FARM II Attachment 7 Seed Project SOW_dwgs.pdf

FACILITIES ACQUISITIONS

FOR

RESTORATION AND MODERNIZATION

(FARM) II

TASK ORDER (TO) TITLE: Leg 2 Isolation Valve

STATEMENT OF WORK

(SOW)

AEDC Turbine Engine Altitude Ground T&E

DoD Large Turbine Engine C-Plant

00014941

Design and Install a Leg 2 Isolation Valve

IRL ID: arTSTB177

9 June 2021

Distribution A. Approved for Public Release.

IRA- 3836

Atch 7

FA9101-21-R-0001

Distribution A. Approved for Public Release.

IRA-3836 Index - 1

TABLE OF CONTENTS

1 Scope

1.1 Introduction

1.2 Background

2 APPLICABLE DOCUMENTS

2.1 References, Regulatory, Codes, and Standard Design and Construction Criteria Standards

2.1.1 Publications

2.1.2 AEDC Operating Instructions and Standards

2.1.3 AEDC Safety, Health, and Environmental (SHE) Standards

2.1.4 Regulations

2.1.5 Air Force Engineering Technical Letters

2.1.6 Air Force Instruction (AFI)

2.1.7 Air Force Manuals and Military Handbooks

2.2 Drawings

2.2.1 Contract Drawings

2.2.2 Reference Drawings

2.3 Specifications

2.4 Contracts

2.4.1 FARM II Contract

3 Requirements

3.1 Fast Track

3.2 Meetings

3.4 Statement of Work Tasks

3.4.1 Task 1: Design Leg 2 Isolation Valve and Ducting Modifications

3.4.2 Task 2: Design a Work Platform

3.4.3 Task 3: Modify Ducting, Build and Install Isolation Valve

3.4.4 Task 4: Build and Install Work Platform

3.5 Design Reviews

3.6 Construction:

IRA-3836 Index - 2

3.7 Outages

3.8 Verification and Testing

3.8.1 Verification and Validation (V&V)

3.8.2 Testing and Inspection Responsibilities

3.8.3 Inspection

3.8.4 Demonstration

3.8.5 Acceptance

3.8.6 Factory Acceptance Testing (FAT)

3.8.7 Site Acceptance Testing (SAT)

3.8.8 User Acceptance Testing (UAT)

3.9 Demolition

3.10 Submittals

3.11 Government-Furnished Equipment/Property

3.12 Exclusions

3.13 Historical

APPENDIX A - REFERENCE DOCUMENTS ............................................................ A - 1

APPENDIX B - DRAWINGS ....................................................................................... B - 1

APPENDIX C - SPECIFICATIONS............................................................................ C - 1

APPENDIX D – PHOTOGRAPHS ............................................................................. D - 1

APPENDIX E - DESIGN SUBMITTAL ITEMS ............................................................ E - 1

APPENDIX F - DESIGN SUBMITTAL REQUIREMENTS .......................................... F - 1

IRA-3836 Index - 3

APPENDICES

Appendix A – Reference Documents

Appendix B – Drawings

Appendix C – Specifications

Appendix D – Photographs

Appendix E – Design Submittal Items

Appendix F – Design Submittal Requirements

IRA-3836 Page - 1

1 SCOPE

This TO SOW describes the design, fabrication, procurement, installation and checkout of the proposed system to meet the requirements stated in this SOW.

The contractor shall provide all labor, materials, equipment, transportation, supervision, quality control and other items necessary to design, manage and accomplish the work. The contractor shall participate in site visits as required to obtain information, perform site surveys and conduct design reviews with the Government. The work includes but is not limited to ducting modifications, and installation of a valve, support structure, footings, electrical power/control wiring, and a work platform. The existing flange pair gaskets are anticipated to contain asbestos and shall be handled in accordance with (IAW) the requirements herein.

1.1 Introduction

The C-Plant Airside system provides pressurized process air supply in support of turbine engine test cells at Arnold AFB, TN. The system includes four low stage and two high stage compressor drives with process air distribution ducting and conditioning equipment for regulating pressure, temperature and flow of inlet air to turbine test cells.

1.2 Background

To perform maintenance affecting ducting to C cells, all flow must be stopped, which also interrupts supply to other test areas such as J and Sea Level (SL) cells. The addition of an isolation valve as described in this TO SOW will provide needed isolation with no interruption of service to the other test areas. See photograph D-1, in Appendix D.

2 APPLICABLE DOCUMENTS

2.1 References, Regulatory, Codes, and Standard Design and Construction Criteria Standards:

The FARM II Contract SOW Attachment 1 contains a list of the organizations, instructions, standards, regulations, letters, manuals, and handbooks. It shall be the contractor’s responsibility to identify and comply with these documents. The following paragraphs list additional organizations or documents that apply this TO

SOW.

2.1.1 Publications

N/A.

2.1.2 AEDC Operating Instructions and Standards

N/A.

IRA-3836 Page - 2

2.1.3 AEDC Safety, Health, and Environmental (SHE) Standards

N/A.

2.1.4 Regulations

N/A.

2.1.5 Air Force Engineering Technical Letters

N/A.

2.1.6 Air Force Instruction (AFI)

N/A.

2.1.7 Air Force Manuals and Military Handbooks

N/A.

2.2 Drawings

2.2.1 Contract Drawings

N/A.

2.2.2 Reference Drawings

The reference drawings in Appendix B of existing infrastructure, systems, structures, and conditions are provided “for information only”.

