WP 07B - AC Controls Upgrades V1.pdf

Abstract The intent of this work package is to describe the replacement of A/C temperature controls at air handlers and duct reheaters throughout the vessel. This will require replacement of temperature controllers AHU controllers, temperature sensors, existing heating control enclosures, heater box assemblies, and partial replacement of the chilled water piping branches and valves at each cooling coil. This work package also replaces all duct reheaters throughout the vessel. Other HVAC-related Work Packages reference this WP for Controls requirements.

Revisions

References

1. Work Package: General Requirements, ECS, WP-00, 18 DEC

2. Work Package: AC Spaces General Modifications, ECS, WP-07A, 10 DEC 2020

3. Work Package: AHU-5 Zone Redesign, ECS, WP-07C, 10 DEC 2020

4. Work Package: AHU-9 Installation, ECS, Document No. WP-07G

5. Work Package: Overhead Lighting Upgrades, ECS, WP-24, 16 DEC 2020

6. Drawing: R/V Atlantis AC Control System Modification Diagram, Glosten, 10B-514-01, 11

DEC 2018

7. Drawing: R/V Atlantis Chilled Water System Modifications Diagram, Glosten, 12-514-01, 3

DEC 2018

8. Drawing: HVAC Electrical Heater List, NAVSEA, 6932964, 26 AUG 1993.

WP-07B AC CONTROLS UPGRADES

NOAAS Ronald H. Brown | Rev 1

PREPARED FOR: PREPARED BY: DATE:

NOAA Office of Marine & Aviation Operations 8403 Colesville Road, Suite 500 Silver Spring MD 20910-3282

Stephen Laverty ECS 01 October 2020

CHECKED BY: DATE:

Jamie LeCompte NOAA 10 Dec 2020

APPROVED BY: DATE:

CONTRACT #: - James Repp NOAA 15 Dec 2020

Section Rev Description Date All 300.1

Initial Release Minor updates to equipment

15 Dec 2020 28 Jul 2021

WP-07B AC Controls Upgrades NOAAS Ronald H. Brown

1 October 2020 1 Rev 1

000 GENERAL REQUIREMENTS

The scope of work described in this work package shall include modifications to the heating and cooling temperature controls of the following existing HVAC equipment listed in Table 000.1-1.

Controls for AHU-5 are within the scope of WP-07C, AHU-5 Zone Redesign (Reference 3) and reference this Work Package.

The control modifications of the equipment listed in Table 000.1-1 shall include removal of existing, and installation of new, temperature sensors and temperature controllers. Installation shall include modifications of existing power distribution and testing and configuration of the new temperature controls.

All reheaters installed on the vessel shall be replaced in-kind and shall include removal of existing reheaters and associated power cable, and installation of new duct reheaters and power cable.

Ducting shall be modified to suite the installation of the new reheaters. New temperature controls shall be integrated into the new reheaters. The as-built reheater list (Reference 8) includes details of current reheaters.

Equipment indicated in Table 000.1-1 to include heating control modifications shall be integrated with the new heater controls associated with that equipment. Installation of new AHUs (along with their associated cooling coils and preheaters) is described in Work Package 07A, Reference 2. The Contractor shall integrate the new heater controls as described in Section 300.

Equipment indicated in Table 000.1-1 to include cooling control modifications shall require modifications to the chilled water piping connecting to the new chilled-water cooling coil associated with the respective AHU. The Contractor shall integrate these piping modifications with the rest of the chilled water system.

TABLE 000.1-1 HVAC EQUIPMENT

Control Modifications

HVAC Equipment Description Heating Cooling AHU-1 03 Level X X AHU-2 Mess X X AHU-3 Bio/Analytic Lab X X AHU-4 Main Lab X X AHU-6 1st Platform Staterooms X X

AHU-7 Switchboard Room X X AHU-8 Scientific Storeroom X X All Vessel Reheaters Duct Reheaters No. 1-84 X

The new temperature control systems for the HVAC equipment listed in Table 000.1-1, as well as for the new AHUs installed in Reference 2, shall all use a similar control method and components from the same manufacturer. The temperature controls shall allow the operator to easily adjust setpoint temperatures and change control parameters. The controllers shall provide multi-stage heater control in a manner similar to the existing system. The Owners preference for standalone temperature controllers are Honeywell’s most current T775 model series with improved adjustability and troubleshooting. Electric duct heaters used as reheaters for compartments served by mechanical supply and as reheaters on air conditioning supply branches shall have a temperature rise across the heater not below the heater manufacturer’s recommended minimum temperature rise. The new

2 Rev 1 components in the chilled water system shall provide a properly balanced system that achieves the design flow rates for each branch regardless of control valve position. The new modulating chilled water control valves shall have sufficient valve authority to provide steady and consistent control of cooling load. The new preheater coils, heating assemblies, and control enclosures shall provide functionality equal to the original design.

