2016-04-18_-_Procurement_Spec_REV_-FINAL.docx

REVISION NO. - .

PROCUREMENT SPECIFICATION

THRUSTER CIRCUIT BREAKER REPLACEMENT

225’ WLB MMA

Table of Contents

Table of Figures

Figure 1, Zones of Protection 7

Table of Tables

SCOPE

The U. S. Coast Guard requires the replacement of three SIEMENS SB family circuit breaker assemblies installed aboard the 225’ WLB cutters. The circuit breakers provide protection of the auxiliary propulsion thruster electrical power distribution system. The system consists of a MDE driven generator, thruster switchboard, phase-shift transformer, cabling and two thruster DC motors with drives. See reference drawings and technical publications below for system details.

The Contractor shall:

Conduct and submit a Protective Device Coordination analyses for the new circuit breaker assemblies.

Provide a circuit breaker replacement kit which includes the 3 new insulated case or low voltage power circuit breaker assemblies, bus work, switchboard doors and any ancillary material and equipment required to retrofit the circuit breakers into the existing switchboard.

Provide installation and commissioning services on at least two cutters; One “A” class and one “B” class cutter. Following the installation and commissioning of the first two cutters, the kit identified in 1.2.2 above, and the technical data identified in 1.2.4 below shall be complete enough to allow for the U.S. Coast Guard to either self-perform the effort on the remaining vessels, or contract the installation effort to any suitable contractor.

Provide technical data to include, but not limited to installation drawings, technical manuals, and parts lists.

Provide technical support services for operational testing, training, troubleshooting, installation and repair as needed.

Provide spare parts.

APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein. The documents listed are by title and effective date, unless otherwise documented.

Military specifications MIL-DTL-24643, Rev C, Cables, Electrical, Low Smoke Halogen-Free, For Shipboard Use, General specification, 2011.

MIL-STD-1399C Section 300B, Rev B, Interface Standard for Shipboard Systems, Electric Power, Alternating Current, 2008.

DI-MISC-80508B, Technical Report-Study/Services Report, 2006.

DI-MGMT-81648, Condition Found Report, 2004, MIL-DTL-15024F, Rev F, Plates, Tags and Bands for Identification of Equipment, General Specifications for, 1997.

Other Government Documents Code of Federal Regulations (CFR) Title 46 (Shipping), Subchapter J – Electrical Engineering, 2013.

USCG Specifications and Standards SFLC-D-084-0481, Rev B, Equipment Unit Preservation, Packing and Marking.

COMDTINST 9085.1C, Naval Engineering Computer Aided Design Standards, 2011.

SFLC standard 0860, General Requirements for Technical Publication Preparation, 2014.

Commercial Documents Institute of Electrical and Electronic Engineers (IEEE) IEEE Std 45, Recommended Practice and Electrical Installation on Shipboard, 2002.

IEEE Std. C37.010, Application Guide for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis, 2005.

ANSI/IEEE C37.13, Standard for Low-Voltage AC Power Circuit Breakers Used in Enclosures, 2008.

National Electrical Manufacturers Association (NEMA) NEMA Standard 250, Enclosures for Electrical Equipment (1000 Volts Maximum), 2008.

NEMA Standard ICS 2 (R2005), Industrial Control and Systems Controllers, Contactors and Overload Relays Rated 600 Volts, 2005.

Underwriters Laboratory (UL) UL-891, Standard for Safety - Switchboards, 2005.

UL-489 Supplement SB, Section SB2. UL listed Naval circuit breakers intended for use aboard non-combatant and auxiliary naval ships over 19.8 meters in length, 2013.

USCG Technical Publications and Drawings See table below to determine what technical documents apply to each vessel.

