Attachment_2_-_SOW_400_Hz_Motor_Generator_Set.pdf

Specification for 270 WMEC 400HZ Motor Controllers and Nr 2 Motor Generator Set

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USCG 270 FOOT MEDIUM ENDURANCE CUTTERS

SPECIFICATION FOR PROCUREMENT OF 400 HZ Motor Controllers and Nr 2 Motor Generator Set

November 3, 2015

Developed By: Celestin Jules

Specification for

270 WMEC 400 HZ Motor Controller & MG Set

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270 WMEC CLASS SPECIFICATION FOR

400 HZ Motor Controllers & Nr 2 Motor Generator Set

Table of Contents

1.0 SCOPE

1.1 General

1.2 GFE, GFM, and GFP

1.3 GFI

2.0 APPLICABLE DOCUMENTS

2.1 Coast Guard Drawings

2.2 Coast Guard Publication

2.3 Other Documents

2.4 Order of Precedence

3.0 REQUIREMENTS

3.1 General Requirements

3.2 Ship Check and 400 HZ Motor Controller Design Requirements

3.3 400 HZ Motor Controllers Removal, Installation and Removal of Nr 2 MG Set

3.4 Spare Parts

4.0 NOTES

4.1 Document Sources

5.0 APPENDIX A

5.1 Motor Generator Power Supply Front Panel Controls: Figure 2-1

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1.0 SCOPE

1.1 General - This specification covers the requirements for the design, procurement, installation, and testing of a new 400 HZ Motor Controller to replace the existing 400 HZ Motor Controller on the 270-FT WMEC Class cutters. It also covers the removal of Nr 2 400 HZ Motor Generator set

1.1.1 Contractor shall conduct a ship check, design a system and create and/or modify drawings.

1.1.2 Contractor shall install newly designed 400 HZ Motor Controller.

1.1.3 Contractor shall provide spare parts.

1.1.4 Contractor shall provide warranty and technical service.

1.2 Government Furnished Equipment (GFE), Government Furnished Material (GFM) and Government Furnished Property (GFP) – None

1.3 Government Furnished Information (GFI) – As noted in Section 2.0.

2.0 REFERENCES

2.1 Coast Guard Drawings - The following specifications and standards form a part of this specification to the extent specified herein.

a. Coast Guard Drawing 901-WMEC-314-002, Rev E, 400 HZ MG Wiring Diagram

b. Coast Guard Drawing 901-WMEC-314-003, Rev J, 400 HZ MG Schematic Diagram

c. Coast Guard Drawing 901-WMEC-324-009, Rev F, 400 HZ Switchboard

EWD

d. Coast Guard Drawing 905-WMEC-314-003, Rev A, 400HZ MG Schem Diag

e. Coast Guard Drawing 905-WMEC-324-009, Rev A, 400 HZ SWBD EDW

2.2 Coast Guard Publications - The following specifications and standards form a part of this specification to the extent specified herein.

a. Coast Guard Commandant Instruction (COMDTINST) M9085.1C, 2011, Naval Engineering Computer Aided Design Standards.

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b. CGTO PG-85-00-230-S, USCG Planned Maintenance System Development Process GuideD-083-0351, Rev -, Dated 1/00, Data for Provisioning

c. Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements

d. Surface Forces Logistics Center Standard Specification 0450 (SFLC Std Spec 0450), 2012, Electrical Power for Contractor’s Tools and Equipment

e. Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2012, Welding and Allied Processes

f. Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041), 2012, Shipboard Electrical Cable Test

g. Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2012, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation

h. Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures.

i. Surface Forces Logistic Center D-083-0351, 2000, Rev B, Data for Provisioning.

j. Surface Forces Logistic Center D-084-0481, 2006, Rev B, Engineering Change Equip. Unit, Preservation, Packing & Marking - Name

k. Surface Forces Logistic Center D-086-0508, 2007, Rev A, Technical Documentation Specification (Tech Publications & Drawings)

m. Tech Pub 5078, CONTROL PANEL, 60 TO 400 HZ MG SET, SWBS 314, Section A, SWBS Element Title POWER CONVERSION EQUIPMENT,

2.3 Other Documents - The following specifications and standards form a part of this specification to the extent specified herein.

2.3.1 American Bureau of Shipping

a. ABS does not apply in this specification. The Electrical and Control regulations apply to factory standard applications, opposed to installation regulations.

2.3.2 American Society for Quality Control (ASQC)

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a. ANSI/ASQC 9001-2008 – Quality Management Systems - Model for Quality Assurance in Design, Development, Production, Installation, and Servicing Requirements

2.3.3 Department of Transportation

a. 46 CFR Part 111 (2012), Electrical Systems- General Requirements

2.3.4 Federal Standards

a. Code of Federal Regulations (CFR), Title 29 (Labor), Standards 1926.62

(Lead), SubPart D (Occupation Health and Environmental Controls)

b. Code of Federal Regulations (CFR), Title 40 (Protection of Environment), Chapter I – Environmental Protection Agency

2.3.5 International Engineering Consortium (IEC)

a. IEC 60529 (2001), Degrees of protection provided by enclosures (IP Code).

