140L0618R0011_NHTIC_Boiler_Replacement_SOW.pdf

National Historic Trails Interpretive Center

HIGH PLAINS DISTRICT

CASPER, WYOMING

CASPER TRAILS CENTER

BOILER REPLACEMENT

CONTRACT SCOPE OF WORK

BUREAU OF LAND MANAGEMENT

HIGH PLAINS DISTRICT OFFICE

1/5/2018

Casper Trails Center Boiler Replacement - Contract Scope of Work Page 2 of 22

Table of Contents

I. Project Description 3

II. Project Location 3

III. Contractor’s Use of Premises 3

IV. Existing Systems Description 4

V. Project Work Elements 5

VI. Submittals 20

VII. Attachments 20

Boiler Replacement - Contract Scope of Work Page 3 of 22

Contract Scope of Work

Boiler Replacement Bureau of Land Management

I. Project Description

A. The work of this contract consists of:

1. Replacement of the existing boiler at the Bureau of Land Management (BLM) National Historic Trails Interpretive Center (NHTIC) in Casper, Wyoming (aka ‘Casper Trails Center’), including demolition of the existing heating system boiler; installation of new heating system boilers and boiler circulator pumps; installation of new piping, valves, and pipe insulation; and connecting the controls for the new boilers to the existing Building Automated System (BAS).

2. Demonstration and training of new system for BLM site personnel.

B. All work shall be performed under a single contract.

II. Project Location

A. The National Historic Trails Interpretive Center is located at 1501 North Poplar Street, Casper, Wyoming 82601 (LAT 42.866873, LONG -106.337161). Attendance at the pre-bid site inspection by potential bidders to verify existing conditions at the project site is highly recommended, but not mandatory.

III. Schedule and Contractor’s Use of Premises

A. Schedule: All work shall be limited to weekday hours 8:00 AM to 5:00 PM unless otherwise approved by the Contracting Officer’s Representative. No work shall occur on Federal holidays or weekends without prior approval. Demolition work will be allowed to start after June 11 and the system shall be operational by September 30. The contractor’s on site work shall be limited to 3 continuous weeks between the earliest start date of June 11 and latest finish date of September 30 to complete all on site work. Utility outages shall be scheduled for Mondays unless approved by the Contracting Officer’s Representative. Schedule outages at least two weeks prior to the desired outage date.

B. Construction Camp: Establishment of a camp within the Trails Center property boundaries will not be permitted.

C. Work Limits: The area within the work limits is mainly in the mechanical room and on the low roof above the mechanical room. These areas are located on the north side of the Trails Center and are normally closed to the public. The Contractor shall conduct operations at all times to ensure the least inconvenience to the site staff and the public, and shall coordinate all activities with the BLM site manager and the Contracting Officer’s Representative. Access to all areas

Boiler Replacement - Contract Scope of Work Page 4 of 22 shall be maintained for BLM administrative and other official business throughout the construction phase. Contractor may use Staff Restroom 134 located east of the mechanical room.

D. Storage of Materials: Confine storage of materials to within the area of the building being worked on or at exterior locations as designated by the BLM site manager and the Contracting Officer’s Representative. The Contractor shall be responsible for safely securing all materials.

E. Salvage of Materials: Materials salvaged by the Contractor shall be removed from the Trails

Center and legally dispose of outside the Trails Center property boundaries. Recycle materials that can be recycled. Keep work areas clean and free of debris.

IV. Existing Systems Description

A. General: The Casper Trails Center is a 24,288 square foot, single story building, constructed in

2002. The existing boiler contains components that have either failed or have reached the end of their useful service lives. Current energy use at this facility is also much higher than average.

B. Existing HVAC System: The existing HVAC system is a two-deck multizone type with a gas-fired boiler for heating, and an air-cooled chiller for cooling. The existing HVAC system is comprised of the following components:

1. One two-deck multizone air handler that serves the entire building. The multizone air handler has a pre-heat coil, hot deck heating coil, cold deck cooling coil, air washer (evaporative cooler) with face and bypass dampers, supply air fan with VFD, and outside air, return air, and relief air dampers. The multizone air handler is connected to outside air and exhaust air louvers sized for 100% outside air (economizer) operation.

