PART A – SECTION 4

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14.20 Special care must be exercised in the installation of screwed valves to avoid straining
their bodies, and preventing the gate or seat from closing tight. The wrench shall always
be applied to the side being attached to the valve. When attaching pipe to a valve
already in place, a second wrench shall be used to hold the valve while the pipe is being
tightened. A pipe shall not be screwed so far into a valve as to damage the seat.

14.21 Unless otherwise indicated, valves on systems with working pressure upto 12 bar shall
be rated for 16 Bar. Valves on systems with working pressure higher than 12 bar shall
be rated for 20 bar. Valves rated for 20 bar shall be cast steel construction or approved
equal.

15.0 STRAINERS

15.1 The Contractor shall install strainers in the pipeline before the following items of
equipment :-

(a) Pressure reducing valves.

(b) Solenoid valves.
(c) Automatically controlled valves.
(d) Pumps.

15.2 Strainers shall be suitable for withstanding the maximum operating temperature and
pressure of the pipeline in which they are installed.

15.3 Install strainers in pipeline before all equipment as recommended by equipment

manufacturers.

15.4 Strainers

Strainers size upto 50mm dia shall be bronze body with threaded ends and open mesh
monel metal screen.

The strainers size 65mm dia and larger shall be of the straight Y- type. The strainers
shall be complete with cast iron / steel body and cap steel screen rods and standard
perforated stainless steel screens.

16.0 ELECTRIC WATER HEATER

Hot water heaters shall be horizontal / vertical type. Heaters shall be fitted with
immersion heaters to give the maximum output KW. Vessel shall be constructed for 125
PSi working pressure. Vessel shall be GLASS-LINED with magnesium anode
protection. Entire Vessel and electrical controls shall be encased in a rectangular or
cylindrical sheet metal enclosure with baked enamel finish. Tank shall be insulated with
fibre glass or polyurethane injected insulation. Enclosure shall have hinged locking doors
over electric controls. Heating elements shall be complete with prewired terminal leads,
control with circuits, master pilot switch, etc. A thermostatic control of contacts shall be
provided to balance the water heating input to the actual demand. (Five years full

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warranty for the body and element shall be provided).

17.0 GAS FIRED HOT WATER BOILER SYSTEM

17.1 Hot water boiler

17.1.1 Boiler characteristics (Hot water)

The Hot Water Boiler capacity shall be as shown on drawing. The maximum water
temperature will be 90°C and the maximum system temperature drop will be 20°C.

17.1.2 General Boiler Design

A. The boiler shall be three pass horizontal fire tube updraft boiler with five (5)
square feet of heating surface per rated boiler horsepower. It shall be mounted
on a heavy steel frame with integral forced draft burner and burner controls. The
complete package boiler shall be approved as a unit by underwriters laboratories
and shall bear the UL / ULC label or equal approved European laboratory.

1 The boiler shall be completely preassembled and fire tested at the

factory. The unit shall be ready for immediate mounting on floor or simple
foundation and ready for attachment of water, steal, fuel, electrical, vent
and blow down connections.

B. Boiler Shell (Hot water)

1. The boiler shell shall be constructed in accordance with ASME Boiler

Code and must receive authorized boiler inspection prior to shipment. A
copy of the inspection report shall be furnished to the purchaser.

2. The hot water return and outlet connections shall be located on the top
center line of the boiler. The boiler shall be designated to rapidly mix the
return water with the boiler water. Forced internal circulation shall be
used.

3. A dip tube shall be included as an integral part of the water outlet.

4. Two lifting eyes shall be located on top of the boiler.

5. Front and rear doors on the boiler shall be hinged or davited. Doors are
to be sealed with fiberglass tadpole gaskets and fastened tightly using
heavy cap screws that thread into replaceable brass nuts.

6. Rear refractory and insulation shall be contained in the formed door,

which must swing open for inspection of brick work.

7. The boiler tubes shall not include tabulators, swirlers or other add-on
appurtenances.

8. Front and rear tube sheets and all flues must be fully accessible for

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inspection and cleaning when the doors are swung open. The shell must
be furnished with adequate hand holes to facilitate boiler inspection and
cleaning.

9. For boilers 125 horsepower and over, a manhole shall be provided.

10. The exhaust gas vent shall be located near the front of the boiler on the
top center line and shall be capable of supporting.

11. 15 – 100hp. 1000 lbs and shall contain a stack thermometer.

