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2.1 GENERAL This Part of the Specification Clearly Defines The

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2.1 GENERAL This Part of the Specification Clearly Defines The 2.1 GENERAL This part of the specification clearly defines the class and quality of materials to be installed and standards of workmanship to be undertaken and shall be strictly observed in the absence of specific details defined in this or other parts of this Specification or shown on the drawings. PPP:::\\\EEEssstttaaattteeesss DDDaaatttaaa\\\CCCuuurrrrrreeennnttt___PPPrrrooojjjeeeccctttsss\\\FFFOOOLLLDDDEEERRR --- SSSTTTAAANNNDDDAAARRRDDDSSS___NNNPPPFFF\\\FFFOOOLLLDDDEEERRR___MMMeeeccchhhaaannniiicccaaalll SSSeeerrrvvviiiccceeesss MMM&&&WWW SSSpppeeeccciiifffiiicccaaatttiiiooonnn___DDDoooccc 222\\\CCClll---222---000111...dddoooccc IIIssssssuuueee 111___111111///111111///000333 --- 111 --- 2.2 BOILER PLANT COMMERCIAL & INDUSTRIAL BOILER PLANT General Boilers and their firing equipment shall be of a standard design and shall conform to the relevant British Standards or EN Standards, and the duties indicated on the schedules and as further specified in Part 3 of this specification. Each boiler shall be supplied complete with all safety controls, the necessary fittings and equipment for automatic control, a set of flue and tube cleaning tools, and be mounted on a base constructed in accordance with the Manufacturer’s details and requirements. The Manufacturer shall provide firing equipment that matches the boiler to provide the stated duties. The space allocated to allow for the correct functioning and for maintenance to be carried out shall be confirmed with the Manufacturer. Sizing, arrangement and compatibility of the flues shall be confirmed with the Boiler Manufacturer. Any discrepancies shall be advised to the Engineer. Materials & British Standards As indicated in Part 3 of this specification and schedules, the boilers shall be manufactured from:- • Cast iron, copper, steel or stainless steel for LTHW (up to 95ºC) and HWS generators. • Cast iron, steel or stainless steel for MTHW (95ºC up to 120ºC) • From steel only for HTHW (pressurised above 120ºC up to 150ºC) and steam installations. • LTHW and MTHW steel boilers shall also be built to BS 855 or BS 2790 as applicable. • LTHW and MTHW cast iron boilers shall be to BS 779. Cast iron and boilers shall only be used up to 3.1 Bar pressure. NOTE: The use of BS 855 is restricted to steam boilers of rated output 45kW to 150kW with maximum operating pressure of 2 Bar and to hot water boilers of rated output 45kW to 3MW with maximum operating pressure of 4.5 Bar and maximum operating temperature of 125ºC. In cases where the above limits are exceeded, BS 2790 will be applicable. Firing Equipment The boilers shall have oil fuel automatic burners; gas burners with automatic forced draught or atmospheric burners; or automatic dual fired oil/gas burners (as defined in Part 3) and arranged to shut down in the event of failure to ignite or loss of pilot light. The efficiency of the matched boiler/burner combination unit shall be based on the gross calorific value of the fuel, and shall be a minimum value over the full firing range as follows:- 82% for oil. 81% for gas up to 1.3 MW rating. 82% for gas above 1.3 MW rating. The efficiency testing for factory assembled “packaged” units shall be carried out on site in accordance with BS 845:Part 2 and test certificates supplied where specified in Part 3 of this specification. On/off burners to be used up to 50kW unless otherwise specified in Part 3 or if a particular make of boiler has a requirement for two stage low fire start. PPP:::\\\EEEssstttaaattteeesss DDDaaatttaaa\\\CCCuuurrrrrreeennnttt___PPPrrrooojjjeeeccctttsss\\\FFFOOOLLLDDDEEERRR --- SSSTTTAAANNNDDDAAARRRDDDSSS___NNNPPPFFF\\\FFFOOOLLLDDDEEERRR___MMMeeeccchhhaaannniiicccaaalll SSSeeerrrvvviiiccceeesss MMM&&&WWW SSSpppeeeccciiifffiiicccaaatttiiiooonnn___DDDoooccc 222\\\CCClll---222---000222...dddoooccc IIIssssssuuueee 111___DDDaaattteee 111111///111111000333 --- 111 --- 2.2 BOILER PLANT Metering equipment for gas and oil firing shall be provided in the fuel supply to the burner if specified in Part 3. Combustion conditions test points shall comprise suitable connections for the insertion of portable instrument probes for measurement at the boiler exit in the case of all fuels to measure flue gas temperature, flue gas oxygen, carbon dioxide and carbon monoxide content and for oil additionally include for connections for smoke measurement. Remote Control Each boiler shall be provided with volt free contacts (which will be enabled from elsewhere and form part of the stop/start circuit, with exception of steam boilers), a set of volt free contacts that shall make when the boiler is firing and a volt free contact that shall make on any of the boiler alarms - as indicated in the