Boiler Retubing

1. COMPLETE TUBE REPLACEMENT The SOW for the tube replacement will be as follows. Tube materials must match the boiler design sheet by Cleaver Brooks. 1. Contractor will secure boiler using proper lockout and tag out procedures. 2. Contractor will open the boiler and remove all boiler tubes. 3. The removed tubes to be discarded in customers supplied recycle dumpster. 4. Once the tubes are removed the contractor will inspect the tube sheet for defects. Contractor will advise of solution. 5. Contractor will clean the tube sheet; polish the tube holes in preparation for the new tube installation. 6. Contractor will supply and install all new ASME SA-178 Grade A domestic boiler tubes matching the design sheet by Cleaver Brooks. 7. Contractor will install the new tubes, cut to proper length, straight-roll and bead-roll the tubes in the front by means of specialized tube expanding equipment. Then straight-roll and seal weld the tubes in the rear section of the boiler. Once the welding process is complete, the contractor will lightly re-roll the rear tubes to relieve stresses inherent during the welding process. 8. Contractor will hydrostatically pressure test the boiler for an authorized inspector to witness. 9. Contractor will assist in closing the boiler and provide new gaskets. 10. Provide R-1 Traveler documentation. Provide a written report of services performed. 2. REAR DOOR EXCHANGE 1. Secure the boiler using the proper lockout and tag out procedures. 2. Contractor will supply and deliver (1) 96” reconditioned monolithic replacement rear door. 3. The door will be refurbished per Cleaver-Brooks specifications and standards using OEM templates to ensure the critical turn-around area is of correct volume and shape. 4. The door construction utilizes a high strength castable refractory lower section, including an all monolithic pour in lieu of baffle tile. The upper section utilizes high temperature ceramic fiber insulation material rated for 3000oF backed by a 1200oF insulating board, encompassed with heavy duty S.S. mesh wire and S.S. anchors. 5. Contractor will remove the existing rear door from the boiler by way of a specialized cart, fork-lift and rigging. 6. Contractor will off load replacement door and rig onto boiler. 7. Once installed, contractor will assist in closing the rear door with new gaskets, ensuring the clearance at the rear tube sheet is correct and true. At this point, the upper anchor nut will be set for tension release. 8. Contractor will perform eight-hour rear door curing procedure. 3. THROAT TILE AND LINER REPLACEMENT 1. Ensure the boiler is secured using the proper lockout and tag out procedures and adhere to OSHA mandated confined space entry directives. 2. Contractor will evaluate the possibility of repairing the throat tile that is dislodged. 3. If throat tile cannot be repaired the contractor will remove existing throat and liner tiles from the boiler furnace and dispose of in a plant supplied refuse container. 4. Contractor will inspect the backside of the fire ring, and advise of condition. 5. Contractor will prep the furnace to accept new tiles, including laying hi-temperature castable refractory where necessary. 6. Contractor will supply and install new Cleaver-Brooks throat and liner tiles as per OEM specs. This includes high temperature mortar, insulating shim board and proper location of the “key” brick. 7. A written report of work performed will be provided. 4. BLOWER MOTOR AND IMPELLER REPLACEMENT 1. Ensure the boiler is secured using the proper lockout and tag out procedures. 2. Open the front of the boiler to allow access to blower motor coupling. 3. The existing blower motor has already been removed from boiler door. 4. Install new blower motor and impeller. 5. Start the boiler to ensure proper operation. 6. Check combustion and adjust fuel air ratio for maximum efficiency throughout the firing rate of the boiler. 7. Provide a written report of work performed. 5. TUNNING OF BOILERS 1. Provide tuning for boiler #1 and #3 once boiler #2 is complete. C. QUALITY ASSURANCE/INSTALLATION REQUIREMENTS All installers/technicians shall be qualified and certified by the manufacturer to install, test. Such certification must be verified in writing by the manufacturer and submitted to the COR seven (7) days before the project starts.

Division 23 -	Heating, Ventilating, and Air Conditioning (HVAC), Heating Boilers.
Division 42 -	Process Heating, Cooling, and Drying Equipment, Process Boilers.