The information on these drawings may or may not reflect exact conditions at the current site. It is at the contractor’s expense and it is the contractor’s responsibility to verify applicable conditions and dimensions before proceeding with any work.

2.3 Specifications

2.3.1 The contractor shall generate specifications to be used during the construction of the proposed solution. The contractor shall determine applicable sections to be included in the construction documents.

Specifications shall not be marked “proprietary” or “company confidential.” All contractor-generated specifications will become the property of the Government.

2.3.2 The FARM II Contract SOW Attachment 1, paragraph 1.1, lists the Construction Specifications Institute (CSI) MasterFormat specifications 02 08 00 Asbestos Removal and 02 08 50 Lead and Heavy Metal Removal, which shall be included in the contractor specifications, as applicable. TO specific sections are listed below and are provided in Appendix C. The contractor shall include these additional specification sections in its Construction Specification.

A. 01 74 19 – Construction Waste Management and Disposal.

B. 23 09 13 – Configuration Valves.

IRA-3836 Page - 3

2.4 Contracts

2.4.1 FARM II Contract.

3 REQUIREMENTS

3.1 Fast Track:

The contractor will be allowed to use the fast-track method for the design and procurement of equipment for this project IAW with FARM II Contract SOW 3.8.

Fast-tracking for this TO means that the contractor shall be allowed to phase the completion of the design documents with the purchase of long lead materials and equipment.

3.2 Meetings:

3.2.1 All meetings shall be conducted at Arnold AFB unless otherwise specified by the Government.

3.2.2 In addition to the design review meetings, each month the contractor shall meet with the Government representative or designee to discuss the project status. The contractor shall provide a report at the meeting that includes the following:

A. Project schedule update including percent complete status of activities

B. Identification of all issues or conflicts.

C. During the project execution phase (construction performance period), the contractor shall meet bi-weekly with the Government representative to provide a status update and coordinate activities.

D. During outage periods, the contractor shall meet with the Government representative daily, or as requested, to provide an update on the status and coordinate activities.

3.3 General:

3.3.1 For each task listed in paragraph 3.4, the contractor shall perform all activities to meet the Government performance criteria and the detailed requirements in the following paragraphs.

3.4 Statement of Work Tasks: This statement of work (SOW) consists of the following items:

• Task 1: Design Leg 2 Isolation Valve, Supports and Duct Modifications

• Task 2: Design a Work Platform

• Task 3: Modify Ducting, Build and Install Isolation Valve

• Task 4: Build and Install Work Platform

IRA-3836 Page - 4

3.4.1 Task 1: Design Leg 2 Isolation Valve and Ducting Modifications

A. Requirements for configuration valves are specified in Attachment 23 09 13 Configuration Valves. This specification establishes the requirements for stainless steel configuration valves and associated electric motorized actuators to be used in process air ducting in the Arnold AFB turbine engine test facilities. The subject valve (see C – 1, Valve Requirements Summary Table, Appendix C) shall be a triple offset butterfly type with flanged ends. Valve size, pressure/temperature ratings, and minimum required Cv(s) shall be specified by the contractor in a table entitled Ducting and Valve Design and Performance Requirements and shall be placed on the contract drawings. The valve shall conform to American National Standards Institute (ANSI)/Fluid Controls Institute (FCI) 70-2 Class V and fit into the spool section space containing the existing removable venturi.

Any shortfall in length shall be made up by a short, contractor supplied, spool section. The contractor design must be capable of being removed and replaced with the original venture spool section using existing flanges. See Appendix B, drawing 5-00- D349 detail 5 and 6. The valve shall be designed to withstand a maximum differential pressure (ΔP) across the valve disk of 159 psid.

B. Asbestos containing gaskets are anticipated at all flange pairs;

therefore, comply with Specification 02 08 00 Asbestos Removal during disassembly.

C. Unless otherwise specified, ductwork fabrication and installation shall conform to American Society of Mechanical Engineers (ASME) Section VIII, Division 1. Design ducting modifications, valve and related support components IAW this SOW and all applicable codes, shall be rated for the following process air flow conditions:

1. Pressure range 0.5 psia to 159 psia

2. Temperature range -24F to 408F

3. Mass Flow 1550 lbm/sec

4. Pressure drop less than 0.5 psid at 1550 lbm/sec, 30 psia, and 250F

D. The ducting foundations and support structures shall not interfere with existing service road access – see photograph in Appendix D, D-2. All foundation design and fabrication shall be IAW applicable codes referenced in the TO SOW. Driven piles shall not be allowed. The contractor shall consider the location of existing underground utilities, existing foundations and other buried structures. Foundation design shall be similar to existing.

IRA-3836 Page - 5

Both permanent and temporary demolition supports shall be designed and/or approved by the Government.

E. All support structures shall be IAW applicable codes referenced.

The design shall incorporate restraints (removable or permanent) that will stabilize the ducting when the subject valve is removed.

3.4.2 Task 2: Design a Work Platform

A. Design a permanent work platform that allows valve inspection and service from both sides of the ducting. Provide integral ladder access to each side. The work platform shall be similar to the adjacent installation in leg 3 at valve AV.A.8 shown in Appendix D, D-4, and designed IAW applicable codes, OSHA and industry standards.

3.4.3 Task 3: Modify Ducting, Build and Install Isolation Valve

A. Install new hardware per approved design package produced in Task 1.

B. Paint all new carbon steel material to be similar in color to surrounding components per AEDC CCP-100, AEDC Protective Coatings and Corrosion Control Program, System #3, Alternate #1, Finish coat Aluminum.

