REFERENCE_2.5_redacted.pdf

PERFORMANCE WORK STATEMENT (PWS)

PEARL HARBOR NAVAL SHIPYARD (PHNSY & IMF)

HOT OIL FLUSH OF THE EXTERNAL HYDRAULICS SYSTEM

1. BACKGROUND:

a. Pearl Harbor Naval Shipyard & IMF, a US Navy industrial facility located on the island of Oahu, Hawaii maintains, overhauls and repairs various vessels of the US Navy. Over 4,500 military, civilian and contractor personnel work to keep the Navy, “Fit to Fight”. This Performance Work Statement (PWS) describes tasks to be performed by the Contractor in support of

Docking Selected Restricted Availability (DSRA-3) at Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility (PHNSY & IMF), Hawaii. The Contractor will provide the equipment and work required to generate the deliverables outlined below.

b. PHNSY & IMF management of planned overhaul and depot level maintenance requires Contractor expertise and support for the comprehensive flush and polishing of the External Hydraulic System on

DSRA. The Engineering and Planning Department of PHNSY & IMF has determined that to meet the Department of Navy o erational Pacific Fleet schedules, national Department of Defense commitments, actual / p oje ted PHNSY & IMF manning, and the unavailability of existing PHNSY & IMF plant equipment (of eq al capability) to support the

DSRA Project, it is in the governm nt’s best interest to have the equipment and service be provided by a Contractor.

2. OBJECTIVE & SCOPE OF WORK:

a. Pearl Harbor Naval Shipyard & IMF (PHNSY&IMF) n support of a 688-class submarine requires a Hot Oil Flush on the External Hydrauli s System due seawater contamination.

b. Complete a Hot Oil Flush of the External Hydr ulics System to restore system cleanliness.

3. PERFORMANCE REQUIREMENTS

a. References:

i. NAVSEA S9086- 4-STM 01 , NSTM Chapter 556, Hydraulic Equipment (Power Transmission and C ntrol)

ii. NAVSEA 905 LP-485 6010, Manual for the Control of Testing and Ship Conditions

b. Contractor F rnished Mat rial:

i. Provide su ficient fl shing units to completely flush the External Hydraulic System using government p ov ded hydraulic oil (2075TH per MIL-PRF-17672D), filtering approximate 1200 gallons of hydraulic oil to achieve oil cleanliness of NAS 1638 NAS 1638 Class 8 or ISO 4406 code -/17/14 or better as verified by PHNSY&IMF designated laboratory. Shipyard shall be able to draw from filtered clean oil reservoir when requested. The equipment shall possess the following features:

1. Two independent means of protecting ships systems, piping and components from overpressure in accordance with criteria outlined in Government specification IPI 5050-002 latest approved version. The primary means shall consist of an automatically operated relief valve designed to automatically relieve overpressure conditions prior to reaching 105% of the maximum allowable pressure for the loop being flushed. The secondary back-up means shall consist of a manually operated relief valve able to relieve overpressure conditions between the range of 105 – 110% of the maximum allowable pressure of the loop being flushed.

2. Provide unit(s) capable of providing flushing loop flow rates that meet or exceed the minimum target flow rates specified by shipyard flushing documents (which are

DRAFT

based on sustained turbulent flows identified by Reynolds numbers of 4000 and higher) as follows:

3. Provide continuous operational flush output flow/pressure rates of between 1 to 100 gpm with an adjustable range of 72 – 1000 psig. Provide positive means able to validate what the output flow/pressure rates are during the entire flushing process (example: install flow meters in loops)

4. Maintain a continuous flushing oil temperature between 160 degrees and 180 degrees Fahrenheit (F) for the oil being used (2075TH, MIL-PRF-17672). Provide positive means that validates that the flushing oil temperature is being maintained throughout the entire flushing process.

5. Provide all parts/components, tools, test equipment, consumables (hazardous materials are subject to approval before being brought into government installation), personnel, labor, technical expertise, and Personal Protection Equipment PPE) to accomplish Hot Oil Flush.

6. Contractor shall ensure contractor provid d oses are capable of connecting to -12 female JIC (37-degree flare) shipyard provide hoses.

7. Movement of flushing equipment after arrival shall b assisted by the Shipyard as required. Delivery and remova of flushi g equipment is the responsibility of the contractor.

