Atch 1 - Air Dryer Regen Package Specification.pdf

15020-22-001A

SPEC NO. 15020-22-001A

28 July 2022

ITEM SPECIFICATION

FOR

AIR DRYER REGENERATION PACKAGE

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TENNESSEE 37389-9998

NOT SENSITIVE

IRA-6082

NOT SENSITIVE – IRA 6082

Table of Contents - 1

TABLE OF CONTENTS

Page

1.0 SCOPE 1

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents 1

2.2 Non-Government Documents 1

3.0 REQUIREMENTS

3.1 Functional/Performance Requirements 3

3.2 Interfaces 5

3.3 Skid 6

3.4 Equipment and Component Requirements 7

3.5 Submittals 20

4.0 VERIFICATION 23

5.0 PACKAGING

5.1 Preparation for Shipment 25

5.2 Handling and Storage 25

Table of Contents - 2

APPENDICES

Appendix A Air Dryer Regeneration Package Schematic

Appendix B Air Dryer Regeneration Package Size and Connection Diagram

Appendix C Low Voltage Induction Motor Requirements

Appendix D Submittal Procedure

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1 SCOPE

1.1 The Contractor shall provide an Air Dryer Regeneration Package (ADRP) designed to supply heated and cooled air to desiccant dryer vessels based on the design requirements in this specification, including requirements contained in the appendices. The ADRP includes piping design, analysis, and verification of the system in accordance with ASME B31.3, and shall include both high temperature and high pressure considerations.

1.2 The ADRP shall consist of one regeneration package to replace the existing system, including an air cooler/separator, booster air blower, compressor, air receiver, air heater(s), instrumentation, drainage/condensate removal system, valves, piping, and other equipment and accessories to form a complete and functioning system. The ADRP shall be mounted and delivered to Arnold AFB, TN on a skid to facilitate shipping, handling, and installation.

1.3 The ADRP shall also include necessary electrical and related equipment, including motors, starters or switches, variable frequency drives (VFDs), silicon-controlled rectifiers (SCRs), solenoid valves, switches, relays, controllers, timers, on-skid wiring and conduit, fittings, and other devices required to properly verify operation of the system.

1.4 The Government will provide the control system that interfaces with the Government plant equipment.

2 APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 AEDC Safety, Health, and Environmental Standards (AEDC SHE Standards):

A. D3 Identification of Piping Systems.

2.1.2 Code of Federal Regulations:

A. 29 CFR 1920.219 Mechanical Power-Transmission Apparatus.

2.2 Non-Government Documents

2.2.1 American Bearing Manufacturers Association (ABMA):

A. ABMA 9-15 Load Ratings and Fatigue Life for Ball Bearings.

2.2.2 American Institute for Steel Construction (AISC):

A. AISC 325-17 Steel Construction Manual.

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2.2.3 American Petroleum Institute (API):

A. API STD 610-21 Centrifugal Pumps for Petroleum, Petrochemical, and natural Gas Industries.

2.2.4 American Society for Testing and Materials Standards (ASTM):

A. ASTM E230-17 Standard Specification for Temperature-EMF Tables for Standardized Thermocouples

2.2.5 American Society of Civil Engineers (ASCE):

A. ASCE 7-16-18 Minimum Design Loads and Associated Criteria for Buildings and Other Structures (7-16).

2.2.6 American Society of Mechanical Engineers (ASME):

A. ASME B16.5-20 Pipe Flanges & Flanged Fittings.

B. ASME B16.34-20 Valves – Flanged, Threaded and Welded Ends.

C. ASME B31.3-20 Process Piping Code.

D. ASME B40.100-13 Pressure Gauges and Gauge attachments.

E. ASME BPVCSection VIII-21 Unfired Pressure Vessels, Div. 1.

2.2.7 American Welding Society (AWS):

A. AWS D1.1-20 Structural Welding Code.

2.2.8 Instrumentation Systems and Automation Society (ISA):

A. ISA S20-81 Instrument Specification Forms.

2.2.9 National Electrical Manufacturers Association (NEMA):

A. NEMA ICS 7-20 Adjustable Speed Drives.

B. NEMA MG 1-21 Motors.

2.2.10 Institute of Electrical and Electronics Engineers (IEEE):

A. IEEE 112-17 Standard Test procedure for Polyphase Induction Motors.

B. IEEE 519-14 Recommended Practice and Requirements for Harmonic Control in Electric Power Systems.

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C. IEEE 841-21 Industrial Motors.

2.2.11 International Electrotechnical Commission (IEC):

A. IEC 60584-1-13 Thermocouples – Park: EMF Specifications and Tolerances.

2.2.12 Manufacturers Standardization society of the Value and Fittings Industry(MSS):

A. MSS SP 61-13 Pressure Testing of Valves.

2.2.13 National Fire Protection Association (NFPA):

A. NFPA 70-20 National Electrical Code (NEC).

2.2.14 Underwriters Laboratories, Inc. (UL):

A. UL.508-18 Standard for Safety for Industrial Control Equipment.

B. UL.1449-21 Surge Protective Devices.

3 REQUIREMENTS

3.1 Functional/Performance Requirements

3.1.1 The ADRP shall be designed to the requirements of this specification, including all information presented in the appendices.

