ICAS and Remote Monitoring Informational Brief AMG2CC Workshop 25 Feb 2015 PRESENTED BY Michael...

ICAS and Remote MonitoringInformational Brief

AMG2CC Workshop

25 Feb 2015

PRESENTED BY

Michael DiUlioNAVSEA [email protected]

Distribution Statement A: Approved for Public Release; Distribution Unlimited

mailto:[email protected]

https://infocenter.caci.com/sites/SMIP/NAVSEA%20Graphics/NAVSEA%2004%20Logo-transparent%20backgrd_111809.png

• Navy’s ACAT IVM Program of Record (POR), via COTS hardware/software, for on-line automated machinery condition monitoring and assessment enabling Condition Based Maintenance (CBM), Remote Monitoring, & Remote Technical Assistance

ELEMENTS OF ICASSOFTWARE• Operating System• ICAS Shell• Over 30 Interfaces

• Industry Standard, Open, etc.

HARDWARE• 1-5 Computer Workstations• High-security Firewall System (HFS)• Multiple View Node Capability• Fiber Optic LAN• Portable Data Collector (PDT)• Sensors for selected equipment• I/O Devices

CONFIGURATION DATA SET (CDS)• Engineering Knowledge Base built on

Reliability Centered Maintenance (RCM) and Failure Mode Effects Analysis (FMEA)

• List of Equipment, Alarm Thresholds, Logsheets, Failure Modes, Rules Based Diagnostic System, Event Capture, Trends

• Varies based on Class, Hull, and System Configuration

2

What is ICAS?



• CBM implementation tool– Machinery Data Trending– Rules based expert system– Vibration Analysis

• Troubleshooting Aid– Rules based expert system– Event capture

• Operational Assessment– Material Assessment– Plant Situational Awareness– Assessment Visit Support

(Availability Planning)• A tool to enable reduced manning• ILS

– Access and linkage to PMS, EOSS and IETMs

• Electronic Logsheets

• Currently installed on:• 106 Ships; 7 Classes• Surface, Carrier

ICAS Expert System:

• performs a continuous analysis of machinery data.

• automatically generates maintenance advisory

ICAS Expert System:

• performs a continuous analysis of machinery data.

• automatically generates maintenance advisory

Continuous Analysis

Data Logging / Situational Awareness

3

ICAS Capabilities – Afloat



Distance

Support

ISEA Review of IPAR

MaintenanceCommunity

Remote Monitoring

MELSIPARs

Formats &Presents Reports

IPAR - Emailed

ICASCollects & Process Data

Manual Data Submission

Brings ISEA Knowledge Base to Maintenance Team Cell

Seamles

s Data O

ffload

via NIA

PS Server

2-KIL

O

Via TYCOM Process

4Distribution Statement A: Approved for Public Release; Distribution Unlimited


Acronyms:CBM – Condition Based MaintenanceDS – Distance SupportHFS – High-Security Firewall SystemICAS – Integrated Condition Assessment SystemMCS – Machinery Control System

MELS – Maintenance Engineering Library ServerNIAPS – Navy Integrated Applications ServerNSWC – Naval Surface Warfare Center NSWCCD-SSES – NSWC Carderock Div – Ships Systems Engineering StationRMU – Remote Monitoring UtilityTM – Transfer Manager

Machinery Control System

NIAPS NSWCCrane

Data AcquisitionData

Qualification Data Packaging and Transmission

Data Processing and Posting

Equipment Sensors IPAR Posted

SHIP SHOREICAS Processes, Qualifies, & Stores Data

RMU packages change data for transmission to NIAPS Server

NIAPS Server holds ICAS Data until Shipboard Server replicates with Shore Server

NSWC Crane passes data from NIAPS Shore NIAPS Server to MELS.

MELS Data Processing and IPAR Generation

Provides Firewall protection between Machinery Network & Shipboard Network

ICAS HFSRMU TMMELS P&D

Engine

MELS Central RMU

ICAS PROGRAM

SHIPBOARD

SHORESIDE

Remote Monitoring Data Flow



Platform Specific System Specific

Same Data, Different Cut6

IPAR vs. ePAR



Bars are a histogram of the failure/fault modes, information,

vice raw data.

Bars are a histogram of the failure/fault modes, information,

vice raw data.

• “Hovering” makes detailed fault information available

• “Single Click” displays supporting data

System

Faults

System

Faults

7

MELS – IPAR View



25 Feb 2015

DDG GTG High Startup Vibrations

Time: -30 Days

ICAS Install

• First ICAS data offload received

• First RDS Event for Ship

Time: 0 Day

Data Verified by SME and compared to failure library

Time: + 1 day

Recommendations documented in pdf

Time: + 3 days

Ship contacted and begins troubleshooting

(waterwash, transducer inspection, etc)

Time: + 11 days Time: +11days

SME Performance review complete

SME Performance review complete

+

MARMC Change out request

Background• Ship preparing for 18 month SEA

SWAP deployment• All Gas Turbines were thought to

be in good condition• Problem identified with first data

offload after install

Analysis performed• Startup vibrations compared to DDG80

GTG high vibe problem that resulted in engine replacement due to 4th Stage turbine blade damage

