Pleated Carbon Adsorber Specification - 25 Jan 23.docx

1/19/2023

PERFORMANCE SPECIFICATION

CELL, GAS PHASE, PLEATED CARBON ADSORBER

- Nominal 24 inches W x 24 inches H x 12 inches D, Box Style, 1,800 ACFM

- Nominal 20 inches W x 24 inches H x 12 inches D, Box Style, 1,500 ACFM

- Nominal 12 inches W x 24 inches H x 12 inches D, Box Style, 850 ACFM

- Nominal 24 inches W x 24 inches H x 12 inches D, Header Style, 1,550 ACFM

NOTE:

ANY AND ALL EXCEPTIONS TO THIS SPECIFICATION SHALL BE SUBMITTED TO THE GOVERNMENT OR CONTRACTING OFFICER WHERE APPLICABLE, FOR APPROVAL / CONSIDERATION / DIRECTION.

1. SCOPE

This specification covers the requirements for procurement of pleated carbon style gas phase adsorber cells used to remove toxic chemical vapors entering air filtration systems for collective protection applications. This specification does not include requirements for the frames into which these adsorber cells are installed. The pleated carbon adsorber shall use high activity carbon that meets the testing requirements of this specification.

1.1 For the number of ready-to-use adsorbers delivered to the U.S. Army Edgewood Chemical Biological Center (USA CBC) refer to SOW and Paragraph 6.4 for Delivery Address.

1.2 Adsorbers to be Destructively Lot Tested.

For each manufactured lot randomly selected adsorbers will be submitted for destructive lot testing, as required by paragraph 3.3.3 and 4.3.5. The adsorbers will be randomly selected by the Government from a list of serial numbers of the lot as provided by the manufacturer. Therefore, the required number of pleated carbon adsorbers to be manufactured is equal to the number required to be delivered to the USA CBC plus the number of adsorber cells to undergo destructive testing. If at least one adsorber cell fails to meet the criteria, the lot shall be rejected and the assembly procedure must be adjusted and another lot submitted for dimethylmethylphosphonate (DMMP) breakthrough life testing. Just prior to running the DMMP test, the airflow resistance will be measured and recorded in inches water gage (IWG) for each adsorber cell. All testing will be at the actual cubic feet per minute (ACFM) design conditions with the adsorber in its service orientation.

1.3 Adsorber cells shall be 100% factory Freon (R134a) tested as required by the manufacturer. The airflow resistance will be tested at the rated airflow. Alternate parameters for subject test may be submitted by the manufacturer to the Government for approval. The designated adsorber cells for destructive testing (at the USA CBC or Government designated test lab) will be challenged with DMMP at 250 mg/m3 (at rated flow rate, Paragraph 4.5 Sec b) to a breakthrough concentration of 0.1 mg/m3. If at least one adsorber cell fails to meet a minimum 55 minute gas-life criteria or the average of all adsorber cells tested fails to meet a 65 minute gas-life, the lot shall be rejected and the assembly procedure must be adjusted and another lot submitted for DMMP breakthrough life testing.

2. SUBMITTALS

NOTE: Submittals must be limited to those necessary for adequate quality control. The importance of an item in the project should be one of the primary factors in determining if a submittal for the item should be required.

Indicate submittal classification in the blank space using "GA" when the submittal requires Government approval or "FIO" when the submittal is for information only.

Government approval is required for all submittals. Product data shall be submitted to adequately demonstrate compliance with contract requirements for the following:

Pleated Carbon Adsorber design drawings and significant interface dimensions

Media Material Safety Data Sheet (MSDS)

Pleated carbon adsorber production, delivery, and sampling schedule

3. REQUIREMENTS

3.1 Adsorber Cell Construction. All filter case materials shall meet the minimum strength and corrosion properties of 20 GA galvanized steel, of box style or header style, with dimensions indicated. Dovetail gaskets shall be applied to the upstream side of each adsorber (for the header style also apply a gasket to the downstream side of the header flange) with neoprene based adhesive that has a minimum shelf life of one year at 70°F, a temperature range of -50°F to +150°F and a minimum peel strength of 5lb/in. The approximate final weight of the adsorber cell will not weigh more than:

60 pounds for the 23 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber 55 pounds for the 23 3/8 inches W x 23 3/8 inches H x 11.5 inches D header style adsorber 55 pounds for the 19 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber 45 pounds for the 11 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber

3.2 Materials. If another material is used other than those materials specified herein, that material shall meet equivalent development performance requirements as the material it replaces, and it shall be approved by the Government prior to use by the contractor. At the time of disposal, materials shall not be a Resource Conservation Recovery Act hazardous waste as defined in 40 CFR 261.21-261.24 or 40 CFR 261.33.

