Baltimore MD Loch Raven Boiler Assessment Report BEI 2020.pdf

BEI Reviewers:

Chase O’Mary, BEI Engineer

Boiler Efficiency Institute LLC.

Baltimore Loch Raven VA Clinic Baltimore, MD Review Date: October 20-22, 2020

Boiler Assessment

Contents 1 Introduction / Background

2 Boiler Program and Operational Issues / Recommendations

2.1 Boiler Oversite and Data Logging

2.2 Remote Start and Lead Lag Control

2.3 Safety Device Testing / Inspections

2.4 Back Up Fuel Requirements

3 Individual Boiler Assessments

3.1 Boilers Serving Building 1

3.2 Boilers Serving Building 2

3.3 Boilers Serving Building 4

3.4 Boilers Serving Building 5

3.5 Boilers Serving Building 6

3.6 Boilers Serving Building 7

4 Conclusion

1 Introduction / Background VAMC Baltimore commissioned Boiler Efficiency Institute (BEI) to perform an engineering assessment on the eleven hot water boilers serving multiple facilities at the VA Baltimore Loch Raven Clinic. The scope was to assess the hot water units currently in operation at the facility for compliance with ES-2018-001 “Low Pressure Steam and Hot Water Boilers: Design and Operation” and the VHA Safety Device Testing Manual 5th Edition as well as other VA standards and codes. It is important to note that the scope did not include actual safety device testing, only an assessment of the current configuration and condition of the equipment in relation to VA standard. VA standard requires that boiler safety devices be installed properly and perform in a certain manner to be considered fully compliant. Installation only, not performance was assessed during this site visit.

2 Boiler Program and Operational Issues / Recommendations As a part of the assessment BEI investigated the overall Boiler Program currently in place at the VA Loch Raven Clinic (VALRC). VALRC provides many services that include CLC, Long Term Care, Hospice, outpatient care, and administration facilities. VALRC boiler equipment is operated and maintained by five USRO personnel directly managed by a USRO supervisor. The USRO personnel dedicated to Loch Raven work an 8-5 schedule and operate and maintain all facility mechanical equipment during the day. Because the facility provides overnight and long term care, USRO personnel from Baltimore VAMC are responsible for the boiler equipment at night.

2.1 Boiler Oversite and Data Logging

ES-2018-001 requires USRO personnel to visits all boilers and log relevant operational data every four hours. According to facility records, this required parameter logging is consistent during the day but can become intermittent and inconsistent after hours. This required 24 hours oversight must be consistent to be fully compliant with VA directive. All equipment must be visited, and the proper parameters logged every four hours by a qualified boiler operator per ES-2018-001. This may require additional manpower to be acquired.

2.2 Remote Start and Lead Lag Control

ES-2018-001 prohibits the remote starting of boilers and lead lag control schemes. All boilers at the VALRC are automatically enabled remotely by Johnson Controls Metasys and the boilers follow a lead lag control scheme for staging. There are also energy efficiency algorithms in place that stage, start and stop boilers based on different outdoor conditions. As stated, VA Directive 1810 and engineering standard ES-2018-001 prohibit operation in this manner. The VA requires each boiler to be enabled manually by a qualified operator local to the boiler, and also be staged locally by a qualified operator. In practice, this means a qualified operator must physically start boilers by turning the boiler on with the local control in the boiler room. This required operational strategy will require 24/7 attendance so that an operator will be available to start and stop boilers anytime it is needed. Additional manpower will likely be needed to comply with this operational directive.

