FINAL SOW 2-12-2024.docx

Rev (2) Statement of Work 154-WPC Digital Twin Development

1. INTRODUCTION

1.1. Background

The U.S. Coast Guard is soliciting services to develop digital twins for the 154-WPC Fast Response Cutter. The major systems for consideration are the propulsion, electrical, and auxiliary systems. These digital twins will be used for CBM (Condition Based Maintenance), operator guidance, and system performance and optimization engineering change planning.

Many systems used for DT/CBM will require interfacing with a Machinery Control and Monitoring System (MCMS) MTU’s shipboard automation system Callosum. The MCMS onboard the 154-WPC is distributed throughout the ship and monitors machinery parameters and faults for onboard systems including main propulsion systems (diesel engines, main reduction gear, fuel oil, etc.), auxiliary systems (machinery cooling water) and electrical systems (control of switchboard bus ties, Ship Service Diesel Generator start/stop, and Emergency Diesel Generator stop control). The Machinery Control System additionally interfaces with a number of systems, see reference 2.9 MCMS I/O schedule. Systems monitored and controlled by the MCMS may have additional sensors that only communicate at the sub-system level.

The 154-WPC propulsion plant consists of two MTU 20V4000M93L diesel engines, two ZF reduction gears, two fixed pitch propellers, and an MTU electronic propulsion control system. Process variables stored within the propulsion control system include Engine Speed, Engine Injection Quantity, Engine Lube Oil Temperatures and Pressures, Engine Cylinder Temperatures and Pressures, Engine Charge Air Pressures and Temperatures, Engine Bearing / Splash Oil Temperatures, Engine Coolant Temperatures, among others. These variables are available with polling of up to 1 sample per second.

The 154-WPC electrical plant consists of two independent Ships Service Diesel Generators (SSDG) Cummins QSM11-DM SSDG’s coupled to Stamford HCM434E AC Generators. Each generator set is capable of independently sustaining the complete electrical load requirements of the vessel while the other is in standby to ensure the availability of electric power during emergency conditions. The cutter is also equipped with one Emergency Diesel Generator (EDG) Cummins 6BTA5.9-DM(FRCA)/QSB7-DM-CM850 (hull33 on) coupled to a Stamford UCM274D generator. The Ship Service Diesel Generators have live diagnostic capabilities utilizing Cummins Insite. The generators primary means of control is via the Electronic Control Module Easygen 3200/ (1101-1138) and DIEF PPM300 (1139 on). The Electrical Plant Control System (EPCS) provides load sharing between generators and digital excitation. The generators output 440V at 60hz which is distributed via the 1S Switchboard, 1E Switchboard, and Emergency/Vital and non-vital power panels; There are auto bus ties for vital panels and step-down transformers that supply 115V throughout the cutter. There are seven battery banks and a 24VDC distribution system for MPDE/SSDG/EDG starting, and 24V critical equipment.

1.2. Scope

The contractor to develop a full ship Digital Twin for the 154 WPC.

1.3. Objective.

This objective of this effort is to enhance cutter readiness and reduce lost patrol days through the development of digital twins and use of condition-based maintenance program standards and processes. For the systems described herein, determine the data requirements to develop digital twins comprising physics-based or data-based models. Based on determination of feasibility and best value to the Government, build the appropriate digital twin, perform VV&A (Verification, Validation, and Accreditation), determine the data required to update and interrogate the digital twins, and provide user training to the USCG.

1.4. Applicable Documents

1.4.0. ANSI/NISO Z39.18 Scientific and Technical Reports - Preparation, Presentation, and Preservation.

1.4.1. 154-WPC Signal List

1.4.2. 8183_252_A (MCMS Automation System 154’ WPC) 04Feb2019

1.4.3. DOD INSTRUCTION 4151.22 “CONDITION-BASED MAINTENANCE PLUS FOR MATERIEL MAINTENANCE” Aug 14 2020 <https://www.esd.whs.mil/DD/>

1.4.4. CGTO PG-85-00-1110-S “SFLC-IOD-01_Rev4_Condition_Found_Report_Form” 04 Jan 2021

1.4.5. CGTO_PG-85-00-400-S “Condition Based Maintenance Process Guide” 12 Jan 2022

1.4.6. CGTO PG-85-00-230-G “Joint Maintenance Procedure Card Development DG” 07 March 2023

1.4.7. 9208_252_A “154-WPC MTU PROPULSION AUTOMATION SCHEMATICS & DRAWINGS MODEL – 20V4000M93L / MCS-5 / RCS-5 FPP SYSTEM GUIDE MTU” 01 APR 2023

