36C26319R0078-0002002.pdf

Addendum #1

12700 West Dodge Road | Omaha, NE 68154 | T 402-330-5900 | farris-usa.com engineering excellence

Date: May 23, 2019 Date of Issuance: March 15, 2019

Project Name: Replace Boilers

VA Project No. 636-13-103 Date of Opening: May 30, 2019

FE Project No.: 182085

NOTICE: This addendum is applicable to the referenced project and is issued to all known planholders prior to receipt of proposals. The information contained herein shall be fully incorporated into the Bid Contract Documents as though originally incorporated. Failure to acknowledge all amendments may be cause for rejection of the bid.

TO: Bidders and Others Concerned

Changes to the Project Manual

1. SECTION 23 09 11 – INSTRUMENTATION AND CONTROL FOR BOILER PLANT: Delete specification section in its entirety and replace with revised new specification Section 23 09 11 attached to this addendum.

2. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 1.3.G.; Delete “SP-127-2014a” reference.

3. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 1.3.J.; Delete paragraph in its entirety.

4. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 2.1.7.; Delete wording “//and to resist seismic shocks (in seismic areas)//”.

5. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 2.29, Piping Support Systems; Delete paragraphs A., D., H., I. J., in their entirety.

6. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 2.29, Piping Support Systems; Delete paragraphs K.14. and K.15., in their entirety.

7. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 2.8, Cold Water Piping.; Delete paragraph in its entirety.

8. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 2.9, Reverse Osmosis Piping; Delete paragraph in its entirety.

9. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 3.2.F.; Delete wording “wafer-type” from paragraph.

10. SECTION 23 21 11 –BOILER PLANT PIPING SYSTEMS: Refer to paragraph 3.3.G.; Delete wording “and also seismic forces where required”.

Changes to the Drawings

1. DWG NO. 7M601 (PAGE 11 OF 17) MECHANICAL – STEAM BOILER PLANT PIPING DIAGRAM:

A. Reference icon designation on steam header; Change wording “FT104” to read “PT101”.

2. DWG NO. 7M603 (PAGE 13 OF 17) MECHANICAL – NATURAL GAS, LP GAS AND FUEL OIL FLOW DIAGRAM:

A. Fuel Oil Pressure Transmitter Detail; reference device icon designation “FT601”; Change wording to read

“PT601”.

P a g e | 2 Addendum #1

12700 West Dodge Road | Omaha, NE 68154 | T 402-330-5900 | farris-usa.com engineering excellence

3. DWG NO. 7M603 (PAGE 13 OF 17) MECHANICAL – NATURAL GAS, LP GAS AND FUEL OIL FLOW DIAGRAM:

A. Gas Pressure Transmitter Detail; reference device icon designation “FT401”; Change wording to read “PT401”.

4. DWG NO. 7M603 (PAGE 13 OF 17) MECHANICAL – NATURAL GAS, LP GAS AND FUEL OIL FLOW DIAGRAM:

A. Natural Gas and Liquified Petroleum Gas – Burner And Igniter Fuel Standard Piping Diagram; delete wording “M-4”.

5. DWG NO. 7EP101 (PAGE 16 OF 17) MECHANICAL – ELECTRICAL FIRST FLOOR PLAN:

A. Reference icon designation on south wall of boiler, room main natural gas supply pressure transmitter; Change wording “PT101” to read “PT401”.

Clarifications

1. Seismic Requirements: There are no seismic requirements for this project.

2. Gas Flow Meters: New gas flow meters are as specified as turbine type meters for the new boilers specified.

3. Gas Detection Panel: Existing gas detection panel will not connect/interface to new computer workstation.

4. Pressure Transmitters: Reference specification Section 23 09 11; provide pressure transmitters with minimum 175 psig operating pressure rating.

Attachments

1. SECTION 23 09 11 – INSTRUMENTATION AND CONTROL FOR BOILER PLANT.

-- END --

FE #182085 VA Boiler Addendum.docx No. 1

08-01-17

23 09 11 - 1

SECTION 23 09 11

INSTRUMENTATION AND CONTROL FOR BOILER PLANT

PART 1 - GENERAL

1.1 DESCRIPTION

A. Automatic controls, instruments, monitoring and dat a management systems and accessories for the boilers, burners and other boiler plant mechanical equipment. The specification classifies the systems into automatic boiler and burner control systems, burner management systems

(flame safeguard), and data management and instrume ntation systems.

B. A complete listing of common acronyms and abbreviat ions are included in

Section 23 05 10, COMMON WORK RESULTS FOR BOILER PL ANT AND STEAM

GENERATION.

C. Existing Boiler Plant Control System: The existing boiler plant contains pneumatic and electric controls.

1. Boiler No. 1 control panel has a electric/electroni c control panel mounted on the boiler.

2. Existing Boilers Nos. 2 and 3 are pneumatic/electri c controls in a freestanding boiler panel for each boiler.

3. Boilers No. 2 and No. 3 are being demolished along with existing controls and remote plant boiler control panel.

D. New Boiler Plant Control System: Provide for new b oiler plant control system to monitor boiler operations.

1. New boilers replacing Boilers No. 2 and No. 3 are t o be equipped with automatic boiler controls and burner managemen t control panels.

2. Boiler Control Configuration: The existing Boiler No. 1 and the new

Boilers Nos. 2 and 3 boiler control panels are to b e connected via

BACnet MS/TP to the existing JCI Boiler Plant Contr ol Station via a new computer workstation located in the Boiler Plan t Control Room adjacent to the boiler room firing aisle area.

3. Johnson Controls Inc. (JCI) is the site energy mana gement system for the VA campus.

a. JCI shall provide and install a Network Control Eng ine panel for the connection of the existing and new plant meteri ng for each boiler for natural gas and steam flow for the plant and each steam boiler, and fuel oil for each steam boiler su pply and return.

