Pisces Shimada MCS Mondernization 1 Sept21REVA.pdf

NOAA Ships PISCES and SHIMADA

MCS System Replacement

Sept 2021- REV A

LIST OF CHANGES: SPECIFICATION REV A

1. Modified Paragraph 6.3.2 to clarify ABS engineering and surveyor cost responsibility.

2. Modified Paragraph 7.1 to clarify the requirements of the Contractor for all industrial level work.

3. Modified Paragraph 7.2 clarifying contractor provision of shipboard spare parts, tooling, and test equipment for each ship.

Machinery Control System Replacement on

1. Introduction

1.1 Scope and Background

This work item replaces the existing Machinery Control System (MCS) on NOAA

Ships PISCES and SHIMADA with a new system based upon a distributed producer/consumer model, consisting of Intel processor-based Human Machine

Interface (HMI) displays, redundant PLC processors, PLC-based Input/Output (I/O) modules, and remote alarm panels networked together. The new system shall consist of

Commercial-Off-The-Shelf (COTS) equipment packaged and mounted in the existing

Machinery Control Station, Pilothouse, and monitoring capability from designated engineering staterooms.

The existing MCS on both PISCES and SHIMADA are manufactured by Robichaux

Automation and Control, Incorporated (RAACI), now a subsidiary of Trident Maritime

Systems using an RTU board communications network. The new PLC based

Machinery Control System incorporates the control and monitoring and display of the following ship systems: throttle controls, TLIs, bilge alarms, automated control of the generators, main motors, bow thruster, and other various machinery parameters.

1.2 Abbreviations

Acronym Definition

ABS American Bureau of Shipping

ABT Automatic Bypass Switch

ACCU Automated Control system Certified for Unattended engine room.

An ABS Class Notation for unmanned propulsion space operation

AI Analog Input

AO Analog Output

CDROM Compact Disc Read Only Memory

CFI Customer Furnished Information

CFR Code of Federal Regulations

CDRL Contract Data Requirements List

COTS Commercial-Off-The-Shelf

DAU Data Acquisition Unit

DE Diesel Engine

DI Digital Input

DO Digital Output

DVD/CDROM Digital Video Disc/Compact Disc-Read Only Memory

DVTP Design Verification Test Procedure

EANA Engineers Assistance Needed Alarm

EAP Engineers Alarm Panel

ECP Engineering Change Proposal

EOS Engineering Operating Station

EOT Engine Order Telegraph

FAT Factory Acceptance Test

FM Firemain

FMEA Failure Mode Effects Analysis

FO Fuel Oil

FW Fresh Water

Hz Hertz

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronic Engineers

LAN Local Area Network

MCC Main Control Console

PLC Programmable Logic Controller

PSTP Periodic Safety Test Procedures

RTD Resistance Temperature Detector

RTU Remote Terminal Unit

SCC Ship Control Console

SW Seawater

TLI Tank Level Indicator

UPS Uninterruptible Power Supply

USCG United States Coast Guard

2. References

The MCS shall meet the requirements of these Performance Specifications. Rules and regulations which are in effect at the time of award shall be used, unless otherwise noted.

Guidance in order of precedence is provided in Section 2.1. Customer Furnished Information is provided in Reference Section 2.4.

The Contractor shall be responsible for acquiring the services of all regulatory bodies involved for certification and design approvals, materials testing, construction survey, shop inspections and shipboard trials for all MCS components and other parts as required.

2.1 Order of Precedence

In the event of a conflict between specification requirements, the following precedence shall be invoked. Any specification conflicts shall be brought to the attention of the

COR.

This Performance Specification

ABS Steel Vessel Rules

U.S. Coast Guard Regulations

2.2 Government Reference Documents

2.2.1 46 CFR, Subchapter J, Electrical Engineering

2.2.2 46 CFR, Part 62, Vital System Automation

2.2.3 MIL-DTL-24784/4B, Associated Detail Specification Manual, Commercial

Off the-Shelf (COTS) Equipment Manual Requirements.

2.3 Non-Government Documents

2.3.1 ABS, "Rules for Building and Classing Steel Vessels", Part 4, Machinery

Equipment and Systems (2019)

2.3.2 US Supplement to ABS Rules for Steel Vessels for Vessels Certified for

International Voyages

2.3.3 ANSI C39.1 "Requirements for Electrical Analog Indicating Instruments"

2.3.4 ANSII/NCSL Z540-1, Calibration Laboratories and Measuring and Test

Equipment General Requirements

2.3.5 IEC 61131-3, Standard for Programming PLC's (Programmable Logic

Controllers).

2.3.6 IEEE-STD-45, Recommended Practice for Electric Installations on Shipboard

2.3.7 ASTM F1166-, Standard Practice for Human Design for Marine Systems, Equipment and Facilities

2.3.8 ISA-S37.1 Electrical Transducers, Nomenclature and Terminology

2.3.9 NEMA 250 Enclosures for Electrical Equipment – 1000 Volts Maximum

2.3.10 National Electric Code, Section 250

2.3.11 IEEE 802.3, Local and metropolitan networks, Part 3: Carrier sense multiple access with collision detection (CSMA/CD) access method and physical layer specifications

2.3.12 IEEE 830, Recommended Practices for Software Requirements Specifications

2.3.13 IEEE/IEA 12207, Standard for Software Life Cycle Processes

2.4 Customer Furnished Reference Documents

2.4.1 Contract Data Requirements List (CDRL)

2.4.2 Technical Manual FRV40-226-014-010 “Control and Monitoring System

Model: NOAA 3 and NOAA 4”

