SCBA_Air_Compressor_Purchase Description.pdf

NGFL-DDC-CD

SUBJECT: Purchase Description

44th WMD-CST SCBA Air Compressor/Fill Station Requirements

General Requirements

1) Must be able to fill at least two SCBA Bottles at the same time

2) Fill SCBA bottles to pressure of minimum 4750PSI

3) Must have a minimum of four 6000psi Fill Bank tanks

4) Must have Digital Carbon monoxide and Water monitoring

5) Noise shall not exceed 76 DB at one meter

6) Must include Freight/shipping, Installation, and Training.

7) Must provide required maintenance services for 36 months from the time of installation.

8) Must include Factory warranty consisting of at least the following;

a. Manufactured compressors, compressor systems and accessory equipment are warrantied for a minimum of eighteen (12) months from date of shipment or twelve (12) months from the date of start-up, whichever occurs first.

b. Compressor pumps installed as an integral part of compressors or compressor systems are warrantied for a minimum total of twenty-four

(24) months, from the date of shipment.

c. Replacement and service parts are warrantied for a minimum of sixty (60) days from the date of shipment.

d. Replacement compressor pumps are warrantied for a minimum of one-hundred (100) days from the date of shipment.

e. Factory repairs are warrantied for a minimum of sixty (60) days from the date of shipment.

Further Technical requirements

I. General Arrangement

The breathing air compressor shall be a packaged appliance designed to deliver high pressure breathing air in compliance with the most current NFPA and CGA air quality standards for the of SCBA and SCUBA cylinders. The system shall include the high-pressure air compressor, electric motor, air purifier, and all operating controls as specified below. The breathing air compressor shall be completely assembled and tested by the manufacturer requiring only electrical power supply to operate. The breathing air compressor shall be designed with all operating controls and performance indicators located on a panel at the front of the appliance allowing “at sight” operator monitoring. The appliance shall comply with the currently applicable OSHA specifications as well as state and local electrical codes.

The external construction of the high-pressure breathing air compressor shall be appliance-like. All structural fasteners shall be concealed, and all access panels shall include concealed hinges and push button latches. Two (2) full height doors on each

SUBJECT: Letter of Justification and Purchase Description side of the appliance shall be provided for maintenance access to the compressor. The doors shall include a shutdown switch to prevent exposure to running gear in the event either is opened while the compressor is in operation.

The cabinet shall be designed to minimize noise emission and include sound abatement insulation. The noise level shall not exceed 76 dB in one meter.

The compressor control panel shall be ergonomically designed and feature graphic design technology to group all control components and indicators logically and by function. For maximum clarity and visibility, colored lines shall isolate each control component group. Each group shall then be located within a graphic flow control schematic background and identified with permanent text integral to the panel surfaces.

High visibility colored text shall identify and provide operator instructions for all critical functions.

The cabinet configuration shall permit installation with the rear “against the wall” and dimensions are a maximum of 71”H x 34-½” W x 41”D. A removable blister panel in the rear will allow for a doorway clearance of 34”, if required.

The appliance shall include an ambient air flow control design that directs the necessary volume of cooling air to the compressor. The cooling system shall also include an integral, top discharge extractor to completely vent the resulting hot air from the compression process out of the cabinet.

All high-pressure air plumbing shall be rated for 6000 psig working pressure and utilize seamless stainless steel tubing. All high-pressure air tube connections shall use compression type fittings.

The electrical control system shall include motor control components with UL, NEMA or IEC approval and 12vdc control circuit housed within a UL® listed, NEMA enclosure.

The breathing air system manufacturer shall be an industry standard NRTL (Nationally Recognized Testing Laboratory) Licensed Panel Shop as per UL® 508A standard.

II. Compressor

The ambient air intake and compression shall be through an air-cooled, reciprocating, pressure oil lubricated, four-stage compressor designed for continuous duty at a minimum of 6000 psig working pressure with a minimum charging rate of 14.0 CFM.

The air compressor design shall include a heavy-duty cast iron crankcase supporting the crankshaft with oversized ball bearings on each end. Must operate at a minimum compressor speed of 1500 RPM. Lubrication shall be accomplished by controlled splash and shall include a crankshaft driven oil pump to supply metered quantities of oil directly to the fourth stage piston through a replaceable (spin-off) full flow filter.

Crankcase level is verified via an oil level sight glass with minimum and maximum indicators.

Each stage of compression shall be protected with a safety relief valve. Valve inspection covers are provided for the first and second stage cylinders to allow for easy access. All valve assemblies shall be designed so they can be repaired without replacing the entire assembly. The cylinders shall include cooling fins to dissipate heat into the cooling air flow from the compressor’s integral flywheel fan. Individually mounted coolers shall be located after each compression stage to cool the discharged air to 18°F. above ambient temperature. Accumulated condensation from cooling the compressed air shall be collected in moisture separators mounted on each stage of the compressor and discharged to an automatic, internal, timed drain system for proper collection and disposal.

