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Sample Specification

Cleaver-Brooks Max-Fire HRSGHeat Recovery Steam Generator

SAMPLE SPECIFICATIONThe following Sample Specifications are provided by Cleaver-Brooks to assist you in meeting your customer’s specific needs and applications.

The Sample Specifications are typically utilized as the base template for the complete boiler specification. Contact your local Cleaver-Brooks’ authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specification.

PURCHASERPROJECT NAME

Table of ContentsPart 1 - GENERAL REQUIREMENTS...........................................................................................................4

1.1 GENERAL.....................................................................................................................................4

1.2 REFERENCES................................................................................................................................5

1.3 Quality assurance........................................................................................................................5

1.4 PROPOSAL INFORMATION...........................................................................................................5

1.5 SUBSTITUTIONS / MODIFICATIONS.............................................................................................5

1.6 SUBMITTALS................................................................................................................................6

1.7 DELIVERY, STORAGE, AND HANDLING.........................................................................................6

1.8 WORK BY OTHERS.......................................................................................................................6

Part 2 - PRODUCTS...................................................................................................................................7

2.1 MANUFACTURES.........................................................................................................................7

2.2 BOILER DESIGN & OPERATING CONDITIONS...............................................................................7

2.3 BOILER CONSTRUCTION..............................................................................................................8

2.4 DRUMS........................................................................................................................................8

2.5 FURNACE.....................................................................................................................................9

2.6 BOILER CONVECTION SECTION..................................................................................................10

2.7 DOWNCOMERS.........................................................................................................................10

2.8 SUPERHEATER (OPTIONAL)........................................................................................................10

2.9 CASING, SETTING, AND INSULATION.........................................................................................11

2.10 TRIM AND INSTRUMENTATION.................................................................................................11

2.11 ECONOMIZER............................................................................................................................14

2.12 DUCT BURNER...........................................................................................................................15

2.13 FUEL TRAINS..............................................................................................................................15

2.14 COOLING AIR BLOWER SKID......................................................................................................16

2.15 FRESH AIR FAN & DRIVE (optional)............................................................................................16

2.16 DAMPER(S)................................................................................................................................17

2.17 Boiler CONTROL SYSTEM...........................................................................................................17

2.18 PLANT MASTER..........................................................................................................................19

2.19 DIVERTER (Optional)..................................................................................................................19

2.20 GUILOTINE DAMPER (Optional).................................................................................................19

2.21 STACK........................................................................................................................................19SECTION 15554 Rev A.WATERTUBE BOILER of 27

PURCHASERPROJECT NAME2.22 DUCTING / BREECHING / SUPPORT STRUCTURE.......................................................................19

2.23 PLATFORMS AND LADDER (Optional)........................................................................................19

2.24 SPARE PARTS.............................................................................................................................19

Part 3 - EXECUTION................................................................................................................................20

3.1 WARRANTY................................................................................................................................20

3.2 SHOP TESTS...............................................................................................................................20

3.3 INSTALLATION...........................................................................................................................20

3.4 PRE-COMMISSIONING / STARTUP / COMMISSIONING..............................................................20

Appendix A - HRSG PERFORMANCE................................................................................................22

Appendix B - SITE AND UTILITY DATA..............................................................................................24

Appendix C - FUEL GAS DATA..........................................................................................................25

Appendix D - LIQUID FUEL DATA.....................................................................................................26

Appendix E - PLOT PLAN AND SPACE REQUIREMENTS....................................................................27

SECTION 15554 Rev A.WATERTUBE BOILER of 27


PART 1 - GENERAL REQUIREMENTS1.1 GENERAL

A. This specification shall govern the construction features, materials, fabrication, inspection, and preparation for shipment of "O-type" shop-assembled, heat recovery steam generator and associated equipment complete including burner assembly, necessary appurtenances, controls and auxiliary equipment mounted to the maximum practical extent (allowed by shipping clearances) as an integral unit on a steel base so as to make a complete self-contained assembly.1. Here is line 1.

a. Here is level a.1) Here is level 1).

a) Here is level a).i) Here is level i).

B. The equipment will generate high pressure steam to be utilized for heating and cooling of Purchaser’s campus | generate high pressure for use in the Purchaser’s manufacturing process.

C. The equipment supplied will be installed indoors with combustion air being drawn from outdoors.

D. Refer to Appendix A - HRSG PERFORMANCE for Gas Turbine DataE. Refer to Appendix B - SITE AND UTILITY DATA for site conditions and available utility data. F. Refer to Appendix C - FUEL GAS DATA for natural gas analysis.G. Refer to Appendix D - LIQUID FUEL DATA for liquid fuel analysis.H. Refer to Appendix E - PLOT PLAN AND SPACE REQUIREMENTS for overall plot space and

available footprint for equipment specified herein.1.2 REFERENCES

A. Equipment provided shall adhere to the latest edition of the following code and standards.1. ASME Boiler Pressure Vessel Code Section I.2. ASME Boiler Pressure Vessel Code Section II.3. ASME PTC 4.4.4. NFPA® 85 Boiler and Combustion System Hazards Code5. CSA B149.3 (optional)6. ASME B31.1 | ASME B31.3 | CSA B517. International Building Code.

1.3 QUALITY ASSURANCEA. The equipment shall, as a minimum, be in strict compliance with the requirements of this

specification and shall be the manufacturer's standard product unless specified otherwise. Additional equipment features, details, accessories, appurtenances, etc. which are not specifically identified but which are a part of the manufacturer's standard product, shall be included in the equipment being furnished.

B. The equipment shall be new and fabricated from new materials and shall be free from defects in materials and workmanship.

C. The equipment must fit within the allocated space, leaving ample allowance for maintenance and cleaning, and must leave suitable space for easy removal of all necessary appurtenances.


PURCHASERPROJECT NAME1.4 PROPOSAL INFORMATION

A. The Vendor’s proposal shall include the following information:1. General Description of steam generating unit(s) and auxiliary equipment.2. Description and make of combustion controls, combustion turbine handshaking control,

feedwater flow control, and flame safety control systems to be furnished by the Vendor.3. Proposal shall include complete commercial details includes the following information at a

minimum:a. Priceb. Schedulec. Payment Termsd. General Terms & Conditionse. Field Service Ratesf. Priced Spare Parts List

4. Heat recovery steam generator performance for the fired and unfired scenarios for the turbine operating scenarios provided in Appendix A - HRSG PERFORMANCE.