3.1.2 The ADRP shall be designed for outdoor installation. All components, steel wiring, panels and instrumentation shall be suitable for the environmental condition in Table 1 and operating conditions up to 460 ⁰F. Environmental design conditions for operation and protection of equipment are as follows:

Ambient Temperature Range -10 °F to 120 °F

Wind Load Requirements (per ASCE- 7)

120 mph

Snow Loads (per ASCE-7) 10 psf

Seismic Requirements (per ASCE-7) Zone 1, Category II, Site Class D, Exposure Category C

Table 1. Environmental and Load Conditions

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3.1.3 The Contractor shall provide corrosion control/protective coatings for all equipment, components and structural steel to protect against the environment and specific operating conditions. Contractor shall not paint stainless steel, galvanized finishes, nameplates, valve stems, flange bolts, or instrumentation.

3.1.4 The Contractor shall design the ADRP to perform to the following Concept of Operations (CONOPS), based on the ADRP Schematic shown in Appendix A.

A. To begin regeneration cycles, the regeneration skid isolation valves (provided by the Government) will be opened. The compressor will engage, intake atmospheric air, and pressurize the air receiver to 120 psig. The system pressure will be regulated to 100 psig due to the pressure regulating valve just downstream. The compressor will then be disengaged, and the blower will be started. The control system will regulate its output to the Variable Frequency Drive (VFD) to achieve the required flow rate and pressure at the outlet of the ADRP. The blower will drive air with a minimum pressure increase of 20 PSI. The compressor, air receiver, and regulating valves will maintain a minimum of 100 psig at the inlet of the blower

B. The heater(s) will then be energized for the heating cycle. The control system will regulate its output to the SCR to achieve the required discharge temperature. The heater(s) controller will trip heater(s) power if the heater(s) sheath temperature reaches the heater(s) manufacturer’s recommended maximum temperature and provide an alarm to the control system. The control system will also monitor the heater(s) sheath temperature to de-energize the heater(s) and provide an alarm.

C. During the heating cycle, recirculated air will pass through the cooler/separator to be reduced in temperature and remove moisture. Raw water will be supplied to the cooler. This cooled air will pass into the blower and heater(s) to be reheated and recirculated. The control system will monitor the cooler inlet and discharge pressures and alarm on low pressure setpoint or high differential pressure setpoint. The control system will also monitor the water filter differential pressure to provide an alarm when the differential pressure is greater than setpoint.

D. A back-pressure regulator shall bleed off a small amount of air during the heating cycle to account for thermal expansion, controlling the system pressure to a maximum of 105 psig at the blower inlet.

E. When the heating cycle is complete, the heater(s) will be de-energized.

To begin the cooling cycle, the blower will modulate to achieve the required flow rate and pressure. Raw water will continue to be supplied to the cooler. The cooler will cool the air to the required temperature range.

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F. During the regeneration cycles, circulated air returning to the ADRP is expected to be close to 100 psig. An air receiver on the ADRP will provide air to make up for any loss of pressure due to leakage or thermal effects.

The compressor will engage as required to maintain the air receiver between 110 psig and 120 psig. Throughout the regeneration cycle, the control system will monitor the air filter differential pressure to provide alarms when the differential pressure is greater than setpoint.

G. When the cooling cycle is complete, the blower will be de-energized, and regeneration skid isolation valves (provided by the Government) will be closed.

3.1.5 The target noise level with equipment in operation shall be 85 dBA or less when measured at a distance of 3 ft. from any point on the ADRP skid.

3.1.6 If the surface temperature of any of the ADRP system components (including equipment, piping, and valves) exceeds 120°F during operation, the components shall be insulated or shielded to protect against such hazards.

3.1.7 The footprint of the ADRP, including skid structure, shall be within the physical constraints envelope identified in Appendix B.

3.1.8 The ADRP shall be designed to facilitate maintenance by including adequate space between components for maintenance access. Contractor shall submit a maintenance plan demonstrating the ability for personnel to access and service each piece of equipment to the Government for approval prior to fabrication. All components shall be accessible and serviceable without requiring dismantling of adjacent equipment.

3.1.9 The ADRP shall be designed so that all Government interface piping nozzle loads conform to API 610.

3.2 Interfaces

3.2.1 Contractor shall coordinate with Government Representative to ensure all interfaces between the Contractor’s furnished equipment and the Government’s plant interfaces shall be compatible with the existing piping, cabling, controls and wiring. Interfaces shall be clearly marked on the Contractor’s drawing submittals.

3.2.2 Piping Terminal Points - The piping terminal points include process piping, equipment drains, vents, and relief valves. Piping terminal points for all equipment shall be terminated at the outer edge of the skid. The Contractor shall clearly identify the piping terminal points in the Submittal documents. The locations of critical piping terminal points for the ADRP are shown in Appendix B. The location of all other terminal points are at the Contractor’s discretion. All Piping Terminal Points shall have a position tolerance of 1” and an angular tolerance of 1°.

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3.2.3 Electrical and Control Terminal Points - The Contractor shall provide a skid mounted main power panel with a 3-pole molded case circuit breaker to interface with the Government-provided single power terminal point. Instrumentation and controls termination points shall be located at a single skid-mounted instrumentation and control terminal box.

3.3 Skid

3.3.1 Provide ADRP as a shop-assembled, complete package ready for installation on the foundation (provided by the Government), including all piping, valves, supports, instrumentation and wiring. Skid-mounted shop-assembly shall include motor drivers with starters for each piece of driven equipment (blower, compressor, heater(s), and valve actuators).

3.3.2 Skid structure shall be fabricated as a unitary frame using structural carbon steel.

The skid frame base shall be constructed of structural steel members with open ends capped and welded closed as necessary. Skid structure shall be braced as necessary, with the area underneath the assembly open enough to allow cleanup and maintenance access. Contractor shall demonstrate maintenance access as part of the submitted maintenance plan.

