USACE / NAVFAC / AFCESA / NASA UFGS-23 52 49.00 20 (November 2008)
-----------------------------------
Preparing Activity: NAVFAC Superseding
UFGS-23 52 49.00 20 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 23 52 49.00 20
STEAM BOILERS AND EQUIPMENT (500,000 - 18,000,000 BTU/HR)
11/08
NOTE: This guide specification covers the requirements for steam boilers and
related equipment for capacities from 150 to 5275 kW 500,000 to 18,000,000 Btu/Hr.
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).
NOTE: This guide specification supersedes the requirements for these boilers
and equipment contained in specification 52Y. Some paragraphs may need to be
supplemented to meet the project requirements. The boilers are equipped for
oil-, gas-, or oil-and-gas combination firing, as specified.
NOTE: The following information shall be shown on the project drawings:
1. Dimensions of construction
2. Relationship of materials
3. Quantities, location and capacity of equipment.
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.
[ACOUSTICAL SOCIETY OF AMERICA (ASA)ASA S1.4(1983; Amendment 1985; R 2006) Specification for Sound Level Meters (ASA 47)][AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)AISC 360(2005) Specification for Structural Steel Buildings, with Commentary][AMERICAN WELDING SOCIETY (AWS)AWS D1.1/D1.1M(2008) Structural Welding Code - SteelAWS Z49.1(2005) Safety in Welding, Cutting and Allied Processes][ASME INTERNATIONAL (ASME)ASME 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 VIII(2007; Addenda 2008) Boiler and Pressure Vessel Codes: Section VIII Rules for Construction of Pressure Vessels, Division 1ASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic CoverageASME CSD-1(2006) Control and Safety Devices for Automatically Fired BoilersASME PTC 4(1998) Fired Steam Generators][ASTM INTERNATIONAL (ASTM)ASTM B 111/B 111M(2008a) Standard Specification for Copper and Copper-Alloy Seamless Condenser Tubes and Ferrule StockASTM B 395/B 395M(2008) Standard Specification for U-Bend Seamless Copper and Copper Alloy Heat Exchanger and Condenser TubesASTM B 75(2002) Standard Specification for Seamless Copper TubeASTM B 75M(1999; R 2005) Standard Specification for Seamless Copper Tube (Metric)ASTM B 88(2003) Standard Specification for Seamless Copper Water TubeASTM B 88M(2005) Standard Specification for Seamless Copper Water Tube (Metric)ASTM D 396(2008b) Standard Specification for Fuel OilsASTM D 888(2005) Dissolved Oxygen in Water][FM GLOBAL (FM)FM P7825(2005) Approval Guide][NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTORS (NBBPVI)NBBPVI NB-27(1991) National Board Rules and Recommendations for the Design and Construction of Boiler Blowoff Systems][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 211(2006) Chimneys, Fireplaces, Vents, and Solid Fuel-Burning AppliancesNFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 EditionNFPA 85(2007) Boiler and Combustion Systems Hazards Code][U.S. DEPARTMENT OF DEFENSE (DOD)MIL-B-18897(Rev F; CANC Notice 1) Boilers, Steam and Hot Water, Watertube (Straight Bare and Finned Tube), Cast Iron and Firebox, Packaged Type (40,000 to 35,000,000 BTU/HR Thermal Output Capacity)][U.S. GENERAL SERVICES ADMINISTRATION (GSA)CID A-A-50562(Basic) Pump Units, Centrifugal, Water, Horizontal; General Service and Boiler-Feed: Electric-Motor or Steam-Turbine-DrivenCID A-A-50566(Basic) Monitoring Devices, Emission, Stack RelatedCID A-A-50573(Basic) Water Softener Unit, Lime-Soda TypeCID A-A-59249(Basic; Notice 1) Filters, Fluid, Pressure, FeedwaterFS A-A-50504(Basic) Analyzers, Flue-Gas, Orsat-Type, PortableFS F-B-2903(Basic) Boilers, Steam and ot Water, Firetube, Scotch Packaged Type (320,001 to 35,000,000 BTU/HR Thermal Output Capacity)FS F-B-2910(Basic) Burners, Single Oil, Gas, and Gas-Oil Combination for Packaged Boilers (320,001 to 125,000,000 BTU/HR Thermal Output Capacity)FS F-F-2901Feeders, Boiler Water Treatment, By-Pass and Compound Receiver TypesFS F-P-2908(Basic) pumping Units, Condensate, Return; and Boiler Feed PackageFS TT-P-28(Rev G) Paint, Aluminum, Heat Resisting (1200 Degrees F.)FS W-H-2904(Basic) Heaters, Fluid, Deaerating (For Water Only) 1,000 to 1,600,000 Pounds Per Hour Capacity][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910Occupational Safety and Health Standards][U.S. NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)NAVFAC MO 225(1990) Industrial Water Treatment][WATER QUALITY ASSOCIATION (WQA)WQA S-100(1995) Household Commercial and Portable Exchange Water Softeners an Equipment Validation Standard]1.2 SYSTEM DESCRIPTION
Describe the performance or design requirements and tolerances of the boiler system.
1.2.1 Heating Surface and Volume Measurements
Submit heating surface and volume measurements, including heat release calculations and performance data at minimum,
25 percent, 50 percent, 75 percent, and 100 percent load sufficient to establish compliance of boilers with heat
release requirements. Base calculations on the specified efficiency and capacity.
1.3 RELATED REQUIREMENTS
Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS applies, with the additions and modifications stated
herein.
1.4 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.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] The following shall
be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Steam boiler system
SD-05 Design Data
Heating surface and volume measurements
Heat release calculations
Performance data at minimum, 25 percent, 50 percent, 75 percent, and 100 percent load
SD-06 Test Reports
Boiler system start-up tests
Submit test reports in accordance with section entitled "Field Quality Control." Submit a
detailed written record of the start-up performance, including burner setting data over the
entire load range, before the Contractor's and sub-contractor's test personnel leave the site.
SD-07 Certificates
Report of prior installations
Qualifications of engineer
Start-up plan
Start-up certification
Boilers
Submit evidence that boilers meet requirements of standards specified. Include with the certificate
of compliance acceptable evidence that standards are met. Acceptable evidence will be the official
UL listing mark prescribed in the UL gas and oil equipment list for oil-fired, gas-fired, or
gas and oil-fired boiler assemblies, as applicable plus the appropriate official ASME symbol
stamp. In lieu of the above certification, acceptable evidence will be a test report from an
independent testing laboratory, indicating that the boilers and accessories have been inspected
and tested and meet requirements of the applicable standards specified.
SD-10 Operation and Maintenance Data
Boilers, Data Package 4
Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.
1.5 QUALITY ASSURANCE
1.5.1 Report of Prior Installations
Boilers shall be shipped to the site of installation as [a] [an] [completely assembled packaged boiler-burner
unit] [unassembled package. A competent installation engineer or technician as stated in paragraph entitled
"Qaulifications of Engineer" shall assemble an unassembled boiler-burner package in strict accordance with the
manufacturer's instructions. ] Boilers and feedwater equipment installed shall be of proven design which has
been tested, successfully installed, and operated in commercial or industrial installations. Submit a certified
written report from the boiler and feedwater equipment manufacturer indicating date of installation, type, model,
capacity, and address location of installed boilers along with maintenance records and operating conditions including
operating load and load swings. Show that substantially identical equipment of comparable capacity, within 20
percent, has been successfully installed and operated in not less than three installations under similar operating
conditions for a period of not less than 2 years.
