Attachment 1 - Salient Characteristics.pdf

Atachment 1 – Salient Characteris�cs FA524023Q3012 – Mobile Air Compressor

Salient Characteristics for Mobile Air Compressor

SCBA fill system that meets or exceeds the requirements of CGA Pamphlet G-7, Compressed Air for Human Respiration, the requirements of ANSI/CGA g-7.1, Commodity Specification for Air, Grade E, and all other recognized standards for respirable air. The complete system shall be built by the same manufacturer and comprised of a high-pressure compressor with prime mover, purification system, system control panel, storage system, fill station and a highway rated trailer. The Manufacturer shall operate under a Quality Management System which complies with the requirements of ISO 9001:2015 for the design, manufacture, inspection, test, and service of air & gas compressors and associated spare parts for commercial and military applications. The station shall be designed for a maximum working pressure of 6,000 PSIG. All equipment shall be new and of current design and manufacture. Used or refurbished equipment is unacceptable.

*Trailer Mounted Compressor System 6000-PSI Service

- High Pressure Compressor

- Prime mover provided with integrated control circuits

- Purification System

- System Control Panel

- Storage System

- Air Control Panel

- 2 position SCBA fill station

- Highway rated Trailer

*Standard Features

- Full compressor instrumentation complete with a gauge for each stage of compression, an oil pressure gauge and hour meter.

- Diesel Engine

- On/Off Switch

- AC/DC Switch

- Operations and fill station panel light for night ops.

- Air Pressure switch (speed reduction at pressure

- Compressor shall be equipped with a low oil pressure and high temperature shutdown switches and indicator lights

- Diesel engine shall be equipped with low oil pressure and high temperature shutdown switches with a common warning light

- Pressure Maintain Valve

- Diesel engine Inlet filter restriction Indicator

- Automatic condensate drain complete with combination separator/muffler, drain solenoid timer, condensate reservoir, level switch and drain hose.

- Electronic purification system monitor with shutdown

- Carbon monoxide monitor calibration kit including 20 ppm and Zero Gases

- Two position NFPA compliant containment type fill station

- Two fill hoses complete with bleed valves and SCBA fill adapters of choice

- Single axle, two wheel, heavy duty highway rated trailer

- Emergency stop switch

- Two (2) DOT air storage cylinders with dual function cascade controls operable by a single valve per bank

The complete compressor/purification/storage system shall be provided on a steel frame bolted to the trailer’s steel frame. The system shall be completely enclosed in a weather resistant enclosure. The enclosure shall provide access panels for operating, servicing and routine maintenance. All control valves, gauges and warning indicators necessary for the operation and control of the system shall be mounted in such a way that they are readily accessible and visible to the operator. Any and all shutdowns and abnormal functions of the compressor or purification system shall be immediately indicated by fault lamps. The compressor is designed for ambient operating temperatures between 40°F and 115°1F.

*Compressor

The compressor shall be an air-cooled, oil lubricated, five stage, four cylinder, single acting, reciprocating compressor. The second and fourth stage of compression shall share one common stepped cylinder. The crankcase shall be cast of a high strength, aluminum alloy. The crankshaft shall be of a single piece Nodular graphite Iron construction, and supported in the crankcase by three long-life roller bearings. The connecting rods shall be of single piece design and constructed of a high strength aluminum alloy. Each connecting rod shall incorporate a roller bearing at the crank end and needle bearing on the pin end. The pistons shall be constructed of an aluminum alloy. Piston rings on the first through fourth stage are of cast iron; fifth stage rings shall be of a high strength polyimide. The final stage shall incorporate a ringed, free-floating, aluminum piston, which is driven by a guide piston and the previous stage’s discharge pressure. The cylinders shall be of cast iron construction with deep cooling fins on the external surface for optimum heat dissipation. The cylinders shall be arranged in a dynamically balanced, diametrically opposed “X” configuration with each cylinder located directly in the cooling fan’s blast. The cylinders shall be removable from the crankcase. The compressor’s flywheel shall be cast iron. A multi-wing, high velocity cooling fan shall be integral to the flywheel. The fan wings shall be replaceable.

