333-F040-01 -- TECHNICAL SPECIFICATIONS.pdf

TECHNICAL SPECIFICATIONS:

TABLE OF CONTENTS

0001 510 - Drag-arm Hoist System

0002 798 - Uninterruptable Power Supply Cabinets

0003 735 - Local Engine Panels

0004 506 - Dredge Pump Motor & Generator Control System

0005 780 - Supervisory System (SCADA)

GENERAL

OVERVIEW

NOTE: The Reference Drawings have been provided for concept and intent guidance.

The Contractor is advised it is wholly responsible for ensuring that the design and installation of the Systems is complete and adequate for the service intended and that they comply with ABS Steel Vessels part 4, 46 CFR Subchapter J, and 46 CFR §62.

Failure of the Reference Drawings or the Technical Specification to outline and describe all of the details required to perform the work does not relieve the Contractor of its responsibility to fulfill the intent of the Technical Specification.

Final system equipment locations shall be approved by the MDC Representative.

This reference document has been compiled to provide a guideline for the design, construction, and installation of the Contractor supplied systems as specified to be installed on the USACE Hopper Dredge McFarland.

CONTRACTOR REQUIREMENTS

The Contractor, sub-contractors and prospective supplier are expected to familiarize themselves with the scope of work, vessel, shipyard working conditions, general requirements, and shall comply with all parts of these documents pertinent to their work order.

The Contractor shall bear the burden of proof providing documentation, and certificates demonstrating adequate experience with the type certification or approval process with marine systems of similar scope and capability.

The Contractor shall be solely responsible for all materials, equipment and labor as specified to meet the entire scope of this specification providing a turnkey application unless otherwise noted.

All work shall be completed in accordance with applicable codes, specifications, federal, state and local laws and regulations.

The Contractor shall be fully responsible for using only drawings and specifications of the very latest dated revision sheets of record.

Any error, inconsistency or omission the Contractor may discover in the bid documents shall be reported to the COR prior to bidding.

If any error, inconsistency or omission is discovered in the MDC supplied drawings or reference documents during the course of construction, the Contractor shall not proceed with any work without the written decision of the COR.

In case of any inconsistencies in the specifications or MDC supplied drawings, or between specifications or drawings, the COR will determine which requirement will be the most consistent with the design intent.

All drawings shall be self-certified as described under USCG NVIC requirements.

The Contractor will direct the work using his full attention and shall be entirely responsible for all construction means and methods, acts or omissions of employee’s and sub contractors and any other persons performing any work with the Contractor.

The Contractor shall assume responsibility for the performance of material and products used in the system. All contractor furnished material shall be new and shall be manufactured to marine standards.

Upon acceptance of a functional delivered system to MDC, the Contractor shall guarantee in writing the system, materials, and workmanship for a period of at least one

(1) year.

REGULATORY BODIES

The Contractor furnished systems unless specified otherwise shall be constructed to meet marine specifications and all components must be approved for use on shipboard applications involving remote control and monitoring systems. The systems shall be designed to meet ABS classification rules and specifications. The systems must be constructed to meet or exceed the application criteria(s) governed by society classification rules and guidelines set forth but not limited to the following regulatory agencies:

1. USCG Marine Safety – Code of Federal Regulations

2. American Bureau of Shipping (ABS)

3. Institute of Electrical and Electronics Engineers Standard IEEE-45

4. Underwriters Laboratories Standard UL-508A

EQUIPMENT CONSTRUCTION STANDARDS

Contractor supplied equipment inherent in design must be constructed to provide many years of trouble free operation. Each element must be suitable and intended for installation on shipboard applications for remote control & monitoring systems.

1. The systems equipment and associated cabinets shall comply with 46

CFR §111.40-5.

2. The system equipment and associated cabinets shall be designed and constructed to an IP22 degree of protection. Each system component shall meet or exceed the criteria listed in this document and be designed and capable of providing continuous operation and duty in an ambient temperature range as required by ABS within each specified location.

3. System bus and lug connections shall provide a dead front cover and be clearly marked and labeled to designate voltage and shock hazard.

4. System doors shall be hinged and provide a “door stop” to secure and lock the door in an open position at 90 degrees for service purposes.

5. The system equipment cabinets shall be clearly labeled. The labels shall be constructed of engraved black phenolic label plates with white letters. The plates shall be fastened externally to the enclosure doors with stainless steel Phillips- head fasteners, and then threaded into tapped holes on the sheet metal doors. Lock-Tite shall be used on the threads. Two inch engraved white letters on black phenolic plates shall be used for system designations.

One-quarter inch (¼”) engraved white letters on black phenolic plates shall be used for all operator and pilot devices. The manufacturer’s nameplate markings and data, system ratings, model number, and serial number shall be mounted externally and clearly marked on the lower right corner of the each system cabinet.

6.The system equipment enclosures (with exception to free standing) shall be mounted to vertical angle stanchions. The stanchions will provide a kinetic isolation pad/gasket between the cabinet and stanchion. The cabinet will be thru-bolted to an isolator. The isolators will kinetically isolate the equipment cabinets from bracing hard mounted to the vessel. The bracing should be arranged to complement a drip shield/pan mounted to the top of the system cabinets. Free standing enclosures shall be mounted to formed angle foundations as described in each system mechanical drawing package.

7. A drip shield will be provided as part of each field equipment enclosure/cabinet and part of the scope of supply. The drip shield shall be watertight and no thru fasteners are allowed to anchor the drip shield to the system frame tops.

