ATTCHMENT 2 - MACKINAW (WLBB 240) IPP FY24-FY28_R0.pdf

USCGC MACKINAW (WLBB 30)

SPECIFICATION FOR SUPPORT OF THE SWITCH GEAR SYSTEM AND ASSOCIATED

EQUIPMENT

FY2024 - FY2028

Developed By: Michael L. Dougall

(Rev-0, 4 January 2023)

USCGC MACKINAW (WLBB-240) SWITCH GR SYSTEM FY2024 - FY2028

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ...................................................................................................................................................... iii Consolidated List of References ............................................................................................................................... iv Consolidated List of Government-furnished Property ............................................................................................ vii Consolidated List of Critical Inspection Items ....................................................................................................... viii Principal Characteristics ........................................................................................................................................... ix

GENERAL REQUIREMENTS

WORK ITEM 1: Integrated Power Plant, Groom WORK ITEM 2: Integrated Power Plant, Configuration Management WORK ITEM 3: Integrated Power Plant, Technical Support iii (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

• MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

• Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

• Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws::

www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

• American Welding Society (AWS): http://www.awspubs.com/index.php

• ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

• NFPA: http://www.nfpa.org

• SSPC Standards and pictorial guides: http://www.sspc.org/

COAST GUARD DRAWINGS

Coast Guard Drawing (FD&CC LANT), Project No. 09-L00004, Homeport 240’ GLIB Coast Guard Drawing 240-WLBB 320-1, Rev T, Electrical One Line Diagram Coast Guard Drawing 240-WLBB 320-14, Rev C, Block and Elementary Wiring Diagrams for

Switchboards, Gen/Diesel Engines & MG Sets Coast Guard Drawing 240-WLBB 320-15, Rev D, Miscellaneous Power System Elementary Wiring

Diagrams Coast Guard Drawing 240-WLBB 320-16, Rev C, Motor Controllers Elementary Wiring Diagrams

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3701A, Ship’s Information Book (SIB), Apr 2017 Coast Guard Technical Publication (TP) 3702, Engineer’s Operating Manual (EOM) Vol I & II, May

Coast Guard Technical Publication (TP) 3713, Bow Thruster, June 2021 Coast Guard Technical Publication (TP) 3786, Automatic Bus Transfer Switches (ABT), Feb 2005 Coast Guard Technical Publication (TP) 3835, Motor Controllers, Jan 2007 Coast Guard Technical Publication (TP) 3836, Motor Controllers, – Appendices, Jan 2007 Coast Guard Technical Publication (TP) 3851, Main Propulsion Switchboard, Nov 2006 Coast Guard Technical Publication (TP) 3853, Ship’s Service Switchboard, Nov 2006 Coast Guard Technical Publication (TP) 3854, Emergency Switchboard, Nov 2006 http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://www.sspc.org/ v (Rev-0)

Coast Guard Technical Publication (TP) 3855, Power Management System Volume 1 – System Overview, Oct 2015

Coast Guard Technical Publication (TP) 3856, Power Management System Volume 2 – Component User Manuals, Jan 2007

Coast Guard Technical Publication (TP) 3857, Power Management System Volume 3 – Component User Manuals, Jan 2007

Coast Guard Technical Publication (TP) 3866, Bow Thruster & Motor Generator Set AC Drive System, Oct 2007

Coast Guard Technical Publication (TP) 3867, Motor Generator Set, Oct 2007 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0850, 2020, General

Requirements for Drawing Preparation Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3020, 2020, Overhaul AC

Electrical Motors Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3041, 2020, Shipboard

Electrical Cable Test Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3100, 2020, Inspect, Test and

Recondition AC Synchronous Machines In-Place 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 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

OTHER REFERENCES

American National Standards Institute/National Electrical Manufacturers Association (ANSI/NEMA) AB

4, 2017, Guidelines for Inspection and Preventive Maintenance of Molded Case Circuit Breakers Used in Commercial and Industrial Applications

Code of Federal Regulations (CFR) Title 33 CFR, 2022, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2022, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2022, Pipeline and Hazardous Materials Safety

Administration, Department of Transportation Institute of Electrical and Electronics Engineers (IEEE) Std C57.93, 2019, IEEE Guide for Installation and Maintenance of Liquid-Immersed Power Transformers Institute of Electrical and Electronics Engineers (IEEE) Std C57.94, 2016, IEEE Recommended Practice for Installation, Application, Operation, and Maintenance of Dry-Type General Purpose Distribution and Power Transformers

Institute of Electrical and Electronics Engineers (IEEE) Std C57.104, 2022, IEEE Guide for the Interpretation of Gases Generated in Oil-Immersed Transformers

Institute of Electrical and Electronics Engineers (IEEE) Std C57.106, 2015, IEEE Guide for Acceptance and Maintenance of Insulating Oil in Equipment

MIL-C-24368, Mar 1987, Connector Assemblies; Plugs and Receptacles, Electric Power Transfer, Shore to Ship and Ship to Ship, General Specification for

NAVSEA Technical Publication T9074-AD-GIB-010/1688_Rev-1, Jul 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure vi (Rev-0)