2.3 Safety Device Testing / Inspections

VA Directive 1810 and ES-2018-001 require safety device testing to be performed on a monthly and semiannual basis for certain devices as given in the aforementioned documents. Currently there is no safety device testing program in place. Per site personnel, a contract has been awarded to implement this program. Safety device testing is a key to a complaint boiler program and extensive oversight will likely be required for proper implementation. A proper safety device testing program must also keep proper documentation. It is the recommendation of BEI that site personnel and/or contractor complete and file the test sheets for each test given in the VHA Safety Device Testing Manual 5th Edition. This documentation must be accurate and kept onsite for at least 3 years. Per ES-2018-001, site specific testing procedures for each device to be tested on all equipment must be created. Refer to the VHA Safety Device Testing Manual 5th Edition for additional safety device testing information. Extensive modification detailed in later sections of this report will be necessary before proper safety device testing can even begin. Also, some devices as detailed in later sections may not be able to be made fully complaint with VA standard due to design constraints of some of the current boiler equipment. These issues must all be properly documented and guidance from VA HEFP 10A must be obtained moving forward.

Numerous other inspections are required by ES-2018-001 such as pressure vessel inspections and cleaning. Semi annual combustion tuning is required. All instrumentation must be calibrated semi-annually, and gages and thermometers must be calibrated annually. Currently there are no records of any of these required actions.

2.4 Back Up Fuel Requirements

The boilers serving Building 1 are equipped with back up fuel. Per Directive 1810 and ES-2018- 001, these boilers must be test fired monthly for one hour minimum on back up fuel oil and backup propane pilot. This monthly test firings must be documented and retained. This activity is currently not occurring and must begin immediately to sustain compliance with VA directive.

ES-2018-001 also requires at least 10 days worth of boiler dedicated back up fuel oil storage must be continuously maintained. The amount of storage is calculated based on most extreme weather conditions as determined from previous operation logs. Currently, the site is equipped with a single 5,000 gal fuel oil tank that serves both the boilers and backup generator.

Preliminary but not official calculations made onsite require at least approximately 4,000 gals for the boilers needs alone. Further evaluation should be performed to determine the proper required amount of storage and equipment needs as it appears the current storage level is inadequate.

3 Individual Boiler Assessments Per contract each boiler was assessed by BEI and site personnel to ascertain what required safety devices are in place vs what is required per VA standard. The following sections provide a breakdown of the assessment performed on each boiler and presents data and possible guidance on recommended possible paths forward. The following sections are broken down per the boiler equipment serving facilities or buildings.

3.1 Boilers Serving Building 1

The two hot water boilers located in building one are currently serving a critical care facility that is occupied continuously. They are remotely enabled by Johnson Control Building Metasys Building Management with a lead lag control scheme. Building efficiency algorithms are in place that command boilers on and off based on outdoor conditions. The boilers serving building one appear to be manufactured per ASME CSD-1 code requirements. CSD-1 is insufficient to meet VA standard, however these units can be modified to meet VA standard. Table 1 below provides specific equipment information, type of facilities served, redundancy and back up fuel service, and applicable VA standards and other codes.

Table 1: Equipment Info

Boiler Service Back Up

Fuel N+1

Applicable VA Specification /

Code

Applicable Non VA

Code

Cleaver Brooks

CBE 200 60 30HW

0L094489

MAWP – 30psig

2520 MMBTU

Webster Burner Single Point

Position Fireye EP170 BMS

CLC / Long Term Care /

Hospice / Admin

Yes Yes

VA Master Spec 235225 Low Pressure Water

Heating Boilers VHA Boiler and

Associated Plant Safety Device Testing Manual

5th Edition VA Heating Hot Water

Design Manual VA Directive 1810

ES-2018-001

NFPA 85

CSD-1

Cleaver Brooks

CBE 200 60 30HW

0L094490

MAWP – 30psig

2520 MMBTU

Webster Burner Single Point

Position Fireye EP170 BMS

CLC / Long Term Care /

Hospice / Admin

Yes Yes

VA Master Spec 235225 Low Pressure Water

Heating Boilers VHA Boiler and

Associated Plant Safety Device Testing Manual

5th Edition VA Heating Hot Water

Design Manual VA Directive 1810

ES-2018-001

NFPA 85

CSD-1

VA specification requires numerous safety devices be in place. Table 2 gives a list of the applicable required safety devices and their status regarding compliance with VA standard. Any device marked as not installed is required to be place. Table 2 applies to both boilers serving building 1.

