Attachment 9 - Standard ES - 2018 - 001.pdf

Engineering Standard

ES–2018–001

LOW PRESSURE STEAM

AND HOT WATER

BOILERS:

DESIGN and OPERATION

February 2018

O C

A M

ES

H ea lt h ca re

E n gi n ee ri n g https://vaww.visn23.portal.va.gov/min/SiteDirectory/mm/Logos/New Signature with VHA.jpg

Table of Contents

1. Purpose and Scope

2. Definitions

3. Boiler Oversight and Operation

4. Notification of OCAMES

5. On-Site Reserve Fuel

6. Operation, Maintenance and Testing

Attachment A –Policies and Procedures for Low Pressure Boiler Plant Operations

Attachment B – Inspection and Testing Procedures for Low Pressure Steam Boilers and

Equipment

Inspections and Operational Tests

Inspection and Testing Frequency Chart

Low Pressure Boiler Plant and Low Pressure Equipment Safety and Operational Duties

Attachment C – Codes, Standards, and References

1. Purpose and Scope

Purpose: This document establishes mandatory standards for the operation and design of Low

Pressure (LP) steam boiler plants, Low Pressure steam boilers, Hot Water (HW) boilers, and associated equipment that generate steam or hot water.

Scope: The Scope of this document includes all VHA owned or operated facilities that are equipped with Low Pressure steam boiler(s), Hot Water boiler(s), or other equipment that generates steam or hot water; regardless of whether the equipment is centralized or decentralized.

Background: Boilers and boiler plants are essential to the operation of a VA facility by providing steam/heating hot water, space heating, hot water (for sanitation, food production and preparation, and infection control, etc.), heat for process equipment, and a healthful environment for the delivery of healthcare.

Safe and reliable operation of boilers and boiler plants is dependent on:

uninterrupted (24 hours a day, 7 days a week) presence of qualified operators and attendants; including the monitoring and operation of all decentralized boilers (i.e. outside of the boiler plant);

oversight by a supervisor or leader qualified in boiler plant operations;

properly functioning safety equipment;

availability of equipment-specific operational and maintenance procedures;

well-maintained boilers and support equipment; and commitment to continuous quality improvement.

Continued technological advances and increases in equipment capacities are enabling expanded applications of low pressure steam and hot water to improve energy efficiency and optimize the operation of heating systems at VHA facilities. While their increased use is logical, the design, maintenance, and operation processes for the equipment and systems must also evolve in order to ensure the continuation of a safe and resilient means of facility heating and process support. This Engineering Standard document establishes mandatory requirements for this equipment and systems, and clarifies the locations in which these standards apply (e.g.

utility plants) to ensure safe and resilient designs, appropriate installations, necessary maintenance, and effective operations.

2. Definitions

A. Boiler Plant – The boiler plant consists of all equipment and systems required to generate and/or distribute steam (low and/or high pressure) and/or hot water, including equipment not housed in the boiler plant building, e.g., Sterile Processing

Service (SPS) steam generators, system regulating stations, circulation pumps, system condensate pumping equipment, and safety and control devices.

B. High Pressure Boiler – A closed vessel in which water or other liquid is heated to generate steam or vapor, or is superheated, or any combination thereof, under pressure for use external to itself. Energy for heating can be produced by the direct application of thermal energy from the combustion of fuels or from electric heating elements. High pressure boilers are those equipped with safety relief valve(s) set at a pressure of 15 psig or greater. Also included are equipment and systems meeting the above definition, even if decentralized from the main boiler plant. The design, installation, maintenance, and operation of such equipment and systems are governed by VHA Directive 1810.

C. Low Pressure Steam Boilers (LPSB) - A closed vessel in which water or other liquid is heated to generate steam or vapor for use external to itself. Energy for heating the liquid can be produced by the direct application of thermal energy from the combustion of fuels or from electric heating elements. Low pressure boilers are those equipped with safety relief valve(s) set at a pressure less than 15 psig. Also included are equipment and systems meeting the above definition, even if it is decentralized from the main boiler plant.

D. Hot Water Boiler (HWB) – A closed vessel in which water or other liquid is heated to generate hot water for use external to itself. Energy for heating the liquid is produced by the direct application of thermal energy from the combustion of fuels. If temperature of operating fluid is at or greater than 212F but less than 257F the hot water boiler is subject to the same requirements as a low pressure steam boiler, even if the boiler is not vaporizing the fluid. If the operating fluid temperature is at or above

257F the boiler is governed by the requirements of VHA Directive 1810.

