SOW Containerized Vacuum Pump System Expansion.pdf

22 December, 2020

STATEMENT OF WORK

FOR

Containerized Vacuum System Expansion

FA9101-21-Q-0016

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

AEDC IRA- 3738

Table of Contents-1

Table of Contents

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Standards

3. CLIN 1: General System Requirements

4. Option CLIN 2: 24” Main Isolation valve

5. Option CLIN 3: Additional Isolation valves for Existing CVS

6. Option CLIN 4: Additional Pressure Sensors

7. Option CLIN 5: CVS Data Recorder

8. Option CLIN 6: 403 HMI CVS Operator Station

9. Option CLIN 7: New Container Roof Railings

10. Option CLIN 8: Existing Container Roof Railings

11. CLIN 9: Verification and Submittals

Appendix A – Concept Drawing Containerized Pump Layout Appendix B –Tunnel 9 CVS Electrical Single Line Drawing Appendix C – HMI Control Panel Layouts Concepts Appendix D – Report of Geotechnical Study

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1. SCOPE

1.1. The vendor shall furnish AEDC White Oak -Tunnel 9 with a containerized vacuum pump system that will be used in combination with the existing containerized vacuum system (CVS) units to reduce the pressure in a 203,417 ft3 vacuum sphere from atmospheric or sub-atmospheric pressure to 1.5 mmHg or less. The new containerized pump system shall be a duplicate of one of the existing container systems installed per contract FA9101-19-C-0051 (in 2019) in both function and the equipment used.

1.2. The containerized vacuum pump system furnished by the vendor shall be able to operate starting from atmospheric pressure (approximately 760 mmHg) or sub atmospheric pressure and achieve pressure of 1.5mmHg or less in the sphere.

1.3. The vendor shall provide construction services to install and integrate the containerized vacuum pump system into the AEDC Tunnel 9 facility in accordance with the designs provided.

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1 GSA Facilities Standards PBS P100/2018 Edition

2.1.2 CVS Commissioning Test Plan – AEDC to supply after 70% design review

2.1.3 Building 430 Drawings / AutoCAD Files

2.1.4 OSHA 1926.502 – 1995, Fall Protection Systems Criteria and Practices

2.1.5 OSHA 1910.29 – 2019, Fall Protection Systems and Falling Object Protection-

Criteria and Practices

2.2. Non-Government Standards:

2.2.1. ACI 301-16 Specifications for Structural Concrete.

2.2.2. ACI 318-19 Building Code Requirements for Structural Concrete.

2.2.3. ACI 347R-17 Guide to Formwork for Concrete.

2.2.4. ACI 305.1-14 Specifications for Hot Weather Concreting.

2.2.5. ACI 306.1-16 Specification for Cold Weather Concreting.

2.2.6. API Standard 609, Eighth Edition, February 2016, Errata: April 2017

2.2.7. ASME/ANSI B16.5 – 2017, Pipe Flanges and Fittings

2.2.8. ASME Standard B31.9 – 2017, Building Services Piping

2.2.9. ASTM A1064/A1064M-18 Specification for Carbon - Steel Wire and Welded Wire

Reinforcement, Plain and Deformed, for Concrete.

2.2.10. ASTM A615/A615M-18 Specification for Deformed and Plain Carbon-Steel

Bars for Concrete Reinforcement.

2.2.11. ASTM B3-18 Standard Specification for Soft or Annealed Copper Wire.

2.2.12. ASTM B8-17 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft.

2.2.13. IEEE 142-14 Recommended Practice for Grounding of Industrial and

Commercial Power Systems- IEEE Green Book (Color Book Series).

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2.2.14. NEMA C80.1-15 Electrical Rigid Steel Conduit (ERSC).

2.2.15. NEMA 250 – 2018, Enclosures for Electrical Equipment (1000 Volts Maximum)

2.2.16. NFPA 70 2020 Edition, National Electrical Code

2.2.17. UL 467-17 Grounding and Bonding Equipment.

3. CLIN 1: System Requirements:

3.1. Containerized Vacuum System Requirements

3.1.1. The vendor shall provide a vacuum pump system capable of bringing a volume of a 203,417 ft3 vacuum sphere with a leak rate of 17,000 CFM-mmHg from atmospheric pressure (approximately 760 mmHg) to 1.5 mmHg or less, in no more than 2.15 hrs, when used in parallel with the existing containerized vacuum system (CVS) which consists of two containers.

3.1.2. The containerized vacuum pump system provided by the vendor shall be capable of bringing a volume of 203,417 ft3 with a leak rate of 17,000 CFM-mmHg from 40 mmHg to 1.5 mmHg or less in no more than 45 min, when used in parallel with the existing containerized vacuum system (CVS).

