12-R-0021_Specs.pdf

Design-Build Request for Proposal (RFP)

Carbon Monoxide Emissions Control System

For Radford Army Ammunition Plant

Radford, Virginia

31 January 2012

Prepared for:

US Army Corps of Engineers Norfolk District

SAIC Energy, Environment & Infrastructure, LLC | 622 Emerson Road, Suite 600 | St. Louis, MO 63141-6728 | tel: 314.821.7017 | fax: 314.821.8499

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Design-Build Request for Proposal (RFP)

Carbon Monoxide Emissions Control System For Radford Army Ammunition Plant (RFAAP) Radford, Virginia

31 January 2012

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Table of Contents Carbon Monoxide Emissions Control System Radford Army Ammunition Plant Radford, VA

Competition Sensitive Information

TABLE OF CONTENTS

DESIGN-BUILD REQUEST FOR PROPOSAL

STATEMENT OF WORK

1.0 EXECUTIVE SUMMARY

2.0 PROJECT SCOPE

3.0 GENERAL REQUIREMENTS

4.0 CODES, REGULATIONS AND STANDARDS

4.1. Industry Standards

4.2. Military Standards

4.3. Applicable Criteria

5.0 TECHNICAL REQUIREMENTS

5.1. Process/Thermal Oxidation System

5.2. Mechanical/Piping

5.3. Electrical

5.4. Instrumentation

5.5. Structural

SPECIFICATIONS

DIVISION 01 - GENERAL REQUIREMENTS

01 11 00 STATEMENT OF WORK

01 30 00 ADMINISTRATIVE REQUIREMENTS

01 30 00.10 50 PROJECT WORK REQUIREMENTS AND RESTRICTIONS (DESIGN BUILD)

01 31 19.00 50 PROJECT MEETINGS

01 32 01.00 10 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 00.00 10 QUALITY CONTROL

01 45 00.10 10 QUALITY CONTROL SYSTEM

01 50 00 TEMPORARY CONSTRUCTION FACILITIES AND CONTROLS

01 57 20.00 10 ENVIRONMENTAL PROTECTION

01 62 35 RECYCLED / RECOVERED MATERIALS

01 78 00 CLOSEOUT SUBMITTALS

Table of Contents Carbon Monoxide Emissions Control System

01 78 23.00 50 OPERATIONS AND MAINTENANCE DATA

DIVISION 03 - CONCRETE

03 30 53 MISCELLANEOUS CAST-IN-PLACE CONCRETE

DIVISION 05 - METALS

05 50 13 MISCELLANEOUS METAL FABRICATIONS

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07 84 00 FIRESTOPPING

DIVISION 09 - FINISHES

09 90 00 PAINTS AND COATINGS

DIVISION 26 - ELECTRICAL

26 20 00 INTERIOR DISTRIBUTION SYSTEM

DIVISION 33 - UTILITIES

33 11 23 NATURAL-GAS PIPING

APPENDICES

Appendix A List of Drawings

Appendix B Contract List of Deliverables

Appendix C Characterization of NAC/SAC Process Gas Stream

Appendix D Geotechnical Report

Appendix E Drawings

Appendix F Existing Utility Survey

Appendix G Reference Drawings and Photos

Appendix H Existing NAC/SAC Permit

Appendix I List of Preferred Vendors

-- End of Table of Contents --

Statement of Work Carbon Monoxide Emissions Control System

1.0 EXECUTIVE SUMMARY

1.1 The Radford Army Ammunition Plant (RFAAP) is located 40 miles southwest of Roanoke, Virginia, and 5 miles northeast of Radford, Virginia in the New River Valley. Construction began in 1940 in anticipation of the United States involvement in World War II and production of propellants began in 1941.

1.2 This project is located at the Nitric Acid/Sulfuric Acid Concentration (NAC/SAC) facility, which produces approximately 134 tons/day of nitric acid and 80 tons/day of sulfuric acid. The NAC/SAC facility operates 24 hours per day, 7 days per week as a normal operating schedule. This manufacturing facility is Government (US Government) Owned, Contractor Operated (GOCO).

1.3 As part of the munitions manufacturing process, the operating contractor uses a nitric acid (HNO3) and sulfuric acid (H2SO4) concentration process (NAC/SAC) to generate concentrated HNO3 and H2SO4. This process recovers spent HNO3 and H2SO4 from the production areas and concentrates the weak HNO3 that is produced by the ammonia oxidation process (AOP). The HNO3 and H2SO4 products are 99 and 93 percent pure, respectively.

1.4 On December 2, 2008, the Site Operating Contractor was granted a permit by the Virginia Department of Environmental Quality (VADEQ) to construct and operate a new NAC/SAC facility consisting of two concentrators. The concentrators replaced the previous NAC/SAC process units. The new process consisted of two separate production units. The vent gases from each concentrator are combined and vented to the atmosphere through a common stack. An air emissions test program was conducted. The purpose of this test program was to demonstrate the compliance with the permit limits established for the facility. Emission limits had been established for nitrogen oxide (NOx) and carbon monoxide (CO), in terms of pounds per hour. Visible emissions limits were also established in terms of percent opacity. A summary of the emission limitations in the December 2008 permit and findings of the test program are summarized below:

Permit Limit Test Results NOx Emissions: 0.25 lb/hr 0.16 lb/hr CO Emissions: 6.53 lb/hr 16.46 lb/hr Visible Emissions: 10% opacity (See Note1) 0% Opacity

(Note 1: Except for one six-minute period per hour in which visible emissions cannot exceed 20 percent Opacity.)

