Replace Boiler in Building 1407 3/5/2015
Project Title: Replace Boiler in Building 1407
Address:
Building 1407 Engine Shop, 5187 Selma Hwy Montgomery, AL 36108
CE Work Order #:
Building 1407
NGB PROJECT #: FAKZ152407
I. GENERAL SCOPE OF WORK: The work covered by this Statement of Work consists of furnishing all labor, equipment, materials, travel, physical security, testing and permits necessary to replace the existing hot water boiler with a hot water pulse boiler, pumps, and piping per the work described herein. At the completion of the project we expect to have completely operational efficient hot water boiler heating system in this building.
A. INTENT OF PROJECT: This work takes place in Building 1407, Engine Shop on the Alabama Air National Guard Base, See Figure #1 for general project location. Following are short narrations of the main items of work:
1. The primary intent of this project is to replace the existing failed boiler with a high efficiency condensing boiler. The basis of design is the AERCO Benchmark condensing boiler and other boilers that meet the minimum boiler efficiency and the minimum materials specified may be acceptable.
2. Building 1407: Replace the existing hot water boiler with one each high efficiency 2,000,000 BTU condensing vertical boiler as described in this statement of work. The work also includes the removal of the existing boiler and supporting systems, alteration of the existing piping, modifications to the existing flue, supply, return, insulation of the new and altered piping, repair all damaged insulation within the mechanical room, labeling, and replacement of existing controls as necessary to have a complete and operational system.
a. See figure 2 for proposed boiler configuration.
b. Figures 3 and 4 provides photos of the boiler in building 1407.
B. Physical Security: Building 1407 is located in close proximity of the high security areas of the installation. There are no additional escort requirements after initial clearance although the prime contractor is responsible in ensuring contract personnel abide by all security requirements on base. The Air National Guard is not responsible for the security of the Contractor’s equipment and storage of materials.
II. REQUIRED SERVICES:
A. SPECIFIC PROJECT SCOPE:
1. General Installation Requirements: These requirements are typical for all buildings unless otherwise noted.
a. The general requirement of this project is to replace the boiler in building 1407 with a hot water condensing boiler sized as noted below in the specifications.
b. Pre-Construction: Upon award of the contract, the Contracting Officer will host a pre-construction meeting in the Civil Engineering classroom to acquaint all parties participating in this project. The successful contractor should invite any subcontractors who have a part in the work to attend. The purpose of this meeting is to ensure all parties have a complete understanding of the individuals involved and their responsibilities. All parties will have time to participate in the discussing the project’s requirements, accessibility, and other aspects of this project. At the close of this meeting we should have a tentative schedule for all parties involved in this project. New boiler startup must be completed no later than October 1st or end of contract period, whichever comes first.
c. Prior to any demolition the contractor must advise necessary State Boiler entity if required by law, in writing, that boiler for building 1407 is being replaced with new hot water boiler and give a complete description of the boiler being removed and installed.
d. A “Hot Work Permit” will be issued, on a daily basis, by the base fire department personnel. The contractor must call the fire department a minimum of 30 minutes in advance to obtain this permit.
e. Demolition: Upon approval of the proposed schedule, the contractor may start the removal of the existing boiler and any other related equipment. Any materials being removed and not being incorporated back into the heating system will become the property of the contractor and must be removed from the site. The contractor shall provide, to the owner, an estimate of weight of all demolished materials removed for reporting purposes.
f. Pre Installation Site Visit: Prior to completing the piping work the contractor shall schedule a site visit with the COR, to pre-approve the boiler location and other installation details of the new boiler.
g. Remove and/or reconfigure the existing piping to accommodate the new boiler/boilers on the existing concrete pad. All new piping installed as part of this project must meet the requirements as described below:
1. Thoroughly flush the system, before the new piping is installed and without the new boiler connected to remove sediment.
2. A proposed piping arrangement shown in Error! Reference source not found. and is supplied for informational purposes only. This plans show typical equipment and a practical arrangement suggested in the boiler manufacturer standard drawings. The contractor will be responsible to modify this plan as required to accommodate existing conditions, at no additional cost to the Government. Accessibility for operation and maintenance personnel shall be given a high priority in the new layout.
3. All piping shall be installed parallel to walls and column centerlines (unless shown otherwise). All piping shall be accurately cut, true, and beveled for welding. Threaded piping shall be accurately cut, reamed and threaded with sharp dies. Copper piping work shall be performed in accordance with best practices requiring accurately cut clean joints and soldering in accordance with the recommended practices for the material and solder employed.
4. Provide valved air vents at top of rise and valved drains at low points. Gas piping may be run level as it is presumed to be dry, but dirt pockets shall be provided at base of risers.
5. Valves shall be located to permit proper and easy operation and maintenance. Valve stems shall not be below centerline of pipe. Refer to plans for stem orientation. Where valves are more than 7ft Above Finished Floor stems shall be horizontal unless shown otherwise.
6. Concrete equipment pads shall be modified/expanded as necessary to accommodate the new boilers.
h. Completely remove the existing condensate system including all piping, hangars, threaded rod, anchor bolts, etc. This will also include condensate tanks, pumps, electrical boxes, conduit, etc.
i. All new hot water piping will be fully insulated in the same manner as the existing pipe insulation or current code whichever is greater. All new piping will be painted and labeled with utility description and direction of flow in the same color scheme as the existing piping or updated to meet current code. Contractor shall inspect and repair any additional damaged piping insulation within the mechanical rooms.
j. Install pressure temperature plugs on all boiler supply and return piping. Install thermometers on supply and return piping of each boiler.
k. Install new 5 gallon, 125 psi working pressure, funnel type chemical feed devices in all boilers. Coordinate the location of these pot feeders with base personnel.
l. Remove the existing boiler flues and make permanent roof repair as required. Install new flues as required and specified by boiler manufacturer. Modify or create new combustion air intake if required by the boiler manufacturer. Patch or fill any fastener holes, or other openings left in the flue or ductwork as required by codes.
m. The new boiler must interface with the existing base Johnson Controls system for purposes of enable/disable, remote start from DDC system, alarm notification, and status. Interface must include supply and return water temperature monitoring capability.
n. Completely remove the existing combustion air dampers and actuators from all buildings and close these openings as described herein. Existing bird screens shall be left in place, all work will take place on the inside of the building except as noted. Remove the damper, actuator, and all the electrical controls and install in their place a 2” insulated panel similar to the panels fabricated by Mapes Industries. Install through these new insulated panels, PVC combustion air duct, size specified by boiler manufacture, routed to the new boilers. Route new combustion air ducts as high as possible to provide clearance around the existing and new piping, and provide required spacing or separation between boiler intake and exhaust if required by boiler manufacture.
III. Boiler Specification – GENERAL
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract apply to this Section, including General and Supplementary Conditions and Division 01 Specification Sections.
1.2 SUMMARY
A. This Section includes packaged, factory-fabricated and assembled, gas-fired, vertical fire-tube condensing boilers, trim and accessories for generating hot water.
B. Boiler Schedule:
1. Building 1407: One (1) each 2,000.000 BTU (2.0 MBTU) Boiler
1.3 SUBMITTALS
A. Product Data: Include performance data, operating characteristics, furnished specialties and accessories.
Prior to flue vent installation, engineered calculations and drawings must be submitted to COR to thoroughly demonstrate that size and configuration conform to recommended size, length and footprint for each submitted boiler.
B. Efficiency Curves: At a minimum, submit efficiency curves for 100%, 50% and 7% input firing rates at incoming water temperatures ranging from 80°F to 160°F. Test protocols shall conform to boiler manufacturers standards.
C. Pressure Drop Curve. Submit pressure drop curve for flows ranging from 0 gpm to 375 gpm for the 2.0 MBTU boiler.
1. If submitted material is different from that of the design basis, boiler manufacture shall incur all costs associated with reselection of necessary pumps. Possible differences include, but are not limited to, the pump type, pump pad size, electrical characteristics and piping changes.
D. Shop Drawings: For boilers, boiler trim and accessories include:
1. Plans, elevations, sections, details and attachments to other work
2. Wiring Diagrams for power, signal and control wiring
E. Source Quality Control Test Reports: Reports shall be included in submittals.
F. Field Quality Control Test Reports: Reports shall be included in submittals.
G. Operation and Maintenance Data: Data to be included in boiler emergency, operation and maintenance manuals.
H. Warranty: Standard warranty specified in this Section
I. Other Informational Submittals:
1. ASME Stamp Certification and Report: Submit "A," "S," or "PP" stamp certificate of authorization, as required by authorities having jurisdiction, and document hydrostatic testing of piping external to boiler.
1.4 QUALITY ASSURANCE
A. Electrical Components, Devices and Accessories: Boilers must be 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. Performance Compliance: Condensing boilers must be rated in accordance with applicable federal testing methods and verified by AHRI as capable of achieving the energy efficiency and performance ratings as tested within prescribed tolerances.
C. ASME Compliance: Condensing boilers must be constructed in accordance with ASME Boiler and Pressure Vessel Code, Section IV “Heating Boilers”.
D. ASHRAE/IESNA 90.1 Compliance: Boilers shall have minimum efficiency according to "Gas and Oil Fired Boilers - Minimum Efficiency Requirements."
E. DOE Compliance: Minimum efficiency shall comply with 10 CFR 430, Subpart B, Appendix N, "Uniform Test Method for Measuring the Energy Consumption of Furnaces and Boilers."
F. UL Compliance: Boilers must be tested 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.
G. NOx Emission Standards: When installed and operated in accordance with manufacturer’s instructions, condensing boilers shall comply with the NOx emission standards outlined in South Coast Air Quality Management District (SCAQMD), Rule 1146.1; and the Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117, and Rule 117.465.
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. If boilers will effectively rest on existing housekeeping pads, equipment will be securely anchored by means of mechanical anchors.
1.6 WARRANTY
A. Standard Warranty: Boilers shall include manufacturer's standard form in which manufacturer agrees to repair or replace components of boilers that fail in materials or workmanship within specified warranty period.
1. Warranty Period for Fire-Tube Condensing Boilers
2. The pressure vessel/heat exchanger shall carry a 10‑year from beneficial occupancy, non-prorated, limited warranty against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship.
3. Manufacturer labeled control panels are conditionally warranted against failure for (2) two years from beneficial occupancy.
4. All other components, with the exception of the igniter and flame detector, shall be conditionally guaranteed against any failure for 18 months from shipment.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
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:
C. Basis-of-Design Product: Subject to compliance with requirements, provide AERCO International, BMK 2000 or a comparable product. Comparable product specifications will need to be submitted with initial proposal. A comparable product must meet all requirements stated in this contract.
2.2 CONSTRUCTION
A. Description: Boiler shall be natural gas fired, fully condensing, vertical fire tube design. Power burner shall have full modulation; for the 2.0 MBTU boilers the minimum firing rate shall not exceed 100,000 BTU/HR input. Boiler efficiency shall increase with decreasing load (output), while maintaining setpoint. Boiler shall be factory-fabricated, factory-assembled and factory-tested, vertical fire-tube condensing boiler with heat exchanger sealed pressure-tight, built on a steel base, including insulated jacket, flue-gas vent, combustion-air intake connections, water supply, return and condensate drain connections, and controls.
B. Heat Exchanger: The heat exchanger shall be constructed of 439 stainless steel fire tubes and tubesheets, with a one-pass combustion gas flow design. The fire tubes shall be 5/8” OD, with no less than 0.049” wall thickness. The upper and lower stainless steel tubesheet shall be no less than 0.25” thick. The pressure vessel/heat exchanger shall be welded construction. The heat exchanger shall be ASME stamped for a working pressure not less than 160 psig. Access to the tubesheets and heat exchanger shall be available by burner and exhaust manifold removal. Minimum access opening shall be no less than 10-inch diameter for the 2.0 MBTU boilers.
C. Pressure Vessel:
1. 2.0 MBTU boiler: The pressure vessel shall have a maximum water volume of 49 gallons. The boiler water pressure drop shall not exceed 3 psig at 258 gpm. The boiler water connections shall be 4‑inch flanged 150‑pound, ANSI rated. The pressure vessel shall be constructed of SA53 carbon steel, with a 0.25‑inch thick wall and 0.50-inch thick upper head. Inspection openings in the pressure vessel shall be in accordance with ASME Section IV pressure vessel code. The boiler shall be designed so that the thermal efficiency increases as the boiler firing rate decreases.