APPENDIX A. 15 DUAL WELD STATION FUME EXTRACTION with 30 WELDING BOOTHS

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Phyllis Griffith
5 years ago
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1 APPENDIX A 15 DUAL WELD STATION FUME EXTRACTION with 30 WELDING BOOTHS The Technology Center of DuPage is seeking bids for fifteen (15) dual weld stations (total of 30 individual welding booths) with fume extraction as described below. Companies or individuals submitting bids must include the name of the manufacturer and the model of the welding booth proposed in their bid. Those submitting bids must include the technical specifications of the welding booth proposed and the technical specifications provided by the bidder shall be used for comparison to the specifications required in the bid request. Bids submitted must include any costs for shipping to the Technology Center of DuPage, full assembly and onsite testing of the welding booths to be provided. I. Compliance Specifications 1. The welding booths shall be utilized primarily for weld smoke removal, but must be capable of use in other applications including but not limited to plasma cutting and steel grinding. 2. Each bidder must include in their bid information for 10 references that shows the proposed Weld Station in operation for 3 years or longer in educational facilities. 3. The 15 Dual Weld Station systems must be completely modular, utilizing one Power Drop and one Compressed Air Drop for two welding booths. A total of 30 welding booths are requested. 4. No DUCTING (Hard or Flex) is to be required or used with the welding booths. 5. No Central Collector is to be required or used with the welding booths. 6. The welding booths shall capture weld smoke from positional and overhead pipe welding. 7. Must use BACK DRAFT inlet only. Will not use a downdraft or overhead inlet (hood) method of capturing weld smoke. The BACK DRAFT method of smoke extraction is the ACGIH s (American Conference of Governmental Industrial Hygienist) preferred method. 8. Electrical Panel shall include the following: Shall be manufactured by an approved UL 508A and CAN/CSA C22.2 panel shop Shall comply with all UL 508A and CAN/CSA C22.2 certifications Shall have a NEMA 12 enclosure Shall utilize electrical breakers not fuses Shall utilize safe touch wiring per UL508A Shall utilize wire segregation per UL508A Shall utilize wire labeling per UL508A Shall utilize terminal labeling per UL508A Shall utilize fire retardant gasket Shall utilize strain relief incoming outgoing couplings 9. The welding booths shall use an integrated Variable Frequency Drive (VFD) that will perform the following: Shall be NRTL compliant in US & Canada Shall be CE Compliant Shall have a NEMA 12 Enclosure Shall be able to restart from an already spinning blower Shall have Cooling isolated from the Electronics Shall convert incoming fixed 3 phase power into a variable frequency and voltage for controlling the speed of 3 phase AC induction motors.

2 Shall produce an output waveform capable of handling maximum motor cable distances of up to 165 ft (unshielded) without tripping Shall be capable of DC resistor braking to dissipate energy into resistors or AC braking to dissipate excess energy back into the motor without the need to add external braking resistors. Shall have Soft Start capabilities Shall have 30% - 40% potential energy savings Shall Lower noise levels Shall automatically produce constant air to cloth ratio which dramatically increases filter life. 10. Will be illuminated from a High Intensity LED Light. 11. Shall use GA 100% recycled steel and GA 100% recycled steel for the booth. 12. Work area/work bench shall be adjustable to (3) heights and the ability to easily slide in and out from the cabinet. 13. Shall be a self contained unit consisting of the following: (One) four cartridge collector housing per two welding booths Two welding booths with back draft inlet One motor/blower system (4) filter cartridges positioned vertically with patented Down Flow Technology One on-line pulse on demand filter cleaning system, this device pulses filters in two stages based on delta P, no simple pulse timer will be used II. Configuration Specifications: 1. The dual weld station system shall consist of two welding booths with a single air filtration unit. 2. One air filtration unit shall be integrated and inseparable from one of the booths. 3. The booths shall have the ability to be placed in a side-by-side configuration or a back-to-back configuration. 4. The booth without the air filtration system shall have the ability to be placed on the left, right, or back side of the booth with the integrated air filtration system. 5. These configurations shall be bolted together and retain the ability to change configurations. NO DUCTING IS TO BE USED. 6. Shall be shipped in two main parts (Drive Booth and Secondary Booth) each separate booth is shipped completely welded and assembled. 7. The bid shall include installation with such installation to only require: Up righting the main drive booth Bolting the secondary booth to main drive booth Connecting secondary booth lights Attaching cover plates to unused inlets Sliding in the metal mesh filter and baffle filter Connecting three phase power drop Connecting compressed air drop Install Internal Baffle III. Housing Specifications 1. Shall be constructed of gauge steel with a welded body. 2. Shall have a powder coated exterior and interior finish. 3. Shall have an enclosed work space for each booth of 72 H x 58 W x 41 D. 4. Shall have a height of Shall have 2 access panels to motor/blower compartment. 6. Shall have 1 access panel to pulse valve compartment. 7. Each booth shall utilize back draft source capture filtration design 8. The booth shall utilize 5 levels of fire protection: 2 slide-in replaceable baffles, 2 metal mesh filters, 2 proprietary internal baffle plates, fire retardant filters and internal plenum.

