File 06 Design Analysis REPLACE BOILER FINAL SUBMITTAL.pdf

Veterans Affairs Loma

San Bernardino

605-09-303 REP

DESIGN A

100% Final D

June 01June 01

Contract No. W91

Task Ord

US Arm Eng

Los Ang

Linda Healthcare System

County, California

PLACE BOILER

ANALYSIS

esign Submittal

1 20101, 2010

12PL-09-D-0033

er: 0006 my Corps of gineers® geles District

605-09-303 REPLACE BOILER

Veteran Affairs Loma Linda Healthcare System

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

605-09-303 REPLACE BOILER

Loma Linda, San Bernardino County, California

100% FINAL DESIGN SUBMITTAL

TABLE OF CONTENTS

1.0 Executive Summary

1.1 Project Background

1.2 Project Authorization

2.0 Design Criteria

3.0 Architecture

3.1 General Description

4.0 Mechanical / Plumbing

4.1 Boiler

4.2 Boiler Controls

4.3 Steam Traps

5.0 Electrical

5.1 General Description

APPENDICES

Appendix A Statement of Work (SOW) (Note: SOW does not reflect current schedule requirements)

Appendix B Catalog Cut Sheets / Equipment Data

Appendix C RFI Log and RFIs

Appendix D Calculations

Appendix E Phasing Plan

Appendix F Engineering Considerations and Instructions to Field Personnel

Appendix G Water Quality Reports

Appendix H 95% Submittal DrChecks Report

PROJECT SPECIFICATIONS – Under Separate Cover

CONSTRUCTION COST ESTIMATE – Under Separate Cover (To Follow)

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

DESIGN NARRATIVE

1.0 EXECUTIVE SUMMARY

1.1 PROJECT BACKGROUND

The Jerry L. Pettis Memorial Veterans Medical Center (Loma Linda VA) is located in Loma Linda California.

The hospital was constructed in the mid 1970s and includes approximately 1.4 million square feet of hospital, clinic, convalescent and administrative spaces. Heat for the building is provided by three, dual fuel fired, 500 hp water tube steam boilers which provide high pressure steam at 125 psig. The high pressure steam is reduced to medium pressure (35 psig) and low pressure (15 psig) and distributed to users throughout the hospital.

These boilers are approaching the end of their useful life, and cannot meet the new Tier IV Air Quality Management District (AQMD) discharge requirements (9ppm NOx and 100ppm CO). Therefore the boilers must be replaced. The scope of the replacement includes:

Replacing the three existing water tube boilers with new dual fuel, low NOx fire tube steam boilers designed and sized to deliver 125 psi steam at a rate which meets current and future hospital demands. The Scope of Works also indicates that the boiler shall be of the highest efficiency available.

Replace the existing Deaerator, Condensate Tank and Blowdown Tanks.

Replace the Feedwater and Condensate Pumps.

Replace the existing Motor Control Center (MCC), and Boiler Controls with an integrated direct digital control (DDC) system.

Add leak detection to all steam traps throughout the hospital, and integrate the leak detection system into the boiler DDC system.

Paint and label the piping in the Boiler Room and Chiller Room.

Patch and paint the walls in the Boiler Room and Chiller Room.

Provide a phasing plan to replacement boiler system equipment.

Also include in the Scope of Work is a requirement to install a back pressure turbine at the pressure reducing station. The Loma Linda Facilities staff indicated that they did not believe the turbine would be cost effective and the requirement was removed from the Scope of Work (see RFI-002 in Appendix C).

1.2 PROJECT AUTHORIZATION

The boiler replacement project is one of three project awarded under IDIQ contract W912PA-09-D-0033, Task Order 006. The other two projects are the design of an emergency generator and critical electrical system, and the design of an Operation Enduring Freedom/Operation Iraq Freedom (OEF/OIF) veteran’s center. The design each project is being conducted under independent submittal schedules. The construction cost limit for the boiler replacement project is $6,000,000.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

Project Number: 605-09-303 Contract Number: W912PL-09-D-0033 Task Order Number: 0006 Task Order Issue Date: September 28, 2009 Task Order Amount: $379,647.00 Construction Cost Limit: $6,000,000

The funding source for the project was changed to American Recovery and Reinvestment Act 2009 funding in mid February, 2010. As a result the design schedule was revised to eliminate the 65% design submittal review and accelerated to meet a June 1, 2010 delivery as noted below (items completed or in progress are shown in bold-italics).

605-09-303 Replace Boiler; VA, Loma Linda Task Start Date Finish Date NTP (Project Kickoff Meeting) 11/16/09 11/17/09 Task 1 - On-site Investigation & User Interviews 11/16/09 11/17/09 Task 2 - 35% Design Submittal 11/18/09 1/15/10

Government Review 1/15/10 2/14/10 Review Conference 2/14/10 2/14/10 Task 3 - 65% Design Submittal 2/14/10 4/15/10 Government and Reviews 4/15/10 5/18/10 Review Conference 5/15/10 5/15/10 Task 4 - 95% Design Submittal 2/19/10 4/23/10 Government and Review 4/23/10 5/7/10 Review Conference 5/7/10 5/8/10 Task 5 - 100% Design Submittal 5/8/10 6/1/10

Note: Durations are per the statement of work. When delivery dates fall on a weekend or holiday, tasks will be submitted the following business day. HDR QC to be performed 7days before the submittal date.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

2.0 DESIGN CRITERIA

Mechanical Design Criteria:

VA Office of Construction and Facilities Management (CFM) - HVAC Design Manual, Feb.

