ZEUS_CHE_-_Amendment_0001.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of amendment 0001 is to:

- Revise the schedule for Deliverable items No. 64 and 68 in Section 12 of the PWS, and remove Shipyard Availability dates from 52.212-1, Subfactor 2: Schedule.

- Revise paragraphs 3.3.1.6 in the Performance Work Statement.

- Revise the Requirements Document (Attachment 1).

- Revise the Price Factor.

- Revise the proposal due date.

Revisions are made in red font. All other conditions remain unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 69

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 01-Jun-2015

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X N62387-15-R-8015

X 9B. DATED (SEE ITEM 11)

29-Apr-2015

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

01-Jun-2015

CODE

MILITARY SEALIFT COMMAND N10 WASH

914 CHARLES MORRIS COURT SE

WASHINGTON NAVY YARD DC 20398-5540

N62387 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

N62387-15-R-8015

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 1449 - CONTINUATION SHEET

SOLICITATION/CONTRACT FORM

The required response date/time has changed from 09-Jun-2015 02:00 PM to 16-Jun-2015 02:00 PM.

The following have been modified:

ATTACHMENTS & EXHIBITS

ATTACHMENTS

a) Attachment 1: Requirements Document

b) Attachment 2: System and Interface Description Document

c) Attachment 3: Performance Assessment Plan (PAP)

d) Attachment 4: Non-Disclosure Agreements

e) Exhibit 1: Past Performance Data

f) Exhibit 2: Past Performance Questionnaire

ATTACHMENT 1: REQUIREMENTS DOCUMENT

Requirements For The Cable Handling Equipment Control System and SCR Drive Upgrade For the USNS

ZEUS (T-ARC 7).

1. Purpose The purpose of this Requirements Document is to establish the requirements for the design of the new control system and other upgrades to the Cable Handling Equipment (CHE) aboard the USNS ZEUS.

2. Background The USNS ZEUS (T-ARC 7) is a 502 ft long vessel that was specifically designed for cable lay and cable repair operations. She was launched in 1982 and is still in service. The USNS ZEUS is under the operational control of the US Navy, but is manned and operated by personnel from the Military Sealift Command (MSC). The vessel is equipped with large cable tanks, multiple sets of cable handling equipment (CHE), cranes and other handling systems, seafloor survey systems, dynamic positioning, provisions for ROV and cable plow systems when needed, etc.

The USNS ZEUS has four sets of cable handling equipment that were originally designed and fabricated by Western Gear (now Westech, a division of Control Flow). Two sets are forward and two sets are aft. Each of the forward and aft sets of CHE has a port set of equipment and a starboard set of equipment. Therefore, the four sets of CHE are forward/port, forward/starboard, aft/port, and aft/starboard. The four sets of CHE are controlled and operated independently. The forward/port and the forward/starboard sets of CHE are controlled by the forward Control Console. Similarly, the aft/port and the aft/starboard sets of CHE are controlled by the aft Control Console.

For the purposes of this document, each of the four sets of cable handling equipment consists of a:

Dynamometer/Fairleader Self-Fleeting Cable Drum Engine

Draw-Off and Holdback (DOHB) tension machine Control Console (more accurately, half of a Control Console)

The four sets of CHE are functionally the same, but there are a few differences in implementation. For example, the two aft cable drum engines have dual caliper brakes but the forward two cable drum engines have single caliper brakes. The existing cable handling equipment is described in the System and Interface Description document.

In the existing cable handling system, the rotational speed of the cable drum engine is currently controlled by a human operator using a stick-type lever and therefore does not provide automatic, closed loop control of the cable drum engine. A major objective of the cable handling system upgrade project is to provide a new control system for the cable handling equipment that includes closed loop control of the cable drum engine in several modes of operation. In addition, the upgrade project will replace aging SCR drives, replace existing cable speed/distance sensors with more robust and accurate ones, and upgrade load cell systems. The requirements that are to be met in executing the cable handling equipment upgrade project are provided in the sections that follow.

3. Applicable Documents The following documents are invoked as standards to be used in the design, fabrication, testing, and installation of the systems comprising the cable handling equipment upgrade:

ABS Rules for Building and Classing Steel Vessels Guidance Notes on the Application of Ergonomics to Marine Systems, ABS Code of Federal Regulations (CFR) Title 46, Shipping ASTM F1166, Human Engineering Design for Marine Systems, Equipment, and Facilities IEEE Standard 45, Recommended Practice for Electrical Installations Aboard Ship NEMA ICS 2, Industrial Control Devices, Controllers, and Assemblies NEMA ICS 3, Industrial Systems MSC General Technical Requirements (GTR)

The “System and Interface Description” document is available for information only. The System and Interface Description document describes the existing cable handling equipment.

4. Requirements

The following requirements are to be used to design, fabricate, test, and install the cable handling equipment upgrades.

4.1 Rotometers (Cable Speed and Distance Sensors, commonly nicknamed “Rotos”)

4.1.1 Number of Rotos: The new ROTO system shall incorporate two Rotos per DOHB for a total of 8 installed Rotos. Currently, each DOHB has only one Roto shaft encoder. Each DOHB has a pair of pinch rollers mounted on the outboard end of the DOHB which serve as cable guides. The Roto is currently part of only the inboard roller drum assembly of the roller pair.

