SECTION 202 MACHINERY CONTROL SYSTEMS.pdf

LHA 10

6 APRIL 2023

SECT. 202 SECT. 202 1

SECTION 202

MACHINERY CONTROL SYSTEM

202a. Definitions 5 Automated control.- Control actions performed without watchstander intervention.

Base load control mode.– A mode of MCS Diesel Generator (DG) control where a DG operates at a constant output, or variable output, as commanded by an MCS operator.

The associated DG mode remains in Normal (or Isochronous) condition during base load control mode. 10 Central Control Station (CCS).- The area of the ship remotely located from the machinery spaces, which is the central control point for machinery control and monitoring. In addition, damage control functions shall be monitored and controlled or coordinated from this space.

Centralized control.- Control of multiple functions, processes, equipment or 15 systems from a central control location.

Control.- The action by which an operator or machine-generated commands are implemented to regulate, govern or direct the performance of machinery or systems.

Control can be classified by type as either automated or manual and by location as either remote or local. 20 Data Acquisition Unit (DAU).- The Machinery Control System (MCS) unit that provides a hardwire or other signal interface to the sensors and local control elements.

Electric Plant Controller (EPC).– Real-time controller with power management functions and I/O capability that communicates, controls, and exchanges information 25 with field devices and EPCCs within the boundaries of the electric plant in order to coordinate the operation of electric plant equipment.

Electric Plant Control Consoles (EPCC).- A console with two HMI monitors dedicated for electric plant control and monitoring.

End-to-end testing capability.– The ability to check MCS functionality from the 30 point of stimulated ship signal input to HMI output and from MCS control input to MCS signal output/simulated ship system response, including hardware and software Input/Output (I/O) in the Land Based Test Equipment (LBTE).

Fatal fault.- A fault which results in the loss of the ability of the MCS to monitor or control equipment or systems to which it is connected. 35 Functional group.- A logical grouping of related equipment or functions, for example, shaft 1 thrust or ship service auxiliaries.

Graphic User Interface (GUI).- The GUI provides graphic display interface capability to the front end user.

Hardwired.- Direct point-to-point wiring where each signal is transmitted over 40 one unique signal path. No signal path shall be considered hardwired if it is used to transmit more than one signal; for example, serial, Ethernet, and multiplexed signals in general are, by definition, not hardwired. This definition is applicable to this section only.

Hull, Mechanical and Electrical Local Area Network (HM&E LAN).– The primary 45 network infrastructure for all intra and inter HM&E system communication as specified herein including the following HM&E systems:

a. Machinery Control System

b. Ship Control System

c. Damage Control Action Management System (DCAMS) 50

SECT. 202 SECT. 202 2

Human-Machine Interface (HMI).- The HMI provides an advanced system of displays, controls, keyboards, and other machine-to-operator interfaces to monitor and control the engineering plants.

Lowest Replaceable Unit (LRU).- For the purposes of this section, LRUs are defined as components or assemblies intended for ship’s force replacement including 5 but not limited to Printed Circuit Boards (PCBs), power supplies, cooling fan assemblies, and certain chassis mounted assemblies as determined during the design phase.

Logging Unit (LU).– The MCS unit which stores the log data required in this section. 10 Machinery Control Consoles (MCC).- A MCS console with two HMI monitors used for monitoring and control, excluding electric plant control.

Machinery Control System (MCS).- The system used to actuate/facilitate control and monitoring of selected machinery equipment and systems (propulsion, electric, auxiliaries and damage control). 15 Manual control.- MCS control where the final control element is controlled directly by a corresponding operator action. Manual control may be local or remote to the machinery. It may be purely mechanical, electrical or power assisted.

MCS station.- Any MCS Console, or Remote Monitoring and Control Unit (RMCU).

MCS unit.- A defined portion of MCS equipment. Units may consist of more than 20 one physical section or enclosure.

Monitoring.- Surveillance carried out by sensors for interpretation by watch-standers, automated systems, or both.

Non-fatal faults.- Any fault that is not critical to system performance.

Portable Maintenance Unit (PMU).- A ruggedized (3 foot drop tested) laptop 25 computer that interfaces to the MCS and enables maintenance, troubleshooting, system recovery and control, and monitoring of the propulsion gas turbine/shaft control unit.

Propulsion gas turbine/shaft control unit.– MCS units containing the gas turbine controller and all I/O for control and monitoring of the propulsion unit, except 30 APS I/O signals.

Propulsion unit.- A propulsion gas turbine, auxiliary propulsion motor, reduction gear, shafting and propeller.

Remote control.- Control of equipment, machinery or systems from a location remotely located from the operating machinery, equipment and systems. 35 Remote Monitoring Unit (RMU).- A computer unit, running MCS software that provides monitoring of all machinery, electric plant and damage control parameters.

Remote Monitoring and Control Unit (RMCU).- A computer unit, running MCS software that provides monitoring and control of all machinery and damage control parameters, excluding electric plant control. 40 Ruggedized.- A COTS computer or other equipment which passes the following test:

the equipment is clamped onto a seesaw-like crane, lifted 3 feet above a 50 pound steel block and then dropped. If the equipment functions after rebooting, then it passes the test and qualifies as ruggedized.

Ship Control Console (SCC).- A console, as specified in Sects. 438 and 561, 45 which provides the following: steering and propulsion unit thrust control input.