The Society for Protective Coatings (SSPC)/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No.2, 2015, Near-White Blast Cleaning

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP 11), 2020, Power Tool Cleaning to Bare Metal vii (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

This section is not applicable to this package.

viii (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

This section is not applicable to this package.

ix (Rev-0)

PC_240_WLBB_1011

PRINCIPAL CHARACTERISTICS

240' WLBB (30 CGC MACKINAW)

PHYSICAL CHARACTERISTICS

Length Overall 240’ 0” Depth (main deck at side to baseline) 24' 0" Maximum Beam 58’ 0” Height of Highest Projection (above DWL) 95' 6" Full Load Draft 16’ 0” Full Load Displacement (Icebreaking) 3426.73 LT Freshwater Shore Tie Voltage Requirements 1,200 Amp total

3EA 400A 450VAC 3PH

Ungrounded forward/aft stations

HULL CHARACTERISTICS

Frame Spacing FR 19-25 = 19"

FR 33-39 = 21"

ALL Else = 20"

MACHINERY CHARACTERISTICS

Number of Propellers 2 Number of Blades per Propeller 4

Diameter of Propeller 10.25' Pitch 96.98" Revolutions per Minute (RPM) 226 rated 270 max Shafting/Propulsion System Azipod

TANK CAPACITIES

Diesel Oil 115,538 gallons Fresh Water Capacity 27,948 gallons Hydraulic Oil Capacity 696 gallons Lube Oil Storage 1,159 gallons Grey Water Tank 27, 080 gallons Sewage Holding Tank 5,313 gallons

1 (Rev-0)

00000_0213_FLT

REC_0000_FLT_ Commercial Project @ CG Facility (1212)

GENERAL REQUIREMENTS

1. SCOPE

1.1 Intent. This standard specification invokes general requirements while conducting tasks specified in this performance work statement (PWS).

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

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 6310 (SFLC Std Spec 6310), 2020, Preserve Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 33 CFR, 2022, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2022, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2022, Pipeline and Hazardous Materials

Safety Administration, Department Of Transportation The Society for Protective Coatings (SSPC)/NACE International (NACE), Joint Surface

Preparation Standard SSPC-SP 10/NACE No.2, 2015, Near-White Blast Cleaning The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP

11), 2020, Power Tool Cleaning to Bare Metal

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

2 (Rev-0)

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

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

3.4 HW disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Label and package all hazardous wastes in 49 CFR-approved containers, and in accordance with all other applicable Federal, state, and local laws and regulations. In addition, comply with applicable parts of 40 CFR 262, applicable to handling of hazardous wastes.

3.4.1 Along with the Government, the Contractor shall be contractually considered the co-generator of all hazardous wastes; be aware that the Government will make available its facility’s EPA Generator Identification (ID) Number for manifesting of hazardous wastes.

3.4.2 The Contractor shall identify, arrange, and be responsible for the turnover of all hazardous wastes, within the confines of the Coast Guard shore facility, to the facility’s HM/HW Coordinator. Notify the ship’s HW Coordinator prior to any transfers of HW from ship to shore.

3.4.3 The Contractor shall prepare a manifest of hazardous waste to be reviewed and signed by the HM/HW Coordinator. Contact the HM/HW Coordinator for turnover of any hazardous waste; in addition, notify the COR in writing 24 hours prior to any waste removals, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.4.4 If MACKINAW’s Crane is not available due to a casualty or otherwise, the contractor shall provide a crane to facilitate any and all onloads and offloads of equipment, machinery, and parts. The Contractor shall provide notification of requested MACKINAW crane services at minimum 48 hrs prior to usage.

3.4.5 The Contractor shall be aware of the following:

3.4.5.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

3.4.5.2 Local environmental regulations at the Government facilities may be more stringent than in many jurisdictions. As with all environmental regulations, it is the Contractor's responsibility to research, prepare for, and comply with local and state regulations.

3.4.5.3 Coast Guard facilities do not have Facilities Response Plans (see 33 CFR 154 Subpart F). It is the Contractor’s responsibility to furnish the Facility Response Plan (FRP) when required for over-the-water liquids transfers to and from vessels. This requirement is applicable to transfers to/from vessels with an oil/fuel capacity of 250 barrels or more.

3.5 Scope of work.

3.5.1 Work. The Contractor shall provide all personnel, labor, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment required to maintain and support the Switch Gear System and associated equipment as defined in this PWS.

3 (Rev-0)

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment, perform electrical tag-outs in support of maintenance, and be available to advise on rigging safety procedures as necessary. All other labor associated with maintenance tasks (i.e. rigging, parts delivery, repairs, etc) shall be provided by the Contractor.

3.5.2 Travel. The Contractor shall provide all travel to support tasks onboard the vessel at the vessel’s homeport (Cheboygan, MI).

3.5.3 Parts. The Contractor shall use only new, Original Equipment Manufacturer (OEM)-approved parts for accomplishments of tasks.

