SOW Pressure Relief Valve.docx

Boiler Maintenance and safety device testing For Eastern Colorado Health Care System (ECHCS) at Rocky Mountain Regional VA Medical Center (RMRVAMC) Statement of Work

1.0 Objective: To bring RMRVAMC into compliance per VHA Directive 1810 January 4, 2023 and the VHA Boiler and Associated Plant Safety Device Testing Manual 8th Edition January 2023.

1.1 Combustion Analysis/Tuning – Semi-Annually

1.2 Pressure Relief Valve Replacement and Certification

1.3 6-year Inspection and Magnetic Particle Testing

1.4 Service Hours for H Stamp Welding, Testing, and Certification

2.0 Equipment

2.1 Boilers

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

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

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

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

2.2 Deaerator Tanks

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

2.3 Condensate/Surge Tank

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

3.0 Combustion Analysis/Tuning (Semi-Annual)

3.1 The inspections, testing, and adjustments shall comply with:

3.1.1 The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual.

3.1.2 The written recommendations of the equipment manufacturers.

3.1.3 The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazard Code including applicable appendices.

3.1.4 Burner performance requirements in this document.

3.2 A summary of the work is as follows:

3.2.1 Review boiler plant log sheets and alarm and trouble reports.

3.2.2 Review records that show combustion performance (flue gas oxygen).

3.2.3 Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VA requirements stated in this contract.

3.2.4 Test the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Record the settings and compare with required settings. Adjust as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation.

3.2.5 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.

3.2.6 Compare the combustion performance data with VA requirements (see below) 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. If further work, such as repairs or burner modifications, is needed to correct any problems, provide recommendations to the COR.

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

3.2.8 Immediately inform COR and POC of any recommended repairs, modifications, or safety related problems.

3.3 List of interlocks and safety devices to be inspected and tested on each boiler/burner:

3.3.1 High and low fuel pressure switches (gas/oil).

3.3.2 Low fuel oil atomizing media (steam/compressed air) pressure switches.

3.3.3 Low differential pressure switch, atomizing media/fuel oil (if provided by burner manufacturer).

3.3.4 Oil burner position switch (if provided by burner manufacturer).

3.3.5 Fuel safety shut off valves proof of closure (over-travel/valve seal switch).

3.3.6 Leak test fuel safety shut off valves (main and pilot burners) (leakage into burner).

3.3.7 Leak test gas fuel vent valves.

3.3.8 Forced draft motor interlock.

3.3.9 Forced draft damper wide-open interlock for purge.

3.3.10 Outlet damper open interlock for purge (if outlet damper provided).

3.3.11 Purge airflow interlock.

3.3.12 Purge timing.

3.3.13 Ignition timing.

3.3.14 Low fire position interlock if present.

3.3.15 Combustion airflow interlock.

3.3.16 Main flame out – time to close fuel valves.

3.3.17 Ignition flame out – burner shutdown.

3.3.18 Scanner not sensing ignition spark (ultraviolet scanner).

3.3.19 Scanner not sensing hot refractory (infrared scanner).

3.4 Required burner performance (natural gas and fuel oil):

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

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

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

3.4.4 Maximum NOx (Nitrous Oxide): Refer to original burner specification.

3.4.5 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).

3.4.6 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).

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

3.4.8 Flames shall be stable with no pulsations, shall be retained near burner, no blow-off or flashbacks, no constant flame impingement on refractory or water-walls.

4.0 Pressure Relief Valve Replacement & Certification

4.1 Pressure Relief Valve Replacement

4.1.1 Labor, equipment, and supporting material costs to remove current valves, replace and install the new valves listed below:

4.1.1.1 8 EA 1 ½” Kunkle 6030HGE01-AM

4.1.1.2 4 EA 2” Kunkle 6252AKH01-AS

4.1.1.3 3 EA Kunkle 6252KNM01-LS

4.1.1.4 2 EA Kunkle 6252ALJ01-LS

4.1.1.5 10 EA Ashcroft 04V012VASS50 Block & Bleed Valves

4.1.2 Labor, equipment, and material costs to bench test and certify the following removed valves and return to the Government:

4.1.2.1 8 EA 1 ½” Kunkle 6030HGE01-AM

4.1.2.2 4 EA 2” Kunkle 6252AKH01-AS

4.1.2.3 3 EA Kunkle 6252KNM01-LS

4.1.2.4 2 EA Kunkle 6252ALJ01-LS

4.1.2.5 10 EA Ashcroft 04V012VASS50 Block & Bleed Valves

4.2 Repair and Replacements due to Bench Test Failures

4.2.1 Vendor to supply quote for replace/rebuild of any valve(s) that failed the bench test requirement in section 4.1.2

5.0 Inspection and Magnetic Particle Testing

5.1 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.

5.2 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.

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

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

5.5 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.

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

5.7 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.

5.8 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, 7th Edition.

5.9 Repairs and Re-Inspections

5.9.1 Repairs

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

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

5.9.1.3 Contractor to provide repairs not to exceed $25,000 per year of contract and all testing/certification documents within 10 business days.

5.9.2 Emergencies

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

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

5.9.2.3 Contractor to provide emergent repairs not to exceed $15,000 per year of contract and all testing/certification documents within 10 business days.

5.10 Summary of the minimum inspection requirements for boilers:

5.10.1 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.

5.10.2 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.

