Waesche ssdg load bank testing

THIS IS TO BE AWARDED BASED OFF LOWEST PRICE TECHNICALLY ACCEPTABLE AND PAST PREFORMANCE

31100_BEC_0924_418

WORK ITEM 1: Ship Service Diesel Generator, Load testing, perform

1.  SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform load testing of designated Ship Service Diesel Generator (i.e., SSDG) listed in Table 1.

TABLE 1 – LIST OF SHIP SERVICE GENERATOR

CATERPILLAR mODEL NO.

DESCRIPTION

location

3512B

No. 2 Ship Service Diesel Generator,1360 KW, 450 Volt AC, 3 Phase, 60 Hz

Forward Main Machinery Room (5-44-01-E)

3512B

No. 3 Ship Service Diesel Generator,1360 KW, 450 Volt AC, 3 Phase, 60 Hz

Ship Service Diesel Generator Room (2-76-5-Q)

1.2 Government-furnished property.

None.

2.  REFERENCES

Coast Guard Drawings

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

Coast Guard Drawing 418A-WMSL-801-001, Rev A, Booklet of General Plans

Coast Guard Publications

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Coast Guard Technical Publication (TP) 7119, Ship Service Diesel Generator - Model 3512B

Coast Guard Technical Publication (TP) 7165B, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 1

Coast Guard Technical Publication (TP) 7166B, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 2 & 4

Coast Guard Technical Publication (TP) 7167, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 3

Other References

COMDTINST 9077.1 (series) Equipment Lockout-Tags-Plus Instruction

MIL-STD-1310, Sep 2009, Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility and Safety

3.  REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. 

None.

3.1.3 Protective measures.  The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.4 Interferences.  The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

• Piping
• Electrical Cables
• Switchboard Enclosure
• Vent Ducting
• Motor Operated Valves

3.1.5 Background information.  SSDG listed in Table 1 will be modified by the Coast Guard for any or all of the following tasks:

• Generator Bearing Replacement
• Shaft Alignment
• Pinning and Machine Work
• Diesel Engine Top-end Overhaul

3.1.5.1 After completion of above listed tasks, this Work Item is to be used for the Contractor to perform load testing of designated SSDG listed in Table 1.

3.2 Work location. The concerned work area is listed in Table 1. See the applicable drawings in References in Paragraph 2 for guidance, locations, and details.

3.2.1 Proposed temporary cable routing must be developed using USCG Dwg 418A-WMSL-801-001. Submit a CFR.

3.2.1.1 Temporary load bank cables must be routed from the switchboard to the load bank via a single route, and must not be routed separately by any method which would lead to unbalanced phase cables to transit through hull or bulkhead openings.

3.3 Grounding.  The Contractor must ensure conductive surfaces of the load bank enclosure are appropriately bonded and grounded for protection of personnel.

3.4 Contractor Furnished Materials (CFM).  The Contractor must furnish materials listed in the Table 2 for load testing of the SSDG listed in Table 1.

TABLE 2 – CONTRACTOR furnish MATERIALS

MATERIALS

description

Load Bank

1500 KW, 450 Volt AC, 3 Phase, 60 Hz, Resistive

Load Bank Cables

Approximate length of 300 Feet Cables with ring tongue compression lugs, 6 Paralleled #4/0 copper (single conductor) per phase (18 Total x 300 Feet) and one additional length for the equipment grounding conductor or Six LSTSGU-400

3.4.1 The contractor must provide miscellaneous hardware required for electrical installation (i.e. Nylon Stuffing Tubes, Chafing Gear, Box Connectors, Lugs, Fasteners, Wire Nuts, Tapes, Cable ties & Cable Mounting Brackets, etc) of the electrical equipment.

3.5 Load testing.  The Contractor must provide labor and crane services as necessary for placing load bank at suitable location (i.e., On the pier or the ship). After completion of load bank testing of SSDG, the Contractor must remove all installed equipment and cables used during testing.

3.5.1 Testing plan. The Contractor must submit a plan for load testing of the SSDG in accordance with TP 7119. Submit the load testing plan no later than one week after the Arrival Conference in a CFR.

3.5.1.1 The plan must cover the following topics at a minimum:

• Steady increase of load in multiple steps up to 100% real power load
• No less than 2 hours of continuous testing at 100% load
• Simulated start of 450 HP load (assume no more than 200% FLA)
• Emergency shutdown procedures
• Load bank specification and location
• Cable locations for load bank
• No-load tests 
• Data to be collected during tests
• All proposed connections, cable and load bank configurations

3.5.1.2 The Contractor must start testing of the SSDG after COR Approval of submitted Test Plan and official acceptance by the Contract Officer (KO).

3.5.2 After placing load bank at suitable location (i.e., On the pier or the ship) the Contractor must install the cables from the load bank to associated SS Switchboard bus bars (i.e. Back side of SS Switchboard No.2S), according to the agreed upon cable routing. 

CAUTION

THE BACK SIDE OF THE SWITCHBOARD SHOULD BE ROPED OFF AS A PERSONNEL EXCLUSION AREA (APPROXIMATELY 10 FOOT RADIUS FROM ANY VISIBLE LIVE BUS

3.5.2.1 The Contractor must route the cables from designated SSDG to load bank through hatches and passageway. The Contractor must run cables in overheads as much as possible to avoid trip hazards.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

SAFETY

At any point in the load test or operational testing period if the need presents itself the engine – Prime mover may be shut down by the Tech rep with communication to the USCG operational Engineer utilizing the local EOS, E stop or shut down from the switch gear.  Any of the three options will automatically open the SSDG buss breaker

3.5.3 After warmup of SSDG until coolant temperature reaching 140 Degree F, the Contractor must perform the load testing of designated SSDG listed in Table 1 at following load condition.

TABLE 3 – LOAD TESTING

LOAD

TIME (HOURS)

 *No Load

0.25

50 % Load

0.25

75 % Load

0.25

100 % Load

1.75

50% Load

0.25

No Load

0.25

• Running no load testing. No load testing will consist of running the engine at idle rpm until the engine coolant temperature reaches 140 deg. F during that warmup time safety testing will be performed for oil pressure, temp warning, emergency shut down conditions, and coolant temp. warning and shutdown. Shipboard alarm verification will be observed at that time as well.

3.5.3.1 Engine parameter readings during the load bank test must be taken every 15 minutes including, but not limited to the bullet points in this paragraph. Submit a CFR.

• Engine temp, Coolant temp, oil pressure, boost pressure, intake air temp after the aftercooler, exhaust stack temp, left and right bank exhaust temperatures.
• In addition to the generator load test form, a Caterpillar steady state engine performance file shall be recorded on the engine ECM all related available information.
• Voltage reading per phase, amperage readings per phase, frequency, bearing and winding temps.
• Pre and post-test PSSRP shall be saved on the ECM to provide verification of all available diagnostic codes and events.
• All electronic files and reports must be submitted via CFR.

3.6 Load test documentation.  After completion of testing, the Contractor must provide all collected data sheets to the Contracting Officer.

4.  NOTES

This section is not applicable to this work item.