1.4.8. 154B-WPC-202-302 “MCMS I/O Schedule” 02 Nov 2020

1.4.9. 154B-WPC_202_301 “MCMS Cable Block Diagram” 31 Dec 2019

1.4.10. 8051_311_A “SHIP SERVICE DIESEL GENERATOR (SSDG) - SERIES QSM11-DM Tech Pub” 16Aug2018

1.4.11. 8192A_324_A “GENSET CONTROL -EASYGEN MODEL-3200” (up to hull 38) 31Oct2017

1.4.12. 8193_324_A “DIGITAL EXCITATION CONTROL SYSTEM - MODEL DECS-200” (up to hull 38) 07Jan2017

1.4.13. 8912A_086_A “TECHNICAL REPAIR STANDARD FOR USE ON FRC - SHIP SERVICE DIESEL GENERATOR UNIT MODEL - QSM11-DM AND HCM434E” 17Mar2020

1.4.14. 8340A_324_A FRC Ship Service Switchboard (1139 and On) 01 Jul 2023

1.4.15. 154-WPC_310_301 “FRC Electrical One Line Diagram” 15 Feb 2023

1.4.16. 154-WPC_310_303 “Electrical Power Load Analysis” 10 March 2009

1.4.17. 154-WPC_310_403 “Protective Device Coordination Study”

1.4.18. 154-WPC_256_201 “Main Propulsion Cooling System Arrangement”

1.4.19. 154-WPC_256_301 “Main and Auxiliary Cooling System Diagram”

1.4.20. 154-WPC_256_302 “Stern Tube Seawater Supply Modifications”

1.4.21. 154B-WPC_256_201 “Main Propulsion Cooling System Arrangment”

1.4.22. 154B-WPC_256_301 “Main and Auxiliary Cooling System Diagram”

1.4.23. 154-WPC Main and Auxiliary Seawater System PipeFLO models (placeholder).

1.4.24. 154-WPC_541_201 “Fuel Oil Transfer System Arrangement”

1.4.25. 154-WPC_541_301 “Fuel Oil Service and Transfer System Diagram”

1.4.26. 154B-WPC_541_201 “Fuel Oil Transfer System Arrangement”

1.4.27. 154-WPC Fuel Oil Service and Transfer System PipeFLO models (placeholder)

1.4.28. MIL-STD-3022 “Documentation of Verification Validation and Accreditation for Models and Simulation”, 5 April 2012 (https://assist.dla.mil)

1.5. Definitions for this SOW

1.5.0. Digital Twin shall mean a virtual representation of a physical asset, along with its environment and processes, comprised of one or more integrated models that are updated through data exchange to provide decision-making support over its lifecycle.

1.5.1. Physical Asset shall mean a representation of the physical reality that may be attempted to be modeled, since the physical reality encompasses the entirety of the asset, both known and unknown. The physical reality can be decomposed into the physical system, the physical environment, and physical processes.

1.5.2. Virtual Representation shall mean a cohesive digital representation comprised of stored representations, computational representations, and supporting data for the entity(ies) and processes of the idealized representation of the physical asset.

1.5.3. Model shall mean an idealized representation (physical, mathematical, or otherwise logical) of reality that consists of the key characteristics or behaviors of the selected system, entity, phenomenon, or process.

1.5.3.0. A First-principles or physics-based model shall mean a model that expresses formalized domain knowledge, generally through 2, 3, or 4D representations of the geometry and processes of the system, e.g. CFD (Computational Fluid Mechanics) of hull hydrodynamic flow and structural loading, or a static or time-domain calculation or simulation of a piping system.

1.5.3.1. A Data-Based model shall mean a class of computational models that primarily rely on historical data collected throughout a system’s or process’ lifetime to establish relationships between input, internal, and output variables.

1.5.4. Algorithm shall mean a finite sequence of instructions typically used to solve a class of specific problems or to perform a computation.

1.5.5. Condition Based Maintenance shall mean maintenance processes and capabilities derived from real-time or approximate real-time assessments and historical failure data obtained from embedded sensors or external tests and measurements using either portable equipment or actual inspection and the application and integration of appropriate processes, technologies, and analytics to ensure maintenance is performed based on the evidence of need while ensuring safety, reliability, availability, and reduced total ownership cost.

1.5.6. Use Case shall mean a set of circumstances for detailing the use of something (in this case, a Digital Twin) to achieve a desired outcome, which is typically associated with constraints or other requirements.

