13414 SPECS.pdf

252301_WCCF_Boiler Replacement Facilities Services Statement of Work 03/10/2025

Statement of Work

PROJECT SCOPE OF WORK:

DEMO: REMOVE EXISTING BOILERS (B-3 & B-4) AND REPLACE WITH NEW.

REMOVE/REPLACE PRIMARY LOOP PIPING RELOCATE BOILERS B-1 & 2

MECHANICAL: REPLACE B-3 & B-4 WITH SPECIFIED UNITS. MODIFY EXISTING

PROPANE PIPING AND CONNECT TO NEW BOILERS. REPLACE SYSTEM PUMPS WITH

NEW PACKAGED PUMP SYSTEM. POUR NEW/ENLARGED CONCRETE HOUSE KEEPING

PAD FOR NEW BOILERS. BASIS OF DESIGN IS RIELO ARRAY 4000 BOILERS.

CONTRACTOR RESPONSIBLE FOR SITE WORK/CONCRETE PAD AND INSTALLATION

NEEDED FOR NEW BOILERS. CONTRACTOR RESPONSIBLE FOR TESTING OF BOILERS

AND FACTORY START UP. CONTRACTOR MUST BE LICENSED IN THE STATE OF

OREGON REPLACE PRIMARY LOOP PIPING AS SHOWN ON THE BOILER PIPING

DIAGRAM. PROVIDE UNIT LABELS ON ALL NEW BOILERS. CONTRACTOR

RESPONSIBLE FOR UNIT SEISMIC ANCHORS & CALCULATIONS. INSULATE ALL PIPING

PER CODE AND SPECIFICATIONS

CONTROLS: SEE CONTROL POINTS LIST FOR AINSWORTH/DELTA WORK

ELECTRICAL: DISCONNECT AND RECONNECT NEW UNITS. PROVIDE DISCONNECTS.

PROVIDE ALL REQUIRED ELECTRICAL WORK TO POWER NEW 3 PHASE UNITS.

PROVIDE NEW POWER CONNECTIONS FOR SYSTEM PUMP PACKAGE.

TEMP BOILER-PHASING: PRE-PIPE NEW 6'' HWS & 6'' HWR LINES FROM BOILER ROOM

ENTRY POINT TO NEW PUMP LOCATION REPLACE PUMP WITH NEW PUMP PACKAGE

CONSTRUCT NEW 6'' HWS & HWR LOOP BETWEEN NEW PUMP AND TEMP BOILER

PROVIDE TEMP BOILER (WITH QUICK CONNECTS INSIDE BUILDING ENVELOPE)

PROVIDE TEMP BOILER RATED FOR 8 MILLION INPUT (MIN) TO RUN FACILITY WHILE

NEW BOILERS ARE REPLACED.

WCCF Boiler Upgrade Hydronic Piping and Pumps 2-11-25 23 21 00 - 1

SECTION 23 21 00 - HYDRONIC PIPING AND PUMPS

PART 1 - GENERAL

1.1 DESCRIPTION

A. The requirements of this section apply to the HVAC heating and cooling water systems. Provide pipe, pipe fittings, pumps, and related items required for complete piping system.

B. Related Work: The requirements of Section 23 05 00, Common HVAC Materials and Methods, also apply to this section.

1.2 QUALITY ASSURANCE

A. General: ASTM and ANSI Standards are indicated. In addition, special standards are referenced where neither ASTM nor ANSI Standards are applicable.

B. Labeling: All piping shall be continuously and legibly labeled on each length as required by codes and standards and including as a minimum, country of origin, manufacturers identification marking, wall thickness designation, and applicable standards and approvals. Fittings shall be labeled as required by the referenced standard.

C. Concealed Plastic Piping: No concealed plastic piping inside the building unless approved by Code or Governing Authorities.

D. Definitions: Where piping fluid is not indicated in the following paragraphs, provide similar piping materials for similar fluids.

E. To assure uniformity and compatibility of piping components in grooved piping systems, all grooved products utilized shall be supplied by a single manufacturer.

Grooving tools shall be supplied from the same manufacturer as the grooved components.

1. All castings used for coupling housings, fittings, and valve bodies shall be date stamped for quality assurance and traceability.

F. See Commissioning specification for additional requirements.

1.3 STORAGE AND HANDLING

A. Provide factory-applied end caps on each length of pipe and tube. Maintain end caps through shipping, storage and handling as required to prevent pipe-end damage and eliminate dirt and moisture from inside of pipe and tube. Protect flanges and fittings from moisture and dirt by inside storage and enclosure, or by packaging with durable, waterproof wrapping.

1.4 SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES (SUBMITTALS)

2-11-25 23 21 00 - 2

A. See the General Conditions, Section B – Administration of the Contract, B.18 – Submittals, Shop Drawings, Product Data and Samples for detailed requirements of shop drawings.

1.5 PRODUCT SUBSTITUTION

A. Materials other than those specified may be approved for this project in compliance with the General Conditions, Section B – Administration of the Contract, B.19 – Substitutions.

1.6 CHANGE ORDERS

A. All Change Orders shall be in compliance with the General Conditions, Section D

– Changes in the Work.

PART 2 - PRODUCTS

2.1 PIPING MATERIALS

A. Copper Pipe and Tube:

1. Application:

a. Heating water

2. Pipe: Type L hard temper copper with soldered joints, ASTM B88.

3. Fittings: Wrought copper solder-joint fittings, ANSI B16.22.

4. Preinsulated Piping: Type K solder joint copper piping with 1" thick urethane insulation protected by 20 gauge PVC outer jacket. Rovanco "Insul/80," equivalent Rikwil or approved substitute.

