Chapter 5.5 Shop Area General Specifications QRC General...

Chapter 5.5 Layout and Construction of a QRC, Shop Area General Specifications Flow Solutions of 20

Chapter 5.5 Shop Area General Specifications

QRC General Building Specifications For Most North American Locations

Origination Date: 12/2003 Revision 10, Date: 04/15/08

This document is confidential and is the property of Flowserve Corporation. It may not be copied, reproduced, or disclosed in any way without the expressed written consent of Flowserve Corporation.




Shop Area Specifications

This document includes specifications for the following areas: Reference Description Room#

S1. Manufacturing / Seal Repair Demising Wall D10 S2. Shop or Supervisor Office S3. Lapping Room D18 S4. Assembly Room D1 S5. Seal Repair Area D2/D6 S6. Inventory / Shipping Area D9/D5 S7. Machinery Area S8. Wash Area S9. Carbon Room D13 S10. Dust Collection Room C1 S11. Air Compressor Room S12. Canopy-Backyard

Specifications are guidelines to follow for building or tenant improvement (TI’s). These specifications are written to meet Flowserve Corporation Branding Standards.


S1. Separation Wall / Demising Wall Manufacturing to Seal Repair l

Construction This wall is to run from floor to roof panels to minimize dirt and coolant migrating on the machine shop side. It will also reduce noise from the seal repair side. The wall should be constructed with steel stud construction, 5/8” drywall on both sides and have R-11 or greater insulation. Flooring The base of this wall is to have a 4-inch (15cm) rubber cover base (Figure 4.1) allowing for easier sweeping and a cleaner shop. Painting The entire wall is to be painted (Figure 10.2) with High Quality washable paint. Electrical Shop and seal repair areas need several house power 20 amp duplex outlets located inside the wall at bench height, 31 to 36 inch (79 x 91cm) from the floor. (Refer to QRC Type for number of outlets).






S2. Shop or Supervisor Office For a Supervisor and foreman on the machine shop side and/or for the Seal Repair side construct one or two offices, the construction is the same. Modular offices can also be used in the shop. Construction Refer to office section (05) where dry wall (Gypsum board) may be used. If constructing a seal repair or shop floor supervisor office plan for dry wall to extend to ceiling in shop or 12ft (4m) whichever is less. This allows for duct work, wiring and IT to be hidden. Ceiling tiles and fluorescent lighting as per office specs are preferred. Flooring Shop offices may use vinyl flooring (Figure 6.2) and a top set (Figure 4.1). Painting All walls inside the office and on the outer side should be High Quality and washable. Electrical House power duplexes are needed on two walls. Ventilation Design ducting from the shop or office HVAC as pre-forced.


S3. Lapping Room

Construction If the walls are not of tilt-up concrete or block wall construction, steel stud with 5/8” drywall is required. FRP to be placed over drywall from floor to ceiling. Flooring This area is to be 6-inch (15cm) reinforced concrete. No flooring or external sealer should be used. Solvent resistant non slip epoxy coating may be considered. Floors must be level and of a smooth finish. Gray color VCT can be optional flooring cover. Painting Purlins, columns, and plywood need to be painted with a High Quality latex paint, Swiss Coffee color. This allows for better lighting and housekeeping. The HVAC ducting needs to be painted out with High Quality latex. Electrical Locate the sub-panel on one of the perimeter walls within the seal repair equipment area. This allows for short cleaner runs when hooking up the equipment and enables safer shutting down of equipment. Each workbench should have an electrical five-plug strip for the convenience of using small hand tools. Electrical strips should have a pig tail plugged for house keeping or re-arrangements. Ventilation This room only requires one HVAC unit. Design of the system to be done by the HVAC contractor. Plumbing Consider a small hand washing sink in this area.




S4. Assembly Room

Construction Same as Lapping room Flooring Same as Lapping room Painting Same as Lapping room Electrical Same as Lapping room Ventilation Same as Lapping room Plumbing No plumbing would be required in this room.




