Safety Device Testing Procedures

St. Louis John Cochran VAMC Boiler Plant

Monthly Safety Device Testing

Procedures

St. Louis John Cochran VAMC Boiler Plant REF: MCM FES-138-01 SDMSOP 01_P

Checklist for Low Water Alarm and Cutoffs (LWA/LWCO/ALWCO) – 2 Person 1. IN PERFORMING TEST NEVER LET WATER LEVEL LEAVE SIGHT GLASS!!! 2. Drain sight glass without draining alarm column by opening the 1,2,3 drain valve and quickly closing it. (water level should quickly rise to indicate good communication) 3. Verify that there is both a float and probe device on separate columns. Verify that there are no valves that can isolate either the float or probe column. 4. Start the boiler and place in low fire. 5. Ensure one person has constant visual on sight glass at all times. 6. Close the feedwater valve. 2 7. Crack blowdown valve to create a 1”/ minute drain rate as seen in the sightglass. 8. Allow boiler to drain until LWA alarm activates. 9. Record LWA activation point (inches above bottom of glass) 10. Continue to drain boiler until primary (first, float) LWCO activates. (Probe annunciates “LWCO”) 11. Secure / Close the blowdown valves. 6,16 12. Record the first LWCO activation point. (inches from the bottom). Re-establish water level above LWCO activation point. 13. Press and hold the LWCO float shunt button and reset the Fireye to restart the boiler. a. If boiler does not restart after resetting the Fireye and holding shunt, increase boiler water level above cutout point and repeat step 13.

10,15 7,11,14

14. Crack blowdown valve to create a 1”/ minute drain rate as seen in the sightglass. 15. Allow boiler to drain until the second (Probe) ALWCO activates. After Activation close the blowdown valve. Measure and record activation point. (annunciates “3-P Low Water”) 16. Open feedwater valve and bring water level back to normal operating level. 17. Reset the Fireye and return to normal operation.

REF: MCM FES-138-01 SDMSOP 02_P

Checklist for High Water Alarm and Cutoffs (HWAB) 1. Turn the burner switch off. 1 2. Drain sight glass without draining alarm column and quickly close drain valve. Water level should quickly rise in sight glass indicating good communication with tank.

3. With boiler off, open the bypass valve on the feedwater and fill boiler. Use water level in sight glass to observe and record alarm point on the data sheet (measure from top of sight glass). The alarm should sound before water level leaves sight glass. DO NOT ALLOW WATER LEVEL TO LEAVE SIGHT GLASS

3,4

4. Shut feedwater bypass valve and return boiler water level to normal. REF: MCM FES-138-01 SDMSOP 03_P

Checklist for Flame Scanner-for main flame out (FSMFO) – 2 Person

1. Close the lockable manual valve between the fuel line and the High Gas Pressure Cutoff Switch.

2. Start the boiler and increase the firing rate to approximately 1,4 20%.

3. Have a second operator quickly close the manual valve in fuel line before burner. Use a stopwatch to record the time required for the flame scanner to close the automatic fuel safety shutoff valves. (Valves should close within 3 to 4 seconds from the time the flame goes out in the firebox). The BMS should annunciate “Flame Failure”

4. Open and lock the lockable manual valve between the fuel line and the High Gas Pressure Cutoff Switch.

5. Reset the Fireye

6. Return the boiler to normal. REF: MCM FES-123-01 SDMSOP 04_P

Procedure for Firing Boiler on Fuel Oil and Propane Pilot

Procedure Created: September 1, 2019 Procedure Expires: September 1, 2022 Directive: 1810 1,2 1. Locate fuel oil pump set. 2. Locate Oil Supply line into oil pumps. a. Open all required valves to align flow to selected oil pump and to return tank. 3. Locate Oil Pump Electrical Panel

4. Start Selected Oil Pump by turning pump switch to Auto or Hand. 5. Setup propane pilot equipment and align propane valves.

a. Turn propane / natural gas selector valve to propane position. b. Open propane inlet valve to boiler. 3,4 c. Locate propane tank outside of boiler plant. Open valve on top of propane tank.

5a 5b

REF: MCM FES-123-01 SDMSOP 04_P

Continued -Procedure for Firing Boiler on Fuel Oil and Propane Pilot

6. Locate fuel oil supply line into boiler. a. Open valves to align fuel oil. b. Verify Oil pressure on gage. 6a 7. Push in Oil Gun until it makes gun position switch and clasp latch to hold. 8. Close main natural gas valve. 9. Select oil on fuel select switch to start. 10. Start Boiler

11. Do not make multiple successive light off attempts. If boiler fails to light after 3 lightoff attempts abort and move to another boiler.

7 9 6a

Semi -Annual Ancillary

Equipment Safety Device Testing

Procedures

St. Louis John Cochran VAMC Boiler Plant REF: MCM FES-138-01 SD6MSOP 01_P

Condensate Tank - High Water Alarm Test Procedure 1. Drain sight glass by using ball valve. a. Fully open blue handle ball valve on sight glass column. b. Fully close blue handle ball valve on sight glass column. Water level should quickly rise to re-establish water level. Quick recovery indicates good communication with tank. 2. Open Soft Water Makeup Bypass Valve to establish no more than a 1 inch per minute fill rate (maximum).

2,6

Measure from here.

3. Observe and record alarm point. a. Once alarm activates, mark activation point, and silence alarm. b. Alarm point should be measured on the sight glass water column from the bottom of sight glass. c. Measure and record (on data sheet) alarm activation point.

d. Verify High Level Alarm on Annunciator panel. 1a,1b 4. Continue to allow water to rise to the overflow point. 5. Verify water flow through overflow line and that sight glass water level stabilizes and does not continue to increase above overflow water level. Verify for 1 minute. 6. Close the Soft Water Makeup Bypass Valve. 7. Return to Normal Operation.

