SECTION 15481 COMPRESSED AIR SYSTEM PART 1 - GENERAL 1.1 SECTION INCLUDES A. Pipe and pipe fittings, including valves, unions and couplings. B. Air compressor. C. After cooler. D. Refrigerated air dryer. E. Air receiver and accessories. F. Pressure reducing station. 1.2 RELATED SECTIONS A. Section 03300 - Cast-in-Place Concrete. B. Section 15140 - Supports and Anchors. C. Section 15190 - Mechanical Identification: Identification of piping system. D. Section 15245 - Vibration Isolation. E. Division 16 - Equipment Wiring Systems: Electrical characteristics and wiring connections. 1.3 REFERENCES A. ASME - Boiler and Pressure Vessel Code. B. NFPA 70 - National Electrical Code. 1.4 SUBMITTALS FOR REVIEW A. Product Data: Provide manufacturers catalog literature with capacity, weight, and electrical characteristics and connection requirements. B. Shop Drawings: Indicate piping system schematic with electrical characteristics and connection requirements. C. Test certificate: Submit certificate of performance testing at the factory. 1.5 SUBMITTALS FOR INFORMATION COMPRESSED AIR SYSTEM 15481-1
A. Test Reports: Submit inspector's certificate for air receiver for inclusion in Operating and Maintenance Manuals. B. Certificates: Provide certificate of compliance from authority having jurisdiction indicating approval of air receiver. C. Manufacturer's Instructions: Indicate manufacturer's installation instructions, hoisting and setting requirements, starting procedures. 1.6 SUBMITTALS AT PROJECT CLOSEOUT A. Project Record Documents: Record actual locations of equipment and components. Modify shop drawings to indicate final locations. B. Operation Data: Submit for air compressor, air receiver and accessories, after cooler, refrigerated air dryer, and pressure reducing station. C. Maintenance Data: Submit for air compressor, air receiver and accessories, after cooler, refrigerated air dryer, and pressure reducing station. D. Warranty: Submit manufacturer warranty and ensure forms have been completed in Owner's name and registered with manufacturer. 1.7 QUALITY ASSURANCE A. Manufacturer Qualifications: Company specializing in manufacturing the Products specified in this section with minimum three years experience. B. Compressor shall be tested at the factory and shall be certified to meet specified performance. 1.8 REGULATORY REQUIREMENTS A. Conform to ASME code for installation of pressure vessels. B. Products Requiring Electrical Connection: Listed and classified by Underwriters Laboratories Inc. 1.9 DELIVERY, STORAGE, AND PROTECTION A. Accept air compressors, refrigerated air dryer on site in factory fabricated containers with shipping skids and plastic pipe end protectors in place. Inspect for damage. B. Protect piping and equipment from weather and construction traffic. 1.10 WARRANTY A. Section 01700 - Execution Requirements: Product warranties and product bonds. COMPRESSED AIR SYSTEM 15481-2
B. This Contractor shall furnish as part of his bid, an unlimited one year parts and labor warranty on equipment provided in this section. At the end of the two year warranty period any parts listed in the Extra Materials section of this specification that were used shall be replaced at no additional charge. The two year warranty period shall begin at the Date of Substantial Completion. 1.11 MAINTENANCE PRODUCTS A. Section 01700 - Execution Requirements: Requirements for maintenance service. B. Furnish service and maintenance of the compressor, dryer and all components provided in this section for one year from Date of Substantial Completion. 1.12 EXTRA MATERIALS A. Furnish two quart containers of compressor oil. B. The compressor shall be supplied with two years of operational spare parts. PART 2 - PRODUCTS 2.1 PIPE AND PIPE FITTINGS A. Simplair Evolution aluminum piping by Ingersoll Rand or approved equivalent.. 1. Fittings and Joints: Anodized extruded aluminum with double o-ring seals, Simplair Evolution by Ingersoll Rand. B. Threaded-End, Standard-Weight Steel Pipe: ASTM A 53/A 53M, ASTM A 135, with factoryor field-formed threaded ends. 1. Steel Threaded Pipe Nipples: ASTM A 733, made of ASTM A 53/A 53M or ASTM A 106, Schedule 40, seamless steel pipe. Include ends matching joining method. Plain-End, Standard-Weight Steel Pipe: ASTM A 53/A 53M, ASTM A 135.. 1. Steel Welding Fittings: ASTM A 234/A 234M, and ASME B16.9 or ASME B16.11. 2. Steel Flanges and Flanged Fittings: ASME B16.5. 2.2 VALVES A. Ball Valves 1. Manufacturers: a. Ingersoll Rand. 2. Forged bronze body with PTFE seats, blowout proof stem, chrome plated brass ball, lever handle with o-rings at the stem. Full flow design. 3. Valves at equipment drops and hose stations will be equipped with relief port to discharge downstream air pressure when valve is closed. B. Butterfly Valves COMPRESSED AIR SYSTEM 15481-3
