Single Steam Generator-SOW.pdf

AREA 1-42

STEAM GENERATOR

STATEMENT OF WORK

JULY 10TH, 2024 REV 2

UNITED STATES AIR FORCE RESEARCH LABORATORY

(AFRL)

Statement of Work for

AREA 1-42

STEAM GENERATOR

AREA 1-42 STATEMENT OF WORK

JULY TBDTH, 2024 REV 2

STEAM GENERATOR PAGE 2 of 55

TABLE OF CONTENTS

1. INTRODUCTION 4

2. BACKGROUND 5

3. REFERENCE DOCUMENTS 6

4. SCOPE OF WORK 8

4.1 DESIGN AND ENGINEERING 8

4.2 PROCUREMENT OF MATERIALS, PARTS, EQUIPMENT FOR

FABRICATION 12

4.3 FABRICATION OF STEAM GENERATORS AT AFRL STAGING AREA 12

4.4 TRANSPORT AND PLACEMENT OF STEAM GENERATOR 14

4.5 FINAL INSTALLATION OF GENERATOR AND PERIPHERY

SYSTEMS, PIPING, INSULATION, BLOWERS AND OTHER PARTS

AND EQUIPMENT 15

4.6 FINAL ACCEPTANCE TESTING AND TRAINING 16

5. TECHNICAL REQUIREMENTS 18

5.1 GENERAL REQUIREMENTS 18

5.2 STEAM GENERATION REQUIREMENTS 19

5.3 STEAM VESSEL 20

5.4 NOZZLES AND MAN WAY 22

5.5 WATER HEATING SYSTEM 24

5.5.1 BURNER GAS TRAIN SUPPLY 24

5.5.2 BURNER 25

5.5.3 BURNER BLOWER 26

5.5.4 FIRE TUBE 26

5.5.5 BURNER EXHAUST STACK 27

5.6 STEAM VESSEL SUPPORT SADDLES 28

5.7 PRESSURE RELIEF VALVES 29

5.8 VESSEL INSULATION 30

5.9 EXTERNAL STAIRS AND MAINTENANCE PLATFORM 31

5.10 EXTERNAL PIPING AND COMPONENTS 33

5.11 INSTRUMENTS AND CONTROLS 34

5.12 STAMPING AND NAME PLATES 34

5.13 ENVIRONMENTAL AND NATURAL PHENOMENA CONDITIONS 35

5.14 ANALYSIS FOR LIFTING AND TRANSPORT OF STEAM

GENERATOR 35

5.15 ELECTRICAL 36

6. STAGING OF STEAM GENERATOR AT AFRL FOR FABRICATION AND

TRANSPORT TO AREA 1-42 37

7. WELDING 37

8. INSPECTION AND EXAMINATION 40

9. TESTING IN ACCORDANCE WITH ASME B&PVC SECTION I 41

10. CLEANING 42

11. DRAWINGS AND CALCULATIONS 43

12. OPERATIONS AND MAINTENANCE MANUAL 43

13. DELIVERABLES 44

14. PROJECT PLAN AND SCHEDULE 46

15. SAFETY 48

16. QUALITY CONTROL 49

17. SECURITY 50

18. HOLD POINTS 51

19. PROPOSAL 51

20. OTHER 53

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ACRONYMS

AFRL AIR FORCE RESEARCH LABORATORY

AI AUTHORIZED INSPECTOR

AISC AMERICAN INSTITUTE OF STEEL CONSTRUCTION

ANSI AMERICAN NATIONAL STANDARDS INSTITUTE

ASCE AMERICAN SOCIETY OF CIVIL ENGINEERS

ASME AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASNT AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING

ASTM AMERICAN SOCIETY OF TESTING AND MATERIALS

AWS AMERICAN WELDING SOCIETY

BEP BOILER EXTERNAL PIPING

B&PVC BOILER AND PRESSURE VESSEL CODE

CMTR CERTIFIED MATERIAL TEST REPORT

FCAW FLUX CORE ARC WELDING

FOB FREE ON BOARD

GMAW GAS METAL ARC WELDING

GTAW GAS TUNGSTEN ARC WELDING

IBC INTERNATIONAL BUILDING CODE

MAWP MAXIUM ALLOWABLE WORKING PRESSURE

NFPA NATIONAL FIRE PROTECTION ASSOCIATION

NOx NITROGEN OXIDES

O&M OPERATIONAL AND MAINTENANCE

OSHA OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

PWHT POST WELD HEAT TREATMENT

PP POWER PIPING

PRV PRESSURE RELIEF VALVE OR PRESSURE REDUCING VALVE

PSV PRESSURE SAFETY VALVE

P&ID PROCESS AND INSTRUMENTATION DIAGRAM

PQR PROCEDURE QUALIFICATION RECORDS

ROV REMOTE OPERATED VALVES

SAW SHIELDED ARC WELDING

SMAW SHIELDED METAL ARC WELDING

SOW STATEMENT OF WORK

SS STAINLESS STEEL

WPS WELDING PROCEDURE SPECIFICATION

WQR WELDER QUALIFICATION RECORD

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1. INTRODUCTION

The United States Air Force Research Laboratory (AFRL), Edwards Air Force Base, California, requires the design, fabrication, testing, inspection and installation of one (1) new steam generator to be installed at the AREA 1-42 Steam Plant.

