J044--SAFETY TESTING OF ALL BOILER SAFETY DEVICES
Statement of Work Inspection, Safety Device Testing and Calibration Boiler Plant Burners, Controls, Instruments, and Data Management Introduction: A. The Kansas City, VA Medical Center requires the semi-annual services for the inspection, testing and certification of all boiler safety devices on: The four, high pressure steam boilers, in the plant at Building 4. These boilers produce the steam to the Medical Center Main Campus. The six, outlying low-pressure hot water (hydronic) boilers used for heating and domestic hot water at Buildings 2 and 56. The safety device testing is a critical service for the Boilers at the Medical Center, so it is critical that the testing is completed within 14 calendar days of the 6-month pre-scheduled testing date provided by the Medical Center. There may be occasions where the Medical Center may extend the schedule for burners in limited service. Technicians performing the inspections shall be certified and credentialed Boiler Inspectors. . B. Boiler plant safety, reliability, efficiency, and equipment longevity are critical safety and property concerns of the Medical Center. Malfunctioning burners or controls can cause catastrophic events resulting in injuries and death and massive property damage. Inaccurate or inadequate data management and monitoring systems can fail to warn of unsafe or inefficient performance. Regular inspections, testing, and calibration by expert technicians are an essential part of a program to address these concerns. C. This Statement of Work describes the requirements for the inspection, testing and calibration of the boiler plant burners, burner management system, controls, instruments, gauges and transmitters by qualified technicians. This will include the 3 Hydronic Boilers at Building 2 and the 3 Hydronic Boilers at Building 56. Objective: The services we require are for semi-annual preventative maintenance services that includes the testing, inspection and certification for all the Boilers in the 3 buildings of the Medical Center s main campus. Key Deliverables: Inspection of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices Testing of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices Calibration of 4 High Pressure Steam and 6 Hydronic Boiler Safety Devices Inspection, Testing and Calibration Report, Including Certifications. Contractor will provide all tools, materials, labor, supervision and all specialized testing equipment needed to perform semi-annual testing, inspection and calibration on all boiler safety devices, Boiler Plant Burners, Controls, Instruments, and Data Management System. D. Attachment A shows the equipment inventory and includes the Boiler information along with the primary supporting equipment that is included in this contract. E. Appendix B, covers the inspections of the six, hydronic boilers at Buildings 2 and 56.; F. It is assumed as part of any boiler testing and inspections that whether a hot water boiler or steam boiler that repairs, adjustments or replacement of components may be required at additional cost. G. It is assumed as part of any gauge or transmitter testing and calibrations that whether a hot water boiler or steam boiler system that repairs, adjustments or replacement of components may be required at additional cost. Technician and Test equipment Qualifications: Technicians performing the testing and inspections on all the boilers at the Kansas City, VAMC, shall have completed at least a one-year trade school and have five consecutive documented years of successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the Kansas City VAMC. The Boiler Plant Supervisor at the Kansas City, VAMC, may define and accept equivalent qualifications. The contractor and all individuals working on the Kansas City, VAMC Boilers, shall have taken the OSHA Certified 10-hour construction safety course. B. Technicians shall demonstrate familiarity with and have ready access to the current versions of the following references: NFPA 85, Boiler and Combustion Systems Hazards Code. NFPA 70E VHA Boiler Plant Safety Device Testing Manual, Fifth Edition. VHA Directive 1810(1) Boiler and Boiler Plant Operations C. Technicians shall be equipped with portable electronic flue gas analyzers and all test Instruments and materials necessary for the required tests and calibrations, D. All test equipment must be calibrated and have calibration documentation demonstrating calibration was performed within one month of the site visits. E. The Kansas City, VAMC uses programmable logic controls, the technicians must be proficient in programming the controls and have the appropriate hardware and software for this. 3. Inspection, Testing and Calibration Requirements: A. Technicians shall provide all tools and labor necessary to perform internal inspection, component inspection, tuning, testing, calibrating, and adjustments of duel fuel burners and boiler plant controls as specified below. This shall be done every six months in accordance with a schedule provided by The Kansas City, VAMC. The VA may extend the schedule for burners in limited service. B. Instrumentation, monitoring and data management systems as listed below shall be calibrated every six months. C. Provide at least two weeks notice to the Contracting Officer s Representative (COR) prior to performing the work. Work cannot be scheduled during heavy steam load periods. Only one boiler at a time can be out of service for the inspection, testing and calibration procedures. Work must be conducted when the COR or his/her designate is available on site to monitor the work. D. The Kansas City, VAMC will have the boilers that are to be serviced and or internally inspected, prepared for the technicians upon their scheduled arrival. This includes having the boilers clean of soot and loose scale; fully warmed and at normal steam pressure; steam exhaust silencer system operable; pressure/temperature correction factors provided if available. E. The Kansas City, VAMC will comply with any other requirements of the test personnel that are considered reasonable to the VA and have been presented in writing, to the VA, at least two weeks prior to the scheduled testing. F. The inspections, testing and calibrations shall comply with: 1) The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition. A copy of the Testing Manual is available upon request. 