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Enclosure 1 - Work Item (WI) 519 Refrigeration Compressor Safety Valve Test (5YR)

T-AKE CLASS

MACHINERY, AUXILIARY SYSTEMS

ITEM NO. 519 Category “A”

519-1

1.0 ABSTRACT

This item describes replacement/repair, testing and certification of safety valves.

2.0 REFERENCES/ENCLOSURES

2.1 References

2.1.1 T9516-A8-MMC-01C; Technical Manual for

Refrigeration Plant, Cargo for USNS AKE 1 Class

2.2 Enclosures

2.2.1 List of Safety Valves

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: See Enclosure 2.2.1

3.1.2 Quantity: Four (4) compressor, Twelve (12)

total

3.2 Item Description/Manufacturer’s Data: Leser Safety

Valve

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE: None

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of

tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTR’s including but not limited to GTR’s 1 through 7, 22, 23, 24, 28, and 29.

5.2 The contractor and all subcontractors, regardless of

tier are advised to review other work items under this contract, 519-2 including but not limited to Work Items XXX and XXX to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL

SYSTEMS. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING

SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME

APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER

AUTHORIZATION.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT

FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE

CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND

WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED

AND PROVEN OTHERWISE. TEST ALL ELECTRICAL CABLES TO ENSURE THEY

ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 With the assistance of ship’s force, tag-out all

required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state, and local regulations.

7.2 Notify MSCREP before starting any work.

7.3 Provide the services of an ABS Qualified Valve Testing

Facility, to perform the repair, testing, and certification of the cargo refrigeration system safety valves.

7.4 Prior to removal, each safety valve shall have a

temporary metal identification tag installed, showing valve size, pressure setting, space, and frame location. Temporary tags shall remain attached to the valves until reinstallation.

7.5 Temporarily remove insulation and lagging in way of

each safety valve. Retain for reuse. Identify areas that are soiled and deemed unfit for reuse.

7.6 Temporarily remove safety valves identified in

519-3

Enclosure 2.2.1 from location and temporarily plug/blank openings to prevent system contamination. Remove temporary plug/blank at time of valve reinstallation.

7.6.1 Retain, bag and tag fasteners for reuse. Mark

bagged hardware to each safety valve location.

7.6.2 Inspect for damaged fasteners. Any damaged

fasteners shall be renewed. For estimated bidding purposes, assume ten percent (10%) of fasteners shall be renewed.

7.7 Rig and convey safety valves from ship to shop, including new GFM valves.

7.8 Perform a preliminary pressure test of all safety

valves. Valves shall lift at the proper pressure and shall re-seat fully when pressure is reduced below test pressure.

7.8.1 Make minor adjustments where required. Submit

a condition report identifying valves that do not pass testing and identify required repairs. Repair recommendations will be the subject of a change order as deemed necessary by the MSCREP.

7.8.2 Upon completion of approved repairs, retest the

repaired safety valves.

7.9 Accomplish final pressure test of all safety valves.

Valves shall lift at the proper pressure and shall re-seat fully when pressure is reduced below test pressure.

7.9.1 Test shall be witnessed by MSCREP and ABS

Surveyor.

7.10 Upon satisfactory completion of final acceptance

testing, convey all safety valves from shop to ship.

7.11 Remove all temporary plugs/blanks. Reinstall valves

in original locations. Replace and renew all removed and disturbed gaskets. Reuse existing fasteners.

7.11.1 For all high-pressure valves, renew Viton O-

rings prior to reinstallation.

519-4

7.12 After reinstallation, provide and install a permanent

stainless-steel metal tag identifying system, test date, pressure setting, and facility name used to conduct the testing.

Metal tags shall be secured to valves using stainless-steel metal wire.

7.13 Clear all system tags. Energize systems and conduct

an operational leak test. Each valve shall be checked with Ship’s Force in attendance. No leakage allowed.