5. Heating Water, 2” and Larger: Rolled groove fittings with UPC approval.

a. Fittings: Cast bronze to ASME B16.18 or wrought copper to

ASME B16.22, manufactured to copper-tube dimensions. (Flaring of tube or fitting ends to accommodate alternate sized couplings is not permitted.) Victaulic Copper-Connection.

b. Grooved Joint Couplings: Couplings shall be manufactured ro copper-tube dimensions, with offsetting, angle-pattern, bolt pads, Grade EHP gasket rated to +250 deg F (+120 deg C), and ASTM A449 electroplated steel bolts and nuts. Victaulic Style 607H (Quick-Vic™), Installation ready rigid coupling for direct stab installation without field disassembly.

c. Victaulic CTS approved. -

B. Plastic Pipe:

1. Application: Where approved by Code.

a. Cooling coil condensate drain where concealed in walls.

b. Cooling coil condensate drain in mechanical or service areas located above 6' from the floor and continuously supported per specifications.

2. Pipe:

a. Polyvinyl Chloride and Chlorinated Polyvinyl Chloride Plastic

Pipe for Water Service: SDR-PR pipe, ASTM D2241; Schedules 40, 80 and 120, ASTM D1785.

2-11-25 23 21 00 - 3

3. Fittings: Provide fittings of the type indicated, matching piping manufacturer. Where not otherwise indicated, provide socket style, solvent weld fittings produced and recommended by the piping manufacturer for the service indicated.

2.2 MISCELLANEOUS PIPING MATERIALS/PRODUCTS

A. Insulating (Dielectric) Fittings: Do not use. See Section 3.2, G.

B. Welding Materials: Provide welding materials as determined by the installer to comply with installation requirements.

C. Soldering and Brazing Materials: Provide soldering materials as determined by the installer to comply with installation requirements.

1. Tin-Antimony Solder: ASTM B32, Grade 95TA.

2. Lead-Free Solder: ASTM B32, Grade HB. Harris "Bridgit" approved.

3. Silver Solder: ASTM B32, Grade 96.5TS.

D. Gaskets for Flanged Joints: ANSI B16.21; full-faced for cast-iron flanges; raised-face for steel flanges. Pressure and temperature rating required for the service indicated.

E. Strainers: "Y-pattern," ductile iron or bronze body (depending on pipe system) rated for pressures indicated with blow-off connection and 20 mesh stainless steel screen or perforated metal basket with 1/16" or 1/8" openings. Basis of Design:

Victaulic Style 732.

F. Hot Water Valves up to 12": Model #’s listed are Nibco unless noted otherwise.

Approved equal are Watts, Hammond, Appollo, and Victualic.

1. Ball (to 2”):

a. Two-piece, cast bronze body, full port, 600 psi WOG, T/S 585-70.

b. Two-piece, forged brass body, standard port, 300 psi, Victaulic

Series P589.

2. Butterfly: Ductile iron body, electroless-nickel coated ductile iron aluminum bronze disc, 300 psi WOG, pressure responsive elastomer seat, and stainless steel stem that is offset from the disc centerline to provide complete 360-degree circumferential seating, suitable for water temperatures to +250 degrees F. Lugged body – LD-2000, Wafer body – WD-2000, Grooved body – Victaulic Vic300 MasterSeal.

3. Check: Bronze or ductile iron body, spring-assisted swing check, 300 psi WOG, T/S-413B and F-918B, Grooved body – Victaulic Series 716.

2.3 HEATING WATER SPECIALTIES

A. Air Vents: Install at all system high points whether shown or not;

1. At all locations not in mechanical rooms use manual air vents.

2. At mechanical rooms fabricate of 2" diameter or larger pipe at least 12" long. At the high point of each main install an Armstrong No. 1AV autovent, or equivalent Bell & Gossett, Armstrong, Dunham-Bush approved substitute. Route discharge line to over floor sink.

2-11-25 23 21 00 - 4

B. Triple Duty Valve: Combination spring loaded vertical check, calibrated balancing and shut off valve with balance point memory in angle or straight pattern as required or as shown on the Drawings. Bell & Gossett, Taco, Armstrong, Thrush, Victaulic, Wheatley, Patterson or approved equal.

C. Suction Diffusers: Where indicated on Drawings provide a suction diffuser with stainless steel inlet vanes, combination diffuser-strainer orifice cylinder 20-mesh stainless steel and temporary start-up strainer on the inlet of base mounted pumps.

Bell & Gossett, Taco, Armstrong, Thrush, Victaulic, Wheatley, Patterson or approved equal.

D. Flow Control Valve:

1. Install where shown on plans, flow metering fittings complete with quick disconnect, flow meter valves, with safety shut-off valves and with size and series identification tags. Install as recommended by manufacturer, Victaulic, Griswold, Pro-Hydronic Specialties or approved equal.

2. Valves shall be dynamic flow limiting devices sized to the nearest 0.5 gpm. Stainless steel cartridge and spring with body and ends to match piping system.

3. Unless noted otherwise all flow control valves are flow limiting not balancing valves.

E. Circuit Setter and Balancing Valves: Globe style with calibrated handle style balancing fitting with differential pressure taps, brass or bronze body and trim.

TA Hydronics STAD Series, or equal Nexus, Wheatley or approved equal.

Valves shall only be used where specifically called out for balance valve, otherwise use flow control valve.

G. Air Eliminator, Dirt Separator, Hydraulic Separator: Full flow coalescing type combination air eliminator, dirt separator, hydraulic separator. Selection shall be based upon system flows with pipe size as a minimum. Separator shall be fabricated steel, rated for 150 psig minimum working pressure, stamped and registered in accordance with ASME for unfired pressure vessels. Unit shall include internal elements filling the entire vessel to suppress turbulence and provide air elimination efficiency of 100% free air, 100% entrained air, and 99.6% dissolved air at the installed location. Dirt separation efficiency shall be a minimum of 80% of all particles 30 micron and larger within 100 passes. The elements shall consist of:

1. A copper core tube with continuous wound copper wire medium permanently attached and followed by a separate continuous wound copper wire permanently affixed.