5. Water quality requirements to be maintained for proper boiler operation.6. Vendor to indicate guarantees within the proposal.7. Any deviations or expectations taken to the specification must be listed or statement of

compliance with the specification.8. General Arrangement Drawing showing arrangement, overall dimensions, and foundation

loading of all equipment proposed.1.5 SUBSTITUTIONS / MODIFICATIONS

A. The bidder must submit in writing to the engineer any request for a proposed deviation, omission, modification, or substitution to this specification for evaluation no later than ten (10) days prior to bid date.

B. Technical data, drawings, product samples, and complete data substantiating compliance of proposed substitution with these specifications shall accompany a request for any substitution.

C. No materials shall be deemed acceptable if not in strict and full compliance with these specifications.

D. All bidders must bid solely on the specified materials unless acceptance by the engineer of a deviation, omission, modification, or substitution is granted in writing to all bidders prior to the bid date.

1.6 SUBMITTALS A. The contractor shall submit, in eight (8) weeks, all submittals for approval by the engineer.

Under no circumstances shall the contractor install any materials until the engineer has made final approval on the submittals.

B. The engineer shall review and stamp submittals. Work may proceed and equipment released for fabrication after contractor receives returned submittals stamped with “NO EXCEPTIONS TAKEN” or “MAKE CORRECTIONS NOTED”.

C. Shop Drawings - Shop drawings shall be submitted to the engineer and shall consist of the following information:1. Vendor shall submit document list, project datasheet, boiler performance, shipping

sketch.



2. General Arrangement Drawing showing arrangement, overall dimensions, and foundation loading of all equipment.

3. P&iD including all instruments provided as part of the equipment package. 4. Line size and utility consumption information.5. Schematic wiring diagram with SAMA logic of the burner management system and control

narrative of boiler control system showing all components, interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field wiring by others.

6. Vendor shall provide installation details and system assembly drawings.7. Provide two (2) Operating and Maintenance manuals including approved submittal

drawings, instructions for maintenance and inspections, complete spare parts list, and ASME Documentation and other certificates.

1.7 DELIVERY, STORAGE, AND HANDLINGA. The Vendor | Purchaser shall be responsible for the timely delivery of the equipment to the

jobsite. B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's

handling and storage instructions.1.8 WORK BY OTHERS

A. Gas Turbine.B. Site Preparation.C. Foundations.D. Off-loading and transportation to foundations or storage, if required.E. Installation of Equipment.F. Boil-out chemicals and disposal.G. CEMs or PEMs.

PART 2 - PRODUCTS2.1 MANUFACTURES

A. Equipment must be furnished only by a qualified Manufacturer. The qualified Manufacturer must have a minimum of fifteen (15) years’ experience providing similar equipment in size and scope to this Project. The Manufacturer shall submit experience list upon request by Customer.

B. Basis of Design: Cleaver-Brooks Max-Fire heat recovery steam generator.C. Acceptable Manufacturers are listed herein.

1. Cleaver-Brooks, Inc.2.2 BOILER DESIGN & OPERATING CONDITIONS

A. Boiler Operating Conditions1. Design Pressure - psig:...................................................................................xxx2. Fired Steam Capacity – lb/hr:........................................................................xxx,xxx3. Unfired Steam Capacity – lb/hr:....................................................................xxx,xxx4. Operating Pressure – psig:.............................................................................xxx5. Operating Temperature - °F:.........................................................................Saturated6. Temperature Control Range - % MCR firing natural gas................................100 – xx7. Temperature Control Range - % MCR firing fuel oil.......................................100 – xx8. Steam Purity – ppm TDS................................................................................1



9. Steam Quality - % dry steam:........................................................................99.510. Feedwater Temperature - °F:........................................................................xxx11. Duct Burner Heat Input – mmbtu/hr (HHV) (Natural Gas):...........................x12. Flue-gas pressure drop - inH2O:.....................................................................x

B. Design Exhaust Information1. Ambient Temperature - °F.............................................................................xx2. Relative Humidity - %....................................................................................xx%3. Exhaust Flow – lb/hr......................................................................................xxx,xxx4. Exhaust Gas Temperature - °F.......................................................................x,xxx 5. Exhaust Gas Pressure - psia...........................................................................xx.x 6. Exhaust Gas Analysis

a. CO2 - % vol...............................................................................................xx.xb. H2O - % vol..............................................................................................xx.xc. N2 - % vol.................................................................................................xx.xd. Ar - % vol.................................................................................................xx.xe. O2 - % vol.................................................................................................xx.xf. SO2 - % vol...............................................................................................xx.x

7. Exhaust Emissionsa. NOx - ppmvd @ 15% O2............................................................................x b. CO - ppmvd @ 15% O2..............................................................................x c. VOC - ppmvd @ 15% O2............................................................................x

C. The gas turbine is design to fire natural gas | natural gas and fuel oil |fuel oil. Refer to Appendix C - FUEL GAS DATA & Appendix D - LIQUID FUEL DATA

D. Boiler shall be design to fire natural gas | natural gas and fuel oil |fuel oil. Refer to Appendix C - FUEL GAS DATA & Appendix D - LIQUID FUEL DATA for fuel analysis, temperature, and available pressure.

E. Turndown – Supplemental Firing:1. Natural Gas....................................................................................................xx:x2. Fuel Oil..........................................................................................................xx:x

F. Turndown – Fresh Air Firing:1. Natural Gas....................................................................................................xx:x2. Fuel Oil..........................................................................................................xx:x

G. Burner Emissions – Supplemental Firing:1. Natural Gas

a. NOx – lb/mmbtu (HHV):.......................................................................... xxb. CO – lb/mmbtu (HHV):............................................................................ xx



2. Fuel Oil (100-25% of rated heat input)a. NOx – lb/mmbtu (HHV):.......................................................................... xxb. CO – lb/mmbtu (HHV):............................................................................ xx

H. Burner Emissions – Fresh Air Firing (Optional):1. Natural Gas

a. NOx – lb/mmbtu (HHV):.......................................................................... xxb. CO – lb/mmbtu (HHV):............................................................................ xx

2. Fuel Oil (100-25% of rated heat input)a. NOx – lb/mmbtu (HHV):.......................................................................... xxb. CO – lb/mmbtu (HHV):............................................................................ xx

I. Noise Sound Levels shall be 85 dBA max and based on ABMA test code for packaged boilers measured @ 4 ½ feet vertically above the bottom of the base and 3'0" horizontally in front of the end of the burner or front surface of control cabinet. Sound levels dBA on the scale in reference to 0.0002 microbars.

