SECTION WATER-TUBE BOILERS

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1 PART 1 - GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Specification Sections, apply to this Section. B. Related Sections include the following: 1. Section "HVAC Water Treatment" for feedwater treatment and connections. 2. Section "Breechings, Chimneys, and Stacks" for connections to breechings, chimneys, and stacks. 3. Section HVAC Instrumentation and Controls for control wiring for automatic temperature control. 1.2 SUMMARY A. This Section includes fuel-fired, water-tube boilers and accessories for heating hot-water systems. 1.3 SUBMITTALS A. Product Data: Include rated capacities; shipping, installed, and operating weights; furnished specialties; and accessories for each model indicated. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, required clearances, method of field assembly, components, and location and size of each field connection. 1. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate between manufacturer-installed and field-installed wiring. C. Source Quality Control Tests and Inspection Reports: Indicate and interpret test results for compliance with performance requirements before shipping. D. Field Test Reports: Indicate and interpret test results for compliance with performance requirements. E. Maintenance Data: Include in the maintenance manuals. Include parts list, maintenance guide, and wiring diagrams for each boiler. 1.4 QUALITY CONTROL A. Listing and Labeling: Provide electrically operated components specified in this Section that are listed and labeled. 1. The Terms "Listed" and "Labeled": As defined in NFPA 70, Article Listing and Labeling Agency Qualifications: A "Nationally Recognized Testing Laboratory" as defined in OSHA Regulation Page 1 of 9

2 B. ASME Compliance: Fabricate and label boilers to comply with the ASME Boiler and Pressure Vessel Code: Section IV, "Heating Boilers." C. ASME Compliance: Fabricate and label boilers to comply with the ASME Boiler and Pressure Vessel Code: Section I, "Power Boilers." D. FM Compliance: Control devices and control sequences according to requirements of FM. E. I=B=R Compliance: Boilers tested and rated according to the Hydronics Institute's "Testing and Rating Standard for Heating Boilers," with I=B=R emblem on a nameplate affixed to the boiler. F. IRI Compliance: Control devices and control sequences according to requirements of IRI. G. Comply with NFPA 70 for electrical components and installation. 1.5 COORDINATION A. Coordinate size and location of concrete bases. Concrete, reinforcement, and formwork requirements are specified in Division 3 Section "Cast-in-Place Concrete." 1.6 WARRANTY A. General Warranty: The special warranty specified in this Article shall not deprive the Owner of other rights the Owner may have under other provisions of the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by the Contractor under requirements of the Contract Documents. B. Special Warranty: Submit a written warranty, executed by the contractor for the heat exchanger. 1. Warranty Period: Manufacturer's standard, but not less than 10 years from date of Substantial Completion. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering boilers that may be incorporated into the Work include, but are not limited to, the following: B. Manufacturers: Subject to compliance with requirements, provide boilers by one of the following: 1. Ajax Boiler, Inc. 2. Bryan 3. Cleaver-Brooks 2.2 BOILERS AND TRIM - GENERAL Page 2 of 9

3 A. All equipment or apparatus of any one system must be the product of one manufacturer or equivalent products of a number of manufacturers which are suitable for use in a unified or assembled system. B. All materials or equipment to be furnished under this Contract shall be new, American made and shall conform to the grade, quality and standards specified herein. Major items of equipment shall be the latest standard products as advertised in printed catalogs by reputable manufacturers for the purpose intended and shall have replacement parts available. C. Mechanical fastenings used throughout the equipment on parts subject to wear and replacement shall be of a type capable of removal and replacement without physical deformation. D. Belts, pulleys, chains, gears, couplings, projecting set screws, keys and other rotating parts shall be fully enclosed or properly guarded. E. When equipment is relocated to a place other than that shown on the Drawings or when equipment other than that specified is used, the Contractor shall pay the entire cost of required revisions to such items as structural steel, concrete, electrical work, piping and ductwork. F. All equipment installation shall conform to the recommendations and standards of the respective manufacturers. The installer shall obtain these recommendations and standards and shall review them prior to the actual installation of the work. Where the contract documents indicate deviation from manufacturer's recommendations or standards, the Contractor shall call such deviations to the attention of the Owner before proceeding with the work. In all cases, work shall be subject to approval by the Owner. 2.3 HOT WATER BOILERS GENERAL A. Each hot water boiler shall be provided with the following trim: 1. ASME NB labeled safety relief valve with hand test lever rated for not less than the boiler burner output capacity. These valves shall be of the type designed for hot water use. Pressure relief rating shall not be in excess of 30 psig for cast iron boilers regardless of static water pressure in the system, and a pressure relief rating shall not to be in excess of 6 psig above the maximum allowable working pressure for pressure up to and including 60 psig, and 10 percent of maximum allowable working pressure over 60 psig for steel boilers, regardless of static water pressure in the system. 2. Safety relief valve discharge pipe shall be piped at full size of valve discharge to within 6 inches of the floor. 3. External low water cut off (manual reset) arranged and wired to cut off burner on fall in water level below the safe water level of the burner. 4. Paddle type flow switch to be mounted in the boiler return nozzle and wired to the burner control to stop the burner and fuel supply when flow is not detected. 5. A minimum 4 1/2 inch water pressure gauge with a scale equal to a minimum of one and one half times the maximum boiler operating pressure. The gauge shall be mounted directly on the boiler. 6. A dial or column type hot water thermometer 250 deg. F maximum temperature, which shall be located to indicate the true temperature of the water. This device may be provided as a separate device or as a combination device with the pressure gauge. Page 3 of 9

