Stimulus Project Combined without3A 12-15-09.pdf

SPECIAL REQUIREMENTS FOR CONTRACTOR PERFORMANCE:

USMARC MECHANICAL ’09

SEGMENT 2, Replace Boilers, Deaerator, Bldg. #17

SEGMENT 3, Freezer System Replacement, Refrigerated Rm.

Product Cooling Unit Replacement, Bldg. #17:

- Due to scheduled use of the facility and ongoing research, work for segments #2 and #3 (including add items #2 and #3) consisting of boiler, deaerator, and product cooling unit (refrigerated rooms) replacements, shall be done in May 2010.

- Boiler, deaerator, and product cooling unit replacements shall be accomplished within 30 calendar days.

SEGMENT 4, Replace Chiller, Install Well Water Pipe, Bldg. #19:

- On-site work shall be 45 days.

- Chiller shall be “down” for no more than 3 weeks.

- It is anticipated that this work shall be done in the non-cooling season.

Note: Segments #2 and #3 shall be started after completing Segment #4.

SEGMENT 5, Replace Heating System, Feedmill, Bldg. #3:

- On-site work shall be 3 weeks.

- Rotating schedule of 8 days of no feedmill operations followed by 4 days of operations shall apply. Work days shall be Monday through Friday, 7:00 am to 5:00 pm.

- Contractor may work during feedmill operations as long as it doesn’t affect the heating system work adversely.

- No weekend work shall be permitted.

- This schedule may be affected by unexpected requests for feed.

CONSTRUCTION PERIOD SHALL BE 270 CALENDAR DAYS.

TABLE OF CONTENTS USMARC MECHANICAL ‘10

SEGMENT 2 - Replace Boilers, Bldg. #17

SEGMENT 2 TABLE OF CONTENTS………………………………………..4

DIVISION 1- GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK………………………………………5

0130 - SHOP DRAWINGS……………………………………………6

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)…7

0180 – CLEANUP……………………………………………………..8

DIVISION 2-DEMOLITION

0211 – DEMOLITION AND REMOVAL…………………………..9-10

DIVISION 15-MECHANICAL

1515 – GAS PIPING………………………………………………..11-13

1525 – INSULATION……………………………………………....14-18

1530 – BOILERS……………………………………………………19-29

1551 – STEAM, HOT WATER, CONDENSATE PIPING………...30-34

DIVISION 16 – ELECTRICAL

1605 – ELECTRICAL SYSTEMS………………………………….35-38

SEGMENT 3 - Freezer System Replacement, Refrigerated Rm. Product Cooling Unit Replacement, Bldg. #17

SEGMENT 3 TABLE OF CONTENTS………………………………………..39

DIVISION 1- GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK……………………………………….40

0130 - SHOP DRAWINGS………………………………………...….41

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)…42

0180 – CLEANUP……………………………………………………..43

DIVISION 2 - DEMOLITION

0211 – DEMOLITION AND REMOVAL………………………….44-45

DIVISION 15 - MECHANICAL

1505 – WATER AND REFRIGERANT PIPING…………………...46-53

1510 – CHILLED BRINE PIPING…………………………………..54-59

1525 – INSULATION……………………………………………….60-64

1565 – FREEZER EQUIPMENT……………………………………65-78

1591 – PRODUCT COOLING UNIT……………………………….79-83

1605 – ELECTRICAL SYSTEMS…………………………….…….84-87

SEGMENT 4 - Replace Chiller, Install Well Water Pipe, Bldg. #19

SEGMENT 4 TABLE OF CONTENTS………………………………………..88

DIVISION 1- GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK……………………………………….89

0130 - SHOP DRAWINGS…………………………………………….90

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)….91

0180 – CLEANUP………………………………………………………92

DIVISION 2-DEMOLITION & SITE WORK

0211 – DEMOLITION AND REMOVAL……………………………93-94

0220 – EXCAVATION, BACKFILL, AND GRADING……………..95-97

DIVISION 15-MECHANICAL

1505 – WELL WATER PIPE…………………………………………….98-101

1510 – CHILLED AND WELL WATER PIPE (MECHANICAL RM)...102-

1565 – REFRIGERATION EQUIPMENT………………………………107-

1605 – ELECTRICAL SYSTEMS……………………………………....117-120

SEGMENT 5 - Replace Heating System, Feedmill, Bldg. #3-25

SEGMENT 5 TABLE OF CONTENTS…………………………………………121

DIVISION 1- GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK………………………………………….122

0130 - SHOP DRAWINGS………………………………………………123

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)……124

0180 – CLEANUP……………………………………………………

DIVISION 2 - DEMOLITION

0211 – DEMOLITION AND REMOVAL…………………………….126-127

DIVISION 8 – DOORS & WINDOWS

0810 – HOLLOW METAL DOORS…………………………………..128

DIVISION 15 - MECHANICAL

1515 – GAS PIPING…………………………………………………..129-131

1530 – HEATING EQUIPMENT……………………………………..132-139

1551 – HOT WATER, CONDENSATE PIPING……………………..140-144

1605 – ELECTRICAL SYSTEMS……………………………………145-148

SEGMENT 2 TABLE OF CONTENTS

0101 - SUMMARY OF WORK

0130 - SHOP DRAWINGS

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

0180 - CLEANUP

DIVISION 2-DEMOLITION

0211 – DEMOLITION AND REMOVAL

DIVISION 15-MECHANICAL

1515 – GAS PIPING

1525 – INSULATION

1530 - BOILERS

1551 – STEAM, HOT WATER, CONDENSATE PIPING

1605 – ELECTRICAL SYSTEMS

SEGMENT 2

DIVISION I

SECTION 0101

SUMMARY OF WORK

The work consists of providing all labor, material, and equipment and performing all work to replace natural gas fired steam boilers in Buildings #17-24 for complete and fully functioning boilers incorporated into the existing building heating systems.

