Section J Attachment B Technical Specification for Energy Magazine Rev 1.0.2.pdf

UNCLASSIFIED // FOR OFFICIAL USE ONLY

REV 1.0.2

TECHNICAL SPECIFICATION

FOR

ENERGY MAGAZINE

Revision 1.0.2

July 14, 2020

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Record of Changes

Revision Date Changes

1.0 3/1/2020 Initial Release for Energy Magazine Competition [Purchase Request

N0002419NR59839]

1.0.1 6/25/20 Removed “in” from 3.3.13.2. Added definition for pressure boundary component to 3.3.15.18.9.

1.0.2 7/14/20 Removed “unless” from 3.3.12.3. Temperature range corrected in

3.3.14.14. Paragraph 3.4.1.2.7.1 is designated “information”.

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TECHNICAL SPECIFICATION

FOR

ENERGY MAGAZINE

Approved By

Vincent Kane Date

PMS 320 Technical Director

INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE REV 1.0.2 4

TABLE OF CONTENTS

1 SCOPE

1.1 Designations

1.1.1 Type Designation

1.1.2 Front-End Converter

1.1.3 ES Form & Functionality/Usable Capacity/Peak Power

1.1.4 Output Converters

2 APPLICABLE DOCUMENTS

2.1 GENERAL

2.2 GOVERNMENT DOCUMENTS

2.2.1 Military Specifications and Standards

2.2.2 Other Publications

2.2.3 Federal Regulations

2.2.4 NAVSEA Specifications, Manuals, and Instructions

2.3 NON-GOVERNMENT PUBLICATIONS

2.3.1 ASTM Specifications

2.3.2 Commercial Item Descriptions

3 Energy Magazine General Requirements

3.1 Energy Magazine System Definition

3.2 EM Acquisition Parameters and Specification Sheets

3.2.1 Ship Class

3.2.2 Application Electrical Characteristics

3.2.3 Allowable Segmentation of Application

3.2.4 EM Composition

3.2.5 Application Duration

3.2.6 Stored Energy

3.2.7 Time to Recover

3.2.8 Life

3.2.9 EM Geometrics

3.3 EM General Requirements

3.3.1 System Safety

3.3.2 EM Storage Media

3.3.3 EM Storage Media Management System

3.3.4 Materials and Insulation

3.3.5 Cabling and Wiring

3.3.6 Fault Detection and Protection

3.3.7 Valves and Piping

3.3.8 Design of EM Component Mounting Features

3.3.9 Equipment Lifting Provisions

3.3.10 Equipment Designation and Marking

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3.3.11 Shock

3.3.12 Equipment Availability

3.3.13 Maintainability

3.3.14 Environmental

3.3.15 System Thermal Management

3.3.16 System Drains

3.3.17 EM Controls

3.3.18 Security Requirements

3.4 Application Unique Requirements

3.4.1 EM to Source MIL-STD-1399, Section 300

3.4.2 EM to Source LVDC Class I, Type I

3.4.3 EM to Source LVDC Class II, Type I

3.4.4 EM to Source LVDC Class III, Type I

3.4.5 EM to Source LVDC Class III Type II

3.4.6 EM to Source MVDC Class I

3.4.7 EM to Source MVDC Class II

3.4.8 EM to Source MIL-STD-1399, Section 680

3.4.9 EM to 120/208 VAC Interface

4 VERIFICATION

4.1 CLASSIFICATION OF INSPECTIONS

4.2 FIRST ARTICLE INSPECTION

4.2.1 Success/failure criteria

4.2.2 Verification methods

4.3 Requirement/Verification cross-reference matrix

5 PACKAGING AND HANDLING

6 NOTES

6.1 Definitions

6.2 Acronyms

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List of Figures Figure 1: Example of Energy Magazine Type Designation

Figure 2: Components used within Cabinets for EM

Figure 3: Family of Cabinets to be Used in Energy Magazine

Figure 4: Shipboard Interfaces for Generalized EM Application

Figure 5: Maintenance Allowance (for PCC & ESC) Diagram (inches)

Figure 6: Voltage Tolerance Envelope for LVDC Class I, Type I Interface

Figure 7: Voltage Spike Waveform for LVDC Class I

Figure 8: Voltage Tolerance Envelope for LVDC Class II, Type I Interface

Figure 9: Voltage Spike Waveform for LVDC Class II

Figure 10: Voltage Tolerance Envelope for LVDC Class III, Type I Interface

Figure 11: Voltage Spike Waveform for LVDC Class III

Figure 12: Voltage Tolerance Envelope for LVDC Class III, Type II Interface

Figure 13: Voltage Tolerance Envelope for MVDC Class I Interface

Figure 14: Voltage Tolerance Envelope for MVDC Class II Interface

List of Tables Table 1: EM Type Designators (See Figure 1)

Table 2: Requirements Verification Matrix

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1 SCOPE

This Technical Specification for Energy Magazine contains the requirements necessary to completely define a family of Power Conversion Modules (PCM)s with a closely coupled energy storage subsystem capable of supporting pulsating mission loads in existing and future Ship Service Distribution Systems. The intent of this specification is to provide components that can be combined to create low impedance distribution systems necessary to enable minimization of front end power conditioning equipment traditionally associated with each individual mission load. This front end equipment has historically been necessary to meet shipboard distribution specifications, such as MIL-STD-1399, Section 300B, MIL-STD- 1399, Section 390, MIL-STD-1399, Section 680 and MIL-STD-1399, Sections 300-1 and 300-2. [EM_FRD-2] [Information]

The need for the Ship Service Distribution System to provide shared energy storage is due to the increased quantity of pulsed mission loads as well as their increased fraction of total installed shipboard power which, traditionally, may have driven requirements for each new load to include a stored energy component downstream of the interface with the Ship Service Distribution System. The pulsed loads of concern for this Technical Specification are those of 1000VDC or below, highly pulsating loads (0 to 100% steps) of periodic nature, and moderate pulsating loads (50 to 100% steps) of continuous nature. [EM_FRD-3] [Information]

1.1 DESIGNATIONS

The electrical interfaces associated with Energy Magazines (EM) are of the types specified in Table 1. Application specific electrical and physical requirements for individual EM acquisitions are to be defined on specification sheets as explained in Section 3.2. The principal energy storage functionality for the acquisition along with usable capacity and peak power will also be defined on the specification sheet. [EM_FRD-5] [Information]

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Table 1: EM Type Designators (See Figure 1)

Front-End Converter

ES Form & Functionality

(See Section 4.0)

(See Sec 3.0)

No. Type No. Function No. Type

0 None X Unspecified 0 None

1399/300

B

Battery

Class 1

375VDC, Type I

1399/680 Class I

C

Capacitor

Class 2

650VDC, Type I

1399/680 Class II

FW

Flywheel

Class 3

1000VDC, Type I

1399/680 Class III

FC

Fuel Cell

Class 3

1000VDC, Type II

5 MVDC Class I 1 Back-up Power for SSDS Reconfig.

5 120/208VAC

6 MVDC Class II 2 Back-up Power for GTG Restart.

7 MVDC Class III 3 Emergency Start of GTG

4 Load Leveling of

Pulse Loads

5 Primary Power

Special Designator (used with any of the above)

N Non-isolated GI Galvanically Isolated

BD Bidirectional

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1.1.1 Type Designation

The type designation of an EM for a single acquisition will use the designations as defined in Table 1 and will use the form as defined in Figure 1. [EM_FRD-8] [Information]

Figure 1: Example of Energy Magazine Type Designation

In this example Energy Magazine, the breakdown of the desired system is as follows:

• No front end converter

• Energy storage is battery

• Application is load leveling

• Minimum useable energy storage rating is 22.5 kWh

• Peak power discharge rating is 660 kW

• Provides power to 650 LVDC Class 2, Type I bus with galvanic isolation

[EM_FRD-10] [Information]

1.1.2 Front-End Converter

The Front End Converter functions as the interface between the DC link internal to the Energy Magazine architecture and the input distribution bus which will typically be sourced by generators. Special designators will be used to identify when the application requires galvanic isolation between the generation distribution system and the rest of the EM or when power is to be bidirectional. [EM_FRD-12] [Information]

1.1.3 ES Form & Functionality/Usable Capacity/Peak Power

The type of energy storage media will be defined along with the principal purpose of the EM within the application distribution system. Multiple energy storage media can be combined to create optimum performance in terms of Energy Density, Power Density and Life. Lastly, the minimum amount of usable energy storage capacity (in kWh) and peak power discharge (in kW) for the application will be identified by the part number. [EM_FRD-1103] [Information]

If the particular type of energy storage (ES) media is unimportant for the acquisition agency, then an "X" should be used on the acquisition documentation in place of the ES Form designator. When the final design is approved, then the appropriate designator should be substituted for the "X". [EM_FRD-14] [Information]

1.1.4 Output Converters

The last designator will identify all the forms of output power conversion associated with the specified EM. As with the front end converter, each output that requires galvanic isolation from the energy storage or the other converters will be identified with a special designator. [EM_FRD-951] [Information]

EM 00 – B04/22.5/660 – 02GI

Front End Converter (1.1.2)

ES Form & Functionality

(1.1.3)

Output Converter (1.1.4)

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2 APPLICABLE DOCUMENTS

The following list is included for reference only; applicable sections are referenced in the individual requirements listed in Section 3.0 below. [EM_FRD-939] [Information]

2.1 GENERAL

The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation. The active revision of the referenced specifications at the time of contract award shall apply. [EM_FRD-941] [Information]

2.2 GOVERNMENT DOCUMENTS

2.2.1 Military Specifications and Standards

DoD-STD-1399/70-1 D.C. Magnetic Field Environment

MIL-C-15730 Coolers, Fluid, Naval Shipboard: Lubricating Oil, Hydraulic Oil, and Fresh Water

MIL-DTL-2036 Enclosures for Electric and Electronic Equipment, Naval Shipboard

MIL-DTL-15024 General Specification for Plates, Tags, and Brands for Identification of Equipment

MIL-DTL-24640 Cables, Light-Weight, Electric, Low Smoke, for Shipboard Use, General Specification for

MIL-DTL-24643 Cables, Electric, Low Smoke Halogen-Free, For Shipboard Use General Specification for

MIL-DTL-32529 Power Electronic Conversion Equipment, Naval Shipboard

MIL-DTL-917 Electric Power Equipment Basic Requirements

MIL-HDBK-217 Reliability Prediction of Electronic Equipment Cables, Fiber Optics, (Metric), General Specification for

MIL-M-24519 Molding Plastics, Electrical, Thermoplastic

MIL-PRF-85045 Generator Sets, Gas Turbine, Direct and Alternating Current, Naval Shipboard Use

MIL-PRF-20042 Flanges, Pipe, Bronze (Silver Brazing)

MIL-DTL-16036 Switchgear, Power, Low Voltage, Naval Shipboard

MIL-DTL-901 Shock Tests, H.I. (High-Impact) Shipboard Machinery, Equipment, and Systems, Requirements for

MIL-STD-129 Department of Defense Standard Practice Military Marking for Shipment and Storage

MIL-STD-1310 Shipboard Bonding, Grounding, and other Techniques for Electromagnetic Compatibility, Electromagnetic Pulse (EMP) Mitigation, and Safety

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MIL-STD-1399/300 Electric Power, Alternating Current

MIL-STD-1399/300-1 Department of Defense Interface Standard Section 300, Part 1 Low Voltage Electric Power, Alternating Current

MIL-STD-1399/300-2 Department of Defense Interface Standard Section 300, Part 2 Medium Voltage Electric Power, Alternating Current

MIL-STD-1399/390 Interface Standard for Shipboard Systems, Section 390, Electric Power, Direct Current, (Other Than Ship's Battery) for Submarines (Metric)

MIL-STD-1399/680 Department of Defense Interface Standard Section 680 High Voltage Electric Power, Alternating Current (Superseeded by MIL-

STD-1399/300-2)

MIL-STD-1472 Department of Defense Design Criteria Standard Human Engineering

MIL-STD-1474 Department of Defense Design Criteria Standard Noise Limits

MIL-STD-167-1 Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited)

MIL-STD-1683 Connectors and Jacketed Cable, Electric, Selection Standard for Shipboard Use

MIL-STD-1686 Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

MIL-STD-461 Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems

MIL-STD-740-2 Structure-borne Vibratory Acceleration Measurements and Acceptance Criteria of Shipboard Equipment

MIL-STD-810 Department of Defense Test Method Standard for Environmental Engineering Considerations and Laboratory Tests

MIL-T-16366 Terminal, Electrical Lug and Conductor Splices, Crimp Style

MIL-W-21965 Water Cooling Of Shipboard Electronic Equipment, General Specification for

2.2.2 Other Publications

ANSI/AIAA S-

096-2004

Standard for Space Systems – Flywheel Rotor Assemblies, 2004

ANSI B16.5 Pipe Flanges and Flanged Fittings: NPS ½ through NPS 24 Metric/Inch Standard

ANSI/AWS C3.4 Specification for Torch Brazing

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2.2.3 Federal Regulations

FAA 25.1461 Equipment containing high energy rotors, Federal Aviation Administration, Department of Transportation

2.2.4 NAVSEA Specifications, Manuals, and Instructions

DoDI 6055.11 Protection of DoD Personnel from Exposure to Radio Frequency Radiation and Military Exempt Lasers

NAVSEA 802-5959353 Schedule of Piping, Valves, Fittings and Associated Piping Components (MIL-STD-777 Modified for DDG 51 Class)

NAVSEA S6430-AE-TED-010 Technical Directive for Piping Devices and Flex Hose Assemblies

NAVSEA S9074-AR-GIB-010/278 Technical Publication: Requirements for Fabrication, Welding, and Inspection, Casting Inspection and Repairs for Machinery, Piping and Pressure Vessels

NAVSEA T9300-AF-PRO-020 Electrical Systems Design Criteria and Practices (Surface Ships) for Preliminary and Contract Design

NAVSEA T9070-AJ-DPC-010/(C) 072-1 Shock Design Values

NAVSEA T9070-AJ-DPC-050/072-5 Equipment Sway Brace Design

NAVSEA T9070-AJ-DPC-120/3010 Shock Design Criteria for Surface Ships

NAVSEA T9070-AL-DPC-020/077-2 NAVSEA Hazardous Material Avoidance Process Design Practices and Criteria Manual

NAVSEA S9086-CJ-STM-010 Naval Ships’ Technical Manual (NSTM), Chapter 075, Fasteners

NAVSEA S9086-KC-STM-010/300 Naval Ships' Technical Manual (NSTM) Chapter 300:

Electric Plant-General

NAVSEA S9310-AQ-SAF-010

Technical Manual for Batteries, Navy Lithium Safety Program Responsibilities and Procedures

OPNAV Letter N6/N7/5U916276 Office of the Chief of Naval Operations (OPNAV) Requirement Letter 9010, dated 23 Dec 05, Subj:

Requirement for Open Architecture (OA) Implementation

SG270-BV-SAF-010 High-Energy Storage System Safety Manual

2.3 NON-GOVERNMENT PUBLICATIONS

2.3.1 ASTM Specifications

ASTM E662 Standard Test Method for Specific Optical Density of Smoke Generated by Solid Materials

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ASTM E8/E8M Standard Test Methods for Tension Testing of Metallic Materials

ASTM F1166 Marine Systems, Equipment and Facilities, Human Engineering Design for

ASTM F992 Standard Specification for Valve Label Plates

2.3.2 Commercial Item Descriptions

ASME B18 Standards for Mechanical Fasteners ASME B31.1 Power Piping IEC 60529 Degrees of Protection Provided by Enclosures (IP Code).

IEEE 802.3 IEEE Standard for Information Technology, Telecommunications and

Information Exchange Between Systems. Local and Metropolitan Area Networks, Specific Requirements. Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD) Access Method and Physical Layer Specifications

IEEE-STD-1584 IEEE Guide for Performing Arc-Flash Hazard Calculations IEEE-STD-3007.3.d IEEE Recommended Practice for Electrical Safety in Industrial and

Commercial Power Systems

IETF RFC 791 Internet Protocol DARPA Internet Program Protocol Specification NASM 77072 Terminal, Lug, Solder Type, Phosphor Bronze Stamping, Locking

Type, Flat, One Hole

NASM 77073 Terminal, Lug, Solder Type, Phosphor Bronze Stamping, Locking Type, Flat, One Hole

NFPA 70E Standard for Electrical Safety in the Workplace, 2015 Edition SAE AS604 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400 °F, Heavyweight, Hydraulic

SAE AS620 Hose Assemblies, Convoluted Polytetrafluoroethylene Metallic Reinforced, High Temperature, Medium Pressure, Aircraft

SAE AS1227 Hose Assembly, Convoluted Polytetrafluoroethylene, Metallic Reinforced, Low Pressure, Up to 400 °F, Aircraft

SAE AS1339 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400°F, Lightweight, Hydraulic and Pneumatic

SAE AS1424 Hose Assembly, Metal, Medium Pressure, High Temperature SAE AS1975 Hose Assembly, Polytetrafluoroethylene, Para-Aramid Reinforced, 3000/4000 psi, 275 °F, Standard Duty, Hydraulic, Aircraft Systems

SAE AS7928/1 General Specification For Terminals, Lug: Splices, Conductor: Crimp Style, Copper, SAE AS85049 General Specification For Connector Accessories, Electrical UL 840 UL Standard for Safety Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment

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3 ENERGY MAGAZINE GENERAL REQUIREMENTS

This document provides requirements of a modular family of power electronic and energy storage cabinets which can be assembled into Energy Magazines to source large pulsating loads from a MIL-STD-1399 specified distribution system.

This specification has been divided into requirements that pertain to all cabinets and then those associated with specific interfaces. Although, some configurations of EM hardware will not incorporate all styles of cabinets, the entire specification should be reviewed to make sure the hardware delivered for a particular acquisition is compatible with the other configurations.

The latest version of the Design Criteria and Practices (Surface Ships) [NAVSEA T9300-AF-PRO-020] defined various functions for Energy Storage within a ship. The five functions identified are:

• providing back-up power to uninterruptible loads during short-term power interruptions as a consequence of fault detection and system reconfigurations [Function 1 (F1)]

• providing back-up power to uninterruptible and short-term interruptible loads upon failure of a generator or to provide for reserve load [Function 2 (F2)]

• providing emergency starting for an electrically-started generator set [Function 3 (F3)]

• providing load leveling to reduce the variability of the electric load about its average value [Function 4 (F4)]

• providing primary power for the ship either by itself or in conjunction with one or more generator sets [Function 5 (F5)]

Although initial EMs acquisitions may focus on single applications, eventually EMs will be distributed throughout the power system architecture in order to achieve the different design objectives, and be configured to address multiple energy storage functions as described above. If an EM is used to fulfill multiple functions, it must have sufficient power and energy capacity to satisfy the functions that would be applicable in any scenario.

[EM_FRD-17] [Information]

3.1 ENERGY MAGAZINE SYSTEM DEFINITION

The EM is a group of power conversion and energy storage components combined together into one or multiple cabinets to enable directed energy weapons and sensors to meet present shipboard distribution system requirements while allowing multifunctional use of the energy storage assets. Figure 2 identifies the components which will be used within the cabinets associated with an EM. All EM will have an application control cabinet which handles shipboard communications, provides all Human Machine Interfaces (HMI), monitors the energy storage media cabinet, provides control power for all the EM cabinets, stores all recorded data during EM operations, and provides EM thermal management. While all the electrical interface cabinets for an EM will be connected together with the application control cabinet, the energy storage cabinet may be physically separated from the conversion and application control cabinet. Auxiliary blocks shown in Figure 2 are functions that are not classified as a filter, power conversion, or energy storage. For example control, disconnect, and thermal management functions are considered auxiliary functions. [EM_FRD-1104] [Information]

Figure 3 shows examples of aligning the components into a family of cabinet sections, which when combined are defined as Power Conversion Cabinets (PCC) and Energy Storage Cabinets (ESC), required for various shipboard electrical interfaces. The various cabinets will be combined into EM and placed as needed by shipboard loads and power quality requirements. The interface cabinets should be self-contained as related to controlling their output electrical interface, providing output terminals, maintaining cabinet safety requirements, etc. in order to enable complete modular assembly.

The electrical interface cabinets will obtain their application control limits from the application control cabinet. The arrangement in the Figure 3 is notional and placement of components within an EM is up to the vendor of the equipment.

[EM_FRD-1105] [Information]

Figure 4 references DC interfaces that will be used in EM. The specific parameters for these interfaces will be changing during the review process; however, requirements have been included later in Section 3.4 under the individual interface cabinet requirements identifying initial values. Type I power interfaces are those that have controlled voltage parameters, while Type II power interface allows the bus voltage to float according to the energy storage impedance. [EM_FRD-1106] [Information]

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Figure 4 shows the typical shipboard interfaces associated with an EM. Section 3.3.1 through Section 3.3.18 will identify requirements for each of these interfaces. [EM_FRD-19] [Information]

Figure 2: Components used within Cabinets for EM

Controls & Cntrl Power

PWR I/O

Thermal Management

Cabling I/O

CTRL

& PWR

EMS & DC

Disconnect

CABINET AUXILIARY BUILDING BLOCKS

Energy Storage

DC / DC

Galvanically

Isolated

DC / DCAC / DC

or

DC / AC

AC / AC

Line

Frequency

ENERGY MAGAZINE BUILDING BLOCKS

PE Filters Differential Mode & Common Mode

DM & CM

FILTERS

CTRL &

THRML

Cabinet Controls &

Thermal

THRML

MGMT

AC

DC

Nom. Voltage

DC

DC

Nom. Voltage

DC

DC

Nom. Voltage

AC

AC

Nom. Voltage

HMI

(LOCAL)

HMI

ES

1kV – 680V

EMS & DC

DSCNT

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Figure 3: Family of Cabinets to be Used in Energy Magazine

THRML

MGMT

PWR I/O

CTRL

& PWR

Application Control

DM & CM

FILTERS

PWR I/O

MIL-STD-1399/

300 Interface

(450Vac, Type I)

DM & CM

FILTERS

LVDC Interface (375Vdc, Type I)

LVDC Interface (1kVdc, Type I)

LVDC Interface (1kVdc, Type II)

PWR I/O

DM & CM

FILTERS

PWR I/O

CTRL &

THRML

CTRL &

THRML

OR

DM & CM

FILTERS

LVDC Interface (650Vdc, Type I)

PWR I/O

DM & CM

FILTERS

PWR I/O

CTRL &

THRML

CTRL &

THRML

OR

CTRL &

THRML

DM & CM

FILTERS

PWR I/O

CTRL &

THRML

PWR I/O

HMI

(LOCAL)

CTRL &

THRML

DC

DC

1k-680 : 650

DC

DC

1k-680 : 1k

ES

1kV – 680V

DC

AC

1k-680 : 120/208

DC

DC

1k-680 : 650

DC

DC

1k-680 : 1k

AC

DC

450 : 1k-680

PWR I/O

CTRL &

THRML

AC

DC

450 : 1k-680

AC

AC

450 : 450

OR

EMS & DC

DSCNT

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Figure 4: Shipboard Interfaces for Generalized EM Application

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3.2 EM ACQUISITION PARAMETERS AND SPECIFICATION SHEETS

The Energy Magazine Specification Sheet will be utilized and provided by the acquisition program specifying the Energy Magazine being procured. The Energy Magazine Specification Sheet will identify the desired electrical interfaces and will be used to capture the following performance characteristics: [EM_FRD-24] [Information]

3.2.1 Ship Class

3.2.1.1 The amount and type of auxiliary services vary for the different US Navy ship classes, as well as, different flights or blocks within a class. [EM_FRD-26]

3.2.2 Application Electrical Characteristics

3.2.2.1 A summary of unique electrical characteristics required by the application is necessary to properly size and assemble the interface cabinets. For example, the requirement to provide galvanic isolation between the input and the energy storage media or the energy storage media and a specialized output load is essential to know in order to identify the proper components. [EM_FRD-28]

3.2.2.2 Load details, including impedance characteristics, necessary to perform stability analysis will be provided as GFI. [EM_FRD-31] [Information]

3.2.3 Allowable Segmentation of Application

3.2.3.1 This shall define the maximum number of EM that can be used for an application based on shipboard integration issues. [EM_FRD-33]

3.2.4 EM Composition

3.2.4.1 This shall define the components that will make up a particular EM system. [EM_FRD-35]

3.2.5 Application Duration

3.2.5.1 The minimum amount of time the application shall be supported at full load or the expected duty cycle for a given engagement time. [EM_FRD-37]

3.2.6 Stored Energy

3.2.6.1 The minimum usable stored energy capacity that shall be delivered to the application (in kWh).

[EM_FRD-39]

3.2.7 Time to Recover

3.2.7.1 This is the maximum time allowed between full power discharges in order to recharge the energy storage media from no usable energy to full usable energy. [EM_FRD-41]

3.2.8 Life

3.2.8.1 This shall be information regarding how the application will be using the EM and application specific reliability parameters. [EM_FRD-43]

3.2.9 EM Geometrics

3.2.9.1 The expected overall size and weight for an EM for the specified application. Each self-contained EM's physical extent shall fit within the space defined by the acquisition slant sheet. The dimensions shall include allowance for vertical shock excursion (horizontal shock excursion must fit within the maintenance allowance). [EM_FRD-45]

3.2.9.1.1 Hardware used to connect to the ship's resources (water, power, controls) or used for maintenance (grab rails, handles, etc.) are not required to be included in the physical extent.

[EM_FRD-46]

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3.2.9.1.2 Any hardware for maintenance (grab rails, handles, etc.) that extend beyond the physical extent shall be removable or retractable within the physical extent. [EM_FRD-1063]

3.2.9.1.3 Horizontal shock excursions shall be identified in drawings such that installation arrangements can account for overlap of maintenance space without overlap of horizontal shock excursions. [EM_FRD-747]

3.2.9.1.4 Grab rails or handles specified in MIL-DTL-16036, Par. 3.18, shall be provided at EM HMI and local controls. [EM_FRD-1079]

3.2.9.1.5 Grab rails/bars shall be attached in such a manner that hinged or removable panels can be opened or removed without removal of the rail from the member to which it is attached.

[EM_FRD-1080]

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3.3 EM GENERAL REQUIREMENTS

3.3.1 System Safety

3.3.1.1 The flame resistance and toxicity of self-extinguishing insulation materials utilized throughout the EM shall satisfy the test requirements specified by MIL-M-24519. [EM_FRD-49]

3.3.1.2 The EM electrical grounding, bonding, and shielding provisions shall be in accordance with MIL-STD- 1310. The provision shall be available for terminating the cable ground shields on incoming and outgoing cables. MIL-HDBK-454 may be used for guidance for testing with Wheatstone bridge or equivalent method. [EM_FRD-50]

3.3.1.3 Components that are provided with more than one source of power shall be provided with the following warning plate:

WARNING:

THIS EQUIPMENT IS SUPPLIED WITH MULTIPLE SOURCES OF POWER. ENSURE THAT

ALL SOURCES ARE SECURED PRIOR TO SERVICING THIS EQUIPMENT. [EM_FRD-51]

3.3.1.3.1 Components that contain stored energy shall be provided with the following warning plate:

WARNING:

THIS CABINET CONTAINS ENERGIZED BATTERIES AT ALL TIMES. [EM_FRD-1108]

3.3.1.4 Creepage over surface and clearance through air spacing between electrical circuits shall be in accordance with MIL-DTL-917. [EM_FRD-52]

3.3.1.4.1 When commercial power electronic devices are used such as control card assemblies, active or passive components, IGBTs, diodes, and other semiconductor devices, the creepage and clearance distances shall be accordance with UL 840 considering the EM system operating voltage, Pollution Degree (PD), and the Comparative Tracking Index (CTI) of the insulation material. [EM_FRD-53]

3.3.1.4.1.1 A minimum PD of 3 and CTI of IIIa shall be used for all Navy applications. [EM_FRD-54]

3.3.1.4.2 When the operating voltage is in between the value cited in the requirement, the higher voltage rating shall be used. [EM_FRD-55]

3.3.1.4.3 All busbar and associated buswork associated with input and output terminations internal to the PCC shall be separated without regard for applied insulation, per the creepage and clearance distances specified in MIL-DTL-917 for uninsulated electrical circuit. [EM_FRD- 1109]

3.3.1.4.3.1 Such buswork shall be assumed to be uninsulated for the purpose of designing minimum separation distances per the specified creepage and clearance distances. [EM_FRD- 1110]

3.3.1.4.3.2 High voltage safety grounding points (e.g. grounding balls) shall also be assumed to be uninsulated for the purpose of designing minimum separation distances per the specified creepage and clearance distances. [EM_FRD-1111]

3.3.1.5 When the maintenance or operation of equipment employing potentials of 1000V or more requires that these voltages be measured, the equipment shall be provided with test points that permit all the high voltages to be measured at potential levels of less than 1000 V relative to ground. [EM_FRD-56]

3.3.1.5.1 All measurement test points shall be accessible from the front maintenance envelope of the

EM. [EM_FRD-57]

3.3.1.5.2 Test points accessible via the front panel shall be 30 V or less. [EM_FRD-1068]

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3.3.1.5.3 Test points greater than 30 V and less than 1000 V shall be physically and electrically segregated from areas of the cabinet where operators can be exposed to voltages of 1000 V or greater, and be subject to Navy approval. [EM_FRD-1069]

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3.3.1.6 Electrical safety for EM shall follow the following guidance: [EM_FRD-58]

3.3.1.6.1 EM electrical safety requirements shall be in accordance with MIL-DTL-917. [EM_FRD-59]

3.3.1.6.2 The requirements for EM shall be satisfied by following the safety guidance of NSTM Naval Ships' Technical Manual (NSTM) Chapter 300: Electric Plant-General. [EM_FRD-60]

3.3.1.6.3 Recommended practices for electrical safety shall be used in accordance with IEEE-STD- 3007.3.d. [EM_FRD-61]

3.3.1.7 EM shall provide protection to personnel against accidental contact with voltages in excess of 30 volts root mean square (rms) or DC with all removable panels in place and hinged doors closed.

[EM_FRD-62]

3.3.1.8 EM shall provide the following features for the safe operation and maintenance: [EM_FRD-63]

3.3.1.8.1 When door interlock is required, interlocking device(s) shall be installed in cover(s), door(s), or power Line Replaceable Unit (LRU)(s) that have access to live circuits greater than 30 volts and are not protected by guards or barriers. [EM_FRD-64]

3.3.1.8.1.1 An LRU is a modular component that is designed to be replaced quickly. [EM_FRD-276] [Definition]

3.3.1.8.2 The interlocking device shall isolate power to the components behind the cover(s), door(s), or power LRU(s) inside EM. [EM_FRD-65]

3.3.1.8.3 Danger plates shall be supplemented by physical barriers or other positive protection where feasible. Danger plates reading “DANGER – HIGH VOLTAGE” or “DANGER [insert maximum voltage] VOLTS” shall be displayed prominently on safety covers, access doors, and inside equipment where hazardous voltages are exposed. [EM_FRD-66]

3.3.1.8.4 Markings on electrical equipment shall be in accordance with NFPA 70E. [EM_FRD-67]

3.3.1.9 The EM shall be designed for Incidental Energy (IE) and arc flash in accordance with IEEE-STD-

1584. [EM_FRD-68]

3.3.1.9.1 The EM shall be designed to meet the level of fault current available from the source and provide source protection by removing the fault, as specified (determine if arc blast pressure relief rupture discs are required) which would happen if the cabinet differential pressure that can occur during an arc event is greater than the cabinet differential pressure rating).

[EM_FRD-69]

3.3.1.9.2 The EM shall be marked with the ratings and arc flash boundaries for personnel safety in accordance with S9086-KC-STM-010/300 and NFPA 70E. [EM_FRD-70]

3.3.1.10 Warning, caution and danger plates for EM shall be in accordance with the following: [EM_FRD-71]

3.3.1.10.1 Warning and caution plates shall be formatted in accordance with MIL-STD-1472.

[EM_FRD-72]

3.3.1.10.2 Danger plates shall be supplemented by physical barriers or other positive protection where feasible. [EM_FRD-73]

3.3.1.11 Hinged panels shall be electrically grounded to the unit framework in both the open and closed positions by a separate conductor. [EM_FRD-75]

3.3.1.11.1 Acceptable grounding paths for hinged panels shall be independent of hinges connecting the panel to the cabinet. [EM_FRD-76]

3.3.1.12 EM protection requirements not covered elsewhere in this specification are as follows: [EM_FRD-77] [Information]

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3.3.1.12.1 The EM shall have protection from excessive output terminal voltage variation and transients.

[EM_FRD-78]

3.3.1.12.1.1 After recovery, The EM shall operate and supply the load with the same output voltage that was provided prior to the output overvoltage. [EM_FRD-79]

3.3.1.12.1.2 The EM output voltage shall be controlled in such a way to prevent the EM component failure due to output overvoltage condition. [EM_FRD-80]

3.3.1.12.1.3 The overvoltage protection set point, as specified (setpoint requirement), shall be adjustable by the user at the operator interface to permit adjustment. [EM_FRD-81]

3.3.1.12.2 Electronic parts and assemblies that are subject to electrostatic discharge (ESD) damage shall be handled and packaged in accordance with MIL-STD-1686 and using the guidance provided in MIL-HDBK-263. [EM_FRD-82]

3.3.1.12.3 Electrostatic discharge sensitive (ESDS) parts shall be marked in accordance with MIL-STD-

129. The symbol shall be located in a position readily visible to personnel when that assembly is incorporated into its next higher assembly. [EM_FRD-83]

3.3.1.12.4 When specified (partial discharge requirement), the EM shall be designed to be partial discharge-free (corona-free) with an acceptance criterion of less than 15 picocoulombs.

[EM_FRD-84]

3.3.1.12.4.1 Test equipment and procedures commercially approved for similar testing may be used.

[EM_FRD-758] [Information]

3.3.1.13 The method used to electrically ground the hinged panels shall not prevent quick opening of the panel. [EM_FRD-85]

3.3.1.14 Chassis grounding. All external parts capable of electrical conduction shall be at ground potential at all times in accordance with MIL-STD-1310. All removable covers with indicators, controls, or any electrical device over 30 volts shall be bonded to main structure. [EM_FRD-86]

3.3.1.15 The method used to electrically ground the removable panels shall not interfere with panel removal.

[EM_FRD-87]

3.3.1.16 EM shall include knob-type connection points to which electrical safety ground conductors can be clamped, to protect personnel against inadvertent energization of high voltage supply >=4160Vac or >=1000 VDC system. [EM_FRD-1086]

3.3.1.16.1 Maintenance grounding required in Paragraph 3.3.1.16 shall be from the front maintenance access space. [EM_FRD-1087]

3.3.2 EM Storage Media

3.3.2.1 Auxiliary input power used within an EM ESC shall be supplied via the EM PCC. [EM_FRD-89]

3.3.2.1.1 The auxiliary input power line shall provide up to 70 A to the ESC. [EM_FRD-90]

3.3.2.1.2 The auxiliary power connection between the PCC and ESC shall use LSTSGU-23 (MIL-DTL-

24643/16). [EM_FRD-91]

3.3.2.2 EM shall provide an auxiliary input power sourced maintenance charger contained within the ESC.

[EM_FRD-92]

3.3.2.2.1 The maintenance charger shall be used for energy storage management. [EM_FRD-93]

3.3.2.2.2 The maintenance charger shall limit current ripple harmonics below 5% Individual Harmonic Distortion (IHD) and 10% Total Harmonic Distortion (THD). [EM_FRD-94]

3.3.2.3 Cabinet control power, if used within an ESC shall be supplied by the EM PCC. [EM_FRD-95]

3.3.2.4 A hardwired E-Stop circuit shall be supplied from the EM PCC to the EM ESC. [EM_FRD-96]

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3.3.2.4.1 The hardware E-Stop shall electrically open all energy storage string(s). [EM_FRD-97]

3.3.2.4.2 There shall be a physical E-Stop button on the ESC. [EM_FRD-98]

3.3.2.5 Allowable EM Storage Media Inrush Current: When power is applied or when the equipment is powered up subsequent to application of power: [Information] [EM_FRD-99]

3.3.2.5.1 The peak inrush current shall not exceed 1.5 times the maximum operating current of the equipment. [EM_FRD-100]

3.3.2.5.2 During the inrush period, the current shall recover to a level less than or equal to the maximum operating current within 20 milliseconds. [EM_FRD-101]

3.3.2.6 If a Lithium Ion battery over 1kWh is used for the energy storage media, the EM auxiliary input power feed shall be considered a Mission Critical Equipment (MCE) load and will be fed from a vital load panel. [EM_FRD-102]

3.3.2.7 Any use of Lithium Ion Batteries shall be characterized in accordance with NAVSEA S9310-AQ-SAF-

010. [EM_FRD-103]

3.3.2.8 Any Lithium Ion battery shall go through the process of NAVSEA SG270-BV-SAF-010 prior to shipboard installation. [EM_FRD-104]

3.3.2.9 If Lithium Ion Batteries are used, the EM shall provide a separate compartment for battery LRUs which can be flooded by a fire suppression system. [EM_FRD-105]

3.3.2.10 If a single cabinet section houses Lithium Ion Battery LRUs, as well as other EM components, the battery compartment shall be located such that the suppression system does not flood or damage any non-battery compartments within the EM. [EM_FRD-106]

3.3.2.11 If the EM has lithium battery within itself, it shall be capable of removing fumes from a credible battery failure (as defined by the Navy during NAVSEA SG270-BV-SAF-010 characterization) within the ESC.

[EM_FRD-107]

3.3.2.11.1 Any EM cabinet section housing lithium batteries shall include an exhaust port. [EM_FRD- 1060]

3.3.2.11.2 ESC section lithium battery fume exhaust ports shall connect to a single exhaust manifold.

[EM_FRD-1061]

3.3.2.11.3 The ESC exhaust manifold shall be capable of connecting to an external ventilation system as determined when meeting requirements 3.3.2.7 and 3.3.2.8. [EM_FRD-1062]

3.3.2.12 Battery LRUs shall incorporate a means to be bypassed when unpowered or following a cell failure within the battery LRU. [EM_FRD-108]

3.3.2.12.1 Any battery LRU bypassing circuit shall prevent unintentional short circuit of any capacitors in the circuit in which it is installed, including output filter capacitance. [EM_FRD-1059]

3.3.2.13 If batteries are selected as the energy storage media, the EM shall incorporate a means to automatically or remotely, disconnect battery strings to voltages less than 250VDC from the ESC HMI for maintenance or in an emergency. [EM_FRD-109]

3.3.2.13.1 If batteries are selected as the energy storage media, LRU nominal voltage shall be less than

120VDC. [EM_FRD-880]

3.3.2.13.2 When installed or in storage, Battery LRU interconnects (terminals and conductors) shall include bolted covers to prevent inadvertent contact or wetting of interconnects. [EM_FRD- 881]

3.3.2.13.3 Battery LRUs shall incorporate separate bolted covers for positive and negative interconnects. [EM_FRD-882]

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3.3.2.13.4 Energy storage LRUs shall incorporate features and barriers in accordance with MIL-DTL- 917 to limit personnel exposure to voltages less than 30VDC. [EM_FRD-883]

3.3.2.14 If a flywheel energy storage system (FESS) is used, the FESS shall meet FAA FAR 25-1461 Equipment Containing High Energy Rotors. [EM_FRD-110]

3.3.2.15 If a FESS is used, it shall adopt the design guidance of ANSI/AIAA S-096-2004 Space Systems – Flywheel Rotor Assemblies. [EM_FRD-111]

3.3.2.16 A FESS shall be equipped with a vent(s) to exhaust gases from within the “safety containment” vessel in the event on an internal rotor or shaft failure. [EM_FRD-112]

3.3.2.17 The vents from all the Flywheel LRUs shall vector gases to within the FESS envelope in a manner that does not pose a hazard to other components within the FESS or personnel exterior to the FESS.

[EM_FRD-113]

3.3.2.18 The vent(s) installed in any Flywheel LRU shall be dimensioned to reliably exhaust the gas from the “safety containment” vessel without causing an internal overpressure in the “safety containment” vessel that may rupture the casing. [EM_FRD-114]

3.3.2.18.1 The rotor debris contains carbon dust that shall be vectored away from high voltages.

[EM_FRD-115]

3.3.2.18.2 The exhausted gases will be in excess of the ignition temperatures of many materials and consequently need to be vectored away from such vulnerable materials; else sufficient protection should be afforded to those vulnerable areas of the FESS. [EM_FRD-116] [Information]

3.3.2.19 The EM shall control charging rate and charge balance. [EM_FRD-117]

3.3.2.20 The Energy Storage subsystem shall be designed in such a way as to prevent a failure within an LRU from propagating to adjacent Energy Storage LRUs and other components with in the ESC external to the failed LRU. [EM_FRD-118]

3.3.2.21 The EM shall monitor status of its major subassemblies and LRUs. [EM_FRD-119]

3.3.2.21.1 The EM shall display status of the PCC and ESC locally at the PCC. [EM_FRD-120]

3.3.2.21.2 The EM shall display the status of the ESC locally at the ESC. [EM_FRD-121]

3.3.2.21.3 The EM shall communicate status to the Machinery Control System (MCS) via the EM PCC.

[EM_FRD-122]

3.3.2.22 The EM shall incorporate an automated means of disconnecting the Energy Storage LRU from any energy storage within the EM PCC. [EM_FRD-123]

3.3.2.23 A method to precharge the power electronic LRU upon reconnection with energy storage media shall be incorporated within the automated disconnect detailed in requirement 3.3.2.22 and 3.3.2.25.

[EM_FRD-124]

3.3.2.24 The EM shall incorporate an automated means to discharge stored energy associated with the power electronics to less than 30V within 30 seconds when the system is placed in the UNAVAILABLE/SECURED state (see 3.3.17 for state definitions). [EM_FRD-125]

3.3.2.25 The EM shall detect and isolate faulted Energy Storage LRUs such that transient power quality requirements specified herein are maintained with a single faulted Energy Storage LRU present following proper isolation of the faulted Energy Storage LRU and if the EM is capable of continued operation. [EM_FRD-126]

3.3.2.26 If lead acid batteries are selected as the energy storage media, batteries shall be valve regulated.

[EM_FRD-127]

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3.3.2.27 The ESC electrical interface shall meet those requirements as detailed in Section 3.4.5. [EM_FRD- 128]

3.3.2.28 If the ESC is physically separated from the PCC via cabling, a means to automatically disconnect both ends of the DC cabling upon application of a fault shall be provided. [EM_FRD-129]

3.3.2.28.1 The interconnecting DC cable shall have an inductance of less than 10 uH. [EM_FRD-130]

3.3.2.29 Not Used.

3.3.2.30 If an energy storage media is used that gives off volatile or potentially explosive gas during operation or during a creditable fault event, a means of monitoring and reporting the gas shall be provided.

[EM_FRD-132]

3.3.2.31 When EM is subject to stored energy such as capacitors, batteries, or stray voltages, S9086-KC-STM- 010/300 shall be used to remove the potential energy. [EM_FRD-133]

3.3.3 EM Storage Media Management System

3.3.3.1 The ESC shall include an Energy Management System (EMS) composed of electronics, control elements, and sensors to autonomously control, monitor, and report the status of the Energy Storage Media to the EM Application Controller. [EM_FRD-135]

3.3.3.1.1 Application controller is defined as the hardware/software used to perform the prescribed EM function. [EM_FRD-136] [Definition]

3.3.3.2 The data interface between the EMS and the EM Application Controller shall be via a CAN Bus (Version 2.0B) allowing communication of energy storage media status, as well as, control of charging and special modes of the EMS operation. [EM_FRD-137]

3.3.3.3 The EMS shall monitor the internal conditions of any Energy Storage LRUs and prevent operation outside ES manufacturer specification of those assets. [EM_FRD-138]

3.3.3.4 The EMS shall contain sufficient redundancy to provide MTBF greater than 25,000 hours with no maintenance. [EM_FRD-139]

3.3.3.5 The EMS shall control means of isolating the Energy Storage Media from the main electrical power bus between the ESC and PCC. [EM_FRD-140]

3.3.3.6 If the EMS detects a condition within an Energy Storage LRU that can jeopardize personnel or equipment safety, the EMS shall isolate the appropriate energy storage media string. [EM_FRD-141]

3.3.3.6.1 String is defined as energy storage media connected in series to get the required voltage output. [EM_FRD-142] [Definition]

3.3.3.6.2 Battery LRUs connected in parallel shall incorporate a means to prevent current flow into a failure in a paralleled LRU or LRUs. [EM_FRD-750]

3.3.3.6.3 The devices used to prevent current flow into a failure as required in 3.3.3.6.2 shall be monitored by the EMS or higher level controller. [EM_FRD-751]

3.3.3.7 In Battleshort Mode, the EMS shall obtain permission from the EM Application Controller before isolating an energy storage media string. [EM_FRD-143]

3.3.3.7.1 Battleshort Mode is an override of normal safeties which prevent circumstances that could damage the equipment or personnel. [EM_FRD-144] [Definition]

3.3.3.8 The EMS shall at a minimum provide the following data to the EM Application Controller: [EM_FRD- 145]

- Cell Voltage [EM_FRD-729]

- Storage Medium Charge Current [EM_FRD-994]

- Storage Medium Discharge Current [EM_FRD-995]

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- LRU Current Charge Current Limit [EM_FRD-996]

- Discharge Current Limit [EM_FRD-997]

- Instantaneous Current Limit [EM_FRD-998]

- Charge Voltage Limit [EM_FRD-999]

- Discharge Voltage Limit [EM_FRD-1000]

- Sufficient LRU Temperatures for Thermal map of LRU [EM_FRD-1001]

- State of Charge (SOC) [EM_FRD-1002]

- Amp-Hour Capacity [EM_FRD-1003]

- Fault status / errors [EM_FRD-1004]

- Memory Records [EM_FRD-1005]

- Time Stamp (Real Time Clock) [EM_FRD-1006]

- Battle Short [EM_FRD-1007]

- Contactor Status [EM_FRD-1008]

- Fuse Status (if applicable) [EM_FRD-1009]

- Communication Heart Beat [EM_FRD-1010]

- Maintenance charge status [EM_FRD-1011]

- Temperature Limit [EM_FRD-1012]

3.3.3.9 The EMS shall contain accessible non-volatile memory to record significant sensor events to be used for maintenance, diagnostics and failure evaluation. [EM_FRD-146]

3.3.3.9.1 Significant Sensor Event is defined as when one of the sensors exceeds its programmed alarm and/or fault level. [EM_FRD-147] [Definition]

3.3.3.9.2 In order to maintain SoC awareness and accuracy, the EM shall self-power any EMS during normal maintenance lasting longer than a configurable time between twice the MTTR to two hundred times the MTTR (settable in 24 hr increments). [EM_FRD-752]

3.3.3.9.3 The EMS shall be capable of executing a user initiated recalibration of the SOC algorithms.

[EM_FRD-753]

3.3.3.9.4 SOC recalibration shall be executed by charging and discharging the energy storage media.

[EM_FRD-1013]

3.3.3.10 The collected sensor data shall be time tagged based on a clock that is settable by the EM Application Controller. [EM_FRD-148]

3.3.3.11 The EMS shall collect sensor data collected at two rates based on ES Media use: EMS Ramping Data and EMS Idle Data. [EM_FRD-149]

3.3.3.12 The EMS Ramping…