01/22/09 – After making it most of the winter with little problem, the boilers started performing badly last Friday. ThermalTech was on site with the Duke employees to monitor the situation. TTC asked Stoermer and Duke to provide solutions, TTC believes our two options are a new regulator in the boiler room for 14″ or modified regulators at the boilers to handle the boiler pressure better.
03/09/08 – Duke installed a new regulator and it worked good until last Wednesday when there were three low pressure alarms and flame outs on Boilers 2 & 3. TTC sent an email to Duke and SA explaining the latest problems and asked to bring in another expert to look over the entire system.
02/29/08 – Duke installed the 461-S regulator this week and if this works, they will install a larger vent for the regulator to use. We will monitor the boilers over the next few weeks and see if this is the answer.
02/06/08 – Duke Energy replaced the regulator yesterday with the new CL-38-2 but did not use the pilot line. The regulator seems to work okay and settles down in about 2 seconds of a boiler start. TTC sent an email to everyone outlining the results and asked SA to program the boilers one more time with the new regulator in place. The residual static is now up at 47″ with a running static of 27.6″wc. TTC witnessed a dip in pressure down to 17″wc with the new regulator but it recovered quickly and evened out as the boilers started.
02/01/08 – We had a conference call with Duke Energy today. They are willing to try a new gas regulator and meter at the building. We are going to try a CL-38-2 regulator with the new meter next Tuesday at 9am when Duke comes out to install the new meter set. Darnell will coordinate the visit and TTC will stop by to check on progress around noon. They think this meter with the external sensing line and 1.25″ orifice will do the trick.
01/24/08 – Boiler #3 went out on a flame failure last night at 10:30pm. John Gilbert came in to reset the boiler and it has been working fine since then. TTC had emails with Duke & Stoermer to try to get these final issues resolved.
01/23/08 – On 01/18 SA and Duke met on site to work and reset the boilers. What we discovered was that Duke was not comfortable with having the pressure under 1psig because we were testing the boilers at 24 psig and 20 psig. At these pressure the boilers worked pretty well but there are still concerns with Duke regulator. Because of this TTC talked AKM into paying PHB to come on on Sa 01/19 to install a 1″ weld-o-let and valve so that Duke could move the sensing line downstream about 20ft. On 01/21 TTC met Duke back on site and they piped up the regulator sensing line. The regulator is still surging. The boilers are however running great. TTC check the pressure at the inlet to the boilers and it is bouncing around between 19 psig and 29 psig every second. The burnertip pressure however is stead between 7.8 & 8.0 inches. I believe the biggest change in the boilers is that TTC talked SA into changing the low pressure setpoint down to 13″wc and not 19″wc so the boilers are not going out on low gas pressure as much any more. The Sellers regulators seems to be able to handle the incoming gas variations very well and the boilers are firing very smoothly.
01/15/08 – Darnell Edwards called yesterday to say they were having more trouble with the boilers. I met Duke Energy on site today because they responded immediately to a request to test the gas pressure at 15″ wc. It turns out that the boilers can’t be run at the pressure because the low limit on the boilers are set to 19″wc for some reason. Duke set the regulator down to 24″wc incoming for now and the boilers seem to run fine during the day. I am waiting to see how they operate overnight and tomorrow morning. I have talked to Tom Schmidt and Joachim at Duke about this situation too. We are currently trying to schedule Duke and SA back out at the building at the same time to adjust the incoming gas pressure to 20″ wc which should put us right in the middle of the operating range for this boiler. I am also trying to get some chart recorders to log the gas pressure in the main and at the boiler burnertips for testing purposes. When we watched the pressure after the regulators today they were steady at 7.5″wc on BLR-1 and 7.9″wc on BLR-2. BLR-3 is having some startup issues and according to Tony Martini there is sooting on the fire tip inside the boiler. When the boiler cools down, he will clean it off and then it should be back in server as well. I am trying to coordinate a meeting for Friday morning at the 800 Broadway building between TEI, Duke and Stoermer. I am also trying to get chart recorders for history recordings of gas pressures.