REF: MCM FES-138-01 SD6MSOP 02_P

Condensate Tank - Low Water Alarm Test Procedure 1. Drain sight glass by using ball valve. a. Fully open blue handle ball valve on sight glass column. b. Fully close blue handle ball valve on sight glass column. Water level should quickly rise to re-establish water level. Quick recovery indicates good communication with tank. 2. Remove Lock and Close Condensate Tank Alarm Water Column isolation valve. 3. Slowly Open Water Column Drain as shown in picture to establish a slow drain rate of no more than 1 inch per minute. 4. Wait for Low Water Alarm to sound. a. Once alarm activates, mark alarm point. 5. Close Condensate Water Column Drain Valve. 6. Measure alarm point on sight glass and record on data sheet in the designated area. a. Alarm point should be measured on the sight glass water column from the bottom of the lowest sight glass. b. Verify Low Level Alarm on Annunciator panel. 7. Open Condensate Tank Alarm Water Column Isolation Valve and replace Lock. Make sure water level returns to normal. 8. Return to Normal Operation. 6

Measure from here.

1a,1b

2,7

3,5

REF: FMS POLICY 548-138 SD6MSOP 03_P

Deaerator Tank - High Water Alarm Test Procedure 2,5

1. Drain sight glass. a. Open sight glass blowdown ball valve on sight glass water column and let water drain. b. Close sight glass blowdown ball valve. Water level should quickly rise to re-establish water level. Quick recovery indicates good communication with tank. 2. Open Bypass Valve on line to DA Tank to establish no more than a 1 inch per minute fill rate (maximum). 3. Observe and record alarm point. a. Once alarm activates, mark activation point, and silence alarm.

b. Alarm point should be measured from bottom of sight glass water column. c. Measure and record alarm activation point on the

data sheet. d. Verify DA High Level Alarm on Annunciator panel.

4. When required, recommend performing DA Overflow 3 Test at this point. 5. Close bypass valve on condensate line to DA tank. 6. Return to Normal Operation.

Measure from here. REF: MCM FES-138-01 SD6MSOP 04_P

Deaerator Tank - Low Water Alarm Test Procedure

1. Drain sight glass.

a. Open sight glass blowdown valve on sight glass water column and let water drain. b. Close sight glass blowdown valve. Water level Iso Valve (LOO) should quickly rise to re-establish water level. Drain Valve Quick recovery indicates good communication with tank. 2. Remove lock and Close DA Alarm Column Isolation Valve. 3. Open Deaerator Tank Alarm column sight glass drain valve. Establish one inch per minute (maximum) drain rate. 4. Wait for Low Water Alarm to sound. a. Once alarm activates, mark alarm point then silence alarm on panel.

b. Verify DA Low Level Alarm on Annunciator Panel. 5. Close Deaerator Alarm Column sight glass drain

valve. 6. Measure alarm point on sight glass and record on data sheet in the designated area. a. Alarm point should be measured on the sight 6 glass water column from the bottom sight glass. LWA Probe 7. Return to Normal Operation.

Measure from here. REF: MCM FES-138-01 SD6MSOP 05_P

Checklist for Deaerator Overflow Drain System (DAODS) 2,4,7 1. Drain sight glass. a. Open sight glass blowdown valve on sight glass

water column and let water drain. b. Close sight glass blowdown valve. Water level should quickly rise to re-establish water level.

Quick recovery indicates good communication with tank. 2. Open Bypass Valve on condensate line to DA Tank to establish no more than a 1 inch per minute fill rate (maximum). 3. Observe and record alarm point. a. Once alarm activates, mark activation point, and silence alarm. b. Alarm point should be measured from bottom of sight glass water column. c. Measure and record alarm activation point on the data sheet. d. Verify DA High Level Alarm on Annunciator panel.

4. Continue to allow water to rise to the overflow point. Ensure bypass valve is fully open. 5. Observe and record overflow open point. a. Once overflow activates, mark overflow activation point. b. Overflow point should be measured from bottom of sight glass. c. Measure and record overflow activation point on 3,5 the data sheet. 6. Verify water flow through overflow line and that sight glass water level stabilizes and does not continue to increase above overflow water level. Verify for 1 minute. DO NOT ALLOW WATER LEVEL TO LEAVE SIGHT GLASS. 7. Close Bypass Valve. 8. Verify Overflow Valve is closed. 9. Return to Normal Operation. DA Overflow Measure from here. Valve

3b REF: MCM FES-138-01 SD6MSOP 06_P

Checklist for Deaerator Safety Valve (DASV)

1. Locate the Safety Relief Valve on top on the Deaerator Tank. 1,2 2. Record the Safety Relief valve set pressure and flow capacity as read from the tag on the safety valve. 3. Pour water in the drip pan drain and confirm that it is unobstructed. 4. Close isolation valve to blowdown heat exchanger. 5. SLOWLY open steam bypass valve on steam supply line to DA tank. DO NOT INCREASE TANK PRESSURE MORE THAN 2 PSI ABOVE THE SAFETY VALVE SET PRESSURE. 6. Using the pressure gage on the DA tank, observe and record the pressure at which the safety valve lifts. 7. Observe and record the reseat pressure. 8. Return to Normal Operation. 3

4 6 5 REF: MCM FES-138-01 SD6MSOP 07_P

Checklist for Comparing DA Steam Pressure & Temperature

1. Record deaerator steam pressure.

2. Record deaerator water temperature.

3. Find the saturated steam temperature from the table below for the steam pressure. Steam Pressure in St. Louis, Saturated Steam MO (PSIG) Temperature (F) 3 222 4 224 5 227 6 230 7 232 8 233 9 237 10 239 11 242

REF: MCM FES-138-01 SD6MSOP 08_P

Checklist for Safety Valve Following PRV (SVFPRV) – Pictures depict only DA – Steam PRV. Procedure can be used for all PRV Stations 1,2,3

1. Locate the Safety Valve following the PRV pressure reducing station.

2. Read the lift pressure and flow capacity from the tag on the safety valve. 3. Pour water in the drip pan drain and confirm that it is unobstructed. 4. Close isolation valves in the steam line. 5. SLOWLY open bypass valve around PRV to raise pressure until the safety valve lifts. DO NOT RAISE PRESSURE MORE THAN 2 PSIG ABOVE SETPOINT PRESSURE. 6. Observe and record the pressure at which the safety 4,10 valve lifts. 7. Fully open the bypass valve to perform accumulation test. The pressure should not rise more than 2 psi over lift pressure during accumulation test.