A. Provide anchorage brackets/plates for mounting on a concrete slab.

Brackets or anchor plates shall be located within the overall constraint envelope of the skid.

B. Submit connection details and recommendations for mounting the skid frame to the foundation. Include loads and how they are transferred to the foundation.

C. Provide lifting lugs located such that a level lift can be accomplished.

Permanently identify the load capacity (in pounds) on or near the lifting lugs.

D. Identify the total weight of the skid assembly on the steel frame.

3.3.3 All vent and drain valves shall be supplied by the Contractor. The Contractor shall route drain piping to the edge of the skid to interface with the Government’s piping.

3.3.4 The Government will provide ASME B16.5 class 150 raised face flanged inlet and outlet connections to the piping interfaces on the ADRP skid. Contractor shall coordinate with the Government representative to ensure inlet and outlet connections are compatible with the ADRP skid interfaces.

3.3.5 Preparation and Painting – Skid Structure

A. All welds, weld splatters, cutting scars, sharp points, and edges shall be ground smooth, providing a smooth, clean, sound surface prior to painting.

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B. Paint all exposed carbon steel surfaces of the skid with a minimum a suitable primer and of two full coats of epoxy paint to withstand temperatures up to 460 ⁰F. Submit paint system and color options to the Government for approval.

3.3.6 The Contractor shall include provisions for connecting skid to the Government's external ground grid. Provide NEMA 2-hole grounding pads located at diagonal corners of the skid structure. Ensure grounding pads are not painted and are protected from overspray.

3.3.7 All electrical equipment shall be electrically bonded to the skid structure grounding system. Instruments and control panels shall be bonded by connecting to grounded metallic conduit.

3.4 Equipment and Component Requirements

3.4.1 The Contractor shall identify, purchase or manufacture, design and assemble all mechanical items shown on the schematic in Appendix A and all other mechanical, electrical, control, and instrumentation components necessary to provide a complete and functional system.

3.4.2 Compressor

A. The compressor shall be capable of continuous operation, providing a minimum of 100 CFM of air to pressurize and the receiver to a minimum of 120 psig from ambient air. Compressor shall be oil-free. The maximum size of the compressor shall be 30 hp.

B. The compressor shall have inlet filters and moisture removal features per the manufacturer recommendations.

C. The compressor shall be completely assembled with a line reactor, motor, overcurrent protection, inlet air filter/silencer, and discharge silencer.

D. The compressor assembly shall be mounted and supported on the skid structure.

E. The compressor shall be located on skid such that connecting piping need not be dismantled for access to casing/housing internals.

F. Provide suitable coupling guards for all couplings, as well as all other guards necessary to eliminate safety hazards. Design coupling guards to meet 29 CFR 1910.219.

G. The compressor shall have an associated air receiver tank and a pressure regulating valve capable of providing makeup air to the skid. Compressor, receiver, and regulating valve shall be designed to provide the necessary makeup air during the cooling cycle to maintain a minimum system

Page - 8 pressure of 100 psig at the inlet of the blower. The receiver shall be 400 gallons, at a minimum, with a minimum design pressure of 150 psig. The air receiver shall be designed per ASME BPV Code Section VIII, Division 1, and shall be code stamped. The tank shall include features to drain moisture automatically, as well as appropriate pressure relief devices.

3.4.3 Blower

A. The blower shall be capable of continuous operation, providing 1,400 to 1,420 SCFM and a minimum pressure increase of 20 psi with 100 psig inlet air. The minimum output requirements of the ADRP, including pressure losses through piping and components, shall be 1,400 SCFM at 120 psig.

B. The air blower shall be completely assembled with variable frequency drive (VFD), motor, line reactor, overcurrent protection, and discharge silencer.

C. The blower-motor assembly shall be mounted and supported on the skid frame.

D. The blower shall be located on the skid such that connecting piping need not be dismantled for access to casing/housing internals.

E. Provide suitable coupling guards for all couplings, as well as all other guards necessary to eliminate safety hazards. Design coupling guards to meet 29 CFR 1910.219.

3.4.4 Cooler/Separator

A. Provide a water-cooled air cooler with separator as part of the ADRP. The cooler/separator shall reduce the circulated inlet air temperature to the blower. Design requirements for the cooler/separator are as follows:

Raw Water Inlet

Design Temperature

Air Inlet Temperature Maximum

Air Exit Temperature Maximum

Air Flow Rate

Cooler 85°F 450 to 460 °F +10 °F of Water Inlet

1,400 to 1,420

SCFM

Table 2. Cooler/Separator Design Requirements

B. Raw water supply and return will be provided by the Government via the interface points identified in Appendix B. Raw water will be provided at a

Page - 9 maximum temperature of 85°F, with a minimum inlet pressure of 67 psig and a maximum inlet pressure of 150 psig. For cooler design and performance evaluation, cooling water temperature shall be assumed to be at the raw water inlet design temperature.

C. Cooler/separator shall include a means for draining condensed moisture.

Make provisions for preventing the accumulation of entrained moisture during operation and furnish all equipment necessary to remove moisture.

D. Cooler/separator shall be designed, fabricated, tested, and marked in accordance with ASME BPVC Section VIII Division 1.

E. Cooler/separator shall be sized to remove a minimum of 5 gallons of water per hour from the circulated air stream during regeneration.

3.4.5 Heater(s)

A. The electric heater(s) shall be selected to heat ADRP blower effluent.

B. Heater(s) shell shall be code-stamped in accordance with ASME BPVC Section VIII Division 1.

C. The heater(s) shall be sized to heat the blower effluent to 450 to 460 °F for delivery to the ADRP outlet during the heating cycle when provided with 480 VAC, 3 phase power.

D. The electric heater(s) shall be electric resistance type and skid mounted.

E. The heater(s) shall include type K thermocouples welded to sheath for high temperature protection.

F. The heater(s) shall include all necessary instrumentation and controls to fulfill the design requirements.

G. Heater(s) shall include a silicon-controlled rectifier (SCR) to electronically adjust power applied.

3.4.6 Filters

A. Contractor shall provide at a minimum two filters as detailed in Appendix A; a high-temperature particulate filter on the closed loop inlet, and a coalescing filter downstream of the blower.

B. Particulate filter shall be rated for the maximum supply/return temperature of 460 °F.

C. Particulate filter filtration rating shall be 1 micron.

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D. Coalescing filter shall be rated to 0.5 microns or better filtration, and shall be capable of removing all oil that enters the air stream.

E. Provide a weather hood and screen to the compressor inlet filter.

F. All filter installations on the skid shall include bypass piping and isolation valves.

G. All filters shall include inlet and outlet isolation, drain, and vent valves.

H. Contractor shall provide one extra set of filter media/cartridges for each filter supplied.

I. All filters shall be designed such that they are removable and cleanable.

J. All filters shall include differential pressure transmitters across the filters to predict/plan preventative maintenance.

3.4.7 Piping and Valves

A. General

1. All piping/ducting, fittings, and valves shall be designed, fabricated, installed, and tested in accordance with ASME B31.3, Process Piping.

B. Piping

1. The Contractor shall design the ADRP pipework to meet the design pressure of 150 psig and design temperature of 460 °F. It is the Contractor’s responsibility to ensure proper design of the pipework in order to avoid blower cavitation or excessive fluid velocity and pressure drop. Fluid velocity shall not exceed 65 fps.

2. Pipe wall thickness shall not be less than schedule 40.

3. High point vents and low point drains shall be provided with accessible valves for all Contractor-furnished equipment and piping/ducting to allow venting and draining of the entire system.

All piping shall be sloped towards low-point drains to facilitate draining. Drains shall be freeze-protected.

4. All flanges shall be at minimum ASME B16.5 class 150 raised face.

5. All carbon steel used for piping, pipe supports, and miscellaneous structures shall be painted per section 3.3.5 of this specification.

6. Pipe supports shall be constructed of standard steel shapes, per the AISC Steel Construction Manual. Threaded rod supports are not allowed.

7. Pipe supports shall be attached to skid structure. Piping shall be supported in such a way as to allow for thermal growth and contraction without overstressing the pipe or damaging other structural components.

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8. All piping shall be routed to minimize interference with maintenance activities. Contractor shall include routing considerations on the submitted maintenance plan.

9. Piping design shall include sufficient pipe breaks to allow removal of equipment without ADRP system demolition.

10. All piping shall be identified as to content, pressure and direction of flow per AEDC SHE Standard D3.

11. All piping and piping components shall be flushed prior to operation of the system, including shop testing.

C. Valves

1. Contractor shall provide inlet, outlet, vent, drain, sampling, control, and instrument valves for proper operation of the system, including all valves shown in Appendix A.

2. Skid shall include a back-pressure regulating valve for thermal protection, sized to control system pressure to no greater than 105 psig at the inlet to the blower during heating cycle.

3. Valves shall be of the full line size, and accessible from ground level.

4. Provide a permanently attached handle and latching mechanism for positioning the valve for all manual valves NPS 6 and smaller.

Valve handles shall provide position indication for all manual valves. Actuators for all other valves shall be provided with a mechanical position indicator (rod or dial type).

5. Provide actuators mounted on valves with all adjustments and switch settings complete and checked for functional operation.

6. Fabricate, inspect and test all valves per the requirements of ASME B16.34.

7. Isolation valve seat leakage shall be in accordance with MSS SP- 61.

8. Valves less than NPS 2 shall have a stainless steel body and stainless steel internal components (balls, plugs, gates, and shafts).

9. Valves NPS 2 and larger shall have carbon or stainless steel bodies and internal components (balls, plugs, gates, and shafts) shall be stainless steel or have a corrosion resistant surface treatment.

10. All valves shall be lockable in the full open and full closed positions.

11. Ball and gate valves shall not be used for pressure and flow control.

12. Check valves larger than NPS 2 shall be of the swing check type.

13. All valves shall be suitable for the pressure and temperature they operate in but shall not be less than ASME B16.34 class 150.

14. All HPA isolation/block valves shall be full port ball valves for the piping in which they are installed.

15. Handwheels shall be furnished on those valves that do not have manual bypasses and where it shall be possible and safe to control the process by using a handwheel. Handwheels shall not be

Page - 12 provided where they can prevent automatic protective actions required of the valve. Handwheels shall have a diameter no larger than 24 inches and require no more than 30 lbs of rim pull to operate.

16. Control valves shall be designed to fail in a safe position. Raw water valves shall fail open. Air regulator shall fail open.

17. Valve open and close position switches shall be provided for all on/off-duty actuated valves. Valves shall include visual valve position indicator.

18. Submit a valve list detailing the size, type, materials, minimum design pressure, actuator function, manufacturer and model number for each valve.

D. Relief Valves

1. Provide relief valves at the outlet of the heater(s) to protect against blower head and at the air receiver, as shown in Appendix A.

2. Provide thermal relief valves on the water return for the cooler.

3. All relief valves shall be fabricated, inspected, tested, certified, and installed per the requirements of ASME BPVC Section VIII Division 1.

4. Relief valves shall be set at maximum 10% above the normal working pressure of 120 psig.

5. Relief valve discharge lines shall be vented in such a way as to not pose a hazard to nearby personnel.

6. Relief valves NPS 1-1/2 pipe size or larger shall be flanged with ASME B16.5 flanges suitable for the pressures and temperatures involved.

7. All relief valves shall be suitable for the system design pressure, flow and temperature, but shall not be less than ASME B16.34 class 150#.

8. Submit a list of all pressure relief valves detailing size, material, pressure setting, capacity, manufacturer, and model number for each relief valve.

3.4.8 Controls and Instrumentation

A. General

1. The Contractor shall supply instrumentation and control elements necessary to form a complete and working ADRP. Government will provide controller to control and monitor ADRP skid equipment.

2. All work shall comply with the latest edition of the NEC.

3. All control and instrumentation equipment shall be skid mounted to the extent possible.

4. Instrumentation, junction boxes, panel boxes, and control enclosures shall be water-tight, dust protected, and NEMA 4 as a minimum. The Contractor shall provide necessary arc suppression for skid mounted inductive loads. The suppression shall be

Page - 13 installed as close to the load as feasible. Running feedback shall be provided for all contactors.

5. All motor operated valves shall have at a minimum one spare open limit switch and one spare closed limit switch dedicated for use by the Government’s control system and wired to the Contractor’s instrumentation and controls interface junction box.

6. Control wiring shall occupy separate conduits from instrumentation wiring. Instrumentation wiring in control cabinets and panels shall be separated from power and control wiring.

7. Control and monitoring of all ADRP skid equipment will be performed by the Government’s controller.

8. Control power (24 VDC or 120 VAC) shall be separated from 480

VAC.

9. The ADRP shall include an emergency stop button on the skid to de-energize the system and allow shutdown safely. The emergency stop button shall be readily accessible from outside the skid and highly visible.

10. Control panels, cabinets, and junction boxes shall be furnished in a suitable manner to maintain internal temperatures within manufacturer’s limits for contained equipment. Heater(s), heat exchangers, and/or air conditioners shall be provided if necessary.

11. Electric valve actuators shall have local control capability including local/remote, open, and close functions.

12. Instruments and control panels shall be bonded by connecting to grounded metallic conduit.

13. Contractor shall submit a signal list. This shall include all analog and digital signals in electronic format (MS Access or Excel) with information on tag name, service description, process range, process units, voltage level, and signal range.

B. Interface Junction Box

1. The Contractor shall provide an interface junction box where all skid instrumentation and control wiring shall terminate on terminal blocks. Include all pressure and temperature measurements, valve commands and limits, heater(s) command, setpoint, and alarms, VFD command, setpoint, feedback, and alarms, etc.

2. The interface junction box panel insert shall include at least 25% unutilized area.

3. A separate set of terminals shall be provided for discrete signals, analog signals, and thermocouple signals. Provide at least 20% installed spare terminal blocks of each type used.

C. Instrumentation and Control Power

1. Source of field power for control element status and control signals shall be the individual control element control power transformer.

2. Provide individual circuit breakers for all accessories and each 120

VAC control power circuit.

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3. The Government will provide 24 VDC for analog signals at the Contractor’s interface junction box.

D. Heater(s) Controller

1. Contractor shall provide a controller for the heater(s) that includes a silicon-controlled rectifier capable of maintaining heater(s) discharge temperature within +/- 10 ⁰F across a temperature set point range of 400 to 450 ⁰F. An across-the-line contactor shall not be an acceptable means of controlling temperature. Overcurrent protection shall be included.

2. The controller shall receive a 4 to 20 mA set point command. The heater(s) shall provide heater(s) on/off status and at a minimum a general alarm contact. The controller shall disable heater(s) power in the event of heater(s) over temperature.

E. Compressor Controller

1. Compressor shall be wired only for on/off control.

F. Blower Controller

1. The Contractor shall provide a variable frequency drive capable of maintaining blower discharge flow of 1,400 to 1,420 scfm (out of the ADRP). The VFD shall meet IEEE 519.

2. The controller shall receive a 4 to 20 mA speed setpoint command and provide at minimum a general alarm output. The controller shall provide 4 to 20 mA motor frequency and motor current outputs.

3. Line side reactors shall be provided for the VFD.

G. Pressure Gauges

1. The pressure gauges shall be liquid filled and of the industrial type.

2. Pressure gauges shall be sized such that the normal system operating pressure shall fall within the middle third of the range.

3. Pressure gauges shall have male tapered pipe thread connections.

4. Pressure gauges shall be designed and manufactured in accordance with ASME B40.100.

5. Pressure gauges shall be installed with double block and bleed features such that the gauge can be safely removed and replaced while the system is in service.

6. All pressure gauges shall have a blow-out plug or case opening sufficiently sized to prevent rupture of the case. Pressure gauges with an operating pressure of 160 psig or higher are required to have a solid front and a blowout back, or equivalent. Blowout plugs are acceptable for a range less than 0-160 psig.

7. The pressure gauge face shall be as follows:

a. Acrylic or shatterproof glass.

b. 4-1/2 in. (110 mm) in diameter.

c. White with black markings.

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d. Dial-type.

e. Stainless steel case.

f. Provide linear indicating scales or digital readouts reading directly in lbs/in2.

g. Accuracy per ASME B40.100 Grade 1A (+/-1% of span).

H. Pressure Transmitters

1. Contractor shall provide pressure transmitters with integral 316 stainless steel two-valve instrument manifolds.

2. Contractor shall provide differential pressure transmitters with integral 316 stainless steel five-valve instrument manifolds.

3. Pressure transmitters shall have an accuracy of at least +/- 0.035% of span across their measured range.

4. Water pressure transmitters shall be gauge measurement.

5. Transmitters shall have a 316L stainless steel diaphragm.

I. Flow Transmitter

1. Contractor shall provide flow transmitters.

2. Flow measurements shall have a minimum accuracy of +/- 2.0% of flow across their measured range.

J. Temperature

1. Provide spring-loaded, grounded junction thermocouples with weatherproof aluminum head, internal grounding screw, and external ground terminal. Provide test thermowells with a brass or bronze plug or cap permanently attached with a chain or wire and with lagging extensions where required.

2. If a thermocouple is inaccessible, the leads shall be brought to a junction box in an accessible location. The thermocouples and extension wire shall be manufactured and shall comply with the standard limits of error according to the latest edition of ASTM E230 (IEC 60584-1) and shall be applicable to the appropriate temperature range. Initial tolerances shall be per “Special Tolerances” of Table 1 of ASTM E230 (Tolerance Class 1 of Table 12 of IEC 60584-1).

3. All thermocouples shall be type T with the exception of the heater(s) thermocouples which shall be type K. Thermocouples shall have stainless steel sheathed elements, spring loaded to provide good thermal contact with the thermowell. All connection heads shall be weatherproof equivalent to NEMA 4, with screwed covers, and supported from the well by an extension nipple.

4. Thermocouples shall terminate in the instrumentation and control interface junction box on terminal blocks of the same alloys as the thermocouples.

5. Provide bimetallic, any-angle, minimum 4 in. nominal, dial thermometers with white face and black scale marking.

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K. Instrumentation

1. Gauges shall be visible from the operator’s normal stance at skid or floor level.

2. Instruments shall be located where they are accessible for normal operation and maintenance and can be easily read from walkways.

Instruments shall be oriented so that controls, dials, or displays are upright and facing in a direction for easy readability.

3. Instrument installations shall consider maintenance access.

Sufficient flexibility shall be left in instrument installations to permit instrument removal without damaging the tubing installation or the instrument.

4. Pressure and temperature indicator scales shall be such that the normal readout of the indicator shall be between 1/3 and 2/3 of the scale.

5. Provide all pressure and temperature switches with DPDT (Double Pole Double Throw) (two form c) contacts except where the high deadband of DPDT switches is unacceptable for the application.

Switch actuation point shall be in the center one-third of the instrument range.

6. Calibration certificates shall be provided for all instrumentation. The certificate shall document proof of measurement traceability to the National Institute of Standards and Technology (NIST).

7. Transmitters shall have a 4 to 20 mA output with HART protocol.

8. Transmitters shall have field adjustable zero and span.

9. Transmitters shall have an integral LCD display.

3.4.9 Electrical Power

A. Low voltage induction motors shall be in accordance with the data sheet in Appendix C.

B. All work shall comply with the latest edition of the NFPA 70.

C. All overcurrent protection shall be provided in accordance with the latest edition of the NFPA 70.

D. Minimum short circuit ratings for 480V equipment shall be 65kA, and for 120V equipment shall be 22kAIC.

E. All electrical equipment shall be electrically bonded to the ADRP structure grounding system.

F. All electrical equipment and components, including grounding and bonding materials, shall be UL listed.

G. Provide control panel wiring and workmanship, in compliance with UL 508.

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H. Provide transient voltage surge suppression to protect all power and control systems. Surge suppression shall meet the requirements of UL 1449.

I. Operating temperature range shall be -10 ⁰F to 140 ⁰F. Conform to NEMA ICS 7 service conditions during and after installation.

J. The Government will provide one 480V three-phase, three-wire service to the skid. The service conductors will be delivered to and terminated by the Government at a skid mounted main control panel circuit breaker disconnect. Provide terminal shields for IP20 ingress finger protection.

Provide space for Government routing of overhead conductors and conduit sweeps for bottom or side entry into the main termination point.

No top entry into enclosures will be allowed.

K. The main circuit breaker disconnect shall disconnect all 480V power on the skid. Provide a push to test “POWER ON” pilot light mounted on the door.

L. The Contractor shall be responsible for all interconnecting wiring to distribute power to all electrical equipment located on the skid.

M. All wiring shall be copper conductors.

N. All wiring terminations and cable identifications shall match the skid wiring diagrams.

O. Electrical Enclosures:

1. All electrical enclosures shall be weatherproof and in accordance with the NFPA 70. Enclosures shall be sloped from front to rear side to prevent standing water on the top and channel water from the front side of the enclosure.

2. Provide a copper grounding bar or plate mounted inside the enclosure. The ground bar shall be bonded to the enclosure doors.

3. Power distribution blocks shall have finger-safe terminals.

4. Low voltage terminal blocks shall be rated for 600VAC. Furnish 20 percent spare terminal blocks in each enclosure.

5. All pushbuttons, pilot lights, relays, and switches shall be heavy duty NEMA Type 4. Control terminal blocks shall be rated for

600VAC.

6. Provide interior LED lights and door switch to activate the lights when the enclosure door is opened. Provide thermostatically controlled anti-condensation strip heaters. Provide cooling equipment for the SCR control enclosures and VFD control enclosure.

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7. Provide circuit breakers for isolation of all 120V power. Provide circuit breakers for all accessories and each 120VAC control power circuit.

8. Provide separate low voltage transformers for control power and utility power.

P. Electrical raceway systems shall be in accordance with the NFPA 70 and of a material suitable for the application. All fittings shall be gasketed and oriented to preclude entry of water and chemicals. Conduit shall be galvanized steel rigid conduit. Where flexible conduit is required, liquid-tight flexible metal conduit shall be used. Minimum conduit size shall be ½".

