J044--safety testing of all boiler safety devices

Statement of Work

Inspection, Safety Device Testing and Calibration

Boiler Plant Burners, Controls, Instruments, and Data Management

Introduction:

A. The Kansas City, VA Medical Center requires the semi-annual services for the inspection, testing and certification of all boiler safety devices on:

The four, high pressure steam boilers, in the plant at Building 4. These boilers produce the steam to the Medical Center Main Campus.

The six, outlying low-pressure hot water (hydronic) boilers used for heating and domestic hot water at Buildings 2 and 56.

The safety device testing is a critical service for the Boilers at the Medical Center, so it is critical that the testing is completed within 14 calendar days of the 6-month pre-scheduled testing date provided by the Medical Center. There may be occasions where the Medical Center may extend the schedule for burners in limited service.

Technicians performing the inspections shall be certified and credentialed Boiler Inspectors.

.

B. Boiler plant safety, reliability, efficiency, and equipment longevity are critical safety and property concerns of the Medical Center. Malfunctioning burners or controls can cause catastrophic events resulting in injuries and death and massive property damage. Inaccurate or inadequate data management and monitoring systems can fail to warn of unsafe or inefficient performance. Regular inspections, testing, and calibration by expert technicians are an essential part of a program to address these concerns.

C. This Statement of Work describes the requirements for the inspection, testing and calibration of the boiler plant burners, burner management system, controls, instruments, gauges and transmitters by qualified technicians. This will include the 3 Hydronic Boilers at Building 2 and the 3 Hydronic Boilers at Building 56.

Objective:

The services we require are for semi-annual preventative maintenance services that includes the testing, inspection and certification for all the Boilers in the 3 buildings of the Medical Center s main campus.

Key Deliverables:

Inspection of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices

Testing of 4 High Pressure Steam and 6 Hydronic Boilers and Safety Devices

Calibration of 4 High Pressure Steam and 6 Hydronic Boiler Safety Devices

Inspection, Testing and Calibration Report, Including Certifications.

Contractor will provide all tools, materials, labor, supervision and all specialized testing equipment needed to perform semi-annual testing, inspection and calibration on all boiler safety devices, Boiler Plant Burners, Controls, Instruments, and Data Management System.

D. Attachment A shows the equipment inventory and includes the Boiler information along with the primary supporting equipment that is included in this contract.

E. Appendix B, covers the inspections of the six, hydronic boilers at Buildings 2 and 56.;

F. It is assumed as part of any boiler testing and inspections that whether a hot water boiler or steam boiler that repairs, adjustments or replacement of components may be required at additional cost.

G. It is assumed as part of any gauge or transmitter testing and calibrations that whether a hot water boiler or steam boiler system that repairs, adjustments or replacement of components may be required at additional cost.

Technician and Test equipment Qualifications:

Technicians performing the testing and inspections on all the boilers at the Kansas City, VAMC, shall have completed at least a one-year trade school and have five consecutive documented years of successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the Kansas City VAMC. The Boiler Plant Supervisor at the Kansas City, VAMC, may define and accept equivalent qualifications.

The contractor and all individuals working on the Kansas City, VAMC Boilers, shall have taken the OSHA Certified 10-hour construction safety course.

B. Technicians shall demonstrate familiarity with and have ready access to the current versions of the following references:

NFPA 85, Boiler and Combustion Systems Hazards Code.

NFPA 70E

VHA Boiler Plant Safety Device Testing Manual, Fifth Edition.

VHA Directive 1810(1) Boiler and Boiler Plant Operations

C. Technicians shall be equipped with portable electronic flue gas analyzers and all test

Instruments and materials necessary for the required tests and calibrations,

D. All test equipment must be calibrated and have calibration documentation demonstrating calibration was performed within one month of the site visits.

E. The Kansas City, VAMC uses programmable logic controls, the technicians must be proficient in programming the controls and have the appropriate hardware and software for this.

3. Inspection, Testing and Calibration Requirements:

A. Technicians shall provide all tools and labor necessary to perform internal inspection, component inspection, tuning, testing, calibrating, and adjustments of duel fuel burners and boiler plant controls as specified below. This shall be done every six months in accordance with a schedule provided by The Kansas City, VAMC. The VA may extend the schedule for burners in limited service.

B. Instrumentation, monitoring and data management systems as listed below shall be calibrated every six months.

C. Provide at least two weeks notice to the Contracting Officer s Representative (COR) prior to performing the work. 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 designate is available on site to monitor the work.

D. The Kansas City, VAMC will have the boilers that are to be serviced and or internally inspected, prepared for the technicians 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; pressure/temperature correction factors provided if available.

