23_52_00_HEATING_BOILERS.pdf

23 52 00-1 03/07/12

SECTION 23 52 00

HEATING BOILERS

PART 1 GENERAL

1.1 REFERENCES

1.1.1 The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Unless other wise noted, the latest published version and/or revision shall be used.

1.1.1.1 AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA)

a. AMCA 801 Industrial Process/Power Generation Fans: Specification

Guidelines

1.1.1.2 AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

a. ASHRAE 52.1 Gravimetric and Dust-Spot Procedures for Testing Air-Cleaning

Devices Used in General Ventilation for Removing Particulate

Matter

1.1.1.3 AMERICAN WATER WORKS ASSOCIATION (AWWA)

a. AWWA C606 Grooved and Shouldered Joints

1.1.1.4 AMERICAN WELDING SOCIETY (AWS)

a. AWS A5.8 Specification for Filler Metals for Brazing and Braze Welding

b. AWS B2.2 Brazing Procedure and Performance Qualification

1.1.1.5 ASME INTERNATIONAL (ASME)

a. ASME B1.20.1 Pipe Threads, General Purpose (Inch)

b. ASME B16.11 Forged Fittings, Socket-Welding and Threaded

c. ASME B16.15 Cast Bronze Threaded Fittings Classes 125 and 250

d. ASME B16.18 Cast Copper Alloy Solder Joint Pressure Fittings

e. ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral Wound, and Jacketed

f. ASME B16.22 Standard for Wrought Copper and Copper Alloy Solder Joint

Pressure Fittings

g. ASME B16.26 Standard for Cast Copper Alloy Fittings for Flared Copper Tubes

h. ASME B16.3 Malleable Iron Threaded Fittings, Classes 150 and 300

i. ASME B16.34 Valves - Flanged, Threaded and Welding End

j. ASME B16.39 Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300

23 52 00-2 03/07/12

k. ASME B16.4 Standard for Gray Iron Threaded Fittings; Classes 125 and 250

l. ASME B16.5 Standard for Pipe Flanges and Flanged Fittings: NPS 1/2

Through NPS 24

m. ASME B16.9 Standard for Factory-Made Wrought Steel Buttwelding Fittings

n. ASME B19.3 Safety Standard for Compressors for Process Industries

o. ASME B31.1 Power Piping

p. ASME B31.5 Refrigeration Piping and Heat Transfer Components

q. ASME B40.100 Pressure Gauges and Gauge Attachments

r. ASME BPVC SEC IV Boiler and Pressure Vessel Code; Section IV, Recommended

Rules for the Care and Operation of Heating Boilers

s. ASME BPVC SEC IX Boiler and Pressure Vessel Code; Section IX, Welding and

Brazing Qualifications

t. ASME BPVC SEC VIII D1 Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels

Division 1 - Basic Coverage

u. ASME CSD-1 Control and Safety Devices for Automatically Fired Boilers

v. ASME PTC 10 Performance Test Code on Compressors and Exhausters

1.1.1.6 ASTM INTERNATIONAL (ASTM)

a. ASTM A 105/A 105M Standard Specification for Carbon Steel Forgings for Piping

Applications

b. ASTM A 167 Standard Specification for Stainless and Heat-Resisting

Chromium-Nickel Steel Plate, Sheet, and Strip

c. ASTM A 183 Standard Specification for Carbon Steel Track Bolts and Nuts

d. ASTM A 193 Standard Specification for Alloy-Steel and Stainless Steel

Bolting Materials for High-Temperature Service

e. ASTM A 234 Standard Specification for Piping Fittings of Wrought Carbon

Steel and Alloy Steel for Moderate and High Temperature

Service

f. ASTM A 515 Standard Specification for Pressure Vessel Plates, Carbon Steel, for Intermediate- and Higher-Temperature Service

g. ASTM A 516 Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

h. ASTM A 53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

i. ASTM A 536 Standard Specification for Ductile Iron Castings

j. ASTM A 653 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip

Process

k. ASTM B 32 Standard Specification for Solder Metal

l. ASTM B 62 Standard Specification for Composition Bronze or Ounce Metal

23 52 00-3 03/07/12

Castings

m. ASTM B 75 Standard Specification for Seamless Copper Tube

n. ASTM B 813 Standard Specification for Liquid and Paste Fluxes for Soldering of Copper and Copper Alloy Tube

o. ASTM B 828 Standard Practice for Making Capillary Joints by Soldering of

Copper and Copper Alloy Tube and Fittings

p. ASTM B 88 Standard Specification for Seamless Copper Water Tube

q. ASTM C 155 Standard Specification for Insulating Firebrick

r. ASTM C 27 Fireclay and High-Alumina Refractory Brick

s. ASTM C 34 Structural Clay Load-Bearing Wall Tile

t. ASTM C 401 Alumina and Alumina-Silicate Castable Refractories

u. ASTM D 1784 Standard Specification for Rigid Poly(Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC)