To prevent the Roto from being a single point failure, a Roto system will be part of both roller drum assemblies of the roller pair, for each DOHB.

4.1.2 Roto Selection Function: The new Roto system shall incorporate a 3-position “A/B” and “Averaging” selection function at the Control Console to select whether the inboard, the outboard, or the average of the inboard and outboard Roto assembly output is used for cable speed and distance measurement.

4.1.3 Units for Cable Speed: The units used for linear cable speed display shall be selectable by the operator at the Control Console in units of feet per minute (fpm), meters per second (m/sec), kilometers per hour (km/hr), and nautical miles per hour (kn).

4.1.4 Units for Cable Distance: The units used for linear cable distance (also often referred to as “Cable Count”) display shall be selectable by the operator at the Control Console in units of meters (m), kilometer (km), feet (ft), fathoms (fm), and nautical miles (nm).

4.1.5 Cable Distance Reset: Cable distance shall be re-settable by the operator at the Control Console.

4.1.5.1 Cable Distance Reset to Zero: Cable distance shall be re-settable to zero during operation.

4.1.5.2 Cable Distance Reset to Any Number: Cable distance shall be re-settable to any number selected by the operator during operation.

4.1.5.3 Cable Distance Reset from Event File: Cable distance shall be re-settable from an Event

File during operation. The event file can be an uploaded Excel file or can be manually created at the Control Console prior to the start of operations. The Event File is created by cable engineers using the data contained in the cable manufacturer’s one-line-diagram or equivalent data. “Events” correspond to the locations of bodies in the integrated product cable system such as repeaters, splices, sensors, etc. These locations are known to high degrees of accuracy. The Event File will consist of a table with columns for Event Number, Segment Length, and Cumulative Length, and enough rows for up to 100 Events. If the control console operator so chooses, the ROTO can be reset to the Cumulative Length for a given Event (i.e., passage of a given body) by entering the Event Number via some means. The Event File must be displayed upon command by the operator at any time.

4.1.6 Fathometer Counter: On the forward Control Console only, port and starboard “fathom counters” shall be displayed, in addition to the regular cable count from the Rotos.

4.1.6.1 Fathom Counter Reset to Zero: The port and starboard Fathom Counters shall be re-settable to zero by the operator during operation.

4.1.7 Roto Calibration Factor: A means shall be provided for adjusting the Roto “calibration factor” during operation. Currently, the Rotos are calibrated periodically in port using test cables of known length. However, it is often the case that, during subsequent cable operations at-sea, the Roto-based cable distance measurement between two points on the cable differs from the accurately known distance between the two points. For example, the distance between repeaters is very accurately known from factory-provided data and can be measured very accurately optically with on-board test equipment at any time. A discrepancy between the known repeater span distance and the Roto-measured distance cannot currently be corrected. It is the intention of this requirement to provide a means for the operator, if he so chooses, to use the known cable distance and the Roto-based cable distance to change the Roto calibration factor in real time from the Control Console. This will ensure that Roto speed and distance outputs are kept as accurate as possible during cable operations.

4.1.8 Cable Speed Resolution: The resolution of the Roto-based measurement of linear cable speed shall be 0.01 m/sec or smaller.

4.1.9 Cable Speed Accuracy: Roto-based measurement of linear cable speed shall be accurate to

0.25%.

4.1.10 Cable Speed Display Resolution: The Resolution of linear cable speed displays at the Control Console and at other remote displays shall be 0.01 m/sec.

4.1.11 Cable Distance Resolution: The resolution of the Roto-based measurement of cable distance shall be 0.01 m or smaller.

4.1.12 Cable Distance Accuracy: Roto-based measurement of cable distance shall be accurate to 0.25%.

4.1.13 Cable Distance Display Resolution: The Resolution of cable distance displays at the Control Console and at other remote displays shall be 1 m.

4.2 Electric Motor SCR Drives

4.2.1 New Electric Motor SCR Drives: The new electric motor drives (consisting of Silicon

Controlled Rectifiers (SCRs), motor controllers, and other components) that are procured to replace the motor drives for the four cable drum engines and the two aft DOHBs shall maintain the existing form, fit, and function

4.2.2 Motor Drive Overload: The electric motor drives shall be capable of sustaining a 200% current overload for 6 minutes.

4.2.3 Electric Motor SCR Drives for the Cable Drum Engines:

4.2.3.1 Each cable drum motor SCR Drive shall be fully capable of driving and controlling the existing 250 HP GE electric motor installed on each cable drum engine. There is one 250 HP GE electric motor per cable drum engine. Therefore, four new Electric Motor SCR Drives will be installed.

4.2.3.2 Detailed information on the existing equipment can be found in references provided as GFI. Salient characteristics are as follows:

4.2.3.2.1 Existing Cable Drum SCR Drives:

Model: 6V600F4004-DC3064R Rated: 600 HP continuous, 1500 HP for one minute Power Supply: 460 VAC (WYE), 3 phase, 60 Hz

4.2.3.2.2 Existing Cable Drum Motors

Armature Volts:

o Rated: 230 VDC (250 HP and 435 RPM) o Operating: 500 VDC (540 HP and 1160 RPM)

Armature Amps: 880 A Field Volts: 230 VDC Field Amps: 9 A Speed Base: 435 RPM Speed Max: 1160 RPM

4.2.3.3 At least two additional SCR Drives will be stored on board as spares (50% spares).

4.2.3.4 Each cable drum motor SCR drive is fed by an isolation transformer. These transformers are new and can either be retained or replaced depending on the Contractor’s proposed solution. Should the Contractor proposed to replace these transformers, two (2) additional transformers shall be provided as spares (50% spares).

4.2.3.5 New drive control circuit breakers feeding each of the cable drum motor SCR drives shall be provided, including two (2) additional as spares (50% spares).

4.2.4 Electric Motor SCR Drives for the Aft DOHBs

4.2.4.1 The Electric Motor SCR Drives for the two aft, electrically powered DOHBs shall be fully capable of driving and controlling the existing 20 HP Reliance electric motors.

There are two 20 HP Reliance Electric motors per DOHB. Therefore, four new Electric Motor SCR Drives will be installed. The forward DOHBs are hydraulically powered and do not use electric motors.

4.2.4.2 Detailed information on the existing equipment can be found in references provided as GFI. Salient characteristics are as follows:

4.2.4.2.1 Existing Aft DOHB SCR Drive

Model: Reliance Digital DC Drive Rated: 20 HP Power Supply: 460 VAC (WYE), 3 phase, 60 Hz

4.2.4.2.2 Existing Aft DOHB Motors:

Armature Volts: 500 VDC Armature Amps: 34 A Field Volts: 300 VDC Field Amps: 2.7 A Speed Base: 2500/2875 RPM Speed Max: 4500 RPM

4.2.4.3 At least two additional SCR Drives will be stored on board as spares (50% spares).

4.2.4.4 Each Aft DOHB SCR drive is fed by an isolation transformer. Four (4) new transformers shall be provided. Two (2) additional transformers shall be provided as spares (50% spares).

4.3 Control System

4.3.1 Closed loop Control: The new control system shall provide closed loop control of the cable handling system (in addition to open loop control based on the settings of control devices on the operator’s control console).

4.3.2 Modes of Closed Loop Control: The new control system shall provide three modes of closed loop control of the cable handling equipment.

4.3.2.1 Constant Speed Mode of Operation: The new control system shall provide a closed loop, constant speed mode of operation when selected by the operators at the Control Console or by cable engineers in Mission Control. The feedback parameter used for closed loop control in constant speed mode will be the difference between the linear cable speed as measured by the Roto and the desired linear cable speed as commanded by operators.

4.3.2.2 Constant Slack Mode of Operation: The new control system shall provide a closed loop, “constant slack” mode of operation when selected by operators at the Control Console or cable engineers in Mission Control. The feedback parameter used for closed loop control in constant slack mode will be the difference between the measured surface slack percentage and the commanded surface slack percentage. Measured surface slack percentage is the linear cable speed as measured by the Roto times the current ship speed divided by the original ships speed at the time that constant slack mode was activated. In equation form, the measured surface slack is [(V)/(Vo)](LCS) – (LCS) where V is current ship speed, Vo is the original ship speed at the time that Constant Slack Mode was activated, and LCS is the current linear cable speed measured by the Roto. In Constant Slack Mode, variations in ship speed will result in the control system automatically speeding up or slowing down the cable handling machinery to compensate, thereby maintaining constant deployed surface slack. Ship speed is to be obtained from the GPS in Mission Control that is used by the cable lay software. It is envisioned that cable operations will be in steady state in Constant Speed Mode before the Constant Slack Mode is selected. Upon selection of Constant Slack Mode, ship speed, V, will be the initial ship speed at the time that Constant Slack Mode is selected, Vo. In other words, V = Vo at the time that Constant Slack Mode is selected. The control system will then automatically compensate for variations in ship speed, and will increase or decrease the commanded linear cable speed to maintain a constant surface slack value. The control system will not automatically compensate for other factors such as changes in bottom slope. Therefore, once in Constant Slack Mode, cable engineers will monitor the “solutions” for installed bottom slack as provided by the cable lay software, and make adjustments to the commanded surface slack percentage as needed.

4.3.2.3 Constant Tension Mode of Operation: The new control system shall provide a closed loop, constant tension mode of operation when selected by the operator at the Control Console. The feedback parameter used for closed loop control in constant tension mode will be the difference between the cable tension as measured by the Dynamometer and the cable tension set point entered by the operator. It is envisioned that cable operations will be in steady state before the Tension Mode of Operation is selected. The initial tension set point used by the Tension Mode of Operation will be the tension measured by the Dyno at the time the Tension Mode is selected. The operator can then adjust the tension set point up or down as required. When in Constant Tension Mode, the CDE will operate in a “payout-only” manner. That is, the product cable will only be payed out, should tension rise above the constant tension set point. If cable tension remains below the constant tension set point, then no actions are taken. If cable tension drops to a point that operators desire to pick up some cable, then the CHE will be put into Manual Mode and the adjustment will be made. Then, the operators can re-enter the Constant Tension Mode if desired.