S5. Seal Repair Area This is an open bay, to be laid out for optimum process flow. Construction Same as Lapping room, except FRP not required on walls. Flooring Same as Lapping room Painting Same as Lapping room Electrical Same as Lapping room Ventilation The open bay should have at least two HVAC units. In most cases (two) 5 ton units will suffice. Several designs can be utilized for supplying heat or cool air. One spiral duct with 360-degree diffuser spaced out over the bay. Spiral ducting does not collect much dust and puts air exactly where needed. Another can be dropped directly down from the roof with square ducting using four sided supply grills. In both cases air supplies should be 6 to 12 inches (15 x 30 cm) above the lights and 16’ (18m) – 6” (15cm) to 17’ (5m) – 6” (15cm) AFF (above finished floor). A local HVAC contractor can validate design. Ceiling fans may be a sufficient option for our circulation over this area. Plumbing Same as Lapping room




S6. Inventory / Shipping Area This area covers a construction of steel inventory bin racks (finished goods) and, second floor (used primarily for storing packaging goods, maintenance, and boxed seals) with guardrails and a stairway. Some fire codes will not allow plastic bin boxes. Construction Before erection of inventory racks, the separating wall (between shop and seal repair area) should have a cross over aisle located at the end of the wall and the end of the building. Aisle needs to be at least 5 ft (4.5 m) wide. Consider an opening constructed somewhere in the separation wall allowing for a walkthrough from the machine shop side into the inventory area, near final inspection area. Cover any wall exposed to equipment or daily use from packaging, etc., with FRP to reduce wear and tear maintenance. Flooring This area is congruent with the main concrete floor of 6 inch (15cm) using re-bar and is to be a smooth finish. Painting This area should be part of initial painting of the shop / seal repair and should be painted with High quality latex. Electrical The back door to the outside should be close to the shipping/packaging area. Locate light switches here. There should be 2-lamp, TB 4’ (2.5m) light fixture mounted under the floor of the inventory in the aisles. The shipping/packaging area may also need 2 lamp 4’ (1.2m) fixtures. Light switches should be located on one column holding up the floor in the shipping/packaging area and next to the opening towards the back of the inventory. Ventilation In large facilities that will have more than two rows of inventory, ventilation may be a problem. Consider an HVAC duct to create a flow of hot or cold air down the aisle. Adding a small circulating fan at the back of the aisle may help.






S7. Machinery Area This area houses engine lathes, mills, saws, drills and possibly an inspection area. No external sealer should be used, as they may become tacky from coolant/chemicals from machines. Solvent resistant non slip epoxy coating may be considered. Construction This portion of the building will have been finished out with Cinder block bricks, Concrete or Dry wall (Gypsum board). If machinery is to be placed close to wall, apply FRP board or ¾ “(18MM) plywood behind machinery fixed against the wall to minimize absorption of coolant spray or oil. Plywood should be painted. Floor Minimum of a 6-inch (15cm) floor with re-bar, having a level and smooth finish for the existing size machines. If CNC machinery is selected, consider isolated pads to cover the footprint of the machine. Flooring at this point may be as deep as 12 inches with re-bar, dependent on the size and weight of the CNC Equipment. Painting As the ceiling and walls are already finished out with High quality Swiss Coffee color latex. Electrical Main power panel sizes for QRCs are as follows: Type A – 400 amp service, Type B – 800 amp service, Type C&D – 1200 amp service. All QRCs require 480 volt 3 phase service. Lighting for high bays should be 2’x4’ (60x120M) – 6 lamp T8 overhead fixtures are to be used whenever possible in the shop areas. The mountings of these fixtures will very depending on what city/state the facility is being built. Ventilation The machine shop side of the facility is in need of larger HVAC units and need for redundancy due to the larger heat load. Two each 5-ton units are typical for temporary control in hot humid areas (e.g. Houston). It may be necessary to use three 5 ton units or two 7 1/2-ton units. Never use only one HVAC unit in seal repair or the machine shop areas. If one unit goes down extreme heat can cause business interruption and in most cases, fixing a unit will take longer than 24 hours. Multiple units allows for better efficiency of the air distribution. If at all possible, run these units on 440V, a higher voltage (e.g. 440V in USA). Ceiling fans may be a sufficient option for our circulation over this area.


