Model 4WI 100 800 HP Boilers

Touch Screen graphical operator interface and monitoring

Manual control of the boiler firing rate using control screens on the HMI
to increment or decrement the firing rate
On screen indication of burner management controller status and
diagnostics
On screen display of system alarms and faults
On screen history of alarms and faults
On screen recommendations for troubleshooting of fault conditions
On screen water level indication and alarm(s)
Stack Flue Gas, Combustion Air and Shell (water) temperature indication
Boiler efficiency calculation
Low Fire Hold with Minimum Temperature Control
Assured Low Fire Cut-Off (ALFCO)
The Boiler Control System shall incorporate the following safety provisions:
Examine all load terminals to assure it is capable of recognizing the true
status of the external controls, limits and interlocks. If any input fails this test,
the Burner Management System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves)
and must be able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal
checked during Standby and Pre-Purge.
Dynamic checking of the flame signal amplifier.
Safe start check and expand check to include monitoring flame signal during
standby.
High and Low fire switches checked for proper sequencing.
The Boiler Control System shall provide the ability to communicate with external
digital via Ethernet as a standard. OPC compliant Internet communications shall be
supported, with the Boiler Control System supplied with its own IP address.
2.8 SHOP TEST
A. Shop test: The complete packaged boiler shall receive factory tests to check
construction and function of all controls. All shop tests may be witnessed by the
purchaser at his own c upon sufficient notice to the company.
2.9 ACCESSORIES - BOILER FLUE VENT
2.10 ACCESSORIES - FEEDWATER SYSTEM (BOILER FEEDSET OR DEAERATOR)
2.11 ACCESSORIES - FEEDWATER HEATER OR ECONOMIZER
2.12 ACCESSORIES - BLOWDOWN SEPARATOR AND/OR BLOWDOWN HEAT RECOVERY
2.13 ACCESSORIES O2 TRIM SYSTEM
2.14 ACCESSORIES - CHEMICAL FEED SYSTEM AND/OR WATER TREATMENT

Section A2-40 Rev. 09-09

Model 4WI 100 800 HP Boilers

2.15 MANUFACTURER FIELD SERVICES

A. General: The boiler and accessories supplier shall be responsible for performance of
inspections, start up and testing of the package boiler and accessory equipment and
materials furnished under this section. A detailed written record of the start up
performance, including burner setting data entire load range shall be furnished to the
test engineer before test personnel leave the site. Equipment and test apparatus
shall be furnished by the supplier. All equipment defects discovered by the tests shall
be rectified. The minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide _____hours of job site
assistance to inspect boilers and other equipment upon arrival, verifying
completeness of equipment supplied or damages. Responsibility of making freight
claims to be performed by contractor or owner personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site
reviewing with mechanical contractor to be conducted approximately 1 week prior to
startup.
D. Start-up shall be conducted by experienced and factory authorized technician in the
regular employment of the boiler supplier, and shall include:
1. Demonstrate that boiler, burner, controls and accessories comply with
requirement Section as proposed by the boiler and accessories supplier. Pre-test
all items prior to scheduling the final testing that will be witnessed by the test
engineer.
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating
burner shall be taken with a written report of the tests submitted to the test
engineer. The reports shall include readings for each firing rate tested and
include stack temperatures, O2, CO, NOx and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans,
electric motors and other accessories and appurtenant equipment during the
operational and capacity tests for leakage, malfunctioning, defects, and non
compliance with referenced standards or overloading as applicable.
4. Commissioning Requirements:
a). Fireside inspection
b). Waterside inspection
c) Closing and resealing of doors, manways and hand holes
d). Set up fuel train and combustion air system
e) Set up operating set points
f) Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow,
Fuel pressures, High limits
g). Set up and verify efficiencies at 25%, 50%, 75%, and 100%
h) Set up and verify burner turndown.
I) Set up and verify feedwater/level controls
j). Set up and verify Emissions Compliance
E. Training to include all safety procedures, maintenance procedures, control
operations, and diagnostic procedures.
Training to be provided in a single _____ hour continuous session to accommodate
operators availability on site.

