Fulton Boilers Statement of Work.pdf

STATEMENT-OF-WORK

REPLACEMENT OF THE

HOT WATER BOILERS AT FULTON HALL

LOCATED AT

U.S. MERCHANT MARINE ACADEMY

KINGS POINT, NEW YORK

April 5, 2022

U.S. DEPARTMENT OF TRANSPORTATION

MARITIME ADMINISTRATION

KINGS POINT, NEW YORK 11024-1699

Contents

SECTION 1 - INTRODUCTION

SECTION 2 - PURPOSE

SECTION 3 - SCOPE

SECTION 4 - NORMAL WORKING HOURS

SECTION 5 - CLEAN UP

SECTION 6 - CONTRACTOR’S REPRESENTATIVE

SECTION 7 – REFERENCE INFORMATION

STATEMENT-OF-WORK

REPLACEMENT OF THE HOT WATER BOILERS LOCATED AT

FULTON HALL

LOCATED AT THE

SECTION 1 - INTRODUCTION

1.1 This statement of work describes the Mechanical services for the replacement of the hot water boiler #1 and boiler #2 at Fulton Hall located at the USMMA.

The USMMA campus consists of 82 acres along the Long Island shoreline, about 50 buildings, waterfront structures and facilities, berthing of vessels and small craft and athletic fields.

1.2 The Academy is in operation 365 days a year, 24 hours a day and must continue to be in operation during all phases of construction.

1.3 All work shall be performed by a contractor licensed to perform work in New

York State in their respective trade. All new work shall be in accordance with the New York State Plumbing Code, New York State Mechanical Code, New York State Fuel Gas Code, OSHA and New York State Department of Labor.

1.4 The contractor shall have a minimum of 7 years of experience installing condensing type boilers and be a manufacturer approved installer of new condensing boilers systems.

1.5 A survey of asbestos containing materials at the Academy was completed in 2021 and is available for reference.

SECTION 2 - PURPOSE

2.1 The primary purpose of this statement of work is for the contractor to provide mechanical services for the replacement of the hot water heating boilers located in the Fulton Hall central plant. The existing fire tube boilers Boiler #1 and Boiler #2 located in the Fulton Hall central heating plant manufactured by Kewanee, model L3W-300-GO2, approximately 300 BHP. The existing boilers are connected for natural gas and fuel oil as the energy source. The contractor is required to furnish and install a complete working primary hot water boiler plant as described in this statement of work.

SECTION 3 - SCOPE

3.1 This project will include the following but not be necessarily limited to:

3.1.1 The contractor shall supply all materials, labor, equipment, tools and rigging to perform all of the tasks required in this statement of work

3.1.2 All demolition and removal work shall be performed in accordance with the New York State Environmental and safety regulations. The contractor is responsible for obtaining all required environmental permits for the replacement of the boilers. The Academy will handle the air permit requirement with New York State.

3.1.3 All rubbish, demolished equipment, insulation, etc. shall be disposed in accordance with New York State regulations including logs keeping track of date, material disposed and location of disposal.

3.1.4 The contractor shall disable the (3) existing hot water pumps and mark out and tag out the (3) existing primary hot water pumps to remain.

3.1.5 The contractor shall disconnect, lock out and tag out the electrical power supply switches connected to Fulton Boiler #1 and Fulton Boiler #2.

3.1.6 The contractor shall isolate the natural gas supply valve and fuel oil supply piping.

3.1.7 The contractor shall disconnect all electrical power supply connections and electrical controls connection to Boiler #1 and #2.

3.1.8 The contractor shall drain down Fulton Boilers #1 and #2 and drain down and isolate the primary hot water distribution piping and remove piping, valves and supports back as required to accommodate the installation of the new boilers.

3.1.9 The contractor shall drain down the fuel oil supply and return piping and remove the existing branch piping back to the main header and valves to accommodate the installation of the new boilers.

3.1.10 The contractor shall evacuate the existing natural gas supply piping and remove all existing branch piping back to the main to accommodate the installation of the new boilers including valves and supports. The natural gas main header shall remain to keep the Clayton steam generator available for Academic use.

3.1.11 The contractor shall disassemble, remove and dispose of Boiler # 1 and

Boiler #2.

3.1.12 The contractor shall coordinate the footprint of the new boilers and associated access requirements with the existing pads and extend the (2) 6” boiler pads as required.