23 09 11 - 2

b. Continuous display of critical operating parameters monitored from each boiler control panel to include but not l imited to the following:

1) Master header steam pressure.

2) Boiler steam pressure.

3) Water level.

4) Draft pressure.

5) Firing rate.

c. A graphic display shall be produced for each boiler to graphically show the individual boiler graphics nat ural gas, fuel oil, and steam meters for each boiler, and the exis ting plant natural gas and steam flow meters.

d. Firing Rate: Provide means of automatic and manual operation of boiler firing rates and burner management status if work station screen fails.

e. BACnet MS/TP communication cable from each boiler s hall be connected to the Network Control Engine. COR and p lant operator selected points shall be mapped to the Operator Con trol Station in the Plant Control Room.

f. Individual boilers will be controlled from there in dividual boiler control panel and burner management system p rovided by the boiler manufacturer.

1.2 RELATED WORK

A. Section 01 00 00, GENERAL REQUIREMENTS.

B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

C. Section 01 81 13, SUSTAINABLE CONSTRUCTION REQUIREM ENTS.

D. Not Used

E. Not Used

F. Section 23 05 10, COMMON WORK RESULTS FOR BOILER PL ANT AND STEAM

GENERATION.

G. Section 23 05 51, NOISE AND VIBRATION CONTROL FOR B OILER PLANT.

H. Not Used

I. Section 23 08 11, DEMONSTRATIONS AND TESTS FOR BOIL ER PLANT.

J. Not Used

K. Section 23 21 11, BOILER PLANT PIPING SYSTEMS.

L. Not Used

M. Section 23 51 00, BREECHINGS, CHIMNEYS, AND STACKS.

N. Not Used

23 09 11 - 3

O. Section 23 52 39, FIRE-TUBE BOILERS.

P. Section 26 05 11, REQUIREMENTS for ELECTRICAL INSTA LLATIONS.

Q. Section 26 05 19, LOW-VOLTAGE ELECTRICAL POWER COND UCTORS AND CABLES.

R. Section 26 05 33, RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS.

S. Section 26 27 26, WIRING DEVICES.

T. Section 26 29 11, MOTOR CONTROLLERS.

1.3 APPLICABLE PUBLICATIONS

A. The publications listed below form a part of this s pecification to the extent referenced. The publications are referenced in the text by the basic designation only. Where conflicts occur these specifications and the VHA standard will govern.

B. American National Standards Institute (ANSI):

INCITS 154-1988(S2009)..Office Machines and Supplie s - Alphanumeric

Machines - Keyboard Arrangement

C. American Society of Mechanical Engineers (ASME):

B31.1-2014..............Power Piping

B40.100-2013............Pressure Gauges and Gauge A ttachments

PTC 4-2013..............Fired Steam Generators

D. National Electrical Manufacturers Association (NEMA ):

ICS 6-1993(R2001, R2006) Industrial Control and Sys tems:

Enclosures

WC 63.2-1996(R2003).....Performance Standard for Co axial Premise Data

Communications Cables

E. National Fire Protection Association (NFPA):

70-2014.................National Electrical Code

85-2015.................Boiler and Combustion Syste ms Hazards Code

F. Underwriters Laboratories Inc. (UL):

508-1999(R2013).........Standard for Industrial Con trol Equipment

1449-2014(R2016)........Standard for Surge Protecti ve Devices

1998-2013...............Standard for Software in Pr ogrammable

Components

G. Department of Veterans Affairs (VA)

........................VHA Boiler Plant Safety Dev ices Testing Manual, Third Edition

1.4 SUBMITTALS

A. Submittals, including number of required copies, sh all be submitted in accordance with Section 01 33 23, SHOP DRAWINGS, PR ODUCT DATA, AND

SAMPLES.

23 09 11 - 4

B. Information and material submitted under this secti on shall be marked

“SUBMITTED UNDER SECTION 23 09 11, INSTRUMENTATION AND CONTROL FOR

BOILER PLANT”, with applicable paragraph identifica tion.

C. Manufacturer's Literature and Data including: Full item description and optional features and accessories. Include dimensio ns, weights, materials, applications, standard compliance, model numbers, size, and capacity.

D. Certificates of compliance with paragraph, QUALITY ASSURANCE of this section (subparagraphs 1.5.A, B, D & F). In additio n, submit Past

Performance Questionnaire (form attached) for five (5) past projects of the same class (scope & complexity) as this project .

E. Submit information sufficient to verify compliance with all contract requirements as specified and shown on project draw ings.

F. Automatic Boiler Control and Burner Management and Safety Interlock

Systems:

1. Catalog cuts and specification sheets providing des cription and performance data on: Controllers, control and indic ating stations, sensors and transmitters, signal conditioners, elec tric switches and relays, indicators and annunciators, safety interlo ck devices, drive units and actuators, control valves, mechanical lin kage systems, compressed air filters and regulators.

2. Statement from controller manufacturer that the typ e and model submitted is the current generation and that the ma nufacturer will support the units with parts and service for at lea st ten years, and that the equipment submitted meets all VA specifica tions.

3. Information on all the specific systems that is suf ficient to allow complete troubleshooting. As a minimum, this should include explanation of the control logic, and wiring diagra ms of equipment and systems to include locations and wire numbers o f all safety device test points that will be required to complet e safety device testing in accordance with VA requirements, and seq uence of operation of all components of the system.

4. Hardware systems schematics showing field and panel equipment interface block diagram.

5. Location of interlock devices on the burners, boile rs, fuel trains and accessory equipment, all safety devices shall b e easily accessible for testing.

