Spec_rev_a 1.doc

REVISION No. A . CHANGE No. .

ATTACHMENT 1

378 WHEC, 270 WMEC & 210 WMEC

REFRIGERATION PLANT INSTALLATION PROJECT

ORGINATED BY CWO4 George Lausen DATE 9/1/09 ORIGINATOR’S COMMAND Engineering Logistics Center (ELC) .

DEPARTMENT / DIVISION Platform Division (011) .

INTERNAL REVIEWER . DATE .

SOWRB APPROVAL . DATE .

378 WHEC, 270 WMEC & 210 WMEC

REFRIGERATION PLANT INSTALLATION PROJECT

1.0 SCOPE

1.1. The 378 WHEC, 270 WMEC and 210 WMEC Cutters have obsolete refrigeration plants and the walk-in refrigeration storerooms are deteriorated to a condition that replacement is needed to meet Legacy asset life cycles for the next 15-20 years.

1.2. Classification

1.2.1. Types

a. (TYPE I) - TYPE I refrigeration plants shall be installed on the 378 WHEC Cutters, which consist of the following classes: the 378 FRAM-W, and 378 FRAM-E. See Appendix 1 for basic deck layout for 378 FRAM-W Cutters and basic deck layout for 378 FRAM-E Cutters.

b. (TYPE II) - TYPE II refrigeration plants shall be installed on the 270 WMEC Cutters, which consist of the following classes: the 270 “A” Class, and 270 “B” Class. See Appendix 1 for basic deck layout for 270 “A” and “B” Class Cutters.

c. (TYPE III) - TYPE III refrigeration plants shall be installed on the 210 WMEC Cutters, which consist of the following classes: the 210 “A” Class, and 210 “B” Class. See Appendix for basic deck layout for 210 “A” and “B” Class Cutters.

1.3. Government Furnished Property (GFP): TYPE I, II, III Reefer Condensing Units, TYPE I, II, III Unit Coolers, TYPE I PLC and Defrost Controls, TYPE I Modular Walk-In Refrigerated Boxes. Contractor shall provide all other necessary materials and equipment necessary to perform the install.

1.4. Government Furnished Information (GFI): See Appendix 1 for United States Coast Guard (USCG) Drawing List.

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 5.2

2.2. Government Documents – The following specification and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements therein.

2.2.1. Federal Specifications

a. QQ-B-654, Dated 1980, Brazing Alloys, Silver.

2.2.2. Military Specifications:

a. 1995 Edition of the General Specification for Ships of the United States Navy (Gen Specs), Section 305, Electrical and Electronic Designating and Marking

b. MIL-DTL-24643: General Specification for Low Smoke Electric Cables and Cords

2.2.3. Military Standards

a. MIL-STD-1399, Section 300A, Dated 1992, Interface Standard for Shipboard Systems Section 300A Electric Power, Alternating Current (Metric).

b. MIL-STD-777, Dated 2002, Schedule of Piping, Valves, Fittings and Associated Piping Components for Naval Surface Ships.

c. DOD-STD-2003, Electric Plant Installation Standard Methods for Surface Ships and Submarines.

2.3. Other Government Documents – The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.3.1. Handbooks

a. Naval Ships’ Technical Manual (NSTM), Chapter 635, Dated 7/98, Thermal, Fire and Acoustic Insulation.

b. NAVSEA Technical Publication, 0900-LP-001-7000 with Change 1, Dated 1/81 Fabrication and Inspection of Brazed Piping System.

2.3.2. United States Coast Guard (USCG) Instructions

a. COMDTINST M4500.5A, Dated 1998, Property Management Manual.

b. COMDTINST M9085.1B, Dated 2004, Naval Engineering Computer Aided Design Standards.

c. COMDTINST 9077.1C, Dated 1995, Equipment Tag Out Procedure.

d. COMDTINST M10360.3B, Dated 2001, Coatings and Color Manual.

e. Coast Guard YARD Safety Instruction

2.3.3. USCG Engineering Logistics Center (ELC) Specifications

a. D-083-0351, REV -, Dated 1/00, Data for Provisioning.

b. D-000-0100, REV E, Dated 7/96, Bar Coding for USCG ELC Material.

c. P-638-0499, REV -, Specification for Renewal of the 210’ WMEC Refrigeration Boxes.

2.3.4. Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specifications

a. 0000_STD, Dated 2004, General Requirements

b. 0740_STD, Dated 2004, Welding and Allied Processes

2.4. Commercial Documents – The Following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Index of specifications and Standards (DODISS)

2.4.1. American Society of Heating, Refrigeration and Air-Conditioning Engineers (ASHRAE)

a. ASHRAE 15-2004, Dated 2004, Safety Standard for Refrigeration Systems.

b. ASHRAE 26-1996, Dated 1996, Mechanical Refrigeration and Air-Conditioning Installations Aboard Ship.

2.4.2. American National Standards Institute (ANSI)

a. ANSI B16.24, Dated 2001, Cast Copper Alloy Pipe Flanges and Flanged Fittings: Class 150, 300, 400, 600, 900, 1500, and 2500

2.4.3. American Society of Mechanical Engineers (ASME)

a. ASME Code Section V2I, Dated 1998, Boiler and Pressure Vessel Code Section V2I Rules for Construction of Pressure Vessels Division 1.