4 2.5 BURNERS 7. Boiler drain valve opening(s) with valves so installed to completely drain the boiler. 8. High hot water temperature cut off (manual reset) which shall be located to sense the true temperature of the water. A. Each hot water boiler shall be provided with a combination multiple orifice flame retention type burner, which is the boiler manufacturer's standard offering which meets the performance requirements and contains the features outlined in this Specification. B. Burner output shall be controlled using Lo Hi Lo Off method for burners 1500 MBTUH gross output and smaller and shall be controlled using modulating method for burners with greater than 1500 MBTUH gross output. Minimum required turndown on modulating burners shall be 4 to 1. Burner shall always return to low fire position for ignition and burner shall provide ignition and then shall be fired at low fire until the boiler water temperature or pressure reaches the minimum temperature or pressure required to prevent thermal shock or condensation on the boiler surface. Burner control shall be provided with purge cycles which are initiated before starting a burner and following shut down of the burner. C. The gas train shall be IRI approved type consisting of: 1. Main gas shut off valve. 2. Gas pressure regulator with vent. 3. Low gas pressure interlock 4. Two (2) normally closed motorized safety shut off valves. 5. Normally open solenoid vent valve (connected between two motorized safety shut off valves). 6. Gas test vent. 7. Gas shut off valve (down stream of test vent). 8. Two (2) unions for removal of main gas train. 9. Gas pilot shutoff valve. 10. Gas pilot manifold valve and regulator. 11. Pilot. 12. Butterfly firing valve with operator. 13. High gas pressure interlock. D Gas pilot shall be of premix type with automatic electric ignition. Electronic detector shall monitor pilot so that primary fuel valve cannot open until pilot flame has been established. E. Combustion air shall be provided by a forced draft blower. Blower shall be complete with air damper with operator and sound attenuator section on the combustion air inlet. Motors shall be the standard motors provided by the burner/boiler manufacturer for application. See the boiler schedules for the motor electrical requirements. F. Ignition system shall include: 1. Ultraviolet flame detector 2. Combustion air flow switch 3. Gas electric ignition assembly consisting of a pilot burner, 6000 volt ignition transformer, spark plug, and gas pilot valve fuel train. 4. Direct spark ignition for oil consisting of an ignition transformer, combination pilot regulator/valve and fuel train. Page 4 of 9

