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DaimlerChrysler Construction StandardsAME-PT Plants

Revision Date: 06/11/07

SECTION 15889 – Oil Mist / Dust Collection Systems

PART 1 - GENERAL

1.1 SUMMARY

A. It is the purpose and intent of these specifications to establish guidelines for the design, construction, installation and testing for conformance of oil mist and/or dust collection systems that are purchased and supplied by DaimlerChrysler AMEPT (Advanced Manufacturing Engineering – Power Train Operations).

B. A typical oil mist/dust collection system consists of the machine enclosure(s), the ductwork system and the oil mist/dust collection/filtration unit. This system MUST contain the vapor and mist or dust to a target exposure level of 0.5 mg/m3 around the machine(s). Air discharged from the collector, whether ducted to the outside of the building or re-circulated in the plant, must be of such quality to meet or exceed the levels established by local, state or Federal governmental agencies and if more restrictive shall override limits established elsewhere in this specification. The collection unit’s filters MUST also provide for a minimum of 8,760 hours between filter changes with a 24 hour/ 7 days per week operation.

C. Related Sections include the following:

1. Industrial Ventilation, a Manual of Recommended Practice" published by the committee on Industrial Ventilation - American Conference of Governmental Industrial Hygienists (latest version).

2. Considerations for the Design of Exhaust Ductwork for Machine Tool Enclosures - ANSI B11 TR 2-1997.

3. Ventilation Guide For Automotive Industry – Section 6 “Machining Processes” published by Heating/Piping/Air Conditioning, HPAC Engineering.

4. SMACNA (Sheet Metal and Air Conditioning Contractor's National Association) Industrial Duct Construction Standards for round, rectangular and tapered ductwork systems.

5. Department of Consumer & Industry Services Bureau of Safety Regulation Consultation Education & Training Division “Exhaust Recirculation Policy.

6. Department of Public Health Chapter III-Health Hazard Control Measures Part I-Ventilation control. (for Michigan available at http://www.michigan.gov/documents/CIS_WSH_r3101_7.htm)

7. Division 07920 Section "Joint Sealants" for fire-resistant sealants for use around duct penetrations and fire-damper installations in fire-rated floors, partitions, and walls.

8. Division 15081 Section "Duct Insulation" for plenums, sheet metal and flex duct insulation.

9. Division 08311 Section "Access Doors" for wall- and ceiling-mounted access doors for access to concealed ducts.

10. Division 15820 Section "Duct Accessories" for dampers, sound-control devices, duct-mounted access doors and panels, turning vanes, and flexible ducts.

OIL MIST/DUST COLLECTORS SPECIFICATION15889 Oil Mist/Dust Specification.doc of 14

http://www.michigan.gov/documents/CIS_WSH_r3101_7.htm



11. Division 15950 Section "Testing, Adjusting, and Balancing" for air balancing and final adjusting of manual-volume dampers.

12. AMEPT Cad Standards.

(https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.html)

13. DOC - 100109 - 10-01-02 Oils/Coolant Tables 1-12 “Recommended Mist Control Airflow Based upon Machine Horsepower” reprinted with permission from Helical Dynamics, Inc. – Plymouth, MN see tables below.

14. AMEPT Powertrain Control Standards.

15. Division 09910 Painting.

16. Division 15980 Total Maintenance Spare Parts.

17. AMEPT Machine & Tool Specifications Section 8 - Dry Floor & Mist Guarding

18. Safety Standards ( https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.html)

1.3 SUBMITTALS

A. Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for DaimlerChrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.

B. DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.

C. All floor plan drawings must show the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.

D. The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to DaimlerChrysler prior to altering the machine, ancillary equipment or orientation.




E. All engineering drawings shall be developed using the CAD software and version agreed upon in CAA. All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.

F. Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.

G. The OEM shall provide a recommended spare parts list for all of the supplied machines. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS (Total Maintenance System) electronic format refer to web site https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htm

H. Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.

I. Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire

J. All installation submittals must show code clearances such as 42 inches from front of a panel to any obstruction and 48 inches from the fronts of two opposed facing panels.

