2_PPD 516-8627963 1.5-ton MRS 20190128.pdf

PROJECT PECULIAR DOCUMENT

NAVSEA NO. 516-8627963

PROCUREMENT SPECIFICATION

MODULAR REFRIGERATION SYSTEM, 1.5-

TON CAPACITY

DISTRIBUTION STATEMENT D: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES AND THEIR SUPPLIERS; ADMINISTRATIVE/OPERATION USE (8 FEBRUARY

2016). OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO THE

NAVSEA TECHNICAL AUTHORITY (SEA05Z4)

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS

RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751, ET.

SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, (TITLE 50,

U.S.C.,APP. 2401 ET. SEQ.). VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO

SEVERE CRIMINAL PENALTIES

DESTRUCTION NOTICE: DESTROY THIS DOCUMENT BY ANY METHOD THAT WILL

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

NAVSEA NO 516-8627963

DISTRIBUTION: Refer to Title Page

28 Jan 2019

1.5 Ton MRS

RECORD OF REVISIONS

Date/Rev Paragraph Description

03 May 16 Sect 1 Revised to specify that equipment list is for each MRS.

03 May 16 Sect 2 Added Mil-S-901, MIL-STD-167-1, MIL-STD-461; and added acronym (BIW)

03 May 16 Sect 3 Added Figure 1

03 May 16 Global Added BIW to identify source of ‘Appendix’

03 May 16 6.11 Added requirements for care and protection and referenced to

Section 5.

03 May 16 7 Clarified that Contract SOW takes precedence for data requirements.

28 Jan 19 Sect 3 Changed EMI requirements

28 Jan 2019

1. ITEMS.

Equipment for each Modular Refrigeration System (MRS) shall be provided as described in

Table I.

Table I

LIST OF ITEMS

Item Description Quantity

1 Modular Refrigeration Units (MRU) 1

2 Control Panels for MRUs 1

3 Condensers for MRUs 1

4 Wire Harness(es) between MRU and Control Panel (max length 70 ft):

5 Remote Temperature Devices (RTD’s) and RTD cables for Storerooms, 72 ft

6 Heating Cable Kits for MRU Condensate Drains, 20 ft 1

9 Resilient Mount Kit for MRU 1

10 Electrical Power Connectors for Control Panels 1

11 Rupture Disk Assembly 1

2 APPLICABLE DOCUMENTS

2.1 Effective Issue. Unless otherwise specified, the effective issue of referenced documents shall be that in effect on (1 January 2012) except for documents whose initial issue is after (1 January

2012). For such documents, the effective issue shall be the initial issue. In the event of conflict between this specification and the documents referenced by this specification, the requirements of this specification shall take precedence. Use of later or earlier issues requires approval by the

Buyer.

2.2 List of Documents. The documents listed in paragraphs 2.2.1 and 2.2.2 form a part of this purchase specification to the extent specified herein.

2.2.1 Government Documents

SPECIFICATIONS

Federal

40 CFR § 82 (2012) Protection of Stratospheric Ozone

A-A-59666B Cylinder, Compressed Gas: DOT Specifications

4B, 4BA, 4BW, and 4E

28 Jan 2019

TT-P-645 Primer, Paint, Zinc-Molybdate, Alkyd Type

Military

MIL-S-901D Shock Tests, High Impact Shipboard Machinery, Equipment, and Systems, Requirements For

MIL-C-2212G Contactors and Controllers, Electric Motor

AC or DC, and Associated Switching Devices

MIL-M-17508 Mounts, Resilient: Types 6E2000, 6E900, 6E900BB, 7E450, 7E450BB, 6E150, and 6E100

MIL-C-20079H Cloth, Glass, Tape; Textile Glass; and Thread, Glass and Wire reinforced Glass

MIL-I-24172 Insulation, Plastic, Cellular Polyurethane, Rigid

Preformed and Foam-In-Place

DOD-I-24688 Insulation Panel, Thermal and Acoustic Absorptive, Open-cell Polyimide Foam

MIL-I-45208A Inspection System Requirements

MIL-STD-167-1 Mechanical Vibrations of Shipboard Equipment

MIL-STD-167-2 Mechanical Vibrations of Shipboard Equipment

Types III, IV, and V

MIL-STD-271F Requirements for Nondestructive Testing Methods

MIL-STD-278F Welding and Casting Standard

MIL-STD-454 Standard General Requirements for Electronic

Equipment

MIL-STD-461F Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and

Equipment

MIL-STD-740 Airborne and Structureborne Noise Measurements and Acceptance Criteria of Shipboard Equipment

MIL-STD-769J Thermal Insulation Requirements for

Machinery and Piping

28 Jan 2019

MIL-STD-882 Standard Practice for System Safety

DOD-STD-1399, Section 300Interface Standard Section 300 Electric Power, Alternating Current

MIL-STD-1472 Human Engineering

NAVSEA Technical Publications

T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods

0900-LP-001-7000 Fabrication and Inspection of Brazed Piping

Systems

Navy Manuals

NAVMED P-5010 Manual of Naval Preventive Medicine

Project Peculiar Documents (PPD)

802-5959353 Military Standard 777D Modified for DDG 51

Class, Schedule of Piping, Valves, Fittings, and

Associated Piping Components

2.2.2 Other Publications

AMERICAN SOCIETY OF HEATING, REFRIGERATING, AND AIR-

CONDITIONING ENGINEERS (ASHRAE)

ASHRAE 15-2010 Safety Standard for Refrigeration Systems

ASHRAE 34-2010 Designation and Safety Classification of Refrigerants

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

BPVC Section VIII Boiler & Pressure Vessel Code, Section VIII, Rules for

Construction of Pressure Vessels

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING, INC. (ASNT)

ASNT-TC-1A Recommended Practice for Personnel Qualification

And Certification in Nondestructive Testing

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

28 Jan 2019

Q9001-1994 Quality Management Systems – Requirements

BATH IRON WORKS CORPORATION (BIW)

Appendix B General Technical Requirements

Appendix E Electromagnetic Interference Requirements

Appendix N General Requirements for Noise Testing and Reporting

Appendix S High Impact Shock Qualification Requirements

Appendix V Vibration Qualification Requirements

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

ANSI/IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

NATIONAL AEROSPACE STANDARDS COMMITTEE

NASM20995 Wire, Safety or Lock

NASM33540 Safety Wiring, Safety Cabling Cotter Pinning, General

Practices for

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

70 National Electrical Code (NEC)

SAE INTERNATIONAL

J518-1 Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw

Flange Connection Part 1: 3.5 MPa to 35 MPa (Code 61)

2.3 Sources for Documents

2.3.1 Government Documents. Unless otherwise indicated, copies of Government documents are available from the Standardization Documents Order Desk, Bldg. 4D, 700

Robbins Avenue, Philadelphia, PA 19111-5094, or, may be available on the internet at http://astimage.daps.dla.mil/quicksearch.

2.3.2 Other Publications. Technical society and technical association specifications and standards are generally available for reference from libraries. They are also distributed among technical groups and using federal agencies.

http://astimage.daps.dla.mil/quicksearch http://astimage.daps.dla.mil/quicksearch

28 Jan 2019

2.3.3 Buyer’s Documents. Application for the Buyer’s documents should be made to the

Buyer’s procurement representative indicated on the purchase order.

3 DESIGN

3.1 Item Definition. A Modular Refrigeration System (MRS) shall consist of one modular refrigeration unit, MRU control panel, condenser, and all other components necessary to perform the refrigerating applications. System components shall be commercial grade, modified as necessary to ensure satisfactory performance as specified herein.

3.1.1 Definitions

CFR – Code of Federal Regulations

ICAS – Integrated Condition Assessment System

IDD – Interface Design Description

MCS – Machinery Control System

MRS – Modular Refrigeration System

MRU – Modular Refrigeration Unit

MTBF – Mean Time between Failures

MTTR – Mean Time to Repair

PLC – Programmable Logic Controller

3.1.2 Functional Diagrams. Figure 1 provides a notional arrangement for one modular refrigeration unit, control panel, condenser, and associated components.

28 Jan 2019

3.1.3 Interface Definition

3.1.3.1 Chilled Water System. Each condenser shall be connected to the ship’s chilled water system. This system is in accordance with 802-5959353, Category and group C-1. The system fluid is fresh water cleaned to a level of 200 microns. The normal supply temperature is

44 degrees F and the maximum operating pressure is 110 lb/in . Supply and return lines to each condenser will be provided with individual cutout valves. A 500 micron strainer will be installed in each supply line and a constant flow fitting will be installed in each return line. The maximum off-normal temperature of the chilled water system is 100 degrees F. Each modular refrigeration system shall be capable of safely operating during this off-normal condition, but is not required to produce the rated refrigeration capacity

3.1.3.2 Refrigerant Piping System. Each modular refrigeration unit (MRU) and condenser will be connected to the ship’s refrigerant piping system. This system is in accordance with 802-

5959353, Category and group Q-1. Piping between the MRU and the condenser will be seamless copper tube. A capped self-sealing refrigerant service valve will be installed in either the supply or the return piping between the MRU and the condenser. Piping from the MRU refrigerant pressure relief connection will be seamless copper tube. The rupture disk will be located on the inlet side of the condenser external to the storeroom. Refrigerant piping will be provided with

28 Jan 2019 flexible connectors consisting of a corrugated metal core with wire braid reinforcement as specified 3.2.2.1.3.

3.1.3.3 Condensate Drain System. Each MRU will be connected to the ship’s condensate drain system. Drain connection size shall be 3/4 inch NPS minimum. This system is in accordance with 802-5959353, Category and group R-3. Continuously energized self-regulating heating cables shall be provided to prevent the condensate from freezing. Self-regulating shall be understood to mean that during conditions when the storeroom temperature is elevated, the power draw by the heating cable will automatically adjust to prevent any burn hazard. Heating cables shall be Chromalox Type SRL5-1CR, or equal, and shall be powered by the MRU control panel. Drain piping will be provided with flexible connectors.

3.1.3.4 Electrical Power. Each MRU and control panel will be connected to the ship’s

440 volt alternating current electrical power system. This system is in accordance with DOD-

STD-1399, Section 300, Type I. The maximum continuous current draw by each MRU during any mode of operation, refrigeration or defrost, shall not exceed 20 amperes. The wiring for each MRU control panel shall be designed for a maximum peak connected current draw equal to a systemic failure of the control system allowing all relays to energize.

3.1.3.5 Electrical Signals. Each control panel shall have a communication module capable of transmitting data by Ethernet or RS485. The details of the signals and the hardware and software interfaces with these systems shall be agreed to between the Government and the

Contractor and documented in a Joint Interface Design Description (IDD).

3.2 Characteristics

3.2.1 Performance

3.2.1.1 Capacity Rating. Capacity rating is the rate of heat removal from a medium or space to be cooled at specified conditions and shall be stated in tons of refrigeration. A ton of refrigeration shall be defined on the basis of heat removal at the rate of 12,000 British thermal units (Btu) per hour.

3.2.1.2 Ship’s Stores Application. Each MRU shall be rated for not less than 1.5 ton at freeze conditions. The design of the modular refrigeration units, condensers, and components for each system shall be based on the following maximum conditions of operation:

3.2.1.2.1 Pull-down Condition. 24 hours per day and the pull-down will be completed in

72 hours using only one modular refrigeration unit and condenser. Pull-down condition shall be considered as that operating condition which exists during the period in which the temperature of the products within the compartment is being reduced to the designed holding temperature.

