Updated Draft SPEC-WFD-Rotary Screw Compressor.doc

SPEC617WFD43423

SPEC617WFD43423

ROTARY SCREW AIR COMPRESSOR SYSTEM

1.0

SCOPE

1.1 Scope. This specification describes the minimum requirements for the removal of an existing and the design, manufacture, delivery, installation, and testing of a new rotary screw air compressor system, to include a rotary screw air compressor, a refrigerated air dryer, dew point monitor, coalescing filter, piping, valving and accessories (herein referred to as the RSC). 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, 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 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.

2.2 Non - Government documents. The following documents (i.e., most recent versions), 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 Drawing

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

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

2.2.2 Non-Government Documents.

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

Standards.

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 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

2.2.3 Other publications

EM 385-1-1 U.S. Army Corps of Engineers, Safety and Health Requirements Manual

NFPA 70 National Electrical Code

NFPA 79 Electrical Standard for Industrial Machinery

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 or MS standards), 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 existing RSC and design, installation, and testing of a new RSC associated piping from established Contractors having experience in the design, installation, and testing of low pressure rotary screw air compressors, refrigerated dryers, and compressed air piping. 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.

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:

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 item (1) (compressor - P/A: 65923074618) and item (3) (dryer - P/A: 65923074619) that is removed for proper storage. Item (2) (compressor - P/A: 65923X02082) the Contractor shall provide a turnkey relocation and turnkey installation inside the metal shed, per section b of this section 3.2 titled Work to be accomplished. The Contractor shall follow original manufacture recommendations for proper storage recommendations. The Contractor shall physically place in to storage (i.e., storage location will be 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, one refrigerated compressed air dryer and one dew point monitor and accessories. . The designated refrigerated 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. 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 (a) of this section 3.2, titled Work to be accomplished, shall be relocated to an acceptable location (i.e., the location shall be acceptable per Government and be acceptable per current electrical codes and current OSHA regulations) inside the existing metal shed. 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 (i.e., equipment is termed 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, gas compliant.

(8) The Contractor shall install one properly sized coalescing filter (i.e., specified in section 3.3.3.1 titled Coalescing Filter Requirements 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 (i.e., specified in section 3.3.3.1 titled Coalescing Filter Requirements 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.

c. The Contractor shall design and install, per compressor and dryer manufacture 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.

3.2.1 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.

3.2.3 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 and/or designated as this specification states as disposable parts (i.e., see paragraph 3.1.5 Disposable Part(s)..

3.2.4 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.

3.2.5 Disposable Part(s). All stated items of this specification that are subject for removal shall be properly disposed of by the Contractor. 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) (i.e. control panel, relays, etc.) shall be disposed of until the Government has approved and officially accepted the complete system stated in this specification.

3.2.6 Turnkey installation. The Contractor shall provide all materials, labor, shipping, tools, handling equipment, and supervision required to remove existing and construct, deliver, assemble, preparation of equipment for storage, place equipment in storage, install, test, and put into operation the new and existing equipment specified herein.

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 for outside installation in an unconditioned shed. The expected summer and winter outdoor design conditions shall be 92oF 60%RH, and 20oF, respectively. The air compressor shall be a two stage rotary screw compressor. In addition, the air compressor shall be equipped with a variable capacity control and a variable speed drive motor. The air compressor shall maintain a stable set point pressure of 100 psig + 2 psig with a variable compressed air demand for 15% to 100% of compressor rated flow. The Contractor shall prove this variable capacity control (i.e., efficiently operate between 15% and 100%) of the compressor, in the required Performance Acceptance test of this specification.

3.3.1.3. Drive Train. The air compressor shall have a two-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 15% 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 FMS (i.e., FMS = Johnson Controls METASYS Facility Management System, Contact Johnson Control, Randy Reed at (910) 520-3681). All compressor readings (i.e., readings shall include all monitored control panel readings, faults, alarms, warnings, and shutdowns) provided by the compressor shall be displayed and monitored by 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.

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

a) The dryer shall be design to operate in the following summer and winter outdoor design conditions which are 92 degrees Fahrenheit, 60% relative humidty and 20 degrees Fahrenheit, respectively. The dryer shall have variable capacity control to efficiently operate between 0% and 100% of full load capacity conditions. 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.

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 maintained a constant pressure dew point 39 degrees Fahrenheit.