1.5 As a result of the CO Permit Limit exceedance demonstrated by the air emissions test program referred to above in paragraph 1.4, a CO emissions control unit is required to be designed and installed on the new NAC/SAC common stack to reduce the NAC/SAC CO emissions. The emissions control unit will be designed to reduce the CO emissions by greater than 98 percent resulting in the NAC/SAC being environmentally compliant. The VADEQ issued a revised draft permit for the NAC/SAC on January 10, 2012. The draft permit increased the permit limits for both CO and NOx. The new limits are presented below:

Permit Limit NOx Emissions: 0.46 lb/hr CO Emissions: 6.66 lb/hr Visible Emissions: 10% opacity

1.6 The Department of the Army/Program Executive Officers (DA/PEOs) for Ammunition requires a design, procurement, construction, and startup of a new Thermal Oxidizer at the RFAAP NAC/SAC building.

2.0 PROJECT SCOPE

2.1 The Design Build (D-B) Contractor will subcontract the Thermal Oxidation System to a Vendor, who has knowledge and expertise in the area of Thermal Oxidation of CO in an acidic gas stream containing heavy metals. The Vendor shall be responsible for designing, fabricating, and shipping a skid mounted Thermal Oxidizer to the site.

2.2 The following is an overview of the existing NAC/SAC exhaust gas stream:

2.2.1 The gas stream has the potential to have a wide variation in CO concentration ranging from 6-60 lb/hr.

2.2.2 The gas flow rate for the NAC/SAC Absorber is approximately 140scfm - 230scfm.

2.2.3 There is potentially small concentration of metals (e.g., Si, Fe, Pb) as particulate in the gas stream.

2.2.4 There is nitric acid present in the gas stream at concentrations up to 50 ppmdv.

2.3 Near the NAC/SAC building, 75 psi Natural Gas will be available for the Thermal Oxidizer.

Also, electrical power for Thermal Oxidizer will come from the existing NAC/SAC Motor Control Center (MCC) on the first floor of the facility. Additional details on these utilities are identified in the Appendices.

2.4 The D-B Contractor shall refer to Statement of Work and Appendices for the technical requirements of the project. The D-B Contractor will be responsible for selecting a qualified vendor to design and furnish a Thermal Oxidizer System. The D-B Contractor will be responsible for installation, start-up, prove-out and commissioning of the Thermal Oxidation System that achieves the CO and NOx emissions permit requirements.

2.5 The system shall be designed to operate 24 hours per day, 7 days a week, and 50 weeks per year. This schedule will allow for approximately two weeks of shutdown. For shutdowns, the Thermal Oxidation System shall be capable of being shutdown remotely and brought back on-line locally within a 2-hour time period.

2.6 The D-B Contractor shall design the Thermal Oxidation System, associated piping, and all appurtances for a 20-year operating life.

2.7 A preliminary and final Hazard and Operability Analysis (HAZOP) shall be performed by the D-B Contractor to further develop requirements to mitigate the hazards associated with the installation of the new skid.

2.8 The project shall be constructed safely with a goal of zero OSHA recordable events throughout construction, startup, prove-out, and commissioning.

2.9 System operation and levels of quality shall be verified and documented during construction, startup, prove-out and commissioning.

2.10 A 100 percent acceptance rate shall be achieved on process performance and emissions tests at the conclusion of commissioning. The demonstration of the unit shall take place in two phases. The first phase will be a Performance Test to demonstrate the capabilities of the Thermal Oxidizer to the RFAAP staff and the Government. The second phase of testing will be a Compliance Test that will be coordinate by the RFAAP staff with VADEQ to demonstrate the Thermal Oxidizer’s ability to meet the permit requirements in compliance with the permit conditions.

2.11 The project shall provide a functional system within the site constraints that meets the needs of the users and the installation within the available construction budget.

3.0 GENERAL REQUIREMENTS

3.1 Requirements stated in this Request for Proposal (RFP) are minimums. Design and construction shall meet or exceed the requirements. Innovative, creative and life cycle cost effective solutions, which meet or exceed these requirements are encouraged. Further, the Offeror is encouraged to seek solutions that will expedite the project and minimize the impact on the NAC/SAC operations.

3.2 The intent of the Government is to emphasize the functional/operational requirements.

Materials and methods shall be the most appropriate for the Type of Construction allowed by code and criteria for this project.

3.3 D-B Contractor shall provide all labor, materials, equipment, supplies, construction permits, fees, and consultant services to design, procure, construct, start-up, prove-out and commission the CO Emissions project. Environmental permitting will be applied for jointly by the RFAAP Operating Contractor and Administrative Contracting Office (ACO) staff. The D-B Contractor will be responsible for providing input to the RFAAP ACO staff to support permitting.

3.4 Any discrepancies found in these RFP documents by the Offeror shall be identified to the Government before the submittal of the Offeror’s proposal. The D-B Contractor, as Architect/Engineer of Record, is solely responsible for the design intent and the accuracy of the D-B Contractor’s proposal and its compliance with all RFP requirements and all referenced codes and criteria.

3.5 Professional Engineers/Architects Seal Requirement: The referenced Unified Facilities Criteria (UFC) and Unified Facilities Guide Specifications (UFGS) documents are the governing standards for this facility. Any discrepancies in this specification or other referenced codes and standards shall be resolved per the requirements of the UFC except where the UFC references older codes and standards. Equipment supplied to this specification shall comply with the latest edition of the codes and standards. The design of the CO Emissions Project is to meet or exceed all local codes. All engineering documents produced during the execution of this project must be sealed by a professional engineer in accordance with the laws and rules of the Commonwealth of Virginia. It is noted that US Army policy allows engineers registered in other states to seal drawings on federally owned installations; but in this case, the Engineer of Record is required to be registered in the Commonwealth of Virginia. In 1988, Congress passed Public Law 100-678, which amended the Public Buildings Act of 1959 (40 USC 601-616). The law directs Federal agencies to comply “to the maximum extent feasible” with “one of the nationally recognized model building codes and with other applicable nationally recognized codes”, and provides special rules for state and local government consultation, review, and inspection of federal projects for construction or alteration of buildings. All local, state, and federal required Environmental Permits necessary for construction will be prepared and processed through D-B Contractor.

3.6 All design documentation and associated engineering reports will be the intellectual property of the Government.

3.7 The Government will have unlimited rights to all schedules, process drawings, production procedures, reports, test data, project documentation, all process related control programming, and operational documentation as a result of this solicitation. Accordingly, the final documentation shall not include any restrictive legends or markings that prevent the Government from obtaining information.

3.8 Any licensing requirements shall list the Government as the licensee.

3.9 The D-B Contractor shall refer to the Contract List of Deliverables in the Appendix B and Submittal Register in Specification 01 33 00 SUBMITTAL PROCEDURES for the required deliverables of the project.

3.10 Conflicts, if any, between this Statement of Work and Department of Defense (DoD) UFC or other standards listed in Appendices, shall be resolved by the Contracting Officer’s Representative (COR) on a case-by-case basis.

3.11 The D-B Contractor shall provide a preliminary completion schedule with milestone dates in their proposal provided in a work breakdown structure (WBS) format. The engineering kick-off meeting will occur within 10 days of contract award date.

3.12 This project will be monitored and directed by the following team: Procuring Contracting Officer (PCO) or the Administrative Contracting Office (ACO) in conjunction with Armament Research, Development and Engineering Center (ARDEC); the Project Manager for Joint Services (PMJS); United States Army Corps of Engineers (USACoE), RFAAP Operations and Commander and the office of Industrial Base at Joint Munitions Command (JMC).

4.0 CODES, REGULATIONS AND STANDARDS

4.1 Industry Standards

4.1.1 The applicable publications listed below form a part of this RFP. The text references the basic title only.

American Concrete Institute, ACI 302.1 Guide for Concrete Floor and Slab Construction ACI 318 Building Code Requirements for Structural Concrete ACI 315 Details and Detailing of Concrete Reinforcement ACI 360 Design of Slabs on Grade

American Gas Association (AGA) AGA Report No. 3 Orifice Metering of Natural Gas

American National Standards Institute 11 (ANSI)

ANSI B16.34 Valves – Flanged, Threaded, and Welding End ANSI A117.1 Accessible and Usable Buildings and Facilities ANSI MFC-3M-2004 Measurement of Fluid Flow in Pipes Using Orifice, Nozzle, and Venturi ANSI Z53.1-1979 Safety Color Code for Marking Physical Hazards ANSI Z535.1-1991 Safety Color Code ANSI / ISA See ISA

American Petroleum Institute (API) API 520 Sizing Selection and Installation of Pressure-Relieving Devices in Refineries API 521 Pressure-Relieving and Depressuring Systems API 607 Fire Test for Soft-Seated Quarter Turn Valves

American Society of Mechanical Engineers International (ASME)

ASME A13.1 Scheme for Identification of Piping Systems ASME B31.8 Gas Transmission and Distribution Piping Systems

American Institute of Steel Construction Manual, 13th Edition

American Welding Society, Welding Handbook

AWS D1.1 American Welding Society – Structural Welding Code- Steel

Code of Federal Regulations (CFR)

10 CFR 430 Energy Conservation Program for Consumer Products 29 CFR 1910 Occupational Health and Safety Standards 29 CFR 1926 Occupational Health and Safety Standards for

Construction 33 CFR 328 Definitions 40 CFR 50-99 Air Programs 40 CFR 68 Chemical Accident Prevention Provisions 40 CFR 100–149 Water Programs 40 CFR 150–189 Pesticides Program 40 CFR 239-282 Solid Wastes 40 CFR 260 Hazardous Waste Management System: General, 40 CFR 261 Identification and Listing of Hazardous Waste 40 CFR 262 Standards Applicable to Generators of Hazardous Waste 40 CFR 279 Standards for Management of Used Oil 40 CFR 300-399 Superfund, Emergency Planning, and Community 40 CFR 302 Designation, Reportable Quantities, and Notification 40 CFR 355 Emergency Planning and Notification 40 CFR 400 - 471 Effluent Guidelines and Standards 40 CFR 82 Protection of Stratospheric Ozone 49 CFR 171–178 Hazardous Materials Regulations 49 CFR 192 Transportation of Natural and Other Gas by Pipeline:

Minimum Federal Safety Standards

Department of Energy

DOE 440.1-1A Explosives Safety Manual

Factory Mutual FM I-90 FM 3600 Approval Standard for Electric Equipment for Use in

Hazardous (Classified) Locations General Requirements FM 3611 Approval Standard for Nonincendive Electrical

Equipment for Use in Class I & II, Division 2, and Class III, Division 1 & 2 Hazardous (Classified) Locations

FM 7420 Approval Standard for Gas Safety Control Cocks FM 7422 Approval Standard for Electric Interlocking Fuel Gas and

Fuel Oil Cocks FM 7440 Approval Standard for Fire Safe Valves

International Code Council (ICC) International Building Code (IBC) International Mechanical Code (IMC) International Fuel Gas Code (IGC)

Institute of Electrical and Electronics Engineers Inc. (IEEE)

Standard for Use of the International System of Units (SI): the Modern Metric System C2-2007 National Electrical Safety Code C62.41.91 Recommended Practice on Surge Voltage in Low

Voltage AC Power Circuits Standard 142 Recommended Practices for Grounding of Industrial and

Commercial Power Systems Standard 241 Recommended Practices for Electrical Power Systems in Commercial Buildings Standard 242-2001 Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems Standard 399-1997 Recommended Practice for Power Systems Analysis Standard 519-1992 Recommended Practices and Requirements for

Harmonic Control in Electrical Power Systems Standard 1584 Guide for Performing Arc-Flash Hazard Calculations

National Association of Corrosion Engineers International (NACE)

NACE RP0286 Electrical Isolation of Cathodically Protected Pipelines

National Electrical Manufacturers Association (NEMA)

National Electrical Safety Code (NESC)

National Fire Protection Association (NFPA)

NFPA 1 Uniform Fire Safety Code NFPA 30 Flammable and Combustible Liquids Code NFPA 31 Standard for the Installation of Oil-Burning Equipment NFPA 54 National Fuel Gas Code 2009 NFPA 58 Liquefied Petroleum Gas Code NFPA 70 National Electrical Code NFPA 70E Standard for Electrical Safety in the Workplace NFPA 82 Standard on Incinerators and Waste and Linen Handling

Systems and Equipment NFPA 101 Life Safety Code 2009 NFPA 211 Standard for Chimneys, Fireplaces, Vents, and Solid

Fuel-Burning Appliances NFPA 241 Safeguarding Construction, Alteration and Demolition

Operations NFPA 495 Explosive Material Code NFPA 780 Standard for the Installation of Lightning Protection

Systems

National Institute on Building Sciences Commissioning Process Guideline Series (1 – 11)

National Institute of Standards and Technology (NIST) HDBK 135 (Rev)

“Life Cycle Cost Manuals for Federal Energy Management Programs”

National Institute for Occupational Safety and Health (NIOSH)

NETA: Acceptance Testing Specifications for Electric Power Distribution and Systems

Occupational Safety and Health Administration (OSHA)

OSHA Construction Industry Standards, Title 29, Code of Federal Regulations, Part 1926, Safety and Health Regulations for Construction OSHA Construction Industry Standards, Title 29, Code of Federal Regulations, Part 1910, Occupational Safety and Health Standards

Public Works Construction

The Green Book

State/Local Regulations

State/Local Sedimentation and Erosion Control Design Requirements State/Local Environmental Control Requirements State/Local Storm Water Management Requirements

State of Virginia

Virginia Stormwater Management Regulations, 2001, Virginia Department of Conservation & Recreation

Virginia Pollution Control Board - Virginia Air Pollution Control Laws Form 7 -New, Modified and State Operating Permits Application Form

Technical Release No. 55 Method (TR-55) Technical Release No. 20 Method (TR-20)

Underwriters Laboratories (UL)

UL 96A Installation Requirements for Lightning Protection Systems UL 698 Standard for Industrial Control Equipment for Use in

Hazardous (Classified) Locations

Uniform Federal Accessibility Standards (UFAS)

4.2 Military Standards

4.2.1 The project shall conform to the following criteria. Certain design impacts and features due to these criteria are noted for the benefit of the Offeror. However, all requirements of the referenced criteria will be applicable, whether noted or not, unless otherwise specified herein.

Criteria shall be taken from the most current references as of the date of issue of the contract unless otherwise noted.

Army Regulation AR 190-11 Physical Security of Arms, Ammunition, and Explosives

Army Regulation AR190-13 The Army Physical Security Program (30 September, 1993)

Army Regulation AR 200-1 Environmental Protection and Enhancement AMC-R 385-100 Safety Manual Army Regulation AR 385-64 Explosives Safety Program Army Regulation PAM 385-64 Ammunition and Explosives Safety Standards Army Regulation PAM 385-65 Explosive and Chemical Site Plan Development and Submission Army Corp of Engineers TI 800-01 Technical Instructions – Design Criteria Army Technical Manual TM 5-1300 Structures to Resist the Effects of Accidental

Explosions

Department of Defense DoD 4145.26-M Contractor’s Safety Manual for Ammunition and

Explosives DoD 6055.9-STD DoD Ammunition and Explosives Safety

Standards.

DA PAM 385-64 Ammunition and Explosive Safety Standards

4.2.2 Unified Facility Guide Specifications

UFGS Specifications must be utilized.

Refer the WBDG website: http://www.wbdg.org/ccb/browse_org.php?o=70

4.2.3 Unified Facilities Criteria

Refer the WBDG website: http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

General UFC 1-300-01 Criteria Format Standard UFC 1-300-02 Unified Facilities Guide Specifications (UFGS) Format Standard UFC 1-300-07A Design Build Technical Requirements UFC 1-300-08 Criteria for Transfer and Acceptance of DoD Real Property UFC 1-300-09N Design Procedures, with change 8 UFC 1-900-01 Selection of Methods for the Reduction, Reuse and Recycling of

Demolition Waste

Civil UFC 3-200-10N Civil Engineering UFC 3-220-01 N Geotechnical Engineering Procedures UFC 3-220-04FA Backfill for Subsurface Structures UFC 3-220-05 Dewatering and Groundwater Control UFC 3-220-06 Grouting Methods and Equipment UFC 3-250-01FA Pavement Design for Roads, Streets, Walks, and Open Storage Areas UFC 3-250-04FA Standard Practice for Concrete Pavements UFC 3-250-08FA Standard Practice for Sealing Joints and Cracks in Rigid and Flexible

Pavements UFC 3-250-11 Soil Stabilization for Pavements UFC 3-250-18FA General Provisions and Geometric Design for Roads, Streets, Walks and

Open Storage Areas UFC 3-260-17 Dust Control for Roads, Airfields and Adjacent Areas UFC 3-430-05 FA Gas Distribution

Structural UFC 3-301-01 Structural Engineering UFC 3-320-06A Concrete Floor Slabs on Grade Subject to Heavy Loads UFC 3-320-01A Welding - Design Procedures and Inspections UFC 3-320-07N Weight Handling Equipment

Mechanical UFC 3-400-01 Energy Conservation UFC 3-450-01 Noise and Vibration Control UFC 3-600-01 Fire Protection http://www.wbdg.org/ccb/browse_org.php?o=70 http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4

Plumbing UFC 3-420-02FA Compressed Air

Electrical UFC 3-501-03N Electrical Engineering Preliminary Considerations UFC 3-520-01 Interior Electrical Systems UFC 3-550-03FA Electric Power Supply and Distribution UFC 3-550-03N Power Distribution Systems UFC 3-560-01 Electrical Safety, O&M UFC 3-570-02A Cathodic Protection

Cost Engineer UFC 3-700-02A Construction Cost Estimates

4.2.4 Other Codes and Standards

Energy Policy Act of 2005 (Public Law 109-58)

Executive Order 12770: Metric Usage in Federal Government English, rather than Metric design and construction shall be used.

EM 385-1-1 (2008) U.S. Army Corps of Engineers Safety and Health Requirements Manual

U.S. Army Center for Health Promotion and Prevention Medicine – Army Green Procurement Guide; Version 1, August 2006

4.3 Applicable Criteria

4.3.1 Applicable design and construction criteria references are listed above. Criteria shall be taken from the most current references as of the date of issue of the contract unless otherwise noted. This list is not intended to include all criteria that may apply or to restrict design and construction to only those references listed.

5.0 TECHNICAL REQUIREMENTS

5.1 Process/Thermal Oxidation System

5.1.1 General

5.1.1.1 D-B Contractor will select a qualified Thermal Oxidizer Vendor to design and furnish a Thermal Oxidation System for the NAC/SAC Carbon Monoxide Treatment Project at Radford Army Ammunition Plant (RFAAP) in Radford, Virginia. This specification, along with the referenced drawings and documents define the scope of work.

5.1.2 Codes, Regulations and Standards

5.1.2.1 Refer to Section 4 for all applicable codes, regulations and standards to be used for this project.

5.1.3 Submittals

5.1.3.1 Government approval is required for submittals. The following is a summary of the Deliverables that are required for the Thermal Oxidation System; a complete Contract List of Deliverables is presented in Appendix B and on the Submittal Register in Specification 01 33 00 SUBMITTAL PROCEDURES. These documents should be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

Shop Drawings, Product Data and Calculations

• Mechanical General Arrangement Drawings

• Piping and Instrumentation Diagrams (PIDs)

• Equipment Installation/Fabrication Drawings

• Design calculations (e.g. oxidizer calculations, natural gas requirements, dilution/ combustion air requirements, heat exchanger calculations equipment designs, lift points)

• Electrical Installation Drawings (One-Line, Schematics, etc)

• Blower Drawings

• Piping Drawings

• Structural Steel Fabrication Drawings

• Foundation Loads

• Instrumentation and Control Specifications

• Standard Operating Procedures (SOP’s)

• Preventative Maintenance Plan

• As-Built Drawings

Design Calculations

• At the start of the design process, the Vendor shall model the Thermal Oxidation System and associated process systems based on the feed stream composition and emission requirements provided in this specification. The model shall include an estimate of the emissions from the system. The results of this model shall be used as the basis for the size of the system (including dilution and combustion air requirements, operating temperature, and natural gas requirements), size of the heat recovery unit, cost benefit analysis for the heat recovery system, etc. The results of the model and the associated conclusions shall be provided to the Government for review and approval.

Test Plans and Test Reports

• D-B Contractor/Vendor shall furnish quality examination records, tests, and supporting documents (e.g., welding qualification records, welding procedures, welding maps, welding records). Shop and Factory Acceptance Testing (FAT) test procedures and inspection plan.

Operation and Maintenance Manuals

• D-B Contractor/Vendor shall furnish three electronic and three hardcopies of Standard

Operating Procedures and Preventative Maintenance Plan with list of recommended spares parts for the Thermal Oxidizer System. Along with one year supply of spare parts.

Schedules

• D-B Contractor shall furnish milestone schedule for design, fabrication, testing, inspection, delivery, installation, start-up, prove-out and commissioning of equipment within 45 days of Contract award.

5.1.4 Design Criteria

5.1.4.1 The D-B Contractor will subcontract the Thermal Oxidation System to a Vendor, who has knowledge and expertise in the area of Thermal Oxidation of CO in an acidic gas stream containing heavy metals to design, fabricate, and ship the skid mounted Thermal Oxidation System. The D-B Contractor/Vendor will furnish and install the following equipment and their associated components (Note: This equipment listed below shall be designed for a 20 year operating life.) :

• Thermal Oxidation Unit

• Heat Recovery Unit with a minimum of 50% heat recovery efficiency

• Combustion Air Blower

• Stack

• Induced Draft Fan

• Instrumentation and Controls

• Process control description, system requirements, and controls strategy for the Thermal

Oxidation System

• Assembly of the units and controls on a skid for ease of installation at the site

• One year supply of spare parts

The D-B Contractor/Vendor will design and furnish all piping, instrumentation, controls, and power distribution to interconnect the process equipment listed above.

5.1.4.2 Characterization of Gas Stream

5.1.4.2.1 The inlet to the Thermal Oxidizer will be the exhaust of the NAC/SAC Absorption Column.

The gas flow rate will be 140-230 scfm and will not change significantly whether one train or two trains are being operated. The contaminant of concern in the gas stream is Carbon Monoxide (CO). The CO loading in the gas stream is dependent on the organics coming into the NAC/SAC from the Pyro Acid. Based on current operations in the Nitrocellulose Area, the range of CO expected is 6-60 lb CO/hr. Detailed characterization of the NAC/SAC Absorption Column exhaust stream is shown in Table 1 below. The Detailed Analytical report for the gas stream is presented in Appendix C.

5.1.4.2.2 The NAC/SAC system does experience upset conditions that can significantly increase the NOx and nitric acid concentrations in the NAC/SAC Absorption Column gas stream. The Thermal Oxidation System does not need to control the emissions from the upset, but the system does need to be designed to minimize the impact of the emissions on the oxidizer equipment.

5.1.4.2.3 The gas flow rate increases to 400 scfm for a short period of time (5 minutes or less) when there is a switch over from one air compressor to another. The Thermal Oxidizer shall be designed to handle the short term increase in gas flow rate with minimal operator input and without reducing the destruction efficiency of the system.

Table 1: Characterization of the NAC/SAC Absorber Exhaust Gas

Parameter Units Measured Range

Nov 2010 & Jun 2011 Nov-11 Gas Temperature °F 53 - 81 55 - 60 Moisture % 0 - 1.2 1.06 - 2.2 Gas flow rate dscfm 68 - 207 148 - 159 Oxygen (O2) % 16.7 - 19.2 16.3 - 17.9 Carbon Dioxide (CO2) lb/hr 12.8 - 25.0 23.5 - 31.9

Carbon Monoxide (CO) lb/hr 16.2

- 16.7 16.7

- 19.9

Nitrogen Oxide (NOx)(a) lb/hr 0.14 - 0.17 0.1319 - 0.1504

Parameter Units Measured Range

Nov 2010 & Jun 2011 Nov-11 Sulfur Dioxide (SO2) lb/hr Not Measured 0.002 - 0.0072 Particulate lb/hr Not Measured 0.000095 - 0.00012 Total Reduced Sulfur (b) lb/hr 0.00048 - 0.00062 ND - ND Nitric Acid (HNO3) lb/hr 0.026 - 0.034 0.022 - 0.027 Sulfuric Acid (H2SO4) lb/hr 0.000032 - 0.000075 0.000041 - 0.000094

(a) NOx measured, reported as NO2

5.1.4.3 The Thermal Oxidation system shall be designed to oxidize greater than 98% of the CO in the effluent gas stream from the NAC/SAC Absorption Column and/or reduce the CO concentration to below 6.66 lb/hr, which ever leads to a greater reduction in CO. In addition, the system shall be designed to minimize the NOx emissions from the oxidation system and limit the NOx emissions to below 0.46 lb/hr. The ability of the installed Thermal Oxidizer to achieve the system requirements will be demonstrated during a three day Performance Test.

The Performance Test will be conducted after the vendor, RFAAP Operating Contractor, Plant Process Control Board have agreed that all HAZOP findings are closed and the system has been installed properly and is operating in a safe and representative condition. The purpose of the Performance Test will be to demonstrate that the Thermal Oxidizer can meet the system requirements to the RFAAP and Government Staff before the VADEQ required Compliance Test is performed. After the Performance Test has been successfully completed, the RFAAP staff will coordinate a Compliance Test with the VADEQ. The purpose of the Compliance Test will be to demonstrate the Thermal Oxidzer can meet the NAC/SAC permit requirements with the VADEQ observing. The D-B Contractor will be responsible for conducting both the Performance and Compliance tests.

5.1.4.4 The system shall be designed to operate 24 hours per day, 7 days a week, and 50 weeks per year. This schedule will allow for approximately two weeks of shutdown. For shutdowns, the oxidation system shall be capable of being shutdown remotely and brought back on-line locally within a 2 hour time period.

5.1.4.5 The Vendor shall design the Thermal Oxidation System for a 20-year operating life.

5.1.4.6 Space is limited around the NAC/SAC facility; therefore, the Thermal Oxidation System shall be designed to efficiently use the space provided without sacrificing maintenance and operation of the system.. Currently the system has to fit on a pad that is less than 14ft x 14ft.

5.1.4.7 The Thermal Oxidation System shall include a low NOx burner to minimize the NOx generated during operation. In addition, the Vendor shall design the outlet of the Thermal Oxidation System to allow for the easy installation of a catalytic converter if it is found to be required. In the design the Vendor shall clearly discuss how the catalytic converter can be installed, the level of NOx that the converter will remove, and the impact the expected gas stream will have on the converter. The D-B Contractor/Vendor shall include the cost for procuring and installing the catalytic converter as an option in their proposal.

5.1.4.8 The Thermal Oxidation System shall include a flashback protector in accordance with FM APP GUIDE at the inlet to the oxidation system. The D-B Contractor and the Vendor shall be responsible for selecting the type of flashback protector that is applicable to the system. The flashback protector shall have a clean-out cover to facilitate maintenance.

5.1.4.9 The Thermal Oxidizer is a considered a critical piece of equipment for the operation of the NAC/SAC facility. If the Thermal Oxidizer fails for any reason the NAC/ SAC facility will have to be shut down until the Thermal Oxidizer can be brought back on-line. Therefore, the Thermal Oxidizer shall be designed to minimize unplanned outages. As part of the design report, the D-B Contractor shall include a discussion of the reliability, availability, and maintainability (RAM) of the system and their recommendations for increasing the RAM. At a minimum, the D-B Contractor and selected Vendor shall include an in-line spare induced draft fan and combustion air blower to allow the Thermal Oxidizer to continue to operate if the fan or blower fails.

5.1.4.10 Ignition System/Burner Assembly

5.1.4.10.1 The Thermal Oxidation System shall include an earthquake actuated automatic gas shutoff system conforming to ASCE 25-06. The pilot assembly shall be removable and shall be provided with pressure indicator, pressure regulator, solenoid valve, manual shutoff valve and pilot gas pressure manometer port.

5.1.4.10.2 The Thermal Oxidation System shall include an electronic spark ignition. The igniter assembly shall be removable from outside the combustion chamber without disconnecting conduit or wiring.

5.1.4.10.3 The primary air mixed burner shall be compatible with natural gas, shall have multiple small gas ports or jets, and shall be constructed of 304/316 stainless steel, heat and corrosion resistant alloy steel, ceramic, and/or castable refractory. The burner shall be of adequate capacity to maintain the required combustion temperature at the maximum flow with no fuel value in the off-gas.

5.1.4.11 The system shall be designed to consider condensation collection and removal from the unit including associated piping, equipment and stack.

5.1.4.12 The Vendor shall design a stack to release the treated gas stream at 10 feet above the NAC/SAC buildings upper roof. The design shall assume that the stack is supported vertically by the building structure.

5.1.4.13 Each major item of equipment shall have the manufacturer’s name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.

Valves shall bear a securely attached tag with the manufacturer’s name, catalog number and valve identification permanently displayed. The tags and plates shall be 304SS and the identification numbers shall follow the current nomenclature used at the NAC/SAC facility.

5.1.4.14 The Thermal Oxidation System and associated equipment shall be designed to comply with applicable fire codes and regulations including, but not limited to, NFPA.

