Attachment 2_Performance Work Statement_With Exhibits_8May25.pdf

Ford’s Farm Maintenance & Repair Services Contract

C.1. General:

C.1.1 SCOPE OF WORK:

The Contractor shall furnish all Labor, Parts and Materials for:

Inspection, Preventative Maintenance, Repair and Modification (henceforth referred to as

“maintenance”) of the FORD’S FARM test site to include its constituent systems and components.

The two (2) Contract Line Items (CLINs) shall be:

CLIN #1: Quarterly Maintenance, CLIN #2: Repairs: Emergency & Routine.

The “Superbox” (aka “Depleted Uranium (DU) Containment Facility”) is located at the

FORD’S FARM test site of U.S. Army Aberdeen Proving Ground (APG), Md. & will be maintained in accordance with the Performance Work Statement (PWS) Section C.3.

System Description:

The Superbox is an environmentally safe, enclosed facility for testing weapons and targets that have components made from depleted uranium (DU) (see photo below).

The SUPERBOX started operations in 1990. Its operations are licensed, regulated, and inspected by the following agencies: Nuclear Regulatory Commission (NRC), Department of Energy (DOE), Environmental Protection Agency (EPA), Occupational Safety & Health Administration (OSHA), and the US Army Center for Health Promotion and Preventive Medicine (CHPPM).

It is composed of Seven (7) Air Trains , an 84’ diameter hemispherical Containment Vessel, a Flight Tunnel with high- and low-speed doors, and ancillary systems (to include mechanical, electrical, compressed air, and power distribution). Also included are support buildings for maintenance. (See drawing, Exhibit 1).

Support buildings include the following:

910 E2 - Evaporator building 910 E1 - Workshop 910 E11 - Core cutting building 910 E10 - Target storage 909A - Dome Electrical building 909B - Dome Supply Room 906A - Maintenance building 906C - Weld shop 906B - Warehouse

Fresh air is pumped into the top of the containment vessel via the AIR SUPPLY system, forcing suspended air particulates down toward the floor where it is drawn out through the EXHAUST system. Dampers, which control air flow, are closed, open, and throttled in accordance with operating modes. (See drawing, Exhibit 2).

The maximum air flow through the system is 64,000 cfm (cubic feet per minute). The AIR FILTRATION system is comprised of cartridge filters and HEPA (High Efficiency Particulate Air) filters which ensure that clean, uncontaminated air is discharged through the exhaust stack.

SALIENT HARDWARE is listed in Section C.3.1. (Please note that the listed Salient Hardware may not encompass all hardware covered in this maintenance contract, nor does it constitute separate systems. The Salient hardware merely lists prominent and representative items.)

C.1.2 PERIOD OF PERFORMANCE.

The period of performance of the contract is for one-year base (“Base Year”), with two (2) one-year options (“Option Years”).

C.1.3 PLACE OF PERFORMANCE. Performance will take place at the Aberdeen Test Center (ATC), Aberdeen Proving Ground (APG), Maryland, 21005-5059 at Fords Farm test site. (See map, exhibit 3).

C.1.4 HOURS OF NORMAL OPERATIONS.

ATC is operating under an Alternate Work Schedule. The work schedule is 8 workdays of 9 hours each, 1 workday of 8 hours, and every other Friday off as depicted below.

Sunday Monday Tuesday Wednesday Thursday Friday Saturday

Week 1 hrs

0 9 9 9 9 8 0

Week 2 hrs

0 9 9 9 9 OFF 0

Nominal hours of operation are 6:00 a.m. to 3:30 p.m. with the exception of the first Friday in the Government’s bi-weekly pay period, which is 6:00 a.m. to 2:30 p.m.

The Contractor shall adhere to curtailing operations and ATC closures. Curtailments and ATC closures include any time when ATC is in a non-operational status for events including but not limited to emergency situations, power curtailments, furlough, ATC events, or planned training days. . The COR will notify the Contractor of the dates of curtailment and closure.

Maintenance shall be performed between the hours of 0600 and 1530, Monday through Friday and alternating Fridays. Weekends, second Friday and Federal holidays are exceptions.