2. One 2,520 MBH input gas-fired atmospheric boiler with staging controller.

3. A heating water loop, with two 5 HP circulating pumps, chemical pot feeder, air separator, air-over-water expansion tank, and make-up water connection with backflow preventer.

4. A snowmelt system for the main entry walkway and exhibit area egress ramp, with one 2 HP circulating pump, air-over-water expansion tank, and heat exchanger that derives its heat from the heating water system.

5. An indirect water heater for the domestic water that derived its heat from the heating water system was recently removed and replaced with a 40 gallon electric tank type water heater.

6. The original 90 ton air-cooled chiller located in the service area outside the mechanical room was recently removed and replaced with a new 58 ton air-cooled chiller and new 200 gallon chilled water buffer tank in the same location as the original 90 ton chiller. Chilled water piping connecting the chiller to the chilled water pumps in the mechanical room runs exposed outside the building along the service area concrete retaining wall, up into the building soffit, then into the mechanical room.

7. A chilled water loop, with two 3 HP circulating pumps, chemical pot feeder, air separator, air-over-water expansion tank, 200 gallon chilled water buffer tank and glycol make-up system with backflow preventer. The chilled water system contains 33% propylene glycol solution for freezing burst protection of the chiller evaporator and the outdoor chilled water piping.

8. Exhaust fan for the public restrooms, the administration restroom, the janitor’s closet, and the storage room.

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C. Existing HVAC System Controls: The existing HVAC system controls consist of a Johnson Controls “Metasys” direct digital control (DDC) system. There is no front end personal computer (PC) for accessing the control system on site; however the DDC system is connected to the Department of Interior (DOI) intranet, which is secured behind the DOI firewall, and the BLM site manager has access on site.

V. Project Work Elements

A. Remove Existing Boiler: Shut off the makeup water feed and completely drain the heating water system. Shut off and disconnect existing gas piping serving the existing boiler. Remove and recycle the existing 2,520 MBH input gas-fired boiler in the boiler room. Existing boiler will require disassembly/demolition because approximate dimensions are 78” L x 56” W x 44” H and doorway is only 35” W x 81” H. Electrical feeds to the existing boiler and exterior combustion air damper shall remain for re-use of the existing exterior receptacle. See Figures 1 and 2 and the NHTIC Boiler Room Demolition Plan SK-1 below.

Figure 1 - Existing Boiler, side view through doorway

Remove Existing Boiler

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Figure 2 - Existing Boiler, front view

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B. Remove Existing Boiler Piping: Remove and dispose of existing supply piping, return piping, 3-way automatic control valve, heating water expansion tank, and pipe insulation from the existing boiler to disconnect points as shown on the Existing Hydronic Piping Removal Diagram SK-2 above, and Figures 3 and 4 below. The existing air separator located in the boiler room shall remain for reuse; however it will need to be relocated.

Disconnect Existing 4” HWR Piping Here

Disconnect Existing 4” HWS Piping at Downstream Elbow

Remove Existing Boiler Vents

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Figure 3 - Existing Heating Water Return and Supply Piping Disconnect Points

Figure 4 - Existing Heating Water Expansion Tank and Boiler Combustion Air Duct

Remove Existing Heating Water Expansion Tank

Remove Existing Boiler Combustion Air Duct

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C. Remove Existing Boiler Vents: Remove and dispose of the existing boiler vents, vent supports, boiler combustion air ducts, and damper. See NHTIC Boiler Room Demolition Plan SK-1 above, Figures 3 and 4 above, and Figures 5, 6 and 7 below.

Figures 5 and 6 - Existing Boiler Vents

Figure 7 - Existing Boiler Vent and Combustion Air Ducts

Vent and Vent Supports

Vents and Vent Supports

Combustion Air Ducts and Damper

Existing Receptacle to Remain

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D. Remove Existing Boiler Combustion Air Chase: Remove and dispose of the existing boiler combustion air chase (approximately 36” W x 36” D x 190” H). Reroute electrical to corner with EMT conduit and reroute receptacle to CMU wall. See NHTIC Boiler Room Demolition Plan SK-1 above, and Figures 8 and 9 below. Provide new insulated interior wall to cover exposed exterior concrete wall per detail 5 and key notes from original building drawing A8.1 below.

