APPENDIX F SPECIFICATIONS.docx
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- Attached to
- IFB 26. 0001 Allen Elementary Boiler Replacement
- Solicitation number
- IFB 26.0001 Allen Elementary Boiler Replacement
- Issued by
- Washtenaw County, Michigan
About this file
This document is a detailed Invitation for Bid (IFB) Specification for a boiler replacement project for Allen Elementary School in Michigan, issued under IFB 26.0001. The project involves removing one existing boiler and installing three new AERCO Benchmark 200 with Edge (iii) Control condensing boilers, with work to be completed between September 1, 2025, and December 31, 2025. The substantial completion date for heating functionality is December 1, 2025, with the contractor responsible for purchasing, installing, testing, and performing all necessary demolition, electrical reconnection, venting, and disposal in accordance with EPA guidelines and local codes.
The project requires comprehensive services including detailed work planning, qualified labor, material handling, factory startup, owner training, and submission of commissioning reports and warranty documentation. The specifications are extremely precise, mandating specific boiler characteristics such as 20:1 turndown ratio, natural gas firing, 9 ppm NOx emissions, and advanced control systems with features like O2-trim technology and building automation compatibility. The contractor must provide two bound copies of commissioning reports, operational manuals, and include all mechanical permit and plan review fees for the State of Michigan. No substitutions to the specified AERCO Benchmark 2000 boilers are permitted without written approval 30 days prior to the bid date.
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Other files
| File | Type | Posted |
|---|---|---|
| APPENDIX E Ichat packet 5-2021.pdf | ||
| APPENDIX D Familial Disclosure Form (ONLY REQUIRED FOR CONSTRUCTION).docx | DOCX document | |
| APPENDIX B Certification Form.docx | DOCX document | |
| APPENDIX H BID PRICING FORM.docx | DOCX document | |
| APPENDIX I Prevaliling Wage.pdf | ||
| APPENDIX G MECHANICAL PLANS MODIFIED.pdf | ||
| APPENDIX C Iran Economic Sanctions Form.docx | DOCX document | |
| IFB 26.0001 ALLEN ELEMENTARY BOILER REPLACEMENT.docx | DOCX document | |
| APPENDIX A Contractor Information.docx | DOCX document |
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IFB 26.0001 Allen Elementary Boiler Replacement
APPENDIX F: SPECIFICATIONS
SCOPE OF WORK: Provide and install three (3) AERCO Benchmark 200 with Edge (iii) Control condensing boilers at Allen Elementary School. Installation to be in strict accordance with manufacturer’s written installation instruction and code requirements.
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, specifically | designed to match the performance and control capabilities of AERCO Benchmark 2000 | with Edge [ii] Control. |
1.3 SUBMITTALS
| A. | Product Data: Include performance data, operating characteristics, furnished | specialties, and accessories specific to AERCO Benchmark 2000, including Edge [ii] | Control system details. |
| B. Efficiency Curves: Submit efficiency curves for 100%, 50%, and 7% input firing rates at | entering water temperatures from 80°F to 160°F, matching the performance profile of the | AERCO Benchmark 2000. |
C. Pressure Drop Curve: Submit pressure drop curves for the following flow ranges:
1. 2000 MBH: 25 - 350 GPM, consistent with AERCO Benchmark 2000 specifications.
D. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work, with wiring diagrams for power, signal, and control wiring specific to the Edge [ii] Control system.
E. Source and Field Quality Control Test Reports: Include reports in submittals, demonstrating compliance with AERCO’s factory testing protocols.
F. Operation and Maintenance Data: Include data for emergency, operation, and maintenance manuals tailored to AERCO Benchmark 200
G. Warranty: Submit warranty documentation as specified, matching AERCO’s standard warranty for the Benchmark 200
H. ASME Stamp Certification: Submit "H" stamp certificate and hydrostatic test documentation for piping external to the boiler, per AERCO’s manufacturing standards.
1.4 QUALITY ASSURANCE
| A. Manufacturer Qualifications: Manufacturer must have at least 30 years of experience in | condensing hydronic boiler manufacturing, be headquartered in North America, and | produce pressure vessels in an ASME-certified, wholly owned facility. Factory visits for | test firing must be available. |
| B. Electrical Components: Boilers must be listed and labeled per NFPA 70, Article 100, by a | testing agency acceptable to authorities having jurisdiction. | ||
| C. AHRI Performance Compliance: Boilers must be rated per federal testing methods, | achieving energy efficiency and performance ratings within prescribed tolerances. | ||
| D. ASME Compliance: Boilers must comply with ASME Boiler and Pressure Vessel Code, | Section IV “Heating Boilers.” | ||
| E. ASHRAE/IESNA 90.1 Compliance: Boilers must meet minimum efficiency | requirements for gas-fired boilers. |
