TX1 1600 CFM Diesel LPAC SOW-UPDATED.pdf

Diesel Powered Low Pressure Air Compressor [LPAC]

Spec #: Diesel1600CFMLPACTX1112321 Rev: Orig. Page 1 of 9

STATEMENT OF WORK

1. SCOPE

1.1. Portsmouth Naval Shipyard (PNSY) is seeking to lease a diesel powered Low Pressure Air Compressor (LPAC) system. The application is to support blast air equipment. The diesel driven compressed air system will have a dedicated compressor with a built-in double wall fuel tank (i.e. UL 142 Double Wall Tank Assembly), shall be Tier 4 emissions certified and be equipped with all necessary controls, pressure regulator, desiccant air dryer, and compressed air hoses. The minimum allowable requirements for the system is detailed in the Statement of Work (SOW) below. The compressor plant shall be designed for outdoor use and will be subjected to inclement weather year round. The vendor shall be responsible for supplying all fittings and adaptors required to make all equipment and hose connections. The vendor shall be responsible for setting up the compressor and support equipment and also provide equipment startup and commissioning, as requested by PNSY. The application for the compressed air systems is located at the Portsmouth Naval Shipyard.

2. APLLICABLE DOCUMENTS

2.1. Issues of Publications - The following documents in effect on the date of this requested proposal is a part of this specification to the extent applicable, or as specified herein. Within the specification, they shall be referred to by their basic designation only.

2.1.1. Government Furnished

2.1.1.1. PNSY: General Specification For Integral Lifting Attachment Design

2.1.2. Nongovernment Furnished

2.1.2.1. N/A

2.2. Order of precedence - In the event of conflict between the text of this specification and that of the references cited above, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws or regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Component List

3.1.1. Required components.

PIECE

NO.

QTY. NAME OF PART PARA NO.

CP-01 2 1600 CFM Diesel LPAC 3.2 CP-02 2 1550 CFM Desiccant Dryer 3.6 CP-03 375 FT 3 IN Air Hose 3.7.1 CP-04 375 FT 3 IN Air Hose 3.7.1

Rev: Orig. Page 2 of 9

3.2. Diesel Driven LPAC Requirements

3.2.1. Nominal compressed air flow rate: 1600 SCFM @ 145 PSIG

3.2.2. Maximum system pressure working pressure: 150 PSIG

3.2.3. System regulated air pressure set point: 145 PSIG

3.2.4. The air compressor shall be capable of continuous operation providing uninterrupted delivery of compressed air, 24hrs/day, seven days a week for the duration of the rental.

3.2.5. Minimum Compressor Stages: 2

3.2.6. Compressor connection: 3 Inch M SPUD Fitting.

3.2.7. Compressor shall be capable of developing instrument quality air and shall have the following features integrated into the machine:

3.2.7.1. Compressor shall be equipped with Integral After Cooler & Intercooler (for multi stage compressor).

3.2.7.2. Built in after-cooler (intercooler) capable cooling the compressed air stream by developing and cold temperature differential (CTD) of 25°F above ambient temperature.

3.2.8. Compressor shall be air-cooled and enclosed in a weatherproof enclosure suitable for outdoor operation with an ambient operating temperature range of -10°F to 110°F without the need for additional shelter/protection.

3.2.9. Unit must be less than 5 years old and have less than 10,000 operating hours.

3.2.10. Unit must have a 3” Ground Joint female spud for connection on the compressor.

3.2.11. All opening/connections/flanges are to be cleaned and capped.

3.3. LPAC Physical Dimension

3.3.1. Maximum Allowable Footprint (L x W x H) Inches: 18’ X 8’ x 9’

3.3.2. Maximum Allowable Weight (lbs): 21,500

3.3.3. LPAC shall be trailer mounted.

3.3.3.1. The trailer for the diesel shall be of recent vintage, and be capable of being moved by tractor or mule. The trailer may be either double or triple axel. The trailer shall meet all DOT regulations and shall be registered and road legal.

3.3.3.2. Tongue / hitch mount shall be either ball or pintle style hitch. (Gooseneck and 5th wheel couplers are not permissible.)

