SOW_WFRC_Chiller_Plate_Heat_Exchanger_Maintenance.docx
DOCX document 22 KB Posted
- Solicitation number
- 140G0326Q0200
About this file
This is a Statement of Work (SOW) for chilled process water plate heat exchanger maintenance services at the U.S. Geological Survey Water Resources Research Center (WFRC). The SOW outlines requirements for the rebuild and maintenance of plate heat exchanger equipment used in the facility's chilled process water system. The contractor shall be responsible for preventive maintenance, inspection, repair, and rebuilding of plate heat exchanger units to maintain optimal operational performance and extend equipment lifespan. Services include cleaning, gasket replacement, plate inspection and replacement as needed, pressure testing, and reassembly of exchanger plates according to manufacturer specifications. The contractor must maintain documentation of all maintenance activities, including work performed, parts replaced, and equipment performance metrics. Work shall be performed by qualified technicians with experience in plate heat exchanger systems, and all work must comply with applicable industry standards and the equipment manufacturer's requirements.
The SOW specifies that the contractor shall coordinate with USGS facility personnel to schedule maintenance activities with minimal disruption to facility operations. Parts and materials used must be compatible with existing equipment and approved by the government. The contractor is responsible for providing all tools, equipment, and materials necessary to complete maintenance work, except for those items specifically provided by the government. Performance standards require that all maintenance work be completed to manufacturer specifications and that equipment be returned to full operational capability. The SOW establishes the framework for ongoing maintenance support under the related solicitation 140G0326Q0200 for chilled process water plate heat exchanger rebuild services.
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Other files
| File | Type | Posted |
|---|---|---|
| HX-3_Drawing.pdf | ||
| IMG_3059.jpg | JPG image | |
| WFRC_heat_exchanger_rebuild_TandC.docx | DOCX document | |
| Sol_140G0326Q0200.pdf | ||
| HX-4_Drawing.pdf | ||
| IMG_3075.jpg | JPG image | |
| IMG_3074.jpg | JPG image |
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Text version
STATEMENT OF WORK
WFRC PROCESS WATER PLATE HEAT EXCHANGER DISASSEMBLY, CLEANING, RESEALING, FRAME RESTORATION, INSTRUMENTATION BUNG WELDING, AND INSULATION
1.0 INTRODUCTION AND BACKGROUND
The Western Fisheries Research Center (WFRC) requires disassembly, plate cleaning, resealing, frame rust removal and epoxy repainting, titanium instrumentation bung welding, and insulation of the facility's APC chilled process water plate heat exchanger (HX2). This work must be performed during the winter seasonal shutdown window when cold process water and chilled water usage is at a minimum and the heat exchanger can be taken offline, and must be completed within a six-week shutdown period.
The United States Geological Survey (USGS) Western Fisheries Research Center (WFRC) is located in Seattle, Washington. The WFRC carries out research and provides technical assistance to support the best possible stewardship of the Nation's natural resources, emphasizing fish populations and aquatic ecosystems of the West. The WFRC has a 50-year history of excellence in fisheries disciplines and is a leader in the field of molecular and microbiology within the U.S. Geological Survey.
The WFRC operates an APC gasketed plate heat exchanger designated HX2 that transfers cooling energy from the facility's magnetic bearing chiller system to the laboratory cold process water loop. The heat exchanger has accumulated fouling on the plate surfaces that has degraded thermal transfer efficiency. As a result, cold process water temperatures are currently measuring above the 3.5°C–4°C range required for temperature-sensitive biological research. The carbon steel frame has experienced surface corrosion and rust requiring treatment and protective recoating. The existing titanium fluid connections lack instrumentation ports, preventing facility staff from measuring inlet and outlet temperatures and differential pressure across the heat exchanger. Instrumentation bungs welded to the titanium inlet and outlet connections on both the chilled water and process water sides will allow installation of temperature and differential pressure sensors required for ongoing performance monitoring and early detection of future fouling. HX2 can only be taken offline during the late fall and winter months when laboratory cold process water demand is reduced sufficiently to allow a planned maintenance outage without disrupting active research operations.
