Archetype Vietnam

Medochemie Factory

0712 BOILERS
TABLE OF CONTENTS
1

GENERAL........................................................................................................................... 2
1.1

SUMMARY......................................................................................................................2

1.2

REFERENCES..................................................................................................................2

1.3

SUBMITTALS..................................................................................................................3

1.4

CLOSEOUT SUBMITTALS..................................................................................................3

1.5

QUALITY ASSURANCE......................................................................................................3

1.6

QUALIFICATIONS............................................................................................................3

1.7

PRE-INSTALLATION MEETINGS.........................................................................................3

1.8

DELIVERY, STORAGE, AND HANDLING...............................................................................3

1.9

WARRANTY....................................................................................................................4

1.10

MAINTENANCE SERVICE...............................................................................................4

1.11

MAINTENANCE MATERIALS............................................................................................4

1.12

EXTRA MATERIALS.......................................................................................................4

PRODUCTS.........................................................................................................................4
2.1

GENERAL.......................................................................................................................4

2.2

CAST-IRON BOILERS.......................................................................................................4

2.3

FINNED WATER-TUBE BOILERS.........................................................................................5

2.4

ELECTRICAL CHARACTERISTICS AND COMPONENTS...........................................................6

EXECUTION.......................................................................................................................7
3.1

INSTALLATION...............................................................................................................7

3.2

FIELD QUALITY CONTROL................................................................................................7

3.3

MANUFACTURERS FIELD SERVICES..................................................................................7

3.4

CLEANING.....................................................................................................................7

3.5

DEMONSTRATION...........................................................................................................7

SELCTION..........................................................................................................................7

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Medochemie Factory

1 GENERAL
1.1

SUMMARY
a)

b)

Section Includes:
1.

Hot water cast-iron boilers.

2.

Hot water boiler trim.

3.

Steam cast-iron boilers.

4.

Steam boiler trim.

5.

Boiler controls.

6.

Fuel oil fired burner.

7.

Boiler controls.

8.

Boiler trim.

Related Sections:
1.

1.2

All relevant mechanical and electrical sections.

REFERENCES
a)

b)

British standards:
1.

BS 779 Specification for cast iron boilers for central heating and
indirect hot water supply (rated output 44 kW and above).

2.

BS 2790 Specification for design and manufacture of shell boilers of

welded construction.

3.

BS 5258 part 1 Specification for central heating boilers and circulators

4.

BS 5978 Safety and performance of gas-fired hot water boilers (60 kW

to 2 MW input).

5.

BS 6332 part 1 Specification for thermal performance of central

heating boilers and circulators.

American National Standards Institute:

1.

c)

American Society
Engineers:
1.

d)

e)

g)

of

Heating,

ASHRAE 90.1 - Energy

Residential Buildings.

Refrigerating

Standard

for

and

Buildings

Air-Conditioning
Except

Low-Rise

American Society of Mechanical Engineers:

1.

ASME Section IV - Boiler and Pressure Vessel Code - Heating Boilers.

2.

ASME Section VIII - Boiler and Pressure Vessel Code - Pressure Vessels.

Hydronics Institute:
1.

f)

ANSI Z21.13 - Gas-fired Low Pressure Steam and Hot Water Boilers.

H.I. Heating Boiler Standard - Testing and Rating Standard for Heating
Boilers.

National Fire Protection Association:

1.

NFPA 31 - Standard for the Installation of Oil-Burning Equipment.

2.

NFPA 54 - National Fuel Gas Code.

3.

NFPA 58 - Liquefied Petroleum Gas Code.

Underwriters Laboratories Inc.:

1.

UL 726 - Oil-Fired Boiler Assemblies.

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1.3

Medochemie Factory

SUBMITTALS
a)

Product Data:
Submit capacities and accessories included with boiler. Include general layout,
dimensions, size and location of water, steam, fuel, electric and vent
connections, electrical characteristics, weight and mounting loads.

b)

Test Reports:
Indicate boilers meet or exceed specified performance and efficiency. Submit
results of combustion test.

c)

Manufacturer's Installation Instructions:

Submit assembly, support details, connection requirements, and include startup instructions. Submit maintenance instruction manuals.

d)

Manufacturer's Certificate and contractor compliance sheet:

Certify products meet or exceed specified requirements.

e)

Manufacturers Field Reports:

Indicate condition of equipment after start-up including control settings and
performance chart of control system.

1.4

CLOSEOUT SUBMITTALS
a)

1.5

1.6

Operation and Maintenance Data: Submit manufacturer's descriptive literature,

operating instructions, cleaning procedures, replacement parts list, and
maintenance and repair data.

QUALITY ASSURANCE
a)

Conform to ASME Section I or Section IV (depending on system pressure and

temperature) and ANSI Z21.13 Code, UL 726 for construction of boilers.

b)

Boiler Performance Requirements: Conform to minimum efficiency prescribed by

ASHRAE 90.1 when tested in accordance with H.I. Heating Boiler Standard.

c)

Unit Certification: UL certified.

d)

Conform to applicable code for internal wiring of factory wired equipment.

e)

Products Requiring Electrical Connection: Listed and classified by Underwriters'

Laboratories, Inc., as suitable for purpose specified and indicated.

f)

Perform Work in accordance with country applicable standards.

g)

Maintain one copy of each document on site.

QUALIFICATIONS
a)

Manufacturer:
Company specializing in manufacturing products specified in this section with
minimum ten years documented experience and with service facilities.

b)

Installer:
Company specializing in performing Work of this section with minimum five
years.

1.7

PRE-INSTALLATION MEETINGS
a)

1.8

Convene minimum one week prior to commencing work of this section (One
whole day)

DELIVERY, STORAGE, AND HANDLING

a)

Accept boilers and accessories on site in factory shipping packaging. Inspect for
damage.

b)

Protect boilers from damage by leaving packing in place until installation.

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1.9

WARRANTY
a)

1.10

1.11

Medochemie Factory

Furnish two year manufacturer warranty to include coverage for complete

assembly including materials and labor or as the period mentioned in the
condition of contract whichever is greater.

MAINTENANCE SERVICE
a)

Furnish service and maintenance of boilers for two years from Date of
Substantial Completion or in accordance to condition of contract.

b)

Provide emergency call back service during working hours for this maintenance
period.

c)

Maintain locally, near Place of the Work, adequate stock of parts for
replacement or emergency purposes. Have personnel available to ensure
fulfillment of this maintenance service, without unreasonable loss of time.

d)

Perform maintenance work using qualified personnel under supervision of boiler

manufacturers representative or original installer.

MAINTENANCE MATERIALS
As mentioned in conditions of contract

1.12

EXTRA MATERIALS
As mentioned in conditions of contract

2 PRODUCTS
2.1

GENERAL
a)

The boiler shall be of the fully packaged, designed and constructed, and
certified in accordance with the latest version of ASME standard.

b)

The boiler shall be equipped with integral forced draft fuel burning equipment
specifically supplied for burning Number 2 light oil, boiler trim and accessories,
operating and safety controls, refractory and insulation all assembled, piped and
wired at the factory and delivered as a packaged unit ready for installation and
operation with simple piping, power and smoke outlet connections. The
complete packaged boiler shall be UL approved and shall bear its label.

c)

The completed unit shall be fire tested at the factory prior to shipment and a
copy of the test report shall be furnished with the boiler.

d)

The boiler shall be subjected to shop inspection and approval by an authorized

Boiler Inspection, and stamped with all identifying markings and symbols as
required by ASME. A certified inspection report shall be furnished with the
boiler.

e)

The boiler shall be insulated with minimum 80 mm thick mineral wool blanket
insulation and covered with heavy gauge galvanized steel removable jacket with
factory applied heat resisting enamel finish.

2.2

CAST-IRON BOILERS

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Medochemie Factory

i.

