RFQ_Attachment_B_-_Specification.docx

Rev (A) 16 DEC 2015 Specification for HEALY Refrigeration Plants REVISION No. A . CHANGE NO. .

USCGC HEALY

SPECIFICATION FOR

SHIP STORES AND SCIENCE STORES

REFRIGERATION PLANTS

P-516-0646

ORIGINATED BY Michael Sirak . DATE 28 MAR 2013

DIVISION SFLC-ESD-NAME-AMS .

INTERNAL REVIEWER Steve Sharpe . DATE 28 MAR 2013

HEALY SPECIFICATION FOR

SHIP STORES AND SCIENCE STORES

REFRIGERATION PLANTS

Table of Contents

1.0 SCOPE

1.1 General

1.2 GFE, GFM, and GFP

1.3 GFI

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability

2.2 Government Documents

2.3 Other Government Documents

2.4 Commercial Documents

2.5 Specification Order of Precedence

3.0 REQUIREMENTS

3.1 General

3.2 Equipment Salient Characteristics

3.3 Integrated Logistics Support

3.4 Technical Publications

3.5 Software

3.6 Warranty

3.7 Technical Support

4.0 QUALITY ASSURANCE

4.7 Failure Responsibility

4.8 Inspection and Test Reports

4.9 Preservation, Packing and Marking Inspection

5.0 PRESERVATION, PACKING AND MARKING

5.4 Marking

5.5 Parts Packaging

6.0 NOTES

6.1 Document Sources

Table of Contents (Cont’d)

ENCLOSURES

1.0

SCOPE

1.1 General - The HEALY refrigeration plants for ship stores and the science stores have become obsolete and are deteriorated to a condition that replacement is needed to meet the Legacy asset life cycle. This specification is for the design, procurement, and technical support for installation of new units aboard the vessel.

1.2 Government Furnished Equipment (GFE), Government Furnished Material (GFM) and Government Furnished Property (GFP) – None.

1.3 Government Furnished Information (GFI) - None.

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability - 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. To obtain other referenced documents. (See 6.1)

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 Standards

a. 46 Code of Federal Regulations, Subchapter J (2004), Electrical Engineering

2.2.2 GSA Standards

a. None.

2.2.3 Military Standards

a. MIL-STD-1399, Section 300B, Dated 2008, Interface Standard for Shipboard Systems Section 300B Electric Power, Alternating Current.

2.2.4 Military Specifications

a. None.

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. United States Coast Guard (USCG) documents will be available to bidders and the contractor.

2.3.1 USCG Drawings and Technical Publications

a. 420 WAGB 436-011

b. 420 WAGB 436-012

2.3.2 USCG Instructions

a. COMDTINST M9085.1C, Naval Engineering Computer Aided Design Standards.

2.3.3 USCG Surface Forces Logistics Center (SFLC) Specifications

a. D-000-0100, REV G, Dated 2/06, Bar Coding for USCG SFLC Material.

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

c. D-086-0508, Rev A, Dated 4/08, Technical Publications and Drawings.

2.4 Commercial Documents - The following documents form a part of this specification to the extent specified herein.

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

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

2.4.2 American Society of Mechanical Engineers

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

2.4.3 American Society for Testing and Materials

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

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

2.4.4 International Engineering Consortium (IEC)

a. IEC 61131-3 (2003), Part 3 Programming Languages.

2.4.5 Institute of Electrical and Electronics Engineers

a. IEEE Std 45 (2002), Recommended Practice for Electrical Installations on Shipboard.

2.4.6 National Electrical Manufacturers Association (NEMA)

a. NEMA standard 250 (2008), Enclosures for Electrical Equipment.

b. NEMA standard ICS 1 (2000), Industrial Control and Systems General Requirements.

2.4.7 Underwriters’ Laboratory (UL)

a. UL 486A-486B (2010), 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 following salient characteristics are compiled to provide refrigeration plants for ship stores and science stores aboard the CGC HEALY.