Compounds

v. ASTM D 2000 Standard Classification System for Rubber Products in

Automotive Applications

w. ASTM D 596 Reporting Results of Analysis of Water

x. ASTM F 1097 Mortar, Refractory (High-Temperature, Air-Setting)

y. ASTM F 1139 Steam Traps and Drains

z. ASTM F 876 Crosslinked Polyethylene (PEX) Tubing

1.1.1.7 COPPER DEVELOPMENT ASSOCIATION (CDA)

a. CDA A4015 Copper Tube Handbook

1.1.1.8 CSA AMERICA, INC. (CSA/AM)

a. CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

1.1.1.9 EXPANSION JOINT MANUFACTURERS ASSOCIATION (EJMA)

a. EJMA Stds EJMA Standards

1.1.1.10 HYDRONICS INSTITUTE DIVISION OF GAMA (HYI)

a. HYI-005 I=B=R Ratings for Boilers, Baseboard Radiation and Finned

Tube (Commercial)

b. HYI-400 Radiant Floor Heating

1.1.1.11 MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

a. MSS SP-110 Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends

b. MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and

Unions

23 52 00-4 03/07/12

c. MSS SP-58 Standard for Pipe Hangers and Supports - Materials, Design and

Manufacture

d. MSS SP-69 Standard for Pipe Hangers and Supports - Selection and

Application

e. MSS SP-70 Standard for Cast Iron Gate Valves, Flanged and Threaded Ends

f. MSS SP-71 Standard for Gray Iron Swing Check Valves, Flanged and

Threaded Ends

g. MSS SP-72 Standard for Ball Valves with Flanged or Butt-Welding Ends for

General Service

h. MSS SP-73 Brazing Joints for Copper and Copper Alloy Pressure Fittings

i. MSS SP-78 Cast Iron Plug Valves, Flanged and Threaded Ends

j. MSS SP-80 Bronze Gate, Globe, Angle and Check Valves

k. MSS SP-85 Standard for Cast Iron Globe & Angle Valves, Flanged and

Threaded Ends

1.1.1.12 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)

b. NEMA MG 1 Standard for Motors and Generators

1.1.1.13 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances

b. NFPA 31 Installation of Oil Burning Equipment

c. NFPA 54 National Fuel Gas Code

d. NFPA 70 National Electrical Code - 2008 Edition

e. NFPA 85 Boiler and Combustion Systems Hazards Code

1.1.1.14 UNDERWRITERS LABORATORIES (UL)

a. UL 1738 Venting Systems for Gas-Burning Appliances, Categories II, III and IV

b. UL 296 Oil Burners

c. UL 726 Oil-Fired Boiler Assemblies

d. UL 795 Commercial-Industrial Gas Heating Equipment

e. UL Gas&Oil Dir Flammable and Combustible Liquids and Gases Equipment

Directory

1.2 SUBMITTALS

Government approval may be required on any of the following items. Items requiring submittals will be listed on the AF Form 66. Provide copies of all submittals per the requirements in Section 01 33 00, Submittal Procedures, or as listed on the AF Form 66.

1.2.1.1 SD-02 Shop Drawings

23 52 00-5 03/07/12

a. Piping Installation

b. Installation

(1) Detail drawings consisting of equipment layout including installation details and electrical connection diagrams; combustion and safety control diagrams; ductwork layout showing the location of supports and hangers, typical hanger details, gauge reinforcement, reinforcement spacing rigidity classification, and static pressure and seal classifications; and piping layout showing the location of guides and anchors, the load imposed on each support or anchor (not required for radiant floor tubing), and typical support details. Include on the drawings any information required to demonstrate that the system has been coordinated and will properly function as a unit and to show equipment relationship to other parts of the work, including clearances required for operation and maintenance.

1.2.1.2 SD-03 Product Data

a. Materials and Equipment

Manufacturer's catalog data included with the detail drawings for the following items:

(1) Boilers

(2) Fuel Burning Equipment

(3) Combustion Control Equipment

(4) Pumps

(5) Fittings and Accessories

Data showing model, size, options, etc., that are intended for consideration. Data submitted shall be adequate to demonstrate compliance with contract requirements. Data shall include manufacturer's written installation instructions and manufacturer's recommendations for operation and maintenance clearances for each item.

b. Spare Parts

(1) Spare parts data for each different item of material and equipment specified.

c. Heating System Tests

d. Fuel System Tests

e. Welding

(1) A copy of qualified welding procedures, at least 2 weeks prior to the start of welding operations.

(2) A list of names and identification symbols of qualified welders and welding operators, at least 2 weeks prior to the start of welding operations.

f. Field Instructions

(1) System layout diagrams that show the layout of equipment, piping, and ductwork and typed condensed operation manuals explaining preventative maintenance procedures, methods of checking the system for normal, safe operation, and procedures for safely starting and stopping the system, framed under glass or laminated plastic, at least 2 weeks prior to the start of related testing. After approval, these items shall be posted where directed.

23 52 00-6 03/07/12

g. Tests

(1) Proposed test schedules for the heating system and fuel system tests, at least 2 weeks prior to the start of related testing.

1.2.1.3 SD-06 Test Reports

a. Heating System Tests

b. Fuel System Tests

(1) Test reports for the heating system tests and the fuel system test, upon completion of testing complete with results.

1.2.1.4 SD-07 Certificates

a. Continuous Emissions Monitoring

(1) Written certification by the boiler manufacturer that each boiler furnished complies with

Federal, state, and local regulations for emissions. The certification shall also include a description of applicable emission regulations. If any boiler is exempt from the emission regulations, the certification shall indicate the reason for the exemption.

1.2.1.5 SD-10 Operation and Maintenance Data

a. Operation and Maintenance Instructions

(1) Complete manuals listing step-by-step procedures required for system startup, operation, shutdown, and routine maintenance, at least 2 weeks prior to field training. The manuals shall include the manufacturer's name, model number, parts list, simplified wiring, control diagrams, and troubleshooting guide for each item of equipment.

1.3 QUALITY ASSURANCE

1.3.1 WELDING: Boilers and piping shall be welded and brazed in accordance with qualified procedures using performance-qualified welders and welding operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.1. Notify the Contracting Officer 24 hours in advance of tests, and the tests shall be performed at the work site if practical. The welder or welding operator shall apply the personally assigned symbol near each weld made as a permanent record. Structural members shall be welded in accordance with Section 05 05 23 Welding, Structural.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Protect equipment delivered and placed in storage from the weather, humidity and temperature variations, dirt and dust, and other contaminants.

