Boiler Inspection Testing

Added: Aug 11, 2016 11:03 am

STATEMENT OF WORK

Boiler & Safety Device Inspection, Testing and Repair



1.0 INTRODUCTION

The VA Medical Center at 830 Chalkstone Avenue, Providence, RI 02908 has steam generating boilers that require annual inspections and monthly safety device testing. The Contractor shall provide all labor, tools, and testing equipment required for proper boiler inspections and safety device testing. Services will be bid as a firm fixed price. The contract will have a one-year base period for the period of October 1, 2016 thru September 30, 2017 with four additional option years. Technical and Quality factors will be weighted more than cost when evaluating bids.



2.0 BACKGROUND

The VA Medical Center in Providence has three steam generating boilers #1, #2, & #3 (Appendix A) and equipment that require annual inspections and monthly safety device testing services. All the boilers are water tube boilers. The boiler inspections are conducted annually and are scheduled in a manner such that at least two of the three boilers are available for full duty at all times. One boiler is in use, a second boiler is always available on stand-by, and the third boiler is off-line and available for any required maintenance, cleaning, or inspection. The goals are safety, reliability and longevity of the steam generating equipment in the boiler plant of the VA facility.



3.0 SCOPE

Provide all labor, tools, and testing equipment required for proper boiler inspections and safety device testing program services for boilers #1, #2, & #3. See Appendix A.



a. Safety Device Testing: Contractor shall provide all labor, tools, and all testing equipment required to perform monthly and annual Safety Device testing for all Cleaver-Brooks water-tube boilers and other plant equipment as identified in the VHA Boiler Plant Safety Device Testing Manual, Third Edition. Testing manual will be available upon request. Contractor shall provide a detailed report including a picture of each device as installed on the system and all other information required by the Testing Manual. Safety Device Testing shall be scheduled in advance with the Boiler Plant Supervisor. See Appendix B.



b. Annual Internal/External Inspection and Operational Testing: Contractor shall perform an annual internal/external inspection on each Cleaver-Brooks water tube boiler. The inspections will be performed over several weeks on two (2) boilers at a time during the warm weather months. One boiler will be shut down for the interior inspection and a second boiler will have its exterior inspection and operational testing done. This sequence will continue until all interior and exterior inspections. Only one interior and one exterior inspection will be scheduled per week. This procedure typically takes three (3) consecutive weeks. The annual operational testing will be accomplished at three (3) separate times during the year. All inspections and testing will be scheduled through the Boiler Plant Supervisor. See Appendix B. The inspector shall be a Commissioned National Board Certified Inspector, and the inspections will be in compliance with National Board Inspection Code & ASME Code. The inspector is responsible for performing and adhering to his own Confined Space Entry Program in accordance with OSHA regulations when entering boilers. Program must be submitted to the COR and approved prior to scheduling any work. Contractor will provide all required inspection and certification documents for the inspections, along with color pictures of the internals and externals of the boilers. Contractor is responsible for providing all specialized tools and equipment required to perform the work.



4.0 APPLICABLE DIRECTIVES

4.1 The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, 3rd Edition.

4.2 The written recommendations of the equipment manufacturers.

4.3 The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazards Code including applicable appendices.

4.4 Medical Center, Facility Services Policy, FS-7.

4.5 VA Directives 2008-62.

5.0 PERFORMANCE REQUIREMENTS

All work shall be completed such that the integrity of the systems is maintained. All work shall be done in accordance with OSHA, EPA regulations, NFPA codes, with particular attention to NFPA 85, VA codes, Federal, State, and local regulations throughout the course of this project. The Contractor will be required to sign in and out at Building #10 with the Boiler Plant Operator on duty. All inspections and testing will be performed between the hours of 7:30am to 4:30 pm Monday thru Friday by the 15th working day of each month, excluding holidays. All service shall be accompanied by an electronic slip for inspection and testing of boilers and auxiliary equipment. All personnel performing testing and inspections services will have available and wear proper personnel protective equipment for the task.



1. Coordinate the boiler inspections and testing with the Plant supervisor. VA personnel will prepare equipment for inspection.



2. Any deficiencies or problems noted with VA test results are to be reported immediately to the plant supervisor. If problems are found, corrective actions must be recommended immediately and followed up in the service report.



