SECTION FLUID HEATER. 1.2 RELATED SECTIONS A. Division 16 - Equipment Wiring Systems: Electrical characteristics and wiring connections.

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1 SECTION FLUID HEATER PART 1 - GENERAL 1.1 SECTION INCLUDES A. Heater. B. Controls and heater trim. C. Hot oil connections. D. Fuel burning system and connection. E. Heat exchanger. F. Boiler flue. G. Drum tank with pump for make-up oil. H. Boiler combustion air duct. I. Access panels and ladders. J. Expansion tank. 1.2 RELATED SECTIONS A. Division 16 - Equipment Wiring Systems: Electrical characteristics and wiring connections. 1.3 REFERENCES A. AGA - Directory of Certified Appliances and Accessories. B. NFPA 31 - Installation of Oil Burning Equipment. C. NFPA 54 - National Fuel Gas Code. D. NFPA 70 - National Electrical Code. E. UL - Gas and Oil Equipment Directory. F. Kentucky Boiler Code. 1.4 SUBMITTALS FOR REVIEW A. Shop Drawings: Indicate general assembly, components, controls, safety controls, and wiring diagrams with electrical characteristics and connection requirements, and service connections. Shop drawings shall indicate all piping, valves, pumps and components furnished by the manufacturer, Heatec, B. Product Data: Provide data indicating general assembly, components, controls, safety controls, and wiring diagrams with electrical characteristics and connection requirements, and service connections. C. Test Reports: Indicate specified performance and efficiency is met or exceeded. Provide combustion test that includes boiler firing rate, overfire draft, gas flow rate, heat input, burner manifold gas pressure, percent carbon monoxide (CO), percent oxygen (O), percent excess air, flue gas temperature at outlet, ambient temperature, net stack temperature, percent stack loss, percent combustion efficiency, and heat output. D. Submit manufacturer's installation instructions: Indicate assembly, support details, connection requirements, and include start-up instructions. E. Submit drawings of access ladders and panels

2 F. Manufacturer's Certificate: Certify that units meet or exceed specified requirements. G. Manufacturer's Field Reports: Indicate condition of equipment after start-up including control settings and performance chart of control system. H. Operation and Maintenance Data: Include manufacturer's descriptive literature, operating instructions, cleaning procedures, replacement parts list, and maintenance and repair data. 1.5 QUALITY ASSURANCE A. Manufacturer: Company specializing in manufacturing the Products specified in this section with minimum three years documented experience. B. Installer: Company specializing in installing and servicing the products of this section with minimum three years documented experience approved by manufacturer. 1.6 REGULATORY REQUIREMENTS A. Conform to ASME SEC 1 and UL 726 for construction of boilers. B. Units: UL labeled. C. Conform to applicable NFPA 70 code for internal wiring of factory wired equipment. D. Products Requiring Electrical Connection: Listed and classified by Underwriters' Laboratories, Inc., testing firm acceptable to the authority having jurisdiction as suitable for the purpose specified and indicated. 1.7 DELIVERY, STORAGE, AND PROTECTION A. Protect boilers from damage by leaving factory inspection openings and shipping packaging in place until final installation. 1.8 WARRANTY A. Section Execution Requirements: Product warranties and product bonds. B. This Contractor shall furnish as part of his bid, an unlimited two year parts and labor warranty on equipment provided in this section. At the end of the two year warranty period any parts listed in the Extra Materials section of this specification that were used shall be replaced at no additional charge. The two year warranty period shall begin at the Date of Substantial Completion. 1.9 MAINTENANCE SERVICE A. Provide service and maintenance of boilers for two years from Date of Substantial Completion

