05/15/15
DESIGN NO. _____
SECTION 15559
FLEXIBLE WATER-TUBE BOILERS (STEAM)
PART 1 - GENERAL
1.01
DESCRIPTION OF WORK
A.
3
1.02
Provide
low-pressure
(steam)
flexible
water-tube
boilers/burners units suitable for burning No. 2 fuel oil or
natural gas, as specified herein, as shown on the Drawings,
and as needed for a complete and proper installation. The
burner specified on Section 15592 shall be part of the
package boiler-burner units. Product specific requirements
are contained herein; Section 15501, General Provisions for
Heating, Ventilating and Air Conditioning Work, shall be
referred to for general requirements.
RELATED SECTIONS
1.03
A.
Division 1 Sections (General Requirements)
B.
Division 3 Sections
C.
Division 5 Sections
D.
Division 15 Sections
E.
Division 16 Sections
SUPPLEMENTAL SUBMITTALS
A.
Product Data
1.
B.
3
NYCSCA
Submit manufacturer's
technical data.
refractory
floor
and
wall
Shop Drawings
1.
Submit wiring diagrams for power and control wiring
required for final connections to boiler/burner units
and controls. Clearly differentiate between portions of
wiring that are factory-installed and portions to be
field-installed.
2.
Submit details of the boiler construction and combustion
chamber.
3.
Gas Piping or Fuel Oil Piping Diagrams
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 1
05/15/15
C.
D.
DESIGN NO. _____
Test Report
1.
Submit a factory inspection report prior to shipping
along with all the tests performed at the factory.
2.
Submit a field inspection report prior to placing the
boiler in operation along with all the tests performed
at the site.
Certificates
1.
DEP Permit:
Provide for boilers with
equaling or exceeding 2,800,000 BTUH.
2.
DEP Certification of Compliance:
Verification of
meeting DEP Assembled Equipment Acceptance Requirements
per DEP Rules Effective Feb. 17, 2014: (on DEP’s list of
accepted equipment; or UL, CSA Group or ETL Listed with
Contractor’s Professional Engineer’s Certification of
Compliance;
or
Unlisted
Custom
equipment
with
Contractor’s Professional Engineer’s Certification of
Compliance).
3.
Burner UL Listing: Submit UL 726 listing for oil burning
boilers, UL 795 (or ANSI Z21.13) listing for gas burning
boilers, UL 726 and UL 795 (or ANSI Z21.13) listings for
boilers with dual fuel burners. Per DEP requirements
effective Feb. 17, 2014, it is permissible that a new
burner be listed by UL, CSA Group, ETL, or any other
national recognized testing laboratory that uses UL
testing conditions and have their Listing Mark label.
4.
Department of Buildings (DOB) ‘H-2’ Certification:
Furnish and deliver in duplicate (prior to field start
up), one copy to the Authority (CID) and one copy to the
Boiler and Licensing Division of the Department of
Buildings of the City of New York, a certificate of test
and inspection for each boiler issued by the boiler
insurance company or State Labor Department which made
the inspection. These certificates shall furnish all
data required by the New York State and ASME Codes.
5.
DOB Certification of Compliance (Refer to Article 3.03).
6.
DEP Certificate of Operation,
Registration if applicable:
a.
NYCSCA
or
fuel
input
Certificate
of
Boilers with fuel input equaling or exceeding
2,800,000 BTUH: At the completion of the burning
system installation Work, obtain a "Certificate of
Operation" from the Department of Environmental
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 2
05/15/15
DESIGN NO. _____
Protection (Air Resources) and deliver this
Certificate of Operation to the Authority before
the
request
for
final
payment
is
made.
Certificate shall name the Department of Education
as the owner.
b.
7.
E.
Projects with boilers with fuel input less than
2,800,000 BTUH but greater than or equal to
350,000 BTUH: Must be registered with the DEP.
Deliver this Certificate of Registration to the
Authority before the request for final payment is
made. Registrations shall name the Department of
Education as the owner.
Contractor’s start-up and demonstration affidavit.
Contract Closeout Submittals:
1.
Submit factory certified prototype testing reports
indicating that all boiler/burner combinations have the
following minimum combustion efficiencies as defined
below in Table A:
TABLE A
Equipment
Type
Size
Category
Input
Minimum
Efficiency
Test
Procedure**
Boilers
Gas
Fired
>2,500,000
BTUH
80%Et per
DOE 10 CFR Part 431
ASHRAE 90.12010 and
2014 NYCECC
Boilers
Oil
Fired
>2,500,000
BTUH
DOE 10 CFR Part 431
83%Et per
ASHRAE 90.12010 and
2014 NYCECC
** Test procedures are based on 2014 New York City
Energy Conservation Code and ASHRAE 90.1-2010 as
modified by Appendix A of the 2014 NYCECC.
2.
Submit operating instruction manuals, complete with
schematic
wiring
and
piping
diagrams
for
the
boiler/burner units, all combustion and operating
controls and maintenance data.