3.4.4 Task 4: Build and Install Work Platform

A. Build and install all equipment IAW relevant OSHA and industry standards. Submit installation plan and schedule in conjunction with Task 3.

B. Install new hardware per approved design package produced in Task 2.

C. Paint all new carbon steel material to be similar in color to surrounding components per AEDC CCP-100, AEDC Protective Coatings and Corrosion Control Program, System #3, Alternate #1, Finish coat Aluminum. Handrails shall be painted Safety Yellow.

3.5 Design Reviews

The Government requires as a minimum, the design reviews described in paragraphs 3.5.1 through 3.5.5 and the items defined in Appendix F. Value engineering should be considered in the design review process in regards to the number of design reviews and content. During the design phase, the contractor may propose additional or fewer design reviews as well as tailoring the design review content. Any deviation from the below must be approved in writing by the

CO.

IRA-3836 Page - 6

3.5.1 10-Percent Design N/A.

3.5.2 30-Percent Design 30-Percent Design is required and the design submittal requirements are stated in Appendix F.

3.5.3 60-Percent Design N/A.

3.5.4 90-Percent Design 90-Percent Design is required and the design submittal requirements are stated in Appendix F.

3.5.5 Final Design

Final Design is required and the design submittal requirements are stated in Appendix F.

3.6 Construction: Refer to Attachment 1-1, Addendum to Statement of Work (Arnold, AFB) FARM II Contract SOW for construction requirements and site specific job conditions. Additional requirements are provided herein.

3.6.1 Site Conditions:

The system shall operate in an industrial setting. The contractor shall become familiar with the existing site conditions, including site location, site configuration, topography, climate, site accessibility and adjacent land use.

3.6.2 Safety:

A. The contractor shall maintain a safe and healthy work environment for its employees IAW OSHA requirements.

B. The contractor shall provide cranes and rigging support for all work associated with the SOW. The contractor shall be responsible for ensuring that the crane can be sited appropriately and for working with the Government to ensure that the crane does not exceed any road or site load ratings as specified by the Government. A portion of this work is considered to be in a confined space. Perform work in confined space IAW OSHA and industry code standards.

3.6.3 Tool Control:

A. The contractor shall coordinate tool control with the Government representative.

3.6.4 Asbestos: Asbestos material is anticipated in existing gaskets.

IRA-3836 Page - 7

3.6.5 If additional asbestos is found during construction, the contractor shall notify the Government representative. Disturbance to or disposal of asbestos containing materials shall be IAW Asbestos Removal CSI Section 02 08 00 modified for AEDC.

3.6.6 Lead: All existing painted surfaces are considered to contain lead materials. The contractor shall handle and dispose of lead containing materials IAW Lead and Heavy Metal Removal CSI Section 02 08 50 modified for AEDC.

3.6.7 All wastewater shall be contained and managed IAW 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 manifests shall be coordinated through the Government.

3.6.8 The contractor shall not make any connections to a potable water system without specific approval from the Government representative.

The contractor shall notify the Government representative if connections to hose bibs are needed. The contractor shall not connect to any hose bibs without Government-approved backflow preventer and specific approval from the Government representative.

3.6.9 If excavation is required, the contractor shall not cause any damage to existing facilities and shall allow for on-going test operations during excavation. Removal of subsurface rock utilizing detonation methods shall not be permitted. Construction shall not interfere with or damage any elevated by-pass line.

3.6.10 Equipment shall include attached nameplates with manufacturer’s data.

3.6.11 Soil within the industrial area may contain petroleum (POL), volatile organic compunds (VOCs), or other regulated compound contaminants.

Discrete areas with known contamination have been designated as Solid Waste Management Units (SWMU’s) and require worker soil contact be limited. This project is within a SWMU, or has the potential to disturb contaminated soil. Excavation of soil or gravel shall conform to the following methods:

A. Excavated soil and gravel shall be staged adjacent to the open hole and replaced as backfill if possible, IAW backfill specifications. Workers shall wear appropriate personal protective equipment (PPE) to limit soil contact.

B. Soil and gravel removed from the immediate area of the excavation site shall be staged in piles, and lined and covered with poly sheeting to protect the staged area from cross contamination. Workers shall wear appropriate PPE to limit soil

IRA-3836 Page - 8 contact. The proposed staging area shall be approved by the Government representative.

C. Excess soil determined unsuitable for reuse as backfill will be sampled by AEDC for potential POL, VOCs, or other regulated compound contamination prior to offsite disposal or other disposition. The contractor shall not proceed with disposal until receiving direction from the Government representative.

3.7 Outages

3.7.1 The FARM II Contract SOW, Section 2, Paragraph 2.3, describes the AEDC Integrated Scheduling for the TO SOW outages. The contractor shall coordinate with base support personnel and submit outage(s) per FARM II SOW to install new hardware. A two-month outage is available with dates to be determined.

Task/Subtask Number(s)

Asset ID(s) Description Outage Dates Outage

Duration Task 3 and 4 C-AS Duct Modify Ducting and Install

Supports and Valve Either Summer 2022 or 2023

60-days total

3.8 Verification and Testing

3.8.1 Verification and Validation (V&V)

The contractor shall submit a V&V plan for Government approval to verify that all the requirements have been met. The V&V plan shall include verification for all components and systems. Verification may consist of analysis, inspection, demonstration and testing. V&V plans are required as part of design submittals; the plan(s) shall be submitted as designated for each review listed in Appendix F.

3.8.2 Testing and Inspection Responsibilities

The contractor shall be responsible for all testing and inspections of the valve assembly as listed in the relevant specification(s), to include hydrostatic and/or pneumatic testing. The contractor shall supply all interfacing equipment needed to conduct the tests.