8. Close bypass valve. 9. Observe and record the pressure at which the safety valve reseats.

10. After the safety valve has fully reseated, slowly open the Isolation Valves. 11. Return to Normal Operation. 6,9

5,7,8

REF: MCM FES-138-01 SD6MSOP 09_P

Checklist for Safety Valve Following PRV (SVFPRV) – HEAT EXCHANGERS 1,2,3

1. Locate the Safety Valve following the PRV pressure reducing station. 2. Read the lift pressure and flow capacity from the tag on the safety valve. 3. Pour water in the drip pan drain and confirm that it is unobstructed. 4. Close isolation valve in the steam line. 5. SLOWLY open bypass valve around PRV to raise pressure until the safety valve lifts. DO NOT RAISE PRESSURE MORE THAN 2 PSIG ABOVE SETPOINT PRESSURE. 6. Observe and record the pressure at which the safety valve lifts. 7. Fully open the bypass valve to perform accumulation test. The pressure should not rise more than 2 psi over lift pressure during accumulation test. 8. Close bypass valve.

9. Observe and record the pressure at which the safety valve reseats. 10. After the safety valve has fully reseated, slowly open

the Isolation Valve. 5,8 11. Return to Normal Operation

6,9

REF: MCM FES-138-01 SD6MSOP 10_P

Checklist for Liquid Relief Valve on Oil Pump Set (LRVOPS)

1. Locate Fuel Oil Pump Set. 2. Make sure all necessary valves are lined up and open. (Supply and Return to the tank and valves in between. Will test both pumps.) 3. Select Fuel Oil Pump 1 and start pump.

4. Locate Manual Valve. See Picture. 5. Slowly Close Manual Valve 1 to raise oil pressure until relief valve opens. Record pressure the valve lifts by using pressure gage indicated in the photo below. 6. Verify Oil flow in view port.

7. Slowly close Manual Valve fully. Abort if pressure continues to rise and doesn’t stabilize or spikes. Do not dead head oil pumps. 8. Slowly Open Manual Valve and record the pressure when the valve reseats. 9. Turn off Fuel Oil Pump. 10. Select Fuel Oil Pump 2 and start pump.

11. Repeat steps 4-9 and return to normal operation.

Pressure Gage

Manual Valve REF: MCM FES-138-01 SD6MSOP 11_P

Checklist for Carbon Monoxide and Combustible Gas Alarms in the Boiler Plant CO / LEL Sensor Procedure 1. Assemble test gas setup for CO or LEL sensor test.

a) Use 50 ppm CO or less test gas for CO sensors. b) Use 10% LEL or less test gas for LEL sensors. 2. Locate and connect test gas setup to CO or LEL sensor inlet or remote test tubing.

3. Open test gas regulator valve to allow test gas to flow into sensor 4. Record concentration of CO or LEL at which the alarm activates. 5. Close test gas valve and disconnect test gas setup Repeat on all other sensors.

LOCATIONS Number / Type Location #1 / CO Boiler 2 #2 / CO Boiler 3 #3 / LEL Panel On South Wall, Sensor at roof height #4 / LEL Panel On South Wall, Sensor at roof height

1,2,3,4 REF: MCM FES-138-01 SD6MSOP 12_P

Checklist for Outside Air Damper Alarm

1. Measure and verify on data sheet approximate outside air damper inlet area.

2. Required inlet area is based on total Boiler Capacity. 3. If Air Inlet is not Fixed Open, an alarm must be configured.

REF: MCM FES-138-01 SD6MSOP 13_P

Checklist for Emergency Stop/Panic Buttons (ESPB)

1. Perform the following test for each of the Estop buttons. Be prepared to recover the plant after each test. 2. Turn on Fuel Oil Pumps 3. Fire at least one boiler on Natural Gas.

4. Activate the Estop Button. 5. Verify the Main Natural Gas Shutoff Valve to the plant closes within 3 seconds. 6. Verify that the Fuel Oil Pumps shut off within 3 seconds. 7. Reset the Main Natural Gas Shutoff Valve by rotating the lever to open

the valve. It should catch and remain open.

West Chiller Plant North Exit Door on West North Exit Door on East East Chiller Plant Exit Exit Door Side of Boiler Plant Side of Boiler Plant Door

Boiler Plant Exit to Boiler Plant Control Boiler Plant Control Main Natural Gas Chiller Plant Panel Room Shutoff Valve

Third Floor

Semi -Annual Boiler Safety

Device Testing Procedures

St. Louis John Cochran VAMC Boiler Plant REF: MCM FES-138-01 SD6MSOP 15_P

Checklist for Recycle and Non-Recycle Boiler Steam Pressure Limit Switches (RBSPLS & NRBSPLS)

Danger: Proper PPE Required (NFPA 70E)

1. Close the steam stop valve and/or the steam header valve on the boiler you are about to test. 2. On the boiler panel, place the boiler firing rate in manual. 1,13 3. Start the boiler. 4. Observe and Record the pressure at which the boiler trips offline on the data sheet. (Recycle) 5. Secure Power to the Boiler. (Prove the circuit dead with

multimeter) 6. Locate the Recycle Steam Pressure Limit Switch. (See Picture.)

7. Install an electrical jumper across the common and normally closed terminals on the Recycle Steam Pressure Limit Switch. (See Picture).

8. Restore Boiler Power. Recycle Non-Recycle 9. Start the Boiler. 10. Observe and Record the pressure at which the boiler 6 trips offline. (Non-Recycle) 11. Secure power to the boiler. (Prove Circuit Dead with multimeter). 12. Remove electrical jumper on Recycle Steam Limit Switch. 13. Slowly open Steam Stop and/or Header valves to bleed excess pressure. 14. Restore Boiler Power 15. Return boiler to normal.

4,10, 7,12

REF: MCM FES-138-01 SD6MSOP 16_P

Checklist for Steam Safety Valves on Boiler (SVB)

1. Inspect safety relief valve plumbing. 1,2,3,4 2. Check for gap (min ½ inch) between pipe and drip pan ell. 3. Pour water down drip pan eel and verify the plumbing is free of obstruction.