3.
3
Framed Piping and Wiring Diagram: Provide “As Built”
wiring diagram and piping layout of the oil or gas for
the boiler/burner system. The diagram and layout shall
NYCSCA
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 3
05/15/15
DESIGN NO. _____
be framed and mounted where directed in the Boiler Room.
Frame shall be of aluminum satin finish, with one side
of frame removable and with a plywood backing. Provide
safety glass in the front.
All parts of the
installation shall be indicated exactly as installed and
shall be properly identified.
Valve identification
numbers shall agree with valve tags of Section 15502:
HVAC Identification and all piping shall be clearly
shown and labeled.
4.
1.04
F.
Maintenance Materials
G.
Provide a set of guarantees for each boiler and burner.
SUPPLEMENTAL QUALITY ASSURANCE
A.
Codes and Standards
1.
NYCSCA
Maintenance Data: Submit Maintenance Manual for
boilers/burners, controls, and accessories; including
"trouble-shooting"
maintenance
and
preventative
maintenance schedule and procedures.
Minimum Combustion Efficiency: Minimum Combustion
efficiency shall be as indicated in Table A of
Supplemental Submittals for the prototype when tested
according to the referenced test procedures to determine
efficiency for commercial space heating boilers. The
provisions related to prototype testing conducted after
the boiler submittals for the project (with interim
conditional approval of the submittals) shall only be
allowed until May 1, 2012.
a.
At the time boiler shop drawings are submitted,
Contractor shall also furnish a report certifying
that a prototype boiler of the same construction
type, fuel type and using the same burner as
specified for this project has been tested in the
factory in accordance with the requirements of
Table A. This report shall include all test data
that confirms that the requirements of Table A
have been met. This prototype testing shall be
valid for all boilers similarly configured in the
range of approximately 75 – 300 horsepower.
Prototype testing need not have been conducted by
independent third party.
b.
In the event that factory prototype testing has
not been completed prior to submittal of boiler
shop drawings this boiler submittal may be granted
"conditional" approval after verifying that all
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 4
05/15/15
DESIGN NO. _____
other aspects of the submittal comply with the
basis of design, subject to subsequent Factory or
Field prototype testing.
NYCSCA
1)
Factory Prototype Testing for Conditionally
Approved Boilers (where the prototype is
identical to the project specific boiler(s)
and functions as the prototype for testing):
Contractor/manufacturer shall proceed to
fabricate the boilers at the factory at its
own risk. Before the boiler(s) is shipped to
the site, the prototype boiler shall be
tested in accordance with the testing
methodology
as
defined
in
Table A.
Contractor/manufacturer shall submit a report
certifying the boiler(s) meets or exceeds the
applicable boiler efficiencies.
This report
shall include all data associated with the
testing
that
confirms
meeting
the
requirements of Table A. If the boiler
factory prototype testing does not indicate a
minimum combustion efficiency as required in
Table A, the boiler(s) shall not be shipped
to the site, final approval will not be
granted, and the Contractor/manufacturer
shall not be entitled to any compensation.
Contractor/manufacturer
shall
provide
a
different boiler(s)/burner combination that
complies with the specification.
2)
Field Prototype Testing for Conditionally
Approved Boilers (where project specific
boiler(s) will be the prototype for testing):
Contractor/manufacturer shall proceed to
fabricate the boiler(s) at the factory at its
own risk and ship to the site for subsequent
field manufacturer prototype testing in
accordance with the testing methodology as
defined
in
Table A.
Testing
shall
be
conducted within seven (7) working days after
boiler startup. Contractor/manufacturer shall
submit a report certifying the boiler(s)
meets or exceeds the applicable boiler
efficiencies. This report shall include all
data associated with the testing that
confirms meeting the requirements of Table A.
If the test does not indicate a minimum
combustion efficiency as required in Table A,
final approval shall not be granted and the
Contractor/manufacturer shall remove the
installed boiler(s) and/or burner and replace
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 5
05/15/15
DESIGN NO. _____
with a different boiler(s)/burner combination
that
complies
with
the
specification
including the testing requirements contained
in Table A, at no additional expense to the
Authority. All associated costs shall be
borne
by
the
Contractor/manufacturer
including, but not limited to, all removal
costs, temporary heat expenses, the costs of
the replacement boilers and/or burners and
any related General Contracting expenses such
as rigging costs, costs to open/close the
building envelope, etc.
2.
NYCSCA
DEP Bureau of Air Resources
Effective Feb. 17, 2014:
Assembly
Requirements
a.
List of accepted equipment: If the application for
the work permit is to install equipment that
appears on DEP’s list of accepted equipment, no
additional certification is required.
b.
UL/CSA/ETL listed equipment: If the application
for the work permit is to install equipment that
is listed by UL, CSA Group, or ETL, a
certification of compliance from a professional
engineer must be submitted on a form prescribed by
the DEP.
c.
