SPECIFICATIONS.pdf

Scope of Work for

35 CFM @ 100 PSIG BREATHING AIR PURIFIER

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a Breathing Air Purifier at San Diego California, North Island Naval Complex, Building 73.

2. REQUIREMENTS

2.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. The Breathing Air Purifier shall be constructed of parts that are new, without defects, and free of repairs. The assembly shall withstand all forces encountered during operation of the Breathing Air Purifier to its maximum rating and capacity without distortion.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

2.2.3. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion. All paint shall be lead and chromate free.

2.2.4. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

2.2.5. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

2.2.6. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

2.2.7. OSHA Compliance. The equipment installation and its component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph

1910.303 and paragraph 1910.399.

2.2.8. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

2.2.9. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. The safety devices shall not interfere with the operation of the Breathing Air Purifier.

The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.10. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 dB(A) as measured on the "A" scale and 92 dB(C) as measured on the "C" scale, at any point three feet from the equipment.

2.2.11. Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. All oil holes, grease fittings, and filler caps shall be accessible. A lubrication plate shall be securely attached to the equipment, see 2.15.2.

2.2.12. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.13. Measuring and Indicating Device Graduations. All measuring and indicating devices shall be graduated in United States Customary units and visible without magnification.

2.2.14. Calibration. The contractor shall provide calibration control instructions for each calibrated item.

2.3. Components. The Breathing Air Purifier shall consist of not less than the following components.

2.3.1. Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all valves, piping, cylinders, and pressure controls including protection from over-pressurization.

2.3.2. Electrical System. The machine shall conform to NFPA 79. The existing electrical power source available at the installation site is 120vac/single phase/60 hz. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

2.3.2.1. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

2.3.2.2. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the minimum requirements of NEMA Type 12.

2.3.3. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

2.4. Size and Capacity. The size of the Breathing Air Purifier shall be not less than specified in Table I.

Table I Size Max Allowable Installation Space (Width, Depth, Height) Width x Depth applies to existing equipment mounting pad.

37 inches wide x 38 inches deep. Assembled equipment height not to exceed 79 inches.

2.4.1. Performance Requirements:

2.4.1.1. The Breathing Air Purifier shall process 40 to 45 standard cubic feet per minute (SCFM) at 100 pounds per square inch gage (psig) and deliver 35 scfm meeting the Grade D Quality Verification Level (QVL) of CGA G-7.1. For this specification SCFM is defined at a temperature of 68oF, 14.7 psia, and 36 percent relative humidity at sea level.

Two banks of desiccant shall be used for drying the compressed air. Only one bank shall be in operation. To minimize energy consumption, the second bank while offline shall be recharged to adsorb moisture by using a portion of the on-line bank discharge air.

2.4.1.1.1. The Breathing Air Purifier shall process a continuous inlet air stream with Carbon Monoxide (CO) concentrations of 200 parts per million (ppm) and discharge air meeting CGA G-7.1 QVL level Grade D for CO for a minimum of 2000 hours before catalyst service is required.

2.4.1.1.2. The Breathing Air Purifier shall process a continuous inlet air stream with condensed oil concentrations of TBD ppm and discharge air meeting CGA G-7.1 QVL level Grade D for CO for a minimum of 2000 hours before catalyst service is required.

2.4.1.1.3. The Breathing Air Purifier shall process a continuous inlet air stream with a dew point of 100oF and discharge air meeting CGA G-7.1 QVL level Grade D for Dew Point for a minimum of 2000 hours before catalyst service is required.

2.4.1.1.4. The Breathing Air Purifier shall be equipped with a carbon monoxide monitor that displays current purified CO concentration, user adjustable high and low alarms with visual and auditory indication, push to silence alarm button, and method of calibration.

2.4.1.1.5. The Breathing Air Purifier shall be equipped with an Oxygen (O2) monitor that displays current purified O2 concentration, user adjustable high and low alarms with visual and auditory indication, push to silence alarm button, and method of calibration.

2.4.1.1.6. The Breathing Air Purifier shall be equipped with a dew point indicator that displays current purified dew point oF, user adjustable high and low alarms with visual and auditory indication, push to silence alarm button, and method of calibration.

2.4.1.1.7. The Breathing Air Purifier shall be equipped with a temperature indicator that displays current purified air temperature oF, user adjustable high and low alarms with visual and auditory indication, push to silence alarm button, and method of calibration.

2.4.1.1.8. The Breathing Air Purifier shall be equipped with processed air sample ports for processed air analysis.

2.4.1.1.9. The working pressure of the compressed air is 100 psig with maximum operating pressure not to exceed 150 psig and minimum operating pressure greater than 60 psig.

The Breathing Air Purifier shall operate over this range of pressure including air temperatures ranging from 50oF to 120oF.

2.5. Lifting attachments. The allowable bending strength shall be 1/3 of the yield strength or 1/5 of the ultimate strength, whichever is the most conservative, of the lifting attachment material.

2.5.1. Shear strength. The shear strength shall be equal to 0.58 times the allowable design bending strength defined above.

2.5.2. Bearing strength. The bearing strength shall be equal to 0.3 times the ultimate strength of the lifting attachment material.