• Vibe signature matched and suspected 4th stage turbine damage on GTG#1

Action Taken• Ship notified (in POM period) and

begins troubleshooting• MARMC performs borescope

inspection during connection of independent vibration gear

• Borescope revealed, (as suspected), 4th stage turbine blade damage

Results\Benefits• Engine replacement accomplished

stateside prior to ship deployment• Reduced replacement cost• Increased Ship/System Readiness

DDG80 GTG3 and DDG66 GTG1 VIBS vs RPM

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

8.5

9.0

9.5

10.0

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000

RPM

MIL

SDDG66 TG1 VIBS

DDG80 TG3 VIBS

THIS IS A COMPARISON BETWEEN DDG66 GTG1 VIBS WITH DDG80 GTG3 VIBS, BOTH

VERSUS RPM. DDG80 GTG3 WAS REPLACED DUE TO 4TH STAGE TURBINE DAMAGE FROM

2ND AND 3RD STAGE SHROUD FAILURE. BOTH GTG'S EXHIBIT PEAK VIBS IN THE SAME RPM

ZONE. COULD THIS INDICATE TURBINE DAMAGE ON DDG66 GTG1?

MARMC SME performed borescope inspection. Damage found on 4th stage blade



9

IPAR Expansion / Evolution• The GTG ISEA, RMC & ICAS team has further

evolved the GTG IPAR• “Start Vibrations High” discovered (2005 –

Gonzalez)– applicable to approx 180 GTGs monitored by ICAS

• Further analysis yielded an unsat amount of “false positives”

• Failure mode split between “Cold start”, “hot start” or “running high” vibe condition

• Better assessment with close to zero false positives



• Remote Monitoring used to identify and solve in service problems

Below LPD 17 MPDE EPAR is used to identify class wide problem

Engine light loading condition identified over 95% of operational time during the last 365 days on LPD-19

Lower right depicts an LPD-19 IPAR data screen used to identify that the existing system design is not capable of maintaining the Diesel fluids operational temperatures within design specification

10

LPD-17 Remote Monitoring

25 Feb 2015



Time: 0 Days

ICAS Data received from ship

Problem DescriptionISEA review of IPAR data indicated possible compressor surging on AC Plant No. 2 and AC Plant No. 3 based on the combined motor current spike, suction pressure/temperature increases, and chilled water inlet/outlet temp increases.

Analysis performedDay 1: ISEA emailed ship and TYCOM directly addressing possible compressor surging. IPAR sent to ship.

Day 30: ISEA emailed ship for the second time and TYCOM directly addressing possible compressor surging. IPAR sent to ship.

Action TakenShip ordered 15 cylinders of R-134a and have recharged AC Plants Nos. 1, 1A, and 2. Ship’s force has scheduled NSSA to assist in repairing leaks on AC Plant No. 3 during upcoming CMAV.

Results\BenefitsISEA was able to remotely identify fault conditions while conducting weekly IPAR reviews. Using Distance Support the ISEA was able to alert ship’s force to the fault and provide recommended maintenance actions in a timely manner.

This prevented possible AC Plant Compress failure.

Estimated cost avoidance = $500k

ICAS Data processed into MELS

Data Verified by ISEA

Recommendations documented

IPAR sent to ship. ISEA emails ship through TYCOM on two different occasions.

A/C ISEA (Code 921)

reviews performance data

A/C ISEA (Code 921)

reviews performance data

Ship responds to TYCOM with action taken based upon ISEA recommendations

Time: + 1 Day

Time: + 30 Days

Time: + 33 Days

DDG AC Compressor Surge



• Allows ISEAs the ability to view available maintenance data (CSMP) in addition to MELS diagnostics in order to make informed recommendations and generate trackable work candidates

• Creates (“J” coded) 2Kilos that can be attached to an IPAR• Less work for the Ship (no need to create

2Kilos from IPAR) • Better data collection (can see which jobs

were completed and how long they took)• Allows validation of ICAS/MELS fault logic

• The 2Kilos are injected into the shipboard OMMS making them part of the CSMP• Improved shore side (ISEA) analysis• Better recommendation based on current

CSMP and history

• Began implementation in FY14

ISEA Reviewed IPAR 2-KiloEffort (IRI2K)

CLOSING THE MAINTENANCE LOOP 12



13

ICAS RM Process w/ CSMP Link



11/21/2011

11/21/11: Problem DescriptionISEA review of AC#2 indicated SW flow Low or insufficient. 2K candidate EA01-J022 issued with IPAR

12/5/11: Problem DescriptionISEA noted that AC#2 plant returned to “GREEN” IPAR on Insufficient SW flow, review of closed WC EA01-J022 indicated that S/F troubleshoot and investigated SW system found it properly aligned but also noted that the SW strainers were fouled. They were cycled and cleaned.

Summary Inadequate SW flow can lead to poor heat exchange, leading to poor AC plant performance, excessive strain on the compressor, and internal damage requiring a compressor overhaul. This example shows that review by the ISEA can lead to remotely triggered maintenance actions and correlate those actions/solutions to Failure Modes and logic improvements as well as maintenance and energy savings

11/21/2011

EA01-J022 opened in CSMP

11/23/2011

EA01-J022 closed in CSMP

11/27/2011

AC2 Run again

12/5/2011

Limited run time on AC # 2 during this time period

Next IPAR on 12/5 indicated condition cleared. Fault remained green for subsequent IPARs.