1.5 EXTRA MATERIALS

1.5.1 Submit spare parts data for each different item of material and equipment specified, after approval of the detail drawings and no later than 2 months prior to the date of beneficial occupancy. Include in the data a complete list of parts and supplies, with current unit prices and source of supply, and a list of the parts recommended by the manufacturer to be replaced after 1 file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/05%2005%2023.doc

23 52 00-7 03/07/12 and 3 years of service.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

2.1.1.1 Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

2.1.2 Nameplates

2.1.2.1 Secure a plate to each major component of equipment containing the manufacturer's name, address, type or style, model or serial number, and catalog number. Also, display an ENERGY

STAR label as applicable. Each pressure vessel shall have an approved ASME stamp.

2.1.3 Equipment Guards

2.1.3.1 Belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts exposed to personnel contact shall be fully enclosed or guarded in accordance with OSHA requirements. High temperature equipment and piping exposed to contact by personnel or where it creates a potential fire hazard shall be properly guarded or covered with insulation of a type specified. Catwalks, operating platforms, ladders, and guardrails shall be provided where shown and shall be constructed in accordance with Section 05 50 13 Miscellaneous Metal

Fabrications.

2.2 BOILERS

Each boiler shall have the output capacity in British thermal units per hour (Btuh) as indicated when fired with the specified fuels. The boiler shall be furnished complete with gas burning equipment, boiler fittings and trim, automatic controls, forced or induced draft fan, natural draft/atmospheric burner, electrical wiring, insulation, piping connections, and protective jacket.

The boiler shall be completely assembled and tested at the manufacturer's plant. Boiler auxiliaries including fans, motors, drives, and similar equipment shall be provided with at least 10 percent excess capacity to allow for field variations in settings and to compensate for any unforeseen increases in pressure losses in appurtenant piping and ductwork. However, the boiler safety devices shall not be sized for a 10 percent excess capacity. The boiler and its accessories shall be designed and installed to permit ready accessibility for operation, maintenance, and service. Boilers shall be designed, constructed, and equipped in accordance with ASME BPVC SEC IV. Each boiler shall be of the condensing type and designed for water steam service as specified herein. The boiler capacity shall be based on the ratings shown in HYI-005 or as certified by the American Boiler

Manufacturers Association, or American Gas Association.

2.2.1 Condensing Boiler

file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/05%2050%2013.doc

23 52 00-8 03/07/12

2.2.1.1 Each boiler shall be a self-contained packaged type, complete with accessories, mounted on a structural steel base or a steel base which is integral to the boiler shell. Each boiler shall conform to the commercial design used by the manufacturer and shall permit free thermal expansion without placing undue stress on any part of the boiler. Each boiler which experiences the formation of condensate within the flue gas shall be specifically designed for condensing application. Each boiler shall withstand the corrosive effects of condensate for each part which may be in contact with the condensate at all possible operating conditions.

Each boiler shall be provided with a separate air intake, exhaust, and condensate drain. Each boiler shall be designed to withstand the water temperature differentials anticipated at the required operating conditions without experiencing any damage due to thermal shock.

2.2.2 Hot Water Heating Boilers

2.2.2.1 The hot water heating boiler shall be capable of operating at the specified maximum continuous capacity without damage or deterioration to the boiler, its setting, firing equipment, or auxiliaries. The rated capacity shall be the capacity at which the boiler will operate continuously while maintaining at least the specified minimum efficiency. The following boiler design conditions shall be as indicated:

a. Boiler design pressure.

b. Operating pressure at boiler outlet.

c. Hot water temperature.

d. Temperature differential between boiler discharge and system return.

e. Water pressure drop.

f. Outdoor ambient air temperature.

g. Site elevation.

h. Maximum continuous capacity.

i. Rated capacity.

j. Maximum exhaust stack temperature.

k. Condensing boilers shall have an Annual Fuel Utilization Efficiency of at least 90 percent.

2.3 FUEL BURNING EQUIPMENT

Boiler shall be designed to burn gas, oil or combination gas and oil as indicated. Each boiler shall comply with Federal, state, and local emission regulations. As a minimum, the following emission requirements shall be met:

NOx - parts per million (ppm) corrected to 3% 02 as indicated.

SO2 - parts per million (ppm) corrected to 3% 02 as indicated.

Particulate - parts per million (ppm) corrected to 3% 02 as indicated.

2.3.1 Burners

2.3.1.1 Gas Burners and Controls

23 52 00-9 03/07/12

Burners shall be UL approved mechanical draft burners with all air necessary for combustion supplied by a blower where the operation is coordinated with the burner or natural draft/atmospheric burners as indicated. Burner shall be provided complete with fuel supply system in conformance with the following safety codes or standards:

a. Gas-fired units with inputs greater than 400,000 Btuh per combustion chamber shall conform to

UL 795. Gas fired units less than 12,500,000 Btuh input shall conform to CSA 4.9. Single and multiple burner gas-fired units greater than or equal to 12,500,000 Btuh input shall conform to

NFPA 85.

2.3.2 Draft Fans

Fans conforming to AMCA 801 forced-draft and induced-draft shall be furnished as an integral part of boiler design. Fans shall be centrifugal with backward-curved blades, radial-tip blades or axial flow type. Each fan shall be sized for output volume and static pressure rating sufficient for pressure losses, excess air requirements at the burner, leakages, temperature, and elevation corrections for worst ambient conditions, all at full combustion to meet net-rated output at normal firing conditions, plus an overall excess air volume of 10 percent against a 20 percent static overpressure. Noise levels for fans shall not exceed 85 decibels in any octave band at a 3 foot station. Forced draft fan bearings shall be air cooled. Induced-draft fans shall be designed for handling hot flue gas at the maximum outlet temperature in the boiler. Induced draft fan housings shall be provided with drain holes to accommodate the drainage of condensation. Induced draft fan bearings shall be air-cooled or water-cooled. Induced draft fan scroll sheets and rotor blades shall have protective liners.