4.3.3 Transfer of Control: Provision shall be made to transfer control from the Control Console to Mission Control when in the Constant Speed Mode of operation. Once control is transferred to Mission Control, cable engineers may switch to and from Constant Slack or Constant Speed modes. Control will remain solely at the Control Console for the Manual and the Constant Tension modes of operation. Control modes available at the Control Console are Manual, Constant Speed, Constant Slack, and Constant Tension. Control modes available in Mission Control are Constant Speed and Constant Slack.

4.3.3.1 Control Parameters from Mission Control: Provision shall be provided to allow cable engineers in Mission Control to vary the commanded linear cable speed when in Constant Speed Mode, and the commanded surface slack percentage when in Constant Slack Mode. Direct control of the cable handling system by the cable lay software is not allowed. To keep a human in the loop, the cable engineers will use and interpret the cable lay software output and then manually enter the commands they desire into the cable handling system’s control system.

4.3.3.2 Transfer Enabling: The control transfer process shall require two deliberate actions to transfer control from the Control Console to Mission Control. The first action is for the operator at the Control Console to grant permission for control transfer, and the second action is for personnel in Mission Control to accept control, as described below. Transfer of control from the Control Console to Mission Control is only enabled when in the Constant Speed Mode of operation.

4.3.3.2.1 Transfer Permission: The first deliberate action needed to transfer control to

Mission Control shall be for the operator at the Control Console to give permission via a hardware or software based Permission Switch. The intent of this requirement is to prevent control from being taken from the Control Console without the operator’s knowledge or before the operator is ready. The transfer of control from the Control Console to Mission Control will be well coordinated in advance via appropriate communications. It is envisioned that after operations are in steady state and proceeding without issue, that the cable engineer in Mission Control will contact the operator at the Control Console and discuss the potential transfer of control to Mission Control. The operator will make an assessment and, if conditions warrant, will activate the Permission Switch.

4.3.3.2.2 Transfer Acceptance: The second deliberate action needed to transfer control shall be for cable engineers in Mission Control to accept control via a hardware or software based Acceptance Switch in Mission Control. The intent of this requirement is to ensure that control remains at the Control Console unless and until the cable engineers in Mission Control are ready to take over.

4.3.3.2.3 Transfer Permission Switch Timing: The Permission Switch permission shall expire within 30 seconds. Therefore, Mission Control must activate their Acceptance Switch within 30 seconds of the operator activating the Permission Switch or control will not be transferred. The intent of this requirement is to prevent the Permission Switch from accidentally remaining permanently open and for control to later be transferred without the operator’s knowledge.

4.3.3.2.4 Transfer Action: Control of the cable handling equipment shall remain at the

Control Console until both the Permission Switch on the Control Console and the Acceptance Switch in Mission Control are both activated.

4.3.3.3 Control Console Functionality While Control is Transferred to Mission Control:

Whenever control is transferred to Mission Control, control of all functions other than the commanded linear cable speed or commanded slack percentage shall remain at the Control Console.

4.3.3.4 Control Re-Set: Provision shall be made for the operator at the Control Console to take control back from Mission Control at any time. The operator at the Control Console will continue to monitor the Control Console and visually observe the cable handling equipment at all times, independently of the mode of operation. If, while control is transferred to Mission Control, the operator notices a problem or potential problem, this provision allows him to take back control immediately. No permission from Mission Control is needed or desired. At the appropriate time after re-taking control at the Control Console, the operator can inform personnel in Mission Control about the conditions and rationale of his action to re-take control. Once all issues have been satisfactorily resolved on the cable highway, control can once again be transferred to Mission Control.

4.3.3.4.1 Mode of Control Upon Control Re-Set: Upon activation of the Control Re-Set function by the operators at the Control Console, control will be transferred from Mission Control to the Control Console, and the system shall be placed in Constant Speed mode.

4.3.4 Control Indicators: There shall be a clear indication on the Control Console and on the

Mission Control Remote Console showing which station has control of the cable handling equipment.

4.3.5 Mode of Operation Indicator: There shall be a clear indication on the Control Console and the Mission Control Remote Console showing which mode of operation is currently being utilized.

4.3.5.1 Mode of Operation Indicator Choices: The mode of operation displayed by the mode of operation indicator shall be one of the following: “Manual”, “Constant Speed”, “Constant Slack”, or “Constant Tension”. The “Manual” mode of operation is open loop in which the cable drum engine rotational speed is determined solely by operator adjustment of the cable drum engine speed control. The other modes of operation provide closed loop, automatic control of the cable drum engine speed.

4.3.6 Constant Speed Data Entry: The linear cable speed desired shall be entered into the system by operators at the Control Console by using a virtual or hardware Human/Machine Interface (HMI) increment/decrement device to increase or decrease the value. Using an increment/decrement method is preferred over typing in a value to decrease the likelihood that an errant value can be entered. The increment/decrement device could increment slowly for individual presses of the increase-key and increment in larger amounts if the increase-key is pressed and held.

4.3.6.1 Increment/Decrement Magnitude in Constant Speed Mode: The Increment/Decrement device shall produce linear cable speed changes of .1 kn for individual presses of the keys.

