SBA TOWB Boiler Specs --.pdf

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United States Department of Transportation Federal Aviation Administration

Western Service Area Western Pacific Region Engineering Services

777 S Aviation Boulevard El Segundo, CA 90245

Santa Barbara (SBA) ATCT Boiler Replacement Project Santa Barbara, California

Prepared by:

Alonzo Perez

Mechanical Engineer

AJW-2W15F

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DIVISION 1

GENERAL REQUIREMENTS

1-1.0 SCOPE:

Project consists of removing and installing a new boiler system at the Santa Barbara (SBA) TOWB. Contractor is required to purchase all necessary components, perform all tasks and supply equipment to complete project. New boiler must be fully functional and operate to manufacturer’s requirements.

1.-1.1 DAMAGES:

As reflected in the contract, the use of Actual Damages will be in effect. Any damages to the FAA structures and or equipment will be replaced or repair at the Contractors expense within 24 hours of notification to the Contracting Officer. Actual damages will be applied to the period of performance minus the Contracting Officers determination of unforeseen circumstances and government delays.

Project to consist of the following:

1. Removal RITE (B-1) (Model 63 WG) Heating boiler and related mechanical equipment.

2. Install one RITE (Model 63 WG) Heating Boiler and related mechanical or equal.

3. Isolate boiler water piping system.

4. Removal of two (P-1 and P-2) Taco FE Series Pumps (Model FE-1208).

5. Install two new Taco Series Pumps (P-1 and P-2) or equal.

6. Install all necessary pipe fitting and valves for proper system operation.

7. Replace pump stands spring isolators.

8. Install all necessary natural gas piping components for proper system operation.

9. Remove one boiler flue.

10. Install one boiler flue in accordance with all government codes, regulations and supported in compliance to manufacturer’s specifications.

11. Name and label all equipment components.

12. Install all necessary electrical for proper system operation.

13. Removal Taco (ET-1) horizontal wall mount existing expansion tank.

14. Install one new horizontal wall mount expansion tank for proper system operation.

15. Replace Boiler Air Separator in-kind and all necessary piping components for proper system operation.

16. Removal of existing chemical POT Feeder.

17. Install one new chemical POT Feeder in-kind.

18. Removal of pump pressure gages.

19. Install new pump pressure gages.

20. Boiler system hot water treatment

21. Install boiler power disconnect switch if not provided by boiler manufacture.

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22. Insulate all necessary outdoor piping with 1” thickness fiberglass insulation and aluminum jacketing.

23. Insulate all necessary indoor piping with 1” thickness fiberglass insulation and PVC jacketing.

24. Seismically secure all equipment.

25. Direct Digital Controls (DDC) system shall control the new boiler.

26. System start-up and calibration.

1-2.0 PROJECT LOCATION:

Santa Barbara (SBA) TOWB KSBA Tower 119.7 Santa Barbara, CA 93117

1-3.0 WARRANTY:

The Contractor shall warrant all materials, equipment and labor for all work performed under this contract. This warranty shall be for a period of one calendar year beginning upon the date of contract acceptance inspection (CAI). The warranty shall be unconditional and the Contractor shall furnish all labor and materials required to repair or replace defective or failed portions of the contract work. Warranty repair work shall be performed in the same manner as new work in accordance with the technical requirements of this specification. Any warranty repairs shall be completed by the Contractor within a maximum of 24 hours after notification by the Government for any failure which causes a mechanical system to be inoperative. Other failures or defects which have no operational impact to the facility shall be corrected within a maximum of 15 calendar days after notification by the Government. The specific items of work performed under warranty shall then themselves be unconditionally warranted for a period of one calendar year beginning upon the date of completion of the repair work.

The Contractor shall guarantee that each piece of apparatus shall have a capacity or performance of not less than that specified or indicated on drawings, when the apparatus is operating under specified design conditions.

1-4.0 SUBMITTALS:

Within fourteen (14) calendar days after the date of contract award, the Contractor shall submit to the RE a list of all materials and equipment to be used under this contract. This list shall include a brief description of the materials or equipment, the name of the manufacturer, and the model or type number.

The use of brand name with, or without, an or approved equal statement following the purchase description in this specification or on the project drawings is intended to promote competition by encouraging the offering of products that are equal in all material respects to the brand name products cited in such descriptions. The reference by brand name does not indicate a preference for the products mentioned but identifies a product known to furnish the quality and characteristics that meet the requirements of this specification. All characteristics of a specified brand name product which are essential to the Government are described in this specification or on the project drawings. The Contractor shall obtain product literature from the manufacturer of

4 | P a g e the specified brand name product to determine its general quality and functional characteristics and shall use that information in making any desired substitutions.

Where the Contractor elects to use the manufacturer and model number specified herein, no further technical information or shop drawings need to be submitted. Where the Contractor desires to utilize the products of another manufacturer or where no make or model is specified, a complete set of shop drawings and descriptive literature shall be submitted. Contractor shall submit three (3) copies of descriptive literature, shop drawings, and/or samples to the RE for approval for any item he wishes to submit as equal to the brand name(s) as specified.

