A00001,_P4500200,_Specification,_CGC_DIAMOND_BACK_(WPB_87),_Rev1.pdf

USCGC DIAMOND BACK (WPB 87) DOCKSIDE AVAILABILIBILITY FY 2019

Rev 1

De ECNNN_3110_LNM_0818_87WPB

WORK ITEM 1: Ship Service Diesel Generator Sets, Replace

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to replace the existing Ship

Service Generators, Main Switchboard and two (2) 440 VAC Panels. The Contractor shall provide all equipment and materials unless designated as Government-furnished as listed below.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

Y Ship Service Diesel

Generator Set, Port

NSN: 2815-01-F13-3325 1 ea. 40,925.00

Y Ship Service Diesel

Generator Set, STBD

NSN: 2815-01-F18-5409 1 ea. 40,925.00

N Main Switchboard, includes

7-inch touch screen HMI for

Pilothouse installation

NSN: 6110-01-F17-5033 1 ea. 150,500.00

N Magnetic Speed Pickup NSN: 2920-01-663-1295 2 ea. 250.00

N SSDG Exhaust Insulation

Blankets

Advanced Thermal Products

Inc, Marine Wrap

NSN: 2990-01-674-5103 1 ea. 1,495.00

N SSDG Exhaust Insulation

Blankets

Advanced Thermal Products

Inc, Marine Wrap

NSN: 2990-01-674-9188 1 ea. 1,485.00

N Repair Kit, Soft Patch Kit NSN: 8040-01-601-2062 2 ea. 1,028.19

N Clamp Synchro 8" NSN: 5340-01-568-6899 12 ea. 47.02

N Sealant Compound NSN: 8030-01-593-2919 4 ea. 117.28

N Clamp Synchro (12" V-Band

Clamp)

NSN: 5340-01-590-8152 6 ea. 55.24

N Clamp Synchro NSN: 5340-01-593-2913 4 ea. 277.18

N Clamp Synchro 4.5” NSN: 5340-01-593-2907 2 ea. 31.41

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 131-001, Rev J, Deck Construction Plan

Coast Guard Drawing 87 WPB 182-001, Rev C, Main Engine and Generator Foundation

Coast Guard Drawing 87 WPB 201-001, Rev E, Machinery Arrangement

Coast Guard Drawing 87 WPB 233-001, Rev A, Remote Emergency Shutdowns

Coast Guard Drawing 87 WPB 252-001, Rev G, Pilot House Console Arrangement

Coast Guard Drawing 87 WPB 252-002, Rev N, Alarm and Monitoring System

Coast Guard Drawing 87 WPB 256-001, Rev Y, Sea Water Cooling Piping

Coast Guard Drawing, 87 WPB 259-001, Rev H, Engine Exhaust Piping

Coast Guard Drawing, 87 WPB 259-002, Rev B, Propulsion Engine/SSDG Exhaust Piping

Insulation Modifications

Coast Guard Drawing 87 WPB 261-001, Rev L, Fuel Oil Service Piping

Coast Guard Drawing 87 WPB 261-003, Rev -, Fuel System Mods Incidental to John Deere

SSDG Installation

Coast Guard Drawing 87 WPB 310-001, Rev G, Ship Service One-Line Diagram

Coast Guard Drawing 87 WPB 313-001, Rev M, DC System

Coast Guard Drawing 87 WPB 324-001, Rev B, Switchboard Wiring Diagram & Details (Hulls

1-12)

Coast Guard Drawing 87 WPB 324-002, Rev C, Switchboard Wiring Diagram & Details (Hulls

13-On)

Coast Guard Drawing 87 WPB 324-003, Rev B, Switchboard Wiring Diagram & Details (Hulls

52 & )

