1333ZN01 SPECIFICATIONS.pdf

SPECIFICATIONS FOR

6,000 CFM VENT UNIT

Rev B

3/14/2019

ATTACHMENT (2) DOCUMENT 1333ZN01

References:

(a) NNSY DWG 2310-284 REV. A “6,000 CFM NEGATIVE PRESSURE UNIT”

(b) Nuclear Air Cleaning Handbook: DOE-HDBK-1169-2003

1. GENERAL REQUIREMENTS:

1.1. Purpose: The purpose of this solicitation is to provide specifications for the fabrication and testing of a 6,000 Cubic Feet per Minute (CFM) ventilation unit.

The vent unit shall be delivered complete and ready for operation. The capacity of the unit shall not be less than indicated. The unit shall consist of a High

Efficiency Particulate Air (HEPA) filter bank housing, exhaust fan, airflow measuring station for measurements of total system flow rate, environmental monitoring probe, ductwork, gages and meters, associated electrical equipment, and vent skid.

2. TECHNICAL REQUIREMENTS:

2.1. Fabrication Criteria:

2.1.1. All work shall be in accordance with references (a) and (b) and shall be in accordance with the latest revisions, along with addenda or supplements, to those documents which are in effect at the time construction begins.

2.1.2. Items not specified in Reference (a), shall be decided by the contractor, and detailed in the submitted construction drawings. Specifically designated material items may be substituted only when authorized in writing from contracting agency.

2.2. Equipment

2.2.1. Exhaust Fan: The fan shall be certified to deliver the specified quantity of air and pressure when tested in accordance with the Air Moving Council of America (AMCA) standard test codes for air moving devices. Fan shall bear the AMCA Certified Rating Seal. The fan shall deliver 6,000 CFM of air with an external static pressure of 18 inches w.g. or greater, based on standard air using no more than 26 BHP at 3500 RPM.

A. The fan shall be centrifugal, square housing design, backward inclined blade design, class 4 construction, arrangement 4 (direct drive), with 3/16” carbon steel casing; discharged with a clockwise (CW 360) upward blast housing orientation, 1-5/8” wide inlet/outlet flanges with 9/16” diameter bolt holes with max 3” spacing on center.

B. The fan shall be driven by a 30 HP totally enclosed fan cooled (TEFC) drive motor with 3 Phase, 460 Volts, 60 Hz power. The motor shall have a service factor of 1.15 or higher at 40 ºC ambient temperatures designed for direct drive for variable frequency drive (VFD) service.

C. The fan shall have spring isolators mounted to the bottom of the blower housing; drain plug at the lowest point of the housing. Maximum overall dimensions of fan are: 39” (L) X 43” (W) X 40” (H).

D. The fan shall be Fan Equipment Co. Inc.: Model 222 BISC with wheel size 22.25 inches; square fan, arrangement 4; UB-CW heavy duty housing orientation or equal.

2.2.2. Bag-in/Bag-out Filter Housing Unit: The bag-in/bag-out prefilter and HEPA filter housing shall be two filters high x two filters wide (2x2) and shall have separate doors for prefilters (24” L x 24” W x 6” D) and HEPA filters (24” L x 24”

W x 11-1/2” D). The housing shall be designed for 6,000 CFM airflow and shall have straight air passage through the housing. The filter access shall be through side doors with left hand access. The filter housing shall be constructed from type 304 stainless steel. The filter housing shall be 100% seam-welded on all joints across the pressure boundaries and shall be pressure decay tested up to

10” w.g. positive or negative pressure. All joints and seams shall be welded airtight and shall be free of all burrs and sharp edges. Welding shall be performed in accordance with American Society of Mechanical Engineers

(ASME) Boiler and Pressure Vessel Code, Section IX. To accommodate gel seal filters, the housing shall incorporate a knife edge that mates into the gel filled perimeter channel on the face of the filter. The filter housing components shall be:

SECTION DESCRIPTION FLANDERS MODEL NUMBER

HEPA Filter Section BF1-2H2W-6GGF-304-D3 as manufactured by AAF / Flanders, Bath, NC. The filter housing shall have the following cataloged and uncatalogued options:

A. Both inlet and outlet duct transitions shall be constructed from type 304 stainless steel or aluminum. The transitions shall be welded or bolted to the filter housing. Splitters shall be installed on inlet transition and shall be properly reinforced with structural angles to withstand vibrations caused by airflow.

