WI_14_(225)__WI_30_(EAGLE)_Reefer_Procurement_Specification_Rev2.pdf

REVISION NO. 0 . CHANGE NO. - .

225 WLB MMA & WIX 327 EAGLE SLEP

PROCUREMENT SPECIFICATION

REFRIGERATION PLANT

ORGINATED BY: Jim Calvert DATE: 2/17/2014

ORIGINATOR’S COMMAND: Coast Guard YARD

DEPARTMENT / DIVISION: Engineering - Machinery Branch

ISVS REVIEWER: Andrew Dize DATE: 7/2/2014

USCG SFLC – Refrigeration Plant

REVISION: 0

Contents

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Standards, Military

2.1.2 Specifications, Military

2.2 Other Government Documents

2.2.1 Code of Federal Regulations (CFR)

2.2.2 USCG Surface Forces Logistics Center (SFLC) Drawings

2.2.3 USCG Surface Forces Logistics Center (SFLC) Documents

2.3 Commercial Documents

2.3.1 American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)

2.3.2 American Society of Mechanical Engineers (ASME)

2.3.3 American Society for Quality Control (ASQC)

2.3.4 American Society of Testing and Materials (ASTM)

2.3.5 Institute of Electrical and Electronic Engineers (IEEE)

2.3.6 International Electrotechnical Commission (IEC)

2.3.7 National Electrical Manufacturers Association (NEMA)

2.3.8 Society of Naval Architects and Marine Engineers (SNAME)

2.3.9 Underwriter’s Laboratory (UL)

2.4 Order of Precedence

3.0 REQUIREMENTS

3.1 225’ WLB System Performance and General Requirements

3.1.1 Refrigeration Plants

3.1.2 Modular Construction

3.2 225’ WLB System Specific Requirements

3.2.1 Compressors

3.2.2 Compressor Crankcase Oil Heater

3.2.3 Electrical Requirements

3.2.4 Electrical Controls Requirements

3.2.5 Condensers

3.2.6 Receivers

3.2.7 Thermal Expansion Valve

3.2.8 Main Liquid Line Solenoid Valve

3.2.9 Control Liquid Line Solenoid Valve

3.2.10 Moisture Indicators

3.2.11 Sight Flow Indicators

3.2.12 Suction Pressure Regulating Valve

3.2.13 Dehydrators

3.2.14 Strainers

3.2.15 Oil Separators

3.2.16 Suction Line Accumulators

3.2.17 Heat Interchanger

3.2.18 Gauge, Thermometers and Test Connections

3.2.19 Relief Valve

3.2.20 High Pressure Rupture Disc

3.2.21 Low Pressure Rupture Disc

3.2.22 Sea Water Regulating Valve

3.2.23 Charging Valve

3.2.24 Safeties

3.2.25 Environmental Requirements

3.2.26 Miscellaneous

3.2.27 Unit Coolers

3.2.28 Defrost Control Panel

3.2.29 Cabling and Wiring

3.2.30 Identification and Labeling

3.3 WIX 327 EAGLE System Performance and General Requirements

3.3.1 Refrigeration Plants

3.3.2 Modular Construction

3.4 WIX 327 EAGLE System Specific Requirements

3.4.1 Compressors

3.4.2 Compressor Crankcase Oil Heater

3.4.3 Electrical Requirements

3.4.4 Electrical Controls Requirements

3.4.5 Condensers

3.4.6 Receivers

3.4.7 Thermal Expansion Valve

3.4.8 Main Liquid Line Solenoid Valve

3.4.9 Control Liquid Line Solenoid Valve

3.4.10 Moisture Indicators

3.4.11 Sight Flow Indicators

3.4.12 Suction Pressure Regulating Valve

3.4.13 Dehydrators

3.4.14 Strainers

3.4.15 Oil Separators

3.4.16 Suction Line Accumulators

3.4.17 Heat Interchanger

3.4.18 Gauge, Thermometers and Test Connections

3.4.19 Relief Valve

3.4.20 High Pressure Rupture Disc

3.4.21 Low Pressure Rupture Disc

3.4.22 Sea Water Regulating Valve

3.4.23 Charging Valve

3.4.24 Safeties

3.4.25 Environmental Requirements

3.4.26 Miscellaneous

3.4.27 Unit Coolers

3.4.28 Defrost Control Panel

3.4.29 Cabling and Wiring

3.4.30 Identification and Labeling

3.5 Data Requirements

3.5.1 Technical Data (TD)

3.5.2 Data for Provisioning (DFP)

3.5.3 Data Submission Format

3.6 Technical Support

3.6.1 Training

3.6.2 Field Services – Installation and Testing Assistance

3.7 Onboard Repair Parts Kit

3.8 System Stock Parts

3.9 Deviation from Specification

3.10 Provisioning Quality Control

3.11 Provisioning Conferences

3.12 Tests, Inspections, and Reports

3.12.1 First Article Testing (FAT)

3.12.2 Factory Testing (FT)

3.12.3 Shipboard Test Plan

3.13 Workmanship

4.0 QUALITY ASSURANCE

4.1 General

4.2 Records

4.3 Calibration System

4.4 Quality Assurance Plan

4.5 Tests and Inspections

4.6 Responsibility for Tests and Inspections

4.7 Responsibility for Compliance

4.8 Failure Responsibility

4.8.1 Test Failure

4.8.2 Corrective Action Remedies

4.9 Test and Inspection Reports

5.0 PRESERVATION, PACKING, AND MARKING

6.0 NOTES

6.1 Potential Sources

6.2 Government and Commercial Document Sources

6.2.1 Government Documents

6.2.2 Commercial Documents

1.0 SCOPE

This specification describes the requirements for the procurement of a new Refrigeration Plant

System, technical documentation and supporting equipment for each of the 225’ WLB Class

Cutters (9 shipsets) and the WIX 327 EAGLE (1 shipset). This specification DOES NOT include installation of the equipment by the Vendor, but DOES include on-site technical support by the

Vendor to ensure that the equipment is installed and functions correctly.