Information shall be submitted within fourteen (14) calendar days after the date of contract award and shall include, but not be limited to the following, where applicable:

(1) Boilers

(2) Insulation

(3) Controls

(4) Electrical equipment

(5) Piping and accessories

(6) System Pumps

Shop drawings shall include manufacturer's catalog data and certified capacity data. Information submitted shall be complete to enable the item to be evaluated from an engineering viewpoint and shall be sufficient to show compliance with this specification.

The project drawings are designed for the particular manufacturer and model specified.

However, where required to show specific details of equipment interface, attachment, support, wiring, etc., the Contractor shall provide any additional shop drawings or descriptive literature for any equipment, including that specified, as required by the RE.

The Contractor shall carefully select equipment and materials, furnish shop drawings and other documentation required above, place and confirm orders for equipment and materials, and schedule all delivery dates in a manner which conforms with the performance time and advance acquisition time allotted by this contract.

Notice-To-Proceed with on-site work will not be granted until the Contractor certifies to the Contracting Officer that all required materials and equipment, as approved by the Government, are in his possession and ready for installation.

1-5.0 PERFORMANCE TIME:

The Contractor shall be required to commence work under this contract within one day after the date of Notice-To-Proceed, prosecute the work diligently and complete the entire work ready for use no later than 30 calendar days after the date of Notice-To-Proceed.

Prior to the effective date of the Notice-To-Proceed with on-site work, a maximum of 12-13 week lead time after the date of Contract Award will be allowed to obtain the required materials and equipment. All shop drawing submissions shall also be accomplished during this lead-time.

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The time required from submission of shop drawings to approval by the Government will not be included in the above specified lead time. Notice-To-Proceed with on-site work will not be granted until the Contractor certifies to the Contracting Officer that all required materials and equipment, as approved by the Government, are in his possession and ready for installation. The Contracting Officer will coordinate the Notice-To-Proceed date with the Contractor to ensure his ability to commence work upon that date.

1-6.0 WORK SCHEDULE:

All work shall be scheduled for 8 hours work shift and performed between the hours of 7:00 AM to 5:00 PM except when prior approval has been obtained from the Resident Engineer. Alternate work schedules such as 10 hours per day for 4 days per week are acceptable subject to the total work time per week shall not exceed 40 hours. All work schedules proposing more than 8 hours of work per day shall be approved in advance by the Resident Engineer. No work shall be scheduled or performed on Saturdays, Sundays or Federal holidays.

1-7.0 AVAILABILITY OF UTILITIES:

Water is available for the Contractor’s use.

Electricity is available for the Contractor’s use.

Sanitary facilities are available for the Contractor's use at Government expense and escorted.

Public telephone service is not available for the Contractor's use at the project location. It is suggested that the Contractor furnish his personnel with electronic paging equipment, cellular telephones or make other arrangements to maintain communications. The Government will not be responsible for receiving telephone calls, taking messages or contacting Contractor personnel to deliver messages.

Trash removal shall be the Contractor’s responsibility. Furnish appropriate waste receptacles and service to pick-up and transport all waste material to an approved commercial dump or waste processing facility. Trash must be collected and no loose debris at the end of work shift.

1-8.0 PERFORMANCE OF WORK BY CONTRACTOR:

The Contractor shall accomplish a minimum of 85% of the contract work by personnel employed by his own organization.

1-9.0 PRECONSTRUCATION CONFERENCE:

Prior to the start of construction, it is required the contractor and FAA personnel conduct a preconstruction meeting to discuss project implementation. Contractor’s Project Manager must be in attendance as well as any personnel who will be involved in decision making for the duration of project. Safety requirements will be reviewed to discuss site specific health and safety procedures. All potential hazards and mitigation information will be clarified. The government representatives will comment on submittals and project plans to then proceed for approval.

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1-10.0 SECURITY REQUIREMENTS:

Contractor must follow all SBA Airport security procedures. Daily badging and escorting is required.

Contractor may use necessary facility water, electricity and keep clean rest rooms under escort.

1-11.0 SITE VISIT:

Interested bidders may make arrangements to visit the site by contacting:

Santa Barbara (SBA) TOWB KSBA Tower 119.7 Santa Barbara, CA 93117

Michael A. Ballard SBA SSC Coordinator

(805) 797-1108

Alonzo Perez Engineering Services

(424) 304-4393

1-13.0 LIST OF PROJECT DRAWINGS:

Santa Barbara, California Air Traffic Control Tower

Number Title

SBA-D-ATCT-G031 BOILER REPLACEMENT PROJECT TITLE SHEET AND

DRAWING INDEX

SBA-D-ATCT-M048 BOILER REPLACEMENT PROJECT MECHANICAL

SCHEDULES

SBA-D-ATCT-M049 BOILER REPLACEMENT PROJECT MECHANICAL PLAN

SBA-D-ATCT-M050 BOILER REPLACEMENT PROJECT HOT WATER PIPING

DIARAMS

1-14.0 WASTE MANAGEMENT:

Contractor must comply with all federal, state and local waste regulations of the disposal of all waste. A waste disposal plan must be prepared for any transporting, storing and/or location. It is encouraged that any recyclable material be handled appropriately.

