200 CFM LPAC SOW.docx

STATEMENT OF WORK

1. SCOPE

1.1. Portsmouth Naval Shipyard (PNSY) is seeking to lease an electric powered Low Pressure Air Compressor (LPAC) system. The application is for a multipurpose Tooling Air system. The compressed air system will have a dedicated compressor with controls, pressure regulator, storage tank, air dryer, distribution manifold, and compressed air hoses. The minimum allowable requirements for the system is detailed in the Statement of Work (SOW) below. The compressor plant shall be designed for outdoor use and will be subjected to inclement weather year round. The application for the compressed air systems is located at the NLON detachment in Groton, CT.

2. APLLICABLE DOCUMENTS

2.1. Issues of Publications - The following documents in effect on the date of this requested proposal is a part of this specification to the extent applicable, or as specified herein. Within the specification, they shall be referred to by their basic designation only.

2.1.1. Government Furnished

2.1.1.1. PNSY: General Specification For Integral Lifting Attachment Design

2.1.2. Nongovernment Furnished

2.1.2.1. CGA G-7.1-2018: Commodity Specification for Air, Seventh Edition

2.1.2.2. OSHA 29 CFR 1910.134 – Respiratory Protection 2.1.2.3. ISO 8573-1:2001

2.1.2.4. OSHA 29 CFR 1910.169, Compressed Gas and Compressed Air Equipment, Air Receivers

2.2. Order of precedence - In the event of conflict between the text of this specification and that of the references cited above, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws or regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Component List

3.1.1. Required components.

Low Pressure Air Compressor [LPAC]

Spec #: NLON200CFMLPAC Rev: Orig.

3.2. Tooling Air & Multipurpose LPAC Requirements

3.2.1. Nominal Compressed air flow rate: 186 SCFM

3.2.2. Maximum system pressure: 125 PSIG

3.2.3. Regulated delivered Air Pressure Set point: 105 PSIG

3.2.4. Minimum Compressor Stages: 2

3.2.5. Compressor Airend design shall be 100% Oil Free. Oil flooded compressors are not acceptable.

3.2.5.1. Compressor shall deliver 100% Oil Free Air per requirements defined in Section 2.1.2.1 and 2.1.2.2

3.2.5.2. Compressor shall deliver ISO Class 0 Air per requirements defined in section 2.1.2.3

3.2.6. Compressor connection: 3 Inch M SPUD Fitting.

3.2.7. Compressor shall be equipped with Integral After Cooler (Intercooler)

3.2.8. Compressor shall be air-cooled and enclosed in a weatherproof enclosure suitable for outdoor operation with an ambient operating temperature range of -10°F to 110°F without the need for additional shelter/protection.

3.2.9. Compressor Shaft HP: Maximum Allowable 60 HP

3.2.9.1. Note: Maximum allowable running amperage cannot exceed 100A at 460 VAC 3 PH

3.2.10. Compressor RPM: 1750

3.3. LPAC Physical Dimension

3.3.1. Maximum Allowable Footprint (L x W x H) Inches: 90 X 54 x 74

3.3.2. Maximum Allowable Weight (lbs): 8,500

3.4. LPAC Electrical Requirements:

3.4.1. Operating Voltage: 460 VAC 3 Phase 60 Hz

3.4.2. Motor RPM: 1750

3.4.3. Maximum Starting Amperage: 200A

3.4.4. Maximum operating Amperage (FLA): 100A

3.4.5. All onboard low voltage controls must have integral transformer to provide necessary voltage stepdown. Compressor must operate from one 460VAC circuit.

3.4.6. The Compressor shall be equipped with electrical power cable, 200 FT in length.

3.4.7. The power cable wire gauge must be sized properly to minimize voltage drop over 200 Ft and handle full load run amperage as well as start-up in rush current.

3.4.8. Power cable shall be delivered as bare wire ends to allow PNSY electrical shop to wire “shop owned” Duraline connectors to power cable.

3.5. LPAC Operating and Safety Controls:

3.5.1. Low pressure cut in

3.5.2. High Limit Pressure cut out

3.5.3. High Pressure safety relief valve

3.5.4. Pressure Relief valve set to 125 PSIG. Pressure relief set point shall not exceed the working pressure ratting of any component in line with the compressed air system.

3.5.5. High Temp Alarm

3.5.6. High temperature compressor cutoff

3.5.7. High pressure compressor cutoff

3.5.8. Oil sensor & alarm

3.6. Compressed Air Receiver Tank Requirements:

3.6.1. 250 Gal, ASME rated Pressure Vessel

3.6.2. Minimum working pressure rating: 125 PSIG

3.6.3. Tank maintenance & construction shall meet all requirements in accordance with Section 2.1.2.4

3.6.4. Vertical mounting Orientation.

3.6.5. Tank shall be equipped with lashing/ tie down points and base mount bolt pattern to enable the tank to be properly secured.

