FOURNITURE, INSTALLATION, CONNEXION ET MISE EN

Bd. Alfred Naccache
BP 166830
Achrafieh - LIBAN
DOSSIER DE CONSULTATION
FOURNITURE, INSTALLATION, CONNEXION ET MISE EN SERVICE
D’UNE CHAUDIERE A VAPEUR
Mars 2015
Date limite de remise des offres : 15/4/2015
1/25
I. OBJET DE LA CONSULTATION
Objet : La consultation a pour objet la fourniture, la connexion et la mise en service d’une
chaudière à vapeur.
Lieu : HOTEL-DIEU de France bâtiment technique.
Utilisateurs : Blanchisserie et stérilisation centrale.
II. AVERTISSEMENT
Tout Fournisseur devra respecter dans son offre les conditions décrites dans ce dossier.
L’offre doit être présentée en langue française à l’exception des documentations
techniques et commerciales qui peuvent être en langue anglaise.
Toutes les pages de ce dossier doivent être paraphées par le Fournisseur ce qui
l’engagera sur toutes les conditions indiquées vis-à-vis de l’HDF.
La date limite de remise des offres doit être respectée sous peine de rejet de l’offre.
Le non-respect des conditions précitées peut entraîner le rejet de l’offre.
Une visite des lieus s’impose afin de s’assurer que l’équipement proposé peut être introduit
et installé ; et que les connections existantes sont suffisantes..
Le Fournisseur pourra éventuellement proposer une (ou plusieurs) variante(s) mais
celle(s)-ci devra être suffisamment claire et précise pour qu’elle puisse être étudiée sans
avoir besoin de renseignements supplémentaires (notamment au niveau des coûts qui
doivent toujours être prévus « rendus et installés HDF, clef en main».
III. ITEMS
Item 1
Item 2
Item 3
Chaudière à vapeur avec accessoires
Compteur(s) de précision pour la consommation de mazout
Bâche de relevage des condensats. En option
Quantité : 1
Quantité : 1
Quantité : 1
IV. CONDITIONS D’ACHAT
1) Remise des offres
L’offre sera transmise à l’HDF sous pli fermé et cacheté et remis à la direction générale qui
délivrera un reçu attestant la participation du Fournisseur dans les délais impartis.
Une version numérique de l’offre devra être aussi remise sur un support numérique (CD,
clef USB) avec le questionnaire technique sous format Excel.
La date limite de remise des offres est fixée au 15/4/2015 à 12h00
2) Contenu des offres
Chaque offre devra contenir l’ensemble des éléments suivants :
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1. Le dossier de la consultation imprimé et signé à chaque page preuve de
l’engagement par rapport à toutes les conditions citées.
2. Le questionnaire technique rempli, imprimé et signé.
3. Toute déviation sur les spécifications données ci-après devra être notée et
expliquée.
4. Les prix détaillés des équipements proposés (rendus, installés, mis en service
à l’HDF)
5. Les prix individuels et détaillés des options éventuelles (rendues, installées et
mis en service à l’HDF)
6. Les prix individuels et détaillés des variantes éventuelles (rendues, installées
et mis en service à l’HDF)
7. Les prix des accessoires avec leur degré de dépendance entre eux et avec
les équipements.
8. Les prix individuels et détaillés de tout type de consommables éventuels.
9. La liste des pièces détachées avec leurs prix.
10. Les documentations techniques et commerciales des produits proposés avec
les caractéristiques techniques précises.
11. Le schéma d’implantation en coupe avec les distances de débattement.
12. La liste des principales références au Liban et au moyen orient.
13. Le certificat des équipements (FDA, CE, …)
14. Les délais de livraison, d’installation et de mise en service.
15. L’organisation du SAV.
16. Engagement sur les durées d’approvisionnement.
17. Durée de la garantie.
18. Le coût d’un contrat de maintenance annuel pour les 5 années suivant la
période de garantie :


Contrat main d’œuvre seule
Contrat main d’œuvre avec pièces de rechange
N.B. : Toute offre qui manque d’information déjà demandée plus haut sera rejetée.
3) Prix
Les prix seront donnés « LOCO HDF » frais d’installation et mise en marche inclus. Les
formalités et les taxes de douane seront à la charge du fournisseur. En cas de possibilité
d’exemption, l’Hôtel-Dieu de France pourra en formuler la demande, et le fournisseur devra
présenter une garantie bancaire. Les frais de la démarche seront également couverts par le
fournisseur.
4) Mode de paiement
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Le paiement sera effectué à l’ordre de votre société, échelonné de la manière suivante :
o
o
o
15 % à la confirmation de commande.
25 % à l’établissement de l’attestation du bon fonctionnement et présentation de la
facture.
60 % en trois paiements mensuels égaux. Le premier se fera un mois après
l’établissement de l’attestation du bon fonctionnement et présentation de la facture.
V. CONFIGURATION DES EQUIPEMENTS
1) Adéquation au besoin
La solution proposée par le Fournisseur devra être conforme aux spécifications
fonctionnelles et techniques demandées et devra être complète, parfaitement
opérationnelle et intégrer tous les accessoires et petites fournitures ainsi que d’autres
éventuelles pièces nécessaires au bon fonctionnement de l’ensemble et qui ne sont pas
forcement mentionnés dans ce dossier.
2) Spécifications fonctionnelles
La vapeur produite par la chaudière sera utilisée pour chauffer les autoclaves du service de
la stérilisation centrale et essentiellement pour les équipements de la blanchisserie qui ont
besoin d’une pression de 12 bars.