Personal Protective Equipment:

The contractor must provide all necessary OSHA appropriate PPE to workers onsite.

1-15.0 WORK SITE AREA:

Keep a clean and well maintained work area indoor and outdoor. All debris and waste must be cleaned and properly disposed of at end of daily work and prior to final inspection.

1-16.0 INSPECTION:

A final inspection will be conducted by qualified FAA personnel that the project has met all requirements and specifications. The inspection will verify that all purchased components

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1-17.0 GENERAL NOTES:

Depending on time of year the construction is performed, temporary heating may be required.

Temporary heating cab be accomplished in multiple ways.

1-17.1 PR Notes:

1. Request contracting bit walk

2. Request licensed HVAC contractor for installation.

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DIVISION 2

1.0 SCOPE:

Project consists of removing and installing a new boiler system at the Santa Barbara (SBA) TOWB. Contractor is required to purchase all necessary components, perform all tasks and supply equipment to complete project. New boiler must be fully functional and operate to manufacturer’s requirements.

2.0 CODES AND STANDARDS:

All labor and material shall be in strict conformance with the rules and regulations of the Air Conditioning and Refrigeration Institute (ARI), National Fire Protection Association (NFPA), American Society for Testing and Materials (ASTM), and American Society of Mechanical Engineers (ASME), where such standards have been established for the particular item of equipment used.

All equipment and materials shall be installed in accordance with the manufacturer's instructions.

A copy of the manufacturer's installation instructions shall be maintained on site and made available to the Resident Engineer (R.E.) before any equipment is installed or any work with that material begins.

3.0 APPLICABLE DOCUMENTS:

The following standard publications, of the issues currently in force, form a part of this specification. The Contractor shall perform all work not included in this specification in accordance with these publications:

International Conference of Uniform Mechanical Code Building Officials 2021 Edition

International Conference of Uniform Plumbing Code Building Officials 2021 Edition

Sheet Metal and Air Conditioning HVAC Duct Construction Contractors National Association Standards, Metal and (SMACNA) Flexible, 2021 Edition with 11/97 Addendum

National Electrical Code, National Fire Protection 2020 Edition Association

(Manufacturer of Installed Equipment Installation Equipment) Instructions, Applicable Edition for Specified or Approved Model Number

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FAA- STD-019f Lightning and Surge Protection July 14, 2020 Grounding, Bonding, and Shielding Requirements for Facilities and Electronic Equipment

FAA-C-1217H Electrical Work, Premises Wiring January 5, 2021

FAA-C-1391e Installation, Termination, Splicing, May 2019 and Transient/Surge Protection of Underground Electrical Distribution System Power Cables

4.0 NATURAL GAS PIPING SYSTEM:

4.1 QUALITY ASSURANCE:

Type S steel pipe with heat numbers rolled, stamped, or stenciled to each length or each bundle, depending on the size of the pipe, and in accordance with the appropriate ASTM specification.

Any installed material not meeting the specification requirements must be replaced with material that meets these specifications.

Install all necessary gas piping components pre code and boiler manufacturer’s recommendations for proper system operation.

Comply with the International Fuel Gas Code for installation and purging of natural-gas piping.

4.2 DELIVERY, STORAGE, AND HANDLING:

Promptly inspect shipments to insure that the material is undamaged and complies with specifications.

Cover pipe to eliminate rust and corrosion while allowing sufficient ventilation to avoid condensation. Do not store materials directly on grade. Protect pipe, tube, and fitting ends so they are not damaged. Where end caps are provided or specified, take precautions so the caps remain in place.

Offsite storage agreements will not relieve the contractor from using proper storage techniques.

Storage and protection methods must allow inspection to verify products.

4.3 DESIGN CRITERIA:

Use only new material, free of defects, rust and scale, and meeting the latest revision of ASTM specifications as listed in this specification.

Construct all piping for the highest pressures and temperatures in the respective system in accordance with ANSI B31, but not less than 125 psig unless specifically indicated otherwise.

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Steel Pipe: ASTM A 53/A 53M, black steel, Schedule 40, Type S, Grade B.

Unions: ASME B16.39, Class 150, malleable iron with brass-to-iron seat, ground joint, and threaded ends

4.4 UNIONS AND FLANGES:

2" and Smaller: ASTM A197/ANSI B16.3 malleable iron unions with brass seats. Use black malleable iron on black steel piping and galvanized malleable iron on galvanized steel piping. Use unions of a pressure class equal to or higher than that specified for the fittings of the respective piping service but not less than 250 psi.

