0705_B_Calibration_Lab_Vent_Mods.doc

USS FRANK CABLE

(AS-40)

7 November 2016

OVERHAUL AND UPGRADE OF Calibration Laboratory (CAL LAB) COMPLEX HVAC “SPECIAL CONTROL SPACES”

1.0 ABSTRACT:

This item provides the detailed information and references for the modifications to the CAL LAB’s HVAC on the O-1 and main deck between frames 84-92. This includes removal and replacement of Cooling Coils, Heating Mediums, Filters, Ducting, Electrical Components, Foundation, Piping and Insulation required to obtain NAVAIR 17-35FR Facility Requirements for Navy and Marine Corps Calibration Laboratories Certification of the Calibration Lab Complex on USS FRANK CABLE.

2.0 REFERENCES/ENCLOSURES:

2.1 REFERENCES

2.1.1 American Bureau of Shipping Steel Vessel Rules (SVR)

2.1.2 NAVSEA Drawing 800-7362894 Rev C, USS Frank Cable Nuclear / Non-Nuclear Interface Booklet. (FOUO)

2.1.3 MSC Drawing No. 803-7081122, Military Sealift Command General Technical Requirements (GTRs)

2.1.4 MSC DWG 512-8494764_A, HVAC MOD INCIDENTAL TO CAL LAB HVAC UPGRADE

2.1.5 MSC DWG 108-8494762, FDN INSTALLATON INCIDENTIAL TO CAL LAB HVAC UPGRADE

2.1.6 MSC DWG 302-8494765, POWER SYSTEM REMOVAL – CAL LAB HVAC IMPROVEMENTS

2.1.7 MSC DWG 302-8494766, POWER & CONTROL SYSTEM INSTALLATION – CAL LAB HVAC IMPROVEMENTS

2.1.8 MSC DWG 302-8494767, LIGHTING SYSTEM REMOVAL – CAL LAB HVAC IMPROVEMENTS

2.1.9 MSC DWG 514-8494763, CHILLED WATER MOD INCIDENTAL TO CAL LAB HVAC UPGRADE

2.1.10 MSC DWG 528-8494784_A, CONDENSATE DRAIN MOD INCIDENTAL TO CAL LAB HVAC UPGRADE

2.1.11 MSC DWG 635-8494768, INSULATION MOD INCIDENTAL TO CAL LAB HVAC UPGRADE

2.1.12 MSC DWG 512-8494786, HVAC DIAGRAM INCIDENTAL TO CAL LAB HVAC UPGRADE

2.1.13 2.1-004-ALL Lockout-Tagout, MSFSC Safety Management Procedures Manual.

