ADD1_-_BOD_COMBINED_-_657-23-115JB_UPDATED_8.1.24.pdf

01 AUG 2024

CORRECT CAMPUS

STEAM SYSTEM

FAILURES

PROJECT #: 657-23-115 JB

JEFFERSON BARRACKS VA MEDICAL CENTER

ST. LOUIS, MISSOURI

BASIS OF DESIGN

ADDENDUM 1

CONSTRUCTION DOCUMENTS

Correct Campus Steam System Failures

Jefferson Barracks VA Medical Center – St. Louis, MO Project #: 657-23-115JB

TABLE OF CONTENTS PAGE 02

TABLE OF CONTENTS

TABLE OF CONTENTS

EXECUTIVE SUMMARY

ARCHITECTURAL NARRATIVE

MECHANICAL NARRATIVE

ELECTRICAL NARRATIVE

APPENDIX A – ENVIRONMENTAL INVESTIGATION

APPENDIX B – PREVENTIVE MAINTENANCE PLAN

EXECUTIVE SUMMARY PAGE 03

EXECUTIVE SUMMARY

The overall intent of this project is to analyze the current design of the campus steam system. This analysis will culminate in the production of a full set of construction documents to correct deficiencies within the system at the St. Louis VA, Jefferson Barracks (JB). The corrections will address dangerous conditions within the steam manholes and improve the steam supply and condensate return systems.

The corrections will also address steam and condensate system functionality, manhole access, safety considerations, remote valve operation, monitoring of manhole system components, and conditions of non-compliance with VA specifications and industry standards.

This narrative will detail the initial findings and recommendations from the A/E for consideration by the

VA. The A/E will submit a technical report on the condition of the existing campus steam system and provide recommendations to the VA for next steps and possible design solutions in following submittals.

Design Parameters U.S. Department of Veterans Affairs, Office of Construction & Facilities Management Design and Construction Standards, latest version.

Master Construction Specifications (PG-18-1) Design & Construction Procedures (PG 18-3) Standard Details & CAD Standards (PG-18-4) International Building Code (IBC) National Fire Protection Agency (NFPA) OSHA Standards National Electric Code Equipment Guide List (PG-18-5) Design Manuals (by discipline) (PG-18-10) Design Guides (graphical, by function) (PG-18-12) Minimum Requirements for A/E Submissions (PG-18-15, vol. C&F) Environmental Planning Guide (PG-18-17) Physical Security Design Manual for VA Mission Critical Facilities VA PACT (Patient Aligned Care Team) Design Manual VA Handbook 0730/4 Security and Law Enforcement VA Interior Design Manual for New Construction & Renovations of Hospitals/Clinics VA Signage Design Guide VA Sustainable Design Manual TIL Alerts: A/E Quality, Design, & Standards Alerts Federal Information Processing Standards Pub. (FIPS-201-1) Federal Information Processing Standards Pub. (FIPS-140-2) Government Smart Card Interoperability (GSC-IS) (IR 6887 V2.1) Electronic Authentication Guideline (Special Pub 800-63) Security Controls for Federal Information Systems (NIST Sp Pub 800-53) Sustainable Design & Energy Reduction Manual Equipment Guide List (H-7610) Hardware (Equipment Symbols) (H-08-6) VAMC Approved Hardware Locking Standards (H-08-6) Seismic Design Requirements (H-18-8)

ARCHITECTURAL NARRATIVE PAGE 05

ARCHITECTURAL NARRATIVE

GENERAL

This project will upgrade the existing campus steam distribution system at the Jefferson Barracks VA

Medical Center.

Architectural scope for this project is expected to be limited and will focus on the following elements:

1) Updated manhole access using ladder systems that can extend beyond the manhole opening.

The new ladders will meet all current code requirements.

2) Hydraulic assisted manhole lids to reduce force required to open.

EXISTING CONDITIONS

The existing access to manholes is provided by ladder systems that do not extend beyond the manhole opening creating possible dangerous conditions when entering and exiting the manhole, and lids are heavy steel doors and are very difficult to operate and pose a slamming danger to anyone inside the manhole.