2008 including Addendums A, B & C

VA CFM - Steam Generation Systems Design Manual (Including Energy Centers), May 2006 American Society of Mechanical Engineers (ASME) B31.1 Code for Pressure Piping and Power

Piping, 2007 International Fuel Gas Code, 2000 International Mechanical Code, 2006 South Coast Air Quality Management District Rule Book NFPA 31, Standard for the Installation of Oil Burning Equipment, 2006 NFPA 85-07 Boiler and Combustion System Hazard Code, 2007

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

3.0 ARCHITECTURE

3.1 GENERAL DESCRIPTION

The architectural scope of work includes painting the Boiler and Chiller rooms. After all mechanical and electrical work is completed, the floors of the Boiler and Chiller Rooms will receive a new non-skid epoxy floor coating. In addition the walls, doors, and window/filter frames will be painted. Doors and window frames will be painted to match the existing colors. Electrical panels and instrumentation along the walls will be masked. Conduit mounted to the walls will be painted.

Fabric liner inside existing boiler stack contains asbestos. The grout inside the existing boiler is determined to be non-detect. Window frames and door frames are known to contain lead based paint.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

4.0 MECHANICAL / PLUMBING

4.1 BOILER

Per the statement of work, the new boilers are to be dual fuel, low NOx fire tube steam boilers designed and sized to deliver 125 psi steam at a rate which meets current and future hospital demands. The Scope of Works also indicates that the boiler shall be of the highest efficiency available.

Boiler Replacement Calculation – 001, Boiler Sizing is included in Appendix D and documents the methodology for determining the boiler size. Per the conclusion of the calculation the boilers are to be fire tube boilers sized for 66% of the peak steam demand (estimated to be 16,200 lbs/hr). Assuming 15% margin for future demand and 10% for calibration errors, a 66% capacity boiler is show to be 400 hp. The calculation also shows that if the boilers are sized for 66% of peak steam demand, assuming a typical 5 to 1 turndown, the boilers will supply the minimum steam demand (estimated to be 3,200 lbs/hr) without cycling.

With this approach, one boiler will be able to supply the full steam demand approximately 75% of the time based on the boiler performance logs. The second boiler will be idle and will be brought on line when the lead boiler reached 90% of capacity. The third boiler will act as the spare should one boiler fail. Fire tube boilers are not susceptible to thermal shock like water tube boiler, and can be brought on line quickly. There is also significant thermal capacitance in the system. Therefore with this scheme, it is not necessary to maintain one boiler in hot standby.

To maximize boiler efficiency as required by the Statement of Work, the boilers will be equipped with:

High efficiency, low NOx burners designed to meet the new AQMD air permit requirements.

An O2 sensor and a combustion air blower with a VFD drive which will be provided to maintain excess O2 in the stack to approximately 3%.

A single stage economizer which will be provided in the boiler stack. Feed water will be circulated through the economizer coil and preheated by the flue gas.

A surface blowdown heat exchanger to preheat the soft water makeup to the condensate tank.

New feedwater and condensate transfer pumps with VFD drives and automatic recirculation valves will be provided. Feedwater pump speed will be controlled off boiler water level and trimmed off of steam pressure. This control strategy along with the requirement to have two boilers running at peak load requires that three pumps be provided, each coupled with one boiler.

The pump feed water piping will be configured to allow any one of the three pumps to serve one of two boilers thereby providing redundancy should a pump fail.

With these performance enhancing features, the boiler efficiency is estimated to be over 85%. The proposed boilers will fit on the current 500 hp fire tube boiler housekeeping pads. The drawings show the interface connection points for natural gas, fuel oil, feedwater, blowdown, sampling and high pressure steam. The existing catwalks and boiler piping support system will be modified to provide support for the catwalks necessary to maintain the boilers and economizer, the boiler flue, piping and conduit.

The new spray type feedwater deaerator, designed to limit feedwater oxygen concentrations to less than 0.005cc/liter, will be installed in the same location as the existing deaerator. The deaerator will be sized for a minimum of twenty minutes of storage assuming two boilers firing at a combined steam rate of 120% the design steam rate; or 19,500 lbs per hour (equal to two boilers operating at approximately 73% of full) load.

The deaerator specified is actually larger than required and is designed to match the condensate tank. This feature will allow for redundancy should the condensate tank or the deaerator be down for maintenance.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

The existing deaerator is located in the mezzanine and supported on concrete saddles. These saddles will saw cut to accept the integral saddles of the new deaerator thereby minimizing mezzanine structural changes.

Tank connections will be arranged to minimize piping changes during installation. The new condensate tank will be located in the same location as the existing tank. The tank will be sized for 20 minutes of storage using the same criteria as for the deaerator tank. Tank connections will be arranged to minimize piping changes during installation. . The tank will be designed to use the existing condensate housekeeping pads, there by minimizing structural changes.

The boiler blowdown tank will be located in the same location as the existing blow down tank.

The feed water pumps will be located on the boiler room floor below the deaerator. This arrangement will eliminate any net positive suction head issues and improve pump efficiency. The pumps will be sized to match the feedwater demands of the boilers. The pumps will be vertical, multistage centrifugal pumps equipped with Variable Frequency Drives (VFDs) and automatic recirculation valves to assure stable operations. VFDs will improve boiler plant efficiency by minimizing parasitic electrical loads. The discharge piping off the pumps will be arranged such that each boiler can be served by two of the three pumps, this added redundancy will improve overall boiler plant reliability.

Two 100% capacity, low net positive suction head (NPSH) centrifugal pumps, with VFDs will be installed in the basement in the same location as the existing pumps. The existing natural gas piping and fuel oil piping systems will be utilized with minor modifications. The existing fuel oil storage capacity is sufficient for the new boiler installation.

4.2 BOILER CONTROLS

The boiler control system will be Programmable Logic Controller (PLC) based with an Operator Workstation located in the control room. Each boiler unit, the condensate tank, and the deaerator will have a control panel that communicates via Ethernet. An Ethernet link from each unit will connect back to a central Ethernet switch located in the control room. The boiler control panels will perform all system coordination functions over the network, working together with the Operator workstation to assign duty and standby units. Critical failure and shutdown notifications, alarms and interlocks will be hardwired between the units to provide additional system integrity.