3.1.1 Refrigeration Plants - 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. One purpose of this specification shall be providing commonality across the plants. 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 ball valves designed for refrigerant service with brazed end connections except as noted herein. All refrigerant piping shall have brazed joints except as noted herein. The refrigerant shall be HFC-134a; no substitution shall be accepted.

3.1.1.1 TYPE 1(Science Stores) – The Science Stores Refrigeration Plant serves one walk-in freeze box and one walk-in chill box; each box contains a single unit cooler to maintain design temperature. The refrigeration plant shall have minimum refrigeration producing capacity of 1.50 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 and have a maximum wet weight not to exceed 4000 lbs. One (1) each refrigeration plant shall be provided. Each condensing unit, on the refrigeration plant, shall have the capacity to handle the normal steady state load. For the pulldown 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.

3.1.1.2 TYPE 2(Ship Stores) – The Ship Stores Refrigeration Plant serves one walk-in thaw box, one walk-in chill box and two walk-in freeze boxes. The chill box and both freeze boxes contain two each units coolers and the thaw box contains a single unit cooler. The refrigeration plant shall have minimum refrigeration producing capacity of 2.0 tons. 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 consist of a single compressor, condenser system and have a maximum wet weight not to exceed 2000 lbs. Three (3) each refrigeration plants shall be provided. Each refrigeration plant shall have the capacity to handle the normal steady state load. For the pulldown condition, the system shall be piped such that one plant shall operate to cool the thaw box and freeze box #2. Another plant shall operate to cool freeze box #1 and the chill box. The third plant shall be idle and is available as a backup. The condensing units shall be cross connected such that any one may be operated to maintain the total normal steady-state load.

3.1.2 Modular Construction (TYPE 1) – The refrigeration plant shall be of modular construction so as to fit through an opening of 23” x 66” unless the fully assembled refrigeration plant can fit through the stated minimum opening. The maximum refrigeration plant size shall be 52” width x 66” height x 61” length when fully assembled on the skid. The compressors shall be installed on the plant such that the compressor shafts are parallel with the width dimension of the skid, i.e. the width shall be the fore and aft direction of the plant. No brazing or welding shall be required to fully assemble the components into a complete refrigeration plant. Where refrigerant piping must be disassembled, unions or flanges shall be provided at the break points. The refrigerant side of system shall be sealed and charged with nitrogen; the condenser shall be isolated with shut off valves and contain the refrigerant charge. As an alternate, the condenser can also be charged with nitrogen and the required refrigerant charge can be supplied separately in 50 lb cylinders.

3.1.3 Modular Construction (TYPE 2) – The refrigeration plant shall be of modular construction so as to fit through a marine door with an opening of 28” x 68” and 6” radius corners unless the fully assembled refrigeration plant can fit through the stated minimum opening. The maximum refrigeration plant size shall be 31” width x 66” height x 61” length when fully assembled on the skid. The compressor shall be installed on the plant such that the compressor shaft is parallel with the length dimension of the skid, i.e. the length shall be the fore and aft direction of the plant. No brazing or welding shall be required to fully assemble the components into a complete refrigeration plant. Where refrigerant piping must be disassembled, unions or flanges shall be provided at the break points. The refrigerant side of system shall be sealed and charged with nitrogen; the condenser shall be isolated with shut off valves and contain the refrigerant charge. As an alternate, the condenser can also be charged with nitrogen and the required refrigerant charge can be supplied separately in 50 lb cylinders.

3.2 Equipment Salient Characteristics:

3.2.1 Compressors (TYPE 1 and TYPE 2) - Each compressor shall be equipped with an oil pump and/or pressurized oil system, suction and discharge service valves, 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. The compressors 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. 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.

3.2.1.1 (TYPE 1) - Dual accessible hermetic reciprocating or scroll type compressors, each shall produce a minimum 1.50-ton capacity.

3.2.1.2 (TYPE 2) - A single accessible hermetic reciprocating or scroll type compressor, each shall produce a minimum 2.0-ton capacity.