Provide ASTM A 193 B7 grade bolts and A 194 2H grade nuts & hardened washers for connections.

4.5 PREPARATION:

Close equipment shutoff valves before turning off natural gas to premises or piping section.

Inspect natural-gas piping according to the International Fuel Gas Code to determine that natural-gas utilization devices are turned off in piping section affected.

Comply with the International Fuel Gas Code requirements for prevention of accidental ignition.

Remove all foreign material from interior and exterior of pipe and fittings.

Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly

4.6 THREADED PIPE JOINTS:

Use a Teflon based thread lubricant or Teflon tape when making joints; no hard setting pipe thread cement or caulking will be allowed.

Ream ends of pipes and remove burrs.

Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.

Threaded Joints:

1. Thread pipe with tapered pipe threads complying with ASME B1.20.1.

2. Cut threads full and clean using sharp dies.

3. Ream threaded pipe ends to remove burrs and restore full inside diameter of pipe.

4. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified.

5. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds.

4.7 SHUT OFF VALVES:

2" and smaller: Ball valve, bronze body, threaded ends, chrome-plated bronze or stainless steel ball, full or conventional port, Teflon seat, blowout-proof stem, two-piece construction, suitable for 150 psig working pressure, U.L. listed for use as natural gas shut-off.

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4.8 GAS PRESSURE REGULATORS:

2" and smaller: Cast iron body, aluminum spring and diaphragm, Nitrile diaphragm, threaded ends, 150 psi W.O.G., -20°F to 150°F.

A. General Requirements:

1. Single stage and suitable for natural gas.

2. Steel jacket and corrosion-resistant components.

3. Elevation compensator.

4. End Connections: Threaded for regulators NPS 2 and smaller; flanged for regulators NPS 2-1/2 and larger.

B. Line Pressure Regulators: Comply with ANSI Z21.80.

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Actaris.

b. American Meter Company.

c. Eclipse Combustion, Inc.

d. Fisher Control Valves and Regulators; Division of Emerson Process Management.

e. Invensys.

f. Maxitrol Company.

g. Richards Industries; Jordan Valve Div.

2. Body and Diaphragm Case: Cast iron or die-cast aluminum.

3. Springs: Zinc-plated steel; interchangeable.

4. Diaphragm Plate: Zinc-plated steel.

5. Seat Disc: Nitrile rubber resistant to gas impurities, abrasion, and deformation at the valve port.

6. Orifice: Aluminum; interchangeable.

7. Seal Plug: Ultraviolet-stabilized, mineral-filled nylon.

8. Single-port, self-contained regulator with orifice no larger than required at maximum pressure inlet, and no pressure sensing piping external to the regulator.

9. Pressure regulator shall maintain discharge pressure setting downstream, and not exceed

150 percent of design discharge pressure at shutoff.

10. Overpressure Protection Device: Factory mounted on pressure regulator.

11. Atmospheric Vent: Factory- or field-installed, stainless-steel screen in opening if not connected to vent piping.

12. Maximum Inlet Pressure: 2 psig.

Install all necessary gas piping components for proper system operation.

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4.9 FIELD QUALITY CONTROL:

A. Perform tests and inspections.

Verify that the piping system being tested is fully connected to all components and that all equipment is properly installed, wired, and ready for operation. Provide all piping, fittings, blind flanges, and equipment to perform the testing.

B. Tests and Inspections:

Test, inspect, and purge natural gas according to the International Fuel Gas Code and authorities having jurisdiction.

C. Natural-gas piping will be considered defective if it does not pass tests and inspections.

D. Prepare test and inspection reports.

5.0 WATER SYSTEM VALVES:

All water system valves to be rated at not less than 125 psig water working pressure at 240°F unless noted otherwise.

5.1 SUBMITTALS:

Refer to division 1, General Conditions, Submittals.

Contractors shall submit a schedule of all valves indicating type of service, dimensions, materials of construction, and pressure/temperature ratings for all valves to be used on the project.

Temperature ratings specified are for continuous operation.

5.2 BALL VALVES:

2" and smaller: Two piece bronze body; threaded; solid stainless steel ball; port; glass filled Teflon seat; threaded packing gland follower; blowout-proof stem; 600 psig WOG.

Valve stems shall allow operators to clear insulation without interference. Provide stem extensions when valve operators interfere with pipe insulation.

2" and smaller: Use ball valves; gate valves will not be accepted in sizes 2" and smaller.

6.0 PRESSURE GAUGES:

Cast aluminum case of not less than 4 inches in diameter, double strength glass window, black lettering on a white background, phosphor bronze bourdon tube with bronze bushings, recalibration from the front of the dial, 99% accuracy over the middle half of the scale, 98.5% accuracy over the remainder of the scale.

Install in locations where indicated on the drawings and/or details, including any gauge piping, with scale range appropriate to the system operating pressures.