Each boiler unit control panel will be responsible for all of the boiler unit functions including the gas train, flame control, air control, economizer, tank and steam line monitoring, and emissions (O2, NOx, CO). It shall also be responsible for the start and speed request signals sent to the feed water pump.

A feed water pump shall be dedicated to each boiler unit. The feed water pump will be driven by a Variable Frequency Drive (VFD). The speed control signal (4-20mA) received from the boiler control panel will be based on the boiler tank water level with a steam header pressure feedback loop. The condensate tank will have a PLC based control panel and will work with the transfer pumps and the deaerator to provide a collection point for the condensate return and make-up water. The controls will provide a constant operating level within the tank. If a feed water pump fails, the standby boiler will start, along with the dedicated feed pump. It is possible to reassign a redundant feed water pump to a boiler. To do so the operator must adjust the valve settings, and reassign the feedwater pump through the BACnet software.

The deaerator will have a PLC based control panel that will control the water and steam inlets to provide low oxygen and carbon dioxide free feed water. The feed water pumps will pump this water from the deaerator to the boiler.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

The economizer will be monitored by the boiler control panel to provide temperature profiles across the exhaust flue and feedwater. This data can be used to create reports on energy recovery and efficiency of the economizer.

The existing Boiler Room CO and Gas Detection Monitors will be integrated into Boiler Control System.

The control room Operator Workstation will be a stand alone operator interface for the boiler and ancillary systems control. System set points and supervisory control will be available for use by the operations staff.

System data will be logged and archived for historical trending and reporting.

A Network Automation Engine (NAE) will be provided and installed to allow operations and maintenance staff to monitor and supervise the boiler system. The NAE will communicate using BACNet over Ethernet to each of the system control panels. Each manufacturer of the control panels is responsible for providing a BACNet communication channel to interface with the NAE.

4.3 STEAM TRAPS

In addition to the boiler system upgrades described above, a wireless steam trap leak detection system shall be provided for all steam traps listed in the steam trap monitoring schedule and the steam trap replacement schedule. Steam traps located in the interstitial space, that have not been replaced recently, shall also be replaced. The traps to be replaced are noted on the equipment schedules.

The steam trap detection system will consist of acoustic sensors with wireless communication. A controller will receive the status of the sensors and the trap and transmit this data to the operator workstation. A gateway will be used to translate the modbus protocol into a format suitable to the NAE. The NAE system will display an alarm notification of a steam trap fault.

It is estimated that 50 signal repeaters will be required to transmit the wireless signal from the steam traps.

The contractor is required to provide an RF study to optimize the actual number of repeaters required.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

5.0 ELECTRICAL

5.1 GENERAL DESCRIPTION

The boiler room electrical system consists of a Motor Control Center “MCC”, boiler control panels, and equipment. The existing, outdated Type-W, Westinghouse MCC is rated at 600A, 480/277V, 3 ǿ, 4 wires.

The main feed for the existing MCC is from main switch board MDBCP located in the electrical room.

The goal of this project is to:

Replace the existing MCC with new 600A, 480/277V, 3ǿ, 4 wires, MCC.

Remove the flame failure panel and boilers along with the associated wiring.

Remove main boiler control panel along with associated wiring.

Remove unused exposed conduits and plug unused under floor conduits Replace the feeder conductors from the main distribution board MDBCP to MCC.

Provide power for temporary boiler skid.

Provide power for new boilers, feed water pumps and condensate transfer pumps.

Replace conductors for the existing equipments that will not be replaced with this contract.

Replace existing fluorescent fixtures along with associated wiring.

The conduit for existing equipment (not being modified) shall remain and will not be replaced, but the conductors will be removed and replaced. The equipment that is replaced will have its conduit and conductors removed and replaced. During the boiler phase out process, new power for temporary boiler will be provided from MCC “MCBB” located in the chiller room. Additional conduits (if necessary) from the temporary boiler to the control room will be provided for controls.

The New boilers will come with a control panel. Conduit and conductors will be installed between boiler control panel, boiler equipment and MCC. Also conduit and conductors will be installed between feed water pumps and MCC and between condensate transfer pumps and MCC. Conduit and Ethernet cable will be installed from network switch in the control room to the boiler control panels, deaerator control panel, and condensate tank control panel.

Loma Linda, San Bernardino County, California Contract No.: W912PL-09-D-0033; Task Order: 0006

APPENDICES

Appendix A Statement of Work (SOW) Note: Statement of Work does not reflect current schedule requirements

Appendix B Catalog Cut Sheets / Equipment Data

Appendix C RFI Log and RFIs

Appendix D Calculations

Appendix E Phasing Plan

Appendix F Engineering Considerations and Instructions to Field Personnel

Appendix G Water Quality Reports

Appendix H 95% Submittal DrChecks Report

APPENDIX A

STATEMENT OF WORK (SOW)

APPENDIX B

CATALOG CUT SHEETS / EQUIPMENT DATA

This page intentionally left blank.

APPENDIX C

RFI LOG AND RFI’S

CONTRACT NO. W912PL-09-D-0033 DO 0006 / 605-09-303

PROJECT: Replace Boilers; Loma Linda VA Hospital, California

REQUEST FOR INFORMATION LOG

RFI # SUBJECT RFI DATE

RESP

REQ'D

DATE

RESP

DATE

CLOSED

Y/N

REMARKS/NOTES

001 Steam Trap Leak Detection 30-Nov-09 10-Dec-09 21-Apr-10 Yes @ the 35% design review meeting HDR agreed to monitor all traps.

002 SOW Requirement for a Back Pressure Turbine 1-Dec-09 9-Dec-09 14-Dec-09 Yes Removed from scope

003 Boiler Emissions Requirements 1-Dec-09 9-Dec-09 14-Dec-09 Yes Req'ts are as stated in the RFI

004 Water Chemical Analysis for City Water and Softened Wate 1-Dec-09 9-Dec-09 15-Nov-09 Yes Water analysis were supplied to HDR

005 Margin for Future Growth to use in Boiler Sizing 1-Dec-09 9-Dec-09 14-Dec-09 Yes To be as stated in the RFI

006 MCC- "MCC" Replacement 13-Dec-09 22-Dec-09 17-Dec-09 Yes MCC to be replaced as part of boiler roomproject

007 Paint & Epoxy type/color 1-Mar-10 5-Mar-10 5-Mar-10 Yes HDR to provide recommendation

008 Use of Wireless Steam Trap System within Hospital 12-Mar-10 19-Mar-10 15-Mar-10 Yes Use Approved

009 0 0-Jan-00 0-Jan-00 0-Jan-00

010 0 0-Jan-00 0-Jan-00 0-Jan-00

011 0 0-Jan-00 0-Jan-00 0-Jan-00

012 0 0-Jan-00 0-Jan-00 0-Jan-00

013 0 0-Jan-00 0-Jan-00 0-Jan-00

014 0 0-Jan-00 0-Jan-00 0-Jan-00

015 0 0-Jan-00 0-Jan-00 0-Jan-00

016 0 0-Jan-00 0-Jan-00 0-Jan-00

017 0 0-Jan-00 0-Jan-00 0-Jan-00

018 0 0-Jan-00 0-Jan-00 0-Jan-00

019 0 0-Jan-00 0-Jan-00 0-Jan-00

020 0 0-Jan-00 0-Jan-00 0-Jan-00

021 0 0-Jan-00 0-Jan-00 0-Jan-00

022 0 0-Jan-00 0-Jan-00 0-Jan-00

023 0 0-Jan-00 0-Jan-00 0-Jan-00

024 0 0-Jan-00 0-Jan-00 0-Jan-00

025 0 0-Jan-00 0-Jan-00 0-Jan-00

026 0 0-Jan-00 0-Jan-00 0-Jan-00

027 0 0-Jan-00 0-Jan-00 0-Jan-00

028 0 0-Jan-00 0-Jan-00 0-Jan-00

029 0 0-Jan-00 0-Jan-00 0-Jan-00

030 0 0-Jan-00 0-Jan-00 0-Jan-00

PM / PROJECT COORDINATOR ONLY

5/27/2010 RFI LOG RFIs & RFI LOG-BOILERS VA LL

APPENDIX D

CALCULATIONS

605‐09‐303 REPLACE BOILER

Contract No.: W912PL‐09‐D‐0033; Task Order: 0006

Appendix D ‐ Page 1

CALCULATIONS

Feed water tank (FWT‐1) calculations:

1 Boiler HP = 34.5 lbs/hr steam

1 gallon water = 8.37 lbs

BHP X 34.5 / 8.337 lbs / 60 min. X 10 min. = min. usable capacity in gallons

VA requires feed water tank to be sized for 20 minutes storage from overflow.

Current bldg. load = 16,200 lbs/hr

Current bldg. load + 15% future expansion + 10% safety margin = 20,250 lbs/hr or equivalent to 600 HP

600 X 34.5 /8.337 /60 X 20 min. of storage = 828 gallons.

Cannot operate tank totally flooded so allow some extra room by adding 1.5 safety factor as general rule of thumb.

828 gallons X 1.5 = 1,242 gallons

Select a 1,400 gallon feed water tank

Feed water pump (FWP) calculations:

BHP X 34.5 / 8.337 / 60 X 1.5 safety factor = GPM

For a 400 HP boiler: 400 X 34.5 / 8.337 / 60 X 1.5 safety factor = 41.4 GPM

Select a 40 GPM feed water pump

Existing hospital pump is sized for 175 psi FT HD.

Power Plan Data Log recorded avg. 208 psi feed water pressure

Select a 40 GPM feed water pump with 208 psi FT. HD

Appendix D ‐ Page 2

Condensate Receiver Tank (CRT‐1) calculations:

For normal operation, select a receiver of sufficient size to hold volume equivalent to condensate evaporated by boiler in a 1/3 to 1/2 hour period at normal firing rate of boiler.

Current bldg. load = 16,200 lbs/hr

Current bldg. load + 15% future expansion + 10% safety margin = 20,250 lbs/hr or equivalent to 600 HP

(20,250 lbs/hr)/8.33 = 2,400 gallon/hr.

1/3 hour: 2,400/3 = 800 gallons

1/2 hour: 2,400/2 = 1,200 gallons

Assume 75% of tank is usable, a receiver should have a gross volume of 1,000 to 1,500 gallons, which on average would result in a 1,250 gallon receiver.

Select a 1,400 gallon condensate receiver tank (CRT‐1).

New feed water tank (FWT‐1) is also 1,400 gallon. This will allow the hospital to isolate one tank from the other and still be able to maintain the building in operation

Condensate Transfer Pump Calculations:

Current bldg. load = 16,200 lbs/hr

Current bldg. load + 15% future expansion + 10% safety margin = 20,250 lbs/hr

Evaporation rate X 3 = Pump GPM Required

(Lbs of Steam / Hr) / 500 = Evaporation rate (GPM)

(20,250 lbs/hr)/500 = 40.5 GPM

Sizing factor for 1/3 hour = 3

Condensate pump rate = 40.5 x 3 = 121 GPM

Existing hospital pump is 108 GPM with 50 psi FT. HD.

Power Plant Log recorded 42 psi condensate transfer pump pressure.

Select condensate transfer pump at 120 GPM with 50 psi FT. HD.