2.4.3 Drawing M283-202-FE24 “Machinery Control System Block Diagram”

2.4.4 Drawing M283-202-PE28 “Machinery Control & Alarm System Termination

List”

2.4.5 List of New Alarm and Signal Data

2.4.6 FE30-002-03 “NOAA FRV40 Periodic Safety Test Procedure”

2.4.7 Drawing SH-085-FZ31-Rev 2 “Final Drawing Index”

2.4.8 PISCES Engineer’s Operating Manual

2.4.9 SHIMADA Engineer’s Operating Manual

2.4.10 SH-202-FE25 Alarm and Control Points List Drawing (I/O List)

2.4.11 Technical Manual FRV40-226-008-010 Bow Thruster Model: 40 T3S

2.4.12 Drawing NHB901-E-001 “Henry Bigelow Automation Upgrade”

2.4.13 Technical Manual “Upgrade Vessel Monitoring and Control System NOAA

Ship HENRY B. BIGELOW Failure Mode Effect Analysis”

3. Government Furnished Material

3.1 None

4. Existing Machinery Control System

4.1 Overview of Machinery Control System

The MCS continuously controls and monitors specific points in the vessel’s equipment and machinery spaces. Operators are immediately alerted to any abnormal conditions by

Audible Alarms and Visual Indicators located on the Main Control Console (MCC), Pilothouse Console and Engineer Remote Notifier Panels. See Reference 2.4.2 for further details on the existing MCS.

4.1.1 Main Control Station Console (MCC)

The Main Control Station Console (MCC) is the central terminal for the monitoring and alarm system. All signal conditioning and alarm functions are located in card racks within the console and various DAUs providing easy access for maintenance and repair.

Dual Lamp Indicators are used to display all alarms and status indications.

Digital Meters provide continuous display of pressure, temperature, and alarms.

Illuminated Push Buttons are provided to activate and display the function.

The Propulsion Control, Engine Order Telegraph, Watch Call, and Attendance

Monitor units are mounted on the MCS Panels. A push-button transfers all

Propulsion Control functions to the Pilothouse Console for unattended operation.

4.1.2 Pilothouse Console

The Pilothouse has full control of the propulsion system when transferred from the MCC. In addition, the console provides vital and summary alarm indicators from the monitoring and alarm system, Engine Order Telegraph controls; the

Attendance Monitor unit and a supervised Fire Detection System Annunciator panel.

4.1.3 Engineers Remote Notifier Panel

Summary alarms for the vital/non-vital alarms are visually displayed along with an audible alarm. A selector switch activates the Chief Engineer’s, First

Assistant Engineer’s, and Second Assistant Engineer’s stateroom panel as designated from MCS Duty Selector Screen.

The audible alarm on these Notifier Panels only can be silenced (not acknowledged), however the visual indication continues to flash, and the system audibles are active until acknowledged at the MCS.

The audible alarm on the Mess Notifier Panel can only be silenced from the

MCS.

4.1.4 Engineers Stateroom Alarm Notifier Panel

Identical Notifier Panels are located in the Chief, First, and Second Engineer’s

Staterooms. In addition to the summary alarms displayed on the Watch Call

Notifier panels, WATCH CALL and ASSISTANCE NEEDED alarms are provided.

4.1.5 Power Supply

The Main Power Supply converts the ship’s supply to 24VDC using high reliability solid state and heavy-duty components. An integral battery charger and battery bank provide instantaneous backup power in the event of failure of the normal and emergency ship’s power. An Automatic Bus Transfer (ABT) switch provides rapid failover from the normal power feed to the emergency bus.

4.1.6 Indications

Several types of transducers, RTDs, and various switches are displayed on the ship’s Machinery Control System. Most are displayed within the various computer control screens on the consoles, but both vessels have several stand-alone analog gauges mounted in the MCS console.

Several other dual lamp indicator switches are installed in the console which are used to display machinery operating status and allow for starting and stopping certain essential equipment, such as start and stop buttons for the Main Fire

Pump and Bilge Pump.

4.1.7 Sensors

The basic elements of the monitoring system are the sensors. The various types used are dry contacts (positioned mechanically), pressure switches, temperature switches, flow switches, level switches, thermocouples, RTDs and transducers.

Each performs a specific function or provides an analog signal that is processed for either display, alarming at set points, or both.

4.1.8 Engine Order Telegraph

The Engine Order Telegraph System (EOT) allows the bridge operating personnel to communicate propulsion orders to the engineer on watch in the

MCS for attended operation. Indicators display the command and response action and an alarm bell advises of any misaligned selectors. A wrong direction alarm bell or buzzer will sound if the MCS selector is aligned in the opposite direction and until the shaft has stopped and rotates in the ordered direction.

4.1.9 Watch Call System

The Watch Call System consists of a master control MCS screen, pushbutton, and remote Notifier Panels located in the engineer’s staterooms. To initiate a call, the selected engineer’s switch is depressed. The switch illuminates, and the audible and WATCH CALL indicates in the stateroom. The correct response by the called engineer is to depress the ACK button. This silences the audible and extinguishes both illuminated indicators. (The master station can cancel the initiated call by pressing the MASTER CANCEL switch)

4.1.10 Assistance Needed Alarms

Two actions will cause the Assistance Needed Alarm to activate: (1) depressing the ASSISTANCE NEEDED push button on the MCC, and (2) failure to acknowledge any alarm at the MCC after a five minute time delay.

Visual indicators are also located on the engineer stateroom alarm panels.

4.1.11 Attendance Monitor

Console has the ability to select different operating modes per USCG regulations. The Attendance Monitor allows the bridge operating personnel to monitor the engineer on watch in the machinery spaces during attended conditions. The pilothouse console initiates operation of the monitor, and the engineer on watch must respond to the cyclic monitor audible and visual indicator, ATTENDANCE MONITOR, by depressing the illuminated push button within a set time period. Failure to respond results in a FAIL TO

REPORT alarm which should be investigated. There is also an UNATTENDED mode which does not require an operator to report.

4.1.12 Miscellaneous MCS Subsystems

4.1.12.1 Shaft Revolution Counters

The Shaft Revolution Counter employs a non-contact method of counting the total number of revolutions a shaft has accumulated, turning in either direction (TACHTROL 30 RPM Counter). The system consists of a small steel target attached to the propeller shaft or shaft coupling, one proximity sensor, and one junction box. A centrally located driver and readout module completes the system.

The MCS enclosure contains all the remaining circuitry, printed circuit board, power supply, digital display, battery back-up, and other components required for system operation.

The Digital Revolution Counter display is a self-contained, 6-digit, 7-segment LED PCB which contains all the circuitry necessary to provide a continuous total revolution count readout for the shaft. A means of clearing (reset) each display is provided. Inadvertent resets are prevented by use of a keylock switch located on the MCS console.

4.1.12.2 Bilge Level System

The bilge level is monitored in the machinery spaces, winch rooms, Bow thruster, transducer, and Domestic stores/Domestic Equipment

Room. The level sensors for machinery bilges are located at different levels to monitor high and/or high-high levels.

4.1.12.3 Ground Fault Detection

Ground fault on the 24VDC power system is provided by two lamp indicators.

4.1.12.4 Watertight doors

Five (QTY 5) watertight doors and two (QTY 2) Centerboard doors are currently monitored for OPEN/CLOSE indication.

4.1.12.5 H2S Detection

MCS monitors the H2S sensors in the Domestic Equipment Room and alarms at the predetermined set-point.

4.1.12.6 Fire Monitoring and Detection

MCS monitors Fire Pump discharge pressures, HAZMAT locker temperatures, and signals alarms from the Fire Monitoring and

Detection System.

5. Replacement MCS Requirements

5.1 General MCS Requirements

5.1.1 Overall Description

The new MCS shall retain or exceed the current ACCU ABS Classification of the vessel and be ABS approved. The new system shall meet or exceed the capability of the existing RAACI MCS using industry best practices for the system described below. The new MCS shall be based on a PLC solution to provide integrated control and monitoring of the machinery plant, including the propulsion system, electric plant, diesel engine prime movers, and auxiliary systems. Material applications and hardware shall be COTS to the maximum extent practical. Use of custom designed or proprietary equipment without a commercial equivalent shall not be used without specific authorization from the

COR. MCS software shall be in an industry standard high level non-proprietary open source operating system. A similar PLC based Machinery Control System installed on NOAA Ship’s DYSON and HENRY BIGELOW is provided as

Reference 2.4.12 and may be used to assist the Contractor to create a new

Machinery Control System applicable to NOAA Ship’s PISCES and SHIMADA.

The new MCS shall incorporate all monitoring and control capabilities of the existing MCS provided in Reference 2.4.2 and Section 4, Existing Machinery

Control System, including all alarms and monitoring data provided in Reference

2.4.4.

The new MCS shall utilize a common system architecture for both vessels.

When operating in Unattended mode, the MCS shall maintain all existing capabilities for initiating automatic start of standby equipment upon failure of the operating unit and provide notification of the casualty and change in equipment operating status.

Existing instruments and data input/output points are to be retained and reused in the new system.

5.1.2 System Hardware

Allen Bradley PLCs shall be utilized. The new PLC platform shall be the Allen-

Bradley Controllogix platform to match other equipment currently installed aboard the vessels and reducing overall spares inventory requirements. Each PLC model shall be supportable for 10 years after it is installed on the vessel. The new

MCS design shall utilize a minimum of seven (7) or ten (10) slot chassis in order to provide the most effective and efficient distribution of shipboard I/O, as well as limiting the loss of I/O in the event of a chassis failure. All chassis shall be provided power from dedicated power supplies, UPS, and be connected to vital ship’s power. PLC modules shall be hot swappable allowing for removal and replacement while under power.

All new MCS enclosures shall be rated NEMA 4 (IP65) or higher.

The new MCS shall be designed with the ability to change-out (replace) a spare backup computer in the event of any single computer failure. Contractor shall furnish one spare back-up PC workstation computer for each vessel that can be installed in any of the workstations to resume operation.

PLCs and PLC Cabinets/DAUs shall be centralized and consolidated to the maximum extent practical.

5.1.3 HMI Displays

The PLC processor shall transmit its data to all HMI displays via the LAN to provide the operator(s) with machinery monitoring capability and situational awareness. Each HMI display will share its data with all other HMI displays over the LAN such that they are all synchronized. Commands issued from the HMI displays will be sent to the PLC processors and acted upon as plant conditions allow.

The MCS monitors shall display graphics of the propulsion system, electric plant, diesel generators (including prime movers), and auxiliary systems. The bridge station is to be provided with a single monitor identical to those required for the MCC. The monitors must display all control and monitoring parameters shown on the guidance drawing for List of Inputs and Outputs (LIOP) and include all alarms required by regulatory bodies.

Screen displays are to be designed so that an incoming alarm will provide clear indication of the graphics page where the alarm exists. All alarm conditions must have both an audible and visual indication. The audible indication may be silenced by a push button on the MCC, however the alarm will remain as a visual display until acknowledged on the graphics page where the condition exists. Each alarm must be individually acknowledged and is to continue to have an indication that an alarm condition exists until the condition is cleared.

The most recent alarm conditions are to be displayed on screen as per industry practices. All alarms are to be recorded on an event log within the program per

Section 5.12.5.

5.1.4 New Signals and Alarms

The new MCS shall install and incorporate the new monitoring and alarm points listed on Reference 2.4.5. These items shall require the installation of new sensors/transducers and cabling between them and the DAU terminal specified by the system integrator. These are to be included in the system design and HMI screens. Any industrial work that requires new penetrations and changes of existing ship configuration for the incorporation of the sensors and cabling must be updated in the Ship’s Drawing Index.

5.1.5 Control and Monitoring Stations

The new MCS must include control and monitoring stations with the capabilities listed in Table 1. Each station shall be connected to the new MCS and have power supplied using existing connections and cables or replaced as necessary. Full monitoring and command capability of the existing system via administration permission shall be retained and provided in the new MCS as well as the full monitoring and command capability from each engineering station listed below:

PISCES BELL M. SHIMADA

State Room Name Space Number Space Number

Chief Engineer 02-29-2 02-29-2

First Assistant Engineer

02-46-2 02-37-2

Second Assistant Engineer

02-37-2 02-46-2

Third Assistant Engineer

01-32-4 2-29-4

Third Assistant Engineer/ Engineering Electronics Tech

2-46-1 2-34-2

Table 1. MCS Control Station Capabilities

Station Location Capabilities

Main Control Console

(MCC)

EOS Single lever throttle control/engine order telegraph and propulsion shaft RPM indication. Control and monitoring of all propulsion plant and auxiliary machinery plant parameters and alarms. Full View, Monitoring, Command and Control capability.

Ship Control Console

(SCC)

Bridge Single lever throttle control/engine order telegraph, steering control, DPS control, Bow Thruster control. Monitoring of propeller rev/min, rudder angle and bow thruster speed and angle. Monitoring of propulsion and auxiliary machinery plant parameters and alarms. Full View, Monitoring, Command and Control capability.

Aft Control Station

(ACS)

Bridge (Aft Control Station)

Single lever throttle control/Engine Order Telegraph, steering control, DPS control, Bow Thruster control. Monitoring of propeller rev/min, rudder angle and bow thruster speed and angle.

Port and Starboard Bridge Control Stations

Bridge (Port and Starboard)

Single lever throttle control/Engine Order Telegraph, steering control, Bow Thruster control. DPS control at Starboard Station.

Monitoring of propeller rev/min, rudder angle and bow thruster speed and angle.

Chief Engineer

Chief Engineer’s Stateroom

Full MCS View, Monitoring, Command and Control capability based on administrative permission.

1st Assistant Engineer 1st Assistant Engineer Stateroom

Full MCS View, Monitoring, Command and Control capability based on administrative permission.

2nd Assistant Engineer

2nd Assistant Engineer Stateroom

Full MCS View, Monitoring, Command and Control capability based on administrative permission.

3rd Assistant Engineer 3rd Assistant Engineer Stateroom

Full MCS View, Monitoring, Command and Control capability based on administrative permission.

3rd Assistant Engineer 3rd Assistant Engineer Stateroom

Full MCS View, Monitoring, Command and Control capability based on administrative permission.

5.1.6 Bow Thruster and Dynamic Positioning Systems

Addition of a separate command and control screen for the Bow Thruster in the

EOS/MCS, including the ability to start and stop the Bow Thruster.

The new MCS must interface between Bow Thruster, Dynamic Positioning and in addition to the propulsion systems.

5.1.7 EasyGen SSDG Governor Controls

The new MCS shall be integrated with the existing EasyGen SSDG Governor controls already installed on the vessel. The new MCS shall incorporate the

SSDG CAT ET monitoring data points, alarms, and faults into the Command and

Control Screens. The new MCS shall not duplicate the capabilities of EasyGen, but shall receive input and monitoring of the EasyGen controls, including the ability to automatically start and stop SSDGs. Contractor shall utilize the expertise of the EasyGen installation design engineer while planning the new system design. FSV EasyGen design engineer contact information is provided below:

Current Power Solutions, Inc.

5050 West Greens Road

Houston, TX 77066

POC: Arseniy Farafanov

Phone: 832-680-6826

Email: arseniyf@currentpsi.com

5.1.8 Notifier Panels

New alarm annunciator panels (henceforth called Notifier Panels) shall be provided in all locations listed in Section 5.5 as required by ABS regulations for

ACCU operation. During attended operations only the Engineer’s Assistance

Needed Alarm shall be active on the stateroom panels. An engineer call system mailto:arseniyf@currentpsi.com and dead man timer function must be provided. Rotating beacons and audible alarms must be provided in each machinery space to alert watch standers of alarm conditions at the MCC and be able to visually differentiate between vital and non-vital alarms.

5.1.9 Software Rights

At expiration of the warranty period, all developed MCS software and coding shall be turned over to the Government and the Government shall OWN, MAINTAIN, and CONTROL the MCS code. All licenses for software shall be transferred to the Government at the acceptance of the system.

5.1.10 Data Logging and Recording

The new MCS shall have a graphic generator module with online and historical trending capabilities.

5.2 Main Control Console

The Machinery Control Console (MCC) enclosure may be reused. At a minimum, Contractor shall replace the console panels with new panels fabricated to house and mount all new monitors and equipment as well as remounting equipment retained for re-use. The MCC console has two upper panels and two lower panels. The majority of the components shall be removed from both inside the MCC enclosure and from the face and desk panels of the MCC. The old console panels shall be discarded.

The panel-mounted components that shall be retained and mounted in the new panels include the following:

1. Throttle

2. Throttle selector switch

3. Rudder angle indicator

4. Steering station control lever

For the MCC two upper panels, a minimum of four HMI displays shall be installed. These

HMI displays shall include connections to shared console mounted keyboards and electronic pointing device. Two keyboard and electronic pointing device units shall be installed in the lower panels; one on each panel. These keyboards and pointing device units shall be dustproof and protect against water splashes per IP64 standard.

The functionality of all console mounted controls shall be retained but may be replaced with new industry standard pushbuttons.

All operation data must be logged continuously to the HMI computers and stored on the computer and a remote onboard location for a minimum of 3 years.

5.3 Remote Data Acquisition Unit Boxes (DAU)

The Contractor shall minimize the number of DAUs and enclosures as technically allowable. The existing DAU control panels and enclosures shall be removed and replaced with new industry standard panels/enclosures to minimize physical footprint.

5.4 Pilothouse Console

The existing hardware in the Pilothouse console shall be removed and the single panel replaced to fit the new single HMI display. Monitor connections shall include shared keyboards and electronic pointing device. The keyboard/ electronic pointing device unit shall be installed in the lower panel. The keyboard/trackpad units shall be dustproof and protect against water splashes per IP64 standard.

In addition to the HMI display, space shall be reserved for the new Contractor provided

HMI brick computer, remote PLC I/O rack, any associated signal termination panels, and network switches as required to be mounted inside the Pilothouse console.

Cabling shall be run between the Pilothouse to Main Control Station to connect the switch to the rest of the network. The length of the run may exceed the capabilities of network cable and may necessitate use of fiber optic cabling. Additionally, a set of properly terminated spare cabling shall be installed for use and/or troubleshooting purposes.

5.5 Engineer’s Notifier Panels

Additional monitoring capability will be available in the Chief Engineer’s state room, the 1st, 2nd, and two 3rd Engineer’s state rooms, the ship’s Mess, and Lounge. The

Mess and Lounge Notifier Panels shall have audible and visual alarm only with indication of alarm type. The Notifier Panels, as discussed in Section 4.1.3, will be installed in the Chief, 1st, 2nd, and the two 3rd Engineer’s state rooms.

Network connections shall be installed from Network enclosure to these locations to allow communication to the MCS. Due to the length of the runs, these connections may need to be fiber-optic cables.

All of the state rooms have temporary ceiling material that may be needed to be removed to facilitate the installation of the new cables. The ceiling material shall then be re-installed after the cable installation has been completed.

The Mess and Lounge currently contain one Notifier Panel each that will be removed and replaced with a limited functionality remote alarm panel. The existing cable will be removed, and a new cable installed to the Main Control Console (MCC).

5.6 Power Supply

The existing MCS UPS and power supply shall be removed and replaced.

All existing DAU 24VDC power supplies shall be removed.

All remote PLC enclosures shall receive power from a new redundant 24VDC Power

Supply system, centralized to the maximum extent practical.

5.7 Sensors

The MCS Signal List that provides details for signals that interface to the MCS is provided as Reference 2.4.4. The Contractor shall validate this information prior to incorporating it into the new MCS design.

All signals per Reference 2.4.4 shall be terminated in the PLC I/O chassis, junction box, or to a pushbutton or indicator as required.

A new signal interface specification shall be developed using References 2.4.4 and

2.4.5 to encompass new derivations and set points of the new signal requirements per

Contractor.

This new Signals List shall be delivered in iterations, as required, to NOAA when there is an official revision that impacts the baselined software or hardware.

5.8 Engineer Order Telegraph (EOT)

The Contractor may re-use or replace the existing EOT and integrate into the new

MCS.

5.9 Fire Detection System

The existing Fire Detection System is an Intelligent Fire Detection and Alarm System

(AFP-200). The system includes two remote panels; one in the Pilot House and one in the Engineering Operating Station (EOS) The Fire Detection System shall be integrated into the new MCS to include receiving alarms, and output alarm acknowledgement and controls.

5.10 Operator Interface Panels and HMI Displays

All monitor displays must be LED touch screen and provided with an alternate equipment/system control in event of failure of touch screen functionality. All HMIs shall be of the same make and model, to the greatest extent practical. Each monitor shall be configurable to display desired operating parameters as selected by the end user. Pointing device functionality shall be incorporated. Hardwired pushbuttons, indications, and gauges shall be installed as required to meet ABS certification requirements or operational requirements. The Bridge display monitor shall be dimmable.

Displays shall be touchscreen and shall be designed to take into human factors engineering standards from ANSI/ISA-101.01-2015, Human Machine Interfaces for

Process Automation Systems or similar.

The Analog parameters which are displayed by value and which are subject to rapid fluctuations shall be filtered for readability.

The application shall incorporate provisions to disable the keystroke combinations that permit immediate system shutdown. These keystrokes are as follows: CTRL-ALT-

DEL, ALT-TAB, ALT-ENTER, ALT-F4, SHIFT-DELETE, CTRL-F4 and CTRL-

ESC.

Means shall be provided for the operator to disable the touchscreen such that the display can be cleaned without activating HMI functions, without interruption of the display of HMI/GUI pages, and while maintaining control of the HMI functions using an alternative method.

Each monitor shall be furnished with dimming capabilities.

Abbreviations used on MCS HMI screens shall conform to ASME Y14.38-2013.

5.11 Machinery Control System Network

The Contractor shall install a redundant set of properly terminated spare cabling for every MCS unit within the network for use and/or troubleshooting purposes.

If additional cable runs are required, additional multi-cable transits (MCT) shall be provided by the Contractor. For bidding purposes, Contractor shall estimate installation of eight (QTY 8) Multi-cable transits of approximately 4-inch x 6-inch each.

5.12 Monitoring and Control System Requirements

All MCS stations per Section 5.1.5 Table 1 shall have the ability to monitor the engineering plant signals and status of the MCS. Control shall be at any console with the applicable privileges based on the operator rights and the node designated for control of machinery and or space(s). New MCS Control Algorithm capability shall be identical to the original MCS Algorithm capability.

During plant operation, the MCS must continuously monitor temperatures, pressures, flows, levels and electric load characteristics. Abnormal conditions, including analog sensors out of range alarms, shall be monitored and sensed at the MCS and shall actuate alarms to warn of the condition. Adjustable time delays shall be provided for alarms so that normal vessel motions or the automatic starting and stopping of equipment do not cause nuisance alarms.

The system shall be capable of temporarily disabling alarms due to malfunctioning equipment or during startup or maintenance procedures. Any disabled alarm shall be clearly indicated on the monitoring screens until the alarm is re-enabled.

The system shall allow users to reset or adjust alarm parameters from the MCC screen without need of any software modifications, with changes broadcast to all other workstations automatically. Unauthorized modification of MCS software data and set points shall be precluded by use of security features with multiple access levels. The

MCS shall provide self-diagnostic capability down to the replaceable module level.

An MCS page shall be provided to display a list of out of service signals and their default values.

5.12.1 MCS Control Transfer

The MCS transfer logic shall recognize a single transfer protocol for all MCS

Station-In-Control transfers as follows:

The Machinery Control System shall permit complete throttle operation and control over the full range of plant operation from all control stations in accordance with the ABS ACCU requirements for unattended machinery room operation, without intervention of engineering personnel.

Throttle control heads at all control stations shall be powered units that have control levers automatically follow the station in control to ensure bumpless transfer when changing station in control locations. Control heads shall have dual potentiometers, dimmable internal illumination, and alarms for system failures or loss of power. The control and monitoring system shall be designed for primary control and monitoring from the

MCC, with normal operation from the Bridge. The MCS shall permit the

Main Control Console to take control from any remote control stations without Bridge personnel action in the event of a casualty.

5.12.2 General Software Requirements

The Contractor should demonstrate CMMI 2 or 3 level type practices without the necessarily requiring certification (some are outlined below to endorse repeatability and good software development practices).

Creation and development of software shall be disciplined with proper development and change management processes. There shall be no ad-hoc software builds or patches in a deployed or locked down version of the MCS software package. Configuration Review Board (CRB) shall be held with all stakeholders which shall include documented Peer reviews and a Software

Quality Assurance approval. All discrepancies from the system test shall be documented and reviewed in the CRB for the purpose of analysis, correction, implementation in a future revision, and subsequent testing.

All source code and executable files shall be managed in a central repository and maintained using CM software Subversion, Rational, or similar and then turned over to NOAA program office after successful commissioning and warranty period of the developed system.

PLC programming languages shall be in accordance with Reference 2.3.5 or similar.

The Contractor shall prepare software documentation as detailed in Section 6.3.

The Contractor shall follow Reference 2.3.13 to establish a common framework for software processes, activities, and tasks that are to be applied during development of MCS. The overall system requirements shall be identified and documented in the System

Design Requirements (SRDs). These system requirements shall be further derived into software and hardware requirements specifications documented as HWRS and SRS respectively. After completion and acceptance of these requirements by NOAA, then the

Contractor shall proceed with software and system development.

The Contractor shall prepare and conduct MCS Design Reviews as detailed in Section 6.2.

5.12.3 Alarm Requirements

Each signal along with new MCS derived signals shall be checked and verified in accordance with the information and updated requirements of this section.

Alarm audible tones shall be annunciated and listed in the highest order at the associated station in control on a priority basis, such that higher priority alarm unacknowledged tones will mask lower priority alarm unacknowledged audible tones.

All alarms and video displays should be similar visually and audibly to current conditions but using latest industry best practices.

5.12.4 MCS Supportability

The new MCS must be 3rd party supportable and shall be non-proprietary.

Materials shall be COTS to the maximum extent practical. Use of custom designed or proprietary equipment without a commercial equivalent is prohibited without specific prior approval by the government. MCS software shall be in an industry standard, high level, non-proprietary language.

The Contractor shall identify all software products used in the design, development, testing, installation, and troubleshooting of the MCS including the network, PLCs, GUIs, component level firmware, and configuration thereof.

The Contractor shall provide the configuration of and data within all software products. This shall include but is not limited to pseudocode, automated configuration management tools, test software, troubleshooting tools, simulation programs, compilers, and linkers. The source code, configuration and data for all noncommercial software shall be provided.