3.6 Contractor qualifications. The Contractor shall provide qualified personnel to perform all contract work and services within specified time frames. Qualification requirements are as follows:

3.6.1 Tech Rep. The Contractor shall provide the services of a certified Tech Rep, who is familiar with the IPP System, 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.

• Provide genuine, OEM-approved parts

3.6.1.1 Tech Rep should be knowledgeable and competent with performance of mechanical and electrical tasks / troubleshooting as well as hardware and software applications for the systems outlined in Work Item 1, Paragraph 3.2. When working on NIDEC / AVTRON components, the tech rep shall be certified by NIDEC / AVTRON to perform maintenance to those components or systems.

3.6.2 Contractor’s personnel in training. The Contractor may not use trainees to perform any of the required services unless each trainee performs all work under the close supervision of a technical representative. At least a (1:1) technical representative to trainee ratio shall be strictly maintained. The full cost associated with trainee efforts shall be funded by the Contractor and shall not be charged to this contract.

3.6.3 Employee identification and access. At least seventy two (72) hours prior to each ship visit to perform work under this contract, the Contractor shall submit a list of all employees who shall be performing that work to the COR. In the case of a ship visit as a result of a casualty, the list of all employees who will be performing the work shall be submitted within 8 hours after the ship visit is authorized by the KO. To gain access to the ship or other Government facilities to perform any work under this contract, each Contractor employee shall carry a picture identification card furnished by the Contractor, or other servicing agent authorized by the Contractor/Manufacturer. The employee shall prominently display this card on their person in the chest area at all times when on any Government facility, except when actively engaged in labor wherein the card might get caught in tools or operating machinery and represent a hazard to the employee.

3.6.4 Security clearances. No special security clearances are normally required to perform any work under this PWS. The Contractor shall supply a list of all employees who may be required to perform work under this PWS and periodically update that list. Prior to each ship visit to perform work under this PWS, 4 (Rev-0) the Contractor shall submit information on visiting employees. Should the cutter be berthed at a Department of Defense or foreign government military facility, the KO will provide instructions on the method by which the cutter crew will assist the Contractor’s representatives in meeting facility access requirements at the time the Contractor is tasked.

3.6.5 Government facility regulations. The Contractor shall observe and comply with all USCGC MACKINAW (WLBB-30) and Homeport Facility policy/instructions that might affect work performance under this PWS. A copy will be provided to the contractor after contract award.

3.7 Touch-up preservation, general. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310.

3.8 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

4. NOTES

This section is not applicable to this work item.

5 (Rev-0)

32002_WJW_0313_240

WORK ITEM 1: Integrated Power Plant, Groom

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a full system assessment of the Integrated Power Plant (IPP) and complete the grooming tasks specified below.

1.2 Government-furnished property.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 240-WLBB 320-1, Rev T, Electrical One Line Diagram Coast Guard Drawing 240-WLBB 320-14, Rev C, Block and Elementary Wiring Diagrams for

Switchboards, Gen/Diesel Engines & MG Sets Coast Guard Drawing 240-WLBB 320-15, Rev D, Miscellaneous Power System Elementary

Wiring Diagrams Coast Guard Drawing 240-WLBB 320-16, Rev C, Motor Controllers Elementary Wiring

Diagrams Coast Guard Drawing (FD&CC LANT), Project No. 09-L00004, Homeport 240’ GLIB

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3701A, Ship’s Information Book (SIB), Apr 2017 Coast Guard Technical Publication (TP) 3702, Engineer’s Operating Manual (EOM) Vol I & II, May 2013 Coast Guard Technical Publication (TP) 3713, Bow Thruster, June 2021 Coast Guard Technical Publication (TP) 3851, Main Propulsion Switchboard, Nov 2006 Coast Guard Technical Publication (TP) 3853, Ship’s Service Switchboard, Nov 2006 Coast Guard Technical Publication (TP) 3854, Emergency Switchboard, Nov 2006 Coast Guard Technical Publication (TP) 3855, Power Management System Volume 1 – System

Overview, Oct 2015 Coast Guard Technical Publication (TP) 3856, Power Management System Volume 2 –

Component User Manuals, Jan 2007 Coast Guard Technical Publication (TP) 3857, Power Management System Volume 3 –

Component User Manuals, Jan 2007 Coast Guard Technical Publication (TP) 3786, Automatic Bus Transfer Switches (ABT), Feb

Coast Guard Technical Publication (TP) 3866, Bow Thruster & Motor Generator Set AC Drive

System, Oct 2007

6 (Rev-0)

Coast Guard Technical Publication (TP) 3835, Motor Controllers, Jan 2007 Coast Guard Technical Publication (TP) 3836, Motor Controllers, – Appendices, Jan 2007 Coast Guard Technical Publication (TP) 3867, Motor Generator Set, Oct 2007 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3020, 2020, Overhaul

AC Electrical Motors Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3041, 2020, Shipboard

Electrical Cable Test Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3100, 2020, Inspect, Test and Recondition AC Synchronous Machines In-Place

OTHER REFERENCES

American National Standards Institute/National Electrical Manufacturers Association

(ANSI/NEMA) AB 4, 2017, Guidelines for Inspection and Preventive Maintenance of Molded Case Circuit Breakers Used in Commercial and Industrial Applications

