SPECIAL FORCES FACILITY



SECTION 1

HOT WATER BOILERS, WATER HEATERS AND ACCESSORIES

PART 1 – GENERAL

1.01 RELATED DOCUMENTS

Drawings and general provisions of the contract, including Conditions of Contract and Division 1 Specification Sections apply to this section.

1.02 SECTION INCLUDES

A. Packaged Three Pass Reverse Flame Hot Water Boiler

B. Burner

C. Hydraulic Separator

D. High Capacity Water Heaters

E. Master control panel

F. Chimney

G. Pre-Assembling

H Installation at site

1.03 SUBMITTALS

A. General: Submit the following according to Conditions of Contract and Division 1 Specifications Sections.

B. Product Data: Size, dimensions, capacity, pressure rating, accessories and special features and operating characteristics of all equipments.

C. Shop Drawing: Detailed equipment assemblies indicating dimensions, required clearances, method of field assembly, components and location and size of each field connection.

D. Wiring Diagrams: Detailed wiring diagram for each item of equipment with electric power supply. Include ladder type wiring diagrams for interlock and control wiring required for final installation. Differentiate between portions of wiring that are factory installed and portion that are field installed.

E. Maintenance Data: Submit maintenance data and parts list for each boiler, control and accessories, including “trouble shooting” maintenance guide. Include this data and product data in maintenance manual in accordance with the requirements of Division – 1.

1.04 QUALITY ASSURANCE

A. The boilers shall comply with CE certificate and with the following regulations (or harmonized regulations): EN 60335-1, EN 303-1, pr EN 303-3

In accordance with the board’s regulations:

- Gas Directive 90/396/CEE

- Low Voltage Directive 73/23/CEE (modified by 93/68)

- Efficiency Directive 92/42/CEE

- EMC Directive 89/336/CEE

B. Manufacturer must be in possession of a valid ISO quality assurance certificate.

C. Boilers tested and rated according to the Testing and Rating Standard for Boilers and shall be rated according to 92/42/CEE directives on efficiency.

D. The boiler shall be completely pre-assembled at the factory. All controls shall be tested and controls set as for normal operation.

E. Manufacturer’s Qualification: Firms regularly engaged in manufacture of boilers or types and capacities required whose products have been satisfactory used in similar services for not less than 10 years.

1.05 COORDINATION

A. Coordinate size and location of concrete bases. Concrete, reinforcement and framework requirements are to be coordinated with respective civil work.

1.06 DELIVERY STORAGE AND HANDLING

A. Product shall be delivered to site stored and protected under provisions of General Conditions of Contract.

B. Factory packaged items shall be stored in shipping containers until time of installation.

1.07 SYSTEM DESCRIPTION

A. Fully packaged three pass reverse flame hot water boilers (XXX working and XXX standby) will be installed in the boiler room of the building along with Duplex St steel High Capacity Water Heaters and all other specified related equipment to generate required temperature for the proper operation of hot water supply for the equipments.

PART 2 – PRODUCT

A. HOT WATER BOILER

2.01 GENERAL

Supply, deliver and install where indicated of hot water boiler & burner package automatic fully packaged, forced draft horizontal Three Pass Reverse Flame, fire tube type hot water boiler designed and constructed in accordance with current edition European Pressure Equipment Directive and comply with the requirements of the latest Factories Act as well as the Health and Safety Executive Guidance Notes.

2.02 MANUFACTURERS

A. Ecotherm - Austria or approved equivalent

2.03 CHARACTERISTICS OF BOILER: Quantity: XXX Nos

The hot water boiler shall be completely factory assembled with all necessary components, refractory, insulation, pipes and shall be on a heavy structure steel skids base ready for installation and operation. The wiring between control components and all safety devices shall be completed at the factory. Each unit shall have all safety and operating controls adjusted, set and tested at the factory.

The boiler shall have a capacity as stated on the drawings and the following design / working and test pressures:

Type Horizontal, forced draft, fire tube Packaged Three Pass Reverse Flame, gas or oil fired packaged steel construction.