K. All means of egress between equipment must have a minimum of 28 inches.

L. The OEM shall provide a recommended spare parts list of this machine. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS electronic format (contact DCX plant engineer).

M. Equipment layouts per DaimlerChrysler CAD standards showing all utility requirements including electrical, drains, air flow monitor insertion tubes. Layouts must show phantom lines showing recommended maintenance clearances for motors and air flow monitor tubes etc.

N. Quotation must list equipment Horsepower, FLA (full load amps), RLA (running load amps)

O. Compressed air required in CFM at pressure.

P. All piping connections including drains, sizes, locations including elevations.

Q. Proposals to list similar systems installed in last five (5) years with this type of equipment (your proposed collectors to DCX supplied machine tools and filtration equipment, see spreadsheet on sheet 5 & 6)

R. Supplier to provide schematic concept duct design sketches.

S. Alternate system design are accepted, however must quote base design.

T. Supplier to state max dBa noise level of system.

U. Provide foot print information for each type/size of collector units.

V. Mean time to complete a full filter change.


https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htm



W. Cubic volume and weight of spent filters.

X. The successful oil mist or dust collection supplier must design the oil mist or dust collection ductwork, which shall be reviewed for structural coordination and lighting coordination by a registered professional engineer for the state in which the work is being performed.

Y. The Supplier shall contract with the Engineering firm retained by DaimlerChrysler so as to coordinate the design with other utilities, and cranes, and structural supports.

Z. All catalog cuts and lists of materials and all components which are shipped loose must be identified as such and submitted to both the Architect Engineer and the appropriate DaimlerChrysler project engineer. The Architect Engineer will review the drawings within (5) business days with comments. The Architect Engineer will review these comments and obtain any owner comments from the appropriate DaimlerChrysler project engineer. The Architect Engineer will return these to the supplier for incorporating any changes as so noted and then revised drawings shall be submitted for review until accepted by all parties involved. Note, corrections or changes indicated on such drawings shall not be considered as an order to perform extra work. Any and all credits or additions to Purchase Orders will be authorized from Purchase Order Changes.

AA. If code numbers or letters are used to identify specific design of submitted equipment and components and such code designations are not clearly and unequivocally defined in the manufacturer’s published literature, a glossary shall be submitted identifying in complete detail the meaning of number and letter combinations used.

BB. Include all safety devices such as safety relief valves and circuit breakers or fused disconnects for motors.

1.2 QUALITY ASSURANCE

A. Installations shall comply with all National and local codes.

B. Installations shall comply with DaimlerChrysler standards.

C. Provide recommended settings for adjustable components.

D. Warranty shall be at a minimum 1 year from V1 Launch date of product.

1.3 DELIVERY, STORAGE, AND HANDLING

A. Installation Contractor must inspect all equipment prior to unloading and all damage must be reported on the shipper and to the appropriate DaimlerChrysler project engineer.




B. All equipment delivered to the project site must be unloaded promptly and placed in it’s intended rough in location or at a minimum inside of a facility which provides protection from the elements.

C. All equipment must be inspected to assure that the equipment drawings are included with the shipment which identifies the required information to allow a quick and accurate installation. Failure to find these drawings must result in notification of the appropriate DaimlerChrysler project engineer.

1.4 INTRODUCTION TO GOOD DESIGN PRACTICES

A. Metalworking processes create numerous types of airborne pollutants. The mist collection system must be able to handle liquid particles, solid particles, and coolant vapor.

B. There are many factors that need to be considered, including type of machining process, machine load and unload process and all openings and location of openings. The Machine tool suppliers recommend oil mist capture air flows in their “Appendix 6 Utility summaries. This should be used as a basis for determining the oil mist or duct collection air flows but shall not be the sole factor for determining the capture air flow. Best practices shall prevail where questionable or seemingly insufficient capture air flows are identified by machine tool suppliers.