3.6.6. 3 IN connections: SPUD Fittings, M & F

3.7. Desiccant Dryer Requirements:

3.7.1. Nominal Inlet Flow rate: 260 SCFM

3.7.2. Nominal Dew Point Operating points: -40°F and -100°F

3.7.3. Ambient Operating Temperature range: 100°F to -10°F

3.7.4. Nominal Outlet Flow at Dew Point:

3.7.4.1. @ -40° P.D.P (SCFM): 223 3.7.4.2. @ -100° P.D.P (SCFM): 220

3.7.5. Maximum Allowable Footprint (L x W x H) Inches: 90 X 42 x 47

3.7.6. Maximum Allowable Weight (lbs): 8,500

3.7.7. Nominal Rated Working Pressure (PSIG): 150

3.7.8. Inlet / Outlet Connections: 3IN NPT

3.7.8.1. Note: If the air dryer is manufactured with 2 IN NPT connections, adaptors shall be required to enable 3 IN SPUD connections for hose connections.

3.7.8.2. NPT to 3 IN SPUD adaptors.

3.7.9. Dryer shall be equipped with particulate and oil removal pre-filters c/w automatic condensate drains and a one micron after filter.

3.7.10. The desiccant dryer shall consume no more than 18% of the LPA input volume for purging to a –40°F setting and no more than 20% LPA input volume for purging to a –100°F setting

3.7.11. NOTE: A larger capacity desiccant dryers (larger than 300 SCFM nominal rating) shall be considered for substitution as long as the proposed equipment contains adjustable air purge / regeneration cycle setting. This is required to accurately accommodate the moisture loading developed by a nominal 200 SCFM compressor and maintain 18% and 20% air consumption ratings for the respective dew point operation.

3.7.12. The Desiccant dryer shall operate from one circuit rated at: 120 VAC, single phase, 20 Amp, 60Hz.

3.8. Equipment Air Hose Connection & Distribution Hose Requirements:

3.8.1. The contractor shall, on delivery, make all 3 IN hose connections between compressor, dryer, and air receiver, and all hose connections must have safety cables (Safety Restraint Devices) installed to prevent hose whip in case of accidental separation of coupling or clamp device. 150 FT of hose length is estimated as a minimum, however, if the equipment layout requires additional hose, the contractor shall provide the necessary length to make all connections.

3.8.2. Compressed air hose: 1 ¼ IN hose- 1200 FT total length; 50 FT. hose length sections. NPT connections. (24 hose sections total)

3.8.3. Compressed air hose: 5/8 IN hose- 500 FT total length; 50 FT hose length sections. NPT connections (10 hose sections total)

3.8.4. All compressed air hose shall have a minimum working pressure of 150 PSI.

3.9. Distribution Manifold & Tooling Air Hose:

3.9.1. The compressed air system will require a distribution manifold to supply air to various tooling equipment from the receiving air tank.

3.9.1.1. Manifold Input: The distribution manifold shall be supplied from the receiving air tank via a 3 inch inlet hose equipped with MXF SPUD connections.

3.9.1.2. Manifold Outputs: The distribution manifold shall contain 4 output connections, 1 ¼ IN NPT. Each output shall have an isolation valve so branches may be individually isolated.

4. NOTES:

4.1. Construction:

Except as noted for a particular machine type, units shall be a single integrated framed structure manufactured as a complete entity to include all devices, accessories, and fittings necessary to perform the function for which it was designed. Each unit shall be capable of continuous, year-round, outdoor, unmanned operation even at minimal loading while exposed from inclement to extremely harsh weather (e.g. deep snow, strong & gusty winds, and/or heavy rain) and varied ambient conditions (–10 to +110°F & 0 to 100% RH). Machines shall meet State and federal requirements for its type such as the National Electrical Code (NEC) for electrical devices / components and the American Society of Mechanical Engineers (ASME) for pressurized vessels / components. Machines shall be modular in design so as to act as a stand-alone unit; compact so as to fit in the tight confines of a drydock; portable so as to be transported by forklift and then lifted by crane; and ruggedly constructed so as to endure a marine industrial environment. Machines shall be newly manufactured / completely refurbished and factory tested within ten (10) years.

4.2. Supplemental Equipment:

For the protection and cleanliness of the machinery components, all steam connection points shall be shipped with plug/cap fittings.