3) Spécifications techniques
A- Chaudière et accessoires :
Les spécifications techniques détaillées de la chaudière et ses accessoires sont
citées ci-dessous en langue anglaise :
FIRETUBE BOILER PACKAGE SPECIFICATIONS
1) BOILER ASSEMBLY
1.01 BOILER/BURNER PACKAGE
A firetube boiler, mounted on skid or steel frame, equipped with complete forced draft modulating
burner assembly, and controls, as described later. The Boiler with all piping and wiring shall be
completely factory assembled as a self-contained unit.
It shall be provided with full trimmings, controls and accessories, attached to the unit at the Factory
and fully inspected and Factory fire-tested before shipment, as detailed elsewhere.
The unit shall have a capacity as indicated in the technical sheet below.
The Boiler-Burner Package shall be under the responsibility of one manufacturer. This is to ensure
undivided responsibility and simplified servicing.
The boiler shall be completely pre-assembled and fire-tested at the factory. It shall be fire-tested
and controls set as for normal operation. All readings shall be consigned in an official Factory Firetest report.
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The factory Fire-Test report shall be supplied to the Purchaser, along with the standard Literature
supplied such as Manuals, Brochures, etc...
1.02 PRESSURE RATING
The Boiler shall be stamped by the National Board Inspector for the required Design Pressure. The
Safety Valves shall be factory-set and sealed for this Pressure. Actual Working Pressure could be at
any setting below this Design Pressure, however, must not exceed Design Pressure less 5 PSI to
avoid chattering of the Safety valves when the operating pressure is too close to the pop-out setting.
Required Design Pressure is indicated in the Technical Schedule.
1.03 POWER AND OUTPUT
Power as referred to throughout these specifications and in the technical schedule shall be the
nominal Boiler HP, or nominal Boiler KW rating. Power is indicated in the Technical Schedule.
Max. Output as referred to in these specifications, shall be regarded as max. continuous output. It
shall be the weight of steam generated from and at 212 deg.F (100 deg.C) water on continuous
operation, with max. 100 % Firing Rate.
1.04 BOILER HEATING AREA
The Heating area shall be based on 5 Sq.Ft. / BHP Fireside Area and not less than 5.2 Sq.Ft / BHP
Waterside Area as evidenced by the Manufacturer's Production Data and Technical Manuals.
Comparison of different Boiler Makes with same nominal capacity shall be based on the Fireside
Heating Area.
1.05 FUEL
The Main Fuel shall be Light Domestic Oil #2 (Diesel) Heating Oil as indicated in the technical
schedule.
1.06 FIRING MODE – TURN-DOWN RATIO
Firing Mode to be Full Modulation. This shall be over the range of 33 % Lo-Fire through 100 %
full firing rate (Hi-Fire) , with enforced and guaranteed Lo-Fire Start as per applicable U.L Safety
Codes. The turn-down ratio will be min. 3:1.
1.07 EFFICIENCY
Efficiency as referred to in these specs is the “fuel-to-steam” efficiency.
This shall be guaranteed by the Manufacturer to be not less than 80 % over the complete range. The
Efficiency shall be computed as per the A.P.I Standards using the Gross Calorific Value (Higher
Heating Value). Efficiency computed with the Lower Heating values (giving higher figures) shall
not be considered.
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1.08 GENERAL BOILER DESIGN & CONSTRUCTION
The Boiler shall be of the fully packaged, Automatic Horizontal return tubular, fire tube, welded
steel construction, Three-pass, dry back with 5 Sq Ft/BHP Heating Area Fireside.
It shall be designed as per the relevant and current ASME Code for this Boiler Application.
It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls.
The unit shall be ready for immediate mounting on floor or simple foundation and ready for
attachment of water, steam, fuel, blowdown, electrical and vent connections, to be operational.
The boiler shell shall be welded construction and in accordance with the latest edition of the ASME
Boiler code and must receive authorized boiler inspection prior to shipment, as detailed elsewhere
in the Specs. It shall include all the required stay tubes and stay rods.
The Furnace tube shall be located along the shell center line. All laterally off-centered furnace Tube
Boilers shall be rejected.
All refractory brickwork shall be high-temperature fire-brick and/or pre-cast refractory shapes laid
with high-temperature cement. All refractory shall be factory pre-installed, cured and dried. These
castable refractory mixes shall be in such a way to assure strength and avoid cracking during
transport or due to cyclic thermal stress.
The rear turning chamber shall be lined with high-temperature pre-cast refractory and backed with
seal welded steel lining to prevent flue gas short-circuiting.
The Fire-Tubes Size and Gauge (Wall Thickness) shall be as per Code requirements, welded steel
construction, fitted in accordance with Boiler & Pressure Vessel Code for the Design Pressure into
accurately drilled tube sheet holes.
Tubes shall be attached to tubesheets by expanding, roll-flare and beading operations, or by rollflare operation with fillet welding, to the tubesheets.
The Tubes shall be properly located, staggered & aligned to permit adequate water circulation,
exposure and tight rolling on the tubesheets without noticeable deformation or undue stress.
Tube ends at rear end, bottom pass (start of 2nd pass) shall be expanded and fillet welded. All other
tube ends shall be rolled and flared in one operation, then beaded when required by Code.
All beads shall be flat tight against tube-sheet allowing no voids. A final parallel-cylindrical touchup roll shall be applied to the tube ends after the beading operation.
The front and rear doors shall provide quick and full access to complete tube-sheets and tubes for
inspection, cleaning and repair.
The doors shall be lined with fire resistant gasketing and sealant material to ensure complete gastight joints.
The rear door shall be designed in three sections for ease of removal and to allow access to any
section of the fireside surface without removing the entire door.
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The lower rear section shall be refractory-lined as required.
The refractory-lined section shall be adequately supported or davitted for ease of removal and
pivoting by one person.
All doors and sections of cover shall be bolted with heavy duty nuts and washers to studs welded to
the shell.
The rear door shall include a rear Hi-temperature Pyrex peepsight glass assembly to enable viewing
the flame in the furnace tube.
The front door shall be insulated where necessary. It shall include a front peepsight glass and cover.
Further, the front door shall include a clean-out opening for cleaning the Front Turning Box without
need for opening the door. The clean-out cover shall be adequately insulated and gasketed with fireresistant material and bolted with stainless steel bolts to front cover.
The Boiler shell shall be fitted with oval handholes as per the ASME Code requirements, to allow
for inspection, cleaning and draining of the boiler shell. The handholes shall be located at judicious
locations to enable inspection of the Vessel and firetubes at different areas along the Boiler shell.
The number of handholes shall be as required by the ASME Code.
The handholes openings shall be 3 1/2 x 4 1/2, Oval, equipped with yoke-type clamp covers.
The Boiler Shell shall be fitted with one large oval Manhole, when ASME Code requires, with size
per latest requirements of the ASME Code, equipped with Yoke and Clamp cover, located close to
the crown of the Boiler.
All flanged connections shall be Class 300 PSI Rating, and all threaded and socket weld fittings
shall be 3000 PSI rating.
The flue outlet located at rear 3rd pass end, on top center line of shell, shall be vertical with collar
flanged end for easy connection to vertical breaching and stack.
Boiler Shell outlets shall include for the following connections:
- Safety valves
- Pressure gauges
- Vent Valve
- Flanged vertical flue gas outlet at top rear end.
-
Bottom blow-downs & drains on front and rear ends
300 PSI Flanged Steam Outlet, with drying pan to ensure 99.5% steam dryness
Feed water Supply, with internal diffuser tube or deflecting baffle plate
Low water cut-offs
Other outlets for Steam controls & trim, such as:
Pressuretrols, surface blow-down, Chemical Feed and others.
The boiler skid should be high enough to allow space for clearing the piping connections on
bottom of the boiler.
The Boiler shell shall include 2 heavy lifting-lugs for transport facility
7/25
The Boiler shall be covered on sides and top with a minimum of 2" glass wool or fiberglass
insulation, strapped to the Boiler shell and protected by a 22 gauge sheet steel jacket.
The entire boiler, base frame and other components shall be factory painted before shipment, using
a hard-finish synthetic fire-resistant enamel. All nameplates, gauges, valves shall be masked and
left unpainted.
Each Boiler shall be neatly finished and properly packaged for shipping.
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1.09 BOILER TRIM & CONTROLS
The following trim and controls shall be factory-mounted and piped, in accordance with the ASME
Code and the Underwriters Laboratories Requirements.
The boiler shall be equipped with the following trim fittings:-
One Low-water cut-off and Pump control with alarm switches, mounted on side of the
Boiler shell, complete with Tricocks and Drain Valves.
One Auxiliary Probe Type Low-water-cut-off.
One Level Indicating gauge glass set, mounted integrally to primary low-water cutoff, with
Valves, and Drain Cocks
Safety Valves, number and sizes as per A.S.M.E. Code
Pressure Gauge, with Siphon, Inspector Tee and cocks.
Main Steam Header Valve
Quadruple Blow-down Valves for bottom and surface
Feed, Stop and Check Valves at Feedwater connection
1 Vent or Air release valve
In addition, the boiler shall be equipped with :
a)
b)
c)
d)
e)
A Steam Pressure Safety/Hi-Limit control,
A separate Pressure operating Limit control,
A Steam Pressure lo-fire hold control
A Steam proportional/modulating pressure control
A Stack Thermometer/Factory mounted at vent outlet of boiler
All the above trim and fittings shall be so located in the boiler shell as to provide ease of
maintenance of Boiler and Burner without disturbing or dismantling the controls.
1.09.1 LOW WATER CUT OFF'S AND PUMP CONTROLS.
The primary Low-Water Cut-Off shall be a Mc Donnell & Miller 157 S, automatic reset, located on
the right hand side of boiler or similar. It shall be rated at 200PSI. The pump control switch shall be
an integral part of the unit.
The Primary LWCO switch shall be wired in the burner control circuit to prevent burner operation
if the boiler water falls below the safe working level. It will incorporate a pump control to start and
stop the feeding pump and shall be equipped with a Manual blow-off valve to enable regular blowdown of the float chambers.
The Secondary Low-Water Cut-Off (Extra Safety LWCO) shall be an Electrode type, mounted on
the top of the boiler shell.
The Secondary LO-Water Cut-Off shall be wired in series in the burner control circuit to prevent
Burner operation if the Boiler Water recedes below a safe level, and the primary Low-Water CutOff fails to shut down the burner.
This unit shall be of with a Manual Reset. The Burner shall not re-start until Boiler Operator has
ascertained the cause of the burner shut-down. It can then be manually re-set.