The components shall be replaced in kind where possible.

The Contractor shall coordinate with the manufactures of the new AHUs (Marlo Coil and Carrier) to determine specific control/interface requirements. Similarly, the Contractor shall coordinate with the manufacture of the new reheaters (Indeeco) to determine specific control/interface requirements.

The majority of overhead ceiling systems will be removed during execution of Overhead Lighting Upgrades, Reference 5. Installation of new reheaters shall be performed while overheads are removed.

The end result of this work package shall be a fully functional, approved A/C temperature control system installation for all equipment listed in Table 000.1-1 meeting applicable ABS, USCG, and SOLAS requirements. The Contractor shall be responsible for all removals, inspections, modifications, installations, and testing as described below and in Reference 1. All fees for these services shall be the responsibility of the Contractor and included in the bid.

The Contractor shall include removal and reinstallation of insulation, piping, HVAC components, electrical cables, and incidental interferences in way of all work described herein. Upon completing the work, the Contractor shall clean the work area and its surfaces of all work debris and recoat existing coated surfaces damaged by welding and other hotwork in accordance with Reference 1 and this section.

All temporary openings and removals necessary to facilitate the work described in this package shall be carried out as part of this work package. All temporary openings and removals shall be reinstalled and restored to original condition. All affected mechanical and electrical components shall be tested to the Owner’s satisfaction after reinstallation.

Reference 1 contains general design, production, and documentation requirements relevant to the work described in this package. Reference 1 contains Contractor responsibilities for providing or arranging and integrating all required work. The requirements included in Reference 1 shall be applied to all aspects of this work. The requirements described herein shall be considered as additional to the requirements of Reference 1. Unless otherwise noted, all equipment and material permanently removed from the vessel shall become the property of the Contractor.

000.1 NOTES

000.1.1 Related Work Packages

000.1.1.1 WP-07A HVAC General (Reference 2)

WP-07A contains scope to replace all AHUs on the vessel (including heating and cooling coils). Chilled water piping will be modified and will include installation of control valves for the AHUs. The scope also includes general cleaning and inspection of the HVAC systems.

000.1.1.2 WP-07C AHU-5 Zone Redesign (Reference 3)

WP-07C includes removal of AHU-5 and installation of three smaller units (AHU-5a, AHU-5b, and AHU- 5c), each with its own control requirements. Ducting in way of Reheaters in the Hyrdo Lab and Computer Lab will also be modified.

000.1.1.3 WP-07G Addition of AHU-9 (Reference 4)

WP-07G includes removal of existing, and installation of new, ducting serving the forward staterooms on the 01 Level. Installation of new reheaters shall take into account new ducting runs.

3 Rev 1

000.1.1.4 WP-24 Overhead Lighting Upgrades (Reference 5)

WP-24 includes removal ceiling systems and overhead lighting in various places throughout the ship.

Installation of new reheaters shall be performed while the ceiling systems are down.

000.2 BID REQUIREMENTS

000.2.1 Costs

The Contractor shall include in their bid the following costs:

1. The effort to complete the work described in this specification.

000.2.2 Documentation

The Contractor shall include in their bid the documentation listed in Reference 1 and the following:

1. Proposed make/model(s) for temperature control components

100 HULL STRUCTURE

100.1 REMOVALS

No items.

100.2 INSTALLATIONS

Upon completion of modifications, any unused deck, bulkhead, and tank penetrations shall be inserted to match surrounding structure in accordance with Reference 1.

200 MAIN PROPULSION SYSTEMS

200.1 REMOVALS

No items.

200.2 INSTALLATIONS

No items.

300 ELECTRICAL POWER PLANT

All electrical equipment and cable associated with the temperature control of AHUs, cooling coils, and preheaters shall be removed for HVAC equipment listed in Section 000. Execution of this work shall be conducted in conjunction with References 2 through 5. The contractor is responsible for coordinating with the vendor of the new AHUs to determine specific control requirements.

All reheaters, as listed in Section 000, shall be removed. Power cables associated with reheaters shall also be removed.

300.1 REMOVALS

The Contractor shall remove all electrical equipment and cable. This includes the components associated with temperature controls for the heating and cooling equipment listed in Section 000.

Removals shall include temperature sensors, thermostats and/or temperature controllers, solenoid operators for chilled water control valves (see Section 500.1), heater controllers, and connected cable.

Figure 300.1-1 shows typical heater enclosures. Figure 300.1-1 shows some typical electrical equipment but is not exhaustive.

