USACE / NAVFAC / AFCESA / NASA UFGS-23 72 00.00 10 (January 2008)
----------------------------------
Preparing Activity: USACE Superseding
UFGS-23 72 00.00 10 (October 2007)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 23 72 00.00 10
ENERGY RECOVERY SYSTEMS
01/08
NOTE: This guide specification covers the requirements for energy recovery
systems for power plant installations where a steady source of waste heat is
available.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[ASME INTERNATIONAL (ASME)ASME B31.1(2007; Addenda 2008) Power PipingASME B40.100(2005) Pressure Gauges and Gauge AttachmentsASME BPVC SEC I(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section I, Power BoilersASME BPVC SEC IV(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IV, Recommended Rules for the Care and Operation of Heating BoilersASME BPVC SEC IX(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing QualificationsASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic CoverageASME PTC 19.3(1974; R 2004) Temperature Measurement Instruments and Apparatus][ASTM INTERNATIONAL (ASTM)ASTM D 1066(2006) Sampling SteamASTM D 2186(2005) Deposit-Forming Impurities in Steam][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA MG 1(2007; Errata 2008) Standard for Motors and Generators]1.2 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Installation
Detail drawings consisting of a complete list of equipment and material, including manufacturer's
descriptive and technical literature, performance charts and curves, catalog cuts, drawings,
and installation instructions. Include in the Drawings complete piping and wiring drawings,
schematic diagrams, and any other details required to demonstrate that the system has been coordinated
and will properly function as a unit. Also show proposed layout and anchorage of equipment
and appurtenances, and equipment relationship to other parts of the work including clearances
required for maintenance and operation.
SD-03 Product Data
Calculations
Manufacturer's design data and structural computations for walls, roof, foundations, and other
features for specialty type of construction, with design data for lateral forces that may be
encountered due to wind loads and seismic zone forces.
Welding Procedures and Qualifications
A copy of qualified procedures and a list of names and identification symbols of qualified
welders and welding operators.
Spare Parts
Spare parts data for each item of equipment provided, as specified.
Posted Instructions
Proposed diagrams, instructions, and other sheets, prior to posting, as specified.
Performance Tests[; G][; G, [_____]]
A proposed performance test procedure, 30 days prior to the proposed test date. Include in
the procedure a complete description of the proposed test with calibration curves or test results
furnished by an independent testing laboratory of each instrument, meter, gauge, and thermometer
to be used in the tests. Do not start the test until the procedure has been approved.
SD-06 Test Reports
Tests
Test reports in booklet form showing all field tests performed to adjust each component and
all field tests performed to prove compliance with the specified performance criteria, upon
completion and testing of the installed system. Indicate in each test report the final position
of controls.
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals[; G][; G, [_____]]
[Six] [_____] complete copies of operation manual for energy recovery system outlining the
step-by-step procedures required for system startup, operation, and shutdown. Include in the
manuals the manufacturer's name, model number, service manual, parts list, and a brief description
of all equipment items and their basic operating features. [Six] [_____] copies of maintenance
manual listing routine maintenance procedures, possible breakdowns and repairs, and troubleshooting
guide shall be provided. Include in the manuals piping layout, equipment layout, and simplified
wiring and control diagrams of the system as installed.
1.3 WELDING PROCEDURES AND QUALIFICATIONS
NOTE: If the need exists for more stringent requirements for weldments, delete
the first bracketed statement.
[Piping shall be welded in accordance with qualified procedures using performance qualified welders and welding
operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures
qualified by others, and welders and welding operators qualified by another employer, may be accepted as permitted
by ASME B31.1. Contracting Officer shall be notified 24 hours in advance of tests and the tests shall be performed
at the work site if practicable. The welder or welding operator shall apply his assigned symbol near each weld
he makes as a permanent record. Structural members shall be welded in accordance with Section 05 05 23 WELDING,
STRUCTURAL.] [Welding and nondestructive testing procedures are specified in Section 43 02 00 WELDING PRESSURE
PIPING.]
1.4 DELIVERY, STORAGE, AND HANDLING
Protect all equipment delivered and placed in storage from the weather, humidity and temperature variation, dirt
and dust, or other contaminants.
1.5 EXTRA MATERIALS
NOTE: If fire-tube boilers are specified, delete paragraph "Tube Cleaner;"
if water-tube boilers are specified, delete paragraph "Tube Brush." If the
boiler design utilizes bent tubes, both paragraphs "Tube Cleaner" and "Tube
Brush" should be deleted.