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1.09.2 GAUGE GLASS SETS
The Gauge Glass set mounted on the Primary LWCO Unit shall be of the Ball-Check Safety Type
and consist of the top and bottom gauge isolating cocks, a hi-temperature, hi-pressure tubular Pyrex
glass 5/8' x 10' complete with pet cock, rubber Washers, and protective glass rods.
1.09.3 SAFETY VALVES
Safety valves shall be of the full bore, spring-loaded self-resetting type with side outlet. The
number, size and capacity of same to conform with ASME Code requirements.
These will be of the adjustable type, with hand lever for manual Testing and factory-set and sealed
to open at the required Design Pressure.
1.09.4 STEAM PRESSURE GAUGE
A Steam-pressure gauge shall be located at the top center line of the boiler shell, close to the front
end. It shall be of the Bourdon type and size.
It shall be equipped with a pig-tail siphon, Inspector test Tee and shut-off cock.
1.09.5 MAIN STEAM HEADER VALVE
The main Steam Header Valve shall be of the Open Stem and Yoke (O.S.& Y) 300 lb. flange to
match the boiler outlet flange class.
1.09.6 BLOW-DOWN VALVES
The Blow-Down Valves shall be a set consisting of quick-opening type and slow-opening types.
These shall be supplied loose by the Boiler Manufacturer for field installation to conform to the
Code requirements for size, and Capacity.
The quick opening valves shall be installed at the rear and front bottom connections, and at the
surface blow-down locations.
The slow-opening valve shall be installed at the main blow-down Drain line
1.09.7 FEED, STOP AND CHECK VALVES
The Feed, Stop and Check Valve set shall include a gate valve, a swing check and a spring-loaded
check valves to be installed at the water feed connection of the boiler.
The check valves shall be of the accessible type.
The gate valve shall be installed closest to the Boiler preceded by the Swing Check Valve and
Spring-Loaded Check Valve. They shall all be supplied Factory mounted
1.09.8 VENT VALVE
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A Vent valve of the globe type, bronze, shall be fitted on the top center line of the shell.
1.09.9 STEAM PRESSURE CONTROLS
The Pressure controls shall be mounted on one manifold.
The Controls shall include :
a) A Hi/Safety limit with Manual reset
b) An Operating limit with subtractive differential, Auto reset
These two automatic controls with adjustable ranges will provide on-off operation and will be
wired in series for added protection.
They will be of the automatic type, 'break' on Pressure Increase, similar to Honeywell L404A
c) An Automatic low-fire hold switch, to prevent burner going to hi-fire at cold start, thus
preventing negative Thermal Shock of the Boiler Vessel.
This will be wired in conjunction with the Modulating Control and will "make" upon pressure
increase.
It will be with adjustable main Pressure range and differential with automatic reset, similar to
Honeywell L404B
d) The Modulating control shall be of the proportional wire-wound potentiometer type. It
will be of the adjustable setting and modulation range, similar to Honeywell L91
series. It will be wired in the modmotor circuit.
1.09.10 STACK THERMOMETER
A Stack Thermometer - factory mounted at the vent outlet of the boiler shall allow reading of the
out-flowing flue-gases temperature.
It will be of the bi-metal, 3" min., dial type - 1000 degree F Range, with 12” stem. It shall be used
to monitor the flue gas Temperature .
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2) BURNER ASSEMBLY
2.01 BURNER ASSEMBLY
The Burner shall be designed for firing light-oil #2 fuel and will be of the pressure mechanical type
(up to 350HP) or air atomized type (over 400HP).
It shall be supplied factory mounted and fully wired to the boiler controls by the Boiler
Manufacturer.
The - Boiler-Burner package shall be single source responsibility.
The blower shall be direct driven, by the burner motor with the blower supplying all the necessary
air for the combustion.
The blower air supply shall be governed by an Air Damper at the blower inlet.
The full Modulation Arrangement shall use a modulating motor with built-in end switch for
guaranteed low-fire start.
The modmotor shall control through a set of linkages the oil or gas flow through a metering valve
or butterfly valve and the air flow with the air damper to the Blower.
The Burner shall use a by-pass nozzle arrangement with an air swirl for maximum combustion
efficiency.
The Oil flow shall be provided by a fuel oil existing pumps.
The Modulation turn-down ratio shall be 3:1(or more) (at Lo-fire, Boiler Output shall be 33% (or
less) of Capacity at full firing rate).
The max. firing rate shall be as per technical specs.
The Ignition shall be accomplished by a 10,000 V Ignition Transformer, ignited at Low-fire
position of the Air Damper.
The Burner shall include a bolted access plate removable for easy access to the nozzle/Electrode
assembly. The plate shall include an observation port for viewing the flame.
2.02 BURNER FLAME AND PROGRAMMING RELAY
The burner shall be equipped with a Micro-Processor based Burner Management Flame Safeguard
and Parallel Positioning Control System. The control shall fully integrate the Flame Safeguard
functions and combustion control functions into a single control module.
The controller shall provide the following features :
 Automatic sequencing of the burner startup and shutdown
 Flame proving and lockout. The control to be able to interface with Infra-Red or UltraViolet Scanner, provided by same manufacturer, via parameter selection.
 Individual control of up to three servo positioning motors. One servo will be for the air
damper, and the other for the fuel metering valve or gas butterfly valve.
12/25








Servo Motors to be directly driven by the control, and not through interface relays.
Two PID Control loops for firing rate control of burner based on setpoint of pressure or
temperature.
