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FACILITIES MANAGEMENT Planning, Design & Construction

PROJECT MANUAL FOR

BOILER PROCUREMENT WEST CAMPUS ENERGY PLANT – CONSTRUCT FACILITY

Project #0549701 Package P-01

THE UNIVERSITY OF IOWA IOWA CITY, IOWA The University of Iowa Planning, Design & Construction 200 University Services Building Iowa City, Iowa 52242-1922 DESIGN PROFESSIONAL: Stanley Consultants, Inc. 225 Iowa Avenue Muscatine, Iowa 52761 Issued for Bids October 2, 2015

JANUARY 2009 EDITION Supersedes May 2008 Edition

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INTENTIONALLY

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JANUARY 2009 EDITION Supersedes May 2008 Edition

WEST CAMPUS ENERGY PLANT – CONSTRUCT FACILITY UI PROJECT NO. 0549701 BOILER PROCUREMENT

TABLE OF CONTENTS DIVISION 0 – PROCUREMENT AND CONTRACTING REQUIREMENTS EDITION PAGES 00 01 07 SEALS & SIGNATURES March 2008 00 01 07-1 thru 2 00 01 10 TABLE OF CONTENTS December 2012 00 01 10-1 thru 2 DIVISION 01 – GENERAL REQUIREMENTS 01 11 00 SUMMARY OF WORK 01 11 00-1 thru 4 01 25 13 PRODUCT SUBSTITUTION PROCEDURES 01 25 13-1 thru 2 PRODUCT SUBSTITUTION REQUEST FORM 1 01 32 19 SUBMITTAL SCHEDULE 01 32 19-1 thru 4 01 33 00 SUBMITTAL PROCEDURES 01 33 00-1 thru 5 TRANSMITTAL FORM 1 01 40 00 QUALITY REQUIREMENTS 01 40 00-1 thru 4 01 45 16 FIELD QUALITY CONTROL 01 45 16-1 thru 2 01 78 23 OPERATION AND MAINTENANCE DATA 01 78 23-1 thru 4 OPERATING AND MAINTENANCE MANUAL COVER DIAGRAM 1 BOILER TRAINING TABLE 1 thru 2 01 91 00 COMMISSIONING 01 91 00-1 thru 26 DIVISION 23 – HEATING, VENTILATING AND AIR CONDITIONING 23 52 33 PACKAGED BOILER 23 52 33-1 thru 16 DIVISION 26 – ELECTRICAL 26 05 00 COMMON WORK RESULTS FOR ELECTRICAL 26 05 00-1 thru 8 26 05 09 LARGE MOTORS 26 05 09-1 thru 12 DIVISION 40 – PROCESS INTEGRATION 40 05 23 GENERAL DUTY PROCESS VALVES AND ACCESSORIES 40 05 23-1 thru 10 DIVISION 44 – POLLUTION AND WASTE CONTROL EQUIPMENT 44 11 39-13 FABRICATED STACK 44 11 39-13-1 thru 6 DRAWINGS Bound Herein SKETCH 1 BOILER ARRANGEMENT – OPERATING FLOOR SKETCH 2 BOILER ARRANGEMENT – MEZZANINE FLOOR SKETCH 8 BOILER SCOPE OF SUPPLY SCHEMATIC

END OF SECTION

DECEMBER 2012 EDITION TABLE OF CONTENTS ms1692 00 01 10-1

26153.02.00 SUMMARY OF WORK ms1692 SECTION 01 11 00 - Page 1

PART 1 GENERAL

1.01 WORK COVERED BY CONTRACT DOCUMENTS

A. Procurement of packaged water-tube steam generating boiler. Procurement shall include design, manufacture, and furnish boiler system. Boiler shall have natural gas as primary fuel. Boiler shall be capable of producing 175,000 pounds per hour (pph) of steam at 825 psig at superheater steam stop valve outlet and 750°F at superheater attemperator outlet. Boiler shall be factory-fabricated boiler package including following items: 1. Steam generation boiler with superheat system. 2. Feed water economizer with support steel and inlet and outlet transition duct work including

expansions joints. 3. Sweet water condenser. 4. Mud drum heater system. 5. Forced draft fan, motor and variable frequency drive with silencer and connecting ductwork

including dampers and expansion joints. 6. Natural gas burner system with NFPA 85 required safety systems, devices and logic. 7. Burner management system (BMS) and combustion control system (CCS) logic sheets. 8. Boiler flue gas stack and connecting duct work including dampers and expansion joints. 9. Flue gas recirculation system with connecting duct work including dampers and expansion joints. 10. Superheater attemperator. 11. Boiler trim. 12. Boiler instrumentation to implement fully metered, cross-limited combustion control strategy with

oxygen trim and FGR. 13. Equipment and access platforms as defined herein. 14. Instrument flange connections as defined herein. 15. Services of qualified installation Service Engineer during offloading, placement, start-up and

commissioning, witnessing of distributed control system (DCS) factory acceptance test (FAT), and field performance testing of boiler equipment package.

16. Services of qualified technical training representative for training of operating and maintenance personnel at University of Iowa’s West Campus Energy Plant.

17. Priced spare parts lists. 18. Seller may propose a contract price for yearly preventative maintenance contract. 19. Delivery of boiler via rail to railroad siding. 20. Bonding and insurance of boiler.

1.02 AGREEMENT

A. Request for Proposal Form: 1. Shop Drawings: Owner will issue Professional Services Agreement for both boilers including

breeching from boiler outlet to economizer and from economizer outlet to stack. 2. Boiler 1: Owner will issue Purchase Order based on Memorandum of Agreement to release and

fabricate for delivery between April 21, 2016 and November 1, 2016. a. Base:

1) Fabrication and delivery of boiler to railroad siding at Magellan Pipeline Company, Pipeline Road in Iowa City, Iowa. Final delivery location to be determined by Owner’s installing contractor. Economizer, stack, FD fan, and other boiler auxiliary equipment fabricated and delivered to site for installation by others.

2) Include in stipulated sum an amount of Fifty Thousand Dollars ($50,000.00 US) be used by Owner for Service Engineer site time. Daily service rates and per diem rates shall be included with Proposal so Owner has option to purchase additional Service Engineer time.

3) Include in stipulated sum an amount of Ten Thousand Dollars ($10,000 US) for operator and mechanic training on Owner’s site. Up to 3 trips will be required to cover all shifts of Owner’s employees. Training shall cover equipment components provided under this Contract. Allowance is in addition to allowance for Service Engineer’s time.

b. Adder for delivery and setting of boiler in position at new WCEP. c. Adder for breeching from boiler outlet to economizer and from economizer outlet to stack.

SUMMARY OF WORK 26153.02.00 Page 2 - SECTION 01 11 00 ms1692

d. Adder for stack testing platform and accessories. 3. Boiler 2: Owner anticipates issuing Purchase Order based on Memorandum of Agreement to

release and fabricate for delivery between May 1, 2017 and November 1, 2018. a. Base:

1) Fabrication and delivery of boiler to railroad siding at Magellan Pipeline Company, Pipeline Road in Iowa City, Iowa. Final delivery location to be determined by Owner’s installing contractor. Economizer, stack, FD fan, and other boiler auxiliary equipment fabricated and delivered to site for installation by others.

2) Include in stipulated sum an amount of Fifty Thousand Dollars ($50,000.00 US) be used by Owner for Service Engineer site time. Daily service rates and per diem rates shall be included with Proposal so Owner has option to purchase additional Service Engineer time.

3) Include in stipulated sum an amount of Ten Thousand Dollars ($10,000 US) for operator and mechanic training on Owner’s site. Up to 3 trips will be required to cover all shifts of Owner’s employees. Training shall cover equipment components provided under this Contract. Allowance is in addition to allowance for Service Engineer’s time.

b. Adder for delivery and setting of boiler in position at new WCEP. c. Adder for breeching from boiler outlet to economizer and from economizer outlet to stack. d. Adder for stack testing platform and accessories.

1.03 CASH ALLOWANCES

A. Seller responsibilities: 1. Prepare Change Order. 2. Differences in costs will be adjusted by Change Order.

1.04 WORK BY OTHERS

A. Work on Project which will be executed after completion of Work of this Agreement, and which is excluded from this Agreement is as follows: 1. Receiving, unloading, and installation of boiler and ancillary equipment. 2. Burner management system (BMS) and combustion control system (CCS) DCS hardware. 3. Programming and configuration of BMS and CCS logic.

1.05 WORK SEQUENCE

A. Furnish Owner with schedule of engineering, fabrication, testing, and delivery dates.

B. Changes to final delivery date will be approved in writing by Owner.

C. Anticipated Project sequence: 1. Shop drawings:

a. Anticipated Notice to Proceed (NTP): November 13, 2015. b. Professional Services Agreement (PSA) for Shop Drawing completion to be awarded

November, 2015. c. Seller submits Shop Drawings: 8 weeks after NTP.

2. Boiler 1: a. Release for fabrication: Prior to November 1, 2016. b. Equipment delivered on Site: on or before December 1, 2017. c. Installation complete, by others: September 30, 2018. d. Startup: October 31, 2018. e. Testing and commissioning complete: December 20, 2018.

3. Boiler 2: a. Release for fabrication: Prior to November 1, 2018. b. Equipment delivered on Site: on or before LATER. c. Installation complete, by others: LATER. d. Startup: LATER. e. Testing and commissioning complete: LATER.

26153.02.00 SUMMARY OF WORK ms1692 SECTION 01 11 00 - Page 3

D. Final schedule: 1. Final schedule shall be coordinated with Owner following Notice to Proceed. 2. Proposal shall allow variation in schedule of plus or minus 8 weeks, at Owner’s option, from

anticipated dates without change in price.

E. Coordinate delivery schedule with Owner and installing contractor.

1.06 DELIVERY OF GOODS

A. Boiler is being installed into newly constructed energy plant. Cooperate with Owner and installing contractor in all operations to minimize conflict and to facilitate ongoing construction.

B. Access to site for delivery of Goods shall be coordinated with Owner prior to shipment.

C. Economizer, stack, FD fan, and boiler auxiliary equipment delivered to site for installation by others.

D. Base: 1. Location: Freight on Board (f.o.b.) delivery of boiler to railroad siding at Magellan Pipeline

Company, Pipeline Road in Iowa City, Iowa. Final delivery location to be determined by Owner’s installing contractor.

2. Installing contractor will be responsible for rigging and offloading equipment under supervision of boiler equipment manufacturer’s Service Engineer.

3. Include bonding and insurance for value of boiler through lifting of boiler off of transport railcar by installing contractor.

E. Alternate: 1. Location: Freight on Board (f.o.b.) delivery and setting of boiler in position at new University of

Iowa, West Campus Energy Plant Iowa City, Iowa. 2. Include bonding and insurance for value of boiler through delivery of equipment and setting of

boiler into place at WCEP.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

NOT USED

END OF SECTION

SUMMARY OF WORK 26153.02.00 Page 4 - SECTION 01 11 00 ms1692

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26153.02.00 PRODUCT SUBSTITUTIONS PROCEDURES ms1692 SECTION 01 25 13 - Page 1

PART 1 GENERAL

1.01 SUBSTITUTIONS

A. Proposed Substitutions must be submitted to the Owner by October 9, 2015. Owner will respond to request for substitution no later than October 15, 2015. After this date, substitution requests will be considered only in case of product unavailability or other conditions beyond control of Seller.

B. Submit copy of request for substitution for consideration using attached Product Substitution Request Form. Limit each request to one proposed Substitution. Support each request with: 1. Complete data substantiating compliance of proposed substitutions with requirements stated in

Contract Documents. Burden of proof is on proposer. a. Product identification, including manufacturer's name and address. b. Manufacturer's literature; identify:

1) Product description. 2) Reference standards. 3) Performance and test data.

c. Samples, as applicable. d. Name and address of similar projects on which product has been used, and date of each installation.

2. Itemized comparison of proposed substitution with product specified; list significant variations. 3. Data relating to changes in construction schedule. 4. Any effect of substitution on separate contracts. 5. List of changes required in other work or products. 6. Accurate cost data comparing proposed substitution with product specified. Amount of any net

change to Contract Price. 7. Designation of required license fees or royalties. 8. Designation of availability of maintenance services, sources, or replacement materials.

C. Substitutions will not be considered for acceptance when: 1. They are indicated or implied on Shop Drawings. 2. They are requested directly by Seller’s supplier(s). 3. Acceptance will require substantial revision of Contract Documents.

D. Substitute products shall not be ordered or installed without written notification from Design Professional of Owner's acceptance.

E. Design Professional will determine acceptability of proposed substitutions.

1.02 SELLER'S REPRESENTATION

A. In making formal request for substitution Seller represents that: 1. It has investigated proposed product and has determined that it is equal to or superior in all

respects to that specified. 2. It will provide same warranties or Bonds for substitution as for product specified or as required by

Owner. 3. It will coordinate installation of accepted substitution into Goods, and will make such changes as

may be required for Goods to be complete in all respects. 4. It waives claims for additional costs caused by substitution which may subsequently become

apparent. 5. Cost data is complete and includes related costs under its Agreement, but not:

a. Costs under separate contracts. b. Design Professional's costs for redesign or revision of Contract Documents.

6. It will reimburse Owner for charges of Design Professional or Design Professional's consultants for evaluating any proposed substitute, whether proposed substitute is accepted or rejected.

PRODUCT SUBSTITUTION PROCEDURES 26153.02.00 Page 2 - SECTION 01 25 13 ms1692

1.03 DESIGN PROFESSIONAL DUTIES

A. Review Seller's requests for substitution with reasonable promptness and advise Owner.

B. Notify Seller in writing of Owner's decision to accept or reject requested substitution.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

NOT USED

END OF SECTION

PRODUCT SUBSTITUTION REQUEST FORM To: Project: Specified Item: Section Page Paragraph Description The undersigned request consideration of the following: PROPOSED SUBSTITUTION Attached data includes product description, specifications, drawings, photographs, performance, and test data adequate for evaluation of the request; applicable portions of the data are clearly identified. Attached data also includes a description of changes to the Contract Documents that the proposed substitution will require for its proper installation. The undersigned certifies that the following paragraphs, unless modified by attachments are correct:

1. The proposed substitution does not affect specified dimensions.

2. The undersigned will pay for changes to the design, including engineering design, detailing, and construction costs caused by the requested substitution.

3. The proposed substitution will have no adverse affect on other trades, the construction schedule, or

specified warranty requirements.

4. Maintenance and service parts will be locally available for the proposed substitution. The undersigned further states that the function, appearance, and quality of the proposed substitution are equivalent or superior to the specified item. Submitted by: Signature For use by Design Professional Firm � Approved � Approved as noted Address � Not Approved � Received too late By Date Date Telephone Remarks Attachments

26153.02.00 SUBMITTAL SCHEDULE ms1692 SECTION 01 32 19 - Page 1

PART 1 GENERAL

1.01 DOCUMENT SUBMITTAL SCHEDULE

Item Description

Reference Section Number

Time of Submittal (Weeks after Notice to Proceed unless noted

otherwise)

GENERAL

1. Progress schedule With first application for payment and monthly thereafter.

2. Welding procedures, including procedure qualification records.

01 40 00 4 weeks prior to first fabrication.

3. Installation manuals and other information required for erection of all equipment, breeching/flue materials, trim and accessory details, electrical wiring details.

8 weeks before shipment.

4. List of similar units (capacity, pressure, temperature) in operation with locations and point of contact for reference.

With Proposal.

5. Operating and maintenance manuals including startup and shutdown procedures.

01 78 23 26 05 00 26 05 09 40 05 23

44 11 39-13

Preliminary: 8 weeks before shipment. Final: At shipment. Record “As-Built”: 2 weeks after Field Performance Testing (with results incorporated).

6. Training manual. 01 78 23 Outline of training manual/program with Proposal. Preliminary: 8 weeks before shipment. Final: At shipment.

7. 3D model 01 33 00 With Proposal. Initial submittal: 8. Provide monthly updates.

8. Data Sheets (All fill-in information must be completed).

23 52 33 26 05 09

With Proposal. Final: 8.

9. Guaranteed Performance correction curves. 01 45 16 With Proposal. 10. Daily Service Engineer rates and per diem. 01 11 00 With Proposal. 11. Daily training rates and per diem. 01 78 23 With Proposal. 12. Boiler equipment package general arrangements.

Drawings shall show required maintenance areas including tube pull, and burner pull space requirements. Drawings shall include all boiler system equipment being provided by boiler manufacturer.

23 52 33 With Proposal. Final: 8.

13. Startup/Commissioning spare parts list with prices and validity period identified.

01 78 23 23 52 33 26 05 00

With Proposal. Final: With O&M manual.

14. Recommended spare parts list with prices and validity period identified.

01 78 23 23 52 33 26 05 00

With Proposal. Final: With O&M manual.

SUBMITTAL SCHEDULE 26153.02.00 Page 2 - SECTION 01 32 19 ms1692

Item Description



otherwise)

15. MSDS sheets for applicable materials. With Proposal. Final: 8.

16. Estimated maintenance yearly repair requirements and hourly effort for first 10 years of operations using manufacturer maintenance and repair contract personnel

With Proposal.

17. Manufacturer's data report including shop and field inspection certificates as required by ASME Boiler and Pressure Vessel Code (i.e., P-4, MTR, R-1, etc.).

23 52 33 2 weeks before shipment.

STRUCTURAL 18. Weight and center of gravity of boiler empty,

operating and flooded, including burner and accessories.

23 52 33 Preliminary: With Proposal Final: 6.

19. Dead load, live load, and seismic loads of equipment and related support frames, at each support point. Dynamic loads of rotating equipment at each support point.

23 52 33 Preliminary: 4 Final: 8.

20. Recommended anchorage of boiler skid to foundation.

23 52 33 Preliminary: 4 Final: 8

21. Weight and center of gravity of economizer empty and operating.

23 52 33 Preliminary: With Proposal Final: 6.

22. Recommended anchorage of auxiliary equipment, fans and economizer support frame.

23 52 33 Preliminary: 4 Final: 8

23. Recommendations for hoisting and moving equipment.

23 52 33 8.

24. Support and platform frame drawings. 23 52 33 8. 25. Fabricated stack, ductwork and breeching structural

design criteria 44 11 39-13 Preliminary: 4

Final: 8 26. Fabricated stack, ductwork and breeching loading

information. 44 11 39-13 Preliminary: 4

Final: 8. 27. Stack base detail showing support interface.

Number, type, size, and location of anchor bolts, and connection detail at base.

44 11 39-13 Preliminary: 4 Final: 8.

28. Fabricated stack, ductwork and breeching drawings identifying dimensional outline, materials of construction, and shipping and installed weight.

44 11 39-13 8.

29. Fabricated stack, ductwork and breeching - recommendations for hoisting, moving, and installing.

44 11 39-13 8.

30. Structural Statement of Special Inspection, per IBC Section 1704

IBC Section 1704 Prior to steel delivery

MECHANICAL 31. Flow diagram of air and flue gas system locating and

identifying function of each instrument and tap connection.

23 52 33 8.

32. Flow diagram of pressure parts locating and identifying function of each instrument connection.

23 52 33 8.

26153.02.00 SUBMITTAL SCHEDULE ms1692 SECTION 01 32 19 - Page 3

Item Description



otherwise)

33. Complete catalog information of boiler, burner and accessories showing arrangement and construction of pressure parts, casing, internals and support frame.

23 52 33 8.

34. Technical data including temperature rating and arrangement of refractory and insulation.

23 52 33 8.

35. Amount of heating surface and combustion volume. 23 52 33 8. 36. Auxiliary equipment general arrangement and

outline drawings, weights, performance data – Gas Burners.

23 52 33 8.

37. Auxiliary equipment general arrangement and outline drawings, weights, performance data – Ductwork dampers.

23 52 33 8.

38. Auxiliary equipment general arrangement and outline drawings, weights, center of gravity, anchor bolt locations, performance data – Economizer.

23 52 33 8.

39. Auxiliary equipment general arrangement and outline drawings, weights, center of gravity, anchor bolt locations, performance data – Sweet water condenser.

23 52 33 8.

40. Auxiliary equipment general arrangement and outline drawings, weights, center of gravity, anchor bolt locations, performance data – FD fans and fan motors.

23 52 33 8.

41. FD fan curves, including curves for following speeds, as a minimum: Maximum, minimum, 100% (MCR), 75%, 50%, and 25% speeds.

23 52 33 8.

42. Ductwork arrangement drawings 40 05 23 8. 43. Information on insulation including binders. 23 52 33 8. 44. Boiler trim:

a. Design, construction, and arrangement on boiler. b. Pressure drop across boiler non-return valve and boiler stop valve. c. Size, set pressure and capacity of safety relief valves. d. Bill of materials.

23 52 33 8.

45. Burner, fuel valves, and piping trains: a. Main burner natural gas pressures and flows at maximum required firing rate. b. Natural gas main fuel pressure at inlet and outlet of burner-mounted pressure regulator. c. Igniter (pilot) fuel (natural gas) pressures at inlet and outlet of burner-mounted pressure regulators. d. Bill of materials.

23 52 33 8.

46. Certified valve drawings. 40 05 23 8. 47. Safety valve outline drawings and performance data. 23 52 33 8.

SUBMITTAL SCHEDULE 26153.02.00 Page 4 - SECTION 01 32 19 ms1692

Item Description



otherwise)

48. Piping and Instrument Diagrams (P&IDs) which includes normal operating conditions, flows, pressures, temperatures for each piece of equipment using Owner-supplied instrument tag numbers. AutoCad drawing of boiler P&ID shall be electronically submitted for Owner to incorporate Owner instrument tagging convention.

23 52 33 8.

49. Piping connection information including sizes, locations, wall thicknesses/class ratings, and types.

23 52 33 8.

50. Connection allowable loads. Capability of steam nozzle and attachments to boiler shell to withstand forces and moments imposed by connecting piping.

23 52 33 8.

51. Design pressures and temperatures. 23 52 33 8. 52. Furnace view port construction and locations. 23 52 33 8. 53. ASME manufacturer's data sheets. 23 52 33 8.

ELECTRICAL AND CONTROLS 54. Burner management system (BMS) - Sequence of

operations. 23 52 33 8.

55. Burner management system (BMS) - Logic diagrams.

23 52 33 8.

56. Burner management system (BMS) - Input/output list.

23 52 33 8.

57. Combustion control system (CCS) - Sequence of operations.

23 52 33 8.

58. Combustion control system (CCS) - Logic diagrams. 23 52 33 8. 59. Combustion control system (CCS) - Input/output list. 23 52 33 8. 60. Instrument data sheets (in ISA format) for each

instrument supplied. 23 52 33 8.

61. Logic diagrams and Input/Output listing for programming and configuration of CCS.

23 52 33 8.

62. Medium voltage motor data sheets, starting current and power factor curves, torque versus speed curves, load versus efficiency curves, hot and cold thermal damage curves, required kW, kVA, full load amps, locked-rotor amps, voltage, and other product data – FD fan.

26 05 09 8

63. Cut sheets, accessory wiring diagrams, power (kW, voltage) requirements, and accessory field wiring termination details –

a. Fuel gas control skid b. Ignitors and Gas Burners c. Control Valves d. Instrumentation e. Electric Actuated Dampers (if equipped) f. Air actuated Dampers (if equipped)

23 52 33 8.

64. Control Valve sizing calculations 23 52 33 8.

END OF SECTION

26153.02.00 SUBMITTAL PROCEDURES ms1692 SECTION 01 33 00 - Page 1

PART 1 GENERAL

1.01 SUBMITTAL PROCEDURES

A. Submit Shop Drawings as follows: 1. One set electronic shop drawings to Design Professional at [email protected]. 2. One set electronic shop drawings to Owner at [email protected].

