P09 - Boiler and Presure Vessel Inspections SOW 05082023.pdf

STATEMENT OF WORK

BOILER INSPECTIONS AT LYONS & EAST ORANGE VAMC

General Scope of Work: The VA Medical Center East Orange/Lyons Campus is requesting a National Board of Boiler and Pressure Vessel Certified Boiler Inspector to conduct required yearly inspections for the below. The inspector shall also supply Inspection Certificate's for the

Boilers and Pressure Vessels.

• Five (5) Cleaver Brooks 700 HP Fire Tube Boilers and Pressure Vessel (DA Tank) &

(Storage Tank) as required at the VA Medical Center Lyons, NJ after C&I's [cleaning and inspection] have been completed.

• Four (4) Cleaver Brooks 600 HP Fire Tube Boilers and Pressure Vessel (DA Tank), (Condensate receiver Tank) as required at the VA Medical Center East Orange, NJ after

C&I's [cleaning and inspection] have been completed.

1. Inspection requirements for Boilers shall include:

• Assess the external parts of the boilers and boiler accessories and piping and valves for safety, accessibility, proper maintenance and operation, cleanliness, and compliance with ASME codes.

• Inspect for evidence of leakage of combustion gases or fluids, externally and internally, including all gaskets.

• Inspect foundations for signs of stress such as cracking or movement.

• Inspect boilers externally and internally for defects including bulges, blisters, cracks, wasted or eroded material, warping, general corrosion, grooving and pitting, and damaged insulation.

• Inspect all accessible internal surfaces for waterside and fireside deposits, including scaling, sediment, debris, and carbon deposits.

• Examine all stays and stayed plates.

• Inspect gas side baffles.

• Inspect internal drum surfaces and steam separating internals.

• Inspect tubes, tube ends and tube alignment. Check for sagging tubes.

• Inspect seating surfaces of manways and hand-holes.

• Check for missing items such as bolts and nuts.

• Examine all valve and pipe connections to the pressure vessel.

• Inspect refractory including burner throat, expansion joint, bull ring, furnace seals, furnace walls and floor.

• Verify proper alignment of burner assembly.

• Inspect furnace for evidence of flame impingement.

• Test operation of water level gage glass.

• Perform mechanical and electrical inspection of disassembled low water cutouts. After reinstallation test operation. Test low water cutouts on hot boilers by lowering water level gradually.

• Verify that Boiler steam pressure gage is properly calibrated.

• Test operation of Boiler high steam pressure cutouts on hot boilers by raising steam pressure.

• Inspect safety valve installations and verify that the valves have proper capacity and set pressure, and valves, drains, and vents are properly installed. Verify that valve locking seals are not broken. On boilers that are hot, perform an operation test under pressure to confirm operation at proper set pressures. Operate boiler with burner at high fire to verify adequate steam flow capacity of the safety valves ("accumulation test").

• Inspect piping to the water column, low water cutoffs and alarms, and gage glass. Verify that interior of piping is clear of obstructions.

• Verify that all nozzles of internal piping such as feed water admission and bottom blowoff collection are clear with no obstructions.

• Inspect valves on Boilers, Feed water, Blowdown, Drains and Steam Systems.

2. Technician Qualifications:

Qualified Professional Inspector (QPI).

A. QPI is any one or combination of the following:

1 . A boiler inspector who has a valid and current certificate from the National Board of Boiler and Pressure Vessel Inspectors.

2. A boiler inspector who has qualified for licensure by passing a written examination under the laws, rules, and regulations of a jurisdiction of the State and holds a current State license.

3. A boiler inspector who is currently employed as a boiler inspector/testing by a jurisdiction that has adopted and administers one or more sections of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code as a legal requirement, and has a representative serving as a member of the ASME Conference Committee; or

4. A boiler inspector who is currently employed by an insurance company that has been licensed or registered by the appropriate authority of a State to write boiler and pressure vessel insurance.

B. Technicians shall demonstrate familiarity with and ready access to the current versions of the following references:

1. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, latest edition.

2. National Fire Protection Association (NFPA) 85 Boiler and Combustion Systems Hazards Code, latest edition.

3. VHA Boiler Plant Safety Device Testing Manual, latest edition; and

4. NFPA 70E Standard for electrical safety in the workplace, latest edition.

C. Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests.

3. Inspection Requirements:

A. Technicians shall provide all tools and labor necessary to perform inspection for all specified equipment under this Statement of Work.

B. Contractor shall provide at least two days' notice to the designated VA COR prior to performing the Inspections. Only one boiler at a time can be out of service for the inspection, and testing.

4. Reports:

Contractor shall provide a 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 with four columns:

1. The first column labeled "FUNCTION" did the device pass or fail.

2. The second column labeled "Device" list the device number and description in accordance with the VI-IA Boiler Plant Safety Devices Testing Manual, 2017.

3. The third labeled "Deficiencies-Recommendations"

4. The fourth column labeled "corrective actions" list any corrective actions taken or recommended because of the inspection.

The next section shall be in paragraph/bulleted form and list each device individual in accordance with the VHA Boiler Plant Safety Devices Testing Manual, 2017, plus the section must reference the correct Master Specification and Standard Detail for that device. See sample below.

Condensate Storage Tank 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 feed water 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.

Potential hazards due to failure of high-water alarm: Feed water 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 i f 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.

VA Master Specification section: 23 50 1 1 (old 15625).

https://www.cfin.va.gov/til/spec.asp#23

VA Standard Detail: SD2321 1 1-05.pdfhttps:/Avww.cfm.va.gov/til/sDetail.asp

Failure rate of float types: 48% (BEI study of VA boiler plants).

Make and Model: Mercoid Float

Did it function properly: No Category & Action Time Limit: Upon Failure or Within 5 Years 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.

5. Performance Monitoring:

Performance monitoring shall be conducted by the designated VA POC in accordance with all described inspections steps by this Statement of Work, all applicable regulations, and the guidance indicated by VHA Directive 1810 Appendix B (Inspection and Testing for Boiler Plant Operations). No invoices shall be pay until final acceptance in accordance with procedures listed above occurs.

6. Period of Performance:

Annual boiler inspections starting May 1st, 2023, with 4 option years.

Vendor shall commence work within 15 days from notice to proceed by each individual facility.

7. Place of Performance:

VA Medical Center Lyons Campus 151 Knollcroft Road Lyons, New Jersey 07035

VA Medical Center East Orange Campus 385 Tremont Avenue East Orange, New Jersey 07018

8. Type of Contract:

Firm Fixed Price (FFP) with 4 option years.