Restricted SW flow to the unit could lead to serious damage and increased energy consumption

14

DDG 101 Case Study EA01-J022



ICAS & EnergyICAS Energy Dashboard• R&D Efforts (funded by FRRDP – NAVSEA

05T)– Shipboard ICAS tool that presents energy &

fuel usage real-time• Provides feedback against established “Energy

Profiles”• Provides energy saving recommendations• Data sent off-ship to support Energy Summary

Reports

– Initiated in 2010, started with DDG-51 FLT IIA Class

• Proof of Concept completed in 2012

– Currently installed on 6 ships (DDGs 90, 95, 100, 102, 103, 108)

– Prototype efforts in progress for LPD-17 & DDG-51 FLT I

• Implementation Efforts (funded by COMPACFLT & USFF, N43)

– Install ICAS Energy Dashboard on 5 FLT IIA DDGs in FY-14

• DDGs 92, 94, 97, 109, 112 • DDG-51 FLT IIA implementation funding to

transition to PMS400F in FY-15



Energy Summary Reports

Energy Summary Reports• R&D Efforts (funded by FRRDP – NAVSEA 05T)

– Initially modeled after IPARs to present monthly Energy/Fuel Usage

– Evolved to include operational equipment lineups and act as energy “report card”

– Distribution modeled similar to IPAR community• Support efforts (funded by COMPACFLT, N43)

– FLEET is funding development of Energy Summary Reports in FY-14

Energy Summary Report Automation Tool (ESRAT)• R&D Efforts (funded by FRRDP – NAVSEA 05T)

– Developed to automate data processing in the Energy Summary Report

– ESRAT v2.0 released in Dec. ’13– Next generation of ESRAT currently in development stages

• Support Efforts (funded by COMPACFLT, N43)– Tasking to develop interface from MELS/ESRAT to Fleet

Energy Conservation Dashboard (FECD)

GTGs - (Electric Plant) Electric Production Breakdown

Table 8: GTGs Detail Analysis of Electric Production, Fuel Usage, and Configuration

Figure 5: Gas Turbine Generator Operational Analysis

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only. Other requests shall be referred to NSWCCD Philadelphia Code 951

Executive Energy Summary

Table 1: Monthly Electrical Usage NOTE: “Theoretical” value indicates optimal energy usage based on time spent in different energy profiles. “Actual” value is the sum of actual energy usage in each energy profile.

Table 2: Energy Profile Summary NOTE: TIME ON PROFILE VALUE RELIES ON MANUAL INPUT FROM SHIP’S FORCE.

Table 3: GTM Configuration Breakdown

Table 4: Fuel Usage Summary

Table 5: Environmental Summary Table 6: Runtime Summary



Energy – Complementary ToolsICAS Fuel Management System (FMS) SBIR• SBIR Effort (funded by SBIR Program Office & FRRDP)

– Currently Phase II SBIR (ESRG)– Shipboard ICAS tool that provides planning info for

fuel/equipment configurations– Prototype installed on DDGs 95, 100– Complementary to ICAS Energy Dashboard– New SBIR contract awarded May 2014

TRITON• Navy Propellers are inspected & cleaned twice per year: Hulls are inspected at the

same periodicity, but cleaned every 3-5 years • The goal of this project is to develop, install and optimize a system capable of

reporting in real time when a ship’s powering condition has degraded due to increased drag from biofouling.

• Any improvement in fuel economy results in more days on station and/or fewer UNREPS during a deployment



REDI - Data Interface Overview

REDI is not replacing any tools. It is providing access to Program of Record Logistics & Maintenance Tools at the Point of Performance in a Single, Enterprise Solution

SKED

RMAIS

Ship 3M/OARS

AWN/OMMS

CDMD-OA

REDI

ICMP

TDKM

Single unified view of maintenance & logistics data

Assist Reliability Engineer with planning and assessing all work candidates in an electronic format

Validate work packages and track deferrals

Add and order parts during assessment periods to created 2Ks

Provides visibility and tools for planning maintenance into prescribed periods

View Technical Manuals



CDMD-OA(configuration data managers database) Search: By key fields: location, work center, HSC, equipment system description and equipment function description

OMMS/AWN: Assessor is two clicks away from submitting 2K candidate to OMMS/AWN

Configuration information and standard statements assist

EOSS PMS TDKM CSOSS

REDI Screen Captures

INSURV: Digitized CHECKLIST with Automatic Discrepancy GenerationDiscrepancy to Work Candidate Functionality Reverse Parts Identification SearchTech Manual to APL Verification CHECKLIST with Automatic



FUTURE STATE

20

REDIOn NIAPS

Machinery Control System

HFSRMU NIAPS NSWCCrane

MELS P&D

Engine

MELS Central RMU

TM

CSMP

IPAR

ICAS PROGRAMSHIPBOARD SHORESIDE

2 KILOAssessment

Team / RMC /Ship’s Force

REDI2 KILO

REDI

IRI2KAWN or

OMMS-NG

SKED 3.2

Prognostic Engine

REDI

ICAS- NG(eRM)

