SSDG_Phase2_SOW.pdf

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Statement of Work for the Design of Main Switchboard & Associated Controls of Existing Ship

Service Diesel Generators Onboard 87 Foot Coastal Patrol Boats

1.1 Background. A new ship service diesel generator (SSDG) set has been prototyped onboard USCGC Gannet (87334), homeport Dania Beach FL. The installation consists of two (2) John Deer/Stamford - Diesel Generators, PEECO Model No. DSSJDM-60-60MX, Diesel Generator P- 311-0637 (Qty 2 ea.) and controlled by 2 Woodward eazYgen-3000 series generator controls.

The prototype installation is not the optimal design configuration because it did not include a new Main Switchboard (1 ea.). In addition the reliability of installed eazYgen-3000 series controls have ongoing technical deficiency such as any particular generator dropping off line unintentionally. Installation Drawings for this prototype (minus Main Switchboard and Controls/Alarms) are currently being developed and they include, Main Engine and Generator Foundations, Machinery Arrangement, Sea Water Cooling Piping, Engine Exhaust Piping, and Fuel Oil Service Piping.

NOTE

SSDG’s and Associated Controls have already been selected for the prototype installation, however it shall be noted that the Controls for the Main Switch Board can be (Woodward eazYgen) or equal. Main Switchboard with controls and 24 VDC system as described below will require market survey of existing commercial marine grade equipment as described in ABS, Part 4, Chapter 6. A site visit of this installation is encouraged and should be used as a base line for the final design since the preselected generators are in place.

1.2 Scope. The Contractor shall perform the following tasks:

• Task I – With the pre-selected SSDG equipment, provide all the necessary design/installation drawings, technical information and guidance to replace the existing main switchboard and controls for the SSDG system on 87’ patrol boat fleet. The new design shall include the replacement of the SSDG Main Switchboard, replacement of system controls, and a new 24 Volt DC system based on the requirements stated below in section 3.1.2. The deliverables shall include, but are not limited to the installation and rip-out drawings, schematic diagrams, and technical manuals for the Main Switchboard (1 ea,) system controls (2. ea.) and 24 Volt DC system.

• Task II – First Article Testing/Build a Mock-up of the SSDG system at Contractor’s Facility for demonstrating system operation. The Government-furnished SSDG’s shall remain the property of the Coast Guard. The Main Switchboard and associated controls shall become the property of the Coast Guard.

• Task III – Serve as the SSDG System Integrator, using Contractor developed drawings, technical publications, and drawings provided by the Coast Guard. The Contractor shall be the On-site Technical Representative for the Installation of the new SSDG System.

Installation of the new prototype SSDG system may be under a separate contract or under a Government task order such as a Coast Guard Industrial Division installation. Provide training and Equipment Operating Procedures the crew of cutter receiving the prototype installation.

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1.2.1 Written proposal. Provide a written proposal for approval by the Coast Guard to include all salient characteristics for the new Main Switchboard Panel and associated generator controls and a 24 Volt DC system which shall integrate with PEECO Model No. DSSJDM-60-60MX, Diesel Generator. Controls for the new design may be the eazYgen Control Panels or equivalent. The Main Switchboard and associated controls shall have the ability to operate in the Engine Room where typical operating temperatures reach between 135 – 145 degrees Fahrenheit. The new main switchboard at a minimum shall conform to ABS, NEMA, and IEEE 45.

1.3 Applicable Documents. Documents listed in Government Furnished Equipment and Information will be furnished.

2.1 Kick-off meeting. The Contractor shall participate in a background/kick-off meeting with the Patrol Boat Product Line (PBPL) personnel within 7 calendar days of award of Contract.

2.1.1 Additional information. During the meeting the PBPL will provide additional points of contacts and background information to facilitate a ship check.

2.1.2 Ship check. The Contractor may conduct ship checks to the prototype vessel (CGC Gannet), and other 87’ cutters to obtain all data and information necessary to develop Installation and Rip-out Drawings. Use all references listed below in section 4.1 Government-Furnished Equipment and Information, for the purposes of integrating the new Main Switchboard, SSDG’s eazYgen Panels (or another selected system controls), and 24 VDC System into the existing ship’s configuration. In addition to ship check of the prototype installation onboard CGC Gannet, it may be prudent to ship check 3 additional cutters (to be named at a later date) since 87 WPB Coastal Patrol Boat class has three (3) slightly different variations of main switchboards.

