08-T-9023 Amended SOW - 9-05-08.doc

STATEMENT OF WORK

STATEMENT OF WORK (SOW)

ROTARY SCREW AIR COMPRESSOR SYSTEM

1.0

SCOPE

1.1 Scope. This specification describes the minimum requirements for the removal of an existing rotary screw air compressor system (herein referred to as the RSC) and the design, manufacture, delivery, installation, and testing of a new RSC system, to include: a rotary screw air compressor, with either a refrigerated air dryer or a desiccant dryer; a dew point monitor; coalescing filters; piping; valving; and accessories. The RSC will be used to provide clean, dry, compressed air to Building 4032 and Building 4173 located at the FRC East, Cherry Point, NC. The compressor shall be capable of providing at least 400 scfm at 125 psig.

2.0 APPLICABLE DOCUMENTS. The following documents, of the issue in effect on date of invitation for bids or request for proposals (i.e., the most recent versions), form a part of the specification to the extent specified herein.

2.1 Government documents. The following documents, of the issue in effect on date of request for quote, invitation for bids or request for proposals, form a part of the specification to the extent specified herein. Documents listed below are referenced in the specification by alphanumeric code only. Copies of these documents can be obtained from the publication sources listed in section 5.1.

OTHER GOVERNMENT AGENCY

CODE OF FEDERAL REGULATIONS (CFR) U.S. DEPARTMENT OF LABOR

OCCUPATIONAL

SAFETY AND HEALTH (OSHA)

OSHA 29 CFR 1910.147 Control of Hazardous Energy (Lockout/Tagout)

OSHA 29 CFR 1910.1026 Hexavalent Chromium

UFGS Section 15211N NAVFAC Unified Facilities Guide Specifications –

( Low Pressure Compressed Air

Piping (Non – Breathing Air Type)

UFGS Section 15216N NAVFAC Unified Facilities Guide

Specifications –

Welding Pressure Piping

UFC 1-200-01 General Building Requirements EM 385-1-1 U.S. Army Corps of Engineers, Safety and Health

Requirements Manual

FACILITY DRAWINGS

PE–20440(M) FRC EAST, Drawing titled: Building. 4173

Compressor and Dryer Site Plan, (Code 6.2.3.5.2), Bldg 4173

2.2 Non - Government documents. The following documents of the issue in effect on date of invitation for bids or request for proposal, form a part of the specification to the extent specified herein. Documents listed below are referenced in the specification by alphanumeric code only. Copies of these documents can be obtained from the publication sources listed in section 5.1.

2.2.1 Non-Government Documents.

ASME BPVC Construction of Pressure Vessels, Section VIII, Division I Rules for

ASME Section IX “Welded and Brazing Qualifications.”

ARI 520 Air-Conditioning and Refrigeration Institute(ARI)

– (1997) Positive Displacement Condensing Units

ASME B31.1 ASME International (ASME) – (2001) Power

Piping

ASME B31.9 ASME Building Services Piping

NFPA 70 National Electrical Code

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 79 Electrical Standard for Industrial Machinery

SMACNA MANUAL Sheet Metal and Air Conditioning Contractors National

Association, Inc.,

2.3 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein (except for associated detail specifications, specification sheets), the text of this specification shall take precedence. However, this specification shall not supersede applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 General information and coverage. This specification was written for the purpose of soliciting technical proposals for the removal of an existing RSC and the design, installation, and testing of a new RSC with associated piping and accessories. Contractors having experience in the design, installation, and testing of low pressure rotary screw air compressors, refrigerated and/or desiccant dryers, and compressed air piping are invited to offer quotes. All equipment specified herein shall be installed at the FRC East, Cherry Point, NC. The equipment provided shall be the manufacturer’s current production model, new and unused, capable of performing its intended function in accordance with the operation and performance requirements of this specification. The equipment, piping, and associated accessories shall form a complete system so that when connected to the utilities identified herein, it can be used for all functions for which it is designed and constructed. The Contractor shall provide all calculations in all subject work (i.e., sizing components, etc.).

3.1.1 System definition: The RSC system shall dry 100% saturated air at various volume flow rates for two Buildings 4032 and 4173 that are located at FRC East, Cherry Point, NC.

3.2. Work to be accomplished. The following objectives shall be accomplished by this specification:

3.2.1 Equipment installation. The contractor shall provide and complete the following.

a. The Contractor shall provide a full turnkey removal of two existing compressors (P/A: 65923074618) and (P/A: 65923X02082) and dryer (P/A: 65923074619). The Contractor shall remove the following three pieces of equipment:

(1) one Ingersoll-Rand (50 hp) rotary screw air compressor (P/A: 65923074618);

(2) one Ingersoll-Rand (25 hp) air compressor (P/A: 65923X02082);

(3) one dryer (P/A: 65923074619).