APPENDIX E

PHASING PLAN

APPENDIX E

Appendix E – Page 1

1. Introduction:

The following is a suggested phasing plan for the replacement of the boilers, deaerator, condensate tank, pumps and related equipment as defined in the Scope of Work. The contactor may submit an alternative phasing plan for approval as part of his bid.

The existing boilers are the sole source of heating for the Loma Linda Medical Center. The existing system consists of three 500 hp water tube boilers which deliver steam at 125 psig, and common deaerator and condensate tanks, pumps and accessories. The scope of this project involves replacing the major components. As the boiler plant is the only source of heat, it is imperative that the hospital steam demand be maintained, with a minimum number of planned outages, throughout the construction process.

2. Phasing

The temporary boiler plant shall be installed, tested, commissioned and approved by the USACE Project

Manager prior to beginning the boiler replacement project. The temporary boiler plant shall continue to be functional until the renovated boiler plant has been commissioned and accepted by the USACE

Project Manager.

3. Hospital Steam Demand and Reliability

Table 1 summarizes the high and low steam demand for the medical center for each month over the last

4 years. The recommended phasing plan requires that the contractor supply temporary boilers to meet the maximum historic steam demand, plus 10%, over the duration of the construction period. In addition, the contractor shall provide redundant capacity such that with one temporary boiler down, the operating boiler can meet a minimum of 66% of the maximum historical steam demand over the duration of the construction process.

A minimum of two 100% capacity feed water pumps and condensate pumps shall be provided.

4. Codes and Standards

The temporary boiler plant shall meet the following codes and standards:

NFPA 70 ‐ 2008 National Electric Code, 2008 NFPA 54 ‐ 2006 International Mechanical Code, 2006 NFPA 85 – 2007 Boiler and Combustion Systems Hazard Code NFPA 106 – 2006 Life Safety code International Fuel Gas Code 2003 ASME B31.1, Power Piping, 2007 ACME Boiler Pressure Vessel Code, Section I – 2007

Power Boilers

Appendix E – Page 2

5. Site Limitations

Drawing G‐002 shows the location of the boiler room relative to other hospital facilities. Throughout the construction duration access to the loading dock must be maintained. If access to the loading dock must be closed to unload equipment, it shall be scheduled with the USACE Project Manager a minimum of one week in advance.

The fenced in area east of the boiler room and adjacent to the soiled linen room and the area east of the chiller room are available for temporary equipment.

The contractor shall provide a temporary safety fence around the temporary boiler plant, and provide safety signage as required by Cal OSHA.

6. Submittal Requirements

The contractor shall provide scaled drawings and equipment documentation of the proposed temporary boiler plant installation. The drawings shall be stamped and signed by a registered engineer. At a minimum, the package shall include:

Copies of all operating permits

Safety Plan.

Operating Plan

Catalog data showing the capacity and operating characteristics of the boilers, tanks, and pumps.

All temporary equipment including dimensions and clearance requirements for all equipment skids.

All temporary pipe routing and all interconnections with the existing steam system.

Electrical single line drawings.

Electrical equipment location drawings

7. Operator Staffing Requirements

The contractor shall have a licensed boiler operator familiar with the type of temporary boiler installed, on site 24 hours a day, 7 days a week so long as the temporary boiler plant is operational. Failure of any one boiler or the boiler plant shall be brought to the attention of the USACE Project Manager and the

Loma Linda Medical Center Energy Manager (Larry Barrett, 909.825.1084 x2980) immediately.

If any fire rated doors are removed or rendered inoperable to accommodate temporary boiler plant related piping, cable, conduit or equipment, a 24 hour, 7 day a week fire watch shall be instituted.

Appendix E – Page 3

8. Interface With Existing Boiler Plant

The main source for electric power to the temporary boiler installation is the MCC in the chiller room

(See E‐405). Power from this MCC for the temporary boiler installation is limited to 150 A at 480 Vac. If additional power is required it shall be routed from the main MCC room.

Mechanical system interfaces are shown on drawings M401 to M403. New Mechanical equipments and all pipe connections to existing are shown on drawings M002, M401 to M403.

Temporary steam service to the building to be provided by connecting a temporary steam line (size as required by the temporary boiler) from the temporary boiler plant to the existing 6” steam stub out located at the existing 10” steam header in the boiler room.

Temporary gas service to the temporary boiler plant to be provided by disconnecting one of the existing boiler gas train assembly from the existing gas shut off valve and connecting a temporary gas line (size as required by the temporary boiler) from the existing gas shut off valve to the temporary boiler plant.

A temporary make up water line (size as required by the temporary boiler plant) can be connected from the existing soft water main downstream of the existing soft water meter to provide temporary make up water to the temporary boiler plant.

Condensate return from building back to the temporary boiler plant can be handled by providing a temporary packaged condensate transfer tank with pumps located in the basement to provide pumping of condensate return back to the temporary boiler plant.

All boiler plant outages and electrical shutdowns necessary to install or remove the temporary boiler system shall be scheduled with the USACE Project Manager and minimum of 2 weeks in advanced.

Any temporary openings in interior and exterior walls and floor necessary to support the temporary boiler installation shall be repaired to a “like new” condition. Stairwells may not be used to route temporary piping, cables or conduit.

9. Temporary Boiler Plant Installation Requirements

A. Temporary equipment may be new or previously used. Previously used equipment shall show no evidence of wear or deterioration that would effect the safe, reliable operation.

B. Equipment to be utilized in the new plant shall not be used in the temporary plant, except with permission of the RE/COTR.

C. Remove all temporary facilities from Government property after final use.

D. Equipment must be clean inside and outside.

E. Boilers and Accessories:

1. Design pressure exceeding maximum safety valve set pressure.

Appendix E – Page 4

2. Construction and accessories in compliance with ASME Boiler and Pressure Vessel Code, Section I.

3. After installation and prior to operation, provide internal inspection by authorized inspector certified by National Board of Boiler and Pressure Vessel Inspectors. Submit signed report.