Ship Control System (SCS).– The system used to control the rudder position and provide helm/lee helm operator stations via the SCC.

Software.- Computer programs and databases:

Computer database means a collection of recorded data in a form capable of 50 being processed by a computer. The term does not include computer software.

Computer program means a set of instructions, rules, or routines, recorded in a form that is capable of causing a computer to perform a specific operation or series of operations.

SECT. 202 SECT. 202 3

Computer software means computer programs, source code, source code listings, object code listings, design details, algorithms, processes, flow charts, formulae, and related material that would enable the software to be reproduced, recreated, or recompiled. Computer software does not include computer databases or computer software documentation. 5 Computer software documentation means owner's manuals, user's manuals, installation instructions, operating instructions, and other similar items, regardless of storage medium, that explain the capabilities of the computer software or provide instructions for using the software.

Computer code that executes from or is stored in read-only memory (firmware) 10 is considered software for the purpose of this section.

Trailshaft mode.- A propulsion plant operating mode in which only one shaft is providing propulsion thrust (driving shaft). In the trailshaft mode, the driving shaft is operated at a propeller pitch equal to or less than design ahead pitch and the trailing shaft propeller is set to a setting greater than 15 design pitch to minimize drag.

202b. Machinery Control System (MCS) An MCS shall be provided. The MCS shall provide remote monitoring and remote control as specified herein. MCS units shall be named and provided as follows: 20

QUANTITY UNIT LOCATION

7 Machinery Control Console (Note 1) 25 15 RMCU (Note 2) 5 Electric Plant Control Consoles (Note 8) 10 Electric Plant Controller (Note 7) 2 Propulsion gas turbine/shaft Machinery Room No. 1 control unit and No. 2 30 AR DAU (Note 3) 2 Portable Maintenance Unit (PMU) 7 Remote monitoring unit (Note 4) 2 Color printer CCS 1 Color printer Secondary Damage Control 35 Central and Forward Repair 2 Main 1 On Board Trainer Node room (Note 5) 2 Logging unit (Note 6) ------------------------------------------------------------------------------ 40

NOTES:

1. The Machinery Control Consoles (MCCs) are located as follows: three in CCS, two in Machinery Room No. 1, two in Machinery Room No. 2. MCCs located in the Machinery Rooms No. 1 and No. 2 shall be centrally located on the mid-level of the machinery room to the maximum extent practicable. 45

2. The RMCUs shall be located as follows: one in each Repair Station as specified herein, one in Conflagration Station No. 4 and Well Deck Debark, one in the Oil and Water Test Lab, one in the Auxiliary Machinery Room and two in CCS as shown on the drawings.

3. DAUs shall be provided and located as required. 50

4. Remote monitoring units shall be centrally located in JP-5 Pump Rooms No. 1 and No. 2, in the Aviation Fuel Lab and Office, in the Pilot House as shown on the drawings, in the Chief Engineer’s Stateroom, in the Master at Arms Office, and in the Engineering Dept. Office. RMUs shall be bulkhead mounted.

SECT. 202 SECT. 202 4

5. The On Board Trainer shall be located in any node room.

6. One logging unit shall be located in Node Room No. 2; the other in Node Room No. 3.

7. The Electric Plant Controllers are located as follows: two in Machinery Room No. 1, two in Machinery Room No. 2, one in Generator Room No. 1 Operating Station, 5 one in Generator Room No. 2 Operating Station, and one in each of the electrical equipment rooms for the following 4160V switchboards: 4HA, 4HB, 5HA, and 5HB.

8. The Electric Plant Control Consoles (EPCCs) are located as follows: one in CCS, one in Machinery Room No. 1, one in Machinery Room No. 2, one in Generator Room No. 1 Operating Station, and one in Generator Room No. 2 Operating Station. 10 All MCS units shall directly interface to the HM&E-LAN as specified herein.

Failure of any MCS unit, except DAUs and EPCs, shall not affect control or monitoring of equipment and systems from another MCS unit. Failure of any single DAU shall not affect manual control or monitoring of equipment connected to other DAUs. No single failure shall inhibit control or monitoring of more than one 15 propulsion unit, or one DG and its associated SG switchboard, or one longitudinal switchboard. The MCS shall be designed to be fail-safe, or fail-set for safety of personnel during the installation, operation, maintenance, and repair or interchanging of a complete equipment assembly or component part thereof. The equipment shall be constructed such that failure of any part or subassembly shall 20 not result in unsafe operating conditions and any resulting damage shall be confined to the minimum replaceable part or subassembly within which the failure occurred.

MCS equipment and wiring shall be located to ensure adequate natural cooling and to avoid excessive heating. Unless unavoidable, MCS wiring and equipment shall not 25 be located above or adjacent to heat producing apparatus, piping, ducts, or thermal insulating barriers where high local ambient temperature may occur.

Where remote control from MCS is required and the controlled equipment is equipped with local control, a local/remote selector switch shall be provided on or adjacent to the local controls to prevent concurrent local and MCS remote control 30 unless otherwise specified herein. For valves, a local/remote selector switch is not required unless otherwise specified herein. The MCS shall monitor the local/remote selector switches and the MCS control enable/disable switches of all remote equipment, so fitted. Unless otherwise specified, MCS control (operator and automatic) of remote equipment shall be disabled when the selector switch is in the 35 local or MCS control disabled position.