8. Contractor shall ensur flushing unit capable of transferring oil to the ship via contractor provided ho es thr ugh 3 mi ron or finer filters. Flushing unit must be hydrostatically tested to 15 p rcen of the nominal pressure of the temporary system to verify integrity. A ditionally, prior to conduct of the flush, Shipyard developed flush pr cedure will accomplish a pre-use test consisting of a 15 psig pneumati groom f the ent e flush assembly (flush unit, hoses, adapters, and ship’s sy em).

9. The c tractor shall ensure the flushing unit and equipment has the ability to achieve p ssure temperatures, and flow rates as specified in Section 3.c

10. Contractor hose to Shipyard provided hose connection point might need to be ad usted b the contractor when requested by the Shipyard.

11. Contractor personnel assigned to operate the flushing units must be briefed on all procedures, safety precautions. Contractor personnel will participate in pre-shift briefings as directed by Shipyard.

12. Contractor shall ensure contractor provided hose/equipment utilized during the Hot Oil Flush is verified clean, equal or better than the cleanliness outlined in Section 3.c.i prior to connecting to Shipyard provided flushing hose.

ii. Contractor shall provide spill containment.

1. Contractor shall be responsible for containing fluid from hose connection to hose connection. The contractor shall provide personnel to monitor the temporary system for leakage during the flushing evolution. Contractor shall be familiar with references and work with PHNSY&IMF shops, C260, C290, and C106 personnel to follow guidelines to protect the environment.

iii. Contractor shall provide two eyewash stations.

iv. Contractor shall perform a supplemental “final fill” of ships oil storage tank upon completion of the flush evolution using excess oil remaining from the Hot Oil Flush (if available) or Shipyard provided oil.

v. During the Hot Oil Flush evolution, contractor shall inform Shipyard if the government provided 1,000 gallons of oil is running low. Shipyard will provide additional oil to support the flush. Contractor shall coordinate with Shipyard to connect Shipyard oil supply to Contractor flush unit/equipment to limit stop work.

vi. The Contractor shall comply with all applicable Federal, State and local laws, regulations, standards and guidelines in fulfilling requirements described in this PWS.

vii. Contractor operating procedures are subject to review by the shipyard Occupational Safety and Health Office, Code 106.

c. TECHNICAL REQUIREMENTS:

i. Required Specification: Hydraulic oil (2075 TH per MI PRF-17672D) verified to be equal or better than NAS 1638 Class 8 or ISO 4 06 code -/17/14 for particulate contamination, and 0.03 percent (300 ppm) maximum f r water contamination. The hydraulic oil shall also be free of biological growth and microo ganisms. Reprocessed, reclaimed, or recycled oil is not acceptable to be delivered for use dur the Hot Oil Flush. All government delivered oil will be re-verified clean by Shipyard prior to c nnecting to Shipyard flushing connections.

Prior to disconnecting supply a d ret n lines, PHNSY&IMF C260 and C290 personnel will review contractor’s data to verify flushi g m ts specifications.

1. A total of 6 flushin zones refer to Enclosure (1), with multiple test procedures (each test procedu e entails numerous flushing loops) will be conducted and may consist o revers fl hing as required by engineering procedures developed by the Engineering a d Planning Department, PHNS & IMF. The Contractor shall provide c ntinu us sup ort during the Flushing Schedule. The systems flushing loops, refer to Enclosu e (1) f r detailed pipe size & approximate length for each loop.

ii. Prior to ach flushin phase, the Contractor shall perform a tightness test on the entire temporary ystem ncluding the attached ship’s piping within the flushing boundary) to a minimum 75 psi (dockside air) or system operational pressure (if lower than 75 psig) prior to use.

iii. Attachment points to the ship’s hydraulic system will be provided by Shipyard. Clean oil shall be used to clean/flush through the system. Contractor to provide documentation of cleanliness of flushed oil returning via return line. Final verification and acceptance of flushing will be performed by PHNSY&IMF C260 and C290 personnel, via the PHNSY&IMF designated laboratory.