Closing the Maintenance Loop



21

ICAS vs CBM

• ICAS is a Program Of Record for CBM• CBM is more than just any single program

– It’s a Policy– It’s a Process– It’s the People– It’s the Requirements– It’s the Resources– Add a “+” and it’s the Prognostics

It’s a CommitmentDistribution Statement A: Approved for Public Release; Distribution Unlimited


Cyber Certification and Accreditation



Challenges

• CBM as an end-to-end solution crosses many organizations, programs and swim lanes– Individual programs band-aided together to form an end-to-end solution– 90% of 90% of 90% yields 73%– Everyone not always on same page– Can’t come to parade ground every time someone doesn’t agree

• Sensors (and systems) are determined during procurement phase– Limitation on sensors results in limitations on algorithms– Maintenance community needs a voice up front regarding parameters, sensors,

etc.• Not inculcated in daily practice

– Policies not reinforced– Some think CBM is not a requirement– ICAS is ACAT IVM program from 1996– School house starts ICAS training in 2015

CBM is a systems engineered solution



BACKUPS



25

ICAS Equipped Ships

USS BUNKER HILL CG 52 San Diego, CA USS ARLEIGH BURKE DDG 51 Norfolk, VA USS WINSTON S CHURCHILL DDG 81 Norfolk, VA USS FORREST SHERMAN DDG 98 Norfolk, VAUSS MOBILE BAY CG 53 San Diego, CA USS JOHN PAUL JONES DDG 53 San Diego, CA USS LASSEN DDG 82 Yokosuka, Japan USS FARRAGUT DDG 99 Mayport, FLUSS ANTIETAM CG 54 Yokosuka, Japan USS RAMAGE DDG 61 Norfolk, VA USS HOWARD DDG 83 San Diego, CA USS KIDD DDG 100 San Diego, CAUSS LEYTE GULF CG-55 Norfolk, VA USS GONZALEZ DDG 66 Norfolk, VA USS BULKELEY DDG 84 Norfolk, VA USS GRIDLEY DDG 101 San Diego, CAUSS SAN JACINTO CG-56 Norfolk, VA USS THE SULLIVANS DDG 68 Mayport, FL USS MCCAMPBELL DDG 85 Yokosuka, Japan USS SAMPSON DDG 102 San Diego, CAUSS LAKE CHAMPLAIN CG 57 San Diego, CA USS MILIUS DDG 69 San Diego, CA USS SHOUP DDG 86 Everett, WA USS TRUXTUN DDG 103 Norfolk, VAUSS PHILIPPINE SEA CG-58 Mayport, FL USS HOPPER DDG 70 Pearl Harbor, HI USS MASON DDG 87 Norfolk, VA USS STERETT DDG 104 San Diego, CAUSS PRINCETON CG 59 San Diego, CA USS ROSS DDG 71 Rota, Spain USS PREBLE DDG 88 San Diego, CA USS DEWEY DDG 105 San Diego, CAUSS NORMANDY CG-60 Norfolk, VA USS MAHAN DDG 72 Norfolk, VA USS MUSTIN DDG 89 Yokosuka, Japan USS STOCKDALE DDG 106 San Diego, CAUSS MONTEREY CG-61 Norfolk, VA USS DECATUR DDG 73 San Diego, CA USS CHAFEE DDG 90 Pearl Harbor, HI USS GRAVELY DDG 107 Norfolk, VAUSS CHANCELLORSVILLE CG 62 San Diego, CA USS MCFAUL DDG 74 Norfolk, VA USS PINCKNEY DDG 91 San Diego, CA USS WAYNE E. MEYER DDG 108 San Diego, CAUSS GETTYSBURG CG 64 Mayport, FL USS DONALD COOK DDG 75 Rota, Spain USS MOMSEN DDG 92 Everett, WA USS JASON DUNHAM DDG 109 Norfolk, VAUSS CHOSIN CG 65 Pearl Harbor, HI USS HIGGINS DDG 76 San Diego, CA USS CHUNG-HOON DDG 93 Pearl Harbor, HI USS WILLIAM P. LAWRENCE DDG 110 San Diego, CAUSS HUE CITY CG-66 Mayport, FL USS O'KANE DDG 77 Pearl Harbor, HI USS NITZE DDG 94 Norfolk, VA USS SPRUANCE DDG 111 San Diego, CAUSS SHILOH CG 67 Yokosuka, Japan USS PORTER DDG 78 Norfolk, VA USS JAMES E WILLIAMS DDG 95 Norfolk, VA USS MICHAEL MURPHY DDG 112 Pearl Harbor, HIUSS ANZIO CG 68 Norfolk, VA USS OSCAR AUSTIN DDG 79 Norfolk, VA USS BAINBRIDGE DDG 96 Norfolk, VAUSS CAPE ST. GEORGE CG 71 San Diego, CA USS ROOSEVELT DDG 80 Mayport, FL USS HALSEY DDG 97 Pearl Harbor, HI

