A04-Revised_Boiler_Repair_SOW_Mariano_Lake_Community_School_UPDATED_0002.docx

New Mexico Navajo Central Facility Management Agency Mariano Lake Community School Scope of Work (SOW)Project Title: Repair and Modernization of Two Iron Fireman Boilers – Building #414 Project Location:

Mariano Lake Community School Navajo Route 49 Crownpoint, NM 87313

1. Purpose The purpose of this Scope of Work (SOW) is to obtain the services of a qualified boiler contractor to inspect, repair, modernize, test, and place into reliable operation two existing Iron Fireman boilers located in the boiler room of Building #414.

The primary objective is to restore both boilers to safe and reliable operating condition and establish a lead/lag operating configuration so either boiler can serve as the primary heating boiler while the second boiler remains available as backup and can automatically operate when additional heating capacity is required or the lead boiler is unavailable.

This SOW is intended to describe the existing conditions, required performance, and desired outcome. Except where specifically stated as a requirement, the Contractor shall be responsible for evaluating the existing equipment and determining the appropriate repair components, burner sizing, controls, programming, fuel delivery requirements, and installation methods necessary to achieve the required performance.

2. Existing Equipment There are two existing Iron Fireman/Dunham-Bush boilers located in the boiler room of Building #414. The boilers provide heating service to campus facilities, including the dormitory and main school building.

Based upon the equipment identification information available at the site, the boilers include the following characteristics:

· Manufacturer: Iron Fireman / Dunham-Bush, Inc.

· Model: 501A-L-50-15

· Rated Output: 1,673 MBH

· Rated Horsepower: 50 HP

· Heating Surface: 253 square feet

· Minimum Valve Capacity: 2,024 lbs./hr.

· Maximum Working Pressure – Steam: 15 PSI

· Maximum Working Pressure – Water: 30 PSI

· ASME construction

· National Board No.: 9370

· Year Built/Stamped: 1984/1985 era

· Existing burner equipment: Iron Fireman/Dunham-Bush

· Existing burner model: HP-2-2.0L

· Existing burner electrical service: 230 volts, 60 Hz, single phase

· Existing fuel: Oil/diesel

· Existing burner motor: approximately 7.5 amps at 230 volts

· Existing burner arrangement includes No. 2 oil capability.

The Contractor shall independently field verify all equipment information, dimensions, electrical characteristics, fuel requirements, capacities, piping arrangements, and existing conditions before ordering equipment or beginning work. The information above is provided for reference and shall not relieve the Contractor of responsibility for field verification.

3. Existing Conditions At present:

1. Boiler #2 is operational and is currently the only boiler available to provide heat during the winter heating season.

2. Boiler #1 is out of service and partially disassembled and is not currently available as a backup heating source.

3. The existing burners and associated burner controls are aged and require replacement.

4. The control systems associated with the two boilers are outdated and are not standardized between the two units.

5. The boilers were originally integrated into an air/pneumatic control system that controlled heating to the dormitory and main school building.

6. The air compressor previously used to operate pneumatic dampers and vents based upon temperature demand is no longer functional.

7. The existing configuration does not provide the desired reliable lead/lag operation between Boiler #1 and Boiler #2.

8. The campus is therefore dependent primarily upon one operational boiler during winter conditions, creating a significant loss-of-heat risk if Boiler #2 experiences a mechanical or control failure.

4. Required Contractor Assessment Prior to performing repairs, the Contractor shall conduct a complete field assessment of both boiler systems and associated equipment necessary for successful operation.

