ATTCH_chiller_replacement_guide.pdf

TS GOLDEN BEAR Chiller Plant Replacement

Photo Removal and Installation Guide

Rev. 1

This Photo Removal and installation Guide details suggested methods for the removal of three A/C chilled water plants and the installation of two replacement plants. Variations from the guide are allowed to the satisfaction of the owner’s representative.

This guide forms part of the contract specification and is to be read in conjunction with the specification.

In case of a conflict between this guide and the specification, the specification shall govern.

Before removing any components from the existing units, the refrigerant must be removed by an EPA-Certified technician. It is recommended that an EPA-Certified Refrigeration Reclaimer is contacted to recover and reclaim the refrigerant. Refrigerant is to be removed from the three chiller units, the three refrigerant overflow tanks located below each chiller unit, and the refrigerant recovery machinery behind chiller plant #1.

View from engine room looking up at proposed hatch location. To facilitate the equipment removals outlined in this guide, a new equipment removal hatch is to be installed at the bottom of the existing equipment removal trunk. The new hatch is located just forward of the main engines and to starboard of centerline. The design of the new hatch is not covered in this guide and requires additional engineering and ABS approvals.

Proposed New Hatch

Chiller Unit Piping Removals:

Units 1 & 2:

Units 1 & 2 will be removed and replaced with new units (detailed later in this guide).

Drain the seawater from the chiller plants and attached piping. On each unit, remove and discard the small pipe spool between the sea water inlet and the shutoff butterfly valve. Retain the valve for installation with the new chiller. Protect the pipe stub from damage and contaminants.

On each unit, remove and retain the sea water outlet piping, this pipe branch will be modified and re‐ installed with the new unit.

Remove and discard

Remove, to be modified and reinstalled

Drain the chilled water from the chiller plants and attached piping. Retain chilled water for filling the new units. Remove the inlet piping up to the valve (located below the deck). Retain the bellows for installation with the new unit.

Remove and retain the chilled water outlet piping.

Retain bellows under insulation

Remove and discard the pressure relief assembly from each unit (Unit #1 shown on left, Unit #2 shown on right)

Remove and discard the refrigerant overflow tank from below each unit.

Unit 3:

Unit 3, the aft‐most unit, will not be replaced. Piping connections from this unit are to be removed and blind flanges are to be installed.

Remove the sweater inlet piping and bellows below the deck, install blind flange.

Remove the seawater outlet piping to the manifold on the forward, outboard side of the unit and install a new blind flange. Retain the control valve, manual valves, and strainer and hand over to the Chief

Engineer for ships spares.

Remove and discard

Install new blind flange

Install new blind flange

Remove chilled water inlet to below deck. Remove valve and install blind flange.

Remove chilled water outlet piping to flange shown above. Install blind flange.

Photo is taken outboard of chiller plant #1. Remove and cap refrigerant vent line aft of deck vent.

Chiller Unit Removal:

The units will be removed in 4 major parts: control panel, compressor, condenser, and cooler.

Control Panel:

Remove the electrical connections on the left side of control panel (left photo). On compressors 1 and

2, pull the electric supply cable and the summary alarm cable below deck and protect for re‐installation on the new unit. Remove the gauge connections on the right side of panel (right photo). Un‐bolt and remove control panel.

Compressor:

The seawater manifold on Unit #1 is welded to the compressor frame. Install 2” x 2” angle supports

(approx 48” long) from the manifold frame to the deck (2 places). Cut connections between manifold and compressor frame.

Remove the electrical and oil connections from the compressor frame. On compressors 1 and 2, pull the electric cable below deck and protect for re‐installation on the new unit.

Disconnect the flanges connecting the compressor to the cooler and condenser.

Cut the support plate on the end.

When rigged for removal, cut the 4 support columns beneath the compressor skid. Remove.

Cooler and condenser:

The cooler and the condenser are welded together. The units can be removed together or cut apart and removed separately.

Remove the head plates and any remaining pipe connections from both sides of the units.

To cut apart, remove the insulation on the cooler to expose the weld seam. Cut at weld to separate the units.

Unbolt cooler and condenser from foundation and remove. Remove leveling plate from foundation.

Refrigerant Recovery Unit Removal:

The refrigerant recovery unit is installed outboard of chiller unit #1. Disconnect piping and remove unit in one piece. Cap relief vent piping. Remove associated piping.

Electrical Removal:

Remove the motor starter for chiller unit #3, remove all disconnected cables. Remove feed circuit back to switchboard.

The motor starter panels for chiller units #1 and #2 remain in place and will be re‐used for the new units.

New Plant Installation:

Foundation:

A new foundation (sketch shown above) has been designed to convert the existing foundation to support the new units. Details of the new foundation are found in drawing 2013‐052‐00‐01. The new foundation is to be welded on top of the existing foundation and the new chillers will be bolted to the new foundation. Dimensions of each existing foundation should be confirmed before prefabrication.

The foundations are designed to be oriented with the heavy frame members towards starboard.

Drill holes for mounting after confirming mounting locations on chiller unit. Place each chiller and mount each unit with 7/16” diameter bolts (Qty. 24 per unit).

Piping Connections:

Install seawater and chilled water piping connections to new units. Modify retained piping where possible. Reinstall expansion bellows and valves on each pipe. Insulate chilled water piping.

Connect the refrigerant relief valves (2 each) to the refrigerant vent line.

Electrical:

The existing motor start panels are to be modified for the new chiller unit. The internal components of each panel is to be stripped leaving only the terminal blocks and the disconnect switch.

The existing cables will be re‐used where possible. Connect the 3 phase 440V cable to the new starter in the new units control panel (terminals 21, 22, 23). Connect the summary alarm cable (Terminals 11, 12).

Remove all other unused cables.

Remove

Internal

Components