3 PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Heatec B. A company approved by the Owner a minimum of seven days prior to the bid opening. 2.2 FLUID HEATER COMPONENTS A. Heatec model HCI D thermal fluid heater. B. Burner C. Blower for burner. D. Control panel. E. Gas train F. Economizer. G. Air pre heater. H. Flue gas stack. I. Expansion tank. J. Drain tank. K. Triplex pump package. L. Barrell pump. M. Boiler combustion air duct. 2.3 SPARE PARTS TO BE SUPPLIED AT TIME OF STARTUP A. All parts shall be replenished for a two year period after startup. B. Scanner C. Module programmer EP170 D. Module display ED510 E. Module amplifier EUVS4 F. Cable ribbon E350-3 (Expansion) G. Module expansion E320 H. Relay RH4B-UL AC240V I. Silicone tube red high temp RTV J. Ignition transformer K. Control temp limit UL350L-00 L. Control temp module UT M. Spark igniter eclipse vorto N. Electrical damper actuator. 2.4 EQUIPMENT SCHEDULE IP UNITS SI UNITS Heater Capacity (Btu/hr) (MW) 11,904, Heater Circulation Rate (Gal/min) (m 3 /hr) 1, Heater Inlet Temperature ( F) ( C) Heater Outlet Temperature ( F) ( C) Minimum Allowable Circulation Rate (Gal/min) (m 3 /hr) 80 %

4 Minimum Allowable Circulation Rate (Gal/min) (m 3 /hr) 5 fps Input (HHV) (Btu/hr) (MW) 14,290, Stack Temperature ( F) ( C) Calculated Heater Efficiency % LHV Heater Calculated P (psid) (kpa) (Clean) 8 56 Pump Head Design (psid) (kpa) Heater Volume (Gallons) (m 3 ) 1,023 4 Tank Cold Volume (Gallons) (m 3 ) Total Volume (Gallons) (m 3 ) 3, Tank Capacity (Gallons) (m 3 ) 1,800 7 Total Surface Area (ft 2 ) (m 2 ) 4, Overall Flux Rate (Btu/hr-ft 2 ) (kw/m 2 ) 2, SYSTEM PARAMETERS The following system parameters are incorporated into this proposal. Plant location KY, USA * Plant elevation (fasl) Less than 2,000 Heater location indoor * Ambient Temperature (ºF) -20 to 100 * Burner turndown 8:1 Gas, Excess air% 15 to 20 Heater orientation Horizontal Primary fuel Natural 5 PSI Nitrogen required (psig) 25 psig Electrical 480 V / 3 PH / 60 Hz Controls NEMA 4 Electrical enclosure NEMA 4X (316 Stainless Steel) Control voltage 110 V / 1 PH / 60 HZ Area classification Not Classified Average skin temperature(@ 5mph wind&70 F ambient) 170 F Fuel Train typical design UL / NFPA 86 Motors TEFC Burner manufacturer Eclipse Thermal fluid Therminol 66 or Equal 2.6 APPROXIMATE PHYSICAL DATA Equipment Length (Ft) Width (Ft) Height (Ft) Weight (Lbs) Mounting Horizontal Heater ,600 Skid Expansion Tank ,939 Top of Heater Triplex Pumps (HP) TEFC Duplex Pump Skid