F. DOE Compliance: Boilers must comply with 10 CFR 430, Subpart B, Appendix N.
| G. UL Compliance: Boilers must comply with UL 795 and be listed by an acceptable | testing agency. | ||
| H. NOx Emission Standards: Boilers must achieve 9 ppm NOx corrected to 3% oxygen at | all firing rates on natural gas, per South Coast Air Quality Management District | (SCAQMD) Rules 1146, 1146.1, or 1146.2, and Texas Commission on Environmental | Quality (TCEQ) Rule 117.465, matching AERCO Benchmark 2000 performance. |
· BMK2000: 9 ppm NOx corrected to 3% oxygen at all firing rates when firing on natural gas
1.5 WARRANTY
A. Standard Warranty: Manufacturer shall repair or replace components failing due to materials or workmanship within the specified period:
1. Pressure vessel/heat exchanger: 10-year non-prorated warranty against condensate corrosion, thermal stress, or defects. Pressure vessel: Lifetime Warranty against thermal shock failure, provided installation and operation follow AERCO’s manual.
2. Burner: 5-year conditional warranty from shipment.
3. Edge [ii] Control panels: 2-year conditional warranty from shipment.
4. Other components (except igniter, flame detector, O2 sensor): 18-month conditional warranty from shipment.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
| A. Basis-of-Design Product: AERCO International, Benchmark 2000 Boiler with Edge [ii] | Control (2,000,000 BTU/hr. input). No substitutions permitted without written approval | 30 days prior to bid date, demonstrating equivalent performance, turndown, O2-trim, | and control capabilities. |
| B. Approved Equals: None, unless proven to match AERCO Benchmark 2000’s patented | AERtrim system, 20:1 turndown, dual returns, and Edge [ii] Control features. Water | tube boilers are not permitted. |
2.2 CONSTRUCTION
| A. Description: Boiler shall be natural gas-fired, fully condensing fire-tube design with a | 20:1 turndown ratio (minimum firing rate 100,000 BTU/hr.), matching AERCO | Benchmark 2000. Boiler shall operate in variable primary or primary-secondary piping | configurations, with full modulation and positive/negative pressure vent capability. | Efficiency shall increase with decreasing load while maintaining setpoint. Boiler shall be | factory-fabricated, assembled, and tested, with insulated jacket, flue-gas vent, | combustion-air intake, dual inlet returns, condensate drain, and Edge [ii] controls. |
| B. Heat Exchanger: Constructed of 439 stainless steel fire tubes (1/2” OD, 0.049” wall | thickness) and tube sheets (0.25” thick), with one-pass combustion gas flow. | |||||
| ASME-stamped for 150 psig working pressure. Access to tubesheets via burner and | exhaust manifold removal, with minimum 8-inch diameter opening. | |||||
| C. Pressure Vessel: Maximum water volume of 40 gallons, with flanged 150-pound | ANSI-rated 4-inch connections. Water pressure drop shall not exceed 3 psig at 170 | gpm. Constructed of ASME SA53 carbon steel (0.25” wall, 0.50” upper head), with | inspection openings per ASME Section IV. Thermal efficiency shall increase as firing | rate decreases. | ||
| D. Dual Returns: Boiler shall include dual return connections for low and high return | temperature zones, with no minimum flow rate requirement through either return, | provided total minimum flow is met. Single-return boilers are unacceptable. | ||||
| E. Modulating Air/Fuel Valve and Burner: Burner shall achieve 20:1 turndown without loss | of combustion efficiency, operating below 7.5% oxygen (55% excess air) and producing | less than 9 ppm NOx corrected to 3% oxygen on natural gas. Burner shall be metal-fiber | mesh over stainless steel, with spark ignition and flame rectification. Modulating air/fuel | valve shall use a single linkage for gas and air valves, requiring no field adjustment. | Variable-speed cast aluminum pre-mix blower shall ensure optimal air/fuel mixing. | |
| F. Fuel: Natural gas only, with ventless gas train designed and calibrated for AERCO | Benchmark 2000 performance. |
Minimum Boiler Efficiencies (20ºF delta-T):
EWT
| 100% Fire |
| 50% Fire |
| 7% Fire |
160 °F
| 86.5% |
| 87% |
| 87% |
140 °F
| 87% |
| 87.5% |
| 87.5% |
120 °F
| 88.5% |
| 89% |
| 90% |
100 °F
| 93.2% |
| 94.5% |
| 95.2% |
80 °F
| 95.6% |
| 96.8% |
| 98.2% |
| G. Exhaust Manifold: Corrosion-resistant 316 stainless steel or cast aluminum, with 8- | inch flue connection and gravity drain for condensate. | |
| H. Blower: Variable-speed DC centrifugal fan, with motor complying with Division 23 | motor requirements. | |
| I. Ignition: Spark ignition with 100% main-valve shutoff and electronic flame | supervision. |