Furnish all special tools necessary for the operation and maintenance of boilers, pumps, fans, and other equipment.
Furnish small hand tools with a suitable cabinet, mounted where directed.
1.5.1 Tube Cleaner
Tube cleaner shall be the water-driven type with three rotary cutters and rotary wire brush, complete with the
necessary length of armored water hose, valves, and other appurtenances necessary for operation. Tube cleaner
and rotary brush shall be provided for each size of water tube in the boiler, with one extra set of cutters for
each size cleaner. Necessary valves and fittings shall be provided to permit quick connection of the raw water
supply hose to one boiler feed pump for operation of the cleaner.
1.5.2 Tube Brush
Provide tube brush, with steel bristles and jointed handle of sufficient length to clean full length of fire
tubes.
1.5.3 Smoke Pipe Cleaner
Provide smoke pipe cleaner to clean the breeching and smoke connections. Cleaner shall have jointed handle long
enough to clean breeching and smoke connections without dismantling the system.
1.5.4 Special Wrenches
Provide special wrenches as required for opening boiler manholes, handholes, and cleanouts.
1.5.5 Spare Parts
Submit spare parts data for each different item of equipment specified, after approval of the detail drawings
and not later than [_____] months before the date of beneficial occupancy. Include in the data a complete list
of spare parts and supplies with current unit prices and source of supply.
1.6 OPERATION AND MAINTENANCE MANUALS
NOTE: The designer should require the Contractor to prepare (in addition to
providing O&M manuals for each piece of equipment) O&M manuals for the
completed work which consists of diverse equipment integrated into a system
not covered by instructions from a single manufacturer; in that case retain
the first bracketed sentence. Remove the first bracketed sentence when the
manufacturer's instructions are sufficient to operate and maintain the completed
work.
[The manuals will be approved by [the Contracting Officer] [_____] before acceptance of the installed system.]
PART 2 PRODUCTS
NOTE: In order to comply with Executive Order 13423 and Public Law 109-58 (Energy
Policy Act of 2005), designs must achieve energy consumption levels that are
at least 30 percent below the level required by ASHRAE 90.1 - 2004. In accordance
with P.L. 109-58 (Energy Policy Act of 2005), Executive Order 13423, and Federal
Acquisition Regulation (FAR) Section 23.203 energy consuming products and systems
shall meet or exceed the performance criteria for ENERGY STAR®-qualified or
FEMP-designated products as long as these requirements are nonproprietary. The
FEMP and ENERGY STAR product requirements are available on the web at www.eere.energy.gov/femp/procurement
and www.energystar.gov/products. Where ENERGY STAR or FEMP products are not
applicable, energy consuming products and systems shall meet or exceed the requirements
of ASHRAE 90.1.
2.1 MATERIALS AND EQUIPMENT
2.1.1 Standard Products
Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture
of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years
prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the
Contracting Officer, reasonably convenient to the site.
2.1.2 Nameplates
Each major item of equipment shall have the manufacturer's name, address, type or style, model or serial number,
and catalog number on a plate secured to the item of equipment.
2.1.3 Prevention of Rust
Unless otherwise specified, surfaces of ferrous metal subject to corrosion shall be factory prime-painted with
a rust-inhibiting coating and subsequently factory finish-painted in accordance with the manufacturer's standard
practice. Heat recovery equipment exposed to high temperature when in service shall be prime and finish painted
with the manufacturer's standard heat resistant paint to a minimum thickness of 0.025 mm 1 mil.
2.1.4 Equipment Guards and Access
Fully enclose or guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating
parts located where personnel contact is possible. High temperature equipment and piping located within personnel
contact or where a potential fire hazard exists shall be properly guarded or covered with insulation of a type
specified. Provide items such as catwalks, operating platforms, ladders, and guardrails where shown and construct
them in accordance with Section [05 50 13 MISCELLANEOUS METAL FABRICATIONS][05 51 33 METAL LADDERS].
2.2 HEAT RECOVERY EQUIPMENT
NOTE: Heat recovery equipment is closely associated with the prime mover and
it will frequently be more advantageous to specify this equipment in the same
section in which the prime mover is specified. The designer must insure that
drawings defining the interrelationship between all components and design data
such as flows, pressures, temperatures, and heat transfer rate are included.
Specify 2, 3, 4, or 8 degrees C (3, 5, 8, or 15 degrees F) for the maximum temperature
differential for coolant in and out of engine. Differential selected must be
in accordance with engine manufacturer's recommendations. The 2 degree C (3
degree F) range is for conventional ebullient cooling where the heat of evaporation
is used to remove the rejected heat from the engine. A 8 degrees C (15 degree
F) differential across the engine is desirable for all other systems but may
be limited by engine manufacturer's recommendations.
A heat recovery system shall be an integrated design package compatible with the prime mover [cooling] [and]
[exhaust] system in accordance with the drawings and data sheets. The heat recovery system shall be a [diesel
engine exhaust waste heat boiler only to generate [saturated steam at [_____] Pa psig pressure] [hot water at
[_____] degrees C degrees F and [_____] Pa psig pressure].] [diesel engine [jacket water cooling and heat reclaim
system] [and] [lube oil cooling and heat reclaim facilities].] [diesel engine ebullient cooling system combining
jacket water heat reclaim and exhaust waste heat boiler to generate up to 105 kPa 15 psig steam.] [gas turbine
exhaust heat reclaim unit to generate [steam at [_____] Pa psig] [hot water at [_____] degrees C degrees F and
[_____] Pa psig pressure].]
2.2.1 Diesel Engine Cooling
2.2.1.1 Antifreeze
[For ebullient cooling, the cooling system shall be suitable for a combination of water and an azeotropic antifreeze
compatible with the equipment (methoxy propanol) as a cooling medium, hereafter called the coolant.] [For cooling
systems where steam is not required, an ethylene glycol permanent type antifreeze shall be utilized. Size of
cooling system shall be based upon the use of an antifreeze solution which will protect the system down to minus
45 degrees C minus 50 degrees F.] Antifreeze for cooling the lube oil and auxiliaries shall be a permanent type
suitable for use with water, or the antifreeze solution specified above may be used and shall be connected to
a separate section of the waste heat condenser from the engine coolant. Valve trim and materials shall be compatible
for use with the antifreeze solution. Operation of the cooling system shall be fully automatic while the prime
mover is running.
2.2.1.2 Water Jacket Temperature
For diesel engine ebullient cooling, jacket water temperature shall be not lower than 110 degrees C 230 degrees
F, nor higher than 120 degrees C 250 degrees F in the steam separator at all loads with a maximum differential
of [_____] degrees C degrees F for coolant in and out of the engine.
2.2.1.3 Construction
Where cooling system design is part of prime mover installation, components other than the wasteheat condenser
and condensate receiver or pump units may be mounted on the engine skid extension. For any antifreeze cooling
system, a PVC makeup tank with an electric motor-driven pump unit shall be provided as indicated. Pump shall
be manifolded to allow using it as a mixing unit by shunting the flow back to the tank. System fill shall be
[manual] [automatic] with feed into the piping system steel expansion tank connection line as indicated.
2.2.2 Electrical Equipment
Electric motor-driven equipment specified shall be provided complete with motors and necessary motor control
devices. Motors and motor control devices shall conform to the applicable requirements of Section 26 20 00 INTERIOR
DISTRIBUTION SYSTEM including requirements for hazardous area locations. Integral size motors shall be the premium
efficiency type in accordance with NEMA MG 1.
2.2.2.1 Motor Ratings
Motors shall be suitable for the voltage and frequency provided. Motors 373 watt 1/2 horsepower and larger shall
be three-phase, unless otherwise indicated. Ratings shall be adequate for the duty imposed, but shall not be
less than indicated.
2.2.2.2 Motor Controls
Where a motor controller is not shown in a motor control center on the electrical drawings, a motor controller
shall be provided. Where required, motor controllers shall be provided complete with properly sized thermal
overload protection and other equipment at the specified capacity including an allowable service factor, and
other appurtenances necessary for the motor control specified. Manual or automatic control and protective or
signal devices required for operation specified and any wiring required to such devices, not shown on the electrical
drawings, shall be provided. Where two-speed or variable-speed motors are indicated, solid-state variable-speed
controllers may be provided to accomplish the same function.
2.2.3 Heat Recovery Silencer for Diesel Engine
NOTE: The degree of silencing will match the environmental requirement. In
a retrofit installation, the unit should match the original silencer installation.
As a general guide the attenuation will be approximately as follows:
Measured at
Type of Attenuation Octave Band
Silencer in dB Frequency (Hz)
Industrial 25 250
Semi-Residential 30 250
Residential, Critical Area 35 250
Quiet Residential 37.5 250
Indicate pressure required. For most low-pressure installations this will be
345 kPa (50 psig).
