J-2 MSP Boiler-Pumps - SECTION 235216 CONDENSING BOILERS 042220.pdf

MSP BOILERS HOT WATER PUMPS AND PCS ROOM HVAC REPLACEMENT PROJECT

MINNEAPOLIS ATCT / MINNEAPOLIS, MINNESOTA APRIL 22, 2020

CONDENSING BOILERS 235216-1

SECTION 235216 - CONDENSING BOILERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes packaged, factory-fabricated and -assembled, gas-fired, fire-tube condensing boilers, trim, and accessories for generating hot water.

1.3 SUBMITTALS

A. Product Data: Include performance data, operating characteristics, furnished specialties, and accessories.

B. Shop Drawings: For boilers, boiler trim, and accessories. Include plans, elevations, sections, details, and attachments to other work.

1. Wiring Diagrams: Power, signal, and control wiring.

C. Manufacturer Seismic Qualification Certification: Submit certification that boiler, accessories, and components will withstand seismic forces defined in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment." Include the following:

1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation.

a. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."

2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions.

3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements.

D. Source quality-control test reports.

E. Field quality-control test reports.

F. Operation and Maintenance Data: For boilers to include in emergency, operation, and maintenance manuals.

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G. Warranty: Special warranty specified in this Section.

H. Other Informational Submittals:

1. ASME Stamp Certification and Report: Submit "A," "S," or "PP" stamp certificate of authorization, as required by authorities having jurisdiction, and document hydrostatic testing of piping external to boiler.

1.4 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

B. ASME Compliance: Fabricate and label boilers to comply with ASME Boiler and Pressure Vessel Code.

C. ASHRAE/IESNA 90.1 Compliance: Boilers shall have minimum efficiency according to "Gas and Oil Fired Boilers - Minimum Efficiency Requirements."

D. UL Compliance: Test boilers for compliance with UL 795, "Commercial-Industrial Gas Heating Equipment." Boilers shall be listed and labeled by a testing agency acceptable to authorities having jurisdiction.

1.5 COORDINATION

A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03.

1.6 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of boilers that fail in materials or workmanship within specified warranty period.

1. Warranty Period for Fire-Tube Condensing Boilers:

a. Leakage and Materials: 10 years from date of Substantial Completion.

b. Heat Exchanger Damaged by Thermal Stress and Corrosion: No prorated for five years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements contractors may provide products by one of the manufactures listed below. Products from other manufactures will be considered on case-by-case basis and must be in compliance with the requirements.

Katherine Fogle Highlight

CONDENSING BOILERS 235216-3

1. Cleave Brooks, Inc.

2. Gasmaster Industries Incorporated.

3. Hydrotherm, Inc.; a division of Mestek, Inc.

4. AERCO International.

5. Heat Transfer Products, Inc.

6. Bryan Boiler.

7. Laars Heating Systems; a division of Waterpik Technologies, Inc.

2.2 MANUFACTURED UNITS

A. Boiler shall be a compact Firetube type, single pass, and down-Fired design with ultra-low emission (<20ppm) and high efficiency condensing technology herein listed. The boiler shall be designed for natural gas firing. Gas supply pressure to the boiler gas pressure-regulating valve shall be 1.0 to 5.0 psig. The burner will be a forced draft design with gas and combustion air premixed prior to the burner head. The boiler, and burner, will be supplied by the same manufacturer to assure compatibility and single source responsibility for the package performance. The boilers will be constructed in accordance with ASME Section IV Code. Boiler to be manufactured within an ISO9001 certified facility.

B. The boiler will be constructed with a minimum of 10 square-feet of fireside heating surface per boiler horsepower.

C. The pressure vessel will be constructed with stainless steel boiler tubes with titanium stabilized aluminum extended internal heating surface (AluFer). Firetube internal surface shall be a minimum of 4 times the external waterside surface area. The pressure vessel shall be of a counter flow design with separated return flow connections and no minimum system flow requirements

D. The condensing capability shall allow the boiler to be operated without the use of a 3-way valve for the boiler supply water temperature reset.

E. No minimum boiler return water temperature or secondary pump or minimum flow rate shall be required. Secondary pump to maintain flowrate through the boiler will not be accepted.

F. The top tube sheet shall be fully accessible by lifting the burner assembly which shall come complete with lifting hinges and pneumatic lifters. The boiler shall have a built in hinged plat-form allowing the operator to access the tube sheet, burner, ignition assembly and flame rod without the use of a ladder.

