235216-BIOMASS_BOILER_A02.pdf

Sitka Ranger District Office Renovation Sitka, Alaska 100% Construction Documents May 23, 2014

SECTION 235216 - BIOMASS BOILER

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes packaged, factory-fabricated and -assembled, wood-pellet boilers, day hoppers, trim, and accessories for generating hot water.

1.2 ACTION 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. Mounting Details. Detail fabrication including anchorages and attachments to structure and to supported equipment.

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

3. Piping schematic from boiler to thermal storage tank, include controls, pump location, connection types, M&V monitoring, backup hot water generation tie into thermal storage tank.

4. Fuel feeder vacuum hoses connection from bulk storage to day hopper. Include grounding for feeder hoses.

1.3 INFORMATIONAL SUBMITTALS

A. 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."

B. EN-303-5 Boiler Certification

C. UL 391 Boiler Certification

D. CSA B366.1 Boiler Certification

E. Warranty: Special warranty specified in this Section.

1.4 CLOSEOUT SUBMITTALS

A. Operation and maintenance data.

B. Commissioning Report performed by a factory trained and authorized equipment rep.

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AG-0116-S-14-0021

Amendment 002

1.5 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. EN 303-5 Class 5 European Boiler Standard for solid fuel pressure vessels

C. CSA/UL Compliance: Test boilers for compliance with CSA B366.1, "Solid Fuel Fired Central Heating Appliances." and UL 391, Solid Fuel and Combination-Fuel Central and Supplementary Furnaces”. Boilers shall be listed and labeled by a testing agency acceptable to authorities having jurisdiction.

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 Water-Jacketed Condensing Boilers:

a. Boiler Vessel Leakage and Materials: 20 years from date of Substantial Completion.

b. Parts - 3 years from date of Substantial Completion.

c. Electrical Components – 1 year from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Basis-of-Design Product: Subject to compliance with requirements, provide Froling P4, 32 (Output 9-32 kW (30-109 Btu/hr)) or a comparable product meeting all of the requirements of this specification and by one of the following:

1. Windhager

2. Maine Energy Systems

2.2 WATER-JACKETED SOLID FUEL PELLET BOILER

A. Description: Factory-fabricated, -assembled, and -tested, water-jacketed non-condensing boiler with carbon steel heat exchanger sealed pressure tight, built on a steel base; including insulated jacket; flue-gas vent; water supply, return,; and controls. Water heating service only.

B. Heat Exchanger: Carbon Steel primary combustion chamber, 3 pass heat exchanger with 2 ash collection chambers

C. Pressure Vessel: Carbon steel with welded heads and tube connections where not in contact with combustion or flue gases.

D. Burner: Hot air forced draft; swing-open front and burner observation port.

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E. Blower: Variable Speed Centrifugal fan, forced draft. Include prepurge and postpurge of the combustion chamber.

1. Motors: Comply with requirements specified in Division 23 Section "Common Motor Requirements for HVAC Equipment."

a. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0.

F. Ignition: Electric-hot air combustion (1200W) burner

G. Pellet Pickup: Pellet Pickup via pneumatic suction shall have no moving parts and not require any power connection. Pickup shall be completely passive.

H. Fuel Delivery: Pellets shall be gravity dropped into burner from above and not delivered horizontally.

I. Ash Discharge: Ash collection shall consist of 2 drop collection bins within the boiler. Boiler shall include a self-cleaning motorized ash grate.

J. Casing:

1. Jacket: Sheet metal, with snap-in or interlocking closures.

2. Control Compartment Enclosures: NEMA 250, Type 1A.

3. Finish: Powder-coated protective finish.

4. Insulation: Minimum 2-inch- thick, mineral-fiber insulation surrounding the heat exchanger.

5. Combustion-Air Connections: Inlet and vent duct collars with flue collar adaptors for conversion from metric to English nominal vent sizes.

6. Mounting base to secure boiler.

a. Seismic Fabrication Requirements: Fabricate mounting base and attachment to boiler pressure vessel, accessories, and components with reinforcement strong enough to withstand seismic forces defined in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment" when mounting base is anchored to building structural slab.

K. Characteristics and Capacities:

1. Solid Fuel Permitted: Wood Pellets Diameter (1/4”-5/16”) 6mm. Must have a PFI rating of Premium or Super Premium. Pellets must be made from natural wood.