2) Any written recommendations of the equipment manufacturers. 3) The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazards Code including applicable appendices. 4) Burner performance requirements in this document. 5) VHA Directive 1810(1) Boiler and Boiler Plant Operations G. A summary of the work is as follows: 1) Review boiler plant log sheets and alarm and trouble reports. 2) Review records that show combustion performance (flue gas oxygen and carbon monoxide). 3) Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VAMC requirements stated in this contract. 4) Test and record the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Verify that the set points and operating points are within approximately 10% of normal operating parameters. Adjust or repair/replace as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation. 5) Operate burner(s) on each fuel from low fire to high fire and back to low fire with VFD in auto and again with the VFD in bypass in at least six increments and record combustion performance (flue gas oxygen, carbon monoxide, NOx (where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output) at each increment. 6) Compare the combustion performance data with VAMC requirements (see below) and previous readings. If necessary, adjust the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data. 7) Verify accuracy of instrumentation listed below. Verify that all devices are properly selected for the application in terms of type, size, set point range, performance, code approval. Calibrate all instruments that are not within manufacturer s specifications for accuracy. 8) Immediately inform COR of any recommended repairs or modifications. H. A list of all interlocks and safety devices to be inspected and tested on each boiler/burner/equipment, are contained in the VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition, along with testing procedures. A copy of the Testing Manual is available upon request. I. Required burner performance with VFD and VFD bypass (natural gas and fuel oil): 1) Turndown (ratio of maximum and minimum firing rates): 10/1 8/1 5/1 4/1 (Refer to original burner specification). 2) Achieve, but do not exceed, boiler maximum steam flow output rating. Measure fuel input at minimum and maximum firing rates. 3) Maximum carbon monoxide: 200 parts per million (ppm) 4) Maximum NOx: _____ (Refer to original burner specification). 5) Flue gas oxygen: 2.5 4.2% (Up to 5.2% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single-point positioning systems). 6) Flue gas oxygen (low excess air burners): 1.0 2.0% (Up to 2.5% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single point positioning systems). 7) No visible smoke Comply with local emissions regulations. 8) Copies of the applicable emissions regulations must be available in the boiler plant office. 9) Flames shall be stable with no pulsations, shall be retained near burner, no blow-off or flashbacks, no constant flame impingement on refractory or water-walls. J. List of instrumentation and controls to be inspected and calibrated: The Kansas City, VAMC has preferred PCCIV programmable logic controls on all four boilers plus FIREYE YB110 burner management system on all four boilers in the central plant. 1) Steam flow transmitters (all). 2) Steam flow recorders/computer readout. 3) Feed flow transmitters (all). 4) Feed flow recorders/computer readout. 5) Drum level transmitters (all). 6) Drum level recorders/computer. 7) Flue gas oxygen sampling, analyzing and recorder/computer readout. 8) Boiler and economizer stack temperature transmitters and recorder/computer readout. 9) Master steam pressure and combustion controllers. 10) Boiler outlet draft controllers. 11) Boiler water level controllers. 12) Feedwater deaerator and condensate storage tank water level controllers including overflow. 13) All pressure and temperature sensors and transmitters. 14) All signal processing and readout devices. 15) All pressure and temperature gauges 4. Report Requirements: A VA compliant test report will contain certification on the first page following the report cover page that includes the technicians name, signature, date and the name of the company performing the testing. Provide complete written report of the inspection fully describing all tests performed, all findings, and recommendations. The report shall have two sections. The first section will be in a table form that has four columns: a. The first column labeled FUNCTION did the device pass or fail. b. The second column labeled Device list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition. c. The third column labeled Deficiencies-Recommendations d. The fourth column labeled corrective actions list any corrective actions taken during the inspection. The second section shall be in paragraph/bulleted form and list each device individual in accordance to the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition. In addition, the section must reference the correct Master Specification and Standard Detail for that device. 