Attachment__2_STEAM_BOILERS_AND_EQUIPMENT_Spec.pdf

SECTION 23 52 49.00 20

STEAM BOILERS AND EQUIPMENT (500,000 - 18,000,000 BTU/HR)

July 2016

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 360 (2010) Specification for Structural Steel Buildings

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 2015) Structural Welding Code - Steel

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASME INTERNATIONAL (ASME)

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

ASME BPVC SEC I (2010) BPVC Section I-Rules for Construction of Power Boilers

ASME BPVC SEC VIII (2010) Boiler and Pressure Vessel Codes:

Section VIII Rules for Construction of Pressure Vessel

ASME CSD-1 (2012) Control and Safety Devices for Automatically Fired Boilers

ASME PTC 4 (2013) Fired Steam Generators

ASTM INTERNATIONAL (ASTM)

ASTM B88 (2014) Standard Specification for Seamless Copper Water Tube

FM GLOBAL (FM)

FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/

NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTORS (NBBI)

NBBI NB-27 (1991) National Board Rules and Recommendations for the Design and Construction of Boiler Blowoff Systems

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 211 (2016) Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-50562 (Basic) Pump Units, Centrifugal, Water, Horizontal; General Service and Boiler-Feed: Electric-Motor or Steam-Turbine-Driven

FS F-B-2903 (Basic; Notice 2) Boilers, Steam and or Water, Firetube, Scotch Packaged Type (320,001 to 35,000,000 BTU/HR Thermal Output Capacity)

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

1.2 SYSTEM DESCRIPTION

Provide two complete identical boilers, complete with appropriate trim, controls, and appurtenances, in accordance with the drawings and specifications for this project.

1.2.1 Heating Surface and Volume Measurements

Submit heating surface and volume measurements, including heat release calculations and performance data at minimum, 25 percent, 50 percent, 75 percent, and 100 percent load sufficient to establish compliance of boilers with heat release requirements. Base calculations on the specified efficiency and capacity.

1.3 RELATED REQUIREMENTS

Section 23 00 00 BASIC MECHANICAL MATERIALS AND METHODS applies, with the additions and modifications stated herein.

1.4 SUBMITTALS

Government approval is required for submittals. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Steam Boiler System

SD-05 Design Data

Heating Surface and Volume Measurements

Heat Release Calculations

Performance Data at Minimum, 25 Percent, 50 Percent, 75 Percent, and 100 Percent Load

SD-06 Test Reports

Boiler System Start-Up Tests

Submit test reports in accordance with section FIELD QUALITY CONTROL. Submit a detailed written record of the start-up performance, including burner setting data over the entire load range, before the Contractor's and sub-contractor's test personnel leave the site.

SD-07 Certificates

Report of Prior Installations

Qualifications of Engineer

Start-Up Plan

Start-Up Certification

Boilers

Submit evidence that boilers meet requirements of standards specified. Include with the certificate of compliance acceptable evidence that standards are met. Acceptable evidence will be the official UL listing mark prescribed in the UL gas and oil equipment list for oil-fired, gas-fired, or gas and oil-fired boiler assemblies, as applicable plus the appropriate official ASME symbol stamp. In lieu of the above certification, acceptable evidence will be a test report from an independent testing laboratory, indicating that the boilers and accessories have been inspected and tested and meet requirements of the applicable standards specified.

SD-10 Operation and Maintenance Data

Boilers, Data Package 4

Submit in accordance with Section 01 78 23 OPERATION AND

MAINTENANCE DATA.

1.5 QUALITY ASSURANCE

1.5.1 Report of Prior Installations

Boilers shall be shipped to the site of installation as a completely assembled packaged boiler-burner unit. A competent installation engineer or technician as stated in paragraph QUALIFICATIONS OF ENGINEER shall assemble an unassembled boiler-burner package in strict accordance with the manufacturer's instructions. Boilers and feedwater equipment installed shall be of proven design which has been tested, successfully installed, and operated in commercial or industrial installations. Submit a certified written report from the boiler and feedwater equipment manufacturer indicating date of installation, type, model, capacity, and address location of installed boilers along with maintenance records and operating conditions including operating load and load swings. Show that substantially identical equipment of comparable capacity, within 20 percent, has been successfully installed and operated in not less than three installations under similar operating conditions for a period of not less than 2 years.