3.1.13 The contractor shall provide and install a fully functional primary hot water plant including (4) natural gas fired high mass, high mass nominal 6,000 MBH fire tube high efficiency condensing boilers. There are (3) existing 1000 gpm primary hot water pumps that are to remain. The contractor will connect the new condensing hot water boilers to the existing primary hot water distribution pumps and associated piping. Each boiler will have an individual circulator pump and tie in to the primary hot water piping header with a 6” supply and return connection, each with an isolation valve to the 8” steel header with a de-coupler section as per the boiler manufacturer’s instructions. The contractor shall provide and install a strainer at the inlet of each boiler. The contractor shall provide and install all required dielectric fitting to connect dissimilar piping materials. The piping to each boiler shall include hot water supply and return isolation valves, hot water supply and return pressure and temperature sensors, circulator pump with discharge check valve, boiler drain with valve. The contractor shall provide and install new 1-1/2” fiberglass insulation on all new hot water piping and hot water piping at all primary hot water pumps.

3.1.14 The proposed boilers are to have a minimum thermal efficiency of 94% as established by an Air-conditioning Heating and Refrigeration Institute (AHRI) certificate.

3.1.15 Each condensing boiler will be designed for a maximum working pressure

(MAWP) of 125 PSIG constructed in accordance with ASME Section IV with the “H” stamp. The boiler shall be insulated on a base. The boiler shall be factory powder coated steel casing.

3.1.16 Each boiler shall be equipped low water probe type cut-off with manual reset, high water temperature cut-off with manual reset, sensor for negative temperature sensor for hot water supply, and hot water return, ASME safety valve set at 125 psig, combustion temperature/pressure gauge.

3.1.17 Each boiler shall be equipped with a boiler manufacturer furnished burner controller with touch screen display and operator interface. Each burner controller shall include (2) heating loops with PID control, burner sequencing with safe start check, pre-purge, direct spark ignition and post purge cycle, electronic ignition, flame supervision, safety shutdown with time stamped display of lock-out condition, variable speed of combustion fan, supervision of low and high gas pressure, air proving, stack back pressure, high limit and low water, annunciation for first out, data trending,

(3) pump/auxiliary relay outputs, Modbus communication capability, outdoor temperature reset, remote firing rate or set point control, setback/time of day set point, lead lag for up to 8 boilers.

3.1.18 Each boiler shall be equipped with a forced draft burner, variable speed motor for full modulation, low NOx emission less than 20 PPM, main flame direct spark ignition, UV flame supervision, combustion air proving switch, high pressure switch to ensure burner lockout if blocked stack occurs, high turndown burner, easy access to burner, electrodes, tube sheets, tubes.

3.1.19 Each boiler shall be equipped with a UL certified burner complying to

ASME CSD-1 gas train including low pressure interlock with manual reset, high pressure interlock with manual reset, ASME CSD-1 test cocks, downstream manual ball type shut-off valve, single body dual safety shut-off gas valve, proof of valve closure.

3.1.20 Each boiler shall be equipped with boiler condensation neutralization tank assembly including neutralizing media, filer, PVC condensate holding tank with drain trap.

3.1.21 Each boiler shall be equipped with outdoor temperature sensor for outside air reset controls, header temperature sensor for multiple boiler lead/lag control, auxiliary low water cut-out, horn alarm for safety shutdown, relays for burner on signal and fuel valve open signal, stack thermometer, stack temperature limit sensor, auto air vent, boiler drain valve, adjustable legs, seismic anchoring brackets, protocol translator for BMS communication, automatic boiler isolation valve, remote monitoring capability.

3.1.22 The boiler monitoring system shall be integrated into the Academy’s existing building management system for monitoring functions.

3.1.23 The contractor shall provide and install a boiler vent stack system and draft dampers in accordance with the NYS Fuel Gas Code, manufacturers installation instructions, NYS Mechanical Code. Each Boiler shall be equipped with a vent sized in accordance with the manufacturer’s installation requirements. The combined vent header shall be routed and coordinated with the existing conditions and sized as per the boiler manufacturer’s installation requirements. Note: the Kewanee boiler exhausts are connected to a common boiler breaching and connected to an existing masonry chimney. A Clayton steam generator that is existing to remain and used in the Academy’s steam lab is also connected to the same breaching and chimney. The breeching will need to be modified once the Kewanee boilers are removed to maintain the functionality of the Clayton steam generator breeching to this chimney. The Clayton boiler will need to be available for Academic classes during the course of the construction.

3.1.24 The contractor shall provide and install a boiler manufacturers’ lead/lag panel to control all 4 boilers and communicate with each of the boilers individual control panel. The lead lag panel shall maintain water supply temperature (adjustable) based on system demand, maximize system efficiency, automatic boiler rotate sequence, optimize fuel savings, lead/lag start and lead/lag modulation, lead/lag modulation with unison.

