PWS for Aircraft Fire Training Facilities.pdf

FA480921Q0068

PERFORMANCE WORK STATEMENT

FOR

INSPECTION, MAINTENANCE AND REPAIR

OF

AIRCRAFT FIRE TRAINING FACILITIES

AT

SEYMOUR JOHNSON AFB, NC

REVISED 2/18/2021

DWIGHT D. YOUNG

Deputy Chief Operations Flight

1. DESCRIPTION OF SERVICES. The contractor shall provide all supplies, materials, tools, equipment, and qualified labor necessary to inspect, test, and maintain the Aircraft Fire Training Facility (AFTF) at SEYMOUR JOHNSON AFB in a manner that will ensure its serviceability and prevent deterioration in operational effectiveness. The contractor shall comply with manufacturer’s recommendations and procedures, Air Force Technical Order (TO) 35E1-2-13-1 Operation and Maintenance Instructions for Aircraft Fire Training Facilities, 25 June 2013 and local, state and federal guidelines as applicable to the work involved. Installation, testing and replacement of gas piping, gas utilization equipment or accessories, repair and servicing of equipment, shall be performed only by qualified personnel. In the interest of safety, all persons employed in handling LP-Gases shall be trained in proper handling and operating procedures, which the employer shall document. After major maintenance or when a major problem is discovered, the owner the Government will contact Air Force Civil Engineer Center (AFCEC), the commissioning authority to determine what actions will be taken. AFCEC will determine if the AFTF will remain out of service, and if a site visit is necessary. Examples of major problems include: Any safety related condition that could lead to an imminent hazard such as: LPG piping or tank corrosion that has reduced the wall thickness to less than that required for the maximum allowable operating pressure. Any crack or other material defect that impairs the structural integrity or reliability of a LPG tank or piping. Any abnormal movement by environmental causes, such as earthquakes, landslides or floods that may impair the serviceability of a pipeline, tank or controls. Any malfunction or operating error that causes the pressure of a LPG pipeline or tank to rise above its maximum allowable working pressure or a leak in the LPG pipeline or tank that constitutes an emergency. Periodic reviews of the AFTF’s will be conducted by AFCEC to determine the effectiveness of the normal 6 month inspection procedures.

1.1 INSPECTION, TESTING, AND MAINTENANCE SERVICES. The contractor shall maintain the AFTF by scheduling and conducting two semi-annual inspections (not to exceed 180 days) in conjunction with winterization/de-winterization (Appendix B) activities where applicable. The contractor shall perform all inspections, testing and maintenance IAW T.O 35E1-2-13-1, 25 June 2013 Edition. The inspections shall be IAW Table 1 WP 006 and Table 3 WP 007 of the T.O. The contractor shall provide a written summary of the conditions found during the inspection to the Contracting Officer Representative (COR). The contractor shall provide a cost estimate to repair/replace item identified as discrepancies including labor.

Materials, supplies, and parts needed for AFTF repairs. All invoices submitted for payment of services shall include a line(s) for materials, parts and supplies the contractor has procured. The cost estimate shall include:

a. Identification of source that supplied the item

b. Manufacturer or brand name of item

c. Unit of issue

d. Suggested list price

e. Actual cost to contractor (government reimbursable)

f. Identification of where the item was used

1.1.2. HDPE LINER MAINTENANCE. The 80-mil thick HDPE liners are located in the water conservation pond, burn area, and trench. The liners in the trench and burn pit are buried. If a leak is detected or reported, the contractor shall locate the liner leak and repair in accordance with extrusion welder manufacturer's instructions (National Seal Company, 1245 Corporate Blvd., Suite 300, Aurora, IL 60504. Telephone (708) 898-1161 or (800) 323-3820). The contractor shall submit to CES for approval and repair procedures, materials, and techniques prior to the specific repair of the HDPE liners. Additionally, the contractor shall adhere to the following general guidelines.

1.1.2.1. Yellow plastic warning tape, buried 12 inches below the surface, indicates underground wiring, anodes, grounding cells, or reference electrodes. The contractor shall properly replace the warning tape prior to backfilling.

1.1.2.2. Examine all seams and non-seam areas of the geomembrane to identify holes, blisters, defects, unsupervised raw materials, and any signs of contamination by foreign matter. Record repair/corrective action.

1.1.2.3. Do not weld or replace geomembrane during precipitation or if excessive moisture, blowing dust, high winds, or standing water is present.

1.2. RESPONSE TIMES. The contractor shall respond to propane leak service calls by providing immediate verbal assistance and physical assistance within 2 hours. After the leak has been stopped, the contractor shall complete the repairs by the next workday. Liner maintenance response shall be determined by the severity of the damage. For all other repairs, the contractor shall respond within 5 days.