E. Electric Hot Water Boiler (EHWB) – A closed vessel in which water or other liquid is heated to generate hot water use external to itself. Energy for heating the liquid is produced by the direct application of electrical energy to thermal heating elements. If temperature of operating fluid is at or greater than 212F but less than 257F, the electric hot water boiler is subject to the same requirements of a low pressure steam boiler, even if the boiler is not vaporizing the fluid. If the operating fluid temperature is at or above 257F the boiler is governed by the requirements of VHA Directive 1810.

F. Hot Water Heaters – Tanks and vessels in which domestic hot water is produced at temperatures below 160F for domestic use (excluding instances where temperatures are elevated to perform thermal eradication for microbiological control). The policies and procedures for this equipment are not within the scope of this Engineering

Standard.

G. Electric Steam Generator (ESG) – Electrically powered equipment that generates steam for use external to itself. This type of equipment is sometimes installed to generate steam for use with Sterile Process sterilizers or other such equipment that delivers steam at 15 psig or greater, and is governed by VHA Directive 1810. Equipment that generates steam at less than 15 psig is subject to this Engineering Standard.

H. Instantaneous Boiler (INST) – Equipment that generates steam “instantaneously” on demand without the use of an integral reservoir.

I. Decentralization – Reduction or supplementation of the capacity of centralized systems such as steam generation, hot water production and fluids used for environmental heating through the relocation or addition of the capacity to locations other than the central boiler plant or energy plant.

J. Qualified Third Party–

a) Design Engineer - A vendor that has documented knowledge and experience in the design and construction of boiler plants, as well as VA’s standards for construction and safety devices. In addition, the individual shall have demonstrated experience in such design and equipment assessments on three (3) or more VA facilities sites within the past three (3) years.

b) Testing and Inspection Contractor - A vendor that has documented knowledge and experience with VA’s standards for boiler and boiler plant construction and testing of associated safety devices. In addition, the individual shall have demonstrated experience in conducting equipment inspection and performing testing in compliance with the VA safety device testing manual at three (3) or more VA facilities within the past three (3) years.

K. Qualified Boiler Operator –An individual that has met the requirements of a Boiler Plant

Operator WG-5402 as described in the Office of Personnel Management (OPM) qualification standard, and can demonstrate knowledge and competency in boiler plant operations, systems, theory, safety devices, and safety topics (detailed in VHA Directive

1810, this Standard, in the later referenced VA training, and in safety device and steam generation system publications). The operator shall satisfactorily complete a minimum of three (3) months continuous, full-time on-the-job training with high pressure steam generation systems under the supervision of a Qualified Boiler Operator before being eligible for Qualified Boiler Operator designation.

L. Qualified Boiler Attendant –An individual that is:

a) Trained and proficient in performing

a. Startup, warm up and shutdown of boiler;

b. Operation of all equipment and controls;

c. Gradual warm up of piping system for placement into service;

d. Maintenance of water quality to protect the equipment from damage;

e. Resolution of malfunctions and emergency situations;

f. Collection and organization of plant and equipment performance records

g. Routine equipment maintenance and testing.

(Note: Equipment and system maintenance and testing may be contracted or performed by a qualified VA employee, but the attendant must be knowledgeable in maintenance and testing procedures/processes to provide required work performance oversight.)

b) Knowledgeable of the location, purpose and proper function of all safety devices, with documented formal and on the job training.

c) Able to provide documentation of successful completion of VA’s applicable Safe

Steamin’ training course (electric boiler attendants are not required to complete flame safety material).

d) Able to provide documentation of a satisfactory annual competency assessment by a

Qualified Boiler Operator.

3. Boiler Oversight and Operation

Centralized Low Pressure Steam and Hot Water Boiler Plants: A Qualified Boiler Operator shall conduct daily rounds of the boiler plant at least once every four hours, 24 hours a day, 7 days a week (24/7) to inspect equipment and verify status, and must document the rounds. A

Qualified Boiler Operator must be present on station 24/7 to respond to alarm or trouble conditions within the boiler plant.

This applies to both centralized low pressure steam boilers and centralized hot water boilers.

The facility must perform a risk analysis and develop a facility level policy to ensure the reliability of operations and staffing levels to comply with the requirements in this Standard.

Decentralized Low Pressure Steam and Hot Water Boilers: A Qualified Boiler Operator shall conduct rounds of the boiler at least once every four hours (24/7) to inspect equipment and verify operational status. Completion of rounds and equipment operational conditions shall be documented. A Qualified Boiler Operator must be present on station 24/7 to promptly respond to alarm or trouble conditions at the remote boiler location(s).

This applies to both decentralized low pressure steam boilers and decentralized hot water boilers. If the Qualified Boiler Operator is attending a high-pressure boiler plant and cannot leave, then a Qualified Boiler Attendant may be utilized to conduct the rounds in coordination with and the guidance of the Qualified Boiler Operator on duty in the plant. Facility leadership shall perform a risk analysis and develop a policy to ensure reliability of operations, staffing levels, and staffing types to fulfill the requirements of this standard.