Multiple Boiler/Burner Sequencing
Current status and system diagnostics via alphanumeric display unit
Remote Communications capabilities with software
Oxygen trim capability to ensure O2 level is maintained at all times, with automatic
trimming capability
Variable Speed Drive capability for variable speed control of blower motor
Two separate firing curves (profiles) for each fuel fired.
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3) CONTROL PANEL & ELECTRICALS
3.01 BURNER PANEL
A fully factory prewired, tested and Boiler-mounted Electric panel shall be installed at the front or
side of the boiler. It shall be conveniently located for the operator. It shall be ready for field connection of the 3-phase
380V Power mains to be operational.
The control panel shall be fully enclosed, hinged, dust-proof Enclosure. It shall be painted with the
same color as the boiler casing and complete with latch and lock.
The Control Panel shall include:
A step-down Control Transformer
Control and Power Fuses
All relays and transformers
A 3-phase motor starter with overloads, undervoltage protection and auxiliary contacts
The Flame safeguard and Programming Relay complete: Base, Chassis and Modules as
outlined elsewhere
- Terminal strips, numbered for easy wire tracing, complete with all hardware
- Extra free terminals and Earth lugs.
-
3.02 WIRING
All wires shall be neatly strapped and color coded/numbered in agreement with the schematic of the
Boiler Panel.
All wires running out of the panel shall be installed within conduits and terminated at the punched
holes to the panel sides, with the required hardware as per N.E.C Code.
Exceptionally, the lead sulfide Infra-red scanner cell wires shall be routed in a separate conduit.
All wiring to conform to N.E.C. applicable Codes.
3.03 PANEL SWITCHES AND SIGNAL LIGHTS
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The panel shall include further, mounted externally :
- Signal lights with Amber, Red and White lens for visual indication of Ignition on- Main flame
on-Alarm condition
- An On-Off toggle type switch
-
A manual Potentiometer for manually setting the firing rate motor, with a Manual-Auto switch.
A High-Fire Limiting Potentiometer for limiting the firing rate in periods of prolonged low
load demands.
-
An Alarm Bell or Horn to sound out in case of Flame Failure or Low Water condition, with a
silencing switch. The switch shall turn-off the bell but the alarm light shall stay on until the
failure condition has been corrected.
The Panel shall include a small glass window to view the digital display of the Flame Safeguard
and Programming Relay, without the need for opening the panel Door.
3.04 WIRING DIAGRAMS AND FIRE TEST REPORTS
A copy of the Boiler Electric schematic Diagram shall be placed inside the panel board and covered
with adhesive transparent plastic for protection.
A copy of the Factory Fire Test Report shall also be placed to the inside of the Electric Panel
Board.
Additional copies of both above shall be included with the boiler literature as outlined elsewhere.
14/25
4) CODES, MANUALS, DRAWINGS, TESTS, DELIVERY , TRAINING OF PERSONNEL
4.01 BOILER CODES, APPROVALS, CERTIFIED REPORTS
4.01.1 The Boiler Shell shall be designed and constructed in accordance with the ANSI / ASME
Boiler Code – Sec I – Power Boilers, and must be tested and receive boiler inspection and approval
prior to shipment, by an authorized Inspector from the National Board.
A copy of the Inspection Report duly stamped & signed shall be supplied to the Purchaser.
4.01.2 The Boiler shall conform to the recommendations of an international accreditation board
4.01.2 The boiler shall be completely pre-assembled and fire-tested at the factory. It shall be firetested and controls set as for normal operation. All readings shall be consigned in an official
Factory Fire-test report.
The factory Fire-Test report shall be supplied to the Purchaser, along with the standard Literature
supplied such as Manuals, Brochures, etc... detailed elsewhere.
The Report shall be made available for any agency authorized by the Customer to inspect same.
4.02 TECHNICAL MANUALS
The Manufacturer shall supply 2 sets of Boiler Technical literature comprising:
-
Start-up and Operating Instructions
Boiler Service and Spare Parts Manuals
Burner Service and Spare Parts Manuals
Installation Instructions
Wiring Diagrams, (Boiler control Panel, Feedwater Pumps & interconnection)
Factory Fire-Test Reports, Boiler Production Data Report, conforming to ASME Code (P-2
Form).
Submittal: Manufacturer shall submit a complete booklet containing shop drawings as listed
below, together with catalogues and Brochures of major components.
-
-.
4.03 TESTS & CERTIFICATES
4.03.1 FACTORY TESTS
The packaged Boiler must be Factory Fire Tested prior to shipment as detailed elsewhere to check
the performance construction, controls and operation of the unit. Copies of this test shall be included in the Technical Literature Package supplied by the
Manufacturer.
4.03.2 TEST CERTIFICATES
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Upon Owner's request, the Contractor shall submit Test Certificates for equipment and items
supplied. These could be the National Board Inspector Test Certificates for the Boiler Vessel.
Test Certificates shall be issued by an approved inspection authority testifying that equipment or
item in question meet its testing conditions and are in conformity with the stipulations of these
specifications.
4.03.3 START-UP, FIRE TESTS AND REPORTS
- After Boiler Installation, the manufacturer representative will provide a Field Representative
Engineer - for Starting-up the Boiler, Pump Sets and Auxiliaries.
- Upon Conclusion of the commissioning of the Boiler by the Manufacturer's Representative, an
Operation and Performance test shall be scheduled to be witnessed by the Owner, the Consultants
and Technical personnel.