8. The system equipment enclosures shall provide a tinned copper isolated grounding bus bar. The bar shall be anchored to isolators and provide a grounding station for branch circuits supplied by each system. Each system section shall provide a single grounding lug suitable for the cross section of each branch circuit’s ground conductor.

9. The system components shall be grounded in accordance with 46 CFR

§111.05.

10. The systems enclosures shall each provide an internal florescent lamp to be activated on a door switch, and to be situated to provide illumination of the system electronics interior for servicing as indicated in the drawings.

11. Each system section will be equipped with a 120VAC duplex receptacle.

The make shall be Phoenix Contact Part No. EM-DUO/120/20/GFI or equivalent. The receptacle will be mounted in a covered J-box and connected to a 20A internally mounted circuit breaker. The Drag-arm hoist system receptacle power will be supplied from an external feeder.

12. All wire, cable, and floaters must be constructed to meet zero halogen requirements.

ENCLOSURES

Free-Standing Modular Enclosure Specifications:

All Freestanding enclosures shall be a Rittal TS or equivalent. All other System Junction boxes and Cabinets shall be Rittal AE or equal.

GENERAL

The system enclosure(s) and accessories shall be a total manufactured solution, providing a uniform system of assembly within a family of system components. The enclosures used shall, inherent in design, allow for:

1. Simple installation/removal of roof (i.e. drip shield)

2. Simple installation/removal of side-walls

3. Simple installation/removal of rear wall

4. Simple removal of doors and access panels

5. A drip collar/channel to divert fluids (oils, cutting fluids, water) away from the gasket.

6. Doors with four (4) point locking capabilities for security and environmental seal.

7. Reversible hinging.

8. Removable eyebolts fitted in the top corners of the cabinet. Each attachment point shall be of sufficient strength and shall have internal bracing to support the entire weight of the finished product without damage to installed components. The eyebolt bosses will be covered with the integral drip shield when installed on the vessel.

9. Enclosure surfaces that are electrically bonded and maintain electrical continuity between all points of attachment, without the aid of additional grounding straps and braids.

10. Closed cell, foamed-in-place, polyurethane gaskets.

11. Finishes:

Frame: Electrophoresis fully immersed primer coat

Panels: Electrophoresis fully immersed primer coat Polyester powder top coat

TERMINAL BLOCK SYSTEM SPECIFICATIONS

Each system shall include Phoenix Contact brand (or equivalent) terminal block systems.

Each system controller will provide 6.2mm spaced terminal blocks utilizing one (1) two

(2) to three (3) levels as indicated in the drawings.

The system terminal blocks should be as listed or equal to the following:

1. UKK 5-TG Terminal Blocks ST-SILA 250 UK4 -120VAC fuse holders with blown fuse LED

2. SLKK-5 Jumpers

3. 35mm perforated DIN rail

4. ZB-6 label marking system with embossed black letters on white 6.2mm TB labels.

ELECTRO-MECHANICAL PROPERTIES

System control wiring must provide ferrules on each circuit. All wiring installed ferrules must be crimped in accordance to IEC 60 9780 and IEC 60 947-1.

Unless indicated otherwise general low voltage system terminal blocks must be rated to:

1. 400VAC minimum

2. 16Amps minimum

3. 24-12 AWG conductor size range

4. 6.2mm spacing

5. Polyamide construction

6. No dissimilar metals can be used in the clamping mechanism (i.e. all nickel-plated copper components used in terminal block construction).

Clamping mechanism must use the Reakdyn principle.

LOCAL AND REMOTE INPUT AND OUTPUT (I/O) SIGNAL MODULES

The local and remote I/O modules will consist of one base model. The modules shall be the Siemens Simatic “M” style signal modules configured with a “hot swap” backplane or equal for rack rail-mounting local or distributed, where the process signal counts are high density. The sub rack rails shall be configured to allow hot removal and replacement of the signal modules.

The signal modules shall consist of mixed Analog Inputs (AI), Digital Inputs (DI), Digital Outputs (DO), and Analog Output (AO) modules. The Contractor shall submit a list of proposed signal modules indexed to the signal list subject to approval by the COR.

The COR must approve the signal modules and distribution locations prior to construction. The Contractor shall provide 20% installed spare signals in ratio to each analog and digital signal module location.

The Contractor shall ensure the application and use of Siemens I/O modules providing diagnostic capabilities to the PLC CPUs for error reporting in the event of any module failure.

Contractor supplied analog input signals shall be 4-20ma, two (2) wire loop style for signal runs greater than twenty feet, or where there is a close proximity to areas of high levels of parasitic energy (EMI or EMF), including galvanic or capacitive coupling between the signal cables and existing power cables or transmission cables in the wire-ways.

The Contractor shall supply Simatic “M” style AI 331 analog signal modules used to interface with analog inputs. The AI 331 will support eight (8) analog inputs configured into two (2) channel groups.

The digital or discreet input signals shall use Contractor supplied DI 321 signal modules (or equivalent) in the sixteen (16)-channel version operating on 24VDC.

The Contractor shall determine which modules are most suitable in each instance for each location requirements subject to approval by the COR. The Contractor shall ensure the input signal modules are arranged with provisions to protect the system’s integrity, so a failure in one input signal will not affect the other input signals. Contractor supplied fast-acting interrupts shall be used, so that a direct short in any input signal will not affect the remaining channels in the signal module, or the integrity of other modules located in the rack or system. The Contractor shall ensure that non-sourcing signal interfaces included as the system inputs are provided with Din style Form–C relays with 10A rating.