| 2.0 | SCOPE |
| 2.1 | Place of Performance - The USGS WFRC, 6505 NE 65th Street, Seattle, WA 98115, mechanical equipment room housing APC plate heat exchanger HX2. |
| 2.2 | Period of Performance - Work shall be performed during the winter seasonal shutdown window, as coordinated with the WFRC TPOC. All work shall be completed within a six-week shutdown period from the date HX2 is taken offline. |
| 2.3 | Site Inspection - Contractor to meet onsite no later than 5 days after notice to proceed to review project requirements, inspect HX2 and adjacent piping, and confirm scope prior to scheduling the winter shutdown. |
| 2.4 | Work Hours - Work will be performed during normal business hours, Monday through Friday, 7:00 AM to 5:00 PM. Overtime or weekend work may be authorized by the WFRC TPOC if required to complete all work within the six-week shutdown window. |
| 2.5 | Special Considerations - HX2 serves the laboratory cold process water system supporting 24/7 live animal research operations. All work must be completed and HX2 returned to service within the six-week shutdown window. The contractor shall maintain a work schedule that ensures this deadline is met. Titanium welding requires certified welders with demonstrated experience in titanium GTAW (TIG) welding in a process piping environment. The contractor must comply with all OSHA standards and WFRC facility safety requirements during performance. Any work involving grinding, welding, or painting in the mechanical room shall comply with applicable hot work permit requirements. |
| 2.6 | General Requirements - The purpose of this project is to restore APC plate heat exchanger HX2 to full thermal performance through plate cleaning and resealing; protect the frame from continued corrosion through rust removal and epoxy recoating; provide instrumentation access points on all four titanium fluid connections through threaded bung welding; and restore insulation on the completed HX2 and any adjacent piping disturbed during the work. |
| 2.7 | Qualifications - Plate heat exchanger service shall be performed by personnel with demonstrated experience in gasketed plate heat exchanger disassembly, cleaning, and resealing. Titanium bung welding shall be performed by a welder certified in GTAW (TIG) welding of titanium per AWS D10.12 or equivalent, with demonstrated experience welding titanium process piping components. All work shall meet applicable mechanical and plumbing code requirements. |
| 2.8 | Administration – Point of Contact: |
John Allen Supervisory Facility Operations Specialist
USGS – WFRC
6505 NE 65th Street Seattle, WA 98115 Email: jsallen@usgs.gov
| 3.0 | TECHNICAL REQUIREMENTS |
| 3.1 | Site Inspection and Submittal - Perform a site inspection of APC plate heat exchanger HX2, adjacent piping, and mechanical room. Confirm HX2 model, plate count, connection sizes, and frame dimensions. Confirm titanium inlet and outlet port sizes and locations on both the chilled water and process water sides. Provide a submittal identifying proposed gasket materials, epoxy coating product, bung specifications, and insulation materials for Government approval within 5 days of the site inspection. |
| 3.2 | HX2 Isolation and Draining - Coordinate with WFRC facilities staff for shutdown and isolation of HX2 from both the chilled water and process water systems. The contractor shall confirm both sides are fully isolated, depressurized, and drained prior to beginning disassembly. |
| 3.3 | Disassembly - Disassemble HX2 completely, including removal of all plate pack plates, frame bolts, end plates, and existing gaskets. All components shall be staged in an organized manner to facilitate inspection, cleaning, and reassembly. All frame bolts shall be inspected for condition during disassembly; damaged or corroded bolts shall be reported to the TPOC for replacement authorization. |
| 3.4 | Plate Cleaning - Clean all HX2 titanium plates to remove accumulated fouling, scale, and deposits from both plate surfaces using methods appropriate for the plate material. Cleaned plates shall be inspected for cracks, pitting, deformation, or other damage. Any plates found to be damaged shall be reported to the TPOC prior to reassembly. |
| 3.5 | Frame Rust Removal and Epoxy Repainting - Prepare the HX2 carbon steel frame for recoating as follows: |
| 3.5.1 | Remove all surface rust, scale, and deteriorated existing coating from the frame using mechanical methods (wire brushing, grinding, or abrasive blasting as appropriate to the space and applicable regulations). Surface preparation shall achieve a minimum SSPC-SP 3 (Power Tool Cleaning) standard or better. |
| 3.5.2 | Apply a coat of rust-inhibiting primer compatible with the specified epoxy topcoat to all prepared frame surfaces. |
| 3.5.3 | Apply a minimum of two (2) finish coats of two-part epoxy paint formulated for industrial mechanical equipment in a high-humidity environment. Paint color to be approved by WFRC TPOC. |
| 3.5.4 | Contractor shall submit product data sheets for proposed primer and epoxy coating for TPOC approval prior to application. |
| 3.6 | Titanium Instrumentation Threaded Bung Welding - Furnish and weld eight (8) threaded instrumentation bungs onto the HX2 titanium fluid connections as follows: |
Two (2) threaded bungs per connection port, one at each inlet and one at each outlet on both the chilled water side and the process water side, providing a total of eight (8) threaded bung ports. Threaded bung sizing, locations, and orientations shall be confirmed with the WFRC TPOC prior to welding to ensure accessibility for sensor installation and maintenance.
| 3.6.1 | All welding shall be performed by a welder certified in GTAW (TIG) welding of titanium. Weld procedures shall be appropriate for the titanium alloy of the existing heat exchanger connections. The contractor shall confirm titanium alloy grade prior to welding. |
| 3.6.2 | Bungs shall be of compatible titanium or corrosion-resistant alloy material compatible with both the existing titanium piping and the process fluids (chilled water and cold process water). Bung thread size shall be confirmed with the WFRC TPOC prior to fabrication or procurement to ensure compatibility with planned temperature and differential pressure sensor fittings. |
| 3.6.3 | All welds shall be fully penetrating and leak-tight. Weld areas shall be cleaned and passivated following welding per standard titanium weld finishing practice. |
| 3.6.4 | All eight (8) threaded bung ports shall be fitted with threaded plugs or caps to protect threads until sensors are installed by WFRC staff. |
| 3.7 | Resealing and Reassembly - Furnish and install new gaskets on all HX2 plates and reassemble the plate pack and frame as follows: |
| 3.7.1 | New gaskets shall be of a material compatible with both the chilled water and process water fluids, operating temperature range, and operating pressure. Contractor shall confirm gasket material selection with the TPOC prior to procurement. |
| 3.7.2 | All plates shall be reinstalled in the correct sequence and orientation per the APC manufacturer's reassembly requirements. |
| 3.7.3 | Frame bolts shall be torqued to the manufacturer's specified values. A torque record shall be provided to the TPOC. |
| 3.8 | Insulation - Following completion of all welding, repainting, and reassembly work, furnish and install insulation on the completed HX2 and any adjacent piping sections disturbed during the work as follows: |
| 3.8.1 | Insulation type and thickness shall be appropriate for the cold service operating temperature range of HX2 (chilled water supply approximately 3.5°C–5°C) and shall provide a vapor barrier suitable for cold piping service. |
| 3.8.2 | Insulation shall be installed with all joints, seams, and terminations properly sealed to prevent condensation and moisture ingress. |
| 3.8.3 | Insulation installed over instrumentation bungs shall be removable or fitted with access provisions to allow future sensor installation and maintenance without full insulation removal. |
| 3.8.4 | Contractor shall submit proposed insulation product data sheet for TPOC approval prior to installation. |
| 3.9 | Pressure Testing and Return to Service - Prior to returning HX2 to service, the contractor shall perform a pressure test of both the chilled water and process water circuits to confirm leak-tight integrity of all resealed plate joints, reassembled connections, and new bung welds. Any leaks identified during pressure testing shall be corrected by the contractor prior to closeout. The contractor shall coordinate the return to service with WFRC facilities staff. |
3.10 APC Manufacturer Performance Calculations - Following reassembly and pressure testing, the contractor shall arrange for APC to perform updated heat transfer, pressure drop, and flow calculations for HX2 using APC's proprietary sizing and performance software. Calculations shall be based on the as-cleaned plate configuration and shall confirm that the restored heat exchanger meets the design thermal performance requirements for the WFRC process water cooling application. The contractor shall provide the completed APC performance calculation report to the WFRC TPOC prior to project closeout.
4.0 APPLICABLE DOCUMENTS
The following documents apply to the performance of this contract:
| 4.1 | APC HX2 manufacturer's operation and maintenance manual if available (to be provided by WFRC). |
| 4.2 | AWS D10.12 - Guide for Welding Mild Steel Pipe, or applicable AWS standard for titanium GTAW welding. |
| 4.3 | SSPC-SP 3 - Power Tool Cleaning surface preparation standard. |
| 4.4 | ASME B31.3 - Process Piping, applicable sections for pressure testing. |
| 4.5 | OSHA 29 CFR 1910 - General Industry Safety Standards. |
| 4.6 | NFPA 51B - Standard for Fire Prevention During Welding, Cutting, and Other Hot Work. |
| 5.0 | DELIVERABLES |
The contractor shall provide deliverables in accordance with the Reporting Requirements Checklist:
| Reference |
| Requirement |
| Due |
| 2.3 & 3.1 |
| Site inspection of APC plate heat exchanger HX2, adjacent piping, and mechanical room. Confirm make, model, plate count, connection sizes, and titanium port locations. |
| No later than 5 days after notice to proceed. |
| 3.1 |
| Submittal identifying proposed gasket materials, epoxy coating products, bung specifications, and insulation materials for Government approval. |
| Within 10 days of site inspection. |
| 3.2 |
| Heat exchanger isolated, depressurized, and drained on both chilled water and process water sides. Confirmed safe for disassembly. |
| Prior to disassembly. Coordinated with WFRC facilities staff. |
| 3.3 |
| Complete disassembly of APC HX2 including all plates, gaskets, frame bolts, and end plates. Damaged bolt report to TPOC if applicable. |
| Deliverable - within scheduled shutdown window. |
| 3.4 |
| All plates cleaned of fouling and scale. Damaged plate report to TPOC if applicable. |
| Deliverable - prior to reassembly. |
| 3.5 |
| Frame rust and scale removed to SSPC-SP 3 minimum. Rust-inhibiting primer and minimum two (2) finish coats of approved two-part epoxy applied to all frame surfaces. |
| Deliverable - prior to reassembly and insulation. |
| 3.6 |
| Eight (8) threaded titanium instrumentation bungs welded to heat exchanger titanium inlet and outlet connections (two per port, all four connections). Bung ports fitted with protective threaded plugs. Weld certification documentation provided to TPOC. |
| Deliverable - prior to reassembly and insulation. |
| 3.7 |
| All plates resealed with new approved gaskets. HX2 fully reassembled and frame bolts torqued to manufacturer's specification. Torque record provided to TPOC. |
| Deliverable - within six-week shutdown window. |
| 3.8 |
| Approved cold service insulation with vapor barrier installed on completed HX2 and all disturbed adjacent piping. Bung access provisions installed. |
| Deliverable - prior to return to service. |
| 3.9 |
| Pressure test of both chilled water and process water circuits confirming leak-tight integrity of all joints, connections, and bung welds. Written pressure test results provided to WFRC TPOC. Heat exchanger returned to service. |
| Prior to project closeout. All work completed within six-week shutdown window. |
| 3.10 |
| APC manufacturer performance calculation report confirming heat transfer, pressure drop, and flow performance of HX2 following cleaning and reassembly. Report generated using APC proprietary software and provided to WFRC TPOC. |
| Prior to project closeout. |
File details come from the government source that posted it. Updated .