3.2.2 Compressor Crankcase Oil Heaters (TYPE 1 and TYPE 2) - 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. An Indicator light in the control door shall be provided and illuminated to indicate when heater is energized.

3.2.3 General Electrical Requirements (TYPE 1 and TYPE 2) – As a minimum, the refrigeration plants shall meet the following:

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

3.2.3.2 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, and 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. 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.

3.2.3.3 Electrical power on board USCG Cutters is derived from a 450 VAC, 3 phase, 60 hz, ungrounded system. All control voltages shall be 115 VAC or less.

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

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

3.2.4 Junction boxes (TYPE 1 and TYPE 2) - Junction boxes shall NEMA Type 12 with a drip shield as a minimum. 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 or equivalent.

3.2.5 Electrical Controls (TYPE 1 and TYPE 2) - Electrical controls shall be in accordance with the requirements contained in IEC Standard 6-1131-3, IEEE-STD-45 and 46CFR Subchapter J. All control power shall be 120 VAC, single phase. Any controller for a motor rated at 50 HP or greater shall have reduced voltage start.

3.2.5.1 The electrical controls, if provided, shall use programmable devices. The Contractor shall provide development software, executable software, communication cables, network configuration information and necessary software to download codes to programmable devices. All programmable devices shall be marine approved. All software shall be compatible with Microsoft Windows operating system 8.0 or higher.

3.2.6 Enclosures (TYPE 1 and TYPE 2) - Electrical enclosures for wiring, controls and components shall be NEMA Type 12 with a drip shield as a minimum. Enclosure construction shall be of a gauge, which will accept standard nylon stuffing tubes for cable entry.

3.2.7 Wiring (TYPE 1 and TYPE 2) - Wiring shall be in accordance with the requirements contained in IEEE-STD-45, 46CFR Subchapter J and NEMA ICS. 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.

3.2.8 Compressor Motor (TYPE 1 and TYPE 2) - The compressor motor shall be designed to operate on a 440 volt, 3 phase, 60 hz, ungrounded system. Compressors shall be supplied with combination motor starters in accordance with NEMA ICS Series, 46 CFR Subchapter J and IEEE-STD-45 that also include an interface with the refrigeration plant control microprocessor. The microprocessor shall be in compliance with IEC Standard 6-1131-3 written in a ladder logic program.

3.2.9 Condensers (TYPE 1 and TYPE 2) – All 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. Shell material shall be seamless carbon steel. 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. Design parameters shall be 90 deg F seawater inlet temperature and a maximum seawater velocity in the tubes of 7 feet per second. A condenser waterside fouling factor of 0.0005 hr x sq ft x deg F/BTU shall be applied. Condenser heads shall have replaceable zinc anode protection. Isolation valves shall be provided at the liquid refrigerant drain lines and the refrigerant high-pressure gas connections. A connection shall be provided complete with shutoff valve for the seawater regulating valve capillary tube. The shutoff valve shall have a flared end connection sized for the seawater-regulating valve supplied capillary tube. Condensers shall be built, tested and stamped in accordance with ASME Code Section VIII.

3.2.9.1 (TYPE 1) – 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 refrigerant circuit.

3.2.9.2 (TYPE 2) – A single seawater cooled shell and tube type condenser with 90-10 copper nickel tubes and tube sheets and removable bronze heads shall be provided.

3.2.10 Receivers (TYPE 1 and TYPE 2) - 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. The receivers shall be arranged to insure a liquid seal in the receiver outlet under conditions of rolling and pitching of the cutter. Receivers shall be constructed of brass with brazed or welded dished heads or seamless carbon steel tubing with welded dished heads. If the diameter exceeds 10 inches, welded or brazed in lieu of seamless may be used. Isolation valves shall be provided at the refrigerant inlet and outlet connections. Each receiver shall be provided with a liquid level indicator to show the refrigerant level. The indicator internal parts shall withstand the test pressure of the receiver.