Component, documentation, and technical support items covered under this Procurement

Specification are as follows:

a. 225’ WLB and WIX 327 Refrigeration Plant System Assemblies

b. Technical Data (TD)

c. Data for Provisioning (DFP)

d. Technical Support

e. Onboard Repair Parts Kit

f. System Stock Parts

2.0 APPLICABLE DOCUMENTS

The following documents form a part of this Specification to the extent specified herein. The documents listed are by title and effective date, unless otherwise documented. Commercial documents may be listed in the Department of Defense Index of Specifications and Standards

(DODISS). To obtain the referenced documents, see Section 6.2.

2.1 Government Documents

2.1.1 Standards, Military

a. MIL-STD-1399, Section 300B, Dated 2008, Interface Standard for Shipboard

Systems Section 300B Electric Power, Alternating Current.

2.1.2 Specifications, Military

a. None.

2.2 Other Government Documents

2.2.1 Code of Federal Regulations (CFR)

a. Title 46, Subpart J (2012), Electrical Engineering

2.2.2 USCG Surface Forces Logistics Center (SFLC) Drawings

a. None

2.2.3 USCG Surface Forces Logistics Center (SFLC) Documents

a. D-084-0481 Rev B, Preservation, Packaging, and Marking

2.3 Commercial Documents

2.3.1 American Society of Heating, Refrigerating and Air-Conditioning Engineers

(ASHRAE)

a. ASHRAE Standard 26-2010, Mechanical Refrigeration and Air-Conditioning

Installations aboard Ship.

2.3.2 American Society of Mechanical Engineers (ASME)

a. ASME Boiler & Pressure Vessel Code, VIII, Division 1 (2011), Rules for

Construction of Pressure Vessels.

2.3.3 American Society for Quality Control (ASQC)

a. ANSI/ASQC 9001-2008, Quality Management Systems – Model for Quality

Assurance in Design, Development, Production, Installation, and Servicing

Requirements.

2.3.4 American Society of Testing and Materials (ASTM)

a. ASTM B88 (2009), Standard Specification for Seamless Copper Water Tube.

b. ASTM D3951 (2010), Standard Practice for Commercial Packaging.

2.3.5 Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE Standard 45, Recommended Practice and Electrical Installation on

Shipboard, 2002

2.3.6 International Electrotechnical Commission (IEC)

a. IEC Standard 61131-3, Part 3 Programming Languages.

2.3.7 National Electrical Manufacturers Association (NEMA)

a. NEMA 250-2008, Enclosures for Electrical Equipment

b. NEMA Standard ICS-1– Industrial Control and Systems (series), 2003

2.3.8 Society of Naval Architects and Marine Engineers (SNAME)

a. T&R Bulletin 3-47, Guide for Sea Trials

b. T&R Bulletin 3-39, Guide for Shop and Installation Tests

2.3.9 Underwriter’s Laboratory (UL)

a. UL 486A-486B (2010), Wire Connectors

2.4 Order of Precedence

In the event of a conflict between the text of this Specification and the references cited herein, this Specification takes precedence. The Vendor must notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these Specifications prior to proceeding with any work.

3.0 REQUIREMENTS

The Vendor must provide all labor and material to provide new Refrigeration Plant System

Assemblies. The US Coast Guard will install the new systems. Any materials, components, and labor sub-contracted in meeting the requirements herein are the responsibility of the Vendor.

3.1 225’ WLB System Performance and General Requirements

3.1.1 Refrigeration Plants

a. The refrigeration plants shall be manufactured from marine grade materials, suitable for marine service. The plants shall be built in accordance with

ASHRAE Standard 26-2010. If this document is in conflict with ASHRAE

Standard 26-2010 this document shall take precedence. All stop valves / isolation valves / shutoff valves shall be valves designed for refrigerant service with brazed end connections except as noted herein, packless valves shall not be provided. All refrigerant piping shall have brazed joints except as noted herein. The refrigerant shall be HFC-134a; no substitution shall be accepted.

b. The refrigeration plant shall have a minimum refrigeration producing capacity of 1.09 tons per compressor. This capacity shall be achieved at a saturated suction temperature of minus 15 degrees F and a saturated discharge temperature not to exceed 110 degrees F. The refrigeration plant shall be a dual compressor, dual condenser system. One (1) each refrigeration plant shall be provided per cutter. Each condensing unit, on the refrigeration plant, shall have the capacity to handle the normal steady state load. For the pull down condition, the system shall be piped such that one condensing unit shall operate to cool the chill box and the other condensing unit shall operate to cool the freeze box. The condensing units shall be cross connected such that either may be operated to maintain the total normal steady-state load. The maximum refrigeration plant dimensions shall be 28” width x 72” height x 66” length when fully assembled on the skid.