USS HALYBURTON FFG 40 Mayport, FL USS SAN ANTONIO LPD 17 Norfolk, VA USS WHIDBEY ISLAND LSD 41 Norfolk, VA USS AVENGER MCM 1 Sasebo, JapanUSS McCLUSKY FFG 41 San Diego, CA USS NEW ORLEANS LPD 18 San Diego, CA USS GERMANTOWN LSD 42 Sasebo, Japan USS DEFENDER MCM 2 Sasebo, JapanUSS TAYLOR FFG 50 Mayport, FL USS MESA VERDE LPD 19 Norfolk, VA USS FORT MCHENRY LSD 43 Norfolk, VA USS SENTRY MCM 3 Sasebo, JapanUSS ELROD FFG 55 Norfolk, VA USS GREEN BAY LPD 20 San Diego, CA USS GUNSTON HALL LSD 44 Norfolk, VA USS CHAMPION MCM 4 San Diego, CAUSS SAMUEL B ROBERTS FFG 58 Mayport, FL USS NEW YORK LPD 21 Mayport, FL USS RUSHMORE LSD 47 San Diego, CA USS DEVASTATOR MCM 6 Bahrain, UAEUSS KAUFFMAN FFG 59 Norfolk, VA USS SAN DIEGO LPD 22 San Diego, CA USS ASHLAND LSD 48 San Diego, CA USS PATRIOT MCM 7 Sasebo, Japan

USS ANCHORAGE LPD 23 San Diego, CA USS HARPERS FERRY LSD 49 San Diego, CA USS SCOUT MCM 8 San Diego, CACVN-Class Ships USS ARLINGTON LPD 24 Norfolk, VA USS PIONEER MCM 9 San Diego, CA

USS CARL VINSON CVN 70 SAN DIEGO,CA USS SOMERSET LPD 25 San Diego, CA USS WARRIOR MCM 10 Sasebo, JapanUSS ABRAHAM LINCOLN CVN 72 NEWPORT NEWS< VA USS GLADIATOR MCM 11 Bahrain, UAEUSS GEORGE WASHINGON CVN 73 YOKOSUKA, JAPAN USS ARDENT MCM 12 San Diego, CAUSS JOHN C STENNIS CVN 74 BREMENTON, WA USS DEXTROUS MCM 13 Bahrain, UAEUSS HARRY S TRUMAN CVN 75 NORFOLK, VA USS CHIEF MCM 14 San Diego, CA

* Red denotes Ship is not equipped with RMU System

LSD-Class Ships MCM-Class ShipsFFG-Class Ships LPD-Class Ships

DDG-Class ShipsCG-Class Ships



26

CG-Class ShipsAir Conditioning Units

Controllable Reversible PropellerDesalinization Plants

Gas Turbine GeneratorsGas Turbine Mains

High Pressure Air CompressorLow Pressure Air Compressor

Main Reduction GearsRefrigeration Plants

Fuel OilLine Shaft Bearings

Lube OilSounding and Security

DDG-Class ShipsAir Conditioning Units

Controllable Pitch PropellerDesalinization Plants

Gas Turbine GeneratorsGas Turbine Mains

High Pressure Air CompressorLow Pressure Air Compressor

Main Reduction GearRefrigeration Units

Fuel OilHeat Stress

Lube OilPotable Water

Sounding and Security

LPD-Class ShipsAir Conditioning Units

Controllable Pitch PropellerLow Pressure Air Compressor

Main Propulsion Diesel EnginesMain Reduction Gear

Ship Service Diesel GeneratorsASW System

Ballast SystemChill Water Pumps

Desalinization PlantsFire Pumps

Fuel OilFuel Oil Purifiers

Line Shaft BearingsLube Oil

Lube Oil PurifiersMedium Pressure Air Compressor

Potable WaterRefrigeration Units

Sounding and SecuritySpace Temperatures

VCHT

LSD-Class ShipsAir Conditioning Units

Controllable Pitch PropellerHigh Pressure Air CompressorLow Pressure Air Compressor

Main Propulsion Diesel EnginesMain Reduction GearRefrigeration Units

Ship Service Diesel GeneratorsCHT

Fuel SystemHot Water

Line Shaft BearingsLube Oil SystemPotable Water

Sounding and SecuritySpace Temperatures

MCM-Class ShipsAir Conditioning UnitsDesalinization Plants

Main Propulsion Diesel EnginesMain Reduction Gears

Refrigeration UnitsShip Service Diesel EnginesControllable Pitch Propeller

Fuel OilLube Oil

Medium Pressure Air CompressorMMGTG

Potable WaterSounding and SecuritySpace Temperatures

CVN-Class Ships12 TM

Air Conditioning UnitsAircraft Elevators

Bilge LevelsCatapults

CHT PumpsFire PumpsList ControlLoad Center

Low Pressure Air CompressorRefrigeration Plants

Sounding and SecuritySteering Gear

TVSS

FFG-Class ShipsAir Conditioning Units

Controllable Pitch PropellerDesalinization PlantsGas Turbine Mains

High Pressure Air CompressorLine Shaft Bearings

Low Pressure Air CompressorMain Reduction GearRefrigeration Units

Ship Service Diesel EnginesSounding and SecuritySpace Temperatures

* Red denotes Systems available in MELS* Blue denotes Systems avaiable in MELS and are reviewed by ISEAs weekly