All plumbing, mechanical, and electrical work and related materials shall be provided and installed to meet the requirements of national, state, and local codes, and this specification.

Work in Bldg. #17-24 shall include but shall not necessarily be limited to the following (Basic Bid item #1):

1. Removal of two (2) 400 bhp fire tube, natural gas/oil fired, packaged, steam boilers including piping, fittings, insulation, boiler controls, conduit, wires, starter, etc. to the extent shown on the drawings.

2. Removal of existing inside and outside boiler stacks and breeching.

3. Installation of new boiler exhaust stacks extending out roof directly above each boiler.

4. Removal of existing gas meter as shown on drawings.

5. Installation of new boiler motor starters and associated electrical conduit, wire, boxes, etc.

6. Installation of two (2) packaged 150 bhp , 150 psi, natural gas fired, fire tube, wet back, three (3) pass, steam boilers complete with all piping, insulation, stacks, starters, safeguards, controls, gauges, valves, operating lights, etc. required for complete and fully functional boilers.

7. Installation of a gas meter to each new boiler.

8. Controls for emergency shutdown of new boilers at each entrance to mechanical room.

9. Replacement of spray type deaerator feed system in Bldg. #17.

SEGMENT 2, 0101-1

* End of Section

SECTION 0130

SHOP DRAWINGS

1. Submit shop drawings to the Contracting Officer’s Representative (COR) for approval prior to installation. Information in the form of drawings, product literature, manufacturer’s specification, equipment lists, etc. shall be submitted on the following:

Specification Description Drawings Literature Schedule

a. Packaged Boiler x x

b. Valves x x

c. Regulating Valves & Controls x x

d. Insulation x

e. Piping x

f. Electrical Items including x Starter, Panels, Conduit, Conductors, etc.

g. Deaerator System x x

h. Flow Meters x x

The Contracting Officer may request submittals in addition to those listed when deemed necessary to adequately describe the work covered in the respective sections.

2. Each submittal shall be complete and in sufficient detail for ready determination of compliance with the contract requirements.

3. Submittal shall be submitted in four (4) copies to the COR using the transmittal form.

The form shall be properly completed by filling out all the heading block spaces and identifying each item submitted. Special care should be exercised to insure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the data submitted for each item. A separate transmittal form shall be attached to each copy of the data being submitted.

4. Brand Name: Identification of items in the contract documents is intended to be descriptive, not restrictive, and is to indicate the quality and characteristics of products that will be satisfactory.

SEGMENT 2, 0130-1

SECTION 0160

USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

1. Water, Gas, Electricity:

a. As mutually agreed upon between the Contractor and the COR, the Contractor may use nearby utilities required for his performance under this contract.

b. Contractor shall bear the cost of temporary connections (if necessary) and restoration upon conclusion of use.

c. The Government shall bear the cost of reasonable utility consumption.

Government will not pay the cost of utilities if usage is abused.

d. The Contractor shall submit for approval written notification not less than 4 working days in advance of requirement to shut down any utilities or other services to or within existing building or facilities used by others.

2. Telephone:

a. Contractor shall arrange and pay for any telephone service they choose to provide for themselves.

3. Toilet:

a. Contractor may use building bathroom facilities as approved by owner.

4. Access to Buildings:

a. Contractor’s access to buildings shall be limited to those areas where work is being performed. This includes being restricted from the lunch room in Building #1.

5. Material Receiving:

a. Contractor shall be on-site to receive materials. Contractor shall arrange for own storage of materials unless other arrangements have been agreed to by owner.

SEGMENT 2, 0160-1

SECTION 0180

CLEANUP

1. Cleanup:

a. The Contractor shall keep the premises clean during construction and shall remove all rejected material, rubbish, etc., after completion of work and prior to final inspection.

b. Materials removed by the Contractor shall become the property of the contractor and shall be removed from the site unless otherwise agreed to by the owner.

c. Government dumpsters shall not be used by the contractor.

SEGMENT 2, 0180-1

DIVISION 2

SECTION 0211

DEMOLITION AND REMOVAL

1. General:

a. This section includes the removal of:

1. Two (2) packaged steam boilers in Building #17-24

2. Exterior boiler stack and all breeching for boilers in Building #17-24

This shall include the packaged steam boilers, boiler stack and stack pad, all breeching, piping, valves, fittings, insulation, control panel, starter, all conductors and conduit from the existing starter to the existing boilers, and any other materials, as noted on the drawings, or as obviously required to complete the project.

b. Contractor shall be responsible for temporarily securing pipe, conduit, electrical conductors, etc. during removal operations and prior to installation of the new chiller packages.

c. It is believed that there is a ¼” thick coating of asbestos containing material on the inside of the insulation breeching. This is to be removed and disposed of by owner prior to the construction for this project.

d. Do not begin demolition until authorization is received from owner. Remove rubbish and debris from the work area daily. Do not allow accumulations inside or outside the building.

2. Regulatory and Safety Requirements:

a. Comply with federal, state, and local hauling and disposal regulations. In addition to the requirements of the “Contract Clauses,” Safety Requirements.”

3. Protection of Existing Facility:

a. Protect existing work which is to remain in place, be reused, or remain the property of the government. Any damage shall be repaired/replaced at the Contractor’s expense.

4. Schedule:

SEGMENT 2, 0211-1

a. A written schedule of equipment removal and shutdowns shall be submitted to the

Owner, for approval, 10 days, prior to the start of work.

5. Title to Materials:

a. All materials and equipment removed, and not reused, shall become the property of the contractor and shall be removed from the property. Not withstanding the above, the Governments retains first right of refusal on all equipment and material to be demolished or removed.

SEGMENT 2, 0211-2

SECTION 1515

GAS PIPING

a. Furnish and install a complete system if gas piping as described herein and as indicated on the drawings.

b. The Contractor shall assume full responsibility for the installation of the gas piping system.