B. Static pressure ports (304 stainless steel) shall be located on the top of the filter housing, and shall be arranged in such a manner that differential static pressure across each set of filters (prefilters and HEPA filters) can be measured.

C. The following magnehelic gages shall be installed on the mechanical instrument panel described in paragraph 2.2.10.A. The gages shall be connected to the static pressure ports of the filter bank using ¼” OD

CRES tubing. The gage lines shall include in-line HEPA filters as shown in Detail 62-A of Reference (a).

1. To measure D/P across prefilters and HEPA filters: The gage shall be 0”-5” w.g, flush mounting, DWYER Model 2005.

D. Prior to shipment from the factory, both the filter sealing surface and the complete assembly pressure boundary shall be leak tested by the

“pressure decay method”, in accordance with ASME N510-2007, “Testing of Nuclear Air Treatment Systems”, paragraphs six and seven. There shall be a maximum leak rate of 0.0005 CFM per cubic foot of housing volume at 10” w.g. Leak test of the housing shall be performed after all the required mechanical penetrations are made.

E. The filter housing shall have a stainless steel mounting base approximately four (4) inches high to prevent all door-securing knobs from interfering with the deck of the vent unit.

2.2.3. Variable Frequency Drive (VFD): Provide a VFD for use with the fan motor. The

VFD shall convert the input AC power to an adjustable frequency and voltage.

The VFD shall have a 32-character back-lit digital display and a sealed user-friendly key pad. The VFD shall have the maximum dimensions of 18” (H) x 11”

(W) x 10” (D) and meet the following requirements:

A. Electrical Specifications

Power rating: 30 HP (22 kW) for Normal Duty; 25 HP (18 kW) for Heavy

Duty

Input Voltage: 380 to 460 Vac, 3 phase, +/- 15%

Line frequency: 60 Hz +/-2 Hz

Frequency range: 0.1 to 400 Hz

Frequency stability: 0.1 Hz (digital), 0.1% (analog) over 24 hours +/-

50ºF

Overload capacity: 120% of rated normal duty rms current for 60 seconds 150% of rated heavy duty rms current for 60 seconds

Frequency setting: By key pad or external signal (Speed Pod 0 to 5 Vdc;

0 to 10 Vdc; 0 to 20 mA, or 4 to 20 mA)

Control system: V/Hz or Sensorless Vector Control (SVC)

B. Environmental Specifications

The VFD shall operate properly at full rated capacity under the following conditions:

• The operating temperature ranging from 14ºF to 104ºF

• Storage temperature ranging from -4ºF to 149ºF

• Altitude up to 3,300 feet above mean sea level without derating

• Humidity range from 0% to 95% (non-condensing)

• Acoustic noise shall be no greater than 85 dba sound power at 3 ft

• Forced air cooling

C. Protective Features: The VFD shall have the following protective features: overcurrent, overvoltage fault, ground fault, short circuit, dynamic break overload, drive temperature, power wiring fault. Drive-timed overload, input voltage quality, overvoltage ride through.

D. Suggested Model: ABB-Drives ACS550-U1-045A-4+B055 or equal.

2.2.4. Airflow Measuring Station and Flow Meter

A. Provide one (1) exhaust airflow measuring station complete with combination air equalizer and straightener with automatic-averaging pitot tube transverse station, 6,000 CFM capacity minimum, and shall be sized for use with 11”x14” duct. The casing shall be stainless steel with 1-1/2” flanges, with stainless steel headers. Airflow Monitor Corporation, Model

FAN-E.

B. Provide direct reading airflow gage to read in “CFM” (top scale) and pressure (lower scale), in inches of w.g. The gage shall be complete with fittings (304 stainless steel) for 1/4” OD tubing (1/4” NPT fitting). Airflow rate range and the corresponding duct size shall be as specified in the following table:

FLOW RATE

RANGE

DUCT SIZE

QUANTITY

REQUIRED

END USE

0-6,000 CFM 11” x 14” 1 EXHAUST FLOW

1. The gage shall have intermediate ranges labeled on gage face. As an example, 0 to 6000 CFM gage shall have the following readings: 0, 1000, 2000, 3000, and 4000 etc.