3.1.3. The containerized vacuum pump system provided by the vendor shall be capable of bringing a volume of 203,417 ft3 with a leak rate of 17,000 CFM-mmHg to a minimum pressure of 1 mmHg or less within 4 hours, when used in parallel with the existing containerized vacuum system (CVS).

3.1.4. Equipment used and installed in the new CVS unit shall exactly match that of the existing equipment previously supplied per contract FA90101-19-C-0051.

Deviations other than those specifically listed in this SOW shall require specific approval from the contracting officer before proceeding.

3.1.5. Vendor shall conduct at least 3 design reviews with the government and its representatives for approval: conceptual design review (~30% completion), Preliminary design review (~70% completion), and final review (~90% completion). Government will approve the final review before work shall commence. Meetings may be conducted in person at Tunnel 9, or virtually in accordance with the standing COVID-19 policies at the time.

3.1.6. All equipment and materials provided shall be furnished as new. Use of pre-owned equipment and materials is not allowed.

3.1.7. The vendor shall procure, install, and commission containerized vacuum pump system in a period not to exceed 35 weeks from date of award.

3.1.8. The vacuum pump system shall be housed in an identical container as the existing containers.

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3.1.9. The maximum footprint of the container shall not exceed 8ft x 40ft. Container shall be 9.5ft tall.

3.1.10. Container shall be located (south of) building 430 in the parking lot area near the existing CVS. See appendix A: Concept Drawing Containerized Pump Layout.

3.1.11. The containerized vacuum system shall be as self-contained as possible. Oil, cooling, filtration, and other ancillary systems shall be housed in the container with as few external connections as possible.

3.1.12. Cooling system shall be supplied in a closed loop system within the container.

Cooling system shall be equipped with a low level alarm.

3.1.13. All penetrations of the container exterior shall have sealing around the penetration (pipe, conduit, etc.) of the container. Seal shall prevent entry of water, dust, animals, insects, or other contaminants from entering the container.

3.1.14. The container shall be complete with ventilation, heating, lighting, and insulation sufficient for operation in central Maryland climate throughout the year.

3.1.15. Vendor shall install external overhead lighting hanging over the container end doors. Lights and stanchions shall not interfere with operation of the door or maintenance activities.

3.1.16. Vendor shall install roofing material on the supplied container. Roof shall include impermeable membrane to protect the roof structure from water and outdoor elements. Install flashing or sealant to seal all penetrations in the container roof.

3.1.17. Container doors shall have gaskets or flexible seals around all doors to prevent water and outdoor elements from entering through door gaps.

3.1.18. Container internal and external layout shall match the configuration of the existing CVS system at Tunnel 9.

3.1.19. The containerized vacuum pump system shall have standard ASME/ANSI B16.5 flanges and 12” pipes for air inlet.

3.1.20. The pump(s) installed in the containerized vacuum pump system shall have a carbon steel, vacuum rated, pneumatically actuated control valve at its inlet, inside the container, for isolation from the vacuum chamber. Valve shall fail closed.

3.1.21. Pump(s) shall have a 12” maintenance isolation valve upstream of the pneumatic control isolation valve. Maintenance valve shall be a carbon steel, manually controlled, vacuum rated, butterfly valve. Valve shall be compact and light weight as possible to minimize or eliminate the need for additional supports.

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3.1.22. Pump(s) inlet piping shall have a 12”, carbon steel, flexible connector at the entry point, outside the container. The flexible connector shall be flanged at both ends and flanges shall conform to ASME/ANSI B16.5.

3.1.23. Manual isolation valves and flexible connectors shall be rated for uncovered outdoor environments.

3.1.24. Manual isolation valves shall have local position indication.

3.1.25. A bleed port shall be installed between the two valve bodies. Valve arrangement shall be sufficient such that with Lockout Tag out applied this provides double block and bleed protection. This shall allow for any maintenance work performed downstream on the pump or booster while other CVS units are running and vacuum is in the sphere and 24” pipe.

3.1.26. The bleed line installed between the pneumatic control valve and the manual isolation valve shall be sufficiently sized and no smaller than ¾” NPT to provide double block and bleed protection. Bleed line shall have an inline manual, vacuum rated ball valve.

3.1.27. All piping and connections for the cooling system shall be stainless steel to prevent corrosion.

3.1.28. Discharge of air shall be through the side of the container. Discharge pipe shall have a standard ASME/ANSI B16.5 flange for ducting to be attached at the penetration outside of the container.

3.1.29. Discharge shall be ducted down or covered to prevent rain entry.

3.1.30. Discharge and inlet pipe shall be on the north side of the container (same side as inlets). See Appendix A – Concept Drawing Containerized Pump Layout Exhaust air shall be free of visible oil mist.

3.1.31. The current draw from this container system to be installed per this SOW shall be identical to the existing containers. A delay between the sequential startup of all pumps (existing and new) shall be used to ensure the system load does not exceed 1500A threshold during initial startup.