The Contractor shall use dry contacts for linking the parameter with the signal module. In all instances where signal potentials are mixed, the Contractor shall provide clear labeling indicating each of the hazardous or mixed potentials and each of the mixed circuits and elements in the system.

The Contractor shall supply Digital Output DO 322 signal modules to be used for system outputs. The Contractor shall arrange the outputs to provide a fast acting interrupt on each output signal. This arrangement is intended to isolate any direct short(s) in any output signal and not to affect the other output channels in the signal module or other elements in the rack or system. Output channels greater than 500ma shall incorporate a Contractor supplied Din-style, form-C relay with a 10A rating for interfacing with field controls and actuators.

WIRE, TERMINATIONS, AND LABELING SYSTEMS AND INSTALLATION

SPECIFICATIONS

The work under this section consists of furnishing materials, equipment, labor, and services necessary for the installation of circuits and cables as shown in the Contract drawings and as hereinafter specified. Wires and cables for power, low voltage, signals, and control systems are specified in the contract drawings.

All Contractor furnished wiring shall be in accordance with the NEC, IEEE-45, and ABS specifications.

All wiring and cables shall be installed in dedicated cable ways unless otherwise specified. In panel boards, cabinets, wire ways, and equipment assemblies, the Contractor shall neatly form, train, and tie the cables into bundles.

The Contractor shall provide suitable installation techniques to prevent cutting or abrasion on conductors and cables during and after installation.

The Government will have the shipyard contractor provide point to point cabling under a separate contract.

The Contractor shall provide the cut in, floater labeling, termination, and inspection of all system interconnections as part of the Contractor’s scope of supply.

The Contractor shall be responsible for all internal materials required to make the interconnections.

INTERNAL WIRING

System internal control wiring must be of the THHN/TEW type wire using 18, 16, and 14 AWG stranded-copper for individual signal circuits as applicable, and 12 AWG stranded

- copper for control feeder circuits.

The wires shall be color coded to designate function. The control circuits shall use a Raychem (or equivalent) shrink tube labeling system for all circuit floaters. All internal wiring and floaters must be constructed of Polyofin (or equivalent), meeting low smoke zero halogen criteria.

Floaters shall contain information directly indicating the drawing and sheet of the drawing where the attached wire can be found.

EXTERNAL SIGNAL CABLES

System external electronic signaling cables employed with analog/digital sensors will be of zero halogen construction and provide 85% screened conductors.

All signal cables will be grounded by the Contractor on a single end at the control cabinet. In no instances shall the signal cables be grounded on more than one end.

PROFIBUS CABLES

System Profibus copper segments shall employ the Siemens Profibus cable.

Part No. 6XV1-830-0EH10. Each end will be equipped with a Siemens Part No. 6ES7- 972-0BA40-0XA0 Bus connector.

SENSORS AND SIGNAL CONDITIONING

Contractor supplied system sensors will require product recognition for suitability in marine applications. Sensors will be selected to match the appropriate operational ranges of the ships machinery. Sensors, which do not closely match the optimum resolution of a systems parameter, will not be accepted by MDC. Contractors supply shall include all parts, fittings, hoses, mounting plates, isolators, etc required to make up a complete and installed monitoring system. Every sensor must provide excellent vibration stability, robust construction, and a high degree’s of EMI, EMC protection, and a simple method of field calibration.

PRESSURE SENSORS

Contractor supplied pressure sensing will be provided with analog and contact based signal modules. In locations where two (2) or less sensors are used the sensors may be mounted stand-alone. The Contractor shall be responsible to mount sensors either off the machinery or provide shock mounting to reduce mechanical stress on the sensor, which must be mounted directly on the machinery. Sensors shall be located to prevent damage to the sensor during routine maintenance of the vessel and machinery.

All Contractor supplied pressure sensors shall provide a means of isolating the sensor from the pressurized circuit for calibration or servicing. Equipment using pressure sensors in groupings greater than three (3) sensors shall use an integrated pressure block providing integrated valves and test fittings.

Unless otherwise specified the Contractor shall use the following pressure sensor devices or equal:

1. Analog pressure sensors stand alone - Danfoss MBS 3100.

2. Analog pressure sensors grouped off or on equipment - Danfoss MBS

5100.

3. Analog pressure sensor Block valves- Danfoss MBV 5000.

4. Pressure Switch – dry contact- Danfoss MBC 5100-5000, Kolbold

KPS/KAS series as applicable.

5. Differential pressure switches- dry contact- Danfoss MBC 5180, Kobold

KRT series as applicable.

TEMPERATURE SENSORS

Contractor supplied temperature sensors shall be installed in a manner to ensure reliable operation and mounted or positioned in a way to prevent damage during routine maintenance and operation of the equipment. The Contractor shall provide and install temperature sensors using units of matched resolution to the system parameters being measured in each process. In instances where sensors must mount directly to the machinery, bearings or motors, media adapters shall be used in conjunction with appropriate fittings and fixtures. In instances where there are several temperature sensors located on a machine the Contractor may install the unit’s standalone with signal cables prepared and secured to the machinery at appropriate intervals The Contractor shall prepare 2% spares pre configured with connectors as replacement units. Unused connectors on the rail shall provide for dust/liquid protector caps.