1.5.2 Start-Up and Installation Engineer

Provide the services of a qualified engineer or technician for start-up and tests and installation of equipment as specified below. More than one engineer or technician may be employed based on the types of specific equipment. One engineer or technician appointed by the Contractor shall supervise and be responsible for the overall installation, start-up, test, and checkout of systems.

1.5.3 Qualifications of Engineer

Submit a printed certified qualification resume of the engineer or technician. The engineer's or technician's resume shall list applicable experience related to installation, start-up, and testing of equipment and applicable factory training and education. Qualifications require the engineer to have supervised two installations of similar size and type which are operating satisfactorily. If more than one engineer or technician is employed, provide a certified resume for each one indicating their specific specialty and item of work.

1.5.4 Not used

1.5.5 Start-Up Plan

Submit a written schedule with dates of start-up tests, installation, and checkout of equipment.

1.5.6 Start-Up and Test

Start-up and test engineer or technician shall be approved by the manufacturer of the specific piece of equipment including boiler, boiler controls, boiler instrumentation, and feedwater equipment. The start-up and test engineer or technician shall remain on the job until the unit has been in successful operation for 3 days, and has been accepted by the Contracting Officer.

1.5.7 Start-Up Certification

After installation of equipment, the engineer or technician shall submit a signed certificate or certified written statement that the equipment is installed in accordance with the manufacturer's recommendations.

PART 2 PRODUCTS

2.1 PRODUCT SUSTAINABILITY CRITERIA

For products in this section, where applicable and to extent allowed by performance criteria, provide and document the following:

2.1.1 Energy Efficient Equipment for Boilers

Provide boilers meeting the efficiency requirements as stated within this section.

2.2 BOILERS

Firetube, packaged type of standard duty conforming to FS F-B-2903.

Boilers shall have gross output capacity of at least 4,313 pounds per hour when operating at a steam pressure of 50 pounds per square inch gage (psig) at the site under design conditions when the burner is firing natural gas having a higher heating value of 1,000 Btu per cubic foot and a pressure of 2 psig at the fuel train connection. Boilers shall comply with local, state, and federal emission regulations for the fuel being used. Smoke emission shall not exceed Ringlemann No. 1, except during start-up, cleaning, or soot blowing. Boiler furnaces shall be equipped with combustion control safety devices conforming to ASME CSD-1, for boilers of less than 12,500,000 BTU/HR thermal heating capacity. Burner shall be forced draft gun design. Burners of the rotary type are not acceptable.

Programming controls shall be of the automatic recycling type and shall incorporate means for automatic self-checking of the circuit at the beginning of each start-up cycle. Include a repetitive self-checking circuit to check components at intervals not to exceed the specified flame failure response time in FS F-B-2903 as applicable during the entire period of burner operation. Boilers shall be mounted on a heavy steel frame, and shall be factory painted before shipment. Design basis boilers are 3-pass wetback "Ohio Special" boilers. Other boiler styles and configurations may be used, but contractor will bear the cost and responsibility to adjust all utility and service connections (including exhaust stack, steam output, water and fuel input, electricity and controls) to provide fully functional boilers.

a. Combustion controls shall be of the modulating-positioning type.

Provide connections for remote starting or stopping of the boilers.

Boilers shall be automatic start.

b. Boiler shall be complete with davited front and rear doors capable of being fully cleared from the tube pulling and cleaning ranges, and tightly sealed.

c. Observation ports shall be provided on both front and rear of boilers.

d. Manholes and handholes shall be provided to allow boiler inspection and cleaning.

e. Boiler shall be insulated with minimum 2 inches of blanket insulation, installed under a sectional pre-formed sheet metal skin which can be removed and re-installed without damaging the insulation.

f. Boiler minimum efficiency shall be:

81.2% at 25% load 82.3% at 50% load

81.3% at 75% load and 80.4% at 100% load.