Texture and paint new interior wall to match adjacent wall.

Figures 8 and 9 - Existing Boiler Combustion Air Chase and Associated Electrical

Detail 5 and Key Notes from Original Building Drawing A8.1

Combustion Air Chase

Reroute electrical to corner

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E. Remove Existing Gas Piping: Remove and dispose of existing gas piping from the existing boiler to the vertical section of gas pipe located on the boiler room north wall (cut point as shown on NHTIC Gas Piping Schematic SK-6 below).

F. Relocate Existing Water Softener and Reroute Piping: Relocate the existing water softener and associated electrical service from the northwest corner of the boiler room to the southwest corner of the boiler room. Reroute associated 1-1/2” copper piping to water softener in new location, provide (3) new 1-1/2” full port two piece bronze ball valves, and reinsulate piping. Piping shall be Type L copper with wrought copper solder fittings. See NHTIC Boiler Room Demolition Plan SK-1 above, NHTIC New Boiler Room Plan SK-4 below, and Figure 9 below.

Figure 9 - Existing Water Softener and Associated Piping

G. Patch Existing Boiler Vent through Roof: The existing vent penetration through the single-ply membrane roof shall be patched and sealed weathertight. Weld in matching structural steel deck patch, patch vapor retarder, provide 4” minimum polyisocyanurate roof insulation patch, and matching single-ply membrane roof patch. The vent penetration patch shall be installed so that the roof manufacturer’s warranty is maintained.

H. Patch Existing Boiler Combustion Air Duct Holes through Walls: The existing combustion air duct holes in both the exterior and interior walls shall be patched and sealed weathertight. Openings shall be infilled with 8” CMU, set back ½” from exterior wall surface, and parge coated with mortar to match the existing exterior concrete color as closely as possible.

I. Furnish and Install New Concrete Boiler Pad: Furnish and install a new boiler pad in the location shown on NHTIC New Boiler Room Plan SK-4 below. Boiler pad shall be 4” thick; furnish and install dowels into the existing slab and furnish and install welded wire fabric in the boiler pad prior to placing the concrete.

Relocate Existing Water Softener

Existing Floor Drain

Reroute Piping to Relocated Water Softener

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J. Furnish and Install New Boilers (B-1, B-2 and B-3): Furnish and install three (3) new high efficiency, gas-fired modular boilers as shown on NHTIC New Boiler System Piping Schematic SK-3 below and NHTIC New Boiler Room Plan SK-4. Boilers shall be modulating condensing type with stainless steel heat exchanger, suitable for firing with natural gas, shall be rated for 160 psig ASME working pressure, and shall be 97.5 percent thermally efficient, with an input capacity of 600,000 BTU/hr and an output capacity of 585,000 BTU/hr. Provide the high altitude model manufactured with a different control module for altitude operation from 3,000 to 12,000 feet (boiler does not require de-ration up to 5,400 feet). Provide each boiler module with automatic reset high limit thermostat, adjustable high limit thermostat with manual reset, variable-speed boiler circulator pump (PUM20077), BACnet interface module, manual reset high and low gas pressure switches, 30 psig ASME pressure relief valve, flow switch, manual reset low water cutoff switch, temperature/pressure gauge, condensate neutralizer (KIT 100157700), and sidewall venting kit (KIT 100157611). Provide two (2) hot water supply temperature sensors (#100170581 aka “system supply sensor”, “system sensor”) and two (2) hardwired outside air temperature sensors for the boiler system. The boilers shall be installed and configured in accordance with the manufacturer’s installation instructions. Lochinvar FTX600N High Altitude model, by Lochinvar, LLC, Lebanon, Tennessee 37090, or approved equal. The new boilers shall be installed on the new concrete boiler equipment pad and shall be anchored to the equipment pad in accordance with the manufacturer’s recommendations.

