USCGC Stone AC Condenser Renewal

PLease see full SOW in attached documents

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard facility for Coast Guard vessels.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), 2022, Fire Prevention and Response

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements of this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Contractor-provided fire watch personnel. The Contractor must provide fire watch personnel and equipment.

3.3 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

3.4 Fire Prevention Specification. The Contractor must submit a Fire Prevention Plan in accordance with paragraph 3.1 of SFLC Standard Spec 5550

SN23_NNNN_51400_ BJA_1225_418

1. ITEM 1: Air Conditioning Plant, Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew the AC condenser for the #1B circuit, flush the refrigerant side of the #1B circuit, renew or overhaul various components on the refrigerant side of the #1B circuit and restore the plants back to service on the USCG Cutter Stone in Charleston, SC. Location of work is Air Conditioning Equipment Room, Compartment 3-22-0-Q. The USCG has determined that the #1B refrigerant circuit was exposed to seawater.

1.2 Government-furnished property. 

MTI

ITEM DESCRIPTION

NSN/PN

QTY

ESTIMATED COST
($/UNIT)

Y

Condenser, 130 Ton Chill Water

NSN: 4130-01-549-7737 

1 ea.

54,287

Y

York Semi-hermetic screw compressor

PN: YCWS

1 ea

69,474.00

N

Indicator, Moisture

NSN: 01-670-3068

1 ea

21.89

N

Valve, Thermal Expansion, Economizer

NSN: 01-583-7241

1 ea

1037.89

*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 Drawing FL-1204-3, Rev A, Fleet Welded Padeyes and Links

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), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

Other References

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 AC Tech Rep. The Contractor must provide the services of a Qualified Technical Representative who is familiar with the York 130-Ton capacity, HFC-134A Air Conditioning plants to accomplish the following on site:

• Advise on manufacturer’s system information.
• Assist with disassembly, inspection, repair, modification, calibration, testing and reassembly of the equipment/system.
• Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable.

3.1.2.1. Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their résumé.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000.

3.1.3.1 Protective measures - environmental. The Contractor must abide by all applicable environmental protection tasks as specified in paragraph in SFLC Std Spec 0000, Appendix A (Requirements for Environmental Protection).

3.1.3.2 Protective measures – refrigerant. The Contractor must take all necessary precautions to prevent introduction of contaminants and moisture into refrigeration system piping and components by sealing all openings.

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

• Plant piping & fittings
• Refrigerant (134a)
• Lagging
• Work benches

3.1.5 Refrigerant handling.

3.1.5.1 Personnel qualification. The Contractor must provide the Port Engineer 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.

3.1.5.2 Refrigerant draining and disposal. 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.

3.1.6 Repair plan. The Contractor must supply a written plan of work to the Port Engineer 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.

3.1.7 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.

3.1.8 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.

3.1.9 Rigging. The Contractor is responsible for all rigging with the following considerations:

3.1.9.1 All existing padeyes that will be used for a lift must be pull tested to 1.5 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.9.2. If new padeyes are required, fabricate them in accordance with Coast Guard Drawing FL-1204-3 and SFLC Standard Spec 0740. Newly fabricated padeys must be pull tested to 2 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.9.3. Upon completion of testing, install a label plate in accordance with SFLC Standard Spec 5000 Paragraph B2.9.

3.1.10 Vital Loop. Contractor must keep one AC compressor from the #2 AC Plant or #3 AC Plant operating at all times. This will require installing blank flanges in the condenser supply and discharge piping for various plants throughout the work. 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. 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 Port Engineer review.

3.3 Refrigerant evacuation. The contractor must pump down each plant in accordance with Paragraph 6-1.2.1 of TP S9514-F1-MMA-010. Deviation from this procedure must be consulted with the Port Engineer. Submit a CFR reporting the amount of refrigerant removed.

3.3.1 Prior to disposal, the Contractor must test the oil for acid and check for Air/Non-Condensable in the recovery bottle. CG Inspector must be present to verify Pressure/Temperature Relationship on recovery cylinders after recovery cylinders have settled for a minimum of 24 hours. Submit a CFR.

3.3.2 Dispose of recovered refrigerant in accordance with Federal, state, and local regulations and SFLC Std Spec 0000.

3.3.3. The Contractor must drain the lube oil from Compressor and the Oil Separator/Reservoir and dispose of it in accordance with the local, state and Federal regulations. The Contractor must also inspect the oil removed for any evidence of contamination such as water and any solid particles. Submit a CFR to the Port Engineer.

3.4 Condenser renewal. The Contractor must renew the condenser using GFP on the 1B refrigerant circuit. Model information for the condensers is shown in Table 1.

3.4.1 The Contractor must renew all gaskets and seals disturbed during the condenser renewal condenser end bells, piping and components disturbed in accomplishing this work item using new gaskets and seals.

3.4.2. Vent the air from the condenser in accordance with Paragraph 4-5.1 of TP S9514-F1-MMA-010.

3.4.3. The Contractor must install the necessary mounting brackets for the condensers in accordance with Figure 8-10 of TP S9514-F1-MMA-010. Conduct welds and NDE in accordance with SFLC Standard Spec 0740

3.4.4  In the presence of the Coast Guard inspector, the Contractor must pressure test the condenser in accordance with Paragraph 6-7.2. upon completion of the installation. The Contractor is only required to correct leaks in joints that they disturb.  Submit a CFR to the Port Engineer.

Table 1

Fuctional Service

Manufacturer

Model number

notes

Air Conditioning Unit Condenser

KETEMA

MHX-1208A-2P

Each condenser contains 84 tubes

3.5 Borescope Inspection. The Contractor must provide a borescope inspection for the #1B refrigeration circuits that includes the following components:

• Piping leading to and from the condenser barrel, oil separator and compressor.
• Refrigerant side of evaporator

3.6 A/C plants flush. The Contractor must plan and execute a flush of the refrigerant circuit for the #1B AC circuit. This plan must be approved by the Port Engineer prior to execution. Components that are being renewed or overhauled do not need to be flushed. The flush must accomplish the following tasks:

• Remove particulate contamination
• Remove rust
• Remove saltwater residue and growth
• Uses techniques and materials that are compatible with the AC system.
• Include a 10-micron filter somewhere in the flushing circuit
• Remove contamination in the evaporator tubes mechanically

3.7 Component Renewal. The Contractor must renew the following components in Table 2 of refrigeration circuit #1B in accordance with TPS9514-F1-MMA-010. The Contractor must provide any materials that are not furnished as GFE 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 EXCEPT do not flush with water.

Table 2

Component

Dwg 077-18317-001 Item Number

Quantity

York Part Number

Manufacturer/Model

Compressor, Screw Semi-Hermetic

2

2

364-49094-215

York DXS45LA-A46/50

Separator, Oil, Right Hand

3

2

075-56077-001

Westermeyer OS6-I5R

Separator, Oil, Left Hand

4

2

075-56077-002

Westermeyer OS6-I5L

Control, High Refrigerant Pressure

9

2

025-35948-000

Alco PS3-XF5HNB297

Transducer, Suction Pressure

15

2

025-29583-000

Danfoss 060G2154

Transducer, Discharge Pressure

16

2

025-29139-001

Danfoss 060G2153

Transducer, Oil Pressure

17

2

025-29139-001

Danfoss 060G2153

Valve, Solenoid, Liquid Refrigerant Injection

26

2

025-00245-000

Danfoss 032F4023

Valve, Solenoid, Capacity Control

27

2

025-33205-000

NA

Core, Dehydrator*

30

6

026-37540-000

Emerson HX-48

Indicator, Moisture, Cartridge

42

4

026-32800-000

Sporlan AC-20

Economizer Theral Expansion Valve.**

24

1

075-56077-002

Emerson

*The Contractor must remove all rust from the steel components of the STAS retainer assembly. See figure 2.

**Contractor must supply the packing nut wrench

3.8 Component Overhaul. The Contractor must overhaul the following components in refrigeration circuit #1B 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).

3.8.3 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, DWG 077-18317-001) – Disassemble valve and mechanically remove all internal rust.

3.9 Post-work Leak Test. The Contractor must perform a leak test of each AC circuit in accordance with Paragraph 6-2.1 of TP S9514-F1-MMA-010 upon completion of all work. The Contractor is responsible for repairing any leaks from equipment that they disturbed over the course of the work. Report results via a CFR.

3.10 A/C plants. The Contractor must restore the affected system 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 charge refrigerant to the unit in accordance with Paragraph 6-2.3 of TP S9514-F1-MMA-010 in the presence of a CG Inspector.

3.10.2 Prior to charging the refrigerant, the system must be pulled down to a vacuum below 500 microns for at least 5 minutes. This may be done separately or simultaneously with the vacuum requirements in 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 Port Engineer.

3.11.1 During final testing of the AC units, run each individual compressor by itself (no other compressors operating) for an hour, record the following data shown in Table 1-1 of TP S9514-F1-MMA-010 every five minutes and submit a CFR .

• Compressor Speed
• Saturation Suction Temperature
• Saturation Discharge Temperature
• Chilled Water Circulation flow (in GPM)
  • Chill Water Temperature Entering
  • Chill Water Temperature Leaving
• Condenser Water Flow (in GPM)
  • Condenser Water Temperature Entering
• Condenser Water Temperature Exiting

3.11.2 The Contractor must install additional drier cores as needed after the initial start to ensure the system is dry and free of acids and moisture.

3.11.3 The Contractor must collect two oil samples from the compressor oil after startup. One sample must be tested per C2.1.3.1 of SFLC Std Spec 5000 and one must be provided to the Port Engineer. Submit a CFR to the Port Engineer.

3.12 Touch-up preservation, general. The Contractor must prepare and coat all new and disturbed exterior and interior surfaces, as applicable, to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

3.13  FLETC Base Access Requirements: Contractors must have a valid REAL ID. Form 121 will be provided via email by the Port Engineer and must be submitted for a background check 5 business days prior to the start of the period of performance.

4. Selection Process

4.1  Best value criteria - Award of this requirement shall be made to the vendor whose proposal offers the greatest value to the government. Technical factors, past performance are more important than price.

• Factor 1 – Past Performance

Sub-Factor 1: Quality of Performance

Sub-Factor 2: Schedule Performance

Sub-Factor 3: Management Performance

Sub-Factor 4: Cost Control

• Factor 2 – Personnel Qualification

Sub-Factor 1: Key Personnel

Sub-Factor 2: Subcontractors

• Factor 3 – Management Plan

Sub-Factor 1: Management Sub-Factor 2: Initial Staffing Sub-Factor 3: Phase-in Transition

Sub-Factor 4: Subcontracting Plan

• Factor 4 – Cost

Sub-Factor 1: Realism Sub-Factor 2: Reasonableness

Sub-Factor 3: Completeness

4.2  Prior to contract issuance the prospective contractor MUST HAVE completed and/or current enrollment into System Award Management (SAM), enrollment information for which can be found at: https://sam.gov/content/entity-registration, failure to do so WILL result in disqualification and reissuance of the contract. All bids submitted by contractor shall include break down of cost for labor, materials, transportation, O/P, G/A, etc… For any further enrollment assistance and/or questions, please contact CWO3 Jason Garris +1 (555) 000-0000

4.3   Type of Contract Contemplated: This will be a firm-fixed priced purchase order.

Period of performance: January 26th, 2026- February 13th, 2026.

Address:

CGC Stone

1050 Register St

North Charleston, SC 29405

5. NOTES

FIGURE 1. Air conditioning plant configuration

Figure 2. Filter Assembly