2.3 BOILER CONSTRUCTIONA. Each heat recovery steam generator shall consist of a two drum O-type, shop-assembled,

package type watertube boiler assembly with integral watercooled furnace.2.4 DRUMS

A. Steam and water drums shall be located directly over one another to ensure uniform loading of the tubes.

B. Steam Drum – shall be xx” inside diameter steam plate of 70,000 U.T.S., fusion welded, x-rayed, and stress relieved. All internals shall be installed in a manner as to allow their easy removal and replacement for cleaning and maintenance. Internals shall be provided which will insure good distribution of incoming feedwater and steam quality in the generated steam.

C. Steam Drum shall be provided with the following connections:1. Main Steam Outlet2. Safety Valves3. Auxiliary Steam (Optional)4. Atomizing Steam (Optional)5. Boiler Feedwater6. Sootblower (Optional)7. Water Column8. Drum Level9. Chemical Feed10. Continous Blowdown11. Drum Vent12. Auxilary Low Water Cut-out

D. Water (Mud) Drum – shall be xx” OD of either fusion welded plate or seamless steel pipe. The water drum shall have suitable internal baffle or angle to insure proper blowdown of boiler.



E. Water Drum shall be provided with the following Connections1. Intermittent Blowdown2. Lower Drum Heating Coil (Optional)

F. Each steam and water drum shall be provided with two (2) hinged manhole openings (12” x 16” minimum) to assure visibility and ventilation during inspection and maintenance. Each manhole opening shall be complete with manhole plate, yoke, nuts, bolts, washers, and gaskets.

G. No part of the boiler drums shall be directly exposed to furnace radiation. Refractory shall be utilized to protect from radiant heat.

H. Drums shall include a corrosion allowance of 0.0625” | 0.125”. (optional)I. All connections larger than 1.5" shall be flanged.J. Connections less than or equal to 1.5” shall be flanged or welded.K. Tube to drum connections shall be rolled and flared. Compression fittings or alternate tube to

drum configurations shall not be accepted.L. Tube to drum connections shall be rolled and seal welded. Compression fittings or alternate

tube to drum configurations shall not be accepted. (optional)2.5 FURNACE

A. The steam generating units shall be provided with a 100% welded gas-tight enclosure. Refractory gas seals are not allowed. The seal shall be formed entirely by finned tube walls and headers, continuously seal-welded together forming a gas-tight water-cooled enclosure.

B. All tubes shall be 2" OD, electric resistance welded / seamless, and shall be designed and arranged to provide for natural circulation in the proper direction at all loads. Tubes of variable diameter, such as swaged tubes, shall not be permitted.

C. Membrane tubes shall be a minimum of 0.105” | 0.120” | 0.135” wall thickness.D. Tube shall be bent on a minimum of 4 x OD radius with mandrel inserted during bending to

prevent distortion at the bend.E. Outer wall shall be constructed as follows:

1. Shall consist of headers at the front and rear of the steam generator forming a 100% welded gas tight enclosure.

2. Walls shall be 100% water-cooled membrane surface. Membrane design will consist of 2" OD tubes on 4" centerlines, with membrane fins between tubes. The adjacent fins of each outboard furnace and convection tube shall be continuously seal-welded together, forming a water-cooled, gas-tight inner seal.

3. Fins shall be ¼”x 1” steel, fused continuously to opposite sides of the tubes by electric welding. Membrane finned construction which utilizes a fin-to-tube weld on only one side is not acceptable.

F. Burner / Front Wall shall include a mating flange for the duct burner and shall be of sufficient size to restrict flame impingement on the mating flange, insulation, and liner material.

G. Radiant heating surfaces shall be calculated on a flat projected basis.H. Furnace volume shall be determined with the furnace limit being considered as not extending

beyond the first row of water screen tubes or superheater tubes, whichever first comes in contact with the furnace's exit flue gases.



I. The furnace shall be designed to restrict flame impingement and permit long flame travel. Furnaces shall be provided with the necessary water-cooled radiant surface to assure the reduction of the furnace exit gas temperatures prior to entry into the convection zone.

J. Furnace Access - An access opening, 15" x 18" minimum, shall be provided to the boiler furnace area. The access opening shall be gasketed and shall have a 1/4" steel cover with handles and shall be secured properly for a gas tight seal.

2.6 BOILER CONVECTION SECTIONA. All tubes shall be 2" OD, electric resistance welded | seamless, and shall be designed and

arranged to provide for natural circulation in the proper direction at all loads. Tubes of variable diameter, such as swaged tubes, shall not be permitted.

B. No tube shall enter the lower drum below the horizontal drum centerline. Tubes shall not have any reverse bends or "pockets" which would prevent complete drainage of the boiler through the lower blowoff opening.

C. Each tube hole shall be serrated to assure the tightest possible mechanical joint.D. All tubes shall be a minimum of 0.105” | 0.120” | 0.135” wall thickness.E. Tube rows immediately downstream of the duct burner shall be bare tube.F. Tubes shall be inline | staggered and shall utilize extended (finned) surface. Maximum fin

density shall be 4 | 5 | 6 fins/inch with a minimum thickness of 0.049” and a maximum height of 0.75” | 0.875”.

G. Flue Gas Outlet Wall shall be horizontal | vertical. All tubes shall be 100% water-cooled membrane surface except where the gases leave the steam generator. Membrane design will consist of 2" OD tubes with membrane fins between tubes continuously seal welded together.

2.7 DOWNCOMERSA. An adequate number of downcomer tubes shall located near the flue gas outlet of the steam

generator to ensure B. Downcomers shall be located at both the front and rear of the boiler.C. No downcomers shall enter the steam drum above the normal water level.

