2016-32_800_LPAC_NLON.doc

A rental specification — Overview of Machinery & Equipment Requirements Table A1:

Blast Machinery & Equipment Requirements

SYSTEM

Flow:

800 ± 50 scfm Press:

≥130 psig Motor:

≥180 hp @ LS Hose:

3" M & F spud × 400' Air:

3" M spud ftg Tee:

1 F in×2 M out Rgl:

130 ± 5 [V] Rgl:

110 ± 5 [M/T]

RMK L-1:

100% Oil-Free

RMK L-2:

Electric Fuse ≤400A

RMK L-3:

System [components]

DAD + Tank (500 gal) b

[ M / DAD ] + TK

tLPA–M [ m / DAD ]

LPA for Multiple Purposes

Table A2:

Low Pressure Air Compressor (LPAC) Abbreviations (per MIL–STD–12D) Low Pressure Air Compressor (LPAC) Machine or System:

CTD

Cold Temperature Difference: ∆T between ambient air and compressed air.

TANK

Receiver / Accumulator / holding type Tank or Vessel / pressurized Container.

HS | LS

High Speed motor i.e. ~3500 rpm (±100) | Low Speed motor i.e. ~1750 rpm (±50).

ASME

American Society of Mechanical Engineers.

LPAC

Low Pressure Air Compressor (≤150 psig).

Oil-Free Compressor design prevents any oil from entering the compression chamber.

LPAC–M

Medium (M) capacity LPAC in that electric-drive requires one 200A 3Ф breaker.

LPAC–N

Normal (N) capacity LPAC in that electric-drive requires one 400A 3Ф breaker.

LPAC–L

Large (L) capacity LPAC in that electric-drive requires two 400A 3Ф breakers.

TLPA–B

Temporary Low Pressure Air (system) for Breathing [ B ] air only.

TLPA–M

Temporary Low Pressure Air (system) for Multi-Purpose [ M ] i.e. [ T / V / etc. ].

TLPA–T

Temporary Low Pressure Air (system) for pneumatic Tooling [ T ] only.

TLPA–V

Temporary Low Pressure Air (system) for Vacuum [ V ] Blast Recovery only.

Compressor / Dryer / Etc:

[elec] Electric-driven [stm] Steam-driven [dsl] Diesel-driven [pneu] Pneumatic-driven (LPA) [rad] Refrigerant Air Dryer [dad] Desiccant Air Dryer [ B ] Breathing air [ M ] Multi-Purpose [ T ] pneumatic Tooling [ V ] Vacuum Blast Recovery

PWT

Pure Water Trailer

Capacity Identifier:

–G: Gigantic (–X: Extra Large (–L: Large (–N: Normal (–M: Medium (–S: Small (–B: 06-5-Ph I BASE Identifier:

PNSY: Portsmouth Naval Shipyard, NH ( NLON: New London, CT ( NBPL: Naval Base Point Loma, CA

A rental specification — Overview of Machinery & Equipment Requirements:

L-1 100% Oil-Free (Compressor): Although filtration may be included for safety reasons, the compressor design shall incorporate sealing technology to prevent any oil from entering the air side of the compressor such as the compression chamber so that no oil (i.e. 100% Oil-Free) comes in contact with the compressed air. The compressor shall not be "wet-ended" or "oil-flooded" type in which filtration is the means that removes practically all of the oil from the air usually after the air has been compressed. The compressed air discharged from these type compressors are not "100% Oil-Free" in that there exists some residual oil, albeit minute. Not only is residual oil incompatible for Breathing [B] air, but residual oil is also incompatible to support Vacuum Blast Recovery [V] machines in that even the most minute amount of oil sprayed on newly blasted near white metal has a deleterious effect for the adherence of coatings. Residual oil would not even be compatible for a compressor isolated to support pneumatic Tooling [T] alone in that the same air hoses are used for all three system air types with no intent to create a special program to differentiate air hoses by the type of LPA system. Hence, the compressor shall have the following words boldly stenciled on its housing: "100% OIL – FREE AIR" L-2 Utility [Fuse Amperage if Electric]: The utility (diesel-driven or electric-driven) shall be as indicated. If the compressor is electric-driven, the protective fuse amperage shall be no greater than as indicated.

