before beginning on-site work

Appendix A-1

APPENDIX A

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the specification or statement of work.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime contractor.

B. Listing: At the end of the Statement of Work is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents. The listing may not be all inclusive and additional item submittals may be required. Within 10 days after receiving contract award, Contractor shall submit a copy of the summarized submittal listing with calendar dates assigned to each item submittal indicating when submittal will be received by the Government. If contract requires a pre-construction conference, Contractor may submit completed submittal listing at the conference.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received. Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit

Appendix A-2 related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 10 working days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals.

Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to

Appendix A-3 the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 10 working days beyond normal submittal review period for consideration by the Government of submittals with deviations.

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 10 working days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the applicable specification section or Statement of Work (SOW). Except as otherwise indicated in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop

Appendix A-4 drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy.

B. Product Data: This data includes standard printed information on manufactured products that has not been specially prepared for this contract, including manufacturers' product specifications illustrating size, physical appearance and other characteristics of materials, installation instructions, standard color charts, catalog cuts, illustrations, schedules, standard wiring diagrams, standard product operating and maintenance manuals, and samples of warranty language when the contract requires extended product warranties. General information required specifically as product data includes manufacturers' standard printed recommendations for application and use, compliance with recognized standards of trade associations and testing agencies, the application of their labels and seals (if any), special notation of dimensions which have been verified by way of field measurement, and special coordination requirements for interfacing the material, product, or system with other work. Furnish three hard copies and one electronic copy.

C. Design Data: Design data includes design calculations, analyses or other data pertaining to a part of work. Refer to individual sections of the specification or statement of work for required quantities, formats, and signatures or certifications required. Furnish three hard copies and one electronic copy.

D. Test Reports: These include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements. Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

Appendix A-5

E. Manufacturer’s Instructions: Preprinted material describing installation of a product, system or material, including special notices and Material Safety Data sheets concerning impedances, hazards and safety precautions.

Furnish three hard copies and one electronic copy.

F. Operation and Maintenance Data: Data furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer’s help and product line documentation necessary to maintain and install the equipment, and needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. The data is intended to be incorporated in an operations and maintenance manual or control system.

Furnish two hard copies and one electronic copy.

G. Final Design Drawings and Documentation: Final design documentation including drawings, specifications, estimates, and other required deliverables. Electronic documentation submitted shall include every associated component file of drawings and other documentation, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Furnish a CD-ROM of all final design documentation, and drawings in AutoCAD 2005 format or later, to the Contracting Officer for approval prior to applying for final payment.

H. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Project photographs. Furnish both hard copies and digital files.

2. Qualification certificates. Furnish one hard copy and one electronic copy.

3. Warranties.

Appendix B-1

APPENDIX B

JOB CONDITIONS AT AEDC

PART 1 GENERAL

1.1 DEFINITIONS

A. Certain terms used in the contract documents are defined below.

Definitions and explanations contained in this section are not complete, but are general for the work to the extent that they are not stated more explicitly in another element of the contract documents.

1. Furnish. The term "furnish" means to supply and deliver to the project site, ready for unloading, unpacking, assembly, installation, and similar operations.

2. Install. The term "install" describes operations at the project site, including the actual unloading, unpacking, assembly, erection, placing, anchoring, applying, working to dimensions, finishing, curing, protecting, cleaning, and similar operations.

3. Provide. The term "provide" means "provide complete in place";

that is, "furnish and install.”

4. Indicated. Where "as indicated" or words of similar import are used, it shall be understood that the reference is made to the drawings accompanying this contract unless stated otherwise.

5. Postconsumer material (FAR 52.223-9): a material or finished product that has served its intended use and has been discarded for disposal or recover, having completed its life as a consumer item. Postconsumer material is a part of the broader category of “recovered materials”.

6. Recovered material (FAR 2.101): waste materials and by-products recovered or diverted from solid waste. The term does not include those materials and by-products generated from, and commonly reused within, an original manufacturing process.

7. Biobased product (FAR 2.101): a product determined by the U.S.

Department of Agriculture (USDA) to be a commercial or industrial product (other than food or feed) that is composed, in whole or in significant part, of biological products, including renewable domestic agricultural materials (including plant, animal, and marine materials) or forestry materials.

