Air Supply House

GENERAL TECHNICAL REQUIREMENT
34835B
AIR SUPPLY &

FILTER HOUSES
GM GENERAL TECHNICAL SPECIFICATION

Document Number.Rev: 34835.B
Air Supply & Filter Houses

Engineer(s):
Dave Dobias
Mathias Geilich
Burkhard Stber
Center Topic: GM Global Paint & Polymers Center

Date: 1JAN06
Manufacturing Partition Codes: 63
Applies To: All GM Paint Shops
Table of Contents
1. Scope .......................................................................................................................... 1
2. Air Supply House General .......................................................................................... 3
3. Enclosure..................................................................................................................... 7
4. Structural Steel.......................................................................................................... 12
5. Fresh Air Intake Fitting ............................................................................................. 12
6. Fresh Or Return Air Intake Ductwork ...................................................................... 12
7. Fresh Air Intake Dampers......................................................................................... 13
8. Air Supply Fan ........................................................................................................... 14
9. Fan And Motor Vibration Control Base ................................................................... 17
10. Motors ...................................................................................................................... 17
11. V-Belt Drives And Motor Bases.............................................................................. 18
12. V-Belt Drive Guard .................................................................................................. 19
13. Primary Filter Inlet Perforated Plate And Recirculation
House Inlet Compartments................................................................................... 19
14. Air Supply Filters..................................................................................................... 20
15. Air Filter Gauges And Differential Pressure Switches ......................................... 22
16. Humidifier ................................................................................................................ 23
17. Central Humidifier Recirculation System.............................................................. 26
18. Air Heater/Cooling................................................................................................... 37
19. System Valves, Pressure Gauges, And Expansion Fittings................................ 49
20. Combustion Safeguard........................................................................................... 50
21. Temperature And Humidity Controls..................................................................... 52
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2006 GENERAL MOTORS CORPORATION

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Rev. A, 15AP00
When printed, this copy is uncontrolled. GM users should verify latest revision at http://paint.gm.com
Users outside of GM should verify latest revision at http://www.gmsupplypower.com.

34835B
AIR SUPPLY &

FILTER HOUSES
22. Supply Fan Volume Control System...................................................................... 60

23. Motor Controls And Electrical Components ......................................................... 60
24. Central Booth Monitoring And Control System .................................................... 62
25. Air Supply House Lighting ..................................................................................... 63
26. Floor Drains ............................................................................................................. 64
27. Painting .................................................................................................................... 64
28. Special Air Or Filter House Considerations.......................................................... 65
29. Fire Protection......................................................................................................... 65
30. Instruction And Training......................................................................................... 66
31. Manuals.................................................................................................................... 66
32. Manufacturing Systems Qualifications - Testing And Adjusting ........................ 67
33. Signs ........................................................................................................................ 69
34. Codes And Standards............................................................................................. 69
Revision Status
Date:
1JAN06
15AP00
Change Control No.:

009-006
Revision:
B
A
Reason/Need:
Update/Lessons Learned
Update/Lessons Learned
1. SCOPE
1.1. The purpose of this specification is to describe requirements for all new or replacement
air supply and filter houses for General Motors Paint Shop Facilities.
1.2. For International Projects, all dimensional criteria, metal thickness and codes and
standards shall be as available using metric equivalents or approximations or using
European equivalent standards. Where specific equipment or manufacturers are
described the contractor shall provide the described equipment or an owner approved
equivalent in quality and design.
1.3. Basic requirements include the following:
1.3.1. An easily cleaned, non-combustible enclosure.
1.3.2. An air supply system to provide filtered, down draft ventilation at proper velocities,
temperature, humidity, and uniformity with 99.9% of all particles exceeding 3 microns
removed. Every attempt should be made to keep air supply houses relatively consistent
in size. Refer to the attached drawings for typical Compartment/Air Supply Layout.
1.3.3. Compliance with all codes and standards as listed.
1.4. The specification does not address local codes which must be considered in every
installation.
1.5. When used in this specification the word provide shall mean furnish and install.
1.6. Pipe schedules listed are USA standard. Wall thickness varies with pipe diameter.
There is not an iternational standard for pipe schedule. Contractor required to convert and
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1.7.
1.8.
1.9.
1.10.
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FILTER HOUSES
consider wall thickness listed in Schedule as a minimum when selecting locally available
metric sizes.
Exceptions to this Specification must be submitted to and approved by GM Global Paint &
Polymers Center. Any equipment or design found not in compliance with this
specification will be required to be appropriately revised prior to shipment to the job site.
GM retains the right to refuse to accept any equipment not in compliance and the
supplying contractor will be responsible for any cost impacts required to correct the
discrepancy and maintain the established schedule.
All air supply houses shall address the conservation of manufacturing floor space, while
allowing sufficient maintenance access for servicing of related spray booth and air supply
equipment.
All air supplies shall be constructed from material and with workmanship of the highest
quality to provide an expected life of 40 years of service for the spray booth, air supplies
and equipment. Air supply house design shall allow for removal and replacement of air
supply house components such as filters, fans, burners, coils, and all other replaceable
components, without revisions or reworks to the spray booth or air supply houses. Hoist
rings shall be provided where component removal requires the use of a hoist and none
ids specified. Accessibility for normal maintenance functions (lubrication, fan belt
checking and replacement, etc.) shall be of prime importance. Maintenance access shall
include motor removal carts, lifts, straps, chains, etc..
The contractor must ensure that the air supply house designs and installation enables all
air supply doors to be opened fully, without other equipment or parts interfering. Fan
wheels and motors shall be designed to be removed easily and taken from the area for
servicing. Filters must be easily replaceable. Cooling coils must be accessible for
cleaning. Insulation and cladding shall be designed to insure that frequently inspected
areas or equipment are accessible without destroying the insulation or lagging (i.e.
removable panels and lagging sections). The ductwork shall be designed to avoid
positioning dampers in inaccessible locations. All areas of the spray booth, air supply
houses and related equipment must be accessible for cleaning purposes. Clean out
hatches shall be accessible and not obscured by equipment, roof steel, lights, pipe work,
etc.
2. AIR SUPPLY HOUSE GENERAL

2.1. Air supply houses (ASH) shall be provided to supply the proper volume of fresh air as
specified for the spray booth, deck, enclosure, building, paint mix, etc. . When referring
to the spray booth within this specification, all areas and related ASHs for the paint shop
will be covered by this specification with changes as required in each individual areas
specification. Generally, all air houses shall be similar in design with specific area
requirements applying to filtration and operating design parameters.
2.2. Each spray booth shall include one or more air supply houses dedicated to that booth. A
single house shall not serve more than one spray booth. Smaller enclosures can be
combined as appropriate. Every attempt should be made to keep air supply houses
relatively consistent in size. If recirculation is used for a spray zone, the ASH shall be
dedicated to that zone. See Recirculation Air house Additional Requirements. All air
supply fans shall be VFD volume controlled by a volume sensor. Any air supply house
that serves more than one zone of a booth shall have motorized dampers and volume
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2.3.
2.4.
2.5.
2.6.
2.7.
2.8.
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FILTER HOUSES
control utilizing a pitot array and differential pressure transmitter for those dampers at
every branch drop from the main duct. All sensors and control will be available on the
monitoring and control screen system.
All recirculation filter houses and related components shall be constructed of Din 1.4306
(304L) S.S..
Spray booth recirculation filter houses shall be provided with three stage filtration,
entering and exiting perforated plate walls, vacuum relief wall sections for excess static
protection and reheat coils as appropriate. All doors, walls and related connecting duct
will have excess static capability of 20% assuming fully loaded (dirty) filters. These areas
shall be considered NEC Zone 1 (Class 1 Division 1 Group D) areas internally. GM
Security Considers the doors maintenance and not normal use access. As a result, the
area outside is to be considered non-hazard class electrically.
A mixing box will be required after the supply fans from the filter houses to blend the fresh
and recirculated air prior to supply to the booth. Mixers shall be Din 1.4306 (304L) S.S.
#16 gauge sized for 65 Pa (0.26 W.C.) at the design air flow rate. The mixers shall be
located and arranged per the manufacturers recommendations. Design shall insure
proper inlet and discharge conditions to insure optimized blending. This same method will
be employed on all mixed air streams such as powder recirculation or where air is
recycled and reused with other fresh air sources.
Recirculation houses or fresh air houses with multiple fans or connected to a common
discharge/inlet plenum shall have motorized discharge shut off dampers to permit
individual starting without backspin. Anti-backspin clutches shall not be utilized for this
application.
Shop fabricated modular air supply houses shall be erected on a concrete slab
mezzanine located above the spray booths. All floor openings for piping or other
penetrations must be curbed and epoxy filled around metal core to prevent leaks to the
level below. Similar treatment will be provided for all roof penetrations. Prefabricated,
package type air houses shall be erected on a0.3 m (12) high curb beam, or equal
support. Air supply houses shall be located inside a penthouse provided by the
contractor. Roof mounted air supplies shall be used only with the approval of the
appropriate owners of this specification. All air house materials or prefabricated
assemblies shall be weather protected with tarps and plastic during shipment and until
completion of installation. All openings shall be wrapped and taped with plastic or closed
with temporary decking until installation. Shipping sections for all air/filter houses shall
not be stored outdoors until installation. If completed units or materials in fabrication are
stored outdoors, contractor will be responsible to clean and repair/replace all corroded
material and equipment at the owners discretion prior to installation or use in fabrication.
Each air supply design shall incorporate gas burner heating, humidification, and primary
filtering of the system make-up air. Where utility availability dictates, a system of preheat
coils, spray coil or air washer humidifiers, chilled water coils and reheat coils as required.
Secondary filtration will be included in the spray booth plenum. Only with the approval of
GM Global Paint & Polymers Center will secondary filtration be installed in the ASH for
paint spray booths. All building/deck/enclosure, building zone migration and paint mix
ASHs shall have secondary and final filtration in the air supply house.
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2.9. Space shall be provided for the future installation of cooling and reheat coils for
dehumidification for systems installed with solvent born basecoat initially. This area shall
have S.S. drain pans as described in the Humidifier Section.
2.10. The air supply shall be capable of maintaining the following seasonal operating ranges
within the spray booth. Refer to the GM Global Paint & Polymers CenterBill of Process
Section 34000 for design temperatures and humidity levels Other set points may be
specified depending on local climate, plant conditions, and specific equipment and/or
processes. The contractor shall coordinate the necessary requirements with the owner
and owners coating supplier. Final requirements shall be submitted to the owner for
approval prior to design and fabrication. See humidifier section for additional information.
See Process Decks and Enclosures Specification for additional information regarding
these areas.
2.11. Sheet metal screw use shall not be permitted where disassembly and reassembly of a
component may be required. All exposed shafts of screws shall be removed where deep
cleaning or maintenance of an area may be required. Caps on exposed shafts shall not
be permitted.
2.12. Any S.S. welding performed within an air house compartment shall be electro-chemical
cleaned after dye testing for leaks. All welding of stainless steel materials shall be by TIG
or SAWS process or by other process and/or treatment that preserves the corrosion
resistance and mechanical strength of the original material. All discoloration at outside
visible welds (including field welds) shall be removed by electro-chemical removal and
rinsing. Testing of all welds shall be required prior to shipment and after field installation
to insure water and air tight construction and proper temperature/penetration of welds.
2.13. All planes and surfaces shall be supported and reinforced with structural members and
stiffeners properly spaced, elevated, and leveled so that no bulging of planes or surfaces
occurs. All internal baffles and supporting structures shall be minimum 2 mm (14 ga.),
Din 1.4306 ( 304L) Stainless Steel.
2.14. All recirculation air supply houses shall require sprinklers in all compartments and duct
work. Unit heaters may also be required to protect the sprinklers or coils in the
compartments or ducts from potential freeze conditions. Heaters in recirculation houses
shall comply with NEC Zone 1 (Class 1 Div. I Group D) Requirements and be indirect
fired or hot water. See humidifier section regarding unit heaters for details of installation.
2.15. Low pressure water hose bibs and compressed air connections shall be provided at the
center of all ASH compartment door walls including filter houses. Compressed air lines
shall be provided with plant selected quick disconnects. Electrical service outlets shall be
provided at the center and ends of each ASH door wall and within 7.6 m (25) of all
recirculation ASH doors. Welding outlets shall be provided within 15 m (50) of all ASH
compartment doors.
2.16. Mounting brackets inside of all ASH enclosures shall match the material used for
construction of the enclosure.
2.17. For all air supply houses, filters shall be provided and installed complete with initial supply
of media after all air supply areas have been deep cleaned and a full identical preliminary
set for use prior to deep cleaning. Lower efficiency filter shall not be permitted for the
preliminary set. Filter selection shall be coordinated with and purchased from the plants
filter supplier. The 2 sets of filters shall be per the specifications. Temporary panels
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filters will also be required ahead of the primary filters until the system is turned over to
the owner.
2.18. The prime contractor will be responsible for providing storage sufficient for a complete
set of filtration for all ASHs and plenums as well as service access ladders and cleaning
equipment. Space requirements with be as required by the plant cleaning and filter
contractors.
2.19. Exception to or deviations from this specification by an air house manufacturer will not
be permitted unless specifically approved by GM Global Paint & Polymers Center. A
check list of all specified equipment and construction details listed will be required to be
submitted by the manufacturer during the project showing compliance with all
specifications. If any items not in compliance with the specifications are found during
engineering, fabrication or pre-shipment review, GM Global Paint & Polymers Center
reserves the right to refuse shipment to the site until discrepancies are corrected. It will
be the Prime contractors and air house manufacturers responsibility to maintain
schedule and to absorb any cost impact associated with this type of delay. The above
statements apply to all manufacturers. Refer to the Approved Equipment List for
manufacturers. This statement also applies to all listed components and materials in
this specification. Alternate suppliers will not be considered during bidding or before
award.
2.20. Building and Misc. Deck and Enclosure Air Supply Houses shall utilize the following
basic design criteria:
2.20.1. Space temperatures shall meet GM Global Paint & Polymers BOP section 34000.
2.20.2. Base steel for units mounted indoors shall be M.S. primed and painted with 2 coats of
epoxy. This assumes all steel is exterior to the air stream. Steel exposed to air stream
will be galvanized with weld repair as described in this spec..
2.20.3. Humidifiers for these houses may be four-bank style with one slow acting S.S. solenoid
and pressure compensating flow control valve and orifice with transmitter and gauge per
bank. All other materials of construction and details will be followed per the humidifier
section.
2.20.4. Single stage line burners will be permitted on small houses. Each house will reviewed
individually and approved by Spec. owner for acceptance of single stage burner.
Typically houses less than ?? 60,000 CFM (28.317 m/s) will meet the necessary
criteria.
2.20.5. Prefabricated wall panels per the approved equipment list will be considered for use on
walls of exterior building units and for process units. Interior surface must be smooth
galvanized surface. All corner, bottom and top joint details will require review and
approval by spec. owner. Both sides and interior joint will require full sealing. Panels
will be 150 mm (6) minimum.
2.20.6. Inlet perforated plate may deleted only if modeling is provided that shows filter velocity is
consistent within +/- 5% across entire face of frame area.
2.20.7. Building and other process (i.e. Phosphate/ELPO) air supply houses shall comply with
the typical air supply house specifications, bid drawing requirements and the following
special conditions:
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2.20.8. All air supply house and building exhaust components shall be monitored and alarmed
by the central paint shop monitoring system. Both supply and exhaust shall also have
velocity sensors with low velocity alarms.
2.20.9. Primary and secondary filtration will be provided in the air supply house.
2.20.10. The fresh air intake, aisle heater intakes, indirect fired burner location and all other
aspects of the exhaust and supply systems shall take into account other exhaust
systems and vents for the paint shop.
2.20.11. Air houses shall consider overall ventilation requirements in terms of temperature
and humidity control. Some ASHs will use hot water coils for heating.
2.20.12. Any house exceeding m/sec. (400 FPM) on filters and coil velocities specified will
require compartment to compartment walls distances to spread 2X minimum 2 m (6).
Cooling coil or humidifier velocities in excess of specification will require mist eliminators
and all downstream walls/ceilings/floors to Din 1.4306 (304) S.S. downstream.
3. ENCLOSURE
3.1. Interior mounted air Supply houses shall have galvanized or aluminized siding , interior
metal liner, and roof deck. Interior unit roofs shall be capable of being walked on without
damage. The exterior and interior walls and roof of a penthouse located unit shall be
insulated with minimum 38 mm (1-1/2) thick, 12.25 kg/m2 (2-1/2 lb./ft2) density
fiberglass or 14.65 kg/m2 (3#/ft2) rock wool fiberboard insulation which shall be held
securely in place between the panels All small gaps at corners and ends shall be
completely filled with insulation. All joints shall be sealed so that moisture does not come
in contact with insulation. Areas to be insulated will be based on local conditions for
ambient temperatures in the penthouse and air house supply temperatures. At a
minumim the area from and including the fresh air intake to the humidifier will be
insulated. Cooled air supply houses and all air supply houses in an unheated penthouse
will be fully insulated.
3.2. For outdoor installation, the enclosure shall be completely weather proofed. Outdoor
placement of Air Supply houses requires the approval of GM Global Paint & Polymers
Center. Outdoor units are NOT to be base bid. Outdoor units shall have exterior metal
siding with appropriate gasket tape and screws with covers and gaskets. Roof on exterior
units shall have edge clip attachment to the support and shal not have screws through
drainage surface.. . Exterior units shall be constructed to withstand a minimum 150 kg
/m2 (30-pound per square foot) wind load, plus snow load. Roofs shall be capable of
being walked on without damage. Flashings, moldings, and metal closures shall be
provided as required to completely weather proof the unit and to provide a neat finished
appearance. All insulated materials shall be weather protected prior to installation. All
roof penetrations shall be sealed with pitch pockets and not with sealing tape. Roof
penetrations will be avoided and shall require the approval of the owner. All outdoor
units shall require 0.15 m (6) thick high density insulation. All exterior units shall use
bottom lift lugs only. Roof mounted lift lugs will not be permitted. Appropriate lift
spreader bars, section weights and required rigging practice descriptions will be provided
with all sections whether bottom or top lift. It shall be both the prime contractor and ASH
manufacturers responsibility to coordinate lift methods and maximum weights during
engineering.
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3.3. Floor deck for all air houses shall be composed of a wearing surface of 3.5 mm (10 ga.)
minimum Type II Aluminized or galvanized steel smooth plate or as noted later, welded to
the structural floor framing and reinforced with structural shapes, so that the fan motor,
filters, dampers, etc., can be supported without sagging or warping the floor. Provide
alternate pricing for all S.S. floor deck inside compartments. All edges shall be sealed
with a continuous weld. Wherever possible floor sheeting shall be machine welded.
Grinding of floor surfaces shall be minimized to the greatest extent possible. All welds on
galvanized material shall be coated with a galvanized adhering zinc rich primer and
urethane top coat (see painting section). Where holes are provided in the floor for duct or
pipe openings, they shall be carefully cut and the exposed edges of the insulation
covered by structural angles for large openings or by steel sleeves for smaller openings,
all welded in place water-tight. Floor decks shall be insulated with minimum 50 mm (2)
12.25 kg /m2 (2-1/2 lb./ft2) density fiberglass or 14.65 kg/m2 (3#/ft2) rock wool fiberboard
fiberglass insulation and clad with 1mm (20 ga.) minimum Type II aluminized steel. If
exposed to outdoor temperatures 150mm (6) will be used to help protect exterior piping.
3.4. In addition to the above construction, the entire floor of the service compartment shall be
coated with a layer of non-skid compound; refer to the Approved Equipment List for nonskid compound manufacturers.
3.5. The entire floor area in the compartments before and after the humidifier and before and
after any cooling or heating coils and in all compartments of recirculation filter houses
shall be 3.5 mm (10 ga.) Din 1.4306 (304 L) S.S. sloped to a drain (this is not an
alternate). All pan areas shall have a minimum 50 mm (2) lip around the pan section.
The joint between the pan and wall shall be caulked before assembly sufficiently to insure
a watertight joint. Wall panels shall shingle the pan with 25 mm (1) overlap to prevent
water from running between the wall and pan. All pan welded joints shall be dye tested
for leaks prior to installation of components on top of the pans.
3.6. All compartments and aisles shall have drains. All drains shall be trapped to prevent air
movement from compartment to compartment and from the drain system and when
drains are exposed to outside conditions Contractor shall heat trace and insulate to the
point of entry into the building on exterior units. Drain traps shall be kept full by a tubing
connection form the humidifier feed line or designed to function without water. Flow for
the feed line shall insure central tank blow down is not excessive and water conditions
can be controlled. Where possible all traps shall be located below the roofline. All drains
shall be provided with screwed removable drain covers. Drain covers on interior drains
shall be S.S. or galvanized steel to match the flooring material. All service aisles shall
have drains spaced on not less than 4.5 m (15) centers, including penthouse aisles. As
an alternate, all cooling drains will be piped separately with corrosion resistant piping to
the gray water holding system described in the sludge system specification for reuse.
3.7. All recirculation filter houses shall have flooring of 3.5 mm (10 ga.) minimum Din 1.4306
(304L) S.S.. Flooring shall be welded air and water tight per the spray booth eliminator
specifications. All welds shall be passivated and dye test prior to the installation of any
internal components.
3.8. Exterior Siding Sheets shall be roll-formed 1.25 mm (18 ga.) minimum galvanized or type
2 aluminized with factory applied paint finish if outdoors (color to match building) and
installed in continuous lengths to eliminate all intermediate horizontal joints. Exterior
siding shall be erected with the ribs positioned vertically. All side laps between exterior
sheets shall be sealed with preformed tape sealer. Refer to the Approved Equipment List
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3.9.
3.10.
3.11.
3.12.
3.13.
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for preformed tape sealer manufacturers. Exterior siding sheets shall be as