When the removal is completed the Contractor shall provide a turnkey installation of a new RSC system. The location for the RSC system is provided on PE-20440(M). The Contractor shall properly prepare removed item (1) (compressor - P/A: 65923074618) and item (3) (dryer - P/A: 65923074619) for proper storage. The Contractor shall provide a turnkey relocation and turnkey installation of item (2) (compressor - P/A: 65923X02082) inside the metal shed, per section 3.2.1.b.(2). The Contractor shall follow original manufacturer recommendations for proper storage recommendations. The Contractor shall physically place in to storage (storage location will be provided by the Government within 6 miles of site) all equipment removed from site.

b. The Contractor shall provide a turnkey installation of one new air cooled rotary screw compressor, either one refrigerated compressed air dryer, or one blower purge desiccant air dryer, and one dew point monitor and accessories. The designated air dryer shall be sized to sufficiently handle the selected compressor. Therefore, all of the following items shall be completed by the Contractor:

(1) Due to the lack of space in the shed, the Contractor shall make sure the compressor and dryer is configured correctly. Given the overall size of the compressor and dryer and the lack of availability of space in the shed, the Contractor shall determine the compressor and dryer orientation prior to any selection and ordering of compressor and dryer. The compressor, dryer, piping (i.e., valving, etc.), and the associated electrical panels shall be ordered, designed, manufactured, and placed to fit per code (i.e., current electrical code, current OSHA regulations, etc.) in the available space of the designated metal shed.

(2) The Ingersoll-Rand (25 hp) air compressor (P/A: 65923X02082) that is removed in sub section 3.2.1.a. shall be relocated to an acceptable location inside the existing metal shed. The location within the shed shall be acceptable to the Government and shall comply with current electrical codes and OSHA regulations. The Contractor shall provide a turnkey installation of the designated compressor (P/A: 65923X02082). The designated compressor (P/A: 65923X02082) shall be tied into the new RSC compressor in a parallel piping arrangement. The designated parallel piping arrangement shall provide the ability to isolate one compressor from the system and run the other compressor. The designated compressor (P/A: 65923X02082) shall have properly sized isolation valves with unions on the inlet and outlet side of the compressor. In addition, the Contractor shall provide one correctly sized zero loss automatic drain (supplied with heating element) with all required piping, and valves that shall allow the zero loss automatic drain to properly drain to the outside of the metal shed and also connect correctly to the compressor (P/A: 65923X02082).

(3) The Contractor shall install all compressor controls required for the compressor to communicate status and settings and effectively operate with another compressor.

(4) The Contractor shall install and provide all properly sized isolation valves, per compressor manufacturers’ recommendation, on both the outlet and inlet side of the compressor.

(5) In addition, the Contractor shall ensure the existing pipe layout (i.e., does not include size of actual pipe) for the compressor and dryer remains in tact for the new compressor and dryer.

(6) The Contractor shall ensure all inline equipment that is hard pipe shall have isolation valves and unions on both inlet and outlet sides of the installed equipment. For purposes of this subparagraph, equipment is defined as being any one of the following items: compressor, separator, filters, dryer, etc..

(7) The Contractor shall ensure the isolation valves match size of the connecting pipe and all valves shall be water, oil, and gas compliant.

(8) The Contractor shall install one properly sized coalescing filter as specified in section 3.3.3.of this specification immediately following the outlet side on both the receiver and dryer.

(9) The Contractor shall ensure a bypass is provided for each coalescing filter.

(10) The Contractor shall ensure each bypass that is provided for a coalescing filter has all of the following items:

(a) one properly sized coalescing filter (as specified in section 3.3.3 of this specification)

(b) one isolation valve for the inlet and one isolation valve for the outlet of the filter

(c) two unions for each coalescing filter. The first union shall be placed between the isolation valve and the inlet side of the coalescing filter. The second union shall be placed between the isolation valve and outlet side of the coalescing filter.

(11) The Contractor shall provide and fully install the required (i.e., manufacturer recommended) intake hood(s) for the compressor. That is, the compressor intake shall draw air from the outdoors and not from air inside the existing shed. The intake hood shall have the appropriate sized louver to prevent rain and debris from blowing into the compressor. Also the louver shall have appropriate sized screen to prevent birds and other animals from building nests or flying into the duct work.

(12) The Contractor shall provide and install one oil/water separator with all required filtration and piping. Oil/water separator provided by the Contractor shall be placed on the condensate line of the compressor. The Contractor shall select an oil/water separator that shall prevent any oil (to include any oil mist or oil vapor) discharging into the environment from the compressor discharged liquid/condensate. All filtration provided by the Contractor shall be monitored with differential pressure gauges. All differential pressure gauges shall indicate service levels by color designation (e.g., green color indicating filter is operational, red color indicating filter needs to be changed).

(13) The Contractor shall make all necessary repairs to the existing shed to ensure it is weatherproof. Seal roof and wall of metal shed of existing and new penetrations using flashing (hood, drip cap, drip edge, can’t strip) and sealant to prevent entry of water and blowing rain into the building. All flashing and counter flashing shall be stainless steel in accordance with the latest SMACNA sheet metal manual.

(14) The Contractor shall modify shed to have louvers and an appropriate sized exhaust fan based on the total equipment load. The exhaust fan shall have a thermostatic (adjustable) control which will be activated to run when the inside shed temperature hits or exceeds 85 degrees Fahrenheit. The contractor shall provide insect screens on all shed penetrations to outside air.

(15) All fluids (i.e., oil, refrigerant, etc.) and materials (i.e., desiccant, filters) required to operate equipment shall be provided by the Contractor.

c. The Contractor shall design and install, per compressor and dryer manufacturer recommendations, the required louver system for the metal shed. The louver system shall provide adequate ventilation for the operation of one 100 hp compressor and one matching sized air dryer. The Contractor shall provide adequate structural support for the louver. The Contractor shall make use of the existing rectangle opening in the metal shed for the new louver system or the existing rectangle opening shall be sealed if another opening is to be cut for the new louver system. The Contractor shall provide the proper filter and bird screen for the louver system.

d. Space limitations: The new RSC system shall fit in the metal shed where the current RSC system is located.