Table 2: Safety Device Status

Required Safety Device Installed Compliant

Installed But Not

Compliant

Not Installed

Boiler Flame Scanner X Hot Water Low Water Cutout X

Liquid Relief Valves X High Water Temperature Switch X

Flow Switch X Low Fuel Gas Pressure Cutoff Switch X

High Fuel Gas Pressure Cutoff Switch X Auto Main Fuel Gas Valve/ Vent Valve X Auto Pilot Fuel Gas Valve / Vent Valve X

Main Gas Valve Proof of Closure X Low Pilot Gas Pressure Cutoff Switch X

Boiler Ignitor Timing X Boiler Main Flame Ignition Timing X

Boiler Pre Purge and Post Purge Timing X Low Fire Proving Switch X

Forced Draft Damper Wide Open Proving Switch X

Combustion Air Pressure Switch X Purge Airflow Proving Switch X

Forced Draft Motor Interlock Switches (Current Relays) X

Low Flue Gas Oxygen Interlock X Low Fuel Oil Pressure Cutoff Switch X High Fuel Oil Pressure Cutoff Switch X

Automatic Oil Valves X Oil Valve Proof of Closure X

The following list provides further detail to the devices listed in table 2 as “installed but not compliant” or “not installed”. This list applies to both boilers serving building one. The standard by which these devices must perform and be installed and/or modified is given in the VHA Boiler Safety Device Testing Manual 5th Edition.

• Boiler Flame Scanner o The VA requires Ultraviolet Self Checking type flame scanners. Both boilers serving building 1 are currently equipped with Infrared style flame scanners which are not allowed by VA specification. It is important to note that for this burner type the mounting position of the current IR scanner cannot accommodate a compliant UV scanner due to size constraints. Significant modification will be required to adapt a UV flame scanner to this burner and boiler combination. Consult with a Cleaver Brooks representative for possible path forward.

• Hot Water Low Water Cutout o The units are currently equipped with a compliant low water probe device, however there is no sight glass installed. VHA SDTM 5th Edition requires there be a water level sight glass installed for testing purposes. It should also be noted that the boiler drain is not piped to the building drain. Testing will require the boiler to be drained of water. This water will be high temperature. Refer to the VHA SDTM 5th edition for proper installation requirements for this device.

• Liquid Relief Valves o The installed liquid relief valve setpoint is at the MAWP of the boiler which is 30 psig. The VA requires that liquid relief valves be set below the MAWP of the boiler. Replace the current liquid relief valve with a relief valve with a setpoint below the MAWP of the boiler. Refer to SDTM 5th Edition for proper installation and performance standards.

• Flow Switch o A flow switch is installed, however there is no method to measure water flow.

The VHA SDTM 5th Edition requires that there be ability to measure flow so that the setpoint of the flow switch can be determined and evaluated. Add a flow meter or acquire a portable flow meter that can be installed during testing.

• Low Fuel Gas Pressure Cutoff Switch o A low fuel gas pressure switch is installed; however, it is not plumbed for proper testing as required by the VHA SDTM 5th edition. Add an isolation valve modified to be lockable only in the open position (LOOP) and a test port as shown in the VHA SDTM 5th Edition.

• High Fuel Gas Pressure Cutoff Switch o A high fuel gas pressure switch is installed; however, it is not located properly.

The VA requires the high fuel gas pressure switch be located upstream of the flow control valve. The current switch is installed downstream of the flow control valve. Relocate the switch per the VHA SDTM 5th Edition and plumb with a LOOP isolation valve and test port as required by the VHA SDTM 5th Edition.

• Auto Main Fuel Gas Shutoff Valve / Vent o The current installation does not include a vent or automatic vent valve. Install a vent to properly vent gas outside of the building and an automatic vent valve in the configuration given the VHA SDTM 5th Edition.

• Auto Pilot Fuel Gas Shutoff Valve / Vent o The VA requires two automatic shutoff valves and an automatic vent valve on pilot gas trains as shown in the VHA SDTM 5th Edition. The current installation only has one auto shutoff valve and no vent.

• Main Gas Valve Proof of Closure o The VA requires both main gas automatic shutoff valves be equipped with proof of closure switches. The current automatic shutoff valves are not equipped with proof of closure switches. Proof of closure switches can be easily retrofitted to the current automatic shutoff valves. Install and properly wire proof of closure switches in both automatic shutoff valves. The switches should be wired into the designated Fireye proof of closure circuit.

• Low Pilot Gas Pressure Cutoff Switch o The VA requires a low pilot gas pressure switch be installed per the VHA SDTM

5th Edition. The switch should be wired in the Fireye 3-P running interlock circuit.

• Low Fire Proving Switch o The VA requires an external position switch be installed to ensure the fuel flow control valve returns to the low fire position. Install a low fire proving switch and set it per the VHA SDTM 5th Edition. The switch should be wired into the Fireye M-D circuit. Linkages must be drilled and pinned to prevent slippage.

• Force Draft Damper Wide Open Proving Switch (FDDWOPS) o The VA requires and external position switch be mounted to ensure the combustion damper reaches the wide open purge position. Install a FDDWOPS proving switch and set it per the VHA SDTM 5th Edition. The switch should be wired into the Fireye D-8 circuit. Linkages must be drilled and pinned to prevent slippage.

• Combustion Air Pressure Switch (CAPS) o There is a CAPS switch installed however it is not properly plumbed per the VHA

SDTM 5th Edition. Refer to the VHA SDTM 5th edition for the proper CAPS plumbing setup and modify accordingly.

• Purge Airflow Proving Switch (PAPS) o There is no PAPS switch installed. Refer the VHA SDTM 5th Edition for the proper installation requirements and install and set a PAPS switch. The PAPS switch should be wired into the Fireye D-8 circuit.

• Forced Draft Motor Interlock Switches o The VA requires forced draft motor interlock switches (current relays) on all three phases. There is currently only one interlock installed and it is not the proper type. Refer to the VHA SDTM 5th Edition for the proper setup and device.

• Low Flue Gas Oxygen Interlock o The VA requires a low flue gas oxygen alarm and interlock. There is currently no alarm or interlock installed. Install an in-situ zirconium oxide style O2 monitor with built in built in alarm and interlock relays into the boiler flue. Refer to VA master specification 230911 for further detail on a proper system. The system should be wired into the Fireye 3-P running interlock circuit.

• Low Fuel Oil Pressure Cutoff o There is a low fuel oil pressure cutoff installed, however the device is not properly plumbed per the VHA SDTM 5th Edition. Add a LOOP isolation valve and test port as shown in the VHA SDTM 5th Edition.

• High Fuel Oil Pressure Cutoff o The VA requires a high fuel oil pressure cutoff be installed per the VHA SDTM 5th

Edition. Install a High Fuel Oil Pressure Cutoff per the VHA SDTM 5th Edition and wire it into the Fireye 3-P running interlock circuit.

• Automatic Oil Valves / Oil Valve Proof of Closure o The are currently two automatic oil shutoff valves installed, but the valves do not meet VA specification. Install automatic shutoff valves that meet VA specification that are equipped with proof of closure switches wired into the Fireye proof of closure circuit.

• Outside Air Damper o Currently there is no provision for combustion air into the space containing the boilers serving building 1. The VA requires there be sufficient fixed outside air opening area calculated by the formula given in the VHA SDTM 5th Edition. There should be at least 5 square feet of free area per the VHA SDTM 5th Edition.

• Provision for Combustible and Carbon Monoxide Alarms o There is no dangerous gas monitoring system in place in the space containing the boilers serving building 1. Install industrial grade carbon monoxide and methane detection equipment in the boiler space. Refer to VA master specification 230911 for details on a compliant system.

It should also be noted that because the boilers serving building 1 are equipped with the capability to fire fuel oil as a backup fuel, the VA requires both these boilers to be test fired on back up fuel monthly for 1 hour. It should also be noted that backup pilot propane fuel must also be maintained and tested monthly. The system should provide for easy changeover to propane pilot fuel.