B. Submittals shall be in English language.

C. Weights, measures, and units shall be English units with SI metric values following in parenthesis.

D. Symbols and drawings shall conform to ANSI Y32.2/IEEE 315/CSA Z99.

1.02 SELLER RESPONSIBILITIES

A. Review submittals prior to submission.

B. Determine and verify: 1. Field construction criteria. 2. Catalog numbers and similar data. 3. Conformance to Specifications.

C. Coordinate each submittal with other submittals and with requirements of Goods and Special Services and of Contract Documents.

D. Notify Design Professional in writing, at time of submission, of any deviations in submittals from requirements of Contract Documents. Any such deviations permitted by Design Professional will require modification of Contract Documents.

E. Submittals containing language imposing duties on others (such as verification of dimensions or supply of related information) inconsistent with contract language shall be null and void.

F. Submittals shall not be used as media for inquiries for information or for verification of information that must be supplied by others to Seller. Inquiries or verification of information shall be made by separate Seller submittal using Request for Information (RFI) process.

G. Begin no fabrication of Goods requiring submittal review until return of submittals by Design Professional with stamp, as either “For Information Only”, "Reviewed", “Reviewed as Noted", or “Reviewed as Noted-Resubmit.”

H. Distribute copies of reviewed submittals to subcontractors to extent appropriate. Instruct parties to promptly report any inability to comply with requirements.

I. Submittals not requested will not be recognized or processed.

1.03 DESIGN PROFESSIONAL DUTIES

A. Review required submittals with reasonable promptness and in accord with schedule, only for general conformance to design concept of Project and compliance with information given in Contract Documents. Review shall not extend to means, methods, sequences, techniques, or procedures of construction or to safety precautions or program incident thereto. Review of a separate item as such will not indicate approval of assembly in which item functions.

B. Affix stamp and initials or signature, and indicate requirements for resubmittal, or review of submittal. Design Professional's action on submittals is classified as follows:

mailto:[email protected]

SUBMITTAL PROCEDURES 26153.02.00 Page 2, SECTION 01 33 00 ms1692

1. Reviewed: Submittal has been reviewed and appears to be in conformance to design concept of Project and Contract Documents. Seller may proceed with fabrication of work in submittal.

2. Reviewed As Noted: Submittal has been reviewed and appears to be in conformance to design concept of Project and Contract Documents, except as noted by reviewer. Seller may proceed with fabrication of work in submittal with modifications and corrections as indicated by reviewer.

3. Reviewed As Noted-Resubmit: Submittal has been reviewed and appears to be in conformance to design concept of Project and Contract Documents, except as noted by reviewer. Seller may proceed with fabrication of work in submittal with modifications and corrections as indicated by reviewer. Seller shall make any corrections indicated by reviewer and resubmit for review.

4. Resubmit: Submittal has been reviewed and appears not to be in conformance to design concept of Project or with Contract Documents. Seller shall not proceed with fabrication of work in submittal, but instead shall make any corrections required by reviewer and resubmit for review.

5. Returned without Review: Submittal is being returned without having been reviewed because: 1) not required by Contract Documents; 2) grossly incomplete; 3) indicates no attempt at conformance to Contract Documents; 4) cannot be reproduced; 5) lacks Seller's completed approval stamp; or 6) lacks design professional's seal when required by law or Contract Documents. If submittal is required by Contract Documents, Seller shall not proceed with Work as detailed in submittal, but instead shall correct defects and resubmit for review.

6. For Information Only: Submittal has not been reviewed but is being retained for informational purposes only. Seller may proceed with fabrication of work in submittal.

7. Void: Submittal is voided because it is no longer required or has been superseded by another submittal.

C. Return submittals to Seller electronically.

D. Review of submittals shall not relieve Seller from responsibility for any variation from Contract Documents unless Seller has, in writing, called Design Professional's attention to such variation at time of submission, and Design Professional has given written concurrence pursuant to Contract Documents to specific variation, nor shall any concurrence by Design Professional or other reviewer relieve Seller from responsibility for errors or omissions in submittals.

1.04 SHOP DRAWINGS SUBMITTALS

A. Submit for review for limited purpose of checking for conformance to information given and design concept expressed in Contract Documents.

B. Make submittals promptly in accordance with approved schedule, and in such sequence as to cause no delay in Work or in work of others.

C. Present in clear and thorough manner, complete with respect to dimensions, design criteria, materials of construction, and like information to enable review of information as required.

D. Indicate special utility and electrical characteristics, utility connection requirements, and location of utility outlets for service for functional equipment and appliances.

E. Equipment which is identified on Contract Documents with tag number or name shall be identified on Shop Drawing with same tag.

F. For each submittal for review, allow 15 calendar days.

G. Identify variations from Contract Documents and product or system limitations which may be detrimental to successful performance of completed Work.

H. 3D model design coordination: 1. Seller shall submit their 3D model and their subsupplier’s 3D model for following equipment for

Design Professional’s use in developing overall project 3D model. a. Package steam generator, natural gas burner, and piping tie-point connections. b. Feed water economizer with inlet and outlet transitions. c. Sweet water condenser.


d. Forced draft fan. e. Combustion air and flue gas duct work and stack. f. Access platforms and equipment support steel.

2. Seller shall notify Owner and Design Professional upon award of above equipment packages whether a 3D model will be available from that sub-supplier and the timing of submittal.

3. The preferred 3D format is MicroStation (.dgn) V8 or AutoCAD (.dwg) R2008 or newer. 4. Seller shall submit software, version and file format the original models were authored in. 5. Progress submittals of the 3D model may be required to facilitate coordination.

I. Shop Drawings: Submit in electronic format: 1. Text documents shall be submitted in .pdf format. 2. Drawings shall be submitted in .pdf format. 3. Electronic submittal shall be suitable for reproduction in black and white.

J. Submittals shall contain: 1. Date of submission and dates of any previous submissions. 2. Project title and number. 3. Contract identification. 4. Names of:

a. Seller. b. Supplier. c. Manufacturer.

5. Identification of product, with Specification section number and article number. 6. Applicable standards, such as ASTM or Federal Specification numbers. 7. Identification of deviations from Contract Documents. 8. Identification of revisions on resubmittals. 9. An 8" x 3" blank space for Seller stamps and reviewer comments. 10. Indication of Seller's approval, initialed or signed, with wording substantially as follows:

"Seller represents to Owner and Design Professional that Seller has either determined and verified all quantities, dimensions, materials, catalog numbers, and similar data, or assumes full responsibility for doing so and has reviewed or coordinated each submittal with requirements of Work and Contract Documents."

K. Product Data: 1. Mark each copy to identify applicable products, models, options, and other data. Supplement

manufacturers' standard data to provide information specific to this Project. 2. Indicate product utility and electrical characteristics, utility connection requirements, and location

of utility outlets for service for functional equipment and appliances.

L. Design data: 1. Submit for Design Professional's knowledge as contract administrator or for Owner. 2. Submit for information for limited purpose of assessing conformance with information given and

design concept expressed in Contract Documents.

M. Data sheets: 1. Data sheets may require information not known until Seller’s engineering is complete. Furnish

estimated values based on good engineering judgment. Estimated values shall be identified by placement of “(est.)” next to value.

2. Data Sheets shall be updated and resubmitted by Seller once final values are known. 3. Do not leave items blank or labeled “To Be Determined” or “Later.” 4. Do not submit manufacturer Product Data instead of completed data sheets.

N. Test reports: 1. Submit for Design Professional's knowledge as contract administrator or for Owner. 2. Submit test reports for information for limited purpose of assessing conformance with information

given and design concept expressed in Contract Documents.

SUBMITTAL PROCEDURES 26153.02.00 Page 4, SECTION 01 33 00 ms1692

O. Certificates: 1. When specified in individual specification sections, submit certification by manufacturer. 2. Indicate material or product conforms to or exceeds specified requirements. Submit supporting

reference data, affidavits, and certifications as appropriate. 3. Certificates may be recent or previous test results on material or product, but must be acceptable

to reviewer.

P. Manufacturer's instructions: 1. When specified in individual specification sections, submit instructions for delivery, storage,

assembly, installation, start-up, adjusting and finishing. 2. Indicate special procedures, perimeter conditions requiring special attention, and special

environmental criteria required for application or installation. 3. Recommended long term and short term storage requirements and procedures.

Q. Erection drawings: 1. Submit for information for limited purpose of assessing conformance with information given and

design concept expressed in Contract Documents. 2. Data indicating inappropriate or unacceptable Work may be subject to action by Design

Professional or Owner.

R. Operations and maintenance manuals: 1. Designate in construction schedule, or in separate coordinated schedule, dates for submission

and dates that reviewed operations and maintenance manuals will be needed. 2. Operations and maintenance manuals shall be presented in clear and thorough manner, complete

with respect to dimensions, design criteria, materials of construction, and like information to enable reviewer to review information as required.

1.05 RESUBMISSION REQUIREMENTS

A. Make any corrections or changes in submittals required by Design Professional and resubmit until stamped as either "Reviewed," "Reviewed as Noted," or “For Information Only.”

B. Text and depictions changed on Submittal shall be back-circled (clouded).

C. Design Professional will assume that portions of Submittal not back-circled have not been changed by Seller from previous submission.

D. Indicate revision number and date in document revision block.

1.06 SUBMITTAL TRANSMITTAL FORM PROCEDURES

A. Submittals shall be accompanied by completed copies of Submittal Transmittal form, bound herein. An electronic version of transmittal form is available and may be obtained from Design Professional. Reproduce additional copies required.

B. Submit transmittal form for initial submittals and resubmittals. Sequentially number transmittal form. Revise submittals with original number and sequential alphabetic suffix.

C. Prior to submittal, complete information under heading “Seller's Transmittal.”

D. Design Professional will complete information under “Reviewer's Action.”

E. Do not include submittals for more than one section of Specifications in each transmittal.

F. Identify project title, location, and number and contract title and number.

G. Identify preparer name and, submittal number, including preparer’s submittal revision number.


H. A brief description under "Title" should clearly identify specific application of equipment or material covered by Submittal, utilizing same title used in Contract Documents, where possible.

I. Identify Specification Section number.

J. Apply Seller's stamp, signed or initialed certifying that review, approval, verification of products required and coordination of information is in accordance with requirements of Contract Documents.

PART 2 PRODUCTS NOT USED

PART 3 EXECUTION NOT USED

END OF SECTION

Date Received Date Distributed SUBMITTAL TRANSMITTAL Transmittal No.

Project Title 0549701 West Campus Energy Plant – Construct Facility Project No. 26153 Contract No. 1 Project Location University of Iowa, Iowa City, Iowa Contract Title Boiler Procurement

SELLER'S TRANSMITTAL

REVIEWER’S ACTION Status Abbreviations:

R - Reviewed RS – Resubmit RN - Reviewed as Noted RET - Returned Without Review RNR – Reviewed as Noted Resubmit FIO - For Information Only

V – Void

Preparer Preparer Submittal No.

Rev. No. Title Section

No. SC

Submittal No.

Status Distribution (No.)

Cont RPR Own Des

Seller Remarks Address

By _________________________________ Date ______________________________

By Signature above, the Seller shall certify that they have reviewed the submittal and that they comply with all applicable specification sections and contract drawings. Action of any kind on submittal by Design Professional does not relieve Seller from responsibility for errors, correctness of details, or conformance to the contract.

Design Professional Remarks

By

Date

SC3001 R4 0907 SHOP DRAWING TRANSMITTAL

26153.02.00 QUALITY REQUIREMENTS ms1692 SECTION 01 40 00 - Page 1

PART 1 GENERAL

1.01 QUALITY CONTROL

A. Monitor quality control over suppliers, manufacturers, products, services and workmanship, to produce Goods of specified quality.

B. Comply with specified standards as minimum quality for Goods, except where more stringent tolerances, codes or specified requirements indicate higher standards or more precise workmanship.

C. Perform Work by persons qualified to produce required and specified quality.

1.02 TOLERANCES

A. Monitor fabrication and installation tolerance control of Goods. Do not permit tolerances to accumulate.

B. Comply with manufacturers' tolerances. Should manufacturers' tolerances conflict with Contract Documents, request clarification from Design Professional before proceeding.

C. Adjust products to appropriate dimensions; position before securing products in place.

1.03 REFERENCES

A. For products or workmanship specified by association, trade, or other consensus standards, comply with requirements of the standard, except when more rigid requirements are specified or are required by applicable codes.

B. Conform to reference standard by date of issue current on date for receiving proposals, except where a specific date is established by code.

C. Obtain copies of standards where required by product specification sections.

D. Should specified reference standards conflict with Contract Documents, request clarification from the Design Professional before proceeding.

E. Neither contractual relationships, duties, nor responsibilities of the parties in Contract nor those of the Design Professional shall be altered from the Contract Documents by mention or inference otherwise in any reference document.

F. Abbreviations used in Contract Documents are as specified in ASME Y14.38 and IEEE 260.

G. Schedule of references: 1. ABMA - American Bearing Manufacturers Association 2. AISC - American Institute of Steel Construction 3. ANSI - American National Standards Institute 4. ASME - American Society of Mechanical Engineers 5. ASTM – International Standards Worldwide 6. AWS - American Welding Society 7. CSA - Canadian Standards Association. 8. ICEA - Insulated Cable Engineers Association 9. IEEE - Institute of Electrical and Electronics Engineers 10. ISO - International Standards Organization 11. NEMA - National Electrical Manufacturers' Association 12. NFPA - National Fire Protection Association 13. OSHA – U. S. Department of Labor, Occupational Safety and Health Administration 14. SSPC – The Society for Protective Coatings

QUALITY REQUIREMENTS 26153.02.00 Page 2 - SECTION 01 40 00 ms1692

15. UL - Underwriters' Laboratories, Inc.

1.04 WELDING REQUIREMENTS

A. Welding shall be performed by qualified welding operators using procedures which have been qualified in accordance with applicable codes and standards: 1. ANSI B31.1 Code for Pressure Piping. 2. ASME Boiler and Pressure Vessel Code. 3. AWS D1.1 Structural Welding Code.

B. Procedure qualification: 1. Fabricator performing welding under jurisdiction of referenced codes shall be responsible for

obtaining and qualifying welding procedures. Structural welding procedures conforming to AWS D1.1 are prequalified as defined in AWS D1.1, Chapter 5 and Appendix E.

2. Seller shall maintain records, and make available to Design Professional and Owner when requested, certifying successful completion of procedure qualification tests.

C. Performance qualification: 1. Fabricator performing welding under jurisdiction of referenced codes shall be responsible for

testing and qualifying its welding operators in accordance with applicable codes, using qualified procedures.

2. Unless welding operators have been previously qualified by Seller within last 6 months and have been continuously employed as welders by Seller following qualification, requalification tests must be performed.

D. Submittals: 1. Except for procedures exempted to AWS D1.1, Section 5.1, submit copy of each welding

procedure to Owner and Design Professional with certificate demonstrating successful qualification of welding procedures for each welding process: AWS D1.1 - Forms E-1, E-2, E-3, or ASME QW-483.

2. Prior to execution of any welding, submit to Owner and Design Professional copy of welder qualification form for each individual performing welding: AWS D1.1 Form E-4 or ASME QW-484.

1.05 SERVICE ENGINEER RESPONSIBILITIES

A. Seller shall provide a qualified Service Engineer(s), as necessary to: 1. Sustain Seller’s and Seller’s suppliers warranties on equipment furnished under this contract. 2. Supervise assembly of equipment. 3. Inspect equipment after it is installed to assure that all details of installation are correct and that

equipment is prepared for operation in accordance with manufacturer's instructions and recommendations.

4. Check connections to equipment and adjust, or supervise adjustment of, control and indicating devices after equipment has been installed and connected.

5. Fully instruct Owner's operating personnel in operation and maintenance of equipment. 6. Provide Seller and Design Professional with duplicate copies of final alignment and clearance

measurements on all rotating or reciprocating equipment. Measurements shall clearly identify each piece of equipment.

7. Supervise preliminary operation of equipment and necessary adjustments. 8. Witness distributed control system (DCS) factory acceptance test (FAT). 9. Participate in boiler tuning with third party commissioning agent and DCS vendor representative.

B. Work and abilities of Service Engineer shall be subject to review of Owner, Design Professional and Contractor. If Owner, Design Professional or Contractor determines that any Service Engineer is not properly qualified, Seller shall replace Service Engineer upon written notification by Contractor. Seller shall provide resume of service technicians for boiler, burner, and FD fan packages for review by Owner.

26153.02.00 QUALITY REQUIREMENTS ms1692 SECTION 01 40 00 - Page 3

C. Seller shall provide continuity in assignment of Service Engineer to Work. In event substitution of Service Engineer is made which is not at request of Design Professional, substitute's time for "familiarization" shall be at Seller's expense.

D. Seller will provide, from manufacturer of equipment, Service Engineer who will perform functions specified for equipment provided.

E. Seller shall pay for cost of time and trips to site of Service Engineer if additional time or trips are required because of defective workmanship, materials, or equipment furnished under this Agreement.

F. Owner will be sole determining agent as to reasonableness of Service Engineer's claim for added compensation.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

NOT USED

END OF SECTION

QUALITY REQUIREMENTS 26153.02.00 Page 4 - SECTION 01 40 00 ms1692


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26153.02.00 FIELD QUALITY CONTROL ms1692 SECTION 01 45 16 - Page 1

PART 1 GENERAL

1.01 FIELD PERFORMANCE TESTS

A. After system or equipment and other equipment necessary for operation of Work are installed and in operating condition, Seller shall supervise operation of equipment or system for period sufficient to assure proper functioning, and make necessary observations, investigations, and adjustment.

B. Owner will conduct tests it deems necessary to determine if equipment or systems function properly. Guaranteed performance offered by Seller and as identified on Data Sheets included in Section 23 52 33 will be verified using mutually agreed upon field performance testing procedures prepared by Seller and reviewed by Owner and/or Design Professional. Seller shall provide necessary certified performance correction curves with its Proposal.

C. Guaranteed emissions offered by Seller and as identified on Data Sheets included in Section 23 52 33 will be monitored by others during field performance testing. Guaranteed performance shall be met without exceeding guaranteed emissions.

D. It is intent of Owner to conduct, simultaneously, performance tests on all heat cycle and electric generating equipment components. These include steam generator and related equipment.

E. Performance tests will be scheduled as soon as practicable but not later than 120 days after all associated equipment have been placed in "on-line" operating service and proved capable for continuous normal operation. Shutdowns of limited duration for normal operational checks, inspections, and adjustments will not be considered as causing Goods to be incapable of continuous operation.

F. Delayed testing: 1. If any individual equipment component is operable but is not declared ready for testing within time

limit stated above and cannot be tested during initial scheduled performance tests, delayed performance tests will be conducted upon these Goods at later scheduled date.

2. All costs incidental to conducting delayed performance tests, except for cost of fuel, water, and Owner’s operating personnel, shall be borne by Seller responsible for equipment which are not ready for testing at time of initial performance tests.

G. Seller shall be responsible for each equipment component and shall notify Owner in writing when installation of its Goods is considered to be complete, in good operating condition, and ready for performance tests. 1. This notice shall not be given until such time as all designed operational functions have been

positively proved in actual operation or by simulated operational tests. 2. Simulated operational tests shall be made only when it is impractical to conduct an actual "in

operation" test. 3. When simulated operational test involves sensing device, test shall establish operational ability of

sensing device.

H. Owner will coordinate between concerned parties and will establish schedule for performance tests. Upon establishment of test schedule, Owner will give minimum of 10 days' notice to all concerned parties.

I. Such tests as are deemed necessary by Owner and Design Professional to establish that equipment function properly and that guarantees are met will be conducted by Owner.

J. Owner will furnish fuel, water, and one operating engineer for tests.

K. Seller shall witness tests and assist in their performance.

L. Station instruments, meters, pressure gages, and thermometers, supplemented by necessary portable test instruments, will be used for tests.

FIELD QUALITY CONTROL 26153.02.00 Page 2 - SECTION 01 45 16 ms1692

M. Costs for initial performance tests, except for costs of Seller's personnel, will be borne by Owner.

N. Retesting or supplemental testing: 1. Owner, after giving notice, will perform retesting or supplemental testing it deems necessary to

further check performance of Goods. 2. All costs including Owner’s Design Professional and Commissioning Agent’s services, except for

costs of fuel, water, and Owner’s operating personnel, shall be borne by Seller. 3. Owner will render bill to be paid by Seller covering costs incurred by retesting or supplemental

testing, except as noted herein.

O. If there is serious question or disagreement regarding accuracy of test results and Seller considers tests of greater refinement necessary or desirable, Owner, at Seller's request, may direct that further tests be conducted in accordance with ASME Power Test Codes by a third party. If so directed: 1. Seller shall make arrangements and provide facilities necessary for performance of ASME Power

Test Code 4. 2. Owner will furnish fuel, water, and one operating engineer for tests. 3. Seller shall witness and assist in performance of tests. 4. Owner shall reimburse Seller for actual cost of labor and materials for furnishing and installing

testing facilities only, as listed on itemized statement of costs to be submitted by Seller, only if ASME Power Test Codes tests reveal that equipment is performing in accordance with guarantees.

5. If ASME Power Test Codes tests indicate that equipment is not performing in accordance with guarantees, all costs of Owner, Commissioning Agent, Design Professional, and Seller incidental to ASME Power Test Codes tests, except for fuel, water, and Owner’s operating personnel, shall be borne by Seller.

6. Billings to Seller for Owner’s, Commissioning Agent’s, or Design Professional’s costs for delayed testing, retesting, supplemental testing, and ASME Power Test Codes testing as specified hereinbefore, shall be paid directly to Owner, Commissioning Agent, or Design Professional, as appropriate, within 30 calendar days from receipt by Seller. Seller's failure to pay such billings shall be cause for withholding final payment in amount equal to such costs.

P. Commissioning Agent’s and Design Professional’s costs, when applicable, will be determined at their respective current per diem rates, plus direct expenses.

Q. If equipment or systems fail to function properly, or guaranteed performance is not indicated, Seller shall make necessary corrections, including replacement, at no cost to Owner, and after such corrections are completed, demonstrate to Owner that equipment or systems function properly and guaranteed performance is obtainable.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

NOT USED

END OF SECTION

26153.02.00 OPERATING AND MAINTENANCE DATA ms1692 SECTION 01 78 23 - Page 1

PART 1 GENERAL

1.01 OPERATING AND MAINTENANCE DATA REQUIREMENTS

A. Operating and maintenance data shall be in English language.

B. Compile product data and related information appropriate for Owner’s maintenance and operation of products furnished under Agreement.

C. Prepare operating and maintenance data as specified in this section and as referenced in other pertinent sections of Specifications.

1.02 QUALITY ASSURANCE

A. Preparation of data shall be done by personnel: 1. Trained and experienced in maintenance and operation of described products. 2. Familiar with requirements of this section. 3. Skilled as technical writers to extent required to communicate essential data. 4. Skilled as draftsmen competent to prepare required drawings.

1.03 FORM OF SUBMITTALS

A. Prepare data in form of an instructional manual for use by Owner’s personnel.

B. Format: 1. Sheet size: 8-1/2" x 11" minimum. 2. Paper: 20 lb minimum, white, for typed pages. 3. Text: Manufacturer's printed data, or neatly typewritten. 4. Drawings:

a. Provide reinforced punched binder tab, bind in with text. b. Larger size drawings shall be folded to 8-1/2” x 11”, and inserted into pockets.

5. Provide fly-leaf for each separate product, or each piece of operating equipment. a. Provide typed description of product, and major component parts of equipment. b. Provide indexed tabs.