iv. Contractor shall ensure flushing unit is capable of providing flushing oil at a variable flow rates, from 3.75 GPM to not exceeding 90 gallons per minute at up to 250 psig, at contractor flushing unit discharge, maximum, except for flushing circuits of ¼ inch, which may require higher flushing pressures, where a booster pump flushing system shall be installed by contractor to increase the pressure from 250 psig to 350 psig maximum, at a flow rate of at least 3 GPM, while maintaining a return line, at the last point on the hydraulic system, located on or at the point of measurement nearest to the ship, prior to flow into temporarily-installed contractor return circuitry, fluid temperature of 170 ±10° F. In the event that a return line fluid temperature of 170 ±10° F, as measured via contractor-provided, temperature indicators which utilize in-line, fluid immersion, thermowells, cannot be maintained, contractor shall ensure the provided flushing system is satisfactorily modified to perform effectively and safely, at a temperature of up to 220 ±10° F, as measured at the contractor flushing unit discharge, to provide a return line fluid target temperature of 215 ±10° F, hydraulic circuit thermodynamic radiant heat loss permitting. Further, contractor shall provide at least 800 feet of specialized flushing hoses of at least 1.5 inch in internal diameter, metal armor-guarded and insulated, of stainless-steel, flexible, metal construction, for all contractor-provided, temporarily-installed contractor oil flushing circuitry prior to tie-in points to hydraulic circuits on the ship as this will remediate any unnecessary pressure drops which would otherwise be realized (and likely would be substantial if smaller-bore, contractor-provided, temporarily-installed contractor oil flushing circuitry were to be used) through fluid-flow, line loss, pressure drop resulting from internal fluid friction in the contractor-provided supply and return flow circuitry. These specialized, contractor-provided, temporarily installed contractor oil-flushing hoses shall be of sufficient design to allow for safe operation at the simultaneously required tempera ures, pressures and flushing flow rates deemed necessary to achieve flow turbulenc for effective cleaning, especially the higher temperatures and pressures mentioned abov The specialized, contractor-provided, temporarily installed contractor oil flushing hoses shall p ssess sufficient insulative properties as to render thermodynamic rad ant heat loss to a minimum to and from the ship’s hydraulic circuit(s) tie-in points. Return ne shall have an isolatable sample point to allow PHNSY&IMF to sample oil during flush g for f nal verification by PHNSY&IMF certified laboratory.

v. For ship hydraulic circuits of ¼ nch hich requ e flushing, contractor shall provide a second booster pump flushing system, d signed to e readily adaptable to the main contractor flushing system, capabl of provid ng flushing oil at a pressure of 350 psig maximum, at a flow rate of at least GPM while maintaining a return line, at the last point on the ¼ inch portion of the hyd aulic sys em, loca ed on or at the point of measurement nearest to the ship, prior to flow to temporari y nstalled contractor return circuitry, fluid temperature of 170 ±10° F In the e nt that a return line fluid temperature of 170 ±10° F, as measured via contract -provi d, temperature indicators which utilize in-line, fluid immersion, therm wells, canno be maintained, contractor shall ensure the provided second booster pump ushing system is satisfactorily modified to perform effectively and safely, at a temperat e of up t 220 ±10° F, as measured at the contractor flushing unit discharge, to provide a re rn line fluid target temperature of 215 ±10° F, hydraulic circuit thermodynamic radiant heat loss permitting. Further, for ship hydraulic circuits of ¼ inch which require flushing, contractor shall provide at least 100 feet of specialized flushing hoses of at least 1 inch in internal diameter, metal armor-guarded and insulated, of stainless-steel, flexible, metal construction, for all contractor-provided, temporarily-installed contractor oil flushing circuitry prior to tie-in points to ¼ inch hydraulic circuits on the ship as this will remediate any unnecessary pressure drops which would otherwise be realized (and likely would be substantial if smaller-bore, contractor-provided, temporarily-installed contractor oil flushing circuitry were to be used) through fluid-flow, line loss, pressure drop resulting from internal fluid friction in the contractor-provided supply and return flow circuitry. These specialized, contractor-provided, temporarily installed contractor oil-flushing hoses shall be of sufficient design to allow for safe operation at the simultaneously required temperatures, pressures and flushing flow rates deemed necessary to achieve flow turbulence for effective cleaning, especially the higher temperatures and pressures mentioned above. The specialized, contractor-provided, temporarily installed contractor oil flushing hoses shall possess sufficient insulative properties as to render thermodynamic radiant heat loss to a minimum to and from the ship’s hydraulic circuit(s) tie-in points.

