Statement of Work .pdf

SOW-PWS Template 21 August 2024 version Page 1

Statement of Work (SOW) for Intake/Uptake Ductwork

1.0 INTRODUCTION

1.0.1 The Naval Surface Warfare Center Philadelphia Division (NSWCPD) is a Department of Defense entity responsible for research and development, test and evaluation, engineering and fleet support organization for the Navy’s ships, submarines, military watercraft and unmanned vehicles. This requirement is for NSWCPD Code 71, which is responsible for Major Programs, FFG-62 Land Based Engineering Site Enterprise (LBESe), and current and future test sites.

1.0.2 This contract is for non-personal services. It does not create employment rights with the U.S. Government whether actual, inherent, or implied

1.0.3 Government/Contractor Relationship

1.0.3.1 The services to be delivered under this Contract are non-personal services and the parties recognize and agree that no employer-employee relationship exists or will exist under the Contract between the Government and the Contractor's personnel. Therefore, it is in the best interest of the Government to provide both parties a full understanding of their respective obligations.

1.0.3.2 The Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishable badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.0.3.3 Contractor personnel under this Contract shall not engage in any of the inherently Governmental functions listed at FAR Subpart 7.5 or DFARS Subpart 207.5.

1.0.4 Employee Relationship:

1.0.4.1 The services to be performed under this Contract do not require the Contractor or its personnel to exercise personal judgment and discretion on behalf of the Government. Rather the Contractor's personnel will act and exercise personal judgment and discretion on behalf of the Contractor.

1.0.4.2 Rules, regulations, directives, and requirements that are issued by the U. S. Navy and NSWCPD under its responsibility for good order, administration, and security are applicable to all personnel who enter a Government installation or who travel on Government transportation. This is not to be construed or interpreted to establish any degree of Government control that is inconsistent with a non-personal services contract.

1.0.4.3 Inapplicability of Employee Benefits: This Contract does not create an employer-employee relationship.

Accordingly, entitlements and benefits applicable to such relationships do not apply.

1.0.4.4 It is the Contractor's, as well as the Government's, responsibility to monitor Contract activities and notify the Contracting Officer if the Contractor believes that the intent of this Section has been or may be violated.

1.0.4.4.1 The Contractor shall notify the Contracting Officer in writing via letter or email within three (3) calendar days from the date of any incident that the Contractor considers to constitute a violation of this Section. The notice should include the date, nature, and circumstances of the conduct; the name, function, and activity of each Government employee or Contractor official or employee involved or knowledgeable about such conduct; identify any documents or substance of any oral communication involved in the conduct; and the Contractor's estimated date when, absent a response, cost, schedule or performance will be impacted.

1.0.4.4.2 The Contracting Officer will, within five (5) calendar days after receipt of notice, respond to the notice in writing. In responding, the Contracting Officer will either:

(i) Confirm the conduct is in violation and when necessary direct the mode of further performance, SOW-PWS Template 21 August 2024 version Page 2

(ii) Countermand any communication regarded as a violation,

(iii) Deny that the conduct constitutes a violation and when necessary direct the mode of further performance, or

(iv) In the event the notice is inadequate to make a decision, advise the Contractor what additional information is required, and establish the date by which it should be furnished by the Contractor.

1.1 BACKGROUND

1.1.1 Naval Surface Warfare Center, Philadelphia Division (NSWCPD) is the Navy’s center for excellence for ships and ship systems. NSWCPD provides full-spectrum research and development, testing, evaluation, in-service engineering, and fleet support organization for the Navy’s surface and under-sea vehicles.

NSWCPD’s expertise spans across more than forty (40) disciplines, from electrical and mechanical engineering to computer engineering and physics. NSWCPD test sites and facilities are responsible for conducting tests, diagnostics and evaluations of new, emerging, production-representative, and in-service systems. The NSWCPD Major Test Programs Division (71) provides services for the planning and coordination of the NSWCPD Test Sites in Philadelphia, PA.

1.1.2 The Naval Surface Warfare Center, Philadelphia Division (NSWCPD) will be installing a GE LM2500+G4 Gas Turbine, referred to as the “Gas Turbine”, in an open bay inside a building in support of a Land Based Engineering Site (LBES).

1.2 SCOPE OF WORK

1.2.1 NSWCPD requires the design, procurement, fabrication, and delivery of Air Intake (Combustion and

Cooling) Systems, an Exhaust System, and a Filter House filtration system to ensure proper, safe, and environmentally compliant operation of the Gas Turbine in the typical Philadelphia, PA regional climate or inclement weather.

1.2.2 The Contractor shall design, fabricate, and deliver the Air Intake and Exhaust Systems listed in Table 1 below. Section 3.0 of this Statement of Work (SOW) outlines the specific operational capabilities and requirements for each System to be procured under this contract.

Table 1: Air Intake and Exhaust Systems Item Number Quantity Systems

1 1 Filter House Filtration System 2 1 Combustion Air Intake Ducting 3 1 Cooling Air Fan and Ducting 4 1 Uptake Ducting

1.2.3 The four (4) systems listed above (Table 1) shall be designed, fabricated, and modeled to operate together and ensure a complete air inlet and uptake system for the Navy’s Gas Turbine in accordance with (IAW) Applicable Document 2.4.1.

1.2.3.1 Filter House System shall contain all air filtering requirements for combustion air for the Gas

Turbine, anti-icing piping, water wash piping and access ports for maintenance and filter cleaning/replacement.

1.2.3.2 Combustion Air Intake System shall provide combustion air from the filter house to the engine inlet and shall contain all required expansion joints, maintenance/inspection access ports, and water drain collection/cleanout points.

1.2.3.3 Cooling Air System shall provide cooling air, at the same filtration criteria as the combustion air, to the engine enclosure and shall contain all required expansion joints, maintenance/inspection access ports and water drain collection/cleanout points.

1.2.3.4 Uptake System shall provide an airtight gas path from the engine outlet to the atmosphere outside building and shall contain all required expansion joints, maintenance/inspection access ports, and emissions monitoring and testing access points.