7.14 Reports

7.14.1 When inspection, service and testing reveal any

deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF).

7.14.2 Submit an “as released” condition report.

Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF). The report is to include and identify the:

a. Safety valve

b. System and pressure setting

c. Test date

d. Facility name used in testing and repair of valves

e. The report is also to include an electronic Excel Spread Sheet of all safety valves tested. Spread sheet is to contain the following info:

1. System description

2. Valve number/designator

3. Location

4. Set pressure

5. Manufacturer

6. Model

7. Serial number

8. Size

519-5

9. Inlet outlet size

10. Date last tested

11. Test facility name used

7.14.3 All reports and checklists are to be completed

and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.15 Painting/Lagging

7.15.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.16 Manufacturer's Representative

7.16.1 Provide the services of OEM authorized field

service technical representative and labor to accomplish all work and testing on the safety valves identified in Enclosure

2.2.1 ensuring compliance with the manufacturer’s standards and performance specifications.

7.17 Preparation of Drawings: None additional.

8.0 GENERAL REQUIREMENTS: None additional.

519-6

Enclosure 2.2.1 – List of Safety Valves

Valve Number Valve Identification Valve Location

SAV01 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 1 Discharge Line

SAV02 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 1 Condenser

SAV03 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 1 Discharge Line

SAV04 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 1 Condenser

SAV01 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 2 Discharge Line

SAV02 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 2 Condenser

SAV03 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 2 Discharge Line

SAV04 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 2 Condenser

SAV01 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 3 Discharge Line

SAV02 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 3 Condenser

SAV03 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 3 Discharge Line

SAV04 CARGO REFRIGERATION (CHILL) COMPRESSOR UNIT NO. 3 Condenser

1.0 ABSTRACT

This item describes replacement/repair, testing and certification of safety valves.

2.0 REFERENCES/ENCLOSURES

2.1 References

2.1.1 T9516-A8-MMC-01C; Technical Manual for Refrigeration Plant, Cargo for USNS AKE 1 Class

2.2 Enclosures

2.2.1 List of Safety Valves

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: See Enclosure 2.2.1

3.1.2 Quantity: Four (4) compressor, Twelve (12) total

3.2 Item Description/Manufacturer’s Data: Leser Safety Valve

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE: None

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of ti...

5.2 The contractor and all subcontractors, regardless of tier are advised to review other work items under this contract, including but not limited to Work Items XXX and XXX to determine their effect on the work required under this work item. Many of...

5.3 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHE...

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 With the assistance of ship’s force, tag-out all required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state, and local regulations.

7.2 Notify MSCREP before starting any work.

7.3 Provide the services of an ABS Qualified Valve Testing Facility, to perform the repair, testing, and certification of the cargo refrigeration system safety valves.

7.4 Prior to removal, each safety valve shall have a temporary metal identification tag installed, showing valve size, pressure setting, space, and frame location. Temporary tags shall remain attached to the valves until reinstallation.

7.5 Temporarily remove insulation and lagging in way of each safety valve. Retain for reuse. Identify areas that are soiled and deemed unfit for reuse.

7.6 Temporarily remove safety valves identified in Enclosure 2.2.1 from location and temporarily plug/blank openings to prevent system contamination. Remove temporary plug/blank at time of valve reinstallation.

7.6.1 Retain, bag and tag fasteners for reuse. Mark bagged hardware to each safety valve location.

7.6.2 Inspect for damaged fasteners. Any damaged fasteners shall be renewed. For estimated bidding purposes, assume ten percent (10%) of fasteners shall be renewed.

7.7 Rig and convey safety valves from ship to shop, including new GFM valves.

7.8 Perform a preliminary pressure test of all safety valves. Valves shall lift at the proper pressure and shall re-seat fully when pressure is reduced below test pressure.

7.8.1 Make minor adjustments where required. Submit a condition report identifying valves that do not pass testing and identify required repairs. Repair recommendations will be the subject of a change order as deemed necessary by the MSCREP.