Table 1 USCG Technical Documentation Applicability by Vessel

CGC JUNIPER

CGC WILLOW

TECHNICAL PUBLICATIONS

3556-568-B, Thruster Motor Model IB2193AA, 1999 3556-568-D, Thruster Generator Model 243226LA, 2003 3556-568-F, DC Motor Drive Unit Model DSD412, 2001 3556-568-G, Thruster Generator Model LS2000, 2002 3534A-324-A, Switchboards, SS, EDG and Thruster, Model D213041-M1, 2000 3534B-324-B, Switchboards, SS, EDG and Thruster, Model D213041-M1, Appendix, 1997

DRAWINGS

225-WLB-437-009, Rev. A, Thruster Control System - Control System Block & Elementary Wiring Diagram Mods 225-WLB-320-001, REV AE, Electrical One-Line Wiring Diagram(Sheet 3A) 225-WLB-202-002, Rev G, MPCMS COED

CGC KUKUI

CGC ELM

CGC WALNUT

TECHNICAL PUBLICATIONS

3556-568-C, Thruster Motor Model IB2333AA, 2001

3556-568-F, DC Motor Drive Unit Model DSD412, 2001 3556-568-G, Thruster Generator Model LS2000, 2002 3534A-324-A, Switchboards, SS, EDG and Thruster, Model D213041-M1, 2000 3534B-324-B, Switchboards, SS, EDG and Thruster, Model D213041-M1, Appendix, 1997

DRAWINGS

225-WLB-437-009, Rev. A, Thruster Control System - Control System Block & Elementary Wiring Diagram Mods 225-WLB-320-001, REV AE, Electrical One-Line Wiring Diagram(Sheet 3A) 225-WLB-202-002, Rev G, MPCMS COED

CGC SPAR

CGC MAPLE

CGC ASPEN

CGC SYCAMORE

CGC CYPRESS

CGC OAK

CGC HICKORY

CGC FIR

CGC HOLLYHOCK

CGC SEQUOIA

CGC ALDER

TECHNICAL PUBLICATIONS

3556-568-C, Thruster Motor Model IB2333AA, 2001

3556-568-F, DC Motor Drive Unit Model DSD412, 2001 3556-568-G, Thruster Generator Model LS2000, 2002 3536A-324-A, Switchboard – Main, Emergency, and Thruster, 2002 3536A-324-B, Switchboard – Main, Emergency, and Thruster – Appendix “A”, 2002 3536B-324-A, Switchboard – Main, Emergency, and Thruster – Appendixes “B” THRU “W”, 2002

DRAWINGS

225-WLB-437-009, Rev. A, Thruster Control System - Control System Block & Elementary Wiring Diagram Mods 225B-WLB-320-001, REV AA, Electrical One-Line Wiring Diagram (Sheet 10) 225B-WLB-202-002, Rev D, MPCMS COED

Order of Precedence USCG SFLC – 225WLB Thruster Circuit Breaker Replacement Specification

REVISION: -

In the event of a conflict between the text of this specification and the references cited herein, this specification takes precedence. The Contractor must notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these specifications prior to proceeding with any work

REQUIREMENTS

Protection Device Coordination (PDC). (CLIN 01) The Contractor shall conduct a PDC analysis for three zones, Figure 1, on a single time current plot to determine the circuit breaker settings, parameters, coordination and identify any issues. Curves shall be plotted on typical log by log format with time on the “x” axis and current on the “y” axis.

Figure 1, Zones of Protection The circuit breaker PDC time / current curves shall include the one-line and the adjustment settings for the generator, stern and bow motors.

Zone 1: Generator circuit breaker PDC shall include ANSI 50 and 51 withstand, decrement and damage curves for the generator, power cables, generator, bow and stern circuit breakers, AC/DC motor drives, phase shift transformer on stern drive.

Zone 2: The zone of protection for the bow circuit breaker PDC shall include ANSI 51 withstand, decrement and damage curves for the power cables, bow circuit breaker, AC/DC motor drive.

Zone 3: The zone of protection for the stern circuit breaker PDC shall include ANSI 51 and line withstand, decrement and damage curves for the power cables, stern circuit breaker, phase shifting transformer, AC/DC motor drive.

The Contractor shall provide a report detailing the PDC plan to include all breaker settings, setup requirements, verification requirements, calculations, and results within 30 days of receipt of the delivery order. The report shall be in accordance with DI-MISC-80508B.

The report shall include all configuration, set-up software, PDC settings for ANSI device numbers and withstand damage curves for line-to-line protection.

System, component data and characteristics can be found in the following reference technical manuals: 3534-324-A, 3534-324-B, 3536-324-A, 3536-324-B, 3536-324-A, 3536-324-B and 3556-568-A through 3556-568-G.

All raw and meta data used for PDC calculations shall be listed or identified in the report. This shall include any “default” settings or data in the PDC calculation software.

The Contractor shall provide the project files to include the electronic database file for the project for the PDC calculations.