G. Boiler shall be built to seismic zone IV requirements and manufacturer shall provide seismic calculations showing tie-down requirements for bolt diameters. Bolts and tie-down shall be by contractor.

H. Boiler shall have:

1. 2" fiberglass blanket insulation and easily removable casing.

2. Burner observation port.

3. Factory paint with durable powder coat paint finish for corrosion protection.

4. ASME Code relief valves with side outlet set for 125 psig.

CONDENSING BOILERS 235216-4

I. Computerized Burner Control

The boiler shall have an integrated burner management and modulation control with a touch-screen display/operator interface. Its functions include the following.

1. Burner sequencing with safe start check, pre-purge, direct spark ignition and post purge.

2. Electronic ignition.

3. Flame supervision.

4. Safety shutdown with display of error.

5. Modulating combustion fan.

6. Low gas pressure, air proving, high limit, and frost protection.

7. Controller shall have an option for outside air reset of boiler operating temperature. Out-side air temperature sensor to be furnished loose for field installation by others.

J. Burner Design

1. Forced draft natural gas fired burner mounted in and integral with the boiler hinged top door so when the door is opened the burner head, furnace, tube sheet, and tubes are ex-posed. The burner door shall utilize easy removable threaded handles, and the burner shall swing upward on hydraulic piston arms, one on each side to provide open support of the burner assembly.

2. The burner shall be of the Unitized Venturi, Gas Valve, Blower, and burner head design.

This pre-mix design shall utilize a variable speed fan connected to a Venturi to Simultaneously modulate fuel and air for a minimum a 5:1 turndown ratio. The Venturi design shall also act as a method for compensating for changes in pressure, temperature and humidity so the excess air levels are not adversely affected by changes in atmospheric conditions. External linkages, damper motor drives and single speed fans shall not be acceptable.

3. Burner head shall be constructed of a Fecralloy-metal fiber for solid body radiation of the burner flame. Combustion shall take place on the surface of the burner mantle, which shall be constructed of a woven Fecralloy material creating a 360 degree low temperature radiant flame.

4. Emissions: The boiler(s) burner shall be guaranteed to limit NOx emissions to 20 PPM or less, as certified by an independent testing lab. NOx emissions shall be at full operating conditions. Proof of such certification shall be made available to the engineer and pur-chaser. External flue gas recirculation shall not be accepted for emission control.

K. Gas Train

The gas train shall meet the requirements of CSA and ASME CSD-1 and shall include:

1. Low Gas Pressure Interlock, manual reset.

2. High Gas Pressure Interlock, manual reset.

3. Upstream and downstream manual test cocks.

4. Ball Type manual shutoff valve upstream of the main gas valve.

5. Unibody double safety gas valve assembly.

6. Gas Pressure Regulator

7. Union connection to permit burner servicing.

L. Combustion Air Proving Switch shall be furnished to ensure sufficient combustion airflow is present for burner firing.

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M. To ensure that proper draft is not blocked in the stack, the burner shall include a High Air Pres-sure Switch sensing the outlet pressure connection relative to stack back draft.

2.3 TRIM

A. Include devices sized to comply with ANSI B31.9, "Building Services Piping."

B. Aqua stat Controllers: Operating, firing rate, and high limit.

C. Safety Relief Valve: ASME rated.

D. Pressure and Temperature Gage: Minimum 3-1/2-inch- diameter, combination water-pressure and -temperature gage. Gages shall have operating-pressure and -temperature ranges so normal operating range is about 50 percent of full range.

E. Boiler Air Vent: Automatic and Manual.

F. Drain Valve: Minimum NPS 3/4 hose-end gate valve.

G. Air Inlet Filter

H. Acid neutralizing pan with anchoring lugs.

2.4 CONTROLS

A. Refer to Division 23 Section "Instrumentation and Control for HVAC."

B. Boiler operating controls shall include the following devices and features:

1. Control transformer.

2. Set-Point Adjust: Set points shall be adjustable.

C. Burner Operating Controls: To maintain safe operating conditions, burner safety controls limit burner operation.

1. High Cutoff: Automatic reset stops burner if operating conditions rise above maximum boiler design temperature pressure.

2. Low-Water Cutoff Switch: Electronic probe shall prevent burner operation on low water.

Cutoff switch shall be manual-reset type.

3. Audible Alarm: Factory mounted on control panel with silence switch; shall sound alarm for above conditions.

4. Fully modulating burner.

D. Building Automation System Interface: Factory install hardware and software to enable building automation system to monitor, control, and display boiler status and alarms.

