SOW BiFuel System v3.pdf

STATEMENT OF WORK

INSTALL, Bi-Fuel/ Dual Fuel/ Blended Fuel System to Emergency Generator at Bldg. P-5

SCOTT AIR FORCE BASE, ILLINOIS

29 May 2020

1. REQUIREMENT:

a. BACKGROUND: Building P-5 houses telecom equipment that is used throughout Scott

AFB. The building is one of the original structures on Scott AFB and is considered a historical building.

b. OBJECTIVES: This project will install a bi-fuel/dual fuel/blended fuel system that will substitute an equal amount of natural gas for a corresponding amount of diesel fuel. The system needs to be install on the emergency backup generator located in the generator/mechanical room inside bldg. P-5.

2. PROJECT SCOPE:

a. Install new bi-fuel/dual fuel/blended fuel system and all associated equipment for the proper operation of existing generator. The bi-fuel/dual fuel/blended fuel contractor shall supply the following requirements to the system:

1) be of the following design principles:

i. gas delivered to diesel engine at a regulated and monitored “zero” or “negative” pressure relative to ambient conditions – inherent level of safety

ii. use of a primarily supervisory control scheme (“gas ON” or “gas OFF”, no primary “active” gas flow control) –inherent level of safety and greater stability

iii. primary gas flow is derived by the direct physical relationship of combustion air flow through a true venture air-gas mixer, thus maintaining a single engine control point for the delivery of both fuels while in bi-fuel mode of operation – inherent level of safety and greater stability

iv. use of dedicated sensors (bi-fuel system supplied) to monitor critical engine parameters related to bi-fuel operation – inherent level of safety and reliability

v. operate autonomously, without any required interface with diesel engine ECM or other control source – inherent level of safety and reliability

2) allow the up-fitted diesel engine to operate on a mixture (blend) of diesel fuel and natural gas, or alternately, on 100% diesel fuel with the ability to be manually or automatically switched between fuel modes with no loss in diesel engine performance or drop / interruption in power output.

3) allow for up to a maximum of 70% gas substitution (diesel replacement) at the engine’s prime rating

4) be of a retrofit technology that allows the diesel engine to be converted on-site, without the need to be taken off-line for any extended time during installation, while allowing for near immediate return to service throughout the complete installation process

5) require that no changes or adjustments be made to the diesel engine, to include but not limited to the engine compression ratio, piston design, valve train, injection timing, diesel injectors, fuel system design, cylinder head design; and further, shall not require removal of valve covers nor cylinder heads

6) require not more than minimally invasive on-site machining of engine intake/exhaust manifolds

7) be able to optionally operate on low or medium gas supply pressure of between .07 psig and .7psig or between 3.0 psig and 15 psig, respectively.

8) meet or exceed diesel transient load performance while operating in bi-fuel mode.

9) meet OEM and site specific requirements for engine operating parameters including:

i. intake manifold temperature

ii. exhaust gas temperature

iii. engine coolant temperature

iv. lube oil temperature

v. compressor inlet restriction

10) include a complete “gas train” consisting of at least the following minimum items:

i. 50 micron in-line gas filter

ii. redundant DC operated, normally closed shut-off valves

iii. “Zero-Governor/Zero-Pressure” type gas regulator

11) utilize materials and component construction suitable to the media, temperatures, vibration and duty cycles which the component is subjected to during normal operation of the diesel engine

12) utilize threaded, JIC type connections between the gas train and air-gas mixers

13) shall include properly rated and sized flexible fuel delivery hoses with female JIC swivel connections between the air-gas mixers and gas train

14) utilize a bi-fuel master control installed in an area adjacent to the diesel engine with the following minimum design features:

i. NEMA 4X rated enclosure

ii. Dual-Microprocessor based controller

iii. option for CSA rated for Class I Div II

iv. 12 or 24 VDC

v. readily visible LED lights showing normal and fault modes

vi. LCD display showing current status of bi-fuel system / monitored channels

vii. hour meter displaying total time accumulated in bi-fuel mode

viii. manual primary-power “on-off” switch

ix. key-pad user interface for selecting monitored channels and entering safety set points and control set points

x. electronically calibrated sensors

xi. selectable RS-232 or RS-485 standards with ASCII of MODBUS RTU

(addressable 01 through 99) protocols communication ports to allow for process system integration

xii. discrete digital inputs to allow for remote/external control, at a minimum, of:

a. Stop – latching, fault level Bi-Fuel off control function

b. Safety – latching, fault level Bi-Fuel off control function

c. Reset – system reset following the “setting” of a latching, fault control

d. Inhibit – non-latching, permissive level Bi-Fuel off control function

xiii. optional interfaces include read-only CAN based SAE J1939, OEM

(Caterpillar, Cummins, …) data links, and IP addressable

15) utilize a control system that monitors at least the following engine / system parameters:

i. exhaust gas temperature for each turbo

ii. manifold air temperature for each operational section

iii. natural gas supply pressure to gas train

iv. natural gas supply pressure from gas train to engine

v. engine manifold air pressure for each operational section

vi. engine vacuum for each air-intake operational section

vii. engine vibration level, minimum of one sensor per cylinder bank

16) monitor critical engine parameters via a system dedicated sensor package; the user shall be able to set the maximum or minimum allowable limits, for both control and safety categories

17) monitor, detect, and record any decrease or increase in values of critical engine/system parameters, to include gas supply pressure, that violate established safety limits

18) monitor and detect a decrease or increase in values of critical engine/system parameters, to include manifold air pressure (turbo boost pressure), that violate established control limits delineating the engine’s window for bi-fuel operation

19) monitor engine vibration level in order to detect multiple conditions of improper combustion and/or elevated vibration to include knock (detonation), misfire, or mechanical failure. User shall be able to set vibration safety limits based on normal engine vibration levels at rated load

3. DESCRIPTION OF WORK: The work consists of furnishing all labor, materials, supervision, and equipment necessary to accomplish, but not limited to, the following:

a. Contractor shall design, provide, and install a bi-fuel/dual fuel/blended fuel system to the generator at bldg. P-5 that gives the ability to burn both diesel fuel and natural gas simultaneously. The system will operate in such a way that it will not impact the operation of the generator whether or not there is a natural gas supply.

b. Delivery of as-built/equipment/schematic drawings showing the electrical wiring and other associated utility changes and installations for the new system.

1) 100% (FINAL) CORRECTED AS-BUILT DOCUMENTS: The final corrected as-built documents will include the previous approved submittal with all review comments incorporated. The documents to be forwarded to the Government will specifically include:

i. One (1) set of corrected final as-built drawings on compact disk labeled with the

Project Number and File Names and written instructions provided.

ii. Additional one set of paper based manuals.

c. The Contractor shall ensure that all items installed as part of this project integrate with any existing systems. The Contractor shall also coordinate all necessary power outages in advance; all outages shall be scheduled for a weekend and be given a minimum of two week notice.

d. All materials and equipment being installed need to be new and confirmed in working order.

Equipment and installation methods shall meet current industry standards. Operational testing and evaluations will be visually presented to SAFB personnel prior to operational testing. Only SAFB approved equipment may be reutilized after operational capabilities have been evaluated and accepted by SAFB personnel. All rehabilitation operations will be visually presented to SAFB personnel prior to operational testing.

e. Contractor shall site verify any and all dimensions and/or existing site conditions prior to the commencement of work. The Government is making the assumption that all dimensions were field verified at the time of site visit. No consideration for additional funding will be made for repairs that are to be made on dimensions and existing site conditions as this should have been found at the site visit. Commencement of work shall begin within ten (10) calendar days upon receipt of the Notice to Proceed (NTP) issued by the Contracting

Officer.

f. Contractor shall be required to apply for and submit to the Contracting Officer an AF Form

103, Work Clearance Request for all work to be accomplished under this delivery order five

(5) days prior to the commencement of work. The AF Form 103 can be obtained from and approved by the 375 CES.

g. Contractor shall make attempts to reduce emergency power disruptions during installation.

h. Contractor shall make every effort to restore generator to fully operation to support the real world outage should a real world power outage occur during installation.

i. Scott AFB personnel will provide an appropriately sized supply gas line to the generator at the point of connection to the bi-fuel/dual fuel/ blended fuel system to include manual shut off valve.