23 09 11 - 5

G. Boiler Plant Instrumentation:

1. Catalog cuts and specification sheets providing des cription and performance data on instruments and accessories.

2. Installation and troubleshooting instructions for a ll equipment in bound sets shipped with equipment.

3. List of ranges of recorder displays. Paper chart re corders are prohibited.

4. Flow meter primary element design, size, performanc e, and sizing calculation. Steam flow performance data for flow m eters verifying project performance requirements.

5. Complete wiring and piping diagrams for all equipme nt and systems.

6. Wiring and piping materials.

H. Instrumentation and Control Panels:

1. Drawing showing arrangement of instruments and cont rols on panels.

2. Drawing showing panel arrangements, construction, d oor swing clearance allowance, dimensions, finishes.

3. Description of panel construction.

4. Not Used

I. Computer Workstation and Programming:

1. Catalog data with pictures, description, and perfor mance data on all hardware.

2. Hardware specifications.

3. Software model number and supplier. Include complet e documentation on all software with shipment.

4. Confirmation that graphics to be provided complies with the specification.

5. Not Used

J. As-built Logic and Wiring Diagrams: One set of repr oducible prints and

CAD disks delivered to COR prior to turning systems over to VA for operation. Supply revised drawings if changes are m ade during the startup and commissioning process.

K. Fluid Flow Meters:

1. Catalog cuts and drawings with description, specifi cations and dimensions of meters and accessories.

2. Design and construction of meters and accessories.

3. Performance data including flow, pressure drop, acc uracy over the metering range of the actual fluids to be metered.

4. Pressure and temperature limitations.

23 09 11 - 6

5. Manufacturer's installation instructions.

6. Arrangement of register face and remote indicator ( if provided).

L. Pressure Gauges and Thermometers:

1. Catalog cuts showing design, construction, dimensio ns of gauges and accessories.

2. Accuracy.

3. Pressure and temperature limitations of gauges and accessories.

4. List of scale ranges to be provided.

M. Complete operating and maintenance manuals includin g wiring diagrams, technical data sheets, information for ordering rep lacement parts, and troubleshooting guide:

1. Include complete list indicating all components of the systems.

2. Include complete diagrams of the internal wiring fo r each item of equipment.

3. Diagrams shall have their terminals identified to f acilitate installation, operation and maintenance.

N. Completed System Readiness Checklist provided by th e Commissioning

Agent and completed by the contractor, signed by a qualified technician and dated on the date of completion, in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

O. Submit training plans and instructor qualifications in accordance with the requirements of Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS.

1.5 QUALITY ASSURANCE

A. The boiler and burner control, monitoring, data gat hering, instrumentation and associated systems specified in this section shall be provided by one company that has been in busines s at least three years engineering, designing and servicing industri al and institutional boiler control and instrumentation systems similar to those specified herein, as a primary business. That company shall f urnish all components and provide complete calibration, progra mming, start-up, testing, demonstrations, instructions and training services.

B. Submit documented evidence, including start-up and acceptance test data, and references, that the company has performe d satisfactory work on at least six systems similar to those specified, list any VA boiler plant projects completed in the past. For instance, submit experience information on systems involving parallel positioni ng combustion control and on variable speed forced draft fan driv es, if these systems

23 09 11 - 7 are specified. Submit in writing that all specifica tions were read and fully understood.

C. If new burners are part of the contract, the burner manufacturer shall be responsible for the burner management system (fl ame safeguard), including interlocks, all accessories and for coord ination with other control and monitoring systems.

D. Equipment Experience Requirements: Refer to Section 23 05 10, COMMON

WORK RESULTS FOR BOILER PLANT ANDSTEAM GENERATION.

E. Code Approval:

1. All burner management and combustion control system s and devices shall comply with NFPA 85, regardless of boiler typ e or size.

Locations and arrangements of safety devices on fue l trains shall comply with diagrams included in “Annex A” in the c ode, as modified by the VA standard details and the VHA Boiler Plant Safety Devices

Testing Manual requirements.

2. All burner management controls and interlock device s shall be UL listed and FM approved. All controllers that includ e burner management functions shall be UL listed and FM appr oved.

3. Parallel positioning combustion control systems sha ll comply with UL

1998.

4. Computer-based electronic equipment shall conform t o the requirements of FCC Part 15, Subpart J, for Class A computing devices governing radio frequency electromagnetic i nterference (EMI) while continuing to operate normally.

5. All electrical wiring shall be in accordance with N FPA 70.

6. The use of wire nuts is prohibited. All wire connec tions must be made at terminal blocks and terminal strips.

7. The use of liquid tight or other flexible conduit s ystems is limited to 900 mm (3 foot) in length unless longer runs are required for door swings or other equipment access.

8. All wire runs are required to be in conduit.

F. Personnel: All work shall be done by properly train ed, skilled technicians who are regularly employed and qualifie d in the installation, programming, start-up, calibration, a nd testing of the systems provided, and who will be directed by exper ienced engineers employed by the equipment supplier. Personnel must have three years minimum experience with industrial and institutiona l boiler plant

23 09 11 - 8 controls and instruments similar to those being fur nished for this project.

1.6 AS-BUILT DOCUMENTATION

A. Submit manufacturer’s literature and data updated t o include submittal review comments and any equipment substitutions.

B. Submit operation and maintenance data updated to in clude submittal review comments, VA approved substitutions and cons truction revisions shall be in electronic version on CD or DVD inserte d into a three-ring binder. All aspects of system operation and mainten ance procedures, including applicable piping isometrics, wiring diag rams of all circuits, a written description of system design, c ontrol logic, and sequence of operation shall be included in the oper ation and maintenance manual. The operations and maintenance manual shall include troubleshooting techniques and procedures for emerg ency situations.

