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36C25919Q0533 RFI Boiler Safety Testing/Inspection Services Oklahoma City VA Medical Center 921 NE 13th. Street Oklahoma City, Ok 73104-5007 Boiler Safety Testing/Inspection Services BRIEF SCOPE OF WO... 36C25919Q0533 RFI Boiler Safety Testing/Inspection Services Oklahoma City VA Medical Center 921 NE 13th. Street Oklahoma City, Ok 73104-5007 Boiler Safety Testing/Inspection Services BRIEF SCOPE OF WORK (This is for information only) The contractor shall provide Boiler Safety Testing/Inspection/services and Feedwater Deaerator Tank inspection/services in accordance with the terms and conditions stated within this Statement of Work (SOW). All work shall be coordinated with the Oklahoma City VA Health Care System s COR. INSPECTION SERVICES: General: Contractor shall perform combustion analysis and tuning, safety device testing, and boiler inspections on three (3) fire tube boilers as specified within all updated manufacturer specifications and requirements and provide inspections of two (2) feedwater deaerator tanks. Technicians shall have adequate experience, training, and applicable licensing, to perform required preventative maintenance. Contractor shall provide all labor, materials, and equipment necessary for protection of VAMC personnel, furnishings, equipment and buildings from damage, and shall replace or repair any damage due to work performed under this contract equal to its original construction and finish. Contractor must have adequate insurance protection against negligent work and other forms of liability and follow all federal, state, local, and VA Regulations related to this requirement. Upon request, contractor shall provide proof of certification attesting that all gauging and measurement equipment used has been currently calibrated either according to the manufacturer s specifications or a standard traceable to the National Bureau of Standards. Introduction: (VA) Oklahoma City medical center has a central high-pressure boiler plant to provide steam for heating and air conditioning, domestic hot water, sterilizing services, and laundry equipment. The VA has a requirement for: Annual internal and external inspections on three (3) (listed below) high pressure (over 15 psig) steam boilers A semi-annual requirement to perform burner and instrument inspecting, testing, calibrating burners and controls, and testing of all safety devices on the three (3) (listed below) high pressure (over 15 psig) steam boilers and two (2) (listed below) deaerator tanks A semi-annual internal/external inspection of two (2) (listed below) feedwater deaerator tanks. A 6 year inspection and magnetic particle testing of welds of pressure vessel interior of the feedwater deaerator tank (listed below). To be completed in base year of contract only. List of Equipment: Boiler #1 manufactured by: Cleaver-Brooks, Model number 4WI-200-600-200 SN: T-1246-1-2 Boiler #2 manufactured by: Cleaver-Brooks, Model number 4WI-200-600-200 SN: T-1246-1-3 Boiler #3 manufactured by: Cleaver-Brooks, Model number 4WI-200-600-200 SN: T-1246-1-1 Feedwater Deaerator Tank: manufactured by: Wheeler Tank Mfg, Model number: 12309, SN: 07387 Condensate Tank: manufactured by: Wheeler Tank Mfg, Model number 12291, SN: 07384 Qualifications of Testing Personnel: Boiler Inspectors shall be a Qualified Professional Inspector . Proof of qualification shall be provided to the COR upon request. They shall be versed with and have access to the current versions of reference materials defined below. A Qualified Professional Inspector is defined as one who possess one or combination of below requirements: A boiler inspector who has a valid commission from the National Board of Boiler and Pressure Vessel Inspectors (NB). A boiler inspector who has qualified by passing a written examination under the laws, rules and regulations of a jurisdiction of a state. A boiler inspector who is regularly employed as a boiler inspector by a jurisdiction which has adopted and administers one or more sections of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code as a legal requirement, and has a representative serving as a member of the ASME Conference Committee. A boiler inspector who is regularly employed by an insurance company which has been licensed or registered by the appropriate authority of a State of the United States to write boiler or pressure vessel insurance. Combustion Analysis and Safety Device Testing personnel shall be qualified for boiler plant burner, control and instrumentation testing. Proof of qualification shall be provided to the COR upon request. Qualifications include completing at least a one-year trade school and five years successful experience in this field. The experience shall be largely with institutional and industrial boiler plants similar in design to the VAMC plants. Reference Materials are comprised of the latest versions of the below, plus any other materials/manufacture reference materials needed to complete all contract requirements: ASME Boiler and Pressure Vessel Code ASME B31.1, Power Piping Code ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers ANSI/NB-23, National Board Inspection Code NFPA 85, Boiler and Combustion Systems Hazards Code VHA Boiler Plant Safety Device Testing Manual, 5th Ed. Utilize National Board Forms NB-6 and NB-7 NATIONAL BOARD INSPECTION CODE, Part RB, In-service Inspection of Pressure-Retaining Items, The testing personnel shall be equipped with portable electronic flue gas analyzers and all other test instruments necessary for the required tests and calibrations, all currently calibrated either according to the manufacturer s specifications or a standard traceable to the National Bureau of Standards. Inspection and Testing Requirements: At least two weeks notice to the Contracting Officer s Representative (COR) is required prior to an inspection. 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 representative is available on site to monitor the work. The contractor is required to prepare the boilers for inspection by opening, cleaning watersides and firesides, and preparing the boiler for inspection following National Board, ASME, Veterans Administration and industry requirements/guidelines. The contractor will also be required to restore the boiler for service. Each burner and the burner control, monitoring and safety interlock systems shall be inspected and tested and adjusted as necessary. VA will have the boilers that are to be serviced prepared for the test personnel 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; all boiler, burner and fuel train pressure gages and thermometers calibrated; fuel meters in accurate operation (pressure/temperature correction factors provided, if applicable); boiler steam flow, stack temperature and flue gas oxygen instruments operating. VA will comply with any other requirements of the test personnel that are considered reasonable by VA and have been presented in writing at least two weeks prior to the scheduled testing. The COR or his/her representative will observe the work. Combustion Analysis/Tuning and Safety Device Testing summary of requirements: The inspections, testing, and adjustments shall comply with: The recommendations and requirements of VHA Boiler Plant Safety Devices Testing Manual. The written recommendations of the equipment manufacturers. The requirements and recommendations of NFPA 85 Boiler and Combustion Systems Hazard Code including applicable appendices. Burner performance requirements in this document. A summary of the work is as follows: Review boiler plant log sheets and alarm and trouble reports. Review records that show combustion performance (flue gas oxygen). Perform overall visual inspection of systems. Verify that systems comply with referenced codes and VA requirements stated in this contract. Test the operation and set points of all burner/boiler safety interlock devices. Refer to list below. Record the settings and compare with required settings. 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, NOx where applicable), fuel train pressures, atomizing train pressures, burner pressures, stack temperatures, boiler steam output. Compare the combustion performance data with VA requirements (see below) 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. If further work, such as repairs or burner modifications, is needed to correct any problems, provide recommendations to the COR. 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, and code approval. Calibrate all instruments that are not within manufacturer s specifications for accuracy. Immediately inform COR of any recommended repairs, modifications, or safety related problems. List of interlocks and safety devices to be inspected and tested on each boiler/burner: High and low fuel pressure switches (gas/oil). Low fuel oil atomizing media (steam/compressed air) pressure switches. Low differential pressure switch, atomizing media/fuel oil (if provided by burner manufacturer). Oil burner position switch (if provided by burner manufacturer). Fuel safety shut off valves proof of closure (over-travel/valve seal switch). Leak test fuel safety shut off valves (main and pilot burners) (leakage into burner). Leak test gas fuel vent valves. Forced draft motor interlock. Forced draft damper wide-open interlock for purge. Outlet damper open interlock for purge (if outlet damper provided). Purge airflow interlock. Purge timing. Ignition timing. Low fire position interlock, if present. Combustion airflow interlock. Main flame out time to close fuel valves. Ignition flame out burner shutdown. Scanner not sensing ignition spark (ultraviolet scanner). Scanner not sensing hot refractory (infrared scanner). 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 NOx (Nitrous Oxide): _____ (Refer to original burner specification). 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). 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). No visible smoke, except on heavy oil fuel maximum opacity is 20%. Comply with local emissions regulations. 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. Boiler Inspections summary of requirements: Annual internal and external inspections are required for each boiler. Internal inspections of the feed water de-aerator pressure vessel are required every six years or more frequently if welding repairs have been performed. Contractor shall coordinate with COR to schedule an inspection. The Contractor shall ensure coordination and scheduling of any inspection is conducted at least two weeks prior to the intended date of an inspection. Inspections must be scheduled for periods when the VA determines that the boilers that will be inspected internally will not be needed for steam supply and when the COR or his/her designate is available on site to monitor the inspections. To maintain steam service, typically only one boiler at a time will be scheduled for internal inspections per inspection visit. Thus, multiple visits will be necessary every year to inspect all the boilers internally. Feed water de-aerator pressure vessel inspections must be scheduled during periods of low steam demand. Coordinate the inspection schedule with the COR so that VAMC can have personnel available to monitor the inspections. Boilers scheduled for internal inspection will be prepared by the contractor prior to the scheduled arrival of the Qualified Professional Inspector. This includes cooling the boilers to near ambient temperature and having all man ways, hand holes and furnace access doors open; the boilers cleaned of loose materials waterside and fireside; electrical lock-out, tag-out in place; connecting piping isolated; proper illumination provided; compliance with confined space access requirements including having safety personnel present in the boiler plant. Similar advance preparations will be made to the feed water de-aerator when it is scheduled for internal inspection. VAMC will comply with any other requirements of the contractor that are considered reasonable by VAMC and have been presented in writing at least two weeks prior to the scheduled inspection. The boiler and feed water de-aerator inspections shall comply with the guidelines in the current issue of the NATIONAL BOARD INSPECTION CODE, Part RB, In-service Inspection of Pressure-Retaining Items, and ASME Boiler and Pressure Vessel Code, Section VI or VII as applicable. In addition to those guidelines, the inspections shall comply with all requirements listed in statement of work. The inspector must completely enter the internal spaces of the boiler or feed water de-aerator and visually inspect all internal surfaces that can be accessed. Methods for testing safety devices shall comply with VHA Boiler Plant Safety Device Testing Manual, 2nd Edition. Summary of the minimum inspection requirements for boilers: Review the boiler history including: operating conditions, date of last inspection, current inspection certificate, ASME stamping on boiler, National Board registration number, history of repairs and modifications. Review boiler logs, water test reports, and reports on tests performed on the burner controls and interlocks. Assess the external parts of the boilers and boiler accessories and piping and valves for safety, accessibility, proper maintenance and operation, cleanliness, and compliance with codes. Inspect for evidence of leakage of combustion gases or fluids, externally and internally, including all gaskets. Inspect foundations for signs of stress such as cracking or movement. Inspect boilers externally and internally for defects including bulges, blisters, cracks, wasted or eroded material, warping, general corrosion, grooving and pitting, damaged insulation. Inspect all accessible internal surfaces for waterside and fireside deposits, including scaling, sediment, debris, carbon deposits. Examine all stays and stayed plates. Inspect gas side baffles. Inspect internal drum surfaces and steam separating internals. Inspect tubes, tube ends and tube alignment. Check for sagging tubes. Set combustions for boilers number one, two, and three, on natural gas and number two oil. Test all safety devices and perform annually required accumulation tests on boilers one, two and three. Verify that all nozzles of internal piping such as feed water admission and bottom blow off collection are clear with no obstructions. Inspect seating surfaces of man ways and hand holes. Check that boiler structure is plumb and level with no excessive deformations. Check for missing items such as bolts and nuts. Examine all valve and pipe connections to the pressure vessel. Inspect refractory including burner throat, expansion joint, bull ring, furnace seals, furnace walls and floor. Verify proper alignment of burner assembly. Inspect furnace for evidence of flame impingement. Test operation of water level gage glass. Perform mechanical and electrical inspection of disassembled low water cutouts (disassembly by VA). After reinstallation, test operation to the extent possible. Test low water cutouts on hot boilers by lowering water level gradually. Verify that steam pressure gage is properly calibrated. Test operation of high steam pressure cutouts on hot boilers by raising steam pressure. Inspect safety valve installations and verify that the valves have proper capacity and set pressure and valves, drains and vents are properly installed. Verify that valve locking seals are not broken. On boilers that are hot, perform an operation test under pressure to confirm operation at proper set pressures. Operate boiler with burner at high fire to verify adequate steam flow capacity of the safety valves ( accumulation test ). Inspect piping connected to the boilers for evidence of leakage, provision for expansion, provision of adequate support, proper alignment, and evidence of detrimental conditions. Inspect piping to the water column, low water cutoffs and alarms, gage glass. Verify that interior of piping is clear of obstructions. Inspect valves on boiler feed water, blow down, drain and steam systems. Perform service and Calibration of boiler instrumentation and controls. Provide recommendations for non-destructive testing when the inspections indicate that this is necessary to assure continued safety and reliability under current operating conditions. Summary of the minimum inspection requirements for Feed water Deaerators: Review the feed water de-aerator history including: operating conditions, date of last inspection, current inspection certificate, ASME stamping, National Board registration number, materials of construction, extent of post weld heat treatment, history of repairs and modifications. Assess the external parts of the feed water de-aerator and accessories and piping for safety, accessibility, cleanliness, proper operation, and compliance with codes. Test hazardous gas monitoring system. Inspect for evidence of leakage. Note feed water de-aerator pressure gage and thermometer readings and verify gage and thermometer accuracy. Inspect safety valve installation and verify that the valves have proper set pressure and capacity and are properly installed. Perform an operation test under pressure to confirm operation at proper set pressures. Verify that the de-aerator can safety withstand the test pressure prior to testing the valve(s) in-situ. Verify that non-condensable gas vent line is open and proper orifice is provided to permit venting of gases. Inspect support structures for proper integrity and allowance for thermal expansion. Internal Inspections Visually inspect all visible pressure vessel surfaces for corrosion, material thinning, deposits, and weld cracking. Inspect spray nozzles and trays. DOCUMENTATION: Contractor shall provide this VA HCS with individual service reports, which describes the inspection services performed on the equipment. 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 with four columns: 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, 5th Edition. The third labeled Deficiencies-Recommendations The fourth column labeled corrective actions list any corrective actions taken during the inspection. The next 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. Plus the section must reference the correct Master Specification and Standard Detail for that device. See sample below: 5.1. Condensate Storage Tank 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. 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 time period. Recommended type of device: Conductivity probe type switch. Float typeswitches have high failure rate in this application where they are exposed to flash steam that causes seals to harden and prevent float movement. VA Master Specification section: 23 50 11 (old 15625). www.va.gov/facmgt/standard/ VA Standard Detail: SD232111-05.pdf www.va.gov/facmgt/standard/ Failure rate of float types: 48% (BEI study of VA boiler plants). Make and Model: Mercoid Float Did it function properly: No Category & Action Time Limit: Upon Failure or Within 5 Years 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. Furnish report within one week of each facility inspection in Microsoft Word format by email to the COTR and to the VA Headquarters office designated. Provide hard copies of data sheets and flue gas analyzer strip printouts to the COTR within one week of visit. All safety-related deficiencies shall be immediately reported to the COTR, Boiler Plant Supervisor and/or Chief Engineer during the inspection visit. Location of performance VA Eastern Oklahoma Health Care System 921 NE 13th. Street Oklahoma City, OK 73104-5007 IMPORTANTR NOTE: This RFI (Request for Information) is for information only; no award will be made from this RFI. Please communicate via e-mail to Mitchael.Purdom@va.gov by COB August 13, 2019 as to your company s ability to perform service per this brief Scope of Work. If interested please provide the following: Please state your company s business size Please provide DUNS number If you have a FSS/GSA contract that includes this service Provide FSS/GSA contract number if applicable