4 Rev 1

The Contractor shall remove and dispose of all existing reheaters (Refer to Section 000). Reference 8 contains a list and location of reheaters installed during construction. Note: not all reheaters included in Reference 8 are applicable to the R/V Ronald H. Brown. Power cable associated with existing reheaters shall be pulled back and removed from the reheater to its associated power panel. The contractor shall identify and tag associated panels and circuit breakers for reuse during installation of new reheaters. New reheaters shall utilize the same breakers as those removed.

See WP-07A (Reference 2) for scope regarding AHU replacement.

Figure 300.1-1 Typical heater enclosure for air handler heaters (left) and duct reheaters (right)

5 Rev 1

Figure 300.1-2 Typical temperature control items for air handlers to be removed

300.2 INSTALLATIONS

The Contractor shall provide all necessary engineering and modifications to provide temperature control for the heating and cooling equipment listed in Section 000.1. Temperature controls shall be from the same manufacturer. The Contractor shall provide make/model information of proposed temperature control components to Owner and receive approval of selected components prior to procurement (refer to Section 1). The Contractor shall integrate all of the provided components such that the equipment operates as described in Section 000.1.

6 Rev 1

New temperature controllers located in public spaces (i.e., all spaces except for staterooms) shall be provided with new, transparent, and lockable enclosures to prevent unauthorized temperature changes. All new enclosures shall be keyed the same. Provide 10 sets of keys for new enclosures.

300.2.1 Air Handling Units

At each air handler and fan coil unit listed in Table 000.1-1, the Contractor shall provide new temperature sensors, control transformers (where required), and temperature controller to allow operation of the new chilled water cooling coil control valve (see Section 500.2) and new air handler heater stages.

The Contractor shall integrate the new air handler pre-heaters with the new equipment being installed.

This work shall include providing power to the new temperature controllers and chilled water valves from the new pre-heater control power and providing control of the pre-heater stages by the new temperature controllers. New temperature controllers shall have NEMA 1 enclosures at minimum and shall be provided with drip shields per ABS and USCG requirements.

The Contractor shall provide fused protection for all transformer secondary circuits in all locations where none exists.

300.2.2 Reheaters

The contractor shall provide and install new reheaters for those removed per Section 300.1. New reheaters shall be direct replacements for those removed (Refer to Reference 8). The contractor shall coordinate with reheater supplier (Indeeco) for specific installation requirements. Location of new reheaters shall be the same as for the removed reheaters.

The Contractor shall provide and install new power cables from the same circuit breaker serving the removed reheater. Installation of new cable shall be in accordance with Reference 1.

300.2.3 Reheater Controls

At each duct reheat control replacement listed in Table 000.1-1, the Contractor shall provide new room temperature sensors and temperature controller to allow operation of the new duct reheater stages.

The Contractor shall integrate sensor and control components with the new reheater assembly to provide power to the new components and control the heaters.

A single temperature controller shall be provided for the four (4) reheaters in the Main Lab. The controller shall operate with two temperature control zones, dividing the lab forward and aft with two reheaters in each zone. Interposing relays shall be used to allow control of both reheaters by a single zone staged output from the temperature controller.

300.2.4 General Items

The Contractor shall verify all connections made to existing and new equipment to ensure proper installation and that the new system functions as required.

The Contractor shall provide all cable to provide electrical power and control functions required for the equipment and sensors described in this work package. Installation of new cable, and reuse of existing cable, shall be performed as described in Section 2.14.3 of Reference 1. All new and reused cable shall be meggered prior to termination. Installation of cable shall include all cable supports, penetrations, cable tags, conduit, and other items that might be required.

After completion of all electrical modifications, the Contractor shall close all remaining openings in new and disturbed electrical enclosures to meet the intended NEMA/IP rating of the enclosure.

7 Rev 1

400 COMMAND, COMMUNICATIONS, AND NAVIGATION

400.1 REMOVALS

No items.

400.2 INSTALLATIONS

No items.

500 AUXILIARY SYSTEMS

500.1 REMOVALS

The Contractor shall remove chilled water piping, valves, and related components in accordance with Reference 3. This includes the chilled water piping at each of the chilled water cooling coils listed in Section 000.1.

500.2 INSTALLATIONS

The Contractor shall provide new chilled water piping, valves, and related components in accordance with Reference 3. This includes the chilled water piping at each of the chilled water cooling coils listed in Section 000. The new piping system installed at each of the cooling coils shall meet the material schedule, flow balance, and valve control in accordance with Reference 3. The new chilled water control valves shall be provided electrical power and control as described in Section 300.2.