2.8 SUPERHEATER (OPTIONAL)A. A superheater shall be provided to provide steam at the specified design conditions with a

single stage and include a terminal attemporator (optional).B. A superheater shall be provided to provide steam at the specified design conditions via a dual

stage superheater and include an interstage attemporator (optional).C. Tubes shall be inline and shall utilize extended (finned) surface. Maximum fin density shall be

2 | 3 | 4 fins/inch with a minimum thickness of 0.049” and a maximum height of 0.375” | 0.5”. D. The superheater shall be completely drainable by gravity.E. The tubes and the headers shall be of the same material.F. Any dissimilar welds shall be identified in the seller’s proposal.

2.9 CASING, SETTING, AND INSULATIONA. The external casing shall be 12-gauge steel and shall completely enclose the unit with the

exception of the four drum heads. The drum heads shall be insulated in the field by others. The steam drum shall be insulated and cased with 12-gauge steel. (Steel Casing)



B. The external casing for the sides, front, rear, and bottom shall be aluminum cladding. The roof casing shall be 12-gauge steel and shall completely enclose the unit with the exception of the four drum heads. The drum heads shall be insulated in the field by others. (Aluminum Casing)

C. The average surface temperature of the casing shall not exceed 50F over ambient temperature with a surface wind velocity of two feet per second while the boiler is operating at full capacity.

D. All insulating materials shall be not less than first quality, as used in the best commercial practices, and shall conform substantially to the following:1. Sides, roof, floor, front & rear walls of the steam generating unit are to be completely

covered with a minimum thickness of 3 inches of 1000F insulating blanket of the fiber glass or mineral wool type. Insulation over the top of the steam drum is to be a minimum of 3 inches thick 1000F insulating blanket of the fiber glass or mineral wool type.

E. A welded heavy beam and channel boiler base shall support the steam generating equipment and uniformly distribute the loading over the foundation area. (Steel Casing)

F. The steam generating unit shall be supported by steel base beams. (Aluminum Casing)G. The exterior steel surfaces of each unit shall be completely cleaned by solvent cleaning,

scraping, or grinding and have one (1) coat each of high heat resistant primer and finish coat. Corrugated aluminum parts of the outer casing (if applicable) need not be painted.

2.10 TRIM AND INSTRUMENTATIONA. Each unit shall be furnished with the following boiler trim and instrumentation which shall be

in accordance with ASME Code requirements and conforming to the best standards and practice.

B. All flow transmitters shall include at a minimum a three-valve manifold.C. All pressure transmitters and gauges for steam and water service shall include at a minimum a

two valve manifold.D. Boiler Trim and Instrumentation

1. This equipment shall be factory-mounted, complete with integral connecting piping, valves, and fittings. All valves and control apparatus are to be designed for the specific application for which they are utilized in full compliance with the regulatory codes hereinbefore specified. Drain lines, as applicable, shall terminate with a valve 5 feet above operating floor level. If clearances do not permit shipment of all apparatus mounted on the unit, the subassemblies affected can be shipped loose for field mounting by others.a. Drum Safety Valves b. Drum Safety Valve Drip-pan Elbows, Silencers, and Exhaust Stacks (Optional)c. Drum Vent Valved. One (1) drum pressure transmitter and pressure gauge.e. One (1) high-high pressure switch. (Optional – Saturated Boiler Only)f. One (1) high pressure switch and one (1) high-high pressure switch (Optional)g. One (1) Drum Level Transmitterh. One (1) auxiliary low water cut-outi. One (1) Water Column complete with one (1) gauge glass and one (1) low level probe

(250-399#)j. One (1) Water Column complete with two (2) gauge glasses and one (1) low level

probe (>399#)



k. One (1) remote level indication for control room with local indication (Optional) l. Continuous Blowdown: One (1) angled stop valve and one (1) needle valve for

metering m. Continuous Blowdown: One (1) angled stop valve, conductivity probe, automated

metering valve with bypass (Optional) n. Chemical Feed: One (1) angled stop valve and one (1) check valveo. Intermittent Blowdown: One (1) stop and one (1) throttling valve p. Intermittent Blowdown: One (1) stop and one (1) throttling valve per drum end

(Optional)E. STEAM TRIM AND INSTRUMENTATION (Saturated Boiler)

1. Trim shall be made into subassemblies including necessary piping, fittings, etc. for field mounting by others.a. Non-return Valveb. Spool piece with drain valvec. Main steam stop Valved. Steam Flow Element and transmittere. One isokinetic steam sample nozzle and test valve (Optional)f. Steam Pressure Transmitter (Optional)g. Steam temperature transmitter (Optional)

F. STEAM TRIM AND INSTRUMENTATION (Superheated Boiler)1. Trim shall be made into subassemblies including necessary piping, fittings, etc. for field

mounting by others.a. Superheater Safety Valveb. Superheater Safety Valve Drip-pan Elbows, Silencers, and Exhaust Stacks (Optional)c. High steam pressure switch | transmitterd. Superheater start-up vent valve

1) Manual |Motorized block valve2) Pneumatic superheater vent valve3) Superheater vent valve silencer & exhaust stack (Optional).4) Steam temperature transmitter5) Steam temperature gauge6) Steam Pressure transmitter7) Steam Pressure gauge.

e. Non-return Valvef. Spool piece with drain valveg. Manual |Motorized Main steam stop Valveh. Steam Flow Element and transmitteri. One isokinetic steam sample nozzle and test valve (Optional)j. Steam Pressure Transmitter (Optional)k. Steam temperature transmitter (Optional)

G. ATTEMPORATOR TRIM AND INSTRUMENTATION (Optional)1. Trim shall be made into subassemblies including necessary piping, fittings, etc. for field

mounting by others.a. Spray water inlet isolation valveb. Spray water strainerc. Spray water control valve



d. Spray water check & isolation valvee. Drain valvesf. Attemporatorg. Attemporator inlet and outlet temperature transmitterh. Outlet temperature gauge

H. FEEDWATER TRIM AND INSTRUMENTATION1. Trim shall be made into subassemblies including necessary piping, fittings, etc. for field

mounting by others.a. Feedwater Flow Element and transmitterb. One (1) feedwater control valve station including one (1) feedwater control valve, two