4. Read the steam safety relief valve set pressure and capacity from the tag on each steam safety relief valve. 5. Close Steam Stop Valve and/or Steam Header Valve for only the boiler you are about to test. Secure Power to the boiler. 6. 7. Locate the Recycle Steam Pressure Limit Switch. 8. Install an electrical jumper across the common and normally closed terminals on the Recycle Steam Pressure Limit Switch. 9. Locate the Non-Recycle Steam Pressure Limit Switch. 10. Install an electrical jumper across the common and normally closed terminals on the Non-Recycle Steam Pressure Limit Switch. 11. Restore Electrical Power to Boiler 12. On the Boiler Panel, place the boiler firing rate in manual. 13. Ensure the boiler is at a normal operating water level. 14. Start the boiler. (Low Fire) 15. NEVER ALLOW THE BOILER PRESSURE TO EXCEED MAWP. 5,26 16. Observe and record the pressure at which the first steam safety relief valve opens. 17. Increase the firing rate if needed. 18. Observe and record the pressure at which the second steam safety relief valve opens. 19. Increase the firing rate to 100%. 20. Observe and record the pressure at which the third steam safety relief valve opens. (If equipped with three safety valves). 21. Verify that the steam pressure does not continue to increase after final steam safety valve is open. 22. Return to low fire and shut the boiler down. 23. Observe and record the pressure that the third steam safety relief valve reseats. 24. Observe and record the pressure that the second steam safety relief valve reseats. 25. Observe and record the pressure that the first steam safety relief 7,8,9,10,28 valve reseats. 26. SLOWLY open the Steam Stop and/or Header Valve to relieve excess pressure. 27. Secure electrical power to the boiler. 28. Remove the electrical jumpers from the Recycle and Non-Recycle Steam Limit Switches. 29. Restore Power to Boiler. Reset Non -Recycle Steam Limit Switch. 30. Return to Normal Operation REF: MCM FES-138-01 SD6MSOP 17_P

Checklist for Low Fuel Gas Pressure Cutoff Switch (LFGPCS)

2 1. Locate Natural Gas Train on Boiler. 2. Locate Low Gas Pressure Cutout Switch downstream of PRV (Regulator) and upstream of Automatic Shut Off Valves (Maxon) 3. Insert pressure gage and open test port ball valve. 4. Start Boiler 5. With boiler online in Low Fire, observe and record regulated gas pressure on the data sheet. 6. Remove Lock and Close LOO (Lock Open Only) ball valve to isolate switch. 7. Slowly open test port fitting on valve assembly to SLOWLY bleed pressure until the switch trips the boiler offline. 3,5,8 8. Observe and record the pressure at which the boiler trips offline. 9. Close ball valve, and remove test pressure 9 gage. 10. Open LOO (Lock Open Only) Valve and secure lock in place. 6,10 11. Note annunciation on Fireye (LOW GAS PRESSURE) 12. Reset Fireye. 13. Return to Normal Operation.

7 REF: MCM FES-138-01 SD6MSOP 18_P

Checklist for High Fuel Gas Pressure Cutoff 2 Switch (HFGPCS) 1. Locate Natural Gas Train on Boiler. 2. Locate High Gas Pressure Cutout Switch downstream of PRV (Regulator), downstream of Automatic Shut Off Valves (Maxon), and upstream of flow control valve. 3. Remove plug and connect pressure gage / pump setup as shown in picture. Be sure to open test port and ZERO pressure gage if using digital gage. 4. Start Boiler 5. With boiler online in Low Fire, observe and record regulated gas pressure on the data sheet. 8 6. Remove Lock and Close LOO (Lock Open Only) ball valve to isolate switch. 7. Use the pump to SLOWLY increase the pressure until the boiler trips offline. 8. Observe and record the pressure at which the boiler trips offline. Fireye should annunciate “High Gas Press”. 9. Remove test gage / pump setup, close test port, and replace plug. 10. Open LOO (Lock Open Only) Valve and secure lock in place. 11. Reset the Fireye 12. Return to Normal Operation.

5,8

3,6,7,9,1

REF: MCM-FES-138-01 SD6MSOP 19_P

Checklist for Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (AFGSOV & AFGSVV) – Main Gas Line

Test Port 3

LOO Valve Vent Valve

GV 1 GV 2

Test Port 1 8

Test Port 2 10,14

1. On the boiler gas train, locate the automatic shutoff valves (Maxon - GV1 & GV2) with the vent line and vent valve in between. (See Picture). 2. Connect flexible tubing to the three test ports. 3. Start the boiler and place in low fire. 4. Close the manual LOO (lock open only) valve in the vent line. 5. Place the flex tubing connected to Test Port 3 no more than a ¼ inch deep in water. (The test can be accelerated by pressurizing the flex line before submerging in water.) 6. Open the valve (Test Port 3) in vent line. If no bubbles appear in a time of 2 minutes, the vent valve is not leaking. Close Test Port 3. 7. Shutdown the boiler. 8. Close the main gas manual valve downstream of both automatic shutoff valves (Maxon). 9. Locate Test Port 2 downstream of (GV2). 10. Place the flexible tubing no more than ¼ inch deep in the container of water. REF: MCM-FES-138-01 SD6MSOP 19_P

Continued - Checklist for Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (AFGSOV & AFGSVV) – Main Gas Line

16 Test Port 3

LOO Valve

GV 1 GV 2

Test Port 1

Test Port 2 10,14

11. Open Test Port 2 and look for bubbles. There is pressure trapped so bleed pressure before starting timer. If no bubbles are observed for 2 minutes, the downstream automatic shutoff valve (Maxon) is not leaking. Close Test Port 2. 12. Open Test Port 3 and verify that the pressure trapped between the automatic shutoff valves (Maxon) is atmospheric. (Pressure should bleed out of the test port. Close test port 3. 13. Locate Test Port 1 downstream GV1 (Maxon). 14. Place the flexible tubing no more than ¼ inch deep in the container of water. (The test can be accelerated by pressurizing the flex line before submerging in water.) 15. Open Test Port 1 and look for bubbles. If no bubbles are observed for 2 minutes, the upstream automatic shutoff valve (Maxon) is not leaking. 16. Replace and secure the lock on the LOO (lock open only) valve in the vent line. 17. Remove all flex tubing and test setups. 18. Close all test ports. 19. Return to Normal Operation.