Maintenance services shall be scheduled through the Contracting Officer’s Representative (COR) fourteen (14) calendar days before work is to commence to avoid conflicting with the SUPERBOX testing schedules.

C.1.5 PERSONNEL.

C.1.5.1 Training, Education requirements. Personnel performing maintenance services shall be trained and have at least five (5) years’ experience performing services on equipment similar to that listed in Section C.3.

C.1.5.2 Certification requirements. Contractor personnel shall be certified and / or licensed accordingly. Examples include: Engineers, plumbers, carpenters, electricians, HVAC technicians, welders, and painters.

C.1.5.3 Hazardous Conditions. Contractor personnel may be exposed to the following conditions during performance of work:

C.1.5.3.1 High noise levels (impulse and steady state).

C.1.5.3.2 Proximity to electric power sources of high voltage and/or amperage.

C.1.5.3.3 Working in confined spaces.

C.1.5.3.4 Site-specific operations will be conducted at nearby ATC test sites. Contractor personnel shall check with the Facility Manager, range safety official, or person-in-charge to ensure that NO hazardous explosives or ammunition items are within the area where services are to be performed, PRIOR to entering work areas.

C.1.5.3.5 Depleted Uranium (DU): The Contractor will work both inside and outside of posted radiological materials (RAM) areas.

A. DU is a low level radioactive, toxic, heavy metal. It poses a chemical health and ionizing radiation health risk (via ingestion and inhalation). There is not an external hazard.

B. ATC operates the Fords Farm test site under Nuclear Regulatory commission (NRC)

License Number SUB-834 for a “Fuels and Materials Facility” (one of the NRC’s ten broad subdivisions.)

ATC has implemented a very robust radiological protection program which is inspected by the Nuclear

Regulatory Commission. The personnel from the US Army Aberdeen Test Center (ATC) are experienced in handling DU to include complete decontamination and disposal procedures. On-site instrumentation monitors the air quality both inside and outside the containment vessel, to include real-time air quality monitoring.

C. ATC will provide the Contractor initial DU Hazard Awareness Training and recurrent briefings to understand the risks, procedures, and engineering controls.

D. The Contractor’s tasks will generally not require contractor personnel to don, or “dress out” in, DU-specific Personal Protective Equipment (PPE). Although highly unlikely, a Contractor employee may be required to submit a Urine Uranium Bioassay sample if the work required will be in an airborne contamination area. If the ATC Radiation Safety Officer determines the need, then the worker will be placed in the monitoring program.

E. The Contractor may be asked to work in areas adjacent to the Containment Vessel and

Air Trains. Such areas potentially contain DU and are clearly demarcated by rope and “radiation” postings. Ingress and egress points to such areas will be will be controlled.

In these instances the Contractor would be continuously monitored by Fords Farm qualified radiation workers, who would provide instructions and necessary PPE (e.g. rubber over-boots, gloves, and/or respirators), and, upon exit, check the hands, feet, and clothing of the contractor (aka “hand and foot frisk”). This area is not within the airborne contamination area and Bioassay is not required. The monitoring devices used to check the Contractor will be calibrated radiation survey instruments

(containing either a Geiger-Muller (GM) or a scintillating-type detector.)

F. Using procedures and engineering controls, IAW with NRC and Environmental Protection

Agency (EPA) radiation standards, any incidental DU exposure from the licensed operation will not exceed the dose limits for “individual members of the public” (based on the Effective Dose Equivalent

(EDE)), per the NRC 10 CFR 20.1301. (Please note that allowable dose limits for “the public” are approximately 50 times lower than “occupational” dose limits.)

G. ATC accomplishes ALARA (As Low As (is) Reasonably Achievable), by:

(1) Posting hazards and controlling access to radiation sources.

(2) Only using the amount of RAM or radiation sources necessary to accomplish the mission.

(3) Conducting hazard analysis of work processes and tests, and using engineering controls to reduce exposures. Provide feedback and appraisal of processes and procedures to improve work practices and controls.

(4) Limiting the number of personnel being exposed to ionizing radiation.

(5) Limiting the duration in which personnel are exposed to ionizing radiation.

(6) Educating personnel on the hazards of ionizing and non-ionizing radiation.