3.1.2 Modular Construction

a. The refrigeration plant shall be of modular construction. The components shall fit through a marine door with an opening of 26” x 66” and 6” radius corners.

The compressor shafts shall be configured such that the shafts are parallel to the width dimension. No brazing or welding shall be required to fully assemble the components into a complete refrigeration plant. Where refrigerant piping must be disassembled, couplings or other fittings shall be provided for assembly on site.

b. After testing, the refrigerant side of system shall be sealed and charged with nitrogen for shipment and storage. The receiver shall be isolated with shut off valves and contain the refrigerant charge. As an alternative, the receiver can also be charged with nitrogen and the required refrigerant charge can be supplied separately in 50 lb cylinders.

3.2 225’ WLB System Specific Requirements

3.2.1 Compressors

a. The system shall utilize dual accessible hermetic reciprocating or scroll type compressors, each producing a minimum 1.09-ton capacity.

b. Each compressor shall be equipped with an oil pump, suction and discharge service valves with gage ports, crankcase heater, muffler and an oil sight glass.

Each compressor shall have a built-in relief valve, if not available on the supplied models, a relief valve shall be placed near each compressor relieving the high-pressure side back to the low-pressure side.

c. Each compressor shall be mounted on vibration isolators, and have vibration eliminators installed in the refrigeration piping near each compressor. As an alternative the entire refrigeration plant shall be mounted on vibration isolators/resilient mounts. The compressors shall have automatic capacity reduction of at least one (1) step, hot gas by-pass capacity controls are not allowed.

d. The supplied compressors shall be current production models with an anticipated manufacturing life span of at least 10 years before removal from manufacturer’s stock.

3.2.2 Compressor Crankcase Oil Heater

a. Each compressor shall have a compressor crankcase oil heater designed to operate on a 115 VAC, single phase, 60 hertz ungrounded system. The heater shall automatically de-energize upon compressor start-up.

b. An Indicator light in the control door shall be provided and illuminated to indicate when heater is energized.

3.2.3 Electrical Requirements

As a minimum, the refrigeration plants shall meet the following:

a. The compressor motor(s) shall be designed to operate from a 440 VAC, 3-phase, 60 Hz, 3-wire ungrounded system.

b. The refrigeration plant shall be capable of operating from type I power characteristics and tolerances as outlined in MIL-STD-1399-300B (reference

2.1.1.a).

c. The refrigeration unit shall have a single point electrical power connection with a terminal block. The single point for electrical power shall also power the control circuit.

d. 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, 24volts, etc). 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. These connections shall be in accordance with UL 486A or equivalent.

Terminal blocks for external connections shall be located where they are easily accessible for cable routing and connection. A control signal will be sent to

MPCMS for each of the locale controllers for remote shut down in the ECC.

e. The equipment shall be rated for continuous duty and for operation at an ambient temperature of at least 50° C.

f. The unit shall be provided with a service disconnect switch. The disconnect switch shall not rely on semiconductors for isolation.

g. Cables shall be low smoke and zero halogen type (LSZH). Cables shall be approved by a recognized standard, such as those listed in IEEE Std 45.

h. Ground conductors shall not carry load current.

i. Signal or control cables shall not use chassis as a return.

j. Junction boxes shall be NEMA Type 12 with a drip shield as a minimum.

Junction boxes with pre-punched perforated holes are prohibited. Junction boxes shall be provided with terminal blocks for wiring connections.

k. 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 or equivalent.

l. Wiring shall be in accordance with the requirements contained in IEEE-STD-

45, 46CFR Subchapter J and NEMA ICS. Wiring harnesses shall be clamped to minimize chaffing and shall be positioned to not interfere with operation, maintenance and servicing of the compressor unit.

3.2.4 Electrical Controls Requirements

As a minimum, the refrigeration plants shall meet the following:

a. Compressors shall be supplied with combination motor starters in accordance with NEMA ICS Series, 46 CFR, Subchapter J and IEEE-STD-45 that include interface with the refrigeration control.

b. Electrical controls shall be in accordance with the requirements of IEEE-STD-

45, NEMA ICS and 46CFR Subchapter J.

c. If the refrigeration plants are supplied with electronic controls / microprocessor the following requirements apply:

i. If the refrigeration plants are custom designed to meet USCG requirements, the microprocessor control system controller shall be in compliance with IEC Standard 6-1131-3 written in a ladder logic program. Any custom software shall be delivered to the Coast Guard for sustainability purposes. The Contractor shall provide development software, executable software, communication cables, network configuration information and necessary software to download codes to control devices.

ii. The control system shall be microprocessor based. If a computer bus is used, it shall be a non-proprietary design that has been approved by a nationally recognized standardization committee such as IEEE.

iii. The unit shall be automatically controlled and monitored by the microprocessor-based control system. The control system shall modulate the compressor capacity in response to changing unit load conditions.

iv. The control system shall include a local display module, a keypad for command entry if a touch display is not included, sensors and other related control components. The control system shall record the control system set points and the unit’s start up and shutdown history into

Nonvolatile Random Access Memory (NOVRAM) in a manner such that information is not lost when control power is removed from the unit.

v. The date and time of start up or shutdown shall be recorded in the memory, as well as the type of start up or shutdown (e.g., routine or safety control related). The control system shall have built-in-test (BIT) fault finding capabilities that can identify internal and external failures.