(2) isolation valves, one (1) bypass valve, and drain valvesc. One (1) feedwater stop valve and one (1) feedwater check valved. One (1) feedwater temperature transmitter (Optional)e. One (1) post economizer feedwater temperature transmitter (Optional)

I. ECONOMIZER TRIM AND INSTRUMENTATION 1. Trim shall be made into subassemblies including necessary piping, fittings, etc. for field

mounting by others.a. One (1) vent valve and one (1) drain valveb. One (1) inlet and one (1) outlet temperature gaugec. One (1) inlet isolation, one (1) bypass, one (1) outlet isolation valve, and one (1) safety

relief valve (Optional)J. STACK DAMPER AND INSTRUMENTATION (Optional)

1. Provide one (1) stack damper with actuator.K. LOWER DRUM HEATING COIL (Optional)

1. Inlet subassembly including necessary piping, fittings, etc.a. Two (2) inlet isolation valves with drain valve(s).b. One (1) pressure gauge (Optional)

2. Outlet subassembly including necessary piping, fittings, etc.a. Two (2) outlet isolation valves with drain valve(s).b. One (1) strainer, one (1) steam trap with bypass valve arrangement.c. One (1) pressure gauge (Optional)

L. SOOTBLOWERS (Optional)1. Wallboxes & bearings in the boiler and economizer to accommodate the addition of

sootblower at a later date. (Optional)2. An automatic valve-in-head type sootblower system is to be furnished, factory-mounted

to the steam generating unit.3. An automatic valve-in-head type sootblower system is to be furnished, factory-mounted

to the economizer unit.4. Sootblower elements must be perpendicular to the tubes.5. Each boiler tube lane in the convection zone is to be cleaned by an element orifice.

Systems employing alternate lane blowing are not acceptable.6. Each system shall include a chain-operated steam supply shutoff valve and drain valve.

M. FLUE GAS TRIM1. One (1) inlet pressure transmitter2. One (1) inlet temperature transmitter



3. One observation port per duct burner element with a minimum of two and one observation port at the furnace exit viewing the heat transfer tubes at the exit of the furnace

4. Xxx (x) furnace temperature transmitters5. One (1) economizer inlet and one (1) economizer outlet temperature transmitter

(Optional)2.11 ECONOMIZER

A. Vendor shall furnish one (1) economizer per boiler to recover the heat from the hot boiler exhaust gas and optimize boiler efficiency.

B. The economizer shall be a horizontal tube, counter-current flow design arranged to allow the boiler exhaust to travel vertically upward and the feedwater to flow vertically downward.

C. The economizer shall not be allowed to steam and shall be capable of operating at 100% load without having to bypass any flue gas or feedwater.

D. Tube arrangement shall be square pitch, to allow for ease of cleaning with lane sootblowers. (Optional)

E. All tubes shall be electric resistance welded | seamless with a minimum of 0.105” | 0.120” | 0.135” wall thickness.

F. Tube returns shall not be finned in order to ensure ease of maintenance.G. The economizer unit shall be a packaged, rectangular, unit that is double-cased and insulated.

The economizer internal casing shall be 10-gauge, seal-welded (gas tight) steel, externally insulated with 2” of heavy-duty blanket insulation and externally cased with corrugated lagging.

H. The gas side connections on the economizer shall be plate flange type with drilling for bolt holes to align with adjacent components.

I. The water side connections shall be flanged.J. The unit shall incorporate lifting lugs to facilitate loading & unloading.K. Design shall include an access door for tube inspection. (Optional)L. Adjacent ductwork upstream and downstream shall incorporate access doors.M. Economizer shall be completely drainable by gravity.N. Tubes shall utilize extended (finned) surface. Maximum fin density shall be 4 | 5 | 6 fins/inch.O. The tube support lattice or tube sheet shall contact only the fin tips without contacting the

actual tube wall itself.P. Header material shall be SA106B and use RFWN flanged connections. Header wall thickness

and flange rating shall be dependent on economizer design pressure. Plastic-lined headers shall not be acceptable.

Q. Tube-to-header connections shall be all welded. Bonded fittings or compression fittings shall not be acceptable.

R. All pressure parts shall conform to the applicable provisions of the current ASME Section 1 code. The economizer shall be properly named and code stamped. The design pressure of the economizer shall exceed the design pressure of the boiler.

2.12 DUCT BURNERA. The duct burner assembly will be a proven design developed specifically for Low-NOx

emissions. Basis of design shall be the Cleaver-Brooks Low NOx burner.



B. Provide a natural gas & liquid fuel fired, duct burner system to increase the turbine exhaust gas temperature to provide the specified steam flow and pressure. The duct burner system shall be complete with a burner frame and elements, fuel piping skid, scanner blower skid and a Burner Management System (BMS) with a flame safety system designed in accordance with NFPA 85.

C. The duct burner frame shall be constructed of a minimum of 3/16” carbon steel plate. Provide mating flanges for installing the duct burner into the HRSG ductwork. Manufacturer shall coordinate the fit-up of the mating flanges with the HRSG.

D. The duct burner shall be internally insulated with mineral wool or ceramic fiber insulation covered with stainless steel lagging suitable for the maximum operating temperatures and thermal expansion.

E. Fuel gas manifold in the turbine exhaust gas flow shall be seamless stainless steel pipe. Burner castings in contact with the gas flame shall be 309 or 310 stainless steel or equal. Burner elements shall be secured to the burner frame in a manner that allows for sufficient thermal expansion and prevents the elements from sagging or vibrating.

F. Natural Gas Duct Burner and Fuel System:1. The duct burner shall produce a stable flame over the turndown range. There shall be no

objectionable pulsating noise or vibration of the flame to and from the burner face.2. The duct burner shall be designed to operate efficiently at turbine exhaust gas flow rates,

oxygen levels and temperature ranges as specified by the gas turbine manufacturer. The duct burner shall be designed to distribute the fuel gas evenly across the duct with properly sized fuel manifold. Exhaust gas flow distribution device (if required) shall be sized to maintain a pressure drop of less than 1.5" W.C. through both this device and duct burner.

3. The duct burner shall be pre-assembled as much as practical for shipping to minimize field erection time. Where multiple burner elements are used, distribution headers with pressure gauges shall be provided for the fuel gas, pilot gas and scanner cooling air. The headers shall be mounted on the burner assembly to minimize field erection time.