2. 300 Series stainless steel mesh.

3. Caleffi NA 549 SEP4, Spirovent Quad® Series VDX, Thrush, or

2.4 HYDRONIC PUMPS

A. Boil pumps integral to boilers.

2-11-25 23 21 00 - 5

B. Inline Pumps less than 250 GPM and constant flow: Inline configuration with close coupling design, mechanical seals, suitable for hot or cold water service at head and capacity stated on Drawings. Cast iron casing, bronze fitted, roller bearing, 1750 rpm standard frame motor. Impeller size not to exceed 90% of largest diameter impeller which will fit pump casing. Minimum horsepower and efficiency as indicated on Drawings and not less than will be required at any point of the impeller curve. Provide pressure gauge tappings on suction and discharge flanges. Grundfos, Bell & Gossett, Taco or approved equal.

2.5 PACKAGED HVAC PUMP (CHILLER PUMP) (MANUFACTURE = GRUNDFOS)

A. Variable Speed Packaged Pumping System

1. Furnish and install a prefabricated and tested variable speed packaged pumping system to maintain a constant pressure, constant differential pressure, variable differential pressure, constant return pipe temperature, constant differential temperature or control a Distributed Pumping System application.

2. The packaged pump system shall be a standard product of a single pump manufacturer. The entire pump system including pumps and pump logic controller, shall be designed, built, and tested by the same manufacturer.

3. The complete packaged water booster pump system shall be certified and listed by UL (Category QCZJ – Packaged Pumping Systems) for conformance to U.S. Standards.

B. Pumps

1. The pumps shall be split coupled, single stage, end suction top discharge design, cast iron stainless steel fitted construction. Pumps up to 6” discharge shall be centerline discharge, 8” and 10” discharge shall be tangential discharge.

a. The pumps shall have the following features:

1) Seal replacement shall be possible by only removing the coupling and seal cap.

2) Pump shall not require a baseplate or grouting to maintain correct alignment and maintain vibration levels to Hydraulic Institute standards (HI 9.6.4).

3) All pumps shall be of the back pull-out design so that the rotating element can be removed from the casing without disconnecting the suction or discharge piping. Motors shall pull back without requiring lifting.

4) The casing material shall be close-grained cast iron ASTM A48 - Class 35 with a minimum tensile strength of 35,000 P.S.I.

5) Volute shall have integrally cast suction and discharge ports, vent and drain ports. Pump volute shall have and integrally cast diffuser vane to provide balanced flow to the eye of the impeller reducing axial forces and improving efficiency. Casings shall be designed for scheduled working pressure and can withstand hydrostatic test at 150% of the maximum working pressure under which the pump could operate at design speed.

2-11-25 23 21 00 - 6

6) Suction and discharge flanges shall be flat-faced and be drilled to ANSI Class 125 standards.

7) Pump shall be constructed such that grouting, and field alignment are not required and that proper alignment tolerances are continuously maintained throughout the lifetime of the pump.

8) Pump volutes shall have an integrally cast foot to eliminate deflections and distortions.

9) The pump shaft shall be of solid stainless steel AISI 420.

10) The mechanical seal shall have as standard Silicon Carbide

– Silicon Carbide rotating and stationary faces with EPDM elastomers. The silicon carbide shall be of the advanced type having optimized hydrodynamic properties for long life and emergency dry running. The pump manufacturer shall recommend the proper mechanical seal based on the pressure, temperature and liquid outlined on the equipment schedule. On request, application of a mechanical seal shall be internally flushed type, without requiring external flushing lines. Seals shall be capable of being inspected and easily replaced without removing the piping or volute.

11) Recirculation line of copper tubing with brass fitting (optional nylon or stainless) shall be provided to vent the mechanical seal.

12. Impeller shall be of the enclosed single suction design, made of Stainless Steel 304 (UNS S30400), dynamically balanced to ISO 1940-1:2003 balance grade G6.3 and keyed to the shaft.

13. Pump Construction. The standard material of construction for the pump shall be as below. Special material shall be available as an option to suit the liquid pumped.

14. Volute: Cast iron ASTM A48 - Class 35

15. Impeller: Stainless Steel 304 (UNS S30400)

16. Shaft: Stainless Steel AISI 420

17. Coupling: Ductile Iron (ASTM 70-50-05)

18. Motor Support Rails: Carbon Steel (ASTM A36)

19. Mechanical Seal: Silicon Carbide – Silicon Carbide, EPDM Elastomers and Stainless-Steel hardware

20. Recirculation Line: Copper Tubing with Brass Fittings

21. Pump rotating assembly shall be connected to the drive motor by a rigid, ductile iron, axially split coupling capable of maintaining alignment under all torsional, radial and axial loads. The coupling design shall facilitate alignment of the motor and pump shaft.

22. The motor support rails shall be structural steel. The entire unit shall not require grouting for operation within Hydraulic Institute Standards for Vibration.

23. Pump shall be of a maintainable design for ease of maintenance and should use machine fit parts that are easily disassembled.

24. Each pump shall be painted with one coat of high-quality factory approved paint and name-plated before shipment from the factory.

25. Pumps shall be manufactured and assembled in an ISO- 14001 and ISO-9001 certified facility.

2-11-25 23 21 00 - 7

C. Motors

1. Motors shall meet scheduled horsepower, speed, voltage, and enclosure design. Pump and motors shall be factory aligned.

2. Motor shall be of standard NEMA C-face design.

3. Motors shall be suitably sized per ISO5199 and shall meet NEMA specifications and conform to the standards outlined in EISA 2007.