L-3 System [components]: Each compressor is a packaged system that also includes several other machinery components downstream of the compressor unit. The machinery components of a packaged system shall be mutually compatible to each other. The Contractor is responsible for the labor for (no more than eight man-hours) and the supplying of the inter-connecting air lines and fittings between machinery components downstream of the Low Pressure Air Compressor (LPAC) in the following order: (i) Compressor, (ii) Air Dryer, and (iii) Air Tank (a.k.a. Receiver or Holding Tank) to terminate with a three inch (3"), spud male (M) connector.

[a] Aftercooler (AFTCLR): Because of limited available footprint on the pier, a separate (i.e. independent) aftercooler will not be used. Instead, all compressors shall incorporate aftercooling and/or intercooling such that the Cold Temperature Difference (CTD), (temperature differential between the lower ambient air temperature and the higher compressed air temperature) is no greater than 25ºF during the hot weather season (ambient @ 90ºF). Where further cooling is required, a Refrigerant Air Dryer vice a Desiccant Air Dryer shall be deployed.

[b] Air Dryer (DRYER): A separate air dryer shall be the first machinery component downstream of the compressor. For LPAC(s) designated to service pneumatic Tool [ T ] air or have Multiple [ M ] purposes to include Vacuum [ V ] Blast Recovery and/or Dry [ D ] air, the dryer shall be a desiccant type. Hence, the LPAC shall include a desiccant type dryer. Desiccant Air Dryers (DADs) shall have at least two settings for dew point temperatures of –40ºF & –100ºF. Desiccant dryer(s) shall use Low Pressure Air (LPA) from the compressor for its primary power and only a minor amount of 120 volt single phase power to operate its control panel. The desiccant dryer shall consume no more than 18% of the LPA input volume for purging to a –40ºF setting and no more than 20% LPA input volume for purging to a –100ºF setting. Because pneumatic type desiccant dryers operate on LPA, the volume rating in cubic feet per minute (CFM) for the dryer shall be equal to or slightly greater than the rating of the compressor actually delivered and not oversized. Slightly greater is interpreted to be no more than fifty cfm above (–0/+50 cfm).

[c] Air Tank (TANK): The air tank size is based on providing about thirty seconds (~30") of reserve air as an accumulator for surges as computed below. For the pneumatic Tooling [ T ] and/or the Vacuum Blast Recovery [ V ] air systems' 800 scfm compressors, respectively, the tank capacity shall be approximately 500 gallons, correspondingly, and ASME rated to 150 psig minimum.

500 gal [tk] ÷ 800 std-atm – ft3 / min [cprsr] × 60 sec / min ÷ 7.48 gal / ft3 × 105 psig [tool min set] ÷ 14.7 psia / std-atm = 35.8 sec [d] Air Hose & Adapter Fittings (HOSE): The quantity of hose assemblies as listed in Table A1 (column: minimum capacities) is for each compressor machine system and is in addition to the inter-connecting air lines between components. The TRANSITION column states the transition fitting size & type and any adapters.

A rental specification — Overview of Machinery & Equipment Requirements (Notes by ITEM)

LPAC [elec]–N SYSTEM: Besides 100% Oil-Free as defined in the Remarks, the compressor shall be a two-stage rotary screw air-cooled compression design typical of those manufactured by Ingersoll-Rand or the H (Higher pressure) series Model KNW1-G/H as manufactured by Kobelco. The compressor shall be aftercooled and/or intercooled such that the outlet temperature (TO) of the pressurized air is no greater than twenty-five degrees Fahrenheit above ambient when the ambient temperature is at or below ninety degrees Fahrenheit (If TA ≤ 90ºF, then TO ≤ TA + 25ºF; i.e. CTD ≤ 25ºF).

ALL

Oil-Free Inter-Connecting Hardware (Air Hose Assemblies and Adapter Fittings): All inter-connecting [lpac] hardware between compressor components, such as the air hose assemblies and adapter fittings, as well as additional hose as listed in Table A1: Machinery Requirements shall be clean and Oil-Free. If existing hardware has not been maintained in a clean and Oil-Free status or the Contractor has doubt as to its status, then the Contractor shall pre-flush with warm – hot water only and thoroughly drain / dry the inter-connecting hardware.

All Lifting & Handling (L&H) Exception: All compressors and their associated heavy components are to be [lpac] deployed onto the Pier and not in the Drydock. Therefore, there is a L&H exception in that lifting padeye(s) are not required for overhead crane lift. However, the machinery and its associated heavy components do require a foundation base with multiple slotted pockets (i.e. box beams) for forklift handling.

All Machinery Quality Checklist: A Quality Checklist shall be developed, abided to in every operational check, and copies shall both accompany the machine.

all Vendor Identification (ID) of Itemized and Ancillary (w/ Machinery) Equipment: The Contractor shall uniquely tag and permanently mark all of its ancillary and itemized equipment / hardware (e.g. manifolds, hose assemblies, pipe fittings, duct adapters, ducting, etc.) so as to differentiate from that owned by either the Shipyard or other Vendors. Tagging alone is often insufficient. Suggest painting the ferrous metal on hardware and the end fittings on hose assemblies with unique and distinct color(s) associated to that Vendor.

All Machinery / Equipment Marking & Tagging: The Compressed Air Inlet and Outlet (CAI & CAO) for all of the major components as well as other utility line(s) must be clearly marked. Machinery and itemized equipment require tagging to show.

A rental specification — Overview of Machinery & Equipment Requirements (Notes by ITEM)

NLON

Electrical Cable: Each electrically powered high voltage machine (i.e. 460 VAC) shall include a single length of at least fifty feet (50') for each phase plus ground of appropriately rated electrical cable. Electrical power cables shall be single-conductor copper, mineral-insulated 90ºC or better (e.g. Type R90 / RW90 / T90 Nylon). Electrical cables shall have ends that are compatible to the machine's panel-mounted cam-lock connectors. There shall not be a separate fee for electrical cables so furnished. The Shipyard will install and electrically connect the rental equipment to the appropriate power source.

[lpac] If a machine requires more than 400 Amps (e.g. LPAC [ELEC]–L), then include multiple cables for each phase.

NLON

Commercial Delivery Access: There are two independently secure areas that commercial vehicles must gain access in order to effectuate delivery. The first is the main Base and the second is an Enclave inside the Base (Pier 15 @ NLON). The best method to gain access to the Base is via a RAPIDGate® badging program (info: 877.727-4342). A Project Sponsor would be required if the truck driver or repair technician does not have a RAPIDGate® badge. The Sponsor will need to request a Vetting Form from the Physical Security Specialist. After the Sponsor has submitted the completed Vetting Form, it will take seven to ten days for the Vetting process to be completed. After the Vetting process has been completed, a one day Temporary Pass to gain access to the main Base will be available at Bldg 174. Further access into the Enclave will require continuous escort. However, if the individual(s) has RAPIDGate® badge(s), the Sponsor can submit an Enclave Access Request Form to the Physical Security Specialist so that badge(s) can be encoded. This would allow vehicle access into the Enclave without an escort. Considering the aforementioned difficulty in gaining Base / Enclave access, it is highly encouraged that the Contractor utilizes transport Vendor(s) with RAPIDGate® badged drivers to the point of transferring locally either the driver or the trailer load for the final destination delivery of the machinery and/or equipment transported cross-county. Also, because of the Contractual Repair Requirements which would not allow for an extended Vetting process (see paragraph B4.), the Contractor must have, for each machine under lease, qualified service and repair technicians with Rapid Gate badges.

B rental specification — Contractual Requirements 1.

Access: To be allowed onto a government Shipyard, personnel must be US citizens and in possession of appropriate personal identification. Proof of US citizenship may be necessary and can be required for access to the drydock environs. Allowable documentation of US citizenship is an official government issued Certificate of Birth or Naturalization (w/ raised seal & not a photocopy) or a US passport (can be expired). Vehicular access requires a non-expired personal Driver’s License and appropriate vehicle identification or registration. The transport vehicle must have the company’s name / logo prominently displayed. Normal commercial delivery access to NLON: (see NOTE) is from 5:30 am to 1:30 pm Monday thru Friday (excludes Federal Holidays). To gain access to the drydock environs, personnel must be escorted and possess / wear their own personal safety gear which includes: safety glasses w/ side protection, hard hat, safety shoes with an ANSI approved reinforced toe box, and, as posted, adequate hearing protection (i.e. ≥20 dB[A] reduction from ear plugs and/or ear muffs).

2.