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2.0 APPLICABLE DOCUMENTS

2.1 ASTM International (ASTM): https://www.astm.org/

2.1.1 ASTM A376 - Standard Specification for Seamless Austenitic Steel Pipe for High-Temperature Service

2.1.2 ASTM A240 – Standard Specification for Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

2.1.3 ASME BPVC, Section VIII, Division I - Boiler and Pressure Vessel Code, Section VIII: Rules for

Construction of Pressure Vessels - Division 1

2.1.4 Standards of the Expansion Joint Manufacturers Association Inc.

2.1.5 ASME BPVC, Section VIII, Division II – Rules for Construction of Pressure Vessels

2.1.6 ASTM F2362 Standard Specification for Temperature Monitoring Equipment

2.1.7 ASTM E1049 Standard Practices for Cycle Counting in Fatigue Analysis

2.2 Military Standards: http://everyspec.com

2.2.1 MIL-P-24691 – Pipe and Tube, Carbon, Alloy and Stainless Steel, Seamless and welded, general

Specification For

2.2.2 NAVSEA Technical Publication 9074-AR-GIB-010/278, Table VII, Machinery Class M2, Category A

2.2.3 NAVFAC P307, Management of Weight Handling Equipment

2.3 Safety Standards:

2.3.1 OPNAV M-5100.23 – Navy Safety and Occupational Health Manual

2.3.2 OSHA 1910 – Occupational Safety and Health Administration Regulations

2.3.3 ASTM C1055-03, Standard Guide for Heated System Conditions that Produce Contact Burn Injuries

2.3.4 National Fire Prevention Association (NFPA) 70 National Electrical Code

2.4 FFG-62 / OEM Drawings and Standards:

2.4.1 0521-1-234-002 Attachment N MID-IDM-2500-20 Change 7

2.4.2 0521-1-234-003 Attachment B Gas Turbine Top Drawing (L67670)

2.4.3 9482M66 – LM2500 G4 Installation and Removal Rail ICD

2.4.4 0521-1-234-005 REV A GT Removal A&D

2.4.5 Howden Typical Performance Curve, Model IR340-270D2541 Gas Turbine Cooling Fan, 160 HP

2.4.6 0521-1-551-003 Rev A Gas Turbine Bleed Anti-Icing Air System Diagram

2.4.7 0521-1-259-001 Rev C Combustion Air Intake and Exhaust System Diagram

2.4.8 0521-1-234-002 Attachment H Electrical Schematic (L71160)

2.5 Environmental Standards:

2.5.1 40 CFR Part 60 Appendix A-1 – Method 1 – Sample and Velocity Traverses for Stationary Sources

2.5.2 Pennsylvania Department of Environmental Protection (PADEP) Source Testing Manual (STM)

2.6 FFG-62 LBES Drawings:

2.6.1 (CUI) 30632014 R- APPROVED 2024-09-06 FFG-62 GT Intake and Uptake Conceptual Drawing –

Redline

2.6.2 WRA Repair Package:

2.6.2.1 1G007 – Roll Up Door Dimensions

2.6.2.2 2S117 – Location of Gas Turbine Exhaust, SSDG Exhaust

2.6.2.3 2S207, 2S115 – Opening for Filter House/Intake

2.6.2.4 2S207 – Knee Wall Dimensions

2.6.2.5 2S121 – Filter House Platform Dimensions, Location, and Loading

2.6.2.6 2A501 – Weatherproofing at Filter House

2.6.2.7 2A504 – Wall Section

2.6.2.8 2A506 – Weatherproofing for Gas Turbine Exhaust

The Contractor shall reference and utilize the latest version available when performing tasks within this PWS.

3.0 REQUIREMENTS

https://www.astm.org/ http://everyspec.com/

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3.1 GENERAL:

3.1.1 Each System listed in Table 1 shall be designed and fabricated to ensure they:

3.1.1.1 Provide a complete and airtight interface with the Gas Turbine for the complete length of system.

3.1.1.2 Communicate with the LBES Control System(s) as defined in this SOW.

3.1.1.3 Comply with original equipment manufacturer (OEM) air quality and flow requirements for combustion, cooling, and exhaust systems and incorporate design considerations detailed in Applicable Document 2.4.1.

3.1.1.4 Prevent foreign debris from entering the Gas Turbine.

3.1.1.5 Meet all Local, State, and Federal environmental and emissions requirements as defined in this specification.

3.1.1.6 Able to be installed within the building architecture detailed by Applicable Document 2.6.1 and

2.6.2, and as required in Section 3.0 of this SOW.

3.1.2 The Combustion Air Intakes and Uptakes Systems shall be fabricated, inspected, modeled, and shipped by skilled individuals in the various crafts to be executed in a first class and workmanlike manner IAW recognized good industry practice.

3.1.3 Where internal sheathing and insulation are used in fabrication of modular assemblies, the Contractor shall vacuum clean all surfaces prior to installing insulation and perforated sheathing to remove loose material (such as grit blast) that may be left behind and ingested by the engine. In addition, assemblies shall also be vacuum cleaned after fabrication and inspection and prior to shipping. (CDRL A008 “Certification Data Report”)

3.1.4 The Government owned Gas Turbine will be inside an enclosure. Each system shall interface to the Gas Turbine IAW Applicable Document 2.4.1.

3.1.5 Installation design checklist shall comply with Appendix F Chapter 5, 6 & 7 of Applicable Document 2.4.1.

(CDRL A004 Installation/Operation/Maintenance Instructions)

3.1.6 All gasket, fasteners, lagging, etc. required to install the designed systems to itself and to gas turbine shall be furnished with assembly.

3.1.6.1 The Government will assemble the modular sections to complete installation of each system.

3.1.7 Contractor shall supply any special tools and spare parts required to perform maintenance identified in Data Deliverable A004 “Installation/Operation/Maintenance Instructions”.