3.1.25 The contractor shall prepare a full submittal package based on the contractor’s proposed boiler manufacturer. The submittal shall include a scaled boiler room drawing indicating the location of each new boiler, new hot water piping routes and sizes, boiler flue vent system including vent sizes and routes, natural gas piping size and routes, tie in locations for the new hot water piping to the existing hot water piping distribution, natural gas piping, pipe supports sizing and spaces.

3.1.26 The contractor shall provide and install new electric service panel switches in the existing 208 Volt, 3 phase 60 Hz panel and electrical disconnect switches for each boiler, electrical wiring, rigid electrical conduit, malleable iron connectors, junction boxes, supports in accordance with NFPA. The contractor shall provide and install all required step-up or step-down transformers to adapt any difference in the available 208 Volt, 3 phase, 60 Hz to the voltage and phase requirements of the new boilers and accessories.

3.1.27 The contractor shall provide and install all required electrical components required for all lead/lag control and automatic sequence of operation including switches, transformers, wiring, low voltage wiring, controllers, relays, piping temperature wells, conduits supports.

3.1.28 The contractor shall provide and install (2) carbon monoxide sensors with audible alarm, high heat sensors with audible alarm, high flue temperatures with audible alarm in the boiler room. The contractor shall provide and install all required power wiring, transformers, conduits, relays, sound bases as required. These alarms should be connected to the notification system outlined in section 3.1.22.

3.1.29 The contractor shall provide and install individual boiler vents for all (4) boilers and extend the common boiler vent up thru the roof in accordance with NYS building codes and boiler manufacturers’ installation requirements. The contractor shall coordinate the new boiler vent with all existing conditions. The contractor shall provide and install a roof penetration collar, flashing and counter-flashing to ensure the new roof penetration is water tight.

3.1.30 The contractor shall provide and install a gas meter for the common gas header to meter the gas supply provided to all (4) boilers.

3.1.31 The contractor shall provide full start-up and commissioning services by the boiler manufacturer’s technical representative.

3.1.32 The contractor shall provide a full warranty for the new boiler system for parts and labor for two years. The contractor shall have an approved boiler manufacturer repair service provider located within a 50-mile radius of the USMMA capable of responding to a service calls.

3.1.33 The contractor shall provide 5 full 8-hour days of training for USMMA personnel.

3.1.34 The contractor shall install the new boilers and provide training as described in this statement of work by October 1, 2022 in preparation for the fall heating season.

3.1.35 Temporary 6” piping exists as part of the boiler rental configuration. This piping is to remain in place as a back-up until the new boilers are installed.

Once the existing boilers are removed and the new boilers are installed, the temporary piping, hangers, and associated cabling is to be disconnected and removed.

3.1.36 The Academy desires to have a valved tie-in as part of the final piping configuration for the potential to connect to a rental boiler. The contractor shall provide a valved tie-in as part of the piping configuration to allow for the connection of a rental boiler.

3.1.37 The Academy’s welding lab (adjacent to the masonry stack) has a use for some of the temporary piping being used with the rental boiler arrangement. Of the removed temporary boiler piping, the contractor shall remove insulation from a suitable amount of pipe and cut twenty-four (24) six-foot sections of pipe to be left at the welding shop rear entrance. The remaining fittings, hangers, and piping materials are to be removed by the contractor.

3.1.38 The penetration into the building is through a window which will need to be replaced as part of this effort. Temporary piping removal and as-built drawings are to be completed no later than 4 weeks after commissioning of the new units.

SECTION 4 - NORMAL WORKING HOURS

4.1 Normal working hours are 0800 to 1700 hours Monday through Friday excluding Federal Holidays. All work shall be performed during these hours, unless otherwise approved by the CO. The contractor may be required to reimburse the Government for the cost of inspecting work performed outside of normal working hours. No work shall be performed during graduation and homecoming.

SECTION 5 - CLEAN UP

5.1 The contractor shall clean up all debris and discard materials resulting from his operations at the end of each workday. Materials shall be disposed of off campus in accordance with local, state and federal laws and regulations. In case of conflict among these laws and regulations, the most stringent law or regulation will apply. Open burning of scrap or unsalvageable materials is forbidden.

SECTION 6 - CONTRACTOR’S REPRESENTATIVE

6.1 A competent supervisor with authority to act on behalf of the contractor must be present at the job site all times that work is being performed. The name of the supervisor will be furnished in writing to the CO.

SECTION 7 – REFERENCE INFORMATION

Existing boiler

Existing boilers

Temporary piping

Existing boiler entering Fulton Hall