22 15 19 Am-0005.pdf

Depressing Air System Replacement, Big Bend Dam, SD BB81

SECTION TABLE OF CONTENTS

DIVISION 22 - PLUMBING

SECTION 22 15 19

DEPRESSING AIR COMPRESSORS

PART 1 GENERAL

1.1 GENERAL REQUIREMENTS

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Work Plan

1.4.2 Factory Testing Certification

1.5 SAFETY

1.6 WARRANTY

1.7 POSTED OPERATING INSTRUCTIONS

PART 2 PRODUCTS

2.1 AIR COMPRESSOR

2.1.1 Manufacturer's Certifications

2.1.2 Guaranteed Performance

2.1.3 Additional Performance Requirements

2.1.3.1 Critical Speeds

2.1.3.2 Vibration and Balance

2.1.3.3 Pressure Differential Settings

2.1.4 Electrical Service Conditions

2.1.4.1 Air Compressor Drive Motor

2.1.5 Compressor Controls

2.1.5.1 Documentation

2.1.5.2 Compressor Start-Up

2.1.5.3 Monitor and Safety Controls

2.1.5.4 Running/Not Running Contacts

2.1.5.5 Monitoring Instruments

2.1.6 Compressor Design Features

2.1.6.1 Casings

2.1.6.2 Lubrication System

2.1.7 Electric Motors

2.1.7.1 Main Electric Drive Motor

2.1.7.2 Motor Starter

2.1.8 Control Panel

2.1.9 Accessories

2.1.9.1 Outlet Connectors

2.1.10 Sound Attenuating Enclosure

2.1.10.1 Enclosure Frame

2.1.10.2 Panels

2.1.10.3 Ventilation

2.1.11 Isolating Pad

PART 3 EXECUTION

3.1 Access

3.2 COMMISSIONING SERVICES

SECTION 22 15 19 Page 1

Am-0005

3.3 FIELD QUALITY CONTROL

3.3.1 Field Test Procedures

3.3.1.1 Air Compressor Performance Tests

3.3.1.2 Sound Level Tests

3.3.1.3 Operational Deficiencies

3.3.1.4 Testing Tolerances

3.3.2 Approval of Testing Procedure

3.4 TRAINING OF GOVERNMENT PERSONNEL

3.5 Operation and Maintenance Data

-- End of Section Table of Contents --

SECTION 22 15 19 Page 2

SECTION 22 15 19

DEPRESSING AIR COMPRESSORS

PART 1 GENERAL

1.1 GENERAL REQUIREMENTS

Contractor must provide and install the following items to Big Bend Powerplant:

a. Two (2) oil-flooded water-cooled two stage rotary screw air compressors, related controls and accessories.

b. Electrical and components as specified.

Contractor must also provide commissioning by a factory-trained service technician. Commissioning of the new air compressors must be witnessed by a Government Representative.

1.2 REFERENCES

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.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.20.1 (2013; R 2018) Pipe Threads, General Purpose (Inch)

ASME B16.1 (2020) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME BPVC SEC VIII D1 (2019) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM B209 (2014) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM C553 (2013; R 2019) Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications

COMPRESSED GAS ASSOCIATION (CGA)

CGA G-7.1 (2011) Commodity Specification for Air;

5th Edition

SECTION 22 15 19 Page 3

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 112 (2017) Standard Test Procedure for Polyphase Induction Motors and Generators

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 2151 (2004) Acoustics - Noise Test Code for Compressors and Vacuum Pumps - Engineering Method (Grade 2)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2020) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA MG 1 (2016) Motors and Generators - Revision 1: 2018; Includes 2021 Updates to Parts 0, 1, 7, 12, 30, and 31

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-A-3316 (1987; Rev C; Am 2 1990) Adhesives, Fire-Resistant, Thermal Insulation

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.219 Mechanical Power Transmission Apparatus