3.2.1.2.2 Normal condition. 24 hours per day operation with one MRU and the associated condenser secured. Normal condition shall be that operating condition which exists during the period in which design temperatures are being maintained after the pull-down condition has been accomplished.

28 Jan 2019

3.2.1.2.3 Defrost Cycle. Each MRU and associated control panel shall include automatic electric defrost capability that shall be time initiated and pressure terminated with a time termination backup to prevent overheating. The defrost cycle shall be active whenever frost/ice can form on the evaporator coils. The control timer shall be capable of initiating a defrost cycle at least once every 3, 6, 12, or 24-hours, and of being manually controlled. Default defrost cycle shall not be less than 6 hours in normal operating mode and not less than 24 hours in back-up/fan only operating mode.

3.2.1.3 Service Life. Each system and its components shall have a useful life of 200,000 hours when subjected to any or all of the shipboard conditions specified herein. Such life expectancy shall be obtained with up to five MRU overhauls consisting of compressor/motor and other refrigerant component replacement within a period of not more than 10 working days. All other repairs and replacements shall be as specified in Section 3.2.1.4.

3.2.1.4 Reliability and Maintainability (R&M) Requirements. See Section 6.0

3.2.1.5 Shock and Environmental Vibration Resistance. The equipment shall meet Grade

B, Hull Mounted, shock requirements in accordance with MIL-S-901D and BIW Appendix S.

For both the MRU and Control Panel, shock tests shall be for unrestricted shipboard mounting orientation and shall be energized in a normal operating condition. The units need not remain operational during or after the shock test, however shock induced damage shall be limited to the extent that component failures can be readily repaired/replaced using onboard repair parts within six hours after a shock event. Refrigerant boundaries shall not leak or sustain any damage as a result of shock testing. Rotating equipment shall meet the balance requirements for type II vibration in accordance with MIL-STD-167-1 and BIW Appendix V or ISO 1940 Grade 2.5.

Reciprocating equipment shall meet the torsional requirements of MIL-STD-167-2 for type III vibration. All equipment shall meet the requirements for type I vibration in accordance with

Appendix V from 4 through 25 Hz.

3.2.1.6 Noise Limitation. The equipment shall meet the noise requirements in accordance with MIL-STD-740 and BIW Appendix N and Tables V and VI below or as approved by the

Naval Technical Authority

Table V

AIRBORNE NOISE ACCEPTANCE CRITERIA FOR EQUIPMENT

(in dB re: 20 µPa when measured in accordance with MIL-STD-740)

Octave Band Center Frequency in Hz

Equipment 31.5 63 125 250 500 1000 2000 4000 8000

Modular

Refrigeration

System

98 93 88 83 83 78 78 78 78

Table VI

STRUCTUREBORNE NOISE REQUIREMENTS (See Table Note)

One-Third Octave Band Center Frequencies in Hz

28 Jan 2019

Equipment 16 20 25 31.5 40 50 63 80 100

Modular

Refrigeration

88 90 98 103 103 103 103 103 103

Equipment 125 160 200 250 315 400 500 630 800

Modular

Refrigeration

103 103 105 106 108 109 109 109 109

Equipment 1000 1250 1600 2000 2500 3150 4000 5000 6300

Modular

Refrigeration

109 109 109 107 104 104 104 104 104

Equipment 8000 10000 12500 -- -- -- -- -- --

Modular

Refrigeration

104 104 102 -- -- -- -- -- --

Note to Table VI: Structureborne noise is specified in vibration acceleration levels (La) in dB re:

-3 cm/sec . The specification represents individual acceleration levels measured above the mounts which are not to be exceeded in the X, Y, or Z direction.

3.2.1.7 Electromagnetic Interference (EMI) Resistance. The equipment shall meet the

EMI requirements in accordance with BIW Appendix E and MIL-STD-461E.

3.2.1.8 Modes of Operation. Each system shall be selectable to function in either chill or freeze service. The switch or mechanism enabling this selection shall be designed or located so as to not be readily accessible. In either chill or freeze service, each MRU shall have three separate modes of operation plus a standby mode:

3.2.1.8.1 Normal Mode. The MRU automatically maintains the storeroom temperature.

The default temperature settings for normal mode in chill service shall be ON at 36 degrees F

(setpoint) and OFF at 34 degrees F. The default temperature settings for normal mode in freeze service shall be ON at -1 degree F (setpoint) and OFF at -3 degrees F.

3.2.1.8.2 Backup Mode. The MRU automatically backs up the MRU in Normal Mode.

The backup mode in chill service shall cycle ON at 41 degrees F and OFF at 36 degrees F. The backup mode in freeze service shall cycle ON at 4 degrees F and OFF at -1 degree F.

28 Jan 2019 air.

3.2.1.8.3 Fan-Only Mode. The MRU compressor is OFF; only the fan is ON to circulate

3.2.1.8.4 Standby Mode. The control panel is fully operational and the MRU is ready for immediate operation in either Normal, Backup, or Fan-Only modes.

3.2.1.9 Controls. Each system shall be capable of continuous uninterrupted service when operating under the conditions specified herein with a minimum of attention. The control panel shall conform to the following paragraphs of MIL-C-2212G: 3.4, 3.6 (except for last sentence), 3.7, 3.8 (except control circuits shall use 115 VAC or 24 VDC to the coil of 440 VAC contactors), 3.11, 3.12.1, 3.13.1, 3.14, 3.26.6, 3.26.7, 3.26.8, 3.26.15, 3.27; and the following qualification tests specified in Section 4 Table VIII (of MIL-C-2212G) for requirements 3.3

(specific to the requirements specified herein and best commercial practice), 3.26.6, 3.26.7, and

3.26.8. Systems and components shall be fitted with controls and piping accessories to provide for functional operation and protection of equipment. The systems shall not use condenser water control valves. Controls shall include both start inhibit and safety shutdown features to protect equipment. These features shall accommodate all operational modes and conditions including periodic load out and breakdown and handling of stores.

