3f Statement of Work.docx

FEDERAL AVIATION ADMINISTRATION January 15, 2025

KNOXVILLE COMBINED TOWER TRACON (TYS) CAB HVAC REPAIRS

Statement of Work

Existing Split Systems - For Information Only

1) Existing Tower Cab air conditioning systems, 1 and 2

a) Existing Air Handling Units (AHU): AHU-1 and 2

i. Carrier Model 40BA009 300

ii. Serial #s: U596771

iii. Date of MFG: July 1985

iv. Power Supply: 208/3/60

v. 1-1/8” Suction Line Connection

vi. 5/8” Liquid Line Connection

b) Existing Supplemental Electric Duct Heater (EDH)

i. HEATRIX Model DASR-2416

ii. 208/3ph/60

iii. 33.31 FLA

iv. 12 KW

c) Existing Blower Motor

i. 2 Hp

ii. 3,460 RPM

iii. 208/1ph/60

iv. 10.2 FLA

d) Existing Heat Pump Condensing Units (CU): CU-1 and 2

i. Carrier Model 38ARQ008 - - - 501 - -

ii. Serial #s: 2302G30042

iii. Date of MFG: July 2004

iv. Power Supply: 208/3/60

v. 1-1/8” Suction Line Connection

vi. 1/2” Liquid Line Connection (5/8” liquid line to unit)

2) See pictures of existing equipment and nameplates below:

AHU-1 and 2 Nameplate

AHU-1 and 2 Horizontally Stacked

Heat Pump Condensing Unit (HPCU)-1 and 2 Nameplate

HPCU-1 and 2

Demolition

a) Provide, set up, and make ready a stand-by emergency cooling system consisting of a ‘water-cooled’ portable, self-contained air conditioner of not less than 60,000 Btuh (5 nominal tons total) cooling capacity. Field coordinate placement and routing of condensing water supply and removal, condensate drainage, and temporary ducting and power supplies to minimize obstruction and maintain clear access within tower cab and egress. Include manufacturer optional fittings and accessories to augment water supply and air distribution as necessary. Provide and install temporary power feed from source of AHU being worked on, per NEC and FAA Standard C-1217H ‘Electrical Work, Premises Wiring.’

i. Unit may be a rental.

ii. Acceptable make and model of spot cooler shall be OCEAN-AIRE, 5 Ton, Portable, Water-Cooled Air Conditioner, or approved equivalent. Specifications:

1. 60,100 BTUH Voltage:

2. 208-230V, 60Hz, 1PH

3. Amps: 23.7

4. Total Watts: 5000

5. Cooling Ambient: Operating Range 65° to 105° Outdoor Use:

6. Rush Amps: 165

7. Plug Type: 6-30P

8. EER: 12.0

9. NOTE: Dedicated circuit and time delay fuses / circuit breakers are recommended.

10. Compressor: Scroll Compressor

11. HP: 5 Compressor

12. LRA: 158

13. EVAP CFM - High: 1950

14. EVAP Motor HP: 1

15. Water Line Connections Water In: 5/8 MF / Water Out: 5/8 MF / Drain: 3/8 MF Condensate Removal: Pump Automatic 20’ Vertical Lift

16. Refrigerant Charge: 52 oz R-410A

17. Height: 52.2˝

18. Width: 27.2˝

19. Depth: 29.2˝

20. Net Weight: 375 lbs.

21. Estimated Condenser Water Usage* Entering Water Temp: Condensing Water at 60°: 3.8 GPM Condensing Water at 85°: 15 GPM

22. Usages will vary with water conditions and ambient temperatures.

23. Product Features: • 24V Control Circuit with Non-Programmable Electronic Thermostat • Swivel Ball Bearing Casters with Locking Fronts • 2-Speed Fan Switch • Condensate Overflow Alert Light • High Pressure Safety Switch • Washable Electrostatic Air Filter

See sketch on next page:

Sketch Temporary Air Conditioning Unit

b) Selectively demolish and dispose of air conditioning equipment and ancillary components, to include AHU-1, 2, HPCU-1, 2, and associated systems, as necessary to allow for replacement and refurbishment with new. Only work on one system at a time – do not start any work on second unit until first is complete, commissioned, and operational.

c) Recover and dispose of existing refrigerant in accordance with local, State, and Federal (EPA) requirements. Record and keep record of the amount of refrigerant recovered and place of disposal and provide to FAA.

d) Dispose of demolished equipment off site at a licensed and approved scrap metals handling facility or landfill in accordance with local, State, and Federal regulations.