The facility may request approval for a reduction in oversight and rounding interval requirements from OCAMES, based on a documented risk assessment analyzing the impact of failure on facility resilience; patient, employee and visitor safety; and the protection of federal assets for decentralized boilers of limited capacity (e.g. less than 750,000 BTU/HR and with no more than three units covering the building load).

Central Monitoring: It is the facility’s responsibility to evaluate and ensure the following:

a) If the facility does not require the Qualified Boiler Operator to remain in the central hot water and Low Pressure (LP) steam boiler plant 24/7 but allows the Qualified

Boiler Operator to make rounds as part of other duties on site, staff and policies must be in place to monitor systems (e.g. fire alarm, medical gas alarms, and generator status) that require continuous monitoring by code.

b) Centralized LP steam boilers that do not have an operator stationed in the plant

24/7 but have a Qualified Boiler Operator make rounds as part of their other duties on site shall be remotely monitored at a location that is manned 24/7. The staff responsible for monitoring must have the ability to dispatch the Qualified Boiler

Operator to respond to alarms/trouble. The monitoring system must be capable of logging the alarm condition and the individual that acknowledged or canceled it.

Further, the facility must have a process for documenting who responded, the resolution, communication with leadership, and escalation, to ensure alarms are addressed in a timely manner if the qualified operator on site is not available or does not respond.

c) Decentralized LP steam and hot water boilers shall be remotely monitored at a location that is manned 24/7 (e.g. HVAC control center, police post). The staff responsible for monitoring must have the ability to dispatch the Qualified Boiler

Operator to respond to alarms/trouble. The monitoring system must be capable logging the alarm condition and the individual that acknowledged or canceled it.

Further, the facility must have a process for documenting who responded, the resolution, communication with leadership, and escalation, to ensure alarms are addressed in a timely manner if the Qualified Boiler Operator on site is not available or does not respond.

Note: The use of CCTV does not preclude the need for an attendant 24/7 to monitor the systems nor the qualified operator on site to respond to alarms and make rounds every four hours when equipment is in operation.

4. Notification of OCAMES

Facilities are required to notify OCAMES of any the following situations:

a) Planned: installation or replacement of boilers, installation of new fuel burning equipment (burners and/or controls) on existing boilers, or re-tubing thirty (30) percent or more of a boiler. Designs for installation or replacement of boilers must be reviewed by OCAMES and the VA Office of Construction and Facilities

Management (CFM) at the 30%, 60% and 100% design stages, or their equivalents.

b) Planned installation of boilers outside of the central boiler plant. VHA Facilities are to consult with OCAMES during the development of the project application when contemplating decentralization. Adherence to safety, resiliency, and redundancy standards is required.

c) Planned implementation of new technologies, including

a. Oil filled boilers,

b. Low mass boilers, and

c. Combined Heat and Power systems.

d) Within twelve (12) hours of Occurrence:

a. Rupture or explosion of a boiler or pressure vessel;

b. Furnace explosion or extensive damage from overheating;

c. Boiler(s) required to meet the minimum facility N+1 requirement, exclusive of load shedding, are out of service for more than 24 hours;

d. Backup fuel systems or combustion equipment is out of service or inoperable

e. Repeated maintenance issues with boilers or ancillary equipment;

f. The acquisition and operation of rental boilers to meet any part of the N+1 requirement; and

g. Any other unusual occurrence or activity

Note: Following the notification of any of the Occurrences identified above, a thorough investigation by the VISN and facility, including root cause analysis, must be performed, and a written report submitted to OCAMES within 2 weeks of occurrence.

5. On-Site Reserve Fuel

Reserve fuel requirements are only applicable to inpatient and resident care areas and mission critical facilities as defined by VA and VHA policies and regulation. In cold climates, the facility may exceed these requirements to ensure the protection of government assets based on an internal risk analysis of structures that do not fall into one of the two categories above.

Facilities firing oil or propane as the main fuel shall maintain a supply of fuel sufficient to meet the normal demands of continuous operation for a period of fifteen (15) of the most extreme winter days of the year. If the facility is equipped with a backup source of fuel, such as natural gas, the oil supply can be reduced to ten (10) days. The backup fuel source must be on site and connected and have sufficient supply for five (5) days of continuous operation under the most extreme historical and anticipated winter conditions. Plants that generate less than 50 percent of their annual steam demand by natural gas for two (2) consecutive years are considered to be oil-fired, and shall meet the supply requirements for oil-fired plants.