3.2.1 Gasket. Dovetail Gasket Seal (mounted on upstream side). The gasket shall be capable of meeting the minimum physical property requirements of ASTM D1056-91, Type 2 - closed cell rubber, Class C - oil resistant with medium swell, Grade 3- having compression-deflection range of 9 to 13 pounds per square inch (psi), or an approved, alternate Grade. Alternative gasket material(s) may be approved upon submittal, such as materials consisting of Neoprene, ethylene propylene diene monomer (EPDM), ethylene propylene termonomer (EPT), Polyethylene, Butyl rubber, or silicone meeting the requirements of ASTM D6576. Gasket thickness shall be ¼ inch.

3.2.2 Media. Proprietary pleated carbon adsorber media supplied by a government approved vendor shall fully meet the contractors’ specifications for subject media in order to arrive at qualified end items. A Certificate of Compliance (COC) for subject proprietary media shall be provided to include cut sheets for media assembly, specification of carbon, and associated MSDS(s).

3.3 Performance.

3.3.1 Pressure Drop. The pressure drop of the box style adsorber cells shall be a maximum of 1.0 inches water gage (IWG) at standard conditions as determined in paragraph 4.4 Static Pressure Drop.

1,800 ACFM for the 23 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber 1,550 ACFM for the 23 3/8 inches W x 23 3/8 inches H x 11.5 inches D header style adsorber 1,500 ACFM for the 19 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber 850 ACFM for the 11 3/8 inches W x 23 3/8 inches H x 11.5 inches D box style adsorber

3.3.2 Adsorber Cell Freon Leakage Test (R-134a). The downstream concentration of the leak tracer vapor shall not exceed 0.1 percent of the upstream concentration.

3.3.3 DMMP Gas Life Capacity. Each selected adsorber cell per Paragraphs 1.2 and 1.3 shall be destructively tested at 250 mg/m3 for 55 minutes minimum and 65 minutes average per lot of adsorber cells tested, when tested in accordance with (IAW) Paragraph 4.5.

3.4 Identification and Marking. Each adsorber cell shall be permanently and legibly marked with the below information. The outer fiberboard container shall be permanently and legibly marked with the information as identified below. The outer fiberboard container shall include (UP) directional markings, 1 per each side of container, 4 total. Markings to be located on center (vertical and horizontal).

(a) Manufacturer’s name

(b) Serial number

(c) Date of manufacture

(d) Weight (pounds, to the tenths of a pound)

(e) Contract number

(f) Carbon lot number, carbon grade, manufacturer media lot number, and manufacturer media roll number

(g) Freon leakage test (% penetration), and measured airflow resistance (IWG)

3.5 Workmanship. Each adsorber cell shall be free from foreign matter, such as dirt, grease, oil, and from minor damage that is non-mission essential, such as chipped, burred or bent sections, or loose, frayed, or torn gasket material.

Potting shall appear evident and applied correctly to eliminate immediate mechanical leakage paths as a result of incorrect adsorber assembly (validated in acceptance testing). Filter media per Paragraph 3.2.2 shall be free of punctures, tears, voids, abrasions, (both major/minor damage) as associated with the adsorber assembly process (including pleating process, assembly, and manual handling at the factory level).

Pleat spacing and separator/finger spacing/alignment, for applicable adsorber configurations produced, shall be IAW the Pleated Carbon Adsorber Design Drawing(s) submittal as approved by the Government.

3.6 Adsorber Dimensions, Exterior. All exterior dimensions (L, W, and H) referenced in Paragraphs 3.1, and approved design drawing submittals to the Government for each configuration of pleated carbon adsorber cells, shall meet a tolerance of ± 1/8 inch. Exterior dimensions are exclusive of any specified upstream or downstream gasket.

4. VERIFICATION

4.1 Classification of Inspections. The inspection requirements specified herein are classified as follows:

Inspection (see Paragraph 4.2) Production Quality Conformance Inspection (see Paragraph 4.3)

4.2 Inspection. The pleated carbon adsorber cells and lot testing samples shall be submitted for inspection and approved IAW the terms of the contract.