01/07/08 – The County called last week with more boiler problems. TTC investigated and found that on November 9, 2007 that the boiler were setup for 37″ of gas pressure on Jan 3, 2008 during our first cold snap the boilers were not running properly and going out on alarm settings. The owner could not keep a boiler running. TTC visited the building on 01/03, 01/04, 01/05 & 01/07 to check on the boilers and the pressures in the main gas line. According to all the readings that TTC took while onsite there is no gas pressure issue with the natural gas piping or Duke regulator. During all test the natural gas system delivered 30″ of pressure to the boilers all the time. At startup or when both boilers were starting at the same time a dip down to 24″ could be seen for a fraction of a second but nothing that could be thought to effect the way in which the boilers are running. TTC, John Gilbert & Will check the boilers at Boiler #1 and at the main building entrance. There is no appreciable loss in the piping system in gas pressure. The new Duke meter seems to be controlling pressure well. Today the temperature was back up to 60 degrees and TTC tested the natural gas pressure with no boilers running and it was found to be at 30″ with both of the domestic water heaters running. Later after they both shutdown the pressure slowly rose to 37″ just like the Duke representative Mike Hoffer said it would. The regulator used back pressure from the high pressure main to ensure positive shutdown of the valve. This means the residual pressure in the gas main is 37″ when no equipment is running and 30″ when anything is on. This correlates exactly to what to Ron Eaton told us by phone last week. The next step is for Sellers to provide a new regulator on one boiler sized for 30″ of static pressure when the boilers are running. This regulator should be able to handle pressures up to 40″ of gas and down to 28″ nominal and even down to 20″ under heavy load conditions or even better if it can go down to 14″, that is what I will make them provide. In my opinion, this is absolutely a boiler regulator issue and not a Duke Energy gas issue. We can hopefully get a new regulator in this week and have ONE of the boiler retrofitted before the next cold snap but your also stand a great chance of the boilers working well right now since they have been adjusted down from 37″ of pressure to 30″ (I think that is just a misunderstanding on Stoermer’s part about what they have at your building).
11/09/07 – Tom Schmidt called today to say that the boilers could not be adjusted so that all 3 boilers run at once. TTC sent an email to the County and Tom stating that all 3 boilers can’t run at the same time. The design is to have one boiler running at a time, at 0 degrees a second boiler can come out to help out but it doesn’t have too. The third boiler does not come on until -20F which really means never because the 6″ gas main isn’t sized for (3) 125 HP boilers to operate simultaneously. TEI had Tom Schmidt come in to discuss the problems and talked to Ron Eaton after he got to the building today about inlet pressures. On Nov 9 the pressure was 37″ and the boiler were adjusted for that pressure. Today the pressure is 29″ and this changes the inlet pressure to the boiler after the Siemens gas train from 8.5″ to 7″ which causes the boiler to run way to lean. Gary and Todd are helping me figure out how to solve these problems for the County. TEI has a conference call with the boiler mfgr at 2pm to work on this some more.
05/19/07 – Duke Energy replaced the gas regulator to the building with the new model specially designed for our load with a tighter tolerance to the outlet pressure.
05/02/06 – Tony called today about flame failure on the boilers at the end of the last season. TTC recapped what has transpired since the 3-22-06 call. TTC has talked to both Stoermer and Cinergy about this problem and it appears to be rooted in the fluctuations of gas pressure not the absence of gas pressure. The building has at least 1 psig of gas pressure which is twice as much as the boilers require but when boilers are running with the water heaters and various units shutdown, there are flame failures in the system. Apparently, the fluctuation of gas pressure on the high side is causing gas delivery problems to the boilers. TEI may recommend having the water heaters moved ahead of the boilers or changing the control sequence so that 3 boilers are never online at any one time. TEI will contact Stoermer, Cinergy and Automation to make sure this problem is resolved going into next heating season. We might need a meeting between TE, Cinergy, Stoermer and A&M to resolve this issue.
03/22/06 – County called about Boilers 1 & 3 going out on flame failure last Thursday and Boiler 2 going out on Saturday.