3.2.1.10 Diagnostics. Each system shall continuously and automatically perform diagnostics on all Seller-furnished equipment to troubleshoot failures. Diagnostic items shall include visual indicators (e.g. fault codes) for the following items:

(a) Low MRU Inlet Air Temperature (chill service only)

(b) High MRU Inlet Air Temperature

(c) High Refrigerant Outlet Pressure

(d) Refrigerant Outlet Pressure Transducer Is Out-Of-Range High

(e) Refrigerant Outlet Pressure Transducer Is Out-Of-Range Low

(f) Low Refrigerant Inlet Pressure

(g) Refrigerant Inlet Pressure Transducer Is Out-Of-Range High

(h) Refrigerant Inlet Pressure Transducer Is Out-Of-Range Low

(i) Compressor Motor Overload

(j) Fan Motor Overload

(k) Compressor Motor Fails to Operate Properly

(l) Fan Motor Fails to Operate Properly

(m)Defrost Heaters Fail to Operate Properly

(n) Condensate Line Heater Failure

(o) 440 VAC Fault

(p) Compressor Short Cycling

(q) MRU Control Panel High Internal Air Temperature (if required)

(r) Rupture disk failure (refrigerant inlet pressure = refrigerant outlet pressure = 14.7 psia)

3.2.2 Major Component Characteristics

3.2.2.1 Modular Refrigeration Units. Each MRU shall be identical. Principal dimensions shall be not greater than 24-inches high x 86-inches wide x 32-inches deep. Each MRU shall be

28 Jan 2019 self-contained with all internal piping and wiring terminating at the same-side. Wiring shall terminate with military specification electrical connections. Piping shall terminate with military specification or commercial equivalent mechanical connections. All wiring and piping connections shall be designed for repeated and quick disconnect for easy removal of the MRU for maintenance or replacement. The MRU structure and all panels and drain pans shall be constructed of stainless steel and shall not be painted. All removable exterior panels shall be affixed with corrosion resistant fasteners. The drain pans shall be affixed to the MRU structure with stainless steel rotary-closure latches and/or bolts. Removable exterior panels shall be provided for all in-place shipboard repairable items. To the maximum extent possible, the design of the MRU structure and enclosure shall allow the unit to be recessed into the overhead of the storeroom insulation.

3.2.2.1.1 Refrigerant Pressure Vessel. The design pressure for each MRU shall not be less than the saturation pressure (gauge) corresponding to 150 degrees F. MRU equipment shall be designed for a vacuum of 5 mm Hg (0.2 inches Hg). The combined refrigerant capacity of all

MRU’s and remote condensers shall be less than 45.4 kg (100 lbs) refrigerant. The refrigeration boundary shall not be repairable in-place, but access panels shall be installed to ease repair once the MRU is lowered from its normal operating position or removed from the storeroom for repair. The compressor shall be a fully hermetic design having mechanical O-ring connections to allow isolation during transport and for removal. The evaporator shall consist of two physically separate coils. The evaporator coils can be supplied by a dedicated expansion valve to each coil the refrigerant outlet of the two evaporator coils shall combine for a common return to the compressor. If the evaporator coils are supplied by a single expansion valve each coil shall be served by an equal number and length of distributor feeds, and the expansion valve sensing bulb shall be located downstream of the combined suction. The refrigerant boundary shall incorporate service proven commercial off-the-shelf components selected and arranged for absolute minimum leakage (goal of a total of 1.5-ounces per MRU per year) and to allow for easy substitution and obsolescence avoidance. The design of all refrigerant pressure vessels, including the compressor hermetic boundary and the refrigerant receiver shall be validated by burst test not less than 1200 psig or as approved by the Naval Technical Authority

3.2.2.1.2 Pressure Relief Device. Overpressure protection shall be provided by a pressure relief device. The Seller shall obtain Buyer approval of any MRU overpressure protection using other than a rupture disk that will be connected to Buyer relief piping as described in Section

3.1.3.2. Fusible plugs shall not be used on MRU’s. The minimum required discharge capacity of the pressure-relief device for each pressure vessel shall be determined by the following formula from ASHRAE 15 and based on fire conditions:

Where:

C = fDL kilograms

C = minimum required discharge capacity of the relief device in per second (kg/s) or pounds of air per minute (lbm/min)

D = outside diameter of vessel in meters (ft)

L = length of the pressure vessel in meters (ft) f = factor dependant upon the type of refrigerant

28 Jan 2019

Refrigerant Value of f

HFC-134a, 0.131(1.6)

HFC-407a

The rated discharge capacity of a rupture disk shall be determined in accordance with paragraph

9.7.7 of ASHRAE 15-2010. For R-407a, the rupture disk pressure rating shall be 500 +/- 50 psig. The seats and discs of pressure relief devices shall be constructed of suitable material to resist refrigerant corrosion or other chemical action caused by the refrigerant.

3.2.2.1.3 Flexible metal connectors. - Refrigerant piping to and from each resilient mounted MRU shall be provided with flexible metal connectors arranged in a 90 degree configuration consisting of a CRES corrugated core with wire braid reinforcement and welded

CRES tube end fittings at the refrigerant inlet and outlet. All flexible metal connectors shall meet the requirement of ISO-10380 Type 1-50 rated for high flexibility and long life and shall be suitable for R-407a, having a design pressure not less than 450 lb/in , a working pressure not less than 300 lb/in , and a burst test rating of not less than 1,500 lb/in

3.2.2.1.4 Refrigerant service connections. - Each MRS shall be provided with a capped self-sealing 0.25 inch SAE 45 degree flare, 7/16-20 UNF external thread fitting with Schrader® valve refrigerant service connections installed at the condenser outlet refrigerant line, located outside of the refrigerated spaces, for evacuation, charging and troubleshooting. The service valve shall be part of an access tee design C&D valve CC series, or equal design. The service valve brass cap shall be secured to the service valve with a lanyard C&D valve Part No.

