Attachment 1 SOO B252 Environmental controls 8 Jan.pdf

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STATEMENT OF OBJECTIVES

FOR

Building 252 Paint Booth #1

NELLIS AIR FORCE BASE, NEVADA

8 January 2025

OFFICE OF THE BASE CIVIL ENGINEER

NELLIS AIR FORCE BASE, NEVADA

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STATEMENT OF WORK

1. OVERVIEW: The existing environmental controls and HVAC system at building 252 paint booth #1 is not sufficient for current OSHA requirements and is beyond its expected life span. The Existing Booth has an approximate 1200 square foot cross sectional area. The existing booth is uninsulated and has a 100% outside air (OA) design at approximately 75 Feet per Minute (FPM) if averaged over the 1200 sqft. To increase the airflow through the booth to an average of 100 FPM this will require 120,000 total Cubic Feet per Minute (CFM). The equipment is to be located (Behind the Paint Hangar Building) is insufficient to locate a 100% (OA) design. The system should be converted to a paint booth with 33/67 recirculation design. This is a turnkey project. All supporting work such as demolition and removal of equipment, piping, ducting, concrete pads, concrete curbing etc., and the addition or modification of equipment, piping, ducting, concrete pads, curbing, etc. will be covered under the contractors work.

SCOPE: Provide the following replacement equipment for 252-1 Paint Booth to include removing all old equipment.

1) Modification Equipment

a) 1ea. New Exhaust Plenum:

i) new structural steel for the new updated exhaust plenum

ii) New plenum walls will be constructed of 20ga panels fabricated from dual-skin 20 gauge, 2 ½” insulated

iii) New 3-Stage NESHAP Filter Grid

(1) Exhaust filter face velocity will be increased to150-164 FPM

iv) New Carbon Filter grid

(1) Carbon filter grid will ONLY be provided for the Exhaust to Atmosphere discharge

(2) The Recirculation air will not be carbon filtered

v) New LED exhaust chamber lighting

vi) New recirc/exhaust air internal plenum divider walls (Carbon Section)

vii) New Plenum access doors (2’6” x 7’)

viii) New Exhaust 3-Stage Filters (Blanket stg 1)(20x20 stg 2,3)

ix) Carbon Filters (20x20X3)

b) 2 ea. Backward Curve USF, or equivalent exhaust fan(s) (19850 CFM each @ 7.5” SP) with 40 HP 480v/60/3 TEFC motor(s). USF fans are designed for maximum performance at higher static pressures and higher air volumes. The housings are constructed of continuously welded heavy gage steel, to assure no air leakage. The exhaust fans will be located outdoors.

c) 2 ea. Exhaust air energy recovery coil boxes (EAER).

i) Outdoor heat recovery coil boxes.

ii) G-90 Galvanized exterior and internal liner (unpainted)

iii) Outdoor Insulated

iv) Run around coil will lay horizontal, like a bed in the middle

v) 8” high base for rain water isolation from ground

vi) Box to be approximately 5’4” wide 10’8” long 8’ high

vii) Flanged Air connections

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viii) Access door above and below the coil Drain pan under for just in case (should not be a condensing situation)

ix) Pipe 3” from coil to box outer wall connections

x) The EAER will be located outdoors behind the building back wall.

d) 2 ea. Backward Curve USF, or equivalent recirculation fan(s) (40150 CFM each @ 7.8” SP) with 75 HP 480v/60/3 TEFC motor(s). USF fans are designed for maximum performance at higher static pressures and higher air volumes. The housings should be constructed of continuously welded heavy gage steel, to assure no air leakage. The recirculation fans will be located outdoors.

e) 20-gauge, galvanized, uninsulated spiral exhaust ductwork with duct rings, cleanout doors and ARV stack head(s). The exhaust stack height is estimated to be 41’-10” above the finished floor. Duct work will be attached to the outside of the back wall of the building.

Galvanized, insulated (FSK wrap indoors) (weatherized insulation on outdoor section) recirculation ductwork with duct rings and cleanout door(s).

2) Booth Supply Air System

a) Two (2) Model TA-125 custom or equivalent direct fired make-up air unit (MAU) designed for a maximum of 20,000 CFM at 2.0” E.S.P. Unit will include the following equipment:

i) Mushroom intake hood.

ii) Motorized inlet damper with end switch.

iii) V-bank inlet air filter section with 2”, MERV-8 pleated filters. Filter pressure drop indicating transmitter provided.

iv) Supply air energy recovery coil. Coil to be copper tube/aluminum fin design, mounted in inlet of make-up air unit.

v) Two (2) water circulating pumps (100% standby) rated for 150 gpm at 50’ TDH. Pumps provided with 5 HP, 480/3/60 ECM motor and local disconnect switch. Pumps located in makeup air unit intake vestibule and factory piped to supply energy recovery coil.

