Chrysler Construction Standards
AME-PT Plants
Date 11-12-07
SECTION 15700 – BOILERS
PART 1 – GENERAL
1.1 Submittals
1.2 Quality Assurance
1.3 Delivery, Storage, and Handling
1.4 Summary
PART 2 – DESIGN AND PRODUCT
2.1 Approved Hot Water Boiler Manufacturers.
2.2 Performance Requirements.
2.3 Components.
2.4 Hot Water Boiler Trim.
2.5 Source Quality Control.
2.6 Sound Level/Noise Abatement
2.7 Paint Finish
2.8 Supervision/Service.
2.9 Training.
2.10 Electrical Controls
PART 3 -DOCUMENTION
3.1 Site Prep
3.2 Installation
3.3 Preparation for Shipment
3.4 Field Quality Control
3.5 Commissioning
3.6 Equipment Identification Data
3.7 Training
3.8 Deliverables
3.9 Spare Parts List
RELATED SECTIONS INCLUDE THE FOLLOWING
1 Division 15 Section “Basic Mechanical Materials and Methods
2 Division 15 Section “Hydronic Piping”
3 Division 15 Section “Meters and Gages”
4 Division 15 Section “Valves”
5 Division 15 Section “Hangers and Supports”
6 Division 15 Section “Machine Tool And Equipment Installation”
7 Division 05 Section “Metal Fabrication”
8 Division 17 Section “Safety”
9 Division 15 Section “Fuel Gas Piping”
10 Division 15 Section “Piping Systems Chemical Treatment and Cleaning”
11 Division 15 Section “Breechings, Chimneys and Stacks”
12 Division 15 Section “Total Maintenance Spare Parts”
15700 Boilers Page 1 of 8
Chrysler Construction Standards
AME-PT Plants
Date 11-12-07
PART 1 – GENERAL
1.1 SUBMITTALS
A. Product data shall include rated capacities of selected model, weights (shipping, installed, and operating), furnished specialties, and accessories; and installation and startup instructions.
B. Shop drawings will detail fabrication and installation of equipment assemblies. Indicate dimensions, weights, loading, required clearances, method of field assembly, components, and location and size of each field connection.
C. Wiring diagrams detailing power and control wiring will differentiate clearly between manufacturer-installed wiring and field-installed wiring.
D. Provide maintenance data for each heater, control, and accessory in the operation and maintenance manuals. Include parts list, maintenance guide, and wiring diagrams.
E. Factory test reports indicating and interpreting test results relative to compliance with specified requirements.
F. Manufacturer’s field reports, indicating work supervised and performed and related observations.
G. All installation submittals of control panels must show code clearances such as 42 inches from the front of a panel to any obstruction and 48 inches between the fronts of two opposed facing panels.
H. All exit ways must have a minimum of 28 inches.
1.2 QUALITY ASSURANCE
A. Manufacturer Qualifications: Firm experienced in manufacturing water-tube hot water heater similar to those indicated for this Project and that have a record of successful in-service performance.
B. Comply with NFPA70 “National Electrical Code” for components and installation.
C. Listing and Labeling: Provide products specified in this Section that are listed and labeled.
1. The Terms “Listed” and “Labeled”: As defined in the “National Electrical Code,” Article 100.
2. Listing and Labeling Agency Qualifications: A “Nationally Recognized Testing Laboratory” (NRTL) as defined in OSHA Regulation 1910.7.
D. (I.B.R.) Compliance: Hot Water Boiler tested and rated according to The Hydronic Institute’s “Testing and Rating Standard for Boilers,” with I.B.R. emblem on a nameplate affixed to the heater.
E. Insurance Underwriters Compliance: Control devices and control sequences according to requirements of HSB Industrial Risk Insurers.
F. ASME Compliance: Hot Water Boiler shall bear the ASME stamp and be National-Board listed.
G. Coordination: Coordinate layout and installation of boiler with related work.
1. Furnish a copy of manufacturer’s wiring diagram, (reproducible D size prints) to the electrical Installer.
2. Coordinate size and location of concrete housekeeping pads.
1.3 DELIVERY, STORAGE, AND HANDLING
A. A designated contractor or plant personnel must, prior to unloading, inspect all equipment, and all damage must be reported on the shipper and to the appropriate Chrysler project engineer and supplier.
B. All equipment delivered to the project site must be unloaded promptly and placed in its intended rough in location or inside of a facility which provides protection from the elements.
C. All equipment must be inspected by supplier at time of delivery to insure that the equipment drawings are included with the shipment, which identifies the required information to allow a quick and accurate installation.