1. Manufacturers: Ingersoll Rand. 2. Ten position lever handle, operating pressure 200 psig, operating temperature 0-212 deg. F. 3. Valves at equipment drops and hose stations will be equipped with relief port to discharge downstream air pressure when valve is closed. C. Swing Check Valves 1. Manufacturers: Ingersoll Rand. D. Air Outlets 1. Manufacturers: Ingersoll Rand. 2.3 COMPRESSOR A. Manufacturer: Ingersoll Rand Model R90n. B. Other acceptable manufacturers offering equivalent products. 1. Kaeser. 2. Atlas Copco C. Type: Rotary screw, air cooled, variable speed, packaged air compressor. D. Screw Compressors: 1. Unit: Direct drive, variable speed, rotary screw compressor with control panel. 2. Features: Vibration mounts, lubrication system, coolant air separation, coolers, fan motors, compressor capacity controls, inverter and a microprocessor controller. 3. Motor: Hybrid Permanent Magnet (HPM) utilizing an inverter to control its starting, frequency and speed. Premium 95% efficient with 1.25 service factor. Class F insulation. 4. Lubrication System: a. A full capacity coolant filter monitored by the microprocessor controller with a 5 micron replaceable element. b. Coolant/Lubricant temperature control utilizing a four port valve for (1) the coolant from the receiver/separator, (2) coolant from the valve to the cooler, (3) for the coolant from the cooler and (4) for the coolant to the coolant filter. 5. Coolant/Air Separation: a. Stage one utilizes a vortex action and impingement on baffles. b. Stage two utilizes a coalescing separator. 6. Coolers: Air cooled unit shall utilize two heat exchangers and an after-cooler to cool the discharge air. Unit shall also utilize a coolant conditioner system to ensure that proper lubricant is maintained. 7. Fan Motors: Blowers with TEFC high efficiency motors to force cooling air through the cooler. 8. Compressor/Capacity Control: Variable speed controlled by the microprocessor. 9. Microprocessor Controller: Controller shall sequence compressors, monitor status, take action if an abnormal action occurs and display messages. The standby compressor shall start automatically if the pressure in the outlet header falls below 75 psig. And to stay on until the outlet pressure reaches 100 psig. COMPRESSED AIR SYSTEM 15481-4
10. The hot air from the compressor shall be removed by a duct and exhaust fan on the roof as indicated on the drawings. Operation of the exhaust fan shall be interfaced with the compressor control panel so that the fan operate continuously with operation of the compressor..e. Capacity: Delivery: 665-299 cfm of free air at 100 psig. F. Electrical Characteristics: 1. 90 kw. 2. 460 volts, three phase, 60 Hz., Maximum 174 FLA. G. Wiring Terminations: Provide terminal lugs to match branch circuit conductor quantities, sizes, and materials indicated. Enclose terminal lugs in terminal box sized to NFPA 70. H. Remote display required on a computer in the plant. Provide all cables, etc. required to interface. 1. 4-20 mili amps signal is required to read air pressure on the process computer. 2.4 AIR DRYER A. Manufacturer: Ingersoll Rand Model HB600. B. Other acceptable manufacturers offering equivalent products. 1. Kaeser. 2. Atlas Copco C. Type: Self contained, dual tower type containing absorbent desiccant, complete with drain connection, mufflers, pre-filters, after-filters and energy management system. D. Air Connections: Flanged inlet and outlet connections at same level, factory insulated. E. Operation: The controller (EMS) shall automatically switch with each desiccant chamber in service for 4 hours followed by a 4 hour regeneration cycle. The dryer shall operate as a heatless dryer in event of a heater or blower failure. F. Towers: ASME certified welded pressure vessels, spherical particle, non-corrosive activated alumina desiccant. Desiccant shall be removable without any disassembly of the dryer or interconnecting piping. G. Components: 1.Automatic float drain valve. 2. Pressure gauges mounted in each drying tower. 3. Pressure gauge for dry air cooling pressure. 4. Manual purge adjustment valve. 5. Safety relief valves on each tower. 6. Common alarm indication and dry contact relay. 7. Indicating power ON light. H. Accessories: 1. Energy Management System (EMS) to control operation to COMPRESSED AIR SYSTEM 15481-5