CD2265, or equal. Additional service valves shall be provided as required within each MRU to support manufacture, production testing, evacuation and installation of nitrogen charge for unit layup.

3.2.2.2 Control Panels. Each control panel shall be identical. Overall dimensions

(including the extent of items such as mounting tabs, lights, and switches) shall be not greater than 34-inches high x 25-inches wide x 10-inches deep. From the center of the control panel, within an area not to exceed 24.5-inches high x 19-inches wide, the depth may be increased from

10-inches to 14-inches. Control panels shall not be vented, shall be spray tight in accordance with NEMA 13 or IP65, and shall have a right side hinged door. Each MRU shall be controlled and monitored by a programmable logic controller (PLC) located within the control panel. The

PLC selected shall have proven naval shipboard service. If a fault occurs, the PLC will display a fault code from a list published in the equipment technical manual. Individual displays shall have a service life equal to or greater than that of the selected PLC, and the failure of any individual display shall not result in a shutdown of the system. Also, located within the control panel shall be a selector switch for chill or freeze service. Access within the control panel for inspection of components shall not require disassembly to the extent that major items must be unsecured or removed. Lights, controls, and displays (including windows) shall be located on the front of each control panel and shall include the following items:

(a) Power-available light (white)

(b) Compressor-running light (green)

28 Jan 2019

(c) Defrosting light (blue)

(d) MRU fault light (red)

(e) MRU mode selector switch (Normal, Backup, Fan-Only, Standby)

(f) Defrost cycle selector switch (6, 12, 24, or 48-hours, or manual control)

(g) MRU temperature set point display (°F)

(h) Refrigerated space current temperature display (°F)

(i) MRU compressor operating hours display

(j) MRU fault code display

3.2.2.2.1 PLC Cyber-Security Provision. PLC digital data port(s) necessary for

Vendor control system maintenance and data acquisition shall be accessible without the opening or removal of the control panel door. When not in use, access to necessary digital data port(s) shall be controlled by a physical mechanism. Access shall be physically denied to redundant or unnecessary digital data port(s) located internally or externally to the control panel. Regardless of the location of the unnecessary or redundant digital data port(s), physical measures shall be installed to prevent digital data port accessibility. Acceptable physical measures are those that permanently disable the digital data port(s) (i.e. application of epoxy or disconnection of port wiring) or require special tools to remove physical barriers (i.e. welded or riveted digital data port covers) that prevent access to digital data port(s).

3.2.2.2.2 Software. The PLC application codes should be Department of Navy

Application and Database Management System (DADMS) registered unless otherwise approved by the Naval Technical Authority. Only non-developmental software shall be provided. Non-developmental software includes software provided to the Navy that is functionally similar to that required with only minor changes. For non-developmental software, the Vendor shall be responsible at a minimum, for software safety, qualification testing, and version management and configuration control.

3.2.2.2.3 Pressure Sensors. Commercial electronic pressure transducers shall be in accordance with the following unless otherwise approved by the NTA.

(a) Operation: The output signal shall vary in direct linear proportion to the sensed pressure

(b) Wire connector: as approved by LDY

(c) Linearity: ± 0.25 percent of full scale best fit straight line

(d) Accuracy: ± 1.0 percent of full scale

(e) Temperature compensation: -4ºF to 185ºF

(f) Over-range: 200 percent of full scale

(g) Burst: 400 percent of full scale

(h) Threading: 0.5 inch SAE 45 degree flare, 7/16-20 UNF internal thread fitting with

Schrader® valve depressor.

(i) Material: refrigerant boundary shall be corrosion resistant steel

(j) Initial calibration: National Institutes of Science and Technology (NIST) traceable.

Afterwards, pressure transducers shall be labeled “no calibration required”.

(k) Commercial standards: RoHS compliant and ISO Standard 9001.

3.2.2.3 Condensers. Each condenser shall be identical, shall be a brazed, stainless steel

(appropriate for the service), flat-plate heat exchanger, and shall operate with a fixed chilled

28 Jan 2019 water flow rate of 4.5 gallons per minute per cooling ton, or as otherwise approved by the Naval

Technical Authority. The condenser shall be made from superaustenitic stainless steel (Alloy

SSC-6MO, 254 SMO), and selection shall be approved by the Naval Technical Authority . All water and refrigerant piping connections shall be located on the front of the condenser.

Mounting studs or other means shall be provided to attach the condenser to ship structure and shall be designed to allow the unit to be properly insulated.

3.2.2.4 Resilient Mounts. Each MRU shall be supported by resilient-type mountings.

The mountings shall be designed for the purposes of maintaining alignment during all rough handling, storage, transportation, ship installation, and all ship operating motions. Resilient-type mountings shall comply with MIL-M-17508. Resilient elements shall not be painted. Resilient mounts applied to individual components may be in accordance with best commercial practice.

3.2.2.5 Refrigerant. Each MRU shall be delivered to the Government uncharged with refrigerant. MRU equipment shall use refrigerants that are hydrofluorocarbon (HFC) as a minimum, that are non-ozone depleting, and that are classified as Safety Group A1 in ASHRAE

34-2010. Safety Group A1 includes only those refrigerants with no flame propagation and low toxicity. See ASHRAE 34-2010, Table 1, for Safety (toxicity and flammability) Group

Classifications. In addition, refrigerants must be listed in 40 CFR § 82 as acceptable under the

Environmental Protection Agency’s (EPA) Significant New Alternatives Policy (SNAP)

Program. Approved refrigerants are R-134a and R-407a. Final refrigerant selection shall be approved by the Naval Technical Authority.