Q. Each cable shall be identified by a unique number-letter combination.

Each conductor shall be identified by a number, letter, or number-letter combination. Each cable and conductor shall have the same identification at all terminals and tie points. All cables and conductors connected to the same terminal or tie point shall have the same identification. Where multiconductor cable is used, a color code may be used to supplement identification. Where color-coded multiconductor cable is used for wiring identical components, such as limit switches, the color code shall be consistent.

R. Conduit shall be labeled to clearly indicate size, type, and cabling contained within.

S. Cable trays shall be identified by a unique number-letter combination detailed on nameplates of noncorrosive material, affixed to the tray at a minimum of every 20 ft. and/or at all transition points.

T. Motor Operators for Valves

1. Provide electric motor actuators for valves as shown in Appendix

A or as necessary for safe operation of the equipment.

2. Provide valve electric motor actuators suitable for the environmental conditions specified in Section 3.1.1.

3. Provide valve electric motor actuators suitable for intermittent operation.

4. Provide valve electric motor actuators suitable for mounting in any position (horizontal, vertical, or intermediate). Provide necessary greasing and lubrication.

5. Motor horsepower and torque ratings shall be as specified by the valve manufacturer, rated within +/-5% of 480V. Motor torque shall be capable of stroking the valve at maximum differential pressure at the specified temperature range.

6. All gearing shall be the self-locking type.

7. Motors shall meet requirements of NEMA MG-1 for design, construction and performance for the application.

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8. Treat motor windings so that the insulation is moisture resistant.

9. Motor winding insulation shall be minimum Class F with temperature rise limited to Class B.

10. Design the valve electric motor actuator to withstand stalled torque at maximum voltage to protect against torque and position switch failure.

U. Provide motor starters for all motors.

V. Motors shall be totally enclosed fan cooled (TEFC) or totally enclosed nonventilated (TENV).

W. Contractor shall submit an electrical load list, tabulating the following:

1. Hp, voltage, and number of phases.

2. All motors (load in hp) and heaters (load in kW).

3. All variable speed drives (load in kW).

4. All motors and 120V vital AC loads.

5. KVA requirements.

3.4.10 Fabrication

A. General

1. Furnish all equipment finished and free of burrs and fins.

B. Materials

1. The ADRP shall be constructed using all new materials, parts, and equipment of current manufacture that are free from defects affecting performance or appearance.

2. The ADRP shall not use asbestos or asbestos-containing materials.

C. Welding

1. All welding of piping; welding procedure qualifications; welding material; preheat; postweld heat treatment; and welders’ performance qualifications shall be in accordance with ASME B31.3.

2. All structural welding, welding procedure qualifications, welding material, preheat, postweld heat treatment, and welders’ performance qualifications shall be in accordance with AWS D1.1.

D. Nameplates

1. Provide nameplates for each item of equipment, each enclosure, and for cable trays in the ADRP. Nameplates shall show the equipment, serial number, and service conditions. Nameplates shall be completely visible after complete assembly of the ADRP.

a. Equipment nameplates shall be constructed of brass or stainless steel.

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b. Enclosure nameplates shall be engraved plastic. Equipment mounted in the panel or sub-panels shall be uniquely labeled for ease of identification.

c. Cable tray nameplates shall be constructed of noncorrosive material identifying cable tray number. Nameplates shall be affixed to tray at minimum of every 20 ft. and/or at all transition points.

2. Contractor shall identify all devices with a permanent tag (e.g.

brass, stainless steel, lamacoid, etc.) engraved or stamped with a unique identification number. Contractor shall coordinate with the Government Representative to determine device identification numbers for all devices.

3.5 Submittals

3.5.1 Contractor shall submit the following drawings:

A. Equipment and Skid Piping drawings including the following details:

1. Overall dimensions of the ADRP shown on plan and elevation views.

2. Anchorage brackets and connection details to the slab including bolt hole locations.

3. Location, size, and capacity of lifting lugs necessary to accomplish a level lift.

4. Location of blowers, compressors, tanks, valves, traps, strainers, instrument connections, and other components on the piping drawing.

5. Location of all Government/Contractor interface points (plan and elevation).

6. Locating dimensions with respect to the elevation or centerline of equipment.

7. Piping support location and details on the skid.

8. Calculated bolt torques for all flanges.

9. Allowable loads for all nozzles and interface connections.

10. Identification of piping, valves, and equipment.

B. Piping and Instrumentation Diagrams, including the following:

1. Identification of all instruments and interfaces for each device.

2. Identification of all piping, valves, coolers, compressors, and blowers.

3. Identification of all pipe sizes, materials, schedule, insulation, pressure class breaks, and terminal points.

C. Foundation Interface Drawings, including the following:

1. Anchor bolt hole locations, sizes, and details.

2. Final assembly weight.

3. Operating loads and frequencies.

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D. Final Assembly and General Arrangement Drawings of the completed ADRP skid, including the following:

1. Overall / outline dimensions (plan and elevation).

2. Identification of all access, pull space, and maintenance requirements.

3. Identification of all shipping packages (one expected) and their weights, lifting points, lifting capacity of each lug, and centers of gravity.

E. Cabinet General Arrangement plan, including the following:

1. The general arrangement of each cabinet (internal and external) including overall dimensions, weight, instrument layout, mounting and/or hold down requirements, and heat loads.

2. Cabinet Wiring Drawings – including outline dimensions of all equipment, equipment mounting details, required clearance, weights, cable entry areas, terminal block arrangements and rack locations.