4.3.7 Constant Slack Data Entry: The slack percentage desired shall be achieved by the operators at the Control Console or by cable engineers in Mission Control (after control is successfully transferred to Mission Control) by using a virtual or hardware Human/Machine Interface increment/decrement device to increase or decrease the value of the commanded slack percentage. Using an increment/decrement method is preferred over typing in a value to decrease the likelihood that an errant value can be entered. The increment/decrement device could increment slowly for individual presses of the increase-key and increment in larger amounts if the increase-key is pressed and held. Operators will interpret the output of the Cable lay software, which has the recommended slack percentage already factored in, to adjust the commanded linear cable speed.

4.3.7.1 Cable Slack Percentage Display: The surface slack percentage currently being deployed shall be displayed at the Control Console and on the Mission Control Remote Control Box. Surface slack percentage is defined as linear cable speed divided by ship speed minus one.

4.3.7.2 Increment/Decrement Magnitude in Constant Slack Mode: The Increment/Decrement device shall produce changes in surface slack of .1% for individual presses of the keys.

4.3.8 Constant Tension Data Entry: The constant tension desired shall be entered into the system by operators at the Control Console by using a virtual or hardware Human/Machine Interface (HMI) increment/decrement device to increase or decrease the value. Using an increment/decrement method is preferred over typing in a value to decrease the likelihood that an errant value can be entered. The increment/decrement device could increment slowly for individual presses of the key, and increment in larger amounts if the key is pressed and held.

4.3.9 Cable Handling System Speed Control: The control system shall be capable of controlling the cable handling system sufficiently to maintain constant linear cable speed of plus or minus

0.05 m/sec. This requirement applies to the Constant Speed and Constant Slack modes of operation.

4.3.10 Cable Tension Control: The control system shall pay out when the cable tension exceeds the tension set point by the amount established by the operator with the Tension Payout Value.

4.3.11 Tension Payout Value: An operator adjustable control shall be provided for the Constant Tension Mode of operation for establishing the tension value above the tension set point at which the system will pay out.

4.3.12 Gain Control for Constant Slack Mode: An operator adjustable gain control shall be provided for the Constant Slack Mode of operation. The gain control will adjust the responsiveness of the cable handling system to variations in ship speed. Such a gain control may be used, for example, when environmental conditions cause variations in ship speed. The gain control may be used to smooth the response of the cable handling system to variations in ship speed.

4.3.13 Interlocks and Limits: The new control system shall include interlocks and limits to prevent damage to equipment and increase safety of personnel. Additional interlocks and limits that are not listed below may be implemented where deemed prudent.

4.3.13.1 Cable Drum Motor Drives Interlock: An interlock shall be implemented that prevents the

GE SCR motor drives from being energized unless the Control Console controls are powered, the Emergency Stop button is not depressed, the cable drum is in “Manual” mode of operation (i.e., manual control of drum speed), and the speed control is set to zero speed.

4.3.13.2 Cable Drum Caliper Brake Interlock: An interlock shall be implemented that will not allow movement of the cable drum until the caliper brake is released.

4.3.13.3 DOHB Motor Drives Interlock: An interlock shall be implemented that prevents the

Reliance SCR motor drives from being energized unless the Control Console controls are powered, the Emergency Stop button is not depressed, and the DOHB is set for zero speed if in speed mode and or set for zero tension if in tension mode.

4.3.13.4 DOHB Brake Interlock: An interlock shall be implemented that will not allow movement of the DOHB until the DOHB brakes have been released.

4.3.13.5 Cable Handling System Change of Speed Limit: When in Constant Speed or Constant Slack modes of operation, the change in commanded speed of the cable handling system shall be limited to 0.75 m/sec per minute. The intent of this requirement is to prevent a wildpoint or an errant input value to cause the cable handling system to radically change speed. An exception to this rule is the activation of the Emergency Stop function.

4.3.13.6 Control Transfer from Mission Control to Control Console Interlock: Whenever control is transferred from Mission Control to the Control Console, the Control Console shall automatically be placed in Constant Speed Mode of Operation using the linear cable speed in effect at the time of the transfer. The operator can then switch from Constant Speed Mode to Manual mode if desired.

4.3.13.7 Switch to Manual Mode Interlock: An interlock shall prevent switching to Manual Mode from any other mode of operation until the manual speed control is pre-set by the operator to within 20% of the current linear cable speed. An exception to this rule is the activation of the Emergency Stop function.

4.3.13.8 Interlock and Limits Message: A message shall be displayed on the Control Console whenever an interlock or limit is activated that explains to the operator what actions are necessary to proceed. For example, if the interlock is activated that prevents cable drum rotation from occurring before the drum caliper brake is released, a message will appear that tells the operator to “Release Drum Caliper Brake”.

4.3.13.9 Interlock and Limits Message Characteristics: All messages generated as the result of an interlock or limit being activated shall be visually alerting to the operator. For example, the message should be in larger font than other text, should be of an eye-catching color like red, should flash on and off, or use other means of getting the operator’s attention.

Audible alarms should not be used for interlock messages.

4.3.14 Processing System Architecture: The processing system architecture used in the new control system shall be configured such that loss of any single processor or communications path will not prevent control, monitoring, and operation of port and starboard cable handling systems simultaneously. There are times when both port and starboard cable handling equipment are being utilized at the same time, such as during cable repair operations. Therefore, using a crossover scheme, such as on the existing Control Console, in which port controls may be used to operate starboard equipment, for example, is not sufficient in meeting this requirement.