2.3.6 Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE Standard 45 (2002), Recommended Practice for Electrical Installation on Shipboard

2.3.7 Military/Navsea Specifications

a. MIL-DTL-24643C (2011), Cables, Electrical, Low Smoke Halogen-Free, For Shipboard Use, General Specification

b. MIL-STD-1399-300A Electric Power, Alternating Current

c. MIL-STD-2000 Standard Requirements for Soldered Electrical & Electronic Assemblies

2.3.8 National Conference of Standard Laboratories (NSCL)

a. ANSI/NCSL Z540.3 (2006), Requirements for the Calibration of Measuring and Test Equipment

2.3.9 National Electrical Manufacturers Association (NEMA)

a. NEMA ICS 2 (2000), Industrial Control and Systems Controllers and Overload Relays Rated 600 Volts

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b. NEMA ICS 18 (2007), Motor Control Center

2.3.10 National Marine Electronics Association (NMEA)

a. NMEA-2000 (2004), Appendix C: Certification Criteria and Test Methods

2.3.11 Underwriters’ Laboratory (UL)

a. UL 224 Extruded Insulating Tubing

b. UL 486A-486B (2013), Wire Connectors.

c. UL 508A (2001), Standard for Industrial Control Panels

2.4 Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. However, nothing in this document supersedes applicable laws and regulations unless a specification exemption has been obtained. The Contractor shall notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these specifications.

3.0 REQUIREMENTS

3.1 General Requirements - The Contractor shall provide all labor and materials to provide a new 400 HZ Motor Controller to replace the existing Bogue Electric Manufacturing Company 400 HZ Motor Controller on each 270-FT WMEC Class cutter. The new motor controllers shall meet the system requirement that is designed/built for installation onboard ship. The Contractor shall also remover number 2 400HZ Motor Generator set along with an associated cabling. Any components, materials or services subcontracted for this procurement shall be the responsibility of the Contractor.

3.1.1 General Description. The control panel shall be fastened to the control enclosure with a hinge and knurled thumb screws containing all controls and indicators necessary for control of motor generator supply (reference Appendix A: Figure 2-1). The motor shall be a two step, closed transition type starter with phase lines to protect motor against excessive armature current and low voltage during starting and operation. The Voltage Regulator shall be a static type regulator use to control the output voltage of 400HZ generator. All components of the VR shall be mounted on an open type panel located within the control cabinet. The VR will consist of plug-in printed circuit board assemblies which are readily removable for repair.

3.1.2 Remote Control and Signals: The new motor controllers shall provide remote Signal leads to connect to Engineering Control Console as follows:

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1. Motor O.L. Alarm

2. Start-Stop

3. Motor Overload Alarm

4. Generator O.V/U.V. Alarm

5. Space heater status indicator

3.1.3 Electrical Interface Data: MG set will convert 60 cycles (Hz), to 440V Ac Power, to 400 Hz, underground

3.1.4 Electrical Standards - New equipment, design, installation and support services shall meet the requirements UL, NEMA, IEEE, 46 CFR 111 and IEC listed in section 2.3 (Other Documents)

3.1.5 Environmental Conditions Equipment shall be designed to operate in the following conditions.

a. Operating Temperature: -28.9°C to +40°C (-20°F to +105°F)

b. Storage Temperature: -28.9°C to +55°C (-20°F to +132°F)

c. Humidity: 0% to 100%

3.1.6 Equipment Enclosures - Enclosures for 400 HZ Motor Controller shall be in compliance with National Electrical Manufacturers Association (NEMA) Type

4. In accordance with National Electrical Manufacturers Association (NEMA) 250 or equivalent IP Code specified in International Engineering Consortium

(IEC) 60529.

3.1.7 Workmanship

3.1.7.1 All workmanship, materials and components shall be of the highest quality in every aspect of new manufacture and in full conformance with this specification. No use of used materials/wires or components is permitted.

3.1.7.2 Welded parts shall be free of weld splatter, porosity, undercuts and other defects.

3.1.7.3 All parts shall be free of burrs and sharp or rugged edges.

3.1.7.4 Close attention have to be paid to form of connecting material, dimensions, finish, etc. and shall be in full conformance with this specification and associated drawings and documents.

3.1.8 Departure from Specification - Departure from the Specifications will not be allowed unless there is a direct benefit to the Government.

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3.1.8.1 If the Contractor finds it necessary to change or depart from the applicable requirements, he must request permission to do so from the Contracting Officer (KO) at the earliest possible time.

3.1.8.2 Requests by the Contractor for changes shall clearly describe the changes proposed, the reason for the change, and the advantages of the changes proposed. Also to be included is a detailed list of additional costs or savings (if any) that would result.

3.1.8.3 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 shall be submitted.

3.1.9 Design Improvements – Proposals submitted for design improvements to equipment or process to simplify or improve reliability and/or maintainability, and to improve performance, are encouraged. Such proposals may be submitted at any time during the contract using the specification departure procedures as outlined herein.

