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FBO DAILY - FEDBIZOPPS ISSUE OF MAY 03, 2018 FBO #6005
DOCUMENT

44 -- Boiler Safety Device Repair at Omaha VA Health Care System - Attachment

Notice Date

5/1/2018
 

Notice Type

Attachment
 

NAICS

332410 — Power Boiler and Heat Exchanger Manufacturing
 

Contracting Office

Department of Veterans Affairs;NETWORK 23 CONTRACTING OFFICE;Contract Officer;4801 Veterans Drive;St. Cloud MN 56303
 

ZIP Code

56303
 

Solicitation Number

9593
 

Response Due

5/8/2018
 

Archive Date

5/23/2018
 

Point of Contact

Melanie Stockman
 

E-Mail Address

Contracting Officer's email
(melanie.stockman@va.gov)
 

Small Business Set-Aside

N/A
 

Description

This is a REQUEST FOR INFORMATION (RFI) only. Market research is being conducted to determine the amount of qualified and capable businesses that can provide the items requested below. If you believe your firm is able to provide the items requested below, you are encouraged to respond by the due date with all of the required information indicated below in order to be considered. Due date for responses is noon local time (CST) on Tuesday, May 8, 2018. Email responses to Melanie Stockman at melanie.stockman@va.gov. All questions must be submitted in writing to the Contracting Officer in writing via email. Telephone inquiries will NOT be accepted/returned. When submitting a response to this RFI, offerors must include the following: Indicate socio-economic status Indicate any existing Government contract where item(s) may be purchased (i.e. FSS/GSA contract etc) DISCLAIMER-This RFI is issued solely for information and planning purposes only and does not constitute a solicitation. All information received in response to this RFI that is marked as proprietary will be handled accordingly. In accordance with FAR 15.201 (e), responses to this notice are not offers and cannot be accepted by the Government to form a binding contract. Responders are solely responsible for all expenses associated with responding to this RFI. NAICS: 332410 Size Standard: 750 employees SPECIFICATIONS: This report details the results of the steam generation system safety device testing conducted at the Omaha VAMC in VISN 23. Tests were conducted for the Plant Devices and for One of the Steam Boilers (Boiler No. 1). The references for the testing include: VHA Boiler Plant Safety Device Testing Manual, Third Edition VHA Directive 1810 Boiler and Boiler Plant Operations Reported are: results of each safety device tested, comments and recommendations for repairs. Boiler #2 was also inspected by a different independent contractor and it also failed for the same results. Boiler #1 and Boiler #2 are both Nebraska Boilers constructed by the same company and installed at the same time at the Omaha VA Facility in 1973. The Veterans Health Administration regards boiler safety as so important that they require as a matter of policy that Medical Center Directors be notified if a boiler safety device is found to be non-functional. Each safety device installed on the boilers or serving the whole boiler plant mitigates risk or is part of a system to mitigate risk. Safety devices and systems must be properly installed, properly calibrated, properly tested and maintained to be effective in mitigating risk. Boiler plants inherently have the potential for catastrophic failure. When a device is found to be inadequate, prompt repair is essential to ensure a safe working environment. As this is a new installation, and has not yet been turned over to the VA for operation, it is recommended that all safety devices on this boiler be installed, adjusted and approved before completion of the installation contract. The contractor shall furnish all labor, tools, parts, materials and equipment necessary to repair Boiler s #1 and #2 per the Safety and Inspection Testing VHA Directive 2008-62 & Boiler Plant Safety Device Testing Manual 3rd Edition and provide written reports and checklists for the following boilers: Boiler #1 - 1769 Ser# 2D1623 Boiler #2 - 1769 Ser# 2D1624 NOTE: Inspections were completed with the VHA Boiler Plant Safety Device Testing 3rd Edition. Since October 17th,2017 we are currently using VHA Boiler Plant Safety Device Testing 4th Edition. All repairs will have to be completed using VHA Boiler Plant Safety Device Testing 4th Edition. Listed below are the findings from the BEI report for Boiler #1 and they are the same findings found from the Independent Contractor for Boiler #2. Both Inspections were completed using VHA Boiler Plant Safety Device Testing 3rd Edition.     Plant Safety Device Test Results Sec. Equipment Safety Device Test Status Note 4.1 Condensate Tank High Water Alarm Fail Wrong Device Type 4.2 Condensate Tank Low Water Alarm Fail Wrong Device Type 4.3 Deaerator High Water Alarm Fail Set Point to high 4.6 Deaerator Steam Safety Valve (SSV) Fail Not Tested, no current NDT for tank 4.7 Deaerator SSV Following PRV Fail Not Tested, no bypass valve on reducing station 4.8 Dangerous Gas Sensors Locations and Operations Fail Existing system must be replaced-obsolete and failing 4.9 Outside Air Damper Interlock Fail No interlock and inadequate fixed openings 4.1O Control Air Pressure Interlock   Fail None Installed 4.11 Oil Pump Set Liquid Relief Valve Fail Plumb second pump to be testable Non-Recycle Steam     5.2.3 Boilers 1 and 2 Pressure Switch Fail Wrong Circuit 5.3.1 Boilers 1 and 2 Low Gas Pressure Switch Fail Set point, Wrong Circuit   Pilot Gas Valve Vent Valve     5.3.6 Boilers 1 and 2 Leak Test Fail Downstream valve not plumbed to be leak testable 5.4.1 Boilers 1 and 2 Low Oil Pressure Switch Fail Set point, Wrong Circuit     Low Atomizing Media   5.4.3 Boilers 1 and 2 Pressure Switch Fail Wrong Circuit 5.4.4 Boilers 1 and 2 Fuel Oil Valve Leak Test Fail Downstream valve not plumbed to be leak testable     Fuel Oil Valve Proof of     5.4.5 Boilers 1 and 2 Closure Switches Fail Wiring Accessibility     Low Fire Proving switch     5.5.6 Boilers 1 and 2 All Fail Set point, Drill and Pin     Forced Damper Open     5.5.7 Boilers 1 and 2 Proving Switch Fail Drill and Pin     Combustion Air Pressure     5.5.8 Boilers 1 and 2 Switch Fail Set point, Not Plumbed for Testing     Purge Airflow Proving     5.5.9 Boilers 1 and 2 Switch Fail Set point, Not Plumbed for Testing     FD Fan Motor Current     5.5.10 Boilers 1 and 2 Interlock Fail None Installed     Low Pilot Gas Pressure     5.5.11 Boilers 1 and 2 Switch Fail Set point, Wrong Circuit 5.5.12 Boilers 1 and 2 Propane Pilot Fail Match Operating Pressure to Natural Gas 5.5.13 Boilers 1 and 2 Outlet Stack Damper Fail Circuit, not testable, no switch on 2nd damper 5.5.14 Boilers 1 and 2 Furnace Pressure Interlock Fail None Installed 5.5.16 Boilers 1 and 2 Burier Tuning Fail Adjusted to eliminate CO at low fire 4.1. 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 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: This device must be replaced with the VA required Conductivity Probe type alarm. 4.2. Condensate Storage Tank Low Water Alarm Purpose: Low water level is an indication of make-up water failure or condensate return failure. Immediate action must be taken to avoid plant shutdown. Recommended type of device: Float type or conductivity probe type is acceptable. 4.3. Feedwater Deaerator High Water Alarm Purpose: Warns of high water level before overflow occurs. High water may be due to failure of inlet water control valve system. Recommended type of device: Conductivity probe type switch. Float type switches have high failure rate in this application where they are exposed to steam that causes seals to harden and prevent float movement. Comments: This alarm has a set point approximately 6-inches above the (maximum allowable) 2/3 position. During any such time, extreme caution must be taken to ensure that the correct water level in the Deaerator is maintained. 4.6. Feedwater Deaerator Steam Safety Valve Purpose: Serves as sentinel valve mounted on deaerator warning of excessive steam pressure. In combination with the safety valves on the steam pressure reducing station serving the deaerator, it protects the deaerator pressure vessel from overpressure. Recommended type of device: ASME and National Board-rated steam safety valve. Comments: This Valve was not tested at this time, due to the lack of a current NDT Status. 4.7. Safety Valve following a Steam Pressure Reducing Valve Station (PRV) Purpose: Protect downstream steam systems from overpressure due to failure of PRV. Recommended type of device: ASME and National Board-rated steam safety valve. Comments: This Valve was not tested at this time. There is no manual bypass valve currently installed at the reducing station. This valve was installed during the June plant shutdown after the inspection was completed. 4.8. Boiler Plant Building Combustible and Carbon Monoxide Monitor Purpose: Warns of presence of combustibles or carbon monoxide in the building. This can be the result of flue gas leaks in the boiler setting or breeching and improper burner adjustments. Recommended type of monitoring system: Multiple sensors located near potential sources and in locations where personnel are normally working. Industrial-type automatic system. Recommend 2 combustible sensors high in the plant, CO monitors close to the boilers near potential flue gas leak points and in personnel rooms (particularly those with exhaust systems). Comments: There are portions of a sensing system remaining in operation in the plant, however this system is obsolete, no repair parts are available, and it is failing. This system must be replaced with a modern one, with the proper capability for calibration, testing and adjustment. 4.9. Provisions for Admission of Combustion Air into the Boiler Plant Building Purpose: Air from outside the building is necessary for proper combustion in the boilers. There must be provisions for supplying this air. Recommended type of outside air admission system: The preferred system in cold climates is a heating and ventilating unit that brings in 100% outside air and heats it to at least 60 degrees F. This should be interlocked with the burners so that they can t fire unless the H&V unit is running. In milder climates, louvers in the building wall are acceptable. They should be interlocked with the burner controls so that they are proved open for the burners to fire. Comments: Either a fixed opening, or an interlocked, louvered opening for each boiler must be provided to ensure adequate air supply to the boilers. These openings should total at least 1.5-times the air inlet area of each boiler. 4.10. Control Air Pressure Interlock (Compressed Air) Purpose: Shuts down boiler if pneumatic control system pressure is below normal. This can result from compressed air system failures. Recommended type of interlock: UL listed mercury or sealed snap-acting switch. Comments: The level control system for the Deaerator requires compressed air for operation. A Low Pressure Switch and Alarm should be installed to warn the plant operators of a loss of compressed air. 4.11. Oil Liquid Relief Valve Pump Set Purpose: Protect oil pumping system from overpressure. Overpressure may be due to failure of back pressure regulator (pressure control valve) or starting the pump with the discharge valves closed. Recommended type of device: Liquid relief valve sized for maximum pump capacity and designed to shut tight. Comments: Only one of the two pumps is plumbed for testing. There is no view port in place on either valve discharge piping. The "deadhead" pressure was limited to 170 psig, and re-seats at about 165 psig. 5.2.3. High Steam Pressure Limit Switch (Non-recycling) Purpose: Causes shut down of burner if boiler steam pressure exceeds set point. Does not allow burner to automatically restart when pressure decreases. Recommended type of pressure switch: Switch must be UL and FM approved for this service. Comments: The switch functions correctly, but is wired into the "Run" circuit for the Burner Management System. There is no Safety Shutdown, nor is there any annunciation of the outage. 5.3.1. Low Pressure Gas Fuel Cutoff Switch (LPFCS) Purpose: Shuts down the burner if the fuel pressure drops to the set point. This can be the result of a pressure regulator failure or clogged fuel filter. Recommended type of pressure switch: UL and FM approved for gas fuel service. Comments: Cannot set to correct (80%) set point. The gas pressure regulator exhibits excessive "dip", to a pressure below the allowable set point. Also, this device is wired in the "Run" circuit for the Burner Management System, and generates a "Normal" shutdown, with no annunciation. It must be configured as a Running Interlock, with proper annunciation. Comments: Cannot set to correct (80%) set point. The gas pressure regulator exhibits excessive "dip", to a pressure below the allowable set point. Also, this device is wired in the "Run" circuit for the Burner Management System, and generates a "Normal" shutdown, with no annunciation. It must be configured as a Running Interlock, with proper annunciation. 5.3.6. Automatic Pilot Gas Shutoff Valves Leak Test Purpose: Open-shut, normally closed solenoid valves that operate to start and stop the fuel flow to the pilot burner. It is essential to have two valves in series with an automatic vent in between and with leak test connections. Recommended type of fuel valves: UL and FM approved for the fuel service. Comments: The upstream valve did not leak. The downstream valve is not testable as currently plumbed. 5.4.1. Low Pressure Oil Fuel Cutoff Switch (LPFCS) Purpose: Shuts down the burner if the fuel pressure decreases to the set point of the switch. The pressure decrease can be the result of a pressure regulator failure or clogged filter. Recommended type of pressure switch: UL and FM approved for fuel service. Comments: The set point is too low. This switch is in the "Run" circuit. It must be wired as a Running Interlock, generate a Safety Shutdown, and produce the proper annunciation. 5.4.3. Low Oil Atomizing Media Pressure Switch (LAMPS) Purpose: Shuts down the burner if the atomizing media (steam or compressed air) pressure at the entrance to the atomizing valve train is insufficient for proper atomization of the fuel oil. Recommended type of pressure switch: UL listed for burner service. Comments: The set point is adequate, for the current header pressure in normal operation. This switch is in the "Run" circuit. It must be wired as a Running Interlock, generate a Safety Shutdown, and produce the proper annunciation. 5.4.4. Automatic Oil Fuel Shutoff Valves Leak Test Purpose: Open-shut, normally closed valves that operate to start and stop the fuel flow to the main burner. Valves must shut tightly to prevent unburned fuel from collecting in the boiler when the burner is not firing. It is essential to have two valves in series and with leak test connections. Recommended type of fuel valves: UL and FM approved for fuel service. Comments: No leak was detected in the upstream valve. The downstream valve is not plumbed to be testable for leakage. 5.4.5. Automatic Oil Fuel Shutoff Valves Proof of Closure (POC) Purpose: Proof that the valves are closed is provided by electrical switches in the valves that sense the position of the valves, open or closed. The switches are in an electrical circuit to the burner management control system. The valves must be proven closed before the burner management control allows the ignition sequence to start. Recommended type of POC switch: The switch is furnished with UL and FM approved automatic fuel safety shut off valves. Comments: The POC switches functioned correctly, but the wiring is not readily accessible for testing. This wiring must be routed through an appropriate junction- which can be readily accessed for the required semiannual testing. 5.5.6. Low-Fire Proving Switch Purpose: Signals the burner management programmer that the fuel and air flow are at a low fire position prior to ignition of pilot burner. Recommended type of control: Sealed snap-acting switch actuated by lever contacting fuel valve control arm. See VA Master Specifications for alternatives. Comments: This switch breaks with a 18% Firing Rate set point. This must be corrected to no more than 5%. Ensure that all possible slippage points in the mechanism are adequately secured (drilled and pinned), such that the switch is actually proving the valve/damper position for light off. 5.5.7. Forced Draft Damper Wide-Open Pre-Purge Proving Switch Purpose: Signals the burner management programmer that the forced draft damper is properly positioned to achieve full flow of pre-purge air. Recommended type of control: Position switch actuated by lever arm attached to damper. Comments: This switch has a correct set point, and is wired to the controller, correctly. All possible slippage points in the mechanism must be adequately secured (drilled and pinned), such that this switch is actually proving the damper position. 5.5.8. Combustion Air Pressure Switch Purpose: Signals the burner management programmer that there is combustion air pressure that will cause airflow. Recommended type of switch: UL and FM approved differential pressure switch. Comments: The set point for this device is too low to provide any protection. Additionally, the range of signal (7.4 to 0.9) prevents providing any protection at other than low fire. The possibility of different tap points into the fan housing (to achieve a "flatter" signal) should be investigated. Consider implementing a tachometer feedback system to monitor fan speed (independent of the VFD). The existing plumbing for this switch is not configured for testing. Install the appropriate test ports and valves, per the manual, and make the isolation valves Lockable Only in the Open Position- and keep locked except when testing. 5.5.9. Pre-Purge Airflow Proving Switch Purpose: Signals the burner management programmer that there is sufficient pre-purge air flow. Recommended type of switch: UL and FM approved differential pressure switch. The switch must be piped so that the differential pressure is sensed from the boiler furnace to the boiler outlet. There must be no movable pressure restriction, such as a damper or burner register, between the sensing points. Comments: The set point is below the required (80%) minimum value. The switch is not plumbed to allow proper testing. Plumb as outlined in the Safety Device Testing Manual, with the required Lock Only in the Open Position valves and test ports. 5.5.10. Forced Draft Motor Interlock Purpose: Signals to burner management programmer that proper power supply is flowing to the forced draft fan motor. Recommended type of interlock: Current relay on all power phases. Auxiliary contact on motor starter is not acceptable because it does not prove that power is flowing to the motor. Comments: Install the correct components, and wire as a running interlock- with the correct annunciation. 5.5.11. Minimum Pilot Flame Test and Low Pilot Gas Pressure Switch Purpose: The pilot gas pressure must be sufficient to provide a pilot flame sufficiently large to quickly ignite the main flame. Recommended type of interlock: UL and FM approved pressure switch. Comments: The propane pilot system should be evaluated, and the two pilot fuels configured to operate at the same pressure. This switch must then be set to 80% (minimum) of that regulated pressure. Also, this device is wired in the "Run" circuit for the Burner Management System, and generates a "Normal" shutdown, with no annunciation. It must be configured as a Running Interlock, with proper annunciation. 5.5.12. Propane Pilot Backup System Purpose: Alternate pilot burner fuel for igniting main oil burner when natural gas is not available for the pilot burner (igniter). Recommended type of system: Portable tanks located outside the building connected to pilot burners with permanent piping. Comments: See notation at Low Pilot Gas Pressure (5.5.11.) 5.5.13. Outlet Stack Damper Wide-Open Pre-Purge Proving Switch Purpose: Signals the burner management programmer that the outlet damper is properly positioned to achieve full flow of pre-purge air. Recommended type of control: Position switch actuated by lever arm attached to damper. Comments: The outlet damper on the boiler appears to be stuck in the open position, with the switch blocked into place by the damper arm. This switch appears to be wired in series with the Low Water Cutout (in the "Run" circuit.). There is no annunciation or safety shutdown- even if the switch functions. This damper should be either made operable/testable, permanently fixed open (by welding), or removed. Additionally, there is another stack damper on the roof. That damper has had all pneumatic lines cut, as well as the wiring to the proof-of-open switch. This damper should be removed completely, or welded open. 5.5.14. Furnace Pressure Interlock Purpose: Shuts down boiler if furnace pressure is higher than normal. Recommended type of interlock: UL listed mercury or sealed snap-acting switch. Comments: Unless all outlet dampers are either removed or welded open, a furnace pressure interlock must be provided. It must be configured as a Running Interlock, with proper annunciation. 5.5.16 Burner Tuning The burner was found, at low fire, to be operating with more than 16% O2 in the exhaust. This represents over 300% Excess Air (or, over 4-times the air required to burn the fuel, perfectly.) This resulted in a Carbon Monoxide (CO) level in excess of 600 PPM. VA regulations require all burners to be operating at or below 200 PPM at all conditions. The Air Fuel Ratio was adjusted to bring the excess O2 at low fire below 10% (excess air below 100%). This eliminated all but a trace (4 PPM) of CO generation. Final Report: A final report shall be provided to the COR within fourteen calendar days of work being performed. All reports shall be presented in a format acceptable to the Joint Commission and include the following: An individual listing of all devices/system inspected and tested. This listing should also include the location. Result of any testing performed (i.e. Pass/Fail) Listing of all deficiencies or repairs needed Cross reference to The Joint Commission requirements
 

Web Link

FBO.gov Permalink
(https://www.fbo.gov/spg/VA/SCVAMC656/SCVAMC656/9593/listing.html)
 

Document(s)

Attachment
 

File Name: 9593 9593.docx (https://www.vendorportal.ecms.va.gov/FBODocumentServer/DocumentServer.aspx?DocumentId=4269143&FileName=9593-000.docx)

Link: https://www.vendorportal.ecms.va.gov/FBODocumentServer/DocumentServer.aspx?DocumentId=4269143&FileName=9593-000.docx

 

Note: If links are broken, refer to Point of Contact above or contact the FBO Help Desk at 877-472-3779.
 

Place of Performance

Address: US Department of Veterans Affairs;Nebraska Western Iowa VA Health Care System;4101 Woolworth Avenue;Omaha Nebraska

Zip Code: 68105
 

Record

SN04907146-W 20180503/180501231100-06165eb8b06b685b672d36c1aaaf99b1 (fbodaily.com)
 

Source

FedBizOpps Link to This Notice
(may not be valid after Archive Date)

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