D. Variable Frequency Drives

1. The VFD shall convert incoming fixed frequency single-phase or three-phase AC power into a variable frequency and voltage for controlling the speed of Sigle Phase or three-phase AC induction motors. The VFD shall be a six-pulse input design, and the input voltage rectifier shall employ a full wave diode bridge; VFDs utilizing controlled SCR rectifiers shall not be acceptable. The output waveform shall closely approximate a sine wave. The VFD shall be of a PWM output design utilizing current IGBT inverter technology and voltage vector control of the output PWM waveform.

2. The VFD shall include a full-wave diode bridge rectifier and maintain a displacement power factor of near unity regardless of speed and load.

3. The VFD shall produce an output waveform capable of handling maximum motor cable distances of up to 1,000 ft. (unshielded) without tripping or derating.

4. The VFD shall utilize an output voltage-vector switching algorithm, or equivalent, in both variable and constant torque modes. VFD’s that utilize Sine-Coded PWM or Look-up tables shall not be acceptable.

5. The VFD shall automatically boost power factor at lower speeds.

6. The VFD shall be able to provide its full rated output current continuously at 110% of rated current for 60 seconds.

7. An empty pipe fill mode shall be available to fill an empty pipe in a short period of time, and then revert to the PID controller for stable operation.

8. Switching off the input power to the VFD shall be possible without interlocks or damage to the VFD at a minimum interval of 2 minutes.

9. Switching off power on the output side between the VFD and the motor shall be possible with no limitation or damage to the VFD and shall require no additional interlocks.

10. The VFD shall have temperature-controlled cooling fans for quiet operation, minimized internal losses, and greatly increased fan life.

11. The VFD shall provide full torque to the motor given input voltage fluctuations of up to +10% to -15% of the rated input voltage.

12. The VFD shall provide internal DC link reactors to minimize power line harmonics and to provide near unity power factor. VFDs without a DC link reactor shall provide a 5% impedance line side reactor.

13. The VFD to be provided with the following protective features:

a. Input surge protection utilizing MOVs, spark gaps, and Zener diodes to withstand surges of 2.3 times line voltage for 1.3 msec.

b. Circuitry to detect phase imbalance and phase loss on the input side of the VFD.

c. Current sensors on all three-output phases to detect and report phase loss to the motor. The VFD will identify which of the output phases is low or lost.

2-11-25 23 21 00 - 8

d. Auto-derate of output voltage and frequency to the motor in the presence of sustained ambient temperatures higher than the normal operating range, so as not to trip on an inverter temperature fault.

The use of this feature shall be user-selectable, and a warning will be exported during the event. Function shall reduce switching frequency before reducing motor speed.

e. Auto-derate of output frequency by limiting the output current before allowing the VFD to trip on overload. Speed can be reduced, but not stopped.

f. Integral RFI filter. VFD enclosures shall be made of metal to minimize RFI and provide immunity.

14. VFD to be provided with the following interface features:

a. Alphanumeric backlit display keypad, which may be remotely mounted using standard 9-pin cable. VFD may be operated with keypad disconnected or removed entirely. Keypad may be disconnected during normal operation without the need to stop the motor or disconnect power to the VFD.

b. Display of all faults in plain text; VFDs, which can display only fault codes, are not acceptable.

c. All VFDs shall be of the same series and shall utilize a common control card and LCP (keypad/display unit) throughout the rating range. The control cards and keypads shall be interchangeable through the entire range of drives used on the project.

d. VFD keypad shall be capable of storing drive parameter values in non-volatile RAM uploaded to it from the VFD and shall be capable of downloading stored values to the VFD to facilitate programming of multiple drives in similar applications, or as a means of backing up the programmed parameters.

e. A red FAULT light, a yellow WARNING light and a green POWER-ON light shall be provided. These indications shall be visible both on the keypad and on the VFD when the keypad is removed.

f. A start guide menu with factory preset typical parameters shall be provided on the VFD to facilitate commissioning.

g. VFD shall provide full galvanic isolation with suitable potential separation from the power sources (control, signal, and power circuitry within the drive) to ensure compliance with PELV requirements and to protect PLC’s and other connected equipment from power surges and spikes.

h. All inputs and outputs shall be optically isolated. Isolation boards between the VFD and external control devices shall not be required.

i. There shall be three programmable digital inputs for interfacing with the systems external control and safety interlock circuitry. An additional digital input is preprogrammed for start/stop.

j. The VFD shall have two analog signal inputs. One dedicated for sensor input and one for external set point input.

k. One programmable analog output shall be provided for indication of a drive status.

l. The VFD shall provide two user programmable relays with selectable functions. Two form ‘C’ 230VAC/2A rated dry contact relay outputs shall be provided.

m. The VFD shall store in memory the last 5 faults with time stamp and recorded data.

2-11-25 23 21 00 - 9

n. The VFD shall be equipped with a standard RS-485 serial communications port for communication to the multi-pump controller. The bus communication protocol for the VFD shall be the same as the controller protocol.

15. VFD Service Conditions:

a. Ambient temperature operating range, -10 to 45ºC (14 to 113°F).

b. 0 to 95% relative humidity, non-condensing.

c. Elevation to 1000 meters (3,300 feet) without derating.

d. VFD’s shall be rated for line voltage of 525 to 690VAC, 380 to

480VAC, or 200 to 240VAC; with +10% to -15% variations. Line frequency variation of ± 2% shall be acceptable.

e. No side clearance shall be required for cooling of the units.

E. Pump System Controller

1. The pump system controller shall be a standard product designed, developed, and supported by the pump manufacture. The controller shall be microprocessor based capable of having software changes and updates via personal computer (notebook). The controller user interface shall have a color display with a minimum screen size of 3-1/2” x 4-5/8” for easy viewing of system status parameters and for field programming. The display shall have a back light with contrast adjustment. Password protection of system settings shall be standard.

2. The pump system controller shall be mounted in a UL Type 12 rated enclosure. A self-certified NEMA enclosure rating shall not be considered equal. The entire UL Type 12 control panel shall be UL 508A listed as an assembly. The control panel shall include a main disconnect, branch circuit protection for each pump and the control circuit and control relays for alarm functions.

