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- W52P1J-18-T-3054
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Qualifying Statement for Compressor System
Three each, Gardner Denver compressed air system, skid unit with following components or equal: Gardner Denver model VS-110 variable speed, air cooled, 150 HP compressor rated at 663 CFM at 125 psig. Compressors shall be wired for 460 Volt, 3 Phase, 60 Hertz. Each compressor shall include a communication sequencing module for lead/lag/sequencing operation. Gardner Denver model DGH75EF3 heatless desiccant dryer rated at 750 CFM at 100 psi. The dryers are wired for 115 Volt, 1 Phase, 60 Hertz electrical service. Dryers shall include a 3 valve by-pass and energy saving control system “E”. One compressor and dryer shall be assembled, piped, and mounted onto an epoxy coated structural steel skid to make one compressor/dryer skid unit. Three units are required in total. Piping shall be 3” welded schedule 40 black pipe (painted). The package dimensions shall not exceed 240” long X 72” wide X 112” high. The skid structure must be complete with fork pockets and mounting holes. The package shall be completely tested prior to shipment. Factory trained technician for start-up, and training on operation/maintenance included.
LIST OF REQUIRED FEATURES:
NOTE: The offeror shall specifically indicate whether or not each of the following required features will be met. If any required feature cannot be met, the offeror will include explanatory remarks for customer review.
COMPRESSOR:
1. GENERAL
The air compressor shall be a VS 110 single stage, oil flooded, rotary screw type, air-cooled compressor or equal utilizing an integrated variable speed drive control. At full load, the compressor capacity shall be 663 ACFM at a discharge pressure of 125 psig. Capacity is the actual CFM at inlet conditions, delivered at the final discharge of the compressor package. The capacity will vary based upon system demand and will range from 100% to 20% of full capacity over a pressure range of 70 to 175 psig. The unit shall be completely assembled and factory tested under full load and part load conditions.
2. INLET AIR FILTER
Ambient air shall be directed inside the enclosure to a radial seal type air filter. The element shall be rated 99.9% efficient at 3.0 micron. This inlet filter arrangement shall provide clean air for compression in normal industrial applications.
3. AIREND
To ensure volumetric efficiency and finite tolerance control, the rotors shall be manufactured in multiple steps of high-precision milling and grinding. The airend housings shall be manufactured utilizing precision CNC machining centers to provide precise tolerance control and to obtain mechanical alignment with the rotor set.
All bearings shall be designed for long life and reliability. A large ball bearing coupled with a cylindrical roller bearing is used at the thrust end of each rotor in the airend. These premium quality bearings shall carry both radial and thrust loading by utilizing their combined strengths of the bearings. The cylindrical roller inlet bearings shall carry radial loading.
4. MOTOR
The compressor drive motor shall be a 110 kW inverter-duty motor that utilizes a Pulse Width Modulation inverter to control its starting, frequency, and speed. The motor optimizes torque, efficiency, and power factor through the following features:
A) Unlimited number of starts/stops per hour and precise variable speed control to accurately match air demand changes.
B) Premium 95% efficiency.
C) A 1.0 service factor and increased air gaps shall allow cooler operating temperatures with an ambient rating of 115°F (46°C).
D) Direct, flange mounting of the motor to the airend maintains near perfect alignment. The motor shaft shall be coupled to the airend shaft via a flexible, dropout style coupling.
In summary, the design of this motor to perfectly meet the specific requirements of the airend and the motor's direct mounting to the airend shall increase efficiency and reliability by eliminating energy robbing components and by significantly reducing the number of serviceable parts.
5. INVERTER DRIVE
The package shall have a standard integral Pulse Width Modulation inverter. The inverter will be a standard type with a minimum efficiency of 97%. The drive, which shall be programmed with firmware at the time of shipment, shall communicate with the AirSmart controller for control of the unit.
6. BASEPLATE
The fabricated steel base shall be manufactured to provide maximum rigidity and minimizes sound levels. The base shall be sufficient for final installation. MCAAP will not need to provide special foundations for the skid units.
7. ENCLOSURE
A sound level of 76 dBA (per ISO 2151) shall be required through the use of an engineered sound enclosure. The enclosure shall be designed with hinged/removable doors that allow for easy access and servicing of all internal components. Powder coat paint shall be externally applied via an electrostatic coating process to a minimum thickness of 50 μm.
8. COOLANT/FILTRATION
Coolant filtration shall be accomplished by a 12-micron rated, spin-on-type filter. Filter condition shall be monitored by the AirSmart controller, which provides a warning when filter reaches the pre-determined operational hours. The controller will keep track of the number of hours remaining on the filter before it needs to be changed. When the advisory displays on the screen it will indicate the part number of filter. The system shall contain an internal pressure relief valve that bypasses at 1.5 to 2 bar differential pressure. This shall protect the compressor in the event of the oil filter plugging or upon cold starts that cause a high differential.
9. COOLANT/AIR SEPARATION
Coolant separation in the unit shall be made in two stages. First, most of the coolant shall be separated by gravity and centrifugal force inside the oil reservoir. Second, separation shall be completed through use of a highly efficient coalescing element.
The reservoir unit is rated at 16.9 bar (245 psig) and all the units shall be tested per standard ASME design. The vessel meets all of the requirements of ASME/CSN and has a nameplate indicating compliance.
The package shall contain a hinged, latched door over the reservoir which allows direct access to change the separator element. Consequently, separator element changes are simple and quick.
10. SEPARATOR ELEMENT
The oil separation element shall be a unitized element with pleated media and an inside-out separation design. The scavenge line connects to the oil reservoir, not to the element, which eliminates the possibility of incorrect re-assembly when the element is serviced. Coolant carry-over will be 2 ppm or less using the ISO 8573-2 test method.
11. HEAT EXCHANGERS
Air-cooled, single pass, radiator-type heat exchanger shall be mounted horizontally at the top of the compressor package. The heat exchanger shall be constructed of high strength aluminum and is designed to efficiently reject the heat of compression in ambient temperatures as high as 46°C (115°F) with a CTD of 8°C (15°F). Airflow through the coolers shall be managed by an axial fan, which pushes an even disbursement of cooling air across the entire surface of the heat exchanger core.
12. TEMPERATURE CONTROL BY OIL MIXING VALVE
Compressor coolant temperature shall be regulated by a unique oil-mixing valve, which directs the coolant either through the heat exchanger or directly to the coolant injection of the airend. An algorithm in the AirSmart controller controls the electronic oil-mixing valve.
13. CONTROL METHODOLOGY
The compressor shall be controlled via the AirSmart controller. This microprocessor allows for turndown range of 100 - 20% of package capacity at a system efficiency of 92% or greater. Below the minimum turndown, the control methodology stops the compressor. The compressor package shall start against load. This eliminates the loss of energy from fully blowing down the system. The compressor shall have the ability to start under a load and as often as required without damage to the drive and/or motor. The compressor will stop when minimum speed is reached at the unload pressure setting. The compressor will remain off until system pressure decays below the load pressure at which time the compressor will restart. The controller methodology is to operate at the lowest possible specific power throughout the entire pressure and turndown range.
14. MICROPROCESSOR CONTROLS
The exclusive AirSmart controller manages control of the compressor. This comprehensive control system includes safety controls, operational instruction, data feedback, capacity control, operational control, maintenance and service information, and inverter interface. All information is displayed for the user at a LCD control center. Information Displays include the following:
MAINTENANCE INFO DISPLAY
| • Total Hours |
| Displays the total number of operational hours of the unit. |
| • Load Hours |
| Displays the total number of hours the unit has been loaded. |
| • Next Oil Filter |
| Displays the number of hours until the next oil filter element change is required. |
| • Next Oil Change |
| Displays the number of hours until the next oil change is required. |
| • Next Oil Separator |
| Displays the number of hours until the next air/oil separator element change is required. |
| • Next Air Filter |
| Displays the number of hours until the next air filter element change is required. |
| • Next Control Box Filter |
| Displays the number of hours until the next control box filter element change is required. |
| • Next Motor Lube |
| Displays the number of hours until the next motor bearing lubrication is required. |
| • Start Timer |
| Displays the set time of the start timer. When the unit is started, the controller will keep the unit at minimum speed until the timer times out and the control pressure is reached to allow the inlet valve to open and begin compressing air. |
| • Blowdown Timer |
| Displays the set time of the blowdown timer. This timer starts timing when the unit reaches unload pressure, minimum speed and the compressor stops. When the timer expires it allows the reservoir to blowdown to zero pressure. |
| • Auto Timer |
| Displays the set time of the auto timer. This timer starts timing when the unit reaches target pressure and minimum speed. When the timer expires it stops the motor. |
| • Average Capacity (CFM) |
| Displays the average capacity in CFM over the last hour of operation. |
| • Average Capacity (%) |
| Displays the average capacity in percent of full capacity over the last hour of operation. |
| • Average Package Power |
| Displays the average package power consumed in kilowatts over the last hour of operation. |
| • Energy Cost |
| Displays the current energy cost in dollars (or Euros) based on operator-defined price per kilowatt-hour. |
| • Total Cost |
| Displays the accumulated energy cost of the package for an operator-defined period of time. |
| • Firmware Version |
| Displays the version of the firmware currently loaded into the controller. |
| • Model Table Version |
| Displays the version of the model table currently loaded into the controller. |
| • Language Table Version |
| Displays the version of the language table currently loaded into the controller. |
MOTOR INFO DISPLAY
| • Motor Current |
| Displays the amperage draw of the drive motor. |
| • Motor Power |
| Displays the kW draw of the drive motor. |
| • Motor Voltage |
| Displays the AC voltage level delivered to the drive motor. |
| • Motor Speed |
| Displays the rpm of the drive motor. |
| • Motor Frequency |
| Displays the frequency (Hz) of the drive motor. |
PRESSURE & TEMP DISPLAY
| • Inlet Temperature |
| Displays the current ambient temperature outside of the compressor package. |
| • Discharge Temperature |
| Displays the temperature at the discharge of the compressor prior to entering the air/coolant reservoir. |
| • Reservoir Pressure |
| Displays the pressure on the “wet side” of the air/oil separator element. |
| • Plant Pressure |
| Displays the system pressure at the aftercooler discharge into the plant system. |
| • Dryer Temperature |
| Displays the air temperature entering the integrated dryer, if so equipped. |
ADVISORY HISTORY DISPLAY
| • Advisory History 1 - 6 |
| Displays the last six advisory issues for the unit. The pressure, temperature, motor amps, motor power, motor speed, etc. data recordings are saved at each advisory. |
SHUTDOWN HISTORY DISPLAY
| • Shutdown History 1 – 6 |
| Displays the last six shutdown issues for the unit. The pressure, temperature, motor amps, motor power, motor speed, etc. data recordings are saved at each shutdown. |
DRIVE INFO DISPLAY
| • V Freq. CMD |
| Displays the controller’s commanded motor frequency (Hz) value of the drive motor. |
| • V DC |
| Displays the DC buss voltage value of the drive motor. |
| • V TEMPERATURE |
| Displays the temperature of the drive heat sink. |
| • Drive FAULT |
| Displays the fault value of the drive, if one should occur. |
If there is a zero next to the drive number there is no current fault. If there is a number, the number will correspond to a specific fault.
For a list of fault codes and their description refer to the Drives User Manual.
| • Drive Firmware Version |
| Displays the current firmware version of the drive. |
DIAGNOSTIC INFO DISPLAY
| • V Calc Min |
| Displays the minimum speed of the drive motor. |
| • V Calc Max |
| Displays the maximum speed of the drive motor. |
| • Target Temperature |
| Displays the target temperature the aftercooler fan is attempting to maintain. |
| • Oil Valve Cmd |
| Displays the percentage of lubricant flow being directed to the bypass vs. the cooler. |
SERVICE MENU TREE
OPERATIONAL ADJUSTMENTS:
| • Language |
| Allows the operator to select the language of the controller. The operator can select from 8 languages. |
| • Target Pressure |
| Allows the operator to adjust the target pressure that is to be maintained at the package discharge. |
| • Unload Pressure |
| Allows the operator to adjust the pressure at which the unit will unload. It can be set no less than the Target Pressure + 5 PSIG. It can be set as high as 180 psig. |
| • Load Pressure |
| Allows the operator to adjust the pressure that the compressor will load again after it has unloaded and/or stopped. |
This pressure can be as low as 30 psig., but no higher than the Target Pressure.
| • Pressure Units of Measure |
| This set point allows you to choose the pressure units you wish to see displayed. These include the following: PSI, BAR, kPa, kg/cm2. |
| • Temperature Units of Measure |
| Allows the operator to select between Centigrade (metric) and Fahrenheit (English). |
• Operating Mode
Automatic/Constant/Sequence Automatic—Normal variable speed operation, motor will stop after unload. If the Auto Timer is programmed for 10 minutes, the compressor motor will stop if the unit runs unloaded for 10 minutes. If the Auto Timer is programmed for 0 minutes the compressor motor will stop as soon as the unit unloads.
Constant—Normal variable speed operation, motor will NOT stop after unload. Machine continues to run unloaded at minimum speed.
Sequence—Modulation is controlled by the communications module.
• Start Timer
The time entered will dictate the time the compressor runs at minimum speed before it goes to maximum speed or to the speed that is required to reach target pressure.
NOTE: The compressor will not run at full speed until the control pressure has reached 60 psig
This timer is adjustable from 0 to 600 seconds.
The compressor is capable of reaching maximum speed within 5 seconds after the run button has been pressed.
• Stop Timer
The time entered will dictate the time between the stop button being pushed or activated and the motor stopping.
When the Stop button is pushed or remotely activated the motor will go to minimum speed, and the compressor will blow down, then the motor will stop when this stop timer has counted down to zero.
This timer is adjustable from 0 and 120 seconds. The default time for the Stop Timer is 0.
• Blowdown Timer
The time entered will dictate the time the unit will wait before blowdown after the unit has stopped.
The blowdown timer is adjustable from 1 to 1,200 seconds.
The unit will blow down immediately if the stop button has been pushed or the unit has shut down due to a fault or an exceeded parameter.
The default set-time for the blowdown timer is zero.
| • Blowdown Counter |
| The value entered will dictate the number of blowdown cycles the unit can perform in a given period of time. Note: the blowdown cycle time is controlled by the blowdown timer. |
• Auto Timer
This is the amount of time the unit will run unloaded before the compressor motor will stop.
If the Auto Timer is programmed for 10 minutes, the compressor motor will stop after the unit runs unloaded for 10 minutes.
If the Auto Timer is programmed for 0 minutes the compressor motor will stop as soon as the unit unloads.
The time is adjustable from 0 to 20 minutes.
The default setting for the Auto Timer is zero.
• Remote Halt
Immediate or Timed Unload.
If Immediate is chosen, the compressor will stop just as if the stop button was pushed. The unit will unload, blowdown and stop when the Stop Timer has reached 0. The Stop Timer has a default time of 0.
If Timed Unload is selected, the Blowdown timer and the Auto Timer must each time out before the compressor stops.
• Auto Restart
This can be selected as either OFF or ON.
When ON is selected, the compressor will automatically RESTART when power is restored after a power failure.
When OFF Is selected, the compressor will NOT RESTART when power is restored. The compressor must be manually restarted.
The factory default is OFF.
• Restart Delay
If the Auto Restart ON is selected, this screen will be displayed.
Here you will select the time the compressor will wait, upon power restoration, before the unit restarts.
• Idle Timer
The value entered controls the number of minutes the reservoir will remain pressurized during periods of no demand.
| MAINTENANCE ADJUST |
| The following counters can be reset after service has been performed. |
• Next Oil Filter
• Next Oil Change
• Next Oil Separator
• Next Air Filter
• Next Control Box Filter
• Next Motor Lube
| SEQUENCE ADJUST |
| The following adjustments affect sequencing. |
• No. of Sequenced Units
• Unit No.
• Sequence Group
• Transfer Interval
• Lag Start Delay Timer
• Set Baud Rate
• IP Address
• Subnet Mask
• Gateway Address
• Transfer Load Decrement
• Transfer Load Increment
• Stable Pressure Time
| UNIT SETUP ADJUST |
| (Password required) Allows the following setup values to be modified from factory default settings. |
• Unit Password
• Oil Filter Change Interval
• Oil Change Interval
• Separator Change Interval
• Air Filter Change Interval
• Control Box Filter Change Interval
• Motor Lube Interval
• High Plant Pressure Limit
• Over Temperature Limit
• Temperature Alarm Limit
• Plant Temperature Limit
• Plant Temperature Alarm
• Dryer Temperature Limit
• Dryer Temperature Alarm
• Select Fan Type
• Motor Jog
• Drain Interval (rev)
• Drain Interval (hrs.)
