SOW DAYTON MANOR HOT WATER.pdf

STATEMENT OF WORK/SPECIFICATIONS

MDC Brooklyn – Dayton Manor

Hot Water Heaters

SPECIFICATIONS:

INTRODUCTION

The Federal Bureau of Prisons (FBOP), Metropolitan Detention Center- Dayton Manor located at 9325 Fort

Hamilton Parkway in Brooklyn, NY intends to make a single award to a responsible entity that will provide all necessary equipment, labor, materials, and incidentals to remove four (4) Lochinvar model # CFN751PM and install two (2) High-output, tankless on-demand water heaters in accordance with the manufacture’s specifications for the units. The installation is to be turn-key operational.

SCOPE OF WORK

The contractor is responsible to provide all equipment and labor to remove four (4) hot water heaters units and unneeded piping (gas, water and electrical) equipment. All removed piping and electrical need to be properly safe off to meet all federal, state and local codes. The contractor will install two (2) natural gas high-out-put, tankless on-demand water heaters. The minimum input should be 1,001,000 BTU/HR with a thermal efficiency of 94%, the units are to have power vent. Performance GPM- hot water capacity (90F Rise) – 20.8. The unit is to have the following safety devices installed on the unit: flame rod, thermal fuse, prevention device, fan speed motor, flue temperature monitor, blocked vent detector, dual flame sensing. The riser and the return water lines are to have water temperature gauges installed. The units are to cascade with each other with automatic rotation setup. The goal is to have 120-degree domestic water at all fixtures in all four buildings. The maximum down time of the hot water is to be no more than 16 hours per day as the buildings are occupied by tenants.

CONSTRUCTION OF UNIT

Water heater shall be direct fired, fully condensing, water-tube design. Power burner shall have full modulation.

The minimum firing rate shall not exceed 30,000 BTU/HR input. Water heaters that have an input greater than

30,000 BTU/Hr at minimum fire will not be considered equal. The water heater shall have the capability of discharging into a positive pressure vent. Water heater thermal efficiency shall increase with decreasing load

(output), while maintaining set point. Water heater shall have an operational set point capability of 100 ºF to

190 ºF and shall maintain the outlet temperature within an accuracy of +/- 4 oF during load changes of up to

30% rated capacity. Water heater shall be factory-fabricated, factory-assembled and factory-tested, water-tube condensing water heater with heat exchanger sealed pressure-tight, built on a steel base, including a sealed insulated sheet metal enclosure that acts as combustion-air intake plenum with a built-in serviceable air filter.

Heat Exchanger: The heat exchanger shall be constructed with 316L stainless steel helical water tube, fully floating with no welded joints in the exchanger. The exchanger will have a single-pass unitary design (no separate primary and secondary heat exchanger). The water tubes shall be 0.75” ID, with no less than 0.0472” wall thickness. The heat exchanger shall be ASME Sect IV (HLW) stamped for a working pressure not less than

160 psig.

Modulating Air/Fuel Valve and Burner: The water heater burner shall be capable of a - 33.3 to 1 turndown ratio of the firing rate without loss of combustion efficiency or staging of gas valves. The burner shall be stainless fiber mesh covering a stainless-steel body with spark ignition and flame rectification. All burner material exposed to the combustion zone shall be of stainless-steel construction. There shall be no moving parts within the burner itself. A modulating air/fuel valve shall meter the air and fuel input. A variable frequency drive

(VFD) controlled pre-mix blower shall be used to ensure the optimum mixing of air and fuel between the air/fuel valve and the burner.

The exhaust manifold shall be of polypropylene with 6” diameter flue connection.

Ignition: Ignition shall be via spark ignition with 100 percent main-valve shutoff and dual electronic flame supervision.

CONTROLS

The water heater control system shall be a Masterless Cascading design with no-master - slave designation. The entire system shall have built-in usage optimization routine.

The control panel shall consist of one individual circuit. The circuit boards shall include:

1. A Digital touch display to indicate temperature and status

Each board shall be individually field replaceable.

The combustion safeguard/flame system shall use spark ignition and a rectification-type flame sensor.

The unit shall have a selectable exhaust temperature limit suitable for venting with PVC or

CPVC/Polypropylene/Stainless Steel (AL29-4C)

The controls shall annunciate water heater and sensor status and include extensive self-diagnostic capabilities.

Set point High Limit: Set point high limit allows for a selectable maximum water heater outlet temperature and acts as temperature limiting governor. Setpoint limit is based on a closed loop function that automatically limits firing rate to maintain outlet temperature.