Systems integration.- The Contractor shall ensure that MCS equipment and software properly interface with each other, with all controlled and monitored equipment, with other systems and networks that interface with these systems, and with the HM&E-LAN. 40 Engineering units.- Analog parameters monitored by the MCS shall be displayed and printed in the applicable engineering units as follows:

SECT. 202 SECT. 202 5

Parameter U.S. Customary Unit angle degrees (°) battery level percent (%) 5 current ampere (A) date year, month, day (y, m, d) differential pressure pounds per square inch differential (psid) (See Note 1) draft feet (ft) 10 electromotive force volts (V) flow gallons per minute (gpm) free chlorine parts per million (ppm) frequency hertz (Hz) fuel consumption rate gallons per hour (gph) 15 gen set differential pressure inches of water (in H2O) gen set fuel rack position millimeters (mm) gen set vacuum inches of water (in H2O) pitch percent (%) power (mechanical items) horsepower (hp) 20 power, real (electrical items) kilowatts (kW) power, reactive (electrical items) kilovars (kVAR) power, total kilovolt-amps (kVA) pressure pounds per square inch gauge (psig) 25 pressure (PGT) pounds per square inch absolute (psia) revolutions revolutions (rev) rotational speed revolutions per minute (rpm) specific fuel consumption pounds per horsepower hour (lb/hp-hr) speed (ship, wind) knot 30 tank capacity gallons (gal) (See Note 2) temperature degrees Fahrenheit (°F) temperature (generator and degrees Celsius (°C) (See Note 3) transformer windings) 24-hour time hours, minutes, seconds 35 time (hour meter) hours torque foot-pounds (ft-lb) torque, shaft thousand foot-pounds (kft-lb) vacuum inches of mercury (in-Hg) vibration thousandths of inch (mil) 40

NOTES:

1. Differential pressure allowed to be displayed in inches of water (in H2O) where a PSID display range results in fractional values.

2. Unless otherwise specified herein. 45

3. APS transformer winding temperatures allowed to be displayed in degrees F.

Monitoring and control signals.- Monitoring and control signals shall be in accordance with the requirements specified herein.

Signal identification.- The Contractor shall assign unique signal identification 50 numbers to all MCS external signals in their corresponding signal group, and shall use these signal identification numbers in all applicable documentation. The signal identification number shall include a system code assigned by the Contractor.

SECT. 202 SECT. 202 6

Power On Self-Test (POST).- The MCS units shall automatically execute a POST during which the unit's internal components are checked and initialized. The POST shall detect and alert the operator to the following errors, as a minimum:

a. CPU/memory devices 5

b. Input/output devices

c. Storage devices.

Built-In Test (BIT).- Each MCS unit shall incorporate a BIT.

The BIT shall not require any hardware reconfiguration by the operator, such as 10 removal of cards or connectors. The BIT shall execute as an automatic background test on power-up and following reset. The BIT shall be performed continuously to monitor MCS unit operation including network/communications integrity. The BIT shall be executed during startup as off-line BIT, and during startup, after execution of POST and during the application software execution as a periodic on-15 line BIT. The startup of the software for each MCC, RMCU, DAU, logging unit, and RMU shall be monitored for correct initialization. Any errors detected during startup and BIT shall be alarmed in accordance with this section. The On Board Trainer (OBT) BIT shall consist of a separate equipment health monitoring capability while an MCS console is in Training Mode. The MCS shall not display 20 tactical unit BIT information on a console in Training Mode.

Fault detection.- The BIT shall detect all fatal and non-fatal faults.

Fault isolation.- The BIT shall isolate 90 percent of all detected faults to one LRU and the remainder to two or three LRUs.

202b1. MCS hardware requirements General hardware requirements shall be as specified in this section.

The MCS equipment shall operate on 115 Vac, single phase, or three phase, 60 Hz, type I, ungrounded power in accordance with MIL-STD-1399, Section 300.

Primary input power.- MCS units shall be powered from external UPS units, as 30 specified in this section, and in accordance with Sect. 314.

Alternate input power.- MCS units, with the exception of RMUs, PMUs, OBT, and printers, shall be powered from Category I power in accordance with Sect. 320.

A zonal UPS approach shall be designed to minimize the quantity of UPS units per electrical zone. MCS units shall be powered from an external UPS unit located 35 within the same electrical zone. Within an electrical zone, MCS units serving the port switchboards shall not be powered from the same UPS unit as the MCS units serving the starboard switchboards. All external UPS units providing power to MCS units shall be of the same make and model. A manual bypass switch shall be provided to bypass the UPS in accordance with Sect. 314. 40

a. The status of each UPS unit providing power to any MCS unit or HM&E network switch shall be monitored by MCS to include, but not limited to, condition reporting as specified in Sect. 314.

b. The MCS shall provide an alarm for each UPS unit serving MCS units for the following conditions: 45

1. Upon switching from primary power to battery power.

2. Upon UPS battery charge capacity reaching 10 minutes remaining.

3. Upon each UPS fault condition detected by the UPS unit.

SECT. 202 SECT. 202 7

Each MCS unit, except RMUs, the OBT server, printers, and PMUs, shall include an internal automatic input power transfer switch. Upon loss of primary input power, the switch shall automatically transfer to alternate input power. The switch shall automatically return to primary input power when primary input power is restored.