E. The Kansas City, VAMC will comply with any other requirements of the test personnel that are considered reasonable to the VA and have been presented in writing, to the VA, at least two weeks prior to the scheduled testing.

F. The inspections, testing and calibrations shall comply with:

1) The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition. A copy of the Testing Manual is available upon request.

2) Any written recommendations of the equipment manufacturers.

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

4) Burner performance requirements in this document.

5) VHA Directive 1810(1) Boiler and Boiler Plant Operations

G. A summary of the work is as follows:

1) Review boiler plant log sheets and alarm and trouble reports.

2) Review records that show combustion performance (flue gas oxygen and carbon monoxide).

3) Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VAMC requirements stated in this contract.

4) Test and record the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Verify that the set points and operating points are within approximately 10% of normal operating parameters. Adjust or repair/replace as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation.

5) Operate burner(s) on each fuel from low fire to high fire and back to low fire with VFD in auto and again with the VFD in bypass 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) at each increment.

6) Compare the combustion performance data with VAMC 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.

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

8) Immediately inform COR of any recommended repairs or modifications.

H. A list of all interlocks and safety devices to be inspected and tested on each boiler/burner/equipment, are contained in the VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition, along with testing procedures. A copy of the Testing Manual is available upon request.

I. Required burner performance with VFD and VFD bypass (natural gas and fuel oil):

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

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

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

4) Maximum NOx: _____ (Refer to original burner specification).

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 on single-point positioning systems).

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 on single point positioning systems).

7) No visible smoke Comply with local emissions regulations.

8) Copies of the applicable emissions regulations must be available in the boiler plant office.

9) 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.

J. List of instrumentation and controls to be inspected and calibrated:

The Kansas City, VAMC has preferred PCCIV programmable logic controls on all four boilers plus FIREYE YB110 burner management system on all four boilers in the central plant.

1) Steam flow transmitters (all).

2) Steam flow recorders/computer readout.

3) Feed flow transmitters (all).

4) Feed flow recorders/computer readout.

5) Drum level transmitters (all).

6) Drum level recorders/computer.

7) Flue gas oxygen sampling, analyzing and recorder/computer readout.

8) Boiler and economizer stack temperature transmitters and recorder/computer readout.

9) Master steam pressure and combustion controllers.

10) Boiler outlet draft controllers.

11) Boiler water level controllers.

12) Feedwater deaerator and condensate storage tank water level controllers including overflow.

13) All pressure and temperature sensors and transmitters.

14) All signal processing and readout devices.

15) All pressure and temperature gauges

4. Report Requirements:

A VA compliant test report will contain certification on the first page following the report cover page that includes the technicians name, signature, date and the name of the company performing the testing.

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 has four columns:

a. The first column labeled FUNCTION did the device pass or fail.

b. The second column labeled Device list the device number and description in

accordance with the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition.

c. The third column labeled Deficiencies-Recommendations

d. The fourth column labeled corrective actions list any corrective actions taken during the inspection.

The second section shall be in paragraph/bulleted form and list each device individual in accordance to the VHA Boiler Plant Safety Devices Testing Manual, 5th Edition. In addition, the section must reference the correct Master Specification and Standard Detail for that device.

5.1. Condensate Storage Tank and Deaerator Tank.

A. High Water Alarm

Purpose: High water level may be an indication of condensate transfer pump

failure that could lead to low water condition in the feedwater deaerator and in the boilers. There may be a failure of make-up water controls.

Recommended set point: 4 inches below overflow level and 2/3 of tank height or as described in Safety Device Testing Manual, Fifth Edition.

Potential hazards due to failure of high-water alarm: Feedwater deaerator

running dry and, consequently, boiler feed pumps running dry will cause

overheating and damage to pumps and potential for plant shut down. Failure of

make-up water controls (in open position) could lead to significant cost from

waste of water and condensate from the tank overflow if this occurs over a long

period.

Recommended type of device: Conductivity probe type switch. Float type

switches have high failure rate in this application where they are exposed to flash

steam that causes seals to harden and prevent float movement.

Comments: Float type switches are not allowed for high water alarms. The VA

recommended switch type is a conductivity probe type switch. Install the VA

recommended switch and set to alarm at 2/3 of the tank height. There are valves

that can isolate this alarm. These valves must be made lockable only in the

operating position.

B. Furnish report within one week of each facility inspection in Microsoft Word format by email to the COR and to the VA Headquarters office designated. Provide hard copies of data sheets and flue gas analyzer strip printouts to the COR within one week of visit.

