11.1__Work_Item_308.1_Upgrade_Switchboards.pdf

USS FRANK CABLE

(AS-40)

ELECTRICAL 8 February 2016 ITEM NO.308.1 Category “A” TMMG/GRILLS/DNG

UPGRADE SWITCHBOARDS

308.1-1

1.0 ABSTRACT

This item describes the requirements to upgrade Ship Service (1S and 2S) and Ship Along Side (1SAS and 2SAS) switchboards.

2.0 REFERENCES

2.1 MSC Drawing 803-7081122, General Technical Requirements

(GTRs)

2.2 MSC Drawing 301-8496019, 1S Switchboard Mod Incidental

to Circuit Breaker Replacement

2.3 MSC Drawing 301-8496020, 2S Switchboard Mod Incidental

to Circuit Breaker Replacement

2.4 MSC Drawing 301-8496021, 1SAS Switchboard Mod

Incidental to Circuit Breaker Replacement

2.5 MSC Drawing 301-8496022, 2SAS Switchboard Mod

Incidental to Circuit Breaker Replacement

2.6 IEEE Standard 45, Recommended Practice for Electric

Installations on Shipboard

2.7 DOD-STD-2003-1, Department of Defense Standard Practice

Electric Plant Installation Methods for Surface Ships and Submarines (Cable)

2.8 MSC Drawing 302-4792483, Coordination of Circuit

Breakers

2.9 MSC Drawing 320-8496061, 1S Switchboard Test Procedure

2.10 MSC Drawing 320-8496062, 2S Switchboard Test Procedure

2.11 MSC Drawing 320-8496063, 1SAS Switchboard Test

Procedure

2.12 MSC Drawing 320-8496064, 2SAS Switchboard Test

Procedure

2.13 TE681-AS-MMO-010, Technical Manual for Switchboards:

Ships Service, 1S, 1SAS, 2S, 2SAS, 1E, and Control Unit for USS Frank Cable (AS-40)

2.14 302-8389031, Power Distribution System One-Line Diagram

2.15 302-8389032, Power System Load Analysis

2.16 302-8389010, AS 40 Fault Current Analysis

308.1-2

2.17 MIL-DTL-16036L, Switchboard, Power, Low Voltage, Naval

Shipboard

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity:

3.1.1 Location

a. 1S Ship Service Switchboard, Engine Room 5- 110-0-E

b. 2S Ship Service Switchboard, Engine Room 5- 110-0-E

c. 1SAS Switchboard, Engine Room 5-110-0-E

d. 2SAS Switchboard, Engine Room 5-110-0-E

3.1.2 Quantity: None

3.2 Item Description/Manufacturer’s Data

3.2.1 Bill of Material

a. See References 2.2 through 2.5.

b. Quantities are considered estimates. The contractor shall provide the exact quantities and additional material such as miscellaneous pipe fittings, elbows, caps, valves, pipe hangers, weld material, cable hangers, cable tags, buswork, etc., which are not included in the List of Materials, in order to install a fully functional system which meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM): None

4.3 Government Furnished Services: (GFS):

4.3.1 ABS surveyor onsite services will be provided

and funded by MSC under a separate contract.

4.3.2 Shipyard support services will be provided and

funded by MSC under a separate contract.

4.4 Government Furnished Information (GFI): None

5.0 NOTES

308.1-3

5.1 The contractor and all subcontractors, regardless of

tier, must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors, regardless of tier, must comply with the requirements of all applicable GTRs, including but not limited to GTRs 1 through 7, 21, 22, 23, 24, 25, 26, 28 and 29.

5.2 The contractor and all subcontractors, regardless of

tier, are advised to review other work items under this contract, including but not limited to Work Items 308.2, 308.3, and 308.7, to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3 A shipyard shall furnish temporary power, lighting, and

ventilation, as well as crane, forklift and heavy-laborer services required in this work item under a separate contract. It is the contractor’s responsibility to coordinate all work with the shipyard Technical Point of Contact (TPOC) and onsite MSC Representative (MSCREP).

5.4 A shipyard shall provide, install and operate a load

bank and associated cabling in support of tests required in this work item under a separate contract. It is the contractor’s responsibility to coordinate all testing with the shipyard TPOC and MSCREP.

5.5 Switchboard upgrade personnel shall be responsible to

disconnect/remove and install/connect all electrical cables associated with Work Item 308.3 and associated electrical connections internal to switchboards.

6.0 QUALITY ASSURANCE REQUIREMENTS

6.1 All work shall be performed to the satisfaction of the

onsite MSCREP, Port Engineer, ABS Surveyor, and ship’s Chief Engineer.

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting

7.1.1 Remove all interference items necessary to

accomplish the requirements of this Work Item. Mark, protect and properly store all interference items removed. Reinstall

308.1-4 interference items and prove them operational when the requirements of this Work Item are complete.

7.2 Structural:

7.2.1 Removals

a. Remove 1S, 2S, 1SAS, and 2SAS switchboard front and rear covers using Removal Notes R-1 and R-2 of References 2.2 through 2.5 as guidance. Mark, protect and properly store 1S and 2S FDC Breaker covers and associated hardware for reuse.

b. Remove 1SAS and 2SAS switchboard Vent Fan filters using Detail 39-B and General Note 3 of References 2.4 and 2.5 as guidance.

c. Dispose of removed material as directed by the MSCREP.

7.2.2 Modifications

a. Modify switchboard top covers using Detail 36-D and Sheet 5, Note 2 of References 2.2 through 2.5 as guidance. Mark, protect and properly store all top covers upon completion of modifications.

b. Prior to making vent cuts identified in section 7.2.2.a, provide temporary non-conductive covering inside switchboards over all electrical components to minimize contamination of switchboard components by debris.

7.2.3 Fabrications

a. Provide all material and fabricate 24 each, Hinged and Latched Doors to replace removed front covers for 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

b. Provide all material and fabricate 26 each, Vent Hoods for Hinged and Latched Doors for 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

c. Provide all material and fabricate 40 each, Rear Covers, complete with Handles, to replace removed rear covers for 1S, 2S, 1SAS, and 2SAS switchboards using References

2.2 through 2.5 as guidance.

308.1-5

d. Provide all material and fabricate 20 each, Vent Hoods for rear covers for 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

e. Provide all material and fabricate 8 each, Roof Vent Assemblies for 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

f. Provide all material and fabricate 4 each, Blanking Plates for 1SAS, and 2SAS switchboards using Detail 39-B and General Note 3 of References 2.4 and 2.5 as guidance.

7.2.4 Installations

a. Template bolt-hole patterns from existing shipboard conditions, where appropriate. Template new mating surfaces together to ensure bolt-hole patterns align, where appropriate.

b. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 24 each, Hinged and Latched Doors to replace removed front covers on 1S, 2S, 1SAS, and 2SAS switchboards using Installation Note I-4 of References 2.2 and 2.3 and Installation Note I-3 of References 2.4 and 2.5 as guidance. Reinstall 1S and 2S FDC Breaker covers and associated hardware retained in Section 7.2.1.a.

c. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 26 each, Vent Hoods on Hinged and Latched Doors on 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

d. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 40 each, Rear Covers, to replace removed rear covers on 1S, 2S, 1SAS, and 2SAS switchboards using Installation Note I-5 of References 2.2 and 2.3 and Installation Note I-4 of References

2.4 and 2.5 as guidance.

e. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 20 each, Vent Hoods on rear covers for 1S, 2S, 1SAS, and 2SAS switchboards using References 2.2 through 2.5 as guidance.

308.1-6

f. After completion of electrical work identified on this Work Item, remove temporary non-conductive covering from switchboard, installed to minimize contamination of switchboard electrical components during roof vent modifications.

g. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 8 each, Roof Vent Assemblies on 1S, 2S, 1SAS, and 2SAS switchboards using Installation Note I-6 of References 2.2 and

2.3 and Installation Note I-5 of References 2.4 and 2.5 as guidance.

h. After completion of electrical work identified on this Work Item, provide all mounting hardware and install 4 each, Blanking Plates on 1SAS, and 2SAS switchboards using Detail 39-B and General Note 3 of References 2.4 and 2.5 as guidance.

7.3 Mechanical/Fluids: None additional

7.4 Electrical

7.4.1 Accomplish all work required under this work

item using References 2.6 and 2.7 as guidance.

7.4.2 Removals

a. Remove 6 each, NDC, 51 each, KDC Circuit Breakers and associated Trip Elements from 1S and 2S switchboards using Removal Note R-3 of References 2.2 and 2.3 as guidance.

b. Remove FDC Circuit Breaker 1S-4P-(2-72-2) from 1S switchboard and FDC Circuit Breaker 2S-4P-(1-116-2)(1) from 2S switchboard using Removal Note R-3 of References 2.2 and

2.3 as guidance.

c. Remove 60 each, SAS Station KDC Circuit Breakers and associated Breaker Bases (60 each), Installation Plates (60 each), and Run Back Busses [180 each (to 2” horizontal switchboard bus)] from 1S, 2S, 1SAS and 2SAS switchboards using Removal Note R-4 of References 2.2 and 2.3 and Removal Note R-3 of References 2.4 and 2.5 as guidance.

d. Remove 3 each, ¼” X 1½” copper buswork from 1S switchboard using Removal Note R-5 of Reference 2.2. Retain removed ¼” X 1½” copper buswork to utilize to template mounting holes for replacement buswork.

308.1-7

e. Remove 1SAS and 2SAS switchboard Vent Fans using Detail 39-B and General Note 3 of References 2.4 and 2.5 as guidance.

f. Dispose of all removed material and components as directed by the MSCREP.

7.4.3 Modifications

a. Modify approximately 180 cable leads, internal to the switchboards, that were previously spliced.

b. Remove existing splices where any one or more of the following conditions are detected:

Splices are located in cable bend radii.

Splices result in insufficient lead lengths to allow for proper support of cable leads.

Splices result in mechanical stress to breaker connection terminals.

c. Provide and install new cable lead extensions from new splice points to breaker termination points.

Provide sufficient lead lengths to insure leads are properly routed and supported to prevent stress on breaker terminal connections. Properly insulate and stagger splices to minimize potential short-circuit faults.

d. Treat all cable lead splices as single conductor cable and assemble in accordance with Method 1E-2-1 of Reference 2.7.

7.4.4 Installations

a. Provide all material and install new NGC, KDC and LGC circuit breakers and associated plug-in assembly, mounting pan and trip units in 1S and 2S switchboards using Installation Notes I-1 and I-2 of References 2.2 and 2.3, and 2.8 as guidance.

b. Provide all material and install run back bus and run back supports in 1S and 2S switchboards using Installation Notes I-3 and I-7 of References 2.2 and 2.3 as guidance.

308.1-8

c. Provide all material and install new ¼” X 2” horizontal bus in 1S switchboard using Installation Note I-8 of Reference 2.2 as guidance. Template mounting holes utilizing buswork retained in paragraph 7.4.2.c as guidance.

d. Provide all material and install new FDC circuit breakers in 1S and 2S switchboards using Installation Note I-9 of Reference 2.2, Installation Note I-8 of Reference 2.3, and 2.8 as guidance.

e. Provide all material and install new LGC circuit breakers and associated plug-in assemblies and mounting pans in 1SAS and 2SAS switchboards using Installation Note I-1 of References 2.4 and 2.5, and 2.8 as guidance.

f. Provide all material and install run back bus and run back supports in 1SAS and 2SAS switchboards using Installation Notes I-2 and I-6 of References 2.4 and 2.5 as guidance.

g. Set all 1S, 2S, 1SAS and 2SAS switchboard circuit breakers in accordance with Reference 2.8.

7.5 Electronics: None additional

7.6 Preparation of Drawings/Documentation

7.6.1 Upon completion of upgrades to the 1S, 2S, 1SAS, and 2SAS switchboards, revise References 2.2 through 2.5 and 2.8 through 2.12 to incorporate the as-is results of this work item and Work Item 308.3.

7.6.2 Incorporate revised References 2.2 through 2.5

into Reference 2.13, where appropriate.

7.6.3 Make redline changes to References 2.14 through

2.16 to incorporate the as-is results of this work item and Work Item 308.3.

7.6.4 Deliver updated references 2.2 through 2.5 and

2.8 through 2.13 and the redlined References 2.14 through 2.16 to the MSCREP within thirty (30) days of successful completion of inspections and tests. Deliver copies of revised drawings and test procedures, 1 each in AutoCAD and 1 each in .pdf; revised technical manual, 1 each in MS Word and 1 each in .pdf; and redlined drawings, 1 each in a format acceptable to the MSCREP.

7.7 Inspection/Test

308.1-9

7.7.1 Inspections

a. Clean all switchboards prior to final acceptance. Remove all dirt, dust, foreign objects and fabrication debris upon completion of removals, installations, modifications and repairs. Notify the MSCREP and the Chief Engineer to inspect switchboards for cleanliness prior to final closeout and before energizing switchboards.

b. Verify all connections are properly torqued using Section 3.10 of Reference 2.17 as guidance.

c. Inspect all welds in accordance with the shipyard’s Quality Assurance Plan. Deliver a copy of a report containing the results of all weld inspections associated with this work item to the ABS Surveyor, MSCREP and the ship’s Chief Engineer for approval. Where the ABS or MSCREP deems necessary, perform Nondestructive Tests (NDT) at no additional cost to the Government. MSC reserves the right to reject any welds based on a visual inspection, review of the inspection report, or result of the NDT.

7.7.2 Tests

a. Perform switchboard testing using References

2.9 through 2.12 as guidance. Test and calibrate the ships new SAS Switchboard breakers at rated loads per station. The SAS breakers are rated at 450VAC, 3PH, .8PF, 400 amps. The stations are rated at 450VAC, 3PH, .8PF, 4000 amps. Contractor to assume two weeks of testing and troubleshooting. Testing may not occur immediately upon completion of installation of breakers and shall be coordinated by the contractor with the shipyard and MSCREP.

See Note 5.4.

b. ABS Surveyor and MSCREP shall witness and approve workmanship during performance of all work and accomplishment of all test procedures.

7.8 Painting

7.8.1 Paint all new and modified surfaces to match

surrounding surfaces. Touch up all surfaces where paint was damaged in the conduct of work required under this work item to match surrounding surfaces.

7.9 Markings

308.1-10

7.9.1 Fabricate and install new name plates, notices, cable tags, labels, and markings for all new or modified areas using Reference 2.1, GTR No. 29 and as noted on referenced drawings.

7.10 Manufacturer’s Representative: None additional

8.0 GENERAL REQUIREMENTS: None additional