j. Contractor shall be completed no later than 30 September 2020. The intent is for the awardee to immediately provide submittals and position themselves for an immediate start date upon issuance of NTP from the Contracting Office.

k. Contractor shall submit design drawings, to include shop drawings on an AF Form 3000, Material Approval Submittal for approval by the Contracting Officer and/or his/her appointed representative in conjunction with the Contractor’s proposal for said delivery order. All corrections or modifications to these drawings shall be accomplished and approved prior to the scheduled commencement of work.

l. Contractor shall brief all Sub-Contractors on all safety and fire prevention regulations, emphasizing the requirement to obtain a daily AF Form 592, Welding, Cutting, and Brazing

Permit, when welding, cutting, or brazing operations are to occur under this delivery order.

The AF Form 592 can be obtained from and approved by the 375 CES.

m. All documents related to the disposal of hazardous material must be supplied to the 375 CE

Environmental section. The Contractor must obtain the proper documents from 375 CES to ensure all materials leaving Scott AFB can be tracked and accounted for in accordance with all governing laws.

n. Under the 1992 Clean Air Act, all products used in executing this project must not be related to the Class I Ozone Depleting Chemicals (ODCs) identified in Air Force Policy. The following products are considered Class I ODCs: CFC-11, CFC-12, CFC-113, CFC-114, CFC-115, Halon 1211, Halon 1301, Halon 2402, CFC-13, CFC-111, CFC-112, CFC-211, CFC-212, CFC-213, CFC-214, CFC-215, CFC-216, CFC-217, Carbon tetrachloride, and

Methyl Chloroform.

o. Contractor shall complete and submit the appropriate DD Form 1354, Transfer and

Acceptance of DoD Real Property, as outlined in Section 01010, General Requirements.

The DD Form 1354 can be obtained from the 375 CES.

4. FIELD CONDITIONS: The Contractor shall be responsible for all field measurements to accomplish work. Quantity and sizes of materials shall be determined from site visits and drawings. The Contractor shall carefully examine the entire site and building and shall make all necessary investigations to become thoroughly aware of the existing conditions and all difficulties involved in the completion of the work in accordance with the contract documents.

5. ACCOMPLISHMENT OF WORK: The work areas of the existing building will be in occupied and unoccupied areas. The Contractor must ensure that all access to the existing building remain clear for occupants and emergency access at all times during the construction period. All temporary closures, barriers, and protective procedures shall be coordinated with the

Contracting Officer. All work shall be accomplished during the standard 8-hour day, 5-day week, Monday through Friday, between the hours of 7:30 A.M. and 4:30 P.M. local time, excluding Federal holidays, Family days, and non-work days resulting from holidays occurring on weekends.

6. WORK CONDITIONS: The Contractor shall coordinate work with the Contracting Officer, in conjunction with the User and 375 CES. The Contractor shall notify the Contracting Officer or the inspection representative the day he/she moves onto the work site to commence work. The

Contractor shall again provide notification the day he moves back to the work site after an interruption of work of two or more days in duration. The Contractor shall also provide an original work schedule and updates as required. This schedule shall describe major work items and projected completion dates.

7. PROTECTION OF BUILDING PROPERTY: The Contractor shall protect from damage all building property located in or adjacent to the building and shall repair, replace, or otherwise be held liable for all such damage. Building properties include but are not limited to, furniture, vehicles, or items of supplies. Exercise control measures of all dust and toxic fumes associated with cretin construction operations in order to prevent hazards or illness to base and Contractor personnel.

8. CLEANUP: The Contractor shall cleanup each work site at the end of each work day to the satisfaction of the Construction Inspector/Project Manager All construction equipment and debris shall be removed from the site and the area shall be left in a neat and completely acceptable condition as required by the General Provisions. Contractor must always recycle materials, such as, but not limited to cardboard and paper. The Contractor will use whatever means necessary to store all recyclable materials and is responsible for turning in recyclable materials to an off base center.

