WP-11 Ships Stores Refrigeration Equipment Replacement V1.pdf

Abstract The intent of this work package is to describe the replacement of the ship stores refrigeration units.

The Ron Brown has a walk-in freezer and a walk-in refrigerator for cold storage of food. Both spaces are currently served by a pair of 2.2 Ton Carrier Transicold refrigeration units (model PRU-17.5-WX) running on R-404A (original compressors were replaced with Carlyle 06DR316 semi-hermetically sealed units). A single unit meets refrigeration and freezer needs, though it is possible to operate them in parallel. Due to age and the type of refrigerant, there is a desire to replace the two units with new units operating on environmentally friendlier refrigerants.

The evaporator unit coolers for the ship stores refrigerator and freezer rooms are in good condition and shall be retained with only minor modifications.

Revisions

References

1. Work Package: General Requirements, ECS, WP-00, 18 DEC 2020.

2. Drawing: Ship Stores Refrigeration System Piping Modifications, ECS, 11-516-01.

3. Not Used

4. Drawing: Seawater Cooling System Diagram, Glosten, 01-532-01, Rev. P1, 13 NOV 2020.

5. Drawing: Integrated Control and Monitoring System Block Diagram, Glosten, 01-440-01.

6. Drawing: Integrated Monitoring and Control System (IMACS) Points List, Glosten, 01-440-02, Rev. A, 5 JUN 2019.

7. Work Package: Repower, Glosten, WP-01, 11 DEC 2020.

8. Work Package: Scientific Refrigeration System Modifications, ECS, WP-12, 4 NOV 2020.

WP-11 SHIPS STORES REFRIGERATION

EQUIPMENT REPLACEMENT

NOAAS Ronald H. Brown | Rev 1

PREPARED FOR: PREPARED BY: COMPANY DATE:

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

Scott A. Tuttle II ECS 15 September 2020

CHECKED BY: DATE:

Stephen Laverty ECS 4 November 2020

APPROVED BY: DATE:

CONTRACT #: - James Repp NOAA 7 December 2020

Section Rev Description Date All

Initial Release Removal of Reference 3

15 Sep 2020 28 Jul 2021

WP-11 Ships Stores Refrigeration Equipment Replacement NOAAS Ronald H. Brown

15 September 2020 1 Rev 1

000 GENERAL REQUIREMENTS

Each of the existing ship stores refrigeration units shall be replaced with a unit of equal or greater capacity. The general scope of this work package is described below:

Removal of both ship stores refrigeration units in the upper generator room, along with all associated electrical equipment, cabling, and hoses.

Installation of two new, refrigeration units, including necessary piping modifications for integration.

Installation of all new refrigerant piping throughout the system, including pressure relief lines to atmosphere.

Replacement of thermal expansion valves, pressure/temperature gages, and liquid line sight glasses.

Electrical modifications to accommodate the new system, including installation of new cabling.

Charging the new system with environmentally friendly refrigerant, and subsequently commissioning the system to ensure proper operation.

Replacement of piping insulation.

The end result of this work package shall be a fully functional, approved ship stores refrigeration system, meeting all ABS and SOLAS requirements. The new refrigeration system shall functionally replace the existing system.

The ship stores freezer is currently designed for storage at 0ºF and the refrigerator is designed for storage at 37ºF. The new system shall provide refrigeration to the freezer and refrigeration spaces at these same nominal temperatures using either of the two new refrigeration units

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-01 Repower (Reference 7)

WP-01 includes the replacement of the vessel’s alarm and monitoring system, modifications to the auxiliary seawater system, and installation of new generator exhaust piping.

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The new ship stores refrigeration system shall be connected to the alarm and monitoring system as described in Section 400.

Draining, flushing, and testing of the modified seawater piping will be within the scope of WP-01.

The new generator exhaust piping may interfere with the existing route of the ship stores refrigerant piping near the casing in the Upper Generator Room. Where there is an interference, the Contractor shall reroute the refrigerant piping to avoid the new exhaust system.

