PD_W25G1Q710100EJ__REVISED.pdf

LETTERKENNY ARMY DEPOT

PURCHASE DESCRIPTION

Test Cell Dynamometer (Dyno) Cooling Loop System - BLDG 350

1. GENERAL REQUIREMENTS

1.1. SCOPE: This specification shall apply to a cooling loop system for the 350 test cell Dyno. The purpose for this cooling loop is to reduce single pass cooling water that is sent to the industrial waste water treatment plant (IWTP). The cooling loop system will be located at building 350 at Letterkenny Army Depot (LEAD), Chambersburg, PA. The system will recirculate a cooling mixture for the test cell Dyno that is currently using single pass fresh water for cooling. The system will come equipped with a closed circuit fluid cooling system (CCFC), process storage tank or tanks, a support structure, flow controls for the Dyno, pumps, valves, piping, controls tying information back to the Dyno controls, and all other materials needed for a fully operational system. The specification calls for a turnkey operation and the successful contractor shall install the new system and associated components herein in their entirety, including all necessary electrical, plumbing for water, plumbing for compressed air, ventilation, fire alarm system tie in, and spill containment required for system operation. The contractor shall furnish all materials, equipment, and labor needed to meet all requirements described in this solicitation and shall provide a complete and usable system. The contractor shall also perform testing to indicate full operational compliance with this contract and shall also provide system training for necessary personnel at 350.

1.2. GENERAL INFORMATION

1.2.1. Place and Performance of Installation: The cooling loop system will be installed in the south end of building 350 between doors 1 and 34. The CCFC system shall be outside the building on a support structure with controls inside the building. See attachment A for a layout showing approximate locations. All work will be performed between the hours of 6:00 AM and 3:30 PM, Monday thru Thursday, exclusive of Federal Holidays and special depot closures (Typically the Monday before or Friday after Federal Holidays that fall on a Saturday, Sunday, Tuesday or Thursday). Other hours, weekend, and holiday work will be considered separately as requested by the contractor and approved by the Contracting Officer.

1.2.2. Security Requirements: The contractor shall be responsible to ensure that all employees and subcontractor employees that will visit the depot shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce shall comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy. Should the Force Protection Condition (FPCON) change, the Government may require changes in contractor security matters or processes.

1.2.3. Security, Safety, and Fire Protection: All work shall comply with LEAD pamphlet 385-4. The equipment and the installation shall also meet all the safety criteria set forth in OSHA 1926.501 and ANSI/ASSE Z359.

1.2.4. AT Level I Awareness Training: All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, and controlled access areas shall complete AT Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee to the COR or to the contracting officer, if a COR is not assigned, within 15 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website: www.lead.army.mil.

1.2.5. iWATCH Training: The contractor and all associated sub-contractors with an area of performance within an Army-controlled installation, facilities or area shall brief all employees on the local iWATCH program. This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the TPOC or contracting officer. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance. The contractor shall report completion for each affected contractor employee and subcontractor employee, to the TPOC and contracting officer within 15 calendar days after completion of training. iWATCH training is available on the Letterkenny Army Depot homepage – www.lead.army.mil

1.2.6. OPSEC Training: Per AR 530-1, Operations Security. Contractor employees and associated sub-contractor employees shall complete Level I OPSEC training within 30 calendar days of their reporting for duty and annually thereafter. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer if a COR is not assigned, within 15 calendar days after completion of training. Level 1 OPSEC training is available on the Letterkenny Army Depot homepage – www.lead.army.mil

1.2.7. Badges: Identification badges will be issued for admittance of personnel before performing work or service on this contract. The identification badge is the property of the US Government and shall be returned upon termination or demand. The contractor/vendor shall ensure all badges issued to employees are returned to the Badge and Identification Section, Security Division, Letterkenny Army Depot promptly on termination of need or on expiration, which occurs first. The badge room is located in Bldg. 2, phone # 717-267-5301. Hours of operation are 7:30 AM to 3:30 PM, Monday thru Thursday, exclusive of Federal Holidays.

