Statement of Work (v3) Restore Power at Multiple High Sites SE Alaska.pdf

SOW v3

INSPECT AND REPAIR SCADA SYSTEM AT MULTIPLE REMOTE HIGH SITES:

BEDE MT, RUGGED IS, CAPE GULL, SITKINAK DOME, MT MCARTHUR

STATEMENT OF WORK

PN# 14300750

PART 1 - GENERAL

1.1 PROJECT INTENT: Conduct inspection and repairs on Mechron Supervisory Control and Data Acquisition (SCADA) networked system at U.S. Coast Guard remote fixed facility (RFF) high-sites: BEDE MT, RUGGED IS, CAPE GULL, SITKINAK DOME, MT MCARTHUR. These sites are part of the USCG emergency communication system.

SCADA is a category of software application programs for process control and gathering data in real-time from remote locations.

The power has failed at BEDE MT site due to the engine controller and monitoring system issues and presents an urgency to reestablish power as soon as possible. This site is priority 1 in this project. The generator systems have tripped off line, suspected due to SCADA system failure.

Multiple RFF high sites are scheduled to be replaced within the next 24 months. This effort to inspect, repair and restore power is a temporary measure to bridge that gap.

Failure of the Mechron SCADA system has now happened at several of these remote high sites, to the point where the remaining sites with this antiquated and end-of-life system are expected to fail at any time. It had been hoped that these systems would remain operational until the entire power plant was replaced programmatically, but the recent failures at multiple sites exposes this hope as unrealistic and the risk of failure as unacceptable. Therefore the remaining four (4) sites with this antiquated SCADA system, RUGGED IS, CAPE GULL, SITKINAK DOME, MT MCARTHUR, shall have their SCADA systems preventatively inspected and repaired.

1.2 BACKGROUND: These RFF sites are Rescue 21 (R21) remote federal emergency VHF communications sites that are a critical part of the U.S. Coast Guard’s lifesaving mission in Alaska. Each of the Coast Guards’ RFF sites are located remotely on mountaintop locations throughout Alaska and are unstaffed. These sites operate using battery banks that kept charged using two L.P. gas generators and solar equipment. All of the sites communicate with the central monitoring and control computer at the Rescue 21 facility in Douglas, AK, which is referred to as the Douglas Detachment of Rescue 21.

In 2018 a similar RFF site at Point Pigot, 18 miles due east of Wittier, Alaska, suffered the same type of failure and again most recently at Zarembo, Althorp, and Sukkwan. now Bede Mountain are all experiencing. Based on recent and similar projects, inspections and repairs which were successfully executed by replacing the existing control system with a new control system using an off the shelf Allen Bradley PLC, this effort requires the Contractor to assess, implement, replicate, and document repairs at the five (5) identified high sites in order to establish uniformity as much as possible. Repairs and component parts must be compatible with the existing SCADA networked system using the Allen Bradley PLC in order for the life safety VHF system to operate properly. The same Allen Bradley PLC 1769-L30ER shall be used for this project at BEDE MT, RUGGED IS, CAPE GULL, SITKINAK DOME, MT MCARTHUR high sites.

Prior to the repairs at Point Pigot, the system was comprised of a MECHRON main rotary battery system (RBS) control panel with dual engine controllers and an Omron programmable logic controller (PLC) rack to control two three-phase 208/120 VAC propane generators. There was a remote input/output (I/O) panel in the communications hut that monitored the propane tank fuel levels. The engine controllers consisted of circuit boards with digital and analog I/O capable of monitoring and controlling the voltage output of the generators.

Overview of Inspections, Repairs and Modifications at Point Pigot (Alaska):

Replaced both engine controllers and the Omron PLC system with a single Allen Bradley PLC control system. The new system has a single PLC processor and two I/O racks in the existing RBS and an additional remote I/O rack to replace the fuel monitoring system in the communications hut:

• I/O Rack 1: Replaces existing I/O Rack in RBS Panel.

• I/O Rack 2: Replaces Omron PLC System.

• Fuel Panel I/O Rack: Replaces Existing Fuel Monitoring Remote I/O Rack.

1.3 GENERAL REQUIREMENTS: The Contractor shall coordinate the work schedule with USCG CEU Juneau prior to any site visit, inspection or repair work. The Contractor shall start work within 21 calendar days and restore all sites within 150 calendar days from the notice to proceed or date of Award. Weather delays will be considered and safety will not be compromised to meet this deadline.

Travel is required to each site. Access to remote sites will require barge or helicopter.

Contractor’s vessel and aircraft operators are required to adhere to NOAA’s marine mammal approach guidelines and regulations to mitigate potential for harassment.

As appropriate to each site, aircraft and operators must:

1. (Helicopers) climb immediately to and maintain a 1,500 foot minimum when taxiing crew or equipment over water to the high site

2. Not approach within 100 yards of a protected whales or Steller Sea Lion

3. Not place the vessel in the path of oncoming whales causing them to surface within 100 yards of the vessel

4. Operate the vessel at a slow, safe speed when near whales or other marine mammals

5. Ensure that rookery/haul out sites are not disturbed by vessel/aircraft traffic.

As a result of this effort, all five (5) RFF high sites shall be repaired and fully operational within the existing USCG communication network. The work shall be compatible with the existing RFF high site operations and maintenance standards.

1.4 SCOPE: The Contractor shall provide all equipment, materials, labor, mobilization, demobilization, supervision, transportation, equipment disposal and other related items for work specified for each site in accordance with this Statement of Work, specifications and drawings as required.

The Contractor shall also protect all Government property, etc. from damage during demolition or new work. THE CONTRACTOR IS RESPONSIBLE FOR

VERIFYING ACTUAL DIMENSIONS AND SITE CONDITIONS.

Phase 1: Planning

A. Review Point Pigot and Mechron RBS documentation. Consult with C3CEN System Engineer on correct IP Scheme.

B. Visit remote site mock up in Juneau, AK (Mayflower Island) to familiarize with Mechron and generator set up as well as expectations for Ignition SCADA reporting capabilities.

C. Procure PLC and ancillary components to replace Mechron SCADA system at site based on Point Pigot project and any diagnostic information specific to each site.

D. Procure Touch Panel PC, Emergency Stop and automatic voltage regulator for each site. Also provide an integrated remote control interface for the AVR to provide means to remotely monitor and adjust the voltage.

Phase 2: Site visit to inspect and install new SCADA system, and restore/reestablish power to site.

A. Provide helicopter transportation to and from the remote high-sites for you and your crew.

B. Provide transportation for Government Quality Assurance Evaluator (QAE).

This will allow one USCG engineer to accompany and perform the System Operational Verification Test.

C. If site is not operational upon arrival, diagnose system failure and attempt to restore power to site.

D. Demo existing SCADA and install new Allen Bradley PLC based SCADA, E-Stop, Panel PC and automatic voltage regulator.

E. Restore site to operational status.

F. Government QAE to observe/assist in commissioning of site, and validation that new SCADA is reporting properly to Douglas detachment G. Salvage or dispose of equipment and materials offsite

Phase 3: Post site visit analysis, USCG Douglas detachment (Douglas, AK) SCADA work.

A. Modify Ignition SCADA system at Douglas Detachment to incorporate new SCADA data.

Phase 4: Documentation, discrepancies, lessons learned A. Bill of materials to include part numbers, brand, model numbers, B. Ladder Logic .pdf as well as all Software files (.ACD, .SQL, .GQBK) C. SCADA Operating Instructions D. CAD drawings depicting all items removed from operation E. CAD drawings depicting all items added to site F. Theory of operation G. Username and password lists H. IP scheme documentation

1.5 Prioritization of Work: The priority of site inspection, repair and restoration is as follows:

1. BEDE Mountain

2. Rugged Island

3. Cape Gull

4. Sitkinak Dome

5. Mt McArthur

The BEDE MT high site is the highest priority. Contractor shall submit a recommendation for the most efficient and cost effective sequence of site repairs for USCG consideration and approval.