5 Panel Front of Heater Gas Train 3 Inch NPT Side of Heater Combustion Air Stack ** OD (In) = ,203 Top of Blower Exhaust Stack * OD (In) = Top of Heater Blower (HP) 30 TEFC Front Cover of Heater Economizer ,343 Top of Heater Air pre heater ,957 Pedestals Beside Heater *Exhaust stack shall be extended from the top of the heater up through the roof complete with flashing, storm collar, rain cap including all structural supports as part of this package. Insulating of the stack will be provided as part of the insulation section. ** Combustion air stack shall be extended from the heater through the roof complete with flashing and rain cap and all other accessories as required by the Manufacturer. All structural supports shall be a part of this package. 2.7 PAINTING: A two coat system will be applied to the following: A. Heater shell, front head, rear head, economizer, skid frame, and saddles will receive an SSPC- SP6 commercial blast cleaning and Highland series 860 Light Yellow Primer (2 3 mils thk) and a finish coat of Highland series 865 Heatec Gray (2 3 mils thk.) This series of paints is designed to withstand up to 350 F temperatures. B. Stack throat and stack will receive an SSPC-SP10 near white blast cleaning and Highland series 810 Drum Mix Black (2 4 mils thk) This series of paint is designed to withstand up to 1,300 F temperatures. C. Piping and expansion tank will receive an SSPC-SP6 commercial blast cleaning and Highland series 810 Drum Mix Black (2 4 mils thk) This series of paint is designed to withstand up to 1,300 F temperatures. D. The fuel train will receive an SSPC-SP6 commercial blast cleaning and Highland series 865 CEI Yellow (2 4 mils thk) This series of paint is designed to withstand up to 350 F temperatures. E. All purchased items will remain as painted from respective vendors. Thickness is 2-3 mils DFT. 2.8 CODE DESIGN DATA (Maximum metal temperature and fluid pressure) The equipment will be designed to the requirements stated below. Quality is assured by our in house quality control department. Thickness of coil and shell will not be affected by the manufacturing process as we keep all diameters above the limits that would have an impact on it. Hydrostatic testing will be carried out at our facility and witnessed by our quality control manager. Heater coil design: ASME Section VIII Div I 650 ºF to Psig to FV w/ CA =.0625 Heater shell design

6 Non-code 300 ºF to W.C. w/ CA =.0625 Expansion Tank: ASME Section VIII Div I 650 ºF to Psig to FV w/ CA =.0625 Fuel train design: UL / NFPA 86 Heater stack design: Non-code 800 ºF to W.C. w/ CA =.0625 Panel: UL/NEC/NFPA Drain Tank: Atmospheric FLEX FILMS, U.S.A, LLC 2.8 EQUIPMENT CONSTRUCTION A. Heater: The heater shall be completely packaged, wired and tested and shall include the following: Carbon steel (SA106 Gr. B seamless) schedule 40 tight-wound helical coil Dual split inlet and outlet headers. Single inlet and outlet 300 # (SA105) flanges Heater coil hydro-testing per ASME code Coil will be stamped and receive National Board Registration 304 SS coil supports (skip welded to shell to help dissipate heat transmission). Coil is enclosed by an (minimum ¼ thick) A36 carbon steel shell with bolted end covers (w/ lift eyes) Internally insulated with ceramic fiber blanket, using welded 310 SS pins with washers for support. Blanket will receive a coat of rigidizer. Peep sight in rear cover Inert gas smothering connection in front cover. (Gas and controls by others) Structural steel skid with saddles welded to channels to form a skid mounted frame, and a five foot skid deck extension for mounting controls Skid lifting lugs (minimum of four) Stack with flanged bottom connection, 150 # RFWN EPA type sampling ports, rain cap, flashing and bird screen (Un-insulated) Structural bracing and support of stack and heat exchanger. 18 diameter bolted access door in front of heater(models # and larger only) Coil butt welds receive 100% radiography in radiant section and spot radiography in convection section Extra convection section to increase heater efficiency. Economizer (Extra Convection Section) with stack transitions and piping to heater inlet (Crossover piping). Economizer consists of a serpentine carbon steel pipe coil with carbon steel serrated fins. Piping to heater inlet is included (Insulation of piping is not included). Air pre-heater to increase the efficiency to 91% LHV (304 SS Material). B. Burner: Direct spark ignited natural gas pilot (Interrupted type) Forced draft (Eclipse or North American) Ignition transformer UV Self checking flame detection scanner for proving main and pilot flames (Self checking scanner is required by NFPA if operating over 12 hours continuously without a shutdown)