Switching shall not cause an interruption to the operation of the MCS unit. The 5 primary input power shall be provided from a power source not being used to provide alternate input power to the MCS unit.

a. The MCS shall monitor the status of each MCS unit internal automatic input power transfer switch.

b. The MCS shall provide an alarm for each MCS unit internal automatic input 10 power transfer switch upon switching from primary input power to alternate input power.

Machinery Control Consoles (MCCs).- MCCs shall each be provided with two 20 inch minimum viewable Liquid Crystal Displays (LCDs) or Light-Emitting Diodes (LED) 15 displays. The MCC shall provide the HMI to control all machinery and damage control functions, except electric plant control functions. The MCC shall provide the HMI to monitor all machinery, electric plant, and damage control functions, including cybersecurity monitoring and alarming functions for non-electric plant equipment and VLANs. The MCC HMI shall be as specified herein. All MCCs shall 20 have an identical HMI. The MCCs shall be for stand up operation, except that for MCCs located in CCS, the operator shall have seated access to all console controls.

All consoles shall be equipped with a full size keyboard and trackball with two select pushbuttons. All MCCs shall be equipped with an internal DVD drive. The DVD drive shall be used for software maintenance only and is not required to 25 function through Mil. Spec. MIL-S-901D grade A shock and MIL-STD-167 vibration environments.

All consoles shall be operable with flash gloves. If touchscreens are utilized, this requirement shall apply to the keyboard and trackball.

Electric Plant Control Consoles (EPCCs).- EPCCs shall be the same design as the 30 MCCs, except the EPCC HMI shall be limited to controlling and monitoring of all functions and equipment for the electric plant and associated auxiliaries within the electric plant VLANs, including cybersecurity monitoring and alarming functions for electric plant equipment and VLANs. The EPCC HMI shall be as specified herein. All EPCCs shall have an identical HMI. The EPCCs shall be for stand up operation, 35 except that for the EPCC located in CCS, the operator shall have seated access to all console controls. All EPCCs shall be equipped with an internal DVD drive. The DVD drive shall be used for software maintenance only and is not required to function through Mil. Spec. MIL-S-901D grade A shock and MIL-STD-167 vibration environments. 40

Remote Monitoring Unit (RMU).- The remote monitoring units shall each be provided with a 20 inch minimum viewable LCD or LED display for the full monitoring of all machinery, electric plant, and damage control parameters. The integral display shall graphically depict the same images as the console displays. All RMUs shall be equipped with a full size keyboard and trackball with two select 45 pushbuttons. If touchscreens are utilized, the keyboard and trackball are not required. Means shall be provided at the RMU located in the MAA office to acknowledge alarms assigned to the Security functional group.

Data Acquisition Units.- DAUs shall be provided as required to accommodate the signal Input/Output (I/O) as specified herein plus an additional 20 percent spare 50 capacity per DAU hardwired I/O signal type. The DAUs shall provide control functions, local machinery plant monitoring and control, signal processing, and interfaces to machinery plant and Damage Control (DC) equipment and sensors. The signal cables that connect DAUs to their associated sensors and actuators shall not cross fire zone boundaries except for I/O servicing equipment powered by a load 55

SECT. 202 SECT. 202 8

center for which the associated 450V switchboard is located outside its fire zone.

Electric Plant (EP) I/O signals supporting electric plant functionality shall not be shared in the same DAU with non-EP I/O signals. I/O signals for multiple 4160V longitudinal switchboards shall not be shared in the same DAU. I/O signals for multiple SSDGs and associated SG switchboards shall not be shared in the same DAU 5 or the same EPC as specified herein. The DAUs shall be provided with a means for isolating and troubleshooting hardwired 4-20 mA and serial data sensor and actuator signals to and from the machinery. Each DAU shall contain a minimum of 20 percent spare card slots. The enclosures shall provide a minimum of 20 percent hardwired I/O signal connection growth. Each DAU shall be provided with power supplies and 10 cooling capacity sufficient for the additional card slots at the maximum power consumption capability of the card slot. The Contractor shall assign the signals to be connected to each DAU.

EPC.- An EPC shall be provided, for each SSDG, to control and monitor each SSDG, its associated Generator Control Unit (GCU) and its associated SG switchboard as 15 specified herein. All I/O serving each SSDG and its associated SG switchboard shall terminate at the associated EPC to the maximum extent practicable. SSDG I/O shall include all supporting equipment required for SSDG starting, stopping and continuous operation, as specified in Sect. 310, and I/O required for SSDG start permissives, including but not limited to, enclosure cooling, seawater cooling, 20 fuel oil service, and start air systems. An EPC shall be provided for each 4HA, 4HB, 5HA and 5HB switchboard to provide control and monitoring for these longitudinal switchboards as specified herein. All I/O serving each 4HA, 4HB, 5HA, 5HB, and DG switchboard shall terminate at the associated EPC to the maximum extent practicable. Auxiliary interface equipment that cannot be housed within the same 25 enclosure as the EPC, for example, analog signal and fuse interface boxes, shall be located within the same space as the associated EPC. For the purposes of this requirement, the Generator Rooms and Generator Operating stations shall be considered the same space. The EPC shall include a Woodward Atlas IITM, or equal.

Each SSDG EPC may be combined within the same enclosure as its associated SSDG 30 GCU. If the SSDG EPC and GCU are combined, then each combined unit shall meet the requirements as specified in this section and Sect. 310.

The potential transformers in switchboards 1HB, 2HA, 7HB and 6HA, where required for EPCC breaker controls, shall be allowed to interface directly with the EPC for 1SG and 6SG respectively. 35 Each EPC shall contain a minimum of one spare card slot if a chassis with plugin cards is used. These spare slot requirements shall not apply to the Woodward AtlasTM, or equal, controllers.

If used to facilitate a back-up means of 4160V synchronizable breaker control, excluding generator breakers, upon loss of an ATLAS II™ within a given EPC, the 40 following non-HM&E LAN direct communication buses shall be allowed:

DIRECT INTER-EPC COMMUNICATION BUS PAIRS FOR BACK-UP SYNCHRONIZABLE BREAKER CONTROL ----------------------------------------------------------------------------------- 45

1SG 4HB

6SG 5HB

3SG 2SG

5SG 4SG

5HA 4HA 50

SECT. 202 SECT. 202 9

Propulsion Gas Turbine/Shaft Control Unit.– The PGT/SCU Gas Turbine core controller shall contain one or more spare card slots if a chassis with plugin cards is used. Each PGT/SCU Gas Turbine core controller shall be provided with power supplies and cooling capacity sufficient for the additional card slots at the maximum power consumption capability of the card slot. 5 Remote Monitoring and Control Unit (RMCU).- RMCUs shall each be provided with a minimum 20 inch viewable LCD or LED display. The integral display shall graphically depict the same images as the MCC console displays providing the operator with a uniform method of operation. The RMCU shall provide the HMI to control all machinery and damage control functions, except electric plant control 10 functions. The RMCU shall provide the HMI to monitor all machinery, electric plant, and damage control functions, including cybersecurity monitoring and alarm functions for non-electric plant equipment and VLANs. The RMCU HMI shall be as specified herein. The RMCU shall have a full size keyboard and trackball with two select pushbuttons. 15 One of the RMCUs located in CCS shall include a video output which shall be used to drive the MCS flat panel display located in the CCS, as specified in Sect. 252.

RMCUs shall be operable with flash gloves. If touchscreens are utilized, this requirement shall apply to the keyboard and trackball.

CCS RMCUs shall be installed for seated operation. 20 Logging units.– Logging units shall provide nonvolatile storage for the engineering, security and bell logs, and cybersecurity logs for MCS as specified herein. The logging units shall store both electric plant and non-electric plant data. Each shall be capable of storing a minimum of 12 months of log data.

Portable Maintenance Units (PMUs).– PMUs shall be ruggedized COTS laptop 25 computers. The POUPMUs are exempt from the accelerated life test requirements.

Microprocessor boards.- DAU microprocessor boards shall employ Read Only Memory (ROM), Random Access Memory (RAM), and Electrically Erasable Programmable Read Only Memory (EEPROM) as appropriate. Program parameters that are alterable as well as backup control algorithms shall be stored in non-volatile memory. 30 Printers.- Three color printers shall be provided. The printers shall be mounted on shock isolation mounts and interface with the HM&E-LAN. The printers shall print the bells, alarms, warnings and error messages generated by the MCS and also be able to print parameter logs selected by the operator at specific intervals.

The color printer shall also provide, on demand hard copies of pages displayed 35 on the screen of the MCCs in CCS. Securing or malfunction of printers shall not cause malfunction of other parts of the MCS. The printers are exempt from the accelerated life test requirements.

Video display.- The MCS display size, with the exception of PMUs, shall have a minimum viewable dimension of 20 inches measured diagonally and have a resolution 40 of at least 1280 x 1024 pixels. Touch screens may be utilized in MCS.

Audible controls.- Controls shall be provided to adjust the volume of audible alarms associated with control system units. Controls shall not reduce alarm volume below 70 dBA nor increase it over 90 dBA. The operator shall have access to the volume controls. 45 Equipment access.- MCS equipment shall require front access only for service and maintenance, with the exception of service and maintenance of terminal boards and connectors used for external cable connections. Each MCS unit, except PMUs, shall be lockable with each lock being keyed to use a common key for all enclosures. If padlocks are used to fulfill this requirement they shall be in accordance with 50 Sect. 604. The printers shall be installed such that access to the network connection shall be lockable. Each MCS unit, except PMUs and printers, shall have a lockable external data port for connection of a PMU. The data port may be in a separate enclosure located adjacent to the associated MCS unit.

Equipment mounting.- MCS consoles shall be deck-mounted and braced if required. 55

SECT. 202 SECT. 202 10

Environmental conditions.- The MCS shall provide continuous reliable operation under the environmental conditions specified in this section and as follows:

Ambient temperature.- The MCS equipment, with the exception of the OBT and printers, shall operate continuously without mechanical or electrical damage and in accordance with the performance and functional requirements, in any 5 compartment ambient temperature between the limits of 50 degrees F and 122 degrees F. The equipment shall be capable of meeting a non-operating temperature range between the limits of -40 degrees F and 158 degrees F without damage except as modified herein. The OBT shall operate continuously without mechanical or electrical damage and in accordance with the performance and 10 functional requirements, in any compartment ambient temperature between the limits of 50 degrees F and 81 degrees F. MCS equipment with non-operating temperatures different than the specified range above shall not be used without approval.

Humidity conditions.- The MCS equipment, with the exception of the OBT and 15 printers, shall operate with a relative humidity ranging up to 95 percent for both intermittent and continuous periods, including conditions wherein condensation takes place in and on the equipment in the form of both water and frost. The OBT shall operate with a relative humidity ranging up to 85 percent for both intermittent and continuous periods, including conditions wherein 20 condensation takes place in and on the equipment.

Shock.- The MCS equipment shall meet grade A except for the RMUs, OBT, printers and PMUs. The two RMCUs located in CCS, RMUs and OBT shall meet grade B shock.

Vibration.- MCS equipment, with the exception of the OBT and printers, shall 25 not fail when subjected to the type I vibration tests of MIL-STD-167/1 as specified in Sect. 073. The MCS equipment may be mounted using resilient mounts. Vibration requirements shall not apply to the printers and PMUs.

Electromagnetic interference.- The MCS equipment shall meet the requirements of 30 and be tested in accordance with the applicable requirements of MIL-STD-461 for surface ship equipment mounted below deck, metallic hull installations, except for printers and PMUs.

Design and construction.- Design, construction, and testing of the MCS units, except for printers and PMUs, shall be as specified in this section. 35

202b1a. Safety requirements Electrical.- The design and construction shall incorporate methods to protect personnel from inadvertent contact with voltages capable of producing shock hazards. 40 Ground.- The design and construction of the MCS equipment shall ensure that all external parts, surfaces, and shields are single point grounded to the hull at all times. The entire hull acts as a single point ground. The design shall include consideration of ground currents and voltage limits (possible arcing) established on a basis of hazardous location. 45 Accidental contact.- The design and construction shall incorporate methods to protect personnel from accidental contact with voltages in excess of 30 Volts rms or dc during normal operation of the MCS equipment.

Guards and barriers.- All power switches, contacts, terminals, and like devices that have voltages between 70 and 500 volts rms or dc with respect to ground shall 50 be guarded from accidental contact by personnel if such points are exposed to contact during direct support or operator maintenance. Guards or barriers may be provided with test probe holes where maintenance testing is required.

SECT. 202 SECT. 202 11

Equipment safety markings.- Warning plates shall be provided to warn of specific hazards such as voltage, current, thermal, or physical. The plates and markings shall be as permanent as the normal life expectancy of the MCS equipment on which they are affixed. Guards, barriers, and access doors, covers or plates shall be marked to indicate that a hazard may be present upon removal of such devices. When 5 possible, markings shall be located such that it is not removed when the barrier or access door is removed. Additionally, hazards internal to a unit shall be marked adjacent to hazards if they are significantly different from those of surrounding items. Such a case would be a high voltage terminal in a group of low voltage devices. Physical hazards shall be marked with color codes in accordance with ANSI 10 Z53.1 where applicable to electronic equipment. For potentials between 70 and 500 volts, warning plates shall be in accordance with ANSI Z35.1, class II and ANSI Z35.4 and shall read, as a minimum:

DANGER 15

HIGH VOLTAGE

(Insert maximum voltage applicable) VOLTS

Laser labels shall be in accordance with 21 CFR 1040.

202b1b. Electrical Characteristics Harnessing.- All wiring shall be neatly formed into groups that shall be laced, strapped or secured by sleeving. The groups shall be supported or clamped in such a manner as to prevent chafing of the wire insulation. There shall be no splices in the wires. All connections shall be made at the terminals of parts, connectors, 25 or at terminal boards.

Wire bundles.- Flexible wire bundles running between hinged panels or drawout assemblies shall avoid cutting or chafing of the wires. The wire bundle shall be protected by a plastic sleeving over the length of the cable bundle subject to chafing. Both ends of the sleeving shall be securely clamped. Wire within the 30 sleeving shall be free to maintain flexibility. Wire groups running from hinged panels or drawout assemblies shall be formed and clamped so that sharp bends do not occur in either the open or closed position.

Slack.- Sufficient slack shall be provided so as not to impair movement or put undue stresses on the wire or components in those places where movement of 35 components may be expected. Slack shall also be provided to prevent undue stress on terminal connections due to shock or vibration. Where wire terminals are used, sufficient slack shall be provided for at least two replacements of the part in the event that the wires are damaged or have to be clipped at the terminals during disassembly. 40 Mechanical supports.- All electrical connections shall be provided with supports so as to prevent breakage and minimize changes in performance due to vibration, inclination or shock.

Terminal block connections.- Electrical connections shall not be dependent upon wires, lugs, terminals, etc. clamped between a metallic member and an insulating 45 pliable material. Such connections shall be clamped between metal members.

Semiconductors mounted in accordance with the manufacturer's recommendations may be exempted from this requirement.

SECT. 202 SECT. 202 12

External cable connections.- External cables shall be connected via connectors or terminal boards. Where terminal boards are used, they shall be located near the cable entrance. Terminal boards or cable connectors for external connections shall be accessible from the front or back of the equipment. Both male and female portions of the cable connectors shall be provided by the supplier and shall be 5 keyed to prevent improper connections. Circuitous routing of wire shall be avoided. Care should be taken in the design and construction to allow space for the proper bending radii of conductors of external cable going between the cable entrance and terminal boards. Grounded terminals shall be provided for grounding the shields of each group (such as, pair and triplet) of external cables and shall 10 be located on or near the terminal boards. Each individual pin socket contact shall be properly identified to facilitate wiring installation.

Insulation protection.- Wherever wires are run through holes in metal partitions, the holes shall be equipped with grommets for mechanical protection of insulation. Care shall be exercised in the running of wires to ensure that they 15 are not carried over or bent around any sharp corner or edge.

Shielded wire.- Conductors using metallic shielding unprotected by an outer insulation shall be so secured as to prevent the shielding from coming into contact with exposed terminals or conductors. Shielding shall be terminated as close to the circuit terminal as practical without the risk of grounding the terminal. 20 Where required by the circuit design and construction, shielding shall be grounded and the connection to the chassis shall be by means of terminal lugs on screw type terminals or bolts.

Wire end connections.- The ends of each wire, except for pigtail leads or parts requiring solder connections, shall be terminated by crimp type connector contacts 25 or crimp type terminal lugs for connection to screw type terminals on parts and terminal boards. WAGO, Model 289 series, or equal, cage clamp compression type terminal blocks may be used in place of screw type terminal boards. Terminal lugs shall be ring type and shall be selected so that the terminal board screw or stud size and the terminal lug attaching hole size are the same nominal size. Terminal 30 lug width shall be at least that of the terminal board screw head or stud nut size but no more than the terminal board barrier width. WAGO terminal blocks, if used, shall be terminated with crimp-type ferrules. Parts with solder terminals or pigtail leads may have soldered connections. No more than 3 wires, including wires from parts, shall terminate at any one stud or terminal, except on multi-section 35 turret type terminals a maximum of 5 wires may be terminated.

Spare terminals.- Terminal boards or cable connectors used for external cable connections in equipment and terminal boards or multicontact connectors used for connection of assemblies within equipment shall have at least 10 percent spare terminals. There shall be not less than two such spare terminations. All spare 40 terminals shall be in the outermost row of the connecting device. Where cable connectors, terminal boards are used only for primary or alternate power connections, or for serial, Ethernet, or multiplexed signal connections in general, no spare terminations need be provided. If more than one terminal board or connector is needed at a common place only 10 percent of the total number of 45 terminations at this place are required as spare terminals.

SECT. 202 SECT. 202 13

Wire identification.- Wiring for an internal chassis, any wire less than 12 inches in length, or wires connecting studs on a single part shall be marked for identification in the center unless such wires are laced or secured by sleeving into a wire bundle. All other internal wires of the MCS equipment shall be marked for identification at both ends. Markings shall be applied in a permanent legible 5 manner, resistant to water, oil and abrasion. Designations at each end shall consist of the part and terminal number for both ends of the wire, as assigned in the wire list or schematic diagram. Marking of internal chassis wiring or color-coding may be used as an aid in manufacture or maintenance. Wire markings shall be clearly visible in the assembled MCS equipment. Internal wiring in a wire bundle 10 terminating at a multi-pin connector does not require wire markers at the end of the wire that terminates at the connector.

Mounting of parts with pigtail leads.- Parts provided with pigtail leads which are not mounted on printed wiring board, such as small resistors and capacitors, shall be secured between solder-type terminals on part mounting boards by 15 soldering. Parts with pigtail leads shall be secured to prevent damage or lead fatigue from shock and vibration. The arrangement of parts shall be such that replacement of any part is possible without the removal of or damage to adjacent parts.

Isolation.- The MCS equipment shall employ isolation between the assembly 20 outputs such that the shorting or opening of any output circuit will not produce a change in any other assembly output. A failure in a remote control or assembly circuit shall not cause failure or malfunction of its associated local control or assembly circuit.

Electrical protection.- Protection devices such as power switches, surge 25 protectors, fuses, and circuit breakers shall be provided for protection of the MCS equipment. Protective devices shall be easily accessible for maintenance purposes.

Power switches.- Power switches shall interrupt all conductors.

Fuse location.- Fuses, when used, shall be located on the load side of on-off switches. If extractor post type fuse holders are used, they shall be connected so 30 that the load is connected to the fuse terminal that terminates in the removable cap assembly. At least one extra fuse of each type and rating shall be provided for each fuse holder, mounted adjacent to the fuse holder for which they are intended.

Clearance and leakage (creepage) distances.- Clearance between solder 35 connections or bare conductors, such as on terminal strips, stand-offs or similar connections, shall be such that no accidental contact can occur between adjacent connections when subjected to service conditions specified in the equipment specification. Clearance and leakage distances shall be in accordance with Table I. 40

TABLE I.- ELECTRICAL CLEARANCE AND CREEPAGE DISTANCES

Voltage ac Condition Clearance (rms) or dc (inches) 45 To 150 A 1/16 B 1/8 C 1/4 --------------------------------------------------------------------- 50

SECT. 202 SECT. 202 14

Condition A.- For use where the effect of a short circuit is limited to the unit, and where normal operating power does not exceed 50 watts.

Condition B.- For use where short circuit protection in the form of fuses or circuit breakers is provided, and where normal operating power does not exceed 2,000 watts. 5 Condition C.- For use where short circuit protection in the form of fuses or circuit breakers is provided, and where normal operating power exceeds 2,000 watts.

Dielectric withstanding voltage.- The equipment shall be constructed such that insulation used in completed assemblies shall not be damaged due to corona, flashover (surface discharge), sparkover (air discharge) or breakdown (puncture 10 discharge) when the electrical power circuits are stressed with the dielectric test voltages shown in Table II for one minute. The test voltage shall be sinusoidal with a frequency the same as the primary input power frequency.

TABLE II.- DIELECTRIC TEST VOLTAGES 15

Circuit Voltage of Equipment Rms Value of Dielectric Test Tested (Volts) Voltage (Volts) Less than 60 450 20 60 to 120 900 Circuits containing parts whose specification requires a different dielectric withstanding voltage than shown in Table II shall be tested at the parts specification voltage, but in no case shall the test voltage be less than 450V rms. 25 Circuits directly connected to external power sources shall be tested at those voltages shown in Table II.

Electromagnetic compatibility.- The MCS equipment shall be self-compatible and compatible with peripheral equipment. Switching functions and internally generated EMI shall not cause inadvertent alarms, false data logging, or other out of 30 tolerance perturbation.

Equipment shielding and filtering.- Shielding on cables that are wholly contained within one unit may be terminated at the discretion of the Contractor.

202b1c. Mechanical features 35 Construction.- The equipment structure shall be aluminum or steel construction.

Enclosures.- The rated enclosure for the MCS units shall be NEMA 4 or IP65, with the exception of:

a. the Propulsion gas turbine/shaft control unit enclosure containing the gas turbine controller shall be a minimum rating of IP54. 40

b. the EPC shall be a minimum rating of IP54.

c. the OBT shall be a minimum rating of NEMA 2 or IP54.

d. the printers and POUs shall be in accordance with the manufacturer’s standards.

Temperature indication.- If temperature sensitive components are used, high temperature alarms shall be provided to signal that the interior of the equipment has reached the supplier's recommended maximum operating temperature.

Grab rails.- When specified, the equipment shall be provided with non-rotating grab rails located along the front or side of each section. Grab rails shall be 50 made of a nonconductive material and supported with a sufficient number of brackets to provide adequate support for personnel under all operating conditions of the ship. Grab rails shall be attached in such a manner that all hinged panels can be opened without removal of the rail from the member to which it is attached.

SECT. 202 SECT. 202 15

Cable entrance.- The external connections (excluding test connections) shall be on the bottom, sides or back of the MCS equipment, with the exception of the printers and PMUs. The MCS equipment enclosures, with the exceptions of the printers and PMUs, shall be provided with cable transits capable of preserving the rated enclosure specified herein. 5 Maintenance, repair and installation access.- Access shall only be from the front.

Cooling and heating.- If active cooling is used, for enclosures that are not sealed, it shall be via forced air. If active cooling is used for sealed enclosures, it shall be via internal fans, thermoelectric, or other as approved by 10

NAVSEA.

Forced air cooling.- If forced air cooling is used, air filters shall be located at all air intakes and shall be installed so as to be readily removable for cleaning or replacement without disassembly of the equipment. The filters shall be located on the equipment enclosure. Equipment shall be designed to operate in an 15 ambient temperature up to 122 degrees F, with 25 percent reduction in airflow, without impacting operation of the equipment or exceeding the manufacturer’s recommended maximum operating temperatures. Power for blowers shall be supplied from a source separate from the power supply for instrument and control circuits.

Thermoelectric cooling.– Thermoelectric cooler capacity shall be a minimum of 20 125 percent of that required to meet the ambient temperature requirements specified in this section.

Protection of parts.- Internal parts which are subject to damage, change in physical characteristics, or malfunction from accumulation of dust, soot, or other contaminates shall be protected from the direct path of natural or forced air 25 circulation by enclosures or barriers.

Heating.- The use of heaters to obtain proper operation of the equipment under the various ambient temperatures shall be prohibited. However, heaters shall be provided in the equipment as required to prevent condensation during non-operating periods. 30 Component accessibility.- The construction of the equipment shall be such that all wiring, terminals, and electrical connections shall be accessible for servicing and test purposes without requiring the removal of a part or subassembly from the enclosure in which it is mounted except where connectors are used. Parts which are subject to replacement or servicing under normal maintenance shall not be secured 35 by rivets, welding, or other means which prevent ready removal. The arrangement of parts on repairable items shall be so that replacement of any part is possible without removal of or damage to adjacent parts.

Locating pins.- The access panel of each chassis, assembly or subassembly shall be furnished with locating pins or other means to effect proper alignment and to 40 reduce strain when the equipment is subjected to vibration and shock, except for printers and PMUs.

Handles.- Handles shall be provided for removing chassis or assemblies from the equipment. A means shall be provided to protect parts when the chassis is removed and inverted for servicing. Each type of removable chassis or module shall have a 45 mechanical keying provision to prevent inserting the chassis or module into the wrong location.

Thread length.- The length of the threaded portion on all bolts and nut ends of studs shall be not less than 1.5 times the bolt or stud diameter. Studs shall engage the part into which they are set for a length equal to at least one diameter 50 and shall be welded or securely staked.

Thread engagement.- Bolts and screws in tapped parts other than nuts shall enter and have full thread engagement for an axial distance at least equal to the diameter of the externally threaded fastener without bottoming.

SECT. 202 SECT. 202 16

Thread cutting screws.- Thread cutting (self-tapping) screws shall not be used.

Flat head screws.- Flat head screws, 82 degree head, shall not be used in sheet or thin material, the thickness of which is less than one and one-half times the screw head height. Flat head screws, 100-degree head, shall not be used in sheet or thin material, unless the thickness of the material is at least equal to the 5 screw head height. Wherever flat head screws are used, the screw head shall be completely seated in the material.

Threads in aluminum and plastics.- Threads in…