557-21-3-5151-0042 - SOW - EVALUATION OF BOILER LIFE EXPECTANCY.docx

ENGINEERING EVALUATION OF BOILER, DEAERATOR AND CONDENSATE TANK RELIABILITY/LIFE EXPECTANCY

STATEMENT OF WORK

557-21-3-5151-0042

1. INTRODUCTION:

VA medical centers provide critical health care which requires reliable steam supply for sterilization, domestic hot water, kitchens, and building heating/air conditioning.

Boilers and associated equipment serving VA medical centers must be reliable, safe and efficient. The age of boilers and associated equipment is often a major indicator of reliability.

The VHA Directive 1810 (1), BOILER AND BOILER PLANT OPERATIONS, assigns “useful life expectancy”, in years, to the boilers and plant equipment. The Directive requires that retention of certain equipment beyond the “useful life expectancy” must be based on an engineering evaluation of the reliability, efficiency and cost effectiveness of continued operation.

2. SUMMARY OF REQUIREMENTS:

The consultant shall supply all labor, material and equipment to inspect and test the boilers and ancillary equipment at the Carl Vinson VAMC. The work shall be documented in a full report of findings and recommendations. The report must be stamped by a licensed professional engineer. The following is a general list of equipment that must be addressed.

Deaerator (DA) Tank

Maximum Working Pressure (MAWP) – 50 Psig at 300F

Condensate Tank

MAWP – 150 Psig at 250F

3. QUALIFICATION REQUIREMENTS FOR CONSULTANT AND INSPECTION PERSONNEL:

A. A professional engineering firm (Professional License (PE)) that specializes in life expectancy evaluations must be part of the team and provide an analysis and recommendations under their seal based on the evaluation of the boiler and associated equipment by means of visual inspection and non-destructive testing conducted by experienced boiler inspectors and non-destructive testing experts on the team.

B. The inspections shall be supervised on-site by a “Qualified Professional Inspector”, defined as anyone or combination of the following:

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 a jurisdiction of a state.

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 of a state of the United States to write boiler and pressure vessel insurance.

Proof of qualifications shall be provided with the offer AND as part of the final report.

C. 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.

4. 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, current 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

5. VA RESPONSIBILITIES FOR PREPARATION OF BOILER INSPECTION:

1. Since steam production cannot cease, the consultant and the VA COR will have to work closely to develop an inspection schedule that will ensure the facility can always meet steam demand with sufficient backup.

2. The boiler will be prepared by VAMC for the inspection prior to the scheduled arrival of the inspector. This includes cooling the unit to near ambient temperature and having all manways and access doors open, the unit cleaned of loose materials, “lock-out, tag-out” in place, connecting piping isolated, proper illumination provided, compliance with “confined space” access requirements including having safety personnel present in the boiler plant.

3. VAMC will comply with any other requirements of the inspector that are considered reasonable by VAMC and have been presented in writing at least two weeks prior to the scheduled inspection.

4. Coordinate preparation work with the requirements of the inspection firm.

5. All records of maintenance and repair activities, water treatment logs, operational logs, inspection reports, and all histories of prior problems shall be readily available during the inspection. Records for three years are suggested. If the consultant requires copies, they will need to sign out the documents and return them upon completion.

6. Remove all manway and handhole covers, access panels.

7. Remove all drum internals.

8. Clean all fireside and waterside surfaces.

9. Remove insulation from water tube boilers steam and mud drum ends and from locations where pipes are connected to the boiler.

10. Arrange for ladders, lifts and other devices necessary to allow access to the boiler.

11. Furnish copies of the original National Board (NB) “Manufacturer’s Data Report” inspection form that was prepared for the boiler when it was new and NB “Report of Repair” forms if boiler pressure vessel repairs have been performed.

6. INSPECTION REQUIREMENTS FOR BOILERS

A. Consultant shall develop a detailed list of information required at least two weeks prior to the inspection to allow the VA to compile the information.

B. Consultant shall develop a detailed schedule of the inspection in consultation with the VA COR to ensure availability of equipment as needed during the execution of the project.

C. Visually inspect the following items and document the locations with a sketch or pictures. Any adverse findings must be documented with pictures and notes in detail. All data shall be included in the final report as supporting documentation.

1) Review the boiler/s history including operating conditions, date of last inspection, current inspection certificate, ASME stamping, National Board registration number, materials of construction, extent of post weld heat treatment, history of repairs and modifications.

