A01_PWS_ATC_ENGINE_UPGRADE_rev_1106-2.docx

Performance Work Statement Stationary Engine Emission Reduction

C.1 GENERAL.

C.1.1 SCOPE. This is a non-personal services contract to modify seven (7) existing stationary engines at U.S. Army Aberdeen Test Center (ATC) to meet current Environmental Protection Agency (EPA) National Emission Standards for Hazardous Air Pollutants (NESHAP) requirements for Reciprocating Internal Combustion Engines (RICE).

C.1.2 BACKGROUND. The RICE Maximum Achievable Control Technology (MACT) Rule (40 CFR 63 Subpart ZZZZ) requires existing, non-emergency, stationary Compression Ignition (CI) RICE located at an area source of Hazardous Air Pollutants (HAP) emission to comply with the applicable emission limitations and operating limitations. A summary of the requirements is below:

· Minimize engine idle and limit startup period to less than 30 minutes

· Limit CO concentration in exhaust to 23 ppmvd or less (at 15% O2) OR reduce CO emissions by 70% or more

· If using oxidation catalyst, maintain dP across the catalyst within 2 inches of water (at 100% load +/- 10%) from dP measured during performance test AND maintain catalyst inlet temperature between 450 and 1350 degrees F (based on 4-hr rolling average)

· Install a closed crankcase ventilation system or an open crankcase filtration emission control system. Follow manufacturer’s recommended PM.

· Conduct initial performance test C.1.3 PERIOD OF PERFORMANCE (POP). The POP shall be one year from date of award.

C.1.4 CONTRACT TYPE. This will be a Firm Fixed Price (FFP) contract.

C.1.5 PLACE OF PERFORMANCE. Work shall be performed at the U.S. Army ATC, Aberdeen Proving Ground, MD in the following locations: Littoral Warfare Environment (LWE), Bridge Crossing Simulator (BCS), and UNDEX Test Facility (UTF). All work shall be performed in the ATC restricted area.

C.1.6 WORK SCHEDULE.

C.1.6.1 ATC is currently operating under an alternative work schedule. The contractor shall perform modification services within the hours of the government alternative work schedule. The work schedule is 8 workdays of 9 hours each, 1 workday of 8 hours, and every other Friday known as the Regular-Day-Off (RDO) as shown below. All workdays commence at 0700.

C.1.6.2 Work shall be performed during normal business hours. Government will provide clear access to and from the work areas and at the sites. Work shall not be scheduled during the following Federal Holidays: New Years Day, M.L. King Birthday, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Day, Thanksgiving Day, and Christmas Day.

C.1.6.3 All work shall be scheduled in advance with the Government TPOC. Access to the test sites will be dependent upon test schedule. Government will provide access.

C.1.7 SAFETY. The contractor shall provide all safety equipment required for contractor personnel operating in an industrial area in accordance with OSHA standards and ATC regulations and procedures. Contractor personnel shall have personal protective equipment in their possession at all times while performing modification services and shall utilize this equipment in accordance with OSHA standards, ATC regulations, and as conditions warrant. This may include, but is not limited to safety shoes, hard hats, eye protection, hearing protection, work gloves and personal fall arrest systems. The Contractor shall abide by all ATC Safety Policies at no additional cost to the government.

C.1.7.1 PERSONAL PROTECTIVE EQUIPMENT (PPE). All contractor personnel shall wear the appropriate PPE when in the following work areas: range areas where entrance is controlled by the Range Operations Team, industrial buildings, at construction sites, test sites and test facilities. Other areas may be reviewed to determine if hazards are present which necessitate the use of PPE. Failure to wear/use PPE may cause removal from the job site and/or seizure of non-compliant equipment/items.

C.1.7.2 Contractor shall have a Health and Safety Plan that is accepted by the Government prior to any work commencing. Government will assist Contractor in obtaining local hot work permits for any cutting or welding activities.

C.2 APPLICABLE DOCUMENTS AND AVAILABILITY.

C.2.1 APPLICABLE DOCUMENTS.

a. RICE MACT Rule (40 CFR 63 Subpart ZZZZ)

b. All applicable Occupational Safety and Health Administration (OSHA) regulations

c. All applicable ATC Safety Regulations and Standard Operating Procedures (SOP)

C.2.2 AVAILABILITY OF DOCUMENTS. The government will be responsible for providing the contractor all ATC and/or Department of the Army SOPs or regulations. The contractor shall be responsible for having access to applicable EPA documents and OSHA regulations.

C.3 REQUIREMENTS. The requirement is to modify seven (7) existing engines, identified in the table below, to meet current EPA NESHAP requirements for RICE.

Engine Locations and Identification

Note: LWE = Littoral Warfare Environment; BCS = Bridge Crossing Simulator; UTF = UNDEX Test Facility C.3.1 MODIFICATIONS. The required modifications are:

· For each listed engine: Supply and install one closed crankcase ventilation system. This includes any brackets, piping, or other modifications required to mount the systems, even if they must be fabricated.

· For each listed engine: Supply and install one oxidation catalytic converter (DOC) to control CO emission in accordance with EPA RICE NESHAP requirements and based on engine exhaust parameters below. Emissions of CO must be reduced by 70%. Two-inch insulating blankets shall be provided for each catalytic converter.

· Back Pressure: 3in Hg or 15kPa

· Exhaust gas temperature (advertised power): 930 F, Peak Torque: 1040 F

· Exhaust gas flow (advertised power): 3270 cfm or 1543 L/sec, Peak Torque: 2335 cfm or 1102 L/sec

· Intake manifold pressure (advertised power): 45 in Hg or 1125 mm Hg

· For each listed engine: Supply and install one Continuous Parametric Monitoring Systems (CPMS) with pressure differential and temperature instrumentation, data logging, and alarming. CPMS shall be mounted on each system.

· Insulation shall be provided on the UTF Cummins Engine exhaust pipe from the turbo to the first flange connection.

· For each listed engine: Existing exhaust systems can be reused, but shall be modified to support the additional weight of the oxidation catalytic converter.

· For UTF engine: The insulation shall be extended up to the catalyst.

· For each listed engine: Oxidation catalytic converters, exhaust transitions, flanges and hardware to seal flanges shall be stainless steel.

C.3.2 Contractor shall conduct commissioning and start-up of the new systems.

C.3.3 Contractor shall provide operator training on the systems to personnel identified by the TPOC, including education on any future preventive maintenance requirements for the systems.

C.3.4 Contractor shall conduct an initial performance test. The performance test must show that the system is meeting the EPA RICE standards. The initial performance test includes measurement of carbon monoxide and oxygen emissions and demonstration of compliance with the applicable emission standards. The contractor must submit a Performance Test Protocol through the Government TPOC to be sent to Maryland Department of Environment for approval. Once the protocol is approved, the test can be conducted. If the system does not meet the standards, corrections to the oxidation catalytic converter and/or CPMS are the responsibility of the contractor before the service is considered complete. Draft and Final Performance Test Reports must be submitted to the Government TPOC for review and approval. The Government will send the reports to MDE to demonstrate compliance.

C.3.5 Contractor shall provide all relevant documentation for proper operation and maintenance of the new equipment.

C.3.6 Any solid waste generated shall be cleaned up and disposed of by the contractor. Any hazardous waste generated shall be turned over to the Government for disposal.

C.3.7 Government will provide the load profiles of each engine to ensure that the initial performance testing occurs at the highest load feasible.

C.3.8 Government will provide all fuel for the engines. Government will provide an operator for the engines for start up and testing and to advise on any engine-specific concerns during installation and testing.

C.3.9 All communications with Maryland Department of Environment (MDE) must be approved by the ATC Technical Point of Contact (TPOC).

C.3.10 DELIVERABLES:

1. Engine exhaust retrofits as described in the requirements.

2. Operator training as described in the requirements.

3. Performance Test Protocol as described in the requirements.

4. Performance Test Reports as described in the requirements.

5. All relevant documentation for proper operation and maintenance of the new equipment.

6. Any deliverable defined in this PWS shall be submitted under official company letterhead signed by designated company official. The cover letter shall be addressed to the customer’s Technical Point of Contact, unless otherwise directed. The cover letter shall include, as a minimum, the title of the applicable deliverable, date performed, contract and delivery order numbers.

7. Vendor must submit invoices through Wide Area Workflow (WAWF). E-mail notification shall be sent to the COR and TPOC when vendor submits invoices in WAWF.

8. Labor and cost data must be input into the Contractor Manpower Reporting Application (CMRA) by 31 October of each year.

C.4 CONTRACTING OFFICER’S REPRESENTATIVE (COR) AND TECHNICAL POINT OF CONTACT (TPOC): David Goad, Phone 410-278-2051, david.w.goad6.civ@mail.mil

C.5 SECURITY.

C.5.1 Usage of Privately Owned Personal Electronic Devices (PEDs) Within the Restricted Area (RA). Contractors are not authorized to bring any personally owned electronic devices into the Restricted Area (RA). A privately owned personal electronic device (PED) is defined as a civilian multifunction cell phone, Smartphone, personal digital assistant, tablet, blackberry, digital inventory devices and electronic recording/storage devices.

C.5.2 Reports of Adverse Information. The ATC Security Manager may deny a contractor access into APG restricted areas based upon adverse information that is discovered on that individual.

C.5.3 Installation Access. All contractor personnel will comply with the requirements of APG Regulation 190-4, Movement Control Within the Installation, for entry, exit and internal control of personnel, material and vehicles on APG. To gain access to APG, the contractor will provide a valid driver’s license and a valid vehicle registration. All vehicles and personnel are subject to search and seizure of contraband and/or unauthorized Government property in accordance with Army Regulation 190-13, The Army Physical Security Program.

C.5.4 Access into the Restricted Area (RA). All access into the Restricted Area (RA) under this contract will be by escort only.

C.5.5 Foreign Nationals/Immigrant Aliens. Foreign nationals/immigrant aliens cannot be granted access to the Restricted Area and shall not be scheduled to perform work under this contract.

C.6 CONTRACTOR MANPOWER REPORTING (CMR).

The Office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) has established a secure data collection site, entitled Contractor Manpower Reporting System, for the purpose of capturing contractor (and subcontractor) manpower utilized during the performance of this contract. As a result, the contractor shall report all the information required by the Contractor Manpower Reporting System. The information requiring completion by the contractor includes, but may not be limited to the following: Contracting Office, Contracting Officer, Contracting Officer's Technical Representative, Contract number, Requiring activity identification code (UIC), Command, Obligated Dollars, Fund cite information, Contractor name, address, phone number, e-mail address, Direct labor hours, Direct labor dollars, Federal Service Code (FSC) and Locations of service. The contractor shall submit all required information before final invoice. The contractor shall access the Contractor Manpower Reporting System database on the internet and fill-in the required data entry fields. The system can be accessed at the following internet address: https://cmra.army.mil.