Statement of Work.docx

Statement of Work

A. Scope

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:

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 State of South Carolina.

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 State of South Carolina 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 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 + or – 30 days.

B. All instrumentation, monitoring and data management systems shall be calibrated in accordance with the latest VA Directive 1810.

C. Provide at least two weeks’ notice to the Contracting Officer’s Technical Representative (COR) 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 COR or his/her designee 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. 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.

E. 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.

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

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.

G. 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.

e) Operate burner(s) on each fuel from low fire to high fire and back to low fire in at least ten 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, adjust 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.

h) Immediately inform COR or Designee 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.

H. List of instrumentation and controls to be inspected:

1) Steam flow transmitters (calibrate 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.

I. 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 + or – 30 days. 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 (COR) 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 COR or Designee so that VAMC can prepare the boilers and feedwater deaerator for the inspections in advance and have personnel available to monitor the inspections.

5) 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.

6) 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.

7) 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.

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

9) Methods for testing safety devices shall comply with VHA Boiler Plant Safety Device Testing Manual.

10) 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.

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.

J. 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 post weld 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.

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

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

b) Inspect spray nozzles and trays.

c) 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.

d) 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:

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 VHA Boiler Plant Safety Devices Testing Manual.

3) The third labeled “Deficiencies-Recommendations.”

4) 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 with the VHA Boiler Plant Safety Devices Testing 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 COR. Provide hard copies of data sheets and flue gas analyzer “strip” printouts to the COR within one week of visit. Page 13 of 38

C. (Semi-annuals) All safety-related deficiencies shall be immediately reported to the COR, 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.

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 COR.

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

SECTION B

1) 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:

A. Clever Brooks Fire Tube Boiler Model # CBLE-200-125-200ST, 125 HP, Serial # T3287-1-1

B. Clever Brooks Fire Tube Boiler Model # CBLE-200-250-200ST, 250 HP, Serial # T3287-2-1

C. Clever Brooks Fire Tube Boiler Model # CBLE-200-250-200ST, 250 HP, Serial # T3287-2-2

D. Cleaver Brooks Deaerator Feed Water Tank

E. Condensate Tank

SECTION C

1) DELIVERIES OR PERFORMANCE

A. 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 + or – 30 days.

SECTION D

1) 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 – non-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/compare) pressure switches.

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

12) Low flue gas oxygen.

13) Oil burner position switch

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) Purge airflow interlock.

20) Purge timing.

21) Ignition timing.

22) Low fire position interlock.

23) Combustion airflow interlock.

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

25) Ignition flame out – burner shutdown.

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

27) Low flue gas oxygen interlock.

28) Flue gas recirculation damper set for pre-purge.

29) Check PRV safety valves

30) Oil pump set liquid relief valves

31) Minimum igniter flame test

32) Low oxygen alarm/cutout

33) DA safety valves

34) DA overflow

35) Check combustion gas leaks into boiler room

36) Boiler fouling and combustion gas flow check

37) Adjust burning of fuel

38) Calibrate gauges, sensors, and controls

39) Calibrate oxygen trim

40) Check economizer Liquid relief valve

1. INTRODUCTION

1.1. OBJECTIVE

This manual represents a minimum standard for boiler and associated plant safety device functionality and testing. The purpose of this manual is to support the development of an individual boiler and associated plant safety device testing program for your specific facility as required by the VA. The text presents a concise and thorough treatment of boiler safety as applied to automatically fired gas and oil, heating and process boilers and boiler support equipment servicing healthcare facilities. The text includes a description of each boiler safety device’s function and purpose. Device testing guidance, and failure consequences are also given. Safety devices are organized by category in four chapters: Water Level Control, Pressure Containment, Fuel Train Safety Devices, and Burner and Air Train Safety Devices. Appendix A provides general procedures for testing every device covered for steam boilers and many of those devices required for hot water boilers. Devices not applicable to hot water boilers are noted in Appendix A. Appendix B contains four test procedures that are specific to hot water boilers. Appendices A and B can be used as a checklist and guide for safety testing and as a template for developing a site-specific test procedure. It is important to understand that VA directive calls for each facility to develop a written, site specific safety testing procedure. Some boilers will not include all devices explained in Appendix A.