3.1.8 Contractor shall provide the following information specifically for each of the four Systems listed in Table 1:

3.1.8.1 CDRL A002 Packaging Plan

3.1.8.2 CDRL A003 Commercial Engineering Design Data and Associated Lists

3.1.8.3 CDRL A005 Commercial Off-the-Shelf (COTS) Manuals and Associated Supplemental Data

3.1.8.4 CDRL A007 Interface Design Description (IDD)

3.2 GENERAL – SYSTEM MODULAR REQUIREMENTS:

3.2.1 Each system listed in Table 1 shall be modular to the greatest extent possible to meet the Government’s installation requirements.

3.2.2 Each System shall be designed and fabricated to allow for Government lifting, installation, and final connections.

3.2.2.1 Each modular section shall not exceed 10,000 LBS

3.2.2.2 System/modular sections, to be installed inside the building, shall be sized to fit through the south roll-up door.

3.2.2.2.1 Roll-up door dimensions are depicted in Applicable Document 2.6.2.1.

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3.2.2.2.2 Size of system/modular sections shall allow for delivery through roll-up door opening accounting for lifting and handling equipment.

3.2.2.3 Other constraints that Contractor shall adhere to are detailed in Applicable Document 2.6.1.

3.2.3 Modular sections shall be designed with lifting attachment points that support lifting and handling of individual components.

3.2.3.1 Rigging and lifting plan, to include design of lifting pad-eyes, shall comply with Applicable

Document 2.2.3. (CDRL A004 “Installation/Operation/Maintenance Instructions”)

3.2.4 All systems, ducting, expansion joints, and connections shall contain internal surfaces which are as smooth as practical, with strengthening members on external surfaces where required.

3.3 GENERAL – SYSTEM DESIGN REQUIREMENTS: (applies to all four systems listed in Table 1)

3.3.1 The systems shall be designed and supported to prevent loads exceeding the capabilities of flexible connections and expansion joints.

3.3.2 The design shall minimize the transfer of vibration to the supporting structure and withstand stresses induced by weight, steady-state and transient thermal expansion, engine vibration, pressure pulsations, and pressure thrust caused by exhaust gas and intake air.

3.3.2.1 Vibration generated by the Gas Turbine propulsion system and associated components shall be accounted for into the design of the system.

3.3.2.2 Design and arrangement of systems shall minimize turbulence.

3.3.3 System Inlets shall be located as to not ingest fumes or discharge from other systems.

3.3.4 All components of each system, excluding expected replacement parts (i.e. filters, etc.), shall be designed and fabricated to have a fatigue life at or longer than LBES predicted service life (35 years).

3.3.4.1 Fatigue life shall include thermal cycling representing approximately 200 gas turbine stop-start cycles per year.

3.3.5 Instrumentation connections (i.e. sample ports, sensor ports) shall be accessible from platform levels defined in Applicable Document 2.6.1.

3.3.6 Thermal and sound requirements for the building and operator safety shall be taken into account for design.

3.3.6.1 Sound pressure levels produced by the system shall be minimized in design and shall not exceed

84 dBA from one meter away.

3.3.6.2 Any surface accessible to personnel during operation and maintenance shall not exceed 125 degrees Fahrenheit.

3.3.7 Ducting and insulation shall be designed to comply with Applicable Document 2.3.1 chapters 13, 18, 27, and 35 and Applicable Document 2.3.2.

3.3.8 Structural adequacy of the ducting, including anchors and hangers, shall be verified using FEA and linear analysis methodology of Applicable Document 2.1.5. Structural adequacy shall be approved by a licensed professional engineer. (CDRL A006 Performance Analysis Report)

3.3.8.1 Maximum loading for anchors, hangers, resilient mounts, and other duct stiffeners shall be specified.

3.3.8.2 Anchors, hangers, resilient mounts, and other duct stiffeners shall be evaluated to withstand thermal transient and vibration loading and shall not exceed loading identified in analysis.

3.3.9 Cyclic stress ranges and cycle counting methods specified in Applicable Document 2.1.7 shall be employed to establish the stress histogram used to assure the uptake design meets its design fatigue life. (CDRL A006 Performance Analysis Report)

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3.3.10 Computational fluid dynamic analysis, scale model test, or full-scale inlet distortion test shall be conducted to validate design. (CDRL A006 Performance Analysis Report)

3.3.11 Lightning rod and grounding leash attachment points shall be provided for ducting exterior of the building.

3.3.11.1 The Government will determine appropriate grounding points and make connections.

3.3.12 Each system shall contain proper drainage to remove any water collected within the system prior to connecting to the Gas Turbine.

3.3.12.1 Drains shall be placed at any low points contained in each system.

3.3.12.2 All drains shall incorporate a “U” shaped water trap and siphon breaker (a.k.a P-traps). Customer interface will be directly downstream of water trap.

3.3.12.3 Drains shall be sized to accommodate worst-case loading.

3.3.12.4 Drains shall be located to avoid freeze-up or back-flow.

3.3.12.5 Each drain shall prevent backflow of air or water by use of a check valve or diaphragm.

3.3.12.6 Maximum drain backpressure allowable is 3 inches of water IAW Applicable Document 2.1.4.

3.3.13 All walking/working surfaces of the system shall comply with Applicable Document 2.3.2 Subpart D, Walking-Working Surfaces to the extent possible. Where OSHA 1910 requirements for walking/working surfaces cannot be met, Contractor shall inform NSWCPD, and on-site fall protection requirements shall meet Applicable Document 2.3.1 Chapter 13 after system receipt.

3.3.14 Electrical equipment shall be designed and fabricated IAW Applicable document 2.3.1 chapter 35, and IAW Applicable Document 2.3.4, National Fire Prevention Association (NFPA) 70 National Electrical Code.

3.3.15 All fasteners shall be made of Corrosion-Resistant Steel (CRES 316).

3.3.15.1 All fasteners in the airflow path shall be positively retained and shall not be rivets.

3.4 GENERAL – SYSTEM ARRANGEMENT DESIGN:

3.4.1 Each system shall be designed to be arranged within the dimensions referenced in Applicable Document

2.6.1 as the conceptual foundation which defines the constraints of design.

