CGC KIMBALL #2 A-C REPAIRS

ITEM 1: Air Conditioning Condenser, Repair 1. SCOPE 1.1 Intent. This work item describes the requirements for the Contractor to renew 110 damaged tubes on the #2A Air Conditioning condenser, develop a flushing plan for the refrigerant side of the #2A circuit and provide various components of the refrigerant side of the #2A circuit. The Contractor will also provide a technical representative to oversee Coast Guard personnel as they execute the flushing plan, renew or overhaul various components of the refrigerant side of the #2A and restore the plant back to service. Location of work is Air Conditioning Equipment Room, Compartment 3-22-0-Q. The USCG estimates that the #2A circuits was exposed to seawater for about two months. 1.2 Government-furnished property. MTI ITEM DESCRIPTION NSN/PN QTY Y 90/10 Cu/Ni -3/4 x 96 enhanced tubes PN: 0034948 110 ea. Y York Semi-hermetic screw compressor PN: YCWS 1 ea *Government-loaned property, which must be returned to the vessel upon completion of the availability. 2. REFERENCES Coast Guard Drawings Coast Guard Drawing 750 WMSL 508-001, Rev C, Piping and Machinery Insulation Schedule and L/M Coast Guard Drawing 750 WMSL 516-001, Rev E, A/C & Refrigeration Piping Diagram Coast Guard Drawing 750-WMSL_520_001, Rev H, Seawater Cooling System Diagram (ASC520001) Coast Guard Drawing 750-WMSL-520-004, Rev E, Salt Water Cooling Unit 1320 (ASC520132-SW) Coast Guard Drawing 750-WMSL_520_506, Rev E, Auxiliary Seawater Piping Mods FWD of FR 52. Coast Guard Publications Coast Guard Technical Publication (TP) 7608, SWBS 514, February 2012, York/Thermaflo Oz Saver Portable Refrigerant Recovery Unit, Model 4000 (418 WMSL) Coast Guard Technical Publication (TP) S9514-F1-MMA-010, SWBS 514, Jan 2012, Air Cond Plant HFC-134A 130 Ton Capacity Description, Operation and Maintenance Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2020, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Other References American Society of Mechanical Engineers (ASME) B16.34, 2017, Valves-Flanged, Threaded, and Welding End ASTM International (ASTM) F992, 2017, Standard Specification for Valve Label Plates ASME/BPVC Section V, Jul 2021, Section V Nondestructive Examination Ketema LP, Sep 2002, DXT Direct Expansion Evaporator Installation, Operation, and Maintenance Instructions. 3. REQUIREMENTS 3.1 General. 3.1.1 CIR. None. 3.1.2 Air Conditioning Tech Rep. The Contractor must provide the services of a certified Tech Rep, who is familiar with the York HFC-134A 130 Ton Air Conditioning Plant to accomplish the following tasks - on site: Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system. Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system. The Tech Rep must be present to advise, oversee and supervise USCG personnel when called for in this work item[ABJC1] . 3.1.2.1 Submit the Tech Rep's name and r'sum to the COR at the Arrival Conference. I removed the protective measures requirements. USCG personnel will be doing that I also removed interference requirements. USCG personnel will do this as well 3.1.4 Refrigerant handling. 3.1.4.1 Personnel qualification. The Contractor must provide the COR documentation that ensure all prime and sub contractors servicing refrigerant-based Air Conditioning and Refrigeration (AC&R) equipment hold a current Environmental Protection Agency (EPA) Technician Certification, Type IV (Universal Certification), and meet all State and local regulations and licensing requirements. 3.1.4.2 Refrigerant draining and recovery. The Contractor must ensure all vessels Air Conditioning Plant refrigerant is drained, recovered and disposed of in accordance with all Federal, state and local environmental regulations. 3.1.5 Repair plan. The Contractor must supply a written plan of work to the COR at least 24 hours in advance of beginning work. Plan must include sequencing of work, flushing procedures, source of supply for the renewal and overhaul parts and any planned deviations from this work item. 3.1.6 Guidance. The Contractor must refer to CG Drawing 750 WMSL 516-001 for requirements, location and shipboard arrangement. The Contractor must refer to CG TP S9514-F1-MMA-010, for general & safety information, parts, operation and maintenance procedures. 3.1.7 Safety. The Contractor must familiarize themselves with and comply with applicable Warning, Caution and Attention notes invoked in CG TP S9514-F1-MMA-010, SWBS 514, Jan 2012, Air Conditioning Plant HFC-134A 130 Ton Capacity Description, Operation and Maintenance Manual. USCG will be responsible for handling all rigging 3.1.8 Vital Loop. Contractor must keep one AC compressor of the three AC plants operating at all times. This will require installing blank flanges in the condenser supply and discharge piping for AC Plant #2. The Contractor may bring down the AC plant for no more than an hour at a time to install the necessary blanks. 3.2 Operational test - initial[ABJC2] . Prior to commencement of work, the Contractor must witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR. 3.2.1 The Contractor must submit an operational report following startup utilizing figure 2-16 of TP S9514-F1-MMA-010. 3.2.2 Initial operational test of the Air Conditioners can be waived if operating the AC plant will risk personnel safety and/or further damage to the system. Submit a CFR for this request for COR review. 3.3 Refrigerant evacuation. The Tech Rep must oversee USCG personnel as they evacuate the refrigerant. 3.4 Condenser tube renewal. The Contractor must renew [ABJC3] 140 tubes across the #1A and #1B condensers based upon results from the Eddy Current Testing. Model information for the condensers is show in in Table 1. Follow the procedures for removal of the tubes, prepping of the tube sheets, and installation of new tubes, outlined in the CG Tech Pub S9514-F1-MMA-010, Section 6-7. The Contractor must also follow all necessary steps outlined in the same Tech Pub to keep contaminants such as metal shavings out of the system during the tube renewal process. 3.4.1 In the presence of the Coast Guard inspector, The Contractor must pressure test the tube side of the condenser at 150% of its design working pressure to ensure effectiveness of the repairs performed. Submit a CFR to the COR. USCG can clean and reinstall the end bells Table 1 Fuctional Service Manufacturer Model number notes Air Conditioning Unit Condenser KETEMA MHX-1208A-2P Each condenser contains 106 tubes 3.5 Borescope Inspection. The Contractor[ABJC4] must provide a borescope inspection for the #1A and #1B refrigeration circuits that includes the following components: Condenser barrel Oil Separator Compressor Piping leading to and from these components Refrigerant side of evaporator 3.6 A/C plants flush. The Tech rep must plan and supervise USCG personnel as they flush refrigerant circuit for the #2A AC plant. This plan must be approved by the COR prior to execution. Components that are being renewed or overhauled do not need to be flushed. The flush plan must address the following tasks: Removal of particulate contamination Removal of rust Removal saltwater residue and growth Recommend techniques and materials that are compatible with the AC system. Incorporate 10-micron filtration Instructions for mechanical removal of contamination. 3.7 Component Renewal. The Contractor must provide all necessary materials and the Tech Rep must supervise USCG personnel as they renew the following components of refrigeration circuit #2A in accordance with TPS9514-F1-MMA-010. Any brazing on the A/C unit requires the AC Tech Rep on site to oversee the nitrogen purge during brazing. Comply with all requirements of SFLC Standard Spec 0740 Table 2 Component Dwg 077-18317-001 Item Number Quantity York Part Number Manufacturer/Model Compressor, Screw Semi-Hermetic 2 1 364-49094-215 York DXS45LA-A46/50 Separator, Oil, Right Hand 3 1 075-56077-001 Westermeyer OS6-I5R Separator, Oil, Left Hand 4 1 075-56077-002 Westermeyer OS6-I5L Control, High Refrigerant Pressure 9 1 025-35948-000 Alco PS3-XF5HNB297 Transducer, Suction Pressure 15 1 025-29583-000 Danfoss 060G2154 Transducer, Discharge Pressure 16 1 025-29139-001 Danfoss 060G2153 Transducer, Oil Pressure 17 1 025-29139-001 Danfoss 060G2153 Valve, Solenoid, Liquid Refrigerant Injection 26 1 025-00245-000 Danfoss 032F4023 Valve, Solenoid, Capacity Control 27 1 025-33205-000 NA Core, Dehydrator 30 3 026-37540-000 Emerson HX-48 Indicator, Moisture, Cartridge 42 2 026-32800-000 Sporlan AC-20 USCG will clean the dehydrator core 3.8 Component Overhaul. The Contractor must provide all necessary materials and the Tech Rep must supervise USCG personnel as they overhaul the following components in refrigeration circuits #2A in accordance with TPS9514-F1-MMA-010: 3.8.1 Evaporator Thermal Expansion Valve (PC 23, Dwg 077-18317-001) - renew the cage assembly (PN: X9144B13B), the power head assembly (PN: XC-726MC2B) and the superheat plug (PC: X28124-1), the gasket (PN: X13455-1). The Contractor must also supply the packing nut wrench (PN: E642). 3.8.2 Economizer Thermal Expansion Valve (PC 24, DWG 077-18317-001) - renew the cage assembly (PN: X11873B5B), the power head assembly (PN: XB-1019MC1B), the superheat plug (PN: X28124-1), the gasket (PN: X13455-1) and the packing nut wrench (PN: E642). 3.8.3 Main Liquid Line Solenoid Valve (PC 25, DWG 077-18317-001) - renew internal components using the Solenoid Valve Repair Kit (PN: KS30325) 3.8.4 Air Compressor Discharge Valve (PC 80, Figure 7-3, TPS9514-F1-MMA-010) - Disassemble valve and mechanically remove all internal rust. 3.9 Post-work Leak Test. The Tech Rep must oversee as the USCG conducts a leak test of the AC system in accordance with Paragraph 6-2.1 of TP S9514-F1-MMA-010 upon completion of all work. 3.10 A/C plants. The Tech Rep must oversee as the USCG restores all of the affected systems to original configuration, renew the refrigerant, oil, oil filter cartridge, and all liquid line filter/drier core. 3.10.1 Charging Refrigerant. Upon completion of a successful leak test, the Contractor must oversee as the USCG charges the refrigerant to the unit in accordance with Paragraph 6-2.3 of TP S9514-F1-MMA-010. 3.11 Operational test - post repairs. After completion of work, in the presence of the Coast Guard Inspector, the Contractor must thoroughly test and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR to the COR. 3.11.1 The Contractor must submit an operational report following startup utilizing figure 2-16 of TP S9514-F1-MMA-010. 3.11.2 The Tech Rep must oversee as the USCG installs additional drier cores as needed after the initial start to ensure the system is dry and free of acids and moisture. USCG will do touch up preservation and piping insulation renewal [ABJC1]This is adjusted slightly. We don't need the tech rep there all the time, but we need them whenever the spec says that they need to advise something [ABJC2]We want to keep this. Coast Guard provides most of the labor for this anyway. [ABJC3]The contractor themselves will do the actual renewal of the tubes themselves. I don't think that the coast guard has the equipment to do this. It is only 140 because we are assuming that not all of the tubes will need to be renewed. [ABJC4]We also need the Contractors's borescope