2.2.1 Boiler Connections

Requirements for interconnecting piping, insulation, fuel supply, vibration isolation, and other related work necessary to provide a complete and operable steam system, whether or not specifically mentioned above, shall conform to applicable requirements of other UFGS sections.

a. Gas train: Gas train to include full size quarter turn gas cocks (2 per boiler), regulator, pressure gauges interlocked with boiler controls, relief valves, modulating gas valve, and appropriate unions to allow safe, full, and automatic operation of the boiler.

b. Feedwater control: provide full size items including unions, isolation valves, feedwater control valve, feedwater bypass leg and check valve, to allow safe, full, and automatic operation of the boiler.

c. Provide steam nozzle integral with boiler, sized to allow proper steam flow rate and pressure as specified.

2.2.2 Boiler Instrumentation

In addition to the instruments required by the boiler specifications referenced above, provide the following instruments and locate where shown and where recommended by instrument manufacturer:

a. Flue gas temperature gage, minimum 6" diameter.

b. Draft gage, single point, conforming to ASME B40.100.

c. "Real time" draft gas analyzer system. System shall be designed to constantly test flue gas content, and to independently (of each other) adjust the fuel valve and the air dampers,to ensure that the boiler is operating at peak effieciency with minimal carbon monoxide emissions at all load points, and as fuel caloric value and air temperatures change. Oxygen analyzer shall be the direct probe type utilizing an in-situ zirconium sensing element. Insert element directly in the process flue gas stream and in direct contact with process gasses.

Sensing element shall be contained within a protective shield mounted to the duct work by means of an adapter plate, all furnished by the manufacturer. Analyzer shall be equipped with a facility to allow daily automatic calibration check without removing the analyzer from the process. That is, sample gases may be injected directly on the sensing element while the analyzer is in the process. In order to eliminate the temperature effect of the flue gases, maintain the cell temperature in the probe at 1,550 degrees F by means of an externally mounted temperature controller equipped with cold junction compensation and coupled to the probe with at least 20 feet of flexible cable.

Analyzer shall be FM APP GUIDE approved and certified for "in-stack" analysis technique. Output signal range shall be 4 to 20 milliamps and shall represent 0.25 percent to 25 percent oxygen as a logarithmic function, 0.1 percent to 10 percent oxygen as a logarithmic function, or zero percent to 10 percent as a linear function. Flue gas temperature scale shall be 300 to 800 degrees F. Entire system response shall be not more than 3 seconds.

Analyser and control system output screen to be minimum 6" diagonal color touch screen

2.2.3 Boiler Plant Controls and Instruments

Provide the following plant controls and instruments:

a. Steam pressure gauge with adjustable angled stem, minimum 8" diameter, 0 to 100 psig range, mounted in the steam header of each boiler.

b. Steam flow meter, one per each boiler, mounted in the steam header for each boiler. V-bar insertion vortex meter style, accurate to plus/minus 1.5% of rated conditions. Provide 2" full port bronze gate valve at insertion location. Install with sufficient upstream and downstream straight pipe diameters to produce accurate readings. Two outputs are required per meter, (1) analog 4-20 milliamp 24 volt DC signal and (2) wall mounted 8 character LCD digital display alternately showing flow rate and totalized flow in user-selectable engineering units.

c. Boiler trim: Boilers shall be furnished with all appropriate safety controls. including feedwater pump control, low water cutoff controls, auxilary low water cut-off controls, steam pressure gauge, gas pilot ignitions switches, and ASME safety valve. All items shall be fully integrated into the operational controls of the boiler, such that a major failure shall result in the shutdown and manual reset of the condition before the boiler re-starts.

d. Master Combustion Control: Provide a common boiler master controller on the free standing boiler instrument and control panel to control all boilers with each individual boiler controller acting as a submaster controller. Boiler master control system shall provide for base loading one or more boilers. Base loaded boiler(s) shall be selected manually by an externally accessible switch. On call for heat, lead boiler shall cut in and moderate firing rate to satisfy demands. When maximum desired firing rate is reached, lag boiler or boilers shall cut

in. Maximum desired firing rate for base loaded boiler shall be adjusted initially for boiler peak efficiency and shall be capable of easy manual adjustment by operating engineer. Provide adequate indicators approved by the Contracting Officer to show the method of loading of each boiler, and load being carried by it. Make adjustments at front of panel and no linkage adjustment shall be necessary.