Each combination boiler silencer or supplementary silencer shall reduce the generated sound spectrum to standard
commercial level permitted for [industrial] [semi-residential] [residential, critical] area. Exhaust gas boiler
shall be a combination boiler silencer or a boiler with a supplementary silencer to meet the noise limits, and
heat recovery unit shall be constructed in accordance with ASME BPVC SEC VIII D1 for [_____] Pa psig steam working
pressure. The boiler shall be designed for maximum efficient heat recovery under any load condition up to 110
percent of full load with an exit exhaust gas temperature not less than 165 degrees C 330 degrees F. Each boiler
shall be designed for continuous wet operation or for periods of dry operation without interruption of the diesel
engine operation when located and connected as indicated. Provisions shall be made for expansion and contraction
to prevent overstressed conditions in the pressure vessel during continuous wet or dry operation. Gas side pressure
drop through the boiler shall not exceed the recommendations of the engine manufacturer. Each boiler shall be
provided with standard boiler trim including, but not limited to, pressure gauge, water gauge with try cocks,
water level control, ASME-rated safety relief valve, surface blowoff valve, bottom blowdown valves, and bottom
dump valves. The shell shall be insulated as required by the paragraph "INSULATION" and the insulation shall
be covered by lagging.
2.2.4 Heat Recovery Section for Gas Turbine
The unit shall consist of a [fire tube] [water tube or water wall] exhaust boiler equipped with an exhaust gas
bypass. Unit shall be specifically designed for the specified installation and shall be a complete package with
thermal insulation, controls, accessories, and base. The insulation shall be in accordance with the paragraph
"INSULATION." If heat recovery section does not meet the turbine exhaust sound levels specified, it shall be
supplied with supplementary exhaust silencer to meet specification requirements for both on-stream and bypass
conditions.
2.2.5 Steam Separator Unit
The unit shall be a combination flash tank and steam separator unit of sufficient size for the engine cooling
and waste heat recovery system when engine is operated at 110 percent load in an ambient temperature of [40]
[_____] degrees C [105] [_____] degrees F at [_____] m feet altitude. The unit shall be complete with low-water
alarm switch, low-level cutout switch (set at a level lower than the low-water alarm switch), pressure gauge,
safety valve, gauge glass and cocks, vent valve, water-level control, high-water-level alarm, condensate-motor
control, and blowdown connection. Controls shall be so positioned that coolant level shall be visible in gauge
glass at all times. The vessel shall be constructed and certified in accordance with the ASME requirements and
shall be hydrostatically tested conforming to ASME requirements. Steam at 105 kPa 15 psig from this separator
shall be used for [space heating] [and] [absorption cooling] [_____]. The unit shall be insulated as required
by paragraph "INSULATION."
2.2.6 Condensate Pumps and Receiver
Condensate unit shall have duplex pumps and receiver and shall be skid-mounted. Each pump shall be capable of
full capacity at 120 percent full steam rate when all of the heat is wasted under 110 percent engine load in
an ambient temperature of [40] [_____] degrees C [105] [_____] degrees F. An alternator shall be provided for
automatically switching the pumps under response from the liquid level control of the steam generator units each
time an ON-OFF cycle is completed. Pumps shall be electric motor-driven type with stainless steel shafts and
bronze impellers for operation with condensate at 95 degrees C 200 degrees F. Means shall be provided to control
pump operation to maintain condensate level between high and low visible levels indicated on the glass gauge
of the receiver. The receiver shall be sized to hold at least enough condensate for 15 minutes of operation
without raw water makeup and shall be complete with skid mounting, gauge glass, float-type makeup water valve
with emergency manual valve, air vent, high-and low-level controlled pump switch, low-level alarm, and drain
connection. Air vent shall be suitable for use with coolant selected.
2.2.7 Load Control Condenser
Each condenser unit shall have a capacity to dissipate the heat rejected by the engine and its components at
110 percent full-rated load under temperature of [_____] degrees C degrees F and at [_____] m feet elevation
from above sea level. The maximum coolant temperatures leaving the engine shall not be in excess of that recommended
by the engine manufacturer; however, temperature differential shall not be greater than [_____] degrees C degrees
F for coolant in and out of the engine.
2.2.7.1 Air-Cooled Condenser
NOTE: Designer will select proper speed, based on air requirements. The larger
units will generally require the slowest speed motor but the type of fan drive
must also be considered. The fan speed and pitch of the blades are determined
from manufacturer's rating data.