7 C. Blower: Blower is integral to burner. Inlet Damper (Mild Steel Construction) with modulation motor. Duct with combustion air pressure switch. D. Gas Train: Pilot train with regulator, electric double block & bleed safety shutdown valves, manual valve, 1 x pressure gauge Main train Drip leg Manual shutoff valve Gas Strainer Tee to pilot train Pressure gauge x 2 Gas regulator (Must be vented to a safe location) Vent line with manual shutoff valve for leak testing Low and high pressure switches Leakage test connection with manual shutoff valve Fuel Modulation via Ratiomatic regulator Double block (one with proof of closure switch) safety shutdown valves Safety vent valve. Bleed line with two (1) manual shutoff valves for leak testing Duplex strainer. Emissions estimate: (NOx - 75 PPM, CO 80 PPM) 1. All emissions are at 100% of maximum combustion rating (MCR) and are in the units of PPM referenced to 3% dry stack oxygen. 2. Emissions are valid for natural gas combustion only. The values are based on natural gas containing no fuel bound nitrogen and no sulfur. E. BURNER MANAGEMENT SYSTEM (BMS) ELECTRICAL CONTROL ENCLOSURE: The heater s electrical control enclosure shall contain all of the electrical components to safely operate the heater. The burner managment controller shall provide the proper burner sequencing, pre-purge, ignition and flame monitoring protection for automatically ignited oil or gas fuel burners. The enclosure shall also have a single-loop, 4-20mA modulating, digital temperature controller and two digital temperature limit controllers; one for the thermal fluid and one for the stack. The burner managment controller shall monitor other heater safety limits in it s limit circuit. If a limit condition occurs, the burner managment controller shall safely shut down the burner. The enclosure and installed components shall meet NEMA standards. The enclosure shall be designed and wired to meet the requirments of NFPA 70, National Electric Code (NEC) and the requirements

8 found in Underwriters Laboratories Inc. (UL) 508A Listing for Industrial Control Panels. This listing can be verified on the following website: The BMS control enclosure shall be manufactured and tested by the boiler manufacturer. The panel shall include the following: Siemens breaker disconnect mounted on back panel with a through the door operator handle. Siemens motor starter protectors MSP (breaker, overload and contactor) for blower motor and pump(s), if applicable. Step-down transformer. Yokogawa UT350L (1/4 DIN) high thermal fluid temperature limit controller with primary output relay, manual reset, digital display and 4-20mA re-transmission output capability. Yokogawa UT350L (1/4DIN) high stack temperature limit switch with primary output relay, manual reset, digital display and 4-20mA re-transmission output capability. Lights for: Emergency Shutdown, Power On, Alarm Silenced. Switches for: Burner Off/On, Alarm Silence, Low Fire Hold and Media Circulating Pump Select (if applicable). Emergency Shut Down (ESD) Button. Alarm Horn, to indicate alarm (mounted on side of panel). Control Logix PLC for communication only. This is a slave PLC F. LOCALLY MOUNTED INSTRUMENTS: Digital differential pressure switch for detection of low thermal fluid flow condition Inlet / outlet thermal fluid pressure gauge with isolation valve (NPT) Inlet / outlet thermal fluid Fireye Burner Logix burner management system (BMS) model YB110UVSC with self check scanner amplifier card. The YB110 shall have a display with keypad mounted in the enclosure door allowing user to easily scroll through various menus to view the current operating status, review programmer configurations and lockout history. A flame reset button shall be on the keypad. The YB110 shall have the capability to communicate its status data via Mod- Bus RTU as a slave with a Mod-Bus RTU master device. Programming of the RTU Master to pole the Fireye is responsibility of the customer. The YB110 BurnerLogix shall be cul US Listed, CE and FM approved. Control relays and numbered terminal strips with enclosed wiring raceways. Yokogawa UT55A-040 (1/4 DIN) thermal fluid temperature controller, digital display, 4-20mA analog control output, second input for remote set-point capability and 4-20 ma re-transmission analog output capability. thermometer with thermo-well (NPT) Inlet / outlet thermal fluid temperature thermocouples with thermo-well (NPT) Inlet / outlet thermal fluid temperature transmitters with thermo-well (NPT) Stack temperature transmitter with thermo-well Stack temperature thermocouple with thermo-well ASME Section VIII Type pressure relief valve(s) on the thermal fluid outlet piping (Must be vented to a safe location) Conduit will be used for all wiring G. REMOTE DISPLAY OF CONTROLS Provide display of the following on a computer in the plant. Provide all cables, etc. as required to interface. 1. Fault status from the heater panel. 2. Hot oil temperature leaving the boiler. 3. Heater panels shall be capable of receiving feedback from the plant process computer

9 H. DRAIN TANK: The drain tank shall include a capacity of 4000 Gallons. It shall include the following: Horizontal configuration with saddles for mounting Vent / fill connection with cap Level gauge Low level switch Piping to drain pump inlet Insulation and cladding is not required or included Skid Lifting Lugs I. TRIPLEX (2 X 100% RUNNING, 1 X SPARE) PUMP PACKAGE Dean Pumps sized for 1100 GPM x 70 psig. with 100 HP motors. The pre-piped pump package shall include duplex pumps each with steel base, disc spacer type coupling, full-coverage coupling guard, mechanical seal and electric motor. Each pump shall also include: Suction isolation gate valves Discharge isolation gate valves Suction / discharge pressure gauges with isolation valves Suction / discharge expansion bellows Suction strainer with drain valve Discharge check valves Piping to heater inlet No pipe insulation included Structural steel skid welded to channels to form a skid mounted frame Skid lifting lugs J GALLON EXPANSION TANK The expansion tank should be installed at the highest point in the entire system, (above any piping within the building) and shall include the following: Horizontal configuration with saddles for mounting Vent / fill connection with cap ASME type pressure relief valve Level gauge Low level switch Piping to pump inlet Insulation and cladding is not required or included Heat up leg with isolation gate valve Expansion leg with isolation gate valve Main leg with isolation gate valve Drain with isolation gate valve Inert gas blanket system with manual gate valve, gas regulator, gas relief valve, low-pressure switch and pressure gauge

10 Structural platform as necessary for maintenance with OSHA approved ladder. K. MAKE-UP OIL PUMP WITH TANK FLEX FILMS, U.S.A, LLC 1. As part of this package provide a drum pump capable of injecting 3 gpm of oil into the piping system with the system under normal operating pressure. 2. Electrical Characteristics: volts, single phase, 60 Hz. 2. Cord and Plug: Provide unit with 6 cord and plug for connection to electric wiring system including grounding connector gallon steel oil drum. 4. Flexible hoses and fittings. L. SERVICE ACCESS 1. As part of this package, provide all Kentucky OSHA approved ladders, catwalks, etc. as required to maintain and service equipment provided in this package. M. SHOP DRAWINGS Drawings shall be sent via or provided on disk (ACAD 2010). Drawings shall be submitted to the engineer for review prior to ordering of equipment. Drawings shall include the following: Description Manuals on CD Foundation Loadings Lift Lug Details P & ID Electrical Diagrams (Ladders Type) Motor Curves Motor Data Sheets Bill of Material Electrical Nameplate Details Flue stack Make-up oil pump and tank. Description Mechanical Design Calculations General Arrangement NDT Reports Hydro-test Report Spare Parts Bill of material Mechanical Utility Requirements Quality Control Manual Material Certifications Structural bracing drawings of flue stack Access ladders PART 3 - EXECUTION 3.1 INSTALLATION A. Install in accordance with manufacturer's instructions. B. Install in accordance with NFPA

11 C. Install boiler on concrete housekeeping base, sized minimum 4 inch larger than boiler base. D. Provide connection of natural gas service in accordance with NFPA 54. E. Provide piping connections and accessories as indicated. F. Pipe relief valves to nearest floor drain. G. Provide for connection to electrical service. Refer to Division 16. H. Provide installation of gas flue vent up through roof. I. Provide installation of combustion air duct up through the roof. J. Provide installation of access ladders, catwalks and panels required to service equipment. 3.2 MANUFACTURER'S FIELD SERVICES A. A factory service representative shall supervise installation of the unit ( four one day visits during installation) and shall be present to start the equipment and train Owner personnel. A letter of compliance with all factory recommendations and installation instructions shall be submitted to the engineer with operation and maintenance instructions. END OF SECTION