manufactured by any company on the Approved Equipment List. Exterior siding sheets,
when attached to the framing steel shall extend past the top edge of the curb with proper
flashing in place to form a good seal and shed water.
Insulated siding sheets for interior mounted units shall be 1.25 mm (18 ga.) minimum
galvanized or type II Aluminized steel fluted sections with 38 mm (1-1/2) deep male and
female ribs to provide an interlocking joint between sheets. Sheets shall be the
manufacturers standard type interior liner panels, 0.6 m (24) wide. Sides of sheets
toward interior shall be flush without projecting ribs or seams. However, concave V or
U crimps may be formed into the sheets for stiffening. See the Approved Equipment
List for joint sealer compound manufacturers. Seal all interlocking joints of interior sheets
with sealer compound in the joints and not on the interior surface and clinchlock the
interlocking ribs of sheets with a button punch at intervals not to exceed 2-0 (0.61).
Where flat sheeting is used for interior closure, sheeting shall be 1.5 mm (16 ga.)
galvanized or aluminized anchored on not less than 200 mm (8) centers. All edges of flat
interior sheet shall have 60-130 mm ( - ) featheredge breaks on all sides to insure a
flat tight fit when attached. Flat sheeting shall have caulk applied before attachment to
framing sufficiently to ooze from the edge of the sheet and excess wiped residue free
clean after installation.
All interior sheeting inside recirculation filter house compartments shall have walls and
ceilings of # 10 gauge minimum Din 1.4306 (304L) S.S. welded air and water tight per the
spray booth eliminator specifications. All welds shall be passivated and dye test prior to
the installation of any internal components.
Roof Decking shall be insulated double wall construction consisting of 1.25mm (18 ga.)
minimum exterior panels of the same material as the exterior siding, insulation of equal or
higher quality than the walls, and a interior skin of 1.25 mm (18 ga.) galvanized sheet
steel. All roof deck units shall be in single lengths and shall be supported by framing
pitched to provide proper roof drainage. Deck shall be fastened to the frame at intervals
2
2
to resist uplift of 175 kg/m (35 #/ft ). All roof deck clips and fasteners shall be at the raw
edge of the panel and fastened to the framing steel and not through the decking. Clips
shall be designed to permit expansion and contraction of sheets. Roof decking panels
shall have a minimum 40 mm (1-1/2) high ribs spaced at 150 mm (6) centers. All roof
penetrations shall be sealed with pitch pockets or flashing and curbing methods similar to
typical roof penetration details for the building. Manufacturer will guarantee roof integrity
and provide guarantee to owner for approval. Interior mounted units shall be insulated
and decked similar to wall construction without the exterior details for drainage and
weather protection.
All joints shall be properly caulked to provide a complete weather-tight condition. Roof
panels shall be installed with exterior sheet inverted (narrow ribs up). The enclosure roof
shall slope from the high point to the eaves in one (1) continuous panel.
On exterior units, provide 1.25 mm (18 ga.) (minimum) Aluminum 150mm (6) wide
gutters and down spouts. A 1.5 mm (16 ga.) minimum Aluminized steel splash pan shall
be installed under downspouts. Downspouts shall extend to the roof level. Where
adequate support of downspouts is not possible, a collection system shall be provided.
Collection systems shall be capable of remaining clear of debris through the use of
screened inlet boxes and freeze protection. On roof mounted units, gutters and
downspouts shall be formed of the same color material as the fascia. Stop ends and
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3.15.
3.16.
3.17.
3.18.
3.19.
3.20.
3.21.
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nozzle shall be provided for gutters. Strap hangers shall be spaced 0.8m (32) on center.
All gutter joints shall be coated with gutter sealer to assure a water tight joint.
Downspouts shall be 80mm (3) corrugated square section with stock heads and outlets,
complete with offsets and adjustable conductor straps spaced not more than 1.8 m (6-0)
on center; a minimum of two straps per downspout shall be fastened to the enclosure
wall.
Attach panels to framing with galvanized screws with neoprene washers, spaced not
more than 300 mm (12) on centers.
Space subgirts horizontally approximately 1.2 m (4) on centers and attach them securely
to ribs of interior sheets. Subgirts shall be stud bars, channels or roll formed members
approximately6.3 mm x 25 mm ( x 1) minimum. Subgirts shall be spaced in
accordance with siding manufacturers standard erection procedures.
Provide the necessary flashings as may be required. The enclosure shall be adequately
braced to withstand total fan negative pressure, if the fresh air inlet dampers fail to
function properly. Static relief panels shall be provided on recirculation houses to permit
maximum static relief in the event of damper failure.
Provide 1.5 mm (16 ga.) minimum galvanized or Type II aluminized formed sheet metal
flashings as may be required to completely seal off the clearance space between the
enclosure and the various air house components (filter banks, etc.). The formed sheet
metal flashings shall be provided with companion holes to suit the air house components
being silhouetted.
All the air supply house enclosure panel joints including flashing, door frames, etc., shall
be caulked to insure an air-tight assembly. Caulking shall be of permanent, nonhardening, non-chalking type and installed in a neat professional manner. All excess
material shall be removed from the seams or where applied elsewhere. Refer to the
Approved Equipment List for caulking manufacturers.
Access doors shall be provided in the interior partition wall, along the service aisle, and at
each equipment compartment entrance. The doors shall be installed so that air pressure
holds door tightly closed against rubber gaskets to prevent leakage. The doors shall be
raised approximately 120 mm (4) above the floor to permit sealing of bottom edge. All
door swings shall be shown on submittal drawings and interferences with other equipment
or control panels considered. Heavy-duty door stops and hold open devices shall be
provided for all doors. See approved equipment list for hold open devices.
The doors shall be a commercial product as manufactured by companies on the
Approved Equipment List, galvanized or type II aluminized steel flush type construction,
1 m (36) wide x 2 m (80) high x 45mm (1-3/4) thick complete with vision panels
approximately 250 mm x 250 mm x 6.3 mm (10 x 10 x ) clear wire reinforced plate
glass. Larger vision panels as required shall be provided to permit compartment viewing
from outside floor level or to permit burner viewing. Use of any other door manufacturer
shall required detailed fabrication drawings and a sample to be reviewed and approved by
GM Global Paint & Polymers Center. Fan compartment doors shall be adequately sized
to allow removal of the motor. Doors shall be complete with hardware and door frames.
The door frame design shall incorporate rubber gaskets, of a replaceable type, to seal
doors on all (4) sides. The gaskets shall be mechanically held in place with an extruded
aluminum track, no adhesives.
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3.22. Doors for recirculation filter houses shall as described and constructed of Din 1.4306
(304L) S.S. with EPDM gasketing. These doors and frames shall be rated as per the
enclosure for static surges. Doors on recirculation houses shall be designed to open
outward and the houses themselves shall always operate in a negative pressure state to
insure containment of solvent laden air.
3.23. Provide doors with (3) heavy-duty industrial type ball bearing hinges, and approved
latches which are listed on the Approved Equipment List, operable from both sides.
Shafts shall be steel. One heavy-duty door pull is to be installed on the pressure side of
each door.
3.24. Exterior doors shall be provided in the enclosure service aisle wall.
3.24.1. The doors shall be a commercial product as manufactured by any companies listed on
the Approved Equipment List, insulated flush hollow galvanized or type II aluminized
steel construction, 1m (36) wide x 2.1 m (84) high x 45 mm (1-3/4) thick, complete
with approximately 580 mm x 750 mm x 6.3 mm (23 x 28-3/4 x ) clear wire
reinforced plate glass vision panel, and heavy duty lock sets. Use of any other
manufacturer shall required detailed fabrication drawings and a sample to be reviewed
for approval by GM Global Paint & Polymers Center. Where required, door shall be
sized for largest fan motor removal. Provide an approved type door stop to prevent
wind damage. (3) heavy duty industrial type ball bearing hinges shall be required on all
doors.
3.24.2. The door frame design shall incorporate renewable type weather stripping on three (3)
sides held in place by extruded aluminum and spring loaded automatic seal at the
bottom of the door. Provide an exterior drip shield above the doors.
3.24.3. Each door shall be furnished with a aluminum hydraulic door closer. The closer shall
be installed inside of the service aisle.
3.24.4. Door hardware shall be exterior heavy duty lock sets as specified in the Approved
Equipment List. Locks if desired by the plant, shall be as per the plant specific
requirements and approved by the plants representative.
3.25. The service aisle on roof or outdoor mounted units shall be ventilated with WALL
mounted powered exhaust ventilation fans controlled by a thermostat. Back draft
dampers shall be provided. A weather protected wall opening for air intake shall be
provided with a 50 mm x 600 mm x 600 mm (2 x 24 x 24) pleated filters as required in
the outer wall shall have motorized dampers interlocked with the ventilator operation.
Sizing of the filter openings and the ventilator will be predicated on heat loads within the
air house aisle and exterior radiant heat absorption to insure adequate temperature
protection for all aisle mounted equipment and control cabinets.
3.26. The service aisle in roof or outdoor mounted units shall require a gas or steam unit heater
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to maintain a minimum 10 C (50 F). Gas unit heaters shall be of the high efficiency
outside combustion air type with appropriate PVC fresh air intake and combustion air
discharge through the ASH aisle side wall. For penthouse installed ASH, unit heaters
may be part of the building heating system. It is the contractors responsibility to
coordinate this item with the general building contractor. All heater selections shall be
submitted for approval by the owner. Placement of vent stacks shall conform to the
National Fuel Gas Code requirements and guidelines for combustion vent service.
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Service aisle heaters shall be rated NEC Zone 1 (Class 1 Division 1 Group D ) for
recirculation air filter houses.
4. STRUCTURAL STEEL
4.1. The Air Supply Enclosure on all roof mounted units shall be supported from an interior
structural steel frame. All structural steel shall be fully welded assembled with all welds
primed with cold galvanizing primer and 2 coats of gray epoxy enamel. The base shall
be constructed of galvanized structural tubing. No welding to the structural steel shall be
permitted after galvanizing to prevent destruction of the coating. If the house is field
erected on a concrete pad, the Contractor shall anchor the structural steel base framing
to the concrete floor pad by means of lag bolts. Minimum lag bolt size shall be12.5 mm
( ) diameter, unless specified otherwise, and shall be secured with lag shields, or
Owner approved equal anchors, imbedded in the concrete. Structural steel frames shall
consider the static loading of the air supply or recirculation filter house and provide 20%
excess static capacity with fully loaded filters.
4.2. All structural steel design and construction shall be in accordance with AISC and AISI or
per local country Structural Steel Standards and Specifications . All steel shall conform to
ASTM A36 designation.
4.3. Assembly shall be by bolted connections using high strength bolts, nuts, and washers.
Bolts shall be ASTM A325, properly torqued.
4.4. The structural steel frame shall be properly designed to accept all of the standard wind
150 kg/m2 (30 #/ft2 ), snow, and dead loads plus the additional loads created by the
discharge ductwork, and rapid internal air pressure changes which can be created by a
malfunction of the shut-down dampers in the air intake fitting.
4.5. All structural steel located inside the air supply compartments shall be enclosed with
interior decking described in section 39.9 and
5. FRESH AIR INTAKE FITTING

5.1. The air intake fitting shall be a rain proof fixed vertical mushroom type design,
constructed of minimum 1.5 mm (16 ga.) galvanized steel, properly reinforced. All
exterior surfaces shall be sided to match the building. Top surfaces shall be installed per
the roof specifications for exterior units. The fresh air inlet openings shall be fitted with
removable 20mm () mesh 1.5 mm (16 ga.) galvanized wire bird screen. The wire
screen shall have 25 mm (1) galvanized hair pins around its perimeter for support and be
fastened on minimum 300 mm (12) centers to the intake hood. The velocity through the
bird screen shall not exceed 2.5 m/sec (500 FPM) . All interior framing shall be primed
and painted with an epoxy enamel after all welding is performed. Sheet metal screws
used for exterior siding shall have exposed shafts removed. Intake mounting flanges
shall insure proper design loading for worst case wind conditions.
6. FRESH OR RETURN AIR INTAKE DUCTWORK

6.1. The air intake ductwork shall be sized to pass the required air volume at a maximum
velocity of 7.5 m/sec (1500 FPM). The intake ductwork shall be constructed of minimum
2 mm (14 ga.) galvanized steel, properly reinforced to support the imposed loads. The
exterior of the duct shall be clad with siding to match the building.
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6.2. The intake duct shall be designed to support the air intake fittings, dampers, and also to
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withstand a wind load of 150 kg/m (30 #/ft ) .
6.3. Provide the necessary flashing required at the intake ductwork through the air house roof
to insure a weather tight seal.
6.4. All spray booth recirculation air return ducts shall be Din 1.4306 (304L) S.S. welded water
and air tight. Recirculating air house return air duct shall comply with the above. Duct
transitions shall be provided before the filter house or return air compartment to insure
even distribution and reduce velocities to 1.78 m/sec (350 FPM) or less at the first set of
perforated plates. All recirculation ductwork shall be per spray booth exhaust duct
requirements. Leak testing shall be performed on all recirculation ducting to insure near
zero leakage to the plant.
6.5. All supply and return/exhaust air duct work shall be according to the following gauge
minimums at static ratings: > 1 kPa (7 W.C.) 2.75 mm (12 ga.) ; 1-1.7 kPa (4-<7
W.C.) 2 mm (14 ga.); 500-1000 Pa (2-<4 W.C.) 1.5 mm (16 ga), <500 Pa (<2
W.C.) 1.25 mm (18 ga.)
6.6 Fresh air intake sections will divided at the vertical centerline and 2 sets of control
dampers will be provided above the burner. Burner, controls and intake will be designed
for 50% volume turndown during down periods.
7. FRESH AIR INTAKE DAMPERS

7.1. Parallel blade shutdown dampers shall be installed on the downstream side of the fresh
air intake. The dampers shall be automatically operated.
7.2. The damper blades shall be a maximum of 150 mm (6) wide x 1.2 m (48) long,
constructed of minimum 1.5 mm (16 ga.) galvanized or type II aluminized steel. The
damper blades shall be fabricated with formed overlapping lips 20 mm (3/4)minimum and
shall be formed with reinforcing vee at the center of rotation for the full length of the
blade. Edges and ends of the blades shall be sealed with neoprene gaskets for tight
closure. Blades shall be set in a minimum of #16 gauge galvanized or type II aluminized
steel roll formed frame or minimum #10 gauge galvanized or type II aluminized steel
formed channel complete with standard bearings with lubrication fittings in an accessible
location(bushings or inserts not permitted). The connecting linkage between the blades
shall be concealed in the damper frame out of the air stream. Gear linkage dampers and
alternate materials can be approved with review and approval of the specification owner.
All fresh air intake dampers shall have linkage/gears outside of insulation equivalent to
the cold air intake duct. Refer to the Approved Equipment List for damper manufacturers.
7.3. The dampers shall be operated by a 120 v (or country typical), 2 position, spring return
direct connected electric motor. A minimum of one (1) damper motor operator shall be
provided for each 3.7 m2 (40 ft2) of damper area. The contractor shall be responsible to
verify that the specified motor is capable of the required torque for cracking pressure
under load with 25% excess capacity. The control shall be such that the damper is in the
full open position before the air supply fan can start. Motors shall be rated for the
maximum temperature exposure anticipated and be weather tight NEMA 12 construction.
Motors shall match the manufacturer used for the humidifier dampers and be per the
Approved Equipment list. Motor selection shall be submitted for approval by the
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appropriate specification owner. On indoor units, operators and limit switches will be
mounted outside of the house for simplified access.
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7.4. Each 3.7 m (40 ft ) damper section shall be complete with its own limit switches arranged
to close a contact wired in series, when damper blade is fully open to provide a safe
start interlock for supply fan.
7.5. An additional limit switch shall be provided for monitoring by the PLC for indication of
closed dampers when supply fan is not running.
7.6. Dampers for the inlet and discharge of recirculation filter houses shall be all Din 1.4306
(304L) S.S. construction. These dampers shall insure 99% leak free shut down capability
with S.S. overlapping blade seals in combination with EPDM compression seals and bar
stops. Damper operators and linkages shall be capable of 20% excess torque at
cracking pressure requirements. Refer to the Approved Equipment List for damper
motor manufacturers. All linkage shall be minimum12.5mm () square S.S. bar stock
with threaded rod ball bearing end fittings with accessible lubrication fittings extend to
accessible location is required. Damper shafts shall have ball bearing supports. All shaft
support bearings and linkages shall be externally mounted. Shafts shall have adequate
seals to prevent leakage.
8. AIR SUPPLY FAN

8.1. The air supply fan shall be centrifugal type, suitable in construction for the industrial
service intended. Single inlet fans shall be located outside of the air house with bell
mouth inlet venturi fittings provided by the fan manufacturer on the ASH wall transition to
the fan inlet. S.S. screen guards shall provided at all inlets bolted to the inlet. No sheet
metal screws or sharp protrusions within the housing air stream shall be permitted. There
shall be a minimum of 3 m (10) from the last air supply house component (humidifier or
reheat coils) to the fan inlet. For locations where single inlet fans are not possible
(approval of change by GM Global Paint & Polymers Center Engineering required), fan
placement within the fan compartment shall insure smooth, non-turbulent flow into the fan
inlets. A minimum of 1-1/2 wheel diameters shall be provided on both sides of the fan
inlet and 2 wheel diameters before the fan. DWDI fans shall also be completely painted
inside and out with 2 coats of epoxy enamel including all base members. Sufficient room
shall be provided around the perimeter of the fan to allow for maintenance and cleaning
without climbing on the fan. Fan wheel design shall be non-overloading type, backward
curved, double surface, airfoil blades with weep holes. All supply fans or recirculation
filter house fans shall be VFD controlled. Fans on recirculation filter houses shall have
Din 1.4306 (304L) S.S. wheels and inlet cones, interior epoxy coating and comply with all
aspects of the spray booth exhaust fan specifications.
8.2. All non S.S. components shall be thoroughly pressure washed to remove all mill oils,
grease and dirt and then phoshated prior to priming. An finish coat of epoxy enamel will
be applied to all interior surfaces and standard enamel on exterior surfaces of inside
building mounted fans. Fans mounted outside the building shall be epoxy enamel coated
on the both the interior and exterior of the fan.
8.3. The fan shall be Arrangement I, Class II construction, SWSI, complete with two (2) large
(36x 36 minimum) clamp on clean-out door located at the 5:30 or 7:30 position (not on
discharge side), drain, inlet screens, and inlet volume control dampers (Vortex Vanes).
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8.4.
8.5.
8.6.
8.7.
8.8.
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seize compound (no Silicone). Doors shall be removable without the use of tools. Door
seals shall be mechanically attached.
All supply fans shall have vortex inlet vanes with type Din 1.4306 (304) stainless steel
blade shafts and permanently lubricated, oil impregnated, Oilite bearings located at both
ends of shafts. The single damper control arm shall be arranged for installation of an
electric motor automatic operator or manual lock down. Fan shall be picked for maximum
stability and sized for a discharge velocity of approximately 12.2m/sec (2400 FPM) to
deliver specified air volumes against the system pressure. Where dual fans are used on
a single ASH, either discharge dampers or vortex dampers will be provided with operators
as described to permit staged starting without the use of back spin clutches.
Fan bearing size shall be based on a minimum L-10h average life of 200,000 hours of
continuous operation for this service. Bearings shall be heavy duty, self aligning, ball or
roller, split pillow block, grease lubricated with pressure relief feature tubed to a collection
container. Provide shaft and bearing guards to meet OSHA requirements and all other
applicable rules and regulations. Guards shall be substantially constructed to prevent
crushing. Shaft and bearing guards shall sit between and outside the bearing housings
to permit the use of magnetic vibration sensor mounting and IR guns. Guards shall be
removable without the use of tools. Shafts shall be selected to operate at not more than
70% of the critical speed for proper support of the shaft under maximum load and speed.
Extend grease fittings to outside of any guards or other obstructions using 6.3 mm ()
minimum tubing for easy access and mounting of lubricator. Lubricator mounting shall be
no more than 1.5 m (5) above floor level. Guards shall be removable without removing
grease tubes or lubers. Pans shall be located under each bearing to collect waste grease
and be sealed sufficiently to prevent oil and grease leakage. Pans shall be sufficiently
deep to accommodate one years lubrication Provide an adjustable, automatic lubricator
for each bearing. Lubricator shall be sized for 1 year operation based on the bearing
manufacturers required lubrication frequency and grease type. Refer to Approved
Equipment List for automatic lubricator manufacturers . If fans or other components are
mounted outdoors, a hinged cover shall be placed over the lubricators to protect the
lubricators. All lubricators, including motor, shall be mounted at a single location.
Fan housings shall be heavy gauge continuously welded scroll adequately braced with
channels and angles for rigidity. Channels and angles shall not face upward to collect dirt
or water. All fans shall have a 40 mm (1 ) minimum drain coupling and plug at the
lowest point of the scroll. A flex connection will be provided to the drain piping that will
connect to the suction duct or other suitable location that does not permit any drained
water to become re-entrained. Piping will be galvanized schedule 40. Fan discharge
shall have continuously welded companion flanges. All fan wheel hubs shall be full hubs
either cast steel or weldment, bolted or riveted to the back plate of the fan wheel in an
approved manner. Welding of hub to back plate will not be permitted. Shafts shall be
center drilled to facilitate tachometer reading. Tooling and mounting holes will be
provided by the fan supplier for shaft push out from the fan hub.
All fan design and rating shall be in accordance with AMCA Test Codes and
Specifications. Fan name tags shall be located on face of pedestal under drive and shall
show size and weight, construction, arrangement, bearing manufacturer/style/model
number and shaft sizes, drive and belt sizes/manufacturer and model number (fan and
motor), rated volume and static, speed, and serial number for replacement parts. Tags
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shall be screw mounted and of stamped construction. Painted data or adhesive mounting
are not permitted. Fan serial number and model and date of manufacture shall be on
embossed metal tags only. Special maintenance or access instructions will be
laminated and permanently attached to the housing. Fan instructions will be provided for
all fans on a CD with each serial number listed and referenced or linked to the appropriate
maintenance instructions, fan tag and performance information, pivot base setup
information and calculations, vibration data for both the field and shop compiled with field
corrective actions as required for each fan, fan certified drawings and laminated special
instructions.
8.9. The installed fan assembly shall not exceed the vibration limits specified in the General
Motors Vibration Standard Specification No. V 1.0. All fans shall be shop dynamically
balanced as an assembly with all drives and motors mounted. Field measurements are
required for both individual fans and with all equipment functioning. All shop balance
weights shall be welded in position and all field weights bolted in position. The use of clip
on or clamp on weights will not be permitted. All removable drive and bearing
components shall be permanently marked in relation to their original location. Shop
balancing data for both the fan and motor shall be shipped with the fan to the ASH
manufacturer or job site. Field and shop measurements must be included in the fan
section of the repair and maintenance manuals when submitted to the owner for approval.
Upon completion of the project, field and shop signatures and a list of corrective actions
to achieve spec. will be compiled for each fan on the project will be submitted to this
specification author for review. Fans requiring corrective action will segregated by area
separately. Forms shall comply with the listed Standard. Shop measurements of the fan
and motor shall be attached to the fan at the time of shipment along with the
manufacturers check list.
8.10. Refer to Approved Equipment List for fan manufacturers. Owner reserves the right to
make final selection based on performance and design characteristics.
8.11. A certified fan curve with point-of-rating indicated and sound power levels must be
submitted when obtaining vendor design approval. The lowest sound power level
available without extreme size change shall be provided. Verification of duct and system
static losses calculations must be provided with these curves. Fans shall generally be
selected to run at a point that achieves 75% or more mechanical efficiency and allows for
anticipated changes in static pressure. Selection must be based on stability with the
operating point in the lower 2/3 of the vertical portion of the curve and minimum sound
power levels. If stability is not achievable with standard width wheels, the contractor may
submit for Owners approval partial width wheels as an alternate. Where multiple fans
have common inlet connections, a system curve shall be required showing the effect of
multiple fans on the individual fan performance. Curves shall list the following
information: clean and dirty filter static loads and operating point on curve at BOTH
values; maximum tip velocity for wheel class and design maximum tip speed; fan design
shaft speed; dBA at maximum design speed; brake HP AND selected motor HP; general
arrangement drawing showing mounted motor position and all materials of
construction/options.
8.12. Provide a flexible connection between the fan and inlet and/or discharge fitting fabricated
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from 610 g/m (18 oz./yd ) neoprene covered nylon. Recirculation houses shall be made
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with 5 mm (3/16) high temperature fiberglass or other appropriate material reinforced

