0704_A_TSCIF_ELECTRICAL_UPGRADE.DOCX

USNS YUMA

(T-EPF 8)

SPONSOR EQUIPMENT

April 24, 2017

T-SCIF ELECTRICAL UPGRADE

1.0 ABSTRACT

This item describes the modifications and the installation of the Temporary Sensitive Compartment Information Facility (T-SCIF) electrical upgrade on the USNS YUMA.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 MSC Drawing No. 401-8496958 – Trenton T-SCIF Secure Facility Infrastructure Installation (REDLINE)

2.1.2 MSC Drawing No. 184-8497002 – T-SCIF CMD and Surveillance FDN Mods and Installations (REDLINE)

2.1.3 MSC Drawing No. 100-8497193 – Equipment Support 03 LVL, T-SCIF 03-28.1, COC 03-28-0 (REDLINE)

2.1.4 MSC Drawing No. 303-8496959 – T-SCIF Electrical Diagram

2.1.5 MSC Drawing No. 453-8497087 – T-EPF Scan Eagle Equipment Arrangement and Structural Install (REDLINE)

2.1.6 MSC Drawing No. 180-8496285 – HF-UHF Antennas, Foundations & Locations (REDLINE)

2.1.7 NAVSEA Drawing 8443364, General Arrangement and Profile Drawings

2.1.8 NAVSEA Drawing 631-8443387, JHSV Paint Schedule

2.1.9 MSC Drawing No. 803-7081122, MSC General Technical Requirements (GTR).

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: 05 level Weather Deck, 03 level C4I spaces COC Room (03-28-0), SCO Office (03-35-0) & Briefing Room (03-28-1).

3.1.2 Quantity: Various, use references 2.1.1 to 2.1.6 for guidance.

3.1.3 Quantities are considered estimates. The contractor shall provide the exact quantities and additional material such as paint, weld material, cable hangers, cable tags, fasteners, 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): None

5.0 NOTES:

5.1 The contractor and all subcontractors, regardless of tier, must consult the General Technical Requirements (GTR’s) 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, and 21 through 29. GTR’s are provided as reference 2.1.9.

- These requirements are provided as reference but may also be downloaded at: http://www.msc.navy.mil/instructions/pdf/m470016.pdf

5.2 The contractor and subcontractors, regardless of tier are advised to review other work items under this contract, to determine their effect on the work required by this item. Based on this review the contractor shall plan and schedule work to minimize conflicts between work items.

5.3 Services and materials not listed as Government Furnished in Part 4.0 shall be furnished by the Contractor. The Contractor shall provide all labor and material required to accomplish this work item including but not limited to Marine Chemist, staging, space certification, gas free certification, contamination containment, fire watches, removal and reinstallation of all interferences including insulation and deck coverings in way of repairs to effect a complete and finished end result.

5.4 The contractor must submit a Request for Deviation (RFD) to the MSC Representative (MSCREP) for approval for any areas that appearance, function, and strength are impaired. Upon MSCREP approval minor deviations from the drawings will be authorized if the appearance, function, and strength are not impaired.

5.5 New cable and/or mounting of equipment that requires welding or hot work performed in the service areas (from the interior or exterior) must maintain fire tight integrity to the satisfaction of the MSCREP and the ABS surveyor.

5.6 Any vacated penetrations or equipment removal from the service areas must be plugged and sealed for water tightness and fire tightness to the satisfaction of the MSCREP and the ABS surveyor.

5.7 The contractor must open, vent and furnish a Chemist to provide gas free certification for spaces requiring hot work. Gas Free chits must also be signed and approved by the ships Chief Mate or his designated representative daily until work is completed.

5.8 Prior to initiating any work on the electrical system, de-energize and tag-out all sources of electrical power to the circuits involved in accordance standard electrical safety practices and MSC Lockout Tagout Procedure. Restore electrical power upon completion of all aspects of this work item.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work, testing and materials shall be in accordance with the latest SOLAS regulations, ABS Rule Set, IEEE-STD-45, MIL-STD-1310(G), USCG Requirements, and to the satisfaction of and in the presence of the MSC Representative (MSCREP), ABS Surveyor, and Manufacturer’s Representatives (as required.

6.1.1 All disturbed surfaces shall be repaired utilizing approved methods maintaining the water tight, fire tight, or smoke tight integrity of the bulkheads, decks or equipment.

6.1.2 All shipboard structure, hull insulation, sheathing, etc damaged or disturbed by these modifications shall be repaired similar to the original or surrounding materials.

6.2 Welding shall be accomplished using pulse GMAW to reduce heat in way of welding.

6.2.1 All requests for deviation will require MSC REP and ABS approval prior to cutting or welding. Approval will be based on the weld procedure specification and controls.

6.2.2 GMAW short circuit transfer process shall not be used for any welding unless previously approved by MSC REP and ABS Surveyor.

6.2.3 Pulse GMAW shall be used on repairs and installs where deck plate thickness is below 6mm.

6.3 The contractor shall provide material certs, welder certs, and an ABS approved, ‘reduced heat’ weld procedure specification (WPS) to the MSC REP and ABS surveyor prior to commencing work required to accomplish this work item.

6.3.1 All material, including prefabricated installations, shall be traceable to the material certifications and verified prior to installation.

6.3.2 The welding sequence shall be included in the WPS.

6.3.3 Where welding to thinner aluminum (below 6mm thick) welder certs shall clearly show welder is certified to weld on/to plate thicknesses in question (i.e. welding 25mm plate to 3mm plate will require a weld cert and procedure that shows welder is qualified to complete that work).

6.3.4 All Aluminum Alloy that contains a magnesium content higher than 3%, that will be installed on the exterior of the ship will be required to meet ASTM B928. Where this material is tested using ASTM/G67 testing, the test cert may be used up to 12 months from the date of the certification without further testing. If the certification is over a year old, the aluminum must either be retested via ASTM/G67 testing or through surface preparation penetrant inspection (PT), whichever is lower in cost. Surface preparation PT will include 100 percent PT of four (4) inches from the expected weld area. The PT inspected surfaces shall be free of discontinuities such as linear indications or defects that may affect weld quality of the condition of the base material. If discontinuities exist, a condition found report (CFR) shall be submitted to the MSC REP and ABS surveyor prior to fit-up. After inspection the surfaces shall be thoroughly cleaned.

6.4 All welds and cutting, to and on, thin plate shall meet the requirements for a reduced heat weld process as stated in this work item.

6.4.1 Thin plate is considered plate below 6mm thick.

6.5 All welding requirements shall be accomplished by ABS certified welders and meet MSC REP, ship class welding details, ABS and AWS requirements. All welders shall be certified to perform the type of welding required and documentation of such shall be current. Fire watches shall be posted by the Contractor during hot work.

6.5.1 For aluminum hull:

6.5.1.1 ABS Rules for Material and Welding (Part 2) – Aluminum and Fiber Reinforced Plastics (FRP) (latest revision).

6.5.1.2 AWS D3.7.

6.6 Contractor shall ensure heat on new and existing materials is kept to a minimum in way of removal, installation and repair.

6.6.1 Plasma Arc Cutting shall NOT be used for material cutting unless previously approved by MSC REP.

6.7 The contractor shall use protective enclosures to ensure a draft free environment.

6.8 The contractor shall clean and gas free affected enclosed spaces per SMS Procedure 2.1-010-ALL (Hotwork) as approved by the ship and/or MSC REP.

6.9 Recommended wire is 5183. Typical brands that are ABS approved are Lincoln, Alcotech, and Maxal. Contractor shall verify material requirement with the MSC REP and ABS prior to starting any work.

6.10 Circular saws, reciprocating saws, portable band saws, and saber saws. Cut edges shall be smooth, uniform, and free from burrs, tears, and cracks. A rough surface shall be milled, filed, deburred, or sanded to make it smooth. Plasma cutting shall not be used.

6.11 Aluminum surfaces must be thoroughly cleaned within six (6) hours of welding. Cleaning will be no less than a minimum of four (4) inches on both sides from the expected weld area prior to fit-up and welding. Cleaning shall include degreasing, then the oxide film shall be removed manually cleaned using either a carbide burr, stainless steel wire brush, aluminum oxide coated fiber wheel, or abrasive disk. Stainless steel wire brushes used for surface preparation shall be used for aluminum cleaning only. After oxide film is removed, the joint surface and adjacent base material shall be wiped clean with a rag that has been soaked in approved chemical solvent immediately prior to welding.

7.0 STATEMENT OF WORK REQUIRED

7.1 Electrical:

7.1.1 Contractor shall provide all labor, tools, parts and equipment to upgrade electrical equipment feeding Distribution Board 17 (DB17), located in C4I COC ROOM (03-28-0).

7.1.2 Contractor shall procure one (1) 45kVA transformer, model “BC45H-M/E3R/Z” from Rex Power Magnetics, to allow for 1-for-1 swap based on existing equipment dimensions. If this specific transformer model is unavailable for procurement, provide a recommendation for replacement that meets the following characteristics:

· 45 KVA 450/208/120 V Delta-WYE 60 Hz

· Transformers must comply with IEEE Std 57.12.00, IEEE Std 57.12.90 or IEC 60726 as applicable to size, application and voltage rating.

· Electrical equipment items are to be designed, constructed and tested in accordance with established industrial practices, manufacturer’s specifications. Acceptance will be based on manufacturer’s documentation which is to be made available upon request and on satisfactory performance after installation.

· For purposes of rating of equipment, a maximum ambient air temperature of 45°C (113°F) is to be assumed.

· Dry type transformers must have copper windings, be air cooled by natural circulation, and have a drip proof enclosures as a minimum.

· Enclosures and assemblies are to be constructed of steel or other suitable incombustible, moisture-resistant materials and reinforced as necessary to withstand the mechanical, electro-magnetic and thermal stresses which may be encountered under both normal and short-circuit fault conditions.

· Minimum degree of protection IP22.

· All transformers should be capable of withstanding the thermal and mechanical effects of a short circuit in the terminals of any winding for 2 seconds without damage. Foil wound transformers constructed of conductors that are uncoated must be vacuum impregnated.

· The limits of temperature rise shall be in accordance with the established industrial practice, listed above, without exceeding the recommended hot spot temperature.

· Transformers should be UL or equivalent certified.

· Transformers should be furnished with a permanently attached diagram plate that shows the leads and internal connections and their markings and the voltages obtainable with the various connections.

7.1.3 Contractor shall procure fifteen (15) feet of power cabling type: LSFSGU-100 (NSN: 6145-01-202-6956).

7.1.4 Contractor shall procure one (1) 63A rated 3-pole circuit breaker, model "LV429632" from Schneider-Electric, with Long-Time Pickup Adjustment option.

7.1.5 Coordinate with CHENG to ensure Load Center 13 and Distribution Board 17 are tagged-out prior to opening cabinets and beginning work.

7.1.6 Disconnect cables connected to existing TF020 (30kVA transformer) and remove transformer. Foundation to be re-used for new transformer if Rex Power Magnetics model is procured. If different transformer model is obtained, modify foundation to suit.

7.1.7 Install new 45kVA transformer in same location as removed 30kVA transformer.

7.1.8 Remove cable labeled "LC13-2P-203" (cable connecting TF020 and DB17) and replace with LSFSGU-100 type cable. Ensure new cable is tagged correctly.

7.1.9 Remove one (1) 50A rated 3-pole circuit breaker in position "LC13-403" within Load Center 13. Replace with procured 63A rated 3-pole circuit breaker, with Long-Time Pickup Adjustment set at 56.7A (90%). Produce and attach label plate in similar fashion as removed breaker with updated electrical characteristics.

7.1.10 Connect cables tagged “LC13-1P-403” and “LC13-2P-203” to new transformer.

7.1.11 Verify that all electrical components and cables installed or modified have been properly checked for continuity, and that all cable and equipment is operating satisfactorily.

7.2 Electronics: NONE.

7.3 Preparation of Drawings:

7.3.1 Redline drawings

7.3.1.1 At a minimum the contractors shall markup /redline one 11”x17” or larger copies of references 2.1.1 through 2.1.6 as necessary to track changes or deviations resulting from the initial ship check in section 5.3 to approved changes through installation. The drawing will remain in a previously agreed to location in one of the C4I spaces at all times. This drawing will be turned over to the MSC Port Engineer after installation is complete.

7.3.2 As built drawings

7.3.2.1 Contractor shall provide as-built drawings based on all references drawings provided and Redline drawings to capture any and all approved changes or deviations.

-Deviations include ALL changes to existing information as well as missing information from drawing. This would include but not be limited to missing weld call out, changing weld size, adding missing dimensions needed to install equipment, changes to bill of materials, changing design based on condition reports, etc.

7.3.2.2 All as-built drawing submissions will consist of at least three (3) 11”x17” hard copy prints and one (1) electronic copy on CD/DVD in AutoCAD 2007 and PDF format. These submissions will be provided to the MSCREP and the MSC Tech Library.

7.3.2.3 As-built drawings shall be provided to:

MSCREP AND MSC Tech Library 9276 3rd Ave, Bldg LP-26 Norfolk, VA 23 (NOTE: A letter shall be submitted with the drawings that contains the Contract Number, Ship Name, and Port Engineer/MSCREP details)

7.4 Inspection/Tests:

7.4.1 Shipboard Inspection:

7.4.1.1 Inspection and acceptance of material and work shall be by the ABS Surveyor and MSC representative (MSCREP).

7.4.1.2 The cognizant SSO will inspect all security related items to ensure compliance with this Work Item.

7.4.1.3 Contractor shall provide ABS and MSCREP with inspection checkpoints for fit-up, final welding and NDT as required by this specification and any regulatory specifications.

-The contractor shall contact MSCREP and local surveyor prior to any work to ensure satisfaction is achieved during this installation. The ABS surveyor and MSCREP shall be present at fit-up, testing and prior to any final welds and post weld testing

7.4.2 Shipboard Testing:

7.4.2.1 Functional test using MSC GTR No. 3 (reference 2.1.9) as guidance.

7.4.2.2 Tightness test using MSC GTR No. 3 (reference 2.1.9) as guidance.

7.4.2.3 The Contractor’s quality assurance plan shall be invoked for all aspects of this work item.

7.4.2.4 All welds shall include non-destructive testing (NDT) to MSCREP and ABS satisfaction. Exterior and interior structure shall have a minimum dye penetrate test (PT) where welds contact the shell/house plating and a minimum of visual inspection on internal and prefabricated foundations.

-The contractor shall furnish a hard copy or electronic report for each NDT inspection to MSCREP.

7.5 Painting:

7.5.1 The Contractor and MSCREP shall conduct a joint inspection of welded areas disturbed by the installations. These areas are to be prepared and primed before final painting begins to ensure that protective measures are implemented.

7.5.2 Paint all new and disturbed surfaces on the exterior deck to match the existing in accordance with the ships class paint schedule and manufacturer's recommendations. Use reference 2.1.8 as guidance. Ensure to adequately mask off or protect all electrical/electronic cables or other surfaces not required to be painted. The surfaces shall be mechanically cleaned to SSPC-SP3 with an aluminum oxide based abrasive pad (NOTE THAT NO ABRASIVES THAT INCLUDE IRON OR COPPER MAY BE USED), cleaned to SSPC-SP1 to remove oxidation and aluminum dust created during mechanical cleaning then coated with one coat of Amercoat 240 with a Dry-Film Thickness (DFT) of 5-6 mils color OFF-WHITE and 2 coats of PSX 700SG color Haze Gray with a DFT of 5-7mils. If the area to be coated is in the walkway; PPG 886 non-Skid Additive shall be added to the final coat of PSX 700SG.

7.6 Markings:

7.6.1 Contractor to fabricate and install all applicable labels, using reference 2.1.9 as guidance.

8.0 GENERAL REQUIREMENTS:

8.1 Contractors (subcontractors) called out in drawings for specific parts are to be utilized.

8.2 Exceptions to subcontractors called out in drawings must be approved in writing by the Contracting Officer.

0704-12