Coast Guard Drawing 87 WPB 310-013, Rev-, Powergen Communications SSDG

Coast Guard Drawing 87 WPB 310-014, Rev-, Powergen Interconnection, SSDG

Coast Guard Drawing 87 WPB 310-011, Rev-, Powergen One Line SSDG, One Line

Coast Guard Drawing 87 WPB 310-010, Rev-, Powergen Wiring SSDG

Coast Guard Drawing 87 WPB 310-012, Rev-, Powergen Schematic SSDG, Electrical

Elementaries

NAVSEA Drawing 803-1385866, Rev E, Penetration, Bulkhead and Deck

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0850 (SFLC Std Spec 0850), 2014, General Requirements for Drawing Preparation

Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3040), 2014, Shipboard Electrical Cable Test

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2014, Shipboard Electrical Cable Removal, Relocation, Splice, Repair and Installation

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary Services

OTHER REFERENCES

American Bureau of Shipping (ABS), Steel Vessels Under 90 Meters in Length, Part 4, Vessel

System and Machinery, Chapter 6 Electrical Installations, Feb 2015

Institute of Electrical and Electronic Engineers IEEE STD 45, Recommended Practice for

Electrical Installations on Shipboard, April 9, 2004

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-58, 2009, Pipe Hangers and Supports – Materials, Design, Manufacture, Selection, Application and

Installation

Description of System Operations (DOSO)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the Powergen Switchboard to accomplish the following on site:

Provide manufacturer's proprietary system/ equipment information, software, and tools.

Commission Easygens and program new switchboard.

See Note 4.1

3.1.3 Advance notification. The Contractor shall notify the Contracting Officer's Representative (COR) with 24 hours advance written notice at the following instances:

Prior to placing the existing SSDG sets out of commission.

Prior to performing all inspections and tests specified herein.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.4 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.5 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec

0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

Main Diesel Engines

Exhaust Lagging

Overhead Deck Plating and Supports

Piping (Various)

Electrical wiring (Various)

Bolted Engine Room Removable Plate (BERP)

Fuel Oil

Lube Oil

Coolant, Raw Water

3.1.6 Temporary services. The Contractor shall provide temporary services in accordance with SFLC Std

Spec 8635.

Firemain System

3.1.7 Temporary ventilation. The Contractor shall provide temporary ventilation to the cutter capable of maintaining the onboard temperature between 65°F and 75°F while the HVAC system is temporarily off line in accordance with SFLC Std Spec 0000, section 3.3.1.1 Temporary ventilation.

3.1.8 Sanitary facilities for vessel-personnel – due to disruption of grey water and sewage systems. The

Contractor shall provide a sanitary facility for the crew in accordance with SFLC Std Spec 0000, section

3.2.11.

3.1.9 Fire alarm and bilge alarm. The Contractor shall ensure that the fire alarm and bilge alarms are energized during change out of the main switchboard. This shall include providing 24 VDC Power to the

Engine Room Alarm Panel and to the Fire Alarm Control Panel in the Pilot House.

3.2 Equipment installation/modification. The Contractor shall refer to all references listed in section 2 and accomplish the following:

3.2.1 Removals. The Contractor shall perform the following:

3.2.1.1 Removal procedure. Refer to Coast Guard Drawing 87 WPB 131-001, Detail 11-A and all other referenced applicable drawings as guidance, submit a written procedure to the Coast Guard Inspector for approval, detailing the intended sequence and methods of lifting and removing the existing generator sets, main switchboard and 440 VAC Panels to be performed by the Contractor within 48 hours prior to beginning removal. This shall include the removal and disposal of SSDG fluids (L/O and Coolant).

3.2.1.2 Disconnections. Accomplish all mechanical and electrical work in accordance with ABS, IEEE-

Std 45, SFLC Std Spec 3042, test cables in accordance with SFLC Std Spec 3041 and applicable drawings listed in Section 2 of this work item. Utilize the existing wire ways for new cable runs.

Remote Pull Cables CA-6-350, CA-6-370, CA-300, CA-370 shown on Coast Guard Drawing

233-001. Do not dispose of these pull cable as they will be reused for new installation of

John Deere Generators.

Alarm & Monitoring circuits (a.) Main SWBD Control Battery Charger (b.) Main SWBD P/S

IRM P/S Steering Pump Failure (c.) SSDG, Port L/O Pressure, J/W Temp, Emergency Stop

Activated, J/W Level Low, SSDG, Port/STBD - L/O Pressure, J/W Temp, Emergency Stop

Activated, J/W Level Low

Drain and dispose of all fluids in accordance with applicable Federal, State and Local regulations.