3. Situations requiring more frequent and/or special testing other than the specified requirements may arise. Do not perform any extra cost work without written authorization from the CO. A separate purchase order will be issued to cover the costs associated with these extras upon request and justification from the contractor.

4. All areas will be left in a clean and professional manner.



6.0 DELIVERABLES

" Contractor personnel must meet VA Qualification Requirements as well as qualifications and experience of the company and the inspector or testing specialist.

" Provide complete written report of the inspections or testing fully describing all tests performed, all findings, and recommendations. Reports must include the description of the device, functioning (yes\no), deficiencies\recommendations, corrective actions, and photographs. Report will be given to the Boiler Plant Supervisor verbally prior to leaving the site and written report within one week of inspection\testing activity.

" All safety-related deficiencies shall be immediately reported to the Boiler Plant Supervisor during the inspection visit.

" The contractor shall have been in business at least five years providing services described within this SOW similar in design and annual steam production rates to that of the Medical Center. Provide a list of at least five customers similar to VA who have utilized the services for boiler inspection and safety device testing for at least three years.

" A detailed list of the boiler inspection and testing activities proposed and the frequencies that they will be performed.

" A detailed list of the testing equipment proposed and the related equipment specifications.

" A detailed list of personnel proposed to service our Medical Center along with documented relevant experience and expertise.

" The company's lock-out tag-out procedures.

" The company's Safety Plan.

" The company's Confined Space Program.

" The company's Chemical Hygiene Plan.

" MSDS's for ALL chemicals proposed for use in the boiler plant under this contract.

" Activity Hazard Analysis (AHA). A blank AHA form is available at http://www.swf.usace.army.mil/pubdata/safety/PDF/blank_AHA_Form.pdf.

" Respiratory Protection Program, if respirators are to be used in the performance of the work of this contract (or, if a subcontractor is involved, the subcontractor's Respiratory Protection Program).





7. PRICING SCHEDULE



Base Year: 10/1/16 - 9/30/17



Line Item QTY Unit $ Per unit Total Price

Monthly Maintenance and Boiler Plant Safety Testing 12 MO $ $



Total Base Year: $ ______________________________

Routine Repair Hourly Rate (7:00 am -5:00 pm Weekdays) $_____________ Hourly Rate.

Overtime Repair Hourly Rate inclusive of labor/travel (5:00pm - 7:00am Weekdays)

$ _______________ Hourly Rate.

Minimum Hours Charged per Routine Repairs _____________ Hours.

Parts required during repairs will be charged at cost plus________% mark -up.







Option Year 1: 10/1/17 - 9/30/18



Line Item QTY Unit $ Per unit Total Price

Monthly Maintenance and Boiler Plant Safety Testing 12 MO $ $



Total Option Year 1: $ ______________________________

Routine Repair Hourly Rate (7:00 am -5:00 pm Weekdays) $_____________ Hourly Rate.

Overtime Repair Hourly Rate inclusive of labor/travel (5:00pm - 7:00am Weekdays)

$ _______________ Hourly Rate.

Minimum Hours Charged per Routine Repairs _____________ Hours.

Parts required during repairs will be charged at cost plus________% mark -up.







Option Year 2: 10/1/18 - 9/30/19



Line Item QTY Unit $ Per unit Total Price

Monthly Maintenance and Boiler Plant Safety Testing 12 MO $ $



Total Option Year 2: $ ______________________________

Routine Repair Hourly Rate (7:00 am -5:00 pm Weekdays) $_____________ Hourly Rate.

Overtime Repair Hourly Rate inclusive of labor/travel (5:00pm - 7:00am Weekdays)

$ _______________ Hourly Rate.

Minimum Hours Charged per Routine Repairs _____________ Hours.

Parts required during repairs will be charged at cost plus________% mark -up.





Option Year 3: 10/1/19 - 9/30/20



Line Item QTY Unit $ Per unit Total Price

Monthly Maintenance and Boiler Plant Safety Testing 12 MO $ $



Total Option Year 3: $ ______________________________

Routine Repair Hourly Rate (7:00 am -5:00 pm Weekdays) $_____________ Hourly Rate.

Overtime Repair Hourly Rate inclusive of labor/travel (5:00pm - 7:00am Weekdays)

$ _______________ Hourly Rate.