5 G. Fuel air control shall provide two position or modulating adjustment of the combustion air damper, the butterfly gas valve, and the fuel oil metering valve using an electric positioning motor. Fuel air control shall work in conjunction with either a pressure controller for steam boilers or a temperature controller for hot water boilers. H. The burner control cabinet(s) shall be a NEMA I enclosure complete with the following: 1. Power on off automatic switch with light which illuminates with automatic mode. 2. Electronic flame safeguard and programmer. 3. Manual potentiometer or Hi Lo fire switch. 4. A "stop" switch. 5. A main fuel light. 6. A low water light. 7. A flame failure light. 8. An ignition failure light. 9. A main flame light. 10 An alarm contact for remote detection of failure of any safety device. 11. Remote "start" contacts. 12. Numbered terminal strip for connection of all externally mounted devices including remote ON OFF, low water cutoff(s), high (temperature) pressure, flow switch. 13. Fused and grounded step down control transformer (115 volt 1 phase) for all control devices. 14. All required control devices and relays not mounted on the boiler or its piping. 15. Magnetic starters with overload protection for the burner motors. 2.6 BOILER LEAD LAG CONTROL PANEL A. Each boiler system shall be provided with a lead lag control panel. Control panel shall be furnished by the boiler manufacturer and installed by the contractor including wiring. B. Panel shall be a minimum NEMA I apparatus control panel, powered by an independent 115-volt power source. Refer to Section HVAC Instrumentation and Controls for further functional requirements. 2.7 BOILER (FLEX TUBE/HOT WATER) A. Boilers shall be manufactured in strict accordance with the ASME Heating Boiler Code, Section IV, subjected to a minimum hydrostatic test of 150 psi and shall bear the ASME stamp of approval for a maximum working pressure of 125 psi at 250 deg. F temperature. B. Boiler shell shall be constructed of welded steel boilerplate. Boiler shall be constructed with adequately sized upper drums, water legs and tube headers, providing proper thermal internal water circulation not requiring an external circulation source. Tubes shall be minimum 1 inch O.D., 13 gauge steel, multi pass, flexible serpentine bend design, not subject to thermal shock damage. Individual tubes shall be easily removable and replaceable without requiring either welding or rolling. C. Boiler shall have not less than 5 square feet or heating surface per boiler horsepower. The boiler shall be constructed and assembled as a completely packaged unit. The boiler shall be furnished with and adequate number of tappings and inspection openings Page 5 of 9

6 to facilitate internal boiler inspection and cleaning. The entire tube area shall be easily accessible for fireside cleaning. D. The boiler shall be complete with an insulated metal jacket, consisting of not less than 1 1/2 inch fiberglass insulation and a 16 gauge rust resistant zinc coated steel casing, painted with a suitable heat resisting primer and lacquer. Complete jacket and insulation shall be easily removable and reinstalled, if necessary. E. The boiler shall be forced draft furnished with a refractory type combustion chamber to be constructed of 2,300 deg. F insulating firebrick and properly insulated from steel base. F. Manhole opening is to be provided for access to combustion chamber and burner head. G. The boiler shall be complete with dual fuel burner and trim. H. Design Basis: Bryan Model D (CL), flexible steel tube boiler. See Schedule of Drawings for capacity voltage required and location of boilers. 2.8 MOTORS A. Refer to Section "Motors" for factory-installed motors. B. Motor Construction: NEMA MG 1, general purpose, continuous duty, Design B. C. Enclosure Type: Open drip-proof motors where satisfactorily housed or remotely located during operation. 2.9 SOURCE QUALITY CONTROL A. Test and inspect boilers according to the ASME Boiler and Pressure Vessel Code, Section IV for low-pressure boilers and Section I for high-pressure boilers. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine area to receive boiler for compliance with requirements for installation tolerances and other conditions affecting boiler performance. Do not proceed with installation until unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Install boilers level and plumb, according to manufacturer's written instructions and referenced standards. B. Install gas-fired boilers according to NFPA 54. C. Support boilers on 4-inch-thick concrete base, 4 inches larger on each side than base of unit. Dowel base to floor on 18-inch centers along perimeter of base. Cast anchor-bolt inserts through base into floor. D. Assemble boiler trim according to manufacturer's written installation instructions. Page 6 of 9

7 E. Install electrical devices furnished with boiler, but not specified, to be factory mounted. 3.3 CONNECTIONS A. Connect gas piping full size to boiler gas-train inlet with union. B. Connect hot-water piping to supply- and return-boiler tappings with shutoff valve and union or flange at each connection. C. Install piping from safety-relief valves to nearest floor drain. D. Install piping from safety valves to nearest floor drain. E. Connect breeching to boiler outlet, full size of outlet. F. Electrical: Comply with applicable requirements in Division 16 Sections. G. Ground equipment. 1. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B. 3.4 FIELD QUALITY CONTROL A. Manufacturer's Field Service: Engage a factory-authorized service representative to supervise the field assembly of components and installation of boilers, including piping and electrical connections. Report results in writing. 1. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. B. Hydrostatically test assembled boiler and piping, according to applicable sections of the ASME Boiler and Pressure Vessel Code. 3.5 CLEANING A. Flush and clean boilers on completion of installation, according to manufacturer's written instructions. B. After completing boiler installation, including outlet fittings and devices, inspect exposed finish; remove burrs, dirt, and construction debris and repair damaged finishes including chips, scratches, and abrasions with manufacturer's touchup paint. 3.6 START UP SERVICE A. Engage a factory-authorized service representative to provide startup service. B. Verify that installation is as indicated and specified. 1. Verify that electrical wiring installation complies with manufacturer's submittal and installation requirements in Division 16 Sections. Do not proceed with boiler startup until wiring installation is acceptable to equipment Installer. Page 7 of 9