schedules. Insulation, All Boilers Water backed surfaces shall be externally insulated with not less than 75mm thickness of mineral wool to BS 3958:Part 5 with “K” value of 0.05W/M² at 100ºC mean temperature, and clad with removable metal sheets or panels. Surface temperatures of cladding not to be greater than 50ºC on parts which must be touched, nor greater than 80ºC on parts which could be touched accidentally. Hot flue gas surfaces to be insulated to reduce heat loss and contact temperature. Nameplate, All Boilers All boilers shall have a nameplate fixed to the boiler, indicating:- • Manufacturer’s name and identification mark. • Inspecting Authority’s mark. • Hydraulic test pressure. • Date of hydraulic test. • Design pressure. • BS Number/EN Number. • Rated continuous output, number of sections (if cast iron) and fuel. • Serial No. of boiler. Tests, All Boilers The tests shall demonstrate that the performance criteria have been met, and shall include the following which are to be conducted on site at the conclusion of commissioning. All tests to be witnessed and the results recorded:- • Efficiency Test. • Combustion Test. • Boiler Rating Test. • Turn Down Test. • Noise Criteria Test. • Composition of Exhaust Gas Test. Tests shall be made to ensure that the controls operate as intended and if systems or components malfunction they shall return to a fail-safe condition. PPP:::\\\EEEssstttaaattteeesss DDDaaatttaaa\\\CCCuuurrrrrreeennnttt___PPPrrrooojjjeeeccctttsss\\\FFFOOOLLLDDDEEERRR --- SSSTTTAAANNNDDDAAARRRDDDSSS___NNNPPPFFF\\\FFFOOOLLLDDDEEERRR___MMMeeeccchhhaaannniiicccaaalll SSSeeerrrvvviiiccceeesss MMM&&&WWW SSSpppeeeccciiifffiiicccaaatttiiiooonnn___DDDoooccc 222\\\CCClll---222---000222...dddoooccc IIIssssssuuueee 111___DDDaaattteee 111111///111111000333 --- 222 --- 2.2 BOILER PLANT Water Treatment, All Boilers Pre-treatment plant shall be provided all as indicated in the schedules or in Part 3 of this specification. Site Installation & Testing of Boiler & Firing Equipment The boilers shall be erected on prepared foundations and commissioned by the Boiler Manufacturer and thoroughly cleaned out of all debris, grease etc. before filling with water as BS 2486 and then subjected to a site hydraulic test (and on steam boilers a boil out if specified in schedule). Protection against internal corrosion should be provided if the boiler is not to be used for some time, as specified in BS 2486. NOTE: Steam systems to be filled from a full boiler feed tank by the Boiler Commissioning Engineer. HOT WATER BOILERS Mountings & Fittings (a) Mountings & Fittings for LTHW & MTHW Boilers up to 3MW Output and/or 4.5 Bar Each boiler shall have screwed and/or flanged connections to BS 21 and BS 4504 and be delivered with all connections blanked or capped off. These connections shall include flow and return tappings, open vent, safety valve, drain cock and instruments listed below:- • Emptying/Drain Cock - Bronze gland pattern with hose union and malleable iron handle to BS 2874. • Thermometer - Bezzel type calibrated 0ºC to 120ºC or mercury in steel type, calibrated 0ºC to 120ºC with divisions at 1ºC intervals and numbered at 10ºC intervals with bold figures. • Altitude or Pressure Gauge - Calibrated in both bar and metre head, to approximately twice the working pressure of the system over 3 MW and adjustable red dial pointer set at normal working pressure or head of the system generally to comply with BS 1780:Part 2. Complete with lever handle, cock and siphon. • Flame Observation Port • Safety Valve - To BS 6759, enclosed spring loaded pattern fitted with padlock and galvanised steel (medium grade) discharge pipe run clear of any insulation to terminate 150mm from floor level at the side of the boiler. • Each boiler shall have access provided where operations may be carried out more than 2m above firing floor level and include for gauges to be clearly visible from firing floor. • Level controls and alarms shall meet the requirements of HSE Guidance Note PM5. (b) Mountings & Fittings for Hot Water Boilers that exceed 3 MW Output and/or 4.5 Bar • Each boiler shall have flanged connections to BS 4504 and be delivered with all connections blanked or capped off. • Connections on the boilers should include; flanged flow and return tappings, safety valve, drain cock and instruments listed above or in schedules. • Emptying/Drain Cock - Bronze gland pattern with hose union and malleable iron handle to BS 2874. PPP:::\\\EEEssstttaaattteeesss DDDaaatttaaa\\\CCCuuurrrrrreeennnttt___PPPrrrooojjjeeeccctttsss\\\FFFOOOLLLDDDEEERRR --- SSSTTTAAANNNDDDAAARRRDDDSSS___NNNPPPFFF\\\FFFOOOLLLDDDEEERRR___MMMeeeccchhhaaannniiicccaaalll SSSeeerrrvvviiiccceeesss MMM&&&WWW SSSpppeeeccciiifffiiicccaaatttiiiooonnn___DDDoooccc 222\\\CCClll---222---000222...dddoooccc IIIssssssuuueee 111___DDDaaattteee 111111///111111000333 --- 333 --- 2.2 BOILER
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