3.2.11 Manifold Board (TYPE 1 and TYPE 2) – Each walk-in box shall be provided with a single manifold board not to exceed 38” long x 32” high, i.e. the science stores will require 2 each manifold boards and the ship stores will require 4 each manifold boards. The manifold board shall consist of the following components, at a minimum. A dehydrator, isolation valves, a sight glass, a suction line pressure gauge with associated test connection (see paragraph 3.2.23) and a suction pressure regulating valve with bypass (where required). Manifold board piping and components that are subject to sweating and freezing shall be mounted with stand-offs in order to accommodate a 1-1/2 inch thickness of thermal insulation. See Enclosures 1 thru 6 for general layout of manifold boards.

3.2.12 Thermal Expansion Valve (TYPE 1 and TYPE 2) – Each unit cooler refrigerant circuit shall have a thermal expansion valve installed. The power head shall be replaceable and adjustable. The valve shall have soldered type connections. 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. The valve actuator shall be replaceable. 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. The valve shall have mechanical flare type equalizing connections and soldered piping joints.

3.2.13 Main Liquid Line Solenoid Valve (TYPE 1 and TYPE 2) – Each refrigerant circuit shall have an HFC-134a compatible liquid solenoid valve with brazed type connections. The valve shall be normally closed and have an interchangeable coil, 115 VAC, 1 phase, 60 hertz. Solenoid valves shall be provided with manual operators for opening the valves in case of electrical coil failure.

3.2.14 Control Liquid Line Solenoid Valve (TYPE 1 and TYPE 2) - Each unit cooler shall have a control liquid line 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.

3.2.15 Moisture Indicators (TYPE 1 and TYPE 2) - 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. The moisture indicator shall have a removable moisture indicator element and brazed type connections. Moisture indicators may be provided as an integral part of the sight flow indicator.

3.2.16 Sight Flow Indicators (TYPE 1 and TYPE 2) – 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. Sight flow indicators shall be of the double port type with brazed type connections. Viewing assemblies shall be provided with gasketed caps.

3.2.17 Suction Pressure Regulating Valves (TYPE 1 and TYPE 2) - 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. Valves shall be either direct or pilot operated and shall be externally adjustable. The suction pressure regulating valves shall be provided with isolation and bypass valves to permit servicing and to allow for conversion from chill box to freeze box.

3.2.18 Dehydrators (TYPE 1 and TYPE 2) - 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.

3.2.19 Strainers (TYPE 1and TYPE 2) – 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.

3.2.20 Oil Separators (TYPE 1and TYPE 2) – Each compressor shall have an oil separator installed. Oil separators shall be helical type. The oil return line on the separator shall be connected to the compressor crankcase. The refrigerant inlet and outlet connections shall have brazed type connections. The oil return line shall have an oil filter and isolation valves installed. 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.

3.2.21 Suction Line Accumulators (TYPE 1 and TYPE 2) – 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. The accumulator shall have brazed type connections.

3.2.22 Heat interchanger (TYPE 1 and TYPE 2) - 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. 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. 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. 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. Pressure drop through the heat exchanger shall be kept to a minimum.

3.2.23 Gauges, Thermometers and Test Connections (TYPE 1 and TYPE 2)

3.2.23.1 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 and tees 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 ¼-18NPT threads.

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

3.2.23.3 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 +/- 0.5 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.

3.2.23.4 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” thermowells 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.

3.2.24 Relief Valve (TYPE 1 and TYPE 2) – 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.

3.2.25 High Pressure Rupture Disc (TYPE 1 and TYPE 2) – 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.

3.2.26 Low Pressure Rupture Disc (TYPE 1 and TYPE 2) – 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.

3.2.27 Sea Water Regulating Valve (TYPE 1 and TYPE 2) – 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 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. To be shipped loose for installation by others.

3.2.28 Charging Valve (TYPE 1 and TYPE 2) – Each refrigerant circuit shall have an HFC-134a compatible charging valve installed. Schrader type.

3.2.29 Controls (TYPE 1 and TYPE 2)

3.2.29.1 Refrigeration plant controls shall include the following components as a minimum:

i. Power and control circuit terminal blocks.

ii. ON/OFF control switch.

iii. Pump down at beginning and 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. Normally open (N.0.) isolated contacts to indicate: status of the compressor (run/stop), and Power Available. Any malfunction shall be communicated to the operator via MPCMS.