The text does not replace existing standards. It succinctly states the main import of the standards. The final guide to safety should include all applicable standards. However, the testing envisioned in this text is generally more rigorous than current industrial practice or standards. In situations where adherence to this manual would adversely affect the operation of the boiler, special authority may be requested to deviate from the manual through the Director, Office of Healthcare Engineering (19HEFE).

1.2. BACKGROUND INFORMATION

One must understand that the use of the term “boiler” may refer to the system that includes the generation of steam, hot water, or hot oil. There are many safety devices such as level alarms, safety valves, relief valves, etc. that are found on the components involved in the distribution and use of steam. These safety checks are necessary and must be conducted on all devices in the system to ensure that the system is safe. It is important that one has the manufacturer’s manuals and wiring diagrams on all equipment to be tested before beginning the tests described herein and have a customized testing procedure specific to the boiler plant.

1.3. REQUIREMENTS FOR SAFETY TESTING

1.3.1. Properly test and analyze each safety device to determine VA Compliance

There are three questions that the person conducting the safety test must be able to answer affirmatively for a safety device to be VA compliant. IN THE TEST PROCEDURES GIVEN IN APPENDICES A AND B, THIS SET OF QUESTIONS IS CALLED THE “3 QUESTION CRITERIA”. IT IS SUCCINTLY STATED IN THE BOX ON THE NEXT PAGE.

If any of the three questions are not answered affirmatively for a safety device, the device in question FAILS to be VA compliant. If there is a failure of any safety device that can’t be fixed immediately, the boiler must be removed from service or an Interim Safety Measure (ISM) developed, approved, and instituted until the repair is completed. In this situation, the Medical Center Director must be notified of the situation.

THE 3 QUESTION CRITERIA

1. Is there proper device installation?

• A device approved by the VA that meets all VA requirements and standards.

• The device is in the right location as defined by VA requirements and standards.

• The device is set up to accommodate testing.

• Any valve isolating the device is lockable only in open position.

• If the device is a switch, it must open when it actuates.

• Any signal used in process control cannot be used as an input to a safety system.

• Independent safety control includes the fact that the safety control must be located in an enclosure that contains no other type of control.

• Any shunt on low water cutoffs (bypass switch) must be a non-latching device. No other shunts are allowed.

• The use of a snubber, dampener, pneumatic accumulator or other such device to dampen the pressure provided to a safety switch or gage used in testing the switch is not VA compliant.

2. Does the device activate at the proper set point that is in accordance with the criteria for the set point as defined herein and VA standards?

3. Does the device produce the proper result for its intended purpose (i.e., device must result in actions defined herein)?

1.3.2. REQUIRED CERTIFICATIONS FOR EACH SAFETY DEVICE TEST REPORT

A VA compliant test report will contain the following certification on the first page following the cover page of the report.

I certify that I have properly tested all applicable safety devices listed in this report for boiler #______and its associated equipment and I certify that all of these tests confirm that every device tested “passed” as defined by the following question: Did the device fail or pass the 3 question criteria?

PRINTED NAME SIGNATURE DATE

Position Title Company

I certify that I have properly witnessed all applicable safety device tests listed in this report for boiler #______and its associated equipment and I certify that all of these tests confirm that every device tested “passed” as defined by the following question: Did the device fail or pass the 3 question criteria?