2.4.4. American Society for Testing and Materials (ASTM)

a. ASTM B88-03, Dated 2003, Standard Specification for Seamless Copper Water Tube.

b. ASTM B280-03, Dated 2003, Standard Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service.

c. ASTM C1029-02, Dated 2002, Standard Specification for Spray-Applied Rigid Cellular Polyurethane Thermal Insulation.

d. ASTM C534-03, Dated 2003, Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form.

e. ASTM E797-95, Reapproved 2001, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method.

2.4.5. Code of Federal Regulations (CFR)

a. 46 CFR, Subchapter J, 2004 Edition

b. 46 CFR 113.45, 2004 Edition

c. 46 CFR 56.60-25(b)(2), 2004 Edition

d. 46 CFR 56.01-56.97-40, 2008 Edition

2.4.6. American Bureau of Shipping Rules

2.4.6.1 Steel Vessel Rules, Part 4, Chapter 4 (2004)

2.4.7. Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE-STD-45-2002, Recommended Practice for Electric Installations on Shipboard.

2.4.8. National Electrical Manufacturers Association (NEMA)

a. NEMA 250-2003, Enclosures for Electrical Equipment (1000 Volts Maximum)

b. NEMA ICS Series, Industrial Control and Systems.

c. NEMA MG 1-2003, Motors and Generators.

2.4.9. Underwriters Laboratories (UL)

a. UL 486A, Dated August 2006, Wire Connectors.

2.5. Specification Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3.0 REQUIREMENTS

3.1. General – The Contractor shall provide all labor and materials to fabricate, deliver, install equipment and test all contractor and government provided parts, materials and supplies for the new refrigeration system and walk-in boxes. The Contractor shall not request or be authorized to share any tools or equipment owned or rented by the government. The Contractor shall be responsible to remove and dispose of all existing refrigeration equipment including but not limited to the condensing units, walk-in refrigeration boxes (where required), unit coolers, electrical controllers, cabling, and piping and associated tubing in accordance with all applicable federal, state and local laws and ordnances and the Coast Guard Property Management Manual, COMDTINST M4500.5(series). The contractor will be required to install the government provided refrigeration equipment, unit coolers, PLC and Defrost Controls (TYPE I only). The contractor shall provide the PLC and Defrost Controls (TYPE II and TYPE III) and the serial cable necessary to upload and download the firmware and software for the PLC.

3.1.1 The contractor shall comply with all sections contained in 2.3.

3.1.2 Arrival Conference – The morning of the start of the performance period, ELC will conduct an arrival conference; generally in the wardroom of the Cutter that the installation will take place. Work shall not proceed prior to the arrival conference without the authority of the Contracting Officer (KO) or Contract Specialist (KS). The personnel required to be in attendance will be the KO or KS, Contracting Officers Technical Representative (COTR), Contractor’s Project Manager, representatives from every subcontractor, Cutter Engineer Officer (EO) or Ship Superintendent, Cutter Port Engineer, and Cutter Primary and Alternate Inspectors. The arrival conference may be completed via telephone conference call if all attendees are unavailable to travel to the Cutter’s location

3.1.3 Ship’s Force/ CG Yard Assistance – Contractor shall be aware that the Cutter/Yard work force may be completing maintenance and repair work in the area during the performance period of this contract. As best as possible the maintenance and repair work will be done on a “not to interfere” basis. During certain times of that work, disruptions may occur. In any case during these disruptions, the contractor should call the Contracting Officer’s Technical Representative (COTR) or Contract Specialist (KS) to notify them of the disruption. At which point, the government’s representative shall attempt to mitigate the disruption to the shortest period possible. Every attempt will be made to notify the contractor of planned disruptions due to ship/CG Yard evolutions that cannot be avoided

3.1.4 Hot work – Before starting hot work the Contractor shall open, ventilate, and clean all spaces and components necessary to accomplish this installation to certify them as "SAFE FOR PERSONNEL" and/or "SAFE FOR HOT WORK." The Contractor shall maintain the affected spaces in a certifiable condition for the duration of the project. The contractor shall provide all personnel necessary for fire watches and these shall be established in accordance with section 3.8.1.3 of Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0000_STD. The contractor shall provide, at their expense, all marine chemist and competent persons services necessary to certify and maintain certification of any space that hot work is required during the performance period. The contractor shall provide current and valid licenses/certificates of all personnel designated as the marine chemist and competent persons. The contractor shall provide ventilation during all hot work operations, sufficient to prevent smoke from entering any other areas of the vessel.

3.1.5 Kick-Pipes – Where kick pipes are necessary for installation, the Contractor shall install new kick pipes for cabling that is required. The kick pipes shall be welded in to the deck as defined in 2.3.4.2 and shall be made watertight after the insertion of the cabling. The means to make the kick pipes watertight shall be made using suitable potting compound or manufacturer provided packing.

3.1.6 Vibration Isolation – The contractor shall install a non-metallic hose with 316L stainless steel end fittings in accordance with SAE- J1975 and 2.4.5.3.

3.1.7 Progress Charting – The contractor shall provide the COTR and KS a Gantt chart that has been created on Microsoft Project 2003© for each installation with defined milestones no less than 2 weeks prior to the start of the performance period. The chart shall be formatted in a manner that has a print area that is legible on 8½” x 14” paper. In the event a particular milestone cannot be met in the defined time, a plan must be provided as soon as the delay is recognized along with an updated Gantt chart.