S8. Wash Area

A wash area should be located next to the main rest rooms and utilize the main plumbing. Install a double sink or a hemispherical hand basin so employees can wash off heavy dirt and grime before going into the restrooms. Construction Walls should be lined with either stainless steel or FRP to minimize daily maintenance. This area should be recessed from the main aisle. Flooring The floor is part of the poured concrete floor with a smooth finish. Alternatively, a ceramic tile (Figure 1.2) or Vinyl (Figure 6.2) can be used if specified. Safety mats should be used to prevent slipping due to splashing of rinse water. A 4” (10cm) rubber top set (Figure 4.1) should also be used to prevent walls from being damaged by spills. Painting Any area such as the ceiling that is exposed or not covered with another material should be painted with High Quality latex. Alternatively, FRP panels (Figure 8.1) can be used to make the room more cleanable. Electrical There should be a “HOT” light at this area to act as an emergency light and a full time work light. Ventilation This area is part of the open bay area and does not require any direct ventilation.




S9. Carbon Room Not all QRCs require a carbon room. If needed this room is usually 15’ x 20’ to 24’ (4.5 x 6 to 7.3m). Machinery can vary: small lathe, small mill and lap machine. Location is critical because a joining room will be needed to house the dust collector. This room is better located at the end of the shop with the dust collector in a room adjacent to the carbon room outside the main building. This will minimize carbon dust seepage coming back into the main machine shop. Construction Walls should be lined with FRP board (Figure 8.1) for ease of cleaning. Ceiling is to be a suspended T-bar (Figure 1.1) at 100 feet (30m) AFF. Vinyl covered tiles should be laid in. The wall facing the machine shop should have as many windows as possible. This glazing should be safety-laminated glass. Two 3’0” X 8’0” (1m x 2.5m) double doors (Figure 11.1) should be installed with pull handles. These doors should have metal kick plates at the bottom, push / pull plates on the appropriate areas and Lexan covering any other area of the door that might be damaged by carts. Flooring Either leave as smooth concrete or cover with vinyl tiles as in the lapping or assembly rooms. Painting Doors should be painted with High Quality latex. Outer wall of room is to be painted High Quality latex. Electrical Due to the dust of carbon cutting, all electrical should be of highest integrity and quality (e.g. seal tight boxes and unions). Do not locate the sub-panel for this machinery inside carbon room. Locate instead just outside on a perimeter wall or come off a bus bar. Ventilation This room can use ducting coming from the main shop system. Therefore, when machine sizing is being calculated, the carbon room should be part of those specifications. Machinery / Equipment All machinery and equipment need to have their carbon dust captured and exhausted through a dust collection system. 8-inch (20cm) diameter PVC tubing for the manifold has proven to be effective to duct carbon dust. Tubing needs to penetrate through the wall into the hook-up on the dust collector. See Dust collector specifications and QRC machinery list (S10).




S10. Dust Collection Room This room is connected to the carbon room and, if the carbon room is not part of the facility design, then this room becomes mute. (Another option is to place portable duct collectors within the room). Construction The outer walls can match that of the main building or be erected out of some lighter and more portable type materials. The doors should be either a roll-up garage door (for equipment moving and emptying the spent carbon dust) with a personnel door or double doors 3’-0” (91cm) X 8’-0” (243cm) (Figure 11.1) with a lockset.