(7) Documenting environmental effects of RAM.

(8) Arranging for appropriate medical examinations to detect evidence of adverse ionizing and non-ionizing radiation effects.

F. The point of contact for DU-related issues is the Radiation Safety Officer, Radiation Safety

Team, Aberdeen Test Center, APG, Md. 21005-5059, to include:

• Glenn Clark, 278-4049, glenn.r.clark6.civ@army.mil

• Sobha Thomas, 278-2281, sobha.s.thomas.civ@army.mi

C.1.5.3.6. As deemed necessary and by mutual consent, Contractor personnel may be assisted by ATC personnel to include: crane and rigging operators, electricians, fabricators, mechanics, engineers, and technicians.

C.1.5.4 Program Management and Key Personnel.

The Contractor shall designate and provide a Program Manager (PM) who shall perform overall management of the PWS (Performance Work Statement). The PM shall be the Contractor’s primary point of contact and shall have the authority to make decisions on all matters on behalf of the Contractor. The PM shall interact primarily with the COR (Contracting Officer’s Representative) but may also interact with the Superbox Facility Manager under certain scenarios, such as emergency repairs (see C.3.13 Emergency Repairs). The Contractor shall also designate an Alternate PM who shall be authorized to make decisions in the absence of the PM. This designation shall be accomplished fourteen (14) calendar days, or earlier, prior to start of performance.

C.1.5.5 Identification of Contractor Personnel.

mailto:glenn.r.clark6.civ@army.mil mailto:sobha.s.thomas.civ@army.mil

The Contractor shall wear visible identification that represents them and their company as a Contractor performing a mission support function. Furthermore, the Contractor shall prominently display their Security Badge as required by security regulations.

C.1.6 SAFETY. The Contractor shall provide all safety equipment required for personnel operating in an industrial area in accordance with OSHA standards and ATC regulations and procedures. Contractor personnel shall have personal protective equipment (PPE) in their possession at all times while performing maintenance services and shall utilize this equipment in accordance with OSHA standards, ATC regulations, and as conditions warrant. This shall include, but is not limited to, safety shoes, hard hats, eye protection, hearing protection, work gloves and personal fall arrest systems. The Contractor shall provide all contract personnel with hardhats, safety shoes, eye and ear protection, and gloves.

C.1.6.1 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.

C.1.6.2 Tools. The contractor shall provide all tools, implements, and test equipment necessary to properly and efficiently maintain the covered equipment for the life of the contract.

Exceptions:

a. ATC will provide, upon request and mutual consent, all rigging (e.g., cranes, tow motors/forklifts, operators, and rigging equipment).

b. ATC will provide, upon request and mutual consent, man-lifts and scaffolds.

C.2 APPLICABLE DOCUMENTS The SUPERBOX systems are to be tested and maintained in accordance with the following:

(1) Performance Work Statement (PWS, Section C.3.),

(2) Manufacturer’s instructions, and

(3) Known standards, such as the National Electric Code (NEC), International Building Code (IBC), OSHA and National Fire Protection Association (NFPA) standards, as applicable.

Examples of applicable NEC Articles are:

Article 409 “Industrial Control Panels”, and Article 430 “Motor, Motor Circuits, and Controllers”.

C.3 REQUIREMENTS / PERFORMANCE WORK STATEMENT (PWS): The Contractor shall furnish all labor, parts and materials for “maintenance” of ATC’s Superbox in accordance with the instructions listed in this section.

C.3.1 SALIENT HARDWARE (not all-inclusive):

Electrical Enclosure:

Power Distribution & Motor Control Center (480 V, 3 phase, with 1200 /1600 amp main breaker & disconnect) (Cutler Hammer);

Main Switch Board; Switchgear; H-O-A motor starters.

Four (4) VFDs (Variable Frequency Drives) – (Honeywell “Smart VFD HVAC”).

Field devices (sensors, transmitters, & actuators).

Mechanical Enclosure:

Plant Air (Air Compressor, Instrument Air Distribution) – (Ingersoll Rand).

Field devices (sensors, transmitters, & actuators).

Containment Vessel / Dome:

Equipment Access Door and Inflatable Door Seal.

Staging Pad.