REF: MCM FES-138-01 SD6MSOP 20_P

Checklist for Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (APFGSOV & APFGSVV) – Pilot Gas Line

Vent Valve LOO Valve PV 1

Test Port 1

PV 2

Test Port 2

1. On the boiler pilot gas train, locate the automatic pilot shutoff valves (PV1 & PV2) with the vent line and vent valve in between. (See Picture). 2. Connect flexible tubing to the two test ports. 3. Close the manual LOO (lock open only) valve in the vent line. 4. Place the flex tubing connected to Test Port 1 no more than a ¼ inch deep in water. (The test can be accelerated by pressurizing the flex line before submerging in water.) 5. Start the boiler, and when pilot flame is established, but before the main gas valves open, place the Fireye YB110 in "Check Mode". 6. Open the valve (Test Port 1) downstream of Vent Valve. If no bubbles appear in a time of 2 minutes, the vent valve is not leaking. 7. Close Test Port 1. 8. Stop the boiler. 9. Close the manual valve downstream of Test Port 2. 10. Place the flexible tubing connected to Test Port 2 no more than ¼ inch deep in the container of water. 11. Open the valve for Test Port 2 and look for bubbles. If no bubbles are observed for 2 minutes, the downstream pilot valve is not leaking. Close Test Port 2. Verify that pressure remains trapped between the Pilot Valves.

REF: MCM FES-138-01 SD6MSOP 20_P

Continued - Checklist for Automatic Fuel Gas Shutoff Valves and Solenoid Vent Valve Seat Leakage (AFGSOV & AFGSVV) – Pilot Gas Line 12. Open Test Port 1 and allow the pressure trapped between the automatic shutoff valves to vent. This proves that the Automatic Pilot Vent Valve is open with the Pilot off. 13. Place the flexible tubing from Test Port 1 no more than ¼ inch deep in the container of water. (The test can be accelerated by pressurizing the flex line before submerging in water.) 14. Look for bubbles. If no bubbles are observed for 2 minutes, the automatic pilot vent valve is not leaking. Close Test Port 1. 15. Open the LOO (lock open only) valve in the vent line, and replace and secure the lock on the valve. 16. Open manual valve downstream of PV2. 17. Remove all flexible tubing and test setups. 18. Close all test ports. 19. Return to Normal Operation.

REF: MCM FES-138-01 SD6MSOP 21_P

Checklist for Proof of Closure on Automatic Fuel Shutoff Valves (POC-AFGSOV) – Natural Gas Upstream Valve 2.

1. With the boiler offline, kill the power. 2. Close the LOO (Lock OPEN ONLY) valve in the natural gas vent line located between the automatic shutoff valves. 3. Close the Main Gas Shutoff valve in the natural gas train downstream of the Automatic Shutoff Valves, remove lock from High Gas Pressure

Switch and close LOO valve to isolate High Gas Pressure Switch. 4. Install a pressure gage setup to test port downstream of first Maxon valve. Open Test Port. 5. Locate the GAS POC SAFETY TEST ELECTRICAL BOX 6. Remove the front cover from the box. Remove all wires on front

terminal strip. 3. 7. Locate Wires going to AFGSOV POC 1. (Black and Blue wires). 8. Place a multimeter across wires as shown. 9. Set the multimeter to Continuity (Ohms). 10. Place a toggle switch jumper across the outer front terminals (wires

going back to BMS) as shown. Set the toggle switch jumper to ON. 11. Place the multimeter and pressure gage side by side. 12. Restore power and start boiler. When the automatic shutoff valve begins to open verify that the proof of closure switch opens with a very slight opening of the valve by looking for the multimeter to show OL before pressure rises on the gage. SWITCH THEN PRESSURE RISE. 5 It is a good idea to film this with a cell phone camera so that it can be better viewed. 13. Switch toggle switch jumper to OFF position. Attempt to start the boiler. The boiler should lockout and not be allowed to start. 14. Verify pressure is trapped between the Maxon valves. Pressure gage should show pressure. Close upstream fuel valve Test Port. 15. Secure Power, Remove multimeter. Do not reconnect POC 1 wires yet. 11,12 7,8,9,10

4. REF: MCM FES-138-01 SD6MSOP 21_P

Checklist for Proof of Closure on Automatic Fuel Shutoff Valves (POC-AFGSOV) – Natural Gas – Downstream Valve

16. Install a pressure gage setup to test port downstream 17,18,19, 20 of second Maxon valve. Open Test Port. Open and close Main Gas Shutoff Valve to vent pressure. 17. Locate POC 2 Wires in POC BOX. (Red and Black wires.) 18. Place a multimeter across wires POC 2 wires (red and black) as shown.

19. Set the multimeter to Continuity (Ohms). 20. Leave toggle switch jumper in place. The toggle switch jumper should be set to ON. 21. Place the multimeter and pressure gage side by side. 22. Restore power and start boiler. When the automatic

shutoff valve begins to open verify that the proof of closure switch opens with a very slight opening of the valve by looking for the multimeter to show OL before pressure rises on the gage. SWITCH THEN PRESSURE RISE. It is a good idea to film this with a

cell phone camera so that it can be better viewed. 23. Kill power to boiler and remove multimeter and toggle switch jumper. Reconnect all wires to proper terminals. 16 24. Open the (LOO) vent valve, replace lock, open the

Main gas Shutoff Valve after the Downstream Automatic Shutoff Valve (Maxon), open the LOO isolation valve to the High Gas Pressure Switch and 21, 22 secure lock. 25. Return boiler to normal operation.

24 REF: MCM FES-138-01 SD6MSOP 22_P

Checklist for Low Pilot Fuel Gas Pressure Cutoff Switch (LPFGPCS)

1. Locate Pilot Gas Train on Boiler. 2. Locate Low Pilot Gas Pressure Cutout Switch downstream of the PRV (Regulator) and upstream of Automatic Shutoff Valves (ASCO). (See Picture) 3. Start the boiler 4. When the boiler reaches Pilot Trial For Ignition (PTFI) place the Fireye in Check Mode to hold the boiler in pilot for the test. 5. Observe and record the regulated pilot gas pressure on the pressure gage. 6. Slowly throttle the pilot pressure using the 3 way valve shown in the picture below. Do not throttle below 80% of regulated pilot gas pressure. 7. Observe and Record pressure at which the boiler trips offline. 8. Reset Low Pilot Gas Pressure Switch and Fireye and place Fireye back in run mode. 9. Restart boiler. 10. During PTFI place the Fireye in Check Mode and throttle the pilot gas pressure to 90% of pilot gas regulated pressure.

