request for proposal # 0056018 for central heating plant ... · request for proposal # 0056018 for...

Request for Proposal # 0056018

For

Central Heating Plant Package Boiler No. 12

April 27, 2018

Note: This public body does not discriminate against faith-based organizations in accordance with the Code of Virginia, § 2.2-4343.1 or against a bidder or offeror because of race, religion, color, sex, national origin, age, disability, or any other basis prohibited by state law relating to discrimination in employment.

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RFP 0056018 GENERAL INFORMATION FORM

QUESTIONS: All inquiries for information regarding this solicitation should be directed to: Reed Nagel, Phone: (540) 231-5240, e-mail: [email protected] DUE DATE: Proposals will be received until May 24, 2018 at 3:00 PM. Failure to submit proposals to the correct location by the designated date and hour will result in disqualification. ADDRESS: Proposals should be mailed or hand delivered to: Virginia Polytechnic Institute and State University (Virginia Tech), Procurement Department (MC 0333) North End Center, Suite 2100, 300 Turner Street NW, Blacksburg, Virginia 24061. Reference the due date and hour, and RFP Number in the lower left corner of the return envelope or package. Please note that USPS is delivered to a central location and is not delivered directly to Procurement. Allow extra time if sending proposal via USPS. It is the vendor’s responsibility to ensure proposals are received in the Procurement office at the appropriate date and time for consideration. PRE-PROPOSAL CONFERENCE: A mandatory pre-proposal conference will be held on May 10th 2018 at 10:00 am. See section VIII, Pre-proposal Conference for additional information. TYPE OF BUSINESS: (Please check all applicable classifications). If your classification is certified by the Virginia Department of Small Business and Supplier Diversity (SBSD), provide your certification number: ___________. For assistance with SWaM certification, visit the SBSD website at

http://sbsd.virginia.gov/ .

____ Large

____ Small business – An independently owned and operated business which, together with affiliates, has 250 or fewer employees or average annual gross receipts of $10 million or less averaged over the previous three years. Commonwealth of Virginia Department of Small Business and Supplier Diversity (SBSD) certified women-owned and minority-owned business shall also be considered small business when they have received SBSD small business certification.

____ Women-owned business – A business concern that is at least 51% owned by one or more

women who are U. S. citizens or legal resident aliens, or in the case of a corporation, partnership, or limited liability company or other entity, at least 51% of the equity ownership interest is owned by one or more women who are citizens of the United States or non-citizens who are in full compliance with the United States immigration law, and both the management and daily business operations are controlled by one or more women who are U. S. citizens or legal resident aliens.

____ Minority-owned business – A business concern that is at least 51% owned by one or more

minority individuals (see Section 2.2-1401, Code of Virginia) or in the case of a corporation, partnership, or limited liability company or other entity, at least 51% of the equity ownership interest in the corporation, partnership, or limited liability company or other entity is owned by one or more minority individuals and both the management and daily business operations are controlled by one or more minority individuals.

COMPANY INFORMATION/SIGNATURE: In compliance with this Request For Proposal and

to all the conditions imposed therein and hereby incorporated by reference, the undersigned offers and agrees to furnish the goods or services in accordance with the attached signed proposal and as mutually agreed upon by subsequent negotiation.

http://sbsd.virginia.gov/

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FULL LEGAL NAME (PRINT)

(Company name as it appears with your Federal Taxpayer Number)

FEDERAL TAXPAYER NUMBER (ID#)

BUSINESS NAME/DBA NAME/TA NAME

(If different than the Full Legal Name)

BILLING NAME

(Company name as it appears on your invoice)

PURCHASE ORDER ADDRESS

PAYMENT ADDRESS

CONTACT NAME/TITLE (PRINT)

E-MAIL ADDRESS

TELEPHONE NUMBER

TOLL FREE TELEPHONE NUMBER

FAX NUMBER TO RECEIVE

E-PROCUREMENT ORDERS

I acknowledge that I have received the following addendums posted for this solicitation.

1 _____ 2 _____ 3 _____ 4 _____ 5_____ 6_____ (Please check all that apply) Is any member of the firm an employee of the Commonwealth of Virginia who has a personal interest in this contract pursuant to the Code of Virginia, 2.2 – 3102 - 3112 YES____________ NO_____________

SIGNATURE ____________________________________ Date: _________________________

Revised 01/01/2018

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I. PURPOSE:

The purpose of this Request for Proposal (RFP) is to solicit proposals to establish a contract through competitive negotiations for Central Heating Plant Package Boiler by Virginia Polytechnic Institute and State University (Virginia Tech), an agency of the Commonwealth of Virginia.

II. SMALL, WOMAN-OWNED AND MINORITY (SWAM) BUSINESS PARTICIPATION:

The mission of the Virginia Tech supplier opportunity program is to foster inclusion in the university supply chain and accelerate economic growth in our local communities through the engagement and empowerment of high quality and cost competitive small, minority-owned, women-owned, and local suppliers. Virginia Tech encourages prime suppliers, contractors, and service providers to facilitate the participation of small businesses, and businesses owned by women and minorities through partnerships, joint ventures, subcontracts, and other inclusive and innovative relationships.

III. BACKGROUND:

Virginia Polytechnic Institute and State University (Virginia Tech) is located in Blacksburg, Virginia, approximately 40 miles southwest of Roanoke, Virginia, the major commercial hub of the area. In addition to the university’s main campus in Blacksburg, major off campus locations include twelve agriculture experiment research stations, the Marion duPont Scott Equine Medical Center and graduate centers in Roanoke and Fairfax, Virginia. Regularly scheduled air service is provided at the Roanoke Regional Airport.

Dedicated to its motto, Ut Prosim (That I May Serve), Virginia Tech takes a hands-on, engaging approach to education, preparing scholars to be leaders in their fields and communities. As the Commonwealth’s most comprehensive university and its leading research institution, Virginia Tech offers 240 undergraduate degree programs to more than 31,000 students and manages a research portfolio of nearly $513 million. The university fulfills its land-grant mission of transforming knowledge to practice through technological leadership and by fueling economic growth and job creation locally, regionally, and across Virginia. The Central Steam Plant (Plant) includes five operational boilers installed between 1959 and 1996. The boilers, their source of fuel, and their efficiency rate are listed below in a table. A sixth boiler rests within the plant and this boiler was decommissioned in 1997.

Central Heat Plant Boiler

Boiler ID No. Year Built Fuel Source Steam Output Efficiency

Boiler #6 1949 Decommissioned

Boiler #7 1959 Coal 100,000 lbs/hr 82%

Boiler #8 1968 Gas 80,000 lbs/hr 78%

Boiler #9 1969 Gas 80,000 lbs/hr 78%

Boiler #10 1972 Gas 80,000 lbs/hr 78%

Boiler #11 1996 Coal 100,000 lbs/hr 82%

The university evaluates fuel prices, operating costs, and thermal loads to determine which assets to use to meet thermal demands. In the present environment, gas-fired boilers are more economical because of lower operating costs and are called upon first to meet steam service. The gas boilers operate the entire year and provide 60 percent of thermal needs. Coal-fired boilers provide 40 percent of thermal needs with coal providing service and redundancy during the winter months.

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The university’s proposal calls for installing a new 100,000 pound per hour gas-fired boiler in place of the decommissioned boiler. Beyond the long-term financial benefits, a new gas boiler would result in a reduction of carbon dioxide emissions by nearly 50 percent, increase the Plant’s overall capacity to meet future campus growth, and act as a replacement for the eventual decommissioning of aging coal-fired Boiler #7, installed in 1959. The university would keep a 100,000 pound per hour coal-fired boiler, Boiler #11, in place to maintain a source of redundancy and fuel diversity.

IV. EVA BUSINESS-TO-GOVERNMENT ELECTRONIC PROCUREMENT SYSTEM:

The eVA Internet electronic procurement solution streamlines and automates government purchasing activities within the Commonwealth of Virginia. Virginia Tech, and other state agencies and institutions, have been directed by the Governor to maximize the use of this system in the procurement of goods and services. We are, therefore, requesting that your firm register as a vendor within the eVA system. There are transaction fees involved with the use of eVA. These fees must be considered in the provision of quotes, bids and price proposals offered to Virginia Tech. Failure to register within the eVA system may result in the quote, bid or proposal from your firm being rejected and the award made to another vendor who is registered in the eVA system. Registration in the eVA system is accomplished on-line. Your firm must provide the necessary information. Please visit the eVA website portal at http://www.eva.virginia.gov/pages/eva-registration-buyer-vendor.htm and register both with eVA and Ariba. This process needs to be completed before Virginia Tech can issue your firm a Purchase Order or contract. If your firm conducts business from multiple geographic locations, please register these locations in your initial registration. For registration and technical assistance, reference the eVA website at: http://www.eva.virginia.gov, or call 866-289-7367 or 804-371-2525.

V. SPECIFICATIONS:

Please see Attachment B for Specifications and Drawings VI. PROPOSAL PREPARATION AND SUBMISSION:

A. Specific Requirements

Proposals should be as thorough and detailed as possible so that Virginia Tech may properly evaluate your capabilities to provide the required goods or services. Offerors are required to submit the following information/items as a complete proposal:

1. Provide an outline for providing the boiler as outlined in Attachment B. Detail all warranties

included.

2. Provide experience outline for providing boilers of this type. Provide 3 references with a preference in higher educational power plants. Describe the process for the installation of the boiler. Include a spreadsheet that outlines all incident reports on boilers installed at reference locations. Incident reports should include resolutions.

3. Provide cost detail as outlined in Attachment B. Complete pricing summary. Include all costs. Provide item detail on travel and any other costs not included in pricing summary as provided for in Attachment B. Provide a cost for extended warranties if applicable.

http://www.eva.virginia.gov/pages/eva-registration-buyer-vendor.htm

http://www.eva.virginia.gov/pages/eva-registration-buyer-vendor.htm

http://www.eva.virginia.gov/

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4. Participation of Small, Women-owned and Minority-owned Business (SWAM) Business: If your business cannot be classified as SWaM, describe your plan for utilizing SWaM subcontractors if awarded a contract. Describe your ability to provide reporting on SWaM subcontracting spend when requested. If your firm or any business that you plan to subcontract with can be classified as SWaM, but has not been certified by the Virginia Department of Small Business and Supplier Diversity (SBSD), it is expected that the certification process will be initiated no later than the time of the award. If your firm is currently certified, you agree to maintain your certification for the life of the contract. For assistance with SWaM certification, visit the SBSD website at http://www.sbsd.virginia.gov/

5. The return of the General Information Form and addenda, if any, signed and filled out as required.

B. General Requirements

1. RFP Response: In order to be considered for selection, Offerors shall submit a complete

response to this RFP to include;

a. 1 original of the entire proposal, including all attachments. Any proprietary information should be clearly marked in accordance with 2.e. below.

b. One (1) electronic copy in WORD format or searchable PDF (flash drive) of the entire proposal as one document, INCLUDING ALL ATTACHMENTS. Any proprietary information should be clearly marked in accordance with 2.e. below.

c. Should the proposal contain proprietary information, provide one (1) redacted

hard copy of the proposal and attachments with proprietary portions removed or blacked out. This copy should be clearly marked “Redacted Copy” on the front cover. The classification of an entire proposal document, line item prices and/or total proposal prices as proprietary or trade secrets is not acceptable. Virginia Tech shall not be responsible for the Contractor’s failure to exclude proprietary information from this redacted copy. Response shall be submitted to: Virginia Polytechnic Institute and State University (Virginia Tech) Procurement Department (MC 0333) North End Center, Suite 2100 300 Turner Street NW Blacksburg, Virginia 24061

Reference the Due Date and Hour, and RFP Number in the lower left hand corner of the return envelope or package.

No other distribution of the proposals shall be made by the Offeror.

2. Proposal Preparation:

a. Proposals shall be signed by an authorized representative of the Offeror. All information

requested should be submitted. Failure to submit all information requested may result in Virginia Tech requiring prompt submission of missing information and/or giving a lowered evaluation of the proposal. Proposals which are substantially incomplete or

http://www.sbsd.virginia.gov/

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lack key information may be rejected by Virginia Tech at its discretion. Mandatory requirements are those required by law or regulation or are such that they cannot be waived and are not subject to negotiation.

b. Proposals should be prepared simply and economically providing a straightforward,

concise description of capabilities to satisfy the requirements of the RFP. Emphasis should be on completeness and clarity of content.

c. Proposals should be organized in the order in which the requirements are presented in

the RFP. All pages of the proposal should be numbered. Each paragraph in the proposal should reference the paragraph number of the corresponding section of the RFP. It is also helpful to cite the paragraph number, subletter, and repeat the text of the requirement as it appears in the RFP. If a response covers more than one page, the paragraph number and subletter should be repeated at the top of the next page. The proposal should contain a table of contents which cross references the RFP requirements. Information which the offeror desires to present that does not fall within any of the requirements of the RFP should be inserted at an appropriate place or be attached at the end of the proposal and designated as additional material. Proposals that are not organized in this manner risk elimination from consideration if the evaluators are unable to find where the RFP requirements are specifically addressed.

d. Each copy of the proposal should be bound in a single volume where practical. All

documentation submitted with the proposal should be bound in that single volume.

e. Ownership of all data, material and documentation originated and prepared for Virginia Tech pursuant to the RFP shall belong exclusively to Virginia Tech and be subject to public inspection in accordance with the Virginia Freedom of Information Act. Trade secrets or proprietary information submitted by an Offeror shall not be subject to public disclosure under the Virginia Freedom of Information Act. However, to prevent disclosure the Offeror must invoke the protections of Section 2.2-4342F of the Code of Virginia, in writing, either before or at the time the data or other materials is submitted. The written request must specifically identify the data or other materials to be protected and state the reasons why protection is necessary. The proprietary or trade secret material submitted must be identified by some distinct method such as highlighting or underlining and must indicate only the specific words, figures, or paragraphs that constitute trade secret or proprietary information. The classification of an entire proposal document, line item prices and/or total proposal prices as proprietary or trade secrets is not acceptable and may result in rejection of the proposal.

3. Oral Presentation: Offerors who submit a proposal in response to this RFP may be required

to give an oral presentation of their proposal to Virginia Tech. This will provide an opportunity for the Offeror to clarify or elaborate on the proposal but will in no way change the original proposal. Virginia Tech will schedule the time and location of these presentations. Oral presentations are an option of Virginia Tech and may not be conducted. Therefore, proposals should be complete.

VII. SELECTION CRITERIA AND AWARD:

A. Selection Criteria

Proposals will be evaluated by Virginia Tech using the following: Maximum Point Criteria Value

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1. Quality of products/services offered and suitability for 20 the intended purposes 2. Qualifications and experiences of Offeror in providing 20 the goods/services 3. Specific plans or methodology to be used to provide the 20 Services 4. Cost (or Price) 30 5. Participation of Small, Women-Owned and Minority 10 (SWAM) Business ______ Total 100

B. Award

Selection shall be made of two or more offerors deemed to be fully qualified and best suited among those submitting proposals on the basis of the evaluation factors included in the Request for Proposal, including price, if so stated in the Request for Proposal. Negotiations shall then be conducted with the offerors so selected. Price shall be considered, but need not be the sole determining factor. After negotiations have been conducted with each offeror so selected, Virginia Tech shall select the offeror which, in its opinion, has made the best proposal, and shall award the contract to that offeror. Virginia Tech may cancel this Request for Proposal or reject proposals at any time prior to an award. Should Virginia Tech determine in writing and in its sole discretion that only one offeror has made the best proposal, a contract may be negotiated and awarded to that offeror. The award document will be a contract incorporating by reference all the requirements, terms and conditions of this solicitation and the Contractor's proposal as negotiated. Virginia Tech reserves the right to award multiple contracts as a result of this solicitation.

