SOW_O'Hara_Boiler.docx

STATEMENT OF WORK

STATEMENT OF WORK

O’Hara Boiler Replacement and Repair

U.S. MERCHANT MARINE ACADEMY

KINGS POINT, NEW YORK

U.S. DEPARTMENT OF TRANSPORTATION

MARITIME ADMINISTRATION

BACKGROUND

The United States Merchant Martine Academy (USMMA) is an agency of the Maritime Administration (MARAD) managed by the United States Department of Transportation.

The USMMA is listed on the National Register of Historic Places. Therefore, all work shall be consistent with the Secretary of the Interior's Standards for the Treatment of Historic Properties (36 CFR part 68) http://www.nps.gov/tps/standards/four-treatments/treatment-guidelines.pdf.

All work shall meet or exceed the standards provided in the Secretary of the Interior’s Standards for Rehabilitation and guidelines for applying the standards published by the National Park Service, U.S. Department of the Interior 36 CFR 67.7 - Standards for rehabilitation.

OBJECTIVE

The USMMA seeks the replacement of one steam boiler, domestic hot water heater, and repair of one steam boiler located in O’Hara Hall.

SCOPE

The USMMA is looking for a qualified, licensed and insured contractor to provide labor, material, transportation, tools, equipment and supervision to remove and replace the #2 O’Hara steam boiler and domestic hot water heater and repair the #1 O’Hara boiler. The selected contractor will be responsible for the following:

#2 BOILER REPLACEMENT

A. Furnish and install (1) low pressure steam, wet base, cast iron sectional boiler with power burner that pressurize the firebox and operate under forced and balanced draft.

B. Provide boiler knocked down for field assembly and install in compliance with manufacturer’s installation instructions. All work must be done in a neat and workman like manner.

C. The new steam boiler shall be a cast iron sectional wet base design, hydro-wall with water circulating around the combustion area. No refractory of fire chamber base is required. Sections shall be assembled with high temperature port seals and gas tight rope. Each boiler to be provided with a gas / oil burner capable of burning natural gas at 10” W.C. inlet pressure and/or No. 2 fuel oil.

1. Boiler-burner unit field assembled

2. 15 PSI design steam pressure, 5 – 10 PSI operating pressure.

3. Forced or balanced draft.

The boiler shall have I=B=R Hydronics Institute gross output at 100% firing rate 4,940 MBH per boiler when fired at a rate of 6,136 MBH.

E. Boiler shall be manufactured by ISO 9001 registered company to conform to Section IV of the ASME Boiler and Pressure Vessel Code.

1. Individual sections (and section assembly) to be hydrostatically pressure tested at factory in accordance with ASME requirements.

2. Maximum allowable working pressure 15 PSIG steam cast as part of section with ASME symbol

F. Regulatory Requirements

1. Boiler and controls to comply with ASME, UL, FM CSD-1 regulations.

2. Burners UL 795 and 296 labeled gas / oil combination burners.

G. Submittals

1. Submit shop drawings and product data.

2. Submittal packet to include boiler (and burner) manufacturer descriptive literature, installation instructions, operating instructions, and maintenance instructions.

3. All submittals shall be supplied in one three ring binder to the COR upon completion.

H. Acceptable boiler/burner manufacturer(s) include(s):

Weil-McLain 94 series or approved cast iron construction equivalent. Other boiler manufacturer(s) or other Weil-McLain boiler(s), at a minimum, must comply with the following:

a) Full intent of these specifications, and provide complete submittal including literature, wiring diagrams, fuel piping diagrams, and a list of similar installations.

b) Burner(s) and Energy Management Control System(s) must be tested and approved for installation with specified boiler by boiler manufacturer.

I. Boiler construction:

1. Boiler shipped with individual sections for field assembly

2. Assembled with short, individual draw rods.

3. Cast with sealing grooves for high temperature sealing rope to assure permanent gas-tight seal.

4. Sealed water-tight by elastomer sealing rings, not cast iron nipples. Each port opening is machined to completely capture sealing ring between sections.