The contractor shall notify the Government at least two weeks prior to all test dates.

The Government reserves the right to witness all tests.

IRA-3836 Page - 9

The contractor shall modify valve(s) and related components of the assembly as needed after failed tests, and repeat all tests until valve assembly(s) meets test requirements.

The contractor shall submit all test reports signed by personnel conducting the test and those approving the results. No valve assembly(s) shall be shipped until test reports have been approved by the Contracting Officer.

3.8.3 Inspection

Upon receipt at Arnold AFB, the Government will inspect the valve assembly and all related components and equipment for any visible damage, general cleanliness, craftsmanship, and adherence to final drawings.

3.8.4 Demonstration

Upon installation at Arnold AFB, the contractor shall demonstrate to the Government that the system meets the operational requirements as specified.

3.8.5 Acceptance

After contractor installation and satisfactory operation at Arnold AFB, the Government will accept the valve assembly(s) and all related components and equipment.

3.8.6 Factory Acceptance Testing (FAT)

The Government reserves the right to witness all tests specified by ANSI/FCI 70-2. The contractor shall notify the Government at least two weeks prior to all test dates.

3.8.7 Site Acceptance Testing (SAT)

The Government reserves the right to witness all tests specified by ANSI/FCI 70-2. The contractor shall notify the Government at least two weeks prior to all test dates.

3.8.8 User Acceptance Testing (UAT)

UAT is required by this TO SOW. The contractor shall support the Government in conducting UAT.

3.9 Demolition

Demolition activities are anticipated to be minor for this project. The contractor shall submit a demolition plan describing the sequence of demolition, equipment to be used, and disposition of demolished materials. This shall include the scope of the demolition as documented with photographs and/or drawings in the Appendices. The contractor shall coordinate with the Government to identify salvage items. For disposal of all materials, the contractor shall include and comply with AEDC Specification 01 74 19 Construction Waste Management and Disposal in contractor specifications.

IRA-3836 Page - 10

3.10 Submittals

The contractor shall provide submittals as described in the FARM II SOW paragraphs 2.8 “Submittal Procedures” and 2.9 “Specific Submittal Descriptions and Requirements”. All submittal items including those listed in Appendix E shall be provided electronically to the Government IAW the FARM II SOW.

3.10.1 This Task Order includes a list of submittals in Appendix E that are required during design or prior to installation. Specific information regarding design review submittals are provided in Appendix F.

Additional submittals are provided within this TO and listed as follows.

A. Submit installation plan and schedule 120 days prior to outage.

3.10.2 The following submittals shall be provided during installation / construction and shall be listed in the submittal register prepared by the contractor. Detailed description of the submittal requirements is in paragraph 2.9 of the FARM II Contract SOW.

A. Product/Manufacturer’s data for all components

B. Welding certifications, qualifications and test results as follows:

1. Design or shop drawings detailing material, thickness and weld type and size

2. Welder performance qualifications (WPQ)

3. Weld procedure specifications (WPS)

4. Procedure qualification records (PQR)

5. Welding inspector (CWI) qualifications

6. Welding inspection plan

7. Non-destructive testing reports

C. Operation and Maintenance (O&M) instructions for all equipment furnished to include:

1. Schematic diagrams (wiring diagrams for electric motor actuator and motor starter)

2. Lubrication, cleaning and calibration instructions

3. Parts list and recommended spare parts list. These lists shall give the manufacturer’s name, part number and a vendor for each item.

IRA-3836 Page - 11

D. Warranty: The contractor shall provide a minimum one year warranty for all parts and workmanship, stating that the system is free from any manufacturer defect. The contractor shall repair or replace, at no additional cost, any defects during the warranty period. The warranty period shall begin after acceptance at Arnold AFB.

E. As-Built Drawings: The contractor shall provide final record (as-built) drawings showing the final configuration of work accomplished.

3.11 Government-Furnished Equipment/Property: None.

3.12 Exclusions: None.

3.13 Historical: Not applicable.

Distribution A. Approved for public release.

IRA-3836 Appendix A - 1

APPENDIX A - REFERENCE DOCUMENTS

None

Distribution A. Approved for public release.

IRA-3836 Appendix B - 1

APPENDIX B -DRAWINGS

Drawing/Revision Title

• MAP40G6 - AEDC Base 1x40 – Underground Utilities/GEOTech

• MAP40G7 - AEDC Base 1x40 – Underground Utilities/GEOTech

• 5-00-D300/R - General Notes and Typical Details

• 5-00-D301/C - Expansion Joint System – Schematic – Sheet 1

• 5-00-D303/K - Expansion Joints – Schedules – Sheet 1

• 5-00-D304/E - Expansion Joints – Schedules – Sheet 2

• 5-00-D315/E - Duct Stiffening Rings – Schedule – Sheet 1

• 5-00-D316/L - Duct Stiffening Rings – Schedule – Sheet 2

• 5-00-D318/L - Duct Stiffening Rings – Schedule – Sheet 4

• 5-00-D319/C - Duct Stiffening Rings – Details – Sheet 1

• 5-00-D320/A - Duct Stiffening Rings – Details – Sheet 2

• 5-00-D335/H - Nozzles, Manholes, Penetrations – Schedule – Sheet 1

• 5-00-D342/E - Nozzles, Manholes, Penetrations – Details – Sheet 1

• 5-00-D349/D - Configuration and Control Valves – Details

• 5-00-D351/J - General Ducting – Duct Supports, Guides, Anchors – Schedule

• 5-00-D389/D - General Ducting – Duct Support Structure – Four Leg Towers – Elevations – Sh2

