Attach_2_-_PWS_-_Air_Compressor.pdf

Performance Work Statement

For

Remove and Installation of an Air Compressor

1.0. DESCRIPTION OF SERVICES/GENERAL INFORMATION

1.1. Description of Services. The contractor shall furnish all materials, supplies, parts, tools, equipment, transportation, labor, supervision, installation and management necessary to perform the purchase/installation of an Air Compressor system at the 309th Aircraft Maintenance and

Regeneration Group (309 AMARG), Davis-Monthan AFB, AZ. SE end of building 7456, Hangar 5.

1.1.1. Scope of Work. The primary scope of this project is for the purchase/installation of an air compressor system with all required support equipment to meet user requirements. The contractor shall support the project to complement existing buildings within the 309 AMARG industrial maintenance area. Contractor shall support the project in accordance with the base

Design Compatibility Guidelines (DCG), review it for constructability, and advise of possible problem areas or conflicting guidance prior to delivery order negotiation. A copy of the DCG can be attained from the 309 AMARG/MXDSM Facilities Flight. Under no circumstances is the Contractor to begin any work until a bonafide Notice-to-Proceed is issued by the CO. All work must be in accordance with Unified Facilities Criteria (www.wbdg.org) unless express written permission is received from the Contracting Officer for any deviations. All work must meet or exceed acceptable standards and codes of the building trades; and shall be installed in a neat, substantial, and workmanlike manner.

1.1.2. Project Schedule. The Contractor shall develop, implement, and maintain a shedule of services for all tasks required to accomplish work under this project. The contractor shall submit a project schedule to the Contracting Officer for acceptance with the project design. Changes to the work schedule shall be submitted to the Contracting Officer for acceptance prior to making the changes.

1.1.3. On-Site Performance. Upon acceptance of the project design and project schedule by the Contracting Officer, the contractor shall remove existing compressor and install new compressor in accordance with (IAW) specifications in 1.1.4. The contractor shall obtain all required permits to facilitate compressor installation through the 355 CES. All utility shutdown must be coordinated through the 355 CES and 309 AMARG Facilities section. All request must be submitted two weeks prior to utility disruption.

1.1.4 Removal and Installation. The Contractor shall provide all necessary tools and equipment to accomplish full removal and disposal of existing Quincy QSF-75 air compressor.

The Contractor is responsible for bringing in and connecting all necessary utilities to the designated worksite. Proposed air compressor must meet the following minimal equipment performance standards:

A. General Rotary Compressor Package http://www.wbdg.org/

1. Air compressor shall be a single-stage, fluid-injected, water-cooled rotary screw compressor completely pre-piped and with pre-wired control panel.

2. Compressor shall be manufactured under strict ISO 9001:2008 quality control standards.

3. Compressor shall be tested as a completely assembled, piped and wired unit.

4. Maximum capacity shall be 283 ACFM (per CAGI) at a discharge pressure of

175 psig. Compressor shall be capable of continuous full-flow operation 24

hr. /day at rated capacity and pressure.

5. Motor voltage shall be 480 V, 3 phase, 60 Hz. Control system voltage shall be

115 V, 1 phase, 60 Hz, with a stabilized 24V DC power supply.

6. Standard compressor package shall be suitable for use in a 40ºF to 115ºF ambient temperature range.

B. Air-End

1. Compressor shall be fitted with an air inlet filter rated at 1 micron or better to provide maximum protection to the air-end. Filter shall utilize a pre-separation process to collect larger particles before air enters the filter element.

2. Rotors – Air end rotors shall have a Sigma profile. Rotors shall be precision-machined from ductile cast iron. All cast parts shall be inspected for compliance with design tolerances in accordance with ISO 9001:2008 quality procedures.

3. Casing – Air-end casing shall be cast iron construction.

4. Bearings – Air-end rotors shall be supported on both ends by cylindrical roller bearings to carry radial loads. Angular contact ball bearings shall be installed on the discharge end of each rotor to carry thrust loads with minimal friction.

