36C24719Q0713-001.pdf

Statement of Work 534-19-4-5088-0075 1 Inspection and Testing – Boiler Plant Burners, Controls and Instruments

DEPARTMENT OF VETERANS AFFAIRS MEDICAL CENTERS

BOILER PLANTS

STATEMENT OF WORK

Inspection, Safety Device Testing and Calibration, Boiler Plant Burners, Controls, Instruments, and Data Management.

Inspection of Boilers, Feedwater Deaerators.

SECTION A

1. Introduction:

A. Most Department of Veterans Affairs Medical Centers (VAMC) have a central boiler plant to provide steam for heating and air conditioning, domestic hot water, kitchens and sterilization. Some medical centers have laundries that utilize steam.

B. Boiler plant safety, reliability, efficiency and equipment longevity are paramount concerns of VAMC management. 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, controls and instruments by qualified technicians as well as the requirements for the boiler inspections and feedwater deaerator inspections to be performed by “Qualified Professional Inspectors” under contract.

D. All work will be performed at the R. H. Johnson VA Medical Center

(RHJVAMC) located at 109 Bee Street, Charleston, SC 29401, contact phone numbers include (843)789-6783/7269/6004. RHJVAMC is equipped with two (2)

250 HP Cleaver-Brooks CBLE firetube boilers, one (1) 125 HP Cleaver-Brooks

CBLE boiler, one Deaerator Tank (DA), all located in C104 with associated condensate, feed and steam systems.

E. “Qualified Professional Inspectors” as defined below shall perform internal and external inspections on high pressure (over 15 psig) steam boilers and internal inspections on feedwater deaerators and other pressure vessels.

F. Non-destructive testing of feedwater deaerator pressure vessels shall be performed by certified non-destructive testing technicians as defined below under the guidance of the Qualified Professional Inspector.

2. Technician Qualifications:

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A. Technicians shall have completed at least a one-year trade school and have five years successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the VAMC plant. The

VAMC facility manager/engineer may define and accept equivalent qualifications.

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

NFPA 85, Boiler and Combustion Systems Hazards Code.

VHA Boiler Plant Safety Device Testing Manual

ASME Boiler and Pressure Vessel Code

Section I - Power Boilers

Section IV - Heating Boilers

Section VI - Care and Operation of Heating Boilers

Section VII - Care of Power Boilers

ASME B31.1, Power Piping Code

ASME CSD-1, Controls and Safety Devices for Automatically Fired

Boilers

ANSI/NB-23, National Board Inspection Code

NFPA 85, Boiler and Combustion Systems Hazards Code

VHA Boiler Plant Safety Device Testing Manual

C. Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests and calibrations, all calibrated within one month of the site visits. At facilities with programmable digital controls, the technicians must be capable of programming the controls and have the appropriate hardware and software for this.

D. “Qualified Professional Inspector” is defined as one (1) or a combination of:

1) A boiler inspector who has a valid commission from the National Board of

Boiler and Pressure Vessel Inspectors (NB).

2) A boiler inspector who has qualified by passing a written examination under the laws, rules and regulations of a jurisdiction of a state.

3) A boiler inspector who is regularly employed as a boiler inspector by a jurisdiction which 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.

4) A boiler inspector who is regularly employed by an insurance company which has been licensed or registered by the appropriate authority of a

State of the United States to write boiler or pressure vessel insurance.

E. Qualifications for Non-Destructive-Testing Technicians:

1) The technicians shall be certified as being qualified Level II technicians in the non-destructive testing methods to be utilized. The certification shall

Statement of Work 534-19-4-5088-0075 3 be in accordance with the requirements of the American Society for Non-

Destructive Testing (ASNT).

3. Inspection, Testing and Calibration Requirements:

A. Technicians shall provide all tools and labor necessary to perform inspection, tuning, testing, calibrating, and adjustments of burners and boiler and boiler plant controls as specified below. This shall be done every six months during the months of March and September. Boiler Annual Internal inspections shall be performed in the month of August.

B. All instrumentation, monitoring and data management systems shall be calibrated every six months.

C. Provide at least two weeks’ notice to the Contracting Officer’s Technical

Representative (COTR) prior to performing the work. Work cannot be scheduled during heavy steam load periods.

1) Only one boiler at a time can be out of service for the inspection, testing and calibration procedures.

2) Work must be conducted when the COTR or his/her designate is available on site to monitor the work.

3) To maintain steam service, typically only one boiler at a time will be scheduled for internal inspections per inspection visit. Thus, multiple visits per VAMC facility will be necessary every year to inspect all the boilers internally.

D. The COTR is: Herbert Watson

E. Contractor will supply water and fire side gasket sets to the RHJVAMC personnel annually in time to allow for opening the boilers for cleaning and inspection.

RHJVAMC will have the boilers that are to be serviced 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; all boiler, burner and fuel train pressure gages and thermometers calibrated; fuel meters in accurate operation (pressure/temperature correction factors provided, if applicable); boiler steam flow, stack temperature and flue gas oxygen instruments operating.

F. VAMC will comply with any other requirements of the test personnel that are considered reasonable by VAMC and have been presented in writing at least two weeks prior to the scheduled testing.

G. The inspections, testing and calibrations shall comply with:

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1) The recommendations and requirements of VHA Boiler Plant Safety Devices

Testing Manual

2) The 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.

H. A summary of the work is as follows:

1) Semi-annual testing and calibration;

a) Review boiler plant log sheets and alarm and trouble reports.

b) Review records that show combustion performance (flue gas oxygen and carbon monoxide).

c) Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VAMC requirements stated in this contract.

d) 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 20% of normal operating parameters. Make adjustments as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation.

e) Operate burner(s) on each fuel from low fire to high fire and back to low fire 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.

f) Compare the combustion performance data with VAMC requirements

(see below) and previous readings. If necessary, make adjustments to the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data.

g) 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.

Statement of Work 534-19-4-5088-0075 5

h) Immediately inform COTR of any recommended repairs or modifications.

2) All of 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, along with testing procedures.

3) Required burner performance (natural gas and fuel oil):

a) Turndown (ratio of maximum and minimum firing rates): 10/1

8/1 5/1 4/1 (Refer to original burner specification).

b) Achieve, but do not exceed, boiler maximum steam flow output rating. Measure fuel input at minimum and maximum firing rates.

c) Maximum carbon monoxide: 200 parts per million (ppm)

d) Maximum NOx: Refer to original burner specification.

e) 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).

f) No visible smoke, except on heavy oil fuel maximum opacity is

20%. Comply with local emissions regulations.

g) Flames shall be stable with no pulsations, shall be retained near burner, no blowoff or flashbacks, no constant flame impingement on refractory or waterwalls.

I. List of instrumentation and controls to be inspected and calibrated:

1) Steam flow transmitters (all).

2) Steam flow recorders/computer readout.

3) Flue gas oxygen sampling, analyzing and recorder/computer readout.

4) Boiler and economizer stack temperature transmitters and recorder/computer readout.

5) Master steam pressure and combustion controllers.

6) Boiler outlet draft controllers.

7) Boiler water level controllers.

8) Feedwater deaerator and condensate storage tank water level controllers including overflow.

9) All pressure and temperature sensors and transmitters.

10) All signal processing and readout devices.

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J. Annual Inspection Requirements

1) Annual internal and external inspections are required for each boiler, annual cleaning and interior inspection is required for each deaerator, inspections to be done in the month of August. Internal inspections and wet magnetic particle weld testing of the feedwater deaerator pressure vessel are required every six years (or more frequently if welding repairs have been performed).

2) At least two weeks’ notice to VAMC is required prior to an inspection.

Also, the inspection must be scheduled for periods when VAMC determines that the boilers that will be inspected internally will not be needed for steam supply and when the Contracting Officer’s Technical

Representative (COTR) or his/her designate is available on site to monitor the inspections. To maintain steam service, typically only one boiler at a time will be scheduled for internal inspections per inspection visit. Thus, multiple visits per VAMC facility will be necessary every year to inspect all the boilers internally.

3) Feedwater deaerator pressure vessel inspections must be scheduled during periods of low steam demand.

4) Coordinate the inspection schedule with the COTR so that VAMC can prepare the boilers and feedwater deaerator for the inspections in advance and have personnel available to monitor the inspections.

5) The COTR is: Herbert Watson

6) Contractor will supply water and fire side gasket sets to the RHJVAMC personnel annually in time to allow for opening the boilers for cleaning and inspection. Boilers scheduled for internal inspection will be prepared for the inspection by VAMC prior to the scheduled arrival of the inspector. This includes cooling the boilers to near ambient temperature and having all manways, handholes and furnace access doors open; the boilers cleaned of loose materials waterside and fireside; electrical “lock-out, tag-out” in place; connecting piping isolated; proper illumination provided; compliance with “confined space” access requirements including having safety personnel present is the responsibility of the contractor, the RHJVAMC does not have confined space rescue equipment or trained personnel available. Similar advance preparations will be made to the feedwater deaerator when it is scheduled for internal inspection.

7) VAMC will comply with any other requirements of the inspector that are considered reasonable by VAMC and have been presented in writing at least two weeks prior to the scheduled inspection.

Statement of Work 534-19-4-5088-0075 7

8) The boiler and feedwater deaerator inspections shall comply with the guidelines in the current issue of the NATIONAL BOARD INSPECTION

CODE, Part RB, Inservice Inspection of Pressure-Retaining Items, and

ASME Boiler and Pressure Vessel Code, Section VI or VII as applicable.

In addition to those guidelines, the inspections shall comply with all

Federal, State and local laws, and VAMC regulations/requirements.

9) The inspector must completely enter the internal spaces of the boiler or feedwater deaerator and visually inspect all internal surfaces that can be accessed.

10) Methods for testing safety devices shall comply with VHA Boiler Plant

Safety Device Testing Manual.

11) Summary of the minimum inspection requirements for boilers:

a) Review the boiler history including: operating conditions, date of last inspection, current inspection certificate, ASME stamping on boiler, National Board registration number, history of repairs and modifications. Review boiler logs, water test reports, and reports on tests performed on the burner controls and interlocks.

b) 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 codes.

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

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

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

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

g) Examine all stays and stayed plates.

h) Inspect gas side baffles.

i) Inspect internal drum surfaces and steam separating internals.

j) Inspect soot blowers and verify proper alignment.

k) Inspect tubes, tube ends and tube alignment. Check for sagging tubes.

l) Verify that all nozzles of internal piping such as feedwater admission and bottom blowoff collection are clear with no obstructions.

m) Inspect seating surfaces of manways and handholes.

n) Check that boiler structure is plumb and level with no excessive deformations.

o) Check for missing items such as bolts and nuts.

p) Examine all valve and pipe connections to the pressure vessel.

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

r) Verify proper alignment of burner assembly.

Statement of Work 534-19-4-5088-0075 8

s) Inspect furnace for evidence of flame impingement.

t) Test operation of water level gage glass.

u) Perform mechanical and electrical inspection of disassembled low water cutouts (disassembly by VA). After reinstallation, test operation to the extent possible. Test low water cutouts on hot boilers by lowering water level gradually.

v) Verify that steam pressure gage is properly calibrated.

w) Test operation of high steam pressure cutouts on hot boilers by raising steam pressure.

x) 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”).

y) Inspect piping connected to the boilers for evidence of leakage, provision for expansion, provision of adequate support, proper alignment, evidence of detrimental conditions.

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

aa) Inspect valves on boiler feedwater, blowdown, drain and steam systems.

bb) Provide recommendations for non-destructive testing when the inspections indicate that this is necessary to assure continued safety and reliability under current operating conditions.

K. Summary of the minimum inspection requirements for feedwater deaerators:

1) Review the feedwater deaerator history including: operating conditions, date of last inspection, current inspection certificate, ASME stamping, National Board registration number, materials of construction, extent of postweld heat treatment, history of repairs and modifications.

2) Assess the external parts of the feedwater deaerator and accessories and piping for safety, accessibility, cleanliness. proper operation, and compliance with codes.

3) Inspect for evidence of leakage.

4) Note feedwater deaerator pressure gage and thermometer readings and verify gage and thermometer accuracy.

5) Inspect safety valve installation and verify that the valves have proper set pressure and capacity and are properly installed. Perform an operation test under pressure to confirm operation at proper set pressures. Verify that the deaerator can safety withstand the test pressure prior to testing the valve(s) in-situ.

6) Verify that non-condensable gas vent line is open and proper orifice is provided to permit venting of gases.

7) Inspect support structures for proper integrity and allowance for thermal expansion.

Statement of Work 534-19-4-5088-0075 9

8) Internal inspections (annual cleaning and inspection and 6-year wet magnetic particle intervals unless otherwise recommended because of welding repairs):

i. Visually inspect all visible pressure vessel surfaces for corrosion, material thinning, deposits, and weld cracking.

ii. Inspect spray nozzles and trays.

iii. Certified American Society for Non-Destructive Testing (ASNT)

Level II technicians shall perform non-destructive tests using the wet fluorescent magnetic particle (WFMT), ultrasonic testing

(UT), and any other necessary non-destructive tests.

1. Completely examine all accessible welds utilizing the

WFMT test method. Properly prepare the surfaces before testing.

2. Determine pressure vessel material thickness by UT.

Thickness measurement locations shall be selected by dividing the storage tank heads into quadrants and taking measurements at each quadrant on two imaginary rings in each head (eight measurements total). Measurement locations on the shell shall be on each of the quadrants, on four to six locations along the length of the shell (16 to 24 measurements total). The technician may recommend fewer or more tests to the owner, providing justification.

3. Typically, the pressure vessel section containing the deaerator trays and sprays is not accessible for non-destructive testing. The experience is that this section, which is mainly exposed to steam, is less vulnerable to weld failures and material thinning than the storage section which contains condensate and make-up water.

iv. Calculate maximum allowable working pressure rating of vessel based on thickness measurements. Calculate depletion rate of material thickness.

4. Report Requirements:

A. (Semi-annuals) 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 with 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.

c. The third labeled “Deficiencies-Recommendations”

d. The fourth column labeled “corrective actions” list any corrective actions taken during the inspection.

The next section shall be in paragraph/bulleted form and list each device individually in accordance to the VHA Boiler Plant Safety Devices Testing

Statement of Work 534-19-4-5088-0075 10

Manual plus the section must reference the correct Master Specification and

Standard Detail for that device. See sample below.

5.1. 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 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.

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-time 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 11 (old 15625).

VA Standard Detail: SD232111-05.pdf

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.

B. (Semi-annuals) Furnish report within one week of each facility inspection in

“Microsoft Word” format by email to the COTR. Provide hard copies of data sheets and flue gas analyzer “strip” printouts to the COTR within one week of visit.

C. (Semi-annuals) All safety-related deficiencies shall be immediately reported to the COTR, Boiler Plant Supervisor as soon as discovered.

D. (Annuals) Provide complete written report fully describing all inspections and tests performed, findings, and recommendations. The condition of all items inspected shall be stated whether acceptable or deficient. All deficiencies shall be fully described along with recommendations for methods of correction. Utilize

National Board Forms NB-6 and NB-7, or other similar forms acceptable to owner.

Statement of Work 534-19-4-5088-0075 11

E. (Annuals) Provide sketches and photographs as necessary and as requested by owner to show areas identified as not acceptable for continued service or requiring repair.

F. (Annuals) Include test data and calculations. Show locations and extent of all non-destructive testing by sketches.

G. (Annuals) Furnish report within one week of each facility inspection in

“Microsoft Word” format by email to the COTR.

H. (Annuals) All safety-related deficiencies shall be immediately reported to the

COTR as soon as discovered.

I. (Annuals) Provide recommendations on need for re-inspections after correction of deficiencies. Cost of re-inspections shall be extra cost negotiated with VA

Contracting Officer.

J. (All inspections) Vendor will provide a quote with parts and labor required to correct any deficiencies found that were not corrected by alignment or adjustment on the spot where found deficient.

SECTION B

REQUIREMENTS: Contractor shall provide inspection, testing and calibration services for boiler plant safety devices in accordance with requirements contained herein for the following list of equipment.

1. Clever Brooks Fire Tube Boiler Model # CBLE-200-125-200ST, 125 HP, Serial #

T3287-1-1

2. Clever Brooks Fire Tube Boiler Model # CBLE-200-2500200ST, 250 HP, Serial

# T3287-2-1

3. Clever Brooks Fire Tube Boiler Model # CBLE-200-250-200ST, 250 HP, Serial #

T3287-2-2

4. Cleaver Brooks Deaerator Feed Water Tank

Statement of Work 534-19-4-5088-0075 12

SECTION C

DELIVERIES OR PERFORMANCE

1. Inspection, testing and calibration services are to be performed semi-annually during the following months:

a. March – semiannual maintenance

b. September – semiannual and annual inspections and maintenance

SECTION D

SPECIAL CONTRACT REQUIREMENTS

DEPARTMENT OF VETERANS AFFAIRS MEDICAL CENTERS

BOILER PLANTS

STATEMENT OF WORK

Inspection, Testing and Calibration

Boiler Plant Burners, Controls, Instruments and Data Management

A. List of interlocks and safety devices to be inspected and tested on each boiler/burner (this list is not to be deemed all inclusive, reference VHA Directive 1810):

1) Low water cutoff and shunt switch.

2) Auxiliary low water cutoff and shunt switch.

3) High water alarm.

4) Low water alarm.

5) High operating steam pressure switch – recycle.

6) High operating steam pressure switch – non-recycle.

7) High and low main fuel pressure switches (gas/oil).

8) Low pilot gas (igniter) pressure switch.

9) High and low fuel temperature switches (heated oil).

10) Low fuel oil atomizing media (steam/compr.air) pressure switches.

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11) Low differential pressure switch, atomizing media/fuel oil (if provided by burner manufacturer).

12) Low flue gas oxygen.

13) Oil burner position switch (if provided by burner manufacturer).

14) Fuel safety shut off valves proof of closure (overtravel/valve seal switch).

15) Leak test fuel safety shut off valves (main and pilot burners) (seat leakage).

16) Leak test gas fuel vent valves.

17) Forced draft motor interlock.

18) Forced draft damper wide-open interlock for purge.

19) Outlet damper open interlock for purge (if outlet damper provided).

20) Purge airflow interlock.

21) Purge timing.

22) Ignition timing.

23) Low fire position interlock.

24) Combustion airflow interlock.

25) Main flame out – time to close fuel valves.

26) Ignition flame out – burner shutdown.

27) Scanner not sensing ignition spark (ultraviolet scanner).

28) Scanner not sensing hot refractory (infrared scanner).

29) Control air pressure interlock.

30) Low flue gas oxygen interlock.

31) Flue gas recirculation damper set for prepurge.

32) Check PRV safety valves

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33) Oil pump set liquid relief valves

34) Minimum igniter flame test

35) Low oxygen alarm/cutout

36) DA safety valve

37) DA over flow

38) Check furnace pressure

39) Check combustion gas leaks into boiler room

40) Boiler fouling and combustion gas flow check

41) Adjust burning of fuel

42) Calibrate gauges, sensors and controls

43) Check vibration of boiler

44) Calibrate oxygen trim

45) Check economizer Liquid relief valve