5.1. Condensate Storage Tank and Deaerator Tank. A. High Water Alarm Purpose: High water level may be an indication of condensate transfer pump failure that could lead to low water condition in the feedwater deaerator and in the boilers. There may be a failure of make-up water controls. Recommended set point: 4 inches below overflow level and 2/3 of tank height or as described in Safety Device Testing Manual, Fifth Edition. Potential hazards due to failure of high-water alarm: Feedwater deaerator running dry and, consequently, boiler feed pumps running dry will cause overheating and damage to pumps and potential for plant shut down. Failure of make-up water controls (in open position) could lead to significant cost from waste of water and condensate from the tank overflow if this occurs over a long period. Recommended type of device: Conductivity probe type switch. Float type switches have high failure rate in this application where they are exposed to flash steam that causes seals to harden and prevent float movement. Comments: Float type switches are not allowed for high water alarms. The VA recommended switch type is a conductivity probe type switch. Install the VA recommended switch and set to alarm at 2/3 of the tank height. There are valves that can isolate this alarm. These valves must be made lockable only in the operating position. B. Furnish report within one week of each facility inspection in Microsoft Word format by email to the COR and to the VA Headquarters office designated. Provide hard copies of data sheets and flue gas analyzer strip printouts to the COR within one week of visit. C. All safety-related deficiencies shall be immediately reported to the COR, Boiler Plant Supervisor and/or Chief Engineer during the inspection visit. Reference: VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition APPENDIX B. ADDITIONAL SAFETY DEVICE TEST PROCEDURES FOR HOT WATER BOILERS Appendix B.1 INTRODUCTION Appendix B presents step by step test procedures for safety devices that are specific to hot water boilers. The appendix provides forms for obtaining and recording all necessary data for each safety device being tested. This Appendix is a supplement to Appendix A to be used in testing a hot water boiler. The basic information required in section A.3.3 and certification required in section A.3.4 must be included in the report of safety testing for a hot water boiler in order for the report to be VA compliant. The assumptions for the test procedures given in this Appendix are first listed. This information is then followed by one sheet for each device being tested to be used by the testing agency personnel as a check list and data form. These procedures must be made site specific to be in compliance with VA requirements. It is very important that all data required in these procedures are taken each time a test is made. Forms that contain pre-filled data lead to mistakes. Also, it is important not to use a check list form because a reviewer cannot verify that the test has been done correctly due to absence of data. Appendix B.2. ASSUMPTIONS FOR TEST PROCEDURE The test procedures in Appendix B makes certain assumptions that are listed below. PLEASE NOTE THAT THESE ITEMS ARE NOT ALWAYS REPEATED IN EACH TEST PROCEDURE BUT APPLY TO ALL TESTS. After each test, equipment should be returned to normal operating condition and the boiler should be fired to confirm its operability. Jumping means disabling the switch electrically. Any electric jumper application requires that all power to the device being jumped be shut off and only personnel that are trained and qualified to the correct level by NFPA 70E perform such tests. Pressure gages used in a test must be calibrated within prior 6 months. The set point is the value at which the safety device indicator is set. The trip point is the actual value at which the safety device activates. Some language used in the test procedures assumes that the set point equals the trip point. TEST PROCEDURES TO BE PERFORMED AS PER APPENDIX B.2 AND APPENDIX C. CONTAINED WITHIN SAFETY DEVICE TESTING MANUAL 5TH EDITION ATTACHMENT A.1 Boiler and Supporting Equipment Inventory Boiler Plant at Building 4. Quantity 4 Boiler #1 OEM HURST FIRE TUBE; Model # S5 X 350 200, POWER FLAME DUEL FUEL CMAX BURNER; MOD. LNICM10-GO-30 NG; 2,216 14,700 MBH #2 FO; 19.8 105 GPH Boiler #2 OEM INDECK WATER TUBE; Model # D1 20 R FABER DUEL FUEL; MOD. WB-1-16-IFGR NG; 24,590 SCFH #2 FO; 171 GPH Boiler #3 OEM INDECK WATER TUBE; Model # D1 20 R FABER DUEL FUEL; MOD. WB-1-16-IFGR NG; 24,590 SCFH #2 FO; 171 GPH Boiler #4 OEM HURST FIRE TUBE; Model # S5 X 700 200 POWER FLAME DUEL FUEL CMAX BURNER; MOD.LNICM10C-GO-30 NG; 3,460 29,400 MBH #2 FO; 30.8 210 GPH ATTACHMENT A.2 Boiler and Supporting Equipment Inventory Boiler Supporting Equipment at Building 4 Preferred PCCIV programmable logic controls on all four boilers. FIREYE YB110 burner management system on all four boilers. De-aerating Feed Tank Condensate return tank Fuel Oil Transfer pumps Main Feed Pumps Condensate Return Pumps Boilers at Building 2. Quantity 3 AERCO Model: GF-111 LN Fire Tube 1,000,000 BTU 15 PSIG Boilers at Building 56. Quantity 3 Lochinvar Model: FBN1001 Fire Tube 1,000,000 BTU 30 PSIG DEPARTMENT OF VETERANS AFFAIRS BOILER SAFETY DEVICES - OPERATION CHECK LIST HOSPITAL_________________________PROJECT NO. _______________DATE_________BOILER NO. ________________ BOILER MAKE AND MODEL ____________________________________________________________________________ BURNER MAKE AND MODEL ____________________________________________________________________________ TECHNICIAN AND COMPANY ____________________________________________________________________________ VA REPRESENTATIVE ____________________________________________________________________________ Not Item OK OK Set Point - Remarks Low Water Cutoff [ ] [ ] _____________________________________________ Aux. Low Water Cutoff [ ] [ ] _____________________________________________ High Water Alarm [ ] [ ] _____________________________________________ Low Water Alarm [ ] [ ] _____________________________________________ Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________ Aux. Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________ High Steam Press. Cutout - Recycle [ ] [ ] _____________________________________________ High Steam Press. Cutout - Non-Recycle [ ] [ ] _____________________________________________ Steam Safety Valve No. 1 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 2 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 3 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 4 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Main Gas High Pressure Cutoff [ ] [ ] _____________________________________________ Low Pressure Cutoff [ ] [ ] _____________________________________________ Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Oil High Pressure Cutoff [ ] [ ] _____________________________________________ Low Pressure Cutoff [ ] [ ] _____________________________________________ High Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________ Low Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________ Low Atomizing Pressure [ ] [ ] _____________________________________________ Low Atomizing/Oil Differential Pressure [ ] [ ] _____________________________________________ Oil Burner Position Switch [ ] [ ] _____________________________________________ Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Cold Start/Steam Atomizing Burners [ ] [ ] _____________________________________________ LP Gas Ignitor Operation [ ] [ ] _____________________________________________ Ignitor (Pilot) Low Gas Pressure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Forced Draft Motor Interlock [ ] [ ] _____________________________________________ F. D. Damper Open Wide for Purge [ ] [ ] _____________________________________________ Outlet Damper Open Wide for Purge [ ] [ ] _____________________________________________ Purge Air Flow Interlock [ ] [ ] _____________________________________________ Purge Timing [ ] [ ] _____________________________________________ Ignition Timing [ ] [ ] _____________________________________________ Low Fire Position Interlock [ ] [ ] _____________________________________________ Combustion Air Flow Interlock [ ] [ ] _____________________________________________ Main Flame Out - Time to Close Valves [ ] [ ] _____________________________________________ Ignition Flame Out - Time to Close Valves [ ] [ ] _____________________________________________ Minimum Ignitor Flame Test [ ] [ ] _____________________________________________ Scanner Not Sensing Ignition Spark [ ] [ ] _____________________________________________ Control Air Pressure Interlock [ ] [ ] _____________________________________________ Sound Level - High Fire [ ] [ ] _____________________________________________ Fan Motor Amps [ ] [ ] _____________________________________________ Low Oxygen Alarm [ ] [ ] _____________________________________________ Boiler Soot Blower Operation and Alignment [ ] [ ] _____________________________________________ Economizer Soot Blower Operation [ ] [ ] _____________________________________________ Flue Gas Recirculation Damper Set for Prepurge [ ] [ ] _____________________________________________ _________________________________ [ ] [ ] _____________________________________________ VACO 183A REQUIRED CERTIFICATIONS FOR EACH SAFETY DEVICE TEST REPORT A VA compliant test report will contain the following certification on the first page following the cover page of the report. I certify that I have properly tested all applicable safety devices listed in this report for Boiler #______and its associated equipment and I certify that all of these tests confirm that every device tested passed as defined by the following question: Did the device fail or pass the 3 question criteria? ___________________ ____________________ ____________ Printed Name Signature Date ___________________ ___________________ Position Title Company OR I certify that I have properly tested all applicable safety devices listed in this report for boiler #______ and its associated equipment and I certify that some of these tests failed as defined by the following question: Did the device fail or pass the 3 question criteria? More details of these failures are given in Appendix F (Comments on each individual test) ___________________ ____________________ ____________ Printed Name Signature Date ___________________ ___________________ Position Title Company Table A.3.1 Basic Information SITE INFORMATION VISN VA Medical Center Location Contact Information Phone Email Evaluators Date BOILER DESCRIPTION Boiler # Manufacturer Model and Capacity Serial #: National Board # Typical Operating Pressure Design Pressure Date of Manufacture BOILER CONTROL DESCRIPTION Manufacturer Model Date of Manufacture BURNER DESCRIPTION Manufacturer Model # Fuels Date of Manufacture
36C25521Q0626 Department of Veterans Affairs Veterans Health Administration Veterans Integrated Service Network 15
9/8/21, 4:13 PM J044--SAFETY TESTING OF ALL BOILER SAFETY DEVICES