3.2.30 Safeties (TYPE 1 and TYPE 2)

3.2.30.1 As a minimum, the refrigeration plant shall be equipped with thermistors and 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:

A. High Pressure overload protection.

B. Electrical overload protection.

3.2.31 Environmental Requirements (TYPE 1 and TYPE 2) – The refrigeration plant shall be designed to function properly in the following conditions:

3.2.31.1 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.

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

3.2.31.3 Temperature and Humidity - The refrigeration plant, 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.

3.2.32 Miscellaneous (TYPE 1 and TYPE 2) - Original Equipment Manufacturers’ label plates and other identification supplied on the equipment shall not be removed, erased or otherwise destroyed from the equipment.

3.2.33 Unit Coolers (TYPE 1 and TYPE 2) - Each unit cooler shall be selected based on the information as listed in Tables 1 & 2. The unit coolers shall be in accordance with ASHRAE 26-10 paragraphs 9.2 thru 9.3.1.5 except as stated here. Unit coolers shall be electric defrost type and controlled by a separate defrost control panel. Electric defrost shall operate on 440 volt, 60 Hz, 3 phase or single phase power. Unit cooler coils shall be direct expansion type. Aluminum coil tubes are not allowed. 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. The fan motors and all unit cooler controls shall meet the general electrical requirements specified in 3.2.3 thru 3.2.7. 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. The unit coolers shall have a drain connection at both ends of the drain pan to permit drainage under the environmental conditions specified in paragraph 3.2.31.1 and 3.2.31.2. 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. The current unit coolers installed on HEALY are manufactured by Colmac Coil with the following drawing numbers: B9299356 (14,800 BTU/HR unit) and B9299357 (11,800 BTU/HR unit).

Table 1 (Science Stores)

Temp.

Current Unit Cooler Capacity/Size (Btu/hr) Unit Cooler Quantity (EA)

Table 2 (Ship Stores)

Temp.

Current Unit Cooler(s) Capacity/Size (Btu/hr) Unit Cooler Quantity (EA)

3.2.34 Defrost Control Panel (TYPE 1 and TYPE 2) - 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. 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. 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. 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. The controls shall meet the general electrical requirements specified in 3.2.3 thru 3.2.7. 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. 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.

3.2.35 Unit Cooler Selector Switch (Type 2 Only) – The Ship Stores Freeze Box #1, Freeze Box #2 and Chill Box, all of which contain two each unit coolers, shall each have a unit cooler selector switch installed near its respective manifold boards. The selector switch shall be a 4 position switch and work in conjunction with the defrost control panels. The selector switch shall be labeled to indicate the operation at each position. See Table 3 for the operation of the switch at each position.

Table 3 Selector Switch Positions

Position #1 (Unit Cooler #1) Position #2 (Both ON) Position #3 (Unit Cooler #2) Position #4 (Both OFF)

3.3 Integrated Logistics Support (TYPE 1 and TYPE 2) – The manufacturer shall supply the following items separately for each refrigeration plant:

3.3.1 Provisioning Technical Documentation - The Contractor shall develop and furnish provisioning technical documentation (PTD) in accordance with SFLC Specification D-083-0351. It shall include a list of all end items installed, the OEM cage code, and OEM part or assembly numbers.

3.3.2 Recommended Spare Parts List - The Contractor shall also provide with the PTD a recommended spare parts list for onboard repair parts (OBRP) and stock system parts. The OBRP shall be sufficient to perform shipboard maintenance on the equipment for two years. Spares shall include gaskets or seals as necessary to install components, but not overhaul components. The spare parts list shall include spare parts prices and their lead times at the time of delivery of the equipment. The spare parts list shall be quantified into the number of spares needed per the equipment supplied.