ICAS Monitored Equipment per Class



• MCMAS is the ICAS Interface to the Machinery Control System (MCS) pulling data once per second

• All MCMAS “type” data is automated

• All portable “type” data is manual

• Engineering Logsheets are developed from:

– Technical Documentation– IPAR Requirements– CHENG Additions

27

Detailed – DDG - AC Parameters SENSOR UNITS MACHINE TYPE OUTPUT

USED IN IPAR ALGORITHM DATA TO SHORE

AC1 STATUS AC PLANT #1 MCMAS D(1/0) ON/OFF X X

AC1 CW INLET TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 CW OUTLET TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 CW INLET PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X

AC1 CW FLOW GPM AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 CW CAPACITY TONS AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SW INLET TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SW OUTLET TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SW INLET PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SW STRAINER DP PSID AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 EVAP LIQUID TEMP DEG F AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 COND LIQUID TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 MOTOR SETPOINT % FLA AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 PREROTATIONAL VANES % OPEN AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 VAR GEO DIFF POS % OPEN AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 HOT BYPASS VLV POS % OPEN AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 MOTOR % FLA AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SUCTION PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 SUCTION TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 DISCHARGE PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 DISCHARGE TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 OIL PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X X

AC1 LUBE OIL SUMP TEMP DEG F AC PLANT #1 MCMAS STANDARD ANALOG X

AC1 LO TO BRGS TEMP DEG F AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 LO FILTER DP PSID AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 OIL LEVEL: 1=N 0=L,2=H AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 EXP TK SUPPLY PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X

AC1 EXP TANK LEVEL:1=N 0=L,2=H AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 SUMMARY FAULT AC PLANT #1 MCMAS D(1/0) YES/NO X

AC1 CW OUTLET PRES PSIG AC PLANT #1 MCMAS STANDARD ANALOG X

AC1 HRS SINCE LST FLSH HOURS AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 REFRIG MONITOR:0=GS 1=GF AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 TEMPERATURE SETPT DEG F AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 CNTRL VLV POSITION % COND AC PLANT #1 PORTABLE STANDARD ANALOG X X

AC1 REFRIGERANT LEVEL LEVEL AC PLANT #1 PORTABLE STANDARD ANALOG X

AC1 MOISTURE IND:0=DRY 1=WET AC PLANT #1 PORTABLE STANDARD ANALOG X



28

Detailed – DDG – GTM Parameters

SENSOR UNITS MACHINE TYPE OUTPUTUSED IN IPAR ALGORITHM

DATA TO SHORE

1A GG INLET TEMP - T2 DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A GG INLET PRES - PT2 PSIG GTM 1A MCMAS STANDARD ANALOG X X

1A GG SPEED-NGG - KRPM KRPM GTM 1A MCMAS STANDARD ANALOG X X

1A GG SPEED - NGG RPM GTM 1A PSEUDO ANALOG CALCULATION X X

1A GG COMP DIS PRES-CDP PSIA GTM 1A MCMAS STANDARD ANALOG X X

1A PLA POSITION DEG GTM 1A MCMAS STANDARD ANALOG X X

1A FO MFLD PRES - FMP PSIG GTM 1A MCMAS STANDARD ANALOG X X

1A PT INLET TEMP - T54 DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A PT INLET PRES - PT54 PSIA GTM 1A MCMAS STANDARD ANALOG X X

1A PT SPEED - NPT RPM GTM 1A MCMAS STANDARD ANALOG X X

1A PT TORQUE CALC KFT-LBS GTM 1A MCMAS STANDARD ANALOG X X

1A PT HP CALC KHP GTM 1A MCMAS STANDARD ANALOG X X

1A GG @ NGG VIBS MILS GTM 1A MCMAS STANDARD ANALOG X X

1A PT @ NGG VIBS MILS GTM 1A MCMAS STANDARD ANALOG X X

1A GG @ NPT VIBS MILS GTM 1A MCMAS STANDARD ANALOG X X

1A PT @ NPT VIBS MILS GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUPPLY PRES PSIG GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUPPLY FLTR DP PSID GTM 1A MCMAS STANDARD ANALOG X X

1A LO CLR DIS TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUMP A TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUMP B TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUMP C TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUMP D TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SUMP GB TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A LO SCAV PRES PSIG GTM 1A MCMAS STANDARD ANALOG X X

1A LO SCAV FLTR DP PSID GTM 1A MCMAS STANDARD ANALOG X X

1A LO STORAGE TNK LVL GAL GTM 1A MCMAS STANDARD ANALOG X X

1A FO FLTR DP PSID GTM 1A MCMAS STANDARD ANALOG X X

1A CLG AIR OUT TEMP DEG F GTM 1A MCMAS STANDARD ANALOG X X

1A MAN THROTTLE LEVER VOLTS GTM 1A MCMAS STANDARD ANALOG X X

1A ENG BIAS ADJUST PCT GTM 1A MCMAS STANDARD ANALOG X X

1A PC POWER COMMAND VOLTS GTM 1A MCMAS STANDARD ANALOG X X

1A GG SPEED-NGG KRPM10S KRPM GTM 1A MCMAS STANDARD ANALOG X X

1A SHUTDOWN GTM 1A PSEUDO D(1/0) YES/NO X

1A BLOW-IN DOORS OPEN GTM 1A MCMAS D(1/0) YES/NO X

1A INLET DP HI GTM 1A MCMAS D(1/0) YES/NO X

1A ANTI-ICING ON GTM 1A MCMAS D(1/0) YES/NO X

1A ANTI-ICING OFF GTM 1A MCMAS D(1/0) YES/NO X

1A BLD AIR VLV OPEN GTM 1A MCMAS D(1/0) YES/NO X

1A BLD AIR VLV CLOSED GTM 1A MCMAS D(1/0) YES/NO X

1A GG SPEED HI GTM 1A MCMAS D(1/0) YES/NO X

1A FAILED STARTUP GTM 1A PSEUDO D(1/0) YES/NO X

1A NGG OVERSPEED S/D GTM 1A MCMAS D(1/0) YES/NO X

1A GG SPEED LOST GTM 1A MCMAS D(1/0) YES/NO X

1A PLA @ IDLE GTM 1A MCMAS D(1/0) YES/NO X

1A NGG @ IDLE GTM 1A MCMAS D(1/0) YES/NO X

1A FLAME ON GTM 1A MCMAS D(1/0) YES/NO X

1A TRANS TO OFF GTM 1A MCMAS D(1/0) YES/NO X

1A TRANS TO ON GTM 1A MCMAS D(1/0) YES/NO X

1A TRANS TO ONLINE GTM 1A MCMAS D(1/0) YES/NO X

1A TRANS TO MOTORING GTM 1A MCMAS D(1/0) YES/NO X

1A TRANS TO COOLDOWN GTM 1A MCMAS D(1/0) YES/NO X


DATA TO SHORE

1A PT SPEED HI GTM 1A MCMAS D(1/0) YES/NO X

1A NPT OVERSPEED S/D GTM 1A MCMAS D(1/0) YES/NO X

1A PT INLET TEMP HI S/D GTM 1A MCMAS D(1/0) YES/NO X

1A PT BRAKE ENGAGED GTM 1A MCMAS D(1/0) YES/NO X

1A PT BRAKE DISENGAGED GTM 1A MCMAS D(1/0) YES/NO X

1A PT SPEED LOST GTM 1A MCMAS D(1/0) YES/NO X

1A PT TORQ LIMIT ACT GTM 1A MCMAS D(1/0) YES/NO X X

1A PT SPEED LIMIT ACT GTM 1A MCMAS D(1/0) YES/NO X X

1A MRG CLUTCH ENGAGED GTM 1A MCMAS D(1/0) YES/NO X

1A MRG CLUTCH DISENGAGE GTM 1A MCMAS D(1/0) YES/NO X

1A PT OVERRIDE ON GTM 1A MCMAS D(1/0) YES/NO X

1A PT OVERRIDE OFF GTM 1A MCMAS D(1/0) YES/NO X

1A HIGH LO TEMPS GTM 1A PSEUDO D(1/0) YES/NO X

1A PT TORQ LIMIT INACT GTM 1A MCMAS D(1/0) YES/NO X

1A HIGH VIBS GTM 1A PSEUDO D(1/0) YES/NO X

1A PT SPEED LIMIT INACT GTM 1A MCMAS D(1/0) YES/NO X

1A GG @ NGG VIBS HI GTM 1A MCMAS D(1/0) YES/NO X

1A NPT @ NGG VIBS HI GTM 1A MCMAS D(1/0) YES/NO X

1A GG @ NPT VIBS HI GTM 1A MCMAS D(1/0) YES/NO X

1A PT @ NPT VIBS HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO CLR DIS TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUPPLY FLTR DP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUMP A TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUMP B TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUMP C TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUMP D TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SUMP GB TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO SCAV FLTR DP HI GTM 1A MCMAS D(1/0) YES/NO X

1A LO STOR TNK LVL LW GTM 1A MCMAS D(1/0) YES/NO X

1A LO SCAV PRES LW GTM 1A MCMAS D(1/0) YES/NO X

1A LO SPLY PRES LW S/D GTM 1A MCMAS D(1/0) YES/NO X

1A FO MOD VLV OPEN GTM 1A MCMAS D(1/0) YES/NO X

1A FO MOD VLV CLOSED GTM 1A MCMAS D(1/0) YES/NO X

1A FO FILTER DP HI GTM 1A MCMAS D(1/0) YES/NO X

1A FUEL ON (FMP>50) GTM 1A MCMAS D(1/0) YES/NO X

1A MOD FAN DP LW GTM 1A MCMAS D(1/0) YES/NO X

1A MOD TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A MODULE FIRE GTM 1A MCMAS D(1/0) YES/NO X