Unlisted and custom equipment: If the application
for the work permit is to install custom
equipment, or equipment that is not on the DEP’s
list of accepted equipment and is not UL, CSA
Group,
or
ETL-listed,
a
certification
of
compliance from a professional engineer must be
submitted on a form prescribed by DEP.
3.
Low pressure boiler construction: in accordance with
American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section IV and the
requirements of the City of New York, the State of New
York
and
any
other
public
authorities
having
jurisdiction.
4.
Boilers shall be approved by the NYC Department of
Environmental Protection (Air Resources), and shall be
listed and labeled in accordance with UL 726 for oil or
UL 795 (or ANSI Z21.13) for gas per Section MC 1004.1 of
the 2014 NYC Mechanical Code, Section FGC 631.1 of the
2014 NYC Fuel Gas Code and 2014 NYCECC. The UL listing
shall be indicated on the Shop Drawings, and labeled on
equipment.
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 6
05/15/15
1.05
NYCECC Compliance:
Boilers shall meet the minimum
efficiency requirements of the New York City Energy
Conservation Code.
6.
New York State Industrial Code Rule 4 (12NYCRR4)
7.
Before submitting any equipment shop drawings for
approval, the HVAC Contractor, Automatic Temperature
Controls Contractor and the Equipment Vendor and
Manufacturer shall coordinate the controls required for
the system.
8.
All appliances regulated by the New York City
Construction Codes shall be listed and labeled
(reference Sections MC 301.4 and MC 301.6). Testing of
material shall be in accordance with Section §28-113 of
the NYC Administrative Code (reference Section MC
301.5). Whenever the NYC Construction Codes or the Rules
of the Department of Buildings requires that material be
listed or labeled and material proposed to be used is
not so listed or labeled, the use of such material shall
be subject to prior approval by the Commissioner (Office
of Technical Certification and Research OTCR) and such
material shall be used only to the extent set forth in
such approval. Materials that were previously approved
by the Board of Standards and Appeal (BSA) or by the
Department (MEA) before the effective date of the NYC
Construction Codes may continue to be used, but only to
the extent set forth in such approval, and only if such
approval is not specifically amended or repealed by the
Commissioner.
For factory built boilers (not field assembled) rig
boilers/burners in compliance with manufacturer's rigging and
moving instructions for unloading boilers/burners, and moving
them to final location.
SEQUENCE AND SCHEDULING
A.
NYCSCA
5.
SUPPLEMENTAL DELIVERY, STORAGE, AND HANDLING REQUIREMENTS
A.
1.06
DESIGN NO. _____
Coordinate the size and location of the concrete pad on which
boiler/burner units are to be mounted. For factory built
boilers (not field assembled) coordinate the boiler/burner
unit’s intake opening through the building.
Close the
opening after the boiler/burner units are in place.
Coordinate the placing of the grounding electrode with the
Division 16 Electrical Contractor, before pouring the
concrete. Reference Section 16450.
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 7
05/15/15
1.07
DESIGN NO. _____
MAINTENANCE MATERIALS
A.
1.08
Furnish with each boiler, all necessary tools for opening
manholes, handholes and front and rear covers.
WARRANTY
A.
Warranty period for downcomers, drums, tubes and headers
shall be 20 years for thermal shock. The guarantee period
start date shall be the date of Substantial Completion.
PART 2 - PRODUCTS
2.01
MANUFACTURERS
A.
Subject to compliance with requirements, manufacturers
offering packaged flexible water-tube boilers which may be
incorporated in the work include, but are not limited to, the
following (pending approval with burner utilized and meeting
the efficiency requirements of Table A):
Bryan Steam Corporation.
Cleaver-Brooks; Div Aqua-Chem, Inc.
Unilux Boiler Corp.
B.
Boiler Models:
Bryan Steam
Cleaver Brooks
Unilux Boiler Corp.
FLX
“Z”
DR, CLM, AB,
RV, RW Series
2.02
PACKAGED WATER-TUBE BOILERS
A.
3
NYCSCA
Boilers/Burners shall be fabricated, assembled and tested
packaged flexible water-tube design. Field work shall be done
by factory authorized technicians. All field work shall be
tested and inspected by a boiler insurance company or by NYS
Department of Labor personnel. Boilers/burners shall be
complete with integral forced draft No. 2 fuel oil or natural
gas burner mounted on a hinged backing plate for access to
the furnace; burner controls, boiler trims, operating and
safety controls, control panel, oil pumps and motors, piping
and wiring connections and all other items and accessories.
Assemble and wire boiler/burner units so that only water,
steam, fuel, blowdown, electrical, and vent connections are
required. Capacities and electrical characteristics shall be
as shown on the Drawings.
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 8
05/15/15
DESIGN NO. _____
B.