4.3. Electrical:

Electrical components shall conform to a NEMA standard (NEMA 3 or 4) that allows for unsheltered outdoor use of the unit. Each machine shall require only one type / source of electrical power (460 VAC +5% / three-phase / 60 hertz). The type of electrical power required (voltage & amperage) must be clearly indicated on the outside of the equipment, readily detected, and collocated with all other electrical information. The Vendor shall provide the Project Temporary Services Zone Manager with the following details: (i) electrical power type (amperage & voltage); (ii) type of electrical connectors (for three phase, specify whether or not equivalent to Duraline 4M20); (iii) breaker type/size or recommended capacity for the electrical source; and (iv) whether the machine is furnished with over-current protection.

4.4. Lifting & Handling:

4.4.1. See reference 2.1.1.1.

4.5. Machinery / Equipment Tagging and Markings:

All piping inlet(s) / outlet(s) must be clearly marked. Machinery and itemized equipment require tagging to show Project Number / Technical Specification Identification (ID) Number

4.6. Vendor Identification Of Itemized And Ancillary Equipment:

The Contractor shall uniquely tag and permanently mark all of its ancillary and itemized equipment / hardware (e.g. manifolds, hose assemblies, pipe fittings, duct adapters, ducting, etc.) so as to differentiate from that owned by either the Shipyard or other Vendors.

4.7. Dead Front Control Panel or External Controller:

Access to basic machinery controls, such as a Dead Front Control Panel or External Controller, shall be such that there is non-exposure to energized "live" electrical circuits or other components regardless of voltage, to include control circuitry, by "a person on the operating side of the equipment".

4.8. Maintenance

4.8.1. Except for daily surveillance checks, the Contractor is responsible for all equipment preventative maintenance and repairs for the duration of the lease. Coordinate maintenance with Shipyard Zone Manager.

4.8.2. The vendor shall provide Preventative Maintenance (PM) schedules which are equipment specific. The PM shall meet all requirements determined by the Original Equipment Manufacture (OEM). The vendor shall provide the PM documentation and schedules to PNSY Temporary Services Engineering Code 230 for review and approval prior to being considered for a successful Bid. The routine PM plan for each piece of equipment shall include a comprehensive list of the components to be serviced as well as identifying the service frequency. (e.g. all consumables to be replaced, bearing grease points, belt replacement / tensioning, filter changes, refrigerant charge, oil changes, other lubrication, coolant refills, liquid top-offs, etc.) All PMs conducted shall include a technical service report identifying component, maintenance conducted, date, and next scheduled PM date. Copies of all reports shall be delivered to the project COR and the Zone Manager.

4.8.3. In addition to providing routine preventative maintenance, the vendor shall provide a service technician on a weekly basis for the duration of the lease to perform weekly equipment inspections. Weekly equipment inspections shall consist of checking all functional operating parameters of each individual piece of equipment. This shall include but is not limited to: verifying correct equipment performance and operation, checking for diagnostic or trouble codes, verify amperage of all electric heating coils. Weekly equipment inspections shall include a technical field report identifying the status of each piece of equipment and shall include all data / measurement points verified. All reports are delivered to the project COR.

4.8.4. The vendor shall provide a knowledgeable service technician to cover the repair of all equipment deficiencies and malfunctions. The response time for the repair or replacement of deficient equipment shall meet the requirements defined in section 6.2.

4.9. Training

The Contractor is responsible for and shall provide training sessions to Shipyard Personnel on the operation and setup of all equipment. Training shall be available throughout the duration of the lease to accommodate equipment swap out and seasonal equipment operation.

4.10. Operator / Maintenance Manuals - Documentation will be located within a water proof case affixed to each machine. Minimally, the documentation shall consist of:

4.10.1. Lifting & Handling the equipment with its padeye(s) Certification

4.10.2. Points of contact with telephone numbers for requesting emergency repair regardless of the time or type of day

4.11. Deliverables – In addition to all required equipment, technical documentation shall also be provided electronically to the project COR and Engineering. Minimally, the documentation shall consist of:

4.11.1. Lifting & Handling the equipment with its padeye(s) Certification. (see Reference 2.1.1.1)

4.11.2. Points of contact with telephone numbers for requesting emergency repair regardless of time or type of day

4.11.3. Technical Instructions (TIs) such as an Operations & Maintenance Manual, Controls Manual, and/or Mechanical/Electrical Manual with Schematics.

4.11.4. Operating Instructions, if not in the TI.

4.11.5. Preventative Maintenance Schedules. (See section 4.8)

4.11.6. Equipment Data Sheet (EDS)

5. GOVERNMENT FURNISHED MATERIAL (GFM):

5.1. N/A

6. RESPONSIBILITITES

6.1. Government

6.1.1. Equipment Technical Evaluation: C230 Engineering

6.1.2. Receipt Inspection: Contractor Officer Representative (COR) & Zone Manager (ZM)

6.1.3. Coordination of equipment delivery & returns: COR & ZM

6.1.4. Schedule equipment service, repair, and training: COR & ZM

6.2. Contractor

6.2.1. Any and all required State approved safety features (i.e. safety pressure relief valves, low water cutout, over pressure protection) installed with the State of Connecticut certification.

6.2.2. The contractor shall maintain a stringent maintenance program and be responsible for all routine maintenance, except for daily check of liquid levels. The contractor shall provide oil, filters, coolant, and lubricant for engine and compressor operation during the rental period.

6.2.3. The contractor shall provide service within twelve (12) hours after notification by the Contracting Officer or his/her representative. In the event the machine cannot be returned to service within twenty-four (24) hours of notification, a replacement shall be delivered at no extra charge to the Government.

6.2.4. The contractor shall be responsible for equipment failure not arising out of abuse or negligence by the government.

6.2.5. There shall be no changes unless authorized by the Contracting Officer.

6.2.6. The vendor shall provide technical support to PNSY project personnel as required.

7. DELIVERY / ACCEPTANCE / RETURN

7.1. Delivery- The machinery shall be in a fully-charged, fully-assembled, ready-to-use, and in a first-class- operating condition. Machines shall be functionally tested prior to its delivery and all leased products, including machine / equipment / ancillary component accompanying machine, must fully function as intended. The machinery with its support equipment shall be delivered to the site on or prior to the request date. It is incumbent and the responsibility of the Contractor to either confirm or coordinate the date and time of delivery prior to each shipment via the Point-of-Contact (POC) as designated on the Contract and/or the Contracting Officer's Representative (COR). The Government can provide forklift services for removing machinery from Vendor’s transport during work hours. Documentation with Shipyard copies shall accompany each delivery.

7.2. Acceptance-Upon satisfactory completion of inspection and test of the equipment, the authorized Government Representative (Portsmouth Naval Shipyard, Code 420 COR) will sign and forward the acceptance document(s) to Code 220 Production Control for completion. Unloading of equipment from Vendor’s transport does not signify acceptance.

7.3. Start Up- If requested by the Project, the Vendor shall: (i) start and run the equipment to verify its operability; (ii) confirm that a set of operating instructions was previously delivered; and/or (iii) instruct designated Shipyard personnel on how to properly run the equipment to include its operation, control, daily checks, & service contacts. For multiple sets of comparable equipment with essentially similar operation, the orientation given to a specific Project on a particular type and/or capacity of machine can be accomplished just once regardless of delivery.

7.4. Security- To be allowed onto a government Shipyard, personnel must be US citizens and in possession of appropriate personal identification. Proof of US citizenship may be necessary and can be required for access to the drydock. Allowable documentation of US citizenship is an official government issued Certificate of Birth or Naturalization (w/ raised seal & not a photocopy) or a US passport (can be expired). Vehicular access requires a non-expired personal Driver’s License and appropriate vehicle identification or registration. The transport vehicle must have the company’s name / logo prominently displayed. To gain access to the drydock environs, personnel must be escorted and possess / wear their own personal safety gear.

7.5. Receipt Inspection Criteria- Equipment must meet all criteria defined in this specification.

7.6. Return- The Government will provide a temporary storage location convenient for Contractor pick-up. The Government will notify the Contractor as well as the Contracting Office as to when the rental Item has been released and is available for pick-up. The last day of the rental period shall be the next normal workday after the Contractor has been so notified. The Contractor shall be responsible for shipping. The Government can provide forklift services during work hours for placing the equipment onto the vendor’s transport.

8. GENERAL

8.1. Response to Request

As part of the response to this request, descriptive literature shall be furnished in sufficient detail to show that the proposed design will meet these specifications. Vendor submittals shall include brochures of the model being submitted, assembly sketches with critical dimensions, sketches (with dimensions) of all tooling being provided, statements of compliance with specification, and performance statements with special instructions. Supporting information shall be organized and packaged by unit. If supporting information includes multiple models the vendor shall clearly state model number of proposed unit and redact all information not applicable to proposed unit.

9. ATTACHMENTS

9.1. N/A

10. Approved Equipment Models

10.1. Ingersoll Rand Sierra Oil Free Scroll Compressor: 50 HP

10.2. Hankinson SPX: RDH 260