Institute of Electrical and Electronics Engineers (IEEE) Std C57.93, 2019, IEEE Guide for Installation and Maintenance of Liquid-Immersed Power Transformers

Institute of Electrical and Electronics Engineers (IEEE) Std C57.94, 2016, IEEE Recommended Practice for Installation, Application, Operation, and Maintenance of Dry-Type General Purpose Distribution and Power Transformers

Institute of Electrical and Electronics Engineers (IEEE) Std C57.104, 2022, IEEE Guide for the Interpretation of Gases Generated in Oil-Immersed Transformers

Institute of Electrical and Electronics Engineers (IEEE) Std C57.106, 2015, IEEE Guide for Acceptance and Maintenance of Insulating Oil in Equipment

MIL-C-24368, Mar 1987, Connector Assemblies; Plugs and Receptacles, Electric Power Transfer, Shore to Ship and Ship to Ship, General Specification for

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

None.

3.1.2 Tech Rep.

3.1.2.1 The Contractor shall provide the services of a qualified Tech Rep who is familiar with the Integrated Power Plant to do the following, on site:

• Advise on manufacturer’s proprietary information pertinent to the systems within the scope of this work item.

• 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 and systems.

7 (Rev-0)

3.1.2.2 Ensure the Tech Rep has a résumé of demonstrated experience with the systems and equipment within the scope of this work item. Résumé can be retained on file and referenced if the same Tech Rep is utilized from visit to visit.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the to the COR at least 10 days prior to each visit. Resume can be retained on file and referenced if the same Tech Rep is utilized from visit to visit.

3.1.3 Protective measures – general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces in the vicinity of 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.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5 Reference documents. Refer to the Coast Guard drawings and technical publications listed in section 2 above while performing all tasks specified below. All shipboard work shall be performed in accordance with the General Requirements.

3.1.6 Documentation. Submit all written reports electronically in a .pdf compatible file format.

3.1.7 Condition found reports. Submit a Condition Found Report (CFR) to the Contracting Officer’s Representative (COR) for any discrepancies found during performance of this contract within 24 hours of discovery. Action shall be taken on all CFRs prior to completion of the groom.

3.2 Systems.

3.2.1 Shipboard.

3.2.1.1 Medium voltage (4160 VAC) power distribution system:

• Switchgear and control units (including the power management system, electrical power distribution system, Cutler-Hammer VCPW-ND vacuum circuit breakers, instrumentation, controls, protective components, and terminal connections)

• Main generator dual redundant voltage regulators – Basler DECS-200 (6 each)

• Engine speed governor controls (main diesel generators) – Woodward Series 828

• Woodward Master Synchronizer & Load Control (MSLC)

• Woodward Digital Synchronizer & Load Control (DSLC)

• Ship service transformers (2 each)

• Bow thruster variable speed motor drive transformers (1 each)

• Ship service motor generator (SSMG) variable speed motor drive transformers (2 each)

3.2.1.2 Low voltage (450, 240, and 120 VAC) power distribution system:

• Ship service and auxiliary switchgear (including the power management system, Cutler-

Hammer Magnum DS power circuit breakers, Cutler-Hammer molded case circuit breakers, instrumentation, controls, protective components, and terminal connections)

8 (Rev-0)

• Motor control centers

• Automatic bus transfer (ABT) switches (18 each)

• Load centers and panelboards

• Woodward Master Synchronizer & Load Control (MSLC)

• Woodward Digital Synchronizer & Load Control (DSLC)

• Bow thruster control panel

• Bow thruster motor, including associated variable frequency drive

• Ship service motor generator sets (2 each), including associated variable frequency drives

• SSMG and auxiliary generator voltage regulator – Basler DECS-200 (3 each)

• Shore power cables with MIL-C-24368 plugs (3 cord sets)

• MIL-C-24368 shore power receptacles (3 forward and 3 aft)

• Batteries and battery chargers

3.2.2 Ashore. The following infrastructure serves the cutter at its home port, the Coast Guard wharf in Cheboygan, Michigan near the mouth of the Cheboygan River:

3.2.2.1 Shore power distribution system:

• Main switchboard (480Y/277 volt), including, but not limited to:

o Main circuit breaker, Cutler-Hammer Magnum DS, 3000 A standard width frame, 3000 A sensor, fixed horizontal mounting, manually operated, 520M LSIG electronic trip unit, catalog number MDS6303HEA-30MMNMNNNENNNAX o Shore power isolation transformer primary feeder molded case circuit breakers (2), 1200 A frame, Cutler-Hammer RMS 310 LSI electronic trip unit, catalog number

ND312T32W

• Shore power isolation transformers (2), 480∆ primary voltage, 450∆ secondary voltage, 1000 kVA, electrostatic shield, Cutler-Hammer part number 177691

• Shore tie stations (2), each including, but not limited to:

o Shore power molded case thermal-magnetic circuit breakers (3), 600 A frame, Cutler-

Hammer catalog number LD3500 with 120 VAC shunt trip o Receptacles (3), three phase, 450 VAC, 500 A, Navy Symbol 1161 (MIL-C-24368/2) o Multi-function meters (3), Cutler-Hammer IQ 200 o Ground fault monitor, Bender MarinaGuard MG-1 o Receptacle, duplex, single phase ground fault circuit interrupter, 120 VAC, 20 A o Receptacle, three phase, 450 VAC, switched, either:

Navy Symbol 915.1 (MIL-R-2726/19), with external 30 A fusing (ST-1) Russellstoll Max-Gard DBRS240420000, with integral 200 A circuit breaker

(ST-2)

o Indicator lights (6) o Switch, mushroom head, emergency trip o Transformers (3), control power o Fuse blocks

9 (Rev-0)

3.2.2.2 Main generator load testing system, Avtron part number A33813, including, but not limited to:

• Transformer, oil filled, 4160∆ primary voltage, 480Y/277 secondary voltage, 4600 kVA,Vantran shop order 11V9253

• Reactive load bank (2700 kVAR at 480 VAC) o Reactors (12), 18.75 kVAR, Avtron part number C21055 o Reactor, 75 kVAR, Avtron part number C21033 o Reactor, 150 kVAR, Avtron part number C23159 o Reactors (6), 375 kVAR, Avtron part number C21172

• Resistive load bank (3600 kW at 480 VAC) o Resistor assembly, 2 × 25 kW, Avtron part number D39886 o Resistor assembly, 50 & 100 kW o Resistor assemblies (17), 2 × 100 kW, Avtron part number D27555-1 o Resistive blower motors, 6 × 460V, 10 HP, 1800 RPM, 14 AMP, Leeson Electric part number 140451.00

• Controller, programmable logic, General Electric Fanuc Automation

• Controller, hand held, Avtron part number C26996

• Load cable set, Avtron part number B30874

3.3 Groom. Perform a groom of the system, normally annually, when ordered by the Contracting Officer.

3.3.1 Tasks. A groom shall include the following elements and specific tasks :

• Preparation of the Pre Groom survey Test Plan.

• Preparation of the Performance Test Plan (DS and Post Groom Underway)

• Preparation of Final Reports

• Analysis of Pre-Groom survey results.

• Validation that the system is operating within the manufacturer’s specifications.

• Verification that all system instrumentation, controls, sensors, data acquisition modules, and communication channels are properly operating.

• Confirmation that the system is fully interoperable with other systems with which it interfaces.

• Repair, renewal, adjustment, calibration, and testing of improperly functioning system components.

• Performance of component and system planned maintenance tasks that have been approved by the Coast Guard and or the component manufacture.

• Participation in dockside performance testing, evaluation, and validation utilizing a load bank

(if required).

• Participation in underway performance testing, evaluation, and validation.

• Battery chargers, clean and inspect

• Automatic bus transfer switches, clean, inspect and test ABTs

• Shore power cables, clean, test, and inspect

• Distribution panels, clean and inspect

10 (Rev-0)

• Switchboards, clean and inspect

• Medium voltage switchboards:

o Vacuum circuit breakers. Perform the inspection and maintenance procedures of Section 6-3 in Cutler-Hammer Instruction Book 32-255-1F, Instructions for Installation, Operation and Maintenance of Type VCP-W Vacuum Circuit Breakers (part of Coast Guard Tech Pub 3852), on all installed vacuum circuit breakers.

o Bus. Install appropriate ground straps or the Government furnished Cutler-Hammer VCPW-ND manual ground and test device in place of the generator circuit breaker on the bus to be inspected. Inspect the bus work for evidence of overheating or deformation. Check the torque of all bus fasteners. Inspect insulators and bus supports for evidence of tracking. Remove any dust or debris from the switchboard interior. Check wiring at metering and control power taps for tightness and proper support. Renew any broken lugs. With both bus tie vacuum circuit breakers closed and all other vacuum circuit breakers open or removed, measure and record the main bus insulation resistance in accordance with Section 3.3 of SFLC Std Spec 3041.

o Protection relays. Test all General Electric generator management (489) and feeder protection (735) safety relays in accordance with the applicable instruction manual (Section 7 of GEK-106290 or Section 6 of GEK-106291A), both of which are part of Coast Guard Tech Pub 3852. Plug in a suitable secondary voltage and current injection tester, such as a Megger Protective Relay Test (MPRT) System, at the ABB FT-1 test switch associated with the relay under test. Use a resistance decade box to check the resistance temperature detector (RTD) inputs. Relay input, display, or protective functions that are not used need not be tested. Contractor shall send relays

(489) (735) to OEM for calibration every four years or as needed.

o Instrumentation and control. Inspect all potential, current, and control power transformers for damage and loose connections. Calibrate all medium voltage IPP system transducers.

o Terminations. Inspect the wiring to all terminal boards and control devices for tightness and proper support. Ensure that all anti-chafing protection is in place and effective. Renew any broken lugs.

• Low voltage switchboards and motor control centers:

o Low voltage power operated circuit breakers. Perform the following inspection and maintenance procedures on all installed power operated circuit breakers:

o Rack out the circuit breaker to the test position. Connect temporary control power to electrically operate a generator circuit breaker while its prime mover is shut down.