2. Materials:

a. Gas pipe shall be black steel, schedule 40, seamless pipe. All gas piping shall be run exposed and shall be cleaned and painted yellow.

b, Fittings shall be malleable iron Schedule 40.

c. Hangers and supports shall consist of threaded rod and cast or steel saddles installed at a maximum of 10 foot intervals and at each offset and change in direction.

d. Gas Meter shall be a turbine style totalizing meter, model #GTS, as manufactured by Elster American, or equal, capable of measuring cubic feet of natural gas as follows:

1. Building #17, 1000 to 16000 scfh at a pressure of 5”-6” water column. One for each boiler.

e. Gas Valves shall be a lubricated plug or ball valve with resilient seals. Valve shall be of steel or bronze construction for a maximum of 125 psi operating service.

f. Gas line strainer shall be installed on all pilot lines and main burner lines.

Strainers shall be located ahead of each pressure regulator to prevent valve failures due to rust, dust, or other impurities in the gas supply. Strainer shall be provided with connections full size of piping, and shall be easily cleanable.

Strainer screen shall be 40 mesh or finer stainless steel or monel and shall be packed with Everdur wool, or glass wool. Body shall be iron or bronze, and shall be designed for a working pressure of 125 psig.

SEGMENT 2, 1515-1

g. Gas pressure regulator shall regulate gas pressure at the inlet to each boiler to within plus or minus 5 percent of operating pressure at all firing rates. The control side of the regulator diaphragm shall be vented to the outside atmosphere at a safe location.

3. Installation:

a. The gas service system is intended for the distribution of natural gas, and the materials, appurtenances and workmanship used in the system shall be suitable for the accomplishment of this purpose. System shall be in conformance with the requirements of the gas utility company serving the project. Supply pipe shall be of the size indicated and shall be black steel specified previously.

b. Interior gas piping and appliances shall be installed in accordance with the latest issue of the American National Standards Institute’s “Installation Requirements National Fuel Gas Code”. Hereinafter referred to as ANSI Z 223.1.

c. Joints shall be made with graphite and oil or an approved graphite compound applied to the male thread only. After cutting, and before threading, pipe shall be reamed and all burrs shall be removed. Threads shall be accurately cut, and not more than three threads shall remain exposed outside each fitting after the joint has been made up. Each length of pipe shall be hammered and all scale shall be blown out before assembling. Threaded joint shall not be caulked to prevent or stop leaks.

d. Sleeves shall be built into the walls as the work progresses.

e. Spaces between pipes and sleeves passing through walls, shall be caulked watertight.

f. Unless otherwise indicated, gas piping shall be run exposed. Where concealed piping is indicated, it shall be run as required by Section 2.7 of ANSI Z 2231.

g. An approved type gas cock shall be installed in the branch connection to each riser and near each appliance.

h. Piping shall be graded not less than ¼ inch in 15 feet of length to prevent trapping. Branches from risers to appliance shall grade up toward the appliance.

i. A full size tee fitting and a 6-inch long capped drip pocket shall be installed at the bottom of each riser or drip pocket shall be installed at the bottom of each riser or drop and at each low point in a horizontal gas line.

SEGMENT 2, 1515-2

i. Gas meters shall be vented to exterior of building if needed per applicable codes.

4. Tests:

a. Gas piping shall be tested as required by ANSI Z 223.1. The Contractor shall furnish to the Contracting Officer a certificate showing that tests have been completed satisfactorily.

SEGMENT 2, 1515-3

DIVISION 15

SECTION 1525

INSULATION

1. General::

a. This section covers insulation of piping, valves, fittings, equipment, etc.

2. References:

American Society for Testing and Materials (ASTM) ASTM C547-74 Mineral Fiber Preformed Pipe Insulation ASTM C355 Water Vapor Permanence ASTM E84 Surface Burning Characteristics of Building Materials ASTM C534, Type II

ASTM C1056, 2B1

3. Quality Assurance:

a. Packaging and Labeling: Every package or standard container of insulation, jackets, cements, adhesives, and coatings delivered to project site shall have manufacturer's stamp or label attached giving name of manufacturer, brand and description of material. Insulation, packages, and containers shall be asbestos-free.

b. Materials shall have a fluorescent rating of not more than 25 and a moke-developed rating of not more than 50, when tested in accordance with NFPA 255, ASTM E 84 or UL 723.

c. Piping Systems: Insulating of piping systems shall not proceed until it is proven that the piping systems are free of leaks.

d. It is the intent of this specification that all hot pipes and equipment be insulated unless specifically stated otherwise.

4. Products:

SEGMENT 2, 1525-1

a. Piping Insulation (Includes pipe, valves, fittings, etc.): Insulation material and thickness shall conform to Table 1. Insulation exterior shall be cleanable, grease resistant, non-flaking, and non-peeling. Whenever available, provide pre-molded insulation over pipe, flanges, valves, and fittings. Fiberglass insulation shall be fibrous glass wool and shall be one piece snap-on type. Insulation shall be suitable for use on on hot water pipes with temperature range up to 500 F with a minimum .25 “K” factor. Density shall be nominal 4 pounds per cubic foot.

b. High Temperature Glass shall be good for temperatures up to 850 F, three (3) pounds per cubic foot density, conductivity of .27.

c. For flat surfaces provide mechanical fasteners and ASJ jacket.

d. High temperature glass for curved surfaces shall be in “rigid wrap” form. The material shall be applied per manufacturer’s recommendation. All joints shall be sealed with ASJ tape.

e. Insulation and materials shall be Owens-Corning, Johns-Manville, Armstrong, Certainteed or equal. Special material shall be of manufacturer indicated or equal.