000.2 BID REQUIREMENTS

000.2.1 Costs

The Contractor shall include in their bid the following costs:

1. The cost of 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. None additional.

100 HULL STRUCTURE

100.1 REMOVALS

The Contractor shall completely remove the foundations supporting the existing ship stores refrigeration units and repair all decking in way of the removals. The decking shall be ground smooth and painted to match the surrounding area. See Figure 100.1-1 below showing one of the existing refrigeration unit foundations.

100.2 INSTALLATIONS

The Contractor shall design and install foundations to support new skid-mounted refrigeration units in way of the existing units. The new refrigeration units shall be resiliently mounted, and all foundation work described herein shall comply with Reference 1.

In addition, foundations shall be designed to avoid hard spots and potential cracking of the deck plate.

All foundation structure shall be free of sharp edges and burrs, and shall be designed to facilitate, and not hinder, repair and maintenance activity. Foundation design shall be approved by the Owner prior to fabrication and installation.

Figure 100.1-1 Existing ships stores refrigeration unit foundation

Port side shown, Starboard similar

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Coat all foundations and disturbed decking to match the surrounding area.

200 MAIN PROPULSION SYSTEMS

200.1 REMOVALS

No items.

200.2 INSTALLATIONS

No items.

300 ELECTRICAL POWER PLANT

300.1 REMOVALS

Cabling for the existing ship stores refrigeration units shall no longer be used after completion of this work package. The Contractor shall remove all cabling associated with the existing refrigeration units.

Cables shall be removed back to the power source(s), including breakers.

The Contractor shall remove all electrical equipment associated with the existing ship stores refrigeration units. These removals shall include the following, in addition to the major equipment removals described in Section 500:

Two (2) electrical control panels mounted on the existing refrigeration unit skids.

All associated junction boxes and controls hardware.

Electric strip heater around the door seal for the freeze store room.

300.2 INSTALLATIONS

The Contractor shall install cabling and breakers for the new ship stores refrigeration units. Cabling for these units run to more than one power distribution panel.

Install a new strip heater around the door seal for the freeze storeroom.

Installation of new cable and equipment shall be performed as described in Reference 1. All new cable shall be meggered prior to termination. Installation of cable includes all cable supports, penetrations, cable tags, conduit, and other items that might be required.

400 COMMAND, COMMUNICATIONS, AND NAVIGATION

400.1 REMOVALS

No items.

400.2 INSTALLATIONS

The Contractor shall run new signal cables to the AMS as described in References 5 & 6. Signal cables shall be terminated at the refrigeration units in accordance with vendor information and shall be terminated at RIO #1 and RIO #2 in accordance with Reference 6.

Installation of new signal cable shall be performed as described in Reference 1. All new signal cable shall be loop-tested. Installation of cable includes all cable supports, penetrations, cable tags, conduit, and other items that might be required.

500 AUXILIARY SYSTEMS

500.1 REMOVALS

500.1.1 Refrigerant removal

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Prior to decommissioning, the Contractor shall verify the capabilities of the existing system through operational tests as described in Section 900.3.1, and shall use the results of these tests, as well as industry standards, as benchmarks for the minimum operational capabilities of the new system.

The Contractor is responsible for evacuating the system of R-404A refrigerant and mineral oil down to an acceptable level, per industry standards and manufacturer recommendations. Before the existing system is removed, the evacuation process will require, at minimum, the following steps:

1. Run the existing refrigeration units at steady-state for a minimum of 30 minutes, allowing mineral oil to collect in the compressor.

2. Pump the refrigerant charge into the refrigeration unit receiver, enabling the bulk of the charge to be quickly transferred to the recovery cylinder.

3. Remove the bulk of the refrigerant charge using a recovery machine, capable of evacuating the system down to manufacturer recommended limits, and not to exceed five percent (5%) residual R-404A. Document the mass of refrigerant removed from the system.