C. Connect the airflow measuring station to the corresponding airflow gage using ¼” OD CRES tubing.

2.2.5. Sheet metal duct work: All duct work shall be constructed, braced, reinforced, installed and tested IAW Reference (b) to Level 2 requirements of Nuclear Air

Cleaning Handbook downstream of the HEPA Filters and to Level 4 requirements of the Nuclear Air Cleaning Handbook upstream of the HEPA filters and the following requirements:

A. Where shown in Reference (a), the exhaust duct elbow shall have splitters installed to minimize static pressure loss.

B. Ducts shall be true to the dimensions indicated in Reference (a) and shall be securely anchored in an approved manner and completely free from vibration under all conditions of operations. Duct interior surfaces and component surfaces located within the duct system shall be cleaned by wiping or flushing, where accessible, prior to final assembly.

C. All the flange duct connections shall be made using 1/4” (min.) thick

NEOPRENE continuous rubber gaskets and 3/8" dia. 300 series CRES bolts, nuts and washers.

2.2.6. Duct leak test: After all the vent unit components have been installed on the vent skid (and prior to delivery at NNSY), the contractor shall perform a duct leak test for level 2 requirements of the Nuclear Air Cleaning Handbook downstream of the HEPA filters and to level 4 requirements of the Nuclear Air Cleaning

Handbook upstream of the HEPA filters.

2.2.7. Flexible connectors: The vent unit shall be provided with flexible connectors at both inlet and outlet sections of the blower as shown in VIEW 19-A to isolate the fan-induced vibrations from the rest of the vent unit system components. The flexible connectors shall be installed as shown in Reference (a) or in accordance with the guidelines of section 5.4.2.3 of Reference (b). The contractor may purchase flexible connectors in lieu of fabrication per Reference (a) if desired.

2.2.8. Exhaust duct damper: Provide the duct damper in accordance with Reference

(a). Label “OPEN” and “SHUT” on the damper using self-adhesive photo aluminum plates or vibro-etching.

2.2.9. Vent unit skid: All the components of the vent unit shall be properly assembled on a rigid, structural aluminum skid as shown in sheet 4 of Reference (a) and shall meet the following requirements:

A. The skid shall be designed to withstand the stresses, vibration and shock associated with rough handling and transportation of the vent unit by an overhead crane or forklift in dockside applications. Specific design requirements shall be as follows:

1. Design for 50 psf live load in areas not occupied by vent unit components.

2. Brace the vent unit skid to withstand worse case lateral forces

(wind, seismic) in accordance with International Building Code

(IBC).

B. The floor deck shall be fabricated using corrosion resistant plate with a raised non-skid pattern (e.g. diamond shape).

C. All structural members and side panels shall be fabricated from aluminum.

D. No component part shall extend outside the perimeter of the skid base unless shown in Reference (a).

E. The skid shall be as compact as practical and shall not exceed 11 ft.

(long) x 8 ft. (wide) x 8 ft. (high).

F. The skid shall be equipped with lifting pads to accommodate a four (4) point lift. The pads shall be positioned above the vertical center of gravity for safe handling and transportation by an overhead crane. The lifting pads shall be aluminum. Each pad shall be designed to lift one half (1/2) of the total weight of the vent unit.

G. The skid, when suspended, shall hang perpendicular within, 5⁰ of true vertical. If this requirement cannot be met, the contractor shall provide a sketch showing location of the center of gravity.

H. The arrangement shall provide a stable and balanced lift with a load safety factor of at least five (5) based on the ultimate strength of the lifting pad material, the total weight of the skid, and 20-foot minimum pendant length.

I. The contractor shall provide NNSY with structural and padeye calculations of the vent unit skid.

J. The four (4) lifting pads must pass a Liquid Penetrant Test (LPT) with acceptance to Mil-Std-2035 for class 3 welds and the contractor shall provide results of test to NNSY.

K. The contractor shall weigh the vent skid and its integral equipment and record the weight. The weight shall be stenciled on the skid or label plated with a minimum of 2 inch high lettering which contrasts with the skid coating or label plate background. The location of the weight shall be conspicuous to a crane operator lifting the skid.

L. Stainless steel and aluminum surfaces shall not be painted or primed.

Aluminum and stainless steel shall be used to the maximum extent practical.

2.2.10. Instruments and equipment panels

A. Mechanical instrument panel: A panel shall be fabricated from aluminum and shall be mounted in the vent unit at an approximate location shown on Sheet 2 of Reference (a). A more detailed drawing of the instrument panel is located on Sheet 8 of Reference (a). The following instruments and others (if required) shall be installed on the panel and labeled using self-adhesive aluminum photo plates:

DESCRIPTION REFERENCED PARAGRAPH

PREFILTER DP 2.2.2.C.1

HEPA FILTER DP 2.2.2.C.1

EXHAUST FLOW METERS 2.2.4.C

VARIABLE AREA FLOWMETER 2.2.11

1. The mechanical instrument panel shall have a mylar window with aluminum frame for rigidity. The window shall protect the gages and meters from rain, dust, debris, etc. The aluminum frame shall prevent the mylar window from bending, warping, etc.

2. A rain guard shall be installed over the mechanical instrument panel as shown in Reference (a) to prevent rain from entering the instrument panel.

B. Electrical equipment panel: An equipment panel shall be fabricated from aluminum and shall be mounted in the vent unit at the approximate location shown in Reference (a) DETAIL 50-E (Sheet 7). The major electrical equipment described in paragraph three shall be installed on this panel.

2.2.11. APS Flowmeter

A. A flowmeter shall be installed on the mechanical instrument panel described in paragraph 2.2.10.A. The flowmeter shall have a range of 20-

200 SCFH with ½” NPT pipe connections. The flowmeter shall be connected to an inlet boss upstream of the blower and an environmental monitoring probe in accordance with sheets 10 and 11 of Reference. (a).

2.2.12. Environmental Monitoring Probe

A. Provide a single point isokinetic sampling probe and filter holder as shown in Reference (a). Sampling nozzle shall be stainless steel with

0.313” inlet for use with ¾” stainless steel probe. The probe shall connect to a 47mm paper holder. Probe and filter holder shall be manufactured by

HI-Q Environmental Products.

2.2.13. Flexduct Adapter Fitting: Provide an aluminum ventilation fitting to allow connection of 14” diameter flexduct as shown in View 77-B of Reference (a). The adapter fitting shall connect to the intake of the ventilation unit using ¼” bolts, nuts, and washers.

3. ELECTRICAL SYSTEM:

3.1. Install and connect the electrical power, control, and alarm systems for the ventilation unit as specified in Reference (a). All equipment shall be located such that it can be accessed and serviced.

3.2. All electrical work and installation of electrical equipment/wiring shall be performed in accordance with the latest revision of the National Fire Protection Association’s (NFPA)

70 – “National Electrical Code” (NEC).

3.3. Electrical Equipment: All electrical components/equipment utilized for the vent unit shall adhere to the following requirements:

3.3.1. All electrical components/boxes and equipment shall have a NEMA 4X rating or shall be listed as weatherproof or approved for use in wet locations.

3.3.2. All electrical equipment used shall be Underwriter's Laboratory (UL) listed and approved unless otherwise permitted by the contracting agent and documented in writing prior to award. Material listed in Reference (a) shall be used unless equivalent material specified by the contractor is approved by the appropriate government official and documented in writing.

3.3.3. All electrical equipment shall be installed utilizing stainless steel standoffs seal welded to a structural member or stainless steel fasteners with thread locking

(i.e., Nylok) type hardware. Welding of the equipment's/enclosure’s mounting flange or mounting lugs to plate/structure is prohibited.

3.4. Wiring, Termination and Terminal Block Identification: All wiring and terminations/terminal blocks shall be identified in accordance with the following.

3.4.1. All wiring terminations at terminal blocks shall be labeled using industry standard heat shrink or slip-on type wire identification products. Termination labels shall not be made of adhesive backed paper or clamped metal/plastic tags.

Termination labels may be pre-printed or custom typed and shall adhere to the nomenclature contained in Reference (a) (i.e., TB1-10 refers to terminal block 1, terminal 10).

3.4.2. All wiring terminations at terminal blocks specified in Reference (a) shall be made utilizing barrier type (screw) terminal blocks and ring tongue (irreversible compression or crimp type) terminals/lugs.

3.4.3. All power supply/feed wiring shall be single conductor, stranded copper, 600VAC

(min.), 90⁰ C (min.), type THHN or THWN-2 unless otherwise specified in

Reference (a). All control system wiring shall be 16 AWG wire except for manufacturer’s control wiring in the VACON Variable Frequency Drive (VFD).

3.5. Conduit Installation: All conduits shall be installed/routed as shown in Reference (a) and shall meet the following requirements:

3.5.1. All conduit connections shall be made-up rain tight. All threaded conduit fittings

(after make-up and installation) shall be sealed with 100% silicone caulk (clear or white in color) where O-rings or gaskets are not installed. All conduit bodies (i.e., LBs, LLs, LRs, pulling Ls, Tees, etc.) shall utilize gasketed covers.

3.5.2. Low points in horizontal conduit runs shall include a fitting that can be opened to act as a means to drain any trapped water.

3.5.3. Liquid tight flexible metal conduit of the same diameter may be used on any conduit run as long as no more than six feet is used.

3.5.4. All penetrations made in electrical enclosures/boxes and equipment shall be watertight using watertight conduit hubs/connectors unless otherwise shown in

Reference (a).

3.5.5. The contractor shall utilize conduit bodies specified in Reference (a) when routing/installing conduit on the electrical equipment panel.

3.6. System Design: Ventilation unit control system equipment shall meet the following design criteria:

3.6.1. All control indicator lights shall be heavy duty, oil tight, NEMA type 4 or 4X rating.

The lens of the “ON” indicator light is to be green in color and the lens of the

“OFF” indicator light is to be red in color.

3.6.2. The Variable Speed Drive (VFD) shall be mounted inside the vent unit structure and include an LCD display screen.

3.6.3. The stop switch shall be momentary contact push-button type 30 mm heavy duty, oil tight, NEMA type 4 or 4X rating with appropriate stop legend plate. The stop push- button is to be red in color.

3.7. Ventilation unit lighting is to be provided in order to aid in the performance of maintenance/repair of all equipment as well as to control/operate the unit’s system and read all gages/instruments (both electrical and mechanical). Vent skid lighting shall be controlled via one accessible switch located in a convenient location inside the personnel access door(s).

3.8. System Features: The NPU control system is to incorporate the following features:

3.8.1. The blower and the other circuitry shall be fed via one (1) 480VAC, 3 phase, 60

Hz power source.

3.8.2. Three (3) general purpose power, 120VAC, 20 Amp (min.), GFCI, straight blade, duplex receptacles shall be installed in the vent unit at convenient location(s) to aid in performing maintenance and repair.

3.8.3. Control circuit voltage for the remote indicator lights, switches, etc. is to be 6V

AC/DC unless otherwise specified in this document.

3.8.4. A VFD with user interface keypad/menu screen to allow operation/control (i.e., start, stop, speed adjustment) and provide system information/indication/faults for the R/E fan.

3.8.5. One emergency stop switch shall be installed on each remote control panel to allow the system to be shut-down remotely. 250’ of remote cable is to be provided with each remote control panel. The remote control panel shall have a disconnect connection with the 250’ remote cable.

3.8.6. The VFD shall be interlocked with the blower to control flow rate leaving the vent unit.

3.8.7. A resettable Liquid Crystal Display (LCD) hour meter shall be provided. This hour meter shall be separate from the total run time feature that is provided and accessed via the keypad/menu screen on the VFD. This feature allows personnel to check the run time on the motor without having to operate the VFD keypad.

The hour meter shall be mounted on the mechanical equipment panel as shown in Reference (a).

3.8.8. The loss of negative pressure alarm circuit shall be provided using a normally open contact on the pressure switch. When the VFD is enabled the blower is commanded to run, the normally open contact closes and allows for the alarm condition at a customer supplied remote panel to be cleared. Power for this alarm circuit shall be fed via a transformer inside the vent unit.

3.8.9. All major electrical equipment (i.e., disconnect switches, pull/terminal boxes, the

VFD) shall be mounted on one electrical equipment panel. The panel shall be fabricated using 3/16” thick (min.) type 304 stainless steel plate (ASTM A240).

3.9. Two (2) remote control panels and all appropriate connection cables shall be fabricated in order to test the vent skid built per this document for proper operation and control.

Each remote control panel shall be comprised of one (1) stop button, one (1) green power on indication light, one (1) red loss of flow indication light, one (1) audible alarm, one (1) battery test push button, and one (1) alarm silence two-position selector switch.

The control panels shall have the appropriate Amphenol 4 and 6 pin/socket circular box mount receptacles and connector assemblies/cables (see Reference (a)).

3.9.1. The remote control panels shall contain an electrical disconnect to allow the

250’ cable to be disconnected from the control panel.

3.10. The vent unit shall have an electrical interlock to provide a means to automatically shut down an A/C unit that is interlocked with the ventilation unit once the interlock circuit is opened (i.e. ventilation unit is shut down).

4. DELIVERABLES:

In addition to the vent units meeting the specifications of Sections 1-3 above, the following deliverables are to be included as part of this contract.

4.1. Preliminary Report:

4.1.1. Prior to fabrication of the 6000 CFM Vent Units, the contractor is to review the included specifications. If required, submit a written report to the contracting officer indicating any deficiencies and/or desired deviations in the system specifications that would preclude proper fabrication of the specified vent units.

4.2. Drawings:

4.2.1. Within 30 working days after contract award, the successful bidder will submit a complete set of drawings (including all structural, mechanical, and electrical) and complete list of materials with material specifications to NNSY for review and approval. The material / components used are to be those listed in the bid

(Sections 2 and 3) unless the contractor has first obtained NNSY’s written permission to substitute specific items. No material procurement or manufacture of the vent units is to commence until after the plans and associated bill of materials are approved in writing by NNSY. NNSY will review and approve or disapprove the drawings and list of material within 20 working days after receipt at NNSY.

4.2.2. All final drawings shall be composed using AutoCAD (2016 edition or earlier) in order to be compatible with current NNSY software. The contractor shall submit hard and electronic copies of these drawings. Hard copies shall be a minimum of C size (16” Wide x 21” High) with fully dimensioned layouts of skid structure, equipment, etc. All drawings shall indicate adequate clearance for operation, maintenance, and replacement of operating equipment services. Final approved assembly drawings shall be submitted to NNSY in the form of AutoCAD (2016 edition or earlier) disk with two hard copies.

4.2.3. Drawings and schematics must represent the “as built” system. These drawings and schematics must be developed and printed in a manner that is conducive to ease of use and understanding while troubleshooting.

4.3. Structural Objective Quality Evidence (OQE):

4.3.1. Documentation must be provided to demonstrate the structural integrity of the

Vent Units. This is to include the structural and padeye calculations, Liquid

Penetrant Test (LPT) of lifting pads, and load test per Paragraph 2.2.9.

4.4. Leak Test Data:

4.4.1. Documentation must be provided to demonstrate the integrity of the filter housing and ductwork. This is to include the filter housing leak test per

Paragraph 2.2.2.D and duct leak test per Paragraph 2.2.6.

4.5. Manuals:

4.5.1. Each unit is to be provided with two sets of operation and maintenance manuals, drawings, and replacement parts list. This will include the respective manufacturer’s descriptive literature of cataloged products, equipment drawings, diagrams and performance curves. Installation, operation and maintenance manuals for all equipment shall also be submitted.

4.6. Site Visit & Performance Test:

4.6.1. The Vent Units are to be performance tested by the contractor and witnessed by a NNSY representative from the cognizant technical organization prior to shipment from the contractor’s plant. This contract is to support funding for travel expenses and accommodations for NNSY representative to witness performance testing at the contractor’s plant.

4.6.2. A copy of the performance test for each unit is to be provided with each unit.

There shall be a test result data sheet for each test required by these specifications. Each sheet shall indicate the specific unit, the date, the actual test results obtained, and the name and signature of the person who performed the test(s). The units are to be under warranty for a period of one year or the standard commercial warranty, whichever is longer, from the date of physical receipt at NNSY, Portsmouth, Virginia.

4.7. Certificate of Compliance:

4.7.1. Final acceptance inspection is to be performed at NNSY. Manufacturer shall provide a Certificate of Compliance.

4.8. Training:

4.8.1. The contractor shall provide training/instructions concerning the operation, maintenance, trouble shooting and repair of the vent units. The training shall cover all modes of operation. Instruction shall only be provided by a manufacturer factory representative who is thoroughly familiar with the vent units provided.