flexible connections with glued and sewn lap joints. The flexible connection shall be of
one piece construction with flanges on both sides. The flexible connection shall be
capable of withstanding typical booth cleaning chemicals, high pressure water blasting.
8.13All edges to have sewn and glued folded finished hems. Flexible connection shall have
flanges on both sides to aid in replacement and repair. Weather exposed connections
shall be rated for outdoor service, i.e. rated for low temperature flexibility and exposure to
sunlight. All flange connections will be caulked to insure no leakage.
9. FAN AND MOTOR VIBRATION CONTROL BASE
9.1. The fan and motor shall be mounted on a structural steel base outside the
compartment wall with sufficient stiffness to resist the belt pull without drive distortion.
Spring mounts shall have bonded non-skid pads and be adjusted with leveling bolts
from the steel base for both the fan and the motor. Refer to the Approved Equipment
List for spring mount manufacturers. Spring sizing shall accommodate the motor or fan
weight without excessive adjustment of the leveling bolts. Spring isolators shall be
captive type. Grouting of fan bases is not acceptable. Springs and pads shall be
sized and provided by the fan manufacturer. Isolator settings will be documented on
the fan certified drawings. For spray booth recirculation fans Spray booth exhaust fan
specifications shall apply.
9.2. The fan manufacturer will provide a second angle frame with all isolators mounted to it
with welded studs or bolts. The secondary frame will be temporarily banded to the
structural base for shipment. This frame shall be substantial enough to permit anchoring
using wedge washers on approximate centers. Required minimum center distances for
anchoring and contact surface area for anchors will be provided attached to the fan at the
time of shipment for the installer. This frame will prevent the issues typically associated
with specific bolt pattern locations when spring isolators are directly lagged to the
concrete floor.
10. MOTORS
10.1. All motors shall be totally enclosed NEMA Design B in total compliance with the GM
Standard Specification 7ETA for T Frame Electric Motors. For international projects, the
motor type and specification will be decided by the local owner based on spare
availability. If IEC, all motors must be supplied from the same Manufacturer and premium
efficiency unless approved by the owner. Motors must be rated for Inverter duty. All
motors shall have the bearing end bells positioned vent down. All supply fan motors shall
have the electrical connection pecker head located toward the fan bearing pedestal. All
motors shall be mounted with the shaft facing the same direction as the fan shaft.
10.2. All motors shall have automatic lubricators and grease relief valves as specified in the fan
bearing section. Hard tubing to an extended point for both the vent and lube ports shall be
provided by the motor manufacturer on both ends of the motor. A fixed mounting plate
shall be provided with tubing for both bearings. A method of collecting purged grease will
be provided. Collection container will be removable without tools for emptying. See fan
bearings for additional lubricator information. Motors shall be warranted for three years.
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11. V-BELT DRIVES AND MOTOR BASES

11.1. All drives shall be mounted outside of the enclosure and will be the quick demountable
design type. Drives shall be sized 40% in excess of motor horsepower. Fan speed shall
be selected based on maximum operating total static with 10% excess volume capability.
Belts shall be static dissipating. All belts shall be selected as matched sets where
available. No drive selection shall be less than 2 groove, B section, refer to Approved
Equipment List for belt manufacturers. All drives shall be installed with an appropriate
anti-seize compound on all shafts, screws or bolts and sheaves. All drive assemblies
shall be coated with a protectant after assembly to prevent corrosion. Refer to Approved
Equipment List for corrosion protectant manufacturers. Any areas not protected or
assembled with the proper compound will be disassembled and reassembled to provide
the correct protections and anti-seize materials. All drives shall be dynamically balanced
with welded on weights.
11.2. Fan drive selections shall be based on NEMA drive size selection criteria or drive size
selection criteria for the motors used. Ratio of driver to driven and shaft center distance
shall insure sufficient belt contact on both drives for optimum belt life.
11.3. If a belt size selection results in more than six (6) belts on the drive, a larger section shall
be selected to reduce the number of belts to six (6) or less. Belts must selected to
minimize drive noise.
11.4. The motor base shall be the reaction pivot type sized for two frame sizes than the
selected motor. All pivots, adjustment bolts and hardware shall be factory lubricated with
an appropriate anti -seize compound. Motor mounting position on a pivot base shall be
clearly identified and dimensioned in the Manuals and on the fan drawings. Belt tension
shall be field verified and adjusted. Motor mounting position on a pivot base shall be
clearly identified and dimensioned in the Manuals and on the fan drawings. Pivot base
settings shall be clearly identified on the base by scribe and paint marking of all
adjustable or settable positioning methods. Calculations shall accompany the fan at
shipment showing all motor shaft loads, belt loads, static belt tension and required motor
to pivot base shaft off set and angle. Fan supplier will guarantee that motor hop will
not occur at the range of speeds the fan may operate under. Adjustment or release
hardware shall be easily accessible. Motor to fan shaft center distances shall be
minimized. Minimum stops shall be provided to prevent sheave contact with guard in the
event of belt failure. A bottle jack plate will be provided under all bases to permit the use
of a jack in removing belts. A blocking arm will alos be provided to hold the motor/base in
a safe position while changing belts.
11.5. A motor service rail shall be provided with trolley rated for the weight of the motor. Rail
shall be capable of extending to the end of the service aisle on roof mounted units or to a
clear aisle on penthouse mounted units. A service cart with large rubber wheels shall be
provided for movement of the motors. All roof mounted air supplies shall also have aisles
and outside service catwalks capable of supporting the largest motor. A service rail with
hoist shall be provided to get the motors to ground level. Sufficient room shall be
provided around all motors and pivot bases to allow for full movement of the base. As an
alternate to service rails where accessible by a forklift of sufficient capacity, a jib arm
suitable for use on the forks may be provided. If not fork truck accessible, a cart may be
provided with: jib arm, hydraulic arm lift, counter weight, large rubber wheels for ease of
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movement. Total mass required to be moved shall be considered and submitted for
approval when evaluating cart use.
12. V-BELT DRIVE GUARD

12.1. Provide removable drive and belt guard for the supply fan. Mounting brackets are to be
bolt on type. Removable shaft guards shall be provided as required by OSHA. Drives
shall be protected by guards that have a removable (weather-proof if located outdoors)
cover over fan shaft, bearings, drive and motor. Cover shall have holes for tachometer
readings, a door for belt changing and access holes for vibration measurement with
removable covers. A belt inspection door shall be provided on the top of the guard at the
centerline between the shafts with a clip and wing nut hold down. Door frames and guard
face frames shall be 2.75 mm (12 ga.) minimum with sufficient reinforcement to prevent
distortion when opened. All guards shall be metal and bolted in place shall be removable
without the use of tools. Guard face door shall have rubber pull type latches. Shaft
covers shall be mounted between and outside of the bearings and shall insure not
exposed rotating surfaces. Belt inspection doors with spring loaded hinges shall be
provided on the top of the guard between the drives. The belt tension door and all
covers shall be fabricated with a minimum of 1.5 mm (16 ga.) galvanized steel for outdoor
installations with all hardware galvanized. Indoor mounted fans shall have painted mild
steel guards coated with two coats of safety yellow enamel. Expanded metal opening
size shall be finger-proof to meet OSHA or local country safety requirements if approved
by the owner. Mounting brackets are to be bolt-on-type using minimum 40 mm x 40 mm
(1-1/2 by 1-1/2) angle iron or as required to prevent movement of the guard under
normal maintenance and service. All cover bolts are to be assembled with an appropriate
anti-seize compound. All shaft cover bolts shall be capable of being removed without the
use of tools. Shaft guards shall be between and the outside of bearings with no rotating
exposed surfaces to permit the use of an IR gun and vibration test equipment. Guards
that will be located outdoors will be hot dipped Galvanized after fabrication or coated with
an extreme condition corrosion resistant coating submitted to and approved by the owner.
13. Primary filter inlet Perforated plate and recirculation house inlet
compartments.
13.1. The primary filters of all air houses and recirculation filter houses shall be provided with
an inlet compartment complete with adjustable perforated distribution baffles.
Recirculation filter houses shall have a compartment prior to the perforated plates a
minimum of 2.2m (7) horizontal within which velocities are slowed to a maximum of
1.78m/sec (350 FPM) for the full distance. Inlet transitions will be required to be modeled
to verify even velocity distribution at the start of the 7 area. The perforated baffles shall
be constructed of minimum #18 gauge Din 1.4306 (304) S.S., including fasteners for
recirculation houses and galvanized or type II aluminized steel on all ASH houses. The
adjustable baffle perforations shall be approximately 5.1cm (2) diameter holes on
staggered centers, 60% open area minimum. The adjustable sections shall be locked in
position after final adjustment. Settings shall be recorded in the balance report
incorporated within the manuals. The perforated plates shall be properly supported and
stiffened to withstand turbulence without flapping. A minimum of 1m (3) shall be provided
between the perforated plates and the primary filters or as required for filter service
platform/ladder. Hinged panels may be used for filter access and will be provided with
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industrial hinges and latching hardware. Hinged panels will be of sufficient size to permit
movement of filter service ladders in and out of the space.
14. AIR SUPPLY FILTERS

14.1. A primary air supply filter bank shall be located before the air supply fan and the
humidifier. The filter bank shall be protected from burner flame radiation or impingement
by location and baffles. The distance from the bottom edge of the burner duct closest to
the filters to the nearest air filter shall be at least 3m (10-0). If burner placement is
sufficiently high in the intake to insure maximum uncontrolled flame length is less than
burner duct (8), then the distance shall be no less than 1.5m (5-0) . Velocity
consistency shall be verified by modeling prior to construction for less than 3 (10-0).
14.2. The Primary filter bank shall consist of synthetic media bag filters. Refer to Approved
Equipment List for filter manufacturers. Filters when tested in strict accordance with EN779 (ASHRAE Standard #52.22-1999) shall have a minimum average efficiency of 30% to
35%, F6 Eurovent. Filters shall be 90% efficient on particles greater than 5 microns. All
EN-779 (ASHRAE) filter testing shall be performed by an independent testing laboratory
approved the specification owner. Electrostatic discharge of media as required by the
ASHRAE draft testing standard will be required. Filter size shall be 600 mm x 600 mm x
500 mm (24 x 24 x 20) - 6 pocket bag, rated at 42 m3/sec (2500 CFM) at 7.1 mm
(0.28) water (clean) to (15.2 mm (0.60) water (dirty). Filter units shall have neoprene
gaskets attached to the filter headers or be self-gasketing. Filters shall be self-supporting
and insure full inflation at the design operating velocity. Filters shall be listed Class 1 by
Underwriters Laboratories, Inc or equivalent International Standard.
14.3.
The units shall be assembled into banks by the use of holding frame stiffeners and tack
welding to insure a rigid installation. Units shall minimize the use of caulking by design
by using a fabricated folded frame wall and not individual frames assembled together.
Refer to the Approved Equipment List for caulking manufacturers. Holding Frames
shall be 600 mm x 600 mm x 100mm (24 x 24 x 4) type 2 aluminized or galvanized
steel with welded mitered corners. Each frame shall have 4 S.S. side mounted holding
clips. The filters shall be installed complete with initial supply of media after all air
supply areas have been deep cleaned and a preliminary set for use prior to deep
cleaning.
14.4. The quantity of Primary filters shall be selected to result in a maximum 0.75 m3/sec (1600
CFM) air volume with a maximum velocity of 2.0m/sec. (400 FPM). The air house shall
be designed to insure even, non-turbulent to all filters.
14.5. For secondary filtration located in the air supply house, filters shall be located as the last
component of the house, a minimum distance of 2.15m (7-0) downstream from the
humidifier and 2.15m (7-0) upstream from the fan inlet(s).
14.6. The Secondary filter bank shall consist of synthetic micro-fiber media. Refer to the
Approved Equipment List for filter manufacturers. Filters when tested in strict accordance
with EN-779 (ASHRAE Standard #52.22-1999) shall have a minimum average efficiency
of 90% or better F8 Eurovent. Electrostatic discharge of media as required by the EN779 or ASHRAE draft testing standard will be required. Filters shall be 99% efficient on
particles greater than 2 microns. Filter size shall be a nominal 600 mm x 600 mm x 660
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mm (24 x 24 x 26) Pleated media cartridge filters, rated at 42 m3/sec (2500 CFM) at
`12.7mm (0.5) water (clean) and 30.5 mm (1.20) water (dirty). Filter units shall have
neoprene gaskets attached to the filter headers. Bag filters may only be used with
approval of the owner and must be self-supporting with an internal wire support system.
Filters shall insure full inflation at the design operating velocity.
14.7. Filters shall be listed Class I or Class II by Underwriters Laboratories, Inc. or equivalent
International Standard.
14.8. The units shall be assembled into banks as per above.
14.9. The quantity of filters shall be selected as per above.
14.10.
Recirculation filter houses shall have 3 banks of filtration in the following order and
type:
14.10.1
The primary set of filter shall consist of synthetic media cube filters. Refer to
Approved Equipment List for filter manufacturers. Filters when tested in strict accordance
with EN-779 (ASHRAE Standard #52.2-1999) shall have a minimum average efficiency of
30% to 35%, F6 Eurovent. Electrostatic discharge of media as required by the EN-779 or
ASHRAE draft testing standard will be required. Filters shall be 90% efficient on particles
greater than 5 microns. Filter size shall be 600 mm x 600 mm x 500 mm (24 x 24 x
20), rated at 42 m3/sec (2500 CFM) at 7.1 mm (0.28) water (clean) to 15.2 mm (0.60)
water (dirty). Filter units shall have EPDM gaskets attached to the filter headers or be self
gasketing and be self supporting with an internal wire support system. Filters shall be
listed Class 1 or Class 2 by Underwriters Laboratories, Inc. or equivalent International
Standard.
14.10.2. The secondary set of filters shall consist of synthetic micro-fiber or fiberglass
media. Refer to the Approved Equipment List for filter manufacturers. Filters when
tested in strict accordance with EN-779 (ASHRAE Standard #52.2-1999) shall have
a minimum average efficiency of 60% or better. Electrostatic discharge of media as
required by the EN-779 or ASHRAE draft testing standard will be required. Filters
shall be 95% efficient on particles 5 microns or greater and 90% efficient on
particles 2 microns or greater, F8 Eurovent. Filter size shall be a nominal 600 mm x
600 mm x 660 mm (24 x 24 x 26) - , rated at 42 m3/sec (2500 CFM) at 10.15 mm
(0.4) water (clean) and 25.4 mm (1.0) water (dirty). Filter units shall have EPDM
gaskets attached to the filter headers. Pleated media cartridge filters must be
used. Bag filters may only be used with approval of the owner and must be selfsupporting with an internal wire support system
14.10.3. The final set of filters shall consist of synthetic micro-fiber or fiber glass media.
Refer to the Approved Equipment List for filter manufacturers. Filters when tested
in strict accordance with EN-779 (ASHRAE Standard #52.2-1999) shall have a
minimum average efficiency of 95% or better. Electrostatic discharge of media as
required by the ASHRAE draft testing standard will be required. Filters shall be
99% efficient on particles 1 micron or greater, F9 Eurovent. Filter size shall be a
nominal 600 mm x 600 mm x 660 mm (24 x 24 x 26), Pleated media cartridge
filters, rated at 42 m3/sec (2500 CFM) at 12.7 mm (0.5) water (clean) and 30.5 mm
(1.20) water (dirty). Filter units shall have neoprene gaskets attached to the filter
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supporting with an internal wire support system . Filter units shall have neoprene
gaskets attached to the filter headers.
14.14. All three sets of filters shall be listed Class I or Class II by Underwriters Laboratories,
Inc. or equivalent International Standard.
14.15. The units shall be assembled into banks as per 14.3. above except all frames shall be
Din 1.4306 (304L) S.S., fully welded with no caulking used.
14.16.
The quantity of filters for all banks shall be selected as per above.
14.17. Provide a mobile maintenance platform to service the filters, if the top of the highest
filter is more than 1.53m (5-0) above the air supply floor. Platform shall be constructed
of galvanized structural shapes, heavy-duty grating, and pipe railing. Platform shall
automatically lock stationary when weight is applied. One platform shall be provided per
filter section and left in the compartment. All platforms shall be fully hot dipped
galvanized after welded assembly. (2) Additional platforms shall be provided for each
recirculation filter house. These platforms shall be stored outside the units in the locking
storage crib described.
14.18. Lighting must meet NEC Zone 1 (Class 1 Div. 1 Group C and D) requirements. Portable
floodlights meeting this classification shall be provided for each compartment of a filter
house.
15. AIR FILTER GAUGES AND DIFFERENTIAL PRESSURE SWITCHES