3.1.32. Pump(s) and ancillary systems shall have a main electrical disconnect (located outdoors on the portion of the container not obstructed by the 24” vacuum line).

A distribution cabinet and individual disconnect switches shall also be provided

3.1.33. All electrical cabinets and materials shall be UL approved as applicable.

3.1.34. Main PLC interface and main electrical disconnect shall be on the north side of the container. All equipment shall be positioned to not interfere with door operations.

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3.1.35. System shall have PLC control, digital HMI control interface displaying pump and system status, hour meters, maintenance meters, and pump faults. Dry contacts shall be provided for remote alarm monitoring, and remote control.

A. The controls shall interface to the master control unit located in container 1 via Cat 6 Ethernet connection.

B. Controls shall be a PLC-based system which utilizes an Allen-Bradley

Micrologix 1400 with an Ethernet communications interface.

C. The vendor shall provide a soft copy of the PLC code. The PLC source code shall be provided or accessible via Ethernet.

3.1.36. Control of the new containers installed per this SOW shall be integrated with the control of the existing containers; Such that it is interfaced to the main control unit in container 1 the same as container 2 is interfaced.

3.1.37. Pump startup shall be coordinated together such that all pumps can be operated via one start command and all start sequenced with a delay from the pump started before it. New pumps shall be programmed to start following the pumps in container 2. New pumps shall use the same start delay setting as set for the existing pumps.

3.1.38. Simultaneous startup of pumps shall not be allowed under any circumstances

(normal start command, alarm reset, etc.). Control program shall always prevent multiple pumps from starting at the same time. They shall always be delayed start from the previous pump by the start delay setting.

3.1.39. All electrical components included in the pump assembly shall conform to NEMA 250 standard and rated to NEMA 4 for protection.

A. The control external panel shall be NEMA 4 rated with HMI and weather protection (operational control outside of the container).

B. The external panel shall have control and indicators. The panel-mounted components shall include, but are not limited to, the following:

1. Emergency Stop Button

2. Ready light.

3. Trouble Alarm light.

3.1.40. Each pump booster set shall have an individual panel mounted HMI interface matching the interface design as shown in Appendix C - HMI Concepts Layouts for individual control. Pump booster set will also have Local, Remote, Off switch.

All control described above will be accessible via the container end door.

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3.1.41. Indications and alarms shall be capable of being sent via Ethernet to building 430 monitoring station.

3.1.42. Vendor shall run quantity three (3) new control wires through existing conduit over to building 403 for integration into the existing control panel. Integration with that panel is not part of this SOW.

3.1.43. All Control wire shall be UL approved shielded #10 XHHW-2 and allow for direct control of the CVS from the 403 remote operating station in the same manner as the existing units.

3.1.44. Pump/Booster set individual electrical boxes shall have a view panel installed to allow for view of alarm codes shown on the VFD without needing to power down.

3.1.45. New CVS units shall have the same sensors and indication as the existing units.

3.1.46. New CVS units shall have an additional pressure sensor installed in the discharge of the booster pumps and displayed on the HMI.

3.1.47. The new sensor shall read from 0 to 1400 Torr (0-27 psia) with output of 4-20 mA

3.1.48. The new sensor output shall be readable in the local HMI, at digital remote operating stations, and input into the PLC.

3.1.49. Vendor shall program HMI and PLC for operation from remote station in the Building 430 control room. HMI shall include screens for remote control, overview screen on each container, detailed view of each pump – booster set, and alarm indication. See Appendix C: HMI Control Panel Layout Concepts.

3.1.50. HMI display shall be the same graphically for local operation and remote operation in building 430.

3.1.51. Status beacon shall be installed on the exterior top of the container. Green-running, yellow – alert, red – alarm

3.1.52. Alarm horn shall be mounted on the outside of the container.

3.1.53. Full system shall be prewired and factory tested prior to shipment.

3.1.54. Vendor shall supply operations and maintenance manual in print and digital form.

3.1.55. Vendor shall supply a recommendation of spare parts for the unit (oil, filters, bearings, etc.).

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3.2. General Site work and Installation Requirements:

3.2.1 The Vendor shall design and construct vacuum line pipe extension and supports, control and electrical cables, and level pad for the containerized vacuum pump system.

3.2.2 The Vendor will be responsible for any and all rigging, lifting, and off-loading of construction materials associated with this project including the containerized vacuum pump system from the delivery truck onto the storage pad located in the rear parking lot of AEDC building 430.

3.2.3 Vendor shall supply and install any shimming needed under the container to ensure the unit is level and all equipment and doors function properly.

3.2.4 The Vendor shall be responsible for connecting the vacuum line extension to the containerized vacuum pump system

3.2.5 The Vendor / Vendor A/E shall make site visits and determine the level of effort necessary to complete the project in the time allotted and professional manner.

The site survey shall take into consideration the building support systems, equipment operating environment, and any other requirement necessary to conform to this Statement of Work (SOW).

3.2.6 The Vendor shall minimize impact to site schedule. Work will be scheduled around the facility operations should conflicts exist.

3.2.7 Vendor shall coordinate all site work that will render the existing CVS system inoperable (ie: loss of power, cutting into the pipe, etc.) with Tunnel 9 and shall not interrupt the tunnel operational schedule. Such work shall be planned for a period between July 2021 and September 2021 to coincide with the site planned maintenance period. Updates to this period will be provided throughout the design phase of the project.

3.2.8 The following includes, but is not limited to the work required to fulfill the objectives of this project as necessary for each technical discipline.

3.3 Architectural Requirements:

3.3.1 The Vendor / Vendor A/E shall verify existing field conditions to design and construct the storage pad, vacuum line extension, electrical cable and control cable.

3.3.2 Items currently stored on the concrete slab just south of building 430 will be removed by AEDC. The Vendor/Vendor A/E shall be responsible for removal of the permanent “deck cover” structure (to include concrete berm) in the area between the south wall of building 430 and the concrete column.

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3.3.3 The container described in this SOW shall be fit on a 40.5 ft x 8.5 ft concrete pad between the maintenance area pit and the existing CVS as shown in Appendix A:

Concept Drawing Containerized Pump Layout.

3.3.4 The new container shall be located such that there is a minimum 18 ft. (at their closest point) of clear space between the new container and the existing north container to allow for forklift access between both containers. There must be a minimum of 6 ft of clear space on each container end and minimum of 5 ft of clear space between the container and the 24” pipe to allow for door clearance.

3.3.5 All equipment and infrastructure shall be situated to allow access to pumps though the end doors.

3.3.6 Container shall be positioned such that none of the doors, equipment access, or function are impeded by existing or new site infrastructure. Equipment and infrastructure shall be located with a mind toward access to the equipment and ease of maintenance. As shown in Appendix A an existing column is located in the vicinity of the new container.

3.3.7 The Vendor / Vendor’s A/E shall design and construct the vacuum line extension to interface with the existing vacuum line 24” elbow to the existing CVS shown in Appendix A –Concept Drawing Containerized Pump Layout.

3.3.8 Vacuum line extension main header shall be 24” schedule 20 (or greater) vacuum rated steel pipe up as shown in Appendix A –Concept Drawing Containerized Pump Layout.

3.3.9 Each pump shall have a dedicated 12” schedule 20 (or greater) vacuum rated steel pipe to its inlet coming off the 24” main header extension, as shown in Appendix A –Concept Drawing Containerized Pump Layout.

3.3.10 The Vendor / Vendor’s A/E shall design the vacuum line extension, including all piping, valves and components to support 0-30 psia.

3.3.11 The Vendor / Vendor’s A/E shall remove the north 90°, long radius elbow and replaced with a tee to join the new vacuum line extension to the existing CVS 24” vacuum line as indicated in Appendix A.

3.3.12 The 24” main header is known to have polychlorinated biphenyls (PCB) contamination less than 50 ppm (as last tested at the 24” manway entrance).

3.3.13 The Vendor shall test and clean the existing pipe to be free of polychlorinated biphenyls (PCB) contamination to the degree required to complete the tasks required by this SOW, including any hot work. The Vendor is responsible for the

Page | 9 disposal of any wastes, and scrap pipe produced in accordance with local, state, and federal law.

3.3.14 The Vendor / Vendor’s A/E shall design and construct the storage pad, vacuum line extension, electrical, and control cables so that they do not interfere with the existing vacuum line, CVS, valves, building foundations, and other infrastructure.

3.3.15 The Vendor / Vendor’s A/E shall design and construct the storage pad(s), vacuum line extensions, electrical, and control cables with no interference of existing bridge crane, bridge crane structure, and other infrastructure.

3.3.16 The Vendor / Vendor’s A/E shall evaluate, design, and construct any additional required structural supports for vacuum line extension.

3.3.17 The Vendor / Vendor’s A/E shall design and construct a thrust block on the vacuum line extension if deemed necessary.

3.3.18 Vendor shall install pipe such that there is clear ingress and egress paths to both East and West sides away from the containers. This shall be accomplished by adding a vertically raised section of pipe as show in section A-A of Appendix A.

3.3.19 Vertical pipe loop shall be 8.5’ high at low point and 4’ wide at the inner sides of the pipe. See Appendix A –Concept Drawing Containerized Pump Layout.

3.3.20 Vendor shall install a manual 1” vacuum rated ¼ turn ball valve in the upstream side of the vertical loop on the underside (low point) of the pipe. Valve shall serve as a drain before vertical section of pipe.