VIII. MANDATORY PRE-PROPOSAL CONFERENCE:

A mandatory pre-proposal conference will be held on May 10th 2018 at 10:00 am in the Procurement Office Conference Room. The purpose of this conference is to allow potential Offers an opportunity to present questions and obtain clarification relative to any facet of this Request for Proposal. Due to the importance of all Offerors having a clear understanding of the scope of the work and requirements for this solicitation, attendance at this conference will be a prerequisite for submitting a proposal. Proposals will only be accepted from those Offerors who are represented at this pre-proposal conference. Attendance at the conference will be evidenced by the representative's signatures on the attendance roster. If a representative appears on your behalf, the representative must provide a signature and also identify the name of the Offeror. Bring a copy of this solicitation with you. Any changes resulting from this conference will be issued in a written addendum to this solicitation. No one will be admitted after 10:05 am. It is strongly recommended that you obtain a Virginia Tech parking permit for display on your vehicle prior to attending the conference. Parking permits are available from the Virginia Tech Parking Services Department located at 605 Research Center Drive, phone: (540) 231-3200, e-mail: [email protected].

mailto:[email protected]

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IX. INQUIRIES: All inquiries concerning this solicitation should be submitted in writing via email, citing the particular

RFP section and paragraph number. All inquiries will be answered in the form of an addendum. Inquiries must be submitted by 3:00pm on May 18th 2018. Inquiries must be submitted to the procurement officer identified in this solicitation.

X. INVOICES:

Invoices for goods or services provided under any contract resulting from this solicitation shall be submitted by email to [email protected] or by mail to:

Virginia Polytechnic Institute and State University (Virginia Tech) Accounts Payable North End Center, Suite 3300 300 Turner Street NW Blacksburg, Virginia 24061

XI. METHOD OF PAYMENT:

Virginia Tech will authorize payment to the contractor as negotiated in any resulting contract from the aforementioned Request for Proposal. Payment can be expedited through the use of the Wells One AP Control Payment System. Virginia Tech strongly encourages participation in this program. For more information on this program please refer to Virginia Tech’s Procurement website: http://www.procurement.vt.edu/vendor/wellsone.html or contact the procurement officer identified in the RFP.

XII. ADDENDUM:

Any ADDENDUM issued for this solicitation may be accessed at http://www.apps.vpfin.vt.edu/html.docs/bids.php. Since a paper copy of the addendum will not be mailed to you, we encourage you to check the web site regularly.

XIII. COMMUNICATIONS:

Communications regarding this solicitation shall be formal from the date of issue, until either a Contractor has been selected or the Procurement Department rejects all proposals. Formal communications will be directed to the procurement officer listed on this solicitation. Informal communications, including but not limited to request for information, comments or speculations regarding this solicitation to any University employee other than a Procurement Department representative may result in the offending Offeror’s proposal being rejected.

XIV. CONTROLLING VERSION OF SOLICITATION:

The posted version of the solicitation and any addenda issued by Virginia Tech Procurement Services is the mandatory controlling version of the document. Any modification of/or additions to the solicitation by the Offeror shall not modify the official version of the solicitation issued by Virginia Tech Procurement Services. Such modifications or additions to the solicitation by the Offeror may be cause for rejection of the proposal; however, Virginia Tech reserves the right to decide, on a case by case basis, in its sole discretion, whether to reject such a proposal.

mailto:[email protected]

http://www.procurement.vt.edu/vendor/wellsone.html

http://www.apps.vpfin.vt.edu/html.docs/bids.php

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XV. TERMS AND CONDITIONS:

This solicitation and any resulting contract/purchase order shall be governed by the attached terms and conditions, see Attachment A.

XVI. ATTACHMENTS:

Attachment A - Terms and Conditions Attachment B - Specifications and Drawings

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ATTACHMENT A

TERMS AND CONDITIONS

RFP GENERAL TERMS AND CONDITIONS See: http://www.procurement.vt.edu/content/dam/procurement_vt_edu/docs/terms/GTC_RFP_01012018.pdf ADDITIONAL TERMS AND CONDITIONS A. ADDITIONAL GOODS AND SERVICES: The University may acquire other goods or services that the

supplier provides other than those specifically solicited. The University reserves the right, subject to mutual agreement, for the Contractor to provide additional goods and/or services under the same pricing, terms and conditions and to make modifications or enhancements to the existing goods and services. Such additional goods and services may include other products, components, accessories, subsystems, or related services newly introduced during the term of the Agreement, and should be provided at favored nations pricing, terms and conditions.

B. AUDIT: The Contractor hereby agrees to retain all books, records, and other documents relative to

this contract for five (5) years after final payment, or until audited by the Commonwealth of Virginia, whichever is sooner. Virginia Tech, its authorized agents, and/or the State auditors shall have full access and the right to examine any of said materials during said period.

C. AVAILABILITY OF FUNDS: It is understood and agreed between the parties herein that Virginia Tech

shall be bound hereunder only to the extent of the funds available or which may hereafter become available for the purpose of this agreement.

D. CANCELLATION OF CONTRACT: Virginia Tech reserves the right to cancel and terminate any

resulting contract, in part or in whole, without penalty, upon 60 days written notice to the Contractor. In the event the initial contract period is for more than 12 months, the resulting contract may be terminated by either party, without penalty, after the initial 12 months of the contract period upon 60 days written notice to the other party. Any contract cancellation notice shall not relieve the Contractor of the obligation to deliver and/or perform on all outstanding orders issued prior to the effective date of cancellation.

E. CONTRACT DOCUMENTS: The contract entered into by the parties shall consist of the Request for

Proposal including all modifications thereof, the proposal submitted by the Contractor, the written results of negotiations, the Commonwealth Standard Contract Form, all of which shall be referred to collectively as the Contract Documents.

F. IDENTIFICATION OF BID/PROPOSAL ENVELOPE: The signed bid or proposal should be returned in

a separate envelope or package and identified as follows:

From: ____ Name of Bidder or Offeror Due Date Time Due

____ Street or Box No. Solicitation Number ____ City, State, Zip Code Solicitation Title

Name of Procurement Officer: ____

http://www.procurement.vt.edu/content/dam/procurement_vt_edu/docs/terms/GTC_RFP_01012018.pdf

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The envelope should be addressed to:

VIRGINIA POLYTECHNIC INSTITUTE AND STATE UNIVERSITY (Virginia Tech) Procurement Department (MC 0333) North End Center, Suite 2100 300 Turner Street NW Blacksburg, Virginia 24061

The offeror takes the risk that if the envelope is not marked as described above, it may be inadvertently opened and the information compromised, which may cause the proposal to be disqualified. Bids or Proposals may be hand delivered to the designated location in the office issuing the solicitation. No other correspondence or other bids/proposals should be placed in the envelope.

G. NOTICES: Any notices to be given by either party to the other pursuant to any contract resulting from

this solicitation shall be in writing, hand delivered or mailed to the address of the respective party at the following address

If to Contractor: Address Shown On RFP Cover Page Attention: Name Of Person Signing RFP If to Virginia Tech: Virginia Polytechnic Institute and State University (Virginia Tech) Attn: Reed Nagel Procurement Department (MC 0333) North End Center, Suite 2100 300 Turner Street NW Blacksburg, Virginia 24061 and Virginia Polytechnic Institute and State University (Virginia Tech) Attn: Gerard Folio Capital Construction & Renovations Department Sterrett Facilities Suite 90F Blacksburg, Virginia 24061

H. SEVERAL LIABILITY: Virginia Tech will be severally liable to the extent of its purchases made against any contract resulting from this solicitation. Applicable entities described herein will be severally liable to the extent of their purchases made against any contract resulting from this solicitation.

I. CLOUD OR WEB HOSTED SOFTWARE SOLUTIONS: For agreements involving Cloud-based Web-

hosted software/applications refer to link for additional terms and conditions: http://www.ita.vt.edu/purchasing/VT_Cloud_Data_Protection_Addendum_final03102017.pdf

http://www.ita.vt.edu/purchasing/VT_Cloud_Data_Protection_Addendum_final03102017.pdf

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SPECIAL TERMS AND CONDITIONS

1. ADVERTISING: In the event a contract is awarded for supplies, equipment, or services resulting from this solicitation, no indication of such sales or services to Virginia Tech will be used in product literature or advertising. The contractor shall not state in any of the advertising or product literature that the Commonwealth of Virginia or any agency or institution of the Commonwealth has purchased or uses its products or services.

2. AS-BUILT DRAWINGS: The contractor shall provide Virginia Tech a clean set of reproducible "as

built" drawings and wiring diagrams, marked to record all changes made during installation or construction. The Contractor shall also provide Virginia Tech with maintenance manuals, parts lists and a copy of all warranties for all equipment. All "as built" drawings and wiring diagrams, maintenance manuals, parts lists and warranties shall be delivered to Virginia Tech upon completion of the work and prior to final payment.

3. MATERIALS CONTAINING ASBESTOS: The contractor shall not incorporate any materials into the work containing asbestos. The contractor shall not incorporate any material known by the contractor to contain a substance known to be hazardous to health when the building is occupied unless specifically approved by Virginia Tech or required by the specifications. If the contractor becomes aware that a material required by the specifications contains asbestos, it shall notify Virginia Tech immediately and shall take no further steps to acquire or install any such material

4. COMPLETE INFORMATION: All offerors/Bidders shall state manufacturer and product offered, and

enclose complete and detailed specifications with Proposal/Bid for all products offered. This is required even if quoting on the exact brand name as shown. Failure to do so may cause Proposal/Bid to be considered nonresponsive.

5. CONTRACTOR/SUBCONTRACTOR LICENSE REQUIREMENT: By my signature on this

solicitation, I certify that this firm/individual and/or subcontractor is properly licensed for providing the goods/services specified

Contractor Name: _______________________Subcontractor Name: _______________________

License #:_____________________________Type: ____________________________________

6. CONTRACTOR'S TITLE TO MATERIALS: No materials or supplies for the work shall be

purchased by the Contractor or by any Subcontractor subject to any chattel mortgage or under a conditional sales or other agreement by which an interest is retained by the seller. The contractor warrants that he has clear title to all materials and supplies for which he invoices for payment.

7. ELECTRICAL INSTALLATION: All equipment/material shall conform to the latest issue of all applicable standards as established by National Electrical Manufacturer's Association (NEMA), American National Standards Institute (ANSI), and Underwriters' Laboratories, Incorporated (UL) or other Nationally Recognized Testing Laboratories (NRTL) currently listed with the US Department of Labor. All equipment and material, for which there are NEMA, ANSI, UL or other NRTL standards and listings, shall bear the appropriate label of approval for use intended.

8. EXTRA CHARGES NOT ALLOWED: The Proposal/Bid price shall be for complete installation

ready for Virginia Tech use, and shall include all applicable freight and installation charges; extra charges will not be allowed.

9. FINAL INSPECTION: At the conclusion of the work, the contractor shall demonstrate to the authorized owner’s representatives that the work is fully operational and in compliance with contract

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specifications and codes. Any deficiencies shall be promptly and permanently corrected by the contractor at the contractor's sole expense prior to final acceptance of the work.

10. INSPECTION OF JOB SITE: My signature on this solicitation constitutes certification that I have inspected the job site and am aware of the conditions under which the work must be accomplished. Claims, as a result of failure to inspect the job site, will not be considered by Virginia Tech.

11. INSTALLATION: All items must be assembled and set in place, ready for use. All crating and other

debris must be removed from the premises.

12. INSURANCE: By signing and submitting a Proposal/Bid under this solicitation, the offeror/bidder certifies that if awarded the contract, it will have the following insurance coverages at the time the work commences. Additionally, it will maintain these during the entire term of the contract and that all insurance coverages will be provided by insurance companies authorized to sell insurance in Virginia by the Virginia State Corporation Commission. During the period of the contract, Virginia Tech reserves the right to require the contractor to furnish certificates of insurance for the coverage required. INSURANCE COVERAGES AND LIMITS REQUIRED: A. Worker's Compensation - Statutory requirements and benefits. B. Employers Liability - $100,000.00 C. General Liability - $1,000,000.00 combined single limit. Virginia Tech and the Commonwealth of Virginia shall be named as an additional insured with respect to goods/services being procured. This coverage is to include Premises/Operations Liability, Products and Completed Operations Coverage, Independent Contractor's Liability, Owner's and Contractor's Protective Liability and Personal Injury Liability.

D. Automobile Liability - $500,000.00 E. Builders Risk – For all renovation and new construction projects under $100,000 Virginia Tech will provide All Risk – Builders Risk Insurance. For all renovation contracts, and new construction from $100,000 up to $500,000 the contractor will be required to provide All Risk – Builders Risk Insurance in the amount of the contract and name Virginia Tech as additional insured. All insurance verifications of insurance will be through a valid insurance certificate.

F. The contractor agrees to be responsible for, indemnify, defend and hold harmless Virginia Tech, its officers, agents and employees from the payment of all sums of money by reason of any claim against them arising out of any and all occurrences resulting in bodily or mental injury or property damage that may happen to occur in connection with and during the performance of the contract, including but not limited to claims under the Worker's Compensation Act. The contractor agrees that it will, at all times, after the completion of the work, be responsible for, indemnify, defend and hold harmless Virginia Tech, its officers, agents and employees from all liabilities resulting from bodily or mental injury or property damage directly or indirectly arising out of the performance or nonperformance of the contract.

13. MAINTENANCE MANUALS: The contractor shall provide with each piece of equipment an

operations and maintenance manual with wiring diagrams, parts list, and a copy of all warranties.

14. ORDERS: Applicable departments, institutions, agencies and Public Bodies of the Commonwealth of Virginia may order by issuing a purchase order against any contract resulting from this solicitation.

15. PRODUCT INFORMATION: The offeror/bidder shall clearly and specifically identify the product

being offered and enclose complete and detailed descriptive literature, catalog cuts and specifications with the Proposal/Bid to enable Virginia Tech to determine if the product offered meets the requirements of the solicitation. Failure to do so may cause the Proposal/Bid to be considered nonresponsive.

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16. PROPOSAL/BID ACCEPTANCE PERIOD: Any Proposal/Bid received in response to this solicitation shall be valid for (60) days. At the end of the (60) days the Proposal/Bid may be withdrawn at the written request of the offeror/bidder. If the Proposal/Bid is not withdrawn at that time it remains in effect until an award is made or the solicitation is cancelled.

17. SAFETY: The contractor bears sole responsibility for the safety of its employees. The contractor

shall take all steps necessary to establish, administer, and enforce safety rules that meet the regulatory requirements of the Virginia Department of Labor and Industry (VDLI) and the Occupational Safety and Health Administration (OSHA). The contractor shall take steps as necessary to protect the safety and health of university employees, students, and visitors during the performance of their work. In addition, the contractor must also provide the university with a written safety program that it intends to follow in pursuing work under this contract. By entering into a contract with Virginia Tech, the contractor and its subcontractors agree to abide by the requirements described in Safety Requirements for Contractors and Subcontractors located on Virginia Tech’s Environmental, Health and Safety Services (EHSS) web site at this URL http://www.ehss.vt.edu/programs/contractor_safety.php. A copy of the publication may also be obtained by contacting EHSS at 540/231- 5985. No work under this contract will be permitted until the university is assured that the contractor has an adequate safety program in effect.