1A MODULE FIRE GTM 1A MCMAS D(1/0) YES/NO X

1A MODULE FAN ON GTM 1A MCMAS D(1/0) YES/NO X

1A MODULE FAN OFF GTM 1A MCMAS D(1/0) YES/NO X

1A MOD VENT DAMP OPEN GTM 1A MCMAS D(1/0) YES/NO X

1A MOD VENT DAMP CLOSED GTM 1A MCMAS D(1/0) YES/NO X

1A BATTLE OVERRIDE ON GTM 1A MCMAS D(1/0) YES/NO X

1A BATTLE OVERRIDE OFF GTM 1A MCMAS D(1/0) YES/NO X

1A CLG AIR OUT TEMP HI GTM 1A MCMAS D(1/0) YES/NO X

1A IEC SYS FAULT GTM 1A MCMAS D(1/0) YES/NO X

1A IEC SYS SHUTDOWN GTM 1A MCMAS D(1/0) YES/NO X

1A ST REG/SOV FL TO CLO GTM 1A MCMAS D(1/0) YES/NO X

1A STARTER FAILURE GTM 1A MCMAS D(1/0) YES/NO X

1A NORMAL STOP FAILURE GTM 1A MCMAS D(1/0) YES/NO X

1A FL TO RCH IGN S/D GTM 1A MCMAS D(1/0) YES/NO X

1A FL TO LIGHTOFF S/D GTM 1A MCMAS D(1/0) YES/NO X


DATA TO SHORE

1A FL TO RCH 4500 S/D GTM 1A MCMAS D(1/0) YES/NO X

1A IEC BATT POWER ON GTM 1A MCMAS D(1/0) YES/NO X

1A EMERGENCY STOP GTM 1A MCMAS D(1/0) YES/NO X

1A MOT AIR REG STRT POS GTM 1A MCMAS D(1/0) YES/NO X

1A MOT AIR REG POS GTM 1A MCMAS D(1/0) YES/NO X

1A NORM STOP INITIATED GTM 1A MCMAS D(1/0) YES/NO X

1A STARTER REG/SOV CLSD GTM 1A MCMAS D(1/0) YES/NO X

1A IGNITION OFF GTM 1A MCMAS D(1/0) YES/NO X

1A NORMAL STOP COMPLETE GTM 1A MCMAS D(1/0) YES/NO X

GTM 1A/1B ONLINE AVG RPM GTM 1A/1B PSEUDO ANALOG CALCULATION X

GTM FULL POWER AVG RPM GTM 1A/1B PSEUDO ANALOG CALCULATION X

GTM T2 AVG DEG F GTM 1A PSEUDO ANALOG CALCULATION X

ER1 START AIR PRES LW GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 START AIR PRES HI GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HULL MASKER ON GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HULL MASKER OFF GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 PRARIE ON GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 PRARIE OFF GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HP AIR BNK PRES LW GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 GTM STRT AIR TEM HI GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HP AIR ST VLV OPEN GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HP AIR ST VLV CLOSE GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 BA XFR VLV STRT POS GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 AIR START HP ACTIVE GTM 1A/1B MCMAS D(1/0) YES/NO X

ER1 HP STRT AIR BK PRES PSIG GTM 1A/1B MCMAS STANDARD ANALOG X

ER1 STBD ACTUAL PITCH PCT GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 STBD ACT SHAFT SPD RPM GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 STBD SHAFT TORQUE KFT-LB GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 STBD SHAFT TORQUE KFT-LB GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 FULL AHEAD ADJUST PCT GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 ZERO THRUST ADJUST PCT GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 FULL ASTERN ADJUST PCT GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 PCL STBD SCU POS COUNTS GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 PCL STBD PACC POS COUNTS GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 PCL STBD BCU POS COUNTS GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 STBD PITCH COMMAND VOLTS GTM 1A/1B MCMAS STANDARD ANALOG X X

SHIP SPEED KNOTS GTM 1A/1B MCMAS STANDARD ANALOG X X

ER1 GTM START AIR T HI GTM 1A/1B MCMAS D(1/0) YES/NO X

1A ENG ONLINE IND GTM 1A/1B MCMAS D(1/0) YES/NO X

1B ENG ONLINE IND GTM 1A/1B MCMAS D(1/0) YES/NO X

2A ENG ONLINE IND GTM 1A/1B MCMAS D(1/0) YES/NO X

2B ENG ONLINE IND GTM 1A/1B MCMAS D(1/0) YES/NO X

FULL POWER GTM 1A/1B PSEUDO D(1/0) YES/NO X

1A SPLIT PLANT GTM 1A/1B PSEUDO D(1/0) YES/NO X

1A TRAIL SHAFT GTM 1A/1B PSEUDO D(1/0) YES/NO X

1B SPLIT PLANT GTM 1A/1B PSEUDO D(1/0) YES/NO X

1B TRAIL SHAFT GTM 1A/1B PSEUDO D(1/0) YES/NO X

ABNORMAL LINEUP GTM 1A/1B PSEUDO D(1/0) YES/NO X

1A NGG (PSEUDO) -KRPMGTM 1A

COLD IRON PSEUDO ANALOG CALCULATION X

1A FMP (PSEUDO) -PSIGGTM 1A


1A TIT-T2 (PSEUDO) -DEG FGTM 1A




ICAS and Remote Monitoring Informational Brief AMG2CC Workshop 25 Feb 2015 PRESENTED BY Michael...

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Transcript of ICAS and Remote Monitoring Informational Brief AMG2CC Workshop 25 Feb 2015 PRESENTED BY Michael...