Attachment 1 Scope of Work (SOW).doc

TABLE OF CONTENTS

DIVISION 1- GENERAL REQUIREMENTS

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

1530 – HEATING EQUIPMENT

1551 – HOT WATER PIPING

DIVISION 16 – ELECTRICAL

1605 – ELECTRICAL SYSTEMS

DIVISION 1

SECTION 0101

SUMMARY OF WORK

The work consists of providing all labor, material, and equipment to replace all components of the existing hot water heating system serving the feedmill control floor and the basement below the control floor at the feedmill, Bldg. #3-24. This shall include, but shall not necessarily be limited to the following:

1. Removal of 1-500 Btuh hot water condensing boiler and all other material and equipment associated with the boiler and heating operation. This shall include the expansion tank, hot water reservoir (Boiler Buddy), pump, piping, gauges, and insulation.

2. Removal of combustion air fan and closure of this opening on the south wall of the boiler room.

3. Removal of existing exhaust duct and closure of the roof opening if not reused.

4. Removal of 6 forced air hot water unit heaters and all piping, fittings, valves, pumps, and pipe insulation to these heaters.

5. Removal of electrical components including wiring, conduit not reused, thermostats, and all other electrical components comprising the existing hot water heating system.

6. Removal of existing gas line strainer, flow meter, pressure regulator, valves, piping, safety valve, gauges.

7. Installation of one new hot water condensing boiler with all safeguards (including new emergency boiler shutdowns) and components required for complete operation of the hot water heating system. Also included are the exhaust duct and combustion air duct.

8. Installation of 6 new forced air hot water unit heaters.

9. Installation of insulation on all hot water pipe. This shall include pipe in boiler room and in feedmill control floor and basement.

10. Installation of a hot water reservoir, expansion tank, zone pumps, pipe, boiler pump, pump controller, check valves, air vents, ball valves, thermostats, and all other components required for a complete and functioning hot water heating system.

11. Installation of combustion air fan, gravity damper, pleated filter holder, and duct for fan and filter holder. Fan shall be for commercial use and shall provide a minimum of 250 cfm. Filter holder shall be for a nominal 9” x 12” filter.

12. Installation of new natural gas pipe, valves, strainer, regulators, safety valve, pressure gauges.

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. Valves x x

b. Boiler x x

c. Unit Heaters x

d. Pumps x

d. Pipe Insulation x

e. Piping, Fittings x

f. Pump Controller x

g. Pressure gauges, Thermometers x

h. All hydronic components x

i. All items under Division 16 x

j. Combustion air fan, damper 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.

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.

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.

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. Rm. #53 shall be left in a hose clean condition upon completion. Owner will sanitize.

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.

0180-1

DIVISION 2

SECTION 0211

DEMOLITION AND REMOVAL

1. General:

a. This section includes the removal of all components of existing heating system serving the feedmill control floor and basement below the control floor. This shall include the following:

1. One (1) packaged 500 Btuh ModCon hot water condensing boiler, Boiler Buddy, pumps, expansion tank, and associated pipe, valves, fittings, insulation, wiring, conduit

2. Boiler exhaust duct and combustion air duct and fan.

3. 6 hot water unit heaters and piping, valves, fittings, insulation, wiring, conduit for these heaters.

4. 4 existing thermostats.

5. Gas line including valves, strainer, regulators, gas meter, fittings.

This shall include the control panel, starter, all conductors and conduit from the existing starter to the existing boiler, 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 boiler and associated equipment.

c. 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.

d. Contractor shall repair walls and roof where stacks, vents, duct, doors, etc. are removed. Materials and methods for repairing walls and roof shall match those existing.

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.” Refrigerant and oil shall be properly reclaimed and recycled according to the applicable regulations. The Clean Air Act Amendment of 1990 shall be strictly followed.

3. Protection of existing facility:

0211-1

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. Roof and Wall Repair:

a. Contractor shall repair wall and roof where stacks, vents, combustion air, etc. were removed. Materials and methods to match those existing shall be used.

5. Schedule:

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.

