Kongsberg_Mechanical_and_Controls_Assistance_2018_Final.pdf

KONGSBERG MECHANICAL AND CONTROLS ASSIST - 2018

General Statement of Work – Kongsberg Mechanical and Controls Assist

Awarded contractor (Contractor) to supply all necessary labor, material, transportation, and rigging to complete the assistance of the installation of the Kongsberg Maritime (KM) controls aboard TS Golden Bear (TSGB). KM will be concentrating on the installation of their supplied hardware and software and will not have the mechanisms or tooling necessary to complete some of needed mechanical and electrical controls preparations and unforeseen requirements to complete their work.

The primary part of the contract will be the mechanical work listed below, as specified by KM. The secondary subcontractor to the contract will be a specialized electrical controls contractor to assist with specific listed work items necessary to prepare ship’s controls to be adapted to KM supplied hardware and software. This electrical controls subcontractor is specialized and must have at least 5 years of experience with retrofitting marine alarm monitoring and propulsion controls.

The assistance and support of KM will be prior to KM’s planned installation start date of 20 February 2018 and continue through the completion of the installation expected to be 01 April 2018.

Item No 1 – SR No Kongsberg Mechanical Assistance

ABSTRACT

KM Assistance will be during the complete operation by KM to install their hardware and software during the retrofit of the Alarm Monitoring and Propulsion Controls aboard TSGB. This assistance will include but is not limited to the following:

• Hot work and mechanical work necessary to mount KM supplied hardware such as speed and direction sensors and local controls and Engine Control Room (ECR) console modifications

• Transportation and rigging necessary to assist KM with their set up and final acceptance of their installation of their hardware and controls

• Bridge location – interference removal and reinstallation; modification to the console to support the install of new KM hardware; panel removal and interference removal to support cable installation between engine room, bridge, and bridge wings, mounting of new repeaters and equipment; kickpipes and necessary bulkhead fittings to protect cables and maintain watertight integrity

• Modification of existing panels to fit new hardware

• Clean up and scale and prime and paint disturbed painted surfaces

• Supply the services of an electrical controls specialist who has 5 years of experience doing retrofitting of Marine alarm and propulsion controls

LOCATION AND DESCRIPTION

Location:

Engine Room and Bridge locations as wells as cable runs between same

Description:

Contractor must provide all labor, material and transportation and rigging necessary to assist KM in their efforts to supply and install hardware to upgrade the ship’s Alarm Monitoring and Propulsion Controls. Refer to the listed work within the Statement of Work for specifics. Additionally, Contractor must supply a professional Electrical Controls Specialist who has 5 years of experience retrofitting marine controls.

REFERENCE

1) KM installation drawings and details (to be provided)

STATEMENT OF WORK

ENGINE ROOM;

1 => RPMD tacho pickup on main shaft; Weld bracket at main shaft aft of main shaft support bearing, pulls band delivered by KM to be mounted on shaft and sturdy pickup bracket to be welded for pickup mount, see sample drawing A and B for RPMD cabinet dimension. RPMD cabinet to be mounted not longer than 18 meters from pickup measuring point due to fixed cables. Note: Sample drawing A represented below, drawing B to be provided prior to the start of work.

Figure 1: Shaft Pickup Location

Figure 2: Sample Drawing A: Shaft Equipment

2 = > RPMD tacho pickup on at each engine;

4 pickups to be mounted on each clutch flywheel to detect RPM counting holes in clutch wheel housing, bracket support has to be extended from intercooler support barres with crossbar over flywheel to fix 4 pc. pickup. Pickup installation guidance C show pickup data and maximum distance. NOTE, to be able to take out flywheel for clutch overhaul crossbar should be removable.

Same as with main shaft, one pickup RPMD cabinet unit to be mounted right beside each engine with maximum 18 pickup cables and drawing B.

Figure 3: Main Engine RPM pickup installation, with Pickup Installation Guidance C excerpt (at bottom)

3 = > Main engine local stand;

Existing main engine local control cabinet to be replaced by KM fabricated cabinet.

Manual gauges on the sides to be refurbished/replaced and arranged on the sides on new gauge plates. Gauge refurbishment/replacement and fabrication/installation of side gauge plates shall be accomplished by the Contractor.

