05/15/15
DESIGN NO. _____
SECTION 15555
FIRE-TUBE BOILERS (STEAM)
PART 1 - GENERAL
1.01
DESCRIPTION OF WORK
A.
6
5
1.02
1.03
Provide equipment required for complete installation of low
pressure, fire-tube (steam) boilers/burner units suitable for
burning No. 2 fuel oil or natural gas. The burner specified
in Section 15592 shall be part of the packaged 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
A.
Division 1 Sections
B.
Divisions 2 to 9 Sections
C.
Division 15 Sections
D.
Division 16 Sections
SUPPLEMENTAL SUBMITTALS
A.
Product Data
1.
B.
6
C.
NYCSCA
Submit manufacturer's refractory floor technical data.
Shop Drawings
1.
Submit details of the boiler fabrication and combustion
chamber.
2.
Wiring Diagrams: Detail power, signal, and control
wiring. Differentiate between manufacturer-installed and
field-installed wiring.
3.
Gas Piping or Fuel Oil Piping Diagrams.
Test Reports
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.
FIRE-TUBE BOILERS (STEAM) 15555 - 1
05/15/15
D.
11
5
NYCSCA
DESIGN NO. _____
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:
or
fuel
input
Certificate
of
a.
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
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.
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.
FIRE-TUBE BOILERS (STEAM) 15555 - 2
05/15/15
DESIGN NO. _____
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.
5
5
E.
7.
Contractor’s start-up and demonstration affidavit.
8.
DOB Field Certification for field assembled pressure
vessels. Provide completed ‘H-2’ Manufacturer’s Data
Report and the completed Appendix C of ASME CSD-1
required by the ASME Boiler and Pressure Vessel Code for
field assembled pressure vessels or boilers per Section
MC 1011.1.
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
80Et
per DOE 10 CFR Part 431
ASHRAE 90.12010
and
2014 NYCECC
Boilers
Oil
Fired
>2,500,000
BTUH
10
83Et
per DOE
Part
431
ASHRAE 90.12010
and
2014 NYCECC
CFR
** 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.
6
NYCSCA
2.
Submit operating instruction manuals, complete with
schematic wiring and piping
diagrams,
for the
boiler/burner units and all combustion and operating
controls.
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
be framed and mounted where directed in the Boiler Room.
Frame shall be of aluminum satin finish, with one side
FIRE-TUBE BOILERS (STEAM) 15555 - 3
05/15/15
DESIGN NO. _____
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
Maintenance Data: Submit Maintenance Manual for
boilers/burners, controls, and accessories; including
"trouble-shooting"
maintenance
and
preventative
maintenance schedule and procedures.
F.
Maintenance Materials
G.
Provide a set of manufacturer’s guarantees for each boiler,
burner and other fuel burning systems.
SUPPLEMENTAL QUALITY ASSURANCE
A.
Codes and Standards
1.
Boiler Testing and Rating: in accordance with American
Boiler Manufacturer's Association (ABMA): Packaged FireTube Rating.
2.
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.
NYCSCA
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 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.
FIRE-TUBE BOILERS (STEAM) 15555 - 4
05/15/15
DESIGN NO. _____
b.
NYCSCA
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
other aspects of the submittal comply with the
basis of design, subject to subsequent Factory or
Field prototype testing.
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
FIRE-TUBE BOILERS (STEAM) 15555 - 5
05/15/15
DESIGN NO. _____
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
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.
3.
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.
4.
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.
5.
Ancillary electrical components along with the boilers,
burners or boiler/burners shall be Underwriters’
Laboratories (UL) listed.
FIRE-TUBE BOILERS (STEAM) 15555 - 6
05/15/15
5
5
DESIGN NO. _____
6.
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 Energy
Conservation Code. The UL listing shall be indicated on
the Shop Drawings, and labeled on equipment.
7.