Facilities firing natural gas as the main fuel with oil or propane back-up shall maintain a sufficient on-site and connected supply of back-up fuel to meet the normal demands of continuous operations for a period of ten (10) days under the most extreme anticipated winter conditions. Sites with electric steam generators must have those generators connected to the either the hospital’s Essential Electrical System (EES) or stand-by electrical power systems, as allowed by codes and standards, which must have sufficient fuel reserves to provide a minimum of ten (10) days continuous operation under the most extreme winter conditions at full connected load.

Fuel storage requirements shall be re-evaluated annually against actual fuel used under the most extreme winter conditions. For other requirements, see Attachments A and B. Fuel shall be tested for quality annually and polished/filtered as required to meet the fuel quality requirements defined by ASTM D975.

Note: Where unusual conditions exist, the facility Director or qualified designee must request approval from OCAMES to deviate from the above requirements.

6. Operation, Maintenance and Testing

Facilities shall contract directly with a qualified independent third party engineer to review and comment during design, inspection, startup, testing, and commissioning of new plants or equipment repair/replacement projects. Submissions to OCAMES and CFM shall only be made after review by the independent third party. Review documentation shall be included in the submission to OCAMES and CFM.

Maintenance and operation policies and procedures must be developed, and training conducted, to ensure operators and attendants are competent and qualified with the specific equipment on site. Attachment B outlines requirements for inspection and testing procedures, which must be incorporated into the facility’s policies and SOPs.

Inspection and Testing shall be conducted and documented by qualified individual(s) as defined in the VHA Boiler Plant Safety Device Testing Manual, 4th edition, and Attachments A and B of this document. Qualifications of individuals performing inspections and testing must be documented and retained with the testing records. The facility shall retain a qualified third party to perform the both the annual and semi-annual inspections and tests.

Compliance with this Standard and associated documents must be assessed quarterly by each VA medical center covered by the content of this document, through completion of the web-based survey, located on the Center for Engineering Occupational Safety and Health

(CEOSH) Web site at http://vaww.ceosh.med.va.gov/ no later than two (2) weeks after the start of each fiscal quarter (October 1, January 1, April 1 and July 1) for the previous quarter.

This survey requires certification by the Chief Engineer and the facility Director.

http://vaww.ceosh.med.va.gov/

Attachment A –Policies and Procedures for Low Pressure Boiler Plant Operations

1. GENERAL: Written policies and procedures shall be established, reviewed annually, and updated whenever significant changes are made. At a minimum they must include:

a) A clear statement and definition of safety as the first priority for boiler and Boiler Plant Operations. Boiler safety must not be compromised to maintain service.

b) A requirement that all required safety devices are installed (including in the boiler plant and in the fuel, steam distribution, and condensate return systems) and tested to ensure their proper function in accordance with requirements in Appendix B. All devices must be identified and itemized within the local policy/procedures.

c) A procedure for notification to the VA medical facility Director, VISN, and OCAMES when any boiler safety device is non-functional, regardless of the status of the boiler (e.g.

spare, backup).

d) A procedure for notification to the VA Medical Facility Director, VISN, and OCAMES when one or more boilers are out of service and the redundancy required by policy (minimum N+1) is compromised, or when backup fuel capacity and capability is not available

e) Site specific testing procedures that are in accordance with the VHA Boiler Plant Safety Devices Testing Manual, 4th edition (available from vaww.ceosh.med.va.gov). Qualified Boiler Operators must be knowledgeable of the location, purpose, and proper function of all safety devices.

f) A policy requirement that ensures that there is a Qualified Boiler Operator present on site/Station while boilers are in operation and that the Qualified Boiler Operator:

(1) Cannot leave the station at any time unless relieved by another Qualified Boiler Operator

(2) perform rounds of the boilers at least every four hours (exception- at OCAMES approved alternate interval)

(3) documents boiler performance and operational status of all equipment

(4) Documents alarm status and corrective actions

g) A prohibition on the use of remote restarting of boilers. This includes the ability to start a boiler from an office within the boiler plant or adjacent area or by automation such as lead lag control.

h) A written program for ongoing training to develop, maintain, and regularly refresh Qualified Boiler Operator proficiency in safe boiler and boiler plant operations. The training program must include the requirement for documentation of formal and on-the-job training (OJT) for every specific piece of equipment that the individual is to obtain and maintain qualifications. OJT shall be conducted by experienced instructors and be verified and signed off on by the boiler plant supervisor or Chief Engineer. The program must include the http://vaww.ceosh.med.va.gov/ following:

(1) Steam Boilers training (Safe Steamin’ 1 and 2 in VA’s Training Management System [TMS]) courses MUST be completed by all Boiler Plant Operators as one of the conditions to obtain qualification.

(2) Hot water boiler training shall include all the modules in Safe Steamin’ 1 and 2 related to water quality and combustion systems. Additionally, the operator must have training on the specific boiler(s) in use (i.e. manufacture and model) and its safety devices and the testing of those devices.

(3) The Boiler Plant Supervisor or Lead and Contracting Officer Representative (COR) for the Third-Party Safety Device Inspection/Testing shall complete annual refreshers on the Safe Steamin’ 2 course in TMS as defined above based on the type of boiler.

(4) All boiler plant staff members must attend the VISN Boiler Safety Device Training provided via contract by CEOSH when scheduled at their VA medical facility (Supervisor shall use sound judgment in accomplishing this task, while maintaining boiler staffing for operation, which may mean 1 or 2 operators may not be able to attend every training).

(5) The Boiler Plant Supervisor, Lead and COR for the Safety Device Testing Contract must be knowledgeable of Safety Device Testing and the requirements of the VHA Safety Device Testing Manual, current edition.

(6) The Boiler Plant Supervisor, Lead and/or COR (2 persons are preferred) shall be designated as the Site Boiler Plant Boiler Safety Device Training Champions. The Champions shall be responsible for training other boiler plant staff members in safety device testing.

(7) Operators, Assistants, and testers/inspectors must be trained in the requirements of NEC 70E, provided with the appropriate Personal Protective Equipment (PPE), be deemed “Qualified Person” in accordance with NEC 70E competency requirements to complete work/maintenance requiring such PPE.

(8) Requirements to ensure that boiler plant operators are well trained and fully proficient in properly performing the following on each type of boiler and/or system being utilized, for which procedures must be developed to ensure consistency of operation:

(a) Lighting off, warming up, placing in service, and shutting down the boilers;

(b) Firing on each of the available fuels;

(c) Operating all plant equipment and controls, including start-up and shutdown;

(d) Gradual warm-up of hot piping system and placing them into service;

(e) Maintaining water quality to protect the equipment and piping from damage;

(f) Handling malfunctions and emergency situations including emergency or backup generator operation in the central plant;

(g) Collecting and organizing the equipment and plant performance records;

(h) Operation of boiler plant emergency generators within the central plant and associated electrical equipment;

(i) Routine equipment maintenance;

(j) Preparation of equipment for inspections;

(k) Operation and testing of all safety devices and control equipment;

(l) Facilitating and monitoring the receipt of fuels and supplies;

(m) Operation of all equipment at the highest cost-effectiveness and efficiency.

This means maintaining pressures, temperatures, and fuel consumption at the minimum necessary for the proper operation of the equipment, plant, and connected loads.

(9) Retention of operator training records for at least three (3) years. This includes all training required by this directive, as well as those developed at the local level as part of the written boiler/boiler plant training program

i) A written steam/heating hot water conservation program focused particularly on maintaining steam traps, condensate/heating hot water pumps, and the integrity of piping systems and pipe insulation. Steam, condensate and water leaks and other necessary repairs shall be reported to the boiler plant supervisor and given a high priority. This part of the written policy must include

(1) The title(s) and name(s) of the person(s) responsible for implementing and oversight of the program;

(2) The title(s) and name(s) of person(s) responsible for conducting the inspections;

and

(3) An inspection report format that identifies the frequency of inspections;

method and date of inspection; location of devices; types of devices or equipment;

discrepancies identified, if any, and corrective action taken.

j) A written steam/heating hot water load-shedding plan for implementation during a boiler or boiler plant emergency that reduces steam/heating hot water-generating capability, and identifies the critical loads that must continue to be served to the greatest extent possible, without compromising boiler or boiler plant safety.

k) Provisions that the emergency electrical generator(s) and associated equipment serving the boiler plant are included as part of the VA medical facility’s Essential Electrical System or stand-by system testing and maintenance program. Testing and maintenance of the generators shall comply with NFPA 110 Standard for Emergency and Standby Power Systems, latest edition, and all applicable VHA requirements.

l) A written water treatment program that includes required water treatment and testing

(at frequencies detailed in Attachment B), records of the tests, and a monthly review of the water treatment program by a technical representative of the chemical supplier or an independent water treatment consultant. No chemical treatment systems are to be manual.

Note: Magnetic/Electronic water treatment systems are prohibited in VHA boiler plants.

m) A utility systems security program ensuring restricted access to the boiler or boiler plant, on site fuel facilities (including fuel storage), and distribution piping systems.

n) A written procedure for checking on the condition of the boiler operator at a minimum of twice during each eight (8)-hour shift to ensure that their ability to perform assigned duties has not been impaired due to an accident or other event; for example, radio or phone checks by security/ police officers or remote alarms that the operators must carry.

o) A requirement that, in accordance with VA Handbook 5019 Employee Occupational Health Service, Part II Examinations and Evaluations, Appendix A, paragraph 4, each boiler plant operator have an annual physical and audiological examination to ensure physical fitness to perform assigned duties.

p) An organizational structure that promotes continuous quality improvement in safe boiler operations.

q) Written procedures for boiler, support equipment, and distribution system components to be shut down (e.g. Lock-Out/Tag -Out [LOTO]) for maintenance, repairs, and construction work.

r) Requirements that repairs to boilers and pressure vessels comply with the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. No welded repairs are permitted except by certified welders using Code-approved procedures. Repair and records of certification, and the qualification of welders must be retained until equipment is replaces.

s) An equipment replacement program based on the following useful life expectancies.

Note: Retention of equipment beyond the useful life expectancy must be based on an engineering evaluation of the reliability, efficiency, and cost effectiveness of continued operation. Remaining service life of equipment may actually be shorter than expected due to site specific service conditions; an engineering evaluation should be performed when excessive maintenance, repair, and reliability issues are identified.

Equipment Useful Life Expectancy (in years)

(1) Fire tube boilers and burners 30

(2) Water tube boilers and burners 40

(3) Condensing boilers 15

(4) Feed water Deaerator 30

(5) Economizers 15

(6) Burner management controls 20

(7) Combustion controls 20

(8) Instrumentation 20

(9) Boiler feed and condensate pumps 20

(10) Condensate and blow-off tanks and heat recovery 40

(11) Fuel oil pumps 40

(12) Fuel oil tanks 40

(13) Shut off and control valves 20

(14) Water treatment equipment 20

2. DOCUMENTATION: The following documentation must be available to all operators in the boiler plant or accessible location for decentralized equipment. Facility shall annually, at a minimum or when changes occur, review and update documentation to ensure information is kept current.

a. General.

(1) One-line diagrams of boiler plant systems, including Low Pressure Steam/ Heating hot water Systems, Make Up and Supply Water Systems, Condensate System, Primary and Alternate Fuel Systems, Control Systems, and the Electrical Distribution System

(2) Manufacturer’s literature on installed equipment

(3) Boiler Efficiency Improvement Operator Manual

(4) VHA Boiler Plant Safety Devices Testing Manual

(5) VHA Boiler Plant Operations guidance document and directives

(6) VA medical facility Boiler Operations Policy

(7) Normal and emergency operations procedures, including: start-up, operating, and shut down of all boiler plant equipment, fuel systems, and steam distribution systems

(8) List of connected equipment and their pressure and quantity requirements

(9) LOTO procedures for all equipment in the boiler plant

(10) Confined space entry procedures, as applicable

(11) Load shedding plan

b. Maintenance and Testing Records. Inspection, Testing, and Maintenance records for all critical components of the utility system must be retained for at least three (3) years. All components of the utility system associated with the production and use of steam as well as all combustion and support systems (e.g. pumps, valves, dampers) at the VA medical facility, including fuel, must be individually reviewed for inclusion in the preventive maintenance program. At a minimum: all safety devices, alarm annunciators, controllers, and major operating components of boilers, fuel systems, control systems, and alarm systems shall be deemed critical utility system components. Records must include

(1) Date of test, inspection, or maintenance;

(2) Results of the test, inspection, and maintenance procedures accomplished;

(3) Parts installed, if any;

(4) Names of individuals performing testing, inspection, or maintenance;

(5) Subsequent required notification of the VA medical facility Director regarding any device failures; and

(6) Repairs or adjustments made to safety devices and the date(s) of their return to service.

c. Performance Data. Performance data must be retained for at least three (3) years and include

(1) Total steam/heating hot water production and fuel consumed (daily, monthly, and yearly);

(2) Daily outside temperature range;

(3) Make-up water quantity and the percent of make-up in relation to amount of steam generated;

(4) Minimum and maximum steam/water demand per shift;

(5) Boiler efficiency based on steam/water output or fuel input (daily);

(6) Water treatment data, including all test reports and chemicals utilized; and

(7) Boiler flue gas oxygen and stack temperature in relation to burner firing rate.

Attachment B – Inspection and Testing Procedures for Low Pressure Steam Boilers and Equipment

Inspections/testing shall be performed in accordance with the following:

a) Testing and inspection must be executed and documented by a Qualified Boiler Operator or Qualified Professional Inspector.

i) Hydrostatic testing of boilers and pressure vessels must be conducted after a repair or a tube replacement, or when the boiler or pressure vessel integrity is in doubt.

Hydrostatic pressure must be limited to 150 percent of normal operating pressure of the boiler or pressure vessel.

ii) Selection of contractors for plant services including boiler inspections, burner adjustments, testing of safety devices, calibration of instruments, and monitoring of water treatment must be based on qualifications and experience as the first priorities.

b) A Qualified Professional Inspector (QPI) is any one or combination of:

i) A boiler inspector who has a valid certificate from the National Board of Boiler and

Pressure Vessel Inspectors.

