J--Boiler Services VA Medical Centers New England

Sources Sought Notice Boiler Inspection, Maintenance, Repairs, Testing, Calibration of Burners, Controls Instruments and Data Management for Veterans Integrated Service Network (VISN) 1, VA Medical Centers of New England PURPOSE: The VHA Network Contracting Office (NCO) 1 is conducting market research to enhance NCO 1 s understanding of the market s offered services, capabilities and potential small business sources. A draft scope of the boiler services is included below. Interested vendors shall submit a capability statement with the following information. Which locations does your firm service? Does your firm have the capability to meet the minimum four (4) hour response time for emergency services at all medical centers? If not, to which centers are you capable of responding to an emergency call in 4 hours? Does your firm service all equipment listed below? If not, please provide a list of which equipment you are capable of servicing. Briefly describe your firm s qualifications for the services listed. Are you capable of providing the following? National Board of Boiler and Pressure Vessels Commissioned Inspector Five years successful experience in this field to include experience with institutional and industrial boiler plants Factory training certificates or credentials or acceptable equivalent? Percentage of work your firm will provide _____, % of subcontractors ______ Company Name and Address DUNS and CAGE Code Point of Contact Size of Business (i.e. SDVOSB/VOSB, Small Business, 8 (a), HubZone, WOSB) Submit response (along with any supporting documentation) directly to: tammy.davis6@va.gov. This is a Sources Sought notice and not a request for quotes. This request is solely for the purpose of conducting market research to enhance NCO 1 s understanding of the market s offered services, capabilities and potential small business sources. The Government will not pay any costs for responses submitted in response to this Sources Sought. DRAFT SCOPE Boiler Inspection, Maintenance, Repairs, Testing, Calibration of Burners, Controls Instruments and Data Management for Veterans Integrated Service Network (VISN) 1 VA Medical Centers of New England as follows: VA CT Medical Center Newington, 555 Willard Ave. Newington, CT 06111 3 - Zurn industries - 1975 ,water tube, 12,000 lbs./hr,90psi. VA CT Medical Center West Haven, 950 Campbell Ave. West Haven, CT 06516 3 Cleaver brooks DL-60 - 1981, water tube 41,000 de-rated 31,000 lbs./hr., 110psi. 2 Victory boilers - 2016, 21,468 lbs./hr. REQUIREMENTS: Annual inspection of each boiler (internal and external), deaerator tank (internal and external) and hot well system. Preventative maintenance and emergency repairs Emergency repairs VA Medical Center Edith Nourse Rogers, 200 Springs Rd, Bedford MA 01730 Preferred Instruments, CB Hawk, Foxboro, Yokogawa, Siemens & Johnson Controls 3 Cleaver Brooks CB700LE boilers 2 HB Smith, 14 section cast iron low pressure boilers, Model Numbers 28A-14-060779 & 28HE-S/W-14, combination gas/oil firing 3 Cleaver Brooks Low Emission (LE) fire-tube boilers REQUIREMENTS: Semi-annual calibrations of boiler plant controls and instrumentation for three boilers and other plant equipment. Contractor will also provide all labor and materials required to perform burner calibration on 3 Cleaver Brooks CB700LE boilers. Contractor must have a laptop computer and required software to plug into & back-up all settings in the PCCIII controls and provide a back-up flash drive Provide calibration reports for each piece of equipment, indicating date, settings, pass/fail, technical data, and name of technician performing calibrations. The following is a list of devices that will require calibration: PLANT MASTER PCIII: Outside Air Temp; Plant Steam Flow; Distribution Steam Flow; Plant Demand; Steam Header Press Hi/Lo & Alarms; Oil Pressure Transmitter & Alarms; Propane Pilot Gas Transmitter & Alarms; Main Gas Pressure Transmitter & Alarms; Control Air Pressure Transmitter & Alarms; Low Main Gas Pressure Alarm; High Main Gas Pressure Alarm; Explosive Gas & Carbon Monoxide Detection System 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 #1& #2 BOILER MASTER PCIII : Plant Demand; Boiler Demand; Firing Rate; Steam Flow; Economizer Flue Temp In #1 & #2 DRAFT PCIII: Oxygen Transmitter; Damper %; Outlet Temp; Jackshaft Position; Efficiency #1 & #2 FUEL FLOW PCIII : Boiler Gas Flow; Boiler Oil Flow; Flue Gas Temp; Monitor Calibration; Flue Gas Temp Hi & Low Temp Alarms #1 & #2 ECONOMIZER FW TEMP IN & OUT #3 BOILER: Steam Flow ; Oil Flow; Gas Flow; Oxygen Transmitter; Water Flow; FW Press; FW Temp; Economizer