Unless otherwise specified the Contractor shall use the following temperature sensor devices or equal:

1. Thermocouples – Danfoss MBT 5111 (for use distribution channel and with media adapter).

2. Analog Thermocouples – Danfoss MTB 5113, Kobold TST as applicable.

3. Analog RTD temperature sensors – Danfoss MBT 5250 (with media adapter).

4. Analog Bearing/journal temperatures – Danfoss MBT 5310.

5. Thermostat/Temp switches – Danfoss MBC 8100, Kobold

Kt/KTS/DTS/TWR series as applicable.

6. Media Adapters - Kobold TSH.

PROXIMITY SENSORS

Unless otherwise specified the Contractor shall use the following discreet proximity sensors devices or equal as follows:

1. Turk IP67 Sensors with circular mil 8mm style adapters and integral indication.

2. Turk IP 67 molded circuilar mill harness & assemblies.

ENCODERS, INCLINOMETERS, & ETC

Unless otherwise specified the Contractor shall use the devices or equal as specified within the contract drawings.

SENSOR INSTALLATION

All Contractor furnished system sensors will be provided by the Contractor and installed by the Government.

EQUIPMENT AND MACHINERY SIGNAL INTERFACING

The Contractor furnished systems shall adopt uniform practices for machinery and equipment interfacing with sensors and actuators. Each installation shall be in keeping with the best marine practices. The goal of these installation criteria’s is to produce an installation that will provide many years of trouble free service to the vessel, and not to interfere with the operation or maintenance of the ships equipment & machinery.

The Contractor will be responsible to coordinate the installations with MDC’s representative and the Shipyard to provide the best approach, and application solution with the specified equipment and materials in each instance.

SHIPPING

The system equipment must be individually packed with desiccant, shrink-wrapped, and wood crated. Each crate will be clearly marked on all sides. Picking points and lifting points on crates lifting equipment must be clearly marked.

TRAINING WORKSHOPS

WINCC OPERATOR WORKSHOP

WINNCC Operator Personnel Training course Location: Vessel

Estimated duration: 3 days with hands-on exercises.

Hands-on training shall provide, at a minimum, a computer station for every two trainees

A: General Introduction

1) Scope, purpose, content

2) System overview – applications in the package, multi-user system, system requirements, etc.

B: Operator Functionality in the WINCC Software

a. Monitoring & Controlling the Process

b. Navigation – area and diagram

c. Open by name

d. Viewing component status

e. Sending commands

f. Object notes

3) Handling Alarms

a. Alarm list

b. Customizing

c. Filters

d. Freezing

e. Acknowledging

f. Finding objects

g. Alarm report printing and stats

4) Graphs and Trending

a. Predefined graphs

b. User defined graphs – dynamic and static

5) Viewing Process Data and Events (Object Historian)

a. Selecting objects and data source

C: Customizing the System

6) Operator Customization

a. MRU

b. Milliseconds on/off

c. Alarm filtering and Maintenance filtering (previously demonstrated)

d. User defined graphs (previously demonstrated)

10) System Integrator Customization

a. Pre-defined graphs (previously demonstrated)

b. Access to extra items in the object properties menu (so-called pop-up menu)

c. Special tool bar in Supervise

d. Settings determining what operators are permitted to do/not do in Setup

e. Security for the process (User Administration, Protect object and Exclusive control on workstation)

E: Expanding the WINCC System and Upgrading

11) Adding More Objects and/or Components to Existing System

12) Upgrading the license

13) Upgrading from an Older to the Newest Version of WINCC

STEP 7 WORKSHOP

Siemens Step 7 PLC workshops shall be provided as one integral training module.

Location: Vessel

The module shall run (3) three days and address general operations, maintenance, installation, and management of the system. The course shall provide the trainee with the skills required to configure the S7 300/400 PLC hardware components, to program using Step 7, and to utilize the diagnostics functions to trouble shoot the system. The Second module will address more advanced issues involving Step 7 advanced programming, including configuration of the system and PLC to integrate Sinec L2 Profibus and Sinec Industrial Ethernet. The course will focus on the specific details of the Drag-arm hoist system systems architecture and configuration. The course shall be custom tailored to meet the scope and requirements of MDC.

Hands-on training shall provide, at a minimum, a computer station for every two trainees

1. Basic Instruction –3 days including:

Summary-

a. Basic PLC components and operations.

b. Digital I/O concepts

c. Analog I/O concepts

d. Memory concepts

e. Numerical formats

f. Systems Architecture

g. Communications overview

h. S7-300 set-up & configuration

i. Program management

j. System configurations

k. Module parameterization

l. Uploading /Downloading the CPU

m. Troubleshooting

n. Documentation

SYNAMICS WORKSHOP

Siemens Synamics workshops shall be provided as one integral training module.

Location: Vessel

The module shall run (3) three days and address general operations, maintenance, installation, and management of the system. The course shall provide the trainee with the skills required to configure the hardware components, to program using the Synamics SW tooling, and to utilize the diagnostics functions to trouble shoot the system. The Second module will address more advanced issues involving advanced programming, including configuration of the system and VFD to integrate Sinec L2 Profibus. The course will focus on the specific details of the Drag-arm hoist system systems architecture and configuration. The course shall be custom tailored to meet the scope and requirements of MDC.

Hands-on training shall provide, at a minimum, a computer station for every two trainees

1. Basic Instruction –3 days including:

Summary-

a. Basic components and operations.

b. Digital I/O concepts

c. Analog I/O concepts

d. Memory concepts

e. Numerical formats

f. Systems Architecture

g. Communications overview

h. Set-up & configuration

i. Program management

j. System configurations

k. Module parameterization

l. Uploading /Downloading the CPU

m. Troubleshooting

n. Documentation

DECS WORKSHOP

Basler DECS workshop & training module.