3.3.21 The Vendor / Vendor’s A/E shall design and construct flexible bellows at each inlet connection to the container.

3.3.22 The Vendor/Vendor’s A/E shall tie in to the existing 1”, copper compressed air (CA) line and route the new line over to the new container. The new CA line shall be routed along the new 24” CVS vacuum line to facilitate its support. Extended CA line will supply air to the pneumatic receiver located in the container to be installed per this SOW.

3.3.23 Vendor / Vendor’s A/E shall provide paint on any exposed vacuum line extension piping. Paint shall match the color of the existing CVS vacuum header.

3.3.24 The Vendor / Vendor’s A/E shall clean all newly installed vacuum piping of all slag, debris, and foreign objects capable of causing damage prior to running the new equipment for commissioning.

3.3.25 Vendor / Vendor’s A/E is responsible for disposal of all wastes generated as part of the completion of this project to include any potential contaminated or hazardous

Page | 10 wastes. All wastes shall be disposed of in accordance with local, state, and federal law.

3.4 Civil & Geotechnical Requirements:

3.4.1 The Vendor / Vendor’s A/E shall verify existing field conditions and make use of to the previous borings (See appendix D – Report of Geotechnical Study). The Geotechnical work provided in appendix D shall serve as the basis for any geotechnical information related to this project. New borings are not required.

3.4.2 Vendor shall coordinate with the GSA to ensure that any utilities are not affected by this work.

3.5 Electrical Requirements:

3.5.1 The Vendor / Vendor’s A/E shall verify existing field conditions to design and construct additional needs for power to the containerized vacuum pump system and any other electrical elements as needed.

3.5.2 The Vendor shall furnish, and install power cabling, and controls cabling in separate conduits to connect container power and controls as described in this

SOW.

3.5.3 The new CVS container enclosure shall be connected to ground in two points. The new container shall tie into the existing ground system that was installed for the existing CVS containers or have its own individual ground system (i.e., ground rods).

3.5.4 All grounding materials shall be listed in accordance with UL 467. The grounding electrode conductor shall be bare stranded copper, soft drawn, sized in accordance with NFPA 70. Ground rod material shall be copper plated steel.

Buried connectors shall be compression type, listed for direct burial. Above grade connectors shall be either mechanical or compression type.

3.5.5 Vendor / Vendor’s A/E shall make calculations to determine that the new electrical/mechanical equipment loads for the containerized vacuum pump system will remain under the stated load limit per this SOW. Provide such calculations to the contracting officer.

3.5.6 The Vendor / Vendor’s A/E shall design and construct electrical and control cables, runs to the storage pad, and separate NEMA 4 rated enclosure at the storage pad to integrate the containerized vacuum pump system.

3.5.7 The Vendor / Vendor’s A/E shall design and construct the electrical cables and runs for the containerized vacuum pump system with 20% spare for future use.

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Refer to the GSA Facilities Standards PBS P100/2018 Edition for additional information.

3.5.8 The Vendor / Vendor’s A/E shall design and construct all line voltage conductors to be made of copper and be of adequate size to meet the full load requirements of selected equipment as recommended by the manufacturer. Insulation shall be UL approved either Thermoplastic THW-2 or THWN-2 or Thermoset type XHHW-

2. Cables shall be rated 90 degree C.

3.5.9 The Vendor / Vendor’s A/E shall design and construct all electrical wall penetrations to be sealed in accordance with NFPA and NEC requirements.

3.5.10 The Vendor / Vendor’s A/E shall design and construct all wiring to comply with all applicable NEC codes and authorities having jurisdiction.

3.5.11 The Vendor / Vendor’s A/E shall design and construct all electrical conductors including control conductors in mechanical rooms to be installed in NEMA rated RMC (RGS) conduit with appropriate fittings used.

3.5.12 The Vendor / Vendor’s A/E shall design and construct standard terminal block layout per code compliance. All cable terminations to be NEC compliant for supplied Control and Power Cabling.

3.5.13 The Vendor / Vendor’s A/E shall terminate all cabling at a terminal block per code compliance. Use of wire nuts is not permitted. Final power hook up shall be the responsibility of the vendor.

3.5.14 Power to the system shall be run from the 480V 60 Hz Distribution cabinet VS located between the two containers at the end of the existing CVS 24” main header pipe. The new 600A breaker (identical to the existing 600A breakers) shall be installed in place of the surge suppression device as shown in Appendix B Tunnel 9 CVS Single Line Electrical Drawings (Sheet 2 Coord E12).

3.5.15 The Vendor will be responsible for running conduit and control wire from the new container into the existing master control unit (existing south most container) and connecting the controls of the new container into the existing master controller.

Conduit shall be NEMA rated RMC with appropriate fittings.

3.5.16 Control and power cable shall be run in separate conduit and shielding shall be sufficient to prevent noise or spurious signals.