Notes on all special systems or devices shall be in cluded. A List of recommended spare parts (manufacturer, model number , and quantity) shall be furnished. Information explaining any spec ial knowledge or tools the owner will be required to employ shall be inserted into the

As-Built documentation.

C. The installing contractor shall maintain as-built d rawings of each completed phase for verification; and, shall provid e the complete set at the time of final systems certification testing. Should the installing contractor engage the testing company to provide as-built or any portion thereof, it shall not be deemed a confl ict of interest or breach of the ‘third party testing company’ require ment. Provide record drawings as follows:

1. Not Used

2. As-built drawings are to be provided, with a copy o f them on AutoCAD version 2018 provided on CD or DVD. The CAD drawing s shall use multiple line layers with a separate individual lay er for each system.

3. Not Used

D. The as-built drawings shall indicate the location a nd type of all lockout/tagout points for all energy sources for al l equipment and pumps to include breaker location and numbers, valv e tag numbers, etc.

Coordinate lockout/tagout procedures and practices with local VA requirements.

23 09 11 - 9

E. Certification documentation shall be provided to CO R 21 working days prior to submitting the request for final inspectio n. The documentation shall include all test results, the names of indivi duals performing work for the testing agency on this project, detail ed procedures followed for all tests, and provide documentation/c ertification that all results of tests were within limits specified. Test results shall contain written sequence of test procedure with wri tten test results annotated at each step along with the expected outc ome or setpoint. The results shall include all readings, including but n ot limited to data on device (make, model and performance characterist ics), normal pressures, switch ranges, trip points, amp readings , and calibration data to include equipment serial numbers or individ ual identifications, etc.

PART 2 - PRODUCTS

2.1 AUTOMATIC BOILER/BURNER CONTROL SYSTEM, NOT INCLUDING BURNER MANAGEMENT

(FLAME SAFEGUARD)

A. Basic Description of Controllers and Control Functi ons:

1. Controllers shall be industrial-process-grade multi -loop programmable microprocessor or programmable logic c ontrollers (PLC).

2. Controllers shall be manufactured separate from and shall be separate assemblies, in a separate electrical cabin et from the

Burner Management (Flame Safeguard System).

3. Control functions:

a. Control of burner firing rates to maintain steam he ader pressure.

b. Parallel-positioning combustion control (air/fuel r atio, excess air) with flue gas oxygen trim.

c. Not Used

d. Not Used

e. Boiler outlet draft.

f. Boiler water level, 1 element system.

4. Control features:

a. Operator interface on controller faceplates and tou ch screens and computer workstation. Operator interface shall incl ude manual/automatic selection, manual loading, and dis plays that show set point, process variable, and signal to act uator, process status and controller status. Touch screens have ad ditional display requirements; refer to the following paragr aph.

23 09 11 - 10

b. Provide separate dedicated controllers/panels for e ach boiler and for the master steam pressure control. Fuel/air con trol loops, including FGR and oxygen trim may be incorporated i nto one station for each boiler. Boiler/economizer outlet d raft and boiler water level control shall have separate stat ions for each item on each boiler. All control items for one boil er may be shown on one touchscreen for that boiler. Each boil er shall have its own touch screen located in the panel for that boiler.

c. VA Boiler Plants PROHIBIT any boiler to be automati cally or remotely started and lead lag control systems are p rohibited within the VA boiler plants, regardless of the size or type of boiler. The boiler shall be started by an operator standing at the boiler.

d. Variable frequency drives on forced draft fan motor s.

5. Refer to paragraph, BURNER MANAGEMENT (FLAME SAFEGU ARD CONTROL)

SYSTEM WITH SAFETY INTERLOCKS AND ACCESSORIES for b urner management controls.

B. Controllers: Multiple-loop programmable microproces sor or programmable logic (PLC) proportional-integral-differential (PID ) solid state electronic controllers shall control all functions except burner management.

1. Accuracy: 0.1 percent analog inputs and outputs.

2. Resolution: 16-bit input and output.

3. Environment: 0 to 50 degrees C (32 to 122 degrees F ), 15 percent to

95 percent RH, non-condensing.

4. As a minimum, each controller shall have capability for four analog and four digital inputs, two analog and four digita l outputs, and two PID loops.

5. Memory retention for twelve months minimum for powe r failure or for storage as spare parts.

6. Membrane push buttons with tactile feedback.

7. Displays shall be a combination of English language , color graphics, and digital with 0.5 percent resolution, visible fr om wide angle.

8. Bumpless manual/automatic transfer.

9. High and low alarms for all inputs.

10. Programming: Controllers shall have capability for quick (5 to 10 minutes) reloading of memory by operating personnel upon memory

23 09 11 - 11 loss. Provide all software and hardware necessary t o allow field downloading of configuration memory to the micropro cessors.

11. Password Protection: Provide levels of password pro tection for all safety related options and parameters including all commissioning programming. Provide all passwords to COR.

12. In the event of a controller fault, the controller shall have a dedicated relay output that results in the shutdown of the boiler and provides an alarm to a panel-mounted light and audible alarm.

Failure of control system for one boiler shall not affect automatic and manual operation of other boilers.

13. Controllers and software that operate variable freq uency drives shall be manufactured and tested in accordance with UL 508.

14. Controllers shall provide serial RS232/RS485 Modbus communication with computer workstation running latest Microsoft Windows based operating system. This includes data gathering and processing, report generation, monitoring, annunciation and con trol. Refer to paragraph, COMPUTER WORK STATION AND PROGRAMMING. I t shall be possible to defeat the remote control from the fron t panel of each individual controller, preventing any status change s from being initiated at the computer workstation.

