J045--Boiler Calibrations and Safety Device Testing Bedford VA Medical Center

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VA Bedford HCS
STATEMENT OF WORK

Boiler Plant Burners, Controls, Instruments, and Data Management
Inspection, Safety Device Testing and Calibration

General Scope of Work
1. Semi-Annual Calibrations of Boiler Plant Controls and Instrumentation
2. Semi-Annual Combustion Testing of Boilers
3. Semi-annual Safety Device Testing
4. Semi-Annual Calibrations of Boiler Plant Controls and Instrumentation.

A. OVERVIEW
1. Contractor shall provide all labor, tools, testing equipment and supplies required for semi-annual calibrations of Boiler plant controls and instrumentation for three boilers located in Building #22, two boilers in Building #70, and other plant equipment.

2. Contractor shall ensure all work is in accordance with the procedures outlined in VHA Boiler and Associated Plant Safety Device Testing Manual Eighth Edition, or the most current edition.

3. Contractor must have a laptop computer and required software to plug into and back-up all settings in the PCCIII controls and provide a back-up flash drive to Plant Supervisor.

4. Contractor will not be accessing any sensitive VA Information Systems, these are boiler controls only. Control devices will include but are not limited to the following: Preferred Instruments, CB Hawk, Foxboro, Yokogawa, Siemens, and Johnson Controls.

5. Contractor shall also supply to customer, calibration reports for each piece of equipment, indicating date, settings, pass/fail, technical data, and name of technician performing calibrations.

6. Contractor will provide a list of line items that require parts/replacement and the costs required to repair/replace those items. Additional work beyond the scope of this contract, requires approval from the Contracting Officer. See attached list of controls and instrumentation to be calibrated.

B. CALIBRATION
The following is a list of devices that will require calibration:

1. Plant Master PCIII
Outside air temp
Plant steam flow
Distribution steam flow
Plant demand
Steam header press Hi/Lo and alarms
Oil pressure transmitter and alarms
Propane pilot gas transmitter and alarms
Main gas pressure transmitter and alarms
Control air pressure transmitter and alarms
Low main gas pressure alarm
High main gas pressure alarm
Explosive gas and carbon monoxide detection system
2. DA PCIII
High oil header press alarm
Low oil header press alarm
DA steam PSI
DA temp
DA level
High DA level alarm
Low DA level alarm
Cond PCIII: Condensate tank level
Condensate tank high level alarm
Condensate tank low level alarm
Condensate tank temp
Condensate tank make-up valve

3. Hawk Controllers Boilers, 1, 2, and 3
Plant demand
Boiler demand
Firing rate
Steam flow
Economizer flue temp-in

4. #1 and #2 Draft PCIII
Oxygen transmitter
Damper %
Outlet temp
Jackshaft position
Efficiency

5. #1 and #2 Fuel Flow PCIII
Boiler gas flow
Boiler oil flow
Flue gas temp monitor calibration
Flue gas temp High and Low temp alarms

6. #1, #2, and #3 Feedwater Pump Variable Frequency Drive Units

Note; there is a new DA Tank installed as of October 2024. Testing will reflect the new parameters required on the new system.

C. SEMI-ANNUAL COMBUSTION TESTING OF BOILERS
1. Contractor will provide all labor and materials required to perform burner calibration on three (3) Cleaver Brooks CB700LE boilers. Each burner assembly will be inspected and adjusted to manufacturer s settings. Each boiler will be calibrated on gas and oil firing twice a year, approximately 6 months apart, as scheduled by the Maintenance and Operations Supervisor.

2. Contractor will provide burner calibration printouts for each pin on the gas and oil cams 20 on CB Hawk for all three boilers. Settings will be as close and safe as possible for max input for gas and oil firing at high fire as per the inputs listed on the boiler plate.

3. Contractor will calibrate the burners and not exceed the requirements of this facilities permit for emissions. Contractor will perform a smoke test on boilers.

4. Contractor is responsible for providing all tools and specialized equipment required to perform the work.

D. SAFETY DEVICE TESTING
1. Contractor shall provide all labor, tools, and all testing equipment required to perform Semi-Annual Safety Device testing on three (3) Cleaver Brooks LE fire-tube boilers, and other plant equipment as identified in the VHA Boiler and Associated Plant Safety Device Testing Manual, Eighth Edition, or current edition. Testing shall be in accordance with the procedures outlined in VHA Boiler and Associated Plant Safety Device Testing Manual Eighth Edition or the most current edition. Testing manual will be available upon request.

2. Contractor shall provide a detailed report including a picture of each device as installed on the system and all other information required by the VHA Boiler and Associated Plant Safety Device Testing Manual, Eighth Edition or current edition shall be scheduled with the Boiler Plant Supervisor.

3. Contractor will furnish all tools, parts, and specialized equipment to accomplish this.

4. Devices tested shall include, but not be limited to the list below as changes may be made to the VHA Boiler and Associated Plant Safety Device Testing Manual Eighth Edition.
High-steam pressure cut-out (recycle), High-steam pressure cut-out (non-recycle).
Steam safety valves (raise boiler pressure until valves lift and reset).
Check gas vent for leaks.
High-gas fuel pressure cut-off.
Low-gas fuel pressure cut-off.
Gas fuel safety shut off valves proof of closure.
Leak test fuel oil safety shut off valves.
Check operation of Liquid Propane Gas pilot.
Low-pilot gas pressure cut-out.
Forced draft fan motor interlock.
Forced draft fan damper wide open for purge.
Boiler outlet damper wide open for purge.
Purge air flow interlock.
Timing for pre-purge.
Timing for post-purge.
Igniter timing.
Leak test gas fuel safety shut off valves.
High-fuel oil temperature cut-off (heated fuel, N/A).
Low-fuel oil temperature cut-off (heated fuel, N/A).
Low-atomizing air pressure for fuel oil (HH) Low fire position interlock.
Combustion air interlocks.
Main flame out; i.e., time to close valves.
Ignition flame out; i.e., time to close valves.
Minimum igniter flame test.
Scanner not sensing ignition spark.
Low-oxygen alarm and/or cut-out.
Pre-purge setting of flue gas recirculation damper.
Interlock of building outside air damper with burner control.
High-fuel oil pressure cut-off.
Low fuel oil pressure cut-off.
DA tank high- and low-level alarms.
DA tank overflow device.
DA tank high pressure alarm.
DA tank safety valve.
Condensate Receiver tank high- and low-level alarms.
Economizer safety valve.

E. BUILDING #70 BOILER MAINTENANCE, INSPECTION AND TUNE UP
1. Contactor shall open the boilers water and firesides, for 2 HB Smith, 14 section, cast-iron, low-pressure boilers.
2. Contractor shall prepare the boiler and its auxiliary devices for an internal inspection by a Contractor supplied ASME Board Certified Inspector.
3. Contractor will perform all required safety device testing per the VHA Boiler and Associated Plant Safety Device Testing Manual Eighth Edition.
4. Upon completion of the inspection, if any repairs are required at that time, a written quote will be provided to the facility. No repairs will be made unless approved separately by the Contracting Officer.
5. Once the boiler is inspected and/or repaired, the Contractor will put the boiler back together, fill with water, fire up the unit, and perform an operational and combustion test on oil and gas, making any adjustments needed for proper operation.
6. Contractor will be responsible for any gaskets and seals that may be required to put boiler back together after inspection such as inspection port gaskets, low water cutout gaskets.
7. Contractor is responsible to provide any specialized tools or equipment to perform the work.
8. Contractor will provide a service report and all combustion printouts to the Contracting Officers Representative (COR) upon completion of work.
9. Contractor will sign in/out at the Main Boiler Plant, Building #22, and will be escorted to the work site.
10. No changes to this Statement of Work can be made without prior written approval of the Contacting Officer

Attachments:
VHA Boiler and Associated Plant Safety Device Testing Manual Eighth Edition
VHA Directive 1810, Boiler and Boiler Plant Operations, January 4, 2023

Attachments/Links