P09 - SOW Boiler Plant Repairs Miles City 436-24-123.pdf

Statement of Work Boiler Plant Repairs Miles City CLC, MT

Project Number: 436-24-123

1. Description of Services/Introduction: The contractor shall provide all personnel, equipment, supplies, transportation, tools, materials, supervision, and other items consisting of service parts necessary to perform the corrections to each boiler as detailed in this statement of work (SOW). All work shall be performed on existing two low pressure boilers and ancillary equipment located in Miles City Community Living Center (CLC) Boiler Plant. The two boilers are manufactured by Hurst.

Boiler #1: Hurst LPS Boiler; Model DS100-15-11; SN: DS-1000-15-11

Boiler #2: Hurst LPS Boiler; Model DS100-15-11; SN: DS-1000-15-12

2. Background: This VA Medical Center relies on these two boilers to supply steam for a multitude of processes that are critical to the operation of this facility. The need to properly maintain these boilers are critical for patient care services at this facility. These boilers are inspected annually by a 3rd party consultant. The Consultant provided report details on non-compliance from the Boiler Safety Device Testing Manual - 8th Edition.

3. Technical Specifications:

4. Period of Performance: The period of performance for this project shall be 365 days from the Notice to Proceed (NTP).

5. Place of Performance:

Miles City CLC 210 S Winchester Ave Miles City, MT 59301

6. Scope: Correct all non-compliance/failures on two boilers and ancillary equipment as described in 3rd party reports and in accordance with this Statement of Work (SOW). Each repair will then be required to be inspected/tested in accordance with VHA Boiler Safety Testing Manual 8th Edition.

• Miles City CLC Boiler Plant (bldg. #1) o Low Pressure Boilers #1 and #2.

o Boiler Plant Ancillary Equipment

Deaerator Tank Condensate Tank Fuel Oil Pumps Metering Equipment Emergency Fuel Shutoff Dangerous Gas Monitoring

7. Technical Documents/VHA Policy: The following technical documents, manuals, and VHA policy directives must be adhered to achieve acceptable results. Applicable documents include the following:

• VA Master Construction Specification PG-18-1 Division 23 (i.e., view and access the VA Master

Construction documents listed under this bullet point at https://www.cfm.va.gov/til/spec.asp#23) o 23-09-11 Controls o 23-52-39-Firetube boilers o 23-52-35-Low pressure and Hot water boilers o 23-50-11 Boiler Plant Mechanical Equipment

• Boiler Safety Device Testing Manual - 5th Edition

• VHA Steam Design Manual

• VHA Directive 1810 (1) Boiler and Boiler Plant Operations.

• Boiler Plant Inspection Report Miles City MT 2023 (i.e., Please be advised this document is being provided as reference only, thus not all discrepancies in this audit report are part of the scope of this project, it is important to make that distinction and follow the statement of work).

8. Mandatory Tasks/Requirements: Site Investigation is required for this project to ensure accuracy of design. The Contractor shall be responsible for field verifying all conditions and quantities that may affect the project work prior to bid of this project. Site investigation is to be included in the cost proposal. All services/work performed shall meet manufacturers performance and technical speciation’s, all applicable reference documentation listed in section 7, and in accordance with all information listed below:

https://www.cfm.va.gov/til/spec.asp#23

8.1 Building 1 (Low Pressure Boilers #1 and #2). The following tasks must be performed on Boilers 1 and 2. A site visit is mandatory to

• Burner Management / Flame Safeguard System o Provide and install Fireye YB-110UVSC (UV self-checking model) Burner Management System with YP100 programmer card.

o Program unit for adequate purge timing, 10 second ignitor timing / pilot trial for ignition time, and 10 sec main flame trial for ignition time.

o Provide and install YZ-300 expanded annunciator.

o Wire YZ-300 expanded annunciator to match the given Fireye factory wiring diagram so that all safeties annunciate properly. Program accurate annunciations for any auxiliary terminals used.

o Provide and install Fireye 45UV5 Self Checking Flame Scanner. Position Flame Scanner so that it does not detect the ignitor spark, and detects an adequate flame signal on both natural gas and #2 fuel oil operation throughout the firing rate.