Main core unit shall be suitable for condensing the vapor generated during engine operation from zero to 110
percent of full load when there is no utilization of the steam for useful purposes. A secondary core shall be
used for cooling the auxiliary system coolant. The condenser shall be the [vertical] [horizontal] air discharge
type with round tubes. Fins and tubes shall be constructed of nonferrous materials; headers shall be of carbon
steel and of the plug type. Fins shall be firmly bonded to tubes; tanks and supporting framework shall be constructed
of steel; and fan shall be adjustable-pitch type constructed of aluminum. Inlet and outlet coolant connections
shall be on one side. A drain cock shall be installed at the low point of each core. A welded structural frame
shall be provided for entire unit, drilled and arranged for mounting on a concrete base, and designed to withstand
winds up to [80] [_____] km/hour [50] [_____] mph. [Hail screens shall be provided in areas where hails storms
are prevalent.] Reliefs shall be provided to protect against excessive pressures and temperatures developed in
the system.
a. The condenser shall be complete with motor-driven fan or fans and with face dampers controlled by
the condensate temperature. [Two fans per bay shall be provided.] Excessive subcooling of the condensate
by overexposure to the air stream shall be avoided. Freeze protection for all modes of operation shall
be provided. Fan tip speed shall not exceed 60 meters/second 12,000 feet/minute.
NOTE: Where motor starters for mechanical equipment are provided in motor control
centers, delete the reference to motor starters.
b. The fan motor shall be direct-connected or belt-connected to the fan and shall have sealed bearings.
The motor shall be three-phase, squirrel cage induction type, [208] [460] volts at 60 Hz, synchronous
speed not to exceed [1,200] [1,800] rpm. Motor size shall be such that seasonal adjustments of the fan
blade pitch are not necessary to prevent motor overloads when ambient air temperature drops to lowest
value or rises to highest value specified for the prime mover operating conditions. A 60 Hz, across-the-line,
enclosed type, magnetic motor starter having thermal overload protection in each ungrounded phase shall
be provided. If the condenser fan motor is large enough to cause a transient voltage dip of 20 percent
or more during starting inrush, a reduced-voltage type magnetic motor starter shall be used. Connections
shall be such that the fan motor shall start automatically as its respective engines are started.
c. The distance between condenser and engine shall be [[_____] m feet] [as shown]. Unit shall be furnished
complete with a matched float and thermostatic trap installation. Air flow shall be from the fan motor
[upward] [downward] [inward] [outward] through the condenser. Furnish 300 mm twelve-inch lengths of
flexible hose or pipe for all inlet and outlet pipe connections. A valved vent for release of noncondensible
gases shall be provided. Condenser shall be sized by the engine manufacturer for this application.
Auxiliary system coolant temperature shall not exceed 80 degrees C 180 degrees F, with a maximum differential
of 8 degrees C 15 degrees F. Temperature for the system shall be maintained by regulating the steam
pressure.
2.2.7.2 Water-Cooled Condenser
Unit shall be a shell-and-tube type rated for 30 degrees C 85 degrees F entering water and 40 degrees C 105 degrees
F leaving water. Unit shall be furnished complete with a matched float and thermostatic trap installation as
well as a subcooler unit to reduce flashing of condensate. A valved vent for release of noncondensible gases
shall be provided.
2.2.8 Pressure-Operated Control Valve
The control valve shall be the butterfly type with maximum 60 percent full open operating position for good control
characteristics. Nominal rating shall be with 7 kPa 1 psig pressure drop at 60 percent of full open position.
For use as a back pressure valve when there is no auxiliary fired boiler, metal-to-metal seats which do not provide
100 percent shutoff to condenser shall be provided. For use with an auxiliary fired boiler, high temperature
butyl or silicone rubber or EPDM seats for bubble-tight shutoff to the condenser shall be provided. Valve operator
shall be [electric proportional operator with pressure control mounted internally] [pneumatic with controller
with proportional band, reset and filter regulator mounted on operator]. Valve shall open on loss of air supply
pressure.
2.2.9 Auxiliary Boiler for Supplemental Firing
NOTE: Delete this paragraph if auxiliary fired boiler is not required. Auxiliary
boiler is required when a constant source of heat must be maintained during
maintenance or overhaul of prime movers or to supplement heating requirements
during peak demands which are beyond the capacity of the heat recovery installation.
Boiler and related equipment shall be as specified in Section [_____].
2.2.10 Forced Circulation Pump
Where an engine-driven pump is not provided for jacket water circulation, a separate electric motor-driven pump
interlocked with engine operation shall be provided as required by the engine manufacturer.