3.4.1.1 Systems shall be designed to connect to the Gas Turbine installed in the center bay at NSWCPD.

3.4.1.2 Each System and all system modular components shall be designed to interface with each other and the existing structural members detailed in Applicable Document 2.6.1.

3.4.1.2.1 Each System shall only use the structural supports detailed in Applicable Document

2.6.1.

3.4.1.2.2 No structural elements of the building structure can be used.

3.4.2 Personnel access shall be made available to both the interior of ducting and within filter house to perform all scheduled maintenance and inspections on system components and structures.

3.4.2.1 Access platforms to service gas turbine systems and removal of the gas turbine are defined in

Applicable Document 2.6.1.

3.4.2.2 Access points for personnel within duct work and for regularly scheduled maintenance tasks shall be accessible from platform levels defined in Applicable Document 2.6.1.

3.4.2.2.1 The bottom of each access point shall be between 3’ – 5’ above each deck.

3.4.2.3 Replacement of system ducting shall be incorporated as a maintenance task.

3.4.3 Airtight access shall be provided via access openings, removable cover plates, and internal welded grab rods.

3.4.3.1 Access plates shall be bolted and open outwards.

3.4.3.2 Access doors shall be designed with a lock so that they can be locked during normal operation.

3.4.3.3 Intake and uptakes too small for entry shall have opening with removable cover plates at the ends of horizontally installed sections for clean out.

3.4.3.4 Access points shall be accessible from each platform detailed in applicable document 2.6.1.

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3.4.3.4.1 The bottom of each access point should be between 3’ – 5’ above each deck. If not possible to be between 3’ – 5’, then the Contractor shall specifically point this out.

3.4.3.5 Additional access shall be provided to horizontal sections of ducting.

3.5 GENERAL – SYSTEM AND MODULAR CONNECTIONS:

3.5.1 Components that are pre-drilled for mechanical connections shall be designed such that the potential for misalignment of expansion joints during installation is minimized and shall not exceed expansion joint manufacturer misalignment specifications.

3.5.2 The use of expansion joints during installation shall be minimized but shall be used as required for flexibility and to allow free thermal expansion and contraction of piping.

3.5.3 Expansion Joints used in each system shall be IAW Applicable Document 2.1.4.

3.5.3.1 Where metal expansion joints are used, they shall be of the bellows type.

3.5.3.2 Bellows sections shall be of corrugated or plate construction.

3.5.3.3 Corrugated bellows shall be multi-ply.

3.5.3.4 Internal flow liners shall be used to prevent erosion of the bellows.

3.5.3.5 Materials that are subject to work hardening shall not be used for expansion bellows.

3.5.4 Flange connections shall not be used except where required for maintenance, equipment removal, expansion joints or where installation precludes welding.

3.5.5 Three flex joints are supplied by the gas turbine vendor for the intake, module cooling and exhaust connections on the top of the gas turbine enclosure. Systems shall interface at flex joint flange connection shown in Applicable Document 2.4.2.

3.5.6 Wherever flanges are utilized, they shall be IAW Applicable Document 2.1.3.

3.6 FILTER HOUSE SYSTEM SPECIFIC:

3.6.1 DESIGN:

3.6.1.1 Shall include, at a minimum, the following design elements: Filter house, Foreign Object Debris (FOD) screen, ducting, inlet filters, water wash, anti-icing system and insulation.

3.6.1.2 Filter house shall be designed such that weather protection is provided over air inlet to reduce the ingestion of water.

3.6.1.3 Opening of the duct shall be designed so that flow is uniform across the face of the filter.

3.6.1.4 Flared section at the entrance is required to ensure uniform flow downstream.

3.6.1.5 FOD screen shall be installed upstream of anti-icing piping, water wash piping and screens shall be fabricated using Wire Mesh, 0.063 IN DIA wire, No. 4 Mesh, CRES 316.

3.6.1.6 Filters shall provide clean filtered air to the Combustion Air Intake and meet the flow and cleanliness requirements of the Gas Turbine as required by applicable document 2.4.1.

3.6.1.6.1 If advantageous, and the Gas Turbine air flow requirements are not impacted, cooling air inlet may come from the filter house through an independent intake and shall meet requirements in SOW Section 3.8 Cooling Air System Specific.

3.6.1.7 The filters shall be sized to facilitate handling and cleaning.

3.6.1.7.1 Filter materials shall be fire resistant and of consistent material density throughout.

3.6.1.7.2 Removable filters shall be enclosed in a rigid, self-contained frame fabricated of CRES, Class 316L, IAW Applicable Document 2.1.1.

3.6.1.8 The Filter House shall be equipped with a moisture separator meeting the performance requirements outlined in performance section 3.3.12.

3.6.1.9 Zinc plating shall NOT be used to protect the intake structure exposed to the engine inlet air.

3.6.1.10 All fasteners used in the Filter House shall be self-locking and made of Corrosion-Resistant Steel

(CRES 316).

3.6.1.11 ANTI-ICING SYSTEM: The Filter House shall have an anti-icing system installed upstream of filters.

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3.6.1.11.1 The anti-icing system shall be capable of keeping the Filter House and its components sufficiently operable without affecting the required engine performance or operation.

3.6.1.11.1.1 The anti-icing system shall ensure the compressor inlet or inlet plenum meets the requirements of paragraph 5.5 and figure 5-2 of Applicable Document 2.4.1.

3.6.1.11.1.2 Material Schedule shall be designed to meet the design requirements defined in applicable documents 2.4.6.

3.6.1.11.2 Anti-Icing System Manifolds shall:

3.6.1.11.2.1 Be designed to raise the combustion air inlet temperature a minimum of

10 Deg F at all operating conditions.

3.6.1.11.2.2 Be installed between the weather and the filters and shall be directed to promote mixing.

3.6.1.11.2.3 Anti-icing air manifold discharge hole patterns shall be designed to distribute air evenly as possible across the intake filters.