An intercooler shall be provided after each stage of compression and an aftercooler shall be provided after the final stage of compression. The coolers shall be individually detachable from the compressor, located directly in the cooling fan’s blast and made of stainless steel. The aftercooler shall be designed to cool the discharge air to within 18°F of ambient temperature. A cool-down cycle shall not be required prior to stopping the compressor.

A separator shall be supplied after the second, third and fourth stages of compression, and a coalescing separator shall be supplied at the discharge of the compressor. An automatic condensate drain (A.C.D.) system shall be supplied for all of the separators. The drain solenoids shall be controlled by the Programable Logic Controller (PLC) and factory preset to drain the separators approximately every fifteen minutes for approximately six seconds. The A.C.D. system shall unload the compressor on shutdown for unloaded restart. An exhaust muffler and condensate reservoir shall be supplied. The condensate reservoir shall have a high liquid level indication system to provide system shutdown and to alert the operator that the condensate reservoir is at capacity. The operator shall be alerted that the reservoir is at capacity via a visual indicator light and equipment shutdown. Manually operated valves shall be supplied to override the automatic operation of the A.C.D. system for test and maintenance purposes.

The compressor shall be lubricated by a combination splash and low pressure lubrication system. The final stage of compression shall be lubricated by a pressurized lubrication circuit. The other stages and the driving gear shall be splash lubricated. The pressure lubrication circuit shall include a positive displacement oil pump, gear driven by the crankshaft, and a non-adjustable oil pressure regulator and full flow replaceable oil filter.

A highly visible sight glass shall be included to check the oil level. The oil drain for the compressor shall be provided with an isolation valve and hose.

The compressor shall be equipped with an inlet filter with replaceable particulate elements and fitted with a maintenance indicator.

*Prime Mover

Drive belts shall be equipped with self-tensioning idlers. A unique de-tensioning devise shall be provided that precludes the need for shifting the compressor or both primary movers.

The scope of supply for the prime mover shall be as follows:

Diesel Engine

— The system shall be equipped with a water-cooled 27 HP diesel engine

— Electric start, 12 volt D.C.

— Fuel filter/fuel pump and sediment bowl

— Oil filter

— Alternator

— Voltmeter

— Speed control solenoid

— Electric clutch

— Inlet filter, replaceable element type with DP Indicator

— 8-gallon fuel tank with fuel gauge

— Battery and enclosure

— Glow plugs

— High temperature switch

— Low oil pressure switch

— Bearing supported output shaft

— Exhaust muffler with spark arrestor

— Fuel consumption shall be approximately 8-gallons per 4.3-hour period.

*Electrical Control

The electrical panel installed in the NEMA enclosure shall be built in compliance to UL’s Industrial Control Panel Custom Builders Program, UL 508A, and shall be affixed with a U.L. label.

The PLC compressor control system consists of a programmable logic controller for the monitoring, protection and control of standard compressor systems.

Standard features include:

– A NEMA Type-4 enclosure

– Ignition Switch

– On / off selector switch

– Emergency stop

– Warning and alarm indicator lights o All lamps shall be as a minimum 22 mm diameter o Lamp test function built in o Lamps will flash code representing faults and warnings

– Built in overtime timer set at 5 hours

– Final separator counter warning and alarm functions

– Full support of SECURUS warning and alarm functions

– Full support of CO monitor alarm functions

– UL listed panel

– Compressor hour meter

– LCD voltmeter

– Control power fuses with blown fuse indication shall be provided

One nonresettable hour meter shall be supplied to record the number of compressor operation hours. The hour meter shall be installed in the instrument panel.

The compressor oil pressure shall be monitored by a pressure switch and pressure gauge installed locally on the compressor. The compressor shall shut down and a fault code will flash should the compressor’s oil pressure drop below the factory preset value during operation. The oil pressure switch shall be by-passed during start-up to permit the oil pump to achieve the normal operating pressure.

A temperature switch shall be supplied on the final stage head of the compressor. The compressor shall shutdown and a fault light code will flash should the final stage discharge temperature exceed the tamper-proof set point during operation.

For ease of system diagnosis and maintenance, the low oil pressure and high pressure air shutdown switches shall be equipped with DIN type connectors. Additionally, all of the wiring shall be color coded and encapsulated within a split corrugated type loom. Each wire end connection shall be machine crimped.

Two warning lamps shall be provided to annunciate flash codes, one amber and one red.