3. The control panel shall include the following:

a. 80 dB System Fault Audible Alarm with push button to silence.

b. Emergency/Normal Operation Switches

c. Individual Service Disconnect Switches (accessible outside of panel).

d. Pump Run Lights

e. System Fault Light

f. Surge Arrestor

4. SCCR: The complete control panel assembly shall have a Short Circuit Current Rating of 100 kA.

5. Galvanic Isolation: The controller shall provide internal galvanic isolation to all digital and analog inputs as well as all fieldbus connections.

6. Backup Battery: The controller shall have the ability to be connected to a backup battery to supply power to the controller during periods of loss of supply power.

7. BMS Integration: BMS Contractor shall have the capability to monitor and communicate with the Grundfos CU352 Controller via the available protocols listed below. All data points will have read capabilities. Crucial setpoints and start/stop shall also have write capabilities.

a. LON Works (CIM 100)

b. PROFIBUS DP (CIM 150)

c. Modbus RTU (CIM 200)

d. GSM/GPRS (CIM 250)

e. 3G/4G cellular (CIM 260)

2-11-25 23 21 00 - 10

f. GiC/GRM 3G/4G (CIM 280)

g. BACnet MS/TP (CIM 300)

h. PROFINET IO (CIM 500)

i. Modbus TCP (CIM 500)

j. BACnet IP (CIM 500)

k. Ethernet IP (CIM 500)

F. Home Status Screen: The controller shall display the following as status readings from a single display on the controller (this display shall be the default):

1. Current value of the control parameter, (typically differential pressure).

2. Most recent existing alarm (if any).

3. System status with current operating mode.

4. Status of each pump with current operating mode and rotational speed as a percentage (%).

5. Estimated flowrate, (or actual flow if flow sensor is used).

6. One user defined measured parameter (i.e. power consumption).

G. Inputs/Outputs: The controller shall have as a minimum the following hardware inputs and outputs:

1. Three analog inputs (4-20mA or 0-10VDC)

2. Three digital inputs

3. Two digital outputs

4. Ethernet connection (built-in web server)

5. Field Service connection to PC for advanced programming, software and/or firmware upgrades and data logging.

H. Pump system programming: As a minimum, the following parameters shall be available and/or field adjustable:

1. Sensor Settings: Suction, Discharge, Differential Pressure [analog supply/range], Temperature, Differential Temperature.

2. PI Controller: Proportional gain (Kp) and Integral time (Ti).

3. Low suction: Pressure/level shutdown via digital contact.

4. Limit Exceeding Function: For low system, low suction warnings and shut down [via analog input].

5. Flow meter settings (if used, analog signal).

I. Pump Characteristic Data: The controller should be capable of algorithmically extrapolating the pump characteristics with 97% accuracy. Pump characteristic data shall be used for the following:

1. Sequence pumps based on optimal energy - power efficiency.

2. Variable pressure control (quadratic or proportional)

3. Pump outside of duty range protection

2-11-25 23 21 00 - 11

J. Variable Pressure Control (setpoint changes as load demand changes): The controller shall have variable pressure control to compensate for pipe friction loss by decreasing the pressure set-point at lower flowrates and increasing the pressure set-point at higher flow-rates by using the actual flow rate or calculated flow rate.

Variable pressure control that uses power consumption and speed only shall not be considered equal to variable pressure control that uses actual differential pressure measurement along with pump power and speed.

K. Multi-Sensor: The controller shall be able to control using up to six differential pressure (DP) sensors (zones). Each zone shall have a programmable maximum and minimum DP range. The controller shall be capable of an energy optimal mode where pump speed/energy shall be reduced until any of the zones reach the minimum DP setting.

L. Check Valve Failure Detection (Systems with integrated VFD motors): The system controller shall be able to detect motors turning in the opposite direction and give check valve failure notification.

1. For minor leaks the pump shall start with a warning indicated

2. For major leaks the pump shall remain off to prevent damage with an alarm indication.

M. Pulse flow meter: The system controller shall be able to receive pulse readings from a digital pulse meter and log/display accumulated flow.

N. DP Subtraction: The system controller shall be able to control off subtraction of two pressure or temperature sensors for differential pressure or differential temperature control.

O. programmable set- points via a digital input, (additional input/output module may be required).

P. Setpoint Influence: The system pressure set-point shall be capable of being automatically adjusted by using an external set-point influence. The set-point influence function enables the user to adjust the control parameter (typically differential pressure) by measuring an additional parameter. (Example: Lower the system differential pressure set-point based on a flow or outdoor temperature measurement).

Q. Remote Control: The controller shall be capable of receiving a remote analog set-point (4-20mA or 0-10 VDC) as well as a remote system on/off (digital) signal.

R. Setpoint Ramp: The controller shall be able to adjust the ramp time of a change in set point (increase and decrease).

S. Warnings and Alarms: The pump system controller shall store up to 24 warnings and alarms in memory. The time, date and duration of each alarm shall be recorded. A potential-free relay shall be provided for alarm notification to the building management system. The controller shall display the following alarm conditions:

1. Individual pump failure

2. Check valve failure

2-11-25 23 21 00 - 12

3. VFD trip/failure

4. Loss of sensor signal (4-20 mA)

5. Loss of remote set-point signal (4-20mA)

6. External Fault

7. Pump outside of duty range

8. Limit 1 and 2 exceeded*

a. The controller shall be capable of monitoring two analog signals (i.e. suction pressure and discharge pressure) for additional pump or system protection.