Statement of Work Inspection, Safety Device Testing and Calibration Boiler Plant Burners, Controls, Instruments, and Data Management Introduction: A. The Kansas City, VA Medical Center requires the semi-annual services for the inspection, testing and certification of all boiler safety devices on: The four, high pressure steam boilers, in the plant at Building 4. These boilers produce the steam to the Medical Center Main Campus. The six, outlying low-pressure hot water (hydronic) boilers used for heating and domestic hot water at Buildings 2 and 56. The safety device testing is a critical service for the Boilers at the Medical Center, so it is critical that the testing is completed within 14 calendar days of the 6-month pre-scheduled testing date provided by the Medical Center. There may be occasions where the Medical Center may extend the schedule for burners in limited service. Technicians performing the inspections shall be certified and credentialed Boiler Inspectors. . B. Boiler plant safety, reliability, efficiency, and equipment longevity are critical safety and property concerns of the Medical Center. Malfunctioning burners or controls can cause catastrophic events resulting in injuries and death and massive property damage. Inaccurate or inadequate data management and monitoring systems can fail to warn of unsafe or inefficient performance. Regular inspections, testing, and calibration by expert technicians are an essential part of a program to address these concerns. C. This Statement of Work describes the requirements for the inspection, testing and calibration of the boiler plant burners, burner management system, controls, instruments, gauges and transmitters by qualified technicians. This will include the 3 Hydronic Boilers at Building 2 and the 3 Hydronic Boilers at Building 56. Objective: The services we require are for semi-annual preventative maintenance services that includes the testing, inspection and certification for all the Boilers in the 3 buildings of the Medical Center s main campus. Key Deliverables: Inspection of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices Testing of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices Calibration of 4 High Pressure Steam and 6 Hydronic Boiler Safety Devices Inspection, Testing and Calibration Report, Including Certifications. Contractor will provide all tools, materials, labor, supervision and all specialized testing equipment needed to perform semi-annual testing, inspection and calibration on all boiler safety devices, Boiler Plant Burners, Controls, Instruments, and Data Management System. D. Attachment A shows the equipment inventory and includes the Boiler information along with the primary supporting equipment that is included in this contract. E. Appendix B, covers the inspections of the six, hydronic boilers at Buildings 2 and 56.; F. It is assumed as part of any boiler testing and inspections that whether a hot water boiler or steam boiler that repairs, adjustments or replacement of components may be required at additional cost. G. It is assumed as part of any gauge or transmitter testing and calibrations that whether a hot water boiler or steam boiler system that repairs, adjustments or replacement of components may be required at additional cost. Technician and Test equipment Qualifications: Technicians performing the testing and inspections on all the boilers at the Kansas City, VAMC, shall have completed at least a one-year trade school and have five consecutive documented years of successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the Kansas City VAMC. The Boiler Plant Supervisor at the Kansas City, VAMC, may define and accept equivalent qualifications. The contractor and all individuals working on the Kansas City, VAMC Boilers, shall have taken the OSHA Certified 10-hour construction safety course. B. Technicians shall demonstrate familiarity with and have ready access to the current versions of the following references: NFPA 85, Boiler and Combustion Systems Hazards Code. NFPA 70E VHA Boiler Plant Safety Device Testing Manual, Fifth Edition. VHA Directive 1810(1) Boiler and Boiler Plant Operations C. Technicians shall be equipped with portable electronic flue gas analyzers and all test Instruments and materials necessary for the required tests and calibrations, D. All test equipment must be calibrated and have calibration documentation demonstrating calibration was performed within one month of the site visits. E. The Kansas City, VAMC uses programmable logic controls, the technicians must be proficient in programming the controls and have the appropriate hardware and software for this. 3. Inspection, Testing and Calibration Requirements: A. Technicians shall provide all tools and labor necessary to perform internal inspection, component inspection, tuning, testing, calibrating, and adjustments of duel fuel burners and boiler plant controls as specified below. This shall be done every six months in accordance with a schedule provided by The Kansas City, VAMC. The VA may extend the schedule for burners in limited service. B. Instrumentation, monitoring and data management systems as listed below shall be calibrated every six months. C. Provide at least two weeks notice to the Contracting Officer s Representative (COR) prior to performing the work. Work cannot be scheduled during heavy steam load periods. Only one boiler at a time can be out of service for the inspection, testing and calibration procedures. Work must be conducted when the COR or his/her designate is available on site to monitor the work. D. The Kansas City, VAMC will have the boilers that are to be serviced and or internally inspected, prepared for the technicians upon their scheduled arrival. This includes having the boilers clean of soot and loose scale; fully warmed and at normal steam pressure; steam exhaust silencer system operable; pressure/temperature correction factors provided if available. E. The Kansas City, VAMC will comply with any other requirements of the test personnel that are considered reasonable to the VA and have been presented in writing, to the VA, at least two weeks prior to the scheduled testing. F. The inspections, testing and calibrations shall comply with: 1) The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition. A copy of the Testing Manual is available upon request. 