Flooring Concrete Painting Optional. High Quality latex, if used. Add picture of portable Dust collector Electrical All electrical needs to be sealed tight

Ventilation N/A




S11. Air Compressor Room If the facility is being constructed in a warm weather area, the need to build an enclosed room is not necessary. However, if it is located in an extremely hot or cold area, a room may be required. It may be a less costly approach to re-locate the air compressor inside the main machine shop. It is best to maintain the air compressor in a temperature range from 45 to 90 F (7 to 30 C). Construction This room can be attached to the side of the carbon room and be constructed out of the same materials. There has to be a separation wall in between the carbon dust collector and the air compressor/drier. The air compressor must not suck in the dirty carbon dust! Flooring Concrete Painting None Electrical Use seal tight, as this equipment, in most cases, will be exposed to the elements. If in-door, then seal tight or the electrician can hook it up as he would with an engine lathe. Ventilation If located outside, openly exposed to the atmosphere or in an outside room, the air compressor must have lots of airflow. If necessary an HVAC unit may have to be added. If located inside the machine shop, it is already in a conditioned environment. However, airflow must still come across the suction side of the unit. Machinery / Equipment Air compressor capacity is the main parameter that must be calculated. Calculate by pressure requirements. Proper sizing of the airlines is critical and will save downtime and maintenance of equipment.




S12. Canopy / Side/ Backyard New facilities should consider adding a 20 foot (6M) to 40 foot (12M) canopy onto the back of the building. The canopy may eliminate an air compressor room and allow for the building to expand. Concrete flooring should be continuous from the inside finished floor and the same specifications should apply as the machine shop / seal repair. This will prevent the tearing out of concrete if expansion is needed. If sidewalls are needed add a back wall or re-locate the existing back wall.






General Notes Outside hose bibs (water) – Add, at least, two, if not four, hose bibs to the outside. Ventilation – Redundancy is very critical to the efficiency of the facility, both in the office and the manufacturing areas. Fire Sprinklers – Some locations require full sprinkler systems. The owner or contractors need to fully disclose what the locality demands. Parking Lots – Parking is usually dictated by a local code. Most sites classify as warehouses which creates a shortage in their parking needs. This is particularly true when dealing in a multi-tenant building. Landscaping – If the building is a stand-alone, then landscaping needs to be designed and funded based on low maintenance plants and appearance desired by Flowserve. Usually there will be a small allowance by the development owner. Flowserve will need to add funding to complete any substantial project. (e.g. automatic sprinklers, trees, sidewalks, and grassed areas. Building Security – Local management determines this. (e.g. building and/or parking area, perimeter fencing, alarms, security etc). Carpet Specifications – The following is a standard specification for a 7-year guaranteed carpet. (Carpet squares can be installed as an option). It should be glued down with no carpet matting underneath. Carpet should be level loop, solution dyed. Machine gauge: 1/10. Yarn type: Nylon based. Pile height: .187” (4.74mm) approx. Weight: 28 oz (.793 Kilg). It should have some type of “action back” to keep the carpet from breaking down. A carpet should carry a 10-year warranty and this will provide a 7 to 8 year real life. The carpet should be manufactured in 12 feet (4m) widths. Which reduces the amount of seems. Depending on locality, carpeting may need to pass certain fire rating tests. If using carpet squares (e.g. by Collins – Aikman), it will not be necessary to change an entire carpet. Vinyl Specifications – Armstrong, Inc. in 6’ (1.8m) widths X 0.86 (21.8 mm) thickness. Backing is designed to be suitable for all applications. Vinyls for Stairwells – Use anti-slip rubber based stairwell treads. Do not use carpet which can become slippery when wet or worn.


Seismic Gas Shutoff – In areas prone to seismic activity, an automatic seismic shutoff valve should be installed.

FRP = Fiberglass Reinforced Plastic Lexan = GE Plastics or Equal




Signage Exit Signs – Exit signs should be placed strategically throughout the building pointing towards exits as outlined in the FLS Emergency Evacuation Plan. Signs preferred are LED lighted.