ARCHITECTURAL NARRATIVE PAGE 06

PROJECT UPGRADES

A new ladder system will be provided that will meet all code requirements and improve safety at the manholes. This system will include retractable handrails that will lock in the upright position and will extend above the manhole opening to allow for safe manhole entry and exit for maintenance personnel.

See cut sheet on the next page for ladder basis of design.

A new manhole lid system will also be installed to provide ease of operation and will provide a gas shock system that will assist the operator in opening and closing the door to prevent overexertion when opening and slamming of the lid closing. The new system will also include a “hold-open” arm to lock the door open and prevent the door from slamming closed while the manhole is occupied.

MECHANICAL NARRATIVE PAGE 08

MECHANICAL NARRATIVE

GENERAL

The scope of this project and the objectives of the VA are as follows:

1) Investigate and assess current compensators, thrust blocks, and any other relevant accessory within the steam manholes.

2) Investigate and access current steam condensate return system including tanks, pumps and overall system installation.

3) Design and provide construction plan drawings for the repair and installation of any components in the campus steam and condensate distribution loop (between the building condensate return tank and the Energy Plant) that are identified to be non-compliant with VA specifications, VA design guides, manufacturer recommendations, or that are identified as anything less than industry best practice.

4) Investigate, design, and install components to allow remote steam trap monitoring, and valve operation from outside the manholes.

5) Moisture monitoring in the steam vaults using visual indicators (like a light on the outside of the manhole) if water is detected

6) Investigate pipe scaling conditions

7) Preventative maintenance plan for steam vaults

8) Duplex sump pumps as needed in manholes

*Note – This narrative does not include previous design document updates. Initial intent and/or final solutions are presented per scope objective

CODES AND REGULATIONS

• VA Steam, Heating Hot Water, and Outside Distribution Systems Design Manual Sept 1, 2022 Vol.3

• ASME B31.1 Standards

MECHANICAL NARRATIVE PAGE 09

ITEM 1: Investigate and assess current compensators, thrust blocks, and any other relevant accessory within the steam manholes.

Summary: The campus steam distribution system has had several equipment failures over the years despite repairs, reports, and analysis being performed. Per the IMEG report and the observations made, it appears to be the consensus that the failures are due to the thrust block, or mount plate. This may be a contributing factor however it would appear water hammer is also a likely factor for compensator failure.

Items to consider:

1) Per the IMEG report “Expansion joint review update” conclusions, ADSCO concluded a water hammer event may have damaged the MH-16 compensator and compromised its integrity

2) The trap in MH-16 per the IMEG report had likely failed and allowed condensate to build in within the system near the corresponding compensator.

3) It was recommended that 2 traps be installed in parallel at MH-16. Per the site visit this addition was made with disk traps. It’s also worth noting that per 5.4.2 of the design manual inverted bucket traps are recommended.

4) Per the design manual the steam lines should slope at 2” per 40 ft in the direction of flow.

5) Other manholes are problematic, and these should also be investigated further for proper equipment, thrust block condition etc.

100% Solution: Based on design analysis and site investigation completed by the design team, 3 compensators will be replaced. At manholes 12 and 15, they will receive slip style compensators.

Manhole 16 will receive a bellows style compensator which addresses lateral load concerns. New slip style compensators will be ordered to withstand higher pressures if water hammer does persist, and leaks can be fixed by adding packing which will allow maintenance staff to complete repairs without shutting down the steam system. The Bellows style compensator per the schedule is designed to accept lateral forces. Manholes 8, 13, and 16 will receive a pressure powered condensate receiver pumps to assist with removing condensate from the HPS lines.

MECHANICAL NARRATIVE PAGE 10

ITEM 2: Investigate and assess current steam condensate return system including tanks, pumps and overall system installation.

Summary: A condensate system per the design manual should return most if not all condensate to the boiler plant except where deemed not economical. The piping infrastructure is present however the maintenance staff have expressed some concerns including some buildings not returning condensate at all.

