Loren Data's SAM Daily™

FBO DAILY ISSUE OF JULY 09, 2009 FBO #2782
MODIFICATION

Y -- RECOVERY Y--Recovery - Boiler Plant Deficiencies

Notice Date

7/7/2009
 

Notice Type

Modification/Amendment
 

NAICS

238220 — Plumbing, Heating, and Air-Conditioning Contractors
 

Contracting Office

Department of Veterans Affairs, Wilmington VAMROC, Department of Veterans Affairs Medical and Regional Office Center, Department of Veterans Affairs;Acquisition (460);1601 Kirkwood Hwy.;Wilmington DE 19805
 

ZIP Code

19805
 

Solicitation Number

VA-244-09-RA-0297
 

Response Due

7/21/2009
 

Archive Date

9/19/2009
 

Point of Contact

Chuck PeckContracting Officer<br />
 

E-Mail Address

Contracting Specialist
(Charles.peck@va.gov)
 

Small Business Set-Aside

Service-Disabled Veteran-Owned
 

Description

RECOVERY ACT: The Wilmington VA Medical Center, 1601 Kirkwood Highway, Wilmington, DE intends to issue a construction contract. The contractor will supply all materials, trained labor, tools and equipment needed to correct safety and reliability deficiencies in four boilers and boiler plant auxiliary equipment. These deficiencies were identified in an inspection of the boiler plant by ACCE Facilities Management in February 2009. See attached Statement of Work below. The ACCE Facilities Management Testing Report Performed in February 2009 and VHA Boiler Plant Safety Device Testing Manual, Third Edition will be attached to the solicitation that will be posted in approximately two weeks. The North American Industry Classification System (NAICS) code is 238220. The U.S. Small Business Administration Size Standard is $14,000,000.00. The solicitation issue date will be approximately July 21, 2009 with an approximate response date of August 21, 2009. The project magnitude is between $250,000.00 and $500,000.00 The solicitation will result in a Firm-Fixed Priced Contract. Contact Mr. Chuck Peck (Contracting Officer) at Charles.Peck@va.gov or (302) 994-2511 x 7526 if you have any questions. STATEMENT OF WORK Project No. 460-09-505 Project Title: Boiler Plant Deficiencies As of June 16, 2009 This project addresses Correction of Safety and Reliability Deficiencies in Boilers and Boiler Plant Auxiliary Equipment VAMC Wilmington, DE. These work items were identified in an inspection of the boiler plant by ACCE Facilities Management in February 2009. General Requirements: Contractor to provide all materials, trained labor, tools and equipment to complete the work as outlined in the statement of work. Work on burners and control systems must be performed by skilled boiler/burner controls service technicians. Upon completion of each work item, test operation and provide data sheet showing test results including set point and operating point. All testing procedures must comply with VHA Boiler Plant Safety Device Testing Manual, 3rd Edition. Scope of work: Boiler Nos. 1, 2, 3 and 4 (Work common to all boilers): 1.The low water cutoffs (LWCO) and the auxiliary low water cutoffs (ALWCO) share common lower (water) connections to the boiler steam drums. This is hazardous because the single connections could become clogged and make both devices inoperative. Also, there are manual valves in the water connections to the steam drums that are not locked open. (Safety Testing Evaluation Report Par. 5.1.2, 7.1.2) a.Disconnect the lower (water) connections on the ALWCO from the LWCO (water column) lower (water) piping. The upper (steam) connections to the steam drum can remain unchanged. b.Connect the ALWCO water piping to the pipe connections on the steam drums that are now connected to the Copes feedwater regulator thermostatic tubes. Verify that these steam drum water connections are 1 pipe size minimum (ASME Code requirement). Note that the Copes regulators and thermostatic tubes will be removed in the new controls project. c.All changes in piping direction must be done with cross fittings. d.Lock the manual valves in the steam and water piping between the LWCO, ALWCO and the steam drums in the open position. e.The work on Boilers 2 and 3 will require rerouting the existing 2 feedwater lines at the fronts of the boilers. 2.The auxiliary low water cutoffs (ALWCO) did not activate when the water level was within the limits of the gage glasses. The set points of the low water alarms (LWA), low water cutoffs (LWCO), and auxiliary low water cutoffs (ALWCO) should be adjusted so that there is water visible in the sight glasses when the ALWCO is actuated. (5.1.1, 5.1.2, 5.1.3, 7.1.1, 7.1.2, 7.1.3, 9.1.1, 9.1.2) a.Recommended set points for the devices: i.LWA: 4. 