Location: Vessel

The module shall run (3) three days and address general operations, maintenance, installation, and management of the system. The course shall provide the trainee with the skills required to configure the hardware components, to program using the DECS BESCOMM SW tooling, and to utilize the diagnostics functions to trouble shoot the system. The module will address more advanced issues involving advanced programming, including configuration of the system. The course will focus on the specific details of the DECS SMCS systems architecture and configuration. The course shall be custom tailored to meet the scope and requirements of MDC.

Hands-on training shall provide, at a minimum, a computer station for every two trainees

Basic Instruction –2 days including:

Summary- Basic components and operations.

Systems Architecture Set-up & configuration Program management System configurations Module parameterization Uploading /Downloading the CPU Troubleshooting Documentation

40.5.2 WOODWARD 2301D

Woodward 2301D Operator Personnel Training course

Location: Vessel Estimated duration: 1 day with hands-on exercises.

Hands-on training shall provide, at a minimum, a computer station for every two trainees

A: Objectives:

Develop basic understanding of governor control theory Develop basic understanding of the Woodward software tooling set up and operation.

Field adjust & calibrate the control, actuator & linkage.

Develop a basic understanding of troubleshooting.

B: Course Outline

Concept of governor controls & theory:

a. Governor fundamentals

b. Electrical governors

c. Terminology

d. Power generation systems

Mechanical overview:

a. Actuator fundamentals

b. Terminology

c. Adjustments

d. Linkage Adjustments

2301D control system

a. Hardware fundamentals

b. Terminology

c. Inputs and Outputs

d. Software configuration

e. Software communications

f. Digital control basics

g. Closed loop speed control exercises

h. Troubleshooting

SPARE PARTS AND INSTRUCTION MANUALS

Provide a list of recommended spare parts and special tools, along with pricing information, for those items which are Contractor furnished. MDC shall select and purchase spares by way of a Change Order.

Provide 3 sets of original instruction manuals. Manuals shall provide information necessary to maintain and service provided equipment and accessories. Data shall include parts breakdown, sources for parts, trouble shooting techniques, component location Drag arm Hoist PLC system, and other information necessary to properly maintain, service, and repair the equipment.

TESTS, TRIALS, AND INSPECTIONS

Tests and trials shall be in accordance with this Section of the Technical Specifications.

Inspections shall be performed as defined in this Section of the Technical Specification.

Testing will be done in coordination with FAT factory Acceptance Testing (FAT),.the Pre commissioning installation tests, Harbor Acceptance Trials (HAT) schedule, and the Sea Acceptance Trials (SAT) schedule produced by the Government.

The contractor shall coordinate all testing protocols with the COR. The contractor shall provide detailed documents identifying the functional test criteria’s. These documents shall be presented in the form of a Design Verification Test Procedure (DVTP) Document and Failure Mode Effect Analysis (FMEA) document.

All Testing (including FAT) shall be performed in such a manner as to demonstrate the entire system response. Load testing, Sensor tests, etc shall be completed with a functional test by mechanical force (i.e. pressure tests, temperature tests, with physical medium etc) under no circumstances shall circuits be jumpered, lifted or contrived in the system software to simulate the fault and subsequent response of the system.

Power system testing shall include but is not limited to the following criteria:

Visual Inspections –

Verify that the system components are constructed and installed in accordance with the specifications, drawings, and design intent.

Check markings of the components in accordance with the systems drawings.

Verify wire types and sizes.

Verify that there are no chafe or wear points with the installation.

Insulation tests –

Measure the dielectric strength of every newly installed cable prior to field interconnection.

Functional Tests –

Check interchangeability of components.

Test protection circuits.

Test ground detection system

Test UPS back up time interval and dimension.

Verify the calibration of measuring and alarm signals. Denote calibration set points on drawings and test documentation.

Check any protective interlocks.

Test DVTP with COR/ABS to witness.

Test FMEA with COR/ABS to witness.

Following the test procedure the contractor shall update any documents and drawings to changes.

DEFINITIONS

AI Analog Input AO Analog Output COR Contracting Office Representative CPU Central Processing unit DI Digital Input DO Digital Output DVTP Design Verification Test Procedure.

EOS Engineers Operator Station (centralized) FMEA Failure Mode Effects Analysis HD High Definition Monitor HMI Human Machine Interface Graphical Operator Panel.

ICMS Integrated Control & Monitoring System I/O Inputs/Outputs LAN Local Area Network MPI Multi Point Protocol (Siemens distributed bus protocol) OLM Optical Link Module OP Operator Panel ( Siemens OP 177b or MP370) OSM Optical Switch Module OS Operator Station (PC) PMS Power Management System PLC Programmable Logic Controller Profibus Distributed serialized bus communications protocol SCADA Supervisory Control & Data Acquisition systems Scalence Siemens Ethernet managed switch (OLM) Step -7 Siemens PLC programming software SY Ship Yard VAT Variable Allocation Table within Step 7 VFD Variable Frequency Drive

END OF SECTION

SECTION 0001 – DRAGARM HOIST SPECIFICATIONS

The existing Drag arm hoist electrical system and controls consists of two separate drag arm hoist systems. The systems are arranged in a Port & Stbd Configuration.