6. 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.

0211-2

SECTION 1515

GAS PIPING

1. General:

a. Furnish and install a complete system of 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:

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.

g. Gas pressure regulator shall regulate gas pressure at the inlet to 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.

1515-1

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.

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

1515-2

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.

1515-3

SECTION 1530

HEATING EQUIPMENT

1. Scope:

a. The work consists of providing all labor, equipment, materials, etc, to furnish and install a new factory assembled hot water condensing boiler, a circulating hot water surge tank, and forced air horizontal unit heaters. Equipment shall be installed complete for a fully functioning hot water hydronic heating system with all equipment including piping, insulation, valves, gauges, thermometers, etc. required for efficient and proper operation, testing, and maintenance. Other than the boiler room, equipment shall be for Div I, Class II, Group G atmosphere.

2. Quality Assurance:

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

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

1. ANSI Z21.13 5. UMC

2. NFPA 54 National Fuel Gas Code 6. UEC

3. NFPA 85 7. UL

4. ASME CSD-1 Controls and Safety Devices 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 boiler provides 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 a complete and operable boiler.

2. ASME, UL, and CSD-1 certification

3. The specified tests have been satisfactorily performed

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.

1530-1

1. 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.

2. Existing Boiler (To be removed, see “Demolition” section)

a. Steam Boiler, Bldg. #3-25: The existing boiler is a 500 Btuh hot water condensing boiler.

3. Products

b. Hot Water Boiler

General: Boiler shall be factory packaged and shall include boiler, burner, painted steel jacket with fiberglass insulation, controls and accessories, all piped and wired for single point field connections to water, fuel, electrical, vent, and blow down 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 tested at 150 psig, minimum, in accordance with Section (I or IV) of ASME code.

1. Performance: Boiler shall have a minimum turndown ratio of 15:1 with no more than 20% excess air at any firing level. Overall fuel to hot water efficiency shall be 94%, as a minimum. Written verification of overall efficiency shall be provided.

2. Boiler Design

a. Boiler shall comply with the energy requirements of the latest edition of the ASHRAE 90.1 Standard and the minimum efficiency requirements of the latest edition of the ASHRAE 103 Standard. Boiler shall be certified for indoor installation.

b. The boiler shall be supplied with a gas valve designed with negative pressure regulation and shall be equipped with a variable speed blower system to precisely control the fuel/air mixture to provide modulating boiler firing rates for maximum efficiency. The boiler shall operate in a safe condition at a de-rated output with gas supply pressures as low as 4 inches of water column to 14” WC maximum at full fire.

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

1530-2

d. The boiler vent shall include a stack thermometer.

e. Boiler jacket shall be constructed with a heavy gauge steel jacket assembly, primed and pre-painted on both sides. The boiler jacket shall afford easy access to all components through access doors. The combustion chamber shall be sealed and completely enclosed, independent of the outer jacket assembly, so that integrity of the outer jacket does not affect a proper seal.

f. The boiler shall be equipped with a condensate collection system equipped with an internal float switch which will protect the boiler from condensation backing up into the combustion chamber. The condensate collection system will be equipped with a 2” IPD threaded cleanout port to allow for easy cleaning and sediment removal.

3. Gas Train

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

4. Boiler Controls

a. The control system shall have a LED display for boiler set-up, boiler status and boiler diagnostics. All components shall be easily accessed and serviceable from the front, right and left side of the jacket. The boiler shall be supplied with a temperature/pressure gauge (field installed), high limit temperature control with manual reset, ASME certified pressure relief valve, outlet water temperature sensor, return water temperature sensor, blocked vent pressure switch, flue temperature sensor, and built-in freeze protection. The boiler shall also be equipped with an outdoor air reset function. The manufacturer shall verify proper operation of the burner, controls, safety devices and the heat exchanger by connection to water and venting for a factory fire test prior to shipping. High and low gas pressure switches and UL 353 approved low water cut-off switch shall be provided.