3.4. Diesel Requirements:

3.4.1. The diesel LPAC shall meet all Federal, State and Local regulations with regards to the emission standards of the Environmental Protection Agency (EPA). The unit shall be compliant with all regulations defined by EPA Tier 4 Emissions.

3.4.2. LPAC unit must be diesel powered with a built-in fuel tank. The built-in fuel tank shall have its own containment (i.e. UL 142 Double Wall Tank Assembly).

3.4.3. Diesel enclosed in a weatherproof enclosure suitable for outdoor operation with an ambient operating temperature range of -10°F to 110°F without the need for additional shelter/protection.

3.4.4. Diesel shall operate as a self-contained, air cooled unit. No cooling water shall be required to support operation.

3.4.5. The Diesel shall be equipped with a cold weather operating package. Required featured include:

3.4.5.1. Glow plugs / Air intake grid heater

3.4.5.2. Engine oil sump heating element

Rev: Orig. Page 3 of 9

3.4.5.3. Coolant / antifreeze system heating

3.4.6. Unit must be able to run for at least 8 hours without fuel or Diesel Exhaust Fluid (DEF) being refilled while operating at 100% Full load.

3.4.7. The diesel shall be equipped with a self-contained cooling/ (and if applicable) heating system.

3.4.8. When operating at 100% Full load, noise levels shall not be over 85 dB[A] at three feet from the unit.

3.4.9. Unit must be configured so that fuel and DEF can be refilled during operation.

3.4.10. Unit must be delivered with at least ¾ tank of fuel and DEF must also be filled sufficiently to perform operational testing.

3.4.11. The diesel LPAC shall be capable of being lifted by crane (i.e. a four-point lift). A Lifting &

Handling diagram/sketch that is applicable to the trailer situation shall be provided.

3.4.12. Diesel shall be delivered with brand new filters, oil and all fluids. The unit shall be provided additional new spare filters including 2 spare fuel filters and 2 spare engine oil filters. The spare filters shall be stored within the Diesel LPAC service / maintenance cabinet or compartment.

3.4.13. Maintenance shall be provided per section 6.4. The estimated monthly runtime operation for each diesel LPAC is approximately 500 Hours.

3.5. LPAC Operating and Safety Controls:

3.5.1. Low pressure cut in

3.5.2. High Limit Pressure cut out

3.5.3. High Pressure safety relief valve

3.5.4. Pressure Relief valve set to 125 PSIG. Pressure relief set point shall not exceed the working pressure ratting of any component in line with the compressed air system.

3.5.5. High Temp Alarm

3.5.6. High temperature compressor cutoff

3.5.7. High pressure compressor cutoff

3.5.8. Oil sensor & alarm

3.6. 1550 CFM Desiccant Dryer Requirements:

3.6.1. Nominal Inlet Flow rate: 1550 SCFM @ 145 PSIG

3.6.2. Nominal Dew Point Operating points: -40°F and -100°F

3.6.3. Ambient Operating Temperature range: 100°F to -10°F

3.6.4. Nominal Outlet Flow at Dew Point:

3.6.4.1. @ -40° P.D.P (SCFM): 1327

3.6.4.2. @ -100° P.D.P (SCFM): 1309

3.6.5. Maximum Allowable Footprint (L x W x H) Inches: 110 X 80 x 96

3.6.6. Maximum Allowable Weight (lbs): 5,000

3.6.7. Nominal Rated Working Pressure (PSIG): 150

3.6.8. Inlet / Outlet Connections: 3IN SPUD

3.6.9. Dryer shall be equipped with particulate and oil removal pre-filters c/w automatic condensate drains and a one micron after filter.

3.6.9.1. Post compressor shall be equipped with particulate and coalescing oil removal pre-filters w/ automatic condensate drains and a one micron after filter.