6. Cover: Identify each volume with typed or printed title "OPERATING AND MAINTENANCE INSTRUCTIONS." List: a. Title of Project. b. Identity of general subject matter covered in manual.

7. Binders: a. Commercial quality 3-ring binders with durable and cleanable plastic covers. b. Maximum ring size: 1". c. When multiple binders are used, correlate data into related consistent groupings.

1.04 CONTENT OF MANUAL

A. Neatly typewritten table of contents for each volume, arranged in systematic order. 1. Seller, name of responsible principal, address, and telephone number. 2. Indicated Owner-provided equipment number for each item in manual. 3. List of each product required to be included, indexed to content of volume. 4. List, with each product, name, address, and telephone number of:

a. Manufacturer or subsupplier. b. Maintenance contractor, as appropriate. c. Identify area of responsibility of each. d. Local source of supply for service, parts and replacement and list of recommended spare parts.

5. Identify each product by product name and other identifying symbols as set forth in Contract Documents, including nameplate information and shop order numbers for each item of equipment furnished.

OPERATING AND MAINTENANCE DATA 26153.02.00 Page 2 - SECTION 01 78 23 ms1692

B. Product data: 1. Include only those sheets which are pertinent to specific product. 2. Annotate each sheet to:

a. Clearly identify specific product or part installed. b. Clearly identify data applicable to installation. c. Delete references to inapplicable information.

C. Drawings: Supplement product data with Drawings as necessary to clearly illustrate following. 1. Relations of component parts of equipment and systems. 2. Control and flow diagrams. 3. Drawings shall use Owner provided instrument and valve tag numbers.

D. Written text, as required to supplement product data for particular installation. 1. Organize in consistent format under separate headings for different procedures. 2. Provide logical sequence of instructions for each procedure.

E. Copy of each warranty including start date, Bond, and service contract issued. Provide information sheet for Owner’s personnel, giving: 1. Proper procedures in event of failure. 2. Instances which might affect validity of warranties or Bonds.

1.05 MANUAL FOR EQUIPMENT AND SYSTEMS

A. Submit: 1. Preliminary manual: 3 bound hard copies and 1 electronic copy. 2. Final manual: 3 bound hard copies and 1 electronic copy. 3. Record “as-built” manual: 6 bound hard copies and 1 electronic copy.

B. Contents, for each unit of equipment and system, as appropriate: 1. Description of unit and component parts:

a. Function, normal operating characteristics, and limiting conditions. b. Performance curves, engineering data, and tests. c. Complete nomenclature and commercial number of replaceable parts.

2. Operating procedures: a. Startup, break-in, routine, and normal operating instructions. b. Regulation, control, stopping, shutdown, and emergency instructions. c. Summer and winter operating instructions. d. Special operating instructions.

3. Maintenance procedures: a. Routine operations. b. Guide to "trouble-shooting." c. Disassembly, repair, and reassembly. d. Alignment, adjusting, and checking. e. Welding procedures used during shop construction.

4. Servicing and lubrication schedule: List of lubricants required with cross reference to compatible Mobil lubricant number

5. Manufacturer's printed operating and maintenance instructions. 6. Description of sequence of operation by control manufacturer. 7. Original manufacturer's parts list, illustrations, assembly drawings, and diagrams required for

maintenance. a. Predicted life of parts subject to wear. b. Items recommended to be stocked as spare parts.

8. As-installed control diagrams by controls manufacturer. 9. Chart of valve tag numbers, with location and function of each valve using Seller-provided valve

tag numbers. 10. List of original manufacturer's spare parts, manufacturer's current prices, and recommended

quantities to be maintained in storage. 11. Other data as required under pertinent sections of Specifications.

26153.02.00 OPERATING AND MAINTENANCE DATA ms1692 SECTION 01 78 23 - Page 3

C. Content, for each electrical and electronic system, as appropriate. 1. Description of system and component parts:

a. Function, normal operating characteristics, and limiting conditions. b. Performance curves, engineering data, and tests. c. Complete nomenclature and commercial number of replacement parts.

2. Circuit directories of panelboards: a. Electrical service. b. Controls. c. Communications.

3. As-installed color-coded wiring diagrams. 4. Operating procedures:

a. Routine and normal operating instructions. b. Sequences required. c. Special operating instructions.

5. Maintenance procedures: a. Routine operations. b. Guide to "trouble-shooting." c. Disassembly, repair, and assembly. d. Adjustment and checking.

6. Manufacturer's printed operating and maintenance instructions. 7. List of original manufacturer's spare parts, manufacturer's current prices, and recommended

quantities to be maintained in storage. 8. Other data as required under pertinent sections of Specifications.

D. Additional requirements for operating and maintenance data: Respective sections of Specifications.

E. Provide complete information for equipment furnished under this Contract.

1.06 SUBMITTAL SCHEDULE

A. Preliminary O&M manual shall be submitted for review by Owner, Commissioning Agent, and Design Professional 8 weeks prior to shipment of Goods. Preliminary O&M manual shall contain final estimated operating condition data sheets.

B. Final O&M manual shall be submitted for review by Owner, Commissioning Agent, and Design Professional with shipment of Goods. Final O&M manual will be returned after acceptance, with comments, as necessary.

C. Record “as-built” O&M manual shall be submitted to Owner 2 weeks after completion of field performance testing. Approved field performance testing data (curves, parameters, results data, etc.) shall be incorporated into record “as-built” manual.

1.07 DEMONSTRATION AND INSTRUCTION OF OWNER’S PERSONNEL

A. Instruct Owner’s personnel in maintenance of products and in operation of equipment and systems. See Boiler Training Table at end of Section.

B. Provide daily training rate and per diem with Proposal.

C. Demonstrate operation and maintenance of products to Owner’s personnel 2 weeks prior to date of acceptance.

D. Demonstrate operation and maintenance of Goods to Owner’s personnel by a qualified representative who is knowledgeable about the Project.

E. Utilize operating and maintenance manual as basis for instruction. Review contents of manual with Owner’s personnel in detail to explain all aspects of operation and maintenance.

OPERATING AND MAINTENANCE DATA 26153.02.00 Page 4 - SECTION 01 78 23 ms1692

F. Demonstrate start-up, operation, control, adjustment, trouble-shooting, servicing, maintenance, and shutdown of each item of equipment at scheduled time, at equipment location.

G. Prepare and insert additional data in operating and maintenance manual when need for additional data becomes apparent during instruction.

H. Provide outline of training program to be provided to Owner’s operations and maintenance personnel with Proposal in Gantt chart format covering manufacturing recommended training topics and duration.

I. Training sessions will be videotaped by Owner at Owner’s discretion for documentation purposes.

PART 2 PRODUCTS

NOT USED

PART 3 EXECUTION

NOT USED

END OF SECTION

OPERATING AND MAINTENANCE MANUAL COVER DIAGRAM

UNIVERSITY OF IOWA

BOILER NO(S). _____

BOILER PROCUREMENT

VOLUME NUMBER _____

UNIVERSITY OF IOWA

OPERATING AND MAINTENANCE MANUAL FOR

BOILER NO(S). _____

VOLUME NUMBER _____

MANUFACTURER’S NAME MANUFACTURER’S ADDRESS

STANLEY CONSULTANTS, INC. MUSCATINE, IOWA

36 pt 36 pt

24 pt

36 pt 36 pt 36 pt

36 pt

24 pt 24 pt

14 pt 14 pt

SPINE

COVER

1. Imprinting shall be in Arial font. 2. Spine printing shall be 12-point. 3. Cover printing shall be in point sizes indicated. * If more than one volume is necessary, imprint cover with volume numbers.

OPERATING AND MAINTENANCE DATA 16000.02.00 Page 6 - SECTION 01785 ms159


LEFT BLANK

WEST CAMPUS ENERGY PLANT – CONSTRUCT FACILITY UI PROJECT NO 0549701 BOILER PROCUREMENT

JULY 2015 Edition BOILER TRAINING TABLE1 of 2

Notes:

- BLS/UEM to be invited to all first installations and equipment startups as optional attendees. -2 Sessions carried for shift change personnel

Training By: IC: Installing Contractor DP: Design Professional MR: Manufacturer’s Rep MT: Manufacturer’s Engineer

or Service Tech UEM: Utilities and Energy

Management

Trainees: AM: Area Mechanic ESM: Environmental Systems

Mechanic PF: Pipe Fitters EC: Electricians FPR: Fire Protection PL: Water Plant US: User Staff CS: Custodial Staff

Specification Section and System (Number and) Minimum Length of each session in Hrs.

Training Conducted by Trainees

Section 23 52 33- Package Boilers (2) 4-6 Hrs. Classroom Training (2) 2-4 Hrs. of Hands on Training

MR, IC AM, US, PF, EC

Section 23 52 33 – Package Controls

(2) 4 Classroom Training [60 days between sessions] (2) 4 Hands on Training [60 days between sessions]

IC, MT AM, US, ESM ,EC

Section 25 51 00 – Balance of the plant (integration) (2) 2 Classroom Training (2) 2 Hands on Training

IC, MT (both BOP and Boiler) AM, US, ESM, EC

BOILER TRAINING TABLE

WEST CAMPUS ENERGY PLANT – CONSTRUCT FACILITY UI PROJECT NO 0549701 BOILER PROCUREMENT

JULY 2015 Edition BOILER TRAINING TABLEPage 2 of 2

Section ## ## ## - Generator and Transfer systems (2) 2 IC, MT AM, EC, ESM

Section ## ## ## - Lighting Controls: Daylight harvesting, software, hardware

(2) 4 IC, MT, UEM AM, EC

Section ## ## ## - Specialty Lighting, Ballasts, Lamps (2) 2 MR AM, EC

Section ## ## ## - Lighting Fixtures Re-lamping and cleaning 2 IC CS

Section ## ## ## - VFD Maintenance and Programming (2) 4 MT AM, EC, ESM

Section ## ## ## - Life Safety – Fire Alarm/Fire Protection 2 IC UI Fire Protection, AM

Section ## ## ## - Lab Gasses 2 IC AM, PF, ESM, US

Section ## ## ## - Lab Controls (2) 2 IC, MT AM, ESM, EC, US

Section ## ## ## - Site Utility Distribution – Flow Diagrams and Component Locations

4 DP, IC Utilities

Section ## ## ## - Flooring System Repair and Maintenance 2 IC CS

Section ## ## ## - Fire Alarm Systems

Section ## ## ## - Fire Protection Systems

WEST CAMPUS ENERGY PLANT – CONSTRUCT FACILITY UI PROJECT NO. 0549701

BOILER PROCUREMENT

NOVEMBER 2014 EDITION COMMISSIONING

01 91 00 -1

SECTION 01 9100 - COMMISSIONING

PART I GENERAL

1.1 SECTION INCLUDES

A. Commissioning objectives.

B. Roles and responsibilities.

C. Installation verification, startup, and functional performance testing requirements.

D. Systems to be commissioned.

1.2 RELATED REQUIREMENTS

A. The following sections contain commissioning-related activities and requirements:

1. Section 01 33 00 - Submittals2. Section 01 40 00 - Quality Requirements3. Section 01 45 16 - Field Quality Control4. Section 01 78 23 - Operating and Maintenance Manual5. Section 23 52 33 - Packaged Boiler6. Section 26 05 00 - Common Work Results for Electrical7. Section 26 05 09 - Large Motors8. Section 26 05 09 - Medium Voltage Variable Frequency Drives9. Section 40 05 23 - General Duty Valves

10. Specific Product, Equipment, and Assembly Technical Sections.

B. Refer to ASHRAE Guideline 0-2013 and NIBS Guideline 3-2012 for commissioning process overview, standard of care, and definitions.

1.3 COMMISSIONING PROGRAM OBJECTIVES

A. Commissioning is intended to achieve the following specific objectives:

1. Verify and document that systems, equipment and components are installed inaccordance with the Contract Documents and manufacturer's recommendations, and havereceived adequate pre-functional checkout.

2. Verify and document the functional performance of systems, equipment and components.3. Verify continuity between systems, equipment and components.4. Verify that operation and maintenance documentation is complete and accurate.5. Verify that Owner's personnel have received the required training.

B. The commissioning process is not a substitute for the Contractor's quality control procedures, and does not diminish or subtract from the Contractor's responsibility to provide a finished and fully functioning product in accordance with the Contract Documents.

1.4 ROLES AND RESPONSIBILITIES

A. COMMISSIONING AGENT (CxA)

1. The Owner will retain the Commissioning Agent(s) unless noted otherwise within theContract Documents.

2. The CxA shall develop and coordinate the execution of a quality assurance plan for thesystems, equipment and components to be commissioned, shall observe and documentperformance, and shall determine whether the systems, equipment and components arefunctioning in accordance with the Contract Documents.

3. The CxA shall review submittals for the purposes of preparing Construction Checklists andFunctional Performance Testing procedures.

4. The CxA shall review Contractor’s documentation submittals for completeness.


BOILER PROCUREMENT


01 91 00 -2

B. CONTRACTOR’S COMMISSIONING COORDINATOR (CCxC) 1. The Contractor shall designate a person with authority to direct work, separate from the

Contractor’s superintendent or project manager, as the CCxC. The proposed CCxC shallhave documented experience managing verification, startup, and closeout of similarsystems, equipment and components. The Owner’s Representative shall have finalapproval of the proposed CCxC.

2. The CCxC is responsible for planning, scheduling, coordinating, conducting and verifyingall commissioning activities required by the Contract Documents, ensuring that allsystems, equipment and components are complete and functioning.

3. The CCxC shall communicate and coordinate with the Owner’s Representative, the CxAand the Testing and Balancing Agent to schedule and execute the commissioningprocess, including Construction Checklists, Functional Performance Testing, and otheractivities described in the Contract Documents.

4. The CCxC shall visit the site as required by the Owner’s Representative to observe theprogress of the Work and to determine if the commissioning activities are proceeding inaccordance with the Contract Documents. The CCxC shall keep the Owner’sRepresentative and CxA informed of the progress of the work and commissioningactivities.

5. The CCxC shall coordinate the scheduling and execution of Owner training.

C. CONTRACTOR'S RESPONSIBILITIES

1. The Contractor shall provide all labor, supervision, materials, tools, equipment, and otherservices, as necessary, to complete the Contractor’s commissioning activities inaccordance with the Contract Documents.

2. The Contractor shall ensure that all system, equipment and component warrantyrequirements are followed throughout the startup, commissioning, and training process.

3. The Contractor shall coordinate, manage and ensure completion of all commissioningdocumentation.

4. The Contractor shall invite the Owner’s Representative, Owner’s Operations Personneland CxA to all equipment startup as optional attendees. The purpose of this invitation isto familiarize personnel with equipment and systems prior to training and turnover.

5. The CCxC shall conduct regular commissioning coordination meetings with the DesignProfessional, Owner’s Representative, Commissioning Agent, and all Subcontractors ofcommissioned systems, equipment and components. The purpose of these meetings willbe to coordinate schedule, work activities, and deficiency resolution. These meetings shallbe independent from the regularly scheduled construction progress meetings. The CCxCwill prepare and distribute meeting minutes.

6. With input from the CxA, the Contractor shall integrate commissioning activities into itsmaster construction schedule. Each commissioned system, piece of equipment andcomponent shall be identified separately on the Contractor’s schedule. At a minimum, theschedule shall identify the following activities and milestones:

a. Permanent utilities connected - by individual utility typeb. IT interface completedc. Start and completion of each project phased. End of dust producing activitiese. Construction checklists complete – by individual systemf. Equipment startups completed – by individual piece of equipmentg. Functional performance testing completed - by individual system.h. Owner training Section 01 78 23 - Operating and Maintenance Manuali. Substantial completionj. Warranty start datesk. Warranty walkthrough date (two (2) months prior to end of warranty);l. Lessons learned meeting

PART 2 PRODUCTS

2.1 TEST EQUIPMENT

A. The Contractor shall provide all test equipment required for installation, verification, startup, and


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01 91 00 -3

checkout of systems, equipment and components.

B. The Commissioning Agent shall provide all specialized equipment required for Functional Performance Testing.

C. Specialty equipment, tools and instruments necessary to conduct testing (e.g., available only from the manufacturer for a specific piece of equipment) shall be included in the Contractor's bid and shall be turned over to the Owner at the end of the project.

D. All test equipment shall be of sufficient quality and accuracy to test and/or measure system performance within the specified tolerances. If not otherwise noted, the following minimum requirements apply:

1. Temperature sensors and digital thermometers shall have an accuracy of 0.5 °F and aresolution of plus or minus 0.1 °F.

2. Pressure sensors shall have an accuracy of +/- 2.0% of the value range being measured(not full range of meter).

E. All test equipment shall be calibrated according to the manufacturer's recommendations or within the past year whichever is more stringent. Calibration tags shall be affixed to test equipment or certificates available upon request.

PART 3 EXECUTION

3.1 SYSTEMS TO BE COMMISSIONED BY OWNER’S COMMISSIONING AGENT

A. MECHANICAL SYSTEMS

1. Boiler- Steam generator including burner and combustion management,a. Conduct 100% check of equipment, controls, and interlocks.

3.2 ONSITE COMMISSIONING SUPPORT PROVIDED BY EQUIPMENT VENDOR

A. The Owner will engage the services of a Commissioning Authority. Provide all required support to the Commissioning Authority during all phases of the Commissioning process. Final Closeout will depend on approval of Boiler operation by the Engineer, the Commissioning Authority and the Owner.

1. Assist in demonstrating Boiler system performance under the guidance of theCommissioning Authority in accordance with the procedures that they will develop.Demonstration shall be witnessed by the Owner’s Representative, Engineer,Commissioning Authority, the University’s Code Enforcement and the University’soperating staff.

2. Include 40 hours (per Boiler) of on-site commissioning demonstration assistance by afactory-trained service representative in addition to facilities and operator training.

3. Provide the normal complement of tools and test instrumentation that a factory-trained,field service representative would have during startup for the Boilers installed.

B. Scheduling of the demonstration shall be dependent on the availability of the

appropriate members of the Owner’s staff.


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01 91 00 -4

3.2 COMMISSIONING PROCESS

A. Construction Activities:

1. The CxA will review the commissioning process with the Contractor and Subcontractors atthe pre-construction meeting.

2. Within 60 days of Contract Award, the CxA will schedule and conduct a commissioningkickoff meeting to be attended by the Design Professional, Owner’s Representative,CCxC, and Contractor, and Subcontractors and Suppliers of systems, equipment andcomponents to be commissioned. The purpose of the meeting is to review commissioningrequirements, procedures, and documentation. The CxA will prepare and distributemeeting minutes.

3. Contractor shall submit manufacturer's material and equipment shop drawings anddocumentation to the Design Professional per Section 01 33 23 - Submittals.

4. CxA shall review the submittal data and prepare final Construction Checklists andFunctional Performance Testing Procedures.

5. The Contractor and Subcontractors shall complete the Construction Checklists and anyadditional testing requirements found in the Construction Documents.

6. CCxC shall review Construction Checklists for completeness and verify that alldocumentation requirements have been met.

7. After verifying correct installation of systems, equipment and components and approval ofthe Construction Checklist, the CCxC shall schedule and coordinate startup and checkoutof the equipment, systems and components.

8. The Contractors and Subcontractors shall perform Functional Performance Testing.9. The CxA shall witness commissioning-related testing.

10. Systems, equipment or components which fail to meet the Functional PerformanceTesting requirements shall be corrected by the Contractor and the tests shall repeated atno additional cost to the Owner.

11. The CCxC shall review, schedule, coordinate and document required Owner training perSection 01 78 23 - Operating and Maintenance Manual.

3.3 CONSTRUCTION CHECKLISTS

A. See sample Construction Checklist, attached at the end of this section.

B. The objective of Construction Checklists is to verify and document that the systems, equipment and components are installed in accordance with the manufacturer’s instructions and Contract Documents. The CxA shall create Construction Checklists after the shop drawings have been submitted and reviewed.

C. Contractor shall complete the Construction Checklists during the course of system, equipment and component installation and not as an activity at the end of the project. The Construction Checklists shall certify the individual verification items have been performed, inspected and found to be complete for all systems, equipment and components. (Random sampling and testing of equipment and components is not acceptable.)

D. The Construction Checklists for a given system must be successfully completed prior to its startup. By completing and signing the Construction Checklists, the CCxC certifies that the system, equipment and components are properly installed and ready for startup and functional performance testing.

E. The CCxC shall notify the Owner’s Representative and CxA when Construction Checklists are complete.

F. The Construction Checklists may be in addition to other testing, verification, and startup required elsewhere in the Contract Documents.

3.4 FUNCTIONAL PERFORMANCE TESTING

A. See sample Functional Performance Test, attached at the end of this section.


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01 91 00 -5

B. The objective of functional performance testing is to demonstrate and document that systems, equipment and components operate in accordance with the Contract Documents.

C. The CxA shall prepare Functional Performance Testing procedures based on the system sequences of operation and the manufacturer's product data.

D. All tests that will impact the operations of existing building or utility systems are to be identified by the CCxC and coordinated with the Owner’s Representative.

E. The CxA shall oversee and document the Functional Performance Testing.

F. The Contractor shall provide assistance as needed to complete the Functional Performance Testing, including, but not limited to, providing access to equipment and components, including the use of ladders, lifts, scaffolding and platforms, Personal Protective Equipment, removal of access panels, opening of equipment, manipulation or operation of equipment or components, etc.

G. The CxA shall test each system through all modes of operation where there is an expected system response.

1. Normal and Maintenance Operations: Each system shall be tested through all modes andsequences of operation (maintenance, seasonal changes, occupied, unoccupied, warm-up, cool-down, etc.). Testing shall also demonstrate that the system has the requiredaccess, etc., for proper maintenance, adjusting, and cleaning.

2. Abnormal, Failure, and Emergency Operations: Each system shall be tested to simulateconditions such as power failure, freezing, low/no flow, deviation from standard operatingconditions, human error, etc., to verify proper system responses, shutdowns, alarms andannunciation, and inter-system communications.

3.5 DEFICIENCIES

A. The terms "failure", "deficiency" and "non-conformance" shall be used interchangeably and shall be defined as any condition in the installation or function of a system, piece of equipment or component that is not in compliance with the Contract Documents.

B. The CxA shall track all deficiencies on the CxA’s Issues Log. Items on the Issues Log are to be corrected by the Contractor prior to Substantial Completion. Any remaining open Items not accepted by the Owner may be added to the project punch list at the discretion of the Owner’s Representative.

C. At the discretion of the Owner’s Representative, costs associated with retesting systems, equipment and/or components due to deficiencies may be assigned to the Contractor.

1. Contractor’s incomplete or inaccurate Construction Checklists may be considered causefor retesting.

2. 10% failure rate of any Functional Performance Test sampling shall be cause for retesting100% of similar systems, equipment, or components.

3.6 ENDURANCE PERIOD

A. The Endurance Period is to be conducted prior to substantial completion. The Contractor will include the individual activities and durations for the Endurance Period on the master construction schedule. Initial duration should be set at 30 days (minimum) until actual duration is established by the Contractor, CCxC, CxA and Design Professional.

B. The objective of the Endurance Period is to exercise and challenge the functionality of mission critical systems and components to test against potential catastrophic failure.


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01 91 00 -6

COMMISSIONING SAMPLE SYSTEM READINESS CHECKLIST

Boiler

System Readiness Checklist

Equipment ID B-1,

Building

Location

Statement of Readiness

The above equipment and/or systems integral to them are complete and ready for functional testing, except as noted. None of the outstanding items preclude safe and reliable functional tests being performed. This checklist does not take the place of the manufacturer’s recommended checkout and startup procedures or report.