15. All controllers, including those assigned to data p rocessing, shall be same model and series.

16. Controllers shall be the current generation product that will be supported by the manufacturer, with parts and servi ce, for a minimum of ten years from time of installation.

17. All controllers shall be mounted within specified c ontrol panels.

18. Examples of acceptable controllers: Hays-Cleveland “AC Station”;

MicroMod “Mod 30 ML”; Toshiba “LC500”; and Fireye N exus “PPC 4000”.

All controllers with integrated flame safeguard are prohibited.

C. Power Supplies: Provide separate uninterrupted powe r supply for each boiler controller. Any signal that is common to all boilers, such as plant master control signals, shall be isolated fro m all other boilers so that failure in one boiler circuit will not affe ct other boilers.

D. Touch Screen Operator Terminals:

1. Provide one touch screen control station and displa y for each boiler mounted on the boiler control panel. Touch screen s hall be in complete communication with all controllers associa ted with the boiler and with the burner management system. Provi de alternate

23 09 11 - 12 control station to replace touch screen control fun ctions if touch screen fails. Direct communications to a new remote work station to monitor/control each new and existing boiler.

2. Control Station and Display Requirements:

a. Local operation and programming of controllers, gra phic display of information, alarm message display, historical a nd real-time trending, remote controller tuning, x/y plots of fu el air curve data for intuitive commissioning of controllers, Et hernet connectivity and standard Internet browser remote c ommunication.

Network to boiler control and burner management sys tems.

b. Selection of automatic or manual control of firing rate. Local manual control to increase and decrease the firing rate.

c. Indicate burner management control status and diagn ostics in

English messages: control on, pre-purge, trial for ignition, igniter flame signal, main flame signal, post purge , burner off, all diagnostic information available from burner ma nagement system, continuous indication of flame signal.

d. Real time display of all connected process paramete rs including control output, set point, process variable, all da ta gathering and processing from all controllers associated with the boiler.

e. Display of all control system alarm messages and fa ults. History of alarms and faults and recommendations for troubl eshooting.

f. Complete display and facilities to allow programmin g all controllers associated with the boiler or the maste r control.

Burner management is excluded from this requirement .

g. Provide alternate means of automatic and manual ope ration of boiler firing rates and burner management status if touch-screen fails.

h. Provide continuous display of critical operating pa rameters, including but not limited to the following:

1) Steam Pressure

2) Water Level

3) Draft Pressure

4) Firing Rate

3. Touch Screen System Hardware and Software:

a. 265 mm (10.4 inch) panel-mounted display, TFT with 256 colors, 640 x 480 pixel LCD resolution. Locate to allow eas y viewing and access from operating floor.

23 09 11 - 13

b. Aluminum case allowing entire enclosure to be rated NEMA 4X.

c. Not Used.

d. Multiple RS485 Modbus and BACnet communication inte rfaces.

e. Field-replaceable backlight, real-time clock, batte ry-backed clock time stamps critical data, 8 MB on-board flas h application memory, 512 MB memory-card, application expanded me mory-card for historical, alarm and event storage, resistive anal og touch screen with free formable to fit target shape.

f. Operation interaction shall be touch-based allowing easy selection of screens, manual/automatic status chang es, start/stop functions, set point changes, output changes and PI D tuning parameters without any special programming skills. Screen selection shall also be available through tactile f eedback function keys.

g. Show facsimiles of each controller and clearly labe led English language and engineering unit display of the contro l parameters.

h. Graphic X/Y curve data plotting capability. When us ed in conjunction with fuel/air ratio control, provide au tomated fuel/air ratio curve and oxygen trim set point curv e adjustment for rapid, error free burner tune-up. Only a single operator action shall be required to store commissioning dat a into multiple characterizer curves for a particular load point.

i. Configuration software Microsoft Windows based. Pro vide all necessary software to allow field modification or e xpansion of the system including graphics drawing programs and data base builders. Systems based on “run time only” programs are not acceptable.

E. Drive Units and Actuators for Dampers, Fuel Flow Co ntrol Valves, Feedwater Flow Control Valves:

1. Electric drive units are required.

2. Electric drive units shall have continuous modulati ng duty cycle without any duty cycle or thermal motor limitations . Shall start instantaneously at full rated torque, stop instanta neously without coast or overshoot. Shall smoothly operate all conn ected devices without overload. Provide 100 percent duty cycle ma intenance free motors that never overheat or burnout under stalled conditions.

Gearing shall eliminate backlash. Movement shall be constant speed

23 09 11 - 14 and shall be coordinated with the controlled proces s so that performance parameters remain within specified limi ts.

3. Additional Requirements for Electric Drive Units on Parallel-

Positioning Combustion Control Systems:

a. Drive units shall have precise positioning and repe atability to provide air-fuel positioning ratios with a maximum hysteresis of

2 percent.

b. Provide continuous precise feedback signals from dr ive units to controllers.

c. Provide auxiliary contacts to prove low and high fi re positions.

Feedback signals are prohibited to perform this fun ction within the VA. Belt-type drive units are prohibited.

d. Drive unit shafts shall be keyed to fuel flow contr ol valves and damper shafts to eliminate the possibility of slipp ing.

e. Drive units shall be industrial rated.

f. All gearing shall be brass or better. Plastic gears of any kind are prohibited.

4. Boiler outlet damper drive units may be different m odel than drive units for fuel valves and forced draft damper. Driv e units shall be capable of 136 Nm (100 ft-lb.) torque minimum. Less powerful drive units may be utilized if certified as adequate by t he burner manufacturer.

F. Variable Frequency Drives (VFD) for Forced Draft Fa ns:

1. Refer to Section 26 29 11, MOTOR CONTROLLERS, for e lectrical requirements. In addition, there shall be a VFD mou nted operator interface unit that allows configuration of drive p arameters and displays diagnostic information for troubleshooting . The minimum speed is limited to 40 Hz.

2. Provide feedback system including motor speed and d irection of rotation to combustion controller. Feedback transmi tter must have no-drift guarantee. Feedback system shall not be af fected by position of HOA switch on motor control system.

3. Provide noise filters.

4. The VFD shall automatically limit the rate of fan s peed increase to that which will prevent an over-current trip in the event of a

“step” speed increase of 0 to 100 percent.

5. Provide constant speed feature and operator-selecta ble air/fuel program in the controller for constant speed operat ion maintaining

23 09 11 - 15 specified air/fuel ratios at all firing rates or po sitions (excess air).

6. Forced draft fan damper operation is required in co njunction with operation of the VFD at the lower firing rates.

7. Provide a means of proving fan RPM to control set p oint at any firing rate. Deviation from set point RPM or greate r than 10 percent will cause a safety shutdown of the boiler. As an o ption the contractor may install a fully metered system where air flow is proven at all firing rates and a shutdown will occu r if the airflow varies by more than 10 percent.

G. Transmitters: See paragraphs, PRESSURE SENSORS AND TRANSMITTERS and

TEMPERATURE SENSORS AND TRANSMITTERS.

H. Final Control Elements:

1. Fuel flow control valves, forced draft fan dampers, FGR dampers (if provided), variable frequency forced draft fan driv es (VFD) (if provided), feedwater control valves: Refer to Secti on 23 52 39, FIRE-TUBE BOILERS.

2. Dampers in stacks and breechings: Refer to Section 23 51 00, BREECHINGS, CHIMNEYS, AND STACKS.

I. Uninterrupted Power Supplies:

1. Provide separate complete protected power condition ers for each boiler control and for master control. Power supply shall protect all computers, controls, instruments and accessorie s from damage due to ground leakage, spikes, sags, surges, transients and overloads in the incoming power supply.

2. Line interactive, UL 1449 rated, interactive digita l display.

Automatic internal bypass. Smooth sine wave output.

3. Suitable for ambient temperature of 43 degrees C (1 10 degrees F) in boiler room panel.

4. Hot swappable batteries.

5. Audible and visual alarms to signal failure of powe r supply.

6. This UPS system can be deleted from the project if controls furnished have integral protection from power suppl y irregularities listed above, and if software can be immediately re loaded by plant personnel.

J. Spare Parts and Tools:

1. Master control steam pressure transmitter: One comp lete unit, calibrated for the service.

23 09 11 - 16

2. Hardware and software sufficient for downloading an d uploading all programming configurations with all the controllers .

3. Electric power drive unit: One of each size and typ e used

K. Detailed Control Functions:

1. Control of Burner Firing Rates to Maintain Steam He ader Pressure:

a. Automatic modulation of burner firing rates on all boilers to maintain set pressure of main steam-header. Master controller receives signal from header pressure transmitter, p rocesses and transmits signal to submaster controller for each b oiler/burner.

Submaster controls fuel flow and combustion air flo w.

b. Set Points and Performance: Accuracy plus or minus two percent of the set pressure when steam load changes do not exc eed 20 percent of the maximum continuous rating of the largest boi ler in service in a 60 second period. System oscillations shall be minimal. Set point 85 psig. Second set point 105 psig. Individua l set point adjustment range: +/- 138 kPa (20 psig).

c. Control Stations: Individual control stations for m aster and submaster controllers. Locate control stations on m ain instrumentation panel unless otherwise shown. Maste r controller shall have capability for two set points with easy selection.

d. Low fire hold capability and user definable optimum ignition position.

e. Interface with burner management system for automat ic positioning of forced draft fan damper, forced draft fan speed and fuel flow control valves during pre-purge, ignition, shutdown and post-purge.

f. Interlocks to prove proper positions of forced draf t fan damper, forced draft fan speed, boiler/economizer outlet da mper, and fuel flow control valves for ignition and running cycles . Refer to paragraph, BURNER MANAGEMENT (FLAME SAFEGUARD CONTROL) SYSTEM

WITH SAFETY INTERLOCKS AND ACCESSORIES.

g. The steam header pressure transmitter(s) shall be d edicated to header pressure control. Suppressed range transmitt er(s), each with range +/- 20 percent of required set point. Re fer to

Paragraph, PRESSURE SENSORS AND TRANSMITTERS.

2. Parallel-Positioning Combustion Control (Air/Fuel R atio, Excess

Air):

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a. Boiler/burner submaster controller provides firing rate signals to separate drive units (actuators) for forced draf t fan dampers and for each of the fuel flow control valves and to the variable frequency drive (VFD) of the forced draft fan. Air/ fuel ratio maintained by firmware and software programming of the submaster controller. Software shall be factory-programmed by the controller manufacturer only, for the specific appl ication. Only tuning and scaling shall be performed in the field. Any and all other field adjustments are prohibited.

b. Hardware, firmware and software shall comply with U L 1998.