vi. Contractor shall provide in-line flow metering devices, two in total, one on the main contractor flushing system and another on the second booster pump flushing system with a published accuracy factor of ±5% or less. These flow metering devices shall be positioned by the contractor on the return line circuitry at a point where inadvertent fluid bypass or diversion is not possible so as to accurately and repeatedly measure return line flow rates constantly and in real time with a high degree of accuracy for purposes of flow rate data dissemination to the customer engineering team. These flow metering devices shall be of sufficient design to perform effectively and safely, at a pressure of 250 psig maximum on the main contractor flushing system and 350 psig on the second booster pump flushing system, with all flow metering devices capable of effective and safe operation at a temperature of up to 235 ±10° F, as measured at the contractor flushing unit discharge and/or a return line fluid temperature of 225 ±10° F.

vii. It should be noted that certain laws of fluid dynamics and thermodynamics are present in every flushing situation and that these physics are at play, in various ways, in each of the ship’s hydraulic circuits. In order to achieve turbulent ow, as calculated using a Reynold’s Number formula, certain goals are inherent. The th ee main things that can affect or can be used to improve a Reynold’s Number are A) remedia ion of cumulative pressure drop through line loss (accomplished by increasing the diam ter of supply and return lines to the circuit to flushed and/or shortening the tota linear length o line to be flushed by implanting techniques such as breaking longer circ its into two or more shorter circuits), B) reducing fluid viscosity, either through temperatu e incr ase of the fluid to render a lower viscosity and/or through use of a lower-viscosity, s ficial flushing fluid (where and when possible), C) increasing flow rate to incre se the Reyn d’s Number; however, as a non-compressible fluid, oil flushing pressure incre ses ave dimin hing value as pressure increases, with significant improvements to flow and c rre onding Reynold’s Numbers from 0-150 psig, modest improvements f om 151-250 psig and little improvement from 251 and above psig.

Therefore, it is actu lly the imitatio s imposed by physics, the laws of nature and, ultimately, the flow circuitry being flus ed itself hat can be considered the only obstacles to achieving target Reynold’s Numbe s. The ntractor shall implement all reasonable strategies regarding temperatu pressures and those prescribed guidelines listed herein for the achievement of e high st Reynold’s Numbers and cleaning-force turbulence possible;

however, certain limitations to Reynold’s Number and turbulence achievement can be expect d, despite th effective implementation of the above-listed strategies and guidelines, in areas of extreme otal linear length of a single circuit to be flushed, especially of concern in this regar are hose circuits of an extremely small inner-diameter, such as in the case of the ¼ inch circ its, where extra attention should be given as extreme lengths and minimal diameters will limit flow rates due to pressure line loss and temperature retention due to thermal radiation.

viii. Contractor shall, simultaneous to in-line, real-time, laser particle counting (per ISO 4406:1999) to determine acceptable NAS 1638 cleanliness standards, which measure invisible particles of low mass and size, provide, periodically install as required, remove and report on in-line, 2-hour run interval, 100-mesh (149 micron) screens (in accordance with API 614) to determine acceptable large contamination cleanliness standards, which measure visible particles of higher mass and size than laser-particle counting does, with those larger particles being of substantial risk to hydraulic system reliability and performance. Contractor shall promptly archive and report all API screening findings along with NAS findings at intervals determined by the shipyard and the shipyard shall make all determinations on project progression based on those findings, both NAS and API screening.

ix. Contractor may be required by Shipyard to isolate flushing equipment if shipboard condition changes.

d. Reports:

i. Submit one legible copy, in electronic media, of a Condition Found Report (CFR) for identification of conditions differing from the requirements of this Statement of Work within 24 hours of discovery.

ii. After completion of flushing provide a final summary of contamination findings and results to PHNSY&IMF throughout the different loops.

e. Parts: This PWS does not cover parts acquisition.

f. Meetings: The Contractor shall attend the following meetings during the period of performance:

i. Daily Project Scheduling Meeting

ii. In-brief meetings as required.

g. Other: The Contractor shall submit the following plans as prio to start of work:

i. Safety/Accident Prevention Plan – provide to the TPOC for submittal to PHNSY & IMF Code

106.2. The Contractor shall ensure that Contract r p rsonnel are in compliance with the following:

1. Safety glasses with side shields ar worn when p rsonnel are conducting eye hazardous operations and when n an eye hazardou area.

2. Hardhats and safety shoes ar worn in esignated areas within the CIA and on-board ship.

3. That Contractor personnel underst nd fire safety requirements at PHNSY & IMF, and actions to be take hen fire or a emergency occurs during work onboard ship.

4. Eating, smoking or drink ng is prohib ed except for designated areas identified by the ship.

ii. Heavy weather/Envi onme tal Plan – provide to the TPOC for submittal to PHNSY & IMF Code 106.2.

iii. Quality Control Pl n – s e par g ph 5.0

4. SERVICE DELIVERY SUMMA Y

TABLE B

Description Reference Notes Performance

1. Provide Technical assista ce and Repair services as described in this PWS.

Paragraph 3 100% delivery and compliance.

2. Provide written reports and plans.

Paragraph 3.d, 3.g 100% delivery and compliance.

3. Attend meetings Paragraph 3.f 100% delivery and compliance.

5. QUALITY ASSURANCE:

a. The Contractor is responsible for implementing and maintaining a Quality Control Program (QCP) to ensure that the work performed meets or exceeds contract requirements and results in the correction of potential and actual problems. The QCP shall be implemented on the first day of contract performance and a copy shall be provided to the Technical Point-of-Contact (TPOC) prior to contract award.

b. The QCP shall outline the Contractor’s plan, what will be reviewed and actions to be taken by the Contractor, should the review(s) identify areas requiring remedial action. Of interest to the

c. Security Requirements:

i. Defense Biometric Identification System (DBIDS) Program: Commander, Navy Installations Command (CNIC) has established the Defense Biometric Identification System (DBIDS) for access control to CNIC Installations via Entry Control Points (ECP). DBIDS is an enterprise identity management and perimeter installation access control solution in which Contractor personnel who enroll, and are approved, are subsequently granted access to the installation for a period up to three years, or the length of the contract, whichever is less, and are not required to obtain a new pass from the Base Pass and Identification Office for each visit. There are no fees associated with obtaining a DBIDS credential.

ii. The Government performs background screening and credentialing. Throughout the year the Contractor employee must continue to meet background-screening standards. Periodic background screenings are conducted to verify continued DBIDS participation and installation access privileges. DBIDS access privileges will be immediately suspended or revoked if at any time a Contractor employee becomes ineligible.

iii. Access to Installation. All Contractor personnel shall ob ain access to the installation through enrollment and registra on into the De ense Biometric Identification System (DBIDS). The Cont actor shall provide he Contracting Officer with the name of their designated Ser ce Cont actor Administrator (SCA) for enrollment in DBIDS. Contact the Contra ting Officer’s Representative (COR) or Contracting Officer’s Security Officer for as stance as needed. Once enrolled, the Contractor must provide the D IDS Register with an approved employee list and then direct their employees to r gister i o DBIDS.

iv. DBIDS Credentials. C ctor em loyees shall furnish a completed copy of the

SECNAV 5512/1 fo m to o ain the required background check and visit the local Navy Installation Visitor C ntrol Cen er to obtain a DBIDS credential once approved.

The SECNAV 5512/1 fo m and ditional information about DBIDS can be found at:

https://www cnic.nav mil/om/dbids.html. (NOTE: All requests must be received 15 to 30 usine s day prior to desired access date).

v. Unes rted Access Requires authenticating an individual’s identity and determining their fitn ss using th following guidelines:

1. Identi roofing. The process of providing sufficient information (e.g., identity history, credentials, and documents) when attempting to establish an identity. The following credentials are identity proofed at the card issue site from federally authorized identity documents, and will be considered identity proofed. CAC, Uniformed Services Identification (ID) Card issued to military retirees and military family members, Non-DoD Federal Personal Identification Verification, United States (U.S.) Passport or Passport Card, Foreign passport that contains a temporary I-551 stamp or temporary I-551 printed notation on a machine-readable immigrant visa, or others listed in reference (a) and chapter 16. (NOTE: While certain identification is approved for identity proofing, in order to register a visitor into DBIDS, the visitor must have an ID with an ID number associated. U.S. Citizens are required to provide their Social Security Number (SSN), Certificate of Naturalization or Taxpayer ID Number to receive a DBIDS pass to access the installation).