5. Products:

a. Hot Water Boiler: Provide and install one (1) new natural gas fired, hot water condensing boiler having a modulating input rating of

750,000 Btu/hr. It shall have a stainless steel fire tube heat exchanger.

It shall be as manufactured by AERCO and shall be a model BMK 750, standard Benchmark hot water condensing boiler, or equal. Boiler controller shall be equivalent to the Edge control.

1530-3

b. Horizontal Forced Air Unit Heater: Units shall be rated at a nominal 95,000 Btuh input capacity with adjustable horizontal directional vanes. Units UH 1 and UH 2 shall be for Class II, Div. I, Group G, atmospheres. Units UH 1, UH 2, and UH 3 shall be as manufactured by Sterling, HS series or equal. The 3 basement units shall be wired for 480 V, 3 phase while the 2 units on the main floor and the unit in the boiler room shall be wired for 120 V, 1 phase.

c. Boiler Circulation Surge Tank: To prevent short cycling of the boiler, a surge tank shall be included as shown on the drawings. It shall be a model #BB-80

(“Boiler Buddy”) as manufactured by Hot Water Products, or equal.

c. Controller for controlling zone pumps and unit heaters shall be as manufactured by Taco, Grundfos, Bell & Gossett, or equal.

7. Boiler Concrete Pad

a. Existing concrete boiler pad may be used for new boiler. If necessary to accommodate new boiler, concrete pad shall be enlarged and doweled into existing pad.

8. Exhaust Vent and Combustion Air

a. Combustion air shall be a direct vent system with horizontal sidewall termination or as recommended by the manufacturer.

b. Exhaust vent shall be a direct vertical roof top termination or as recommended by the manufacturer.

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 one (1) boilers is three (3) days.

1530-4

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:

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.

1530-5

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

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 heat exchanger shall be warranted for 10 years. The control panel shall be warranted for 2 years. All other parts shall be warranted for 18 months.

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.

1530-6

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.

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

e. 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.

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

1530-7

SECTION 1551

HOT WATER, CONDENSATE PIPING

1. General:

a. The work shall include furnishing, installing, and testing of hot water, boiler feed water piping. This shall include piping, flanges, circulating pumps, expansion tank, backflow preventer, air separator, bolting, gaskets, valves, fittings, flow control equipment, and other hydronic equipment and associated appurtenances necessary for a complete and operable hydronic heating system. Work includes modifications and connections to existing water and condensate systems.

b. Hot water and 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. Hot Water, Water Piping:

1. Piping shall be welded or threaded, Schedule 40 black steel pipe conforming to ASTM A53 Grade A and B to the extent shown on the drawings..

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.

1551-1

d. Strainers:

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. Check Valves:

Check valves shall be swing type and as manufactured by Nibco, Watts, DynaQuip, or equal.

g. Cast Iron Gate Valves:

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

h. Globe and Angle Valves:

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

i. 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.

j. Drain Valves:

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

k. Air Vent Valves:

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

1551-2

l. Pressure relief, Pressure Limiting, Venting:

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

m. Pressure Gauges:

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.

n. Zone Circulating Pumps:

1. Circulating pumps shall be provided for each of the two (2) zones. They shall be as manufactured by Grundfos, Taco, Bell & Gossett, or equal. The pumps shall be 1/2 hp, 115 V, 1 phase, TEFC. Pumps shall produce approximately 30 gpm at 25’ head.

o. Main Circulating Pump:

1. Main circulating pump shall be as manufactured by Grundfos, Taco, Bell &

Gossett, or equal. The pump shall be ¾ hp, 460 V, 3 phase, TEFC. Pump shall produce approximately 55 gpm at 20’ head.

p. Backflow Preventer:

1. Backflow preventer shall be as manufactured by Watts, Nibco, or equal.

q. 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.

1551-3

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.

j. Pipe Insulation:

All heating water pipe shall be insulated with 1-1/2”” thick fiberglass jacketed insulation with pvc jacket for elbows.