3.5.17 Power and control conduit shall be run above ground following the 24” pipe route.

3.5.18 Power conduit shall be electrically isolated from all surrounding structures to include but not limited to the containers and vacuum pipe.

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3.5.19 A ground fault return cable (sized per the NEC) shall be routed in the same conduit as the power cables.

3.5.20 AEDC shall adjust the protection setting of the upstream Main heater switchgear Cubical C1 1600 amp breaker.

3.6 Structural Requirements:

3.6.1 The Vendor / Vendor’s A/E shall verify existing field conditions to design and construct the vacuum line extension and storage pad; to include supports, footing systems and slab systems.

3.6.2 The Vendor / Vendor’s A/E shall verify the vacuum line extension and storage pad foundation system does not interfere with the existing 48” diameter vacuum line, other structures, or any other utilities both above and below ground.

3.6.3 The Vendor / Vendor’s A/E shall design and construct the storage pad(s) to support the containerized vacuum system expansion shown in “Appendix A – Concept Drawing/Vacuum Pump Containerized Integration.”

3.6.4 The vendor shall evaluate, design, and construct an appropriate concrete leveling pad on which to situate the new container.

3.6.5 Leveling pad shall be laid on top of existing asphalt/concrete. Pad shall be 4” above grade at minimum, and level on the resting surface to support the container.

3.6.6 Asphalt/concrete surface shall be roughened prior to pouring concrete to ensure proper bonding between the pad and subsurface.

3.6.7 Vendor / Vendor’s A/E shall ensure storage pad and vacuum line extension support structures shall meet all applicable architectural and MEP requirements.

4. Option CLIN 2: 24” Main Isolation valve

4.1. Vendor shall supply and install a 24” isolation valve in the main 24” vacuum line.

See Appendix A concept drawings for the proposed location upstream of the new tee.

4.2. Valve shall be located such that the minimal amount of pipe and support work is required to support this valve.

4.3. Valve shall be vacuum rated to less than 1 Torr.

4.4. Valve shall be carbon steel, pneumatically driven, fail closed, quarter turn, flanged or wafer style, butterfly valve.

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4.5. Vendor/Vendor’s A/E shall tie in to the existing 1”, copper compressed air (CA) line to serve as the supply for CA to the 24” valve pneumatic actuator. Connection to the valve shall be the vendor’s responsibility.

4.6. Valve shall be integrated into the CVS PLC such that it is controllable from the local HMI panels and CVS remote operating station(s).

4.7. Valve shall be installed such that when closed it provides isolation for all three containers from the vacuum sphere.

4.8. Vendor shall clean from inside the pipe, remove, and dispose of any debris or metal shavings generated during this work.

5. Option CLIN 3: Additional Isolation valves for Existing CVS

5.1. Vendor shall supply and install a manual maintenance isolation valve on each of the existing CVS pump/booster unit’s inlets. Total of four (4) additional valves.

5.2. Manual maintenance valves shall be installed such that Pump(s) shall have the maintenance isolation valve upstream of the pneumatically controlled isolation valve located inside the container.

5.3. Vendor shall remove pipe and reroute as needed to fit the isolation valves. Flexible bellows at the pump inlets are still required in the final installation.

5.4. The 12” main header is suspected to have polychlorinated biphenyls (PCB) contamination less than 50 ppm (based on the last test at the 24” manway entrance).

5.5. The Vendor shall clean the existing pipe to be free of polychlorinated biphenyls

(PCB) contamination to the degree required to complete the tasks required by this SOW, including any hot work. The Vendor is responsible for the disposal of any wastes, and scrap pipe produced in accordance with local, state, and federal law.

5.6. Maintenance valve shall be a carbon steel, manually controlled, vacuum rated, wafer style, butterfly valve, requiring as little space as possible to minimize additional pipe work.

5.7. Vendor shall supply and install a bleed port between the two valve bodies. Valve arrangement shall be sufficient such that with Lockout Tag out applied this provides double block and bleed protection. This shall allow for any maintenance work performed downstream on the pump or booster while other CVS units are running and vacuum is in the sphere and 24” pipe.

5.8. The bleed line installed between the pneumatic control valve and the manual isolation valve shall be sufficiently sized and no smaller than ¾” NPT to provide double block and bleed protection. Bleed line shall have an inline manual, vacuum rated ball valve.

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5.9. Manual isolation valves shall be rated for uncovered outdoor environments.

5.10. Manual valves shall have local position indication

5.11. Vendor shall clean from inside the pipe, remove, and dispose of any debris or

6. Option CLIN 4: Additional Pressure Sensors

6.1. Vendor shall supply and install an additional pressure sensor at the booster discharge of each existing CVS booster. Quantity four (4) in total.