Product Description: Hot Water boilers with forced draft, insulated jacket,
sectional cast-iron heat exchanger, fuel oil burning system, refractory and,
controls.

ii.

Product Description (for steam): Steam boilers with forced draft, insulated
jacket, sectional cast-iron heat exchanger, fuel oil burning system, refractory
and, controls.

iii.

The boiler shall be provided with hinged access doors and inspection openings
to provide full access to all fire surfaces for inspection, cleaning and
maintenance without disconnecting any fuel oil piping or electrical wiring. The
access doors shall be lined with high quality refractory, fully gasket and bolted
on for complete gas tightness.

iv.

The boiler shall be provided with all necessary threaded and flanged
connections for boiler inlet and outlet, boiler drain, relief valve, controls and
smoke outlet all as required by ASME.

v.

The boiler inlet and outlet pipe connections shall be provided with isolating
valves and thermometers of glass stem type.

vi.

Furnish water wall design consisting of water backed combustion area with
water circulating around firebox. Refractory chamber or separate base not
required.

vii.

Steam Boiler Trim:

viii.

1.

ASME rated pressure relief valve.

2.

Steam pressure gage, 0 to 207 kPa.

3.

Water column gage glass set with shutoff valves.

4.

Low water cut-off to prevent burner operation when boiler water drops
below safe level and boiler condensate return pump control to maintain
water level by controlling pump operation.

5.

Second low water cut-off.

6.

Operating pressure controller for burner to maintain steam pressure

setting.

7.

High limit pressure control with manual reset for burner to prevent
steam pressure from exceeding system pressure.

8.

Low limit pressure control.

Boiler Fuel Burning System:

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2.3

Medochemie Factory

1.

Burner Operation: On-off with low fire position for ignition.

2.

Oil Burner: High pressure forced draft atomizing type for No. 2 fuel oil
with combustion air blower, one stage fuel pump mounted on burner,
hinged flame inspection port, cadmium sulfide electronic flame sensor,
ignition electrodes, ignition transformer, oil atomizing nozzle, oil solenoid
valve, oil control valve, oil supply & return pressure gauges, fuel filter,
low fire start interlock, working temperature controls, totally enclosed
electric control panel mounted on the unit at the factory and all
necessary controls and accessories.

3.

Oil Burner Safety Controls: Energize burner motor and electric ignition,
limit time for establishment of main flame, monitor flame continuously
during burner operation and stop burner on flame failure with manual
reset necessary, solenoid oil delay valve opens after burner motor
energized and closes when de-energized.

4.

Collector and Draft Hood: refer to related sections

5.

Controls: Pre-wired, factory assembled electronic controls in control

cabinet with flame scanner or detector, programming control, relays, and
switches. Furnish pre-purge and post-purge ignition and shut down of
burner in event of ignition pilot and main flame failure with manual
reset.

FINNED WATER-TUBE BOILERS

a)

ii.

Product Description: Hot water induced draft boiler with horizontal grid, finned
tube heat exchanger, gas burning system, refractory combustion chamber,
controls, and boiler trim.
Boiler Fabrication:
1.

Assembly: Finned steel tube heat exchanger assembled within

combustion chamber conforming to ASME Section IV and Section VIII
requirements, and tested for maximum working pressure of 1100 kPa.

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iii.

2.

Combustion Chamber: Line with interlocking refractory insulating panels

of vermiculite, high temperature cements, ceramic tile insulation fiber
and refractory clay for service temperatures to 1150 degrees C.

3.

Exchanger: Fabricate of finned steel tubing with baffles and welded into
steel headers

4.

Jacket: Galvanized steel with factory applied baked enamel, insulated

with foil faced fiberglass insulation.

Hot Water Boiler Trim:

iv.

v.

vi.
2.4

Medochemie Factory

1.

ASME rated pressure relief valve set with rating in accordance to the
working pressure.

2.

Low water cut-off to automatically prevent burner operation when water

falls below safe level.

3.

Inlet flow switch to automatically prevent burner operation when low

flow through boiler.

4.

Temperature gage to indicate outlet water temperature.

5.

Pressure gage with scale graduated from 1-1/2 to 3 times safety relief
valve set pressure.

6.

Control transformer.

7.

On-off switch with indicator lights.

8.

Alarm bell.

Boiler Fuel Burning System:

1.

Induced Draft Gas Burner: Stainless steel burners for On-OFF firing and
either natural gas or LPG (according to the drawings) with adjustable
combustion air supply, gas pressure regulator, diaphragm gas valves,
manual shut-off, intermittent spark or glow coil ignition, thermistor
flame sensing device, and automatic 100 percent safety gas shutoff.

2.

Safety Controls: Energize ignition, limit time for establishment of flame,

prevent opening of gas valve until pilot flame is proven, stop gas flow on
ignition failure, energize blower motor, and after air flow proven and
allow gas valve to open.

3.

Flue Gas Collector and Draft Hood: External draft diverter with automatic
motorized vent damper

Boiler Controls:
1.

Operating Controls: Factory wired, factory assembled electric control

including pilot safety and thermocouple transformer, 24-volt gas valve,
manual main and pilot valves, and junction box.

2.

Operating temperature controller with outdoor reset] to control burner

operation to maintain supply water temperature.

3.

High limit temperature controller with manual reset for burner to prevent
boiler water temperature from exceeding safe system temperature.

4.

Pump controller.

5.

Pump delay relay.

6.

Boiler sequencing control.

Performance: Refer to schedules on the drawings

ELECTRICAL CHARACTERISTICS AND COMPONENTS
a)

Electrical Characteristics: In accordance with related sections in specs.

b)

Refer to Electrical drawings and schedules for related electrical data.

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c)

Medochemie Factory

Disconnect Switch: Factory mount disconnect switch in control panel.

3 EXECUTION
3.1

3.2

3.3

INSTALLATION
a)

Install boilers plumb and level, to plus or minus 2 mm over boiler base.

b)

Maintain manufacturer's recommended clearances around and over boilers.

c)

Install boiler on concrete housekeeping pad, minimum 100 mm high and 150
mm larger than boiler base on each side. Refer to detailed mechanical drawings
for exact base dimension.

d)

Install boiler on vibration isolators in accordance with related Section.

e)

Connect fuel oil piping in accordance with NFPA 31.

f)

Connect fuel oil piping to boiler, full size of boiler gas train inlet. Arrange piping
with clearances for burner removal and service.

g)

Install the following piping accessories on fuel oil piping connections.

2.

Shutoff valve.

3.

Check valve.

a)

Perform combustion test including boiler firing rate, over fire draft, gas flow
rate, heat input, burner manifold gas pressure, percent carbon monoxide,
percent oxygen, percent excess air, flue gas temperature at outlet, ambient
temperature, net stack temperature, percent stack loss, percent combustion
efficiency, and heat output. Perform test at minimum, mid-range, and high fire.

b)

Arrange with local authorities having jurisdiction for inspection of boiler, piping,
and for certificate of operation.

MANUFACTURERS FIELD SERVICES

Start-up boilers according to manufacturer's start-up instructions and in
presence of boiler manufacturer's representative. Test controls and demonstrate
compliance with requirements. Adjust burner for maximum burning efficiency.
Replace damaged or malfunctioning controls and equipment.

CLEANING
a)

3.5

Strainer.

FIELD QUALITY CONTROL

a)

3.4

1.

Flush and clean boilers upon completion of installation, in accordance with

manufacturer's start-up instructions.

DEMONSTRATION
a.

Demonstrate operation and maintenance procedures.

b.

Furnish services for manufacturer's technical representative for five working

days to instruct Owner's personnel in operation and maintenance of boilers.
Schedule training with Owner, provide at least 7 days notice to Engineer of
training date.

4 SELCTION

END OF SECTION

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