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

Reference: VHA Boiler Plant Safety Devices Testing Manual, Fifth Edition

APPENDIX B. ADDITIONAL SAFETY DEVICE TEST PROCEDURES FOR HOT WATER BOILERS

Appendix B.1 INTRODUCTION

Appendix B presents step by step test procedures for safety devices that are specific to hot water boilers. The appendix provides forms for obtaining and recording all necessary data for each safety device being tested. This Appendix is a supplement to Appendix A to be used in testing a hot water boiler. The basic information required in section A.3.3 and certification required in section A.3.4 must be included in the report of safety testing for a hot water boiler in order for the report to be VA compliant.

The assumptions for the test procedures given in this Appendix are first listed. This information is then followed by one sheet for each device being tested to be used by the testing agency personnel as a check list and data form. These procedures must be made site specific to be in compliance with VA requirements. It is very important that all data required in these procedures are taken each time a test is made. Forms that contain pre-filled data lead to mistakes. Also, it is important not to use a check list form because a reviewer cannot verify that the test has been done correctly due to absence of data.

Appendix B.2. ASSUMPTIONS FOR TEST PROCEDURE

The test procedures in Appendix B makes certain assumptions that are listed below.

PLEASE NOTE THAT THESE ITEMS ARE NOT ALWAYS REPEATED IN EACH TEST PROCEDURE BUT APPLY TO ALL TESTS.

After each test, equipment should be returned to normal operating condition and the boiler should be fired to confirm its operability.

Jumping means disabling the switch electrically.

Any electric jumper application requires that all power to the device being

jumped be shut off and only personnel that are trained and qualified to the correct level by NFPA 70E perform such tests.

Pressure gages used in a test must be calibrated within prior 6 months.

The set point is the value at which the safety device indicator is set. The trip point is the actual value at which the safety device activates. Some language used in the test procedures assumes that the set point equals the trip point.

TEST PROCEDURES TO BE PERFORMED AS PER APPENDIX B.2 AND APPENDIX C. CONTAINED WITHIN SAFETY DEVICE TESTING MANUAL 5TH EDITION

ATTACHMENT A.1

Boiler and Supporting Equipment Inventory

Boiler Plant at Building 4. Quantity 4

Boiler #1

OEM HURST FIRE TUBE; Model # S5 X 350 200,

POWER FLAME DUEL FUEL CMAX BURNER; MOD. LNICM10-GO-30

NG; 2,216 14,700 MBH

#2 FO; 19.8 105 GPH

Boiler #2

OEM INDECK WATER TUBE; Model # D1 20 R

FABER DUEL FUEL; MOD. WB-1-16-IFGR

NG; 24,590 SCFH

#2 FO; 171 GPH

Boiler #3

OEM INDECK WATER TUBE; Model # D1 20 R

FABER DUEL FUEL; MOD. WB-1-16-IFGR

NG; 24,590 SCFH

#2 FO; 171 GPH

Boiler #4

OEM HURST FIRE TUBE; Model # S5 X 700 200

POWER FLAME DUEL FUEL CMAX BURNER; MOD.LNICM10C-GO-30

NG; 3,460 29,400 MBH

#2 FO; 30.8 210 GPH

ATTACHMENT A.2

Boiler and Supporting Equipment Inventory

Boiler Supporting Equipment at Building 4

Preferred PCCIV programmable logic controls on all four boilers.

FIREYE YB110 burner management system on all four boilers.

De-aerating Feed Tank

Condensate return tank

Fuel Oil Transfer pumps

Main Feed Pumps

Condensate Return Pumps

Boilers at Building 2. Quantity 3

AERCO Model: GF-111 LN

Fire Tube

1,000,000 BTU

15 PSIG

Boilers at Building 56. Quantity 3

Lochinvar Model: FBN1001

Fire Tube

1,000,000 BTU

30 PSIG

DEPARTMENT OF VETERANS AFFAIRS

BOILER SAFETY DEVICES - OPERATION CHECK LIST

HOSPITAL_________________________PROJECT NO. _______________DATE_________BOILER NO. ________________

BOILER MAKE AND MODEL ____________________________________________________________________________

BURNER MAKE AND MODEL ____________________________________________________________________________

TECHNICIAN AND COMPANY ____________________________________________________________________________

VA REPRESENTATIVE ____________________________________________________________________________

Not

Item OK OK Set Point - Remarks

Low Water Cutoff [ ] [ ] _____________________________________________

Aux. Low Water Cutoff [ ] [ ] _____________________________________________

High Water Alarm [ ] [ ] _____________________________________________

Low Water Alarm [ ] [ ] _____________________________________________

Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________

Aux. Low Water Cutoff Shunt Switch [ ] [ ] _____________________________________________

