P09_SOW_Annual Boiler Maint_with contracting 10.06.doc

Statement of Work

Inspection and Testing – Boiler Maintenance

DEPARTMENT OF VETERANS AFFAIRS – Eastern Colorado Healthcare

BOILER PLANTS

STATEMENT OF WORK

Semi-Annual Inspection, Safety Device Testing and Calibration Boiler Plant Burners, Controls, Instruments, and Data Management

1. Objective:

A. Combustion Analysis/Tuning/Safety Device Testing – Semi-Annually B. Pressure Relief Valve Replacement and Certification C. 5-year Inspection and Magnetic Particle Testing D. Service Hours for H Stamp Welding, Testing, and Certification

2. Technician Qualifications:

A. Technicians shall have completed at least a one-year trade school and have five years successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the Rocky Mountain Regional VA Medical Center (RMRVAMC) plant. The RMRVAMC facility manager/engineer may define and accept equivalent qualifications.

B. Technicians shall demonstrate familiarity with and ready access to the current versions of the following references:

Current issue of the National Board Inspection Code, Part RB, In service

Inspection of Pressure-Retaining Items Code

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

Code, Sections VI and VII, as applicable.

VHA Directive 1810, Boiler and Boiler Plant Operations (Most Recent Version)

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

Hazard Code, latest edt.

National Fire Protection Association (NFPA) 70E, Standard for Electrical Safety in the Workplace

VHA Boiler Plant Safety Device Testing Manual, (Most Recent Edition) C. Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests and calibrations, all calibrated within one month of the site visits. At facilities with programmable digital controls, the technicians must be capable of programming the controls and have the appropriate hardware and software for this.

3. Site Specific Equipment Information:

A. Boilers

i. Boiler #1: Cleaver Brooks; Model No. 4WI-200-700-200ST; Serial No. T3786-1-1

ii. Boiler #2: Cleaver Brooks; Model No. 4WI-200-700-200ST; Serial No. T3786-1-2

iii. Boiler #3: Cleaver Brooks; Model No. 4WI-200-700-200ST; Serial No. T3786-1-3

iv. Boiler #4: Cleaver Brooks; Model No. 4WI-200-700-200ST; Serial No. T3786-1-4

B. Deaerator Tanks

i. De-Aeration tank: Cleaver Brooks, Spray master; Model No. SM-4000; Serial No. T3786-5-1; 100,000 lbs/hour capacity

C. Condensate/Surge Tank

i. Condensate/Surge Tank: Cleaver Brooks; Model No. SRG-4096-4F; Serial No. T3786-6-1; 4,096-gallon capacity

4. Inspection, Testing and Calibration Requirements:

A. Technicians shall provide all tools and labor necessary to perform inspection, tuning, testing, calibrating, and adjustments of burners and boiler and boiler plant controls as specified below. This shall be done every six months in accordance with the schedule provided by RMRVAMC. RMRVAMC may extend the schedule for burners in limited service.

B. Instrumentation, monitoring and data management systems as listed below shall be calibrated every six months.

C. Provide at least two weeks notice to the Contracting Officer’s Representative (COR) prior to performing the work. Work cannot be scheduled during heavy steam load periods. Only one boiler at a time can be out of service for the inspection, testing and calibration procedures. Work must be conducted when the COR or his/her designate is available on site to monitor the work.

D. RMRVAMC will have the boilers that are to be serviced prepared for the technicians upon their scheduled arrival. This includes having the boilers clean of soot and loose scale; fully warmed and at normal steam pressure; steam exhaust silencer system operable; all boiler, burner and fuel train pressure gages and thermometers calibrated; fuel meters in accurate operation (pressure/temperature correction factors provided, if applicable); boiler steam flow, stack temperature and flue gas oxygen instruments operating.

E. RMRVAMC will comply with any other requirements of the test personnel that are considered reasonable by RMRVAMC and have been presented in writing at least two weeks prior to the scheduled testing.

F. The inspections, testing and calibrations shall comply with:

1) The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, Current Edition.

2) The written recommendations of the equipment manufacturers.

3) The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazards Code including applicable appendices.

4) Burner performance requirements in this document.

G. A summary of the work is as follows:

1) Review boiler plant log sheets and alarm and trouble reports.

2) Review records that show combustion performance (flue gas oxygen and carbon monoxide).

3) Perform overall visual inspection of systems. Verify that systems comply with referenced codes and RMRVAMC requirements stated in this contract.

4) Test and record the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Verify that the set points and operating points are within approximately 20% of normal operating parameters. Make adjustments as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation.

5) Operate burner(s) on each fuel from low fire to high fire and back to low fire in at least six increments and record combustion performance (flue gas oxygen, carbon monoxide, NOx where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output.

6) Compare the combustion performance data with RMRVAMC requirements (see below) and previous readings. If necessary, make adjustments to the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data.

7) Verify accuracy of instrumentation listed below. Verify that all devices are properly selected for the application in terms of type, size, set point range, performance, code approval. Calibrate all instruments that are not within manufacturer’s specifications for accuracy.

8) Immediately inform COR and contracting officer (CO) of any recommended repairs or modifications.

H. All of interlocks and safety devices to be inspected and tested on each boiler/burner/equipment, are contained in the VHA Boiler Plant Safety Devices Testing Manual, Current Edition, along with testing procedures.

I. Required burner performance (natural gas and fuel oil):

1) Turndown (ratio of maximum and minimum firing rates): 10/1 8/1 5/1 4/1 (Refer to original burner specification).

2) Achieve, but do not exceed, boiler maximum steam flow output rating. Measure fuel input at minimum and maximum firing rates.

3) Maximum carbon monoxide: 200 parts per million (ppm)

4) Maximum NOx: IAW original burner specification.

5) Flue gas oxygen: 2.5 – 4.2% (Up to 5.2% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single-point positioning systems).

6) Flue gas oxygen (low excess air burners): 1.0 – 2.0% (Up to 2.5% at loads below 40% of maximum steam output; no upper limit at minimum firing rate; oxygen can be one percentage point higher on oil firing on single point positioning systems).

7) No visible smoke, except on heavy oil fuel maximum opacity is 20%. Comply with local emissions regulations.

8) Copies of the applicable emissions regulations must be available in the boiler plant office.

9) Flames shall be stable with no pulsations, shall be retained near burner, no blowoff or flashbacks, no constant flame impingement on refractory or waterwalls.

J. List of instrumentation and controls to be inspected and calibrated:

1) Steam flow transmitters (all).

2) Steam flow recorders/computer readout.

3) Flue gas oxygen sampling, analyzing and recorder/computer readout.

4) Boiler and economizer stack temperature transmitters and recorder/computer readout.

5) Master steam pressure and combustion controllers.

6) Boiler outlet draft controllers.

7) Boiler water level controllers.

8) Feedwater deaerator and condensate storage tank water level controllers including overflow.

9) All pressure and temperature sensors and transmitters.

10) All signal processing and readout devices.

5. Report Requirements:

A. Provide complete written report of the inspection fully describing all tests performed, all findings, and recommendations. The report shall have two sections the first section will be in a table form that with four columns:

A. The first column labeled “FUNCTION” did the device pass or fail.

B. The second column labeled “Device” list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual Current Edition.

C. The third labeled “Deficiencies-Recommendations” D. The fourth column labeled “corrective actions” list any corrective actions taken during the inspection.

The next section shall be in paragraph/bulleted form and list each device individual in accordance to the VHA Boiler Plant Safety Devices Testing Manual, Current Edition. Plus the section must reference the correct Master Specification and Standard Detail for that device. See sample below.

5.1. Condensate Storage Tank High Water Alarm

Purpose: High water level may be an indication of condensate transfer pump failure that could lead to low water condition in the feedwater deaerator and in the boilers. There may be a failure of make-up water controls.

Recommended set point: 4 inches below overflow level and 2/3 of tank height.

Potential hazards due to failure of high water alarm: Feedwater deaerator running dry and, consequently, boiler feed pumps running dry will cause overheating and damage to pumps and potential for plant shut down. Failure of make-up water controls (in open position) could lead to significant cost from waste of water and condensate from the tank overflow if this occurs over a long time period.

Recommended type of device: Conductivity probe type switch. Float type switches have high failure rate in this application where they are exposed to flash steam that causes seals to harden and prevent float movement.

VA Master Specification section: 23 50 11 (old 15625).

www.va.gov/facmgt/standard/

VA Standard Detail: SD232111-05.pdf www.va.gov/facmgt/standard/

Failure rate of float types: 48% (BEI study of VA boiler plants).

Make and Model: Mercoid Float

Did it function properly: No

Category & Action Time Limit: Upon Failure or Within 5 Years

Comments: Float type switches are not allowed for high water alarms. The VA recommended switch type is a conductivity probe type switch. Install the VA recommended switch and set to alarm at 2/3 of the tank height. There are valves that can isolate this alarm. These valves must be made lockable only in the operating position.

B. Furnish report within one week of each facility inspection in “Microsoft Word” format by email to the COR and to the VA Headquarters office designated. Provide hard copies of data sheets and flue gas analyzer “strip” printouts to the COR within one week of visit.

C. All safety-related deficiencies shall be immediately reported to the COR, Boiler Plant Supervisor and/or Chief Engineer during the inspection visit.

6. Inspection and Magnetic Particle Testing

A. Annual internal and external inspections are required for each boiler. Internal inspections of the feed water de-aerator pressure vessel are required. All inspections to be completed on the base year and will be the top priority of the contractor’s proposed schedule.

B. Contractor shall coordinate with COR to schedule an inspection. The Contractor shall ensure coordination and scheduling of any inspection is conducted at least two weeks prior to the intended date of an inspection. Inspections must be scheduled for periods when the VA determines that the boilers that will be inspected internally will not be needed for steam supply and when the COR or his/her designate is available on site to monitor the inspections. To maintain steam service, only one boiler at a time will be scheduled for internal inspections per inspection visit. Thus, multiple visits will be necessary every year to inspect all the boilers internally.

C. Feed water de-aerator pressure vessel inspections must be scheduled during periods of low steam demand.

D. Coordinate the inspection schedule with the COR so that RMRVAMC can have personnel available to monitor the inspections.

E. Boilers scheduled for internal inspection will be prepared by the contractor prior to the scheduled arrival of the Qualified Professional Inspector. This includes cooling the boilers to near ambient temperature and having all man ways, hand holes and furnace access doors open; the boilers cleaned of loose materials waterside and fireside; electrical “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. Similar advance preparations will be made to the feed water de-aerator when it is scheduled for internal inspection.

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

G. The boiler and feed water de-aerator inspections shall comply with the guidelines in the current issue of the NATIONAL BOARD INSPECTION CODE, Part RB, In-service Inspection of Pressure-Retaining Items, and ASME Boiler and Pressure Vessel Code, Section VI or VII as applicable. In addition to those guidelines, the inspections shall comply with all requirements listed in statement of work.

H. The inspector must completely enter the internal spaces of the boiler or feed water de-aerator and visually inspect all internal surfaces that can be accessed. Methods for testing safety devices shall comply with VHA Boiler Plant Safety Device Testing Manual, Current Edition.

I. Repairs and Re-Inspections

i. Repairs

1. Contractor to provide quote (to include subsequent re-inspection) to the CO and COR within 5 business days of discovery for all deficiencies identified through inspections required as part of section 6.1.

2. All repairs must be approved and coordinated with CO and COR prior to scheduling any work.

3. Contractor to provide repairs not to exceed the amount identified in the CLINS per year of contract and shall provide all testing/certification documents within 10 business days.

ii. Emergencies

1. Contractor to provide up to 6 emergency call outs per year of contract (after hours and/or weekend/holiday).

2. Contractor to provide quote for any emergent repairs needed within 24 hours of site visit to the CO and COR via email

3. Contractor to provide emergent repairs not to exceed the amount identified in the CLINS. The contractor must respond to emergency call back service, within four hours or less and will be provided in response to requests by telephone or otherwise from the (1) Contracting Officer, (2) COR, or (3) their designees in case of a malfunction or if emergency trouble should develop between regularly scheduled maintenance.

J. Summary of the minimum inspection requirements for boilers:

i. Review the boiler history including operating conditions, date of last inspection, current inspection certificate, ASME stamping on boiler, National Board registration number, history of repairs and modifications. Review boiler logs, water test reports, and reports on tests performed on the burner controls and interlocks. The contractor is expected to do this work on station.

ii. Assess the external parts of the boilers and boiler accessories and piping and valves for safety, accessibility, proper maintenance and operation, cleanliness, and compliance with codes.

iii. Inspect for evidence of leakage of combustion gases or fluids, externally and internally, including all gaskets.

iv. Inspect foundations for signs of stress such as cracking or movement.

v. Inspect boilers externally and internally for defects including bulges, blisters, cracks, wasted or eroded material, warping, general corrosion, grooving and pitting, damaged insulation.

vi. Inspect all accessible internal surfaces for waterside and fireside deposits, including scaling, sediment, debris, carbon deposits.

vii. Examine all stays and stayed plates.

viii. Inspect gas side baffles.

ix. Inspect internal drum surfaces and steam separating internals.

x. Inspect tubes, tube ends and tube alignment. Check for sagging tubes.

xi. Set combustions for boilers number one, two, and three, on natural gas and number two oil.

xii. Test all safety devices and perform annually required accumulation tests on boilers one, two and three.

xiii. Verify that all nozzles of internal piping such as feed water admission and bottom blow off collection are clear with no obstructions.

xiv. Inspect seating surfaces of man ways and hand holes.

xv. Check that boiler structure is plumb and level with no excessive deformations.

xvi. Check for missing items such as bolts and nuts.

xvii. Examine all valve and pipe connections to the pressure vessel.

xviii. Inspect refractory including burner throat, expansion joint, bull ring, furnace seals, furnace walls and floor.

xix. Verify proper alignment of burner assembly.

xx. Inspect furnace for evidence of flame impingement.

xxi. Test operation of water level gage glass.

xxii. Perform mechanical and electrical inspection of disassembled low water cutouts (disassembly by VA). After reinstallation, test operation to the extent possible. Test low water cutouts on hot boilers by lowering water level gradually.

xxiii. Verify that steam pressure gage is properly calibrated.

xxiv. Test operation of high steam pressure cutouts on hot boilers by raising steam pressure.

xxv. Inspect safety valve installations and verify that the valves have proper capacity and set pressure and valves, drains and vents are properly installed. Verify that valve locking seals are not broken. On boilers that are hot, perform an operation test under pressure to confirm operation at proper set pressures. Operate boiler with burner at high fire to verify adequate steam flow capacity of the safety valves (“accumulation test”).

xxvi. Inspect piping connected to the boilers for evidence of leakage, provision for expansion, provision of adequate support, proper alignment, and evidence of detrimental conditions.

xxvii. Inspect piping to the water column, low water cutoffs and alarms, gage glass. Verify that interior of piping is clear of obstructions.

xxviii. Inspect valves on boiler feed water, blow down, drain and steam systems.

xxix. Perform service and Calibration of boiler instrumentation and controls.

xxx. Provide recommendations for non-destructive testing when the inspections indicate that this is necessary to assure continued safety and reliability under current operating conditions.