4.04 DELIVERY AND TRAINING
4.04.1 DELIVERY
After the Test and Report are successfully completed as witnessed by the Customer and Consultant
, a Certificate of Delivery will be issued by the customer..
4.04.2 TRAINING OF PERSONNEL
a. The Manufacturer Representative shall train the Owner's Operators during Commissioning and
Start-up, and after Delivery.
The Training shall cover standard Start-up and Operation Procedures and Regular Maintenance
works.
b. The Contractor shall be responsible to instruct the personnel team that may be assigned to him
by the Owner during execution at no extra charges.
Personnel instruction shall include allowing the personnel team to attend installation works, be
instructed on the use, operation and maintenance of the various systems, components and
equipment.
c. The Manufacturer Representative shall, at the completion of the project, demonstrate the
operation of each system and piece of equipment to the Owner and Engineer. Demonstration shall
include automatic operation of controls and safety devices to show proper setting of these items.
Instruct the Owner personnel in the proper method of operation, maintenance and lubrication.
Equipment shall be demonstrated and instructions given by the Representative of the Manufacturer.
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5) BOILER CONDENSATE / FEEDWATER TANK AND PUMPSETS ASSEMBLIES
5.01 GENERAL
5.01.1 The supply of the CONDENSATE AND FEEDWATER TANK IS to be quoted as option.
An existing tank could be used. Only a feeding pump is required from the same boiler
manufacturer.
5.01.2 The packaged unit shall consist of the following:
 Pump set: function, and allocation to Boiler shall be as per the technical schedule with
piping and connecting fittings to tank.
 Electric panel for above factory-prewired and tested.
 The unit shall be supplied, fully piped as a package, ready for field connection to the
condensate, pump discharge lines and power lines.
5.02 FEEDWATER PUMP AND FITTINGS
The boiler feed water pump shall be centrifugal multi-stage vertical, direct drive, mounted and
secured to the stand bed-plate. The pump shall have stainless steel body, shaft and impeller, and
designed for hot water duty (T  200 deg.F).
The pumps suction shall be connected separately to the tank.
5.02.1 The pump shall be capable to supply the required GPM and at Head 10 PSI above M.A.W.P.,
as detailed in the Technical Schedule.
5.02.2 Pump set Fittings:
The pump suction line shall be supplied assembled with the following:
 Shut-off valve
 Strainer
 Compound gauge and cocks – Range 0-30” W.C.
This assembly can be supplied sub-assembled for shipping facility.
A thermometer will also be supplied loose to be field-fitted on the discharge side of the pump.
5.02.3 At discharge the pump line shall be fitted with the following fittings:
 One Shut-Off valve
 One swing check
5.03 FEEDWATER PUMP ELECTRIC PANEL
5.03.1 The pump panel shall be of the enclosure cabinet-type with hinged door and will comprise :
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








One step-down control transformer
Circuit breakers,
Magnetic contactors (starters), with thermal overloads
Hand-off auto selector switch for manual / auto operation
Pilot lights – for power-on and Hi-Lo- Water Alarm light.
Hi-Lo Alarms
Alarm Bell and Silencing Switch
Junction terminal board, numbered , with additional free terminals
Control voltage fuse and hardware.
Earth lugs, etc..
It shall be mounted on the wall, and completely prewired and factory tested ready for connection to
the electric mains (3-phase), boiler pump switch terminals, and pump circuits.
Other specifications shall be as outlined generally for the boiler panel.
5.06.2 Copy of the wiring diagram shall be glued to the inside cover of the panel . Additional copies
will be included with the technical literature Package of the Boiler to be supplied, as outlined
elsewhere.
Formatted: Left
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7.02 BOILER AUTOMATIC BLO-DOWN SYSTEM AND EQUIPMENT(As option)
7.02.1 PRINCIPLE OF OPERATION
To maintain the correct total dissolved solids (TDS) level in the boiler, an automatic blowdown
control system shall be installed for each boiler.
7.02.2 TDS CYCLE CONTROL
This will check Blowdown Boiler water TDS against pre-set values at the controller. The
system shall include boiler TDS controller, probe and valve assembly and a set of
replacement orifices.
Boiler Controller: This will check water TDS by conductivity . If TDS valves of
boiler water is above pre-set valves, it will energize the motorized / solenoid valve to
open the drain, otherwise it will stop the cycle and wait for the next sampling period.
This unit shall be Solid State programmable and Controller with facilities for
adjustment of cycle periods and TDS levels, with visual Pilot lights to indicate
Operation and cycling and in a NEMA enclosure. Power to Controller shall be 120
V.
Motorized / Solenoid Valve and Probe: This assembly will be mounted at the surface
blo-down connection of the boiler. When cycle period is energized, the solenoid /
motorized valve shall open surface blo-down water to drain, passing and energizing
the probe. This probe will connect current proportional to the TDS level and feed
this information to the controller. The pressure rating of the assembly is 250 PSI.
The solenoid / motorized valve shall be stainless steel ball stem and the assembly
will be ¾” size. It will be supplied pre-assembled ready for mounting on boiler.
Power requirement is 120 V and step-down transformer could be used to obtain the
required voltage.
Accessories: A set of different orifices shall be supplied to control surface blo-down
flow for proper testing. These are easily interchangeable into a union part of probe
and valve assembly.
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9) WARRANTIES AND WARRANTY PERIOD
9.01 WARRANTY OF BOILER EFFICIENCY
The Boiler must be guaranteed to operate at a minimum fuel efficiency of 80 % throughout 30 to
100 percent of max. Firing Rate Capacity based on the HHV (Higher heating value).