Rev: Orig. Page 4 of 9

3.6.10. The desiccant dryer shall consume no more than 18% of the LPA input volume for purging to a –40°F setting and no more than 20% LPA input volume for purging to a –100°F setting

3.6.11. The Desiccant dryer shall operate from one circuit rated at: 120 VAC, single phase, 20 Amp, 60Hz.

3.7. Equipment Air Hose Connection & Distribution Hose Requirements:

3.7.1. The contractor shall provide 3 IN hose with (FxF) 3 IN Ground Joint female spud for connections at each hose end. The contractor shall, on delivery, make all 3 IN hose connections between compressor / dryer, and all hose connections must have safety cables (Safety Restraint Devices) installed to prevent hose whip in case of accidental separation of coupling or clamp device. Each hose section shall be a maximum length of 25 Feet long.

3.7.1.1. The contractor shall also provide 3 IN Spud BOSS (MxM) couplers to support all hose connections. These connections will be between each hose section and at each piece of equipment.

4. NOTES:

4.1. 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 to extremely harsh weather (e.g. deep snow, strong & gusty winds, and/or heavy rain) and varied ambient conditions (–10 to +110°F & 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. 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. Machines shall be newly manufactured / completely refurbished and factory tested within ten (10) years.

4.2. Diesel Compressor Sound Pressure Level Requirement:

Compressors will operate in the immediate proximity of the work environment either on the Pier or in the floating drydock where there is an inherent echo chamber affect. Hence, noise intensity when operating at full speed must not exceed 85 dB[A] (threshold for hearing protection) and preferably, less than 80 dB[A].

4.3. Supplemental Equipment:

For the protection and cleanliness of the machinery components, all steam connection points shall be shipped with plug/cap fittings.

4.4. 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 (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. The Vendor shall provide the Project Temporary Services Zone Manager with the following details: (i) electrical power type (amperage & voltage); (ii) type of electrical connectors (for

Rev: Orig. Page 5 of 9 three phase, specify whether or not equivalent to Duraline 4M20); (iii) breaker type/size or recommended capacity for the electrical source; and (iv) whether the machine is furnished with over-current protection.

4.5. Lifting & Handling:

4.5.1. See reference 2.1.1.1.

4.6. Machinery / Equipment Tagging and Markings:

All piping inlet(s) / outlet(s) must be clearly marked. Machinery and itemized equipment require tagging to show Project Number / Technical Specification Identification (ID) Number

4.7. Vendor Identification Of Itemized And Ancillary 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.

4.8. Dead Front Control Panel or External Controller:

Access to basic machinery controls, such as a Dead Front Control Panel or External Controller, shall be such that there is non-exposure to energized "live" electrical circuits or other components regardless of voltage, to include control circuitry, by "a person on the operating side of the equipment".

5. GOVERNMENT FURNISHED MATERIAL (GFM):

5.1. Blast equipment gear: Blast Pot with 3 inch female Ground Joint female spud connection.

6. RESPONSIBILITITES

6.1. Government

6.1.1. Equipment Technical Evaluation: C230 Engineering

6.1.2. Receipt Inspection: Contractor Officer Representative (COR) & Zone Manager (ZM)

6.1.3. Coordination of equipment delivery & returns: COR & ZM

6.1.4. Schedule equipment service, repair, and training: COR & ZM

6.2. Contractor

6.2.1. Any and all required State approved safety features (i.e. safety pressure relief valves, low water cutout, over pressure protection) installed with the State of Maine certification.

6.2.2. The Contractor shall provide the material and labor to install the interconnecting air lines and fittings between machinery components downstream of the Low Pressure Air Compressor (LPAC) in the following order: Compressor, built-in Aftercooler, Air Dryer, and receiver or holding tank, terminating in three inch (3") spud male (M) connectors. The components of a packaged system shall be mutually compatible to each other

6.2.3. The contractor shall maintain a stringent maintenance program and be responsible for all routine maintenance, except for daily check of liquid levels. The contractor shall provide oil, filters, coolant, and lubricant for engine and compressor operation during the rental period.

Rev: Orig. Page 6 of 9

6.2.4. The contractor shall provide service within twelve (12) hours after notification by the Contracting Officer or his/her representative. In the event the machine cannot be returned to service within twenty-four (24) hours of notification, a replacement shall be delivered at no extra charge to the Government.

6.2.5. The contractor shall be responsible for equipment failure not arising out of abuse or negligence by the government.