3.1.8 Housekeeping - The Contractor shall maintain good housekeeping conditions, clean up the job site, and dispose of scrap and waste in accordance with sections 3.13 through 3.14 of Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0000_STD. The Contractor shall provide a sufficient number of dumpsters at his expense, to handle the disposal of wastes generated during the installation.

3.1.9 Sanitary Facilities/Lavatories – The Contractor shall, at his expense, provide temporary toilets for all contractor and subcontractor employees. The use of shipboard facilities is not permitted.

3.1.10 Parking – Parking for Cutter crews and contractors is generally very limited. Parking onboard any facility that an installation is being completed will be arranged through the security office for the particular location.

3.1.11 Security – The Contractor shall provide an access list of all contractor and subcontractor employees on a single list; that are expected to work on each installation. The information contained on the list will be defined at a later date due to the varying requirements of each installation location.

3.1.12 Equipment Storage – The Contractor shall arrange all equipment stored at a designated location and at the work site.

3.1.13 Tag-Out - The Contractor shall secure and tag out all equipment affected by this work item, both electrically and mechanically, in accordance with COMDTINST 9077.1C and the vessel’s tag out procedure.

3.1.14 Preparation - Inspect all effected equipment and systems, including those subject to interference/removal, to document original condition. Submit a Condition Found Report to the COTR for each affected space and area noting any discrepancies in equipment and system operation. Any repairs needed as a result of inspection may be cause for a contract change and a proposal shall be submitted in accordance with the quick chit procedures or condition found report procedures.

3.1.15 Access Plan and Protective Deck Coverings - Develop a routing and access plan. Considerations shall include disruption of services and safety. Shipping access routes are the responsibility of the Contractor, but shall be coordinated with the Cutter Engineering Officer prior to accomplishment. The Contractor shall provide suitable protective deck covering material in accordance with section 3.12 of Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0000_STD over all Cutter interior passageways, work areas, and living spaces used to access the work sites on the Cutter.

3.1.16 Interferences - The Contractor shall, in accordance with section 3.10 of Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0000_STD, handle all interferences.

3.1.17 Disposal of Hazardous, Other Regulated Materials and Non-Hazardous Materials and Wastes: The Contractor is solely responsible for all costs, handling, storage and disposal of all hazardous, other regulated materials and non-hazardous materials in accordance with all applicable local, state and federal laws and regulations. The Contractor shall provided, at their expense sufficient dumpsters capable of storing such waste products while preventing the intermingling of the waste streams. The Contractor shall dispose of all waste streams at his own expense. Whether on site or off site, contractor shall be responsible for all handling, storage and disposition of hazardous waste, and other regulated materials and non-hazardous materials and waste according to all federal, state and local regulatory requirements generated on site.

3.1.18 Safety Equipment/Safety Postings – The contractor is responsible for the compliance with all applicable OSHA standards/regulations, including providing safety equipment necessary for its personnel. This includes but is not limited to hard hats, safety glasses, hearing protection and safety shoes. The contractor is responsible to identify and post all Department of Labor posters in a prominent area in all work areas occupied by contractor and subcontractor employees.

3.1.19 Tank Work – The Contractor shall be responsible for all work associated with hot work performed on a tank boundary and/or inside of a tank. This includes but is not limited to the following: draining, cleaning, gas free certification, painting, testing, inspection and returning the tank to original condition. Painting of tanks shall be in accordance with COMDTINST M10360.3B, appendix B.

3.1.20 Space Restoration – The contractor shall restore any disturbed areas in accordance with 2.3.4.a

3.1.21 Condition Found Reports (CFR) and Quick Chits (QC) - Often during the progress of work the contractor discovers conditions, which are considered abnormal for reasons of safety, expected reliability, health or habitability and growth work. These conditions must be brought to the attention of the Coast Guard using a CFR/QC. Details provided by the contractor in a CFR/QC are important because the CFR may result in a contract change. Contractor submits CFR with statement of condition/project found; recommended corrective action and indicates whether the estimate cost will exceed $2,500.00.

3.1.21.1 – Quick Chit (QC) Procedures:

a. For conditions estimated under $2500.00 a Quick Chit shall be submitted.

b. QC is submitted to the COTR and KS for review and approval.

c. Contractor does not need to sign, as a modification will be issued reflecting all QC at the end of the project.

d. Modifications will require contractor’s signature.

NOTE: The Quick Chit procedures can only be used if the cost does not exceed $2,500.00; does not extend the delivery date as required by the contract (even by one day) and no overtime is required. Only the Contracting Officer can authorize work beyond the $2,500.00 threshold; a delivery date extension and/or overtime.

3.1.21.2 – Condition Found Reports (CFR) Procedures:

a. For conditions estimated over $2500.00 a CFR shall be submitted.

b. CFR is submitted to the COTR and KS for review and approval.

c. Modifications will require contractor’s signature.

d. Contracting Officer’s Technical Representative (COTR) or his/her designated person will review the “Condition Found Report” (CFR) and advise when a decision is made. A copy of ALL Condition Found Reports shall be forwarded to the Cutter Engineer Officer for information purposes only and to retain in the Cutter’s machinery files.

e. To speed the contract change progress, the contractor should include in its CFR the following information and details as a minimum:

1. A sequential number

2. The contract item with the CFR related to

3. A clear statement, definition, and description of the condition found, including but not limited to labor and materials as appropriate.

4. A proposed or recommended corrective action for the defective condition

5. Indicated whether the report requires Coast Guard action, or if it is provided “for information” only. If action is required, indicate the response time required by the Coast Guard and whether or not a contract extension is needed if the additional work were authorized.