2.3.2.1 Draft Fan Control

a. Forced-draft centrifugal fans shall have inlet vane controls or shall have variable speed control where indicated. Inlet vanes shall be suitable for use with combustion control equipment.

Induced-draft centrifugal fans shall have outlet dampers and shall have variable speed control.

Induced-draft fans shall have inlet vane controls. Axial propeller fans shall have variable propeller pitch control.

2.3.2.2 Draft Fan Drives

a. Fans shall be driven by electric motors. Electric motor shall be drip proof, totally enclosed, nonventilated, totally enclosed fan cooled, totally enclosed fan-cooled, suitable for installation in a Class II, Division 1, Group F, hazardous location conforming to NFPA 70. Motor starter shall be magnetic across-the-line or reduced voltage start type with enclosure suitable for the operating environment and shall be furnished with four auxiliary interlock contacts.

2.3.3 Draft Damper

2.3.3.1 Boilers shall be provided with manual or automatic dampers, draft hoods, or barometric dampers as recommended by the boiler manufacturer to maintain proper draft in the boiler.

Draft damper shall be provided in a convenient and accessible location in the flue gas outlet from the boiler. Automatic damper shall be arranged for automatic operation by means of a damper regulator, furnace draft regulator or damper motor.

2.3.4 Ductwork

2.3.4.1 Air ducts connecting the forced-draft fan units with the plenum chamber shall be designed to convey air with a minimum of pressure loss due to friction. Ductwork shall be galvanized sheet

23 52 00-10 03/07/12 metal conforming to ASTM A 653. Ducts shall be straight and smooth on the inside with laps made in direction of air flow. Ducts shall have cross-break with enough center height to assure rigidity in the duct section, shall be angle iron braced, and shall be completely free of vibration.

Access and inspection doors shall be provided as indicated and required, with a minimum of one in each section between dampers or items of equipment. Ducts shall be constructed with long radius elbows having a centerline radius 1-1/2 times the duct width, or where the space does not permit the use of long radius elbows, short radius or square elbows with factory-fabricated turning vanes may be used. Duct joints shall be substantially airtight and shall have adequate strength for the service, with 1-1/2 x 1-1/2 x 1/8 inch angles used where required for strength or rigidity. Duct wall thickness shall be 16 gauge (0.0598 inch) for ducts 60 inches or less and 12 gauge (0.1046 inch) for ducts larger than 60 inches in maximum dimension.

Additional ductwork shall be in accordance with Section 23 00 00 Air Supply, Distribution, Ventilation and Exhaust System.

2.4 COMBUSTION CONTROL EQUIPMENT

Combustion control equipment shall be provided as a system by a single manufacturer. Field installed automatic combustion control system shall be installed in accordance with the manufacturer's recommendations and under the direct supervision of a representative of the control manufacturer. The boiler water temperature shall be controlled by a water temperature controller.

The equipment shall operate either electrically. On multiple boiler installations, each boiler unit shall have a completely independent system of controls responding to the load and to a plant master controller. If recording instruments are provided, a 1 year supply of ink and 400 blank charts for each recorder shall be furnished.

2.4.1 Electrical controls

2.4.1.1 Electrical control devices shall be rated for 0-10mA, 4-20mA, or 24 volts, and shall be connected as specified in Section 26 20 00 Interior Distribution System.

2.4.2 Water Temperature Controller

2.4.2.1 The controller shall be of sturdy construction and shall be protected against dust and dampness.

The thermostatic element shall be inserted in a separable socket installed in the upper part of the boiler near the water outlet or in the boiler return piping as indicated. Fixed position (on-off) and three position (high-low-off) controller shall operate on a 10 degree F differential over an adjustable temperature range of approximately 140 to 220 degrees F. Modulating controllers shall control the fuel burning equipment to maintain set boiler water temperature within 2 percent. Controller shall be furnished with necessary equipment to automatically adjust the setting to suit the outside weather conditions. The outside air reset controller shall be operated in such a manner that the operating temperatures required by the boiler manufacturer are not compromised.

2.4.3 Boiler Combustion Controls and Positioners

a. Modulating control function shall be accomplished using positioning type controls. Air flow ratio and fuel control valve shall be controlled by relative positions of operative levers on a jackshaft responding to a water temperature controller or steam pressure controller. Positioning type combustion control equipment shall include draft controls with synchronized fuel feed and combustion air supply controls, while and shall maintain the proper air/fuel ratio. The desired furnace draft shall be maintained within 0.01 inch of water column.

file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/23%2000%2000.doc file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/26%2020%2000.doc

23 52 00-11 03/07/12

2.4.4 Combustion Safety Controls and Equipment

2.4.4.1 Combustion safety controls and equipment shall be UL listed, microprocessor-based distributed process controller. The system shall include mounting hardware, wiring and cables, and associated equipment. The controller shall be mounted completely wired, programmed, debugged, and tested to perform all of its functions. The controller shall process the signals for complete control and monitoring of the boiler. This shall include maintaining boiler status, starting and stopping all control functions, sequencing control functions and signaling alarm conditions. The program shall be documented and include cross references in description of coils and contacts. Microprocessor shall be able to perform self diagnostics and contain a message center to provide operator with status and failure mode information. Controllers for each boiler shall be mounted on a separate, free standing panel adjacent to the boiler or for packaged boilers on the boiler supporting structure. Control systems and safety devices for automatically fired boilers shall conform to ASME CSD-1. Electrical combustion and safety controls shall be rated at 120 volts, single phase, 60 Hz and shall be connected as specified in