1.3. REPORTS. Records of each inspection shall be in sufficient detail to demonstrate the adequacy of the inspection and shall be received by the COR within 10 working days of the inspection.

1.4. ENVIRONMENTAL CONTROLS. The contractor shall be knowledgeable of and comply with all applicable Federal, State, and local laws, regulations, and requirements regarding environmental protection. The contractor shall ensure policies and procedures are established that protect the health and safety of employees and the community and minimize/eliminate the risk of environmental pollution.

1.5. NOTIFICATION OF ENVIRONMENTAL SPILLS. If the contractor spills or releases any hazardous substance into the environment, the contractor shall immediately report the incident to the COR, base fire department 919-722-3837, and base civil engineering at 919-722- 5139. The contractor shall be liable for containment and environmental clean up of the spill or release of such substance per OPLAN 32-7 Oil and Hazardous Substance Spill Prevention and Response Plan.

1.6. SAFETY. Liquid propane used in the facility is potentially explosive. Personnel shall practice proper grounding procedures in accordance with the National Electrical Code (NEC).

Personnel working with or near high voltage equipment should be familiar with modern methods of resuscitation. Personnel shall wear appropriate protective clothing and be aware of emergency procedures to perform emergency shutdown and start-up.

1.7. ACCIDENT PREVENTION. The contractor shall comply with the Air Force Occupational Safety and Health (AFOSH) Standards, Occupational Safety and Health Act (OSHA) 1926 Standards, OSHA 1910 standards, and the Army Corps of Engineers Manual (EM 385-1-1). It is the responsibility of the contractor to obtain these publications.

1.8. WARRANTY OF WORK. The contractor warrants that work performed under this contract shall conform to the contract requirements and shall be free of any defects including work performed by a subcontractor. The contractor shall be responsible for replacing any warrantied/guaranteed items. The contractor shall remedy at the contractor’s expense any damage to Government-owned, or controlled real or personal property. A one year warranty shall be provided on all workmanship. The manufacturer’s warranty will apply to all installed parts/equipment.

2. SERVICE DELIVERY SUMMARY.

Performance Objective SOW Para Performance Threshold

Maintain and Repair the AFTF.

Items requiring maintenance are timely and correctly repaired or replaced. Submit accurate and timely reports.

1.1. & 1.3. The AFTF is operational at all times to permit ARFF training when needed. Submit reports within 10 working days. 100%

Response Time.

Response to propane leaks and liner maintenance are timely.

1.2. Provide immediate verbal

assistance and respond to propane leaks within 2 hours.

Respond to liner maintenance as conditions dictate.

Environmental Controls.

Contractor shall comply with all Federal, State, and local environmental requirements.

1.4. & 1.5. 100% Compliant

3. GOVERNMENT FURNISHED PROPERTY. The government shall provide a man-lift with operator for maintenance and repair of AFTF.

4. GENERAL INFORMATION.

4.1. CONTRACTOR EMPLOYEES. The contractor shall utilize responsible, capable employees in the performance of tasks on this contract. The contractor shall employ experienced personnel who are qualified to inspect, perform maintenance and repair Aircraft Fire Trainer Systems. The contractor may be asked to remove persons who pose a threat to the health, safety, security, general wellbeing, or operational mission of the installation and its population.

Contractor personnel, while on duty, shall be easily recognized as contractor employees and shall have badges bearing the name of the company and the employee’s name.

4.1.1 The contractor shall ensure all employees working on Seymour Johnson Air Force Base possess proper identification and/or citizenship documentation. Under the Immigration and Nationality Act (INA), employers may hire only persons who may legally work in the United States (i.e., citizens and nationals of the U.S.) and aliens authorized to work in the U.S. The employer must verify the identity and employment eligibility of anyone to be hired (Ref: U. S.

Department of Labor: http://www.dol.gov/compliance/guide/aw.htm#whowhich)

4.2. Motor Vehicle Operations. Contractor personnel operating motor vehicles or equipment on the installation must possess a valid state driver’s license for the type of vehicle or equipment they are operating, provide vehicle registration and the proof of insurance document from insurer.

4.3. GOVERNMENT REMEDIES. The contracting officer shall follow the requirements of FAR 52.212-4, Contract Terms and Conditions -- Commercial Items, for contractor’s failure to correct nonconforming services.

4.4. HOURS OF OPERATION. The contractor shall establish a work schedule, which requires work to be performed during normal duty hours (7:30 AM to 4:30 PM) Monday through Friday. These hours are concurrent with the local Base Civil Engineer maintenance shops.

4.4.1. Service Call work shall be provided and rendered at all hours any day of the week including holidays. The contractor shall respond to call back work no later than twenty-four (24) hours after initial notification for service.