• Main Natural Gas Train and Fuel System and Pilot Gas Train.

o Specify, provide, install a Natural Gas Pressure Regulator that meets VA performance specification given in VA master specification 23 52 39 Fire tube boilers. Regulator must have no more than 5% droop from the set pressure and a response so that pressure does not dip below 20% regulated pressure at start up.

o Provide and install Low Fuel Gas Pressure Cutoff Switch to meet VA Specification 23 09 11 and 23 52 39. Switch activation point should be in the middle of operational switch range. Plumb the Low Fuel Gas Pressure Switch upstream of the automatic shutoff valves and downstream of the pressure regulator. Plumb an Isolation ball valve modified to be Lockable Only in the OPEN Position and a test port as shown in the VHA Safety Device Testing Manual 5th Edition. Wire Low Fuel Gas Pressure Cutoff Switch into Fireye YB-110 terminals 3-P running interlock circuit and to proper terminals on YZ-300 Expanded Annunciator. Upon activation of the switch boiler must shutdown and lockout. The Fireye must Annunciate “Low Gas Pressure”.

Set Low Fuel Gas Pressure Cutoff Switch to activate at 80% of regulated gas pressure.

o Provide and install High Fuel Gas Pressure Cutoff Switch to meet VA Specification 23 09 11 and 23 52 39. Switch activation point should be in the middle of operational switch range. Plumb the High Fuel Gas Pressure Switch upstream of the automatic shutoff valves and downstream of the pressure regulator. Plumb an Isolation ball valve modified to be Lockable Only in the OPEN Position and a test port as shown in the VHA Safety Device Testing Manual 5th Edition. (SDTM) Wire High Fuel Gas Pressure Cutoff Switch into Fireye YB-110 terminals 3-P running interlock circuit and to proper terminals on YZ-300 Expanded Annunciator. Upon activation of the switch the boiler must shutdown and lockout and Fireye must Annunciate “High Gas Pressure”. Set High Fuel Gas Pressure Cutoff Switch to activate at 120% of regulated gas pressure.

o Provide and Plumb Manual isolation ball valve downstream of the automatic vent valve on main natural gas train. Modify valve to be lockable only in the open position. Add test port upstream of isolation valve. Refer to figure on page 63 in the SDTM 5th Edition for the proper plumbing configuration.

o Provide materials and plumb pilot vent line between Automatic Pilot Shutoff Valves.

Vent line must vent to roof. Provide and install Normally Open Automatic Vent Valve (ASCO Red Hat). Add manual isolation valve lockable only in the open position downstream of vent valve and add test port upstream of manual isolation valve. Add test port downstream of first automatic pilot shutoff valve and downstream of second automatic pilot shutoff valve. Refer to VHA Boiler and Plant Device Safety Device Testing Manual 5th Edition for proper pilot gas train plumbing configuration.

o Drill and Pin all possible gas valve linkage slip points from actuator to flow control valve /Cam.

o Specify, provide, and install Low Pilot Fuel Gas Pressure Cutoff Switch to meet VA master specification 23 09 11 and 23 52 39. Plumb Low Pilot Fuel Gas Pressure Cutoff Switch downstream of the pilot regulator and upstream of automatic pilot shutoff valves. Plumb isolation ball valve, modified to be lockable only in the open position, before the switch. Plumb test port downstream of Lockable only open isolation valve. Mount switch in an accessible location. Switch activation point must be in the middle of the switch operational range. Wire switch into Fireye YB-110 terminals 3-P running interlock circuit and to proper terminals on YZ-300 Expanded Annunciator. Upon activation the boiler must shutdown and lockout and Fireye must Annunciate “Low Pilot Gas Pressure”. Set Low Pilot Fuel Gas Pressure Cutoff Switch to activate at 80% of regulated pilot gas pressure.

• Boiler Air Train, Stack, and Fan o Specify, provide, and install Combustion Air Pressure Switch (CAPS) to meet VA specification 23 09 11 and 23 52 39. Switch must be a differential pressure switch with switch activation point in the middle of the operational switch range. Plumb low-pressure line / tubing from the forced draft fan inlet downstream of any dampers to low pressure leg of Combustion Air Pressure switch. Provider should select a proper location so that adequate pressure signal can be obtained. Provide and install test port with valve in low pressure line leading to CAPS switch in an accessible location near the switch. Plumb high-pressure line / tubing from the forced draft fan outlet upstream of any damper to high pressure leg of Combustion Air Pressure switch. Contractor should select a proper location so that adequate pressure signal can be obtained.