4. The gas pilot shall be provided as indicated in NFPA 85. The design of the pilot shall be stable under all turbine exhaust firing conditions. In case of pilot light-off failure, the safety shutoff valve on both the main and the pilot line shall be proven closed with a visual indication displayed on a local HMI screen.

5. Burner ignition source shall be spark ignited gas pilots per NFPA, Class III interruptible design. Pilot heads shall be made of 304 or 309 stainless steel. Each burner element shall have one pilot and ignition transformer. The transformers shall be pre-wired to the pilots and located in a NEMA 4 enclosure on the duct burner assembly. Pilots shall have a removable electrode to allow maintenance during turbine operation.

G. Burner shall be designed for the fuel(s) listed in Appendix C - FUEL GAS DATA & Appendix D - LIQUID FUEL DATA.

2.13 FUEL TRAINSA. Vendor shall provide necessary fuel trains based on the fuel(s) utilized and designed as

indicated in NFPA 85.B. All fuel gas piping shall be mounted on a freestanding pipe rack skid with all piping trains

mounted and instruments wired to the BMS controller.



C. All solenoid or motor operated valves and all limit devices shall be mounted on the piping skid.

D. All components shall be configured for easy maintenance access with gauges visible from the front side of skid. All wiring shall be run in conduit.

E. Field terminations shall be wired to numbered terminal blocks located in junction boxes in accordance with NFPA 70 (NEC).

F. Fuel trains shall be pre-wired, tested, and shall include:1. The following fuel gas train components shall be shipped loose to be installed by others

on the gas metering run.a. One (1) Main burner manual shutoff valveb. One (1) “Y” type strainerc. One (1) Gas Pressure regulatord. One (1) Flow meter & transmitter

2. All piping shall be neatly and compactly arranged. The following components shall be pre-piped and pre-wired to a junction box installed on the windbox piping rack and shall include the following:a. Two (2) 4 | 4 ½ | 6” burner pressure gauges with isolation valveb. One (1) Leak test cock valvec. One (1) Low fuel gas pressure switchd. One (1) High fuel gas pressure switche. Two (2) Electric | Pneumatic operated shut-off valves c/w position limit switch.f. One (1) Electric | Pneumatic operated vent valve between both shut-off valvesg. One (1) Flow control valveh. One (1) Manual shut-off cocki. One (1) Flexible hose to burner front header

3. Pilot fuel train – Natural | Propane Gasa. One (1) Manual shut-off valveb. One (1) Pressure regulatorc. Two (2) Electrically-operated shut-off valvesd. One (1) Electrically-operated vent valve between both shut-off valvese. One (1) 2-1/2” Pilot gas pressure gauge with shut-off cockf. One (1) “Y” type strainerg. One (1) Flexible hose

2.14 COOLING AIR BLOWER SKIDA. Provide two (2) scanner blowers, each sized for 100% flow, including cooling air to the

observation ports. B. The scanner blowers shall be mounted on a separate skid. C. The starters for the scanner blowers will be provided by the others along with the motor

control center (MCC). D. Provide controls to automatically start the second scanner blower in the event the operating

scanner blower fails. Blowers shall be complete with inlet air filter silencers. All wiring and conduits shall be in accordance with NFPA 70 (NEC).

2.15 FRESH AIR FAN & DRIVE (OPTIONAL)



A. Fresh air fan, centrifugal type with grease-lubricated bearings, arrangement 4 with flanged housing for wheel removal, shall be windbox mounted (if capacity is < 200 BHP). Fan larger than xx BHP to be mounted per arrangement X

B. Fresh air fan is designed to include sufficient margin to operate within the guaranteed burner performance. Fan shall be constructed of ¼ inch steel, as a minimum, with sufficient stiffeners to control vibration and noise (less than 85dBa at 3ft).

C. 480 V/3 PH/60 Hz motor, 3,600 RPM up to 25 BHP | 1,800 RPM, PREMIUM efficiency, Totally enclosed fan cooling (TEFC), motor service factor: 1.15.

D. A silencer shall be provided to dampen the sound emitted from the inlet of the combustion air system. Noise level shall be limited to less than 85 dBa at 3ft.

E. Provide one (1) fresh air damperF. Provide one (1) double louver | tandem louver damper with actuator and seal air fan to

isolate the fresh air fan from the hot exhaust.2.16 DAMPER(S).

A. Each multi-blade damper shall include all equipment to deliver a complete and functional system: damper actuator, positioner, limit switches and mechanical stop(s). The limit switches shall be positioned at the damper end opposite to the actuator.

B. The damper actuator shall not drive the damper directly from the main drive shaft. The actuator shall be mounted remotely, and shall be connected to the damper main drive shaft by an interconnecting linkage assembly. The interconnecting linkages and linkage arms shall be designed such that they allow a slower damper opening at the beginning of the damper travel (Square root curve type). It shall also be designed such that the output curve can be adjusted.

C. All damper blades shall be of airfoil type and shall be supported by bearings equipped with grease fittings

D. The damper leakage, in the fully closed position, shall not exceed 10% of the wide open flow condition.

E. The damper shall not exceed 0.5’’ wc permanent pressure loss when in full open position at the maximum flow

F. FGR damper shall be of the butterfly type mounted on graphite packing gland with pneumatic actuator. Position switches for high fire and low fire shall be mounted on the damper shaft.1. The damper leakage, in the fully closed position, shall not exceed 10% of the wide open

flow condition.2. The damper shall not exceed 0.5’’ wc permanent pressure loss when in full open position

at the maximum flow.2.17 BOILER CONTROL SYSTEM

A. A control panel will be provided and mounted on the fuel train | within a freestanding panel. B. The combustion and feedwater controls shall consists of one (1) PLC based controller

mounted and wired in the boiler control panel.C. Duct burner firing rate control shall be control via the drum pressure transmitter | main steam

header pressure transmitter | demand signal provided by purchaserD. Turbine Handshaking E. Feedwater Controls.