The boiler shall be of a two-drum flexible watertube design
with a tangent tube waterwall furnace mounted on a heavy
steel frame. Top, bottom and sides of the furnace shall be
water-cooled. Provide with lifting lugs on top of boiler and
accessible drain and blowdown tappings, both high and low,
for surface and mud removal.
C.
Boiler tubes shall be no less than 1½” diameter, .095" wall
thickness SA178A, electric resistance, welded carbon steel
and shall be easy to remove and replace without expanding,
rolling or welding the tube attachment to the drums. Limit
tube configuration to a maximum of three.
D.
The boiler shall have sufficiently sized
provide natural internal circulation.
E.
The boiler shall be provided with an adequate number of
inspection openings to facilitate internal boiler inspection
and cleaning. Observation ports for the inspection of flame
conditions.
F.
The tangent wall tubes shall be covered with manufacturer's
recommended thickness of insulation under a gas-tight, 11gauge inner casing and a 22-gauge steel outer casing. The
boiler base frame and other components shall be factorypainted before shipment, using a hard enamel finish.
G.
Grounding of Boilers: Coordinate with the Division
Electrical Contractor for the grounding and bonding
equipment (Reference Section 16450).
H.
Boiler Number Plate: provide a number plate for each boiler,
as required by New York City Ordinances. Numbers shall be of
solid brass, not less than 2" in height. Each number shall
be permanently mounted on the steel front wall.
I.
Every boiler shall have a shutoff valve in the supply and
return piping. For multiple boiler installations, each boiler
shall have individual shutoff valves in the supply and return
piping. (Refer to Section MC 1005.1).
downcomers
to
16
of
Exception: Shutoff valves are not required in a system having
a single low-pressure steam boiler of 350,000 Btu/h output or
less.
J.
NYCSCA
A remote control shall be provided to stop the flow of oil
and/or gas and combustion air to any burner or fuel burning
internal combustion equipment. Such control shall be located
outside all means of egress to the room in which the burner
or equipment is located and as close to such entrances as
practicable, except that when an outside location is
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 9
05/15/15
DESIGN NO. _____
impracticable, such control may be located immediately inside
the room in which the burner or equipment is located,
provided such location is accessible at all times. All such
controls shall be labeled: “REMOTE CONTROL FOR BURNER”.
(Refer to Section MC 1006.8.1).
2.03
NYCSCA
BOILER TRIM
A.
Steam Gauges: 8½" compound 30-0-30 dial pressure gauge, cast
aluminum case with a metal slip ring and black baked enamel
finish on each boiler. Gauges shall have bronze bourdon tube,
bronze or brass socket and a geared movement of stainless
steel. Tube and movement shall be mounted on a rigid socket.
Gauges shall be installed with a gauge-cock and a syphon as
shown on the Drawings. Piping for gauge shall be brass with
malleable brass screw fittings.
B.
Safety valve or valves, in number and size to provide the
relief capacity required by the ASME Boiler and Pressure
Vessel Code. (Refer to Section 15570: Boiler Accessories)
C.
Combination water column, feed pump control and low water
cut-off where indicated on the Drawings on each boiler. The
device shall provide visual water level indication, maintain
a safe boiler water level by automatically opening a
motorized valve which shall start the boiler feed pump
whenever the water in the boiler drops to the minimum safe
level and shall also stop the burner from operating should
the water drop below the minimum safe level.
The boiler
water levels shall be in accordance with the boiler
manufacturer’s
standard
for
safe
operation,
proper
evaporation rate and mandatory code compliance. (For the feed
water pump: Refer to Section 15580: Feedwater Equipment).
The combination water column, feed pump control and low water
cut-off shall be complete with an alloy metal float, magnetic
switches, linkage, and all other items and accessories
contained in a cast iron or semi-steel housing, factory
assembled and designed to operate on 120 volts A.C.
Combination water column, feed pump control and low water
cut-off with try cock shall be McDonnell & Miller, Inc. 157SRL-1/158S, Conbraco Bronze Liquid Level Gage No. 24-651-10,
1/2" Shank, Automatic Ball Check Feature with H-2485 Pull
Handle and Chain, 5/8” Redline Gage Glass with a safe gauge
glass illuminator, (4) Gage Glass Guard Rod, Full Flow Ball
Drain Valve and (3) No. 26-504-02 1/2" Spring Loaded Lever
Air Try Cock with Pull Handle and Chain. Combination Water
Column, the Feed Pump Control and Low Water Cutoff without
try cock shall be McDonnell & Miller, Inc. Model 150S.
D.