J. Combustion Air: Drawn from boiler enclosure to preheat air and increase efficiency.
| K. Combustion Air Filter: High-flow automotive filter for efficient combustion and | unhindered burner components operation. | ||
| L. Enclosure: Fully removable plastic and sheet metal enclosure for servicing access.O2 | Sensor: Patented AERtrim O2 sensor located in combustion chamber, measuring oxygen | content directly. Sensors in exhaust manifold or stack are unacceptable due to moisture- | related inaccuracies. Sensors requiring annual replacement are unacceptable. |
2.3 CONTROLS
A. Edge [ii] Control System: Integrated control with 5-inch color touchscreen, six navigation buttons, multi-color LED firing indicator, and dual three-digit seven-segment displays for temperatures. Enable/Disable toggle switch and Low Water Cutoff test/reset buttons required. Controls without navigation buttons are unacceptable.
B. Control Capabilities: Without external controls, the system shall:
1. Sequence up to 16 boilers.
2. Control variable-speed or single-speed pumps and modulating valves.
3. Operate/modulate system pumps with lead/lag rotation.
4. Control up to 6 SmartPlate domestic water heaters and pumps.
5. Communicate via RS485 using Modbus protocol.
| C. Control Architecture: Segregated into Edge [ii] Control Panel, Power Panel, and | Input/Output Connection Box, Underwriters Laboratories-recognized, with seven | |
| field-replaceable circuit boards (microcontroller, 7-segment display, interface, low-water | cutoff, power supply, ignition/combustion, connector). | |
| D. The control panel shall consist of seven individual circuit boards using surface-mount | technology in a single enclosure. Each board shall be individually field replaceable. These | circuit boards shall include: |
| 1. A microcontroller board with integrated 5-inch touchscreen color display providing the | user interface. | |
| 2. A 7-segment display board. This board includes two 3-digit 7-segment | displays. These displays shall be used to view a variety of temperature | sensor values and operating and startup function status. |
| 3. An Interface board connects the microcontroller board to internal components us- ing | ribbon cables. | |
| 4. An electric low-water cutoff board connects to the test and manual reset functions | on the microcontroller board. | |
| 5. A power supply board is designed to provide the different DC voltages to the rest of | the boards. It also acts as voltage regulator and reduce power noise. | |
| 6. An ignition and combustion board. This board controls the air/fuel valve and | Safety Shutoff Valve, flame status and ignition transformer |
7. A connector board used to connect all external electrical connection
| E. System Pump Lead/Lag Rotate: two system pumps based on user-defined intervals | without external controls, unless integrated with building management system. Variable | Speed Pump: Modulate pump based on firing rate, plant firing rate, or return header | temperature differential. | ||
| F. Variable Speed Pump: The control shall be capable of modulating a variable speed | pump. | It shall modulate the pump based on the boiler firing rate, the boiler plant firing | rate, or based on the return header temperature differential from supply water | temperature on a primary secondary piping application. | |
| G. Minimum number of boiler plant open valves: The control shall manage the minimum | number of boiler motorized valves to reduce variable speed pump flow and energy | used. The control shall offer a setting to control the number of valves open during low | load and standby operation. Manufacturers without this feature shall offer additional | pump controller and a smaller single speed pump to run during the low load and | standby periods. |
| H. Combustion calibration: The control shall offer at least 5 calibration points. The use of | less than 5 calibration points is not permitted to improve overall system efficiency | under all firing rates. Each combustion calibration point shall operate with 5 to 7% O2 |
| levels to improve operating efficiency. Deviating away from these values shall not be | acceptable. | |
| I. Combustion Calibration: Minimum 5 calibration points at 5-7% O2 levels. Fewer | points or deviation from O2 range are unacceptable |
J. Assisted Combustion Calibration: Adjust O2 levels automatically, log O2, NOx, CO, and flame strength, and flag out-of-range values. Manual calibration also required. Controls without assisted calibration are unacceptable.
K. Valve Balancing: Control modulating motorized valves to optimize flow, closing valves for off boilers while keeping one valve open to protect pumps.