5. Adhesives, Sealants, and Coating Compounds:

a. Insulation and Vapor Barrier Adhesive: Provide ASTM C916, Type 1 adhesive for securing insulation to metal surfaces and for vapor barrier lap only in building interior.

b. Lagging Adhesive: MIL-A-3316, Class 1, for bonding fibrous glass cloth to unfaced fibrous glass insulation; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bonding fibrous glass tape to joints of fibrous glass board, or for bonding lagging cloth to thermal insulation, or Class 2, for attaching fibrous glass insulation to metal surfaces.

Provide for pipe and duct insulation.

c. Mineral Fiber Insulation Cement: ASTM C 195.

d. Vapor Barrier Coating: Provide in accordance with insulation manufacturer’s recommendations.

6. Accessory Materials:

a. Staples ASTM A 167, Type 304 or 316 stainless steel outside-clinch type.

SEGMENT 2, 1525-2

b. Fibrous Glass Cloth and tape; 20 by 20 maximum size mesh. Tape shall be 4-inch (100mm) wide rolls. Class 3 tape shall be 4.5 ounces per square yard (10.6 Kg.m2). In lieu of glass cloth and tape, open weave glass membrane may be provided.

c. Soft annealed stainless steel, 18 gage.

d. Vapor Barrier Tape: Wherever tape is used for sealing purposes, it shall be of type and applied as recommended by the non-conductive covering manufacturer.

e. Vapor Barrier Materials ASTM C 1136. Resistant to flame, moisture penetration, and mold growth, color white.

f. All Purpose Jacket (APJ) on piping shall be a vapor barrier laminate. Jacket shall have a water vapor permeance of .02 perms and a Beach puncture of minimum 50 units. Insulation shall be applied over clean dry surfaces butting adjoining sections firmly together.

7. Execution:

a. Preparation: Clean and test mechanical systems prior to application of insulation.

b. Pipe Insulation: Place sections of insulation around pipe and joints tightly butted into place. Draw jacket tight and smooth. Secure jacket with fire resistant adhesive, factory-applied , self-sealing lap, or stainless steel outward clinching staples spaced not over 4 inches (100mm) on center (l.c.) and ½-inch (12.5mm) minimum from edge of lap. Cover circumferential joints with butt strips, not less than 3 inches (k75mm) wide, of material identical to jacket material. Overlap longitudinal laps of jacket material not less than 1-1/2inches (37.5mm). Adhesive used to secure butt strip shall be same as that used to secure jacket laps. Apply staples to both edges of butt strips.

Vapor Barrier Jacket: On ends of sections of insulation that butt against flanges, unions, valves, fittings, and joints, provide a vapor barrier coating (insulating cement). Apply vapor barrier coating at longitudinal and circumferential laps.

Patch damaged jacket material by wrapping a strip of jacket material around the pipe and cementing, stapling, and coating as specified for butt strips. Extend patch not less than 1-1/2 inches (37.5m m) past the break in both directions. At penetrations by pressure gages and thermometers, fill voids with vapor barrier coating for outside service. Seal with a brush coat of the same temperatures below 35 degrees F (1.6C).

c. Hangers and Anchors:

SEGMENT 2, 1525-3

Pipe insulation shall be continuous through pipe hangers. Where pipe is supported by insulation, provide galvanized steel shields and protection saddles.

Where shields are used on pipes 2 inches (50mm) and larger, provide insulation inserts at points of hangers and supports. Insulation inserts shall be of calcium silicate, cellular, glass, minimum 8 pcf (0.1 Kg/m3), molded glass fiber, minimum 8 pcf (0.1 Kg/m3), or other approved material of the circumference and be not less in length than the protection shield. Vapor-barrier facing of insert shall be of same material as facing on adjacent insulation. Seal inserts into insulation with vapor barrier coating or weatherproof coating as applicable. Where protection saddles are used, fill voids with same insulation material as used on adjacent pipe.

Where anchors are secured to chilled piping that is to be insulated, insulate anchors same as piping for a distance not less than four times the insulation thickness to prevent condensation. Vapor seal insulation around anchors.

d. Sleeves and Wall Chases:

Where interior wall is penetrated, extend an aluminum jacket 2 inches (50mm) out on either side of wall and secure on each end with a band. Where roof is penetrated, extend a metal jacket from a point below back up material to a point 10 inches (250mm) above roof with one band at the roof and one not more than one inch (25mm) from end of metal jacket.

e. Flanges, Unions, Valves and Fittings for Piping:

Provide insulation for cold piping and hot piping of 110 degrees F (43C) or higher. Factory fabricated removable and reusable insulation covers may be used.

When nesting size insulation is used, overlap 2 inches (50mm) or one pipe diameter, whichever is larger. Use insulating cement to fill voids. On pipe sizes larger than 2-1/2 inches (62.5m ), elbows insulated using segments shall not have less than three segments per elbow. Place and joint segments with manufacturer’s recommended water-vapor resistant, fire retardant, and adhesive appropriate for the temperature limit of the service. Overlap tape seams one inch. Extend adhesive onto adjoining insulation not less than two inches. Total dry film thickness shall not be less than 1/16 inch (1.5mm). Where unions are indicated not to be insulated, taper insulation to union at a 45 degree angle.

f. Insulation Finishes and Joint Sealing:

SEGMENT 2, 1525-4

1. Fill breaks, punctures, and voids with vapor barrier coating compound. Vapor seal joint by embedding a single later of 3-inch (75mm) wide open weave glass membrane, maximum 20 by 20 mesh per linear inch (25.4mm) between two 1/16-inch (1.5mm) wet film thickness coats of vapor barrier coating compound. Draw glass fabric smooth and tight with a 1-1/2 inch (37.5mm) overlap. At jacket penetrations such as hangers, thermometers, and damper operating rods, fill voids in insulation with vapor barrier coating. Provide vapor barrier jacket continuous across seams, reinforcements, and projections.