New Work

Provide and install new ancillary parts, fittings, and components to complete the refurbishment and make each system’s operation and function like new. As a minimum, replace and/or incorporate the following:

a) Refurbish existing 9-ton, split system ‘heat pump’ air conditioning systems 1 and 2.

b) Existing AHU cabinet, vibration isolation and steel support steel-frame stand may be re-used; but modify with equivalent materials and methods as necessary to enlarge for recommended equipment clearances. Re-paint with one coat of industrial oil-based, low VOC, red oxide primer and two coats of industrial, oil-based ‘exterior’ hi-gloss enamel – color brown.

c) Provide and install Carrier Corporation Original Equipment Manufacturer (OEM) or equivalent, replacement parts, components, and assemblies to restore respective AHUs condition and function to like new.

d) As a minimum, perform complete replacement of the following equipment and sub-systems:

i. Complete all new, sole sourced, Carrier ‘Gemini’ 10-ton Heat Pump Condensing Units 1 and 2 (HPCU-1, 2), to include:

a. R-410A refrigerant only

b. Hail guards

c. 2-stage capacity control

ii. Selectively salvage and/or replace all external refrigeration circuits, including tubing, metering, filter, valving, and control devices, to include:

a. Any new refrigerant tubing external to and between AHU evaporator coil and HPCU must be type ‘Air Conditioning and Refrigerant’ (ACR) (hard or annealed) of seamless copper in accordance with ASTM B 280 - minimum allowable tube wall thickness shall be 0.81mm (outside diameter dependent), and stronger refrigeration (R-410A minimum) copper fittings.

b. Any refrigerant tubing to be salvaged must be flushed, dried, pressure tested, purged and capped prior to re-use.

c. May re-use same path and penetrations as existing where beneficial to progress. However, all routing must be parallel and perpendicular to building lines. Replace damaged fire-stopping with new where penetrating fire-rated assemblies.

d. Joining copper tube and fittings by silver brazing carried out by tradespersons using brazing principles and safety procedures in accordance with industry standards. Contractor shall provide for and perform nitrogen purging in accordance with best industry practices when brazing refrigerant tubing. Must use 15% silver solder to braze tube and a suitable brazing flux. Post fire watch at all times and exhaust brazing fumes outdoors. Evacuate refrigerant system, pressure test, and charge with initial fill of new R-410A.

e. New thermostatic expansion valve with bypass check-valve option, equalization line, and sensing bulb; sized and selected for R-410A refrigerant and 9-ton evaporator capacity [Note: basis of design is that 10-ton heat pump condensing unit will experience reduced capacity due to height of vertical lift, and therefore a more appropriate size for 9-ton evaporator].

f. New liquid line site glass with moisture indicator

g. New liquid line filter drier with isolation valves. Used flared connections at filter drier.

h. New suction and discharge service valves at connections to equipment and bypasses.

i. New discharge line solenoid valve with line voltage control.

j. Addition of field-installed liquid-suction sub-cooler as needed for prevention of flash gas due to high vertical lift. Must coordinate selection and sizing with heat-pump condensing unit manufacturer’s recommendation.

Note: all new refrigeration circuit tubing, fittings, and devices shall be the products of Parker Sporlan Refrigeration & Air Conditioning, a Division of Parker Hannifin; or approved equivalent. Applies to a-j above.

k. New refrigerant suction and liquid line neoprene insulation, minimum ¾” thick, where new lines are added, or existing insulation damaged. Provide and install pre-fabricated metal jacketing system over exposed exterior insulation within 8’ above roof.

l. New ‘refrigerant configuration’ field selection label appropriately marked for ‘R-410A’

iii. Re-build existing AHUs-1, 2 to include:

a. Evaporator fan assembly motor, pulley, and belts. Inspect motor and fan mounts for weld or metal cracks, fatigue or bending, and report to FAA the condition of motor and fan mounts for re-use - replace in kind if damaged. Size, select and install replacement motor, fan pulley, and belt for unit airflow in relation to coil capacity at 350 – 400 cfm per ton of refrigeration at full load conditions for 74F indoor air temperature. New electric motor must be heavy duty and no less horsepower than existing - double check amp ratings of new motor against existing power feeds. Use new wire nuts or lugs; and apply di-electric grease to wiring connections. Start-up and check-out fan operation for correct spin, alignment, and air flow.

b. New condensate pans, SS-304, and pitched to drain.

c. New high-side service connections

d. New low-side service connections

Note: new AHU components shall be OEM equivalent products of the CARRIER Corporation; or approved equivalent. Applies to a-d above.

e. New horizontal slab, copper tube / aluminum fin, replacement evaporator coils; R-410A rated, to include cabinet grommets and bushings. Minimum 9-ton nominal capacity. Replacement coil shall be by SFI Coils, Flower Mound, TX; or approved equivalent.

f. Protect and re-use existing filter frame sections. Clean inside and out. Provide standard 2” MERV 10 replacement filters and install upon completion of component upgrades.

g. Do not disturb and re-use in place existing mixing dampers and linkage. Note: electric actuators for control of exhaust, outdoor, and mixed air to be replaced with controls work.

h. Salvage and re-use in place the existing Type ‘L’ Cu condensate drain lines to existing floor drain.

i. Note: existing supply trunk back-draft dampers must not be disturbed and are to remain in place. Auxiliary electric duct heaters, to include associated power feeds and control wiring, may be removed as needed; but must be replaced and returned to working condition.

iv. Replace existing HPCUs-1, 2 exterior electrical power, to include:

a. New fused safety disconnect switch, NEMA 4X, 3-phase, 600V heavy duty, with double lug kit, sized for load; to include:

b. Electrical wiring and conduit between disconnect and unit. Use THWN wire, sized for load.

c. HACR fuses sized for load.

d. HPCU outdoor electrical low voltage control wiring and conduit.

g. Note: bond and ground new air conditioning equipment in accordance with FAA Standard 019f Chg-3. See Appendix.

v. Repair existing HVAC controls system to restore function and operations, to include but not limited to:

a. Correct direct digital control (DDC) programming regardless of system 1 or 2, to perform:

i. normal heat pump cooling and heating

ii. auxiliary electric heating

iii. outdoor air economization

iv. automatic change over per an adjustable schedule

v. automatic lead/lag fail over

vi. fire alarm shut-down

b. Field investigate existing controls system beforehand to determine requirements of new work without jeopardizing operation of the system still in service. Provide work-arounds to maintain acceptable air conditioning control at all times when tower cab is occupied.

c. Provide and install updated and new low voltage control devices, electric actuators, wiring, software and programming, relay modules, and user interface as needed to restore normal system operating sequences. Existing power source and cabinet may be salvaged in place for re-use, as may any other device still in good condition and operating normally.

d. Salvage in place and re-use existing duct 'smoke' detector on AHU supply trunk. Do not disturb interface with existing fire alarm system.

e. Note: existing HVAC controls are a custom PLC platform made and installed by the current service company:

QUAD CITY CONTROL COMPANY

3110 Henson Road, Suite 12 Knoxville, TN 37921 Phone: (865) 588-5510 POCs: Teddy Wayland, Ops Manager Gary Grinder, Apps Engineer

vi. Clean ductwork in place and inside of AHU per NADCA Standard, 2021 Edition. Note: connected ductwork is internally lined and any cleaning effort may only proceed if inspection by FAA first determines that it will not be damaged. Duct cleaning must be coordinated with Air Traffic Operations during off-peak hours, early a.m., on a weekend.

vii. Modify the HPCUs support stand if additional room is needed to fit new units with allowable clearance for maintenance. Use same manner of construction and materials as existing, with exception that bolted connections are permitted. Bolted connections shall be not less than ½” hot-dipped galvanized and installed per AISC standard 360-10. Prep, prime, and paint the entire steel, roof-mounted support frame on which the HPCUs sit. Clean and wire brush loose dirt and rust; prime with one coat of heavy-duty red oxide rust-converter and alkyd resin primer; and two coats of exterior grade, acrylic enamel hi-gloss paint, color gray. Brush or spray methods are acceptable. Protect surrounding building surfaces and finishes from over-spray and drips.

viii. Selective demolition and replacement of existing refrigerant lines must include all methods and materials necessary to open through penetrations in walls and floors to allow demolition and re-routing of new refrigerant tubing, electrical and control wiring. Restore weatherproofing and fire-stopping to match same after new lines are installed, tested and approved. Provide and install through-penetration fire stopping in accordance with ANSI/UL 1479 (ASTM E-814) for all wall and floor penetrations.

ix. Wall demolition and restoration work shall include turn-over of SDS, dust-free (wet) sanding techniques, and immediate clean-up to prevent spread of airborne contaminants or residue beyond work area.

x. Perform a complete start-up, check-out, and test of the system in accordance with manufacturer’s recommended procedures before beginning work on the next unit.

3) Existing Conditions

a) ASBESTOS. No asbestos will be impacted by this work.

b) LEAD. No lead will be impacted during this contract.

c) RESTROOMS. No restroom facilities are available at the site.

d) WATER. No water (potable or non-potable) is available at the site.

e) ELECTRICITY. Power shall be made available to contractor at the site. Coordinate this need at the preconstruction conference.

f) DUMPSTER. There are no available dumpster or disposal facilities onsite.

g) SITE VISIT. The contractor shall carefully examine the site and all areas of proposed to see firsthand the extent of work involved. It shall be the contractor’s responsibility to make own interpretations of existing site conditions. To schedule a site visit, contact Richard ‘Allen’ Couch, FAA TYS SSC site coordinator, at (865) 306-3235 cell / (865) 980-3051 office.