3.6.1.11.2.4 Test connections shall be provided at each end of the anti-icing manifold header pipe.

3.6.1.11.2.5 Test connections shall be capped when not in use.

3.6.1.11.2.6 Test connections shall be oriented up to prevent water from collecting.

3.6.1.11.2.7 Be accessible for maintenance.

3.6.1.11.3 The anti-icing system shall be equipped with a temperature/humidity sensor capable of communicating with the Government Control System.

3.6.1.11.3.1 The sensor shall be located in the Filter House to minimize exposure to wind and rain.

3.6.1.11.3.2 The anti-icing system shall activate automatically when freezing is possible

(Relative Humidity greater than or equal to 70%; Ambient temperature less than or equal to 40 deg F).

3.6.1.11.3.3 Activation of the anti-icing system will be accomplished by the Government Control System and Gas Turbine control valve.

3.6.1.11.4 The Filter House shall be designed and provided with piping to connect the anti-icing system to the Gas Turbine bleed air interface, shown in Applicable Drawing 2.4.2.

3.6.1.11.4.1 The piping shall include a manual throttling valve located near the Gas

Turbine to control the amount of air sent to the manifolds.

3.6.1.11.5 Anti-icing piping shall be designed to the following design requirements from Applicable

Document 2.4.6:

3.6.1.11.5.1 Piping shall be IAW the Material Schedule table in Applicable Document

2.4.6.

3.6.1.11.5.2 Design Pressure equal to 320 PSI

3.6.1.11.5.3 Design Temperature 975 Deg F

3.6.1.11.5.4 Test Pressure 430 PSI

3.6.1.12 Filter house shall be equipped with water wash hose bibs near access points to allow for manual wash down of filters.

3.6.1.12.1 Water connections and piping will be provided by the Government.

3.6.1.13 Filter house shall be designed with a minimum of two access points: Qty (1) upstream of filters and Qty (1) downstream of filters.

3.6.1.13.1 Access point upstream of filters not required if filters are accessible outside of filter house.

3.6.1.13.2 If applicable, an access shall be provided to all horizontal sections of ducting.

3.6.2 INTEROPERABILITY / CONNECTIONS:

3.6.2.1 Differential pressure gauge and transducer shall be installed to measure the air pressure difference across the filter. This signal will communicate to LBES Control System.

3.6.2.1.1 Pressure transducers shall be able to accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.6.2.2 The filter house anti-icing temperature sensor shall connect with the Government Control System and the Gas Turbine Sensor and Control Valve. The temperature sensor shall also meet the following requirements:

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3.6.2.2.1 Accurate within 1.5 deg F.

3.6.2.2.2 Provide one of two possible electrical signal output: 1 4-20mA, DC in accordance with applicable document 2.1.6, or a continuous digital volt-free contact output. (Signal type will be clarified by the government at a later date)

3.6.2.2.3 Have signal conditioning, either integral to the sensor or provided in addition to the sensor.

3.6.2.3 Electrical Connections

3.6.2.3.1 Filter House shall be equipped with a waterproof power panel on the interior weather side of the filter populated with breakers which serve all electrical loads in the Filter House including interior and exterior lighting, exit signs, etc.

3.6.2.3.2 Filter House electrical loads requiring uninterruptable power shall be equipped with a local UPS to power emergency lighting and other necessary loads in the event of loss of facility power.

3.6.3 PERFORMANCE:

3.6.3.1 The filtered air supplied by the Filter House shall have acceptable pressure, velocity, and temperature profiles IAW Applicable Document 2.4.1.

3.6.3.2 IAW Applicable Documents 2.4.1, Filter House System shall ensure that filtered air reaching the Gas Turbine does not contain:

3.6.3.2.1 95% of the time – solid particles exceeding .004 grains/1,000 ft^3

3.6.3.2.2 5% of the time - .04 grains/1,000 ft^3

3.6.3.3 Filtration requirements shall be IAW Applicable Documents 2.4.1 with the following exceptions:

3.6.3.3.1 The amount of water entering the Intake Systems (Combustion Air and Cooling Air) shall not exceed 3 percent of the inlet flow.

3.6.3.3.2 There is no requirement to limit salt intake.

3.6.3.4 Intake filters shall reflect Gas Turbine requirements for installation and operation in an industrial environment as defined by Applicable Document 2.4.1.

3.6.3.5 Filter house design shall prevent the collapse of the ducting due to blockage of the weather inlet or air filter.

3.6.4 INSTALLATION LOCATION / REQUIREMENTS:

3.6.4.1 The Filter House shall be designed to be mounted to an existing roof top structural steel platform detailed in Applicable Document 2.6.1. (Sheet 6 Section Views 43A and 46A) and 2.6.2.5. This includes the foundation platform, structural support members and building penetration.

3.6.4.1.1 Filter house representation in Applicable Document 2.6.1 is for reference only and design is not required to match geometry.

3.6.4.2 The Filter House shall be outdoor rated and constructed with protective coatings and seals capable of operating in the typical Philadelphia, PA regional climate and during inclement weather.

3.6.4.3 The Contractor shall validate that there will be no corrosion issues between the Filter House manufactured frame and the existing structural steel.

3.6.4.4 The Filter house shall connect to combustion air intake system, and Cooling Air System (if applicable), via airtight connection point.

3.6.4.5 System design shall provide means to weatherproof the penetration between filter house and the building. Penetration and wall details can be found in Applicable document 2.6.1 and 2.6.2.

3.7 COMBUSTION AIR INTAKE SYSTEM SPECIFIC:

3.7.1 DESIGN:

3.7.1.1 Shall include, at a minimum, the following design elements: ducting, expansion joint, lagging/insulation and interface with gas turbine/ filter house.

3.7.1.2 Ductwork shall contain the minimum required number of bends and contractions to meet installation and operational requirements.

3.7.1.3 There shall be no projections inside the inlet ducting.

3.7.1.4 The duct material shall not contribute corrosion products to the air stream.

3.7.1.5 Zinc plating shall NOT be used to protect the intake structure exposed to the engine inlet air.

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3.7.1.6 Shall contain design features to allow for removal of the gas turbine through the combustion air intake via hoist and crane hook lift fixtures.

3.7.1.6.1 Intake duct design shall include design of removable rail system.

3.7.1.6.2 Intake duct rail system shall interface with Gas Turbine rail system IAW Applicable

Document 2.4.3.

3.7.1.6.3 Gas Turbine transition pieces shall accommodate rake angle, and rails exit normal to Gas

Turbine module detailed in Applicable Document 2.6.1 (Sheet 6 Section View 43A).

3.7.1.6.4 Rail path shall mimic ship design IAW Applicable Document 2.4.4 to the greatest extent possible. Extraction point of gas turbine shall differ from ship design to meet the constraints of the support structure and the building.

3.7.1.6.4.1 Rail path and GT extraction point are shown in Applicable Document 2.6.1

(Sheet 6 Section View 43A).

3.7.1.6.5 Rail system holes shall be marked and drilled by the Government during fit-up to ensure proper alignment.

3.7.1.6.6 Alignment fixture shall be provided to test rail installation and alignment verification.

3.7.1.6.6.1 Fixture shall fully mimic the engine roller positions and be used to set the rails for welding to the structure and to confirm the rail alignment after welding.

3.7.1.6.6.2 The overall dimensions of the alignment fixture will be 6 FT DIA x 12 FT to mimic the gas turbine.

3.7.1.6.7 Complete combustion air intake system and removal point shall be sized to allow for the removal of a 6FT DIA x 12 FT gas turbine as stated in Applicable Document 2.4.1.

3.7.1.6.8 All welding of the rails and foundations should be complete before the thermo-acoustic insulation is installed.

3.7.1.7 System shall be provided with a minimum of two access points: QTY (1) at inlet plenum, QTY (1) at gas turbine removal location. Access points are shown in Applicable Document 2.6.1 (Sheet 6 Section View 43A).

3.7.1.7.1 Additional access shall be provided to horizontal sections of ducting.

3.7.1.8 Intake connection to filter house shall remain as true as possible to the 100 IN x 100 IN duct size represented in the ship design as represented in Applicable Document 2.4.7.

3.7.1.9 Shall utilize a flex joint assembly to connect the inlet duct to the Gas Turbine and the seal must place no more than 100 lb./f of axial load, no bending, and no shear load on the engine.

3.7.2 INTEROPERABILITY / CONNECTIONS:

3.7.2.1 Instrumentation connections are shown in Applicable Document 2.6.1 (Sheet 5 Section View 37A.

3.7.2.1.1 RTD temperature transmitters shall provide an integrated programmable 4-20 mA output that can accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.7.2.1.2 Pressure transmitters shall accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.7.2.2 The Combustion Air System shall connect to the Filter House System via an airtight connection point.

3.7.3 PERFORMANCE:

3.7.3.1 Shall be sized to meet the Gas Turbine manufacturer’s requirements for combustion air intake and provide no less than 200 lbs./s (90.7 kg/s) combustion airflow plus package ventilation air flow.

3.7.3.2 Shall contain splitters and turning vanes as necessary to minimize turbulence and pressure drop to meet the Gas Turbine manufacturer’s performance requirements for compressor inlet flow as defined within applicable document 2.4.1.

3.7.3.3 Shall be designed to withstand compressor surging without collapse as specified by the engine manufacturer within applicable document 2.4.1.

3.7.3.4 The maximum total pressure loss shall not exceed 12 inches of water measured as measured at the inlet opening of the engine IAW Applicable Document 2.4.1.

3.7.4 INSTALLATION LOCATION / REQUIREMENTS:

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3.7.4.1 The Combustion Air System shall be designed for installation within the constraints detailed within Applicable Document 2.6.1.

3.7.4.2 The combustion intake shall be routed through the opening identified in Applicable Document

2.6.2.3. Opening size and location detailed in attached Applicable Document 2.6.1 and 2.6.2.3.

3.7.4.2.1 Contractor shall design and provide weatherproofing for the intake duct opening.

3.7.4.2.2 Dimension of the opening does not include weatherproofing.

3.7.4.2.3 Opening is intended for the combustion air intake from exterior filter house to interior of the building.

3.7.4.2.4 Opening may also be used for cooling air system, if required, and it does not impact Gas

Turbine operation.

3.8 COOLING AIR SYSTEM SPECIFIC:

3.8.1 DESIGN:

3.8.1.1 Shall include at a minimum, the following design elements: ducting, cooling fan, inlet filters and lagging/insulation.

3.8.1.2 Shall interface with Gas Turbine IAW Applicable Document 2.4.1.

3.8.1.3 Shall be designed to house Howden Model IR340-270D2541 Gas Turbine Cooling Fan, 160 HP.

3.8.1.3.1 Fan will be provided and installed by the government.

3.8.1.3.2 The cooling fan will connect to and be controlled by the gas turbine engine control system.

3.8.1.4 Cooling air fan bell mouth shall be fitted with a ½ IN mesh FOD screen.

3.8.1.5 Shall provide cooling air during all Gas Turbine operation and for post shut-down cooling.

3.8.1.6 Ductwork shall contain the minimum required number of bends and contractions to meet installation and operational requirements.

3.8.1.7 Shall be provided with a minimum of two access points: QTY (1) immediately upstream of Gas

Turbine, QTY (1) between inlet filter and cooling fan.

3.8.1.7.1 Additional access shall be provided to horizontal sections of ducting.

3.8.1.8 Applicable Document 2.6.1 depicts cooling drawn from inside the building with additional filtration. It also provides an example of cooling air being drawn from combustion air intake ductwork inside of the building.