3. Front view including all lights and switches with color, all tagging/labeling, and panel NEMA or IEC rating identified.

F. Electrical Diagrams, including the following:

1. Electrical equipment layout drawings that detail the physical location for termination of incoming Government-provided power, junction boxes, motor control panels, heater control panel(s), and transformers.

2. Contact development for all control switches.

3. One-line, three-line, schematic, and wiring diagrams for the skid electrical equipment showing primary and secondary circuits, contractor wiring, and locations for field wiring connections.

4. Panel arrangement drawings – layout of devices on the panel doors and interior panels.

5. Detailed schematics showing all lights, switches, controllers, relays, timers, etc., associated with systems control circuit.

6. Conduit identified by number, letter, or number-letter combination.

7. Cable trays identified on drawings per affixed nameplate.

8. All voltage and current ratings.

3.5.2 Provide submittals in accordance with Table 3 below and Appendix D - Submittal Procedure. In addition to the submittals identified throughout this specification, provide the following for all components and equipment:

A. Contractor shall submit component datasheets for all components, including ISA S20 or equal forms for all instrumentation. Contractor shall include the following:

1. Compressor datasheets and performance curves.

2. Blower datasheets and performance curves.

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3. Heater(s) datasheet and U-1 Form.

4. Heat exchanger datasheet and U-1 Form.

5. Filter datasheets.

6. Relief valve datasheets.

7. Control valve and regulator datasheets and sizing forms.

8. Air receiver datasheet and U-1 Form.

B. Contractor shall submit a detailed parts list, and a recommended spare parts list required for routine maintenance.

C. The Contractor shall submit Operation and Maintenance (O&M) Manuals for all equipment on the ADRP.

3.5.3 Contractor shall provide an analysis package demonstrating that the design satisfies all requirements specified herein to the Government for approval prior to fabrication. Analysis package shall include, at a minimum, calculations and analysis, per applicable codes, for the following:

A. Piping flexibility analysis.

B. Structural analysis of pipe supports.

C. Pipe sizing calculations.

D. Pipe wall thickness calculations.

E. Relief valve sizing calculations.

F. Heat transfer calculations for the heater and cooler.

G. Bolt torque calculations.

H. Structural analysis of Skid frame.

I. Control valve, regulator, filter, and other equipment sizing calculations.

Table 3. Required Submittal List

No. Section Reference Description Due 1 3.3.2 Maintenance Plan 90 days after award 1 3.3.5 Paint Samples Before equipment purchase 2 3.4.5.C Filter Media Cartridges With ADRP 3 3.4.6.C.18 Valve List 120 days after award 4 3.3.6.D.8 Pressure Relief Valve List 120 days after award 5 3.4.7.A.13 Signal List 90 days after award 6 3.4.8.W Electrical Load List 90 days after award

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7 3.5.1.A Equipment / Skid Piping Drawings

90 days after award

8 3.5.1.B Piping and Instrumentation Diagrams

30 days after award

9 3.5.1.C Foundation Interface Details 90 days after award 10 3.5.1.D General Arrangement

Drawings 30 days after award

11 3.5.1.E Cabinet General Arrangement and Front View

110 days after award

12 3.5.1.F Electrical Diagrams 110 days after award 13 3.5.2.A Component Datasheets for

Instrumentation 120 days after award

14 3.5.2.B Parts List and Recommended Spare Parts List

120 days after award

15 3.5.2.C O&M Manuals 120 days after award

3.5.3 Analysis Package 120 days after award

16 4.1 Verification and Validation plan

110 days after award

17 4.3.1 Pressure Test Report After Pressure Test 18 4.3.1 Functional Test Report After Functional Test 19 Appendix C Motor Datasheet 45 days after award 20 Appendix D 1.2B Summarized submittal listing with delivery dates 14 days after award

4 VERIFICATION

4.1 The Contractor shall submit a verification and validation (V&V) plan for Government approval to verify that all the requirements have been met and demonstrate the system can operate to meet the performance spec. The V&V plan shall include verification for all components and systems. Verification may consist of analysis, inspection, demonstration and testing.

4.2 The Contractor shall submit documents for the Government's review in accordance with Appendix D.

4.3 Factory Testing

4.3.1 The Contractor shall perform all factory acceptance testing required per ASME B31.3, including inspection and pressure testing. The Contractor shall, at a minimum, pressure test all fabricated components. The Contractor shall provide all power to perform all required testing and checkout. Government reserves the right to witness any pressure testing done by Contractor or Subcontractors/Suppliers and shall be notified a minimum of two weeks prior to the date of the pressure test. All inspection and pressure testing documentation

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A. Air Dryer Regeneration Package – Mechanical Run Test

1. Assemble regeneration package and perform a mechanical run test in the Contractor’s shop.

B. Air Dryer Regeneration Package – Functional Test

1. Perform functional tests on the instruments and control elements before shipment, including the following:

a. Each control element shall be energized and tested for proper operation.

b. Motor valves shall be moved electrically to full open and full closed positions and checked for correct movement and limit switch adjustment and operation.

c. A 4 to 20 mA source shall be used via the VFD to vary blower motor speed from zero to motor rated full speed. Controller frequency and speed outputs shall be verified.

d. A 4 to 20 mA source shall be used via the SCR to vary heater(s) output from zero to heater(s) rated maximum wattage. Heater(s) on/off status output shall be verified. The sheath thermocouple shall be heated to heater(s) manufacturer’s recommended maximum temperature to ensure the heater(s) controller trips power to the heater(s) and provides the associated alarm.

e. All…