5 inches water in gage glass. ii.LWCO: 3.0 inches water in gage glass. iii.ALWCO: 1.5 inches water in gage glass. b.Adjust set points per recommendation. c.Test set points and operation of the low water devices. 3.The steam safety valve drip pan ells are contacted by J bolts welded to the bottoms of the vent pipes. The thermal expansion of the vent pipes may place excessive stresses on the safety valves and affect their operation. (5.2.1, 7.2.1, 9.2.1) a.Provide clearance between the drip pan and the vent pipe components. b.Refer to attached Steam Safety Valve Details. 4.The main burner gas pressure regulators do not maintain a constant pressure over the firing range and allows too much pressure droop. This adversely affects the ability to properly set the set points of the low gas pressure fuel cutoff switches (LPFCS). (5.3.1, 7.3.1) a.Repair or replace the pressure regulators so that they maintain a nearly constant gas pressure throughout the firing range. The allowable droop must not exceed 10% of the regulated pressure setting. b.Adjust the LPFCS set points to 80% of the regulated pressure. c.Test the switch and interlock operation. 5.The high gas pressure fuel cutoff switches (HPFCS) are set at pressures which are too high. The switches are not plumbed for testing. (5.3.2, 7.3.2, 9.3.2) a.Add lockable isolation valves (lockable only in the open position) and pressure test ports between the gas mains and the switches. b.Refer to attached Burner Gas Piping Schematic Diagram. c.Correct the pressure regulation problems as listed in Par. 5 above. d.Set the pressure switches to 120% of the regulated pressure. e.Test the switch and interlock operation. 6.Make provisions to allow seat leak testing of the main gas automatic solenoid vent valve. (5.3.4, 7.3.4, 9.3.4) a.Add pressure taps and manual valves (lockable only in the open position) downstream of the automatic vent valves. b.Refer to attached Burner Gas Piping Schematic Diagram. c.Test the vent valves for seat leakage. 7.On the pilot gas trains, the automatic vent valves have no provision for seat leak testing. (5.3.7, 7.3.7, 9.3.7) a.Install a pressure tap after the automatic vent valve. b.Install a manual valve lockable only in the open position after the automatic vent valve. c.Refer to attached Burner Gas Piping Schematic Diagram. d.Test valves for seat leakage. 8.The high fuel oil pressure cutout switches (HFOPCS) and low fuel oil pressure cutout switches (LFOPCS) on each boiler are connected to the fuel oil piping upstream from the Cleaver-Brooks fuel oil controllers. This location does not protect against failure of the pressure regulators in the C-B controllers. (5.4.1, 5.4.2, 7.4.1, 7.4.2, 9.4.1, 9.4.2) a.Disconnect the pressure switches from the current locations and connect them to the pressure gage connections on the Cleaver-Brooks fuel oil controllers. b.Reconnect the pressure gages. c.Set the HFOPCS to 110% of regulated pressure. Set the LFOPCS to 90% of regulated pressure. 9.On the combustion air pressure switches, the valve between the windbox and the sensor must be lockable only in the open position and a keyed lock provided. The set pressures of the switches were too low. The pressure settings must be adjusted to 80% of the minimum pressure seen across the firing range. (5.5.8, 7.5.8, 9.5.8) a.Provide valves lockable only in the open position. b.Adjust pressure settings as listed below: i.Boiler No. 1: 12.8 inches wc. ii.Boiler No. 2: 12.8 inches wc. iii.Boiler No. 3: 13.2 inches wc. 10.The prepurge airflow proving switches close at 0.1 inch wc which is not effective, considering that the normal prepurge air differential pressure is 13 inches wc. The required setting is 80% of 13 inches wc. Also, the switches have a maximum pressure rating of 13.9 inches wc, which indicates that the switches are not suitable for the application. (5.5.10, 7.5.10, 9.5.10) a.Replace the switches with switches which have the correct pressure range. b.Adjust the pressure settings so that the switches close at 10.4 inches wc. c.Verify proper operation of the switches and interlocks. 