All new piping provided by the Contractor shall include all required fittings, valves, instrumentation, pipe hangers, structural modifications, and all other items required for the work.

All new, modified and disturbed chilled water piping shall be insulated with closed cell foam pipe insulation suitable for chilled water systems in accordance with Reference 1.

The Contractor shall repair ventilation in way of removed duct air temperature sensors which are removed and provide any duct modifications required for installation of new duct air sensors.

600 OUTFIT AND FURNISHINGS

600.1 REMOVALS

The Contractor shall temporarily remove any joiner work in way of removal or installation of cable, temperature sensors, temperature controls, or other related items.

600.2 INSTALLATIONS

The Contractor shall reinstall any temporarily removed joiner work. The Contractor shall repair any holes or openings left in joiner panels in way of removed equipment or sensors and shall modify joiner work as required to install new temperature sensors and control components. All modifications to joiner work shall use materials, fit, and finish to match the surrounding joinery.

All new and disturbed surfaces above and below decks shall be prepped and painted in accordance with Reference 1.

700 SCIENTIFIC MISSION SYSTEMS

700.1 REMOVALS

No items.

8 Rev 1

700.2 INSTALLATIONS

No items.

800 INTEGRATION AND ENGINEERING

Reference 1 provides requirements regarding regulatory body inspections and requirements for certificates and other documentation associated with regulatory body certification processes.

Reference 1 provides requirements pertaining to schedule, drawings development and revision, material control, engineering, estimates, purchase technical specifications, technical documentation, signage, paint schedule, test memorandums, instruction books, equipment identification, and spare parts.

800.1 DOCUMENTATION

All documentation shall be revised to the as-built condition at the conclusion of sea trials. Technical documentation necessary for this work package, in accordance with the documentation requirements in Reference 1, shall include, at the minimum:

New as-built detailed electrical schematics of the temperature control systems modified by this work package.

Installation, operation, and technical manuals for new temperature controllers, valves, sensors, reheaters, and associated components.

Spare parts and special tools lists for the chilled water system.

Test procedures for all affected systems.

Completed and signed test reports.

Documentation listed above that is part of the chilled water system may be included with the similar documentation required in related Work Packages, see Section 000.1.1.

800.2 TRAINING

Crew members shall be trained in accordance with Reference 1 on the installed equipment in this work package. The Contractor shall provide a minimum of 4 hours specific crew training to be provided by the manufacturer to the ship’s crew for the temperature controllers. At a minimum, the training shall include the following:

Equipment and system overview.

Safety and environmental concerns.

Making simple changes in the process control, such as adjusting temperature setpoints, reset values, control outputs, and control loop parameters.

Performing routine maintenance work and inspection.

Troubleshooting equipment and system malfunctions.

Recommended spare parts.

900 TESTS AND TRIALS

The Contractor shall prepare, commission, and test the system and all modified or disturbed equipment in accordance with ABS and USCG requirements and Reference 1. The testing shall be witnessed by the Owner, and regulatory bodies where required. The Contractor shall conduct testing in conformance with Contractor-developed test memorandums approved by the Owner and meeting the test program requirements of Reference 1.

900.1 STAGE 1 – SHOP INSPECTIONS AND FACTORY ACCEPTANCE TESTS

No Stage 1 tests are required for this work package.

9 Rev 1

900.2 STAGE 2 – CONSTRUCTION INSPECTIONS AND TESTS

Stage 2 Construction Inspections and Tests for this work package shall include:

All piping systems affected by the modifications described in this work package shall be hydrostatically tested in accordance with ABS and USCG requirements and to the satisfaction of the Owner’s Representative.

All electrical cable affected (new or existing) by the modifications in this work package shall be tested for insulation resistance (meggering) in accordance with ABS and USCG requirements and to the satisfaction of the Owner’s Representative.

All instrument cable affected (new or existing) by the modifications in this work package shall be loop tested.

900.3 STAGE 3 – OPERATION AND PERFORMANCE TESTS

Stage 3 Operation and Performance Tests for this work package shall include:

Flow balance testing of the chilled water branches at each cooling coil.

Temperature controller operational testing: Testing shall demonstrate proper operation of the controller, heaters, and cooling coils. Verifications shall include forcing the temperature sensor input such that a full range of system responses are observed between full cooling (chilled water valve open) to full heating (all heater stages on).

Testing requiring the seawater system may be postponed to Dock Trials with Owner approval. This may include operation of the chilled water system as condenser cooling is required for proper operation of the chillers.

900.4 STAGE 4 – DOCK TRIALS

No Stage 4 tests are required for this work package.

900.5 STAGE 5 – SEA TRIALS

No Stage 5 tests are required for this work package.