I. Base Bidding Requirements Attachment A 00 Boiler Replacement This is a Base Bid project; the following describes the Base Bid requirements. Contractors are to provide bids for Base Bid #1. BASE BID #1 All work listed II. Work Included The following items are site specific requirements of the project. A. The project is intended to provide for the replacement of the existing #1 boiler, burner, and associated controls and safety devices to match the system of Boiler # 2. B. The Contractor shall provide and perform all labor, material, apparatus, trucking, tools, demolition, superintendence, and service required for the completion of the work. C. The Contractor is responsible for obtaining all permits, inspections, and certifications. A copy of all required shall be provided to the Facilities Administrator. D. The Contractor shall coordinate all aspects of this project with PENNDOT -0 Facilities, and Maintenance Units. E. The Contractor shall be responsible for providing and installing a new boiler per the specifications and scope of work, including addendum(s). The specifications and scope of work will be refined at the scheduled pre-bid meeting and changes disseminated prior to the bid opening date. F. The Department shall have the option of retaining ownership of all serviceable boiler sections, burner, controls, and safety devices not reused from the existing boiler. Unserviceable boiler sections, burner, controls, and safety devices from the existing boiler or unwanted parts shall become the property of the contractor and shall be removed from the premises. Page 1 of 12
00 Boiler Replacement G. When existing equipment meets or exceeds this specification, does not require extensive modification, and is verified to be in good working condition, the Department requires the contractor re-use the equipment. H. The Contractor shall provide and perform field modifications to existing piping, connections, mounting pad, gas supply and distribution lines/manifold, exhaust, valves, shut-offs, etc. as necessary and required to complete the project in accordance with the contractors design and installation requirements. I. The new boiler controls shall be compatible with and shall be connected to the existing building automation system by fully trained and qualified technician(s). III. SECTION 15550 -HVAC BOILERS AND RELATED EQUIPMENT A. GENERAL 1.1 STIPULATIONS A. The specification section "General Conditions", "Special Requirements" and General Requirements form a part of this section and shall have the same force and effect as if printed herewith in full. B. The specification Section 15000 - HVAC GENERAL forms a part of this section and shall have the same force and effect as if printed herewith in full. C. When existing equipment meets or exceeds this specification, does not require extensive modification, and is verified to be in good working condition, the Department may require the contractor re-use the equipment. 1.2 GENERAL A. The boiler, tanks, safety devices, piping, accessories, etc., in the boiler room shall meet the requirements of the Pennsylvania Department of Labor & Industry, Boiler Division. B. The Contract Drawings have received preliminary approval from the Boiler Division. It shall be the responsibility of this Contractor to furnish and install the equipment and accessories so that the complete installation will meet the Boiler Division's current requirements. This work will not be considered complete until after final approval of the boiler room is given by the Boiler Division. Page 2 of 12
00 Boiler Replacement C. The Contractor is responsible for obtaining all permits, approvals, and inspections required for boiler operation and certification. B. PRODUCTS A. BOILER/BURNER UNITS (CAST IRON) B. Provide boiler burner unit designed for use with flame retention type combination power gas burner capable of burning gas. C. The boilers will be of a low pressure, cast-iron, sectional type capable of developing full I-B-R gross output capacity of 100% firing rate. The boilers shall have pressurized fireboxes for forced draft and the burners shall be capable of delivering the necessary air for proper combustion and to pressurize the firebox. D. The boiler shall be a H. B. Smith Model 28A-SW-11or approved equal, with burners capable of burning gas. E. The boilers shall be constructed in accordance with the provisions of Section IV of the ASME boiler and Pressure Vessel Code and shall be stamped with the required official ASME symbol and meet all requirements of the Pennsylvania Department of Labor and Industry Boiler Division. Each boiler section shall be hydrostatically tested for 50 psig ASME working pressure. F. The boilers shall be capable of being overfired up to 20% or underfired as much as 20% providing burner capacity is adequate and adjustments are made for good combustion at the actual firing rate. G. The boilers shall be tested in accordance with the requirements of the Hydronics Institute (Institute of Boiler and Radiator Manufacturer's) and shall have 2,201 MBH per hour I=B=R net capacity rating at one-hundred percent firing rate. H. Flame safety guard controls shall automatically restart the boiler firing sequence only in the event of a power failure. I. The boiler sections shall be assembled with individual draw rods that distribute tension evenly on all boiler sections. The boiler sections will not be face ground in order that the corrosion protective outer skin will remain intact. The boiler sections shall be provided with accommodating sealing grooves and high temperature sealing rope shall be employed to assure a permanent gas-tight seal between the sections. The sealing rope shall be compressible and shall be impervious to heat and moisture. J. The boilers shall be provided with a flexible elastomer sealing ring for each port opening to assure a permanent water-tight seal between the boiler sections. Each section shall be provided with aligning lugs to assure positive alignment with the adjoining sections. Page 3 of 12
00 Boiler Replacement K. The boilers shall be provided with a flue collar adaptor with adjustable built-in breeching damper. Flue shall be top or back outlet to match existing. L. The water boiler shall be provided with built-in air elimination system to assure positive separation of air from circulating water. Separated air shall be diverted to the compression tanks from the compression tank tappings located at the top of the boilers. The water boilers shall be constructed to provide balanced water flow through the entire section assembly so that single supply and return connections can be employed; external headers will not be necessary. M. The boilers shall be of a compact low silhouette design to assure minimal space for headroom clearance and for servicing. N. The boiler sections shall be of the Hydro-Wall design to provide a completely water-backed combustion area with water circulated around the entire firebox. O. The boiler sections shall be provided with integral, cast-on legs to maintain ample space between the bottom of the boiler sections and the boiler foundation for natural aeration. P. The boilers shall be furnished with refractory insulated burner mounting plates, which shall be provided with the necessary holes and tappings to mount the burners. High temperature sealing rope shall be employed to provide a permanent gas-tight seal between the front sections and the burner mounting plates. Q. The boilers shall be furnished with observation ports, which shall be mounted on the front sections to permit visual inspection of the burner flame. R. The boilers shall be designed to assure efficient and rapid heat transfer from the combustion gases to the boiler water. The firebox design shall insure maximum radiant heat transfer from the burner flame, and the boiler sections shall be provided with cast-on heat absorbing studs for an enlarged prime heating surface. S. The boilers shall be designed to provide vertical to horizontal flue gas travel, and a horizontal flueway shall be cast into each intermediate section and back section to serve as an internal flue gas collector. T. The boilers shall be furnished with heavy gauge steel cleanout opening covers for the cleanout openings at the top of the boilers. High temperature sealing gaskets shall be employed to insure a permanent gas-tight seal between the boiler sections and the cleanout opening covers. The cleanout opening covers shall be readily removable for the purpose of cleaning the flueways between the boiler sections. U. The front and back sections of the boilers shall be provided with water passage inspection tappings at the bottom and just above the crown sheet. Page 4 of 12
00 Boiler Replacement V. The boilers shall be provided with insulated heavy gauge steel jackets with durable baked enamel finish. The jackets shall be insulated with heavy density, fiberglass on the front, back, top and side panels. The jackets shall be designed to permit installation after the connection of the supply and return piping. W. All electrical safety boiler controls are to be of accepted quality manufacture bearing UL Certification. X. Water Boiler Standard Controls 1. The boilers shall be furnished with combination low temperature limit operating and high temperature limit controls. The low temperature limit control shall be set according to the design requirements of the heating system. The high temperature limit control should be set at least 20 F higher than the low limit control setting (250 F maximum allowable boiler water temperature). 2. The boilers shall be furnished with combination pressure- temperature gauges to indicate boiler water temperature and system pressure; the combination gauges shall be of rugged guarded type construction and the gauge dial shall be clearly marked and easy to read. 3. The boilers shall be furnished with ASME certified pressure relief valves and the valves shall be set to relieve at the rated boiler ASME working pressure. The relief valves shall be of the side outlet discharge type. Y. The boilers shall be furnished with UL certified low water fuel cut-offs. The low water fuel cut-off shall have an ASME working pressure rating of at least the ASME working pressure of the boiler. Required if not already installed Discuss at Pre-Bid Meeting Z. The burner motor and control electrical characteristics shall be [120V/60 Hz/1 phase] match to existing. Discuss at Pre-Bid meeting. AA. The gas burner shall be UL certified and shall be of a design which produces flame retention with rapid intimate mixing of the fuel and combustion air. The burner shall be designed to insure high efficiency and good performance under either balanced draft or forced draft venting conditions. BB. The combination gas burners shall be arranged for on-off operation with pre-purge, low fire start, high fire run, and one-position air control. The burner shall be furnished with a prewired control panel which incorporates an electronic combustion safeguard burner primary control with pre-purge timing and an ultraviolet sensitive electronic flame detector Page 5 of 12
00 Boiler Replacement CC. For gas firing, each burner unit shall be complete with main as shutoff cock with wrench, spring loaded gas pressure regulator, Maxon Series 5000 main electric valve, ASCO vent valve, Honeywell V4055A block gas valve, Honeywell C437 high and low gas pressure switches with manual reset, gas regulating cock, and gas pressure gauge. Burner train shall be sized for a minimum pressure of 7 oz. to inlet of gas pressure regulator at burner, all to meet [FM] [IRI] approval. Discuss the use of existing equipment at pre-bid meeting. When existing equipment meets or exceeds this specification, does not require extensive modification, and is verified to be in good working condition, the Department may require the contractor re-use the equipment. i. Additionally, provide the following: 1. Stack thermometers mounted at boiler flue outlet 2. Low fire hold switches 3. ASME pressure temperature gauges 4. Necessary relief valves 5. Boiler burner mounted fused disconnect to allow one electric connection by Electrical Contractor, all other power and control wiring by this Contractor. 6. Fireye FP-2 combination control or equal. 7. Honeywell L4006A aquastat to maintain constant boiler water temperature. 8. (1) A second Honeywell L4006A aquastat to function as a high limit. 9. (2) Low water cut off mounted in boiler 10. [Limit switches, flame failure, fuel valves, etc., all [FM] [IRI] approved starters, switches, relays and transformers, all mounted and factory wired in a totally enclosed cabinet with three (3) panel mounted signal lights (limit pilot and main).] Match existing, Discuss at Pre-Bid meeting 11. Lead-lag switch (single 4PDT manual toggle switch). DD. Provide all additional controls to meet [FM] [IRI] requirements.] Match existing, Discuss at Pre-Bid meeting EE. The boiler manufacturer shall appoint a Service Contractor who will conduct a prestart-up inspection of the boiler burner unit. The Service Contractor shall then Page 6 of 12
00 Boiler Replacement perform start-up service including the initial start of the unit after installation, including burner adjustments, an efficiency check test, and instructions to the Owner and/or Owner's representative as to the proper burner operation. In addition, the Service Contractor will provide free service on the complete burner for twelve (12) calendar months following initial start-up. FF. Service during the twelve-month period shall be performed as necessitated by the physical condition of the burner and burner controls, defective material, workmanship or improper start-up, and include replacement of defective parts. Service calls for reasons such as incorrect or inadequate wiring, improper or inadequate fuel supply, unusual operating conditions, misapplied controls of equipment of other manufacturers not a part of the burner shall be charged for on a time, material and mileage basis by the Service Contractor to this Contractor. 