SOW_N4044320Q0002_EARHART_CARGO_AC_SOR.pdf

STATEMENT OF WORK

USNS AMELIA EARHART

1.0 ABSTRACT:

1.1 This item describes the requirement for original equipment manufacturer (OEM) representative to inspect, operate and test the shipboard Chill Water Air Conditioning Plants, Cargo Refrigeration Plants and their supporting equipment, as well as make repairs.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 T/M T9516-BB-MMC-010 HVAC/Cargo Refrigeration Operation and Maintenance

2.1.2 T/M T9516-A8-MMC-01C Refrigeration Plant, Cargo for USNS AKE 1 Class

2.1.3 T/M T9516-BF-MMC-010 Cargo Refrigeration Pump Out Unit R134a

2.1.4 T/M T9516-BG-MMC-010 AC System Pump Out Unit 404a

2.1.5 T/M T9516-BN-MMC-01A Cargo Brine System

2.1.6 T/M T9512-BN-MMC-010 to 060 HVAC Systems

2.1.7 T-AKE Cargo Refrigeration and Air Conditioning System Shipboard Automated Maintenance Module (SAMM) Maintenance Actions

2.2 Enclosures:

2.2.1 Enclosure 1 - Ship Material Assessment & Readiness Testing A/C Chill Water Units, SWBS Test # 50102

2.2.2 Enclosure 2 - Ship Material Assessment & Readiness Testing Cargo Refrigeration Compressors, SWBS Test # 50202

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location:

3.1.1 Auxiliary Machinery Room (5-58-01)

3.2 Quantity:

3.2.1 AC Plants:

a. Four (4) ea York VSM 89 AC Plants

3.2.2 Cargo Refrigeration Plants

a. Three (3) ea York Marine AB VSB 151L

3.2.3 HVAC Support Equipment

3.2.4 Electronic Control System:

a. Stalectronic 2200

b. NOTE: This will require OEM access passwords supplied by the Tech Rep.

3.3 Contractor Furnished Material (CFM):

Part Number Description Qty 534B0834H01-H33 Slide Valve Overhaul Kit 1 959-534-980 Gasket O-Ring Kit 1

BASM-89 Tool, Socket Extract 1

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES: None.

5.0 NOTES:

5.1 Performance Location: Chinhae, Korea.

5.2 Period of Performance: 21 Oct – 19 Nov 2019.

5.3 Port Engineers Information: Scott Ketterman, Scott.ketterman@navy.mil, Phone (757) 285-2075.

5.4 Provide an access list of all personnel boarding the ship. The list shall include the following:

• Persons full name

• SSN, or passport #, or naturalization #

• Place of birth

• Date of birth

5.5 The Contractor shall be responsible for proper and timely submittal of all access requirements to include, but not limited to, EPIC and base/port access.

5.5.1 There are additional access requirements for Diego Garcia. Contractor shall complete all requirements for access.

5.6 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. OBEY ALL

POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH

VOLTAGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA

WITHOUT PROPER AUTHORIZATION.

5.7 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. ASSUME ALL ELECTRICAL

CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHERWISE. TEST ALL ELECTRICAL

CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work to be done to the satisfaction of the Chief Engineer and the Port Engineer.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Provide the services of Authorized York Service Representative to accomplish system checks on each Air Conditioning Plants, Cargo Refrigeration Plants and including, but not limited to, Cargo Brine Systems, Chilled Water Systems, R134a and R404a Pump-Out Recovery Units, and the Electronic Control System found aboard the T-AKE Class ships.

7.1.1 The OEM Reps shall be familiar with the T-AKE Class and installed equipment onboard the vessels listed in Paragraph 3.2.