Each fault light shall be labeled as to the fault.

* Purification System

The purification system shall purify high pressure air to a quality that meets or exceeds the requirements of CGA Pamphlet G-7, Compressed Air for Human Respiration, ANSI/CGA G-7.1, Commodity Specification for Air, Grade E, and all other recognized standards for breathing air. Purification shall be achieved by mechanical separation of condensed oil and water droplets, adsorption of vaporous water by a desiccant, adsorption of oil vapor and elimination of noxious odors by activated carbon and conversion of carbon monoxide to respirable levels of carbon dioxide by catalyst.

The high pressure purification chambers shall have a working pressure of 6000 PSIG.

The purification system shall utilize replaceable cartridges. The purification system shall process 150,000 cubic feet of air prior to purification cartridge replacement. The purification system shall be designed so that the replacement of the cartridges can be accomplished without disconnecting system piping. The design of the chambers shall preclude the possibility of operating the system without cartridges installed or with improperly installed cartridges. Each purification cartridge shall be constructed utilizing an anodized aluminum shell to inhibit corrosion. A bleed valve shall be provided to vent the purification system to facilitate replacing the cartridges. A pressure maintaining valve and a check valve shall be supplied downstream of the purification system to increase the efficiency of the purification system by maintaining a positive back pressure.

A check valve shall be supplied between the coalescing separator on the compressor’s discharge line and the purification system to maintain the positive pressure in the purification system when the compressor shuts down.

Per NFPA 1901, A piping connection shall be provided downstream of the pressure maintaining valve to provide an air sample for the air quality monitors.

The purification system shall include a Securus®5 Electronic Moisture Monitor System.

A sensor shall be located in the Securus purifier cartridge for direct monitoring of moisture levels. A display module shall be supplied to indicate the status of the Securus cartridge. Securus system shall warn the operator, in advance, of the impending expiration of the Securus cartridge. The compressor shall shut down automatically should the operator fail to change the Securus cartridge within the warning period. The compressor shall not be capable of restarting until the used cartridge is replaced with a new one6. The moisture monitoring system shall be of a fail-safe design. For absolute safety and highest quality breathing air, no manual override shall be supplied for the moisture monitor.

The unit shall be equipped with an electronic carbon monoxide monitoring system. The system shall be designed to provide continuous monitoring of the carbon monoxide levels in the processed breathing air and shall shut the compressor system down if the monitor detects trace elements of carbon monoxide in excess of 10 ppm. Along with system shutdown, the panel mounted fault indicator shall illuminate upon high CO. The instruments electronics shall be encased within a NEMA 4X polycarbonate enclosure.

The case is corrosion resistant, positively pressurized by the compressor air supply line, and sealed except for a bleed hole to exhaust the compressor’s processed air. The unit shall operate on system voltage. Along with a built in flow meter, the system shall include an illuminated display and internal switches to check the system circuitry.

There shall be no calibration adjustments or controls as the system functions are managed by the system microprocessor. The chemical cell shall have a life expectancy of approximately two to three years with a calibration period recommendation of every 30-days. The system shall include two cylinders of test gas; 20-ppm carbon monoxide and zero test gas. Additionally a regulator shall be provided. Recalibration shall only require the following:

- Shut off the compressor supply line. If the operator fails to close the valve a prompt on the monitor display shall indicate, “Supply Off”.

- Connect the test gas to the cal port connector on the instrument

- The monitor display will read “Cal Gas” and shall automatically initiate a 60 second countdown.

After the unit has automatically calibrated itself, a message will appear “CO G Set” indicating that the CO adjustment has been set for 20 ppm.

*Storage System

The air storage system shall include two high pressure, DOT code stamped vessels. The vessels shall be mounted inside the trailer enclosure in a horizontal configuration in such a way that they are accessible for periodic inspection. Each vessel shall have a capacity of 509 cu ft at 6000 PSI. To comply with OSHA 29 CFR 1910.169, each pressure vessel will have an indicating pressure gauge.