produce a constant dew point. 2. Pre-filters: High efficiency coalescing air filters to remove particles down to 1 micron and with a 0.1 ppm micron oil carryover at 65 deg. F. and 100 psi.. 3. After-filters to remove oil, water, dust, metal particles and pipe scale.solids shall be removed down to 0.1 micron with an oil carryover of 0.1 ppm at 65 deg. F. and 100 psi.. I. Capacity: 1. Discharge Air: -40 degrees F atmospheric dew point. 2. Rated Air Flow: 600 cfm. 3. Inlet Air Temperature 100 degrees F. 4. Pressure Differential from Inlet to Outlet: Minimum 100 psi. J. Electrical Characteristics: 1. 460 volts, three phase, 60 Hz. 2. 28.1 minimum circuit ampacity. 3. 30 amperes maximum overcurrent protection. K. Motor: Refer to Section 15170. L. Controls: Energy management system in NEMA 4 enclosure. M. Wiring Terminations: Provide terminal lugs to match branch circuit conductor quantities, sizes, and materials indicated. Enclose terminal lugs in terminal box sized to NFPA 70. 2.5 AIR RECEIVER A. Manufacturer: Ingersoll Rand. B. Other acceptable manufacturers offering equivalent products. 1. Kaeser. 2. Atlas Copco C. Receiver: Vertical, built to ASME regulations for a maximum operating pressure of 150 psi. Flange inlet and outlet connections. D. Fittings: Safety valve, pressure gage and drain cock. E. Tank External Finish: Beige enamel. F. Tank Internal Finish: Industrial epoxy. G. Size: 1. Diameter: 48 inches. 2. Length: 144 inches. 3. Capacity: 1060 gallons. 2.6 PRESSURE REDUCING STATION COMPRESSED AIR SYSTEM 15481-6
A. Manufacturer: Ingersoll Rand Model PacE II. B. Other acceptable manufacturers offering equivalent products. 1. Kaeser. C. Pressure Reducing Station: Consisting of automatic reducing valve and bypass, and low pressure side relief valve and gage. D. Valve Capacity: Reduce pressure from 150 psi to 7 psi, adjustable upwards from reduced pressure. 2.7 MOISTURE DRAINS A. All moisture drains shall be the automatic drain bucket type. PART 3 - EXECUTION 3.1 INSTALLATION A. Install compressor unit on concrete housekeeping pad. Refer to Section 03300. B. Install compressor unit on vibration isolators. Level and bolt in place. C. Make air cock and drain connection on horizontal casing. D. Install line size gate valve and check valve on compressor discharge. E. Connect condensate drains to nearest floor drain. F. Install valved bypass around air dryer. Factory insulate inlet and outlet connections. G. Install valved drip connections at low points of piping system. H. Install take offs to outlets from top of main, with shut off valve after take off. Slope take off piping to outlets. I. Install compressed air couplings, female quick connectors, and pressure gages where outlets are indicated. J. Install tees instead of elbows at changes in direction of piping. Fit open end of each tee with plug. K. Identify piping system and components. L. Valves at equipment drops and hose stations will be equipped with relief port to discharge downstream pressure when valve is closed. M. Each equipment drop shall be equipped with a 6 full pipe size dirt leg beneath the shut off valve. COMPRESSED AIR SYSTEM 15481-7
N. Each hose station shall be mounted 42 above finished floor and will be equipped with a shut off valve, tee with female quick disconnect, and 6 full sized dirt leg. Station will be of ¾ pipe. 3.2 FIELD QUALITY CONTROL A. Compressed Air Piping Leak Test: Prior to initial operation, clean and test compressed air piping in accordance with ANSI B31.1. B. Repair or replace compressed air piping as required to eliminate leaks, and retest to demonstrate compliance. C. Cap and seal ends of piping when not connected to mechanical equipment. END OF SECTION COMPRESSED AIR SYSTEM 15481-8