Items to consider:

• Condensate comes in surges according to staff. Sometimes there is little to no flow.

• Buildings 1, 3, 18, 23, 24, 53, and 54 either do not have condensate return or the pumps are inoperable.

• Low condensate return means the boiler plant is making up all the water that is lost and decreased overall system efficiency.

100% Solution: It has been determined that Buildings 18, 24, 53 and 54 already have condensate receiver pump replacements in process or are already completed. Buildings 23 have been identified as needing condensate receiver pumps.

ITEM 3: Design and provide construction plan drawings for the repair and installation of any components in the campus steam and condensate distribution loop (between the building condensate return tank and the Energy Plant) that are identified to be non-compliant with VA specifications, VA design guides, manufacturer recommendations, or that are identified as anything less than industry best practice.

100% Response: Drawings have been completed. Where possible equipment has been repaired and/or brought into compliance.

ITEM 4: Investigate, design, and install components to allow remote steam trap monitoring, and valve operation from outside the manholes.

100% Solution: Remote valve actuation and steam trap monitoring have been built into the design.

Valves will have an operating time of approximately 60 seconds. All steam traps will have a steam blow-by sensor and a water logged sensor. These sensors will be wired for long term reliability and simplicity. Failures will be reported to a Sprirax Sarco monitoring panel within the controls cabinet.

Note – Manhole 1 will not have new motorized valves or trap monitoring. This manhole is under building 75 and can be easily accessed without a confined space permit. For this reason the A/E recommends not installing remote/monitoring devices in this location.

ITEM 5: Moisture monitoring in the steam vaults using visual indicators (like a light on the outside of the manhole) if water is detected.

100% Solution: Each manhole will be equipped with a high level alarm switch on the sump pump controls which will activate an alarm state on the control panel and provide a visual indicator alarm to maintenance personnel.

ITEM 6: Investigate pipe scaling conditions.

100% Response: Pipe scaling occurs when continuous water total hardness and high levels of minerals, such as calcium and magnesium, are present in a piping system at above tolerance limits.

Based on the station provided water condition reports, it is unlikely any major scaling is occurring in the high-pressure steam lines. Some recent water condition reports indicated out of tolerance total hardness in the condensate return lines. Multiple possible situations can contribute to water condition that can cause pipe scaling. Recent construction affecting piping, breaks in lines, maintenance issues with condensate collection equipment, old piping, etc. can all be potential causes of pipe scaling. To identify where the hard water source is coming from, water testing should be done at the condensate receiver tank of each building before it enters the site return system. Other items to consider include evaluation of any condensate return systems that were repaired or site work around the same time as the out of tolerance hardness was detected. These events could potentially introduce impurities into the system, causing unfavorable water conditions that can lead to pipe scaling.

ITEM 7: Preventative maintenance plan for steam vaults

100% Solution: A checklist style plan has been created. This includes checking steam traps, pumps, ITEM 8: Duplex sump pumps as needed in manholes.

Intent: Any sump that does not have a duplex, or sump that is not pumped shall be fitted with a duplex style sump pump.

100% Solution: Duplex sump pumps are shown in the design.

100% Final updates

The primary intent of this project and investigation included determining why compensators have failed and what can be done to prevent this from happening in the future. After the investigation was completed it was determined that water hammer was the cause of the failures. The engineering team has implemented two solutions to mitigate the water hammer issues. The first being pressure powered condensate receiver pumps in manholes 8, 13, and 16. These manholes specifically have positive slopes on either side meaning these areas are prone for condensate to building up in the high pressure steam line. These pressure pumps will allow for more condensate to be removed compared to steam traps alone. At manholes 12 and 15, they will receive slip style compensators. Manhole 16 will receive a bellows style compensator which addresses lateral load concerns. These manholes specifically are on the lowest side of the loop and have the greatest potential for water hammer events. The new slip style compensators will withstand higher pressures if water hammer does persist, and leaks can be fixed by adding packing without shutting down the steam system. The manhole 16 compensator has been designed to accept lateral loads due to the existing pipe conditions. Replacing low spot compensators will add safety value and durability. In conclusion, these two solutions will greatly reduce the risk of compensator failures and water hammer in general.