WARNING

Do not drain any fluids including fresh water, into any space, bilge, or exterior location.

3.2.1.3 Generator set removals. Remove the existing generator sets using the approved removal procedure, and Coast Guard Drawing 87 WPB 182-001, 201-001, 233-001, 252-002, 259-001, 261-001, and 310-001, as guidance.

3.2.1.4 Main switchboard and associated 440 VAC distribution panels removals. Remove the existing main switchboard and associated 440 VAC distribution panels using Coast Guard Drawing 87 WPB 310-

001. 324-001, 324-002 and 324-003 as guidance. Retain circuits 1SGA-4P-1S AND 1SGB-4P-1S, cable type LSTNW-75 for later reinstallation. Disconnect and discard all control and indicating circuits as shown on referenced Drawings 324-001 through 324-003 as applicable.

3.2.2 Bilge cleaning and inspection. Clean and visually inspect the bilge areas under the SSDG, and

Main Switchboard foundations for signs of corrosion or defect, and submit a Condition Found Report

(CFR).

3.2.3 Generator set foundations. Preserve the SSDG foundations in accordance with the applicable coating system listed in SFLC Std Spec 6310.

3.2.4 Installations. The Contractor shall:

3.2.4.1 Main Switchboard and associated 440 VAC Panels. Install Government-furnished Main

Switchboard, 440 VAC Panels and all associated controls and monitoring systems as shown on Coast

Guard Drawings 87 WPB 310-012, Powergen Schematic SSDG, Electrical Elementaries, 87 WPB 310-

014, Powergen Interconnection, SSDG and 87 WPB 310-011 Powergen One Line SSDG, One Line.

Switchboard installation entails all interface interconnections including wiring from the Easygen Panels to each generator for control and monitoring.

3.2.4.1.1 The 5.7-inch Operator Interface shall be installed in the Pilot House starboard side, aft section overhead as designated by the Coast Guard inspector. See Figure 1, Pilot House SSDG Display, in the last page of this work item. The Coast Guard Drawings 87 WPB 310-013 and 87 WPB 310-014 should be used for guidance only. Additional guidance shall be provided by the Technical Representative.

3.2.4.2 Generator sets. Install Government-furnished generator sets as shown on Coast Guard Drawing

87 WPB 201-001. Provide all fluids to include approximately 8 gallons of 50/50 mixture of John Deere

Cool-Gard II J/W coolant and approximately 7 gallons of John Deere Break-In Plus oil per engine. All system interconnections shall be performed as follows:

3.2.4.2.1 Fuel oil (F/O) piping. The intent of this modification is to create a dedicated fuel line for each ship’s service generator set. Modify the existing F/O piping using Coast Guard Drawing 87 WPB 261-

003 as guidance except the Item 1 and Item 4. Item 1 shown on the Materials List shall be 1-1/4” IPS to

¾” OD stainless steel Tee with Lokring, and Item 4 shall be 3/4” OD stainless Steel tubing with 0.065” wall thickness.

3.2.4.2.2 Sea water cooling. Make all sea water cooling connections and modifications as shown on

Coast Guard Drawing 87 WPB 256-001.

3.2.4.2.3 Exhaust piping and insulation blankets. Remove and discard the existing port and starboard

SSDG exhaust insulation blankets. Modify exhaust piping from muffler to turbo as shown in Coast Guard

Drawings 87 WPB 259-001 and 87 WPB 259-002. Install the Government-furnished insulation blankets.

3.2.4.2.4 Remote emergency shutdowns. Connect all remote emergency shut downs using existing pull cables as shown in Coast Guard Drawing 87 WPB 233-001.