PART 2 – PRODUCTS

2.1 Panel PC Must support Windows 10 Secure Host Baseline (SHB) with the following minimum specs (see Ref: Datasheet_IndustrialPanelPC.pdf for a Panel PC that meets these requirements):

• Processor: 1 gigahertz (GHz) or faster compatible processor or System on a Chip (SoC)

• RAM: 2 gigabyte (GB)

• Hard drive size: 32GB or larger hard disk

• Graphics card: Compatible with DirectX 9 or later with WDDM 1.0 driver

• Display: 800x600 Touchscreen

• Internet Connection: Yes

• Windows 10 operating system with most recent security updates, patch(es) and version

2.2 Automatic Voltage Regulator (AVR) minimum specs (Stamford SX460 or equiv):

Sensing Input

• Voltage: 95 VAC to 132 VAC or 190 VAC to 264 VAC, 1 phase (jumper selectable)

• Frequency: 50 Hx to 60 Hz nominal.

Power Input

• Voltage: 95 VAC to 264 VAC max, 1 phase

• Frequency: 50 Hz to 60 Hz nominal Power Output

• Voltage: maximum 90 VDC at 207 VAC input

• Current o Continuous 4A o Intermittent 6A for 10 seconds

Regulation

• +/- 1.0% r.m.s. (with 4% engine governing) Thermal Drift

• 0.05% per 1 ˚C change in AVR ambient temperature (After 10 minutes) Typical Response

• AVR response in 20 ms

• Field Current to 90% in 80 ms

• Machine Volts to 97% in 300ms External Voltage Adjustment

• +/- 10% with 1kΩ, 1 W trimmer (Applies to Mod status F onwards. Generator de-rate may apply.)

Under-Frequency Protection

• Set point 95% Hz (Factory set, semi-sealed, jumper selectable.)

• Slope 170% down to 30Hz Unit Power Dissipation

• 10 W maximum Build-up Voltage

• 4 VAC at AVR terminals Environmental

• Vibration o 20 Hz to 100 Hz: 50 mm/sec o 100 Hz to 2 kHz: 3.3g

• Operating temperature: -40 ˚C to +70 ˚C

• Relative Humidity 0 ˚C tp 70 ˚C: 95% (non condensing)

• Storage Temperature: -55 ˚C to +80 ˚C

2.3 Remote Control Interface for (AVR) minimum specs (Stamford remote control interface or equiv):

Control Input

• Voltage: 0 Vdc to 10 Vdc, input resistance 100Ω

• Current: 4 mA to 20 mA, input resistance 38 k Ω

• Optical isolation: 1 kV input to output Power Input

• Voltage: 110 VAC to 125 VAC, 50 Hz to 60 Hz

• Voltage: 200 VAC to 230 VAC, 50 Hz to 60 Hz

• Voltage: 231 VAC to 250 VAC, 50 Hz to 60 Hz

• Voltage: 251 VAC to 290 VAC, 50 Hz to 60 Hz

• Power: 5 VA Output

• Single pole changeover relay rating: 5 A@ 30 VDC, 5 A@ 240 VAC

• Optical isolation: 2 kV Preset Range

• Power factor control: 0.7 lead (4 mA) to 0.7 lag (20 mA) or 0.7 lead (-10

VDC) to 0.7 lag (+10 VDC)

PART 3 – ATTACHMENTS: References

# Description File Name A Previous Point Pigot Generator and SCADA repairs drawings.

Ref A Point Pigot Generator Repair CASREP.pdf

B Point Pigot Theory of operations and SCADA instructions

Ref B Point Pigot Repair – Theory of Operation and SCADA Instructions.pdf

F Datasheet for a Panel PC that meets requirements

Ref F Datasheet_IndustrialPanelPC.pdf

*** END OF STATEMENT OF WORK**