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 35.0 degrees Fahrenheit throughout the following stated operating inlet range conditions (i.e., 1 through 4) shown below:

(1) Inlet pressure range, psig 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 115

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 40.0 degrees Fahrenheit at the following operating conditions:

(1) Inlet pressure, psig 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 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 (i.e., FMS = Johnson Controls METASYS Facility Management System, Contact Johnson Control, Randy Reed at (910) 520-3681).

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 monitor the outlet dryer air. The dew point monitor shall be connected to and be fully functional with FMS (i.e., FMS = Johnson Controls METASYS Facility Management System, Contact Johnson Control, Randy Reed at (910) 520-3681).All dew point readings (i.e., readings shall include all monitored control panel readings, faults, alarms, warnings, and shutdowns) provided by the dew point monitor shall be displayed and monitored by FMS.

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 Physical Characteristics.

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

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

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

3.3.4.4 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.

3.3.4.5 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.

3.3.4.6 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.

3.3.4.7 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.

3.3.4.8 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..

3.3.4.9 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.

3.3.4.10 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.

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

3.3.4.12 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.

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

3.3.4.14 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.

3.3.4.15 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.

3.3.4.16 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.

3.3.4.17 Accessibility. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

3.3.4.18 Support equipment. The Contractor shall provide all support equipment (i.e. tools, fixtures, jigs, instruments etc.) required to operate, maintain and calibrate each of the subsystems and the overall RSC components.

3.3.4.19 Environmental conditions. The RSC shall be so designed and constructed that, under the transportation, storage, operating, and service conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prescribed by Federal, State, or local statutes in effect at the point of installation.

3.3.4.20 Temperature and humidity. The RSC design shall provide continuous, convenient, efficient, and safe operation in a normal factory environment defined as ambient conditions of 32 degree Fahrenheit to 110 degree Fahrenheit, and 10% to 95% relative humidity.

3.4 Design and construction.

3.4.1 Piping components. All piping components (i.e. valves, gauges, pipe material etc.) shall be designed, constructed, installed, and hydrostatically tested per ASME B31.3.

3.4.1.1 Compressed Air Piping. All piping components (i.e., valves, gauges, pipe material, etc.) of the RSC shall be constructed/installed in accordance with ASME B 31.1, 29 CFR 1910 Subpart Q and ASME BPVC IX Pressure Vessel Code. Welding, brazing, or soldering shall be employed only where specified in the original design. These processes shall not be employed as a repair measure for any defective part. All welding shall be completed by a current certified welder. The subject welder(s) shall have maintained qualification in accordance with ASME Section IX “Welded and Brazing Qualifications.” All welding procedures and personnel certification shall be in accordance ASME BPVC IX Pressure Vessel Code. All welding required for this specification shall follow and adhered to the most recent editions of ASME B31.1 and NAVFAC Unified Facilities Guide Specifications Section 15216N – Welding Pressure Piping. If a conflict develops between the interpretations of two different specifications (i.e., ASME B31.1 and Section 15261N) then alert the contracting officer of the discrepancy and request a ruling or guidance on that specific issue. The Contractor shall have all piping components (i.e., valves, gauges, pipe material etc.) designed, constructed, installed and leak tested per the most recent edition of ASME B31.9. The Contractor shall only leak test new piping. The Contractor shall provide all blind flanges and all other equipment to isolate the new section of piping from old piping and existing equipment when performing leak test. The Contractor shall provide all equipment to perform the leak test as stated by ASME B31.1. The Contractor is 100% responsible for securing and protecting all people and all equipment in the entire area (i.e., within 500 feet of any pipe under test) during all testing phases. The Contractor shall provide and turn into the Government a detailed Non-Destructive Examination (NDE) report for all sections of pipe welded required by this specification. The Contractor shall have all fabrication, assembly, welding, and brazing conform to ASME B31.9 for all piping of the air system. Piping shall follow the general arrangement shown. Work piping into place without springing or forcing, except where cold-springing is specified. Piping and equipment within buildings shall be entirely out of the way of lighting fixtures and doors, windows, and other openings. Locate overhead piping in buildings in the most inconspicuous positions. Do not bury or conceal piping until it has been inspected, tested, and approved. Where pipe passes through building structure, pipe joints shall not be concealed, but shall be located where they may be readily inspected and building structure shall not be weakened. Avoid interference with other piping, conduit, or equipment. Except where specifically shown otherwise, vertical piping shall run plumb and straight and parallel to walls. Piping connected to equipment shall be installed to provide flexibility for vibration. Adequately support and anchor piping so that strain from weight of piping is not imposed on the equipment. All piping (i.e., valves, pipe, gauges, etc.) installation, unless otherwise stated, shall adhere in all aspects to NAVFAC Facilities Guide Specifications – Section 15211N – Low Pressure Compressed Air Piping. The Contractor shall install all new piping that shall be ASTM A53, type S, grade B, schedule 40, seamless steel. The Contractor shall ensure all new piping materials, support, hangers, installation and testing shall conform to ASME B 31.9. The Contractor shall ensure all horizontal piping shall be supported to prevent excessive sagging, bending and shear stress inn the pipe. Acceptable hanger types and supports for bare and covered pipe shall conform to MSS SP-69.