3 IV. Features Specifications 1. The workspace in each booth shall be illuminated using High Intensity LED Lighting fed from a 24V DC power supply. 2. Each booth shall have a removable, adjustable worktable. The worktable shall be capable of (3) height adjustments and slide-out to extend the work space. 3. Each booth shall utilize back draft ventilation with removable and replaceable baffle spark arrestors and metal mesh. 4. Shall have a built-in acoustical lining in the blower compartment. 5. Shall utilize an air reservoir connected directly to the valves. The air reservoir shall have the ability to be connected to an air line regulated at 90 PSI using a 1 inch NPT connection. 6. Shall have a sound rating of 74 5ft ear level or OSHA Standard. 7. Shall be configured for electrical connections of 460VAC, 230VAC, or 208VAC three-phase power. Single phase is available. V. Filtration Specifications 1. Shall utilize vertically mounted cartridge type filters. 2. Filters shall have an SAE 726J initial filter efficiency of 99%, and an overall filter efficiency of 99.9% using AC fine dust. MERV Rating Filters shall have an ASHREA standard of initial atmospheric dust spot efficiency of 40% with an average atmospheric dust spot efficiency of 93%, and an average synthetic dust weight arrestance of 100%. 4. Shall utilize four fire retardant, 100% cellulose filter cartridges. Each of these filters shall provide 226 square feet of filter media for a total of 904 sq/ft of filter media. 5. Filters shall be retained using a screw down, T-Handle style system. 6. Shall utilize two baffler type spark arrestors in each booth. The baffle spark arrestors and metal mesh filters shall be 23.6 W x 23.6 H x D. 7. Shall utilize True Down Flow Technology patented filtration technology, 8. Shall utilize (4) vertically mounted cellulose filters x Shall have a self-cleaning filter design. 10. Shall utilize a reverse pulse cleaning technology. The reverse pulse cleaning must pulse air back through the filters to dislodge the filtered dust into the dust collection area. 11. Shall have the ability to pulse on demand. Simple timer shall not be used due to excessive compressed air usage. 12. Shall utilize a programmable pulse controller which has an integrated pressure differential display. 13. Shall be set up to perform a shut down pulse sequence automatically if the pressure differential across the filters reaches a set value. The filters shall be pulsed when the motor is stopped. 14. Shall be set up to perform an operating pulse sequence automatically if the pressure differential across the filters reaches a set value. The filters shall be pulsed when the motor is running. 15. Shall utilize a pulse controller which measures the pressure differential across the filters and controls (2) 1 inch valves. The valves must be actuated independently. VI. Electrical Specifications 1. Shall utilize an integrated interlocking disconnect switch which disconnects all power to the unit. 2. Electrical box shall be at a height that can be maintained at floor level. 3. Shall utilize a momentary on/off button located on the electrical box at eye level. 4. Shall utilize a programmable pulse controller, which is operated on 24VDC power fed from an integrated power supply. 5. Electrical Panel shall include the following: Shall be manufactured by an approved UL 508A and CAN/CSA C22.2 panel shop Shall comply with all UL 508A and CAN/CSA C22.2 certifications Shall have a NEMA 12 enclosure Shall utilize electrical breakers not fuses Shall utilize safe touch wiring per UL508A