ELECTRICAL NARRATIVE PAGE 12

ELECTRICAL NARRATIVE

Scope of work consists of electrical design to support the rehabilitation/upgrading of the existing campus steam system. The electrical design shall include the following:

1) Provide electrical to support remote steam trap monitoring and valve operation from outside of the manholes.

2) Provide electrical and controls to support manhole duplex sump pump stations.

EXISTING CONDITIONS

Based on field investigation to verify existing conditions, we observed that not all manholes have power available. For manholes that do not have power available, we do not know where to circuit power from to get power to the manhole. The circuits in the following manholes do not have power:

• MH-2

• MH-3

• MH-4

• MH-5

• MH-6

• MH-12

• MH-13

• MH-15

The rest of the manholes within the project scope were observed to have circuits with power available.

Based on conversations with VA electricians as well as site investigation of electrical panels, it is our understanding that the manholes are fed from buildings 18, 55, and 75. Building 18 feeds Manhole MH-

18. Building 55 appears to feed manholes MH-7, MH-8, MH-9, and MH-10. The remaining manholes under our project scope appear to be fed from building 75. VA electricians also advised that multiple manholes are fed from a panel located in manhole MH-5, however the underground circuit from building

75 to manhole MH-5 was severed during a construction project and it isn’t known if the circuit has been repaired.

Currently, remote operation of manhole valves and remote monitoring of manholes/piping does not exist.

ELECTRICAL NARRATIVE PAGE 13

PROJECT UPGRADES

Power – As stated above, AE has worked with the VA to confirm the existing power sources of each manhole as practical without resorting to more invasive investigations such as circuit tracing. Due to this, exact sizing, condition, and routing of circuits is unknown and will be required by the construction contractor to investigate and as-build the existing conditions. In order to reduce phasing efforts, shutdowns, and ensure panelboard capacity, new panelboards have been provided for Buildings 55 and 75 to provide power to the new sump pump control panels. The existing building 18 panelboard has been verified to have adequate capacity based on as-built loading information, therefore, the existing panel is being reused; however, the existing feeder supporting the manhole is being upsized to account for the new sump pump control panel load.

Duplex Pump Control Panel and Associated Rack Equipment – The duplex sump pump control panel requirements and installation details are as follows:

1. Control panel shall be mounted to a stainless steel Unistrut rack.

2. Control panel enclosure shall be stainless steel, NEMA 4x.

3. Control panel enclosure shall house the following equipment:

a. Swing door mounted pilot devices including open-off-close dials for motorized valves, lead-lag selector switch, available power light, pump running, pump fault, high-level alarm. All pilot devices shall be 30mm type; pilot lights shall be LED push-to-test.

b. One (1) motor starter for each pump. Starter shall be Across-The-Line (ATL), Full-

Voltage Non-Reversible (FVNR), NEMA rated with electronic overloads. Each starter shall be protected by a circuit breaker.

c. Hardwired, relay-based controls: All controls shall be provided by readily available off-the-self components including pilot devices, control relays, control circuit breakers, control power transformer, seal fail/moisture sensor controller, float switches, pump runtime meter, terminals, and fuse blocks.

d. Enclosure auxiliary devices shall include motion activated panel light, thermostatically controlled panel heater, GFCI duplex receptacle (120v), externally mounted audio-visual alarm, remote steam trap monitoring, and remote valve operation.

e. Please note that the control panel wiring diagram has not been completed as final instrumentation selections are still being coordinated with vendor.

4. All control panel locations are mounted in the field outside of the vault, with the only exception being Manhole “MH-2”. Manhole “MH-2” is located in an asphalt/driveway area and is unable to

ELECTRICAL NARRATIVE PAGE 14

safely and practically place a control panel directly adjacent to the manhole. AE has provided an

RFI to the VA for possible control panel locations; AE awaits VA direction for proposed control panel location.

Lighting – Sump pump control panels have been provided with motion activated panel lights interior to the control panel.

Conduits - Conduits shall be rigid where used in damp or exposed locations, or where specifically required by the NEC. PVC conduits shall be used where routed underground. Electrical metallic tubing shall be used in dry concealed locations and in furred, ceiling spaces. Flexible conduits shall be used for final connections to motor driven equipment and vibrating equipment. Conduit shall not be used as a ground path; all electrical circuits shall contain a ground wire. All IT/special system conduit minimum size shall be 1”; all other minimum conduit size shall be 3/4-inches. Conduit seal-off fittings will be provided if required due to classification of manholes.

Conductors – We will provide copper conductors with 600-volt insulation for low voltage distribution.

Conductors No. 8 and larger shall be stranded, type THWN. Smaller conductors shall be a solid type

THHN/THWN. Aluminum conductors will not be permitted. Conductors for use in high temperature locations shall be insulated as required by the NEC. The minimum size of power conductors shall be

No. 12 AWG.

Codes and Standards

1. National Electrical Code (NEC), NFPA 70

2. Veterans Affairs Electrical Design Manual for Hospitals

3. Veterans Affairs Design Guide, Office and Information Technology

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 15

APPENDIX A – ENVIRONMENTAL INVESTIGATION

Project Overview and Background

Riverfront Safety & Health, LC (Riverfront), a Service-Disabled Veteran Owned Small Business, has provided the required limited asbestos & lead identification field surveys and historical records review in support of the 100% Construction Documents phase of the Correct Campus Steam System Failures (VA Project 657-23-115JB) located at the Jefferson Barracks VA Medical Center, St. Louis, MO (The Project).

The only site features included in the scope of this project are steam manhole/vault locations. No tunnel inspections are currently in the scope of work. Principal contacts for this project are Kimberly Rumpsa of the VA Medical Center and Steve Butros from Spees DB. Currently, RSH understands the scope of work may impact the following related systems:

Steam manhole/vault locations only

The following generalized analysis is provided for your review and future design considerations related to potential asbestos, lead, and mold issues associated with The Project:

Mold impacted building materials are not anticipated and where present are a highly localized condition. Areas will be visually inspected for suspect mold growth on materials located within or near the projected pathways of work.

As a general course of action, reuse of existing wall penetrations and pathways is recommended.

The steam manhole/vaults were operational at the time of the site visits and, due to safety concerns, observations and samples were taken from above. RSH’s inspection was also limited to manholes 12, 15, and 16. Because access was not possible, the inspection was limited only to the visible aluminum-jacketed mineral wool thermal system insulation system over an unpainted steel steam line. The potential for concealed asbestos (TSI, caulks, sealants, and associated fittings) exists. Should additional suspect materials (i.e. caulking, sealants, gaskets, non-mineral wool insulation, or other) be encountered within manholes and within scope of work, stop work immediately and contact VA COR for direction.

Asbestos Inspection Summary

RSH performed limited asbestos and lead surveys on 12/04/2023 – 12/05/2023, to identify the presence, location, quantity, and condition of all asbestos containing materials and lead bearing building components present within the pathways of The Project which may be impacted during the execution of work. The site survey was completed by Justin Rhyneer (CIH) and Charles Davis. Mr. Rhyneer and Mr.

Davis are Missouri licensed Asbestos Building Inspectors and Missouri licensed Lead Risk Assessors.

The surveys were performed in accordance with all applicable local, State and Federal regulations pertaining to asbestos and lead building inspections.

Based on the age of the facility and potential methodology of contract work, anticipated suspect materials included asbestos pipe insulation.

A total of nine (9) samples were collected which included Manhole 12, 15, and 16. A total of zero (0) samples were found to be greater than 1% asbestos.

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 16

Please see attached Appendix A for representative photographs of the aluminum-jacketed duct system and associated mineral wool insulation.