1. A communication interface with building automation system shall enable building automation system operator to remotely control and monitor the boiler from an operator workstation. Control features available, and monitoring points displayed, locally at boiler control panel shall be available through building automation system.

2. Multi boiler sequence modulator, Modsync or equal.

CONDENSING BOILERS 235216-6

2.5 ELECTRICAL POWER

A. Single-Point Field Power Connection: Factory-installed and -wired switches, motor controllers, transformers, and other electrical devices necessary shall provide a single-point field power connection to boiler.

1. House in NEMA 250, Type 1 enclosure.

2. Wiring shall be numbered and color-coded to match wiring diagram.

3. Install factory wiring outside of an enclosure in a metal raceway.

4. Field power interface shall be to circuit breaker.

5. Provide branch power circuit to each motor and to controls with a disconnect switch or circuit breaker.

6. Provide each motor with overcurrent protection.

2.6 SOURCE QUALITY CONTROL

A. Burner and Hydrostatic Test: Factory adjust burner to eliminate excess oxygen, carbon dioxide, oxides of nitrogen emissions, and carbon monoxide in flue gas and to achieve combustion efficiency; perform hydrostatic test.

B. Test and inspect factory-assembled boilers, before shipping, according to ASME Boiler and Pressure Vessel Code.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Before boiler installation, examine roughing-in for concrete equipment bases, anchor-bolt sizes and locations, and piping and electrical connections to verify actual locations, sizes, and other conditions affecting boiler performance, maintenance, and operations.

1. Final boiler locations indicated on Drawings are approximate. Determine exact locations before roughing-in for piping and electrical connections.

B. Examine mechanical spaces for suitable conditions where boilers will be installed.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 BOILER INSTALLATION

A. Install boilers level on concrete base. Concrete base is specified in Division 23 Section "Common Work Results for HVAC," and concrete materials and installation requirements are specified in Division 03.

B. Vibration Isolation: Elastomeric isolation pads with a minimum static deflection of 0.25 inch.

Vibration isolation devices and installation requirements are specified in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment."

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C. Install gas-fired boilers according to NFPA 54.

D. Assemble and install boiler trim.

E. Install electrical devices furnished with boiler but not specified to be factory mounted.

F. Install control wiring to field-mounted electrical devices.

3.3 CONNECTIONS

A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties.

B. Install piping adjacent to boiler to allow service and maintenance.

C. Install piping from equipment drain connection to nearest floor drain. Piping shall be at least full size of connection. Provide an isolation valve if required.

D. Connect piping to boilers, except safety relief valve connections, with flexible connectors of materials suitable for service. Flexible connectors and their installation are specified in Division 23 Section "Common Work Results for HVAC,"

E. Connect gas piping to boiler gas-train inlet with union. Piping shall be at least full size of gas train connection. Provide a reducer if required.

F. Connect hot-water piping to supply- and return-boiler tappings with shutoff valve and union or flange at each connection.

G. Install piping from safety relief valves to nearest floor drain.

H. Boiler Venting:

1. Connect full size to boiler connections. Comply with requirements in Division 23 Section "Breechings, Chimneys, and Stacks."

I. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."

J. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power Conductors and Cables."

3.4 FIELD QUALITY CONTROL

A. Perform tests and inspections and prepare test reports.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

B. Tests and Inspections:

1. Perform installation and startup checks according to manufacturer's written instructions.

2. Leak Test: Hydrostatic test. Repair leaks and retest until no leaks exist.

3. Operational Test: Start units to confirm proper motor rotation and unit operation.

Adjust air-fuel ratio and combustion.

4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

a. Check and adjust initial operating set points and high- and low-limit safety set points of fuel supply, water level and water temperature.

b. Set field-adjustable switches and circuit-breaker trip ranges as indicated.

C. Remove and replace malfunctioning units and retest as specified above.

D. Occupancy Adjustments: When requested within 12 months of date of Substantial Completion, provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to two visits to Project during other than normal occupancy hours for this purpose.

3.5 DEMONSTRATION

A. Engage a factory-authorized service representative to train FAA's maintenance personnel to adjust, operate, and maintain boilers. Refer to Division 01 Section "Demonstration and Training."

END OF SECTION 235216

MSP BOILERS HOT WATER PUMPS AND PCS ROOM HVAC REPLACEMENT PROJECT MINNEAPOLIS

ATCT / MINNEAPOLIS, MINNESOTA APRIL 22, 2020