FRC_HSM_SOW_10-29-2018.docx

STATEMENT OF WORK

ENGINEERING SERVICES IN SUPPORT OF

FRC HULL STRUCTURE MONITORING SYSTEM

CONTENTS

1. INTRODUCTION

1.1 The US Coast Guard is involved in a number of efforts supporting hull structural life maintenance strategies for high speed cutters operating in the semi-displacement speed range. A Hull Structure Monitoring (HSM) system is required to monitor hull girder loading and fatigue life budget to support operational and maintenance planning decisions for the USCG 154 foot FRC Sentinel class of high speed cutters. General information on the Cutter may be found at https://www.uscg.mil/acquisition/frc/ Objectives of this effort are construct, installation, and support of a prototype HSM system for the USCG FRC to monitor fatigue budget and maximum load limits for fleet maintenance and operational decisions.

2. REFERENCE MATERIAL

2.1 The Tasks of this project require information about FRC-B cutter class, their performance and design. Specific references that will be provided as GFI are as follows:

3. SCOPE OF WORK – The work is to be accomplished through the following tasks.

3.1 Task 1 –FRC HSM System Documentation

· The contractor shall provide the detailed documentation of the instrumentation system. This detailed documentation shall include the following:

· An overall block diagram illustrating all system components and interconnections

· A list of all system components including key specifications for each component

· A complete system wiring diagram, a detailed wire list, and drawings of all junction boxes and connections

· Installation drawings for all system components showing exact locations, methods of attachment to the cutter, and the design of enclosures or other physical protection

· A cutter interface drawing and specification detailing all connections to shipboard systems, including but not limited to power, grounding, data connections to other shipboard instrument systems, and in-port data communication system

· A software development specification and plan detailing planned data collection, data analysis, data display, data recording, data transfer, system self-diagnostic, and setup functions. Cyber security shall be addressed in the plan. In addition, all planned data processing and analysis algorithms shall be detailed.

· The system documentation package shall be delivered to the SFLC in hard copy and electronic form. This package shall include all drawings, specifications, operating and maintenance manuals for system components, and an overall system Operating and Maintenance Manual. This documentation shall be provided to the SFLC.

3.2 Task 2 – Construct and install FRC HSM System

· The Contractor shall construct and supply a hull structural monitoring system, suitable for a ten-year service life, to include:

· Measure strain using thermally balanced, fiber optic strain measurement with two gauges located under the main deck in one transverse section near the midship area to infer and monitor hull girder bending induced strains. Three additional fiber optic gauges in rosette (three axis strain measurement) or equal strain gauges shall be located at detailed location, two forward in the machinery space and one forward at Frame 17. The specific transverse section and gauge locations shall be selected in coordination with the USCG. Sampling rates shall be at least 80 Hz.

· Data processing and recording system and computer shall be located on a standard electronic equipment rack to fit on and be bolted to a 22” by 22” foundation and no taller than 26”

· The system shall process recorded data onboard. The strain data shall be filtered and processed to identify characteristics of the wave frequency induced strains and the wave plus hull girder whipping induced strain. The onboard processing shall include fatigue cumulative damage using rain flow counting for each deployment (approximately 5 days) and extreme load related statistics (e.g. max, min, mean, stdv) for each 30 min time interval, the 250 maxima and minima for the deployment, and the 30 minute time history of the maximum values for each deployment. Weekly deployment reports shall be in pdf format. Data processed onboard shall be transferred electronically from the monitoring systems to a GSA approved SD card reader installed for data collection by maintenance teem local to the cutter or manually through a secure connection with software and password protections. The summary data shall be provided in an Excel-compatible format to be processed by the shore based data processing system at the SFLC.

· The HSM shall consist of off-the-shelf components and systems currently available for this application and utilize proven off-the-shelf equipment intended for long-term marine applications in harsh environments (i.e. internal machinery space without air conditioning).

· All equipment, junction boxes and cabling shall be carefully isolated to protect them from damage and interference with crew functions. The gauges shall be bonded, coated and otherwise protected from physical damage and internal environments such as a machinery space. The contractor shall run all cabling through existing cable ways as to not interfere with existing cabling. The Primary data collection system shall be compact, ruggedized and centrally located below deck, on the foundation provided in the climate controlled store room just forward of the main machinery space. The system shall be plugged into a wall receptacle for power and not draw over 2 amps at any given time in its operation. The system shall synchronize and time stamp with the onboard computer and updated annually with a GPS time code (UTC). All instrumentation shall be provided with calibration factors traceable to an internationally recognized standard.

· The contractor shall provide a strain gauge calibration test report for each type of sensor installed. The calibration test shall included testing of typical strain gauges bonded to steel structure and load tested to determine the stress strain characteristics of the gauge up to half material yield stress. Results shall be compared to published data for the modulus of elasticity for steel. The test report shall be provided as an appendix in the Concept Design report.

· All cabling shall be of low smoke and zero halogen construction in accordance with MIL-DTL-24643B, “Cables and Cords, Electric, Low Smoke, for Shipboard Use, General Specification for” or MIL-DTL-24640B. Any cabling that penetrates watertight bulkheads or decks shall be watertight. Where special system design features require cable types other than those covered by MIL-DTL-24643B) those special system cables shall be in accordance with IEEE-STD-45, “Recommended Practice for Electrical Installations on Shipboard”. Certification shall be provided that all cables provided meet MIL-DTL-24643B, MIL-DTL-24640B, or IEEE-STD-45. Electric cable applications shall be in accordance with 46 CFR, Subchapter J, Electrical Engineering and IEEE-STD-45. All cable installation shall be in accordance with DOD-STD-2003. Information plates, label plates, and tags shall be installed for equipment, circuits, conductors and cables for and other electrical systems in accordance with NAVSEA S9AA0-AA-SPN-010/GEN-SPEC sections 305 and 400e "General Specifications for Ships of the US Navy”.

· The contractor shall construct the FRC HSM System documented in Task 1 and approved by the USCG. Prior to shipping the system to the cutter, a system burn-in period and a Factory Acceptance Test shall be completed at the contractor’s facility. This test results will be provided to the USCG and shall demonstrate all system features are calibrated and set up for installation and operation. All software shall be fully configured and operational prior to shipment. In addition, all components, calibration certificates and manuals shall be provided for inspection.

· The contractor shall install the HSM system post FRC delivery in Key West Florida. The contractor is responsible for all shipping, importing and customs fees involved in delivery of all hardware to the installation destination. Installation of the prototype system shall include locating and installing all system hardware including, processing unit, displays, cabling, cable banding, junction boxes and distribution system in the FRC. In addition to pulling cable, the contractor shall be responsible for small bolted or bonded foundations for all equipment. Upon completion of system installation, the contractor shall initialize system parameters based on the current cutter loading condition and demonstrate proper system operation to the USCG prior to departing from the installation.

· The contractor shall provide a system setup process description detailing the step by step instruction for system signal gain settings, calibration factors for use as a training guide and data quality assurance document for USCG approval after installation.

· As part of the installation quality assurance process, the contractor shall perform one annual data collection and statistical analysis of at least six months of the Weekly reporting for USCG review and approval prior to submitting the final invoice for payment. The contractor shall provide system hardware and software maintenance and calibration on each HMS system in order to ensure continued operation for a minimum of 10 years with a warranty period of 5 years. A minimum of one trip to each cutter home port shall be conducted to execute the data collection and maintenance within 6 months of installation. The trips shall be scheduled with the USCG guidance on cutter availability.

· The contractor shall price options for installation for lots of five to be installed within a one year time period on FRCs located in Key West Florida. All shipping costs including customs fees to the installation destination shall be paid by the contractor as part of the installation costs.

4. DELIVERABLES AND SCHEDULE

4.1 DELIVERABLES – The Contractor shall provide deliverables that include all drawings, specifications, manuals, illustrations, charts, tables, calculations, text, analyses, algorithms, conclusions and recommendations developed as a part of this project. Upon receipt of a deliverable, USCG SFLC shall have four weeks to review the draft deliverable and provide comments. After receiving USCG SFLC’s comments, the Contractor shall produce the final deliverable within four weeks.

4.2 Modifications to contractor submittals required by the government reviewers, if judged by the contractor to be outside the scope of this Statement of Work shall be discussed at a meeting of the government technical and contracting personnel with contractor representatives.

4.3 SCHEDULE – The following schedule of events shall be followed by both the U.S. Coast Guard and the Contractor in carrying out the provisions of this Statement of Work. When either party becomes aware of their inability to conform to this schedule, they shall so advise the other party, in writing, propose an alternate schedule, and provide justification. The Period of Performance for the contract is five (5) years from date of award.

Item Number

8 weeks after contract award of each set of systems in approximately 3 month intervals

Submission of the deliverables in electronic format is an acceptable substitute to paper copies provided the electronic file format is agreeable to both the Contractor and the U.S. Coast Guard. Preferred format for drawings is AutoCAD 2016 and MS Word for Text documents.

5. QUALITY ASSURANCE

5.1 The government reserves the right to witness the validation procedures and validation processes of any part of the project development at whatever site such action is taking place.

5.2 The government will review the contents and format of the deliverables in their entirety prior to issuing approval.

6. SECURITY CLEARANCE

6.1 This work is not classified. No security clearance is required.

7. USE OF GOVERNMENT FURNISHED MATERIAL

7.1 Government furnished material shall be used for the delivery order only and shall not be used or disseminated for any other purpose.

8. NOTES

8.1 DELIVERY DESTINATION – All items to be delivered under this work statement shall be delivered to the SFLC-ESD-NAME-NAS technical point of contact, Mr. Karl Stambaugh, at the following address:

For each deliverable a copy of the cover letter shall be provided directly to the Contracting Officer at the following address:

8.2 RIGHTS IN DATA – All data regardless of form or medium are considered to be solely the property of the USCG and shall not be released without the written consent of the USCG.