3.3.3 All spare parts necessary for overhaul of a unit shall be identified in the printed technical documents supplied.

3.4 Technical Publications (TYPE 1 and TYPE 2) – The TYPE 1 and TYPE 2 systems shall each have a separate technical publication provided for the equipment and accessories. The Contractor shall develop and furnish the technical publications in accordance with SFLC Specification D-086-0508. In addition to the requirements of SFLC Specification D-086-0508 the following items shall also be included in the technical publications.

3.4.1 Drawings - Drawings shall be included in the technical publication and shall be legible.

3.4.1.1 A piping diagram shall be provided for the refrigeration plants/units. The diagram shall show the complete refrigerant circuit, sea water and refrigerant overboard connections. Set points for relief valves shall be provided on the diagram. The refrigerant circuit and refrigerant overboard lines shall include line sizing for the installing activity to use in creating the installation drawings.

3.4.1.2 Drawings to cover the manufacture, arrangement, and assembly of each refrigeration plant shall be provided. Sub-assembly drawings of each hardware item shall be included. Drawings shall completely identify the physical characteristics, weight, center of gravity, locations and function of each major piece of the unit.

3.4.1.3 Drawings to support the shipboard installation of the refrigeration plant shall be provided. The installation drawings shall include plan view and all side/elevation views of the refrigeration plant. These drawings shall provide complete information necessary to install the control panels, system boxes, interconnecting cables, all pipe connections, and any other associated items. These drawings shall also identify system dimensions, mounting arrangement, weight and center of gravity for the refrigeration plant as a whole or the individual sub-assemblies depending on the particular design.

3.4.2 Review and Approval - One paper copy and one electronic copy on CD-ROM of each draft Technical Publication shall be submitted to the Coast Guard Contracting Officer for review and approval. Documents prepared for this contract by the contractor shall be in electronic format that allows imbedded text and graphics and shall be Microsoft® Office Word format or Microsoft® Office Excel format (where applicable) that is compatible with Windows® 7. Drawings shall be developed in AutoCAD® as required by COMDTINST M9085.1C. Any Commercial Off the Shelf (COTS) manuals from vendors that cannot be in the above format shall be an unlocked .pdf file.

3.5 Software (Type 1 and 2) – The Contractor shall provide two hardcopies (paper copies) and two copies on electronic media of the software used to operate the refrigeration plant, ladder logic program, as stated in requirements 3.2.5. All software shall be compatible with Microsoft Windows operating system.

3.6 Warranty (Type 1 and 2) - The Contractor shall provide a minimum of a one-year commercial warranty, from date of installation, for all major components except consumable parts such as filter elements, etc.

3.7 Technical Support (Type 1 and 2) - The contractor may be requested to provide installation technical support services to commission the equipment. The government reserves the right to install systems without contractor support services.

3.7.1 Technical Support services to commission the installations would include a technical representative to provide technical assistance to the independent installing activity to ensure that the equipment is installed correctly and to observe and possibly participate in shipboard testing. Services may also include approximately ½ day of informal training for cutter personnel [4 persons] in the operation, maintenance and adjustment of the equipment. Training would be based on operation, maintenance and adjustment information included in the Technical Manuals.

3.7.2 The Contractor shall identify the daily rate for technical support.

4.0 QUALITY ASSURANCE (QA)

4.1 General (TYPE 1 and TYPE 2) - The contractor shall maintain an inspection system to insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard Quality Assurance Representative (QAR).

4.2 Records (TYPE 1 and TYPE 2) - The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3 Inspections and Tests (TYPE 1 and TYPE 2) - The inspections and tests required by this specification are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the item in question.

4.4 Factory Quality Assurance (TYPE 1 and TYPE 2):

4.4.1 The Contractor shall prepare factory test plans for testing of equipment, and shall submit them for approval to the Contracting Officer Representative at least 30 days in advance of testing.

4.4.2 The contractor shall be responsible for the performance of all inspections and tests, using calibrated test equipment. The contractor shall provide space, personnel, and test equipment for the conduct of all inspections and tests. All factory inspections and tests shall be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the rights to verify or have performed any of the inspections and tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.4.3 The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.5 Operational Testing (Type 1 and 2) - In addition to factory testing, the units will be tested at pier side and/or under normal operation conditions while under way.

4.6 Notifications (Type 1 and 2) - The contractor shall be responsible for notifying the Contracting Officer at least seven (7) working days prior to said contractor being ready for any inspections or testing. Notice to the Contracting Officer shall be written, and transmitted electronically by fax or email.

4.7 Failure Responsibility (Type 1 and 2) – If an item fails to pass any inspection or test, the contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken.

4.7.1 General Statements

4.7.1.1 The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

4.7.1.2 If an item fails an inspection or test, the inspection or test process shall be discontinued until all corrective action has been taken.

4.7.1.3 After corrective actions have been taken, the inspection or test shall be continued or repeated at the option of the Contracting Officer.

4.7.1.4 Acceptance shall be withheld until re-inspection or re-test demonstrates the corrective action was successful and the item satisfactorily passes all inspections and tests.

4.7.1.5 All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

4.7.1.6 Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.8 Inspection and Test Reports (Type 1 and 2) - The contractor shall provide one copy of any required inspection or test report to the Contracting Officer and one copy shall be retained by the contractor for review by the QAR upon arrival at the contractor’s plant.

4.9 Preservation, Packing and Marking Inspection (Type 1 and 2) - The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 5 of this specification.

5.0 PRESERVATION, PACKING and MARKING

5.1 Preservation (Type 1 and 2) - Exposed shafting and working machined surfaces, gear-trains, the inside of gearboxes, and other surfaces dependent on lubricant for preservation shall be lubricated or coated with an appropriate preservative suitable for protection of equipment stowed in an unheated warehouse for up to one year. Preservatives shall be compatible with the intended working lubricants. Special treatments should not be necessary to remove preservatives. Notations of the preservative shall be included in the Technical Publication under Installation Requirements. Warning tags shall be attached to all gearboxes indicating that they have been drained, preserved with a specific product, and require filling with lubricant before equipment use.

5.1.1 Major components shall be shrink-wrapped or otherwise covered and sealed to prevent water damage. Where the protective covering is installed directly on painted surfaces, it shall not be applied until the paint has dried and cured sufficiently to prevent its adhesion with the protective covering.

5.2 Packing (Type 1 and Type 2) - Material shall be packed in boxes meeting ASTM D3951 and shall be suitable for shipment by rail or motor freight. The Contractor shall package and mark the items in such a manner as to prevent damage to the equipment during shipment. The Contractor is responsible for correcting and repairing any damage due to shipment. The boxes shall be assembled with screws to permit ease of removal of the cover or lid from the base. Each shipping container shall be skid mounted, be completely enclosed and be suitable for stacking. Shipping containers shall be suitable for outside covered stowage in the weather. Individual major components shall be bolted to the frame of the palletized framing system. Loose components shall be boxed and restrained within the shipping container.

5.2.1 A copy of the packing list for each container shall be prepared and electronically forwarded to the Contracting Officer for use as a check-off sheet by receiving personnel. A copy of the list shall also be posted on the outside of Box 1 inside a waterproof, clear plastic envelope.

5.3 Refrigeration Plant Packaging (TYPE 1 and TYPE 2) – Refrigeration plants and controllers shall be packaged as a unit. The government will assign Acquisition Control Numbers (ACN) to the refrigeration plant for the USCGC HEALY.

5.4 Marking (TYPE 1 and TYPE 2) - Each packaged item shall be marked in the upper left-hand corner of the two longest sides of each box. If the lettering is stenciled, the lettering shall be at least ½ inch high, in black print on a highly contrasting background. This marking shall consist of the Acquisition Control Number (ACN), System Description, Contract Number and CLIN Number, Delivery Order Number, Box X of Y, Shipping Weight, Condition Code, and Quantity and unit of issue, and the words U.S. Coast Guard SFLC Material.

Example:

ACN: XXXX-XX-XXX-XXXX

ITEM NAME: (STATE SHIP…