Provide and install test port with isolation ball valve modified to be lockable only open position in high pressure line leading to CAPS switch in an accessible location near the switch. Refer to VHA SDTM 5th Edition for proper plumbing diagram. Locate switch in an easily accessible location. Wire switch into Fireye 3-P running interlock and proper YZ-300 terminals. Upon activation of switch, boiler must shutdown and lock out. Annunciation must read “Low Combustion Air” or equivalent. Switch must be set to activate at 80% of minimum differential pressure sensed across the fan.

o Specify, provide, and install Purge Airflow Proving Switch (PAPS) to meet VA specification 23 09 11 and 23 52 39. Switch must be a differential pressure switch with switch activation point in the middle of the operational switch range. Plumb low-pressure line / tubing from boiler stack upstream of any dampers to low pressure leg of Purge Airflow Proving switch. Provider should select a proper location so that adequate pressure signal can be obtained. Provide and install test port with valve in low pressure line leading to PAPS switch in an accessible location near the switch. Provide drip leg for low pressure line. Plumb high-pressure line / tubing from the forced draft fan outlet downstream of any damper to high pressure leg of Purge Airflow Proving switch.

Contractor should select a proper location so that adequate pressure signal can be obtained. Provide and install test port with isolation ball valve modified to be lockable only open position in high pressure line leading to PAPS switch in an accessible location near the switch. Refer to VHA SDTM 5th Edition for proper plumbing diagram. Locate switch in an easily accessible location. Wire switch into Fireye M-8 Purge proving circuit. Upon activation of switch purge count must start and when switch opens purge count must stop. Switch must be set to activate at 80% of maximum differential pressure sensed across the boiler.

o Specify, provide, and install clamp on, hinged current relays on each phase leg of the fan (total of 3). These current relays must be accessible for testing and not installed in a panel with high voltage exposure. Refer to page 78 of SDTM 5th Edition. Wire current relays in series with each other and to Fireye 3-P running interlock. Wire into proper YZ-300 annunciator terminals. Upon activation, boiler should shut down and lock out.

Annunciation should read “FD current relays” or equivalent.

o Specify, provide, and install zirconium oxide in situ stack oxygen analyzer into boiler stack. Unit must be calibratable with test gas and include output relays for Low Oxygen level interlock. Plumb line for test and calibration / reference gas application to accessible location. Wire low oxygen cutout relay into Fireye 3-P running Interlock and YZ-300 annunciator. Upon activation of Low oxygen level interlock, boiler must shutdown and lockout. Annunciation must read “Low oxygen Interlock” or equivalent.

• Water Level Protection o Specify, provide, and install low water alarm conductivity probe that meets requirements of VA specification 23 09 11 and 23 52 39. Conductivity probe must be wired to relay that upon low water condition triggers an audible alarm that can be heard throughout boiler plant and visual annunciation. Low water alarm should not shut down the boiler. The length of the conductivity probe must be so that the activation point of the alarm is sufficiently below normal water level as to not cause nuisance alarms but sufficiently above first low water cutout as to provide reasonable operator response time. Typically, this is approximately 1 inch or more below normal water level and at least 1 inch above first low water cutout.

o Wire current primary low water cutout conductivity probe device into Fireye 3-P running interlock and YZ-300 annunciator. Upon activation boiler must shutdown and lockout requiring manual reset. Annunciation should indicate “Primary Low Water Cutout” or equivalent. Provide and install momentary push button shunt “bypass” switch for Primary Low Water Cutout that only bypasses the primary low water cutout probe device. Primary Low water cutout must activate above Auxiliary low water cutout with visible water in the sight glass and visible separation between the cutouts. The preferred separation is 1 inch apart.

o Wire current auxiliary low water cutout float device into Fireye 3-P running interlock and YZ-300 annunciator. Upon activation boiler must shutdown and lockout requiring manual reset. Annunciation should indicate “Aux Low Water Cutout” or equivalent. Provide and install momentary push button shunt “bypass” switch for Aux Low Water Cutout that only bypasses the aux low water cutout probe device.

Auxiliary low water cutout must activate with visible water in the sight glass and visible separation between the cutouts. The preferred separation is 1 inch apart.

Plumb the Aux Low water cutout float device so that it activates above the low water cutout level mark on the side of the boiler.

o Specify, provide, and install high water alarm conductivity probe that meets requirements of VA specification 23 09 11 and 23 52 39. Conductivity probe must be wired to relay that upon high water condition triggers an audible alarm that can be heard throughout boiler plant and visual annunciation. High water alarm should not shut down the boiler. The length of the conductivity probe must be so that the activation point of the alarm is 1 inch or more below top of sight glass. Alarm must activate with burner switch in the OFF position.