Section 26 20 00 Interior Distribution System. A 4 inch diameter alarm bell shall be provided and shall be located where indicated or directed. The alarm bell shall ring when the boiler is shut down by any safety control or interlock. Indicating lights shall be provided on the control panel. A red light shall indicate flame failure, and a green light shall indicate that the main fuel valve is open. The following shutdown conditions shall require a manual reset before the boiler can automatically recycle:

a. Flame failure.

b. Failure to establish pilot flame.

c. Failure to establish main flame.

d. Low-water and supplementary low-water cutoff.

e. High temperature cutoff or high pressure cutoff.

2.4.4.2 Low-water Cutoff

Low water cutoff shall be float actuated switch or electrically actuated probe type low-water cutoff. Float chamber shall be provided with a blow-down connection. Cutoff shall cause a safety shutdown and sound an alarm when the boiler water level drops below a safe minimum level. A safety shutdown due to low water shall require manual reset before operation can be resumed and shall prevent recycling of the burner. The cutoff shall be in strict accordance to the latest version of code,ASME CSD-1 Controls and Safety Devices for Automatically Fired

Boilers.

a. Supplementary Low-Water Cutoff: Supplementary low-water cutoff of the electrically operated probe type or float activated type shall be provided in addition to the low-water cutoff required above on each boiler. Supplementary low-water cutoff shall be mounted directly in the boiler shell and shall be set below the low-water cutoff required above.

2.4.4.3 Water Flow Interlock

a. Hot water boiler limit controls shall be provided to include protection for low boiler water flow and high boiler water temperature. The limit controls shall be interlocked with the combustion control system to effect boiler alarm and shutdown. The controls shall not allow boiler startup unless hot water flow is proven.

23 52 00-12 03/07/12

2.5 PUMPS

2.5.1 Hot Water and Boiler Circulating Pumps

2.5.1.1 Circulating pumps for hot water shall be electrically driven single-stage centrifugal type and have a capacity not less than indicated. Boiler circulating pumps shall be supported on a concrete foundation with a cast iron or structural steel base or by the piping on which installed and shall be flexible-coupled shaft. The boiler circulating pumps shall be vertical split case type. Hot water circulating pumps shall be supported on a concrete foundation with a cast iron or structural steel base or by the piping on which installed and shall have a flexible-coupled shaft. The hot water circulating pumps shall be vertical split case type. The pump shaft shall be constructed of corrosion-resistant alloy steel, sleeve bearings and glands of bronze designed to accommodate a mechanical seal, and the housing of close-grained cast iron. Pump seals shall be capable of withstanding 240 degrees F temperature without external cooling. The motor shall have sufficient power for the service required, shall be of a type approved by the manufacturer of the pump, shall be suitable for the available electric service, and shall conform to the requirements of paragraph Electrical Equipment. Each pump suction and discharge connection shall be provided with a pressure gauge as specified. The boiler and hot water circulating pump discharge heater shall be provided with a flow switch or pressure switch.

Flow switch unit shall be a self-contained swinging vane type to indicate fluid flow. Pressure switch unit shall be a self-contained snap action type to indicate fluid pressure. Switch shall be a SPDT with 120-volt, 15-ampere rating.

2.6 COLD WATER CONNECTIONS

2.6.1 Connections shall be provided which includes consecutively in line a strainer, reduced pressure principle backflow preventers, and water pressure regulator in that order in the direction of the flow. The reduced pressure principle backflow preventers shall be provided as indicated and in compliance with Section 22 00 00 Plumbing, General Purpose. Cold water fill connections shall be made to the water supply system as indicated. Necessary pipe, fittings, and valves required for water connections between the boiler and cold water main shall be provided as shown. The pressure regulating valve shall be of a type that will not stick or allow pressure to build up on the low side. The valve shall be set to maintain a terminal pressure of approximately, lately 5 psi in excess of the static head on the system and shall operate within a 2 psi tolerance regardless of cold water supply piping pressure and without objectionable noise under any condition of operation.

2.7 FITTINGS AND ACCESSORIES

Boiler fittings and accessories shall be installed with each boiler in accordance with ASME BPVC

SEC IV, unless otherwise specified.

2.7.1 Direct Vents

Direct venting shall be used for condensing type boilers. Both the air intake and exhaust vents shall be sized and located as indicated on the drawings and as recommended by the boiler manufacturer. A separate combustion air intake vent and exhaust vent shall be provided for each boiler.

2.7.1.1 Combustion Air Intake Vent

file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/22%2000%2000.doc

23 52 00-13 03/07/12

a. The combustion air intake piping shall be constructed of Schedule 40 PVC in accordance with

ASTM D 1784. The vent shall be suitable for the temperature at the boiler combustion air intake connection point. Each intake shall be provided complete with bird screen.

2.7.1.2 Exhaust Vent

a. The exhaust vent piping shall be constructed of Schedule 40 CPVC or stainless steel conforming to UL 1738 and the boiler manufacturer's recommendations. Plastic materials polyetherimide (PEI) and polyethersulfone (PES) are forbidden to be used for vent piping of combustion gases. The exhaust vent shall be suitable for the maximum anticipated boiler exhaust temperature and shall withstand the corrosive effects of the condensate. A 0.3125 inch diameter hole shall be provided in the stack not greater than 6 inches from the boiler flue outlet for sampling of the exit gases. A method shall be provided to seal the hole to prevent exhaust gases from entering the boiler room when samples are not being taken. Each exhaust stack shall be provided complete with bird screen.