Temp In/Out; Boiler Water Temp; Boiler Oxygen #3 FEEDWATER PUMP VARIABLE FREQUENCY DRIVE UNIT Note; there will be new DA High and Low level alarms and Condensate High and Low level alarms installed separate from the PCIII alarms. Separate testing and calibration will be required for these beginning with the first calibration cycle of this contract. Contractor will provide all labor and materials required to perform burner calibration on 3 Cleaver Brooks CB700LE boilers. Each burner assembly will be inspected & 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 Plant Supervisor. Contractor will provide burner calibration printouts for each pin on the gas and oil cams (12 for Boilers 1 & 2) & (20 on #3 CB Hawk). Settings will be as close & safe as possible for max input for gas & oil firing at high fire as per the inputs listed on the boiler plate. Vendor will calibrate the burners and not exceed the requirements of this facilities permit for emissions. Work to be performed on 2 HB Smith, 14 section cast iron low pressure boilers, Model Numbers 28A-14-060779 & 28HE-S/W-14, combination gas/oil firing. Responsible for annual opening & cleaning of water and firesides and preparing the boilers for internal inspections Once inspections are complete, the contractor will return, close up the boilers, fill the boilers and then perform combustion testing on both oil and gas firing. Combustion reports will be provided to COR. Perform a combustion efficiency test and provide a written report to designated personnel. Set up a boiler room logbook to be signed by all persons entering the boiler room Prepare boiler for annual inspection: schedule cleaning during the summer months. Vacuum clean all fireside surfaces. Flush and clean waterside, open and clean mud drums where applicable. Open and clean all low water, feeder and pump controls. Reassemble, replace gaskets and install new strainers. Clean flue and chimney base. Reseal any leaks around boiler doors or plates after inspection. Full pre-season maintenance cleaning of the burners, adjust for maximum efficiency. Contractor will respond within 4 hours when a call is placed for emergency service. Perform Semi-Annual Safety Device Testing on 3 each Cleaver Brooks Low Emission (LE) fire-tube boilers, and other plant equipment Devices tested shall include, but not limited to: 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 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; De-aerating (DA) tank high and low level alarms; DA tank overflow device; DA tank high pressure alarm; Condensate Receiver tank high and low level alarms; DA tank low pressure alarm. VA Medical Center Providence, 830 Chalkstone Avenue, Providence, RI 02908 3 Boilers Manufacturer: Cleaver Brooks Model and Capacity: D Shape Water Tube 16,000 lb/hr Serial #: National Board No.: Typical Operating Pressure: 115 lbs Design Pressure 250 lbs Date of Manufacture: 1978 Boiler Controls: Fireeye Burner Manufacturer: Cleaver Brooks Type of Burner: Ring Fuels: Natural Gas/#2 Oil Date of Manufacture: Installed 1988 REQUIREMENTS: Annual boiler inspections and monthly safety device testing. All the boilers are water tube boilers. Only one interior and one exterior inspection will be scheduled per week. This procedure typically takes three (3) consecutive weeks. The annual operational testing will be accomplished at three (3) separate times during the year. Inspections will be in compliance with National Board Inspection Code & ASME Code Provide complete written report of the inspections or testing fully describing all tests performed, all findings, and recommendations. All safety-related deficiencies shall be immediately reported to the Boiler Plant Supervisor during the inspection visit VA Medical Center Central Western Massachusetts, 421 North Main Street, Leeds, MA 01053 (3) 250 BHP Johnston Firetube Boilers, Model PFTA250-4LG200S, Built 2011, max capacity 8,368 LBS/HR, 4,000 sq. ft. heating surface, max gas firing rate 9,800 MBTU/HR, operating at 70 psig (1) 19 BHP Cain Heat Recovery Steam Generator, max capacity 647 LBS/HR, 478 sq. ft. heating surface, safety valve setpoint 15 psig (1) 840 Gallon Feedwater Deaerator Preferred Utilities Boiler Control System REQUIREMENTS: Inspection, testing and calibration of the boilers, burners, controls, instruments and data management system, HRSG, and deaerator. Technicians shall be equipped with portable electronic flue gas analyzers and other test instruments necessary for the required tests and calibrations, all calibrated within one month of the site visits. This facility has programmable digital controls; all technicians must be capable of programming the controls