9. PATCHING AND REPAIRING: After the work has been completed, holes, cuts, and damages made in the finished surfaces of the work site and adjacent areas shall be properly repaired and restored to match the existing finishes. Any abrasion or disfigurement of the finish work or any portion of the building where any such abrasion or disfigurement is caused by the activities of the Contractor shall be repaired and neatly refinished to match the adjacent work to the satisfaction of the Contracting Officer. Patching includes but not limited to brick, block, pavements, drywall, vinyl, carpet, etc. Any finished disturbed area needs brought back to its original or NEW look.

10. PRODUCTS: All products shall conform to their respective manufacturing and performance publications. All materials and equipment used during this project shall be the products of manufacturers regularly engaged in the manufacture of construction products.

11. SUBMITTALS: The Contractor shall submit for approval all items as required by other parts of these specifications. The Contracting Officer may request submittals in addition to those required by the other parts of this specification or Statement of Work when deemed necessary to adequately describe the work. Submittals shall be made to the Contracting Officer in two (2) copies using AF Form 3000, Material Approval Submittal. In general, submittals shall be provided a minimum of thirty (30) calendar days in advance of scheduled installation to allow satisfactory time for Government review. Additionally, unless stated otherwise, submissions on test results and other submissions of a similar nature shall be made within fourteen (14) calendar days after the work or test is to be performed. Each submittal shall be complete and in sufficient detail to determine compliance with contract requirements. Submittals shall include such items as Contractor’s or manufacturer’s shop drawings, descriptive literature, catalog cuts, samples, certifications, installation procedures and recommendations, templates, and other descriptive literature as may be required by the Contracting Officer. Catalog cuts and other descriptive data which may have more than one model or type shall be clearly marked to show the model, type, size, and all optional or accessory equipment the Contractor proposes to install. Submittals on component items forming a system of interrelated items shall be submitted at one time as a single submittal in order to demonstrate that the items have been properly coordinated and will function as a unit. Approval of submittals will not relieve the Contractor of compliance with the project drawings and specifications. Submittal items that are disapproved will be promptly corrected and resubmitted by the Contractor. No materials shall be installed until submittals are approved by the Contracting Officer. All submittals involving color selections, patterns, and other decorative architectural features shall be submitted at the same time for both interior and exterior materials.

12. SPECIFICATIONS: Work shall be performed in strict accordance with these contract general specifications, as well as all applicable local, state, and national Building and Life Safety Codes and American Society for Testing and Materials (ASTM) specifications. Safety issues must adhere to all applicable Occupational Safety and Health Act (OSHA) regulations. Electrical work shall comply with National Fire Codes and Standards, specifically NFPA 70, and most-current governing National Electrical Code (NEC).

GENERAL INFORMATION:

13. Contractor Consent to Background Checks: The contractor and, as applicable, subcontractor shall not employ persons for work on this contract if such employee is identified as a potential threat to the health, safety, security, general well-being or operational mission of the installation and its population, nor shall the contractor or subcontractor employ persons under this contract who have an outstanding criminal warrant as identified by Law Enforcement Agency Data

System (LEADS) through the National Crime Information Center. LEADS checks will verify if a person is wanted by local, state, and federal agencies. All contractor and subcontractor personnel must consent to LEADS background checks. Contractor and subcontractor personnel who do not consent to an LEADS check will be denied access to the installation. Information required to conduct an LEADS check includes: full name, driver’s license number, and/or social security number, date of birth of the person entering the installation, and completion of a background check questionnaire. The contractor shall provide this information using the Scott

AFB Form 21, Contractors Consent for Background Check, and shall submit it in conjunction with the contractor’s request for either base or vehicle passes. Completion of a successful

LEADS check does not invalidate the requirement for an escort when contractor or subcontractor personnel are working within controlled or restricted areas. All identifying credentials will be compliant with the REAL ID Act.

14. Contractors shall ensure their employees and those of their subcontracts have the proper credentials allowing them to work in the United States. Persons later found to be undocumented or illegal aliens will be remanded to the proper authorities. The contractor shall not be entitled to any compensation for delays or expenses associated with complying with the provisions of this clause. Furthermore, nothing in this clause shall excuse the contractor from proceeding with the contract as required.