3.1.10 Schedule Requirement – The Contractor shall participate in regularly scheduled status meetings and adhere to the following schedule (all time requirements refer to calendar days):

ITEM SCHEDULE DUE BY

1 Kick-off Meeting at SFLC in Norfolk, VA 7 Calendar days after Task Award

2 Kick-Off Meeting Minutes

4 Calendar days after Kick-Off Meeting

3 Ship Check 14 Calendar days after the start of the base period of performance

4 Ship Check Report 14 Calendar days after ship check

5 Monthly Status Meeting 30 Calendar days after Task Award

6 Monthly Status Meeting 60 Calendar days after Task Award

7 Preliminary Design Drawings 90 Calendar days after Task Award

8 Final Design Drawings 120 Calendar days after Task Award

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9 Provisioning Technical Documentation

120 Calendar days after Task Award

10 Technical Publication 120 Calendar days after Task Award

3.1.10.1 Monthly Progress Report – The Contractor shall prepare and submit a Monthly Progress Report in contractor format approved by the Government Program Manager and modified to meet COR needs starting 30 calendar days after the task is awarded. The report shall include a summary of activities and accomplishments for the current reporting period, schedule information, planned activities for the next reporting period and planned travel for the next reporting period. The Contractor shall identify any issues or problems that the Contractor perceives as impacting their ability to satisfy requirements.

3.1.10.2 Approvals – Contractor shall provide to USCG design drawings for the new 400 HZ Motor Controller. Contractor shall receive USCG approval of the new 400 HZ Motor Controller upon satisfactory First Article Test and approve design drawings.

3.2 Design Requirements - The contractor shall design and deliver a 400 HZ Motor Generator Controller. The controller shall start, stop, and provide short circuit and overload protection for the existing motor. The controller shall be able to monitor and display, via a selector switch, any one of the three output phases of the existing generator’s voltage, ampere and frequency. The controller shall be able to sense and display the following conditions (1) Generator “ON” [green light], (2) Motor “ON” [green light], (3) Heater “ON” [white light], and Motor Overload alarm [red light]. The controller shall be to automatically control the generator’s output voltage. The controller shall provide low voltage, over voltage and over current protection for the generator. Additional data for the controller being replaced and existing motor/generator set can be found in Coast Guard Technical Publications 2704 [A Class] and 2822 [B Class].

a. 400 HZ Motor Controllers (2)

b. Nr 2 Motor Generator Set

3.2.1 Check and validate all Physical Dimensions for the motor controller prior to designing a new motor controller. The new 400 HZ motor controller shall not exceed the size of the existing motor controller. The size of the existing motor controllers is listed below;

a) Height: 52.5 inches

b) Width: 27.25 inches

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c) Depth: 14 inches

d) Weight: 350 lbs

3.2.2 Check and validate all mounting and foundation requirements for the controller:

3.2.3 The equipment shall be designed/built for automatic control of the generator output voltage (no provisions are made for manual control). The static type voltage regulator shall maintain the mean voltage with +/- 1% of rated voltage for any preset value within the specified range of 108-132 volts AC, from no load to rated load.

3.2.3.1 Controller Functionality: Ships will provide 440 volt, 3 phases, and 60 cycle power connected to the motor controller input terminals located in the control panel. The controller monitors the prime power applied to windings of 3 phase synchronous motor, and shall generate necessary torque to drive rotating elements.

3.2.3.2 Regulator Functionality: A static type automatic voltage regulator shall meet regulation requirements of 400 cycle output voltage of generator and within +/- 1% (NL to FL) of the preset voltage. Regulator senses output voltage of the generator to control the field of the exciter.

3.2.4 Check and validate all electrical connectors to or from the controller: The replacement motor generator shall meet the following panel requirements:

3.2.4.1 Drip proof: Control Panel shall be fabricated from a steel enclosure designed/built for bulkhead mounting. All control components (i.e.

transformers, rectifiers, motor controller, voltage regulator, and terminal blocks) shall be mounted within the steel enclosure, with access provided by a hinged front panel door, and secured by knurled thumb screws.

3.2.4.2 Frame: Four 21/23 inch diameter mounting holes shall be provided on the supporting frame to facilitate mounting to a suitable bulkhead.

3.2.4.3 Entrance Access: A removable cable plate, located at the bottom panel of the enclosure shall be provided to permit entry of external cable which terminates on the terminal board.

a) The Government prefers for all cable entrances to the motor controllers to enter in through the bottom of the control panel, as recommended in industry best practice.

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b) The second option is for the cable to enter from the side of the motor controller, utilizing all appropriate cable penetrations to ensure there is no moisture penetration at the cable site.

c) The third option is for the cable to enter at the top of the motor controller, utilizing all appropriate cable penetrations to ensure there is no moisture penetration at the cable site.

d) The Contractor shall state their suggested cable arrangement as part of their proposal.

3.2.5 Check and validate all motor short circuits and overload requirements:

Contractor shall provide to USCG design drawings for the new 400 HZ Motor Controller. Contractor shall receive USCG approval of the new 400 HZ Motor Controller upon satisfactory First Article Test and approval system drawings.