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G, HDC, PO

Field Test Procedures; G, HDC, PO

SD-03 Product Data

Air compressor; G

SD-06 Test Reports

Air compressor performance tests; G

Sound level tests; G

SD-07 Certificates

Factory Testing Certification; G, HDC

SECTION 22 15 19 Page 4

*Am-5 Manufacturer's Certifications; G, HDC **Am-5

*Am-5 Guaranteed Performance; G, HDC **Am-5

SD-10 Operation and Maintenance Data

Operation And Maintenance Data; G, HDC, PO

SD-11 Closeout Submittals

Posted operating instructions for air compressor

1.4 QUALITY ASSURANCE

1.4.1 Work Plan

Submit a written schedule of dates of installation, start-up, checkout, and test of equipment. Additionally, for the submitted work plan, include a narrative of the proposed procedure for removing the existing compressors and installing the new compressors. Detail which equipment hatches will be used and what lifting equipment, including cranes, hoists and rigging equipment, will be used by the Contractor to transport equipment to and from the removal and installation location.

1.4.2 Factory Testing Certification

Submit a statement that the air compressor factory is equipped to perform all required factory tests. Submit in accordance with paragraph entitled "Manufacturer's Certifications."

1.5 SAFETY

Construct all components of the unit in accordance with the requirements of OSHA 29 CFR 1910.219 . Requirements include insulation and jacketing with manufacturer standard covering or aluminum sheet of all surfaces at 125 degrees F and higher within a height of 7 feet from floor level, and use of electrical safety devices. Thermal insulation, furnished by equipment manufacturer, must conform to ASTM C553, Type I (flexible resilient), Class B-5 (up to 400 degrees F), 2 pcf nominal. Cement insulation to surface with MIL-A-3316 , Class 2, adhesive and fasten with 16-gage wire bands at maximum 16 inches on center spacing. Cover insulation with ASTM B209 sheet aluminum jacket. However, insulation is not required for hot piping inside sound enclosure.

1.6 WARRANTY

A minimum of *Am-3 one 5**Am-3 year warranty will be provided for all *Am-5 components. Motors, AirEnds and Air Dryers. A full one year warranty must be provided for all components provided under paragraph Electrical Switches and Components. **Am-5

Upon receipt of notice from the Government of failure of any part of the guaranteed equipment during the period, the affected part or parts must be replaced promptly with new parts and at the expense of the Contractor.

1.7 POSTED OPERATING INSTRUCTIONS

Provide for air compressor. Include start-up and shutdown sequence instructions.

SECTION 22 15 19 Page 5

PART 2 PRODUCTS

2.1 AIR COMPRESSOR

The air compressors must be packaged, positive displacement oil flooded two stage rotary screw compressors. Include air compressor, electric motor driver, coolers, lubrication system, and regulation and control systems mounted on a common base frame, and completely enclosed for noise control. The air compressor system must be microprocessor (digital) controlled.

2.1.1 Manufacturer's Certifications

The manufacturer must certify that the air compressors proposed are of the same design, construction, size, and of equal or not more than 10 percent smaller in capacity as compressors which have been in satisfactory continuous service *Am-5 for at least five years at not less than three locations. for at least 2 years at not less than two locations. **Am-5 Furnish the name of the owner, the address of the installation, and the name of a person at the installation who can be contacted for verification.

2.1.2 Guaranteed Performance

a. Type: Base Mounted, Water Cooled, two-stage Lubricated Air End Rotary Screw.

b. *Am-5 Minimum capacity (cfm) 720 ACFM @ 110 PSIG. Capacity (cfm):

800 ACFM @ 110 PSIG. **Am-5

c. Aftercooler: Required; Water-cooled. Stainless Steel. A centrifugal moisture separator is also required. Any water-wetted surfaces in the air compressor MUST be stainless steel.

d. *Am-5 Inlet air compressor must be as designed by the compressor manufacturer. Inlet Air Filter: 3-5 micron, Canister-Type. **Am-5

e. Minimum Output pressure immediately downstream of aftercooler: 110 psig.

f. Output air maximum temperature downstream of aftercooler: 100 degrees F.

*Am-5 g. Inlet air filtration efficiency: 99.9 percent of 0.5 micron size.

gh. Compressor Controls: microprocessor controlled with built in communication modules for automatic sequencing for alternating lead/lag operation.

hi . Maximum sound levels one meter horizontal from compressor and 1.5 meters above floor as measured per ISO 2151 Test Code for the Measurement of Sound from Pneumatic Equipment: 78 dBA, 90dB for any octave band.

i j . Compressors must operate without use of existing back pressure tank. Back pressure requirements or regulation needs to be contained within the compressor unit. **Am-5

SECTION 22 15 19 Page 6

2.1.3 Additional Performance Requirements

2.1.3.1 Critical Speeds

Actual critical speeds must not encroach upon operating speed ranges at specified loads ranges. *Am-5 Rotors must be of a stiff shaft construction with the first actual rotor bending critical speed at least 120 percent of the maximum operating speed. **Am-5

2.1.3.2 Vibration and Balance

*Am-5

Compressor must not exhibit excessive vibration. Ensure major rotating parts of the compressor are dynamically balanced by the compressor manufacturer.

Major parts of rotating elements, such as rotors, gears, and similar items must be individually dynamically balanced. During the site tests of the assembled machine at operating speed, the double amplitude of vibration in any plane measured on the shaft adjacent and relative to a radial bearing must not exceed the limits of API Std 619 , paragraph 2.7.2.5. For shafts which are not accessible, the manufacturer must submit a testing procedure to the Contracting Officer for approval.

**Am-5

2.1.3.3 Pressure Differential Settings

The new air compressors must be programmable such that they can be set to compress when the system senses a loss of pressure of 5 psi from working pressure. The compressors must therefore be programmable such that they can be set to start compressing when the system pressure drops from a working pressure of approximately 100 PSI to approximately 95 PSI. Clearly state in compressor product data or other documentation that this is possible for the compressors provided.

2.1.4 Electrical Service Conditions

2.1.4.1 Air Compressor Drive Motor

460 volts, 3 phase, 3 wire, 60 hertz electrical service.

2.1.5 Compressor Controls

Provide a complete load regulation and control system with the compressor.

Provide additional electrical, electro-pneumatic, or solid state electronic controls for other specified control and monitor functions.

All electrical controls must conform to NEMA ICS 2 as selected by the compressor manufacturer. Control system enclosure must conform to NEMA ICS 6 . Controls must be suitable for individual operation of the compressor or parallel operation with one or more other compressors.

2.1.5.1 Documentation

Provide compressor communications documentation needed for programming the existing plant control system for communicating desired information with the compressors. Include in this documentation a Modbus register list for

SECTION 22 15 19 Page 7 information available via *Am-5 Modbus RTU **Am-5 . At a minimum, the Modbus register list must include the following:

a. Compressor Running

b. Compressor On Standby (Not Running)

c. Low Sump Pressure

d. High Air Pressure

e. High Airend Temperature

f. Starter Fault

g. Motor Overload

h. Fan Motor Overload

i. Temperature Sensor Fail

j. Remote Start Failed

k. Remote Stop Failed

l. Loss of Control Power

2.1.5.2 Compressor Start-Up

The compressor must start unloaded. The manual starting circuit for the compressor must have interlocks to prevent the compressor drive motor from starting until pre-lubrication pump (if provided), oil pressure have been established to the required values for safe operation as determined by the compressor manufacturer.

2.1.5.3 Monitor and Safety Controls

Provide supplementary electric, electro-pneumatic, or solid state electronic controls to provide running, alarm, and shutdown requirements, plus interlocks with accessories. Provide additional dry form C contacts for each of the below conditions rated for 125VDC, 0.25 Amp. Requirements are as follows:

a. Shutdown requirements must cause the controlled compressor to shut down, energize alarms, and light labeled red lights.

b. Alarm only requirements must not cause the controlled compressor to shut down, but must sound the same alarms and light labeled amber lights.

c. Light only requirements must not cause the controlled compressor to shut down, but must light labeled amber lights.

2.1.5.4 Running/Not Running Contacts

Provide supplementary electric, electro-pneumatic, or solid state electronic controls to provide "running" and "not running" status of the compressors. Provide separate dry form C contacts for the "running" and "not running" status, rated for 125VDC, 0.25 Amp.

2.1.5.5 Monitoring Instruments

*Am-5

Compressor must display the following information in a location easily viewable by an operator without the use of additional equipment.

a. Oil temperature.

b. Inlet air pressure.