2.2 Performance period. The performance period for Tasks I & II shall Commence on 21 September, and be completed within 6 months. Task III which is optional shall be for the duration of a separate Installation Activity which may require approximately 8 weeks for installation of the new SSDG system. This separate installation activity may commence approximately 6 months after the completion of Tasks I & II.

2.2.1 Plan submission. Submit a copy of the plan to both the Contracting Officer and the Contracting Officer’s Representative at the kick-off meeting. The planning document shall have the following characteristics:

• Graphical in format see Sample Planning Document Below

• Show overall period of performance for each task, with start and stop dates.

• Identify the critical path for the overall project.

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FIG. 1 - SAMPLE PLANNING DOCUMENT SUBMITTAL

3.1 Design. The Contractor shall design a Main Switchboard and SSDG Controls in accordance to all references listed below in section 4.1 and shall include the following requirements

3.1.1 Main Switchboard. The main switchboard and associated controls shall integrate with the Port and Starboard Generators, Shore Power and Pilothouse Alarm Panel. The main switchboard shall have both manual and automatic controls and monitoring capabilities for both SSDG’s and Shore Power. The Main Switchboard shall have the following salient principal characteristics:

3.1.1.1 Main Switchboard Generator Controls. The main switchboard and associated controls shall have the following manual and automatic controls and audible and visual (analogue & digital) operating and alarm features for SSDG’s and shore power:

Controls:

• Two-way Soft Transfer from ship to shore and back.

• Parallel Operation of P/S SSDG’s

• Single Generator Operation for either Generator.

• Voltage Regulation (Manual/Auto).

• Manual capability to open/close SSDG/Shore power C/B’s

• Speed Control Manual/Auto).

• Fuel Cut-off (Shall not cause auto restart).

• Air Cut-off (Shall not cause auto re-start).

• Manual Controls shall be capable of overriding automatic controls.

• Start/Stop Logic for Diesel Engine

Operating Parameters/Alarm Indications (analogue/digital):

• Voltage

• Current

• Kilowatts

• Power factor

• Frequency

• Phase Rotation

• Auto Shut Down Indication showing the cause.

• Circuit Breaker Positions (Open/Closed).

• Synchroscope and associated lights.

• Ground Detection for 24 VDC System and 450/120 VAC System

• Insulation resistance monitoring for generator windings.

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Data log: Shall have the capability to log (30 days minimum) and display on screen (17-inch minimum) the following:

• All John Deer Engine Control Unit ECU Emergency Shut-offs, such as High J/W Temp Low L/O Pressure.

• Manual Emergency Shut-offs.

• Ability to download all data to a portable laptop.

3.1.1.2 Pilothouse Alarms. The main switchboard and associated controls shall integrate with the Pilothouse Alarm Panel and have the following audible and visual features:

NOTE

Current Pilothouse Alarm Display may not be able to accommodate additional alarm indications, therefore a dedicated alarm indicating panel/display for SSDG monitoring may have to be factored into the design proposal.

Alarms:

• Low Oil Pressure

• High Jacket Water Temperature

• Low Insulation/Insulation Breakdown for P/S SSDG’s

• Run Indication (ON/OFF) for P/S SSDG’s

• Circuit Breaker Indication On/Off/Tripped for P/S SSDG’s

• Emergency Stop Indication

3.1.2 24 Volt DC System. For the 24 Volt DC System, CDI a commercial Contractor was previously tasked to conduct a feasibility study for a new 24 VDC System Design. The study contained three (3) scenarios for a new 24 Volt DC System. Subsequently Coast Guard Engineering Services Division (ESD) provided its assessment and has proposed a 4th version which includes parts of the CDI report. Based on ESD’s recommendation (4th version), develop and design a new 24 VDC system using the following reports.

• See - CDI Engineering Solutions, USCGC 87 FT Coastal Patrol Boat 24 VDC Feasibility Study Technical Report

• Surface Forces Logistics Center, ESD Assessment Input for Technical Documentation Review: 87 Ft CPB 24 VDC Feasibility Study Technical Report

3.2 Technical documentation. The Contractor shall provide all technical documentation (Drawings, Technical Manuals) for the Main Switchboard and associated controls which shall be formatted in accordance with SFLC Tech Std 085. The technical documentation shall include the Original Equipment Manufacturer (OEM) Instruction Book/Manuals, OEM parts list containing all installed parts, part numbers keyed to the provided drawings, the quantities used in each piece of the equipment (SWBD & Controls), associated weights for each component and the OEM’s name and address.