2.2 ENCLOSURES

2.2.1 Information on K-Flex Thermal Insulation

2.2.2 Information on K-Flex Installation

2.2.3 Information on K-Flex Clad In

2.2.4 MSC Technical Manual 0809075-76_0_SCAC

3.0 ITEM LOCATION AND DESCRIPTION:

3.1 Locations/Quantity

3.1.1 Locations:

3.1.1.1 MAIN LAB 1-90-1-Q

3.1.1.2 FLOW CAL ROOM 1-86-1-Q

3.1.1.3 02 CAL ROOM 1-87-0-Q

3.1.1.4 DIM ROOM 1-92-1-Q

3.1.1.5 TEMP ROOM 1-95-0-Q

3.1.1.6 FCA ROOM 1-96-1-Q

3.1.1.7 MIRCS SHIPPING AND RECEIVING

1-96-3-Q

3.1.1.8 FORCE ROOM 1-96-5-Q

3.1.1.9 FAN ROOM 1-84-1-Q

3.1.1.10 CABLE REEL ROOM & SAS POWER STA NO. 1 1-86-3-A

3.1.1.11 PASSAGE 1-65-1-L

3.1.1.12 PASSAGE 1-86-1-L

3.1.1.13 ELECTRONICS STANDARDS LAB

01-90-1-Q

3.1.1.14 ELECTRONIC STANDARDS LAB STRM

01-92-1-A

3.1.1.15 MICROWAVE ROOM 01-94-1-Q

3.1.1.16 MICRO-MINIATURE FACILITY AND TEST EQUIPMENT REPAIR 01-86-1-Q

3.1.1.17 AIR LOCK 01-97-1-Q

3.1.1.18 AIR LOCK 01-95-2-Q

3.1.1.19 ELECTRONIC SHOP 01-98-1-Q

3.1.1.20 MEDICAL WARD 01-79-1-L.

3.1.1.21 CABLE REEL ROOM AND SAS POWER STA NO. 2 1-86-2-A

3.2 Item Description/Manufacturer’s Data

3.2.1 Bill of Materials

PC NO. QTY Description

(See Reference 2.1.3 to 2.1.12 for guidance)

NOTE: MATERIAL CALLED OUT IN References 2.1.5 and 2.1.11 FOR INSULATING THE DUCTING AND PIPING IN FAN ROOM 1-84-1-Q AND CABLE REEL ROOM & SAS POWER STA NO. 1 1-86-3-A SHALL BE EB 4013 (K-FLEX brand or equivalent) AS IDENTIFIED IN ENCLOSURES 2.2.1-2.2.3. FAN ROOM 1-84-1-Q AND CABLE REEL ROOM & SAS POWER STA NO. 1 1-86-3-A ALL DUCTING AND PIPING WITH EB 4013 INSULTATION WILL BE COVERED WITH AN AIR BARRIER (K-Flex Clad In or equivalent). THE SPACE SHOULD BE CONSIDERED EXTERIOR TO THE SHIP.

3.2.2 The contractor shall perform a shipcheck prior to starting work the HVAC system, structural, lighting, electronics, and piping for the previously identified spaces; provide accurate measurements and information for additional equipment and material needed to complete the work; and provide redlines to drawings provided by MSC before conducting work.

3.2.3 Quantities given in the List of Materials are considered estimates. The Contractor shall provide these quantities and reasonable additional material in order to install a fully functional system that meets the requirements of this specification.

3.2.4 Additional material/components necessary to accomplish work required by this work item, such as hangers, mounting hardware, weld material, paint etc. are not required to be included in this description, and shall be provided by the Contractor as needed.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIALS/SERVICES: NONE

5.0 NOTES:

5.1 The contractor and all subcontractors, regardless of their tier must consult Military Sealift Command’s General Technical Requirements, (GTR’s), to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of their tier must comply with the requirements of all applicable GTR’s including but not limited to GTR’s 1 through 7, 22,23, 25, 27, 28 and 29.

5.2 The contractor and all subcontractors, regardless of their tier are advised to review other work items under this contract, included but not limited to work items 009, 010, and 015, to determine their effect on the work required under this work item. Based on this review the contractor should plan and schedule work to minimize conflicts between other repairs ongoing during the same time frame. Many of the definitions relating to the performance of this work item are found in Work Item 001.

5.3 The contractor shall perform ship check to retrieve accurate measurements and information before conducting work.

5.4 The Contractor shall provide all labor and material required to accomplish this work item including but not limited to staging, space certification, contamination containment, full penetration welds, fire watches, removal and reinstallation of all interferences including insulation in way of repairs to effect a complete and finished end result.

5.5 Prior to initiating any repair work on any part of the electrical or electronic systems, the circuits involved with this work item will be de-energized, locked out and tagged out from all sources of electrical power, and verified to be de-energized. Restore electrical power upon the completion of all aspects of the work on that component and Lockout/Tagout re-positioned as required.

5.6 All Electrical work shall be performed in accordance with ABS, USCG, and IEEE-45, MIL-STD-1310(G) requirements.

5.7 Do not test any cable connected to a detector with a Megohm meter. Disconnect detectors before testing cables.

5.8 All new cables may require new penetrations. If additional wire-way material is required, the installing activity shall provide miscellaneous material to suit.

5.9 New cable and/or mounting of equipment that requires welding or hot work performed in the service areas (from the interior or exterior) shall maintain the fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.10 Any vacated penetrations or equipment removal from the service areas must be plugged and sealed for water tightness and fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.11 All welding shall be in accordance with ABS rules for building and classing steel vessels.

5.12 All disturbed surfaces will be repaired utilizing approved methods maintaining the water tight, fire tight, or smoke tight integrity of the bulkheads, decks or equipment.

5.13 All shipboard structure, hull insulation, sheathing, etc. damaged or disturbed by these modifications shall be repaired similar to the original or surrounding materials.

5.14 Minor deviations from the drawings are authorized if appearance, function and strength are not impaired.

5.15 Submit Request for Deviation (RFD) to the MSC Representative for approval for any areas that appearance, function and strength are impaired.

5.16 All dimensions and quantities as shown in drawings are approximate.

5.17 Space, ducting and overhead work will be completed prior to cleaning the space and retuning the HVAC systems and Self Contained Air Conditioner (SCAC) to normal operation.

5.18 IAW 2.1.7 the heater controls will be located in an central control cabinet located in Fan Room 1-84-1-Q and components as listed for installation will be installed.

5.19 NO FLEXIBLE DUCT WORK OUTSIDE THOSE SPECIFIED IN THE DRAWING WILL BE USED FOR THIS INSTALLATION.

5.20 SAFETY OF PERSONNEL AND EQUIPMENT IS PARAMONT AND WILL NOT BE COMPROMISED. AT NO TIME WILL SHORT CUTS BE TAKEN CIRCUMVENTING STANDARD SAFETY PROCEDURES SUCH AS TAGOUT/LOCKOUT, ELECTRICAL SAFETY, GAS FREE CERTIFICATION, HOTWORK PROCEDURES OR FOR PERSONNEL WORKING ALOFT. SAFETY IS A MUST.

5.21 THE RADIOLOGICAL CONTROL OFFICER (RCO) SHALL BE NOTIFIED PRIOR TO THE START OF THE REQUIREMENTS OF THIS WORK ITEM. THE RADIOLOGICAL CONTROL OFFICER (RCO) SHALL MONITOR THE REQUIREMENTS OF THIS WORK ITEM WHERE THE CONTRACTOR IS REQUIRED TO INTERFACE WITH THE NUCLEAR SUPPORT FACILITY(NSF) BOUNDARIES. THE RADIOLOGICAL CONTROL OFFICER (RCO) SHALL ENSURE ALL RADIOLOGICAL REQUIREMENTS AND PRECAUTIONS OF NAVSEA 0989-058-8000 FIGURE 1A-24 OR 1B-24 (AS APPLICABLE) ARE MET.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work and testing shall be in accordance with the latest SOLAS regulations, ABS Rules for Building and Classing Steel Vessels, IEEE-STD-45, USCG Requirements, in addition to Ref 2.1.3; and to the satisfaction of and in the presence of the ABS Surveyor (if required), Manufacturer’s Representatives (as necessary), and MSC Representative (MSCREP).

6.2 All welding requirements shall be accomplished by ABS certified welders and meet ABS and USCG requirements. All welders shall be ABS certified to perform the type of welding required and documentation of such shall be current and available upon the request of the MSCREP. Fire watches shall be posted by the Contractor during all hot work.

6.3 Clean and gas free affected enclosed spaces per local procedure as approved by the ship and/or MSCREP.

6.4 The following will apply to any work in the CAL LAB Spaces:

6.4.1 Activity will cover all tables and workbenches with protective plastic sheeting to prevent space contamination.

6.4.2 Cover and protect the fume hood, permanently mounted equipment, and file cabinets with plastic sheeting to keep foreign material out.

6.4.3 Cover deck with protective matting in the CAL LAB spaces.

6.5 A fume hood is located inside 02 Level CAL Room 1-87-0-Q the contractor must arrange protection of the unit while conducting work inside the space.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Arrangements/Outfitting:

7.1.1 The Contractor shall design and make all necessary arrangements (temporary accesses, install padeyes and lifting gear, rigging path, etc) to safely install the HVAC modifications and auxiliary fixtures, using Reference 2.1.4-2.1.12.

7.1.2 Isolate and tag out the sections of electrical being worked using Reference 2.1.13 as guidance or MSCREP-approved local tag out procedures.

7.1.3 Removals

7.1.3.1 Access the HVAC ducting in the CAL LAB spaces’ overheads by removing non-equipment supporting overhead panels. Document location of each panel for replacement.

7.1.3.2 Overhead panels that support HVAC diffusers will be removed with the removal of the existing ducting removal IAW Reference 2.1.4.

7.1.3.3 Overhead light fixtures will be removed as needed to access the HVAC and insulation for ducting for removal. Any light fixtures that are removed will be retained for reinstallation. If feasible the fixtures will be retained in place. Any overhead section with light fixtures can remain in place if desired.

7.1.3.4 Remove any overhead support framing or vertical supports to access the HVAC ducting or to complete work in the overhead of the spaces. Retain as needed or documented where to replace with new.

7.1.3.5 Remove insulation in accordance with Reference 2.1.11.

7.1.3.6 Remove any insulation attaching hardware from the bulkheads and overheads.

7.1.3.7 Remove all chill water piping insulation in Fan Room 1-84-1-Q and Cable Reel Room & SAS Power STA #1 1-86-3-A.

7.1.4 Installation

7.1.4.1 Install insulation in accordance with Reference 2.1.11.

7.1.4.2 Those items from the removal of the overhead and retained in Section 7.1.2 will be installed in the same locations as close as possible.

7.1.4.3 Install HVAC ducting and diffusers penetrations in the overhead panels, frames or supports to support installation IAW with Reference 2.1.4.

7.1.4.4 Replace the overhead panels and lights making adjustments for fitting and placement of the newly installed ducting and louvers from Reference 2.1.4.

7.1.4.5 Replace all chill water piping insulation in Fan Room 1-84-1-Q and Cable Reel Room & SAS Power STA #1 1-86-3-A after sections 7.3.3 and section 7.3.4 (Modifications and Installation of piping are complete.)

7.2 Structural

7.2.1 Isolate and tag out the sections of piping and electrical components being worked using Reference 2.1.13 as guidance or MSCREP-approved local tag out procedures.

7.2.2 Removals

7.2.2.1 Remove foundations for equipment removed in accordance with Reference 2.1.5.

7.2.3 Installation

7.2.3.1 Fabricate and install new foundations in accordance with Reference 2.1.5.

7.2.3.2 Special notice for the installation of the cooling coil for system 1-85-1 in Fan room 1-84-1-Q using Reference 2.1.11 for 8.5 inches above the deck. Also utilize References 2.1.4, 2.1.9, and 2.1.10 for the install of this cooling coil.

7.2.3.3 Install grounding straps on all fans and heaters installed by Reference 2.1.3 in accordance with Reference 2.1.7.

7.2.3.4 Any existing penetrations between CABLE REEL ROOM & SAS POWER STA #1 1-86-3-A and interior spaces will be sealed to prevent unconditioned air from entering the space.

7.3 Mechanical/Fluids

7.3.1 Drain, isolate and tag out the sections of piping being worked using Reference 2.1.13 as guidance or MSCREP-approved local tag out procedures.

7.3.2 Removals

7.3.2.1 Remove piping in accordance with References 2.1.4, 2.1.9 and 2.1.10.

7.3.2.2 Remove ventilation ducting, piping and equipment in accordance with Reference 2.1.4.

7.3.2.3 Any ducting or piping removal that leaves penetrate through a bulkhead or deck that will not be re-used will be sealed.