Responsible Contractor Sign Here:

General Contractor (GC) Date Printed Name

CONTRACTOR PRINTED NAME INITIALS DATE

Mechanical Contractor (MC)

Electrical Contractor (EC)

Controls Contractor (CC)

This statement of readiness has been received by the Commissioning Agent on ___________________ and will be incorporated as part of the final commissioning report.


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01 91 00 -7

Equipment Information Boiler Name Plate Data

Make Model Number

Serial Number

Capacity BTUH

PPH

Volts/Phase Function Service Area

Notes:

Documentation Submitted Description Yes N/A Initials Date Comment

s

Contract One Line Diagram Dwg. No. Rev.

Contract Plan/P&ID Dwg. No. Rev.

Equipment Shop Drawings (submittals) Final Approved

Operation and Maintenance Manuals

Installation and Startup Manual

FAT Documentation

Material Receipt Verification form (complete and damage repaired/replaced/acceptable)

Warranty information

Training Agenda

Training Schedule

Piping Flush report

Piping Pressure test report

Loop Check Documentation Field Installation Checklists Complete

Factory Start-up is completed and report attached


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01 91 00 -8

System Readiness Checklist Yes = Checked and Completed, N/A = Not Applicable

General Installation Description Yes N/A Initials Date Comments

General appearance good, no apparent damage

Pipe, gas, fittings and accessories complete

System flushing complete, strainers cleaned

Pumps complete

Pressure gages installed

Water treatment operational

Proper boiler fluid level

Equipment labels affixed

Access door space adequate and to code

Combustion air supply installed

No leaking apparent

Boiler water pumps and accessories installed

Boiler safeties, burner controls and accessories installed

Boilers Burners tuned and firing properly

Notes:

Gas Train Description Yes N/A Initials Date Comments

Gas train Installed in accordance with NFPA, FM and IRI

Gas train checked for leaks

Gas piping installed and tested

Gas train vents are terminated per code

Gas train safety devices are operational

Drip leg provided in gas main

Gas cock valve orientation per manufacturers recommendations

Gas cock valve accessible and travels freely

Gas cock checked for leaks in closed position with the other gas train valves open

Gas regulator installed per manufacturer’s instructions

Gas regulator properly located in non-turbulent section of pipe


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01 91 00 -9

Gas Train Description Yes N/A Initials Date Comments

Gas regulator is wired correctly

Gas regulator is accessible for test and service

Gas pressure adjusted and verified within acceptable range

Confirmed gas PRV operation

Gas pressure sensor limits are appropriate for application

High gas pressure switch installed per manufacturer’s instructions

High gas pressure switch is properly wired

Low gas pressure switch installed per manufacturer’s

instructions

Low gas pressure switch is properly wired

Gas control valve installed per manufacturer’s instructions

Gas control valve installed vertical with direction of flow confirmed

Gas control valve accessible and travels freely

Gas control valve checked for leaks in closed

position with the other gas train valves open

Gas control valve had no visible damage

Gas control valve nameplate readings checked

against application and is applied correctly


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01 91 00 -10

Piping Description Yes N/A Initials Date Comments

Piping complete, elbows minimized, , makeup water piping and safety reliefs installed

Piping supported independently of the boiler

Piping type and flow direction labeled on piping

Isolation valves and piping specialties installed

System flushing complete and strainers cleaned

Pressure gauges have been installed

Notes:

Electrical and Controls Description Yes N/A Initials Date Comments

Power disconnect is located within site of the unit it controls and labeled

All electric connections tight and installed properly

Grounding installed for components and unit

Safeties installed and operational

Starter overload breakers installed and correct size

All control devices, pneumatic tubing and wiring complete

Control system interlocks connected and functional

Size of over current heater in motor starter correct (where applicable)

HOA Switch installed per manufacturer’s instructions (if applicable)

Operation of HOA switch checked in all positions

Proper safeties in control when HOA switch in Hand position

Sensors calibrated (see calibration section below)

Multiple boiler interlocks completed

Notes:


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01 91 00 -11

Stack Description Yes N/A Initials Date Comments

Installed per manufacturer’s instructions

Sloped toward boiler

Clearance to combustibles per code

Protection in place to prevent burning hazard

Discharge is protected from rain and blockage

Provisions in place for expansion compensation

Discharge is located to preclude re-entrainment back into the building

Draft checked and meets minimum requirements of boiler manufacturer

Notes:

Operational Checks Description Yes N/A Initials Date Comments

Measure line to line voltage phase imbalance for all three-phase motors: (%Imbalance = 100 x (avg. - lowest) / avg.) Imbalance less than 2%

Record full load running amps for all three-phase motors. _____rated FL amps x ______srvc factor = _______ (Max amps). Running less than max?

No unusual noise and vibration when running

Boiler safeties energized and tested

Specified sequences of operation and operating schedules have been implemented with all variations documented

Specified point-to-point checks have been completed and documentation record submitted for this system

Startup report completed with this checklist attached. Includes full listing of all internal settings with notes as to which settings are BAS controlled or monitored and which are integral

Startup report includes written certification from boiler manufacturer that all specified features, controls and safeties have been installed and are functioning properly and that the installation and application comply with the manufacturer’s recommendations


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01 91 00 -12

Completed By: GC Signature: ___________________________________

Title: _______________________________________

Company Name: ______________________________

Date: _______________________________________

Completed By: Mech. Signature: ___________________________________

Title: _______________________________________

Company Name: ______________________________

Date: _______________________________________

Completed By: Electrical Signature: ___________________________________

Title: _______________________________________

Company Name: ______________________________

Date: _______________________________________

Completed By: Controls Signature: ___________________________________

Title: _______________________________________

Company Name: ______________________________

Date: _______________________________________


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01 91 00 -13

Sample Commissioning Functional Test Procedure

BOILER

FUNCTIONAL PERFORMANCE TEST

Equipment ID

Building

Location

1.1 SYSTEM DESCRIPTION

This test will verify the function of the boiler, including burners, forced draft fan and dampers. Any failures or abnormal operations require correction and subsequent re-testing of the system.

Included equipment:

YB2 boiler unit and associated appurtenances, including: boiler, burner, burner management, fuel trains,

combustion air damper, forced-draft fan, induced-draft fan and controls.

The Plant Control System (PCS) controls the boiler steam drum level, firing rate, combustion air, stack

draft, and oxygen trim. The Burner Management System (BMS), controls flame safety functions, burner

startup and shutdown.

Operational Assumptions:

Fuel oil system operational

Fuel gas system operational

480V electrical systems available

Steam system available

Compressed air available

Boiler feed water system operating

Boiler YB2 is available to operate

Water treatment system is operating


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01 91 00 -14

Functional Testing Start

Date End Date Initials

Results (Check one) Explanation:

Pass

Fail

Partial Test w/Corrective Actions

Complete Test w/Corrective

Actions

Other

Deferred/Seasonal Test/Retesting Start

Date

End

Date Initials

Results (Check one) Explanation:

Pass

Fail

Partial Test w/Corrective Actions

Complete Test w/Corrective Actions

Other

TEST PARTICIPANTS

Organization Required Optional

General Contractor

Mechanical Contractor

Electrical Contractor

TAB Contractor

Controls Contractor

Owner’s O&M Personnel

Equipment Startup Representative

Commissioning Agent


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01 91 00 -15

SUPPLIES REQUIRED FOR TESTING (TO BE PROVIDED BY THE CONTRACTOR)

Tools / Supplies

Access to plant control system Access to Burner Management System

SYSTEM READINESS SUMMARY

Description (Y/N/NA) Initial Date

Pre-functional Checklist (PFC) has been completed and is

available for CxA review.

Contractor startup and checkout procedure has been complete

and report is available for CxA review.

Trending data, reflective of approved programming and

equipment operation, is available for CxA review.

1.2 TREND DATA REQUIRED TO SUPPORT TESTINGVerify what trending data was provided prior to functional testing.

Trending Points

Pre-

Testing

During

Testing

Post

Testing Point Frequency Duration Provided

Steam drum pressure Yes No

Steam flow out Yes No

Fuel gas flow Yes No

Fuel oil flow Yes No

Steam drum level Yes No

Header pressure PI-

12001 Yes No

Combustion air

damper position input Yes No

Combustion air Yes No


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01 91 00 -16

Trending Points

Pre-

Testing

During

Testing

Post

Testing Point Frequency Duration Provided

temperature

Stack gas temperature Yes No

Stack O2 (AI-

30001B/40001B) Yes No

Water inlet

temperature Yes No

Feed water pressure

(PI-14509) Yes No


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01 91 00 -17

SET-POINTS, LIMITS, AND SCHEDULES The following set-points shall be identified before functional performance test.

Point Design Set-Point Actual Set-Point

Steam header pressure control set point

PC-12001

Drum level control set point LC

High steam header pressure alarm PIT-

12001

Low drum level alarm

Furnace pressure

Oxygen Trim

INITIAL CONDITIONS The following initial conditions shall be identified before functional performance test.

Condition Value Condition Value

Dry-bulb air temp

Enthalpy

Outside air RH %

Dew-point temp

Steam drum pressure

Steam flow out

Fuel gas flow

Fuel oil flow

Steam drum level

Header pressure PI-12001


BOILER PROCUREMENT


01 91 00 -18


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01 91 00 -19

FUNCTIONAL PERFORMANCE TEST -- (VERIFY ALL COMPONENTS ARE READY BEFORE ENERGIZING OR OPERATING

THE SYSTEM.)

The Commissioning Authority will make and document any changes/addition/deletions to this test

procedure required by current system conditions (i.e. weather, system load, utility availability, etc.).

R = Retest (Check () retest required) Y= Checked and Passed

C = Corrected (Check () when correction verified) N = Not Passed

ACTION REQUIRED

REACTION

Y

()

N

() COMMENTS

R

()

C

()

BOILER DRUM LEVEL ALARMS

1. With boiler

offline: manually

fill, if necessary,

the boiler steam

drum to normal

water level

(NWL)

NWL indicated at gauge

glass

NWL indicated at level

indicator mounted in control

room

NWL indicated at PCS

interface

Record issues Initial Date

2. Close the boiler

feed water

manual isolation

valve and open

intermittent

blowdown

valves, observe

water level

indicators

Water level drops as

indicated at gauge glass


indicated at level indicator

mounted in control room


indicated at PCS interface

Water level drops low level

alarm received


BOILER PROCUREMENT


01 91 00 -20

3. Close blowdown

valves

Level stops decreasing,

remains stable


4. Put level control

mode in

automatic, enter

level set point at

0.5” above Aux

LWCO

Valve modulates open


5. Open boiler feed

water manual

isolation valve

Level rises, Aux LWCO

alarm clears

BMS master fuel trip

clears


6. Adjust level

control set point

to 0.5” above

LWCO

LWCO alarm clears



BOILER PROCUREMENT


01 91 00 -21

7. Adjust level

control set point to

0.5” above HWA

Drum level rises, low level

alarm clears at BMS

Low level alarms clears

Water level rises, high

level alarm LAH


alarm

Boiler feed water level

control valve is 0% open


8. Adjust level

control set point

to NWL, open

blowdowns,

observe water

levels

Level control valve closed

(0% open) until NWL

reached

Level drops, high level

alarm clears

Master fuel trip removed


9. Close manual

blowdown valves

Drum level does not rise

or fall

No alarms indicated,

boiler indicates ready to

operate



BOILER PROCUREMENT


01 91 00 -22

BOILER STARTUP ON NATURAL GAS

10. Initiate normal

startup sequence

on natural gas

Boiler goes through purge

and startup sequence

FD fan runs

ID fan runs

Combustion air damper

modulates from minimum

to part open as dictated by

firing rate


HEADER PRESSURE CONTROL OPERATION ON NATURAL GAS

11. Place boiler in

header pressure

control mode with

set point at existing

header pressure PI-

12001/22001

Firing rate modulates to

maintain pressure


and ID fan speed

modulate with firing rate

Stack O2 and furnace

pressure remain near

set point

Drum level at or near

NWL


12. Decrease pressure

control set point in 1


maintain pressure


BOILER PROCUREMENT


01 91 00 -23

psi steps; 5 total

steps; pause at

each step until

operation is stable


and ID fan speed




set point


NWL


13. Increase pressure

control set point in

1 psi steps until

original set point is

reached; pause at

each step until

operation is stable


maintain pressure


and ID fan speed




set point


NWL


14. Manually isolate

fuel gas supply

downstream of fuel

train

BMS Master Fuel Trip,

burner shuts down on loss

of flame



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01 91 00 -24

15. Initiate burner start Burner will not start


16. Open gas valve,

re-start burner

Burner re-starts


17. Manually isolate fuel gas supply upstream of fuel gas train


burner shuts down on loss

of fuel pressure


18. Initiateburner start

Burner will not start


19. Open gasvalve, re-start burner

Burner re-starts



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01 91 00 -25

20. Initiate normal

boiler shutdown

Burner shuts down

no alarms


21. Initiate burner start Burner re-starts


22. Manually disable FD

fan at MCC

Alarm – FD fan fault

Burner shuts down


23. Initiate startup Burner will not start


24. Manually enable

FD fan

FD fan fault alarm clears


25. Release all

Overrides

System returns to

normal and alarms clear



BOILER PROCUREMENT


01 91 00 -26

FINAL SIGN-OFFCommissioning Agent Printed Name Initials Date

Sebesta

PARTICIPANTS

CONTRACTOR PRINTED NAME INITIALS DATE

General Contractor (GC)

Mechanical Contractor (MC)

Electrical Contractor (EC)

TAB Contractor (TAB)

Controls Contractor (CC)

Owner’s O&M Personnel

END OF SECTION

26153.02.00 PACKAGED WATER TUBE BOILER ms1692 SECTION 23 52 33 - Page 1

PART 1 GENERAL


A. Furnish and deliver shop-assembled, packaged-type, forced draft, D-type water tube boiler, and accessories.

B. Boiler trim.

C. Low-NOX burner.

D. Instrumentation and controls.

E. Flue gas recirculation equipment.

F. Mud drum heater.

G. Forced draft fan.

H. Ductwork.

I. Economizer and structural steel support frame.

J. Superheater.

K. Sweet water condenser.

L. Safety relief valve access platform above boiler drum.

M. Other components and services included in this specification or required for a fully functioning package.


A. Packaged boiler, economizer and accessories shall be designed and constructed in strict accordance with ASME Boiler and Pressure Vessel Code, Section I, Rules for Construction of Power Boilers, requirements and stamped and registered with National Board.

B. Packaged boiler and accessories shall conform to NFPA 85, NFPA 54, NFPA 31, state and local laws, regulations and codes having jurisdiction where plant is located, Iowa City, Iowa.

C. Applicable components shall be designed and constructed in accordance with ASME Power Test Code and ABMA Manual of Industry Standards with additions or modifications as required by this specification.

D. Design boiler package structural components in accordance with 2009 International Building Code and ASME STS-1. Ductwork shall be designed in with ASCE “Structural Design of Air and Gas Ducts for Power Stations and Industrial Boiler Applications”. Structural component and load drawings shall be signed and sealed by Professional Engineer licensed in the State of Iowa. Structural components include support skids, frames, access platforms, ladders, and related items.

E. Motors shall be in accordance with NEMA MG-1 and IEEE 112.

F. State and local building codes regarding pressure vessel design and installation shall supersede manufacturer’s recommendations.

G. Nonboiler external piping shall be in accordance with ASME B31.1.

PACKAGED WATER TUBE BOILER 26153.02.00 Page 2 - SECTION 23 52 33 ms1692 1.03 DELIVERY, STORAGE AND HANDLING

A. Shipping: Minimize ship loose components of boiler package. Maximum size opening into boiler plant is 18’ (5.5 m) high x 15’ (4.5m) wide. Ship components in maximum sizes to minimize reassembly and still fit through plant opening.

B. Piping connections and other openings shall be plugged or capped to prevent entrance of foreign material.

C. Thoroughly coat exposed machined surfaces with rust preventative material.

D. Equipment shall be properly covered, skidded, and crated to facilitate handling and to withstand normal shipping and handling shocks and vibration.

E. Place desiccant in drums prior to shipping to prevent rust. Desiccant shall not contain silica.

1.04 TYPICAL FUEL ANALYSES

A. Natural gas (primary fuel, by mole): 1. Heating value (Btu/ft3): 1059.2. 2. Ethane (%): 6.9218. 3. Propane (%): 0.8009. 4. Butane (%): 0.0802. 5. Isobutane (%): 0.0398. 6. Pentane (%): 0.00094. 7. ISO Pentane (%): 0.0085. 8. Methane (%): 89.7873. 9. Carbone Dioxide (%): 0.8383. 10. Nitrogen (%): 1.4867. 11. Hexane (%): 0.0031. 12. Hydrogen (%): 0.0061. 13. Helium (%): 0.0149.

1.05 SITE CONDITIONS

A. Elevation above sea level (approximate): 723’.

B. Barometer (mean), inches of Hg: 29.14.

C. Outdoor temperature, dry bulb: 1. Maximum: 115°F. 2. Minimum: -20°F.

D. Relative humidity: 60%.

E. Indoor temperature, dry bulb: 1. Maximum: 130°F. 2. Minimum: 40°F. 3. Boiler components shall be rated for 140° F.

1.06 COMPRESSED AIR

A. Available instrument and service air, psig: 80 to 120 normal.

1.07 SEISMIC DESIGN

A. Design equipment and structures in accordance with applicable provisions of 2009 IBC. Seismic site Class C. Structure occupancy Category III.

26153.02.00 PACKAGED WATER TUBE BOILER ms1692 SECTION 23 52 33 - Page 3 1.08 WATER CHEMISTRY

A. Feedwater, pH: 8.3 – 10.0.

B. Boiler water, concentration (ppm) maximum: 1. Total dissolved solids, TDS: - 0.7 x 20 {limit for uS/cm} = 14 ppm. 2. Total suspended solids, TSS: Provided after award of Contract. 3. Silica, as SiO2: <0.30 ppm supplemental chemicals, including oxygen scavenger and neutralizing

amines will be added to feedwater as required at points external to boiler. 4. Conductivity: < 20 uS/cm.

C. Owner uses Nalco/Suregaurd/Nextguard Polymer system.

PART 2 PRODUCTS

2.01 GUARANTEES

A. Design conditions: 1. Maximum continuous rating: 175,000 lb/hr. 2. Steam pressure at stop valve outlet: 825 psig. In addition to pressure drop through non-return

valve and stop valve furnished by Seller, Seller shall account for pressure drop through following piping and fittings furnished by Owner: a. 1 – 8” x 10” concentric reducer, if needed for transition at superheater outlet tie-point. b. 2 – 8”, 90 degree long radius elbows. c. 15’ of 8” schedule 100 pipe.

3. Steam temperature at stop valve outlet: 750°F +/- 10 °F from 50% MCR through 100% MCR. 4. Feedwater temperature to boiler: 242°F. 5. Plant floor main elevation: Approximately 723’ above sea level. 6. Ambient air temperature available to forced draft fan: 80°F (105°F maximum; 50°F minimum).

B. Performance guarantees: Identified on Data Sheets as “Guaranteed”.

C. Emission guarantees: Identified on Data Sheets as “Guaranteed”.

2.02 PACKAGED WATER TUBE BOILER

A. Factory-assembled, water tube boiler including: 1. Boiler drums. 2. Steam baffle system. 3. Boiler tubes. 4. Full membrane outer wall. 5. Two manways per drum (located on opposite ends), each manway shall be a minimum of 12" x

16" (300 mm x 400 mm). 6. Doors and access panels to permit access to tubes and furnace for cleaning, repairs, and

replacement. Doors and access panels shall be provided for ductwork between FD fan and burner, and between boiler outlet and economizer inlet.

7. Piping connections: a. Flanged or butt welded connections for pipe sizes 2-1/2” (64 mm) and greater. b. Flanged or socket welded connections permitted for pipe sizes less than 2-1/2” (64 mm). c. Connections include, but are not limited to, following:

Number Size Type Steam Outlet 1 As Req’d Butt welded Feedwater Inlet 1 As Req’d Butt welded Continuous Blowdown 1 1-1/2” Flanged Bottom Blowdown 1 1-1/2” Flanged Chemical Feed 1 1” Flanged

PACKAGED WATER TUBE BOILER 26153.02.00 Page 4 - SECTION 23 52 33 ms1692

Number Size Type Safety Relief Valves As Req’d As Req’d Flanged

Air Vents/Boiler Drains As Req’d As Req’d Flanged Steam Sampling (on drum steam outlet piping acceptable)

As Req’d 3/4” Flanged

Instrument Control (see applicable section) Mud drum standby warming coils As Req’d As Req’d Flanged

8. Boiler base: Construct of heavy I-beams. Boiler weight shall be uniformly distributed over entire

area of I-beams. Water shall be completely drainable from boiler through blow-off valves. Material shall be SA-36.

9. Base frame for mounting on flat concrete base. Elements shall be level. Provide attachments for anchorage to concrete foundation.

10. Provide lifting lugs and provisions for jacking. 11. Refractory and insulation: Boiler manufacturer's standard and experience proven design. Except

for areas within 12” (300 mm) of casing penetrations, no part of external casing shall exceed 140ºF when exposed to ambient air at temperature of 80ºF, air velocity of 50 fpm, and emissivity of 0.09. In addition, equipment skin temperature shall comply with OSHA requirements where human contact can occur.

12. Casing: Manufacturer’s standard material minimum thickness 20-gage all areas of boiler shell. Flash or seal openings at top of boiler at piping and flue connections to prevent leakage of water into insulation.

13. Casing: Provide provisions for casing water drain should tube rupture cause casing flooding. 14. Observation ports:

a. Provide at least 2 ports at strategic points in furnace wall. Ports shall be minimum 3” (75 mm) diameter, totally enclosed glass ports and provided with scavenging air connections.

b. Observation ports shall afford complete vision of burner throat and flame.

B. Completed boiler assembly shall be inspected in accordance with requirements of ASME Boiler and Pressure Vessel Code, Section I, Rules for Construction of Power Boilers.

C. Boiler tubes shall include corrosion allowance for minimum wall calculations. See Data Sheets for corrosion allowance requirements.

D. Dimensions: 1. Maximum building entry width: 15’-0” (4.5 m). 2. Maximum building entry height: 18’-0” (4.5 m). 3. Bottom of boiler will be located on grout 1” above operating floor. Operating floor at elevation

723’-0”. Mezzanine top of grating 17’-4” above operating floor. Mezzanine floor frame 1’-6” high. Top of building roof steel is 35’ above operating floor.

2.03 BOILER TRIM

A. Conform to ASME Boiler and Pressure Vessel Code, Section I.

B. New boiler shall be installed on common steam and feedwater header shared with multiple other boilers.

C. Provide boiler trim as specified below and as indicated on Sketch 8 found at end of Project Manual: 1. Steam trim:

a. Safety relief valves. b. Continuous blowdown manual isolation valves. c. Bottom blowdown manual isolation valves. d. Vent valves. e. Main steam nonreturn and stop valve.

2. Feedwater trim: a. Boiler feedwater flow control valve.


b. Feedwater stop valve and feedwater check valve: By others.

D. Refer to Section 40 05 23 for additional valve requirements.

E. Refer to article “Instrumentation and Controls” for additional requirements.

2.04 LOW NOx BURNER ASSEMBLY

A. Type: Factory-mounted firing of natural gas, packaged, forced draft, modulating firing.

B. Suitable for burning natural gas.

C. Windbox and air inlet damper as required, with electric actuator.

D. Natural gas pilot train in accordance with NFPA 85.

E. Natural gas train in accordance with NFPA 85.

F. Control or supply tubing: ASTM A213 Type 316 seamless stainless steel.

2.05 FLUE GAS RECIRCULATION (FGR) EQUIPMENT

A. FGR ducting from boiler outlet to FD fan inlet with electric or pneumatic controlled FGR damper. Provide as required to meet specified emissions limits included in Data Sheets at end of this Section.