4 Shall utilize wire segregation per UL508A Shall utilize wire labeling per UL508A Shall utilize terminal labeling per UL508A Shall utilize fire retardant gasket Shall utilize strain relief incoming outgoing couplings VII. Motor/Blower Package Specifications 1. Motor size shall be 5 HP running at 3450 RPM at 60Hz supply power. 2. Blower shall be a backward incline, airfoil high efficiency plug type blower. 3. Shall utilize a direct drive method for a motor/blower design. No gearing or pulley system shall be utilized. 4. Shall achieve 4000 CFM using the specified motor and blower at a pressure drop of 4 inches of water. 5. Shall have a premium efficiency motor. VIII. Fire Prevention 1. System shall include the following CAA Smart Safe System. This system is to be located inside the main drive and secondary booth. The layers of this fire prevention method shall include: Reverse flow spark baffle Metal mesh spark baffle Drop out area 1 Internal panel spark baffle Drop out area 2 Down flow technology Fire retardant filters IX. Additional Required Features MUST be capable of starting the motor when first initial welding arc is struck at the work station and shutting off the motor after 15 minutes of welding inactivity. MUST have a sleep function can be set as described in the Option Mode. The sleep function is set to last 5 minutes by default which can be adjusted in one minute intervals up to a maximum of 60 minutes. When the one minute timer ends, sleep mode is activated. During this time, the VFD ramps down the speed of the motor to about 20% of the maximum speed. During this time, the drive uses only 2% of the energy, but is able to maintain the blower speed and eliminates much of the power required at the unit start up. 1. VFD (Variable Frequency Drive) Shall be NRTL compliant in US & Canada Shall be CE Compliant Shall have a NEMA 12 Enclosure Shall be able to restart from an already spinning blower Shall have Cooling isolated from the Electronics Shall convert incoming fixed 3 phase power into a variable frequency and voltage for controlling the speed of 3 phase AC induction motors. Shall be a six-pulse input design, and the input voltage rectifier shall employ a full wave diode bridge. Shall include a full-wave diode bridge rectifier and maintain a displacement power factor of unity regardless of speed and load. Shall produce an output waveform capable of handling maximum motor cable distances of up to 165 ft (unshielded) without tripping Shall have conformal coated printed circuit boards meeting Class 3C3 as a standard for resistance to chemicals and environment.

5 Shall be capable of DC resistor braking to dissipate energy into resistors or AC braking to dissipate excess energy back into the motor without the need to add external braking resistors. Shall include a loss of follower function to detect the loss of process feedback or reference signals with a live zero value, with a user selectable choice of responses (freeze speed, set speed, max speed, stop, stop and trip. Shall have Soft Start capabilities which allows the motor ramp up to speed rather than across the line starting contactors. This eliminates starting amperage spikes as well as inertial effects of the blower. In non-vfd systems these spikes can be as high as eight times the full load amps. Shall have 30% - 40% potential energy savings Shall Lower noise levels Shall automatically produce constant air to cloth ratio which dramatically increases filter life. 2. REDUCED MAINTENANCE The Weld Station will use a Variable Frequency Drive (VFD) to manage the motor's operating speed. This in turn controls the airflow inside the unit and allows for more efficient operation through the Pressure Tracking feature. This reduces the impaction of dust upon the filters inside the unit. The reduced impaction means the dust can be cleaned easier and every cleaning cycle is more efficient. This feature can increase the life of the filter by up to 100% which reduces maintenance time and costs. 3. REDUCED NOISE Noise is created inside a unit by moving parts such as the blower wheel and moving the air through the unit. In the Weld Stations to be provided the air flow needs to be managed through the blower control. By managing the airflow, the noise due to moving parts and moving air is reduced. Measurements will show that the noise level with clean filters can be dropped from 74 db to 61 db. This is a reduction of 16 times lower. X. Accessories Specifications to be included with weld stations: Risers: Lift booth internal height to 7 for overhead pipe welding 2. Weld Curtains: (attachable) 7 ft w x 29 d frame with yellow curtain and heavy duty rings

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