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Manual - Amico
Source Equipment Air Compressors Source Equipment Table of Contents 6.1 How To Use This Section..................................................................................................................................................................................................1 6.2 Introduction.............................................................................................................................................................................................................................1 6.2.1 The Four Essentials To Building a Medical Air System.............................................................................................................................1 6.3 Steps to Implementing The Medical Air Systems............................................................................................................................................2 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 Discovery........................................................................................................................................................................................................................2-3 Design...................................................................................................................................................................................................................................3 Plant Sizing....................................................................................................................................................................................................................3-4 Altitude Adjustments..................................................................................................................................................................................................4 Compensating for “Future Expansion” .............................................................................................................................................................5 Plant Selection................................................................................................................................................................................................................ 5 General Layout............................................................................................................................................................................................................5-6 Specification.....................................................................................................................................................................................................................6 Technology Comparison Chart.............................................................................................................................................................................6 6.4 Medical Air Systems Glossary.......................................................................................................................................................................................7 6.4.1 Summary of CSA Specification Division 15 (Air Compressor)....................................................................................................8 -17 6.5 Quick Guide to Configuration...................................................................................................................................................................................18 6.6 Examples and Figures Figure 1 Air Intake Location Diagram............................................................................................................................................................................. 2 Figure 2 CSA Method Medical Air Flow Calculation..............................................................................................................................................3 Figure 3 Compensation for altitude for Medical Air Compressor System................................................................................................4 6.7 Medical Air System Drawings Medical Air Scroll Compressor Specification Sheet......................................................................................................................................19-21 Duplex Scroll Modular Stacking Configuration Air Compressor (7.5 HP - 15.0 HP).........................................................................22 Duplex Scroll Tank Mounted Horizontal Configuration Air Compressor (2.0 HP – 7.5 HP).........................................................23 Triplex Scroll Modular Stacking Configuration Air Compressor (7.5 HP – 15.0 HP).........................................................................24 Quadruplex Scroll Modular Stacking Configuration Air Compressor (7.5 HP – 15.0 HP).............................................................25 Oil-Less Reciprocating Air Compressor Specification Sheet..................................................................................................................26-28 Duplex Reciprocating Modular Stacking Configuration Air Compressor (5.0 HP - 15.0 HP)......................................................29 Duplex Reciprocating Tank Mounted Horizontal Air Compressor (2.0 HP – 10.0 HP)....................................................................30 Triplex Reciprocating Modular Stacking Configuration Air Compressor (5.0 HP– 15.0 HP)........................................................31 Quadruplex Reciprocating Modular Stacking Configuration Air Compressor (5.0 HP – 15.0 HP)...........................................32 Amico Source Equipment 6.1 How to Use This Section The following section is structured in such a manner that the medical air system for a project may be established and executed in a sound and simple progression. Examples are given whenever possible. The basic milestones in designing the medical air system are as follows: • Definitions – Definitions are provided in the glossary section which contains terminologies which may be frequently utilized within the Medical Air Systems section. These terms may also be helpful (Understanding & Specifying) the appropriate medical air system. • Design – General outline pertaining to the procedural involvement in designing your Medical Air Systems. • Sizing and Selecting the Medical Air System – Step by step calculation exemplifying how to calculate the Peak Calculated Load (PCL) Requirements for the medical facility. • Installation – Steps to building your medical air systems. 