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, Piping:

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 water, or compressed air, as necessary, to remove rust, scale, oil, and debris. Before final connections are made, wash interior of piping with water. 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. to install insulation. Provide unions and flanges, as necessary, to permit removal of tube bundles, control valves, etc. Provide shutoff valves to vessels to permit servicing without draining system. Locate valves so as not to interfere with head removal. Pipe penetrations from boiler room into feedmill control floor shall be sealed around pipe (after insulation installed) to prevent grain dust from migrating into boiler room.

1551-4

b. Valves:

Install at equipment to allow maintenance or isolation, and to establish proper and sequential operation of complete system. Shell and tube liquid coolers shall have fluid valves installed so that tubes are accessible for cleaning or replacing. Provide globe valves or plug cocks where required to regulate flow to obtain equal distribution of fluid handled.

c. Pressure Gages and Thermometers:

1. Pressure Gage: Provide a shutoff valve or pet cock between pressure gages and pipe line.

2. Thermometers: Provide thermometers and thermal sensing elements of control valves with a separate socket. Install sockets (thermowells) in pipe lines in such a manner to sense temperature of flowing fluid and minimize obstruction to flow.

d. Identification of Piping:

Identify piping in accordance with 29CFR 1910.144, ANSI A13.1, ANSI 253.1. All pipe shall be clearly marked with contents and flow direction with labels specifically for intended purpose. Tag gages, thermometers, and valves with tags of brass.

e. Field Inspections:

Prior to initial operation, examine and inspect piping systems for conformance to plans and specifications.

f. Field Tests:

After completion of piping installation and prior to initial operation, conduct hydrostatic tests on piping. Test piping systems at 1-1/2 design pressures with water. Before tests, remove or isolate gages and other apparatus in new and old systems which may be damaged. Repair leaks. Do not caulk joints. Install a calibrated pressure gage in system to observe any loss in pressure. Maintain test pressure for a sufficient period of time. Correct defects.

g. Startup:

Start up and initially operate hot water, water, steam, and condensate water systems. During this time, periodically clean strainers until no further accumulation of foreign material occurs. Correct deficiencies.

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DIVISION 16

SECTION 1605

ELECTRICAL SYSTEMS

1. Scope:

2. The work covered by this section of the specifications consists of furnishing all labor, equipment, supplies, materials and in performing all operations necessary for installing a hot water boiler and associated equipment, a starter for boiler motor, circulating pumps, circulating pump controller, thermostats, hot water unit heaters, and all other electrical components as required for a complete boiler installation for these systems as shown on the drawings for Building #3-25. Also included is the installation of emergency shutdown switches for new boiler at all doors of egress to boiler room of Bldg. #3-24 interlocked to boiler controls. Other than the boiler room, electrical equipment and material shall be for Div I, Class II, Group G atmosphere.

2. General:

a. Rules:

The installation shall be in strict accordance with the requirements of the latest rules of the National Electrical Code and the National Fire Protection Association and as indicated on the drawings.

b. Coordination:

The drawings indicate the extent and general location and arrangement of equipment, conduit and wiring. The contractor shall study building plans and details so that the outlets and equipment shall be properly located and readily accessible. Equipment and outlets shall be located to avoid interference with mechanical or structural features.

c. Materials and Schedules:

As soon as practical and before starting installation of any material and equipment, the contractor shall submit to the Contracting Officer’s Representative (COR) for approval, a complete list in triplicate of materials and equipment proposed for installation. This list shall include manufacturer’s names and materials equipment identification such as styles, types, catalog numbers, etc., to permit ready and complete identification. The label or listing of the Underwriters’ Laboratories, Inc. will be acceptable as evidence that the materials or equipment conform to the applicable standards of that Agency.

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3. Materials and Equipment:

a. Raceway

1. All wiring exposed within the building shall be installed in raceways. Raceway shall be installed exposed in general. Conduit shall be concealed in finished areas.

2. Raceways exposed to weather, and any other area subject to damage shall be zinc-coated, rigid steel conduit.

3. Rigid steel conduit and steel electrical metallic tubing shall be hot dipped galvanized as manufactured by Allied Tube and Conduit Corporation, or approved equal. IMC conduit shall be as manufactured by Allied Tube and Conduit Corporation, or approved equal.