High Steam Press. Cutout - Recycle [ ] [ ] _____________________________________________

High Steam Press. Cutout - Non-Recycle [ ] [ ] _____________________________________________

Steam Safety Valve No. 1 - Pop [ ] [ ] _____________________________________________

Blowdown [ ] [ ] _____________________________________________

Steam Safety Valve No. 2 - Pop [ ] [ ] _____________________________________________

Blowdown [ ] [ ] _____________________________________________

Steam Safety Valve No. 3 - Pop [ ] [ ] _____________________________________________

Blowdown [ ] [ ] _____________________________________________

Steam Safety Valve No. 4 - Pop [ ] [ ] _____________________________________________

Blowdown [ ] [ ] _____________________________________________

Main Gas

High Pressure Cutoff [ ] [ ] _____________________________________________

Low Pressure Cutoff [ ] [ ] _____________________________________________

Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________

Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________

Oil

High Pressure Cutoff [ ] [ ] _____________________________________________

Low Pressure Cutoff [ ] [ ] _____________________________________________

High Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________

Low Temperature Cutoff (Heated Oil) [ ] [ ] _____________________________________________

Low Atomizing Pressure [ ] [ ] _____________________________________________

Low Atomizing/Oil Differential Pressure [ ] [ ] _____________________________________________

Oil Burner Position Switch [ ] [ ] _____________________________________________

Safety Shut-Off Valves Proof of Closure [ ] [ ] _____________________________________________

Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________

Cold Start/Steam Atomizing Burners [ ] [ ] _____________________________________________

LP Gas Ignitor Operation [ ] [ ] _____________________________________________

Ignitor (Pilot)

Low Gas Pressure [ ] [ ] _____________________________________________

Leak Test Safety Shut-Off Valves [ ] [ ] _____________________________________________

Forced Draft Motor Interlock [ ] [ ] _____________________________________________

F. D. Damper Open Wide for Purge [ ] [ ] _____________________________________________

Outlet Damper Open Wide for Purge [ ] [ ] _____________________________________________

Purge Air Flow Interlock [ ] [ ] _____________________________________________

Purge Timing [ ] [ ] _____________________________________________

Ignition Timing [ ] [ ] _____________________________________________

Low Fire Position Interlock [ ] [ ] _____________________________________________

Combustion Air Flow Interlock [ ] [ ] _____________________________________________

Main Flame Out - Time to Close Valves [ ] [ ] _____________________________________________

Ignition Flame Out - Time to Close Valves [ ] [ ] _____________________________________________

Minimum Ignitor Flame Test [ ] [ ] _____________________________________________

Scanner Not Sensing Ignition Spark [ ] [ ] _____________________________________________

Control Air Pressure Interlock [ ] [ ] _____________________________________________

Sound Level - High Fire [ ] [ ] _____________________________________________

Fan Motor Amps [ ] [ ] _____________________________________________

Low Oxygen Alarm [ ] [ ] _____________________________________________

Boiler Soot Blower Operation and Alignment [ ] [ ] _____________________________________________

Economizer Soot Blower Operation [ ] [ ] _____________________________________________

Flue Gas Recirculation Damper Set for Prepurge [ ] [ ] _____________________________________________

_________________________________ [ ] [ ] _____________________________________________

VACO 183A

REQUIRED CERTIFICATIONS FOR EACH SAFETY DEVICE TEST REPORT

A VA compliant test report will contain the following certification on

the first page following the cover page of the report.

I certify that I have properly tested all applicable safety devices listed in this report for Boiler #______and its associated equipment and I certify that all of these tests confirm that every device tested passed as defined by the following question: Did the device fail or pass the 3 question criteria?

___________________ ____________________ ____________

Printed Name Signature Date

___________________ ___________________

Position Title Company

OR

I certify that I have properly tested all applicable safety devices listed in this report for boiler #______ and its associated equipment and I certify that some of these tests failed as defined by the following question: Did the device fail or pass the 3 question criteria? More details of these failures are given in Appendix F (Comments on each individual test)

___________________ ____________________ ____________

Printed Name Signature Date

___________________ ___________________

Position Title Company

Table A.3.1 Basic Information

SITE INFORMATION

VISN

VA Medical Center Location

Contact Information

Phone

Email

Evaluators

Date

BOILER DESCRIPTION

Boiler #

Manufacturer

Model and Capacity

Serial #: National Board #

Typical Operating Pressure

Design Pressure

Date of Manufacture

BOILER CONTROL DESCRIPTION

Manufacturer

Model

Date of Manufacture

BURNER DESCRIPTION

Manufacturer

Model #

Fuels

Date of Manufacture