3.4.1.2 Contractor Shall Ensure That During All Construction And Testing Each Designated Working Sections of Sections of Existing Piping Shall Be 100% Secure and 100% Isolated. All section of piping the Contractor performs any work or testing on or to existing piping shall be fully 100% isolated and secured from the existing piping network. The Contractor shall ensure the existing pipe structure (includes fittings, valves, pipe, equipment attached to and/or next to pipe structure) is not affected in any way from any excessive force, vibration, shaking, heat, chemicals that may alter and or deter existing piping (i.e., piping includes all valves, fittings, and attached equipment). That is, the Contractor shall fix and replace all items the Contractor damaged while under demolition, construction, flushing, cleaning, and testing phase of this project. In addition, Contractor shall fully replace and correct all leaks (i.e., at no cost to the Government) associated and attached with the pipe structure (i.e., pipe structure includes the new piping and the attached existing piping and equipment) within one year following the completion of this construction. No part of the existing piping network shall the Contractor apply a procedure (heat, force, fluid, pressure, etc.) that will alter the original configuration and/or alignment of the system in any shape or manner. The Contractor shall provide the necessary structural bracing required to offset any and all forces incurred by any Contractor activity done to existing piping. Contractor activity includes all of the following procedures: alignment, fitting pipes into place, removing/inserting sections of pipe, cutting, welding, brazing, cleaning, flushing, etc. Contractor shall confirm and record alignment prior to and after the work is completed. All alignment results shall be provided to the Government.

3.4.1.3 Welding Permits. Prior to any welding or any hot flame the Contractor shall contact Marine Air Core Station at 252-466-2241 to apply for and receive all hot air permits required for each area and/or process.

3.4.1.4 Contractor Pre-Construction Requirements. Before any work is started, the Contractor shall secure (i.e., close, lock out and tag out) all shut off valves that reside closest to but not on or within the designated construction site and/or demolishing side of each of the designated pipe sections. The Contractor shall provide a complete written procedure 24 days prior to any work. The written procedure shall clearly identify procedure and all the valves that the Contractor intends to isolate and secure prior to performing any work. It is mandatory, that all valves that have been previously secured and closed by the Contractor for cleaning and isolation purposes, shall be unsecured and open after the Contractors has completed the specified work of this contract. At no instance, valves remain close or in a state that differs from pre-construction period.

3.4.1.5 Additional Pressure Piping Requirements

3.4.1.5.1 Country of Fabrication

a. All piping, fittings, piping accessories, and valves shall be manufactured, fabricated, and/or assembled in the United States of America or Canada and shall be manufactured, fabricated, and/or assembled by an ISO 9001 registered corporation. The Contractor shall provide proof to the Government on all materials (i.e., piping, fittings, accessories, etc.)

3.4.2 RSC materials.

3.4.2.1 Castings and forgings. All castings and forging shall be free from defects such as scale and mismatching. Processes such as welding, peening, plugging, or filling with solders or pastes shall not be used on castings or forging to reclaim any defective components. Such processes may be used only for enhancing surface finish and appearance.

3.4.2.2 Welding, brazing or soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. These processes shall not be employed as a repair measure for any defective part. Welding shall be accomplished by a certified welder.

3.4.2.3 The Control of Hazardous Energy (Lockout/Tagout). A written procedure for locking out all energy sources shall be provided in accordance with 29 CFR 1910.147. The written procedure shall be included in the equipment manuals.

3.4.2.4 Fastening devices. All screws, pins, bolts, and other fasteners shall be installed in a manner to prevent change of tightness. Fastening devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed.

3.4.2.5 Surfaces. All surfaces shall be clear and free of sand, dirt, fins, spurs, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be in accordance with the manufacturer’s commercial practice.

3.4.2.6 Painting. All surfaces to be painted shall be cleaned of all foreign matter. The RSC shall be painted in accordance with manufacturer’s standard commercial practice. All piping, not constructed from stainless steel or copper, shall be painted with a minimum of one coat of primer and one coat of finish color.