The BIT shall operate with minimal operator intervention. The system shall indicate the type of failure on the display. Probable causes for the failures and corrective measures shall also be displayed by the control system. In addition, each electronic module shall have a visual indicator which shall become lit when the BIT detects a failure. The control system shall have the capability of clearing past failures for continued unit operation.

vi. The refrigeration control system shall provide an EIA-STD-RS-485 connection that will allow it to be integrated with a MPCMS.

d. All control power shall be 2-wire and less than 120 Volts.

e. Reduced voltage starting motor controls shall be used for motors rated at 100

HP or greater.

f. The refrigeration system shall provide the following alarm, status and control inputs and outputs to the shipboard centralized monitoring and control system.

The refrigeration system shall interface with the cutter’s automation system that is called the MPCMS (Machinery Plant Control and Monitoring System).

Database ID Name RTU Type Description

HVAC-105 REFRIGERATION

COMPRESSOR 1 SHUTDOWN

RTU3/1/8 Dry Contact Refrigeration Compressor Shutdown Alarm

HVAC-106 REFRIGERATION

COMPRESSOR 2 SHUTDOWN

RTU3/1/8 Dry Contact Refrigeration Compressor

Shutdown Alarm

i. Include remote field I/O for all compressors used in the refrigeration unit.

ii. Dry contacts for field connection shall be rated for 10A, 120VAC. Each

I/O contact shall be S.P.D.T. (Single Pole Double Throw) with N.O.

(Normally Open) and N.C. (Normally Closed) contacts.

iii. Refrigeration Compressor Shutdown Alarm - The refrigeration system shall monitor the all refrigeration compressors for indication of a shutdown. An open contact shall be normal operation and a closed contact as shall be a compressor shutdown alarm. These alarms are to be output to the MPCMS system.

g. The refrigeration unit shall include local start/stop control.

h. The refrigeration unit shall include local start/stop indication.

i. Electrical enclosures for wiring, controls and components shall be at least

NEMA Type 12 with a drip shield as a minimum. NEMA 4 enclosures are also acceptable. Enclosure construction shall be of a gauge, which will accept standard nylon stuffing tubes for cable entry.

j. Refrigeration plant controls shall include the following components and functions as a minimum:

i. Power and control circuit terminal blocks.

ii. ON/OFF control switch.

iii. Pump down at the end of every circuit cycle.

iv. Capacity control shall be an integral part of the controls.

v. A terminal block and/or an easy connection point to permit future remote monitoring of the refrigeration plant.

vi. Dry isolated contacts to indicate: status of the compressor (run/stop), and Power Available shall be provided for field connection. The contacts shall be S.P.D.T (Single Pole Double Throw) Form C

(Normally Open and Normally Closed) and rated for 10A, 120VAC.

3.2.5 Condensers

a. Two separate seawater cooled shell and tube type condensers with 90-10 copper nickel tubes and tube sheets and removable bronze heads shall be provided, one for each condensing unit. Shell material shall be seamless carbon steel.

b. The condensers shall be sized to remove the total heat load of the refrigeration system. The total heat load includes required system tonnage for the refrigeration application, the heat load generated to cool the electric motor, heat load from the oil cooler (if required), etc.

c. The shell shall have double liquid refrigerant drains on the bottom and the heads shall have 150 lb ANSI B16.24 flanged seawater cooling connections.

d. Design parameters shall be 95 deg F seawater inlet temperature and a maximum seawater velocity in the tubes of 7 feet per second.

e. Condenser heads shall have replaceable zinc anode protection.

f. Isolation valves shall be provided at the liquid refrigerant drain lines.

g. A connection shall be provided complete with shutoff valve for the seawater regulating valve capillary tube.

h. The shutoff valve shall have a flared end connection sized for the seawater-regulating valve supplied capillary tube.

i. Condensers shall be built, tested and stamped in accordance with ASME Code

Section VIII.

3.2.6 Receivers

a. Each compressor shall have a separate receiver provided. Receivers shall have a capacity to hold the full operating charge of the refrigerant circuit plus at least 20 percent additional to provide a liquid seal in the receiver.

b. The receivers shall be arranged to insure a liquid seal in the receiver outlet under conditions of rolling and pitching of the cutter.

c. Receivers shall be constructed of brass with brazed or welded dished heads or seamless carbon steel tubing with welded dished heads.

d. If the diameter exceeds 10 inches, welded or brazed in lieu of seamless may be used.

e. Isolation valves shall be provided at the refrigerant inlet and outlet connections.

f. Each receiver shall be provided with a liquid level indicator to show the refrigerant level.

g. The indicator internal parts shall withstand the test pressure of the receiver.

3.2.7 Thermal Expansion Valve

a. Each unit cooler refrigerant circuit shall have a thermal expansion valve installed.

b. The power head shall be replaceable and adjustable.

c. The valve shall have soldered type connections and a mechanical flare type equalizing connection.

d. The thermal expansion valve shall be installed within the unit cooler casing and be accessible for servicing. As an alternate an electronically operated expansion valve can be provided.

e. The valve actuator shall be replaceable.

f. The valve must operate via pressure and temperature differential and assure a constant and settable superheat after the evaporator and be manufactured to accommodate large load swings.