2.2.11 Heat Exchangers
Heat exchangers shall be provided as shown. Heat exchangers shall be of the shell-and-tube design, either U-tube
type or helical coil type. Other types of construction are not acceptable unless prior written approval is received.
Heat exchangers shall be designed, fabricated, tested, and stamped in accordance with ASME BPVC SEC VIII D1.
a. Materials of construction shall be suitable for the intended service except that no cast material
shall be used. The manufacturer's drawing submittal shall indicate the grade of material that has been
used, giving the full ASME specification number designation for each component. U-tube materials shall
be furnished as light drawn temper; helical coils shall be furnished fully annealed. The materials of
construction on the shell side [casing] shall be carbon steel. The tube side materials shall be 90-10
Copper-Nickel for the tubes, tubesheets, and channel bonnets for U-tube designs. Tubing and headers
for the helical coil designs shall be 90-10 Copper-Nickel.
b. Tube-to-tube sheet connections and tube-to-header connections for helical coils shall be either rolled
or welded for the condensate cooler and lube oil cooler, and shall be welded for lube oil preheater.
2.2.11.1 Lube Oil Cooling
Lube oil cooling and heat reclamation exchangers shall be furnished as part of the engine. The designs shall
provide for the oil to be on the outside of the tubes and the cooling water on the inside. A thermal sensing
unit shall be provided in the oil outlet piping where it can sense the mixed average temperature of the oil leaving
the cooler and actuate the control valve on the cooling water flow to prevent overcooling the lube oil.
2.2.11.2 Fuel Oil Preheating
If fuel oil preheating is required, this heat exchanger shall be provided as part of the boiler package. The
designs shall provide for the oil to be on the outside of the tubes and the steam or high temperature water on
the inside. A thermal sensing unit shall be provided in the oil outlet piping where it can sense the mixed average
temperature of the oil leaving the preheater and actuate the control valve on the high temperature hot water/steam
to ensure that oil temperature is in the proper range for the prime mover.
2.2.11.3 Condensate Heat Exchanger
High pressure condensate heat exchanger shall provide heating of domestic or boiler feedwater while reducing
the condensate temperature to minimize flashing in the condensate surge tank. The designs shall provide for
the condensate to be on the outside of the tubes and the cooling water (domestic or boiler feedwater) to be on
the inside.
2.2.12 High Temperature Water Heat Recovery Systems
NOTE: Delete this paragraph if high temperature water heat recovery is not
utilized.
Where high temperature water is utilized as a heat recovery system medium, the system shall be provided with
proper expansion tank, dump tank, pressurization system, circulation pumps, makeup water facilities, controls,
unit heaters, and piping as specified in Section 33 60 00.00 10 CENTRAL HIGH TEMPERATURE WATER (HTW) GENERATING
PLANT AND AUXILIARIES.
2.2.13 Pressure Gauges
Gauges shall be heavy-duty industrial type conforming to ASME B40.100, style as required, suitable for pressure
or vacuum specified, with minimum 152 mm 6 inch diameter dial, except as otherwise specified. Pressure gauges
shall be installed on each boiler, on the low-pressure side of each pressure reducing valve, on the discharge
side of each pump, and where shown or where required for proper operation. Gauges shall be readily accessible
and easily read from the operating floor. Gauges shall be equipped with integral or separate siphons and shall
be connected by brass pipe and fittings with shutoff cocks. Where pressure-reducing valves are used, gauges
shall be placed close to the pressure-reducing assembly, both downstream and upstream, but connected approximately
3 m 10 feet therefrom. Operating ranges of the gauges shall be as follows:
Operating Pressure, Pressure Range,
Gauges kPa kPa
Boiler 690-860 0-1380
Medium-Pressure Steam 345 0-690
Low-Pressure Steam 14-35 0-210
Boiler Feed Pump 1034 0-1380
Other Pumps 140-345 0-690
Operating Pressure, Pressure Range,
Gauges Psig Psig
Boiler 100-125 0-200
Medium-Pressure Steam 50 0-100
Low-Pressure Steam 2-5 0-30
Boiler Feed Pump 150 0-200
Other Pumps 20-50 0-100
2.2.14 Thermometers
Thermometers shall conform to ASME PTC 19.3, Type I, Class 3, with wells. Mercury shall not be used in thermometers.