Cycle the main circuit breaker several times, at least once in each local and remote operating mode, to make certain that it operates freely. Check the latch mechanisms and their engagements, both open and closed. Verify that electrical and mechanical position and status indicators are operating properly. Observe that all auxiliary contacts are functioning correctly by use of a meter or direct observation of the interfacing circuit’s response.

o Remove control power by disconnecting the temporary source or pulling the secondary control power fuses, as applicable. Attempt to close the circuit breaker manually. For a generator circuit breaker, observe that the undervoltage release actuates an immediate trip. Manually open the circuit breaker. Verify that the closing spring is discharged.

o Continue withdrawal of the circuit breaker to the disconnect position. Inspect the

11 (Rev-0) primary and secondary disconnects for signs of wear and erosion. Clean all dust and dirt from the circuit breaker, its cassette, and associated switchboard compartment.

o Remove and inspect the arc chutes for any cracking, breakage, or extensive burning that would indicate a need for replacement.

o For a circuit breaker equipped with an under voltage release, perform the following:

Insert a narrow sheet of paper between the moving and stationary main contact on each pole.

Manually recompress the closing spring and attempt to close the breaker manually.

Verify that the under voltage release prevented the main contacts from making as evidenced by no marking of the paper strips. Remove the paper strips.

o Check the condition of the main contacts, both moving and stationary, and ensure proper contact penetration and pressure. Measure and record the resistance of each closed main contact with a digital low resistance ohmmeter (DLRO). Reinstall the arc chutes.

o Lubricate, as necessary, per the manufacturer’s instructions.

o Reinsert the circuit breaker to the TEST position. Reconnect control power from the temporary source or reinstall the removed secondary control power fuses, as applicable o Using a calibrated electronic test unit, check the electronic trip device for proper operation in response to simulate long-time delay overcurrent, short-time delay overcurrent, and instantaneous overcurrent.

o If installed, disconnect temporary control power.

o Test long-time delay overcurrent, short-time delay overcurrent, instantaneous overcurrent, and ground-fault trips using primary current injection to verify that all current sensors are operating properly.

o Reinsert the circuit breaker to the CONNECTED position.

• Molded case circuit breakers. Perform Section 4.3 of ANSI/NEMA AB 4 on each switchboard and motor control center molded case circuit breaker connected to an active circuit:

o Clean all dust and dirt from the base plate or bucket in the associated enclosure.

o Perform Sections 5 through 7 of ANSI/NEMA AB 4 on each designated molded case circuit breaker.

• Bus. Inspect the bus work in each switchboard and motor control center for evidence of overheating or deformation. Remove any dust or debris from the enclosure interior. Check wiring at metering and control power taps for tightness and proper support. Renew any broken lugs. With all low voltage switchboard circuit breakers open or removed, measure and record the

12 (Rev-0) main bus insulation resistance on the sensitive (S1), non-sensitive (S3 & S4), and auxiliary buses and the S1-SA and S3-SA bus tie cables in accordance with Section 3.3 of SFLC Std Spec 3041.

• Protection relays. Using appropriate test equipment, verify proper operation of the following protection relays, measuring and recording trip values and time delay settings for units with such adjustments:

o Single phase undervoltage (ANSI device 27) o Three phase reverse power (ANSI device 32) o Single phase underfrequency (ANSI device 81U) o Synchronization check and dead bus closing (ANSI device 25) o Auto synchronization and dead bus closing (ANSI device 25A) o Three phase sequence (ANSI device 47)

• Instrumentation and control. Inspect all potential, current, and control power transformers for damage and loose connections. Calibrate all low voltage IPP system transducers.

• Terminations. Inspect the wiring to all terminal boards and control devices for tightness and proper support. Ensure that all anti-chafing protection is in place and effective. Renew any broken lugs.

• Ground fault detection. Perform the following to verify the proper operation of each ground detector.

o Bus. At a convenient panelboard, motor control center, or switchboard, temporarily connect a 10 to 25 kΩ power resistor (rated for no less than 8 watts and 500 volts) between any phase and ground at a load side terminal of a spare 450 volt circuit breaker.

Close the circuit breaker and verify that each ground detector monitoring the intentionally grounded bus indicates a fault. Open the spare circuit breaker and disconnect the resistor.

o Meg-Alert. Record initial insulation resistance. Secure power to the Meg-Alert GP-500- G module and temporarily connect a 10 to 25 kΩ power resistor (rated for no less than 8 watts and 500 volts) between any phase and ground at the monitored deenergized load (transformer or generator low voltage winding). Reenergize the Meg-Alert GP-500-G module and verify that it indicates a fault and that the remote meter displays the resistance of the test resistor. Reverse the process and disconnect the test resistor.

Reenergize the Meg-Alert GP-500-G module. Verify that the ground fault alarm clears and insulation resistance is as it was before the test.

o Motor controllers. For motor controllers equipped with an integral ground fault monitor, temporarily connect a 10 to 25 kΩ power resistor (rated for no less than 8 watts and 500 volts) between any phase and ground at the load side terminals of the deenergized main contactor. Verify that the ground detector indicates a fault. Disconnect the test resistor and verify that the fault indication clears.

