SOW.pdf

STATEMENT OF WORK

Hudson Valley Health Care System - Castle Point & Montrose Campus

I. Contract Title:

Maintenance, Repair, Tuning, Calibration and Safety Device Testing of High-Pressure Boilers at the VA Hudson

Valley HCS

II. Background:

The Hudson Valley Health Care System has a requirement for the Inspection, Safety Device Testing, Tuning, Calibration, Maintenance and Repair of the High Pressure Boilers at the Montrose and Castle Point Boiler Campuses. Hudson Valley Health Care System has a central boiler plant to provide steam for heating, air conditioning, domestic hot water, kitchens, sterilization, and laundry services. The contract also includes repair and maintenance for both campus low pressure boilers.

III. Place of Performance:

Department of Veterans Affairs Hudson Valley Health Care System

VAMC-FDR-Montrose Campus

2094 Albany Post Road

Montrose, New York 10548, Building 20 Boiler Plant

Department of Veterans Affairs Hudson Valley Health Care System

VAMC – Castle Point Campus

41 Castle Point Road

Wappinger Falls, New York 12590, Building 35 Boiler Plant

IV. Estimated Period of Performance:

The base period of performance will be one (1) year from the date of award with provision of four (4) Option Years

V. Scope:

1. GENERAL REQUIREMENTS:

a. The vendor shall provide all labor, management, tools, supplies, and equipment to provide routine and emergency repair service, boiler safety device testing, tuning, and calibration for Government owned boilers and associated equipment in accordance with this contract. The vendor shall have the ability to provide or procure specialty services such as R-stamp welders, Boiler technicians, controls technicians, controls engineers as needed.

b. Vendor shall remove from service one boiler at a time for the boiler tests, tuning and calibration procedures.

Work must be conducted when the COR or his/her designate is available on site to monitor the work.

c. Boiler Plant Preventive Maintenance shall be in accordance with Veterans Affairs (VA) Directive 1810 dated January 4, 2023, VHA Boiler Plant Safety Device Testing Manual 8th edition (or current edition), NFPA 85A, Boiler and Burner manufacturers’ requirements, industry standards and statutory requirements.

d. The vendor while performing preventive maintenance, safety device testing, tuning and calibration shall inform the COR of any required repairs, equipment malfunction and/ or abnormalities

2. HIGH PRESSURE (HP) BOILER PLANT SAFETY DEVICE TESTING REQUIREMENTS:

a. The vendor shall perform the below safety device testing in accordance with VHA Directive 1810 & VHA Boiler Plant Safety Device Testing Manual 8th edition (or current edition). All safety device test results and data shall be recorded and submitted in the VHA Boiler Plant Safety Device Testing Manual current edition, see reporting requirements for additional information. The safety device tests shall be performed at the frequencies indicated in the below tables, where (6M) indicates tests that shall be performed every six months (for our campus that is typically August and February), and (Y) indicates tests that shall be performed annually.

Operational Testing of Boiler Safety Devices Boiler Safety Device test Frequency

(a) Low-water cutoff (slow drain)