2) Any written recommendations of the equipment manufacturers. 3) The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazards Code including applicable appendices. 4) Burner performance requirements in this document. 5) VHA Directive 1810(1) Boiler and Boiler Plant Operations G. A summary of the work is as follows: 1) Review boiler plant log sheets and alarm and trouble reports. 2) Review records that show combustion performance (flue gas oxygen and carbon monoxide). 3) Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VAMC requirements stated in this contract. 4) Test and record the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Verify that the set points and operating points are within approximately 10% of normal operating parameters. Adjust or repair/replace as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation. 5) Operate burner(s) on each fuel from low fire to high fire and back to low fire with VFD in auto and again with the VFD in bypass in at least six increments and record combustion performance (flue gas oxygen, carbon monoxide, NOx (where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output) at each increment. 6) Compare the combustion performance data with VAMC requirements (see below) and previous readings. If necessary, adjust the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data. 7) Verify accuracy of instrumentation listed below. Verify that all devices are properly selected for the application in terms of type, size, set point range, performance, code approval. Calibrate all instruments that are not within manufacturer s specifications for accuracy. 8) Immediately inform COR of any recommended repairs or modifications. H. A list of all interlocks and safety devices to be inspected and tested on each boiler/burner/equipment, are contained in the VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition, along with testing procedures. A copy of the Testing Manual is available upon request. I. Required burner performance with VFD and VFD bypass (natural gas and fuel oil): 1) Turndown (ratio of maximum and minimum firing rates): 10/1 8/1 5/1 4/1 (Refer to original burner specification). 2) Achieve, but do not exceed, boiler maximum steam flow output rating. Measure fuel input at minimum and maximum firing rates. 3) Maximum carbon monoxide: 200 parts per million (ppm) 4) Maximum NOx: _____ (Refer to original burner specification). 5) Flue gas oxygen: 2.5 4.2% (Up to 5.2% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single-point positioning systems). 6) Flue gas oxygen (low excess air burners): 1.0 2.0% (Up to 2.5% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single point positioning systems). 7) No visible smoke Comply with local emissions regulations. 8) Copies of the applicable emissions regulations must be available in the boiler plant office. 9) Flames shall be stable with no pulsations, shall be retained near burner, no blow-off or flashbacks, no constant flame impingement on refractory or water-walls. J. List of instrumentation and controls to be inspected and calibrated: The Kansas City, VAMC has preferred PCCIV programmable logic controls on all four boilers plus FIREYE YB110 burner management system on all four boilers in the central plant. 1) Steam flow transmitters (all). 2) Steam flow recorders/computer readout. 3) Feed flow transmitters (all). 4) Feed flow recorders/computer readout. 5) Drum level transmitters (all). 6) Drum level recorders/computer. 7) Flue gas oxygen sampling, analyzing and recorder/computer readout. 8) Boiler and economizer stack temperature transmitters and recorder/computer readout. 9) Master steam pressure and combustion controllers. 10) Boiler outlet draft controllers. 11) Boiler water level controllers. 12) Feedwater deaerator and condensate storage tank water level controllers including overflow. 13) All pressure and temperature sensors and transmitters. 14) All signal processing and readout devices. 15) All pressure and temperature gauges 4. Report Requirements: A VA compliant test report will contain certification on the first page following the report cover page that includes the technicians name, signature, date and the name of the company performing the testing. Provide complete written report of the inspection fully describing all tests performed, all findings, and recommendations. The report shall have two sections. The first section will be in a table form that has four columns: a. The first column labeled FUNCTION did the device pass or fail. b. The second column labeled Device list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition. c. The third column labeled Deficiencies-Recommendations d. The fourth column labeled corrective actions list any corrective actions taken during the inspection. The second section shall be in paragraph/bulleted form and list each device individual in accordance to the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition. In addition, the section must reference the correct Master Specification and Standard Detail for that device. 