4.2.1 Inspections to be performed. Unless otherwise specified by the terms of the contract, the adsorber cells shall be subjected to all of the examinations and tests specified in this specification and shall be inspected for compliance with all of the requirements of the applicable packaging requirements of Paragraph 5. All nondestructive tests shall be performed before destructive tests are performed as identified in Paragraph 4.3.

4.2.2 Acceptance criteria. If any lot tested adsorber cells fail to comply with any of the applicable requirements, the adsorber cell lot shall be rejected. The Government reserves the right to terminate inspection upon any failure to comply with any of the requirements. The contractor shall obtain written approval from the proper authority of the contracting activity before shipping the regular production adsorbers.

4.3 Production Quality Conformance Inspection.

4.3.1 Lotting. A lot shall consist of the adsorber cells produced by one manufacturer, at one plant, from the same materials, under the same manufacturing and process conditions. Any one lot of adsorber cells shall contain no more than one lot of non-woven adsorbent media. A new lot of adsorber cells shall be started whenever any adsorbent production media change is made. The Government/Government Contracting Authority shall be informed of alterations made to the accepted adsorbent media configuration. Each lot shall be produced in its entirety before any adsorber cells of another lot are produced on that production line.

4.3.2 Sampling. Inspection and testing shall be conducted IAW the Classification of Characteristics Paragraph 4.3.5 and when specified, Table I.

4.3.3 Inspection procedure. If any adsorber cell is found that does not conform to any characteristic, such as adsorber cell Freon leakage or pressure drop requirements, the non-conforming adsorber cell shall be rejected and removed from the lot. Every item in the lot shall be inspected for critical characteristics (DMMP Gas Life Capacity testing on randomly selected adsorber cell samples only). Lot sample adsorber cells shall be examined and tested as indicated herein. For characteristics other than leakage and pressure drop, failure of any sample adsorber cell to conform to any Critical Characteristic (DMMP Gas Life Capacity) based on the sampling and acceptance criteria specified herein shall be cause for rejection of the lot represented.

4.3.4 Inspection characteristics. Critical characteristics are those whose nonconformance to specified requirements is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product, characteristics whose nonconformance to specified requirements is likely to prevent performance of the tactical function of a major end item. Major characteristics are those whose nonconformance to specified requirements is likely to result in failure or to reduce materially the usability of the item for its intended purpose. Minor characteristics are those whose nonconformance to specified requirements is not likely to reduce materially the operation or usability of the item for its intended purpose.

4.3.5 Classification of Characteristics. Conformance examinations and tests shall be as specified in the following Classification of Characteristics paragraphs. Only when specified herein, accept on “0” and reject on “1” attributes sampling inspection shall be performed on the designated characteristics using the stated levels in Table I for selection of sample sizes.

TABLE I. Sampling

Inspection level and samples sizes

2 to 8 9 to 15 16 to 25 26 to 50 51 to 90 91 to 150 151 to 280 281 to 500 501 to 1200

· Asterisk means 100% inspection of lot. Unless specified in this specification, accept the lot if there are zero non-conforming major characteristics and reject the lot if there are one or more non-conforming major characteristics for all inspection levels.

CLASSIFICATION OF CHARACTERISTICS

PARAGRAPH

4.3.5

TITLE

Cell, Gas Phase, Pleated Carbon Adsorber

CATEGORY

CHARACTERISTIC

SAMPLING

REQUIREMENT

PARAGRAPH

INSPECTION METHOD and/or PARAGRAPH NUMBER

Critical

Major

Minor

DMMP Gas Life Capacity

Adsorber Cell Leakage

Static Pressure Drop

Media

Gasket Material

Adsorber Dimensions, Exterior

Identification and Marking

Workmanship

Table 1, Level XI

100 %

3.3.3

3.3.2

3.3.1

3.2.2 & 3.5

3.2.1

3.1& 3.6

3.4

3.5

4.6

4.5 & Para 2 (COC)

4.4 & Para 2 (COC)

VI & Para 2 (COC)

VI & Para 2 (COC)

Para 2 & CE

VI

VI

NOTES:

CE - Commercial Inspection Equipment VI - Visual Inspection COC - Certificate of Compliance

4.4 Static Pressure Drop. The static pressure drop, also called “airflow resistance”, of the adsorber cell shall be determined at the rated flow with an air stream temperature of 70 2F and a barometric pressure of 29.9 1% inches of Hg (standard conditions). The adsorber cell shall be placed in the test tunnel in its service orientation.