1. A single element feedwater control system shall control the drum level. (Optional)SECTION 15554 Rev A.WATERTUBE BOILER of 27


2. A two element feedwater control system shall control the drum level. (Optional)3. A three element feedwater control system shall control the drum level. (Optional)

F. BURNER MANAGEMENT SYSTEM1. Vendor to provide a complete package pre-wired and tested burner management system

for single | dual fuel.2. The BMS shall be comprised of hardwired relay contacts, a Programmable Logic Controller

(PLC) and a flame detection system. The hardwired relay contacts shall provide safety interlocks, control trip functions and serve as input/output interface between the PLC and selected field devices. The PLC shall be manufactured by Allen-Bradley with Ethernet communications capabilities to HRSG or User’s Balance of Plant (BOP) Control System. A minimum of 20% spare analog and discrete I/O shall be provided. The BMS shall include a Human Machine Interface (HMI). The HMI shall be manufactured by Allen-Bradley.

3. The BMS control panel shall include a flame scanning system to properly shutdown the burner system in the event of pilot or main flame failure during duct burner operation. The flame scanners shall be mounted with an adjustable base joint to allow optimal flame sighting and shall be pre-wired to local panel mounted on the duct burner assembly. The flame scanners shall be air purged and properly cooled to protect them from excessive heat and debris.

4. The flame scanner(s) shall detect only flames of sufficient intensity to safely light or maintain each duct burner element.

5. The BMS shall shut down the duct burner in the event of power failure or failure of the electrical supply to the BMS.

6. An audible alarm shall be provided to signal any BMS shutdown.7. The BMS control panel shall include an emergency stop pushbutton.8. The BMS panel shall have as a minimum the following displays or indicating lights on the

panel:a. Power onb. Limits completec. Purge in progressd. Purge completee. Pilot Valves Energized.f. Main Gas Valves Energizer (Gas Fuel Only)g. Flame Detected

9. The BMS shall have as a minimum the following safety interlocks to insure safe startup of the burner.a. Low Exhaust Gas Pressure Switchb. Low Fuel Gas Pressure Switchc. High Fuel Gas Pressure Switchd. Low Scanner Air Pressure Switche. High Combustion Chamber Temperature Switchf. Low Instrument Air Pressure Switchg. Position Switch on Main Downstream Fuel Gas Safety Shutoff Valveh. Low Fire Switch on the Main Fuel Gas Flow Control Valve

10. The BMS shall be shipped fully assembled and factory tested. All field terminations shall be wired to numbered terminal blocks. All wiring shall be in accordance with NFPA 70 (NEC).


PURCHASERPROJECT NAME2.18 PLANT MASTER

A. Vendor to provide a complete package pre-wired and tested plant master control.B. The IWT Plant Master shall control the boilers in unison modulation | lead-lag. C. The system shall include auto-rotation control to maintain equal amount of run hours on each

boiler in the system. Setup and control are easy with the HMI’s user-friendly menu system and setup screens.

2.19 DIVERTER (OPTIONAL)2.20 GUILOTINE DAMPER (OPTIONAL)2.21 STACK

A. Vendor to provide one freestanding stub stack mounted atop the economizer | grade mounted with overall height of xx ft with the necessary inlet ducting and expansion joints as required.

B. Shell material shall be carbon steel and painted | weathering steel | stainless steel.C. Stack shall include x number of port(s) complete with ladders and platforms to access.D. Stack shall include personal protection at grade (if required), ladder, platform. (Optional)E. Stack shall be external insulated and lagged. (Optional)

2.22 DUCTING / BREECHING / SUPPORT STRUCTUREA. Vendor to provide inlet hot-to-cold expansion joint (optional)B. Vendor to provide inlet ductwork from gas turbine to heat recovery steam generator.C. All require flow correction devices shall be provided integral to the ductwork provided and

require no additional field work to install.D. Vendor to provide all necessary structural supports for the ducting, equipment, and stacks.E. Vendor to provide all necessary combustion air ducting with necessary gaskets material.

(optional)F. Vendor to provide all necessary breeching between the boiler and stack with necessary gasket

material.G. Access doors shall be provided between equipment to allow for proper maintenance.H. Expansion joints as needed to allow for expansion of equipment.I. Support structures and ducting shall be bolted to allow for ease of installation at site. Welded

connections shall be minimized.J. Insulation and lagging of breeching, ductwork, and expansion joints downstream of the boiler

shall be by others.2.23 PLATFORMS AND LADDER (OPTIONAL)

A. Vendor to provide a steam drum length platform with support clips and necessary ladders.B. Vendor to provide access platforms and ladders to each end of the steam drum.C. Vendor to provide access platforms and ladders to economizer.D. Platforms and ladders shall be hot dipped galvanized | painted.E. Platform and ladders connections shall be bolted to allow for ease of installation at site.

Welded connections shall be minimized.2.24 SPARE PARTS

A. Vendor shall provide an itemized priced spare parts list with proposal.



B. Vendor to include two additional sets of drum manway gaskets, additional gauge glass, and additional observation port lenses.

PART 3 - EXECUTION 3.1 WARRANTY

A. All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-up, or 18 months from date of shipment; whichever comes first.

B. 5-year pressure part and burner proprietary parts warranty. (Optional)3.2 SHOP TESTS

A. Prior to shipment, the vendor shall perform the following tests as applicable to the steam generating units:1. Before being enclosed in the setting, the pressure vessels shall receive a hydrostatic test

as required by Section 1 of the ASME Boiler and Pressure Vessel Code. The manufacturer shall furnish properly executed ASME Manufacturer's Data Sheets as required by ASME code.

2. Before the application of insulation and casing, the unit(s) shall be given an enclosure air tightness test. The air test pressure shall be 2 inches W.G. above the predicted maximum furnace operating pressure. The air shall be admitted to the unit(s) until the test pressure is reached, then the unit sealed. If the pressure drop does not exceed 5.0 inch W.G. in ten minutes, the unit(s) will considered satisfactorily tight.

B. Prior to shipment, the vendor shall perform the following tests as applicable to the control system:1. The vendor shall perform a Factory Acceptance Test (FAT) on the Burner Management

System and Combustion Control System.3.3 INSTALLATION

A. Install equipment in strict compliance with manufacturer's installation instructions.B. Install equipment in strict compliance with state and local codes and applicable ASME and

referenced standards.C. Maintain manufacturer's recommended clearances around sides and over top of equipment.D. Install components that were removed from equipment for shipping purposes.E. Install components that were furnished loose with equipment for field installation.F. Provide all interconnecting electrical control and power wiring. (Optional)G. Provide all fuel gas vent and service piping.H. Provide all piping for boiler pipe connections.

