J045--BOILER REPAIR HUDSON VALLEY VAHCS - MONTROSE CAMPUS

shall be performed in accordance with attached VA specifications, VA Design Manual, and VA Boiler and Associated Plant Safety Device Testing Manual, Eighth Edition. Background: Boiler # 2 is a Victory Energy, D-type Water-tube boiler rated at 30,000 lb/hr steam (approximately 37.5MMBtu/h input). The boiler was originally installed in 2011 with a Webster model HDSXC-105C-9V-750 Burner. The Micro-Mod Parallel Positioning (Metering) Combustion Controls were installed in a separate project, in 2019. The burner is equipped for Natural Gas Firing, as well as Number 2 Fuel Oil with the option for either compressed air or steam atomization. The back-up (Propane) pilot system is via a small (portable) bottle, connected by a temporary hose- when needed. The Burner Flame Safeguard system is a Fireye YB110, with a Fireye YZ300 Expanded Annunciation Module and a Fireye 45UV5 Scanner- all original to the 2011 project. Item #1 Replace Boiler #2 Burner Assembly and Controls - The existing Webster Burner for Boiler #2 is damaged from a fire side explosion and shall be replaced in kind as listed as the same model identified in the above background (Webster model HDSXC-105C-9V-750 Burner). All existing burner fuel train field devices (for both gas and fuel oil) located downstream of their associated isolation valve shall be replaced in kind. All burner atomization field devices located downstream of associated isolation valve shall also be replaced in kind. Replace the burner air intake manifold and all associated ductwork, fittings, filters, alarms, etc. Replace all existing field devices for combustion air in kind (See Attachment D - List of field devices to be replaced). All existing field devices being replaced shall be handed over to the VA for spare parts. The existing MICROMOD and Fireye controls systems shall remain. a.) The contractor shall inspect the existing burner, field devices, and control systems serving Boiler #2 including all wiring and integrations points. Document current operational parameters and deficiencies. The VA shall provide the contractor with the as-built wiring diagrams of the existing MICRO MOD Burner Management System. Contractor shall field verify information from as-built documentation in the field and notify the VA COR of any discrepancies. b.) Provide submittals of all equipment, field devices, and materials to be installed under contract for VA review and approval. c.) Delivery Upon approval of submittals, Contractor shall order and then deliver the replacement equipment and material to site. d.) Removal - Once the replacement burner is delivered to site, the contractor shall safely disconnect and remove the existing burner, field devices, associated wiring, and fuel connections. Contractor shall hand over existing equipment and field devices to VA who will use equipment for spare parts. e.) Installation and Integration Contractor shall set the replacement burner and field devices in place and make all necessary connections to the existing Victory boiler and existing MicroMod system as well as all electrical and utility connections. Make connections to fuel supply, electrical systems, and control panels. Integrate new controls with existing boiler hardware. f.) Start Up - Contractor shall start up replacement burner. g.) Testing & Commissioning a. Once boiler is refilled, Contractor shall perform a hydrostatic test to ensure that there are no potential tube leaks on Boiler 2. b. Contractor shall calibrate all gauges and transmitters and test for proper operation on Boiler #2. Submit all test reports to VA COR c. Perform operational tests, combustion analysis, and adjustment to ensure optimal performance. Submit a completed Combustion Test Report showing the results from the combustion test. Use the attached Combustion Test Report, Attachment C. d. For controls, program control logic for optimal efficiency and safety. Conduct functional and safety tests, including failover and alarms systems. Submit all test reports to VA COR e. Contractor shall test all safety devices and tune the combustion on Boiler 2 using the testing methods specified in the VHA Boiler and Associated Safety Device Testing Manual, Eighth Edition (See Attachment A). Submit the completed test reports from the Safety Device Testing Manual to the VA COR. h.) Training Provide basic operational and maintenance training to VA staff i.) Deliverables - Contractor shall provide all manuals and warranty documentation, test and commissioning reports, operator training completion certificates. j.) Standards and Compliance All work must comply with applicable local, state, and federal codes, as well as manufacturer s specifications and safety regulations. Acceptance Criteria The project will be considered complete when Boiler 2 with its replacement burner operates in accordance with manufacturer s specifications and testing requirements, passes all VA performance and safety inspections, and documentation is delivered to the VA. VA performance and safety inspections shall be considered passed when Boiler #2 with its replacement burner successfully passes the tests mentioned in this Statement of Work (SOW) and all tests outlined in the VHA Boiler and Associated Plant Safety Device Testing Manual, Eighth Edition and all fully completed test reports, as described in this SOW and the Safety Device Testing manual, is submitted to the VA. OTHER REPAIR SERVICES TO BE PERFORMED UNDER THIS CONTRACT The scheduling and completion of work items not contingent upon the delivery and installation of the replacement burner for Boiler 2 can be scheduled and performed any time after the issuance of the NTP but must be completed and accepted by the VA prior to the completion date of the contract. Item #2: Replace the damaged refractory in Boiler #2 Replace the refractory around the boiler throat to match existing refractory as installed by boiler manufacturer. Consult with Victory Boiler on their recommended replacement method and design. Provide Victory s recommendation to the VA COR prior to replacement. (NOTE: This work item must be performed prior to the installation of the replacement burner). Item #3: Provide hard piped atomizing train to Burner #2 Current piping configuration on the atomizing train (for steam and air) does not meet VA requirements. Re-pipe both steam and air atomization chains to be in compliance with VA Standard Detail SD235239-04 (See Attachment B). Item #4: Install propane header sized for proper capacity to accommodate all four boilers in the Boiler Plant. Propane is used for fueling each burner s pilot ignition. The existing propane delivery system in the Boiler Plant is inadequate per VA specifications. Contractor shall hire engineering services to evaluate the capacity needed for the Webster burners on all four (4) boilers and to size an alternate pilot propane tank, main header, and branch piping to the Boiler #2 burner. Main header shall have T connection for future installations to burners on Boilers 1, 3, and 4. The size of the propane tank and main header shall have the capacity to supply four (4) Webster burners in the plant. For bidding purposes, assume that a 200 gallon pad mounted propane tank is needed just outside of the Boiler Plant and a 250 long header of 1 black iron pipe is needed to be hung in front of all four (4) existing boilers. Install black iron branch