1790_Test_Cells_Opacity_Reduction_Systems_-_SOW_-_11_Jul_2019.pdf

REVISED 11 July 2019

WORK SPECIFICATION

1. Scope. This specification establishes the requirement for six (6) turnkey diesel oxidation catalyst / diesel particulate filter (DOC/DPF) systems hereafter referred to as the “system” and “equipment”, to be installed at Anniston Army Depot, Anniston, Alabama (ANAD). The Contractor shall provide all resources necessary to design, manufacture, deliver, install, demonstrate functional operation, and provide operator and maintenance training for the system. The system shall meet or exceed all functionality, capabilities and features as described herein.

ANAD remanufactures and tests diesel reciprocating engines used in military vehicles.

Stationary engine testing takes place at multiple locations throughout the installation. The DOC/DPF systems will be installed on four (4) test cells in Building 410 and two (2) test cells in Building 474.

ANAD operates these six test cells under a Major Source Operating Permit issued by the Alabama Department of Environmental Management (ADEM). This permit requires ANAD to maintain the emissions opacity from each of the test cell exhaust stacks to below 20% opacity.

ANAD measures opacity per Environmental Protection Agency (EPA) Method 9 – Visual Determination of The Opacity of Emissions from Stationary Sources which requires that visual determination of opacity is recorded to the nearest 5%, meaning that any determination greater than 15% violates the requirements of the permit.

The purpose of the DOC/DPF systems are to ensure compliance with the opacity requirements of this permit through the reduction of total particulate matter (PM) in the engine exhaust stream.

The system will provide the maximum reduction possible using current DOC/DPF technology.

2. Applicable Documents. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. Publications may include a revision date. In the absences of a revision data, the latest revision in effect on the date of contract award shall be used

2.1 Government References Documents. The following references are available from ANAD and will be made available upon request made to the Contract Officer Representative

(COR).

Army Corp of Engineers (ACOE)

ACOE Drawing 35-14-01 Dynamometer Test Facility Addition (Bldg. 410)

ACOE Drawing 35-08-02 Dynamometer Test Cells and Water Treatment

Facilities

ACOE Drawing 35-14-01 Dynamometer Test Facility Addition (Bldg. 410)

Contract W91278-04-R-0071 Powertrain Flexible Maintenance Facility, Anniston Army Depot, Anniston, AL, FEV 100% Submittal Drawings for Engine Test Cells

Anniston Army Depot (ANAD) Directorate of Production Engineering (DPE)

PE-19-055 Bldg. 410 Cell 9 Source Test Report

PE-19-056 Exhaust Temperature and Fuel Consumption

Profiles (AVDS-1790-8CR)

PE-19-057 Exhaust Temperature and Fuel Consumption

Profiles (AVDS-1790-2DR)

National Maintenance Work Requirement (NMWR)

NMWR 9-2815-220 Engine Model AVDS-1790-2DR

NMWR 9-2815-247-2 Engine Model AVDS-1790-8CR

2.2 Other Reference Documents. The following references are available from the governing organization. If the Contractor is unable to locate these documents, a request for assistance may be made to the COR.

American Conference of Governmental Industrial Hygienist (ACGIH)

ACGIH Pub. TLVs and BEIs Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices

Alabama Department of Environmental Management (ADEM)

ADEM Division 335-3 ADEM Air Division – Air Pollution Control Program

ADEM Permit No. 301-0023 ADEM Major Source Operating Permit for ANAD

Electrical Generating Systems Association (EGSA)

EGSA 201S Guide for Rating Generator Exhaust Silencers

American National Standards Institute (ANSI)

ANSI AS35411 Fittings and Lubrication

ANSI B93.114M Pneumatic Fluid Power Systems - Standard for

Industrial Equipment and Machine Tool Applications

ANSI 14.2-2017 Ladders, Fixed – Safety Requirements

ANSI B16.5 Standards for Pipes and Fittings

Code of Federal Regulations (CFR)

40 CFR Part 63, Subpart PPPPP National Emissions Standards for Hazardous Air Pollutants for Engine Test Cells/Stands

40 CFR Appendix A-4 to Part 60 Test Methods 6 through 10B

Electrical Generating Systems Association (EGSA)

EGSA 201S Guide for Rating Generator Exhaust Silencers

Institute of Electrical and Electronics Engineers (IEEE)

IEEE C2-2017 2017 National Electrical Safety Code

IEEE STD 142-2007 Recommended Practice for Grounding of Industrial and Commercial Power Systems

International Organization for Standardization (ISO)

ISO 4413:2010 Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components

ISO 4414:2010 Pneumatic Fluid Power - General Rules and Safety

Requirements for Systems and Their Components

National Electrical Manufacturers Association (NEMA)

NEMA 250-2014 Enclosures for Electrical Equipment (1,000 V Maximum)

NEMA MG 1-2016 Motors and Generators

NEMA ICS 1-2000 Industrial Control Systems: General Requirements

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code - 2017 Edition

NFPA 79 Electrical Standard for Industrial Machinery - 2018

Edition

Occupational Safety and Health Administration

29 CFR 1910 Occupational Safety and Health Standards

2.2 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained by the Government.