3.8.1.8.1 If advantageous, and Gas Turbine air flow requirements are not impacted, cooling air inlet may come from different sources. Regardless of cooling air inlet source, cooling air requires the same filtration criteria as the combustion air. Alternate, allowable cooling air configurations include, but are not limited to:

3.8.1.8.1.1 Cooling air drawn from combustion air filter house.

3.8.1.8.1.2 Cooling air is drawn from inside the building with additional filtration.

3.8.1.8.1.3 Cooling air is drawn from the combustion air intake ductwork inside of the building, downstream of the combustion air filter house.

3.8.1.9 If system originates from weather, the cooling air system shall hold the same environmental requirements as filter house as described in 3.6.1.6 and 3.6.1.6.1.

3.8.2 INTEROPERABILITY / CONNECTIONS:

3.8.2.1 Differential pressure gauge and pressure transducer shall be installed to measure the air pressure difference across the filter. This signal will communicate to LBES Control System.

3.8.2.1.1 Pressure transducers shall be able to accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.8.2.2 If cooling air originates from weather and not from the combustion air filter house, the filters shall be equipped with anti-icing temperature/humidity sensor.

3.8.2.2.1 Sensor location shall be chosen to minimize exposure to wind and rain.

3.8.2.2.2 Sensor shall alarm anti-icing system at 40 Deg F or less and a relative humidity 70 percent or higher.

3.8.2.3 If cooling air originates from weather, activation of anti-icing system shall be communicated to

LBES Control System.

3.8.3 PERFORMANCE:

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3.8.3.1 Shall evenly distribute cooling air flow over the outside of the module at a rate of 3-4 cubic feet per second when the Gas Turbine is operating.

3.8.3.2 Shall provide the Gas Turbine with adequate cooling airflow as specified by the OEM within Applicable Documents 2.4.1.

3.8.3.2.1 Cooling air shall be sized to 40 lb./s.

3.8.3.3 Filtration requirements shall be IAW Applicable Documents 2.4.1 with the following exceptions:

3.8.3.3.1 The amount of water entering the Intake Systems (Combustion Air and Cooling Air) shall not exceed 3 percent of the inlet flow.

3.8.3.3.2 There is no requirement to limit salt intake.

3.8.4 INSTALLATION LOCATION / REQUIREMENTS:

3.8.4.1 The Cooling Air System shall be designed for installation within the constraints detailed within

Applicable Document 2.6.1.

3.9 UPTAKE SYSTEM SPECIFIC:

3.9.1 DESIGN:

3.9.1.1 Shall include at a minimum, the following design elements: ducting, expansion joint, emission sampling ports, and lagging/insulation.

3.9.1.2 The interface between the exhaust duct and Gas Turbine Module is shown as interface M1 in Applicable Document 2.4.2.

3.9.1.3 Ductwork shall contain the minimum required number of bends and contractions to meet installation and operational requirements.

3.9.1.4 Maximum operating temperature of the uptake system shall be 1200 F in accordance with applicable document 2.4.2.

3.9.1.5 Inner surfaces of the exhaust ducts shall be restrained using retainer clips welded to the duct structure with sufficient clearance to include thermal expansion of all operating temperatures.

3.9.1.5.1 Retainer clips are only required if internal insulation is required for sound and/or thermal isolation.

3.9.1.6 The Exhaust Air System shall contain pipe connection sample ports for emission testing.

3.9.1.6.1 Emission testing sample ports depiction and location are described in Applicable

Document 2.6.1.

3.9.1.6.2 Emission port caps shall be airtight flange connections.

3.9.1.7 Design shall have sway cable connection locations to limit movement of exhaust ducting above roof top.

3.9.1.7.1 The Government will determine appropriate building anchor points and anchor.

3.9.1.8 The ducting shall be resistant to oxidation at high temps.

3.9.1.9 The ducting shall be resistant to corrosion from salts and acids.

3.9.1.10 Exhaust duct shall not buckle at loads 30 percent greater than operational loading.

3.9.1.11 Insulation material for ducting shall be designed to prevent personnel from being exposed to elevated temperatures and hot surface, to include removable insulation pads for all mechanical connections of ducting or access covers, shall be supplied by vendor.

3.9.1.11.1 Insulation shall reduce surface temperature below 125 Deg F assuming maximum operating exhaust temperature of the LM2500+G4.

3.9.1.11.2 Hot surface warning plates shall be fabricated and installed per OSHA Safety Requirements anywhere the Second and Third Deck (Applicable Document 2.6.1) are near uptake.

3.9.1.11.3 The First 8 Inches (203 MM) of Exhaust duct above the gas turbine module exhaust connection flex joint shall not be provided with external thermal lagging IAW Applicable Document 2.4.2.

3.9.1.12 Shall be provided with a minimum of two access points: QTY (1) directly above the module of Gas Turbine, QTY (1) at highest platform level within the building.

3.9.1.12.1 If applicable, an access shall be provided to horizontal sections of ducting.

3.9.1.13 All exhaust components shall be designed to connect with self-locking hardware suitable for applications up to 1200 DEG F.

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3.9.1.14 A modal (frequency) analysis of the exhaust duct shall be performed at room temperature and maximum duct temperature. The duct modal frequencies shall not be within +/- 25 percent of excitation frequencies. (CDRL A006 Performance Analysis Report)

3.9.1.15 The weight of the Uptake System shall be fully supported based on the depiction shown on Sheet 13 Details 103B and 99B of Applicable Document 2.6.1.

3.9.2 INTEROPERABILITY / CONNECTIONS:

3.9.2.1 Maximum allowable vertical load on exhaust collector flange is +/- 800 lb./ft IAW Applicable Document 2.4.1.

3.9.2.2 Maximum allowable moment in any plane at exhaust collector flange is 1,690 lb./ft and the max allowable shear load is 2,500 lb./ft IAW Applicable Document 2.4.1.

3.9.2.3 Maximum allowable loads on connecting fittings between the uptake ducting and Gas Turbine exhaust collector are 100 lb./ft shear, +/- 100 lb./ft axial and 220 lb./in bending moment IAW Applicable Document 2.4.1.