1.5.7. VV&A Verification, Validation, and Accreditation shall mean:

1.5.7.0. Verification – The process of determining the extent to which a model/Digital Twin is compliant with its requirements and specifications as detailed in its conceptual models, mathematical models, or other constructs. (“Did I build the thing right?”).

1.5.7.1. Validation – The process of determining the degree to which a model/DigitalTwin is an accurate representation of the real world from the perspective of the intended use (“Did I build the right thing?”).

1.5.7.2. Accreditation – The official certification that a model, simulation, federation of models and simulations, or Digital Twin and its associated data are acceptable for use for a specific purpose. (“Is this thing useful?”)

2. REQUIREMENTS/TASKS

2.1. The Contractor shall use the following 154-WPC systems in performance of the tasks as described herein:

2.1.1. 233 – Diesel Engines

2.1.2. 241 – Main Reduction Gears

2.1.3. 256 – Main and Auxiliary Cooling System

2.1.4. 262 – Lube Oil System

2.1.5. 311 – Ship Service Power Generation

2.1.6. 312 – Emergency Generators

2.1.7. 324 – Switchgear and Panels

2.1.8. 541 – Fuel Oil Service and Transfer System

2.2. The digital twins developed under the performance of the SOW will have the following use cases:

2.2.0. Condition Based Maintenance use case includes evaluation of triggering events, including,:

2.2.0.0. Optimize Time between overhauls by monitoring condition of MPDE’s and SSDG’s.

2.2.0.1. Evaluate Filter/strainer cleaning/change intervals hourly/calendar based to reliability centered and condition based.

2.2.0.2. Heat exchanger evaluation and optimal cleaning interval based on condition.

2.2.0.3. Evaluate condition of analog and digital gauges and determine sensor condition and recommend necessary calibration intervals.

2.2.0.4. Condition Analysis for oil viscosity testing Maintenance Procedure Card D13210.0 and A54012.0.

2.2.0.5. Condition Analysis on lube oil sample Maintenance Procedure Cards D13212.0 and D13218.0.

2.2.0.6. Prognostic- predict failure modes given operational characteristics and historical datasets.

2.2.1. System Performance and Optimization Planning use cases include:

2.2.1.0. Capability to make system performance inferences on cutters with different environmental operating parameters.

2.2.1.1. Compare, evaluate, and optimize fleetwide system performance.

2.2.1.2. Predict end of life expectancy.

2.2.1.3. Support the engineering change process for future modifications.

2.2.2. Operator Guidance

2.2.2.1. Evaluate system performance and alert operator to imminent casualties.

2.2.2.2. Provide baseline condition for comparison to current operations.

2.2.2.3. Support operational risk guidance and operational envelope modifications for off design-point conditions.

2.2.2.4. Repository to store and view historical machinery history data, failure modes, parts locations, and availability for shipboard operator to schedule and perform maintenance. Utilizing a hierarchical structure from system level down to the component level.

2.2.2.5. Provide operational availability metrics for shoreside analysis.

2.3. Digital Twins will be utilized without modifications for computational analysis, including Finite Element Analysis if physics-based or prognostic analysis if a data-based model that can provide performance forecasting.

2.4. The contractor shall provide artifacts and input to the Risk Management Framework (RMF) process, including all necessary documentation to obtain an Authority to Operate in accordance with DoDI 8510.

2.5. Contingency Plan – The Contractor shall, where cloud services are provided, develop a contingency plan for records and data preservation should the Cloud service provider cease operations or become unavailable.

2.6. DIGITAL TWIN ASSESSMENT – For each 154-WPC system identified in 2.1, the Contractor shall:

2.6.0. Determine the information required to develop a physics-based digital twin

2.6.1. Determine the information required to develop a data-based digital twin

2.6.2. Determine the data required to update the digital twins for the use cases defined herein; the Contractor shall leverage existing installed monitoring and control systems and the associated hardware, noting where data requirements differ between digital twin types:

2.6.3. Review the technical data provided by the USCG and recommend the digital twin type, fidelity, and scope for each system based on technical feasibility.

2.6.4. For each recommendation, provide the minimum data storage and computing requirements necessary for operation and updating of the digital twin.

2.7. DIGITAL TWIN DEVELOPMENT – For each digital twin type and system agreed to under Task 2.6, develop that specific digital twin.

2.7.1. The Contractor shall propose to the USCG the tools and software codes being used to develop the digital twins. Preferably Open Source, applications include:

2.7.1.1. Python

2.7.1.2. MatLAB

2.7.1.3. PipeFLO

2.7.1.4. AutoCAD

2.7.1.5. Other well-established, open-source or commercially available tools / software with a minimum of 3 full-access user licenses, including all permissions needed to modify, edit, query, and view the digital twins per asset provided by contractor.

2.8. VV&A – The Contractor shall provide the following VV&A artifacts:

2.8.1. Verification and Validation (V&V) Plan. The plan focuses on defining the methodology for scoping the V&V effort to the application and the acceptability criteria; defining the V&V tasks that will produce information to support the accreditation assessment; defining the resources needed to perform the V&V; and identifying issues associated with performing the V&V. The plan shall be reviewed and approved by the USCG.

2.8.2. Accreditation Plan. The plan focuses on; defining the criteria to be used during the accreditation assessment; defining the methodology to conduct the accreditation assessment; defining the resources needed to perform the accreditation assessment; and identifying issues associated with performing the accreditation assessment. The plan shall be reviewed and approved by the USCG.

2.8.3. V&V Report. The report focuses on documenting the results of the V&V tasks; documenting M&S assumptions, capabilities, limitations, risks, and impacts; identifying unresolved issues associated with V&V implementation; and documenting lessons learned during V&V. The report shall be reviewed and approved by the USCG.

2.8.4. Accreditation Report. The report focuses on documenting the results of the accreditation assessment; documenting the recommendations in support of the accreditation decision; and documenting lessons learned during accreditation. The report shall be reviewed and approved by the USCG.

2.9. DIGITAL TWIN UPDATING DATA PLAN

2.9.1. The Contractor shall develop a plan with recommendations for the shipboard data and machinery history data to be collected for each digital twin developed for the use cases defined herein, including:

2.9.1.1. Type

2.9.1.2. Number

2.9.1.3. Accuracy

2.9.1.4. Sampling frequency

2.9.1.5. Model updating frequency

2.9.1.6. Calibration requirements

2.9.1.7. Identify if the necessary data is included in the existing MCMS system, Reference 1.4.9; or other system specific interfaces.

2.9.1.8. Other recommended use cases as applicable.

2.10. TRAINING AND SUPPORT

2.10.1. The Contractor shall develop a user’s guide for each digital twin that describes the twin, the methodology, how it is updated with shipboard data, and interrogated for the use cases as described herein.

2.10.2. The Contractor shall provide eight (8) hours training per digital twin on the operation, uses, updating, and maintenance. This can be either in person or remote (virtual through TEAMS).

2.10.3. The Contractor shall provide up to 80 hours of post delivery support for troubleshooting, training, and modification of the digital twins delivered under this SOW.

2.10.4. The contractor shall notify the government if they find insufficient data in the Coast Guard provided references to develop one or more digital twins, detail the data collection, machinery history, or other information necessary to meet the requirements of this contract via email to the contracting officer.

3. CONTRACTOR PERSONNEL

4. OTHER APPLICABLE CONDTIONS

4.1. Security.

4.1.1. This work is not classified. No security clearance is required, but technical data is under STINFO (Scientific and Technical Information) Distribution Statement D.

4.1.2. The Contractor and all individuals working on the project are required to complete a DHS Non-Disclosure Agreement; form 11000-6. Contract will not be awarded until NDA forms are in place.

4.1.3. Data Rights – The GOVERNMENT shall retain Usage Rights in all data, including software, developed as part of the effort regardless of form or medium. Government furnished data are considered to be solely the property of the Government and shall not be released without the written consent of the Government. The Contractor shall retain Commercial Rights to all software developed under this task. Where software or source code is proprietary this software shall be placed in software escrow and delivered to Government upon non-support.

4.1.3.1. The Coast Guard owns the rights to all data and records produced as part of this contract. All deliverables under the contract are the property of the U.S. Government for which the Coast Guard shall have unlimited rights to use, dispose of, or disclose such data contained therein as it determines to be in the public interest.

4.2. Period of Performance. This contract is two years from the date of award.

4.3. Place of Performance. The primary place of performance will be the Contractor’s facilities with infrequent visits to the United States Coast Guard facilities in the Cape May, NJ.

4.4. Travel

4.4.1. Travel may be required for sections 2.10.2, 2.10.3, and 5.2 of this SOW. Travel will be to a 154 WPC located in Cape May, NJ.

4.4.2. All required travel will be reimbursed to the Contractor in accordance with Federal Travel Regulations. All travel that is invoiced to the USCG shall be pre-approved in writing, in advance, by the COR or the KS.