6M

(b) Fire each boiler and the pilot on the alternate fuel for one-hour 6M

(c) Low-water cutoff shunt switch 6M

(d) Auxiliary low-water cut-off (slow drain) 6M

(e) Auxiliary low-water cut-off shunt switch 6M

(f) High-water alarm 6M

(g) Low-water alarm 6M

(h) High-steam pressure cut-out (non-recycle) 6M

(i) Steam safety valves (accumulation test at high fire) Y

(j) Flame scanner 6M

(k) Check gas vent for leaks 6M

(l) High-gas fuel pressure cut-off 6M

(m) Low-gas fuel pressure cut-off 6M

(n) Gas fuel safety shut off valves proof of closure 6M

(o) Leak test gas flue) safety shut off valves 6M

(p) Low-atomizing pressure for fuel oil 6M

(q} High-fuel oil pressure cut-off 6M

(r) Low-fuel oil pressure cut-off 6M

(s) Fuel oil safety shut off valves proof of closure 6M

(t) Leak test fuel oil safety shut off valves 6M

(u) Check operation of Liquid Petroleum Gas pilot 6M

(v) Low-pilot gas pressure cut-out 6M

(x) Forced draft fan motor interlock 6M

(y) Forced draft fan damper wide open for purge 6M

(z) Boiler outlet damper wide open for purge 6M

(aa) Purge airflow interlock 6M

(bb) Timing for pre-purge 6M

(cc) Timing for post-purge 6M

(dd) Igniter timing 6M

(ee) Low fire position interlock 6M

(ff) Combustion air interlock 6M

(gg) Main flame out; i.e., time to close valves 6M

(hh) Ignition flame out; i.e., it is time to close valves 6M

(ii) Minimum igniter flame test 6M

(jj) Scanner not sensing ignition spark 6M

(kk) Low-oxygen alarm and/or cut-out 6M

(ll) Pre-purge setting of flue gas recirculation damper 6M

(mm) Interlock of building outside air damper with burner control 6M

(nn) Burner control 6M

Operational Testing of Plant Safety Device Test

Safety Device tests Frequency

(a) Check furnace pressure 6M 6M

(b) Check combustion gas leaks into boiler room 6M 6M

(c) Operation of deaerator high and low water alarms 6M

(d) Operation of Deaerator steam pressure or temperature control 6M

(e) Operation of condensate storage tank high and low water alarms 6M

(f) Operation of all other plant alarm devices 6M

3. HIGH PRESSURE BOILER TUNING AND CALIBRATION REQUIREMENTS:

a. The following required combustion tuning shall be completed by the vendor semi-annually in the months of February and August of each contract year:

i. Boiler fouling and combustion gas flow check (natural gas and #2 fuel oil).

ii. Vendor shall provide o2 bottle for testing oxygen sensor.

iii. Adjust burner combustion settings and calibrate oxygen trim (natural gas and #2 fuel oil).

iv. Check vibration of burner fans.

v. Calibrate instrumentation, monitoring, and control systems (natural gas and #2 fuel oil).

vi. Change all batteries in boiler controls where applicable.

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

viii. Operate burner(s) on each fuel from low fire to high fire and back to low fire in at least 10 increments on natural gas and 7 increments on fuel oil and record combustion performance (flue gas oxygen, carbon monoxide, Nitrogen Oxides (NOx) where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output.

ix. Compare the combustion performance data with Hudson Valley requirements as stated herein and previous readings.

If necessary, adjust the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data.

x. 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, and code approval. Calibrate all instruments that are not within manufacturer specifications for accuracy.

xi. Vendor shall perform boiler tuning to meet or exceed the following minimum requirements, and shall provide all combustion analyzers (Calibrated) as well as performance data indicating these requirements have been met or exceeded:

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

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

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

iii. Maximum Carbon Monoxide: 200 PPM throughout the firing rate.

iv. No visible smoke; must comply with local emissions regulations.

v. Must follow all Boiler Efficiency Institute (BEI) guidelines (provided locally).

vi. Flue gas oxygen: 2.5 – 4.2% O2 (Up to 5.2% at loads below 40% of maximum steam output, no upper limit at minimum firing rate, oxygen can be 1% point higher on oil firing on single point positioning systems).

vii. Flames shall be stable with no pulsations, shall be retained near burner, no blowoff or flashbacks, no constant flame impingement on refractory or water walls.

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

All instruments shall be calibrated in accordance with applicable manufacturers standards.

i. Steam flow transmitters (all)

ii. Steam flow recorders/computer readout.

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

iv. Boiler and economizer stack temperature transmitters and recorder/computer readout.

v. Master steam pressure and combustion controllers.

vi. Boiler outlet draft controllers.

vii. Boiler water level controllers.

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

ix. All pressure and temperature sensors, recorders and transmitters.

x. All signal processing and readout devices.

xi. Square Root Extractors

xii. Fuel Oil pressure transmitter and receiver gauge

xiii. See appendix A for combustion test data form, collected date shall be inputted into the test data form and submitted to the VA COR.

4. HIGH PRESSURE BOILER MAINTENANCE AND REPAIR REQUIREMENTS:

a. High Pressure Boiler Repair Requirements for castle Point Campus:

i. In the base year of the contract the vendor shall provide and install three new O2 analyzers and probes for Boilers # 1 thru 3. The existing units are Hays units and are no longer available. The vendor shall make all field adjustments to transition from the existing system fittings to the applicable fittings for the new oxygen analyzer system and appurtenances.

The vendor shall provide the following as part of the installation…

Three (3) Oxygen Analyzers (Yokogawa or approved equal)

Three (3) Oxygen Probes (Yokogawa or approved equal)

Three (3) Manual Calibration Stations for Oxygen Analyzer (Yokogawa or approved equal)

Three (3) Air Regulators (Fairchild or approved equal)

Three (3) Cables (Yokogawa or approved equal)

Three (3) Flange Adapters for Probes.

Electrical and Mounting accessories

ii. In the base year of the contract the vendor shall provide the following safety relief valves….

Three (3) 130 PSI Safety Relief Valve (Kunkle or approved equal). Vendor shall field verify relief valve sizes.