6. A space on the form for the Coast Guard representative to make comments.

7. All CFR’s shall be dated, submitted and signed by the Contractor’s Project Manager.

3.2. Ship Checks – The contractor shall complete, at their expense, ship checks of completed and non completed Cutters. The purpose of completing ship checks on completed cutters is to allow the contractor to create install sketches. This will ensure that all installations are completed identically.

3.3. Progress Meetings – The government will host weekly progress meetings onboard or at a designated location. The time and day for progress meetings will be mutually agreed upon at the arrival conference.

3.4. Personnel – All personnel shall be qualified as stated below:

3.4.1 – Project Manager – The designated project manager for any installation shall have documented experience of at least five (5) years in marine repair including refrigeration, pipefitting, steel fabrication, welding and electrical work. The contractor shall provide evidence of these qualifications prior to the acceptance of any project manager. Project manager shall not be changed without the prior authorization of the contracting officer.

3.4.2 – Refrigeration Technicians – Any refrigeration technician or helper employed to install, test, service or repair the installed systems shall be OEM trained. The contractor shall provide current certificates of the training for all technicians working with the Carrier systems. Additionally, any refrigeration technician or helper working on the refrigeration system shall be certified and shall present a copy of the EPA issue certificate and card.

3.4.3 – Other Trades – Any other technician, welder, and pipe fitter shall be qualified by the industry they are employed for. Copies of any certificates, license or diploma shall be provided prior to the start of any work.

3.5. Materials – All materials used in the fabrication and installation of the refrigeration systems shall be designed for use on ships in the marine environment as specified in the 2.4.5 a - d and elsewhere in this specification. The materials of construction for piping, fittings and valves shall be in accordance with MIL-STD-777. The Coast Guard permits the use of commercial valves and fittings as long as they are designed for use on ships in the marine environment.

3.6. Welding & Allied Processes – The contractor shall conform to all parts contained in 2.3.4 b.

3.7. Refrigeration Plants (TYPE I, TYPE II, and TYPE III) - The materials used for the installation of the refrigeration plants shall be manufactured from marine grade materials, suitable for marine shipboard service. The plants shall be built in accordance with ASHRAE Standard 26-1996. If this document is in conflict with ASHRAE Standard 26-1996 this document shall take precedence. One purpose of this specification shall be providing commonality across different classes of Cutters. The Contractor shall supply the same components to the maximum extent possible on the different “TYPE” refrigeration plants. All stop valves / isolation valves / shutoff valves shall be refrigeration type ball valves with brazed end connections. All refrigerant piping shall have brazed joints except as noted herein. The refrigerant shall be HFC-134a; no substitution shall be accepted.

3.7.1. General Electrical Requirements (TYPE I, TYPE I and TYPE III) – As a minimum, the refrigeration plants shall meet the following:

a. Single point electrical power connection with terminal block. This shall include power for the control circuit.

b. Control points shall be accessed through the terminal block. Separate terminal blocks are to be provided for different functions and voltage levels (i.e. power, control, 440 volts, 120 volts). Wire and cable connections for power and control within controllers and junction boxes shall be connected to devices or terminal blocks by means of compression/crimp type loop terminal lugs. Manual twist on connectors (wire nuts) is prohibited. These connections shall be in accordance with UL 486A. Terminal blocks for external connections shall be located where they are easily accessible for cable routing and connection.

c. The Contractor electrical components shall operate on electrical power, which on board USCG Cutters is derived from a 450 VAC, 3 phase, ungrounded system.

d. All electrical and electronic equipment shall be capable of operating on Type-1 power in accordance with MIL-STD-1399, Section 300a.

e. The contractor shall replace all internal components of the multi-cable transits (MCT) in all watertight bulkheads. The contractor shall ensure that upon completion of repair of the MCT’s they will maintain watertight integrity. The steel sleeve shall be restored and painted in accordance with 2.3.2.a

3.7.2. Electrical Controls (TYPE I, TYPE II and TYPE III) - Electrical controls shall be in accordance with the requirements contained in IEEE-STD-45 and 46CFR Subchapter J. All control power shall be 120 VAC, single phase. Any controller for a motor rated at 20 HP or greater shall have reduced voltage start. The electrical controls shall utilize a Contractor Furnished Programmable Logic Controller (PLC) for Type II and III (GFE for TYPE I only) and Defrost Control Panel (GFE for TYPE I only) for the purpose of operating the refrigeration system in all modes of operation and sequences of operation. The contractor shall write the software in accordance with the sequence of operations as provided by the government. Upon completion the successful testing of the software, the contractor shall provide a hard copy of the Logic Diagram and an electronic copy on CD of the software for the TYPE II and TYPE III. Upon completion of each installation, the contractor shall provide all necessary software to download codes to programmable devices to each Cutter crew. In addition all software shall utilize Logic Diagram as programming tools as much as possible. The Contractor shall deliver to the Cutter, the serial cable necessary for the uploading and downloading software and firmware. At the delivery of the CD and cable, the contractor shall obtain a signature from the Engineer Officer or his/her designated representative. The Contractor shall forward a legible copy of the signed receipt to the Contract Specialist.

