Attachment_23-_DEIF_Crompton_Site_Visit_Power_Point.pdf

INLS Generator/Switchboard Control, Monitoring and

Protection System Replacement

N64498-16-R-5019

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INLS Project Team

• Contract Specialist: Andrea Merlino

• Contract Specialist: Jane Dematto

• Contracting Officer: John Stefano

• Software Support: Joseph Messenger

• Diesel Engine Support: Alan Tibbetts

• Electrical Support: David Senos

• Control System Support: Ken Fischer

• Control System Support : Ghanshyam Dhamelia

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BIC Base Information

• Follow the speed and other signs strictly while driving on base

• Do not park the vehicle on grass surface

• No photos or video allowed anywhere outside except inside the INLS craft

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Improved Navy Lighterage System (INLS)

• What is INLS?

- New and improved lighterage system that can be assembled into causeway, docks or ferries

Presenter Presentation Notes Rev 2 submitted to EXWC Nov 14 APL and TM impacts from Rev 2

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• Provides the Navy and Marine Corps with a safer, more versatile way to deliver vehicle and critical supplies from ship to shore during war or peacetime operations

INLS Mission

Presenter Presentation Notes This alteration provides failsafe alignment of the battery charging circuit to prevent inverter damage.

SAR package is ready for EXWC review and W7M input as soon as we validate that upgraded breaker will resolve last remaining problem in this circuit.

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INLS Overview

• Consists of powered and non-powered floating modules

- Warping Tug (WT) - powered

- Causeway Ferry (CF) – The CF is an assembly of Causeway Ferry Powered Module (CFPM) -powered Beach Module (BM) - powered Intermediate Module (IM) – non-powered

- Combination Module (CM) – non-powered

- Docking Module (DM) – non-powered

- Ramp Module (RM) – non-powered

• There are 22 Warping Tugs, 38 Causeway Ferry Powered Modules and 38 Beach Modules in fleet

Presentation Notes Joe Messenger to speak to this.

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Warping Tug (WT)

• Used for assembling non-powered modules, towing, anchoring and salvaging operations

• Contains two generators system and two switchboard system, one for each side

Presenter

Joe Messenger to speak to this.

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Causeway Ferry (CF)

• An assembly of the CFPM, BM and IM used to transport cargo from ship to shore

• The CFPM has two generators system and two switchboard system, one for each side

• The BM has one generator system and one switchboard system

The majority of DEIF failures have been due to repetitive high rate input (i.e. pressure switches) and repetitive high rate output (i.e. pulse width modulation governor control signal) failures. In December 2012 at ACB-1 we found a DEIF that had failed for this same reason. The emerging pattern indicates that the I/O internal to the DEIF is not durable enough for our application. ACB-1 has been able to get repairs done and ACB-2 /CAT D&FP are trying to set up the local Cat dealer.

Replacing the DEIF is an extensive engineering and testing effort, requiring OEM support.

To that effect, we hosted a sources sought industry day where several companies with ideas on how to resolve the problem were shown the current Configuration, from this, we received Order of Magnitude estimates on how much this alteration would cost and used it to develop the SSCP.

We have an RFP ready to go and the plan is for us to approve one proposal and have a prototype installed prior to full scale rollout.

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Non-powered Module

• Does not have any electrical system

• Used as roll on roll off discharge facility and/or the floating causeway, which supports the discharge ramp from the cargo ship and serves as pier to transfer rolling stock to a barge

Presenter Presentation Notes The majority of DEIF failures have been due to repetitive high rate input (i.e. pressure switches) and repetitive high rate output (i.e. pulse width modulation governor control signal) failures. In December 2012 at ACB-1 we found a DEIF that had failed for this same reason. The emerging pattern indicates that the I/O internal to the DEIF is not durable enough for our application. ACB-1 has been able to get repairs done and ACB-2 /CAT D&FP are trying to set up the local Cat dealer.

Replacing the DEIF is an extensive engineering and testing effort, requiring OEM support.

To that effect, we hosted a sources sought industry day where several companies with ideas on how to resolve the problem were shown the current Configuration, from this, we received Order of Magnitude estimates on how much this alteration would cost and used it to develop the SSCP.