SECTION 22 15 19 Page 8

c. Inlet air temperature.

d. Downstream air pressure.

e. Downstream air temperature.

f. Total compressor run time

Provide the following monitoring instruments in addition to the monitor and safety controls. Pressure gages must conform to ASME B40.100 , 4 1/2 inch diameter, red marking pointer, single bourdon tube, brass case, black enamel finish. Provide pressure gages with a pressure snubber and a stainless steel barstock needle isolation valve. Thermometers must be extended stainless steel sheathed bimetallic stem, 3 1/2 inch dial, and separable 4 inch stainless steel wells. Temperature measurements at inaccessible locations must be made with remote reading thermometers conforming to MIL-T-19646 , Class C separable well of Type 304 stainless steel. Select pressure and temperature gage ranges to give a normal operating reading near the midpoint of the scale range.

a. Oil cooler outlet temperature gages for oil.

b. Lubrication oil bearing supply pressure gage.

c. Compressor seal air pressure gage (if applicable).

d. Inlet air filter differential pressure gage with 8"-0-8" inch water gage. Provide selector valve, tubing, and tap to measure static gage pressure downstream of each filter stage.

e. Total running time readout.

f. Compressed air pressure downstream of aftercooler pressure gage.

g. Compressed air temperature downstream of aftercooler temperature gage.

h. Compressor inlet air temperature gage.

**Am-5

2.1.6 Compressor Design Features

An aftercooler must be provided after the final stage of compression.

Silencers, lubricating system, cooling system, control system, and driver must be mounted as part of the package. Provide a common base frame for the compressor system and driver. Provide a sound enclosure over the compressor and driver. Equipment must be designed for economical and rapid maintenance. Casing components, bearing housings, and other major parts must be shouldered, dowelled, or designed with other provisions to facilitate accurate alignment or reassembly. Shaft seals and bearings must be accessible for inspection or replacement with a minimum of disassembly; however, compressors with compression elements (air end) provided as a factory-assembled not repairable in the field may be approved by the Contracting Officer if determined to be in the interest of the Government.

SECTION 22 15 19 Page 9

2.1.6.1 Casings

Casings must be cast iron, ductile iron, cast steel, or fabricated steel.

Casing stresses must be within the limits allowed by ASME BPVC SEC VIII D1 .

Casings, supports, and baseplates must be designed and fabricated to preclude excessive and injurious distortion from temperatures, pressures, and forces encountered in service conditions. Provide jackscrews, lifting lugs, eyebolts, guide dowels, and casing alignment dowels to facilitate disassembly and reassembly. When using jackscrews for parting contacting faces, relieve one of the faces by counterboring or recessing to prevent marring the face, which result in leaking or improper fit. Provide lifting lugs or eyebolts for removable portions of the casings. Flanged casing connections for external piping must conform to ASME B16.1 or ASME B16.5 . Threaded connections for external piping must conform to ASME B1.20.1 . Air compression portion of the casing must be one-piece and must be provided with integral coolant passages and a large inlet port.

Gear cases must be enclosed, accessible, force lubricated, and designed with seals and slingers to keep oil out of air system.

*Am-5

2.1.6.2 Shafts

Shafts must be of forged or rolled alloy steel and must have a machined finish throughout their entire length. All rotating components must be positively secured to shafts by approved mechanical means or interference shrink fits.

2.1.6.3 Rotors

Rotors must be steel, and of one-piece construction, with an asymmetric profile to minimize leakage losses, and ensure high efficiency. Rotors must be treated for corrosion resistance. It rotors are welded to the shaft, the assembly must be stress relieved and heat treated for proper strength. Rotors must be dynamically balanced to ensure vibration-free operation.

2.1.6.4 Thrust Bearings

Thrust bearings must be anti-friction ball or roller type or hydrodynamic (fluid film) type. Anti-friction bearings must have an L-10 life of 80,000 hours in accordance with ABMA 9 or ABMA 11. Axial rotor thrusts due to air compression must be absorbed by main thrust bearings or transferred to auxiliary thrust bearings by a load balancing arrangement.

Hydrodynamic thrust bearings must be Kingsbury type or other approved type and must be adequate to accommodate all operating conditions. Speed increaser bull gear thrust bearings must be sized for equal thrust in both directions and must be adequate for any axial loads transmitted through the driver coupling.