4) Work Location

a) Address: 2207 Airbase Road; Louisville, TN 37777

b) Latitude / longitude: 35.8196 / -83.9954

5) Permits: the contractor will be responsible for obtaining all required permits, to include local, State, and Federal; and permit compliance with FAA Orders.

6) Work Access: access to the site requires passing through a security gate. Therefore, the local FAA will escort the contractor to and from the site on a daily basis, unless alternate arrangements are agreed upon at the preconstruction conference. The contractor shall coordinate working schedule with FAA facility management to secure a daily escort.

7) Working Hours (day work): all site work shall occur during normal business hours, Monday-Friday, between 07:00 and 16:00, excluding FAA moratoriums and Federal holidays.

8) Workers: due to security regulations, no foreign national workers will be allowed on the job site without 30-day calendar notification and approval. Contact the SSC Manager for further information.

9) Demolition: any equipment or material to be removed, unless specified to remain the property of the FAA, shall become the property of the contractor and shall be transported from the site and disposed of in a legal manner. Demolition and removal work shall be performed in compliance with safety procedures, applicable requirements of the State and local regulations, and with Federal and FAA requirements.

10) Safety Standards: contractors shall comply with all applicable federal, state, and local requirements for protecting the safety of the contractors’ employees, building occupants, and the environment. In particular, all applicable standards of the Occupational Safety and Health Administration (OSHA) shall be followed when working in accordance with this specification.

11) Working Conditions: associated demolition and construction must not interfere with Air Traffic Control Operations. Extreme care must be taken to not cause any harm, interference or interruption to occupants or building systems. Any damage caused as a result of contractor’s construction activity must be repaired promptly at no cost to the Government.

12) Drawings: all drawings (including sketches, details, figures and pictures) submitted for this project are for reference only; and are not to be scaled or interpreted as indicating an exact placement.

13) Submittals: prior to performing any site work, contractor shall submit the following to the CO for approval:

a) Manufacturer’s product literature, drawings, samples and/or explanation of the following methods and materials:

i. Heat pump condensing units, HPCUs-1 and 2

ii. New ancillary components, assemblies, and fittings for refurbishment of AHU-1 and 2, to include but not less than: evaporator coil, condensate pan, and fan assembly blower motor and pulleys/belt.

iii. ACR refrigerant tubing, fittings, site glass, service valves, TX valve, sub-cooler, and filter drier.

iv. Refrigerant lines insulation and jacketing

v. Nitrogen purging gas and control device

vi. Silver solder and brazing flux

vii. Electrical disconnects, fuses, wiring, conduit (metal and flex) and connectors, hangers and supports

viii. Modification measures of HPCU-1, 2 support frame

ix. Caulks, sealants, fire-stopping, paints and adhesives, to include Safety Data Sheets (SDS).

x. Complete controls package, to include but not less than: controls diagram, operating sequence, points list, and product literature on all devices and wiring.

b) All submissions should be submitted within 10 days from contract award for a determination of specification compliance by the Government prior to said product manufacture.

14) Material: all material specified herein shall be supplied, transported, maintained handled installed and stored by the contractor. All material estimates and measurements are the responsibility of the contractor.

15) Installation:

a) The existing split system air handling units and associated heat pump condensing units are the only air conditioning for the air traffic control tower cab. The units operate in a primary/secondary configuration. Only one unit at a time may be worked on. Work on the second unit must not begin until the first is complete and operating normally.

b) Both systems shall be refurbished in an expeditious manner.

c) All work shall be performed by a Tennessee State licensed commercial refrigeration and conditioned air contractor, and similarly licensed electrician.

d) Coordinate Lock-Out/Tag-Out precautions with Facility Manager before doing any electrical work. No work may be performed on energized circuits.

e) Ensure that existing supply and return ducts are securely attached before placing AHU unit back in operation.

f) Ensure that existing condensate drain lines are securely attached and unobstructed before placing AHU unit back in operation.

16) Clean-up:

a) Before final inspection, the contractor shall thoroughly clean within the construction limits and the surrounding areas affected by this work, including the following:

b) All construction facilities, debris, and rubbish shall be removed from the buildings and the site on a daily basis.

c) All tools, temporary utility connections, building materials and debris, etc., belonging to the contractor, or used during construction, shall be removed from the site.

d) All grounds, walkways, and other areas adjacent to the work shall be restored to the original condition before project completion.

17) Inspections:

a) The contractor shall allow FAA representative designated by the CO complete access to all portions of the work. The FAA representative shall coordinate and schedule a final (Joint Acceptance Inspection – JAI). All work shall be accepted when all work required by this contract, including punch list items are complete and pass JAI.

END

Statement of Work PAGE 2 of 16 image4.png image5.png image1.png image2.png image3.png