*Control Panel

The system control panel shall be illuminated by a 12 volt, lighting fixture for nighttime operation and include the following standard features:

— Four air storage bank gauges

— Dual function four bank cascade controls

— A storage refill port and valve per NFPA 1901 with CGA connection shall be provided

— A system air direction valve shall be provided to allow the system operator to select “filling from storage” or “filling from the compressor”

— Inlet pressure gauge

— Adjustable pressure regulator

— Regulated pressure gauge

— Two SCBA (2) fill control valves

— Two SCBA (2) fill pressure gauges

— One (1) relief valve for regulated fill pressure

— Engine controls

— Cover to protect the system controls from road debris and or inclement weather

*Two Position Containment Fill Station

A front-loading, two position, containment type fill station shall be provided and located at the rear of the trailer. The fill station shall be built and tested to conform to NFPA 1901. The fill station shall totally enclose the SCBA cylinders during the refilling process. The fill station will vent the expanding air away from the operator and contain the fragments of a ruptured cylinder in the unlikely event of a bottle failure while being filled.

The fill station’s outer enclosure and door assemblies shall be constructed of formed ¼ inch thick plate steel. Venting shall be provided in the bottom of the fill station to allow the rapidly expanding air from a ruptured cylinder to escape from the fill station. The fill station shall be ergonomically designed for maximum operator convenience and safety for refilling cylinders. The fill station door and cylinder holder assembly shall tilt out towards the operator 89 degrees, providing unobstructed access to the cylinder holder to load and unload the cylinders. A handle and heavy-duty gas spring shall be incorporated into the design of the fill station to assist the operator in opening and closing the fill station door. It shall take approximately eighteen pounds of effort to open or close the fill station door thereby eliminating operator fatigue.

Each cylinder holder shall be lined to prevent scuffing the outer surface of the SCBA cylinders. For complete operator protection, the fill station shall include a safety interlock system that will prevent refilling SCBA cylinders unless the fill station door is closed and secured in the locked position. The automatic interlock will require no actuation of secondary latching mechanism on the outside of the fill station.

Two fill hoses shall be located within the fill station. Each fill hose shall be equipped with a bleed valve and SCBA fill adapter of choice. Fill hose retainers shall be provided to anchor the fill hoses when not in use.

A fill control panel shall be installed on the front of the fill station. The control panel shall be factory piped and designed to fill two SCBA, up to 30” in length, either independently or simultaneously.

*Trailer

All of the components shall be mounted to a heavy duty, highway rated trailer. All of the components shall be sheltered from the elements by a weather resistant enclosure. Door panels are to be opened during the operation of the compressor to facilitate ventilation of the enclosure and equipment.

The Following Features Shall be Incorporated onto The Trailer

— Single torflex axle, two wheel chassis

— 5,000 lbs GVW

— Hydraulic surge brakes with break away actuator

— 2” Ball Coupler (Lunette eye hitch available)

— Red exterior powder coat top coat finish (optional colors are available)

— DOT required lights with a four-pin connection point shall be provided.

— Fenders

— Maximum towing speed of 55 MPH

— Safety chains

— Weight-load matched radial tires

— Tongue jack

— Chrome plated wheels

— Completed unit shall weigh approximately 4600 lbs and have a 370 lbs tongue weight

— when equipped with four (4) each 6000 psi DOT air storage cylinders.

— Completed unit shall weigh approximately 5500 lbs and have a 450 lbs tongue weight

— when equipped with four (4) each 6000 psi ASME air storage cylinders

Include cabinet interior lighting and a 75-ft high pressure hose reel. The lighting shall consist of two (2) 12-volt lights strategically located within the enclosure, for maximum illumination. The hose reel feature shall consist of a spring rewind hose reel, remote fill hose connection including adjustable regulator for up to 6000-psi service, panel mounted pressure gauge and operations panel mounted service valve connected to a cabinet enclosed hose reel with 75-feet of hose rated for 6000 psi.

*Virtual Training

— Virtual Training on basic use and operation of Mobile Air Compressor

— 2-day virtual training after arrival of the Mobile Air Compressor

— Training days will be for A-shift and the other training day will be for B-shift

The Mobile Air Compressor must be fully assembled and ready for use when it arrives on Guam. Contractor must have a passed Air Sample before shipment in accordance with NFPA 1989 chapter 5.1. This ensures that the Mobile Air Compressor produces breathable compressed air for Andersen FD Firefighters.

Shipment/Delivery Information:

Andersen Fire Station 1 Bldg. 17002 Arc Light Blvd.

Yigo, Guam 96929