01004_A_NSTR_Upgrade_Station_6_Rev_P4.docx

USNS WALLY SCHIRRA

(T-AKE 8)

1.0 ABSTRACT:

1.1. This work item describes the requirements for upgrade of UNREP Station No. 6, including:

1.1.1. Structural removal of UNREP Station No. 6 Motor Control Room (MCR) foundations and backing structure and Sliding Block Drive Jaw Clutch housing brackets.

1.1.2. Structural installation of UNREP Station No. 6 MCR foundations and backing structures for relocated Navy Standard UNREP system components and new NSTR Drive Cabinets.

1.1.3. Mechanical modifications to UNREP Station No 6 Highline and Hauling Winches and the installation of a new Sliding Block Drive encoder assembly mount.

1.1.4. Electrical modifications to UNREP Station No 6 MCR Ventilation, Lighting Components, and miscellaneous electrical components, cabling and Penetrations.

1.1.5. Post installation inspection and functional testing, No Load Testing, Static Load Testing, Structural Integrity Testing, Rated Load Testing, Overload Testing and system operational testing.

2.0 REFERENCES:

2.1. NAVSEA Drawing 53711-100-8289440, T-AKE 8, NSTR UPGRADE STATION 6 - TEMPORARY SHIPPING ACCESS MOTOR CONTROL ROOM - 01 LEVEL

2.2. NAVSEA Drawing 53711-180-8289441, T-AKE 8, NSTR UPGRADE STATION 6 - CONTROL BOOTH MODS 02 LEVEL

2.3. NAVSEA Drawing 53711-180-8289442, T-AKE 8, NSTR UPGRADE STATION 6 – FOUNDATION REMOVALS MOTOR CONTROL ROOM 01 LEVEL

2.4. NAVSEA Drawing 53711-180-8289443, T-AKE 8, NSTR UPGRADE STATION 6 – FOUNDATION INSTALLATION MOTOR CONTROL ROOM 01 LEVEL

2.5. NAVSEA Drawing 53711-302-8289444, T-AKE 8, NSTR UPGRADE STATION 6 – ELECTRICAL REMOVALS

2.6. NAVSEA Drawing 53711-302-8289445, T-AKE 8, NSTR UPGRADE STATION 6 – LIGHTING MODIFICATIONS

2.7. NAVSEA Drawing 53711-302-8289446, T-AKE 8, NSTR UPGRADE STATION 6 – DETAILED WIRING DIAGRAM

2.8. NAVSEA Drawing 53711-321-8289447, T-AKE 8, NSTR UPGRADE STATION 6 – CABLE ROUTING & PENETRATION MODS

2.9. NAVSEA Drawing 53711-445-8289448, T-AKE 8, NSTR UPGRADE STATION 6 – MOTOR CONTROL ROOM MODS 01 LVL

2.10. NAVSEA Drawing 53711-512-8289449, T-AKE 8, NSTR UPGRADE STATION 6 – MISC. HVAC MODIFICATIONS - 01 LEVEL FR 51.5 - 58 (P)

2.11. NAVSEA Drawing 53711-521-8289451, T-AKE 8, NSTR UPGRADE STATION 6 – WINCH CTRL & PUSH/PULL CABLE MODS, 01 - 02 LVL, (P)

2.12. NAVSEA Drawing 53711-180-8289452, T-AKE 8, NSTR UPGRADE STATION 6 – BACKING STRUCTURE INSTALLATION, 01 LEVEL

2.13. NAVSEA Drawing 53711-521-8289453, T-AKE 8, NSTR UPGRADE STATION 6 – TEST REQUIREMENTS

2.14. NAVSEA Drawing 53711-521-8289454, T-AKE 8, NSTR UPGRADE STATION 6 – SLIDING BLOCK DRIVE MOD DETAILS

2.15. NAVSEA Drawing 53711-521-8289455, T-AKE 8, NSTR UPGRADE STATION 6 – HIGHLINE WINCH MODS

2.16. NAVSEA Drawing 53711-521-8289456, T-AKE 8, NSTR UPGRADE STATION 6 – HAULING WINCH MODS

2.17. NAVSEA Drawing 53711-521-8289306, – NSTR RAM TENSIONER

3.0 ITEM LOCATION/DESCRIPTION:

3.1. Location/Quantity:

3.1.1. Locations: Various

3.1.2. Quantity: None Additional

3.2. Item Description/Manufacturer's Data:

3.2.1. Bill of Materials: None Additional

3.2.2. 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, bus work, 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. The contractor shall supply material to repair deck, insulation, and other material damaged or removed in the course of this installation.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1. Government Furnished Equipment:

4.1.1. One NSTR RAS Highline Winch Drive Enclosure

4.1.2. One NSTR RAS Hauling Winch Drive Enclosure

4.1.3. One NSTR RAS STREAM Power Panel

4.1.4. One NSTR RAS RAM/ARC Panel

4.1.5. One NSTR RAS HW/SB Control Panel

4.1.6. One NSTR RAS Twin Master Operator

4.1.7. One NSTR Local Control Panel (RAS Highline Winch)

4.1.8. One NSTR Local Control Panel (RAS Hauling Winch)

4.1.9. Two Local Control Panels

4.1.10. Twenty-five Encoder Cable

4.1.11. One Sliding Block Drive Encoder Mount Assembly w/encoders, sprockets and Roller Resolver chain.

4.1.12. One NSTR Ram Tensioner Encoder Assembly

4.2. Government Furnished Technical Services: The Government will provide an In-Service Engineering Agent (ISEA) representative from Naval Surface Warfare Center, Port Hueneme Division to respond to inquiries regarding technical requirements/interpretations in support of the NSTR upgrade of UNREP Station No. 6.

5.0 NOTES:

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 GTR’s including but not limited to GTR’s 1 through 7, 22, 23, 25, 26, 27, 28 and 29.

5.2. The Contractor and all subcontractors, regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED:

7.1. Arrangement/Outfitting:

7.1.1. Removals:

7.1.1.1. Disconnect Highline Winch Controlex cable assembly and Hauling Winch Controlex cable assemblies A & B using reference 2.11 as guidance. Cable assemblies shall be stowed and protected for reassembly.

7.1.1.2. Remove the following components from the UNREP Station No. 6 Kingpost: Geared Limit switch (retain for reinstallation), mounting plates and coupling using reference 2.14 as guidance.

7.1.2. Installations:

7.1.2.1. Install new components, assemble and adjust NSTR Sliding Block Drive position indication components as specified in the general notes of reference 2.14.

7.2. Structural:

7.2.1. Removals:

7.2.1.1. Remove Geared Limit switch mounting brackets using reference 2.14 as guidance.

7.2.1.2. Cut and remove temporary shipping access supporting shipping of NSTR power and control system equipment into UNREP Station No. 6 Motor Control Room (01-54-2) using reference 2.1 as guidance.

7.2.1.3. Remove approximately 7’section of foundation supporting MCR06-01 Gypsy Winch #1 Motor Controller, MCR06-02 Highline Winch Motor Controller, MCR06-03 Highline Winch Replenishment Pump Motor Controller, MCR06-08 Hauling Winch Replenishment Pump Motor Controller, MCR06-06 Hauling Winch Motor Controller, MCR06-04 & 05 Highline Winch ASD Motor Controller, and MCR06-09 & 10 Hauling Winch ASD Motor Controller using reference 2.3 as guidance.

7.2.1.4. Remove Uninterruptable Power Supply (UPS) foundation & sway brace, motor control room common foundation with upper support, and transformer mounting clips from the Station 6 Motor Control Room (01-54-2) using reference 2.3 as guidance.

7.2.2. Installations:

7.2.2.1. Install mounting bracket inside jaw clutch housing for new Sliding Block Drive system resolvers using reference 2.14 as guidance.

7.2.2.2. Reinstall temporary shipping access upon completion of shipping of NSTR drive system equipment into UNREP Station No. 6 Motor Control Room (MCR) (01542) using reference 2.1 as guidance.

7.2.2.3. Install twelve (12) equipment mounting pads for NSTR Winch Drive Cabinets in the UNREP Station No. 6 MCR, using reference 2.4 as guidance.

7.2.2.4. Install backing structure for NSTR Drive Cabinets using reference 2.12 as guidance.

7.2.2.5. Install two (2) equipment sway-brace assemblies for UPS in the UNREP Station 6 MCR using reference 2.4 as guidance.

7.2.3. Relocations: None

7.3. Mechanical/Machinery:

7.3.1. Removals:

7.3.1.1. Remove ventilation duct in UNREP Station No. 6 Motor Control Room (01-54-2) and Electric Substation LCB (01-56-2) using reference 2.10 as guidance. Retain components as specified in reference 2.10 for reinstallation.

7.3.1.2. Remove Highline Winch components and disposition using reference 2.15 as guidance.

7.3.1.3. Remove Hauling Winch components and disposition using reference 2.16 as guidance.

7.3.1.4. Remove ARC sending unit and ARC cable bracket using reference 2.17 as guidance.

7.3.2. Installations:

7.3.2.1. Perform modifications to Sliding Block Drive system lower drive shaft and install driveshaft extension using reference 2.14 as guidance.

7.3.2.2. Install Vaneaxial Fan, Filter Housing and new ventilation duct in UNREP Station No. 6 Motor Control Room using reference 2.10 as guidance.

7.3.2.3. Install new Highline Winch components and disposition using reference 2.15 as guidance.

7.3.2.4. Install new Hauling Winch components and disposition using reference 2.16 as guidance.

7.3.2.5. Install new ram encoder support bracket and cable weldment bracket using reference 2.17 as guidance.

7.3.3. Relocations: None

7.4. Electrical:

7.4.1. Removals:

7.4.1.1. Remove and disposition multiple electrical cables supporting UNREP Station 6 UNREP equipment as detailed in the removal list of materials of reference 2.9.

7.4.1.2. Remove NSTR Stream Power Panel (SPP), Ram/Automatic Ram Control (RAM/ARC) Panel, Hauling Winch/Sliding Block (HW/SB) Control Panel, Twin Master Operator and Servo Motor from Station 6 UNREP Control Booth using reference 2.5 as guidance.

7.4.1.3. Remove all Sliding Block Drive system geared limit switch and retain for reinstallation using reference 2.14 as guidance.

7.4.1.4. Remove UNREP Station No. 6 Electrical Equipment, Cargo Handling Power and Control System Equipment using reference 2.4 & 2.5 as guidance. Retain Gypsy Winch No. 1, 2 & 3, RAS KP Sliding Block Control, RAS KP Sliding Block Drive Motor Controller Cabinets, Hauling Winch Air Clutch Overload Relay Blower Motor, UPS Battery Rack and Transformer for installation.

7.4.2. Installations: The method of termination of cables and grounding of shields is critical to the operation of NSTR equipment; specific requirements for termination of cables and grounding of shields are provided in the general notes of reference 2.7.

7.4.2.1. Install new NSTR SPP, RAM/ARC Panel, HW/SB Control Panel, Twin Master Operator and Servo Motor in the Station No. 6 Control Booth using reference 2.2 & 2.7 as guidance.

7.4.2.2. Install new UNREP Electrical Equipment, Cargo Handling Power and Control System Equipment using reference in the Station No 6 MCR 2.7 as guidance.

7.4.2.3. Install and connect electrical cables from IDS panel (01-48-2), UNREP Station No. 6 Motor Control Room to the Battery Pack Enclosure and Transformer using reference 2.7 as guidance.

7.4.2.4. Install Electrical Penetrations and MultiCable Transits using reference 2.7 as guidance.

7.4.2.5. Install temperature switch mounts (DIN rail, mounting bracket and DIN terminal block end stops) and temperature switch using reference 2.7 as guidance.

7.4.2.6. Install NSTR STREAM Power Panel in the UNREP Station 6 Control Booth using reference 2.2 & 2.7 as guidance.

7.4.2.7. Install Highline Winch and Hauling Winch Local Control Panels adjacent to their respective winches on the 02 Level Winch Deck using reference 2.7 as guidance.

7.4.2.8. Reinstall Gypsy Winch No. 1, 2 & 3, RAS KP Sliding Block Control, RAS KP Sliding Block Drive Motor Controller Cabinets, Hauling Winch Air Clutch Overload Relay Blower Motor, UPS Battery Rack and Transformer using reference 2.7 as guidance.

7.4.2.9. Install NSTR RAS Highline Winch and Hauling Winch Drive Enclosures (2 total) in UNREP Station 6 MCR using reference 2.7 & 2.9 as guidance.

7.4.2.10. Install, route and hook-up electrical cabling supporting the equipment installed via paragraphs 7.4.2.1 – 7.4.2.9 above using reference 2.8 as guidance.

7.4.3. Relocations:

7.4.3.1. Relocate lighting fixtures in the UNREP Station No. 6 Motor Control Room (01-54-2) using reference 2.6 as guidance.

7.5. Electronics: None

7.6. Preparation of Drawings/Documentation:

7.6.1. Provide detailed red line markup of each drawing (three (3) paper copies and one (1) electronic copy) within 2 weeks of completing the work depicted on each drawing.

7.7. Inspection/Test:

7.7.1. Conduct post installation inspections and functional tests of Highline and Hauling Winches using the general notes of reference 2.13 as guidance.

7.7.2. Conduct static load testing of the Highline and Hauling Winches using the general notes of reference 2.13 as guidance.

7.7.3. Conduct no load testing of the Highline and Hauling Winches using the general notes of reference 2.13 as guidance.

7.7.4. Conduct dynamic overload testing of the Highline and Hauling Winches using the general notes of reference 2.13 as guidance.

7.7.5. Conduct rated load testing of the Highline and Hauling Winches using the general notes of reference 2.13 as guidance.

7.7.6. Conduct system operational testing of UNREP Station No. 6 NSTR equipment using the general notes of reference 2.13 as guidance.

7.8. Painting/Insulation/Deck Covering:

7.8.1. Paint all new and modified surfaces to match surrounding surfaces.

7.9. Marking: Fabricate and install name plates, label plates, notices, and markings for all new and modified systems. Label Plates to be built and located using reference 2.13 as guidance.

7.10. Manufacturer's Representative:

7.10.1. Government Technical Representative: The Government will provide an In-Service Engineering Agent (ISEA) representative from Naval Surface Warfare Center, Port Hueneme Division to respond to inquiries regarding technical requirements/interpretations in support of the NSTR upgrade of UNREP Station No. 6.

8.0 General Requirements: None Additional

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