Attachment 1 BEI testing report.pdf

Reference Test point Recommendations Correction needed Solution Is ILSM req'd yes/no

4.1 Condensate Storage Tank High Water Alarm

4 inches below overflow level and 2/3 of tank height.

Fail Installation- Valves (Upper) that can isolate column are not lockable only open. Device activated at 2/3 of tank height.

Lock valve in the open position, adjust controls no

4.2 Condensate Storage Tank Low Water Alarm

Recommended set point: Approx. 1/3 of tank height.

Fail Installation/setpoint- Valves that can isolate column are not lockable only in open position.

Lock valve in the open position.

Darren to calibrate Warrick controls no

4.3 Feedwater Deaerator High Water Alarm

Recommended set point: 4 inches below overflow level and 2/3 of tank height.

Fail installation/setpoint- Isolation valves in column are not lockable only open.

BP to calibrate controls and lock valve open no

4.4 Feedwater Deaerator Low Water Alarm Recommended set point: Approx. 1/3 of tank height..

Fail installation – Valves that can isolate column are not lockable only in open position

BP to calibrate controls and lock valve open no

4.5

Feedwater Deaerator overflow system Recommended set point: This level should be at least 4” below the top of the tank.

Fail installation/setpoint- Setpoint same as high alarm. capacity ok.

Valve in drain line is not lockable only in open position and locked.

(Locked open but not lockable only open). Valves in the water column containing probe are not lockable only open.

Darren to calibrate Warrick controls .

Remove valve and add spool piece no

4.6 Feedwater Deaerator Steam Safety Valve

Recommended set point and capacity: 10 psig. Fail installation- No bypass in place to test safety valve. NDT overdue under contract already to be done.

Waiting for start date . BP to replace bypass valve no

4.7 Safety Valve following a Steam PRV Station

Recommended type of device: ASME and National Board-rated steam safety valve. Fail installation- No bypass valve in place to test safety valve. On order completed in house no

4.8

Boiler Plant Building Combustible and Carbon Monoxide Monitor

Fail Installation-There are 6 combustible sensors and 6 Carbon monoxide sensors. Carbon monoxide sensors alert at 20 ppm.

Combustible sensors are mounted at floor level below carbon monoxide sensors. These sensors must be mounted at ceiling level to be effective.

Install remote test gas system to permit testing from mezzanine level and/or floor level. There is no carbon monoxide sensors at mezzanine level in boiler area. No CO sensor in control room.

Purchase 2 new monitors and install in overhead. Add monitors to mexinine level and control booth Electric shop to install. BP to purchase no

4.11

Oil Liquid Relief Valve – Pump Set Approx. 10 psi above setpoint of back pressure regulator.

Fail installation – Valves are not plumbed for testing. There is no pressure gage at relief valve location or test port. The system does not utilize a back pressure regulator. There is no visual flow indication.

Need to review BEI drawings and add sightglass, gauges, loop controller valve and flow indicator by BP no

4.12 Control Air Pressure Alarm

Fail installation- Device is located upstream of all control regulators.

VA requires alarm to be downstream of any final control regulator.

Add pressure switch to sound audible alarm‐ BP no

4.14

High Fuel Gas Pressure Alarm on Main Gas Line

Comments: Fail installation / setpoint- Isolation valve is not lockable only open and no annunciation of failure. Shut main natural gas automatic shutoff valve. Regulated gas pressure is 10 psig. Device activated at 15 psig. Device must be set to activate no higher than 120% of regulated pressure.

Reset switch to 12psig, and add audible alarm on ALC or remote alarm Lock valve open, adjust pressure switch by BP no

5.1

Low Water Cutoff (LWCO)

As required by boiler manufacturer. Located at least 1” below the low water cutoff (LWCO) setpoint. Water must be visible in gage glass at the setpoint.

Fail Installation- No independent comment section. Probe cutout activated with 6 inches of water in the sight glass. Boiler shutdown and locked out properly. Darren to follow up with ACS. Adjust setpoint and modify probe no

5.1.2 Auxiliary Low Water Cutoff (ALWCO) Recommended setpoint: At least 1” above the primary low water cutoff (LWCO).

Fail Installation- No independent shunt installed. Probe cutout activated with approx. 4.5 in of water in the sight glass. Boiler shut down and locked out properly WO into electric shop no

BEI BOILER SAFETY TESTING REVIEW

5.2.1

Steam Safety Valves (SV) ASME/NB certified steam safety valves rated for power boiler (ASME Section I) service.

Fail Installation -SV1 – 149 psig lift and reseat at 142 psig. SV2 lifted at 150 and reseated at 145 psig. Max pressure 150 psig. Vents adequate.

Valve is cast iron construction. Cast iron is not allowed in systems exposed to 15 psig steam or greater. Valves must be cast steel per VA master specification and design alert. Need 8 new valves at $4000.00 each. no

5.2.2 High Steam Pressure Limit Switch Recommended setpoint: Approximately 10 psig above normal steam header pressure.

Fail Logic- Switch Recycles. Switch activated at 133 psig. Normal steam pressure is 112 psig. SV 1 is set at 145 psig.. BP to adjust switch to 130 PSI no

5.2.3 High High Steam Pressure Limit Switch

Approximately 5 psig above set point of high pressure switch. 5 psig below lowest set point of boiler safety valves.