7.2 Point of Contact for Services:

IMECO, Inc. (CAGE 0V369) Sean Greenwood Phone (Direct): 906-779-3027 Phone (Office): 906-774-0202 x3027 Phone (Cell): 906-396-3242 Fax: 906-774-7029 E-mail: sean.greenwood@tridentllc.com

7.3 The OEM Representative shall complete the following for each ship listed in Para 5.1.

7.3.1 All system operational tests and inspections shall be accompanied by the MSCREP.

mailto:Scott.ketterman@navy.mil

7.3.2 Perform pre-operational inspections and operational performance tests for the equipment in 3.0.

7.3.3 Perform the following operational tests on the HVAC Chill Water Units:

a. Local Emergency Stop.

b. High Pressure Monitor Cut Out, electronic.

c. High Pressure Monitor Cut Out, mechanical.

d. Low Pressure Monitor Cut Out, electronic.

e. Low Pressure Monitor Cut Out, mechanical.

f. Low Oil PSI Trip.

g. Chilled Water Outlet Temp Alarm.

h. Chilled Water Inlet High Temp.

i. Chilled Water Inlet Low Temp.

j. Low Oil Temp Start Block.

k. Oil Heaters Operate in STBY.

l. AC Plant Shuts Down When Condenser Cooling Wtr Stops.

m. AC Plants do not start with failure of Condenser Cooling Water flow.

n. AC Plant stops when chill water flow stops to Evaporator.

o. AC Chill Water Pump Interlock prevents start with no Chill Water flow.

p. Check status of Refrigerant leak detection in bilge and main alarm console.

q. Test operate manual capacity increase and decrease on Control Cabinet and on top of compressor.

r. Summary alarm at MCCS is operational.

7.3.4 Perform the following operational tests on the HVAC Cargo Refrigeration Systems:

a. Local Emergency Stop.

b. High Pressure Monitor Cut Out, electronic.

c. High Pressure Monitor Cut Out, mechanical.

d. Low Pressure Monitor Cut Out, electronic.

e. Low Pressure Monitor Cut Out, mechanical.

f. Low Oil PSI Trip.

g. Evaporator Brine Outlet Temp Alarm.

h. Evaporator Brine Inlet Temp Alarm.

i. Low Oil Temp shutdown.

j. Condenser Water Outlet Temp Alarm.

k. RCS Expansion Tank Low level Alarm.

l. Oil Heater Operates when unit in STBY.

m. Cargo Plants do not start without condenser cooling water flow.

n. Cargo Plants shuts down when condenser cooling water stops.

o. Check status of refrigerant leak detection in bilge and main alarm console.

p. Demonstrate operation of manual capacity increase and decrease controls.

q. Record all associated Storage Box Temperatures in operation.

r. Verify all preset values prior to system operational test and record.

s. Readings shall be included for chilled water, cooling water, refrigerant and oil.

Readings shall include Chill Water and Brine Systems.

7.3.5 Perform refrigerant leakage search of each unit listed in 3.0.

7.3.6 Perform an operational test of the gas detection system.

7.3.7 Perform inspection and operational test of R134a and R404a Pump-Out Units.

7.3.8 Perform visual inspection of couplings of both cargo and domestic AC compressors.

7.3.9 Operationally test the Cargo Refrigeration and Air Conditioning STALECTRONIC 2200 control and operating computers OP1, OP2, OP3, and OP4. (NOTE: This will require OEM access passwords supplied by the Tech Rep.)

a. Verify computer software is programed as per iHVAC T-ALT 319.

b. Check and adjust OP1 and OP2 stations as when one station goes down, the other will not take over as normal.

c. Check and troubleshoot why OP4 is not working.

d. Adjust software settings, and perform software reprograming as required to ensure the STALECTRONIC 2200 control and operating computers OP1, OP2, OP3, and OP4 monitoring and properly controlling the Cargo refrigeration and Air Conditioning Units.

e. Verify and record all OP Station programming settings compared to original (delivered) settings. Reprogram the OP stations back to the default settings.

f. Provide training to Ship’s Force on basic operation and navigation of the STALECTRONIC 2200 System. This shall also include training on how to re-install OP Station control software and install/load/reboot a system.

g. Provide a system backup, and instructions for recovery/reinstallation, for each operating system.

7.4 Repairs:

7.4.1 Remove slide valve from AC compressor No 1 and overhaul with proper C-ring and Gaskets. Note: Rigging support will be provide under a separate Contract WI. Fill unit with oil to compression side of positioning spring. Align compressor and motor coupling. Start-up and test unit operation when completed.

7.4.2 AC740-VSD unit is not operating in maintenance mode.

7.4.3 AC741-VSD check VSD system for operation as it was removed by ship force, due to smoking when running.

7.4.4 Check fault on CSU2SB Channel alarm (2nd deck STBD)

7.4.5 Check the following AHU Units sensor issues:

a. AC910-No room Temp Reading

b. AC960-No room Temp Reading

c. AC745-No room Temp Reading

d. AC743-No room Temp Reading

e. AC740-No room Temp Reading

f. AC930-No room Temp Reading

g. AC121-No room Temp Reading

h. AC241-No room Temp Reading

i. AC221 TC 50 PKL-Screen has failed.

7.4.6 Review onboard spare allowance and conduct survey of onboard spare parts.

7.4.7 Review, witness, and document ship's force standard operating procedures.

7.4.8 Provide crew training to questions and conditions encountered.

7.4.9 Provide a Service Report after each attendance that includes:

a. The "as found" condition of cargo refrigeration and air conditioning plants including, but not limited to, cargo refrigeration and air conditioning compressors, cargo brine system, chilled water systems, and R134a and R404a Pump Out Units.

b. Unit serial number and operational hours for each unit.

c. Current software and firmware version information.

d. Current passcodes.

e. Details of all actions and adjustment that were accomplished.

f. Documentation of troubleshooting activities and recommendation for repair.

g. Recordings of all operational OEM Factory Set Points and the actual values found during tests. Include all temperatures, pressures and fluid levels.

h. Equipment status for last oil and filter replacement, Filter Dryer Replacement by hours for each unit.

i. Documentation of the last oil, oil filter and filter dryer replacement by hours for each unit.

j. Recommendation for improvement to shipboard and shore based spare allowances.

k. List of current obsolete parts or parts near obsolescence with recommended replacement parts.

l. Recommendations for improvement to standard cargo refrigeration and air conditioning plant operating procedures.

m. Review of Shipboard Maintenance Actions (for ship’s crew and industrial support) with recommendations for improvement.

7.5 Emergent Work:

7.5.1 Any repairs identified outside of the scope of the references and /or listed within this Statement of Work shall be submitted to the Port Engineer and Contracting Officer via Condition Report for resolution and direction.

a. In addition, any additional required repairs, outside of the scope of this SOW, identified prior to the start of any of the period of performances identified in Paragraph 5.1, shall be submitted to the Contracting Officer by the Port Engineer and/or Contractor.

8.0 GENERAL REQUIREMENTS:

8.1 The Contractor shall provide all of his/her own equipment and tools to perform this work. All instruments/tools that require calibration shall have a current calibration label affixed to it.

Enclosure 1: SWBS Test # 50102

SHIP & HULL NUMBER:

USNS SACAGAWEA (T-AKE 2)

TEST MEMO:

A/C CHILL WATER UNITS

SWBS TEST #

50102

NOTES: >> UNIT WILL NOT START IF CONTROL CABINET DOOR IS AJAR.

>> ALL SOFTWARE SET POINTS TO BE VERIFIED AGAINST SYSTEM DRAWING.

NOTE (1) = RANDOM TESTING OF 1 OR 2 UNITS TO BE CONDUCTED. SETPOINTS

VERIFIED ON REMAINING UNITS. NOTE (2) = TEST CONDUCTED BY LIFTING

CIRCUIT LEAD FROM SENSOR IF NO BETTER METHOD IS AVAILABLE. NOTE (3) =

TET CONDUCTED BY CHANGING SETPOINT

SAFETY DEVICES AND CONTROLS:

PARAMETER DESIGN

AC 4

(No. 1)

AC 5

(No. 2)

AC 6

(No. 3)

AC 7

(No. 4)

AC 8

(No. 5)

A/C SERIAL NUMBER. #

LOCAL EMERGENCY STOP AT

CCU. (1) SAT

HIGH PRESSURE MONITOR CUT-

OUT, ELECTRONIC, ° (1) 122-124

HIGH PRESSURE MONITOR CUT-

OUT, MECHANICAL, PSIG

(1)

177-184

LOW PRESSURE MONITOR CUT-

OUT, ELECTRONIC, °F

(CORRESPONDING TEMP)

(3)

16-18

LOW PRESSURE MONITOR CUT-

OUT, MECHANICAL, “ PSIG (1) 12-13

LOW OIL PRESSURE TRIP. -

LIQUID CHILLER STOPS, PSIG (1) ~ 29

CHILLED WATER OUTLET TEMP.

ALARM, °F (3) 41

CHILLED WTR INLET HIGH

TEMP. ALARM, °F (3) 66-68

CHILLED WATER INLET LOW

TEMP. ALARM, °F (3) 39-41

LOW OIL TEMP START BLOCK, °F

(1) 32

OIL HEATERS OPERATE WHEN

UNIT IN STANDBY. (3) SAT

A/C PLANT SHUTS DOWN WHEN

CONDENSER COOLING WATER

STOPS. (1)

SAT

A/C PLANTS DO NOT START

WITHOUT CONDENSER COOLING

WATER FLOW. (1)

A/C PLANT STOPS WHEN CHILL

WATER FLOW TO EVAP STOPS.

(1)

A/C CHILL WATER PUMP

INTERLOCK PREVENTS START

W/NO CHILL WATER FLOW. (1)

CHECK STATUS OF

REFRIGERANT LEAK DETECTION

IN BILGE AND MAIN ALARM

CONSOLE FOR 404A. (1)

DEMONSTRATE OPERATION OF

MANUAL CAPACITY INCREASE/

DECREASE CONTROLS ON

CONTROL CABINET AND ON TOP

OF COMPRESSOR. (1)

SUMMARY ALARM AT MCCS

OPERATIONAL. (1) SAT

A/C UNIT LAST OIL CHANGE. HOURS

A/C UNIT LAST OIL FILTER

REPLACEMENT. HOURS

A/C UNIT LAST FILTER DRYER

REPLACEMENT. HOURS

Enclosure 2: SWBS Test # 50202

SHIP & HULL NUMBER:

USNS SACAGAWEA (T-AKE 2)

TEST MEMO:

CARGO REFRIGERATION

COMPRESSORS

SWBS TEST #

50202

SAFETY DEVICES AND CONTROLS:

NOTES:

(1) DENOTES TESTING TO BE PERFORMED FOR ALL UNITS. RANDOM TESTING WILL

BE PERFORMED FOR REMAINING PARAMETERS.

(2) JUMPER INSTALLED TO BYPASS SWITCH IN CCU SO UNIT WILL NOT CUT OUT ON LOW

CONDENSER FLOW.

(3) VERIFY ALL SOFTWARE SETPOINTS FOR EACH UNIT.

(4) TEST CONDUCTED BY CHANGING SETPOINT.

(5) SINCE THE TEMPERATURE SENSORS ARE LOCATED ABOVE THE CEILING GRID AND OUT

OF THE AIR FLOW PATH, RECORD THE CPU “RETURN AIR” TEMPERATURES.

PARAMETER PARAMETER

ON MIMIC

ALARM

MESSAGE DESIGN No. 1 No. 2 No. 3

COMPRESSOR SERIAL

NUMBER. N/A N/A #

LOCAL EMERGENCY

STOP.

(1)(3)

N/A EMERGENCY

STOP

CCU: SAT

MOTOR

CONTROLLER:

HIGH PRESSURE

MONITOR CUT-OUT,

ELECTRONIC.

(1)(2)(3)(4)

DISCHARGE

SATURATED

HIGH

CONDENSING

PRESSURE

116.6°F +/-2°F (47°C

+/-1°C)

HIGH PRESSURE

MECHANICAL.

(1)(2)(3)

DISCHARGE

SATURATED

HIGH

DISCHARGE

PRESSOSTAT

118.4ºF-125.1ºF (332.6 psig +0/-27.6)

(22.9 BAR +0/-1.9)

(48ºC-51.7ºC)

LOW PRESSURE EVAPORATING

LOW EVAP

-52.6°F +/-2°F

ELECTRONIC.

SATURATED TEMP -47°C +/-1°C (3)(4)

LOW PRESSURE

MONITOR CUT-OUT,

MECHANICAL.

(1)(3)(4)

EVAPORATING

SATURATED

LOW SUCTION

PRESSOSTAT

-66.8°F - -61.8°F (-9.4 psig -0/+1.4) (-0.56 bar -0/+0.1) (-54.9ºC - -52.1ºC)

OIL PRESSURE

MONITOR

(TEST ONLY IF

ISOLATION VALVE IS

INSTALLED IN

GAUGE LINE) (1)(3)

OIL PRESSURE

LUBRICATION

OIL FAILURE

UNIT STOPS (SAT)

LIGHT ON CCU

ILLUMINATES

(SAT)

EVAPORATOR BRINE

OUTLET

TEMPERATURE

ALARM.

(1)(3)(4)

N/A LOW ALARM >-34°C (-29.2°F)

EVAPORATOR BRINE

INLET TEMPERATURE

ALARM.

(1)(3)(4)

N/A HIGH ALARM

LOW ALARM

HI:<50°F(<10ºC)

LO: -29.2°F (>-34ºC)

LOW OIL

TEMPERATURE

SHUTDOWN.

(1)(3)(4)

OIL LOW OIL TEMP >86ºF (>30°C)

CONDENSER WATER

OUTLET TEMP ALARM.

(3)(4) N/A

HIGH ALARM

LOW ALARM

HI: <111°F (<44ºC)

LO: >66.2ºF (>19ºC)

CONDENSER WATER

INLET TEMP ALARM.

(3)(4)

N/A HIGH ALARM

LOW ALARM

HI: <105.6ºF (<41ºC)

LO: >64.4°F (>18ºC)

RCS EXPANSION TANK

LOW LEVEL ALARM.

(1)(4) N/A N/A

SAT

OIL HTR OPERATES

WHEN UNIT IN

STANDBY. (4)

N/A N/A SAT

CARGO REFRIG

PLANTS DO NOT

START WITHOUT

CONDENSER COOLING

WATER FLOW.

N/A

START NOT

ALLOWED; NO

CONDENSER

FLOW

CARGO REFRIG PLANT

SHUTS DOWN WHEN

CONDENSER COOLING

WATER STOPS.(1)

N/A

NOT ENOUGH

FLOW

CONDENSER

CHECK STATUS OF

REFRIGERANT LEAK

DETECTION IN BILGE

AND MAIN ALARM

CONSOLE FOR R-404a.

(1)

N/A N/A

BILGE SENSOR

POWER LIGHT ON

CONSOLE POWER

LIGHT ON (SAT)

NO ALARMS (SAT)

DEMONSTRATE

OPERATION OF

MANUAL CAPACITY

INCREASE/DECREASE

CONTROLS. (1)

LOAD N/A

CONTROL PANEL

(CCU) INCREASING

CONTROL PANEL

(CCU) DECREASING

COMPRESSOR

INCREASING (SAT)

COMPRESSOR

DECREASING (SAT)

RECORD ALL

ASSOCIATED STORAGE

BOX TEMP. IN

OPERATION. (1)

TEMP N/A

VERIFY ALL PRESET

VALUES PRIOR TO

SYSTEM

OPERATIONAL TEST &

RECORD. (1)

N/A N/A

RECORD CHILL WATER

TEMP. FOR EACH UNIT. TEMP N/A

RECORD COOLING

WATER TEMP. FOR

EACH UNIT.

TEMP N/A

RECORD

REFRIGERANT TEMP.

FOR EACH UNIT.

TEMP N/A

RECORD OIL TEMP.

FOR EACH UNIT. TEMP N/A

RECORD BRINE TEMP.

FOR EACH UNIT. TEMP N/A

7.2 Point of Contact for Services: