Attachment__1_Salient_Characteristics_Specifications.docx

June 14, 2018 Containerized Chiller Purchase Specification

The purpose of this document is to define the requirements for the acquisition of a containerized chilled water plant that will be permanently installed aboard the USNS Hershel Williams (ESB-4). The containerized chilled water plant shall be a “turn-key” system that will only require the installation team to make shipboard interface connections to electric, seawater and chilled water distribution piping, alarms, and communications. The T-ESB class ships are considered hybrid vessels. They are governed and inspected under both commercial, American Bureau of Shipping (ABS), and US Navy regulations. The primary commercial regulatory body is ABS using Steel Vessel Rules (SVR) 2010. In the event this document contradicts ABS rules, the Technical Point of Contact (TPOC) shall be immediately notified for resolution.

I. General:

1. The use of Victaulic fittings are not acceptable.

2. All piping such as seawater, chilled water, refrigerant etc. that is susceptible to condensation shall be insulated to prevent condensation.

3. The container exterior shall be painted haze gray, Federal Standard Color (FSC) code 26270 using Interthane 990 polyurethane.

4. The container interior and equipment shall be painted or powder coated as commercially provided.

5. Chilled water and seawater piping shall be 90/10 copper nickel in accordance with Mil-T-16420.

6. Two chillers shall be installed, each chiller shall be 50 nominal tons (176 kW). See section II, Item 7.

II. Container:

1. The container shall be a standard 20’ International Organization of Standardization (ISO) container also commonly referred to as a Twenty Foot Equivalent Unit (TEU), with an 8’ height. For the purposes of this document, it will be generically referred to as a container.

2. Standard ISO double cargo access doors shall be provided on the aft end of the container, see figure 1.

3. An additional, standard minimum 30” wide, maximum 36” wide personnel access door shall be positioned on the left side of the container when facing forward, viewed from the aft end double cargo doors. The door shall open outwards from the container. See attached figure 1.

4. The wet weight of the container, including chillers, all associated equipment, tanks and controls shall not exceed 40,000 lbs (18,144 Kg).

5. The container shall be weather tight.

6. The container shall be cooled with its own cooling coil, associated fan, and equipment to prevent overheating of the interior equipment. The cooling coil shall feed from the container’s chilled water system. It shall maintain interior container ambient temperatures to no greater than 95°F with an outside air temperature of 122 ºF Dry Bulb and 50% relative humidity. The container maximum interior relative humidity shall be less than or equal to the maximum allowable operating relative humidity of the equipment installed within the container.

7. Chilled water connected loads, less the container cooling system, are 33 tons. The total connected load for a single chiller, including the container cooling system shall not exceed the capacity of a single chiller rated at the system design conditions listed herein. It is desired to maximize the system design margin within the limitations above, while also not oversizing the chiller system, resulting in suboptimal chiller performance. If a 50 ton (nominal) chiller is deemed oversized, a smaller capacity unit may be offered instead, as long as the unit satisfies the total connected load requirements.

8. Fluorescent or LED lighting shall be provided inside the container to perform all operational and maintenance activities. A light switch shall be provided just inside the personnel access door, opposite the hinge side of the door.

9. At least two 120 VAC / 20 amp outlets for portable accessories shall be provided. The outlets shall be ground fault protected.

10. Electric heat shall be provided inside the container to ensure that inside air temperature does not fall below 40 ºF (4° C).when the outside air temperature is -4 ºF (-20° C).

11. Interior wiring runs shall be conduit or armored and secured to the interior bulkheads or overhead.

12. The container shall be insulated to prevent condensation on the container and to minimize cooling and heating load.

13. Components shall be arranged such that preventive maintenance can be accomplished without removal of the chiller from the container.

III. Required Equipment in the Container

Chillers:

1. Two 50 ton (nominal) marine grade chiller plants, each shall be a complete operational unit such as Carrier Model 30MPW and include at a minimum, compressor(s), compressor insulation, evaporator, condenser (remote or co-located w/ isolation valves), controls, controls-interface panel, expansion valve(s), refrigerant, and refrigerant compliant oil.

2. Each chiller shall be configured to run independently of the other.

3. Hot gas bypass shall not be required or used as a method of capacity control.

4. Refrigerant reliefs shall relieve to atmosphere, external to the container.

5. Each chiller shall utilize replaceable filter dryers.

6. Each chiller shall operate on 460 VAC/3 Phase/ 60 Hertz

7. There shall be electrical overload protection for each chiller located in the container.

8. Each chiller shall have its own dedicated condenser, designed for seawater cooling with a maximum inlet temperature of 95º F (35º C) and be capable of operating down to 40º F (4° C).

9. Galvanic protection shall be provided at the container to pipe interface.

10. Chilled water temperature leaving the evaporators will be regulated to obtain 44º F (7º C) based on an evaporator chilled water inlet temperature of 54º F (12º C).

11. The seawater inlet shall have two simplex “Y” strainers located inside the container to provide downstream component protection. The strainers shall be configured in parallel such that strainer maintenance can be performed without shutting down the in-service chiller.

12. All shipboard interface connections such as seawater and chilled water shall have inlet and outlet isolation valves located inside the container.

13. All seawater and chilled water piping, and components shall have drain valves installed such that the entire system, including system low points and components can be drained.

Outfitting:

Along with the necessary, specification compliant piping, chiller and associated equipment, the container shall include smoke detection, flood detector, fire extinguisher, refrigerant leak detector, and public address/general alarm (5MC) capabilities. At a minimum, the container shall have the following installed:

1. (1) 15 lb C02 fire extinguisher in accordance with (iaw) Mil-E-24269, mounted inside the container near the personnel access door

2. (1) Salwico addressable smoke detector, Salwico EV-P 040020 or equal

3. (1) Salwico addressable manual call point, Salwico MCP-A IP23 manual call point or equal.

4. (1) Hose McCann Public Address and General Alarm (PA/GA) speaker - 5MC

5. (1) Refrigerant Leak Sensor, with 4-20mA output signal

6. (1) Hose McCann Sound Powered Telephone

7. (1) PSM BLS 9200 Float assembly for flood detection

8. (1) Hose rack and 50 feet of ¾” hose Grainger part # 423H85 or equal.

9. Spare refrigerant shall be provided. The amount of refrigerant provided shall be no less than the amount to completely recharge a single chiller. The refrigerant bottles shall meet the requirements of the Defense Logistics Agencies (DLA) compressed gas program (NAVSUPINST 4440.128D) and the appropriate DOT standard such as 4BA/W300. Additionally the total weight of the cylinder including contents shall not exceed 75 lbs and shall be securely mounted inside the container.

10. Empty refrigerant cylinders shall be provided to contain a full charge of refrigerant for a single chiller. The cylinders shall be identical as the spare refrigerant cylinders listed above. The cylinders shall be securely mounted inside the container.

11. Special tools required for preventive maintenance shall be provided.

IV. Systems

Chilled Water:

1. Chilled water tank(s) and expansion tank(s) with level indicators shall be provided as necessary.

2. (2) Distribution chilled water pumps (1 for each chiller) shall be supplied and installed in the container. Each pump shall be rated for normal operation at 125 gpm @ 95 psi.

Seawater:

1. The seawater condenser piping shall have a seawater regulating valve on the seawater discharge of the condenser. The valve shall be located inside the container.

Potable water:

1. Piping, valves and a backflow preventer shall be installed in the container such that when a potable water source is connected to the exterior interface connection, the chilled water system can be filled from inside the container.

Electrical:

460 VAC / 120 VAC:

1. (1) Power panel shall be provided with a power rating of 460 VAC, 3 phase, 60 hertz. The power panel shall have a minimum of two spare 460 VAC circuits and supply for continuous current-carrying capacity equal to 125% of the largest motor plus the sum of the nameplate ratings of all other motors supplied, including 50% of the rating of spare switches on the distribution unit.

2. A 460 VAC/120 VAC step-down transformer shall be provided to power lighting, two 20 amp GFCI protected receptacles, controls, and alarm system sensors as required.

Systems Interface Panel:

A systems interface panel shall be provided centrally located between the personnel access door and the end cargo doors. Figure 1 depicts the seawater and chilled water deck penetrations, the interface panel shall be located in this general vicinity to allow for connections using flanged flexible hoses. The panel shall consist of the following connections:

a. Chilled water inlet shall be 2 ½”, 150 lb, Navy, flange.

b. Chilled water outlet shall be 2 ½”, 150 lb, Navy, flange.

c. Seawater water inlet shall be 2 ½”, 150 lb, Navy, flange.

d. Seawater water outlet shall be 2 ½”, 150 lb, Navy, flange.

e. Potable water connection shall be a ¾” female garden hose connection for use with the industrial rated hose provided within the container.

f. Electrical connections shall be located on the interface panel and shall be provided as follows:

1. Power to the container shall be provided through an ESL Power System receptacle assembly, part number 2217-90, installed on the interface panel. The contractor shall supply the male mating plug, Russelstoll part number F228077.

2. The combination smoke detector and manual call box container connection shall be provided using Glenair receptacle, part number, 220-07E16-6SN installed on the interface panel. The contractor shall supply the male mating plug Glenair, part number 220-06E16-6PN.

3. The 5MC container connection shall be provided using Glenair receptacle, part number, 220-07E16-6SN installed on the interface panel. The contractor shall supply the male mating plug Glenair, part number 220-06E16-6PN.

4. The sound powered phone connection to the container shall be provided using a Dynalec 4 Jack, part number A343-G15C installed on the interface panel. The contractor shall supply the Hose McCann mating connector, part number H39A.

5. The gas leak detector and flooding alarm shall be connected through the interface panel using a Glenair receptacle 220-07E16-19SN or equal. The contractor shall supply the mating connector Glenair, part number 220-06E16-19PN for later installation. The receptacle is larger than currently required however this is intentional to allow for additional remote system monitoring if needed.

g. All interface connections shall be provided with plugs, caps or blanks.

V. Testing and Factory Acceptance Test (FAT)

1. The seawater piping shall be hydrostatically tested to 169 psi.

2. The chilled water piping shall be hydrostatically tested to 141 psi.

3. The FAT shall be conducted at the manufacturer’s facility.

4. The FAT shall demonstrate the operation of all components to the satisfaction of the government’s witnesses.

5. At the successful conclusion of the FAT, all water systems shall be drained including all pumps and system low points.

VI. Safety

1. The personnel access door shall have a mechanism to hold the door in the fully open position.

2. The personnel access door shall have a keyed lock, lockable from the exterior of the container. The door will remain operational from inside the container and capable of being opened from inside even when locked

3. An emergency shutdown button shall be provided in the container near the personnel access door.

VII. Documentation

The contractor shall provide commercial documentation and include at a minimum:

1. Safety instructions,

2. Functional description,

3. Operational instructions,

4. Maintenance instructions,

5. Troubleshooting,

6. Parts list,

7. Consumable requirements,

8. Electrical and control schematic diagrams,

9. Container equipment arrangement layout,

10. Piping and instrumentation diagram (P&ID).

VIII. Miscellaneous

1. Delivery of the containerized chiller shall be to Naval Operating Base (NOB) Norfolk, Virginia.

2. The container and systems shall be winterized to prevent freezing during shipping and storage.

3. Operation, troubleshooting and maintenance training shall be provided at the contractor’s facility during factory acceptance testing.

4. Special tools required for preventive maintenance shall be provided.

5. A 12-month warranty shall be provided on all electrical, mechanical and structural components.

6. Preliminary and final drawings, including a P&ID shall be submitted to the government for approval before the start of construction.

7. In addition to item 3 above, the manufacturer shall provide on-site (NOB Norfolk, Virginia) training, start-up and commissioning assistance for up to 3 days.

Figure 1: Excerpt of AC plant Enclosure SK-820-2 Rev-image1.emf