3.2.4.2.5 Adhesive-Bond fasteners. To avoid any hot work and gas freeing, the Contractor shall use adhesive-bond fastening system wherever the application can be used. The adhesive-bonded fasteners shall be American Bureau of Shipping (ABS) approved, and meet the appropriate loading requirement for each application. The adhesive-bond fasteners shall be Click Bond or equal. See Note 4.2

3.2.4.3 Hydrostatic test. Conduct hydrostatic test to the new piping/tubing to 150% of its operational pressure using fresh water. Check for any leaks, and submit CFR.

3.2.4.4 Pipe flushing. Flush all new and disturbed piping with clean fresh water until all debris is removed but no longer than five minutes. Ensure flushing fluid is directed to move scale and foreign debris away from installed machinery to prevent possible damage upon operational testing. Submit a CFR documenting date and time of flushing process and level of pipe cleanliness.

3.2.4.4.1 Dispose of flushing fluid in accordance with all applicable Federal, state, and local regulations.

3.2.4.4.2 Ensure all water is removed by blowing dry all flushed piping with dry, low-pressure air.

3.2.4.4.3 Inspect the piping interior using a borescope in the presence of the COR, to verify that all solid deposits visible to the unmagnified eye have been removed. Continue the cleaning process until all visible solid deposits are removed from the pipe wall. Inspect piping interior walls for deterioration and metal failure. Submit a CFR.

3.2.4.5 Pipe hanger installation. The Contractor shall furnish, fit, and install new pipe hangers in accordance with MSS SP-58. In lieu of welding use adhesive bond fasteners. See Note 4.2.

3.2.4.6 Pipe labeling. The Contractor shall label affected piping in accordance SFLC Std Spec 0000.

3.2.5 Nameplate label installations. The Contractor shall furnish and install a nameplate labels in accordance with SFLC Std Spec 0000.

3.2.6 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.

3.3 Requirements for test performance. The Contractor shall prepare and submit to the COR for approval, all test procedures, operational demonstrations, and a schedule of tests for all equipment.

3.3.1 Operational test, post-repair. The Contractor shall perform the operational test using the services of the authorized technical representative as specified above Tech Rep. The Technical Representative shall perform the operational test using the “Description of Operational Procedures” (DOSO) which the tech rep has developed for the new Main Switchboard. Provide a copy of the DOSO to the COR prior to performing test. The technical representative shall thoroughly test and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Operational tests shall include the following modes. Submit a CFR.

Initial Conditions/Manual Control Gen 1/Gen 2/Shore Power – All C/B’s in Off Position

Auto Mode Test Off Gen 1/Gen 2/Off

Auto Mode Test Off/Shore Power/Off

Generators/Shore Power Hot Parallel transfer test

Generators Manual Test

Post Test Actions – All Buses and Generators in Automatic Mode

Initial Conditions/Manual Control Gen 1/Gen 2/Shore Power – All C/B’s in Off Position

Auto Mode Test Off Gen 1/Gen 2/Off

Auto Mode Test Off/Shore Power/Off

Generators/Shore Power Hot Parallel transfer test

Generators Manual Test

Post Test Actions – All Buses and Generators in Automatic Mode

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.4 Redlined drawing deliverable(s). The Contractor shall “red-line” referenced drawings listed in section

2. above to reflect the work or deviations specified in this work item in accordance SFLC Std Spec 0850.

3.4.1 Preliminary/draft submission. No later than 24 hours after completion of this work item, submit a draft copy of the "red-lined" drawing(s) to the COR for review and approval.

3.4.2 Final submission. No later than 10 calendar days after receiving Coast Guard comments or completion of the availability, whichever occurs first, incorporate all comments and deliver one set of the final red-lined drawing(s) to the COR.

4. NOTES

4.1 Powergen Controls LLC contact information.

Main Office: 7322 Almeda Genoa Rd

Houston TX 77075

Phone +1(832) 730-5220

E-mail: info@powergencontrols.com

4.2 Click Bond contact information.

2151 Lockheed Way

Carson City, NV 89706-0713 www.clickbond.com mailto:info@powergencontrols.com

FIGURE 1. PILOT HOUSE, SSDG OPERATOR INTERFACE DISPLAY

(LEFT INTENTIONALLY BLANK)