1.5 ALTERNATE PRICING

A. As an option, the oil mist / dust collector suppliers may suggest recommended design air flows which may differ from the above described design recommendations. All recommendations must be based on experience and test data. Any recommendations must guarantee compliance with attainment of 0.5mg/m3 or better for the plant environment.

B. Any such recommendations must identify energy reduction results with projected annual energy savings. Provide experience references and documented test data for similar installations with the use of the same machine tool equipment as that which is used on the subject program(s).

C. All recommendations must not compromise the recommended flux rates for the filter media. All recommendations must provide for HEPA filter service life of 8760 hours. If during the life of equipment if it is found that media life is not in compliance, the oil mist / dust collector supplier shall be responsible for all corrective costs and shall be responsible for all media replacements until such time that full service life is attained.

D. Provide alternate pricing for variable speed drives for all mist or dust collection fan motors, refer to details in part 2 of this specification

E. Use of direct drive fan motors if approved must be listed as an alternate price.

PART 2 - EQUIPMENT

2.1 Machine Enclosures

A. Machine builder to provide an enclosure that serves as a box around the machine (note, aspiration openings may be required). The mist or dust inside the metal cutting compartment insofar as possible shall be isolated from the plant’s atmosphere especially during




loading/unloading of the parts being processed. To assure that pollutants will NOT escape the machine enclosure, a collection system of minimal size shall be provided to place the box under a negative pressure at all times.

B. Important factors about the design of the machine such as the total area of all openings in the enclosure and location of openings and length of flume and turns of flumes beneath or beyond equipment impact the collection air flow requirements.

C. The location and size/shape of the extraction point(s) are also important so that chips and coolant stay in the enclosure. The use of pre separation units and deflectors and spark arrestors are critical to system performance.

D. Machine enclosure drawings (including integration information to the machine)MUST be submitted to the owner for review and approval “prior to build” regardless of machine type or supplier – NO EXCEPTIONS.

E. The Following is the DaimlerChrysler Dry Floor Guarding Inspection Test Procedure:

1. This process identifies a simple procedure to verify that machine tool equipment is properly dry floor guarded.Before runoff of the equipment on the supplier’s floor they shall perform this test and validate the machine guarding satisfies the test before “:Authorization to Ship”Test Procedure:

a .Install a high wattage (100 watt min.) light within the machine enclosure using either the chip discharge chute or oil mist opening.

b. Close all doors and gantry hatches.

c. Reduce or shut off ambient lighting in the area of the machine tool equipment.

d. Visually inspect the complete exterior of the machine and identify with an erasable marker or chalk or other means to temporarily identify areas where light leaks out of the enclosure. (pay particular attention to areas where cabling or tubing enters the guarding) (note, a ladder or scaffold will be required to inspect the top of the guarding)

e. If leaks are identified, the Supplier shall design and implement Corrective Action and a validation test shall be preformed prior to authorizing to ship. Corrective action shall utilize flashing or coolant seals or a combination of both.

2.2 Ductwork




A. Philosophy - The ductwork system is the transport (conveying) system used to connect the machine enclosure(s) with the oil mist or dust collection/filtration unit (air cleaning device). It is NOT the intent of the ductwork system by design to remove oil from the machining operations. Simply stated, air is drawn into the machine enclosure through the aspiration openings. Contaminants (i.e.; oil mist, smoke, dust or particulate) generated from the metal cutting process are drawn into the ductwork system and carried in the air stream to the collector. The air is then filtered and discharged back into the plant (re-circulated) or ducted outside.

