Radioactive Liquid Waste Processing Process Controls Replacement (PLC Upgrade)

Form / Attachment / Pricing Sheet

This document outlines the design parameters for a new process control system, detailing specific requirements for components, alarms, and pump operations. It serves as a technical specification for potential bidders to understand the system's functionality and hardware needs.

• Process Control Requirements: Specifies functionality for low-level override, conductivity monitoring (including "Satisfactory"/"Unsatisfactory" status and interlocks), automated process valves, and audible alarms for various events (high-level, low-level, tank full, conductivity issues).
• Pump Operations: Details operational logic for specific pumps (SMP-P-1, PPD-P-1, RLW-P-1 & RLW-P-2, PLW-P-1 & PLW-P-2, CPW-P-1 & CPW-P-2) including transfer and recirculation modes, safety disconnects, enable switches, and tank level conditions.
• Hardware Design Parameters: Lists existing major system components and specifies which will be replaced, including flowmeters, CPUs, power supplies, input/output cards, and conductivity meters. It also notes which components (tank level indicators, solenoid valve, tanks, conductivity cells) will not be replaced.
• Process Control Stations: Outlines the required control instrumentation (buttons, switches, lights) for each process control station, organized by instrument.
• Human Machine Interface (HMI): Describes HMI capabilities, including system diagrams, flow path identification, pump status, tank levels, and conductivity levels.
• Software Information: Mentions current programming software (Cutler Hammer GPC 5) and the existing ladder logic, and specifies new PLC design parameters for digital and analog inputs.

This document is critical for bidders to understand the technical scope of the process control system. It details the required functionality, specific hardware to be replaced or retained, and operational logic for pumps and alarms. Bidders must use this information to assess their capability to meet the requirements, estimate costs, and prepare their technical proposals.

Statement of Work (SOW) / Performance Work Statement (PWS)

To upgrade the current outdated Programmable Logic Controller (PLC) system for the water processing system at Naval Station Norfolk (NSN). The goal is to improve maintenance efficiency, reduce operational complexity, enhance reliability, efficiency, and security, and achieve standardization with existing infrastructure.

• Provide an upgraded PLC system that is a direct duplicate of an existing system at Norfolk Naval Shipyard (NNSY) to ensure component and software interchangeability.

• Modernize the control system, including pumps, valves, level indications, and alarms.

• Perform all work at NSN, within building CEP-198, except for prefabrication of processing equipment and software development.

• Remove and dispose of components of the existing PLC system, including the cabinet, electrical buttons, switches, wiring, panels, motor control center relays, input/output cards, control stations, central processing unit, and insulation. Facility infrastructure will not be affected.

• Period of Performance: 12 months from the date of award, with an option for a 6-month extension.

• Place of Performance: NSN, building CEP-198.

• Adherence to numerous referenced documents, including Federal Regulations, NAVSEA Standard Items, Local Standard Items, and specific drawings and procedures.

• Compliance with all applicable laws, ordinances, and regulations (NRC, EPA, OSHA, DOT, TSCA).

• Contractor personnel must be qualified and experienced, with specific academic and specialized experience requirements for engineering roles.

• Strict adherence to radiological requirements, including dosimetry, potential incident reporting, and Team Learning Sessions for any issues.

• Hazardous Energy Controls (HEC) procedures must be followed, including Lockout/Tags-Plus.

• Obtain authorization for all Portable Electronic Devices (PEDs) and adhere to strict policies regarding their use on site.

• Requirements for access to Navy installations, including potential participation in the Defense Biometric Identification System (DBIDS).

• Provide a 3-day on-site training course for up to 12 personnel on the new system's software interface.

• Provide one new laptop computer configured with necessary software.

• Submit a Safety plan for review and approval prior to work commencement.

• Enter into a Memorandum of Agreement with NNSY for lifts requiring rigging within the CEP-198 high bay.

• All work products must be reviewed and approved by NNSY before proceeding.

• Contractor will not operate the RLW system independently; NNSY approval and support are required.

• NNSY will provide water and power to the facility. NNSY will also provide schematics and electrical diagrams of the RLW system.

• NNSY will support Contractor work on 1st shift (0720-1550), Monday-Friday. Overtime is not compensated and requires advance notification.

• NNSY will maintain facility security and provide personnel to escort the contractor within CEP-198.

• NNSY will perform all lifts requiring rigging within the CEP-198 high bay.

Statement of Work (SOW) / Performance Work Statement (PWS)

This Performance Work Statement (PWS) outlines the requirements for the removal and replacement of the Process Controls for the Naval Station Norfolk (NSN) Radioactive Liquid Waste (RLW) Processing System. The primary objective is to remove the existing, antiquated, and frequently malfunctioning process control equipment and install modernized process controls.

• Removal of existing process control equipment, including programmable logic controllers (PLCs), inlet/outlet cards, wires, and Process Control Panels.

• Furnishing and installation of a new process control system.

• Installation of new PLCs, wires, inlet/outlet cards, and process control stations with Human Machine Interface (HMI) screens.

• PLCs must be micro-processor based, capable of discrete analog inputs and control of discrete/analog outputs, and communication with external devices.

• PLCs must meet Class A computing device requirements and withstand conducted susceptibility tests as outlined in NEMA ICS 1, NEMA ICS 2, NEMA ICS 3, and IEEE C37.90.1.

• PLCs must function at temperatures between 32 and 122 degrees F (5-95% relative humidity non-condensing) and tolerate storage temperatures between -40 and 140 degrees F (5-95% relative humidity non-condensing).

• PLC systems must be modular and field expandable.

• CPU modules must be self-contained and microprocessor-based.

• Communications modules must allow peer-to-peer communication and utilize Ethernet architecture and protocol.

• Input/Output (I/O) modules must be self-contained and microprocessor-based, providing interface to field devices.

• Program storage requires manufacturer's standard non-volatile memory for the operating system and EEPROM for user programs and battery-backed RAM for application memory.

• Controllers must allow for analog input, analog output, discrete input, and discrete output, with specified spare capacity.

• Wiring connections must use heavy-duty, self-lifting, pressure type screw terminals.

• Each controller must have an integral on-off power switch.

• PLCs must have implemented diagnostic routines.

• Controllers must have an accuracy of +/- 0.25 percent of input span.

• PLC software must support IEC 61131-3 programming methods and include startup software for automatic operation commencement.

• System must measure and transmit analog values, including calculated analog points.

• Alarm processing software for AI, DI, and PA alarms is required.

• Control points must have defined constraints (e.g., max cycles per hour, min off/on time, high/low limits).

• Control panels must conform to NEMA 250 requirements and be constructed of appropriate materials based on installation environment.

• Workstation equipment must meet specified configuration and performance standards.

• Human Machine Interface (HMI) screens must be industrial rated with specified display and keypad features.

• HMI software must provide communication, programming, and control capabilities, with an object-oriented graphical user interface.

• Factory testing of the control system is required prior to shipment.

• Place of Performance/Delivery Location: TBD

• Period of Performance (PoP)/Completion Date/Delivery Date: TBD

• Security Requirements: Defense Biometric Identification System and NAVSEA Badging, potential need for DBIDS card, and possible security clearance requirements (Secret or Final).

• Privacy Act compliance and Controlled Unclassified Information (CUI) handling are required.

• Portable Electronic Devices (PEDs) policies must be adhered to within controlled areas.