Inspector must certify boilers as clean and safe for operation.

4. Steam output flow range and pressure as shown on drawings.

5. Dual low water cutoffs, dual high steam pressure cutouts, high water alarm.

6. Calibrated steam pressure gage, 150 mm (six inch) minimum diameter.

7. One set of spares for all gaskets and water column gage glasses.

F. Burners and Accessories, Fuel Trains:

1. Automatic operation over entire firing range. Turndown capability 6/1 or greater.

2. Comply with NFPA 85 regardless of burner input rating.

3. All safety devices UL listed for the service.

4. Fire fuels as shown on the drawings.

5. Filtration devices at entrance to each fuel train designed to protect all downstream devices from clogging or plugging.

6. Pressure regulating valves on main gas and igniter (pilot) gas.

7. Pressure gages at burners and outlets of pressure regulating valves.

8. One set of spare drive belts for all belt‐driven equipment.

G. Burner Control (Flame Safeguard) System:

1. Automatic operation, self‐checking circuits.

2. UL listed, FM approved.

3. Self‐checking ultraviolet flame detectors. Infrared flame detectors with self‐checking amplifiers permitted on fire tube boilers.

4. Provide one spare scanner and control chassis for each type utilized.

H. Combustion Control System: Automatic control of steam pressure, with provision for manual control.

I. Feedwater System:

1. Provide system, including feedwater deaerator, to furnish minimum water temperature of

104 degrees C (220 degrees F), pressure and quality recommended by boiler manufacturer.

Maximum oxygen content of feedwater from deaerator twelve parts per billion (12 ppb).

Appendix E – Page 5

2. Capacity shall exceed maximum steam flow requirement of Medical Center.

3. Provide automatic feedwater deaerator water level control and high and low level alarms.

4. Provide one full size redundant feed pump.

5. Automatic boiler water level control with three‐valve bypass.

6. Automatic water softener for make‐up water.

7. Prior to operation, provide internal inspection of feedwater deaerator by Authorized

Inspector certified by the National Board of Boiler and Pressure Vessel Inspectors. Submit signed report. Inspector must certify deaerator as clean and safe for operation.

J. Instrumentation:

1. Record steam flow rate and provide totalizer for each boiler.

2. Pressure gage for main steam, feedwater header, fuel oil and natural gas headers.

3. Mount recorders and pressure gages in painted, reinforced sheet metal panel.

4. Provide 100 recorder charts of each type and two replacement recorder pens for each pen arm.

K. Chemical Treatment System: Provide individual pump type systems to deliver proper chemicals to each boiler. Water quality shall be maintained as directed by contractor‐retained water treatment firm. All chemicals must be FDA approved for use where steam contacts food. Provide chemical treatment, or maintain existing chemical treatment, which protects all site condensate lines from corrosion.

L. Blowoff System: Provide system to collect boiler bottom blowoff and to discharge it to sanitary sewer at temperature not exceeding 65 degrees C (150 degrees F).

M. Fuel System: Provide systems to furnish sufficient natural gas and No. 2 fuel oil to generate steam to satisfy maximum steam flow demand of Medical Center. Comply with NFPA 31 and 54.

Provide filtration systems to protect pumps, flow meters, and pressure control valves. Fuel oil systems shall operate with no air entrainment or pump cavitation.

N. Access Platforms and Ladders: Provide for access to all valves, controls and instruments not accessible to personnel standing on floor. Design of platforms and ladders must comply with

OSHA requirements.

O. Enclosure of Temporary Equipment: Provide clean, dry, ventilated, lighted, heated shelter for all equipment and for operating personnel. Heating system shall maintain 18 degrees C (65 degrees

Appendix E – Page 6

F) under all weather conditions and when boilers are not in operation. Shelter construction must comply with all state and local codes.

P. Pipe, Stack, and Breeching Supports: Support all hot systems on roller and spring hangers.

Anchor and support all systems in compliance with recommendations and requirements of

ASME B31.1, and MSS‐SP69.

Q. Pipe, Equipment, Boiler Stack and Breeching Insulation:

Provide material and thickness as specified for permanent installation, except maximum thickness shall be 50 mm (two‐inches) and all pipe insulation may be fiberglass with all‐service jackets.

R. Power Supply: Provide full time power and emergency power to serve full load operation of all equipment in temporary boiler plant.

S. Repairs and Maintenance: Contractor shall furnish labor and material for all repairs at no cost to the Government. Malfunctions that reduce the steam supply to the facility shall be repaired within four hours of notice. Other repairs shall be accomplished within 24 hours of notice.

Routine maintenance requiring standard tools and supplies and less than one man‐hour per day will be performed by the Government. Cleaning made necessary by Government operation will be performed by the Government.

Appendix E – Page 7

Table 1

Historic Steam Demand

Year Month High Steam Demand

(Lbs/hr ) Low Steam Demand

(Lbs/hr)

2006 January 17,900 3,200

2006 February 16,100 10,100

2006 March 18,200 3,100

2006 April 16,800 9,800

2006 May 14,100 4,600

2006 June 12,500 6,900

2006 July 11,400 5,400

2006 August 12,400 7,000

2006 September 13,300 6,400

2006 October 15,100 6,500

2006 November 16,700 5,300

2006 December 18,100 6,400

2007 January 15,800 4,600

2007 February 16,300 5,500

2007 March 18,100 6,500

2007 April 15,600 7,300

2007 May 13,500 8,000

2007 June 12,400 4,300

2007 July 12,100 6,800

2007 August 12,600 5,300

2007 September 12,800 4,900

2007 October 14,500 8,100

2007 November 16,400 5,900

2007 December 17,200 6,200

2008 January 16,800 4,200

2008 February 16,500 6,300

2008 March 16,500 7,800

2008 April 13,300 5,500

2008 May 13,200 6,000

2008 June 11,400 6,700

2008 July 10,500 6,000

2008 August 11,100 6,100

2008 September 10,100 6,200

2008 October 12,800 6,700

Appendix E – Page 8

Year Month High Steam Demand

(Lbs/hr ) Low Steam Demand

(Lbs/hr)