T. Built-in data log: The controller shall have built-in data logging capability.

Logged values shall be graphically displayed on the controller and shall be downloadable to a notebook/pc as a delimited text file. A minimum of 7200 samples per logged value shall be available for the following parameters:

1. Estimated flow-rate (or actual flow if flow sensor is connected).

2. Speed of pumps

3. Process Value/sensor feedback (usually differential pressure).

4. Power consumption

5. Controlling parameter (setpoint)

6. Inlet pressure (when remote differential pressure is the primary sensor).

U. Redundant Primary Sensor: The controller shall be capable of receiving a redundant sensor input to function as a backup to the primary sensor.

V. Secondary Sensor: Upon loss of signal from the remote sensor, the controller shall be capable of reverting control to the pump system mounted sensors with a programmable setpoint. The pumps shall maintain a constant, proportional, or quadratic pressure across the system until the remote setpoint signal is restored.

W. Pump Test: The controller shall have a pump “Test Run” feature such that pumps are switched on during periods of inactivity (system is switched to the “off” position but with electricity supply still connected). The inoperative pumps shall be switched on for a period of three to four seconds every 24 hours, 48 hours or once per week and at a programmable time of day.

X. Reduced Operation: During backup generator operation, the controller shall be capable of reducing the power consumed by the pump system by either limiting the number of pumps in operation or by limiting the amount of power consumption (kW). The controller shall receive a digital input indicating backup generator operation.

Y. Power and Energy Consumption: The controller shall be capable of displaying instantaneous power consumption (Watts or kilowatts) and cumulative energy consumption (kilowatt-hours).

Z. Specific Energy: When a flow sensor is connected, the controller shall be capable of displaying instantaneous specific energy in Watt-hours per gallon (Wh/gal) or Watt-hours per 1,000 gallons (Wh/kgal).

AA. Built-in Ethernet: The controller shall have an Ethernet connection with a built-in web server allowing for connection to a building computer network with read/write access to the controller via a web browser.

2-11-25 23 21 00 - 13

BB. Service Contact Information: The controller shall have a programmable Service

Contact Field that can be populated with service contact information including:

contact name, address, phone number(s) and website.

2.6 SEQUENCE OF OPERATION

A. The system controller shall operate equal capacity variable speed pumps to maintain a constant differential pressure (sensor feedback from remote DP sensor) or variable differential pressure setpoint [sensor feedback from local mounted sensor(s)]. The system controller shall receive an analog signal [4- 20mA] from the factory installed pressure transducers on the discharge and suction manifolds, indicating the actual system pressure and inlet pressure. The controller shall be capable of controlling off the subtraction of discharge minus suction pressure for differential pressure across the manifolds. The controller shall be capable of regulating flow (based on analog signals from temperature sensors to maintain a required differential temperature.

B. Energy Optimization Pump Sequencing:

1. The pump system controller shall adjust pump speed as necessary to maintain system set-point pressure as flow demand changes. Utilizing the pump characteristics information (derived from internal controller algorithm) combined with suction and discharge pressure measurements, the pump system controller shall stage additional pumps when pump hydraulic efficiency is determined to be higher with additional pumps in operation. When the flow and head are outside the operating pumps allowable operating range, the controller shall switch on an additional pump, distributing flow and allowing all pumps to operate within their allowable operating range. When the system pressure is equal to the system set point, all pumps in operation shall reach equal operating speeds.

C. The system controller shall be capable of switching pumps on and off to satisfy system demand without the use of flow sensors, flow switches, motor current monitors or temperature measuring devices.

D. All pumps in the system shall alternate automatically based on demand, time, and fault. If flow demand is continuous (no flow shutdown does not occur), the system controller shall have the capability to alternate the pumps every 24 hours, every 48 hours or once per week. The interval and actual time of the pump change-over shall be field adjustable.

2.7 SYSTEM CONSTRUCTION

A. The suction and discharge manifolds material for 8 inch and smaller shall be 316 stainless steel; 10 inch and larger shall be carbon steel.

1. Manifold connection sizes shall be as follows:

a. 8 inch and smaller: ANSI Class 150 floating flanges.

b. 10 inch and larger: ANSI Class 150 fixed flanges.

2-11-25 23 21 00 - 14

B. Isolation Valves: Pump Isolation valves shall be provided on the suction and discharge of each pump. Isolation valves shall be a full lug style butterfly valve.

The valve disk shall be of stainless steel. The valve seat material shall be EPDM and the body shall be ductile iron, coated externally with epoxy.

C. Check Valves: A spring-loaded non-slam type check valve shall be installed on the discharge of each pump. The valve shall be a wafer style type fitted between two flanges. The head loss through the check valve shall not exceed 5 psi at the pump design capacity. Check valves shall have a body material of epoxy coated cast iron with an EPDM resilient seat. Spring material shall be stainless steel.

Disk shall be of stainless steel.

D. Pressure Transducers: Pressure transducers shall be factory installed on the suction and discharge manifolds. Pressure transducers shall be made of 316L stainless steel. Transducer accuracy at 20°C shall be +/- 0.5% full scale. The output signal shall be 4-20 mA with a supply voltage range of 8-28 VDC.

E. Pressure Gauges: Pressure gauges will be 4½" dial size with a flangeless cast aluminum case, stainless steel friction ring and glass window. Movement will be brass with a bronze bourdon tube and brass socket. Dial face will be white with black figures; pointer will be friction adjustable type. Accuracy will be ±1% of scale range, ASME B40.1 Grade 1A.

F. Base Frame: The base frame shall be constructed of ASTM A36 structural carbon steel, electrostatically epoxy powder coated RAL 9005. Base shall be modular -with minimal number of unique components - firmly bolted together with serrated washers.

G. Control Panel Mounting: The control panel shall be mounted on a rack attached to the system skid.

2.8 TESTING

A. The tester used for testing the pump system shall be constructed and calibrated according to the requirements of hydraulic test standard ISO 9906.

B. The pump station shall undergo a continuity test to ensure that the resistance of non-fused earthed conductors between the earth in the control panel and each pump do not exceed 0,1 ohm.