5.1. Condensate Storage Tank and Deaerator Tank. A. High Water Alarm Purpose: High water level may be an indication of condensate transfer pump failure that could lead to low water condition in the feedwater deaerator and in the boilers. There may be a failure of make-up water controls. Recommended set point: 4 inches below overflow level and 2/3 of tank height or as described in Safety Device Testing Manual, Fifth Edition. Potential hazards due to failure of high-water alarm: Feedwater deaerator running dry and, consequently, boiler feed pumps running dry will cause overheating and damage to pumps and potential for plant shut down. Failure of make-up water controls (in open position) could lead to significant cost from waste of water and condensate from the tank overflow if this occurs over a long period. Recommended type of device: Conductivity probe type switch. Float type switches have high failure rate in this application where they are exposed to flash steam that causes seals to harden and prevent float movement. Comments: Float type switches are not allowed for high water alarms. The VA recommended switch type is a conductivity probe type switch. Install the VA recommended switch and set to alarm at 2/3 of the tank height. There are valves that can isolate this alarm. These valves must be made lockable only in the operating position. B. Furnish report within one week of each facility inspection in Microsoft Word format by email to the COR and to the VA Headquarters office designated. Provide hard copies of data sheets and flue gas analyzer strip printouts to the COR within one week of visit. C. All safety-related deficiencies shall be immediately reported to the COR, Boiler Plant Supervisor and/or Chief Engineer during the inspection visit. Reference: VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition APPENDIX B. ADDITIONAL SAFETY DEVICE TEST PROCEDURES FOR HOT WATER BOILERS Appendix B.1 INTRODUCTION Appendix B presents step by step test procedures for safety devices that are specific to hot water boilers. The appendix provides forms for obtaining and recording all necessary data for each safety device being tested. This Appendix is a supplement to Appendix A to be used in testing a hot water boiler. The basic information required in section A.3.3 and certification required in section A.3.4 must be included in the report of safety testing for a hot water boiler in order for the report to be VA compliant. The assumptions for the test procedures given in this Appendix are first listed. This information is then followed by one sheet for each device being tested to be used by the testing agency personnel as a check list and data form. These procedures must be made site specific to be in compliance with VA requirements. It is very important that all data required in these procedures are taken each time a test is made. Forms that contain pre-filled data lead to mistakes. Also, it is important not to use a check list form because a reviewer cannot verify that the test has been done correctly due to absence of data. Appendix B.2. ASSUMPTIONS FOR TEST PROCEDURE The test procedures in Appendix B makes certain assumptions that are listed below. PLEASE NOTE THAT THESE ITEMS ARE NOT ALWAYS REPEATED IN EACH TEST PROCEDURE BUT APPLY TO ALL TESTS. After each test, equipment should be returned to normal operating condition and the boiler should be fired to confirm its operability. Jumping means disabling the switch electrically. Any electric jumper application requires that all power to the device being jumped be shut off and only personnel that are trained and qualified to the correct level by NFPA 70E perform such tests. Pressure gages used in a test must be calibrated within prior 6 months. The set point is the value at which the safety device indicator is set. The trip point is the actual value at which the safety device activates. Some language used in the test procedures assumes that the set point equals the trip point. TEST PROCEDURES TO BE PERFORMED AS PER APPENDIX B.2 AND APPENDIX C. CONTAINED WITHIN SAFETY DEVICE TESTING MANUAL 5TH EDITION ATTACHMENT A.1 Boiler and Supporting Equipment Inventory Boiler Plant at Building 4. Quantity 4 Boiler #1 OEM HURST FIRE TUBE; Model # S5 X 350 200, POWER FLAME DUEL FUEL CMAX BURNER; MOD. LNICM10-GO-30 NG; 2,216 14,700 MBH #2 FO; 19.8 105 GPH Boiler #2 OEM INDECK WATER TUBE; Model # D1 20 R FABER DUEL FUEL; MOD. WB-1-16-IFGR NG; 24,590 SCFH #2 FO; 171 GPH Boiler #3 OEM INDECK WATER TUBE; Model # D1 20 R FABER DUEL FUEL; MOD. WB-1-16-IFGR NG; 24,590 SCFH #2 FO; 171 GPH Boiler #4 OEM HURST FIRE TUBE; Model # S5 X 700 200 POWER FLAME DUEL FUEL CMAX BURNER; MOD.LNICM10C-GO-30 NG; 3,460 29,400 MBH #2 FO; 30.8 210 GPH ATTACHMENT A.2 Boiler and Supporting Equipment Inventory Boiler Supporting Equipment at Building 4 Preferred PCCIV programmable logic controls on all four boilers. FIREYE YB110 burner management system on all four boilers. De-aerating Feed Tank Condensate return tank Fuel Oil Transfer pumps Main Feed Pumps Condensate Return Pumps Boilers at Building 2. Quantity 3 AERCO Model: GF-111 LN Fire Tube 1,000,000 BTU 15 PSIG Boilers at Building 56. Quantity 3 Lochinvar Model: FBN1001 Fire Tube 1,000,000 BTU 30 PSIG DEPARTMENT OF VETERANS AFFAIRS BOILER SAFETY DEVICES - OPERATION CHECK LIST HOSPITAL_________________________PROJECT NO. _______________DATE_________BOILER NO. ________________ BOILER MAKE AND MODEL ____________________________________________________________________________ BURNER MAKE AND MODEL ____________________________________________________________________________ TECHNICIAN AND COMPANY ____________________________________________________________________________ VA REPRESENTATIVE ____________________________________________________________________________ Not Item OK OK Set Point - Remarks Low Water Cutoff [ ] [ ] _____________________________________________ Aux. Low Water Cutoff [ ] [ ] _____________________________________________ High Water Alarm [ ] [ ] _____________________________________________ Low Water Alarm [ ] [ ] _____________________________________________ Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________ Aux. Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________ High Steam Press. Cutout - Recycle [ ] [ ] _____________________________________________ High Steam Press. Cutout - Non-Recycle [ ] [ ] _____________________________________________ Steam Safety Valve No. 1 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 2 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 3 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Steam Safety Valve No. 4 - Pop [ ] [ ] _____________________________________________ Blowdown [ ] [ ] _____________________________________________ Main Gas High Pressure Cutoff [ ] [ ] _____________________________________________ Low Pressure Cutoff [ ] [ ] _____________________________________________ Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Oil High Pressure Cutoff [ ] [ ] _____________________________________________ Low Pressure Cutoff [ ] [ ] _____________________________________________ High Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________ Low Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________ Low Atomizing Pressure [ ] [ ] _____________________________________________ Low Atomizing/Oil Differential Pressure [ ] [ ] _____________________________________________ Oil Burner Position Switch [ ] [ ] _____________________________________________ Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Cold Start/Steam Atomizing Burners [ ] [ ] _____________________________________________ LP Gas Ignitor Operation [ ] [ ] _____________________________________________ Ignitor (Pilot) Low Gas Pressure [ ] [ ] _____________________________________________ Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________ Forced Draft Motor Interlock [ ] [ ] _____________________________________________ F. D. Damper Open Wide for Purge [ ] [ ] _____________________________________________ Outlet Damper Open Wide for Purge [ ] [ ] _____________________________________________ Purge Air Flow Interlock [ ] [ ] _____________________________________________ Purge Timing [ ] [ ] _____________________________________________ Ignition Timing [ ] [ ] _____________________________________________ Low Fire Position Interlock [ ] [ ] _____________________________________________ Combustion Air Flow Interlock [ ] [ ] _____________________________________________ Main Flame Out - Time to Close Valves [ ] [ ] _____________________________________________ Ignition Flame Out - Time to Close Valves [ ] [ ] _____________________________________________ Minimum Ignitor Flame Test [ ] [ ] _____________________________________________ Scanner Not Sensing Ignition Spark [ ] [ ] _____________________________________________ Control Air Pressure Interlock [ ] [ ] _____________________________________________ Sound Level - High Fire [ ] [ ] _____________________________________________ Fan Motor Amps [ ] [ ] _____________________________________________ Low Oxygen Alarm [ ] [ ] _____________________________________________ Boiler Soot Blower Operation and Alignment [ ] [ ] _____________________________________________ Economizer Soot Blower Operation [ ] [ ] _____________________________________________ Flue Gas Recirculation Damper Set for Prepurge [ ] [ ] _____________________________________________ _________________________________ [ ] [ ] _____________________________________________ VACO 183A REQUIRED CERTIFICATIONS FOR EACH SAFETY DEVICE TEST REPORT A VA compliant test report will contain the following certification on the first page following the cover page of the report. I certify that I have properly tested all applicable safety devices listed in this report for Boiler #______and its associated equipment and I certify that all of these tests confirm that every device tested passed as defined by the following question: Did the device fail or pass the 3 question criteria? ___________________ ____________________ ____________ Printed Name Signature Date ___________________ ___________________ Position Title Company OR I certify that I have properly tested all applicable safety devices listed in this report for boiler #______ and its associated equipment and I certify that some of these tests failed as defined by the following question: Did the device fail or pass the 3 question criteria? More details of these failures are given in Appendix F (Comments on each individual test) ___________________ ____________________ ____________ Printed Name Signature Date ___________________ ___________________ Position Title Company Table A.3.1 Basic Information SITE INFORMATION VISN VA Medical Center Location Contact Information Phone Email Evaluators Date BOILER DESCRIPTION Boiler # Manufacturer Model and Capacity Serial #: National Board # Typical Operating Pressure Design Pressure Date of Manufacture BOILER CONTROL DESCRIPTION Manufacturer Model Date of Manufacture BURNER DESCRIPTION Manufacturer Model # Fuels Date of Manufacture
36C25521Q0626 Department of Veterans Affairs Veterans Health Administration Veterans Integrated Service Network 15
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