SECTION 15540 Hot Water Boiler

Project Specs Compliance Remarks

PART 2 CAST IRON HEATING BOILER
Type: cast iron, sectional type, designed for firing by forced
draught burner, with pressurized combustion chamber. It is to be
factory assembled, sealed and hydrostatically tested to 6 bars for
an operating pressure of 6 bars at 110 deg. C.

Combustion Chamber: to be water cooled by being completely

surrounded with water. It is not to require firebrick or refractory
except at limited locations such as on rear wall and at bottom in
front of burner to evaporate oil drippings from burner nozzle.
Boiler Sections: high grade cast iron, ribbed to provide sinuous
path for combustion gases for best efficiency of heat transfer.
Boiler to have integrally cast supporting legs to permit it to rest
directly on concrete support with uniform distribution of load
throughout length. Boiler to be assembled with steel tie rods and
nuts and externally sealed with special high temperature mastic
for complete gas tightness.
Access Doors: cast iron cleanout doors to be provided on front
section to permit easy access to internal combustion gas passages.
Hinged cast iron burner mounting door to be provided for full
access to combustion chamber. Doors to be sealed gas-tight with
asbestos rope gaskets, stud bolts and brass nuts.
Burner Mounting Door: to be fitted with thick steel front plate for
securing burner, supplied undrilled and provided with internal
frame to support factory supplied refractory. Hole for burner
nozzle to be formed in refractory. Door to have Pyrex observation
port with cover for inspecting flame condition.
Accessories: boiler to have cast iron rear smoke hood with
horizontal smoke outlet fitted to boiler with asbestos rope gasket
to ensure permanent gas-tight seal. Necessary threaded
connections to be integrally cast with boiler sections for boiler fill,
boiler drain, altitude gauge, thermometer and two thermostats.
Connections to be plugged at factory.
Accessories: the following are to be packed separately for field
installation: all-around fiberglass insulated heavy gauge sheet steel
jacket, sectionalized for fitting to boiler without removal of door
fittings or pipe connections, cast iron flanged outlet and return
headers with steel counter flanges, gaskets, bolts and nuts, brass
separable socket wells for insertion of thermometer and
thermostat bulbs into boiler and decorative control panel designed
for fitting on boiler.
Control Panel: to contain the following: burner on-off switch,
burner signal lights for operation and malfunction, boiler water
thermometer with remote bulb and adequate length capillary
tube, two adjustable boiler water operating thermostats with
remote bulb and adequate length capillary tube, with manual
reset, excess temperature release button for high limit thermostat
and numbered terminals strip for electrical connections to mains,
burner and heating control devices.
Maintenance Equipment: boiler to be provided complete with set
of cleaning brushes with handle, special tools required for
maintenance and installation, gun for application of sealing mastic
and recommended quantity of sealing mastic in sealed containers
required for field sealing of joints.
PART 3 SMOKE PIPE AND BREECHING
Construction: fabricate from 3 mm thick black steel plate, welded, Not Applicable
stiffened and reinforced for maximum rigidity.
Contractor Scope
Cleanout doors: provide adequate number of approved design
PART 4 OPEN EXPANSION TANK
Tank: to be open rectangular, fabricated from 3 mm thick black Not Applicable Contractor Scope
steel plate of welded construction. Provide tank with cover of
same thickness hung on approved heavy duty hinges.
Connections: tank to have female threaded pipe coupling
connections as indicated.
Support: tank to have welded 50 x 50 x 5 mm structural angle
support all around tank bottom and 200 mm high 50 x 50 x 5 mm
angle legs with 100 x 100 x 6 mm steel sole plates welded on.
Paint Finish: wire brush tank and support down to base metal and
paint inside and outside with two coats of zinc chromate primer
and two coats of heat resistant aluminum paint.
PART 5 CLOSED EXPANSION TANK
Tank to be closed, cylindrical, welded, pressure vessel type, with Not Applicable Contractor Scope
fixed spherical ends, fabricated from high quality black steel plate
for design working pressure of 1030 kPa at 150 deg. C. It is to be
hydrostatically tested at factory to 1 1/2 times design working
pressure. Tank to have rubber composition spherical balloon
diaphragm to prevent system water coming into contact with air
cushion. Tank to be provided with means for easy removal of
diaphragm for inspection and for inspecting inner wall of tank.
Accessories: 25 mm female threaded expansion line connection on
bottom spherical end and appropriate air valve for field
adjustment of cushion pressure to suit cold fill pressure.
Support: provide adequate legs for floor mounting tank vertically.
Paint: tank to be painted at factory with durable enamel paint on
outside and with adequate treatment against corrosion on inside.
Tank to be precharged at factory with air at cold fill cushion
pressure indicated on the Drawings.
PART 6 EMERGENCY FUEL SHUT OFF VALVE
Supply and install fuel shut off valves at fuel pipes crossing the fuel Not Applicable Contractor Scope
storage room to the boiler room.
Fuel shut off valve shall be solenoid type controlled by fire alarm.
PART 7 TESTING OF THE SYSTEM
Once the pipe laying has been completed, it is necessary to Not Applicable Piping test is Contractor Scope
proceed with the plants hydraulic test. Connecting to the Boiler start up, Testing & commissioning is
Saudi boiler Scope
distribution collector, the various circuits are filled while
taking care to vent the air sacks. The manual pressure pump will
be connected to the collector and, choosing the various circuits,
they will be tested individually leaving the plant in pressure (10
bars) for at least 24 hours. A physiological drop of the hydrostatic
pressure can occur according to variation of the temperature of
(10C and can change the pressure by 1 bar on the circuits.
Once the hydraulic trial is finished, proceed to covering the pipes
with building mix, mixed with the additive for thermal plants.
Pre-trial
Duration of 30 minutes.
While filling and venting the air, the pressure (10 bar) of each
single ring should be checked and restored every 15 minutes.
Verify eventual leaks. At the end of the pre-trial, the hydrostatic
pressure should be stable.
Final Trial
Duration of 2 hours.
Recharge the plant with 10 bars of pressure which, over the
duration of the final trial, should undergo a maximum drop of 0.3
bar.
Testing Protocol
It is advisable to have a protocol that attests that the trials have
been performed for each single plant.
Notes:
b. The testing pump pressure gauge should allow control of 0.1 bar
variations.
c. If severe temperatures are present (from +5C), it is possible to
carry out the test by adding antifreeze fluids to the water to
protect the plant from eventual.

END OF SECTION