Three (3) 135 PSI Safety Relief Valve (Kunkle or approved equal). Vendor shall field verify relief valve sizes

Vendor shall submit shop drawings and other applicable submittals for the valves for VA approval prior to vendor purchasing the valves. Vendor shall be responsible for selecting valves that meet the requirements VA requirements, approval from the VA shall not absolve the vendor from this responsibility.

b. Non-Emergency Boiler Service Requirements Vendor shall provide support for non-emergency repairs include phone support, troubleshooting within 10 days of receiving notice from the VA, and repair quotes within 14 days of troubleshooting the boiler issue. Repair quotes shall be approved by the CO and COR prior to the vendor proceeding with the repair work. The vendor shall make best effort to repair the problem with 30 days of receiving the notice to proceed from the VA (unless the part is a long lead item which delays the start of the repair).

c. Emergency Boiler Service Requirements:

Vendor shall provide repair service call support for emergency corrective maintenance to the VA Hudson Valley HCS Boiler plant 24 hours a day, 7 days per week. Emergency service shall include labor, parts, and travel. In an emergency such as an event that jeopardizes VA “N+1” boiler redundancy requirements, an emergency service call will be initiated by a VA Hudson Valley HCS boiler plant operator or facilities engineer to the vendor’s service center via telephone, email, and/or text messaging.

Vendor shall acknowledge the call for emergency service within 4 hours, shall provide support by qualified technicians on site within 8 hours, and shall endeavor to return equipment to normal operation within 24 hours. Normal operation means that defective parts have been replaced with parts that meet or exceed manufacturer's original specifications and VA requirements, and that the equipment meets or exceeds the manufacturer's original performance specifications.

For emergency calls/service the vendor will furnish all Factory repair parts and service not to exceed a TBD amount per year. The vendor shall provide by email, a requested itemized quote to include hourly rate and travel within 24 hours for any scheduled services and or parts. The vendor shall provide by email, an invoice for any emergency call outs within 48 hours of emergency service completion. The vendor shall be familiar with all terms, conditions, and requirements herein contained with warranty items and conditions.

The vendor shall be responsible for all damages to persons or property that occurs because of the vendor’s fault or negligence.

Repair quotes shall be approved by the CO and COR prior to the vendor proceeding with the repair work.

5. HIGH PRESSURE BOILER PLANT EQUIPMENT LIST (BOTH CAMPUS):

a. Castle Point

(1) 400 Horsepower Superior Boilers (fire tube, 3-pass, wet back) –

National Board Number - NB1107

(1) 400 Horsepower Superior Boilers (fire tube, 3-pass, wet back) –

National Board Number – NB15624

(1) 200 Horsepower Superior Boiler (fire tube, 3-pass wet back) –

National Board Number – NB15451

(1) De-Aeration Tank – George Marker & Sons Serial Number 9467-08-05A National Board Number –NB1108

(1) Condensate Tank – NB1107

b. Montrose

(1) Victory 1000HP Voyager Water Tube Boilers Serial Number 10828-1 National Board Stamp 318

(1) Victory 1000HP Voyager Water Tube Boilers Serial Number 10828-2 National Board Stamp 317

(1) Victory 1000HP Voyager Water Tube Boilers Serial Number 10828-3 National Board Stamp 320

(1) Burnham 200HP Fire Tube Boiler NB 31050

(1) De-Aeration Tank Alstrom Heat Transfer LLC ADA120SS Serial Number 74931, National Board Stamp 2096

(1) Condensate Storage Surge Tank Alstron Heat Transfer LLC AST-2500V Serial Number 749.32, National Board Stamp 2097

6. LOW PRESSURE (LP) BOILER PREVENTIVE MAINTENANCE REQUIREMENTS:

a. The vendor shall maintain, and repair elements of the low-pressure boiler systems identified herein. The vendor shall inspect and service components in accordance with the manufacturer’s recommendations, prevailing industry standards and local, state, national, and international (where applicable) codes and this agreement. Vendor shall perform this service on a semi-annual basis.

b. The vendor shall furnish all material, labor, supervision, tools and equipment necessary to provide a full preventive maintenance program. All work shall be in strict compliance with regulatory agencies as follows:

(a) Open heat exchangers and brush and vacuum fireside of boilers

(b) Inspect refractory and insulation, note any deficiencies

(c) Inspect all boiler tapping for sighs of leakage

(d) Re gasket fire doors with new material and close

(e) Test fire unit

(f) Visually inspect entire burner

(g) Check combustion air interlocks

(h) Visually inspect piping filters and pumps for leaks

(i) Check oil pump drive

(j) Check combustion air intakes to building

(k) Replace electrode assembly

(l) Replace oil nozzle

(m) Check, clean and lubricate combustion air fan and air circulation fan

(n) Visually inspect stacks

(o) Check all electrical connections and tighten as required. Inspect all motor starters