2.1.6.5 Radial Bearings

Radial bearings must be anti-friction roller or ball type or hydrodynamic type. Anti-friction bearings must have an L-10 life of 40,000 hours in accordance with ABMA 9 or ABMA 11. Hydrodynamic bearings must be precision bored sleeve or pad type, designed for easy replacement by a split design or axially removable arrangement. High speed hydrodynamic pinion bearings must be anti-oil whip, tilting pad type. Hydrodynamic bearing design must provide low vibration and sufficient damping at rated

SECTION 22 15 19 Page 10 speed and all operating modes, including rated capacity and unloading down to 20 percent of unloaded power.

2.1.6.2 Lubrication System

Compressor must have lubrication system included as designed by the compressor manufacturer. Supply oil recommended by compressor manufacturer in volume sufficient to fill each compressor with the amount of oil recommended by the compressor manufacturer for normal operation.

Include an integral sump, positive displacement pump, oil cooler, and twin filter\strainer (readily replaceable cartridges while operating). Provide a prelube lubrication oil pump for start-up and standby for hydrodynamic bearings or if required by the compressor design. System must be factory assembled. Lubricating oil must conform to recommendations of the compressor manufacturer. Spray lubricate drive gear, anti-friction bearings, and timing gear in each stage. Pressure lubricate hydrodynamic bearings. Provide the oil sump with a level indicator and drain and fill connections.

a. Prelubrication pump, if required, or motor-driven main lubrication pump must be sized by air compressor manufacturer for the requirements of the system, but must meet the following requirements. Pump must be positive displacement gear pump separately mounted with motor on a common base plate with drip lip and drain.

(1) Performance: Pump must have separate safety valve bypass set at 25 psi above peak expected pressure.

(2) Materials must be hardened steel gears and shaft, cast iron case, bronze bearings, mechanical seal.

(3) Flexible coupling with shaft guard must be provided, except that these items are not required for a close-coupled pump.

4) Motor must be NEMA MG 1, Design A or B, Class B insulation, of open drip-proof type. Furnish combination type starter for motor.

*Am-2

b. A lubrication oil pump is not required if the compressor is designed such that the compressor lubricating oil may be adequately pressurized via the pressure created by the compressor through its normal compression cycle during operation. All compressor lubrication configurations (pump-pressurized or otherwise) must be of a design typical to the compressor provided and must be consistent with manufacturer recommendations for that compressor. Custom configurations to achieve lubrication without the use of a pump are not allowed.

**Am-2

**Am-5

2.1.7 Electric Motors

2.1.7.1 Main Electric Drive Motor

The main drive motor for each compressor must be an induction motor, 150 horsepower (hp), with a continuous service factor of 1.15. Size the motor so that the name plate hp rating is not exceeded under the entire range of

SECTION 22 15 19 Page 11 operating conditions specified. Efficiency and losses must be determined in accordance with IEEE 112 . Polyphase motors larger than 125 horsepower must be tested in accordance with IEEE 112 with stray load loss determined by direct measurement or indirect measurement (test loss minus conventional loss). The efficiency must be identified on the motor nameplate by the caption NEMA Nominal efficiency or NEMA Nom eff.

Electrical service will be as specified. Motor must be designed for reduced voltage starting 58 percent of full voltage, allowing for characteristics of the connected load, and must start without undervoltage tripping. The motor must meet the requirements of NEMA MG 1 with Class F insulation. Provide space heaters for protection of windings during motor shutdowns.

2.1.7.2 Motor Starter

A magnetic starter conforming to NEMA ICS-2 must be furnished. When specified, motors rated above 50 hp must have reduced voltage, partial winding, or other means to limit starting current inrush to 200 percent of the normal full load value for lubricated rotary compressors. The starter must include thermal overload protection and type 1 enclosure conforming to NEMA ICS-6.

2.1.8 Control Panel

*Am-5

Control unit panel must conform to NEMA ICS 6 or higher , floor or frame mounted, factory designed, and assembled, and must be provided complete.

The panel must be fabricated of formed stretcher leveled sheet steel, reinforced, and assembled into a rigid unit. Gasketed access doors must be provided as required. Panel must be factory finish painted. The panel must meet NEMA 12 requirements.

a. Panel must contain electric and safety control work required, including either alarm annunciation or individual labeled pilot lights arranged in a group. Panel must contain alarm device with light and silencing. Generalized arrangement in accordance with drawings.

b. Panel must contain start and stop buttons (the latter with lockout feature), discharge air pressure gage, control test switch and lights, reset button, green unit running light, and control selector switch.

c. Oil pressure gages must be mounted separately from panel.

Control unit panel must conform to NEMA ICS 6 , floor or frame mounted, factory designed, and assembled, and must be provided complete. *Am-2 Control panels that are integrated into the compressor body may be considered frame mounted. **Am-2 The panel must be fabricated of formed stretcher leveled sheet steel, reinforced, and assembled into a rigid unit. Gasketed access doors must be provided as required. Panel must be factory finish painted. *Am-2 The panel must meet NEMA 12, requirements.The panel must meet or exceed NEMA 12 requirements. **Am-2

a. Panel must contain electric and safety control work required, including either alarm annunciation or individual labeled pilot lights arranged in a group. Panel must contain alarm device with light and silencing. Generalized arrangement in accordance with drawings.

b. Panel must contain start and stop buttons (the latter with lockout

SECTION 22 15 19 Page 12 feature), discharge air pressure gage, control test switch and lights, reset button, green unit running light, and control selector switch.

c. Oil pressure gages *Am-2 must be mounted separately from panel. may be mounted separately from the panel unless oil pressure readings can be read from the panel itself. **Am-2

2.1.9 Accessories

Required accessories include:

2.1.9.1 Control Valves

*Am-2 Pneumatically or hydraulically controlled valves on suction inlet of compressor and on bypass or vent line.Provide pneumatically, hydraulically, or electronically controlled valves on the suction inlet of the compressor and on bypass or vent lines where bypass/vent lines are required per these specifications or are included in the compressor design. **Am-2

2.1.9.2 Intake Devices

Compressor air inlet must consist of the following:

a. Intake Pipe from Filter Enclosure to Compressor: Aluminum alloy ASTM B209, Alclad alloy 5052-H32 or equivalent, minimum 10 gage, flanged, welded with 5XXX welding rod using TIG method and including expansion bellows.

**Am-5

2.1.9.1 Outlet Connectors

Compressor air outlet flexible connection of stainless steel bellows with braided steel cover jacket, with stainless steel liner sleeve, 18-inch (457-mm) nominal length bellows, flanged ends, Class 150. If air bypass connects separately to the compressor from the outlet line, provide a second flexible connection of stainless steel bellows with braided jacket for the bypass. Outlet connectors will have a lockable ball valve as shown on the contract drawings.

2.1.10 Sound Attenuating Enclosure

The compressor package, including the driver motor, must be contained within a noise reducing enclosure. Design of the enclosure must be such as to limit noise transmission to *Am-5 84 78 **Am-5 dBA or less at a distance of one meter from the compressor in any direction.

2.1.10.1 Enclosure Frame

The enclosure frame must be designed to support the weight of the sound suppression panels and easily demountable. Connections to the base frame must be designed *Am-5 to allow the enclosure frame to be detached and lifted away without damage to the connections, enclosure frame or base frame, and **Am-5 to allow accessibility and replacement of any component.

SECTION 22 15 19 Page 13

2.1.10.2 Panels

The panels must be of rigid construction to allow repeated access without damage or distortion. Sound absorbing material must be mineral fiber, treated to preclude shedding of fibers. Other approved insulation may be used except that polyurethane foam must not be permitted. *Am-5 Panels must be fabricated to allow easy hand removal for maintenance. Top panels must be secured to the enclosure frame with quick disconnect fittings and fabricated to allow easy hand removal for maintenance. End and side panels must be hinged or lift out with positive closure latches. Panels must be designed to allow the maximum access area when opened. Provide acoustic seals as required. **Am-5 Controls and instrumentation mounted on the panels must have flexible connections for panel opening and disconnects for enclosure removal. Disconnects must be of the male-female plug type. Panels must split around all piping connections to allow enclosure removal without detaching piping. Controls must be visible and operable from outside the enclosure.

2.1.10.3 Ventilation

Fan(s) and sound baffled ventilation grilles must be provided as part of the enclosure. Ventilation must be sufficient to limit interior temperature to that required for cooling the motor.