Technical Data

Rated heating capacity max.: XXX kW

Rated heating capacity min.: XXX kW

Boiler efficiency: XXX %

Max. Operating pressure: XXX bar

Test pressure: XXX bar

Max. Temperature: XXX °C

Insulation boiler body: 80 mm

Electrical 230 v/1PH/50 Hz

The boilers shall be high performance reverse flame hot water boilers designed for gaseous and liquid fuel supply and shall combine excellent reliability and long-lasting life with high thermal efficiency (>90%) fully meeting the requirements provided 92/42/CEE, directive on efficiency.

Product quality and reliability shall be guaranteed by ISO 9001 Quality Certification of materials, components and processing precision, but also by correctly sizing thermal loads according to the volume of the combustion chamber and the boiler transfer surfaces. The design shall be well balanced to provide high performance with a focus savings on fuel, low gas temperature and reduction of polluting emissions (CO and NOx).

The front tube shall be flanged towards the furnace thus enabling efficient mechanical and thermal stress absorption.

The combustion chamber should be cylindrical with a fully wet back. A stay support is to be welded between the bottom and the rear tube plate supports of the furnace.

In designing the boiler, special attention should be given to the problem of scaling. Since this problem affects the areas in which temperature is higher, this risk should be eliminated by removing all sources of overheating and by adopting a unique tube and front plate that distribute the temperature evenly.

The boiler shall be fitted with special devices that reduce the risk of gas condense, and Improve the working life of a generator.

The design shall include a special system that conveys internal hot water flows to protect the rear plate and tubes where the risk of excessive gas cooling is the highest.

The inside of the manhole shall be made of ceramic fibre for high insulation and low thermal inertia. This shall contribute to a higher seasonal efficiency of the plant. The boiler has to be insulated with 80-mm high-density rock wool panels. Casing shall be made of easy-to-mount steel panels and reduce heat dispersions by almost 1%.

The boiler above 1400 KW shall be lagged and clad with circular stucco aluminium casings which are fitted at the factory.

The efficiency shall be guaranteed by the manufacturer to be not less than 90% over the complete range. The efficiency shall be complete as per the EN Standards using the net calorific value.

The control panel supplied with the boilers is made of self-extinguishing plastic and houses the regulation and safety instruments.

Control panel shall be complete with:

- 2 boiler control thermostats

- 2 safety limit thermostats – manual reset

- pump thermostat

- main switch

- pump on/off switch

- boiler thermometer

B. Burner: Quantity – XXX Nos

Oil, gas or dual Fired burner

BURNER EQUIPMENT

Burners shall oil, gas or dual fuel, forced draft with capacities and electrical characteristics as scheduled on the Drawings and as outlined herein.

Burners shall be of a modular design so that if any major components require replacement, the burner can be removed and the part replaced without major welding or other intrusive repairs.

Operating signals for the combustion controls shall be provided by Control System supplied by the burner manufacturer with the burner controls factory mounted in the remote burner control panel.

As a minimum, each burner shall be equipped with the following components:

Factory built and painted refractory adapter plate to bolt directly to existing boiler, built and designed as required by burner manufacturer.

TEFC blower motor with thermal overloads.

Fully two stage or modulating controls with low fire start and high turndown ration

Combination Combustion Flame Safeguard Controller with pre-purge, post-purge, UV scanner and Boiler Control System/Temperature Controller.

Gas pilot with ignition transformer, gas cock, solenoid valve and gas regulator.

Manual fuel selector switch.

Fully two stage or modulating, pressure atomizing oil burner with gas pilot oil ignition.

Burner mounted oil pump c/w magnetic clutch switching.

Oil nozzle and dual safety oil valves.

Combustion air switch.

Oxygen trim with module complete with sensor.

Control panel shall be equipped with the following:

On-off control switch.

Two indicating and alarm lights with interface/connection to building automation system for alarm monitoring.

Alarm buzzer.

Auto-manual switch with firing rate potentiometer.

Signal/duty relays.

Control transformer.

Control fuses.

Terminal strip.

Power – Min: …..kW

Power – Max: .. kW

Electric power: ..... kW

DOCUMENTATION

������ CE Certificate of Conformity

������ Burner User’s Manual

C. Hydraulic SEPERATOR

Function

To optimise the variable volume flows, the hydraulic separator is required between the heating boiler and heat exchangers cycle.

The hydraulic separator has to facilitate the water distribution, the differential pressure maintenance and the constant regulation of the forward and return flow temperature. The heating boilers will be uncoupled from the control cycles. The hydraulic separator has the task of distributing and collecting the heating water flows, however, it must not decrease the pressure. The planner and engineer must have precise knowledge of the subject and design the hydraulic separator according to system capacity.

The zero point of the heating system has to be located exactly at the centre (vertical) of the hydraulic separator. Subsequently, different volumes shall flow during operation without the various cycles being affected by one another hydraulically.

The hydraulic separator shall provide a sensible adjustment and distribution of different volume flows. All control cycles shall be supplied with the required quantity of water at all times.

D. HIGH CAPACITY WATER HEATERS

Quantity: XXX nos.

Manufactures / Type

A. ECOTHERM – Austria

B. Hoval - Switzerland

General

High capacity water heaters completely of stainless steel AISI 316 Ti or Duplex St steel, with internal flat coil located at the bottom of the tanks, shall have an anti legio design fully compliant with European Anti Legionella recommendations – heating with hot water from boiler

Units completely pre-assembled and wired with all accessories acc.

Quantity: XXX units complete with internal flat coil heat exchanger-unit

manufactured to European industrial TÜV standard

1 unit consists of: Storage tank XXX ltr with one internal heat exchanger XXX kW

Rating per unit: XXX KW, XXX litres storage capacity

Capacity per unit / four units:

XXX kW: continuous: / ltr/hr at XXX°C ( XXXC, (primary XXX(XXX°C)

Storage Tank

XXX litres storage capacity, stainless steel AISI 316 Ti or Duplex St Steel, all joints welded front and back for smooth inside joint seams and maximum corrosion resistance.

Material: Stainless Steel AISI 316 Ti or Duplex St Steel.

Anodes:

The storage tank shall be equipped with non-sacrificial titanium electric anodes. This anode with its titanium oxide element remains permanently intact and should have an unlimited lifespan. It shall not require replacement or maintenance. Once the wires are connected correctly, the green light should indicate that effective corrosion protection is activated. (A red light indicates that flow of current is not providing protection.)

Welding quality:

- Automatic inert gas (front and back) welding for exact seams with constant grain structure, free of oxidation pockets and highly resistant to corrosion.

- All finished products are submerged in pickling baths to give a smooth surface finish and further enhancing resistance to corrosion and fouling.

- 100% full penetration welding

Insulation:

Insulation shall be made of Polyester Fiber Fleece minimum 80 mm thick, all connection openings shall be precise laser cut to reduce heat loss; the material shall be flame retardant to DIN 4102-1 class 2. The insulation shall be enclosed in a Poly propylene outer sheeting of 1.2 mm which shall have aluminum closure strip which shall allow quick opening.

Heat Exchanger:

Technical description: Stainless steel high capacity Internal flat coil heat exchanger shall have an anti legio design fully compliant with European Anti Legionella recommendations.

Accessories:

Temperature sensors, motorised control valve, adjustable safety thermostat automatically disable microprocessor.

Wired and pre-assembled for easy installation. (Maximum ambient air temperature 40°C). dial thermometer 60mm 0–120°C, pressure gauge 60mm, fitted inspection flange cover 200/400 mm, built-in connections for optional heat exchanger sludge flushing.

Dielectric isolator kits for piping connections & non-sacrificial electric anodes.

The above descripted elements: storage-tank, controls and heat-exchanger shall be delivered totally pre-assembled, below sealed stop valves, motor valve, dial thermometers, temperature sensors, electric anodes (non sacrificial) and accessories, mounted and ready wired.

Warranty:

5 years warranty against corrosion leakage on all stainless steel parts. All connections to copper piping to be fitted with dielectric isolator kits & e-anodes operational at all times. 1 year warranty on electrical and other parts.

Documentation:

CAD technical drawings, parts list, start-up report.

Laws & Standards:

o ISO 9001 : 2015 for calculation, construction, production and sale of pressure vessels, heat exchangers as well as solar, hot water and steam systems and insulation systems.

o Designed and produced acc. to European Pressure Vessel Directive 2014/68/EC.

o TÜV certified welding and manufacturing facility according to ISO 3834-2 : 2005

o TÜV certified welding facility AD2000 HP0/HP100R

o Approved product certifications to SVGW, WEA Bern, UDT

o Approved test facility certification to SVGW, WEA Bern, UDT

o ISO 14001 Environment Management (certificate no. 14303599)

o Erection of electrical installations with rated voltages up to AC 1 000 V and DC 1 500 V ÖVE/ÖNORM EN 8001

o Electrical appliances - Safety:

▪ ÖVE-HG/EN 60 335-1/2012, ÖVE-HG/EN 60 335-1 A2

▪ ÖVE-HG/EN 60 335-1 A5, ÖVE-HG/EN 60 335-1 A6

▪ ÖVE-HG/EN 60 335-1 A51, ÖVE-HG/EN 60 335-1 A52

▪ ÖVE-HG/EN 60 335-1 A53

o Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics:

ÖVE-FE/EN 55011/2018 and ÖVE-F62/77, Limit Class B

o Low voltage standard: 73/23/EWG

o Safety of machinery - Electrical equipment of machines EN 60 204-1

o EMV standard 89/336/EWG

o EN61000-6-1 EMV Electromagnetic compatibility (EMC)

o EN61000-6-3 EMV Emission standard for residential, commercial and light-industrial environments

o Low-voltage switchgear and controlgear assemblies ÖVE/ÖNORM EN 61439

E. Master control panel with touch screen display: 1 no.

The Master control panel shall be touch screen display and manage the complete Hot water-system, including Pumps, valves, heat exchanger for hot-water, pressure transmitter, burner, chemical dosage and all other inputs and outputs shall be connected with the master controller. The complete Visualisation of the system shall be displayed on a touch control panel and shall guarantee a clear overview of the plant room.

General specification

• Industrial standard metal basic control panel, IP 54 protection (dust, spray)

• Mains power cut-off switch coupled to door lock

• Power-On LED

• Automatic electric cut-outs

• Control Voltage for all components

• Automatic turn-over of the pumps and burners in case of fault

• Automatic interval changing of pumps and burners operation (duty/standby)

• Auto-Off-Manual on the control Panel for each component

• Alarm-List of all Faults with appeared-time and gone-time

• All parameter are to be password protected against changes (three access levels) and all parameters should have an adjustment range

• All temperature sensors and transmitter should be displayed on the monitor, incl. their set points and values

• The hydraulic schematic shall be represented in the display, incl. operation and fault of pumps, valves and burners

• BMS connection (temperature sensors, operation signals, faults, alarms)

• The Controller shall be equipped for remote maintenance, if connected to the internet

• Boiler low pressure switch

• Boiler pump with fault signal

• TR/STB Automatic temperature limiter 0-70°C with height limit switch at 90°C

• Alarms for Boiler:

o Fault burner

o Fault high temperature STB (safety temperature limiter)

o Warning TR

o Fault boiler pump

o Fault pressure switch

o Sensor fault temperature transmitter boiler

F. CHIMNEY

The stack shall be supplied by the boiler manufacturer in sections complete with rain-cap and hardware, with sizes and gauge steel as per his recommendations.

The stack sections shall be twin shell insulated stainless steel or as recommended by manufacturer 316 L inside and outside.

Number of sections as required clearing the top roof by 2 m min.

The sections supplied loose shall be delivered with the necessary assembly hardware, bolts, nuts and gaskets.

An inspection opening assembly complete with the relevant hardware shall be supplied loose for field assembly and mounting.

A rain-cap assembly complete with the relevant hardware shall be supplied loose for field assembly and mounting.

If guying is required for stack stability and wind effect, this will be done locally and the section flange bolts shall be used as guy lines tie joints to suit local conditions.

G. PRE-ASSEMBLING

The whole equipment shall be turnkey pre-assembled in the factory (except chimney), pre-piped; automatically welded (orbital) and pre-wired for easy site installation.

Components, pipes and cables numbered and indicated delivered together with set-up/installation plan for site installation.

H. INSTALLATION AT SITE

Examine area to receive boiler for compliance with requirements for installation tolerances and other conditions affecting boiler performance. Do not proceed with installation until unsatisfactory conditions have been corrected.

A. Install boilers level and plumb, according to manufacturer's written instructions and referenced standards.

B. Install according to local codes.

C. Support boilers on minimum 200-mm thick reinforced concrete base, 100 mm larger on each side than base of unit. Dowel base to floor on 450-mm centers along perimeter of base. Cast anchor-bolt inserts through base into floor.

D. Assemble boiler trim according to manufacturer's written installation instructions.

E. Install electrical devices furnished with boiler, but not specified to be factory mounted.

CONNECTIONS

A. Connect gas piping full size to boiler gas-train inlet with union.

B. Connect as indicated, boiler feed water piping, vents, drains etc

C. Connect breeching to boiler outlet, full size of outlet

D. Electrical: Comply with to applicable requirements in Division 16 –Electrical works.

E. Ground equipment

Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values.

FIELD QUALITY CONTROL

A. Manufacturer's Field Service: Engage a factory-authorized service representative to supervise the field assembly of components and installation of boilers, including piping and electrical connections. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

B. Hydrostatically test assembled boiler and piping, according to applicable sections of the Pressure Vessel Code.

CLEANING

A. Flush and clean boilers on completion of installation, according to manufacturer's written instructions.

B. After completing system installation, including outlet fittings and devices, inspect exposed finish. Remove burrs, dirt, and construction debris and repair damaged finishes including chips, scratches, and abrasions with manufacturer's touchup paint.

COMMISSIONING

A. Engage a factory-authorized service representative to provide startup service.

B. Verify that installation is as indicated and specified.

Verify that electrical wiring installation complies with manufacturer's submittal and installation requirements in Division 16 Sections. Do not proceed with boiler startup until wiring installation is acceptable to equipment Installer.

C. Complete manufacturer's installation and startup checklist and verify the following:

1. Boiler is level on concrete base.

2. Flue and chimney are installed without visible damage.

3. No damage is visible to boiler jacket, refractory, or combustion chamber.

4. Pressure-reducing valves are checked for correct operation and specified relief pressure. Adjust as required.

5. Clearances have been provided and piping is flanged for easy removal and servicing.

6. Heating circuit pipes have been connected to correct ports.

7. Labels are clearly visible.

8. Boiler, burner, and flue are clean and free of construction debris.

9. Burner blower rotates in correct direction.

10. Pressure and temperature gages are installed.

11. Control installations are completed.

Before starting the boiler, check that:

- The rating plate specifications and power supply network (electricity, water, gas or fuel oil) specifications correspond.

- The burner power range is compatible with the power of the boiler.

- The boiler room also contains the instructions for the burner;

- The flue gas exhaust pipe is operating correctly;

- The air inlet supply is well dimensioned and free from any obstacle;

- The manhole, the smoke box and the burner plate are closed in order to provide a complete flue gas seal;

- The system is full of water and that any air pockets have therefore been eliminated;

- The water circulation pumps are operating correctly.

- The expansion vessel and the safety valve(s) have been connected correctly (with no interception) and are properly operating.

- Check the electrical parts and thermostat operation.

END OF SECTION

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