• 5-20-D4/ L - Air Supply Area Ducting

• 5-20-D5/N - (1) Heater H2 Discharge Area – Plan – Air Supply Area Ducting

• 5-20-D12 /P - Cold Leg Duct Elevation Air supply Area

• RU632838.01/C - Header Isolation Valve (AV.A.8)

• RW621952/B - Nozzle Installation – ASTF

END OF APPENDIX B

IRA-3836 Appendix C - 1

APPENDIX C -SPECIFICATIONS

01 74 19 Construction Waste Management and Disposal 23 09 13 Configuration Valves C – 1 Valve Requirement Summary

IRA-3836 Appendix C - 2

SECTION 01 74 19

CONSTRUCTION WASTE MANAGEMENT AND DISPOSAL

PART 1 - GENERAL

1.1 SUMMARY

A. This section is applicable to construction/demolition debris, reusable and salvageable items, and recyclable and non-recyclable wastes. Hazardous or special wastes are identified in separate related sections.

B. Section includes:

1. Construction waste management plan

2. Construction waste recycling instructions

C. Related Sections:

1. Section 02 08 00 - Asbestos Removal

2. Section 02 08 50 - Lead and Heavy Metal Removal

1.2 CODES AND STANDARDS

A. AEDC SHE Standards latest version, available upon request from the

Government.

1. E09 Wastewater Discharge Management

2. E18 Managing Wastes Containing Chemical or Petroleum Products B. Code of Federal Regulations (CFR):

1. 40 CFR 82 Subpart F Protection of Stratospheric Ozone, Recycling and Emissions Reduction

2. 40 CFR 82.161 Technician Certification

3. 40 CFR 261 Identification and Listing of Hazardous

Wastes

1.3 DEFINITIONS

A. Clean: Not contaminated with oils, solvents, caulk, or other chemicals or materials that result in the waste being considered hazardous or special waste.

B. Construction/Demolition Debris: Building materials, debris, and rubble resulting from construction, remodeling, repair, and demolition operations.

C. Construction waste management plan: Required project submittal documenting the project activities and procedures to be used to minimize landfill disposal of construction and demolition waste and to optimize recycling opportunities within the project.

D. Hazardous Waste: A used or discarded material that can damage the environment and be harmful to health. Hazardous waste possesses at least one of four characteristics (ignitibility, corrosivity, reactivity, or toxicity

IRA-3836 Appendix C - 3 as defined by applicable state and federal regulations) or appears on federal or state official lists of hazardous wastes.

E. Non-Recyclable Waste: Any non-hazardous product or material (not including construction/demolition debris) unable to be reused, returned, recycled, or salvaged.

F. Recyclable: The ability of a product or material to be recovered at the end of its life cycle and remanufactured into a new product for reuse.

G. Recycle: To remove a waste material from the project site for reuse.

H. Recycling: The process of sorting, cleaning, treating and reconstituting solid waste and other discarded materials for the purpose of reuse.

Recycling does not include burning or incinerating waste.

I. Reusable: Able to be used again, especially after salvaging or special treatment or processing.

J. Salvageable: Discarded or damaged equipment or material that can be saved for further use.

K. Source Separation: The act of keeping different types of waste materials separate beginning from the first time they become waste.

L. Special Waste: Waste which is not regulated hazardous waste, which has physical or chemical characteristics, or both, that are different from construction/demolition debris, recyclable, and non-recyclable wastes, and which potentially requires special handling. Some examples include oil-contaminated soil, oily sorbents, and water treatment plant sludge.

M. Waste: Extra material or material that has reached the end of its useful life in its intended use. Waste includes salvageable, returnable, recyclable, and reusable material.

1.4 SUBMITTALS

A. Construction waste management plan describing methods to be used for waste recycling and minimization, procedures for implementation, and compliance monitoring to include the following:

1. Construction waste materials anticipated for recycling and reuse

2. Method of waste stream segregation prior to disposal or reuse

3. Identification of disposal or recycling facility destination for each waste stream (construction/demolition landfill, Recycling Operations Center, Arnold AFB Salvage Yard, or off-site)

4. Method of temporary site storage of wastes

5. Method of transporting waste to recycling facility or to landfill

PART 2 - PRODUCTS – Not Used

PART 3 - EXECUTION

3.1 CONSTRUCTION WASTE MANAGEMENT PLAN

IRA-3836 Appendix C - 4

A. Develop and implement construction waste management plan with approval by the Government

B. To the maximum extent possible, divert/dispose of construction demolition, and land-clearing debris from landfill

C. Direct recyclable material to Arnold AFB recycling D. Dispose of hazardous wastes IAW AEDC SHE Standard E18 E. Implement construction waste management plan at start of construction F. Distribute approved construction waste management plan to subcontractors and others affected by plan requirements G. Review construction waste management plan with Government and all onsite contractor personnel at preconstruction meeting and progress meetings

H. Oversee construction waste management plan implementation, and instruct construction personnel for plan compliance

3.2 CONSTRUCTION WASTE MANAGEMENT AND DISPOSAL

A. Use source separation method suitable to sorting and processing of wastes selected for recycling. Separate recyclable materials from construction/demolition debris and non-recyclable waste prior to transportation to Arnold AFB recycling facilities as described herein.

B. Store construction waste materials to prevent environmental pollution, fire hazards, hazards to persons and property, and contamination of stored materials.