3.2.2 Contactor’s License. All general construction work indicated in this solicitation shall be accomplished by a contractor possessing a current general contractors license obtained in accordance with the North Carolina Adminstrative code or the Adminisrative code for the state in which license is currently held. The Contractor shall provide a copy of his general contractors license with his bid. Additional Licensing and certifications may be required as indicated by other notes on this solicitation. All construction work shall follow and adhered to UFC 1-200-01 General Building Requirements. The Contractor shall provide a copy of all license(s) with their bid. Contractors who fail to provide a copy of their license(s) may not be considered for contract award.

3.2.3 Current production model. The equipment provided by the Contractor shall be a current production model. A current production model is the manufacturer’s current production which, on the date the Contractor’s proposal, has been designed, engineered, and sold or offered for sale through advertisements or manufacturer’s published catalogs or brochures. Products such as a prototype unit, pre-production model, or a highly modified current model, where major components have been redesigned, do not qualify as meeting this requirement.

3.2.4 New Parts. New parts are parts that have never been used in any machine. Parts that are removed by the Contractor and replaced with a new part are the Government’s property unless designated as disposable parts (see paragraph 3.2.6 Disposable Part(s)).

3.2.5 Reconditioned Parts. Government will not accept any reconditioned parts. Reconditioned parts are defined as parts that have been removed from the RSC, cleaned, inspected, and reworked by the Contractor to meet the original manufacturer’s performance specifications.

3.2.6 Disposable Part(s). Parts designated for removal shall be properly disposed of by the Contractor unless otherwise stated in this specification. The Contractor shall comply with all Federal, State and local environmental regulations. Contractor shall follow FRC EAST INSTRUCTION 5090.1H, Chapter 3 for appropriate spill response procedures and proper handling and disposal of hazardous waste. No replacement part(s) (e.g., control panels, relays, etc.) shall be disposed of until the Government has approved and officially accepted the complete system stated in this specification.

3.2.7 Turnkey installation. The Contractor shall provide all materials, labor, shipping, tools, handling equipment, and supervision required to remove existing RSC; to construct, deliver, assemble, install, test and put in to operation new RSC; and to prepare and place in storage equipment designated for storage.

3.3 RSC Design, Performance, Physical Characteristics. The RSC shall meet, at minimum, the performance, design, and physical characteristics.

3.3.1.1 Air Compressor Requirements.

3.3.1.2 Capacity. The air compressor shall have a delivered capacity of not less than 400 scfm at an operating pressure of 125 psig. The compressor shall be designed to operate outdoors in an unconditioned shed with an ambient temperature range of 20 to 100 degrees Fahrenheit and humidity range of 60% to 90%. The air compressor shall be a single stage rotary screw compressor. In addition, the air compressor shall be equipped with a variable speed drive motor (i.e., The requirement is to have the motor speed controlled by a variable frequency drive.). The air compressor shall maintain a stable set point pressure of 100 psig + 2 psig. Due to possible large variations in loads (i.e., 15% to 100%), the air compressor shall be configured with a soft start and any other required components that shall allow numerous shutdowns and startups of the compressor in one hour.

3.3.1.3. Drive Train. The air compressor shall have a single-stage, oil-lubricated airend. In addition, the compressor shall be equipped with a high-efficiency flange-mounted ODP motor with Class F insulation.

3.3.1.4 Inlet Air Filters. The air compressor shall have inlet air filters to achieve final filter efficiency of 99.9 percent of .01 microns. Total pressure drop shall not exceed the compressor’s manufacturer recommended total pressure drop.

3.3.1.5 Cooling System. The air compressor shall be equipped with an integral air-cooled aftercooler (15oF CTD) with mounted moisture separator. The air compressor shall be rated for a maximum ambient temperature of at least 115oF.

3.3.1.6 Lubrication System. The air compressor shall be factory filled with coolant and shall be equipped with a two-stage air/coolant separator with no more than 2 ppm carryover beyond the aftercooler and condensate separator. The air compressor shall be equipped with a coolant dam that insures that bearings are submerged in a supply of coolant when the air compressor is shut down, assuring adequate lubrication at restart. SAE O-Rings shall be used on all fittings 1/4” and larger to prevent oil leaks. The compressor shall be equipped with a 10 micron spin-on oil filter for ease of maintenance.

3.3.1.7 Package Design. All components of the air compressor shall be mounted on a steel frame equipped with forklift holes for mobility. The air compressor shall have an integral aftercooler and oil cooler. The air compressor shall be equipped with a 0.3 micron inlet filter rated at 99.9% efficiency. The air compressor shall be equipped with an automatic zero air loss condensate drain with heating element. The air compressor shall be equipped with condensate drain valve. The compressor shall be equipped and operational with the required cold weather package (i.e., cold weather package shall include frost free trap, heat trace, sump heater, and control box heater) to protect it from temperatures of 20 degree Fahrenheit.