6.2.6. There shall be no changes unless authorized by the Contracting Officer.

6.2.7. The vendor shall provide technical support to PNSY project personnel as required.

6.3. Machinery Quality Checklist (MQC): The vendor shall develop and provide a Machinery Quality Checklist (MQC) unique for each machine. The MQC shall include an operational checklist and Objective Quality Evidence (OQE) of Functional Performance Testing identified in 6.3.1 and 6.3.2 of each machine prior to shipment. An MQC report shall be generated for each specific piece of rental equipment being provided to fulfill the contract that shall identify the piece of equipment, Make, Model Number, and serial number, and test date of equipment. The MQC reports shall be authored by the vendor. The vendor shall provide blank templates of each MQC report and provide these to PNSY along with the Equipment Bid/Proposal package. The MQC template reports (blank) shall be reviewed for technical acceptance during the Technical Evaluation of the Vendors Bid/Proposal. Any changes to the MQC’s shall be identified at the proposal review. All equipment testing and validation to support the MQC report shall be completed within one month of ship date to PNSY, or detachment location. Copies of the completed MQC reports shall be provided to PNSY Contracting Office C400 and Temporary System Design Engineer for review one week prior to equipment ship date.

6.3.1. MQC Report Operational Checklist: At a minimum, MQC reports shall include 2 primary sections:

first is a basic functional check list to verify all equipment components are in place, intact, and in good working order. This check sheet shall include, at a minimum include items such as gaskets, new filters, valves operational, airend discharge pressure gauges, air pressure relief valves, strainers cleaned, piping end caps to maintain cleanliness. If components (such as an after cooler) within a packaged unit configuration (such as an LPAC) are found to be non-operational, damaged, etc. the original item is to be replaced or repaired, and not substituted with an auxiliary replacement system.

Example Line item format of an MQC Checklist:

Item / Component Inspection Date Technician Signature

Condition:

Satisfactory or Unsatisfactory

Desiccant Dryer Bed Media Bed replaced

LPAC pressure regulator installed, set to correct operation pressure.

Air Receiver Tank free from oil, water & debris

Moisture separator operationally tested

Compressor Inlet filter replacement date, New filter

Rev: Orig. Page 7 of 9

6.3.2. MQC Report Functional Performance Testing: The vendors shall perform a complete functional performance test of each piece of equipment. This shall include fully testing the equipment’s performance capabilities. The Vendor shall measure and record the performance of the equipment.

If the vendor does not have the capability to test the equipment in house, a certified Testing & Balancing agency may be subcontracted by the vendor to complete the functional performance testing of the equipment.

6.3.2.1. LPAC Units: the equipment shall be powered and all electrical circuits, fuses, contactors & relays, control panel functions, control panel indicators, verified motor speed (RPM), filter static pressure drop, motor FLA, rotational verification, pressure regulator performance test, pressure control set point test, cooling oil leak check and pressure test, component leak check and pressure test, after cooler performance check.

6.3.2.2. Dryer: the equipment shall be powered and all electrical circuits, fuses, contactors & relays, control panel functions, control panel indicators, flow switch safety interlock function verified, discharge air dew point verification, system leak check and pressure test.

6.4. Maintenance

6.4.1. Except for daily surveillance checks, the Contractor is responsible for all equipment preventative maintenance and repairs for the duration of the lease. Coordinate maintenance with Shipyard Zone Manager.

6.4.2. The vendor shall provide Preventative Maintenance (PM) schedules which are equipment specific.

The PM shall meet all requirements determined by the Original Equipment Manufacture (OEM).

The vendor shall provide the PM documentation and schedules to PNSY Temporary Services Engineering Code 230 for review and approval prior to being considered for a successful Bid. The routine PM plan for each piece of equipment shall include a comprehensive list of the components to be serviced as well as identifying the service frequency. (e.g. all consumables to be replaced, bearing grease points, belt replacement / tensioning, filter changes, refrigerant charge, oil changes, other lubrication, coolant refills, liquid top-offs, etc.) All PMs conducted shall include a technical service report identifying component, maintenance conducted, date, and next scheduled PM date.

Copies of all reports shall be delivered to the project COR and the Zone Manager.

6.4.3. In addition to providing routine preventative maintenance, the vendor shall provide a service technician on a weekly basis for the duration of the lease to perform weekly equipment inspections.