vi) 20 gallons, ASME rated expansion tank, mounted, and piped in make-up air unit vestibule. Instrumentation to include inlet and outlet water temperature and coil discharge air temperature.

vii) One (1) copper tube/ aluminum fin chilled-water cooling coil with stainless steel drain pan. Coil rated for 82 tons of cooling. Includes factory mounted chilled water piping assembly including three-way flow control valve with position feedback signal, isolation valves, circuit setter and supply/ return water temperature transmitters with thermowell. Piping must be field insulated.

viii) Direct fired natural gas burner rated for 1,250,000 BTUH (55° F temperature rise) based on natural gas provided at 2-5 psig. Burner to have 1” ANSI/ FM gas train, spark ignition, motorized burner profile plates and high limit reset switch.

ix) Evaporative Cooler/ Humidifier Module complete with duplex circulating pumps, sump water level control and low-level switch. Unit to be constructed with 304 stainless steel with 12” GLASdek™ media. Unit control to be provided with automatic water supply valve, drain valve, and time backflush cycles. Module provided with face and bypass damper assembly for control. Unit provided with conductivity monitor to control flow of bleed stream for maintaining solids level in the humidifier.

x) Belt driven 33” plenum fan with 25 HP, ODP, inverter duty, 480/3/60 motor. Main disconnect provided. Unit mounted 25HP VFD with Ethernet communication to main PLC panel.

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xi) 2” double wall insulated unit with epoxy interior coating and epoxy with enamel exterior coating for corrosion protection.

xii) Unit mounted remote I/O rack for all make-up air unit discrete and analog signals (CP101/102). Remote I/O system to be Allen-Bradley 5069 Series and will communicate via Ethernet to the main control panel (CP100)

xiii) Field instrumentation to be provided at each make-up air unit:

xiv) One (1) Outdoor air temperature/humidity transmitter.

xv) Two (2) Energy recovery water temperature transmitters with thermowell.

xvi) One (1) Energy recovery coil discharge temperature transmitter.

xvii) Two (2) Chilled Water temperature transmitters with thermowell.

xviii) One (1) Averaging cold deck temperature transmitter.

xix) One (1) Discharge temperature transmitter (ship loose).

xx) One (1) Duct mount CO detector.

xxi) Unit built in accordance with ANSI-Z83.4 and will include ETL label.

b) One (1) Model 30RBX190 or equivalent packaged air cooler chiller with duplex pumps.

Chiller to have a rating of 181 ton based on R410A refrigerant at 45F EWT/55F LWT.

Chiller package shall include the following:

i) 450 Amp Main non-fused disconnect switch.

ii) Digital scroll compressor

iii) Micro Channel heat exchanger .

iv) Evaporator heater

v) Dual factory mounted pumps, 15 HP each. 100% backup.

vi) Fixed speed condenser fans (Qty 12)

vii) BACNet communications

viii) 35KA SCCR

ix) 700 gallon ,125 psig design pressure chilled water buffer tank.

x) 30 gallon expansion tank with sight glass.

xi) Modulating bypass control valve with differential pressure transmitter for maintaining chiller flow/pressure requirements.

c) 1 set Intake filters, 20” x 20” x 1”, high diffusion, new for start-up

d) 2 lot Galvanized, uninsulated intake ductwork that transfers fresh air from the mushroom hood intake to the air make-up unit. The intake ductwork includes all necessary duct elbows and connections. The mushroom hood intake will be approximately 10’ above the ground elevation

2 lot Galvanized, insulated (FSK wrap indoors) (weatherized insulation on outdoor section) discharge ductwork that transfers conditioned air from the air make-up unit to the existing intake chamber. The discharge ductwork includes all necessary duct elbows and connections.

e) 1 lot Sprinkler heads in new exhaust plenum.

3) Booth Controls (New)

a) 1 ea. Main PLC remote IO control panel (CP100) (480v/3 PH/3- or 4-wire) is NEMA 12 rated and includes:

i) Main panel fused disconnect

ii) Panel Air Conditioner

iii) Exhaust filter pressure monitoring transmitters

iv) Booth Plenum Door 1 & 2 controller branch circuit protection

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v) Booth Roll up Door controller branch circuit protection

vi) Door-mounted start/stop push buttons

vii) PLC (Allen Bradley Compact Logix, 5069)

viii) Booth lighting contactors (120V/277V) (Lights will be PLC controlled)

ix) PLC I/O w/ethernet com card to PLC processor in HMI panel

x) SCCR Rating to be same as existing Load Center Circuit Breaker Panel (LCCBP)