Secondary low water cut-off with manual reset function where
indicated on the Drawings on each boiler. Secondary low water
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 10
05/15/15
DESIGN NO. _____
cut-off shall be set to function at a level lower than the
operating level of the primary cut-off specified above and
above the lowest portion of the gauge glass. It shall
interrupt the burning process should the water level in the
boiler drop below the primary cut-off and above the boilers
lowest permissible water level. The secondary low water cutoff shall be so designed that electric power will not be
restored to the burner until the manual reset button, located
on the cut-off, has been activated. Control shall be the
electric probe type, designed for 120-volt operation, UL
approved and installed in a manifold. Electric probe type
low water cut-off with manual reset shall be by McDonnell &
Miller Model No. PS801M-120/Manifold No.60-101, HYDROLEVEL
COMPANY SENSIT SAFGARD® Model No. LC967/Model No. 1214C-2
Manifold or Warrick.
E.
Water Columns/Try cocks/Glass gage/Illuminators: If not
combined with Combination Water Column, Feed Pump Control and
Low Water Cut-off specified in Paragraph C, each boiler shall
be provided with water column complete with gauge glass and
fittings, try-cocks, and all other items and accessories.
Water column shall have a heavy cast iron or steel body with
bossed tappings for water gauge, 3 try-cocks, and for steam,
water, and blow-off connections. Try cocks shall be 150 psi,
3/4" NPT, bronze body with stainless steel stem, seat and
chain hooks and pull handles. 3/4" gage valves shall be
bronze with chains and handles that indicate open/closed
position. Gage glass shall be 3/4" red lined, suitable for
pressures up to 250 psi. Gage illuminator shall consist of
60-watt lamp that provides light through 3/4" slot of 1/4"
plate glass with swing-away fasteners for easy lamp
replacement. All columns, components and welding, if any,
shall be designed and manufactured in total compliance with
ASME Code provisions and hydrostatically tested at 1.5 times
design pressure.
Provide all above equipment as a package from one of the
following manufacturers:
1.
NYCSCA
Clark-Reliance:

Cast iron column 1(without float) or steel series
W0350

Bronze gage try-cocks: Model GC451

Bronze gage valves: Model 403RS with chains and
handles

3/4" Redline Tubular gage glass
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 11
05/15/15
DESIGN NO. _____

2.
3.
NYCSCA
Water gage illuminator: Model GL53
Eugene Ernst Product Co.

EEP 58-5-2 safety boiler water column (without
float)

EEP GC451 3/4" bronze try cocks

EEP rust proof chain, chain hooks, pull handles

EEP 403RS 3/4" heavy bronze vertical water gauge
with EEP 501 red-line gauge glass

EEP 509 illuminator
Ernst Gage Co.
F.
Drain valves: 3/4" or nozzle size per manufacturer with hoseend connection.
G.
Motor Operated Boiler Feed Valves
1.
Provide in the feed water piping to each boiler, in the
location shown on the Drawings, a motor operated valve
which will be actuated by the feed pump control and low
water cut-off. The motor operated valve shall be
equipped with an auxiliary switch which, through a
relay, shall cause the feed pump to start when the valve
is open and shall cause the feed pump to stop when the
valve begins to close. Power supply to valve shall be
wired to load side of feed pump disconnect switch.
2.
Valve shall be single seated, 150 psi packed globe type,
with bronze body renewable seat and composition disc.
Motor operator shall be of heavy duty design, with gear
train completely submerged in oil, designed for 120 volt
operation. Spring return motors are not acceptable. Cam
operated limit switch shall be snap-acting, single-pole
double throw type which shall stop the operator at the
valve open and valve closed position.
3.
Provide a single-pole double throw toggle switch in the
top cover of the valve motor housing. Switch shall be
connected into the wiring circuit between the pump
control and valve motor to affect the following: With
the switch in the "Normal" position, the motorized valve
will respond to the pump control, and with the switch in
the "Closed" position, the motorized valve will close
and will remain closed until the switch position is
changed. Provide a suitably marked plastic nameplate at
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 12
05/15/15
DESIGN NO. _____
the switch. Provide identification of
boiler/burner as built wiring diagrams.
H.
2.04
switch
on
Steam Pressure Controls: refer to Section 15592: Fuel Burning
Equipment.
SOURCE QUALITY CONTROL
A.
Boiler: Designed, constructed, and hydrostatically tested in
accordance with ASME Boiler and Pressure Vessel Code; and
bearing the appropriate ASME label. For boilers designed for
15-psi steam, construct in accordance with Section IV Heating
Boilers.
2.05
9
SHOP QUALITY CONTROL
2.06
BOILER CONTROL POINTS
4
A. Boiler manufacturer shall provide integration of monitoring
and alarm functions by providing controls as indicated in
Section 15985. Boiler manufacturer shall provide gateway to
convert from their protocol to the LonWorks protocol
(LonTalk).
A. The boilers/burners shall be inspected during construction in
the shop of the manufacturer by an inspector of an approved
boiler insurance company, or of a State Labor Department and
the Authority (CID). After completion of construction, each
boiler shall be successfully tested at the shop. The boiler
shall be stamped legibly with all identifying marks and
symbols, the manufacturer's name, the allowable working
pressure in pounds per square inch, the year of manufacture,
and all other markings required by the latest editions of the
New York State and the ASME Boiler Codes. Insulating covering
shall be left off the above stampings.
PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
Examine and verify size, location, and condition of concrete
pad upon which boilers/burners are to be installed. Do not
proceed with installation until unsatisfactory conditions
have been corrected.
INSTALLATION
A.
General
1.
NYCSCA
Comply with NYC Department of Buildings regulations
concerning the installation of the boilers/burners and
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 13
05/15/15
DESIGN NO. _____
file with that department all required information
before starting the boilers/burners installation.
8
B.
2.
Boilers/burners shall be set level on the concrete base
provided in Section 03300: Cast-in-Place Concrete in the
boiler room.
3.
Boilers/burners shall not be installed until the boiler
room floor finish (whether waterproof type or not) has
been completed.
The grounding electrode shall be
installed by the Division 16 Contractor prior to the
pouring of the concrete base for the boilers/burners.
Each boiler/burner unit shall be electrically grounded
as specified and recommended by the manufacturer and
regulatory agencies.
4.
Boilers/burners shall be not less than the rating shown
on the Drawings, and the height shall fit the space
available, leaving ample allowance for replacing tubes,
vent connections, piping, and all other items and
accessories along with manufacturer's recommended
clearances around and over boilers/burners.
5.
Provide platform and/or ladders in order to grant access
to safety valves in accordance with Section MC 1004.3.1.
Per Section MC 1004.3, clearances shall be maintained
around boilers, heaters and tanks and related equipment
and appliances so as to permit inspection, servicing,
repair, replacement and visibility of all gauges. When
boilers are installed or replaced, clearance shall be
provided to allow access for inspection, maintenance and
repair. Passageways around all sides of boilers shall
have an unobstructed width as required by the
manufacturer and in no case less than 18”, unless
otherwise approved by the DOB Commissioner.
6.
Approved piping and wiring diagrams and installation
instruction shall be obtained from the manufacturer and
followed in the installation of the boilers/burners
7.
Install boilers/burners in accordance with State Code,
New York City Code and Local Utility Company
Requirements.
8.
Contractor shall provide liquid tight flexible metal
conduit (Sealtite) for final conduit connections to all
the motors.
3
Gas Piping: refer to Section 15416: Gas Piping System.
Connect gas piping to boiler/burner, full size of
boiler/burner gas train inlet as a minimum or as shown on
NYCSCA
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 14
05/15/15
DESIGN NO. _____
Drawings. Provide union with sufficient clearance for burner
removal and service.
C.
3
NYCSCA
1.
Install gas piping as per approved Shop Drawings and as
shown on the Drawings Details.
Submit to approvals
prior to fabrication and installation. Provide required
boiler clearances
2.
Gas vent piping of the gas trains shall be as specified
under plumbing work.
Oil Piping: refer to Section 15592: Fuel Burning Equipment
and Section 15510: HVAC Piping. Connect oil piping to
boiler/burner, full size of inlet to burner as a minimum or
as shown on Drawings. Provide shutoff valve and union with
sufficient clearance for burner removal and service.
1.
Install fuel oil piping as per approved Shop Drawings
and as shown on the Drawings Details. Submit for
approvals prior to fabrication and installation.
2.
Provide 100 mesh strainer baskets on strainers serving
the burners oil pumps and strainers serving the transfer
oil pumps.
D.
Steam and Condensate Piping: refer to Section 15510: HVAC
Piping. Connect supply, return, and blowdown boiler tappings
as indicated on the Drawings, with shutoff valve and union or
flange at each connection.
E.
Breeching: refer to Section 15575: Breeching, Chimneys, and
Stacks. Connect breeching to boiler/burner outlet full size
of outlet with all accessories.
F.
Installation of Boiler Trimmings: water columns shall be
mounted on the boilers at locations shown on the Drawings in
the piping size for the 3 try-cocks. Water column shall be
mounted with the visible part of gauge glass at the lowest
permissible water level defined by the manufacturer with
steam, water, and 1/2" or 3/4" valved blow-off connections.
The water connection to boiler shall not be below the center
line of the boiler shell. Blow-off and drain piping shall be
fastened to boiler with steel brackets with bolts. All drain
piping shall be brass with the unused outlets plug with brass
and shall terminate at a height of about 18" above the
finished floor.
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 15
05/15/15
3.03
3.04
CLEANING
A.
Flush and clean boilers/burners upon completion of
installation, in accordance with manufacturer's instructions
and Section 15516: Water Treatment for Boilers.
B.
Painting: Boiler/burner units shall be primed painted at the
shop with one coat of heat resistant primer. The shop coat
shall provide a complete protective covering. All damaged
spots shall be touched up before insulation is applied (Refer
to Section 09900: Painting).
FIELD QUALITY CONTROL
A.
B.
3.05
Hydrostatic Test/Safety Valve Operation Inspection
1.