5. Must be hydro-wall design to provide completely water-cooled combustion chamber.

6. Provided with sufficient tappings to install required controls.

7. Limited 10 year warranty against workmanship and defects to be in writing by manufacturer.

J. Boiler

1. Constructed to provide balanced water circulation around combustion chamber. The contractor must furnish and install a steam external header 24” minimum from the waterline to the bottom of the header.

2. Designed with a low silhouette to provide maximum headroom.

3. Furnished with insulated burner mounting plate having necessary holes and tappings to mount burner. High temperature sealing rope is used to provide permanent gas-tight seal between front section and plate.

4. Furnished with two observation ports (one in front and one in back) to allow visual inspection of the flame.

5. Provided with cast iron flue collar with a built-in adjustable damper capable of being locked into place after adjustment.

6. High temperature sealing rope used to provide permanent gas-tight seal between hood and section assembly.

7. Furnished with cast iron cleanout plates to cover cleanout openings on the front of the boiler(s).

8. Elastomer sealing rings are to be used to provide permanent water-tight seal between sections. Unlike cast iron or steel push nipples, the elasticity of the seals fills any gaps caused by misalignment or expansion or contraction.

9. Shipped with insulated heavy gauge steel jacket(s) with durable powdered paint enamel finish. Jacket designed to be installed after connecting supply and return piping.

K. Boiler foundation(s):

1. All new equipment is to fit in the existing footprint of the current equipment.

L. Boiler trim:

1. All electrical components to be of high quality and bear the UL label.

Steam boiler standard controls furnished:

1) Low pressuretrol (operating) and high, manual reset pressuretrol set at maximum pressure as a safety control. Honeywell model L404F & L4079B or equivalent.

2) 8-1/2” Steam compound gauge with dial clearly marked and easy to read.

3) Gauge cock water set with gauge glass, guards and aluminum water level plate.

4) ASME certified pressure relief valve, set to relieve at 15 PSIG. Side outlet discharge type; contractor to pipe outlet to floor drain or near floor, avoiding any area where freezing could occur.

5) Barometric damper – double swing type with thermal spill switch

2. Low water cut-off for water or steam boiler(s):

1) Boiler to be furnished with UL labeled low water cut-off with ASME working pressure rating equal to the ASME rating of the relief valve.

2) Do not use quick-connect fittings on boiler(s).

3) Install cut-off according to manufacturer’s instructions.

4) Locate so burner shuts down if boiler water level falls below allowable safe waterline (steam boilers, ¼” above bottom of gauge glass).

5) Steam boiler primary low water cut-off shall be a float type – McDonnell & Miller # 193 auto reset or equivalent

6) Steam boiler secondary low water cut-off shall be a float type – McDonnell & Miller # 63M manual reset or equivalent.

M. All boiler discharges shall be piped to existing floor drains. Blowdown valves shall be brass, ball type and shall be full size of tapping. Pipe ends shall be cut at a 45 Degree to prevent a cap or plug from being installed. All such discharge piping shall be supported by hangars or standoffs to prevent the valve body from undue stress or strain. Boiler drain valves shall be connected to the lowest water space available.

N. Stop valves shall be provided in the supply and return pipe connections to the boiler. Provisions shall be made for the expansion and contraction of the heating mains connected to the boiler by providing substantial anchorage at suitable points and assisted by the use of swing joints to allow the piping to expand and contract without imposing excessive forces on the boiler piping.

O. Boiler shall be furnished as a knocked down unit for field assembly, erection and connection on site and it shall be furnished with all castings, fittings and appurtenances necessary for the assembly, connection and operation of the boiler as specified. Boiler installation shall be accomplished within acceptable A.S.M.E. piping practices and requirements and in strict accordance with the boiler manufacturer’s recommendations and instructions.

Gas\Oil Burner Unit:

3. Automatically operated main motorized gas valve with proof of closure interlock switch.

4. Automatically operated auxiliary motorized gas valve with proof of closure interlock switch.

5. Manual reset Low and High Gas Pressure switches

6. Manual leak test cock.

7. Burner manifold gas pressure gauge.

8. Gas metering valve

Burner Control Panel:

The Burner Graphic Management System shall be the "Director" as manufactured by Power Flame, Inc. or equivalent.

E. The burner control panel shall include the following interfaces:

Boiler Feed System:

A. Furnish and install one (1) Fabtek packaged Type HFM tri-plex boiler feed system as manufactured by Fabtek or equivalent. The system shall be designed to collect condensate returns, blend with required make-up and supply boiler feed water to boiler(s) operating at 8 PSIG. Furnish a stainless steel rectangular, floor mounted style, non code receiver constructed of not less than 1/4” thick 304L stainless steel plate steel and necessary pipe connections (including two vents - one internally un-restrictable). The receiver capacity shall be no less than the capacity of the existing equipment. System shall include pumps, control panel and accessories as described below.

NOTE: Receiver width must not exceed 32” Receiver height must not exceed 48”. Pumps and control panels may be removed in order to gain access to the boiler room through a standard 36” wide doorway.

B. The entire assembly shall be factory pre-assembled and shall consist of the following components:

e. One (1) low water cut off switch

f. Pump discharge solenoid valves

Boiler Master Control Panel:

3. Power Flame Sync-matic two boiler PLC based lead/lag system w/steam transmitter capable of interfacing with the building management system using BacNet protocol. The controller shall be of the fully programmable microprocessor type and shall provide both boiler sequencing and firing rate control. Firing rate output signal shall be 4-20MA for interface with burner air/fuel ratio controls. The controller shall be complete with an auto / off / manual switch for each boiler to provide backup control function, digital display with programming keypad, boiler indicating lamps and control circuit protection.

4. Automatic fuel changeover, Power Flame AC2-TI-PLC or equivalent, microprocessor based, Utility approved.

5. Color-coded and numbered wiring with ladder type wiring diagram.

Boiler Burner Commissioning:

Overview of the burner operation Detailed instructions regarding the applicable combustion control Detailed instructions regarding the modulating motor applied to the burner, including linkage.

Detailed gas & oil fuel flow diagrams.

These items are in addition to the standard service manual provided with the equipment.

Field Training:

A. Field training course shall be provided for Academy staff personnel. Training shall be provided for a total period of 8 hours of normal working time and shall be scheduled after system is functionally complete. Field training shall cover items contained in approved safety, operation and maintenance instructions as well as demonstrations of routine maintenance operations. Mechanical contractor should notify manufacturer in writing at least 10 days prior to training.

DOMESTIC HOT WATER HEATER REPLACEMENT:

A. Complete removal of existing 225 gallon steam fired indirect domestic hot water heater and associated equipment.

B. Furnish and install new steam fired indirect domestic hot water heater with a capacity and rating no less than existing equipment.

C. Furnish and install all necessary controls, motors, fittings and hardware to maintain an output temperature of 125 degrees F.

#1 BOILER REPAIR

The contractor shall provide a turnkey waterside repair of the existing #1, Weil McLain boiler. The boiler currently leaks down in the lower port seal area requiring diagnosis and replacement of defective component (port seals and or boiler sections). The repair shall include, but not be limited to the following work.

A. Remove the boiler jacket to expose the cast iron sections. Isolate the steam supply and condensate return lines. Disconnect the boiler relief valve(s) and plug the tapping. Remove the pressure controls and sensors and plug the taps. Fill the boiler with water to 40 PSI and perform a hydro test to determine the location of the leaks. Mark sections as needed.

B. Drain the water from the boiler, working from the closest boiler end to the sections that need replacement, carefully disconnect either the burner unit, fuel trains and electrical wiring and remove from the boiler front, or the boiler flue piping from the rear as needed. Isolate and disconnect the steam header piping, boiler sub header piping and condensate return piping as needed to be able to separate the boiler sections.

C. Working from one or both boiler ends as needed, loosen the boiler draw rods and prepare to separate the sections. Remove the corresponding draw rods and carefully separate the sections with light tools as needed. Carefully move the sections to gain access to the leaking area. Examine the port seals and perform a dye penetrant test on the cast iron section(s) to determine possible cracks. Replace section with new if cracked. Provide new port seals for all disassembled sections.