Temperature ranges shall be suitable for the intended use. Thermometers shall be installed in the feedwater
pipeline between the feedwater heater and boiler feed pump in the main condensate return line before entering
the surge tank, and elsewhere as indicated or specified. Thermometers shall have straight or angle stems as
required and shall be easily read from the operating floor.
2.3 WATER TREATMENT EQUIPMENT
NOTE: The proper condition of feedwater and boiler water is of major importance
in assuring long life and minimum maintenance of any heat recovery system. Due
to varying conditions in different locations, it is impossible to set forth
specific control standards. If water treatment is covered in another section,
the requirements should be reviewed for compatibility with the requirements
of waste heat recovery systems. A study should be made as follows:
a. Internal Treatment: Conventional internal water treatment should be used
along with regular boiler blowdown. Water treatment should consist of alkalinity
adjustments and chemical additions for the removal of dissolved oxygen and treatment
of residual hard-scale-forming materials. Treatment may also be required for
sludge dispersal and to prevent foaming.
The following values can be used as a guide:
pH 10.5 - 11.2
O2 0 ppm
PO4 20-40 ppm
TDS 3500 ppm, max.
b. External Treatment: Makeup water must be treated to remove calcium, magnesium,
and total iron. Special attention should be given to water which contains suspended
solids, a high residual of iron and sodium chloride, and dissolved oxygen.
c. Condensate Return Line Corrosion: Corrosion in the return line will allow
harmful iron oxide to enter the boiler system where it can adhere to the internal
surfaces and reduce the heat transfer. It is recommended that steps be taken
to protect the condensate return system from the corrosive effects of oxygen
and carbon dioxide.
For additional information concerning control of internal chemical conditions,
refer to ASME Boiler and Pressure Vessel Code, Section VII (Recommended Rules
for Care of Power Boilers), Subsection C7.
Water treatment equipment is required and shall be as specified in Section [_____].
2.4 BUILDING HEATING EQUIPMENT
Unit heaters and radiators for building heating shall be as specified in Section [_____].
2.5 PIPING
Piping shall be as specified in Section [_____].
2.6 INSULATION
Apply insulation in sufficient thickness to limit the surface temperature of the lagging to not more than [50]
[65] degrees C [120] [150] degrees F when in still air at site maximum dry bulb temperature. Submit Heat transfer
calculations to the Contracting Officer to substantiate insulation material and thickness selection. Provide
insulation with waterproof lagging when installed outdoors. Comply with EPA requirements in accordance with
Section 01 62 35 RECYCLED / RECOVERED MATERIALS.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting
Officer of any discrepancy before performing the work.
3.2 INSTALLATION
NOTE: All pertinent piping and related equipment supports are to be designed
and indicated in accordance with UFC 3-310-04 for seismic design.
Install equipment in accordance with manufacturer's instructions and recommendation. All pieces of equipment
shall be bolted in place on foundations unless they are skid-mounted on the prime mover base skid. Flexible
connectors shall be used to connect any piping to the prime mover. Piping for interconnecting various components
of the heat recovery equipment shall conform to the requirements of ASME B31.1. Submit calculations as specified
in the Submittals paragraph.
3.3 CLEANING OF BOILERS AND PIPING
3.3.1 Boiler Cleaning
After the hydrostatic tests have been made and before starting the operating tests, the boiler shall be thoroughly
and effectively cleaned of foreign materials, including mill scale, grease, and oil deposits. The Contractor
may use the following described procedure or may submit his own standard procedure for review and approval by
the Contracting Officer. Wherever possible, surfaces in contact with water shall be wire-brushed to remove loose
material before filling the boiler with a solution containing:
a. 11 kg caustic soda
b. 4 kg sodium nitrate
c. 11 kg disodium phosphate, anhydrous
d. 230 g approved wetting agent, 3,785 liters water
a. 24 pounds caustic soda
b. 8 pounds sodium nitrate
c. 24 pounds disodium phosphate, anhydrous
d. 1/2 pound approved wetting agent, 1,000 gallons water
Chemicals shall be thoroughly dissolved in the water before being placed in the boilers. The boiler shall then
be operated at 210 to 345 kPa 30 to 50 psig and minimum rating for 24 to 48 hours, exhausting the steam to atmosphere.
After the boiling period, the boiler shall be allowed to cool before being drained and thoroughly flushed out.
Piping shall be cleaned by operating the boilers for a period of approximately 48 hours, wasting the condensate.
3.3.2 Boiler Water Conditioning
Provide chemical treatment and blowdown of boiler water during periods of boiler operation to prevent scale and
corrosion in boilers and in steam and return distribution systems from initial startup of the system, through
the testing period, and to final acceptance by the Government. Chemicals used and method of treatment shall
be approved by the Contracting Officer.