B. Wet system - On machines where oil based coolants are used, a plenum type ductwork system shall be used with a carrying velocity less than 2,000 fpm. The plenum duct shall be of minimum 16 gauge round painted hot rolled steel and be slightly pitched toward the machine for self draining. Three inch (3”) drain traps on forty foot (40’) centers shall also be provided only where natural drainage does not occur back to the machine connections. Drain lines shall return the coolant back to the machines. Cleanout doors shall be placed just upstream from each drain point or at 40’ centers. Ductwork drops to the machines shall make a transition with the plenum duct from the bottom of the plenum duct only (this allows for drainage back to the machine tool without the use of drain traps.) Ductwork drops shall be of minimum 16 gauge round painted hot rolled steel. Connections to the machine enclosure shall be with white, reinforced polyvinyl chloride (PVC) flex duct. All ductwork connections shall be with standard flanges on ten foot (10’) centers and shall be drip free. Gaskets shall be oil/coolant resistant “Viton” or Geltek by the 3M company. The entire ductwork system shall be capable of being balanced. Drip proof blast gates shall be provided. Prior to entry into the mist collector, an oil mist pre-separation unit called a “Pipeclean” may be installed. This unit is available from Rerucha Gmbh/Herding Filtration (248) 673-4514 and will be used to enhance condensing of the vapor cloud and minimize the load on the oil mist collection/filter unit. In All cases provide alternate pricing for these Pipeclean units. Similar pre-separation via centrifugal tubes or other technology may be proposed as an alternate.

C. Dry system - On dry machining operations where dust is generated, a tapered type round ductwork system shall be used and a 3,500 – 4,000 fpm carrying/transport velocity maintained. Settling in the ductwork system is to be avoided. Branch entries shall be 30 degrees maximum. Elbows shall be as smooth as possible and have a centerline radius of 2 – 2½ duct diameters. All ductwork shall be of 14 gauge painted hot rolled steel. Cleanout doors shall be installed in the sides of the duct and shall be on twenty foot (20’) centers. All ductwork connections shall be with sealed standard flanges. Gaskets shall be “Viton” or Geltek by the 3M Company. Blast gates shall be abrasion resistant.

D. Ductwork supports (wet or dry systems) – Main duct supports shall be saddle type strap clamps around the duct using bolts, nuts and washers. Duct supports shall be on ten foot (10’) centers maximum. Hangers shall be from threaded rod or galvanized steel or stainless steel cable. Attachment to building steel shall be by clamping; welding or drilling is NOT permitted. All necessary attachments to machinery shall be by bolting. All machine attachment locations and types must be coordinated with the machine supplier and the responsible DCX Process Engineer..

2.3 Oil Mist/Dust Collection Equipment

A. Philosophy – Oil mist and or dust collection equipment is used to filter the air drawn from a machine enclosure, hood, or welding booth to an acceptable performance level, and return that air to the plant or to the outside atmosphere. Because of the high cost of filter replacement and the cost of special handling of the contaminated, spent filters in a land fill, it is a MUST to obtain extended filter life. In addition, ever increasing energy costs mandate that the ”total cost of operation” or “life cycle cost” of any new oil mist or dust collection system be as low as possible.




B. Total cost of operation – The total cost of operation shall be calculated as follows :1. Capital cost of equipment including installation/ 10 years = $ _________2. Cost of energy usage over(12 months) for:

electricity = $ _________water = $ _________

3. Filter disposal cost over(12 months) pro-rated = $ _________4. Cost of replacement filters = $ _________5. Labor to change filters = $ _________6. Labor to maintain unit for(12 months) = $ _________

Total annual cost = $_________

C. Oil Mist Collectors (Performance) – The bottom line regardless of the type of collector chosen for the operation is compliance to clean air standards and filter life. A maximum of 1.0 mg/m3 of airborne contaminants shall exit the collector and be exhausted outside of the building with a non-recirculating system. This is with a 20 mg/m3 loading for 8,760 hours. A maximum of 0.5 mg/m3 of airborne contaminants averaged over an 8 hour period shall exist in the plant with the collector recirculating inside of the building. This is with a 20 mg/m3 loading for 8,760 hours. The cleanable or replaceable filters in the collector, including the HEPA filter, will NOT need service or changing for a minimum of 8,760 hours of continuous operation in production. During this time the airflow CFM shall not drop below the specified design CFM.