12. Observation ports for the inspection of flame conditions shall be provided
at each end of the boiler.

13. The boiler insulation shall consist of 2 inch blanket under a sectional
preformed sheet metal lagging. This insulation must be readily
removable and capable of being reinstalled, if required.

14. The entire boiler based frame and other components shall be factory
painted before shipment using a hard finish enamel coating.

18.1.3 Hot Water Boiler Trim

A. Low Water Cutoff

A low water cutoff control (manual reset) shall be mounted on the top centerline
of the boiler wired into the burner control circuit to prevent burner operation if
boiler water falls below a safe level.

B. Pressure and Temperature Gauges

Pressure and temperature gauges shall be mounted on the boiler with

temperature sensing element located adjacent to the hot water outlet.

C. Relief Valves

Water relief valves of a type and size to comply with ASME code requirements
shall be shipped loose.

D. Temperature controls

Temperature controls to regulate burner operation shall be mounted on the unit

with temperature sensing elements located adjacent to the hot water outlet.
Controls shall be high limit (manual rest), operating limit (auto reset), and firing
rate control (30 – 800 hp).

18.1.4 Burner and Controls

A. Mode of Operation

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- 30 and 40hp boilers. Burner operation shall be high-low-off principle.

The burner shall always return to low fire position for ignition.

- 50 – 800 hp boilers. Burner operation shall be full modulation principle.

The burner shall always return to low fire position for ignition.

18.1.5 Blower

A Air for combustion shall be supplied by a forced draft blower mounted in the front
boiler door, above the burner, to eliminate vibration and reduce noise level.

B. Maximum sound level of the boiler / burner package shall not exceed 70 dbA
(when measured in accordance with ABMA Sound Test Standards).

C. The impeller shall be cast aluminium, radial blade, carefully balanced, and
directly connected to the blower motor shaft.

18.1.6 Combustion Air Control

A. 30 and 40 hp combustion air damper shall be linked to damper motor. Auxiliary

switch on the damper motor shall control high or low firing rate.

B. 50 – 800 hp combustion air damper and cam operated fuel metering valves shall
be operated by single damper control motor that regulates the fire according to
load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor (remove this sentence when a CB-HAWK
flame safeguard is used).

18.1.7 Fuel specification and piping

1. Fuel Series 700 – Gas Fired

1. Burner Type – The burner shall be integral with the front head of the
boiler and of high radiant multi-port type for gas. The burner shall be
approved for operation on natural gas fuel.

2. Gas Pilot – The gas pilot shall be a premix type with automatic electric
ignition. An electronic detector shall monitor the pilot so that the primary
gas valve cannot open until pilot flame has been established. The pilot
train shall include two manual shut-off valves, solenoid valve, pressure
regulator and pressure gauge.

3. Gas Burner Piping – Gas burner piping on all units shall include primary
gas shutoff valve, motor operated with proof of closure switch and
plugged leakage test connection. The main gas valve(s) shall be wired to
close automatically in the event of power failure, flame failure, low water
or any safety shutdown condition. A lubricating plug cock or butterfly
shutoff valve shall be provided as a means for a tightness check of the
primary shut off valve. An additional plug cock on butterfly valve shall be

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furnished at entrance to gas train. Select one of the following:

- 60 – 100 hp high and low gas pressure switches shall be

provided.

125 – 250 hp high and low gas pressure switches shall be

provided. A second motorized safety shutoff valve, plus an
additional plugged leakage test connection shall be provided.

181.8 Boiler Flame Safeguard Controller and Control Panel

The controller and control panel shall comprise of the following:

1. Flame safeguard

2. Boilers with control – Each boiler shall be factory equipped with flame safeguard
controller providing technology and functions.

Controller shall be computerized solid state having sequence and flame-on lights
and digital “first out” fault code indications of flame safeguard trip functions. It
shall include dynamic self-check logic. The controller shall have a fixed
operating sequence incapable of being manually altered. The sequence shall
include start, pre-purge, pilot and main fuel ignition run and post-purge cycles.

The controller shall have a run / test switch. It shall allow interruptions to
sequence just after prepurge, during pilot ignition trial and run cycles for
adjustments to firing rate motor, damper linkages and pilot flame for minimum
turndown tests.

3. Control panel: The control panel shall be mounted on the front door of the boiler
in a location convenient to the operator. The hinged metal cabinet will have
NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type
lock.

The panel shall contain the boiler flame safeguard controller, blower motor
starter, indicating lights and selector switches.