C. The entire pump station shall as a minimum be factory tested for functionality and documented results of functionality test supplied with pump station.

D. Functionality testing shall include the following parameters:

1. Complete System Hydrostatic Test – 1.5 times the nameplate maximum pressure.

2. Water Shortage Test

3. Two-Point Setpoint Performance Test.

E. Water used for testing shall be treated with three different filtration systems to ensure only clean water is used for testing pump station.

2-11-25 23 21 00 - 15

1. 25 micron mechanical filter – removes solid parts from water

2. Activated carbon filter – keeps water clear and eliminates odor

3. Ultraviolet light system – kills all bacteria growth

F. Optional performance testing shall include: (Select one)

1. 10-Point Verified Performance Test

2. Witnessed Verified Performance Test

2.9 WARRANTY

A. The warranty period shall be a non-prorated period of 24 months from date of installation, not to exceed 30 months from date of manufacture.

PART 3 - EXECUTION

3.1 PIPE INSTALLATION

A. General: Install pipe, tube and fittings in accordance with recognized industry practices. Install each run accurately aligned with a minimum of joints and couplings, but with adequate and accessible unions and flanges for disassembly, maintenance and/or replacement of valves and equipment. Reduce sizes (where indicated) by use of reducing fittings.

1. Unions and flanges for disassembly, maintenance and/or replacement of valves and equipment are not required in installations using grooved joint couplings. (The couplings shall serve as disconnect points.)

B. Piping Runs: Route piping close to and parallel with walls, overhead construction, columns and other structural and permanent-enclosure elements of the building (pitched for drainage). If not otherwise indicated, run piping in the shortest route which does not obstruct usable space or block access for servicing the building or equipment and avoid diagonal runs. Wherever possible in finished and occupied spaces, conceal piping from view. Do not encase horizontal runs in solid partitions.

C. For pipes below grade backfill should be tamped compactly in place so as to assure a stable surface. Unless otherwise required by manufacture in their installation instructions install min. of 4” sand bedding with 3” of sand on each side of pipe or 2” between pipes. Provide 6” of sand over the top of the pipe. The balance of the fill above, below or beside the pipe shall not include rocks larger than 2” in diameter. Provide at least 24 inches of cover from top of pipe to grade.

Where located below vehicle traffic area compacted fill shall meet H-20 Highway Loading. Install with trace wire (per these specifications) on each line.

3.2 PIPING JOINTS

A. General: Provide joints of the type indicated in each piping system, and where piping and joint as manufactured form a system, utilize only that manufacturer's material.

2-11-25 23 21 00 - 16

B. Ferrous Threaded Piping: Thread pipe in accordance with ANSI 82.l; cut threads full and clean using sharp dies. Ream threaded ends to remove burrs and restore full inside diameter. Apply pipe joint compound or pipe joint tape (Teflon) where recommended by pipe/fitting manufacturer, on male threads at each joint and tighten joint to leave no more than 3 threads exposed.

C. Solder Copper Tube and Fitting Joints: In accordance with recognized industry practice. Cut tube ends squarely, ream to full inside diameter, and clean outside of tube ends and inside of fittings. Apply solder flux to joint areas of both tubes and fittings. Insert tube full depth into fitting, and solder in a manner which will draw solder full depth and circumference of joint. Wipe excess solder from joint before it hardens. "T-Drill" field formed tees may be utilized where the main is at least two pipe sizes larger than the branch.

D. Braze Copper Tube and Fitting Joints: Where indicated, in accordance with

ANSI/ASME B31.5. Pass a slow stream of dry nitrogen gas through the tubing at all times while brazing to eliminate formation of copper oxide.

E. Weld Pipe Joints: In accordance with recognized industry practice and as follows:

1. Weld pipe joints only when ambient temperature is above 0 degrees F.

2. Bevel pipe ends at a 37.5 degree angle, smooth rough cuts, and clean to remove slag, metal particles and dirt.

3. Use pipe clamps or tack-weld joints with 1" long welds; 4 welds for pipe sizes to 10"; 8 welds for pipe sizes up to 20".

4. Build up welds with a stringer-bead pass, followed by a hot pass, followed by a cover of filler pass. Eliminate valleys at center and edges of each weld. Weld by procedures which will ensure elimination of unsound or unfused metal, cracks, oxidation, blow-holes and non-metallic inclusion.

5. Do not weld out piping system imperfections by tack-welding procedures;

refabricate to comply with requirements.

6. Install forged branch-connection fittings wherever branch pipe is indicated, or install regular "T" fitting at Contractor's option.

F. Flanged Joints: Match flanges within piping system, and at connections with valves and equipment. Clean flange faces and install gaskets. Tighten bolts to provide uniform compression of gasket.

G. Insulating (Dielectric) Fittings: Where the "joining of ferrous and non-ferrous piping". Use brass valve or brass nipple with length/nominal dramatic ratio of 8 or greater rather than dielectric fitting.

H. Changes in Direction: Use fittings for all changes in direction. Run lines parallel with building surfaces.

I. Line Grades: Pitch steam piping 1" to 40' minimum to low point drips or drains.

J. Unions and Flanges: At all equipment to permit dismantling and elsewhere as consistent with good installation practice.

K. Expansion: Provide loops, swing joints, anchors, runouts and spring pieces to prevent damage to piping or equipment. Flexible hoses are not allowed.

2-11-25 23 21 00 - 17

L. Press Fittings: MegaPress Cold Press Mechanical Joint Fittings shall be installed in accordance with the manufacturer’s installation instructions. The protective corrosion coating shall be removed from the outside of the pipe end. The pipe shall be fully inserted into the fitting and the pipe marked at the shoulder of the fitting. The fitting alignment shall be checked against the mark on the pipe to assure the pipe is fully engaged (inserted) in the fitting. The joints shall be pressed using the tool(s) approved by the manufacturer.

