235233 water-tube boiler - needs new header.pdf

F5W61607 Combined Support Maintenance Shop - Phase II Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio 30 January 2009 Bid Final

WATER-TUBE BOILERS 235233 - 1

SECTION 235233 - WATER-TUBE BOILERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes packaged, factory-fabricated and -assembled, gas-fired, finned water-tube boilers, trim, and accessories for generating hot water.

B. This Section includes packaged, water-tube boilers, trim, and accessories for generating hot water with the following configurations, burners, and outputs:

1. Factory assembled.

2. Forced-draft gas burner.

1.3 SUBMITTALS

A. Product Data: Include performance data, operating characteristics, furnished specialties, and accessories.

B. Shop Drawings: For boilers, boiler trim, and accessories. Include plans, elevations, sections, details, piping diagrams, and attachments to other work.

1. Design calculations and vibration isolation base details, signed and sealed by a qualified professional engineer.

a. Design Calculations: Calculate requirements for selecting vibration isolators and seismic restraints and for designing vibration isolation bases.

b. Vibration Isolation Base Details: Detail fabrication including anchorages and attachments to structure and to supported equipment. Include auxiliary motor slides and rails and equipment mounting frames.

2. Wiring Diagrams: Power, signal, and control wiring.

C. Manufacturer Seismic Qualification Certification: Submit certification that boiler, accessories, and components will withstand seismic forces defined in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment." Include the following:

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1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation.

a. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified."

2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions.

3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements.

D. Source quality-control test reports.

E. Field quality-control test reports.

F. Operation and Maintenance Data: For boilers, components, and accessories to include in emergency, operation, and maintenance manuals.

G. Warranty: Special warranty specified in this Section.

1.4 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

B. ASME Compliance: Fabricate and label boilers to comply with ASME Boiler and Pressure Vessel Code.

C. ASHRAE/IESNA 90.1 Compliance: Boilers shall have minimum efficiency according to "Gas and Oil Fired Boilers - Minimum Efficiency Requirements."

D. I=B=R Compliance: Boilers shall be tested and rated according to HI's "Rating Procedure for Heating Boilers" and "Testing Standard for Commercial Boilers," with I=B=R emblem on a nameplate affixed to boiler.

E. UL Compliance: Test boilers for compliance with UL 795, "Commercial-Industrial Gas Heating Equipment." Boilers shall be listed and labeled by a testing agency acceptable to authorities having jurisdiction.

F. Comply with requirements of the EPA and other state and local authorities having jurisdiction. Include permitting and registering of fuel-fired boilers, as necessary per the local authority having jurisdiction.

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1.5 COORDINATION

A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.

Concrete, reinforcement, and formwork requirements are specified in Division 03.

1.6 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace heat exchangers and pressure vessel damaged by thermal shock in materials or workmanship within specified warranty period.

1. Warranty Period for Heat Exchangers: 5 years from date of Substantial Completion.

2. Warranty Period for Pressure Vessel: 5 years from date of Substantial Completion, for thermal shock.

PART 2 - PRODUCTS

2.1 FINNED WATER-TUBE BOILERS

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

B. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

1. Basis-of-Design Product: Subject to compliance with requirements, provide the product indicated on Drawings to match existing boilers from Phase 1 construction.

C. Description: Factory-fabricated, -assembled, and -tested boiler with tubes sealed into headers pressure tight, and set on a steel base; including insulated jacket, flue-gas vent, combustion-air intake connections, water supply and return connections, and controls.

D. Heat Exchanger:

1. Finned copper tubing with stainless-steel baffles.

2. Cast-iron headers.

3. Two-pass, horizontal coil configuration.

4. Tubes shall be sealed in header by mechanically rolling tubes in header.

E. Combustion Chamber Internal Insulation: Interlocking panels of refractory insulation, high-temperature cements, mineral fiber, and ceramic refractory tile for service temperatures to 2000 deg F.

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F. Casing:

1. Jacket: Sheet metal, with snap-in or interlocking closures.

2. Control Compartment Enclosure: NEMA 250, Type 1A.

3. Finish: Baked enamel over primer or Powder coated.

4. Insulation: Minimum 1-inch-thick, mineral-fiber insulation surrounding the heat exchanger.

5. Combustion-Air Connection: Inlet duct collar and sheet metal closure over burner compartment.

6. Mounting base to secure boiler..

a. Seismic Fabrication Requirements: Fabricate mounting base and attachment to boiler pressure vessel, accessories, and components with reinforcement strong enough to withstand seismic forces defined in Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment" when mounting base is anchored to building structure.

G. Burner:

1. Burner Tubes and Orifices: copper, for natural gas.

a. Direct Vent: Factory-mounted centrifugal fan to draw flue gas out of boiler and discharge into boiler vent.

2. Vertical Burner:

a. High-temperature stainless steel to fire in a 360-degree pattern.

b. Burner shall have a viewing port for observation of burner operation and a factory-mounted centrifugal fan to supply outside air to boiler burner.

c. Fan shall be controlled to prepurge and postpurge the combustion chamber before firing.

3. Gas Train: Control devices and proportional control sequence shall comply with requirements in IRI and UL. In addition to these requirements, include shutoff cock, pressure regulator, and control valve.

4. Pilot: Hot-surface pilot ignition with 100 percent main-valve and pilot-safety shutoff with electronic supervision of burner flame.