• Steam Over Pressure Protection o Wire current steam operational high limit switch into Fireye 3-P Running Interlock and YZ-300 annunciator. Upon activation the boiler must shut down and lockout requiring operator reset. Annunciation should show “High Steam Limit” or equivalent.

o Wire current steam Excess boiler pressure limit switch into Fireye 3-P Running Interlock and YZ-300 annunciator. Upon activation the boiler must shut down and lockout requiring operator reset. Annunciation should show “Excess Steam Limit” or equivalent.

o Specify, provide, and install Two ASME code steam safety relief valves that meet VA specification 23 53 39. Safety valve one setpoint must be 14 psig. Safety valve two setpoint must be 15 psig. Relief capacity of safety valve 1 should be approximately 70% of total boiler capacity. Relief capacity of safety valve two should be higher than SV1 capacity and sum total relief capacity of the two valves must exceed the total boiler steam generation capacity.

o Engineer, provide, and install individual steam relief vents for each safety valve that discharges steam outside through the building roof. Provide and install individual water drains for each valve.

• Fuel Oil Train o Provide, and install pressure gages of the proper range in the fuel oil train. Install pressure gage upstream of the metering pump. Install pressure gage downstream of metering pump. Install pressure gage near burner inlet.

o Specify, provide, and install Low Fuel Oil Pressure Cutoff Switch downstream of the metering pump. Switch must be specified such that the desired activation point of the switch is in the middle of the switch operational range. Plumb switch leg with an Isolation valve in piping leg to the switch modified to be Lockable only in the OPEN position. Install test port with ball valve downstream of the isolation valve. Locate switch in easily accessible location. Wire switch into #2 fuel oil string of Fireye 3-P Running Interlock and YZ-300 annunciator. Upon switch activation the boiler must shutdown and lockout. Annunciation should read “Low Oil Pressure” or equivalent.

The switch must be set to activate at 80% of oil pressure at the switch at low fire.

o Specify, provide, and install High Fuel Oil Pressure Cutoff Switch downstream of the metering pump. Switch must be specified such that the desired activation point of the switch is in the middle of the switch operational range. Plumb switch leg with an Isolation valve in piping leg to the switch modified to be Lockable only in the OPEN position. Install test port with ball valve downstream of the isolation valve. Locate switch in easily accessible location. Wire switch into #2 fuel oil string of Fireye 3-P Running Interlock and YZ-300 annunciator. Upon switch activation the boiler must shutdown and lockout. Annunciation should read “High Oil Pressure” or equivalent.

The switch must be set to activate at 120% of oil pressure at the switch at high fire.

o Specify, provide, and install two automatic shutoff valves equipped with Proof of Closure switches. Both valves must be installed such that proof of closure switches are easily accessible for testing or Proof of closure wiring must be wired to an external terminal block. Proof of closure switches must be wired in series and must not allow boiler to start if switches are not satisfied. Wire proof of closure switches into Fireye 13-3 proof of closure circuit.

o Install test port downstream of first automatic shutoff valve in oil train. Install test port downstream of second automatic shutoff valve in oil train.

• Atomizing Media Train o Specify, provide, and install Low Atomizing Media Switch near atomizing media burner inlet. Plumb switch with an isolation valve modified to be Lockable only in OPEN Position in switch pipe leg and a test port downstream of the isolation valve.

Switch must be located in an accessible location and wired into the Fireye 3-P running Interlock and YZ-300 annunciator. Upon switch activation, boiler must shutdown and lock out. Annunciation must display “Low atomizing media” or equivalent. Switch must be set to activate at 80% of atomizing media pressure at purge.

o Specify, provide, and install second Low Atomizing Media Switch near atomizing media compressor. Plumb switch with an isolation valve modified to be Lockable only in OPEN Position in switch pipe leg and a test port downstream of the isolation valve. Switch must be located in an accessible location and wired into the Fireye 3-P running Interlock and YZ-300 annunciator. Upon switch activation, boiler must shutdown and lock out. Annunciation must display “Low atomizing media” or equivalent. Switch must be set to activate at 80% of atomizing media pressure at purge.

• All other issues as per VHA Directive 1810 that have been added as MODIFICATIONS to the Fort Harrison VAMC BP Repairs Project:

o Combustion Air Interlocks as per BP Safety Device Testing Manual 8th Edition o Replace Cast Iron Fittings (if applicable at design steam pressures) o Any other deficiencies that as per VHA Directive 1810 and VHA Boiler Plant Safety

Device Testing Manual 8th Edition

9. Additional Requirements:

9.1 General

• Contractor is responsible for all subcontractors required to complete the project.

• Contractor shall supply all tools and equipment required to perform the stated work.

• Contractor shall comply with all OSHA and VA safety guidelines to include required PPE and lockout/tagout procedures.