8. USDA-designated item (FAR 233.401): a generic grouping of products that are or can be made with Biobased materials (1) that is listed by USDA in a procurement guideline (7 CFR 2902, Subpart B); and (2) for which USDA has provided purchasing recommendations.

Appendix B-2

1.2 CODES AND STANDARDS

A. AEDC Safety, Health, and Environmental Standards latest version, available at http://www.aerospacetestingalliance.com/en/vendors/-site-work/safety-standards:

1. A2 Mishap Investigation and Reporting.

2. A5 Hazard Abatement Program.

3. A6 with Supplement User and Subcontractor Safety (AEDC

Outside Contractor Safety Program).

4. A8 Environmental Impact Analysis Process.

5. A9 Hazard Communication.

6. A10 Job Safety Analysis.

7. B1 Master Work Permit.

8. B2 Lockout/Tagout (LOTO).

9. B3 Control of Hazardous Areas Using

Safety Signs, Tags, and Barricades.

10. B5 Confined Spaces.

11. C2 Contaminated Equipment.

12. D5 with Annex Hoisting Devices (AEDC Hoisting and

Rigging Handbook).

13. D6 Aerial Work Platforms.

14. D7 Grinding Wheels.

15. D8 Portable Power Tools.

16. D10 Scaffolds.

17. E9 Wastewater Discharge Management.

18. E18 Managing Wastes Containing Chemical or Petroleum Products.

19. F2 Personal Protection Equipment (PPE).

20. F4 Respiratory Protection.

21. F5 Hazardous Noise and Hearing

Conservation.

B. Air Force Federal Acquisition Regulation:

1. AFFARS 2.101 Definitions of Words and Terms.

2. AFFARS 233.401 Use of Recovered Materials Definition.

3. AFFARS 52.223-9 Estimate of Percentage of Recovered

Material Content for EPA-Designated Items.

4. AFFARS 5352.223-9000 Elimination of Use of Class I Ozone Depleting Substances (ODS).

C. Code of Federal Regulations (CFR):

1. 7 CFR 2902 Subpart B Guidelines for Designating Biobased

Products for Federal Procurement, Designated Items, 2013.

2. 29 CFR 1926.1101 Asbestos, 2013.

3. 40 CFR 261 Identification and Listing of Hazardous

Waste, 2013.

Appendix B-3

4. 40 CFR 370 EPA Hazardous Chemical Reporting and Community Right to Know Requirement, 2013.

D. US Army Corp of Engineers:

1. USACE EM 385-1-1 Safety and Health Requirements

Manual, 2008.

1.3 JOB CONDITIONS

A. Work shall be performed in a test area. Plan and execute this project in a manner to minimize downtime. Schedule all work in advance with the Government Representative. Total downtime duration shall not exceed 4 months.

B. Furnish new components and devices, complete, with all necessary materials for installation to meet this objective.

C. Do not interrupt existing utilities or commence power outages without signed authorization from the Government Representative. Submit each utility outage request for Government approval at least two weeks prior to each requested outage date. Outages may be granted depending upon the Government’s schedule for facility use, and may occur on weekends and/or holidays.

D. A 100 ton overhead crane in Building 929 is available for Contractor’s use.

Contractor shall coordinate crane use and provide certified crane operator.

AEDC will certify operator.

E. Keep work area clean and free from waste and debris. Dispose of waste as directed by the Government Representative.

F. Do not close or obstruct egress width to any building or site exit without written permission from the Government Representative.

G. Do not disable or disrupt building fire or life safety systems without written permission from the Government Representative.

H. Conform to applicable procedures when any hazardous or contaminated materials are discovered.

I. Cease operations immediately for any unsafe conditions and notify the Government Representative. Do not resume operations until authorized by the Government Representative.

J. Provide temporary barricades and other forms of protection as required to protect Government personnel and the general public from injury due to the work. Provide temporary signage as needed or directed.

Appendix B-4

K. Remove protections at the completion of work.

L. Do not close, block, or otherwise obstruct streets, walks, or other occupied or used facilities without written permission from the Contracting officer.