2.7.2 Gaskets

2.7.2.1 Gaskets shall be nonasbestos material in accordance with ASME B16.20, full face or self-centering type. The gaskets shall be of the spiral wound type with graphite filler material.

2.7.3 Steel Pipe and Fittings

2.7.3.1 Steel Pipe

a. Steel pipe shall be ASTM A 53, Type E or S, Grade A or B, black steel, standard weight.

2.7.3.2 Steel Pipe Fittings

a. Fittings shall have the manufacturer's trademark affixed in accordance with MSS SP-25 so as to permanently identify the manufacturer.

2.7.3.3 Steel Flanges

a. Flanged fittings including flanges, bolts, nuts, bolt patterns, etc. shall be in accordance with

ASME B16.5 class 150 and shall have the manufacturers trademark affixed in accordance with

MSS SP-25. Flange material shall conform to ASTM A 105/A 105M. Flanges for high temperature water systems shall be serrated or raised-face type. Blind flange material shall conform to ASTM A 516 cold service and ASTM A 515 for hot service. Bolts shall be high strength or intermediate strength with material conforming to ASTM A 193.

2.7.3.4 Welded Fittings

a. Welded fittings shall conform to ASTM A 234 with WPA marking. Buttwelded fittings shall conform to ASME B16.9, and socket-welded fittings shall conform to ASME B16.11.

2.7.3.5 Cast-Iron Fittings

a. Fittings shall be ASME B16.4, Class 125, type required to match connecting piping.

2.7.3.6 Malleable-Iron Fittings

a. Fittings shall be ASME B16.3, type as required to match connecting piping.

2.7.3.7 Unions

23 52 00-14 03/07/12

a. Unions shall be ASME B16.39, Class 150.

2.7.3.8 Threads

a. Pipe threads shall conform to ASME B1.20.1.

2.7.3.9 Grooved Mechanical fittings

a. Joints and fittings shall be designed for not less than 125 psig service and shall be the product of the same manufacturer. Fitting and coupling houses shall be ductile iron conforming to

ASTM A 536. Gaskets shall be molded synthetic rubber with central cavity, pressure responsive configuration and shall conform to ASTM D 2000 for circulating medium up to 230 degrees F. Grooved joints shall conform to AWWA C606. Coupling nuts and bolts shall be steel and shall conform to ASTM A 183.

2.7.4 Copper Tubing and Fittings

2.7.4.1 Copper Tubing

a. Tubing shall be ASTM B 88, ASTM B 88M, Type K or L. Adapters for copper tubing shall be brass or bronze for brazed fittings.

2.7.4.2 Solder-Joint Pressure Fittings

a. Wrought copper and bronze solder-joint pressure fittings shall conform to ASME B16.22 and

ASTM B 75M( ASTM B 75). Cast copper alloy solder-joint pressure fittings shall conform to

ASME B16.18 and ASTM B 828.

2.7.4.3 Flared Fittings

a. Cast copper alloy fittings for flared copper tube shall conform to ASME B16.26 and ASTM B

62.

2.7.4.4 Adapters

a. Adapters may be used for connecting tubing to flanges and to threaded ends of valves and equipment. Extracted brazed tee joints produced with an acceptable tool and installed as recommended by the manufacturer may be used.

2.7.4.5 Threaded Fittings

a. Cast bronze threaded fittings shall conform to ASME B16.15.

2.7.4.6 Brazing Material

a. Brazing material shall conform to AWS A5.8.

2.7.4.7 Brazing Flux

a. Flux shall be in paste or liquid form appropriate for use with brazing material. Flux shall be as follows: lead-free; have a 100 percent flushable residue; contain slightly acidic reagents;

contain potassium borides, and contain fluorides. Silver brazing materials shall be in accordance with AWS A5.8.

2.7.4.8 Solder Material

a. Solder metal shall conform to ASTM B 32 95-5 tin-antimony.

23 52 00-15 03/07/12

2.7.4.9 Solder Flux

a. Flux shall be either liquid or paste form, non-corrosive and conform to ASTM B 813.

2.7.4.10 Grooved Mechanical Fittings

2.7.4.11 Joints and fittings shall be designed for not less than 125 psig service and shall be the product of the same manufacturer. Fitting and coupling houses shall be ductile iron conforming to

ASTM A 536. Gaskets shall be molded synthetic rubber with central cavity, pressure responsible configuration and shall conform to ASTM D 2000, for circulating medium up to

230 degrees F. Grooved joints shall conform to AWWA C606. Coupling nuts and bolts shall be steel and shall conform to ASTM A 183.

2.7.5 Dielectric Waterways and Flanges

2.7.5.1 Dielectric waterways shall have temperature and pressure rating equal to or greater than that specified for the connecting piping. Waterways shall have metal connections on both ends suited to match connecting piping. Dielectric waterways shall be internally lined with an insulator specifically designed to prevent current flow between dissimilar metals. Dielectric flanges shall meet the performance requirements described herein for dielectric waterways.

2.7.6 Flexible Pipe Connectors

2.7.6.1 Flexible pipe connectors shall be designed for 125 psi or 150 psi service. Connectors shall be installed where indicated. The flexible section shall be constructed of rubber, tetrafluoroethylene resin, or corrosion-resisting steel, bronze, monel, or galvanized steel.

Materials used and the configuration shall be suitable for the pressure, vacuum, and temperature medium. The flexible section shall be suitable for service intended and may have threaded, welded, soldered, flanged, or socket ends. Flanged assemblies shall be equipped with limit bolts to restrict maximum travel to the manufacturer's standard limits. Unless otherwise indicated, the length of the flexible connectors shall be as recommended by the manufacturer for the service intended. Internal sleeves or liners, compatible with circulating medium, shall be provided when recommended by the manufacturer. Covers to protect the bellows shall be provided where indicated.

2.7.7 Pipe Supports

2.7.7.1 Pipe supports shall conform to MSS SP-58 and MSS SP-69.

2.7.8 Pipe Expansion

2.7.8.1 Expansion Loops

a. Expansion loops and offsets shall provide adequate expansion of the main straight runs of the system within the stress limits specified in ASME B31.1. The loops and offsets shall be cold-sprung and installed where indicated. Pipe guides and anchors shall be provided as indicated.

2.7.9 Valves

Valves shall be Class 125 and shall be suitable for the application. Grooved ends in accordace with AWWA C606 may be used for water service only. Valves in nonboiler external piping shall meet the material, fabrication and operating requirements of ASME B31.1. The connection type

23 52 00-16 03/07/12 of all valves shall match the same type of connection required for the piping on which installed.

2.7.9.1 Gate Valves

a. Gate valves 2-1/2 inches and smaller shall conform to MSS SP-80 bronze rising stem, threaded, solder, or flanged ends. Gate valves 3 inches and larger shall conform to MSS SP-70 cast iron bronze trim, outside screw and yoke, flanged, or threaded ends.

2.7.9.2 Globe Valves

a. Globe valves 2-1/2 inches and smaller shall conform to MSS SP-80, bronze, threaded, soldered, or flanged ends. Globe valves 3 inches and larger shall conform to MSS SP-85, cast iron, bronze trim, flanged, or threaded ends.

2.7.9.3 Check Valves

a. Check valves 2-1/2 inches and smaller shall conform to MSS SP-80, bronze, threaded, soldered, or flanged ends. Check valves 3 inches and larger shall conform to MSS SP-71, cast iron, bronze trim, flanged, or threaded ends.

2.7.9.4 Angle Valves

a. Angle valves 2-1/2 inches and smaller shall conform to MSS SP-80 bronze, threaded, soldered, or flanged ends. Angle valves 3 inches and larger shall conform to MSS SP-85, cast iron, bronze trim, flanged, or threaded ends.

2.7.9.5 Ball Valves

a. Ball valves 1/2 inch and larger shall conform to MSS SP-72 or MSS SP-110, ductile iron or bronze, threaded, soldered, or flanged ends.

2.7.9.6 Plug Valves

a. Plug valves 2 inch and larger shall conform to MSS SP-78. Plug valves smaller than 2 inch shall conform to ASME B16.34.

2.7.9.7 Grooved End Valves

a. Valves with grooved ends in accordance with AWWA C606 may be used if the valve manufacturer certifies that their performance meets the requirements of the standards indicated for each type of valve.

2.7.9.8 Balancing Valves

a. Balancing valves shall have meter connections with positive shutoff valves. An integral pointer shall register the degree of valve opening. Valves shall be calibrated so that flow rate can be determined when valve opening in degrees and pressure differential across valve is known.

Each balancing valve shall be constructed with internal seals to prevent leakage and shall be supplied with preformed insulation. Valves shall be suitable for 250 degrees F temperature and working pressure of the pipe in which installed. Valve bodies shall be provided with tapped openings and pipe extensions with shutoff valves outside of pipe insulation. The pipe extensions shall be provided with quick connecting hose fittings for a portable meter to measure the pressure differential. One portable differential meter shall be furnished. The meter suitable for the operating pressure specified shall be complete with hoses, vent, and shutoff valves, and carrying case. In lieu of the balancing valve with integral metering connections, a ball valve or

23 52 00-17 03/07/12 plug valve with a separately installed orifice plate or venturi tube may be used for balancing.

2.7.9.9 Butterfly Valves

a. Butterfly valves shall be 2-flange type or lug wafer type, and shall be bubbletight at 150 psig.

Valve bodies shall be cast iron, malleable iron, or steel. ASTM A 167, Type 404 or Type 316, corrosion resisting steel stems, bronze, or corrosion resisting steel discs, and synthetic rubber seats shall be provided. Valves smaller than 8 inches shall have throttling handles with a minimum of seven locking positions. Valves 8 inches and larger shall have totally enclosed manual gear operators with adjustable balance return stops and position indicators. Valves in insulated lines shall have extended neck to accommodate insulation thickness.

2.7.9.10 Drain valves

a. Drain valves shall be provided at each drain point of blowdown as recommended by the boiler manufacturer. Piping shall conform to ASME BPVC SEC IVand ASTM A 53.

2.7.9.11 Safety Valves

a. Safety valves shall have steel bodies and shall be equipped with corrosion-resistant trim and valve seats. The valves shall be properly guided and shall be positive closing so that no leakage can occur. Adjustment of the desired back-pressure shall cover the range between 2 and 10 psig. The adjustment shall be made externally, and any shafts extending through the valve body shall be provided with adjustable stuffing boxes having renewable packing. Boiler safety valves of proper size and of the required number, in accordance with ASME BPVC SEC IV, shall be installed so that the discharge will be through piping extended to the blowoff tank or to a location as indicated. Each discharge pipe for steam service shall be provided with a drip pan elbow to prevent accumulation of water on the valve. A slip joint shall be provided between drip pan elbow and riser. Each discharge pipe for hot water service shall be pitched away from the valve seat.