18. SIDEWALK POLICY: Driving on sidewalks is allowed when there is no other way to get a needed

vehicle to a designated place or building on campus. The vehicle operator shall be made aware that extreme caution shall be used to operate the vehicle in a way that will not be a hazard or hindrance to pedestrians using the walk. The contractor shall be responsible for any damage to turf and anything that is located adjacent to the walk. Parking an unattended vehicle on a sidewalk is strictly prohibited by State Law. The contractor is allowed to park a vehicle on a sidewalk if there is no other way to perform necessary work. The procedure to obtain a permit to operate a vehicle on sidewalks is the same as for the turf as outlined in Turf Policy. Any vehicle parked illegally on sidewalks shall be subject to ticketing, fines and towing if necessary.

19. SUBCONTRACTS: No portion of the work shall be subcontracted without prior written consent of

Virginia Tech. In the event that the contractor desires to subcontract some part of the work specified herein, the contractor shall furnish Virginia Tech the names, qualifications and experience of their proposed subcontractors. The contractor shall, however, remain fully liable and responsible for the work to be done by his subcontractor(s) and shall assure compliance with all requirements of the contract.

20. TURF POLICY: Parking or driving on campus turf or sidewalk is strictly prohibited, except as specifically directed or otherwise allowed by the Physical Plant Grounds Department. In this case, a turf permit must be obtained from Virginia Tech Parking Services and displayed by the vehicle. Turf parking is not allowed under the canopy of any tree on campus. Any vehicle parked illegally on turf or sidewalks shall be subject to ticketing and fines.

21. WARRANTY (COMMERCIAL): The contractor agrees that the supplies or services furnished under

any award resulting from this solicitation shall be covered by the most favorable commercial warranties the contractor gives any customer for such supplies or services and that the rights and remedies provided therein are in addition to and do not limit those available to Virginia Tech by any other clause of this solicitation. A copy of this warranty must be furnished with the Proposal/Bid.

22. WORK SITE DAMAGES: Any damage to existing utilities, equipment or finished surfaces resulting from the performance of this contract shall be repaired to the Owner's satisfaction at the contractor's expense.

http://www.ehss.vt.edu/programs/contractor_safety.php

16

ATTACHMENT B

Specifications and Drawings (Continue)

Central Heating Plant Package Boiler No. 12

VT Project No.: 208-L00047-000

Early Procurement Package

Issued for Request for Proposal April 16, 2018 Submitted by: Affiliated Engineers Inc. 200 International Circle, Suite 5888 Hunt Valley, MD 21030 AEI Project No. 17976-00

Central Heating Plant Package Boiler No. 12 VT Project No. 208-L00047-000

AEI Project No. 17976-00 Packaged Water Early Procurement Package Tube Boiler April 16, 2018 Page 1 of 36

PACKAGED WATER TUBE BOILER (EARLY PROCUREMENT)

PART 1 - GENERAL

1.1 DEFINITIONS

A. The term "Manufacturer" as used in this specification, shall mean the Manufacturer of the packaged water tube boiler.

B. The term "Purchaser" in this specification shall mean the Owner.

C. The term “Owner” as used in this specification shall mean Virginia Tech University and its authorized representatives.

D. The term "packaged water tube boiler” or “boiler” as used in this specification shall mean one unit, consisting of a burner, windbox, boiler, evaporator, economizer, breeching/ductwork, stack, fuel gas and oil trains, forced draft fan, access platforms, ladders, feedwater controller and control system, burner management system, combustion control system, control instrumentation, valving and protective devices necessary to meet the requirements of this specification.

E. The term "Bidder" shall mean anyone who submits a proposal in response to this specification.

F. "Provide" or "provided" shall mean "furnish and install".

G. "Furnish" or "furnished" does not include installation.

H. "Install" or "installed" does not include furnishing.

1.2 REFERENCES

A. American Boiler Manufacturer’s Associations (ABMA)

B. American Society for Testing and Materials (ASTM)

C. American Society of Mechanical Engineers (ASME)

D. American National Standards Institute (ANSI)

E. American Welding Society (AWS)

F. American Institute for Steel Construction (AISC)

G. Factory Mutual (FM)

H. Heat Exchange Institute (HEI)

I. National Electrical Manufacturers Associations (NEMA)

J. National Fire Protection Association (NFPA)

K. Occupational Safety and Health Standards (OSHA)

L. Instrumentation Society of America (ISA)

M. Underwriter Laboratories (UL)



1.3 EQUIPMENT PURCHASE

A. Proposal Summary

1. The purpose of this solicitation is to obtain competitive proposals for the best value for Virginia Tech University in association with procuring one packaged water tube steam boiler complete with all ancillary equipment. The package will be pre-purchased by Virginia Tech University. This package will become “Boiler No. 12” within the existing plant.

2. The package will be installed within an existing bay of the existing Central Heating Plant. All components of the packaged water tube boiler system will be required to be rigged into their final location thru an opening in the plant’s exterior wall that is directly adjacent to the structural bay indicated. Please refer to the “Appendix A” for four reference sketches (SK-1, SK-2, SK-3 and SK-4) illustrating available footprint and volume within the existing plant for the installation of this boiler.

3. The packaged water boiler system will be received by the installing Contractor. All equipment shall be delivered to the site within two eight-hour periods. All deliveries to be made between 7:00 pm and 5:00 am or on weekends. The Manufacturer’s representative shall be at the site during all deliveries and assist in the supervision of the rigging. The Manufacturer shall provide all interconnecting devices for the main system components. During the installation and start-up, the Manufacturer’s representative shall make visits to the site in accordance with section 1.7.

4. The proposal shall be F.O.B. to Virginia Tech University, Central Heating Plant in Blacksburg, Virginia. Bidders should provide a separate proposal form for each proposal submitted. Proposal amounts shall remain unchanged and effective for a period of 90 days from receipt. The Owner has the right to refuse or accept any portion of any bid.

5. Proposal forms shall include, but not be limited to, the following.

a. Base Proposal Pricing

1) One dual fuel water tube steam boiler with all associated trim.

2) One flue gas/boiler feedwater economizer and all associated trim.

3) One low NOx modulating natural gas and No. 2 fuel oil fired burner and associated trim.

4) Forced draft fan, inlet silencer and ductwork.

5) Flue gas recirculating ductwork between flue gas ductwork downstream of flue gas / feedwater economizer and forced draft fan inlet ductwork.

6) Ductwork between the boiler and flue gas / feedwater economizer.

7) Expansion / flexible connections joints required for the package to compensate for thermal growth / contraction between all of the package’s components.

8) Flue gas economizer structural steel support.

9) Forced draft fan structural steel support.

10) Programmable logic controller (PLC) and panels with feedwater, combustion control and burner management systems.

11) Finish painted access platforms and ladders for boiler non-return valve, all safeties, flue gas economizer valving and manways, forced draft fan/motor, windbox, burners steam drum trim and flue gas testing ports.

12) Factory testing – ASME pressure vessel and casing soap bubble tests.

13) Spare parts as specified.

14) Standard warranty.

15) Manufacturer’s field services which shall include start-up, inspection, witness of performance test and operating training as specified herein.

b. Alternate Pricing



1) Optional extended warranty and/or extended coverage warranty if available.

2) Attendance of a minimum of two of the Owner’s personnel at a factory performance test.

c. Unit Prices

1) Proposal shall also include per diem rates for additional site visits for assistance and/or training as requested by the Owner.

B. Proposal Requirements

1. Proposal information: Furnish complete detailed information with proposal describing equipment including:

a. Firm, net price.

b. Delivery schedule for all equipment and materials, including shop drawings for approval in number of days from date of contract award. Shop drawings shall be adequate for final design of structural, electrical, and mechanical systems. Shop drawings shall include those indicated herein, as well as foundation drawings, arrangement drawings, system schematics, electrical schematics, P&ID drawings and control interface drawings for connection to the existing plant control system.

c. Unitary pricing for the storage of the fabricated package boiler at the Manufacturer’s site. Unitary pricing shall be base storage cost along with a per month and per day cost for storage. Also provide maximum days of storage possible.

d. Erection procedure for the boiler.

e. Delivery time of equipment, in number of days from date of submittal approval, including Manufacturer’s handling of drawings.

f. Equipment size, configuration, total weight, and weight of individual components. Include general description of the style of the boiler proposed and materials of construction.

g. Preliminary sketches showing arrangement and overall dimensions of equipment.

h. Equipment data sheets, including electrical characteristics of all equipment.

i. Piping and instrumentation drawings with all terminal points clearly defined and items included in bidder’s scope of work and supplied by the bidder clearly delineated.

j. Provide complete list of items that are furnished in package with the Manufacturer identified and listed for each item. Clearly indicate items shipped loosely that are to be installed by the installation contractor.

k. Provide certified mill test reports for all metals being utilized within the package. This includes fabrication metals as well as piping and tubing metals.

l. Provide steam drum residence time at 100% load.

m. Provide the boiler’s expected performance at varying firing rates for both natural gas and No. 2 fuel oil. At a minimum, these firing rates shall be 100%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20% and 12.5%. At a minimum, the submitted boiler’s expected performance shall include the following:

1) Gross output, MMBtu/h

2) Fuel input (hhv), MMBtu/h

3) Steam output at non-return valve, Drum operating pressure

4) Superheater flow pressure drop.

5) Steam temperature (degrees F)

6) Steam quality, ppm and %

7) Operating pressure (PSIG) at non-return valve

8) Feedwater Temperature entering and leaving the economizer (degrees F)



9) Excess Air (%)

10) Flue gas recirculation (%)

11) Furnace exit temperature (degrees F)

12) Superheater exit temperature (degrees F)

13) Flue gas temperature leaving boiler (degrees F)

14) Flue gas temperature leaving economizer (degrees F)

15) Surface blowdown (%)

16) Gas flowrate leaving boiler (ACFM and lb/hr)

17) Gas flowrate leaving the economizer (ACFM and lb/hr)

18) Gas flowrate thru flue gas recirculation (ACFM and lb/hr)

19) Gas flowrate leaving the stack (ACFM and lb/hr)

20) CO2 leaving the economizer (PPM and lb/mmbtu)

21) CO leaving the economizer (PPM and lb/mmbtu)

22) NOx leaving the economizer (PPM and lb/mmbtu)

23) O2 leaving the economizer (%)

24) PM10 leaving the economizer (PPM and lb/mmbtu)

25) SO2 leaving the economizer (PPM and lb/mmbtu)

26) VOC leaving the economizer (PPM and lb/mmbtu)

27) Excess air leaving the economizer

28) Furnace backpressure (in/WC)

29) Draft in furnace (in/WC)

30) Draft loss through boiler (in/WC)

31) Draft loss through flue (in/WC)

32) Draft loss through economizer (in/WC)

33) Draft loss total (in/WC)

34) Forced draft fan static required (in/WC) (include boiler and economizer and assumptions for stack and breeching)

35) Heat Losses (MMBtu/H)

36) Radiation and Convection Losses (%)

37) Unmeasured Losses (%)

38) Total Losses (%)

39) Combustion Efficiency (%)

40) Thermal Efficiency (%)

41) Volumetric Heat Release (Btu/hr-ft3)

42) Area Heat Release (Btu/hr-ft2)

n. Provide the recommended start up times for 25%, 50%, 75% and 100% load conditions.

o. Provide the earliest date of delivery from notice to proceed in weeks. Identify reasonable methods of shortening the delivery time.

p. Location of nearest factories from which replacement parts will be available for all major equipment supplied with proposal.

q. Location of boiler manufacturer's nearest service headquarters to the job site with proposal.

r. Number of qualified service engineers permanently employed at this headquarters of service location with proposal.



s. The bidder shall include with the proposal an itemized specification compliance response. The response shall include a copy of these specifications with each paragraph noted with the comment, “compliance”, “deviation”, “alternate” or “exception”. The definition of these terms appears below:

1) By noting the term “compliance”, it shall be understood that the Manufacturer is in full compliance with the item specified and will furnish the same with no deviation.

2) By noting the term “deviation” it shall be understood that the Manufacturer proposes to furnish a different component, system, or controls which is considered equal to that component, system, or controls specified. The Manufacturer shall indicate all deviations. Any deviation shall be considered “equal” only upon acceptance by the Owner and the Engineer.

3) By noting the term “alternate”, it shall be understood that the Manufacturer proposes to furnish the same operating function but prefers to accomplish it in a different manner. Any alternate shall be fully described as to what the Manufacturer proposes to furnish and shall only be considered upon acceptance by the Owner and Engineer.

4) By noting the term “exception”, it shall be understood that the specification section does not apply to the responsibilities of the Manufacturer, or the Manufacturer is unable to fulfill the specification section and is excluding it from the proposal.

1.4 PROJECT CONDITIONS

A. The boiler shall be designed for an indoor mechanical room installation in a non-hazardous area. The following conditions apply:

1. Location: Central Heating Plant, Virginia Tech University, Blacksburg, Virginia.

2. Altitude: 2080 feet.

3. Seismic Design Requirements:

a. Mapped Short Period Spectral Response Acceleration, Ss = 0.239

b. Mapped 1-Sec Period Spectral Response Acceleration, S1 = 0.083

c. Site Class = D

d. Design Short Period Spectral Response Acceleration, Sds = 0.255

e. Design 1-Sec Period Spectral Response Acceleration, Sd1 = 0.133

f. Importance Factor, Ie = 1.25

g. Seismic Design Category = B

4. Wind Requirements (Exterior Stack Only):

a. Design Wind Speed, V = 120 mph

b. Exposure Category = B

c. Wind Directionality Factor, Kd = 0.95 for stacks

d. Topography Factor, Kzt = 1.0

e. Velocity Pressure Coefficient, Kz = 0.91

5. Indoor Temperature / Humidity:

a. Maximum: 115 deg F / 45% RH

b. Minimum: 50 deg F / 45% RH

6. Outdoor Temperature / Humidity

a. Maximum: 115 deg F / 95% RH

b. Minimum: (-) 10 deg F / 20% RH

7. Natural Gas:

a. Quality: Utility Grade Natural Gas



b. Supplied pressure at natural gas train: 15 PSIG

8. No. 2 Fuel Oil:

a. Quality: Ultra Low Sulfur

b. Supplied pressure at fuel oil train: 150 PSIG

9. Boiler Feedwater:

a. Temperature: 280 deg F

b. Pressure: 750 PSIG (header)

10. NEMA Classification 4

11. Instrument air exists in the plant and is supplied between 80 and 100 PSIG.

12. Electrical:

a. All power cabling and controls cabling shall be installed in rigid conduit. All conduit/raceways shall be installed in a neat orderly fashion such to prevent exposure of conduit/raceways and cabling to temperatures in excess of 160 degrees F.

1.5 PACKAGE PERFORMANCE REQUIREMENTS

A. General:

1. The packaged boiler shall be constructed with a steam outlet nozzle and standard manufacturer’s internals to support operation at the indicated pressure and temperature while providing the indicated guaranteed steam quality.

2. Specified steam flow rate shall be the total delivered steam flow rate downstream of the non-return valve. Non-impinging, controlled flame profile at all loads within the boiler control range. Flame control and profile shall be maintained when firing on natural gas or No. 2 fuel oil.