Weekly equipment inspections shall consist of checking all functional operating parameters of each individual piece of equipment. This shall include but is not limited to: verifying correct equipment performance and operation, checking for diagnostic or trouble codes, verify amperage of all electric heating coils. Weekly equipment inspections shall include a technical field report identifying the status of each piece of equipment and shall include all data / measurement points verified. All reports are delivered to the project COR.

6.5. The vendor shall provide a knowledgeable service technician to cover the repair of all equipment deficiencies and malfunctions. The response time for the repair or replacement of deficient equipment shall meet the requirements defined in section 6.2.

6.6. Training

The Contractor is responsible for and shall provide training sessions to Shipyard Personnel on the operation and setup of all equipment. Training shall be available throughout the duration of the lease to accommodate equipment swap out and seasonal equipment operation.

6.7. Operator / Maintenance Manuals - Documentation will be located within a water proof case affixed to each machine. Minimally, the documentation shall consist of:

6.7.1. Lifting & Handling the equipment with its padeye(s) Certification

Rev: Orig. Page 8 of 9

6.7.2. Points of contact with telephone numbers for requesting emergency repair regardless of the time or type of day

6.8. Deliverables – In addition to all required equipment, technical documentation shall also be provided electronically to the project COR and Engineering. Minimally, the documentation shall consist of:

6.8.1. Lifting & Handling the equipment with its padeye(s) Certification. (see Reference 2.1.1.1)

6.8.2. Points of contact with telephone numbers for requesting emergency repair regardless of time or type of day

6.8.3. Technical Instructions (TIs) such as an Operations & Maintenance Manual, Controls Manual, and/or Mechanical/Electrical Manual with Schematics.

6.8.4. Operating Instructions, if not in the TI.

6.8.5. MQC Reports. (See Section 6.3)

6.8.6. Preventative Maintenance Schedules. (See section 6.4)

6.9. Equipment Data Sheet (EDS)

7. DELIVERY / ACCEPTANCE / RETURN

7.1. Delivery- The machinery shall be in a fully-charged, fully-assembled, ready-to-use, and in a first-class-operating condition. Machines shall be functionally tested prior to its delivery and all leased products, including machine / equipment / ancillary component accompanying machine, must fully function as intended. 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 Point-of-Contact (POC) as designated on the Contract and/or the Contracting Officer's Representative (COR). The Government can provide forklift services for removing machinery from Vendor’s transport during work hours. Documentation with Shipyard copies shall accompany each delivery.

7.2. Acceptance-Upon satisfactory completion of inspection and test of the equipment, the authorized Government Representative (Portsmouth Naval Shipyard, Code 420 COR) will sign and forward the acceptance document(s) to Code 220 Production Control for completion. Unloading of equipment from Vendor’s transport does not signify acceptance.

7.3. 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.

7.4. Security- 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. 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. To gain access to the drydock environs, personnel must be escorted and possess / wear their own personal safety gear.

7.5. Receipt Inspection Criteria- Equipment must meet all criteria defined in this specification.

Rev: Orig. Page 9 of 9

7.6. Final Acceptance- Upon satisfactory completion of inspection and test of the equipment, the authorized Government Representative (Portsmouth Naval Shipyard Code 990 Equipment Manager or Project Temporary Service Zone Manager) will sign and forward the acceptance document(s) to the POC as designated on the Contract and/or the COR for completion. Unloading of equipment from Vendor’s transport does not signify acceptance.

7.7. Return- The Government will 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.

8. GENERAL

8.1. Response to Request

As part of the response to this request, descriptive literature shall be furnished in sufficient detail to show that the proposed design will meet these specifications. Vendor submittals shall include brochures of the model being submitted, assembly sketches with critical dimensions, sketches (with dimensions) of all tooling being provided, statements of compliance with specification, and performance statements with special instructions. Supporting information shall be organized and packaged by unit. If supporting information includes multiple models the vendor shall clearly state model number of proposed unit and redact all information not applicable to proposed unit.

9. ATTACHMENTS

9.1. N/A

10. Approved Equipment Models

10.1. N/A