6.2. Vendor shall clean from inside the pipe, remove, and dispose of any debris or

6.3. Sensor shall read from 0 to 1400 Torr (0-27 psia) with output of 4-20 mA

6.4. Sensor output shall be readable in the HMI and input into the PLC

7. Option CLIN 5: CVS Data Logger

7.1. Vendor shall supply a data logger capable of interfacing and communicating with the Micrologics1400 PLCs currently used in the CVS.

7.2. Vendor supplied data logger shall have at a minimum:

A. 275 channel recording capacity B. 50 sample/ms C. Internal storage of 16,000,000 record count minimum D. Event Triggering E. Tagging capability F. Record time stamps (both time of day and time since trigger) G. FILO data retention once memory is full H. Output to windows computer as .CSV file format

7.3. Vendor shall set up data logger to record and output values in engineering units from:

A. all thermocouples (discrete temperature value, record 1 sample per minute)

B. pressure sensors (discrete pressure value, record 1 sample per 2 minutes)

C. isolating valve state (Open/ Closed, record on state change) D. modulating valve position (open %, record on change) E. pump run state (On/Off, record on state change) F. booster run state (On/Off, record on state change) G. cooling fan run state (On/Off, record on state change) H. alarm status (On/Off and alarm name, record on state change)

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7.4. Vendor shall set the data logger to begin recording when the pump start command is given. Data will continue recording until all pumps are no longer running.

7.5. Vendor shall set up the data logger to record output from listed values in section

7.3 on all six (6) pump booster sets; all three (3) containers.

7.6. Vendor supplied data logger shall be capable of DIN Rail mounting and rated for location in the outdoor CVS PLC control cabinets.

7.7. Vendor supplied data logger shall output data over the existing Cat 6A Ethernet cable to Bldg 430 control room. Data will be accessible for download from Tunnel 9 control system computer.

7.8. The data logger shall record and output data as part of the checkout in the commissioning process.

8. Option CLIN 6: 403 HMI CVS Operator Station

8.1. Vendor shall supply and install an HMI panel in the 403 vertical board in place of the hardwired panel currently used. The Hardwired Emergency button and sphere pressure indication shall remain in place and functional.

8.2. The HMI panel shall be connected to the Main CVS control unit. Communication method used shall accommodate the long run distance ~450ft without significant signal degradation, noise or reduction in response time.

8.3. Vendor shall supply and run communication line through the existing conduit connecting the 403 interface with the CVS control PLC. Existing control wire may be removed to allow conduit space as needed, with the exception of wires needed for the E-stop and sphere pressure gauge. Exercising this option will remove the need for the three (3) new control wires as stated in line 3.1.42

8.4. HMI panel screens shall mirror exactly what is shown in the 430 control room and the local container indication. Local panel shall still have the remote operations panel to support testing and commissioning.

8.5. See Appendix C – HMI Control Panel Layouts concepts for overview of the desired interface.

8.6. Vendor shall design the control scheme such that only one remote control station can be in control at a time. Local control will always have priority over either remote control station.

9. Option CLIN 7: New Container Roof Railings

9.1. Vendor shall in install railings on the edge of the new containers roof to serve as fall protection for personnel on roof during maintenance activities.

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9.2. Railings shall be compliant with OSHA standards for fall protection. In particular:

OSHA 1926.502 in particular Subpart M line b(1), and OSHA 1910.29(b)(1)-(b)(15) & (k)(1)

9.3. Vendor shall install railings enclosing the entire perimeter of the container roof

9.4. Vendor shall install a total of two safety access gates; one on each of the long sides of the container. Safety access gates shall be 3’ wide.

9.5. Safety railings system shall be rated for an outdoor environment and protected from corrosion.

9.6. Safety railings and their mounting system shall not compromise the structure of the container or interfere with the operation of any doors or equipment.

9.7. Safety railings and their mounting system shall not compromise the roofing materials ability to protect the container interior from water and element protection.

9.8. Vendor may attach the safety railing after the unit is delivered to Tunnel 9 but before the commissioning process site if desired.

10. Option CLIN 8: Existing Container Roof Railings

10.1. Vendor shall install railings on the edge of both existing containers roofs to serve as fall protection for personnel on roof during maintenance activities.

10.2. Railings shall be compliant with OSHA standards for fall protection. In particular:

OSHA 1926.502 in particular Subpart M line b(1), and OSHA 1910.29(b)(1)-(b)(15) & (k)(1)

10.3. Vendor shall install railings enclosing the entire perimeter of the container roof

10.4. Vendor shall install a total of two safety access gates; one on each of the long sides of the container. Safety access gates shall be 3’ wide.

10.5. Safety railings system shall be rated for an outdoor environment and protected from corrosion.

10.6. Safety railings and their mounting system shall not compromise the structure of the container or interfere with the operation of any doors or equipment.