The existing drag head hoist motor is a horizontally mounted Allis Chalmers, 3 phase 60 cycle wound rotor motor rated at 175 hp, 900 (sync) rpm, 440 volts AC. It is rated for 2 hour full load, reversing duty with an overload capacity of 25% for five minutes and 50% for 2 minutes. The motor develops 1120 ft-lbs of full load torque at 820 rpm. The motor has a double shaft with a brake mounted on the back end. The brake is rated for continuous duty and 1350 ft-lbs. It is a wheel and shoe type brake solenoid operated spring set and electronically released using DC voltage.

The existing motors, brakes, and wound rotor controllers will be removed by the Government. They shall be replaced with a new contractor supplied AC Motor, Safety Brake and a new AC Variable Frequency Drive (VFD) and new controls.

The Contractor shall supply Two (2) fully functional & independent Drag-arm hoist control systems. One system will be used for the Port drag-arm arrangement and the second system will be for the Stbd side arrangement.

Each Drag-arm hoist system will be identical in every respect, except that the consoles on the port and starboard side shall be mirrored. Further in this document the description for the two systems will be specified as the “Drag-arm hoist system”.

The upgrade shall replace the existing AC drives, motor, safety brake systems and associated infrastructure. The Drag Arm hoist control panels shall be constructed to UL508A and meet ABS and IEEE-45 requirements for the intended application.

The Drag-arm hoist systems are to be integrated with two (2) Programmable Logic Controllers (PLC) main processing units which process the input data of the sensors and output information to several operator workstations, control elements, and actuators.

The contractor shall upgrade the existing hoist system by:

a. Replacing hoist motors, safety brake, VFD and control system.

b. Renew control wiring & cables between drag consoles and hoist control utilizing fiber-optic transmission.

c. Renew power wiring and cable between the ships service switch board and VFD control. Wiring & cable must be shielded and approved for VFD operation.

FUNCTIONAL SPECIFICATION

As previously mentioned each Drag-arm hoist system shall include an integrated system consisting of a variable frequency drive, motor, safety brake, and distributed PLC based control system. The overall solution shall provide enhanced operator capabilities including accurate speed control of the hoist, high torque levels and enhanced operational safety. The drag arm hoists are manned operations. The operators or “tenders” shall be primarily operating the hoist in a “Hand” mode. The system shall provide limited automatic functionality. The Drag-arm hoist system shall integrate to a local HMI display as part of this scope of work & integrate remote HMI displays as part of F780 scope of work. The displays shall (on request) display any measured quantity; to actuate an appropriate alarm whenever any measured quantity exceeds preset limits; and to log the transgression of that limit.

The contractor supplied systems upgrade will include:

a. A system that can be controlled precisely and predictably, improving safety and productivity.

b. A system that shall provide smoother hoist operation resulting in an accurate and soft control which avoids erratic movements of the load.

c. A Flexible control program for adapting old start/stop and reference logic states with the new integrated systems platform.

d. Easy to use program interface with macro defined parameters which are dedicated for use with a hoist.

e. PLC controls will integrate dredge tender manual functions into automated pre-set functions/conditions.

f. Elimination of difficult to detect ground faults between control systems.

g. Built in component and system diagnostics to expedite troubleshooting and minimize down time.

The Drag-arm hoist operator system shall display (on request) any measured quantity; to actuate an appropriate alarm whenever any measured quantity exceeds preset limits; and to log the transgression of that limit. The Contractor shall provide all PLC elements, parts, connectors, accessories, including sensors and actuators required to integrate the system as detailed.

The Drag-arm hoist system will be divided into two (2) functions. The first function is to provide all necessary control functions, alarm and instrumentation systems as required.

The second function is to provide specified monitoring diagnostics points not required by the automation process for the systems operators to diagnose, troubleshoot and maintain the vessels operations.

The Drag-arm hoist system will be designed to provide speed monitoring functions to ensure that the motor speed remains within safe limits to prevent over speed. The speed matching function continuously compares the speed reference and the actual motor shaft speed to detect any possible difference.

High and low limit sensors shall be installed to stop the drive at the end positions.

Position sensors shall be employed to limit the drag arm from being positioned under the keel of the vessel.

The system shall be equipped to provide flexible signal interfaces for different types of analog, digital and Profibus DP signals allowing integration of the drive local controls to be integrated by hardwire and the distributed remote control systems utilizing a serialized network (Profibus).

The Drag-arm hoist system shall utilize a program to include an adaptive “motor model” in the program that can operate with or without pulse from the motor shaft. The drive shall use a function block (FB) type programming eliminating the need for an external PLC to handle the entire control application.

The drive shall be equipped and programmed to ensure that the drive and motor are able to produce torque and that the mechanical brake does not slip before the drive releases the brake and starts operating the hoist system.

The program should include load speed control to maximize the hoist speed for the given load and ensures that there is sufficient motor torque in the field weakening area.

The Drag-arm hoist system shall be programmed to provide 'slow down' safety control function limits the speed to a preset level in critical zones. High and low limit sensors shall be installed to stop the drive at the end positions. As shown on the contract drawings position sensors shall be employed to limit the drag arm from being positioned under the keel of the vessel.

The Drag-arm hoist system shall be equipped and programmed for a 'fast stop' safety control function to be used in emergency situations. Based on programming and hard wired interlocks the drive shall be able to stop the motor immediately if a fault should occur in the operation of the motor drive, PLC and or transmission system.

The Drag-arm hoist system shall be programmed to provide 'slow down' safety control function limits the speed to a preset level in critical zones.

