P09 SOW for Boiler plant retrofit 20240912.pdf

Project No: 640-25-900 Retrofit Boiler Plant in B40, PAD

Scope of Work (SOW)

1.0 General Intent

1.1 The contractor must provide all personnel, expertise, equipment, tools, materials, supervision, due diligence and other items and services necessary to retrofit three (3) boilers at boiler plant building # 40 located at 3801 Miranda Ave., Palo Alto, CA 94304.

1.2 The contractor must perform to the standards in this contract. This project shall take no longer than 120 calendar days from the notice to proceed to complete. This period includes submittals for materials by contractor. Allow 7 calendar days for VA to review submittals. Contractor to provide a schedule of major tasks within 5 business days of contract award.

1.3 This project shall be coordinated with the appointed COR to ensure no impact to boiler plant operations and boiler plant operators’ duties, with at least two (2) boilers in operation at any given time.

Scheduling of work shall be at the convenience of the VAPAHCS.

2.0 General Information and Requirements

2.1 The objective of this project is to retrofit three (3) existing boilers at the Palo Alto Facility boiler plant to meet the safety standards required per Directive 1810, Master Specifications and Boiler Safety Manual, 8th Edition found on Technical Information Library (TIL) Technical Information Library (TIL) - Office of Construction & Facilities Management (va.gov), and remove deficiencies as delineated in the Boiler Efficiency Institute (BEI) Boiler Safety Device Testing report dated July 20, 2023, attached herewith.

The scope of the project is to address the deficiencies listed in section 3.1 of this SOW and identified in the report with corresponding numbers.

2.2 The contractor shall provide operation and maintenance instructions, and manufacturer documentation at the completion of the project. Manufacturer documentation and maintenance schedule to be provided in close out documents.

2.3 The contractor shall provide a one-year full parts and labor warranty on all the work performed under this contract.

2.4 The contractor shall provide all tools, equipment, and personal protective equipment necessary to complete this project as deemed by industry standards, this SOW, all related specifications, applicable code requirements, and site policy.

2.5 The contractor shall provide daily cleanup and securing of work site, including securing tools and equipment. Disposal of all waste and debris is at the contractor’s own expense.

2.6 The contractor shall provide quality control of all work conducted and the individual appointed shall be competent and educated/experienced in the field of work this scope encompasses.

2.7 All work shall be coordinated with the COR assigned to this project and only commence once approved.

2.8 Badges: Contractor will obtain required ID badges for all employees used on project at start of each workday; Report the COR for escort to the station police service for sign in and badge issuance.

https://www.cfm.va.gov/TIL/ https://www.cfm.va.gov/TIL/

Project No: 640-25-900 Retrofit Boiler Plant in B40, PAD

2.9 Security: The contractor and their personnel shall be subject to the same Federal laws, regulations, standards, and VA policies as VA personnel regarding information and information system security.

2.10. Wherever work is performed, parts of boiler plant and boilers that are to remain in place shall be adequately protected prior to starting work, and this protection shall be maintained intact until all work in the area is completed.

2.11 Schedule: Normal work hours will be 8:00am – 4:30 pm Monday-Friday excluding Government holidays (Federal Holidays (opm.gov)) unless otherwise approved by the COR. Any request for utility shutdowns must be made in writing at a minimum of 21 days prior to the requested day of shutdown.

2.12 Codes and Standards: The Contractor shall follow all applicable codes and standards to this type of work including but not limited to Health Care System Memorandums (HCSM), OSHA Guidelines, Lock-out-Tag-out, Rules of Station, NFPA, and etcetera. If any code/standard is found to be contradictory; the authority having jurisdiction (COR) shall make the final determination and work shall proceed at no additional cost to the Government.

3.0 Specific Tasks

3.1 The contractor shall provide all supervision, Engineering and design, administrative and technical support, labor, subcontractors, tools, transportation, materials, supplies and equipment. The contractor shall plan, schedule, and ensure effective completion of the tasks 1 through 16 listed below, applicable to each of the three boilers in the boiler plant. Contractor to provide task 17 as a single set of drawings if identical modifications have been made to all three. Notes may be added on the drawings for differences to a specific boiler as applicable. Contractor to provide submittals for all parts to be installed for approval by VA before purchase or installation. Contractor to also refer to attached BEI report with references to VA design policy, VA boiler plant design spec sections and Technical Information Library (TIL) details. BEI report is provided with this solicitation as a reference for further clarification of deficiency, and what action is required by contractor to remove deficiency.

3.2 Contractor to provide verifiable documented proof of all corrections made to the deficiencies under this contract. Verification to be in the form of test results and/or inspection by third party inspector qualified to perform boiler plant inspections.

3.3 Contractor to document existing conditions prior to start of work or at various stages of work as needed and provide documentation to VA COR.

Task Item

BEI

report # Deficiency

Action required by contractor (Also refer to BEI testing report for clarification of action required).

1 4.7

PRV station serving Deaerator steam supply tank is a 1/3- 2/3 parallel setup. Safety valve is only sized to relief larger PRV but not both. Per VA spec relief valve must be sized to relief combined flow capacity of both PRVs.

Install new cast steel relief valve to be sized to relief combined flow capacity of both PRVs. Indicate how new size is calculated.

https://www.opm.gov/policy-data-oversight/pay-leave/federal-holidays/#url=Overview

Project No: 640-25-900 Retrofit Boiler Plant in B40, PAD

2 4.13

VA master specification requires a manual reset automatic shutoff valve in the propane line serving the boiler plant. These valves must be wired into the Estop circuit to close upon activation. Currently there is no valve installed.