NOTE: This Statement of Work (SOW) addresses the design, fabrication, transport, testing and related work for one (1)new steam generator. Because of the complexity and magnitude of the steam generator, this separate SOW has been developed. This SOW, which addresses providing the steam generator is an integral part of a larger project identified in the document

STATEMENT OF WORK NEW STEAM GENERATOR INSTALLATION AT

AREA 1-42 which includes the propane system, connecting piping systems to the steam generator and other related work. These two (2) SOWs need to be worked and referenced TOGETHER to describe the entire scope of this project.

A third and separate SOW has been developed to address concrete and civil work. This work will be bid and issued separately—but is mentioned here for reference and context about the scope of the overall project. The document for the concrete and civil work is titled STATEMENT OF WORK

FOR CONCRETE AND CIVIL WORK IN SUPPORT OF NEW STEAM

GENERATOR INSTALLATION.

The steam generator will be used to replace an aging steam generation system in use at AREA 1-42 that includes large spherical saturated steam storage vessels, heat exchangers, process heaters, pumps, supply and return piping and other hardware to generate and provide the required mass quantity of steam at specified pressure and temperature.

NOTE: The Air Force is planning to install a total of three (3) identical steam generators starting with the single generator described herein and the other two

(2) steam generators will be installed as part of the overall system in the future.

This scope of work includes ONLY the first, single steam generator at this time.

The Contracting Officer has made a good faith effort to update all relative project documents to address the inclusion of ONLY the single steam generator and clearly identify other two (2) steam generators are intended for installation in the future but are NOT included as part of the current scope of work. Likewise, the Contracting Officer has endeavored to identify interface points on piping, platforms, conduit and other systems where connections to provide service to the future steam generators will be required. If the Contractor identifies ANY scope, interfaces or other items that are not clear as to the intent of what is to be included

STEAM GENERATOR PAGE 5 of 55 in the current scope of work and what is intended future installation, the Contractor shall bring this to the attention of the Contracting Officer immediately.

For the purposes of this SOW the term Contractor shall apply to the vendor who will perform the work identified herein. The term Contracting Officer shall apply to the US Air Force or it’s designated representative.

For any contradiction between this SOW and the documents referenced herein, the SOW shall take precedence.

This is a fixed price, lump sum contract. Steam Generator shall be FOB, AFRL, Edwards AFB, California.

The intent of this project is for the Contractor to provide the Contracting Officer one

(1) safe, complete, fully functional and operable steam generator to be used to supply saturated steam for the AFRL Area 1-42 Steam Plant as described herein.

As shown on the referenced drawings the Contracting Officer has assigned a tag number to the steam generator. This tag number shall be used by the Contractor to reference the steam generator on documents, drawings, records, spare parts and wherever a unique identifying tag number is required.

2. BACKGROUND

The current steam plant is comprised of nine (9) ~19’-0” ID carbon steel spherical vessels used to store heated, saturated water. The system includes a process heater that heats oil and a shell and tube heat exchanger used to heat water to high temperatures. The heated oil is on the shell side of the exchanger and water on the tube side. Supply and return piping is used to circulate feed water through the system to the storage vessels.

The current system includes three “strings”. Each string includes three large storage vessels, one process heater, one heat exchanger, one circulation pump and associated piping. The overall system is designed so one, two or three strings can be operated in parallel.

The purpose of the described steam plant is to allow high temperature saturated water to continuously flash to high pressure saturated steam. The steam is then used to drive a two stage ejector system which is connected to a number of test cells. The first stage ejector is horizontal, followed by a condenser and the second stage vertical ejector which exhausts to the atmosphere. The low pressure generated by the ejectors is used to simulate high altitude atmospheric pressure for testing of rocket motors and other hardware. There are three ejector systems

STEAM GENERATOR PAGE 6 of 55 which can be operated simultaneously for maximum vacuum and flow rate for large engines or singularly for reduced flow and pressure for smaller engines. The steam system is designed such that three spheres can operate each ejector system or all 9 spheres can operate a single ejector system for an extended duration test.”

While providing functionality and a reasonably high level of reliability, the current system requires significant and constant maintenance in terms of vessel inspection and repairs, replacement of heat exchanger tube bundles, repairs of heat exchanger shells, inspection and maintenance of the process heaters, inspection, maintenance, repair and replacement of piping systems and components.

The current system was built in ~1966 and has been in periodic use since that time, but as mentioned above has required considerable inspection, repair and at times replacement of major equipment, parts and systems.

Because of the age of the current system and need for on-going maintenance and monitoring, the Air Force is seeking to replace the current system with new large capacity steam generators. Figure 1 indicates an aerial view of the AFRL Area 1- 42 Steam Plant.