10/28/05 – County called about erratic boiler controls for gas usage. SA worked on setting the boilers up again with Cinergy regulators.
06/14/05 – TE received and sent out all final paperwork to complete this project for County and PHB.
06/09/05 – TE and PHB discussed final paperwork requirements on this project. TE received a final invoice in January 2005. The final paperwork was received in January also. Now, TE has all the final paperwork in house but can’t find the final application # 5, so PHB is sending over a new original. TE will submit these final documents to County as soon as they are received, copies and signed.
05/03/05 – A&M straightened out the program and released some unpronounced overrides. The provided a little more training for the operators and building manager. The plant appears to be working properly.
05/02/05 – 800 reported some anomalous behavior from the boiler plant. TTC called A&M for dial in assistance and TTC will stop down at building on Tuesday morning to investigate.
04/27/05 – TTC and Tony Martini witnessed the laptop working remotely today. Dennis set it up for home use and left it for Tony to take home for use. TTC observed the entire system while the Free Cooling system was offline because of a condenser water pump rebuild. I found many things in the “override” position. This certainly happens upon occasion but overrides should be release to allow the automatic controls to handle the building most of the time. TTC pointed out that with the boilers overridden off at the DDC through their enable point that this does not disable the feedwater pumps so we actually had 0 boilers running but 3 feedwater pumps running just using up energy. TTC stated that a better way to control the boiler plant “off” would be to lower its enable setpoint below the current OA temperature. The same goes for the Chiller plant which can also be run at lower temperatures when the FREE cooling is disabled to keep temperatures in the building from overheating the space as they were beginning to do today.
04/26/05 – TTC could not get the laptop working from home. TTC delivered to Dennis Brown. A&M called to report the laptop is working and will be dropped off to 800 on Wed morning with training. TTC will stop by to supervise this training. Does the County want Tony Martini and Glenn Wilhoit to attend this laptop training and can they be there at 8:15 a.m.?
04/22/05 – TTC to work on laptop for DDC access. PHB is complete on job. Ron Eaton with Stoermer Anderson made some boiler adjustments today. Cinergy increased building pressure to 2 psig at the meter and in the building. SA said boilers are working fine and building staff is happy with performance at this time. SA also said that PHB had a regeneration line from the water softener to a floor drain that still has to be piped. Everything else appears to be complete.
04/18/05 – TE contacted A&M about 800 boiler items that need to be worked on such as Laptop control from remote location, outdoor air sensor is not calibrated and 2nd floor ventilation CFM issues. TE dispatched SBO to assist in troubleshooting the airflows on the second floor. Sam recommended a change in airflow deflection and balancing and further suggested relocating one of the airflow devices away from the center. Watch changes made and notify TE if you would like to proceed further. A&M will schedule onsite time with John Noyes to work on OA sensor and laptop programming.
03/24/05 – Tom Schmidt reported that all devices are up and running with the Boiler system. Ron reported that a setting was changed on the softener system and that is now running also. This should make all items complete for the 800 Broadway Project.
03/11/05 – PHB delivered the O&M’s to ThermalTech for this project. TE will review and turn into the County for record keeping.
03/07/05 – TTC contacted all contractors to resolve issues at the 800 Broadway Building. (1) Trap on boiler # 1, (2) Sample Cooler on Boilers, (3) Low Fire control on boiler, (4) Draft controls on boilers.
03/01/05 – Tom Schmidt reported that 2 of the 3 draft controls are upgraded and working. The third one has a bad magnahelic. It will take one week to get a replacement mag from the vendor. SA will return to install the final automatic draft control components at that time. PHB will have a pipe fitter to pipe in the replacement sample cooler within a week according to PHB.
02/25/05 – PHB will have a pipe fitter down to install the sample cooler and remove the outlet drain valve within a week. TTC is trying to find out the status of the draft controls upgrade.
02/15/05 – O’Shea patches the concrete yesterday. SA is supposed to be installing the draft controls today.