Note: Correction for nonstandard conditions (temperature, pressure ,or both) is not required when it is clear that the passage or failure of the filter is not in doubt.

4.5 Adsorber Cell Leakage. Install the adsorber cell in the test tunnel in its service orientation. Adjust airflow as required by the manufacture but not less than 1% of the rated airflow capacity. Challenge the adsorber cell with R-134a or equivalent refrigerant vapor at a concentration equal to at least 5,000 times the minimum sensitivity of the monitor used to measure adsorber cell leakage. The challenge-gas injection port shall be located in such a manner to ensure uniform mixing of the tracer gas. The downstream test port shall be located to ensure a representative sample. The leak tracer chemical shall be injected continuously into the adsorber cell over a duration sufficient to ensure the effluent monitor is capable of accurately measuring the required leakage level or as approved by the Government.

4.6 DMMP Gas Life Capacity.

a. Prior to performing the test, verify that sample cells have been tested for airflow resistance (Paragraph 4.4) and Freon leakage (Paragraph 4.5).

b. Install adsorber cell in test tunnel in its service orientation. Adjust the airflow to the rated air flow for the specific filter design as follows:

· 1,800 ACFM (23 3/8 inches W x 23 3/8 inches H x 11.5 inches D) box style adsorber

· 1,550 ACFM (23 3/8 inches W x 23 3/8 inches H x 11.5 inches D) header style adsorber

· 1,500 ACFM (19 3/8 inches W x 23 3/8 inches H x 11.5 inches D) box style adsorber

· 850 ACFM (11 3/8 inches W x 23 3/8 inches H x 11.5 inches D) box style adsorber

The rated airflow rate shall be indicated on the adsorber cell. The adsorber cell shall be tested using DMMP and run to adsorber cell life at the following test conditions:

Challenge concentration of DMMP: 250 mg/m3 Breakthrough concentration of DMMP: 0.1 mg/m3 Relative Humidity: less than or equal to 50 % Temperature: 25 5C

c. The test tunnel shall be operated at the rated flow. The inlet face of the adsorber cell shall be challenged as specified above. The total time from the start of the adsorber cell challenge until the breakthrough concentration is reached (i.e., the life of the adsorber cell) shall be recorded as the breakthrough time.

d. The DMMP vapor challenge concentration shall be created to ensure uniform mixing of the DMMP vapor with the air once it reaches the test adsorber cell. Qualification testing to verify the DMMP vapor concentration is uniform across the adsorber cell face shall be on file and available for Government inspection.

e. The breakthrough time for the adsorber cell’s effluent to increase to 0.1 mg/m3, while being challenge with a 250 mg/m3 concentration of DMMP vapor, shall be a minimum of 55 minutes minimum per selected adsorber and at least an average 65 minutes for the adsorber lot samples as indicated in Paragraph 1.3 to accept the adsorber cell lot. While the challenge concentration is permitted to vary within the stated range during the course of the test, the breakthrough time measured must be normalized to the 250 mg/m3 concentration by the following calculation:

Corrected breakthrough time = Measured breakthrough time Average concentration during test (determined from DMMP challenge mass rate) 250 mg/m3

5. PACKAGING.

For acquisition purposes, the packaging requirements shall be as specified herein. The following packaging instructions shall be implemented for production quantities of Cell, Gas Phase, Pleated Carbon Adsorbers, for all cited configurations above. The prototype packaging configuration(s) (or alternate configuration(s)) shall be submitted to the Government for approval prior to packaging of contract deliverables. All deliverables shall be packaged IAW the approved packaging instructions (latest approved revision on file) until revised packaging instructions have been submitted by the contractor and approved by the Government. Incorporation of the revised packaging instructions shall be determined by the proper authority of the contracting activity at a predetermined point in the contract schedule.

5.1 Adsorber Cell Identification and Markings. Referencing Paragraph 3.4, confirm each pleated carbon adsorber cell has the required permanent and legible identification and markings.