1.4 SUMMARY
A. This specification includes gas-fired, flexible water-tube hot –water boilers.
B. This specification includes a closed hot water chemical treatment system.
PART 2 - DESIGN AND PRODUCT
2.1 APPROVED HOT WATER BOILER MANUFACTURER
A. Hot Water Boiler Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the Work include, but are not limited to, the following:
1. Cleaver-Brooks V.C. - 23485
2. Any Approved Source
2.2 PERFORMANCE REQUIREMENTS
A. Hot Water Boiler:
1. Fuel: Natural Gas
2. Thermal Efficiency: 80% Minimum
3. Output: As Scheduled
4. Flow Rate: As Scheduled
5. Temperature Rise: As Scheduled
6. Pressure Drop: As Scheduled
7. Maximum Operating Temperature: As Scheduled
8. Gas Pressure: As Scheduled or Verified at Site
B. Bypass (Shot) feeders; Cast iron or steel, for introducing chemicals into system; with funnel, shutoff valve on top, air release valve on top, drain valve on bottom and recirculating shutoff valves on sides.
1. Capacity: 5 gal.
2. Maximum Working Pressure: 100 psi.
2.3 COMPONENTS
A. Combustion Chamber Internal Insulation: Interlocking panels of vermiculite refractory insulation, high temperature cements, mineral fiber, or refractory clay for service temperatures to 2100 deg F., with a gas tight inner 16 gauge liner.
B. Heat Exchanger: Two drum, flexible water tube with tangent-tube waterwall mounted on a heavy steel frame, top, bottom and sides of the boiler shall be water cooled.
C. The boiler drums shall have handholes to facilitate boiler inspection. Boiler tubes shall be 1.5 inch I.D. with minimum 0.095 inch walls. Downcomers shall be sufficiently sized to provide natural circulation.
D. Outer Jacket: Galvanized steel with Chrysler approved paint.
E. Gas Burner: Forced Draft 460 volt 3 phase Burners with adjustable combustion air supply, gas pressure regulator, diaphragm gas valves, manual shutoff, Flame Scanner-sensing device, and automatic 100-percent safety gas shutoff.
1. Burner Firing: Modulating.
2. Burner Ignition: Electronic Intermittent Pilot with lockout.
3. Safety Controls: Energize ignition, limit time for establishment of flame, prevent opening of gas valve until pilot flame is proven, and allow gas valve to open. Stop gas flow on ignition failure. Include a redundant safety shutoff valve for the gas, utilize a (“Fireye E- 110” Flame Control).
4. Flue Gas Collector and Draft Hood: Integral with boiler casing with built-in induced draft fan, with draft gage and draft providing switches.
5. Observation port for flame adjustments.
6. Air flow switch, diaphragm type.
2.4 HOT WATER HEATER TRIM
A. Relief Valve: ASME-rated pressure relief valve, setting as scheduled at 125 psig.
B. Gage: Combination water pressure and temperature.
C. Low-Water Cutoff and Inlet Flow Switch: Automatically prevents burner operation when water falls below a safe level or on low flow through generator.
D. Operating Controls: Prewired, factory-assembled electric fixed water temperature control including pilot safety, and transformer, 24-V DC gas valve, manual main and pilot valves, and junction box.
E. A local alarm horn or bell will annunciate any safety shutdown with momentary contact alarm silencing switch.
F. Remote Controls: Provide an interface to accept a 24 VDC discrete signal for remote shutdown. Provide a local control panel to include, as a minimum, a dry contact for status indication of power on, low water cutoff, low flow cutoff, remote status and heater operating.
G. High Limit: Temperature control with automatic reset limits heater water temperature.
H. Provide hot water boiler air vent.
I. Local controls to show start lights for “call for heat”, “main fuel valve on”, “low water”, and “main flame failure”.
2.5 SOURCE QUALITY CONTROL
A. Test and inspect hot water boiler according to ASME B&PV Code, Section IV for low-pressure hot water boiler.
2.6 SOUND LEVEL/NOISE ABATEMENT
A. Comply with noise limits as set by the machine tool noise standards.
2.7 PAINT FINISH
A. Sheet Metal Parts; Prime coating prior to final assembly.
B. Exterior Surfaces: Color to be machine white, Sherwin-Williams #NPVP 5Y 9/1.
C. The supplier will be responsible for ensuring that any and all parts of this system will be painted to conform to Chrysler Standards. This will include all electrical components, piping,, tankage, guarding, and all equipment that are not immersed in liquid. (DO NOT PAINT INTERNALS OF ANY TANK).