D. The collector shall have stages and can be any combination of the following types: drop-out box, mesh or screen filter, pre-filter panel, fiber filter bed, helix type permanent tubes, sintered polyethylene permanent media, fiberglass pocket filter, fiberglass bag filter or HEPA ASHRAE 95% DOP filter. The cleanable or replaceable filters in the collector, including the HEPA filter, shall NOT require any service or changing for a minimum of 8,760 hours of continuous operation (in full production). This “guarantee” shall be put in writing as part of the original quotation (with NO exceptions). The permanent media life shall be at least 5 years and the supplier shall put in writing the expected life of this media.

1. Recommended sources (for oil mist collectors) – * Herding – Waterford, MI.* Absolent - c/o Industrial Air Controls, Rockford, MI.* Monroe Environmental Corporation, Monroe, MI.* CECO Environmental, Defiance, OH.

2. Recommended sources (for dust collectors) – * Herding, Waterford, MI.* Monroe Environmental Corporation, Monroe, MI.* Donaldson Company – Torit Division, Minneapolis, MN.

E. Oil Mist Collectors Filter Flux Rate – shall meet minimum industry standards but not exceeding 350 CFM/square foot for conventional type filters or 4.00 CFM/square foot for “Sintered Polyethylene permanent” type design.

2.4 Oil Mist Construction




A. Oil Mist Collector (Construction) – The collector housing shall be of 12 gauge painted hot rolled steel ASTM A30 minimum and shall be equipped with lifting lugs. The collector frame shall be of structural steel shapes with bracing as required to suit the unit’s size. The collector floor shall be pitched to a 2” NPT coupling (minimum). A drain trap shall be supplied with the unit to overcome the fans static pressure. Access doors shall be provided for each stage of filtration and to the floor pan area for inspection and clean-out. All access doors shall be gasket sealed. Gaskets shall be resistant to all oils and coolants. Replaceable filters shall have positive sealing gaskets with adjustable latching release mechanisms.

B. The fan shall be a centrifugal AMCA class II backward inclined industrial type with a drain plug. The fan MUST comply with DaimlerChrysler Corporation sound level and vibration specifications and must be housed as necessary to meet sound levels less than 80 DbA. The fan shall be sized to run at the mid-range of the fan curve. The fan if belt driven shall be vibration isolated from the collector housing at the inlet and the fan mounting surface. The fan belt guard if belt driven must meet O.S.H.A. requirements. Belts and motors shall be to DCX standards and be readily available. All replacement belt sizes must be clearly identified (labeled) external of the belt guard on the housing. The fan motor shall be U-frame premium efficiency T.E.F.C.B.B. or premium efficiency T–frame, 480 volt, 3-phase, 60 cycle and must meet or exceed all applicable DCX Controls Standards and Specifications. Alternate pricing will be considered for direct drive motors. (Provide a technical justification letter with bid). Fan bearings shall have an L10 bearing life of 100,000 hours. Bearings shall be lubricated per the AMEPT Controls Lubrication Specification.

E. The static pressure loss across all filter stages shall be with Dwyer photohelic gauges and be hard piped to the collector housing.

F. The main collector electrical enclosure shall be NEMA 12 with combination disconnect/starter, control circuit transformer, start-stop pushbuttons and push to test run lights. Enclosure shall be mounted in a remote location and field wired to the fan motor. The solid state timer and the solenoid junction box enclosures shall also be NEMA 12. All electrical components MUST meet or exceed DCX and J.I.C. standards. The electrical control panel shall have a local and remote fault light to indicate “dirty filters” and a local and remote alarm beacon to indicate collector fault. NOTE: Each unit must be provided with an Ebtron GT x116 transmitter package and properly sized duct flow sensor probe for the discharge side of the fan. The unit shall be viewable without opening the electrical cabinet. This air flow monitor shall control the variable speed drive if the alternate for variable speed drives are selected and shall annunciate to the floor operator via a stack light in the event airflow drops below 90% of design flow. (For required signals and interlocks see AMEPT Control Standards).

G. Note, lockout valves must be provided with equipment and all units must include DaimlerChrysler lockout graphics.

H. Flow Measurement and Control – Provide a thermal dispersion air flow measuring system to control the variable frequency drive system. The device shall consist of an “Ebtron” GT x 116- PC probe mounted in the duct work per the manufacturers recommended location from transitions and elbows. Transmitter sensors shall be type GP-1. Microprocessor shall be mounted to read air flow through a lexan cover on the panel. Control signal shall be 4-20ma and power to processor shall be 24VAC. Accuracy shall be +/- 3%. Unit shall come complete including plenum rated cable. Control shall be set up to alarm if air flow drops below 90% of design flow rate. The alarm shall designate that filters require service.

I. Variable Frequency Drive – Provide alternate pricing for variable frequency drive to maintain a designated air flow as set from the flow measurement control. Provide alternate pricing for each of the following drive options:




1. SQD

2. Allen Bradley

3. Siemens

4. Yaskawa

Varible Frequency Drive shall control from 4-20ma signal.

J. Stack Lights

Mist / Dust Collector machines shall have stack lights with two (2) colors red and green. Refer to Controls Standards for details

Stack light function chart:

2.5 Dust Collector (Performance)

A. Regardless of the type of collector chosen for the operation is compliance to clean air standards and filter life. A maximum of 1.0 mg/m3 of airborne contaminants shall exit the collector and be exhausted outside of the building with a non-recirculating system. A maximum of 0.5 mg/m3 of airborne contaminants shall exist in the plant. The final filter section shall allow for insertion of 95% HEPA DOP at 0.3 micron. Air Permit restrictions shall dictate if HEPA filters are to be furnished with the equipment. The cleanable or replaceable filters in the collector, including the HEPA filter, will NOT need service or changing for a minimum of 8,760 hours of continuous operation (in full production). This “guarantee” shall be put in writing as part of the original quotation (with NO exceptions). The collector shall have a pneumatic Pulse-Jet type or similar self cleaning system for continuous, automatic on-line cartridge cleaning. Permanent media shall be sintered teflon impregnated polyethylene.

2.6 Dust Collector (Construction)

A. A typical dust collector assembly shall include structural supports, enclosure, hopper, access platform, filtration, fan, power train, belt guard, screw conveyor rotary air lock, static pressure gage(s), electrical components and noise attenuation facilities.

B. Structural supports to be 6” (minimum) structural steel beam and cross-braced with structural steel angle or channel. The enclosure shall have a minimum of two (2) sections, lower and upper. The lower section shall house the filter media (cartridge or permanent filters). The upper section shall house the pulse-jet blow tubes and HEPA filter enclosure and have an exhaust outlet and inspection door. All enclosure connections MUST be dust tight. The enclosure shall be fabricated from 12 ga. hot rolled steel with structural angle flanges and reinforcement (as required) and have lifting lugs. Access and inspection doors shall be fabricated from 12 ga. hot rolled steel and shall have heavy duty catches, latches,


LightOFF

Light SolidON

Light Blinking1sec ON1sec OFF

Red No Fault Fault N/AGreen Not in Cycle Machine in Cycle N/A



handles and hinges for quick opening. All doors shall be fitted with dust tight gaskets glued securely in place.

C. The storage-discharge hopper shall be fabricated from 12 ga. hot rolled steel with structural angle flanges and have a slope of 60 degree (maximum) slope from horizontal. The hopper bottom shall be equipped with a screw feeder and rotary airlock (for units 10,000 cfm or larger) or a rotary airlock and drum adapter (for units 10,000 cfm or smaller) interlocked with the blower fan. The hopper shall have an air inlet with a diffuser to absorb the impact of high velocity dust particles and distribute the flow of incoming air. The diffuser shall be of abrasion resistant plate or be lined with high density polypropylene. The hopper to enclosure connection MUST be dust tight. Your proposal shall provide the required dumping hoppers or 55 gal. drums to collect the refuse discharged from the collector.

D. Access platform to inspect or service the filters and the pulse-jet solenoid valves shall be O.S.H.A. approved assembly and shall include access ladder or stairs.