M. Submit sketches of proposed scaffolding, if utilized. All scaffolding shall be in accordance with AEDC Safety Standard D10 and shall be inspected, approved, and tagged by AEDC Safety Representative after it has been erected and prior to use.

1.4 PROTECTION OF EXISTING IMPROVEMENTS:

A. Protection of the grounds, walkways and structures from deterioration due to excessive vehicular traffic, equipment disturbance, and material staging is critical to maintaining the quality appearance of AEDC. The Contractor shall protect against damage incurred by service vehicles, construction activities, maintenance and repair, and all other work that detracts from the overall appearance of the grounds and increases the costs of grounds maintenance.

B. Prior to commencement of work, inspect areas in which work will be performed. Submit a report with the Contracting Officer listing existing conditions which could be construed as damage resulting from the work.

The Government Representative may also photograph or video tape areas or improvements susceptible to damage to document conditions prior to the start of work.

C. The activity of vehicles and equipment on the grounds shall be limited to only that which is essential and required for completing the work. The Government Representative will approve all access and haul routes required for the work prior to any on site operations to preclude damage to sensitive utilities or improvements which may not be readily apparent.

D. Minimize travel paths and staging areas to limit the impact and damage to work areas. Lay out the work site, material and equipment staging, and vehicle and equipment activity to minimize visibility and aesthetic impact of activities to surrounding areas.

E. Protect above and below grade utilities, plant life, lawns, and other features or improvements to remain.

F. Protect benchmarks, existing structures, sidewalks, curbs, and pavements from excavation equipment and vehicular traffic.

G. Use protective materials, such as sheeting, steel plating, rigger pads, to protect grounds and pavement from heavy equipment activity and damage.

Appendix B-5

H. Protect existing facilities from falling debris during construction such as roof materials, ductwork scraps, or other materials, by use of protective materials such as sheeting, steel plates, netting, or other materials.

I. Provide temporary weather protection during any interval between demolition and removal of existing construction on exterior surfaces and installation of new construction to ensure no water leakage or damage occurs to the structure, interior areas, or contents of the existing facility.

J. Implement a daily procedure for area clean up and organized parking of vehicles and equipment.

K. Provide temporary barricades, shoring, bracing, supports or other forms of protection as required to protect all existing improvements not scheduled to be demolished for both above and below ground improvements and to prevent movement, settlement, collapse or damage of any kind.

L. Maintain personnel and vehicular access and existing utilities to all buildings and other structures during the course of the work. Any changes or interruptions shall be coordinated and approved by the Government Representative well in advance. Temporary protections or services may be required as a condition of approval of any such change or interruption.

M. The Contractor shall be responsible for damage caused by the work and shall repair or replace same to the satisfaction of the Government. Obtain Government Representative’s approval of methods, materials, equipment or products for repair or replacement prior to use. All such repair or replacement shall be performed promptly at no additional cost to the Government. The Government will place special emphasis and requirements for repair or replacement of damage to underground utilities, lawns, grassed areas, existing structures, sidewalks, curbing, railings and pavements.

N. Remove all temporary barricades, shoring, bracing, supports or other forms of protection at completion of work. Restore all adjacent structures and surfaces to conditions existing prior to construction. Clean up all stockpiles and spoil areas, and restore all surrounding areas to conditions existing prior to construction.

1.5 SAFETY REQUIREMENTS:

A. All work shall be accomplished in compliance with AEDC Safety Standards A2, A5, A6 with supplement, A8, A9, A10, B1, B2, B3, B5, C2, D5 with Annex, D6, D7, D8, D10, E9, E18, F2, F4, and F5. Submit a safety and health plan in accordance with AEDC Safety Standard A6 and

USACE EM 385-1-1.

Appendix B-6

1.6 DISPOSAL OF CONTAMINATED EQUIPMENT

A. The Contractor shall clean equipment or material of contaminants prior to disposal at the AEDC Salvage Yard (with the exception of lead paint, unless the paint is flaking in which case the flaking paint shall be removed prior to transport to prevent contamination during transport). If cleaned equipment is to be turned-in to the Government for storage or excessing, a GC-1785, Special Material Turn-in Certification, shall be completed and submitted to the Government with the equipment or material prior to disposal. The Government Representative will assist the Contractor in filling out the form and in coordinating with Industrial Hygiene and Environmental Quality.