Prior to shutdowns, the compressor shall be allowed to run unloaded (with opened drains) for a timed period (Purge Cycle) in order to purge all cylinders, separators and crankcase of damaging condensation that develops as compressors cool down. The compressor control panel shall also include a condensate purge test switch in order to verify proper operation of the automatic condensate drain system on demand.

The ambient air filter element shall be located in a housing piped to the compressor air intake to draw air from the installation room. Additionally, an inlet port shall be provided with a connection to facilitate connecting to outside air intake piping.

III. Electric Motor

Minimum 60 Hertz Current - 1 Phase, 208/230 volts.

The motor shall be located under the compressor and driven via v-belt drive arrangement utilizing a hinged motor base to facilitate belt tension adjustment. The compressor and motor base shall include zinc plated, steel encased neoprene mounts to isolate vibration from the appliance.

IV. Electrical Control System

The breathing air compressor shall include all the necessary controls to assure safe, efficient operation and monitor performance. The control system shall be of an anti-flutter circuit design and include a latched fault protection circuit to prevent automatic restarting after an abnormal fault has occurred.

As a minimum, the control system must include the following:

• Air pressure switch to automatically start and stop the compressor based on demand.

• High air temperature shutdown switch.

• Low oil pressure shutdown switch.

• Magnetic, across-the-line starter with electric motor overload protection.

• Compressor access door safety shutdown switch.

• Compressed air Air Monitor system including CO and H2O detectors with pre-set warning, shutdown limits and audible alarm. A shutdown audible alarm shall be supplied for all abnormal conditions.

• Auto-drain condensate reservoir capacity shutdown switch r.

V. Instrumentation

The control system must include all monitoring devices as indicated below. These shall be mounted on a control panel located at the front of the compressor with all indicators.

and gauges grouped logically, and each group positioned within a graphic flow control schematic and identified with integral text. The panel background color shall be matte.

black shade with a textured finish to eliminate glare. Panel component and indicator groups shall be offset by colored lines to enhance operational visibility and safety.

The compressor’s instrumentation panel shall also be engineered for quick and convenient access to all key electrical control components, minimizing the need to use the appliance maintenance access doors. Indicator lights, pressure switch and all control wiring shall be accessible for routine maintenance and adjustments through hinged, “knockdown” sub-panels on the front of the compressor. The operator control panel shall be designed and prewired to permit the easy plug and play installation of optional CO or H2O monitor additions. The unit must be designed to allow full integral installation of any future upgrades without the use of external wiring, piping or remotely mounted components.

As a minimum, the instrumentation required is as follows:

• Compressor inter-stage and final pressure gauges.

• Compressor oil pressure gauge.

• Hour-meter.

• Normal high air pressure shutdown indicator light.

• Purge cycle indicator light and test switch.

• Enhanced shutdown indicator light package including low oil pressure, high compressed air temperature, motor overload, auto-drain reservoir limit and door ajar shutdown conditions.

• General fault shutdown indicator light.

• Emergency stop button.

• Digital CO and H2O panel with actual content display in PPM and prompter software keypad for CO monitor calibration. A flow panel with factory plumbed calibration gases shall be included.

VI. Air Purification System

The high-pressure air purification system shall be a multi-chamber arrangement that utilizes disposable cartridges manufactured to provide breathing air that meets or exceeds NFPA and CGA Grade “E” specifications and all other equivalent and recognized standards in use worldwide.

All system components shall be rated for 6000 psig working pressure with a four-to-one safety factor. All chambers in the system shall be constructed of 304 stainless steel to enhance safety and corrosion resistance.

The purification system shall be sized to process 35,000 cubic feet of air at 70°F and compressed to 6000 psig between cartridge changes.

The system shall include the following:

• Final separator chamber connected to the automatic condensate drain system.

• Check valve to prevent back pressure to the compressor.

One (1) 33” purifier cartridge chamber.

• Pressure maintaining valve to assure that the system is maintained pressurized in order to attain the rated processing capacity of the air purification cartridge(s).

• Safety relief valve.

• Drain valve to relieve the system pressure for maintenance.

• Stem-mounted gauge for system pressure verification.

The system shall be designed so that filling cannot occur in the event that the purification cartridge is not installed. Additionally, the purification system shall have “keyed” chambers so that the filter cartridges can only be installed in their proper sequence.

Fill Station

I. General Arrangement

The fill station shall be designed for filling two (2) or more SCBA cylinders simultaneously or separately. The fill station shall be designed for filling one (1) SCUBA cylinder with a maximum height of 30-½” and a maximum diameter of 7-¾”, including service valve, boot, and fill attachment. The enclosure shall be designed to contain the impact of suddenly expanded high pressure air and all displaced fragments in the unlikely event of a cylinder or fill component rupture.