2.5.3. Lifting attachment size. The lifting attachments shall be sized based on actual weights plus 10% for unexpected growth in the weight of the load. The resulting value shall be further increased to reflect the loads induced by the angle the slings make to the plane the lifting attachments lie on. The attachments shall be oriented so the slings shall not pull out of the plane of the individual lifting attachment by more than 5º unless they are designed to withstand the resulting side load. The attachments shall be arranged so the load is lifted relatively level. If the equipment is intended to be stackable, provisions in the design shall be made to prevent damage to the lift points of the lower item if the upper item is not landed accurately or symmetrically. In addition, the individual loads for each point shall be calculated based on the configuration of the rigged equipment and the location of its center of gravity. These final values shall be referred to as the Working Load Limit (WLL).

2.5.4. Use of three or more lifting attachments. When installing three or more lifting attachments, only two shall be assumed to carry the load unless a spreader or strongback is used. The use of spreaders or strongbacks shall be kept to a minimum, but if they are deemed necessary, a lift sketch detailing the required spread, capacity and orientation of that gear shall be provided for review with the lifting sketches and designs.

2.5.5. Allowable Stress Design. The structure supporting the lifting attachments shall be designed to sustain the various lateral loads imparted by the arrangement of the lifting attachments and the induced sling angle loads based on a buckling analysis per the American Institute of Steel Construction (AISC), Allowable Stress Design.

2.5.6. Lifting attachment load testing. The lifting attachments are required to withstand a load test of 200% (+5%-0%) of the Working Load Limit (WLL) for 2 minutes. Acceptance criteria shall be: No bending, cracking, or permanent deformation of the lifting attachments or associated structure. The contractor’s certified representative shall perform the load testing plus a pre- and post-load VT per the inspection requirements of American Welding Society (AWS) D1.1 and submit documentation of the satisfactory results of all the various tests. The lifting attachments shall be labeled with the WLL and the test date.

2.5.6.1. In certain cases, the prior concurrence of the cognizant technical Code at PSNS & IMF, the load test may be waived and a magnetic particle test (MT) of the attachment weld substituted, meeting the acceptance criteria of MIL-STD-2035, Class 3 or equivalent standard as approved by the Government, provided the testing is performed by a certified third party and documentation of the satisfactory results are provided with the receipt of the equipment.

2.5.7. Calculations. All calculations required for the design of the lift points shall be performed by a Professional Engineer, and shall be provided for review with the lifting sketches and designs.

2.6. Swivel hoist rings. The total weight of the equipment for determining lift point capacity shall be the estimated weight of the item plus 10% for unexpected growth in the weight of the item.

2.6.1. Sling load. The sling load at a given lift point shall be the vertical load at that point increased by the resultant sling angle.

2.6.2. Use of three or more swivel hoist rings. When installing three or four swivel hoist rings, only two shall be assumed to carry the load, unless a spreader or strongback is used.

2.6.3. Spreader or strongback use. The use of spreaders or strongbacks shall be kept to a minimum, but if they are deemed necessary, a lift sketch detailing the required spread, capacity and orientation of that gear shall be submitted. In addition, the individual loads for each point shall be calculated based on the rigged configuration of the equipment and its center of gravity.

2.6.4. Swivel hoist ring interface. The swivel hoist ring interface (i.e., threaded fitting, etc.)

shall be designed for the resultant sling load and be able to withstand the manufacturer’s required bolting torque, but it will not require proof testing. For steel, the minimum thread engagement shall be 1-1/2 times the diameter of the hoist ring fastener. An alternate method is to bolt through the structure using a washer and a SAE Grade 8 nut with full thread engagement (minimum two threads protruding). The hoist ring manufacturer may be consulted about the adequacy of the hoist ring/structure interface.

2.6.5. Supporting structure. The structure supporting the swivel hoist ring attachments shall be designed to sustain the various lateral loads imparted by the arrangement of the swivel hoist rings and their induced sling angle loads.

2.6.6. Manufacturer certification. When swivel hoist rings are provided with the equipment, the hoist rings manufacturer’s certification shall be provided with the receipt of the equipment confirming each hoist ring has been proof tested to 200% of the ring’s rated capacity (working load limit).

2.6.7. Calculations. All calculations required for the design of the lift points shall be performed by a Professional Engineer, and shall be provided for review with the lifting sketches and designs.

2.7. Standard Equipment. All standard equipment required for proper operation of the Breathing Air Purifier (such as special tools) shall be furnished.

2.8. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

2.8.1. Polychlorinated Biphenyls (PCB) Label Plate. A label plate containing the PCB Certification information shall be permanently and securely attached in the vicinity of the manufacturer’s identification plate.

2.8.2. Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of lubricant application Servicing interval Type of lubricant Viscosity

Military or Federal Specification for each lubricant (If applicable)

2.8.3. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, frequency) Contract Number or Order Number Date of manufacture

2.8.4. Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

2.9. Technical Data. Three (3) hard copies and one (1) electronic copy(s) of technical data shall be provided with the machine. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

2.9.1. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

i. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

2.10. OSHA Approved Certification. The equipment and its installation specified herein shall be inspected and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7 and approved as defined in section 2.2.7 of this statement of work, OSHA Compliance. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

2.11. PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

2.12. Workmanship. Workmanship of the Breathing Air Purifier shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

2.13. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

2.13.1. Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

2.14. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55 degrees F to 100 degrees F and 10 percent to 95 percent relative humidity.

2.3.3. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the compone...

2.5.7. Calculations. All calculations required for the design of the lift points shall be performed by a Professional Engineer, and shall be provided for review with the lifting sketches and designs.

2.14. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55 degrees F to 100 degrees F and 10 percent to 95 percent relative humidity.