9.02 WARRANTY OF INSTALLATION AND WORKMANSHIP
a. A warranty for all Materials and Equipment installed for defects of workmanship and materials
for a period of 24 months after final acceptance of completion of the work, and repair or replace, at
no additional cost to the Owner, any materials or equipment developing such defects and also make
good any damage caused by said defects or the rectification of same, within that time, promptly on
due notice being given by the Engineer or Owner.
Such repairs or replacements shall bear additional 24 months guarantee as original, dated from final
acceptance of repair or replacement.
b. During the warranty period, regular maintenance will be conducted by the manufacturer
representative
c. When failures are due to Owner's fault, it shall be the Contractor's responsibility to submit
supporting evidences.
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TECHNICAL SCHEDULES
BOILER BURNER PACKAGE
TYPE
APPLICATION
FIRETUBE BOILER
STEAM
Power
300 HP (4,500 kg/hr
steam from and at
100°C)2940Kw
200 PSI
LIGHT
DESIGN PRESSURE
FUEL FIRED
ELECTRICALS
QUANTITY
PUMP ASSEMBLY
CAPACITY
NUMBER OF PUMPS
PUMPSHEAD
380V / 3PHASE/ 50 HZ
1
adequate to the boiler
1
210 PSI
-
B- Compteur de précision pour la consommation de mazout :
-
Un compteur ou deux qui fournissent la consommation réelle de la chaudière.
Le plus petit digit affiché : 1 litre.
Le plus grand digit affiché doit être suffisant pour enregistrer la consommation
d’au moins une année avant une remise automatique à zéro.
C- Réparation des pannes et anomalies dans le réseau :
-
Une visite d’inspection du réseau vapeur allant de la chaudière jusqu’à la
blanchisserie est obligatoire.
Une offre pour la réparation des pannes éventuelles et anomalies sera
présentée en option avec l’offre de la chaudière.
4) Notes importantes
-
-
Toutes les dis-concordances avec les spécifications fonctionnelles et techniques
citées en haut doivent être clairement indiquées dans l’offre dans un
paragraphe intitulé « Dis-concordances avec le cahier de charge ».
Une visite des lieux avant la soumission de l’offre est obligatoire pour voir et
mesurer l’emplacement de la chaudière dans le bâtiment technique et aussi voir
si les alimentations électriques et hydrauliques de la chaudière existante sont
suffisantes pour la nouvelle chaudière.
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VI. IMPLANTATION
Prestations à la charge du Fournisseur :
o
o
o
Fourniture du plan de disposition des équipements dans le local.
Fourniture des schémas des connexions électriques et hydrauliques.
Installation et connexion et mise en marche des équipements.
VII. HYGIENE, NETTOYAGE
Les équipements doivent être livrés propres avec nettoyage du local après la fin de
l’installation.
VIII. SERVICE APRES VENTE
1) Pièces détachées
Pour apprécier les coûts de fonctionnement liés aux équipements, seront fournis les
renseignements suivants :
Liste, quantité estimée et prix des pièces détachées, des pièces d’usure et consommables
techniques, dont le changement sera nécessaire pendant la période de garantie, puis audelà de cette période, y compris les éléments changés par les utilisateurs dans le cadre de
l’entretien courant du matériel.
2) Organisation SAV
Pour apprécier l’assistance technique après-vente mise en place par le fournisseur, seront
fournis les renseignements suivants relatifs à l’agence assurant les prestations techniques :
o
o
o
o
o
Localisation.
Numéro de téléphone.
Jours et horaires d’ouverture du service après-vente.
Qualification et nombre de techniciens de l’agence.
Délai d’intervention et de correction de défaut.
3) Engagement du fournisseur sur les durées d’approvisionnement
Le fournisseur indiquera la durée d’engagement de sa société pour la fourniture des pièces
détachées sur ce matériel et ceci à compter de la date de livraison.
Il précisera la liste des pièces détachées exclusives.
La fourniture d’une indication sur l’estimation de la durée de vie de l’appareil sera
appréciée.
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IX. INSTALLATION
1) Délais de livraison :
Le candidat devra préciser les délais de livraison des équipements qui comprennent :
- Les délais de transport.
- Les délais pour les formalités administratives et de dédouanement.
- Les délais de livraison à l’HDF, mise en place et réglage.
- Les délais pour les essais et la mise en service.
2) Arrivée du matériel
Le fournisseur préviendra les Services Techniques de l’HDF de l’arrivée du matériel au
minimum une semaine à l’avance.
3) Travaux d’installation
Si l’installation des nouveaux équipements demande des travaux ou branchements
particuliers le fournisseur est tenu de les mentionner dans son offre. Il rentre en contact
avec le Responsable des Services Techniques de l’HDF dès réception du bon de
commande.
4) Etapes de l’installation
D’une manière générale, les matériels seront installés et mis en ordre de marche dans le
local où ils sont affectés. Cette installation est entièrement à la charge et sous l’entière
responsabilité du Fournisseur et comprendra :
Débranchement et enlèvement des anciens équipements existants se fera par
le service technique de l’HDF.
o Le fournisseur fournira au service technique tous les plans d’installation 10 jours
après que le bon de commande lui a été envoyé.
o Le service technique de l’HDF préparera le site.