We have an RFP ready to go and the plan is for us to approve one proposal and have a prototype installed prior to full scale rollout.

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Generator System

• All INLS Diesel Generators use the Caterpillar C4.4 diesel engine along with a Caterpillar generator rated at 78.6KW

• The device that provides diesel generator control, monitoring and protection is the DEIF Protection and Paralleling Unit (PPU)

– This system is beginning to experience failures due to high repetition input/output signals

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DEIF PPU

• There are two DEIF PPUs, one for each generator on Warping Tug and Causeway Ferry Power Module, and one DEIF PPU for Beach Module generator

• They share the same capability

PPU

Main Controller

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• In local mode, DEIF allows control and monitoring at local panel

• In remote mode, built in serial Modbus Remote Terminal Unit (RTU) communication allows control and monitoring at Machinery Control System (MCS) station

• Refer to PWS document for control and monitoring requirements

DEIP PPU Local/Remote Mode

Presentation Notes This alteration provides failsafe alignment of the battery charging circuit to prevent inverter damage.

SAR package is ready for EXWC review and W7M input as soon as we validate that upgraded breaker will resolve last remaining problem in this circuit.

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DEIF PPU Wiring Diagram

• Integrates with existing C4.4 instruments as shown in schematic below

• Refer to attachment 6 on solicitation package for wiring diagram

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INLS Switchboard Control, Monitoring and Protection

• The device that provides switchboard control, monitoring and protection is the Crompton Switchboard Protection Relay

– Obsolete with no fit, form and function replacement

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Crompton Switchboard Protection Relay

• There are two cromptons, one for each side on Warping Tug and Causeway Ferry Power Module, and one crompton for Beach Module switchboard

• They share the same capability

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• In manual mode, crompton provides control and monitoring at switchboard

• In power management mode, built in serial Modbus Remote Terminal Unit (RTU) communication allows control and monitoring at MCS station

• On both mode, crompton provides protection to switchboard.

• Refer to PWS document for their requirements

Switchboard Manual/Power Management Mode

Presenter Presentation Notes This alteration provides failsafe alignment of the battery charging circuit to prevent inverter damage.

SAR package is ready for EXWC review and W7M input as soon as we validate that upgraded breaker will resolve last remaining problem in this circuit.

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Crompton Switchboard Protection Relay Wiring Diagram

• Integrates with existing switchboard instruments as shown in schematic below

• Refer to attachment 7 on solicitation package for wiring diagram

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• In auto mode, both systems acts together upon detecting deadbus

– DEIF starts the generator and closes the breaker

– Crompton provides monitoring and protection to switchboard

Switchboard Auto Mode

Presentation Notes This alteration provides failsafe alignment of the battery charging circuit to prevent inverter damage.

SAR package is ready for EXWC review and W7M input as soon as we validate that upgraded breaker will resolve last remaining problem in this circuit.

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Purpose of RFP

• To provide a replacement for the current DEIF and Crompton control, monitoring, and protection system

– Refer to Performance Work Statement (PWS) for system requirement

• Looking for modern integrated control, monitoring, synchronization and protection system

• The current system basically interface to the MCS. We are looking for a fit, form and function type solution that will interface to our MCS.

• Ethernet TCP/IP communication is desirable.

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RFP Clarification

• N64498-16-R-5019, Section 4.1.1 & 4.2.2 (remote monitoring) will be controlled and monitored at INLS MCS station

– Refer to PWS documents for details

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RFP Modification

• N64498-16-R-5019, Section 4.18.3.2 steps h to j is not available as government furnished equipment

– Sync check relay (ANSI 25D)

– Power reverse relay (ANSI 32R)

– Power available relay (ANSI 59) (QTY 2)

– Under voltage relay (ANSI 27)

• The above relays are part of the Crompton and should be included in proposed replacement

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RFP Modification

• N64498-16-R-5019, Section 4.1.1.c.i.7 remote indication monitoring is not required at MCS station

– Switchboard mode for generator

• Auto

• Power Management

• Manual

• Off

• This capability already exists so please make sure not to break

it. Refer to solicitation drawings for more details.

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Questions