The water heater control system shall incorporate the following additional features for enhanced external system interface:

1. Temperature set point

2. High Exhaust temp monitor and control. Turn down the Gas valve until the exhaust temp is kept below selected material (PVC or CPVC).

3. Cascading via RS232

4. Error Code Display / Error Code History

a. Blower Fault

b. Blocked Flue Fault

c. Ignition Failure

d. Temp Sensor Short

e. Temp Sensor Wiring Fault

f. Flue Temp Fault

g. Heat Exchanger Temp Fault

h. Cascading Fault

i. Water Valve Fault

j. Pump Fault

k. Software Fault

Monitor and access to daily, weekly, monthly water usages data.

Monitor inlet/outlet temperatures, flow rates, flue gas temperatures, combustion rates via onboard system.

Water Heater Management: the water heater control system shall incorporate onboard multi-unit sequencing logic that would allow Masterless Cascading (Not Lead/Lag) functionality & sequencing between multiple water heaters operating in parallel and must have the following capabilities:

Efficiently sequence 2 up to 16 (4,000,000 Btu) heat exchangers on the same system to meet the load requirement.

Individual heat exchanger logic to enable accurate temperature control.

Operate one motorized valve per heat exchanger as an element of the load sequencing, Valves shall close with decreased load as heaters turn off, minimum of one (depending upon Mode selection) must always stay open for recirculation.

Automatically rotate Start/Stop amongst the heat exchangers in the chain based upon an internal calculation of run hours, water through put, burner starts and stops and length of time each burner has been firing. Sequencing is not based upon next in line (Lead/Lag), it is based upon the most logical (least used) heat exchanger in an effort to equalize unit run hours.

Automatic bump-less transfer of sequencing in case of heat exchanger failure. All systems must be able to fail all but one heat exchanger in any order or for any reason and the last will continue to operate.

Each heat exchanger will default to individual control upon failure of the sequencing chain.

Automatic isolation of heat exchanger module from water circuit in case of failure and prevention of cold water from exiting the system

Masterless control, change any parameter in any one of the units and all the rest in the series will automatically adjust to the most recent parameter change.

CONDENSATE

Condensate traps, manufactured from only non-corrosive materials.

Optional Accessory: Smart condensate neutralizer with capability of monitoring pH levels Smart Neutralizer to also include:

1. Monitor water temperatures

2. CO detection, flue gas detection, water leak detection of boiler room w/ audible/visual alarms and alerts

3. Water flow recording/monitoring

4. View history of above parameters

VENTING

The exhaust vent must be PVC, CPVC, Polypropylene, Stainless Steel (AL29-4C) compatible with positive pressure, condensing flue gas service.

The minimum exhaust vent duct size for each water heater is six-inch diameter.

Combustion-Air Intake: Water heaters shall be capable of drawing combustion air from the outdoors via a metal or PVC duct connected between the water heater and the outdoors.

The minimum sealed combustion air duct size for each water heater is 6” diameter.

QUALITY ASSURANCE/INSTALLATION REQUIREMENTS

All installers/technicians shall be qualified and certified by the manufacturer to install, test and certify the new tankless hot water heaters. Such certification must be verified in writing by the manufacturer and submitted to the COR seven (7) days before the project starts. The plumbing contractor must be NYC a licensed plumber for this work.

All requirements, environmental compliance, Life Safety, NFPA, ADA-ABA, and Federal, State and Local codes and regulations will be considered during all phases of this project.

Services and materials provided by the contractor will adhere to and shall be consistent with the most current industry standards, the Underwriters Laboratories (UL) and the General and the National Electric Code (NEC).

It is the contractor’s responsibility to obtain permitting, should it be required. Copies of all permits must be submitted to the COR upon receipt from local agency.

These parts shall be currently manufactured and available through authorized dealers. Such certification must be verified in writing thru submittals by the manufacturer and submitted to the COR on a timely basis.

The installer is to fill and submit to NYS DEP all paperwork necessary to update the buildings NYS Air Permit to include the new Hot Water heaters. The permit should have the Bureau of Prisons, Facility Manager as the

Point of Contact.

WARRANTY

Standard Warranty: Water heaters shall include manufacturer's standard form in which manufacturer agrees to repair or replace components of water heaters that fail in materials or workmanship within specified warranty period.

Warranty Period for Condensing Water heaters:

The heat exchanger coil shall carry a 10 year from commissioning, non-prorated, limited warranty against any failure due to waterside corrosion, mechanical defects, or workmanship. The heat exchanger coil shall carry a

10 year from commissioning, non-prorated, limited warranty against any failure due to condensate corrosion, thermal stress, mechanical defects, or workmanship.