11. Place the Fireye back into “run” mode and verify the boiler lights smoothly. 12. Return to normal operation.

4,8,10,11

7,10

6, 10 REF: MCM FES-138-01 SD6MSOP 23_P

Checklist for Flame Scanner Not Sensing Igniter Spark (FSNSIS)

1. Close manual valves in main fuel line and pilot gas line. (Close Pilot valve closest to the burner inlet).

2. Attempt to start boiler.

3. Determine if the scanner output indicates a Flame signal indicating that it senses a spark.

REF: MCM FES-138-01 SD6MSOP 24_P

Checklist for Igniter Timing (IT) 1. Close manual valves in main fuel line and pilot gas line.

2. Start boiler.

3. Use non-contact voltage detector to observe when the ignitor is activated (detector will illuminate when ignitor is on).

4. Observe the duration of the ignition spark with a stop watch. (Start timer when detector lights up. Stop when light goes out.)

REF: MCM FES-138-01 SD6MSOP 25_P

Checklist for Main Flame Ignition Timing (MFIT)

1. Close the lockable manual valve between the fuel line and the HFGPCS

2. Close manual valve in main fuel line closest to burner.

3. Attempt to start boiler 2 4. Time the AFGSOV from the time they begin to open until they close with a stopwatch. (Start timing when the Maxon Valves “click”).

5. Open (LOO) and replace lock. Open main gas valve. Return to normal operation.

4 REF: MCM FES-138-01 SD6MSOP 26_P

Checklist for Pre-Purge and Post-Purge Timing (PPT) 1. Start the boiler 2. Use a stop watch to record the time it takes for the Fireye to begin counting purge. (The time from when the fan comes on till the count starts) 2 3. Observe and record (on the data sheet) the time in high fire purge. (The amount of time the jack shaft is in the high fire position). 4. Use a stopwatch to record (on the data sheet) the time it takes the jack shaft to go from high fire purge to lightoff position. 3 5. After boiler is lit and firing turn the burner switch off.

6. Use a stopwatch to record (on the data sheet) the time “Postpurging” (The amount of time the fan is on after the boiler shuts down).

REF: MCM FES-138-01 SD6MSOP 27_P

Checklist for Low-Fire Proving Switch (LFPS) 1. Locate the control cabinet on boiler front and open cabinet to LFPS access wiring.

2. Turn control power off. 3. Verify the circuit is dead. 4. Disconnect one electrical lead from terminal 55 or 58. Tape the end of the exposed wire with electrical tape. 5. Turn power on. 6. Start the boiler and allow boiler to go through purge. Boiler 1,4,8 should hold in low fire position and not try to light. 7. Turn boiler off and disconnect power. Verify circuit is dead. 8. Reconnect electrical lead to proper terminal. 9. To test the LFPS setpoint insert multimeter into terminals 55 and 58 as shown. 10. Set the multimeter to AC Voltage (V⁓). 11. Turn power on and restart boiler. 12. Once boiler is lit (while watching the multimeter) manually raise the firing rate until the switch opens (displays voltage). 13. Determine and record the % firing rate at which the switch opened. 12 14. Turn boiler off, disconnect power, remove multimeter. 15. Restore power and return boiler to normal operation.

REF: MCM FES-138-01 SD6MSOP 28_P

Checklist for Forced Draft Damper Wide- Open Pre-Purge Proving Switch (FDDWOPS) 1. Locate the control cabinet on boiler front and open cabinet to access wiring. 2. Turn control power off. 3. Verify the circuit is dead. 4. Disconnect one electrical lead from terminal 5 or 1 54. Tape the end of the exposed wire with electrical tape. 5. Turn power on. 6. Start the boiler and allow boiler to go purge. Boiler should hold in purge and not count. 7. Turn boiler off and disconnect power. Verify 4 circuit is dead. 8. Reconnect electrical lead to proper terminal. 9. To test the FDDWOPS setpoint, insert multimeter into terminals 5 and 54 as shown. 10. Set the multimeter to AC Voltage (V⁓). 11. Turn power on and restart boiler. 12. Once boiler is lit (while watching the multimeter) manually raise the firing rate until the switch closes (shows Zero Volts). 13. Determine and record the % firing rate at which the switch closed. 14. Turn boiler off, disconnect power, remove multimeter. 15. Restore power and return boiler to normal 12 operation.

REF: MCM FES-138-01 SD6MSOP 29_P

Checklist for Combustion Air Pressure Switch (CAPS)

Test Port 1

7,10 LOO Valve

1. Locate the CAPS Switch. 2. Locate Test Port 1 on the high-pressure side of the CAPS. 3. Connect flex tubing to the top port of the tee above Test Port 1 to the high-pressure side (+) of the manometer. Clamp off loose end of tubing as shown. 4. Open Test Port 1. 5. Start the Boiler. 6. Record the lowest stable pressure seen on the manometer during purge. 7. With the boiler in low fire, close the LOO (lock open only) on the high-pressure line to isolate the switch. 8. Slowly decrease the pressure by using the bleed line. (Note: You may need to apply a slight suction to the line to activate the switch.) 9. Observe and Record the pressure at which the boiler shuts down. 10. Open LOO valve and secure lock. 11. Remove the flex tubing and close test port 1. 12. Reset the Fireye & return to normal operation. REF: MCM FES-138-01 SD6MSOP 30_P

Checklist for Purge Air Flow Proving Pressure Switch (PAPS)

Test Port 2

Test Port 1

7 LOO Valve

Bleed Line

1. Locate the PAPS Switch. 2. Locate Test Port 1 on the high-pressure side of the PAPS. 3. Connect flex tubing tee setup to Test Port 1 and to the high-pressure side (+) of the manometer. Clamp off loose end of tubing as shown. 4. Locate Test Port 2 on the low-pressure side of the PAPS. 5. Connect one end of flex tubing to Test Port 2 and connect the other end into the low pressure (-) side of the manometer as shown in picture. 6. Open Test Port 1 and Test Port 2. 7. Kill the power. Remove cover from PAPS switch and place multimeter (set to voltage) across Common and Normally Open terminals. 8. Restore the power and start the Boiler. 9. Record the highest stable pressure seen on the manometer during purge. 10. With the boiler in purge, close the LOO (lock open only valve) on the high-pressure line to isolate the switch. 11. Bleed the pressure by using the bleed line. (Note: remove clamp from bleed line.) 12. Verify the boiler is holding in purge on the Fireye panel. 13. Slowly pressurize the switch by blowing into the bleed line. 14. While watching the manometer, record the pressure that the switch makes (0 volts). 15. Stop the boiler and open the LOO valve and secure lock. 16. Kill the power. Remove the multimeter and the flex tubing and close test ports 1&2. 17. Restore power and return to normal operation.