FIGURE 1—AERIAL VIEW OF AFRL AREA 1-42 STEAM PLANT

3. REFERENCE DOCUMENTS

The following are documents to be referenced in the execution of the work:

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REFERENCE DOCUMENTS FOR NEW STEAM GENERATORS AT

AREA 1-42

DOCUMENT NUMBER DOCUMENT TITLE

202236363 NEW STEAM GENERATORS EQUIPMENT AND PIPING

LAYOUT

202236364 NEW STEAM GENERATORS FABRICATION AREA SITE

PLAN

202236367 NEW STEAM GENERATOR FOUNDATIONS (INCLUDED

FOR REFERENCE ONLY)

202236371 NEW STEAM GENERATORS P&ID

202236372 NEW PROPANE P&ID

202236376 STEAM GENERATOR AND PIPING CONCEPTUAL

INSULATION PLAN

202236381 STEAM GENERATOR RIGGING AND TRANSPORT PLAN

STATEMENT OF WORK FOR AREA 1-42 STEAM

GENERATORS

STATEMENT OF WORK FOR CONCRETE AND CIVIL WORK

IN SUPPORT OF NEW STEAM GENERATOR

INSTALLATION (INCLUDED FOR REFERENCE ONLY)

COMPONENT DATA SHEETS

Technical Documents and Standards

-AISC Manual of Steel Construction

-ASCE 7 Minimum Design Loads and Associated Criteria for Buildings and Other Structures

-ASME Boiler and Pressure Vessel Code (B&PVC) Section I Rules for Construction of Power Boilers

-ASME B&PVC Section II, Material, Part A, Part B, Part C, Part D

-ASME B&PVC Section V Nondestructive Examination

-ASME B&PVC Section VIII Rules for Construction of Pressure Vessels

-ASME B&PVC Section IX Welding, Brazing and Fusing Qualifications

-ASME B31.1 Power Piping

-ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers -AWS D1.1 Structural Welding Code

-IBC International Building Code

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-NFPA 54 National Fuel Gas Code

4. SCOPE OF WORK

In general, the scope of work for this task includes the Contractor providing the resources to furnish one complete, installed and ready to operate steam generator as described herein.

There are six (6) major tasks associated with supplying the steam generator. The tasks include:

4.1 Design and Engineering

The Contractor shall be responsible to perform all engineering, design, analyses and related work to provide for the steam generator. All design and related technical tasks shall be based on the requirements in ASME B&PVC Section I Power Boilers latest edition and as further identified herein.

In general, the Contractor shall be responsible to perform sizing, analyses, design, modeling, preparation of drawings, calculations and related tasks in support of this effort. The following are disciplines for which the Contractor shall prepare the necessary technical documents to describe the overall configuration, performance, capacities, fabrication, materials, welding and other related tasks to produce the steam generator. These identified disciplines and tasks may not be all inclusive and the Contractor may need to supplement these with additional work tasks.

Process Engineering—Develop a set of Process and Instrumentation Diagrams (P&IDs) to describe the overall capacities, expected performance, sizes, flow rates, temperatures, instruments, process components such as Remote Operated Valves (ROVs), Pressure Safety Valves (PSVs), Regulators, Filters, Flow Meters and other similar hardware. The P&IDs shall be prepared in a schematic format to represent the overall process design and function of the steam generator.

Reference Drawing No. 202236371 which indicates a conceptual P&ID to be used as a basis for development of the final P&IDs for the steam generator.

Layout and General Arrangement—Prepare detailed drawings to indicate the overall layout, arrangement and configuration of the steam generator. This drawing will include overall envelope and other critical dimensions, will show key parts of the steam generator to include the saturated water vessel, burner, fire tube arrangement, man ways, nozzles and piping connections, all instrumentation and connection points on the steam generator, structural support saddles, external blower for the burner, burner exhaust stack, external access ladder and platform and in general all primary parts that comprise the steam generator proper. As

STEAM GENERATOR PAGE 9 of 55 noted below separate drawings will be required for connecting piping, insulation and other items. Reference Drawing No. 202236363 which indicates a conceptual layout and general arrangement for the steam generator and its connecting components.

Steam Generator Fabrication Drawings—prepare a detailed set of fabrication drawings for use by shop and field personnel to fabricate the new steam generator.

This will include roll out drawings indicating the placement, fit up and welding of plates for the main saturated water vessel, details of all penetrations and nozzles, details for the installation of the burner assembly, fire tube, burner exhaust, structural saddles, details for external stairs and access platform, fabrication and installation of vessel heads and all other pertinent details necessary to identify materials, cut and fit all parts, segments, sub-assemblies and pieces to produce a safe and complete steam generator.

As described elsewhere in this document it is anticipated the steam generator will be built on site at AFRL at a designated staging area (approximately 1.5 miles from AFRL Area 1-42). It will then be lifted, placed on a heavy transport, and set into final position at AFRL Area 1-42. As the Contractor determines, he may need to develop “phased” drawings indicating the required sequencing and other key details for fabrication of the steam generator. If the Contractor develops such drawings these shall be provided as part of the fabrication drawing package.

External Piping—prepare drawings and perform analyses for several segments of external piping to connect from the steam generator to the Contracting Officer designed facility piping systems. Interface/connection points where Contractor provided steam generator external piping and Contracting Officer designed systems will interface are shown on drawings provided in this bid package.

Reference Drawing No. 202236363 showing the overall routing and interfaces of external piping. Design will include all piping, pipe supports, valves, instruments, ports, drains, insulation and any other required parts and segments to provide for a complete piping system. Note that as shown on the drawing, interface points are identified for piping systems, some as a blinded flange connection, to allow for connection to piping for the installation of the future steam generators.

Steam Generator Insulation Details—prepare drawings showing details for extent of installation and details for installation of insulation over the steam generator for retention of heat and personnel protection. The Contracting Officer will work with the Contractor to define locations on the steam generator and external piping to install inspection ports that will include removeable “plugs” to allow for visual inspection as well as obtaining NDE measurements. These plugs will be approximately 3” to 4” in diameter and shall be weatherproof. There will likely be several dozen plugs installed on the steam generator and connected

STEAM GENERATOR PAGE 10 of 55 piping systems. The Contractor shall determine the need for any insulation anchors, clips or pins that may need to be installed on the surfaces of the items to be insulated to ensure proper anchorage and placement of the insulation.