L. Building Automation: Communicate via BACnet (MS/TP, IP/Ethernet) and Modbus (RTU, IP) without external gateways. BACnet IP requires mapping to server IP/MAC for security. External gateways are unacceptable.
| M. Status Displays: Unit status (setpoint, temperatures, firing rates, run hours) and plant | status (setpoints, temperatures, boiler statuses). Log 500 plant events or 200-unit | events. | |
| N. Software Updates: Field-updatable via USB or Internet with password-secured | menus, retaining prior settings. | ||
| O. Copy settings from one boiler to the other: To significantly reduce installation | time by reducing long repetitive work, the control shall have the capability of | saving its settings to a USB flash drive. In addition, the control shall have the | ability of copying new settings from a flash drive. |
| P. Programmable I/O: Two programmable relay outputs (e.g., swing valve, | system pump), inputs (e.g., flow, damper switch), three analog outputs (e.g., | boiler pump, valve), and three analog inputs (e.g., remote setpoint). | |
| Q. Safety: Include single-seated safety shutoff valve/regulator with proof of closure | and dual over-temperature protection per ASME Section IV and CSD-1. | ||
| R. AERtrim O2-Trim: Patented system with automotive O2 sensor in combustion | chamber, adjusting blower speed for optimal air/fuel ratios. Features self- | diagnostics, adjustable O2 targets, and daily/weekly diagnostics. Exhaust- | mounted sensors or annual replacement sensors are unacceptable. |
| S. onAER Service: Include 5-year subscription with real-time monitoring, efficiency | trends, O2 levels, maintenance alerts, predictive algorithms, and customizable | dashboards via Ethernet port. | |
| T. Boiler Sequencing Technology (BST): Sequence 2-16 units with lead-lag, | parallel operation, motorized valve control, automatic lead rotation, and bump- | less master transfer. |
2.4 ELECTRICAL POWER
A. Controllers and Wiring: Per Division 26 sections. B. Single-Point Connection:
Factory-wired switches, motor controllers, and transformers for single-point field power connection. C. Electrical Characteristics: Voltage: 120 V Phase: 1 Frequency: 60 Hz Full Load Current: 13-16 Amps
2.5 VENTING
A. Vent Material: UL-listed Polypropylene or Al 29-4C stainless steel for Category II, III, and IV appliances, compatible with condensing flue gas. PVC/CPVC unacceptable for Benchmark 2000.
B. Exhaust Vent Size: Minimum 8-inch diameter.
C. Combustion-Air Intake: Metal or PVC duct, minimum 8-inch diameter.
D. Common Vent/Air: Support common venting with parallel modulation for multi-boiler systems. Non-parallel modulation systems are unacceptable.
E. Venting Guidelines: Follow AERCO’s venting guide.
2.8 SOURCE QUALITY CONTROL
| A. Burner and Hydrostatic Test: Factory-adjust burner to eliminate excess oxygen, CO2, | NOx, and CO, achieving combustion efficiency. Perform hydrostatic testing per ASME | standards. |
| B. Factory Testing: Test and inspect boilers per ASME Boiler and Pressure Vessel Code | before shipping. |
PART 3 – SCOPE OF LABOR
1.1 All work will be performed and completed with minimum impact to the facility. Substantial completion date in order to heat the building is December 1, 2025 and fully functional completion date is December 31, 2025. Earliest start date for performing work is September 1, 2025 (based on Board of Education approval).
1.2 Respondents to provide all necessary Supervision and qualified labor to deliver a complete and functioning system. All work to be performed to industry best practices standards. To be executed with minimal disruption to facilities and operations, and with the utmost respect for the operation of daily business
1.3 Respondents to perform necessary detailing and coordination for a successful replacement of existing boilers.
1.4 Provide detailed work plan with tentative schedule and qualified sage lifting and rigging strategy per the project requirements.
1.5 Respondents will be responsible for purchasing, installing and testing of the boilers.
1.6 Respondents to provide qualified labor and materials to perform demolition, cut and cap and removal of one (1) existing boiler. Includes removal and disposal of the existing hot water piping, gas piping and electrical per the project requirements.
1.7 Includes equipment and scrap disposal in the strict accordance with the EPA guidelines.
1.8 Provide and install three (3) AERCO Benchmark 200 with Edge (iii) Control condensing boilers to be installed in strict accordance with manufacturer’s written installation instructions and code requirements. Refer to the attached specification for the Condensing Boilers.
1.9 Electrical reconnect and existing circuit.
1.10 Include allowance for new boiler(s) venting per manufacturer’s recommendations
1.11 Includes labeling and identifying all new equipment.
1.12 Includes all necessary material handling and shipping and rigging and lifting per the project requirements.
1.13 Includes complete start up by factory qualified personnel including performance verification and warranty registration
1.14 Includes all work to be performed in a safe and workmanlike manner, per all MIOSHA rules, regulations and guidelines.
1.15 Includes all work to be performed in strict accordance with local codes and governance.
1.16 Provides owner’s training on operation and maintenance of installed systems.
1.17 To include two (2) bound copies of commissioning reports with all critical parameters recording in spreadsheet format, all pertinent operational and maintenance manuals and documentation.
1.18 To include warranty certificate with date of substantial completion.
1.19 Include cost for State of Michigan mechanical permit fees, and plan review fees.
1.20 All garbage, waste materials and old equipment (i.e. Boilers, Pumps, Venting) will be removed off-site by the Respondent.
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