02/11/05 – Stoermer dropped off the sample cooler yesterday. TTC will contact Peck about installing it. TTC will have Automation setup training next week and upgrade Tony Martini’s Laptop. TTC contacted SA about a $300 service ticket for the water softener as we believe this is only
02/10/05 – Stoermer reported today that the boiler draft controls will be installed on 2/14 or 2/15 with Ron Eaton. Tom Schmidt will personally be delivering a new sample cooler today to the building and he also stated that this type of failure is normally associated with the cooling water to the cooler not being turned on quick enough and an over-pressurization occurs in the shell vessel. This may have been what happened here? Who knows. To be safe, I would advise opening the drain first, then the cooling valve and the test water valve last? I am sure Tony Martini already does it this way anyways, but just in case, I thought I should report what was given to me.
02/02/05 – 800 reported today that the new softener cannot keep up with the water load into the CR tank. TE is investigating this situation and will advise soon.
02/01/05 – TE request updates from contractors for these issues: Water Sampling Station, Draft Controls, Steam Leak at Flange (up high & extra charge) and Concrete Repair.
01/26/05 – TE faxed request for final documents to the attention of Amy Reeves of Peck Hannaford & Briggs. TE coordinated with PHB on fixing concrete flooring in boiler room. TE to discuss with County painters about re-epoxying the floor to match existing red floor previously installed.
01/19/05 – TE faxed back seal pump replacement quotes to Tony for Chiller Room.
01/18/05 – TE talked to Stoermer Anderson about wiring the drafts controls and we still haven’t received new wiring schematics. Tom Schmidt convinced them that just wiring schematics isn’t what we need, so they are sending new internals to the site for installation with new operator manuals that will be up to date and correct so that in the future the wiring schematic will match what is inside the draft control boxes. This work, however, won’t happen until next week at the soonest.
01/03/05 – TE trying to finalized punchlist and get control system backed up on CD format for County. PHB to begin final punchlist work and SA to retrofit draft controls this week according to Tom Schmidt.
12/13/04 – 800 called today because unit heater was not running in electric room and the space was cold. TE advised that the heater should come on anytime the sensor on the interior wall reached 45 degrees. Also, there is no graphic for this heater or control over this heater from Metasys. TE will stop down to check on situation today and help out.
12/10/04 – TE confirmed that SA should be on site on 12/14 or 12/15 to fix the water softener and the draft controls for the boilers. TTC told the building staff that the OA setpoint for the boilers can be used to adjust the start temperature of the plant at anytime. 800 reset the temperature up to 55 degree F.
12/02/04 – TTC stopped at building today and observed that boiler 2 is not running well. He sent emails to contractors for repairs. TTC noted punchlist items that need to be completed and contacted PHB about schedule to finish.
12/01/04 – Automation made final control changes at the site today to fix runtime accumulation modules, labeling the DX-9100 modules and verify the operator control points for lead and lag boiler start. TE forwarded the email received in response to that visit. A&M will update the sequences and get as-builts drawings to TE for inclusion in the final O&M’s for the County soon.
