1730 Shop Air Compressor and Dryer Specification 17Oct19.pdf

Specifications for a Shop Air Compressor at Arnold Air Force Base, TN;

Arnold Engineering Development Complex (AEDC)

Suggested Sources: This requirement is for three (3) Shop Air Compressor and Dryer systems.

The Shop Air Compressors shall be gear driven, oil lubricated, single staged air cooled rotary screw compressors. Each Shop Air Compressor shall provide greater than 220 CFM at 125 psi with in the ISO standards. Each Shop Air Compressor shall be provided with a dedicated twin tower self-regenerating absorption pressurized air dryer package. These three Shop Air

Compressor and Dryer systems shall replace two GA45 compressors with matching dryers. Approved manufacturers shall be certified under ISO quality and environmental standards. The manufacturer shall participate in the CAGI verification program and shall have manufactured compressors and/or air dyers for at least 10 years. Note: The intent of adding a third unit is to allow maintenance to be performed on one unit while the other two remain in service, thus positively improving the life cycle of each and reducing emergency repairs. A reduction in energy requirements will be achieved by utilizing the smaller units.

Provide all materials, labor, and equipment necessary to provide three (3) new fully functional Shop Air Compressor and Dyer systems. Refurbished or remanufactured parts are not authorized for this requirement.

Compressor and Dryer System Capabilities (applies to three units):

o Each system shall maintain minimum working pressure of 125 psi.

o Each compressor shall provide at least 220 SCFM at 125 psi with in the ISO standards.

o Each compressor shall produce and deliver 100% of the required air demand at standard operating conditions.

o Each dryer shall be a twin tower desiccant design with purge air for regeneration of the wet tower.

o Each dryer shall be designed to match the air compressor discharge flow, pressure and temperature conditions.

o Each dryer shall dry 100% of the air demand to a PDP (Pressurized Dew Point) of -

40oC (-40oF) during all stages of operation.

o The compressor/dryer systems shall not have a continuous noise level greater than 70 dB at ten feet from unit at full load.

o The compressors/dryer systems shall operate at ambient temperatures between 32⁰F and 115⁰F.

o Each system shall have a programmable regulating controller.

o Each compressor motor shall be at least 50 HP but not greater than 60 HP, type TEFC or equivalent from an approved manufacturer.

o See attached Atlas Copco Compressor Data Sheet for additional performance details.

Note: Dual tower driers are considered a proven design, however a single rotary drier tower system can be proposed for government consideration of the application. All the functional requirements shall be met/addressed.

General o Compressor Package Design (applies to three units):

Each compressor shall be supplied as a complete package equipped with the following components inlet filter, air compressor element, drive motor, after cooler w\moisture separator, oil cooler, cooling fan, Wye-delta motor starter, microprocessor and control system. All items shall fully enclosed and mounted to a solid base.

Compressor enclosures shall be made of steel with flame retardant sound proof/attenuating material and removable panels.

Compressor package voltage shall be 480 volt 3 Phase.

A wye-delta starter or equivalent electronic soft starter shall be used for the motor starter.

Each compressor element shall be a rotary screw design, made of cast iron with controllable slide valve for turn down flow control.

Each compressor’s drive motor bearings shall be lubricated by the compressor’s lubrication or greased for the life of the drive motor.

Each drive shall be a direct mounted gear drive design and designed to offset loads during operations.

Each compressor shall be equipped with manual and automatic condensate drains.

Each compressor shall be equipped integrated moisture trap in the after cooler.

Each compressor inlet air filter shall be monitored by the control system and have an efficiency rating of 95.0% or better.

Each compressor control station shall meet NEMA or IP standards and include cooling fans to circulate ambient air.

Each compressor’s oil system shall include a spin-on type oil filter and an air oil separator with a level indicator. The system shall use O-rings sealing. No gaskets allowed.

The oil temperature shall be regulated by a thermostatic valve or chiller.

Each compressor’s controller shall be capable of controlling and monitoring status of operations, motor load, air flow, discharge pressures, shutdowns , motor overloads , high temperatures, run times, display service indicators, air pressures and have the capability of providing control and monitoring locally or remotely though a local area network (ethernet).

o Dryer Package Design (applies to three units):

Each dryer shall be designed and supplied as a complete package with all necessary equipment, completely wired and equipped with all interconnecting pipe work and fittings. All equipment as listed is mounted on a single common frame, completely wired and ready to operate, including but not limited to the following components:

microprocessor regulation and control system, desiccant, desiccant towers, control and check valves.