PRINTED NAME SIGNATURE DATE

Position Title

I certify that I have properly tested all applicable safety devices listed in this report for boiler #______ and its associated equipment and I certify that some of these tests failed as defined by the following question: Did the device fail or pass the 3 question criteria? More details of these failures are given in Appendix H (Comments on each individual test)

PRINTED NAME SIGNATURE DATE

Position Title Company

I certify that I have properly witnessed all applicable safety device tests listed in this report for boiler #______ and its associated equipment and I certify that some of these tests failed as defined by the following question: Did the device fail or pass the 3 question criteria? More details of these failures are given in Appendix H (Comments on each individual test)

PRINTED NAME SIGNATURE DATE

Position Title

1.3.3. Confirming That All Devices Actually Function for Intended Purpose

In testing any safety device, it is paramount that the testing procedure verifies compliance with the 3 Question Criteria.

1.3.4. Lockable Valve Requirements

To facilitate testing of some types of safety devices, it is sometimes necessary to temporarily isolate the safety device and provide test ports by means of manual valves. These modifications cannot be allowed to increase risk by locking out a safety device during normal operation and must clearly indicate test and normal position. Any such manual valve that could isolate a safety device from its normal operating circuit must be lockable and the lock must be lockable only in the correct operating position. It is most important that in normal operation the valve is actually locked.

1.3.5. Confirming That Jumpers Are Removed and Valves Properly Locked

In many cases to test a device, it will be necessary to either electrically jumper (bypass) a device or to valve out the device. The safety testing personnel should only carry a fixed number of jumpers and should make sure that at the end of a test that all jumpers being used are accounted for and that all lockable valves are locked in their correct position.

1.3.6. Adherence to Electrical Safety

The VA complies with NFPA 70E Electrical Code. In executing the safety procedures described herein, it is sometimes necessary to open an electrical panel with a voltage sufficient to require various levels of protection. No personnel should perform such operations without being qualified with the proper training and gear. While this requirement will not be listed for each safety test, it must be understood that all personnel must rigidly adhere to the requirements of NFPA 70E.

1.4. NOMENCLATURE

AFOSV Automatic Fuel Oil Shutoff Valves ALWCO Auxiliary Low Water Cutoff on steam boilers ALWCOHW Auxiliary Low Water Cutoff on Hot Water Boilers APFGSOV Automatic Pilot Fuel Gas Shutoff Valves APFGSVV Automatic Pilot Fuel Gas Solenoid Vent Valve AMSOV Atomizing Media Shut Off Valve BMS Burner Management System CAPA Control Air Pressure Alarm CAPS Combustion Air Pressure Switch DA Deaerator DAODS Deaerator Overflow Drain System DASV Deaerator Safety Valve ESPB Emergency Stop/Panic Button FDDWOPS Forced Draft Damper Wide-Open Pre-Purge Proving Switch FDMIS Forced Draft Motor Interlock Switches FGRDI Flue Gas Recirculation Damper Interlock AFGSOV Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve AFGSVV Automatic Fuel Gas Shutoff Solenoid Vent Valve FPI Furnace Pressure Interlock FS Flow Switch on Hot Water Boilers FSMFO Flame Scanner-for main flame out FSNSIS Flame Scanner Not Sensing Igniter Spark HFGPCS High Fuel Gas Pressure Cutoff Switch HFOPCS High Fuel Oil Pressure Cutoff Switch HWAB High Water Alarm on Boiler HWACT High Water Alarm on Condensate Tank HWTS High Water Temperature Switch on Hot Water Boiler HWADT High Water Alarm on Deaerator Tank IT Igniter Timing LAMDPS Low Atomizing Media Differential Pressure Switch LAMFS Low Atomizing Media Flow Switch LAMPS Low Atomizing Media Pressure Switch LFGOLI Low Flue Gas Oxygen Level Interlock LFGPCS Low Fuel Gas Pressure Cutoff Switch LFOPCS Low Fuel Oil Pressure Cutoff Switch LFPS Low-Fire Proving Switch LPFGPCS Low Pilot Fuel Gas Pressure Cutoff Switch LOOP Lockable ONLY in OPEN Position LRVE Liquid Relief Valve on Economizer LRVE\HW Liquid Relief Valve on Hot Water Boiler LRVOPS Liquid Relief Valve on Oil Pump Set LWA Low Water Alarm LWACT Low Water Alarm on Condensate Tank LWADT Low Water Alarm on Deaerator Tank LWCO Low Water Cutoff on Steam Boiler LWCOHW Low Water Cutoff on Hot Water Boiler MFIT Main Flame Ignition Timing MV Manual Valve HHBSPLS High High Boiler Steam Pressure Limit Switch OADA Outside Air Damper Alarm OBPS Oil Burner Position Switch OSDPI Outlet Stack Damper Position Interlock Switch PAPS Purge Airflow Proving Switch POC_AFOSV Proof of Closure on Automatic Fuel Oil Shutoff Valves POC-AFGSOV Proof of Closure on Automatic Fuel Shutoff Valves PPT Pre-Purge and Post-Purge Timing PRV Pressure Reducing Valve HBSPLS High Boiler Steam Pressure Limit Switch SVB Steam Safety Valves on Boiler SVFPRV Safety Valve Following PRV TP Test Port