Steam Generator Rigging, Transport and Placement—prepare drawings to address rigging, lifting, transport and placement of the steam generator from the AFRL Fabrication Staging Area to the new and permanent location at AFRL Area 1-42 Steam Plant. Drawings shall indicate layouts for the steam generator, positions of cranes and transport vehicles, transport route, rigging hardware and arrangements. The Contractor may use as a basis rigging drawings prepared by the Contracting Officer and included as part of this bid package. Reference AFRL Drawing No. 202236381 which indicates conceptual layouts for lifting and placement of the steam generator and the transportation route.

Steam Generator Staging Area—The Contractor shall prepare a layout of the proposed arrangement for storage of materials, fabrication of the steam generator, traffic and equipment flow through the staging area, offices and temporary buildings/trailers, fenced off areas, equipment storage and routing of utilities. Any grading, excavation, trenching or similar activity that disturbs the ground in the staging area shall be clearly identified on the drawing and will include an estimate as to how much soil will be required to be moved or otherwise disturbed.

Reference AFRL Drawing No. 202236364 which indicates the area designated for use by the Contractor for staging of the steam generator and identifies specific use areas.

Instrumentation and Controls—The Contractor shall be responsible to develop an overall control scheme for operation of the steam generator. This scheme shall account for normal start up, normal operation and normal shut down of the steam generator. It shall also address emergency and anomalous conditions that could occur with operation of the steam generator. The Contractor shall be responsible to identify the need for, select and design for the installation of all individual instruments including, but not limited to, sight glasses, thermocouples, pressure and temperature gages, pressure and temperature transducers, level indicators and monitors, NOx emission monitors and alarms and any other identified instruments required to effect the overall normal operation and emergency shut down of the steam generator.

Whichever manufacturer the Contractor selects for the steam generator burner, the unit will require a burner management panel. This panel will be expected, to manage and control overall operation of the steam generator, control burner gas shut off, valve controls, adjust and control air/gas ratio for combustion, monitor UV flame detection and perform numerous other control, alarm and shut off functions.

As part of the overall scheme for management and control of the steam generator

STEAM GENERATOR PAGE 11 of 55 the Contractor shall select a burner management panel that shall be designed and integrated to provide for safe control of and the overall operation of the steam generator. This panel will be required to be operated locally at the steam generator and wired and connected to the Contracting Officers site control system so the steam generator can be monitored and operated remotely from the Area 1-42 Blockhouse/control room.

The Contractor shall select and integrate into the overall design a sight glass located near the control panel on the steam generator. The sight glass shall be of sufficient size to allow for field personnel to determine through visual inspection the level of fluid in the steam vessel. The sight glass shall be fabricated from stainless steel and shall be rated for all service conditions. The sight glass shall also be capable of being integrated into the overall steam generator control system so the level of fluid in the steam vessel can be indicated and read remotely at the Contracting Officer’s site control facilities. Note that any piping connecting to the sight glass shall be designed, fabricated and installed to meet the requirements of ASME B&PVC Section I and ASME B31.1 Power Piping requirements. The sight glass shall be provided with necessary block valves, drains and other components to allow for the removal and maintenance of the sight glass as may be required.

The Contractor shall provide all monitoring and emergency shut down and alarm systems as required by ASME B&PVC Section I. These systems shall specifically be identified in the overall design and shall state the ASME B&PVC Section I requirement they address. All systems, instruments or other hardware required by ASME B&PVC Section I shall be fully integrated with the overall control systems and shall be identified on the local control panel and shall be able to be integrated into the Contracting Officer’s site control system.

Design Reviews

As an integral part of the engineering and design effort the Contractor shall arrange for and host three (3) design reviews. Reviews shall be held when the design task is approximately 30% complete, 60% complete and 95% complete. Design reviews shall focus on how the design meets stated SOW and ASME B&PVC Section I requirements.

The 30% and 60% design reviews shall be conducted via tele conference. The 95% review shall be conducted in person at the Contractor’s facilities. The Contractor shall arrange for all design reviews. The Contractor shall also take notes and document action items for each design review and publish the same to all design review participants.

The Contractor shall advise the Contracting Officer a minimum of one (1) week in advance of each scheduled design review.

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The 30% review will focus on developing advanced concepts for the steam generator to include size, key dimensions, material selection, preliminary sizing calculations, meeting steam production requirements, and key systems and components such as the burner, fire tube, exhaust stack, external piping, control system and instrumentation. All key safety systems shall be identified and concepts for each selected.

The 60% review will advance previously approved concepts for the steam generators. All basic calculations, analysis, material selection and other key engineering functions should be complete or nearly completed to a point where final design can proceed. Safety systems shall be well developed and selected designs shall clearly demonstrate meeting ASME B&PVC Section I requirements.

The 95% review will feature completed design drawings, all supporting calculations and analyses and a complete review of how the design meets all stated requirements. It is anticipated only minor comments will be made during the final design review.

Once comments from the 95% review have been incorporated, the Contracting Officer shall perform a backcheck of the design package to verify all comments and issues have been satisfactorily addressed prior to final issuance of the design package.