C. Drive Motor

1. Motor

a. Motor shall have TEFC enclosure.

b. Motor winding shall be 100% copper (aluminum is not acceptable) and designed for reduced voltage wye-delta starting.

c. Motor service factor shall be a minimum of 1.2.

d. Motor nominal speed shall be 3600 rpm.

e. Motor insulation shall be Class “F” (Class “B” is not acceptable).

f. Motor must meet or exceed Energy Independence and Security Act

(EISA 2007) standards for motor efficiency. Motor efficiency shall be

94.5 % or higher.

g. Motor pull-up torque shall be 150% or higher.

h. Drive motor grease fittings shall be mounted on motor exterior for ease of maintenance.

2. Direct Drive

a. Compressor drive shall be 1:1 direct drive via torsional elastic coupling for high efficiency and minimal maintenance. Gear and belt drives are not acceptable.

b. Compressor drive shall require no regular maintenance other than regular greasing of motor bearings.

c. Coupling shall be enclosed in a cast housing with alignment pins for proper alignment, and wide opening for easy access.

D. Control Cabinet

a. Control cabinet shall be designed to meet or exceed NEMA 12 standards.

b. Electrical components shall be UL and/or CSA listed and labeled as required.

c. Electrical schematic diagram shall be included in the service manual for reference.

d. Cabinet backplane shall be galvanized for improved grounding.

e. Starter(s) shall be integrally mounted and wired in the compressor package and located in the control cabinet. Starter(s) shall be magnetic, wye-delta, reduced voltage starter(s), to ensure low starting current and reduce thrust-bearing loads.

E. Standard Compressor Instrument Panel

a. Control system shall be designed for temperatures ranging from – 4ºF to +140ºF.

b. The controller shall be an industrial PC with a centralized database. The unit shall include a stabilized 24V DC power supply and a real-time clock with a scheduling timer. A buffer battery with a lifetime of ten years shall be included for protection of system memory and internal clock. The unit shall be EMI (electromagnetic interference) protected to ensure proper functioning of the industrial PC in industrial conditions. The unit shall include additional digital and analog inputs and outputs for monitoring of standard and optional sensors.

c. Standard communications include or equivalent: RFID for user access and security, Ethernet for remote monitoring with included Web Server, and an SD card reader slot to enable long term data logging and saving of system parameters.

d. A user interface shall be integral to the unit, and shall include ergonomic controls with LED indication of important functions, and a background illuminated, plain text and graphical display capable of displaying information in many languages.

e. The controller shall monitor critical compressor and control functions and shut the compressor down in the event of motor overload, high air-end temperature, incorrect rotation, or loss of drive.

F. Compressor Control

a. Compressors shall have the option of Quadro, Vario, Dual, Continuous and

Dynamic control as standard. Switchable modulation control is an acceptable option. Compressors shall start and automatically load if system demands it.

Compressors shall have adjustable time delay to shut down the compressors after running unloaded for a pre-determined period of time to avoid excessive motor starting.

b. Compressor shall cut in at 160psig and cut out at 175 psig.

G. Compressor Enclosure

a. Compressor shall have steel frame assembly and be completely enclosed, including bottom. Shall include hinged doors and/or removable access panels for easy access to the compressor for maintenance.

b. Enclosure shall be heavily sound insulated, and compressor shall have a maximum full load sound level of 72 dB (A) at 3 feet in accordance with ISO

2151 and ISO 9614-2. All sound dampening material shall be oil repelling and cleanable.

c. Compressor frame shall be isolated from the floor by rubber vibration pads. No special foundation.

d. Additional vibration proofing shall be provided for the air-end, drive motor and separator tank to reduce stress on piping and electrical connections.

e. All access panels/doors shall have slotted key locks or handles, and shall be gasket to minimize dust and dirt entering the enclosure. A door key shall be provided.

f. The air inlet to the compressor air-end shall enter the package through a separate port and not through the fluid and/or air coolers to avoid preheating.

g. Cabinet panels shall have a “powder coat” type paint finish, which shall be durable and scratch- resistant.

h. Ambient cooling air shall enter the electrical cabinet of the enclosure after passing through a 40-micron filter mat.

H. Internal Piping

a. All major air and oil pipes shall be made of steel and feature flexible connections with O-ring seals to reduce the likelihood of cracks and leaks.

I. Lubrication/Cooling System

a. Compressor shall have a differential pressure fluid circulation system.