3.9.2.4 The mating flange shall have the same thermal expansion characteristics as the exhaust collector exit flange.

3.9.2.5 The uptake System shall contain ½ IN pipe connection immediately downstream of the Gas Turbine exhaust outlet for the purpose of obtaining static pressure and gas samples as shown in Applicable Document 2.6.1.

3.9.2.6 Instrumentation connections are shown in Applicable Document 2.6.1 (Sheet 11, Section View 85A.

3.9.2.6.1 RTD temperature transmitters shall provide an integrated programmable 4-20 mA output that can accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.9.2.6.2 Pressure transmitters shall accept +24 VDC power, loop resistance 250 ohms, with a connector or terminal board external wiring connection.

3.9.3 PERFORMANCE:

3.9.3.1 Shall ensure that the Gas Turbine’s uptake system will not:

3.9.3.1.1 Contaminate ventilation of combustion air intakes on the building roof, shown in

Applicable Document 2.6.1.

3.9.3.1.2 Interfere with operating crews

3.9.3.1.3 Create a fire hazard

3.9.3.1.4 Create a health hazard

3.9.3.2 Shall be supported with features that allow for thermal growth, pressure pulsations, and vibrations experienced during regular operation of the Gas Turbine.

3.9.3.2.1 Structural strength shall be capable of withstanding elevated temperatures of up to 1,200° F and rapid thermal expansion.

3.9.3.3 Shall contain splitters and turning vanes as necessary to minimize turbulence and backpressure to meet the Gas Turbine manufacturer’s performance requirements for exhaust flow.

3.9.3.4 Backpressure of the complete system shall be minimized to the greatest extent possible and meet the engine requirements detailed the Applicable Document 2.4.1.

3.9.3.5 Design shall attempt to maximize output velocity while remaining within specifications for Gas Turbine backpressure.

3.9.4 INSTALLATION LOCATION / REQUIREMENTS:

3.9.4.1 The Exhaust Air System shall be designed for installation within the constraints detailed within Applicable Document 2.6.1.

3.9.4.2 Gas turbine uptake shall be routed through the opening on roof of the building specified in Applicable Documents 2.6.1 and 2.6.2.2.

3.9.4.2.1 Contractor shall provide weather proofing for the uptake ducting using design provided in Applicable Document 2.6.2.8.

3.9.4.2.1.1 Dimension of opening does not include space required for weatherproofing opening.

3.9.4.2.1.2 Contractor shall verify that weatherproofing and uptake diameter meet maximum allowable opening size.

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3.9.4.2.2 Opening shall not be used to support the uptake system.

3.9.4.3 Shall discharge gases clear of the building. Refer to the Applicable Document 2.6.1 for depiction.

3.9.4.3.1 90 feet from ground level per the Government’s permit with the City of Philadelphia.

Approximate stack height is 66 FT in length from gas turbine interface.

3.9.4.3.2 Stack diameter of 8.5 feet at its outlet per the Government’s permit with the City of Philadelphia.

3.9.4.3.3 Centerline of exhaust discharge at 485,694.62 m Easting (X) and 4,415,342.40 m Northing (Y). This location is shown in Applicable document 2.6.2.2.

3.10 REPORTING, INSPECTION, AND MODELING:

3.10.1 The Contractor shall track and provide monthly updates regarding all material/equipment procurements, fabrication/construction efforts, inspections, and modeling in accordance with CDRL A001.

3.10.2 The Contractor shall perform and document all Inspections validating each system, and all components meet the requirements of the SOW and submit documentation IAW CDRL A008 “Certification Data Report”.

3.10.3 The Contractor shall submit all Modeling documentation/results IAW CDRL A006 “Performance Analysis Report”.

3.10.3.1 All Contractor or supplier-performed Proof-load, Environmental and Reliability Data, when applicable, should be completed prior to start of the fabrication and assembly.

3.10.3.2 Should any modeling item fail to conform to the specified requirements, the Contractor shall perform a failure analysis identifying the cause(s) of such failure along with the corrective action(s) to be taken. This analysis and corrective actions shall be supplied to the Government for review and approval.

3.10.3.3 If previously modeled items are changed or modified, the Contractor shall perform a complete rework the model to demonstrate conformance with specified requirements.

3.11 NAVY LIFTING STANDARDS:

3.11.1 System components shall be capable of being lifted by overhead crane. The Contractor’s standard Lifting and Handling Plan shall be included in the submission of CDRL A004 “Installation/Operation/Maintenance Instructions”.

3.12 NAMEPLATES, MARKINGS, AND NOTICES:

3.12.1 Nameplates, notices and the like shall be permanently attached to the equipment to bring the attention to the following:

3.12.1.1 Notices required by statutory regulations such as maximum safe working load.

3.12.1.2 Warning notices such as “DANGER”.

3.12.1.3 Equipment nameplates with the Manufacturer’s model and data.

3.12.1.4 Should personnel access to equipment interiors through openings, plates, ports or doors create a confined space as defined by OSHA 1910.146 contractor shall identify the existence, location and danger of the accesses to the confined spaces.

3.12.2 Suitable nameplates shall also be attached to meters, indicators and control switches furnished with the equipment.

3.12.3 Nameplates and notices shall be of appropriate size and the information contained thereon be easily read from all operating positions. They shall be affixed to the equipment so that they cannot be removed or destroyed through wear and tear.

3.12.4 Stampings and engravings shall be of sufficient depth so that the letters, numbers, and wording shall not be worn away by the prevailing environmental conditions.

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3.12.5 System component terminals and wires shall be labeled with markings that remain visible after connections are made.

3.12.6 Nameplate material shall be of stainless steel or equivalent approved by NSWCPD.

3.12.7 All interconnecting wiring, equipment and terminal board points shall be properly identified using identification marking.

3.12.8 System equipment nameplates shall have all necessary information to facilitate identification and installation and shall include but not be limited to (as applicable):

3.12.8.1 Name of Manufacturer

3.12.8.2 Contract number (when applicable)

3.12.8.3 Equipment tag…