• Limit Capacity
• Motor Heater
• Minimum Target Pressure
• Oil Type
| CONFIGURATION ADJUST |
| (Password required) Allows the following configuration values to be modified from factory default settings. |
• Compressor Model
• Remove Reservoir Pressure
• Remove Separator Pressure
• Remove Plant Pressure
• Distributor Info 1 (Contact Name)
• Distributor Info 2 (Contact Number)
• Energy Cost
• System Voltage
• Elevation
| ADVISORY MESSAGES |
| Description |
| • Change Separator |
| Differential pressure > 8 PSIG. |
| • Change Air Filter |
| Vacuum switch on package inlet has tripped. |
| • Change Air Filter |
| Maintenance timer for air filter change has expired. |
| • Change Oil Filter |
| Maintenance timer for oil filter change has expired. |
| • Change Oil |
| Maintenance timer for oil change has expired. |
| • Low Amb Temp A |
| Package discharge temperature < 40°F (4°C). |
| • Low Amb Temp B |
| Separator temperature < 40°F (4°C). |
| • High Inlet Temp |
| Temperature at package inlet > 113°F (45°C). |
| • Change Separator |
| Maintenance timer for separator element change has expired. |
| • High Disch Temp |
| Temperature at airend discharge > 230°F (110°C). |
| • Optional Alarm |
| Digital input programmed for Optional Alarm has tripped. |
| • Low Voltage |
| Digital input programmed for Low Voltage has tripped. |
| • Motor Overtemp |
| Digital input programmed for Motor Over Temperature has tripped. |
| • Water Pressure |
| Digital input programmed for Water Pressure has tripped. |
| • High Vibration |
| Digital input programmed for High Vibration has tripped. |
| • High Dryer Temp |
| Temperature at dryer > 200°F (93°C). |
| • Change Motor Lube |
| Motor lubrication interval timer has expired. |
| • Plant Pressure |
| Compressor is unable to maintain target pressure setting. |
| • V1 Max Sink Temp |
| Main drive heatsink temperature > 170°F (76.7°C). |
| • Chng Ctrl Box Filter |
| Control box filter change interval timer has expired. |
| ALARM MESSAGES (Shutdowns) |
| Description |
| • Fan Fault |
| Cooler or vent fan over temp fault. |
| • Drive 1 Fault |
| Main motor VFD has shut down. |
| • Emergency Stop |
| Compressor stopped using Emergency Stop button. |
| • Open Xducer XD5 |
| Connection to pressure transducer XD5 is open. |
| • High Plant Pres |
| Pressure at package discharge > 190 psig (13 bar). |
| • Shorted Xducer XD5 |
| Connection to pressure transducer XD5 is shorted. |
| • Open Xducer XD3 |
| Connection to pressure transducer XD3 is open. |
| • High Resvr Pres |
| Pressure at airend discharge > 190 psig (13 bar). |
| • Shorted Xducer XD3 |
| Connection to pressure transducer XD3 is shorted. |
| • Open Therm T3 |
| Connection to thermistor T3 is open. |
| • High Disch Temp |
| Temperature at airend discharge > 240°F (115°C). |
| • Shorted Therm T3 |
| Connection to thermistor T3 is shorted. |
| • Open Therm T1 |
| Connection to thermistor T1 is open |
| • High Inlet Temp |
| Temperature at package inlet > 113°F (45°C) |
| • Shorted Therm T1 |
| Connection to thermistor T1 is shorted. |
| • Fan Starter |
| Fan Aux input does not match Cooler Start digital output. |
| • Drive 1 Starter |
| Main motor VFD start failure. |
| • Power Failure |
| Loss of power to compressor package. |
| • XB1 Comm Error |
| Controller internal communications failure. |
| • Drive 1 Comm Error |
| Communications failure between controller and main motor VFD. |
| • Optional Shutdown |
| Digital input programmed for Optional Shutdown has tripped. |
| • Low Voltage |
| Digital input programmed for Low Voltage has tripped. |
| • Phase Sequence |
| Digital input programmed for Phase Sequence has tripped. |
| • Motor Overtemp |
| Digital input programmed for Motor Over Temperature has tripped. |
| • Water Pressure |
| Digital input programmed for Water Pressure has tripped. |
| • High Vibration |
| Digital input programmed for High Vibration has tripped. |
| • Zero Xducer XD5 |
| Pressure transducer XD5 not calibrated. |
| • Zero Xducer XD3 |
| Pressure transducer XD3 not calibrated. |
| • Controller Error |
| Controller internal failure. |
| • EEPROM Restored |
| Main parameter set in nonvolatile memory restored with backup set. |
| • Invalid Model |
| Valid compressor model not selected during factory setup or controller replacement. |
| • DC Power Low |
| 24 VDC input to controller < 20 VDC. |
| • High Dryer Temp |
| Temperature at dryer > 220°F (104°C). |
| • Open Therm T6 |
| Connection to thermistor T6 is open. |
| • Shorted Therm T6 |
| Connection to thermistor T6 is shorted. |
| • CM Table Invalid |
| Model Table in memory has been corrupted. |
| • Actuator Comm Error |
| Communications failure between controller and mixing valve. |
This comprehensive list of controls and information ensures that the compressor is operated safely and efficiently.
15. WARRANTY & STARTUP
A. Standard Warranty The compressor package shall be warranted to be free of defects in material and workmanship for a minimum period of 18 months from the date of shipment or 12 months from the date of start-up; whichever occurs first. The compressor air end assembly shall be warranted to be free of defects in material and workmanship for a minimum period of 27 months from the date of shipment or 24 months from the date of start-up; whichever occurs first.
B. Extended Warranty In addition to the standard warranty, the air end assembly shall be warranted for 123 months from the date of shipment or 120 months from the date of start-up. All major package components (i.e. package controller, both drive motor and cooling fan motor, and air/oil reservoir.) shall be warranted to be free of defects in material and workmanship for a minimum period of 63 months from the date of shipment or 60 months from the date of start-up; whichever occurs first.
C. Start-Up Service Start-up service shall be coordinated by factory trained technicians to ensure equipment is running properly and adjusted to factory specifications. Maintenance instructions will be discussed with the end user to ensure they understand routine maintenance procedures. The maintenance training shall be conducted at the time of equipment start-up.
16. ACCEPTANCE TEST STANDARD
Before shipment, each compressor shall be tested under CAGI/PNEUROP standard PN2CPTC2 (US) or ISO1217 Appendix C (Europe).
DRYER:
1. GENERAL
Vendor shall supply one packaged, fully assembled, piped, and wired pressure-swing (heatless) type regenerative desiccant dryer. Dryer shall be complete with: two pressure vessels (towers) each containing a desiccant bed fully charged with activated alumina; controller and control valves to direct inlet and purge air flows from tower to tower; and a means of regulating purge air usage. All components shall be mounted within a boxed structural steel frame to shield valves, piping, pre-filtration, and afterfiltration from accidental impact. Dryer shall be ready for startup after utility connections are made. Package shall be produced by an ISO 9001 registered manufacturer and, carry agency approvals for CSA, and CE.
Dryer design shall incorporate upward gas flow transmission during the compressed air stream dehydration cycle for maximum efficiency and desiccant bed protection and, operate automatically and continuously in producing the required ISO 8573.1 Quality Class levels for Solids, Moisture, and Oil as specified for the site conditions documented herein under the “System Specifications” sub-header. Purge air shall flow downward.
Industry Standard product design typically dictates an ISO Air Quality Class “2” Pressure Dew Point of -40F (-40C) at 100 PSIG (7 bar) with site conditions of 100F (37.8C) ambient and, 100F (37.8C) inlet air temperature at pressure. Integral package filtration shall be included to afford the desiccant bed protection from particulate and oleophilic contamination and shall be provided prior to the compressed air ingress portal. At a minimum, ISO Class 2 Filtration shall take the forms of a Particulate (1 micron) Pre-filter and a Coalescing (.008 ppm) Filter. Plant piping shall be protected from desiccant particulate migration by a (1 micron) Desiccant After-filter to be located within the discharge conduit after the dry compressed air egress portal. An RS232 communications port shall be included to allow for remote monitoring capabilities in real-time directly from the manufacturer.
2. DESICCANT TOWER DESIGN
Dryer shall include two (2) drying towers (pressure vessels) containing the desiccant beds. Towers shall be designed so that compressed air velocity does not exceed 60 feet (18.3 meters) per minute @ 100 psig., (6.9 bar) through the desiccant bed to ensure bed stability and prevent premature desiccant deterioration. This velocity shall provide each tower with a minimum contact (residence) drying time of 4.8 seconds per measured unit of gas flow to ensure the specified dew point can be delivered and maintained with saturated inlet conditions.
Desiccant bed shall achieve maximum adsorption and release rates by incorporating 3mm ball size activated alumina. Shall also include tower desiccant surpluses of 30% to neutralize and account for the normal losses to bed efficiency attributed to desiccant aging prior to reaching operational stability. Achieving this shall require that each tower contain a minimum of 0.6 pound (0.27 kg) of activated alumina desiccant for each SCFM of rated flow while operating at industry standard conditions. Specified design conditions shall ensure desiccant bed regeneration efficiencies of no less than 98% by reclaiming the heat of adsorption. Resultant specified dew point stabilities will then be achieved under full rated flow conditions. The average purge rate shall not exceed 13.7% at rated flow conditions.
Purge air shall be regulated by an adjustable valve and pressure-reducing orifice. Purge rate shall be indicated by a purge flow indicator. Purge air shall be exhausted through oversized mufflers to minimize backpressure and reduce the noise level as it expands back to atmosphere. Each tower shall have its own muffler. An extra set of muffler inserts shall be included for replacement when excessive backpressure through the muffler (such as might occur on initial start-up after dryer transport) is experienced. Mufflers shall be equipped with a pressure relief device to prevent excessive backpressure.
After the purge process is completed and prior to tower switchover, the tower being purged shall slowly be repressurized to line pressure to prevent bed movement and desiccant abrasion. Minimum acceptable repressurization cycle times per ISO 8573.1 for moisture content shall be as follows for 150 PSIG models: ISO Class 1 (48 seconds); Class 2 (60 seconds); Class 3 (65 seconds) and, Class 4 (70 seconds.) 250 PSIG models shall be as follows: ISO Class 1 (72 seconds); Class 2 (120 seconds); Class 3 (140 seconds) and, Class 4 (160 seconds.)
3. DESICCANT TOWER CONSTRUCTION
Each tower shall be furnished with separate drain and fill ports so that the desiccant can be replaced without disconnecting the piping. Cleanable stainless steel air diffusers shall be removable through 2100 SCFM (3,566 Nm3/hr.,) and internally affixed on larger flow rates. This shall apply to both the upper and lower ports on each tower. Diffusers shall prevent desiccant channeling, reduce dusting and bed attrition caused by bed fluidization, and ensure maximum drying capacity can be extracted from the desiccant. A pressure relief valve and pressure gauge shall be provided for each tower. Pressure relief valves shall be mounted after the flow diffusers to prevent desiccant migration or operational interference with safety function. Pressures vessel diameters in excess of six-inches shall require ASME certification to assure code compliance. Said vessels shall be built and stamped in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.
4. PIPING
Tower discharge piping shall be threaded, grooved or flanged and properly sealed to prevent leakage.
5. CONTROLLER
A 100% repeatable solid state controller shall be furnished to sequence operation of inlet and purge/repressurization valves so that one tower is drying the inlet compressed air stream while the other tower is depressurized, regenerated, and repressurized. Controller shall be panel mounted in a NEMA 4, 4X rated control box affixed to the front of the package. Said controller shall come complete with user replaceable internal fuse protection. Controller design shall accept a customer supplied open/closed electrical contact signal to initiate a Controlled Dryer Shut-Down sequence to maximize efficiencies by synchronizing dryer to an air compressor’s “unloaded” or, “off” operational status. Controller cycle time shall be field adjustable via an externally mounted panel dial to afford the flexibility of selection from four outlet pressure dew point (pdp) quality class levels per ISO 8573.1 as follows:
Economies of operation shall be further achieved with an external panel mount dial to manually vary the regeneration time cycle and ensure accurate settings. Said dial shall allow the user to save up to seventy percent (70%) of purge air energy by reducing purge air consumption in relation to actual load levels. Savings shall be expressed as an inverse percentage of maximum design flow capacity. Controller shall provide a method to allow manual sequencing through the modes of operation to verify proper operation of control valves.
6. INSTRUMENTATION
Standard Controller shall include the following:
· NEMA 4X (IP66) control panel construction
· Soft on/off switch with two power recovery modes
· Tower status LED’s (green=drying, yellow-regenerating)
· Process valve status LED’s (on=valve open, off=valve closed)
· Operating mode LED’s (ISO Class fixed cycle)
· Load Factored Purge Savings LED’s (user selectable from 0 to 70%)
· Alarm LED (red)
· Voltage-free alarm contacts, 5A rating
· Alarm reset button/Manual cycle advance
· Service Reminder LED’s (Filters & Drains (3), Inlet, Purge & Tower Switching (6), and Desiccant Towers (4)
· RS232 Communications Capabilities
· Moisture Indicator (indicates elevated outlet dew point)
· Tower pressure gauges (indicate pressure in tower)
· Purge rate indicator (indicates pressure of purge air upstream of pressure reducing orifice)
· Switching failure alarm (monitors system and indicates if tower fails to pressurize or depressurize after switchover)
Note: Maximum energy savings may be achieved through an Energy Saving Controller that automatically varies the regeneration time cycle to align purge air consumption to the actual system load requirements.
7. ENERGY SAVING CONTROLLER
Swift Return-on-Investment shall be achieved through the addition of an automatic Energy Saving Purge Control System. Said system shall utilize feedback from temperature thermistors to calculate the actual load on the desiccant bed to determine the precise purge time required for efficient tower regeneration. Once regenerated, said off-line tower shall become a repressurized sentinel in preparation for its future drying cycle. Purge air losses shall then be eliminated until the on-line drying tower has achieved optimal desiccant bed saturation levels. Only then, shall the tower switchover sequence be initiated and the process begins anew. Systems that use flow meters or hygrometers instead are not deemed acceptable.
Optional Energy Savings Controller shall carry the following added benefits:
· Automatic, load-matched, purge air Energy Savings
· Vacuum Fluorescent Text Display (complete text communications)
· Demand Sensitive Thermistors (two per tower to establish purge requirements)
· High Humidity or Dew Point Alarm
· Filter Monitor Alarm (1 or 2 filters with optional Filter Monitor)
· Electric Drain Alarms (1 or 2 filters with optional Demand Drains)
· Electric Drain Test (1 or 2 filters with optional Demand Drains)
8. VALVES
System shall be rated for 150 psig (10.5 kgf/cm2) maximum working pressure (250 psig/17.6 kgf/cm2 optional) and supplied with air operated, butterfly type valves. Said butterfly type valves shall use dual piston, rack and pinion type actuators that are isolated from the compressed air stream, for the purge function and, dual check valves and purge check valves for the tower inlet air function. Butterfly type air control valves shall possess a manual override mechanism and a visible indicator to show valve position. Non-lubricated solenoid operated valves with hermetically sealed coils shall be used to engage the compressed air power necessary for pneumatic control valve actuation. Said valve engagement air shall be dried and filtered to one micron prior to being deployed to both open and close these control valves.
Valves shall not require field lubrication and, shall be constructed with resilient elastomeric seats to minimize wear and assure seal-tight closures. Purge/repressurization valves shall include a spring assist to hold valves closed prior to start-up and upon loss of air pressure. Valves shall be able to be rebuilt in the field.
9. STANDARD CONFORMITY
Dryers shall be certified by the Certification and Testing Division of the Canadian Standards Association to comply with the standards as documented by UL No. 1995 and CAN/CSA-22.2 No. 236-M90.
10. SYSTEM SPECIFICATIONS
Rated Capacity in SCFM 750 System Design Working Pressure in PSIG 125 Maximum Working Pressure in PSIG 150 Maximum Inlet Air Temperature in °F 100 (saturated) Maximum Ambient Air Temperature in °F 90 Electrical Requirements: 120 Voltage, 1 Phase, 60 Hertz NEMA (IP) Rating: 4X Dew Point Quality Class: 2 (1= -100°F/-73°C; 2= -40°F/-40°C; 3= -4°F/-20°C; 4= +38°F/+3°C) Integral Pre-Filtration Quality Class: 4 (Class 1 requires 1 micron; Class 2, 3 and 4 require .008 ppm) Integral After-Filtration Quality Class: 4 (Class 1 requires 1 micron; Class 2, 3 and 4 require .008 ppm) Specified Heatless Desiccant Air Dryer shall be Gardner Denver Model #DGH 750 or approved equal.
ADDITIONAL REQUIRMENTS:
DETAILED DESCRIPTION REQUIRED PRIOR TO AWARD: The MCAAP Engineering Support Division will validate and verify/approve the contractor’s listed equipment concept before award is granted. In order to meet this review requirement, the offeror shall submit with their proposal a detailed technical description of each item. The offeror’s description submittal shall account for each one of the required product features located in this qualifying statement. The description shall also clearly portray/describe how each item will function.
CONCEPTUAL DRAWING REQUIRED PRIOR TO AWARD: Conceptual drawings that are not detail “as built” drawings are required for submittal with the detailed description. Drawing must provide overall height, width, and length dimensions. Drawing must show dimensioned locations of inlets and outlets for piping. Drawing must clearly label and display all major components and anchor holes/locations.
OPERATION & MAINTENANCE MANUALS DUE DELIVERY: The Contractor shall submit two (2) O&M manuals at the same time that the components are delivered. The Government shall review and approve these O&M manuals.
SPARE PARTS LIST: The contractor shall submit a spare parts list at the same time that the components are delivered. It is requested, not required, that the list cover high wear, low life expectancy items, and provide information to help the customer forecast lead times and costs for procuring replacement parts for the listed components.
3D MODELS: If the contractor has a 3D CAD model or models as part of its design and production processes, the Government requests to take possession of the models when the components are delivered. Note: Offeror submittal of 3D models is not a contractual requirement.
image1.wmf
Microsoft_Excel_97-2003_Worksheet1.xls Sheet1
Quality Class Pressure Dew Point Cycle Time
ISO 8573.1 Degrees F/C Minutes
1 -100 / -73 4
2 -40 / -40 10
3 -4 / -20 16
4 +38 / +3 24
Sheet2
Sheet3
File details come from the government source that posted it.