Section A2-41 Rev. 09-09

Model 4WI 100 800 HP Boilers

2.16 OPERATING & MAINTENANCE MANUALS

A. Provide two (2) Operating and Maintenance manuals including cut-away views of
boiler and burner, schematics including fuel trains, general instructions for
maintenance and inspections, complete spare parts lists and trouble shooting
procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the
electrical panel.
2.17 WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler
manufacturer. Warranty shall include all parts for a period of (12) months from the
date of start-up or beneficial use or 18 months from shipment, whichever comes first.
PART 3 EXECUTION
3.1 GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of
the codes specified hereinbefore. All of the contractors work shall be performed by
experienced workman previously engaged in boiler plant construction and shall be
under the supervision of a qualified installation supervisor.
3.2 INSTALLATION
A. Install equipment in strict compliance with manufacturers installation instructions.
B. Install equipment in strict compliance with state and local codes and applicable NFPA
standards.
C. Maintain manufacturers recommended clearances around sides and over top of
equipment.
D. Install components that were removed from equipment for shipping purposes.
E. Install components that were furnished loose with equipment for field installation.
F. Provide all interconnecting electrical control and power wiring.
G. Provide all fuel gas vent and service piping.
H. Provide all piping for boiler pipe connections.
3.3 FIELD TESTING
A. The manufacturers representative shall test all boiler and burner interlocks,
actuators, valves, controllers, gauges, thermometers, pilot lights, switches, etc. Any
malfunctioning component shall be replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the
manufacturers representative.
3.4 START-UP, INSTRUCTION AND WARRANTY SERVICE
The manufacturers representative shall provide start-up and instruction of each new
boiler, including burner and boiler control system as specified herein. Start-up and
instruction shall cover all components assembled and furnished by the manufacturer
whether or not of his own manufacture.

Section A2-42 Rev. 09-09

Model 4WI 100 800 HP Boilers

SAMPLE SPECIFICATIONS - MODEL 4WI HOT WATER BOILERS

PART 1 GENERAL
1.1 SCOPE
The work to be performed consists of providing all labor, equipment, materials, etc. to
furnish and install new factory assembled steam boiler(s) as described in the
specifications herein.
1.2 REFERENCES
A. ASME Section IV (Heating Boilers)
B. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
C. NFPA 54 (ANSI Z221.3)
D. National Fuel Gas Code
E. FACTORY MUTUAL
F. ASME CSD-1 (Controls and Safety Devices)
G. GE-GAP (GE Global Asset Protection)
H. UBC (Uniform Building Code)
I. UMC (Uniform Mechanical Code)
J. NEC (National Electrical Code)
K. UL (Underwriters Laboratories)
1.3 QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of
this specification and shall be the manufacturers standard commercial product
unless specified otherwise. Additional equipment features, details, accessories,
appurtenances, etc. which are not specifically identified but which are a part of the
manufacturers standard commercial product, shall be included in the equipment
being furnished.
B. The equipment shall be of the type, design, and size that the manufacturer currently
offered for sale and appears in the manufacturers current catalogue. The equipment
shall be new and fabricated from new materials and shall be free from defects in
materials and workmanship.
C. The equipment must fit within the allocated space, leaving ample allowance for
maintenance and cleaning, and must leave suitable space for easy removal of all
equipment appurtenances.
D. All units of the same classification shall be identical to the extent necessary to insure
interchangeability of parts, assemblies, accessories, and spare parts wherever
possible.
E. In order to provide unit responsibility for the specified capacities, efficiencies, and
performance, the boiler manufacturer shall certify in writing that the equipment being
submitted shall perform as specified. The boiler manufacturer shall be responsible for
guarantying that the boiler provides the performance as specified herein.

Section A2-43 Rev. 09-09