5.2 Upstream Fiberboard. Place cut sheet of engineered fiberboard over upstream (U/S) adsorber cell face with fiberboard strands oriented in the vertical orientation (adsorber pleats vertical) and secure to pleated carbon adsorber cell with tape fasteners, spaced equidistant, (2) places top and (2) places bottom ((4) places total). Fiberboard sheet to run full width and full height of pleated carbon adsorber cell face. Entire surface area of U/S adsorber gasket, if applicable, shall be covered and protected by the engineered fiberboard sheet. Do not secure fiberboard to adsorber gasket such that gasket is under compression.

Engineered Fiberboard Dimensions (configuration dependent):

· 23 3/8 inch W x 23 3/8 inch H (24x24 box style)

· 21.8 inch W x 21.8 inch H (24x24 header style)

· 19 3/8 inch W x 23 3/8 inch H (20x24 box style)

· 11 3/8 inch W x 23 3/8 inch H (12x24 box style)

5.3 Downstream Fiberboard. Repeat procedure for downstream (D/S) adsorber cell face; same as above. Fiberboard sheet to run full width and full height of pleated carbon adsorber cell face. Entire surface area of D/S adsorber gasket, if applicable, shall be covered and protected by the engineered fiberboard sheet. Do not secure fiberboard to adsorber gasket such that gasket is under compression.

Engineered Fiberboard Dimensions (configuration dependent):

· 23 3/8 inch W x 23 3/8 inch H (24x24 box style and header style)

· 19 3/8 inch W x 23 3/8 inch H (20x24 box style)

· 11 3/8 inch W x 23 3/8 inch H (12x24 box style)

5.4 Barrier Bag. Place pleated carbon adsorber cell, with secured fiberboard sheets over U/S and D/S adsorber cell faces into the barrier bag. Barrier bag shall be fabricated of a suitable material to protect the deliverable from moisture NTE 1-year. Barrier bag dimensions shall be of sufficient width, height, and depth to allow sealing the bag around the pleated carbon adsorber cell in its service orientation. Prior to sealing, excess air shall be removed from the barrier bag. Sealed package shall not cause deformation to the pleated carbon adsorber cell assembly (packaging, frame, media/pleats, and gasket).

5.5 Side End Caps. Place (2) side caps onto pleated carbon adsorber cell (sealed inside barrier bag), with adsorber pleats in vertical orientation. Side end caps shall be constructed from engineered fiberboard. Fiberboard to form around perimeter of adsorber cell such that U/S or D/S gasket (as applicable) is not compressed. Secure side end caps to barrier bag with (2) tape fasteners front and (2) tape fasteners back; spaced equidistant. Flanges of side fiberboard end caps to be 2 inches H, minimum. Note: Side end caps for header style pleated carbon adsorber cell shall require full fiberboard blocking to allow adsorber cell to seat plumb prior to fastening side end caps to the barrier bag. Fiberboard blocking negates damage.

5.6 Fiberboard Container. Place pleated carbon adsorber cell assembly (in barrier bag with side end caps attached – Paragraph 5.5) into outer engineered fiberboard container. Pleated carbon adsorber cell assembly shall not move freely in any direction within outer container. Container to be secured, top and bottom, with tape closures, 1 each, such that bottom and top tape closures extend to each respective side of the outer fiberboard container.

5.7 Fiberboard Container Identification and Markings. Referencing Paragraph 3.4, confirm each outer fiberboard container has the required permanent and legible identification and markings. Outer fiberboard container shall have markings, 1 per side ((4) total), indicating (UP) direction. Markings to be located on center (vertical and horizontal). For box style adsorbers, mark the side of the container that has the gasket attached with “Gasketed Side”. For header style adsorbers, mark the side of the container that has the header with “Header Side”

5.8. Palletizing. Final assembled packaging containers can be stacked on standard pallet, 24 containers of the 12” per pallet, and 12 containers of the 20” and 24” per pallet. Apply shrink-wrap and banding as required to secure palletized containers.

6. NOTES.

6.1 Intended Use. The gas phase adsorber cell is used to remove low-volatile toxic chemical vapors that enter the air filtration systems used for collective protection applications.

6.2 Moisture and Contaminant Control.

The manufacturer may implement various process controls to minimize the damaging impact of moisture to the carbon media. Ensuring any air streams entering the adsorber cell, especially during refrigerant leakage testing, is not laden with excessive moisture or contaminant is strongly recommended.

6.3 Delivery Address:

Adam Smelser US Army DEVCOM CBC Bldg E4301 Bay 76 8500 Otto Rd Gunpowder, MD 21010-5424

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