Area Labels – Red acrylic signs are to be placed above all doors advising the traveler where they are going. These signs should be 3/8” thick with tapered edges. White letters and trim should be used. Hanging Area Labels – Red Vinyl signs should hang

above each exposed area of the shop not blocked by a wall. Signs should be approximately 34” x 14” (86 X 35cm) and should have white lettering and trim. Hang signs at a height which is noticeable but not intrusive.

Pipe Color Coding Label – At least one 3/8” (10mm) (safety color coding label should be placed in the shared areas to prevent cutting or mistreatment lines. All applicable piping in the machine shop should adhere to this color code.

Evacuation Plan Sign – Evacuation Plan signs should be located throughout the building. Signs should be placed next to all doors that pass between 2 public areas. Signs should be 1/8” thick.

External Logo – An External Flowserve logo should be located on the outside of each QRC. (See Flowserve’s branding standards).

Bulletin (or Accountability) Boards – Bulletin boards should be placed throughout each facility (e.g. canteen or shop area etc.). Boards can be used for Flowserve announcements, Metrics, Current events, Safety and Motivational posters.



First Aid – First aid kits should be present in central location between the shop and office areas. Kits should be unobstructed. Signage does not have to be elaborate; Workers must know where to quickly obtain first aid equipment in the case of an injury.


Other Signage – Each facility may come across signage needs specific to their location. It is important for signs to be very visible and keep with the theme of other signage if possible. There may be other facility specific signage needs. Style, size and color should be consistent.

Fire Extinguisher Signs – Fire extinguisher signs should be located above all fire extinguisher emplacements. Red is the preferable color for these signs. Nothing should ever block these signs.




Paint Color and Specifications Building exterior = Gray, RAL code 7045 Roof (if metal building) = Dark Gray Interior Walls = Desert Suede (light tan), Dunn Edwards DE6206, eggshell finish Office electrical plates = Ivory Walls, Shop = Swiss Coffee, Dunn Edwards W7500-341, gloss finish, RAL code 9010 Floor, Shop = Gray, RAL code 7047 Metal door Trim office = Black Timely frames. Wooden doors = Medium Oak Metal doors = Medium gray Filing cabinets = Warm Brown Value one from Steelcase Baseboard kick protector = Black Carpet office = Brown with multi-colors Steelcase furniture desktop = G226 Cantata Steelcase metal trim = Warm Brown Value one from Steelcase, Laminate is Medium Oak Steelcase fabric material = Spinel Guilden (grade1) Office chairs = Black Conference room chairs = Black Ceramic tiles = Light gray with dark gray grout Vinyl tiles VCT = Light gray Office ceiling tiles = White panels with White T-Bar grid Kitchen / Break room counter tops = Pointe, AG361, Graphite Talc Break tables and chairs = Light gray Break chairs = Red Kitchen cabinets = Light Oak or Pionite, PFA 60 Suede, Negotiating in Geneva Shop Trim Light Gray = 52”Gray area From Floor - Dunn Edwards DE6382/Formal Gray, RAL code 7039 8” Red line = From Top of Gray area - Dunn Edwards DEA104/Red Icon, RAL code 3020

Machines in shop = Light Machine Gray= Dunn Edwards DE6323/White Lake, RAL code 7047




** All paint colors and brands as specified or equivalent. Reference resource: http://brandstandards.flowserve.com/identity_standards/color_palettes.asp Flowserve Red Print, 1- and 2-color Print, 4-color Web color On-screen RAL PMS 485 C = 0 R = FF R = 255 3020 M = 100 G = 00 G = 0 Y = 100 B = 00 B = 0 K = 0 Flowserve Gray Print, 1- and 2-color Print, 4-color Web color On-screen RAL PMS Warm Gray 8 C = 0 R = 99 R = 144 7039 M = 9 G = 99 G = 132 Y = 15 B = 99 B = 116 K = 43 Black RAL 9004 White RAL9003



Chapter 5.5 Shop Area General Specifications QRC General...

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