Arrange for hydrostatic tests and the witnessing of
operation of all safety valves at rated pressure of the
boilers by the Department of Buildings.
Notify the
Authority and the Custodian or building manager (DoE) by
letter, at least 48 hours in advance of the time at
which such tests are to be made.
2.
Each boiler shall be connected completely, including
water feed, steam connections, boiler trim, drains, and
all other items and accessories, with valves inserted in
connections to mains, and ends left open until after
tests have been applied to prove that the valves are
tight under the specified pressure.
3.
Obtain a Certificate of Compliance (Form 276) from the
Department of Buildings and deliver to the Authority
immediately after the boiler tests have been completed.
Refer to Section 15592: Fuel Burning Equipment for testing
procedures and requirements.
DEMONSTRATION
A.
NYCSCA
DESIGN NO. _____
Preliminary Requirements: provide the services of the field
service representative of the boiler-burner unit manufacturer
for the following:
1.
Inspect each boiler/burner unit installations prior to
start-up.
2.
Supervise initial firing of boilers/burners.
3.
Instruction of Authority Designated Personnel.
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 16
05/15/15
DESIGN NO. _____
4.
B.
Instruction of Maintenance Personnel: The manufacturers'
representative shall instruct all New York City Department of
Education custodial (or building manager) maintenance
personnel and DOE Maintenance Representative in the operation
and maintenance of the boilers/burners and all items and
accessories. Provide a minimum of 40 hours for instruction
purposes, exclusive of all pre-start-up, start-up and service
call time.
C.
Start-up:
The
Contractor
shall
perform
necessary
Interdisciplinary Tests and Functional Performance Tests
(FPT) according to the manufacturer’s procedures. Start-Up
operational and safety checks, checking of alarms and
performance checks shall be witnessed by the Authority’s
Construction Inspection Division (CID).
D.
E.
NYCSCA
Calibrate the parallel positioning linkage-less
burners.
1.
A water treatment system shall be operational before any
attempt is made to start the boiler/burner units.
2.
Replace
damaged
equipment.
3.
Perform services in accordance with manufacturer's
written start-up instructions. Field start up reports to
be provided by the authorized start up representative
upon completion. Refer to Section 15592: Fuel Burning
Equipment.
or
malfunctioning
controls
and
Maintenance and Operation Training
1.
Contractor shall prepare a detailed, coordinated stepby-step maintenance and operations manuals covering all
boilers/burners equipment, tube removal and replacement
demonstration and all other items and accessories as per
Section G01730 and Section 15501.
2.
As a part of the maintenance and operating instructions,
review data in operating and maintenance manual,
including tube removal and replacement demonstration,
preventative maintenance schedule and procedures, and
procedures for obtaining repair parts and technical
assistance. Demonstrate all phases of operation
including start-up and shut-down.
Schedule training with the Authority. Provide at least 4
days notice to the Authority and the Custodian (or building
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 17
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DESIGN NO. _____
manager) and DOE Maintenance Representative. Training shall
be for a minimum of 40 hours.
3.06
3.07
BOILER CLEANING AND WATER TREATMENT
A.
The Contractor shall retain the services of a reputable water
treatment service company. This company shall test boiler
water and provide a written report with recommendation for
chemical treatment as soon as the system is filled with
water. This same company shall provide water treatment
service and inspection every two (2) weeks during temporary
heating and for one (1) year after Substantial Completion of
the school. Refer to Section 15516: Water Treatment for Steam
Boilers.
B.
Prior to start-up the Contractor shall flush and clean the
boiler to remove all rust and deposits. Cleaning agents to be
used shall be as recommended and approved by the Chemical
Treatment Firm and by the Boiler Manufacturer. Refer to
Section 15516: Water Treatment for Steam Boilers.
ACCEPTANCE TEST
A.
3.08
Boilers/Burners shall not be placed in operation until
completion of construction, inspection and testing and only
after a Certificate of Compliance has been issued by the
commissioner.
All
final
inspections
and
tests
for
boilers/burners shall be subject to the provision for Special
Inspections except that such inspections and tests shall be
made by a qualified boiler inspector in the employ of the
department or a duly authorized insurance company as provided
in section 204 of the labor law.
Equipment having a Btu
input of not more than three hundred and fifty thousand Btu
per hour shall be exempt from this requirement.
INTERDISCIPLINARY TESTS AND FUNCTIONAL PERFORMANCE TESTS
A.
Interdisciplinary Pre-Start-Up and Start-Up Tests:
The Contractor shall conduct interdisciplinary pre-start up
and start up tests as per the manufacturer’s start up
procedures. Contractor shall submit signed start up affidavit
signed by the factory authorized service representative
indicating that all of the manufacturer’s pre-start up and
start up procedures have been successfully completed.
B.
Functional Performance Tests:
Contractor shall also submit signed functional performance
testing affidavit signed by the factory authorized service
representative indicating that all of the manufacturer’s
NYCSCA
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 18
05/15/15
functional
performance
tests
have
been
successfully
completed. Refer to the Drawings and Section 15985 since a
BMS/DDC system is to be provided and the equipment is to be
integrated into the BMS/DDC system.
5
3.09
DESIGN NO. _____
COMMISSIONING OF FLEXIBLE WATER TUBE BOILERS (STEAM)
A.
7
B.
3
HVAC Contractor shall comply with the Commissioning
Requirements of Contract Specification Section S01660 for
Flexible Water Tube Boilers (Steam).
All testing for steam and condensate piping, gas piping, oil
fuel piping, hydrostatic testing of boilers, and smoke test
of boiler chimney shall be completed prior to commencement of
the commissioning process.
END OF SECTION
BB:JV
05/15/15
Notes to Specifier (Delete from Specifications)
1.
Section 15503 is to be utilized if the project involves
construction of a New Building or Addition to building in Seismic
Design Category C or D. Section 15503 is also to be utilized if
project involves retrofit work in Existing Buildings in Seismic
Design Category C or D constructed after LL17/1995 went into
effect. Use Section 15504, Vibration Isolation, (without seismic
restraints) for retrofit work on Existing Buildings constructed
prior to the effective date of LL17/1995 and for any buildings in
Seismic Design Category B.
2.
Not used.
3.
Edit as required for the type of fuel selected (No. 2 oil or
natural gas).
4.
For Boilers installed in schools with LonWorks BMS/DDC temperature
control system. Flexible water-tube boilers should only be used on
CIP projects as New Construction and Major Modification projects
will utilize gas fired condensing boilers. CIP projects will not
be provided with a BMS/DDC network. The integration of a flexible
water-tube boiler into a BMS/DDC network would be for a special
case only. Edit as required.
5.
Edit as required if no BMS/DDC network is to be provided.
6.
Not used.
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FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 19
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7.
This paragraph is intended for projects that must comply with the
NYC Green Schools Rating System (generally all capacity projects)
and the following CIP projects:
a.
b.
8.
DESIGN NO. _____
HVAC
upgrades
(boiler
replacements/
DDC-only systems/ AC upgrades, etc)
Temperature Control systems
BMS/DDC
Systems
Per Section MC 1004.3.1, steam-heating boilers and hot water
heating boilers that exceed one of the following limits: 5,000,000
BTUH input, 5,000 pounds of steam per hour, or a 1,000 square foot
heating surface and all boilers with manholes on top of the
boiler, shall have a minimum clearance of 3 feet from the top of
the boiler to the ceiling. Package boilers, steam heating boilers
and hot water heating boilers without manholes on top of the shell
and not exceeding one of the limits described herein, shall have a
minimum clearance of 2 feet from the ceiling. Where the required
clearances cannot be provided due to physical limitations, file a
reconsideration request (form BC-1) during the filing process
demonstrating the physical limitations. Show platform/ladder
details on the Drawings in accordance with Article 4-6.6 of the
New York State Industrial Code Rules for low pressure boilers.
Article 4-6.4 of the NYS Industrial Code Rules for low pressure
boilers installed in a space or room not previously used to house
a boiler (after March 31, 1965), requires access platforms over
boilers where the distance from the floor to the top of the boiler
or boiler setting exceeds eight (8) feet and the clearance of the
working surface of such platform to the lowest point of any
overhead structure shall be not less than seven feet. Edit
specification references to ladders/platforms if not required.
9.
Edit as required if work is to be done in the field.
10.
Note deleted.
11.
Note deleted.
* * *
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FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 20
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DESIGN NO. _____
LIST OF SUBMITTALS
SUBMITTAL
DATE SUBMITTED
DATE APPROVED
Product Data:
______________
_____________
______________
_____________
1.
2.
3.
4.
Manufacturers Product Data
Installation Instructions
Capacities
Refractory Technical Data
Shop Drawings:
3
1. Wiring Diagrams
2. Details of the Boiler Construction
and Combustion Chamber
3. Gas Piping Diagrams
4. Fuel Oil Piping Diagrams
Test Reports:
______________
_____________
______________
_____________
1. Factory Test and Inspection
2. Field Test and Inspection
Certificates:
1.
2.
3.
4.
5.
6.
DEP Permit
DEP Certification of Compliance
Burner listing
DOB ‘H-2’ certification
DOB Certification of Compliance
DEP Certificate of Operation
(or Registration as applicable)
7. Start-up and demonstration affidavit
Contract Closeout Submittals:
______________
_____________
1. Certified Prototype Testing
Reports (combustion efficiencies)
2. Operating Instruction Manuals
3. Framed Piping and Wiring Diagrams
4. Maintenance manual
Maintenance Materials:
______________
_____________
Manufacturer’s Guarantees:
______________
_____________
* * *
NYCSCA
FLEXIBLE WATER-TUBE BOILERS (STEAM) 15559 - 21