(p) Check combustion air system including fresh air dampers for proper operation and filters and screens are free of obstructions

(q) Check pilot assembly and adjust as required

(r) Check and lubricate combustion air control damper

(s) Visually inspect piping and supports

(t) Test gas valves for tight close off (no leaks)

(u) Check modulating valves and linkages for proper stroke

(v) Check gas supply and manifold gas pressures

(w) Test inspect calibrate as needed all safety pressure switches, gas etc

(x) Verify air flow switch operation

(y) Check all gauges

(z) Check low water cut off and auxiliary low water cut off

(aa) Inspect & test safety relief valve

(bb) Check operating and limit and water level controls

(cc) Check all safety and operating control functions

(dd) Check flame detector

(ee) Check timing of all stages

(ff) Check for proper shutdown

(gg) Make combustion adjustments as required. Utilizing an electronic combustion analyzer, adjust burner for best possible achievable performance throughout operating range and document same.

Documentation will include:

Excess air

Carbon Dioxide

(hh) Carbon Monoxide

Stack Temperature

Boiler efficiency – stack loss method

(ii) Complete all regulator documentation for NYSDEC and USEPA of 40 CFR Part 63 Subpart JJ for the four boilers that burn oil.

(5) Bound written copies of results the work shall be provided to the COR within 7 business days of completion of work

c. Low Pressure Boiler Equipment List (BOTH CAMPUS):

MONTROSE CAMPUS

BUILDING MAKE/MODEL FUEL

26 PVI Turbo Power Series water heater BG600 Burner (3 Boilers)

Gas

27 Power Flame Burner JR30A-10 Peerless Boiler series TC

Gas

29 Power Flame burner C2-G-20B Peerless boiler series TC

Gas

31 Burnham model IN6PUNI-M2 serial number 64837106 Gas

CASTLE POINT CAMPUS

Building MAKE/MODEL FUEL

88 Weil McLain 80 Series 639 MBTU/HR # 2 Fuel Oil

88 Renzor Model OH 95 95,000 BTU/HR # 2 Fuel Oil

89 Renzor Model OH 140 170,000 BTU/HR # 2 Fuel Oil

89 Armstrong Air Furnace 160,000 BTU/HR # 2 Fuel Oil

41 Renzor Model OH 190 230,000 BTU/HR # 2 Fuel Oil

45 Weil Mclain SGO-4 # 2 Fuel Oil

1 Weil Mclain SGO-4 # 2 Fuel Oil

7. REPORT REQUIREMENTS:

a. Vendor shall provide two complete written reports for the High Pressure Boilers at the Boiler Plants. The first report shall be the burner tuning report for each boiler and the second shall be a safety device testing report fully describing all safety device tests performed, all findings, and recommendations.

i. The burner tuning report shall be a separate file for each boiler (see appendix for the Boiler Combustion Test Data & Instrument Calibration Sheet to complete and submit) and shall contain all tuning data for natural gas and fuel oil combustion. The following data shall be the minimum information listed on each tuning report: Boiler manufacturer, serial, model, burner manufacturer, model, serial, input, fuel, steam flow, fuel%, air%, sleeve%, Variable Frequency Drive ( VFD)%, stack O2, analyzer O2, CO (ppm), CO2, NOx (ppm), stack temp, room temp, outside temp, combustion efficiency, windbox inches water column (in. WC), steam pressure, flame signal pilot, flame signal main, manifold gas pressure, and supply gas pressure. For fuel oil, also include fuel oil valve%, breeching draft in. WC, oil nozzle pressure, bypass oil pressure, and supply oil pressure.

ii. The safety device testing report shall have two sections. The first section will be in a table form that with four columns:

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

The second column labeled “Device” shall list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual 8th, (or Current Edition).

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

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

Example:

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.

b. See section 6 – LP Boiler Preventive Maintenance for low pressure boiler reporting requirements.

c. Vendor shall furnish reports within 7 business days of each facility inspection for review and approval.

8. QUALIFICATION/ CERTIFICATIONS:

a. Technicians shall have completed at least a 1 year of trade school and have 5 years of successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the Hudson Valley plants.

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

c. National Fire Protection Association (NFPA) 85: Boiler and Combustion Systems Hazards Code.

VHA Boiler Plant Safety Device Testing Manual, 8th Edition (or current edition)

d. Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests and calibrations, all calibrated within 1 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.

e. R-stamp Welder on-staff or the ability to procure third party services of an R-stamp welder.

VI. Appendix

Appendix