5.1.4.15 The D-B Contractor/Vendor shall perform a stress analysis on all system components. The Vendor shall analyze flanges, piping and other components as necessary to prevent damage from thermal expansion and contraction.

5.1.4.16 The systems performance and CO destruction efficiency shall be the responsibility of the D-B Contractor and the chosen Vendor. The control strategy and instrumentation related to those controls shall be determined by the Vendor. The Thermal Oxidizer shall have a minimum of three temperature monitoring locations: inlet process gas temperature, temperature within the oxidizer, and outlet gas temperature. The system shall also be designed to monitor the gas flow rate of the inlet process gas, combustion air, dilution air, and outlet gas. The system shall be designed to monitor the natural gas flow rate and pressure to the system. In addition, the system shall have a UV Flame Scanners to monitor the pilot and burner flames.

If additional controls or instrumentation are suggested by the Vendor or are required by the Vendor for proper operation of the Thermal Oxidation System these controls and instruments shall be included and shall be shown on the documentation and P&IDs produced by the Vendor.

5.1.4.17 In addition to the monitoring requirements discussed in the paragraph above, the system shall include the capability to continuously monitor CO concentration into and out of the Thermal Oxidizer. The D-B Contractor and Vendor shall evaluate whether there is a need for two continuous monitors or if one unit can monitor both streams. The monitors shall be housed in the NAC/SAC Mechanical Room.

5.1.4.18 Programming will be provided by the D-B Contractor, the Vendor shall provide all system requirements, process control descriptions and controls strategy to the D-B Contractor for integration.

5.1.4.19 D-B Contractor will insulate the Thermal Oxidizer, associated equipment, and piping. The insulation shall follow the requirements outlined in Section 5.2, Mechanical/Piping.

5.1.4.20 Equipment lubrication fittings shall be minimized and easily accessible for flushing. Units containing mechanical components shall be designed to permit lubrication of the components without disassembly. Extension fittings shall be provided to lubricate parts not readily accessible or visible.

5.1.4.21 Thermal Oxidizer Utilities

5.1.4.21.1 Refer to Mechanical/Piping Section 5.2 and Electrical Section 5.3 for definition of utilities that are available.

5.1.4.22 Structural Design Criteria

5.1.4.22.1 Refer to Structural Section 5.5 for definition of the structural requirements.

5.1.4.23 Connections

5.1.4.23.1 Field Connections shall be bolted to the maximum extent possible.

5.1.4.23.2 Shop and field high-strength bolts shall be sized by D-B Contractor and meet, ASTM A325, type N, unless specified otherwise, mechanically galvanized. Connections shall be completely designed and design calculations shall be stamped and signed by a registered engineer from the State of Virginia prior to submission for review.

5.1.4.23.3 Permanently separate dissimilar and incompatible metals or other materials to prevent galvanic reaction.

5.1.4.23.4 Painting shall be performed following machining and welding, but prior to assembly. After satisfactory factory testing, final inspection, and before shipment, the components shall be cleaned and any damaged paint shall be touched up using the original paint. Painting for motors shall be in accordance with UFGS 09 90 00 Paints and Coating and the motor manufacturer’s standard painting specification suitable for outdoor installation.

5.1.4.23.5 Where indicated carbon steel framing and components shall be prepared, primed, painted with an intermediate and finish coat in accordance with Exterior Coating of Steel Structures

UFGS 09 90 00 - Paints and Coating. The color of the equipment shall be approved by Government prior to purchasing equipment.

5.1.4.23.6 Where indicated carbon steel framing and components shall be galvanized in accordance with UFGS 05 50 13 – Miscellaneous Metal Fabrications.

5.1.4.24 Instrumentation

5.1.4.24.1 Vendor shall refer to Section 5.4 for instrumentation requirements.

5.1.4.24.2 Vendor shall provide all Instrumentation, control devices, terminal blocks, conduit and wiring, and programmable logic controllers necessary to locally control the Thermal Oxidizer within design operating ranges and communicate required operations data to the NAC/SAC control room. Vendor shall provide communications link and termination points inside the skid control panel for communications of required operations data to and from the NAC/SAC control room via I/O rack IO-RP-02 located in the mechanical room. Also, included in this communications link, the vendor shall provide for remote system shutdown capability from the NAC/SAC control room, designed to bring the system to a safe shutdown condition. Control panel shall be lockable and equipped with a 120v receptacle and light fixture.

5.1.4.25 Electrical

5.1.4.25.1 Refer to Section 5.3 - Electrical for detailed discussion of electrical requirements.

5.1.4.25.2 The D-B Contractor shall provide a single electric power feed from MCC-003 to the Thermal Oxidizer skid control panel main circuit breaker. The D-B Contractor/Vendor shall also provide all power distribution equipment necessary to operate the Thermal Oxidizer including motor starters, motor circuit protectors, and overloads as well as auxiliary devices such control transformer, pilot lights, HOA switch, motor selector switch, control transformers, wiring and cabling, grounding, conduit, and required fittings and boxes.

5.1.4.25.3 Area Classifications and Designations: NEMA 4X

• Hazardous (Classified) Locations: All electrical materials, equipment and installation in Hazardous (Classified) Locations shall comply with the requirements of Articles 500, 501 and 504 of the NEC, applicable Standards and Recommended Safeguards of NFPA, and all federal, state, and local laws, codes, and regulations.

• In Hazardous (Classified) Locations, all equipment and materials required to be

'approved' shall be Underwriters Laboratories, Inc. (UL) listed, or factory mutual approved, and shall be marked by Vendor for the service in which such items are applied.

Special material requirements and installation procedures shall be followed in these areas.

• Electrical equipment, components, controls, and wiring shall comply with NFPA 70.

Electrical enclosures shall be NEMA Type 4X and/or explosion proof as approved for the area. Power to motors will be 480 volts, 3-phase, 60 hertz. Control power shall be 24VDC. Reference UFGS 26 20 00 ELECTRICAL DISTRIBUTION for details.