3.3 MISCELLANEOUS PIPING EQUIPMENT

A. Floor, Wall and Ceiling Plates: Chrome plated pressed steel or brass screw locked split plates on all pipe penetrations in finished spaces.

B. Strainers: Install in a manner to permit access for cleaning and screen removal and with blow-off valve.

C. Sleeves: At all penetrations of concrete or masonry construction. PVC, 24 gauge galvanized steel or Schedule 40 galvanized steel pipe. Use steel pipe sleeves through beams, footings, girders or columns and for all penetrations of walls or floors below grade. Where floor finish is ceramic tile, terrazzo, or similar material extend standard steel pipe sleeves 1-1/2" above finished floor. Fabricate sleeves 1" diameter larger than pipe or insulation. PVC and sheet metal sleeves at non-structural penetrations only.

D. Sleeve Caulking: Grout uninsulated pipe with cement mortar or approved waterproof mastic. All caulking or grouting shall extend full depth of sleeve.

Install UL sealing caulk, putty and/or system at all penetrations of fire rated walls, floors and ceiling.

E. Valves: Install valves in accordance with Section 23 05 00. Install control valves specified in other Division 23 Sections.

3.4 EQUIPMENT INSTALLATION

A. Installation and Arrangement: Install and arrange as shown on the Drawings.

Comply with manufacturer's recommendations for installation connections and start-up.

B. Lubrication: Lubricate all moving and rotating parts in accordance with the manufacturer's recommendations prior to start-up.

C. Expansion Joint and Compensator Installation: Carefully align joint or compensator and make proper allowance for temperature of pipe at time of installation.

D. Air Vents: Conduct 1/4" copper tubing from high end of air chambers to accessible locations and terminate with screwdriver cock. Conduct 1/4" copper tubing from outlets of automatic air vents to floor drains indicated or to the outside when approved by Governing Authorities.

E. Pumps: Mount in a manner to allow disassembly of pump and motor without disturbing piping.

2-11-25 23 21 00 - 18

F. Mechanical Contractor and Balancing Contractor shall be trained on installation, connection, and balancing procedures by certified representative of differential pressure control valves.

3.5 CLEANING

A. General: Clean all dirt and construction dust and debris from all mechanical piping systems and equipment and leave in a new condition. Touch up paint where necessary.

B. Heating Piping Systems:

1. Add cleaning chemical in proper concentration to clean system of manufacturing and installation contamination and residue.

2. Fill, vent and circulate the system with this solution at design operating temperature. After circulating for four hours, bleed out cleaning solution by the addition of fresh water to the system.

3. Test for pH and add sufficient amount of the cleaning chemical to obtain a pH between 7 and 8.

4. Clean all strainers and remove start-up strainers (from suction diffusers) after the system has operated for one week.

3.6 TEST

A. General:

1. Minimum duration of two hours or longer, as directed for all tests.

Furnish report of test observation signed by qualified inspector. Make all tests before applying insulation, backfilling, or otherwise concealing piping or connecting fixtures or equipment. Where part of the system must be tested to avoid concealment before the entire system is complete, test that portion separately, same as for entire system.

2. Provide all necessary temporary equipment for testing, including pump and gauges. Remove control devices before testing and do not use piping system valves to isolate sections where test pressure exceeds valve pressure rating. Fill each section with water and pressurize for the indicated pressure and time.

3. Observe each test section for leakage at end of test period. Test fails if leakage is observed or if pressure drop exceeds 5% of test pressure.

B. Repair:

1. Repair piping system sections which fail the required piping test by disassembly and re-installation, using new materials to the extent required to overcome leakage. Do not use chemical stop-leak compounds, solder, mastics, or other temporary repair methods.

2. Drain test water from piping systems after testing and repair work has been completed.

C. Heating Piping: 75 psig hydrostatic for 30 psig systems without loss for four hours.

D. Tanks and Equipment: Hydrostatic pressure to 1.5 times operating pressure.

2-11-25 23 21 00 - 19

END OF SECTION

WCCF Boiler Replacement Heating Boilers and Equipment 2-11-25 23 52 00 - 1

SECTION 23 52 00 - HEATING BOILERS AND EQUIPMENT

PART 1 - GENERAL

1.1 DESCRIPTION

A. The requirements of this section apply to the heat generation (boiler) systems.

B. Equipment capacity and size shall be as indicated on the Drawings.

C. Related Work: The requirements of Section 23 05 00, Common HVAC Materials and Methods, also apply to this section.

A. Acceptable Manufacturers: Standard, nationally recognized manufacturers of products listed by ANSI, ASTM, or ASME quality standards as specified, or

B. Labels: Underwriters Laboratories (UL) labeled or certification by a nationally recognized electrical testing laboratory having the facilities for testing, factory inspection and field inspection as required by the National Electrical Code is required for all fans, controls, all electrically-operated equipment and other electrical items incidental to the work specified, as required by code.

C. Code Requirements: Comply with or exceed the minimum standards of the

National Electrical Code (NEC), State of Oregon modifications to the NEC, and all local ordinances applicable to electrical wiring, contacts, controls, safeties, etc., included with or contained within manufactured items.

D. Regulatory Requirements: Comply with all Federal, State, and Local requirements for boiler emissions.

E. Field Wiring: It is the intent of these specifications that all systems shall be complete and operable. Refer to all drawings and specifications, especially the electrical drawings, to determine voltage, phase, circuit ampacity and number of connections provided. Provide all necessary field wiring and devices from the point of connection indicated on the electrical drawings. Bring to the attention of the Architect in writing, all conflicts, incompatibilities, and/or discrepancies prior to bid or as soon as discovered.

1.3 SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES (SUBMITTALS)

A. See the General Conditions, Section B – Administration of the Contract, B.18 –

1.4 PRODUCT SUBSTITUTION

2-11-25 23 52 00 - 2

A. Materials…