15.1. One (1) air filter gauge shall be provided at all filter banks to measure the resistance to
airflow through the filters. A map of gauge and transmitter locations with their respective
settings shall be included in the maintenance and repair manuals. Plastic tubing will be
required with compression fittings and must be supported in unistrut or electrical raceway
with raceway caps.
15.2. Each gauge shall be complete with mounting panel, two (2) right angle static pressure tips
and integral compression fittings, tees, two (2) 1.5 m (5-0) lengths of 6.3 mm () plastic
tubing and two (2) 3-way vent valves with compression fittings.
15.3. The gauges shall be mounted near the filter bank in the equipment service aisle. The
static pressure tips shall be located a minimum 300 mm (12) upstream and downstream
from the filters in an area of least turbulence. Gauges shall be located for convenient
viewing from the building floor or catwalk as selected by Owner.
15.4. The gauges shall be diaphragm actuated direct reading dial type with zero adjustment as
manufactured by the specified companies on the Approved Equipment List. Range for
each gauge will selected based on the operating maximum being approximately 90% of
full scale of the gauge.
15.5. In addition to the air filter gauges, differential pressure transmitters shall be provided as
manufactured by the specified companies on the Approved Equipment List. Transmitters
will only be required for one complete zone of each booth or building zone and ASH
feeding that zone and not at all zones/ASHs. This will apply to all fresh air houses on a
common booth that utilize similar volumes and air sources. This will not apply to
recirculation filter houses. Magnehelic gauges with vent valves and barb connections for
calibration/verification will still be required for all zones/filters. Range of the transmitter will
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be selected to have maximum pressure drop equal to approximately 90% of full scale of
the transmitter. The pressure transmitters shall be connected into the air filter gauge inlet
and outlet tubing through the use of tees and wired to a remote PLC rack. All switches
shall have their calibration verified by simulating dirty filter pressure drop with a hand
vacuum pump. All actual settings for dirty filter pressure drop and clean filter pressure
drop including original filter model number and manufacturer and process name (i.e.
Secondary Filters) shall be recorded on screw mounted phenolic tags adjacent to the
pressure gauge. The transmitter output will be displayed on the booth central monitoring
display with clean and dirty pressure drop reference text. An alarm will be displayed if the
upper (dirty filter) or lower (filter failure) pressure control pressures are exceeded. This
data will be capable of being trended to assist in evaluating change interval requirements
for full years of operation.
16. HUMIDIFIER
16.1. The Humidifier shall be a Media type humidifier with face and bypass dampers as base
bid. An alternate bid shall be provided for spray coil humidifiers with hot or chilled water
capable coils and also for water volume controlled air washers. The water supply system
for either type shall be a central recirculating system as described below. The method
used shall be submitted with bid proposal for review and clarification.
16.2. The humidifier shall be sized for a maximum air face velocity of 2.286m/sec (450 FPM).
Specific calculations showing total system pressure drop and velocities with bypass
dampers open and closed will be provided for approval by the Owner. Minimum
differential between open and closed dampers shall be maintained by adequate sizing of
the media and damper openings. No sizing selection shall cause a variance in supply fan
volume of more than 2% with damper operation. Excess humidification capacity will be
provided at the required worst case conditions by providing a minimum of 200 mm (8)
additional media depth or nozzle spray capacity. The humidifier shall be designed for
central tank recirculating operation. Any ASH not connected to the central system must
be approved by the specification owner. Any ASH not connected will require a
dedicated chemical feed and control system for water quality per section 17. Base bid
will include design for the use of Reverse Osmosis Water and associated chemical/water
controls . This system shall be capable of providing sufficient controlled capacity of both
city and RO water to insure control of conductivity to minimize blow down requirements at
the highest possible humidification rate for all humidifiers attached the system. This
system shall be bid per GM Global Paint & Polymers Center requirements for R/O
systems typically used in the Phosphate system. If practical, additional capacity to the
Phosphate system R/O system or central utilities system may be alternate bid.
Regardless of the source, RO will be piped to the humidifiers in sufficient volume to
maximize cycles of concentration.
16.4. The humidifier casing shall be constructed from minimum 2 mm (14 ga.), type Din 1.4306
(304L), stainless steel. End panels shall be 2.6 mm (10 ga.) type Din 1.4306 (304L) shall
not have bolted or flanged panel construction. All end panels shall have welded seams
and all connections to end panels shall be made by clips welded to the interior surface.
End panels shall overlap (shingle) the top surface the tank. Temporary sheet metal
panels shall be installed on both sides of the humidifier face for protections during
shipping and field installation. Temporary panels shall not be attached to the outer face
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16.5.
16.6.
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of the end panels, they shall be attached to the flange of the end panels. Temporary
panels shall be secured sufficiently to prevent release during helicopter lifts and be small
enough to permit piping of units without removal. Covers shall not be removed until units
are placed in service.
Media shall be 6.3 mm () fluted fiberglass bonded with wettable acrylic adhesive and
shall be non-flammable UL900 Class 2 or equivalent International Standard, noncorrosive, and impervious to fungus growth or decay organisms. Refer to the Approved
Equipment List for media manufacturers. The media shall be arranged in separate
sections with bypass dampers between each section. The sections shall consist of a
minimum of two sections 150 mm (6) in depth and two sections 300 mm (12) in depth
with a 45 mm (4) air gap between the 150 mm (6) and 300 mm (12) sections. Each
bank of media will be held in place by compression plates to maintain a tight fit and also
to allow easy removal of media packs without disassembling unit components.
Compression system will be spring loaded and removable without tools. Media shall be
completely installable from the exit air side. The bottom of the media shall be supported
by a 50% open area 2 mm (14 ga.) stainless steel expanded metal screen spanning the
gap between the media support angles. Media height unsupported will be limited to 48.
Intermediate supports as required will be as described above. All flashings supports and
sealing plates shall be broken to return toward the media to insure a tight seal and
prevent water carry off. Water shall be distributed to each of the sections over a 50 mm
(2) thick distribution pad. Water distribution headers shall be fabricated from schedule
#80 PVC or stainless steel pipe. Each distribution header shall be center fed and shall
have automatic flush out valves located at each end at positions accessible from the unit
floor level. All distribution headers shall be self-draining. Headers will be supported and
not resting on the media and be designed for easy removal and cleaning through access
panels. For air washers, all piping, nozzles and supports shall be Din 1.4306 (304) S.S..
Entire air washer shall be designed to tolerate 100% RO/DI use.
Face and bypass or bypass only humidifiers shall have S.S. mist eliminators on the
leaving side of the humidifier over the tank. Air washers shall have heavy-duty
polypropylene rated for the maximum temperature service of 66oC (150oF). Orientation
of the blades shall be designed to reduce to a minimum temperature and humidification
stratification.
All removable components of the humidifier shall be bolted in place, Sheet metal screws
shall not be used for assembly.
Each humidifier shall have its water flow controlled by (1) regulator valve, (2) slow acting
solenoid operated water valves (no differential pressure required for operation), (2) water
flow control valves and (3) shut off ball valves. Air washers shall require 2 flow control
valves and flow measuring orifice meters with pressure transmitters. (1) manual delta P
flow meter will be provided for each project to verify flows at the valves. Refer to the
Approved Equipment List for the following valve manufacturers: regulator, water flow
control, shut off ball valves, flow meter. The staged bypass regulators at the central
system shall be capable of the full bypass flow of the humidifier when all solenoids are
closed to insure that pressure to the valves remains constant at all humidifiers. All piping
outside the air stream of the air supply house shall have PVC insulation jacketing and 25
mm (1) insulation. Refer to the Approved Equipment List for insulation manufacturers.
Wherever traffic may cause wear on the jacketing, aluminum jacketing will be used.
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16.9. A differential pressure transmitter connected to a flow orifice on the main feed line shall
be provided for each humidifier section. Refer to the Approved Equipment List for
pressure transmitter manufacturers. The differential pressure transmitter shall have a
Dwyer Magnehelic or capsulhelic of the appropriate range parallel connected to the
transmitter to display the differential pressure. Transmitters shall always be located
above the valves with S.S. vent and shut off valves for calibration and maintenance. All
tubing to gauges and transmitters shall be S.S. with compression fittings. Plastic tubing
shall not be allowed.
16.10.
A flow rate chart shall be located adjacent to the transmitter showing flow rate
correlation to the differential across the orifice. The transmitter tubing shall allow for
connection of the portable flow meter to allow for manual verification of the transmitters
accuracy. Chart shall reference flow for each solenoid operation and for combinations of
solenoids. Value shall referenced and displayed along with the process control variable
on the monitoring system. Upper and lower control limits and alarms will be provided for
each mode of operation.
16.11.
The drain pan shall be minimum 250 mm (10) high, constructed of 2.6 mm (10 ga.),
Din 1.4306 (304L), stainless steel, welded watertight. All welds shall be dye tested to
insure leak free integrity. The pan bottom shall be pitched from the air exiting to air
entering side and to the drain to promote solids migration to the drain. The pan shall
have an inlet and outlet lip pitched into the tank to catch any water that may splash out of
the media. The pan shall not require an inlet lip if the media is placed a minimum of 150
mm (6) from the tank edge. The pan drain connection shall be piped to discharge
directly above and into a drain connected to the central recirculation tank. The air house
compartment floor drain shall not be used for this purpose. Drains shall be Cleanable box
type pressure trapped drains (P-trapped will not be allowed) with heat traced piping to the
point of entry into the building for outdoor units. Drain flow design shall accommodate the
flow of a flush down cycle (bypass flow capacity) from all humidifiers simultaneously. A
separate manual drain valve for wash down cleaning purposes at the low point of the tank
and an overflow shall be provided connected to the central system.
16.12.
The water solenoid valves shall be operated by a programmable controller to
modulate water flow as required in conjunction with the bypass damper modulating motor.
For air washer systems, both bank and vfd pump controls will be modulated control
humidity. One solenoid valve shall be used to maintain a fixed flow rate to the drain pan to
insure wash down of solids and prevent air bypass. The discharge of this line shall be at
a point opposite of the drain in one end of the tanks length.
16.13.
The programmable controller shall be controlled from a humidity sensor located in
the discharge air supply duct for general distribution ductwork and deck/enclosure
applications and in the booth plenum for spray booths. Field reference measurements
shall be required to profile actual humidity readings and to determine the point of least
turbulence and least lag time at the intended location of the sensor before mounting. An
average sensing point shall be selected from these readings and the sensor placed in that
location. For recirculation systems, an additional location shall be selected in the return
air steam based on the same criteria.
16.14.
One outside weather station (one per system) shall be provided to measure outside
temperature and humidity. This weather station may be located in the top of the fresh air
intake above the burner for protection.
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16.15.
The controller shall determine the quantity of needed humidification based on
outside and return air (if applicable) conditions and operate both the solenoid valves for
gross staging control and the dampers for fine control. Each solenoid valve shall be
installed with PVC or S.S. valves for manual by-pass. Upstream and downstream shut off
valves and unions shall be provided for each solenoid.
16.16.
The humidifier controls shall be interlocked with operation of the central recirculation
control system. Upon sequence shutdown of the air house, a 1-hour flush cycle shall be
initiated with full flow to all of the humidifier pads and air off. After this flush cycle, the
humidifier header flush valves will be opened for a period of 2 minutes then all water will
be shut off to the media and the fans restarted and left in operation for 30 minutes to
insure the media dries completely. Building balance will not be effected during this
process.
16.17.
Refer to the Approved Equipment List for bypass damper control motors
manufacturers and be rated for 150% of the required operating torque of the dampers.
Damper motors must be rated for the possible exposure temperature and be mounted
shaft down if vertical shaft configuration is required.
16.18.
A unit heater shall be provided in the humidifier compartment of all roof or outdoor
mounted Air supply houses. Filter houses or remote coil boxes shall also have unit
heater protection. Upon ASH shut down, a gas unit heater will be started to maintain a
minimum 10oC (50o F) throughout the ASH. Gas unit heaters shall be of the high
efficiency outside combustion air type with appropriate PVC fresh air intake and
combustion air discharge through the ASH aisle side wall. Heaters shall be mounted in
the service aisle space and ducted with the intake on the leaving air side of the humidifier
and the discharge on the entering air side. The intake duct shall be provided with a
motorized damper interlocked with the unit heaters operation and shall remain closed
when the air house is in operation. The unit heater shall have electronic ignition and be of
heavy-duty construction. Temperature sensing shall be on the opposite wall of the
humidifier compartment. Separate heaters shall be provided for aisle service on outdoor
units. All heater selections shall be submitted for approval by the appropriate
specification owner. Placement of vent stacks shall conform to the National Fuel Gas
Code requirements and guidelines for combustion vent service. On recirculation systems
an NEC Zone 1 (Class 1 Division 1 Group D) compliant heater will be provided.
17. CENTRAL HUMIDIFIER RECIRCULATION SYSTEM