The new boilers shall include manufacturer start-up, and shall be commissioned by manufacturer’s authorized personnel in accordance with the manufacturer’s Installation, Operation and Maintenance manual.

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K. Furnish and Install New Boiler Piping: Furnish and install new boiler piping to the connection points as shown on NHTIC New Boiler System Piping Schematic SK-3, NHTIC New Boiler Room Plan SK-4, and Figure 3 above; and NHTIC Hydronic Piping Connection Diagram SK-5 below. Piping shall be Schedule 40 black steel with grooved fittings, grooved flange adapters, and grooved couplings with EPDM gaskets. Furnish and install clevis type pipe hangers for individual pipes and unistrut type trapeze hangers for multiple pipes.

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L. Furnish and Install New Valves and Appurtenances: Furnish and install new valves and appurtenances that do not come as standard equipment on boilers as required to conform to manufacturer’s Installation, Operation, and Maintenance manual. Components shall include the following:

1. Shutoff, Drain, and Blowdown Valves: Bronze ball valves, full port, two piece, with chrome plated ball. Drain and blowdown valves shall be furnished with 3/4” hose pipe thread fittings.

2. Check Valves: Bronze, swing type, regrinding type, Y pattern, with renewable bronze disk.

3. Boiler Drain Valves: Brass, angle pattern, with 3/4” hose pipe thread outlet.

4. Magnetic Dirt Separator: Epoxy resin coated steel with 4” ANSI flange connections and removable stainless steel internal element. Particle separation capacity 5 μm (0.2 mil).

Caleffi 546510AM, or approved equal. Furnish separator with 3/4” automatic air vent on top connector; Caleffi 501502A, or approved equal. Also furnish with 3/4” hose pipe thread fitting on separator’s 1” FNPT drain valve.

5. Automatic Air Vent: Furnish and install a new 3/4” automatic air vent on top connector of existing air separator; Caleffi 501502A, or approved equal

6. Pressure and Temperature (P&T) Taps: Combination pressure and temperature test taps designed to receive either temperature or pressure probe, with gasketed and threaded cap with retention chain.

M. Insulate New Boiler Piping: Furnish and install pipe insulation on all new boiler piping, and on all other boiler piping where insulation has been removed to perform the modifications described in this scope of work. Pipe insulation shall be fiberglass with all-service jacket. Fiberglass insulation with molded PVC covers shall be provided at all fitting locations. Furnish and install rigid insulation inserts and insulation shields at all hanger locations. Fiberglass pipe insulation thickness shall be as follows:

1. 1-1/2” Pipe and Smaller: 1” thick.

2. 2” to 6” Pipe: 1-1/2” thick.

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N. Furnish and Install New Expansion Tank (ET-1): ASME stamped pressurized diaphragm type, with replaceable elastomer bladder, suitable for operating temperatures up to 240º F, 27 gallons acceptance volume, 44 gallons tank volume. Bell & Gossett B-165LA, by Xylem, Inc., Morton Grove, Illinois 60053, or approved equal. The new expansion tank shall be installed on the existing concrete boiler equipment pad near the new boilers. Furnish with drain valve with 3/4” hose pipe thread fitting on expansion tank’s 3/4” drain hole. Field adjust expansion tank air precharge pressure to 18 psig.

O. Furnish and Install New Pressure Relief Valve Discharge Piping: Furnish and install new pressure relief valve discharge piping from the boiler pressure relief valves to the floor drain;

pressure relief piping shall terminate pointing down into floor drain. Piping shall be Type L copper with wrought copper solder fittings.

P. Furnish and Install New Condensate Drain Piping: Furnish and install new condensate drain piping from the boiler condensate drain connections to the floor drain. Condensate drain piping shall be Schedule 40 PVC with solvent-weld socket fittings. Furnish and install condensate neutralizers (as specified under “Furnish and Install New Boilers” above) in the condensate drain lines to neutralize acid in the condensate before it reaches the floor drain.

Q. Furnish and Install New Boiler Vents: Furnish and install new Schedule 40 PVC boiler exhaust vent and boiler combustion air piping. Vent terminations shall be sidewall type, with the combustion air piping terminating on the north wall, and exhaust vent terminating 2” beyond the edge of the building soffit as shown on NHTIC New Boiler Room Plan SK-4 above. Vent piping and vent terminations shall be installed in accordance with the manufacturer’s installation instructions and shall be adequately supported from the structure above. Horizontal sections of boiler vent piping shall be pitched a minimum of 1/4” per foot back toward the boiler for proper condensate drainage.

Furnish and install bird screen on both combustion air piping and exhaust vent terminations. Vent terminations at the wall shall be sealed tightly to the existing wall with polysulfide sealant; the sealant color shall match the existing wall color. Paint vent terminations and vent piping located on the outside of the building with two coats of acrylic paint; the paint color shall match the existing soffit color.

R. Reconnect Gas Piping: Furnish and install new gas piping from the cut point to the new boilers as shown on NHTIC Gas Piping Schematic SK-6 below. Gas piping shall be Schedule 40 black steel with Class 150 malleable iron threaded fittings. Gas valves shall be bronze ball valves, full port, two-piece, with chrome plated ball. Gas piping shall be adequately supported.

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S. Clean the Heating Water System: After the new boiler system piping is complete, close the six

(6) new shutoff valves to isolate the three (3) new boilers and protect them from scale and sediment cleaned from the system. Open the heating control valves to all 17 VAV reheat coils, all 5 baseboard heaters, the heating coil in the air handling unit (AHU-1), the snow melt heat exchanger, and the AHU’s preheat coil heat exchanger. Completely drain the heating water system as indicated in Paragraph “V.A” above. Fill the system with water from the water softener, vent air out of all high points in the system, and flush the system until clear. Add cleaner at a rate of 1% of the system volume (3.5 gallons of cleaner for 350 gallon approximate system volume). Cleaner shall be Hercules Sludgehammer System Restorer & Noise Reducer by Oatey, or approved equal. Recirculate cleaner in system for 24 hours minimum. Open and close all heating control valves using the BAS a minimum of six times during cleaning process. Field verify the operation of each valve to confirm that valves are properly operating and not sticking.

Completely drain system, fill with water and flush until clear to remove all cleaner. Clean the magnetic dirt separator a minimum of three times; once half-way through system cleaning, once after system cleaning, and once after system flushing. Notify Contracting Officer’s representative before the system will be cleaned, and for inspection of each magnetic dirt separator cleaning.

Open the six (6) new shutoff valves above the three (3) new boilers.

T. Refill and Adjust Heating Water System Cold Fill Pressure: Refill the heating system with distilled or deionized water and vent air out of all high points in the system. Casper’s water hardness is over 200 ppm per the City of Casper’s Public Utilities Division. Results of a water test from the water softener indicate that the water softener is eliminating the hard water (Ca++, Mg++ and CaCO3 were not detected); however chloride is 27 ppm and sulfate is 185 ppm, so do not use water from the water softener. Add corrosion inhibitor at a rate of 1% of the system volume (3.5 gallons of corrosion inhibitor for 350 gallon approximate system volume).

Corrosion inhibitor shall be Hercules Sludgehammer Universal Corrosion Inhibitor by Oatey, or approved equal. Fill out and attach a service card in boiler room as a reminder for annual system maintenance. Adjust the expansion tank air precharge pressure to 18 psig. Adjust the existing makeup water cold fill pressure setting to 18 psig.

U. Electrical Work: Modify the existing boiler power circuit as necessary to furnish power to the new boilers B-1, B-2 and B-3; and through the boilers to their respective boiler pumps BP-1, BP-2 and BP-3 such that each boiler/boiler pump combination is fed by its own dedicated 20A 120V circuit. Pull three (3) new circuits into conduit from panel PB (B-37, 39 and 41) to the three (3) new boilers located in boiler room. Existing boiler circuit PB-17 to remain for existing exterior receptacle. Furnish and install new disconnect switches for each boiler/boiler pump combination, and new EPO (emergency power off) switch.