and have the appropriate hardware and software for this. Technicians shall perform inspection, tuning, testing, calibrating, and adjustments of burners and boiler and boiler plant controls. This shall be done every six months in accordance with the schedule provided by VAMC. This service specifically covers (2) Semiannual services for each Boiler, and (2) Tune Up Services for each Boiler. Instrumentation, monitoring and data management systems shall be calibrated every six months 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. Refer to list below. Verify that the set points and operating points are within allowable 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 four 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 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, code approval. Calibrate all instruments that are not within manufacturer s specifications for accuracy. List of interlocks, safety devices, and gauges to be inspected, tested, or calibrated (including but not limited to). Semi Annually on each boiler/burner: Low-water cutoff (slow drain); Fire each boiler and the pilot on the alternate fuel for 1 hour; Low-water cutoff shunt switch; Auxiliary low-water cut-off (slow drain); Auxiliary low-water cut-off shunt switch; High-water alarm; Low-water alarm; High-steam pressure cut-out (recycle); High-steam pressure cut-out (non-recycle); Steam safety valves (raise boiler pressure until valve pops); Flame scanner; 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 gas fuel safety shut off valves; High-fuel oil temperature cut-off (heated fuel); Low-fuel oil temperature cut-off (heated fuel); Low-atomizing pressure for fuel oil; High-fuel oil pressure cut-off Low-fuel oil pressure cut-off; Leak test fuel oil safety shut off valves; Check operation of Liquid Petroleum 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; Low fire position interlock; Combustion air interlock; Main flame out; i.e., time to close valves; Ignition flame out; i.e., it is 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; Fuel oil safety shut off valves proof of closure The following items will be completed on an annual basis: Steam safety valves (accumulation test at high fire); 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); 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 on single-point positioning systems); 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 on single point positioning systems); Flames shall be stable with no pulsations, shall be retained near burner, no blowoff or flashbacks, no constant flame impingement on refractory or waterwalls. List of instrumentation and controls to be inspected and calibrated semi-annually (including but not limited to):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 outlet draft controllers; Boiler water level controllers; Feedwater deaerator and condensate storage tank water level controllers including overflow; All pressure and temperature sensors and transmitters; All signal processing and readout devices. Emergency Response: emergency 4hr call back with 24 hour response time. VAMC Manchester, 718 Smyth Road, Manchester, NH 03104 3 Cleaver Brooks REQUIREMENTS: Technicians shall perform inspection, tuning, testing, calibrating, and adjustments of burners and boiler and boiler plant controls every 6 months. Instrumentation, monitoring and data management systems shall be calibrated every six months Review boiler plant log sheets and alarm and trouble reports. 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% 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, NOx 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, code approval. Calibrate all instruments that are not within manufacturer s specifications for accuracy. List of interlocks and safety devices to be inspected and tested on each boiler/burner: Low water cutoff and shunt switch; Auxiliary low water cutoff and shunt switch; High water alarm; Low water alarm; High operating steam pressure switch recycle; High operating steam pressure switch non-recycle; High and low main fuel pressure switches (gas/oil); Low pilot gas (igniter) pressure switch; High and low fuel temperature switches (heated oil); Low fuel oil atomizing media (steam/compr.air) pressure switches; Low differential pressure switch, atomizing media/fuel oil (if provided by burner manufacturer); Low flue gas oxygen; Oil burner position switch (if provided by burner manufacturer); Fuel safety shut off valves proof of closure (overtravel/valve seal switch); Leak test fuel safety shut off valves (main and pilot burners) (seat leakage); 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; 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); Control air pressure interlock; Low flue gas oxygen interlock; Flue gas recirculation damper set for prepurge. 