D. Prepare the boiler and replacement sections for re-assembly, cleaning all the port seal areas and fireside seal areas. All sections that have been separated must receive new waterside and fireside gaskets. All sections that have been separated must receive new boiler draw rods and hardware.

E. Using the new sections, gaskets and parts, reassemble the boiler following the directions as noted in the boiler manufacturers installation manual for Weil McLain 94 series boilers. Torque all draw rods per instructions. After the boiler block is re-assembled, isolate the supply, return, relief valve and control connections and perform a hydro test per ASME section IV. Upon successful completion of hydro test, re-assemble the steam header piping, boiler sub header, condensate piping, breeching and or burner and associated controls. Fill boiler with water, perform start up and boiler cleaning per the boiler installation manual instructions. The boiler must be made ready for operation with complete test and check.

The contractor shall be aware of the potential presence of hazardous materials, specifically lead-based paint and asbestos, in any buildings located at the USMMA. It is the responsibility of the contractor to take appropriate measures in accordance with all local, state, and federal environmental and occupational safety and health laws and regulations.

DELIVERY

1. The contractor shall furnish all labor and material, transportation and supervision in the performance of all tasks detailed in this statement of work.

2. The contractor will be responsible for the removal of all existing equipment from Academy Grounds.

3. The Contractor will ensure all materials and parts are compatible with the specific unit specified in this statement of work.

4. Contractor shall ensure that all systems will be checked, tested and started.

5. All work is to conform to federal, state and local building regulations and codes.

6. Maintain a work area compliant with safety standards.

7. Area worked on shall be cleaned and secured on a daily basis.

8. Any damage to existing facilities or appurtenances shall be repaired or replaced in kind, by the contractor at no additional cost to the Government.

9. Examine existing conditions prior to any repair activities, a site visit will be scheduled to inspect the site where services are to be performed.

10. Excess material and debris shall be disposed of in accordance with local and state ordinances.

11. No vehicles shall be driven on the sidewalks or grass. Unless granted specific exception due to site access limitations. Repair of landscape, if any, will be the sole responsibility of the contractor.

12. Make every effort to minimize the impact to the daily routine of the Academy.

13. Contractors shall be licensed, bonded and insured as mandated by federal, state and local municipal regulations.

CLOSE OUT:

The contractor shall provide a signed warranty of any damage, defective material and improper workmanship on any material provided in this contract.

Materials and labor to be warranted for a minimum of one year after completion of installation, and equipment to be warranted per manufacturer.

EVALUATION CRITERIA

The quote that is determined to be the lowest price, technically acceptable will be awarded this procurement. The following criteria will be evaluated in determining best value;

1. Technical Approach (40%) The Contractor will demonstrate through documentation submitted, technical expertise in performing the tasks detailed in this statement of work.

2. Past Performance (25%) The Contractor must have worked satisfactorily for a minimum of three (3) years on projects of this type and size.

3. Price (35%)

GOVERNMENT FURNISHED PROPERTY, MATERIAL, EQUIPMENT OR INFORMATION.

N/A

CONSIDERATIONS

• Submit schedule seven (7) days in advance of work to be accomplished for approval.

• Submit schedule showing area to be worked on, dates of work, and estimated timeline for completion of the task(s).

• Maintain communication with the COR (and immediately inform the COR of any unforeseen issues or problems that arise).

• Inform COR of any anticipated disruption in services for construction at least three (3) days in advance

PLACE OF PERFORMANCE

Contractor will perform the task at O’Hara Hall, USMMA, 300 Steamboat Road, Kings Point, N.Y. 11024

PERIOD OF PERFORMANCE

Work is to be completed within 45 calendar days after NTP is approved. Work is to be performed during normal business hours 0700 to 1630, Monday through Friday unless approval is granted by the Contracting Officer.

ACCRONYMS

ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers CFR Code of Federal Regulations

NEC National Electrical Code ANSI/NFPA 70 NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association

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