8 C. Complete manufacturer's installation and startup checklist and verify the following: 1. Boiler is level on concrete base. 2. Flue and chimney are installed without visible damage. 3. No damage is visible to boiler jacket, refractory, or combustion chamber. 4. Pressure-reducing valves are checked for correct operation and specified relief pressure. Adjust as required. 5. Clearances have been provided and piping is flanged for easy removal and servicing. 6. Heating circuit pipes have been connected to correct ports. 7. Labels are clearly visible. 8. Boiler, burner, and flue are clean and free of construction debris. 9. Burner blower rotates in correct direction. 10. Blower is in alignment and is lubricated 11. Pressure and temperature gages are installed. 12. Control installations are completed. D. Check electrical connection. E. Ensure pumps operate properly. F. Check operation of pressure-reducing valve on gas train, including venting. G. Check that fluid-level, flow-switch, and high-temperature interlocks are in place. H. Start pumps and boilers, and adjust burners for maximum operating efficiency. 1. Fill out startup checklist and attach copy with Contractor Startup Report. 2. Check and record performance of factory-provided boiler protection devices and firing sequences. 3. Check and record performance of boiler fluid-level, flow-switch, and hightemperature interlocks. 4. Run-in boilers as recommended or required by manufacturer. I. Perform the following tests for each firing rate for high/low burners and for 100, 66, and 33 percent load for modulating burners. Adjust boiler combustion efficiency at each firing rate. Measure and record the following: 1. Gas pressure on manifold. 2. Combustion-air temperature at inlet to burner. 3. Flue-gas temperature at boiler discharge. 4. Flue-gas carbon-dioxide and oxygen concentration, stack temperature. 5. Natural flue draft. 6. Voltage and amperage. J. Measure and record water (GPM) flow rate, pressure drops, entering water temperature and leaving water temperature through each boiler. K. Record all barrier and control settings. L. Inspect expansion tank, makeup water meter, tank pressure, pressure-reducing valve, water level, and backflow preventer. M. Check ph and condition of system water. Page 8 of 9

9 N. Submit report to the Owner outlining all results of startup service prior to acceptance of the individual boiler. See Section Commissioning of Mechanical Systems. 3.7 TESTS AND GUARANTEES A. Efficiency Guarantee Complete unit shall be guaranteed to operate at a fuel to gross heat output efficiency of 80 percent or greater over the operating range, when fired with gas. This efficiency shall be field verified at boiler startup. B. Shop Test Complete packaged boiler shall receive factory tests to check construction, operation and function of all controls. C. After the burners and combustion control systems have been placed in operation, all equipment shall be adjusted for maximum combustion efficiency. In the process of effecting these adjustments, a combustion efficiency test shall be conducted with the use of an absorption type analyzer capable of measuring carbon dioxide, oxygen and carbon monoxide. This test shall continue for the length of time necessary to adjust the burners for maximum efficiency at 100, 75, 50 and 25 percent of rating. Stack temperature, overfire draft, carbon dioxide and oxygen shall be recorded. A written report on the combustion test shall be rendered in duplicate to the Owner. 3.8 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner's maintenance personnel as specified below: 1. Operate boiler, including accessories and controls, to demonstrate compliance with requirements. 2. Train Owner's maintenance personnel on procedures and schedules related to startup and shutdown, troubleshooting, servicing, and preventive maintenance. 3. Review data in the maintenance manuals. Refer to Section "Contract Closeout." 4. Review data in the maintenance manuals. Refer to Section "Operation and Maintenance Data." 5. Schedule training with Owner with at least 7 days' advance notice. B. Boiler manufacturer's service representative shall provide proof of his ability to render competent service for the maintenance and repair of all equipment on a 24 hour basis. He shall further attest that a complete inventory of parts, controls, etc. is maintained locally and that an effective service organization with these qualifications has been maintained locally for five (5) years or more. END OF SECTION Page 9 of 9

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