15. Badges: The contractor is required to provide identification badges for their employees. All contractor personnel shall wear these badges while on duty on the government site. Badges are required to identify the individual, company name, and be clearly and distinctly marked as contractor. Size, color, style, etc. are to be mutually agreed to by contractor and government.

The contractor’s identification badge will not be used as an entry requirement for installation entry or into any government designated controlled or restricted area. All DBIDS cards/passes will be turned in to the Dixon Visitor Control Center upon expiration of pass and/or completion of contract.

16. Contractor Registration of Vehicles on Scott AFB: All contractor or contractor employees’ vehicles used for the performance of this contract shall comply with all local, state and federal regulations. Additionally any pass shall be surrendered to Security Forces upon demand to positively identify a person’s need to be on Scott AFB.

17. Access to Installation during Force Protection Conditions (FPCONs): Contractors will be assigned a mission essential designation IAW requirements contained in SAFBI 31-

101/Installation Security Instruction. Only the installation commander or the unit commander requesting contract support will assign the mission essential designation.

18. Property Protection: Property protection for facility where the contractors’ primary work center is located will be the responsibility of the local facility manager and local Government

Security Manager, or their duly authorized representative IAW AFI 31-101, Integrated Defense and command/local directives. The contractor shall safeguard all government-owned equipment and materials in his/her possession or use.

19. Safeguarding Classified or Unclassified Information: The contractor shall meet Air Force standards for storing, processing, and handling classified information and systems. Additionally, all resources (e.g. maps, publication/instructions, photos) provided by the government to assist the contractor in the performance of their contract will be surrendered upon termination of employment or the end of the contract performance period.

20. Non-Disclosure Agreements: To safeguard information, the contractor shall enter into non-disclosure agreements with the responsible local security manager.

21. Privacy Act: Work on this project requires that personnel have access to Privacy Information.

Personnel shall adhere to the Privacy Act, Title 5 of the U.S. Code, Section 552a and applicable agency rules and regulations.

22. Contractors Working in Controlled or Restricted Areas: The unit requesting contract support will provide escort (s) for contractors’ at all times when within a controlled area.

Contractors shall not escort other contractor employees within controlled or restricted areas. In addition, contractors shall fulfill, maintain, and comply with all security requirements IAW AFI

31-101, Integrated Defense, and command/local directives.

23. Access to Government Facilities with Controlled or Restricted Areas: The contractor shall comply with security regulations imposed by the installation commander and/or the agency responsible for the project location. Due to specific mission requirements inherent in the nature of controlled or restricted areas on Scott AFB, the government may direct the contractor to leave the controlled or restricted areas at any given time.

24. Contractors Responsibilities while Working within Controlled or Restricted Areas: Only contractor personnel with proper authority and qualifications shall enter a controlled or restricted area. Certain facilities require the issuance of an AF Form 1199CD. The government, at any time, may revoke the AF Form 1199CD. The procedures for the issuance of an AF Form

1199CD are contained in SAFBI 31-1 Integrated Defense/Antiterrorism Plan. Contractors shall not escort other contractor employees within controlled or restricted areas. Upon completion of the contract, all 1199CDs will be turned into the sponsor and in turn delivered to 375th SFS/S5B, Line Badges. In addition, contractors shall fulfill, maintain, and comply with all security requirements contained in SAFBI 31-1 Integrated Defense / Antiterrorism Plan.

25. Access to Government Facilities with Controlled or Restricted Areas for Replacement

Contractors: The unit requesting contract support will continuously escort replacement contractors, not initially possessing the proper clearances and requiring entry to controlled or restricted areas. Replacement contractors shall submit paperwork within 30 days of being assigned to obtain an approved security clearance or favorable review. Replacement contractor personnel shall obtain a security clearance prior to working with, or having direct access to, classified material. In addition, replacement contractor personnel shall obtain a “Favorable review” prior to having access to a Controlled Area. The above information shall be submitted to 375 AMW/IP.

26. PROJECT MANAGER: The 375th Civil Engineer Squadron Project Manager for this project is William McDade, 618-256-2683. The Project Manager is the point of contact for all matters of design and, unless a construction inspector is designated, construction. For matters going to terms and conditions of the contractor’s contract with the Government, the 375th Contracting

Squadron’s designated official is the point of contact.