The contractor shall provide a one person licensed installation copy of the PDC software used. The software will be used by USCG for validation of the PDC calculations and thruster power distribution system sustainment.

Circuit Breaker Installation Kits and Software. (CLIN 02) The Contractor shall supply new draw-out insulated-case or low voltage power circuit breakers to replace the existing insulated-case, draw-out circuit breakers identified in drawing 225-WLB-437-009, Rev. A. Replacement circuit breakers shall meet or exceed the identified performance requirements and physical dimensions shall be smaller than identified in Table 2 below. The replacement circuit breakers shall also include the functions and auxiliary equipment listed below.

Table 2 Breaker Performance Requirements and Compliance.

3 phase, 60Hz

1200AF/900AT, 480VAC,

3 phase, 60Hz

800AF/750AT, 480VAC,

3 phase, 60Hz

W: 20.000" D: 21.820" H: 20.000" W: 20.875" D: 21.820" H: 14.000" W: 20.875" D: 21.820"

Remote Open (contacts rated for at least)

Shunt Trip (contacts rated for at least)

Status Indicator Contacts (contacts rated for at least)

Normally Open Contacts (contacts rated for at least)

Normally Closed Contacts (contacts rated for at least)

Insulated case or low voltage power circuit Breaker

These circuit breaker assemblies including the carriage or mounting frame shall be standard manufactured components. The use of custom built or special carriage or mounting frames shall not be used.

The circuit breakers shall be draw-out insulated-case or low voltage power circuit breaker type.

The circuit breaker assemblies with carriage or truck shall physically fit the existing switchboard cubicle without modification of the switchboard cubicle structure.

The circuit breakers shall be calibrated for an ambient environment of 40° C.

The circuit breaker installation assembly kit shall include the frame, trip unit, carriage assembly, bus, fasteners, software, configuration files and other ancillary materials needed for installation.

The thruster circuit breakers and associated draw-out carriages shall fit into the existing switchboard cabinet without modification of the switchboard or circuit breaker except as directed in section 3.4.

The trip unit shall include adjustable continuous, long time, short time and instantaneous curve adjustments.

The thruster circuit breakers shall interface with the existing MPCMS interface and configuration, (Drawing 225-WLB-437-009, REV A) without the use of external hardware.

Fabricated bus work shall be ANSI B700 silver-plated copper. Silver-plating shall not be less than 0.0002 inches thick.

All joints shall be installed using nuts, bolts, and Belleville-type washers or similar locking means.

Software. (CLIN 02) The Contractor shall provide all software/licenses needed to accomplish diagnostic testing, troubleshooting and configuring of the circuit breaker and trip units. A list of all those software/licenses shall be provided.

Software used to operate the Protection Device Coordination of the replacement Thruster Circuit Breakers, trip units etc as a minimum, shall include the following:

COTS technical documentation on all common programmable devices.

Licensed copy of the thruster circuit breaker configuration software for programming the trip units.

Configuration files containing parameters, setpoints and modes for each circuit breaker and trip unit.

Software Passwords Circuit Breaker Kit Installation. (CLIN 03) The Contractor shall perform installations in accordance with this specification and applicable sections of 46 CFR, subpart 111 and IEEE Std 45, at the Coast Guard Shipyard in Baltimore, MD unless otherwise specified in the delivery order. The government will provide the installation schedule and location no later than 30 days before the required start date. The Contractor shall:

Verify exact conditions and dimensions aboard the vessel. There are minor differences between “A” and “B” class switchboards.

Remove existing (3) thruster circuit breakers, substructure, doors and associated equipment, and interferences. The vendor is responsible for disposal of removed equipment.

Modify existing line side and load side bus to attach to each breaker.

Modify secondary control wiring from each breaker to maintain the same functionality that presently exists.

Install the three (3) new thruster circuit breakers, substructure, doors and associated equipment necessary to satisfy this specification.

Install all configuration, set-up software, PDC settings for Generator, Bow and Stern Thruster Circuit Breakers.

Perform all commissioning and operational test and evaluations.

Label plates shall be permanently affixed to each of the components provided. Label plates and cable tags shall be in accordance with MIL-DTL-15024F or other commercial equivalent standard identified by the vendor and approved by the USCG. Label plates shall be corrosion resistant.