3.3.1.8 Microprocessor Control Panel. The air compressor shall be equipped with a microprocessor control system that delivers efficient, real-time energy management by operating the compressor in on-line/off-line mode during low demand periods and in upper range modulation mode when demand is between 40% and 100% of the compressor’s rated capacity. The air compressor shall have a control panel that contains the following digital displays, adjustable operating parameters, fault warnings, and fault shutdowns. The control system shall provide for all starting, capacity, and operating control requirements and shall support all safety controls. The control system shall be connected to and be fully functional with the Johnson Controls METASYS Facility Management System (FMS). All compressor readings including all monitored control panel readings, faults, alarms, warnings, and shutdowns, provided by the compressor, shall be displayed and monitored by FMS. (Contact FMS POC: Heather Hogan at 910-523-1286.). The intent of the connection to the Johnson METASYS system is to display RSC status and values at the FMS.

3.3.1.8.1 Digital Display. The air compressor shall have a digital display that displays the following: Package discharge pressure, Package discharge temperature, Total hours/loaded hours, Airend discharge temperature, Injection coolant temperature, Sump pressure, inlet filter condition, Coolant filter condition, and separator element condition.

3.3.1.8.2 Adjustable Operating Parameters. The air compressor operator shall be able to adjust the following operating parameters: Off-line pressure, On-line pressure, Control mode selection (Modulation, On-Line/Off-Line), Display cycle time, Auto Start and Stop shutdown time, Auto Start and Stop on/off, and Sequencer control on/off.

3.3.1.8.3 Fault Warnings. The air compressor shall give a fault warning for the following faults: Change inlet filter, Change coolant filter, Change separator element, and High airend discharge temperature.

3.3.1.8.4 Fault Shutdowns. The air compressor shall be equipped with an automatic shutdown should any of the following occur: High airend discharge temperature, High sump pressure, Low unloaded sump pressure, High inlet vacuum, Starter failure, Main motor overload, Fan motor overload, Low voltage, Reverse rotation, Inlet control, Sensor failure, and Microprocessor failure.

3.3.1.9 Electrical. The air compressor shall normally operate from a single electrical service. The electrical service shall be 480 Vac, 3 phase, 60 Hertz (nominal). All other required voltages shall be derived from the single electrical service via transformers, power supplies, etc. All control voltages shall be 120 Vac, single phase, 60 Hertz (nominal). The air compressor shall have a variable speed motor.

3.3.1.9.1 Input Power. The unit shall operate on input power having a nominal voltage of 480 Volts and a nominal frequency of 60 Hertz. The input shall be a three wire, three phase system with a ground. The unit shall not be damaged when the input voltage phase rotation is in reverse from the normal A-B-C phase sequence.

3.3.1.9.2 Overload Protection. The unit shall operate as specified throughout this specification for an input voltage as specified in section 3.3.1.9.1. The unit shall be provided with current overload protection to remove the unit from service during electrical faults and abnormal operation.

3.3.1.9.3 Main Motor Ratings. The main motor rating of the unit shall be as follows: 100 HP AC Induction Motor, 460 Vac, 3 Phase, 60 Hertz, Sealed Lubricated Bearings, 1.15 Service factor (or higher), Class F Insulation.

3.3.1.9.4 Efficiency. The unit shall be at least 90 percent at rated load and at least 85 percent at half-rated load.

3.3.1.9.5 Overload. The unit shall be capable of operating as specified herein at 110 percent rated load continuously. The unit shall be designed to operate at 200 percent rated load for a minimum of 5 seconds before protective devices operate.

3.3.1.9.6 Short Circuit Protection. The unit shall protect itself with minimal damage from short circuit current on any or all phases. Fuses shall be utilized for current limiting protection.

3.3.2 Refrigerated Air Dryer Requirements. Note the specifications detailed in this subsection apply to RSC’s utilizing refrigerated air dryers. If the RSC to be provided utilizes a desiccant air dryer, refer to subsection 3.3.4.

3.3.2.1 Capacity. The refrigerated air dryer shall be capable of providing a constant 39oF pressure dew point over the entire operating range of the compressor, with a selected discharge pressure range of 100 to 125 psig.

a) The dryer shall be designed to operate in the following summer and winter outdoor design conditions which are 92 degrees Fahrenheit, 60% relative humidity and 20 degrees Fahrenheit, respectively. The dryer shall be equipped and operational with the required cold weather package (i.e., heaters, heat trace) to protect it from temperatures of 20 degree Fahrenheit. Hot weather package if operating environment temperatures exceed normal manufactures guide lines.

b) Dryer design. The air dryer shall be designed, constructed, and controlled to sufficiently handle a wide load range (0 scfm to 400 scfm or maximum rated flow of compressor). One mandatory requirement is that the dryer shall be maintained at a constant pressure dew point + 39 degrees Fahrenheit.

c) Design Conditions Requirements: At operating conditions of barometric pressure of 14.7 psia and 95 degree Fahrenheit ambient air, the dryer shall be able to operate and provide a constant pressure dew point of 39.0 degrees Fahrenheit throughout the following stated operating inlet range conditions shown below:

(1) Inlet pressure range, psig 100-125

(2) Inlet flow rate range, scfm 0- 400 or maximum rated flow of compressor

(3) Saturated Inlet air temperature, degrees Fahrenheit 50 to 110

(4) Maximum ambient temperature, degrees Fahrenheit 110

Note: The unit of scfm is defined by the Compressed Air Institute as standard air at the following conditions: 60 degrees Fahrenheit and 14.7 psia and dry air.

d. Operating requirements at specified conditions: At operating conditions of barometric pressure of 14.7 psia, to Fahrenheit ambient air the dryer shall be able to operate and provide a constant pressure dew point of 39.0 degrees Fahrenheit at the following operating conditions:

(1) Inlet pressure, psig 100-125

(2) Inlet flow rate, scfm 0-400 or maximum rated flow of compressor

3.3.2.2 Refrigerant Compressor Cycle. The refrigerated air dryer shall utilize a cycling refrigerant compressor that matches operation to the actual moisture load of the compressed air. This cycling allows the refrigerant compressor to turn off when an intermediate fluid has been sufficiently chilled. This intermediate fluid shall be what actually cools the compressed air through the use of a recirculation pump.