3.2.3 Physical Requirements

3.2.3.1 Environmental Conditions. The equipment shall meet the requirements of

Appendix B, Sections 4.3 and 4.4.

3.2.3.2 Service Operation during Ship Motion in a Seaway. The equipment shall meet the requirements of BIW Appendix B, Section 3.0. Drain pans be designed so there will be no spillage when the ship is rolling up to 15 degrees either side of the vertical.

3.2.3.3 Installation Considerations. The equipment shall meet the requirements of BIW

Appendix B, Section 5.0. The operation of the equipment shall not be adversely affected by the installation orientation on the ship, whether fore and aft or athwart ship.

3.2.3.4 Weight limits. Equipment shall not exceed the following maximum weight limits.

3.2.3.4.1 Modular Refrigeration Unit – 880 lbs (wet weight)

3.2.3.4.2 Control Panel – 90 lbs

3.2.3.4.3 Condenser – 20 lbs (wet weight)

3.3 Design and Construction

3.3.1 Materials, Parts and Processes

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3.3.1.1 Casting and Welding. Machinery, piping, and pressure vessels shall be fabricated and inspected in accordance with ASME Boiler and Pressure Vessel Code, Section VIII. The evaporator(s) shall not be classified as a pressure vessel. The MRU structure and enclosure shall be fabricated and inspected in accordance with MIL-STD-278F and BIW Appendix B, Sections 8.0 and 9.0.

3.3.1.2 Brazing. Brazing of piping shall be performed in accordance with NAVSEA

NAVSEA Tech Pub 0900-LP-001-7000, as modified herein.

(a) Maximum permissible diametrical clearances specified in 0900-LP-001-7000 Table 5-2 for Class P-3b joints may be used for Class P-3a joints at interfaces with commercial components.

(b) The BCuP series of phosphorous-bearing filler metals shall not be used for brazing base materials containing more than 10 weight percent nickel due to the risk of brittle intermetallic formation.

(c) Cadmium-bearing brazing filler metals shall not be used.

(d) Brazing of electrical connections is permitted and shall be performed using best commercial practice.

(e) Where reference is made to MIL-STD-271, replace with NAVSEA T9074-AS-GIB-

010/271 including Change Notice 1.

(f) Union O-ring joints may be seal brazed in accordance with NAVSEA PRESSURE SEAL

BRAZING PROCEDURE, AWS 5.8 BAg Alloy, UNION O-RING JOINT date 12 Aug 2015 with Naval Technical Authority approval.

3.3.1.3 Threaded Fasteners. Threaded fasteners shall be in accordance with best commercial practice or may be in accordance BIW Appendix B, Sections 7.0 and 11.0.

Fasteners associated with MIL-M-17508 resilient mounts shall be in accordance with NAVSEA

Handbook S9073-A2—HBK-010

3.3.1.4 Materials and Lubricants. Materials and Lubricants shall be in accordance with

BIW Appendix B, Section 6.0. Food grade lubricants shall be used where appropriate and when available. Equipment shall be non-combustible or fire retardant under the most hazardous conditions to be expected in the application. Fire retardance shall not be achieved by use of non-permanent additives to the equipment.

3.3.1.5 Electrical. The equipment shall meet the requirements of BIW Appendix B, Section 17.0. The requirements of MIL-M-17060 are not applicable to hermetically sealed compressor-motor assemblies and motorized impellers that are UL approved. MRU total power required shall be determined for pull-down, normal, and defrost cycle operating conditions.

Defrost heaters shall be designed and constructed for use in a high humidity environment and to avoid ground faults. The Seller shall consider, and may offer to the Buyer for review and approval, energy-saving materials and designs not included in this specification. Cable access shall be provided at suitable locations at the top and bottom of the control panel by way of removable mounting plates. Military specification electrical connections may be used for the interface with the ship’s 440 volt alternating current electrical power system. The Buyer may specify the drilling required for the installation of Buyer supplied cable feed-through fittings. In lieu of Appendix B, Section 17.23, the following fuses and motor overloads may be used:

28 Jan 2019

(a) Fuses may be provided for the power transformer primary and secondary per NEC

450.3(B)

(b) Fuses may be provided for 440 VAC heaters per NEC 424.3

(c) Fuses may be provided for the compressor motor per NEC 440.22

(d) Fuses may be provided for the fan motor per NEC 430.52

(e) Overloads may be provided for the fan motor per NEC 430.32

(f) Overloads may be provided for the compressor motor per NEC 440.52.

3.3.1.6 Instruments. Instruments shall be in accordance with best commercial practice or may be in accordance with Appendix B, Section 12.0. Instruments wetted with refrigerant shall not require calibration. The Seller shall obtain Buyer approval of any instrument that requires periodic calibration.

3.3.1.6 Piping. Piping shall be in accordance with BIW Appendix B, Section 11.0.

Interfaces with ship’s piping systems shall be made using mechanical take-down joints such as unions or flanged connections. Refrigerant o-rings shall be of laboratory tested, service proven, and materially compatible formulations. Refrigerant union joints that may be subject to loosening from relative motion of attached piping or components shall be secured with lock wire in accordance with NASM33540, or as otherwise approved by the Buyer. Lock wire shall be

MS20995C32 in accordance with NASM20995. Refrigerant Loctite shall be used on threaded joints in the refrigerant boundary where lock wire installation is not practicable, such as at pressure transducer locations. Refrigerant flanged connections in accordance with SAE J518-1 may be used when approved by the Buyer.