3.2.1 Spare parts list. In addition to listing all parts used during installation, the Contractor shall provide a list of recommended spare parts for the proposed Main Switchboard based on an analysis from similar systems on navy and/or Coast Guard vessels. The list shall include an estimated lead time for each spare part listed.

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3.2.2 Physical dimensions requirements. The propose equipment, (Main Switchboard & associated Controls and 24 VDC System) shall fit the physical envelope as depicted on the referenced Coast Guard Drawings listed in section 4.1.1 below.

3.3 New drawing deliverable(s). The Contractor shall produce new drawings of proposed installation of the ship service diesel generator replacement in accordance with SFLC Std Spec 0850, and COMDINST M9085.1C, Naval Engineering Computer Aided Design Standards.

http://www.uscg.mil/SFLC/drawings/CIM_9085_1C.pdf. At a minimum the following new drawings shall be developed:

• Switchboard Wiring Diagram and Details

• Ship Service One-line Diagram

• Direct Current System

3.3.1 Stability calculations. The Contractor shall provide a list of weights added and removed for the main switchboard and associated controls and for the new 24 VDC system with the location of installation and removals for the purposes of developing Stability Calculations by the Coast Guard.

3.3.2 Preliminary/draft submission. Before 50 percent completion of this work item, submit a draft copy of the drawings to the Contracting Officer’s Representative (COR) for review and approval.

3.3.3 Final submission. Within 30 calendar days after receiving final Coast Guard comments on the draft submission or completion of this work item, whichever occurs first, accomplish the following:

• Incorporate all final Coast Guard comments.

• Jointly sign the drawing with the Coast Guard Inspector.

• Deliver four bound paper copies and an electronic media/AutoCAD generated copy on CD-ROM to the KO.

3.4 First article system testing. The Contractor shall set up a first article/mock-up of the proposed ship service diesel generator system and subsystems. The first article system/mock-up shall consist of Coast Guard provided (Government-furnished) Generator Sets, and Contractor furnished Main Switchboard to include all associated controls and alarms. The first article testing shall be at the Contractor’s facility for the purposes of demonstrating the design of the main switchboard and control equipment to be installed onboard 87 WPB Patrol Boats integrates and operates satisfactorily with the Government-furnished SSDG’s. The Contractor shall also have a load bank to be sized based on 87 WPB 310-002, Rev N, Electrical Plant Load Analysis on the Contractor’s facility to simulate ship’s full load conditions. Prior to performing the first article testing, the Contractor shall ensure the SSDG diesel engines have the appropriate break-in hours necessary to perform load testing. The Contractor shall demonstrate that the Control Panels provide control for single generator operation, (port alone/starboard alone) and load sharing parallel operation. The Contractor shall demonstrate/simulate load transfer between SSDG’s and Shore-Power. The Coast Guard representative shall be present for all testing for approval of control system operating performance.

3.4.1 Advance notification. Provide a 7-day advance notification to COR and KO prior to the mock-up test.

http://www.uscg.mil/SFLC/drawings/CIM_9085_1C.pdf

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3.4.2 Test report. Within 3 days after completion of test, the Contractor shall provide a mock-up test report listing all the test parameters, and performance data for both ship service diesel generator sets.

3.4.3 Revisions. Upon completion of a successful mock-up test, the Contractor shall make all the necessary updates to the drawings, and technical publications based on any refinement and lesson learned from the test.

3.4.4 Property. The Main Switchboard and associated controls shall become the property of the Coast Guard.

3.4.6 Warranty. A minimum warranty period of five (5) years from the date of installation onboard the first 87 WPB to be determined at a later date shall be included for the installation of each ship set. Written warranty terms and conditions shall be included in the quotation.

3.5 Integrator. Upon completion of the a successful Mock-up SSDG System demonstration as stated above in section 3.4, the Contractor shall be the Systems Integrator for the prototype Ship Service Diesel Generator system. As an integrator, the Contractor shall use the process necessary for bringing together all component subsystems into one system and ensuring that the subsystems function together as one system. This shall be accomplished using Contractor developed drawings, technical publications; Coast Guard provided drawings of all other associated systems and subsystems.

3.5.1 Prototype installation technical support. As an Integrator, the Contractor shall provide On- Site technical Support (Technical Representative) during the installation of the initial main switchboard, associated controls and a 24VDC system on-board an 87 WPB Coast Guard vessel which will be accomplished under a separate contract. Vessel name and location to be determined at a later date.