Field devices (sensors, transmitters, & actuators).

Flight Tunnel:

High Speed Door.

Low Speed Door.

Field devices (sensors, transmitters, & actuators).

Supply Air Ductwork:

Two 50 HP electric motors, 3 phase, 460 volts. (WEG: TEFC).

Dampers (Scotch Yoke and rack-and-pinion types). (FlowServe/ AutoMax).

Damper Actuators & Positioners.

Field devices (sensors, transmitters, & actuators).

Exhaust Air Ductwork:

Dust Filtration System.

HEPA Filter assemblies.

Two 100 HP electric motors, 3 phase, 460 volts (WEG: TEFC).

Dampers (Scotch Yoke and rack-and-pinion types). (FlowServe/ AutoMax) Damper Actuators & Positioners.

Field devices (sensors, transmitters, & actuators).

Other ductwork: (Return Air Header, Bleed Bypass, Dilution Air Supply):

Dampers (Scotch Yoke and rack-and-pinion types). (FlowServe/ AutoMax) Damper Actuators & Positioners.

Field devices (sensors, transmitters, & actuators).

Distributed Control System:

Allen-Bradley; three cabinets with ancillary equipment; Ethernet and AB data highways; ~ 200 channels of IO (Analog and Discrete).

Field devices (sensors, transmitters, & actuators).

Analog Transmitters include: Flow, Temperature, Dew Point, Aerosols.

Management Station (computer) in the Instrumentation Enclosure.

Evaporator Room (Bldg 910E2):

Wastewater Evaporator (LakeView Engineered Products).

Air Operated Double Diaphram Pump (Ingersoll Rand).

Water Tanks (22,000 gallons, and 500 gallons).

Field devices (sensors, transmitters, & actuators) (e.g, Princo Instruments).

Change-out Room (attached to Dome):

Split System Heat Pump (Mitsubishi).

Water Lift Station:

Sump Pump.

Floats.

visual/audible alarm.

C.3.2 Plan of Action: The Contractor shall create a Plan of Action prior to conducting specific maintenance on the SUPERBOX components and subsystems, and present it to the COR for review and approval, in align with Contract Data Requirements List (CDRL) reporting requirement Data Item A001. Such maintenance shall be conducted by the Contractor in accordance with the equipment manufacturer’s recommendations and industry practices.

Upon reaching a consensus the Contractor will proceed with the agreed‐upon Plan of Action.

The Plan of Action shall include functional test and general inspection of all systems and subsystems identified in the Salient Hardware, PWS Section C.3.1, above. Also incorporated into the Plan of Action shall be common industry‐accepted tasks (such as quarterly lubrication of the electric motors.)

C.3.3 Services: The Contractor shall provide - or arrange via Subcontractor - such services as:

A. Vibration Analysis and Correction.

B. Predictive and Preventive Maintenance.

C. Motor reconditioning and rewiring.

D. Electrical Testing to include:

1. Megger and “Hipot” Insulation tests.

2. Electrical Center Testing.

3. Rewinding / Reconditioning.

4. Power quality analysis.

5. Switchgear.

E. Laser Alignment.

F. Mechanical Repairs to include:

1. On-site and off-site machining.

2. On-site dynamic balancing.

G. Control Systems Service.

H. Thermal Imaging for detecting temperature differences on motors, controls, or process equipment.

I. Installation Services.

J. New Equipment and Parts, to include:

1. AC/DC Motors.

2. Industrial Controls and Starters (e.g., Soft-Starters, VFD’s).

3. Wire and Cable.

4. Drives.

5. Field devices (sensors, transmitters, & actuators).

C.3.4 Restoration of system function: Contractor shall place the system(s) back into working order upon completion of all tests, maintenance, and repairs.

If the system requires service above the capabilities of personnel performing tests, the Contractor shall notify the COR and expedite repair services to place the system back in working order so that downtime will be kept to a minimum.

C.3.5 Repair work: Any deficiency discovered as a result of inspection or operation that is not correctable through normal maintenance shall be considered REPAIR WORK. The Contractor shall promptly notify the COR of any deficiency or safety hazard not correctable through maintenance.