2. Government Furnished property and Materials: The government will provide the facilities, equipment, materials and/or services listed below http://www.lead.army.mil/

2.1. Facilities: The government will provide clear access to all working areas necessary for the contractor to perform the installation outlined, during the hours listed in section

1.2.1 above

2.2. Equipment: An SE 400HS Eddy Current Dynamometer with pressure and temperature sensors. Pressure sensors at inlet and outlet to the orifice plate shall be utilized to track flow rates for the requirements in this document. Temperature sensors are built into the process before and after the orifice plate for flow rate requirements as specified in this document.

2.3. Materials/Services:

2.3.1. Provide a single point of connection for power and compressed air within 25 feet of the test cell. Power will be provided via a fused disconnect switch or circuit breaker depending on availability.

2.3.2. Provide access to water within 25 feet of the test cell.

2.3.3. Provide staging space for parts and equipment near the project.

2.3.4. Provide a work area for installation crew and their tools near the project.

2.4. Utilities: Provide electricity and compressed air for vendor tools.

3. Contractor Responsibilities: The contractor shall be responsible for the following:

3.1. Provide design and construction drawings completed by an engineer licensed in the state of Pennsylvania for review and approval prior to ordering equipment (see 3.2 for time requirements).

3.2. Provide a summary of the required utilities and general layout 60 days prior to the equipment delivery, and the detailed installation requirements (to include installation schematics and installation schedule) 30 days prior to equipment delivery.

3.3. Supply all equipment, parts, labor and materials necessary for off-loading, positioning, installation and operation of the system.

3.4. Provide all labor and materials required to install and make a complete CCFC system, cooling tower, PLC controller, pumps, valves, tanks, support structure, and all installation parts and labor for a complete and usable system.

3.5. All materials shall be specified to function within system guidelines for temperatures, flow rates, pressure, and chemicals to be used.

3.6. Ensure that all welding is performed in accordance with AWS D1.1.

3.7. Ensure that all plumbing follows the applicable codes for ASME B31.3 process piping.

3.8. Ensure that the electrical installation is performed in accordance with the National Electrical Code. All electrical work shall be subject to inspection by LEAD electricians.

3.9. Contractor shall make final connection to a government installed disconnect switch or breaker located within 25 feet of the test cell. Supplied voltage will be 480 Volt, 3-phase, 3-wire with a separate equipment grounding conductor. Contractor shall provide any transformation to other required voltages.

3.10. Remove all excess equipment, shipping crates, scrap and consumable materials used by the contractor for shipment and installation of the system.

3.11. The contractor shall supply no fewer than two of each special tool required to service the system and its components.

3.12. The contractor shall be responsible for obtaining site/equipment measurements and dimensions. Any dimensions provided by government personnel shall be considered approximate and shall not be used for design purposes. Failure of the contractor to acquaint himself with conditions attending the work site will not be considered sufficient reason for changing the cost or performance schedule of this project.

3.13. The contractor shall coordinate all layout, saw cut, and wall penetrations with the government representative for plumbing, electrical, and ductwork.

3.14. No structural members shall be removed or modified to make penetrations. All penetrations shall be sealed with a material acceptable for use on existing walls in the test cell area.

4. SPECIFICATIONS

4.1. General Requirements

4.1.1. The system shall utilize one cooling loop. The cooling loop shall contain a 40% propylene glycol mixture for freeze protection. A primary/standby pump arrangement shall circulate water between the dynamometer and the CCFC.

4.1.2. The dyno cooling loop shall utilize a glycol water mixture that circulates through the dynamometer, an indoor holding tank, and a heat exchanger.

4.1.3. All equipment within the complete system shall be sized for specified loads and run times.

4.1.4. The CCFC shall utilize domestic water for tower makeup supply.

4.1.5. The operating load for the tower shall be 75 gpm, entering solution temperature = 140 degrees F, leaving fluid temperature = 100 degrees F with a wet bulb of 78 degrees F.