7.3.3 Modifications

7.3.3.1 Modify piping systems in accordance with References 2.1.9 and 2.1.10 to provide fully functioning system. All valves will be accessible and installed in the correct orientation.

7.3.3.2 Piping will be operationally tested prior to installation of lagging.

7.3.3.3 Modify ventilation systems in accordance with Reference 2.1.4 to provide a fully functioning system.

7.3.4 Installations

7.3.4.1 Install a fully functioning piping system in accordance with References 2.1.9-2.1.10.

7.3.4.2 Install a fully functioning HVAC system in accordance with Reference 2.1.4.

7.3.4.3 Install condensate drains IAW Reference 2.1.10 to ensure terminations are located at deck drains.

7.3.4.4 Installation of check valves IAW Reference 2.1.10 for correct direction of flow.

7.3.5 Contractor shall verify fan rotation and direction of air flow for Exhaust System E1-90-2(153) at location Cable Room & SAS Power STA #2 1-86-2-A to the satisfaction of the MSCREP.

7.3.6 Contractor shall clean all interior surfaces of all modified ventilation systems using Reference 2.1.4 as guidance to the satisfaction of the MSCREP.

7.3.7 Inspect and clean the Self Contained Air Conditioning (SCAC) cooling coils, replace filters and clean condensate drains.

7.3.8 Charge the SCAC refrigerant system to the pressures per Enclosure 2.2.4.

7.4 Electrical

7.4.1 Isolate and tag out the sections of electrical components being worked using Reference 2.1.13 as guidance or MSCREP-approved local tag out procedures.

7.4.2 Removals

7.4.2.1 Electrically disconnect all powered components prior to starting mechanical work.

7.4.2.2 Remove wiring and equipment in accordance with Reference 2.1.6.

7.4.2.3 Remove wiring and equipment in accordance with Reference 2.1.8.

7.4.3 Installation

7.4.3.1 Install a fully functioning electrical and controls system in accordance with Reference 2.1.7.

7.5 Electronics:

7.5.1 Provide manufacturer(s) representative. or qualified technician(s), for the heaters and temperature control components verify installation of the systems for the control of temperature and humidity to include thermostats and humidistats, heaters and cooling coil chill water control for items installed per Reference 2.1.7.

7.5.2 Provide manufacturer(s) representative. or qualified technician(s), to test of the thermostats and humidistats.

7.5.3 Provide manufacturer(s) representative. or qualified technician(s), to adjust thermostats and humidistats to the dry bulb temperature and relative humidity design parameters provided by Reference 2.1.12.

7.5.4 Position thermostats/humidistats IAW with Section 4 STR (Reference 2.1.4) and Reference 2.1.7.

7.6 Preparation of Drawings/Documents:

7.6.1 Redline drawings-

7.6.1.1 Contractor shall provide redline markup of all affected ship’s Selected Records Drawings (SRDs) including, but not limited to: HVAC Diagram, HVAC Calculations, Chilled Water Diagram, and Electrical One Line.

7.6.1.2 Redline markups shall be provided in AutoCAD 2007 and PDF (electronic format).

7.6.1.3 Redline markups shall be provided to MSCREP and MSC Tech Library:

9276 3rd Ave., Bldg LP-26

Norfolk, VA 23511

7.6.2 As-built drawings

7.6.2.1 Contractor shall provide as-built drawings based off References 2.1.4 to 2.1.12 and the installed conditions.

7.6.2.2 As-builts shall be provided in AutoCAD 2004 and PDF (electronic format).

7.6.2.3 As-builts shall be provided to MSCREP and MSC Tech Library:

9276 3rd Ave., Bldg LP-26

Norfolk, VA 23511

7.7 Inspection/Test:

Shipboard Inspection and Testing:

7.7.1 Ducting will be inspected for holes, gaps at flanged connection and welded seams.

7.7.2 Prior to installation of lagging and overhead newly installed HVAC ducting will be operationally tested for air tightness IAW Ref 2.1.4 and correct air flow.