NYCECC Compliance:
Boilers shall meet the minimum
efficiency requirements of the New York City Energy
Conservation Code.
8.
New York State Industrial Code Rule 4 (12NYCRR4).
9.
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.
10.
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.
11.
All boiler combustion systems shall be compliant with
ASME CSD-1-2004 per Section MC 1004.1 of the 2014 NYC
Mechanical Code and Section FGC 631.1 of the 2014 NYC
Fuel Gas Code.
12.
Field
Erected
MC 1004.1.1:
a.
NYCSCA
Boiler
Requirements
per
Section
The vessel erector shall hold the appropriate ASME
stamp for vessel construction. The licensed
FIRE-TUBE BOILERS (STEAM) 15555 - 7
05/15/15
DESIGN NO. _____
installer is responsible for the installation of
all controls and burners which shall be designed
and
constructed
in
accordance
with
the
requirements of ASME CSD-1 and, as applicable, the
ASME Boiler and Pressure Vessel Code, 12 NYCRR
Parts 4 and 14, and NFPA 85.
b.
The New York City Department of Environmental
Protection shall approve the installation of the
boiler and burner for compatibility, controls and
safety devices.
c.
Boiler vessels shall
following listings:
1)
UL 726 or
applicable;
2)
UL 2106; or
UL
comply
795
(or
with
ANSI
Exception:
Unlisted
equipment
Department of Buildings approval.
1.05
Z21.13)
shall
the
as
obtain
d.
Controls and safety devices shall be tested and
inspected in accordance with ASME CSD-1 and, as
applicable, the ASME Boiler and Pressure Vessel
Code, 12 NYCRR Parts 4 and 14, and NFPA 85.
Testing and inspection shall be performed by the
burner manufacturer’s authorized representative in
the presence of the licensed installer.
e.
Inspection of the installed boiler assembly shall
be performed by the Department of Buildings.
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
of
SUPPLEMENTAL DELIVERY, STORAGE, AND HANDLING REQUIREMENTS
A.
1.06
one
Coordinate the size and location of the concrete pad on which
boiler/burner units are to be mounted.
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.
FIRE-TUBE BOILERS (STEAM) 15555 - 8
05/15/15
1.07
MAINTENANCE MATERIALS
A.
1.08
DESIGN NO. _____
Furnish with each boiler, all necessary tools for opening
manholes, handholes, front and rear covers; also brushes for
cleaning boiler tubes.
WARRANTY
A.
The guarantee period – one year - start date shall be the
date of Substantial Completion.
PART 2 - PRODUCTS
2.01
MANUFACTURERS
A.
Subject to compliance with requirements, manufacturers
offering packaged fire-tube boilers which may be incorporated
in the work include, but are not limited to, the following:
Burnham Corp.
Cleaver-Brooks; Div Aqua-Chem, Inc.
Johnston Boiler Co.
Easco Boiler Corp.
Best Boilers Inc.
B.
Acceptable Boiler Models (pending approval with burner
utilized and meeting the efficiency requirements of Table A):
Burnham
Cleaver
Brooks
Johnston
Easco
Series 5
4WI
509-PFTA
PLW, FST, 5A,B,C,D,
ESP
E
Firetube and
4F Firebox
2.02
2
11
6
NYCSCA
Best Boilers
and
PACKAGED FIREBOX
A.
General: All materials used in the fabrication of the boilers
shall be manufactured in the United States.
Boilers/Burners shall be factory assembled and tested and
shall be packaged three or four-pass wetback of the firebox
design. Boilers shall be mounted on heavy steel base frame,
complete with integral forced draft No. 2 fuel oil or natural
gas burner, burner controls, and boiler trim, automatic
combustion, operating and safety controls; draft fan, piping
and wiring and shall include all additional steel members
required to mount the control panel, fans and motors, oil
pumps and motors, forced draft No. 2 fuel oil or natural gas
burners and all other items and accessories. Assemble and
FIRE-TUBE BOILERS (STEAM) 15555 - 9
05/15/15
DESIGN NO. _____
wire boiler/burner units so that only water, steam, fuel,
blowdown, electrical, and vent connections are required.
Provide 5 square feet of heating surface per rated bhp.
NYCSCA
B.
Smoke Boxes; front and rear smoke boxes shall be constructed
of not less than 1/4" steel plate and welded to the boiler
with a continuous seam. Rear smoke box shall have top or
back outlet fitted with a collar for connection to the smoke
pipe.
Provide an ample size removable gasketed pressure
tight access panel in the rear smoke box. Panel shall be
located at the bottom of the smoke box when a rear smoke
outlet is required, and at the back of the smoke box when a
top smoke outlet is required. Where a rear smoke outlet is
supplied, length of smoke box shall provide access for
expanding, rolling, and beading of the tubes.
A fully
gasketed pressure-tight inspection door shall be located on
both sides of the rear smoke box. One of these doors shall
be fitted with a spring-equipped closing device to provide
explosion relief.
Explosion relief door can be provided
elsewhere on the boiler, as approved. The front smoke box
shall be provided with doors.
C.
Doors: steel plate hinged, sealed with heat resistant
gaskets, fitted with an explosion relief device. Doors and
door hardware shall not become a missile nor should they
separate from the boilers during explosion. Design doors so
front and rear tube sheets and all flues are fully accessible
for inspection and cleaning when doors are open. Provide
observation ports at each end of boiler for inspection of
flame conditions. Provide refractory and insulation in door
construction, accessible for inspection and maintenance.
D.
Refractory: Provide all boilers with refractory and
insulation. Provide easy access to all refractory surfaces.
All fire clay brick and shapes utilized in lining the
combustion chamber and flue gas baffling shall be super duty
fireclay brick.
E.
Insulation and Jacket: minimum of 2" thick fiberglass blanket
insulation on boiler shell, cover with sheet metal jacket of
manufacturer's standard gage.
F.
Painting: hard enamel finish on boiler, base frame, and
components assembly.
Ample touch up paint must be made
available at project completion.
G.
Tubes: each boiler shall be provided with tubes of such
number and length as to obtain the required heating surface
indicated on the Drawings. Tubes shall be 2", 2½" or 3" in
diameter with a wall-thickness not less than 0.105". Their
positions shall be staggered and spaced to permit free water
FIRE-TUBE BOILERS (STEAM) 15555 - 10
05/15/15
DESIGN NO. _____
circulation. Tubes shall be formed of hot finished seamless
steel (ASTM A192 or ASME SA-192), or of electric resistancewelded low carbon steel (ASTM A178 or ASME SA-178). Tubes
shall be tightly expanded into openings in tube sheets by
means of a roller type expander, with the ends of uniform
length and not broken with chipping chisel. Ends of tubes
shall not extend more than 3/8" or less than 1/4" beyond the
face of the tube sheets and shall be flared, rolled over and
beaded.
H.
NYCSCA
Outlets
1.
Each boiler shall be provided with outlets welded to the
shell, of the size and type required. All outlets shall
be protected with shipping plugs or metal caps, and
flanged outlets with suitable blank flanges before the
boilers are shipped from the factory. Unused outlets
shall be plugged with brass plugs after installation of
the boilers, and shall be proven tight under pressure.
2.
Provide an overfire draft sampling tube in the rear wall
or side wall (near the rear) of the combustion chamber.
Vent outlet taps are not permitted. Tube shall be 1¼"
minimum size, Schedule 80 pipe, with male thread at
outside end and shall extend not more than 1/2" beyond
the combustion chamber wall surface at least 3" beyond
the outer wall (to allow for boiler insulation) where it
shall be fitted with a full size cross tee. This shall
be utilized for sequential draft control signal piping
and shall contain a cross tee at every directional
change. All unused openings shall be plugged with a
brass plug.
I.
Manhole, Handholes: Provide manhole in top of the shell of
each boiler with a steel manhole cover having bolt, yoke and
gasket. Each boiler shall be equipped with a suitable number
of handholes or screwed washout openings with brass plugs.
J.
Grounding of Boilers: Coordinate with the Division
Electrical Contractor for the grounding and bonding
equipment (Reference Section 16450).
K.
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 mounted on a steel plate secured to front smoke box door.
L.
Steel Base: mount boiler/burner units on a minimum 6" height
heavy structural steel base, designed to support the
completely assembled unit. Provide base with jacking pads
and lugs to facilitate lifting and handling.
FIRE-TUBE BOILERS (STEAM) 15555 - 11
16
of
05/15/15
DESIGN NO. _____
M.
Rings shall be provided for the bottom of water legs, for the
burner opening, and for the inspection door.
N.
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).
Exception: Shutoff valves are not required in a system having
a single low-pressure steam boiler of 350,000 Btu/h output or
less.
O.
2.02
2
PACKAGED FIRETUBE SCOTCH DESIGN
A.
Scotch Marine boiler/burners shall be factory assembled and
tested, packaged three-pass or four-pass horizontal firetube
boilers of the wetback type. Boiler/Burner units shall be
mounted on heavy steel base frame, complete with integral
forced draft No. 2 fuel oil or natural gas burner, burner
controls, boiler trim, and refractory and shall include all
additional steel members required to mount the control panel,
fans and motors, oil pumps and motors, forced draft No. 2
fuel oil or natural gas burners 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. Provide 5 sq. ft of heating surface
per rated BHP.
B.
Smoke Box, Burner Windbox: a smoke box of 1/4" min steel
plate, fitted with a collar for connection to the smoke
breeching, shall be welded to the boiler with a continuous
seam. A fully gasketed pressure-tight inspection door shall
be located on both sides of the rear smoke box. One of these
doors shall be fitted with a spring-equipped closing device
to provide explosion relief. Explosion relief door can be
provided elsewhere on the boiler, as approved. The front
smoke box shall be provided with doors.
11
6
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
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).
FIRE-TUBE BOILERS (STEAM) 15555 - 12
05/15/15
DESIGN NO. _____
C.
Doors: steel plate hinged, sealed with heat resistant
gaskets, fitted with an explosion device. Doors and door
hardware shall not become a missile nor should they separate
from the boilers during explosion. Design doors so front and
rear tube sheets and all flues are fully accessible for
inspection and cleaning when doors are open.
Provide
observation ports at each end of boiler for inspection of
flame conditions. Provide refractory and insulation in door
construction, accessible for inspection and maintenance.
D.
Refractory: Provide all boilers with refractory and
insulation. Provide easy access to all refractory surfaces.
All fire clay brick and shapes utilized in lining the
combustion chamber and flue gas baffling shall be super duty
fireclay brick.
E.
Insulation and Jacket: minimum of 2" thick fiberglass blanket
insulation on boiler shell, cover with sheet metal jacket of
manufacturer's standard gage.
F.
Painting: hard enamel finish on boiler, base frame, and
component assembly.
Ample touch up paint must be made
available at project completion.
G.
Tubes: each boiler shall be provided with tubes of such
number and length as to obtain the required heating surface
indicated on the Drawings. Tubes shall have a wall-thickness
not less than 0.105". Their positions shall be staggered and
spaced to permit free water circulation.
Tubes shall be
formed of hot finished seamless steel (ASTM A192 or ASME SA192), or of electric resistance-welded low carbon steel (ASTM
A178 or ASME SA-178). Tubes shall be tightly expanded into
openings in tube sheets by means of a roller type expander,
with the ends of uniform length and not broken with chipping
chisel. Ends of tubes shall not extend more than 3/8" or
less than 1/4" beyond the face of the tube sheets and shall
be flared, rolled over and beaded.
H.
Outlets
NYCSCA
1.
Each boiler shall be provided with outlets welded to the
shell, of the size and type required. All outlets shall
be protected with shipping plugs or metal caps, and
flanged outlets with suitable blank flanges before the
boilers are shipped from the factory. Unused outlets
shall be plugged with brass plugs after installation of
the boilers, and shall be proven tight under pressure.
2.
Provide an overfire draft sampling tube in the rear wall
or side wall (near the rear) of the combustion chamber.
Vent outlet taps are not permitted. Tube shall be 1¼"
FIRE-TUBE BOILERS (STEAM) 15555 - 13
05/15/15
DESIGN NO. _____
minimum size, Schedule 80 pipe, with male thread at
outside end and shall extend not more than 1/2" beyond
the combustion chamber wall surface at least 3" beyond
the outer wall (to allow for boiler insulation) where it
shall be fitted with a full size cross tee. This shall
be utilized for sequential draft control signal piping
and shall contain a cross tee at every directional
change. All unused openings shall be plugged with a
brass plug.
I.
Manhole, Handholes: Provide manhole in top of the shell of
each boiler with a steel manhole cover having bolt, yoke and
gasket. Each boiler shall be equipped with a suitable number
of handholes or screwed washout openings with brass plugs.
Locate wash-outs openings on the front of boilers in order to
clear the burner windbox.
J.
Grounding of Boilers: Coordinate with the Division
Electrical Contractor for the grounding and bonding
equipment (Reference Section 16450).
K.
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 mounted on a steel plate secured to front smoke box door.
L.
Steel Base: Mount boiler/burner units on a minimum 6" height
heavy structural steel base, designed to support the
completely assembled unit. Provide base with jacking pads
and lugs, or equivalent method as approved, to facilitate
lifting and handling.
M.
Saddles: Each boiler shall be supported on cast iron or steel
saddles as indicated on the Drawings. Height shall be in
accordance with the requirements of the boiler/burner unit
manufacturer.
N.
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).
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.
O.
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
FIRE-TUBE BOILERS (STEAM) 15555 - 14
05/15/15
DESIGN NO. _____
practicable, except that when an outside location is
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: Provide each boiler with an 8½" compound 30-030 dial pressure gauge having a cast aluminum case with a
metal slip ring with a black baked enamel finish. 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. 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: Each boiler shall be equipped with a combination
water column feed pump control and low water cut-off device.
Combination water column, feed pump control and low water
cut-off shall be manufactured by McDonnell & Miller, Inc.
157S-RL-1/158S, incorporating 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.
If not provided with the Combination Water Column, the Feed
Pump Control and Low Water Cutoff shall be manufactured by
McDonnell & Miller, Inc. Model 150S.
D.
Secondary Low Water Cut-Off: Each boiler shall be equipped
with a secondary low water cut-off with manual reset
function. Secondary low water 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. 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. PS801M120/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: Each boiler,
if not provided with Combination Water Column, Feed Pump
FIRE-TUBE BOILERS (STEAM) 15555 - 15
05/15/15
DESIGN NO. _____
Control and Low Water Cut-off, as described in Paragraph C.,
shall be provided with separate Feed Pump Control and Low
Water Cutoff and shall be equipped with water column complete
with gauge glass and fittings, try-cocks, and all other items
and accessories.
Provide all above equipment as a package from one of the
following manufacturers:
1.
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
Water gage illuminator: Model GL53
2.
Eugene Ernst Product Co.
EEP
EEP
EEP
EEP
EEP
EEP
58-5-2 safety boiler water column (without float)
GC451 3/4" bronze try cocks
rust proof chain, chain hooks, pull handles
403RS 3/4" heavy bronze vertical water gauge with
501 red-line gauge glass
509 illuminator
3. Ernst Gage Co.
F.
NYCSCA
Motor Operated Boiler Feed Valves
1.
Provide in the feed water piping to each boiler, a motor
operated valve that 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, singlepole double throw type which shall stop the operator at
the valve open and valve closed position.
FIRE-TUBE BOILERS (STEAM) 15555 - 16
05/15/15
G.
2.04
NYCSCA
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 effect 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
the switch.
Provide identification of switch on
boiler/burner as built wiring diagrams.
4.
Motor operated boiler feed valves shall be in accordance
with the following:
a.
Steel boilers having a waterside heating surface
of 1250 square feet or less: 1" valve size, having
a capacity index (Cv) of not less than 9.
Actuator shall be two-position type with 30-second
(maximum) timing and 160o stroke. It shall have
the ability to close against a pressure of at
least 100 psi.
b.
Steel boilers having a waterside heating surface
of more than 1250 square feet (but not more than
2500 square feet): 1¼" valve size, having a
capacity index (Cv) of not less than 16. Valve
body, linkage and actuator shall be as specified
in (a.) above.
Steam Pressure Controls: refer to Section 15592: Fuel Burning
and Handling Equipment.
Boiler shell: Designed, constructed,
tested in accordance with ASME Boiler
Code; and bearing the appropriate ASME
designed for 15 psi steam, construct
Section IV Heating Boilers.
and hydrostatically
and Pressure Vessel
label. For boilers
in accordance with
SHOP QUALITY CONTROL
A.
11
3.
SOURCE QUALITY CONTROL
A.
2.05
DESIGN NO. _____
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 at 60 psi
hydrostatic pressure. The boiler shall be stamped legibly
with all identifying marks and symbols, the manufacturer's
name, the allowable working pressure in pounds per square
FIRE-TUBE BOILERS (STEAM) 15555 - 17
05/15/15
DESIGN NO. _____
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.
2.06
BOILER CONTROL POINTS
4
A.
Boiler manufacturer shall provide integration of monitoring
and alarm functions by providing control points as indicated
in Section 15985. Boiler manufacturer shall provide gateway
to convert from their protocol to the LonWorks protocol
(LonTalk).
PART 3 – EXECUTION
3.01
SUPPLEMENTAL INSTALLATION
A.
10
NYCSCA
General
1.
Comply with Department of Buildings regulations
concerning the installation of the boilers/burners and
file with that department all required information
before starting the boilers/burners installation.
2.
Boilers/burners shall be set level on the concrete base
provided in Section 03300: Cast-in-Place Concrete in the
boiler pit. The water line in all boilers shall be the
same height above the finished floor. Install steel
shims, if necessary, to accomplish this result.
3.
Boilers/burners shall not be installed until the boiler
pit 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.
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 drawing tubes,
smoke connections, piping, and all other items and
accessories along with manufacturer's recommended
clearances around and over boilers/burners.
5.
Provide platforms/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
FIRE-TUBE BOILERS (STEAM) 15555 - 18
05/15/15
DESIGN NO. _____
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.
NYCSCA
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
Each boiler/burner unit shall be electrically grounded
as specified and recommended by the manufacturer and
regulatory agencies.
9
Contractor shall provide liquid tight flexible metal
conduit (sealtite) for final conduit connections to all
the motors.
B.
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. Provide union
with sufficient clearance for burner removal and service.
C.
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.
Provide shutoff valve and union with sufficient clearance for
burner removal and service.
D.
Steam and Condensate Piping: refer to Section 15510: HVAC
Piping.
Connect supply, return, and blowdown boiler
tappings, 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
6
6
6.
FIRE-TUBE BOILERS (STEAM) 15555 - 19
05/15/15
DESIGN NO. _____
and shall terminate at a height of about 18" above the
finished floor.
3.02
3.03
SUPPLEMENTAL 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.
3.04
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, surface and
bottom blow-offs, 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
Hydrostatic Test/Safety Valve Operation Inspection
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.
FIRE-TUBE BOILERS (STEAM) 15555 - 20
05/15/15
3.
Instruction of Authority Designated Personnel.
4.
Calibrate the parallel positioning burners.
5.
The Contractor shall perform necessary Interdisciplinary
Tests and Functional Performance Tests 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).
B.
Instruction of Maintenance Personnel: The manufacturers'
representative shall instruct all DOE 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
D.
E.
NYCSCA
DESIGN NO. _____
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 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
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
manager). Training shall be for a minimum of 40 hours.
FIRE-TUBE BOILERS (STEAM) 15555 - 21
05/15/15
3.05
3.06
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 the
Steam Boilers.
B.
Prior to start-up the Contractor shall flush and clean the
water/steam side of 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
Boilers.
ACCEPTANCE TEST
A.
3.07
DESIGN NO. _____
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.
7
5
NYCSCA
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
functional
performance
tests
have
been
successfully
completed. Refer to the Drawings and Section 15985 since a
FIRE-TUBE BOILERS (STEAM) 15555 - 22
05/15/15
DESIGN NO. _____
BMS/DDC system is to be provided and the equipment is to be
integrated into the BMS/DDC system.
3.08
COMMISSIONING OF FIRE TUBE BOILERS (STEAM)
A.
9
5
B.
HVAC Contractor shall comply with the Commissioning
Requirements of Contract Specification Section S01660 for
Fire 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:RE
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.
Engineer shall select appropriate Article based on the nature of
the boiler shown on the Drawings. Clarify if the boilers are to be
gas fired or oil fired.
3.
The salvage of equipment scheduled to be removed is to be
addressed in the scoping/design phase of new projects. The A/E of
Record shall contact the DoED Central Repair Shops in order to
determine whether there is any interest in salvaging the
components scheduled to be removed. Equipment designated to be
salvaged shall be specified by the A/E to be delivered by the
Contractor to a location designated by Shops.
The specific
equipment to be salvaged and specific delivery location shall be
precisely detailed in the bid documents.
4.
For Boilers installed in schools with LonWorks DDC temperature
control systems. Firetube 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 firetube
NYCSCA
FIRE-TUBE BOILERS (STEAM) 15555 - 23
05/15/15
DESIGN NO. _____
boiler into a BMS/DDC network would be for a special case only.
Edit as required.
5.
Delete field erection requirements if factory fabricated only
units are being installed (Factory fabricated units are typical
for most SCA projects).
6.
Edit as required for the type of fuel selected (No. 2 oil or
natural gas).
7.
Edit as required if no BMS/DDC network is to be provided.
8.
Not Used.
9.
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.
10.
11.
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.
The Authority’s preference is factory fabricated boilers.
If
project conditions are such that a field fabricated unit is
appropriate and has been approved for use on the project by the
Authority, revise language to indicate use of field erected
boilers.
NYCSCA
FIRE-TUBE BOILERS (STEAM) 15555 - 24
05/15/15
12.
Note deleted.
13.
Note deleted.
NYCSCA
DESIGN NO. _____
FIRE-TUBE BOILERS (STEAM) 15555 - 25
05/15/15
DESIGN NO. _____
LIST OF SUBMITTALS
SUBMITTAL
DATE SUBMITTED
DATE APPROVED
Product Data:
______________
_____________
1.
2.
3.
4.
Manufacturers Product Data
Installation Instructions
Capacities
Refractory Floor Technical Data
Shop Drawings:
______________
_____________
1. Details of the Boiler Fabrication
and Combustion Chamber.
2. Wiring Diagrams
3. Gas Piping Diagrams
6 4. Fuel Oil Piping Diagrams
Test Reports:
______________
_____________
______________
_____________
1. Factory Test and Inspection
2. Field Test and Inspection
Certificates:
1.
2.
3.
4.
5.
6.
5
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
8. ‘H-2’ Certification for Field
erected boilers
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
FIRE-TUBE BOILERS (STEAM) 15555 - 26