7.8.2 Upon completion of approved repairs, retest the repaired safety valves.

7.9 Accomplish final pressure test of all safety valves. Valves shall lift at the proper pressure and shall re-seat fully when pressure is reduced below test pressure.

7.9.1 Test shall be witnessed by MSCREP and ABS Surveyor.

7.10 Upon satisfactory completion of final acceptance testing, convey all safety valves from shop to ship.

7.11 Remove all temporary plugs/blanks. Reinstall valves in original locations. Replace and renew all removed and disturbed gaskets. Reuse existing fasteners.

7.11.1 For all high-pressure valves, renew Viton O-rings prior to reinstallation.

7.12 After reinstallation, provide and install a permanent stainless-steel metal tag identifying system, test date, pressure setting, and facility name used to conduct the testing. Metal tags shall be secured to valves using stainless-steel metal wire.

7.13 Clear all system tags. Energize systems and conduct an operational leak test. Each valve shall be checked with Ship’s Force in attendance. No leakage allowed.

7.14 Reports

7.14.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Fo...

7.14.2 Submit an “as released” condition report. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF). The report is to include and identify the:

a. Safety valve

b. System and pressure setting

c. Test date

d. Facility name used in testing and repair of valves

e. The report is also to include an electronic Excel Spread Sheet of all safety valves tested. Spread sheet is to contain the following info:

1. System description

2. Valve number/designator

3. Location

4. Set pressure

5. Manufacturer

6. Model

7. Serial number

8. Size

9. Inlet outlet size

10. Date last tested

11. Test facility name used

7.14.3 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.15 Painting/Lagging

7.15.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.16 Manufacturer's Representative

7.16.1 Provide the services of OEM authorized field service technical representative and labor to accomplish all work and testing on the safety valves identified in Enclosure 2.2.1 ensuring compliance with the manufacturer’s standards and performance ...

7.17 Preparation of Drawings: None additional.

8.0 GENERAL REQUIREMENTS: None additional.

Enclosure 2.2.1 – List of Safety Valves

Enclosure 2 - Work Item (WI) 525 Cargo Reefer Compressor Overhaul (20KHRS)

ITEM NO. 525 Category "A"

525-1

1.0 ABSTRACT:

1.1 This item requires disassembly, restoration to new

condition and reassembly of Cargo Reefer Compressors.

2.0 REFERENCES:

2.1 T9516-A8-MMC-01; Technical Manual for Refrigeration

Plant, Cargo for USNS AKE 1 Class

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location: AMR 5-58-01

3.1.2 Quantity: XX Compressors

3.2 Item Description/Manufacturer's Data:

3.2.1 Bill of Materials:

PART NO DESCRIPTION

QTY

(per compressor)

534M0602G06 JACK SHAFT KIT INCL SHAFT SEAL 1

534M0602G03 BEARINGS SET 1

534M0602G01 O-RING GASKETS 1

98A0012B91 O-RING SUCTION FILTER COVER 1

959A0057H09 GASKET DISCHARGE LINE 1

3921 5201 125 GASKET SUCTION LINE 2

OR43.69x3xNBR O-RING ECO SUCTION 1 OR23.47x2.95xNBR O-RING OIL PIPE 1

3952 6453 025 OIL FILTER CARTRIDGE 1

1331.175 O-RING COVER 2

1912 144-5 FILTER BAG 1

9479 0002 000 DISSECANT 1

1517.061 FILTER ELEMENT 1

534B102H01 ROD INDICATOR 1

534A0883H01 SPRING 1

1926 185-1 LINEAR TRANSMITTER CAPACITY 1

2417.232 POV 40D111 1

3.3 Description of Equipment/Systems

3.3.1 York Marine AB VSB 151 L

525-2

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None.

4.2 Government Furnished Material (GFM):

4.2.1 Oil for compressors

a. For TAKE 1 through 5: 160 liters of Stal/Sabroe K Oil, CPI Solest 180 per unit

b. For TAKE 6 and later: 160 liters of York H, CPI Solest 68 per unit

4.2.2 Heat Exchanger tubes:

PART NO DESCRIPTION QTY

(per compressor)

1916 893-1 Condenser Tube 33 per unit, 99 total 1914 630-2 Evaporator Tube 25 per unit, 75 total

4.3 Government Furnished Services (GFS): None.

4.4 Government Furnished Information (GFI): None.

5.0 NOTES:

tier, must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs.

5.2 The contractor and all subcontractors regardless of

tier are advised to review the other work items under this contract to determine their effect on the work required under this work item.

SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME

525-3

CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND

WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED

AND PROVEN OTHERWISE. TEST ALL ELECTRICAL CABLES TO ENSURE THEY

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Tag-Out all required systems and equipment. Drain and

dispose of any liquid in accordance with all federal, state, and local regulations.

7.2 Provide the services of the Original Equipment

Manufacturer (OEM) representatives identified in paragraph 7.19.

7.3 Move the refrigerant associated with each compressor

to be overhauled to an external receiver in accordance with reference 2.1 document number GB00532; “Service Instructions - General”

7.3.1 Save refrigerant for re-use using appropriate

gas cylinders.

7.4 Remove interferences and reinstall upon completion.

7.4.1 Each refrigeration compressor removal is

interfered by ventilation ductwork.

7.5 Remove each compressor to be overhauled.

7.6 Complete an overhaul of each compressor identified in

paragraph 3 using reference 2.1 for guidance.

7.6.1 Perform all compressor overhauls in a “Frick by

Johnson Controls” authorized shop. Effort is not to be completed onboard ship.

7.6.2 Overhaul of each compressor includes the

following for each:

a. Measure current clearances

b. Check internal wear and tear on Gear set, rotors, slide valve, housing

c. Submit report of conditions found

d. clean of all internal parts

525-4

e. Replace items listed in paragraph 3.2.1

f. Change the oil using “Service Instructions –

General”, Document number GB00532 as guidance (included in reference 2.1). Oil is provided as GFM per paragraph 4.2.1.

g. Clean the refrigerant Level Indicator

h. Replace safety valves

i. Replace pressure overflow valves

j. Check modulation and tightness of expansion valve

k. Replace Motor Bearings

l. Check clearances against factory standard

7.7 Reassemble each compressor identified in paragraph 3

using reference 2.1 for guidance

7.8 Install compressor back on unit.

7.9 Properly align compressor and motor using reference

2.1 as guidance.

7.10 Clean the evaporator using “Service Instructions –

Heat Exchangers”, Document number GB00172 as guidance (included in reference 2.1)

7.11 Clean the condenser using “Service Instructions – Heat

Exchangers”, Document number GB00172 as guidance (included in reference 2.1)

7.12 Clean the suction filter using “Service Instructions –

Suction Filter”, Document number GB00533 as guidance (included in reference 2.1)

7.13 Complete the requirements of reference 2.1 document

number GB00478 “Service Instructions - Heat Exchangers, Finding leaks” for each unit’s condenser and evaporator.

7.13.1 Submit report of conditions found

7.14 Verify the wall thickness of each tube in each

Condenser.

525-5

7.14.1 Either Ultrasonic Internal Rotating Inspection

or Eddy current tube inspection methods for determining wall tube wall thickness is required.

7.14.2 Submit report of findings within three days of

completion of each cooler. Each cooler is expected to be the subject of its own individual report.

7.15 Complete the requirements of reference 2.1 document

number GB00478 “Service Instructions - Heat Exchangers, Repairing Leaks” for each unit’s condenser and evaporator.

7.16 Inspection/Test:

7.16.1 All tests at overhaul facility are to be

witnessed by local area ABS surveyor, at contractor’s expense.

7.16.2 All tests and inspections, regardless of

location, are to be offered to MSCREP and ABS for witnessing.