3.2.8 Main Liquid Line Solenoid Valve

a. Each refrigerant circuit shall have an HFC-134a compatible liquid solenoid valve with brazed type connections.

b. The valve shall be normally closed and have an interchangeable coil, 115

VAC, 1 phase, 60 hertz.

c. Solenoid valves shall be provided with manual operators for opening the valves in case of electrical coil failure.

3.2.9 Control Liquid Line Solenoid Valve

a. Each unit cooler shall have a control liquid line solenoid valve with brazed type connections installed upstream of the Thermal Expansion Valve.

b. The solenoid valve shall be normally closed and have an interchangeable coil, 115 VAC, 1 phase, 60 hertz.

c. 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.

d. Solenoid valves shall be provided with manual operators for opening the valves in case of electrical coil failure.

3.2.10 Moisture Indicators

a. Each refrigerant circuit shall have a moisture indicator installed. Moisture indicators shall visually indicate the presence of moisture in the refrigerant.

This shall be accomplished by means of a reversible color change in an indicating element.

b. The moisture indicator shall have a removable moisture indicator element and brazed type connections.

c. Moisture indicators may be provided as an integral part of the sight flow indicator.

3.2.11 Sight Flow Indicators

a. Each refrigerant circuit shall have a sight flow indicator installed in the main liquid lines so that the presence of vapor bubbles can be determined.

b. Sight flow indicators shall be of the double port type with brazed type connections. Viewing assemblies shall be provided with gasketed caps.

3.2.12 Suction Pressure Regulating Valve

a. A Suction pressure regulating valve 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.

b. Valves shall be either direct or pilot operated and shall be externally adjustable.

c. The suction pressure regulating valve shall be provided with isolation and bypass valves to permit servicing.

3.2.13 Dehydrators

a. Each refrigerant circuit shall have a serviceable replaceable core type dehydrator installed with isolation valves. Each dehydrator shall have a minimum capacity equivalent to the compressor rating.

b. Dehydrators shall be equipped with auxiliary screens or other protective means at the outlet to prevent passage of desiccant.

c. Installation shall also include a valve for draining, purging and charging of dehydrators.

d. Dehydrators shall be installed upstream of main liquid line solenoid valves.

e. Dehydrators shall have brazed type connections.

3.2.14 Strainers

a. Strainers shall be provided in refrigerant circuits where necessary to protect components, such as controls, from dirt and other contaminants.

b. 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.

c. 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.

d. Strainers shall protect all thermal expansion valves and their associated solenoid valves.

3.2.15 Oil Separators

a. Each compressor shall have an oil separator installed. Oil separators shall be helical type.

b. The oil return line on the separator shall be connected to the compressor crankcase.

c. The refrigerant inlet and outlet connections shall have brazed type connections.

The oil return connection shall be a flared connection and an oil filter shall be installed.

d. If the oil separator is installed below the condenser then a check valve must be installed downstream of the oil separator to prevent condensation from flowing into the oil separator.

3.2.16 Suction Line Accumulators

a. Each compressor shall have a suction line accumulator installed to protect the compressor from liquid flood back. The accumulator shall have a built in heat exchanger coil to help boil off liquid refrigerant and raise the oil temperature to help facilitate oil flow.

b. The accumulator shall have brazed type connections.

3.2.17 Heat Interchanger

a. Where it is necessary to superheat the suction gas to prevent saturated liquid from returning to a compressor, or where it is necessary to sub-cool the liquid refrigerant to compensate for static head or excessive piping losses, a heat interchanger shall be installed common to the suction line and the liquid refrigerant line.

b. The liquid line/suction line heat exchanger shall be provided to superheat the suction gas before entering the compressor and to sub-cool the liquid refrigerant to eliminate flashing in the liquid line.

c. The interchanger shall be arranged to prevent the entrapment of oil in the assembly. A refrigerant liquid line bypass valve shall be installed around the interchanger to permit bypassing the interchanger in the event of high discharge temperature to the compressor. Also, a shutoff valve shall be installed at the liquid line inlet of the interchanger.

d. The heat interchanger shall be constructed of brass, steel or copper shell and copper tubes and arranged for counter flow. Tubes shall conform to ASTM

B88 type K.

e. Pressure drop through the heat exchanger shall be kept to a minimum.

f. The heat interchanger can be shipped loose for installation in the field.

3.2.18 Gauge, Thermometers and Test Connections

a. Each compressor shall have a refrigerant suction pressure, refrigerant discharge pressure and oil pressure gauge and associated test connections 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. In addition each compressor shall have ports to install Pressure Transducers to remotely monitor refrigerant suction pressure, refrigerant discharge pressure and compressor oil pressure. The ports shall accommodate a pressure transducer with 1/4-18NPT threads.

b. Each condenser shall have seawater inlet 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.

c. All gauges shall have the following characteristics:

i. 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.

ii. Gauges shall be accurate to +/- 1.0 per cent.

iii. 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.

iv. 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.

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

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

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

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

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

x. Connections on gauges shall be of the threaded or flanged type.