Manufacturer labeled control panels are conditionally warranted against failure for two (2) years from commissioning.

All other components, including the electronic igniter and electrode, are conditionally guaranteed against any failure for 24 months from commissioning.

UTILITIES

The FBOP will provide water, use of restrooms and minimal electricity service (120V) for small hand power tools including battery chargers. The contractor will provide all other equipment, supplies and materials needed to complete this project.

TESTING AND ACCEPTANCE

The Contractor shall notify the COR two (2) days prior to the final system testing and certification so that arrangements can be made to have BOP required staff available to observe testing. A complete plan detailing test procedures must be submitted to the Contracting officer’s representative (COR) in advance for final check out and testing of the complete system.

F. HOUSEKEEPING AND MATERIAL DISPOSAL

The contractor awarded the contract will be responsible to ensure the premises are kept clean and free from accumulations of waste materials and rubbish at all times. The contractor will remove all debris, scrap, and rubbish from the work area daily. Surplus materials and all equipment shall be promptly removed from the site upon completion of the work. The Contractor shall be responsible to remove all debris and waste materials from the job site at Dayton Manor upon conclusion and acceptance of the project. These items must be disposed of in accordance with all Federal, State, and local laws. The Contractor is also responsible to conduct all structural repairs, patch walls, paint, repair ceiling etc., associated with the replacement of the fencing and gate systems.

G. SUBMITTALS & TRAINING

Submittals:

1. The contractor shall provide written submittals to the COR describing recommended equipment within (15) days from receiving the Notice to proceed for approval.

2. All security clearance paperwork/documentation shall be submitted to the COR a minimum of (14) working day prior to the start of work (see below).

3. The Contractor shall provide to the COR three (3) copies of the Safety Data Sheets (SDS) on all materials and substances that may be used during the course of the project. In the event the material is not approved by the Safety Manager, it shall be the responsibility of the Contractor to locate and procure an alternative product.

4. For security and safety purposes, forty-eight (48) hour advance notice in writing, prior to disruption to any utility or control systems must be given to the Contracting Officer and COR.

5. Provide complete narrative descriptions of all system operations.

6. The contractor shall provide one complete set hardcopy D-size drawings of any systems, an electronic version of all the plans in Computer Aided Design (CAD) format (2010edition or later) and in PDF format in disc/s upon completion of the project

7. The contractor shall provide an Installation Certification of the completed and tested systems that contains an affidavit signed by the contractor and manufacturer’s representative, notarized, certifying that the complete systems meet the contract requirements and is fully operational per the manufacturer's recommendations.

8. Any deviations from this Statement of Work will be considered a Change Order Request and must be authorized through the institution’s Contracting Officer prior to the implementation of the requested change.

9. It is the Contractor’s responsibility to repair and/or replace any Government property damaged by contractors/subcontractors’ employees. Damage will be corrected and restored to previous condition at no cost to the Government.

10. It shall be the Contractor’s responsibility for obtaining all measurements and data requirements to comply with manufacturer’s installation recommendations. All installations must be in accordance with product manufacture’s recommendations.

Training:

Upon completion of the installation, testing, and acceptance by the Government, the contractor shall provide the

COR complete hardcopy printout of any system schematics or manuals including schematics and ladder logic diagram, along with CD-ROM disk copies of the program. CD-ROM disks shall include all manufacturers’ software necessary to perform maintenance and adds. The contractor shall provide operation/maintenance manuals for each piece of equipment/system installed. One copy of any required licensed software and associated manuals shall also be supplied to the institution.

The contractor shall furnish manufacturer’s factory-certified training and provide system certification for up to five (5) Bureau of Prisons employees, thus enabling them to maintain and repair all equipment and systems.

Training shall include operations and maintenance of the tankless hot water units.

II. CONTRACTOR SECURITY/WORKING REGULATIONS

A. Work Hours:

Work Hours for the contractor are 6:00 AM – 4:00 PM, Monday - Friday, excluding weekends and federal holidays. Any work required to be completed at any other time than noted above must be requested in writing to the COR five (5) working days prior to the start of the work. In the event of any equipment being replaced that would result in downtime of the normal orderly running of the building, alternate work hours may be authorized in accordance with the time frame stated above.

Access to the site will be available from 6:00 AM – 4:00 PM except during emergencies. It shall be the responsibility of the Contractor to familiarize himself, his employees, and his subcontractors of the working hours and conditions in the correctional facility, as working hours may not constitute a full eight-hour workday.