3.3.1.7 Equipment Insulation

3.3.1.7.1 Application. Refrigerant insulation will be installed in accordance with MIL-

STD-769J, modified as follows: Armstrong ARMAFLEX NH cellular elastomeric non-halogenated polymer foam manufactured by Armstrong World Industries, Inc., or equal, will be used for all anti-sweat and refrigerant applications and will be lagged with MIL-C-20079H, Type

I, Class 6 or 8 fibrous glass cloth manufactured by BGF Industries, or equal. (Note: DOD-I-

24688 Type I pre-formed polyimide pipe covering pre-lagged with reinforced aluminized polyester/aluminum foil with primer coated surface is not considered an equal to ARMAFLEX

NH). Armstrong ARMAFLEX NH insulation may be covered with Armstrong Arma-Chek protective covering system as an alternative to MIL-C-20079H lagging. All seams and butt joints of the insulation will be glued with ARMSTRONG 520 adhesive, or equal, to ensure a continuous insulative boundary is attained. All flexible hoses for refrigerant piping will be insulated with removable insulation.

3.3.1.7.2 Installation. Machinery and pipe covering will be installed in accordance with requirements herein and those specified in MIL-STD-769J. Surfaces to which insulation will be applied shall be cleaned and prepared as specified in BIW Appendix B, Section 10.4. Pipe covering will not be installed over mechanical joints in piping until specified pressure tests have been completed. Machinery and pipe covering will be installed so that movements of the

28 Jan 2019 components, due to thermal or other forces, will not damage the covering in any way. Fastenings will not crush or otherwise reduce the insulating value of insulation.

3.3.1.8 Equipment Openings. Openings to the refrigerant boundary, including piping, controls, compressors, condensers, and evaporators shall be sealed to exclude dirt and moisture except when work requiring their being open is actually in progress. Prior to installation, refrigerant boundary piping, valves and fittings shall have all flux and foreign or loose particles removed and shall be thoroughly cleaned and degreased. Upon completion of cleaning, open ends shall be plugged or capped. Open ends shall be kept closed until final installation.

3.3.1.9 Painting and Coatings. Painting and coatings applied by the Seller shall be in accordance with Appendix B, Sections 10.0 and 13.0, except that specification TT-P-645C may be used in lieu of TT-P-645B. Corrosion resistant material shall not be painted unless approved by the Buyer. Paint may be applied to commercial items delivered painted, such as the compressor hermetic enclosure and the receiver, in accordance with best commercial practices for self-contained refrigeration equipment.

3.3.2 Identification and Marking. Identification and Marking shall be in accordance with

Appendix B, Section 14.0. Each MRU shall be clearly marked with the applicable refrigerant type, such as “R-407a ONLY.”

3.3.3 Interchangeability. Repairable equipment shall be standard equipment where practicable. The Seller shall advise and obtain Buyer approval of repairable items not otherwise used by other Navy ship programs, new construction or otherwise. Equipment which is functionally interchangeable shall be identical. The term “functionally interchangeable” means that two or more items are sufficiently alike in all essential respects to permit replacement of one such item by the other in all applications where the item is used without modification of either the item or the system in which the item is used.

3.3.4 Safety. The equipment shall be designed so that all procedures for installing, operating, inspecting, maintaining, repairing, and adjusting the equipment can be accomplished in a safe manner. To insure maximum protection for operating and maintenance personnel against hazards and accidents, the equipment shall incorporate the necessary safeguards and protective features. Unless a prior form, fit, and functional design has previously been accepted or approved by the Naval Technical Authority, a System Safety Hazard Analyses shall be conducted on the equipment using MIL-STD-882 as guidance. Electrical and electronic equipment design and installation shall conform to Requirement 1 of MIL-STD-454.

3.3.5 Human Engineering. Human engineering shall be applied to the detail design, construction, test and evaluation of the equipment. Applicable anthropometric and strength requirements are identified in MIL-STD-1472, paragraphs 5.6, 5.7.4, 5.9.9.4, 5.9.11.3, and

5.9.11.4 (except 5.9.9.4.2). The 5th - 95th percentile male ground troops of MIL-STD-1472 shall be used.

3.3.6 Integrated Logistic Support (ILS). ILS shall be in accordance with Appendix B, Section 16.0.

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3.4 Documentation

3.4.1. Preventive Maintenance Program. A Preventive Maintenance Program shall be prepared that encompasses the preventive maintenance to be performed from the time of receipt of the equipment until delivery of the ship, including inactive equipment maintenance required pending installation and activation of equipment aboard the ship. The equipment shall require no preventative maintenance of the refrigerant boundary.

3.4.2 Provisioning Technical Documentation (PTD). PTD shall be prepared for the purpose of identification and determination of on board repair parts, consumables, and tool requirements. PTD includes, but is not limited to, provisioning lists, associated drawings, and item descriptions.

3.4.3 Drawings. Drawings shall be in sufficient detail to enable shipboard repairs as specified in Section 3.2.1.4. For depot level maintenance and above, drawing shall be sufficient to enable Naval ship and shore activities to replace and maintain all other parts in an emergency without assistance from the Seller. They include, but are not limited to, drawing lists, outline drawings, assembly drawings, subassembly drawings, and parts lists.

3.4.4 Technical Publications. The technical manual describing the 0.75-ton MRS shall be modified and presented as unique manual prepared in accordance with BIW Appendix B, Section

15.0.

3.4.5 Technical Reviews and Audits. Technical reviews and audits shall be in accordance with BIW Appendix B. Section 20.0

3.4.6 Serialization

3.4.6.1 Equipment to be Serialized. Each MRU, Control Panel, and Condenser shall be permanently and uniquely identified by a serial number. The Seller shall maintain traceability of all serialized components to the ship for which they are delivered. A list of all serialized equipment shall be prepared.

3.4.6.2 Serial Numbers. Serial numbers shall have the following characteristics:

(a) Maximum length of 15 alpha-numeric characters.

(b) In numerical sequence within a family group.

(c) Non-duplicating within the family group.

(d) Permanent for the life of the component.

(e) Not re-used or re-assigned to a different unit within the initial procurement or follow-on procurements.

4 TESTING AND QUALITY ASSURANCE

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4.1 Responsibility for Inspection. The Seller is responsible for the performance of all examinations and tests as specified in this specification. Except as otherwise specified in the purchase order, the Seller may use his own or any other facilities for the performance of the inspection requirements specified in this specification. The Buyer reserves the right to perform any of the inspections set forth in this specification where such inspections are deemed necessary to ensure supplies and services conform with prescribed requirements.

(a) The Seller shall utilize for the performance of required Nondestructive Testing (NDT) only personnel who are currently certified in accordance with NAVSEA Technical Publication

T9074-AS-GIB-010/271 DATED 30 April 1997 and Recommended Practice No. ASNT-TC-1A.

NDT includes radiography, magnetic particle, liquid penetrant, eddy current, ultrasonic inspections and visual inspections. This requirement applies to the Seller and not to Suppliers to the Seller of materials, components, or equipment for the modular refrigeration systems.

(b) Certification of Level III (NDT Examiner) personnel shall be based on (1) successful completion of appropriate American Society for Nondestructive Testing Level III Examinations and (2) successful completion of specific and practical examinations based on NAVSEA

Technical Publication T9074-AS-GIB-010/271 and associated fabrication documents.

Examinations may be developed and administered by the Seller or by an outside agent designated in the Seller’s written practice. If NDT personnel are qualified to the MIL-STD-271F requirements, then their qualifications will be satisfactory until the qualifications expire in accordance with the re-qualification periodicity of MIL-STD-271F. At the time their qualifications expire, they will be required to re-qualify to the requirements stated herein.

Documentation pertaining to the qualification and certification of NDT personnel shall be available to the Buyer for review upon request.

4.1.1 Responsibility for Compliance. The inspection set forth in this specification shall become a part of the Seller’s overall inspection system or quality program. The absence of any inspection requirements in this specification shall not relieve the Seller of the responsibility of ensuring that all products or supplies submitted to the Buyer for acceptance comply with all requirements of the purchase order. Sampling inspection, where permitted by this specification, as part of the manufacturing operations, is an acceptable practice to ascertain conformance to requirements. However, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Buyer to accept defective material.

4.1.2 Quality Program Requirements. The Seller shall provide, maintain, and implement a quality program acceptable to the Buyer for all equipment and services required by this specification. The program shall be in accordance with MIL-I-45208A or ANSI/ASQC Q9001-

1994, “American National Standard, Quality Systems-Model for Quality Assurance in Design, Development, Production, Installation and Servicing”. The quality program shall be described in sufficient depth to ensure that the technical and quality requirements of MIL-I-45208A or

Q9001-1994 will be met. The Seller shall notify the Buyer of any changes in his quality system.

Conformance with these requirements shall not be construed as relieving the Seller of final responsibility to furnish equipment and services meeting specification requirements. Use of a material review board requires the written approval of the Buyer.

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4.2 Quality Conformance Inspections and Tests. All components of the modular refrigeration systems shall be selected for inspection and test unless waived by the Buyer. The first article and production tests shall be conducted as listed in Table VII.

4.2.1 First Article Tests. Tests that are performed on the first unit of each item manufactured, with the intention of demonstrating that the equipment meets required design characteristics. For prior qualification, the Contractor may submit data from form, fit, and functionally equivalent equipment either approved by the Navy Technical Authority or from other Navy ship programs that have received Navy Technical Authority concurrence.

4.2.2 Production Tests. Tests that are performed on every item manufactured, with the intention of demonstrating acceptable fabrication of the item.

Table VII

INSPECTIONS AND TESTS

Line Test First Article Production Test Section a Visual X X 4.3.1 b Pressure and Leak X X 4.3.2 c Inclination X 4.3.3 d Shock X 4.3.4 e Vibration, Type I X 4.3.5 f Vibration, Type II X X 4.3.5 g Vibration, Type III X X 4.3.5 h Noise X X 4.3.6 i EMI X 4.3.7 j Operation X X 4.3.8

4.3 Test Descriptions

4.3.1 Visual. All components shall be inspected to establish conformance with this purchase specification and the Seller’s design and manufacturing documentation. This inspection shall include, but not be limited to, dimensions, finishes, materials, and interface connections. For equipment that will interface with electrical power or signals, the inspection shall verify functionality of these interfaces.

4.3.2 Pressure and Leak. All refrigerant pressure-containing parts shall be pressure tested and leak tested in accordance with a recognized commercial standard. For R-407a, a 400 psig pressure test shall be applied (based on 110 percent of the maximum working pressure); but not to exceed the compressor pressure test limits. The leakage criteria shall be no deformation, porosity, or leakage exceeding one half ounce of refrigerant per year. Also, the Seller shall provide test data certifying each condenser in accordance with a recognized commercial standard.

4.3.3 Inclination. All first article components shall be tested to establish conformance with Section 3.2.3.2.

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4.3.4 Shock. All first article components shall be tested to establish conformance with

Section 3.2.1.5.

4.3.5 Vibration. All first article components shall be tested to establish conformance with

Section 3.2.1.5 for type I vibration. All components shall be tested to establish conformance with Section 3.2.1.5 for type II vibration. Type III vibration is required on the first article only if using reciprocating components, and may be waived by the buyer based on previous qualification.

4.3.6 Noise. One MRU from each shipset shall be tested to establish conformance with

Section 3.2.1.6.

4.3.7 EMI. All first article components shall be tested to establish conformance with

Section 3.2.1.7.

4.3.8 Operation. All components shall be tested to establish conformance with this purchase specification and the Seller’s design and manufacturing documentation. These tests shall include, but not be limited to: performance, modes, controls, signals, and safety.

4.3.8.1…