1.5. PREPARATION OF SYSTEM FOR SAFETY TESTING

The normal boiler installation does not generally allow easy access and control for testing. Safety testing is an ongoing activity for safe boiler plant operation. In this section a discussion is given of system design considerations that will allow easy testing. The discussion is organized around classes of different safety devices. For detailed drawings illustrating an appropriate test setup for each device, refer to the safety testing procedures given in the Appendices A and B.

A list of test equipment that is satisfactory for conducting the safety tests is given in Appendix E. The list is an example, but many other comparable instruments could be utilized.

1.5.1. Setup for testing a Steam Safety Valve Following a PRV

To test a safety valve following a PRV, a manual isolation valve must be installed downstream of the safety valve so that the valve can be tested without raising the pressure on the system, downstream of the valve.

1.5.2. Setup for Testing a Combustion Air Pressure Switch, Purge Air Proving Switch, Furnace Pressure Interlock, Control Air Pressure Interlock, High Fuel Gas Pressure Cutoff Switch, High Fuel Oil Pressure Cutoff Switch, Low Fuel Gas Pressure Cutoff Switch, and Low Fuel Oil Pressure Cutoff Switch.

To test these switches, it is necessary to be able to temporarily isolate these switches from the normal pressure source and either increase or decrease the pressure applied to the switch using the test port to determine the switch trip point. At the same time the piping must be such that the actual pressure that the switch senses can also be measured. The other switches listed above should be set up in a similar manner as indicated in the respective test procedures in Appendix A.

Figure 1.2 Combustion Air Pressure Switch (CAPS) Setup

1.5.3. Setup for Leak Checking Oil and Gas Block Valves and Gas Bleed Vent Valve

To easily test for leaks in the block valves, a test port (TP) and calibrated pressure gage must be available both in the line between the valves and downstream of the second valve. Also, in the case of gas, a lockable manual valve downstream of the solenoid bleed vent valve is required. A port and pressure gage in the line between the solenoid valve and lockable manual valve is also needed. Note, there are two test ports (TP) for determining normal operating pressures and one test port (TP) for testing the automatic fuel gas vent valve for leaks. The arrangement for testing the automatic fuel oil valves is the same with the exception the vent line is absent with its attendant test arrangement as shown in the test procedure for oil leaks in Appendix A. (Note that some boiler manufacturers do include a liquid relief valve between the two automatic fuel shut off valves. If this relief valve is included, it must be tested.) Sample gas with a level of CO and combustibles equal to the sensor set points should be available with a means to supply the gas to the sensor per the manufacturers test procedures.

1.5.4. Setup for Checking the Deaerator Overflow System and Oil Liquid Relief Valve

A sight glass with turbine wheel should be installed downstream of the valve to visually confirm that flow exists. The oil liquid relief valve also requires a pressure gage at the pump discharge.