4.2 Procurement of Materials, Parts, Equipment for Fabrication

The Contractor shall generally be responsible to specify, procure, receive, store and make arrangements for use of all materials, equipment, parts, spare parts, sub-assemblies, subcontracted services and any other material items required for a complete and operable steam generator as identified herein.

The Contractor shall also be responsible to acquire all spare parts as identified herein. These spare parts shall be clearly identified, labeled, organized and ready for transfer to the Contracting Officer at the conclusion of the project.

4.3 Fabrication of Steam Generator at AFRL Staging Area

The Contractor shall be responsible to perform all necessary fabrication of the steam generator to produce a safe, complete and fully operational equipment item.

Because of the magnitude of the steam generator it is planned to perform fabrication of the unit at a staging area at AFRL Area 1-46 ~ 1.5 miles from Area 1-42 Steam Plant where the unit will be permanently installed. This staging area is shown on Drawing No. 202236364. There is adequate space for storage of

STEAM GENERATOR PAGE 13 of 55 materials, fuel storage, areas for work and assembly of the steam generator and as may be required sub- assemblies, adequate space for equipment including cranes, trucks, forklifts, welding equipment and other items. There is adequate space for site offices, secure storage areas and like facilities. No temporary fencing around the entire perimeter of the designated area is permitted. The Contractor may install fencing to protect and secure small areas for material, tools, equipment or other storage and similar purposes. The Contractor shall identify an area for the collection of refuse and materials to be recycled and shall likewise arrange for the proper removal and disposal of all refuse and recycled materials.

The Contractor shall arrange for adequate sanitary facilities for personnel at the staging area. The Contractor shall also arrange for drinking water for their personnel at the staging area.

There is also electrical power and non-potable water available. The Contracting Officer will not make available phone or internet service, however, the Contractor will need to determine if these services are available through third party carriers at the staging area.

A secondary spill containment system for each fuel storage tank shall be required.

The Contractor shall describe the method for secondary containment to the Contracting Officer in advance of use. Installation of fuel tanks, dispensing systems and containment shall be reviewed and approved by the Contracting Officer in advance of installation and use.

The Contracting Officer shall also coordinate with the Contractor on installation of life safety systems such as site alarms and a public address system. These systems will be provided and installed by the Contracting Officer.

Any grading, leveling, soil conditioning or other site improvements in preparation for mobilization to the staging area shall be the responsibility of the Contractor.

Upon demobilization from the staging area the Contractor shall remove ALL equipment, tools, excess materials, trailers, refuse or any other items in possession of the Contractor to restore the area to the as found condition prior to mobilization. Regrading of the area prior to mobilization to restore original ground contours is not required.

Note it is assumed the Contractor will transport at least some equipment, tools and other resources for use at Area 1-42 for final work and testing of the steam generators once they are set into position. The Contracting Officer shall coordinate with the Contractor on available areas at Area 1-42 that can be used by the Contractor for storage of tools and equipment, work areas and other activities and

STEAM GENERATOR PAGE 14 of 55 more details on this topic are included in the document SOW NEW STEAM

GENERATOR INSTALLATION AT AREA 1-42.

4.4 Transport and Placement of the Steam Generator

The Contractor is responsible to perform the lifting, placement on a heavy transport, transporting and final placement of the steam generator at Area 1-42.

Reference Drawing No. 202236381 which indicates conceptual layouts and arrangements for lifting of the steam generator at the staging area, transport and final placement at Area 1-42. When all fabrication work is complete the Contractor shall arrange for lifting and transport equipment to mobilize at the AFRL staging area. The steam generator shall be lifted and placed on a heavy transport for delivery to AFRL Area 1-42. Once placed and secured on the transport, the steam generator shall be transported to Area 1-42, positioned and readied for placement.

The Contractor shall have arranged for a crane at Area 1-42 to lift the steam generator from the transport and place in final position on the foundation.

Note: The Contractor shall evaluate if it is advantageous to arrange for multiple cranes, i.e. located at the staging area and at Area 1-42 Steam Plant simultaneously rather than a single crane that would require multiple assemblies, break downs and transport between the sites for moving the steam generator. The Contractor is responsible to select the arrangement best suited for the Contractor’s plans and execution of the project.

In addition to the drawings described herein to be prepared by the Contractor to illustrate the rigging, lifting, handling, transport and final placement of the steam generators, the Contractor shall also prepare a written Rigging, Lifting and Transport Plan. This plan shall outline in detail the Contractors approach to accomplish this phase of the work. The plan shall include listings of intended equipment to be used, rigging hardware, calculations demonstrating safety factors for all key elements of the lift including, but not limited to, crane capacity based on pick radii, equipment capacities, rigging hardware capacities and other key lift and transport items. The plan, worked closely with the Contractor prepared drawings, shall also include a description of the route planned for transport, evaluation and inspections to verify adequate clearances during all phases of transport. The plan shall also consider the use of plates, mats and other equipment to ensure stable support for cranes during lifting operations. The Contractor is responsible to develop and write a complete and thorough plan to ensure safety and the effective lifting, transport and placement of the steam generator. The rigging and lifting plan shall be submitted to, reviewed and approved by the Contracting Officer prior to performing any lifting, rigging and transport related work.

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NOTE—The foundation for the new steam generator is shown on drawing 202236367. The foundation will be installed by others—but the new steam generator will be transported, rigged, lifted and set in place on the foundation as part of the scope of the overall task identified herein.

In preparation for placement of steam generator into their final position on the foundation, the Contactor is responsible to furnish and install all bearing plates, slide plates, shims and grouting, and torquing of anchor bolt nuts as specified on the steam generator equipment and piping layout, Drawing No. 202236363.

Bearing and slide plates shall be placed level and to the precise elevations as called for on the drawings and shall be fully supported with shims. Anchor bolt nuts shall be torqued as called for on the foundation drawings to ensure the steam generator is secure. Final grouting shall not occur until at least after all piping and other external connections are made to the steam generator. The Contractor shall use care to ensure the pattern of the anchor bolt holes on the bearing and slide plates and steam generator base plates matches the placement of the embedded anchor bolts in the foundation. It is recommended the Contractor use templates and other precision methods to ensure proper alignment and tolerancing between the vessel base plates, the slide and bearing plates and the anchor bolts.

If the Contractor has to procure or custom fabricate any rigging hardware, spreader beams, slings, shackles or other hardware for the planned rigging and lifting of the steam generator these items shall become the property of the Contracting Officer at the conclusion of the project and shall be inventoried and formally transferred to the Contracting Officer.

Preparing the area for location of the crane as shown on Drawing No. 202236381 includes importing, placing, compacting structural fill, and generally readying the area where the crane will be located to the east of the steam generator foundation.

The Contractor shall perform all preparatory work as shown on the drawing to ensure a complete, stable and safe location for the crane. All materials, equipment, labor, and other resources to place and compact the fill area shall be provided by the Contractor.

4.5 Final Installation of Generator and Periphery Systems, Piping, Insulation, Blowers and other Parts and Equipment

Once the steam generator has been set into final position on the foundation, the Contractor shall be responsible to connect and install all other equipment and systems associated with the steam generator. This includes, but is not limited to, designing, furnishing, installing, inspecting and testing all boiler external piping systems (to be PP stamped), the burner blower, the external stairs and access platform, PSVs, instruments, control panels and systems, safety systems and any

STEAM GENERATOR PAGE 16 of 55 other items that connect and interface with the steam generator. Boiler external piping systems provided by the Contractor shall be properly interfaced and connected to Contracting Officer provided facility piping systems.

Once all other systems, piping, instruments and external connections are made, the steam generator shall be insulated as specified as called for elsewhere in this SOW. The extent of insulation to be installed is shown on Drawing No. 202236376.

In general insulation shall be installed over the entire shell, nozzles, the man way, and any other areas of the steam generator that present a potential heat leak path and/or personnel safety hazard. As noted on the insulation drawing, removeable insulation blankets for valves and flanges shall be provided and installed by the Contractor.

4.6 Final Acceptance Testing and Training

Once the Steam Generator has been fully installed at Area 1-42 the Contractor shall work closely with the Contracting Officer to conduct a series of final acceptance tests. These tests will be designed to demonstrate the steam generator operates safely, is fully functional and meets performance requirements.

The Contractor shall first develop a Final Acceptance Testing Plan. This document will form the basis for all final inspections, testing and acceptance of the Steam Generator, culminating in the equipment being ready for operation and use by the Contracting Officer.

An integral part of the Final Acceptance Testing Plan shall be training of Contracting Officer personnel. The Contractor shall develop a comprehensive, rigorous and specific training program that he shall use to train Contracting Officer personnel in the safe operation of the steam generator. Training shall include “classroom” training, simulation training as may be deemed necessary and field training and actual operation of the steam generator. The Contractor shall be responsible to structure the training to indoctrinate personnel in a gradual and thorough manner to all aspects of safe operation of the steam generator. The Contractor shall issue all Contracting Officer personnel a certification at the conclusion of the training verifying the individual has successfully completed the required Contractor sponsored training program.

Besides basic, safe operation of the steam generator the Contractor shall also focus the training program on upset and anomalous conditions that can be expected to occur during operation of the steam generator and how operations personnel shall react for safe shutdown, or other actions, that may be required.

The Contractor shall outline the Contractor’s training plan and length of time required for training of Contracting Officer personnel in the proposal. The

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Contractor shall also recommend the number of Contracting Officer personnel to be trained for operation of the steam generator.

The Contractor is responsible to develop and present a field Final Acceptance Testing Plan for the steam generator and will have considerable latitude in how the final testing is conducted. However, Final Acceptance Testing shall include, at a minimum, the following elements:

1) Safety pre -check of the steam generator conducted prior to each use, and at other specified time intervals with focus on systems for safe shut down of the steam generator.

2) Perform any simulated testing of safety systems to verify safe shut down of steam generator.

3) Perform any other simulated operation of steam generator in preparation for actual operation.

4) Start-up of the steam generator and operation of same to produce a quantity of saturated steam. The initial quantity of saturated steam produced may be a fraction of the amount specified for and anticipated for normal operation of the steam generator, i.e. the quantity of saturated steam produced may be graduated through several tests until the full specified amount (~60% of total volume of steam vessel) is achieved.

5) Once a quantity of saturated steam is produced in the steam generator it shall be released through the steam piping and ducting system of the Area 1-42 steam plant to verify proper overall operation of the system.

6) NOT USED

7) Identify any post operation inspections, checks, tests required to ensure the steam generator is left in a condition fit for the next planned usage.

8) At the conclusion of the field testing the Contractor and Contracting Officer shall plan to enter the steam generator and make a joint careful visual inspection and assessment of the condition of the interior surfaces.