Install all pressure gauges in-kind with existing.

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7.0 BOILER INSTALLATION:

Install units as shown on plans, as detailed, and according to manufacturer's installation instructions.

Set units on concrete housekeeping pads.

Manufacturer shall verify in writing that boilers have been cleaned according to their recommendations and are ready for operation.

Isolate boilers from piping system during boil-out.

Pipe boiler drains to nearest floor drains.

8.0 PIPING:

The Contractor shall check all dimensions and shall establish all lines and levels affecting piping and other work specified herein. Such lines, grades, and levels shall be checked with the work of other trades to assure proper clearance of piping and equipment. The Contractor shall be held responsible for correctness of lines, grades, and levels so established and shall provide all fittings and accessories required to satisfy field conditions affecting pipe installation.

Pipe shall be cut accurately to measurements established at the site by the Contractor and shall be worked into place without springing or forcing. Piping shall be run parallel with the lines of the building unless otherwise indicated. A clearance of not less than one inch shall be kept between pipe, or finished covering, and other work or the different piping services. Branch connections and changes in pipe size shall be made with standard pipe fittings. Change in direction shall be made with fittings.

Allowance shall be made throughout for expansion and contraction of piping. Flexibility shall be provided by use of one or more turns to allow piping to spring without straining.

Pipes in exposed locations shall be grouped and be neatly aligned. Vertical pipes shall be accurately plumbed. Horizontal pipes shall be installed parallel to structural members and level or at a uniform slope when a pitch is required. Groups of vertical pipes shall be aligned parallel to a wall whenever practicable, otherwise, they shall be aligned 90 degrees to a wall. Groups of horizontal pipes shall be aligned either horizontally or vertically

All fuel piping most be Black Steel/Black Iron and painted yellow or PVC coded Natural Gas Line.

8.1 PIPE HANGERS AND SUPPORTS:

All piping shall be supported, anchored, and guided in a manner such that expansion and contraction will take place in the direction desired and vibration and undue strain on equipment will be prevented. Hangers shall have means of vertical adjustment after piping is in place.

Supports on flat surfaces shall be with "Unistrut" P-2558 pipe strap bolted to P-1000 channel, or approved equal. Location of hangers shall be coordinated with the structural work to assure that structural members will support the load under operating conditions.

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Hangers and clamps applied to bare copper shall be electrolytically coated or padded with felt.

Hangers applied to piping specified to be insulated shall be sized for the outside diameter of the insulation. Furnish a rigid non-compressible urethane or calcium silicate block (Dow Corning Trymer, or approved equal) insulation insert of 1" minimum thickness or of equal thickness to the adjoining insulation, whichever is greater, and 12" maximum length at each hanger. Spacing between supports shall be not more than 6 feet for tubing up to 1-1/2 inches in diameter and 10 feet for tubing 2 inches and larger. Also, support at each change of direction. Where concentrated loads, such as valves, flanges, and accessories occur, the above spacing does not apply and each location shall be supported.

Where necessary to maintain support spacing, structural members shall be bridged to suit hanger locations.

8.2 WATER PIPING:

All heating water circulating piping materials and installation shall be as specified herein.

8.2.1 WATER PIPING MATERIALS:

Furnish piping materials in accordance with the following tables:

COPPER WATER PIPING

Item Size Description (model, or equal)

Pipe All Copper, Type L

Fittings All Copper, Class 150, threaded or sweat connections, long radius

Ball Valves 2” & Nibco T/S-585-70, bronze 2-piece smaller body, full port, threaded or sweat.

2-1/2" Nibco T/S-595-Y, bronze 3-piece body, full port, threaded or sweat.

3” Nibco T/S-590-Y, bronze 3-piece body, conventional port, threaded or sweat.

Unions 2-1/2" & Nibco 733 series, or approved equal smaller

Dielectric All Piping Products Plus Unions Type DUFC

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Flanges 3" & larger Cast copper Alloy, Class 150, Nibco 771 - Companion Flange C, or approved equal.

Branch All Cast Copper Alloy, Connections Straight tees, Reducing tees shall be Nibco 711 - Tee, or approved equal.

Plugs 2-1/2" & Cast Copper Alloy, Nibco 716 - Fitting smaller Plug, or approved equal.

Bolting All Hex head machine bolts, with one hex nut each

Gaskets All 1/16 inch thick non-metallic composition

Thread All Non-hardening, lead free, thread Lubricant seal compound

8.2.2 THREADED WATER PIPE JOINT FABRICATION:

Threaded joints in ferrous piping shall have American National taper screw threads conforming to ANSI Standard B2.1. After cutting and before threading, pipe shall be reamed and burrs shall be removed. Screw joints shall be made with thread seal compound applied to the male thread only. Caulking of threaded joints to stop or prevent leak will not be permitted. All short connections such as valve vents, drains, pressure connections and small instrument connections shall have a minimum of Schedule 80 nipple between the header and the first block valve.