Combustion control system shall be capable of maintaining the plant steam pressure at the main header within the tolerance limits of plus or minus 5 percent expressed as a percent of the set point values. The specified tolerance shall apply to a load which, within a one-minute period, swings from a steady-state condition to an increase (or decrease) in load equal to a maximum of 10 percent of the plant.

Combustion efficiency shall not be less than that specified in the boiler specifications.

Turndown ratio: minimum 4:1

Exhaust gas conditions: maximum Nitrous Oxide (NOx) emissions of 100 parts per million (ppm) at all firing rates, maximum carbon monoxide level of 50 ppm at 25% load level and 25 ppm at 50%, 75%, and 100% firing levels, maximum excess air level of 30% at 25% firing rate and 15% at 50%, 75%, and 100% firing rates.

e. Pressure gage conforming to ASME B40.100 for indicating feedwater pressure.

2.2.4 Boiler Control and Instrument Cabinet(s)

Provide boiler control and instrument cabinet(s) as specified in the referenced boiler specification(s) and may be mounted either on the boiler front or adjacent thereto. The arrangement may consist of a boiler mounted cabinet containing controls normally provided by the manufacturer and a supplementary cabinet containing additional controls and instruments required herein. Mount plant master combustion control and steam flow recorder on east wall of boiler room.

2.2.5 Free-Standing Multi-Boiler Plant Control and Instrument Panel

Provide a free-standing panel and locate as indicated. The panel shall contain all individual and multi-boiler controls, monitoring system, and panel-mounted instruments specified herein and in the reference specifications, except that flame safeguard system may remain separately mounted in a cabinet at each boiler.

2.2.5.1 Control Panel Construction

Construct control panel of not less than 11 gage reinforced steel for face, top, and sides. The enclosed panel shall be not less than 24 inches in depth with inside rigidly welded braces. Design control panel so that all indicating and recording devices and manually operated switches shall be flush mounted in a gasketed removable-top front panel with indicating and recording devices at eye-level. Provide a similar removable-top rear panel located opposite front panel to facilitate wiring, piping, and maintenance. Install other operating controls on a sub-panel within the enclosure. Access to panel enclosure shall be through gasketed, double piano-hinged doors of not less than 16 gage steel. The doors shall be reinforced to prevent sagging and shall be provided with a three point compression type fastener and polished key lock handle. Include a full width fluorescent lighting canopy also. Prime coat complete control panel and lighting canopy and finished in baked enamel. Identify flush-mounted devices on panel with engraved lamicore nameplates. Adequately reinforce, skirt, and suitably design panel base to permit anchoring to the floor or foundation.

2.2.5.2 Control Panel Wiring and Piping

Control panel shall be factory pre-wired in accordance with NFPA 70. Wire shall be thermoplastic Type THW, THWN, XHHW, or UL approved for the intended use, color or number coded, and run in plastic ducts to numbered terminal blocks. Control circuits shall be separately fused with properly rated cartridge type fuses. Power leads to and from magnetic starters and contractors shall terminate at terminal blocks so that field wiring is necessary only from terminal blocks to external equipment. Control leads to and from external control devices shall terminate at separate terminal blocks from power leads. Steam-, draft-, and air-operated devices shall be factory piped to permanently affixed external connections. Pneumatic signals shall be either 3 to 15 psig or 3 to 30 psig. Piping connections to indicators shall be copper tubing conforming to ASTM B88. The boiler operating switch shall be a dust-tight sealed snap-action type. The precision switches shall have cadmium, silver, or platinum contacts, wiping action type, rated at 10 amperes. Electrically or pneumatically tested, controls and equipment shall be to simulate complete operational sequence.

2.3 BOILER BREECHING

2.3.1 Round Breeching

Construct round breeching of black iron or steel in accordance with NFPA 211 for metal connectors for medium-heat appliances and shall be constructed with welded beams and joints. Round breechings also may consist of approved factory-built chimney sections for medium-heat appliances if the sections are joined together with continuous welds, flanges, or couplings.

Provided suitable cleanouts that will permit cleaning the entire breeching without dismantling.