REF: MCM FES-138-01 SD6MSOP 31_P

Checklist for Forced Draft Motor Interlock Switches (FDMIS)

1. THIS TEST MUST BE PERFORMED WITH THE PROPER NFPA 70E PPE!!! ONLY SPLIT CORE CT SHOULD BE TESTED. 2. Turn Power to Fan and Main Boiler Breaker off. 3. Unclamp and remove (split core) FDMIS from one electrical power lead to fan from terminal block. 4. Restore power and attempt to start boiler. Boiler should shut down quickly. a. If boiler does not lock out within 15 seconds of purge turn boiler off. 5. Kill the power and replace the wire. Repeat the procedure for the other two legs.

3 2

3 REF: MCM FES-138-01 SD6MSOP 32_P

Checklist for Low Flue Gas Oxygen Level Interlock (LFGOLI)

1. During the required 6-month tuning of boiler combustion, have the contractor determine the minimum %O2 that holds the CO levels below 200 ppm. (Gas and Oil)

2. Start the boiler and supply calibrated test gas (at a level above the minimum %O2 found above) through the sensor calibration test port. 3. Observe and record cutoff point.

3 2

Turn switch to zero to line up supply gas. REF: MCM FES-138-01 SD6MSOP 33_P

Checklist for Low Fuel Oil Pressure Cutoff Switch (LFOPCS)

1. Locate the Low Oil Pressure switch on the boiler oil train. (See Picture). 2. Install Pressure Gage into Test Port 1. Open Test Port 1. 3. Start the boiler with oil as the fuel. 4. Place the boiler in manual mode and put the boiler in low fire. 5. Observe the regulated oil pressure on the pressure gage and record on the data sheet.

6. Remove lock and close the LOO (lock open only) ball valve. 7. SLOWLY crack the fitting on Test Port 1 to bleed pressure. Use a towel or container to capture fuel oil. 8. Observe the pressure at which the boiler shuts down and record on the data sheet. 9. Close Test Port 1.

10. Open LOO (lock open only) valve and Lock Open. 11. Return to normal operation.

Low Oil Pressure 1 Switch

2,5,8

Test Port 1

7,9

6,10 Lock Open Only (LOO)Valve REF: MCM FES 138-01 SD6MSOP 34_P

Checklist for High Fuel Oil Pressure Cutoff Switch (HFOPCS)

1. Locate the High Oil Pressure switch on the boiler (See Picture) 2. Locate the Test Port downstream of the LOO (lock open only) valve. 3. With the Test Port closed, connect pressure gage / pump setup to the test port. (Be sure to

use High Pressure Hard Plastic Tubing and High-Pressure gage (Gage rated at pressure greater than max oil pressure). Use rag or oil drip bucket to catch leaking oil.) 4. Open the Test Port to pressurize gage / pump setup. 5. Start the boiler with oil as the fuel. 6. Place the boiler in manual mode and put the boiler in low fire. 7. Observe the regulated oil pressure on the pressure gage and record on the data sheet. 8. Close the LOO (Lock Open Only) valve. 9. Use Pump to SLOWLY raise the pressure until the boiler trips offline. 10. Close the Test Port, remove test setup and replace plug 11. Open the LOO (lock open only) valve. 12. Return to normal operation.

High Oil Pressure Switch

Test Port

LOO Valve REF: MCM FES-138-01 SD6MSOP 35_P

Checklist for Low Atomizing Media Pressure Switch (LAMPS)

1. Locate Low Atomizing Media Switch 2. Install Pressure gage setup and open test port ball valve. 3. Place the Boiler in Manual Mode and set to low fire. 4. Start the Boiler 5. Observe and record the atomizing media pressure during purge.

6. Observe and record the atomizing media pressure at low fire and high fire. 7. With boiler in low fire, close the LOO isolation valve for the Low atomizing media pressure switch. 8. Slowly bleed pressure by cracking the test port fitting on the valve. 9. Observe and record the atomizing media pressure at which the boiler trips offline.

10. Reset the Fireye and return to Normal Operation.

Test Port Low Atomizing Media Switch

LOO Valve REF: MCM RES-138-01 SD6MSOP 36_P

Checklist for Automatic Fuel Oil Shutoff Valves (AFOSV) - for Seat Leakage

AFOSOV 1 AFOSOV 2

Test Port 1

Test Port 2

1. Verify Oil Pump Set is online. 2. Locate the Automatic Fuel Oil Shutoff Valves. 3. Verify that a pressure of approximately regulated pressure or higher is trapped between the Automatic Fuel Oil Shutoff Valves. (If not, fire the boiler and quickly close the manual valve located after the fuel oil automatic shutoff valves to trap pressure between them. 4. Close the manual valve downstream of the automatic fuel oil shutoff valves just before the burner entrance. 5. Locate the downstream Automatic Fuel Oil Shutoff Valve. (AFOSV2) 6. Locate Test Port 2. 7. Place an approved container to capture oil under Test Port 2. 8. Open Test Port 2 and observe oil flow. 9. Some time is needed for residual oil to drain and equilibrium to be established. In order to consider the valve as not leaking, oil flow should be less than 1 drop in 10 seconds.

