H344--Boiler Plant Safety Device Testing (Va-21-00037611)

The VANJ HealthCare System (VANJHCS) requires an annual service contract to calibrate all pressure gauges, boiler and plant controls and instrumentation (recorders and transmitters). Boiler Plant Safety Device maintenance, inspection, testing and calibration. Boiler Combustion / Emissions testing and tuning and Emergency Repair Service on nine (9) Cleaver Brooks Fire Tube Boilers and Auxiliary Equipment that provide steam to the East Orange and the Lyons VA Medical Center. Both VAMC s have a central boiler plant to provide steam for heating and air conditioning, domestic hot water, kitchens and sterilization. Boiler plant safety, reliability, efficiency and equipment longevity are paramount concerns of Veterans Affairs Medical Center (VAMC) management. Boilers are extremely dangerous if not maintained properly. Malfunctioning burners or controls can cause catastrophic events resulting in injuries and death as well as 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. This statement of work describes the requirements for the inspection, testing and calibration of the boiler plant burners, controls, instruments and safety devices by qualified technicians in accordance with VHA Directive 1810 and the VHA Boiler Safety Device Testing Manual (5th Edition). VHA Directive 1810 requires annual and semi-annual Boiler and associated plant safety device inspection, testing, calibration and semi-annual combustion / emissions adjustments / tuning, VHA Directive 1810 requires these services to be performed by a qualified professional third party that has documented knowledge and experience in the design and construction and VA s standards for construction and testing of safety devices. In addition, the individual shall have demonstrated experience in conducting equipment assessments and performing testing in compliance with the VA safety device testing manual on at least 5 sites within the past 3 years. OBJECTIVE: This service contract is an annual maintenance contract on the Boilers and associated plant equipment at the East Orange VA Medical Center and the Lyons VA Medical Center to meet the requirements for the inspection, testing, tuning and calibration of the boiler plant burners, controls, all instrumentation including pressure gauges, transmitters and safety devices by qualified technicians in accordance with VHA Directive 1810 and the VHA Boiler Safety Device Testing Manual (5th Edition). SCOPE OF WORK: The contractor will furnish all labor, materials, supplies, equipment and transportation necessary to accomplish the services contained within this contract. The selected contractor will perform annual and semi-annual calibration of all pressure gauges, boiler and plant controls, controllers, transmitters, recorders and all other instrumentation contained within the Boiler Plant IAW VA Directive 1810. The selected contractor will perform annual and semi-annual Boiler and Plant Safety Device testing on all nine (9) of the boilers and associated plant equipment at the VANJHCS Lyons and East Orange Campuses. Ensuring that all safety devices are plumbed correctly and in its correct place, safety device set point is correct, safety device activates at the correct set point and the safety device produces the required effect. Safety device identification and labeling including set point and normal operating range is to be determined and set prior to test. Calibration/test sticker shall be affixed to each equipment and device after completion of tests. The selected contractor will also perform semi-annual Boiler Combustion Emissions Tuning of all nine (9) of the boilers. All testing will be as specified in VHA Directive 1810 and the VHA Boiler Safety Device Testing Manual (4th Edition) and where not defined will be IAW good engineering and proven past practice accepted by industry standards and equipment manufactures. The following Equipment is included in the annual service contract. VA NJ HealthCare System East Orange Campus: Boiler #1 Cleaver Brooks Model CB 200X-600 Serial# OLO88369 SWP 200 20700 lbs/hr Input 25,106,000 BTU/HR Nat Gas Boiler #2 Cleaver Brooks Model CB 200X-600 Serial# OLO88368 SWP 200 20700 lbs/hr Input 25,106,000 BTU/HR Nat Gas Boiler #3 Cleaver Brooks Model CB 200X-600 Serial# OLO88367 SWP 200 20700 lbs/hr Input 25,106,000 BTU/HR Nat Gas