3.7.3. Enclosures/ Bulkhead Penetrations (TYPE I, TYPE II and TYPE III) - Electrical enclosures for wiring, controls and components shall be NEMA 250 Type 12 with a drip shield as a minimum. All cable penetrations shall be via steel or nylon stuffing tubes. Romex connectors are prohibited. Multi cable entrance via a single connector is prohibited. To the maximum extent possible all entries will be from the enclosure bottom.

3.7.4. Wiring (TYPE I, TYPE II and TYPE III) – The Contractor shall provide all wiring and cabling necessary to complete the installation. Wiring shall meet 2.2.2. and be in accordance with the requirements contained in IEEE-STD-45, 46CFR Subchapter J and NEMA ICS Series. Wiring harnesses shall be clamped so as to minimize chaffing and shall be positioned so as not to interfere with operation, maintenance and servicing of the compressor unit. Cable installation shall be in accordance with DOD-STD-2003.

3.7.5. Junction boxes (TYPE I, TYPE II and TYPE III) - Junction boxes shall be NEMA 250 type 4X. Junction boxes with pre-punched perforated holes shall be prohibited. Junction boxes shall be provided with terminal blocks for wiring connections. Wire and cable connections for power and control within controllers and junction boxes shall be connected to devices or terminal blocks by means of compression/crimp loop type terminal lugs. These connections shall be in accordance with UL 486A.

3.7.6. Thermal Expansion Valve (TYPE I, TYPE II and TYPE III) – Each unit cooler refrigerant circuit shall have a thermal expansion valve installed. The power head shall be replaceable and adjustable. Valve shall have brazed type connections. The thermal expansion valve shall be installed within the unit cooler casing and be accessible for servicing.

3.7.7. Control Liquid Line Solenoid Valve (TYPE I, TYPE II and TYPE III) – Each unit cooler shall have a control liquid solenoid valve with brazed type connections installed upstream of the Thermal Expansion Valve. The solenoid valve shall be normally closed and have an interchangeable coil, 115 VAC, 1 phase, 60 hertz. Temperature within a refrigerated space is controlled by a thermostat that actuates the control solenoid valve in the refrigerant line to start and stop the flow of refrigerant as required. Solenoid valves shall be provided with manual operators for opening the valves in case of electrical coil failure.

3.7.8. Combination Sight Flow – Moisture Indicators (TYPE I, TYPE II and TYPE III) – Each refrigerant circuit shall have a combination sight flow - moisture indicator installed. The contractor shall use Sporlan Model SA14S.

3.7.9. Suction Pressure Regulating Valves (Evaporator Pressure Regulating Valve) (TYPE I, TYPE II and TYPE III) – Suction pressure regulating valves shall be provided, where it is necessary to maintain a minimum evaporating pressure or a relatively higher temperature than is required for other coils on the same circuit. The contractor shall use Henry Valve Model G-15.

3.7.10. Dehydrators (TYPE I, TYPE II and TYPE III) – Each refrigerant circuit shall have a serviceable replaceable core type dehydrator installed with isolation valves. Each with a minimum capacity equivalent to the compressor rating. Dehydrators shall be equipped with auxiliary screens or other protective means at the outlet to prevent passage of desiccant. Installation shall also include a valve for draining, purging and charging of dehydrators. Dehydrators shall be installed upstream of main liquid line solenoid valves. Dehydrators shall have brazed type connections. The contractor shall install Sporlan Model C-R424.

3.7.11. Strainers (TYPE I, TYPE II and TYPE III) – Strainers shall be provided in refrigerant circuits where necessary to protect components, such as controls, from dirt and other contaminants. Strainers shall be of the angle type arranged to permit replacement of strainer baskets without the necessity to cut refrigeration lines or undoing of brazed connections. Strainers shall be designed to retain dirt on the inside of the screen basket. Screens shall be 100 mesh for liquid line applications and 50 mesh for suction line applications. Strainers shall protect all thermal expansion valves and their associated solenoid valves.

3.7.12. Refrigerant Leak Detector (TYPE I, TYPE II and TYPE III) – The contractor shall install the government furnished MSA Chillgard refrigerant leak detector in accordance with the manufacturer’s installation guide. The contractor shall utilize the OEM or an authorized manufacturer’s representative to test and calibrate the unit after installation. Upon completion of installation the representative shall train the Cutter crew on the operation, maintenance, troubleshooting and calibration of the leak detector. The contractor shall provide the Cutter with a new calibration kit.

3.7.13. Gauges, Thermometers and Test Connections (TYPE I, TYPE II and TYPE III)

a. Each condenser shall have a seawater inlet test connection and seawater outlet gauge and associated test connection installed. Test connections shall include shut off valves for each so that a Coast Guard supplied gauge can be connected to the unit while the unit is operating.

b. All gauges shall have the following characteristics:

1. Gauge movements shall be bonze or stainless steel. Bourdon tube and socket material shall be phosphor bronze/brass or stainless steel except for seawater service, which shall be K Monel.

2. Gauges shall be accurate to +/- 0.5 per cent.

3. Scale readings shall be chosen so that the normal operating range is in the middle one-third of full-scale reading. Scales shall cover an arc of not less than 270 degrees on the dial.

4. Figure intervals shall be on the order of five percent to ten percent of the full-scale reading. Smallest scale graduations shall be on the order of one percent to three percent of the full-scale reading.

5. Dial sizes shall range from 3 -inch to 5-inch diameter, inclusive.

6. Dials shall be metal with painted white background permanently marked with black graduations, figures and letters.

7. Lenses shall be of shatterproof glass or clear acrylic plastic.

8. Gauge cases shall be painted steel or stainless steel and provide a weatherproof and dustproof enclosure for movements.

9. Units of measurement for pressure gauges shall be pounds per square inch gauge (psig) and/or inches HG.

10. Connections on gauges shall be of the threaded or flanged type. Tapered threads shall not be used.

11. All gauges shall be fitted with snubbers or pulsation dampeners to reduce needle fluctuations.

12. Gauges shall be provided with a jam nut, union or other connection arrangement to facilitate installation of the gauges so that their removal and reinstallation does not cause misalignment in their orientation on gauge boards.

c. Each condenser shall have a seawater inlet and seawater outlet thermometer installed.

1. Thermometers shall be bi-metal type with angularly adjustable frame.

2. Thermometers shall be accurate to +/- 1.0 per cent.

3. Scale readings shall be chosen so that the normal operating range is in the middle one-third of full-scale reading. Scales shall cover an arc of not less than 270 degrees on the dial.

4. Dial sizes shall range from 3 -inch to 5-inch diameter, inclusive.

5. Dials shall be metal with painted white background permanently marked with black graduations, figures and letters.

6. Lenses shall be of shatterproof glass or clear acrylic plastic.

7. Brass “dry type” thermowells shall be provided.

8. Units of measurement for thermometers shall be degrees Fahrenheit.

9. Connections on thermometers shall be of the threaded. Tapered threads shall not be used.

3.7.14. Relief Valve (TYPE I, TYPE II and TYPE III) – Each refrigerant circuit shall have a relief valve installed. The valve shall relieve the high-pressure side to the atmosphere. Setup shall be emergency refrigerant discharge thru the high-pressure rupture disc, then the relief valve and then thru the low-pressure rupture disc.

3.7.15. High Pressure Rupture Disc (TYPE I, TYPE II and TYPE III) – Each refrigerant circuit shall have a rupture disc installed, for emergency discharge of the refrigerant charge. This rupture disc shall be installed upstream of the relief valve. The rupture disc shall be a non-fragmenting type. The rupture disc assembly shall come complete with a gauge to determine if the disc has ruptured. The rupture disc shall be set to rupture at the same pressure as the relief valve.

3.7.16. Low Pressure Rupture Disc (TYPE I, TYPE II and TYPE III) – Each refrigerant circuit shall be collected into a single manifold in such a manner that in the event of a refrigerant discharge a back pressure will not be created. The outlet of the relief manifold shall have a 15 PSI rupture disc installed. The purpose of this rupture disc is to protect the relief valve from seawater resting on the relief valve seat. The discharge side of the rupture disc shall be vented to the atmosphere via the weather deck. Any installation that reutilizes the existing auxiliary seawater overboard will not be accepted.

3.7.17. Sea Water Regulating Valve (TYPE I, TYPE II and TYPE III) – Each condenser shall have a two-way seawater-regulating valve supplied, to provide correct seawater flow thru the condenser with seawater temperature range of 28 degrees F to 90 degrees F. Valve construction shall be bronze body and monel trim. A capillary tube shall be provided. Valve shall be rated for seawater service. The Contractor shall include cutout valves on both sides of the regulating valve and a by pass with a cutout valve installed. The Contractor shall provide and install Metrix Valve Model DA-868P-50-SEM.

3.8. Miscellaneous (TYPE I, TYPE II and TYPE III) - Original Equipment Manufacturers’ (OEM) label plates and other identification supplied on the equipment shall not be removed, erased or otherwise destroyed from the equipment.

3.9. Unit Coolers (TYPE I, TYPE II and TYPE III) – The fan motors and all unit cooler controls shall meet the general electrical requirements specified in 3.7.1 thru 3.7.5. Fan motors shall be suitable for minus 20 degrees F air temperature, high efficiency type suitable for 440 volt, 60 Hz, 3 phase or 1 phase power. Cooling coils shall include automatic electric defrost, suitable for 440 volt, 60 Hz, 3 phase or single phase power. The PLC shall automatically control the defrost cycles for all unit coolers. The controls for the electric defrost shall be designed for 120 VAC, single-phase power. The defrosting cycle shall be run time initiated and temperature terminated with a time termination backup to prevent heaters from overheating. Each coil shall have its own separate defrost timer. The defrost cycle shall be initiated automatically or manually. In the automatic mode, defrost is initiated by the timer which clocks the run time of the refrigerant solenoid, or cooling cycle and initiates defrost. In the manual mode, defrost is initiated by a pushbutton switch. When defrost is initiated, the fan shall automatically shut down and restart when the coil reaches its operating temperature upon the conclusion of the defrost cycle. A high temperature safety switch shall be provided which will terminate the defrost cycle, energize the solenoid valve and prevent the cooling coil fan(s) from starting until the coil has returned to its operating temperature. All electrical controls, and indicating lights for each coil shall be contained in a single control box located outside the refrigerated space. The controls, relays and indicator lights shall be designed for 120 VAC, single-phase power. Lights shall be provided indicating defrost (green), defrost trouble (amber), heater failure (red), defrost inhibited (blue) and power on (white). The design of the heating elements and controls shall be such that they can be easily removed and replaced. In addition to indication lights, normally open (N.O.) isolated contacts rated at least 2 Amp AC shall be provided for following conditions: defrost, defrost failure, defrost inhibited and power on. In addition to the refrigerant connections, all electrical and drain connections shall be arranged for easy removal of the cooling coil for maintenance or replacement.

3.9.1. (TYPE I and TYPE II) – The Contractor shall install suitable drain piping from the pan to a commercial available condensate pump outside each refrigerated space to conduct the condensate from each drain pan. The drain pan and drain piping in the freeze spaces shall have 110-volt self‑regulating type electric heating cable. The heating cable shall be energized by the defrost control at the same time as the coil defrost heaters to prevent freezing of the condensate from the drain pans. The electric heating cable shall operate for a sufficient period of time to permit all collected ice and water to completely drain from the piping system. The unit cooler drain pan and drain piping shall be capable of draining under the following environmental requirements:

a. Dynamic Conditions – A roll of 60 degrees (double amplitude) in 9.5 seconds, a pitch of 6 degrees (double amplitude) in 6 seconds and a heave of 4 feet (double amplitude) in 11 seconds.

b. Static Conditions - A 15-degree list (either side) and a 5-degree trim (by bow or stern).

3.9.2. (TYPE III) - The Contractor shall install suitable drain piping from the pan to outside the space to conduct the condensate from each drain pan. The condensate drains shall have a trap external of the space and tie into the existing drainage system, see Drawing 618WMEC-516-002 and 627WMEC-516-002. The drain pan and drain piping in the freeze spaces shall have 110-volt self‑regulating type electric heating cable. The heating cable shall be energized by the defrost control at the same time as the coil defrost heaters to prevent freezing of the condensate from the drain pans. The electric heating cable shall operate for a sufficient period of time to permit all collected ice and water to completely drain from the piping system. The unit cooler drain pan and drain piping shall be capable of draining under the following environmental requirements:

a. Dynamic Conditions – A roll of 60 degrees (double amplitude) in 9.5 seconds, a pitch of 6 degrees (double amplitude) in 6 seconds and a heave of 4 feet (double amplitude) in 11 seconds.

b. Static Conditions - A 15-degree list (either side) and a 5-degree trim (by bow or stern).

3.10. Refrigeration Box Replacement/Reutilization – The refrigeration boxes: Freeze Box, Chill Box and Thaw Box (where applicable) may be replaced. The refrigeration boxes shall be removed without cutting a hole in the Cutter shell or deck.

3.10.1 The existing chill box and freeze box (378 FRAM-W only) shall be removed and new government furnished modular boxes shall be installed. Where the possibility exists for conditioned air to escape from the newly installed box or where floor, wall or ceiling panels are not locked to an adjacent panel; the contractor shall fill all gaps, voids, notches or fissures with 2.2#/ cubic foot spray-in polyurethane foam. The deck area beneath the refrigerated spaces and refrigeration condensing units (all Cutter classes) shall be prepared and coated in accordance with COMDTINST M10360.3B, appendix B for “Bilges, Cofferdams and Forepeaks, Steel” Option I. After surface preparation perform a total of 25 thickness measurements for each area of the prepared deck surfaces in accordance with ASTM E797. Submit a Condition Found Report to the COTR (Contracting Officer Technical Representative). The report shall include the following information for each test point: “Original metal thickness” and “percent deterioration. Based on the report the COTR will determine if structural work is required. The Contractor may be required to replace up to 20 square feet of tank top plating/deck plating, and 20 linear feet of framing. The plate/structural members shall be of the same material type and thickness as the original Cutter structure.

a. New contractor supplied resistive temperature devices (RTD) Omega Model RTD-805 shall be installed in each refrigerated space TYPE I, TYPE II and TYPE III (chill box. freeze box and thaw box). The RTD shall be electrically connected to the PLC to operate the control liquid line solenoid valve for that space. RTD bulbs shall be located and protected similar to thermometer bulbs. The RTD bulbs shall not be placed in the airflow of the evaporator fan. NOTE: The 270 “A” and “B” Class installation shall require two RTDs in each refrigerated space, one RTD for each unit cooler. The RTDs shall be protected from damage using a contractor provided protective cage that allows free movement of air so not to interfere with the normal operation of the sensed walk-in box.

b. The contractor shall provide new electrical cable per 3.7.4, and main circuit breaker for the system.

c. Government furnished new lighting fixture(s) shall be installed using new wiring per 3.7.4.

d. The Contractor shall install new shelving similar in style to the removed shelving. The Contractor shall provide an equal amount of shelving storage that was available to the Cutter prior to the installation of the refrigeration system. The shelving system shall be of equal or greater quality of the existing shelving.

e. The Contractor shall provide and install new fiberglass pultruded vinyl ester composite fire-retardant resin grating system with a minimum tensile strength of 35,000 psi in the longitudinal direction and a minimum tensile strength of 10,000 psi in the transverse direction. The contractor shall measure and fit each floor grating system in the chill box, freeze box and thaw box (as appropriate) in such a manner the grating spans each box from wall to wall in both directions. Once installed the grating system shall not shift more than 1 inch in any direction. The door swing of any interior walk-in box shall not be inhibited by the installation of the grating system. The contractor shall ensure the doors operate normally to the satisfaction of the government. The grating system shall be installed in such a manner that it can be easily removed for cleaning and installed by any 2 members of the crew.

f. The refrigerated space alarms, for signaling trapped personnel in the refrigerated space, will be government supplied and contractor installed in accordance with 46 CFR 113.45.

3.10.2. 378 FRAM-W Class Cutter –

3.10.2.1 Lead Based Paint (LBP) – On previous installations, the ELC has encountered LBP. The contractor shall test for LBP no more than 7 days prior to the beginning of the performance to determine if LBP is present. The only acceptable test is a paint chip test. The results shall be from a certified laboratory. No other test method shall be accepted. The contractor shall obtain one sample from no less than three different locations to determine the lead concentration contained inside the refrigerated box envelope. In the event that LBP is detected and is determined a regulated concentration (0.05 micrograms/cubic meter); the contractor shall remediate the LBP in accordance with all local, state and federal environmental laws and regulations. The only accepted means of LBP removal shall be water hydro-blasting. A copy of all laboratory test results shall be e-mailed to the COTR and KS within 1 one day of testing.

3.10.2.2 The removal of the existing refrigeration walk-in boxes will require the contractor to remove a flat bar stock framing from atop the potable water tank and along an inaccessible wing void on the starboard side of the Cutter. The contractor is also required to remove the existing foam insulation from the wing void space to inspect for water. Upon completion of the inspection, the contactor shall replace all removed foam with 2.2# per cubic feet spray-in low expansion polyurethane foam with a closed system applicator. To create a subfloor for the new modular boxes, the contractor shall use a self-leveling terrazzo type underlayment.

3.10.3. 270 “A” Class and 270 “B” Class Cutters –

a. A new Resistance Temperature Detector (RTD) Omega Model RTD-805 shall be installed in each refrigerated space (chill box and freeze box) to measure temperature remotely. The RTD shall be 100 ohm, 3-wire configuration, platinum, wall mounted.

b. 270 “A” and “B” Class Only - The refrigerant piping from the JP-5 Pump Room (4-186-0-J) shall penetrate Bulkhead 186 into the Refrigerated and Dry Stores Space (4-169-0-A) in lieu of running directly thru Bulkhead 186 into the reefer boxes. If the Cutter currently has refrigerant line penetrations running directly from the JP-5 Pump Room into the reefer boxes the piping and penetrations shall be removed and Bulkhead 186 repaired by cropping and inserting a new welded patch where all previous penetrations exist. The patches shall be tested using a dye penetrant test. The contractor shall repair where the stainless steel sheathing and insulation have been disturbed in the reefer boxes. The new penetrations shall be installed with bulkhead sleeves similar to the type used for installing IPS tubing/pipe.

3.10.4. 210 “A” Class and 210 “B” Class Cutters –

a. Polychlorinated Biphenyl’s (PCB) – A potential exists that insulating tape may contain PCB’s. This tape has been found during earlier installations but not on every Cutter. If a question should arise to the composition of the insulating tape on pipe hangers where the tape has been previous found; the project manager shall notify the COTR or KS immediately. The CG Yard shall identify and remove any tape that contains PCB’s. Any stop work as a result will not automatically qualify as a delay or disruption and may not be considered for compensation.

b. As an option the Coast Guard can request the 210 Chill Box, Freeze Box and Thaw Box be renewed by the stick built method in lieu of the Modular type units. If this option is selected by the Coast Guard the boxes shall be renewed in accordance with Specification P-638-0499, paragraph 2.3.3.c.

3.10.5. Manual (TYPE 1, TYPE II and TYPE III) – A copy of the approved manual in either hard copy or electronic format, will be provided to the contractor for review and to assist in system arrangement and final adjustment of set points.

3.11. Installation Specification/ Test Procedures (TYPE 1, TYPE II and TYPE II) – The Contractor shall be provided a copy of the installation specification and test procedure for each refrigeration system installed. The contractor shall not amend the specification or test procedure without written authority from the government. The installation specification and test procedure shall be on-site at all times while the installation is occurring. Any deviation from either document may result in correction of a discrepancy at the contractor’s expense.

3.12. Training (TYPE I, TYPE II and TYPE III) – The Contractor shall provide on-site training for Coast Guard personnel upon completion of the installation of the refrigeration plants on each Cutter. As a minimum, training shall consist of startup of unit, normal operating procedures, preventative and corrective maintenance and troubleshooting systems. The Contractor shall provide a syllabus with frequently asked questions, and shall include the aforementioned items as well as instruction on the function, operation, uploading and downloading software and troubleshooting of the PLC and control systems.

3.13. Installation (TYPE I, TYPE II and TYPE III) – The Contractor shall provide the following services:

3.13.1. The Coast Guard shall provide the Contractor with 30-day notice to provide on site removal and installation services for each refrigeration system installed. The Contractor shall be capable of performing multiple services at multiple locations at the same time. The contractor shall be capable of performing a minimum of two simultaneous installations either at the same homeport or at two different locations during the same performance period.

3.13.2. The Contractor shall provide the service at the Coast Guard Cutter’s Homeport or other designated location as selected by the Coast Guard, including Coast Guard Yard, Baltimore, MD. The Contractor shall provide crane service and/or rigging service at all sites other than Coast Guard Yard and will be required to provide a credit for the services provided by CG Yard, including but not limited to crane services, rigging services, painting, welding, and pipefitting. The Contractor shall notify the COTR and/or the KS at least 1 business day in advance of the need for CG Yard services. Appendix 1 provides information on the class and quantity of Cutters at each location. The Contractor should understand that during the implementation of this contract homeport locations of Coast Guard vessels could change.

3.13.3. The Contractor shall provide and maintain temporary chill and freeze boxes for the entire length of the installation on the Cutter.