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

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

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

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

5.10.7 Examine all stays and stayed plates.

5.10.8 Inspect gas side baffles.

5.10.9 Inspect internal drum surfaces and steam separating internals.

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

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

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

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

5.10.14 Inspect seating surfaces of man ways and hand holes.

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

5.10.16 Check for missing items such as bolts and nuts.

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

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

5.10.19 Verify proper alignment of burner assembly.

5.10.20 Inspect furnace for evidence of flame impingement.

5.10.21 Test operation of water level gage glass.

5.10.22 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.

5.10.23 Verify that steam pressure gage is properly calibrated.

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

5.10.25 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”).

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

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

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

5.10.29 Perform service and Calibration of boiler instrumentation and controls.

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

5.11 Summary of the minimum inspection requirements for Feed water Deaerators:

5.11.1 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.

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

5.11.3 Test hazardous gas monitoring system.

5.11.4 Inspect for evidence of leakage.

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

5.11.6 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.

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

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

5.11.9 Internal Inspections:

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

5.11.9.2 Inspect spray nozzles and trays.

6.0 Work Standards

6.1 The Contractor shall travel to the RMRVAMC and work in conjunction with the COR, Boiler Plant Supervisor, and other appropriate personnel to complete all deliverables outlined in sections 3.0 – 7.0.

6.2 Contractor must follow the VHA Boiler Plant Safety Device Testing Manual 7th Edition procedures.

6.3 Work site shall be free of debris and returned to original condition upon completion of preventative maintenance. Contractor personnel shall present a neat appearance and wear VA issued identification at all times.

6.4 The Contractor shall assign the appropriate quantity and type of personnel to successfully complete all functions specified in this SOW. The Contractor shall maintain throughout the life of this contract, a current list of technicians and their credentials available for inspection by the Government at any time.

7.0 Requirements and Qualifications of Testing Personnel

7.1 Inspection and Testing Requirements

7.1.1 At least two weeks’ notice to the Contracting Officer’s Representative (COR) is required prior to an inspection. 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 representative is available on site to monitor the work.

7.1.2 The contractor is required to prepare the boilers for inspection by opening, cleaning watersides and firesides, and preparing the boiler for inspection following National Board, ASME, Veterans Administration and industry requirements/guidelines. The contractor will also be required to restore the boiler for service.

7.1.3 Each burner and the burner control, monitoring and safety interlock systems shall be inspected and tested and adjusted as necessary.

7.1.4 VA will have the boilers that are to be serviced prepared for the test personnel 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.

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

7.1.6 The COR or his/her representative will observe the work.

7.2 Qualifications of Testing Personnel

8.0 Reports and Records

8.1 Combustion Analysis/Tuning Report Requirements

8.1.1 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:

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

8.1.1.2 The second column labeled “Device” list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual 7th Edition.

8.1.1.3 The third labeled “Deficiencies-Recommendations.”

8.1.1.4 The fourth column labeled “corrective actions” list any corrective actions taken during the inspection.

8.2 Furnish report within 10 business days of facility inspection in “Microsoft Word” format by email to the COR. Provide hard copies of data sheets and flue gas analyzer “strip” printouts to the COR.

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

8.4 Inspection and Magnetic Testing Report will be furnished within 10 business days of each inspection/testing visit. All visits must be completed within the base year.

9.0 Resources

9.1 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.

10.0 Hours of Work and Scheduling

10.1 Scheduling

10.1.1 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.

10.1.2 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 COR/POC.

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

10.2 Federal Holidays

10.2.1 New Year’s Day

10.2.2 Martin Luther King’s Birthday

10.2.3 President’s Day

10.2.4 Memorial Day

10.2.5 Juneteenth

10.2.6 Independence

10.2.7 Labor Day

10.2.8 Columbus Day

10.2.9 Veteran’s Day

10.2.10 Thanksgiving Day

10.2.11 Christmas Day

10.3 Contractor Check-In

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

11.0 Compliance

11.1 The Contractor shall be fully responsible for compliance with all VA, local, state, and Federal environmental/occupational safety laws, rules and regulations. The Contractor shall follow life and safety codes and take necessary actions to avoid conditions that may be hazardous to the health and safety of hospital personnel and patients. The Contractor is responsible for meeting all applicable OSHA and VA guidelines for safe working processes; example: lockout/tagout. All work for the duration of the contract shall be performed by trained technicians. All safety measures shall be approved as adequate by the safety officer in advance.

11.2 Hazardous material disposal (refrigerant, oil, etc.) shall be the responsibility of the contractor. Quantities of hazardous material disposed of by the contractor shall be included in the service report.

12.0 Reference Materials

12.1 VHA Boiler and Associated Plant Safety Device Testing Manual 8th Edition.

12.2 VA Directive 1810 January 4, 2023

12.3 ASME Boiler and Pressure Vessel Code

12.4 ASME B31.1, Power Piping Code

12.5 ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers

12.6 ANSI/NB-23, National Board Inspection Code

12.7 NFPA 85, Boiler and Combustion Systems Hazards Code

12.8 Utilize National Board Forms NB-6 and NB-7

12.9 NATIONAL BOARD INSPECTION CODE, Part RB, In-service Inspection of Pressure-Retaining Items

12.10 RMR Lockout Tagout SOP

13.0 Period of Performance

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

14.0 Place of Performance

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

15.0 Records Management Language

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.

Additional Requirements:

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.

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.