4.5. SECURITY REQUIREMENTS. The contractor shall ensure that all employees have a current and valid base pass when performing work on this installation (Visitor Control Center is located at 1050 Wright Brothers Avenue, just outside the Berkeley Blvd gate, phone 919-722- 1343). Any employee entering the flight line area must be properly authorized to do so by base operations personnel or must be escorted by authorized Government representatives (Base Operations is located in Bldg. 4507, phone 919-722-4097). The contractor shall conform to all Base Regulations and directives pertaining to safety, security, traffic, fire, and personnel clearances as they apply to contract performance.

4.6. SPECIAL QUALIFICATIONS. The contractor shall have five years’ experience in troubleshooting, modifying and repairing of USAF Standard designed AFTF’s in accordance with T.O. 35E1-2-13-1 and accepted work by AFCEC.

Have a history of at least 10 projects that required troubleshooting, development of scope of work, and performing the scope of work to meet the criteria of T.O. 35E1-2-13-1 and final acceptance of completed work by AFCEC. This requirement is to demonstrate a complete understanding of T.O. 35E1-2-13-1 and the standard USAF designed AFTF.

http://www.dol.gov/compliance/guide/aw.htm#whowhich

Demonstrate ability and experience in structural steel fabrication and erection of equivalent magnitude.

5. APPENDICES.

A. System Particulars B. Winterization/De-Winterization Procedures C. Semi-Annual System Safety Inspection and Operational Checks D. Site Plans/Maps of Area

APPENDIX A

System Particulars

1. This theory of operation is based on the generic design. The Aircraft Fire Training Facility (AFTF) consists of an aircraft mock-up, burn area, control stand, liquid propane fuel system, and cathodic protection system and water conservation pond.

2. The aircraft mock-up, located in the burn area, is constructed of non-coated/unpainted carbon steel. It is approximately 72 feet long, 25 feet high at tip of tail, with a wingspan of 72 feet. The mock-up is configured with three simulated aircraft engines, two on the right wing and one located on the vertical stabilizer. Each engine contains one burner assembly and two ignitors.

The wiring to the engine ignitors is enclosed in a protective water jacket that protects it from possible failure due to extreme heat. Water injection is located in both wing engines and at some sites in the tail engine. The wing engines also have dams installed to simulate a flowing fuel type fire. Wheel well and auxiliary power unit fires are simulated on the right side of the fuselage adjacent to the inboard engine. In the interior of the mock-up, ignitors and burners are installed to simulate flight deck, passenger compartment, and cargo box fires. A water sprinkler system is installed in the top of the mock-up to cool and washout the mock-up. An expansion joint is located midway on the fuselage to allow for expansion and contraction during the training. Cutout panels are located on the left and right aft sides of the fuselage. These 36 inches x 84 inches replaceable panels are constructed of .031 inch thick sheet metal. The panels are used to simulate emergency entrance into an aircraft. Two steel hinged doors are located at the forward left and left amid ships.

3. The burn area is 100 feet in diameter. It is recessed and lined with one 80-mil thick high-density polyethylene (HDPE) liner. The liner is sandwiched between 6 inch thick layers of sand and then covered by a layer of geotextile fabric and then an 18 inch layer of compacted aggregate crushed stone.

4. There are seven ignitors and burners installed in the burn area to simulate six exterior ground fires and one running fuel fire with pool fire on the outboard engine. The ground fires are located on the left and right sides of the forward fuselage, between the right wing engines, under the left wing, and on the left and right sides of the aft fuselage. The weir is used to maintain the proper water level in the burn area. Opening the burn area drain valve allows all the water in the burn area to drain to the water conservation pond.

5. Located on the control stand are the valves, solenoids, and switches used to control the propane flow and ignitors during training events. Turning off the master/emergency switch located on the control stand will turn off power to all ignitors and close the internal valve located on the propane tank via the pneumatic control system, if applicable. The propane piping, water piping, and electrical conduits from the control stand to the burn area are located in an underground HDPE lined trench.

6. The liquid propane system supplies fuel for training exercises. Propane is supplied from 10,000 gallon-WC (water capacity) tank to the various burners in the burn area through a series of pipes and valves.

7. A propane pump may be installed to obtain adequate pressure, if applicable. A corresponding valve located on the control stand, controls propane flow to each individual burner. Safety features of the propane system are provided to stop the flow of fuel to the burners, and will include a pneumatic or manual control system, and an emergency shut-off valve located on the control stand. Pressure relief valves are installed on the piping as required by NFPA Standard

58. Cathodic protection system is used to protect below ground piping from corrosion through sacrificial anodes inside the trench from the control stand to the burn area.