2.7.10 Strainers

2.7.10.1 Basket and "Y" type strainers shall be the same size as the pipelines in which they are installed.

The strainer bodies shall be heavy and durable, fabricated of cast iron, and shall have bottoms drilled and tapped with a gate valve attached for blowdown purposes. Strainers shall be designed for pressure (psig) service and temperature (degrees F) indicated. The bodies shall have arrows clearly cast on the sides indicating the direction of flow. Each strainer shall be equipped with an easily removable cover and sediment screen. The screen shall be made of 22 gauge thick brass sheet, monel or corrosion-resistant steel with small perforations numbering not less than 400/square inch to provide a net free area through the basket of at least 3.30 times that of the entering pipe. The flow shall be into the screen and out through the perforations.

2.7.11 Pressure Gauges

2.7.11.1 Gauges shall conform to ASME B40.100 and shall be provided with throttling type needle valve or a pulsation dampener and shutoff valve. Minimum dial size shall be 3-1/2 inches. A pressure gauge shall be provided for each boiler in a visible location on the boiler. Pressure gauges shall be provided with readings in psi. Pressure gauges shall have an indicating pressure range that is related to the operating pressure of the fluid in accordance with the following table:

Operating Pressure (psi) Pressure Range (psi)

23 52 00-18 03/07/12

76-150 0-200

16-75 0-100

2-15 0-30 (retard)

2.7.12 Thermometers

2.7.12.1 Thermometers shall be provided with wells and separable corrosion-resistant steel sockets.

Mercury shall not be used in thermometers. Thermometers for inlet water and outlet water for each hot water boiler and the feedwater for each steam boiler shall be provided in a visible location on the boiler. Thermometers shall have brass, malleable iron, or aluminum alloy case and frame, clear protective face, permanently stabilized glass tube with indicating-fluid column, white face, black numbers, and a minimum 9 inch scale. The operating range of the thermometers shall be 32-212 degrees F. The thermometers shall be provided with readings in degrees F.

2.7.13 Air Vents

2.7.13.1 Manual Air Vents

a. Manual air vents shall be brass or bronze valves or cocks suitable for the pressure rating of the piping system and furnished with threaded plugs or caps.

2.7.13.2 Automatic Air Vents

a. Automatic air vents shall be 3/4 inch quick-venting float and vacuum air valves. Each air vent valve shall have a large port permitting the expulsion of the air without developing excessive back pressure, a noncollapsible metal float which will close the valve and prevent the loss of water from the system, an air seal that will effectively close and prevent the re-entry of air into the system when subatmospheric pressures prevail therein, and a thermostatic member that will close the port against the passage of steam from the system. The name of the manufacturer shall be clearly stamped on the outside of each valve. The air vent valve shall be suitable for the pressure rating of the piping system.

2.8 ELECTRICAL EQUIPMENT

Electric motor-driven equipment shall be provided complete with motors, motor starters, and necessary control devices. Electrical equipment, motor control devices, motor efficiencies and wiring shall be as specified in Section 26 20 00 Interior Distribution System. Motors which are not an integral part of a packaged boiler and which are integral in size shall be the premium efficiency type in accordance with NEMA MG 1. Motors which are an integral part of the packaged boiler shall be the highest efficiency available by the manufacturer of the packaged boiler. Motor starters shall be provided complete with properly sized thermal overload protections and other appurtenances necessary for the motor control specified. Starters shall be furnished in enclosures appropriate for the operating environment. Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices but not shown shall be provided.

2.8.1 Motor Ratings

2.8.1.1 Motors shall be suitable for the voltage and frequency provided. Motors 1/2 hp and larger shall

23 52 00-19 03/07/12 be three-phase, unless otherwise indicated. Motors shall be of sufficient capacity to drive the equipment at the specified capacity without exceeding the nameplate rating on the motor.

2.8.2 Motor Controls

2.8.2.1 Motor controllers shall be provided complete with properly sized thermal overload protection.

Manual or automatic control and protective or signal devices required for the operation specified and any wiring required to such devices shall be provided. Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers may be provided to accomplish the same function. Solid state variable speed controllers shall be utilized for fractional through 10 hp ratings. Adjustable frequency drives shall be used for larger motors.

2.9 INSULATION

2.9.1 Shop and field-applied insulation shall be as specified in Section 23 07 00 Thermal Insulation for

Mechanical Systems.

2.10 TOOLS

Special tools shall be furnished. Special tools shall include uncommon tools necessary for the operation and maintenance of boilers, burners, pumps, fans, controls, meters, special piping systems, and other equipment. Small hand tools shall be furnished within a suitable cabinet, mounted where directed.

2.10.1 Wrenches

2.10.1.1 Wrenches shall be provided as required for specialty fittings such as manholes, handholes, and cleanouts. One set of extra gaskets shall be provided for all manholes and handholes, for pump barrels, and other similar items of equipment. Gaskets shall be packaged and properly identified.

2.11 BOILER WATER TREATMENT

The existing water treatment system shall be protected during the construction and shall remain.

PART 3 EXECUTION

3.1 EXAMINATION

3.1.1 After becoming familiar with details of the work, verify dimensions in the field, and advise the

Contracting Officer of any discrepancy before performing any work or ordering any materials.

3.2 ERECTION OF BOILER AND AUXILIARY EQUIPMENT

3.2.1 Boiler and auxiliary equipment shall be installed in accordance with manufacturer's written instructions. Proper provision shall be made for expansion and contraction between boiler foundation and floor. This joint shall be packed with suitable nonasbestos rope and filled with suitable compound that will not become soft at a temperature of 100 degrees F. Boilers and firing file:///E:/Revised%20PAFB%20Rewrite%20Spec%202/23%2007%2000.doc

23 52 00-20 03/07/12 equipment shall be supported from the foundations by structural steel completely independent of all brickwork. Boiler supports shall permit free expansion and contraction of each portion of the boiler without placing undue stress on any part of the boiler or setting.