17.1. A central recirculation tank system shall be supplied to provide water to all paint shop air
supply houses, regardless of the humidification method or location of the house. The
system will use two vertical pumps to supply water via an insulated manifold system to the
air houses. Bag filters will be used on the pump discharge to keep solids from plugging
the distribution spray manifolds and the related piping valves and controls on the
humidifiers. A system of staged bypass regulators will be used at the main recirculation
tank and at each humidifier to keep system pressure constant at all of the humidifiers.
Regulators will be staged to permit 75% turndown on one regulator and the remaining
25% on the second regulator. By pass regulators will be installed after the bag filters.
17.2. The tank shall be constructed of 2.6 mm (10 ga.) Din 1.4306 (304L) S.S. sized to
accommodate 2 times the recirculation rate of the pumps plus the total associated
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retention of the humidifiers and piping. A freeboard of 300 mm (12) above the liquid
level will be available when the system is off and all water has drained back to the tank.
The minimum water level for proper pump operation plus 300 mm (1) shall be used as
the operating level of the tank.
17.3. Recirculation tanks shall be double welded continuous watertight, with welds ground
smooth. Welds on stainless steel tanks shall be performed by the shielded TIG or SAW
method. All seams shall be dye tested watertight.
17.4. All tanks shall be free from appreciable buckling or warpage. Tanks shall be constructed
from a minimum number of pieces with sides and bottom smooth, plumb and square.
17.5.
All tanks shall be externally supported using standard ASTM A36 carbon steel
structural shapes to support the hydrostatic tank load without appreciable deflection. Main
structural base members on solution tanks shall be shimmed level to floor, with shim
stacks welded together to the tank base members and tank base epoxy grouted to the
floor.
17.6. All tanks shall have a sloped bottom (minimum 12.5 mm () per horizontal foot) with
drains at a low point sump to allow complete drainage of all liquid and wash down of
solids. Drain lines shall be connected to plant waste treatment.
17.7. The pump well area of the tank shall be protected with (2) parallel 6.3 mm x 6.3 mm ( x
) mesh S.S. screens mounted in vertical tracks. The screens shall extend above the
static water level by at least 8 inches. No controls or piping shall be placed in the path of
the screen removal. Screens shall be sized for 4.07 m3/m2 (100 GPM/ft2). All screens
shall be of the same size to permit interchangeability. Maximum screen width to be 600
mm (24). Screens shall be shall be constructed from type DIN 1.4401(316) stainless
steel, 1.5 mm(16 ga.), 6.3 mm x 6.3 mm (1/4x1/4) mesh woven wire with 25 mm (1)
framed edges, with corners welded and ground smooth. Screen frames shall have two
lifting handles and be adequately reinforced to prevent distortion when removed using a
hoist. A 75 mm x 75 mm (3 x 3) 3 sided box channel shall be place at the bottom of
each screen to catch debris when removed. Screen guides and divider bars shall be
constructed from type Din 1.4306 (304L) stainless steel. Double tank screen assemblies
shall be designed to permit removal of one screen for cleaning purposes while running
the system with the other screen still inserted in the tank.
17.8. Top access doors in all tanks for screen and pump well service and main tank shall be
hinged access covers located in the top of the tank, complete with water seal channels
and counterbalanced to hold the door open in place. All tank covers shall be fabricated
from type Din 1.4306 (304L) stainless steel.. All miscellaneous hardware (hinges,
handles, fasteners, etc.) shall be constructed from stainless steel. Personnel access
shall be 1 m x 1 m (36 x 36) minimum.
17.9. Service rails shall be installed over all pumps and screens. Each service rail shall be
complete with a trolley and chain fall rated to hoist the equipment it services. All service
rails are to be constructed from S 150 x 310 mm (S6 x 12.5) carbon steel. Service rails
shall extend to clear areas away from the tank to lower and hoist motors, pumps, screens.
17.10.
All mild steel components shall be shop painted and field touch-up. Before any paint
is applied, all surfaces of steel members shall be thoroughly cleaned in the shop to
remove rust, loose and tight mill scale, dirt and other foreign matter. Burrs shall be
removed by grinding. All grease and oil shall be removed by solvents.
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17.11.
Remove completely, weld spatter metal, slag and other deposit products adhering to
the steel. Surfaces shall be thoroughly dry before painting.
17.12.
Shop painting shall be two (2) mils dry, no sagging, gray or white shop paint, per the
approved equipment list or other Owner approved equal.
17.13.
Each piece shall be marked with identification mark corresponding to shop
fabrication drawings. All erection shall conform to AISC or local country structural steel
Specifications. All necessary guys, braces or temporary supports shall be provided for
erection and removed at completion by the contractor. All steel shall be vertical or level
within limits specified in AISC Specifications.
17.14.
Each tanks shall have (2) pumps with each capable of the full required capacity. All
pumps shall be vertical, barrel mount, top pullout design. standard black iron casing
pumps with type DIN 1.4401 (316) stainless steel wetted rotating components (impeller,
shaft, etc.). Chair mounted vertical pumps shall not be used. Vertical Turbine pumps
shall be preferred for efficiency. No brass, bronze, aluminum, or silicone shall be used in
the pump construction or in components. Pumps shall be designed for pump down
service. All pumps shall be non-overloading type, and be hydrostatically tested at 150%
of their full pressure rating. Pump suction velocity shall not exceed 0.04 m/sec (8 FPS).
Pump discharge velocity shall not exceed .07 m/sec (14 FPS).
17.15.
Pump bearings shall be protected from dirt and moisture. The double row thrust
bearings and the single row radial bearings shall be designed for grease lubrication with a
30,000 hour minimum (100,000 hours normal) B-10 life rating. Grease relief ports (located
outside the solution tank) shall be provided on all pumps to prevent over-lubrication and
tubed to a collection container to prevent grease from entering the system. Provide an
adjustable, automatic lubricator for each bearing. Lubricator shall be sized for 1 year of
operation based on the bearing manufacturers required lubrication frequency and grease
type. Refer to Approved Equipment List for automatic lubricator manufacturers.
17.16.
The pump and motor shall be coupled directly through a spacer type coupling rated
at 150% of motor horsepower over the operating curve. Refer to Approved Equipment
List for spacer coupling manufacturers. All external rotating components shall be
enclosed in an OSHA or local country Safety approved removable type guard. All pumps
and motors shall be factory aligned, and re-aligned in the field by the Contractor after
installation to the GM Laser Alignment Standard.
17.17.
All pumps shall include an air venting valve located at the high point of the pump
casing.
17.18.
All pumps, where possible, shall be of the same manufacturer and designed so that
a minimum number of various pump sizes are required for parts interchangeability. Pump
selection should be coordinated with the Phosphate/ELPO system for this purpose. The
Owner reserves the right to make final selection based on past performance of the pump
manufacturer.
17.19.
The Pump Supplier must provide General Motors with parts list sheets in each pump
serial number. Pump supplier shall also supply four (4) sets of service and maintenance
manuals for the pumps in electronic format.
17.20.
All pumps shall have stamped or embossed nameplates displayed with the following
information:
17.20.1. Pump Model Number.
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17.20.2. Size.
17.20.3. Rated m3/hr. (GPM) at TDH.
17.20.4. Actual Impeller Diameter.
17.20.5. Serial Number.
17.20.6. Casing and Impeller Material.
17.20.7. Motor Information.
17.20.8. Seal Size and Type.
17.21.
All pump connections over 50 mm (2) in size shall require flexible type joints at
pump suction and discharge flanges. Refer to Approved Equipment List for approved
flexible joint manufacturers. All pumps should be isolated from the piping system by a
shut off valve to allow for disassembly for repairs. Pressure gauges and check valves
shall be provided on all pumps as required.
17.22.
Before start-up of any pump, the Contractor must verify that all bearings are properly
greased, oil levels are correct, seals are lubricated, rotating direction is correct, and all
guards are in place and tight. Impeller clearances shell be verified and recorded.
17.23.
All vertical pump suction inlets shall be extended to within 2 pipe diameters or the
pump manufacturers recommendation from the tank bottom.
17.24.
Refer to Approved Equipment List for vertical pump manufacturers.
17.25.
The vertical centrifugal or turbine pumps shall be capable of pump down service,
with a minimum distance of 410 mm (16) from the cover plate to the centerline of the
volute or impeller.
17.26.
Pump impellers shall be semi-open design. The impeller running clearances shall be
externally adjustable without necessitating the disassembly or removal of the rotating
element.
17.27.
Pump bases shall be fabricated from a minimum 12.5 mm () thick machined steel
plate.
17.28.
The maximum shaft deflection at the throttle bushing shall not exceed 0.229 mm
(0.009) inches, for vertical pumps. The throttle bushing shall be used to reduce the
amount of fluid leaving the backside of the casing. Throttle bushings shall not be used as
a bearing.
17.29.
All motors shall meet GM 7-ETA-frame specifications, sized for maximum 1800-RPM
speed. . For international projects, the motor type and specification will be decided by
the local owner based on spare availability. If IEC, all motors must be supplied from the
same Manufacturer and premium efficiency unless approved by the owner. All motors
are to be wired with sufficient length of seal-tight to permit removal of the motor/pump
without electrically disconnecting the motor. Provide an adjustable, automatic lubricator
for each bearing. Lubricator shall be sized for 1 years operation based on the bearing
manufacturers required lubrication frequency and grease type. Refer to Approved
Equipment List for automatic lubricator manufacturers. Motor bearing relief ports shall
per the motor manufacturers requirements and be connected to collection containers or
pans that are removable for cleaning. When outdoors, the containment will be protected
from the weather. Contractor shall insure motor vent plugs are removed before activating
lubricators during project launch.
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17.30.
All pipe supports inside the tanks shall be constructed from type Din 1.4306 (304L)
stainless steel. All pipe supports exterior of the tanks shall be constructed from mild steel.
17.31.
Process piping to and from the humidifier shall be constructed from Din 1.4306 (
Sch. #10 304) S.S. routed to the main tank. An alternate will be provided for FRP or
PVC if space temperatures do not result in flexibility issues for the material. Neither will
be used for exterior applications. Adequate support for water hammer and dampers shall
be provided. Adequate support and shock absorption chambers shall be provided to
insure that water hammer from solenoid and backpressure regulators will not cause
failures.
17.32.
All piping must be designed for complete gravity drainage. All drains must include a
valve and a threaded cap or plug.
17.33.
Supply piping to the humidifiers shall be sized for a fluid velocity of 1.8-2.4 m/sec.
(6-8 FPS) for pipe sizes up to 100mm (4) diameter, and 2.4-3.6 m/sec (8-12 FPS) for
pipe sizes above 100 mm (4) diameter. Main distribution headers should be designed
near the upper end of this range so that acceptable velocities are maintained. Eccentric
reducers with grove type Victaulics at both ends shall be used at all transformations in
size. Return piping shall insure capacity for maximum flow from all humidifiers during
wash down with no more than pipe fill.
17.34.
S.S. piping shall be of welded construction using properly formed fittings for pipe
sizes 25 mm (1) and above. Smaller sizes may be threaded using Teflon taped joints
and lock -tite. Flanged or grooved pipe joints shall be provided at frequent intervals to
facilitate assembly, maintenance and system revisions as necessary. 3 m (10) intervals
are recommended for pipe sizes 100 mm (4) and larger, sufficient intervals for smaller
sizes for maintenance and valve service. Rigid type grooved couplings or unions shall be
used for pipe sizes 50 mm (2) and smaller, and companion flanges or Victaulic type
couplings for larger pipe sizes.
17.35.
All couplings, flanges, unions, etc. shall be constructed of the same material as its
respective piping.
17.36.
Careful attention to pipe routing and component placement is required to minimize
pressure losses, avoid dead spots, and provide good access for maintenance activities.
17.37.
Proper Y type headers, manifolds, and long radius elbows shall be used to
minimize pressure losses. Throttling valves should be avoided in the process piping.
17.38.
All pipe penetrations into tanks or enclosures shall have a coupling, flange, or union
on each side of the enclosure or tank wall. A pipe stub shall be seal welded to each side
of the enclosure or tank wall. The pipe stub shall be of the same material as the tank wall
regardless of connecting pipe material. On all insulated tanks, the pipe flange on the pipe
stub must be located outside the insulation material. An exception to this requirement will
be for air gap provisions for city water fill lines to all tanks.
17.39.
All pump outlet piping shall be equipped with flexible type couplings as called out in
the Approved Equipment List.
17.40.
All supply, return and city water piping shall be insulated using proper insulation
fittings and jackets. A durable insulation jacket, such as aluminum, shall be used for lower
piping and in areas of frequent service. PVC shall be used for all other jacketing.
Insulation thickness shall be 50 mm (1), refer to the Approved Equipment List for
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insulation manufacturers. For systems where heat exchangers are used on the supply
piping to the humidifiers, both the supply and return piping shall be insulated as follows:
Pipe Size (DIA)
Insulation Thickness
and Less
40 mm (1-1/2)
thru 100 mm (4)
50 mm (2)
thru 250 mm (10)
65 mm (2-1/2)
and Larger
75 mm (3)
17.41.
On all equipment, a pressure gauge shall be installed in the discharge piping
manifold of all pumps, before and after all filter and heat exchanger manifold piping, and
in each branch line to the humidifiers.. Glycol filled pressure gauges shall be supplied on
all other pieces of equipment and systems in order to provide a workable system and to
provide troubleshooting assistance.
17.42.
All gauges shall have flushable diaphragm protection seals and an isolation valve
attached to process piping. The diaphragm seals shall have type DIN 1.4401 (316)
stainless steel bodies and Teflon coated stainless steel diaphragms for gauges 0-4.15 bar
(0-60 PSI) and greater. Gauges less than 0-4.15 bar (0-60 PSI) shall use Teflon low
pressure diaphragm seals.
17.43.
All pressure gauges shall be of 112 mm (4-1/2) diameter size, unless otherwise
noted.
17.44.
All gauges shall be located on equipment and piping at eye level for an operator to
easily read the gauge.
17.45.
All pressure gauges shall have scales indicating bar (PSI). All pressure gauges shall
be selected such that the normal system operating pressure is in the middle of the
displayed range. Minimum and maximum operating pressures shall be indicated on the
scales with mylar colored tape.
17.46.
Temperature gauges shall be installed on both inlet and outlet sides of all heat
exchangers and the supply and return lines of each humidifier. Temperature gauges
shall be 112 mm (4-1/2) diameter dial type, with scale in both OF and Celsius. All
o
temperature gauges shall be scaled from -2o to 38oC (30 -100 F).
17.47.
Refer to the Approved Equipment List for pressure gauge manufacturers.
17.48.
All valves 65.5 mm (2-1/2) diameter and smaller, unless otherwise noted, shall be
full ported S.S. ball valves with union or swing out type ends. Teflon double seals shall be
used on all ball valves. Refer to the Approved Equipment List for ball valve
manufacturers.
17.49.
All valves larger than 65.5 mm (2-1/2), unless otherwise noted, shall be butterfly
valves, either lug or wafer type. All butterfly valves shall have carbon steel bodies, S.S.
stem and disc, and Teflon valve seats. All valves on chemical feed systems shall be all
S.S. construction.
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17.50.
All butterfly valves not automatically actuated must include a 10-position leverlock
handle with padlock feature. Refer to the Approved Equipment List for butterfly valve
manufacturers.
17.51.
All valves 150 mm (6): and larger shall have manual gear operators or pneumatic
actuators as required. Manual gear operators shall be complete with enclosed worm gear,
hand wheel, position indicator, and all necessary brackets.
17.52.
All automatic valve actuators shall be electric type with open-closed limit switches.
The valves shall be rated normally closed, with air or electric to open and return spring to
close. Manual hand wheel overrides shall be included on all actuated valves.
17.53.
All valve actuators, operator linkages and limit switches (where applicable) shall be
factory mounted complete with all brackets and hardware. All actuators are to be of the
same manufacturer for each type of valve with the least number of sizes available.
17.54.
All limit switches shall be of the same manufacturer.
17.55.
All bypass regulators shall be constructed to bypass the full required flow for the
point of use. Diaphragms compatibility shall be verified with all chemicals intended by the
Owners Chemical supplier for humidifier operation.
17.56.
All check valves shall have bodies to match piping and type DIN 1.4401 (316)
stainless steel internal parts. Check valve seats shall be Teflon. Refer to the Approved
Equipment List for check valve manufacturers.
17.57.
Valves shall be installed as close as possible to T formations in piping to permit
flushing of valve disks, and avoid settling in dead areas of the pipe.
17.58.
All tank drain valves shall be full port ball valves or eccentric plug valves, complete
with leverlock handle and padlock features.
17.59.
Isolation valves must be installed on all pumps, heat exchangers, bag filters, and all
other central humidification recirculation system equipment.
17.60. The Contractor shall give the Owners engineer written confirmation that all valves are
silicone free. This includes silicone used either as a valve lubricant or in aiding the
assembly of the valve. If this confirmation is not available, the Contractor shall have the
valves removed from the site, taken apart and cleaned by a third party.
17.60.1. All piping penetrations through walls will be sealed air tight. All floor penetrations shall
be curbed and sealed to prevent inaccessible leak drainage to the level below.
17.61.
CHEMICAL METERING PUMPS
17.61.1. A chemical feed and control system will be installed to control the water conditions to
the process control chart requirements and to prevent biological growth, solids
accumulation on the humidifier media or in the tanks or pans or piping, and to insure
proper wetting of the media. It will be the contractors responsibility to include the
chemical equipment as agreed upon with the plant chemical supplier.
17.61.2. Chemical metering pumps shall be required for all chemical injection points as
required by the plants humidifier chemical supplier. Typically, feed pumps will be
required for Biocide, surfactant, dispersants, and corrosion inhibitors. An analysis of the
local water supply conditions for the humidifier will be submitted to the chemical supplier
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and Munters. The chemical supplier and Munters or the humidifier supplier will review
make-up water conditions and determine chemical feed and blow down requirements
jointly. Final determinations shall be submitted to GM Global Paint & Polymers Center
Facilities Engineering for final approval prior to submittal to the prime contractor.
Additional pumps may be required for pH and solids control. Pump control shall be from
the main operators control panel and sensor/controller requirements from the plants
chemical supplier and the humidifier supplier. All chemical metering pumps shall be
electric gear driven type pumps. Pumps shall be turned on and off by a timer, controlled
by the Central humidifier recirculation control system, which sends power to junction box
with outlet located by each pumping station. All electric chemical pumps shall be
provided with a 110 Volt twist-lock quick disconnect cord. Pumps shall be from the
same manufacturer as those used on the sludge system for commonality of parts and
support.
17.61.3. The chemical metering pumps shall be rated at .045 l/hr. 9.5 l/hr. (0.012 GPH - 2.5
GPH) at 6.9 bar (100 PSI) maximum pressure. The contractor shall be responsible for
verifying the pump flow and pressure requirements with the Owners Chemical Supplier
and based on the feed point conditions using a quill.
17.61.4. Refer to the Approved Equipment List for chemical metering pump manufacturers.
17.62.
BAG FILTERS
17.62.1. Bag filter vessels shall be included for the humidifier supply. Filter size shall be
based an a maximum flow of .28 m3/hr. (75 GPM) per bag and rated to filter 100% of the
pumped volume. Bags shall be rated for a minimum of 0.473 m3/hr. (125 GPM)/bag.
17.62.2. Filter vessels shall be Din 1.4306 (#304) S.S.. Mild steel coated will only be
permitted where operational conditions are shown to be non-corrosive and using city
water only. Refer to the Approved Equipment List for coating materials for bag filter
carbon steel.
17.62.3. Bag filter vessels larger than two (2) bags in size shall be designed and built to
Division I of the ASME Boiler and Pressure Vessel Code, Section VIII. Minimum design
pressure shall be 6.9 bar (100 PSI).
17.62.4. Bag filter vessels shall be sized for 0.14 bar (2 PSI) clean and 0.69 bar (10 PSI) dirty
pressure drop for the units. Bags shall be 178 mm (7) diameter by 819 mm (32) long,
polypropylene material. Filters shall be 100 micron minimum capture efficiency. The
Contractor must supply at least two spare sets of bags, after the cleaning process.
17.62.5. Bag filter vessels shall be designed for gravity drainage with 50 mm (2) bottom
drain equipped with a ball valve located at the bottom of the vessel, piped to process
drain. Bag filter drains shall be constructed from Sch. #10- S.S..
17.62.6. All bag filters shall be set in a 2.75 mm (12 ga.) type Din 1.4306 (304) stainless
steel drain pan if the unit is located on a service platform.
17.62.7. Each bag filter vessel must be provided with the following equipment:
Standard loop head clamping nuts or clamp ring with quick release.
air connection with quick disconnect and air bleed off connection.
Spring loaded or Hydraulic lid jack mechanism for large bag filter vessels, and
mechanical screw mechanisms for small vessels.
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ball valve drain piped back to process drain, unless otherwise noted.
Pressure gauge at inlet and outlet of each bag filter piping manifold, complete
with flushable diaphragm isolators and 6.3 mm () diameter stainless steel
shut-off ball valves. Pressure gauge ports shall be provided on each side of
individual vessels on systems with multiple bag filters.
Butterfly isolation valves on inlet and outlet of each vessel.
Removable type DIN 1.4401 (316) stainless steel perforated or mesh restrainer
baskets.
17.62.8. Bag filter gaskets shall be Teflon or EPDM on all stages.
17.62.9. All tanks shall have multiple bag filter vessels - minimum two (2) vessels, piped in
parallel with isolation valves, such that any one vessel can be serviced during system
operation with the other vessel on line.
17.62.10. All large bag filter vessels shall have steps and/or platforms built around each vessel
for servicing the unit. Platforms shall be 600 mm x 900 mm (24 x 36) minimum size.
Steps and platforms shall be constructed from mild steel, and meet all required
construction and safety standards.
17.62.11. Refer to the Approved Equipment List for bag filter manufacturers.
17.63.
CITY WATER PIPING
17.63.1. The Contractor is responsible for installing all RO AND city water piping tie ins and
supply lines to make the system fully operational.
17.63.2. All RO water lines shall be constructed from Sch. 10 minimum S.S. pipe.
17.63.3. City water tie ins will be schedule 40 galvanized steel.
17.63.4. All RO and city water lines shall be insulated as specified in the Process Piping
section. Proper insulation fittings shall be used.
17.63.5. The tanks shall be provided with both an RO and city water fill line with automatic
make-up capability. All RO and city water piping connections to tanks shall be made with
suitable air gaps. All RO and city water lines shall be equipped with a slow acting S.S.
solenoid valve, S.S. flow control valve complete with Y strainer and manual bypass per
the approved equipment list. RO and city water fill lines shall be sized for quick fill
capabilities, minimum size to be 50 mm (2) diameter.
17.63.6. Solenoid valves shall be stainless steel construction, slow acting, per the approved
equipment list.
17.63.7. The water supply piping to each unit shall be provided with a vacuum breaker, a
strainer with a 100 mesh, 300 series, stainless steel screen sized 50% over capacity,
pressure regulator, and all required shut-off valves and pressure gauges.
17.63.8. The tank shall be provided with a city water connection for cleaning purposes. A
hose bib with shut off ball valve, hose reel, and a minimum 7.6 m (25 feet) of 20 mm
() diameter heavy duty reinforced rubber hose with nozzle shall be provided at each
tank. Each connection to the plant city water line shall be fitted with a suitable back flow
preventer. The back flow preventer shall comply with all Local and National Codes. Back
flow preventers shall be piped to drain sumps. Refer to the Approved Equipment List for
back flow preventer manufacturers.
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17.63.9. The Contractor shall supply a suitable analog flow meter with remote totalizing and
instantaneous flow capability on the incoming RO and city water lines to the humidifier
tank and on the blow down line from the tank. The meters will be used for monitoring
and recording incoming RO and city water usage and blow down rates as well as feed
back to the ratio controller. Ratio control of the RO and city volumes will be available
from the monitoring system and the controller.
17.63.10. A blow down and quick drain line will be provided to the storage tank as described in
the Sludge System Specification.
17.64.
SPARE PARTS
17.64.1. The Contractor shall identify and submit prices for the following components in the
bid proposal. All manufacturers spare parts lists shall be included. The components
shall be itemized and identified as to function, application, make, model, size, material,
etc., and priced separately with recommended quantities shown.
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Each size and type of pump (including rotating element)
Each size and type of motor
Each size and type of automatic valve
Each size and type of pressure gauge and isolator
Each size and type of flow meter
Each type of level control
Each type of limit switch
Each size and type of chemical mixer
Each size of conductivity sensor.
Each size and quantity of heat exchanger plate (if applicable).
Filter restrainer baskets and gasket sets
Two complete sets of system refills of bag filters
Electrical overload fuses of each type and size in the system (this is in addition
to start-up and debug requirements.)
Pilot light bulbs of each size and type in the system
Lighting lamps of each size and type in the system
All other unique operating components

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17.65.
CONTROL SYSTEM
17.66.
The control system for the recirculation system shall perform the following functions
and provide the following interlocks and information output. All wiring and panel design
details shall conform to GM Global Paint & Polymers Center Control Specifications.
17.66.1. The control system shall continuously monitor all process parameters, compare
readings with preset control points, and initiate chemical replenishing systems, fresh
water additions, ratio control, automatic drains, chilled water control valve settings
(where applicable), etc. as required to maintain optimum process conditions. Inter
connection to the central monitoring and control station shall be required. Trending of:
water usage, chemical usage and process control parameters including but not limited
to temperature, pH, Conductivity shall be required. Remote revision of the control logic
shall be required from the Chemical Managers office.
17.66.1.1.
A conductivity and pH controller as per the approved equipment list shall
be required to be interfaced with the plant monitoring and control system. The
controller shall be required to have a remote modem and phone connection for
use by the Chemical Managers Office. Meter inputs and up to 3 chemical feed
pump outlet controls will be integrated into the controller as will ratio control and
solenoid control of the feed water sources. Blow down water meters will also
be integrated.
17.66.2. Tank water additions and auto-drains shall be initiated through the use of stainless
steel slow acting solenoid valves. All solenoid valves shall be as per the approved
equipment list.
17.66.3. The control system shall provide normal operation status indicators and alarms at
the operators console panel, and continuously monitor and record process variables to
archival data storage. The control system shall automatically calculate and provide SPC
data.
17.66.4. The contractor shall provide control hardware to monitor and control all tank levels
and tank level make up water additions. Tank levels shall be sensed using differential
pressure level probes. Refer to the Approved Equipment List for differential pressure
level probes. All stage tank levels shall include four (4) point level detection (High,
Normal, Low, and Low-Low Level). High level detection shall activate auto-drain line to
open. Low level detection shall activate automatic make-up water line. Low-Low level
shall send an alarm to the operators control panel and then shut down the pump(s) after
an adjustable time delay.
17.66.5. The control system shall monitor and record flow on all RO, city water and blow
down water lines entering the system. All flows shall be totaled in SPC data. The
software will permit ratio control and adjustment of same of the city and RO make up
feed volumes.
17.66.6. A pressure switch shall be included for all pumps, located on the pump discharge
header, to monitor output pressures. The pressure switch shall have a high and low
pressure set points, and shall relay an alarm in the control system if pump pressures fall
outside the set points. If the pressure falls below the lower limit, the pump shall be
turned off and an alarm sounded.
17.66.7. All required motor starters, disconnects, fusing, overloads for this system shall be
included in the operators control panel mounted near the tank.
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17.66.8. Water Practical Scaling Index sensors as required by Chemical Supplier to insure
water is treated adequately for scaling, biological, corrosion, and surfactant control.
Chemical supplier to recommend equipment for installation in the main control panel.
All equipment selected will be reviewed and approved by the Owner.
17.66.9. Pressure switches connected to the inlet and discharge of the bag filters with
glycerin filled diaphragm isolators as described in Gauges shall be used to monitor and
alarm bag condition.
17.66.10. This control system will be interlocked with the air house control panels. Once all
ASHs are in shut down sequence, all humidifiers will be flushed for 1 hour prior to
initiation of dry-out sequence with the fans off. Fans will then be restarted and dry out
sequence performed for a minimum of 3 hours.
18. AIR HEATER/COOLING

18.1. All make-up air shall be heated by direct fired, natural gas, parallel line burners designed
for industrial air heating application. Coils may be used if local conditions or supply air
requirements dictate their use (paint mix ASHs must be coils or indirect fired). Design
conditions shall be predicated on local reported minimum temperature conditions minus
5oC (10 deg F) as the entering air temperature and 63oC (145o F) air temperature rise for
Northern climates. Minimum temperatures shall determine maximum rise based on
humidification load. Discharge air temperature into the spray booth shall be per the
temperature and humidity control requirements listed in this document. The line burner
shall be located in the fresh air intake ductwork and shall be split into two parallel full
length sections to avoid overheating at low fire conditions. The two sections shall be 50%
each of the total required burner capacity or as best configured for maximum turn down
for the local area. The two sections shall be bridged together at the pilot end of the main
section. One pilot shall be provided on the main section with a detector. Two additional
flame detectors shall be provided at the opposite end, one on each of the main and
second stage sections.
18.2. Refer to the Approved Equipment List for line burner manufacturers. The installation
shall be designed for a minimum 50:1 turn down ratio with low pressure natural gas.
Burners must be low NOX, low emission. The burner installation shall be designed with
adjustable shrouds such that a burner minimum net air velocity of 1.32 m/sec. (2600
FPM) for Maxon or 12.7 m/sec (2800 FPM) for Eclipse can be maintained with
stratification minimized. Manufacturers specifications for burner profiling shall be strictly
adhered to and adjustment dimensions recorded on the drawings.
18.2.1. Burners and profile dampers shall be used to permit turndown to 25% of the
production air flow volume for maintenance operations. A divider will be
appropriately placed in the fresh air intake to segment the first and second sage
burners into two separate burner ducts each with its own set of shut down
dampers and motors. Burner velocity shall be calculated with one or both
dampers open and appropriate profile plates shall be installed in both openings.
One set of dampers will be closed during operation only to maintain the required
velocity for the burner at the reduced volume. The dampers shall be interlocked
with the burner temperature management system and be activated simultaneously
with the reduction of volume. Maximum burner output shall be limited through
software to prevent overheating while the reduced volume is occurring. A second
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18.3.
18.4.
18.5.
18.6.
18.7.
18.8.
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stage will be provided if required in order to permit sufficient turndown on what

were formerly single line burners.
The burner shall be complete and include all components required for operation. Raw
gas inlet manifold to the burner assembly shall always be symmetrical and shall conform
to the manufacturers recommendations relative to burner feed. Burners shall be installed
in accordance with the manufacturers recommendations regarding support, expansion,
contraction, etc. Distance from the gas train to the burner shall be engineered to insure
gas reaches the burner within the trial for main flame time period.
The air discharge temperature shall be controlled by regulating the volume of gas to the
burner through a gas control valve, an electric control motor, and linkage. Control
arrangement shall be designed for low fire start with a low fire limit switch.
Contractor shall provide minimum 300 mm x 300 m x 6.3 mm (12 x 12 x ) clear, wire
reinforced glass burner vision windows to observe burner and pilot flame from the service
aisle. Also provide a burner access door to service the pilot and flame safety devices.
Windows must permit burner viewing from the floor level adjacent to the ASH.
Contractor shall provide a burner service platform and ladder constructed with aluminized
or galvanized steel and grating approximately 1.53 m (5) below the burner sections for
use in cleaning the burner and servicing components. Alternately, Cotterman style
ladders of full hot dipped galvanized construction and components designed for the
temperatures experienced may be provided. The designs for either will comply with
OSHA or local country safety requirements. One ladder shall be provided for each air
supply house.
A fenced storage crib with a lockable entry gate shall be provided for the storage of
ladders and filters. The crib size shall be based on the total quantity of ladders to be
stored and sufficient space for one complete filter replacement of all air supply houses,
filter houses, enclosures, decks and booths.
Hot/Chilled water or steam coils shall be as per the following:
Coils for recirculation filter houses or spray coil humidifiers shall be constructed as
follows with all materials of construction for housings, tanks, coils, etc. of Din 1.4306
(304L) S.S.. Drain pans as described for the humidifiers shall be provided for all cooling
coils. Manufacturer provided corrosion resistant coatings shall be provided on all nonS.S. coils. Face velocity on cooling coils shall not exceed 21.5 m/sec. (425 FPM) and
heating coils 3.8 m/sec (750 FPM). Any use of chilled water coils found in excess of
these velocities during field testing will require the installation of mist eliminators, drain
pans and piping to the gray water storage system at the contractors expense. Any
areas of coild found over velocity will require water control drain plates of S.S.. Any
additional fan static and resultant horsepower required to maintain original fan
performance will be at the contractors expense.
18.8.1 Chilled water coils shall have S.S. drain and drift pans sufficiently large to insure
condensate is collected. Pans will have pitched bottom cross breaks to the drain
connection to insure complete drainage. Pans will be provided for each 1.22m (4-0)
vertical height coil section. Condensate shall drain to the humidifier central recirculation
system or to the gray water storage tank dependant on water loading calculations and the
operational parameters of the humidification system. Shields will also be provided on
tube end bundles to channel water to the floor.
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18.9. All coils shall be protected during shipment to the manufacturer, installation by the
manufacturer, final shipment to the job site and installation of the ASHs in the field by
either plywood or temporary sheet metal decking. Protection shall not be removed until
commissioning of the system.
18.10.
Coil tube end bundles shall have bolted galvanized covers to reduce cleaning
pockets/requirements.
18.11.
All coils shall be bolted in place in the manufacturer provided holes. Tex screws
shall not be used for mounting. S.S. supports and fasteners are required on cooling coils.
18.12. All coil piping and valve trains shall be mounted external to the air stream compartment
at a serviceable height and location.
18.13. All Chilled and hot water feed and return system shall be balanced using both circuit
setting valves at each coil and system valves. Balancing shall insure proper delta
pressure at the main supply and return points to the paint shop and proper flow to each
coil with minimal coil valves open and all coil valves open to their maximum flow.
18.12.1. WATER COILS
18.12.1.1. Coils shall be of the capacities indicated on the drawings. Coil capacities, pressure
drops and selection shall be in accordance with ARI Standard 410.
18.12.1.2. Coils shall be designed for a working pressure of 13.8 bar (200 psig) at the
operating temperature for the intended service, and shall be tested for 17.25 bar (250
psig) by the manufacturer.
18.12.1.3. Coils shall be drainable type when the casing is installed level.
18.12.1.4. Coils shall be constructed of seamless copper tube, 16 mm (5/8) O.D. of not less
than .61 mm (0.024) wall thickness with fins of copper or aluminum and with
maximum of 4.75 fins/10 mm (12 fins per inch). Minimum fin thickness shall be 0.223
mm (0.009). Number of rows indicated on drawings are the minimum number that will
be accepted. A delta T and delta P requirement for coil operation will be specified by
WFG Utilities services and must be complied with under worst case operating
conditions. Quantity of rows shall be based on these requirements and required air
temperature delta T for temperature control requirements described elsewhere. For
bidding purposes a minimum 20 degree F delta T will be required.
18.12.1.5. Headers shall be type M seamless copper or cupro-nickel tubing with extruded
tube holes to facilitate brazing of tubes. All coils shall be flexible epoxy electro coated.
Coating must be not be able to be cracked from aluminum fins when bent and be
sufficiently flexible to tolerate coil.fin/tube expansion and contraction without cracking
or delaminating. Electro-Fin coating or supplier/coating approved by the owner.
An alternate shall be provided for all galvanized steel coils.
18.12.1.6. Coil casings shall allow for free expansion and contraction of the fin core and
provided with flanged and punched ends. Casings containing coils with tube lengths
exceeding 1m (42 in.) shall have an intermediate tube sheet that supports each tube
individually.
18.12.1.7. Coils used for heating (hot water coils) shall have casing of 1.5 mm (16 ga.) min.
galvanized steel. Coils used for cooling (chilled water coils) shall have casing of 1.5
mm (16 ga.) min. stainless steel.
18.12.1.8. Refer to Approved Equipment List for coil manufacturers.
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18.12.1.9. Recirculation coils shall be S.S., 0.9mm (.035 tube). Straight fins shall be used on
systems 6 rows or more. Maximum 2.5-3.2 fins/ 10 mm (6-8 fins per inch).
18.12.2. STEAM HEATING COILS - NOTE - Steam coils shall only be used as a replacement
to existing equipment. They shall not be used on any new installations.
18.12.2.1. Coils shall be of the capacities indicated on the drawings. Coil capacities, pressure
drops and selection shall be in accordance with ARI Standard 410.
18.12.2.2. Coils shall be of the inner distributing type with 25 mm (1) O.D. seamless copper
outer tube of 0.89 mm (.035) wall thickness and with fins of copper or aluminum and
with maximum of 4.75 fins / 10 mm (12 fins per inch). Coils shall be suitable for 13.8
o
o
bar (200 psig) working pressure and 205 C (400 F.) temperature and shall be tested
at 17.24 bar (250 psig) by the manufacturer.
tube holes to facilitate brazing of tubes.
18.12.2.4. Casings shall be minimum 1.5 mm (16 ga.)n.) min. galvanized steel arranged to
allow for free expansion and contraction of fin core and provided with flanged and
punched ends.
18.12.3. INTEGRAL FACE AND BYPASS HEATING COILS - Steam coils shall only be used
as a replacement to existing equipment. They shall not be used on any new
installations.
18.12.3.1. Steam heating coils shall be of capacities indicated on drawings of vertical integral
face and bypass type, ARI Certified.
18.12.3.2. Heating coil shall consist of built-in series of finned heating elements and bypasses
with interlocked dampers controlled by electric damper motor in such a way that the air
stream can be proportioned through them accordingly for temperature control.
18.12.3.3. Finned heating elements shall consist of 205 mm (5/8) O.D. seamless copper tube
with 0.89 mm (.035) wall thickness with rectangular fins of copper or aluminum
mechanically bonded to tubes and spaced not closer than 4.5 fins/10 mm (11 fins/
inch). The tubes shall be mounted in such a manner as to allow for contractions and
expansions without damage to the coil. The tubes are to be brazed to the headers and
shall be easily replaceable.
18.12.3.4. The steam and condensate headers shall be constructed of Schedule 40 steel pipe
for single row coils and 6.4 mm (.25) wall thickness seamless steel structural tubing
for two and three rows coils. The bottom header shall be floating to take up the strain
due to thermal expansion of the core.
18.12.3.5. The casing shall be constructed of 2 mm (14 ga.) hot-dipped galvanized steel.
18.12.3.6. The dampers shall be constructed of 1.5 mm (16 ga.) hot-dipped galvanized steel.
The face dampers are to be normally open and the bypass dampers normally closed.
The dampers shall be completely adjusted and ready to be used.
18.12.3.7. All moving shafts shall have bearings to prevent excessive wear. The minimum size
of all shafts used for linkages shall be 10 mm (3/8).
o
o
18.12.3.8. The temperature override when the coils are fully blocked shall not exceed 2 C (5
F).
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18.12.3.9. The variation in pressure drop across the coil, as the dampers move through their
entire range, shall not cause more than a + 5% variation in air volume.
18.12.3.10.
There shall be full steam pressure on the coil when the outdoor air temperature
o
is below 4.5 C (40 deg. F). Steam is to be modulated into the coil when the outdoor air
temperature is above 4.5oC (40O F).
18.12.3.11.
The coil shall be leak tested with 17.24 bar (250 psig) air under water by the
o
manufacturer. The coil must be capable of operating at 13.8 bar (200 psig) and 205 C
o
(400 F). steam pressure and temperature.
18.12.3.12.
The coil shall be installed to be completely drainable through the installed
condensate line.
18.12.3.13.
All piping shall be supported independently of the coils. Swing joints or flexible
fittings shall be provided in all piping connections adjacent to the coil to allow for
contractions and expansions.
18.12.3.14.
Refer to the Approved Equipment List for steam coils manufacturers.
18.12.4. DIRECT EXPANSION COOLING COILS
18.12.4.1. Cooling coils shall be direct-expansion type of capacities as indicated on the
drawings. Coil capacities, pressure drops and selection shall be in accordance with
ARI Standard 410.
18.12.4.2. Coils shall be factory tested after assembly at 20.7 bar (300 psig) and then cleaned,
dehydrated and sealed before shipment.
18.12.4.3. Coils shall be constructed of seamless copper tube, not less than 15.9 mm (5/8)
O.D. arranged in a parallel pattern with respect to the air flow, with aluminum or copper
fins. Refrigerant shall be distributed to the various coil circuits through a multi-outlet
distributor. All coils shall be flexible epoxy electro coated. Coating must be not be
able to be cracked from aluminum fins when bent and be sufficiently flexible to tolerate
coil.fin/tube expansion and contraction without cracking or delaminating. Electro-Fin
coating or supplier/coating approved by the owner.
tube holes to facilitate brazing of tubes.
18.12.4.5. Coil casings shall allow for free expansion and contraction of the fin core and
provided with flanged and punched ends. Casings containing coils with tube lengths
exceeding 1m (42 in.) shall have an intermediate tube sheet that supports each tube
individually.
18.12.4.6. Coils shall have casing of 1.5 mm (16 ga.) min. stainless steel.
18.12.4.8. The following drawings shall apply to the above hot/chilled or steam coil
specifications:
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18.13.
Controls for the cooling coils shall be as follows:
18.13.1. .The coils shall be sized to cool and dehumidify incoming air from the design
ambient conditions to the condition required to by reheat to obtain the desired state. In
the case of recirculated air, the air will be conditioned to the required state need to be
blended with the recirculated air to obtain the final required state for the spray booth.
18.13.2. Each ASH cooling and dehumidification system shall be configured in a feed and
bleed type arrangement unless specified otherwise by WFG Facilities Mechanical
Engineering or the local owner requirements. The contractor shall verify whether 2 way
or 3 way feed and bleed systems are required. 3 way valves shall be permitted only on
end of system feed lines to insure lines remain at proper temperature. A bypass
regulator shall be installed and used to minimize this flow by testing line temperature
during system balancing. Each system contains chilled water coils, control valve train
and a recirculation pump. When conditions require dehumidification and/or sensible
cooling, the unit pump circulates water throughout the unit cooling coil circuit. The
control valve (3-way converging type) modulates bleed-in of chilled water based on
demand.
18.13.3. All piping shall be insulated using non-fibrous foam insulation per the approved
equipment list with piping in confined areas skinned with aluminum or vinyl outer jackets.
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18.13.4. Control valves shall be flanged 2-way electro-hydraulic actuated type arranged for
converging service. An alternate shall be provided for electric actuated type. Air
operated valves are not permitted. Valves must be rated for the pressure differentials
and ambient temperatures defined by the site requirements. Valves to be cast iron
construction with S.S. equal percentage trim, S.S. shaft and shall include manual
override, electro-pneumatic positioner (4-20 mA input) . Refer to the Approved
Equipment List for control valve manufacturers. All valves will fail closed and have a
manual bypass feature.
18.13.5. Each unit shall be equipped with an orifice plate type flow meter for gross chilled
water flow to each air supply house. Refer to the Approved Equipment List for flow
meter manufacturers. Pipe arrangement shall accommodate orifice plate location
requirements. In addition, the contractor shall provide one read out kit for system
balancing and shall turn this kit over to the owner upon job completion. Refer to the
Approved Equipment List for flow meter read-out kit manufacturers.
18.13.6. Each individual coil shall be equipped with a calibrated balancing valve to insure
uniform water flow. Valve to have read-out ports compatible with the read-out kit
described above, memory stop feature and factory supplied preformed insulation kit.
Refer to the Approved Equipment List for balance valve manufacturers.
18.13.7. The recirculation pumps shall be centrifugal, in line type, all iron construction, bronze
fitted with internally flushed mechanical seal, 1800 RPM, sized as required. Refer to
Approved Equipment List for recirculation pump manufacturers. Typically, recirculation
pumps are not required.
18.14.
Heating coil controls shall be as follows:
18.14.1. The coils shall be sized to take incoming air from the near dew point condition to the
booth desired state. In the case of recirculated air houses, the air will be conditioned to
the state need for blending with the recirculated air resulting in the booth required state.
18.14.2. Furnish hot water control trains as per the schematics above. The hot water control
valve shall a 2-way converging service electro-hydraulic actuated control valve with
balance valves, orifice plate flow meter, pressure gauges, thermometers and all required
isolation valves as per the listings for the chilled water but designed for hot water
service.
19. SYSTEM VALVES, PRESSURE GAUGES, AND EXPANSION FITTINGS

19.1. All system valves shall be as specified in General Motors Piping Standards No. P1.0
available from GM Global Paint and Polymers Center, except as specified below.
19.2. Valves used in chemical feed systems shall be DIN 1.4401 (316) stainless steel
throughout with Teflon seats and seals.
19.3. Water distribution piping will incorporate a sufficient number of valves to insure even
water distribution to all end points. All flood sheet risers shall have S.S. concentric plug
or full port grease lubricatable ball valves for flow adjustment. Any impact type
adjustment valves within the booth shall have 10 mm (3/8) minimum shafts with a swing
away feature. All components of internal valves shall be Din 1.4306 (304L) S.S.. All
valves inside the enclosure shall be shield from over spray build up. Valves handling
spray booth eliminator recirculating water shall be as follows:
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19.3.1. Valves 100 mm (4) and smaller shall be S.S. concentric port, plug valves with Teflon
seats and grease lubrication zerks to prevent seizing and reduce accumulation of paint
around the seals and plug.
19.3.2. Valves larger than 100 mm (4) shall be knife type valves with indicating gear operators.
20. COMBUSTION SAFEGUARD

20.1. All gas heating controls shall be acceptable to the Owners Insurance Underwriters. Type
and manufacturer shall be as listed below, or Owner approved equal.
20.1.1. Regulator:
See Approved Equipment List
20.1.2. Pressure Switch:
20.1.3. Motorized Safety Valve:
See Approved Equipment List (for control and monitoring
full open and closed positions)
20.1.4. Blocking valve and Second Stage Valve:
See Approved Equipment List (for control
and monitoring full open and closed positions).
20.1.4.1. Refer to Approved Equipment List for gas control valve manufacturers. One motor
shall be provided for each stage.
20.1.5. Pilot Solenoid: (2) see Approved Equipment List, direct acting with plugged test valves
and ports before between and after solenoids.
20.1.6. Vent Solenoid: Not permitted base bid - Eclipse - Dungs leak check system.
NOTE: Valves must be U.L. Rated for Gas Valve Service.
20.1.7. Air-Flow Switch:
Note combination required. Air flow sitch across supply fan for
the flame relay. Burner profile plates to use a velocity pressure transmitter with
programmed upper and lower velocity limits for the burner. Either limit will shut down
the burner. All information to be displayed on central monitoring system. See Approved
Equipment List. Must be tubed with plastic tubing and compression fittings. Lines shall
be protected in wiring raceway channel like unistrut. Vent valves and test barb
connections required.
20.1.8. High Temperature Limit:
20.1.9. Ignition Transformer: See Approved Equipment List
20.1.10. End casting heaters as per the approved equipment list to be operated when units
are off at start of main system sequence start. End casting heaters shall require
removable, S.S. expanded metal guards to protect against accidental contact.
20.1.11. Flame Relay and Sensor: See Approved Equipment List with Ultra-violet detector as
specified by CCRW controls . A separate detector and relay shall be provided for the
second stage burner. A sight tube and igniter end casting electric inductive heater as
manufactured per the approved equipment list will be provided to prevent condensation
problems.
20.1.12. Gas trains shall be sequenced in the following manner and be constructed exactly
as laid out and defined in the CCRW specifications:
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20.1.12.1. Entry point shall be at the top of a vertical run with a lock-able main shut off cock.
Cock shall be lockable only in the closed position. A drip leg shall be provided below
this cock with a removable cap.
20.1.12.2. Refer to Approved Equipment List for gas filter manufacturers. The filter shall be
provided with upstream and downstream gauges, a differential gas pressure
switch that alarms at the MOCP and a 10 micron filter. Refer to the Approved
Equipment List for differential pressure switch manufacturers. One filter may be
provided for each main branch line connection to multiple air houses or ovens in
lieu of at each gas train. Filters must be placed upstream of all meters.
20.1.12.3. One totalizing meter with analog output connected to the central monitoring
system will be provided for each booth or building zone. Meter manufacturer will
be as per WFG mechanical specifications. Connection/data transfer to plant
monitoring system will be required.
20.1.12.4. Two main regulators shall be provided each sized for 50% of the total required flow
rate for flows greater than 2930 kWH (10 mmBtu) natural gas or equivalent. One shall
be provided for flows less than 10 mmBtu. All regulators shall be per the approved
equipment list and sized for 1.2 times the maximum gas flow each. Dual main
regulators shall be set to maintain pressure in the following manner: the low fire
regulator will be set with the burner at maximum low fire, the second regulator will be
set with the burner at maximum high fire at a pressure 25-50 mm (1-2) water column.
above that of the low fire regulator. If the entering gas pressure is more than 1.38 bar
(20 psi), a main supply line regulator will be required to stage the pressure at the point
where the tap connection is made at the gas main for all air houses. The regulator(s)
shall be installed in a horizontal position with feed line vertical with a drip leg prior to
entering the horizontal where the regulator is located. Incoming and discharge gauges
shall be required sized to allow operation at 50% of scale.
20.1.12.5. The gas trains shall be tested at two times the incoming line pressure or not less
than 2.4 bar (35 psi) for a minimum of 8 hours both in the shop and in the field. The
trains shall be tested for leak down after pressurizing the train and shutting the cocks
at both the inlet and before the staging lines.
20.1.12.6. A Leak Detection system in the vent line between the safety and blocking valve in
line addition to the vent valve and vent line will be base bid. Refer to the Approved
Equipment List for leak detection manufacturers. This valve shall be programmed to
check the safety and blocking valves for leakage every thirty days. Non-volatile
memory storage of these tests is required on the central monitoring system. An
automatic print-out event shall occur each month of the data. All vent lines shall be
checked for the presence of gas after system start-up and adjustment.
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20.1.12.7. Separate vent lines shall be provided for each regulator, vent valve, and High/Low
gas pressure switches combined with the pilot regulator. Discharge location shall be
verified as creating any potential for venting to be drawn into a nearby fresh air intake.
Basic requirements as listed in the National Fuel Gas Code (NFGC) or local country
equivalent for combustion vents shall be used in determining the location of the gas
vent piping. In addition to the NFGC or equivalent, all vents shall be located a
minimum of 3 above any fresh air intakes and as far as practically possible from the
fresh air intakes. All vent locations must be submitted for approval to GM Global Paint
& Polymers Center. No horizontal vent lines shall be permitted.
21. TEMPERATURE AND HUMIDITY CONTROLS

21.1.
The air supply house temperature and humidity control system shall be capable of
maintaining an air temperature, and a relative humidity within the spray booth, deck,
enclosure, or other specific application. Dehumidification may be required if the
window cannot be maintained. The Contractor should submit alternate pricing if
dehumidification is necessary. The following conditions will be required:
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21.1.1. Humidity And Temperature

21.1.2. Note the following descriptions of temperature and humidity are for
explanation only as examples. Actual design temperature and humidity
conditions to be used for sizing equipment are listed in the section 3400 of the
GM Global Paint and Polymers Center General Technical Requirements.
21.1.2.1. The following are seasonal facility general space design requirements:
Winter:
Temperature
Humidity
23 C 1 K
55% 5% RH
(75 F 2 F)
Summer:
Temperature
29 C 1 K
(85 F 2 F)
Humidity
55% 5% RH
NOTE: The set points for winter and summer are different in order to conserve
energy and reduce operating costs. These temepratures shall be maintained
throughout the building general areas with non-maintenance/equipment areas
permitting higher temperatures. Final limits for the areas will require the approval of
GM Global Paint & Polymers Center.
Building will based on 0.4% ASHRAE design conditions.

21.1.2.2. Deck and enclosures average space temperatures shall be 72oF and 75% RH
design. Delivery temperature shall accommodate heat and equipment loads (i.e.
lighting, product heat) and maintain average space temperatures. Relative humidity
may float during the summer months with minimum conditions year round at 55%
R.H. The 0.4% ASHRAE conditions based on the weather data listed shall be use
for load calculations and equipment sizing for deck and enclosure space conditions.
Due to cascading of air within the building from these points and heat load within the
process and equipment, delivery temperature may be lower. All building final
average conditions and conditions near equipment and controls shall be submitted
for approval. Specific control design tolerance for these areas will be + 2 0 F and
+2% RH.
21.1.2.3. Design conditions for the primer, base coat and clear spray booths shall be based
on the following diagrams. Note that these conditions list both 99.6% conditions and
in some cases 100% worst case design conditions. 100% worst case design
conditions will exclude 3 hours per year. Contractors shall submit loads based on
hourly occurrences for confirmation.
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21.1.2.3.1. Direct Charge and Non-Electrostatic Water Born Base Coat Application
21.1.2.3.1.1. The control condition shall be worst case listed based on hourly weather data for
the last 10 years from the National Climatic Data Center or 100% worst case less
. Exclude occurrences that fall within 3 hours per year.
21.1.2.3.1.2. Equipment shall be designed to accommodate and load calculations based on:
90oF and 62% R.H. Summer
76oF and 55% R.H. Winter
21.1.2.3.1.3.
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21.1.2.3.2. Indirect Charge Water Born Base Coat Application

21.1.2.3.2.1. The control condition shall be worst case listed based on hourly weather data for
the last 10 years from the National Climatic Data Center or 100% worst case.
Exclude occurrences that fall within 3 hours per year.
21.1.2.3.2.2. Equipment shall be designed to accommodate and load calculations based on:
21.1.2.3.2.3.
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21.1.2.3.2.4. Solvent Born Prime and Clearcoat Application

21.1.2.3.2.4.1. The control condition shall be worst case listed based on hourly weather data for
21.1.2.3.2.4.2. The control condition shall be worst case listed based on hourly weather data for
21.1.2.3.2.4.3. Equipment shall be designed to accommodate and load calculations based on:
21.1.2.3.2.4.4.
21.1.2.3.2.4.5.
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21.1.2.3.2.5. In order to permit better design of the chilled water system for thermal storage in
terms of peak and typical demand, please also submit load calculations based
on 0.4% ASHRAE conditions using the same weather data listed above.
Equipment must be based on 100% conditions.
21.1.2.3.2.6. The above design conditions shall be established in conjunction with actual
hourly weather data for the location for a period of not less than 10 years.
21.1.2.3.2.7. For areas specified as requiring 0.4% or 99.6% ASHRAE , the following
description of these conditions shall apply.
21.1.2.3.2.7.1. Winter dry bulb load conditions shall be based on 99.6% annual cumulative
frequency of occurrence (cold). These values may be exceeded in some years
for 35 hours in a total year of 8760 hours.
21.1.2.3.2.7.2. Summer cooling/dehumidifying load conditions shall be based on both: Dry bulb
temperature corresponding to 0.4% annual cumulative frequency of occurrence
and the mean coincident wet-bulb temperature (warm); Dew point temperature
corresponding to 0.4% annual cumulative frequency of occurrence and the mean
coincident dry-bulb temperature and the humidity ratio as calculated for the dewpoint temperature at the standard atmospheric pressure at the elevation of the
location. These values may be exceeded in some years for 35 hours in a total
year of 8760 hours. Data shall be submitted at the start of each project showing
the projected percentages of 2 degree F increments dry bulb occurrences and
corresponding RH for each month for each temperature zone or area in the paint
shop.12.1.5. Based on the above, the following or partial booths will operate
within the within the windows listed for each area.
21.1.2.3.2.8. It is imperative that the job temperature be estimated for first morning start-up
and all possible exposures during various seasons to insure that the job
temperature is a minimum of 3 C (5 F) above the minimum dew point for the
period in question. Addressing the possibility of operating at the higher drying
line temperatures based on minimum winter conditions, would result in a
minimum temperature of 19 C (66 F) dry bulb. Caution should be exercised, to
address the rise required, when dew point conditions in the booth increase.
Ambient conditions for 20 minutes of job time prior to the booth shall be
maintained at 3 C (5 F) above the operating dew point of the booth.
21.1.2.3.2.9. The requirements to provide mechanical refrigeration for control of summer set
points needs to be evaluated on a plant by plant basis considering site specific
processes.
21.1.2.3.2.10. All general processing areas, decks and enclosures shall be maintained at a
minimum relative humidity of 50% year round. Temperature conditions for these
areas shall be based on personnel comfort and local requirements. Spray booth
temperature and relative humidity should be monitored continuously and
controlled automatically. The temperature & relative humidity should be checked
manually twice each shift with a sling psychrometer. Electronic relative humidity
meters used for calibration of process sensors are recommended and should be
used only if they are certified regularly.
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21.1.2.3.2.11. It is required to have monitoring of outside conditions or entering air conditions

for the booth ASH and alarm if incoming conditions are nearing the same dew
point as the booth air. This condition generally happens in Spring and Fall or
during hot summer days. The automatic booth control system should always be
adding humidity to reach target. If the incoming air is nearing the same dew point
as the spray booth the temperature of the spray booth must be increased. One
can use the equal drying chart to find a higher temperature and humidity to set
the system. When increasing booth temperature and humidity set points
remember clean room temperature may require adjustment to insure job
temperature is not significantly below the dew point for the control point being
used at any one time.
21.1.2.3.2.12. If cooling hoods and vests are required, purified, cool, humidified air suitable for
breathing hoods and cooling vests will be provided for all operators for all zones
within the system and spray enclosures from the booth compressed air loop. For
specific requirements, see Spray Booth Specification Section 2.12.
21.2. The control scheme and programmable controller program shall be designed to allow
automatic control of the spray booth temperature and humidity. Three modes of
operation (set points) shall be required for every system: operation, maintenance,
shutdown.
21.3. Temperature set point shall be shall be accessible from the booth monitoring display
panel. Manual adjustment capability should be built in for operation on one of the control
lines for a booth or for seasonal set points for a building.
21.4. Components shall be:
21.4.1. High Temperature Limit - The air supply house high temperature limit shall be solid
state, indicating type, dry contact output, temperature range to suit temperature
detector. The high temperature limit shall be provided with manual reset. Refer to the
Approved Equipment List for high temperature limit switch manufacturers.
21.4.2. Low Temperature Limit - The air supply house low temperature limit controller shall
provide freeze protection for the humidifier and delayed (3 minutes) shutdown of the air
supply house whenever air temperature on the inlet side of the humidifier falls below
o
o
12.8 C (55 F). The controller shall be installed in the air supply house service aisle.
21.4.3. Temperature Sensors - sensors shall be located to insure booth conditions match
process control variable of controller.
21.4.4. All bulb insertions shall be gas-tight. The bulb length shall be suitable for sensing
temperatures inside the ducts or as required for process match.
21.4.5. Discharge Air Temperature sensor bulb located in supply duct to booth or specific
enclosure.
21.4.6. High Temperature (Hi-Limit Shut-down) sensor bulb located downstream of burner.
21.4.7. Gas Valve Operator - The gas valve operator will be a normally closed electrically
controlled motor.
21.4.8. One main booth process ASH will be required to have (1) motor per stage control valve.
The contractor will provide revised logic for testing of improved turn down capability of
both stages.
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21.4.9. RTD/I Transmitter transmitter or circuitry must drive burner control motor to minimum
position, if RTD or wiring or power to transmitter fails.
21.5. The humidity control scheme shall be based on operation of by-pass dampers and water
on-off control. Humidity shall be controlled by sensing air at the discharge of the supply
fan and by automatically or manually opening or closing water supply solenoid valves
once humidification is needed. The dampers will then be modulated to control humidity.
21.6. The relative humidity sensor and transmitter shall have a range of 0-100% relative
humidity independent of temperature and pressure, fast response, resistance to
contamination See approved equipment list for suppliers. Contractor shall comply with
plant preference as to make and model of sensor and transmitter. Sensors shall be
located in the plenum of the section being controlled in a non-turbulent low velocity area
for all spray booths. Similar location criteria shall be used for all ventilation and enclosure
sensor mounted in ductwork after the ASH. Location shall insure match to booth
conditions or delivery condition for decks/enclosures or the building. Output shall be
displayed on the booth or respective areas monitoring panel display and the central
monitoring system.
21.6.1. If specified by the respective assembly plant, contractor shall quote on a chilled mirror
type of dew point sensor combined with a temperature sensor and a suitable controller
arrangement to provide control of relative humidity.
21.7. Automatic control shall be scaled for 0-100% RH.
21.8. The following is a general description of booth process humidifier operation. Contractor
shall refine this operation and restate it for his sequence of operation. As humidity drops
below the adjustable set point the low water volume solenoid is turned on. Dampers will
be in their full open position at this time. After a timed delay, to let the media become
fully saturated, the humidity level is rechecked, if below set point the second high flow
solenoid is turned on. The dampers are then modulated as conditions demand more
humidification. As the humidity exceeds the set point the program shall modulate the
dampers closed to maintain the correct humidity. The program will turn off the high
volume solenoid if the dampers are wide open and the humidity is too high. The program
will then modulate the low volume water solenoid on every 5 minutes for 2 minutes then
off if humidity still remains too high. If humidity remains above the set point by more than
7.5% the low volume water solenoid and the flushing solenoid will be shut off.
21.9. Implementation of the humidifier control program shall be delayed for a timed period after
establishment of supply airflow.
21.10.
Humidity set point shall be settable from the booth monitoring panel display.
21.11.
The high and low humidity limit shall be settable from the booth monitoring panel
display.
21.12. Provide and install one (1) relative humidity sensor inside the spray booth plenum. Out
put shall be displayed on the booth monitoring panel display.
21.12.1. For recirculation systems, an additional humidity sensor and controls will be provided
to control hot water coils for the abatement system supply discharge to a maximum of
50% RH. Sensors shall be classified NEC Zone 1 (Class 1 Div. 1 Groups C&D).
21.12.2. For recirculation systems return flow to the booth, temperature and humidity sensors
will be provided to control chilled water and hot coils in the return flow. Set point control
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shall interface with fresh air makeup controls to insure control for the process blended
air condition requirements. Sensors shall be classified NEC Zone 1 (Class 1 Div. 1
Groups C&D).
21.13.
Provide and install one (1) Potentiometer in the main operator control panel (MOCP)
with an LED display for position indication. The potentiometer will be used to manually
modulate humidifier damper position and will insure all solenoids are activated for a high
flow condition. When manual control is used the automatic control will be disconnected.
21.14.
Provide for each solenoid control valve an on-off switch for maintenance. Interlock
on-off switches with auto-manual and maintenance by pass switches
22. SUPPLY FAN VOLUME CONTROL SYSTEM

22.1. The supply fan inlet volume control dampers (vortex vanes) (required only if dual fans
with common inlet or discharge are used) shall be automatically controlled by the
programmable controller and the electric damper motor. Damper motors shall be rated
for not less than 200% of the damper torque requirements. This requirement shall be in
lieu of the VFD control if VFDs are not used (approval of GM Global Paint & Polymers
Center required). Manual vortex dampers shall be provided on all supply fans with lock
down capability as a back-up system when the VFDs fail. By-pass starters shall be
provided for the VFDs to allow this back up. Dampers shall be automatically sequenced
to prevent backspin of dual fans on start-up.
22.2. Silhouette ultrasound velocity transmitters shall be mounted at each end of the spray
booth, at all internal silhouettes and at all entrance and exit points to the clean room or
paint shop zone areas. Refer to the Approved Equipment List for velocity transmitter
manufacturers. Velocity transmitters will sense velocity from or to the spray booth or area
involved and will be used to control each plenum partition zone motorized control damper.
Each supply duct branch shall use its own in duct velocity array and differential pressure
transmitter sensor to maintain output through its respective motorized damper. The
individual ASH burner silhouette velocity sensors will be used to maintain each total ASH
output. All sensors and damper positions will be displayed on the central monitoring and
control system as a graphic representation of the booth. See section 60. for additional
details.
22.3. The automatic controls shall interact logically to prevent hunting and to alarm abnormal
conditions in any system without unnecessarily reacting to accommodate them. The
system shall be balanced manually first then each system placed in closed loop mode.
Upper and lower control limits will be programmed for each set of controls and be settable
from the central monitoring and control system. An overall system view shall be available
showing pressure interaction between the various air control zones of the paint shop.
23. MOTOR CONTROLS AND ELECTRICAL COMPONENTS

23.1.
All motor controls and miscellaneous electrical components for operation of the
spray booths, associated pumps, and air supply houses shall be included in a motor control
panel and operator control panels. All components and wiring shall comply with GM CCRW
Specifications. Conflicts between this document and CRW specifications will be resolved at the
start of the project. The prime contractor should assume this specification will take precedence
if any item is not listed in the CRW specification.
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23.2. BLANK23.3.
Interconnecting power, control, and wiring between bus ducts, motor
control panels, operator control panels, and the field equipment served shall be furnished,
installed and wired by this Contractor. The Contractor shall provide within his panels all
required terminals and wire ways for field wiring as required for complete and operational
system.
23.4. Air house controls shall be tied into facility monitoring and control system (FMCS) and to
a main booth monitoring and control display panel located on the booth level. The
specific location of this panel shall be approved by the owner.
23.5. BLANK23.6.
The spray booth and air supply houses shall be controlled and operated
in the following manner:
23.6.1. First start sludge pumps. When each pump starts its bearing lube supply solenoid
opens. Contractor shall provide in PLC program a sequence of pump usage from day to
day by means of multiple position selector switch such as: pump 1 and 2 are on, pump 3
stand-by; pump 1 and 3 are on, pump 2 stand-by etc.
23.6.2. With two (2) sludge pumps running, air supply house #1 shall start. With air supply fan
running, designated exhaust fans shall start.
23.6.3. Air supply house #2 starts. With air supply fan running, designated exhaust fans shall
start.
23.6.4. Air supply house #3 shall start in same sequence as air supply house #2.
23.6.5. Sludge pump shutdown will turn off ASHs and exhaust fans.
23.7.
The following conditions to sound alarm:
23.7.1. Pump failure
23.7.2. Fan failure
23.7.3. Any failure of equipment to start during auto sequence start-up
23.7.4. Low temperature discharge
23.7.5. Sludge pit high level
23.7.6. Sludge pit low level
23.7.7. Pump lubrication cycle incomplete
23.7.8. Grease pump over-pressure
23.7.9. PLC failure
23.7.10. Fire shutdown (In case of fire, air supply fans, exhaust fans, and water pumps
continue to operate. Paint pumps stop.)
23.8. Spray booth silhouette velocity control shall be provided as described above accessible
from the booth monitoring display panel.
23.9. Contractor shall provide signal averaging to smooth step functions and avoid frequent
velocity changes on short time velocity interferences. If required in field, Contractor shall
install signal averaging device between velocity transmitter and analog input. Device
shall be as manufactured by Moore Industries, Model ARB/4-20mA/10-50s/120VAC or
Owner approved equal.
23.10.
Indicating lights, push buttons and selector switches provided at MOCP and A.S.H.
MCP shall be installed in logical order for operator convenience to control a process.
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23.11.
This specification for motor, velocity, temperature, and humidity controls represents
minimum requirements necessary for proper operation of the spray booth and associated
equipment. Contractor shall be responsible to design, engineer, and build a complete
control system to accomplish required system operation.
23.12.
Contractor shall be responsible for the calibration of all process control instruments
in the field. Preliminary calibration shall be made during debugging and set-up period.
Final calibration and adjustments shall be performed in presence of Owners Engineer
during start-up period under production conditions. Contractor shall provide report with
all final calibration and function test results for Owner acceptance.
24. CENTRAL BOOTH MONITORING AND CONTROL SYSTEM

When required in the project scope, a Central Booth and Air House Monitoring and
Control System Display Panel will be provided using a color display panel connected to
the common data highway between all systems in the paint shop general area including:
all miscellaneous booths and the clean room ventilation systems, paint mix ventilation
general paint shop area ventilation, spray booth air supply units, the booth water
recirculation system, all exhaust systems, and the monitoring equipment listed below.
The computer shall be as per the requirements for the Paint Shop Area Monitoring
System and shall use Wonderware software. The display panel will be located near the
entrance to the main Color Spray booths with duplicate view only screens for supervisor
use with final locations of all as specified by the owner. The system will have one
master screen showing all major subsystems and their present condition as either OK
or Alarm. Separate screens for each subsystem will display the present Alarm
condition if any and an overview of the equipment related to that system i.e. exhaust,
supply, water, etc. All process variables will be displayed for each subsystem on this
screen. Function screens listed at the bottom of each subsystem screen will take the
user to settable variables for the subsystem. These Function screens will be password
protected with 5 passwords: (1) Master capable of setting (4) operator passwords. This
section of the panel display code will be adequately protected from tampering. Final
approval of the layout of all master and subsystem screens shall be approved by the
owner and GM Global Paint & Polymers Center. The following system items will be
monitored:
24.1. Master display will show each subsystem as OK or Alarm with function keys for each
subsystems display screen.
24.2. Each sub system display will show present Alarms, related equipment status, Process
Variables and function keys for each related piece of related equipment. Related
equipment that is duplicated such as exhaust fans will be grouped on one screen.
24.2.1. Exhaust fan screens will show actual, nameplate, normal and alarm limit motor
amperages and VFD Settings and control variable if appropriate.
24.2.2. Booth water recirculating system screens will show: number of pumps operating,
number of pumps required and pumps on standby; each pump actual, nameplate,
normal and alarm limit motor amperages; tank level actual, upper limit, lower limit, and
pump shut down levels; total system flow based on ultrasonic flow sensor, normal total
flow and upper and lower flow limits. Exercise program sequencing for valves and
flushing will be shown.
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24.2.3. Each air supply house requires the following basic information shall be grouped on the
main ASH screen such as discharge temperature, % relative humidity, and alarm
conditions. This graphic depiction of the ASH will have sub functions for each of the
following items (if equipment is used):
24.2.3.1. Burner status including profile plate actual velocity, upper/lower control limits,
volume calculation based on velocity; output motor %; first/second stage on/off;
temperature actual, upper/lower control limits.
24.2.3.2. Primary Filter pressure drop: actual, clean, dirty, high and low alarm. In the case of
Clean Room or other ASH that use secondary filters provide the same information.
24.2.3.3. Fan: %VFD, %vortex, differential pressure, actual, nameplate, normal and alarm
limit motor amperages.
24.2.3.4. Humidifier: Solenoids on/off, flow rate on high/low griswold differential (calculated)
with high/low control limits; damper motor % output; central circulating system status
on/off; % relative humidity actual, set point, upper/lower control limits.
24.2.3.5. If applicable for chilled water coils, % valve operator output.
24.2.4. Each booth shall have an individual screen with individual silhouette velocities shown on
an elevation which also shows each ASH and its respective: % total output.;
temperature; humidity. A password-protected set point will be available for each ASH
variable. As a sub screen, each respective plenum zone of the booth shall have:
24.2.4.1. Secondary Filter pressure drop: actual, clean, dirty, high and low alarm and trending.
24.2.4.2. Final Filter pressure drop: actual, clean, dirty, high and low alarm and trending.
25. AIR SUPPLY HOUSE LIGHTING

25.1. Contractor shall furnish and install lighting, hand-tool receptacles and switches in air
supply house. Fluorescent light fixtures shall be installed in air supply house
compartments and in the service aisle (roof mounted units only for service aisle). Fixtures
shall be 1.2 m (4-0) industrial fluorescent with 2 rapid start HO T8 lamps, electronic
ballasts, 3 wire SJO cord, and plug. Refer to the Approved Equipment List for lighting
manufacturers. Fixtures for paint booth recirculation filter houses shall be incandescent
using a compact fluorescent lamp rated for NEC Zone 1 (Class 1 Division 1 Group D)
rated fixtures. The light fixture in the service aisle shall be controlled by a switch located
at A.S.H. entrance. Switches for compartment lights shall be located adjacent to the
respective compartment access doors (except recirculation filter houses which shall be
mounted to be outside the hazardous areas). The fixture in the burner compartment and
downstream compartments seeing high temperature shall be jelly jar incandescent or
halogen and be designed for high temperature service. Aisle mounted lights shall be
positioned to insure proper illumination of all electrical panels, MCCs and other aisle
mounted equipment. All aisle switches shall include motion sensing timed delay off
controls with bypass and compartment switches timed delay off with bypass.
25.2. On roof mounted air supplies, an exterior lighting fixture shall be mounted near the
entrance door and shall be enclosed and gasketed high pressure sodium type consisting
of weatherproof cast aluminum housing, single piece prismatic refractor and asymmetric
aluminum reflector. Fixture shall be completely wired and provided with 100 watt metal
halide, guard, photo-control switch and high power factor ballast. Refer to the Approved
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Equipment List for exterior lighting manufacturers. Positioning of photo-control switch

shall not be effected by light operation.
25.3. Exterior lighting shall be shielded such that light is shown only down onto walkways.
Direct light shall not be visible from remote surrounding areas.
25.4. The power feed for the air supply house lighting shall be provided with a lighting panel as
approved by the Owner.
25.5. A separate contactor and relay shall be provided for connection to the shutdown energy
management system with an auto-manual bypass switch. 20% of aisle or area lighting
shall not be connected to this contactor. 20% Area lighting not connected shall be
connected to an emergency power source.
26. FLOOR DRAINS