Fail Logic and Setpoint- High-High cutout activated at 137 psig and is a manual reset switch, but not manual reset at the BMS. Setpoint too close to High Boiler Steam Pressure Limit Switch. BP to adjust switch to 135 PSI no

5.3.1

Low Pressure Gas Fuel Cutoff Switch

(LPFCS)

Fail Installation- No isolation valve in place. Plumb per 7th edition and add isolation valve lockable only in open position. Setpoint and logic is

ok. Activated at 6 psig. WO into plumbing shop no

5.3.6 Automatic Pilot Gas Shutoff Valves – Leak Test

Fail Installation- No Test port between asco valves. Add test port per 7th edition WO into plumbing shop no

5.3.7

Pilot Gas Train Solenoid Vent Valve – Operation and Leak Test

Fail installation- No leaks, open when boiler is offline. Manual valve downstream of vent valve must be lockable only in open position. Lock valve open no

5.4.2

High Pressure Oil Fuel Cutoff Switch

(HPFCS)

Fail logic -Installation, Setpoint. Annunciation is low oil pressure.

Improper annunciation. Darren to contact ACS contract no

5.4.3

Low Oil Atomizing Media Pressure Switch

(LAMPS)

Per burner manufacturer’s recommendations and above the pressure at which the flame becomes unstable or smoky. The set point must not be lower than 80% of the minimum typical atomizing pressure.

Fail installation/setpoint- Switch is plumbed downstream of differential pressure regulator. VA requires switch to be upstream of differential pressure regulator and be set at 80% of regulated atomizing media pressure.

WO into plumbing shop no

5.4.7

Burner Position Switch Mechanical contact arm that is actuated by presence of oil gun in proper position.

Fail logic- Switch prevents atomizing solenoid from receiving power and opening causing the boiler to trip on low atomizing media pressure.

Switch must be wired into L1-3 circuit to prevent boiler from starting purge. Contract no

5.5.6 Low-Fire Proving Switches Recommended setpoint: Within 5% of the low fire position.

Fail Setpoint Air – (Gas SP 8%, Air SP >20%, Oil SP-6%. Mechanical OK on all three.) Air setpoint is too high. Circuit is good on all three. Contract to tune boilers no

5.5.8

Combustion Air Pressure Switch Recommended setpoint: 80% of the minimum pressure differential.

Fail installation/setpoint – Plumbed fan out to atmosphere. Must be plumbed across fan inlet to outlet between any dampers. No lockable only open isolation valve in place for testing. Add valve. Add low pressure leg. Setpoint too low. Fan turndown to 19 hz not allowing CAPS switch to be properly set. Fan turndown is too low. Minimum delta P is around 1 inch wc which is less than the 35% allowable. Fan turndown must be set such that minimum delta P is 43% of the maximum delta P. This will equate to a minimum speed of approx.

Darren to talk with ACS for solution to tune boiler no

5.5.9

Pre-Purge Airflow Proving Switch Must achieve at least 70% of required airflow at maximum capacity of burner. Recommend that switch be set at 80% of maximum delta P.

Fail installation – No lockable only open isolation valve is installed.

Install valve to facilitate testing. Setpoint is too low. Increase PAPS setpoint to within 80% of maximum delta P at purge. Circuit is Good. Contractor tune no

5.5.11 Minimum Pilot Flame Test and Low Pilot Gas Pressure Switch

Fail logic- Switch is wired in series with power to pilot valves. Must be in 3-P running interlock. Switches activates at proper setpoint. Contractor no

5.5.12

Low Flue Gas Oxygen Alarm and Cutout Approximately one percentage point below the lowest normal flue gas O2 for normal burner operation and no more than 200ppm CO or combustibles in the fluegas

Fail installation/logic- No provision for testing. No test gas. No tuning data. No way to access air fuel controller to decrease air damper position. Setpoint is set at 1%. No effect on system when circuit was checked. Unclear if boiler is actually getting O2 signal from hays Cleveland box or from preferred pcc 3. Contract to ACS no

5.5.13 Liquid Relief Valve on Economizer

Not able to be tested. Valves leaked by and no hydro pump Has test port where test can be done already with nitrogen in house no

5.5.15

Boiler Outlet (Stack) Damper Interlock

: Damper must be wide open. The exception is boiler outlet or furnace draft control systems that modulate the outlet damper to control the stack draft. Damper is proven wide open for pre-purge and then is placed under the control of the draft control system for normal boiler operation.

Fail logic- Switch has no effect on control circuit. Wire switch into D-8 if damper modulates. If no modulation wire damper into 3-P. Damper currently does not move, stays in wide open position continually but is not mechanically constrained.

Contractor troubleshooting no