2. Heating Medium: Hot Water with 35% Propylene Glycol, PH of solution should be 8-8.6

3. Design Water Pressure Rating: 60 psig

4. Safety Relief Valve Setting: 120 psig/180 deg F

5. Maximum Design Temperature: 175 deg F

6. Entering-Water Temperature: 115 deg F

7. Leaving-Water Temperature: 170 deg F

8. Design Water Flow Rate: Variable Voltage Control ~ 4-22 GPM

9. Minimum Thermal Efficiency: 85 percent

10. Blower:

a. Motor Horsepower: <1 HP

b. RPM: Variable Speed- 1750

11. Electrical Characteristics:

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a. Volts: 240 V.

b. Phase: Single

c. Hertz: 60.

d. Full-Load Amperes: 15 Amp Circuit (110 Watts)

2.3 TRIM

A. Thermal Buffer Aquastat Controls: Include thermal buffer tank sensor management pack with upper and lower sensors in thermal buffer tank used to control pellet boiler fire rate and pump and blower speed.

B. Safety Relief Valve: ASME rated.

C. Pressure and Temperature Gage: Include temperature gauge on return water and supply water temperature. 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.

D. Boiler Air Vent: Include automatic air vent on top of thermal storage tank.

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

F. Circulation Pump Wiring Control: Contractor to purchase single phase fractional circulator separately (PMP-1), pellet boiler to control operation and speed (via variable voltage) of pump to maintain thermal buffer tank.

G. Fuel feeder hoses. Nominal 2” fuel feeder hoses with grounding ring.

H. Pellet Deduster.

I. Adaptor Rings: Combustion Air intake and flue gas discharge adaptor rings (metric to 6” venting)

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.

3. Sequence of Operation: Electric, factory-fabricated and field-installed panel to control burner firing rate to maintain tank temperature as specified in sequence of operations

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.

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

Cutoff switch shall be automatic reset type.

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

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

Froling Visualization Software

1. Hardwired Points:

a. Monitoring: On/off status, ash collection service, hot water supply and return water temperature, buffer tank temperatures (upper and lower)

b. Control: On/off operation, hot water supply temperature, set-point adjustment.

2. A communication interface with building automation system shall enable building automation system operator to remotely control and monitor the boiler from an operator workstation. Controls shall include password protection for remote changes.

2.5 ELECTRICAL POWER

A. Controllers, Electrical Devices, and Wiring: Electrical devices and connections are specified in Division 26 Sections.

B. 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. Field power interface shall be to fused disconnect switch

2.6 VENTING KITS

A. Kit: Include flue collar adaptor rings to change from metric to English (6” nominal venting)

B. Combustion-Air Intake: Complete system, stainless steel, pipe, vent terminal with screen, inlet air coupling, and sealant. Include adaptor rings for intake air to change from metric to 6”

2.7 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.

PART 3 - EXECUTION

3.1 BOILER INSTALLATION

A. Equipment Mounting: Install boilers onto slab in mechanical room.

1. Coordinate sizes and locations of equipment for rough in layout.

2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete base, and anchor into structural concrete floor.

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3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

4. Install anchor bolts to elevations required for proper attachment to supported equipment.

B. Install wood-fired boilers according to NFPA 54.

C. Assemble and install boiler trim.

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

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

F. Provide 3 tons of bagged pellet fuel on pallets for startup and commissioning. Upon close-out and substantial completion, fill pellet storage bin with pellet fuel.

3.2 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 "Hydronic Piping."

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

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

G. Boiler Venting:

1. Install flue venting and combustion-air intake vent piping collar adaptors.

2. Connect full size to boiler connections. Comply with requirements in Division 23 Section

"Breechings, Chimneys, and Stacks.”

H. Install corrugated fuel feeder tubing into day hopper per manufacturer’s instructions. Ground both ends of tubing. Feed boiler through pellet deduster.

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."

3.3 FIELD QUALITY CONTROL

A. Perform tests and inspections and prepare test reports.

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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.

3.4 COMMISSIONING

A. Include Factory Authorized Commissioning with this boiler installation. Include all expenses for travel, lodging and on-site commissioning of boiler and associated controls in bids.

3.5 DEMONSTRATION

A. Engage a factory-authorized service representative to train owner's maintenance personnel to adjust, operate, and maintain boilers.

END OF SECTION 235216

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2. A communication interface with building automation system shall enable building automation system operator to remotely control and monitor the boiler from an operator workstation. Controls shall include password protection for remote changes.