V. Boiler Controls: The new boiler controls in each boiler shall be connected together and programmed in accordance with the boiler manufacturer’s instructions to execute the control sequence specified below under “Proposed Sequence of Operation”. The boiler supply water temperature sensors, flow switches, and boiler outside air temperature sensor shall be installed in the locations shown on NHTIC New Boiler System Piping Schematic SK-3, NHTIC New Boiler Room Plan SK-4, and NHTIC Hydronic Piping Connection Diagram SK-5 above.

W. Proposed Sequence of Operation: Boiler operation shall be enabled by the DDC system. Boiler control (boiler staging, rotating, boiler pump control, proof of flow, and outdoor reset control) shall be accomplished with the boiler manufacturer’s internal controls.

1. Heating System Enable: Heating system operation shall be enabled whenever the outside air temperature falls below 60º F (adjustable) or there is a minimum 15% call for heating

Boiler Replacement - Contract Scope of Work Page 17 of 22 from any zone temperature sensor. Heating system operation shall be continuously enabled whenever the outside air temperature falls below 50º F (adjustable) regardless of any calls for heating. Heating system operation shall be disabled whenever the outside air temperature rises above 60º F (adjustable).

2. Boiler Staging: Boilers B-1, B-2 and B-3 shall be fired sequentially in response to heating system load changes to maintain heating supply water temperature at setpoint in accordance with boiler manufacturer’s “Efficiency Optimization” control method. As heating demand increases, the Leader boiler shall be fired and shall modulate upward from low fire to 100 percent capacity as necessary to maintain boiler supply water temperature at setpoint. Upon further increase in heating demand, the Member 1 boiler shall also be fired and both boilers shall modulate from 50 percent capacity upward to 100 percent capacity as necessary to maintain boiler supply water temperature at setpoint. Upon further increase in heating demand, the Member 2 boiler shall also be fired and all three boilers shall modulate from 66.7 percent capacity upward to 100 percent capacity as necessary to maintain boiler supply water temperature at setpoint.

3. Hot Water Reset: The hot water supply temperature setpoint shall be reset based on outside air temperature according to the reset schedule below (adjustable):

HEATING HOT WATER RESET SCHEDULE

Outside Air Temperature Heating Supply Water

Temperature 60º F 140º F 10º F 180º F

4. Boiler Rotation: Boiler firing sequencing shall be automatically rotated daily (adjustable) to equalize run time between all boilers.

5. Boiler Failure: If the Leader boiler fails to operate when boiler operation is enabled, the Member 1 boiler shall automatically assume control of the Cascade. Upon failure of any of the boilers to operate, a critical alarm condition shall be reported at the operator workstation for each failed boiler.

6. Boiler High Temperature: Individual boilers shall have automatic reset high limit thermostats that will lock out individual boilers when boiler water temperature rises above 190º F (adjustable). When boiler water temperature falls below 180º F, individual boilers shall be automatically re-enabled.

7. Boiler Lockout and Alarm: Operation of the boilers shall be locked out and a critical boiler alarm condition shall be reported at the operator workstation if any of the following conditions occur:

a. Boiler Water Level Falls below Low Water Cutoff Sensor: After cause of the low water condition has been corrected, the low water cutoff sensor must be manually reset.

b. Supply Water Temperature Rises above 200º F (adjustable): After the cause of the over temperature condition has been corrected, the manual reset high limit thermostat must be manually reset.

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c. No Water Flow through Boiler: No water flow is detected by the boiler flow switch when the boiler is commanded on.

d. Failure to Fire: Boiler ignition failure or flame failure.

e. Blocked Intake or Vent: Blockage of either the boiler combustion air intake pipe or the boiler vent pipe.

f. High or Low Gas Pressure: Boiler inlet gas pressure is outside normal limits (4 inches water column to 14 inches water column, adjustable). After the cause of the high or low gas pressure has been corrected, the gas pressure switches must be manually reset.

g. EPO (emergency power off) Switch Activation: Activation of the EPO switch near the boiler room door shall disable all three (3) boilers, and an emergency power off critical alarm condition shall be reported at the operator workstation.