3.3.2.3 Refrigeration compressor: The selected refrigeration compressor shall abide by Air-Conditioning and Refrigeration Institute - ARI 520. Hermetic, semi-hermetic, or open reciprocating type equipped with automatic start-stop or unloading capacity control; standard components include inherent motor protection, crankcase oil strainer, and suction screen. Refrigerant shall be an acceptable refrigerant for at least the next fifteen years for use in the United States (i.e., based on such protocols as the Montreal and the London and Copenhagen Amendments).

3.3.2.4 Condenser and Moisture Separator. The refrigerated air dryer shall utilize an air-cooled condenser and a centrifugal moisture separator. The dryer shall also be equipped with an adjustable electronic condensate zero air loss condensate drain valve with isolation valve and strainer.

3.3.2.5 Electrical. The refrigerated air dryer shall operate from 480V, 60 Hz, 3 Phase input power.

3.3.2.6 Control Panel. The refrigerated air dryer shall be equipped with a digital control panel that displays the following: Intermediate fluid temperature, Refrigerant suction/discharge temperature, Refrigerant discharge pressure, Ambient air temperature, Dryer on time, Refrigerant compressor on time, Inlet air temperature/pressure, and Outlet air temperature/pressure. The control panel shall also include a power on/off switch, a power “on” light, and a refrigerant compressor “on” light.

3.3.2.6.1 Instrumentation and Control. The refrigerant dryer shall have the following instrumentation and controls.

Include control panel in dryer cabinet containing:

a. Indicators for the following services: Inlet air pressure digital gage, discharge air pressure digital gage, inlet air temperature digital gage, main exchanger temperature digital gage, refrigeration compressor suction pressure digital gage, refrigeration compressor discharge pressure digital gage, green "Power On" light, power interruption light, and high temperature light. All measuring and indicating devices such as pressure and temperature gages on or associated with the dryer (i.e., dew point monitor) shall be graduated and labeled in the United States system of measurements. Range (i.e., temperature range, pressure range, etc.) of all measurement devices shall be inclusive of the entire operating range of the subject dryer.

b. Electrical relays: Locate in an enclosed portion of the panel, accessible for ease of servicing.

c. Controls and interlocks: To maintain required compressed air dew point and to cycle air-cooled condenser with refrigeration compressor while maintaining head pressure control with low ambient temperature.

3.3.2.6.2 Air Dryer: Instrumentation and Controls. Necessary instruments and safety devices shall be installed to facilitate maintenance and avoid damage to the compressed air dryer under foreseeable circumstances and shall as a minimum monitor and display fault for all functions and the items listed in the table titled “Mandatory Functions of Dryer”. In addition, all mandatory functions, faults and alarms of dryer as well as those listed in the table must be conveyed to, and be fully functional with FMS. (Contact FMS POC: Heather Hogan at 910-523-1286.)

Mandatory Functions of Dryer

(i.e., readings that are constantly observed and recorded by and shall be shown on the control panel system screen) Fault

Indicator

(i.e., with clear message as to what needs to be corrected)

High differential Pressure

YES

Low evaporator air temperature

YES

High condensate level (air to air drain)

YES

High condensate level (air to refrigerant drain)

YES

High condensate level (separator drain)

YES

High inlet air temp

YES

3.3.2.7 Faults/Alarms. The refrigerated air dryer shall be equipped with the following fault/alarms that cause an alarm to sound and/or cause the dryer to shut down: High ambient temperature, Low ambient temperature, High intermediate fluid temperature, High refrigerant suction temperature, High refrigerant discharge temperature, High refrigerant discharge pressure, High inlet air temperature, High inlet air pressure, and Sensor failure.

3.3.2.8 Adjustable Operating Parameters. The refrigerated air dryer shall be equipped with the following adjustable operating parameters: Fixed dew point control, Automatic dew point control, Dew point suppression setpoint, Automatic drain open time, Automatic drain off time, and Automatic drain test.

3.3.2.9 Dew Point Monitor.

The dew point monitor shall be accurate to + 0.1 degrees Fahrenheit. The dew point monitor shall have an adjustable dew point selection range of 0 to + 80 degrees Fahrenheit with an operating pressure range up to 150 psig. Dew point monitor shall include monitor and wiring. The dew point monitor shall be connected and be fully operational with the dryer. The dew point monitor shall measure and monitor the outlet dryer air. The dew point monitor shall be connected to and be fully functional with FMS. All dew point readings provided by the dew point monitor shall include all monitored control panel readings, faults, alarms, warnings, and shutdowns, and shall be displayed and monitored by FMS. (Contact FMS POC: Heather Hogan at 910-523-1286.)