E. Cartridge and/or permanent filters MUST be self-positioning, individually gasketed and cam-locked for cartridges and minimal bolts for permanent filters in place for a dust tight seal.

F. Blower fan shall be a centrifugal type and selected for its maximum efficiency range for specified ducting and filter S.P.W.G. loadings. The fan shall NOT generate sound pressure levels over 80dba and MUST comply with the DCX “sound level specifications”. The blower fan if belt driven shall be vibration isolated from inlet duct and framework. All replacement belt sizes must be clearly identified (labeled) external of the belt guard or the housing. The fan motor shall be U-frame premium efficiency T.E.F.C.B.B. or premium efficiency T–frame, 460 volt, 3-phase, 60 cycle and must meet or exceed all applicable DCX controls standards and specifications. Alternate pricing will be considered for direct drive motors. (Provide a technical justification letter with bid). Fan bearings shall have an L10 bearing life of 100,000 hours. Bearings shall be lubricated per the AMEPT Controls Lubrication Specification.

G. The power train for belt driven units shall include Woods or Browning fixed ratio conventional V-belt drive components with Sure-Grip bushings. Belts shall be B or C section chosen for continuous service with a 1.5 safety factor.

H. Drive belt and chain guards MUST meet or exceed O.S.H.A. and DaimlerChrysler standards and shall include heavy duty catches, latches, handles and hinges for quick opening and easy access.

I. Static pressure gage shall be Dwyer Photohelic switch/gage and manometer series 3000 type with a 0”-10” S.P.W.G. dial range (or approved equal). Gage shall be hard piped to collector housing.

J. Flow Measurement and Control – Provide a thermal dispersion air flow measuring system to control the variable frequency drive system. The device shall consist of an “Ebtron” GT x 116- PC probe mounted in the duct work per the manufacturers recommended location from transitions and elbows. Transmitter sensors shall be type GP-1. Microprocessor shall be mounted to read air flow through a lexan cover on the panel. Control signal shall be 4-20ma and power to processor shall be 24VAC. Accuracy shall be +/- 3%. Unit shall come complete including plenum rated cable. Control shall be set up to alarm if air flow drops below 90% of design flow rate. The alarm shall designate that filters require service.

K. Variable Frequency Drive – Provide alternate pricing for variable frequency drives to maintain a designated air flow as set from the flow measurement control. Provide alternate pricing for each of the following drive options:




1. SQD

2. Allen Bradley

3. Siemens

4. Yaskawa

Varible Frequency Drive shall control from 4-20ma signal.

L. For pneumatic air header and lockout requirement refer to DaimlerChrysler Corporation fluid power and control standards. Note, lockout valves must be provided with equipment and all units must include DaimlerChrysler lockout graphics.

M. The dust collector unit will be supplied with a 3/4" Schrader Bellows Super 99 coalescing filter (or approved equal) with automatic drain to be installed just ahead of the unit’s compressed air header.

N. Screw feeder (for large collector units) shall be by Link Belt or approved equivalent. Screw feeder trough to be 12 ga. (minimum). Gear reducer and drive motor to be sized for continuous operation and shall have a 1.5 service factor over design horsepower.

O. Rotary airlock feeder shall be heavy duty, furnished by Roto-Flo or approved equivalent. An O.S.H.A. approved guard shall be installed at the discharge end to prevent contact with the rotor vanes.

P. 55 gal. drum adapter (for units smaller than 10,000 cfm) shall have a flex hose with quick disconnect.

2.5 FIRE PROTECTION

A. Fire protection is required on oil mist collection systems using low flash point cutting oils. Install either a C02 system to protect the operators/personnel, machinery, ductwork and collector.

B. The collector design shall be such to allow the addition of fire doors or baffles/dampers, which can be automatically closed by means of spring loaded and/or gravity powered forces. This will ensure activation in the event of a full loss of all power including electrical or pneumatic. The intent is to isolate the components of the collection system.