At a minimum, the assessment shall include:

· Boiler pressure vessels and accessible fireside surfaces;

· Existing burners and burner mounting arrangements;

· Combustion chambers and refractory condition;

· Fuel oil/diesel piping and associated components;

· Fuel pumps, strainers, valves, regulators, and safety devices;

· Combustion air requirements;

· Breeching, flue, and draft conditions;

· Electrical power serving each boiler and burner;

· Existing boiler operating and safety controls;

· Existing temperature and/or pressure controls;

· Low-water cutoff and other boiler safety devices, as applicable;

· Existing control panels and associated wiring;

· Existing pneumatic controls that affect boiler or heating system operation;

· Pumps, valves, dampers, actuators, and other components necessary for proper boiler sequencing;

· Boiler #1 components currently disassembled or removed; and

· Any additional deficiencies that would prevent either boiler from safely and reliably operating.

The Contractor shall notify the Government/Owner of any condition discovered that requires work beyond this SOW before performing additional work.

5. Burner Replacement The Contractor shall remove and replace the existing burner assembly on each boiler.

A total of two (2) new commercial/industrial oil-fired burner systems shall be provided and installed.

The new burners shall:

· Be appropriately sized and listed for use with the existing boilers;

· Be suitable for No. 2 fuel oil/diesel, based upon the existing fuel system;

· Be compatible with the existing boiler pressure vessel and combustion chamber;

· Provide appropriate firing capacity for the boiler's rated output;

· Include new burner motors, ignition components, flame safeguard equipment, fuel controls, and required safety devices;

· Incorporate efficient burner nozzles appropriate for the required firing rate;

· Provide proper atomization and air-to-fuel mixture throughout the operating range;

· Include all required oil pumps, solenoid valves, regulators, strainers, flexible connections, gauges, and associated accessories necessary for a complete installation;

· Include adjustable combustion air controls;

· Provide reliable ignition and flame supervision;

· Automatically shut down and lock out upon unsafe flame or operating conditions;

· Be UL-listed or otherwise appropriately listed for the intended application; and

· Meet applicable NFPA, ASME, manufacturer, and authority-having-jurisdiction requirements.

Final burner manufacturer, model, firing rate, nozzle configuration, and required accessories shall be determined by the Contractor based upon field conditions and the existing boiler requirements.

6. Boiler #1 Restoration Boiler #1 is currently out of service and partially disassembled.

The Contractor shall inspect Boiler #1 and restore the unit to complete operating condition. Work shall include:

· Inventorying existing and removed components;

· Reassembling boiler components as necessary;

· Replacing missing, damaged, deteriorated, or non-serviceable components necessary for operation;

· Inspecting accessible internal and external boiler surfaces;

· Inspecting refractory, insulation, seals, gaskets, access doors, and combustion chamber components;

· Repairing or replacing deficient components necessary for safe operation;

· Installing the new burner and associated controls;

· Verifying fuel, electrical, control, and heating-system connections;

· Performing required leak and operational testing; and

· Returning Boiler #1 to safe, fully functional service.

Any pressure-vessel repair requiring welding or other code-regulated work shall be performed only by appropriately qualified personnel and in accordance with applicable ASME/National Board and jurisdictional requirements.

7. Boiler #2 Modernization Boiler #2 is currently operational and serves as the primary source of campus heat.

The Contractor shall coordinate shutdown of Boiler #2 with the Government/Owner to minimize disruption to campus heating operations.

Work on Boiler #2 shall include:

· Removal of the existing burner;

· Installation of the new burner system;

· Replacement or modernization of burner controls as necessary;

· Verification of existing boiler safety controls;

· Correction of deficiencies necessary for safe operation;

· Integration into the new lead/lag control system; and

· Complete startup, testing, and combustion adjustment.

8. Lead/Lag Control System The Contractor shall furnish and install a new common lead/lag boiler control system capable of coordinating operation of both boilers.

The control system shall provide, at minimum:

· Automatic lead/lag sequencing between Boiler #1 and Boiler #2;

· Automatic initiation of the lag boiler when heating demand exceeds the capability of the lead boiler;

· Ability for the remaining boiler to operate when one boiler is unavailable or placed out of service;

· Manual selection or override of lead and lag designation;

· Automatic alternation of lead boiler operation where appropriate to balance equipment runtime;

· Individual boiler enable/disable capability;

· Status indication for each boiler;

· Burner run indication;

· Failure/alarm indication;

· Appropriate temperature and/or pressure sensing;

· Required interlocks and safety shutdowns; and

· Controls necessary to prevent unsafe simultaneous or improper boiler operation.