The panel shall have a removable sub-base for mounting the flame safeguard
controller, blower motor starter, and terminal blocks. For combination gas-oil and
heavy oil fired boilers the panel will contain the fuel selector and / or oil heater
selector switch.

4. Lights

- White – load demanded.

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- White – fuel valve open

- Red-low water

- Red – flame failure.

5. Control switches

- Burner ON-OFF.

- Manual-Automatic.

- Manual Firing Rate Control.

6. Oil, heat and moisture resistant wire shall be used and identified with circuit
numbers corresponding to the electrical wiring diagram.

7. All electrical equipment and wiring shall be in conformance with Underwriters

Laboratories requirements.

8. Boiler to be supplied with a control circuit transformer and fuse protection for the
control circuit.

9. Flame Safeguard

Each boiler shall be factory equipped with a Boiler Management Control System
providing technology and functions.

The system shall consist of a computer based boiler controller and solid state
sensors totally integrated to provide automatic burner sequencing, flame
supervision, and indications of system status, faults, and self-diagnostics.

The boiler controller shall consist of chassis, program module, keyboard display, and
flame signal amplifier. It shall be the non-recycle type and have a fixed operating
sequence incapable of being manually altered. The sequence shall include standby,
pre-purge, pilot, main fuel ignition, and run, and post-purge periods.

The system shall incorporate full modulating control of fuel and combustion air as
well as firing rate control based on system demand.
The boiler controller shall have a non-volatile memory that retains history files and
sequence status after interruptions.

An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to
adjust control settings and display 73 fault messages, 12 diagnostic messages, 38
historical messages as well as system status messages and operating pressures
and temperatures. Boiler firing rate shall also be displayed in addition to the last 6
lockouts and boiler operating information when the lockout occurred. Provisions for a
security access code shall be provided.

Separate status indicators will show:

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 Ready: Operational.

 Demand: call for heat.

 Main Valve: fuel valve open.

 Low Water: low water condition.

 Alarm: safety shutdowns.

The boiler controller shall incorporate a five function run/test switch.

The system shall be characterized for each individual model boiler. The system shall
also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses,
while maintaining the maximum required air changes. It shall permit the user to
select a specific rate control program for precise load tracking that reduces on-off
cycling due to load swings. The system shall also provide an integrated thermal
stress protection program to prolong boiler life. An assured low fire cutoff feature
shall also be provided.

The system shall monitor inputs from solid state sensor for gas pressure, oil
pressure, and temperature. A single solid state sensor shall be used for both on-off
and proportioning control of the burner. The high/low limits and operating set points
of all sensors will be programmable from the keyboard display. The system shall be
capable of detecting a jumpered or defective sensor. A dynamic check of the gas
pressure sensor shall be made prior to the main flame establishing period to ensure
it is fully operational.

An optional 2 way communications module with built-in modem to allow for remote
control of non-safety settings and monitoring of up to 6 boilers shall also be
available. Up to 3 preprogrammed telephone numbers shall be called in the event of
a fault condition. Options such as Lead/Lag, Boiler Efficiency, and Heating Boiler
packages can be interfaced to this module without any change to the existing
system structure. The communications module shall be able to interface with an
IBMTM PC or compatible system.

10. Control Panel: The control panel shall be mounted on the front door of the boiler in a
location convenient to the operator. The hinged metal cabinet will have NEMA 1A
rating that includes a neoprene dust seal and a Yale cabinet key type lock.

The panel shall contain the boiler flame safeguard controller, indicating lights and
selector switches.

Panel shall have a removable sub-base for mounting the flame safeguard
controller, and terminal blocks. For combination gas-oil and heavy oil fired boilers
the panel will contain the fuel selector and/or oil heater selector switch.

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11. Oil, heat, and moisture resistant wire shall be used and identified with circuit
numbers corresponding to the electrical wiring diagram.

12. All electrical equipment and wiring shall be in conformance with Underwriters
Laboratories requirements.

13. Boiler to be supplied with a control circuit transformer and fuse protection for the
control circuit.

17.1.9 Efficiency Guarantee

The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve
90% fuel-to-steam efficiency at 100% firing rate when burning natural gas.

The specified boiler efficiency is based on the following conditions.

1. Natural Gas

Carbon, % (wt) = 69.98

Hydrogen, % (wt) = 22.31

Sulfur, % (wt) = 0.0

Heating value, Btu/lb = 21,830

2. Efficiencies are based on ambient air temperature of 80 °F, relative humidity of

30%, and 15% excess air in the exhaust flue gas.