1.7 CONNECTIONS TO POTABLE WATER

A. Contractor shall not make any connections to an AEDC potable water system without specific approval from the Government Representative.

B. Notify Government Representative if connections to hose bibs are needed. Do not connect to any hose bibs without Government-supplied backflow preventer and specific approval from Government Representative.

1.8 TOOL CONTROL: Coordinate tool control with the Government Representative.

1.9 EPA-DESIGNATED ITEMS

A. The Contractor, on completion of this contract in accordance with AFFARS 52.223-9, shall:

1. Estimate the percentage of the total recovered material content for

EPA-designated item(s) delivered and/or used in contract performance, including, if applicable, the percentage of post-consumer material content; and

2. Submit this estimate to the Contracting Officer.

1.10 ELIMINATION OF ODS CHEMICALS

A. The use of Class I ozone depleting substances (ODS) is prohibited.

Reference text of AFFARS clause 5352.223-9000.

1.11 DISALLOWED PRODUCTS

A. Do not use products or materials that contain lead, chromium, mercury, cadmium, silver, barium, selenium, beryllium, or arsenic on this project except as expressly authorized by the Contracting Officer. If no substitutes for products containing the listed materials are available, and the Contracting Officer approves the use of products containing the listed materials, highlight and detail their exact location on the drawings.

Appendix B-7

1.12 ASBESTOS PRODUCTS

A. Do not use products or materials that contain asbestos on this project except as expressly authorized by the Contracting Officer. If no substitutes for asbestos products are available, and the Contracting Officer approves the use of asbestos products, highlight and detail their exact location on the drawings and identify their location in the field following 29 CFR

1926.1101 guidelines. Asbestos abatement l may be required in the scope of this effort. All asbestos abatement shall follow requirements of Appendix D and AEDC SHE Standard.

1.13 WASTE MATERIALS

A. Hazardous Waste: Where hazardous waste (as identified in 40 CFR 261) is generated, follow the procedures in AEDC Safety Standard E18, Chemical and Petroleum Products Waste Management, for storing and disposing of hazardous waste. These procedures include the requirement to complete Forms GC-565 and GC-1337, which will be furnished by the Government. Disposal costs are the sole responsibility of the Contractor.

Storage and disposal of all hazardous waste must be coordinated with the Government. Disposal facilities must be approved by the Government prior to shipment. All waste profiles and manifest will be coordinated through the Government.

B. Non-Hazardous and Special Solid Waste: Where non-hazardous and special hazardous waste is generated, follow the procedures in AEDC Safety Standard E18, Chemical and Petroleum Products Waste Management, for storing and disposal in hazardous waste. These procedures include the requirement to complete Forms GC-565 and GC- 1337, which will be furnished by the Government Representative. Disposal costs are the sole responsibility of the contractor. Storage and Disposal of all hazardous waste must be coordinated with the Government. Disposal facilities must be approved by the Government prior to shipment. All waste profiles and manifest will be coordinated through the Government.

C. Construction Waste: Where construction waste is generated the AEDC Construction Landfill can be used for disposal. Construction waste is defined as masonry, wood, rebar, and paving material. Any use of the AEDC construction landfill must be coordinated with Government and comply with the requirements of the AEDC Construction Landfill Permit No. DML 16-102-0027.

D. Sanitary Waste: Food stuffs and other garbage type waste are to be disposed of in the base brown dumpsters. If location and storage volume is not advantageous the contractor can arrange at their expense supplemental sanitary waste disposal. Use of supplemental sanitary storage must be coordinated with the Government.

Appendix B-8

E. Wastewater: All wastewater must be contained and managed in accordance with AEDC Safety Standard E9 and E18. Storage and Disposal of all wastewater shall be coordinated with the Government.

Disposal facilities will be approved by the Government prior to shipment.

Disposal costs are the sole responsibility of the Contractor. All waste profiles and manifest shall be coordinated through the Government.