2.3.2 Rectangular Breeching

Structural materials shall comply with the applicable sections of AISC 360.

Shop connections may be welded or bolted as required for joining breeching to equipment. Supply hot dipped galvanized bolts and lock washers for bolted connections. Bolts shall be not less than 3/8 inch in diameter, and spaced not more than 3 inches apart. Furnish bolted joints with 1/8 inch thick non-asbestos gaskets. Breeching shall be not less than 12 MS gage steel. Welds shall conform to AWS D1.1/D1.1M. Breeching system shall provide for maximum expansion and contraction. Expansion joints shall be of the guided flexible crease type with flexible element of not less than

0.0625 inch thick stainless steel. Provide access doors and cast iron or reinforced steel plate with non-asbestos gaskets 1/8 inch thick and positive closing latches of sufficient number to ensure a gas-tight seal.

Thoroughly clean breeching of rust and scale after fabrication by commercial sand blasting.

2.3.3 Breeching Hangers

Design breeching hangers to carry not less than five times the breeching weight. Hangers for round breeching shall be of the band type with hanger rods. Provide steel trapeze type hangers for rectangular breeching with angle support member and hanger rods.

2.3.4 Cleanout Doors

Secure cleanout doors to the ends and sides of the breeching where indicated or where required to effectively clean the breeching. Construct cleanout doors of a gage steel not less than that of the breeching and secure to a 1 1/4 by 1 1/4 inch angle frame not less than 1/8 inch in thickness with mounting bolts welded to the angle frame and spaced not over 6 inches on center; provide 1/16 inch thick long fiber non-asbestos gasket between cleanout doors and frames. Doors shall be squared and shall be full height of diameter or side of breeching up to a size of 24 inches by 24 inches maximum, except that cleanout doors less than 12 inches in height shall be rectangular and shall be 12 inches in length. Plug type cleanouts are not acceptable.

2.4 BLOWDOWN EQUIPMENT

Furnish the boilers with all equipment, tanks, and controls necessary for bottom blowdown of the boilers. The equipment for bottom blowdown systems shall include a blowdown tank and quick acting manual blowdown valves.

Install and pipe blowdown equipment as indicated, and conform to recommendations of the NBBI NB-27, Recommended Rules for National Board Boiler Blowoff Equipment.

2.4.1 Bottom Blowdown Tank

Blowdown tank shall be fabricated of welded steel plate in accordance with ASME BPVC SEC VIII. Tank shall be a vertical cylindrical tank designed for the working pressure of the boiler(s). Tank shall be equipped with a tangential blowdown inlet located so as to impinge on a carbon steel wear plate extending at least 180 degrees around the interior circumference of the tank from the point of inlet. Tank shall be equipped with an internal overflow, vent, drain, safety relief valve, and gage glass with try cocks, blowdown cock, and guard. Tank interior shall be protected by an epoxy coating system suitable for continuous water immersion and operation at a minimum temperature of 300 degrees F. The tank shall be fitted with cathodic protection equipment to minimize galvanic corrosion of the exterior. Size and locate blowoff tank shall be size and located as shown.

2.4.2 Manual valves

Manual action valves shall be provided on all boilers to allow full boiler draining.

2.5 FEEDWATER EQUIPMENT

2.5.1 Boiler Feed Pumps

Conform to CID A-A-50562 for motor driven, horizontal split case or support head boiler feed pumps except as otherwise specified herein. Pumps may be of either the centrifugal or peripheral-turbine type with cast iron casing and shall be bronze or alloy steel fitted. For turbine type pumps, provide pressure relief valves and for centrifugal type pumps, provide by-pass orifice. Packed stuffing boxes or mechanical seals suitable for the design conditions indicated shall be provided. Pumps shall be designed for the net positive suction head, discharge head, and water temperature indicated. Capacity of each pump under the above conditions shall be not less than the following percentage of maximum total boiler capacity:

Centrifugal pumps 125 percent; Turbine pumps 150 percent. Pump motors shall be dripproof.

2.6 ELECTRIC MOTORS

Motors which are not an integral part of a packaged boiler shall be rated for high efficiency service per Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Motors which are an integral part of the packaged boiler system shall be the highest efficiency available by the manufacturer of the packaged boiler.