The Government assumes no responsibility to the Contractor nor to any of his subcontractors for shorter hours due to institutional emergencies or entry and/or exit of workers necessitated by normal institution routines.

B. Delivery of Materials:

All construction materials/equipment required for work on this project is required to be processed by the Contractor and coordinated with the institution COR for temporary storage.

Any construction related deliveries which are directly shipped to the contractor can be received between the hours of 7:00 a.m. to 12:00 p.m., Monday through Friday, excluding Federal Holidays. At no point will a Bureau of Prisons (BOP) staff member receive or sign for a delivery if the contractor or his representative is not present to verify and accept the delivery.

Under no circumstances will MDC Brooklyn or its staff be responsible for the acceptance of any Contractor or company deliveries. The contractor shall be responsible for providing their own means of loading and unloading contractor material or equipment.

The contractor shall not use the institution entry/driveway for the loading, unloading, or storage of any materials and equipment. The contractor will not impede/block the driveway at any time during or after the work shift.

C. Storage of Materials and Equipment:

All construction materials/tools shall be stored in a designated area mutually agreed upon between the COR and the contractor. The storage area will be a secure lockable gang box or similar, size to be determined by the contractor and the COR. If required, the contractor shall provide a securable, single point access storage container, such as a Job or Gang Box that will be left in the agreed upon storage area for the duration of the project. Size of the storage container will be determined by the contractor and the COR. The container will be secured using a padlock protocol with two locks to secure it. One shall be a contractor lock and the other lock provided by the institution. If necessary, a heavy-duty chain provided by the contractor may be used to facilitate the locking requirement. All materials and equipment stored within the container will be maintained in a safe an orderly fashion.

Materials cannot be stored at a height that would create a fall hazard. All tools will be inventoried prior to entering the Institution. At the start of each workday all tools will be inventoried out on a daily tool inventory sheet and at the end of the workday all tools will be inventoried back in to ensure accurate accountability of all tools at the end of each workday.

All contractor owned extension cords that will be used during the project, regardless of length, shall be in good condition with no broken outer Insulation. Extension cords are considered a “high risk” tool having a Federal

Bureau of Prisons’ tool classification of Double A. All contractor owned extension cords used for this project will be required to exit the institution at the end of every workday for the duration of the project.

All contractor owned ladders approved for use within Dayton Manor, regardless of the size, shall be stored in a pre-determined area and secured to a stationary fixture with a heavy link chain and lock which would prevent removal.

D. Security Clearance/Contractor Badges:

The contractor shall provide the COR with all the necessary security clearance documents for all contractors and subcontractor employees accessing the institution and be security cleared for badging within 14 days of receiving the Notice to Proceed, as stated above. Security clearance documents will only be accepted from the prime contractor. If submitted by a sub-contractor, they will be rejected. It is the prime contractor’s responsibility to review security clearance submissions to ensure they are complete.

In the event a contractor or subcontractor employee cannot pass the security clearance process, it will be the contractor’s responsibility to provide another candidate. By law the BOP cannot, and will not, release any information to the contractor concerning the nature of why a contractors or subcontractor employee was not able to pass the security clearance process.

All contractors/subcontractors working at MDC Brooklyn will be issued and required to wear a picture ID/contractor badge provided by the institution. For security reasons, the badge will be worn in a visible manner as directed by the COR.

All contractors and subcontractor employees will provide a check list of all employees on site each day to the COR, verifying the number of workers on site each day and that all workers are approved to be on site.

E. Safety and Personal Protective Equipment:

All contractors and employees shall have and wear the required personal protective equipment (PPE) prescribed by industry standards at all times while on the job site. It is the responsibility of the contractor to provide all PPE equipment. All ladders regardless of the size shall be stored and secured to a stationary fixture with a chain and lock in a predetermined area, in a way that they cannot be removed. If ladders are required, immediately consult with the COR to ensure that he or she can make timely notification to appropriate institution staff. All extension cords regardless of length shall be in good condition with no broken outer insulation and will be secured in a locked construction gang box. Should a system require Lock-out/Tag-out, the system will be required to have both Contractor and MDC Brooklyn locks on the isolation point to prevent shock. All Lock-out/Tag-out procedures will be in compliance with the institution Lock-out program.

F. Additional Considerations:

1. Contractor will be permitted to wear jeans, however, shorts, green or khaki-color clothing will not be allowed. The clothes will be proper and suitable for the services that are being provided.

2. Federal smoking policy on Federal property states that smoking is only allowed in outdoor designated areas.

This policy will be strictly enforced.