If new power distribution or control system cabling is being installed, it shall be low smoke zero halogen MIL-DTL-24643 type cable.

The Contractor shall perform the approved Installation Test Plan to validate the installation.

The Contractor shall perform the approved Shipboard Commissioning Test Plan to validate proper functionality and interface with the main propulsion control system.

Technical Data (TD). (CLIN 04) Electrical Drawings and Diagrams.

The Contractor shall update Coast Guard drawing 225-WLB-437-009, REV A in AutoCAD to reflect the thruster circuit breaker replacement modifications. Drawings will be provided in AutoCAD version 2009. Update shall include power and control wiring changes due to new replacement circuit breaker assemblies. Bus bar and connection details shall be provided in drawing.

Modifications to USCG drawings shall follow the guidelines of COMDTINST 9085.1C.

Technical Publications.

The Contractor shall redline “A” class technical publications 3534-324-A, 3534-324-B and “B” class technical publications 3535-324-A, 3535-324-B to reflect only the thruster circuit breaker replacement changes. Redlines to technical publications shall follow the general requirements of SFLC standard 0860.

Technical publication redlines shall include circuit breaker control terminal identification, new bus bar connection details, part number changes and other pertinent details.

The Contractor shall provide technical information that completely describes the end item, end item’s equipment and/or piece parts; material, mechanical, electrical, dimensional characteristics, location, and their function within the assembly. The technical publications shall include theory of operation, equipment and component set points and related information, disassembly procedures, recommended maintenance, lay-up procedures, component repair, a list special tools and diagnostic/test equipment, trouble shooting guide, parts schematic/line diagrams, and complete drawings and diagrams. Catalog cut sheets, manuals or other vendor documentation shall be inclusive of only equipment that is part of the final configuration or identified by arrows or highlighted.

The Contractor shall have the capability to modify Abode .pdf files.

Contractor shall remove old circuit breaker data from the existing thruster switchboard technical manuals and insert new circuit breaker data and pages.

Illustrated Parts Breakdown (IPB).

The Contractor shall provide an IPB that identifies parts associated with the equipment. An exploded IPB must show the location of the parts. The parts list must identify the piece part of the illustration, quantity installed, nomenclature, designation, original equipment manufacturer (OEM) part number. Part numbers are not required for common hardware available from multiple sources, if adequate descriptive data is provided.

Data for Provisioning (DFP) The Contractor shall provide DFP which includes a hierarchical listing that identifies all the piece parts which can be assembled, re-assembled, and/or replaced.

DFP includes name plate data, component characteristics data, end item/component estimated retail prices, manufacturer’s identification (or Commercial and Government Entity Code (CAGE)), Original Equipment Manufacturer (OEM) part number, shelf life, and special material/operating requirements, special tools, and National Stock Numbers for equipment already identified in the Federal Stock System (if available).

Installation Test Plan The Contractor shall perform and deliver an installation test plan to validate proper installation of the new equipment and proper propulsion control interface.

The installation test plan shall identify the equipment being tested, the purpose of the test, the equipment and special tools needed to conduct the test.

The installation test plan shall provide a means for the test conductor to record test measurements and results.

The plan shall also include provisions for test equipment calibration data to be entered.

The Installation Test Plan is to be reviewed and approved by USCG prior to final submittal.

Shipboard Commissioning Test Plan

0. In conjunction with the Installation Test Plan; The Contractor shall provide a Shipboard Commissioning Test Plan to document the procedure for commissioning the newly installed equipment and demonstrate proper interface functionality with the propulsion control system.

The plan shall fully address all features and capabilities of the equipment and must fully demonstrate the proper installation, startup, and operation (including an operational underway trial) of the equipment.

The plan shall monitor and document the required system operation functions.

The Shipboard Commissioning Test Plan is to be reviewed and approved by USCG prior to final submittal.

Step by Step Installation Instructions

0. The Contractor shall provide step by step installation instructions and documentation for use by Coast Guard technicians to retrofit circuit breaker kits aboard other 225’ WLB cutters.

The instructions shall identify equipment, special tools and sequential steps required to install the replacement circuit breaker kits.

This documentation shall be separate from the drawing updates and technical publication redlines.

The Step by Step Installation Instructions is to be reviewed and approved by USCG prior to final submittal.