Boiler #4 Cleaver Brooks Model CB 200X-600 Serial# L99715 SWP 200 20700 lbs/hr Input 25,106,000 BTU/HR Nat Gas D.A. Tank Cleaver Brooks Model# BM-42 Serial# DG-5941 50,000 lbs/hr Condensate Tank Wendland Manuf. Corp NB-5452 Serial# 36616 VA NJ HealthCare System Lyons Campus: Boiler #1 Cleaver Brooks Model CB 200-700 Serial# OLO94344 SWP 200 20000 lbs/hr Input 29,290,000 BTU/HR Nat Gas 209 GPH Oil Boiler #2 Cleaver Brooks Model CB 200-700 Serial# L-90891 SWP 200 20000 lbs/hr Input 29,290,000 BTU/HR Nat Gas 209 GPH Oil Boiler #3 Cleaver Brooks Model CB 200-700 Serial# L-90892 SWP 200 20000 lbs/hr Input 29,290,000 BTU/HR Nat Gas 209 GPH Oil Boiler #4 Cleaver Brooks Model CB 200-700 Serial# L-90890 SWP 200 20000 lbs/hr Input 29,290,000 BTU/HR Nat Gas 209 GPH Oil Boiler #5 Cleaver Brooks Model CB 200-700 Serial# OLO94345 SWP 200 20000 lbs/hr Input 29,290,000 BTU/HR Nat Gas 209 GPH Oil D.A. Tank East Fabricators Serial# 12774 Vessel# NB 3807 Manufactures Rating 3400 Gal Design pressure 30 PSI Safety valve setting 15/20 PSI Shell thickness .3125 Condensate/Surge Tank East Fabricators Serial# 12783 Vessel# NB 3783 Manufactures Rating 3100 Gal Design pressure 25 PSI Vented 3 Line Semi-annual Boiler Safety Device Testing Inspections Perform the required semiannual maintenance specified by VHA Directive 1810 on Boiler Plant Safety Devices. The VHA Boiler Plant Safety Device Testing Manual (4th Edition) will be used as the only procedure to test all Boiler Safety Devices. All Boiler Safety Device Inspections must be scheduled with the COR. Boiler Safety Devices will be tested every 6 mths and must not interfere with Boiler cleanings and inspections. A detailed report of inspection for each safety device tested must be supplied to the COR. All failures must be immediately reported to the COR and the Boiler Plant Operator. Replace any device that fails and is not able to be repaired or calibrated following the guidelines of unscheduled maintenance. Any new device must be calibrated to its proper set point and tested. If a test procedure will not achieve the desired results due to a fault in the written test procedure or configuration of the device the contractor will devise a new procedure that will accomplish the same end results and submit the procedure to the COR for approval. The contractor will then be provided written direction on how to proceed. Inspection, Testing, and Calibration Requirements: Contractor shall provide all tools and labor necessary to perform inspection, tuning, testing, calibrating, and adjustments of burners and boiler and boiler plant controls as specified below. This shall be completed every 6 months in accordance with a schedule provided by VAMC. VAMC may extend the schedule for burners in limited service. Contractor shall calibrate instrumentation, monitoring, and data management systems every 6 months. Contractor shall provide at least 2-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. The VA Medical Center (VAMC) will have the boilers that are to be serviced prepared for the technicians upon their scheduled arrival. This includes having the boilers fully warmed and at normal steam pressure; steam exhaust silencer system operable; all boiler, burner, and fuel train pressure gauges and thermometers calibrated; fuel meters in accurate operation; boiler steam flow, stack temperature, and flue gas oxygen instruments operating. The VAMC will comply with any other requirements of the test personnel that are considered reasonable by VAMC and have been presented in writing at least 2 weeks prior to the scheduled testing. The inspections, testing and calibrations shall comply with: The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual, (4th Edition). The written recommendations of the equipment manufacturers. The requirements and recommendations of NFPA® 85: Boiler and Combustion Systems Hazards Code including applicable appendices. Burner performance requirements from the burner manufacturer. A summary of the contractor work is as follows: Review boiler plant log sheets. Review records that show combustion performance (flue gas oxygen and carbon monoxide). Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VAMC requirements stated in this contract. Test and record the operation and set points of all burner/boiler safety interlock devices. Verify that the set points and operating points are within approximately 20 percent of normal operating parameters. Make adjustments as necessary and record the new settings. The operation of a device must result in burner shutdown and/or proper alarm operation. Operate burner(s) on each fuel from low fire to high fire and back to low fire in at least six increments and record combustion performance (flue gas oxygen, carbon monoxide, nitrous oxide, where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output. Compare the combustion performance data with VAMC requirements and previous readings. If necessary, make adjustments to the fuel flow and combustion air controllers, control valves and dampers to obtain the required performance. Record the new performance data. Verify accuracy of instrumentation. Verify that all devices are properly selected for the application in terms of type, size, set point range, performance, and code approval. Calibrate all instruments that are not within manufacturer specifications for accuracy. Immediately inform the COR of any recommended repairs or modifications. Contractor shall inspect all interlocks and safety devices on each boiler/burner/equipment are contained in the VHA Boiler Plant Safety Devices Testing Manual, (4th Edition), along with testing procedures. Contractor is responsible for the required burner performance (natural gas and fuel oil): Turndown (ratio of maximum and minimum firing rates): 10/1 8/1 5/1 4/1 (Refer to original burner specification). Achieve, but do not exceed, boiler maximum steam flow output rating. Measure fuel input at minimum and maximum firing rates. Maximum carbon monoxide: 200 parts per million (ppm). Maximum nitrous oxide: refer to original burner specification. Flue gas oxygen: 2.5-4.2 percent (Up to 5.2 percent at loads below 40 percent 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). Flue gas oxygen (low excess air burners): 1.0-2.0 percent (Up to 2.5 percent at loads below 40 percent 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). No visible smoke. Flames shall be stable with no pulsations, shall be retained near burner, no blow off or flashbacks, no constant flame impingement on refractory. Contractor shall inspect and calibrate the following list of instrumentation and controls to be inspected and calibrated: Steam flow transmitters (all). Steam flow recorders/computer readout. Flue gas oxygen sampling, analyzing, and recorder/computer readout. Boiler and economizer stack temperature transmitters and recorder/computer readout. Master steam pressure and combustion controllers. Boiler water level controllers. Feedwater deaerator and condensate storage tank water level controllers including overflow. All pressure and temperature devices, sensors and transmitters. All signal processing and readout devices. NOTE: Prior to the semi-annual and annual services, Contractor shall ensure the following is performed: Verify the following boiler safety devices are in the correct locations and plumbed correctly. Verify the safety device set points are correct in relation to normal operating values. Verify the safety device activates and resets at the correct set points. Verify the safety device produces the required flame safeguard shutdown and audible/ visual annunciation. The Contract shall test the following safety devices: High Water Alarm on Condensate Tank (HWACT) Low Water Alarm on Condensate Tank (LWACT) High Water Alarm on Deaerator Tank (HWADT) Low Water Alarm on Deaerator Tank (LWADT) Deaerator Overflow Drain System (DAODS) Deaerator Safety Valve (DASV) Safety Valve Following DA PRV (SVFPRV) Steam Safety Valve Following PRV (SVFPRV)-Other Liquid Relief Valve on Oil Pump Set (LRVOPS) Liquid Relief Valve on Economizer (LRVE) Propane Pilot Backup System Carbon Monoxide and Combustible Gas Alarms in the Boiler Plant High Gas Pressure Alarm Outside Air Damper Interlock (OADI) Low Water Alarm and Cutoffs on Boiler (LWA/LWCO/ALWCO) High Water Alarm on Boiler (HWAB) Recycle and Non-Recycle Boiler Steam Pressure Limit Switches (RBSPLS & NRBPLS) Steam Safety Valves on Boiler (SVB) Low Fuel Gas Pressure Cutoff Switch (LFGPCS) High Fuel Gas Pressure Cutoff Switch (HFGPCS) Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (AFGSOV & AFGSVV) - Main Gas Automatic Pilot Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (APFGSOV & APFGSVV) - Pilot Line Proof of Closure on Automatic Fuel Shutoff Valves (POC-AFGSOV) -Natural Gas Flame Scanner-for main flame out (FSMFO) Flame Scanner Not Sensing Igniter Spark (FSNSIS) Igniter Timing (IT) Main Flame Ignition Timing (MFIT) Pre-Purge and Post-Purge Timing (PPT) Low-Fire Proving Switch (LFPS) Forced Draft Damper Wide-Open Pre-Purge Proving Switch (FDDWOPS) Combustion Air Pressure Switch (CAPS)-Constant Speed or Variable Speed Fan Purge Airflow Proving Switch (PAPS) Forced Draft Motor Interlock Switches (FDMIS) Outlet Stack Damper Position Interlock Switch (OSDPI) Furnace Pressure Interlock (FPI) Low Pilot Fuel Gas Pressure Cutoff Switch (LPFGPCS) Flue Gas Recirculation Damper Interlock (FGRDI) Low Flue Gas Oxygen Level Interlock (LFGOLI) Low Fuel Oil Pressure Cutoff Switch (LFOPCS) High Fuel Oil Pressure Cutoff Switch (HFOPCS) Low Atomizing Media Pressure Switch (LAMPS) Low Atomizing Media Differential Pressure Switch (LAMDPS) Low Atomizing Media Flow Switch (LAMFS) Automatic Fuel Oil Shutoff Valves (AFOSV) - for Seat Leakage Proof of Closure on Automatic Fuel Oil Shutoff Valves (POC-AFOSV) Oil Burner Position Switch (OBPS) Emergency Stop/Panic Buttons (ESPB) Unscheduled Maintenance: Unscheduled maintenance is defined as any problem/defect found during current repair or during annual or semi-annual preventive maintenance, testing, calibration, inspection or tuning that would require the contractor to perform further maintenance and/or replacement of parts. The Contractor shall provide to the COR a complete list of repairs and/or parts required for review and approval before any maintenance /repairs are made at the Lyons or East Orange campus. Report Requirements: Contractor shall provide complete written report of the inspection fully describing all tests performed, all findings, and recommendations. At a minimum the following information will be delivered to the COR in a table (Excel or Word): The first column, labeled Function, did the device pass or fail. The second column, labeled Device, list the device number and description in accordance with the VHA Boiler Plant Safety Devices Testing Manual, (4th Edition). The third column, labeled Deficiencies-Recommendations. The fourth column, labeled Corrective Actions, lists any corrective actions taken during the inspection. The fifth column with the date tested. The sixth column with person performing the test. The seventh column will be for comments. The Contractor shall furnish reports within 1 week of each facility inspection in Microsoft Word format by email to the COR. Provide hard copies of data sheets and flue gas analyzer strip printouts to the COR within 1 week of visit. All safety-related deficiencies shall be immediately reported to the COR, Boiler Plant Supervisor and/or Assistant Chief Engineer during the inspection visit. Semi-annual Boiler Tune Ups Contractor shall tune all nine Boilers must be tuned at least once every six months. A qualified person will be used to tune the boilers and a report of the results of the tuning will be submitted to the COR. The tuning performed will be on Natural Gas and on Fuel Oil. The Boilers will be tuned at a minimum of six points through the entire range of 0-100% Boiler Firing Rate. Qualifications/Certifications The contractor shall have electrical safety training to meet the requirements of NFPA 70e. The contractor and all of the individuals working on the project site shall have taken the OSHA Certified 10-hour construction safety course. Technicians shall demonstrate familiarity with and ready access to the current versions of the following references: National Fire Protection Association (NFPA) 85 Boiler and Combustion Systems Hazards Code VHA Boiler Plant Safety Device Testing Manual, 4th Edition Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests and calibrations, all calibrated within 1 month of the site visits. At facilities with programmable digital controls, the technicians must be capable of programming the controls and have the appropriate hardware and software for this. Safety Regulations All applicable safety regulations shall be observed during all work of this contract.

Division 01 -	General Requirements, Quality Control, Testing and Inspecting Services.
Division 23 -	Heating, Ventilating, and Air Conditioning (HVAC), Heating Boilers.
Division 42 -	Process Heating, Cooling, and Drying Equipment, Process Boilers.