Statement of Work.doc

Temporary HVAC System

STATEMENT OF WORK

1. SCOPE

1.1. PNSY is seeking to lease a temporary HVAC system & Exhaust system. This system is intended to provide continuous tempered air to an industrial work environment, to provide fresh outside air exchanges, to provide exhaust for scavenging effluent fumes from industrial processes, and to maintain positive pressurization with respect to the external environment of the conditioned space. The system must include multiple HVAC Units, Industrial Exhaust Blowers, two Chillers, Chilled Water Pumps, chilled water hose manifolds, hose assemblies as well as the associated onboard controls to operate both the chilled water system, HVAC units and exhaust blowers. All equipment conveying air to and from the industrial space must be pre-wired with remote E-Stop capability in order to provide a means to secure airflow in the event of an emergency response. The intent of the chillers, pumps, hose assemblies, manifolds and ancillary components is to establish two separate temporary chilled water systems serving all of the HVAC cooling coils.

2. REFERENCES

2.1. Issues of Publications - The following documents of the issue date in effect on the date of request for proposal form 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

2.1.1.1. General Specification For Integral Lifting Attachment Design

2.1.1.2. US Federal standard A-A-59326: Standard for cam action couplings.

2.1.2. Nongovernment

2.1.2.1. Spark Resistant Construction (SRC: AMCA Standard 99-0401-86) Type C

2.1.2.2. ARI Standard 410

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. TECHNICAL REQUIREMENTS

3.1. Component List

3.2. Dual Coil HVAC Unit- 20,000 CFM

Physical Attributes

3.2.1. Physical Attributes: Max Dimensions 20’10” x 7’4” x 9’3” [L x W x H] Max Weight: 16,450 Lbs.

3.2.2. HVAC Unit must be pre-wired for and compatible with a remote E-Stop switch (Remote Emergency Stop Switch). This will enable the air handler to be shut down in response to an emergency condition where airflow needs to be secured. Vendor shall route all E-stops to a central location at Topside Watch where all air handling equipment can be secured.

3.2.3. All Components much be fully integrated within single housing.

3.2.4. Electrical Power Requirements: 1 Circuit at [460 Volt AC / 3 Phase / Full Load Amp 400A]

3.2.5. Process air outlets: Quantity of four at 20” Dia. Each

3.2.6. Process air returns: Quantity of eight at 20” Dia. Each

3.2.7. Post Cooling Coil male & female 4 IN diameter Fittings. Water inlet and outlet connection fittings must be quick disconnect style fittings meeting the requirements defined in reference 2.1.1.2

3.2.8. Chilled water coils must have manual air bleed valves to assist with the initial filling of the chilled water loop.

Process Air Requirements

3.2.9. Process Air Flow requirements: 20,000 CFM @ 7 inches External Static Pressure

3.2.10. Process Air Fan: Fan curve capable of delivering specified flow and pressure, installed with TEFC Premium Motors, and VFD controlled

3.2.11. Post Heater requirements: 240 KW Electric heating element, thermostatically controlled to discharge air temperature set point.

3.2.12. Cooling Coil Requirement: 120 Tons = 289 GPM @ 10°F ΔT based on 45°F Entering chilled water temperature.

3.2.13. Cooling Coil & Electric heating element thermostatically controlled to discharge air temperature set point to meet cooling season and heating season demands.

3.2.14. Process Air inlet Filtration: Moisture Separator / Demister type filtration for purging 98% of the moisture. Paper or fibrous filtration media is not acceptable.

3.3. Triple Coil HVAC Unit- 24,000 CFM

Physical Attributes

3.3.1. Physical Attributes: Max Dimensions 20’10” x 7’4” x 9’3” [L x W x H] Max Weight: 16,450 Lbs.

3.3.2. HVAC Unit must be pre-wired for and compatible with a remote E-Stop Switch (Remote Emergency Stop Switch). This will enable the air handler to be shut down in response to an emergency condition where airflow needs to be secured. Vendor shall route all E-stops to a central location at Topside Watch where all air handling equipment can be secured.

3.3.3. All Components much be fully integrated within single housing.

3.3.4. Electrical Power Requirements: 1 Circuits at [460 Volt AC / 3 Phase / Full Load Amp 400A]

3.3.5. Process air outlets: Quantity of four at 20” Dia. each

3.3.6. Process air returns: Quantity of eight at 20” Dia. each

3.3.7. Post Cooling Coil male & female 4 IN diameter Fittings. Water inlet and outlet connection fittings must be quick disconnect style fittings meeting the requirements defined in reference 2.1.1.2

3.3.8. Chilled water coils must have manual air bleed valves to assist with the initial filling the chilled water loop.

3.3.9. Steam Coil Condensate drain line must be fitted with a steam trap rated to a minimum 150 PSI Process Air Requirements

3.3.10. Process Air Flow requirements: 24,000 CFM @ 9 inches External Static Pressure

3.3.11. Process Air Fan: Fan curve capable of delivering specified flow and pressure, installed with TEFC Premium Motors, and VFD controlled

3.3.12. Electric heating element requirements: 260 KW Electric heating element, thermostatically controlled to discharge air temperature set point.

3.3.13. Steam heating Coil Requirements: 2.0 MMBH, 1½" FNPT × ≥3 EA Inlet; ¾” Condensate drain with steam trap.

3.3.14. Cooling Coil Requirement: 172 Tons = 412 GPM @ 10°F ΔT based on 42°F Entering chilled water temperature.

3.3.15. Post Cooling Coil, Electric Heating Element & Steam Heating Coil thermostatically controlled to discharge air temperature set point to meet cooling season and heating season demands.

3.3.16. Process Air inlet Filtration: Moisture Separator / Demister type filtration for purging 98% of the moisture. Paper or fibrous filtration media is not acceptable.

3.4. Industrial Exhaust Blower

3.4.1. Exhaust Blower Airflow capacity: 10,000 CFM @ 14” External Static Pressure

3.4.2. The fan motor shall be NEMA Design B, TEFC premium, industrial, continuous-duty, ball bearing, foot mounted. Motor bearings shall have a minimum L-10 life (40,000 hours).

3.4.3. The fan assembly shall be equipped with a VFD controller that varies the rotation speed (rpm) of the fan by directly adjusting the frequency (hertz) of the power to the motor thereby, efficiently reducing the air volume and thus, significantly reducing its power.

3.4.4. The Exhaust Blower must be pre-wired for and compatible with a remote E-Stop switch (Remote Emergency Stop Switch). This will enable the blower to be shut down in response to an emergency condition where airflow needs to be secured.

3.4.5. The exhaust blower shall have a footprint to allow for normal transport on a flatbed truck regardless of its orientation. Hence, the overall length as well as its width shall not exceed eight and a half feet and the overall height shall not exceed nine feet (≤8'-6"L&W × ≤9'H). For the unit to not exceed the overall height, the Noise Attenuator or Discharge Duct must be hinged so as to fold down.

3.4.6. Exhaust Blower unit must be equipped with suction inlet and discharge outlet fan guards to prevent unintentional debris from being ingested or ejected from the fan housing.

3.4.7. Exhaust Blower Unit Fan wheel and housing must be constructed to meet all requirements of Spark Resistant Construction Type C as per AMCA Standard 99-0401-86, Reference 2.1.2.1.

3.4.8. Exhaust blower shall be consisting of centrifugal fan with a direct drive motor with fan rotation either clockwise (CW) or counter-clockwise (CCW) as long as the discharge is directed vertically up (Up Blast: UB).

3.4.9. Fan wheel shall be constructed as a single inlet, single width wheel with flat blades. Airfoil and backward incline blade wheels are not suitable substitutions. This is to account for air & material stream applications where abrasive particles, granular material, heavy dust or fumes are present in the air stream. The blades shall have continuously welded reinforcement to reduce stress.

3.4.10. The Exhaust Blower shall feature a gasketed access door either bolted or a hinged quick-release type for maintenance or clean-out of the internal fan housing.

3.4.11. OSHA regulations require the drive assembly less than seven feet above ground (<7' AG) to be guarded. Dependent on the design, either Weather Covers and/or Drive Guards are necessary to protect personnel from the drive components such as the motor and shaft.

3.4.12. Since the Exhaust Blower is an up blast configuration, it shall feature a drain pipe coupling at the lowest point of the fan housing.

3.4.13. If there is no Noise Attenuator, then an expanding (at least a doubling of its cross-section) slightly tapered hinged (i.e. fold-down) Discharge Duct of at least four feet in length is necessary.

3.4.14. If there is no Discharge Duct, then on the discharge end of the Exhaust blower, a hinged (i.e. fold-down) Noise Attenuator is necessary.

3.4.15. Discharge Temperature sensor emergency shutdown: The exhaust fan must have a discharge air temperature sensor which secures the fan if a rise in air temperature is detected. The fan will be serving Hot Work procedures including metal grinding and welding. If sparks are ingested in the ductwork and a fire is started, the fan needs to be automatically secured to prevent the fire from propagating, eliminate the addition of oxygen to the fire, and reduce equipment damage.

3.4.16. Vibration Sensor & Shutdown: To protect the machine, mounted to the fan shaft bearings shall be a programmable electronic (vice mechanical) accelerometer sensor that would detect vibrations of varying amplitude and frequency. The unit shall be programmable for two set-points. The lower (less damaging) set-point shall cause an alarm “yellow” caution light to be switched on. The higher (more damaging) set-point shall cause a shutdown & “red” warning light to be switched on and the exhaust blower to be switched off.

3.4.17. Transitions: The vendor shall provide two types of suction wyes so that the end-user can choose the diameter(s) for the semi-flexible ducting lines. The single main suction Wye which is fastened (via bolts) to the circular Flanged Inlet to facilitate removal for maintenance is attached whenever the Industrial Exhauster is operating. The main suction Wye will allow for the connection of two each fourteen inch nominal diameter (14"Ø × 2) semi-flexible ducting lines and/or the attachment to either a single or a pair of branch Suction Wye(s). Each of two branch suction Wyes will allow for the connection of up to three each eight inch nominal diameter (8"Ø × 3) semi-flexible ducting lines.

3.5. 230 Ton Air Cooled Chiller

3.5.1. Nominal operating capacity of 230 Ton heat rejection, air cooled chiller

3.5.2. Actual operating capacity ≥215 Ton heat rejection @ 95°F Ambient conditions

3.5.3. Maximum operating chilled water flowrate of 600 GPM

3.5.4. Chilled water discharge temperature set point: 42°F

3.5.5. Chilled water inlet and outlet must be adapted to 6 IN diameter non-ferrous, non-galvanized, metal cam and groove quick disconnect fittings meeting the requirements defined in reference 2.1.1.2

3.5.6. Chiller controls and interface must provide a display allowing the end user to jog through current and historical performance data. This includes system performance data, record and log system parameters, as well as log system errors during an equipment failure.

3.5.7. Chiller must have a low flow switch and not pressure differential verification as a means for low flow cutoff

3.5.8. Chiller must contain ≥4 compressors and refrigerant circuit loops

3.5.9. Chiller must be compatible with pump performance curve

3.5.10. Must provide inlet and outlet chilled water temperature monitoring. Temperature gauges must provide a minimum resolution of 1 DEG F over a minimum operating range from 30 DEG F to 80 DEG F.

3.5.11. Chilled water outlet must be fitted with a flowmeter rated to 150 PSI providing a minimum accuracy of 1% of reading over a minimum range from 100 to 800 GPM and minimum resolution of 1 GPM. Reference Section 4.7.

3.5.12. Chiller electrical requirements: 460 VAC, 3 PH, 60HZ, Maximum Full Load Amps 400A

3.5.13. Chiller must be operated from a single 460 V, 3 Phase AC power source. Any lower voltage power requirements for controls and/or metering equipment must be met using a vendor supplied integral transformer.

3.6. Pump and Motor Assembly (Supporting 230 Ton Chiller)

3.6.1. Pump must nominally provide 600 GPM at 100 feet of head

3.6.2. Pump may be integral to Chiller unit or may be a stand-alone unit where the inlet and outlet piping must be adapted to 6” diameter non-ferrous, non-galvanized, metal cam and groove quick disconnect fittings meeting the requirements defined in reference 2.1.1.2

3.6.3. Low speed 1750 RPM Electric motor to operate on 460 VAC, 3 PH, 60 HZ

3.6.4. Pump must be fitted with differential pressure gauges rated to from 0 to 150 PSI. If the maximum pump discharge exceeds 150 PSI, the gauge must be rated for 20 PSI above the maximum discharge head pressure.

3.7. 180 Ton Air Cooled Chiller

3.7.1. Nominal operating capacity of 180 Ton heat rejection, air cooled chiller

3.7.2. Actual operating capacity ≥160 Ton heat rejection @ 95°F Ambient conditions

3.7.3. Maximum operating chilled water flowrate of 450 GPM

3.7.4. Chilled water discharge temperature set point: 42°F

3.7.5. Chilled water inlet and outlet must be adapted to 4 IN diameter non-ferrous, non-galvanized, metal cam and groove quick disconnect fittings meeting the requirements defined in reference 2.1.1.2

3.7.6. Chiller controls and interface must provide a display allowing the end user to jog through current and historical performance data. This includes system performance data, record and log system parameters, as well as log system errors during an equipment failure.

3.7.7. Chiller must have a low flow switch and not pressure differential verification as a means for low flow cutoff

3.7.8. Chiller must contain ≥4 compressors and refrigerant circuit loops

3.7.9. Chiller must be compatible with pump performance curve

3.7.10. Must provide inlet and outlet chilled water temperature monitoring. Temperature gauges must provide a minimum resolution of 1 DEG F over a minimum operating range from 30 DEG F to 80 DEG F.

3.7.11. Chilled water outlet must be fitted with a flowmeter rated to 150 PSI providing a minimum accuracy of 1% of reading over a minimum range from 100 to 800 GPM and minimum resolution of 1 GPM. Reference Section 4, Note A.5 for additional details.

3.7.12. Chiller electrical requirements: 460 VAC, 3 PH, 60HZ, Maximum Full Load Amps 200A

3.7.13. Chiller must be operated from a single 460 V, 3 Phase AC power source. Any lower voltage power requirements for controls and/or metering equipment must be met using a vendor supplied integral transformer.

3.8. Pump and Motor Assembly (Supporting 180 Ton Chiller)

3.8.1. Pump must nominally provide 450 GPM at 100 feet of head

3.8.2. Pump may be integral to Chiller unit or may be a stand-alone unit where the inlet and outlet piping must be adapted to 4” diameter non-ferrous, non-galvanized, metal cam and groove quick disconnect fittings meeting the requirements defined in reference 2.1.1.2

3.8.3. Low speed 1750 RPM Electric motor to operate on 460 VAC, 3 PH, 60 HZ

3.8.4. Pump must be fitted with differential pressure gauges rated to from 0 to 150 PSI. If the maximum pump discharge exceeds 150 PSI, the gauge must be rated for 20 PSI above the maximum discharge head pressure.

3.9. Accompanying Hoses Assemblies, & Fittings

3.9.1. Chilled water non-collapsing or collapsible suction/discharge hose, 6 IN diameter, supplied in lengths not to exceed 25 FT, male x female cam and groove quick-disconnect fittings, 150 PSI rated. Total length required specified in section 3.1. All fittings must meet the requirements defined in reference 2.1.1.2

3.9.2. 6 Inch diameter Elbows, fitted with non-ferrous, non-galvanized, metal male x female cam and groove quick-disconnect fittings meeting the requirements defined in reference 2.1.1.2. Total quantity required specified in section 3.1.

3.9.3. Chilled water non-collapsing or collapsible suction/discharge hose, 4 IN diameter, supplied in lengths not to exceed 25 FT, male x female cam and groove quick-disconnect fittings, 150 PSI rated. Total length required specified in section 3.1. All fittings must meet the requirements defined in reference 2.1.1.2

3.9.4. 4 Inch diameter Elbows, fitted with non-ferrous, non-galvanized, metal male x female cam and groove quick-disconnect fittings meeting the requirements defined in reference 2.1.1.2. Total quantity required specified in section 3.1.

3.9.5. All connectors must contain New O-ring gaskets of proper thickness to prevent leaks.

3.10. 3 Way Y Manifold (Male x Female)

3.10.1. The Y manifold is a metal 6-inch diameter 3-way Y fitting (6"Ø × (two) 4” Ø).

3.10.2. The two 4 IN diameter legs shall terminate in a Female camlock w/ Plug.

3.10.3. The Single 6 IN diameter inlet leg shall have a Male camlock w/ Cap.

3.10.4. All cam and groove Camlock fittings shall meet the requirements defined in reference 2.1.1.2.

3.10.5. The Plugs and Cap shall be a Hydrostatic type vice a Cleanliness type so as to withstand test pressure.

3.11. 3 Way Y Manifold (Female X Male)

3.11.1. The Y manifold is a metal 6-inch diameter 3-way Y fitting (6"Ø × (two) 4” Ø).

3.11.2. The two 4 IN diameter legs shall terminate in a Male camlock w/ cap.

3.11.3. The Single 6 IN diameter inlet leg shall have a Female camlock w/ Plug.

3.11.4. All cam and groove Camlock fittings shall meet the requirements defined in reference 2.1.1.2.

3.11.5. The Plugs and Cap shall be a Hydrostatic type vice a Cleanliness type so as to withstand test pressure.

3.12. Transition fittings:

3.12.1. To be provided by the vendor for attachment of 3 IN diameter camlock fittings to each 4 IN hose set connection of the 3-way Y style Manifold. (Required if HVAC chilled water coil connections are 3 IN Diameter)

3.12.2. All cam and groove Camlock fittings shall meet the requirements defined in reference 2.1.1.2.

4. NOTES:

4.1. Chilled Water System:

This System includes all equipment to: (a) produce chilled water via a Chiller with integral built-in pump or stand-alone pump; (b) pressurizes the chilled water (via a built-in pump or a separate pump module); and (c) transports the chilled water via hose assemblies. The pump (motor & impeller) shall be a matched set and shall be a Low Speed (LS i.e. ~1750 rpm) pump capable of delivering the specified flow rate at 100 FT Head. The Chiller rental fee shall be for the Chiller, flow meter and temperature gauges. The Pump rental fee shall include pressure gauges, any hose assemblies, meters, & adapters as well as any independent Pump Module(s) for pressurizing the chilled water.

4.2. Chiller Capacity & Utilities:

4.2.1. Cooling: The primary utility for the Chiller shall be all electric and air-cooled. The minimum nominal chilled water capacity shall be as indicated with the actual capacity, based on an ambient temperature of 95°F dry bulb with an Entering Water Temperature (EWT) of 52°F and a Leaving Water Temperature (LWT) of 42°F, to be not less than 5% of the desired nominal capacity. The unit capacity shall not be greater than one-third above (+⅓) the minimum specified capacity and shall be able to run continuously at one-quarter of that unit's stated capacity.

4.2.2. Flowrate: The pump shall have a minimum specified flowrate of 2.4 gallons per minute (gpm) per ton of minimum cooling capacity at a Head Pressure of one-hundred feet (100'). The evaporator shall function at a maximum flowrate of at least 3.6 gpm per ton of cooling capacity and remain functional at a minimum flowrate of a third or less of the maximum flowrate (≤1.0 gpm per ton). The pump shall have the capability of operating albeit being restricted to one-third of the minimum specified flowrate without damage to the pump or to any other chiller component.

4.2.3. Automatic Operation, Regulation, & Controls: The Chilled Water Unit or Chiller Module shall be equipped with an automatic variable capacity control requiring only initial temperature adjustment of from 38 to 60°F by the operator. Refrigeration circuits shall maintain the specified temperature condition while protecting against coil freeze-up with such devices as a thermostatic expansion valve, suction pressure switch, cylinder unloading solenoid valve, freeze fault protection thermostat, Hot Gas Bypass if specified, etc. The unit / modules shall include permanently mounted control board(s) accessible without opening any panels containing temperature thermometer(s) and pressure gauge(s) as necessary for both monitoring and control. The unit / modules shall be completely wired for safety, capacity, and operation such as a power/switch system with circuit breakers, manual/automatic controller, motor overload protection, high/low pressure cut-outs, energy control system, and other essential components. The unit / modules shall be fully controllable under a wide range of loads even though the daily and seasonal ambient temperatures vary greatly.

4.2.4. Design & Component Integration: The Chiller can either be an integrated unit with combined Chiller and pump capable of both refrigerating and pressurizing water, or, it may be two discrete components consisting of a Chiller Module and separate Pump Module. The unit or each module shall be rigidly mounted within a single integrated framed structure manufactured as a complete entity to include all devices, accessories, and fittings such as cooling coils, condenser fans, compressor(s), pumps with their motors/starters, evaporator & condenser refrigeration circuits, filters, and other auxiliary components necessary to chill fresh water (potable or treated) and deliver that water to ancillary mechanical equipment via a closed loop with little or no make-up water. The unit / modules shall be designed for continuous operation at minimal loading (i.e. one-quarter of full capacity for refrigeration & one-third of full capacity for pumping) despite extreme ambient conditions (e.g. –10 to +100°F and 0 to 100% RH). Additionally, see 4.13 for lifting and handling requirements.

4.2.5. Cooling: The refrigerant shall be internal to the unit with a quantity sufficient for its capacity. The cooling coils shall conform to Reference 2.1.2.2. The condenser(s) shall be air-cooled via fan(s). The chiller shall have a sufficient water storage capacity to run isolated from a make-up water connection.

4.2.6. Energy Efficiency: For energy efficient operation in a fully loaded condition, the Full Load Amperage (FLA) rating for the combined Chilled Water Unit or the FLA summation for a separate Chiller Module plus one Pump Module shall be two and a half amperes or less per ton of actual chilled water capacity. For energy efficient operation in a partially loaded condition, the Chilled Water Unit or Chiller Module shall be designed, if single compressor, with two or more cylinders, but, preferably the unit will have two or more compressors each with its own refrigeration circuit.

4.2.7. Transition: The chilled water end connections on the Chilled Water Unit or the Chiller Module plus the Pump Module where the chilled water "standard" type hose assemblies would connect shall terminate in 6 INCH CAM-LOCK type connections with female fitting(s) on the inlet(s) (supply) and male fitting(s) on the outlet (discharge).

4.3. Coolant Free: Besides manifolds and hose assemblies that are normally flushed and tested, all machinery conveying chilled water such as: the Chiller, Pump and machines with a chilled water coil; shall arrive with no coolant of any type in its piping (i.e. No Water & No Anti-Freeze).

4.4. Chilled Water Hose Assembly / Manifold Construction / Cooling Coil Hydrostatic Testing: For standard Chilled Water Hose assemblies of six inch nominal diameter or less, the exterior cover shall be a thick rubber (Buna-N) type material designed as a CHW insulator in which the nominal hose length is twenty-five feet with one male and one female quick disconnect Fittings. All Chilled water connectors / fittings must be quick disconnect style fittings meeting the requirements defined in reference 2.1.1.3. Chilled Water Hose assemblies shall be non-collapsible and the camlock fittings shall be attached to the hose material via the more secure, newer type, crimp style hose fitting via a single specified diameter, elongated sleeve length and not from the less secure, older type, band clamp style hose fitting via multiple universal diameter, shorter ferrules. Gaskets for couplings shall be pre-installed inside the female coupling(s) of hose assemblies and manifolds. The gasket shall be inspected for presence, tight fit, and lack of deterioration. Gaskets shall not protrude into the waterway. A gasket with a smaller diameter than that of the recess can cause a leaky connection when pressure is applied. Hose/manifold/valve assemblies and all cooling coils shall be hydrostatically tested with new hose gaskets for Strength and Tightness and/or Valve Seat Leakage by an independent (of the Contractor) and certified Vendor to a minimum of 150 psig for five minutes and visually inspected and/or internal valve leakage measured while pressurized. Hydrostatic test date shall be within one calendar year of scheduled Arrival Date of the equipment. Hoses/manifolds/valve assemblies shall have a banded identification (ID) tag or label attached to the assembly displaying the hydrostatic test results. The Hydrostatic Test Certificates issued by the certified testing facility shall provide a copy of the certificates to PNSY Temporary Services Design Engineer and the Contracting Office, Code 400.

4.5. Phase Rotation: To prevent or identify an out-of-phase electrical power situation, three-phase machines shall include either: (a) a reverse phase relay and/or meter that identifies an out-of-phase condition and prevents operation especially applied to complex machinery in which such a condition could cause damage or (b) an arrow prominently displayed at an appropriate location on the machine's housing to indicate the proper direction of shaft rotation with the ability to observe a portion of the shaft after a momentary application of power (a.k.a. jog or bump). A reverse phase relay is not required nor desired for VFD motors, however, the VFD shall have a jog button so as to verify correct rotation.

4.6. Supplemental Equipment: For the protection and cleanliness of the machinery components, all chilled water connection points shall be shipped with plug/cap fittings. Chilled water "standard" type hose assemblies of twenty-five foot lengths with 4 INCH CAM-LOCK type male and female connections shall be provided.

4.7. Hydronic Flow Meter: Attached to the Chiller and its associated pump shall be a continuous reading liquid flow meter, preferably, in-line with flow. The type of meter may be Electronic Metering or Axial Turbine. The physical positioning of the instrument shall downstream of the Chiller immediately after its discharge. The flow meter assembly shall be rated for 150 psig; dimensioned for the heat exchangers nominal 3-inch diameter pipework; and constructed for accuracy as described below. The instrument shall be calibrated by a licensed Metrology Laboratory within five years of its scheduled delivery with certified calibration test results both accompanying the flow meter assembly and reported via E-mail to the Temporary Systems Design Engineer.

If the flow meter is an Axial Turbine type (e.g. McCrometer Model MG100 / MS100 -or- equivalent) with no factory installed straightening vanes, then the entire flow meter assembly shall be constructed so as to provide straight lengths of pipe to the inlet of the instrument housing of at least ten pipe diameters and the outlet of the instrument housing of at least two pipe diameters, unless the manufacturer requires an even greater linear distance. Since the entire Axial Turbine flow meter assembly with no factory installed straightening vanes could be four feet in length, a steel stand would be required for mounting the axial turbine flow meter assembly horizontally with the meter on top so as to meet lifting and handling requirements. This shall be integral with the heat exchanger and pump assembly. Although straightening vanes could reduce the length of the Axial Turbine flow meter assembly by cutting in half the number of pipe diameters upstream to five, a L&H stand would still be required.

4.8. HVAC Capacity & Utilities

4.8.1. Airflow: An integrated blower (air-handler) is required for independent operation of the unit. With the blower operating at full speed, the airflow in cubic feet per minute (cfm) combined with either the fan's external Total Static Pressure (TSP) in inches of Water Gauge (WG) and/or the motor's power rating in horsepower shall be as stated in section 3.2 and section 3.3.

4.8.2. VFD: The unit shall incorporate variable speed control for the process air blower so that the air-handler shall be capable of adjusting the airflow to half or less of the minimum specified airflow.

4.8.3. Control: The unit shall include a permanently mounted control board accessible without opening any panels with temperature thermometer(s) and pressure gauge(s) as necessary for monitoring and control. The unit shall be completely wired for safety, capacity, and operation such as a power / switch system with circuit breakers, manual / automatic controller, motor overload protection, high / low pressure cut-outs, energy control system, and other essential components. The unit shall be fully controllable under a wide range of loads even though the diurnal and seasonal ambient temperatures varies greatly. All equipment must be pre-wired for and compatible with a remote E-Stop Switch (Remote Emergency Stop Switch). This will enable the air handler to be shut down in response to an emergency condition where airflow needs to be secured. Vendor shall route all E-stops to a central location at Topside Watch where all air handling equipment can be secured.

4.8.4. Design & Component Integration: The unit shall be rigidly mounted within a single integrated framed structure manufactured as a complete entity to include all devices, accessories, and fittings such as energy control system, motors, filters, and other auxiliary components necessary to condition ambient air and deliver that air to ancillary mechanical equipment.

4.8.5. Filtration: HVAC Units shall feature permanent metal filters for the Process Air Inlet filtration so as to withstand exposure from wet ambient conditions. Inlet fibrous (paper) filters deteriorate exceedingly soon after the first rain storm and is not an acceptable substitute. Furthermore, air-handling coils that convey fresh outside treated air directly to the industrial space pressurized compartments should feature Moisture Separator / Demister type filtration for purging 98% of the moisture on saturated days.

4.9. Termination Couplers: Process Air outlet(s) for the various ventilation systems shall terminate in nominal twenty-inch diameter (20"Ø) opening(s) either by design or by providing the proper reducer(s). This will allow for the attachment of nominal twenty inch diameter flexible ducting as provided by either the Vendor and/or the Government. The Vendor shall ensure that the flexible ducting furnished is sized to match the Process Air Inlet(s) and Process Air Outlet

4.10. Process Air Doors or Covers: Machinery with blowers for imparting energy to a Process Air stream or in-line with an air stream shall have the quantity and size of round Process Air suction inlets and discharge outlets and shall include tightly-fitting non-detachable doors (preferred) or detachable covers (permitted) for each suction inlet and discharge outlet.