3.4 POSTED INSTRUCTIONS
Submit framed instructions under glass or in laminated plastic, including wiring and control diagrams showing
the complete layout of the entire system, to be posted where directed. Condensed operating instructions explaining
preventive maintenance procedures, methods of checking the system for normal safe operation, and procedures for
safely starting and stopping the system shall be prepared in typed form, framed as specified above for the wiring
and control diagrams, and posted beside the diagrams. Post the framed instructions before acceptance testing
of the systems.
3.5 FIELD TRAINING
Provide a field training course for designated operating staff members. Training shall be provided for a total
of [_____] hours of normal working time and shall start after the system is functionally complete, but prior
to final acceptance tests. Field training shall cover all of the items contained in the approved operation and
maintenance instructions.
3.6 TESTS
Following installation, each boiler shall be tested hydrostatically and proved tight under a gauge pressure of
1.5 times the working pressure specified and in accordance with applicable ASME requirements. Following the
installation of piping and heat recovery equipment, but before the application of any insulation, hydrostatic
tests shall be made and the system proved tight under gauge pressures of 1.5 times the working pressure specified,
but not less than the following:
a. Low-pressure lines 275 kPa
b. Medium-pressure lines 415 kPa
c. High-pressure-steam lines 1035 kPa
d. Boiler feed lines 1550 kPa
a. Low-pressure lines 40 psi
b. Medium-pressure lines 60 psi
c. High-pressure-steam lines 150 psi
d. Boiler feed lines 225 psi
The boilers and the piping shall be inspected by a boiler inspector qualified as required by ASME BPVC SEC VIII D1
, ASME BPVC SEC I, or ASME BPVC SEC IV, as applicable. A certificate of approval shall be supplied for each
boiler.
3.7 EFFICIENCY AND OPERATING TESTS
Upon completion, and before acceptance of the work, the heat recovery plant shall be subjected to such operating
tests as may be required to demonstrate satisfactory functional operation. Each operating test shall be conducted
at such times as the Contracting Officer may direct. Water meter used in the test shall be suitable for hot
water. Provide instruments, test equipment, and test personnel required to properly conduct all tests; the necessary
fuel, water, and electricity will be furnished by the [Government] [_____]. The boiler operating tests shall,
as a minimum, be conducted continuously at the following capacities for the following time:
Test Percentage of Operating Capacity
----------------------------------------
Testing Water Wall or Firebox
Time Water Tube Boilers Boilers
First 2 hours 50 50
Next 2 hours 75 75
Next 6 hours 100 100*
Next 2 hours 110 --
a. Firebox boiler shall not be operated above 100 percent of capacity.
b. The general performance tests on the heating plant shall be conducted by an experienced test engineer
and will be observed by the Contracting Officer. A test report including logs, heat balance calculations,
tabulated results, and conclusions shall be delivered to the Contracting Officer as stated in the paragraph
"PERFORMANCE TEST REPORTS." [An analysis of the fuel being burned on the test shall be submitted to
the Contracting Officer.]
c. Test of capacity of water treatment equipment and quality of the effluent shall meet the requirements
specified. Tests for ion-exchange units shall cover at least two complete regenerations and capacity
runs. Tests for hot process or other precipitation type softeners shall be conducted continuously for
a period of at least 48 hours, with samples taken at 2-hour intervals.
d. Tests for steam quality in accordance with ASTM D 1066 shall be conducted under the operating conditions
specified.
e. Quality of steam used for air conditioning equipment shall be tested in accordance with the conductivity
method in ASTM D 2186 with the conductivity of the steam corrected for carbon dioxide and ammonia content
not to exceed 4.0 microsiemens 4.0 micromhos at 18 degrees C 65 degrees F.
3.8 RETESTING
If any deficiencies are revealed during test, such deficiencies shall be corrected and the tests reconducted
at no additional costs to the Government.
3.9 FIELD PAINTING
NOTE: Where identification of piping is required by the using service, this
paragraph will be amplified to include appropriate requirements, either directly
or by reference to a separate section.
Ferrous metal surfaces not specified to be coated at the factory shall be cleaned, prepared, and painted as specified
in Section 09 90 00 PAINTS AND COATINGS. Exposed pipe covering shall be painted as specified in Section
09 90 00 PAINTS AND COATINGS. Aluminum lagging over insulation shall not be painted.