• Contractor shall terminate all control wiring in accessible labeled terminal blocks.

• Contractor shall provide updated and accurate wiring diagrams of boiler control wiring.

• Contractor shall perform combustion tuning on all boilers on both primary and backup fuels after upgrade work is completed.

9.2 REQUIREMENTS/STANDARDS/REGULATIONS: All services/work performed must meet manufacturers performance and technical specifications, Federal Regulations, VA Regulations, and specifications of the following organizations:

• ASME Boilers and Pressure Vessels Code

• The work must conform with local building codes, or, in the absence of local codes, ANSI Z223.1

(National Fuel Gas Code Publication N0. NFPA-54). Where ASME CSD-1 is required by local authority, the installation must conform to CSD-1.

• NFPA 70, National Electrical Code.

• NFPA 70B, Recommended Practice for Electrical Equipment Maintenance.

• NFPA 70E, Standard for Electrical Safety for the Workplace.

• International Electrical Testing Association, Inc. (NETA) Maintenance Testing Specifications for

Electric Power Distribution Equipment and Systems.

• American National Standard Institute (ANSI)

• Occupational Safety and Health Requirements (OSHA) – Part 1910 Subpart J – The control of hazardous energy (lockout/tagout) (1910.147), OSHA Part 1910 Subpart S – Electrical (1010.301

– 1910.399), and Safety and Health Regulations for Constructions Part 1926 Subpart K – Electrical (1926.400 – 1926.499).

• Operating/Maintenance manuals, and specifications of the electrical equipment to be maintained and tested. These documents may be obtained from the VHA Medical Center, or the equipment manufacturers.

• All test and inspection data shall be tabulated and presented in a format, which complies with NEC, ANSI, and VA standards.

9.3 Qualification Requirements for Consultant and Inspection Personnel:

A. The inspections shall be supervised on-site by a “Qualified Professional Inspector”, defined as anyone or combination of the following. Proof of qualifications shall be provided with the bid and as part of the final report.

1) A boiler inspector who has a valid commission from the National Board of Boiler and Pressure Vessel Inspectors.

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

3) A boiler inspector who is regularly employed as a boiler inspector by a jurisdiction that has adopted and administers one or more sections of the ASME Boiler and Pressure Vessel Code as a legal requirement and has a representative serving as a member of the ASME (American Society of Mechanical Engineers) Conference Committee.

4) A boiler inspector who is regularly employed by an insurance company that has been licensed or registered by the appropriate authority the state of the Michigan to write boiler and pressure vessel insurance.

B. Non-destructive testing personnel shall be certified to American Society for Non-destructive Testing (ASNT) Level II, who are experienced in evaluating boilers and associated equipment.

Inspector:

The “Qualified Professional Inspector” shall demonstrate familiarity with and ready access to the current versions of the following codes and manuals:

a. ASME Boiler and Pressure Vessel Code

b. ASME B31.1, Power Piping Code

c. ANSI/NB-23, National Board Inspection Code

d. NACE International Standard RP0590, Recommended Practice for Prevention, Detection and Correction of Deaerator Cracking

e. VHA Boiler Plant Safety Device Testing Manual (8th Edition)

The NDT technicians shall demonstrate familiarity with and ready access to the current version of:

a. NACE International Standard RP0590, Recommended Practice for Prevention, Detection and Correction of Deaerator Cracking

9.4 Acceptance Testing / Repairs

• Provider must provide 3rd party acceptance safety device testing of all equipment within this scope of work. 3rd Party acceptance safety device testing provider must provide to the prime contractor and the VA completed and accurate safety device testing data sheets found in Appendix A and B for all required tests.

• Any issues found during acceptance testing must be addressed with the VA and repaired prior to project closeout.

10. Phasing Schedule:

Intent is for the Boiler Plant remain active as much as possible during the performance of this project; however, due to safety reasons the Government understands that some of the repairs will require complete shutdown of the Boiler Plant. The contractor will be required to submit a detailed phasing plan to the Government for approval prior to starting any work. The phasing plan should have provisions so the Boiler Plant can be impacted as minimal as possible and continuous of operation of services can be maintained through the project.

No service may be interrupted without prior approval of COR. All shutdowns or outages of the system must be submitted to the Contracting Officer’s Representative (COR) a minimum of fourteen

(14) days in advance for approval.

11. Privacy Statement/Information Security: The C&A requirements do not apply; a Security Accreditation Package is not required. Incidental exposure to protected health information may occur from accessing the work site. Staff will follow all Privacy & Security policies and procedures.