The drive shall include an integrated brake control logic, which in turn utilizes torque memory and pre-magnetizing to open and close a mechanical (safety) brake safely and reliably. The motor control program will be programmed to accommodate different start torque methods, and it will also include a brake monitoring function for start, stop or running sequences. The software should incorporate programmable counters to provide information on total operating time and the number of times the mechanical brake is used.

BASIC SYSTEMS CONFIGURATION

There are four free standing enclosures specified in the system:

a. Two (2) modular H94” x W24” x D24” enclosures used in the VFD line up.

b. One (1) H86” x W24” x D24” PLC cabinet located in the local drive station cabinet lineup.

c. One (1) H94” x W24” x D24” Brake cabinet located in the local drive station cabinet lineup.

All Freestanding enclosures shall be a Rittal TS or equivalent. All other System Junction boxes and Cabinets shall be Rittal AE or equal.

FAULT TOLERANCE

The Drag-arm hoist system shall provide the following fault tolerance functionality:

1. A redundancy scheme providing a seamless transition from the primary system to the redundant system should one system fail for any reason.

2. Uninterrupted service to the vessel’s operations, vessel’s equipment, and all associated machinery.

3. No loss of Drag-arm hoist system functionality in the event of the failure of any single component in the central PLC’s, workstations, or Profibus communications extending through the fiber optic segments.

SYSTEM INFRASTRUCTURE SPECIFICATION

The Drag-arm hoist system will be constructed and function as defined in the following paragraphs. The basic system configuration is made up of the following components.

The Contractor shall submit to the COR for approval a final component list prior to beginning construction. The Contractor shall be required to provide hardware, firmware and software at the most current revision levels produced by the manufacture.

Each Drag-arm hoist system (Port and Stbd) configuration shall include:

a. One (1) Motor

b. One (1) Safety Brake

c. One (1) VFD including specified infrastructure.

d. Two (2) process controllers (PLC’s) in a redundant configuration.

e. Two (2) communications co-processors in a redundant configuration.

f. Two (2) communication buses in a redundant configuration.

g. Local and distributed signal modules to match the machinery Input/Output

(I/O) list to machinery and locations as specified.

h. Two (2) Operator Panels (OP) workstations.

i. One or more uninterruptible power supplies.

MOTORS

Each motor shall be inverter duty, continuous rated, horizontally mounted, 3 phase, integral horsepower, TEBC AC induction motor. The motor shall be a Siemens motor RGZESDI, severe duty 449TS frame TEBC motor or equal 200HP, 460V, 60Hz, 900rpm.

The order number shall comply with the following part number:

1PC29214DD612AA3-Z+A40+M52+G01+J50+BRAKE

The motor shall be equipped with the following options:

a. A40 – 115V single phase space heater

b. M52 – double end shafts, NEMA standard long shaft

c. Y75 – Avtron M85, 5 to 24V, 1024 PPR, double output encoder

d. J50 – main box side conduit box for space heater

e. BRAKE – spring operated disk brake, 24V DC or 110V AC (similar to

IEC motor KFB 160 brake)

Mechanical Requirements:

The Motor shall be designed to permit ready removal of the rotor, stator components, and bearings, and to facilitate bearing maintenance. The Motor should have viewing ports or readily removable covers. Eyebolts or equivalent should be provided for lifting motors.

The Motor shall be provided with terminal boxes appropriate to their type of enclosure.

Terminal boxes should be dimensioned of sufficient size to accommodate wiring without crowding, and each box should be of adequate mechanical strength and rigidity to protect the contents and to prevent distortion under all normal conditions of service.

Cables of different voltage classes shall not be terminated in the same terminal box. Wiring for instrumentation, sensors and safety devices should be installed in separate terminal boxes.

Motors shall have the terminal leads suitably secured to the motor frame. The end of these leads should be fitted with approved connectors suitable for use with terminal lugs on incoming cables. All connections to the interior of motors as well as those to the power supply should be provided with efficient locking devices.

The motor shall be equipped with an anti-condensate heater and RTD’s.

Motor frame, end-shields and inner bearing caps shall be cast iron construction.

Motors shall have a charged lubrication system to inhibit moisture condensation. Grease ports shall be located on the periphery of the motor end-shield. Motor shall be fitted with a shaft slinger for a minimum of IP-54 protection.

Motor ventilating fans shall be corrosion resistant, non-sparking material. All fans shall be suitable for bi-directional rotation.

A grounding provision shall be provided in the connection box. The box shall be oversize as compared to NEMA requirements and diagonally split and rotatable in 90 degree increments. The box shall be field convertible to cast iron.

External screws and bolts - shall be grade five, hex heads and be plated to resist corrosion.

Motor Shaft - shall be provided with an external recessed slinger at the drive end of the motor to provide additional (minimum IP-54) protection from moisture and foreign material. Rotor and stator air gap surfaces - shall be coated so as to prevent corrosion.

External Paint - shall be corrosion resistant - mill and chemical duty paint.

Nameplate - shall be of stainless steel and stamped per NEMA Standard MG1 Part 10 and Part 31.

Nameplate information shall include as a minimum, the nominal efficiency value per NEMA Standard MG1 Part 12, the bearing identification numbers, power factor, Torque values with speed range and amps for that torque value. Nameplate also shall include Full Load Slip RPM, Magnetizing amps and (if included) encoder PPR and Voltage rating.

Motor Vibration - shall not exceed .08 inches/second velocity.