1.5.2 Start-Up and Installation Engineer
Provide the services of a qualified engineer or technician for start-up and tests and installation of equipment
as specified below. More than one engineer or technician may be employed based on the types of specific equipment.
One engineer or technician appointed by the Contractor shall supervise and be responsible for the overall installation,
start-up, test, and checkout of systems.
1.5.3 Qualifications of Engineer
Submit a printed certified qualification resume of the engineer or technician. The engineer's or technician's
resume shall list applicable experience related to installation, start-up, and testing of equipment and applicable
factory training and education. Qualifications require the engineer to have supervised two installations of
similar size and type which are operating satisfactorily. If more than one engineer or technician is employed,
provide a certified resume for each one indicating their specific specialty and item of work.
1.5.4 Installation
NOTE: Delete this paragraph for boilers under 2930 kW 10,000,000 Btu/hr capacity.
Provide an installation engineer or technician to install and supervise the installation of steam boiler system
including instrumentation and boiler controls. Provide the technician or engineer until the installation of
equipment is coordinated and checkout completed.
1.5.5 Start-Up Plan
Submit a written schedule with dates of start-up tests, installation, and checkout of equipment.
1.5.6 Start-Up and Test
Start-up and test engineer or technician shall be approved by the manufacturer of the specific piece of equipment
including boiler, boiler controls, boiler instrumentation, and feedwater equipment. The start-up and test engineer
or technician shall remain on the job until the unit has been in successful operation for [_____] days, and has
been accepted by the Contracting Officer.
1.5.7 Start-Up Certification
After installation of equipment, the engineer or technician shall submit a signed certificate or certified written
statement that the equipment is installed in accordance with the manufacturer's recommendations.
PART 2 PRODUCTS
2.1 BOILERS
NOTE: Only allow option of MIL-B-18897 for low pressure boilers of capacities
less then 2930 kW 10,000,000 Btu/h. On/off combustion controls may be used
for up to 880 kW 3,000,000 Btu/h, hi-low-off type may be used for 585 to 1465
kW 2,000,000 to 5,000,000 Btu/h, and modulating positioning type may be used
for over 880 kW 3,000,000 Btu/h.
NOTE: Research local, state, and federal emission standards and place any new
or unusual requirements in this specification section.
[Firetube, packaged type of standard duty conforming to FS F-B-2903] [or] [Firetube type (horizontal return tubular
and horizontal fire box)] [Water tube type] [Cast iron, sectional type conforming to MIL-B-18897] [except that
treatment and painting shall be in accordance with manufacturer's standard practice,] Boilers shall have gross
output capacity of at least [_____] kW Btu per hour when operating at a steam pressure of [_____] kPa (gage)
pounds per square inch gage (psig) at the site under design conditions when the burner is firing [[No. [_____]
oil conforming to [ASTM D 396] having a higher heating value of [_____] MJ/kg Btu per gallon] [or] [[natural]
[manufactured] [mixed] [liquified petroleum] gas having a higher heating value of [_____] MJ/kg Btu per cubic
foot and a pressure of [_____] kPa (gage) psig at the fuel train connection].] [Gas fired boilers shall have
a steady state combustion efficiency of at least 80 percent when fired at the maximum and minimum rated capacities
which are provided and allowed by the controls.] [Oil fired boilers shall have a steady state combustion efficiency
of at least 83 percent when fired at the maximum and minimum rated capacities which are provided and allowed
by the controls.] Boilers shall comply with local, state, and federal emission regulations for the fuel being
used. Smoke emission shall not exceed Ringlemann No. 1, except during start-up, cleaning, or soot blowing.
Boiler furnaces shall be equiped with combustion control safety devices conforming to [ASME CSD-1, for boilers
of less than 3660 kW 12,500,000 BTU/HR thermal heating capacity.] [NFPA 85, for boilers with thermal heating
capacity of 3660 kW 12,500,000 BTU/HR or larger.] [Burners and controls for boilers conforming to MIL-B-18897
shall conform to FS F-B-2910.] Burners of the rotary type are not acceptable. Programming controls shall be
of the automatic [recycling] [non recycling] type and shall incorporate means for automatic self-checking of
the circuit at the beginning of each start-up cycle. Include a repetitive self-checking circuit to check components
at intervals not to exceed the specified flame failure response time in [FS F-B-2910] [or] [FS F-B-2903] [as
applicable] during the entire period of burner operation. Combustion controls, shall be of the [on-off], [hi-low-off]
[modulating-positioning] type. [Provide connections for remote starting or stopping of the boilers.] [Explosion
relief doors are required.] [Provide steam operated feedwater injectors.] [Cast iron boilers shall be of the
sectional type and shall conform to the requirements above and as specified. Boilers shall be [automatic] [semi-automatic,]
[or] [manual] start.] [For each boiler, provide a steam operated soot blower made of materials that shall withstand
expected temperatures.]
2.1.1 Boiler Connections
Requirements for interconnecting piping, insulation, fuel supply, [vibration isolation,] [_____,] and other related
work necessary to provide a complete and operable steam system, whether or not specifically mentioned above,
shall conform to applicable requirements of other sections of Division 15.
2.1.2 Boiler Instrumentation
In addition to the instruments required by the boiler specifications referenced above, provide the following
instruments and locate where shown and where recommended by instrument manufacturer:
a. A flue gas temperature gage.
b. A draft gage, [single point] [two point], conforming to
ASME B40.100.
NOTE: Select the applicable paragraph(s) from the following:
NOTE: These instruments are not normally required on boilers under 2930 kW
10,000,000 Btu/h.
[c. A carbon dioxide recorder to measure, record, and indicate the percentage by volume of
carbon dioxide detected in the flue gas. Flush mount the recording unit and furnish with locking
device and master key. The carbon dioxide recorder shall in other respects conform to CID A-A-50566
.]
NOTE: These instruments are not normally required on boilers under 2930 kW
10,000,000 Btu/h.
[c. A complete oxygen analyzer system to measure oxygen content of flue gases generated by
combustion of [gas] [or] [oil] as specified in paragraph entitled "Boilers" shall be provided
for each boiler. The output of the analyzer shall range from zero to [_____] [25] percent oxygen:
(1) Provide a complete aspirating system with proper connection to stack, necessary steam or
water aspirating facilities, and piping of proper specification to analyzer. Provide piping
in accordance with the oxygen analyzer manufacturer's recommendations and install tight. Install
equipment in accordance with the manufacturer's instructions.
(2) Provide a paramagnetic analyzer. Analyzer shall provide oxygen analysis in the zero and
25 percent oxygen range, and have means of calibration. Provide zero range and span adjustments
as required.
(3) Analyzer output and recorder input shall be compatible. Provide, connect, and place in
proper operation necessary transducers. Follow special instructions relating to electrical
transmission between analyzer and recorder as to the application of shielded wiring in conduit.
