W7N30001 SOW Replace Boiler Oil Rack_Revised II.pdf

FEDERAL CORRECTIONAL INSTITUTION

FAIRTON, NEW JERSEY

SPECIFICATIONS FOR B&F PROJECT

2D7N REPLACE BOILER FUEL OIL PUMP SE

1.0 GENERAL

1.1 RELATED DOCUMENTS

1.2 SUMMARY

1.3 SUBMITTAL$

1.4 SYSTEMS DESCRIPTION

1.5 INSTALLATION

1.6 COMPLETION

1.0 GENERAL

TABLE OF CONTENTS

1.7 TOOLS

1.8 WORK HOURJi

1.9 COMPLETETION

1.10 SYSTEM ACCEPTANCE

1.11 WARRANTIES

1.12 COVID-19

All work will be performed at Fairton Federal Correction Institution, located 4 miles east of Fairton, New Jersey, on Highway 698, The work will involve the removal of existing fuel oil _pump set in the pow·erhouse area and installation of a new Duplex Fuel Oil Pump Set to include all automated local and field controls in the powerhouse area at FCI Fairton, EXISTING CONDITIONS

The existing duplex fuel oil pump in the powerhouse area supplies #2 fuel oil to FCI Fairton's three primary hot water boilers for the main institution has out lived its life cycle, is beyond repair, and is in need of replacement.

1.1 RELATED DOCUMENTS

Contractor wi II provide manufacturer drawings displaying schematics of proposed installation and operation of the new fuel oi I pump set. Drawings of schematics must be approved prior to work, Drawings of existing line set are available in a .pdf file format dated 1988.

1.2 SUMMARY

A. A certified representative of the contracted company will complete the work and be responsible for all phases of the project to include but not limited to the disconnect and removal of existing fuel oil pump line set, installation and hook up of new fuel oil pump line set, start-up and testing, and certification process.

I. Contractor will remove the existing fuel oil pump set from the powerhouse area at FCI Fairton.

2. Contractor will provide and install one (I) new Duplex Fuel Oil Pump Set supplying fuel oil to the existing three (3) hot water boiler systems.

3. The contractor will also be responsible for providing necessary materials to include all required and associated field devices and wiring to connect to the Facilities Automated Building Management System, (BLS) system located in the Powerhouse.

B. The performance period for this contract is one hundred and twenty (120) calendar days.

C. All work will meet or exceed the following:

1. Local fire/electrical codes.

2. State fire/electrical codes.

3. State and Federal EPA/ DEP guidelines.

4. ASME Boiler codes

1.3SUBMITT ALS

Three (3) copies of submittals, prepared in accordance with these specifications, will be provided to FCI Fairton. A minimum of three (3) weeks will be allotted for the Northeast Regional Office review and approval. Two sets of the submittals will be retained by FCI Fairton and one (1) set will be returned to the contractor. If contractor requires additional approved sets, up to five (5) sets may be submitted for approval. Submittal of installation certification will be provided to both FCI Fairton's Facilities and Business offices.

1.4 SYSTEMS DESCRIPTION

A. GENERAL

OIL PUMP SET CAPACITY: The new fuel oil pump set will be brand name or equal to Preferred Utilities Duplex Model, 325 G.P.H. located onsite.

EXISTING BOILER: The existing hot water boilers are designed for 160 psig (hot water).

Maximum water temperature will be 200 °F, and maximum system temperature drop will be 30°F. The existing three (3) boilers will require a maximum output of 7,200,000 Btu/hr when fired with No. 2 oil, and/or 1,000 Btu/cu- ft. when fired with natural gas. Available electrical power will be 460Volt, 3phase, 60Hz.

BUILDING MANAGEMENT SYSTEM (BMS): The new fuel oil pump set will be connected, programed and controlled by the existing BLS location onsite.