3.2.6 Check and validate all generator field exciter requirements to make sure that the new controller’s voltage regulator can support the existing field

3.2.7 Check and validate all remote control and display connections to the controller

3.2.8 Check and validate the physical condition of any cable that can or will be reused as part of the new controller installation

3.2.9 Check and validate all environmental conditions for the controller.

3.2.10 Check and validate all generator electrical control and display connections.

3.2.11 Design Drawings - The Contractor shall develop Preliminary and Final drawings for removal of the existing three 400 HZ Motor Controller, removal of number 2 400 HZ MG set. The contractor shall develop Preliminary and Final design drawings for the installation of the two new 400 HZ Motor Controller. The removal/installation drawings shall include the following:

a. List of material and equipment being removed and added.

b. System block diagram of all existing components/cable being removed or will remain in place along with the equipment location.

c. Arrangement drawing that indicates the removal of existing 400 HZ Motor Controller.

d. Block Diagram of new 400 HZ Motor Controller, existing/new interconnecting and power.

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e. Arrangement drawing for new 400 HZ Motor Controller

f. Foundation drawing for new 400 HZ Motor Controller

g. Bill of Material for new 400 HZ Motor Controller.

h. All drawings shall become the property of the Government and the Government shall have unlimited production rights.

3.2.11.1 The Contractor shall ship check at a minimum one “A “ class cutter and one “B” class cutter designated for installation in order to obtain all necessary information to produce the design drawings required herein.

The drawings listed in Section 2.1 (Coast Guard drawings) may be used for reference but may not reflect the exact configuration of a cutter. The Contractor shall coordinate with the USCG Contracting Officer’s Representative (COR) to schedule the ship checks. The exact date of a ship check will be determined based on ship availability. Locations for ship checks shall be as specified in the Contract.

3.2.11.2 The design shall provide detailed drawings separated by discipline and removals/installations shall be separate drawings.

3.2.11.3 The Contractor shall develop and provide as-built system/component drawings and diagrams in AutoCAD 2012 in accordance with COMDTINST M9085.1 (Series) "Naval Engineering Computer Aided Design Standards." Standard Coast Guard drawing border templates are available via the internet at: http://www.uscg.mil/sflc/ or upon request via the Coast Guard Contracting Officer or his/her representative.

Drawings shall reflect the system/components after installation is complete (as-built)

3.2.11.4 Draft Deliverable – One (1) paper and one (1) electronic copy of preliminary drawings. Drawings shall be submitted for review and approval. Comments will be returned along with the assignment of a Coast Guard Drawing number.

3.2.11.5 Installation Drawings - One (1) paper (per ship set) on first day of installation and one (1) electronic copy of Coast Guard approved Drawings shall be provided to the Coast Guard Contracting Officer or his/her representative. Electronic files include any source files used to produce the Drawings.

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3.2.11.6 Final Drawings – As-built conditions 30 calendar days after completion of the first installation. All future installations shall utilize these final drawings.

3.2.11.7 The following design drawings listed in 3.2.5.7.1, 3.2.5.7.2, 3.2.5.7.4, and 3.2.5.6.4 can be combined into one drawing and shall be submitted along with the rest of the drawings below at a minimum:

3.2.11.7.1 400 HZ Motor Controller Removals – Drawing shall include removal of Bogue Electric Manufacturing 400 HZ Motor Controller and cables, if necessary.

3.2.11.7.2 Nr 2 400 HZ MG Set Removals – Drawing shall include removal of Bogue Electric Manufacturing MG set and associated cables.

3.2.11.7.3 400 HZ Motor Controller Installation – Drawing shall include installation of new 400 HZ Motor Controller and cables, if necessary. The drawing shall include block diagram and elementary wiring diagrams.

3.2.11.7.4 400 HZ Motor Controller Arrangement Removals – Drawing shall include a scaled arrangement of equipment in compartments delineating 400 HZ Motor Controller equipment removals.

3.2.11.7.5 400 HZ Motor Controller Arrangement Installation – Drawing shall include a scaled arrangement of equipment in compartments delineating 400 HZ Motor Controller equipment.

3.2.11.7.6 Structural Removals IWO 400 HZ Motor Controller

Installation - Drawing shall include structural removals and removal of equipment foundations.

3.2.11.7.7 Structural Installation IWO 400 HZ Motor Controller Installation – Drawing shall include structural installations and equipment foundation installations for motor controller.

3.2.11.7.8 Interface Drawings shall be provided to document the shipboard interface required. The drawings shall identify the physical characteristics, weight, and center of gravity of the assembly, as well as the structural loads and moment reactions transferred to ship structure under design loading conditions.

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3.2.11.7.9 A complete set of design drawings shall be developed for A class and a complete set of design drawings shall be developed for the B class. Each individual cutter shall receive a set of the installation drawings in accordance with paragraph 3.2.4.7.5 (Installation drawings)

3.2.11.7.10 The Contractor shall be required to submit preliminary design drawings for USCG review and approval. All preliminary revision marks (i.e. P1, P2, etc.) and revision notes shall be removed from the drawings and the drawings shall be labeled as “Rev –” when the drawings are submitted to USCG for final review.

3.2.11.7.11 The Contractor shall submit final drawings after the first installation is complete. The contractor shall resubmit any drawings that need updating to reflect as built conditions, as REV A. All future installations shall utilize these final drawings to ensure all cutters receive the same configuration.