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

iii) A boiler inspector who is regularly employed as a boiler inspector/testing by a jurisdiction that 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.

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

Required Inspections and Operational Tests

Key to Abbreviations

i) LPSB – Low Pressure Steam Boiler

ii) HWB – Hot Water Boiler

iii) EHWB – Electric Hot Water Boiler

iv) ESG – Electric Steam Generator

v) INST – Instantaneous Hot Water Boiler

vi) H – Hourly.

vii) S – Once a shift

viii) D – Daily.

ix) M – Once per month.

x) 6M – Once every 6 months.

xi) Y – Once per year.

xii) 6Y – Once every 6 years.

Legend

*if reserve fuel requirements apply ** if gas fired + depends on capacity ++ if equipped with O2 trim

Inspection and Testing Frequency Chart

Frequency Item LPSB HWB EHWB ESG INST

Inspect furnace and other internal surfaces, closures and accessories.

Y Y Y Y Y

Inspect exterior of Unit, casing, supports, closures, accessories, valves, controls.

Y Y Y Y Y

Deaerator: Inspection and wet magnetic particle testing of welds of pressure vessel interior.

6Y N/A N/A 6Y if equipped

N/A

Check all Boilers for fouling and combustion gas flow.

Y Y N/A N/A Y**

5 Tube leak check on all boiler types. Y Y Y Y Y NOTE: Items (1) through (5) in this table above must be accomplished by a documented Qualified Professional Inspector. The following items (6) through (12) must be accomplished by a qualified individual as determined by the medical center’s management. Such a determination must be carefully made for each item and each individual.

Deaerator: interior cleaning and visual inspection. Y N/A N/A Y if equipped N/A

Condensate Tank: interior cleaning and visual inspection

Y N/A N/A Y if equipped

N/A

Adjust burner combustion settings and calibrate oxygen trim.

6M 6M+ N/A N/A 6M++

9 Check vibration of burner fans. 6M 6M N/A N/A N/A

Calibrate instrumentation, monitoring, and control systems.

6M 6M+ 6M+ 6M+ 6M+

11 Calibrate pressure gages and thermometers. Y Y Y Y Y+ 12 Operational Testing of Safety Devices:

a. Low-water cutoff (slow drain) M M M M N/A b.

Fire each boiler and the pilot on the alternate fuel for 1 hour

M* M* M* M* M*

c. Low-water cutoff M M M M N/A

d. Auxiliary low-water cut-off (slow drain) M M M M N/A

e. High-water alarm M M M M N/A

f. Low-water alarm M M M M N/A

g. High-steam pressure cut-out (recycle) 6M N/A N/A 6M N/A

h. High-steam pressure cut-out (non-recycle) 6M N/A N/A 6M N/A i.

Steam/water safety valves (accumulation test at high fire)

Y Y Y Y Y

j. Steam/water safety valve operational test 6M 6M 6M 6M 6M

k. Flame scanner M M N/A N/A M+

l. Check gas vent valve for leaks 6M 6M N/A N/A 6M+

m. High-gas fuel pressure cut-off 6M 6M N/A N/A 6M+

Item LPSB HWB EHWB ESG INST

n. Low-gas fuel pressure cut-off 6M 6M N/A N/A 6M+

o. Gas fuel safety shut off valves proof of closure 6M 6M N/A N/A 6M+ p Leak test gas fuel safety shut off valves 6M 6M N/A N/A 6M+ q Low-atomizing pressure for fuel oil 6M* 6M* N/A N/A 6M*+

r. High-fuel oil pressure cut-off 6M* 6M* N/A N/A 6M*+

s. Fuel oil safety shut off valves proof of closure 6M* 6M* N/A N/A 6M*+

t. Leak test fuel oil safety shut off valves 6M* 6M* N/A N/A 6M*+

u. Check operation of Liquid Petroleum Gas pilot 6M* 6M* N/A N/A 6M*+

v. Low-pilot gas pressure cut-out 6M 6M N/A N/A 6M*+

w. Forced draft fan motor interlock 6M 6M N/A N/A 6M+

x. Forced draft fan damper wide open for purge 6M 6M N/A N/A 6M+

y. Boiler outlet damper wide open for purge 6M 6M N/A N/A 6M+

z. Purge air flow interlock 6M 6M N/A N/A 6M+

aa. Timing for pre-purge 6M 6M N/A N/A 6M+

bb. Timing for post-purge 6M 6M N/A N/A 6M+

cc. Igniter timing 6M 6M N/A N/A 6M+

dd. Low fire position interlock 6M 6M N/A N/A 6M

ee. Combustion air interlock 6M 6M N/A N/A 6M

ff. Main flame out; i.e., time to close valves 6M 6M N/A N/A 6M

gg. Ignition flame out; i.e. time to close valves 6M 6M N/A N/A 6M

hh. Minimum igniter flame test 6M 6M N/A N/A 6M

ii. Scanner not sensing ignition spark 6M 6M N/A N/A 6M

jj. Low-oxygen alarm and/or cut-out 6M 6M N/A N/A N/A kk.