2008 November 11,500 7,000

2008 December 15,900 7,800

2009 January 15,400 7,700

2009 February 16,200 7,300

2009 March 12,900 8,100

2009 April 12,300 7,300

2009 May 11,400 6,800

2009 June 12,400 7,500

2009 July 11,000 6,500

2009 August 11,200 6,700

2009 September 12,400 6,300

2009 October 13,900 7,000

2009 November 15,300 7,300

APPENDIX F

ENGINEERING CONSIDERATIONS AND

INSTRUCTIONS TO FIELD PERSONNEL

Appendix F – Page 1

ENGINEERING CONSIDERATIONS AND

INSTRUCTIONS FOR FIELD PERSONNEL

1. Introduction:

Engineering Considerations and Instructions for Field Personnel is provided to the USACE field personnel as a vehicle to convey additional information on site conditions and design assumptions beyond that described in the Plans and Specifications. In no way is the document to be interpreted as a complete description of the site conditions and design assumptions. USACE personnel are encouraged to contact

Michael Blomquist, the HDR Project Manager at michael.blomquist@hdrinc.com if there are any additional questions or comments.

2. Site Description

The Loma Linda VA Medical Center is a 1.4 million square foot facility providing a full range of medical services to America’s Veterans. The boiler system is the sole source of heat for the facility. The boiler room is located on the east side of the main hospital and sits between the chiller room on the south and the trash and soiled linen collection room on the west side. A maintenance storage facility and the cooling towers sit approximately 80 ft to the east of the main hospital facility. The loading dock approach is on the south side of the chiller room (see site plan on drawing G‐002).

Throughout the construction process, access to the loading dock must be maintained. If closing access is required for unloading equipment it shall be scheduled with the USACE Project Manager a minimum of one week in advance.

The proposed phasing plan for the boiler replacement project recommends the use of temporary boilers during construction. Limited space is available for locating temporary equipment. If the contractor plans to use temporary boilers or other temporary equipment, he shall provide a dimensioned site plan, showing the proposed equipment, for the approval of the USACE contracting officer representative.

The medical center site has limited parking. As a result, contractors and their subcontractors are required to park off site, except as necessary to unload equipment, or to use truck mounted equipment.

The contractor’s laydown area will be limited and will be defined after award. The contractor should limit onsite storage as much as possible. An off‐site storage location is recommended.

3. Boiler Room

The boiler room is designed to allow for the removal and replacement of the existing boilers. The 14’‐6” x 19’ (field verify) combustion air filter wall on the east end of the boiler room is removable for this purpose. Once all work in the boiler room is complete, and the filter frame has been reinstalled and painted (see Section 5), the filters shall be replaced with new filters with a minimum MERV 4 rating.

Appendix F – Page 2

The existing structural steel system supporting the existing catwalks, piping, and conduit, is to be modified by the contractor to accommodate the equipment installed. The modified system shall support the catwalks necessary for boiler and economizer maintenance, as well as supporting the economizer, boiler flue pipe, system piping and conduit. The structural steel system modifications shall be designed by the contractor per the note on the plans and the specifications to support the equipment installed. Drawings and calculations, stamped by a registered structural engineer, shall be submitted to the USACE Project Manager for approval.

The existing deaerator is located on the mezzanine in the boiler room and is support by concrete saddles. The new deaerator shall be equipped with integral saddles, and the existing concrete saddles shall be modified In accordance with the plans and specifications to support the new deaerator. The existing mezzanine structural steel is sufficient to support the new deaerator, so long as the integral deaerator supports sit on the modified existing concrete saddles.

The condensate tank and blow down tank are located in the basement below the existing feed water pumps. There is an 8’ x 6’ 6” (field verify) hatch in the boiler room floor designed to access these components. The new condensate tank, blowdown heat recovery system, and blowdown tank must be constructed such that it can be installed through this hatch. The contractor shall schedule installation to take full advantage of this hatch.

The new condensate tank shall be designed to sit on the existing condensate house keeping pads. New house keeping pads shall be provided for the blowdown heat recovery system.

4. Hazardous Materials

The existing boiler flues contain an asbestos insulation liner. In addition, the windows and door frames as well as the boiler room air intake louver contain lead based paint. As part of the scope of work, the flue pipe and boilers shall be removed and disposed of in accordance with the specifications by the contractor. In addition, the contractor shall remove all lead based paint before repainting per the specifications.

5. Painting the Chiller and Boiler Room, and Labeling Piping

Once all structural, mechanical, and electrical work has been completed, the boiler room and chiller room shall be painted as defined on the drawings and specifications. The contractor shall submit proposed colors for the wall, floors, structural steel supports, doors, window and door frames and piping to the USACE Project Manager for approval prior to painting. Epoxy floor coating shall be applied in phases. The phasing plan shall be submitted to the USACE by the contractor for review and approval one week prior to application. The phasing plan shall take into consideration necessary weekly and daily maintenance tasks. In addition to painting, the contractor shall label all piping as defined in the drawings and specifications.

Appendix F – Page 3

6. Steam Trap Replacement and Steam Trap Monitoring System

As part of the Scope of Work, a number of steam traps in the interstitial space between the floors of the hospital are to be replaced. The traps to be replaced are identified in the steam trap replacement schedule, and the approximate locations are shown on the drawing. The interstitial space is accessible from the service bays as well as the stairwells. The contractor shall submit a schedule for the steam trap replacement for approval by the USACE contracting officer representative. Portions of the interstitial space are very congested, and the contractors schedule should consider access issues. The columns in the interstitial space are labeled.