PART 3 EXECUTION

3.1 INSTALLATION

Arrange work in a neat and orderly manner so that minimum storage of equipment and material is required at the project site. Install equipment and material in accordance with the best commercial practices. A competent installation engineer or technician as stated in paragraph QUALIFICATIONS

OF ENGINEER shall assemble an unassembled boiler-burner package in strict accordance with the manufacturer's instructions. Systems shall be neat in appearance, compact, adequate in construction and assembly, and installed for long and continuous service. Parts shall be readily accessible for inspection, repair, and renewal. Inspect equipment and material upon delivery and test after installation. Protect material and equipment from the weather. Repair damage caused by the Contractor in execution of the work and leave in a condition equal to that existing before work was started.

Remove all conduits and conductors from previous installation that are no longer necessary, back to their original sources and electric panels.

Adjust/modify all existing conduits that can be reused to provide a neat and orderly appearance. Install all conduit in a plumb and true arrangement, installed in parallel groupings.

3.1.1 Equipment Foundations

Locate as shown and construct of sufficient size and weight and of proper design to preclude shifting of equipment under operating conditions or under abnormal conditions that could be imposed upon the equipment.

Install piping in such a manner so as not to place a strain on equipment.

3.1.2 Welding

Work shall be in accordance with the applicable sections of the ASME BPVC SEC I and AWS Z49.1.

3.1.3 Painting

Equipment shall be factory finished to withstand the intended end use environment in accordance with the specifications for the particular end item. Field paint equipment not factory finished as specified herein.

Retouch damaged areas of factory-finished equipment on which the finish has been damaged and then give a complete finish coat to restore the finish to its original condition. The finish coat shall be suitable for exposure in the intended end use environment. Spray painting shall comply with OSHA

29 CFR 1910.

3.1.3.1 Cleaning and Application

Remove dirt, rust, oil, and grease by wire brushing and solvent degreasing prior to application of paint. Apply paint to clean and dry surfaces only. Where more than one coat of paint is specified, apply the second coat after the first coat is thoroughly dry. Retouch damaged painting before applying the succeeding coat. Finished surfaces shall be smooth.

The painting of zinc coated and other corrosion-resistant metal surfaces is not required unless otherwise specified herein.

3.1.3.2 Smoke Flues, Boiler Casing, and Draft Ducts

In unfinished areas, paint smoke flues, boiler casing, and black steel draft ducts with heat-resisting aluminum paint, two coats on the inside of flues and ducts and one coat on the outside, each coat to a minimum dry film thickness of one mil applied directly to clean bare metal surfaces.

Paint exposed surfaces of protective metal covering over insulation, including zinc-coated surfaces, with two coats of heat-resisting black paint to a minimum dry film thickness of two mils applied directly to the clean bare metal surfaces. Do not paint zinc-coated ducts.

3.1.3.3 Gratings, Pipe Railings, and Pit Covers

Apply a pre-treatment coating to gratings, pipe railings, pit covers, and similar plant appurtenances to a dry film thickness of 0.3 to 0.5 mil.

After installation, touch up damaged surfaces with then paint with two coats of finish paint matching type and color of adjacent areas. Do not paint zinc-coated surfaces.

3.1.4 Boiler Cleaning

After installation, each boiler shall be boiled out, under supervision of the manufacturer, with soda ash or equivalent solution to clean internal surfaces of oil, grease, mill scale, and dirt. Following treatment, the boiler(s) shall be flushed, drained and then opened and washed down and inspected to ensure that no traces of oil or foreign matter are present.

The boiler and associated piping shall then be drained and refilled with treated softened water. At all times after initial cleaning, the Contractor shall protect the boiler, tanks, and piping against internal corrosion until testing is completed and the boilers are accepted. Provide chemicals, labor for introducing chemicals, and professional services for control and supervision of the treatment process.

3.1.5 Piping

Material and installation requirements including welding shall be as specified in Section 23 05 00 Piping and Valves for HVAC Work.