B. Damper actuator (if electric) shall be continuous duty.

2.06 MUD DRUM HEATING COILS

A. Internal mud drum heating coils to allow for continuous warming of boiler to reduce start up time.

B. Coils and steam control valve (DCS controlled) to maintain boiler mud drum temperature without use of boiler burner system.

C. Design for operation using either of following sources of steam: 1. Campus steam distribution header: 155 psig, 410°F. 2. Operating boiler superheater outlet: 825 psig, 750°F.

D. Drum heater coils service and access clearances shall be shown on boiler general arrangement drawings.

2.07 FORCED DRAFT FAN ASSEMBLY

A. Service: Design for required excess air and for static pressure based on losses from air intake to stack outlet, including economizer, at jobsite altitude.

B. Mounted above boiler on mezzanine, forced draft fan assembly with airfoil or backwardly inclined wheel on integral steel base. Assembly complete with following components: 1. One inlet silencer to meet 85 dBA at 3' (1 m) in free-field. 2. Expansion joint at fan outlet. 3. Vibration isolators between fan base and mezzanine floor.

C. Interconnecting ductwork and supports from fan to burner windbox inlet.

D. Margin of 110% design flow rate and 121% design static pressure shall be applied to fan.

E. Design fan and motor for required VFD operation.


F. Manufacturer: Buffalo Forge, Chicago Blower Corp., Howden, or Clarage.

2.08 ECONOMIZER ASSEMBLY

A. Tube material: ASTM SA-178A.

B. Maximum fins/inch: 5.

C. Feedwater heating with flue gas exit temperature of 300 F +/- 20°F.

D. Feedwater economizer coil shall operate from 0% to 110% without steaming or flue gas from approaching acid dew point temperature. If needed, measures such as bypassing feedwater around portion of economizer heating surface may be used to prevent steaming. When bypassing is used, material and construction shall allow continuous operation in either normal or bypass mode and shall provide for automatic temperature controlled modulation between modes. Components required to accomplish bypassing shall be provided including control logic (implemented by others), temperature control valve, temperature sensor, and accessories.

E. Accessories: 1. Design of breeching from boiler outlet to economizer inlet and from economizer outlet to stack

inlet by Seller. Seller shall provide Alternate for supply of breeching. Preference to Sellers who self-perform supply of breeching.

2. Upstream and downstream expansion joints. 3. Draft control damper (if required) with electric or pneumatic actuator to accept 4-20 mA signal

from CCS and open and closed limit switches. 4. Steel economizer support structure. Economizer support structure shall be supported from

foundation at operating floor level. 5. Safety relief valve(s).

F. Design so access for tube inspection can be achieved by access doors.

G. Provide 2” (50 mm) threaded coupling at any low points in breeching and downstream of draft control damper.

H. Gas side connections on economizer: Plate flange-type with drilling for bolt holes for aligning to adjacent components.

I. Water side connections: Butt welded.

J. Economizer coil unit shall include vent and drain connections, and appropriate closures. Unit shall incorporate lifting lugs to facilitate loading and unloading.

K. Casing: Manufacturer’s standard material minimum thickness of 20-gage over all areas of economizer shell. Flash or seal openings at top of economizer at piping and flue connections to prevent leakage of water into insulation.

2.09 SUPERHEATED STEAM ADAPTABILITY

A. Provide integral superheater systems with temperature control over turndown range from 100% to 25%.

B. Construct superheaters of seamless high-temperature alloys as required by pressure or temperature conditions. Limit use of 9% chrome alloys such as P91 and T91.

C. Position superheaters inside boiler to optimize performance.

D. Type: Convective, drainable.


E. Steam temperature control and operating range shall conform to specified steam temperature.

F. Use one tube material and nominal thickness throughout each superheater section, as dictated by outlet steam conditions of section to optimize tube monitoring and repairs.

G. Superheater design shall provide supports, corrosion, and erosion protection, gastight roof seal design, and side spacing.

H. Design gastight roof seal so casing is not welded directly to pressure part tubes.

I. Provide thermocouples to measure outside tube temperatures at inlet, middle, and outlet of superheater.

2.10 SWEET WATER CONDENSER

A. Type: Shell and U-tube heat exchangers.

B. Service: Design to use feedwater from economizer outlet to condense saturated steam from boiler drum. Resulting condensate shall be used by the superheater attemperator to control superheater outlet steam temperature.

C. Tubes: 1. Materials: SA 688 TP 304N. 2. Use increased wall thickness at U-bends where necessary to maintain minimum thickness

requirements. 3. Stainless steel tubes with U-bends: Solution annealed after bending. 4. Tube joints: Weld into tube sheet and hydraulically or explosively expand after welding.

D. Shell: 1. Corrosion allowance: 1/16”. 2. Minimum wall thickness: 3/8”. 3. Designed and stamped for full vacuum in addition to positive design pressure.

E. Lifting attachments: 1. Provide attachments as necessary to permit safe handling of heater assemblies including covers. 2. Provide lugs and eyebolts for removable sections.

F. Expansion and contraction: Include provisions as necessary to permit thermal expansion and contraction of parts.

2.11 SUPERHEATER ATTEMPERATOR

A. Provide superheater attemperator located downstream of superheater steam stop valve.

B. Provide spray water control valve and flow meter that serve superheater attemperator. Refer to Sketch 8 found at end of Project Manual.

C. Suitable to control temperature at superheater attemperator outlet to 750F over the entire operating range of the boiler.

2.12 DUCTWORK AND BREECHING

A. Gastight construction.

B. Design thickness corrosion allowance 1/16” minimum.


2.13 EXPANSION JOINT

A. Corrugated metal bellows type with flow liner or fabric expansion joints with liner and insulation pillow, suitable for temperatures and expansion characteristics throughout entire operating range of unit. Expansion joints shall be Vanstone flanged for connection into ducting, if circular.

2.14 ACCESS PLATFORMS

A. Provide relief valve access platform above boiler drum. Design platform for minimum 100 psf live load or equipment maintenance loads, whichever are greater. Provide ladder from operating floor up to relief valve access platform, at each end of platform.

2.15 MOTORS

A. 1800 rpm, nominal.

B. Provide forced draft fan motor in accordance with Section 26 05 09.

C. General purpose motors rated 1/2 horsepower to 250 horsepower: 1. Type: TEFC, of sufficient size to efficiently fulfill horsepower requirements or driven load. 2. Ratings: 460-volts, 3-phase, 60 Hz, for operation at 480-volts, nominal. Rated for continuous duty

under ambient and altitude conditions specified for project. 3. Manufacturer’s: ABB, Baldor, Ideal Electric, Reliance, Siemens, TECO - Westinghouse, Toshiba,

U. S. Motors.

2.16 MEDIUM-VOLTAGE VARIABLE FREQUENCY DRIVES

A. 24-pulse, medium-voltage, air cooled, variable frequency drive (VFD) including input transformer for drive motor.

B. VFD shall be able to ride through voltage dips down to 70% of nominal, for five cycles.

C. Options: 1. Redundant fans, powered from internal 4160/480 volts transformer. 2. Modbus TCP/IP. 3. Output and input filters. 4. Proprietary Windows®-Based WiTool software. 5. Ambient temperature rating of 50⁰C. 6. VFD fans powered from internal input transformer.

D. Manufacturer: Toshiba 300MVi.

2.17 INSTRUMENTATION AND CONTROLS

A. Instrumentation for boiler will be utilized to execute fully metered, cross-limited combustion control strategy with oxygen trim. BMS/CCS hardware, control panel, and programming/configuration by others based on logic diagrams provided by boiler manufacturer.

B. Instrumentation and control valves shall be sized to operate with a minimum of 50 psig and a maximum of 120 psig supply air pressure.

C. Electric actuators shall operate at 120 volts ac.

D. Termination of field wiring (by others) to be made at field devices. No field termination panels for instrumentation are required.


E. Provide following instrumentation and devices as a minimum. Actual boiler configuration may require additional instrumentation and control devices.

F. Steam drum: 1. Three pairs of drum level taps as follows:

a. Pair 1: Guided wave radar level transmitter; column assembly for level electrodes. b. Pair 2: Guided wave radar level transmitter; bi-color backlit gage sight glass. Provide 2 bi-

color gage glasses with two valve isolation and flanges so that one can be removed and repaired while other remains in service.

c. Pair 3: Guided wave radar level transmitter. 2. Shunt button for testing low water cutoffs without tripping boiler. 3. Pressure gage with root valve and 2-valve manifold. Locate on same tap as gage pressure

transmitter; capable of being independently isolated. 4. One gage pressure transmitter with root valve and 2-valve manifold. 5. Remote level relay panel:

a. Low-low water cutoff trip relay. b. High-high water cutoff trip relay. c. Relays as required for one remote level indicator.

G. Combustion air: 1. Differential pressure transmitter with manifold and root valve for measurement of combustion air

flow. 2. Low-low flow switch. 3. Temperature assembly: element, transmitter, and thermowell. 4. Additional thermowell for performance testing. 5. Windbox pressure transmitter with manifold and root valve. 6. Pressure gauge.

H. Boiler feedwater: Level control valve.

I. Steam line: 1. Attemperator. 2. Flow element and transmitter. 3. Steam sampling nozzle with socket-welded isolation valve.

J. Furnace: 1. Triple redundant pressure transmitters with 2-valve manifolds.

K. Continuous blowdown line: 1. Conductivity probe and transmitter: By others. 2. Continuous blowdown control valve.

L. Economizer: 1. Flue side inlet and outlet pressure transmitters with 2-valve manifold and root valve. 2. Flue side inlet and outlet temperature assemblies: Element and thermowell. 3. Thermowells. 4. Feedwater outlet pressure transmitter with 2-valve manifold and root valves. 5. Feedwater outlet temperature assembly: Element thermowell by others. 6. Feedwater outlet temperature gage.

M. Provide local indicating display for transmitters.

N. Impulse tubing: Type 316 seamless stainless steel, 1/2" OD x 0.049" wall, ASTM A213.

O. Control and instrument air supply tubing: ASTM A213 Type 316 seamless stainless steel, 3/8" OD with 0.035" wall.


P. Manufacturers: 1. Pressure:

a. Gages: Ashcroft 1279 Series. b. Switches: Ashcroft Series Type 400 B-Series. c. Gage transmitters (with manifold): Rosemount Model 3051 Series, or equal. d. Differential pressure transmitters (with manifold): Rosemount Model 3051 Series, or equal.

2. Temperature: a. Gages: Ashcroft Model 50-EL-42 Series. b. Gage thermowell: Ashcroft Model 75W. c. Switches: Ashcroft Type 400, B-Series. d. Elements:

1) RTD: Rosemount Series 68 with thermowell, or equal. 2) Thermocouple: Rosemount Series 183 Type E or K with thermowell, or equal.

3. Oxygen analyzers: Rosemount 6888 series. 4. Level:

a. Gage glass and accessories: Simpliport. b. Fuel cutout: High and low water level fuel cutout with bypass switch. Bypass switch and low

water cut out (LWCO) drain test valve shall be located within view of level gage. c. Remote level components:

1) Water column: Electrolev, probes as required. 2) Relay panel: Electro eye-hye, level control unit. 3) Level indicator: Miniature bi-color.

d. Guided wave radar transmitter. e. Manufacturer: Clark-Reliance.

5. Gas train shutoff valves: Maxon. 6. Flow:

a. Natural gas: McCrometer V-Cone with Rosemount Model 3095 series multi-variable mass flow transmitter.

b. DP flowmeter: McCrometer V-Cone. 7. Pneumatic positioner: Fisher DVC6000 (provide positioner with advanced diagnostics for

interface with Owner Asset Management System (AMS). 8. Electric actuators: Beck. 9. Control valves: Fisher.

Q. Burner management system (BMS) and flame safety control system: 1. Provide sequence of operations, logic diagrams, and Input/Output listing for programming and

configuration of BMS logic required to satisfy requirements of latest edition of NFPA 85. 2. Conform to NFPA 85. Components shall be UL-listed and FM-approved. 3. Sequential interlocks and emergency shutdown. Sequential interlocks and controls in accordance

with current NFPA requirements. 4. Complete emergency shutdown of unit including interruption of fuel supply for following, but not

limited to, following trip conditions: a. Boiler steam pressure high. b. Furnace pressure high. c. Low water cutoff. d. Auxiliary low water cutoff from probe switch. e. High natural gas pressure. f. Low natural gas pressure. g. Low instrument air pressure. h. Loss of combustion air supply. i. Flame failure. j. High-high water cutoff from probe switch. k. Local emergency trip pushbutton. l. Remote emergency trip pushbutton. m. Critical input/output failure. n. Loss of combustion control system. o. Loss of control power or interlock power.


R. Combustion control system: 1. Provide sequence of operations for fully-metered, cross-limited combustion control strategy with

oxygen trim, Logic diagrams and Input/Output listing for programming and configuration of CCS logic required to satisfy requirements of latest edition of NFPA 85.

2. Conform to NFPA 85. Components shall be UL-listed and FM-approved. 3. Sequential interlocks and emergency shutdown between CCS and BMS in accordance with NFPA

requirements. 4. Control loops shall include, but not be limited to:

a. Drum level. b. Combustion air (damper control). c. FGR. d. Fuel.

S. Flame scanners: 1. Provide to prove pilot and main flame ignition for natural gas. 2. Quantity: 2 per burner, unless configuration allows pilot and main burner to be observed by a

single scanner. 3. Type: IR. 4. Manufacturer: Fireye.

2.18 PAINTING

A. Steel items shall receive following surface treatment: 1. SSPC-SP10 commercial blast to 1.5 to 2.0 mils profile depth. 2. Apply manufacturer's standard primer and finish coats to 8 mils minimum DFT on all steel items

except no paint within 3” of edges to be welded.

2.19 SOURCE QUALITY CONTROL

A. Factory cleaning, inspection, and testing: 1. Boiler drums, economizer, superheater, and interconnecting piping shall be flushed out with water

at factory in manner to remove foreign material. Thoroughly dry equipment, install desiccant in boiler drum, then seal connections following cleaning. Boiler shall be delivered to site in rust-free state.

2. Notify Owner 2 weeks prior to test and make arrangements for Owner to witness factory tests. 3. Boiler including economizer and superheater shall be individually factory hydrostatically-tested in

accordance with ASME Boiler Code. 4. Furnace casing shall be air tested to 1-1/2 times working pressure and meet boiler manufacturer’s

QA/QC requirements on allowable air leakage. 5. Major boiler modules including ductwork, expansion bellows, boiler, economizer, and superheater

shall be match-marked to ensure match-up of field connections.

B. Factory acceptance test (distributed control system): 1. Attendance of factory software demonstration test by qualified Service Engineers.

a. Anticipated attendance requirements: 2 persons including round trips for 3-day duration to DCS manufacturer’s facility.

b. Verify correctness of implementation of BMS and CCS logic.

PART 3 EXECUTION

NOT USED


DATA SHEET PACKAGED WATER TUBE BOILER

Equipment: Water Tube Boiler Tag No.: Boiler No. LATER

DESCRIPTION UNITS SPEC DATA VENDOR DATA

Boiler Manufacturer Boiler Model Number Performance

Natural Gas Supply Pressure Range (minimum/nominal/maximum)

psig 20/30/50 Rated Capacity (minimum) lb/hr 175,000 Control Range for Specified Operating Temperature % by Mfg Design Pressure psig by Mfg Design Temperature °F 760 Feedwater Normal Operating Temperature (Economizer Inlet)

°F 242

Feedwater Normal Operating Pressure (Economizer Inlet)

psig LATER

Feedwater System Design Temperature °F 300 Feedwater System Design Pressure psig 1300 Guaranteed maximum boiler load at which specified emission limits can be satisfied without flue gas recirculation (FGR) for natural gas

% by Mfg

Mud drum temperature using 155 psig, 410 F warm-up steam.

°F by Mfg

Mud drum temperature using 825 psig, 750 F warm-up steam.

°F by Mfg

Predicted Surface Temperature Front of Boiler °F by Mfg Side of Boiler °F by Mfg Rear of Boiler °F by Mfg

Boiler Load % 25% 50% 75% 100% Required Natural Gas Pressure at Train Inlet psig by Mfg Heat Input (HHV) MMBtu/hr by Mfg Net Heat Release Rate Btu/ft3-hr by Mfg Excess Air % by Mfg Combustion Air Intake Flow lb/hr by Mfg Combustion Air Intake Temperature °F 80 Flue Gas Recirculation Flow lb/hr by Mfg Percent Flue Gas Recirculation % by Mfg Flue Gas Recirculation Temperature °F by Mfg Flue Gas Flow Leaving Furnace lb/hr by Mfg Flue Gas Temperature Leaving Furnace °F by Mfg Economizer Flue Gas Inlet Flow lb/hr by Mfg Economizer Flue Gas Inlet Temperature °F by Mfg Stack Flow lb/hr by Mfg Stack Temperature °F by Mfg Stack Excess O2 % by Mfg Steam Flow at Stop Valve Outlet lb/hr by Mfg *

*Guaranteed





Steam Pressure at Stop Valve Outlet psig 825 * Steam Temperature at Superheater Attemperator Outlet

°F 750 *

Spray Water Flow at Attemperator Inlet lb/hr by Mfg Spray Water Temperature at Attemperator Inlet

°F by Mfg

Feedwater Flow Leaving Economizer lb/hr by Mfg Feedwater Temperature Leaving Economizer °F by Mfg Feedwater Flow Leaving Sweet Water Condenser

lb/hr by Mfg

Feedwater Temperature Leaving Sweet Water Condenser

°F by Mfg

Steam Drum Temperature °F by Mfg FD Fan Brake-horsepower BHP by Mfg FD Fan electric power consumption kW by Mfg Percent Blowdown % by Mfg Boiler Efficiency with Economizer (HHV) % 83 * Moisture Carryover (maximum) % 0.5% *

Emissions Limits: Boiler Load 25 50 75 100

NOx (lb/MMBtu) / (PPM) 0.037 / 30 * / * / * / * /

CO (lb/MMBtu) / (PPM) 0.036 / 50 * / * / * / * /

SOx (based on a sulfur value of 0.2 gr/100 SCF) (lb/MMBtu) 0.0006 * * * *

Particulate PM2.5 (lb/MMBtu) / (PPM) 0.004 / 10 * / * / * / * /

VOC (lb/MMBtu) 0.005 * * * * CONSTRUCTION

Boiler Type Water tube D type Dimensions (L x W x H) feet - inches by Mfg Steam Drum Diameter feet - inches by Mfg Steam Drum Length feet - inches by Mfg Steam Drum Thickness inches by Mfg Steam Drum Corrosion Allowance inches 0.125 Lower Drum Diameter feet - inches by Mfg Lower Drum Length feet - inches by Mfg Lower Drum Thickness inches by Mfg Lower Drum Corrosion Allowance inches 0.125 Furnace Section Tube Wall Thickness (minimum) inches by Mfg

Furnace Section Tube Corrosion Allowance inches by Mfg Evaporator Section Tube Wall Thickness (minimum)

inches by Mfg

Evaporator Section Water Tube Corrosion Allowance

inches by Mfg

*Guaranteed


DATA SHEETPACKAGED WATER TUBE BOILER



Tube Material by Mfg Superheater Tube Wall Thickness (minimum) inches by Mfg Superheater Tube Corrosion Allowance inches by Mfg Tube Material by Mfg Furnace Volume cubic feet by Mfg Total Heating Surface square feet by Mfg Radiant Heating Surface square feet by Mfg Convection Heating Surface square feet by Mfg Superheater Surface Area square feet by Mfg Shipping Weight lb. by Mfg Operating Weight lb. by Mfg Flooded Weight lb. by Mfg Operating Water Volume cubic feet by Mfg Flooded Water Volume cubic feet by Mfg Insulation Thickness / Type inches 2 (min.) Connection Size / Rating:

Main Steam Outlet inches/ANSI by Mfg Steam Vent inches/ANSI by Mfg Safety Relief Valves Outlet inches/ANSI by Mfg Feedwater inlet inches/ANSI by Mfg Blowdown inches/ANSI by Mfg

BOILER TRIM Safety Relief Valves Qty, Size, Type, Mfr inches by Mfg Safety Relief Valves Set Pressures psig by Mfg Continuous Blowdown Valves Qty, Sizes, Type, Mfr inches by Mfg

Bottom Blowdown Valves Qty, Sizes, Type, Mfr

inches by Mfg

Chemical Feed Valve Size, Type, Mfr inches by Mfg Vent Valve Size, Type, Mfr inches by Mfg Main Steam Stop Valve Size, Type, Mfr inches by Mfg Main Steam Nonreturn Valve Size, Type, Mfr inches by Mfg Instrument Manufacturers and Model No. N/A Provide List.

BURNER ASSEMBLY Manufacturer N/A by Mfg Model Number N/A by Mfg Number of Burners N/A by Mfg Turndown N/A 4:1 Main Gas Train Piping schedule 40 Main Gas Connection Size / Rating inches/ANSI by Mfg Main Gas Train Components N/A Provide List. Pilot Gas Train Piping schedule 80 Pilot Gas Train Components N/A Provide List. Sound Level at Max. Firing Rate (at 3 feet) dBA 85 Burner Management System Manufacturer N/A N/A N/A

*Guaranteed





Panel Rating NEMA N/A N/A Instrument Manufacturers and Model No. N/A Provide List.

FORCED DRAFT FAN Manufacturer N/A by Mfg Model Number N/A by Mfg Fan Size N/A by Mfg Test Block Air Flow lb/hr by Mfg Test Block Air Flow ACFM by Mfg Test Block Air Flow SCFM by Mfg Test Block Static Head In wg by Mfg Silencer (at 3 feet) dBA 85 Motor Manufacturer / Model N/A by Mfg Motor size horsepower by Mfg Electrical Requirement volts/phase/Hz by Mfg rpm at rated load (maximum) rpm 1800 VARIABLE FREQUENCY DRIVE Manufacturer Toshiba Model Number N/A by Mfg Nominal Operating Voltage V 4160 Insulation Levels V BIL 60,000 Ambient Temperature Range °C 50°C Input Filter Yes/No Yes Output Filter Yes/No Yes Redundant Cooling Fans (VFD powered) Yes/No Yes Optional Software configuration tool Yes/No Yes Control System Type DCS/PLC DCS Control System Interface Required Yes/No Yes

Communication Modbus TCP/IP

ECONOMIZER Dimensions (L x W x H) feet - inches by Mfg Feedwater bypass control logic, temperature control valve, and accessories included. N/A Yes/no

Design Pressure, water-side Psig by Mfg Design Pressure, gas-side In wg by Mfg

Tube Size and material inches / ASTM No. by Mfg

Tube Wall Corrosion Allowance inches by Mfg Fin number/inch; material; height 5 by Mfg Economizer Area square feet by Mfg Pressure Drop, water-side psi by Mfg Pressure Drop, gas-side In wg by Mfg Shipping Weight lb. by Mfg Operating Weight lb. by Mfg Flooded Weight lb. by Mfg

*Guaranteed





Operating Water Volume cubic feet by Mfg Flooded Water Volume cubic feet by Mfg

SWEET WATER CONDENSER

Heat Exchanger Type N/A Shell and U-tube

Dimensions (L x W x H) feet - inches by Mfg Design Pressure, shell-side Psig by Mfg Design Pressure, water-side Psig by Mfg Shell Thickness and material inches / ASTM

No. by Mfg

Shell Wall Corrosion Allowance inches by Mfg Tube Size and material inches / ASTM

No. by Mfg

Tube Wall Corrosion Allowance inches by Mfg Heating Surface Area square feet by Mfg Pressure Drop, shell-side psi by Mfg Pressure Drop, water-side psi by Mfg Shipping Weight lb. by Mfg Operating Weight lb. by Mfg Flooded Weight lb. by Mfg Operating Water Volume cubic feet by Mfg Flooded Water Volume cubic feet by Mfg STACK

Height (from base of boiler) feet 111 Diameter (inside) inches Material ASTM No. steel Insulated and lagged / thickness N/A /inches Yes/no / Weight lb. by Mfg

ECONOMIZER INLET AND OUTLET BREECHING

Designer N/A Seller Supplier, if furnished under this Contract (Preference for Sellers who self-perform)

N/A by Mfg

END OF SECTION

1) D. R. Einck, C. W. Gruetzmacher, T.J. Mergen 2) B. A. Pankow

*Guaranteed

26153.02.00 COMMON WORK RESULTS FOR ELECTRICAL PACKAGED EQUIPMENT ms1692 SECTION 26 05 00 - Page 1

PART 1 GENERAL


A. General electrical requirements for boiler equipment package and services including, but not limited to: 1. Auxiliary power. 2. Factory wiring. 3. Electrical enclosures. 4. Equipment safety grounding. 5. Low voltage fuses and fuse blocks. 6. Control relays and switches. 7. Pushbuttons. 8. Indicating lights. 9. Alarm and trip contacts. 10. Circuit breakers and disconnect switches. 11. Auxiliary power transformers. 12. Nameplates.