The fill station containment design must be UL® (Underwriters Laboratories) classified and for maximum operator safety certified to meet NFPA 1901-2016 standards. The UL® testing certificate must be included with the bid or request for quotation and included with the operator’s manual when the system is shipped.

The fill station loading door must be designed to be trapped behind the fill enclosure.

cabinet frame when closed and include an automatic, safety interlock to prevent filling.

unless the loading door is completely closed. A safety relief valve, to prevent over.

pressurizing SCBA/SCUBA cylinders above 4750 psig for 4500 psig SCBA filling shall also be included.

The external construction of the high pressure, breathing air fill station shall be appliancelike. All structural fasteners shall be concealed and all access panels shall include concealed hinges and push button latches. The fill station control panel shall tilt down to allow for convenient maintenance access. The overall dimensions of the fill station including up to four integral air storage cylinders shall not exceed 37-½” (W) x 34”(D) x 75”(H).

The fill control panel shall be ergonomically designed and feature graphic design technology to group all control components and indicators logically and by function. For maximum clarity and visibility, colored lines shall isolate each control component group.

Each group shall then be located within a graphic flow control schematic background and identified with permanent text integral to the panel surfaces. High visibility colored text shall identify and provide operator instructions for all critical functions.

The fill station must allow the fill process to be accomplished from the front. The fill station shall be of a design that does not require the operator to have to hold up or otherwise support the weight of the cylinders being filled while connecting them to the fill whips. The front-loading door shall be designed so that, when opened, sleeves that hold the SCBA/SCUBA cylinders tilt forward to ease loading and minimize operator fatigue.

Two (2) fill whips, each fitted with a cylinder fill adapter and shut-off valve, shall be located within the enclosure.

Access Door Control: For maximum operator comfort and ease of use, the fill station access door shall include an air actuator handle designed to provide power assisted, effortless operation when opening and closing. When fully closed, the door shall trip a safety interlock allowing air flow to the fill station. The access door shall be supported on the enclosure frame with an adjustable bearing bushing on each side assuring a balanced and smooth rotation when opening and closing. A damper strut shall secure the assembly to the enclosure so that it does not require operator support and to cushion the access door landing when opened.

The access door design must be fail-safe, permitting manual operation in the event of air pressure loss in the power assist circuit.

II. Air Flow Controls

All air flow components and indicators shall be mounted on a control panel located at the front of the unit grouped logically with each group positioned within a graphic flow control schematic and identified with integral text. The panel background color shall be matte black shade with a textured finish to eliminate glare. Panel component and indicator groups shall be offset by colored lines to enhance operational visibility and safety.

For maximum clarity and safety, the flow control panel shall be divided by function, assuring that the regulated SCBA/SCUBA fill controls are in a dedicated area apart from air storage management components.

In order to minimize operator handling of pressurized components, a fill hose(s) pressure vent valve shall be located on the air flow control panel to relieve all fill hoses of pressure after opening the front-loading door and before disconnection from the SCBA/SCUBA cylinder(s).

The SCBA/SCUBA cylinder fill control system shall include a regulated panel with all the components, devices and piping arrangement necessary to direct supplied compressed high pressure breathing air to the air storage system and the SCBA/SCUBA cylinders being filled. Additionally, a regulated auxiliary outlet to fill remote air storage systems shall be provided.

All high-pressure regulators must be designed so that they cannot be accidentally reset in accordance with NFPA 1901 standards. The regulator knob shall be of the “push-to-reset” design that spins freely if accidentally moved.

A cascade control system shall be included for the number of banks specified below to permit filling or drawing down each air storage cylinder independently of each other and while filling SCBA/SCUBA cylinders. The system shall include a bypass valve to permit filling SCBA/SCUBA cylinders directly from the compressor.

As a minimum, the air control panel must include the following:

• Inlet pressure gauge.

• Adjustable, 0-6000 psig self-relieving regulator.

• Regulated outlet pressure gauge.

• By-pass valve.

• SCBA/SCUBA cylinder(s) fill control valve.

• SCBA/SCUBA cylinder(s) fill pressure gauge.

• SCBA/SCUBA cylinder(s) panel mounted fill hose(s) vent valve.

• Auxiliary outlet with flow control valve and CGA fitting.

• Four (4) bank cascade control with “TO” and “FROM” valves and gauge per bank.

III. High Pressure Air Storage

The breathing air storage system shall be integral to the appliance and include all the cylinders, plumbing and hardware installed in accordance with all current UN/ISO codes, as specified below:

Four (4) UN/ISO 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 psig. The piping of air storage shall be arranged for cascade filling.