11/26/04 – TTC stopped at the building on Wed (11-24) and Fri (11-26) to verify and watch operation. The boiler plant is running in complete automatic operation at this time and ran appropriately over the Thanksgiving holiday. On Friday, the building was warm and there were no critical alarms on the boiler plant or any manual resets required at either the boiler of the condensate receiver. Todd Zurweller provided the final piping punchlist that will be converted to as-builts drawings that will be turned over to GBBN for inclusion into the CAFM sets. TE will follow up with Peck and Stoermer on the completion of punchlist items within two weeks and TTC will follow up on some control issues and boiler ops issues that he would like to see defined a little more clearly. SA completed the replacement of the solenoids valves, additional strainers in the feedwater system, HOA switch on Boiler #2, and new overloads on the all 3 boilers to prevent nuisance inrush tripping. SA still has to repair the water softener control plate assembly and replace the internals to the draft controllers for all 3 boilers. TE to expedite the remaining items. Remaining items to complete on this project (to TE’s understanding) are: CR water temperature at 150 degrees F (design calls for 190 degree F (SA shall adjust control valve to preheat the feedwater to meet spec), water softener repair, draft control replacement, sump lid replacement, seal replacement on vacuum pumps, seal replacement on cooling plant pumps, concrete repair in boiler room, A&M has to fix the runtime hours display, A&M has to label the DX’s inside the panels for points, A&M has to provide updated as-builts for controls (TE reviewed preliminary submissions with Roger Corbett on 11-24), Peck must install breeching cover must be installed, Peck has to replace or fix the trap on B-3 as it blows by when in normal operation. Glen Wilhoit found a bypass valve open on the condensate receiver, which when closed, fix the steam blow by problem into the floor drain behind the CR unit and stabilized the water level inside the CR immensely, TZ commented that the trap on the CR unit overflow meets the 12″ dwg requirement but TE prefers this trap to be as deep as possible as this is what provides the non-mechanical seal on the CR tank to keep any steam from escaping (we will check back at end of project to see about allowance monies left to increase depth). Peck shall have insulator finish up all insulation on project (lots of insulation work left to do). TE instructed SA to disable the high water level alarm on the CR tank because of nuisance tripping (this alarm is for notification only and requires no user input to fix anything so we just turned it off – the staff reported that the old tank would have high water conditions too but never had an alarm so we will just match the old operation, the tank itself is sized for 4 boilers condensate return so it is of ample size for this plant per Todd Zurweller. The water TDS from the sample coolers has been reading like this this week: at the CR 600-900 micro siemens (this makes sense, city water is about 300-600 normally), the boiler samples have shown 3.6 milli siemens or 3600 micro siemens which is also right in line with what we would want (i think 2500 – 4000 is okay, anything in the 6000 or higher would tend to lead to carryover) and lastly, TTC adjusted the gate valves on the outlet of the boilers to about one hands width of stem showing in an attempt to calm down the surging of the boiler sight glasses, this seems to let the water level stay more consistent and allows the make-up water to keep up with the boil off rate at all conditions, the closure of these valves may be changed when the boiler plant is under heavy load if needed.
11/23/04 – TTC watched boilers all day last Friday. The water controls are such that the boiler plant is too finicky to leave in total automatic operation without expecting nuisance alarms from either low water at the boilers, high and low water at the condensate receiver or overfilling of the boiler vessels through the solenoid valves. SA reports that all components replacements are scheduled for Tuesday except for the draft controls which will be done ASAP. TZ is sick so the TTC & TZ field trip has be rescheduled until Wed at 2:30 p.m. If Glen Wilhoit has any questions please have him call TTC at the office. TTC discovered that the solenoids are letting water bleed past even with a pump on all the time and not the check valves as the water level stayed the same all afternoon with the feedwater valves blocked. In addition the traps on the boilers only drain the boiler vessel when there is a positive pressure inside the vessel, once in a vacuum they are not draining enough water to keep the boiler from overfilling on this day.
11/22/04 – TTC talked to Glen today and we discussed looking at these issues: slope of main steam header towards traps, conduit cover on Boiler # 03, Vent on receiver tank. TE will investigate these issues on Wednesday at the TZ walk through.
11/18/04 – Boiler #1 is overfilling with water. Last time this was due to dirt in the feedwater line blocking the solenoid valve. When the new valves and strainer are installed by SA, this problem should be eliminated. 800 could try to run Boiler #3 instead of #1 to alleviate this problem.
11/16/04 – The boilers are carrying over on startup and shutting down on low water forcing the electric overloads to cut out. SA has to replace the overloads on each boiler to correct this problem, replace the HOA on boiler #2, upgrade the draft controls and install cycle timers into the boilers. This work should be done in one week. All 3 boilers are available for use. At morning startup, Tony Martini may want to turn 2 boilers on and back down the gate valves to 30% of so to allow the plant to come up to working temperature to smooth out this hiccup. Very soon, the boilers can be left on full time. TE is worried about the surging in the CR unit and boiler. The water levels are bouncing around more than we would expect. TE to investigate more.