Compressors requiring a pump and/or stop valve are not acceptable.

b. Compressor shall be factory filled with semi-synthetic or optional full synthetic lubricant.

c. Fluid filter shall be snap-in type capable of removing particles down to 10 microns or less and shall be thermally disposable.

d. Compressor shall have an ASME separator tank with integral fluid separator element and minimum of 232 psig working pressure. Separation system shall include three stages, mechanical separation and a two-stage deep-bed coalescing filter. Compressor package shall have a maximum fluid carryover of 1 - 3 ppm.

Separator shall also include sump pressure gauge, fill plug, fluid level sight glass, and quick disconnects. A pressure drop visual indicator shall monitor separator cartridge life for improved efficiency and serviceability. ASME coded safety relief valve(s) shall be installed on fluid separator tank. Separator shall also be equipped with quick disconnect and fluid drain hose for pressurized fluid changes.

e. Fluid coolers and aftercoolers shall be easily accessible for ease of maintenance.

Air-cooled aftercooler and fluid cooler shall be integrally mounted to the compressor enclosure. Ambient air shall be drawn into the package directly through the fluid and air aftercooler so cooling air flow is not pre- heated by the motor and air-end. Aftercooler approach temperature shall be 9 °F or less.

f. Fluid cooler shall include drain plugs to facilitate complete fluid removal without costly flushing.

g. The aftercooler shall include an integral moisture separator with automatic condensate drain. The integral moisture separator shall be of stainless steel to prevent corrosion. The moisture separator and electronic demand condensate drain trap shall be mounted internal to the package as standard equipment. The drain trap shall be monitored by a controller.

J. Air Main Charging Valve, or equivalent

a. Air valves must provide adjustability to block sudden air supply to self-nitrogen generator. The valve must open slowly due to the extreme start up air pressure that would be delivered to the self-nitrogen generator, consequently blowing the membrane filter housing.

b. The air valve must have the capability to rise no more than 10-PSIG every 5 seconds and sustain a pressure of 140 +/- 10 PSIG.

c. Valve must be normally closed; in an event of power outage.

K. Testing and Inspection

a. Parts must be inspected as part of strict ISO 9001:2008 quality control program, if required.

b. After installation the air compressor shall be run and tested for leaks, pressure, temperature, rotation, and full load amp draw prior to completion.

L. Warranty

a. Project shall include standard warranty on workmanship and commercial manufacturer parts coverage; which shall be annotated in proposal.

1.2. GENERAL INFORMATION

1.2.1 Parts and Materials. The contractor shall ensure all parts and materials are new, and conform to the equipment manufacturer’s specifications, unless otherwise approved by the

Contracting Officer.

1.2.2. Project Changes. No alterations, additions, or deletions shall be made unless prior approval from the Contracting Officer. The contractor shall not perform any other work (e.g.

alterations, additions, or deletions), other than that identified in the contract. If the contractor determines there are changes that need to be made to the contract, the contractor shall submit documentation for the changes, to the Contracting Officer. The contractor shall not proceed with any change until a modification reflecting the change is issued by the Contracting Officer.

1.2.3. Contractor Hours of Operation. The contractor shall perform services between the hours of 7:00 a.m. - 4:00 p.m. If the contractor wants to work outside of these hours of operations, the contractor must obtain prior approval from the Contracting Officer.

1.2.4. English Language. Contractor employees must speak, read, write, and understand

English fluently.

1.2.5. Contractor Identification. Contractor employees shall be easily recognized as contractor employees by wearing distinctive clothing bearing the company and employee name, or by wearing commercially manufactured name tags above the waist, bearing the company and the employee’s name. Contractor employees shall wear identification at all times while on D-M

AFB.

1.2.6. Safety. The Contractor shall comply with all applicable safety laws and regulations.

Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor, and the Government will assume no liability or responsibility for the Contractor’s compliance or noncompliance with such responsibilities.

1.2.7. Fire Prevention and Safety. Contractor employees shall comply with the Occupational

Safety and Health Act (OSHA), D-M AFB Fire Protection Program, Air Force Occupational

Safety, and the Fire Prevention and Health Program.