C. Cover construction waste materials subject to disintegration, evaporation, settling, or runoff to prevent polluting air, water, and soil.

D. Separate recyclable, reusable and salvageable materials from construction/demolition debris and non-recyclable waste and sort into separate bins, containers, or lay-down areas, prior to transportation for recycling. The Arnold AFB Recycling Operations Center (ROC) is located in Building 1426 near the Arnold AFB Salvage Yard. Coordinate with ROC personnel (454-6068) to coordinate transfer of recyclable materials.

Recyclable materials shall be further sorted for reuse as follow:

1. Cardboard: Cardboard shall be stockpiled on site prior to transportation to the ROC, or shall be placed in any of the cardboard receptacles located throughout the facility.

2. Aluminum Cans: Aluminum cans shall be stockpiled on site prior to transportation to the ROC, or shall be placed in aluminum can recycling bins located inside many Arnold AFB buildings.

3. Recyclable Plastics: Recyclable plastics shall be stockpiled on site prior to transportation to the ROC. Plastic bottles (such as soft drink bottles) shall be placed in plastic bottle recycling bins located inside many Arnold AFB buildings.

IRA-3836 Appendix C - 5

4. Scrap Metals including non-PCB light fixture ballasts: Unless otherwise directed by the Government representative, scrap metals shall be stockpiled on site prior to transportation to the Arnold AFB Salvage Yard, or shall be placed in scrap metal bins located at some Arnold AFB buildings.

5. Equipment: Equipment left after demolition or remodeling shall be taken to the Arnold AFB Salvage Yard for disposal. The contractor shall clean equipment prior to disposal at the Arnold AFB Salvage Yard (with the exception of lead paint, unless the pain is flaking in which case the flaking paint shall be removed prior to transport). If cleaned equipment is to be turned in to the Government for storage or excessing, a GC1785 “Special Material Turn-in Certification” shall be completed and submitted to the Government with the equipment. The Government representative will assist the contractor in filling out the form and in coordinating with Industrial Hygiene and Environmental Quality.

6. Salvageable/Reusable items: Identify items to be salvaged and/or reused. Protect items of salvageable value and remove as work progresses. Transport salvaged items from site to Government designated location. If salvageable/reusable items are to be turned in to the Government for storage or excessing, a GC1785 “Special Material Turn-in Certification” shall be completed and submitted to the Government with the items. The Government representative will assist the contractor in filling out the form and in coordinating with Industrial Hygiene and Environmental Quality.

7. Paper: Paper shall be disposed of in Cintas recycling bins located in various Arnold AFB buildings. Security-sensitive papers shall be placed into lockable bins, while other paper (magazines, newspapers, etc.) shall be disposed of in yellow open top bins.

8. Other Miscellaneous Recyclable Waste: Other miscellaneous recyclable waste shall be disposed as directed by the Government.

9. Used abrasives: If abrasives are verified as non-hazardous by the Government, used abrasives and lead-containing paint residue shall be placed directly in a roll-off box for disposal at the Arnold AFB construction/demolition landfill. The Government will furnish roll-off boxes and transportation to the landfill.

E. Dispose of construction/demolition debris separately at the Arnold AFB landfill. Food wastes are to be considered non-recyclable wastes and shall not be disposed of in the construction/demolition landfill. Coordinate with Arnold AFB Environmental Quality (454-3521) to obtain a disposal permit prior to transfer of materials and to coordinate schedule for disposal. The Arnold AFB landfill is located on 6th Street near the airfield and may be subject to limited operating hours. Construction/demolition debris shall be further sorted for disposal as follows:

1. Concrete: Concrete shall be stockpiled at the landfill for later reuse

2. Asphalt: Asphalt shall be stockpiled at the landfill for later reuse

IRA-3836 Appendix C - 6

3. Milled Wood: Milled wood shall be placed into a large bin at the landfill for eventual recycling

4. Other Miscellaneous Debris: Other miscellaneous debris shall be placed into the Arnold AFB landfill for disposal

F. Dispose of non-recyclable waste in any of the brown dumpsters located throughout the installation. Examples of non-recyclable waste include food scraps and food containers, empty glass containers, styrofoam, and empty and dry hazardous material containers (without lids).

G. Dispose of trees, shrubs, and other debris resulting from clearing/grubbing at the Arnold AFB landfill in a location as directed by the Government.

H. Clean soil or granular fill material may be taken to the soil stockpile area located just inside Arnold AFB Gate 2. Soil excavated from the industrial area of Arnold AFB may require sampling and analysis to confirm that it is clean and free from contaminants (e.g., oil, solvents, etc.). The contractor shall coordinate with the Government to determine sampling requirements.

I. Capture and recycle refrigerants from all appliances IAW 40 CFR 82, Subpart F. The refrigerant shall be removed by a certified technician as defined in 40 CFR 82.161 (or an apprentice directly under the supervision of a certified technician). Since the types of units being salvaged could be high or low pressure systems, the technician shall possess a “universal” certification. Provide proof of certification to the Government. The reclamation/recovery of all refrigerants shall occur prior to removal of equipment from Government property. All reclaimed/recovered refrigerant shall be turned over to the Government for final disposition. Refrigerant containing equipment may include but is not limited to: A/C units, refrigerators, freezers, water coolers, and dehumidifiers.

J. Hazardous Waste: Where hazardous waste (as identified or listed by 40 CFR 261) is generated, follow the procedures given in AEDC SHE Standard E18 for storing and turning in hazardous waste for proper disposal. These procedures include the requirement for completion of Forms GC-565 and GC-1337, which will be furnished by the Government representative. Return the completed forms to the Government representative and coordinate with the Arnold AFB Hazardous Waste Operations Group (454-3628 or 454-3521) prior to transporting the waste to the designated Arnold AFB accumulation point or Arnold AFB permitted storage facility as directed.

3.3 CLEANUP

A. Clean up and dispose of all waste continuously throughout construction and thoroughly at job completion.

END OF SECTION

IRA-3836 Appendix C - 1

SECTION 23 09 13

CONFIGURATION VALVES

PART 1 - GENERAL

1.1 SUMMARY

A. This specification establishes the requirements for stainless steel configuration valve and associated electric motorized actuators to be used in process air ducting in the Arnold AFB aircraft engine test facilities. The valve shall be triple offset butterfly type with flanged ends. The requirements presented herein require the manufacturer to perform special design/analysis. The valve size(s), pressure/temperature rating(s), and minimum required Cv(s) are specified in the table entitled "Ducting and Valve Design and Performance Requirements" on the contract drawings.

1.2 GENERAL REQUIREMENTS

A. Standard Products:

1. The proposed valve shall be the standard product of a manufacturer (or very similar to as modified to meet the requirements of this specification) regularly engaged in the manufacture of the product and shall essentially duplicate valves that have been in satisfactory use for at least two years prior to bid opening. The valve and all components thereof shall be supported by a service organization that is reasonably convenient to the Arnold AFB site and can be on-site within four hours if required.

B. Verification of Dimensions:

1. The contractor shall become familiar with details of the work, verify dimensions in the field, and shall advise the authorized representative of the Contracting Officer of any discrepancy before performing the work.

C. Valve and flange dimensions shall be coordinated with the duct design.

D. The configuration valve shall have ratings that meet or exceed the service conditions of the ducting in which installed. All components shall be suitable for use with the design system temperatures, pressures, and fluids to which they are exposed. Media through the valves shall be process air. The valves shall be fully capable of flowing process air in either direction without manufacturer-imposed limitations. The configuration valve shall provide positive shutoff or isolation of ducting and equipment from the airflow.

E. The valve will be used as a shut-off valve (i.e., flow/no flow) and not in partially open positions. Unless specifically stated otherwise, all valves

IRA-3836 Appendix C - 2 shall provide Class V bi-directional sealing at the minimum/maximum temperatures and pressures of the ducting in which installed.

F. See Part 2 for further detailed product requirements.

1.3 SUBMITTALS

All drawings, catalog cuts, and instructions which are generic and list more information than is specifically applicable to the piece of equipment involved shall have all copies marked to identify the information applicable to the specific piece of equipment involved. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only.

The contractor shall gain approval from the Government of certain submittals (as discussed below) before the valve Manufacturer can proceed with material purchases and fabrication activities. The following shall be submitted IAW SOW Section 3.10 SUBMITTALS:

A. Shop Drawings: Configuration Valve Assemblies; G.

1. Manufacturer's drawings per ANSI/ASME drafting practice standards using the inch-pound system of units commonly used in the United States showing basic external views with dimensions, cross-sectional views showing all components, a complete list of components and materials (parts list), and drawing notes.

Drawings may use S.I. units if and only if the valve was designed and manufactured using that system of units.

a. Drawings shall also be provided that contain complete wiring and schematic diagrams and other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings for actuators, controls, and other components shall be included. Provide valve actuator list indicating torque requirements of valve and final values of electrical power requirements for the actuators.

b. Dimensioning of the external views of the valve and actuator shall include (as a minimum): valve bore; geometry of body end flanges (and mating duct flanges as reference) (flange O.D. and I.D., thickness, bolt circle description, hub dimensions, raised face, etc.); valve body flange face to face dimensions; gasket O.D., I.D., and thickness (compressed and non-compressed); actuator basic external geometry;

and actuator locating dimensions relative to valve centerline.

c. All dimensions relevant to the valve stress analysis shall be shown.

d. All geometry that was designed specifically for this contract shall be fully detailed and show all dimensions and description. Dimensions that are proprietary relative to geometry that was designed prior to this project are not required.

IRA-3836 Appendix C - 3

e. Drawing notes shall include (as a minimum): pressure and temperature rating; valve weight including valve body flanges; actuator weight; total weight and center of gravity of complete valve and actuator assembly; fastener description (size, thread data, ASME/American Society for Testing and Materials (ASTM) designation, quantity, etc.); gasket description (manufacturer, model number, basic materials, etc.); valve mounting requirements; and installation and operational safety precautions.

2. Contractor's drawings showing proposed layout and anchorage of valves and appurtenances, and valve relationship to other parts of the work including clearances required for maintenance and operation. Details shall include loadings and types of frames, brackets, stanchions, and other supports for actuators and appurtenances.

a. The contractor shall gain Government approval of the manufacturer's and contractor's drawings prior to commencement of material procurement and fabrication.

B. Product Data; G.

1. Manufacturer's descriptive and technical literature; catalog cuts;

performance charts and curves.

2. The contractor shall gain Government approval of the product data prior to commencement of material procurement and fabrication.

C. Spare Parts; G.

1. Spare parts data for each different item of material and equipment specified. Provide one set of the Original Equipment Manufacturer’s (OEM’s) recommended on-hand spare parts. The data shall include a complete list of parts and supplies, including lubricants and fluids, current unit prices, sources of supply, and a list of the parts recommended by the manufacturer to be replaced after one and three year(s) of service.

2. The data shall be submitted to the Government after approval of detail drawings and not later than two months prior to the date of beneficial occupancy.

D. Design Data Analysis; G.

1. The contractor shall provide the Government the manufacturer's complete stress analysis of the valve to show that the valve is structurally adequate and meets all applicable code requirements and requirements contained herein for the contractor-specified loading conditions.

2. The stress analysis shall address all major components of the valve under load including, but not limited to, the valve body, body flanges, mating duct flanges, bolting, bearings, bearing housings, disk, shaft, and all connective components and fasteners. Flange

IRA-3836 Appendix C - 4 analysis requirements are presented in paragraph 2.18. Special requirements for stress calculations beyond B16.34 and ASME Boiler and Pressure Vessel (BPV) VIII requirements are given in paragraphs 2.23 and 2.24.

3. The stress analysis shall also include the external keyed connection of the actuator to the valve shaft (see paragraph 2.23).

4. The stress analysis shall address all applicable stresses due to all loadings attributable to, but not limited to, actuator torque, air flow and pressure, gravity, and thermal.

5. Detailed mathematical steps including all formulas and descriptive narrative and annotations shall be provided so that the Government can follow the analysis from beginning to end. All results shall have units shown. Spreadsheets are permissible and shall be fully annotated and show all formulas used (in terms of physical quantities - not row/column arithmetic). Formulas used within Finite Element Analysis (FEA) programs are not required.

6. Valve flow coefficient data/analysis shall be provided to the Government (see paragraph 2.5).

7. The contractor shall gain Government approval of the stress analysis and valve flow coefficient data/analysis prior to commencement of material procurement and fabrication.

E. Cleanliness and Cleanliness Inspection Procedure; G.

1. Manufacturer's proposed cleaning and cleanliness inspection procedure. The procedure shall include a list of all cleaning materials. The manufacturer shall furnish Material Safety Data Sheets for proposed materials. The procedure shall also state how iron contamination of stainless steel will be avoided. The procedure shall include a copper sulfate test and atomizer test per

ASTM A380.

2. Fabrication and material procurement shall not commence until Government approval of the procedure is obtained.

F. Test Plans; G.

1. Test plans for conducting factory tests including but not limited to:

1) calculations performed to determine the hydro test pressure, 2) sketch of any special hardware/fixturing that will be used in the test, and 3) procedural steps that describe the structural checks that will be made (see paragraph 3.2).

2. Factory tests shall not be conducted until Government approval of the test plans is obtained.

3. Test plans for conducting field tests of the valve assembly installed in the ducting (see paragraph 3.7).

IRA-3836 Appendix C - 5

4. Field tests shall not be conducted until Government approval of the test plans is obtained.

G. Certificates & Experience; G.

1. The contractor shall submit to the Government a list of the proposed manufacturer's successfully completed jobs demonstrating five years of experience in the manufacture of large butterfly valves for the purpose of providing positive shutoff of compressed air in sizes, pressures, and temperatures greater than or equal to the value being purchased. For the valve listed, the following shall be listed: valve size, pressure/temperature rating, model number (if applicable), and site location including company name, city/state, name of contact, and phone number. Listed valves that cannot be easily verified via the contact information will not be considered.

2. The contractor shall submit to the Government a letter from the proposed manufacturer indicating the manufacturer's agreement to submit the stress analyses required herein.

3. The contractor shall obtain Government approval of the proposed manufacturer prior to awarding the valve procurement contract to the manufacturer.

H. Welders' Qualifications and Weld Procedures; G.

1. The contractor shall submit to the Government the manufacturer's applicable weld procedures and welder qualifications IAW ASME

BPV IX.

2. Government approval shall be obtained prior to start of fabrication.

I. Manufacturer's Instructions Installation instructions; G.

1. Manufacturer's instructions shall include information for the contractor that will aid in the safe and timely installation of the valve. Weight, center of gravity, component orientation requirements, and any special rigging instructions and safety precautions shall be included. Flange bolt torqueing instructions describing required thread lubricant, torqueing levels, and tightening sequence.

2. Government approval shall be obtained prior to start of valve installation.

J. Manufacturer's Field Reports Test Reports; G.

1. Test reports in booklet form showing factory tests and field tests

IRA-3836 Appendix C - 6 performed to adjust each component and factory tests and field tests performed to prove compliance with the specified performance criteria. Each test report shall indicate the final position of any system controls.

2. Test reports shall be submitted to the Government for Government approval upon completion and testing of the installed system.

K. Operation and Maintenance Data System Operation; G

1. Six complete copies of operating instructions outlining the step-by-step procedures required for system startup, operation, and shutdown. The instructions shall include the manufacturer's name, model number, service manual, parts list, and brief description of all equipment and their basic operating features. Field cleaning procedures designed to clean the system to the requirements specified.

2. Government approval of the operating instructions (in preliminary form is acceptable) shall be obtained prior to start of 'Valve and Actuator Testing' of the installed valve (see paragraph 3.7.B.2).

Finalized operating instructions shall be provided no later than two weeks prior to the date of beneficial occupancy.

L. Repair Requirements; G

1. Six complete copies of maintenance instructions listing routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. The instructions shall include equipment layout and simplified wiring and control diagrams of the system as installed.

2. Maintenance instructions shall be provided to the Government as a part of the contractor's as-built documentation.

PART 2 - PRODUCTS

2.1 The configuration valve shall be flanged end, electric motor actuated, triple offset butterfly type valve capable of bi-directional flow and sealing, constructed only of stainless steel components (see paragraph 1.2.E for sealing requirements).

2.2 Recommended…