(4) Check the system with two calibrating gases as follows: (a) 100 percent nitrogen, and
(b) 3.5 percent oxygen and remainder nitrogen.]
NOTE: These instruments are not normally required on boilers under 2930 kW
10,000,000 Btu/h.
[c. Direct Probe In-Situ Type: Oxygen analyzer shall be the direct probe type utilizing an
in-situ zirconium sensing element. Insert element directly in the process flue gas stream and
in direct contact with process gasses. Sensing element shall be contained within a protective
shield mounted to the duct work by means of an adapter plate, all furnished by the manufacturer.
Analyzer shall be equipped with a facility to allow daily automatic calibration check without
removing the analyzer from the process. That is, sample gases may be injected directly on the
sensing element while the analyzer is in the process. In order to eliminate the temperature
effect of the flue gases, maintain the cell temperature in the probe at 843 degrees C 1,550
degrees F by means of an externally mounted temperature controller equipped with cold junction
compensation and coupled to the probe with at least 6 meters 20 feet of flexible cable. Analyzer
shall be FM P7825 approved and certified for "in-stack" analysis technique. Output signal range
shall be 4 to 20 milliamps and shall represent 0.25 percent to 25 percent oxygen as a logarithmic
function, 0.1 percent to 10 percent oxygen as a logarithmic function, or zero percent to 10
percent as a linear function. [Circular chart recorder shall consist of a two-pen recording
control mechanism having 110 volt ac electric motor drive. Chart shall be 300 mm 12 inch diameter
and have 24-hour revolution. Output control signal will be 20 to 103 kPa (gage) 3 to 15 psig
pneumatic. Sufficient blank charts and four ink cartridges per pen for 400 days operation
shall be provided. Recorder shall have a dual 30 degrees strip indicator. Strip indicator
and chart paper scale shall be logarithmic or linear and consistent with the analyzer signal
conditioning.] [Strip chart recorder shall consist of a two pen solid state electronic recording/controlling
mechanism. Strip chart shall be 100 mm 4 inches wide and shall be driven at a speed of 19 mm
per hour 3/4 inch per hour. Recording/controlling mechanism will operate on 110 volt ac power.
Recorder shall be furnished with twelve usable 24-hour logarithmic or linear charts consistent
with the analyzer signal conditioning. Inking system shall be a breakaway inking system with
replaceable fiber tip pens and 12 ink cartridges. Strip chart recorder/controller shall have
vertical scale and horizontal driven chart. Output control signal will be 4 to 20 milliamps
dc.] Flue gas temperature scale shall be 149 to 427 degrees C 300 to 800 degrees F. Entire
system response shall be not more than 3 seconds.]
NOTE: These instruments are not normally required on boilers under 2930 kW
10,000,000 Btu/h. However, smoke density recorders are mandatory for all residual
oil fired boilers having capacities above 2930 kW 10,000,000 Btu/h.
d. A smoke density [indicator] [recorder] of the [density limit] [continuous density] type
with a scale calibrated in Ringlemann units. Indicating and recording systems shall include
circuits for the audible warning of the maximum smoke density-limit. Supply a vibrating electric
horn to sound the audible signal. Otherwise the smoke density [indicator] [recorder] shall
conform to CID A-A-50566.
2.1.3 Boiler Plant Controls and Instruments
Provide the following plant [controls and] instruments:
a. Orsat Gas Analyzer : Provide a flue gas analyzer, Orsat type, conforming to FS A-A-50504
. Analyzer shall determine the CO2, CO, and O2 in the flue gas and shall be complete with chemicals
and accessories for use in such determinations.
b. Steam flow recorder: to remotely indicate, record, and totaling the steam flow per hour
through the steam header. Provide the panel-mounted indicating recorder with a tamper proof
case.
NOTE: Insert section number(s) for oil and/or gas piping systems in the blanks
below.
c. Volumetric fuel flow meters in accordance with [_____] [and [_____]].
NOTE: The value of tolerance limit shall be 3 percent for modulating positioning
type, shall be 5 percent for high/low/off type, and shall be 6 percent for on/off
type. See paragraph 3 for which type of combustion control is specified.
d. Master Combustion Control: Provide a common boiler master controller on the free standing
boiler instrument and control panel to control all boilers with each individual boiler controller
acting as a submaster controller. Boiler master control system shall provide for base loading
one [or more] boilers. Base loaded boiler(s) shall be selected manually by an externally accessible
switch. On call for heat, lead boiler shall cut in and moderate firing rate to satisfy demands.
When maximum desired firing rate is reached, lag boiler or boilers shall cut in. Only one boiler
shall be on modulating firing at one time. Maximum desired firing rate for base loaded boiler
shall be adjusted initially for boiler peak efficiency and shall be capable of easy manual adjustment
by operating engineer. Provide adequate indicators approved by the Contracting Officer to show
the method of loading of each boiler, and load being carried by it. Make adjustments at front
of panel and no linkage adjustment shall be necessary. Combustion control system shall be capable
of maintaining the plant steam pressure at the main header within the tolerance limits of plus
or minus [_____] percent expressed as a percent of the set point values. The specified tolerance
shall apply to a load which, within a one-minute period, swings from a steady-state condition
to an increase (or decrease) in load equal to a maximum of 10 percent of the plant. Regulation
tolerances shall apply to any steady state condition within the plant turndown ratio of [_____].
Combustion efficiency shall not be less than that specified in the boiler specifications.
e. Pressure gage conforming to ASME B40.100 or indicating steam pressure in main steam header,
[for indicating atomizing steam pressure,] and for indicating feedwater pressure.
2.1.4 Boiler Control and Instrument Cabinet(s)
Provide boiler control and instrument cabinet(s) as specified in the referenced boiler specification(s) and may
be mounted either on the boiler front or adjacent thereto. The arrangement may consist of a boiler mounted cabinet
containing controls normally provided by the manufacturer and a supplementary cabinet containing additional controls
and instruments required herein. Mount [plant master combustion control] [and] [steam flow recorder] on or adjacent
to control panel for number [_____] boiler.
2.1.5 Free-Standing Multi-Boiler Plant Control and Instrument Panel
Provide a free-standing panel and locate as indicated. The panel shall contain all individual and multi-boiler
controls, monitoring system, and panel-mounted instruments specified herein and in the reference specifications,
except that flame safeguard system may remain separately mounted in a cabinet at each boiler.
[2.1.5.1 Control Panel Construction
NOTE: Select the applicable paragraph(s) from the following:
NOTE: Delete inapplicable paragraph(s).
Construct control panel of not less than 3 mm 11 gage reinforced steel for face, top, and sides. The enclosed
panel shall be not less than 610 mm 24 inches in depth with inside rigidly welded braces. Design control panel
so that all indicating and recording devices and manually operated switches shall be flush mounted in a gasketed
removable-top front panel with indicating and recording devices at eye-level. Provide a similar removable-top
rear panel located opposite front panel to facilitate wiring, piping, and maintenance. Install other operating
controls on a sub-panel within the enclosure. Access to panel enclosure shall be through gasketed, double piano-hinged
doors of not less than 1.52 mm 16 gage steel. The doors shall be reinforced to prevent sagging and shall be
provided with a three point compression type fastener and polished key lock handle. Include a full width fluorescent
lighting canopy also. Prime coat complete control panel and lighting canopy and finished in baked enamel. Identify
flush-mounted devices on panel with engraved lamicore nameplates. Adequately reinforce, skirt, and suitably
design panel base to permit anchoring to the floor or foundation.
][2.1.5.2 Control Panel Wiring and Piping
NOTE: Delete inapplicable paragraph(s).
Control panel shall be factory pre-wired in accordance with NFPA 70. Wire shall be thermoplastic Type THW, THWN,
XHHW, or UL approved for the intended use, color or number coded, and run in plastic ducts to numbered terminal
blocks. Control circuits shall be separately fused with properly rated cartridge type fuses. Power leads to
and from magnetic starters and contractors shall terminate at terminal blocks so that field wiring is necessary
only from terminal blocks to external equipment. Control leads to and from external control devices shall terminate
at separate terminal blocks from power leads. Steam-, draft-, and air-operated devices shall be factory piped
to permanently affixed external connections. Pneumatic signals shall be either 20 to 103 kPa (gage) 3 to 15
psig or 20 to 207 kPa (gage) 3 to 30 psig. Piping connections to indicators shall be copper tubing conforming
to ASTM B 88M ASTM B 88. The boiler operating switch shall be a dust-tight sealed snap-action type. The precision
switches shall have cadmium, silver, or platinum contacts, wiping action type, rated at 10 amperes. Electrically
or pneumatically tested, controls and equipment shall be to simulate complete operational sequence.
]2.1.6 Hot Water Heater
NOTE: Hot water heaters are only used on boilers operating at 103 kPa 15 psi
or less.
[The] [Each] [Number [_____]] boiler shall be equipped with internal hot water heating coils conforming to the
ASME BPVC SEC VIII. Heaters shall have gasketed cast iron or steel flange mountings and shall be designed, fabricated,
and tested to withstand 207 kPa (gage) 30 psig maximum working pressure at 121 degrees C 250 degrees F. The
heating coil shall be finned tube type not less than 19 mm 3/4 inch outside diameter and shall be constructed
of seamless copper or copper alloy that meet the requirements of [ASTM B 75M ASTM B 75,] [ASTM B 111/B 111M,]
or [ASTM B 395/B 395M ASTM B 395/B 395M]. The heating coil while submerged in water under pneumatic pressure
shall withstand 2068 kPa (gage) 300 psig. The pressure drop through the coil at maximum temperature and draw
rate shall not exceed 34 kPa (gage) 5 psig, unless otherwise indicated. The coils shall terminate in threaded
inlet and outlet connections on the exterior of the boiler and shall be designed for the indicated temperature
rise and maximum draw rate. When applicable, provide instrumentation for metering hot water production load
on boiler.
2.1.7 Noise Levels
Noise measurements and exposure analyses should be conducted under the overall supervision of an industrial hygienist
or suitably qualified medical officer from the Navy Regional Medical Center (NRMC). Safety personnel, engineers
and others who have been certified by the Chief, Bureau of Medicine and Surgery (BUMED) also may supervise the
work. Exposure limits for potentially hazardous noise levels of 85 dBA, continuous or intermittent, and 140
dB peak sound pressure, impulse or impact, shall be maintained. The sound level meter shall conform as a minimum
to the Type 2 requirements cited in ASA S1.4.
2.2 BOILER BREECHING
2.2.1 Round Breeching
Construct round breeching of black iron or steel in accordance with NFPA 211 for metal connectors for medium-heat
appliances and shall be constructed with welded beams and joints. Round breechings also may consist of approved
factory-built chimney sections for medium-heat appliances if the sections are joined together with continuous
welds, flanges, or couplings. Provided suitable cleanouts that will permit cleaning the entire breeching without
dismantling.
2.2.2 Rectangular Breeching
NOTE: Specifier should check structural steelwork section of the project specification,
if used, as well as notes on structural drawings to ensure against conflict
of requirements.
Structural materials shall comply with the applicable sections of AISC 360. Shop connections may be welded or
bolted as required for joining breeching to equipment. Supply hot dipped galvanized bolts and lock washers for
bolted connections. Bolts shall be not less than 10 mm 3/8 inch in diameter, and spaced not more than 76 mm
3 inchesapart. Furnish bolted joints with 3.20 mm 1/8 inch thick non-asbestos gaskets. Breeching [plate] shall
be not less than [12 MS gage steel] [4.80 mm3/16 inch thick]. Welds shall conform to AWS D1.1/D1.1M. Breeching
system shall provide for maximum expansion and contraction. Expansion joints shall be of the guided flexible
crease type with flexible element of not less than 1.60 mm 0.0625 inch thick stainless steel. Provide access
doors and cast iron or reinforced steel plate with non-asbestos gaskets 3.20 mm 1/8 inch thick and positive closing
latches of sufficient number to ensure a gas-tight seal. Thoroughly clean breeching of rust and scale after
fabrication by commercial sand blasting.
2.2.3 Breeching Hangers
Design breeching hangers to carry not less than five times the breeching weight. Hangers for round breeching
shall be of the band type with hanger rods. Provide steel tappeze type hangers for rectangular breeching with
angle support member and hanger rods.
2.2.4 Cleanout Doors
Secure cleanout doors to the ends and sides of the breeching where indicated or where required to effectively
clean the breeching. Construct cleanout doors of a gage steel not less than that of the breeching and secure
to a 32 by 32 inch 1 1/4 by 1 1/4 inch angle frame not less than 3.20 mm 1/8 inch in thickness with mounting
bolts welded to the angle frame and spaced not over 152 mm 6 inches on center; provide 1.60 mm 1/16 inch thick
long fiber non-asbestos gasket between cleanout doors and frames. Doors shall be squared and shall be full height
of diameter or side of breeching up to a size of 610 mm by 610 mm 24 inches by 24 inches maximum, except that
cleanout doors less than 305 mm 12 inches in height shall be rectangular and shall be 305 mm 12 inches in length.
Plug type cleanouts are not acceptable.
2.2.5 Stacks
Stacks shall be constructed of not less than [12] [10] MS gage steel, welded construction, and of proper size
to adequately serve the respective boiler. Stacks shall project above the boiler house roof not less than that
indicated and shall be supported by a substantial steel framework. Provide structural steel framework at boiler
room roof around each stack and attached to roof joints to brace stack against swaying and to support new roof
curb and stub stack. Construct stacks as indicated to include automatic damper access door, gas sampling connection,
smoke density indicator, temperature sensing connection, and other features shown or required. When rain can
fall into contact with internal boiler parts, provide stub stacks with rain caps or hoods. Provide stacks with
the following:
a. Provide curb openings in roof and properly flash and counterblock to roofing. Furnish and
install flashing hoods around stacks and over roof curbs.
b. Provide a bellows type flexible [fabric] [_____] type expansion joint approximately 152
mm 6 inches wide in the stacks at the location shown. Joint system shall consist of 4.80 mm
3/16 inch steel plate welded to inside of bottom section of stack. Top section of stack shall
be free to move up and down outside the plate. Weld steel reinforcing angles around both top
and bottom sections of stack. Fit and weld to the angles an expansion angle type bellows of
12 gage steel.
c. Clean stacks of dirt, rust, oil and grease by wire brushing and solvent degreasing and give
one shop coat of heat-resisting aluminum paint conforming to FS TT-P-28 on the inside and outside.