10. Close Test Port 2

REF: MCM RES-138-01 SD6MSOP 36_P

ContinuedChecklist - Checklistfor Automatic for Automatic Fuel Oil Shutoff Fuel Oil Valves Shutoff (AFOSV) Valves (AFOSV)- for Seat - for Leakage Seat Leakage

AFOSOV 1 AFOSOV 2

Test Port 1

11. Verify Oil Pump Set is online. 12. Locate the Automatic Fuel Oil Shutoff Valves. 13.11. VerifyLocate that the aupstream pressure Automatic of approximately Fuel Oil regulated Shutoff Valve.pressure (AFOSV1) or higher. is trapped between 12. theLocate Automatic Test Port Fuel 1 inOil between Shutoff the Valves. valves. (If Remove not, fire pressurethe boiler gage and setupquickly if installedclose the. 13. manualPlace an valve approved located container after the to fuel capture oil automatic oil under shutoffTest Port valves 1. to trap pressure between 14. them.Open Test Port 1 and observe oil flow. 14.15. CloseSome thetime manual is needed ball forvalve residual downstream oil to drain of the and automatic equilibrium fuel tooil be shutoff established. valves To just beforeconsider the the burner valve entrance. as not leaking, oil flow should be less than 1 drop in 10 seconds. 16. Close Test Port 1. 15. Locate the downstream Automatic Fuel Oil Shutoff Valve. (AFOSV2) 17. Open the manual ball valve downstream of the automatic fuel oil shutoff valves just 16. Locate Test Port 2. before the burner entrance. 17.18. PlaceReturn an to approved Normal Operation.container to capture oil under Test Port 2. 18. Open Test Port 2 and observe oil flow. 19. Some time is needed for residual oil to drain and equilibrium to be established. In order to consider the valve as not leaking, oil flow should be less than 1 drop in 10 seconds. 20. Close Test Port 2

REF: MCM FES-138-01 SD6MSOP 37_P

Checklist for Proof of Closure on Automatic Fuel Shutoff Valves (POC- 4 AFGSOV) – Oil This test will check the location, setpoint and the logical

function of the POC switches on both automatic valves. The setpoint will be found by making sure that the POC switch opens before gas pressure is sensed downstream of the valve. Logic is found by setting disconnecting the wires to the POC and trying to start the boiler. 1. Secure Power to the Boiler. 2. Locate electrical panel on front of Boiler. 3. Use a multimeter to prove the circuit dead. 4. Remove wire from terminal 15 and 16 and install a switch jumper across them as show in the picture. (Switch in the OFF position) 5. Restore Power to Boiler. 6. Attempt to start the Boiler. The Boiler should lock out. 7. Secure Power to the Boiler. 8. Use a multimeter to prove circuit is dead. 9 9. Remove second wire from terminal 15 and wire from terminal 65 that leads to upstream AFGSOV and connect a multimeter set to resistance across the wires and shown in the picture (POC for upstream AFGSOV). 10. Install a pressure gage between the upstream and downstream AFGSOV and place the multimeter beside it as shown. 11. Switch the jumper to the ON position, restore power to the Boiler. 12. Start the Boiler. 10 13. When the automatic shutoff valve begins to open verify that the proof of closure switch opens with

a very slight opening of the valve by looking for the multimeter to switch to “OL” (open circuit) before pressure rises on the gage. SWITCH THEN PRESSURE RISE. It is a good idea to film this with a cell phone camera so that it can be better viewed. 14. Shut down the Boiler and verify that pressure is trapped between the automatic shutoff valves. (Does the gage show a pressure greater than zero.) 15. Disconnect power from boiler. 16. Use a second multimeter to prove circuit is dead. 17. Disconnect wire 15 and 65 from multimeter and Reconnect it back to appropriate terminals.

REF: MCM FES-138-01 SD6MSOP 37_P

Continued - Checklist for Proof of Closure on Automatic Fuel Shutoff Valves (POC- AFGSOV) – Oil This test will check the location, setpoint and the logical

function of the POC switches on both automatic valves. The setpoint will be found by making sure that the POC switch opens before gas pressure is sensed downstream of the valve. 19 Logic is found by setting disconnecting the wires to the POC and trying to start the boiler.

18. Secure Power to the Boiler. 19. Remove second wire from terminal 16 and wire 65 that leads to downstream AFGSOV. Connect a multimeter set to resistance across wire 16 and wire 65 as shown (POC for downstream AFGSOV). 20. Restore Power to the Boiler. 21. Place the multimeter beside downstream pressure gage as shown. 22. Start the boiler 23. When the automatic shutoff valve begins to open 21 verify that the proof of closure switch opens with a very slight opening of the valve by looking for the multimeter to switch to “OL” (open circuit) before pressure rises on the gage. SWITCH THEN PRESSURE RISE. It is a good idea to film this with a cell phone camera so that it can be better viewed. 24. Disconnect power from boiler. 25. Use a second multimeter to prove the circuit is dead. 26. Disconnect wire 15 and 65 from multimeter and reconnect them to appropriate terminals. 27. Remove switch jumper and reconnect wires back to appropriate terminals. 28. Restore power and return to normal operation.

REF: MCM FES-138-01 SD6MSOP 38_P

Checklist for Oil Burner Position Switch (OBPS) 1. With the boiler off, retract the gun enough to disengage the switch. 2. Attempt to start the boiler. The boiler controls should not allow the purge process to begin. IF BOILER BEGINS TO MOVE TO THE PURGE POSTION SHUT THE BOILER DOWN IMMEDIATELY. IN THIS CASE THE OBPS SWITCH IS DEFECTIVE.

1 REF: MCM FES-138-01 SD6MSOP 39_P

Checklist for Economizer Liquid Relief Valve (LRVE)

1. Close Inlet and Bypass Valves for Boiler Economizer, 2,3,4 and Boiler Feedwater Inlet Valve.

2. Connect Hydrostatic Pump, equipped with a Calibrated Pressure Gage, to the test port on the economizer water line. 3. Open test port valve. Slowly raise pressure until Liquid Relief Valve opens. Note the Lift Pressure. NEVER EXCEED THE ECONOMIZER ALLOWABLE PRESSURE (MAWP!)

4. Close the Test Port, Shut down pump, and remove connection to Economizer.

5. Open Boiler Feedwater Makeup Inlet and Economizer Inlet Valve. 1,5

Connect Pump Setup Here.