8. Boiler Circulating Pumps BP-1, BP-2 and BP-3: Boiler pumps shall vary their speed as necessary to maintain a constant temperature rise across each boiler.

a. Boiler On: Boiler circulating pump shall be energized when its associated boiler is called upon to fire.

b. Boiler Off: Boiler circulating pump shall be de-energized 10 minutes (adjustable) after its associated boiler stops firing.

c. Boiler Pump Proof of Flow: After boiler pump flow has been proven by the associated boiler hot water flow switch, the boiler firing sequence shall be enabled.

d. Boiler Pump Failure: If the boiler circulating pump fails to operate when it’s associated boiler operation is enabled, a critical alarm condition shall be reported at the operator workstation.

9. Hot Water Circulating Pumps HWP-1 and HWP-2:

a. Heating System Enabled: Lead hot water circulating pump shall be energized.

b. Heating System Disabled: Lead hot water circulating pump shall be de-energized.

c. Pump Sequence Rotation: Hot water circulating pump lead-lag sequencing shall be rotated weekly (adjustable) to equalize run time between the pumps.

d. Hot Water Pump Failure: If the lead hot water circulating pump fails to operate when pump operation is enabled, the lag pump shall be energized and a maintenance alarm condition shall be reported at the operator workstation.

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10. The points list for the heating system shall be as shown below. Some points are existing, but are shown here for completeness:

INPUT-OUTPUT POINT SUMMARY

HEATING SYSTEM

POINT DESCRIPTION HARDWARE POINTS SOFTWARE POINTS

DIGITAL ANALOG ALARMS

Input Output Input Output Critical Maintenance Boiler Enable X B-1 Status X B-2 Status X B-3 Status X BP-1 Status X X BP-2 Status X X BP-3 Status X X B-1 Alarm X X B-2 Alarm X X B-3 Alarm X X Low Water Cutoff X X Manual Reset High Limit

X X

HWP-1 Start/Stop X HWP-1 Status X X HWP-2 Start/Stop X HWP-2 Status X X Boiler EPO Switch X X Hot Water Supply Temperature

X

Hot Water Return Temperature

X

Outside Air Temperature X

X. HVAC Controls Improvements:

1. Reconfigure DDC System Control Points: DDC system control points shall be reconfigured in the existing DDC system to accommodate the new boilers and boiler pumps, to accommodate the new heating valve operators, and to accommodate programming of the DDC system in accordance with the attached Proposed HVAC Control Sequence of Operation. Points shall be reconfigured as listed in the Input-Output Point Summary contained in the “Proposed Sequence of Operation” above.

(Note: Any new controls that may be necessary shall be fully compatible with the existing controls such that the reconfigured control system works as a single, integrated control system, as if the entire control system had been originally installed in the building under a single contract. The intent of this contract is to modify the existing control system with the existing controllers and control system front end remaining in place, and retaining the existing network connection to the ADX server in Denver.)

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2. Reprogram DDC System: Reprogram the reconfigured DDC system in accordance with the Proposed HVAC Control Sequence of Operation to accommodate the new boilers and new control valve operators.

(Note: Reprogramming the DDC system also includes programming any control functions internal to the new boilers as necessary to execute the control sequence specified in the Proposed HVAC Control Sequence of Operation.)

3. Perform Point-to-Point Checkout: After all of the DDC system modifications are complete, perform a point-to-point checkout of all new and reconfigured control points in the system.

This checkout will verify that all control sensors and actuators are connected to the proper inputs and outputs on the DDC controllers, and will verify that all sensors and actuators are working properly. The controls contractor shall prepare and submit a point-to-point (P2P) report upon completion of the point-to-point checkout work.

4. Update DDC System Graphics: Update the graphics package for the DDC system to reflect the new boilers and boiler pumps. (Note: Graphics for the NHTIC currently reside on a Metasys ADX server located in Denver, but can be accessed for updating using a BLM computer connected to the BLM network. The graphics screen specified below currently exists, but shall be updated as noted to match the improved HVAC system configuration.)