11.On each boiler provide low flue gas oxygen interlocks in the burner management control circuits that will automatically shut down the burners if the flue gas oxygen falls below a safe level. (5.5.14, 7.5.14, 9.5.14) a.Utilize the existing flue gas oxygen analyzers to provide the low oxygen signals. b.Adjust the set points of the interlocks to approximately 0.5% oxygen above the point where the flue gas CO starts to climb above 200 ppm. c. Test interlock operation. Boiler No. 1 (Work limited to Boiler No. 1): 1.Steam safety valve No. 2 has a lift pressure of 155 psi which is too high when compared with the set pressure (145 psi). The allowable variation is 3% (4.5 psi). The drip pan ell drains are clogged. (Safety Testing Evaluation Report Par. 5.2.1) a.Repair or replace valve. b.Clean drip pan ell drains. c.Test safety valve set point, blowdown and accumulation. 2.The low oil atomizing media pressure switch (LAMPS) is set too low. It should be set at 80% of the minimum atomizing media pressure during prepurge, which was observed as 10 psi. (5.4.3) a.Adjust the switch to trip the boiler when the atomizing media pressure drops to 8 psi. b.Test switch and interlock operation. Boiler No. 2 (Work limited to Boiler No. 2): 1.The low oil atomizing media pressure switch (LAMPS) is set too low. It should be set at 80% of the minimum atomizing media pressure during prepurge, which was observed as 12 psi. (Safety Testing Evaluation Report Par. 7.4.3) a.Adjust the switch to trip the boiler when the atomizing media pressure drops to 9.6 psi. b.Test switch and interlock operation. 2.The proof of closure (POC) switch on the upstream automatic fuel oil safety shut off valve opens at approximately 50% of the valve travel. The switch should open with minimal valve movement. (7.4.5) a.Consult with a representative of ASCO valves on a solution for this problem. b.After making the corrections, retest the POC operation. 3.The audible alarm did not function. Repair and make audible throughout the plant. Boiler No. 3 (Work limited to Boiler No. 3): 1.The high water alarm (HWA) switch activated with the water level 0.5 inches from the top of the gage glass, which is too high. (Safety Testing Evaluation Report Par. 9.1.4) a.Adjust the set point of the high water alarm to approximately 2 inches from the top of the gage glass. b.Test the alarm operation. 2.The low oil atomizing media pressure switch (LAMPS) is set too low. It should be set at 80% of the minimum atomizing media pressure during prepurge, which was observed as 7 psi. (9.4.3) a.Adjust the switch to trip the boiler when the atomizing media pressure drops to 5.6 psi. b.Test switch and interlock operation. 3.The audible alarm did not function. Repair and make audible throughout the plant. Plant Support Equipment: 1.The condensate storage tank high water alarm switch is a float type. The float type switches have a high failure rate in this service. There are valves in the high and low level alarm switch header that can isolate the alarm switches from the tank and make them ineffective. (Safety Testing Evaluation Report Par. 4.1) a.Install a conductivity probe type switch located at 2/3 of the tank height. Connect to audible and visual alarm system. b.V.A. Specification for the alarm switch: High Level Alarm Switch: Integral unit consisting of conductivity probes, probe housing. Float type not acceptable. Locate external to tank on a vertical header, along with the low level switch, with valved tank connections and valved drain. High level alarm indication shall occur 100 mm (4 inches) below the overflow level. Probes shall be AC, not DC, stainless steel with virgin Teflon insulation. Manufacturer: Warrick, McDonnell & Miller. Provide signals to annunciator. All devices exposed to tank service conditions, including sensing devices and transmitters shall be rated for 120 degrees C, 200 kPa (250 degrees F, 30 psi) minimum. c. V.A. Standard Diagram for condensate storage tank piping, including high and low water alarm switches: Refer to attached Condensate Storage and Transfer Flow Diagram. d.Install valves on the alarm switch header that can be locked only in the open position. e.Test alarm operation. 2.The feedwater deaerator high water alarm is a float type. The float type switches have a high failure rate in this service. There are valves on the high and low level alarm header that can isolate the alarm switches from the tank and make them ineffective. a.Install new conductivity probe type water level sensors for high water alarm and separate conductivity probe type sensor for operation of new overflow valve (see Par. 4 below). Connect to audible and visual alarm system. b.V.A. specification for the conductivity probe sensor system: High Level Alarm Switch and Overflow Control Switch: Conductivity probe type electronic level switches providing relay contacts for separate high level alarm operation and overflow control valve operation completely separate from control system for inlet water flow control valves. Overflow control valve shall automatically open when the water level rises approximately 100 mm (4 inches) above the high water alarm level. Provide high level and overflow signals to annunciator system and computer workstation as specified in Section 23 09 11, INSTRUMENTATION AND CONTROL FOR BOILER PLANT. The principle of operation shall be differential resistivity of steam and water at the operating temperatures and pressures. The system shall include electronics unit, electrodes, special cable between the electrodes and electronics unit, and electrode cover. The unit shall be designed to fail safe. Manufacturer: McDonnell and Miller, Warrick Div. of Gems Sensors, or equal. Electronics Unit: Each unit shall be capable for signal discrimination of two electrode channels. Each electrode and its associated circuitry shall be powered by an independent power source. Power distribution system within the electronics shall be separate for each channel with its own transformer and shall be electrically isolated from other channels. Input power 110 V, 60 Hz, single phase. All input power to each electrode shall be a low voltage, low frequency AC voltage. DC voltages shall not be allowed because this may cause electroplating at the electrodes. The signal discrimination and fault detection system for each electrode channel shall be independent of the other channel and any fault in the electronics circuitry of one channel shall not be transferred to the other channel. The system shall have a continuous on-line fault detection system. The following faults shall be detected: Electrode failure, contamination from dirt on electrodes, electrode open circuit failure, electrode cable short to ground, electrode cable ground sense failure, power source failure, any electronic component failure. Electronic circuitry not monitored by the fault detection system shall be provide with triple redundancy, where the circuit shall continue to operate and provide contact output with up to two component failures. Faults shall be annunciated through separate NO and NC contacts. The front of the unit shall have a LED display for each electrode channel indicating steam or water and status of each electrode. NEMA 4X enclosure suitable for operating temperature of -20 to 70 degrees C (-4 to 158 degrees F), with up to 100% relative humidity. Electrodes: Suitable for 120 degrees C, 200 kPa (250 degrees F, 30 psi) minimum. Electrodes without gaskets are preferred. Teflon insulator media. Electrodes fitted into shrouded inserts which are directly welded onto the stand-pipe. Design to minimize faulty indication due to falling condensate into the electrodes. Electrode Cable: Pure nickel wires for at least the first two meters at the electrode end, with pure nickel crimps. PTFE insulation capable of withstanding up to 265 degrees C (500 degrees F). Continuous cables from the electrodes to the electronic unit. No junction boxes allowed. Manufacturers: McDonnell and Miller, Warrick Div. Gems Sensors. c.Test operation of high water alarm system. 3.The feedwater deaerator low water alarm should be set to alarm at 1/3 the tank diameter. (4.4) a.Relocate water level alarm sensor. b.Test operation of low water alarm system. 4.Replace float type deaerator overflow controller with conductivity probe water level sensor and controller. The deaerator overflow discharges into the condensate storage tank which could potentially pressurize this tank. This may be hazardous. (4.5) A.Replace the float type overflow control switch with conductivity probe type water level sensor. The sensor shall comply with VA spec in Par. 2 above. Overflow control valve system shall comply with the following V.A. spec: Control Valve: a.High performance butterfly valve, double offset design. b.Carbon steel 17-4PH steel valve body conforming to ASME B16.34, Class 150, lug style, 316 stainless steel nitrided disc. c. Self-energizing TFE seat providing bubble-tight shut off service on vacuum and low pressure and pressure sealed for high pressures. Bi-directional seating. d.Packing adjustable, chevron design with TFE seals. e.7 kPa (1 psi) maximum pressure loss at maximum flow rate (120% of peak deaerator capacity if valve flow and pressure drop is not scheduled). f.Flow Seal Fig. No. 061LA171MGB, or equal. 4.Valve Actuator: a.Double rack and pinion, single acting, fail open. b.Seals suitable for 250 degrees F (250 degrees C), using Viton elastomers. c.Actuator shall be controlled by 3-way, normally open solenoid valve with brass body and EPDM or Viton seals for high temperature service. d.Equip with limit switch containing two SPDT, proximity type switches to provide position indication. e.Size actuator for 550 kPa (80 psi) minimum air supply and a 30% safety factor to ensure enough spring capacity to open the valve after long periods of closure. f.Crane Revo Type CA - DVA, or equal. B.Test operation of overflow system. C.Reroute the deaerator overflow so that it does not flow into the condensate storage tank. 5.There is no ASME NB approved steam safety valve following the steam pressure reducing station (PRV) that serves the feedwater deaerator (DA). A safety valve is essential to protect downstream equipment if the pressure reducing valve fails open and allows the pressure to increase. In addition, an isolation valve must be installed on the low pressure steam line between the new safety valve and the DA so that the DA can be isolated to allow testing the new safety valve. (4.7) a.Install new safety valve downstream of the PRV. The safety valve sizing shall be based on the maximum flow capacity of the PRV or the globe bypass, whichever is greater. b.Refer to attached Steam Safety Valve Detail. 6.There are three steam pressure reducing stations (PRV) in the vicinity of the feedwater deaerator. The bypass valves are difficult to turn and therefore could not accommodate the testing of the downstream safety valves. The bypass sizes appear excessive. Downstream safety valve sizes and capacities must be based on the maximum flow capacity of the PRV or the bypass, whichever is greater. There must be isolation valves downstream from the PRV station safety valves to allow testing the safety valves without over pressuring the downstream systems. (4.7) a.Perform an engineering analysis of the flow capacities of the PRVs and bypass valves to determine the required safety valve capacities. b.If the bypass globe valves have excessive capacity, consider installing smaller globe valves. c.Verify that the existing safety valves have proper capacities and set pressures or replace them. d.Test the set points and accumulation of all the safety valves. 7.The propane tanks and connecting piping are inadequate to serve the pilot burners.(4.8) a.Install proper size tanks and piping with proper pressure regulation. b.Test operation of propane pilot burner backup system. 8.The relief valves on each of the fuel oil pumps do not relieve the full flow of the pumps without an excessive increase in pressure above the set pressure. (4.9) a.Replace the valves with properly sized valves with set pressure 10 psi above the regulated pressure. b.Test the relief valve operation. 9.Provisions must be made for admission of combustion air into the boiler room. As an example, at 20,000 lb/hr of steam output, the burners will require 5000 cfm of combustion air. If another boiler is being pre-purged at the same time, the total requirement will be approximately 10,000 cfm. (4.11) i.Replace windows with storm proof louvers with sufficient free area to limit pressure drop to 0.05 inches WC at the maximum air intake rate. It may be necessary to enlarge window openings. a.Develop standard operating procedures to assure adequate combustion air. System Compliance/Reliability Common Issues Noted in the Plant: 1.Many burner/boiler control safety interlock switches require isolating valves to allow testing or servicing. These isolating valves will make the switch inoperative if they are closed. It is essential that these valves be lockable only in the open position. Plant procedures must require that they be locked open. This plant has several isolating valves that were not locked or were lockable in more than one position. 2.Many of the pressure gages are inaccurate. A pressure gage calibration program is required by the VA directive.
 

Web Link

FBO.gov Permalink
(https://www.fbo.gov/spg/VA/WiVAMROC460/WiVAMROC460/VA-244-09-RA-0297/listing.html)
 

Place of Performance

Address: Wilmington VA Medical Center;1601 Kirkwood Highway;Wilmington, DE<br />

Zip Code: 19805<br />
 

Record

SN01867370-W 20090709/090708000911-5e0c68300b5084739f33688e07754fdd (fbodaily.com)
 

Source

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

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