The MOX Fuel Fabrication Facility (MFFF) will produce completed Mixed Oxide (MOX) fuel assemblies for use in domestic, commercial nuclear power reactors. Feed material is uranium dioxide and surplus plutonium dioxide. The manufacturing area is the MOX Fuel Fabrication Building (BMF). It is a multi-functional complex containing all of the plutonium handling, fuel processing, and fuel fabrication operation of the MFFF. This building includes the Aqueous Polishing Area, the MOX Processing Area, and the Shipping and Receiving Area. This Expression of Interest (EOI) is for the development of designs for sealing penetrations, documentation of the qualification basis for each design type (likely to include qualification testing), and installation of the approved seal design for the penetrations scheduled to be sealed through out the facility. MOX Services is seeking companies interested in responding to a two phase Request for Proposal (RFP) for: 1. Development of penetration seal designs and proof of qualification for various configurations of mechanical/electrical penetrations, most in reinforced concrete wall, floor and ceiling slabs. MOX Services estimates that ~75 configuration styles will need to be addressed during the design and qualification phase. 2. Development of final design drawings, bills of materials, and installation specifications detailing the parameters for penetration seals installation. 3. Performance of necessary "proof-of-design" qualification testing as required to demonstrate design adequacy, including preparation of test specifications/plans, conduct of testing and production of documentation that clearly defines the testing conducted, the results achieved and the evaluation of the results to demonstrate design acceptance. 4. Preparation of product specifications, where necessary as determined by MOX Services, to support the procurement of materials and products specified by the penetration seal designs. 5. Installation of the seals themselves. The MFFF is licensed by the Nuclear Regulatory Commission (NRC), and compliance with the applicable Code of Federal Regulations (CFRs) and NRC Regulatory Guides will be required. The NRC regulations are found in Chapter I of Title 10, "Energy", of the Code of Federal Regulations (CFR). All work will be performed under the MOX Services Quality Assurance/Quality Control (QA/QC) program. Firms interested in proposing are not required to have a NQA-1 Quality Assurance Program (American Society of Mechanical Engineers, NQA-1- 1989 Quality Assurance Program Requirements for Nuclear Facilities), but should be able to demonstrate their willingness and experience performing this type of work in a stringent QA/QC environment. Activities and materials associated with final detail design, qualification testing, procurement and installation for penetration seals are considered "Items Related On For Safety" (IROFS) and are classified as Quality Level 1 under the MOX Services qualify assurance program. Procurement of materials and performance of seals installation will be performed utilizing MOX Services processes and approved work procedures. All quality-related inspections and Nondestructive Examinations (NDE) will be performed by MOX Services QC organization qualified personnel. There are an estimated 10,000 penetrations within the entire facility that will require sealing. Seal designs must meet a myriad of applications requirements including fire rating (2 or 3 hour), elimination of air infiltration, smoke containment, radiological shielding, 6-way anchor restraint for selected piping, and allowance for thermal growth movement of hot pipes in the axial direction through the penetration. Not all penetrations seals are required to meet all application requirements. However, many are required to be fire rated and withstand stringent air infiltration and smoke containment limits under high differential pressure conditions. Penetrations may also have several differing system components (electrical, piping, mechanical, etc) passing through the same opening. With the variations and unknowns, the estimate for the design development, fabrication and installation of penetration seals is not available at this time. Subcontracting Approach The work scope will be performed in two phases. In Phase 1 each selected company will be required to develop preliminary designs and qualification bases for the ~75 penetration configuration styles that MOX Services determines to be needed to address the variety of penetration uses employed by the MFFF. Phase 1 will be solicited on a firm-fixed price basis. Deliverables will include, as a minimum: - Preliminary design drawings sufficiently detailed to support a clear understanding and evaluation of the material requirements, the level-of-effort to install, and cost estimate development. - One or more documents that provide the preliminary basis for qualification of each proposed seal design to meet the appropriate application requirements. Designs requiring limited or full-scale "proof-of-design" demonstration testing shall be clearly identified with a preliminary cost and execution time-frame for performance of the qualification testing required. - A proposed approach to structuring the pricing schedule for the installation of penetration seals, so as to allow for development of a schedule of fixed unit rates for installation. At the completion of Phase 1, MOX Services will evaluate the preliminary designs, qualification bases, and proposed qualification testing needs submitted by each company for any issues or concerns and submit comments and clarification needs to each company for disposition. MOX Services will work closely with each company to disposition any concerns developed during review working with each company separately. The goal is to reach a determination with each company that their preliminary designs are reasonable and able to accommodate all of the MFFF penetration sealing needs, and the approach to qualification demonstration is prudent. Upon acceptance of Phase 1 deliverables, each company with an accepted Phase 1 result will be required to submit a bid for Phase 2; final design, qualification and installation. In Phase 2 the selected company will be required to: - Develop final detail designs covering the variety of penetration sealing needs required by the MFFF and enveloped by the preliminary designs accepted by MOX Services in Phase 1. - Perform demonstration testing called for and accepted by MOX Services in the preliminary design phase (Phase 1). - Prepare material procurement specification requirements and installation work procedures to provide standard procurement instructions on purchase of material items specified by the final designs and control of installation work activities, in-process inspections and final acceptance activities. - Installation of penetration seals and all specified locations. The RFP for Phase 1 is planned to be issued in the 4th quarter of 2011. Proposals will be due in the first quarter 2012. Phase 1 is anticipated to be completed within 4 months of award, including one month for MOX Services review and acceptance of company disposition of MOX Services comments. The RFP for Phase 2 is anticipated to be issued approximately 6 weeks after MOX Services acceptance of the Phase 1 deliverables. The selected company is anticipated to begin qualification testing in the 4th quarter of 2012 and be prepared to begin field installation work in the first quarter of 2013 (for any penetration design not requiring qualification testing). Installation of penetration seals is anticipated to be performed over a 2-year time period.