Le fournisseur complètera toute l’installation pour la livrer en état de marche, il fera :
o L’Installation des équipements livrés.
o La connexion hydrauliques et électriques.
o La mise en marche, réglages et essaies.
o La Fourniture d'un manuel utilisateur détaillé, d'utilisation et d'entretien en
fonction du temps et/ou le compteur horaire de fonctionnement effectif pour
chaque élément approprié des équipements livrés.
o La Fourniture d’une documentation technique comprenant les procédures
d’utilisation, d’entretien et de maintenance avec les éclatés des parties
mécaniques et les schémas de câblages électriques et électroniques, et la liste
des pièces constitutives et leurs références.
o La Formation des utilisateurs.
o La Remise en état de tout bien éventuellement détérioré par les opérations de
mise en place des équipements.
o
Tout ce qui est nécessaire aux opérations de vérification de performances durant la
réception sont à la charge du Fournisseur a l’exception du fuel..
5) Réception
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La réception des équipements sera assurée conjointement par le Responsable des
Services Techniques de l’HDF ou son représentant et le Représentant du Fournisseur. Elle
ne sera prononcée que lorsque les équipements auront été testés avec succès durant une
période significative définie d’un commun accord entre les parties et lorsque toutes les
obligations du fournisseur, notamment administratives, auront été remplies. En particulier
tous les documents techniques relatifs à l’entretien, à la maintenance et à la formation des
utilisateurs.
6) Satisfaction
En cas de retard dans la livraison, l’installation ou la mise en exploitation de l’intégralité du
matériel, tel que spécifié dans le bon de commande, l’HDF se réserve le droit de réclamer
des pénalités de retard journalier représentant 1% du prix de l’article non livré jusqu'à
concurrence de 10% et/ou d’annuler le contrat de vente, à l’entière responsabilité du
fournisseur.
Si après installation le matériel ne remplit pas les conditions nécessaires pour une
attestation de bon fonctionnement il sera remplacé par un autre sans charge
supplémentaire pour l’hôpital.
X. FORMATION ET DOCUMENTATION DES UTILISATEURS
Au moment de la livraison, le fournisseur devra remettre aux utilisateurs (en double
exemplaire) tout document (manuel d’utilisation, documentation détaillée du fonctionnement
des appareils et de leur entretien…) ou renseignement en langue française permettant
d’obtenir un fonctionnement correct des appareils livrés ; et assurer, également en langue
française, la formation du personnel affecté à la manipulation du matériel.
La fourniture de ces documents et les formations font partie intégrante de la prestation due
par le titulaire du marché.
La fourniture des documents et la formation initiale des personnels à la manipulation du
matériel devront être réalisées préalablement à la réception technique de l’équipement.
Suivant l’importance et la complexité des techniques utilisées par les nouveaux
équipements il sera demandé, dans l’offre de base, de prévoir :
-
La formation des utilisateurs des équipements du service technique chargés
des taches journalières. Cette formation sera réalisée par un agent du niveau
technicien.
-
La formation des techniciens du service technique à la maintenance et suivi des
équipements.
XI. MAINTENANCE PENDANT LA DUREE DE GARANTIE
1) La durée de garantie minimale exigée par L’HDF est de 24 mois. Cette durée de
garantie est prise en compte dans l’évaluation des offres
2) Pendant la période de garantie, la maintenance complète (pièces LOCO HDF,
main d’œuvre et déplacement) sera intégrée dans la prestation de fourniture des
appareils, c’est-à-dire les maintenances correctives dues à des pannes et les
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maintenances préventives prévues dans les notices d’utilisation des appareils,
ainsi que la fourniture de toutes les pièces nécessaires à ces maintenances.
XII. CONTRAT DE MAINTENANCE
A l’issue de la période de garantie, l’Hôtel-Dieu de France pourra souscrire un contrat de
maintenance pour l’équipement proposé.
A cet effet, les candidats devront proposer un contrat de maintenance selon les modalités
suivantes :
1) Prestations forfaitaires
Le fournisseur proposera un contrat de maintenance annuel forfaitaire (tout compris)
couvrant les frais de main d’œuvre et déplacement et la fourniture des pièces détachées et
les consommables LOCO HDF (les exclusions éventuelles devront être précisées), pour
l’exécution des interventions de maintenances préventive et corrective avec garantie de
renouvellement pour les 5 années succédant la période de garantie.
Le fournisseur devra indiquer le coût du contrat, la durée d’engagement concernant ce coût
de maintenance et les éventuelles clauses d’évolution.
2) Prestations de service
Le fournisseur proposera un contrat de maintenance annuel avec garantie de
renouvellement pour les 5 années après fin garantie, couvrant les frais de main d’œuvre et
déplacement seulement. Il devra également proposer une liste avec les prix des pièces
détachées et les consommables sur une période de 8 ans succédant la période de garantie
ainsi que les éventuelles évolutions sur ces prix.
3) Prestations sur bon de commande
Le fournisseur indiquera le coût des prestations de maintenance réalisées sur bon de
commande :
o
o
o
Forfait déplacement
Tarif horaire de main d’œuvre
Coût des pièces changées systématiquement et coût des consommables.
Il indiquera également la durée d’engagement concernant ces coûts de maintenance et les
éventuelles clauses d’évolution.
XIII. RENSEIGNEMENTS
Pour tout renseignement complémentaire qui lui serait nécessaire en vue de répondre à la
consultation, le Fournisseur pourra s'adresser à :
Mr.Youssef Rahal
Tél. 01 615 300 ext.7260
e-mail : [email protected]
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