Minimum Hours Charged per Routine Repairs _____________ Hours.

Parts required during repairs will be charged at cost plus________% mark -up.







Option Year 4: 10/1/20 - 9/30/21



Line Item QTY Unit $ Per unit Total Price

Monthly Maintenance and Boiler Plant Safety Testing 12 MO $ $



Total Option Year 4: $ ______________________________

Routine Repair Hourly Rate (7:00 am -5:00 pm Weekdays) $_____________ Hourly Rate.

Overtime Repair Hourly Rate inclusive of labor/travel (5:00pm - 7:00am Weekdays)

$ _______________ Hourly Rate.

Minimum Hours Charged per Routine Repairs _____________ Hours.

Parts required during repairs will be charged at cost plus________% mark -up.





Grand Total Base Year plus Option Years 1, 2, 3 & 4 $ ___________________________











Boiler # 1, 2, 3

Manufacturer: Cleaver Brooks

Model and Capacity: D Shape Water Tube 16,000 lb/hr

Serial #: National Board No.:

Typical Operating Pressure: 115 lbs

Design Pressure 250 lbs

Date of Manufacture: 1978

Boiler Controls: Fireeye

Burner

Manufacturer: Cleaver Brooks

Type of Burner: Ring

Fuels: Natural Gas/#2 Oil

Date of Manufacture: Installed 1988

Appendix A. Boiler and Burner Description

Appendix B - Safety and Operational Testing Frequency

Component/Item Frequency

Day Month Year

Water Level Control

Low water cutoff (slow drain test) X

Low water cutoff shunt switch X

Auxiliary low water cutoff (slow drain test) X

Auxiliary low water cutoff shunt switch X

High-water alarm X

Low-water alarm X

DA low water alarm X

DA high water alarm X

Condensate tank low water alarm X

Condensate tank high water alarm X

Pressure Containment

Steam safety valves X

PRV safety valves X

High steam pressure cutout recycle X

High steam pressure cutout non-recycle X

Accumulation Test X

Fuel Train Safety Devices

Gas

Check Gas Vent for Leaks X

High fuel pressure cutoff X

Low fuel pressure cutoff X

Safety shutoff valves proof of closure X

Leak test safety shutoff valves X

Oil

High temp cutoff for heated oil N/A

Low temp cutoff for heated oil N/A

High oil pressure cutoff X

Low oil pressure cutoff X

Low atomizing pressure X

Oil burner position switch (if provided) N/A

Safety shutoff valve proof of closure X

Leak test safety shutoff valves X

Oil pump set liquid relief valves X

Burner and Air Train Safety Devices

LP gas pilot X

Low gas pressure cutout X

Forced draft motor interlock X

F.D. inlet vanes open wide for purge X

Outlet damper open wide for purge N/A

Purge air flow interlock X



VILA Boiler Plant Safety Device Testing Manual - Department of Veterans Affairs

Time for pre-purge X

Time for post-purge X

Igniter timing X

Low fire position interlock X

Combustion air interlock X

Main flame out - time to close valves X

Igniter flame out - time to close valves X

Minimum igniter flame test X

Flame scanner X

Scanner not sensing ignition spark X

Low oxygen alarm/cutout X

Prepurge setting of flue gas recirculation damper N/A

Interlock of outside air damper with burner management X

Deaerator

DA safety valve X

Check operation of DA

Pressure

Temperature



X

X

DA vacuum breaker X

DA overflow X

Cleaning and inspection of DA (non-destructive testing of welds should be performed every 6 years) N/A

Check recirculation of feedwater back to DA X

Other Duties

...

Blowing of water columns N/A

Testing and adjusting water treatment N/A

Check furnace pressure X

Check combustion gas leaks into boiler room X

Boiler fouling and combustion gas flow check N/A

Tube leak check N/A

Clean waterside of boiler N/A

Clean fireside and repair refractory N/A

Adjust burning of fuel X

Calibrate gauges, sensors, and controls X

Check vibration of boiler X

Calibrate oxygen trim X

Economizer liquid relief valve N/A

Check operation of economizer Stack temp entering and leaving Water temp entering and leaving X

X

Review written procedures

Operating, Maintenance, Emergency, Storage, Safety N/A