1.3 BOILER STACK AND BREECHING (DOUBLE WALL TYPE) If Required, Discuss at Pre-Bid Meeting A. Stack system and shall be laboratory tested and listed by the Underwriters Laboratory, Inc., for use with building heating equipment burning: gas, solid or liquid fuels, as described in NFPA 211. The System must maintain airtight integrity for flue gas temperatures up to 1000 F at pressure up to 60 inches of water column at room temperature. The system shall be designed to compensate for all flue gas induced thermal expansion. B. The materials and construction of the modular sections and accessories shall be as specified by the terms of the product's UL listing. C. The stack system shall be installed according to the manufacturer's installation instructions and shall comply with the following additional codes or standards: PA Department of Labor & Industry, Boiler Code Div. #34PA. D. The entire stack system from the boiler to the termination, including accessories, except as noted, shall be from one manufacturer. E. The double wall insulated chimney and breeching will have an outer jacket of aluminum coated steel at 0.025" minimum thickness. The inner gas carrying pipe shall be type 304 stainless steel. The inner liner shall be minimum 0.035" thick. A nominal one (1") inch air space shall exist between walls. F. All exposed chimney shall have type 304 stainless steel outer jacket with nominal thickness of 0.025". G. The inner pipe joints shall be sealed by use of V-bands and sealant as specified by the manufacturer's installation instructions. At higher temperatures the joints shall be sealed with Metalbestos high temperature joint cement. The chimney shall Page 7 of 12
00 Boiler Replacement comply with National Safety Standards and all building codes when installed according to the manufacturers' installation instructions. Chimneys extended above the roof must terminate as required by local code, or as required in NFPA 211. H. When installed according to the manufacturer's installation instructions the piping and its supporting system shall resist side loads at least 1.5 times the weight per foot of the piping. I. The chimney stack and breeching manufacturer shall warrant the complete system against functional failure due to defects in material and workmanship for 10 years from date of delivery. The system manufacturer shall be responsible for checking the sizing, design and installation for the system. If any component fails to perform its intended function of exhausting combustion by-products from the boiler equipment, for any reason within 1 year of shipment, the system supplier shall, at no expense to the owner, provide a replacement part or parts FOB jobsite. J. Drawings showing the actual layout and drawn to scale shall be provided by the manufacturer. The system shall be installed as designed by the manufacturer and in accordance with the terms of the manufacturer's warranty and in conjunction with sound engineering practice. K. The inner diameter for the stack shall be verified by the manufacturer's computations. The computation shall be technically sound, shall follow ASHRAE calculation methods, and incorporate the specific flow characteristics of the inner pipe. The contractor shall furnish the exact boiler model and operating characteristics to the factory representative. Operating characteristics shall include flue gas flow rate, BTU input, outlet temperature, local altitude, stack layout, and available external pressure at boiler outlet, etc., necessary to determine system operation at maximum and minimum levels of burner turndown range. L. Aluminized steel surfaces exposed to the elements shall be protected by a minimum of one base coat of primer and one finished coat of corrosion resistant paint suitable for outer jacket skin temperature of the particular installation (such as Series 4100 or 9400 as manufactured by Rust-oleum) or approved. Paint to be supplied by the installing contractor. (Outer wall of type 304 or 316 stainless steel may be substituted for paint). M. Technical Services Support: The factory-built modular stack system shall be furnished by a vendor organization which assures design, installation and services coordination and provides in-warranty and post-warranty unified responsibility for Owner, Professional and Contractor. N. The chimney stack and breeching shall be Model PS as manufactured by Selkirk Metalbestos with barometric damper or equal as accepted. Page 8 of 12
00 Boiler Replacement 1.4 BOILER BREECHING (Discuss requirement at Pre-Bid meeting) A. Furnish and install breeching size as required by boiler manufacturer and as indicated on the drawings. Breeching shall be 12 gauge black steel with all joints welded gas tight. C. EXECUTION 1.5 GENERAL A. This Contractor shall prepare a rough-in-layout of the boiler room floor. The layout shall show the exact location of boilers, compressors, starters, electrical stubs and plumbing stubs required for the installation. This layout will be used for coordination rough-ins of all trades. 1.6 BOILER A. General 1. The pressure parts including shop installed piping, shall be subjected to a hydrostatic test pressure of one and one-half times the safe working pressure. A certificate of inspection written by the Hartford Steam Boiler Inspection and Insurance Company or its equivalent, and a manufacturer's ASME Data Report shall be furnished for each boiler. 2. If required, this contractor shall modify the existing concrete boiler foundation according to the manufacturer's erecting instructions. 