J044--Boiler Retubing Services

SCOPE OF WORK

The contractor shall provide all personnel, labor, equipment, tools, materials, supervision and any other items and/or services necessary to completely re-tube the 9 boilers. This includes 2 cleaver Brooks 4WG-200-150-15ST fire tube boilers. 1 Cleaver Brooks 4WG-200-125-15ST fire tube boiler. 6 Cleaver Brooks 4WG-200-100-15ST fire tube boilers.

The contractor shall ensure all repairs and materials meet or exceed original specifications. Any changes to the original materials used or recommended changes by the contractor shall be included in the offer with cost and a narrative as to why the changes are required or recommended.

SPECIFIC REQUIREMENTS

The Contractor shall:

Develop and submit a work plan including details on materials and methods planned, a safety plan and schedule. This shall include data on welding and tube materials and workers qualifications and certifications.

Disassemble and reassemble boiler accessories, attaching hardware deemed necessary to successfully complete this project.

The contractor shall be responsible for supplying all equipment, labor, and materials to complete the boil out (chemical cleaning) of the tubes before returning to service, refer to Spec 235239 paragraph 3.2. In accordance with directions given by the current water treatment representative and environmental engineer at VA Illiana VAMC. The contractor shall be responsible for all connections and disconnections.

Prepare for pressure testing of the completed work and pressurization for inspection. The contractor shall conduct the hydrostatic test at 1.3 times the Maximum Allowable Working Pressure (MAWP) of the vessel. The contractor shall verify all devices are capable of that pressure or remove them and ensure all outlets and inlets are secured to accommodate the test. The pressure shall be brought up slowly and allowed to come to equilibrium at 2-4 psi steps and be at pressure at least 15 minutes before the inspector arrives. Pressure shall be maintained until the inspector confirms it can be reduced at which time it shall be reduced slowly in steps as per the pressurization process. The temperature of the water shall not be higher than 120F.

Ensure tube material and thickness shall remain unchanged from what is shown on the original drawings and/or specifications. Substitutions shall be permitted only if approved in writing by the COR and only if the originally specified tube types are no longer available and with the concurrence of a licensed engineer with experience in boiler design or the manufacturers approval. The substitution s quality must be equal to or greater than the original design, and it shall be the contractor's responsibility to provide a side-by-side comparison of tube specifications between the original and proposed substitutions.

At the completion of this project the boilers shall be recommissioned. To include at a minimum tuning and or putting in air, gas, and oil curves as needed. and demonstrated to be fully operational on both natural gas and fuel oil throughout the firing range.

The contractor shall set and test all level controls, and boiler safeties, (electrical and mechanical controls that are affected by the project). All The boiler safety devices shall be fully tested per Veterans Health Administration Safety Device Testing Manual (VHA SDTM). Those that were removed during the work shall be reinstalled and tested by qualified technicians.

The tubes shall be reinstalled in the same fashion as the original design (i.e., rolled or welded). Tubes that are required to be rolled that are damaged during installation shall be removed and replaced. Seal welding is only permitted if required as part of the original design to return the boiler to factory condition. Seal welding that was not part of the original design to address leaks or fit up issues is prohibited.

Provide all seals, gaskets, nuts & bolts.

Provide the following proper storage of tubes and other materials from the weather. The contractor may be required to store the new tubes off site and truck in weekly or as needed because of the limited storage area at VA Illiana VAMC. The COR or designee shall have the authority to approve what, if any, materials the Contractor is allowed to store on-site.

The contractor shall be responsible for returning the boiler to a fully operational state before turning back over to VA Illiana VAMC.

Warranty all welds and rolls for a term of no less than five (5) years.

Remove and ensure proper disposal of all materials removed from the boiler retubing. All waste generated because of contractor work is the property of the contractor except items defined as "salvage" by the Government. The contractor is responsible for the removal of their waste and shall not use government owned or controlled equipment to contain, store, or otherwise handle his trash or debris. The contractor shall provide sufficient containers to remove all the waste created by his operations and remove it from the job site as soon as practicable. The contractor is responsible for assuring that all waste from Government work is disposed of only through a facility that has been certified by the appropriate state or local agency for waste management, or by the Environmental Protection Agency.