3. Smooth operation during increasing firing rate or decreasing firing rate with stable flame over the entire operating range of the boiler with a rate of change for steam demand of 20 percent Maximum Continuous Rating (MCR) per minute.

4. The package’s equipment shall be designed for steady state stresses and seismic stresses for seismic as described in the International Building Code. Under these conditions, the boiler and associated equipment shall shut down safely without damage and be capable of safe and immediate restarting.

5. Boiler noise shall not exceed 85dbA as measured in accordance with American Boiler Manufactures Association (ABMA) testing guidelines.

6. The boiler will be installed on no less than a 0’-4” concrete housekeeping pad (provided by the installing contractor), while access platforms and ladder supports will be installed on no less than a 0.5 inch grout bed.

B. Output Steam:

1. Net to process capacity: maximum continuous rating (MCR) of 100,000 PPH (minimum).

2. Pressure: 600 PSIG downstream of boiler non-return valve while firing on natural gas or No. 2 fuel oil.

3. Temperature: 750 deg F downstream of boiler non-return valve while firing on natural gas or No. 2 fuel oil.

4. Steam purity: 1 ppm TDS.

C. Forced Draft Fan:

1. Design intake temperature: Equal to maximum indoor temperature indicated.

2. Sound Level: Noise levels shall not exceed 85dBA at normal, full operating conditions at a distance of 3’-0”. Provide sound attenuating device on forced draft fan intake ductwork (upstream of flue gas recirculation connection) to achieve this sound level.



3. Maximum excess oxygen (O2) at MCR: 15%

4. Maximum flue gas recirculation flowrate at MCR: 15%

D. Burner:

1. Natural gas, minimum turndown: 10:1

2. Fuel oil, minimum turndown: 8:1

E. Continuous Blowdown:

1. Two percent of feedwater flow.

F. Stack

1. Stack inner diameter shall be designed for a maximum flue gas velocity of 50 feet per second when flue gas recirculation is not in operation.

2. Top of boiler stack shall be 30’-0” above finished (low) roof (or 82’-0” above finished floor level). Stack will be supported by the manufacturer’s furnished support structure and economizer.

G. The furnace heat release rate shall not exceed the following:

1. Volumetric Heat Release: 80,000 Btu/hr-ft3. Volumetric Heat Release Rate shall be calculated as the total heat input divided by the furnace volume. Furnace volume shall not extend beyond the first row of tubes at the inlet to the convection bank.

2. Area Heat Release Rate: 150,000 Btu/hr-ft2. Area Heat Release Rate shall be calculated as the total heat input divided by the furnace flat projected heating surface. Heating surface covered by refractory shall not be counted in the calculation of heating surface.

H. Emissions:

1. Stack emissions shall be controlled by a combination of low NOx burner and induced recirculation of flue gas. Submit complete predicted emissions for natural gas and No. 2 fuel oil thru all required firing rates.

2. Stack emissions of CO shall not exceed the requirements of 40CFR 63 Subpart JJJJJJ. CO test shall be in conformance with EPA 40 CFR Part 63 JJJJJJ. The boiler manufacturer shall be responsible for making any modifications to the boiler, burner or instrumentation such that the CO emissions are in compliance with EPA 40 CFR 63 Subpart JJJJJJ.

3. Emission requirements:

a. While firing on Natural Gas:

1) NOx emissions: 0.03 lb/MMBtu. These limits are 30-day rolling averages.

2) CO emissions: 0.08 lb/MMBtu. These limits are 8-hour rolling averages.

3) Particulate matter emissions (filterable): 0.0019 lb/MMBtu

4) PM-10 emissions (filterable and condensable): 0.0075 lb/MMBtu

5) PM-2.5 emissions (filterable and condensable): 0.0075 lb/MMBtu

6) SO2 emissions: 0.0006 lb/MMBtu

7) VOC emissions: 0.005 lb/MMBtu

b. While firing on No. 2 Fuel Oil:

1) NOx emissions: 0.18 lb/MMBtu. These limits are 30-day rolling averages.

2) CO emissions: 0.04 lb/MMBtu. These limits are 8-hour rolling averages.

3) Particulate matter emissions (filterable): 0.015 lb/MMBtu

4) PM-10 emissions (filterable and condensable): 0.017 lb/MMBtu

5) PM-2.5 emissions (filterable and condensable): 0.012 lb/MMBtu

6) SO2 emissions: 0.05 lb/MMBtu



7) VOC emissions: 0.0015 lb/MMBtu

1.6 QUALITY ASSURANCE

A. Comply with all applicable government regulations including Commonwealth of Virginia regulations and codes.

B. The packaged water tube shall be the standard product of the Manufacturer and shall not be supplied by assemblers who do not manufacture the offered boiler.

C. Proposed package must fulfill the requirements of the Buy American Act.

D. All materials utilized in the fabrication of the boiler shall be made in the United States of America. The use of materials manufactured outside of the United States will not be permitted.

E. All electrical components used on the boiler shall be UL listed and labeled and FM listed for the service intended as applicable.

F. All applicable boiler and burner unit components shall be UL listed and labeled, and as a minimum installed in compliance with UL methods as applicable.

G. The Manufacturer shall provide all code required safety devices per ASME Section I and state and local requirements.

H. Fuel trains shall be in full compliance with NFPA 85 and all state and local codes.

I. Equipment must comply with U.S. OSHA regulations in effect at the time the purchase order is issued.

J. Overall Responsibility

1. The Manufacturer shall have the responsibility of:

a. Sizing of all components and code requirements for water trim.

b. Sizing, layout, and safety requirements of fuel train components.

1.7 SUBMITTALS (POST AWARD)

A. Provide certified mill test reports for all metals being utilized within the package. This includes fabrication metals as well as piping and tubing metals.

B. Shop Drawings: General arrangement drawings shall be submitted within 2 weeks and full shop drawings shall be submitted within 4 weeks of a mutually acceptable purchase order. The drawings shall include the following:

1. P&ID’s of all systems.

2. Forces, weights, and foundation loading drawings for foundation design.

3. Dimensioned skid and equipment drawings with mounting details. Drawings shall indicate the size and locations of all mechanical and electrical connections as well as all required clearances. Include installation documents that indicate the lifted weights of component sections or pieces and the dimensions of the components or pieces to ensure openings into the space are adequate.

4. Materials of construction and shop drawings of ductwork.

5. Water trim components.

6. Steam trim components.

7. Natural gas and No.2 fuel oil train components.



8. Wiring Diagrams: Detailed wiring for power and control connections. Differentiate between factory-installed and field-installed wiring, piping, valves, ductwork, and trim.

9. Control panels, Programmable Logic Controllers, and associated feed water control, burner management, and combustion control logic.

10. Allowable moments and forces for all piping connections.

11. Access platforms, grating, ladders, and handrails.

12. All instrumentation, trim, and valves.

C. Operating Manuals: Five sets of Operating Manuals shall be submitted at the time of equipment delivery. Each manual shall include:

1. General information

2. Spare Parts List.

3. Operating Instructions. This is not to be a collection of submittals and cut sheets.

4. Maintenance Requirements

5. As Fabricated Drawings

6. Field Wiring Diagrams

7. Product Data for all major components

8. Warranty Information. Standard Warranty is 12 months after start-up or 18 months after shipment is received at the job site.

1.8 INSPECTION AND TESTING

A. Following factory assembly, the units shall be inspected by Owner for completeness, quality of construction, and appearance.

B. The Owner shall have free and adequate access to Vendor's facilities for inspection of all work pertaining to Purchaser's equipment in all stages of manufacturing.

C. The Vendor shall notify the Owner of all scheduled factory inspections and tests at least fourteen days prior to the inspection and testing being started, so Purchaser can arrange for representative to witness or waive their right to witness the inspection and testing. Travel expenses for two Owner representatives and an Engineer to witness factory testing shall be included in the base proposal.

D. The Vendor shall submit to the Owner final reports of all inspections and tests within two weeks following their completion.

1.9 PREPARATION FOR SHIPMENT

A. All components shall be delivered on site without damage and in new condition.

B. Piping and valve ends shall be plugged or capped to prevent entrance of foreign material. Boiler and burner shall be properly covered, skidded, and crated to facilitate handling and to withstand normal shipping handling shocks and vibration. The boiler manufacturer shall design and provide any required handling necessities such as handles, lifting lugs or other rigging devices. All devices shall be designed such that handling of the equipment can be performed in a safe expeditious manner without exposing the equipment to risk of damage.

C. The boiler manufacturer shall be responsible for protection of the boiler and all furnished materials during storage and transportation to the job site. This is to include any materials provided directly by the boiler manufacturer and materials provided by any sub-vendor. The boiler manufacturer shall be responsible for any damage to the boiler or any furnished materials during shipping.



D. All pressure components shall be free of rust, mill scale, grease or dirt prior to shipment. Blasting of any pressure part for cleaning purposes is not allowed. All pressure components shall be shop fabricated from clean scale free components.

E. All other materials used in the fabrication of the boiler, boiler structures or boiler components shall be cleaned of all mill scale, welding slag, grease, oil, cutting chips or any other foreign material.

F. Shipping procedures shall be submitted to the Owner and Engineer for approval prior to shipping the boiler or any furnished materials.

G. The manufacturer shall be responsible for FOB shipment of the boiler to the project site. The installing contractor shall be responsible for rigging costs associated with movement of the boiler from the manufacture’s means of transportation and placement of the boiler. The manufacturer shall generate and get approved, all traffic control plans required by the local jurisdiction having authority for shipment of the boiler to the site. The plan for shipment and rigging shall be a combined effort of both the boiler manufacturer and the installing contractor and shall be submitted to the Owner and Engineer for review.

H. On site storage of the boilers is not available. The boiler shipment schedule shall be coordinated with the Owner and the installing contractor for a “just in time” arrival to allow immediate unloading and setting of the boiler by the installing contractor.

1.10 CUSTOMER SUPPORT

A. Start-up Parts

1. Supply one set of spare manhole gaskets and gauge glass inserts for boil-out purposes.

2. Provide one spare observation port glass for each observation port.

3. Provide one spare flow safety shut off valve for natural gas fuel train and one spare for the diesel oil fuel train.

1.11 STARTUP, TESTING, TRAINING, AND OPERATION AND MAINTENANCE DATA

A. Boilers:

1. General:

a. Boiler manufacturer shall provide services of factory-trained field representative/technician to approve installation, oversee boiler boil-out, conduct start-up, test and adjust for proper operation, pre-test, conduct witnessed testing, and instruct and train Owner’s representative in operation and maintenance of equipment. Boiler manufacturer shall submit résumé for representative/technician(s) actually conducting these services. Representative/technician(s) shall have at least 5 yrs of experience commissioning low NOx systems. All procedures shall be conducted for each boiler and the integrated boiler system as specified herein.

2. Boiler Boil-out:

a. Allow 4-6 weeks for necessary documents to be developed and approved.

b. Boiler boil-out will require the Contractor to develop a written boil-out procedure, a waste management plan and a written waste disposal plant. The cleaning plan must identify all chemicals, volumes and schedule for the boil out process and include details of responsible parties for each aspect of the process.

c. The written cleaning, waste management and waste disposal plans must be developed by the contractor and approved by the Owner prior to mobilizing and beginning the boil out process. All cleaning and rinse stages must be retained in frac tanks for sampling and waste profiling at Contractor’s expense.



d. No cleaning or rinsing solution can be disposed of through or to the local municipal waste treatment facility.

e. The contractor is responsible for providing necessary storage tanks with secondary containment (and heating capacity, depending on the season) to hold and store all waste until is profiled, and approved for disposal through an approved treatment facility.

f. The contractor shall propose a waste a transporter and waste disposal facility for transport, treatment and disposal, as part of the waste disposal plan. This transporter and disposal facility must be approved by the Owner prior to mobilizing and starting the boiler boil-out.

g. No waste can be transported to the treatment facility until written acceptance by the treatment facility and authorization by the Owner to transport the waste to the treatment facility.

h. The contractor is responsible for hiring an Owner-approved lab for analysis, an Owner-approved transporter for the waste transfer, and an Owner-approved waste treatment/disposal facility.

i. After piping system has been flushed, boil out boiler using chemical and procedure as recommended by the boiler manufacturer. Perform boil-out under supervision of boiler manufacturer’s representative.

j. Manufacturer’s representative shall verify in writing that boiler has been cleaned according to their recommendations and is ready for operation.

k. Isolate boiler from piping system during boil-out.

l. Owner’s representative and/or Engineer will observe boil-out. Contractor shall notify the Owner and Engineer at least 10 business days prior to boil-out.

m. Boiler manufacturer or Contractor shall provide necessary chemicals and equipment to perform the boil-out of each boiler.

3. Boiler Startup: Boiler manufacturer’s representative shall conduct startup of boiler per manufacturer’s recommended startup procedures. Startup shall include the following in addition to manufacturer’s recommended startup procedures:

a. Complete inspection of installation and boiler condition.

b. Fireside and waterside inspections.

c. Verification of installation of field installed components, connections, wiring, and mountings. This verification shall include remote-mounted burner controller panel and interconnections to boiler skid components, VFD installation, O2 trim panel and all interconnections to boiler skid package, and stack sensors. Verify that control panels are at mounting height allowing easy readability, access, and keyboard manipulation from floor level.

d. Verification of boiler mounting to achieve seismic restraint and allow for boiler thermal expansion.

e. Verification and sealing of doors, manways, hand holes, and all other openings.

f. Verify operation and water/steam tightness of all manual valving including blowdown valves, shut-off valves, bypass valves, stop check valves, check valves, warmup valves, and free blow valves.

g. Verify strainers are clean and watertight.

h. Setup of gas and fuel trains.

i. Setup of combustion air system including complete VFD setup.

j. Setup of all operating parameters.

4. Boiler Pre-Testing: After startup is complete, boiler manufacturer’s representative shall conduct testing of boiler functional operations per manufacturer’s recommended testing



procedures. All testing shall require detailed, written procedures and shall be submitted to Owner and Engineer for approval prior to testing. All testing shall be witnessed by the Contractor’s Test Engineer. Boiler manufacturer’s representative shall provide all temporary testing equipment and instrumentation required for commissioning. Testing shall include the following in addition to manufacturer’s recommended test procedures:

a. Coordinate and assist Distributed Control System (DCS) Contractor and/or third-party integrator in installation and verification of all boiler controls interface functions. Testing shall not be considered complete until all interface functions are verified to operate correctly.

b. Verify operation of all boiler safeties including gas limits, oil limits, flame safeguards including timings, low water cutout, auxiliary low water cutout, proof of air pressure/flow, high limits, relief valves, indication of correct fault messages/codes and alarm reporting at DCS Operator workstations, etc.

c. Verify operation of combustion process for each fuel including timings.

d. Verify operation of feedwater system including interface controls/functions with deaerator feedwater pumps.

e. Testing of boiler combustion air/fuel ratios and emissions analysis throughout firing range and for each fired fuel. Flue gas analysis report shall include measurements of the following throughout the firing range and shall be reported in units to allow comparison with permit limits (rate based):

1) % oxygen

2) % carbon dioxide

3) % carbon monoxide

4) Temperatures

5) % combustion efficiency

6) NOX ppm

7) SOX ppm

f. Verification of boiler turndown for each fired fuel.

g. Verification of boiler efficiency per ASTM PTC 4.1 procedure at conditions indicated herein.

5. Final Report:

a. Upon completion of these services, boiler manufacturer’s representative shall submit complete report, signed by manufacturer’s service representative, including start-up and test log. Final test report shall include reports for all commissioning tests and procedures. Final completed commissioning functional test procedures shall be signed-off from manufacturer’s technician and Contractor’s testing representative for each witnessed function.

6. Owner Training:

a. Provide 40 hours of training on-site as scheduled with Owner. Provide two additional 16 hour training sessions at a later date to be scheduled with Owner. Training shall be for up to 8 people. Training shall include basic system descriptions and operations, safety procedures, maintenance procedures, controls functions and operations, and diagnostic/trouble-shooting procedures.

7. Operation and Maintenance Manuals:

a. Provide Operation and Maintenance (O&M) Manuals including cut-away drawings of boilers, boiler piping diagrams including fuel trains, complete boiler electrical wiring diagrams with interface points, controls sequences and schematic diagrams with interface points, component cut-sheets, complete spare parts lists, maintenance procedures/intervals, inspection procedures, safeties testing procedures, and trouble-shooting procedures.



1.12 GUARANTEE

A. The boiler manufacturer shall guarantee the steam generating capacity, emissions, and thermal efficiency as submitted with the proposals, while the unit is being fired with either natural gas or No. 2 fuel oil at the specified operating conditions. The boiler manufacturer shall guarantee that the burner flame shall not impinge upon the furnace walls when firing throughout the entire firing range of the burner.

B. Prior to third party testing, the boiler manufacturer shall assist in the performance testing and will furnish all personnel, test equipment, materials and consumables required during testing. The Owner shall reserve the right to witness all field testing. The installing contractor shall operate the boiler while the third party tests the boiler.

C. Instrumentation and all test equipment used by the boiler manufacturer shall be factory calibrated and field verified by the boiler manufacturer to the satisfaction of the Owner. Unmetered/unmeasured quantities shall be accounted for in a manner acceptable to the Owner and the boiler manufacturer. All instrumentation shall be in accordance with this specification.

D. All equipment shall be guaranteed against defective design, workmanship, or material for one year commencing on the first day of startup of the boiler not to exceed 18 months from the delivery date of the boiler on site.

1.13 WARRANTY

A. General Warranty: 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. Standard Warranty Period: 12 months after acceptance of Final start-up report by the Owner.

C. Special Warranty: Written warranty, executed by Manufacturer agreeing that the equipment will maintain the specified capacity and to repair or replace the boiler and auxiliary components that fail in materials or workmanship within the specified warranty period. The warranty shall include a 12-hour response time.

PART 2 - PRODUCTS

2.1 GENERAL

A. This specification defines the minimum requirements for design, materials, fabrication, and shipment of a packaged water tube boiler.

B. Boiler shall be constructed and stamped in accordance with the latest ASME Code for the maximum allowable working pressure indicated herein and must be inspected by an authorized boiler inspection agency and registered with National Board.

C. Unit shall be designed to operate within a Central Heating Plant.

D. Unit shall be designed so that it may be rigged into the Central Heating Plant thru an exterior wall opening into its final location.

E. Unit shall consist of the following:

1. Natural gas and No. 2 fuel oil burner.

2. Complete natural gas train.



3. Complete No. 2 fuel oil train.

4. Burner management controls, control panel along with integral panel mounted air conditioner.

5. Combustion controls, control panel along with integral panel mounted air conditioner.

6. Three element feedwater and level controls.

7. Control inter-locks.

8. Specified input and output signals for remote monitoring and controls through the existing Central Heating Plant’s existing control system.

9. Flexible connections between the evaporator and the economizer.

10. Flexible connections between the economizer and stack.

11. Complete set of boiler trim

12. Complete set of boiler feed water trim.

13. Economizer and trim.

14. Economizer instrumentation.

15. Boiler instrumentation.

16. Platform and ladders to access both ends of steam drum, platform for access to safety valve, non-return valve, steam stop valve and economizer access.

17. Steel support structure designed and provided for support of the stack downstream of the economizer up to the indicated termination elevation. Stack shall be provided with means to anchor to the provided structure at its base.

18. Free standing CorTen alloy steel stack with minimum 3/8-inch wall thickness which terminates at the elevation indicated. The economizer and stack will be supported by the boiler manufacturer’s designed and furnished support steel. Provide hot dipped galvanized stack support steel, code compliant access ladders, hand rails, platform, and Commonwealth of Virginia compliant test ports for emissions testing and verification. Stack shall be designed in compliance with all local codes and regulations. Provide a tuned mass damper at stack termination if required for wind loading requirements.

19. Unit shall be complete with all associated equipment, controls, control panel, instrumentation and protective devices provided in accordance with this specification.

2.2 BASE

A. The boiler shall be constructed on a structural steel base frame of welded construction which shall serve for shipping and permanent support of the boiler. All tubes, drums and headers shall be arranged to permit the boiler to be drained by gravity.

2.3 FURNACE

A. Furnace shall be constructed and sized to ensure complete combustion of either fuel without impingement of the flame on heat transfer surfaces or boiler walls. Flue gas passes shall be designed such to prevent “dead zones” or poorly vented flue gas pockets.

B. No portion of the boiler drums shall be directly exposed to furnace radiation.

C. Boiler shall be designed as a D-Type with double enclosure setting. The inner seal shall be formed by the tubed walls, continuously seal welded forming a gas tight water cooled enclosure with welded gas seals as required. The outer casing shall be seal welded construction resulting in a gas tight envelope and shall be insulated and skinned to form the boiler roof, sidewalls and ends.



D. All furnace floor tubes shall have a minimum slope of 6-1/2 degrees to the horizontal to provide good circulation and draining. All roof tubes shall have a minimum slope of 7-1/2 degrees to the horizontal to provide good circulation and maximum steam relieving capacity. If the boiler manufacturer provides a slope other than specified, it must be clearly identified in the submittals with design considerations for why the proposed differs from the above slope requirements.

E. The following boiler walls shall consist of full membrane wall construction made up of 2” diameter tubes with a maximum tube-to-tube fin width of 2 inches. Minimum membrane thickness shall be ¼”. Tubes of variable diameter such as swaged tubes shall not be permitted.

1. Furnace side wall.

2. Division wall between furnace and convection bank.

3. Furnace convection outer wall

4. Furnace floor.

5. Furnace roof.

6. Furnace rear wall.

7. Furnace front wall

F. Membrane furnace tubes shall have a minimum thickness of 0.135”.

G. Furnace “D” tubes shall be fabricated from pre-welded panels. Panels shall consist of a minimum of 6 boiler tubes connected to full 2” wide X ¼” thick membrane. Membrane to tube must be welded on both sides of the membrane.

H. Front and rear walls shall be 100% water cooled with a minimum of 3” of block insulation behind the walls.

I. Refractories shall be installed to protect the tubes and provide proper burner operation as necessary. All components of the furnace enclosure shall be constructed from water-cooled heat absorbing surfaces.

J. Refractories if required shall be firebrick, insulating brick, mortar or castable refractory. Insulation and appurtenances shall be suitable for the application and specified use. All materials and appurtenances must be compatible with each other.

K. In no case shall asbestos or asbestos-based products be used. All material shall be asbestos-free.

L. Refractory materials shall be suitable for a furnace temperature of 2,800 F. Insulating brick or block backing up the refractory shall be suitable for temperatures to be encountered.

M. Refractory shall be laid up with suitable high temperature mortar. Refractory and insulation shall be supported independently of the boiler tubes or headers by the boiler frame or casing.

N. Refractories shall be in accordance with ASTM C64, "Refractories for Incinerators and Boilers", and shall withstand the temperature under maximum load conditions.

O. The boiler manufacturer shall obtain from the burner manufacturer any tile, refractory, components, dimensions and forms necessary for proper protection of the burner.

P. Any proposed refractories to protect the burner shall be formed in place or cast in sections of such size as to be easily replaceable through the boiler furnace opening.

Q. The refractory sections shall be designed and secured in position in such a manner as to withstand any burner combustion pulsation.



R. Furnish boiler with flanges and/or threaded openings for trimmings and external connections, sufficient hand holes for thorough inspection and cleaning per ASME requirements, and lifting loops.

S. Provide front access to the furnace through a refractory lined door in the front wall. Opening shall be minimum of 16”x20” in size.

T. Refractory or ceramic fiber walls shall not be permitted.

U. Fully welded corner gas seals are required. No Refractory corner seals shall be permitted.

V. Furnace and boiler casing must be adequately stiffened to mitigate adverse effects of combustion or flow induced harmonics. Boiler wall deflections (based on furnace operating pressure) shall be limited to 1/8” max on furnace and boiler walls and 1/16” on the target wall.

W. A boiler circulation study shall be delivered to prove the boiler will not operate with heat transfer zones close to DNB conditions. Circulation ratio values must not exceed those published by API RP-538, figure 11. Hydraulic pressure loss of the feeder circuit shall be a nominal value of 50% or greater of the net gravity head.

X. Boiler circulation path must be clearly defined by use of belly pans in the steam drum which will separate riser and down comer tubes.

2.4 CONVECTION BANK

A. Refer to “Tubes” section below for further requirements.

B. Tubes shall be welded to headers.

C. Tubes shall be rolled and expanded into serrated tube holes in the drums.

D. Tubes shall not have reverse bends or pockets which would prevent complete drainage of the boiler.

E. A detailed acoustic analysis of the convection bank shall be performed. It will include expected natural frequencies prevalent in the tube bundle as well as the wake frequencies caused by the flue gas at different tube bundle sections. Results must indicate the proposed method to prevent these conditions from causing harmful resonance.

2.5 DRUMS

A. Steam and water drums shall be fusion-welded throughout with all welds made, tested, radiographed, and stress relieved in strict accordance with ASME Section I Code.

B. Boiler shall consist of an upper steam drum and a lower mud drum that extend the full length of the boiler. Drums and connections shall be designed for the working temperature and pressure indicated.

C. All drums and internal components shall be designed to the latest ASME Boiler and Pressure Vessel Code. Sufficient drum internals shall be provided to preclude thermal shock, assure the steam quality as specified herein and to properly condition the water.

D. Drums shall be of all fusion welded construction, x-rayed, stress relieved and provided with internal distributors, separators, baffles, shields and internal piping.



E. Each drum shall be equipped with a system of centrifugal steam separators to prevent carry-over and to attain the specified levels of steam purity, (steam purity = 99.5%). Pad or mesh type separators/de-misters are not allowed.

F. All internals shall be installed in such a manner as to allow easy removal and replacement for cleaning and maintenance. Internals shall be supplied to ensure good distribution of feedwater. Nuts, bolt and other hardware used in assembly steam separators shall be stainless steel. Where drum internals interfere with the inspection of any part of the boiler drum, provisions shall be made for easy removal and replacement of whatever internals must be removed in order to allow a complete internal drum inspection and to provide access to tubes. The boiler manufacturer shall supply details of the proposed separator devices and all drum internals shall be of the boiler manufacturers design, fabricated and installed in the shop prior to shipment.

G. Drums shall be sized to accommodate water level swings during quick start up without dumping of water. During start up, no water carry over from the drums shall be permitted.

H. Provide hinged elliptical manways,12”x16” in size, yolk and gasket on each end of both the upper and lower drums. Provide one operating set of gaskets for each manway and two additional sets of gaskets with boiler. Provide continuous steel rings for insulation support around each manway. Steel rings shall be welded to the drum.

I. All connections to the drums shall be of flanged type.

J. Drums shall be provided with minimum connections as follows:

1. Steam outlet.

2. Feedwater Inlet.

3. Vent.

4. Safety valves (number and size in accordance with ASME Code).

5. Pressure gauge.

6. Continuous blowdown.

7. Water column.

8. Chemical feed.

9. Drum level transmitter.

a. Instrumentation

b. Drum Pressure gage

c. Drum Pressure Transmitter

d. Level Transmitters

e. Level switches, ALWCO

10. Sampling

11. Two additional 1” connections, valved and blind flanged

12. Bottom Blow Down(s)

K. All connections to boiler drums shall be sized as indicated by ASME Code.

L. Surface blow down piping shall consist of sparge tubes distributed in boiler to maintain water conductivity consistency over the entire boiler.

M. Provide lower drum with internal blowdown channel to ensure uniform blow down



2.6 TUBES:

A. All tubes shall be constructed with material and thickness required for indicated maximum allowable working pressure and temperature pressure in accordance with ASME code for a 50 year operation life. All tubes shall be selected taking the manufacturing tolerances into account. All tubes shall be bent-tube construction. A mandrel shall be utilized for all tube bending to prevent distortion. All tubes shall be completely circular having no blisters, scale, fabrication or mechanical induced defects.

B. Tubes shall be seamless and arranged to provide for free natural circulation in proper direction at all loads. All tubes shall be arranged such that the boiler is gravity drainable.

C. All tubes shall have a diameter not less than two inches and tubes shall have a minimum thickness of 0.134 inches.

D. No tube shall enter the lower drum below the horizontal drum centerline or enter the steam drum above the minimum water level.

E. All tubes shall be attached to the drums by mechanical rolling.

F. The boiler shall be designed to provide removal of tubes and cleaning of internal tube surfaces. No intermediate headers between the lower and upper drums are allowed.

G. The convection tubes and headers shall be fabricated complete with tube supports and internal bracing. Tube design arrangement shall allow for easy removal and cleaning of interior and exterior heat exchange surfaces.

H. All tubes shall be chemically cleaned (“pickled”) internally to remove all traces of contaminants prior to installation.

I. Tubes and drums shall be hydrostatically tested per ASME Section I.

2.7 CASING, SETTING AND INSULATION

A. The outer surfaces of the boiler shall be insulated with mineral fiber insulation. Insulation thickness shall limit the casing surface temperature to a maximum of 125 deg F based on operation at MCR and an 80-degree F ambient temperature and no wind/moving air.

B. The boiler insulation shall be protected by corrugated, pebble grain, aluminum lagging. Lagging shall be designed for removal and re-installation without the need to flame cut or weld.

C. Any boiler non-vertical outer surface that can support walking traffic shall be protected with a minimum 10 gage carbon steel.

D. Exposed steel surfaces shall be prepped, primed, and finish painted per the boiler manufacturers standard suitable for the specified environment.

E. The furnace shall be accessible through a minimum 18”x18” access door located in the rear wall. The opening shall be provided with a davited door complete with one-piece insulated plug. No refractory bricks will be accepted to close the furnace opening.

F. The boiler gas side enclosure shall receive a shop air pressure test by pressurizing to 1-1/2 times the furnace pressure or a maximum of 20 in wc. Air pressure drop on casing shall not be more than 2.0% in ten minutes. Any leaks found shall be repaired.



G. Localized hot spots on any component are not acceptable. The boiler manufacture shall repair equipment or components at the boiler manufacturer’s expense to correct localized hot spots. All repairs shall be made with new materials.

H. The boiler casing, front wall and windbox shall be constructed of ASTM A-36 steel.

I. The boiler casing shall be a minimum of 12 gauge carbon steel plate. The roof of the boiler shall be minimum 10 gauge steel. The casing shall form a fully welded air tight enclosure.

J. Insulated surfaces of the boiler shall be covered with flat or ribbed galvanized steel sheet panels. Galvanized steel lagging panels shall not be less than 20 gauge.