3.2.12 Check and validate technical documentation – Content for technical documentation (technical publications and drawings) to be provided shall be as defined below and as defined in SFLC Document D-086-0508. The Contractor shall provide data rights documentation that allows publication on the Coast Guard Intranet and distribution to the Fleet. Quantities shall be provided as specified herein. Additional requirements for the content of technical documentation shall be as identified in paragraph 3.4.1.1 (Engineering Data for Provisioning (EDFP)).

3.2.12.1 Technical Publications

3.2.12.1.1 The Contractor shall develop and provide a Technical Publication for the installation, operation and maintenance of the new 400 HZ Motor Controller.

3.2.12.1.2 Draft Deliverable – One (1) paper and one (1) electronic draft copy of the Technical Publication shall be submitted for review and approval. Comments will be returned along with the assignment of a Coast Guard Document number.

3.2.12.1.3 Final Deliverable – One (1) paper (per ship set) and one (1) electronic copy of the Coast Guard approved Technical Publication shall be provided to the Coast Guard Contracting Officer or his/her representative. Electronic files shall include any source files used to produce the Technical Publication.

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3.2.12.1.4 Each technical publication shall provide, as a minimum, the necessary information to provide instructions to operate and maintain the equipment at the organizational level. This includes a full description of system start-up, operation, shutdown, safety and emergency procedures. The manuals shall contain information concerning checkout, inspection, preventive and corrective maintenance, calibration, adjustment, troubleshooting, replacement of parts, repair, and use of tools and test equipment in accordance with the maintenance concept. The following sections, as a minimum, shall be included:

a. General Information and Safety Precautions – Identify and describe the purpose, interconnection, and functional use of the equipment including safety issues.

b. Theory of Operation – Identify and describe the theory of operation of the equipment and all components.

c. System Description – Identify and describe the purpose and functional operation of the equipment and components.

d. Component Description – Include sufficient information to identify and describe all major system components.

e. Functional Description – Discuss the control philosophy used in the system design and provide a detailed description of the controls used.

f. Installation – Include drawings and information sufficient to install or remove the equipment, including handling procedures, special tools, access clearances and supporting services (crane, welding, etc.) required. The locations of lifting eyes and special rigging shall be discussed.

g. Operating Procedures – Identify all normal system operations and evolutions which involve personnel.

Detailed step-by-step operating procedures for these normal operations and evolutions shall be provided.

h. Maintenance Procedures – Identify all preventive maintenance and corrective maintenance operations and evolutions, which involve personnel. Detailed step-by-step procedures shall be provided.

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i. Emergency Procedures – Identify conditions requiring emergency operations and provide procedures to be followed in the event of their occurrence. Emergency operation is defined as operation under conditions of system malfunction or failure such as loss of power, component failure, physical damage, or fire. Detailed step-by-step procedures for dealing with emergencies shall be provided.

j. Troubleshooting Procedures – Provide detailed instructions for locating an equipment malfunction including troubleshooting procedures; troubleshooting diagrams;

maintenance schematics and logic diagrams.

k. Equipment Limitations, Precautions, Set Points – Identify all system operational limitations. State all precautions to be taken during normal operation to preclude potentially unsafe conditions. List system operation set points, which represent the normal operation of the system.

l. Illustrated Parts Lists – Identify parts associated with the equipment. An exploded illustration shall show the location of the parts. The parts list shall identify the piece part of the illustration, quantity installed, nomenclature, designation, original manufacturer and manufacturer’s part number. Part numbers are not required for common hardware available from multiple sources, provided that adequate descriptive data is provided. Parts data listed in the technical manual shall be the same as listed on the Provisioning Technical Documentation. If metric system components are provided, they shall be so noted.

m. Spare Parts – The spare parts lists and recommendations developed for the Integrated Logistic Support (ILS) shall be included in the publication.

n. Appendices (as necessary) – Provide tabular appendices for technical data and literature, repair and overhaul information on major subassemblies and supportable components such as motors, motor controllers and gearboxes.

3.2.12.1.5 Format

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3.2.12.1.5.1Text – Text shall be single-column and single-spaced, with one inch left-hand margins and unjustified right- hand margins.

Text size shall be 12 point in a standard, easily readable font. Titles and headers shall follow a heading style hierocracy.

Footnotes, notes and other side information shall be 8 point or larger.

3.2.12.1.5.2 Paper Size – Page size shall be 8-1/2 inches by

11 inches. Text shall be printed on both sides of the paper, head to head. Pages shall be three-hole punched with 3/8 inch diameter holes.

3.2.12.1.5.3 Prefix – The manual shall have a title page

showing the publication title; Technical Publication Number (USCG assigned); hull applicability; the manufacturer’s name; the system or equipment designation and model number; and the equipment serial numbers. The publication shall have a list of effective pages, Table of contents, list of illustrations, list of tables, change record Sheet, a listing of applicable abbreviations and acronyms, and a safety summary.

3.2.12.1.5.4 Page Numbers – Pages shall be numbered

sequentially within a publication. Page numbers shall be shown at the bottom center. The bottom unbound corner shall be reserved for a change identifier. For fold-in pages, the page number shall be shown at the bottom right hand corner, together with the change identifier.

3.2.12.1.5.5 Dividers – Major chapters, sections, and

appendices shall be clearly identified with tab dividers.

3.2.12.1.5.6 Illustrations – Illustrations/figures and parts lists shall be included in the manuals. The maximum illustrations size within the technical publication shall be ANSI size B, 11”h x 17”w, which shall be accordion folded. Prints of larger illustrations sizes shall be reduced, as

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3.2.12.1.5.7 Complete functional block diagrams and

schematic diagrams shall be provided for electrical and electronic circuits. Controller schematics shall be provided in the technical publication for the entire electrical system including ladder diagrams.

3.2.12.1.5.8 The Contractor shall provide the proposed

Technical Manuals for approval by the Government. Comments will be returned along with the assignment of a national stock number and a Coast Guard Technical Publication number, for incorporation into the title page and cover.

3.2.12.1.5.9 Deliverables: The Contractor shall submit one

electronic copy for each DRAFT deliverable manual, for review and comment. The Contractor shall provide one electronic copy of each FINAL approved manual. The Government will be responsible for distribution of the completed manuals.

3.2.12.1.5.10 Electronic Format – Technical Publications and

Amendment Change packages shall be developed in electronic format, using MICROSOFT OFFICE tm compatible electronic file format, with imbedded text and graphic files. All preprinted publications and documents not developed and delivered in Microsoft Office, shall be scanned in and delivered as an unlocked Portable Document Format (PDF) file. The final deliverable publication may be a compilation of the above formats. The electronic publication shall have Bookmarks to the Table of Contents, List of Tables, List of Illustrations, Chapters and Appendices, to permit ease of navigation by the end users. All Electronic reproducible files (PDF, Office and so forth) shall be delivered in CD format with electronic file names and revisions clearly identified.

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3.2.12.1.5.11 In addition, the Contractor shall, over the life of this contract, provide updates to the technical manuals, drawings, and so forth whenever there is a change/update to the equipment. Deliverable requirements are the same as for initial manuals above.

Distribution of manual updates will be the responsibility of the government. At the completion of the contract, the contractor shall provide a final update for each manual to record final configurations of equipment and all serial numbers. All technical publications shall become the property of the Government and the Government shall have unlimited production rights.

3.3. Removals and Installation Requirements – The Contractor shall remove existing Bogue Electric Manufacturing 400 Hz Motor Controller and Nr 2 400 HZ Motor Generator set and install new 400 HZ Motor Controller and cables, if necessary.

3.3.1 The Contractor shall provide all labor, tools, materials and services for removal of the three existing Bogue Electric Manufacturing 400 Hz Motor Controller and number 2 400 HZ Motor Generator set and associated cables as specified in Section

3.2.11 (Design Drawings). The Contractor shall be responsible for removing all Bogue Electric Manufacturing 400 Hz Motor Controller and number 2 400 HZ Motor Generator set and cable, if necessary and foundations whether shown on the drawings or not.

3.3.1.1 The Contractor shall retain the removed motor generator and motor controller panels from the first two (2) installations (total of two (2) motor generators and six (6) motor controller panels). Each retained piece of equipment shall be preserved, packaged and marked for shipping as an Equipment Unit in accordance with SFLC-D-084-0481. Each motor generator shall be packaged individually. Each motor controller panel shall be packaged individually. A copy of the packing list for each container shall be prepared and electronically forwarded to the COR. All the retained components shall be delivered FOB to Baltimore, MD.

3.3.1.2 All other removed equipment shall be disposed of in accordance with federal, state, and local regulations.

3.3.2 The Contractor shall provide all labor, tools, material and services for the installation of the new 400 HZ Motor Controller and cable, if necessary as developed in section

3.2.11 (Design Drawings). All installations shall utilize the Final Drawings as

Page 20 of 37 REV - 0 developed in section 3.2.11 (Design Drawings). All work shall be accomplished in accordance with SFLC Standard Specification 0000.

3.3.3 The Contractor shall include the labor cost of a field service engineer/technician to assist during set-up, testing and commissioning of all cutters to provide for optimum performance of the new 400 HZ Motor Controller. Locations for this requirement shall be as specified in the Contract

3.3.4 The Contractor shall prepare and sign a statement regarding the completion of commissioned services. The COR shall obtain a release signature before the departure of the Contractor or his/her representative from the field service site. The Contractor shall forward a copy of the signed released document to the Contraction Officer (KO), with a Commissioning Test Report.

3.3.5 Electrical Cables - The cable shall be installed, and run in the existing wire ways, using the existing brackets, and cable collars vacated by the removal of the old cable.

The Contractor shall furnish and install new kick-pipes or multi-cable inserts as required to accommodate the installation of this cable. The Contractor shall furnish and install aluminum cable tags near each end of the cable and also adjacent to where the cable passes through a bulkhead or deck fitting.

3.3.5.1 Cables shall be constructed in accordance with MIL-DTL-24643C. All RS- 422 cable shall be shielded twisted pairs and the size of power cable shall not provide voltage drop greater than the 5% of 24VDC Power supply to the connected load.