Incorporate cross-limiting (air leading fuel on loa d increases, fuel leading air on load decreases) and deviation l imiting

(allowable tolerances on air/fuel ratio). Provide a utomatic burner shutdown if deviation exceeds programmed lim its or if there is a controller failure. Cross-limiting and d eviation limiting shall be tested and proven. If at any time it is found this was not preprogrammed at the factory and UL te sted and listed the controller shall be replaced at no addit ional cost or time to the Government. Only tuning and scaling sha ll be performed in the field. Any and all other field adj ustments are prohibited.

c. Provide feedback signals from drives and actuators. Fuel flow shall not increase until appropriate combustion air flow increase is proven. Combustion air flow shall not decrease u ntil appropriate fuel flow decrease is proven. VFD feedb ack transmitters shall have “no-drift” guarantee.

d. Accuracy of control of drive units shall result in fuel-air positioning ratios that are specified by the burner manufacturer for efficient and safe operation with a maximum hys teresis of 2 percent. Excess air in flue gas shall conform to li mits given below.

e. Manual control function accessible to operating per sonnel shall be confined to base loading the firing rate of the burner and shall prohibit separate control of fuel or combusti on air. All other manual functions shall be password protected intended to be accessible only to qualified technicians. If system is improperly placed in a manual control mode, the system shall s hutdown the boiler or maintain safe excess air levels at all ti mes, within

23 09 11 - 18 parameters that limit the carbon monoxide emissions to specified limits.

f. From low fire to high fire the air/fuel ratio (exce ss air) shall be programmed over at least ten evenly spaced incre ments of fuel input.

g. Control positions and display indications shall be linear in relation to firing rate. For example, 20 percent co ntrol position shall be 20 percent firing rate (20 percent of full load).

h. Mechanical connections between drive units and damp ers and valves shall not have hysteresis and shall be keyed to eli minate slippage. Use of linkage systems must be minimized and submitted for approval as a deviation to the contract.

i. Excess Air and Emissions Limits – New Burners: Refe r to the boiler and burner specification.

j. Not Used

3. Automatic Flue Gas Oxygen Trim System:

a. Boiler/burner submaster air/fuel controller shall u tilize signal from flue gas oxygen analyzer and vary the combusti on air flow to maintain the specified air/fuel ratio (excess air) at all firing rates 20 percent of maximum firing rate and greater .

b. Operation and Performance:

1) Separate characterized set point curves for each fu el, minimum ten points per fuel. A single curve with biasing fo r the other fuel is not acceptable. Automatic changeover of set point curves when type of fuel being fired is changed.

2) Maximum deviations from set points shall not exceed ten percent at any firing rate. Combustion shall not ge nerate carbon monoxide (CO) in excess of 200 ppm at any ti me.

3) At firing rates below 20 percent of maximum steam f low, trim shall automatically return to null position (no tri m).

4) Variable gain to decrease output sensitivity at low loads.

5) Adjustable high and low trim limiting. Excessive hi gh or low trim correction, low excess air, or oxygen analyzer failure shall actuate audible and visual alarm on the boile r submaster air/fuel ratio controller. Analyzer failure shall c ause system to go to null position.

6) Manual trim output shall revert to null setting whe n system is placed in automatic control.

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c. During burner start-up and adjustment of air/fuel r atios (excess air) by service technician, trim shall be on manual control at null position.

d. Refer to paragraph, FLUE GAS OXYGEN ANALYZERS.

4. Not Used

5. Not Used

a. Single Element System: Utilize signal from water le vel sensor on boiler.

b. Boiler Water Level Sensors:

1) Differential Pressure Transmitters: Provide on wate r tube boilers. Refer to paragraph, PRESSURE SENSORS AND

TRANSMITTERS.

2) Water Level Sensing and Safety Control Systems: Pro vide on fire tube boilers. Refer to Section 23 52 39, FIRE- TUBE

BOILERS.

3) Probe-Type Capacitance Systems: Optional control fo r fire tube and water tube boilers. Dual probes mounted in wate r column controlled by microprocessor system. Provisions to compensate for shrink and swell of water level due to load cha nges. Self-checking function comparing the signals from each p robe and causing burner shutdown if water level movement is not detected.

c. Steam Flow Sensors: Refer to paragraph, FLOW METERS .

d. Feedwater Pressure Sensors: Refer to paragraph, PRE SSURE SENSORS

AND TRANSMITTERS.

e. Controller: For controller requirements for fire tu be boilers, refer to Section 23 52 39, FIRE-TUBE BOILERS.

f. Set point position as recommended by boiler manufac turer.

6. Boiler Efficiency Calculation and Display: If not p rovided on the computer work station, provide continuous automatic calculations and indication of heat-loss combustion efficiency based on flue gas outlet temperature of (boiler) flue gas oxygen, and type of fuel in use. Base calculation method on ASME Performance Te st Code, HEAT

LOSS EFFICIENCY form, with no consideration for boi ler radiation and unaccounted losses.

23 09 11 - 20

2.2 BURNER MANAGENENT (FLAME SAFEGUARD CONTROL) SYSTEM WITH SAFETY INTERLOCKS

AND ACCESSORIES

A. Complete automatic safety control and monitoring sy stem for burner ignition sequencing, operating cycle, and shut-down sequencing. System shall include microprocessor programmer, self-check ing ultraviolet (UV) flame scanner and amplifier, burner cycle display, first-out diagnostic annunciation display, burner safety shutdown interl ocks, communication with monitoring systems, and accessories. Mount con trollers, control switches and displays in and on individual boiler c ontrol panels. Refer to paragraph, BOILER/BURNER CONTROL PANELS. All int erlock devices shall be designed to permit periodic operational testing, including set points and trip points, without changing set points or programming, and in accordance with the VHA Boiler Plant Safety Devi ces Testing Manual.

1. Controller shall be manufactured separately from th e Burner Control

System controller.

2. Controller shall be a separate and individual assem bly from any other controller.

3. Controller shall have its own mounting and wiring b ase to permit the controller to be replaced without disturbing any wi ring or other components.

B. Code Compliance: Conform to NFPA 85. All components UL listed, FM approved.

C. Operate on 102 to 132 volts; 60 Hertz ac. Operating ambient temperature range 0 to 52 degrees C (32 to 125 degrees F).

D. Flame Scanners: Provide self-checking ultraviolet ( UV) scanners. Self-checking UV scanners shall have minimum checking fr equency six times per minute. Position scanners so that they do not v iew the ignition spark. Scanner sight tubes must be non-reflective t o avoid the scanner detecting the reflection of the ignition spark. UV non-self-checking scanners are prohibited because they can fail in an unsafe mode on continuously operated burners.

E. Control Features:

1. Automatic recycling on high steam pressure only.

2. Interrupted ignition.

3. Electronically prevent UV scanner sensing ignition spark. Methods include early spark termination or by phasing the f iring of the ignition spark off cycle from the scanner activatio n.

4. Flame failure response time four seconds maximum.

23 09 11 - 21

5. Ten seconds trial for ignition except 15 seconds pe rmitted on heavy oil fuel.

6. Pre-purge timing set for 4 air changes on fire tube boilers and 8 air changes on water tube boilers per NFPA 85. The exact timing must be determined by the boiler manufacturer. For examp le, typical pre-purge timing with wide open forced draft damper and forced draft fan at full speed has been 30 seconds for packaged fire tube boilers and

2 minutes for packaged water tube boilers. Once pur ge time has been determined and set it becomes burnt into the progra m and may not be changed.

F. Provide components that can be easily removed from the panel without disturbing wiring.

G. Memory storage and self-diagnostics of at least six most recent causes of burner shutdown, which can be accessed by operat ing and service personnel. Diagnostics shall include all individual interlocks.

H. Provide Modbus RS232/RS485 and modem interface to a llow remote access to detailed available boiler plant operating data a nd memory. Provide a

BACnet (read only) interface to the central VAMC DD C control system.

Existing plant control system is Johnson Control In c. Metasys interface to existing boiler plant workstation. A new boiler plant control work station is required for this project to interface t o the new and existing boilers.

I. Burner cycle indication on face of panel: Separate display from the touch screen. Show instantaneous status of startup, run and shutdown program. Provide indicator for control power on, ig nition, main fuel valve open, and flame failure.

J. Reset button on face of panel. Separate display fro m the touch screen.

K. Annunciator Display and Alarm:

1. Separate display from the touch screen.

2. Locate display on outside face of panel between 120 0 mm and 1500 mm

(4 feet and 5 feet) above the floor.

3. English language read-out with individual identific ation of specific interlocks. Where two or more interlocks serve the same function, individual display of each interlock is not require d.

4. Indicate burner status in English messages: control on, pre-purge, trial for ignition, igniter flame signal, main flam e signal, post purge, burner off.

5. Continuously indicate flame signal strength.

23 09 11 - 22

6. Provide first-out annunciation, including English l anguage message, and audible alarm (horn) for each of the following interlocks:

a. Flame failure.

b. Purge airflow low.

c. Combustion air low.

d. False combustion air (switch activated with combust ion air flow).

e. High main gas fuel pressure.

f. Low main gas fuel pressure.

g. High oil pressure.

h. Low oil pressure.

i. Low igniter (pilot) gas pressure.

j. Low oil temperature (heated oil systems only).

k. Fuel safety shut-off valves not closed prior to ign ition cycle.

l. Low fire position not attained prior to ignition cy cle.

m. Low atomizing media (steam or air) static pressure at atomizing media service connection to burner piping.

n. Low atomizing steam/oil differential pressure. Wher e burner does not maintain differential pressure provide low atom izing media pressure at burner.

o. High steam pressure.

p. Low water cutoff.

q. Not Used

r. Low flue gas oxygen.

s. High furnace pressure.

t. Building combustion air intake louver closed or mak e-up air ventilation system not operating.

7. Audible alarm (horn): Sounds upon all burner shutdo wns except automatic recycle shutdowns on steam pressure. Prov ide silencing control, which automatically resets when burner con trol is reset.

L. Pre-Purge Timing: Integral with the programmer. Non -adjustable after initially set to suit boiler pre-purge requirements .

M. Auxiliary relays: Industrial type rated for the ser vice, enclosed contacts.

N. Selector switches, push buttons and control switche s: Heavy duty, industrial type.

O. Safety shutdown and manual reset required for, but not limited to:

1. Flame signal detected prior to ignition cycle.

2. Pre-ignition interlock open during pre-purge.

23 09 11 - 23

3. High fire purge interlock fails to close within ten minutes or less after firing rate drive unit is commanded to drive to high fire.

4. Low fire interlock fails to close within ten minute s or less after firing rate drive unit is commanded to drive to low fire.

5. Igniter (pilot) or main burner fails to ignite.

6. Malfunction of flame detector.

7. Malfunction of programmer.

8. Malfunction of flame signal amplifier.

9. Combustion air proving switch actuated prior to sta rt-up of forced draft fan.

10. Lock-out interlock open during pre-purge (after 15 seconds), ignition or run period.

11. Interlock open.

12. Flame failure.

13. Building combustion air intake louvers closed or ma ke up air ventilation system not operating.

P. Burner Safety Shutdown Interlock Devices:

1. Basic Requirements:

a. Adjustable Set Points.

b. Maximum Set Point Deviation: 5 percent of full scal e.

c. Minimum Repeatability: 2 percent of full scale.

d. Minimum Set Point Accuracy: 10 percent of full scal e or 20 percent of set point.

e. Scale range shall allow set points to be within 30 to 70 percent of full scale.

f. Safety interlock devices shall be separate from ope rating control elements, such as feedback devices. This is to avoi d having the failure of an operating control device preventing t he operation of the safety device. All safety devices shall be h ardwired directly to the flame safeguard controller without passing thru any other device or control system.

2. Provisions for Testing of Interlocks:

a. Installation of all interlock devices shall permit…