6.2 Introduction Medical Air Systems The CSA standards for Medical Air compressors define an essential foundation of Medical Air Compressors as follows: Air should start clean and be kept clean. For that reason, the air inhaled by the patient at the very least should minimally equal to filtered local outdoor air. All compressors included herein are deemed suitable for medical use under CSA Z7396.1. For further information on CSA compliant medical systems, please consult your Local Amico Source representative. 6.2.1 The Four Essentials To Building A Medical Air System: 1. 2. 3. 4. The intake air location must never be contaminated by placing the medical air systems in a poorly ventilated area. The medical air must be available at all times, including in the event of a dual fault failure. The air must be dry enough to ensure no liquid water can develop under any normal operating conditions (This is not necessarily assured simply by meeting the CSA mandated dew point). Any contamination the system can produce within itself under any conditions (e.g. particulate) must be removed (e.g. by filtration) before it can reach the patient. CSA defines various rules for the construction of the air plant and the safety devices required for each machine type. Additionally, good engineering practice defines crucial elements such as after coolers, drains and traps, dryers, vibration isolation, and hundreds of other small but significant elements of good air system design. Amico Source has pre-engineered all the medical air systems in this section to warrant that they include not only the basic requirements of the principles, but also the many foundations behind good engineering. This section of the design guide also permits the user to make selections of complete medical air packages for reason as specified hereafter. It is impractical to craft a design guide encompassing all the knowledge Amico Source’s engineers have applied to the design of these systems. Nevertheless, within this design guide, you can easily locate the necessary information to ensure you can apply these systems with confidence and provide for your client a fully satisfactory medical air system. Medical air in smaller systems may be provided by manifolds in lieu of compressor systems. The sizing criteria are the same for either source type. www.amico.com 1 6.3 Steps to Implementing the Medical Air Systems 6.3.1 Discovery 1. Should existing equipment is to be incorporated along with the Medical Air System, determine the dimensions, type, capacity and current loading of the existing equipment. Ensure the existing equipment is compatible with the current standard. 2. Verify the number and type of all occupancies in the facility which will require medical air outlets. Determine the number of ventilators required to be in service at any one time and define their type and average inlet air requirement. 3. 4. The intake piping for a medical air compressor system should only be connected to the medical air com pressor system and not used for any other purpose. This piping is to be labeled and equipped with intake filters that are located inside the health care facility, close to the compressor, and are easily accessible for servicing. Examine the location intended for the air intake carefully as The CSA mandates the intake be 3m (10 ft) from any door or operable window; 15m (50 ft) away from any exhaust (or the intended location for the intake) and also located away from all other vents and windows (e.g. vacuum and WAGD exhausts, sanitary waste vents, kitchen exhaust fans, generator exhaust, etc.)The intake opening shall be turned downward and screened. It shall be accessible to authorized personnel for cleaning, inspection and servicing. If the air intake is near a loading dock or at a location whereby vehicles may be present, it must be relocated. In addition, when choosing the location of air source, please take into consideration the prevailing wind and potential snow blockage. It is advisable to place the intake at a height above any other intake or vent on the same roof (See Figure 1 below). For further details regarding the rules and regulation in choosing your medical air system location, please refer to the CSA specification guide. Figure 1: 2 Amico Source Equipment 5. Determine a routing for the intake piping and note it on the building drawings. Piping downstream of the compressor shall be routed in a manner such that it is not subjected to temperatures lower than 4oC (40o F). 6. Ensure the intended location for the air plant is adequately ventilated or is at minimum air conditioned. The plant will emancipate considerable amount of heat into the surrounding. Hence, it must be factored in when selecting a compressor site; determining the adequacy of ventilation; or identifying BTU requirements for air conditioning. (BTU data is furnished in the equipment data sheet). Determine the availability of electrical service. 7. 8. If the medical air system is not already piped to the proposed location, determine the routing for the piping and note it on the building drawings. 6.3.2 Design 1. Follow directions for laying out piped medical gases. This will supply a count of outlets which is necessary for the next steps. 6.3.3 Plant Sizing There are several available methods for sizing Medical Air. For the purpose of this design guide, only The Canadian Standard Method (CSA) will be discussed. The Canadian Standard Method 1. Count all outlets in the facility 2. Factor by facility size 3. Please refer to Figure 2 below Figure 2: CSA Method - Medical Air Flow Calculation Please refer to the table below to obtain an average flow that is required within the facility Medical Air Flow Calculation Table Range of Terminal Units Actual Numbers Of Terminal Units Average Flow Per Terminal Units (%) 1-10 0 100 11-25 0 75 26-100 0 50 >101 298 25 Average Flow Required Per Terminal (L/min) Total Flow Required (L/min) # of terminals x 25 L/ min x 100% 0 250 L/min + (25 L/min x 75% x # of terminals exceeding 10) 530 L/min + (25 L/min x 50% x # of terminals exceeding 25) 1467 L/min + (25 L/ min x 25% x # of terminals exceeding 100) Total 0 0 2704.5 2704.5 L/min 95.51 SCFM www.amico.com 3 SAMPLE SYSTEM SELECTION 1. Site conditions: A new hospital is being built, located in Vancouver, British Columbia with 298 medical air outlets. Space availability will be programmed based on system selection. The hospital is located 2 meters above sea level. Power and emergency generator system will be selected upon system selection. 2. Using Figure 2, an average PCL is determined. 3. Through consultation with medical staff, some adjustments and modification might be necessary to the PCL as previously determined in step two. We will add 3.5 SCFM for correction. 4. Subsequent to the consultation with Facility Planning, we discover that a new addition is being added to the hospital. It will require another 11.98 SCFM. 5. There is no need to compensate for altitude because the elevation is not beyond 152 meters. 6. Based on total PCL of 107.49 SCFM, we can choose from the following systems: Triplex Scroll 15hp with a system Note: All sizing methods are only approximations and should be used judiciously. If an existing compressor is being replaced, the operating characteristics of that compressor can be an important gauge of likely future use. For example, if an existing 5 HP. compressor provides an ample amount of medical air, but the sizing tables yield much larger requirements; it may be suitable to use a smaller compromise unit in preference to simply relying on the results from the Amico Sizing Guide. 6.3.4 Altitude Adjustment If the compressor is to be operated at higher elevations, the peak calculated demand should be multiplied by the corresponding correction factor. Specifically, at altitudes above sea level, all medical air systems have reduced flow. In such cases, the required sizing will need to be adjusted by taking the total PCL (SCFM) and multiplying it by the correction factor (See Figure 3 below). Figure 3: Altitude Correction Chart Multiplie Altitude Multiplier Used for Required SCFM(Hg) Sea Level 1.00 305 m (1000 ft.) 1.01 609 m (2000 ft.) 1.03 900 m (3000 ft.) 1.05 1219m (4000 ft.) 1.06 1525 m (5000 ft.) 1.08 1828 m (6000 ft.) 1.10 2133 m (7000 ft.)1.12 2438 m (8000 ft.) 1.15 2743 m (9000 ft.) 1.17 3048 m (10,000ft.) 1.19 4 Amico Source Equipment 6.3.5 “Future Expansion” Compensation The notion of adding capacity now for any future requirements is wise, but extreme cautions are also advised. It is common to see very badly oversized air plants which were initially sized to accommodate an expansion that never occurred or that was scaled back and was not compulsory after all. In addition to the waste of investment, it generates problems associated with the operation of the system. The best method in preparing for an anticipated expansion is to opt for a plant which is adequate for the present need in a duplex or triplex system but can also be upsized for future need by simply adding additional compressors as required. When specifying for the unit, require it be purchased in preparation for additional compressor(s) yet not populated with those compressors. A representative specification would read: “provide duplex medical air plant with triplex controls and air treatment subsystem ready for a future third compressor”. Such a system provides an effective method of expanding the system capacity; is more capital-efficient, and yields better operating characteristics and reliability when it comes to air quality control. Nevertheless, it is fundamentally important that the intake, electrical service, and system piping are correctly sized for the entire expected capacity, so these larger values should be used in all calculations. 6.3.6 Plant Selection 1. Select a preferred technology (See Sec 6.3.9). More specific assistance in selecting a technology may be obtained by contacting your local Amico Source representative. 2. Choose a Kilowatt (Horsepower) from the preferred technology with the capacity closest to (but typically greater than) the Peak Calculated Demand (PCD). 3. Note that for some technologies, there is more than one plant architecture. Should one or more layout be available for selection, choose the one best suited to the site condition. If in doubt as to which arrangement is most suitable for a particular situation, contact your Local Amico Source representative for assistance. 4. Reference the Technology Comparison Chart for the particular system selected. This sheet entails all the essential information regarding the system and should be utilized as a quick reference in all of the following steps. 6.3.7 General Layout 1. Place the plant in scale on the plan drawings in the designated location. Ensure the plant has sufficient space on all sides for maintenance access and proper ventilation. Amico Source recommends 24” (2ft) clearance all around and 36” (3ft) in front of the control cabinet, but it is sometimes possible to reduce this clearance with exact knowledge of maintenance access requirements. Consult with your Local Amico Source representative if circumstances allow for less space. 2. Place the equipment in elevation views as appropriate. 3. On the plan, finalize the routing for the intake. 4. Size the intake piping. The sizing process is iterative: a. Start with the total actual length of piping, and make an estimate for the line size. b. By using your estimated size, add equivalent lengths for the fittings employed. www.amico.com 5 c. Check the size of the intake piping is still suitable at the new equivalent length. Should there be any discrepancies, re-estimate the next larger size and replicate the steps above. The line may also be sized more precisely by conducting an actual calculation. Intake piping must be sized to induce no more than 4inches water column vacuum at the compressor when all compressors are operating. (Use total capacity for this calculation with all compressors running). For unusual lengths or other circumstances, please contact your Local Amico Source representative for assistance. 5. Finalize the connection to the distribution piping and size the system piping. 6.3.8 Specification 1. Select the sections appropriate to the technology and system layout desired. 2. Note into the specification any exceptional requirements (soft starters, etc.) that are necessary. 3. Schedule on the drawings the medical air plant selected. Schedule at least: a. The capacity per compressor and total system capacity. b. kW per compressor and Horsepower. c. Voltage, Hz, and phase desired. 6.3.9 Technology Comparison Chart Amico Source offers several technologies for medical air, each of which has its own advantages and drawbacks. This page summarizes these as an aid in the selection of the correct technology for your specific application. Characteristics Size Scrolls Reciprocating • 10 HP Format • • • Modular Stacking • Horizontal Tank Mount • Skid Mount • Modular Stacking Horizontal Tank Mount Skid Mount dBa@10 HP • 73 • 84 Maximum Pressure • 862 kPa (125 psig) • 827 kPa (120 psig) LPM@828 kPa • 798 L/Min • 985 L/Min SCFM@ 120psig • 28.2 SCFM • 34.8 SCFM • 10 HP Advantages • Compact and light • Customizable weightconfiguration • Reliable • Extremely reliable • Low noise level • Best efficiency CFM/hp (Very quiet and vibration free) • Easy to maintain Disadvantages • Less convenient when • servicing large capacities 6 Amico Source Equipment Louder than scroll 6.4 Medical Air Systems Glossary Definitions ACFM • Actual Cubic Feet per Minute is an expression of actual air volume, generally corrected for and reference to a particular pressure. ICFM • Conditions at the inlet of the compressor prior to any restrictions or temperature changes. (i.e., inlet filters, inter-coolers, discharge manifolds etc). Continuous Duty • Operational reference to compressors operating 24 hours a day, continuously. Continuous Duty • Air compressors which can operate continuously (24 hours per day) if Rated necessary but normally only operate on demand. Desiccant Dryer • Consists of two towers, whereby the desiccant bed in one tower dries the air stream while a purge of dry air regenerates the desiccant bed in the other tower. Dew Point • Temperature and pressure at which medical air will condense water vapor into liquid water within the medical air pipeline system. Dew Point/CO Monitor • Monitors dew point and carbon monoxide levels in medical air. Displacement • Theoretical physical volume of the air in the compressor chamber based upon 100% pumping efficiency, with no allowances made for heat, friction, clearances, or other losses in the compression cycle. Duplex System • Systems comprised of two (2) compressors, each rated for 100% Peak Calculated Load (PCL). LPM • Abbreviation for Liters per minute; a measure of the flow rate of a gas. NTP • “Normal Temperature and Pressure”, generally accepted as 20˚C (70˚F), 14.969 psi/29.92” Hg barometric pressure, and 36% relative humidity. Oil-Free Compressor • Compressor with oil within the compressor but absent from the compression chamber by means of seals and visible vented distance piece, and a dry compression chamber. Oil-Less Compressor Compressor with no oil contained within the compressor. • Peak Calculated • Load (PCL) • The maximum estimated demand a medical facility will require of a medical air system. Calculated at SCFM at 100 psig. SCFM • Standard Cubic Feet Per Minute is an expression of air at NTP. Simultaneous Demand• Operating reference to a condition where all compressors (Lead and Lag compressors) run simultaneously to satisfy demand in excess of lead compressor(s) capability. Triplex Systems • Medical air system with three compressors (3), each sized for 100% PCL. Quadruplex System • Medical air system with four compressors (4), each sized for 50% PCL. www.amico.com 7 6.4.1 Summary of CSA Specification of Division 15 (Air Compressors System) PART 1 – GENERAL (Medical Air) RELATED DOCUMENTS: Drawings and general provisions of the Contract, including general and supplementary conditions and Division I specification section, apply to this section. SUMMARY EXTENT OF WORK A. This Section pertains to all labor, equipment and services necessary for and complementary to the installation of piped medical gas and vacuum systems (PMGVS) including: oxygen, medical air, medical vacuum, waste anesthesia gas disposal (WAGD), nitrogen, instrument air, nitrous oxide, helium, carbon dioxide, argon, dental air, dental vacuum, laboratory air and mixed gas systems as shown on the drawings and/specified herein. 1. Oxygen systems shall be complete to the source valve, ready for connection to the bulk gas supply system. 2. Medical Vacuum, WAGD and Medical Air systems shall be complete, started, tested and ready for use. 3. Nitrous Oxide, Nitrogen, Carbon Dioxide, Helium, Argon and Mixed Gas. Systems shall be complete, tested and ready for use. PERFORMANCE REQUIREMENTS A. All materials used shall be new and of the best grade and quality available and workmanship shall be first class in every respect. Contractor shall be accountable for compliance with all Local, Provincial or Federal codes. B. Provide all elements and accessories required for complete systems per latest edition of CAN/CSA Standard. C. Contractor shall make all necessary connections to owner furnished equipment. D. Install all piping as shown on Drawings; described herein and using methods of fabrication; grading; testing; repairing; cleaning and other procedures. E. Electrical power wiring for vacuum pump(s), medical air compressor(s), WAGD Producer(s), ceiling columns, alarms, and modular accessories associated with the system(s) shall be part of the electrical contract. Any equipment supplied by a contractor requiring additional electrical services shall be the responsibility of the contractor to supply these services. F. Perform Installer pressure testing, cross connection testing, final testing per CSA Standards, perform a leak test; perform a 24h standing pressure; and purge the terminal units. Specifiers; if contractor will retain Verifier, use this paragraph: G. 8 Retain a qualified third party verifier acceptable to the engineer and owner to perform and attest to final verification of the systems. Make corrections as needed, including additional testing in order to illustrate full and unqualified certification. Amico Source Equipment OR if Owner will retain Verifier, use this paragraph; G. Coordinate with owner retained verifier for final verification of the systems. Make corrections as needed, including additional testing if necessary to illustrate full and unqualified certification. COORDINATION A. Medical Gas Contractor shall coordinate with other trades to ensure timely installations and evade conflicts and interference. B. Work with metal stud partition installer and/or mason to ensure anchors, sleeves and similar items are pro vided in sufficient time to avoid delays; chases and openings are properly sized and prepared. C. Coordinate with owner to ensure medical gas outlets, whether owner supplied or contractor supplied, in walls, ceilings and all