Figure 4: Existing Local Panel

Attached drawing D show KM cabinet dimensions to be fixed to new welded brackets on the hull. Note: Drawing D (excerpted below) to be provided to Contractor prior to start of work.

Figure 5: New Local Panel (Excerpt of Drawing D)

4 = > Main engines governor replaced by SEFA 160.

On each engine the existing Woodward speed actuator will be replaced with KM SEFA160 electronic governor. KM will deliver bracket plate kit un-welded which has to fitted on site, bracket plates has thickness 20mm. Figure 6 below shows one SEFA arrangement for the same after bracket has been fitted on site replacing Woodward on MAN B&W MC engine. Fuel linkage arm might need to be cut and shortened with few

cm. One RS422 communication cable and one 24V DC sq. 3x6mm power cable has to be pulled to SEFA UPS mounted close by.

After Woodward is removed remaining pinion might needs to be removed.

Figure 6: Woodward actuator replacement wtih SEFA Governor

5 = > SEFA UPS’es;

Contractor shall fabricate mounting brackets and install KM-supplied UPS and battery cabinets nearby SEFA governors (one UPS and one battery cabinet per engine.)

Dimensions and arrangement details to be provided to Contractor prior to start of work.

Figure 7: UPS and Battery Cabinets (Cabinet #3 not used)

ECR;

1 = > ECR UPS cabinet;

Contractor to modify existing UPS enclosure to support quantity 3 new KM-supplied UPS units. Modifications shall be directed by KM, and may include the installation of new shelving, brackets, and/or penetrations.

Figure 8: Existing UPS Enclosure

2 = > ECR console;

Automation upgrades will include the replacement of ECR console plates. KM will supply all new plates. The Contractor shall assist mechanical installation of these plates, and/or equipment installation into new plates.

Figure 9: ECR Console prior to KM installation

BRIDGE;

1 = > bridge;

Contractor shall support installation of new automation equipment on the bridge wings as follows:

• Install new cable penetrations from navigation bridge overhead to the bridge wings

• Remove navigation bridge overheads to support cable installation (by others), replace overheads when cable installation is complete.

• Install brackets on bridge wings to support installation of new KM-supplied equipment on bridge wings and bridge overhead.

Figure 10: Existing Bridge Wing Equipment Arrangement, showing equipment to be removed and approximate penetration locations

Figure 11: Existing Bridge CL RPM Indicator, in way of new indicator (support bracketing required)

CABLE PENETRATIONS;

KM will be installing the majority of cable penetrations required for the project (not specifically mentioned here), but may require assistance in some cases. Contractor to install new cable penetrations as required by KM. The Contractor may also be required to install new cable ways in engine spaces.

OVERHEAD REMOVAL;

KM will be installing the majority of new cable runs outside of the machinery spaces, but may require assistance in the removal and re-installation of overheads. Contractor to assist in this effort as required by KM.

REQUIRED QUALIFICATIONS

1) Contractor must be able to supply the services of an electrical controls specialist who has 5 years of experience retrofitting marine alarm monitoring and propulsion controls equipment.

2) Contractor must be able to work with KM on a daily basis to support their effort to remove the old equipment and install their new regulatory approved equipment and start up and commission same.

3) Contractor to gain approval of the MARAD surveyor for any items that are not noted in the Statement of Work before beginning requested work by ship or KM via Condition Found Report (CFR) process

DELIVERABLES

Contractor to supply a worklist of what was accomplished within the contracted listed items and whatever additional work was necessary to support KM.

Item No 2 – SR No Kongsberg Electrical Controls Assist

ABSTRACT

The automation upgrade project planned for the T/S Golden Bear includes some control system upgrades, electrical clean-up/grooming, and system testing that will not be performed by

KM.

The Electrical Controls Specialist (Controls Subcontractor) subcontracted by the Contractor noted above in Item No 1 must have a minimum of 5 years of experience retrofitting marine controls for Alarm Monitoring and/or Propulsion Controls.

The contractor must be capable of the following work to include but is not limited to:

• Loop checking field devices attached to the Alarm Monitoring and Propulsion Controls, testing devices associated with same, and recording discrepancies

• Designing electrical modifications to existing motor controllers to allow KM systems to operate various pumps and motors in ‘remote’ control, representation of these designs in electrical schematics

• Implementing wiring modifications to plant motor controllers, as mentioned above

• Assist KM in identifying retained existing and legacy controls wiring, and removal and/or modification of these circuits to ensure safe and effective operation of all equipment

• Developing ‘As-built’ documentation of motor controllers, console electrical details, and other various control systems (for details not captured in KM documentation), including references to new and existing drawings. The Contractor shall be responsible for ensuring the completeness of the final documentation package

LOCATION AND DESCRIPTION

Location: Bridge and Engine Room Consoles and remote connection panel

Description:

Electrical Controls Specialist to do the following work:

• Loop check and field device testing for all IO items that will be reused by new KM automation

• Design of electrical modifications of existing motor controllers, such that they can interface to the new KM automation system

• Development of electrical schematic drawings of all planned motor controller modifications. These drawings will be submitted for review to ABS and USCG by

MARAD

• Modification of motor controller wiring, as detailed on the modification design schematics.

• Assist KM in the integration of new and legacy automation systems

REFERENCE

1) Existing motor controller schematics (to be provided)

2) Existing console electrical interface schematics (to be provided)

3) I/O connection check list (to be provided)

STATEMENT OF WORK

System Loop Checks and I/O Confirmation

In order to ensure that the installation of the new automation systems is not delayed by problems with retained equipment and infrastructure, MARAD intends to inspect and test existing automation field equipment and cabling that will be retained, prior to the start of new system installation. MARAD will provide a signal list itemizing all signals that shall be retained and reused by the new automation system. For each signal that will be connected to the new KM automation, the Controls Subcontractor shall:

• Confirm the connection point terminal numbers where the signal connects to an existing RIO, PLC, or console terminal strip

• Confirm sense of all digital inputs and outputs (e.g. open contacts = low pressure, etc.)

• Confirm cable connectivity from the device to the connection point

• Confirm the range of analog input and analog output signals (no calibration, just checks)

• Inspect the condition of cables and devices, noting any obvious deficiencies

Motor Controller Modification: Design, Documentation, and Implementation

The motor controllers associated with plant equipment that is currently operable from the main control console in the ECR were originally designed to meet ACCU requirements, relying solely on relay logic to accomplish numerous control functions.

The vessel is no longer classed for ACCU operation, and the KM automation will be taking responsibility for all logical control functions (e.g. standby pump start in the event of pressure loss) that will remain a functional part of the new control system. As such, the existing motor controllers are not practically compatible with the new KM automation as currently wired. The I/O interface between the motor controllers and the KM automation must be simplified, and all unneeded legacy relay logic removed from the ECR console and motor controller cubicles.

The Controls Subcontractor shall design electrical modifications to the motor control circuits listed in the attached motor controller list. Design to be detailed in schematic drawings showing the controllers in the modified state. Modifications to retain local/remote control functionality, and support remote operation by the vessel automation only when switched locally to ‘remote’ operation. Controller modification design shall eliminate extraneous components rendered obsolete by virtue of the conversion to centralized control by the automation system. Typical integration between motor controllers and the automation shall be as follows:

Inputs to automation:

• Run status (dry contacts, closed when running)

• Local/Remote status (dry contacts, closed when in ‘remote’)

• Standby start pressure switch (where fitted for standby start of pumps, dry contacts, closed when pressure switch is satisfied)

Outputs from automation:

• Run command (dry contacts, closed momentarily for start command)

• Stop command (dry contacts, opened momentarily for stop command)

Figure 12: List of Motor Controllers to be Modified

Multi-speed motors will feature additional run status inputs to the automation system for each speed, and additional run command outputs from the automation for each speed

Figure 13: Motor Controller Type Key

The contractor shall develop the motor controller modification electrical schematics, and submit them in preliminary form to MARAD for review and comment. Once the comments have been addressed, the Controls Subcontractor shall perform the modifications to the motor controllers. This work will be accomplished in advance of the new automation installation effort. The motor controller modification drawings will be submitted by MARAD to ABS and USCG for review and comment.

Legacy System Modification and Troubleshooting

Pump / Motor Type Pump / Motor Type

No. 1 main sw pump s/s/s s/s/s PME LO service pump switch & indicators

No. 1 aux sw pump s/s/s SME LO service pump switch & indicators

No. 2 main sw pump s/s/s Reduction gear LO pump #1 r/s/o

No. 2 aux sw pump s/s/s Thrust bearing LO pump #1 r/s/o

No. 3 main sw pump s/s/s Stern tube LO pump #1 r/s/o

No. 1 central fw pump s/s/s Reduction gear LO pump #2 r/s/o

No. 2 central fw pump s/s/s Thrust bearing LO pump #2 r/s/o

No. 3 central fw pump s/s/s Stern tube LO pump #2 r/s/o

PME jacket water pump s/s ME crankcase vent fan #1 a/r/o

SME jacket water pump s/s ME crankcase vent fan #2 a/r/o

PME jacket water keep-warm pump s/s Starting air compressor #1 a/r/o

SME jacket water keep-warm pump s/s Starting air compressor #2 a/r/o

SSDG jacket water keep-warm pump s/s Control air compressor #1 a/r/o

ME booster pump #1 r/s/o Control air compressor #2 a/r/o

SSDG FO press pump #1 r/s/o No. 1 sanitary pump a/r/o

FO Transfer pump #1 a/f/s/o No. 2 sanitary pump a/r/o

DFM transfer pump #1 a/r/o Independent bilge pump s/s

ME booster pump #2 r/s/o No. 1 automatic bilge pump a/r/o

SSDG FO press pump #2 r/s/o No. 2 automatic bilge pump a/r/o

FO Transfer pump #2 a/f/s/o No. 1 oily waste transfer pump a/r/o

DFM transfer pump #2 a/r/o No. 2 oily waste transfer pump a/r/o

SSDG DFM booster pump r/s/o s/s/s start/stop/standby a/f/s/o auto/fast/slow/stop a/r/o auto/run/off s/s/s start/stop

Legend

The planned KM automation upgrade will replace the majority of existing propulsion control and alarm/monitoring system controls hardware. It will not replace the existing ballast control system, GBF IMAC system, or any firepump control systems. The majority of the electrical and controls equipment located in the ECR main control console will be removed and replaced. Where certain control system elements must remain, their retention must be coordinated with the new KM automation installation.

The Controls Subcontractor shall assist KM with the integration of retained legacy control systems and equipment.

Examples of the assistance required for legacy system integration will be the identification and reconnection of retained 120VAC and 24VDC control loads within the ECR console.

REQUIRED QUALIFICATIONS

The subcontractor hired by the primary mechanical contractor must have the following qualifications:

• 5 years of experience retrofitting marine alarm monitoring and main engine propulsion controls including all changes made to the field devices to accommodate the new hardware and software of the new controls

• Powering up UPS installations as power supplies for vital controls such as main engine propulsion controls and alarm monitoring power supplies

• Capability to correct existing drawings and make up “as built” drawings for use as reference by crew and to use for submittal to ABS and USCG for approval as needed

DELIVERABLES

Deliver 2 sets of “as built” drawings in separate hard binders showing the changes made in the motor controllers and circuitry as applied to the KM upgrade. This will be the up-to-date reference for what wiring changes have been made to the field devices that KM is connected to and operates

ADDITIONAL WORK AND SUPPLEMENTARY

Contractor to submit a written Condition Found report (CFR) to the COTR for any additional work outside the contract. Approval for additional work must be approved by either the COTR ($5000 or less) or the Contracting Officer (over $5000)

Contractor to provide cost breakdowns as they relate to labor, material, subcontractors and travel costs, if applicable. Supplementary costs must be approved by COTR by written CFR, RFQ, Quotation and Delivery Order process.

Item No 3 – Supplementary Labor

Mechanical 50hrs @ $______/Hr = $____________________________

Electrical Controls 50hrs @ $______/Hr = $______________________

Item No 4 – Supplementary Material

$15,000