11/12/04 – All contractors and TE were on site to finish up the project. TE hired Geiler directly to replace the Condensate #4 pump seals because Peck could not meet the schedule. Upon disassembly we discovered that both seals needed to be replaced along with one motor bearing and one motor winding. TE authorized this work to be completed so that the plant can be ran in full automatic on Friday 11-12, Peck service was on site to replaced six sets of seals on condensate pumps CR-1, CR-2 and CR-3, Peck was only able to replace one seal on CR-2 (this work was being done at T&M, TE recommends that we re-evaluate having Peck do all the pumps as we don’t believe there will be enough money left in the allowance to pay 2 days of T&M for each of the 5 remaining pumps, we bought all the seals already which cost $1200, Peck and Cinergy upgraded the gas supply line to 1psig pressure, tested it, installed new regulators and put the system into service. 800 now has a new regulator for the water heaters and for AH-43 on the roof. After purging the system, all the equipment was back in service and burning properly by the end of the day on Friday. We permanently disconnected the garage AH unit that was abandoned, the County CANNOT use this unit unless another regulator is put in the gas supply line (this shouldn’t be an issue since this unit hasn’t been used in 10 years – the gas line has been capped. Stoermer Anderson (SA) finished wiring the draft controls and adjusted all the burners to spec. The draft controls need some different components in the upcoming week as they only work in the wide open position right now. The water softener needs to still be replaced since the Crown Engineering unit was damaged in shipping. The sparge tube and control valve were installed by Peck and adjusted by SA. The unit heater was installed by Peck, wired by Glenwood, and wired by Automation for controls. The unit heater and the exhaust fan worked per spec. The punchlist was commissioned by TTC and will be sent in a separate email where TTC will document remaining items including training which should be given Mon, Tue or Wed of the upcoming week.
11/10/04 – Glenwood will finish up the electrical work on Thursday. Final inspection scheduled for Monday. Please make the accommodations to allow the inspector into the building. All contractors are scheduled for work on Thursday as well. TTC will call automation when enough of the boiler is complete to allow control system to take over control of the boiler plant. Final commissioning and punchlist will happen in afternoon on Thursday.
11/08/04 – All gas pressure work is scheduled for Thursday 11-11-04. The building will be shutdown for Veteran’s Day. Peck, Stoermer, Automation and Cinergy will all be onsite connecting and verifying all final workings of the boiler plant. Terry Cannon will also be onsite to assist in the last minute details. Water softener and unit heater are on site ready for installation (softener has ctrl panel issue). Stoermer has sparge tube in town and hoping control valve will arrive on Tuesday. Stoermer needs to finish wiring the remaining local controls on the boilers. Today’s onsite work proved that one boiler and both water heaters cannot run at the same time without the boiler going out on low gas pressure. PHB assured us that the boiler room door will be installed on 11-09-04. The vacuum pump seals were ordered for overnight shipment and should arrive on Tuesday to Peck. Geiler will be in at 7:30 a.m. on Tuesday to install the seals on the Condensate Pump-4 in the chiller room (ttc coordinated with Geiler and Martini for this work). Outdoor louver needs to be installed. Final insulation needs to be installed. Final control programming needs to be implemented. Training for Tony Martini needs to be provided by Automation (ensure the whole system is demonstrated, optimized control of cooling towers, free cooling, boiler sequences, etc).
11/03/04 – TE confirmed today that the Seller’s boilers can handle and are built for 10 psig inlet gas pressure, at worse case a spring needs to be changed in the regulator and SA will provide that service at no charge. TE instructed PHB to buy two regulators at this point: (1) for the water heaters sized for 2 x 199,000 btuh, 1 inch, 1 psig to 9″ w.c. and (1) for the AH-43, 1 x 160,000 btuh (5″ w.c. nominal, 14″ w.c. max), 1 psig to 9″ w.c. Emergency pressure at inlet to be protected up to 10 psig. As soon as we get the new regulators in we will schedule the work and the shutdown and as TE understands it at this time, Tony Matre has instructed PHB to do this work after normal hours or on a Saturday.