The new control system shall use compatible components and provide a standardized control strategy for both boilers.

9. Existing Pneumatic Control System The original heating system utilized pneumatic controls to operate dampers, vents, and other heating-system components based upon temperature demand. The air compressor serving this system is no longer functional.

The Contractor shall evaluate the existing pneumatic system and identify those components that are necessary for proper operation of the boiler/heating system.

The Contractor shall recommend and implement, upon Government/Owner approval, the appropriate method to provide reliable control. The solution may include repair/replacement of essential pneumatic equipment or conversion of necessary boiler-related controls to modern electronic/direct-acting controls.

The Contractor shall not assume that restoration of the entire legacy pneumatic building-control system is required unless necessary to achieve reliable operation of the boilers and heating system.

10. Combustion Setup and Efficiency After installation, each burner shall be individually commissioned using calibrated combustion-analysis equipment.

The Contractor shall:

· Establish the correct firing rate;

· Install appropriately sized fuel nozzles;

· Adjust fuel pressure;

· Adjust combustion air;

· Verify draft conditions;

· Establish proper fuel-to-air mixture;

· Verify reliable ignition;

· Test flame safeguard operation;

· Measure oxygen (O₂);

· Measure carbon monoxide (CO);

· Measure carbon dioxide (CO₂), as applicable;

· Measure stack/flue temperature;

· Determine combustion efficiency; and

· Verify operation throughout the required firing sequence.

The Contractor shall provide a printed or electronic combustion analysis report for each boiler documenting final operating conditions.

Visible smoke, excessive soot production, unstable flame, excessive carbon monoxide, improper draft, or other evidence of incomplete combustion shall not be considered acceptable.

11. Safety Controls and Interlocks The Contractor shall inspect and functionally test all boiler and burner safety devices applicable to the installation.

This shall include, as applicable:

· Flame safeguard;

· Low-water cutoff;

· High-limit controls;

· Operating limit controls;

· Fuel safety shutoff valves;

· Fuel pressure switches;

· Combustion air proving;

· Draft proving;

· Burner interlocks;

· Emergency shutdown;

· Pressure controls;

· Temperature controls; and

· Other manufacturer-required safety devices.

Defective safety controls necessary for proper operation shall be replaced with compatible listed components.

No safety device shall be bypassed, defeated, or permanently jumpered to achieve boiler operation.

12. Electrical and Control Work The Contractor shall provide all electrical and control work necessary for a complete and functional installation.

Work shall include:

· Disconnecting obsolete burner controls;

· Providing required wiring for new burners;

· Providing wiring for the lead/lag controller;

· Installing necessary relays, transformers, starters, disconnects, control devices, and protection;

· Properly grounding and bonding equipment;

· Labeling new control wiring and equipment;

· Removing abandoned wiring associated specifically with replaced equipment where practical; and

· Updating control diagrams to reflect the final installation.

Existing electrical service shall be field verified before equipment procurement.

13. Codes and Standards All work shall comply with the current applicable editions of federal, state, local, and industry requirements, including, as applicable:

· Occupational Safety and Health Administration (OSHA) requirements;

· National Fire Protection Association (NFPA) requirements;

· NFPA 31, Standard for the Installation of Oil-Burning Equipment;

· NFPA 70, National Electrical Code;

· ASME Boiler and Pressure Vessel Code;

· National Board Inspection Code, where applicable;

· Manufacturer installation requirements;

· UL listing requirements; and

· Requirements of the Authority Having Jurisdiction (AHJ).

Where conflicts exist, the more stringent applicable requirement shall govern.