2.8 SUPERVISION AND SERVICE
A. Supplier shall provide in the quotation adequate service time to support the installation, debug and system integration based on the project complexity. No additional funding will be provided for living and travel expenses once the P.O. is awarded. A minimum of ten (10) days of service for start-up and installation supervision for the boiler systems will be included in the quotation.
B. Service should be quoted based upon ten (10) hours per day, Monday through Friday only.
C. As a part of the quotation, supplier will also state per diem and hourly rates, including travel and living for straight time, overtime and holidays.
D. The supervision will be on call and available to the plant within twelve (12) hours of the call at anytime deemed necessary by Chrysler.
2.9 TRAINING
A. Two (2) days of on-site training service for each type of boiler system must be included in the quotation.
B. Training should be quoted based upon two (2) days, 8 hours per day of classroom and field training at the Chrysler facility for ten (10) personnel.
C. Training will include both electrical and mechanical aspects of the boiler systems
D. Pricing will include training manuals per boiler system.
E. Training will include travel and lodging and shall be submitted for straight time only.
2.10 ELECTRICAL CONTROLS
A. All electrical systems shall conform to the latest Chrysler Control Specification that is on the Web page becoming a part of this entire specification.
B. The supplier shall be responsible for supplying any and all electrical components required to make this a complete and operable system.
C. Each individual motor in the system shall have its own non-fused safety disconnect that shall be mounted and wired in close proximity to the motor it serves but not in the way of service.
D. All motors used in this program shall be T.E.F.C.B.B. “U” frame only, design permitting.
E. All motors shall be 1,750 RPM, unless specifically designated and or otherwise approved in writing.
F. All motors 3 HP and larger shall have non-PCB power factor correction capacitors. These capacitors shall be attached to the electrical panel they service and all wiring shall be complete prior to installation of the electrical panel.
G. All separation points in the system shall terminate in a junction box with terminal strips for ease of connection.
H. All wiring shall be wired in rigid (steel) conduit except at points of connections to motors, switches, etc., as defined in the Chrysler control standards.
PART 3 – DOCUMENTATION AND EXECUTION
3.1 SITE PREP
A. Examine area to receive hot water boiler for compliance with installation tolerances and other conditions affecting boiler performance.
3.2 INSTALLATION
A. Installation of the hot water boiler and associated equipment will be by the designated installing trades assigned by Chrysler per the supplier’s recommendations.
B. The supplier shall provide site supervision during the installation, start up and debug of the boiler system.
3.3 PREPARATION FOR SHIPMENT
A. Prior to shipment the vendor shall inspect the unit to verify that the unit is clean and has no foreign material or water inside. The vendor shall also inspect the unit for an external damage. The vendor shall repair any damage prior to shipment
B. All open fittings and flanged connections shall be sealed to insure no foreign materials or water can enter the unit during shipment from the vendor’s facility to the installation site.
3.4 FIELD QUALITY CONTROL
A. Manufacturer’s Field Service: Provide a factory-authorized representative to supervise the field assembly of components and installation of hot water heater, including piping and electrical connections. Report results in writing.
1. Test and adjust controls and safety systems. Replace damaged and malfunctioning controls and equipment.
B. Supervise the Hydrostatic test of the assembled hot water heater and piping, according to applicable sections of ASME B&PV Code.
C. Hot water boiler outside surface temperature shall be equal to or less than 120 deg. F.
3.5 COMMISSIONING
A. Startup Services: Provide a factory-authorized service representative for start up service and to demonstrate and train Owner’s maintenance personnel on procedures and schedules related to startup, shutdown, troubleshooting, servicing, and preventive maintenance.
B. Submit a start-up/commissioning procedure, which includes safety tagging that is brief, concise and suitable for training during closeout of the project.
3.6 EQUIPMENT IDENTIFICATION DATA
A. Nameplate: For each system and major sub-component, provide a permanent operational data nameplate indicating manufacturer, manufacture date, product name, model number, serial number, capacity, operating and power characteristics, labels of compliance, and similar essential data. Locate nameplate in an accessible location.
B. Tag: For each item identified on the Manufacturers drawings and schedules, tag the item with a specific identification number corresponding to the drawings and schedules. Tag shall be as a minimum of water repellent paper marked with permanent marker with corresponding number. The tag shall be attached to the item by means of wire and grommets.
3.7 TRAINING
A. Operation and maintenance training at the Owner’s facility shall be conducted during the On - Site Acceptance Tests. As a minimum, the training duration shall be one-day excluding travel.
B. These Training classes, to be performed by hot water boiler system manufacturer’s personnel provided by a local area distributor, shall be provided with the following: