Attachment 2, Specifications.pdf

Rev (B) 5 JAN 2017 Rev B Specification for

USCGC HEALY Water Chiller Units

REVISION No. B . CHANGE NO. .

USCGC HEALY

SPECIFICATION FOR

WATER CHILLER UNITS

P-514-0645

ORIGINATED BY Michael Sirak . DATE 28 MAR 2013

DIVISION SFLC-ESD-NAME-AMS .

INTERNAL REVIEWER Steve Sharpe . DATE 28 MAR 2013 .

USCGC HEALY Water Chiller Units

USCGC HEALY SPECIFICATION FOR

WATER CHILLER UNITS

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

4.0 QUALITY ASSURANCE

4.1 General

4.2 Records

4.3 Inspections and Tests

4.4 Factory Quality Assurance

4.5 Notifications

4.6 Failure Responsibility

4.7 Inspection and Test Reports

5.0 PRESERVATION, PACKING AND MARKING

5.1 Preservation

5.2 Packing

5.3 Marking

5.4 Parts Packaging

6.0 NOTES

6.1 Document Sources

USCGC HEALY Water Chiller Units

1.0 SCOPE

1.1 General - The USCGC HEALY water chiller units (A/C Plants) 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 procurement of three (3) new water chiller units.

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 (2012), 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

USCGC HEALY Water Chiller Units

a. None.

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.

USCGC HEALY Water Chiller Units

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 three identical HFC-134a water chiller units for the USCGC HEALY.

3.1.1 Water Chiller Units - The water chillers shall be manufactured from marine grade materials, suitable for marine service. The units 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 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 Water Chiller Unit shall have a minimum refrigeration producing capacity of 75 tons when using refrigerant HFC-134a. Each Water Chiller Unit shall have two circuits on the unit. Each circuit shall be a dual compressor, single condenser, and single evaporator system. As an alternative the Water Chiller Unit can be a dual compressor, dual condenser and a single or dual evaporator system. The Water Chiller Unit shall have a maximum wet weight of 6700 lbs.

3.1.2 Modular Construction – The package water chiller unit shall be of modular construction so as to fit through a marine door with an opening of 28” x 68” and 6” radius corners.

The maximum water chiller size shall be 39” width x 72” height x 116” length when fully assembled on the skid. No brazing or welding shall be required to fully assemble the components into a complete water chiller unit. Where refrigerant piping must be disassembled, unions or flanges shall be provided at the break points. The refrigerant side of the 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 - Quadruple accessible hermetic scroll, reciprocating or screw type compressors, each with a minimum 18.75-ton capacity when using refrigerant HFC- 134a shall be supplied. As an alternative dual accessible hermetic scroll, reciprocating or screw type compressors, each with a minimum 37.5-ton capacity when using refrigerant HFC-134a can be supplied. Each compressor shall be equipped with an oil pump and/or pressurized oil system, suction and discharge shutoff valves, and a muffler.

The scroll and reciprocating compressors shall have an oil sight glass. The compressor shall have a built-in relief valve, if not available on the selected model, a relief valve

USCGC HEALY Water Chiller Units shall be placed near the compressor relieving the high-pressure side back to the low-pressure side. Each compressor shall be mounted on vibration isolators, and have vibration eliminators installed in the refrigeration piping near the compressor. As an alternative the entire refrigeration plant shall be mounted on vibration isolators/resilient mounts. Each compressor shall have automatic capacity reduction of at least two (2) steps. The compressor motor shall be designed to operate on 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 water chiller control microprocessor. The microprocessor shall be in compliance with IEC Standard 6-1131-3 written in a ladder logic program.

The compressor shall be a current production model with an anticipated manufacturing life span of at least 10 years before removal from manufacturer’s stock.

3.2.2 Compressor Crankcase Oil Heater - 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. If a crankcase oil heater cannot be provided in the screw compressor then the oil heater shall be installed in the oil separator.

3.2.3 General Electrical Requirements – As a minimum, the water chillers 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, 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 Electrical Controls - Electrical controls shall be in accordance with the requirements contained in IEC Standard 6-1131-3, IEEE-STD-45 and 46CFR Subchapter J. All

USCGC HEALY Water Chiller Units control power shall be 120 VAC, single phase. Any controller for a motor rated at 50 HP or greater shall have reduced voltage start. The electrical controls 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.

3.2.5 Enclosures - 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.

3.2.6 Wiring - 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.

3.2.7 Junction boxes - 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.

3.2.8 Condensers - Dual seawater cooled shell and tube type condensers with 90-10 copper nickel tubes and tube sheets and removable bronze heads shall be provided. The condensers shall be suitable for use with refrigerant HFC-134a. 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 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. The condenser shall have sufficient capacity to hold at least 120% of the complete refrigerant charge required for the normal connected load. 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 Evaporator – Dual brazed plate type evaporators suitable for use with refrigerant HFC- 134a shall be supplied. Materials of construction shall be 316L stainless steel, copper brazed construction. Design parameters shall be 54 deg F chill water inlet temperature and 44 deg F chill water outlet temperature. Evaporator shall be insulated with 3/4” closed cell foam or equivalent. Chill water inlet and outlet shall have 150 lb ANSI

USCGC HEALY Water Chiller Units flanged connections. The brazed plate evaporator shall be UL listed with a minimum pressure rating of 450 psig on both the refrigerant and watersides. Chilled water flow thru the evaporators shall be based on the rate of 2.4 GPM per ton of refrigeration.

3.2.9.1 As an alternative a single or dual direct expansion shell and tube type evaporator(s), suitable for use with refrigerant HFC-134a can be supplied.

Tubes shall be copper tubing. Shell shall be carbon steel, with removable bolt on head(s). Chill water inlet and outlet shall have 150 lb ANSI flanged connections. Design parameters shall be 54 deg F chill water inlet temperature and 44 deg F chill water outlet temperature. Chilled water flow thru the evaporator shall be based on the rate of 2.4 GPM per ton of refrigeration.

Evaporator shall be insulated with 3/4” closed cell foam or equivalent. The evaporator shall be built, tested and stamped in accordance with ASME Code Section VIII.

3.2.9.2 An additional alternative is the use of a flooded evaporator(s); this alternative shall only be allowed in combination with screw compressors. A flooded evaporator has refrigerant on the shell side and chilled water on the tube side. Tubes shall be internally enhanced seamless copper type. Shell shall be carbon steel. Chill water inlet and outlet shall have 150 lb ANSI flanged connections. Design parameters shall be 54 deg F chill water inlet temperature and 44 deg F chill water outlet temperature. Chilled water flow thru the evaporator(s) shall be based on the rate of 2.4 GPM per ton of refrigeration.

Evaporator shall be insulated with 3/4” closed cell foam or equivalent. The evaporator(s) shall be built, tested and stamped in accordance with ASME Code Section VIII. The evaporator(s) shall be mechanically cleanable with removable heads. The design can incorporate 2 independent refrigerant circuits in a single evaporator.

3.2.10 Thermal Expansion Valve – Each refrigerant circuit shall have an HFC-134a compatible thermal expansion valve. The power head shall be replaceable and adjustable. Valve shall have soldered type connections. 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, 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.

3.2.11 Liquid Line Solenoid Valve – 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 and is automatically operated by the microprocessor to provide unit pump down.

3.2.12 Moisture Indicators - 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

USCGC HEALY Water Chiller Units 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.

3.2.13 Sight Flow Indicators – Each refrigerant circuit shall have a sight flow indicator installed in the 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.

3.2.14 Dehydrators - 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 liquid line solenoid valve. Dehydrators shall have brazed type connections.

3.2.15 Oil Separator - Each refrigeration circuit shall have an oil separator installed. The oil return line on the separator shall be connected to the compressor crankcase or to a crankcase equalization line between compressors in the quadruple compressor configurations. The oil return line shall have an oil filter and isolation valves installed.

3.2.16 Gauge and Test Connections

3.2.16.1 Each compressor shall have a refrigerant suction pressure, refrigerant discharge pressure and oil pressure gauge and test connections installed. Test connections shall include shut off valves installed upstream for each so that a Coast Guard supplied gauge can be connected to the unit while the unit is operating.

3.2.16.2 Each condenser shall have seawater inlet and seawater outlet pressure gauge and 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.

3.2.16.3 Each evaporator shall have a chill water inlet and chill water outlet pressure gauge and 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.

3.2.17 Relief Valve – 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.

3.2.18 High Pressure Rupture Disc – Each refrigerant circuit shall have an HFC-134a compatible rupture disc installed, for emergency discharge of the refrigerant charge.

USCGC HEALY Water Chiller Units

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.

3.2.19 Low Pressure Rupture Disc – 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.

3.2.20 Sea Water Regulating Valve – 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.

3.2.21 Charging Valve – Each refrigerant circuit shall have an HFC-134a compatible charging valve installed. Schrader type.