Photographs, notes and a report on observations and findings shall be prepared by the Contractor and included as part of the results of the Final Acceptance Testing.

Development of the Final Acceptance Testing Plan is anticipated to be worked with the Contracting Officer as field testing of the steam generator will require close coordination and dependence on other facility steam plant systems under the control of the Contracting Officer.

The overall structure, development and approach of the Final Acceptance Plan should consider the use of a step by step checklist type format for testing activities.

The Final Acceptance Testing Plan shall identify all key personnel including Contractor and Contracting Officer personnel who will be involved in the Final

STEAM GENERATOR PAGE 18 of 55

Acceptance Testing. Each person shall be assigned a title and their specific function and responsibilities relative to the testing shall be clearly identified.

The Contractor shall plan on several “dry runs” with all personnel to help ensure familiarity and safe operation of the steam generator during actual testing.

The Final Acceptance Testing Plan shall identify clear parameters and metrics defining success thresholds for each test. These shall be carefully monitored and documented during actual testing. Actual measured and observed results shall be noted and compared with predicted results to verify success or the need to make adjustments and alterations in the testing plans.

Copies of all completed testing check lists, results, notes, observations, alterations and adjustments and any retesting shall be provided to the Contracting Officer at the conclusion of each planned field test.

5. Technical Requirements

5.1 General Requirements

The steam generator shall be designed, fabricated, tested, inspected and stamped in accordance with the requirements of the ASME B&PVC Section I, Rules for Construction of Power Boilers, Latest Edition. The steam generator shall be stamped with an ASME B&PVC Section I “ASME” and “S” Certification mark as noted in PG-105 of ASME B&PVC Section I. The Contractor shall be authorized by ASME to perform the identified code construction and shall have the appropriate “S” stamp.

The steam generator shall be a fire tube type boiler and shall meet all requirements for the same.

The Contractor shall provide a Manufacturer’s Data Report Form, Form P-2 for the steam generator. All required documentation, including, but not limited to, calculations, welding certifications, non-destructive testing (NDE) records, Certified Material Test Reports (CMTRs), pressure testing, Master Data Report Form and all other documentation as required by ASME B&PVC Section I for the design, fabrication, welding, inspection, NDE, testing and any other activities shall be furnished as part of the code package for the steam generator.

The steam generator shall be meet the requirements of ASME B&PVC Section I, Part PG General Requirements for all Methods of Construction, Part PW Requirements for Boiler Fabricated by Welding, PFT Requirements for Fire Tube Boilers. The Contractor shall determine, depending on the specific design and methods selected to design and fabricate the steam generator, other parts and

STEAM GENERATOR PAGE 19 of 55 appendices of ASME B&PVC Section I that are applicable to the scope of this project.

All pressure boundary materials used in the fabrication of the steam generator shall be provided with Certified Material Test Reports (CMTRs) as required in ASME B&PVC Section II. All pressure boundary materials shall be clearly stamped or otherwise marked with the corresponding heat number from the CMTR. Any requirements for marking or stamping plates or other pressure boundary materials identified in ASME B&PVC Section I that are in addition to any marking or identification of materials noted in ASME B&PVC Section II shall be met. The Contractor’s Quality Control Plan shall address transfer of heat numbers and traceability for individual pieces and parts that are cut or altered.

5.2 Steam Generation Requirements

The following are approximate values, sizes and requirements for the steam generator as determined by the Contracting Officer. The required production of 110 lbm/sec of saturated steam at an initial temperature of 500°F for 12 minutes total, for the steam generator, is a firm requirement that the Contractor shall meet with the Contractor’s design, sizing and configuration of the steam generator.

See Drawing No. 202236371 for a conceptual Process and Instrumentation Diagram (P&ID) of the steam generator and the overall steam supply system.

The Maximum Allowable Working Pressure (MAWP) of the steam generator is 600 psig. The maximum temperature of the steam within the steam generator is 500°F.

The steam generator shall be designed to provide 110 lbm/sec of saturated steam for a minimum of 12 minutes for a total of 79,200 lbs of steam. Steam pressure within the steam generator shall initially be ~600 psig and when released from the steam generator will be controlled at 100 psig at the point of application. Pressure within the steam generator at the conclusion of a 12 minute run shall be a minimum of 100 psig.

Following a 12 minute steam run, the water in the steam generator shall be able to be reheated until the pressure within the steam generator is ~600 psig without the addition of any make up water. This shall occur for a minimum of 3 times before any make up water is to be added to the steam generator. Reheating from 100 psig to 600 psig should be able to be done over a period of no more than 20 hours.

It is expected the subsequent steam runs will be shorter in duration than 12 minutes, as saturated water is removed from the system for each steam run. The above requirements will mean the fire tube must remain submerged below the waterline in the vessel during all reheating operations.

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The estimated size of the new steam generator main water storage vessel is 15’ diameter X 60’ length for the straight cylinder and an additional length of ~7.5’ for each head (assuming hemispherical heads), for a total length of ~75’. The total volume of the water storage vessel is ~12,369 CF or 92,500 gallons.

For normal operation of the steam generator it is assumed the vessels will be filled to approximately 60% of capacity (55,500 gallons) to produce the specified 110 lb/sec of steam for 12 minutes. The Contractor shall verify the required quantity of steam can be produced with the steam generators filled to the specified capacity.

Feed water is anticipated to be provided to the steam generator at ambient temperature, 40 gpm and ~600 psig. For design purposes the Contractor shall perform calculations for the required heating of the feed water based on the described conditions.

5.3 Steam Vessel

As noted above the estimated size and dimensions for the new steam vessel will be an outside diameter of 15’-0” by 60’-0” (cylinder only) and the vessel heads at an approximate length of 7.5’-0” each (assuming hemispherical heads) for an overall length of 75’-0”. These dimensions provide for an approximate volume of 12,369 CF or ~92,500 gallons.

Fabrication of the cylindrical portion of the steam vessel shall be accomplished using rolled sections of plate. It is assumed hemispherical heads will be preferred for the design of the vessel but the Contractor may select another type of head if that is advantageous to the design and fabrication of the vessel. Vessel heads shall be designed in accordance with the requirements of ASME B&PVC Section I.

The steam vessel shall be fabricated from carbon steel. It is recommended the Contractor use SA516-70 as the primary material. Other materials may be used so long as they are ASME listed materials and approved for use with the fabrication of ASME B&PVC Section I steam generators.

The size and arrangement of rolled plates and weld joints, thickness of materials and other key design considerations shall be determined by the Contractor.

The corrosion allowance for the steam generators is 0.00”.

To protect the interior of the steam vessel from corrosion the Contractor shall apply a layer of stainless steel cladding to the entire interior wetted perimeter of the steam vessel to include the cylindrical shell and heads. It is anticipated the Contractor will select a Flux Core Arc Welding (FCAW) process to apply the

STEAM GENERATOR PAGE 21 of 55 cladding using a E309LT-1 filler metal. However, the Contractor may select the type and grade of stainless steel filler metal to be applied, the weld process(es) to be used for deposition, manual, automatic or semi-automatic methods and other key variables. The Contractor shall specifically note in the proposal the rationale for selection of the stainless steel material, method of deposition, resistance to corrosion and other key factors. There are other requirements for welding noted elsewhere in the SOW.

NOTE: As described above it is assumed the Contractor will use a welding process to apply the cladding. HOWEVER, if the Contractor has alternate methods, such as explosive bonding, that will provide for adequate, long term corrosion protection of the interior of the vessel, these methods may be proposed as a substitute in the proposal. The rationale for using any alternate methods shall be explained and the basis for any technical and/or cost advantage well documented.

The thickness of the cladding is estimated to be ~1/8”. However, the Contractor shall evaluate the optimum thickness of the stainless steel cladding to ensure the applied material is not overly diluted through agitation and mixing with the carbon steel base material. The Contractor shall provide an evaluation in the proposal to demonstrate the recommended thickness of the cladding will not be subjected to corrosion caused by dilution of the weld puddle during deposition. No “credit” may be assumed for the cladding thickness when determining the required thickness of pressure boundary components for the steam generators.

It is assumed, but the Contractor shall verify that prior to application of the cladding all surfaces to receive cladding will be sand blasted to a near white or white metal surface to clean and ensure proper mixing and fusion of the cladding material to the base material.

Since there is a significant difference in the amount of thermal expansion between the carbon steel base material and the proposed stainless steel weld cladding the Contractor shall perform an analysis to determine that there will be no cracking or separation between the different materials when the steam generator is elevated to and at the specified design temperature.

The cylinder and heads described herein comprise the primary structure of the steam generator. Besides internal pressure caused by heating of the water, the Contractor shall investigate, check and analyze the shell and heads to verify they can withstand the weight of fluids, seismic and wind loading, ensuring the structure is rigid enough to be lifted and transported as described herein, can withstand thermal loads and can withstand all combination of loads as described in ASME B&PVC Section I. Internal and/or external support rings, stays and other structural elements may be required to ensure the overall steam generator cylinder is rigid

STEAM GENERATOR PAGE 22 of 55 enough to withstand the identified design loads and the need for any of these structural elements shall be evaluated and provided by the Contractor.

Any clips, brackets, pins, guides, pipe supports, items for the installation of external insulation or any other items that are required to be welded to the external part of the steam generator shall be properly designed, identified and provided by the Contractor. The Contractor shall evaluate and determine the material to be used for these parts.

5.4 Nozzles and Manway

All nozzles and the manway specified for the steam generator shall be designed, analyzed, reinforced, fabricated and installed in accordance with the requirements of ASME B&PVC Section I. The following table is a listing of the nozzles required for the steam generator:

NOZZLES AND MANWAY FOR STEAM GENERATOR

SIZE DESCRIPTION CONNECTION TYPE

2” PURGE CL 600# RF FLANGE

3” WATER SUPPLY INLET CL 600# RF FLANGE (1)

TBD WATER SIDE THERMOCOUPLE BY CONTRACTOR

TBD VAPOR SIDE THERMOCOUPLE BY CONTRACTOR

TBD PRESSURE RELIEF VALVE CL 600# RF FLANGE

16” MAIN STEAM OUTLET CL 600# RF FLANGE

TBD BURNER INLET BY CONTRACTOR

TBD BURNER OUTLET BY CONTRACTOR

3” DRAIN LINE CL 600# RF FLANGE

TBD WATER LEVEL SIGHT GLASS

UPPER CONNECTION

BY CONTRACTOR

TBD WATER LEVEL SIGHT GLASS

LOWER CONNECTION

BY CONTRACTOR

24” MANWAY…