equipments are provided by the same Medical Gas Equipment Manufacturer (MGEM) are satisfactory to the owner. D. Coordinate with bulk cryogenic gas supplier for installation, connection and verification of bulk gas supply systems. E. Medical Gas Contractor shall supply and install the master alarm system (including the signal wiring). The electrical contractor shall provide power wiring to each alarm panel. Medical Gas Contractor is accountable for proper termination, testing and marking of alarm panels. Termination shall be done by or under the supervision of the manufacturer of alarm panels. F. Coordinate with Medical Gas Verifier to deliver a complete, tested medical gas installation ready for owner’s use. SUBMITTALS A. Furnish the following as one package: 1. Medical Gas Equipment Manufacturer (MGEM) submittals shall include at least or at a minimum of the following: a. Complete specifications for the product intended to be installed, dimensional drawings, and wiring schematics where appropriate. For other medical gas products include: b. i. Package drawing indicating package style, dimensions when complete, method of disassembly and sizes of subsections for rigging and installation. ii. Compressor and package capacity expressed in L/min along with SCFM. iii. Lubrication method (if any). iv. Drive detail including adjustment method. v. Motor including frame type, service factor, kilowatts, current draw, and RPM. www.amico.com 9 vi. Air filters including type and replacement element. vii. Pressure regulators including type and manufacturer. viii. Dew point monitor including technology employed calibration interval, and annual drift in degrees. ix. Carbon monoxide monitor including technology employed calibration interval, and annual drift in ppm. x. Air dryers, type, manufacturer, and design dew point at least -40˚C (-40˚ F) at 350 kPa (50 psig). xi. Sound pressure in dB(A) when operated within the capacity as stated in the CAN/ CSA Standards. xii. For other medical gas products include: c. BTU output for the equipment. i.Outlet keying system. ii. Alarms networking instructions. d. Complete installation instructions for the use of the installer. e. Statement of specific compliance with paragraphs of CAN/CSA Standards most recent edition as relevant to the equipment and as listed in those sections. Complete maintenance schedules. f. g. Warranty statement which must encompass all system components. Warranties covering only specific components or containing exclusions are not acceptable. h. Name and contact information for installation assistance, start up, warranty and service. i. Description of available Preventative Maintenance Programs for Owners review. j. B. Information on training programs available to maintenance personnel for Owners review. Medical Gas Verifier Submittals shall include: 1. Name, contact information, and reference list. Reference list should include no less than three references on projects of similar size and complexity. 2. A notarized confirmation from the verifier stating that the verifier undertakes to validate this project and thus agrees to disqualify themselves from supplying any equipment which will be included in the scope of their verification. No verifier who supplies equipment shall be permitted to verify that equipment. 10 Amico Source Equipment 3. Statement declaring that the MGEM has no fiduciary interest in the verifier and that the verifier is not an agent or representative of the MGEM. 4. Statement declaring that the installing contractor has no fiduciary interest in the verifier and that the verifier has no fiduciary interest in the contractor. C.Pre-approval 1. Written preapproval is required for equipment not exactly matching specifications. Submit the information required under Submittals above, attaching a cover letter stating the exact areas of deviation. 2. A request for preapproval of equipment must be received by the Engineer no less than three days (72 hours) prior to bid. QUALITY ASSURANCE A. Regulatory Requirements 1. All medical gas systems work must comply in all respects with requirements of CAN/CSA Standard related standards where applicable; requirements of the Technical Standards and Safety Authority (TSSA). 2. Medical gas systems work must be performed only by tradesmen familiar with the requirements of CAN/CSA Standards who are qualified and certified for silver brazing under requirements of the TSSA. The Consulting Engineer reserves the right to evaluate any tradesman on the basis of the resume provided. Only tradesmen so approved may work on the medical gas systems. 3. As required by the CAN/CSA Standards, joints in the medical gas piping must be done properly with the interior of the piping maintained with a nitrogen atmosphere in order to ensure clean piping. Therefore, submit to the Consultant for review prior to commencing piping work; a detailed account of your proposed procedures for purging the piping, as well as pre and post purging procedures. 4. The Consultant reserves the right to cut out and examine piping joints during the course of the work or after the work is complete. If the interior of the sample piping and/or fittings are found to be contaminated with oxidation or any other material as a result of improper installation, the piping will be considered unaccept able, not in accordance with CAN/CSA Standards and you will be responsible for repair as required by the Consultant to meet the requirements of CAN/CSA Standards. B. Installation and Start-up 1. The MGEM will provide authorized representatives to review installation and perform initial start-up of the system. C.Warranty 1. Warranty will be expressly complete, include all components of the system and be the responsibility of the MGEM for record only. Warranties limiting the responsibility of the MGEM for any system component for which pass through the MGEM to another manufacturer are not acceptable. 2. All source medical gas components shall be warranted by the MGEM of record for a minimum of 30 months from date of shipment. www.amico.com 11 3. Warranties shall include on site repairs including travel, labor and parts. 