5.1.4.25.4 Reference UFGS 40 95 00 PROCESS CONTROL for instrumentation and control requirements.

5.1.4.25.5 Control and alarm circuits shall be designed to be fail-safe.

5.1.4.25.6 All system components that are electrical conductors (such as columns, heat exchangers, tanks, and piping) shall be grounded. Grounding lugs shall be provided on the System as appropriate to permit grounding to the plant grid system. Refer to Section 5.3 - Electrical for additional information and requirements.

5.1.4.26 Personnel Safety

5.1.4.26.1 Sharp edges or protrusions on the equipment and support structure shall be avoided to the maximum extent practicable to minimize the potential for injury. Exposed edges and corners shall be rounded to 0.12-inch radius minimum. In addition, the System shall comply with 29 CFR 1910-212 (ref) and NFPA 69 (ref).

5.1.4.26.2 Guards or other protection shall be provided over moving components that create pinch points to the maximum extent practicable.

5.1.4.26.3 All hot surfaces shall be insulated per the design criteria in the Mechanical Section 5.2.

5.1.4.27 System Accessibility and Maintenance

5.1.4.27.1 Consideration for maintenance by personnel shall be incorporated into the design, arrangement, and selection of system equipment. In the arrangement of equipment, a 42-inch minimum clearance shall be provided and equipment requiring access shall be accessible from at least two directions.

5.1.4.27.2 The following requirements shall be included in the design of equipment:

• More frequently maintained equipment items shall be located close to equipment extremities or at an elevation above the work platform such that kneeling or access by ladders or stairs is eliminated or minimized.

• The maximum one-arm work reach for locations of predicted maintenance tasks shall be within 20 inches of the outside edges of the equipment. Access openings for one-arm reach maintenance tasks shall be a minimum of 12-inch diameter equivalent at the machine’s extremity.

• The maximum two-arm work reach for the locations that two arms are required to perform maintenance shall be 16 inches with access opening of at least an 18-inch diameter equivalent, reducing to no less than 9-inch diameter equivalent at the 16-inch reach point.

• Routing of piping shall be such that the lines are not a potential tripping hazard and do not restrict maintenance access.

• A shield/cover shall be included over the electrical panel to allow the cover on the panel to be opened and maintenance to be performed during inclement weather.

5.1.4.28 Cleanliness

5.1.4.28.1 The equipment shall permit ease of cleaning external exposed surfaces and shall prevent entrapment of materials in blind holes, threads, corners, crevices, and ledges. To the maximum extent practical, access and visibility shall be provided to surfaces or spaces where material is likely to accumulate. Where traps cannot be avoided, weep holes or other suitable means of access for flushing and cleaning shall be provided. Before testing and after fabrication and painting operations are completed, Contractor shall clean the System to remove visible slag, weld spatter, oil, grease, scale, debris, and other foreign material. After successful testing and before shipment, Contractor shall remove debris and potentially detrimental materials as a result of testing or repairs.

5.1.4.29 Delivery, Storage, and Handling

5.1.4.29.1 D-B Contractor and Vendor shall provide an equipment delivery schedule and storage instructions for the equipment to be installed at RFAAP.

5.1.4.29.2 Vendor shall submit handling cautions and instructions for the Thermal Oxidation System equipment to be installed at RFAAP. These instructions shall specify the approximate weight;

pick points, rigging requirement, and other handling instructions for the equipment. Vendor shall submit the associated calculations used to develop these requirements and instructions as part of the document package.

5.1.4.29.3 D-B Contractor will inspect and verify all Vendor-furnished equipment against the Contract Documents, and will report to Contracting Officer any discrepancies within 48 hours after Contractor receives the equipment.

5.1.4.29.4 D-B Contractor will ensure that all preventive maintenance is performed as required including lubrication and inspection during receipt, storage, installation, and start up.

5.1.4.29.5 D-B Contractor will provide covered storage for all items of material that are stored outdoors.

If equipment is stored outdoors, Contractor will place such equipment on dunnage.

5.1.4.30 Equipment Installation

5.1.4.30.1 The equipment shall be delivered to site and placed on the concrete pad that has been constructed. All anchor bolts shall be securely fastened; the inlet and outlet vents connected;

electrical power and natural gas connected to the unit; and the control lines from the NAC/SAC Control Room connected to the control unit. Equipment installation and start up shall be performed before the final connection to the NAC/SAC gas discharge is made in order to minimize the impact of start up on the NAC/SAC Facility.

5.1.4.30.2 After the system has been installed, the D-B Contractor/Vendor, Operating Contractor, and Government shall inspect all equipment to ensure that it is ready to be safely started up; this includes but is not limited to: rotating equipment, instrumentation and controls, electrical and natural gas connections, and the burner unit.

5.1.4.30.3 After the system has been inspected and all necessary maintenance has been performed, the vendor shall calibrate the instrumentation.

5.1.4.30.4 After the instrumentation has been calibrated, the system shall be started up to demonstrate that it operates within required parameters and that the control system is operating properly.

5.1.4.30.5 Upon approval of the Government and the RFAAP Operating Contractor that the system is operating safely and within parameters, the D-B Contractor shall make the final connection to the NAC/SAC gas discharge.

5.1.4.31 Equipment Acceptance

5.1.4.31.1 The equipment shall be inspected and tested by the Vendor prior to shipment to the site for installation. The D-B Contractor will submit a complete factory acceptance test and inspection plan with procedures, including acceptance criteria, to the Contracting Officer for acceptance prior to use. As the system is fabricated, shop component tests will be performed. The RFAAP and Government staff shall be invited to observe the factory acceptance test.

5.1.4.31.2 The ability of the installed Thermal Oxidizer to achieve the system requirements will be demonstrated during a three day Performance Test. The Performance Test will be conducted after the vendor, RFAAP Operating Contractor, Plant Process Control Board has agreed that all HAZOP findings are closed and the system has been installed properly and is operating in a safe and representative condition.