4.3.14.1 Processing System Failover: The processing architecture shall be configured such that a seamless failover occurs that is transparent to the operator if any single processor or communication path fails.

4.3.14.2 Processor System Failure Notification: In the event that a processor, communications path, or other component fails, a notification shall be activated on the affected Control Console and the Remote Control Box in Mission Control.

4.3.14.3 Built-In Test: The processing architecture shall include Built-In Test functions that allow operators to determine status, troubleshoot problems, investigate failures in response to a Processor Failure Notification, etc.

4.3.15 All four cable drums must be able to operate independently and simultaneously.

4.3.16 The maximum design speed for paying out and hauling in cable is seven (7) knots.

4.4 Control Console

4.4.1 Control Console Location: The new Control Consoles shall be placed at the same location as the existing Control Consoles.

4.4.2 Control Console Footprint: The new Control Consoles shall occupy the same or smaller footprint and be within the existing footprint envelope as the existing Control Consoles.

4.4.3 Control Console Height: The height of the Control Consoles above the deck shall permit the operators to visually observe the running cable handling equipment and the cable path from the inboard side of the DOHB to the overboarding sheaves at all times from their seated positions at the Control Consoles. The height of the existing Control Console’s turret obstructs operators’ line of sight, and this condition must be corrected in the new Control Console. The operator console screens can be angled or tilted. However, environmental factors such as glare from overhead lights or sun light must be taken into consideration in the design.

4.4.4 Control Console Layout

4.4.4.1 Control Console Organization: The Control Consoles shall have all the controls, switches, gauges, indicator lights, displays, and data entry devices needed to operate the cable handling equipment arranged in a manner consistent with the physical layout of the cable handling equipment. Implementation of the controls, gauges, etc. on the new consoles need not be the same as the implementation of the controls on the existing consoles. Implementation can be in hardware, in virtual form using Human Machine Interfaces (HMIs), or a mix of both. In this document, devices used on the Control Console for the purpose of navigating menus, entering or changing data values, implementing controls virtually, and/or displaying information will be called HMIs.

4.4.4.2 Port/Starboard Segregation: The Control Console shall have all items related to port-side cable handling equipment on one side of the console, and items related to starboard-side cable handling equipment on the other side.

4.4.4.2.1 Aft Control Console Layout: The aft Control Console, which faces forward, shall have the controls, gauges, switches, displays, etc. that control starboard-side cable handling equipment located on the left side of the console when facing aft toward the front of the console; and those items that control port-side cable handling equipment located on the right side of the console when facing aft toward the front of the console.

4.4.4.2.2 Forward Control Console Layout: The forward Control Console, which faces aft, shall have the controls, gauges, switches, displays, etc. that control starboard-side cable handling equipment located on the right side of the console when facing forward toward the front of the console; and those items that control port-side cable handling equipment located on the left side of the console when facing forward toward the front of the console.

4.4.4.3 Critical Information Display Location: Port and starboard displays showing critical information (such as linear cable speed, cable count, cable tension, etc.) shall be located prominently on the control consoles. The location should be similar to the “turret” of the existing consoles in that the large displays are located in the same general direction as the operator’s line of sight on the outboard cable path.

4.4.4.4 If HMIs are chosen over hardware implementation, a minimum of four (4) displays shall be provided as follows:

Port critical information display

Port display for other data

Starboard critical information display

Starboard display for other data

Additional displays may be provided for data and control for reasons of engineering preference, ergonomics, convenience, redundancy, etc.

4.4.5 Control Console Control Functions: The new Control Consoles shall include all of the functions enumerated below at a minimum. The new consoles will include all of the functions of the existing consoles (see the System and Interface Description document) plus new functions established by this Requirements Document. Implementation of the functions on the new consoles need not be the same as the implementation of the functions on the existing consoles. Additional control functions may be provided.

For each control function listed below, a port and starboard function is needed unless otherwise noted, and each function must be implemented on both the forward and aft Control Consoles unless otherwise noted.

Each function must be available at all times (i.e., not buried in a menu hierarchy, for example) unless otherwise noted.

4.4.5.1 Power On/Off

4.4.5.2 Emergency Stop

4.4.5.3 Dynamometer Traverse

4.4.5.4 Fairleader Traverse

4.4.5.5 Cable Drum Engine Controls:

4.4.5.5.1 Caliper Brake Set/Release

4.4.5.5.2 Motor Start/Stop

4.4.5.5.3 Motor Torque Limit Adjustment (may be in a menu)

4.4.5.5.4 Speed Control

4.4.5.5.5 Mode of Operation Selector (Manual, Constant Speed, Constant Slack, Constant

Tension)

4.4.5.5.6 Control Transfer Permission Switch (active only when in Constant Speed Mode of Operation). Allows transfer of control to Mission control.

4.4.5.5.7 Control Transfer Switch. Takes control back from Mission Control at any time.

Upon activation of the Control Transfer Switch, control will be transferred from

Mission Control to the Control Console and the system will be placed in the Constant Speed Mode of operation.

4.4.5.5.8 Drum Tire Up/Down

4.4.5.5.9 Hour Meter (may be in a menu)

4.4.5.5.10 Fault Alarm

4.4.5.5.11 Alarm Acknowledge

4.4.5.6 DOHB Controls:

4.4.5.6.1 Power On/Off

4.4.5.6.2 DOHB Traverse

4.4.5.6.3 Brake Set/Release

4.4.5.6.4 HPU On/Off (forward Control Console only)

4.4.5.6.5 HPU A/B Selector (forward Control Console only)

4.4.5.6.6 Gear High/Low Selector

4.4.5.6.7 Mode Selector (speed or constant tension)

4.4.5.6.8 Tension Adjustment for DOHB constant tension mode

4.4.5.6.9 Roto Rollers Open/Close (currently labelled Forward Dragboard on existing consoles)

4.4.5.6.10 Aft Dragboard Open/Close

4.4.5.6.11 Tire Squeeze (aft DOHBs only. Aft DOHBs use tire-pairs)

4.4.5.6.12 Track Squeeze/Release (forward DOHBs only. Forward DOHBs use tracks)

4.4.5.6.13 Upper Frame Squeeze/Release (forward DOHBs only)

4.4.5.6.14 DOHB Speed Control

4.4.5.6.15 Normal vs. Load/Calibration Mode Selector: The Load/Calibration Mode powers only the Rotos, but not the rest of the DOHB system. This mode is used during cable loading activities and for ROTO calibration. Normal Mode powers all segments of the DOHBs including the Rotos.

4.4.6 Control Console Gauges/Readouts: The new Control Consoles shall include all of the gauges/readouts enumerated below at a minimum. The new consoles will include all of the gauges/readouts on the existing consoles (see the System and Interface Description document) plus others described in this document. Implementation of the gauges/readouts on the new consoles need not be the same as the implementation on the existing consoles. For example, a virtual gauge can be provided instead of a hardware gauge. Additional gauges/readouts may be provided.

4.4.6.1 Cable Drum Gauges

4.4.6.1.1 Caliper Brake Pressure

4.4.6.1.2 Caliper Brake Charge Pressure

4.4.6.1.3 Cable Drum Motor Amps

4.4.6.1.4 Cable Drum Tire Up/Down Pressure

4.4.6.1.5 Hour Meter (may be in a menu)

4.4.6.2 Control Console Pneumatic Gauges

4.4.6.2.1 Ship’s Service Air Pressure

4.4.6.2.2 Console Regulated Air Pressure

4.4.6.3 Control Console Hydraulic Gauges

4.4.6.3.1 Hydraulic Pressure (used for cable drum engine caliper brake and DOHB traverse system)

4.4.6.3.2 Hydraulic Replenishment Pressure (used for cable drum engine caliper brake and DOHB traverse system)

4.4.6.4 DOHB Gauges

4.4.6.4.1 Roto Rollers Open/Close Pressure (labelled Forward Dragboard on existing consoles)

4.4.6.4.2 Aft Dragboard Open/Close Pressure

4.4.6.4.3 Tire Squeeze Pressure (applies to aft DOHBs only. Aft DOHBs use tire-pairs.)

4.4.6.4.4 Track Squeeze/Release Pressure (applies to forward DOHBs only. Forward

DOHBs use tracks.)

4.4.6.4.5 Upper Frame Squeeze/Release Pressure (applies to forward DOHBs only)

4.4.6.4.6 Hour Meter (may be in a menu).

4.4.7 Control Console Indicator Lights: The new Control Consoles shall include all of the Indicator

Lights enumerated below at a minimum. The new consoles will include all of the Indicator Lights on the existing consoles plus others described in this document. Implementation of the Indicator Lights on the new consoles need not be the same as the implementation on the existing consoles. For example, a virtual Indicator Light can be provided instead of a hardware light. Additional Indicator Lights may be provided.

4.4.7.1 Console Power Available: Green (only one needed since this applies to entire console)

4.4.7.2 Controls Power: Green (one for Starboard portion of the Control Console and one for

Port portion of the Control Console)

4.4.7.3 System Ready: Green

4.4.7.4 Cable Drum Caliper Brake Set: Red

4.4.7.5 Cable Drum Caliper Braked Released: Green

4.4.7.6 Cable Drum Ready to Run: Green

4.4.7.7 Cable Drum Run: Green

4.4.7.8 Cable Drum Stop: Red

4.4.7.9 Cable Drum Fault Alarm: Red

4.4.7.10 DOHB Gear Selection: Separate lights for High (Green), Neutral (White), and Low

(Blue).

4.4.7.11 DOHB Brake Set: Red

4.4.7.12 DOHB Brake Released: Green

4.4.7.13 DOHB Ready: Green

4.4.7.14 DOHB Run: Green

4.4.7.15 UPS activated due to loss of feed power: Red

4.4.8 Human/Machine Interface (HMI) Devices: The Control Consoles shall incorporate HMI devices for the purpose of navigating menus, entering and changing data, and displaying information. The devices can be ruggedized touch screens, keypads or keyboards integrated with displays, softkey-based displays, or other devices intended for industrial applications.

4.4.8.1 Number of HMIs: The Control Consoles shall have at least two HMI devices (at least one for port controls and at least one for starboard controls) installed on the top surface of the console.