Pre-purge setting of flue gas recirculation damper

6M 6M N/A N/A N/A

ll. Interlock of building outside air damper 6M 6M N/A N/A 6M

mm. Burner/heating element control 6M 6M 6M 6M 6M pp.

CO and combustible gas detection equipment testing

6M 6M N/A N/A 6M

qq. Plant/boiler emergency stop buttons testing 6M 6M 6M 6M 6M NOTE: The preceding safety devices are essential for ensuring the safest possible operation. Any boilers not so equipped must be immediately programmed for retrofit, with priority given to providing two low water cutoffs per boiler and two fuel safety shut off valves per fuel per boiler.

Low Pressure Boiler Plant and Low Pressure Equipment Safety and Operational Duties

Frequency

Item LPSB HWB EHWB ESG INST

1 Document and track overall plant operation, including items 1a through 1n below, as applicable to boiler configuration (Logs must be taken by hand even if automatic logs or SCADA system is in place).

4H 4H 4H 4H 4H a.

Document operating equipment and systems .

b.

Inlet and outlet temperature of all equipment (Condensate, DA, economizer, boiler, etc.)

c.

Inlet and outlet pressure of all operating pumps d.

Plant temperature, outside air temperature, and exhaust gas temperature (before and after economizer if installed) e.

Fuel flow (instantaneous and total) and firing rate for each boiler on line.

4H 4H 4H 4H 4H

f. Steam or hot water flow to the system 4H 4H 4H 4H 4H

g. DA pressure and temperature 4H 4H 4H 4H 4H

h. Readings for make-up water meters 4H 4H 4H 4H 4H i.

Fuel train pressures and flows for each boiler that is on line.

j. Boiler pressure or temperature 4H 4H 4H 4H 4H k.

Note any leaks, system problems, or abnormal operating conditions l.

Header pressure, temperature, and, if branches, pressure and temperature of each breach leaving the plant.

m. Calculated boiler combustion efficiency S S S S S n.

Other readings as required or determined by the medical centers

4H 4H 4H 4H 4H

2 Blow down water columns D D D D D 3 Test and adjust water treatment D M M D M 4 Check furnace pressure 6M 6M N/A N/A N/A 5 Check combustion gas leaks into boiler room 6M 6M N/A N/A 6M 6 Clean waterside of boilers Y Y Y Y Y 7 Clean fireside and repair refractory Y Y N/A N/A N/A

Item LPSB HWB EHWB ESG INST

Test and inspect deaerator high and low water alarms

M N/A N/A N/A N/A

Test and inspect deaerator steam pressure or temperature control

M N/A N/A N/A N/A

Test and inspect DA safety valve and supply steam safety

A N/A N/A N/A N/A

Test and inspect condensate storage tank high and low water alarms

M N/A N/A N/A N/A

12 Operate all other alarm devices M M M M M

Document boiler economizers; temperatures in or out

D N/A N/A N/A N/A

14 Test and inspect economizer safety valve A N/A N/A N/A N/A 15 Review written procedures A A A A A

Attachment C – Codes, Standards, and References

It is VHA policy that each boiler and boiler plant be operated in a safe and efficient manner in compliance with current VA/VHA policy requirements, standards, and national codes; including the following:

1. American Society of Mechanical Engineers (ASME) Controls and Safety Devices for

Automatically Fired Boilers. CSD-1

2. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code

3. National Fire Protection Association (NFPA) 85 Boiler and Combustion Systems

Hazards Code,

4. VHA Boiler Plant Safety Device Testing Manual

5. NEC 70E Standard for Electrical Safety in the Workplace.

6. VHA Directive 1810 Boiler and Boiler Plant Operations

7. VHA Directive, Electrical Power Distribution systems, latest edition

8. NFPA 85 Boiler and Combustion Systems Hazard Code

9. The Joint Commission Environment of Care (EC) Standard as applicable

10. Boiler Efficiency Institute Operator Manual

11. VHA Design Manual PG-18-10 Steam Generation Systems Design Manual (Including

Energy Center)

12. VHA Directive 7701 Occupational Safety and Health

13. VHA Handbook 7701.1 Occupational Safety and Health

14. VA Whole Building Commissioning Process Manual