3. Efficiencies are based on manufacturer’s published radiation and convection

losses.

4. Any efficiency verification testing will be based on the stack loss method.

17.1.10 Warranty

1. All equipment is to be guaranteed against defects in materials and/or

workmanship for a period of 12 months from date of start-up or 18 months from
date of shipment, whichever comes first.

17.1.11Shop Tests

1. The packaged boiler must receive factory tests to check the construction, controls,
and operation of the unit. All tests shall be witnessed by the Client and Consultant
Engineers.

2. Start-up Service

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1. After boiler installation is completed, the manufacturer shall provide the

services of a field representative for starting the unit and training the operator
at no additional costs.

a. A factory approved and authorized start-up report shall be submitted

to the customer/user at the time of start-up.

17.2 LADDER AND PLATFORM

To facilitate operation and routine maintenance at boiler top level a mild steel platform
shall be provided to give access to manhole, main steam crown valve, and safety valve.

A vertical ladder shall be provided leading direct from firing floor level to boiler top level.
When necessary safety hoops are fitted to the upper portion of the ladder.

Handrailing shall be fitted to three sides of the platform.

18.3 PAINTING

On completion the boiler is thoroughly cleaned and painted one undercoat and one top
coat in the following colours:-

BOILER SHELL ..... WHITE (Self colour hot

dip Zintec sheeting)

SCREEN PLATES ..... BLUE

BASE, OUTLET BOX & ACCESS DOORS ..... BLUE

17.4 DRAWINGS

Two copies of the Boiler General Arrangement Drawings and Electrical Wiring Diagrams
shall be provided.

17.5 OPERATING INSTRUCTIONS

One set of our Standard Comprehensive Operating and Maintenance Instructions shall
be provided.

17.6 BOILER STACK AND BREECHING COMPONENTS

Boiler stack and breeching components, supports and terminations shall be factory
prefabricated.

All stack and breeching components shall be tested and listed by Underwriters
Laboratories (UL and ULC), and / or equivalent European standards for use with building
heating equipment burning gas, liquid, or solid fuels, as described in NFPA 211, Chapter
2.

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All stacks and breechings will have inner walls of 20-gauge Type 304 stainless steel for
gas and No. 2 oil, or 20-gauge Type 316 stainless steel for coal, solid fuels, and No. 4
thru No. 6 oil.
Outer walls shall be 24-gauge aluminum-coated steel or stainless steel for sizes up to
24" ID and 20-gauge for sizes of 26" to 48" ID.

The stack and breeching shall be engineered, approved, and manufactured for the boiler
equipment manufacturer.

The stack and breeching manufacturer must supply complete CAD system design
drawings which include a complete component bill of materials.

Stack and breeching systems must be designed to adjust to thermal expansion caused
by the heating and cooling of normal boiler operation.

All stack and breeching components must be warranted for a minimum of 15 years when
installed according to the manufacturer's installation instructions.

The stack and breeching shall comply with national safety standards and all building
codes where applicable.

The stack section joints shall be field sealed by use of containment bands with captive
fasteners and high temperature joint sealant.

All stack and breeching components shall be shipped on pallets and shrink-wrapped to
simplify on-site handling and protect materials until installation.

The system is to maintain air-tight integrity at pressures up to 72" WC at room

temperature.

The system shall have a minimum clearance to combustibles with flue gas temperatures
greater than 1000 F and not exceeding 1400 F continuous, and a minimum clearance
to combustibles with flue gases not exceeding 1000 F continuous.

17.7 CHEMICAL FEED SYSTEMS AND METERING PUMPS

17.7.1 GENERAL

Provide two completely preassembled, packaged chemical feed system(s)/chemical

metering pump(s)for the boiler packages. Package shall be hydraulically and electrically
tested at the factory and shall be assembled to the fullest extent possible. Package shall
be furnished with all required lubricants, special tools, and installation instructions.

17.7.2 PUMP

Pump capacity shall be adjustable through 100% of the range by manual micrometer dial
while the pump is running or stopped. Pump stroking speed shall not exceed 60 spm.

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The pump shall be sized to deliver the required capacity at 85% of maximum stroke
length. Stroke adjustment shall be a variable micrometer type mechanism, with the
plunger powered through its entire travel. Lost motion designs are not acceptable.

The pump shall include an automatic vent and refill mechanism on the hydraulic side,
which operates once each stroke. The pump shall have an external hydraulic relief valve
which is adjustable.

Double ball check valves shall be provided on the discharge to ensure accurate
repeatable metering. The pump valves shall be removable for cleaning or replacement
without the need to disturb suction or discharge piping.

The pump shall be field convertible to automatic stroke adjustment without the use of
special tools, and without the need to replace any major frame parts.

The pump shall be furnished with a factory-mounted driver suitably sized for continuous
operation at the maximum relief setting. The motor shall be integrally mounted direct
coupled. No belts or pulleys should be used in the drive train or for capacity adjustment.

17.7.3 FEED SYSTEM

Complete chemical feed system(s) shall be furnished suitable for handling the required
size of plant. Each system will consist of two pump(s), tank, piping, and accessories as
defined below. Manufacturer will select all materials in contact with the chemical and
guarantee their suitability for the particular service.

17.7.4 TANK

The tank shall be constructed of stainless steel and furnished with a removable cover.
Tank shall include connections for pump suction, drain, level gauge, chemical fill, dilution
water, and relief valve return piping. Drain connection shall be separate from pump
suction connection. Drain shall be located in the bottom of the tank for complete
emptying of contents.

Tank shall be furnished with a drain valve and a level switch (level gauge).

17.7.5 MIXER

An angle plate mount mixer with 304SS shaft and propeller shall be furnished. The mixer
propeller shall operate at 1450 rpm. The purpose of the mixer shall be to mix liquids after
pouring it in the tank.

18.0 HOT WATER STORAGE CALORIFIER

Carbon Steel Glass / Copper Lined Hot Water Vertical Storage Calorifiers manufactured
to the following specification:

18.1 Capacity : as shown on drawings.

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18.2 Shell : Carbon Steel lined internally with Glass / Copper sheets

18.3 Supports : 3- Carbon Steel legs 150mm high made from 150x 76 RSC

18.4 Battery : Low –Fin Copper Integron u tubes expanded into a RNB tube
plate with fabricated steel header chest

18.5 Inspection Opening : Each calorifier will be fitted with a 450mm dia carbon steel /
glass copper lined inspection manhole.

18.6 Gaskets : Non asbestos Fibre/ Nitrile Rubber.

18.7 Connections : Carbon steel copper lined flanges to PN16, Gun Metal Screwed.

18.8 Duty : Battery to raise specified capacity in 1 hour with a deg C

temperature rise, when supplied with primary hot water @ 4.5
Bar (g) as show on drawings.

18.9 Insulation : Each calorifier will be supplied with factory fitted insulation
consisting of mineral wool laced to the shell and encased in
stucco aluminium sheets.

18.10 Accessories : Each calorifier will be supplied with 100mm dial thermometer,
100mm dial water pressure gauge, 100mm dial steam pressure
gauge, safety valve , drain cock , anti vacuum valve

18.11 Code : Designed and manufactured to BS853 1996 Part 1 Grade A.

18.12 Testing : In accordance with BS853 1996. Suitable for a secondary

working pressure of 7.0 Bar and hydraulically tested 11.55 Bar.
Primary tested 7.0 Bar, Test certificates are to be supplied.

18.13 Drawings : Full manufacturing drawings shall be submitted for approval.

19.0 HOT WATER CIRCULATING PUMPS

Pumps shall be all bronze construction with cast bronze body rated for 150 psi working
pressure, bronze impeller, stainless steel shaft and mechanical seals. Motor shall be
TEFC, Class “F” insulation, 1450 rpm. Pump shall be controlled and monitored at BMS
as indicated on data point schedules.

20.0 PACKAGED PRESSURE SETS

20.1 The booster pumpset shall be a factory manufactured works tested.

20.2 The pump set shall incorporate two centrifugal pumps with one as duty pump and the
other as as standby. Each pump shall have a duty as scheduled. Pump shall be

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complete with cast iron casing, bronze/stainless steel impeller, stainless steel shaft and
mechanical seal.

20.3 The control panel shall be complete with star-delta starters, door interlocked isolator,
indicator lights, fuses, main isolator, duty select switch, test pushbutton, adjustable 0-6
minute timer for each duty pump, anti-condensation heater an cable numbering, all in
steel enclosure IP 65.

20.4 The diaphragm pressure vessel shall be constructed of a steel shell with polypropylene
lining on internal wetted areas and a butyl rubber diaphragm.