Weight Report

0. The Contractor shall prepare and deliver a Weight Report.

The weight report shall list the weights and approximate locations of equipment added. Equipment being replaced shall list the positive or negative differences in weight between the two pieces of equipment.

The Contractor shall provide updates to TD and DFP for the 1st option year and every year thereafter for the next four years to account for any changes in the end item components or subcomponents.

Data Submission Format Table DFP Format )Drawings must be submitted as electronic media, AutoCAD version 2009 or later. Where electronic media is submitted, it must be with the manufacturer’s permission to use the data on Coast Guard drawings. Text files must be provided in MICROSOFT WORD. Spreadsheets must be provided in MICROSOFT EXCEL. Documentation supplied as electronic media must be one (1) copy.

DFP shall be submitted in a tabular spreadsheet in the format provided in Table 3 DFP Format.

Technical Support Field Services – Installation/Testing Assistance/Training (CLIN 05) If required by the delivery order, the Contractor must provide the services of a field service engineer/technician to assist during set-up, testing, commissioning, light-off, and adjustment for optimum performance of the equipment and system.

The Contractor shall provide onboard training of the ship’s personnel for the thruster switchboard circuit breakers. Training shall include:

Review of maintenance documentation Review of start-up and operational procedures Settings and adjustments Troubleshooting and fault isolation The Contractor must prepare and sign a statement regarding the completion or waiver of commissioning services. The COR must obtain a release signature before departure of the Contractor or his representative from the field service site. The Contractor must forward a copy of the signed release document to the Contracting Officer (KO), with a Commissioning Technical Report.

The government will schedule routine technical support services at least fourteen (14) days in advance.

Recommended Spare Parts Onboard Repair Parts (OBRP). (CLIN 06) The Contractor shall provide an OBRP associated with the equipment. The Contractor shall provide OEM suggested OBRP list with initial proposal. The parts list shall identify the piece part number of the illustration, quantity installed, nomenclature, designation, original manufacturer and part number as identified in the DFP. OBRP consists of parts required to complete OEM recommended maintenance for one year.

System Stock Parts. (CLIN 07) The Contractor shall provide OEM System Stock parts. System Stock consists of repair parts or other spare components that the Coast Guard may require to ensure system availability in the fleet. The parts list shall identify the piece part number of the illustration, quantity installed, nomenclature, designation, original manufacturer and part number as identified in the DFP.

Deviation from specification Deviation from the specifications will only be allowed if there is a direct benefit to the Government and the change has been authorized in writing, by the Contracting Officer.

After contract award, the Contractor shall request permission to change or depart from the specification from the Contracting Officer (KO) within five (5) working days of any changes effecting equipment or part configurations. If the proposed change involves the substitution of another material or method for one specifically required, the complete specification(s) covering the requested method or material must be submitted.

Requests by Contractors for changes, either with their proposal submission as exceptions to the specification or after contract award, must clearly describe the proposed changes and the reason for and the advantages of the proposed changes.

Warranty and Technical Support Material shall be free from defects in materials and workmanship for no less than two (2) years from the date of delivery. The Contractor shall contact the government to arrange a resolution of a warranty claim within twenty-four (24) hours after receiving notification.

Quality Assurance.

General.

Inspections/tests as defined are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item. The Contractor shall provide a certificate of compliance for all required inspection, test or calibration / tolerance with each circuit breaker assembly.

Factory Testing. (CLIN 04) Each circuit breaker shall be factory tested and inspected in accordance with the Contractors normal quality assurance processes. Test results shall be provided with the circuit breaker.

Notifications and Inspections The Contractor shall notify the COR in writing at least fourteen (14) calendar days prior to the performance of any inspections or testing.

Tests, Inspections, and Reports Shipboard test results shall be supplied to the Coast Guard within fourteen (14) days of completion (CLIN 05).

If the specified item fails to pass any inspection/test the Contractor shall provide a Corrective Action Report (CAR) to document the failure and the recommended fix to the Contracting Officer. The CAR shall include the topics covered in DI-MGMT-81648.

Preservation, Packing, and Marking The equipment unit and parts must be preserved, packaged and marked for shipping in accordance with sections 3.3 and 3.4 of SFLC-D-084-0481.

The equipment unit and parts must be packaged suitable for shipment, temporary storage uncovered in the weather, and then reshipment by the Government (within CONUS) to the installing activity.

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