Tapered threads shall not be used.

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

xii. 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.

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

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

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

iii. 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.

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

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

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

vii. Brass “dry type” thermo wells shall be provided.

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

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

3.2.19 Relief Valve

a. Each refrigerant circuit shall have an HFC-134a compatible 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 low-pressure rupture disc.

3.2.20 High Pressure Rupture Disc

a. Each refrigerant circuit shall have an HFC-134a compatible rupture disc installed, for emergency discharge of the refrigerant charge. This rupture disc shall be installed upstream of the relief valve. 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.

3.2.21 Low Pressure Rupture Disc

a. Each refrigerant circuit shall have a 10 to 15 PSI HFC-134a compatible rupture disc installed downstream of the relief valve. The purpose of this rupture disc is to protect the relief valve from seawater resting on the relief valve seat.

Sources of supply for the low pressure rupture disc include Oseco, Fike and

BS&B Safety Systems, Inc.

3.2.22 Sea Water Regulating Valve

a. Each condenser shall have an HFC-134a compatible two-way seawater-regulating valve supplied, to provide correct seawater flow thru the condenser with seawater temperature range of 28 degrees F to 95 degrees F. Valve construction shall be bronze body and MONEL trim. A capillary tube shall be provided. Valve shall be rated for seawater service. To be shipped loose for installation by others.

3.2.23 Charging Valve

a. Each refrigerant circuit shall have an HFC-134a compatible charging valve

(Schrader type) installed.

3.2.24 Safeties

a. As a minimum, the refrigeration plant shall be equipped with all necessary components in conjunction with the control system to provide the unit with the following:

i. Suction Low Pressure Switch.

ii. Condenser Water Failure Switch.

iii. Refrigerant Discharge High Pressure Switch.

iv. Compressor Ground Fault Sensor.

v. Oil Low Pressure Switch.

vi. Compressors shall be equipped with the following manual reset type protections:

Electrical overload protection.

3.2.25 Environmental Requirements

The refrigeration plant shall be designed to function properly in the following conditions:

a. Dynamic Conditions – A roll of 30 degrees either side of vertical in a period of

9.5 seconds, a pitch of 3 degrees up or down from its normal horizontal plane in a period of 6 seconds and a heave of 2 feet up or down from its normal horizontal plane in 11 seconds.

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

c. Temperature and Humidity - The water chiller, complete with all controls and components, shall be capable of continuous operation in an ambient temperature environment from 40 degrees F to 122 degrees F and relative humidity from 0% to 95%, inclusive.

3.2.26 Miscellaneous

a. Original Equipment Manufacturers’ label plates and other identification supplied on the equipment shall not be removed, erased or otherwise destroyed from the equipment.

3.2.27 Unit Coolers

a. Each unit cooler shall be selected based on the rated capacity as listed in Table

1 (6,500 Btu/hr). The unit coolers shall be in accordance with ASHRAE 26-10 paragraphs 9.2 thru 9.3.1.5 except as stated here.

b. The freeze box unit cooler shall be an electric defrost type and the chill box unit cooler shall be an air defrost type.

c. Each unit cooler shall be controlled by a separate defrost control panel.

Electric defrost shall operate on 440 volt, 60 Hz, 3 phase or single phase power.

d. Unit cooler coils shall be direct expansion type. Aluminum coil tubes are not allowed.

e. Fans shall be propeller type axial fans and shall be direct driven. Fans for the unit cooler coils shall be draw through and designed to provide a maximum air velocity across the face of the coil of 600 ft/min. Fans shall be equipped with a fan guard to prevent personnel injury but not to impede airflow.

f. The fan motors and all unit cooler controls shall meet the electrical requirements specified in 3.2.3 and 3.2.4. Fan motors shall be suitable for minus 20 degrees F air temperature, high efficiency type suitable for 440 volt, 60 Hz, 3-phase or single-phase power.

g. The unit coolers shall have a drain connection in each corner of the drain pan bottom. In addition to the refrigerant connections, all electrical and drain connections shall be arranged for easy removal of the unit cooler for maintenance or replacement.

Table 1 (225’ WLB Ship Stores)

Compartment Design

Temp.

Minimum Unit Cooler

Capacity/Size

(Btu/hr)

Unit Cooler

QTY (EA)

Freeze Box 0 deg F 6500 1

Chill Box 33 deg F 6500 1

3.2.28 Defrost Control Panel

a. A separate defrost control panel with a defrost timer shall be provided for each unit cooler. Each defrost control panel shall be provided with a main disconnect switch for securing power for the refrigerant controls, unit cooler, drain line heat tape and the defrost heaters.

b. The defrost controls for each unit cooler shall provide for both manual and automatic defrosting. Automatic defrost switches and relays shall be provided so the defrost cycle is time initiated and temperature terminated and shall include 24 hour clock motors capable of initiating at least three defrost cycles per 24 hour period.

c. The number and spacing of the defrost cycles shall be adjustable. In the manual mode, defrost is initiated by a pushbutton switch. When defrost is initiated, the fan(s) shall automatically shut down and restart when the coil reaches its operating temperature upon the conclusion of the defrost cycle.

d. A high temperature or a time termination safety switch shall be provided to secure defrosting in the event of failure of the normal controls. The safety switch shall 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.

e. The controls shall meet the electrical requirements specified in 3.2.3 and 3.2.4.