3.3.3 Coalescing Filter Requirements.

3.3.3.1 Capacity. The coalescing filter provided shall have a rated capacity of not less than the maximum rated flow of the compressor at 125 psig. The coalescing filter(s) shall remove oil/water particles and mist 0.01 micron and larger with at least 99.9999% efficiency. The filter(s) shall be provided with an automatic drain valve and a differential pressure gauge that signifies when the filter is good or needs to be replaced.

3.3.4 DESICCANT AIR DRYER. Note the specifications detailed in this subsection apply to RSC’s utilizing desiccant air dryers. If the RSC to be provided utilizes a refrigerated air dryer, refer to subsection 3.3.2. The contractor shall provide turnkey installation, start up, testing, and all information required by the specifications that was also requested for the refrigerated dryer.

3.3.4.1 Blower Purge Desiccant Air Dryer Requirements.

3.3.4.1.1 Capacity. The blower purge desiccant air dryer shall be capable of providing at least (i.e., pressure dew point < - 40 degree Fahrenheit) - 40oF pressure dew point over the entire operating range of the compressor, with a selected discharge pressure range of 100 to 125 psig.

a) The dryer shall be designed to operate in the following summer and winter outdoor design conditions which are 92 degrees Fahrenheit, 60% relative humidity and 20 degrees Fahrenheit, respectively. The dryer shall be equipped and operational with a cold weather package (i.e., heaters, heat trace) to protect it from temperatures of 20 degrees Fahrenheit. Also, the dryer shall be equipped and operational with a hot weather package (i.e., vortex cooler on electrical panel to keep the electrical panel cool).

b) Dryer design. The air dryer shall be designed, constructed, and controlled to sufficiently handle a wide load range (0 scfm to 400 scfm or maximum rated flow of compressor). One mandatory requirement is that the dryer shall maintain a constant pressure dew point of -40 degrees Fahrenheit or lower.

c) Design Conditions Requirements: At operating conditions of barometric pressure of 14.7 psia, 95 degree Fahrenheit ambient air the dryer shall be able to operate and provide a constant pressure dew point of -40.0 degrees Fahrenheit or lower throughout the following stated operating inlet range conditions shown below:

(1) Inlet pressure range, psig 125 – 100 psig

(2) Inlet flow rate range, scfm 0- 400 or maximum rated flow of compressor

(3) Saturated Inlet air temperature, degrees Fahrenheit 50 to 110

(4) Maximum ambient temperature, degrees Fahrenheit 110

Note: The unit of scfm is defined by the Compressed Air Institute as standard air at the following conditions: 60 degrees Fahrenheit and 14.7 psia and dry air.

d. Operating requirements at specified conditions: At operating conditions of barometric pressure of 14.7 psia, to 110 degrees Fahrenheit ambient air the dryer shall be able to operate and provide a constant pressure dew point of - 40.0 degrees Fahrenheit or lower at the following operating conditions:

(1) Inlet pressure, psig 100-125

(2) Inlet flow rate, scfm 0-400 or maximum rated flow of compressor

3.3.4.1.2 Basic Design. The design, materials, and construction shall meet all requirements for drying air at the rate and conditions specified. Design, materials, and construction shall be in accordance with manufacturer’s standard practice and must be a cataloged item.

3.3.4.2.2 Desiccant Towers. All pressure vessels shall have welded steel chambers; 125 psig working pressure, and fabricated in accordance with the ASME BPVC VIII D1. Vessels larger than 6” diameter shall be provided with a “U” stamp and be registered with the National Board of Boiler and Pressure Vessel Inspectors.

For personnel protection or to minimize heat loss, the desiccant towers shall be insulated with a 1 ½” thickness of fiberglass and covered by an aluminum jacket.

Separate, adequately sized desiccant fill and drain ports shall be provided on each tower. Fill and drain connections shall be independent of piping assembly.

Each tower shall be provided with an ASME rated pressure relief valve.

The velocity of air through the tower shall be less than that which would disrupt, upset, or fludize the desiccant.

3.3.4.2.3 Desiccant Charge. Contractor shall provide least four charges of desiccant for the dryer.

Desiccant shall be new, spherical activated alumina, 3/16” in size. Maximum design capacity shall not exceed 14% by weight.

3.3.4.2.4 Piping and Valves. Switching valves shall be manufacturer’s standard design. Switching valves shall be non-lubricated, 2-way valves. 3-way and 4-way switching valves are not acceptable.

Valves 2” and smaller shall be non-lubricated, 2-way diaphragm actuated globe valves with valve position indicator. Valves 3” and larger shall be non-lubricated, 2-way high performance butterfly valves with double acting actuators. Butterfly valve internals shall be stainless steel with reinforced Teflon seats.

All piping shall be in accordance with ASME standard B31.1.

3.3.4.2.5 Regeneration System The idle desiccant system bed shall be regenerated by using ambient air from a vortex blower and electric heater. Positive displacement blowers are not acceptable. Motors shall be high efficiency.

Regeneration shall be carried out at atmospheric pressure; no process air shall be lost during heating.

Regeneration air flow shall be upwards through the bed.

The heater shall be rated at a maximum watt density of 14 watts per square inch. Heater shall have a ceramic sheath.

The electric heater shall be mounted externally to the desiccant bed and shall be insulated.

The electric heater shall be controlled by a dual set point indicating temperature controller. The controller shall have a primary and secondary set point with a high temperature alarm. The controller shall be mounted flush to the control panel and it shall display the temperature digitally. Additionally, another thermostat shall be located in the cold zone of the heater.

