A01_PWS.pdf

Aberdeen Test Center

Refrigeration Maintenance Contract

Performance Work Statement

Period of Performance:

14 April 2017 to 13 April 2018

Background:

Aberdeen Test Center (ATC) is a testing agency for the Department of the Army and houses various refrigeration systems that may not be comparable to private industry Heating and Air-conditioning Refrigeration (HVACR). The Aberdeen Test Center requires maintenance and repair services on various test chambers located at the Aberdeen Proving Ground (APG). These services require experienced and qualified technicians in the field of industrial ammonia refrigeration. This contract supports our mechanical integrity program through preventive maintenance, repairs and emergency response during a chemical release. It also is required to meet the Occupational Safety and Health Act (OSHA) requirements of the standard Combined

Federal Regulation (29 CFR1910) and our Process Safety Management (PSM) program.

The main front ammonia plant houses 28,000 pounds of Ammonia (NH3) which feeds three separate test chambers. Because the quantity is over the OSHA CFR-29 threshold of 10,000 pounds, a Risk Management Plan (RMP) and Safety Management Plan (PSM) is enforced and support contractors are required to be familiar with the written plans. These plans are critical to the welfare of the Aberdeen Proving Ground employees and visitors.

Fixed Price Preventive Maintenance:

All preventive maintenance will be performed annually. All work must be completed within ATC scheduled maintenance shutdown period unless otherwise agreed upon by ATC. Shutdown periods include 2 weeks of maintenance during the Christmas holiday timeframe and again during the July 4th holiday timeframe. These dates are not guaranteed and the maintenance period can vary in duration and scheduled dates. Equipment listed for maintenance is for general information. Contractor must field verify for proper make, model, type and/or size.

1. Perform annual vibration diagnostic testing to help identify and prioritize mechanical problems. Testing shall be performed with Original Equipment Manufacturer (OEM) route specific to compressor. Analysis shall be reviewed by a factory trained technician.

The results of the analysis shall be listed in the annual maintenance report.

a. Bldg. 383C

1) (3) 250 HP FES Screw Compressor Packages

2) (3) 150 HP FES Screw Compressor Packages

3) (3) 200 HP FES Screw Compressor Packages

b. Bldg. 450 R-507 Plant

1) (2) 235 HP Frick Screw Compressor Package

2) (2) 350 HP Frick Screw Compressor Package

2. Perform annual instrument calibrations on controls and instrumentation. Calibrations must be performed with certified instrumentation. Liquid probes shall be removed and cleaned before calibration. Results of calibrations shall be listed in the annual maintenance report.

a. Bldg. 383A Mobility Test Chamber (MTC)

1) (2) Chamber temperature resistance temperature detector (RTD)

2) (2) Makeup air system(s) dewpoint sensor

3) (20) Makeup air system(s) temperature RTD

4) (4) Makeup air system(s) relative humidity sensor

b. Bldg. 383B Firing Test Chamber (FTC)

1) (1) Chamber temperature RTD

2) (1) Makeup air system dewpoint RTD

5) (10) Makeup air system temperature RTD

6) (2) Makeup air system(s) relative humidity sensor

c. Bldg. 383C Ammonia Plant

1) (3) Pump Package liquid level probes

2) (1) Transfer vessel liquid level probe

3) (9) Compressor package pressure transducers and temp probes

d. Bldg. 450 R-507 Plant

1) (4) Compressor Packages, pressure transducers and temp probes

2) (1) Intercooler pressure sensor

3) (1) Intercooler suction temperature sensor

4) (1) Intercooler high temperature sensor

5) (1) Intercooler subcooled liquid temperature sensor

6) (1) Surge Drum pressure sensor

7) (1) Surge Drum suction temperature sensor

8) (2) Condenser pressure sensor

9) (2) Warm pump pressure sensor

10) (2) Warm pump inlet and outlet temperature sensor

11) (2) Chiller pump pressure sensor

12) (2) Chiller inlet & outlet temperature sensor

13) (1) Outside air temperature sensor

14) (1) Engine room air temperature sensor

15) (1) High stage discharge temperature sensor

16) (4) Evaporator supply air temperature sensor

17) (4) Evaporator return air temperature sensor

18) (1) Chamber A mobile air temperature sensor

19) (1) Chamber B mobile air temperature sensor

20) (24) Valve actuators on the secondary fluid system

3. Perform annual system safety checks on compressor safety components and controls.

Includes low suction, high discharge, oil pressure and temperature cutouts.

a. Bldg. 383C

1) (3) 250 HP FES Screw Compressor Packages

2) (3) 150 HP FES Screw Compressor Packages

3) (3) 200 HP FES Screw Compressor Packages.