2. Vetting. An evaluation of an applicant or cardholder’s character and conduct for approval, or denial of the issuance of an access control credential for physical access. The SECNAV 5512/1 is the sole means to initiate background checks on all visitors and/or contractors/vendors. Every background check for the purpose of access control requires completion of SECNAV 5512/1 for accountability purposes.

vi. Personnel requiring access for 31 days or more will be issued a DBIDS card once all required documentation is provided to the VCC and registration is completed.

Visits for 30 days or less will receive a DBIDS paper pass.

vii. DBIDS passes require a picture and fingerprints for all visitor registrations. Failure to provide either can result in denial of base access for escorted or unescorted access.

viii. Pre-enrollment. DBIDS pre-enrollment is available at https://dbids-usfj.dmdc.mil/portal/.

d. Access to the work area located in the Controlled Industrial Ar a (CIA) is governed by PHNSY & IMF security procedures and requirements and the Contractor is equired to obtain a Red Badge clearance for all Contractor personnel associated with thi PWS. Contact PHNSY C420 for guidance on forms required for badge requests.

i. Photography is strictly prohibited within HNSY & IMF Data phones, phones with a camera feature and cameras of any type are not allowed wi in PHNSY & IMF.

ii. Confidentiality: This project, all mate als provi ed to the Contractor by the Government, test results, conclusions and recommen atio s obtained thereof for the Contractor shall be considered Government property. The info mation shall not be disclosed, copied, modified, used (except to fulfill contract re uirements) o otherwise disseminated to any other person or entity at any time to include, ut no limited to inclusion in any database external to the Government without the Govern ent xpre consent.

iii. When performing work ssociated w th this PWS, the Contractor shall make clear to all individuals they dea with t at they re contract employees and not DOD employees.

iv. Contractor emplo ees sha clearly i entify themselves as a Contractor (i.e. company shirt, pin, visible compa y iden ific ) in a visible location on the front of exterior clothing and above the waist, (ex pt when safety or health reasons prevent such placement) as to who their empl yer Iden fication badges shall be worn at all times when performing work, including while att nding Government meetings and conferences that may take place outsi e the facility.

v. The Co ractor perf ming services shall be required to comply with all Pearl Harbor Naval Shipyard & IMF rul s, regulations, and training that is applicable to conduct, safety, security, and procedur s governing site entry and exit. Contractor personnel will be escorted when working in sensitive areas as required. The AI will make arrangement to provide escort service if required.

e. HOURS OF OPERATION:

ix. Normal Hours: The normal working hours of PHNSY & IMF is 0630 to 1500 hours, Monday thru Friday, excluding Federal Holidays. This includes half hour lunch break.

x. In addition to normal working hours requirements, the Contractor shall have sufficient labor, including a supervisor and technicians, to work with PHNSY&IMF projected two shifts (10 hours per shift; tentatively 0430-2300) of flushing per day, 6 days a week (Sunday excluded).

f. TENTATIVE Period of Performance: TBD

9. ATTACHMENTS:

The following attachments are provided to the Contractor as part of this PWS:

a. Safety and Health Work Practices for Contractors Working with PHNSY & IMF.

b. Contract Security Classification Specification (DD Form 254).

c. Environmental Agreement for Contractors on Ship Projects.

d. 52.204-2, Security Requirements

e. 252-209-7002, Disclosure of Ownership or Control by foreign Government

10. POINT OF CONTACT:

a. Technical Point-of-Contact (TPOC)

Enclosure (1) Loops Min Flow Rate

(GPM)

Nominal Pipe Thickness

Pipe OD Approximate Total Pipe Length

Secondary Propulsion Motor

17.5 0.113 1.05 620 ft

Power Plant 17.5 0.109 1.315 200 ft Retractable Bow Planes

13.25 0.113 1.05 265 ft

Thin Line Towed Array

10 0.113 1.05 700 ft, (120 @ 0.612" ID)

Sail 13.25 0.113 1.05 80 ft (30 @ 0.815"/0.824" ID) Vertical Launch System

13.25 0.179 1.315 100 ft