4.4.8.2 HMI Design: The design of the HMIs shall be such that no special IT or computer skills are needed to operate them by crewmember/operators. Menus should be intuitive and easy to navigate. Data entry should be quick, easy, and not prone to error.

4.4.8.3 HMI Data: The HMI devices shall provide a menu-based system to allow the data items enumerated below to be entered into the system, changed, or displayed by Control Console operators. The list is not intended to be all-inclusive since the selected vendor’s system approach and architecture will affect the items that are needed. For example, should an approach be taken in which all controls, gauges, indicators, etc. are virtual, then all of the requirements of Sections 4.4.4, 4.4.5, 4.4.6, 4.4.7, and 4.4.8 must be met by the HMIs and the list below would be larger.

4.4.8.3.1 Cable Drum Motor Torque Limit

4.4.8.3.2 Cable Count Markers

4.4.8.3.3 Cable tension value markers for the Cable Tension Graph on the Critical

Information Display.

4.4.8.3.4 Alarm threshold values

4.4.8.3.5 Alarm details (used to gain further information on any alarms that become activated on the Critical Information Displays or elsewhere on the console)

4.4.8.3.6 Help screens

4.4.8.3.7 Hour meters for Cable Drums, DOHBs, and Rotos

4.4.8.3.8 Dyno calibration data

4.4.8.3.9 Roto calibration data

4.4.8.3.10 Roto cable distance re-set to zero

4.4.8.3.11 Roto cable distance re-set to any number

4.4.8.3.12 Roto calibration factor adjustment during cable operations

4.4.8.3.13 Cable speed desired when in Constant Speed Mode

4.4.8.3.14 Slack percentage

4.4.8.3.15 Outboard cable tension desired when in Constant Tension Mode

4.4.8.3.16 DOHB cable tension desired

4.4.8.3.17 Temperature monitoring of multiple pieces of equipment

4.4.8.3.18 Pneumatic pressure monitoring of multiple pieces of equipment

4.4.8.3.19 Hydraulic pressure monitoring of multiple pieces of equipment

4.4.8.3.20 System Diagnostics

4.4.8.3.21 Units selection for displays (e.g., feet, meters, etc.)

4.4.9 Controls Inclusiveness: All the controls, gauges, switches, displays, HMIs, etc. that are needed to properly operate the cable handling equipment shall be located at the Control Console. Controls or other functions cannot be re-located to other locations, such as on individual pieces of equipment, but must be located on the console. This requirement does not apply to control system processors or the UPS function, which may be remotely located.

4.4.10 Number of Operators: The Control Consoles shall be designed to support two operators working simultaneously at each console.

4.4.11 Operator Chairs: All operator chairs are to be replaced and the four new operator’s chairs shall be adjustable for seat height, seat in/out, footrest height, and backrest angle. Two operator chairs are needed for each of the two control consoles.

4.4.12 Critical Information Displays: Each Control Console shall incorporate two monitor displays (one for port-side equipment and one for starboard-side equipment) mounted on the Control Console for displaying critical information.

4.4.12.1 Information for Critical Information Displays: The Control Console’s critical information displays shall display, at a minimum, the following data:

Cable Tension (from the Dynamometer): numerical display Cable Tension Graph: graphical display Cable Speed (from the Roto): numerical display Cable Count (from the Roto): numerical display DOHB Tension (from the DOHB load cell): numerical display Run/Standby Indicator: text with green background window for Run and yellow background window for Standby Payout/Pickup Indicator: text with blue background window Cable Drum Engine Mode of Operation Indicator (Manual, Constant Speed, Constant Slack, or Constant Tension): text with blue background window Control Source (shows whether the Control Console or Mission Control has control):

text with blue background window Cable Count Markers: text with white background window Alarms, as follows:

o Holdback Tension alarm: text with white background window with red border o Cable Tension alarm: text with white background window with red border o Fault alarm: text with white background window with red border o HPU Motor Overload alarm (forward Control Console only): text with white background window with red border o Temperature alarm: text with white background window with red border

4.4.12.2 Remote Critical Information Displays: In addition to the Critical Information Displays on the forward and aft Control Consoles, remote Critical Information Displays shall be located in the following locations:

Mission Control (2 monitors) Port and starboard bow deck display stations (4 monitors) Port and starboard stern deck display stations (4 monitors)

A total of ten monitors plus cabling and two spare monitors are required. The existing weatherproof enclosures for the bow and stern deck display stations may be re-used.

New remote critical information displays located in mission control shall be rack-mounted in a standard 19” rack and shall have a 19” diagonal display.

4.4.12.3 Tension Scales: The Cable Tension graph shall have an operator selectable tension range.

4.4.12.4 Tension Graph Markers: Provision shall be made to allow operators to create up to 4 tension markers on the Tension Graph including labelling annotations. This requirement will allow operators to have the Tension Graph show the Nominal Operating Tension (NOTs) of the cable, for example, and other potentially important tension values on the graph for visual comparison with the current measured tension.

4.4.13 Audible Alarms: An audible alarm shall sound if any of the alarms on the Critical Information Displays becomes activated.

4.4.13.1 Audible Alarm Acknowledgement: Any audible alarm shall be silenced via an alarm-acknowledge function on the…