7.7.3 Hydro all new and disturbed piping systems using References 2.1.1, 2.1.4, 2.1.9 and 2.1.10 as guidance.

7.7.4 Operationally test (does not require the water to chilled for this test) all new and modified piping in accordance with References 2.1.1, 2.1.9 and 2.1.10. This test will be completed prior to pipe insulation install.

7.7.5 Operationally test all newly installed condensate drains with fresh water to verify flow.

7.7.6 Perform an operational test of each thermostat/humidistat the satisfaction of the MSC representative (MSCREP).

7.7.7 HVAC testing shall be performed after complete installation and prior to sea trials, at a time when testing conditions are such that accurate, realistic data can be obtained. All readings shall be recorded at half-hour periods and coordinated with recorded data from the installed system instruments and test instruments. If accurate, realistic data cannot be obtained due to the weather conditions prior to sea trials it will be noted and provided to the MSC representative (MSCREP). Additional testing maybe required when accurate, realistic data can be obtained in the future.

7.7.8 Prior to testing the HVAC system as a complete system, fans, motors, coils, filters, compressors, all control devices and dampers, etc., shall be checked for satisfactory operation, adjusted for full load operating conditions; such components shall not be readjusted during tests. All related companion heating, ventilation and common trunk systems, weather intakes or discharges, shall be in simultaneous operation and all doors closed while these tests are in progress.

7.7.9 Test and balance all new and modified ventilation systems in accordance with References 2.1.4 and 2.1.12

7.7.10 During the testing of the ducting record the values of each of the six (6) filter differential Pressure (DP) gages and provide the results in the following format to the MSC representative (MSCREP)

1. Date

2. HVAC System

3. DP Gage Reading

7.7.11 Perform an operational test of the fully functional HVAC MSC representative (MSCREP).

7.7.12 Inspection and acceptance of work shall be by the MSC representative (MSCREP) and ABS Surveyor.

7.7.13 The Contractor’s quality assurance plan shall be invoked for all aspects of this Work Item.

7.7.13.1 During the testing of the ducting check each of DP gage piping for leaks.

7.8 Painting:

7.8.1 Areas where lagging was removed and not replaced clean and prepare those areas and apply two topcoats of paint to match the surrounding per MSC GTR 7 (Reference 2.1.3).

7.8.2 Clean and prepare the disturbed areas and apply two topcoats of paint to all areas disturbed to match the surrounding areas per MSC GTR 7 (Reference 2.1.3).

7.9 Marking

7.9.1 Contractor to install name plates for all newly installed HVAC systems controls per MSC GTR 29 (Reference 2.1.3) and IAW Reference 2.1.7 for newly installed HVAC controls.

7.9.2 Contractor to reinstall or replace name plates for all electrical circuits and components per MSC GTR 29 (Reference 2.1.3) and IAW Reference 2.2.7 for new and repaired electrical circuits.

7.9.3 Contractor to reinstall or replace name plates and stencil flow direction per MSC GTR 29 (Reference 2.1.3) and per Reference 2.1.7 for new and repaired ventilation and piping.

7.9.4 Contractor to reinstall or replace name plates for all affected areas and to stencil flow direction per MSC GTR 29 (Reference 2.1.3) for or new and repaired ventilation and piping.

7.10 Manufacturer’s Representative: Provide Honeywell, or qualified technical person, to verify the installation and operation of the temperature and humidity controls.

7.11 Provide manufacturer documentation for the temperature and humidity controls and operating instructions on for the newly installed HVAC IAW with Reference 2.1.4.

8.0 GENERAL REQUIREMENTS:

8.1 Contractor shall dispose of all waste materials in accordance with all applicable local, state, and federal laws, after prior approval of the MSCREP. No items shall be left for ship’s force disposal.

705-1