10.7. Safety railings and their mounting system shall not compromise the roofing materials ability to protect the container interior from water and element protection.

11. CLIN 9 : Verification and Submittals

11.1. The Vendor shall notify the contracting officer of the date for Factory Acceptance testing (FAT) prior to shipment with at least 2 weeks advance notice. The government

Page | 17 and its representatives have the right to witness all factory acceptance testing. Failure to provide notice may result in FAT being performed again at no additional cost to the government.

11.2. The Vendor / Vendor’s A/E shall verify vacuum line extension is leak free by pumping it down with the CVS prior to acceptance and shall provide a report documenting test results.

11.3. The Vendor / Vendor’s A/E shall support AEDC during commissioning efforts to include initial set up, leak check, electrical check and controls/operational check of fully integrated containerized vacuum pump system following the commissioning test plan to be supplied after the 70% design review.

11.4. Acceptance: The Government will accept the Containerized Vacuum System, all related components and equipment upon delivery of required submittals and satisfactory operation after installation and commissioning at AEDC, to include a tunnel run cycle.

11.5. Submittals: The vendor shall submit all documentation in accordance with Table

I – Required Submittal List. Vendor shall submit to the contracting officer:

11.5.1. Engineering Analysis, Bill of materials, calculations, and as built drawings for all site modifications, support systems, and infrastructure supplied as part of this project.

11.5.2. Engineering Analysis and Calculations for Containerized Vacuum Pump System:

A. Vacuum Pump Performance Curve showing vacuum pump capacity as a function pressure.

B. Time to pump down a volume of 203,417 ft3 with a leak rate of 17,000 CFM-mmHg to 1.5 mmHg from the following pressures for the Containerized Vacuum Pump System:

1. 760 mmHg

2. 200 mmHg

3. 100 mmHg

4. 40 mmHg

C. Maximum inrush and steady state amperage of the Containerized Vacuum

Pump System.

D. Weight and center of gravity of the container/vacuum pump assembly.

11.5.3. Vendor shall submit designs and drawings as applicable at each design review and a final 100% design of the:

A. Container assembly drawings

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B. Bill of materials C. Site drawings and vacuum line extension

11.5.4. As Built Drawings for the Containerized Vacuum Pump System furnished:

A. Final assembly drawings for the vacuum pump/container assembly.

B. Bills of Material, details, and assembly information for the end user to replace parts or repair the Containerized Vacuum Pump System.

C. Drawings of the as built vacuum extension line, supports, level pad, and electrical and control cables in PDF and AutoCAD.

D. Control system PLC code

11.5.5. Operation and Maintenance Manuals for Containerized Vacuum System.

Include:

A. Schematic diagrams (wiring diagrams for electric motor actuator and motor starter).

B. Operating and maintenance instructions including lubrication, cleaning, and calibration instructions for all equipment installer as part of this SOW.

C. Manufacturer’s bulletins, cut sheets, and descriptive data for each piece of equipment.

D. Parts list and recommended spare parts. The list shall give the manufacturer’s name, part number, and a vendor for each item.

E. Recommended maintenance and PM schedules for all equipment

11.5.6. Warranty: The vendor shall provide a one-year warranty for the Containerized Vacuum Pump System stating that it is free from any manufacturer defects. The warranty period shall begin after acceptance at AEDC.

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11.5.7. Submittal Table:

No. Section Reference Submittal Description Due

1 11.5.2.A Vacuum Pump Performance Curve 4 weeks following contract award

2 11.5.2.B Containerized Vacuum Pump System Pump Down Time Calculations

4 weeks following contract award

3 11.5.2.C Calculation of Containerized Vacuum Pump Maximum Amperage

4 weeks following contract award

4 11.5.2.D Certified container/vacuum pump assembly weight and center of gravity diagram

Delivered with 100% design

5 11.5.3 100% design materials Delivered with 100% design

6 11.5.4.A As built assembly drawings Delivered with Containerized Vacuum Pump System

7 11.5.4.B As built bill of materials, details, and assembly information

Delivered with Containerized Vacuum Pump System

8 11.5.4.C As Built Vacuum Line and Electrical/Control cable drawings

Delivered with Containerized Vacuum Pump System

11.5.4.D Operational version of PCL code Delivered with Containerized Vacuum Pump System

10 11.5.5.A Schematic diagrams Delivered with Containerized Vacuum Pump System

11 11.5.5.B Operating and maintenance instructions Delivered with Containerized Vacuum Pump System

12 11.5.5.C Manufacturer data Delivered with Containerized Vacuum Pump System

13 11.5.5.D Recommended spare parts Delivered with Containerized Vacuum Pump System

14 11.5.5.E Recommended Maintenance Schedules Delivered with Containerized Vacuum Pump System

15 11.6.5 Warranty Acceptance of Containerized Vacuum Pump System

Table I. Required Submittal List – Completed