8.2.3 SOLDERED WATER PIPE JOINT FABRICATION:

Water piping shall be fabricated from Type L, hard drawn copper tubing and standard weight wrought copper fittings. Swaged joints shall not be used. Ells shall be long radius type. Tubing cuts shall be made square, using a sharp wheel cutter or fine tooth hacksaw, reamed after cutting to remove burrs. Soldered joints shall be made in the following manner: (1) Cut tube end square; ream, de-burr and size. (2) Use sand cloth or steel wire brush to clean tube and cup to a bright metal finish. (3) Apply solder flux to outside of tube and inside of cup of fitting carefully so that surfaces to be joined are completely covered. Select flux in accordance with solder manufacturer’s instructions. Use flux sparingly. (4) Apply flame to the fitting to heat tube and solder cup of fitting until solder melts when placed at joint of tube and fitting. (5) Remove flame and feed solder into the joint at one or two points until a ring of solder appears at the end of the fitting (The correct amount of solder is approximately equal to the diameter of the fitting...5/8" solder for 5/8" fitting, etc.). (6) Remove excess solder with a small brush or wiping cloth while plastic.

For domestic water systems (under 100 psi) and drainage piping use 95-5 solder (95% Tin/5% Antimony) with a 4800 psi joint strength and a liquid temperature of 464°F.

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For chilled and heating water hydronic systems and any high pressure (at or above 100 psi) fluid systems use 6% silver/94% tin solder (Harris Stay-Brite 8, or equal) with a 15,000 psi joint strength and a liquids temperature of no greater than 535°F to prevent annealing of the base material.

8.4 PIPING DEVICES:

All piping devices such as shut off valves, flow control valves, flexible connectors, etc., shall be as specified on the project documentation. All such devices shall have a pressure and temperature rating no less than that of the adjoining pipe and shall be installed and adjusted in accordance with the manufacturer's instructions.

8.4.1 DIELECTRIC UNIONS:

All connections between ferrous (steel) and non-ferrous (copper or bronze) piping shall be made with dielectric unions designed to prevent corrosion by insulating against electrical conductivity between dissimilar metals. Bronze fittings are not acceptable alternatives to dielectric unions and shall not be used for this purpose. The means of connection between the pipe and the respective half of the union shall be the same as for the type and size of pipe to be connected (ie;

solder or thread).

8.5 PIPE CLEANING:

Prior to the cutover of the new to the existing piping, new piping shall be thoroughly cleaned.

All equipment, piping, valves, and strainers shall be cleaned inside and outside of oil, grease, metal cuttings and sludge which may have accumulated during construction. Water systems shall be cleaned by flushing, during which each valve shall be operated several times. All strainer baskets shall be removed, cleaned, and replaced.

8.6 INSULATION:

After tests have been successfully completed and pipe surfaces have been cleaned and dried, insulation shall be installed on pipe, valves and equipment of all new and modified piping systems.

8.6.1 HOT SURFACE PIPING INSULATION:

All heating water supply, return and makeup water. Insulation shall be fiberglass with 1-1/2” minimum thickness. Maximum thermal conductivity shall be .23 BTU-In. per sq. ft.-hour-°F at 75°F mean temperature. Insulation shall be jacketed with a reinforced vapor retarder jacket and a factory applied longitudinal acrylic adhesive closure system. Pipe insulation shall be Johns- Manville Micro-Lok, or equal.

8.6.2 INSULATION INSTALLATION:

Insulation shall be applied on clean dry surface after all tests are completed and shall be continuous through walls and equipment openings. Insulation on all cold surfaces where vapor barrier jackets are used shall be applied with a continuous, unbroken vapor seal. Piping at supports shall rest upon 1" thick rigid insulation inserts as specified above. Metal shield shall be applied between hangers or supports and the pipe insulation. Shield shall be formed 18 gauge sheet metal to fit rigid insulation insert and shall be in two halves.

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Fittings at all locations shall be insulated with miter-cut pipe insulation, with insulation sheet cut to size or with insulation tape of the same material as straight pipe insulation. All butt joints and seams shall be sealed with insulation adhesive. All outdoor insulation shall be covered with

0.016 inch thick aluminum with longitudinal Z-joint and secured with 2-inch side locking straps at butt joints. The aluminum shall be carefully cut and mitered around elbows and fittings for a smooth jacket which totally conceals all insulation. All indoor insulation exposed to view shall be finished with polyvinyl chloride (PVC) insulated fitting covers on all pipe fittings, flanges, valves and pipe terminations. Finish all straight pipe sections with 20 mil thick PVC jacketing.