3.3.5.2 There shall be no splices in the internal wiring of equipment. Connections shall be made at the terminal studs of the devices or the terminal boards.

These connections shall be in accordance with UL 486A or equivalent.

3.3.5.3 Internal wiring of equipment shall be marked by fiber tags or by heat shrink tubing meeting the requirements of UL224. Terminal blocks shall be screw clamped, equipped with marking strips and permanently marked at each terminal with a number (for example, 1 to 20).

3.3.5.4 Miscellaneous hardware (wires, cables, terminal blocks, lugs, bolts, washers, fittings, fasteners, etc.) required to complete the installation of the new 400 HZ Motor Controller and not specifically identified in this specification shall be considered Contractor furnished.

3.3.5.5 For equipment that requires mating connector, the connected cable shall be soldering in accordance MIL-STD-2000. Equipment that does not required

Page 21 of 37 REV - 0 mating connectors, a crimping ferrule shall be used. Contractor shall select proper size of ferrules based on wire size.

3.3.5.6 Newly installed and modified cables shall be tested in accordance with SFLC Standard Specification 3041 before energizing the associated circuits.

3.3.5.7 Cable removals and installations shall be in accordance SFLC Standard Specification 3042.\

3.3.5.8 Existing cableway/wire ways shall be utilized for new cable runs as much as possible.

3.3.6 Interferences - The Contractor shall handle all interferences in accordance with NAVSEA S9AA0-AB-GOS-010 General Specifications for Overhaul of Surface ships section 70.

3.3.7 Power for Tools and Equipment - Electric power for Contractor tools and equipment shall be used in accordance with SFLC Standard Specification 0450.

3.3.8 Welding - Welding shall be in accordance with SFLC Standard Specification 0740.

3.3.9 Surface Preservation - The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces, as applicable, to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.).

3.3.10 Protective Measures - The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces 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

3.3.11 Housekeeping - The Contractor shall accomplish the following.

3.3.11.1 Maintain good housekeeping conditions at all times. Maintain adequate aisles and passageways in all work areas. Ensure that all staging platforms, ramps, stairways, walkways, aisles, and passageways on vessels or dry docks are kept clear of all tools, materials, and equipment except that which are in use, and all debris such as welding rod tips, bolts, nuts, and similar material; ensure that hose and electric conductors are elevated over or placed under the walkway or working surfaces or covered by adequate crossover planks.

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3.3.11.2 Ensure that all working areas on or immediately surrounding vessels and dry docks, graving docks, or marine railways are kept reasonably free of debris, and construction material are so piled as not to present a hazard to employees.

3.3.11.3 Avoid any slippery condition on walkways or working surfaces.

3.3.11.4 Maintain free access at all times to all exits and to all fire-alarm or fire-extinguishing equipment.

3.3.11.5 Keep all oils, paint thinners, solvents, waste, rags, or other flammable substances in fire resistant, covered containers when not in use.

3.3.12 Final Cleanup/Jobsite Cleanliness Requirements - Following completion of work, the Contractor shall remove all debris, equipment, and material from the job site and restore all existing facilities affected by the work to their original condition.

3.3.13 Identification and Labeling – A manufacturer’s label plate shall be permanently affixed to each of the components provided. Label plates shall be corrosion resistant showing the following information as a minimum:

a. Manufacturer’s model number

b. Manufacturer’s part number

c. Item description

d. Serial number

e. Year built

3.3.14 Quality Assurance (QA) - The Contractor shall maintain an inspection system to insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard Quality Assurance Representative

(QAR).

3.3.14.1 Records - The Contractor shall maintain records of all inspections and tests.

The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken. The Contractor shall provide the Coast Guard QAR with completed copies of the certification testing results upon request or upon arrival. A copy of the test certification, including any tests by subcontractors or tests of subcontracted materials, shall be provided to the Contracting Officer Representative (COR) and the QAR when issued.

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3.3.14.2 Responsibility for Inspection - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

3.3.14.3 Responsibility for Compliance - All items shall meet the provisions of of this specification. The inspections set forth in this specification shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in this specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the Government to acceptance of defective material.

3.3.14.4 Quality Assurance Plan – The Contractor shall maintain a Quality Assurance Plan in accordance with ANSI/ASQC Q9001-2008 which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Contracting Officer/Quality Assurance Representative.

3.3.14.5 Inspections and Tests - The inspections and tests required by this specification 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 in question.

3.3.14.7 Failure Responsibility – If an item fails to pass any inspection or test, the Contractor shall provide a Corrective Action Report (CAR) to document the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

3.3.14.8 Corrective Action Remedies (CAR)

3.3.14.8.1 The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

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3.3.14.8.2 If an item fails an inspection or test, the inspection or test process shall be discontinued until all corrective action has been taken.

3.3.14.8.3 After corrective actions have been taken, the inspection or test shall be continued or repeated at the option of the Contracting Officer.

3.3.14.8.4 Acceptance shall be withheld until re-inspection or re-test demonstrates the corrective action was successful and the item satisfactorily passes all inspections and tests.

3.3.14.8.5 All corrective actions shall be documented as part of the Contractor’s inspection system and submitted for approval to the Contracting Officer.