The regeneration system shall consist of a depressurizing valve with muffler, pressure switch, and purge exhaust valve. During depressurization, the depressurizing valve shall be energized. When the pressure in the regenerating tower reaches the setting of the pressure switch, the purge exhaust valve shall be energized. At this time, the heater and blower shall be energized. Control of the purge exhaust valve by the dryer timer is not allowed. After a complete regeneration, the depressurizing valve and purge exhaust valve shall close and the repressurize the regenerating tower prior to tower shift.

3.3.4.2.6 Cooling Cycle. The dryer shall operate on an 8 hour time cycle with 4 hours of drying time, 3 hours of heating, and 1 hour of cooling.

The dryer shall be equipped with a selector switch on the control panel that allows the operator to select the mode of cooling. The switch shall allow for ambient air cooling or dried gas cooling.

The dryer shall have the option of using a portion of dry cool outlet air for cooling, thus, eliminating/minimizing dew point spikes at tower shift.

3.3.4.2.7 Controls and Instrumentation.

A control panel shall be mounted on the dryer. Panel shall contain:

- On/Off switch

- Temperature control and over temperature light

- Multi-cam timer

- “Fail to shift” Alarm/light

- Common remote contacts for all alarms, lights, and horns.

- Digital temperature indicators showing:

- left tower temperature

- right tower temperature

- heater outlet temperature

- dryer outlet temperature

The dryer shall be provided with individual valve failure alarm with individual valve position indicators. The dryer enclosure shall have an indicating light for each actuated butterfly valve showing either fail to open or fail to close.

The dryer shall be equipped with a dew point controller that switches towers based on the dew point based on the dew point of the outlet air. The dew point controller shall include a direct reading dew point indicator. The electrical enclosure shall include a high dew point alarm and contacts for remote indication for high dew point. The controller shall be equipped with an adjustable set point and shall have a 4-20 mA output. The controller shall also have a selector switch to allow manual selection of dew point or fixed time control.

The electrical enclosure shall be NEMA 4 suitable for weatherproof service, unless otherwise specified.

Tubing shall be copper, supported throughout the dryer by a series of rigid tubing supports.

Provide differential pressure gauge to read pressure drop across the entire dryer/filter system.

Provide pressure gauge in dry gas cooling loop.

Provide chart recorder. Mount and wire integrally with dew point instrument and Johnson Control Metsays.

All instrument readings (pressure gauge, heater temperatures, etc.) shall be conveyed to Johnson Control Metsays FMS.

3.3.4.2.8 Painting. The dryer shall be either machine cleaned, or sandblasted, prior to painting. Painting shall consist of a prime coat and finish coat of industrial enamel paint. Insulated surfaces shall not be painted.

3.3.4.2.9 Prefilter. A coalescing type prefilter shall be supplied to remove liquid oil, water, and dirt.

Prefilter shall have replaceable cartridges. Cartridges shall consist of fiberglass with an epoxy resin.

Prefilter shall be rated 99.9% efficient at .3 microns.

Prefilter shall be supplied with a dual, automatic drain trap consisting of a mechanical primary trap, water level switch, solenoid valve, and secondary drain valve. When the primary trap fails, water shall backup into the water level switch open the secondary drain. Whenever the secondary trap is activated, a primary drain failure light and horn shall be energized.

Prefilter shall be mounted on the dryer skid with block and bypass valving and shall be provided with a differential pressure gauge.

3.3.4.2.10 Afterfilter. Provide a particulate afterfilter for removal of suspended desiccant particles. The filter shall be capable of removing 99.995 of all particles 1 micron and larger.

Afterfilter shall have replaceable cartridges.

Afterfilter shall be mounted on the dryer skid and shall be provided with a differential pressure gauge.

3.3.4.2.11 Fabrication and Assembly. All dryer components shall be mounted on a structural skid, so as to comprise a single unit.

Dryer shall be designed and fabricated to allow entry through the designated shed.

3.3.4.2.12 Inspection and testing. The complete dryer shall receive a mechanical test assuring that all components operate properly. Additionally, the entire assembly shall receive a soap bubble test assuring the integrity of all joints and fittings.

3.3.4.2.13 Air Dryer: Instrumentation and Controls. Necessary instruments and safety devices shall be installed to facilitate maintenance and avoid damage to the compressed air dryer under foreseeable circumstances and shall, at a minimum, monitor and display faults for all functions and the additional items listed in the table titled “Mandatory Functions of Desiccant Dryer”. In addition, all mandatory functions, faults and alarms of dryer as well as those listed in the table must be conveyed to and be fully functional with FMS. (Contact FMS POC: Heather Hogan at 910-523-1286.). The intent of the connection to the Johnson METASYS system is to display RSC status and values at the FMS.

Mandatory Functions of Desiccant Dryer

(i.e., readings that are constantly observed and recorded by and shall be shown on the control panel system screen)

3.3.5 Physical Characteristics.

3.3.5.1 Air Circuit. The air circuit shall be designed and fully able to meet the following requirements.

3.3.5.2 Materials and Equipment. Materials and equipment complete with accessories shall be selected by the Contractor for performance compatibility.

3.3.5.3 Anchoring. The RSC components and the control cabinet for the new controller shall be securely anchored/fastened to the existing structure.