TABLE 1

Insulation Material

System Location Insulation/Thickness Jacket

Hot water All piping, Fiberglass pipe insulation APJ Heating fittings, valves, ½”-2” Size 1” ** etc. 2-1/2” & Up Size – 1-1/2”

Steam All piping, Fiberglass pipe insulation APJ ** fittings, valves, ½” - 2” Size - 2-1/2” etc. 2-1/2”-4” Size – 3” 5” & Up Size – 3-1/2”

Pumped All piping, Fiberglass pipe insulation APJ Condensate fittings, valves, ½”-1” Size 1” ** etc. 1-1/4”-2” Size – 1-1/2” 2-1/2” & Up Size – 2”

Breeching, 2” high temperature APJ Stack (850 F) glass

* Note: If existing adjoining surfaces of those to be insulated are of a different thickness than above, use the same thickness as existing insulation.

** This line to be coated (painted) to match existing insulation exterior color.

All insulation shall be labeled as to contents and flow direction with manufactured labels.

SEGMENT 2, 1525-5

SECTION 1530

BOILERS

1. Scope:

a. The work consists of providing all labor, equipment, materials, etc, to furnish and install new factory assembled steam boilers with deaerator. Boilers shall be installed complete for fully functioning systems with all equipment including piping, insulation, valves, gauges, thermometers, etc. required for efficient and proper operation, testing, and maintenance.

2. Quality Assurance:

a. Boilers shall be ASME code designed and stamped for steam and hot water pressures specified.

b. Boilers shall also comply with all of the following applicable codes:

1. ANSI Z21.13

2. NFPA 54 National Fuel Gas Code

3. NFPA 85

4. ASME CSD-1 Controls and Safety Devices

5. UMC

6. UEC

7. UL

8. CSA

c. In order to provide responsibility for the specified capacities, efficiencies, and performance, the boiler manufacturer shall be responsible for guaranteeing that the boilers provide the performance as specified.

3. Certifications:

a. The boiler manufacturer shall certify the following:

1. The boiler, burner, and other associated mechanical and electrical equipment have all been properly coordinated and integrated to provide complete and operable boilers.

2. ASME, UL, and CSD-1 certification

3. The specified tests have been satisfactorily performed

SEGMENT 2, 1530-1

b. All boiler inspections during hydrostatic testing shall be performed by an authorized boiler inspector.

c. Factory and field test reports shall be submitted prior to final acceptance by the owner.

4. Delivery, Storage, and Handling

a. The contractor shall be responsible for the unloading and rigging of the equipment and for protecting the equipment from the weather, and from dirt, dust, and other contaminants.

5. Existing Boilers (To be removed, see “Demolition” section)

a. Steam Boilers, Bldg. #17: There are two existing 400 hp steam Kewanee boilers in

Bldg. #17 which are to be replaced.

6. Boilers

a. Steam Boilers

General: Boiler shall be factory packaged and shall include boiler, burner, heavy duty skids, painted steel jacket with two inches of fiberglass insulation, controls and accessories, all piped and wired for single point field connections to water, fuel, electrical, vent, and blowdown connections. The complete unit shall carry packaged label of Underwriters Laboratory (UL) and be in accordance with ASME/CSD-1, all codes required by the local and state authorities and as indicated herein. A certified factory fire-test shall be provided on fuels with data sheets furnished to owner including a national board number. ASME certified (H- 2 data report), labeled, stamped and designed for 150 psig steam in accordance with Section (I or IV) of ASME code.

1. Performance: Boiler shall have a turndown ratio of 5:1 with no more than

15% excess air at any firing level. Overall fuel to steam efficiency shall be 84%, as a minimum. Written verification of overall efficiency shall be provided.

Boiler Design

SEGMENT 2, 1530-2

a. Boilers shall be steel fire tube boilers for positive pressurized firing with forced draft burner. It shall have a minimum five (5) square feet of heating surface per boiler horsepower. Front and rear doors shall be davited and sealed with gaskets using heavy duty cap screws threaded into replaceable brass nuts. When opened, doors shall expose all tubes, tubesheets and furnace for ease of inspection and maintenance. Lifting loops shall be provided. The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection.

b. Provide observation ports at each end of boiler for inspection of flame conditions.

c. The boiler vent shall include a locking blade damper and a stack thermometer.

d. Boiler jacket shall be a minimum of 18 gauge metal with primer and finish coat of polyurethane resin. The top side (exterior) of the jacket shall also be painted with a primer and finish coat of polyurethane resin paint. The entire boiler based frame and other components shall be factory painted before shipment using a hard finish enamel coating.

e. Tubes shall be 13 gauge (12 ga. if same price). Tubesheets shall be manufacturer’s standard thicknesses. Furnace shall have a refractory plug for inspection and access to the furnace. Furnace heat release shall not exceed 160,000 Btu per cubic foot of furnace volume.

Burner Design

a. Gas burner shall be of the gun design and shall be of the high radiant, fan-assisted, multi-port type for natural gas, and shall be integral with the front head of the boiler. Gas turndown shall be 5:1 with a maximum amount of excess air at any turndown to be no greater than 15%. A low fire HVAC actuator designed for low fire every day gas performance shall be provide in addition to a switch designed for high fire. Minimum pilot safety burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas valve, pressure regulator and shut-off cock. The burner shall meet 30 ppm Nox or less while firing on natural gas at all firing levels using flue gas recirculation technology.

b. Minimum main gas train shall include manual shut-off valve, pressure regulating valve, dual safety gas valves, manual test valve high-low pressure switches, manifold pressure gauge and butterfly gas valve. Gas train shall be factory packaged to meet insurance

SEGMENT 2, 1530-3

c. requirements. A vent valve shall be located between the safety shutoff valves.

d. Fuel-Air Control: Modulating fire with proven low fire start.