K. The front wall shall be constructed from minimum 1/4” thick steel.

L. The windbox shall be constructed of minimum 3/8” thick steel plate on all sides and seal welded to the boiler front plate. The steel front plate of the windbox shall be minimum thickness of 1/4”. Provide the windbox with floor support members as required.

M. Casing shall completely enclose the boiler with the exception of the four drum ends.

N. Casing shall be supported off of structural steel frame and shall not be welded or attached to tubing and sized to allow free expansion of the pressure components without interference with the casing enclosure.

O. The structural steel frame shall be designed to include all transportation and rigging considerations and shall allow free expansion of the boiler without causing stresses in the boiler components.

P. Provide a manufactures name plate mechanically attached to the boiler and stamped with the following information:

1. Manufactures Name and Model Number

2. Type of Boiler

3. Year of Manufacture

4. Serial Number

5. Rated Capacity and Maximum Continuous Load

6. Maximum Allowable Working Pressure

7. Effective Radiant Heating Surface

8. Superheater Surface

9. Convective Surface

10. Furnace Volume

Q. All surfaces shall be finished with rust resistant primer and a high-quality, high-temperature finish coat of enamel paint. Surfaces shall be stucco-embossed. Boiler paint color shall be as approved by the Owner.

2.8 OBSERVATION PORTS:

A. Two air-cooled observation ports shall be installed on the rear of the furnace wall which will allow observation of the firing conditions as well as the furnace tubes. Ports shall be located on opposite sides of the rear wall.

B. One air-cooled observation port shall be installed on the burner end of the boiler which will allow observation of the firing conditions as well as the furnace tubes.



C. The minimum observation port diameter shall be 3”. Ports shall be equipped with aspirating air connections and slide gates.

D. Provide air piping mounted to the boiler from the forced draft fan at the front of the boiler to all observation ports.

E. Observation ports shall be shielded such that glass can be replaced while boiler is in operation.

F. Glass shall be quartz type rated for intermittent temperatures of 2800 degree F and continuous operation of 1600 degree F.

2.9 BOILER TRIM

A. Provide the following installed equipment and piping, factory assembled and mounted to the fullest extent practical:

1. Safety valves.

2. Lower drum blow-off valve(s).

3. Water column and gauge glass with integral probes for low and high water cut-off, high alarm, and low alarm.

4. Continuous blow-down valve with isolation valve.

5. Steam drum pressure gauge with isolation valve. Gauge shall be an 8-1/2-inch diameter dial.

6. Steam stop valve. Provide warm-up bypass around valve.

7. Steam stop check valve (non-return valve).

8. ASME Code spool with drain between the steam stop and non-return valves.

9. Feedwater control valve station with manual bypass, isolation valves, and check valve. The feedwater control station shall be accessible at grade along the side of the boiler.

10. All interconnecting steam piping between the steam outlet and superheater inlet flange connection.

11. Steam piping between superheater outlet flange and non-return valve.

12. All interconnecting feedwater piping downstream of the feedwater check valve up to the boiler feedwater connection.

13. Suitable drains, taps, and tees to facilitate testing and safe boiler operation shall be provided.

B. A structural analysis and all required structural supports shall be provided for all piping within the manufacturer’s scope.

2.10 ECONOMIZER

A. Furnish a finned tube rectangular, box type, double-cased and insulate economizer suitable for indoor installation in accordance with the following specification. The boiler manufacturer shall coordinate the structural steel requirements for support of the economizer with the contract drawings.

B. The economizer shall be horizontal tube, counter-current flow arrangement, designed for 1,100 psig working pressure, manufactured and hydrostatically tested in accordance with the requirements of Section I of the ASME Boiler and Pressure Vessel Code and stamped accordingly. Applicable Code papers are to be furnished and included in the Operation and Maintenance Manuals described in this specification.

C. The economizer heating surface shall be two (2) inch O.D. SA-178A boiler tubes with carbon steel fins, not less than 0.06 inches thick, attached by continuous, high-frequency, resistance



welding for maximum heat transfer and resistance to fouling. Spot-welded, soldered or brazed fin attachment is not allowed. The maximum fin density (pitch) shall be 48 fins per foot. Fins shall be solid in construction. Serrated fins are not allowed. Tube connections to header shall be welded.

D. The economizer shall be designed to provide the minimum required boiler efficiency firing on either natural gas or No. 2 oil.

E. Tube arrangement shall be square pitch for greatest ease of cleaning.

F. The economizer pressure parts shall be of welded assembly. Bonded fittings or compression fittings are not allowed nor permitted under ASME Section I guidelines.

G. Headers shall be SA-106B carbon steel, schedule 80 (minimum) pipe with class 600 (minimum) RFWN flanged connections. Header wall thickness and flange rating shall be dependent on economizer design pressure, but not less than specified above. The lower header shall be furnished with a ¾” drain connection and the upper header with a ¾” vent connection. Plastic lined headers are not acceptable. Tube connections to header shall be welded.

H. The economizer enclosure shall be of gas tight, high temperature structure design allowing unrestricted flow of high temperature gas over all internal parts for maximum resistance to corrosion in header boxes and return areas.

I. Fin tips only, not the tube wall, shall be in contact with tube sheets to avoid wear of the pressure parts. Tube returns shall not be finned in order to facilitate reparability.

J. The inner casing of the enclosure shall be a minimum of 10 gauge, SA-36 carbon steel and must be seal welded gas tight and promote structural rigidity.

K. The enclosure shall be furnished with a minimum of 3” thick, factory installed, high mineral wool blanket insulation covered with corrugated, galvanized, carbon steel jacket. The casing shall be water tight suitable for exterior installation.

L. The enclosure shall be fitted with a 16” x 16” carbon steel, insulated access door for inspection and cleaning.

M. The economizer shall be completely drainable by gravity after installation.

N. The economizer shall be non-steaming (30°F minimum approach).

O. The economizer shall be designed to operate at 100 percent load without bypassing any flue gas or feedwater.

P. The economizer outlet feedwater design temperature shall be sufficiently below the saturation temperature of the feedwater to prevent steam in the economizer.

Q. Economizer shall be designed to be supplied with temperature and pressure feedwater indicated herein.

R. All feed water piping, feed water control valve and specialties, economizer bypass, pressure relief valve and shut off valves shall be furnished by the manufacturer for installation by the installing contractor.

S. Economizer shall have integral baffles for the collection and removal of rainwater via header drain system. Provide drain taps for connection by the installing contractor.



T. Size the economizer for a flue gas leaving temperature adequate to prevent condensation of the flue gas.

U. Provide flanged connection for boiler stack and the breeching from the boiler. Expansion joints and breeching shall be designed and furnished by the boiler manufacturer.

V. Economizer trim shall be as follows:

1. Three economizer feed water bypass valves.

2. Safety relief valve(s) and vent stack.

3. Header vent valve and header drain valve. (Shipped loose)

4. Feed water and flue gas inlet and outlet thermowells.

5. Feed water and flue gas inlet and outlet pressure transmitters and gages.

6. Provide smart HART compatible transmitter with local display for economizer feed water inlet and outlet temperature. (Shipped loose)

7. Feed water inlet and outlet temperature gauges. (Shipped loose)

8. Flue gas inlet and outlet temperature gauges. (Shipped loose)

9. One-inch diameter, boiler feedwater recirculation tap for field connection.

10. Provide smart HART compatible transmitter with local display for economizer flue gas inlet and outlet temperature. (Shipped loose)

11. Structural steel supports. Structural steel supports shall be designed to support main stack up to an elevation approximately 82’-0” above finished floor of installation. Manufacturer shall provide all required expansion joints as required to address thermal expansion of the supported system.

2.11 BREECHING AND DUCTWORK

A. Manufacturer shall supply all required ducting and expansion joints from the FD Fan air inlet through the stack flue gas outlet including FGR ducting is required.

B. Flue gas ducting shall be shop insulated with 2” minimum of mineral wool insulation and covered with corrugated aluminum lagging.

C. Rectangular ducts shall be fabricated from plate with a minimum thickness of 1/4-inch. When a draft control damper is present, the upstream ducting and equipment gas side design pressure shall match boiler gas side design pressure.

D. Plate material shall be ASTM A36 for temperatures less than and up to 750º F, and Corten for temperatures above 750ºF and downstream of the flue gas economizer.

E. Provide internal access to ducts via 18-inch by 18-inch access doors. Doors shall be hinged.

F. Provide duct supports as required to support the duct and appurtenances supplied. Duct supports shall be structural steel bearing on the foundation at grade.

2.12 ACCESS PLATFORMS, WALKWAYS AND LADDERS

A. Provide the following minimum platforms with ladder access:

1. Both ends of the steam drum.

2. Walkway along the length of steam drum.

3. Burner front for observation port accessibility and access to oil gun.

4. Economizer access doors.

5. Forced draft fan access.



6. Stack test port access.

B. Equipment shall be designed for normal personnel access, with platform load bearing design of no less than 75 pounds per square foot.

C. Railing, footplates, ladder cages, and gates shall be designed, constructed, and installed in accordance with applicable OSHA Part 1910 Standards.

D. Platforms shall be supported by equipment or by structural steel columns bearing on foundation or grade.

E. Platforms, ladders, and walkways shall be check fitted on the boiler in the shop where possible.

F. All platforms shall be fully assembled, photographed and disassembled prior to galvanizing to assure proper field fit up.

2.13 FORCED DRAFT FAN

A. Boiler shall be complete with one single shaft variable frequency driven forced draft direct drive fan rated for 100 percent capacity of the boiler. Fan shall be driven by a 460V, 60hz inverter duty motor. The drive motor shall be Premium High Efficiency and rated for High Temperature Service. Variable frequency drive shall be provided, wired and mounted by the installing contractor. The boiler manufacturer shall provide a single point electrical connection to the motor. Provide grounding rings and insulated bearings on motor.

B. Forced draft fan shall be of air foil design, horizontal single shaft direct drive, single width single inlet complete with inlet vanes, and inlet attenuation silencer. All connecting ductwork including fittings for flue gas recirculation, expansion joints and outlet damper shall be furnished by the boiler manufacturer. Fan and all associated equipment shall be rated for 450 degrees F service.

C. The forced draft fan will be installed above the boiler with a discharge to the boiler windbox as designed by the manufacturer. The windbox shall be configured to receive a top air connection from the forced draft fan. The forced draft fan shall be mounted on equipment pads above the boiler on structural steel and vibration isolation furnished by the manufacturer.

D. Fan bearings shall be supported on structural steel pedestals independent of the fan housing. Bearings shall have a minimum L10 bearing life of 300,000 hours and shall be located out of the air stream. Bearings shall be sealed ball and race type suitable for 450 degrees F.

E. Forced draft fan shall be capable of meeting the performance requirements without the use of a velocity recovery system downstream of the fan outlet flange and shall meet these requirements under plant operating conditions as specified. Maximum fan speed shall not exceed 1,800 rpm.

F. Fan and shaft shall be all steel construction. Fan bearings shall be protected by an aluminum shaft cooler mounted to the shaft at the inboard bearing. Shaft cooler shall be protected by shaft-cooler guards.

G. Fan housing assembly shall be constructed of steel to be gas tight. Fan housing shall be constructed with external reinforcing steel to withstand operating temperatures and pressures and to prevent excessive noise and vibration. Fan housing internal and external shall be painted with 1,200 degree F rated high temperature paint.

H. Housing and inlet box shall be split for rotor removal. Provide drain connection for housing and inlet box.

I. An access door shall be provided for both the fan housing and inlet box.



J. Provide inlet box silencer with air measurement sensing element.

K. Fan shall be direct drive arrangement, no belt drive fans are allowed. Motor shall be directly coupled to fan shaft by means of a flexible coupling. Provide OSHA compliant shaft guards to enclose shaft and shaft cooler.

L. Fan and motor combination shall be capable of delivering 115% of air flowrate at 130% of the required static pressure. Motor furnished with fan shall not operate into motor service factor in any of these cases.

M. Consider drive efficiency in motor selection according to manufacturer's published recommendation, or according to AMCA Publication 203, Appendix L.

N. Fan shall be provided with fixed pre-rotation inlet vanes. A combustion air damper shall be installed between the forced draft fan and the windbox.

O. Fan wheel shall be statically and dynamically balanced to grade G6.3 per ANSI S2.19. Complete fan assembly shall be factory balanced statically and dynamically in accordance with AMCA Standard 204.

P. Fan assembly shall have factory run test including vibration signatures taken on each bearing in horizontal, vertical and axial direction. Filter-in reading as measured at fan scheduled rpm shall not exceed the following values when fan is rigidly mounted.

1. Direct Drive: 0.08 in/sec peak velocity

2. Written records of run test and vibration test shall be available upon request.

Q. Shaft and impeller shall be capable of withstanding operating temperatures and balanced through the entire operating temperature range. Fan housing, shaft and impeller shall be matched such to allow for thermal expansion and contraction due to operating temperature conditions.

R. Provide flow curves with operation points through the full rpm operational range of the fan with submittal.

S. Outlet modulating control damper (combustion air damper) shall be opposed air foil blade type using wrap around construction. Damper shall be flanged connection type constructed from 304 stainless steel.

T. Control damper (combustion air damper) frame shall have a minimum thickness of 3/16”. Blade ends shall be closed and sealed to prevent accumulation of moisture or dust. Blade width shall be limited to a maximum of 8”. Blade deflection shall be limited to 1/360 of the blade span.

U. Control linkage shall be side linkage type located out of the air stream. All control linkage shall be heavy duty and furnished with corrosion resistant finish. All linkage shall be connected with heavy pin connections. Linkage shall permit adjustment of individual blades and shall be designed to prevent blade vibration. Crank lever shall be provided for attachment to the actuator and designed to transmit the stall torque of the actuator.

V. Dampers, when closed, shall be guaranteed by manufacturer not to leak air in excess of 8 cfm per sq ft at 4" WG differential static pressure.

W. Dampers shall be provided with blade stops for both open and closed positions.

X. Blades and axles shall be 304 stainless steel. Provide damper with outboard bearings and high temperature shaft seals. Damper and all components shall be constructed for minimum 450 degrees F service temperature. Damper casing shall be of gas tight construction.



Y. Lubrication of vane bearing shall be from outside the inlet box.

Z. Fan rotor shall be balanced in accordance with ANSI Standard S2.19.

AA. Critical speed of rotor shall not be less than 30 percent above the operating speed.

BB. Fan shall be sized to provide sufficient static pressure to overcome all system losses.

CC. Design static pressure shall be a minimum of 110 percent of the required volume pressure at MCR. Design volume shall be a minimum of 121 percent of the required static at MCR.

DD. Design capacity and design static pressure shall be calculated at the maximum indoor air temperature indicated.

EE. Fan motor shall be TEFC, inverter duty type per NEMA MG1 part 31, SF = 1.15, with oversized terminal box. The motor shall have an output shaft grounding brush tied to motor ground lead inside motor terminal box.

FF. Fan inlet and outlet dampers shall be modulated at low speeds to maintain flow stability.

2.14 BURNER AND WINDBOX

A. Furnish unit with burner, forced draft fan designed for use with variable frequency drive, combustion air damper, fuel trains, safety devices, flame sensing devices, flue gas recirculation damper.

B. Clearly define number and connection sizes for gas and oil connections to wind box during submittal process.

C. Burner shall be turbulence free, axial airflow type suitable for firing natural gas and fuel oil designed for use with flue gas recirculation.

D. Burner assembly shall be complete with all registers, igniter lance and fuel piping train components as specified herein. The burner shall be sized and selected to provide accurate fuel to air ratio control and thorough mixing of the fuel and air through the full load range of the boiler and shall provide stable flame profile without impingement on heat transfer surfaces.

E. Burner shall be furnished with fuel trains for natural gas and fuel oil. The boiler manufacturer is responsible for providing all control valves, pressure regulators, strainers and all other accessories to conform to the latest NFPA-85. The boiler manufacturer shall coordinate the layout of the fuel trains. All fuel trains are anticipated to be neatly arranged beside of the boiler with a single point connection for natural gas and fuel oil.

F. Burner igniter shall be electric spark type and shall be positioned for reliable ignition of fuel.

G. Provide burner with access port for alternate igniter lance.

H. Provide burner with access port for fuel oil gun.

I. Flue gas recirculation control shall be provided by a system of dampers and ductwork to provide induced flue gas directly to the burner. The flue gas recirculation system including ductwork shall be in accordance with the manufacturer’s standards and shall be integrated with the design of the boiler. The boiler manufacturer shall be responsible for furnishing all FGR ductwork and combustion air ductwork required for the boilers design.

J. Thermal mass natural gas and No. 2 fuel oil flow meters, with pressure and temperature compensation, shall be furnished by the manufacturer and installed by the installing contractor.



K. Boiler Manufacturer shall provide strainer, pressure regulators and fuel train to reduce pressure suitable to burner operation.

L. Burner shall be of the designed to fire the fuels noted above to full steam production and it must meet the specified NOx emission requirement. No steam injection will be allowed as NOx control technique.

M. The windbox shall be fabricated from steel and of thickness suitable for the temperatures and pressures of the boiler. The windbox shall be designed to provide even and uniform air entrance into the burner. The windbox will be seal welded to the boiler front plate. The windbox shall have a drain with plug at its lowest point. An 18-inch by 18-inch windbox access door shall be provided.

N. The burner and burner throat shall be designed to shape the flame to conform to the furnace cross-section.

O. Two view ports shall be provided to observe both pilot and main flames. Air cooling shall be from windbox.

P. Direct spark-ignited, high capacity NFPA Class 3 pilot shall be provided.

Q. Valve trains will be fabricated using Schedule 40 ASTM A-106 Grade B seamless steel pipe, with standard butt-weld fittings and 150 lb. flanges for nominal 3-inch diameter and greater lines, and Schedule 80 ASTM A-106 Grade B seamless steel pipe and 3,000 lb. threaded fittings for nominal 2-1/2-inch diameter and smaller lines. Gas trains will be painted with manufacturer standard.

R. Ignitor gas pilot train, consisting of:

1. Supply manual shut-off valve.

2. Gas strainer with basket "Y" type.

3. Gas pressure regulating valve.

4. Automatic safety shut-off valves.

5. Automatic safety vent valve.

6. Ignitor manual shut-off valve.

7. Ignitor pressure gauge, 2.5 in dial, with isolation valve.

8. Ignitor flexible hose, stainless steel.

S. Main fuel gas train, consisting of:

1. Supply manual shut-off valve.

2. Gas strainer with basket “Y” type.

3. Supply pressure gauge, 4 in dial with isolation valve.

4. Gas pressure regulating valve.

5. Supply pressure gauge, 4 in dial, with isolation valve.

6. Low gas pressure switch.

7. Automatic safety shut-off valve, motor operated, with proof of closure switch.

8. Automatic safety vent valve, solenoid type

9. Manual vent valve, locked in the open position

10. Automatic safety shut-off valve, motor operated, with proof of closure switch

11. High gas pressure switch

12. Leak test connections with isolation valves



13. Gas flow control valve

14. Burner manual shut-off valve

15. Burner pressure gauge, 4 in dial, with isolation valve

T. No. 2 fuel oil train, consisting of:

1. Supply manual shut-off valve

2. Oil strainer with basket "Y" type

3. Oil pressure regulating valve

4. Supply pressure gauge, 4 in dial, with isolation valve

5. Low oil pressure switch

6. Fuel oil control valve


8. Manual pressure relief valve



11. Burner check valve


13. Burner flexible hose, stainless steel

U. Steam train, for fuel oil atomization, consisting of:

1. Supply manual shut-off valve

2. Strainer with basket "Y" type

3. Steam trap

4. Steam trap isolation valve

5. Supply pressure gauge, 4 in dial, with isolation valve

6. Low pressure atomizing medium switch

7. Differential pressure regulating valve

8. Automatic shut-off valve


10. Burner check valve

11. Low auxiliary pressure atomizing pressure switch


13. Burner flexible hose, stainless steel

14. Oil gun purge manual shut-off valve

15. Oil gun purge check valve

V. The following field switches will be mounted on the windbox and wired to a NEMA 12 terminal box:

1. One (1) combustion low air flow switch

2. One (1) purge low air flow switch

3. Two (2) boiler drum steam high pressure switches

4. One (1) furnace high pressure switch

5. One (1) low instrument air pressure switch

6. Two (2) UV flame scanners each with integral flame relay wired to a windbox mounted NEMA 12 terminal box



2.15 INDUCED FLUE GAS RECIRCULATION (IFGR) DAMPER.

A. Induced flue gas recirculation (IFGR or FGR) damper shall be equal to combustion air damper specified above. All ductwork and specialties for IFGR duct and damper shall be 304 stainless steel.

2.16 BOILER TRIM

A. Furnish complete steam trim including but not limited to:

1. Double all valves for water and steam piping connections 2” and smaller including instrumentation connections.

2. ASME safety relief valves. Include drip pan elbows with drain connection.

3. HiEye 180 gauge glasses installed.

4. Water column

5. Steam drum pressure gauge.

6. Minimum (2) observation site glasses, on the non-burner end of the boiler.

7. Minimum (2) observation site glass at the burner end of the boiler.

8. Operating pressure safety switch.

9. Combination water column control and low water cut-off with blowdown.

10. Drain valves.

11. ASME spool piece to non-return valve as required.

12. Main steam non-return valve.

13. Free ample blow between non-return valve and second stop steam valve.

14. Second stop steam shut off valve.

15. Primary low water cut off with blowdown.

16. Second low water cut-off with blowdown.

17. High water alarm switch

18. High water cut-off

19. Auxiliary Low Water Cut Off (ALWCO)

20. Manual bottom blow down valve(s).

21. Fast opening bottom blow down valve(s).

22. Continuous blow down valve.

23. Feedwater level control valve.

24. Feedwater 3 valve bypass for manual fill of boiler.

25. Surface blowdown valve

26. Surface blowdown isolation and bypass valves

27. Dual flame scanners

28. Natural gas train

29. No. 2 fuel oil train

B. Water columns mounted 6 ft above finished floor or above shall be operated by chain operators.

C. Furnish complete feedwater trim including:

1. Feedwater control valve

2. Feedwater stop and check valve



2.17 BURNER MANAGEMENT SYSTEM (BMS)

A. The burner management system (BMS) shall monitor and control the operation of the burner as well as monitor boiler and furnace interlocks. The burner management system shall be interfaced with the existing boiler controls to provide for smooth and automatic transfer of the mode of operation from purge, to light-off, to modulating control.

B. The burner management system shall be PLC based.

C. The BMS shall have a dedicated Ethernet communication port available for remote monitoring and supervisory control from the plant DCS. The DCS communication interface will be done by others.

D. An external watchdog timer relay shall be included to monitor the status of the BMS processor via handshake communications. The watchdog timer with initiate a master fuel trip (MFT) upon processor communication failure.

E. The BMS shall be provided in a control cabinet, mounted on or near the windbox. The cabinet shall have a NEMA 4 rating. All conduits shall be rigid with penetrations only from side, back, or bottom entry. Top entry is not acceptable.

F. Process sensors and control devices on the burner, fuel trains, and the boiler shall be factory installed to the maximum extent possible.

G. System shall be designed to ensure safe purge and burner light-off and shutdown procedures. The system shall monitor main flame and boiler operating conditions to trip all fuel if appropriate interlocks or permissives are not satisfied.

H. System shall be designed to meet the equipment, sequence of operations, and safety trip interlock and alarm requirements set forth in the applicable sections of the NFPA codes.

I. System shall include dual-flame detector(s).

J. Flame detectors shall be suitable for gas and No. 2 fuel oil firing. Flame detectors shall have self-checking features.

K. The burner management system shall include the capability to provide a first-out annunciator and remote display module with the capacity to track the status of all of the system interlocks and limits.

L. As a minimum, the devices listed below shall be included as part of the burner management system controls to operate the boiler:

1. Emergency stop pushbutton.

2. Burner start pushbutton.

3. Power On/Off switch.

4. Power on indicating light.

5. Purge ready indicating light.

6. Purge complete indicating light.

7. Flame failure indicating light.

8. Fuel selector switch (gas/oil).

9. Gas ready indicating light.

10. Oil ready indicating light.

11. Others as required.



M. As a minimum, the following hard-wired contacts shall be provided:

1. Burner trip.

2. Low fire.

3. Purge.

4. Release to modulate.

2.18 BOILER CONTROL SYSTEM (BCS)

A. The boiler control system shall contain the boiler master control, combustion control and feedwater control.

B. Combustion controls shall be metered and cross limited with O2 trim.

C. Feedwater controls shall be three element.

D. The boiler controls shall be PLC based.

E. The boiler control system shall be provided in a rigid, self-supporting, free-standing control cabinet, with a NEMA 4.

F. The controls cabinet will be factory wired to the fullest extent practical. Conduit penetrations shall be only from side, back, or bottom entry. Top entry is not acceptable.

G. Communication between the boiler control system and the burner management system shall be via a Ethernet communication link as well as the hardwired I/O previously listed.

H. The boiler controls shall have a dedicated Ethernet communication port available for remote monitoring and supervisory control from the plant DCS. The DCS communication interface will be done by others.

I. A panel door mounted graphic display human machine interface shall be provided for the operator interface. The following minimum graphical screens shall be configured:

1. Boiler overview.

2. Operator faceplates.

3. Active and historical alarms.

4. Three trend screens.

J. As a minimum, the following instruments, measurement elements, and control devices shall be supplied:

1. Drum level transmitter with three-valve manifold.

2. Drum steam pressure transmitter.

3. Feedwater flow element and transmitter.

4. Steam flow element and transmitter.

5. Feedwater level control valve.

6. Natural gas flow element and transmitter.

7. Natural gas flow control valve.

8. Fuel oil burner pressure transmitter.

9. Fuel oil flow element and transmitter.

10. Fuel oil flow control valve.

11. Combustion airflow element and transmitter.

12. Combustion air temperature element and transmitter.



13. Flue gas oxygen analyzer.

14. Windbox pressure transmitter.

15. Furnace pressure transmitter.

16. Economizer outlet flue gas pressure transmitter.

17. Boiler outlet flue gas temperature element and transmitter.

18. Economizer outlet flue gas temperature element and transmitter.

19. Economizer feedwater inlet temperature element and transmitter.

20. Economizer feedwater outlet temperature element and transmitter.

21. FD fan inlet damper and control drive.

22. FD fan outlet damper and control drive.

2.19 INSTRUMENTATION AND CONTROLS

A. Feedwater Level Controllers

1. A stand-alone controller shall be provided for 3-element feedwater flow control. All controllers shall meet the requirements as herein specified and interface with the new data acquisition system as a matched unit. Controllers shall be microprocessor-based utilizing technologies/ components, which have been used in similar environments for at least five years. Controllers shall be of a single loop design to assure integrity. They shall be powered by 120 volts alternating current at 60 hertz and have integral 24 volt direct current (VDC) and five VDC power supplies for the operation of field devices. Battery back-up shall be possible using 24 VDC battery back-ups. Controllers shall be flush panel mounted in the control cabinet and have splash proof mylar faces or an approved equal. All operator pushbuttons shall be of the membrane type and have tactile feedback. Controllers shall accept a minimum of four analog inputs from primary field devices and a minimum of four discrete inputs. A digit display shall be provided on the front panel of each controller for the viewing of the parameter as well as the value of up to eight displayed variables. Bar-graphs shall be provided on the front panel of the controller to give an analog interpretation of process variables, set-points and deviation and shall be of the 100 segment, LED type or an approved equal. A dedicated 20 segment LED bar-graph shall be provided for the controller output.

2. Each controller shall be provided with a service/ manual station capability to insure operator control in the event of a Central Processing Unit (CPU) or memory failure and for other service requirements. The service/ manual station shall be driven by dedicated analog circuitry, independent of the CPU driver. In the service/ manual mode, the operator shall have control of the output through up/down push buttons on the front panel of the station and shall have output indication through an output bar-graph display. Transfer into and out of the service/ manual mode shall be bumpless and procedureless. A relay contact shall transfer to provide remote indication or control action upon transfer to the service/ manual mode.

3. Controllers shall be capable of being configured in the field. Configuration changes shall be accomplished through a keypad on the controller front panel or other devices or by replacement of the memory modules. Configuration and calibration data stored in the Random Access Memory (RAM) must have on board batter back up or an EEPROM for protection of data up to five years. In addition, a redundant battery backed RAM shall be furnished that may be downloaded into the primary RAM in the event of data corruption. Also, the primary memory shall be able to be copied into the back-up memory to provide back-up of the program as configured in the field. Controllers shall be supplied with an onboard library of analog and discrete functions to allow full utilization of each control. Each controller shall have at least two levels of access security to prevent unauthorized configuration and parameter changes.

4. Each controller assembly shall be a printed circuit card employing a micro-processor based digital controller. Controllers shall be provided with analog and digital filters for filtering out unwanted signals. Each controller shall be configurable for several control applications. As a minimum requirement, these configurations shall include but not be limited to:



5. Basic PID station, with operator adjustable setpoint in automatic, and balance-less, bumpless transfer to operator adjustable output in manual.

6. Cascade PID station, with remote adjustable setpoint in automatic, and balance-less, bumpless transfer to operator adjustable output in manual.

7. Ration station, with operator adjustable setpoint of remote setpoint variable ration when in ratio mode, with operator-adjustable setpoint when in basic mode, and with balance-less, bumpless transfer to operator adjustable output in manual.

8. The controllers shall have a primary controller output of four to twenty milli-amperes direct current (or triac, position proportioning) with that output backed-up by service/ manual as well as auto- manual capabilities. A minimum of two auxiliary analog outputs shall be provided for secondary control and/ or indication and recording. A minimum of four discrete outputs of the open collector transistor or equal type shall also be provided. Additional analog and discrete output logic devices and relays shall be provided as necessary to meet the specified control sequence, recording requirements, alarm requirements, and annunciation requirements.

9. Controllers shall have an overall accuracy of 0.1 percent with input resolution of 12 bits plus or minus one last significant bit (LSB, 0..024 percent) and output resolution of ten bits plus or minus one LSB (0.1%). The controller shall be capable of scanning the entire scheme (configuration, calibration and check sum) at least six times per second. In addition to control capabilities, each controller shall provide annunciation of up to eight alarm conditions on a first in/ first out basis. Alarm status shall be retained in battery backed memory in the event of a power failure.

10. Controllers shall be suitable for connection to, operation with, and data transfer with the specified plant data acquisition system. The contractor shall provide single loop controller programming software licensed to the Owner. The contractor shall also provide programming hardware in the form of a laptop computer, desktop computer or hand held device to facilitate programming. The hardware shall become the property of the Owner.

11. Power supply units: A power supply unit shall be provided for each control station. Each unit shall convert 120 Vac, 60 Hz line voltage to the power required by the plant or boiler control station equipment and field instruments. Each power supply unit shall be compatible with the equipment supplied. A power supply shall be provided for each boiler control station; failure of a power supply shall affect no more than one control station. Optionally, dual identical redundant power supplies may be provided for each control panel, such that failure of one power supply shall not affect boiler operation.

B. Steam Pressure Switch: Steam pressure switch shall be operated by a type 316 stainless steel Bourdon tube actuating a snap-switch. Switch shall have a deadband adjustable up to a maximum of 100 percent of switch range. The switch shall have a calibrated dial and two pointers indicating set and reset points. Switch shall have visible on/off indication and setpoints shall be adjustable without removing switch cover or shutting down steam flow. The switch shall be provided with and mounted on a pigtail siphon suitable for operating pressures of 600 pounds per square inch gauge (psig). The steam pressure switch shall have a weather resistant housing. Pressure switches connection shall be 1/4 inch N.P.T. Switch shall have single-pole, double-throw contacts rated for a minimum of 15 amperes at 120/240 volts alternating current. Switch shall be provided with manufacturer's standard off-surface mounting bracket. The switch shall be UL listed.

C. Air Differential Pressure Switches: Differential pressure air switches shall be diaphragm operated to activate two independent double-pole, double-throw snap switches. Motion of the diaphragm shall be restrained by a calibrated spring which can be adjusted to set the exact pressure differential at which the electrical switch shall be actuated. The motion of the diaphragm shall be transmitted to the switch button by means of a direct mechanical linkage. Switch range shall be subject to field verification by the Contractor prior to final selection and installation. Switches shall have a minimum rated pressure of 50 inches of water column and a maximum surge pressure of two pounds per square inch gauge. Pressure connections shall be 1/8 inch N.P.T. type. Diaphragm



shall be silicone rubber with aluminum support plate and calibration spring shall be stainless steel. Housing shall be sixteen gauge weatherproof type with gasketed cover. Contacts shall be rated for a minimum of fifteen amperes at 120 volts alternating current.

D. Transmitters and Associated Devices: Sensors and transmitters shall be industrial grade and shall be compatible with the controller equipment and data acquisition system provided and shall have accuracies as stated herein. Instrument characteristics such as hysteresis, relaxation time, spare, including maximum and minimum limits, shall be coordinated for each application of the sensors and controls, so the monitoring and control systems operate smoothly and accurately throughout the design range. Transmitters on steam service shall be provided with pigtail siphons. All transmitters provided under this project must be supplied by the same equipment manufacturer and shall be equipped with a single valve calibration manifold assembly. Smart transmitters shall use HART protocol.

1. Differential Pressure Transmitter: Provide differential pressure transmitters (DPT) where indicated. DPT shall be two wire differential pressure transmitter with a microprocessor based electronics - termed a "Smart" transmitter. The DPT shall utilize an all-welded microdisplacement inductive measurement system with integral overpressure protection. The DPT shall be utilized with a hand-held communicator to permit remote reading of the transmitter without interrupting the measurement signal and to permit reranging without the need for applying calibration pressures and for performance of diagnostic checks. The DPT shall be suitable for indicated services and shall have a range suitable for the specific application. Additional performance characteristics shall be as follows:

2. Differential Pressure Transmitter Three-Way Valve Manifold: Provide three-valve manifold. Manifold shall be constructed with a Type 316 stainless steel body and stem. Hand wheel and barrel shall be Type 304 SS. Packing shall be PTFE and seals shall be Teflon. Nominal manifold rating shall be 3,000 psi at 392 degrees Fahrenheit. Differential pressure transmitter shall be flange mounted to valve manifold.

3. Gauge Pressure Transmitter: Provide gauge pressure transmitter (PT) as indicated for point pressure measurement. PT shall be a two-wire pressure transmitter with micro-processor based electronics - termed a "smart" transmitter. The PT shall utilize an all-welded microdisplacement inductive measurement system with integral over pressure protection. The PT shall be utilized with a hand held communicator to permit remote reading of the transmitter without disrupting the measurement signal, to permit reranging without the need for applying calibration pressures, and for performance of diagnostic checks. The transmitter shall be suitable for air, gas and liquid service and shall have a range suitable for the applicable service.

E. Resistance Temperature Detectors: Resistance temperature detectors (RTD's) shall be platinum and shall conform to International Temperature Transmitter Standard (ITTS) No. 68. The resistance shall be 100 ohms at zero degrees centigrade with tolerances per Deutche Industry Norman (DIN) Standard 43760. Sensor shall be spring loaded type when used in conjunction with thermowells. Sheath material shall be type 316 stainless steel and sheath diameter shall be 0.25 inches. Connections shall be made by three copper conductors of number fourteen American Wire Gauge (#14 AWG) or as required. RTD's shall be provided with temperature transmitters and stainless steel thermowell.

F. Thermowells: Temperature transmitters shall be installed in thermowells with extension neck with union type nipple connectors where mounted in pipe lines or stacks unless otherwise specified. Thermowell shall be constructed of type 316 stainless steel for stainless steel piping and carbon steel for carbon steel piping. Unless specified otherwise, thermowells shall be suitable for socket weld installation. Socket welding fitting shall be provided by others. Thermowells for mounting in stacks shall be stainless steel tapered threaded type. The extension neck shall be selected based upon the adjacent insulation thickness.

G. Liquid Level Control/Alarm Switches: Liquid level control/alarm switch shall be of industrial grade and constructed of a carbon steel chamber with type 316 stainless steel float and sleeve. The unit



shall be suitable for operating at a normal operating pressure of 150 pounds per square inch gauge and a temperature of 366 degrees Fahrenheit. The switch shall have electric switch mechanisms housed in a NEMA 4 (weatherproof) enclose with epoxy paint cover. Alarm switch shall be vibration resistant, mercury type and shall have single-pole, double throw contacts in the enclosure for alarm and burner safety system interlocks. Mercury switches shall be suitable for use with maximum liquid temperatures of 550 degrees Fahrenheit.

H. Combination Pressure Reducing Valve/Filter Assembly: Combination air filter-regulators shall be provided for each device utilizing instrument air and/or as indicated and shall have one common inlet/outlet for both filter and regulator, a (psig) calibrated pressure gauge, and five micron-rated reusable element. The bowls shall be transparent with metal bowl guards, capable of operating at 150 psig and 125 degrees Fahrenheit (max.), and shall be of the quick disconnect type. The standard pressure range shall be five to 125 psig. The regulator portion shall be of balanced valve design, diaphragm operated and self-relieving. The filter-regulators shall have 1/4-inch gauge ports and automatic drains.

I. Auxiliary Devices:

1. DC Current Transmitters: Provide a DC current transmitter in any control loop of the combustion control system which has a load greater than 1000 ohms. The transmitter shall accept a four to 20 milli-ampere DC signal and shall accurately transmit the signal into 900 ohms. The calibrated accuracy of the transmitter shall be plus or minus 0.1 percent of span or better. The maximum input impedance shall be 50 ohms. The zero and span shall be screwdriver adjustable. The unit shall have front panel jacks to facilitate testing and calibration. Transmitters shall have a power requirement of 120 volts alternating current, 60 hertz, and 1.3 watts (typical). The line voltage affect shall be plus or minus 0.05 percent of span or better for a plus or minus ten percent line voltage change. The transmitter shall be capable of operating in temperatures of forty to 120 degrees Fahrenheit with the specified accuracy.

2. Current Signal Isolators: Provide a signal isolator for any control circuit connected to a chart recorder if any piece of equipment in the current is not isolated. The isolator shall receive a four to 20 milli-ampere input signal and shall precisely transmit the signal with an accuracy of plus or minus 0.1 percent of span or better. One isolator shall be capable of connecting to as many as three circuits. The unit shall have a single screw driver adjustable potentiometer to provide calibration of each isolator output current to the receiving loop. The unit shall be capable of rack mounting. The isolator shall be loop-powered from input signal currents within a range of four to 20 milli-amperes. The maximum load of the isolator shall be 500 ohms or less. The isolator shall be capable of operating in ambient temperatures of 40 to 120 degrees Fahrenheit with the above specified accuracy.

3. Surge and Spike Protectors: Provide surge and spike protection for all microprocessor based devices including but not limited to panel mounted controllers, circular chart recorders, annunciators and burner management systems. Surge and spike protectors shall be capable of handling 13,000 AMP spikes and start suppressing at 140 volts watt-second capacity minimum. Transient responsive time shall be less than five nano seconds. High frequency noise suppression shall be greater than twenty decibels at 50 kilohertz and greater than 40 decibels at 150 kilohertz.

J. Miscellaneous Components Pressure and Level Sensing Instruments and Transmitters: Instruments installed in liquid or condensable vapor service shall be mounted below the process connection with all sensing lines sloping toward the instrument to avoid trapping gas to the instrument. Contractor shall select the instrument range unless otherwise specified. The range shall be selected such that the normal operating point is in the center one-third of the range. Pressure sensors for steam service applications shall be installed with stop and drain valves and a plugged tee to allow for filling, and shall have a pigtail syphon between the isolation valve and the sensors. A minimum of 1/2-inch piping shall be used. Contractor shall install each pressure sensor such that it is protected from process temperatures. All pressure sensing instruments used in a



differential application shall be provided with isolation and nulling valves (three valve manifold), and on steam applications, shall be provided with stop valves at source, condensate wells and blowdown valves.

K. Pressure-to-Current Transducers: Pressure-to-current transducers shall be solid-state instruments designed to convert process air signals into four to 20 mADC outputs. Transducers shall be designed for two-wire operation with a power input range of 15 to 50 vdc. Operating power shall be supplied from control station dc power supply. Transducers shall be provided with field adjustable zero and span having at least 25 percent range adjustment and have an accuracy within +/- 0.5 percent of span. Transducers shall contain a barrier terminal strip for electrical connections and be provided with a 1/4-inch process port.

L. Current-To-Pressure Transducers: Current-to-pressure transducers shall be designed to convert a four to 20 mADC current input into a proportional pneumatic output. The operating supply pressure shall be no less than 20 psig plus or minus 2 psi. Each transducer shall have an accuracy within +/- 0.25 percent of span. Transducers shall be provided with 1/4-inch NPT supply and output ports and a 1/4-inch conduit connection port. A barrier terminal strip with screw terminals shall be provided for electrical connections. Provide a complete air set (valve, filter, dryer, and pressure regulator) for each transducer. For valve and damper actuators, respective valve or damper manufacturer shall provide the actuator, positioner, air set, and transducer as part of the integrated actuator package.

M. Signal Converters:

1. General: Signal converters shall be plug-in type units for rack mounting. Rack supply power shall be 120 VAC and provided with fuse protection. Each card rack shall be surface mounted, have front terminal access and be provided with a terminal cover plate. All connections shall be made to barrier terminal strips with screw terminals designed to accept a minimum of 12 AWG wire.

2. Current-To-Current Signal Converters: Current-to-current signal converters shall accept a four to 20 mADC input signal and provide a proportion 4-20 mADC output signal. Each converter shall be provided with input/output isolation. Each converter shall be provided with field adjustable zero and span adjustments. Converters shall have an accuracy within +/- 0.1 percent of span. Each rack mounted converter shall receive 120 VAC power which shall be transformed into the power required by the unit.

N. Alarm Indicating Annunciator: Provide solid state type annunciator RIS AN-3100A with 4 point LED display or an approved equal for each boiler control panel and the plant control panel to annunciate boiler alarm conditions and burner safety interlock and limit switch shutdowns as required. The annunciator must fit in the required space as shown on the Contract Documents. The annunciator shall be suitable for flush panel mounting and shall be of modular design. In addition to the specified alarm points, spare points shall be provided for each annunciator as indicated. Each boiler control panel and the plant instrumentation shall have an individual annunciator as specified herein. The annunciator shall be of modular design and each module shall be switch programmable to match normally open and normally closed sequences. The annunciator shall utilize individual modules for each alarm. Modules shall be linked together to enable use of a single system service module. The common system service module shall control the entire annunciator and shall be mounted as an integral part of the annunciator. The service module shall have five push buttons including TEST, ACKNOWLEDGE, SILENCE, RESET and FIRST-OUT RESET. The service module shall also have two common output relays for “critical” and “non critical” audible alarm output. The service module shall have a “power on” indicator and provide for program flash rate adjustment, audible pulsing adjustment and rest status adjustment by dip switch settings. Each alarm shall have a separate input module to detect changes in field contacts and to activate lights on alarm. Modules shall utilize solid-state technology and shall be switch programmable. Standard input- response time shall be no greater than 50 milliseconds. Provide alarm buzzer suitable for flush mounting. Buzzer shall have a minimum rated output of 70 decibels at ten feet. Annunciator shall be suitable for 120 volts, 60 hertz alternating current power supply. The annunciator shall



provide a means to indicate the first limit or off limit condition causing an alarm. Alarms shall be audible with manual silencing through the service module. The annunciator shall have a feature which enables storage of alarm information from subsequent recall when multiple alarms are received. All remote sensing devices as required or annunciation shall be provided. The alarm required for annunciation shall be provided. The alarm output on the plant control panel from the annunciator shall be a bell which shall have a rated output of 90 decibels at ten feet. The buzzer provided at the Boiler Control Panel shall have a distinctly different sound then the bell located on the plant control panel.

O. Boiler Feedwater Flow Meter:

1. Class 600 flanged carbon and stainless steel body and female NPT pressure transmitter connections. Meter shall have calibrated accuracy of plus or minus 0.5% when operated within the calibrated range, and a repeatability of plus or minus 0.2%.

2. Flow meter shall be furnished by the boiler manufacturer and installed by the installing contractor, and shall be suitable for the intended service, with respect to fluid type, pressure, temperature, and flow range as indicated on design documents. Provide code certified meter and MTR for installation in boiler external piping. Low voltage power shall be as specified elsewhere. Differential pressure transmitters associated with differential pressure type flow meters shall be as specified elsewhere, and shall be furnished and installed by the control system supplier, along with three valve manifolds, also as specified elsewhere. Mechanical contractor is responsible for installation of pipe, fittings and valves as detailed for meter installation.

P. Existing Plant Control System:

1. General: The controllers shall be compatible with existing control system.

2. High temperature wiring shall be used in areas having high ambient temperatures.

3. Instrumentation cable for analog signals shall have two stranded No. 16 AWG tinned copper conductors arranged as a twisted, shielded pair, a No. 20 AWG drain wire, 600 volt rated crosslinked polyethylene insulation, and a neoprene jacket. Shielding shall be 100 percent coverage spirally applied, laminated mylar tape.

4. Thermocouple extension wire shall be two wire Type J (Iron-Constantan). Conductors shall be solid No. 16 AWG minimum.

a. Shield and/or shield drain wire for electronic instrument thermocouple cable shall have continuity from the sensing element to the measuring or controlling instrument. The shield shall be grounded only to the control panel ground at a single point.

b. Thermocouples extension wire shall not be installed in conduits or terminal boxes with other systems.

c. Spare thermocouple extension wire and electronic instrument wire shall be provided in home runs to the control panel, and in each multi-conductor or multi-pair cable, at the rate of one spare for a maximum of four circuits and one additional spare for each additional multiple of eight. This will provide approximately 15 percent spares.

PART 3 - EXECUTION (NOT USED)

END OF SECTION



APPENDIX A