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), defrost inhibited (blue), power on (white) and on the freeze box control panel heater failure (red).

f. The design of the heating elements and controls shall be such that they can be easily removed and replaced. Controls shall include fan relays to delay the start of fans while condensate is draining out of the refrigerated spaces once coil defrosting has terminated.

3.2.29 Cabling and Wiring

a. Cabling and wiring must be provided in accordance with IEEE 45 and MIL-

DTL-24643.

b. Cable entry into electrical enclosures must use either nylon stuffing tubes per

ASTM F 1836M or heat-shrink cable entry seals per ASTM F 1837M.

3.2.30 Identification and Labeling

a. A label plate must be permanently affixed to the pressure vessel. The label plate must be engraved with information to document equipment compliance as listed in Section 3.1.1.

3.3 WIX 327 EAGLE System Performance and General Requirements

3.3.1 Refrigeration Plants

a. The refrigeration plants shall be manufactured from marine grade materials, suitable for marine service. The plants shall be built in accordance with

ASHRAE Standard 26-2010. If this document is in conflict with ASHRAE

Standard 26-2010 this document shall take precedence. All stop valves / isolation valves / shutoff valves shall be valves designed for refrigerant service with brazed end connections except as noted herein, packless valves shall not be provided. All refrigerant piping shall have brazed joints except as noted herein. The refrigerant shall be HFC-134a; no substitution shall be accepted.

b. The refrigeration plant shall have a minimum refrigeration producing capacity of 1.05 tons per compressor. This capacity shall be achieved at a saturated suction temperature of minus 15 degrees F and a saturated discharge temperature not to exceed 110 degrees F. The refrigeration plant shall be a dual compressor, dual condenser system. One (1) each refrigeration plant shall be provided per cutter. Each condensing unit, on the refrigeration plant, shall have the capacity to handle the normal steady state load. For the pull down condition, the system shall be piped such that one condensing unit shall operate to cool the Vegetable box and the Dairy Box, and the other condensing unit shall operate to cool the Meat box. The condensing units shall be cross connected such that either may be operated to maintain the total normal steady-state load. The maximum refrigeration plant dimensions shall be 32” width x

72” height x 68” length when fully assembled on the skid.

3.3.2 Modular Construction

a. The refrigeration plant shall be of modular construction. The components shall fit through a marine door with an opening of 26” x 66” and 6” radius corners.

The compressor shafts shall be configured such that the shafts are parallel to the width dimension. No brazing or welding shall be required to fully assemble the components into a complete refrigeration plant. Where refrigerant piping must be disassembled, couplings or other fittings shall be provided for assembly on site.

b. After testing, the refrigerant side of system shall be sealed and charged with nitrogen for shipment and storage. The receiver shall be isolated with shut off valves and contain the refrigerant charge. As an alternative, the receiver can also be charged with nitrogen and the required refrigerant charge can be supplied separately in 50 lb cylinders.

3.4 WIX 327 EAGLE System Specific Requirements

3.4.1 Compressors

a. The system shall utilize dual accessible hermetic reciprocating or scroll type compressors, each producing a minimum 1.05-ton capacity.

b. Each compressor shall be equipped with an oil pump, suction and discharge service valves with gage ports, crankcase heater, muffler and an oil sight glass.

Each compressor shall have a built-in relief valve, if not available on the supplied models, a relief valve shall be placed near each compressor relieving the high-pressure side back to the low-pressure side.

c. Each compressor shall be mounted on vibration isolators, and have vibration eliminators installed in the refrigeration piping near each compressor. As an alternative the entire refrigeration plant shall be mounted on vibration isolators/resilient mounts. The compressors shall have automatic capacity reduction of at least one (1) step, hot gas by-pass capacity controls are not allowed.

d. The supplied compressors shall be current production models with an anticipated manufacturing life span of at least 10 years before removal from manufacturer’s stock.

3.4.2 Compressor Crankcase Oil Heater

a. Each compressor shall have a compressor crankcase oil heater designed to operate on a 115 VAC, single phase, 60 hertz ungrounded system. The heater shall automatically de-energize upon compressor start-up.

b. An Indicator light in the control door shall be provided and illuminated to indicate when heater is energized.

3.4.3 Electrical Requirements

As a minimum, the refrigeration plants shall meet the following:

a. The compressor motor(s) shall be designed to operate from a 440 VAC, 3-phase, 60 Hz, 3-wire ungrounded system.

b. The refrigeration plant shall be capable of operating from type I power characteristics and tolerances as outlined in MIL-STD-1399-300B (reference

2.1.1.a).

c. The refrigeration unit shall have a single point electrical power connection with a terminal block. The single point for electrical power shall also power the control circuit.

d. 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, 24volts, etc). 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. These connections shall be in accordance with UL 486A or equivalent.

Terminal blocks for external connections shall be located where they are easily accessible for cable routing and connection.

e. The equipment shall be rated for continuous duty and for operation at an ambient temperature of at least 50° C.

f. The unit shall be provided with a service disconnect switch. The disconnect switch shall not rely on semiconductors for isolation.

g. Cables shall be low smoke and zero halogen type (LSZH). Cables shall be approved by a recognized standard, such as those listed in IEEE Std 45.

h. Ground conductors shall not carry load current.

i. Signal or control cables shall not use chassis as a return.

j. Junction boxes shall be NEMA Type 12 with a drip shield as a minimum.