Two Plug-in laptops for troubleshooting and maintenance shall be provided, which shall include the following:

Transfer of data logs from system and recording onto removable media.

Loading, configuration, and management of software to all components in the new MCS including the PLC modules.

Ability to select and view all signals in electrical and engineering units, set points, coefficients, etc.

Other maintenance, troubleshooting and system recovery functions as required

All software tools shall be provided configure and load software programs.

5.12.5 Data Logging and Recording System (DLRS)

Redundant Data Loggers shall capture and record all analog and discrete signals in the system with date and time stamp at a frequency of no less than 2 Hz. The recorded data shall be viewable on-demand at an HMI console and shall be exportable to an external laptop and or removable media. The exportable data shall be in a text and *.CSV format or similar. The data loggers shall capture events such as but not limited to:

Commands

Status changes

Alarms

Operator changes in configuration set points

Out of Service Tagging and Return to Service

Actions

System events like Start Up, equipment faults/failures, communication faults/failures, etc.

EOT and Bells

5.12.6 Master Clock

Local time shall be displayed at each HMI.

A means shall be provided for an operator to set local time if local time is not available from the ship's master clock.

Local time shall be automatically updated on each applicable unit at power-up and reset and at least once in every 12 hours thereafter.

5.13 Bow Thruster System:

The new MCS shall provide the ability to start, stop, monitor, and view Bow Thruster alarms from the MCC and all existing current locations and matching current capabilities.

6. Scope of Work: The Contractor shall provide:

6.1 General Program Management

6.1.1 General Program Management

The Contractor shall provide program activities to include preparing, submitting, and adjudicating comments on all CDRLs, developing and maintaining a program Integrated Master Schedule (IMS) (CDRL 006), providing Monthly Status Reports (CDRL 009) and conducting program status review meetings as required. The Contractor is responsible for submitting program review and design review documents, agendas, minutes, and tracking action items (CDRLs 003/004/005). The Contractor shall maintain and update submittal records.

The IMS shall include submittal dates for all CDRLs. It shall include all design phase, product and factory testing phase, and shipboard installation, testing, and commissioning phase activities. The following information shall be included in the IMS as a minimum:

1. Kickoff Meeting

2. Design Verification Ship Check notional planned start date and duration

3. All initial CDRL submission dates, including ABS submittals

4. All Design Review Meeting (SDR, HMIDR, PDR, CDR, TRR dates

5. Major hardware assembly start and completion dates

6. Major software component coding start and completion dates

7. Major hardware component ship testing start and completion dates

8. Major hardware/software integration milestones

9. Factory acceptance testing start and completion date

10. Shipboard installation start and completion date notional dates and Phase

2 planned dates as required)

11. Shipboard testing and trials start and completion dates

Meetings are to be held via video-conference determined by the Customer

(NOAA Project Manager). Physical meetings shall be held as determined by the

Customer.

Meeting minutes shall be reviewed and approved by the Customer prior to official release. The Contractor shall maintain a database of the status of all action items assigned during meetings. The action item database shall include who the action item is assigned to and an expected completion date.

A Post Award/Kickoff Meeting shall be held within 14 days of contract award date. Monthly status review meetings shall be held throughout the project. A design review meeting will satisfy the requirement for a monthly status meeting.

The Contractor shall design and furnish the MCS replacement as a complete system and shall be responsible for design, selection, assembly, programming, ABS certification, shipboard installation, testing, commissioning, and supportability of all components.

6.2 Design Reviews

6.2.1 System Design Review (SDR)

The Contractor shall conduct an SDR, within 60 days of the Kick-Off meeting to address design and integration with other ship systems, including design, reliability, safety, electromagnetic compatibility, maintenance, training, testing, and support, fault detection and isolation, and fail-safe/fail-set conditions. The Contractor shall present a conceptual

MCS architecture. Allocation of requirements to hardware and software configuration items, and the ability of the proposed design to meet the requirements specified in this specification shall be addressed. The Contractor shall include a functional overview of the Computer Software Configuration

Items (CSCIs) and Hardware Configuration Items (HWCIs), the allocation of requirements to each, all interfaces to the CSCIs/HWCIs including CSCI to

CSCI and HWCI to HWCI interfaces, and requirements traceability.

6.2.2 Human Machine Interface Design Reviews (HMIDR)

The Contractor shall conduct two HMIDRs to address the functional design of the HMIs, including hardware and software features, human engineering, display and control modes, use of colors, and symbols. The first HMIDR shall address the Contractor's overall hardware and software design, and the display design guidelines. A subsequent detailed HMIDR shall include the demonstration of HMI features required by this section, including the layout, presentation, and function of all displays and display pages, including log sheet.

The proposed package of graphic displays shall be provided in outline form as part of the PDR, with details on the number of screens per system and their hierarchy. The complete set of graphic displays shall be provided as part of the

Critical Design Review package for Customer review and concurrence prior to implementation. Final approval of mimics shall be during Factory Acceptance

Testing. The HMIDRs shall also address the results of the HMI task analysis.

Equipment arrangements shall be addressed at the HMIDRs. The following layouts shall be submitted to the Customer for approval prior to construction of the equipment:

1. MCC enclosure and internal cabinet layouts

2. SCC Panel Front and internal cabinet layouts

3. DAU enclosures and internal cabinet layouts

6.2.3 Preliminary Design Review (PDR)

The Contractor shall conduct a PDR within 90 days of the Kick-off meeting for the MCS design to address both the hardware and software aspects of the design.

The preliminary design is to include the following as a minimum:

1. System architecture

2. Description of system operations

3. MCS Signal List

4. Desktop layouts and enclosure front panels

5. Console and enclosure layouts

6. Hardware and software specifications

The hardware portion of the PDR shall address subjects such as requirements allocation, functional flow, schematic diagrams, hardware and firmware logic, preliminary equipment assembly drawings. thermal analysis and design, reliability and maintainability assessment and allocation, electromagnetic compatibility, power conversion and distribution, grounding, mechanical design of enclosures, racks and drawers, safety, human engineering, and preliminary parts selection and life-cycle supportability.

The Contractor shall also demonstrate that the selected PLC equipment has a history of supportability and backward compatibility with existing hardware and software applications when new upgrades are provided. End of manufacturing and supportability dates shall be addressed.

The software portion shall address software architecture, allocation of system requirements and resources, such as processor, I/O, and memory, resources to each CSCI, inter-unit and intra-unit communications, and timing requirements.

In addition, the PDR shall address operating system selection and post-delivery software update scheme.

6.2.4 Critical Design Review (CDR)

The Contractor shall conduct a CDR within 60 days of the PDR meeting.

The CDR has a goal to obtain Customer approval to proceed to production.

Customer approval shall be required to proceed to manufacturing and assembly of MCS hardware and for coding and production of the MCS software.

The following shall as a minimum be addressed at the CDR:

1. System architecture

2. System Description of Operations

3. MCS Signal List

4. HMI Design Report

5. Console and enclosure layouts

6. Hardware and software specifications

7. ABS/USCG required drawings/documents approval

8. List of equipment to be retained and reused

6.2.5 Test Readiness Review (TRR)

The Contractor shall conduct a TRR within 90 days of the CDR meeting.

The purpose of the TRR is to assess the readiness of the MCS for each formal software release and factory acceptance testing.

The review shall address the following:

1. Status of the test procedures

2. Test environment

3. Hardware and software configuration management

4. Test schedule

5. Process for managing and recording the tests and test results

6.3 Project Documentation

6.3.1 Project Management Documentation

Contractor shall provide all documentation and procedures as required by the

CDRLs (CDRL 018).

6.3.2 Regulatory and Certification Documentation

The Contractor shall be responsible for obtaining ABS and US Coast Guard regulatory approval of the design and shall include all drawing and design documentation required by ABS SVR. First submission cost, including the FAT and design reviews, shall be provided by NOAA. Re-submission costs shall be borne by the Contractor. Copies of all submittals and regulatory correspondence required for Coast Guard and ABS certification shall be provided as part of this engineering documentation (CDRL 007/008), including Design Verification

Test Procedures (CDRL 043) and Periodic Safety Test Procedures (CDRL 044) in accordance with ABS SVR and USCG requirements. Customer approval of the drawing and design documentation shall be obtained prior to the Contractor proceeding to detail design, production, or testing, as applicable.

The contractor shall provide the Customer with copies of the USCG required

FMEA/DVTP (CDRL 013/043) for review and comment prior to submittal to

USCG/ABS. Drawings shall be prepared as electronic media in most current version of AUTOCAD. Review issues of drawings shall be provided in PDF compatible file format. The electronic media and hard copies submitted shall not include any restriction markings, except for NOFORN, ITAR, or GPLR restrictions where applicable.

Government will provide ABS on-site Surveyor support for installation review as well as for dock and at-sea testing. Contractor shall be responsible for the costs of all cancelled or rejected surveys found to be the fault of the contractor.

6.3.3 Engineering Documentation

The Contractor shall provide engineering documentation to include updated

Ship Drawing and Technical Manual Indexes, Drawings and Associated Lists, Technical Publications/Technical Manuals, and Special Purpose/System

Technical Manuals.

Drawings, plans, and technical manuals for the MCS shall be in the English system of engineering units. Drawings shall be submitted in both AUTOCAD and PDF.

Preliminary versions of the drawings, technical manuals, and logistic support documents shall be provided in PDF format for review and comment by the

Customer. The Contractor shall incorporate the changes into a final version of the drawings, technical manuals, and logistic support documents.

The Contractor shall deliver the final engineering documentation in accordance with CDRL requirements.

The Contractor shall be responsible for providing all updates to all engineering documentation to document the as-built condition reflecting post-commissioning configuration of the vessel.

The Contractor shall review the current list of ship drawings and technical manuals as found in References 2.4.7 – 2.4.9 to remove ship drawing and technical manuals that are no longer applicable, update the revision level on documents that are being revised, and add references for new documents that are being added. The Contractor shall prepare an updated Ship Drawing Index

(CDRL 015) and an updated Technical Manual Index (CDRL 035) to document these updated indices.

The Contractor shall prepare several categories of ship drawings and associated lists (CDRL 016):

1. Removal drawings and instructions that detail removal and modifications to be made to existing machinery control and monitoring subsystems or interfacing equipment

2. Installation drawings and procedures for MCS equipment, including dimensions, locations, size and type of all piping and electrical connections to vessel's systems, as applicable. In addition, specialized footprint drawings shall be provided detailing the foundation/mounting areas and specifying any special interface requirements as may be necessary. Detailed drawings showing each MCS major components showing maintenance access, mounting requirements, cable connection, weight and center of gravity, and any other installation requirements.

3. New MCS drawings and lists to…