3.0 Responsibilities.

3.1 Contractor. In addition to the requirements described herein, the Contractor shall be responsible for the following items.

3.1.1 Site Visit. Within 10 days after the date of contract award, the Contractor shall make at least one site visit to examine and gather information on the engine testing process and installation site characteristics necessary to fulfill the requirements of this specification. The Contractor shall coordinate this and any other site visits with the COR.

3.1.2 Project Plan. The Contractor shall provide to the COR a detailed Gantt type project plan including milestones for design initiation and completion, start of production, shipping dates, delivery, installation, commissioning and all the deliverables herein within 20 days after contract award.

3.1.3 Conceptual Design. The Contractor provide to the COR a conceptual design for all six (6) DOC/DPF systems within 20 calendar days after contract award. The design shall include size and installation location of the DOC/DPF system including ducting, interconnecting cable/conduit and hose/pipe routes, support structure(s), roof penetrations/coring, and any other information required for ANAD to evaluate the feasibility of the design. The Contractor shall be responsible for final design that incorporates all requirements identified in this specification.

3.1.4 Instructions for Installation. The Contractor shall provide to the COR all information necessary for installation of the DOC/DPF systems within 45 calendar days after contract award. The Contractor shall provide one electronic copy of the instructions for installation as specified on attached DD Form 1423. Additional copies shall be included with documentation provided by the Contractor per paragraph 7.0. The Government will use these instructions to review utility and space requirements of the proposed DOC/DPF systems. The installation documentation shall include, but not be limited to, the following:

a. Building plan drawings of the DOC/DPF system and major components.

b. Space required around the DOC/DPF system after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Dimensions sufficient to determine clearance around the DOC/DPF system and its components.

e. Approximate location of utility connections on the DOC/DPF system.

f. All utility requirements including but not limited to electrical, air, water, steam, and drains. Include required utility capacities such as amps and GPM.

g. Industrial waste disposal requirements, if any.

h. Approximate weight of the DOC/DPF system and major components.

3.1.5 Delivery, installation and commissioning and start-up of the first DOC/DPF system shall be completed and the first DOC/DPF system operational and accepted within 90 calendar days after award of contract. Delivery, installation and commissioning and start-up of all DOC/DPF systems shall be completed and all DOC/DPF systems operational and accepted within 120 calendar days after award of contract. Earlier acceptance of the first DOC/DPF system is highly desirable to the Government.

3.2 Government. The Government will have no responsibilities other than those described herein.

4.0 Requirements. ANAD requires a Contractor to design, manufacture, deliver, install, demonstrate functional operation, and provide operator and maintenance training for six (6) turnkey DOC/DPF Systems. The systems will be installed at ANAD to be in-line with exhaust streams from engine test cells 1 and 2 in Bldg. 474 and cells 7, 8, 9 and 18 in building 410. The systems shall reduce stack emissions opacity to 5% or less when evaluated using visual opacity reading as defined by EPA Test Method 9 as defined in 40 CFR Part 60, Appendix A-4.

Systems that reduce stack emissions opacity to the lowest levels are desirable to the Government.

The Contractor’s DOC/DPF system shall provide for continuous engine operation other than during maintenance of the system. Regeneration shall not be considered maintenance of the system, and the system shall regenerate during the normal engine operating cycles. The system shall be compatible with combustion fuels including F-24, JP-8 and DF-2. ANAD is currently using F-24 exclusively. A design allowing up to 50 ppm total sulfur is acceptable, but designs allowing higher sulfur content are desirable to the Government.

The Contractor shall have proven expertise in the design and installation of emissions control systems for 1000 brake horsepower (bhp) or larger stationary diesel engines. It is desirable to the Government that the Contractor’s past performance include successful installations at diesel engine original equipment manufacturers (OEM) facilities and/or other Government installations.

4.1 Installation Site of DOC/DPF Systems. Each of the six (6) engine test cells currently have exhaust ducting leading to the roof of the test cell. There is adequate space on the roof of the test cell, on adjacent roofs and on the ground next to the buildings housing the test cells, where the system may be installed.

The Contractor may request installation site / building drawings including dimensions, structural specifications, and location of existing equipment, electrical systems, plumbing systems, pneumatic systems, safety systems, ventilation systems, underground and overhead utilities, storm drains to aid the Contractor in their system design and installation. Requests shall be for specific information only. Requests shall be directed to the COR, and the Government will provide any such documents and information if available.

4.2 Emissions Source(s). Within the four (4) test cells in Building 410 and two (2) test cells in Building 474, ANAD installs one of two diesel engine models for testing, the 1050 bhp AVDS1790-8 or the 750 bhp AVDS1790-2. The engines are tested under various throttle and load profiles. The throttle and load profile used depends on engine model and test type conducted. The two most common test types are an approximately 15 hour test of the model AVDS1790-8 and an approximately five (5) hour test of the model AVDS1790-2.

ANAD has available and the Contractor may request through the COR, exhaust stream temperature profiles captured in the exhaust duct at the roof of the test cell and the corresponding fuel consumption profiles for these two common tests. ANAD also has available a source test report for the model AVDS1790-8 engine. This engine is considered the worst case, as the model AVDS1790-2 has a significantly lower specific fuel consumption, filter smoke numbers (FSN) and visual opacity than the model AVDS1790-8. Among the information available in the source test report for the AVDS1790-8 are the average engine horsepower, rate of fuel consumption, exhaust volumetric flow rate, rates of production of carbon monoxide (CO), oxides of nitrogen (NOx), total hydrocarbon (THC), filterable particulate matter (PM), condensable PM, total PM, and oxygen (O2), carbon dioxide (CO2) and water (H2O) concentrations. If additional exhaust stream data is required (i.e. chemical analysis of particulate matter), the data must be collected onsite at ANAD and the Contractor shall be responsible for all aspects of collecting this data other than those aspects specifically stated herein as provide by the Government. In this regard, the Government will accommodate any additional data collection and/or any analysis required by Contractor to design the DOC/DPF systems by providing an engine, F24 fuel, an engine test cell, and a test cell operator. In collecting this data, at no time will the Contractor interfere with production activity at ANAD.

4.3 Diesel Oxidation Catalyst / Diesel Particulate Filter. Each of the six (6) turnkey DOC/DPF systems shall consist of a single DOC/DPF device. The device shall be part of the device original equipment manufacturers (OEM) standard product line and designed for removal of PM from stationary diesel engine exhaust. The device shall consist of a housing with one or more DOCs installed upstream of one or more DPF modules each comprised of one or more DPF blocks. The device shall have a maximum pressure loss of 12.0 inches of water (inH2O) when clean. The DPF module(s) shall regenerate while either engine model is running through the common test profiles described in paragraph 4.2 and shall not require the engine to be shut down for regeneration to occur. Passive devices shall regenerate at a temperature of 500 Fahrenheit (F) or lower. The device shall operate at exhaust temperatures up to and including 1250 F. The device shall provide Class 5 of better sound attenuation per EGSA 201S. The device shall have overall dimensions equal to or less than 36” Height x 48” Width x 96” Length, and the weight of the device with catalyst and DPF module(s) installed shall be equal to or less than 1,500 pounds.

4.3.1 Diesel Oxidation Catalyst / Diesel Particulate Filter Housing. The DOC/DPF housing shall provide for support and enclosure of the catalyst and filter elements and direct exhaust flow through these elements. The housing shall be constructed of 304 or 316 stainless steel to the maximum extent possible and be suitable for installation outside and on rooftops at ANAD. The housing shall be constructed of 3/16” or heavier plate except the neck area which shall be 12 gage sheet metal or heavier, the inlet and the outlet flanges which shall be 1/2” or heavier plate, and the access doors which shall be 10 gage sheet metal or heavier. Components sensitive to weather shall be protected. The housing shall be unpainted. The housing shall contain an inlet and outlet flange located in a position that simplifies application specific exhaust duct connections while maximizing device performance and minimizing back pressure at the engine (i.e. ends, top or bottom of housing). Both inlet and outlet flanges shall be minimum Class 150 per ANSI B16.5 with a 14 inch nominal diameter. The housing shall provide access/service doors to allow for maintenance of the device including removal of DPF blocks for cleaning and inspection. Exhaust gasses shall not leak from any part of the housing during normal operation.

4.3.2.1 DOC/DPF Device Structural Support. The DOC/DPF housing shall include structural support as required to support the weight of the housing with catalyst and DPF module installed. The support shall allow for thermal expansion of the system. Metal structural components including fasteners shall be made from all galvanized steel or all stainless steel.

Guy wire assemblies shall be installed as required, and shall be made of stainless steel.

4.3.3 Insulation of DOC/DPF Device. The DOC/DPF device shall be fully insulated.

Insulation shall be of a type and thickness suitable to the application and to minimize the time required to reach minimum regeneration temperature and/or protect personnel from coming into contact with hot surfaces and to prevent damage to adjacent surfaces including but not limited to roofing. The insulation shall be clad with minimum 20 gage aluminized steel or stainless steel sheet metal jacketing.

4.3.4 Catalysts. The catalyst contained in the device shall consist of a metallic substrate.

The substrate shall be coated with precious metals that promote specific oxidation reactions to convert CO to CO2, unburned hydrocarbons to CO2 and H2O and nitric oxide (NO) to nitrogen dioxide (NO2).

4.3.5 Diesel Particulate Filter Module(s). The filter module(s) contained in the device shall consist of filter blocks made of porous Mullite substrate or equivalent. The module shall capture PM with a filtration efficiency of 90% or greater and continuously regenerate by catalytically oxidizing the captured PM. Filter modules that capture the greatest percentage of PM are desirable to the Government.

4.3.6 Diesel Oxidation Catalyst / Diesel Particulate Filter Performance Requirements.

The DOC/DPF system shall utilize Best Available Control Technology to reduce the incoming exhaust stream to an outgoing exhaust stream with an opacity of 5% or less. In addition the system shall reduce the total PM contained in the exhaust stream by 90% or greater and from a level of 2.2 g/bhp-hr to 0.2 g/bhp-hr or less. DOC/DPF devices that capture the greatest percentage of PM and/or reduce levels the most are desirable to the Government.

4.4 Diesel Particulate Filter Monitoring and Data Logging. The Contractor shall supply a DOC/DPF device monitoring and data logging system including all materials and labor required for installation of the system. The system shall monitor and record exhaust temperature and back pressure measured immediately upstream of the DOC/DPF device.

4.4.1 Monitoring. The system shall monitor and display the status of exhaust temperature and back pressure measured immediately upstream of the DOC/DPF device in real-time. The display shall be located at the test cell operator station. The device shall provide alarms when the DOC/DPF device requires regeneration (high back pressure), when there is possible damage to the DOC/DPF device or monitoring system pressure lines (low back pressure), when the DOC/DPF device is at regeneration temperature or above, and when the DOC/DPF device is at or above its maximum operating temperature. Alarms shall be both visible and audible to the operator. The system shall have a measureable temperature range including 125F to 1900F and a measureable pressure range including 0 to 240 inH2O. The pressure levels at which the high and low alarms activate shall be adjustable.

4.4.2 Data Logging. The system shall monitor and log exhaust temperature and back pressure and store this data along with date and time in memory. Data should be measured at 1 second intervals and the mean of every 10 measurements stored in non-volatile memory. The monitor shall have sufficient memory to store 300 hours of data in this way. Memory shall operate in a circular way such that the new data overwrites the oldest data when the memory becomes full. The system shall also log all alarm events including alarm type and the corresponding time and date the alarm activated. These alarms events shall be stored in non-volatile memory with a capacity of 1,000 records.

4.5 Exhaust Ducting. The Contractor shall provide and install all exhaust ducting required to route exhaust from the existing outlet(s) on the roof of each test cell to the DOC/DPF system and from the DOC/DPF system to the exhaust stack. The exhaust ducting shall be routed up, over and out of reach of existing platforms and walkways. When more economical for the Government, the Contractor shall use existing ducting provided such ducting is in good condition and meets the ducting requirements in this specification. The exhaust ducting system shall be designed and constructed to minimize back pressure at the engine. All new exhaust ducting shall be made from 16 gage or heavier 304 or 316 stainless steel and have a 14 inch nominal diameter.

Connection flanges shall be 304 or 316 stainless steel and Class 150 per ANSI B16.5 with a 14 inch nominal diameter. As an exception to this, any new flange where the new exhaust ducting joins to the existing exhaust ducting should be compatible with that existing flange. All fasteners shall be ASME specified and made from 18-8 stainless steel or other stainless steel with equivalent or greater corrosion resistance and tensile strength. Flanged connections shall be sealed together with a flange gasket of a type that is suitable for the application. Flange connections shall be secured using all bolt holes available in the flange. Exhaust gasses shall not leak from any part of the exhaust ducting system. The exhaust ducting system shall include expansion joints as required to allow for thermal expansion of the system. Expansion joints shall be a dual ply bellows made from 304 or 316 stainless steel. Exhaust duct shall not include elbows or other transitional components directly connected to the DOC/DPF housing. Between transitional duct components connecting directly to the DOC/DPF housing there shall be a straight duct section with a minimum duct length of 3 times the duct diameter.

4.5.1 Exhaust Ducting Structural Support. The exhaust ducting system shall include structural support as required to support the weight of the system and to minimize forces or moments acting on the inlet and outlet flanges of the DOC/DPF housing and the outlet of the existing piping. The support located immediately before the DOC/DPF housing inlet shall be fixed, and any supports located after the DOC/DPF housing outlet shall be floating and allow for thermal expansion of the DOC/DPF system. Metal structural components including fasteners shall be made from all galvanized steel or all stainless steel.

4.5.2 Insulation of DOC/DPF Exhaust Ducting. All exhaust ducting on the inlet and outlet side of the DOC/DPF housing shall be fully insulated. Insulation shall be of a type and thickness suitable to the application and to minimize the time required to reach minimum regeneration temperature and/or protect personnel from coming into contact with hot surfaces and to prevent damage to adjacent surfaces including but not limited to roofing. The insulation shall be clad with minimum 20 gage aluminized steel or stainless steel sheet metal jacketing.

4.6 Exhaust Stack System. The Contractor shall provide a vertical discharge exhaust stack system for each DOC/DPF system. The system shall be designed to minimize back pressure at the engine. The design shall be such that exhaust discharge is distributed symmetrically across the available diameter at the exit of the stack. The height of the exhaust stack shall be equal to or greater than the existing single combined exhaust stack on building 410 for stacks installed on that building and for the existing individual test cell exhaust stacks on building 474 for stacks installed on that building. A rain cap shall not be installed unless recommended by the DOC/DPF system manufacturer. The stack shall be made from 16 gage or heavier 304 or 316 stainless steel. Connection flanges shall be 304 or 316 stainless steel and Class 150 per ANSI B16.5. All fasteners shall be ASME specified and made from 18-8 stainless steel or other stainless steel with equivalent or greater corrosion resistance and tensile strength.

Flanged connections shall be sealed together with a flange gasket of a type that is compatible with the application. Flange connection shall be secured using all bolt holes available in the flange. Exhaust gasses shall not leak from any part of the stack system.

4.6.1 Exhaust Stack Structural Support. The exhaust stack system shall include structural support as required to support the weight of the system and to minimize forces or moments acting on the outlet flanges of the DOC/SPF housing. The support shall allow for thermal expansion of the system. Metal structural components including fasteners shall be made from all galvanized steel or all stainless steel. Guy wires assemblies shall be installed as required, and shall be made of all stainless steel.

4.6.2 Insulation of Exhaust Stack System. The exhaust stack system shall be uninsulated except required to protect personnel from coming into contact with hot surfaces and to prevent damage to adjacent surfaces including but not limited to roofing. In these areas, insulation shall be of a type and thickness suitable to the application and to protect personnel from coming into contact with hot surfaces. The insulation shall be clad with minimum 20 gage aluminized steel or stainless steel sheet metal jacketing.

4.7 Exhaust Duct Sections / Ports for Stack Testing. Joined to the roof outlet and before any transitional duct component, there shall be a constant diameter straight duct section with a minimum duct length of 3 times the duct diameter. Between the outlet of the DOC/DPF filter and the exhaust stack and/or as part of the exhaust stack there shall be a constant diameter straight duct section with a minimum duct length of 3 times the duct diameter. The duct sections shall be vertically oriented. The duct sections shall each have installed two 3” internal diameter ports along the centerline, on the same plane and at right angles to one another. The purpose of the ports is to provide access for stack testing, and the ports shall be in a location that makes them accessible by personnel standing on the existing test cell roof and/or platform or newly installed platform. The ports shall be located such that there is a minimum of eight (8) feet of clearance between the port and any obstruction, so that a long probe may be inserted into the port. The ports shall be flanged, have reusable gaskets, and have removable covers that seal the duct during normal operation and can be removed during stack testing.

4.8 Platforms. The Contractor shall provide and install platforms and stairs or ladders to access platforms, such that that access panels/doors/ports and all other areas of the DOC/DPF system requiring access for regular maintenance are directly accessible from the platform. The platform width shall be four (4) feet or equal to the width of the DOC/DPF housing, whichever is greater. The Contractor shall provide and install platforms and stairs or ladders to maintain accessibility to existing areas and equipment. Platform metal structural components including fasteners shall be made from all galvanized steel. Handrails shall be yellow in color. The surface of the platform, treads of stairs and rungs of ladders shall be fabricated from a material with a permanent non-slip surface such as grating.

4.9 Spare Parts Kit.

A spare parts kit shall be included with delivery of the DOC/DPF system. The kit shall include the recommended quantities of all parts in the spare parts list provided by the Contractor per paragraph 7.1.4. The DOC/DPF System OEM shall have additional recommended spare parts in-stock available for shipping within 48 hours from within the continental United States

(CONUS).

4.9.1 Spare Catalysts.

Two complete catalyst for replacement of the catalysts in any two (2) DOC/DPF Systems shall be included in the spare parts kit.

4.9.2 Spare Diesel Particulate Filter Modules.

Two complete sets of DPF modules for replacement of all modules in any two (2) DOC/DPF Systems shall be included in the spare parts kit.

4.10 Special Tools. Tools other than common hand tools required for the complete and proper operation and maintenance of the DOC/DPF system shall be provided. Common hand tools are those tools that are readily available commercially off-the-shelf.

4.11 General Requirements.

4.11.1 General.

4. 11.1.1 OEM's part numbers referenced herein are intended to be descriptive and not restrictive; and are not intended to preclude the use of any item otherwise conforming to this specification.

4. 11.1.2 The DOC/DPF system and its components shall be standard unmodified products of an OEM regularly engaged in the manufacturing of such products. Components of the same type and purpose shall be identical and supplied by the same manufacturer.

4. 11.1.3 The DOC/DPF system (as defined in this specification) includes the engineering, selection, procurement, design, manufacture, assembly, testing, delivery, installation, training and commission, and includes all related equipment, spare parts, materials, supplies, components, documentation, and all other items required to make a production ready system.

4.11.2 Ventilation Requirements.

4.11.2.1 The Contractor shall not design ventilation or exhaust systems to be installed in a manner or location that interferes with existing equipment, or interferes with personnel access to the new or existing equipment for operation or maintenance. The Contractor shall not design ventilation or exhaust systems to be installed in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not design ventilation or exhaust systems to be installed in a manner or location that interferes or in any way limits the full design motion of any crane.

4.11.3 Electrical Requirements.

4.11.3.1 All electrical work shall comply with IEEE C2, NFPA 70, and, unless outdoors or in an electrically hazardous classified area, shall be installed to meet NEMA 13 rating. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratory (UL) listings. Workmanship shall be in accordance with standard commercial practices. All wire shall be copper; no aluminum wire shall be used. Conduit feeds to the DOC/DPF System shall be IMC or rigid conduit. Conduit runs shall be installed perpendicular and parallel to facilities and the DOC/DPF system to be installed. When the DOC/DPF system is installed near existing power lines, the DOC/DPF system shall be located for proper clearances in accordance with IEEE C2. Oil-resistant, liquid-tight, flexible metal conduit may be used to connect to DOC/DPF system components (valves, motors, switches, sensors) but the length shall not exceed six (6) feet.

4.11.3.2 The Contractor shall not install conduit in a manner or location that interferes with equipment, or interferes with personnel access to the DOC/DPF system or existing equipment for operation or maintenance. The Contractor shall not install conduit in a manner or location that interferes with the direct access to WIP, component containers and racking. The Contractor shall not install conduit in a manner or location that interferes or in any way limits the full design motion of any crane.

4.11.3.2.1 DOC/DPF System Service Voltage - Each DOC/DPF system shall be wired to draw all of its electrical power from a single circuit. If the system’s single circuit amperage does not exceed the requirement of a 20-amp circuit, the system may be designed to operate on 120-volt, 1-phase, 60-Hertz (Hz) input power. If the system’s single circuit amperage exceeds the requirement of a 20-amp circuit, the system shall be designed to operate on 480-volt, 60-Hertz (Hz) input power. The system shall be equipped with a manual, fused, or breaker type disconnect switch, readily accessible to maintenance personnel, that will deactivate the entire system.

4.11.3.2.2 Electrical Noise - The electrical power at ANAD may be subject to electrical noise.

If the DOC/DPF system requires clean electrical power for proper operation, a properly sized power-conditioning unit shall be included with the system. If the system is subject to interference from adjacent machinery, the system shall include the proper shielding to prevent malfunctions.

4.11.3.2.3 Electrical Connections - Connections to screw-type terminals shall be mechanically secured with means to prevent loss of tightness. All other electrical connections shall be mechanically secured and soldered or brazed. Rosin base fluxes shall be used in all soldering operations.

4.11.3.3 The DOC/DPF system process parameters and machine functions shall be automatically, continuously monitored and maintenance warnings automatically issued before any parameter reaches unacceptable levels.

4.11.3.4 The DOC/DPF system shall be equipped with suitable grounding devices for static discharge.

4.11.4 Motors.

4.11.4.1 Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors, unless otherwise specified, shall conform to the requirements of NEMA MG 1. Motors shall be AC, 60-Hz, or DC industrial-type motors with drip proof enclosures. All motors 10 HP or greater shall have a soft start controller. Each motor control shall conform to the requirements of NEMA ICS 1.

4.11.5 Pneumatic Systems.

4.11.5.1 If the DOC/DPF system requires a pneumatic system, the pneumatic system shall conform to the requirements of ANSI B93.114M and Section 43 15 00.00 20 E, Low Pressure Compressed Air Piping (Non-Breathing Air Type) applies to this section. The pneumatic system shall comply with ISO 4414:1998 and NFPA T2.25.1R2 200x.

4.11.5.2 The Contractor shall not install pneumatic systems in a manner or location that interferes with the DOC/DPF system or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install pneumatic systems in a manner or location that interferes with the direct access to WIP, component containers and racking. The Contractor shall not install pneumatic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.11.6 Hydraulic Systems.

4.11.6.1 If the DOC/DPF system requires a hydraulic system, the hydraulic system shall conform to the requirements of NFPA / JIC T2.24.1R1. The hydraulic system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. Overpressure protection shall be provided in the high-pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a cleanout access plate if the reservoir is not removable.

4.11.6.2 The system shall be equipped with a hydraulic fluid requirements plate attached to the DOC/DPF system at the hydraulic reservoir fill point. The plate shall contain the Type of fluid (Society of Automotive Engineers (SAE) or Military or Federal specification number) and Type of filter.

4.11.6.3 The Contractor shall not install hydraulic systems in a manner or location that interferes with the DOC/DPF system or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install hydraulic systems in a manner or location that interferes with the direct access to WIP, component containers and racking. The Contractor shall not install hydraulic systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.11.7 Plumbing, Drainage and Waste. All plumbing work shall comply with National Association of Plumbing-Heating-Cooling Contractors/American Society of Plumbing Engineers (NAPHCC/ASPE) Publication - National Standard Plumbing Code. All materials used in the installation of the equipment shall conform to industry standards and shall be compatible with and shall meet the performance requirements of the equipment being installed. Workmanship shall be in accordance with standard commercial practice. Runs shall be installed perpendicular and parallel with existing facilities and the equipment being installed. Bypasses shall not be installed at steam reducing stations. All heating coils shall be trapped independently. Unless otherwise specified, steam and condensate piping shall be insulated with 1-1/2 inch thick calcium silicate with aluminum cover for outside lines and 1-1/2 inch thick fiberglass with all service jacket for interior lines unless subjected to water or vapor.

4.11.7.1 If the DOC/DPF system requires chilled water, incoming water lines shall have adequate anti-siphon provisions to prevent water supply contamination.

4.11.7.2 If the DOC/DPF system requires water, the Contractor shall install a Fresh Water Back Flow Check Valve.

4.11.7.3 The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the DOC/DPF system or existing equipment, or interferes with personnel access to equipment for operation or maintenance. The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes with the direct access to work-in-process (WIP), component containers and racking. The Contractor shall not install plumbing, drainage or waste systems in a manner or location that interferes or in any way limits the full design motion of any crane.

4.11.7.4 Unless otherwise specified herein, the Contractor shall place drain lines and tie into existing sanitary, storm, or industrial waste lines as required. All work shall be coordinated through the COR.

4.11.8 Concrete. Concrete used in the installation of the DOC/DPF systems shall be Class A and shall have a minimum allowable compressive strength at 28 days of 3,000 pounds per square inch (PSI) unless otherwise specified. Samples for concrete strength tests shall be provided, stored, and tested as directed. Unless otherwise specified, the Contractor shall be responsible for the design of all concrete work, including formwork and reinforcing. Ready-mixed concrete shall be used and must be delivered and discharged within 45 minutes after the introduction of water to the cement and aggregate. Placing of concrete shall conform to Chapter 4 of the American Concrete Institute Standard ACI 318. Workmanship shall be in accordance with standard commercial practice.

4.11.9 Foundation Hardware. All foundation hardware shall be furnished by the Contractor and included in the bid price.

4.11.10 Safety and Health Requirements.

4.11.10.1 The DOC/DPF system shall comply with OSHA permissible exposure limits (PELs) and ACGIH threshold limit values (TLVs) for noise levels, radiation, electromagnetic emission, and noxious vapors as applicable.

4.11.10.2 The DOC/DPF system shall be equipped with safety devices to adequately protect the operator from all hazards incident to its operation.

4.11.10.3 The DOC/DPF system shall be in compliance with Occupational Safety and Health Administration (OSHA) 29 CFR 1910. Safety devices shall be provided for all parts of the DOC/DPF system presenting safety hazards. The system shall include warning lights/indicators to alert the test cell operator to unsafe operating conditions. All parts, components, mechanisms, and assemblies furnished on the system, whether or not specifically required herein, shall conform to all requirements of OSHA 29 CFR 1910. Covers, guards, or other safety devices normally furnished as standard on the manufacturer's commercial systems supplied to the commercial market shall be provided for the point of operation and all other parts of the system that present safety hazards. All special guarding shall meet OSHA 29 CFR 1910. The safety devices shall not interfere with the operation of the system. All guards shall allow access to the guarded part(s).

4.11.10.4 Protection against electric shock shall be incorporated into the DOC/DPF system. All front access panels and doors shall be furnished with electrical interlocks to remove power from the cabinets while panels or doors are open.

4.11.10.5 Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment, visible to maintenance personnel and permanently marked.

4.11.11 Energy Efficiency. The DOC/DPF system and its components that directly consume energy in normal operation shall be designed and constructed for energy efficiency in accordance with the developments available within the industry. Pneumatic circuits shall be designed for minimum air consumption.

4.11.12 System of Units. The DOC/DPF system shall display all units of measure in the U.S.

Customary System of Units "English", not Metric.

4.11.13 Nameplates.

4.11.13.1 The DOC/DPF system shall have the manufacturer's name and address, and the model and serial number in a conspicuous place.

4.11.13.2 A nameplate shall be mechanically attached to the DOC/DPF system– adhesive alone will not be considered sufficient to meet this requirement, and shall contain, at a minimum, the following information if applicable:

a. Nomenclature.

b. Manufacturer's name, Address and Phone Number.

c. Serial number.

d. Model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Facility Circuit Breaker or Buss Duct Switch Location Reference Number

g. Short-circuit/over current rating.

h. Contract number.

i. National stock number (if applicable).

j. Date of manufacture.

4.11.13.3 All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background. All plates shall be corrosion resistant. All plates shall be mechanically attached to the DOC/DPF system – adhesive alone will not be considered sufficient to meet this requirement.

4.11.13.4 Maintainability and Interchangeability. The DOC/DPF system shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. When non-commercial off-the-shelf components are used the Contractor shall provide all documentation including any electronic files and a manufacturing source required for production of those components. All replaceable parts shall be designed and manufactured to such standards as shall permit replacement and adjustment without the need for modification of the parts or the system. All replacement parts shall be available domestically.

4.11.14 Construction.

4.11.14.1 The DOC/DPF system shall be so constructed as to be capable of performing the operations specified herein. All surfaces shall be clean and free of extraneous materials.

External surfaces shall be smooth and free from sharp edges, rounded or beveled, unless sharpness is required for performance. All screws, pins, and similar parts shall be installed to prevent loss of tightness. Parts subject to adjustment or removal shall not be permanently installed or deformed. The system shall be constructed of parts, which are new, without defects, and free of repairs. The structures shall withstand all forces encountered during operation of the system to its maximum rating and capacity without permanent distortion or failure.

4.11.14.2 Materials shall conform to the applicable specifications and shall be as specified herein and on the applicable drawings.

4.11.14.3 The DOC/DPF system shall be constructed of corrosion resistant material or material with a finish to resist corrosion to the maximum extent possible. System materials not specifically designated herein or in the contract shall be of a quality commensurate with commercial practice within the applicable industry. When dissimilar metals are used in contact with each other, suitable protection against galvanic corrosion shall be applied.

4.11.14.4 Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in intimate contact with each other.

4.11.14.5 Materials that are nutrients for fungi shall not be used.

4.11.14.6 Any nonmetallic material that is adversely affected by contact with DOC/DPF system compounds shall not be used.

4.11.15 Lubrication.

4.11.15.1 If applicable, a lubrication plate shall be attached to the DOC/DPF system. The information provided on the plate shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

d. Viscosity

e. Federal or Military Specification Number (if applicable)

4.11.15.2 All bearings (except sealed-for-life type), mating gears, and sliding parts shall be provided with standard means for lubrication. Oil holes, grease fittings, and filler caps shall be accessible. Lubrication reservoirs, if applicable, shall have means for checking levels. Means shall be provided to ensure lubrication for all moving parts. Re-circulating lubrication systems shall include a cleanable or replaceable filter. Means for determining oil level in each reservoir shall be by an oil level sight gauge, a low oil level warning light or similar device and shall be in clear view of the operator's normal workstation. An automatic lubrication system shall be provided for all ways and axis screws. Each lubricant reservoir shall have at least a 24-hour capacity and means for determining fluid level. Any greases, oils, or fluids used to initially charge the lubricant system shall be free of contaminants known to be hazardous to human health.

4.11.15.3 Grease fittings conforming to ANSI AS35411 Fittings & Lubrication shall be provided in accessible positions not requiring removal of threaded fasteners at all necessary lubrication points. Pressure relief fittings shall be provided where use of high-pressure lubrication equipment could cause damage.

4.11.16 Drive Train Gears. The gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the DOC/DPF system. Gears in the drive train shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell C-48.

4.11.17 Castings and Forgings. Castings shall be free of visible blowholes, porosity, hard spots, shrinkage, defects, cracks, scale, mismatching or other defects. Forgings shall be free of visible scale, inclusions, cold shuts, mismatching, or other defects. Mechanical and chemical properties of the castings and forgings shall be adequate to meet the performance requirements of this specification. No processes such as welding, peen, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes may be used only for enhancing surface finish and appearance.

4.11.18 Welding, Brazing, and Soldering. Welding, brazing, and soldering shall be of a quality, which shall sustain the performance requirements of the welded, brazed, or soldered part. These operations, however, shall not be employed as repair measures for defective parts.

Welding, brazing, or soldering shall be employed only where specified in the original design.

Any material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

4.11.19 Painting. Unless otherwise specified painting and finishing of the DOC/DPF system shall be in accordance with standard commercial practice provided the following minimum criteria are met or exceeded: all surfaces to be painted shall have been cleaned to be free of all foreign matter detrimental to painting, and at least one coat of industrial primer and one coat of industrial enamel, or equivalent, applied.

4.11.20 Recovered Materials. The Contractor is encouraged to use recovered materials to the maximum extent possible in accordance with Federal Acquisition Regulation (FAR) Subpart 23.403.

5.0 Delivery, Installation and Commissioning.

5.1 Delivery. The Contractor shall be responsible for delivering all DOC/DPF system components to the installation site.

5.1.1 Shipping, Handling, and Storage. The Contractor shall be responsible for all shipping, storage, and handling of the DOC/DPF systems and all materials. The Government will not be responsible for furnishing any labor, equipment, or warehouse space for the loading, unloading, transport, or storing of any materials. The Government will make available if possible, space for a Contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. Should the Contractor not wish to furnish a trailer for equipment storage, then the Contractor shall coordinate with the COR, a date at which time the Contractor may deliver his equipment to the building.

5.2 Installation. The Contractor shall be responsible for installing and commissioning the DOC/DPF systems to include all labor, materials, tools, and equipment required. The Contractor shall be responsible for ensuring the DOC/DPF system installation requirements are compatible with existing facilities. The Contractor shall field verify all dimensions and locations of utilities at the installation site and report any discrepancies to the COR before proceeding with installation. Any discrepancies not reported prior to beginning of installation shall become the responsibility of the Contractor. Unless otherwise approved by the KO, installation shall be done during normal depot working hours and shall not interfere with ongoing Government operations and production.

5.2.1 Installation of DOC/DPF Device. The Contractor shall install the DOC/DPF device per the manufacturer’s instructions and drawings. The housing shall be supported from the bottom. Any lifting point provide on the housing shall not be used for hanging or support of the installed housing.

5.2.2 Installation of Filter Monitoring and Data Logging Device. The Contractor shall install the filter monitoring and data logging device per the manufacturer’s instructions and drawings.