SOW Appendix B.pdf

VHA Safety Device Test Item Device VHA Testing Requirement Deficiency Action Required VA TIL Specification Section Sub‐Section Paragraph

Low Water Alarm:

A separate low water alarm is required from the low water cutouts

Install low water alarm probe, relay, alarm light and alarm bell

Install proper low water alarm

SECTION 23 09 11 Instrumentation & Control for Boiler Plant

2.4 BOILER/BURNER CONTROL

PANELS

G. Boiler water level alarm on face of panel (non lock‐out):

1. Provide separate visual indications and audible alarm (bell) for high water and low water. Low water alarm is separate from low water cutouts and set at higher level than low water cutouts

2 Shunt Switches:

An Independent shunt (bypass) switch is required to be installed for each LWCO

NO shunt switches installed on either device

Need to Install 2 shunt switches

SECTION 23 52 39 Firetube Boilers

2.1 BOILER TRIM (ACCESSORIES)

D. Water Level Safety and Operating Controls and Indicators:

1.b. Primary and auxiliary cutoffs shall require separate manual reset non‐latching shunt switches shall allow blowdown of water columns without shutting down the burner.

3 Primary LWCO Installation:

The VA requires one float low water cutoff. No automatic re‐start after a low water cut out is allowed by the VA

LWCO is wired in limit circuit & not the 3‐P Running Interlock Circuit

Auxiliary LWCO Installation:

The VA requires one probe low water cutoff. No automatic re‐start after a low water cut out is allowed by the VA

ALWCO is manual reset however it is wired in limit circuit & not the 3‐P Running Interlock Circuit

Water Level in Gauge Glass:

Visible separation of water level in sight glass between all alarms is required. Water level in sight glass is required to be visible for all alarms and cutouts

Low Water Alarm trips within the sight glass, however the Low Water Cut Off trips out of the visable glass

Checklist for High Water Alarm on Boiler (HWAB) 6 High Water

Alarm:

Sight glass water level is required to be 1” or more below top of sight glass at alarm

Install high water alarm probe, relay, alarm light and alarm bell

Add High Water Alarm Probe

Checklist for Recycle and Non‐Recycle Boiler Steam Pressure Limit Switches

(RBSPLS & NRBSPLS)

Non‐Recycle Steam Pressure Limit:

The VA requires no automatic re‐start after a trip

NRBSPLS is wired in limit circuit & not the 3‐P Running Interlock Circuit

Verify where limits are wired SECTION 23 52 39 Firetube Boilers 2.1

BOILER TRIM (ACCESSORIES)

F. High Steam Pressure Burner Cutouts

1. Provide two UL listed, FM approved units with different set points.

Unit with lowest set point shall be automatic reset; unit with highest set point shall be manual reset and shall interrupt the power supply to the burner management control system.

Steam Safety Valve 1:

SVB1 is required to be set 5 psig higher than NRBSPLS & 10 psig below boiler MAWP.

Based on Boiler MAWP of 150 psi, SVB2 has a maximum trip point setting of 140 psi, valve is currently set at 150 psi

Steam Safety Valve 2:

SVB2 is required to be set 5 psig or higher than SVB1 & 5 psig or more below boiler MAWP

Based on SVB2 maximum trip point of 140 psi, SVB1 maximum trip point setting must be 145 psi or lower, valve is currently set at 150 psi

10 Test Points:

In order 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 in order to determine the switch trip point.

No locking test valve in place. Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

Need to reset switch to proper range

P. Burner Safety Shutdown Interlock Devices:

9. High and Low Main Burner Fuel (Gas and Oil) And Low Igniter (Pilot) Gas Pressure Interlocks

g. Set points shall be within 20 percent of the normal operating pressure

12 Test Points:

In order 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 in order to determine the switch trip point.

No locking test valve in place. No pressure gauge in place.

Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

13 Wrong Location HFGPCS is required to be downstream of PRV & upstream of flow control with setpoint less than 120% of regulated pressure

HGPS located in wrong location.

Needs to be moved between the Modulating Valve and Main Gas Valve

P. Burner Safety Shutdown Interlock Devices:

9. High and Low Main Burner Fuel (Gas and Oil) And Low Igniter (Pilot) Gas Pressure Interlocks

f. Switch Locations: Must be located where pressure is constant, as controlled by pressure regulator (if provided) on fuel train. Must be upstream of modulating fuel flow control valves.