3.2 FIELD QUALITY CONTROL

Perform inspections and tests as specified herein to demonstrate that the boiler(s) and auxiliary equipment, as installed, are in compliance with contract requirements. During boiler system start-up tests, factory-trained engineers or technicians employed by individual suppliers of such components as the burner, flame safeguard and combustion controls, feedwater treatment equipment, and other auxiliary equipment shall be present, as required, to ensure the proper functioning, adjustment, and testing of individual components and systems. No bypassing, use of jumpers, or other disablement of control systems will be allowed unless specified elsewhere. Labor, equipment, fuel, and test apparatus required for testing shall be furnished by the Contractor. Rectify defects disclosed by the tests by the Contractor within time period specified by the Contracting Officer.

3.2.1 Inspections and Test

Make inspections and tests at the site under the direction of and subject to the approval of the Contracting Officer. The Contractor shall operate each boiler and appurtenances prior to final testing and shall ensure that necessary adjustments have been made. A 24 hour written notice shall be submitted to the Contracting Officer indicating the equipment is ready for inspection or testing. Provide testing equipment, including gages, thermometers, calorimeter, Orsat apparatus, thermocouple pyrometers, fuel flow meters, water meters, and other test apparatus and set up and calibrate prior to the test. Draft, fuel pressure, and steam flow may be measured by permanent gages and meters installed under the contract. Gas flow may be measured by utility company meters. Provide an analysis of the fuel being used for tests. Control of noise levels developed by exhaust steam including muffler, globe, and gate valves shall be conducted in such a manner as not to create a nuisance or hazard and shall be subject to the approval of the Contracting Officer. Tests shall include the following, and shall be performed when feasible, in the sequence listed:

a. Strength and tightness tests

b. Standards compliance tests

c. Combustion tests

d. Operational tests

e. Capacity and efficiency tests

f. Tests of auxiliary equipment

g. Feedwater equipment test

3.2.2 Strength and Tightness Tests

Subject boiler to the following strength and tightness tests:

3.2.2.1 Hydrostatic Test

After installation and connection, subject each boiler to an inspection and hydrostatic test to determine that the boiler and appurtenances have not been damaged in transit or handling. The hydrostatic test shall be in accordance with the ASME Code with the test pressure applied for a period required by the Contracting Officer. This test shall be in addition to the hydrostatic tests performed at the factory.

3.2.2.2 Pneumatic Tests

Pneumatically test air casing and ducts exterior to the furnace at the maximum working pressure. Use the soap bubble method to verify tightness.

Test gas sides of boilers normally operated under pressure for tightness at 10 inches water gage. For this test, tightly seal the boiler with a suitable means to blank off openings. Admit air to the boiler until test pressure is reached and then hold. If in a 10-minute period the pressure drop does not exceed one inch water gage, the casing shall be regarded as tight and accepted. Use air pressure and soap bubble tests or comparative carbon dioxide readings for induced draft boilers.

3.2.3 Combustion Tests

Test the fuel burning and combustion control equipment with the specified fuel at the minimum limit of the turndown range and at increments of 50, 75, and 100 percent of full rated load. Tests shall be conducted by factory-trained combustion equipment engineers as previously specified.

The combustion control system shall demonstrate that equipment installed will meet the requirements of the specification, and that an overall efficiency as specified, with not over 15 percent excess air, can be obtained with boiler operating at 100 percent capacity. Analyze test data and graphically present to show for each boiler at tested loads: rates of steam flow; flue gas temperature; percent excess air; steam quality; and percentages of carbon dioxide, carbon monoxide, and oxygen in the flue gas. Monitor concentrations of sulfur oxides, particulate, and nitrogen oxides in the flue gas to ensure compliance with environmental requirements. Run tests on each fuel until stack temperatures are constant and conformance with the combustion requirements of this specification has been verified and recorded. Verify proper operation of instrumentation and gauges in the control panel during the test.

3.2.4 Operational Test

Continuously test the boiler(s) under varying load conditions to demonstrate proper operability of the combustion control, flame safeguard control, programming control, and safety interlocks. Conduct this test after the adjustment of the combustion controls has been completed under the combustion test. The operational test shall continue for a period of at least 24 hours and shall include the following:

3.2.4.1 Sequencing

The boiler shall start, operate, fully modulate, and stop in strict accordance with the specified operating sequence.