b) 1 ea. Main HMI control panel (CP100-A) (480v/3 PH/3- or 4-wire) is NEMA 12 Wall Mounted and includes:

i) 15-inch touchscreen operator interface

ii) PLC (Allen Bradley Compact Logix, 5069-L320ER)

iii) Ethernet comm

iv) Door-mounted start/stop push buttons (Paint Booth Mode control)

v) Door-mounted pilots

vi) Graceport

vii) 24 vdc backup power supply for Processor

viii) Master control relay

c) 2 ea. Remote VFD control Panels (CP101 & CP102) (480v/3 PH/3- or 4-wire) is NEMA 4 rated and includes:

i) Main panel disconnect

ii) Ethernet communication

iii) Recirc fan piezo ring monitoring transmitter

iv) VFD Branch Fuse circuit protection

v) 40 HP exhaust fan VFD with load reactor

vi) 75HP recirculation fan VFD with load reactor

vii) Exhaust Heat Recovery coil control/monitor

viii) SCCR Rating to be same as existing Load Center Circuit Breaker Panel (LCCBP)

d) 1 ea. reuse the EXISTING Aux 15 kva GP Transformer Panel (480v/3 PH/3- or 4-wire)

i) 240/120 vac outlet distribution

ii) This panel will be relocated to the south booth wall

e) 2 ea. reuse the EXISTING two (2) Plenum Door control panels (480v/3 PH/3- or 4-wire)

f) 1 ea. Real-time Volatile organic compounds, VOC, gas detection to determine high concentration of surrogate gases. Upon sensing a concentration above the programmed limit for the specific compound, the system sounds an alarm, and the booth begins purge mode. The VOC gas detection system monitors the airstream within the exhaust plenum sections. The single unit will be fitted with two (2) sensing heads.

g) 1 ea. Real-time Lower Flammability Limit, LFL, sensors continuously monitor the air within each recirculation duct. Upon sensing a concentration above the programmed limit, the system closes the compressed air that supplies the paint guns, and the booth begins purge mode. The LFL gas detection system monitors the airstream within the recirculation plenum section. The single unit will be fitted with two (2) sensing heads.

h) 1 ea. Auto Balance System designed to automatically keep the paint booth balanced when in operation. The system monitors the interior booth pressure, adjusting the exhaust fan speed so that the air volume is balanced with the supply air volume. The result is a booth that is balanced automatically and stays in balance as the filters load with overspray. The system increases useful filter life and is recommended on all pressurized booths.

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i) 1 ea. Explosion-proof horn and strobe assembly mounted in the ceiling of the booth to alert operators of a booth alarm condition. Note: This alarm system is not associated with the booth’s or building’s fire suppression system. Additional alarm systems are required for fire suppression

4) Equipment Installation, Commissioning & Training

5) Demolition and proper disposal of existing equipment will be required.

6) At the end of each day and at the completion of the project, the contractor will clean all job-related debris from area. A post construction inspection will be conducted with contractor, CE and the customer.

1. LOCATION: The project site is located at Nellis Air Force Base, Nevada. The Main Base is located approximately 9 miles north of downtown Las Vegas on Highway US 93 (Las Vegas Blvd.). NAFB consists of three main areas: the Main Base, Area II, and Area III. The specific project location is on the Main Base in Building 252, the Corrosion Control Facility, located at the intersection of Tyndal and Griffiss, NAFB, NV, 89084.

2. ENVIRONMENTAL PROTECTION: All work and the contractor’s operations shall comply with the requirements imposed by all applicable federal, state, local, and NAFB laws, regulations, codes, and permits (including NAFB Management Plan 12) concerning environmental protection. If required per the task in the area where work is to be performed, an asbestos-containing material and a lead-based paint test will be done by the 99 CES.

3. CONTRACTOR PERSONNEL: The contractor’s personnel shall conduct themselves in a professional manner.

4. QUALITY ASSURANCE: The government, through the 99 CES Representative, will periodically evaluate the contractor’s performance in accordance with the specific contract performance requirements.

5. WORKING HOURS: Standard working hours are from 7:00 a.m. to 4:00 p.m. Monday through Friday excluding Federal Holidays and the day after Thanksgiving.

6. GENERAL CONDITIONS: All work must be in compliance with and conform to industry standards and applicable manufacturer’s recommendations. Any electrical wiring, connections, and structural designs shall be installed IAW latest version of the NFPA 70 National Electric Code (NEC), Uniform Mechanical Code, and NFPA 54, ASME CSD-1 (Controls & Safety Devices).

All work must be in compliance with the International Building Code (IBC). 2009 Edition, DoD Unified Facilities Criteria Standards (UFC) Unified Plumbing Code (UPC) and all accepted industry practices. At the completion of the project, the system should be 100% operational.

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