14 Test Points:

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

No Locking Valve Installed No Gauge Installed No Test Port Installed

Install proper test points SECTION 23 52 39 Firetube Boilers

2.3 BURNER AND FUEL TRAINS

E. Natural Gas Main Fuel Train:

4. Automatic Safety Shut‐Off Valves:

d. Construction: Valves 65 mm (2‐1/2 inches) and greater, flanged ends; valves 50 mm (2 inches) and less threaded ends; position indicator showing open and shut, visible from front or side of boiler.

Aluminum seating surfaces are prohibited. Closed position interlock switch on each valve. Valved leak test fittings before and after each valve

15 Valve Construction:

VA TIL does not allow soft seat valves The Siemens , globe‐type valve body features a soft synthetic seat

Replace main gas valves wih VA approved Maxon Valves

Checklist for Low Water Alarm and Cutoffs on

Boiler

(LWA/LWCO/ALWCO)

Checklist for High Fuel Gas Pressure Cutoff Switch

(HFGPCS)

SECTION 23 09 11 Instrumentation & Control for Boiler Plant

2.2 Burner Management (Flame

Safeguard Control) System with Safety Interlocks and Accessories

Checklist for Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (AFGSOV & AFGSVV) – Main Gas Line

VA safety device testing program has revealed problems with auto safety shut off valves other than Maxon. Problems included proof of closure switches, and pressure pulses upon closure that affect the high gas

Checklist for Steam Safety Valves on Boiler (SVB) Follow VHA Testing Manual Requirements

SECTION 23 09 11 Instrumentation & Control for Boiler Plant

2.2 Burner Management (Flame

Safeguard Control) System with Safety Interlocks and Accessories

Checklist for Low Fuel Gas Pressure Cutoff Switch

(LFGPCS)

Trip Point Setting

LFGPCS is required to be downstream of PRV and upstream of AFGSOV with a setpoint of 80% or higher than regulated pressure. The use of snubbers or dampeners on LFGPCS is prohibited

Set point wrong

Suspect the range is wrong due to regulator dip on startup (tripping LGPS) – Fisher 1098 regulator with dual pilots is usually required

SECTION 23 09 11 Instrumentation & Control for Boiler Plant

2.2 Burner Management (Flame

Safeguard Control) System with Safety Interlocks and Accessories

15. Low Boiler Water Level Interlocks:

Primary and auxiliary low water burner shutdown interlocks.

Operation of auxiliary low water cutoff shall interrupt the power supply to the burner management control system .

SECTION 23 52 39 Firetube Boilers

2.1 BOILER TRIM (ACCESSORIES)

D. Water Level Safety and Operating Controls and Indicators:

2.b. Height of water column and gauge glass shall be sufficient to show water level in the gauge glass at least 15 mm (1/2 inches) above high water alarm set point and at least 15 mm (1/2 inches) below auxiliary low water cutoff set point .

Verify where limits are wired

Replace Safety Valve with properly ranged one ‐ Note new directive for cast iron

Appendix B

H. Igniter (Pilot) Fuel Train, Burner and Ignition System:

1. Arrangement:

1. Arrangment: Comply with typical arrangement in NFPA 85, Annex A, as modified by the following description. Arrange the system to allow selection of either natural gas or propane for the ignition fuel. Provide separate piping with plug valve, pressure gauge, filter and pressure regulator for natural gas and for propane. Connect to the main burner natural gas service downstream of the main burner pressure regulator.

Join the natural gas and propane services by means of a three‐way plug valve. Continue with one pipe line including a low pressure switch, pressure gauge, automatic safety shut off valve, automatic vent, automatic safety shut off valve, igniter.

H. Igniter (Pilot) Fuel Train, Burner and Ignition System:

5. Vent System Manual Plug Valve for Leak Tests:

Located on vent line on outlet side of automatic vent valve. Provide locking device and lock wrench to lock valve to open position. Provide cylinder padlock keyed to VA Engineering key. Provide valved leak test connections between automatic vent valve and plug valve and ahead of the automatic vent valve.

18 Test Points: Test point is required No Locking Valve Installed No Gauge Installed No Test Port Installed

Install proper test points

H. Igniter (Pilot) Fuel Train, Burner and Ignition System:

4. Automatic Safety Shut‐Off and Vent Valves

a. Type: Solenoid‐type, two normally closed shut‐off valves and one normally‐open vent valve, arranged as shown, controlled by the burner control system. Provide threaded leak‐test ports with threaded plugs on each shut‐off valve body.

Checklist for Proof of Closure on Automatic Fuel Shutoff Valves (POC‐ AFGSOV) – Natural Gas

Missing Component

All safety devices that require fuel shutdown rely on the two automatic fuel shutoff valves to perform this task. Proof of Closure switches must be present in both automatic shut off valves. Both oil and gas automatic shut off valves require proof of closure switches.

Not VA approved POC Switches Install Maxon Valves, Oil POC are good

SECTION 23 52 39 Firetube Boilers

2.3 BURNER AND FUEL TRAINS

E. Natural Gas Main Fuel Train:

4. Automatic Safety Shut‐Off Valves:

d. Construction: Valves 65 mm (2‐1/2 inches) and greater, flanged ends; valves 50 mm (2 inches) and less threaded ends; position indicator showing open and shut, visible from front or side of boiler.

Aluminum seating surfaces are prohibited. Closed position interlock switch on each valve. Valved leak test fittings before and after each valve

Checklist for Flame Scanner‐for main flame out (FSMFO)

Checklist for Flame Scanner Not Sensing Igniter Spark (FSNSIS)

Checklist for Main Flame Ignition Timing (MFIT)

22 Test Points:

Maximum timing is required to be 14 seconds from attempt to start boiler until AFGSOVs close. Close the lockable manual valve in the fuel line after the second (AFGSOV) and before the

HFGPCS.

No locking test valve in place. No pressure gauge in place.

Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

Checklist for Low‐Fire Proving Switch (LFPS)

A low fire proving switch can be located in the drive motor that causes the movement of the fuel valve or air damper but, in that case, all linkages between the drive motor and valve/damper must be drilled and pinned.

Single point jackshaft system controlling Gas Valve, Air Damper and Oil Valve – Linkage is NOT drilled and pinned as required

P. Burner Safety Shutdown Interlock Devices:

13. Low Fire Position of Fuel Flow Control Valves Interlocks:

Sealed snap‐acting switches. Actuate switches by levers attached directly to fuel valves. As an option, the switch lever may be pinned to the jackshaft to which the fuel valve proportioning cams are also pinned or provide UL listed and FM approved position sensor (internal snap acting switches within the actuator a feedback signal may not act as any part of this safety device.) on the motor which positions the jackshaft to which all the operating levers are pinned.

Checklist for Forced Draft Damper Wide‐Open Pre‐ Purge Proving Switch

(FDDWOPS)

24 If the switch is not actuated by damper itself, all connections in linkages must be drilled & pinned

Linkage is NOT drilled and pinned as required

P. Burner Safety Shutdown Interlock Devices:

5. Forced Draft Fan Damper, Boiler or Economizer Flue Gas Outlet Damper (if provided) Pre‐Purge Position Interlock:

Prove dampers wide open for pre‐purge. Actuate sealed snap‐action switches by levers attached directly to dampers or to damper linkages, which are pinned to prevent slippage. Parallel positioning systems may have the interlock switches in the drive units. The switches are dedicated for the flame safeguard system and perform no other function or purpose and are make or break switches.

Checklist for Combustion Air Pressure Switch (CAPS) 25 Test Points:

In order 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 in order 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.

Checklist for Main Flame Ignition Timing (MFIT)

Maximum timing is required to be 14 seconds from attempt to start boiler until AFGSOVs close. Close the lockable manual valve in the fuel line after the second (AFGSOV) and before the HFGPCS. SECTION 23 09 11 Instrumentation &

Only a UV – Self checking scanner is VA compliant

Wrong Device

General

Checklist for Automatic Pilot Fuel Gas Shutoff Valves & Automatic Pilot Fuel Gas Solenoid Vent Valve Seat Leakage

(APFGSOV & APFGSVV) –

Pilot Line

General Installation

SECTION 23 52 39 Firetube Boilers

2.3 BURNER AND FUEL TRAINS

Provide self‐checking ultraviolet (UV) scanners. Self‐ checking UV scanners shall have minimum checking frequency six times per minute.

Position scanners so that they do not view the ignition spark. Scanner sight tubes must be non‐reflective to avoid the scanner detecting the reflection of the ignition spark. UV non‐self‐checking scanners are prohibited because they can fail in an unsafe mode on continuously operated burners.

D. Flame Scanners:

Replace Flame Safeguard and Scanner with proper UV self‐checking type

Scanner is not self‐checking type

No Locking Valve Installed No Gauge Installed No Test Port Installed

Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

General Installation

Servo Not allowed for LFS and HFP switch. Drill and Pin all linkage

PAPS is required to make at 80% or more of maximum differential pressure signal at high fire.

Missing Purge Airflow Switch Install purge air switch P. Burner Safety Shutdown Interlock Devices:

7. Pre‐Purge Airflow Interlock:

a.Sense differen al pressure between two points in combus on air system where the differential pressure at high fire is significant, such as several inches water column. There must be no intervening dampers. This is typically between the wind‐box and boiler outlet.

28 Test Points:

In order 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 in order 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.

No Locking Valve Installed No Gauge Installed No Test Port Installed

Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

Checklist for Forced Draft Motor Interlock Switches

(FDMIS)

The FDMIS are required to be current relays (one on each of the three phase legs) that can be unlatched and removed for testing (split‐ core, hinged, clamp‐on).

Missing current relays Install current relays

P. Burner Safety Shutdown Interlock Devices:

3. Forced Draft Fan Motor Operation Interlock:

Provide split ring current relays on each phase of power circuits to fan motor, required on all systems.

Low pressure fuel cutoff switches are found on the main gas line, main oil line, and pilot gas line. The switch in all three of these applications senses the supply fuel pressure after the pressure regulating valve and upstream of any fuel control valve

Missing pilot low gas pressure switch Install pilot low gas pressure switch

P. Burner Safety Shutdown Interlock Devices:

9. High and Low Main Burner Fuel (Gas and Oil) And Low Igniter (Pilot) Gas Pressure Interlocks:

b. Solid‐state sensor, automatic reset. Provide graduated set point indicator, switch position indicator, adjustable set point coordinated with burner requirements either on the switch or as a part of the controller.

31 Test Points:

In order 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 in order 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.

No Locking Valve Installed No Gauge Installed No Test Port Installed

Install proper test points P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

Checklist for Low Flue Gas Oxygen Level Interlock

(LFGOLI)

The VA requires that all boilers have a low flue gas oxygen level alarm and interlock, which protects against firing with a “rich” fuel/air mixture. This system consists of using a zirconium oxide sensor in the stack to continuously measure oxygen. This signal is used to provide an alarm and interlock if the percent oxygen level falls below a set point. The set point should be as low as practical without the possibility of excessive CO and combustibles The VA requires that less than 200 ppm of CO and combustibles are present in the exhaust gas from the boiler. This interlock is electronically integrated into the burner management system for the boiler

Missing low flue gas oxygen interlock Install low flue gas oxygen interlock

P. Burner Safety Shutdown Interlock Devices:

16. Low Flue Gas Oxygen Alarm and Interlock:

Signals from flue gas oxygen analyzer providing low oxygen alarm and low oxygen burner shutdown.

Checklist for Liquid Relief Valve on Oil Pump Set

(LRVOPS)

33 LRVOPS is required not to be used as a backpressure regulator

Oil pump located in CEP with the LRVOPS

Checklist for Low Fuel Oil Pressure Cutoff Switch

(LFOPCS)

Checklist for High Fuel Oil Pressure Cutoff Switch

(HFOPCS)

Checklist for Low Atomizing Media Pressure Switch (LAMPS)

Checklist for Automatic Fuel Oil Shutoff Valves (AFOSV) ‐ for Seat Leakage

37 No Test Port Valve Installed

Siemens LVM installed instead of Fireye

38 Wrong FSG

Checklist for Low Pilot Fuel Gas Pressure Cutoff Switch

(LPFGPCS)

General Installation

Control for Boiler Plant

2.2 Burner Management (Flame

Safeguard Control) System with Safety Interlocks & Accessories

General Installation

Checklist for Purge Airflow Proving Switch (PAPS)

General Installation

a. Installation of all interlock devices shall permit testing of set points and control operation without removing or disconnecting the devices and without adjusting set points of devices. Provide permanent connection points for test instruments, such as manometers and pressure gauges, on sensing piping and tubing. Where necessary, provide lockable valves to allow temporary isolation of device from the service to allow testing of the device.

P. Burner Safety Shutdown Interlock Devices: 2.

Provisions for Testing of Interlocks

No Locking Valve Installed No Gauge Installed No Test Port Installed

Test Points:

In order 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 in order 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.

Install proper test points

SECTION 23 09 11 Instrumentation & Control for Boiler Plant

2.2 Burner Management (Flame

Safeguard Control) System with Safety Interlocks & Accessories