Delivery: The machinery shall be in a fully-charged, fully-assembled, ready-to-use, and in a first-class-operating condition. Disposable type filters shall be replaced with new (virgin) and permanent (metal) filters shall be clean prior to delivery. The machinery with its support equipment shall be delivered to the site on or prior to the request date. It is incumbent and the responsibility of the Contractor to either confirm or coordinate the date and time of delivery prior to each shipment via the Contracting Officer's Representative (COR) and/or Point-of-Contact (POC) as designated on the Contract. The Government can provide forklift services for removing machinery from Vendor’s transport during work hours (NLON: 6A to 3:30P). Documentation [B/L] shall accompany each delivery.

Machines shall be functionally tested to include performance of the Quality Checklist prior to its delivery.

3.

Literature: Although the Bidder shall make known any variances to the Technical Specifications, synopsized literature describing the proposed machinery, i.e. Equipment Data Sheet (EDS), shall be submitted with the bid to Contracting for potential review by the Technical Liaison as to whether the proposal conforms to the requirement.

4.

Repair: The Contractor shall formally (written, E-mail is sufficient) inform the Contracting Officer, Supervisory Contract Administrator, and/or applicable Contract Specialist. The PNS Administrator Point-of-Contact / COR, if above $150K; and the Project's Operation (PEPM) / Execution (TSZM) POCs; as well as display on each machine the name and telephone number for requesting repair. The equipment will be operating around-the-clock under a rigorous off-site deployment performance schedule. Within twelve (12) hours (half-day) of initial notification of the need for repair, the Contractor shall have a knowledgeable and equipped technician on the job-site fully prepared to repair the rental equipment. The defective unit(s) shall be repaired within twenty-four (24) hours (one day) of initial notification or, if the original defective unit(s) cannot be made operational, replaced within forty-eight (48) hours (two days) of initial notification. If the equipment failure is not the fault of the Government, the Contractor shall bear all costs associated with its repair and/or replacement.

6.

Return: The Government will dismantle the equipment and provide a temporary storage location convenient for Contractor pick-up. The Government will notify the Contractor as well as the Contracting Office as to when the rental Item has been released and is available for pick-up. The last day of the rental period shall be the next normal workday after the Contractor has been so notified. The Contractor shall be responsible for shipping. The Government can provide forklift services during work hours for placing the equipment onto the vendor’s transport.

7.

Service: Except for daily surveillance checks i.e. liquid levels, the Contractor is responsible for and shall perform all maintenance (e.g. refrigerant charge, oil changes, replace / clean filters, lubrication, coolant refills, liquid top-offs, etc.) for the duration of the lease. Coordinate maintenance w/ Executing POC particularly shut-downs.

8.

Start-Up: If requested by the Project, the Vendor shall: (i) start and run the equipment to verify its operability; (ii) confirm that a set of operating instructions was previously delivered; and/or (iii) instruct designated Shipyard personnel on how to properly run the equipment to include its operation, control, daily checks, & service contacts. For multiple sets of comparable equipment with essentially similar operation, the orientation given to a specific Project on a particular type and/or capacity of machine can be accomplished just once regardless of delivery.

C rental specification — General Machinery & Equipment Requirements 1.

Construction: Except as noted for a particular machine type, units shall be a single integrated framed structure manufactured as a complete entity to include all devices, accessories, and fittings necessary to perform the function for which it was designed. Each unit shall be capable of continuous, year-round, outdoor, unmanned operation even at minimal loading while exposed from inclement (NBPL) to extremely harsh (PNSY & NLON) weather (e.g. deep snow, strong & gusty winds, and/or heavy rain) and varied ambient conditions (–10 to +110ºF & 0 to 100% RH). Machines shall meet State and federal requirements for its type such as the National Electrical Code (NEC) for electrical devices / components and the American Society of Mechanical Engineers (ASME) for pressurized vessels / components. For emission producing machinery as required by the State, the Contractor shall obtain permits for the duration of the lease and affix them onto the units. Machines shall be modular in design so as to act as a stand-alone unit; compact so as to fit in the tight confines of a drydock; portable so as to be transported by forklift and then lifted by crane; and ruggedly constructed so as to endure a marine industrial environment. Multiple machines of the same type and capacity shall be of similar design and construction.

Machines shall be newly manufactured / completely refurbished and factory tested within ten (10) years.

2.