4. Shipping and installation costs after the first 12 months will be borne by the customer. D.Verification: 1. Medical Gas Contractor shall deliver to the owner a complete system certification. PART 2 - PRODUCTS QUALIFICATION OF MANUFACTURER(S) A. One manufacturer shall supply all of the medical gas systems equipment, including the sources of supply. This supplier shall have a product specialist available to periodically check with the Project Coordinator during initial installation of the pipeline systems equipment. The equipment supplier’s representative shall train the hospital personnel in the use of the piping system and related equipment in operation with those systems. B. The MGEM shall have a product specialist available to periodically check with the Contractor during installation of the pipeline systems equipment. MGEM shall provide service support to the hospital after turnover. Demonstrate factory trained service technician is available within 400 kilometers of facility. C. Approved MGEM: Piping Systems Components and Medical Gas Alarms; 1. Amico Corporation. 2. Alternate by _____________ with pre approval. D. MGEM shall have a minimum of 5 years of experience manufacturing medical air and vacuum systems. E. Written Pre-approval is required for all equipment from other manufacturers. MEDICAL AIR COMPRESSOR SYSTEMS 1. Provide a complete medical air source, complying with all relevant requirements of CAN/CSA Standards and supplying medical air continuously for the life of the equipment. The unit shall be manufactured by Amico or preapproved equal. 2. All components are at least duplexed and valved to allow servicing to any components devoid of interruption of air supply of the facility. System is sized so each filter can meet 100% of the peak calculated demand. 3. 4. Furnish a complete plant consisting of at least three (3) compressors, receiver, air treatment system and controls capable of providing scheduled capacity with two units out of service. A medical air system may have two compressors if the facility requires less than 570 L/min at 345 kPa (20 SCFM at 50 PSI) flow rate. 5. System is modular or field separable, allowing for ease of shipment and handling on site. System is completely factory assembled, requiring only interconnection between modules on site. Systems requiring site assembly other than interconnection are not acceptable (remounting of components removed for shipping is permitted). 12 Amico Source Equipment 6. The compressor modules and motors shall be fully isolated from the main compressor base by means of a four point; heavy-duty seismic restrained approved isolation system for a minimum of 95% isolation efficiency. Engineering data shall be provided supporting isolation efficiency and equal weight distribution between supports. Pumps not having this feature shall have an inertia base sized for that system installed at the contractors’ expense. 7. The compressor shall be capable of supplying the system design flow of the pipeline distribution system with any two units out of service, except for facilities mentioned above where only two compressors are used. 8. All air systems will be equipped with a CO monitor. The monitor will have an alarm to: i) Alarm if the level of CO exceeds 5 parts per million by volume (ppmv) and ii) Alarm and system shutdown if the level exceeds 25 ppmv. A. Air Compressors Specifier: select the paragraph below reflecting the preferred technology: SCROLL COMPRESSORS 1. The compressor shall be a continuous duty rated scroll type with sealed bearings. The design shall be single stage, air-cooled, consisting of one fixed and one orbiting scroll sealed with PTFE tip seals between the scroll halves and rated for 120 PSIG discharge pressure. Orbiting bearings shall be grease filled and permanently sealed type requiring no lubrication at any time. Units requiring re-lubrication are not acceptable. Oil-less type compressor. Noise level shall not exceed 75dB (A) for duplex system, 77dB (A) for triplex system and 79 dB (A) for quad system with pumps running at peak demand. 2. On multiple head applications, belt tightening devices are included. 3. Each compressor shall be equipped with an integral air-cooled after cooler designed for a maximum approach temperature of 7.0°C (15°F) ambient, a CRN certified moisture separator complete with electronic drain valve. 4. The discharge of piping of each compressor shall incorporate an integral valve to prevent more than 1/4 revolution of reverse rotation of the scroll at shutdown. 5. All required Type “K” or “L” copper tubing or brass to interconnect all compressor set components, with unions for ease of servicing. 6. Compressor motors shall be a NEMA rated, open drip proof unit with 1.15 service factor suitable for ___ volt, ___ phase, ___Hz. All moving parts (fans, pulleys and belts) shall be fully protected by an OSHA approved enclosure. 7. 8. Monitor and numerically display the discharge air temperature at each compression chamber outlet port. 9. Initiate an alarm and shut down the compressor if any cylinder discharge temperature exceeds the manufacturer’s recommended level. RECIPROCATING COMPRESSOR 1. The compressors shall be single stage, air cooled, and reciprocating type with corrosion resistant valves with stainless steel reeds. Crankcase ventilation shall be filtered to prevent dust and insects from entering the crankcase. All bearings shall be permanently lubricated and sealed; compressors that require bearings to be re-greased are not acceptable. www.amico.com 13 2. Each compressor shall be equipped with an integral air-cooled after cooler designed for a maximum approach temperature of 7.0°C (15°F) ambient, a CRN certified moisture separator complete with electronic drain valve. 3. All required type “K” copper tubing or brass pipe to interconnect all compressor set components, with unions for ease of servicing. 4. Compressor motors shall be a NEMA rated, open drip proof unit with 1.15 service factor suitable for ______ Volt, ____ Phase, ___Hz. 5. All moving parts (fans, pulleys and belts) shall be fully protected by an OSHA approved enclosure. 6. All support structures shall be a minimum of 10 Gauge Steel. B. Receiver: The receiver is to be a welded steel, ASME certified steel tank that is Canadian Registration Number (CRN) registered, a working pressure of 1378 kPa (200 psi) or greater. The receiver shall be sized in accordance with the requirements of the medical air compressor system and the calculated system design flow, and in compliance with all the requirements for unfired pressure vessels specified in CSA B51. The receiver shall also include: 1. 2. 3. 4. 5. 6. 