0530_A_CARGO_AND_AC_30K_HR_COMPRESSOR_REPLACEMENT_REV_A.docx

USNS CARL BRASHEAR

(T-AKE 7)

CARGO AND A/C 20K HOUR COMPRESSOR OVERHAUL/REPLACEMENT

1.0 ABSTRACT

1.1 This item describes the requirement to perform the Original Equipment Manufacturer (OEM) recommended 20,000 hour compressor replacement for Cargo Refrigeration Plant No. 3 (Chill/Freeze), A/C Refrigeration Plant No. 2.

2.0 REFERENCES

2.1 T/M T9516-A8-MMC-010D; TECHNICAL MANUAL REFRIGERATION PLANT, CARGO FOR USNS LEWIS AND CLARK (T-AKE 1) CLASS - INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

2.2 T/M T9516-BB-MMC-010; TECHNICAL MANUAL REFRIGERATION PLANT, AIR CONDITIONING FOR USNS LEWIS AND CLARK (T-AKE 1) CLASS - INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

2.3 T/M T9516-BC-MMC-010; TECHNICAL MANUAL REFRIGERATION PLANT, SHIP’S STORES, UNIT MODEL 90YS65NSL4NH6Z9Z FOR USNS LEWIS AND CLARK (T-AKE 1) CLASS - INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

2.4 MSC DWG 516-8499012; Refrigeration and Purge Pump-Out System Diagram

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: Auxiliary Machinery Room 5-58-01

3.1.2 Quantity:

a. One (1) Cargo Refrigeration Plant Compressors - Cargo Refrigeration Plant No. 3 (Chill/Freeze)

b. One (1) A/C Refrigeration Plant Compressor - A/C Refrigeration Plant No. 2.

3.2 Item Description/Manufacturer’s Data

3.2.1 Bill of Materials (Contractor Furnished)

534B0834H01

York H Oil or Solest 68

As Required

3.2.2 Quantities are considered estimates. The Contractor shall provide the exact quantities and additional material such as miscellaneous fittings, cable hangers, cable tags, etc., which are not included in the List of Materials, in order to install a fully functional system which meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM)

4.3 Government Furnished Services (GFS): None

5.0 NOTES

5.1 The Contractor and all Subcontractors, regardless of tier, must consult the General Technical Requirements (GTRs) to determine applicability to this work item. In performance of this work item, the Contractor and all Subcontractors, regardless of tier, must comply with the requirements of all applicable GTRs.

5.2 The Contractor and all Subcontractors, regardless of tier, are advised to review other work items under this contract to determine their effect on the work required under this work item.

5.3 This ship contains High Voltage (HV) electrical systems. The Contractor and all Subcontractors shall obey all posted and verbal instructions regarding safety and exclusion from HV areas. At no time shall a Contractor or Subcontractor approach, work on, or enter a HV area without proper authorization.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK AND WHITE. THE CONTRACTOR SHALL ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

5.5 Contractor shall coordinate compressor overhauls with the critical path Work Items 304 and 305 iHVAC Installations.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting: None additional.

7.2 Structural: None additional.

7.3 Mechanical/Fluid

7.3.1 Cargo Refrigeration

a. Pump out refrigerant, depressurize, and tag out the Cargo Refrigeration Plant No. 3 in accordance with References 2.1 and 2.4 and Lock-Out/Tag-Out in accordance with approved procedures. The Contractor will assist ships force with pumping out the refrigerant and depressurizing the unit as necessary.

b. Disconnect and remove the compressors from the Cargo Refrigeration Plant No. 3.

c. Rig the compressors to the Main Deck for removal from the vessel.

d. Transport the compressors from the vessel to the Contractors facility for protecting and packaging/palletizing.

e. Protect (wrap with plastic) and package/palletize the compressors for shipping and long term storage.

f. Return to MSCREP/ILS packaged/palletized compressors for shipping.

g. Rig the replacement compressors in place on the unit and align the coupling to the compressor motor using Reference 2.1 as guidance. Alignment to be witnessed by the Chief Engineer and MSCREP.

h. Re-connect all piping, tubing, electrical, instrumentation, etc.

i. Test over pressurization valves. Provide CFR if replacement is required.

j. Clean suction filters using Reference 2.1 as guidance.

k. Lubricate the motor bearings.

l. Fill compressor with oil.

m. Perform pressure tightness test and leak check in accordance with Reference 2.1. Detect and fix all leaks.

n. Perform drying and vacuum test in accordance with Reference 2.1. Vacuum should be maintained less than 700 microns for 24 hours.

o. Break vacuum with refrigerant in accordance with Reference 2.1.

p. Check unit for readiness. Verify proper operation of the evaporator expansion valve. Perform field calibration as necessary in accordance with Reference 2.1.

q. Perform operational test. Ensure the refrigeration unit set points are properly set in accordance with Reference 2.1.

7.3.2 A/C Refrigeration

a. Pump out refrigerant, depressurize, and tag out the A/C Refrigeration Plant No. 2 in accordance with References 2.2 and 2.4 and Lock-Out/Tag-Out in accordance with approved procedures. The Contractor will assist ships force with pumping out the refrigerant and depressurizing the unit as necessary.

b. Disconnect and remove the compressor from the A/C Refrigeration Plant No. 2.

c. Rig the compressor to the Main Deck for removal from the vessel.

d. Transport the compressor from the vessel to the Contractors facility for protecting and packaging/palletizing.

e. Protect (wrap with plastic) and package/palletize the compressor for shipping and long term storage.

f. Return Ship packaged/palletized compressor to MSCREP/ILS for shipping.

g. Rig the replacement compressor in place on the unit and align the coupling to the compressor motor using Reference 2.2 as guidance. Alignment to be witnessed by the Chief Engineer and MSCREP.

h. Re-connect all piping, tubing, electrical, instrumentation, etc.

i. Testing and/or replacement of the over pressurization valves to be covered under a separate work item.

j. Clean suction filters using Reference 2.2 as guidance.

k. Lubricate the motor bearings.

l. Fill compressor with oil.

m. Perform pressure tightness test and leak check in accordance with Reference 2.2. Detect and fix all leaks.

n. Perform drying and vacuum test in accordance with Reference 2.2. Vacuum should be maintained less than 700 microns for 24 hours.

o. Break vacuum with refrigerant in accordance with Reference 2.2.

p. Check unit for readiness. Verify proper operation of the evaporator expansion valve. Perform field calibration as necessary in accordance with Reference 2.2.

q. Perform operational test. Ensure the refrigeration unit set points are properly set in accordance with Reference 2.2.

7.4 Electrical: None additional.

7.5 Electronics: provide services of OEM to properly diagnose and restore automation of Cargo and AC Plants sequencing.

7.6 Preparation of Drawings: None additional.

7.7 Service Reports

7.7.1 A detailed service report shall be provided no more than 14 days after the period of performance detailing all service performed, compressor clearance readings for as-found and as-installed condition, refrigeration unit operational test performance and set points, and any other pertinent information required for life cycle documentation. Additionally, a comment as to the as-found condition shall be made regarding the need for the 20,000 hour overhaul and possible extension to 30,000 or 40,000 intervals vice 20,000.

7.7.2 The OEM Representative shall orally brief the Chief Engineer prior to departure and provide copies of the rough readings taken during the overhaul process.

7.8 Inspections/Testing

7.8.1 After systems have been restored, systems shall be brought to operating temperatures and pressures in the presence of the ship’s Cargo Engineer. The ship’s First Engineer and MSCREP shall witness the unit operation when the unit is at operating temperatures and pressures.

7.9 Painting/Labeling/Marking: None additional.

7.10 Manufacturer’s Representative:

7.10.1 Recommended sources:

IMECO/Trident, Inc POC: Sean Greenwood Ph: (906) 396-3242 Email: sean.greenwood@tridentllc.com

Johnson Controls POC: James Snider Ph: (954) 707-3454 Email: james.snider@jci.com

8.0 GENERAL REQUIREMENTS: None additional.

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