4.11. 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.

4.12. 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 Technical Liaison with the following details: (i) electrical power type (amperage & voltage); (ii) type of electrical connectors (for three phase, 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).

4.13. Lifting & Handling:

4.13.1. See reference in section 2.1.1.1.

4.13.2. Lifting & Handling Exception:

Although considered to be machinery, individual pump units, being relatively lightweight and compact, are not required to be enclosed in a caged frame. However, the remaining Lifting and Handling requirements pertain in that the unit will be handled by forklift.

4.14. Noise Requirement: When operating at full speed, noise levels must not be over 105 dB[A] and preferably, 85 dB[A] or less 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.

4.15. Machinery / Equipment Tagging and Markings: Fluid piping inlet(s) / outlet(s) must be clearly marked. Machinery and itemized equipment require tagging to show Project Number / Technical Specification Identification (ID) Number

4.16. 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.

4.17. 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. Makeup / feed water hose and filtration connection fittings.

5.2. Electrical power cable to supply 460VAC, 3PH, 60 Hz

5.3. Flex duct adaptors to convert the 20 IN Dia. process air duct to triple branch 8 IN Dia. Local process air duct.

5.4. 8 IN diameter process air flex duct.

6. RESPONSIBILITES

6.1. Government

6.1.1. Equipment Technical Evaluation: C230 Engineering

6.1.2. Receipt Inspection: Contractor Officer Representative (COR) & Temporary Service Zone Manager (TSZM)

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

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

6.2. Contractor

6.2.1. The equipment will be operating around-the-clock under a rigorous deployment performance schedule. Within twenty-four (24) hours 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 forty-eight (48) hours of initial notification or, if the original defective unit(s) cannot be made operational, replaced within seventy-two (72) hours 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.

6.2.2. 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 AHU filters, valves operational, pump suction and discharge pressure gauges, air bleeder valves, pump strainers cleaned, steam traps present, flow meter installation / location, Flow meter calibration certificates from a certified test lab, piping end caps to maintain cleanliness. If components (such as a flow meter) within a packaged unit configuration (such as a chiller) 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:

Flow Meter: installation location provides correct Pipe L/D ratio

Chilled Water Pump Suction and Discharge Pressure gauges installed

Pump suction Strainer: clean and free of debris

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. Air Handling Units: the equipment shall be powered and all electrical circuits, fuses, contactors & relays, control panel functions, control panel indicators, VFD control verified & fan speed (RPM), filter static pressure drop, motor FLA, rotational verification, heating element performance test, amperage of each heating element stage, thermostatic set point test, cooling coil leak check and pressure test, steam coil leak check and pressure test, Steam trap functional performance test.

6.3.2.2. Pumps: Motor speed verification, rotation verification, dead head test (measure & report total dynamic pressure), valves tested operational.

6.3.2.3. Chillers: the equipment shall be powered and all electrical circuits, fuses, contactors & relays, control panel functions, control panel indicators, flow switch safety interlock function verified, Chiller run load amps, discharge water temperature set point satisfied, 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 Temporary Service 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 Manufacturer (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 replace, 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 Temporary Service 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, measuring discharge air temps, assessing DH equipment reactivation air performance, verify amperage of all electric heating coils, verification of chilled water coils performance, verify pump operation, motor speed, and differential pressure, verify HVAC process air fan speeds, DH process air discharge air temperature and RH performance, Chiller performance operation, etc. 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.

6.4.4. 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 6.2.1.

6.5. Training

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

6.6. 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:

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

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

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

6.6.4. Operating Instructions, if not in the TI.

6.6.5. Preventative Maintenance Schedules. (See section 6.4.2)

6.6.6. MQC’s (See section 6.3)

6.6.7. Equipment Data Sheet (EDS).

6.6.8. Hydrostatic Pressure Test Reports.

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 990 Equipment Manager) 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.

7.6. 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

Spec #: HVACTX1101320

Rev: Orig