20.5 All interconnecting pipework shall be copper to BS 2871 Table X with a gate valve on the
suction and discharge of each pump and a silent check valve on the discharge branches
of each pump.

20.6 A pressure switch for each of the pumps and a system pressure gauge should be
mounted on a common Aluminium Pressure Manifold to eliminate using small bore
fittings, to ensure easy replacement of pressure switch or gauge, and to ensure that the
pumpset arrangement is compact and has only one common pressure signal source.

20.7 Demand shall be met in the first instance from the pressure vessel. When the vessel
pressure has fallen to a pre-set minimum (the "cut-in" pressure) the first duty pump shall
start. In the event of the failure of the duty pump the standby pump shall automatically
take its place.

As demand reduces again and the pressure builds up to a pre-determined cut-out

pressure, the pump will stop. An adjustable timer for each pump shall be fitted in the
control panel to ensure frequent switching cannot occur.

20.8 After final assembly of the complete packaged unit, the automatic controls shall be fully
tested in the workshop to simulate site operating conditions and piping tested to 150% of
maximum operating conditions. The unit shall be cleaned down, and painted one
undercoat and one coat hammerite paint.

21.0 WATER TRANSFER PUMPSET

The unit shall be a packaged factory assembled and tested unit complete with
duty/stand-by pump, interconnecting pipework in copper, bronze valves, safety devices
and pre wired control panel.

Pumpset shall in general comply with the requirements of clause 17.0 except that pumps
shall be vertical multistage type.

Control of pumps shall be as follows:

- Pumps switching shall be controlled by float switches installed in the roof storage
tank.

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- A low level float switch installed in the underground storage tank shall prevent
dry running of pumps.

22.0 PACKAGED WATER PUMPSET – VARIABLE SPEED

22.1 General

22.1.1 The pumping unit shall be a variable speed system. The pumping system shall include,
as a minimum, the programmable pump logic controller, adjustable frequency drive,
remote sensor / transmitters, motors and pumps.

The pump manufacturer shall be responsible for the successful operation of the system
supplied by him.

22.1.2 The manufacturer of the packaged pumping system shall provide a minimum of one
day’s training at the job site for the owner’s personnel the operation and maintenance of
the packaged pumping system.

22.1.3 The variable speed pumping system shall be as manufactured by the pump
manufacturer. A pump manufacturer is defined as a company who is regularly
engaged in the design and manufacturer of the pumps specified, herein. The pump
manufacturer shall have been in the business of manufacturing complete pumping
systems for a minimum of ten (10) years and shall catalog variable speed pumping
systems.

An assembler of pumping systems, not engaged in the design and manufacturing of the
specified pumps or a representative of a pump manufacturer assembling systems.,
shall not qualify as a manufacturer of pumping systems.

22.1.4 The system consists of variable speed pump (s) sized to meet system duty condition as
indicated on the pump schedule, adjustable frequency drive(s), bypasses, a pump logic
controller, and sensors / transmitters all as described herein.

22.1.5 At the time of submittal for approval, the pump manufacturer shall provide a complete
system profile analysis which shall include as a minimum : the pumps performance
(variable speed pump curves) and the operating characteristics in the system (system
curve).

22.1.6 This system profile analysis shall include pump motor and adjustable frequency drive
efficiencies, staging points, horsepower, and kilowatt / hour draw.

241.7 A spring loaded non slam triple duty check valve with soft seat shall be installed on the
discharge of each pump. Valve shall be iron body with a pressure rating equal to ANSI
125 lb. Valve trim shall be bronse with stainless steel spring. It shall be equipped with
brass readout valves for more accurate system balance.

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22.1.8 Pump shall be bronze fitted centrifugal, single stage, end suction type or vertical multi-
stage type. Pump shall be rated for a minimum of 175 PSIG working pressure.
Casings shall have gauge ports, vent and drain ports at top and bottom of casing.

22.1.9 Headers shall be copper – type L.

22.1.10 Motors shall be TEFC, Class ‘F’ insulation, 2900 RPM suitable for 415V/3PH/50HZ
supply.

22.2 Pump Logic Controller

22.2.1 The pump logic controller shall be provided and the operator interface flush mounted in
the door of the packaged pumping system control cubicle. The pump logic controller
assembly shall be listed by and bear the label of Underwriters’s Laboratory, Inc. (U.L).
All components within the pump logic controller panel shall be U.L. listed or recognised
components. The pump logic controller shall meet FCC Part 15, for Class A computing
devices.