8. The water conservation pond is a 72 feet by 72 feet square area and 9 feet deep. It is lined with 80 mil thick HDPE. Unlike the burn area, the liner is not covered. A pump located in the pond is used to supply necessary water for the training area.

APPENDIX B

Winterization/De-Winterization Procedures

Winterization shutdown activities will consist of:

1. Test all igniters and verify proper operation, (identify repairs needed for spring start up).

2. Winterize each igniter by cleaning with compressed air and applying non-freezing liquid to dissipate any moisture that may be collected by the igniter throughout the winter.

3. Cover and securely seal each individual igniter.

4. Verify that the rectifier for the impressed current cathodic protection system is operational.

5. Lubricate and service all switches, cabinet hinges, latches, etc.

6. Remove and store water pond aerator as directed by owner.

7. Verify that the water conservation pond pump has a minimum of three feet of water for cover or remove from pond and store as directed by owner.

8. Disconnect water cooling pump in burn area and store if applicable.

9. Introduce a minimum of 90 CFM of compressed air into the water system to blow out all water lines. Maintain air until all moisture is out of lines to keep from freezing for the winter.

10. Exercise, service and lubricate all valves for the water system.

11. Drain the burn area to an absolute minimum and install a temporary sump pump if practicable to prevent freezing of electric, propane and nitrogen systems.

12. Verify that all automatic pumping systems are functional for winter.

13. Check all burner locations for performance and emergency shutdown, (identify repairs needed for spring start up).

14. Exercise thermal cycles on the propane system and perform soap test at all propane connections, (identify repairs needed for spring start up).

15. Introduce a minimum of 90 CFM compressed air into the propane system and remove all water from propane lines and co-ax valves. Maintain air until all moisture is out of lines to keep from freezing for the winter.

16. Pressurize nitrogen/air system and perform leak test of all nitrogen/air connections, (identify repairs needed for spring start up).

17. Drain nitrogen/air accumulator tank of all moisture.

18. Service all nitrogen/air pilot valves.

19. Provide a complete semi-annual inspection report IAW T.O

20. Provide a complete report of all work performed and minor repairs made.

21. Brief and provide a written report to the fire chief or representative of all minor and major repairs needed for spring start up. Provide user with a cost estimate for repairs to allow time for using agency to secure funds by spring start up.

De-winterization/spring start up activities will consist of:

Verify that the rectifier is in service for the cathodic protection service.

1. Lubricate all electrical panel hinges, switches, etc.

2. De-winterize all igniters and assure good solid (functional) ignition.

3. Check that any applicable pumps and/or lift stations are fully operational.

4. Check and verify that all identification and warning labels are installed, clear and legible.

5. Exercise the water system and adjust to assure that all functions are operating at the proper pressures.

6. Fill burn pit to operating level and assure that igniter coolers are adjusted properly.

7. Install water aerator (if applicable) in pond.

8. Treat the water in the water conservation pond to help prevent algae growth if necessary.

9. Verify that the mechanical emergency shutdown valves associated with filling the propane tank are functioning properly and serviced.

10. Check that the propane tank float gauge is operational.

11. Check that the propane tank roto-gauge is operational.

12. Check that the propane tank pressure gauge is functioning.

13. Perform maintenance per manufacturer’s recommendations on all propane valves and equipment.

14. Operate the entire propane system assuring that all burners are functioning properly and that all emergency shutdown times are achieved.

15. Cycle all of the propane system valves and perform leak test at all connections.

16. Perform common maintenance on all the propane parts and equipment as recommended by the manufacturer.

17. Perform a pressure test on the nitrogen/air system.

18. Service and cycle all of the nitrogen/air pilot valves.

19. Have a fire truck and crew stand by while testing live fire scenarios and making any burner adjustments, minor repairs, etc.

20. Provide a complete semi-annual inspection report IAW T.O 35E1-2-13-1.

21. Generate a complete report of all work performed and minor repairs made.

22. Debrief and provide a written report to the COR of all work performed and findings.

APPENDIX C

AIRCRAFT FIRE TRAINING FACILITY SEMI-ANNUAL INSPECTION

1. Conduct a semi-annual inspection per T.O. 35E 1-2-13-1 Operation and Maintenance Instructions for Aircraft Fire Training Facilities, manufacturers' recommendations and procedures, as well as local, state, and federal guidelines as applicable to the work involved.

Installation, testing, and replacement of gas piping, gas utilization equipment or accessories, and repair and servicing of equipment, shall be performed only by a qualified contractor.

2. Inspections shall be performed by March 31st and September 30th each year IAWT.O. 35E 1- 2-13-1.

3. Perform Safety Inspection and Operational checks list from T.O. 35E1-2-13-1, Table 1.

Record and provide copy to the COR.

Appendix D

PERFORMANCE WORK STATEMENT