3.5.1.1 Tech Rep. As a tech rep, the Contractor shall be the subject matter expert with respect to the SSDG System design and all associated sub-systems and do the following, on site:

• Advise on manufacturer's proprietary information pertinent to the system.

• Assist with the installation of main switchboard and associated controls.

• Ensure compliance with manufacturer's procedures and standards during testing upon completion of installation.

3.6 Prototype Main Switchboard and associated controls and 24 VDC System Testing. The Contractor shall be required to conduct shipboard tests which shall include the following:

• Control system tests for all parameters listed above in section 3.1.1.1 and 3.1.1.2 above for a minimum of 8 hours for the following:

• Two-way Soft Transfer from ship to shore and back.

• Parallel Operation of P/S SSDG’s

• Single Generator Operation of either Generator.

• Voltage Regulation.

• Manual capability to open/close SSDG/Shore power C/B’s

• Speed Control.

• Fuel Cut-off (Shall not cause auto restart).

• Air Cut-off (Shall not cause auto re-start).

• Manual Controls shall be capable of overriding automatic controls.

• Data log recording for:

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• All John Deer Engine Control Unit ECU Emergency Shut-offs, such as High J/W Temp Low L/O Pressure.

• Manual Emergency Shut-offs.

• Ability to download all data to a portable laptop.

3.7 Training and Equipment operating procedures. The Contractor shall provide on-site training for the crew of the 87 WPB Patrol Boat and Equipment Operating Procedures in either written form or video CD for the prototype installation.

4.1 References.

Coast Guard Drawings.

Coast Guard Drawing 87 WPB 182-001, Rev B, Main Engine and Generator Foundations Coast Guard Drawing 87 WPB 201-001, Rev B, Machinery Arrangement Coast Guard Drawing 87 WPB 233-001, Rev A, Remote Emergency Shutdowns Coast Guard Drawing 87 WPB 252-001, Rev F, 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 W, Sea Water Cooling Piping Coast Guard Drawing 87 WPB 259-001, Rev D, Engine Exhaust Piping Coast Guard Drawing 87 WPB 261-001, Rev K, Fuel Oil Service Piping Coast Guard Drawing 87 WPB 310-001, Rev F, Ship Service One-Line Diagram Coast Guard Drawing 87 WPB 310-002, Rev N, Electrical Plant Load Analysis Coast Guard Drawing 87 WPB 313-001, Rev M, DC System Coast Guard Drawing 87 WPB 324-001, Rev B, Switchboard Wiring Diagram and

Details (Boats 1-12) Coast Guard Drawing 87 WPB 324-002, Rev C, Switchboard Wiring Diagram and

Details (Boats 13 & On) Coast Guard Drawing 87 WPB 324-003, Rev B, Switchboard Wiring Diagram and

Details (Boats 52 & P52) Coast Guard Drawing 87 WPB 324-004, Rev B, Switchboard Wiring Diagram and

Details (Boats 67 & On)

Coast Guard Publications.

Surface Forces Logistics Center Standard Specification 0850 (SFLC Std Spec 0850), 2014, General Requirements for Drawing Preparation Surface Forces Logistics Center Technical Standard 086,(SFLC Tech Std 085) 2013, Technical Publications (TP) Coast Guard Technical Publication (TP) 4557A, Ship’s Service Generator, 87 WPB Class

Cutters Coast Guard Technical Publication (TP) 4557B, Ship’s Service Generator, Control Panels

1 & 2, 87 WPB Class Cutters

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COMDINST M9085.1C, Naval Engineering Computer Aided Design Standards.

http://www.uscg.mil/SFLC/drawings/CIM_9085_1C.pdf

CDI Engineering Solutions, USCGC 87 FT Coastal Patrol Boat 24 VDC Feasibility Study Technical Report

Surface Forces Logistics Center, ESD Assessment Input for Technical Documentation Review: 87 Ft CPB 24 VDC Feasibility Study Technical Report

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 Code of Federal Regulations 46 CFR, Chapter I, Subchapter J, Part 111.30-25, Alternating Current Ship’s Service Switchboards, Oct, 2014 National Electrical Manufacturer’s Association, NEMA 250, Enclosures for Electrical

Equipment (1000 Volts Maximum) Institute of Electrical and Electronic Engineers IEEE STD 45, Recommended Practice for

Electrical Installations on Shipboard, April 9, 2004 http://www.uscg.mil/SFLC/drawings/CIM_9085_1C.pdf