Standards - Motors shall be in accordance with NEMA Standard MG1-1993, or the latest revision in so far as it is applicable

Motors shall be rated for operation at 450VAC, 3 phase, VFD power supply.

Motors shall operate successfully under running conditions at rated load with variation in the voltage or the frequency not exceeding the following conditions:

+/-10% rated voltage at rated constant volts/hertz ratio except for specific torque boost situations.

Motors shall operate successfully under running conditions at rated load and volts/hertz ratio when the voltage unbalance at the motor terminals does not exceed one percent.

Operating Characteristics - With rated volts/hertz ratio applied, motor performance shall be as follows for critical operating characteristics:

a. Torques - Motors shall meet or exceed the minimum locked rotor (starting) and breakdown torques specified in NEMA Standard MG1 Part 12 for Design B for the rating specified when on sine wave power.

b. Currents - Locked rotor (starting) currents shall not exceed NEMA Design B values for the specified rating on 5:1 constant torque or less and variable torque motors. NEMA Design A values are allowed for 6:1 constant torque or higher value constant torque rated motors. Motors shall be capable of a 20 second stall at six times full load current without injurious heating to motor components.

c. Temperature Rise - The temperature rise, by resistance, shall be 80 degrees C or less when measured at rated load on sine wave power, on inverter power ratings shall be 105 degrees C or less.

d. Service Factor and Ambient - Standard motors shall be rated for a 1.15 service factor on sine wave power and 1.0 service factor on VFD power in a 40C ambient.

Motors shall utilize Inverter Grade insulation system which consists of at a minimum Class F or better insulation materials with additional phase insulating material, extra end-turn bracing and Class H spike resistant wire. The resultant system shall withstand 2000 volt transients without premature motor failure and have no cable limitations in motor application.

Motors shall be given an insulation treatment to increase moisture resistance.

VARIABLE FREQUENCY DRIVES

The VFD should be a Siemens Synamics S150 or equal drive rated for 380-480V, 260A, and 200hp.

The order number shall comply with the following part number:

6SL3710-7LE32-6AA0-Z+K50+L26+L45+L60+M66+M90+L62+E61

The drive shall be equipped with the following options:

a. K50 – SMC30 sensor module cabinet-mounted

b. L26 – Main switch with fuses

c. L45, L60 – Emergency stop button in the cabinet door, 24V DC, controlled stop (category 1)

d. M66 – marine version (strengthened mechanical version of the cabinet, handrails, IP23 protection, anti-condensation heater)

e. M90 – top-mounted crane transport assembly for cabinets

f. L62 – braking unit (50kW)

g. E61 – individual certificate from ABS

Software and tools to include:

a. Sinamics Micromaster SIZER – order 6SL3070-0AA00-0AG0

b. STARTER commissioning tool – order 6SL3072-0AA00-0AG0

c. DCC Sinamics for STARTER – order 6AU1810-1HA20-1XA0

d. PROFIBUS communication board CP 5711 – order 6GK1571-1AM00 (for commissioning)

e. Drive ES Simatic V 5.4 (integration tool) – order 6SW1700-5JC00-4AA0

(single-user license and runtime license)

VFD features shall include:

a. Air cooled

b. Line side - fused disconnect

c. Input Contactor

d. Interior light & receptacle.

e. Operator panel

f. Emergency Stop Pushbutton Mounted in Door

g. Emergency Stop Cat. 0, 24VDC Uncontrolled Stop

h. PT100 Evaluation Unit (up to six PT100)

i. IP23 Degree of Protection

j. Marine Version

k. Top-Mounted Crane Transport Assembly for Cabinets

l. Profibus interface

m. Aux I/O card suitable to integrate local drive specific I/O

n. Brake section

o. Factory supplied cables for peripheral cabinets.

p. Modular cabinet system for baying side by side.

q. Customer Specific Documentation

Electrical specifications:

The System shall provide electrical services on three phase, three wire ungrounded circuits supplied with a nominal voltage of 450 VAC at 60 Hz.

The System shall be designed and constructed to meet the following:

a. The induction motors shall be providing service to both variable and constant loads.

b. All electrical components shall be suitable for voltage and frequency variations in the ships power supply.

c. The components shall be able to sustain service through a voltage variation of +6% to –10% permanent variations and a ± 20% transient variation for duration of 1.5 s.

d. The components shall be suitable for frequency variations to sustain service with a ± 5% permanent variation in frequency and ± 10% for 5 s for transient variations.

PROGRAMMABLE CONTROLLERS

The Contractor shall provide two (2) Siemens S7-317-2DP processors. The two (2) PLCs will be arranged as dual redundant processors. The Contractor shall provide and implement Simatic PLC’s system software redundancy.

1. The Drag-arm Hoist System No. 1 and PLC No. 2 shall share a common process image and program stored in each PLC’s individual FEPROM(s).

2. Each Drag-arm Hoist System PLC will contain individual redundancy operands stored in each of the individual PLC’s program.

3. The Drag-arm Hoist System PLCs are to be arranged with each PLC providing a physical redundancy scheme using redundancy compatible CPUs, CPs, Rack and Power supplies.

PLC SYSTEM PROCESS LEVEL COMMUNICATIONS

The Drag-arm Hoist System shall use a Local Area Network (LAN) using the Profibus Sinec L2-DP Communications Processors IM 153-2. The system shall be configured as illustrated in the contract drawings Each L2-DP processor shall provide process level communications between the main processor units, local signal modules, distributed signal modules and the field sensor and actuator devices. Each main CPU shall include one L2-DP port.