4.5. Post Award Conference. The contractor shall contact the COR to discuss SOW objectives NLT 5 business days after the date of award to schedule the Post Award Conference. The purpose of the Post Award Conference is for the Contractor to provide a detailed POAM (Plan of Action and Milestones) to complete the SOW; Analysis milestone dates; Data required and the data source; Obstacles to completing the analysis on schedule. The contractor will provide written summation of the conference.

4.6. Project Plan. The Contractor shall develop a POAM (Plan of Action and Milestones) defining the tasks and sub-tasks described herein, along with any other tasks or milestones required to complete the work.

4.7. Progress Reports. The Contractor must provide a monthly progress report to the Contracting Officer and COR via electronic mail. This report must include a summary of all Contractor work performed, an assessment of technical progress, schedule status, any travel conducted and any Contractor concerns or recommendations for the previous reporting period.

4.8. Progress Meetings. The Contractor shall participate in Coast Guard meetings as requested by the COR. If discussions are required to address contract performance issues, then they may be initiated by either the Contractor or the COR

4.9. General Reports Requirements and Documents. The Contractor must provide all written reports in electronic format with read/write capability using applications that are compatible with DHS workstations (Microsoft Office Applications).

5. GOVERNMENT FURNISHED RESOURCES

5.1. Government will provide all available information, data, and documents to the Contractor for work required under this contract.

5.2. The Government will provide access to WPC-154.

5.3. The Government will provide available machinery history data from parties that perform maintenance or record discrepancies for the above shipboard systems, including ship’s force, OEM, USCG shoreside maintainers and logisticians, and other third party maintainers.

5.4. The Contractor must use Government furnished information only for the performance of work under this contract and must be responsible for returning all Government furnished information to the Government at the end of the performance period. The Contractor must not release Government furnished information to outside parties without the prior and explicit consent of the Contracting Officer.

6. CONTRACTOR FURNISHED PROPERETY

6.1. The Contractor must furnish all materials, equipment, and services necessary to fulfill the requirements of this contract, except for the Government Furnished Resources specified in SOW 2.0 and SOW 5.

7. GOVERNMENT ACCEPTANCE PERIOD

7.0. The COR will review deliverables prior to acceptance and provide the contractor with an e-mail that provides documented reasons for non-acceptance. If the deliverable is acceptable, the COR will send an e-mail to the Contractor notifying it that the deliverable has been accepted.

7.1. The COR will have the right to reject or require correction of any deficiencies found in the deliverables that are contrary to the information contained in the Contractor’s accepted proposal. In the event of a rejected deliverable, the Contractor will be notified in writing by the COR of the specific reasons for rejection. The Contractor may have an opportunity to correct the rejected deliverable and return it per delivery instructions.

7.2. The COR will have 15 business days to review deliverables and make comments. The Contractor will have 15 business days to make corrections and redeliver.

7.3. All other review times and schedules for deliverables must be agreed upon by the parties based on the final approved Project Plan. The Contractor must be responsible for timely delivery to Government personnel in the agreed upon review chain, at each stage of the review. The Contractor must work with personnel reviewing the deliverables to assure that the established schedule is maintained.

8. DELIVERABLES

8.0. The Contractor must consider items in BOLD as having mandatory due dates. Items in italics are deliverables or events that must be reviewed and/or approved by the COR prior to proceeding to next deliverable or event in this SOW

8.1. The Contractor shall provide all written summaries of all conferences and meetings

DISTRIBUTION

N/A

COR, Contracting Officer

COR

9. CONTRACTING OFFICER’S REPRESENTATIVE

9.0. The Contracting Officer’s Representative (COR) and technical point of contact at the U.S. Coast Guard Surface Forces Logistics Center will be Mr. Tim Wacker, SFLC-ESD-SSD-MPS, Phone: (443) 474-0629, e-mail: Timothy.E.Wacker@uscg.mil.. The Contracting Officer’s Representative (COR) and technical point of contact at the U.S. Coast Guard Surface Forces Logistics Center will be Mr. Tim Wacker, SFLC-ESD-SSD-MPS, Phone: (443) 474-0629, e-mail: Timothy.E.Wacker@uscg.mil.

9.1. The Alternate Contracting Officer’s Representative (ACOR) at the U.S. Coast Guard Surface Forces Logistics Center will be Ms. Elise Hernandez, SFLC-ESD-NAME-ELEC SYS, Phone: (510) 501-5386, e-mail: Elise.S.Hernandez3@uscg.mil.

WPC-154 Condition Based Maintenance and Digital Twin SOW Page 1 of 12