The coat of paint shall have a minimum dry film thickness of one mil.
2.3 BLOWDOWN EQUIPMENT
Furnish the [boiler] [plant] with all equipment, tanks, and controls necessary for bottom [and continuous] blowdown
of the boilers. The equipment for bottom blowdown systems shall include a [blowdown tank] [and sample cooler].
[Continuous blowdown systems shall be of the packaged, proportional type consisting essentially of a heat exchanger,
flow control valve, surge tank, [and] sample cooler, [and blowdown control console with test sink].] Install
and pipe blowdown equipment as indicated, and conform to recommendations of the NBBPVI NB-27, Recommended Rules
for National Board Boiler Blowoff Equipment.
2.3.1 Bottom Blowdown Tank
NOTE: Cathodic protection or magnesium anodes only required when steel tank
is buried.
Blowdown tank shall be fabricated of welded steel plate in accordance with ASME BPVC SEC VIII. Tank shall be
a vertical cylindrical tank designed for the working pressure of the boiler(s). Tank shall be equipped with
a tangential blowdown inlet located so as to impinge on a carbon steel wear plate extending at least 180 degrees
around the interior circumference of the tank from the point of inlet. Tank shall be equipped with an internal
overflow, vent, drain, safety relief valve, and gage glass with try cocks, blowdown cock, and guard. Tank interior
shall be protected by an epoxy coating system suitable for continuous water immersion and operation at a minimum
temperature of [121] [149] degrees C [250] [300] degrees F. The tank [shall be fitted [with renewable magnesium
anodes] [with cathodic protection equipment] to minimize galvanic corrosion of the exterior.] [shall be constructed
of Class A reinforced concrete and shall be fitted with a bolted steel manhole frame and cover. Install blowoff
pipe, vent pipe, and drain pipe in pipe sleeves built into concrete. Fill the space between the pipe and sleeves
and calk with lead wool or equivalent to make a watertight seal. Tank shall be divided into two sections by
means of a baffle to form a sediment chamber.] Size and locate blowoff tank shall be size and located as shown.
2.3.2 Sample Cooler
Provide a water-cooled, shell-and-tube, or shell-and-coil type heat exchanger designed for cooling sample of
boiler water prior to chemical testing. Furnish the sample cooler as a component of the packaged continuous
blowdown system when such a system is being furnished. The cooler shall consist of a cast iron or steel shell
with copper coil or copper alloy tubes and shall be equipped with a brass or bronze sampling cock. [The cooler
shall be connected to a header and so valved that a sample can be withdrawn from any boiler as desired.] [Furnish
a concentrometer kit containing necessary glassware, reagents, and instructions for determining boiler water
concentrations.]
2.3.3 Continuous Blowdown System
NOTE: Specify continuous blowdown only where makeup water ratio is in excess
of 20 percent of the boiler output or where the total dissolved solids of this
makeup water are in excess of 500 parts per million.
NOTE: Include last sentence if a console type unit is indicated.
Provide a complete packaged unit of the [automatic-proportioning] [manual-apportioning] type wherein the amount
of blowdown from the [boiler] [plant] is automatically proportioned to the amount of make-up feedwater [and the
total amount of blowdown from the plant is manually apportioned between boilers according to their steaming rate].
The system shall include either an automatic-proportioning valve and a heat exchanger or a concentric tube automatic
proportioning control which shall be provided with a separate heat exchanger when necessary to meet the performance
requirements indicated or specified herein. The system shall be designed for not less than boiler design pressure
and shall be capable of heating the feedwater from [_____] degrees C degrees F to [_____] degrees C degrees F
at the flow rates indicated. Heat exchanger shall consist of a steel shell and heads with Type 304 stainless
steel tubes arranged in a removable U-bend bundle. Construct and test shell in accordance with ASME BPVC SEC VIII
for the specified boiler operating pressure. Automatic proportioning valve shall be provided with a sensing
orifice on both the makeup and blowdown lines and shall be of the adjustable ratio type in which the ratio of
makeup to blowdown may be set anywhere within a range of [30:1] [_____] to [4:1] [_____]. Automatic proportioning
control shall consist of two concentric tubes, the inner tube being of a thermostatic design which acts directly
against an adjustable seat in response to the temperature differential between the blowdown in the inner tube
and the makeup water between the inner and outer tubes. [Manual apportioning valves shall have bronze bodies
with stainless steel seats and disks and shall be of the indicating type specifically designed for blowoff service.]
Blowdown system shall be complete with strainers, stop valves, [blowdown meters,] thermometers, and other accessories
necessary to form complete packaged units. [Blowdown control console shall include illuminated sight flow indicators,
automatic flushing and cooling valves, and complete panelboard instrumentation as well as a cabinet type laboratory
sink with drain board, back splash, hot and cold service water faucets, [air cock,] and electrical outlets.]
2.4 FEEDWATER EQUIPMENT
2.4.1 Boiler Feed Pumps
Conform to CID A-A-50562 for motor driven, horizontal split case or support head boiler feed pumps except as
otherwise specified herein. Pumps may be of either the centrifugal or peripheral-turbine type with [cast iron]
[or] [alloy steel] casing and shall be [bronze] [or] [alloy steel] fitted. For turbine type pumps, provide pressure
relief valves and for centrifugal type pumps, provide by-pass orifice. Packed stuffing boxes or mechanical seals
suitable for the design conditions indicated shall be provided. Pumps shall be designed for the net positive
suction head, discharge head, and water temperature indicated. [Capacity under the above condition shall be
not less than indicated.] [Capacity of each pump under the above conditions shall be not less than the following
percentage of maximum total boiler capacity: Centrifugal pumps 125 percent; Turbine pumps 150 percent.] Pump
motors shall be [totally enclosed] [dripproof] [dripproof with encapsulated windings].
2.4.2 Boiler Feed Tank
Feed tank and stand construction shall conform to FS F-P-2908 for horizontal, cylindrical, stand-mounted receivers
and shall be [hot dip galvanized or cement lined] [epoxy coated] [coated]. Provide tanks with vents, gage glass,
drain and overflow connections, pressure gage, thermometer, [float operated makeup water feeder] [float switch
and makeup water solenoid valve] [and preheater assembly consisting of corrosion resistant steam diffuser tube,
steam corrosion resistant steam diffuser tube, steam pressure reducing valve, strainer, and thermostatic steam
valve]. Boiler feed tank assembly shall include boiler feed pumps as herein specified, interconnecting piping
including strainer and pump control box. Tank capacity and connection sizes shall be as indicated.
2.4.3 Deaerator
Provide pressurized packaged type conforming to FS W-H-2904, be constructed and stamped in accordance with ASME BPVC SEC VIII D1
, and requirements specified herein. Deaerating assembly and deaerated water storage may be in the same or separate
shells. When external vent condensers are provided, they may be located as recommended by the manufacturer.
Provide a pressure relief valve sized [as indicated] [in accordance with Table II of FS W-H-2904]. Inlet piping
and accessories shall be as indicated. Provide feedwater pumps, as specified herein, interconnecting piping,
and control box as part of the deaerator package. Deaerator capacity shall be not less than [indicated] [1.25
times that required to supply the boiler(s) at maximum firing rate]. The temperature of the water delivered
at maximum capacity shall be equivalent to saturated steam temperature at the operating pressure of the deaerator,
which shall be as indicated and the oxygen content shall not exceed [0.005] [0.003] cubic centimeters per liter
as determined by the Referee Method A (Colorimetric Indigo Carmine) of ASTM D 888. Water storage capacity shall
be sufficient to operate the boilers at maximum capacity for [10] [_____] minutes.
2.4.4 Surge Tank and Transfer System
The condensate storage and surge tank shall be a cylindrical welded steel tank mounted and supported as indicated.
The tank shall be designed and constructed in accordance with the ASME BPVC SEC VIII D1 for the indicated working
pressure. Storage capacity shall be [as indicated] [sufficient to provide adequate water to the deaerator for
[10] [_____] minutes of [boiler] [plant] operation at maximum capacity]. Inlet connections for condensate and
make-up water shall be as indicated. The tank shall be equipped with liquid level controllers and valves and
alarms as indicated. Tank shall be equipped with pressure and temperature gages, water level gage, vent, drain,
and overflow. Tank shall be [hot dip galvanized or cement lined] [epoxy coated] [_____]. Surge tank assembly
shall include condensate transfer pumps and interconnecting piping including strainer and control box as indicated.
Transfer pumps, except for head and temperature requirements which shall be as indicated, shall conform to requirements
for boiler feed pumps specified herein.
2.4.5 Feedwater Treatment Equipment
2.4.5.1 Feedwater Characteristics
NOTE: Insert source of water supply.
Equipment for the chemical treatment of the boiler makeup feedwater shall be designed to reduce the boiler water
concentrations to the limits specified herein when handling raw water having the following impurities reported
as milligrams per liter (mg/liters) (formerly parts per million):
a. Total hardness as CaCO3_______________________
b. Calcium hardness as CaCO3_____________________
c. Magnesium hardness as CaCO3______________________
d. Alkalinity as CaCO3______________________
e. Sodium as Na______________________
f. Chlorides as Cl______________________
g. Sulfates as SO4______________________
h. Sulfites as SO4______________________
i. Phosphate as PO4_____________________
j. Silica as SiO4_______________________
k. Nitrates as NO3______________________
l. Iron as Fe______________________
m. Free carbon dioxide as CO2______________________
n. Total dissolved solids_______________________
o. Suspended solids______________________
Raw water shall be delivered to the plant [from the water distribution system of the [_____]] [from [_____]]
at a normal pressure of [_____] kPa (gage) psig measured at the meter to the plant. See NAVFAC MO 225 for additional
guidance on boiler water concentration limits.
2.4.5.2 Water Softener
Equipment shall be of the type, size, and arrangement indicated. When operating [under the indicated design
conditions] [with an inlet water flow of [_____] liters per second gpm] effluent analysis shall be as follows:
a. Total hardness as CaCO3 less than [_____] Mg/liter
[b. pH [_____] to [_____]
c. Total dissolved solids less than [_____] Mg/liter
d. [_____]]
(1) Zeolite Water Softener: Conform to WQA S-100 and shall have [automatic] [manual] controls.
The softener(s) shall be equipped for [a sodium cycle] [a hydrogen cycle] [the type of cycle
necessary to provide the treated water analysis specified above]. [Each softener tank shall
be provided an operating valve to permit the regeneration of one tank while the other is in
service.]
(2) Lime Soda Softener: Conform to CID A-A-50573 for the type indicated.
(3) Ion Exchange Softener: Refer to NAVFAC MO 225 for additional information.
2.4.6 Pressure Filter
Provide [a] pressure filters of the type and arrangement indicated and with [manual] [automatic] controls. The
filter shall conform to CID A-A-59249. Performance shall be as specified in CID A-A-59249 with raw water analysis
as specified herein, and operating conditions as indicated. Filter shall be equipped to operate properly for
not less than 2 days without operator attention to renew or regenerate filter coatings, chemicals, or other filter
media.
2.4.7 Chemical Feeder
Size and connect as indicated. Chemical feeder shall be suitable for the flow, pressure, and temperature conditions
at the point of connections. Provide chemical feed storage as indicated. [The feeder shall be of the [automatic
proportioning type] [shot-type] conforming to FS F-F-2901.] [The feeder shall be of metering pump type conforming
to the requirements of CID A-A-50573 for chemical feeders.]
2.4.8 Feedwater Test Equipment
Provide for the determination of boiler water condition which includes an assembly of indicator solutions, standardized
solutions, and test glassware with cabinet. The solution types shall permit tests for water hardness, total
alkalinity, hydroxide, carbonite alkalinity, and chloride content in milligrams per liter. Feedwater test equipment
shall employ a standardized soap solution for hardness test and a dilute sulfuric acid solution with a methyl
orange indicator for total alkalinity. The hydroxide and carbonate alkalinity shall be determined with a phenolphthalein
indicator and the chloride content, with a silver nitrate solution. Furnish standardized phenolphthalein color
slides for accuracy in alkalinity tests.
2.5 ELECTRIC MOTORS
NOTE: Select standard efficiency for motors used less thatn 750 hours per year
and high efficiency for motors used over 750 hours per year. Packaged boilers
should utilize the manufacturer's standard efficiency motor.
Motors which are not an integral part of a packaged boiler shall be rated for [standard] [high] efficiency service
per Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Motors which are an integral part of the packaged boiler
system shall be the highest efficiency available by the manufacturer of the packaged boiler.
PART 3 EXECUTION
3.1 INSTALLATION
Arrange work in a neat and orderly manner so that minimum storage of equipment and material is required at the
project site. Install equipment and material in accordance with the best commercial practices. A competent
installation engineer or technician as stated in paragraph "Qualifications of Engineer" shall assemble an unassembled
boiler-burner package in strict accordance with the manufacturer's instructions. Systems shall be neat in appearance,
compact, adequate in construction and assembly, and installed for long and continuous service. Parts shall be
readily accessible for inspection, repair, and renewal. Inspect equipment and material upon delivery and test
after installation. Protect material and equipment from the weather. Repair damage caused by the Contractor
in execution of the work and leave in a condition equal to that existing before work was started.
3.1.1 Equipment Foundations
Locate as shown and construct of sufficient size and weight and of proper design to preclude shifting of equipment
under operating conditions or under abnormal conditions that could be imposed upon the equipment. Foundations
shall meet requirements of equipment manufacturer. Grout equipment mounted on concrete foundations before installing
piping. Concrete shall conform to Army Corps of Engineers Guide Specification Section [03 30 00] CAST-IN-PLACE
CONCRETE, and grout shall be non-shrinkable type approved by the Contracting Officer. Install piping in such
a manner so as not to place a strain on equipment.
3.1.2 Welding
NOTE: Use of the ASME code or the Federal Construction Guide Specification
section on welding depends upon the agency's requirements.
NOTE: Insert appropriate Section number in blank below.
Work shall be in accordance with [the applicable sections of the ASME BPVC SEC I] [[_____] WELDING] and AWS Z49.1
.
3.1.3 Painting
Equipment shall be factory finished to withstand the intended end use environment in accordance with the specifications
for the particular end item. Field paint equipment not factory finished as specified herein. Retouch damaged
areas of factory-finished equipment on which the finish has been damaged and then give a complete finish coat
to restore the finish to its original condition. The finish coat shall be suitable for exposure in the intended
end use environment. Spray painting shall comply with OSHA 29 CFR 1910.
3.1.3.1 Cleaning and Application
Remove dirt, rust, oil, and grease by wire brushing and solvent degreasing prior to application of paint. Apply
paint to clean and dry surfaces only. Where more than one coat of paint is specified, apply the second coat
after the first coat is thoroughly dry. Retouch damaged painting before applying the succeeding coat. Finished
surfaces shall be smooth. The painting of zinc coated and other corrosion-resistant metal surfaces is not required
unless otherwise specified herein.
3.1.3.2 Smoke Flues, Boiler Casing, and Draft Ducts
In unfinished areas, paint smoke flues, boiler casing, and black steel draft ducts with heat-resisting aluminum
paint, two coats on the inside of flues and ducts and one coat on the outside, each coat to a minimum dry film
thickness of 0.025 mm one mil applied directly to clean bare metal surfaces. Paint exposed surfaces of protective
metal covering over insulation, including zinc-coated surfaces, with two coats of heat-resisting black paint
to a minimum dry film thickness of 0.05 mm two mils applied directly to the clean bare metal surfaces. Do not
paint zinc-coated ducts.
3.1.3.3 Gratings, Pipe Railings, and Pit Covers
Apply a pre-treatment coating to gratings, pipe railings, pit covers, and similar plant appurtenances to a dry
film thickness of 0.008 to 0.013 mm 0.3 to 0.5 mil. After installation, touch up damaged surfaces with then
paint with two coats of finish paint matching type and color of adjacent areas. Do not paint zinc-coated surfaces.
3.1.4 Boiler Cleaning
After installation, [the] [each] boiler shall be boiled out, under supervision of the manufacturer, with soda
ash or equivalent solution to clean internal surfaces of oil, grease, mill scale, and dirt. Following treatment,
the boiler(s) shall be flushed, drained and then opened and washed down and inspected to ensure that no traces
of oil or foreign matter are present. The boiler and associated piping shall then be drained and refilled with
treated softened water. At all times after initial cleaning, the Contractor shall protect the boiler, tanks,
and piping against internal corrosion until testing is completed and the boiler(s) [is] [are] accepted. Provide
chemicals, labor for introducing chemicals, and professional services for control and supervision of the treatment
process.
3.1.5 Piping
Material and installation requirements including welding shall be as specified in Section 23 11 25 FACILITY GAS
PIPING, Section 33 51 15 NATURAL-GAS / LIQUID PETROLEUM DISTRIBUTION, Section 33 52 10 SERVICE PIPING, FUEL SYSTEMS,
and Section 23 22 26.00 20 STEAM SYSTEM AND TERMINAL UNITS.
3.2 FIELD QUALITY CONTROL
Perform inspections and tests as specified herein to demonstrate that the boiler(s) and auxiliary equipment,
as installed, are in compliance with contract requirements. During boiler system start-up tests, factory-trained
engineers or technicians employed by individual suppliers of such components as the burner, flame safeguard and
combustion controls, feedwater treatment equipment, and other auxiliary equipment shall be present, as required,
to ensure the proper functioning, adjustment, and testing of individual components and systems. No bypassing,
use of jumpers, or other disablement of control systems will be allowed unless specified elsewhere. Labor, equipment,
fuel, and test apparatus required for testing shall be furnished by the Contractor. Rectify defects disclosed
by the tests by the Contractor within time period specified by the Contracting Officer.
3.2.1 Inspections and Test
NOTE: These field tests shall not be mandatory for all size boilers but shall
be employed where advis able due to largeness, type, or complexity of boiler
plant. The designer shall determine, on a case by case basis, which tests are
appropriate.
Make inspections and tests at the site under the direction of and subject to the approval of the Contracting
Officer. The Contractor shall operate [the] [each] boiler and appurtenances prior to final testing and shall
ensure that necessary adjustments have been made. A [24-] [48-] [_____] hour written notice shall be submitted
to the Contracting Officer indicating the equipment is ready for inspection or testing. Provide testing equipment,
including gages, thermometers, calorimeter, Orsat apparatus, thermocouple pyrometers, fuel flow meters, water
meters, and other test apparatus and set up and calibrate prior to the test. Draft, fuel pressure, and steam
flow may be measured by permanent gages and meters installed under the contract. [Gas flow may be measured by
utility company meters.] Provide an analysis of the fuel being used for tests. Control of noise levels developed
by exhaust steam including muffler, globe, and gate valves shall be conducted in such a manner as not to create
a nuisance or hazard and shall be subject to the approval of the Contracting Officer. Tests shall include the
following, and shall be performed when feasible, in the sequence listed:
a. Strength and tightness tests
b. Standards compliance tests
c. Combustion tests
d. Operational tests
e. Capacity and efficiency tests
f. Tests of auxiliary equipment
g. Feedwater equipment test
3.2.2 Strength and Tightness Tests
NOTE: These field tests shall not be mandatory for all size boilers but shall
be employed where advis able due to largeness, type, or complexity of boiler
plant. The designer shall determine, on a case by case basis, which tests are
appropriate.
Subject boiler to the following strength and tightness tests:
3.2.2.1 Hydrostatic Test
After installation and connection, subject [the] [each] boiler to an inspection and hydrostatic test to determine
that the boiler and appurtenances have not been damaged in transit or handling. The hydrostatic test shall be
in accordance with the ASME Code with the test pressure applied for a period required by the Contracting Officer.
This test shall be in addition to the hydrostatic tests performed at the factory. [The hydrostatic test at the
site shall be certified by an inspector holding an authorized commission from the National Board of Boiler and
Pressure Vessel Inspectors.]
3.2.2.2 Pneumatic Tests
Pneumatically test air casing and ducts exterior to the furnace at the maximum working pressure. Use the soap
bubble method to verify tightness. Test gas sides of boilers normally operated under pressure for tightness at
2.5 kPa (gage) 10 inches water gage. For this test, tightly seal the boiler with a suitable means to blank
off openings. Admit air to the boiler until test pressure is reached and then hold. If in a 10-minute period
the pressure drop does not exceed 250 kPa one inch water gage, the casing shall be regarded as tight and accepted.
Use air pressure and soap bubble tests or comparative carbon dioxide readings for induced draft boilers.
3.2.2.3 Internal Component Pressure Tests
[Hydrostatically test at 1-1/2 times the maximum operating pressure] the part of the pre-assembled fuel oil system
that is furnished integrally with the boiler. [The part of the pre-assembled gas system that is furnished integrally
with the boiler shall be pneumatically tested at operating pressure. Use the soap bubble test method to verify
tightness of the gas system.]