1.02 WORK BY OTHERS

A. Equipment foundations and supports.

B. Receiving, unloading and storing.

C. Final placement and assembly.

D. External power, control and grounding connections.

1.03 INFORMATIONAL SUBMITTALS

A. Product Data: 1. Equipment performance curves. 2. List of recommended spare parts required for equipment start-up, commissioning and operation. 3. List of special maintenance tools required for installation and operation of equipment.

1.04 ACTION SUBMITTALS

A. Shop Drawings: 1. Drawing submittal index. 2. Manufacturer’s catalog sheets marked to indicate specific type, model or catalog number of

equipment to be provided. 3. Equipment drawings showing layout of electrical components. 4. Elementary wiring diagrams and schematics for internal wiring and external connections.

Terminal points shall be clearly labeled.

1.05 CLOSEOUT SUBMITTALS

A. Operation and maintenance manuals. Provide at minimum: 1. Complete set of final drawings submitted for review and comment. 2. Product data. 3. Itemized equipment list. 4. General description and technical data. 5. Receiving, storage, installation, and testing instructions. 6. Operating and maintenance procedures. 7. Complete documentation of inspections and tests performed, including logs, curves, and

certificates. Documentation shall note any replacement of equipment or components that failed during testing.

COMMON WORK RESULTS FOR ELECTRICAL PACKAGED EQUIPMENT 26153.02.00 Page 2 - SECTION 26 05 00 ms1692

8. Lubrication recommendations. 9. Warranty information.

1.06 MAINTENANCE MATERIALS

A. Each piece of equipment shall be furnished with special tools as required for installation, maintenance, and dismantling of equipment. 1. Furnish in quantities as necessary to complete work on schedule. 2. Tools shall be new and shall become property of Owner. 3. Tools and intended use shall be identified in assembly instructions. Tools shall only be used for

their intended purpose.


A. Manufacturer of equipment specified shall be recognized in industry for normally supplying this type of equipment and shall be ISO certified.

B. Materials and equipment furnished for permanent installation shall be new, unused, and undamaged.

C. Asbestos not allowed.

D. Parts shall be manufactured to American industry standard sizes and gages to facilitate maintenance and interchangeability. Metric sized components not allowed unless specifically requested and approved.

1.08 DELIVERY, STORAGE, AND HANDLING

A. Pack, ship, handle, and store in accordance with manufacturer’s requirements.

B. Ship equipment completely factory assembled unless physical size, arrangement, configuration, or shipping and handling limitations make this impracticable.

C. Costs associated with sections, accessories, or appurtenances requiring field assembly shall be Contractor’s responsibility.

D. Separately packaged parts and accessories shall be consolidated and shipped together with equipment. Mark each container clearly to identify contents and as belonging with main equipment. 1. Provide individual weatherproof itemized packing slips attached to outside of each container for

contents included. Provide duplicate inside each container. 2. Attach master packing list, covering accessory items for equipment, to main piece of equipment. 3. Mark each container with project identification number for equipment and container number

followed by total number of containers.

E. Equipment shall be suitably protected during shipment, handling, and storage. Damage incurred during shipment shall be repaired at not cost to Owner.

F. Protect coated surfaces against impact, abrasion, and discoloration.

G. Electrical equipment and insulation systems shall be protected against ingress of moisture. Use space heaters if necessary to protect against moisture.

H. Exposed threads shall be greased and protected.

I. Pipe, tube, and conduit connections shall be closed with rough usage plugs. Seal and tape open ends of piping, tubing, and conduit.

J. Equipment openings shall have covers, and taped to seal equipment.


K. Store materials in clean, dry place. Protect from weather, dirt, water, construction debris, and physical damage in accordance with manufacture’s instructions.

PART 2 PRODUCTS

2.01 DESIGN REQUIREMENTS

A. Equipment and material furnished shall be suitable for intended service and installation location at project site. Equipment enclosures shall be NEMA 12 rated.

B. If equipment will be installed in or required for hazardous locations, equipment shall be carry appropriate UL-listing and have labeling for class, division, and group designation in accordance with NEC Article 500.

2.02 AUXILIARY POWER

A. Design auxiliary equipment for low voltage service, with electrical power designed to operate from one of nominal electrical power sources as follows and as indicated on Drawings:

Volts System Phase Frequency 13800Y/7967 Grounded Wye 3 60 4160Y/2400 Grounded Wye 3 60 480Y/277 Grounded Wye 3 60 208Y/120 Grounded Wye 3 60

B. Electrical power for ac control and instrumentation equipment: 1. Provide devices required for proper operation and protection of equipment during electrical power

supply and ambient temperature fluctuations specified. 2. Design for continuous operation at any voltage from 85% to 110% of nominal voltage. Dropout

voltage shall be 60% of nominal for relays and 75% for contactors and starters.

2.03 FACTORY WIRING

A. Select cable for electrical and environmental conditions of installation, and suitable for unusual service conditions where encountered. 1. Proper temperature application cable shall be used throughout, but shall be not less than 90ºC

rated. 2. Conductors routed over hinges shall use extra-flexible stranding. 3. Cable insulation shall be rated for maximum service voltage used, but not less than 600 volts. 4. Splices not allowed. 5. Mineral insulation (NEC Type MI), and polyvinyl chloride (PVC) insulation and jacketing (NEC

Types AWM, TA, TBS, THHN, THHW, THWN, TW, or THW) shall not be utilized.

B. Control panel cabinet and power wiring shall utilize flame retardant cross-linked polyethylene or flame retardant ethylene-propylene rubber insulation meeting requirements of UL 44 for Types SIS, and XHHW, and MTW. Power wiring shall meet or exceed requirements of UL 44 for Types MTW, SIS, and XHHW. 1. Minimum size: No. 14 AWG. 2. Conductors: Annealed bare copper Class B stranding passing IEEE 1202 and UL VW-1 flame

test. a. Single conductor cables shall have moisture resistant, flame retardant ethylene-propylene

rubber insulation with Hypalon jacket. b. Multi-conductor cables shall have moisture resistant, flame retardant cross-linked

polyethylene conductor insulation (XHHW or RHW) and an overall Hypalon jacket c. For extreme ambient conditions (in excess of 70C) use one of following:

1) NEC Type SF-2 silicone rubber insulated cable with braided glass jacket. 2) NEC Type FEP fluorinated ethylene-propylene insulated cable.


C. Instrumentation, thermocouple, and thermocouple extension wire shall use twisted shielded pairs/triads having flame retardant cross-linked polyethylene (XLPE) insulation, and fiberglass insulated jacket. 1. Minimum size: No. 16 AWG (1.0 mm2). 2. Conductor type:

a. Instrument: Annealed copper Class B stranding. b. Thermocouple: Solid alloy, ANSI MC 96.1.

3. Provide each pair/triad with shield. 4. Shielding shall consist of aluminum-polyester tape and flexible strand tin-coated No.18 AWG (0.75

mm2) copper drain wire. 5. Drain wire for each instrument cable shall be insulated with spaghetti sleeve. One end of shield

wire shall be terminated on grounded terminal. 6. Cables shall pass IEEE 1202 and ICEA 70,000 Btu/Hr vertical tray flame test, and each conductor

shall pass UL VW-1 flame test.

D. Terminations: 1. Conductor terminal connectors shall be insulated, ring tongue, compression type connectors

properly sized for conductor and terminal. a. Connectors shall be constructed of copper and shall be tin-plated. b. Interior surface of connector wire barrel shall be serrated; exterior surface of connector wire

barrel shall be furnished with crimp guides. 2. Non-insulated terminal connectors shall be used for conductors terminated on devices equipped

with individual fitted covers, such as, but not limited to, control switches and lockout relays. 3. Connections requiring disconnect plug and receptacle type devices shall be provided with factory-

terminated conductors on each plug and receptacle. a. Plugs and receptacles shall be factory wired into junction boxes containing terminal blocks for

external connections. b. Conductors on disconnect portion of plug-receptacle assemblies shall be in common jacket.

4. Prior to shipment of equipment, remove temporary wiring installed in factory for equipment testing. 5. Current transformers shall terminate on shorting type terminal blocks. Ship with shorting jumpers

installed.

E. Identification and labeling. 1. Provide conductor identification sleeve on each end of each internal conductor. Mark each sleeve

with opposite end destination identification with nonsmudging, permanent black ink. Sleeves shall be UV-resistant self-adhesive type or PVC, not less than 1/2” (13 mm) long.

2. Permanently label each terminal block, terminal, conductor, relay, breaker, fuse block, and other auxiliary devices to coincide with identification indicated on manufacturer’s drawings.

2.04 ELECTRICAL ENCLOSURES

A. Size junction boxes, pull boxes, and enclosures in accordance with requirements of NEC.

B. Junction boxes and pull boxes 4” (100 mm) trade size or smaller in any dimension shall be galvanized malleable iron, or cast ferrous metal NEMA rated for installed location. Do not use concentric knockouts.

C. Junction boxes, pull boxes, and electrical enclosures 4” (100 mm) trade size and larger in any dimension shall be as follows, unless required otherwise. 1. NEMA rating for electrical enclosures installed in nonhazardous locations:

a. Indoor: 1) Dry environmentally controlled area: NEMA 12. 2) Noncorrosive wet or hose-down area: NEMA 4. 3) Corrosive wet or hose-down area: NEMA 4X.

b. Outdoor: 1) Corrosive area: NEMA 4X. 2) Noncorrosive area hose-down or spray area: NEMA 4. 3) Noncorrosive area nonhose-down area NEMA 3R.


2. Construct noncast-metal electrical enclosures from reinforced steel plate capable of supporting devices mounted on or within enclosure without deflection. Steel plate thickness shall conform to UL requirements.

3. Enclosures shall be of adequate strength to support mounted components during shipment and installation.

4. Conduit entrances shall be field drilled. 5. Provide electrical enclosures located in outdoor, wet, or hose down areas with space heaters.

Provide space heaters completely wired within enclosure. Provide following: a. Space heater. b. Adjustable thermostat with set point temperature indicator. c. One miniature circuit breaker protective device. d. Space heaters, thermostat, and protection shall not interfere with cable into or out of

enclosure, or with maintenance or replacement of devices within enclosure. e. Use of space heaters shall not change or discolor any painted surface. f. Space heater capacity shall maintain enclosure internal temperature above dew point under

specified service conditions. g. Space heaters shall be rated for 240 volts ac minimum, and shall be sized for operation on

applied voltage of 120 volts ac.

D. Outdoor electrical enclosures with ventilating openings: 1. Louver on outdoor electrical equipment and protect in accordance with NEMA type. 2. Equip openings on outdoor electrical equipment with fine mesh filters and stainless steel bug

screens.

2.05 EQUIPMENT SAFETY GROUNDING

A. Furnish equipment that is part of integral shipping unit or assembly with bare copper ground conductor extending to central ground connection lug. Lug shall be suitable for field connection to local ground. Electrical equipment shall be considered any device that is energized.

B. Single-point ground connections required for proper operation of electronic equipment shall be insulated from equipment safety ground. Such connections shall be extended, using insulated cable, to single insolated termination point suitable for field connection to appropriate ground system.

C. Conduits that contain power circuits shall have ground conductor installed inside conduit. Ground conductor shall be bonded to equipment or tray or duct ground at both ends.

D. Provide ground bushing on each conduit containing power circuit. Connect ground bushings together inside enclosure and to enclosure ground lug or ground bus. 1. Use No. 8 AWG conductor for ground bushings trade size 1-1/2” (38 mm) and smaller. 2. Ground bushings larger than 1-1/2” (38 mm) shall be sized in accordance with requirements of

NEC, but in no case shall they be smaller than No. 8 AWG.

E. Ground conductor: Uninsulated, Class B standard, round soft drawn uncoated copper as defined in ICEA S-19-81, unless specified otherwise.

F. Hardware: Clamps, bolts, washers, nuts, and other hardware used with grounding conductor shall be copper, copper ally, high copper alloy, or silicon bronze.

2.06 FUSES AND FUSE BLOCKS

A. Modular-type, Class H screw terminal fuse blocks with Bakelite frame and reinforced retaining clips. Blocks shall be similar in construction and by same manufacturer.

B. Slow blow fuses: Bussmann Type MDL or Gould Shawmut Type GDL with ampere ratings of 1/4, 1/2, 1, or 2.

C. Fast acting fuses: Bussmann Type NON or Gould Shawmut Type OT with ampere ratings of 1, 3, 6, 10, 15, 20, or 30.


D. Extremely fast acting fuses: Bussmann Type KAB with ampere ratings of 1, 3, 6, 10, 15, 20, or 30.

2.07 CONTROL RELAYS

A. General service, industrial grade auxiliary relays rated 600-volt.

B. Contacts shall be reversible from N.O. to N.C. in field.

C. Timing relays for critical service: Agastat solid-state DSC Series digital timers.

2.08 CONTROL SWITCHES

A. Multistage, rotary-type rated 120 volts ac or 125 volts dc, 3 amperes, as required.

B. Handles shall be black, fixed, modern, pistol grip type. Provide engraved black plastic escutcheon plates with targets.

C. Provide with colored LED lamps and nameplates as required.

2.09 PUSHBUTTONS

A. Standard pushbuttons: Heavy-duty, industrial-type rated 120 volts ac or 125 volts dc, 3 amperes, as required.

B. Provide with colored LED lamps and nameplates as required.

2.10 INDICATING LIGHTS

A. Status indicating lights shall be high-intensity, cluster, LED-type for panel mounting.

B. Coordinate indicating light colors with indicated conditions as follows. Indicating lights shall be energized when condition exists and shall be de-energized when condition does not exist: 1. Red: Equipment energized: such as motor running, valve open, or breaker closed. 2. Green: Equipment de-energized: such as motor stopped, valve closed, or breaker open. 3. Amber: Equipment abnormality: such as motor trip, breaker trip, or relay trip. 4. White: Monitoring of control power or trip coil: such as lockout relay trip coil monitor or breaker

trip coil monitor. Light is on during normal circuit operation and off during loss of power or loss of coil.

5. Blue: Loss of control power.

2.11 ALARM AND TRIP CONTACTS

A. Alarm contacts for remote annunciation shall be suitable for operation at 120 volts ac and 125 volts dc. Contacts shall be rated at least 0.5-ampere make and break, minimum.

B. Alarm contacts shall be normally closed contacts that open to alarm condition.

C. Trip contacts for remote trip shall be suitable for operation at 125 volts dc and shall be rated 5 amperes make or break, minimum.

D. Alarm and Trip contacts shall be protected from installation location site conditions by providing enclosure.

2.12 CIRCUIT BREAKERS

A. Provide 3-pole, molded-case, separately enclosed circuit breakers of not less than 25 kA interrupting rating at rated voltage. 1. Provide with thermal and instantaneous trip elements.


2. Breakers shall use high-conductivity copper for current carrying parts. Breaker enclosures shall have NEMA type enclosure as specified.

B. Each breaker shall be manually operated with quick-make, quick-break, and trip-free toggle mechanism. Thermal elements shall withstand sustained overloads and short-circuit currents without injury and without affecting calibration.

C. Circuit breakers shall have "On," "Off," and "Tripped" indication and shall be pad-lockable with 3 padlocks in “On” and “Off” position. 1. Breakers rated over 70 amperes shall be rated 100% and have adjustable electronic trip units. 2. Breakers shall be capable of adding alarm, lockout, shunt trip, and under-voltage as options.

2.13 DISCONNECT SWITCHES

A. Three-pole, nonfusible, heavy-duty, rated 600-volt with continuous current rating as shown on Drawings and as required by load. 1. Type: Either molded-case or blade. 2. Switches shall use high-conductivity copper for current carrying parts.

B. Switches shall be positive, quick-make, and quick-break mechanisms. 1. Switch assembly plus operating handle shall be integral part of enclosure base. 2. Each switch shall have handle whose position is easily recognizable and which can be locked in

“On” and "Off" position with 3 padlocks. "On" and "Off" positions shall be clearly marked.

C. Switches shall be UL-listed and horsepower rated. Where applicable, switches shall have defeatable door interlocks that prevent door from being opened while operating handle is in "On" position.

2.14 AUXILIARY POWER TRANSFORMERS

A. Windings: Copper.

B. Transformers shall be self-air-cooled, dry-type, and enclosed for wiring connection by conduit.

C. NEMA enclosure type protection shall be as specified herein.

D. Transformer shall be capable of at least 150ºC rise above rated site maximum ambient without degrading transformer life.

E. Transformers shall be capable of continuous operation at rated kVA with normal life expectancy as defined in ANSI C57.

F. Sound level shall not exceed NEMA maximum average sound level.

2.15 WIRING DEVICES

A. Standard convenience outlets: Premium, heavy-duty, specification-grade, duplex, 3-wire, grounding, 20-ampere, 125-volt for 120-volt circuits, and rated 250-volts for 240 or 208-volt circuits.

B. Ground fault circuit interrupter (GFI) receptacles: Duplex, 20-ampere, and 125 volts, feed-through type.

2.16 INSTRUMENT IDENTIFICATION

A. Provide stainless steel identification tag on instruments, gages, valves and temperature wells shown on instrument index. Instrument number per Owner-supplied instrument numbering system.


B. Rack-mounted instrumentation shall have tag screwed above or below device with stainless steel hardware. Other instrumentation, control valves, valve actuators, gages and temperature wells shall have tags wired on using stainless steel wire.

C. Following information shall be stamped into each identification tag. Numbers/letters shall be minimum of 3/16” (5mm) high. 1. Purchase order number. 2. Instrument span or range. 3. Instrument identification number (as indicated on Drawings or instrument index).

D. Manufacturer: Panduit MDP series, or equal.

2.17 NAMEPLATES

A. Laminated white-over-black plastic such that face is white with black letters, with 1/8” (3 mm) engraved letters securely fastened with minimum of 2 self-tapping, stainless steel screws.

B. Nameplates for hazardous conditions shall be red plastic laminate engraving stock with white core.

PART 3 EXECUTION

NOT USED

END OF SECTION 1) A. D. Temple 2) L. E. Ingram

26153.02.00 LARGE MOTORS ms1692 SECTION 26 05 09 - Page 1

PART 1 GENERAL


A. Medium-voltage, 3-phase, induction, squirrel cage electric motors rated 250 hp and larger.

B. Soleplates, motor anchor bolts, and leveling screws.

1.02 WORK BY OTHERS

A. Motor foundations and foundation anchor bolts.

B. Receiving, unloading, and storage of motors.

C. Final placement and assembly.

D. Power, control, and grounding connections.

E. Commissioning.


A. Submit with Proposal: 1. Completed Data Sheets. 2. Contractor shall indicate if forced-feed lubrication or water cooling of bearings is required.

B. Quality assurance data: Certified shop test reports.


A. Shop Drawings: 1. Complete and updated Data Sheets. 2. Certified detailed drawings showing dimensions, anchor locations, weight, lifting points, center of

gravity, enclosure construction, and layout of accessories. 3. Interconnection wiring drawings with terminal points clearly labeled. 4. Interface coordination details. 5. Lube oil piping flow diagram as applicable to specific application. 6. Complete dimensional drawings for sliding bases as applicable to specific application.

B. Product Data: 1. List of instruments and accessories, model number, and operating ranges. 2. Motor curves showing starting current and power factor at 80%, 90%, and 100% terminal voltage. 3. Motor torque versus speed curves at 80%, 90%, and 100% voltage. 4. Motor load versus efficiency curves. 5. Motors for use with VFD shall be inverter duty motors. 6. Torque versus speed curve for driven equipment. 7. Motor hot and cold thermal damage curves with motor starting curves, including driven equipment

inertia, based on system characteristics defined in motor data sheets. 8. Bearing and stator temperature alarm and trip limits. 9. Current transformer excitation and ratio correction factor curves for each motor supplied. 10. List of recommended start-up parts, spare parts, and maintenance tools for each type of motor. 11. Recommended long term and short term storage requirements and procedures.


A. Operation and maintenance manuals. Provide at a minimum: 1. General description and technical data.

LARGE MOTORS 26153.02.00 Page 2 - SECTION 26 05 09 ms1692

2. List of instruments and accessories supplied, listing manufacturer, model number, operating ranges, and equipment tag numbers.

3. Receiving, storage, installation, and testing instructions. 4. Operating and maintenance procedures. 5. Complete set of reviewed drawings that require no further action. 6. Completed Data Sheets modified to include field installation conditions. 7. Complete documentation of inspections and tests performed, including logs, curves, and

certificates. Documentation shall note any replacement of equipment or components that failed during testing.

8. Recommended spare parts list that includes bearings. 9. Lubrication recommendations. Provide Mobil lubricant number for lubricants. 10. Bearing temperature limits. 11. Winding temperature limits. 12. Current transformer excitation and ratio correction factor curves as applicable to specific

application.


A. Manufacturer’s qualifications: 1. Manufacturer shall manufacture motor and major motor components and shall be ISO certified. 2. Manufacturer shall have produced similar equipment for minimum period of 5 years. 3. When requested by Design Professional, provide acceptable list of similar equipment installations

complying with requirements of this Section.

B. Regulatory requirements: 1. Motors shall be in accordance with applicable requirements of ANSI C50.41, NEMA MG-1, IEEE

85, NFPA 70, and UL 1004. 2. Standards of foreign organizations shall not be used without written approval from Design

Professional. 3. Testing shall be performed in accordance with IEEE 112.

1.07 DELIVERY AND HANDLING

A. Coordinate transportation with requirements of pertinent authorities.

B. Ship equipment to job Site for installation.

C. Ship, and handle motors carefully to prevent damage, denting, or scoring.

1.08 MAINTENANCE MATERIALS

A. Provide complete set of special tools as necessary for installation and maintenance for each piece of equipment supplied.

B. Tools and intended use shall be identified in assembly instructions.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. ABB.

B. Baldor.

C. Ideal Electric.

D. Reliance Electric.

E. Siemens.


F. TECO-Westinghouse.

G. Toshiba.

H. U. S. Motors.

2.02 SYSTEM DESCRIPTION

A. Furnish motors either separately or as integral part of mechanical system. Motor horsepower and torque characteristics shall be coordinated with driven piece of equipment by manufacturer.