Junction boxes with pre-punched perforated holes are prohibited. Junction boxes shall be provided with terminal blocks for wiring connections.

k. 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 or equivalent.

l. Wiring shall be in accordance with the requirements contained in IEEE-STD-

45, 46CFR Subchapter J and NEMA ICS. Wiring harnesses shall be clamped to minimize chaffing and shall be positioned to not interfere with operation, maintenance and servicing of the compressor unit.

3.4.4 Electrical Controls Requirements

As a minimum, the refrigeration plants shall meet the following:

a. Compressors shall be supplied with combination motor starters in accordance with NEMA ICS Series, 46 CFR, Subchapter J and IEEE-STD-45 that include interface with the refrigeration control.

b. Electrical controls shall be in accordance with the requirements of IEEE-STD-

45, NEMA ICS and 46CFR Subchapter J.

c. If the refrigeration plants are supplied with electronic controls / microprocessor the following requirements apply:

i. If the refrigeration plants are custom designed to meet USCG requirements, the microprocessor control system controller shall be in compliance with IEC Standard 6-1131-3 written in a ladder logic program. Any custom software shall be delivered to the Coast Guard for sustainability purposes. The Contractor shall provide development software, executable software, communication cables, network configuration information and necessary software to download codes to control devices.

ii. The control system shall be microprocessor based. If a computer bus is used, it shall be a non-proprietary design that has been approved by a nationally recognized standardization committee such as IEEE.

iii. The unit shall be automatically controlled and monitored by the microprocessor-based control system. The control system shall modulate the compressor capacity in response to changing unit load conditions.

iv. The control system shall include a local display module, a keypad for command entry if a touch display is not included, sensors and other related control components. The control system shall record the control system setpoints and the unit’s start up and shutdown history into

Nonvolatile Random Access Memory (NOVRAM) in a manner such that information is not lost when control power is removed from the unit.

v. The date and time of start up or shutdown shall be recorded in the memory, as well as the type of start up or shutdown (e.g., routine or safety control related). The control system shall have built-in-test (BIT) fault finding capabilities that can identify internal and external failures.

The BIT shall operate with minimal operator intervention. The system shall indicate the type of failure on the display. Probable causes for the failures and corrective measures shall also be displayed by the control system. In addition, each electronic module shall have a visual indicator which shall become lit when the BIT detects a failure. The control system shall have the capability of clearing past failures for continued unit operation.

d. All control power shall be 2-wire and less than 120 Volts.

e. Reduced voltage starting motor controls shall be used for motors rated at 100

HP or greater.

f. The refrigeration unit shall include local start/stop control.

g. The refrigeration unit shall include local start/stop indication.

h. Electrical enclosures for wiring, controls and components shall be at least

NEMA Type 12 with a drip shield as a minimum. NEMA 4 enclosures are also acceptable. Enclosure construction shall be of a gauge, which will accept standard nylon stuffing tubes for cable entry.

i. Refrigeration plant controls shall include the following components and functions as a minimum:

i. Power and control circuit terminal blocks.

ii. ON/OFF control switch.

iii. Pump down at the end of every circuit cycle.

iv. Capacity control shall be an integral part of the controls.

v. A terminal block and/or an easy connection point to permit future remote monitoring of the refrigeration plant.

vi. Dry isolated contacts to indicate: status of the compressor (run/stop), and Power Available shall be provided for field connection. The contacts shall be S.P.D.T (Single Pole Double Throw) Form C

(Normally Open and Normally Closed) and rated for 10A, 120VAC.

3.4.5 Condensers

a. Two separate seawater cooled shell and tube type condensers with 90-10 copper nickel tubes and tube sheets and removable bronze heads shall be provided, one for each condensing unit. Shell material shall be seamless carbon steel.

b. The condensers shall be sized to remove the total heat load of the refrigeration system. The total heat load includes required system tonnage for the refrigeration application, the heat load generated to cool the electric motor, heat load from the oil cooler (if required), etc.

c. The shell shall have double liquid refrigerant drains on the bottom and the heads shall have 150 lb ANSI B16.24 flanged seawater cooling connections.

d. Design parameters shall be 95 deg F seawater inlet temperature and a maximum seawater velocity in the tubes of 7 feet per second.

e. Condenser heads shall have replaceable zinc anode protection.

f. Isolation valves shall be provided at the liquid refrigerant drain lines.

g. A connection shall be provided complete with shutoff valve for the seawater regulating valve capillary tube.

h. The shutoff valve shall have a flared end connection sized for the seawater-regulating valve supplied capillary tube.

i. Condensers shall be built, tested and stamped in accordance with ASME Code

Section VIII.

3.4.6 Receivers

a. Each compressor shall have a separate receiver provided. Receivers shall have a capacity to hold the full operating charge of the refrigerant circuit plus at least 20 percent additional to provide a liquid seal in the receiver.

b. The receivers shall be arranged to insure a liquid seal in the receiver outlet under conditions of rolling and pitching of the cutter.

c. Receivers shall be constructed of brass with brazed or welded dished heads or seamless carbon steel tubing…