4. Remove the mineral oil from the compressor and document the mass of oil removed.

Mineral oil and R-404A refrigerant quantities shall be referenced when the new system is charged with refrigerant and oil.

The Contractor is responsible for recycling or properly disposing of R-404A refrigerant and mineral oil extracted from the refrigeration system.

500.1.2 Equipment removal

The Contractor shall remove all existing ship stores refrigeration equipment, as well as the related piping, as shown in References 2. These removals include, but are not limited to:

Figure 500.1-1 Existing ships stores refrigeration units

5 Rev 1

Ship Stores Refrigeration Plants #1 & 2 (See Figure 500.1-1).

Refrigerant manifold boards including isolation valves, liquid level gauges, temperature/pressure gauges, etc. (typical, 2 places, see Figure 500.1-2).

Thermal expansion valves (TEV’s, typical, 4 places, see Figure 500.1-3).

All refrigerant piping and insulation, including pressure relief piping to atmosphere.

All evaporator cooling units inside the chill and freeze storerooms.

The Contractor shall remove and discard seawater cooling piping in accordance with Reference 4.

Removal shall include pipe, fittings, valves, hangers/supports, and flexible hose assemblies. See Reference 2 for further details regarding equipment and piping removals.

500.2 INSTALLATIONS

The Contractor shall supply and install two new ship stores refrigeration units in way of the existing.

The cooling capacity of the new refrigeration units shall match, or exceed, that of the existing units.

The Contractor is responsible for supplying new refrigeration units comprised of semi-hermetic compressors, sea water cooled condensers, pressure switches, water control valves, liquid line solenoid valves, accumulators, receivers, filters, evaporator cooling units and any other items which may be needed for proper system operation. This equipment shall be installed in accordance with References 2.

Figure 500.1-2 Existing refrigerant manifold boards

Figure 500.1-3 Existing thermal expansion valve

6 Rev 1

The two new refrigeration units shall use the same type of refrigerant; the refrigerant shall be R442A or another Owner-approved refrigerant with a similarly low global warming potential (GWP). The system shall not use a refrigerant currently scheduled to be phased out, or expected to be phased out, within the lifespan of the equipment. The refrigerant used shall be the same type as that used for the science refrigeration system, unless otherwise approved by the Owner.

Install all new refrigerant piping from the refrigeration units to the chill and freeze rooms, including pressure relief piping to atmosphere. Piping materials and sizes are shown in Reference 2.

Install four new thermal expansion valves, two each in the chill and freeze storerooms.

Fabricate and install new refrigerant manifold boards with all necessary valving and instrumentation for proper operation, and to closely match the existing functionality. Manifold board configuration and installation location shall be approved by the Owner and shall generally be adjacent to the chill and freeze storerooms.

Upon completion of refrigerant piping installation, the system shall be flushed and pressure tested in accordance with Regulatory Body and equipment manufacturers requirements. After successful flushing and pressure testing, all refrigeration piping shall be insulated, lagged, and labeled/stenciled as original, or as approved by the Owner.

Once the new refrigeration units and piping are installed, the Contractor is responsible for completing the following tasks:

1. Charge the compressor with POE lubricant per manufacturer recommendations.

2. Pull a vacuum on the refrigeration liquid and suction lines down to 0.3 mbar and verify the system does not lose suction.

3. Charge the new refrigeration units with refrigerant according to the manufacturers’ instructions.

The Contractor shall corroborate the evacuation and recharging steps described in Sections 500.1 and 500.2 with industry standards and notify the Owner of any changes to this process prior to beginning work.

The contractor shall note the total refrigerant charge installed in the new system and provide results to Owner and compare it to the amount of refrigerant removed from the original system.

600 OUTFIT AND FURNISHINGS

The Contractor shall inspect the insulation panels and linings inside, and the doors into, each of the ships stores chill/freeze spaces and provide the Owner with a condition found report, as well as recommendations if any repair or replacement is required.

These inspections and reports shall be completed within the first 20% of the contracted schedule duration of the midlife refit. A written report outlining all findings and recommendations shall be delivered to the Owner within 48 hours after completion of the inspection.

700 SCIENTIFIC MISSION SYSTEMS

700.1 REMOVALS

No items.

700.2 INSTALLATIONS

No items.

7 Rev 1

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:

Purchase technical specifications for the new ship stores refrigeration system.

Installation drawings, a detailed refrigeration piping diagram, and a detailed electrical and controls schematic.

Structural foundation drawings for Ship stores Refrigeration Units #1 & 2.

Installation, operation, and technical manuals.

Regulatory compliance documentation.

Spare parts and special tools lists.

Test procedures for all affected systems.

Completed and signed test reports.

Detailed engineering for the refrigerant, electrical power, and controls portion of the new system, including integration with other ship systems.

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 eight (8) hours specific crew training to be provided by the system vendor to the ships’ crew, and shall consist of at least the following:

Equipment and system overview.

Safety and environmental concerns.

Monitoring equipment and process (e.g., by reading and interpreting indicator values) Starting and shutting down equipment.

Performing routine maintenance work and inspection.

Troubleshooting equipment and system malfunctions.

900 TESTS AND TRIALS

The Contractor shall prepare, commission, and test the system and all modified or disturbed equipment in accordance with ABS 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’s Representative 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.

8 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 requirements. The systems to be tested include:

Auxiliary seawater system, testing may be performed as part of WP-01.

Refrigerant relief venting system.

Refrigerant piping, pressure tested with dry nitrogen in accordance with industry standards.

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 requirements.

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

All watertight penetrations (e.g., piping, cabling, etc.) shall be leak tested in accordance with ABS requirements.

900.3 STAGE 3 – OPERATION AND PERFORMANCE TESTS

900.3.1 Testing of the existing system

As part of Stage 3 Operation and Performance Tests, the Contractor is responsible for testing the existing system prior to decommissioning. These tests shall benchmark the performance of the following parameters:

Rate of pulldown: The Contractor shall test the rate the system reaches steady state from ambient, for both the freezer and refrigeration spaces.

Temperature variation in steady state: The Contractor shall measure the amount of temperature variation of both the freezer and refrigeration spaces while in steady state, at their respective nominal temperatures:

Freezer Room nominal temperature: 0ºF Refrigeration Room nominal temperature: 37ºF

These tests shall be performed for the following operating configurations, at minimum:

Ship Stores Refrigeration Unit 1 running only, supplying both spaces Ship Stores Refrigeration Unit 2 running only, supplying both spaces Both units running in parallel, supplying both spaces

The Contractor is responsible for consulting vendor data and industry standards in order to verify the intended operating parameters of the existing system, and shall compare these parameters to the results of the operational tests (i.e., rate of pulldown and maximum temperature variation)

The Contractor shall provide the Owner with a ‘Condition Found’ report, detailing all results, as well as any issues noted with the existing system. The Contactor shall consult the Owner to verify the intended operating capabilities of the system and shall use these parameters as the minimum capabilities for the new system.

Note that a full performance test of the existing ship stores refrigeration system requires seawater cooling. In order to complete the requirements of this section, the Contractor shall perform these tests prior to the decommissioning of the sea water system.

900.3.2 Testing of the new system

As part of Stage 3 Operation and Performance Tests, the Contractor shall repeat the tests described in Section 900.3.1 on the new refrigeration system after installation is finalized.

9 Rev 1

The Contractor shall provide the Owner a final performance report, comparing the performance of the new system to the removed system.

Note that a full performance test of the ship stores refrigeration system requires seawater cooling.

Testing requiring seawater cooling may be postponed until dock trials with Owner approval.

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.

500.2 Installations