3.3.5.4 Electrical system. The RSC components shall be furnished complete with all accessories required for full operation, including but not limited to electrical motors, contactors, controls, relays, transformers, and switches pre-wired for operation upon connection to main power source. The complete installation and wiring shall be in compliance with applicable requirements of NFPA 70 and NFPA 79. The Government will provide electrical service 480V, 3-phase, 60Hz fed from panel “M” 480V, 400Amp located in Bldg 4173 to NEMA 3R 200Amp, 600V, 3-phase fusible disconnect switch for new RSC equipment. The safety disconnect will be installed within 50 feet of new RSC equipment.

The contractor shall provide the control voltage 120V, 1-phase, 60Hz from the step-down transformer for the RSC equipment controller.

The existing 120V circuit in the air compressor shed is for the lighting and receptacles only. (The contractor shall not use this circuit for their equipment controller.)

3.3.5.5 Electrical Work - Electrical motor-driven equipment specified shall be provided complete with motors and motor starters and controls. Motor starters shall be provided complete with properly sized thermal overload protection and other appurtenances necessary for the motor specified. Electrical work shall be as specified in Section 16402N INTERIOR DISTRIBUTION SYSTEM Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices, shall be provided.

3.3.5.6 Electrical Power Control - The Contractor shall provide electrical power, control, and instrumentation system as specified or recommended by the equipment manufacturer for the safe operation of the units and related equipment shall be provided. Schematics and interconnection wiring diagrams for power, control, and instrumentation circuits shall be provided to equipment specified. Terminal blocks (plus 25 percent spare terminals) shall be provided in panels to terminate field and interconnection wiring. Control power transformers, relays, adjustable timers, auxiliary contacts, switches, or additional equipment as required shall be provided. Conduit wiring between control panels and control devices shall be furnished as part of this specification. Control circuits shall have maximum voltage of 120 volts derived from control transformer in same enclosure. The Contractor shall provide fuses for the equipment safety disconnect switches per equipment manufacturer’s recommendation.

3.3.5.7 Motors - NEMA MG 1. The Contractor shall provide the size in terms of HP, or KVA, or full-load current, or a combination of these characteristics, and other characteristics, of each motor as indicated or specified. The Contractor shall determine and provide specific motor characteristics to ensure provision of correctly sized starters and overload heaters. All motors for operation on 480-volt, 3-phase circuits shall have terminal voltage rating of 460 volts. Motors shall be designed to operate at full capacity with voltage variation of plus or minus 10 percent of motor voltage rating. The Contractor shall provide size for duty to be performed, not exceeding the full-load nameplate current rating when driven equipment is operated at specified capacity under most severe conditions likely to be encountered. The Contractor shall provide when motor size provided differs from size indicated or specified, make adjustments to wiring, disconnect devices, and branch circuit protection to accommodate equipment actually provided. The Contractor shall provide the soft starter for the motor specified with all overload per manufacturer’s recommendation.

3.3.5.8 Motor Controllers Motor controller must be UL listed, NEMA ICS 1, and NEMA ICS 2. Controllers shall have thermal overload protection in each phase and shall have one spare normally open and one spare normally closed auxiliary contact. Magnetic-type motor controllers shall have under voltage protection when used with momentary-contact pushbutton stations or switches. Interconnecting wires shall be copper. Terminal blocks shall be plug-in type so that controllers may be removed without disconnecting individual control wiring. Controllers shall have thermal overload protection in each phase. Motor starters shall be provided complete with properly sized thermal overload protection and other appurtenances necessary for the motor specified. Overload protective devices shall provide adequate protection to motor windings and be thermal inverse-time-limit type. Cover of combination motor controller and manual switch or circuit breaker shall be interlocked with operating handle of switch or circuit breaker so that cover cannot be opened unless handle of switch or circuit breaker is in “off” position. The Contractor shall provide a new soft starter for the motor specified per motor manufacturer’s recommendation for reducing motor voltage (and current draw) during acceleration..

3.3.5.9 Pushbutton Stations. The Contractor shall provide pushbutton stations with “start/stop” momentary contacts having one normally open and one normally closed set of contacts, and red lights to indicate when motor is running. Stations shall be heavy duty, oil-tight design.

3.3.5.10 Pilot and Indicating Lights The Contractor shall provide pilot and indicating lights that have the transformer, resistor, or diode type or Provide LED cluster lamps.

3.3.5.11 Installation. Electrical installations shall conform to requirements of NFPA 70.

3.3.5.12 Control Voltage. All system controls (including but not limited to motor starters, relays, lights, sensors, all electronic devices, etc.) shall operate on 120 VAC, 60 hertz maximum in accordance with NFPA 70.

3.3.5.13 Wiring. All wiring, conduit, and attaching hardware shall be provided by the Contractor. All wiring shall be in accordance NFPA 70.

3.3.5.14 Measurement systems. The U.S. Customary System of Units (US) shall be used in the design and construction of the RSC. In this specification, all measurements, dimensions, sizes and capacities are given in the US system of measure.

3.3.5.15 Measuring and indicating device graduations. Measuring and indicating devices such as pressure and temperature gauges on the RSC shall be graduated and labeled in the US system of measurements.

3.3.5.16 Servicing. Routine scheduled or as required servicing of the equipment shall be accomplished in such a fashion as to not require disassembly of the equipment.

3.3.5.17 Accessibility. All parts subject to wear, breakage, or distortion shall be accessible…