7. Receiver shall be galvanized inside and outside Automatic and manual drain valves A pressure gauge A sight glass assembly with guard ASME rated pressure relief valve Shut-off valves Equipped with a means of bypassing to allow repair without interruption to the system C. Piping and Control Components The piping and control components for each compressor shall include: 1. Intake filters 2. A non-return valve on the outlet 3. Flexible inlet and outlet couplings 4. Inlet and outlet shut-off valves 5. A pressure relief valve 6. A condensate separator and drain (CRN registered) 7. An unloader valve 8. A means of removal of the compressor for service or replacement without interruption to the system The air source for the compressor shall be outdoor air and the intake shall be: a. At least 3 m (10ft) away from any door or operable window and 15 m (50ft) from any exhaust (e.g. vacuum pump discharge or sanitary vent exhaust). At least 3 m (10ft) above grade. b. c. The intake opening shall be turned downward, screened, and shall be accessible to authorized personnel for cleaning, inspection and servicing. d. Placed in a location where it will not draw in contamination from exhaust systems (e.g. contamination from furnaces, gasoline or diesel engines, vacuum systems, or scavenging systems). 14 Amico Source Equipment e. f. Consideration shall be given to the potential effect of prevailing winds and possible sources of airborne contamination and potential for obstruction by accumulated snow. Piping downstream of the compressor shall be routed in such a way that it is not subjected to a temperature lower than 4˚C (40˚F). g. Piping and components shall be made of corrosive resistant materials such as brass, copper or stainless steel. D. Control Panel and Alarm Sensors The control system is C.U.L. labeled. The control system provides automatic lead/lag sequencing and automatic alternation of pumps based on first-on/first-off principle with provision for simultaneous operation if required. Automatic activation of reserve unit, if required, will activate an audible alarm as well as a visual alarm on the display screen. 1. Control Panel Features: Only panel components that are commercially available and not of propriety design will be considered. a. NEMA 12 control panel enclosure b. Full voltage motor starter shall be UL 508 E self-protected combination starters with overload protection and external operators c. Door interlock disconnect switch d. 90 dB alarm buzzer e. Visible indicator of “power on” and “compressor running” for each compressor f. Two control transformers with secondary circuit breaker g. Manual / Off Auto selector switches (Each Compressor) h. Transducer and RTD based control panel i. The RTD will digitally display the running temperature of each discharge port and shall be field programmable to standard manufacturer’s operating parameter j. The calibration of the pressure transducer can be set so a non-standard transducer can be used 2. Touch screen controls feature a minimum 5.7”screen. Screen displays and functions include: a. WinCE 5.0 operating system b. OPC, TCP/IP and Communication drivers c. Ethernet connectivity with embedded web-page for remote monitoring, multi-level pass word protected remote adjustment of all operating parameters d. Electronic notifications of alarms and warnings e. Communication expansion capability to talk over five Networks/Protocols f. Service alerts, runtime hour meters for each pump, system status, system pressure level all shall be displayed www.amico.com 15 g. Visual/audible indications with isolated voltage free contacts for all alarm h. Event log recording of alarms and system activity i. Event log recording of service warnings and service history j. Trend graphs for compression level, compressor operations, and ambient temperature k. Adjustable settings to accommodate user needs Panel designed with selectable options to fully match applications 3. a. All system settings shall be user adjustable and accessible with the system in operation and the control panel door closed (password protected) b. Adjustments can be made to pressure settings to match the customers’ requirements c. All alarms to require manual reset Specifier: select the paragraph below reflecting the preferred technology: Standard alarms shall open on failure with local audible and visual alarms with dry contacts for the following conditions: 4. SCROLL COMPRESSOR a. Lag pump in use b. High dew point c. High CO level d. High discharge air temperature e. Desiccant dryer tower switching failure f. Main transformer failure g. Motor overload 4. RECIPROCATING COMPRESSOR a. Lag pump in use b. High dew point c. High CO level d. High discharge air temperature e. Desiccant dryer tower switching failure f. Main transformer failure g. Motor overload 16 Amico Source Equipment E. Air Treatment Centre Provide redundant medical air treatment systems that contain CRN registered components including desiccant dryers, filters, and purifiers sized for peak calculated demand. Dew point and carbon monoxide monitoring Medical Air Treatment shall include: 1. Drying and purification units shall dry air to a dew point to -40°C at 350 kPa (-40°F at 50 psi). Refrigerant dryers are not acceptable. Dryer purge flow control through an integral dew point based purge control system. Purge controllers using desiccant temperature are not acceptable. Drying units shall provide a numerical indication of the outlet dew point and initiate an alarm when the outlet dew point exceeds the manufacturer’s pre-set limit. Desiccant dryers shall have alarm sensors for tower switching failure. 3. Mounted pre-filter with corrosion-resistant housing rated for 0.01 µ with automatic drain and element change indicator at the inlet to each dryer. 4. Final line filters rated for 0.1 particulate after filter with element change indicators, duplexed final line regulators, and duplexed safety relief valves shall be factory mounted and piped at the outlet of each dryer. 2. 5. An activated carbon final filter shall be installed upstream of the line pressure regulators to remove volatile organic compounds and reduce odor levels. www.amico.com 17 6.5 Quick Guide to Configuration Modular Stacking Configuration New “A-Frame”, modular stacking configuration allows two compressors to run simultaneously with smaller footprint and compact design. Compressor assemblies include at least one compressor and one motor. Horizontal Tank Mount The compressors are mounted on a horizontal tank which is large enough to accommodate bigger compressors and accessories than the Space Saver. The system is factory piped and wired to a single inlet, outlet and electrical connection. Skid Mount These systems are mounted on separate skid. This configuration is suitable for larger compressors. This type of air system is also designed for ease of transportation. 