The steam trap monitoring system is designed to be wireless. All steam traps shown on the steam trap monitoring schedule and the steam trap replacement schedule are to be monitored. The wireless monitor system includes wireless trap leak detection monitors, signal repeaters and a receiver. The receiver is to be located in the boiler control room. The leak detection system is to be integrated in the

Boiler BACnet control system per the plans and specifications. It is estimated that wireless system will require approximately 50 repeaters. The contractor shall work with the wireless system provider to perform a Radio Frequency (RF) study to determine the optimum location of the repeaters to assure a robust wireless system. The proposed repeater locations shall be submitted to the USACE contracting officer representative for approval prior to finalizing the repeater locations. Per code, repeaters shall not be installed in stairwells. Repeaters proposed to be installed on the exterior of the hospital are subject to approval.

7. Project Schedule

The USACE project manager shall work with the contractor to coordinate the boiler replacement project with other ongoing construction projects. The scope proposed emergency generator and critical power system project potentially overlaps with the boiler project and the location of the temporary boiler plant should be coordinator the emergency generator project.

The lead time for procurement of the boiler is estimated to be 12 weeks. The overall project duration, including procurement is estimated to be 8 months.

APPENDIX G

WATER QUALITY REPORTS

APPENDIX H

95% SUBMITTAL DRCHECKS REPORT

Comment Report: All Comments Project: Loma Linda VA Hospital Boiller Replacement Review: 95% Design Submittal Displaying 126 comments for the criteria specified in this report.

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Id Discipline DocType Spec Sheet Detail

3247882 Architectural Plans n/a' G-002 n/a

(Document Reference: 001) Coordinating Discipline(s): Architectural

Provide asbuilts plans showing the existing system.

Submitted By: Gregory Perpich (661-265-7222). Submitted On: 06-May-10

1-0 Evaluation For Information Only The demolish drawings show the as-built condition and the items to be demolished. As-Built drawings showing the existing condition are typically not provided. MICHAEL BLOMQUIST 916- 817-4804

Submitted By: Stella Gardenour (916-817-4951) Submitted On: 26-May-10

Backcheck not conducted

Current Comment Status: Comment Open

3247887 Architectural Plans n/a' G-002 n/a

(Document Reference: 002) Coordinating Discipline(s): Fire Protection/Life Safety

The existing fire systems-sensors, sprinklers, etc, will most likely require re-work and retesting; has this been covered with the Facility Manager and the Fire Department? Was the Boiler Room checked with the local authorities on the fire warning and suppression system requirements? Design the boiler plant systems to comply with this design manual, and the current editions of VA Program Guides, VA Handbooks, and VA Master Specifications. The design shall also meet the provisions of the current edition of the ASME B31.1 Code for Pressure Piping, Power Piping; ASME B31.9, Code for Pressure Piping, Building Services Piping (Plants which do not generate steam over 100 kPa, 15 psig); National Fire Protection Association NFPA 85, Boiler and Combustion Systems Hazard Code; and National Fire Protection Association NFPA 31, Standard for the Installation of Oil Burning Equipment. If state or local codes are more stringent than the above requirements, discuss with the VA Contracting Officer. Northampton General Hospital Fire protection of service areas were a major concern to the management staff of the hospital. Rarely visited areas can become an issue where plant and boiler rooms produce the power and resources to maintain the hospital. A potential fire could be unnoticed for some time before discovery, prompting management to look for a low pressure water mist fire protection system. Ultra Mist has a very quick fast response discharge head that not only covers 25 square metres but provides a water wall barrier of mist across a ceiling, effectively preventing heat from travelling upwards through the building. An environmentally friendly system clean of any chemicals. Being 8 bar low pressure the Ultra Mist discharge head uses a fraction of the water used during sprinkler installation. Forty litres of pure water as opposed to the traditional systems. In the boiler complex we have used open nozzles controlled by linear heat detection. Stainless steel pipework using Mapress fittings are a clean fast installation method which avoids the problems associated with debris in malleable fittings.

The boiler is currently not sprinklered. HDR was told by the VA at the 95% design review that sprinklers were being added under a separate contract, and the HDR did not need to take any action with regard to sprinklers in the boiler room. MICHAEL BLOMQUIST 916-817-4804

Submitted By: Stella Gardenour (916-817-4951) Submitted On: 27-May-10

Backcheck not conducted

Current Comment Status: Comment Open

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3247890 Architectural Plans n/a' S-001

GENERAL

STRUCTURAL

NOTE:

(Document Reference: 003) Coordinating Discipline(s): Structural

Note G5 ADD "Contractor's engineer will provide an approved drawing stamped, dated, and signed by the Contractor's engineer of all penetrations through structural members, floors, wall, roofs etc.

Revised 06-May-10.

1-0 Evaluation Concurred Will add note. OMID TAVANGAR 916-817-4984

Submitted By: Stella Gardenour (916-817-4951) Submitted On: 26-May-10

Backcheck not conducted

Current Comment Status: Comment Open

3247896 Architectural Plans n/a' S-101

PARTIAL PLAN

AT MEZZANNE

FLOOR:

(Document Reference: 004) Coordinating Discipline(s): Structural

QUESTION – is diagonal or cross bracing required? Or will the floor system be enough structural support?

The design intent is for the floor to provide all the support needed, so diagonal bracings are not required. OMID TAVANGAR 916-817-4984

Submitted By: Stella Gardenour (916-817-4951) Submitted On: 26-May-10

Backcheck not conducted

Current Comment Status: Comment Open

3247898 Architectural Plans n/a' S-101 NOTES:

(Document Reference: 005)

Note 5 – ADD "Grout is to be a complete and full bed covering entire area shown.

1-0 Evaluation Concurred Will…