Solvent welding adhesive shall be used to permanently seal all the PVC circumferential lap joints and longitudinal overlap joints in the system. Bands, straps or mechanical clamps for securing the PVC insulation jacketing will not be acceptable. Apply adhesive with strict adherence to the manufacturer's application instructions. Fitting covers and straight pipe jacketing shall be white in color and be ultra violet resistant. They shall also not exceed flame spread 25 and smoke developed 50, as rated by Underwriter's Laboratories. A PVC insulation fitting cover and jacketing brand name known to meet the requirements of this specification is Zeston 2000 PVC, as manufactured by Johns-Manville, Inc.

9.0 BOILER HOT WATER TREATMENT

HVAC water-treatment personnel must be qualified to analyze water quality, and apply water treatment to achieve proper system operation.

Closed hydronic systems hot-water heating, shall have the following water qualities:

1. pH: Maintain a value within [9.0 to 10.5].

2. "P" Alkalinity: Maintain a value within [100 to 500] ppm.

3. Boron: Maintain a value within [100 to 200] ppm.

4. Chemical Oxygen Demand: Maintain a maximum value of [100] ppm.

5. Soluble Copper: Maintain a maximum value of [0.20] ppm.

6. TDS: Maintain a maximum value of [10] ppm.

7. Ammonia: Maintain a maximum value of [20] ppm.

8. Free Caustic Alkalinity: Maintain a maximum value of [20] ppm.

9. Microbiological Limits:

a. Total Aerobic Plate Count: Maintain a maximum value of [1000] organisms/ml.

b. Total Anaerobic Plate Count: Maintain a maximum value of [100] organisms/ml.

c. Nitrate Reducers: Maintain a maximum value of [100]organisms/ml.

d. Sulfate Reducers: Maintain a maximum value of [0] organisms/ml.

e. Iron Bacteria: Maintain a maximum value of [0] organisms/ml.

10.0 CONTROLS:

The boiler manufacturer or the boiler manufacturer’s representative shall furnish and install automatic boiler temperature controls.

1. Supply water temperature setting/thermostat:

- Water set point 180F High (Adjustable)

- Water set point 160F Low (Adjustable)

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- Safety shutdown 190F (Adjustable)

2. Remote enabled circuit

3. Alarm Circuit:

- Flow (GPM)

- Water temperature Low/High

Upon completion of the contract work, the Contractor shall demonstrate to the RE that all controls are properly calibrated and provide the sequence of operation specified. Provide a minimum of three (3) working days advance notice before this demonstration.

10.1 DIRECT DIGITAL CONTROLS (DDC):

The Contractor shall sub-contract the current maintenance contractor that services the existing DDC Building Environmental Controls to integrate the new boilers into the DDC system.

SIEMENS Industry Ins 6141 Katella.

Cypress, CA Tel: 714-761-2200 Service Dispatch 800-806-0886

Integration shall include, but is not limited to DDC points of connection, programming and testing.

The DDC system shall control the new boiler in the following manner:

1. Boiler to operate at a time by use of an operational contact closure.

2. Upon the “enabled” of the boiler fault that shuts off the boiler, the controller shall automatically perform the following tasks:

a. Indicate an alarm via the DDC operator’s interface.

Contractor to integrate new pumps with existing DDC Controls. The DDC system controls the new boiler pumps in the following manner:

1. Determine one “Enabled” (online) boiler pump and one “Standby” boiler pump.

Only one boiler pump to operate at a time by use of an operational contact closure.

2. Rotate the two boiler pumps through a re-settable rotation schedule (day, week or monthly rotation).

11.0 ELECTRICAL:

Items not shown in detail or covered by detailed specifications shall be as set forth in the National Electrical Code.

11.1 CONDUIT FITTINGS:

All conduit inside building shall be electric metallic tubing (EMT) with compression ring type fittings. All conduit outside building shall be rigid steel with threaded fittings. Conduit below

19 | P a g e ground shall be rigid steel with a factory applied plastic coating. All flexible conduit, both inside and outdoors, shall be metallic, liquid tight.

Conduits shall be installed parallel or at right angles to the building. Conduits shall be securely supported and fastened in place at intervals of not more than 5 feet and at each change of direction. Support from building structural steel, walls, or other R.E. approved structural components. Fasteners shall be conduit hangers or one-hole malleable iron pipe straps with appropriate screws or bolts for the surface material. Conduits shall not be supported from metal roof decking. Suspended ceiling support wires shall not be used for the support of conduits.

Changes in direction shall be symmetrical bends or cast-metal fittings. Each conduit entrance to outlet boxes, panel boards, and equipment cabinets shall be fitted with a lock nut and insulated throat connector.

11.2 WIRE:

All wire shall have copper conductors. Size shall be American Wire Gauge (AWG) with size for power circuits as shown on the project drawings. Size for all control circuits shall be #16 AWG.

Power wire #10 AWG and smaller may be stranded or solid; #8 and larger wire, and all control wire, shall be stranded. Insulation shall be type THW or THWN for power wire and type MTW for control wire and shall be color coded as follows:

Single Phase Three Phase

120 Volts 208/240 Volts 120/208 or 240 Volts 277/480 Volts Line-Black Line 1-Black Phase A-Black Phase A-Yellow Neutral-White Line 2-Red Phase B-Red Phase B-Brown Neutral-White Phase C-Blue Phase C-Orange Neutral-White Neutral-White All Circuits:

Ground Green Control Black with numbered adhesive markers on both ends or multi conductor with unique continuous color coded insulation

Power wires #8 and smaller shall have continuous colored insulation. Wires #6 and larger may utilize continuous colored insulation or colored tape. Where conductors are color coded with tape, they shall be half lapped for a minimum length of 3 inches in all junction and pull boxes, accessible raceways, panel boards, outlets, switches and equipment cabinets.

All wire shall be continuous; no splices will be permitted unless specified on the project drawings. Where permitted, splices shall be accomplished with compression type connectors bonded to the wire with a crimping tool and procedure approved by the connector manufacturer.

Wires shall not be installed until all conduit and fittings are in place. All wires shall be drawn into conduit simultaneously and with adequate lubricating compound to prevent damage to insulation.

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Control wiring installed within control panels shall be neatly routed between the control components and shall run parallel and perpendicular to the sides of the panel. Wires which run diagonally from component to component will not be acceptable. Wiring shall have sufficient slack to prevent tension on the termination connector. Route wires between components in the most direct path possible without overshoots and loopbacks. Wires shall be run in open slot wiring duct (Thomas & Betts model 91XXX, or equal with size as required for application.) or bundles of wires shall be neatly secured with nylon self-locking cable ties. Terminate all control wires with spade type, crimped terminals; Exception: Devices such as relays and terminal blocks which utilize clamp type terminals shall not require crimped terminals on the wire.

Wrapping of wires around screw heads shall not be acceptable. All wires exiting the control panel shall terminate on a screw terminal block with each terminal marked the same as on the control schematic on the project drawings.

11.3 GROUNDING:

All noncurrent carrying metallic parts of the electrical system shall be grounded with an insulated wire sized and installed in accordance with Article 250 of the National Electrical Code.

The existing ground wires shall be connected to the ground terminal in the boiler control cabinets as well as the cabinet itself and boiler frame. The frame connection to wire shall be with a separate machine screw and nut which bonds to a clean, bare metal surface. Self-tapping screws are not acceptable for this purpose. Screws which are used for support of the enclosure shall not be used for this purpose.

12.0 FIRE PROTECTION:

All indoor insulating and acoustical materials, vapor barrier, covering and wrapping materials permanently attached or installed separately shall not exceed flame spread 25 and smoke developed 50, as rated by Underwriter's Laboratories.

13.0 DEMOLITION:

Any existing furniture, cabinets, equipment racks or other items which obstruct the Contractor's access to the work area shall either be temporarily relocated by the Contractor to a storage area designated by the R.E. or be covered in a manner as to provide suitable access while protecting the Government property from construction damage. At the completion of all work, the Contractor shall return all such items to their original location.

Any unused conduit, wire, duct, pipe, structural supports or other fittings associated with equipment or devices to be removed under this contract shall also be removed.

All conduits shall be totally removed unless approved by the R.E to only remove it back to the first existing junction box or electrical fitting. Remove all unused wire back to the source power panel. Any circuit which must continue to operate shall be rewired for continuity. Seal all unused conduit with electrical plugs.

Remove unused structural support angles, channels, bolts, and similar hardware. Patch any holes resulting from removed equipment, hardware, conduit or pipe with the same material as that of the penetrated surface. Paint patch to match adjacent undisturbed surface.

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Any equipment or material to be removed, unless shown to be given to the RE, shall become the property of the Contractor and shall be transported from the site.

14.0 IDENTIFICATION:

The boilers shall be identified to show designator. Identify control panel and all controls to show function.

Identification shall be by plastic engraved nameplates with white letters and black background.

Letter size shall be 1/8" for controls, 3/16" for devices on control panel covers and 3/8" for boiler identification. Nameplates shall be secured to equipment, cabinets and to controls with adhesive backing. In addition, nameplates installed outdoors shall be secured with two screws.

Identify all new and modified pipes to show contents (i.e.: Hot Water Supply/Return, etc.) and flow direction. Identification shall be with color coded, printed plastic bands secured around the entire circumference of pipe insulation. Bands shall be "Set mark" as manufactured by Seton Nameplate Corp., or approved equal. Install bands on maximum 10 foot intervals and at each change of pipe direction.

15.0 CLEANING:

Equipment shall be wiped clean, with all traces of oil, dust, dirt or paint spots removed.

16.0 INSTRUCTION MANUALS:

Upon completion of work, the Contractor shall submit to the RE two (2) bound copies of an instruction manual. This manual shall contain, but not be limited to, instructions for installation, operation and maintenance, replacement parts list, sequence of operation description, sizing and capacity data and manufacturer's guarantee information for all equipment furnished by the Contractor.

END OF DOCUMENT…

SIEMENS Industry Ins