The modified control system graphics shall include the following screens:

a. Boiler System screen, with a heating system flow diagram, and all equipment and control points shown for the boiler system, arranged to reflect three boilers and three boiler pumps in a primary-secondary pumping configuration.

5. Update Existing Control System Shop Drawings: Update the existing control system shop drawings to reflect the new boilers and boiler pumps.

Y. Labeling: Furnish and install engraved plastic labels on the new boilers, switches, and other controls. Furnish and install pipe markers and directional flow arrows on the new boiler piping and gas piping. Pipe markers shall be pre-formed, pre-printed, snap-on, color-coded pipe markers with directional flow arrows integral with the marker. Furnish and install pipe markers at a minimum of 25 feet on center in each section of pipe. Install markers on piping such that lettering is in the most legible position.

Z. Startup and Testing: Before starting the new boilers for the first time, furnish start-up and testing services, performed by a qualified manufacturer’s representative. All start-up and testing procedures shall be in strict accordance with the boiler manufacturer’s start-up and testing instructions, and shall be performed in the presence of the Contracting Officer’s Representative.

In addition to properly setting all of the boiler control parameters, etc. to execute the proposed sequence of operation above, startup and testing shall also include combustion analysis and any necessary adjustments.

AA. HVAC Systems Adjustment and Performance Verification:

1. Demonstration and Training: Provide training on new boiler system functions, control functions, and routine maintenance procedures. Training shall be given to BLM site personnel at a time that is acceptable to both the BLM site manager and the Contracting Officer’s Representative.

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2. Update O&M Manuals: Update O&M manuals to reflect changes and upgrades to the heating system.

VI. Submittals

A. Accident Prevention Program: Submit an accident prevention program. The program must be accepted by the BLM before any on site work can begin. The program shall comply with OSHA and project requirements. Include the following:

Name of responsible supervisor to carry out the program; safety meetings; first aid procedures; outline of each phase of work, hazards associated with each phase and methods proposed to ensure property protection, and safety of the public, BLM staff and Contractor employees; training; planning for possible emergency situations; housekeeping and fire protection.

B. Construction Submittals: Submittals shall be transmitted to the Contracting Officer after contract award, but prior to commencing construction/demolition work for review and approval.

Submittals shall be accurate and complete. Allow 5 business days for submittal review by BLM.

1. Submit manufacturer’s product data and shop drawings for the following:

a. Boilers (B-1, B-2 and B-3).

b. Boiler Pumps (BP-1, BP-2 and BP-3).

c. Magnetic Dirt Separator.

d. Expansion Tank (ET-1).

2. Submit revised control drawings for the reconfigured HVAC control system. The control drawings shall include both the existing DDC system and any revised controls such that the control drawings accurately depict the entire control system as a whole, new plus existing.

3. Material submittals shall be submitted with enough lead time to allow for material delivery prior to the start of demolition of the existing boiler system.

C. Closeout Submittals: Submit operation and maintenance data to the Contracting Officer at project closeout, and update existing O&M manuals located on site with the following:

1. Manufacturer’s operation and maintenance data for the following:

a. Boilers (B-1, B-2 and B-3).

b. Boiler Pumps (BP-1, BP-2 and BP-3).

c. Magnetic Dirt Separator.

d. Expansion Tank (ET-1).

2. Submit as-built control drawings for the reconfigured HVAC control system. The control drawings shall include both the existing DDC system and any revised controls such that the control drawings accurately depict the entire control system as a whole, new plus existing.

Boiler Replacement - Contract Scope of Work Page 22 of 22

VII. Attachments

A. Original Construction Drawings – (additional drawings are available on request)

1. Architectural Drawings (A1.0, A1.2, A2.1, A2.3, A3.0, A5.1, A6.0 and A6.4)

2. Mechanical Drawings (M0 through M15)

3. Electrical Drawings (E0.1, E2.1, E2.2, E7.1, E8.1 and E9.1)

B. Control System Shop Drawings

1. Johnson Controls 4/1/02 Control Drawings

END

10. The points list for the heating system shall be as shown below. Some points are existing, but are shown here for completeness:

Attachment B