3.2.4.2 Flame Safeguard

Verify the operation of the flame safeguard controls by simulated flame and ignition failures. Test burners having intermittent pilots by simulating main flame failure while the pilot is burning. Verify by stop watch the trial-for-pilot ignition, trial-for-main flame ignition, combustion control reaction, and valve closing times.

3.2.4.3 Immunity to Hot Refractory

Operate the burner at high fire until the combustion chamber refractory reaches maximum temperature. Then manually close the main fuel valve. The combustion safeguard shall drop out immediately causing the safety shutoff valves to close within the specified control reaction and valve closing times.

3.2.4.4 Pilot Intensity Required

Gradually reduce the fuel supply to the pilot flame to the point at which the combustion safeguard begins to drop out (sense "no flame") but holds in until the main fuel valve opens. At this point of reduced pilot fuel supply, the pilot flame shall be capable of safely igniting the main burner. If the main fuel valve can be opened on a pilot flame of insufficient intensity to safely light the main flame, readjustment of fire eye is required.

3.2.4.5 Immunity to Ignition Spark

Where ultra violet flame detectors are employed, the pilot and main burner manual safety shut off valves shall be closed. The burner shall then be operated through the trial for pilot ignition period. The flame safeguard relay shall not respond to the presence of electric spark. If the flame safeguard relay responds to the presence of electric spark, reject the boiler.

3.2.4.6 Boiler Limit and Fuel Safety Interlocks

Safety shutdowns shall be caused by simulating interlock actuating conditions for each boiler limit and fuel safety interlock. Safety shutdowns shall occur in the specified manner.

3.2.4.7 Combustion Controls

Demonstrate the accuracy, range, and smoothness of operation of the combustion controls by varying the steam demand through the entire firing range required by the turndown ratio specified for the burner, and in case of automatic recycling burners, by further varying the firing rate to require "on-off" cycling. Control accuracy shall be as specified

3.2.4.8 Safety Valves

The high-pressure limit switch shall be locked out or otherwise made inoperative, and the boiler safety valves shall be lifted by steam.

Determine the relieving capacity, popping pressure, blowdown, and reseating pressure by observation and measurement to be in accordance with the ASME Boiler and Pressure Vessel Code. The ASME standard symbol will be accepted only as indicating compliance with the design and material requirements of the code.

3.2.5 Capacity and Efficiency Tests

Perform the capacity and efficiency tests after satisfactory completion of all tests previously specified herein and after the boilers have been operating continuously for one day with no nuisance shutdowns and without the necessity for frequent or difficult adjustments. Perform these tests on each boiler. Conduct tests using the specified fuel. Test procedures shall be in accordance with the heat loss method of the ASME PTC 4 and shall be reported on the ASME Test Form for Abbreviated Efficiency Test.

The duration of the tests shall be sufficient to record necessary data but in no case shall test duration be less than 8 hours.

3.2.6 Auxiliary Equipment and Accessory Tests

Observe and check blowdown valves, stop valves, try cocks, draft fans, fuel oil heaters, pumps, electric motors, and other accessories and appurtenant equipment during the operational and capacity tests for leakage, malfunctions, defects, noncompliance with referenced standards, or overloading, as applicable.

3.2.7 Feedwater Equipment Tests

Perform the test of the feedwater treatment equipment in two steps.

Conduct one test by the Contractor concurrently with either the combustion test or the capacity and efficiency test. A second test will be performed by the Government during the first period of heavy loading after the plant has been accepted and put in service. Deficiencies revealed during the Government tests will be corrected under the guarantee provisions of the contract.

3.2.8 Preliminary Operational Test

Operate each boiler and appurtenances prior to final testing and insure that necessary adjustments have been made. Provide testing equipment required to perform tests. During this testing period, provide operating instructions and training to persons tasked with operation of the boiler.

Tests shall be accomplished with both fuels on dual fuel units.

Conduct a preliminary operational test prior to requesting an acceptance operational test and inspection by the Contracting Officer or his representative. Ten days advance notice is required for scheduling the inspector to conduct acceptance operational test and inspection.

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