7.16.3 Initial tests:

a. Check chiller unit for readiness

b. Pressure test at 8 bar. No leaks allowed

c. Vacuum test at < 700 microns. No leaks allowed

d. Verify operation of each compressors safety shutdowns and alarm monitoring system

7.16.4 Operationally test

7.17 Paint/Lagging:

7.17.1 Renew lagging where old lagging was removed.

Paint all new and disturbed surfaces to match surrounding surfaces.

7.18 Preparation of Drawings/Documents:

7.18.1 Provide a service report of maintenance actions

performed, measurements recorded, and future recommendations.

7.19 Manufacturer's Representative: Work included in this

item shall be completed by an authorized representative of Frick by Johnson Controls

8.0 GENERAL REQUIREMENTS: None additional.

Enclosure 3 Work Item (WI) 802 Air Conditioning Plant Compressor Overhaul (30KHRS)

HVAC

ITEM NO. 802 Category “A”

802-1

1.0 ABSTRACT

This item describes the requirement to perform the Original Equipment Manufacturer (OEM) recommended 30,000 hour AC plant compressor overhaul.

2.0 REFERENCES

2.1 Tech Manual T9516-BQ-MMC-01A, Technical Manual For

Refrigeration Plant, Air Conditioning For USNS Amelia Earhart (T-AKE 6) - Installation, Operation And Maintenance Instructions

2.2 Section GB90138A, Service Manual Rotary Screw

Compressors SGC 1913 through 2824

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: Auxiliary Machinery Room (5-58-01)

3.1.2 Quantity: XXX (X) AC Plant Compressor(s) - Air

Conditioning Plant No. X.

3.2 Item Description/Manufacturer’s Data

3.2.1 Liquid Chiller Unit, York Marine AB Model No.

VSM 2817E

3.2.2 Compressor, Frick (Johnson Controls) Rotary

Screw Compressor, Model No. SGC 2817 T-AKE, Weight 3,000 LBS

3.3 Bill of Materials (Contractor Furnished)

Description Part Number Quantity Overhauling Kit for SGC2817 AC Comp 534L0283C20 XXX Unloader Spring 534C1360H07 XXX Installation Gasket Kit SGC2817 IMI17000213 XXX

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

802-2

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM)

4.2.1 Refrigerant 404A, XXX Gallons

4.2.2 Solos 68 Oil, XXX Gallons

4.3 Government Furnished Services (GFS): None

5.0 NOTES

tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 7, 22, 23, 24, 28, and 29.

tier are advised to review other work items under this contract, including but not limited to Work Items 002, 022, 023, and XXX to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME

CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND

WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED

AND PROVEN OTHERWISE. TEST ALL ELECTICAL CABLES TO ENSURE THEY

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

802-3

7.0 STATEMENT OF WORK REQUIRED

7.1 With assistance from the crew, pump out refrigerant

and depressurize the AC Refrigeration Plant No. X using References 2.1 and 2.2 for guidance.

7.2 Tag-Out all required systems and equipment. Drain and

7.3 Provide the services of the Original Equipment

Manufacturer (OEM) representative(s) identified in paragraph 7.12.

7.4 Disconnect and remove #X plant AC compressor.

7.5 Temporarily install a hard blank with gasket and plug

all opening to prevent contamination from any outside sources.

7.6 Complete 30,000 hour overhaul of the compressor using

Reference 2.2 for guidance and the contractor furnished material identified in paragraph 3.3.

7.7 Perform and document a satisfactory shop test of

overhauled unit to prove compressor meets OEM operational test criteria.

7.8 Reinstall compressor, ensuring proper alignment to

both the motor coupling and piping attachments per the guidance provided in Reference 2.1.

7.9 Inspection/Test

7.9.1 Check unit for readiness. Verify proper

operation of the evaporator expansion valve (COV01). Perform field calibration as necessary using Reference 2.1 as guidance.

7.9.2 Perform operational test. Ensure the

refrigeration unit set points are properly set using References

2.1 and 2.2 as guidance.

7.9.3 Perform a Hot Alignment Measurement to ensure

802-4 proper alignment when in operation.

7.10 Reports

7.10.1 When inspection, service and testing reveal any

deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3)

7.10.2 Submit a report that includes “as released”

condition of the AC plant compressors. Submit three (3)

7.10.3 All reports and checklists are to be completed

and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.11 Painting/Lagging

7.11.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.11.2 Renew lagging where damaged or disturbed.

7.12 Manufacturer's Representative

7.12.1 Provide the services of an authorized OEM

representative to temporarily remove, inspect, refurbish, and test the A/C plant compressors.

7.13 Preparation of Drawings: None

8.0 GENERAL REQUIREMENTS: None additional

1.0 ABSTRACT

This item describes the requirement to perform the Original Equipment Manufacturer (OEM) recommended 30,000 hour AC plant compressor overhaul.

2.0 REFERENCES

2.1 Tech Manual T9516-BQ-MMC-01A, Technical Manual For Refrigeration Plant, Air Conditioning For USNS Amelia Earhart (T-AKE 6) - Installation, Operation And Maintenance Instructions

2.2 Section GB90138A, Service Manual Rotary Screw Compressors SGC 1913 through 2824

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: Auxiliary Machinery Room (5-58-01)

3.1.2 Quantity: XXX (X) AC Plant Compressor(s) - Air Conditioning Plant No. X.

3.2 Item Description/Manufacturer’s Data

3.2.1 Liquid Chiller Unit, York Marine AB Model No. VSM 2817E

3.2.2 Compressor, Frick (Johnson Controls) Rotary Screw Compressor, Model No. SGC 2817 T-AKE, Weight 3,000 LBS

3.3 Bill of Materials (Contractor Furnished)

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM)

4.2.1 Refrigerant 404A, XXX Gallons

4.2.2 Solos 68 Oil, XXX Gallons

4.3 Government Furnished Services (GFS): None

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tie...

5.2 The contractor and all subcontractors regardless of tier are advised to review other work items under this contract, including but not limited to Work Items 002, 022, 023, and XXX to determine their effect on the work required under this work item...

5.3 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHE...

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 With assistance from the crew, pump out refrigerant and depressurize the AC Refrigeration Plant No. X using References 2.1 and 2.2 for guidance.

7.2 Tag-Out all required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state, and local regulations.

7.3 Provide the services of the Original Equipment Manufacturer (OEM) representative(s) identified in paragraph 7.12.

7.4 Disconnect and remove #X plant AC compressor.

7.5 Temporarily install a hard blank with gasket and plug all opening to prevent contamination from any outside sources.

7.6 Complete 30,000 hour overhaul of the compressor using Reference 2.2 for guidance and the contractor furnished material identified in paragraph 3.3.

7.7 Perform and document a satisfactory shop test of overhauled unit to prove compressor meets OEM operational test criteria.

7.8 Reinstall compressor, ensuring proper alignment to both the motor coupling and piping attachments per the guidance provided in Reference 2.1.

7.9 Inspection/Test

7.9.1 Check unit for readiness. Verify proper operation of the evaporator expansion valve (COV01). Perform field calibration as necessary using Reference 2.1 as guidance.

7.9.2 Perform operational test. Ensure the refrigeration unit set points are properly set using References 2.1 and 2.2 as guidance.

7.9.3 Perform a Hot Alignment Measurement to ensure proper alignment when in operation.

7.10 Reports

7.10.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document For...

7.10.2 Submit a report that includes “as released” condition of the AC plant compressors. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF).

7.10.3 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.11 Painting/Lagging

7.11.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.11.2 Renew lagging where damaged or disturbed.

7.12 Manufacturer's Representative

7.12.1 Provide the services of an authorized OEM representative to temporarily remove, inspect, refurbish, and test the A/C plant compressors.