The Contractor, COR, and Facility Manager shall mutually agree upon the responsible party for, and means of, implementing the repairs. Considerations will be made for the urgency of the repair, the magnitude of the repair, the Contractor’s or government’s ability to implement the repair, the remaining budget, and change‐order options.

Another consideration, especially for lengthy repair efforts, is the need to schedule such repairs/modifications during the Superbox’s “Shutdown periods”, typically lasting many weeks, at multiple times per year, to facilitate continuous, unfettered work and not interfere with normal testing operations.

C.3.6 Post maintenance briefing: Upon completion of maintenance, the Contractor shall notify the COR that all maintenance at the test site is complete and the system is operational and in service/online. The Contractor shall also provide to the COR all maintenance results, suggested preventive maintenance, routine repairs, and associated actions, and shall provide appropriate documentation.

C.3.7 Routine repairs (or modifications) may be requested by the COR at any time. Response time for initiation of routine repairs will be within forty eight (48) hours of notification. The Contractor shall furnish the COR a telephone number designated specifically for the initiation of all repair procedures.

C.3.8 Emergency repairs will be at the request of the COR or the Facility Manager. Response time for initiation of the emergency repairs shall be within four (4) hours of notification. The Contractor shall furnish the COR a telephone number designated specifically for the initiation of emergency repair procedures.

Historical examples of emergency include:

1. Electric Motor replacement, (from fractional HP to 100 HP motors);

2. Repair of watertight floor in radioactive “change out” room;

3. Troubleshooting of the plant’s main air compressor;

4. Repair of overhead doors/ door openers in controlled buildings;

5. Replacement of power train components (e.g, drive belts)

C.3.9 Replacement Parts/Materials: The contractor shall obtain all material, supplies, parts, and components for maintenance services, after obtaining the approval of the COR. All replacement parts, materials, and components shall be Original Equipment Manufacturer (OEM) parts for the unit for which they will be used. Any substitute parts must be approved by the COR prior to use.

C.3.10 Documentation: The Contractor shall provide copies of all maintenance records to the COR. The Contractor shall administer all maintenance records, with a copy stored at the test site where maintenance was conducted. All records shall be updated immediately upon completion of service. The COR shall be provided an additional copy of all records as services are performed. The Contractor shall submit a written service report covering the work accomplished. The Contractor shall notify the COR of any corrective actions required that are not covered by this contract.

C.3.10.1 Inspection and Maintenance Results Report: The Contractor shall provide an Inspection and Maintenance Results Report immediately following inspection and maintenance of the system, in align with CDRL reporting requirement Data Item A002. The format of the report shall be approved by the COR.

C.3.10.2 Written Service Report : The Contractor shall provide a Written Service Report upon completion of remedial services and repairs. The Report shall consist of a description of the work performed, and a detail of the deficiencies, remediation actions taken, work labor hours and materials used, in align with CDRL reporting requirement Data Item A003. This may be hand written on a company form. The format of the report shall be approved by the COR. The form must be signed by the COR. Copy of the record shall be provided to the COR.

SECTION J - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACHMENTS

Exhibit 1 - Drawing of Superbox (Plan View/Simplified).

Exhibit 2 - Air Flow diagram Exhibit 3 - Map of Fords Farm/ Superbox

R e t u r n

A i r

H e a d e r

D i l u t i o n

A i r

S u p p l y

Bleed Bypass

Supply Train 1

Supply Train 2

Exhaust Train 2

Exhaust Train 1

D1

D5

D2

D4

D6

D8

D9

D15

D3

D14

D13

D12

D11

D10

FC4

FC3

yy xx

Solenoid valve (24 volts DC)

I/P (4-20 ma)

Damper /Actuator Assessment:

D1___________________________________

D2___________________________________

D3___________________________________

D4___________________________________

D5___________________________________

D6___________________________________

D8___________________________________

D9___________________________________

D10__________________________________

D11__________________________________

D12__________________________________

D13__________________________________

D14__________________________________

D15__________________________________

FC3__________________________________

FC4__________________________________

24 April 2014

P.Turney

Superbox Dampers / Actuators peter.s.turney Line peter.s.turney Line peter.s.turney Line peter.s.turney Text Box Exhibit 2