B. PRODUCTS

1. GENERAL FUEL OIL RACK DESIGN:

The OIL PUMP SET will be Factory assembled Duplex Fuel Oil Transfer Pump Set sized for (2) Cleaver Brooks and (1) Lux fired boilers. The oil rack units'. relief, check and gate valves must be constructed in accordance with ASME Code, and must receive authorized inspection prior to shipment. A copy of the inspection report will be furnished to the purchaser. The complete packaged Fuel Oil Pump Set unit will be Underwriters Laboratories listed and have the UL/cUL label affixed to the front head. Gauges will be furnished and installed to easily facilitate inspection and cleaning.

2. Pumps and motors will be installed to facilitate easy removal and replacement without major system disassembly.

3. The pump set will be sufficiently sized to provide natural internal circulation.

4. The Tank Level Indicators, (TLI's) and wiring in the field will be mounted for easy access to equipment.

5. Analog controller

6. PLC based network compatible controller

7. Type 1 indoor finish, UL Listed and power coated

8. Disconnect switch interlocked with the door hinge

9. All electrical and mechanical compartments inside enclosure will be separated

10. Industrial motors

11. Drip pan with leak detector

12. Leak detection to provide pump disconnect

13. Pump shut offs with high performance gear pumps

C. POWER AND CONTROLS:

1; The Fuel Oil Pump will be UL/cUL approved power and control system in full accordance with the requirements of state, provincial and local codes, local oil utility, and other applicable regulatory bodies. The pump set will be a Preferred Utilities or equal too.

2. Option (specify both): The complete oil pump system will be in full accordance with Factory Mutual (FM) requirements.

3. The complete fuel burning system will be in full accordance with Industrial Risk Insurers (IRI) requirements.

D. BURNER DISCRIPTION:

1. Option (specify)

a. The duplex pump set will be a combination gas-oil burner system having a rated capacity of MMBtu/hr. of 13tu/ cu-It gas at a pressure of (lbs/sq-in.) (Inches of water column) at the inlet to the burner gas control train or gph of No. 2 fuel.

2. Pump motors will be type suitable for local application and will be rated for 460V, 3phase, 3phase, 60hz.

E. FUEL OIL PRESSURE:

1. Monitoring will be provided by an approved pressure switch interlocked to accomplish a non-recycling safety shutdown in the event of low oil pressure.

F. OIL RACK CONTROLS:

1. Each Oil Control System will be factory equipped with a pre-configured Programmable Logic

Controller with OPC Ethernet I/P standard communication capabilities and a Human Machine Interface (HMI) touch screen.

2. Full Contractor Connection to Institutions Dedicated Building Management System, (BMS) for Fuel Safeguard Control Management.

3. Major system components will include:

Compact Logix Programmable Control Processor.

Touch Screen HMI.

Local Modbus network with Parallel Positioning Actuators Field Controller Input/output Modules (As Required).

One Independent Building Management Controller and Wiring Sub-Base.

Various Temperature and Pressure Sensors (For required field locations).

Alarm Bell

G. MAJOR FUNCTIONS THE FUEL OIL.PUMP CONTOL SYSTEM WILL PROVIDE

Fuel proving and lockout on feed pumps failure during pilot flame proving, main flame proving, or run.

Variable Speed Drive Control with optional VSD By-Pass mode on Install and utilize new solid state controls and field sensors to provide various control functions, such as:

Variable Speed Drive Control Modulating Control algorithm will be Proportional-Integral-Derivative (MD) type.

Local Set Point lead/lag control Thermal Protection based on fuel oil temperature Various High and Low limit alarms and shutdowns.

Touch Screen graphical operator interface and monitoring.

Manual control utilizing control screens on the HMI to increment and decrement the flow rate On screen real-time display of all connected process parameters On screen commissioning of rack set points and configurable alarms On screen display of system alarms and faults.

On screen oil level indication (optional) and alarm(s)

H. EXPANDED ANNUNCIATION:

E-mail of pump set alarms (requires optional CB-PT to use this feature) Building/Plant Automation System interface (requires the optional CB-PT for protocols other than OPC compliant Ethernet 1/P to use this feature) Tamper resistant control logic and password protection.

Dual Set Point (Night/Day Set Back) Capabilities (used for local set point Lead lag control).

Fuel Oil Pump System will provide annunciation and diagnostics:

4. Detects and isolates an alarm, and reports internal circuit faults.

- Primary and Secondary Low Flow Shutdown and Alarms.

- The Fuel Oil Rack Control System will be able to operate in these environmental conditions.

- Supply Voltage: 120vac (+I 0%/- 1 5%) 50 or 60 Hz.

- Maximum total connected load: 2000 VA.

- Operating temperature limits: 32F to 130F.

- 85% RH continuous, non-condensing, humidity.

- 0.50 continuous vibration.

- All Control System wiring will be in accordance with the National Electrical Codes and local electrical codes.

- System will meet current NFPA85 requirements

- System will be meet UL 1998 requirements with Cross Limited Feedback

I. OIL LEVEL (SHELL SENSOR ON STEAM BOILERS: Measures and transmits a signal to the Programmable Controller in relation to fuel oil temperature. Building/Plant Automation System interface (Requires the CB-PT to use this option for protocols other than OPC compliant Ethernet I/P)

1.5 INSTALLATION

All work will be completed in a workmanship like manner. All work will meet all applicable latest local and national codes.

1.6 UTILITIES

1. Rest rooms will be available in the entrance building.

2. Electrical power is available from existing buildings.

3. Staging area for material and supplies will be designated by Facilities department.

1.7 TOOLS

A lock box may be left in the rear sally port. The box will have two different keyed locks, one the contractor will hold, the other FCI Fairton personnel will hold. Class 118 11 tools will be allowed to be stored in this box. Class "B" tools are defined as tools that cannot be readily used for an escape. Tools stored outside the secure perimeter are subject to periodic inspections. Mandatory daily tool inventory/accountability will be required of all tools entering and exiting the institution's secure perimeter. Tools will be checked in and out every day.

Tool inventories when entering and or exiting the institution may account for thirty (30) to sixty (60) minutes each direction. No additional monetary compensation will be granted for mandatory entering and exiting procedures.

1.8 WORK HOURS

Work hours are seven-thirty (7:30) A.M. to three (3:00) P.M. and are subject to change due to institution needs, institution emergencies and or inclement weather. Work days are Monday thru Friday except Holidays. Prior to entering the institution and Sierra Unit, all vendors and or contractors must pass a mandatory NCIC background clearance check and attend a security training class provided by FCI Fairton's volunteer coordinator. No additional monetary compensation will be granted for mandatory entering and exiting procedures. All contractors will be escorted by facilities staff.

1.9 COMPLETlON

General: Upon completion of each work day, the contractor is responsible to remove excess debris, materials, equipment, apparatuses, and tools and will leave the premises clean, neat and orderly. The contractor will be responsible for disposal of old materials from the premises unless otherwise determined by FCI Fairton.

1.10 SYSTEM ACCEPTANCE

Testing: The entire system will be tested and certified by the contractor and vendor certified representative. A written copy of the installation specifications, drawings/blue prints, and system certification will be provided to FCI Fairton Business and Facilities offices for final verification and acceptance.

1. Oil Rack Control System component functions will be as follows: ·system will meet current ASME and NFPA requirements

2. Touch Screen Graphical Interface (4 Inch Color Minimum): Provides user interface to the control system, boiler overview screen with connected boiler parameter readouts, alarm screens, optional water level indication, and system firing rate screen at a minimum. Local closed loop Modbus Communication Network for communication with Parallel Positioning Actuators Various Programmable Controller Input/output modules: Provides interface for discrete powered and/or isolated relay signals, as well as for analog signals, from external input devices. Tank Temperature/Level Sensor: measures and transmits a signal to the Programmable Controller in relation to temperature/level for indication. Also used for high level alarm and shutdown.

1.11 WARRANTIES

All equipment will be guaranteed against defects in material and workmanship for a period of 12 months from the date of start-up or 18 months from the date of shipment. The unit will be warranted against damage resulting from thermal stress for a period of 20 years from date of shipment, provided the oil pump set is operated and maintained in accordance with the conditions specified in the owner's Operating and Maintenance Manual.

1.12 COVID-19 ENTRANCE REQUIREMENT

Prior to entering FCI Fairton, all persons will to adhere to the Federal Bureau of Prisons established COVID 19 protocols.