C. Additionally, the collector system shall be capable of receiving communication signals (dry contacts) from other systems of notification of fire danger. Thirdly, the collector control system shall be designed to coast down and/or apply breaks to motors or fans, if required due to designed enclosure pressure limits for quick stopping and communicate to other warning devices such as alarms (visual and audible).

D. Each system must be reviewed with DCX Corporate Security – Fire Protection Division and as necessary with the approval of the DCX insurance carrier. Each individual system shall be reviewed on a case by case basis to determine any special requirements. (Refer to AAME Plant Engineering and Building Group specification Sections 13900 – Fire Suppression and Section 13905 –FM 200 & CO2 Fire Extinguishing System)

2.6 CONTROL CONCEPT




A. Mist or Dust collectors must be interlocked with the machine tool so that the machine tool cannot operate unless the mist collector is functioning.

B. For mist collectors this may be accomplished via hard interlocks between machine tools and mist collectors or between coolant system supply valves serving machines or direct to the coolant filter system.

C. Dust collectors must interlock to all machines being served by that particular collector. Any sequencing control must allow one or more machines to shut off but still provide for dust collection from the machine tools remaining in operation.

D. If a mist or dust collector fails to start, or is locked out, the logic in the machine tool shall not allow the machine tool to start.

E. The use of a building energy management system to perform this function is acceptable as long as coordination occurs between machine tool suppliers, building automation supplier and coolant filter suppliers.

F. The proposal must clearly state the method utilized to shut down equipment to conserve energy and must clearly state which interlock method will be utilized.

PART 3- EXECUTION

3.1 EXAMINATION

A. All Oil mist & dust collection equipment shall be inspected by a DaimlerChrysler Plant engineer prior to shipment. Equipment shall be operated to verify noise criteria and performance is as expected and that all Authorization to Ship information is complete. Do not ship equipment until Authorization to Ship is complete and signed by all required parties.

B. Installing contractors must examine all non priced proposals for clarification of shipped loose items and field mounted items.

C. Installing contractors shall examine shipments prior to unloading and report all damaged or missing items to the appropriate DaimlerChrysler project engineer.

D. Installing contractors shall examine roughing-in location for equipment for properly cured foundations and for available central utilities.

E. Installing contractors shall examine utilities to verify what other equipment will be affected by any utility tie-ins. Coordinate these tie-ins so as not to affect scheduled production or scheduled debug or scheduled qualifications.

F. Installing contractors shall examine submittal drawings to be sure they have been approved.

G. Installing contractors shall proceed when conditions have been verified and coordinated.

3.2 APPLICATION

A. Installation Contractor to install equipment, in accordance with designations and locations indicated on Drawings and per the directions of the manufacturers representative.




B. Manufacturer’s representative shall include the cost of supervising the installation including checking for proper fluid fills and providing all supervision of all check test and start of equipment

C. Rough in equipment, verify location and final level equipment prior to installing utilities

D. Install utilities and supports for equipment and auxiliaries.

E. Mark all leveling devices once final leveling is complete to record the proper set points of all jam nuts.

F. Extend all mist drains and auxiliary drains to the nearest trench drain or floor sump or to Flume/coolant system which the mist collector serves. NOTE: Do not cross contaminate mist drains to coolant systems for which the mist collector is not connected.

G. Purge all air from all lube lines and fill all fluids with DaimlerChrysler approved fluids or greases per the manufacturer’s recommendations.

H. Attach Temporary (paper) Safety Placards prior to power up and Final Safety Placards when available.

3.3 ADJUSTING, CLEANING AND LABELING BY INSTALLATION CONTRACTOR

A. Adjust air flow control to manufacturers recommended flow rate and verify if alternate is selected that variable speed drive operates to maintain air flow +/- 10% of design air flow. Refer to testing adjusting and balancing specifications.

B. Label all piping and voltages per DaimlerChrysler standards.

C. Clean all equipment and touch up paint as required for final acceptance from DaimlerChrysler.

3.4 PROTECTION

A. Provide protective covering for stored equipment.

B. Do not allow use of equipment for temporary facilities, except when approved in writing by DaimlerChrysler

END OF SECTION


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