3.4 PRE-COMMISSIONING / STARTUP / COMMISSIONINGA. The boiler manufacturer shall furnish the services of a company-trained engineer for a

minimum period of 20 days (single fuel) working days to assist and instruct the owner’s operating personnel in the boiler out, starting up, adjustment and operation of boiler and firing equipment and all other equipment furnished by the boiler manufacturer. All fuel, water, boil-out chemicals, power and labor required during startup, adjustment, and operating of equipment will be furnished by the purchaser. Additional time shall be quoted at a per diem rate. Rates to be provided as part of the vendor’s proposal.



B. All adjustments to boiler, burner, and boiler control system shall be performed by the manufacturer’s authorized service requirements.


PURCHASERPROJECT NAMEAPPENDIX A - HRSG PERFORMANCEFuel Gas Performance

Case Identifier 1 2 3 4 5Turbine Fuel Turbine Exhaust Flow lb/hrTurbine Exhaust Temp. °FAmbient Temperature °FTurbine Load %N2 % vol.O2 % vol.CO2 % vol.H2O % vol.SO2 % vol.Ar % vol.NOx ppmvd @ 15% O2

CO ppmvd @ 15% O2

VOC ppmvd @ 15% O2

HRSG Data Steam Flow lb/hrSteam Temp. °F ± 10°FSteam Pressure (NRV) psigSteam Drum Pressure psigSpray Water Flow lb/hrFeedwater Flowrate lb/hrFeedwater Temperature °FGas Inlet Temperature °FBoiler Outlet Temperature °F ± 10°FGas Exit Temp °F ± 10°FBlowdown %Pinch °FApproach °FTotal Gas ΔP in. WCBurner Data Duct Burner Fuel Flame Temp °FBurner Duty – HHV mmbtu/hrBurner Duty – LHV mmbtu/hrProducts of Combustion N2 % vol.O2 % vol.CO2 % vol.H2O % vol.SO2 % vol.

*Items highlighted in yellow shall be guaranteed.


PURCHASERPROJECT NAMELiquid Fuel Performance

Case Identifier 1 2 3 4 5Turbine Fuel Turbine Exhaust Flow lb/hrTurbine Exhaust Temp. °FAmbient Temperature °FTurbine Load %N2 % vol.O2 % vol.CO2 % vol.H2O % vol.SO2 % vol.Ar % vol.NOx ppmvd @ 15% O2

CO ppmvd @ 15% O2

VOC ppmvd @ 15% O2

HRSG Data Steam Flow lb/hrSteam Temp. °F ± 10°FSteam Pressure (NRV) psigSteam Drum Pressure psigSpray Water Flow lb/hrFeedwater Flowrate lb/hrFeedwater Temperature °FGas Inlet Temperature °FBoiler Outlet Temperature °F ± 10°FGas Exit Temp °F ± 10°FBlowdown %Pinch °FApproach °FTotal Gas ΔP in. WCBurner Data Duct Burner Fuel Flame Temp °FBurner Duty – HHV mmbtu/hrBurner Duty – LHV mmbtu/hrProducts of Combustion N2 % vol.O2 % vol.CO2 % vol.H2O % vol.SO2 % vol.

*Items highlighted in yellow shall be guaranteed.


PURCHASERPROJECT NAMEAPPENDIX B - SITE AND UTILITY DATA

Site Location: TBD, NE USASite Elevation: 0 FASLAtmospheric Pressure: 14.696 psia

Burner Location: OutdoorsControl Panel Location: Outdoors

Ambient Temperature & Combustion Air Temperature / Relative Humidity:Maximum: 100°F / 70%Design: 59°F / 60%Minimum: 32°F / 50%

Indoor Temperature / Relative Humidity:Maximum: 100°F / 70%Design: 59°F / 60%Minimum: 32°F / 50%

Outdoor Instrument Temperature:Maximum: 100°F / 70%Design: 59°F / 60%Minimum: 32°F / 50%

Electrical:Motors < 5 HP: 480 V / 3 Ph / 60 HzMotors ≥ 5 & < 200 HP: 480 V / 3 Ph / 60 HzMotors ≤ 200 HP: 480 V / 3 Ph / 60 Hz

Enclosures Rating:Junction Box & Wiring: NEMA 4Control Panel: NEMA 4Wiring: NEMA 3R

Area ClassificationJunction Box & Wiring: Non-HazardousControl Panel: Non-HazardousWiring: Non-Hazardous


PURCHASERPROJECT NAMEAPPENDIX C - FUEL GAS DATA

Fuel NameMethane CH4 % vol.Ethane C2H6 % vol.Propane C3H8 % vol.Butane C4H10 % vol.Pentane C5H12 % vol.Hexane C6H14 % vol.Ethylene C2H4 % vol.Propylene C3H6 % vol.Butylene C4H8 % vol.Benzene C6H8 % vol.Toluene C6H7-CH3 % vol.Acetylene C2H2 % vol.Ammonia NH3 % vol.Hydrogen H2 % vol.Car monoxide CO % vol.Car dioxide CO2 % vol.Nitrogen N2 % vol.Water vapor H2O % vol.Hydrogen sulfide H2S % vol.Oxygen O2 % vol.Sulfur dioxide SO2 % vol.Total

MW Lb/lbmolLower Heating Value - LHV Btu/lbHigher Heating Value - HHV Btu/lb Minimum Pressure psigNormal Pressure psigMaximum Pressure psig Minimum temperature °FNormal temperature °FMaximum temperature °F


PURCHASERPROJECT NAMEAPPENDIX D - LIQUID FUEL DATA

Fuel NameCarbon % vol.Hydrogen % vol.Sulfur % vol.Oxygen % vol.Nitrogen % vol.Moisture % vol.Ash % vol.Total

Deg APIViscosity SSULower Heating Value - LHV Btu/lbHigher Heating Value - HHV Btu/lb Minimum Pressure psigNormal Pressure psigMaximum Pressure psig Minimum temperature °FNormal temperature °FMaximum temperature °F


PURCHASERPROJECT NAMEAPPENDIX E - PLOT PLAN AND SPACE REQUIREMENTS


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