13 (Rev-0)

• Shore power receptacle cover interlock. Isolate the non-sensitive bus from all power sources and loads. Alternatively, each shore power circuit breaker to be tested may be racked out to the TEST position to ensure that no appreciable current flows through the shore power distribution system during this test. In accordance with standard operating procedures, connect shore power cables to each receptacle to be tested. Energize each cable from shore and close each shore power circuit breaker afloat. Verify that each closed shore power circuit breaker afloat trips open when the associated MIL-C-24368 plug is momentarily unlatched. So as not to expose personnel to energized plug pins, do not separate the plug from its receptacle during this test.

• Bow thruster:

o Visual inspection. Perform the visual inspections of paragraph 3.3.2.1 of SFLC Std Spec 3020. Visually inspect the motor stator leads, as well as protective sleeving and insulation, for cracking and other evidence of physical damage. Check internal wiring and the mating ship’s cable conductors for appropriate spacing, proper support, and signs of overheating. Verify the tightness of each termination and renew any broken lugs.

o Hand cleaning. Using suction and compressed air, clean the accessible ventilation openings, interior surfaces, and windings of the motor in accordance with paragraphs

3.2.4 and 3.2.5 of SFLC Std Spec 3100.

o Space heaters. Verify that all motor, drive, and transformer space heaters and thermostats operate properly and that none are grounded.

o Medium voltage transformer. Perform Section 8.1 of IEEE Std C57.94 on the bow thruster variable speed motor drive medium voltage transformer.

o Variable speed motor drive. Verify that all enclosure cooling fans are operational.

Check all termination points for tightness. Use lint free rags, followed by suction and low pressure (not to exceed 30 psig) compressed air, to clean the ventilation openings and interior surfaces of the drive and resistor brake enclosures.

• Ship service motor generator (SSMG) sets:

o Perform the following offline tests and analyze for the conditions noted in parentheses:

Winding resistance (loose and high resistance connections)

Insulation resistance (ground faults) o Visual inspection. Perform the visual inspections of paragraph 3.3.2.1 of SFLC Std Spec 3020 (motor) and paragraph 3.2.3.1 of SFLC Std Spec 3100 (generator). Visually inspect the motor and generator stator leads, as well as protective sleeving and insulation, for cracking and other evidence of physical damage. Check internal wiring and the mating ship’s cable conductors for appropriate spacing, proper support, and signs of overheating.

Verify the tightness of each termination and renew any broken lugs.

o Hand cleaning. Using suction and compressed air, clean the accessible ventilation openings interior surfaces, and windings of the machine in accordance with paragraphs

3.2.4 and 3.2.5 of SFLC Std Spec 3100.

14 (Rev-0) o Resistance tests. Measure and record SSMG insulation resistances and calculate the polarization index in accordance with Section 3.3.3 of SFLC Std Spec 3020 (motor) and paragraphs 3.2.3.3 through 3.2.3.4 of SFLC Std Spec 3100 (generator). Also observe the procedures in Coast Guard Tech Pub 3867 and do not subject the rotating rectifier diodes to high test voltage. The circuits to be measured include the motor stator, generator rotor (field), generator stator, exciter stator (field), and exciter armature (rotor) o Space heaters. Verify that all motor, drive, and transformer space heaters and thermostats operate properly and that none are grounded.

o Medium voltage transformer. Perform Section 8.1 of IEEE Std C57.94 on each SSMG variable speed motor drive medium voltage transformer.

o Variable speed motor drives. Verify that all enclosure cooling fans are operational.

Check all termination points for tightness. Use lint free rags, followed by suction and low pressure (not to exceed 30 psig) compressed air, to clean the ventilation openings and interior surfaces of the drive and resistor brake enclosures.

• Ship service transformers. Perform Section 8.1 of IEEE Std C57.94 on each ship service transformer (SSTF).

• Grounding resistors. Perform the following for each grounding resistor while the associated main generator is shut down and locked out:

o Remove access covers to facilitate internal inspection.

o Open the disconnect switch to isolate the unit from its generator. Temporarily disconnect the grounding lead.

o Visually inspect all internal components, carefully checking for cracked insulators or bushings.

o Using an applied test potential of 2000 to 2500 volts, measure and record the insulation resistance of the grounding resistor. Insulation resistance should exceed 10 MΩ.

o Measure the grounding resistance using an ohmmeter. Resistance should be 720 to 880 Ω.

o Check all internal connections for tightness. Inspect wiring for signs of damage from heat or overload.

o Vacuum any dirt or debris from the inside of the enclosure.

o Check the mounting bolts for tightness.

o Reconnect the grounding lead and close the disconnect switch to ground the associated generator.

o Reinstall access covers.

15 (Rev-0)

• Shore power groom. When directed by the Contracting Officer via task order, perform a groom of the shore power system ashore. Such scope of such tasking may include one or more of the following elements:

o Shore power isolation transformers. Perform Section 8.1 of IEEE Std C57.94 on each shore power isolation transformer.

o Shore power switchboard:

Cycle the main circuit breaker several times in all operating modes to make certain that it operates freely. Verify that electrical and mechanical position and status indicators are operating properly.

Clean all dust and dirt from the circuit breaker and associated switchboard compartment.

Remove and inspect the arc chutes for any cracking, breakage, or extensive burning that would indicate a need for replacement.

Check the condition of the main contacts, both moving and stationary, and ensure proper contact penetration and pressure. Measure and record the resistance of each closed main contact with a digital low resistance ohmmeter (DLRO).

Check the latch mechanisms and their engagements, both open and closed.

Lubricate, as necessary, per the manufacturer’s instructions.

Using a calibrated electronic test unit, check the electronic trip device for proper operation in response to simulate long-time delay overcurrent, short-time delay overcurrent, instantaneous overcurrent, and ground-fault conditions.

Test long-time delay overcurrent, short-time delay overcurrent, instantaneous overcurrent, and ground-fault trips using primary current injection to verify that all current sensors are operating properly.

o Molded case circuit breakers. Perform Section 4.3 of ANSI/NEMA AB 4 on each molded case circuit breaker:

Clean all dust and dirt from the associated enclosure.

o Inspection. Clean and inspect the shore power switchboard interior. Check all connections for tightness. Inspect the switchboard interior and exterior for corrosion.

Preserve any corroding steel surfaces. Minor touch-up is within the scope of this work item. Submit a CFR when significant effort would be required to prepare and preserve extensively rusted surfaces.

o Shore tie stations. Perform the following on each shore tie station:

Molded case circuit breakers. Perform Section 4.3 of ANSI/NEMA AB 4 on each molded case circuit breaker. Clean all dust and dirt from the power mound

16 (Rev-0) interior. As directed by CFR response or as pre-arranged via task order, perform Sections 5 through 7 of ANSI/NEMA AB 4 on each designated molded case circuit breaker.

Indicators. Verify that all position electrical and mechanical circuit breaker position indicators are operating properly. Renew any burned out lamps.

Ground fault detection. Verify that the ground fault monitor alarms when a 10 to 25 kΩ power resistor (rated for no less than 8 watts and 500 volts) is temporarily connected between any phase and ground inside the ground fault monitor enclosure. Verify that the TEST button on the 120 VAC GFCI receptacle trips the device and that power is restored when the RESET button is depressed.

MIL-C-24368 receptacle cover interlock. Verify that each closed power mound circuit breaker trips open when the associated receptacle cover is unlatched.

Emergency stop. Verify that the main circuit breaker on the shore power switchboard trips when the emergency stop switch is depressed.

Three-phase receptacle. Cycle the switch or circuit breaker on the 30 or 200 ampere receptacle to check operability and wipe the contacts of accumulated oxide film. Ensure that the receptacle is deenergized and the cover is installed at the conclusion of this test unless it is actively being used for another purpose.

3.3.2 Scheduling. Scheduling shall be as shown in Table 1 below.

3.3.2.1 Advance notification. The Coast Guard will provide at least 90 days advance notification prior to scheduling a shipboard equipment groom, a shore power groom, and/or shipboard inspection and maintenance visit. The vessel will be available for the annual groom during a 4 week period. Work performed during each equipment groom or maintenance visit shall be completed within the period identified in the Pre-Groom survey.

3.3.2.2 Task order. The Contracting Officer will order the groom or maintenance visit, in writing, at least 30 days in advance. The Contractor shall acknowledge, in writing, the groom order within 10 business days of receipt of the order.

3.3.2.3 Afloat/Ashore visits. Each groom shall normally be performed underway in the vicinity of the homeport, at the ship’s homeport pier, or at a location designated by the Contracting Officer. If the groom must be performed elsewhere, the Coast Guard will reimburse the Contractor for the travel cost differential from the ship’s homeport or from the nearest Contractor service port (whichever is less).

Coordination and detailed work scheduling with interfacing system groom contractors will be finalized in accordance with section 3.3.6 below.

17 (Rev-0)

TABLE 1 - SCHEDULE

DAYS

BEFORE GROOM ACTION

135 Days KO/COR notifies EO of when the groom process starts. Contractor provides Pre-Groom Survey Performance Test Plan to the COR. Cutter has 60 days to submit results of the Pre- Groom Survey to the KO/COR, who will forward to the Contractor.

90 Days CG provides initial notification of pending system groom date to the Contractor.

75 Days Cutter submits results of the Pre-Groom Survey to the KO/COR, who will forward to the

Contractor if activated.

60 Days Contractor provides Groom Performance Test (Dockside and Underway) Plan based on the

Pre-Groom Survey 30 Days KO orders Groom/Maintenance Visit 20 Days Contractor will acknowledge order within 10 days of receipt (NLT 20 days to Groom)

3.3.3 Shipboard pre-groom survey performance test plan.

3.3.3.1 Preparation. Submit the first shipboard Pre-Groom survey performance test plan to the Contracting Officer for review no later than 60 days after contract award.