11/02/04 – Remaining project items: insulation, water softener, sample coolers, door installation, damper controls, large louver for combustion air, unit heater, sparge tube, boiler #1 falsely enabled, new regulators for water heater, coordinate pressure test, adjust fuel air mixture, sump lid, chain link fence, seal barometric damper, seals on vacuum pumps, reinstall exit sign. Be complete by November 12 including controls.
11/01/04 – PHB coordinated with TE today on boiler requirements for new venting. Sizing requirements are 17,258,000 btuh connected load (5,620,000 each boiler, 199,000 each water heater, 1 psig inlet pressure (with an emergency inlet pressure of 10 psig), 15 inch w.c. outlet, if a 2″ regulator can meet our flow demands, we won’t need a separate relief valve for the regulator (provided it uses rubber seats), Dead End Lock Up Model type, Main burner and pilot applications, static pressures will be allowed to rise slightly above setpoint, an additional regulator will need to be installed for the water heaters in the 1″ line. We will discuss more at Tuesday construction meeting.
10/27/04 – PHB reported today that boiler breechings are welded in. One louver is installed, the other will be installed shortly, the blank off plate on the other pipe space will be installed next. The new water softener shipped 10/26. Then unit heater should be shipped very soon. Controls are supposed to be ready to go but TE and PHB will confirm. TE would like to meet on Thursday morning at the site and call Cinergy for the gas pressure issues and begin the resolution process.
10/21/04 – Door will be installed on Monday. Stoermer Anderson will be onsite on Friday. Automation will be on site on Friday. Boiler #1 will be in automatic operation on Friday 10/22/04. PHB will have flues welded in by Wednesday 10/27/04. Boiler # 2 & # 3 should be ready to fire for Cinergy test on 10/28 or 10/29. Please make accommodations for everyone to be onsite Thursday 10/28 for this work. Water softener should ship today or tomorrow for installation.
10/18/04 – Stoermer Anderson reported that gas pressure was very low for the boilers at the site. Boilers require 10 inches. Today’s readings showed 7 inches available. TE is investigating how to solve this problem.
10/18/04 – PHB submitted a price of $4106 to reroute the PVC vents from the domestic water heaters. Do you want to do this work or should we keep things as is and let the trades do the work in the future if it becomes absolutely necessary?
10/15/04 – One boiler successfully started today right on schedule. On Monday SA will verify gas pressure in building as it appeared to be low today. SA is on site preparing boiler for startup. Draft control damper is installed. The door to the boiler room will arrive on Wednesday of next week and will be installed on Wed-Thur-Fri. The insulator will be installing 2″ fiberglass on the steam header to match the 2″ piping shoes, the entire breeching will be replaced with new insulation, A&M is on site downloading the new boiler control program this morning, the CR-1 unit comes factory equipped with a low water cutout switch that turns the pumps off on low CR-1 conditions. TE has the DDC system programmed such that it will stay enabled if a feedwater pump goes into alarm so that when the CR-1 unit comes out of alarm the pumps plant will be standing ready to re-engage. Alarms will be issued on the front end documenting the history. The exhaust fan is being installed today. For future maintenance on the new exhaust the facility group will be able to remove the louver and the fan but they will need a lift to access the fan just like the old one. The fan is not removable from the alley (TE doesn’t want vandals being able to mess with the fan)
10/14/04 – Boiler inspector approved ALL boilers for use today. PHB, TE A&M and SA were all on-site for an impromptu construction meeting when we really were meeting to discuss the installation of the sparge tube in the DA tank. Final decision was to move the vent over to the middle 3″ connection and put a vertical then horizontal sparge tube utilizing a double bushing into the open 3″ connection. SA will do much of the work for this and the temperature sensor for the steam control valve and PHB will provide the final connections to these steam heating points. PHB is finalizing piping and B-1 will be started up on friday towards the very end of the day. B-1 will be put into test service on Monday October 18 where 800 can keep an eye on it during its maiden day of work.
10/12/04 – Mike Martini the boiler inspector will be onsite on Thursday at 10:00a.m. ThermalTech, Peck and Stoermer Anderson would also like to be on site that morning about 8:30 a.m. PHB is trying to get all equipment on site and the boilers ready to fire by the 15th as promised.