18 Amico Source Equipment www.amico.com 19 20 Amico Source Equipment www.amico.com 21 22 Amico Source Equipment M²) DUPLEX SCROLL MODULAR STACKING CONFIGURATION AIR COMPRESSOR (7.5 HP - 15.0 HP) MODEL L A-SCD-D-120P-TH-C-075 A-SCD-D-080P-TH-C-075 A-SCD-D-120P-TH-C-050 A-SCD-D-080P-TH-C-050 A-SCD-D-080P-TH-C-030 A-SCD-D-080P-TH-C-020 RECEIVER DUPLEX CONTROL PANEL HMI MONITOR AIR COMPRESSOR ELECTRIC MOTOR 2 (1.49) 3 (2.24) 5 (3.73) 5 (3.73) 7.5 (5.60) 7.5 (5.60) HP (kW) 1 1 1 0.75 0.75 0.75 A INLET NPT TANK B SIZE OUTLET GALLON NPT (LITRE) 80G 0.5 (353) 80G 0.5 (353) 80G 0.5 (353) 120G 0.5 (529) 80G 0.75 (353) 120G 0.75 (529) B DISCHARGE CONNECTION A INLET CONNECTION @ 50 psig 7 (198) 10.4 (294) 17.2 (487) 17.2 (487) 25.2 (713) 25.2 (713) @ 120 psig 6.5 (184) 9.6 (272) 16 (453) 16 (453) 24 (680) 24 (680) PUMP ICFM (LPM) H @ 50 psig 7 (198) 10.4 (294) 17.2 (487) 17.2 (487) 25.2 (713) 25.2 (713) @ 120 psig 6.5 (184) 9.6 (272) 16 (453) 16 (453) 24 (680) 24 (680) CSA SYSTEM CAPACITIES WITH ONE PUMP ON STANDBY (LPM) 800 (364 KG) 1300 (591 KG) 1300 (591 KG) 1300 (591 KG) 1235 (561 KG) 1520 (691 KG) WEIGHT IN LBS (KG) W 20.3 (1.89 M) 22.1 (1.94 M) 22.2 (2.06 M) 22.2 (2.06 M) 21.1 (1.97 M) 24.8 (2.30 M) SQ.FT. REQUIRED (M²) 31 31 44 44 34 48 48 19 14 34 21 16 27 27 17 17 12 8.5 22 22 16 16 10 7 18 18 13 13 8 5.6 208V 230V 380V 460V 575V SYSTEM FLA (WITH ALL PUMPS RUNNING) DATE 69 75 75 75 75 75 7,641 10,108 10,108 19,088 19,088 SOUND LEVEL dB (A) 34 (864) 33 (838) 34 (864) 34 (864) 33 (838) 38 (965) 86 (2184) 92 (2337) 94 (2388) 94 (2388) 92 (2337) 94 (2388) www.amico.com 23 66 (1676) 58 (1473) 66 (1676) 66 (1676) 58 (1473) 66 (1676) L W H (mm) (mm) (mm) APPROVAL SIGNATURE 5,090 SYSTEM BTU/HR 1/2 NPT DRAIN AT THE BOTTOM OF THE RECEIVER DUPLEX SCROLL TANK MOUNTED HORIZONTAL CONFIGURATION AIR COMPRESSOR (2.0 HP - 7.5 HP) 24 Amico Source Equipment MODEL A-SCD-T-240P-SS-C-150 A-SCD-T-200P-SS-C-150 A-SCD-T-120P-SS-C-150 A-SCD-T-240P-SS-C-100 A-SCD-T-200P-SS-C-100 A-SCD-T-120P-SS-C-100 A-SCD-T-200P-SS-C-075 A-SCD-T-120P-SS-C-075 1/2 NPT DRAIN AT THE BACK OF THE RECEIVER TRIPLEX CONTROL PANEL HMI MONITOR 7.5 (5.60) 7.5 (5.60) 10 (7.46) 10 (7.46) 10 (7.46) 15 (11.2) 15 (11.2) 15 (11.2) HP (kW) L (16) HOLES 5/8" DIA. FOR ACHORING TO FLOOR A INLET CONNECTION B DISCHARGE CONNECTION 1.25 1.25 1.25 1 1 0.75 0.75 0.75 A INLET NPT TANK B SIZE OUTLET GALLON NPT (LITRE) 120G 0.75 (529) 200G 0.75 (881) 120G 0.75 (529) 200G 1 (881) 240G 1 (1058) 120G 1 (529) 200G 1 (881) 240G 1 (1058) RECEIVER @ 50 psig 25.2 (713) 25.2 (713) 34.4 (974) 34.4 (974) 34.4 (974) 50.4 (1427) 50.4 (1427) 50.4 (1427) @ 120 psig 24 (680) 24 (680) 32 (906) 32 (906) 32 (906) 48 (1360) 48 (1360) 48 (1360) PUMP ICFM (LPM) ELECTRIC MOTOR AIR COMPRESSOR @ 50 psig 25.2 (713) 25.2 (713) 34.4 (974) 34.4 (974) 34.4 (974) 50.4 (1427) 50.4 (1427) 50.4 (1427) @ 120 psig 24 (680) 24 (680) 32 (906) 32 (906) 32 (906) 48 (1360) 48 (1360) 48 (1360) CSA SYSTEM CAPACITIES WITH TWO PUMPS ON STANDBY (LPM) 3080 (1400 KG) 3280 (1476 KG) 2530 (1150 KG) 2825 (1284 KG) 2800 (1273 KG) 3050 (1386 KG) 3345 (1520 KG) 3605 (1639 KG) WEIGHT IN LBS (KG) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) SQ.FT. REQUIRED (M²) W H 138 138 138 93 93 93 72 72 126 126 126 84 84 84 66 66 77 77 77 51 51 51 41 41 63 63 63 42 42 42 33 33 75 75 75 38,160 38,160 38,160 36 36 36 74 74 25,450 33 33 74 25,450 33 25,450 73 19,088 27 SOUND LEVEL dB (A) 73 SYSTEM BTU/HR DATE 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 83 (2108) 88 (2235) 83 (2108) 88 (2235) 100 (2540) 83 (2108) 88 (2235) 100 (2540) L W H (mm) (mm) (mm) APPROVAL SIGNATURE 19,088 27 208V 230V 380V 460V 575V SYSTEM FLA (WITH ALL PUMPS RUNNING) TRIPLEX SCROLL MODULAR STACKING CONFIGURATION AIR COMPRESSOR (7.5 HP - 15.0 HP) 1/2 NPT DRAIN AT THE BACK OF THE RECEIVER QUADRUPLEX CONTROL PANEL ELECTRIC MOTOR AIR COMPRESSOR A-SCD-Q-240P-SS-C-150 A-SCD-Q-200P-SS-C-150 A-SCD-Q-120P-SS-C-150 A-SCD-Q-240P-SS-C-100 A-SCD-Q-200P-SS-C-100 A-SCD-Q-120P-SS-C-100 A-SCD-Q-200P-SS-C-075 A-SCD-Q-120P-SS-C-075 MODEL RECEIVER A INLET CONNECTION 7.5 (5.60) 7.5 (5.60) 10 (7.46) 10 (7.46) 10 (7.46) 15 (11.2) 15 (11.2) 15 (11.2) HP (kW) L 1.25 1.25 1.25 1 1 0.75 0.75 0.75 A INLET NPT @ 50 psig 25.2 (713) 25.2 (713) 34.4 (974) 34.4 (974) 34.4 (974) 50.4 (1427) 50.4 (1427) 50.4 (1427) @ 120 psig 24 (680) 24 (680) 32 (906) 32 (906) 32 (906) 48 (1360) 48 (1360) 48 (1360) PUMP ICFM (LPM) HMI MONITOR TANK B SIZE OUTLET GALLON NPT (LITRE) 120G 0.75 (529) 200G 0.75 (881) 120G 0.75 (529) 200G 1 (881) 240G 1 (1058) 120G 1 (529) 200G 1 (881) 240G 1 (1058) (16) HOLES 5/8" DIA. FOR ANCHORING TO FLOOR B DISCHARGE CONNECTION @ 50 psig 50.4 (1427) 50.4 (1427) 68.8 (1948) 68.8 (1948) 68.8 (1948) 100.8 (2854) 100.8 (2854) 100.8 (2854) @ 120 psig 48 (1360) 48 (1360) 64 (1812) 64 (1812) 64 (1812) 96 (2720) 96 (2720) 96 (2720) CSA SYSTEM CAPACITIES WITH TWO PUMPS ON STANDBY (LPM) 3580 (1627 KG) 3780 (1718 KG) 3030 (1377 KG) 3325 (1511 KG) 3300 (1500 KG) 3550 (1614 KG) 3845 (1748 KG) 4105 (1866 KG) WEIGHT IN LBS (KG) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) 53.5 (4.97 M) SQ.FT. REQUIRED (M²) W 184 184 184 124 124 124 96 96 168 168 168 112 112 112 88 88 103 103 103 68 68 68 55 55 84 84 84 56 56 56 44 44 48 48 48 44 44 44 36 36 208V 230V 380V 460V 575V SYSTEM FLA (WITH ALL PUMPS RUNNING) H QUADRUPLEX SCROLL MODULAR STACKING CONFIGURATION AIR COMPRESSOR (7.5 HP - 15.0 HP) 76,320 76,320 76,320 50,900 50,900 50,900 38,176 38,176 SYSTEM BTU/HR 76 76 76 75 75 75 74 74 SOUND LEVEL dB (A) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 100 (2540) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) 77 (1956) www.amico.com 25 83 (2108) 88 (2235) 83 (2108) 88 (2235) 100 (2540) 83 (2108) 88 (2235) 100 (2540) L W H (mm) (mm) (mm) APPROVAL SIGNATURE DATE 26 Amico Source Equipment www.amico.com 27 28 Amico Source Equipment M²) www.amico.com 29 30 Amico Source Equipment M²) M²) www.amico.com 31 32 Amico Source Equipment M²) www.amico.com Amico Source Equipment | www.amico.com 85 Fulton Way, Richmond Hill Ontario, L4B 2N4, Canada Toll Free Tel: 1.877.462.6426 Tel: 905.764.0800 Fax: 905.764.0862 Email: [email protected] SE - AIR - DG May 2011