1.2.8. Work Area. The contractor shall, at all times, keep work areas free from accumulations of waste material, rubbish, tools, scaffolding, equipment, and materials. Upon completion of the job or when away from the worksite, the contractor shall leave the work area and premises in a clean, neat, safe and workmanlike condition. The contractor is responsible for removal and proper disposal of all job related waste material at a permitted site of their choice.

1.2.9. Contractor Owned/Leased Vehicles. The contractor shall ensure that all contractor owned/leased vehicles are registered, licensed, insured, and operated in accordance with base traffic regulations by a licensed driver. All contractor vehicles must be in operable condition and meet all local, state, and federal safety requirements.

1.2.10. Illegal Aliens. Illegal aliens are unauthorized on D-M AFB. The contractor shall not hire illegal aliens to perform contract services on D-M AFB, nor attempt to bring illegal aliens on the installation. Corrective/punitive action will be taken against the contractor and the illegal alien if the contractor hires illegal aliens to perform contract services on D-M AFB.

1.3. SECURITY REQUIREMENTS

1.3.1 Access to the 309 AMARG. Strict security and personnel access control is maintained at 309 AMARG. Contractor personnel must obtain passes from the security section to enter.

Contractor personnel requiring access to 309 AMARG must submit a list of names with the person’s full name, Drivers License number and social security account number to the

Contracting Officer. The access passes must be worn on the outside of the contractor employee’s clothing at all times when on the property.

1.3.2. Pass and Identification Items. The contractor shall ensure that all necessary pass and identification items required for contract performance are obtained for contractor employees and non-Government owned vehicles.

1.3.3. Retrieving Identification Media. The contractor shall retrieve all identification media, including vehicle passes from contractor employees that depart for any reason before the contract expires (e.g. terminated for cause, retirement, etc.) and turn them in to the issuing office.

1.3.4. Traffic Laws. Contractor employees shall comply with all base traffic regulations.

Contractor employees are subject to random vehicle speed control checks. Contractor personnel cited for speeding on the installation may suffer loss of base driving privileges, debarment from the base, or other administrative action. The use of seat belts is mandatory for all vehicle occupants. The use of cell phones is prohibited while driving on base, unless the phone is a hands-free cell phone.

1.3.5. Random Personnel and Vehicle Searches. Contractor personnel are subject to random personnel and vehicle searches. If contractor personnel refuse to be searched, they will be denied entry to the base, and may result in loss of base driving privileges, debarment from the base, or other administrative action.

1.3.6. Weapons, Firearms, and Ammunition. Contractor employees are prohibited from possessing weapons, firearms, or ammunition on themselves or within their contractor owned vehicle or privately owned vehicle while on D-M AFB.

1.3.7. For Official Use Only (FOUO). The contractor shall comply with DOD 5400.7-R, Chapter 4, DoD Freedom of Information Act (FOIA) Program requirements. This regulation sets policy and procedures for the disclosure of records to the public and for marking, handling, transmitting, and safeguarding FOUO material.

1.3.8. Reporting Requirements. Contractor personnel shall immediately report to an appropriate Government authority any information or circumstance of which they are aware which may pose a threat to the security of DoD personnel, contractor personnel, resources, and classified or unclassified defense information.

1.3.9. Physical Security. Contractor employees are responsible for safeguarding all

Government property and controlled forms provided for contractor use. At the end of each work period, the contractor shall secure all Government facilities, equipment, and materials.

1.3.10. Smoking in Air Force Facilities. Contractors are advised that the Air Force has placed restrictions on the use of tobacco products in Air Force facilities. AFI 40-102, Tobacco Use in the Air Force, outlines the procedure used by the commander to control smoking in any facility.

Contractor employees and visitors are subject to the same restrictions as Government personnel.

Smoking is permitted only in designated smoking areas.

1.4. UTILITIES AND SERVICES

1.4.1 Utilities

1.4.1.1 Water. The Government will provide the contractor with a source of water if available.

1.4.1.2 Electricity. The Government will provide the contractor with a source of electricity if available

1.4.1.3 Emergency Services. The Government will provide security forces services (call 228-

4444 for emergencies only), and fire protection services (call 228-3333). There are no emergency medical services available on D-M AFB; therefore the contractor must dial 911 for emergency medical services.