Documentation: Documentation will be located within a water proof case affixed to each machine. Minimally, the documentation shall consist of: (i) Technical Instructions (TIs) such as an Operations & Maintenance Manual, Controls Manual, and/or Electrical Manual with Schematics; (ii) instructions and a diagram on Lifting & Handling the equipment with its padeye(s) Certification; (iii) government Contract Number to include the cover sheet to the rental Contract; (iv) an Equipment Data Sheet (EDS), preferably on a single sheet of paper (can be double-sided), of the quintessential aspects of the rental machine to include a fan curve for machines with built-in air-handlers; (v) simple Operating Instructions, if not in the TIs; (vi) points of contact with telephone numbers for requesting emergency repair regardless of the time or type of day; and (vii) a copy of the Quality Checklist.

3.

Electrical: Electrical components shall conform to a NEMA standard (NEMA 3 or 4) that allows for unsheltered outdoor use of the unit. Each machine shall require only one type / source of electrical power of either 115 VAC +5% / single-phase / 60 hertz or 460 VAC +5% / three-phase / 60 hertz. The type of electrical power required (voltage & amperage) must be clearly indicated on the outside of the equipment, readily detected, and collocated with all other electrical information. If not included in the synopsized EDS, the Vendor shall provide the Project Technical Liaison with the following details: (i) electrical power type (amperage & voltage); (ii) type of electrical connectors (for 3 Φ, specify whether or not equivalent to Duraline E1016); (iii) breaker type/size or recommended capacity for the electrical source; and (iv) whether the machine is furnished with over-current protection. Three phase powered (i.e. 460V) machines shall have panel-mounted male cam-lock connectors equivalent to a single Duraline E1016 for each phase if ≤285A (preferred, permits 2/0 cable) or ≤385A (minimum, but restricted to 4/0 cable) or below and equivalent multiple connectors for greater amperages.

4.

Lifting & Handling: Unless exempted in advance, machines shall be firmly attached to a single rigid metal (steel if ≥3K#) caged frame (base boxed w/ four vertical corner posts and four horizontal perimeter beams at top) with both multiple slots for forklift handling and, preferably, welded lifting padeye(s), which would result in and permit for safe single point lift operation using an overhead crane without special lifting or handling gear. To minimize a rigging delay or postponement, lifting points other than the preferred welded lifting padeye(s) (e.g. holes drilled thru structural members or bolted padeyes / eyelets) will require an advance design review - consultation - analysis by the Shipyard's Rigging Engineer (Code 713). The design safety factor for each lifting padeye or point shall be at least five (5) times the load based on ultimate strength. For equipment with two (2) or three (3) padeyes / points evenly spaced, the machine’s weight can be considered equally distributed. For equipment with four (4) padeyes / points, the loading shall be as if each lift point would support half of the machine’s weight. The strongest preference is for multiple padeyes to be aligned in the plane of the lift (i.e. padeyes point towards the center) and to be located above the machine’s Center of Gravity (CG). If the lift points are located below the CG, then the machine’s CG shall be accurately indicated as to both its elevation and position. The Contractor shall provide certification that each lift point meets the criteria described above by design (5 to 1 ultimate strength & 3 to 1 minimum yield) or by load test (2 to 1 w/ no yield). Such certification to include the Lifting Schematic along with any other lifting data shall be included with the documentation attached to the machine.

NOTE:

The precise weight of each machine to include its caged frame shall be prominently displayed.

5.

Noise: When operating at full speed, noise levels must not be over 105 dB[A] (assumes hearing protection of 20 dB[A]) and preferably, 85 dB[A] or less (threshold for hearing protection) at six feet from the unit or frame unless a quieter noise level is specified. A hearing protection safety placard shall be posted on each machine generating more than 85 dB[A] at the unit's edge or frame. For equating noise ratings of a particular unit, noise intensity (energy) is cut in half, i.e. reduced by 3 dB[A], as the distance is doubled. Hence, a noise rating of 88 dB[A] at 3 feet and conversely, a noise rating of 82 dB[A] at 12 feet is equivalent to a noise intensity of 85 dB[A] at 6 feet.

6.

Prohibition: For a nuclear shipyard with radiological controls, the colors yellow or magenta on either machinery or associated equipment are strictly prohibited unless approval is requested w/ pictures showing the colors prior to bid submission so that the particular machine / equipment color would be known for an RC List of Exceptions.

TLPAC Specification Sheet 3 of 5