3. The relief valve outlet shall be piped to a floor drain or near to the floor: the relief valve discharge must not be piped to any area where freezing temperatures could occur. 4. The low water fuel cut-off shall be installed according to the manufacturer's instructions and must be located on the boiler so the burner will become de-energized should the boiler water level fall below the lowest safe waterline. 5. The entire fuel burner system and its installation shall conform with the manufacturer's erecting instructions, with applicable codes. All equipment and materials shall be installed in an approved and workmanlike manner and in accordance with the specifications. 6. Make tests after burner has been firing at rated capacity of a minimum of two (2) hours. Make second test at low-fire. Conduct each test (rated capacity and lowfire) for a test duration of two (2) hours minimum with readings taken every fifteen (15) minutes. Page 9 of 12
00 Boiler Replacement 7. Combustion efficiency, based on flue gas analysis, as an acceptable percentage shall be not less than 80%. 1.7 BOILER STACK AND BREECHING A. Breeching to be supported from building steel and with isolation mounts and insulation as herein specified. D. Submittals and final Deliverable items 1. Contractor to provide three (3) copies of the entire project documentation in three (3) ring Binders. 2. Binders to include the following items: a. Bid Documents & Specifications b. All project meeting minutes (pre-bid, pre-job, Interim, and Final inspection) c. Email Correspondence d. Submittals e. L&I approved Engineered Drawings (Paper/CD) f. L&I Building Permits, Inspection Logs, Other correspondence g. Certifications h. Certified Payrolls (Prevailing Wage rates) i. Waste receipts j. Photos Before, during and after i. A sufficient amount of Photos is required for all phases of construction on all buildings, base on award. k. Operation and Maintenance manuals l. Contractors Warranty m. Manufactures Warranty IV. SUBMITTAL PROCEDURE A. Submit Two (2) copies of all items shown on submittal schedule except for "samples". B. Identify project number, project name and location, and contractor's name and address on all submittals. C. Provide space for review stamps of Contractor and Department. Put contractor stamp of approval on each item submitted. Page 10 of 12
00 Boiler Replacement D. Revise and resubmit submittals as required, identify all changes made since previous submittal. E. No work shall be performed until all submittals are approved by the Department. Work performed prior to submittal approval is performed at the Contractor's risk and may be subject to repair, replacement or other corrective measures as deemed necessary by the Department with no additional contract time or money. F. Review of shop drawings will be general and for the limited purpose of checking for general conformance with the design; and shall not relieve the Contractor from the responsibility for proper fitting and construction of the work, nor from furnishing materials and work required by the Contract which may not be indicated on the shop drawings when reviewed. G. The submittals required by this contract are subject to reproduction for the Department's internal use only. By signature on this bid proposal, both the Contractor and the equipment manufacturer authorize the Department to reproduce any materials including printed literature and training aids, submitted in fulfillment of this contract. V. MANUFACTURER'S INSTRUCTIONS A. When specified in individual specification sections, submit manufacturer's printed instructions for delivery, storage, assembly, installation, start-up, adjusting and finishing, and maintenance, in quantities specified for product data. B. Identify conflicts between manufacturer's instructions and contract documents. VI. MANUFACTURER'S CERTIFICATES A. When specified in individual specification sections or on submittal schedule, submit manufacturer's certificates to for review. B. Indicate that material or product conforms to or exceeds specified requirements. Submit supporting reference date, affidavits and certifications as appropriate. C. Certificates may be recent or previous test results on material or product, but in all cases must be acceptable to Department. VII. SUBMITTAL SCHEDULE Page 11 of 12
00 Boiler Replacement A. Abbreviations: SoSu - Source of Supply DeDa - Descriptive Data or Catalog Cuts ShDr - Shop or Installation Drawings CoCh - Color Chart Cert - Certificates Samp Samples B. Schedule: Description of items to be submitted SoSu DeDa ShDr CoCh Samp Cert 1. Cost Breakdown X 2. Work Schedule X 3. Boiler Information X X X 4. Burner information X X X 5. Controls information X X X X 6. Permits and inspections 7. Steel product certifications X X X X 8. Warranties x X X 9. Certified payrolls X X X Page 12 of 12