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: _____ (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 on single-point positioning systems); 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 on single point positioning systems); No visible smoke, except on heavy oil fuel maximum opacity is 20%. Comply with local emissions regulations; Need a copy of the plant permit and references for the plant; Flames shall be stable with no pulsations, shall be retained near burner, no blowoff or flashbacks, no constant flame impingement on refractory or waterwalls. 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 outlet draft controllers; Boiler water level controllers; Feedwater deaerator and condensate storage tank water level controllers including overflow; All pressure and temperature sensors and transmitters; All signal processing and readout devices. Veterans Affairs Medical Center, 150 South Huntington Ave, Jamaica Plain, MA 02130 Cleaver Brooks Boilers and the associated SCADA MANUFACTURER ITEM NAME MODEL # SERIAL# Cleaver-Brooks Fire tube Boiler 4WI-200-805-200ST T4757-1-1 Cleaver-Brooks Fire tube Boiler 4WI-200-705-200ST T2049-1-1 Cleaver-Brooks Fire tube Boiler CB200-300 L-86842 4-Motor, pump and drive Feedwater pumps 2- Make-up Make up pumps Manufacturer Model Serial Number Installation Date Cleaver-Brooks CB200-250 0L093816 1995 Cleaver-Brooks D-24 WL-2670 1977 Cleaver-Brooks CB100-300 NB41330 1977 REQUIREMENTS: basic preventive maintenance and emergency call back services for the boiler systems and the associated boiler controls clean, lubricate, calibrate, test and replace faulty or worn parts and/or parts which are likely to become faulty, fail or become worn, repair or adjust components, or assemblies of components as necessitated by wear, tear, damage, or failure of parts, returning the equipment and/or instrument to the operating condition defined in the manufacturer s specifications. Repair a system according to manufactures' specifications, manufacturer requirements and applicable state of Massachusetts building codes. The Contractor shall respond to emergency call back service within four hours or less. Quarterly inspections include: Clean and adjust burner; Assure positive ignition, adjust and clean as required; Determine response to flame safeguard system for monitoring and safety shutdown; Perform combustion analysis, and adjust fuel/air ratio for optimum efficiency; Check fuel supply (gas/oil) which is affected by pumps, strainers, gauges, and regulators; Check reliability of low water cut-off, pump control, operating and limit controls in accordance with manufacturer's recommendations; Check gaskets on fuel lines, fireside and waterside, and make suggestions for any corrective action required; Check and suggest necessary parts for inventory; Inspect and assure proper operation of related equipment such as boiler feed tank, pumps; Monitor SCADA package for reliability and alert customer to any available updates; Check operation of feed water pumps. Provide preventative maintenance in accordance with manufacturer recommendations; Check operation of variable speed drives for make-up water and feed water pumps. Preventative Maintenance Opening & Cleaning of fire and water sides: Isolate and lock out boiler gas, boiler oil, steam & water valves; Secure and lock out electricity & pumps; Open front & rear doors; Remove all fire & water side gaskets; Clean & inspect tubes (brush/punch tubes); Open Watersides & flush; Suggest itemized list for any parts for replacement Closing of fire & water sides: Provide new front & Rear door gaskets; Close front & rear door; Close Watersides using new gaskets; Re-align boiler gas & water valves; Test safety s; Verify operation & Test fire only Pumps-boiler feedwater and make up water: Monitor and measure vibration. Compare to manufactures tolerances; Check seals and gaskets for leaks and deterioration; Measure and verify shaft deflection. Schedule outage to make adjustments and align; Check for clogs. Clean strainers and remove restrictions; Provide thermal image of pump and motor. Report deficiencies with a plan to correct; Verify operation and demonstrate proper operation. REGULATIONS: All work shall be done in accordance with OSHA, EPA regulations, NFPA codes, VA codes, Federal, State, and local regulations National Board Inspection Code & ASME Code NFPA 85, Boiler and Combustion Systems Hazards Code. VHA Boiler Plant Safety Device Testing Manual, 3rd Edition. Combustion Systems Hazards Code