B. Motor rated power shall exceed driven equipment maximum load by 15% unless otherwise agreed by Owner. Service factor shall not be considered in this calculation.

2.03 ENCLOSURE

A. Provide weather enclosure and cooling class type as specified on Data Sheet.

B. Furnish motors with lifting eyes so lifting slings do not become entangled in any apparatus mounted on motor.

C. Materials potentially exposed to process fluids or corrosive atmospheres shall be Type 316L stainless steel or other corrosion-resistant material specifically selected for expected environment.

D. Do not use copper or copper alloy for air coolers.

E. Bolts and nuts exposed to environment shall be galvanized carbon steel.

2.04 VOLTAGE AND FREQUENCY

A. Design motors for use on power system with fixed frequency or operated on variable frequency drives as defined on motor data sheet.

B. Design motors for full-voltage, across-the-line starting unless specified otherwise.

C. Motor locked rotor current shall be limited to 650% when started full voltage.

D. If indicated, motors shall be braced for full-voltage bus transfer from one source of power to another. Bus transfer time may take as long as 6 cycles as defined by ANSI C50.41, Section 14.3.

2.05 CHARACTERISTICS

A. Motors rated up to 500 hp and less than 5000 volts shall meet or exceed NEMA Premium efficiency levels.

B. Ratings shall include allowance for altitude and maximum temperatures as required by site conditions.

2.06 MOTOR FRAME

A. Motor frames shall be fabricated of heavy-duty cast steel or plate steel weldments. Provide access covers for inspection of windings without removal of bearings or removal of motor base from foundation.

B. Locate air inlet points above centerline of horizontal motors.

C. Machine sealing parts in high-accuracy to minimize breathing.


D. Equip air intakes with reusable stainless filters. Filters shall be surface mounted over openings and capable of replacement with machine in operation.

E. Provide differential pressure switches on each set of filters if required on Data Sheet. Switches shall be Ashcroft, or equal.

F. If specified for hazardous areas, motors shall be enclosed and UL-listed for class, division, and group designation in accordance with NEC Article 500.

G. Motor frame, end brackets, fan covers, drip shields, and bearing housing shall be corrosion-resistant, with motor supporting feet case as integral part of frame.

H. Provide motors with stainless steel drains and plugs. Locate drain holes at low point of motor in mounted position.

I. Drill and tap two 3/8” (10 mm), 16-pitch bolt holes in a NEMA two-hole configuration for use as ground connections. 1. Horizontal frames: Right rear motor foot and left front motor foot as viewed from drive end. 2. Vertical frames: Junction box side and opposite of junction box side.

J. Motor base shall be heavy steel construction provided with 4 vertical leveling screws to facilitate field alignment of motors and driven load.

K. Provide motor sole plates and motor anchor bolts which attach motor frame and sole plates.

2.07 STATOR ASSEMBLY

A. Windings shall be form wound copper.

B. Insulation: Vacuum pressure impregnation (VPI). Windings shall undergo minimum of 2 VPI and bake cycles.

C. Resistance temperature detectors (RTD) shall be 3-wire, platinum, rated 100 ohms at 0°C. 1. Provide 2 per phase in stator windings. 2. RTD leads: Insulated, stranded, copper wire extended and terminated on terminal blocks in

separate instrumentation junction box.

D. Differential protection if required on Data Sheet: 1. Both stator-phase and neutral winding leads shall be brought out to main terminal box. 2. Each set of neutral and line leads shall be run through one core-balance current transformer. 3. Rigidly mount current transformers within motor terminal housing. 4. Wire 6 current transformer leads to control terminal box, terminate on General Electric BE-27, or

equal, shorting type terminal blocks. Provide jumpers between Current Transformer X2 terminals and ground.

E. Motor stator slot wedges shall be nonmagnetic type.

2.08 ROTOR AND SHAFT ASSEMBLIES

A. Machine motor shaft from corrosion-resistant forged steel or cold-rolled steel bar stock; capable of transmitting torque produced by motor. Aluminum rotors are not acceptable.

B. Rotor bars and end rings shall be of copper or copper alloy. Rotor bars shall be brazed to end rings.

C. Rotor: Epoxy-coated.

D. Motor rotating components: Dynamically balanced (at rated speed) after mounting on shaft.


E. Dynamically balance motors by one of following means: 1. Drilling out parent metal in such a manner that structural strength of rotor is not weakened. 2. Use of balance washers securely pinned in place. 3. Chiseling, sawing, or use of solder or similar deposit materials to achieve balance not acceptable.

F. Rotor assembly removal: 1. Horizontal motors: Removable through either bell end of motor without requiring removal of stator

assembly. 2. Vertical motors: Removable from top of motor without requiring removal of motor.

2.09 BEARINGS

A. Horizontal machines: 1. Design bearings so as not to be damaged by axial rotor movement during motor startup or

shutdown. 2. Construct and provide bearing and bearing housing with slingers and seals to prevent dirt or

moisture from entering motor. Provide interior bearing caps to prevent lubricant from entering motor.

3. Bearing supports: Integral to case as part of motor end bell. Rabbet end bell to stator assembly to ensure proper bearing alignment and air gap spacing.

4. Single shaft extension motors: Insulated non-drive end bearing and ground drive end shaft with shaft brushes.

5. Double shaft extension motors: Insulate non-drive end bearing and drive end shall be grounded by use of shaft grounding brushes.

B. Vertical machines: 1. Design spherical roller thrust bearings to carry 200% of maximum thrust, up and down, which

pump may develop during starting or stopping or while operating at any capacity on rated performance curve.

2. Equip with spark-resistant, non-reversing ratchets, and bolted couplings. 3. Provide water cooling of thrust bearing to maintain bearing temperature below 50C when operated

with driven equipment. 4. Provide Kingsbury-style tilt pad thrust bearing when specified on Data Sheet. 5. Extend guide bearing grease zerk outside of motor and pump base. 6. Provide electrically insulated thrust bearing.

C. All machines: 1. Anti-friction type bearings: Grease-lubricated; minimum rated life L10 with a median life no less

than 50% of L10 life, as defined by AFBMA. Reliability of each bearing shall be greater than 90%. 2. Provide bearings sized to carry imposed loads with minimum design safety factor of 2.0. Provide

bearings and housings that can be removed for examination or replacement without removing rotating element.

3. Bearings shall be vacuum-degassed steel, motor quality. 4. Equip each bearing with three wire platinum RTDs rated 100 ohms at 0°C in quantities specified.

Evenly space multiple RTDs around bearing. Wire and terminate RTD leads on terminal blocks in a common externally mounted instrument junction box.

5. Each bearing shall be tapped for 2 vibration probes mounted in an X-Y configuration, 90º apart for measuring radial vibration. Factory wire probes to instrumentation junction box.

6. Shaft grounding brushes provided shall be 2” (50 mm) wide braided, silver-coated, copper shaft grounding brush with copper grounding conductor routed from brush to motor grounding pad.

7. Sleeve bearing manufacturer: Renk, Kingsbury, or equal.

2.10 LUBRICATION SYSTEM

A. Bearing housing shall have extra large oil reservoirs to serve as settling chambers.

B. Fit each sleeve bearing housing with constant-level, sight-feed oiler marked with proper oil level. Oiler shall be located at extent of motor frame, supported, and piped to bearing housing.


C. Oil system shall have sufficient surge capacity to absorb, without overflowing, oil returned from bearings when motor is stopped.

D. Fit bearing housings with fill and drain openings, slingers, equalizers, vents, and other devices to prevent loss of lubricant.

E. Inlet lines shall be not less than 1/2” (13 mm) diameter.

F. Lubricant for motors requiring forced-feed lubrication shall be supplied from same system as driven equipment. Provide permanent identification plate with lubrication type on equipment.

G. Provide motors with forced lube oil supplied from driven equipment system with oil rings for startup and emergency operation and with dial thermometers to indicate oil temperature.

H. Provide motor with forced lubrication as required by site ambient conditions. Lube oil system shall heat and cool oil to maintain temperature within machine bearing limits.

I. Lube oil tank and piping, if supplied, shall be welded stainless steel construction.

J. Provide system for anti-friction bearings with readily accessible grease inlet and outlet plugs in bearing housings to enable regreasing while motor is in service.

2.11 MOTOR FANS

A. Equip totally enclosed fan cooled motors with externally mounted, nonsparking fan and fan housing. Key fan to motor shaft.

B. Equip weather protected I, II, and open drip proof motors with internal shaft mounted fan.

C. Fan material: Bronze alloy, fiberglass or some other nonsparking material. Aluminum, bronze, copper, or copper alloy not acceptable.

2.12 SPACE HEATERS

A. Mount low surface-temperature space heaters on inside of motor frame.

B. When operating at 110% of rated voltage and ambient temperature, sheath temperature shall not exceed 200°C.

C. Space heaters shall be rated and designed to operate at voltages as specified on Data Sheets.

D. Space heaters shall automatically maintain temperature inside motor at 5°C above dew point.

E. Route space heater power leads to dedicated control terminal box near main terminal box.

2.13 MOTOR TERMINAL BOXES

A. Equip each motor with corrosion-resistant terminal boxes. 1. Provide main terminal box for motor power lead terminations, house surge arrestors and

capacitors as required. 2. Provide separate control terminal box for termination of space heaters leads, current transformer

terminations, filter differential pressure switch etc. 3. Provide separate low-voltage instrument terminal box from main and control boxes. Instrument

terminal box shall house terminations for RTDs, thermocouples, vibration probes, etc. Mount instrument terminal box near control terminal box.


B. Size motor main terminal box to allow for bending radius and stiffness of motor supply cables, and for terminating grounding conductor. At a minimum, size main terminal box at least one size larger than listed in NEMA MG-1.

C. Motor leads shall have brass or stainless steel ferrules embossed with appropriate lead number, or leads imprinted with lead number.

D. Motor lead connections shall be tinned.

E. Main terminal boxes shall have required bushings, standoff insulators, insulation barriers, and hardware for completing line connections.

F. Terminal boxes shall be weatherproof and dusttight, and fitted with neoprene gaskets.

G. Provide motor lead seal and separator gasket between motor frame and terminal box.

H. Provide terminal boxes with removable and gasketed bottom plate for field drilling. Knockouts not acceptable.

I. Motor lead insulation shall be oil-resistant.

J. If specified on Data Sheet, current transformers, surge arrestors, and surge capacitors shall be provided and mounted in main terminal box. Main terminal box shall be increased in size accordingly.

K. Provide NEMA MG-1 Type II motor terminal housing for motors provided with current transformers, surge arrestors, capacitors, and for any machine larger than 1,000 hp.

L. Motor leads: 1. Extra flexible. 2. Rated 125% of motor FLA.

2.14 NOISE AND VIBRATION

A. Equipment shall not exceed sound pressure levels of 85dBA at 3’ (1 m) from equipment surface in accordance with NEMA MG-1.

B. Magnitude of vibration values for running speed and 120 Hz vibrations shall not exceed NEMA-MG1 requirements.

C. Provide vibration monitoring if indicated on Data Sheets. Motors not specified with vibration monitoring, shall be furnished with drilled and tapped bearings and capability to add a vibration monitoring system at later date.

D. Design to keep torsional, rotational, and reed natural frequencies of vibration at least 25% above or below motor rated speed ranges to avoid resonant vibration over operating speed range of motor and driven equipment.

E. When vibration monitoring is required, provide following equipment for each motor: 1. X and Y probes, installed: 2 per bearing. 2. Manufacturer: Bently-Nevada.

2.15 SURGE ARRESTERS AND PROTECTIVE CAPACITORS

A. When specified, provide protective capacitors and MOV-type arresters in motor terminal box. Bus arresters and capacitors to motor terminals.

B. Surge capacitors shall be sealed, nonflammable, and shall not contain polychlorinated biphenyl (PCB) dielectric.


C. Ratings shall correspond to system grounding type as described on Data Sheet.

2.16 IDENTIFICATION AND TAGGING

A. Provide motor with stainless steel nameplates attached with stainless steel screws or pins in locations clearly visible and readable without requiring unsafe condition.

B. Nameplate shall contain standard information in accordance with NEMA MG-1 and following additional information: 1. Serial number and year of manufacture. 2. Type of bearing lubricant and specification number. 3. Arrow indicating direction of rotation for main lead connections. 4. Bearing type and manufacturer’s part number. 5. Current transformer ratings and polarity, if applicable. 6. Use Owner’s equipment tag identification number.

C. Motor power and space heater circuits may be derived from different sources. Covers of motor terminal boxes containing space heater leads shall be provided with nameplate reading: “DEENERGIZE AND ISOLATE MOTOR AND HEATER CIRCUITS BEFORE REMOVING COVER.”

2.17 VARIABLE SPEED MACHINES

A. Motors defined on Data Sheet for variable speed application shall be inverter duty rated and operated over speed range defined.

B. Provide motors with external cooling fans to force cool machine if operational speed range defined on Data Sheet reduces integral fan performance below required levels to maintain maximum temperature rise.

C. Provide 2” (50 mm) wide braided, silver coated, copper shaft grounding brush with copper grounding conductor routed from brush to motor grounding pad.

D. Electrically insulate both drive end and nondrive end bearings.


A. Perform following routine and typical tests complying with NEMA MG-1 and tests specified in Data Sheets: 1. Full load current, locked rotor current, and power measurements. 2. Vibration test in accordance with NEMA MG 1. 3. Locked-rotor current measurement. 4. Power factor at full load, 3/4 load, 1/2 load, and under locked rotor conditions. 5. Percent slip at rated load. 6. Vibration measurements. 7. Machine noise level test in accordance with IEEE 85. 8. Breakdown torque calculation, and pullout and starting torque measurements. 9. Efficiency and power factor measurements for 1/2, 3/4, and full-rated loads in accordance with

IEEE 112, Test Method B. 10. Current balance measurement.

B. In event that motor fails tests, additional tests will be witnessed at discretion of Owner at no additional cost to Owner.

C. Test results shall be tabulated, submitted, and accepted by Design Professional prior to shipment.

D. Defects and defective equipment revealed or noted during testing will be corrected prior to shipment.

E. Motor test failures shall be reported to Design Professional immediately. Motors shall not be repaired without written consent of repair method by Design Professional or Owner. Equipment damaged


during testing shall be considered permanently damaged and shall be replaced at suppliers cost with new, not remanufactured or restored, equipment.

PART 3 EXECUTION

NOT USED


DATA SHEETS LARGE MOTOR

Equipment Name: Boiler #1 FD Fan

Tag No.: FD-1 Rev. DESCRIPTION UNITS SPEC DATA VENDOR DATA

Motor Manufacturer - By Manufacturer Motor Catalog No. - By Manufacturer Location of manufacturer - By Manufacturer INSTALLATION Location Indoor/Outdoor Indoor Maximum Ambient Temperature ºC 50 Minimum Ambient Temperature ºC 10 Site Altitude ft 741 Unusual Service Conditions INSULATION Minimum Insulation Class (B, F, or H ) - F Maximum Temperature Rise of Insulation Class (B, F, or H)

- B

SYSTEM REQUIREMENTS System Voltage V 4160 Operating Frequency (50 or 60) Hz 60 System Available Short Circuit kA 60

System grounding method Solid /

Impedance / Ungrounded

Solid

Nameplate Voltage V 4000 Motor Starting Method - VFD Full Inverter Duty Rated Y/N Y Motor Braced for Bus Transfer Y/N N ELECTRICAL DATA Service Factor - 1.15 No. of Speeds 1,2,Variable Variable Speed Range 0-100% 0-100% rpm at Rated Load rpm 1800, nominal No. of Windings 1,2 MECHANICAL FEATURES Protective Enclosure IP Code (NEMA MG-1 Part 5) IP IP 44/54 (TEFC) Method of Cooling IC Code (NEMA MG-1 Part 6) IC IC 411 Maximum Motor Terminal Connection Size kcmil LATER NEMA Frame Designation - By Manufacturer Inertia constant of motor. WR^2 lb-ft^2 By Manufacturer Inertia constant of driven equipment and couplings.

WR^2 lb-ft^2 By Manufacturer

Rated Shaft Output Hp By Manufacturer Driven Load (maximum) Hp By Manufacturer Sound Level at Full Load (3’ distance) dBA 85 max. Bearing Type: - By Manufacturer Drive End By Manufacturer Non-Drive End - By Manufacturer Lube Oil System Y/N By Manufacturer


DATA SHEETS LARGE MOTOR

Equipment Name: Boiler #1 FD Fan

Tag No.: FD-1 Rev. DESCRIPTION UNITS SPEC DATA VENDOR DATA

Motor Space Heater: Rated Voltage V 240 Operating Voltage V 120 Wattage W By Manufacturer Weight Lb By Manufacturer RTDs Bearing: RTD Type - 100 ohm Platinum Number of Sensors Qty 1 for each bearing Maximum Temperature To Trip °C By Manufacturer Stator: RTD Type - 100 ohm Platinum Number of Sensors Qty 2 per phase Maximum Temperature To Trip ºC By Manufacturer ACCESSORIES Differential Pressure Switches on Air Filters Y/N N Surge Capacitor: Y/N N Capacitor Voltage Rating kV N Capacitor Rating per pole F N Surge Arrester: Y/N Y Surge Arrester Voltage Class kV By Manufacturer Surge Arrester MCOV kV By Manufacturer Vibration Monitoring System Y/N N Vibration Probes Y/N Y Differential Protection: Y/N N Number Per Phase Qty N/A CT Ratio A/A N/A Accuracy Class N/A SPECIAL REQUIREMENTS

END OF SECTION 1) G. G. Gardner 2) L. E. Ingram



LEFT BLANK

26153.02.00 GENERAL DUTY PROCESS VALVES AND ACCESSORIES ms1692 SECTION 40 05 23 - Page 1

PART 1 GENERAL


A. Valves as shown in Valve Schedule included herein.

B. Valves: 1. Vent and drain valves for equipment furnished under this Contract. 2. Piping high point vents and low point drains. 3. Connections to metering instruments and controls including pressure gages, transmitters,

controllers, traps, and appurtenances required for proper functioning of instruments and controls. 4. Temporary valves and accessories required for placing equipment into initial service. 5. Valves inherent to operation or protection of equipment furnished under this Contract.

C. Accessories.


A. Shop Drawings: 1. Certified drawings for each valve. As a minimum, Drawings shall contain:

a. Valve tag numbers. Using Owner’s valve tagging nomenclature. b. Materials of construction. c. Valve end-to-end and envelope dimensions with operators. d. Valve weight including operator if applicable. e. Weld end preparation details. f. Operator information. g. Special features such as vacuum service, locking device, limit switches, etc. h. Design conditions.

2. Wiring diagrams for field installation of components. 3. Valve list for all valves provided by contract. Valve tagging scheme will be provided by Owner.


A. Operation and maintenance data. Refer to Section 01 78 23.


A. Valves shall be of same manufacturer for each class of piping and insofar as practicable for entire Project.

B. Design and construct ferrous valves in accordance with ASME B16.10 and ASME B16.34.

C. Valves located in boiler code piping shall be constructed in accordance with ASME Boiler and Pressure Vessel Code.

D. Valves shall be stamped with 100ºF (38°C) rating that meets or exceeds specified hydrostatic shell and closure test pressures.


A. Preparation for shipment: 1. Protect internal parts against rust and corrosion. 2. Protect threads, flange faces, grooves, and weld ends. 3. Set angle, gate, and globe valves closed to prevent rattling. 4. Set ball and plug valves open to minimize exposure of functional surfaces. 5. Block check valves in either closed or open position.

GENERAL DUTY PROCESS VALVES AND ACCESSORIES 26153.02.00 Page 2, SECTION 40 05 23 ms1692

B. Storage precautions: 1. Maintain valve end protection. 2. Store valves indoors and maintain at higher than ambient dew-point temperature. 3. Use sling to handle large valves; rig sling to avoid damage to exposed parts. Do not use

handwheels or stems as lifting or rigging points.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Provide specified manufacturer when indicated in Valve Schedule.

2.02 DESIGN CRITERIA

A. Valve Schedule contains listing of manual, motor-operated, solenoid-operated, and air-operated on/off valves.

B. Verify that valves meet or exceed design pressure and design temperature or respective piping system.

C. Provide high-point vent valves and low-point drain valves. 1. Gas service: 1” (25 mm) or line size, whichever is less, ball valves unless noted otherwise. 2. Steam service: 1” (25 mm) or line size, whichever is less, ball valves unless noted otherwise. 3. Liquid service: 1” (25 mm) or line size, whichever is less, ball valves unless noted otherwise. 4. Vents and drains on ASME Class 600 and higher piping systems shall be provided with two

isolation valves.

D. Valve body materials shall be equivalent to piping material, unless noted otherwise.

Piping Material Valve Body Material Carbon steel ASTM A105, ASTM A216 Grade WCB or ASTM A216 Grade WCC 1-1/4 chromium-molybdenum ASTM A182 Grade F11 or ASTM A217 Grade WC6 2-1/4 chromium-molybdenum ASTM A182 Grade F22 or ASTM A217 Grade WC9 Stainless steel Type 304 or 304L ASTM A182 Grade F304 or F304L or ASTM A351 Grade CF3 or Grade CF8 Stainless steel Type 316 or 316L ASTM A182 Grade F316 or F316L Grade CF3M or Grade CF8M Copper ASTM B88 Type K Bronze ASTM B584-C84400, or equivalent Ductile iron ASTM A126 B cast iron, ASTM A395 or ASTM A536 ductile iron

E. Valve end preparations: 1. Butt weld ends:

a. Nominal pipe wall thickness 0.375” (10 mm) and less: ASME B16.25, Figure 2, Detail (a). b. Nominal pipe wall thickness greater than 0.375” (10 mm): ASME B16.25, Figure 5 or 6.

2. Socket weld ends: ASME B16.11. 3. Threaded joints: ASME B16.3 or ASME B16.11 as applicable. 4. Flanged ends: ASME B16.1, ASME B16.5, ASME B16.47 or AWWA C207, as applicable.

F. Valve ends: In accordance with Data Sheets unless noted otherwise.

G. Valves shall be suitable for operator mounting (handwheel, bevel gear, motor operator, air actuator) with valve in any position without external support.

H. Gate valves installed with stem horizontal shall follow manufacturer’s requirements.

I. Check valves shall be suitable for operation in horizontal and vertical flow up piping arrangements.

J. For gage cocks, use ball valves if practicable.

K. For plug valves, use ball valves if practicable. Verify compliance with local codes.

26153.02.00 GENERAL DUTY PROCESS VALVES AND ACCESSORIES ms1692 SECTION 40 05 23 - Page 3 2.03 STOP CHECK VALVES

A. Manufacturer: Edwards Flite-Flow with equalizing valve.

2.04 PLUG VALVES

A. Service: Natural gas.

B. Type: Lubricated plug, wrench-operated.

C. Size and connection: 1/2" (15 mm) through 3" (80 mm) threaded.

D. Body and plug: ASTM A126 Grade B, semisteel.

E. Supply each valve with wrench operator with set screw.

F. Baseplate springs: Stainless steel.

G. Lubricant: Suitable for natural gas service up to 250°F (121°C).

H. Working pressure: 200 psig (1380 kPa).

I. Manufacturer: Nordstrom Model 114.

2.05 SOLENOID VALVES

A. Type: 2-way.

B. Enclosure: NEMA 4X.

C. Coils: Class H high-temperature construction. Suitable for continuous duty.

D. Electrical power: 120-volt grounded, single-phase, 60 Hz, ac.

E. Manufacturer: Automatic Switch Company (ASCO), MAC Valves.

2.06 VALVE IDENTIFICATION

A. Valve shall be given unique tag numbers. Coordinate valve numbering system with Design Professional.

B. Provide valves with unique tag number as follows: To be provided after award of Contract.

C. Each valve shall have stamped stainless steel tag bearing valve tag number securely fastened to valve with 20-gage (0.9 mm) stainless steel wire.