3.2.3 Combustion Tests
NOTE: These field tests shall not be mandatory for all size boilers but shall
be employed where advisable due to largeness, type, or complexity of boiler
plant. The designer shall determine, on a case by case basis, which tests are
appropriate.
Test the fuel burning and combustion control equipment with [the] [each of the] specified fuel at the minimum
limit of the turndown range and at increments of 50, 75, and 100 percent of full rated load [plus [_____] percent
overload]. Tests shall be conducted by factory-trained combustion equipment engineers as previously specified.
[The combustion control system shall demonstrate that equipment installed will meet the requirements of the
specification, and that an overall efficiency as specified, with not over 15 percent excess air, can be obtained
with boiler operating at 100 percent capacity.] Analyze test data and graphically present to show for [the]
[each] boiler at tested loads: rates of steam flow; flue gas temperature; percent excess air; steam quality;
and percentages of carbon dioxide, carbon monoxide, and oxygen in the flue gas. Monitor concentrations of sulfur
oxides, particulate, and nitrogen oxides in the flue gas to ensure compliance with environmental requirements.
Run tests on each fuel until stack temperatures are constant and conformance with the combustion requirements
of this specification has been verified and recorded. Verify proper operation of instrumentation and gauges
in the control panel during the test.
3.2.4 Operational Test
NOTE: These field tests shall not be mandatory for all size boilers but shall
be employed where advisable due to largeness, type, or complexity of boiler
plant. The designer shall determine, on a case by case basis, which tests are
appropriate.
Continuously test the boiler(s) under varying load conditions to demonstrate proper operability of the combustion
control, flame safeguard control, programming control, and safety interlocks. Conduct this test after the adjustment
of the combustion controls has been completed under the combustion test. The operational test shall continue
for a period of at least [8] [_____] hours and shall include the following:
3.2.4.1 Sequencing
The boiler shall start, operate, and stop in strict accordance with the specified operating sequence.
3.2.4.2 Flame Safeguard
Verify the operation of the flame safeguard controls by simulated flame and ignition failures. Test burners
having intermittent pilots by simulating main flame failure while the pilot is burning. Verify by stop watch
the trial-for-pilot ignition, trial-for-main flame ignition, combustion control reaction, and valve closing times.
3.2.4.3 Immunity to Hot Refractory
Operate the burner at high fire until the combustion chamber refractory reaches maximum temperature. Then manually
close the main fuel valve. The combustion safeguard shall drop out immediately causing the safety shutoff valves
to close within the specified control reaction and valve closing times.
3.2.4.4 Pilot Intensity Required
Gradually reduce the fuel supply to the pilot flame to the point at which the combustion safeguard begins to
drop out (sense "no flame") but holds in until the main fuel valve opens. At this point of reduced pilot fuel
supply, the pilot flame shall be capable of safely igniting the main burner. If the main fuel valve can be opened
on a pilot flame of insufficient intensity to safely light the main flame, readjustment of fire eye is required.
3.2.4.5 Immunity to Ignition Spark
Where ultra violet flame detectors are employed, the pilot and main burner manual safety shut off valves shall
be closed. The burner shall then be operated through the trial for pilot ignition period. The flame safeguard
relay shall not respond to the presence of electric spark. If the flame safeguard relay responds to the presence
of electric spark, reject the boiler.
3.2.4.6 Boiler Limit and Fuel Safety Interlocks
Safety shutdowns shall be caused by simulating interlock actuating conditions for each boiler limit and fuel
safety interlock. Safety shutdowns shall occur in the specified manner.
3.2.4.7 Combustion Controls
Demonstrate the accuracy, range, and smoothness of operation of the combustion controls by varying the steam
demand through the entire firing range required by the turndown ratio specified for the burner [and in case of
automatic recycling burners, by further varying the firing rate to require "on-off" cycling]. Control accuracy
shall be as specified
3.2.4.8 Safety Valves
The high-pressure limit switch shall be locked out or otherwise made inoperative, and the boiler safety valves
shall be lifted by steam. Determine the relieving capacity, popping pressure, blowdown, and reseating pressure
by observation and measurement to be in accordance with the ASME Boiler and Pressure Vessel Code. The ASME standard
symbol will be accepted only as indicating compliance with the design and material requirements of the code.
3.2.5 Capacity and Efficiency Tests
Perform the capacity and efficiency tests after satisfactory completion of all tests previously specified herein
and after the boilers have been operating [continuously] for [one] [5] [_____] days with no nuisance shutdowns
and without the necessity for frequent or difficult adjustments. Perform these tests on each boiler. Conduct
tests using [the] [each of the] specified fuels. Test procedures shall be in accordance with the heat loss method
of the ASME PTC 4 and shall be reported on the ASME Test Form for Abbreviated Efficiency Test. The duration
of the tests shall be sufficient to record necessary data but in no case shall test duration be less than [4]
[_____] hours [on each fuel].
3.2.6 Auxiliary Equipment and Accessory Tests
Observe and check blowdown valves, stop valves, try cocks, draft fans, fuel oil heaters, pumps, electric motors,
and other accessories and appurtenant equipment during the operational and capacity tests for leakage, malfunctions,
defects, noncompliance with referenced standards, or overloading, as applicable.
3.2.7 Feedwater Equipment Tests
Perform the test of the feedwater treatment equipment in two steps. Conduct one test by the Contractor concurrently
with either the combustion test or the capacity and efficiency test. A second test will be performed by the
Government during the first period of heavy loading after the plant has been accepted and put in service. Deficiencies
revealed during the Government tests will be corrected under the guarantee provisions of the contract. Both
the first and second series of tests shall determine compliance with the limits for oxygen content and hardness
concentrations of this specification. Equipment for taking samples and the test kit for analyzing the samples
shall be supplied by the Contractor and shall revert to the Government when the tests are completed.
3.2.8 Preliminary Operational Test
Operate each boiler and appurtenances prior to final testing and insure that necessary adjustments have been
made. Provide testing equipment required to perform tests. During this testing period, provide operating instructions
and training to persons tasked with operation of the boiler.Tests shall be accomplished with both fuel on dual
fuel units.
NOTE: Insert the appropriate Engineering Field Division.
Conduct a preliminary operational test prior to requesting an acceptance operational test and inspection by a
[_____] Division, Naval Facilities Engineering Command Boiler Inspector. The Contracting Officer, upon receipt
of the notice from the Contractor, shall request the boiler be inspected by [_____] Division, Naval Facilities
Engineering Command. Ten days advance notice is required for scheduling the inspector to conduct acceptance
operational test and inspection.
3.3 SCHEDULE
Some metric measurements in this section are based on mathematical conversion of inch-pound measurements, and
not on metric measurements commonly agreed on by the manufacturers or other parties. The inch-pound and metric
measurements shown are as follows:
Products Inch-Pound Metric
a. Boilers
Capacity = 500,000 Btu/hr = 150 kW
= 10,000,000 Btu/hr = 2930 kW
= 18,000,000 Btu/hr = 5275 kW