1.5.5. Setup for Checking Proof of Closure Switches, Low Fire Proving Switches, Force Draft Damper Vane Interlock, Outlet Stack Damper Interlock, High Steam Pressure Switch, High High-Pressure Switch, and Recirculation Damper Interlock

It is necessary to electrically isolate or jumper these switches for testing. Although not necessary, it may be convenient to have the two electrical leads from each of these switches wired into an electrical control panel where it is easy to either remove one lead from the terminal block to isolate the switch or to jumper across the two leads to simulate a switch in the closed position.

1.5.6. Setup for Testing Low Water Cutoffs

A low water cutoff can be treated in the same way as those switches in section 1.5.6. It is required to have independent, non-latching shunt test switches (Momentary bypass switch) for isolating the two low water cutoffs for steam boilers and hot water boilers that are fitted with two low water cutoffs. This shunt test switch is required for each low water cutoff by VA standards for boilers fitted with two low water cutoffs.

1.5.7. Setup for Hydrostatic Testing

To hydrostatically test any device, it is necessary that valves are available to isolate the device, a test port is available to apply the test pressure, and a pressure gage is available to monitor the pressure in the device. All devices that could be damaged by the test pressure must be removed or properly isolated prior to conducting the hydrostatic testing. If it is desired to use a hydrostatic test pressure above the pressure at which the safety valve or liquid relief valve opens, it is necessary to remove the valves and blank off the opening.

2. WATER LEVEL CONTROL

2.1. LOW WATER CUTOFFS

2.1.1. Description

A low water cutoff is a device that causes the automatic fuel safety shutoff valves to close if the water level in the boiler drops below a pre-set safe level. Low water causes about 50 percent of all boiler incidents. Low water can cause the boiler to overheat which could lead to the failure of the pressure vessel with enormous potential damage (explosion). Two low water cutoffs are required for steam boilers while hot water boilers are required to have at least one low water cutoff. Acceptable Low water cutoffs operate either on a “float” system or electrode system (probe) for steam boilers. Any low water cutoff for hot water boilers must be a probe. In the float system there is a pipe connection to the boiler high and low connection points. Between these connection points there is a vertical section containing a volume sufficient to house the float. If the water level falls below a prescribed level, the falling float will cause a switch to actuate causing the automatic fuel valves to close.

2.1.2. Low Water Cutoff

In the electrode system, there is a similar piping arrangement as in the float system. Probes extend vertically downward into the vertical pipe connecting the piping to the high and low boiler connection points or for hot water boilers directly into the boiler. The electrodes are located at the bottom of the probe and are used to measure the conductivity of the media in which the electrodes are immersed. The conductivity of water is much higher than steam. Hence, if the water level drops below the probe, a drastic change in conductivity occurs. This change is used in an electrical circuit to cause the automatic fuel shut-off valves to close. Most safety codes require at least one float system be included to protect against low water for steam boilers. The VA requires one float and one probe for steam boilers. True redundancy requires that the low water cutoffs be in two separate piping arrangements as shown. Placing both low water cutoffs in a single piping arrangement could lead to a situation in which blockage in the piping arrangement renders both level control safety devices useless. Some low-water cutoffs are provided with non-latching “shunt” test switches by which the low water cutoff switch is bypassed. A non-latching shunt test switch means that the test switch must be manually held open in order to bypass the low water cutoff switch. The VA requires individual shunt test switches for both low water cutoffs for steam boilers. Operators can use the shunt test switch in “testing” each low-water cutoff by simply by-passing one low water cutoff by holding in the other low water cutoff shunt test switch and allowing the active low-water cutoff to shut down the boiler. This procedure is then repeated for the other low water cutoff. Operators electrically check the low water cutoff using this method. A boiler control system should never allow the boiler to automatically restart after a low-water cutoff has actuated to stop boiler operation and all trip points must occur with water clearly in the sight glass. A detailed test procedure is given in Appendix A for steam boilers and Appendix B for hot water boilers.