26.1. The Contractor shall provide and install all required cleanable box traps (P-traps shall not
be permitted) and piping from the air house floor drains to the building industrial waste
system or as otherwise required by local codes. Alternates may be considered using dry
traps without wetting lines with submittal and approval and approval of design by owner.
Heat tracing with thermostatic control is required on all drains of roof mounted air
supplies. Screw mounted substantial drain covers shall be provided on all drains. Aisle
drains shall be provided on 15 m (20) centers minimum including penthouse aisles. All
horizontal drain piping shall be pitched and adequately supported.
27. PAINTING
27.1. Air Supply house internal surfaces shall not be painted.
27.2. Contractor shall remove stains, labels, caulking compound, spots, marks and dirt from all
surfaces installed under this Contract, regardless of whether the surfaces are to be
painted or not. Contractor shall vacuum and tack all internal and external surfaces of the
system installed. Final deep cleaning shall comply with Section 33.
27.3. All structural and mild steel shall receive (1) coat of primer. Prior to applying finish coats,
all exposed bare metal shall be touched up with matching primer after erection and
welding.
27.4. All external surfaces shall receive an urethane finish as described below. All surface
preparation shall be in accordance with the coating manufacturers recommendations.
27.5. All stainless steel surfaces shall not be painted.
27.6. Colors and sheens of the finished coats of paints mentioned below shall be as selected
by the Owner from submitted paint samples.
27.7. Paint the various surfaces as follows:
27.7.1. Black Ferrous Metals - exterior exposed surfaces:
27.7.2. One (1) coat metal protective primer
27.7.3. Two (2) coats urethane finish coat
27.7.4. Aluminized or Galvanized Metals - exterior exposed surfaces:
27.7.5. One (1) coat aluminized or galvanized pretreatment
27.7.6. One (1) coat metal protective primer
27.7.7. Two (2) coats urethane finish coats
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27.7.8. Colors shall conform to General Motors Color Guide for Manufacturing Plants or as
approved by the Owner.
27.8. All air supply house interior galvanized surfaces (areas in contact with the fresh air) shall
receive no paint. Air supply house corridor surfaces and utility components shall be
painted.
28. SPECIAL AIR OR FILTER HOUSE CONSIDERATIONS

28.1. Air supply houses for paint mix rooms shall comply with all of the typical air supply house
requirements with the following special conditions:
28.1.1. Paint mix air supply houses shall use either indirect fired burners with DIN 1.4306 (304L)
heat exchangers or hot water coils for heating.
28.1.2. Primary and secondary filtration will be provided in the air supply house.
28.1.3. The air supply house and exhaust system shall be interlocked with the fire protection
system for the paint mix system. Opposed blade fire dampers with fusible links and fast
acting damper operators shall also be interlocked. All dampers, motors and linkages
shall be protected with removable weather covers.
28.1.4. All supply diffusers in the paint mix room shall be provided with filter tracks and
removable filter track covers. Self supporting 600 mm x 600 mm (24 x 24) filters will
be provided for these tracks. Refer to the Approved Equipment List for filter track
manufacturers.
28.1.5. The fresh air intake, aisle heater intakes, indirect fired burner location and all other
aspects of the exhaust and supply systems shall take into account the mix tank vent
locations.
28.1.6. The exhaust system shall have dampers as per 28.1.3. above. Exhaust fans shall be
AMCA type A construction. The exhaust stack shall conform to the spray booth
exhaust stack specifications.
28.1.7. All air supply house and exhaust components shall be monitored and alarmed by the
central paint shop monitoring system. Both supply and exhaust shall also have velocity
sensors with low velocity alarms.
28.1.8. All recirculation/cascade filter houses to building discharge shall insure primary and
secondary filtration and if required cooling coils for building temperature requirements.
Discharge boxes or ducted discharge connections shall insure low noise through low
velocity on diffusers. Diffusers shall be Krantz radial twist diffusers or owner approved
equal.
28.1.9. Transfer fans between building levels shall be clamshell centrifugal fans. Discharge of
fan shall be per 28.1.9.
28.1.10. Building exhaust fans shall be direct coupled and not belt driven. Sound levels from
building fans shall not exceed 80 dbA at 1.5 m (5) from fan.
29. FIRE PROTECTION

29.1.
29.2.
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All recirculation filter houses will require sprinklers. Interior components shall be S.S.
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30. INSTRUCTION AND TRAINING

30.1. The Contractor shall provide training as per GM Global Paint and Polymers Center
section 38000. The following information is required as part of the overall scope listed in
that specification. Field instruction shall include a full process start-up, shutdown,
balancing and calibration procedure description. Class size shall be a maximum of fifteen
(15) persons. Appropriate teaching aids shall be provided for each class. A training
manual shall be provided to all students and a minimum of (6) copies shall be provided
with the final training video marked as Master for future use. Where possible, disk
copies of all training manual material will also be provided in Microsoft Word for
Windows, Powerpoint or Excel for Windows format to each student.
30.2. The instructors shall be both mechanical and electrical individuals involved in the design
of the subject systems and individuals involved in the design of each major piece of
equipment such as fans, Air Supply Houses, Burners as well as Start-Up Personnel. The
training shall concentrate on overall system operations, equipment service schedule
requirements, and trouble shooting techniques.
30.3. The training classes shall be scheduled and arranged through the Owners designated
training coordinator. The first class shall include Owners technical personnel for the
purpose of education and content approval.
30.4. Any information or instruction provided to the Owners personnel during the system startup or debugging process shall not be accepted as training credit. Involvement of the
owners maintenance and engineering personnel shall be required during the start-up
phase of the project and additional hands on start-up involvement is required.
30.5. One class of each type, as called for above, shall be video taped for the Owners future
use on DVD. Video shall become the property of the Owner. The video may, at the
discretion of the Owner, be reproduced for the sole purpose of future and refresher
training classes. The video taping shall be coordinated and arranged by mutual
agreement between the Owner and the Contractor.
31. MANUALS
31.1. The Contractor shall provide manuals as per GM Global Pant & Polymers Center. The
following information is required as part of the overall scope listed in that specification.
Manuals will include information and operating data, parameters, instructions and
maintenance information for the entire system and related components. Where possible,
disk copies of all manual material will also be provided in Microsoft Word for Windows,
Powerpoint or Excel for Windows format in addition to normally provided PDF format.
31.2. The manuals shall meet the referenced specifications as well as the following items:
31.2.1. Design data such as operating temperatures, relative humidity, and air flow rates, static
pressures, operating amperages and voltages, vibration signatures, filter pressure
drops, switch settings. A copy of the spray booth schematic flow diagram shall be
included. Actual values as measured shall be included for all parameters.
31.2.2. Full operating instructions including sequence of operation, start-up and shutdown
procedures, etc. All alarm faults and their meaning shall be listed in a distinct section.
31.2.3. Adjusting instructions for the entire system and equipment. This section shall include a
step-by-step method of booth recirculation system water balancing; airflow balancing;
calibration of all sensors and switches; burner adjustment.
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31.2.4. Cut sheets, parts lists, operating instructions and maintenance manuals for all
purchased equipment which is part of the system installation. This shall include, but not
be limited to, flow sensors, burners, filters, fans, motors, temperature and humidity
sensors and lights. All manufacturer pages that list more than one component shall
have the appropriate item highlighted and the specific part numbers clearly listed.
31.2.5. Detailed information regarding all periodic checks, tests, maintenance, cleaning,
adjustments, and calibrations which will be required to keep the system operating
properly and efficiently. This section shall include a schedule of all events.
31.2.6. Details of lubricating materials recommended for all moving parts and lubricating
schedules. All automatic lubricators shall be listed as described in the respective
sections. A maintenance program shall be included that provides the necessary forms
and frequency of operation verification for all lubricators based on manufacturers
lubrication frequencies and not lubricator change intervals. All lubricators shall have the
installation date permanently marked on the lubricator body.
31.2.7. Details of all other fluids and other materials recommended, approved, or allowed for
use in or on the equipment.
31.2.8. Spare parts list by equipment area such as ASH, exhaust, water recirculation, etc. The
contractor shall also provide all drawings including general arrangement and equipment
material list drawings, air flow schematics and all certified equipment drawings in A3
(11 x 17) format with durable plastic binder covers. All drawings shall be provided on
owners cad system format and electronic media inserted in these drawing books.
31.2.9. A copy of all data measured and recorded during initial testing, with final settings
indicated including all damper positions and settings and switch settings.
31.3. The entire manual shall be divided into logical sections with index tabs. Purchased
equipment shall be alphabetically arranged with alphabetical index tabs.
31.4. The manuals shall include a Table of Contents and a Detailed Index.
32. MANUFACTURING SYSTEMS QUALIFICATIONS - TESTING AND ADJUSTING

32.1. See MSQ document pertaining to all booth and paint shop systems for more details and
requirements.
32.2. Prior to starting the system, the contractor must verify that:
32.2.1. All electrical equipment is properly installed, wired and correctly set.
32.2.2. All mechanical equipment is properly installed and set to design parameters.
32.2.3. All oil and lubrication levels (fan bearings, etc.) have been satisfied.
32.2.4. All fan and motor rotation directions are correct.
32.2.5. All fan belts are installed and properly tightened.
32.2.6. All safety guards and covers are properly installed on all equipment.
32.3. The contractor shall follow the recommended start-up procedure and measure and record
the following information during initial start-up and testing as follows:
32.3.1. Check and record all cold air volumes for all fans including inlet and discharge fan static
pressures.
32.3.2. Check and record all motor amperage draws and voltages at start-up. Check and
record all pivot base settings and belt tensions.
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32.3.3. Test, Calibrate, and record set points of all Safety and control devices. All NFPA 86
guidelines shall be followed. All of these tests shall be performed by the gas train
and/or burner manufacturers representative.
32.3.3.1. Check and record all gas pressure regulator settings.
32.3.3.2. Check and record all pressure and air flow switch settings.
32.3.3.3. Check and record all temperature control limit settings.
32.3.3.4. Check all valves for proper operation. Record all verifications.
32.3.3.5. Check all safety shut off valves for leakage. Record all verifications.
32.3.3.6. Test all vents for presence of gas with train operation.
32.3.4. Test operation of all burners and calibrate. Record all settings
32.3.4.1. Test flame failure safety operation. Record all verifications.
32.3.4.2. Burner operation shall conform to NFPA 86 requirements.
32.3.4.3. Adjust burner profile plates to optimum position to give the correct pressure drop
across the burners and the correct color flame. Gas regulators shall be adjusted to
give correct gas pressure. Record all settings.
32.3.5. Test operation of fans, dampers, motors, etc. with burner on and air supplies at
designed temperature. Record all verifications.
32.3.5.1. Check and record motor running amps, volts, vibration, and resistance.
32.3.5.2. Check and record all fan volumes, pressure drops, sound levels, and vibration.
32.3.5.3. Check and record all air flow rates (CFM and ACFM), inlet and outlet static
pressures ( W.C.) for all fans. Test ports shall be provided in ducts at all fans
designed and located to allow accurate air velocity and temperature readings to be
taken. All ports to be plugged with rubber test tube stoppers. All test port locations
shall be clearly identified in the final balance report and in the maintenance and
operating manuals by identifying the location on a plan view of the system and
describing the location in writing.
32.3.5.4. Vibration analysis of all rotating equipment per GM Vibration Specifications. Record
all data, test locations and signatures.
32.3.5.5. Test and record sound levels of all equipment and location of tests per GM Sound
Specifications.
32.3.5.6. Check and record pressure drops across all filters. Simulate dirty filter conditions
and check and record transmitted outputs.
32.3.5.7. Balance system for air flow control
32.3.5.8. Check and record the ASH humidifier settings.
32.3.5.9. Check and record all settings on central humidifier recirculation tanks. Check and
record all pump amperages, voltage, and pressures including dead head pressure.
32.4. Contractors start-up report shall include completion of the following attached forms.
32.4.1. AIR SUPPLY BURNER SET-UP/SAFETY CHECK LIST
32.4.2. FILTRATION TRANSMITTER/GAUGE CALIBRATION CHECK LIST
32.4.3. VIBRATION SIGNATURES AND DATA REQUIRED IN VIBRATION SPECIFICATIONS
32.4.4. SOUND LEVEL DATA AS REQUIRED ON SOUND SPECIFICATIONS
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34835B
AIR SUPPLY &

FILTER HOUSES
32.4.5. HUMIDIFIER AND RECIRCULATION CHECK LIST
33. SIGNS
33.1. The Contractor shall provide signs along the exterior of all equipment as required below
and as indicated in the respective equipment sections.
33.2. Minimum sign size shall be A4 (8-1/2 x 11). Signs shall be painted (with lettering
stenciled) 1.5 mm (16 ga.) sheet metal panels. All signs shall be hung via chains or sheet
metal screws.
33.3. The following signs shall be provided:
33.3.1. Signs at each fan identifying its respective service (exhaust fan, supply fan, etc.),
3
corresponding zone, airflow m /hr. (CFM), Static, Belt sizes and sheave sizes, bearing
mfg. and number, shaft size, HP, etc. These tags shall be stamped and not painted
data. Rivit or Screw mounting required.
33.3.2. All ductwork and dampers shall be labeled (stenciled) with its respective stage , service,
and flow direction, open closed positions. Final balanced condition settings of all
equipment shall be scored and painted.
33.3.3. All valves, thermocouples, dampers, switches, controls, etc. shall be marked with
phenolic identification tags permanently mounted with cables, chains or screws or S.S.
rivits. No pressure sensitive adhesive shall be permitted.
33.3.4. All gauges will be marked with a fine line of red paint. If a range is possible, extremes
will be marked with high quality plastic marking tape.
33.3.5. All piping shall be clearly labeled every 7.5 m (25) and color traced every 3 m (10).
33.3.6. All safety signs as required will be screw or S.S. rivit mounted.
34. CODES AND STANDARDS

All designs, equipment, and installations shall conform to and be in accordance with the
most current editions of the applicable country codes and standards and as required in
section 3400.
Worldwide Purchasing Training and Manual Specification for Equipment and

Manufacturing Systems
35. ALTERNATES/SITE SPECIFIC CONDITIONS REQUIRED
Sectio Alternate Description
Base Bid Description
n
Numb
er
3.3
Provide Din 1.4306 (304) 10 ga. Provide galvanized or type 2
S.S. flooring throughout.
aluminized 10 ga. flooring
throughout.
16.1
Provide alternate pricing for
See specification Munters
spray coil humidifiers using all media type with face and bypass
S.S. coils.
control.
69 of 60
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34835B
16.2
Base Bid is to provide a

dedicated RO system or
combine feed water with
Phosphate Elpo dedicated RO
system. IF Central RO feed
from WFG is provided for the
humidifiers, dedicated system
may be deleted.
Base bid is for Sch. 10 S.S>
piping on supply and return for
humdifiers.
17.3
18.13.
2
36.0
AIR SUPPLY &

FILTER HOUSES
An alternate will be provided for

FRP or PVC if space temperatures
do not result in flexibility issues for
the material. Neither will be used
for exterior applications.
Specification is for 3 way feed

and bleed systems for chilled
water. Site specific conditions
to dictate if 2 way system
should be quoted instead.
ATTACHMENTS
36.1 Humidification Process Control Parameters and Chemical Control
36.1
Measurable Variable How Tested
Frequency of
Data Points
Langelier Index
Calculated on water
analysis and water
temp.
1x/month, Feed Blowdown revision, pH revision

1x/month
process 1x/week
Ryznar Index
Note: all three indices

may be used

1x/month
process 1x/week
Puckorius Index
70 of 60
15AP00
Corrective Action

1x/month
process 1x/week
Rev. A,
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AIR SUPPLY &

FILTER HOUSES
Conductivity
Manual w/meter or
When recording
auto w/controller when controller is
available.
available, 2X/day
minimum and
when out of
control 3-4x/day
min
UCL-LCL will be established using a spreadsheet

developed to predict scaling indices. Blowdown
will be controlled controller or a metered blow
down line. Monitor makeup tank water feed and
bleed off to establish ratio.-Spreadsheet will
include limits of all pertinent elements, indices,
water parameters. Alarm if conductivity is out of
control and identify corrective action. Increase
sampling frequency until controlled.
pH
Manual w/meter or
auto w/controller if
available
When recording
controller is
available, 2x/day
min, 3-4x/day if
out of control
If pH is high, use additional blowdown. Do not

use acid, use blowdown control, If pH is low,
control not expected unless typical feed water
requires this control
Alkalinity
Test kit (titration)
verify quarterly
To be alarmed by monthly feed and indices of

control. Verify with actual process testing
quarterly.
Silica
quarterly

quarterly.
Iron
Test kit or water

treatment suppliers
laboratory
quarterly

quarterly.
Total Hardness
quarterly

quarterly.
Chlorides
Field test kit or water

treatment suppliers
laboratory.
quarterly

quarterly.
suspended solids
Field test kit or water

treatment suppliers
laboratory, V cone,
weight solids
quarterly, out of
control weekly
Bag filter micron reduction, blowdown, flush and

dump
Oil and Grease
Water treatment
suppliers laboratory
quarterly
Bag filter consider addition of non ionic

surfactant.
71 of 60
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AIR SUPPLY &

FILTER HOUSES
chlorine/bromine
OTO DPD both free

1x/month, if
Remove hockey pucks.
and total
problem 3-4x/day
chlorine/halogen Field
test kit (color
comparison or test
strips)
Biodip slides
Bioscan meter used

only for test frequency
more than 1x/week.
Bio dip slides required
1x/week, Relative
Population Density
(RPD)
RPD when
starting up then
1x/year, Bio dip
1x/week
minimum.
3x/week as
needed if out of
control.
Non-oxidizing
biocides a
combination of 2
different biocides
are required for
every system alternating use.
Consult water
chemical supplier.
1x/week min to
3x/week or more
as needed for
control. Some
chemicals do dot
have a practical
test method
Shock treatment
72 of 60
15AP00
Weekly and monthly biocide addition. -Main dose

sized for 15 min max feed time. Chemical feed
pump sized for full slug volume w/in15 minutes.
Biocide dosage depends on system volume and
blowdown rate. Blowdown will be suspended for
6 hours after biocide addition to allow adequate
contact time. Biocide addition should be targeted
for time of day when evaporation rate is low but
water is running over the media.
Weekly and monthly biocide addition. -Main dose

sized for 15 min max feed time. Chemical feed
pump sized for full slug volume w/in15 minutes.
Biocide dosage depends on system volume
interlocked to and blowdown rate. no Blowdown
will be suspended for 6 hours after biocide
addition to allow adequate contact time. Biocide
addition should be targeted for time of day when
evaporation rate is low but water is running over
the media.
OTO DPD both free
Once per quarter Quarterly flush and dump of system with fans off
and total
for 1 to 5 hours, time permitting. Rinse, flush and
chlorine/halogen Field
return to service
test kit (color
comparison or test
strips)
Rev. A,
All rights reserved

34835B
AIR SUPPLY &

FILTER HOUSES
Note: Frequencies are based on

Process Control Plan development.
Assume highest frequency as
minimum is system is not within
upper and lower control limits. Lower
frequencies assume stable operation.
Some levels must be established as
stable over longer periods before
frequencies can be reduced - i.e. if
feed water is verified for one year and
is stable, sampling may be reduced
to bi-monthly. If feed water is from
multiple sources and ratios vary frequency may need to be increased
as ratios change.
Unit Operating Best practices

Velocity
Cleaning
Units design
Self draining sump sloped in 2 direc
provided for each water distribution h
sump. Add motorized ball to sum
recirculating systems only: - ope
perform
Feed water - provide RO and city/other feed regardless w/meter, ratio of

feeds to be Emos controllable through valve/meter control. Sampling
points required on both make up feed lines.
Non central pump or process s

conditions will not degrade media. If re
Tank
Makeup (1-2)- RO and/or city water.

metered. Tank bottom pitched 2 directio
in addition to larger main control valve a
low conductivity and
Chemicals
73 of 60
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34835B
Biocide to use process supply line tap. Separate process supply line
sampling point required below biocide feed.
Maintenance - dry out and flush
Cleaning
Flushing and Dry out
AIR SUPPLY &

FILTER HOUSES
Feed points, two biocide feeds

connection. If dry DBNPA is used, pro
"Quarterly" media flush, dump and d

July (1 week). Flush and dry media,
replacement annually. Re
Weekly- face and bypass humidifiers media- turn
For 4bank systems, Monday Wednesd
Thursday for 1
To be investigated by Munters - response required: Disinfection procedure;

use of bromine/chlorine (do not use these materials without specific approval
of David Dobias).
Feed Water Information Required for Engineering Initial Design
how treated @city
chlorine dioxide?
chlorine/bromine?
Fluoride?
softening?
RO, Demin
lime soda?
Other treatment locally?
List of proposed chemicals/ dosages/ feed strategy
Langelier Index
Ryznar Index
Puckorius Index
Conductivity
pH
Total Alkalinity
Silica
Iron
Total Hardness
Chlorides
suspended solids
Oil and Grease
chlorine/bromine
Source of water (lake, river, well) and name of source
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