2.1.11 Isolating Pad

If specifically recommended by the compressor manufacturer, each compressor steel or iron base frame must be mounted on a neoprene waffle or rib type isolator pad which extends uniformly and continuously along the base mounting surface. *Am-5 The neoprene material must be of bridge bearing pad quality neoprene and must be formulated for 40 durometer hardness. The maximum bearing pressure on the isolating pad must be 50 psi.

The pads must be composed of two layers or 5/16 inch neoprene bonded to and sandwiching 16 gage galvanized steel. **Am-5 Compressor bolt down through the pad must be accomplished using 1/4 inch thick neoprene impregnated duck washers. Neoprene bushings are not acceptable.

PART 3 EXECUTION

3.1 Access

Main access to the location for the air compressor installation is via multiple access hatches in the ceiling of the equipment gallery. Air compressor and accessories must be lowered through this access. One of the access hatches is serviceable by the powerhouse bridge crane.

3.2 COMMISSIONING SERVICES

After Installation, the Contractor must furnish the services of a compressor manufacturer's authorized representative to supervise prestart checkout, initial start-up, performance testing, and operator instruction. Time available must be as required to properly start up the compressor.

3.3 FIELD QUALITY CONTROL

3.3.1 Field Test Procedures

Complete field performance testing of the total system must be performed

SECTION 22 15 19 Page 14 by the Contractor and witnessed by the Contracting Officer. Air compressor Performance Tests must be conducted by either a compressor manufacturer's factory trained and authorized representative approved by the Contracting Officer or a qualified registered Mechanical Engineer.

Tests will be run on individual components and on the system as a whole.

Field tests require use of the actual compressor drive motor. Test must include operation at rated capacity for not less than 4 hours.

3.3.1.1 Air Compressor Performance Tests

Complete performance test must be run at maximum load, rated load, at point of unload but prior to unload, and unloaded condition. Data must be recorded listing:

a. Air flow, inlet pressure and temperature, humidity; discharge pressure and temperature.

b. Aftercooler temperatures, and pressures.

c. Lube oil flow, pressures, and temperature.

d. Electrical load in volts and amperes for compressor motor (loaded and unloaded), prelube oil pump motor, and compressor auxiliaries.

e. Intake filter pressure differential (clean).

f. Start-up sequence, alarm signals and automatic system shutdown.

g. Test compressor intake and discharge for conformance to CGA G-7.1 .

Compressor discharge must show no increase in contaminants.

3.3.1.2 Sound Level Tests

Sound level tests must be conducted concurrently. Broad Band "A" scale readings and Octave Band readings must be taken. Maximum permissible level must be 84 decibels one horizontal meter from the compressor and 1.5 meters above the floor, with unit in operation and all other significant equipment not required for test within the same building bay shutdown at the same location previously described. A background noise correction to 60 decibels is permissible.

3.3.1.3 Operational Deficiencies

Any operational deficiencies noted in the tests must be promptly corrected and affected portions of the test rerun.

3.3.1.4 Testing Tolerances

A tolerance of plus or minus 2 percent on flow, plus or minus 4 percent on power, or plus or minus 5 percent on any other variable for each item of equipment or fluid with all others conforming is permissible on field test results when compared to guarantee performance and cut sheet data.

3.3.2 Approval of Testing Procedure

Proposed testing procedure must be approved by the Contracting Officer and the individual in charge of testing prior to conducting tests.

SECTION 22 15 19 Page 15

3.4 TRAINING OF GOVERNMENT PERSONNEL

During start-up and field testing, train Government station personnel in the operation and maintenance of compressor, associated equipment, and all control and safety devices. Training must not commence until equipment is operational and station personnel are in attendance. At least one day of classroom training and one day of field training must be furnished for each designated Government personnel. When factory training is required by the compressor manufacturer for proper maintenance and overhaul of the compressors, such training must be furnished by the compressor manufacturer at no additional cost to the Government. The Government will bear the cost of travel and living expenses for Government personnel as necessary for the factory training.

3.5 Operation and Maintenance Data

Submit air compressor Operation and Maintenance Data. O&M Data must contain information required for maintenance and repair and must contain no evidence that proprietary maintenance arrangements with the manufacturer will be necessary.

-- End of Section --

SECTION 22 15 19 Page 16