14. Testing and Commissioning Upon completion of installation, the Contractor shall perform complete startup and commissioning of both boilers.

Testing shall demonstrate:

1. Boiler #1 can independently start, operate, satisfy heating demand, and safely shut down.

2. Boiler #2 can independently start, operate, satisfy heating demand, and safely shut down.

3. Either boiler can function as the lead boiler.

4. Either boiler can function as the lag/backup boiler.

5. The lag boiler responds appropriately when additional heating capacity is required.

6. The system continues to provide heating capability when one boiler is intentionally disabled.

7. All burner and boiler safety devices function properly.

8. Fuel delivery and combustion remain stable throughout operation.

9. The boilers operate without abnormal smoke, soot, vibration, leakage, flame instability, or nuisance shutdowns.

10. The lead/lag controls and associated heating controls function as designed.

The Government/Owner's representative shall be provided an opportunity to witness final functional testing.

15. Contractor Qualifications The Contractor shall possess demonstrated experience servicing and commissioning commercial/industrial boilers and oil-fired burner systems of similar capacity.

Personnel performing regulated boiler, electrical, fuel-system, or pressure-vessel work shall possess all licenses, certifications, and qualifications required by the applicable jurisdiction.

16. Submittals Prior to installation, the Contractor shall provide:

· Proposed burner manufacturer and model;

· Burner technical data and firing-range information;

· Proposed lead/lag control system information;

· Major control and safety-device information;

· Electrical requirements;

· Proposed sequence of operation; and

· Identification of any significant modifications required to the existing boiler or fuel system.

Equipment shall not be ordered until required submittals have been reviewed and accepted.

17. Closeout Documentation At completion, the Contractor shall provide:

· Manufacturer operation and maintenance manuals;

· Burner startup documentation;

· Combustion analysis report for each boiler;

· Final burner firing rates and nozzle information;

· Final fuel pressure settings;

· Lead/lag controller programming and setpoints;

· Updated electrical/control diagrams;

· Equipment model and serial numbers;

· Warranty documentation;

· Recommended preventive-maintenance schedule;

· Recommended replacement-parts list; and

· Documentation of final testing and commissioning.

18. Training The Contractor shall provide onsite operational training to designated facility maintenance personnel.

Training shall include:

· Normal startup and shutdown;

· Lead/lag operation;

· Changing lead/lag designation;

· Burner operation;

· Controller operation and setpoints;

· Alarm and lockout identification;

· Routine operator inspections;

· Basic troubleshooting;

· Required preventive maintenance; and

· Emergency shutdown procedures.

19. Warranty The Contractor shall warrant labor and installation for a minimum of one year following final acceptance, unless a longer period is provided under the Contractor's standard warranty.

Manufacturer warranties for new burners, controllers, and other equipment shall be transferred to the Government/Owner.

20. Required End State Upon final acceptance, both Iron Fireman boilers shall be complete, operational, and available to provide campus heating service.

The completed system shall provide:

· Two operational boilers;

· Two new properly sized oil/diesel burner systems;

· Modern and compatible burner safety controls;

· Properly adjusted combustion and fuel mixtures;

· Reliable automatic lead/lag sequencing;

· Backup heating capability if either boiler is unavailable;

· Functional safety controls and interlocks;

· Reliable integration with the heating distribution system; and

· Documented testing, commissioning, and operator training.

The overall objective is to eliminate the campus's current dependence on a single operational boiler and restore a reliable, redundant, maintainable, and safely controlled heating system for Building #414 and the facilities served by the boiler plant.

21. Contractor Field Verification Because the existing boilers and associated systems are approximately 40 years old and have undergone previous modifications, a mandatory pre-work field investigation is required. The Contractor shall not rely solely upon this SOW or existing equipment nameplate information for final equipment selection.

The Contractor is responsible for verifying existing conditions and providing a complete, compatible, and code-compliant solution capable of achieving the performance requirements established in this SOW.