Provide manual potentiometer with manual-auto switch on boiler control panel in addition to automatic fuel-air controller. Provide parallel positioning controls as linkages controlling fuel/air is not acceptable.

e. Forced Draft Blower: All air for combustion shall be supplied by a blower mounted in the front boiler door above the burner.

f. Burner shall have a minimum 1 year guarantee to include that in event of failure that owner does not have to buy another burner while defective burner is being replaced or repaired.

Boiler Trim

a. The following shall be included:

1. 4” diameter pressure gauge.

2. ASME safety relief valve(s) piped to floor drain.

3. Auxiliary low water cutoff

4. Primary low water cut-off

5. Operating control

6. Limit control with manual reset

7. 4” stack thermometer

8. Feedwater regulating valve with 3 valve bypass

9. Low fire hold controller

10. 1 Slow opening blowdown valve, Class 200#

11. 2 Quick opening blowdown valves, Class 490#

12. Feedwater Globe Valve, Class 240# m

13. 1 Feedwater Check Valve, Class 240# n

14. 1 ASME Spool Piece

15. 1 Stop Valve (Steam Header Valve), Flanged, Cast Iron, Class 250

16. 1 Stop Check Valve (Non-Return Valve), Flanged, Cast Iron, Class 250”

17. Factory mounted, installed, tested, and certified piping (by A, S, or PP

ASME stamp holder) and valves per ASME Code, including”

a. Water Column piping, complete with try-cock, gauge glass set, and water column blowdown valves.

SEGMENT 2, 1530-4

b. Bottom Blowdown (from boiler to last code valve)

c. Feedwater Assembly (shipped loose) d .Surface Blowdown piping with stop valve and metering valve

18. JHB Modulating Feedwater Control Valve, including 3-Valve Bypass

19. Platforms and ladder to access steam header and safety relief valves. Built to OSHA requirements

20. Feedwater pump control as integral part of water column to automatically actuate feedwater pump(s).

21. Steam pressure control to regulate burner operation, mounted near water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and firing rate control.

As a minimum, boiler trim shall include all those items currently on boilers being replaced.

Boiler Controls

a. BOILER MANAGEMENT CONTROL SYSTEM CONTROL PANEL:

Boiler mounted NEMA 1 enclosure(s) with key lock; fusing, magnetic starters; step-down control transformer; flame safeguard and burner management system as indicated; annunciator lights for load demand, fuel on, low water and flame failure; selector switches, required by dry contacts, relays and terminal strips. Oil, heat and moisture resistant wire with circuit number corresponding to electrical wiring diagrams in accordance with UL and National Electric Code.

b. Control of boilers with respect to on/off and lead/lag, etc. shall be maintained.

This shall include alternating boilers each time a boiler fires on and off.

c..BURNER MANAGEMENT SYSTEM: Boiler mounted in control panel enclosure. Microprocessor-based control to monitor all critical boiler and burner interlocks control and supervise burner light off sequence, and initiate an orderly safety procedure in the event of interlock or flame failure. Dynamic self checking system to provide pre-post purge status, fault history, and diagnostic information by means of a two-line alpha-numeric display with alarm/status LEDS.

d. Major functions provided by the Boiler Control System shall be:

1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period, main flame establishing period, run, flame proving and lockout and post-purge

2. Full modulating control of fuel and air

3. Utilize solid state controls and sensors to provide various control functions, such as: SEGMENT 2, 1530-5

a. Modulating control (algorithm shall be proportional-integral-derivative (PID) type)

b. Thermal shock protection

c. High and low limit alarms and shutdowns

4. Touch screen graphical operator interface and monitoring

a. Manual control of the boiler firing rate using control screens on the HMI to increment or decrement the firing rate b .On screen indication of burner management controller status and diagnostics

c. On screen display of system alarms and faults

d. On screen history of alarms and faults

e. O n screen recommendations for troubleshooting of fault conditions

f. On screen water level indication and alarm(s)

5. Stack flue gas, combustion air and shell (water) temperature indication 6 .Boiler efficiency calculation 7 .Low fire hold with minimum temperature control

8. Assured low fire cut-off (ALFCO)

e. The boiler control system shall incorporate the following safety provisions:

1. Examine all load terminals to assure it is capable of recognizing the true status of the external controls, limits, and interlocks. If any input fails, this test, the burner management system shall lockout on safety shutdown.

2. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be able to lockout on safety.

3. Pre-ignition interlocks (fuel valve proof of closure, etc) and flame signal checked during standby and pre-purge.

4. Dynamic checking of the flame signal amplifier.

5.Safe start check and expand check to include monitoring flame signal during standby.

6.High and low fire switches checked for proper sequencing.

7.The boiler control system shall provide the ability to communicate with external digital via Ethernet as a standard. It shall be possible to communicate with any OPC compliant internet communications shall be supported, with the Boiler Control System supplied with its own IP address.

Product:

a. Steam Boilers: Provide and install two (2) new natural gas fired, 150 psi, wet back, three (3) pass, fire tube high pressure steam boiler, 150 bhp output as manufactured by the following, or equal:

SEGMENT 2, 1530-6

1. Cleaver Brooks, ICB Criterion Series

2. Hurst, Series 400

3. Superior, “Seminole”

7. Deaerator System

a. A spray type deaerator system sized for the new 2-150 bhp boilers shall be provided and installed. The following shall be included:

1. Nominal 340 gallon tank or as sized for boilers

2. Gauge glass with shutoff valve

3. Modulating feed water valve

4. Steel stand

5. Factory insulation and jacketing

6. Water level control

7. Make up inlet water control valve

8. Tank drain valve

9. Tank thermometer

10. Vent valve

11. High and low water level controls

12. Overflow trap, tank

13. Pressure gauge

14. Relief valve

15. Steam pressure reducing station

16. Two (2) 460/3/60 pumps

17. Pump suction piping with stop valve and Y strainer

18. NEMA 1 control panel, disconnect with over current protection, motor starter, pump selector switch, alarm buzzer, relays and pressure trolls for pump failure switching. Pumps shall have 15 hp motors, rated for 27 gpm at 350 TDH.