D. When multiple, identical small-bore valves (less than 2-1/2” [64 mm]) are shipped in bulk, tags may be field installed. Other tags shall be factory installed.

2.07 ACCESSORIES

A. Hand wheels and levers: 1. Provide unless noted otherwise. Levers shall be multi-position with positive locking device. 2. Valves installed in areas inaccessible to platforms shall be provided with shaft extenders with u-

joints, or motor operators, chain operators only allowed by exception and approval of Owner. Provide remote operators for manual valves with hand wheel operators in horizontal plane located more than 6’-6” (2 m) above floor, unless noted otherwise. Provide sufficient chain to bring operation down to 6’-6” (2 m) above floor.


3. Hand wheels shall not exceed 24” (600 mm) diameter unless noted otherwise.

B. Gear operators: 1. Gates, globes, plug, and angle valves: Provide bevel gear manual operators on following valves.

Valve Pressure Class Valve Size

150 8” (200 mm) and larger 300 6” (150 mm) and larger 600 4” (100 mm) and larger 900 4” (65 mm) and larger 1500 3” (80 mm) and larger 2500 and above 2 1/2" (65 mm) and larger

2. Quarter turn valves: Worm gear or screw operator on valve sizes 6” (150 mm) and larger. 3. Maximum operator rim pull force required to stroke valve against maximum differential pressure:

75 lb (34 kg). 4. Impact handwheels may be used. Notify Design Professional prior to use. 5. Design valve operators to withstand hydrostatic test without damage.

C. Pneumatic actuators: 1. When fail position is shown on Drawings, provide spring return actuator. Spring shall fully open or

close valve, as applicable, upon loss of air pressure. 2. Operators shall produce required stem forces with 60 psig (415 kPa g) air pressure. 3. Maximum air pressure: 150 psig (1035 kPa g). 4. Equip actuator with combination filter regulator with internal relief valve and pressure gage, if

required, set to limit air pressure to maximum allowable air pressure for each actuator. 5. Provide 4-20 mA (with HART) command and feedback signals for modulating valves. 6. Provide open and close limit switches as required for burner management system. 7. Solenoid valve: Provide with each on/off actuator. 3-way (normally closed) or 4-way type with

threaded conduit connections. 8. Provide stainless steel tubing with Parker or Swagelok stainless steel fittings for control tubing

interconnection of pneumatic accessories. 9. Provide insect screens for vents. 10. Manufacturer: Fisher DVC 6200.

D. Bypass and drains: 1. In accordance with MSS SP-45. 2. Bypasses shall contain globe valves capable of sealing in both directions. 3. Bypass valves and piping shall have pressure-temperature ratings meeting or exceeding main

valve. 4. Minimum piping schedule: 80.

2.08 RELIEF VALVES

A. Service: Steam. 1. Size and connection: Size by Seller, flanged. 2. Body: Carbon steel. 3. Packed lever. 4. Manufacturer: Consolidated 1900 Series, Kunkle, Anderson Greenwood, Farris.

B. Service: Water. 1. Size and connection:

a. Inlet: 3/4" (19 mm), threaded. Verify for given design conditions. b. Outlet: 1” (25 mm), threaded. Verify for given design conditions.

2. Body: Carbon steel. 3. Packed lever. 4. Manufacturer: Consolidated 19000 Series, Kunkle, Anderson Greenwood, Farris.

26153.02.00 GENERAL DUTY PROCESS VALVES AND ACCESSORIES ms1692 SECTION 40 05 23 - Page 5 2.09 SOURCE QUALITY CONTROL

A. Hydrostatic tests: 1. Subject valve to hydrostatic shell and seat leakage tests in accordance with MSS SP-61 for

isolation valves, ASME B16.34 for isolation valves, and FCI 70-2 for control valves. 2. Maximum seat leakage during closure tests shall not exceed following ml/h per inch (25 mm) of

nominal valve size: a. Gates and globe: 10. b. Check valves: 40.

3. Maximum seat leakage for metal seated high performance ball valves; FCI 70-2 Class VI: a. 2" (50 mm): 3 bubbles per minute. b. 6" (150 mm): 27 bubbles per minute. c. 8" (200 mm): 45 bubbles per minute.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install valves in accordance with manufacturer’s recommendations.

B. Install valves with stems horizontal or in upright position.

C. Install globe valves with flow direction from below to above seat.

3.02 DATA SHEETS

A. DS-1 - Gate, Globe, Angle, and Check Valves- Steel.

B. DS-2 - Ball Valves - Steel.

C. DS-3 - Butterfly Valves.

D. DS-4 - Bronze and Iron Valves.

3.03 VALVE SCHEDULE

SERVICE VALVE TYPE DATA SHEET Steam

2 1/2” and smaller Ball DS-2 3” and larger High Performance Butterfly DS-3

Boiler Feedwater 2” and smaller Globe DS-1

Blowdown 2” and smaller Globe DS-1

Instrument Air 1/2” thru 3” Ball or Gate DS-4

Compressed Air 1/2” thru 3” Ball or Gate DS-4

Natural Gas 1/2" thru 4” Ball or Plug DS-4 or paragraph this Section 6” and larger Gate DS-4


GATE, GLOBE, ANGLE, AND CHECK VALVES – STEEL

DATA SHEET DS-1

Size 2” (50 mm) and Smaller 2-1/2” (65 mm) to 5” 2-1/2” (65mm) to 5” Pressure Class 800 minimum 600 and Lower 900 and Higher

MA

TER

IALS

Body Forged - Equivalent to Pipe Cast or Forged- Equivalent to Pipe

Cast or Forged- Equivalent to Pipe

Stems 13 Cr 13 Cr 13 Cr

Wedge / Disc 13 Cr or solid trim material Equivalent to body or solid trim material

Equivalent to body or solid trim material

Wedge / disk seating surfaces

Class 800-13 Cr, 250 HB min Class 1500 and greater-Stellite (HF), 350 HB min

13 Cr, 250 HB min Stellite (HF), 350 HB min

Body seating surfaces Stellite (HF), 350 HB min Stellite (HF), 350 HB min

Stellite (HF), 350 HB min

Backseat Class 800-13 Cr, 250 HB min Class 1500 and greater-Stellite (HF), 350 HB min

13 Cr, 250 HB min Stellite (HF), 350 HB min

BO

NN

ETS

Class 800 and below Bolted Bolted Pressure Seal

Class 1500 and higher Integral or welded bonnet joints N/A Pressure Seal

CO

NS

TRU

CTI

ON

Stem Arrangements Outside screw and yoke with rising Stem

Outside screw and yoke with rising stem

Outside screw and yoke with rising stem

Port Size Conventional except where noted otherwise Full Full

Seat Rings Gates – Pressed-in renewable Others – Integral Seal welded, renewable Seal welded, renewable

Backseat Integral Integral

Gate valve wedge Solid wedge

Flexible wedge preferred. Solid wedge acceptable where flexible wedge not available.

Wedge-flexible; Parallel slide- split

Globe valve disc Solid plug Solid plug, guided Solid plug, guided

Check valve disc Class 800 – swing check Class 1500 – piston check

Swinging except where noted otherwise

Swinging except where noted otherwise

Manufacturer Vogt, Edwards, Control Valves: Fisher.

Pacific, Edwards ,Control Valves: Fisher.

Pacific, Edwards, Control Valves: Fisher.


BALL VALVES – STEEL DATA SHEET DS-2

Service Steam service with design temp greater than 300°F (149°C)

Oil and Natural Gas

Water, Steam, Gas, or Air service with design temp less than 300°F (149°C)

Pressure Class 600 and above 300 and below 300 and below

MA

TER

IALS

Body Equivalent to pipe Equivalent to pipe Equivalent to pipe Ball: Stainless steel Stainless steel

Class 1500 and below 410SS coated or A182-410 / Ram31

Class 2500 and above Inconel 718 or A182-410/Ram31

Stems Stainless steel Stainless steel Class 1500 and below A276 Gr. 431

Nitrided or A638 Gr. 660/H.F.

Class 2500 and above 431SS or A638 Gr. 660/H.F.

Seats: Nylon with seat ring and emergency gasket PTFE or RPTFE

Class 1500 and below 410SS coated or A182-F22 CL3/H.F.

Class 2500 and above Inconel 718 or A182-F22 CL3/H.F.

Seat Ring Equivalent to pipe Equivalent to pipe Seals:

Body TFE PTFE or RPTFE Stem TFE with emergency

backup seal PTFE or RPTFE

CO

NS

TRU

CTI

ON

Valve Style Unibody 3-piece Design Pressure less than or equal to 150 psig- 2 piece unless noted otherwise; Above 150 psig- 3 piece

Design

Fire tested in accordance with API-607.

Bore Size Full Full Full Valve end type

Welded 2” and less- Threaded 2.5” and larger- Flanged

2” and less- Threaded 2.5” and larger- Flanged

Manufacturer Mogas, Valvtechnologies, or Conval

Neles-Jamesbury "Fire-Tite," Marpac, Valvtechnologies

Neles-Jamesbury Corp., Lunkenheimer, Apollo,


BUTTERFLY VALVES DATA SHEET DS-3

Type Resilient Seat AWWA High Performance Service Water 250°F (121°C) and lower

and air 200°F (93°C) and lower Water 250°F (121°C) and lower

Water above 250°F (121°C) and steam

Size 2” through 12" (50 mm – 300 mm)

14” through 20” (350 mm – 500 mm)

Exposed - 24” (600 mm) and larger, Direct Buried – all sizes

6” and above

Pressure rating 200 psi bi-directional minimum disc, 250 psi body

150 psi bi-directional minimum disc, 200 psi body

AWWA C504 Class *150* *250*

ASME CL 150 & 300

ASME CL 600 & 900

MA

TER

IALS

Body Ductile Iron Ductile Iron for Class 250, Cast Iron for Class 150

Equivalent to pipe (carbon steel or stainless steel)

Disc Aluminized Bronze for water service, Ductile Iron for air service

Ductile Iron Stainless steel as required for service

Shaft 416 Stainless Steel 304 Stainless steel Stainless steel Soft Seat EPDM for water service, BUNA

for air service EPDM or BUNA Synthetic rubber, metal, or

fire safe as required for service

Hard Seat 316 Stainless steel Stellite Gr. 21 Weld Overlay Shaft Seal Manufacturer’s standard Chevron V-type packing or

bronze packing gland with TFE impregnated Teflon packing

Teflon or graphite packing as required for service

Coating Not required for ductile iron body, manufacturer’s standard acceptable

Manufacturer’s standard

CO

NS

TRU

CTI

ON

Body Extended neck Lugged unless noted otherwise

Provide mechanical joints for ductile iron piping systems and flanged joints otherwise

Lugged or Flanged-Triple offset unless noted otherwise

Lugged or Flanged – Triple offset unless noted otherwise

Shaft and Disc Connection

Shaft keyed to disk – pinned connection not allowed

Shaft keyed to disc preferred – stainless steel taper pins acceptable

Stainless steel taper pins Stainless steel taper pins

Position indicator

Required Required Required

Hydrostatic and seat leakage

Factory test at 110% pressure rating

AWWA C504 FCI 70-2 or API 598

Manufacturer

Nibco Bray Keystone Series 60 Xomox Series 7500 Demco

Exposed: Rodney Hunt Streamseal, Dezurik BAW, Henry Pratt, Val-Matic

Adams MAK (ASME CL 150, 300, 600, & 900)


BRONZE AND IRON VALVES DATA SHEET DS-4

Gate, Globe, and Checks Ball Size 2” (50 mm) and Less 2-1/2” (65 mm) and

Larger 4" (100 mm) and Less

Pressure class 150 psig (1035 k Pa g)at 220°F (104°C)

125 psig at 220°F (104°C)

125 psig (860 k Pa g)

MA

TER

IALS

Body Bronze ASTM A126 Class B Cast Iron

Bronze

Ball n/a n/a Bronze

Gate valve wedge Bronze Cast iron with bronze face rings

n/a

Globe valve disc TFE Renewable Bronze n/a

Check valve disc Bronze Ductile Iron n/a

Stems Silicon Brass ASTM B16 Brass Bronze Seats and Seals Steam service- TFE

Water, oil, gas- Buna-N Bronze, ASTM B61 RPTFE

Internals Bronze Renewable Bronze

CO

NS

TRU

CTI

ON

Stem Inside screw with rising stem Outside screw and yoke with Rising Stem

Blowout proof

Packing Aramid fibers with graphite Aramid fibers with graphite

PTFE

Bore Size Full Full Full Ball valve body n/a n/a 2 piece

Valve end type Threaded, unless noted otherwise

Flanged, unless noted otherwise

Pipe Material Steel

End Type Threaded

Manufacturer Nibco, Watts, Crane Nibco, Watts, Crane Nibco, Watts, Apollo

END OF SECTION

1) B. A. Pankow 2) D. R. Einck



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26153.02.00 FABRICATED STACK ms1692 SECTION 44 11 39-13 - Page 1

PART 1 GENERAL


A. Stack.

B. Insulation.

C. Test ports and access platforms.

D. Painting and finishes.

E. Testing.

F. Welding inspection.


A. Product Data: 1. Structural design criteria. 2. Installation instructions.


A. Shop Drawings: 1. Manufacturer. 2. Model. 3. Dimensional outline. 4. Materials of construction. 5. Shipping and installed weight. 6. Recommendations for hoisting, moving and installing stack. 7. Details of breeching connection. 8. Loading Information:

a. Provide reactions, magnitude and directions, of all structures (stack, support frames, miscellaneous structures, etc.). Provide individual load cases and load combination.

b. Dead load. c. Live load. d. Wind shear and moment at base, including dynamic wind loads. e. Seismic shear and moment at base. f. Stack system vibration frequency for lowest 6 vibration modes.

9. Stack base detail showing support interface. 10. Number, type, size, and location of anchor bolts, and connection detail at base. 11. Test and sample port size, location, height, position, flange bolt pattern clocking, and flange

spacing from stack. 12. Test port access platforms and ladders.

B. Quality assurance data: 1. Welders’ qualifications. 2. Drawings signed and sealed by a Professional Engineer licensed in State of Iowa 3. Performance data. 4. Performance guarantees. 5. Test reports. 6. Certificates.


A. Operation and maintenance data.

FABRICATED STACK 26153.02.00 Page 2, SECTION 44 11 39-13 ms1692 1.05 QUALITY ASSURANCE

A. Regulatory requirements: 1. Design and construct stack in accordance with latest applicable requirements of standard

specifications and codes of ANSI, ASME, ASTM, AISC, AWS, NFPA, and other such regular published and accepted standards except where modified or supplemented by these specifications; and in accordance with applicable requirements of federal OSHA Standards, and applicable local codes and standards.

2. Design shall be performed by Professional Engineer licensed in State of Iowa. 3. Design shall comply with ASME STS-1 2011 Steel Stacks.

B. Qualifications: Company specializing in stack design with minimum of 10 years documented experience.


A. Clean prior to shipping.

B. Factory seal openings to prevent foreign material from entering during transit.

C. Clearly mark port locations on equipment.

D. Crate and cover equipment to facilitate handling and to withstand normal shipping and handling shocks and vibrations.

E. Unloading of stack from delivery vehicle will be performed by Owner’s contractor.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Amerex Industries, Inc.

B. Commonwealth Dynamics, Inc.

C. Hamon Custodis-Cottrell, Inc.

D. Hoffmann Inc.

E. International Chimney.

F. Schebler.

G. Van Packer.

H. Warren Environment, Inc.

I. Or equal.

2.02 DESIGN REQUIREMENTS

A. Equipment: 175,000 pph natural gas-fired package boiler.

B. Design inner diameter for 30 to 80 fps maximum flue gas velocity with unit at full capacity.

C. Height of stack above boiler base: 111’-0” (34 m), existing roof at approximately 35’ (11 m) above boiler base.


D. Corrosion allowance: 1/8" (3 mm).

E. Design shall comply with 2009 International Building Code, or ASME STS-1 2011, whichever is more stringent.

F. Wind loads: Exposure Category C. Occupancy category III. Design shall include effects of terrain escarpment, and adjacent and future stacks. Design shall include effects of dynamic wind loads.

G. Seismic loads: Site Class C. Occupancy Category III.

H. Allowable stresses shall not be increased due to wind or seismic.

I. Maximum allowable stress in shell shall not exceed permissible stress with appropriate safety factor based on shell buckling criteria.

J. Stack deflection, not considering base rotation, due to wind load and assuming 100% loss of corrosion allowance, shall not exceed 6" per 100’ (150 mm per 30 m).

K. Design stack base anchorage bolts. Design shall include effects of tension and shear forces at base.

L. Building structural steel framing will be provided by others. 1. Bottom of stack support base shall be directly supported on top of building roof framing. 2. Building structural steel will include concentrically braced frame. 3. Building structural steel framing supporting stack will include W-shape beams spanning to column

rows. 4. Stack design shall account for stiffness of building structural steel framing at stack base support. 5. Layout and stiffness of building structural steel at stack base connection will be provided at later

date.

M. Provide 3-1/2” (89 mm) wide steel ring around stack at approximately 2’-6” (760 mm) above roof framing. Ring shall be seal welded to stack, and slope away from stack wall. Flashing around stack at roof penetration will be by others. Details of roof flashing will be provided at a later date.

N. Provide platforms for accessing test ports on each stack. Coordinate height of access platforms with test port elevations. Support access platform from stack. Provide ladders, guardrails, heat shields and related accessories. Coordinate ladder to clear stack flashing at base. Connecting ladder base to building roof is not permitted. Access platforms and ladders shall be galvanized steel or stainless steel.

2.03 STACK

A. Type: Single-wall.

B. Material: ASTM A242 steel.

C. Fabricate in cylindrical sections sized suitable for shipping and space constraints of site.

D. Design: 1. Free-standing, vertical structure. 2. Shell shall resist stresses resulting from weight of stack, effect of wind, and shall resist corrosion

from weather. 3. Provide vertical loads required to be supported on Owner’s structural steel.

E. Form shell of sheared plates to specified diameters; when stack diameters exceed available mill plate lengths or site access conditions, 2 or more plates may be used to form shell.

F. Shell construction: 1. Maximum deviation of base or support ring from centerline of stack: ±3/16" (5 mm).

FABRICATED STACK 26153.02.00 Page 4, SECTION 44 11 39-13 ms1692

2. Plumb to within maximum deviation of 1” per 100’ (25 mm per 30 m) of height. 3. Maximum out-of-roundness of any section (difference between minimum and maximum diameter):

Less than 1% of normal diameter. 4. Maximum misalignment of plates at any joint: 25% of nominal thickness or 1/8" (3 mm) whichever

is less. 5. Pair adjoining plate sections for full 100% development.

G. Include lifting lugs on each stack section.

H. Welded construction with girth and vertical seams of complete penetration butt welds to develop strength of plate; partial penetration welds not acceptable.

I. Flanges or flange type joints not acceptable, except those required for breeching connection.

J. Provide base anchorage system to transmit forces in shell to support steel through anchorage bolts without inducing local stresses of appreciable magnitude in shell.

K. Provide stack inlet connection with angle flange for connection to expansion joint at economizer outlet.

L. Provide perforated or mesh type stainless steel shield for heat protection of personnel, for stack sections located between roof level and up to 8’ (2.4 m) above port access platform.

M. Provide grounding conductor termination pads at the base of the stack.

2.04 INSULATION

A. Field insulation of stack below roof flashing level: By others.

B. Include insulation support clips attached to stack wall.

2.05 ANCHOR BOLTS

A. Furnish stack support steel anchorage bolts to be installed by others in structural steel. Provide necessary installation details.

2.06 TEST PORTS

A. Provide flue gas test ports welded to shell. Terminate with standard 150 lb raised face flange with face 4" (100 mm) outside of shell.

B. Use Type 316 stainless steel flanges and bolts with Monel nuts for test ports.

C. Provide two 4" (100 mm) diameter test ports located approximately 49'-0" (14 m) (to be verified after award of Contract) above boiler base at 90º from each other. Design for 300 lb (136 kg) horizontal load, 300 lb (136 kg) vertical load and 600 ft-lb (800 N-m) moment, applied at outer end of test port.

2.07 SAMPLE PORTS

A. Provide flue gas sample ports welded to shell. Terminate with standard 150 lb raised face flange with face 4” (100 mm) outside of shell.

B. Opacity monitor ports: Two 4” (100 mm) diameter ports, 180º from each other at 50’-6” (15.3 m) (to be verified after award of Contract) above boiler base. Design for 300 lb (136 kg) horizontal load, 300 lb (136 kg) vertical load and 600 ft-lb (800 N-m) moment, applied at outer end of sample port.

C. Provide ports for installation of oxygen and NOx analyzers at suitable location. Two 4” (100 mm) diameter ports at 50’-6” (15.3 m) (to be verified after award of Contract) above boiler base. Design for


300 lb (136 kg) horizontal load, 300 lb (136 kg) vertical load and 600 ft-lb (800 N-m) moment, applied at outer end of sample port.

2.08 COATINGS

A. Perform after fabrication and complete before delivery to site.

B. Clean exterior surfaces and prepare for painting in accordance with SSPC-SP10 to 1.5-2 mil surface profile.

C. Cleaned surfaces shall be painted same day they are cleaned.

D. Primer: Dampney Protective Coatings Thurmalox 260 Series. 1. Apply 1 coat at 2.0 to 2.5 mils DFT. 2. Color: Gray.

E. Finish coat: Dampney Protective Coatings Thurmalox 260 Series. 1. Apply 1 coat at 2.0 to 2.5 mils DFT. 2. Color: Black.

F. Apply each coat at proper consistency and to thicknesses recommended by manufacturers. Materials shall be evenly spread and applied smoothly without runs or sags, by skilled workers. Perform painting under conditions suitable to production of high quality work. Follow manufacturer's directions on container label.

G. Touch up primer and finish coat at job site as needed. Follow manufacturer’s recommendations.


A. QA/QC program manuals shall be available for inspection.

B. Permanently mark plates to identify quality and material.

C. Stack manufacturer shall have developed weld procedures, which, in conjunction with overall fabrication methods, will meet quality requirements of this specification.

D. Welding qualifications shall be available for inspection.

E. Weld inspection: 1. Finish welds shall be clean, showing good fusion, and 100% penetration with extensive visual

inspection. 2. Provide equipment and personnel to perform testing. Testing shall be performed not earlier than 5

days after giving notice to Owner of date for testing. 3. Minimum testing: One radiographic test for each 150 linear feet (45 linear meters) of weld and

one ultrasonic test for each 20 linear feet (6 linear meters) of weld. Perform ultrasonic tests first. Perform nondestructive testing of stack base welds and welds subject to fatigue. Location of other nondestructive tests shall be subject to review by Owner.

4. Welds determined to be inadequate shall be removed and rewelded at Seller's expense. Perform 2 additional tests for each test indicating inadequate weld. Costs of additional tests shall be at Seller's expense.

F. Factory tests: 1. Notify Owner 10 working days prior to conducting factory tests. Owner, at its option, may witness

test. Owner will notify Seller if it chooses to witness factory tests. 2. Perform nondestructive weld tests on equipment prior to shipment.

FABRICATED STACK 26153.02.00 Page 6, SECTION 44 11 39-13 ms1692

PART 3 EXECUTION

NOT USED END OF SECTION

1) B. A. Pankow, C. W. Gruetzmacher 2) D. R. Einck