Additional Asbestos and Lead Paint Observations

Although mechanical room G17 was not included in the environmental scope, RSH has performed an inspection in this room during another previous project and is able to provide historical environmental information. Additionally, RSH was able to perform a brief visual inspection of room G17 on 12/12/2023.

Please see attached Appendix A photo log for pipe insulation photographs from room G17.

Building 23, Room G17

• All steam lines are insulated with fiberglass with the exception of one medium pressure steam line. Work requiring disturbance of steam lines labeled with asbestos warning signage is subject to VA asbestos specification 02.82.11.

• All steam lines are presumed to be painted with lead-containing orange paint unless otherwise tested. All work likely to disturb steam lines must be performed in accordance with VA lead specifications 02.83.33.13.

Please see the included Table 1 for the full RSH asbestos bulk sampling. A photo log is included as Appendix A. Laboratory analytical reports, sample chains of custody, and certifications are contained in Appendices B and C.

Riverfront appreciates the opportunity to assist with this project. It is our intent that this information will assist with project development at this phase. Please feel free to contact us with any questions or concerns.

Sincerely, February 16, 2024 Justin R. Rhyneer, CIH Date Principal

Table 1: RSH Field Sampling Summary Table Appendix A: Photo Log Appendix B: Asbestos Laboratory Results Appendix C: Professional Certifications

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 17

TABLE 1: RSH ASBESTOS SAMPLING SUMMARY

Field Sampling December 5, 2023

Sample No.

Material Description

Sample Location

Homogenous Area

Category Condition Quantity Asbestos Content

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 12 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 12 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 12 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 15 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 15 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 15 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 16 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 16 Non-

Friable Good

None Detected

SH1899-

120523-

Insulation Package

Steam line Main

Manhole 16 Non-

Friable Good

None Detected

Notes:

1) Positive ACM samples are noted in bold type.

2) An asbestos-containing material is defined as a material that contains greater than 1% asbestos.

3) A friable asbestos-containing material is a material that can be pulverized, crumbled, or reduced to powder by hand pressure. Likewise, a non-friable asbestos-containing material is a material than cannot be pulverized, crumbled, or reduced to powder by hand pressure.

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 18

Appendix A: Photo log

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 19

Appendix B: Asbestos Laboratory Results

APPENDIX A – ENVIRONMENTAL INVESTIGATION PAGE 20

Appendix C: Professional Certifications

APPENDIX B – PREVENTIVE MAINTENANCE PLAN PAGE 21

APPENDIX B – PREVENTIVE MAINTENANCE PLAN

Preventive maintenance is crucial for ensuring the reliability and efficiency of a steam distribution system. Regular checks and maintenance activities can help identify potential issues before they become major problems. See below for a list of items that should be done internally and see next page for the manhole preventive maintenance checklist.

Documentation and Record Keeping:

- Maintain a comprehensive maintenance log.

- Document all inspections, tests, and repairs.

- Keep manufacturer's manuals and documentation up-to-date.

Spare Parts Inventory:

- Maintain an inventory of critical spare parts.

- Replace gaskets, seals, and other consumables regularly.

Emergency Response Plan:

- Develop and review an emergency response plan.

- Train personnel on emergency procedures.

APPENDIX B – PREVENTIVE MAINTENANCE PLAN PAGE 22

Date: _______________________

Personnel: ___________________

Preventive Maintenance Checklist for Manholes

All maintenance should be done quarterly unless otherwise indicated.

Steam Pipes and Fittings:

Inspect insulation for damage and repair as necessary.

Check for signs of steam leaks, such as water stains.

Inspect hangers and supports for stability and integrity.

Inspect and note any changes in alignment of compensators.

Steam Traps:

Inspect valves for steam trap isolation and bypass line.

Inspect and clean strainers.

Controls and Instrumentation:

Cycle control valves for proper function

NOTE: this should be done annually and coordinated with the buildings that are affected by the momentary shutdown.

Cycle sump pump by dumping water into the pit.

END OF NARRATIVE

ADD1 BOD Cover Sheet - 657-23-115JB Conformed Set