19. Steam Pre heater Package to raise 28 gpm, 150 F. The following also shall be included:

a. Perforated heater tube

b. 2 Element regulating valve

c. Strainer

d. Pressure gauge

e. Sentinel valve

Any other parts shall be provided and installed for a complete, automatic boiler feed water system.

b. Deaerator system shall be as manufactured by Hurst, Cleaver Brooks, Superior, or equal.

SEGMENT 2, 1530-7

c. Two (2) new chemical feed tanks and pumps shall be provided, interlocked with boiler feed water system with locations as shown on the drawings.

8. Stack/Breeching

a. Unless different stack is recommended by boiler manufacturer, boiler stack and breeching shall be for category III heating systems.

It shall be double wall with 1” air gap, 304 stainless steel inner wall and aluminum coated steel outer jacket. It shall be certified under UL 1738 and ULC-636. Exterior stack shall be painted with 2 coats of high temperature paint made for such application.

b. Provide and install rain caps to terminate the exhaust stacks. Tee covers with corrosion resistant tubing or drain pipes to drains shall be provided.

9. Shop Tests

The complete packaged boiler shall receive factory tests to check construction, function, and operation of all controls and the unit. All shop tests may be witnessed by the purchaser upon sufficient notice to the company.

10. Manufacturer’s Field Services

a. General: The boiler and accessories supplier shall be responsible for performance of testing of the packaged boiler and accessory equipment and materials furnished. A detailed written record of the start-up performance, including burner setting data entire load shall be furnished to the owner before test personnel leave the site equipment and test apparatus shall be furnished by the supplier. All equipment defects discovered by the tests shall be rectified. The minimum time for two (2) boilers is five

(5) days.

b. Equipment inspection: Boiler representative to provide 8 hours of job site assistance to inspect boilers and other equipment upon arrival, verifying completeness of equipment supplied and damages.

c. Pre start-up walk through: Boiler representative to provide 8 hours at job site reviewing installation with mechanical contractor to be conducted approximately 1 week prior to startup.

d. Startup shall be conducted by experienced and factory authorized technician in the regular employment of the boiler supplier, and shall include:

SEGMENT 2, 1530-8

1. Demonstrate that boiler, burner, controls and accessories comply with requirements as proposed by the boiler and accessories supplier. Pre-test all items prior to scheduling the final testing that will be witnessed by the owner.

2. Readings at different firing rates (25, 50, 75, and 100% min.)

of load for the modulating burner shall be taken with a written report of the tests submitted to the test engineer. The reports shall include readings for each firing rate tested and include stack temperatures, O2, CO, Nox, and overall boiler efficiency.

3. Auxiliary equipment and accessories: Observe and check all valves, draft fans, electric motors and other accessories and appurtenant equipment during the operational and capacity tests for leakage, malfunctioning, defects, and non compliance with referenced standards or overloading as applicable.

4. Commissioning requirements:

a. Fireside inspection

b. Waterside inspection

c. Closing and resealing of doors, manways and hand holes

d. Set up fuel train and combustion air system

e. Set up operating costs

f. Check all safeties, including Flame safeguard, LWCO, ALWCO, Air flow, fuel pressures, high limits

g. Set up and verify efficiencies at all firing levels

h. Set up and verify burner turndown

i. Set up and verify feedwater/level controls

j. Set up and verify emissions compliance

5. Training to include all safety procedures, maintenance procedures, control operations, and diagnostic procedures.

Training is to be provided to accommodate operator’s availability on site. It is required to train 3 maintenance personnel for a minimum of 8 hours or until each one is satisfied that they are comfortable operating each boiler.

6. Special tools/safety equipment:

a. Boiler/burner supplier to include in their proposal safety equipment required to perform annual inspections and maintenance per OSHA requirements

b. Special safety training on safety procedures by a qualified trainer to be provided per OSHA.

11. Operating & Maintenance Manuals

SEGMENT 2, 1530-9

a. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and burner, schematics including fuel trains, general instructions for maintenance and inspections, complete spare parts lists and trouble shooting procedures. Operating and maintenance manuals shall be provided including cut-away views of boiler and burner schematics including fuel trains, general instructions for maintenance and inspections, complete spare parts lists and trouble-shooting procedures.

b. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the electrical panel.

12. Warranty

a. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer for a period of twelve (12) months from the date of start-up or beneficial use or 18 months from shipment, whichever comes first.

13. Installation:

a. Installation shall be provided by the contractor in accordance with the requirements of the codes specified herein before. All of the contractor’s work shall be performed by experienced workmen previously engaged in boiler plant construction and shall be under the supervision of a qualified installation supervisor.

b. Install equipment in strict compliance with manufacturer’s installation instructions.

c. Contractor shall be responsible for ensuring that all existing interlocks are maintained after installation of new equipment, including interlocks to feed pump systems, condensate systems, etc.

d. Install equipment in strict compliance with state and local codes and applicable NFPA standards, including State of Nebraska Title 229.

e. Contractor shall be responsible for any required notifications and permits. These shall include, but shall not be limited to: (a) “Boiler and Pressure Vessel Installation Notice” (b) “Manufacturer’s/Installing Contractor’s Report for ASME CSD-1.

f. Maintain manufacturer’s recommended clearances around sides and over top of equipment. Clearances shall also be as per any applicable codes and as necessary for repair and maintenance of boilers.

SEGMENT 2, 1530-10

g. Install components that were removed from equipment for shipping purposes.

h. Install components that were furnished loose with equipment for field installation.

i. Provide all interconnecting electrical control and power wiring

j. Provide all fuel gas vent and service piping

k. Provide all piping for boiler pipe connections.

l. All piping for venting, blowdown, testing, etc. shall be installed as per manufacturer requirements and codes.