Install new manual reset automatic shutoff valve with Estop in the 1” existing propane supply line.

3 5.3.1

Low Fuel Gas Pressure Cutout Switch- LFGPCS.

Fail Installation/Setpoint/logic – There is a snubber in place. Snubbers are no allowed in the VA. Setpoint is too low. Setpoint must be 80% of regulated pressure. There is a 5 second delay between switch activation and boiler shutdown.

Delay is not allowed on safety devices.

Make correction to programming Logic and remove delay. Set point to be adjusted. Snubber to be removed.

4 5.3.5

Proof Of Closure POC-AFGSOV-1 and POC- AFGSOV-2. Fail logic- System does not prevent boiler fan from starting when POC switch is open. This could possibly create a dangerous combustible situation in the event the valves are open and are leaking. Boiler fan could start introducing air into a fuel rich mixture. POC switch logic must not allow the boiler fan to start when the POC switch is open.

Make correction to programming logic and test proof of closure again after programming. Also, provide test results or proof of testing.

5 5.4.6

Proof of Closure POC-AFOSV-1 and POC-AFOSV-

2. Fail logic- POC circuit is not checked until after FD fan is started. This could create a combustible mixture in the boiler. An open POC switch must prevent boiler fan from starting.

Make corrections to programming Logic.

6 5.5.3

The boilers are equipped with a non-compliant safety burner management system. PLC system has adjustable/configurable parameters and programmable logic. VA requires BMS systems to burned in (non-adjustable) after commissioning parameters. Refer to VA spec 230911 for proper system.

Install compliant safety burner management system with non-adjustable, burnt-in parameters and logic.

7 5.5.3 Ignitor Timing -IT - Allen Bradley PLC has adjustable timing which is not allowed by the VA.

Make correction to programming logic and "burn-in" timing.

8 5.5.4 Main Flame Ignition Timing -MFIT. Timing is adjustable. Adjustable timing is not allowed by VA spec.

Make correction to programming logic and "burn-in" timing.

Project No: 640-25-900 Retrofit Boiler Plant in B40, PAD

9 5.5.5

Pre-Purge and Post-purge Timing -PPT . Fail logic-timing is adequate but timing is adjustable.

Adjustable purge timing is not allowed by VA specification.

Make correction to programming logic and "burn-in" purge timing.

10 5.5.6

Low Fire Proving Switch -LFPS-GAS

Adjust setpoints for all switches and provide verification. Low Fire Proving Switch -LFPS-OIL

Low Fire Proving Switch -LFPS-AIR

11 5.5.7

Forced Draft Damper Wide Open Proving Switch -FDDWOPS. Fail Setpoint- inlet Switch makes at 85% wide open damper position. Outlet damper switch makes at 75% wide open. Setpoint too low. Adjust setpoints.

Adjust setpoints and provide verification.

12 5.5.8

Combustion Air Pressure Switch - CAPS. Fail installation/setpoint/logic – Isolation valve not lockable only open. Setpoint too low. Boiler does not lock out during purge. Only locks out while firing. If inadequate combustion air is present, then boiler should not be allowed to light.

Make adjustment to set point and programming logic, Adjust isolation valve in Locatable only in Open Position. Provide verification.

13 5.5.9

Purge Airflow Proving Switch-PAPS. Fail installation/Setpoint – Isolation Valve is not lockable only open. Switch makes at 2.5 in wc.

Setpoint is too low. Increase PAPS setpoint to within 80% of maximum delta P at purge.

Make adjustment to set point and programming logic, Adjust isolation valve in Locatable only in Open Position. Provide verification.

14 5.5.10

Forced Draft Motor Interlock Switch-FDMIS-1 Locate all switches/relays in a new cabinet outside of 480V cabinet.

Forced Draft Motor Interlock Switch -FDMIS-2 Locate all switches/relays in a new cabinet outside of 480V cabinet.

Forced Draft Motor Interlock Switch -FDMIS-3 Locate all switches/relays in a new cabinet outside of 480V cabinet.

Furnace Pressure Interlock -FPI Locate all switches/relays in a new cabinet outside of 480V cabinet.

Project No: 640-25-900 Retrofit Boiler Plant in B40, PAD

15 5.5.11

Low Pilot Fuel Gas Pressure Cutout Switch - LPFGPCS. Zeeco burner is not set up to use a pilot flame ignition system when firing natural gas. System uses a high intensity spark system.

VA spec requires a pilot flame ignition system on all burners.

Set up all three burners to use a pilot flame ignition system when firing natural gas, per spec section 23 0911. The pilot gas pressure must be sufficient to provide a pilot flame sufficiently large to quickly ignite the main flame. Pressure at which the pilot flame will quickly ignite the main flame, which should be within 80% of the normal operating pressure.

16 5.5.12 Low Flue Gas Oxygen Level Interlock -LFGOLI. Fail logic- System does not respond and reads 15% on air. System must be repaired and calibrated.

Repair system and recalibrate it.

Provide as-built drawings of three boilers, showing as-built conditions of gas and steam valves, location of viewports and burner configuration.

Format: 11x17. Digital copy of pdf document.

4.0 Statement of Bid Items

STATEMENT OF BID ITEM(S)

4.1 ITEM I, Work includes tasks # 1 through 17 as identified in section 3.0. Performance period: 120 Days

4.2 ITEM II, provide as ITEM I except omit task # 17. Performance period: 90 days

5.0 Technical Exhibits

5.1 BEI Report for applicable deficiencies as noted in section 3.1 with explanation and applicable specs and VA standards.

5.2 Photos of boilers.