2) All welded and threaded pipe connections to the boiler shell or drum for signs of leakage or defects in the welded areas. Defects must be documented as to location with a sketch or picture and be non-destructively tested.

3) Boiler support structure for proper alignment, evidence of sagging, shifting or misalignment.

4) Boiler casings for signs of warping, misalignment and overheating.

5) All furnace tubes and all accessible convection tubes for alignment, evidence of corrosion, erosion, bulges, sagging, defective or deteriorated welds.

6) Exposed surfaces of steam and mud drum in furnace, particularly ligament areas between tubes, for evidence of corrosion, cracking, scale buildup, other defects.

7) Refractory for cracking, shifting, sagging, bulging or general deterioration.

8) Internal areas of steam drum and mud drum (inside boiler shell in fire tube boilers).

a. Welded outlet connections.

b. Surface of drums for pitting or surface discontinuities.

c. Ligament areas between tube holes for cracking.

d. Each tube end and internal surface of representative number of tubes for pitting, erosion, corrosion and excessive scale buildup. Utilize fiber optic inspection equipment to inspect interior of tubes.

e. Clean and inspect shell or tube sheet between tube holes for cracking.

7. VA RESPONSIBILITIES FOR PREPARATION OF DA AND CONDENSATE TANKS INSPECTION

a. Since steam production cannot cease, the consultant and the VA COR will have to work closely to develop an inspection schedule that will ensure the facility can always meet feed water demand with sufficient backup.

b. The DA will be prepared by VAMC for the inspection prior to the scheduled arrival of the inspector. This includes cooling the unit to near ambient temperature and having all manways and access doors open, the unit cleaned of loose materials, “lock-out, tag-out” in place, connecting piping isolated, proper illumination provided, compliance with “confined space” access requirements including having safety personnel present in the boiler plant.

8. INSPECTION REQUIREMENTS FOR DEAERATOR (DA) AND CONDENSATE TANKS

A. The DA inspections shall comply with the guidelines in the current issues of the following documents:

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

C. NATIONAL BOARD INSPECTION CODE, Part RB, Inservice Inspection of Pressure-Retaining Items.

1) Review the DA and condensate history including operating conditions, date of last inspection, current inspection certificate, ASME stamping, National Board registration number, materials of construction, extent of post weld heat treatment, history of repairs and modifications.

2) Assess the external parts of the DA and condensate and accessories and all connecting piping for safety, accessibility, cleanliness. proper operation, and compliance with codes.

3) Inspect for evidence of leakage.

4) Inspect DA/condensate tank safety valve installation and verify that the valves have proper set pressure and capacity and are properly installed

5) Inspect support structures for proper integrity and allowance for thermal expansion.

6) Internal inspections:

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

b. Inspect DA spray nozzles and trays.

c. Certified American Society for Non-Destructive Testing (ASNT) Level II technicians shall perform non-destructive tests (NDT) using the wet fluorescent magnetic particle (WFMT), ultrasonic testing (UT), and any other necessary non-destructive tests.

· Completely examine all accessible welds utilizing the WFMT test method. Properly prepare the surfaces before testing.

· Determine pressure vessel material thickness by UT. Thickness measurement locations shall be selected by dividing the storage tank heads into quadrants and taking measurements at each quadrant on two imaginary rings in each head (eight measurements total) . Measurement locations on the shell shall be on each of the quadrants, on four to six locations along the length of the shell (16 to 24 measurements total). The technician may recommend fewer or more tests to the owner, providing justification.

· Typically, the pressure vessel section containing the deaerator trays and sprays is not accessible for non-destructive testing. The experience is that this section, which is mainly exposed to steam, is less vulnerable to weld failures and material thinning than the storage section which contains condensate and make-up water.

9. TESTING:

The following Nondestructive testing shall be completed and document as to the location or findings with a sketch or pictures. Any adverse findings must be documented with pictures and notes in detail. All data shall be included in the final report as supporting documentation.

1) Ultrasonic thickness testing of representative samples of all components.

2) Obtain sufficient material thickness measurements to accurately reflect the condition of the entire boiler, DA or condensate tank.

a) Ultrasonic thickness testing of all areas visually noted to have corroded or eroded.

b) Magnetic particle testing of all areas where indications of defects have been found visually.

c) Metallurgical analysis of representative samples of boiler metal if there are indications or a record of overheating.

10. CALCULATIONS: The consultant shall calculate and report the maximum allowable working pressure rating and remaining life expectancy based on the thickness measurements, data obtained, observations and testing for the boiler, deaerator and condensate tanks into which DA discharges.

1) ASME Code formulas must be used and references provided in the final report.

2) Calculate and report the depletion rate of material thickness.

3) Remaining life calculation shall be based on original material thickness, current material thickness, evaluation of other factors in the condition of the boiler.

11. REPORT REQUIREMENTS:

A. Provide complete written report fully describing all inspections and tests performed, findings, and recommendations. The condition of all items inspected shall be stated whether acceptable or deficient. All deficiencies shall be fully described along with recommendations for methods of correction B. Provide oral report of condition of the boiler to VAMC engineering management at the conclusion of the inspection and prior to leaving the site.

C. Provide a draft report Microsoft (MS) Word format withing 7 days of the completion of inspection for review and comment by the COR. Once approved by VA, provide MS Word format and 6 copies of final report to COR.

D. Provide complete narrative of the history of the equipment in the plant and current conditions of the same as well as an analysis of the visual inspections and test results, photographic views of deteriorated areas and photographs to show areas identified as not acceptable for continued service or requiring repair.

E. Provide calculations for remaining life based on calculated present maximum allowable working pressure vs. original maximum allowable working pressure when the boiler was new. Show locations and extent of all non-destructive testing by sketches. (Spec Writer Note: this applies to boiler, deaerator and only condensate tanks that are feed from deaerator).

F. Describe all deteriorated areas; provide expert judgment on need for repairs and repair methods.

G. Provide expert judgment on cost effectiveness of retaining the boiler in service.

H. Provide expert analysis of the condition of boilers/ancillary equipment and recommended extension to useful life in years.

I. Provide photographs and/or drawings and show where each the measurements or negative observation was taken.

J. All safety-related deficiencies shall be immediately reported to the COTR during the inspection visit.

K. Provide recommendations on need for re-inspections after correction of deficiencies. Cost of re-inspections shall be extra cost negotiated with VA Contracting Officer.

12. ADDITIONAL INFORMATION

A. Place of Performance: Carl Vinson VA Medical Center, 1826 Veteran’s Blvd., Dublin GA 31021

B. Period of Performance: Project must be complete within 30 days of contract award.

C. Facility Operations: Normal operating hours are 8:00 a.m. and 4:30 p.m. eastern, Monday thru Friday, excluding federal holidays. The schedule for this project will be coordinated with the Contracting Officer Representative (COR) and request for weekend work must be submitted in writing to the COR.

Federal Holidays

When one of the above designated legal holidays falls on a Sunday, the following Monday will be observed as a legal holiday. When a legal holiday falls on a Saturday, the preceding Friday is observed as a holiday by U.S. Government agencies.

13. INVOICING INSTRUCTIONS

All invoices should be submitted in arrears and must contain the appropriate purchase order number, dates of services corresponding to the invoice, and the servicing representative contact information. Note: if invoice is submitted improperly (too early, incorrect purchase order number, incorrect billing, etc), invoice will be returned to contractor for correction.

Vendor Electronic Invoice Submission Methods Facsimile, e-mail, and scanned documents are not acceptable forms of submission for payment requests. Electronic form means an automated system transmitting information electronically according to the accepted electronic data transmission methods below:

a. VA’s Electronic Invoice Presentment and Payment System – The FSC uses a third-party contractor, Tungsten Network (Formerly OB10), to transition vendors from paper to electronic invoice submission. Please go to this website http://www.tungsten-network.com/us/en/veterans-affairs-us/ to begin submitting electronic invoices, free of charge. More information on the VA Financial Services Center is available at http://www.fsc.va.gov/einvoice.asp.

b. A system that conforms to the X12 electronic data interchange (EDI) formats established by the Accredited Standards Center (ASC) chartered by the American National Standards Institute (ANSI). The X12 EDI Web site (http://www.x12.org).

Vendor e-Invoice Set-Up Information Please contact OB10 at the phone number or email address listed below to begin submitting your electronic invoices to the VA Financial Services Center for payment processing, free of charge. If you have question about the e-invoicing program or OB10, please contact the FSC at the phone number or email address listed below:

· OB10 e-Invoice Setup Information: 1-877-489-6135

· OB10 e-Invoice email: VA.Registration@ob10.com

· FSC e-Invoice Contact Information: 1-877-353-9791

· FSC e-invoice email: vafsccshd@va.gov