The pump manufacturer shall supply and be responsible for the operation of a
programmable solid stage Variable speed pump logic controller. The controller shall
function to a proven program that safeguards against damaging hydraulic conditions
including :

a) Motor overload

b) NPSHR above NPSHA

c) Hunting

22.2.2 The adjustable frequency drives shall be controlled by a direct digital pump logic
controller with discrete input signal selection. Use of a multiplexer for multiple sensor
inputs is not acceptable. All individual sensor / transmitters shall be individually wired to
the pump logic controller for continuous scan and comparison function. The pump logic
controller shall be microcomputer based and hold its software in EPROM. On line field
modified data entries, such as set point, shall be stored in RAM memory.

EPROM memory storage shall prevent accidental loss of data due to voltage surge or
spike. RAM memory shall be backed up by EPROM. In the event of a complete power
outage, all factory preset values remain stored and shall be able to be recalled by the
operator.

22.2.3 The pump logic controller shall be capable of receiving upto two process variable analog
input signals. It will then select the analog signal that has deviated the greatest amount
from its set point. This selected signal will be used as the command feedback input for a
closed loop hydraulic stabilization function to minimise hunting. Each input signal may
be programmed for a different set point and set points shall be able to be changed in the
field by keypad entry through password security.

22.2.4 The pump logic controller shall be capable of displaying an additional analog input

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corresponding to flow. The analog input signal shall be the feedback and the set point
shall be the command. The closed loop hydraulic stabilisation function shall have the
capability of performing the traditional proportional, integral and derivative modes. The
proportional function shall have range and be infinitely programmable with that range.

Rates shall be in percent gain. The integral function shall also be infinitely programmable
and compatible with the adjustable frequency drive (s) AFD(s) and the hydraulic system.
It shall be entered as repeats / minute. Derivative shall be entered in units of seconds
and be fully programmable within the range allowing infinite entries with that range.

22.2.5 The scan and compare rate that selects the command set point and process variable
signal shall be continuous and automatically set for optimum operation. Each sensor
shall be scanned every 20 milliseconds.

22.2.6 The pump controller shall have off line and on line diagnostic software. Off line
diagnostics shall consist of CPU, EPROM, EEPROM and RAM memory test. It shall
have self calibration of all analog inputs with diagnostics, display test, program test, and
all I/O tested and status of above displayed. The controller shall include a watchdog
circuit to provide system protection / operation in the event of a controller failure. In the
event of a controller failure, the system shall be able to be operated manually across the
line operation.

On line diagnostics include off line diagnostics and operational diagnostics including but
not limited to individual pump fault (s), AFD fault (s), overloads and sensor / transmitter
fault(s).

22.2.7 Further fault information may be accessed by interrogating the pump logic controller
through the front mounted keypad. In case of failure, the controller shall fail in a
predetermined safe operating mode. Reset after failure shall not result in a no flow
condition unless all equipment fails.

22.2.8 The pump logic controller and sensor / transmitters shall be self powered. The pump
logic controller shall be powered by 220 / 1Ph / 50 Hz. The incoming power and I/O
circuitry shall reject electromagnetic (EMI) and radio frequency (RFI) interference. All
digital outputs shall be electrically isolated.

22.2.9 All external transmitters furnished by the pumpset manufacturer shall be powered by
the pump logic controller through a quality integral 24 volt power supply. Overvoltage
and short circuit protection shall be on board.

22.2.10 The pump logic controller shall operate the pump (s) in a predetermined manner as
indicated in the sequence of operation section.

Failure of any pump, motor or drive in the system shall cause the controller to not only
display the fault conditions, but alternate or transfer the operation to another operating
unit as indicated in the sequence of operation section. The pump logic controller shall
be capable of utilizing individual differential pressure switches to determine pump
failure.

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22.2.11 Pump, AFD and overload trip faults shall not clear automatically. They must be
manually reset after correction of the fault. All above faults shall be displayed before
starting. First faults shall always be displayed. Faults shall not trigger erroneous fault
messages.

22.2.12 The pump logic controller shall be self prompting. It shall display all messages in plain
English. The messages shall include, but not be limited to, how to obtain default
values, when to turn it on, and if it is in the active remote control mode.

22.2.13 The operator interface shall have the following:

(a) Multi fault memory and recall.

(b) On screen help functions.

(c) LEDs (pilot lights) and switches.

(d) Light and switch shall also be displayed in plain English messages scrolled
continuously.

22.2.14 The operator interface shall be capable of remotely being started / stopped.

22.2.15 The operator interface and process controller units shall be modular. They shall be
able to be interchanged with locally available parts without further programming
required.

22.2.16 The readout shall be bright LCD super twist backlit capable of displaying any set point
value, I input or output signal (s), and alarm function in engineering units. There shall
be forty 6mm characters in a two line display.

22.2.17 The pump logic controller shall be capable of operating in automatic, manual or off line
diagnostic modes.

22.2.18 Three levels of password and software security shall be provided for protection of field
programs and use accessible features.

22.2.19 The pump logic controller shall provide hardware communications to the building
management system.

22.3 Adjustable Frequency Drive

22.3.1 Drive shall be of a microprocessor based PWM design, employing a diode bridge
rectifier to convert 3 phase AC to a fixed DC voltage. No input transformer may be
used for either power supply or DC bus power within the drive. A constant
displacement power factor of .95 shall be at all speeds and rated loads.

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22.3.2 The DC bus shall consist of a choke and a capacitor bank to eliminate line
disturbances. A. switching power supply operating off the DC bus will provide
excellent undervoltage and ride through capability.

Control and invertor logic shall be isolated from the power section.

22.3.4 Bipolar power transistors shall be used in the invertor section converting a fixed DC
voltage to a 3 phase adjustable frequency output with a minimum 97% efficiency at
rated load.

22.3.5 For maintenance purpose, the drive shall be capable of starting, stopping and running
with stable operation with the motor completely disconnected (no load).

22.3.6 Drive must protect itself against all phase to phase and phase to ground faults, removal
of load, single phasing, power outages, and prevent starting with wrong phase rotation.

22.3.7 Protection is defined as normal shut down with no component damage.

22.3.8 The drive shall employ adjustable torque limit control which will override the speed
command and decrease the frequency while maintaining the correct volt/hertz ratio
whenever the load level surpasses the drive design level.

Torque limit shall be setable from 50 to 115% of full drive rating. When torque limit
engages, the output frequency is steadily reduced until the load reduces to the design
capacity. At that point the speed will stabilise. If the load reduces further the drive will
reaccelerate to the preset speed.

Lectronic motor overload provides electronic equivalent to thermal motor overload and
shall be adjustable from 60 to 100% of the drive rating.

The drive shall be capable of being started by a 2 wire control circuit, a 240 Volt AC
signal or application of input power.

Adjustments shall include :

Current Limit Min / Max Speed Motor Boost

Accel Time Decel Time V/Hz Ratio

Speed Reference signals shall be :

Potentiometer input 10,000 ohms

Voltage input 0 to 10 VDC

Current input 0 to 20 or 4 to 20 mAmp.

Analog output shall be a non isolated 0 to 5 VDC, selectable for frequency or

amperage.

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The drive shall provide as standard 3 relays to indicate drive run, drive fault, and
current limit condition.

Full RS 232 communications shall be provided as optional equipment.

The variable frequency drive including all factory installed option shall have ETL or UL
agency approvals.

VFD specifications

For detailed VFD specifications, refer electrical specification volume.

Input voltage : 220V / 1PH/50Hz

415V/3PH/50HZ

Input Range : +/- 10%

Speed Range : 20:1 Maximum or as specified.

Ambient Temperature : 0 – 40 C

Humidity : 0 – 95 % Non Condensing

Altitude : to 3300 feet above sea level

Efficiency : 96% or greater at rated load

Power Factor : 0.95 regardless of speed or load.

Adjustments : Min. / Max. speed, accel / decel independently

adjustable to min. 120 sec., current limit, 12 T.

Drive Protection : Over temperature, under / over voltage, phase to

Status Indication
phase short circuit, phase to ground short circuit,
overcurrent, current limit, decel limit.
: Drive enabled, power fault indication for under /
over voltage, over current, motor trip, accel / decel
limit.

Sequence of Operation

With the pumpset in the “Automatic” mode and the duty pump selector on “pump No. 1,
the duty pump 1 shall operate through the AFD which is being controlled by a signal
generated by the pump logic controller. Pump 2 will start if duty is not met and pressure
can not be maintained. Pump 2 shall generally remain as standby.

In the event of a system differential pressure failure, due to duty pump or overload fault,
the pump logic controller will automatically initiate a timed sequence of operation to start
the backup pump in the variable speed mode. A solid red indicator light shall signal this
condition and a message shall be displayed on the operator interface of the pump logic

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