Note: Dual tower driers are considered a proven design, however a single rotary drier tower system can be proposed for government consideration of the application. All functional requirements shall be met or addressed.

A bed of desiccant in each vessel – single type and size

Desiccant - The entire required desiccant charge is present within the dryer towers when leaving the factory.

Acceptable desiccant materials are Activated Alumina (-40ºF PDP) and Molecular

Sieve (-100ºF PDP)

A purge nozzle for each vessel to control regeneration air. Nozzle material shall be steel.

An exhaust assembly with silencer(s) to reduce noise during pressure release and regeneration. Exhaust valve + silencer - Each vessel pair has an exhaust valve, combined with a silencer to reduce the noise level during depressurization of the vessels.

Filtration - Coalescing Pre and Post air filters.

Dryer inlet filter drains shall be of zero-air loss float drain type.

Dryer pre-filters for filtering dust and oil shall meet filter manufacturer specifications for ISO Class 1:-:2 requirements.

Dryer after-filters for filtering dust shall meet filter manufacturer specifications for ISO Class 2:-:- requirements.

An electrical cubicle shall conform to CSA-UL.

Pressure gauges or sensors shall be provided for each side of the system.

Vessels - The vessels shall be extruded aluminum columns.

Control system- The dryer is designed for automatic operation.

A microprocessor control system including digital Pressure Dew Point readout of the dryer output.

The control system shall allow alternate adsorption and regeneration between the 2 towers, optionally depending on the dew point.

Include dew point control of the purge cycle with timed tower purge control as a backup.

The dryer controller shall be started and stopped locally, via a wired remote switch

Dyer package voltage shall be 110 volt single phase.

Electric Cubicle - All electrical components shall be installed in the cubicle at the dryer.

The cubical contains:

Control System Operator Panel

Customer connection terminals for the customer power supply

Customer connection terminals for the alarm contacts, remote emergency stop and remote start/stop.

PDP sensor shall be provided- A digital Pressure Dew Point readout with local and remote readout capability shall be provided with each unit. A hygrometer sensor mounted in external stainless steel housing with integrated dust filter. The sensor is used to monitor the air dew point and extend the adsorption cycle when the dryer is not 100% continuously loaded. The air inlet side of the housing is connected to the outlet pipe of the dryer with a tube and can be disconnected by a manual ball valve. The air outlet side of the housing is connected to a needle valve to control the flow through the PDP sensor after which the air is silently expanded in a tubular silencer.

General Installation Requirements o Upon placement on a level surface and connection to essential utilities, the unit shall be provided available for immediate operation.

o Bid shall include lifting, leveling, and mounting hardware for each compressor/dryer system.

o Bid shall include all machine preventative and repair maintenance, labor and parts, for the duration of the warranty.

o Two (2) copies of manuals shall be delivered with each compressor/dryer system.

Manuals shall include sections on Operation, Maintenance, Controls, with Electrical and

Mechanical Schematics of the Compressor, Dyer and the PDP sensor.

Verification o After delivery and installation the Contractor shall test run each system at the site in accordance with functional tests for accuracy required by ISO/ANSI Standard.

Independent CAGI Performance Verification or a Factory Compressor Test certificate shall be provided at delivery for items 3, 10 and 12 of the attached Compressor Data

Sheet.

Warranty o These systems (Compressor and Dryer) shall be warranted against any defects in material, parts, and workmanship for 24 months after the date of installation including all mechanical and control components. Parts and Labor for all operations and maintenance shall be included for the period of the warranty. Should standard warranty cover a period less than 24 months, bid shall include additional warranty period to total

24 months.

Maintenance, Parts and Service o The Contractor shall have the capability to service the equipment (labor and parts) during and beyond the warranty period, or the equipment shall be able to be serviced by a local qualified representative.

o The Contractor or representative shall be capable of responding to a repair service call on-site within 36 hours and repair parts delivery within 48 hours after placement of order.

Packaging/Delivery o Provide all preservation, packaging, and packing to ensure safe delivery of the machine and related components to AEDC (FOB Arnold Air Force Base, TN 37389). Deliver

Machine to AEDC for off-loading by AEDC personnel.

Installation/Training o Installation will be at the Arnold Air Force Base, TN; Arnold Engineering Development

Complex’s Model Shop, West Shop, Building 451. Installation of the machine shall be accomplished by AEDC personnel and supervised by factory trained servicemen.

Training shall include on site review of proper operation and maintenance requirements with no less than four technicians for three to four hours. These services shall be included in machine cost.