3.2.22 Controls

3.2.22.1 Water chiller controls shall include the following components as a minimum:

i. Electronically controlled using unit-mounted microprocessor.

ii. Communicate with the cutter’s Machinery Plant Control Monitoring

System (MPCMS) if there is a malfunction in the system.

iii. Power and control circuit terminal blocks.

iv. ON/OFF control switch.

v. Single set point potentiometer for chilled water exiting temperature.

vi. Thermistors or other sensors shall be installed to measure the following functions:

A. Saturated Condensing Temperature (Deg F) B. Evaporator Saturation Temperature (Deg F) C. Compressor Return Gas Temperature (Deg F) D. Evaporator Chilled Water Entering Temperature (Deg F) E. Evaporator Chilled Water Exiting Temperature (Deg F)

3.2.22.2 Display – Minimum one line display capable of being viewed in all types of lighting conditions. As a minimum, the display shall be capable of showing the following:

i. All temperatures and pressures from the installed thermistors.

Temperatures shall be displayed in deg F and pressures in psi.

ii. Indicating the safety lockout condition by displaying a code or a clear English language explanation of the lockout condition. If codes are displayed, all codes and explanations shall be provided to the Coast Guard.

USCGC HEALY Water Chiller Units

3.2.22.3 Unit Controls – As a minimum, unit controls shall be capable of performing the following functions:

i. Automatic circuit lead/lag.

ii. Pump down at beginning and end of every circuit cycle.

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

iv. Limiting the chilled water temperature pull down rate at start up to 1 deg F per minute to prevent excessive demand spikes (charges) at start up.

v. Unit shall be capable of starting with up to 95 deg F chilled water fluid temperature entering the evaporator.

3.2.23 Safeties

3.2.23.1 As a minimum, the water chiller shall be equipped with thermistors and all necessary components in conjunction with the control system to provide the unit with the following:

i. Loss of Refrigerant Charge Protection.

ii. Low Chilled Water Flow Protection.

iii. Low Chilled Water Temperature Protection.

iv. Low Condenser Flow Protection.

v. Low and High Superheat Protection.

vi. Refrigerant High Pressure Switch.

vii. Compressor Ground Fault Sensor.

viii. Oil Safety Switch.

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

A. High Pressure overload protection.

B. Electrical overload protection.

3.2.24 Environmental Requirements – The water chiller shall be designed to function properly in the following conditions:

3.2.24.1 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.

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

3.2.24.3 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.

USCGC HEALY Water Chiller Units

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

3.3 Integrated Logistics Support – The manufacturer shall supply the following items separately for each water chiller unit:

3.3.1 Provisioning Technical Documentation - The Contractor shall develop and furnish provisioning technical documentation (PTD) to the Coast Guard Contracting Officer’s Representative (COR) in accordance with SLFC Specification D-083-0351. It shall include a list of all end items installed, the OEM cage code, and OEM part or assembly numbers. All spare parts necessary for overhaul of a unit shall be identified in the printed technical documents.

3.3.2 Recommended Spare Parts List - The Contractor shall also provide with the PTD a list of recommended spare parts 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 parts pricing and their lead times at the time of delivery of the equipment.

3.4 Technical Publications – A technical publication shall be provided for the equipment and accessories of the system. The Contractor shall develop and furnish the technical publication 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 publication.

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 water chiller unit. The diagram shall show the complete refrigerant circuit, chilled water, sea water and refrigerant overboard connections. Set points for relief valves shall be provided on the diagram. The 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 water chiller 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 chiller units shall be provided.

The installation drawings shall include plan view and all side/elevation views of the water chiller unit. 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

USCGC HEALY Water Chiller Units water chiller unit 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/DVD-ROM of the draft Technical Publication shall be submitted to the Coast Guard Contracting Officer’s Representative (COR) 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® 10. 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 – The Contractor shall provide to the COR for review and approval two hardcopies (paper copies) and two copies on CD/DVD-ROM of the software used to operate the chiller plant, ladder logic program, as stated in requirements 3.2.4. All software shall be compatible with Microsoft Windows 10 operating system.

4.0 QUALITY ASSURANCE (QA)

4.1 General - The contractor shall maintain an inspection system to insure that each item offered to the Coast Guard for acceptance and 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 - 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 - 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:

4.4.1 The Contractor shall prepare factory acceptance test plans for testing of equipment, and shall submit them for review and approval to the COR at least fort-five (45) days in advance of testing. COR responses shall be provided to vendor no later than twenty-one

(21) days before testing is to commence.

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 suitable facilities.

USCGC HEALY Water Chiller Units

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 Notifications - The contractor shall be responsible for notifying the COR at least seven (7) working days prior to said contractor being ready for any inspections or testing. Notice to the COR shall be written, and transmitted via email.

4.6 Failure Responsibility – If an item fails to pass any inspection or test, the contractor shall report the failure and the recommended fix on a Condition Found Report (CFR) to the COR within forty-eight (48) hours via email. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the COR.

4.7 Inspection and Test Reports - The contractor shall provide one copy of any required inspection or test report to the COR within seven (7) days of completed inspection or testing and one copy shall be retained by the contractor for review by the COR upon arrival at the test facility

5.0 PRESERVATION, PACKING and MARKING

5.1 Preservation - 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 - 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

USCGC HEALY Water Chiller Units 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 COR 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 Marking - 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: WATER CHILLER UNITS

FOR USCGC HEALY

CONTRACT NUMBER: DHS-XX-XX-X-XXXXX, CLIN XX

DELIVERY ORDER NUMBER: DELIVERY ORDER XXX

BOX X OF Y BOX X OF Y

SHIPPING WEIGHT: XX LBS GROSS WT (THIS BOX)

CONDITION CODE: CONDITION “A”

QUANTITY & UNIT OF ISSUE: 1 – SHIPSET

U.S. COAST GUARD SFLC MATERIAL

5.4 Parts Packaging - A National Stock Number may be assigned on an individual basis to certain assemblies, subassemblies and/or spare parts for the purpose of stocking. When such items are ordered under this contract, they shall be individually packaged for storage and reshipment without repackaging. Packing shall meet 5.2. Marking shall meet 5.4 except a NSN shall replace the ACN, and the Contractor Part Number shall replace the Delivery Order Number. Each individual package shall be marked on the face or in the upper left-hand corner of the two longest sides of each box. Lettering shall be at least ¼ inch high, in black print on a highly contrasting background.

5.4.1 All packages shall also have a bar code label applied, or incorporated into the packaging label. Bar Code labels shall be in accordance with SFLC specification D-000-0100.

USCGC HEALY Water Chiller Units

The actual labels shall be Type V, Grade B, Style 2, Composition “b” with or without plastic laminate. Each label shall contain encoded data for the stock number, contract number, and the Delivery Order Number, as applicable.

5.4.2 Dimensionally large items (which exceed express carrier shipping limits in standard boxes), and items over 80 lbs shall be packaged in skid mounted enclosed shipping containers for shipment by rail or motor freight, and capable of being stacked during shipment and storage. Each container shall have a lid that is attached with self-tapping wood screws for easy removal and reattachment. Containers shall be suitable for inside covered storage.

5.4.3 Multi-pack - Individual packages of spare parts may be combined for shipping purposes.

The requirements in 5.4 apply. Where multiple items are combined in one shipment the shipping container shall be marked with the word “MULTI-PACK” in addition to the other marking.

6.0 NOTES

6.1 Document Sources

6.1.1 Government Documents

a. 46 Code of Federal Regulations, Subchapter J (2012), Electrical Engineering http://www.access.gpo.gov/nara/cfr/cfr-table-search.html

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

USCG Surface Forces Logistics Center (ESD-TIMB) 2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6581

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

USCG Surface Forces Logistics Center (ESD-TIMB) 2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6646

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

USCG Surface Forces Logistics Center (ESD-TIMB) 2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6646

e. D-086-0508, REV A, Dated 4/08, Technical Publications and Drawings.

USCG Surface Forces Logistics Center (ESD-TIMB) 2401 Hawkins Point Road

USCGC HEALY Water Chiller Units

Baltimore, MD. 21226-5000 410-762-6646

6.1.2 Commercial Documents

a. ASME Standards American Society of Mechanical Engineers International (ASME) Three Park Avenue, M/S 10E New York, NY 10016-5990 800-843-2763

b. ASTM Standards American Society for Testing & Materials (ASTM) 1916 Race Street Philadelphia PA. 19103-1187 215-299-5585

c. IEC International Engineering Consortium (IEC) 233 S. Wacker Drive, Suite 8400 Chicago, IL 60606-6338 USA 312-283-8457 www.iec.org/

d. IEEE Institute of Electrical and Electronics Engineers (IEEE) Park Avenue, 17th Floor New York, NY 10016-5997 212-419-7900 www.ieee.org/

e. NEMA National Electrical Manufacturers Association (NEMA) 1300 North 17th street, suite 1847 Rosslyn, VA 22209 703-841-3200 www.nema.org/

f. UL Underwriters Laboratory Corporate Headquarters 333 Pfingsten Road Northbrook, IL 60062-2096 847-272-8800 www.ul.com/