14. Field Testing

c. The manufacturer’s representative shall test all boiler and burner interlocks, actuators, valves, controllers, gauges, thermometers, pilot lights, switches, etc. Any malfunctioning component shall be replaced.

d. All adjustments to boiler, burner, and boiler control systems shall be performed by the manufacturer’s representative.

SEGMENT 2, 1530-11

SECTION 1551

STEAM, WATER, HOT WATER, CONDENSATE PIPING

a. The work shall include furnishing, installing, and testing of steam, hot water, boiler feed water (water), and condensate water piping. This shall include piping, flanges, bolting, gaskets, valves, fittings, flow control equipment, and associated appurtenances necessary for complete and operable systems. Work includes modifications and connections to existing boiler and condensate water systems.

b. Hot water, steam, water, and condensate water piping shall be designed for a minimum service pressure of 300 psi at 150 degrees F, minimum ANSI Class 125.

c. System design and test pressures shall not be less than 1.5 times the respective maximum operating pressure at design pressure. Piping components shall be suitable for use under design pressures specified.

2. Products:

a. General: All piping, fittings, gaskets, valves, flanges, bolts, and all other products installed in the piping system shall be suitable for the service, temperature and pressure for which it is installed.

b. Steam, Hot Water, Water, and Condensate Water Piping:

Piping shall be welded or threaded, Schedule 40 black steel pipe conforming to ASTM A53 Grade A and B.

c. Fittings and Flanges:

Steel fittings, ASME/ANSI b16.9, butt-welding type, or ASME/ANSI B16.5, flanged type, or convoluted steel flanges conforming to ASME BPVC SEC VIII D1; cast iron fittings, ASME/ANSI B16.1, flanged type; bronze fittings up to 8-inch size, ANSI B16.24, flanged type.

d. Strainers:

SEGMENT 2, 1551-1

Furnish and install strainers ahead of all pumps, regulators and control valves and traps. Strainers shall be as manufactured by Keckley, Muessco, Sarco, or equal.

Keckley model numbers are examples. Strainers shall be self-cleaning, iron body, stainless steel, perforated screens with suitable openings for steam or water lines as required for service involved.

e. Butterfly Valves:

MSS SP-67, Type I tight shutoff valve, and valve ends shall be flanged or lug type. Valve body material shall be cast iron or steel and shall be bubble tight for shutoff at design pressure. Flanged valves shall have 300 series corrosion-resistant steel stems and discs or bronze discs with molded elastomer disc seals.

Flow conditions shall be for regulation from maximum flow to complete shutoff by the throttling effect. Valves shall have throttling handles. Valves shall have a minimum of seven locking positions.

f. Cast Iron Gate Valves:

MSS SP-70, outside screw-and-yoke type with bronze trim.

g. Globe and Angle Valves:

MSS SP-85, with bronze trim, tapped drains, and brass plugs.

h. Ball Valves:

FS WW-V-35; Type II, stationary seat ring and floating ball; Class A, copper alloy; Style I. Flange valve shall conform to MSS SP-72, bronze.

i. Drain Valves:

Gate valves conforming to MSS SP-80, manually operated ¾-inch pipe size and above, with threaded ends.

j. Air Vent Valves:

Manually-operated general service type shall be of ball-float type. Provide ¾-inch pipe size for water and brine piping.

k. Pressure relief, Pressure Limiting, Venting:

All pressure relief, pressure limiting, and vent devices shall be provided and installed per ASHRAE 15.

SEGMENT 2, 1551-2

l. Pressure Gages:

Dial type, liquid-filled, elastic element, ANSI/ASME B40.1 with integrally mounted restrictor, as manufactured by Marshalltown, or equal. Dial size shall be 4-1/2 inches. Valves shall be installed in front of all pressure gages.

m. Thermometers:

1. ASTM E1, liquid-in-glass thermometer. Die-cast case, aluminum finished and baked epoxy enamel, glass front, spring secured, 9 inches long, 180 degree adjustment in vertical plane, 360 degree adjustment in horizontal plane with locking device.

2. Tube shall be red reading, organic liquid-filled with magnifying lens.

3. Scale shall have permanently markings.

h. Thermometer Wells:

Thermometer wells shall be brass or stainless steel and shall have a pressure rating not less than the system design pressure.

i. Pipe Hangers and Supports:

Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP-58, ASME/ANSI B31.9, and MSS SP-69. Provide metal protection shields and inserts for insulated piping.

3. Installation:

Install Piping and piping components to ensure proper and efficient operation of equipment and controls. Provide proper supports for mounting of vibration isolators, stands, guides, anchors, clamps, and brackets. Arrange piping connections to equipment so that removal of equipment or components of equipment including tube withdrawal from condensing unit, pump casing, shaft seals and similar work can be accomplished with the least amount of disassembly or removal of piping systems.

Provide piping connected to equipment with vibration isolators with flexible connections which shall conform to vibration and sound isolation requirements for system. Electric isolation shall be provided between dissimilar metals to reduce rate of galvanic reaction.

a. Water, Hot Water, Condensate, Steam Piping:

SEGMENT 2, 1551-3

1. Welding, heating, and soldering shall conform to ANSI/ASME B31.9 and as specified. Provide pipe, fittings, valves, etc., as necessary, to connect new boilers to existing piping. Horizontal runs of piping shall pitch to assure adequate drainage and venting. Provide drain valves at low points and automatic air vent valves at high points of system where air pockets would occur. Blow out piping with high pressure steam, high pressure water, or compressed air, as necessary, to remove rust, scale, oil, and debris. Before final connections are made, wash interior of piping with water. Chilled water is treated with “Amtreat 084K”. Treatment will not adhere properly to the inside of the pipe if interior is not cleaned properly. Plug or cap open ends temporarily when not at site to prevent foreign objects from entering. Ensure clearance is provided on all piping, fittings, etc.