10/08/04 – Obtained field data on Chilled Water Pumps, in order to get price quote for replacing seals.
09/03/04 – Date Answered: 09/03/04. Question: The Drip Pan Elbows for the boiler relief vents are shown as 3 inch RV’s. The DPL are being supplied as 3.5″ how should we handle? Response: TE instructed PHB that however the DPL’s are delivered to provide a reducer/increaser to 3″ and run the RV’s as 3″ as they are shown on the P&ID. We believe that the 3.5″ might be the OD listing for the 3″ pipe anyways and may be a non-issue.
09/30/04 – Control equipment is on site except for unit heater control valve. Programming will begin at A&M offices on Oct 3. TE has asked contractors to have one boiler online Oct 8 if possible.
09/29/04 – TTC stopped down and told PHB that they can reuse the existing cond header up to the union, TE prefers that the new boiler stack connections be round to round with a saddle at the breeching connection (remove the long skinny rectangular existing connections, TE wants PHB to provide an allowance price to reroute the domestic water heater PVC exhaust vents to the same window outlet as the gas vents are using (TE will provide a sketch to PHB to price), Boiler #2 should be located to miss the existing pit lid, the EOM traps are correctly sized at 3/4″ so bushings from 2″ to 3/4″ are acceptable, one of the intake louvers appears to be 59″ x 59″ the other window will have the EF in it and the vent lines: PHB can build a painted steel or aluminum blank off plate to surround the vents in the remainder of the window – it has to be water tight to prevent rainwater from entering the space (TE to review CA req’s on remaining louver), TE and PHB reviewed CR-1 inlets and agreed where everything goes, Boiler #4 breeching should just be capped as-is, TE told Tony Martini that existing plant is supplied with combustion air without aid of mechanical combustion air: if 4th boiler is ever added, the County can add a forced combustion air fan, increase existing louver size, or provide another opening in the outside air wall (the existing plant CA req’s are sized on 3 boilers connected load per code req’s)
09/24/04 – Glenwood submitted additional cost based on TE request for strobe relocation and alarm conduit relocation of $214.00 and $427.00. Approved by AKM via phone call.
09/23/04 – Boiler are in the rigger’s yard. Peck will deliver them to 800 on October 2. County, please make appropriations to allow PHB in the building for this work.
09/13/04 – Weekend work was exceptional and the large steel tanks was also removed from the premises.
09/08/04 – PHB Advised that first boiler will be delivered and existing boilers will be demolished on 09/11/04 at 7:00 a.m.
09/03/04 – Control submittals have been received.
09/01/04 – TE approved allowances 01, 02 for PHB shown below.
09/01/04 – TE sent a letter to city explaining boiler plant sizing. We sent email with attachment showing fax.
08/31/04 – PHB has submitted door and louver equipment for approval on 08/24/04 – Returned approved. EF needs to be 203V/3Ph version when ordered.
08/27/04 – TE is trying to get final pricing and ok on water softener package for project from PHB and SA.
08/25/04 – Boiler removal and installation scheduled for September 11, 2004.
08/25/04 – CIS will be removing asbestos in the interim.
08/25/04 – Quick ship boiler scheduled to ship on August 31.
08/25/04 – Condensate Water Return system also scheduled to ship on August 31.
08/25/04 – New door has been cut in with plywood secure doors installed.
08/25/04 – Some prefabricated piping has been deposited on site.
08/25/04 | Date Answered: 08/27/04 Question: A conduit shown to be demolished contains boiler and chiller alarm wiring. Should this be kept and maintained?
Response: TE will confirm with John Noyes next week. The alarms provide remote alarming up to the night desk security shack where the on duty security officer is instructed to call John Noyes. The new control system has been installed with alarm paging service which provides the same functionality so this may not be required at all.
08/12/04 | Date Answered: 08/13/04 – Question: For the spool drawings, what is the most important factor for boiler dimensions.Response: TE stated that the boilers are to aligned under the breeching and centered between the columns but the contractor has some leeway with final and exact boiler placements