4. Perform annual Non-Destructive Testing (NDT) on a minimum of 20 locations.

a. Use Ultrasonic test methods to determine wall thickness

b. Supply inspection plugs at all test points

c. Provide test results and list potential issues in a report format

d. Equipment to be tested includes pressure vessels and system piping. Test locations include the plant and chamber equipment, and outdoor pipe rack

5. Perform annual oil analysis for compressor packages.

a. Bldg. 383C

1) (3) 250 HP FES Screw Compressor Packages

2) (3) 150 HP FES Screw Compressor Packages

3) (3) 200 HP FES Screw Compressor Packages.

b. Bldg. 450 450 R-507 Plant

1) (2) 235 HP Frick Screw Compressor Package

2) (2) 350 HP Frick Screw Compressor Package

6. Perform annual ammonia purity test on the Bldg. 383C refrigeration system.

7. Provide water treatment for the condensers at buildings 383C, 450, and the altitude chamber. Treatment will include all necessary chemicals to maintain year round operation and prevent scaling caused by water evaporation. Technician will make quarterly visits to test the condenser water and make all necessary equipment adjustments for optimal performance. Technician will provide the government a visit service report of the results.

8. Perform annual Mechanical Integrity inspections on the ammonia process equipment located in Buildings 383A, 383B, and 383C. Follow industry best practices and recommendations. Use the latest International Institute of Ammonia Refrigeration (IIAR)

Guidelines and check sheets (Example: Bulletin 109 & 110). Document potential Issues generated from the inspection.

a. Plant Equipment

1) +35F Pump Packages

2) -35F Pump Packages

3) -70F Pump Package System

4) Transfer System

5) High Pressure Receiver

6) +35F Compressor Packages

7) -35F Compressor Packages

8) -70F Compressor Packages

9) Condensers

10) Auto Purger

11) Relief Valves

12) Ventilation System

b. Chamber Equipment

1) (8) MTC Evaporators

2) (4) FTC Evaporators

3) (3) Makeup Air Systems

4) (12) Valve stations

c. Emergency Shutdown System

1) E-Stops & Alarms

I. T&M Emergency Maintenance:

1. Contractor shall provide emergency maintenance services, maintenance repair supplies, and refrigeration engineering services at the request of the contract COR.

2. Contractor may be requested to provide a manufacturer representative for a selective piece of equipment. The contract COR shall authorize this request if it is deemed necessary for troubleshooting and/or modifying support equipment and automated controls.

3. Contractor shall provide a minimum (1) year warranty on all repair parts provided during repairs.

4. The contractor shall provide manufacturer cut sheets, specification sheets and manuals for all parts and/or equipment replaced or installed.

5. Materials and/or replacement parts required to perform maintenance may or may not be provided by the contractor under this contract. In some cases ATC may provide the maintenance repair parts and or supplies needed for the repairs.

6. All parts and materials provided under the T&M line item will require a contractor cost proposal for review by the government. No materials will be purchased without the contract COR approval.

7. Contractor shall list labor rates for time and material (T&M) work.

a) Service Technician Labor

b) Pipe Fitter / Welder Labor

c) Engineering Labor

II. General Requirements:

1. Contractor shall provide a Service Manager at his/her cost who will be responsible for the overall management and coordination of the contract and act as the central point of contact with the COR. The Service Manager will provide a Service Technician, Pipe

Fitter, or Control Automation Specialist within 24-hours of notification for repair services by the COR.

2. A worst case scenario ammonia release could affect personnel within 1.5 miles from the point of release over a 60 minute time period. Contractor must be located within 25 miles for emergencies, and under most circumstances capable of responding to a catastrophic ammonia release within 30 minutes.

3. Contractor shall provide fully qualified field personnel to accomplish all HVACR maintenance & repair tasks, piping fitting and control automation calibrations and adjustments as directed by the COR. Technician shall have a minimum (5) years experience working with industrial refrigeration systems that utilize refrigerants such as:

Ammonia, R-507, R-22, 404A, 508B, and secondary fluid D-Limonene systems.

4. Technician shall have current First Responder Training to include Level-A suit, self-contained breathing apparatus (SCBA), full face respirators, and other 29 CFR 1910 required PPE for chemical facilities. Technicians shall be experienced with Process Safety Management and able to follow facility procedures.

5. Contractor shall provide two technicians who are capable of obtaining an unescorted security badge for access behind the ATC secured fence within 60 days of contract award.

6. Contractor’s company shall have an active membership in Refrigeration Engineering Technical Association (RETA) and have experience performing mechanical integrity inspections in accordance with the latest Industrial Institute of Ammonia Refrigeration (IIAR) forms and bulletins.

7. Contractor technician may or may not be requested to work alongside the ATC facility operators. This request will be determined by the COR after reviewing the task at hand.

8. Technician shall not follow task request from anyone other than the COR. Technician shall report task findings to the COR or his assigned POC for that task. Technician shall provide a service ticket at the completion of the task to the COR.