2.1.3. Consequences of Low Water Cutoff Failure

If the low water cutoffs both fail, the boiler would then be fired with no water in the boiler. This will cause the metal temperatures to rise rapidly and the metal strength to be significantly decreased. In fire tube boilers the main Morrison tube typically collapses which could allow steam onto the boiler fireside. The steam pressure has been known to blow the ends out of the boiler through concrete block walls a distance of hundreds of feet. Similar catastrophes could occur in water tube boilers.

2.1.4. Testing a Low Water Cutoff

Low-water cutoffs must be tested in a mode in which they fail. Testing is basically done by allowing the water level to decrease in a “slow drain”. To be in a realistic mode, one must not follow a procedure that actuates the cutoff by rapidly blowing off a volume of water from the water column containing the switch. This is very important in testing a float type cutoff. The rate of decrease in water level is required to be a maximum of 1 inch/minute. A detailed procedure is given in Appendix A for steam boilers and Appendix B for hot water boilers.

2.2. LOW WATER ALARM

2.2.1. Description

The low water alarm provides audible and visual warnings that the water level is approaching a dangerously low level. These alarms are based either on a conductivity probe or float as described in the previous section. These alarms are required on the steam boiler, deaerator, and condensate receiver tanks. On the boiler, the low water alarm must be set to activate before either of the low water level cutoffs shuts off the boiler. On the deaerator and condensate receiver tanks, the alarm is the only indication of a low water problem. On these devices the setting should be at or above 1/3rd of the tank diameter and with visible water in the sight glass. The alarm should not be set so high that it causes excessive alarm activation. Lack of water in the deaerator or condensate receiver will quickly result in loss of water to the boiler with the problems described in the section of low water level control.

2.2.2. Consequence of Water Level Alarm Failure

Low water in a condensate or deaerator tank is a precursor to low water failure in a steam boiler with the problems described above. There is also the hazard of damage to a condensate transfer or boiler feed pump from running dry. A low water alarm on a boiler is a warning to operators of an impending potential problem of a “boil out” of water.

2.2.3. Testing Low Water Alarms

The low water alarm is tested by causing a drop in water level in the vessel being tested. The alarm should activate at the desired set point (the set point must be above the level at which the first low water cutout activates, at a level allowing operators time to restore the proper level, and visible in the appropriate sight glass). A step-by-step procedure is given in Appendix A for three situations: steam boilers, deaerators, and condensate tanks.

2.3. HIGH WATER ALARM

2.3.1. Description

A high-water alarm is required on a steam boiler, deaerator, and condensate tanks to aid in preventing overfilling. Due to the failure rate of float type devices used for this purpose, high water alarms must always be conductivity probe type devices for VA compliance.

2.3.2. Consequence of High-Water Alarm Failure

High water in a condensate tank could lead to backup of condensate in condensate lines. High water in a deaerator will result in poor deaeration but also leads to violent shaking of the vessel. High water in a steam boiler could result in pushing liquid into the steam line. Slugs of water in the steam system can move at high velocity due to the motive force of steam causing water hammer. Water hammer can cause valves and other fittings to explode and steam piping to rupture. Death and injury from these events are a regular occurrence. This same effect could produce high water levels in the steam supply to a steam powered appliance connected to the system with detrimental effects on the process.

2.3.3. Testing the High-Water Alarm

The high-water alarm must be tested off-line. Slowly fill the vessel with water, observe the water level in the sight glass, and note the point at which the alarm sounds. Be careful not to overfill the system, above the level at which the alarm should actuate. A step-by-step procedure is given in Appendix A for three situations: steam boilers, deaerators, and condensate tanks.

2.4. OVERFLOW DRAIN SYSTEM

2.4.1. Description

Deaerator tanks and condensate storage tanks have overflow systems to prevent overfilling. The deaerator overflow is shown in Figure 2.2. The overflow system on the condensate tank also helps guarantee that the condensate tank remains at atmospheric pressure and consists of a drain line connected to the vessel.