4. No raceway smaller than 3/4” shall be used unless otherwise noted. Flexible conduit may be used where conditions warrant its use.

5. All conduits shall be securely supported by means of approved conduit hangers. Suspension of conduits by approved wire hangers and clips shall be permitted only for single conduits ¾” and smaller.

6. All conduit shall be run parallel with the lines of the building.

7. Existing conduit may be reused as approved by owner.

b. Boxes:

1. Boxes and outlets shall be hot dipped galvanized Raco or equal and shall be water tight.

2. Conduit fittings shall be as manufactured by T & B or Raco. Bushings on all conduits 1” and larger shall be the O.Z. Type “B” insulated type, with body, threads and conduit stop of malleable iron or steel, and with phenolic insulation molded on an irregular surface at the top so that it becomes an integral part of the bushing. Grounding bushings shall be the O.Z. Type “BL”.

3. Provide minimum NEC required size pull boxes unless larger box is noted.

d. Conductors:

1. All conductors shall be copper.

2. Conductor insulation shall be of the following type:

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a. THHN, unless otherwise noted.

3. No wire shall be smaller than #12 unless otherwise noted, except that wiring for signal and pilot control circuits may be #14.

4. Insulated ground wires shall be run with circuit conductors for all circuits.

5. All conductors shall be color coded in their entirety for wire sizes where color coding is commercially available. Phase wires of different multi-wire circuits in same raceway shall be of different color to provide identification.

6. Conductors in sizes which are not commercially available in color coding shall be taped with corresponding colors at all termination points and in all pullboxes, wireways, gutters, etc. All conductors found not to conform to these requirements will be directed to be removed and replaced as specified at no additional cost for the Owner.

7. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Junction boxes may be utilized where required. All outlet, junction and pull boxes used with rigid conduit shall be water tight.

8. Splices and taps for smaller than #6 wire shall be made with 3M Ideal, or Buchanan twist-on insulated connectors. Connectors of the porcelain cup type, with or without metal inserts, shall not be used. Splices in wire #6 and larger, shall be made with approved solderless lugs. If any other type of connector is proposed for use in any size conductor, it shall be specifically submitted for approval prior to use.

e. Combination starter for boiler motor shall be supplied and shall be for 480 V, 3 phase, 60 Hz. Starter shall include all fuses, heaters, control transformers, etc. Control power shall be 120 volt. Starter shall have two extra N.O. contacts, overload protection on each of the three phases, fused control circuits.

f. Thermostats on control floor and basement shall be explosion proof and shall be selected to cover, as a minimum a temperature range of 35 to 75 F. Thermostat in boiler room is not required to be explosion proof.

g. Any other electrical devices in addition to the receptacles and switches previously mentioned shall have Carlon, or equal cover plates.

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4. Installation and Workmanship:

a. The installation of all electrical work shall be in accordance with the drawings, these specifications, and shall be accomplished by electricians with a minimum of a “journeyman’s” license.

b. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Conductor identification shall be color coded.

c. All conduit shall be interconnected for continuous electrical connection to ground. All raceways, etc., shall be grounded in accordance with Article 250 of the National Electrical Code. All exposed non-current carrying metallic parts of electrical equipment and raceway systems shall be grounded.

d. All motors and receptacles shall be grounded with a green ground wire extending from the motor or wiring device to the ground lug within the breaker panels.

e. Upon completion of the installation, make tests for operation with and to the satisfaction of the Owner.

f. Motor Wiring: Flexible conduit “runouts” shall be installed in conduit to each motor. Conduit shall be of a liquid tight type.

g. Emergency Boiler Shutdown: Installation of emergency boiler shutdown switches and controls shall be installed per the requirements of NBIC and ASME CSD-1 for boiler in mechanical room.

h. Intake combustion air fan: Fan shall be provided 120 V power for existing panel “A” located in boiler room. Fan shall be wired into boiler controls such that fan turns on whenever boiler is operating and fan shall turn off when boiler is off.

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