3.4.3 Electromagnetic radiation. Conducted and radiated electromagnetic interference shall be suppressed so as not to affect the normal operations of communication and other adjacent items of electrical equipment. The Contractor shall produce documentation to illustrate compliance with this requirement. This documentation shall be provided at the CDR.

3.4.4 Nameplates and product markings. (This section has been deleted since it is covered in the supply DFAR clause.)

3.4.5 Workmanship. Workmanship of the system and accessories shall be commensurate with the requirements specified herein and shall be of a quality prevailing among manufacturers normally producing equipment of the type specified herein.

3.4.6 Interchangeability. All parts shall be manufactured to definite dimensions and tolerances and standards that shall permit replacement or adjustment without modification of machine parts. Where possible, all parts shall be permanently and legibly marked with the manufacturer’s original part number.

3.4.7 Safety. The design and operation of the RSC shall comply with OSHA 29CFR1910. The Contractor shall follow and abide by AWS Z49.1. The Contractor shall follow the 29 CFR 1910.1026 and EM 385-1-1 when performing welding of all piping. The Contractor shall have all MSDS sheets, physically on hand, for all chemicals in use by the Contractor. Any demolition work conducted by the Contractor, the Contractor shall protect, at all times, their workers as well as FRCE employees from any physical or chemical hazardous (i.e. dust particulates, vapors or gases).

3.4.8 Human factors. The RSC shall comply with the human engineering requirements specified by industry standards. All operator controls and instrumentation (i.e. valves, switches, gauges, readouts, indicators etc.) shall be conveniently located for industry standards.

3.4.9 Electrical Labeling. Provide an identification placard for each safety switch, motor controller, heater, and main disconnect with the following information: equipment name, power feed from, circuit breaker number, volt, amp, and hertz. Placard shall be black lettering on a white background and attached with rivets or screws to the center of the motor controller, main disconnect and all disconnect cover. Also, provide all power feed information if the motor controller has multiple power source (120VAC, 230 VAC, 480VAC, etc.).

3.5 Documentation. The Contractor shall provide all technical documentation listed on the Contract Data Requirements List (CDRL) (see section 5.2). The manufacturer’s standard technical documentation format shall be acceptable for all contract data requirements if all information required by the CDRL is provided.

3.5.1 Site Preparation and Installation Plan. Drawings and associated lists detailing site preparation and installation of piping, equipment, and controls shall be provided (CDRL A001).

3.5.2 Calibration Procedures. Calibration procedures shall be provided for all instrumentation and equipment supplied with the RSC (CDRL A002).

3.5.3 List of Recommended Maintenance and Test Support Equipment. A list of maintenance, test, and support equipment shall be provided for each subsystem in the RSC (CDRL A003).

3.5.4 Spare Parts List. A list of recommended spare parts shall be provided for each subsystem in the RSC (CDRL A004).

3.5.5 Technical Manuals. Technical manuals shall be provided describing operation, maintenance, and repair of the RSC (CDRL A005). Documentation shall include:

a. Four (4) sets of Operator’s Manuals (i.e., four sets is define as three being hard copies and fourth copy in an electronic format) for the Complete RSC Control System (CDRL A005)

b. Four (4) sets of Maintenance Manuals (i.e., four sets is define as three being hard copies and fourth copy in an electronic format) for the Complete RSC Control System (CDRL A005)

c. Four (4) sets of technical manuals (i.e., four sets is define as three being hard copies and fourth copy in an electronic format) shall be shipped with equipment. Documentation shall include at a minimum: Operations, Installation, Maintenance, Calibration, Preventive Maintenance, Lockout/Tagout Procedures, Illustrated Parts Break Down, Recommended Spare Parts List, Vendors Literature, Mechanical Design Drawings, Hydraulic/Pneumatic Schematics, and Electrical/Electronics Schematics. (CDRL A005)

d. Four (4) sets of Control System Diagnostic Manuals (i.e., four sets is define as three being hard copies and fourth copy in an electronic format) (CDRL A005) which as a minimum shall include the following: A detailed description of the proposed RSC system control system shall be provided. The description shall include, but not be limited to, the following items:

a. Product information for sensors, switches, relays and instruments.

b. Panels, Consoles, and Cabinets Information

(1) Layout Drawings

(2) Panel schematic and internal point-to-point wiring interconnect diagrams

(3) Electrical control schematics for all circuits indicated in the specifications or on the Contract Drawings. Wires shall be labeled and shown on the submittal drawings.

(4) Plan…