08-T-9035 SOW 9-25-08.doc

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 a refrigerated air 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 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 one existing compressors (P/A: (P/A: 65923X02082) and dryer (P/A: 65923074619). The Contractor shall remove the following two pieces of equipment:

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

(2) 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) (25 HP compressor - P/A: 65923X02082) and item (2) (dryer - P/A: 65923074619) for proper storage. 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, one refrigerated compressed 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 location of RSC system within the shed shall be acceptable to the Government and shall comply with current electrical codes and OSHA regulations. The existing 50 HP compressor (P/A: 65923074618) shall be tied into the new RSC compressor system (i.e., both RSC compressor and RSC dryer) in a parallel piping arrangement. The Contractor shall provide parallel piping arrangement for all equipment. Parallel piping arrangement shall provide the ability to isolate one piece of equipment. In addition, the Contractor shall provide one or two correctly sized zero loss automatic drain(s) (supplied with heating element(s) for RSC system with all required piping, and valves that shall allow the zero loss automatic drain(s) to properly drain to the outside of the metal shed

(3) 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.

(4) 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.

(5) 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..

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

(7) 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.

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

(9) 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.

(10) 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.

(11) 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).

(12) 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.

(13) 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.

(14) All fluids (i.e., oil, refrigerant, etc.) and materials (i.e.,filters) required to operate equipment shall be provided by the Contractor for initial start up and testing.

(15) The Contractor shall provide turnkey relocation of one white air receiver from inside the shed to outside the shed. The Contractor shall provide a rectangular 6 inch reinforced concrete pad that matches the existing overall width of all mounted the existing white receiver brackets. That is, the reinforced concrete pad provided for the white receiver shall be sufficiently large enough to mount all existing receiver brackets to concrete pad. The new location of the white receiver shall be centered with the existing blue receiver (~ 46 inches away from shed) and centered (i.e., placed exactly half way between the road and the existing blue receiver). The piping to the white receiver shall be piped in a parallel arrangement. In a parallel piping arrangement, both receivers feed into one main header and distributes the air from a different header as existing incoming and outgoing air are piped to directly to the main header entering and the main header leaving. That is, in a parallel arrangement both receivers will receive and release air to the same main headers as the existing blue receiver. The white receiver shall have correctly sized isolation valves on both on the inlet and outlet. The actual pipe size shall match existing.

(16) The Contractor shall ensure that RSC system operates only one compressor at a time. That is, either the 100 HP is operational and the 50 HP is off and in a stand by mode or have the 50 HP operational and the 100 HP is off and in a stand by mode (i.e., due to electrical load capacity to main power distribution)

c. The Contractor shall design and install, per compressor and dryer manufacturer recommendations, the required ventilation system (fan, louver system and/or Government accepted shed ducted opening) for the metal shed. The Contractor shall provide adequate ventilation for the operation for one 100 hp compressor and one matching sized air dryer. The Contractor shall provide adequate structural support for proposed louver and/or ducted opening.. 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 installed ventilation system. All calculations for sizing and selecting adequate ventilation (fan, size opening) of the metal shed shall be provided to the Government with CDRL A001.

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 Administrative code or the Administrative code for the state in which license is currently held. 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 110 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%)).

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 10 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 3 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 12 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 10 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 Control Panel. The air compressor shall be equipped with a 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. Some faults and alarms shall be provided by the compressor and dryer.

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. As an optional feature, the Contractor may provide an ampere reading.

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.

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.

3.3.2.1 Capacity. The refrigerated air dryer shall be capable of providing a constant 41oF 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 heat trace (i.e., heat trace wrapped around condensate pipes to protect condensate lines) 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 + 41 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 + 41.0 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 41.0 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, as a minimum, shall be equipped with inlet air temperature, ambient temperature, alarm indicator, compressor run indicator, service due indicator.

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: As a minimum, the indicators shall be provided for the following: inlet air temperature, ambient temperature, alarm indicator, compressor run indicator, service due indicator. .

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”. The Contractor shall provide two (2) dry contacts (run and fault status) and shall be connected to the new RSC system (dryer and compressor) for possible future communication upgrade.

Mandatory Functions of Dryer

3.3.2.7 Faults/Alarms. The refrigerated air dryer shall be equipped with the manufactures standard package.

3.3.2.8 Adjustable Operating Parameters. The refrigerated dryer shall be equipped with the manufactures standard package.

3.3.2.9 Dew Point Monitor.

The dew point monitor shall be accurate to + 2 degrees Fahrenheit. The dew point monitor shall have an adjustable dew point selection range of +10 to + 70 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 dewpoint monitor shall be provided with two (2) dry contacts (low and high dewpoint alarm) and connected to the controller of the dryer and compressor of RSC system for possible future communication upgrade.

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 1 micron and larger with at least 99.999% 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. 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.)

3.3.4.5 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 20 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 intent is to site test only the new piping sections. 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 Existing Piping Shall Be 100% Secure and 100% Isolated. All sections of piping the Contractor performs any work or testing on 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 damage existing piping (i.e., piping includes all valves, fittings, and attached equipment). 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, at no cost to the Government, associated and attached with the pipe structure (pipe structure includes the new piping and the attached existing piping and equipment) within one year following the completion of this construction. The Contractor shall not apply a procedure to any part of the existing piping network (e.g. procedures involving heat, force, fluid, pressure, etc.) that will alter the original configuration and/or alignment of the system in any shape or manner. 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 business 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, be unsecured and opened after the Contractors has completed the specified work of this contract. In no case will valves remain closed or in a state that differs from the pre-construction period.

3.4.1.5 Additional Pressure Piping Requirements

3.4.1.5.1 Country of Fabrication

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. Item identification will be governed by DFARS Clause 252.211-7003, ITEM IDENTIFICATION AND VALUATION (JUN 2005) and is incorporated by reference to this solicitation.

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…