7.13 Preparation of Drawings: None

8.0 GENERAL REQUIREMENTS: None additional

Enclosure 4 Work Item (WI) 812 Cargo Reefer and AC Plants Expansion Joints

ITEM NO. 0812 CATEGORY "A"

0812 - 1

1.0 ABSTRACT:

1.1 This item describes the requirement to remove and

replace expansion joints on the Cargo Refrigeration and AC plants.

2.0 REFERENCES:

2.1 Tech Manual T9516-A8-MMC-010, Cargo Refrigeration

Plant Technical Manual

2.2 Tech Manual T9516-BB-MMC-010, AC Refrigeration Plant

Technical Manual

2.3 MSC Drawing 532- 8387110, Low Temperature Freshwater

Cooling System Diagram

2.4 MSC Drawing 516-8387086, Cargo Refrigeration Secondary

Coolant Circulating System Diagram

2.5 MSC Drawing 514- 8387126, AC Chilled Water System

Diagram

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location: Auxiliary Machinery Room (5-58-01)

3.1.2 Quantity: Three (3) Cargo Refrigeration Plants

and four (4) Air Conditioning Plants

a. Six (6) 150mm (6”) expansion joints

b. Six (6) 200mm (8”) expansion joints

c. Eight (8) 250mm (10”) expansion joints

d. Eight (8) 300mm (12”) expansion joints

3.2 Item Description/Manufacturer’s Data: Your

Refrigeration Plant Cargo and York Refrigeration Plan Air Conditioning

3.2.1 Bill of Materials (Contractor Furnished) CFM:

Quantity Description Part Number

50 sq ft Lagging Material N/A

5 Gal Lagging Paste N/A

Quantity Description Part Number

6 ea 150mm expansion joints JCI-EJ240C-

0812 - 2 w/Control unit NPITR DN 150

6 ea 200mm expansion joints w/Control unit

JCI-EJ240C-

NPITR DN 200

8 ea 250mm expansion joints

NPITR DN250

8 ea 300mm expansion joints

NPITR DN300

3.2.2 Quantities are considered estimates. The

Contractor shall provide the exact quantities and additional material such as miscellaneous pipe fittings, elbows, caps valves, pipe hangers, etc in order to install a fully functional system which meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM): None

5.0 NOTES:

tier, must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs.

tier are advised to review the other work items under this contract to determine their effect on the work required under this work item.

SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME

CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND

WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED

AND PROVEN OTHERWISE. TEST ALL ELECTICAL CABLES TO ENSURE THEY

0812 - 3

6.0 QUALITY ASSURANCE REQUIREMENTS: None.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Tag-Out all required systems and equipment. Drain and

7.2 Remove lagging at from around the expansion joints

where installed.

7.3 Isolate and drain system down to a point that

expansion joints can be removed.

7.4 Remove existing expansion joints on the Cargo

Refrigeration Units using references 2.3 and 2.4 and Air Conditioning units using references 2.3 and 2.5 for location and pipe sizes.

7.5 Retain existing fasteners for reuse. Ensure fasteners

are bagged and tagged so as to be replaced in the same piping flanges.

7.6 Install new expansion joints following instructions

provided in references 2.1 section SB00123A for Cargo Refrigeration Units and reference 2.2 section GB90032B for Air Conditioning Units. Use fasteners retained in paragraph 7.3

7.7 Align System valves and ensure that fluid levels are

at operational levels and system is ready for operation.

7.8 Preparation of Drawings/Documents: None.

7.9 Inspection/Testing:

7.9.1 Perform operational test at system pressure.

Inspect for leakage. No leakage is allowed. MSCREP to witness testing.

7.10 Painting/Lagging:

7.10.1 Reinstall lagging. Prime, paint and insulate

all new and disturbed areas to match the surrounding areas.

8.0 GENERAL REQUIREMENTS: None additional