1.14 HAZARDOUS MATERIAL IDENTIFICATION AND MATERIAL SAFETY DATA

A. The following procedures shall be followed to meet 40 CFR 370, EPA Hazardous Chemical Reporting and Community Right to Know Requirement.

1. Procedures:

a. The Contractor shall furnish information on the hazardous materials he brings on AEDC property prior to beginning on-site work. Hazardous materials may include solvents, paints, adhesives, acids, or any other substance which could be included within the definitions in paragraph 2.

b. The information required is:

1) Company name, point of contact, and phone number.

2) Brief statement indicating how the hazardous material will be used within the scope of the contract.

3) List of all hazardous materials to be used (product name, manufacturer’s name, and address).

4) Amount of each material to be stored on site and where it will be stored.

5) Where the product Material Safety Data Sheets

(MSDS) will be maintained.

c. All unused product is the responsibility of the Contractor and shall be removed from AEDC property at the completion of the project.

d. The Contractor shall coordinate with the Government Representative and the Hazardous Waste Operations Group (454-3628) if any hazardous waste is to be generated.

2. Definitions

a. Hazard communication standard. A chemical right-to-know law under OSHA that requires chemical manufacturers and importers to assess the hazards of chemicals they make or import and to distribute this information to inform workers of the hazards associated with these chemicals. This written information is a Material Safety Data Sheet (MSDS).

b. Hazard classes. Hazardous materials that have been grouped into classes by the Department of Transportation (DOT). These classes include explosives, flammables, oxidizers and organic peroxides, compressed gases, corrosives, and poisons.

c. Hazardous material. Any substance that may be harmful when used. Specific substances have been designated as

Appendix B-9 hazardous under the Clean Water Act, the Resource and Conservation and Recovery Act, and the hazardous air pollutants under the Clean Air Act.

d. Hazardous waste. Any waste that may cause or significantly contribute to serious illness or death or that may pose a substantial threat to human health or the environment, if not properly managed. Hazardous wastes may be solids, liquids, semi-solids, or compressed gases.

1.15 PROPRIETARY AND BRAND NAMES: Proprietary and brand names used in this document are meant to describe physical, performance, and quality characteristics of items and materials, and are not meant to limit competition or exclude Contractors or Manufacturers from submitting like products to the Contracting Officer for approval.

1.16 Job-site bathroom facilities: The Contractor shall provide and manage portable bathroom facilities appropriate for the number of workers on site. At no time will waste from portable toilets be emptied into AEDC storm or sewage drainage system.

Appendix C-1

APPENDIX C

INTERFACES

PART 1 GENERAL

1.1 Description Of Requirements. This section specifies the system interfaces for RC12.1, RC12.2, and RC22.1.

1.2 RC12.1 Interfaces:

1.2.1 Brine (ref. DMJM Drawing 4-20-M205):

A. Brine In - Flange upstream BV.RC12.14 or at branch connection.

B. Brine Exit – Flange upstream of BV.RC12.12 or at branch connection.

1.2.2 Water (ref. DMJM Drawing 4-20-M227):

A. Condenser (~10,000 gpm available, 80 to 120 psig supply, 40 to 80 degrees F – typical all units).

1. Water In – new valve downstream new automatic strainer (device

no. unknown at this time – not yet installed).

2. Water Out – flange downstream of WV.RC12.27 or at branch connection.

B. Auxiliary:

1. Water In – Strainer CW-ST2-RU.

2. Water Out – 3” line off main return header.

1.2.3 Power:

A. Chiller Motors: Existing Switchgear Section A3A Siemens GIS breaker numbers 89-3 and 89-4 (6.9 kV).

B. Lube oil and PLC requires an uninterruptable power supply (UPS). (480 volt and 120 volt).

1.2.4 Instrument Air– At valve AAV.AA.755.

1.2.5 Refrigerant:

A. Vapor – downstream unit’s isolation valves.

B. Liquid - downstream unit’s isolation valves.

Appendix C-2

1.2.6 Instrumentation and Controls (I&C)

A. A commercially-available programmable logic controller (PLC) with an Ethernet connection to the existing plant operations network will be the primary AEDC I&C interface. Specific requirements of the Ethernet topology, communication protocol, and HMI interface details are provided in the chiller specification (13864-14-001).

B.…