File 07 Design Analysis REPLACE BOILER Addend 1.pdf

Veterans Affairs Loma

San Bernardino

605-09-303 REP

DESIGN A

100% Final D

AddendAddend

June 18June 18

Contract No. W91

Task Ord

US Arm Eng

Los Ang

Linda Healthcare System

County, California

PLACE BOILER

ANALYSIS

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8 20108, 2010

12PL-09-D-0033

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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

Addendum No. 1

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

4.4 Testing (added)

5.0 Electrical

5.1 General Description

APPENDICES

Appendix A Statement of Work (SOW) (No Change/Not Included)

Appendix B Catalog Cut Sheets / Equipment Data (No Change/Not Included)

Appendix C RFI Log and RFIs (No Change/Not Included)

Appendix D Calculations (No Change/Not Included)

Appendix E Phasing Plan (No Change/Not Included)

Appendix F Engineering Considerations and Instructions to Field Personnel (No Change/Not Included)

Appendix G Water Quality Reports (No Change/Not Included)

Appendix H 95% Submittal DrChecks Report (No Change/Not Included)

Appendix I VHA Boiler Plant Safety Device Testing Manual, Third Edition (Added)

PROJECT SPECIFICATIONS – Revised Sections Only

CONSTRUCTION COST ESTIMATE (No Change/Not Included)

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 Task 5 – 100% Design Submittal Addendum No. 1 6/18/2010

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.

4.4 TESTING

In addition to the testing procedures listed in the specifications, all new equipment installed shall be tested in accordance to VHA Boiler Plant Safety Device Testing Manual, 3rd Edition, dated September 2008 (Appendix I). Whenever testing procedures are in conflict, the more stringent requirement shall govern.

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)

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 I VHA Boiler Plant Safety Device Testing Manual, Third Edition

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