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Technical Specification Hot Water Boiler 1. 2. 3. 4.

The Hot Water Boilers shall be self contained and complete unit, in all respects and shall comply with the specifications given herein. The hot water boilers shall be compact water tube/fire tube/coil type, oil (HSD/LDO) fired type units. The boiler casing shall be of mild steel welded construction, fabricated of M.S. Plates of suitable thickness as per recommendations of OEM. The water/fire tubes shall be of heavy class M.S., bundled together and circuited for efficient water flow. The tube bundle shall be attached to the top/side cover of the boiler for ease of removal for cleaning and maintenance. The boiler shall be complete with necessary water inlet and outlet flanged connections. The oil firing, pressure jet burner shall be designed for efficient burning of fuel oil, with complete atomization, for an efficiency above 80%. The oil burner shall be complete with self igniting, electric sparking device and photo cell for sensing flame failure. It shall be as per OEM and shall be pre-fitted and calibrated for efficient burning of LDO/HSD to achieve best possible combustion. Electric and control equipments where ever required should be suitable to run on a 3 A.C supply of 415 6% volts, 50 3% Hz frequency. Cylindrical type expansion tank of cap. 300 litres fabricated out of 6 mm MS sheetand capable of withstanding pressure double the working pressure.

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Boiler accessories: The boiler shall be complete with all necessary accessories, including but not limited to the items listed below. 1. There shall be a direct mounted centrifugal blower with motor and inlet damper for providing sufficient air for combustion under all load conditions. 2. A chimney connection shall be provided for exhaust of flue gases, complete with adjustable damper. 3. The electric control panel shall be as per OEM and shall include sequence controller, switch and starter for the water circulating pump, indicating lamps, safety devices etc. 4. A thermostat in the outgoing water line shall sense the heating requirement and control the automatic start stop of the boiler. 5. An audiovisual alarm shall be provided to indicate boiler to indicate boiler failure. 6. The electric control panel shall include sequence controller, switch and starter for the water circulating pump, including lamps, safety devices etc 7. Safety valves & vents to prevent excessive pressure build up. 8. Duplex filter on fuel line. 9. The hot water generator shall be equipped with audio visual alarm, to indicate failure of oil firing equipment. 10. Y- type strainer in pump suction.

11. Water pressure gauge at the inlet and outlet of the boiler and the water pump. The gauge fittings shall be complete with tubing, socket and shut off valve. 12. Digital display of temperature indicating inlet and outlet water temperature with isolating valves. 13. All the tools and tackles of the HOT Water Generator shall be supplied by the Contractor along with the unit. 14. Flue gas duct to be fabricated out of 6mm thick M.S plate of dia corresponding to boiler outlet. Water Circulating Pump 1. Each boiler shall have its independent water circulating pump, to circulate water between the boiler and the heat exchanger. The pump set shall be mono-block type directly coupled to the motor and with suitable water seal for water up to 150 oC. It shall conform to specifications given elsewhere. Gear Oil Pump: 1. A gear oil pump shall be mounted on the blower shaft to provide fuel at high pressure for complete atomization at the burner, as per O.E.M Installation 1. The boiler shall be mounted on cement concrete foundation to be provided by the contractor along with all necessary grouting nuts, bolts, stumps etc. HEAT EXCHANGER. The job comprises of Design, supply, installation, testing and commissioning of heat exchanger having heat output not less than 20 lac Kcal/hr. The heat exchanger must be plate type with plate thickness not less than 5mm, gasketted with Alloy-316, sealing material EPD/MP CLIP-ON and flange rating of ASME 150.The heat exchanger should maintain a secondary circuit temperature of 75 degree centigrade. The successful tenderer shall have to submit the design calculations for approval by the Department before installation of the heat exchanger. The heat exchanger should withstand a pressure of 10 kg / cm2 or double the working pressure. The heat exchanger shall be mounted on a base frame fabricated out of ISMC of suitable size. Necessary connection shall also be provided for mounting of temperature gauges, pressure gauges & air vent (if required). The job also includes design, supply ,installation, testing and commissioning of secondary pumping unit between heat exchanger and mixing tank as per recomedations of OEM. PIPE WORK. The scope shall comprise supply, installation, testing and commissioning of MS C Class ERW Hot water piping including fittings such as bends, shoe bends, flanges, nipples, sockets, unions, nuts, bolts, washers etc complete in all respect. All civil works such as making openings in walls / floor / ceilings, finishing and restoration of the same and other damages, caused during execution of work at the site, to its original dcor/glory are in the scope of this job. The pipe work shall be connected by means of electric arc welding conforming to the relevant IS standards. Providing of smooth, noiseless circulation of the hot water shall be responsibility of the contracting agency. All hot water piping shall be mild steel E.R.W type (Black Steel) heavy class conforming to IS 1239-79, Part-1 with amendments thereafter, if any. b) SCHEMATIC PIPE LAYOUT:

The piping shall be installed in a uniform manner, parallel to or perpendicular to walls or ceilings and all changes in direction shall be made with fittings. The horizontal piping shall be run at right angles. Bull heading, diagonal crossing over other piping and across the rooms should be avoided. All the piping shall be carefully installed to provide for proper alignment, slope and expansion. c) TESTING: In general, tests shall be applied to piping before connection of equipment and appliances. In no case piping shall be subjected to pressures exceeding their test rating. The tests shall be completed and approved before any insulation is applied. Testing of the segments of pipe work will be permitted, provided all open ends are first closed by blank-offs or flanges. After tests have been completed the system shall be drained and flushed 3 to 4 times and cleaned off all dust and foreign matter. All the strainers, valves and the fittings shall be cleaned off all dirt, filings, if any. All the piping shall be tested to a hydraulic test pressure of at least one and a half times the maximum operating pressure, but not less than 10kg/cm2 for a period of not less than 24 hours. All the leaks & defects in the joints revealed during the testing shall be rectified to the entire satisfaction of the engineer-in-charge. d) DRAIN PIPING: The drain piping shall be medium class galvanized steel conforming to IS 1239/1979. The drain line shall be provided at all the lowest points in the system upto the nearest drain trap and pitched towards the trap. e) FITTINGS: The fittings shall confirm to IS: 1239-part-II unless & otherwise indicated in the specifications. All bends shall be ready made, heavy duty of appropriate class. All fittings such as branches, reducers etc. in all sizes shall be fabricated from the same material as that of pipes of similar dia. and thickness used in the circuit. The reducers shall be eccentric type. To avoid pressure drop, shoe bends wherever required shall be preferred. The length of the reducers must be twice the dia. of the pipes. While laying offsets, 45 angles over 90 angles should be preferred. f ) FLANGES: All flanges, if required, shall be of mild steel slip-on type conforming to IS: 6392 / 71 and welded to the pipe. Flange thickness shall suit class-I pressure. Flanges may be tack welded into position, but all final welding shall be done with joints dismounted, 3-mm thick fibre reinforced rubber gaskets shall be used with all flanged joints. Flanged pairs shall be used on all such equipment, which is required to be dismantled for service. g) PAINTING: All pipes shall be applied with two coats of red oxide primer followed by two coats of bituminous paint. INSULATION: External a)MikronNon-woven poyster fibre The insulation for hot water piping shall be of thermally bonded non-woven polyster fibre. The insulating material shall be non-combustible with following specifications:


Operating fluid temperature. Upto 90 C

Non-woven polyester fibre

Thermal Conductivity Average Density Kcal/hr.mC (Gsm) for 50mm thick sheet 0.029 750

The insulating material must be fixed with the piping with the help of chicken mesh. Hot water piping after insulation must be cladded with aluminum sheet of 26 gauge thickness duly screwed. All joints of adjoining section shall be staggered in relation to each other. The insulation of hot water piping shall be provided and fixed as per the specification and diameter of the piping below: Pipe diameter 150mm 100 mm VALVES /GUAGES. a) BUTTERFLY VALVES: All butterfly valves of 100 mm dia. and above shall be flanged type having Cast Iron body with EPDM integrally moulded body lining suitable for pressure & temperature of 10 kg / cm 2 & 90 0C respectively, conforming class PN-1 rating. b) AIR VENTS: Automatic Air vent valves shall be provided at all higher points in the piping system. c) GUAGES. Suitable Pressure Gauges (Glycerine filled) in a range of 0-20bars and Temperature Gauges in a range of 0- 1200c Thickness of Insulation 75mm 50 mm

RADIATORS: The capacity of each radiator shall be measured at heat output 75oC mean water temperature (75 /650C) during the winter season at a room temperature of 22oC. The radiators shall be provided with concealed brackets, air vents and plugs. Each radiator shall be provided with OEM or equivalent make air purging & radiator control valves (inlet valve open type & outlet valve lock shield type). The bleed valve shall rotate around a fixed point. The radiator shall be provided with a drain plug at the bottom with inlet & outlet manifolds for two pipe system on both the sides. The radiator shall be complete with top grill and end/side panels with rounded bottoms for user safety with no visible screws. The radiators shall be joined to the main piping by M.S or composite pipe connections as per site conditions. Only those radiators shall be accepted which are clearly embossed/marked with the manufacturers hologram. The radiators shall be of 32mm pitch. A certificate from an OEM/authorized dealer of OEM/ or an accredited laboratory to the effect that the heat output of radiators conforms to DIN EN442 standard shall be submitted by the firm before installation. The radiators should be able to withstand operating pressure of 10 bars. The allowable heat output of the radiators should be as under:

S.No. 1 2

Type Double Panel (22-PKKP) Triple Panel (33-DKEK)

Required Heat Output (kCal/hr) 1000 3500

Height of Radiators 600 mm 600 mm

The successful bidder shall installed radiators of equal or higher capacity within the contract value depending upon the availability.