3.3.14.8.6 Each CAR shall include, but is not limited to, the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

3.3.14.9 Inspection and Test Reports – The Contractor shall prepare a report for each inspection or test performed including the shipboard tests. The Contractor shall provide one copy of any required inspection or test report to the Contracting Officer and one copy shall be retained by the Contractor for review by the QAR upon arrival at the Contractor’s plant.

3.3.14.10 Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with Section

3.4.3.1 (Preservation, Packing and Marking) of this specification.

3.3.15Training - The Contractor shall provide a one day on-site training of the ship’s personnel for each installed controller system. Training shall comprise operation and maintenance of the new equipment. The contractor shall provide a course document or syllables to the USCG for review 60 calendar days prior to conducting the first training. The training shall include at a minimum but is not limited to:

a. Hands on training

b. Operational theory

c. Review of maintenance documentation

d. Review of start-up and operational procedures

e. Settings and adjustments

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f. Emergency procedures

3.3.15.1 The location and time of training will be onboard the cutter receiving the installation.

3.3.15.2 Training materials will be limited to the onboard technical documentation provided for the new equipment plus any additional training documents which will be provided by the Contractor and included in the training.

3.3.15.3 The Contractor shall prepare and sign a statement regarding the completion of training. The Contracting Officer Representative (COR) or his/her representative shall obtain a release signature before departure of the contractor or his/her representative. The Contractor shall forward a copy of the signed release document to the Contracting Officer (KO).

3.3.16 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.

3.3.17 Schedule Requirement – The Contractor shall participate in regularly scheduled status meetings and adhere to the following schedule (all days refer to calendar days):

ITEM SCHEDULE DUE BY

11 Equipment Delivery 8 Weeks after task award

12 Equipment Removal & Installation

7 Calendar days after equipment delivery

13 System Op-test/Inspection

1 Calendar day after equipment removal and install

14 Training 7 Calendar days after system Op-test/Inspection

3.4 Integrated Logistics Support – The Contractor shall provide the following logistical support and information for the controller system. Revised documentation in response to the Government’s initial review shall be deliverable prior to any subsequent controller system deliveries. Modifications made to the equipment provided during the term of the contract must be accompanied by updates of all the following that relate to those changes.

3.4.1 Engineering Data for Provisioning (EDFP) - The Contractor shall provide Engineering Data for Provisioning (EDFP) including technical manuals, Page 26 of 37 REV - 0 drawings, and specifications in accordance with SFLC Document D-083-0351. The EDFP shall include a parts list containing all of the installed parts, the original equipment manufacturer (OEM), OEM part or assembly numbers, the OEM’s name and address, the OEM’s cage code, quantity used in each equipment, and shall be keyed to the provided drawings. All spare parts necessary for overhaul of a unit shall be identified in the printed technical documents supplied.

3.4.2 Recommended Spare Parts List - The Contractor shall provide with the EDFP/PTD a recommended spare parts list for onboard repair parts (OBRP) and stock system parts. The spare parts list shall list applicable manufacturer’s maintenance tasks for each line item (both preventive and corrective).

3.4.2.1 Onboard Spare Parts – Onboard spare parts are items that unit personnel can replace without additional special tools or technical support.

3.4.2.2 System Stock - System stock shall be the long lead time materials (materials with lead times over 90 calendar days) and manufacturer designated critical items.

3.4.2.3 The spare parts list shall include spare parts prices and their lead times at the time of delivery of the equipment.

3.4.2.4 The OBRP shall be sufficient to perform shipboard maintenance on the equipment for two years.

3.4.2.5 The spare parts list shall be quantified into the number of spares needed per the equipment installed.

3.4.3 OEM Maintenance Requirements - The Contractor shall provide OEM maintenance recommendations, in addition to the maintenance recommendations in the Technical Publication, to allow for USCG development of Maintenance Procedure Cards.

Guidance for providing this information can be found in Chapter 5 of the USCG Planned Maintenance System Development Process Guide, CGTO PG-85-00-230-S.

The Contractor shall identify the following line items, at a minimum:

a. Applicable Maintenance Task Code

b. Maintenance Procedure Title

c. Maintenance Procedure Interval

d. Maintenance Procedure Description

e. Maintenance Procedure Sequenced Tasks

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f. Maintenance Procedure

g. Maintenance Procedure Task Type

h. Associated Parts Logistics Code Number

i. Associated Parts Name

j. Associated Parts Part Number

k. Quantity of Parts per Maintenance Task

l. Associated Parts Unit of Issue

m. Associated Parts Shelf Life

n. Associated Parts Unit Price

o. Special Tools and Equipment Nomenclature

p. Special Tools and Equipment Cage

q. Special Tools and Equipment PN/NSN Task Descriptions

3.4.4 Warranty - The Contractor shall provide a minimum of a one-year commercial warranty, from date of installation. The Contractor shall provide a minimum of two years commercial storage warranty from date of delivery.

3.4.5 Delivery

3.4.5.1 Preservation, Packaging, and Marking

3.4.5.1.1 The new 400 HZ Motor Controller shall be preserved, packaged and marked for shipping as an Equipment Unit in accordance with SFLC-D-084-0481.