K. Summary of the minimum inspection requirements for Feed water Deaerators:

i. Review the feed water de-aerator 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.

ii. Assess the external parts of the feed water de-aerator and accessories and piping for safety, accessibility, cleanliness, proper operation, and compliance with codes.

iii. Test hazardous gas monitoring system.

iv. Inspect for evidence of leakage.

v. Note feed water de-aerator pressure gage and thermometer readings and verify gage and thermometer accuracy.

vi. Inspect safety valve installation and verify that the valves have proper set pressure and capacity and are properly installed. Perform an operation test under pressure to confirm operation at proper set pressures. Verify that the de-aerator can safety withstand the test pressure prior to testing the valve(s) in-situ.

vii. Verify that non-condensable gas vent line is open and proper orifice is provided to permit venting of gases.

viii. Inspect support structures for proper integrity and allowance for thermal expansion.

ix. Internal Inspections:

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

2. Inspect spray nozzles and trays.

6. Resources

The Government will not furnish any resources for the fulfillment of the services required under this contract. The contractor must provide all tools, equipment, materials, transportation, professional expertise, personnel, and supervision for maintenance services required under this contract.

7. Hours of Work and Scheduling

A. Scheduling

i. The work will be performed Monday through Friday from 7:30am to 4:00pm. The majority of the work will have minimal impact on the operation of the VA Medical Center.

ii. Any potential disruption to ongoing medical center operations shall be coordinated 2 weeks in advance and shall be subject to review and approval by the CO/COR.

iii. Any other disruption of operations in any building shall be scheduled at least one week in advance with the CO/COR. Work shall be scheduled to allow continuous operation of all facilities to the greatest extent possible.

B. Unscheduled Maintenance

i. Unscheduled maintenance will be paid per job once price reasonableness is determined and shall not exceed the contracted amount. This will also cover additional parts needed to complete unscheduled repairs.

C. Federal Holidays

i. New Year’s Day

ii. Martin Luther King’s Birthday

iii. President’s Day

iv. Memorial Day

v. Juneteenth

vi. Independence

vii. Labor Day

viii. Columbus Day

ix. Veteran’s Day

x. Thanksgiving Day

xi. Christmas Day

D. Contractor Check-In

i. All Contractor personnel working onsite at the VA facility shall check in and out with the COR located in Building L (ENC). Access to work areas, and performance monitoring, will be provided by the COR. In all cases, the CO/COR shall be notified of any changes which may affect the response time of vital equipment.

8. Period of Performance

This requirement is for one (1) Base Year and four (4) Option Years.

9. Place of Performance

All work will be performed at Rocky Mountain Regional VA Medical Center at 1700 N. Wheeling Street, Aurora, Colorado, 80045.

10. Records Management Language

A. This clause applies to all contractors whose employees create, work with, or otherwise handle Federal records, as defined below:

“Federal Record” as defined in 44 U.S.C. 3301, includes all recorded information, regardless of form or characteristics, made or received by a Federal agency under Federal law or in connection with the transaction of public business and preserved or appropriate for preservation by that agency or its legitimate successor as evidence of the organization, functions, policies, decisions, procedures, operations, or other activities of the United States Government or because of the information value of data in them.

The term Federal Record:

1. Includes (Agency) records.

2. Does not include personal materials.

3. Applies to records created, received, or maintained by Contractors to the (Agency) contract.

4. May include deliverables and documentation as associated with deliverables.

11. TRAINING: All Contractor employees assigned to this contract who create, work with, or otherwise handle records are required to take VHA provided records management training. The Contractor is responsible for confirming training has been completed according to agency policies, including initial training and any annual or refresher training.

12. FLOWDOWN OF REQUIREMENTS TO SUBCONTRACTORS

1. The Contractor shall incorporate the substance of this clause, its terms and requirements including this paragraph, in all subcontracts under this contract, and require written subcontractor acknowledgement of same.

2. Violation by a subcontractor of any provision set forth in this clause will be attributed to the Contractor.