5. Flue-Gas Recirculation Fans: Centrifugal fans on burner assembly to recirculate flue gas to decrease oxides of nitrogen emissions to less than 10ppm.

a. Motors: Comply with requirements specified in Division 23 Section "Common Motor Requirements for HVAC Equipment."

H. Trim:

1. Aquastat Controllers: Operating, firing rate, and high limit.

2. Safety Relief Valve: ASME rated.

3. Pressure and Temperature Gage: Minimum 3-1/2-inch-diameter, combination water-pressure and -temperature gage. Gages shall have operating-pressure

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and -temperature ranges so normal operating range is about 50 percent of full range.

4. Boiler Air Vent: Automatic.

5. Drain Valve: Minimum NPS 3/4 hose-end gate valve.

6. Circulation Pump: Non-overloading, in-line pump with split-capacitor motor having thermal-overload protection and lubricated bearings; designed to operate at specified boiler pressures and temperatures.

I. Controls:

1. Refer to Division 23 Section "Instrumentation and Control for HVAC."

2.2 ELECTRICAL POWER

A. Controllers, Electrical Devices, and Wiring: Electrical devices and connections are specified in Division 26 Sections.

B. Single-Point Field Power Connection: Factory-installed and -wired switches, motor controllers, transformers, and other electrical devices necessary shall provide a single-point field power connection to boiler.

1. House in NEMA 250, Type 1 enclosure.

2. Wiring shall be numbered and color-coded to match wiring diagram.

3. Install factory wiring outside of an enclosure in a metal raceway.

4. Field power interface shall be to fused disconnect switch.

5. Provide branch power circuit to each motor and to controls with disconnect switch or circuit breaker.

6. Provide each motor with overcurrent protection.

2.3 CAPACITIES AND CHARACTERISTICS

1. Reference Boiler Schedule on the drawings.

2.4 SOURCE QUALITY CONTROL

A. Burner and Hydrostatic Test: Factory adjust burner to eliminate excess oxygen, carbon dioxide, oxides of nitrogen emissions, and carbon monoxide in flue gas and to achieve combustion efficiency; perform hydrostatic test.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Before boiler installation, examine roughing-in for concrete equipment bases, anchor-bolt sizes and locations, and piping and electrical connections to verify actual

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locations, sizes, and other conditions affecting boiler performance, maintenance, and operations.

1. Final boiler locations indicated on Drawings are approximate. Determine exact locations before roughing-in for piping and electrical connections.

B. Examine mechanical spaces for suitable conditions where boilers will be installed.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 BOILER INSTALLATION

A. Install boilers level on concrete base. Concrete base is specified in Division 23 Section "Common Work Results for HVAC," and concrete materials and installation requirements are specified in Division 03.

B. Vibration Isolation: Reference Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment."

C. Install gas-fired boilers according to NFPA 54.

D. Install electrical devices furnished with boiler but not specified to be factory mounted.

E. Install control wiring to field-mounted electrical devices.

3.3 CONNECTIONS

A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. Verify piping arrangement with vendor supplied submittals.

B. Install piping adjacent to boiler to allow service and maintenance.

C. Connect gas piping to boiler gas-train inlet with union. Piping shall be at least full size of gas train connection. Provide a reducer if required.

D. Connect hot-water piping to supply- and return-boiler tappings with shutoff valve and union or flange at each connection.

E. Install piping from safety relief valves to nearest floor drain.

F. Install piping from equipment drain connection to nearest floor drain. Piping shall be at least full size of connection. Provide an isolation valve if required.

G. Connect breeching to full size of boiler outlet. Breeching shall match existing breeching installed during Phase 1 construction.

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H. Connect outside air to full size inlet of boiler. Duct shall match existing outside air ducts installed during Phase 1 construction.

I. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."

J. Connect wiring according to Division 26 Section "Low-Voltage, Electrical Power Conductors and Cables."

3.4 FIELD QUALITY CONTROL

A. Perform tests and inspections and prepare test reports.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

B. Tests and Inspections:

1. Perform installation and startup checks according to manufacturer's written instructions.

2. Leak Test: Hydrostatic test. Repair leaks and retest until no leaks exist.

3. Operational Test: Start units to confirm proper motor rotation and unit operation. Adjust air-fuel ratio and combustion.

4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

a. Check and adjust initial operating set points and high- and low-limit safety set points of fuel supply, water level, and water temperature.

b. Set field-adjustable switches and circuit-breaker trip ranges as indicated.

C. Remove and replace malfunctioning units and retest as specified above.

D. Occupancy Adjustments: When requested within 12 months of date of Substantial Completion, provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to two visits to Project during other than normal occupancy hours for this purpose.

E. Performance Tests:

1. Engage a factory-authorized service representative to inspect component assemblies and equipment installations, including connections, and to conduct performance testing.

2. Boilers shall comply with performance requirements indicated, as determined by field performance tests. Adjust, modify, or replace equipment in order to comply.

3. Perform field performance tests to determine the capacity and efficiency of the boilers.

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a. Test for full capacity.

b. Test for boiler efficiency at 50, 60, 80, 100, 80, 60, 50 percent of full capacity. Determine efficiency at each test point.

4. Repeat tests until results comply with requirements indicated.

5. Provide analysis equipment required to determine performance.

6. Provide temporary equipment and system modifications necessary to dissipate the heat produced during tests if building systems are not adequate.

7. Document test results in a report and submit to Architect.

3.5 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain boilers.

END OF SECTION 235233