4.1.6. The maximum pressure drop across the dyno shall be 5.0psi where measured across the orifice plate. See attachment B for orifice plate drawing.

4.1.7. The inlet pressure shall remain between 35 and 60 psi.

4.1.8. The PH range shall be 7.4 to 8.4.

4.1.9. A control system shall be provided that monitors flows, temperatures, and pressures and shall adjust cooling system performance or shutdown the dyno if expected parameters are not achieved.

4.1.10. The system controls shall be located inside the test cell monitoring room.

4.1.11. The system shall have a 2’ high platform for the tower in the area to be cleared by LEAD (see attachment A).

4.1.12. All piping, pumps, valves, etc. shall be provided for a complete system.

4.1.13. Safe guards against equipment, pipes, etc freezing shall be built into the system.

4.1.14. All materials and equipment for electrical and control requirements shall be provided for a complete system.

4.1.15. Closed loop piping shall be schedule 40 steel with mechanical or buttwelded fittings. Gaskets must be rated to handle the fluid mixture.

4.1.16. Makeup water piping shall be type L copper with soldered or pressfit fittings.

4.1.17. Tower drainage piping shall be schedule 40 PVC with solvent welding fittings.

4.1.18. The system installation shall meet the requirements of the international Plumbing Code, International Mechanical Code, and National Electric Code.

4.2. Specific Heat Load Information

4.2.1. The system shall cool the dyno only. The engine attached to the dyno has its own cooling system.

4.2.2. Dyno model SE 400 from SAJ Dynamometers. The largest engine currently tested on the dyno is 300 HP, however the cooling system shall be designed to accommodate the maximum capacity of the dynamometer.

4.3. Equipment

4.3.1. One evaporative cooling tower capable of handling flow rates necessary for cooling requirements of the overall system shall be provided.

4.3.2. An automatic glycol feeder with booster pump, 30 gallon plastic container, low level alarm, and control panel to automatically maintain system pressure shall be incorporated into CCFC design.

4.3.3. A primary and standby pump shall be provided for the cooling loop system. The pumps shall be designed and rated for continuous duty in this type of application.

4.3.4. Pumps shall be complete with triple duty valves, air separator, and expansion tank.

4.3.5. All pumps, valves, piping, etc. shall be compatible with system chemicals and system design requirements.

4.3.6. The CCFC shall have a 304 stainless steel sump with the following:

4.3.6.1. Spray pump axial fan

4.3.6.2. Integral piping

4.3.6.3. Access ladders to service tower

4.3.6.4. NEMA 3R control panel with fan Variable Frequency Drive (VFD), vibration cutout switch, auto temperature controls, with leaving water sensor

4.3.6.5. Three probe water level controls with solenoid fill valve.

4.3.6.6. Electric immersion heaters to prevent the sump from freezing.

4.3.7. The closed circuit coils shall have a maximum of 3 fins per inch so the tower may run without water when the ambient drybulb temperature is at or below 50 degrees F and still provide the necessary cooling.

4.3.8. An alternate (backup) spray pump shall be provided.

4.3.9. The fan motor shall be capable of VFD operation.

4.3.10. The fan motor shall be externally mounted with swing away hinges for serviceability.

4.3.11. A PLC for controlling the system shall be utilized.

4.3.12. Motors and starters shall be included. VFD drives shall be used on all motors.

4.3.13. All cutoff valves and isolation valves shall be ball valves.

4.3.14. Plumbing system shall be designed with adequate couplers, junctions, etc. to allow future maintenance access.

4.3.15. Steel piping and butterfly valves shall be used for all plumbing.

4.3.16. All supplies necessary for a complete turnkey installation shall be provided.

4.3.17. A filtration system that captures 25 micron or larger shall be provided on the dyno cooling loop to protect the Dyno from damage.

4.4. Conditional Tracking

4.4.1. Flow rate in GPM in the dyno shall be tracked utilizing differential pressure across the orifice plate.

4.4.2. The temperature of inlet and outlet liquid shall be tracked and used for system flow requirements and shutdowns if necessary.

4.4.3. The system shall have the ability to monitor flows, temperatures, and pressures and adjust cooling system performance or shutdown the dyno if expected parameters are not achieved.

4.4.4. A maximum high temperature condition shall be setup to shut the dyno down as a system safety feature.

4.5. Closed Circuit Fluid Cooling (CCFC)

4.5.1. The CCFC shall be constructed of durable and corrosion resistant materials and be certified by Cooling Technology Institute (CTI) STD-201.

4.5.2. The CCFC shall utilize energy conservation features to minimize energy consumption.

4.5.3. A chemical treatment system shall be included for the evaporative tower cooling loop to include:

4.5.3.1. The initial chemical treatment and training for follow on treatments.

4.5.3.2. Four site visits and tower chemical testing shall be included for the first year. After that time Letterkenny will pick up this requirement.

4.5.3.3. One year supply of rust inhibitor

4.5.3.4. One year supply of biocides

4.5.3.5. Chemical pumps and pales as necessary for system.

4.5.3.6. A conductivity sensor and automatic blow down valves.

4.5.3.7. An electronic controller capable of operating feed pumps and performing blowdown as necessary based on conductivity.

4.6. Platform

4.6.1. The design and construction drawings for the platform shall be completed by a Professional Engineer licensed in the state of Pennsylvania.

4.6.2. Some flexibility on size is allowed as long 3’ of clearance all around the platform is available after the cooling tower is installed.

4.7. Control Specifications

4.7.1. A Direct Digital Control (DDC) controller with Human Machine Interface (HMI in the door of the NEMA 1 shall be provided and will control tower, pumps, valves, electric, and all necessary aspects for the cooling system.

4.7.2. The controller shall be a programmable logic controller (PLC) with an operator interface screen.

4.7.3. The new controller shall be based on the existing Tridium Niagara Platform as manufactured by Distech Controls.

4.7.4. The DDC controller shall integrate into the building management system (BMS).

4.7.5. The HMI screen shall be a minimum of 5.7”.

4.7.6. The operator shall have the ability to shut down the system utilizing an emergency stop located in the test cell area.

4.7.7. All cables, controls, transducers, etc. needed for control operation shall be included.

4.7.8. The system shall be able to work with a Tridium Niagra Platform that is utilized by the depot.

4.7.9. The control system shall monitor entering and leaving water conditions such as water pressure, temperature, flowrate, tower status, control pumps, and tower startup.

5. Safety/Fire System Requirements

5.1. The system shall include an internal wall mounted grounding bar and the exterior shall have a grounding connection.

5.2. The PLC control shall be mounted in a NEMA 1enclosure and shall include a main disconnect.

5.3. The ability to tie in to the fire alarm system shall be provided in order to shut the system down in the event of a fire alarm.

6. Electrical

6.1. All electrical construction for the cooling system shall be NEC rated as required.

6.2. Complete electrification shall be provided.

6.3. All bus box disconnects, conduit, control boxes, starters, and associated electrical components necessary to make the equipment operational shall be included.

6.4. The primary voltage shall be 480 volt, 3-phase, 60 hertz, and 3 wire with a separate equipment grounding conductor. Contractor shall provide any transformation to other required voltages.

6.5. All enclosures shall have a NEMA 4 rating.

6.6. The equipment provided shall conform to the specifications cited herein and shall be designed and constructed in accordance with NFPA 70.

7. NAMEPLATE: A corrosion resistant metal nameplate shall be securely attached to the dyno cooling system. The nameplate shall contain the information listed below:

7.1. Nomenclature

7.2. Manufacturer’s Name

7.3. Manufacturer’s Model Designation

7.4. Manufacturer’s Serial Number

7.5. Input Voltage, Current, Phase, and Hertz

7.6. Date of Manufacture

8. DRAWINGS AND MANUALS: Two sets of the manufacturer’s design drawings shall be submitted for approval within 4 weeks of award. Approval shall be provided within 10 days after receipt by LEAD engineering personnel. Two sets of operator instruction manuals, maintenance service manuals and parts listing manuals shall be provided for the unit. These manuals shall be written in the English language.

9. HAZARDOUS MATERIALS: Two sets of listing for all lubricants, seals, and/or any other hazardous material necessary for preventive and corrective maintenance along with their respective Safety Data Sheets (SDS) shall be submitted for approval within 4 weeks of award. These lists and SDS shall be written in the English language.

10. WARRANTY: A standard commercial warranty or a one year commercial warranty, whichever is larger, shall be furnished with the cooling loop system in its entirety. The warranty shall cover the CCFC, plumbing, tanks, controls, platform and all other components of the system. The warranty period begins when the LEAD Contracting Officer provides official confirmation that the system has satisfied all operational provisions of the contract.

11. STANDARD PRODUCTS: The unit and ancillary equipment shall be new and regularly advertised products in order to provide a constant source of replacement parts and technical assistance.

12. PRESERVATION, PACKAGING AND DELIVERY: The contractor shall utilize standard commercial methods for preservation and packaging appropriate for the equipment provided. As a minimum, all areas susceptible to damage from exposure to the elements shall be preserved and/or packed to prevent damage. The contractor shall be responsible for ensuring the equipment is delivered to LEAD in good condition.

LEAD will assume no responsibility for off-loading or storage of the provided equipment.

13. INSPECTION AND ACCEPTANCE

13.1. The cooling loop and associated equipment shall be examined for design, construction, materials, components, and workmanship to determine compliance with the contract and this specification. Any deviation from these requirements shall be cause for rejection.

13.2. The contractor shall be responsible for developing test procedures to demonstrate compliance with the requirements of this specification. All test procedures shall be submitted to and approved be Depot Technical Point of Contact (TPOC) prior to the start of testing. To support the testing procedures, LEAD will provide an asset for testing on the dyno for cooling loop performance testing and training.

14. INSTRUCTION: The contractor shall conduct no less than 2 hours of operator training for up to 6 personnel that are already familiar with the operation of LEAD’s dyno operations, and shall conduct no less than 4 hours of maintenance training for up to 6 personnel familiar with the maintenance of LEAD’s dyno equipment.

15. APPLICABLE DOCUMENTS

15.1. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR, 1910 General.

(Copies may be obtained at www.osha.gov)

15.2. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

OSHA Technical Manual (OTM), Section III Chapter 7 Legionaire’s Disease, Section V.

Controls. (Copies may be obtained at www.osha.gov)

15.3. Cooling Technology Institute (CTI), Legionellosis Guideline: Best Practices for Control of Legionaire’s Disease. (Copies may be obtained at www.cti.org)

15.4. AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B31.3 Code for Pressure Piping, Process Piping (Copies may be obtained at www.asme.org)

15.5. NATIONAL ELECTRICAL MANUFACTURER’S ASSOCIATION (NEMA)

NEMA 250 Enclosures for Electrical Equipment (Copies may be obtained at www.nema.org)

15.6. AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M Structural Welding Code (Copies may be obtained at www.aws.org)

15.7. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code (NEC) NFPA 101 Life Safety Code (Copies may be obtained at www.nfpa.org)

15.8. LETTERKENNY ARMY DEPOT (LEAD)

LEAD Regulation 385-1 Safety and Occupational Health Program and 385-4 Safety pamphlet for contractors. Copies may be obtained from LEAD Directorate of Contracting, Bldg. 2) http://www.osha.gov/ http://www.osha.gov/ http://www.cti.org/ http://www.asme.org/ http://www.nema.org/ http://www.aws.org/ http://www.nfpa.org/