SHIP CONTROL CHALLENGE PROBLEM

YB Gautham Reddy
gauthamyb@gmail.com

Abstract: That we are at the brink of being catalogued as a self-sustained

Navy and have ascertained our prowess in building indigenous Ships and Ship
borne systems, the future lies in deeply delving into the design considerations
to formulate and define the threshold parameters of the combat systems vis-à-
vis the systems that are interfaced for more reliability and optimal efficiency.
The paper unusually starts with a disclaimer. The author has put forth his
views based on experiences on certain open-ended problems which served as
a food for thought whilst serving onboard ships. This paper embarks upon a
sensitive issue that is often overlooked in the day to day employability of the
power supplies onboard Indian Naval Ships. The issue in itself arises as a
concerned thought that emerged out of certain defects that have occurred in
certain critical combat electronic systems, towards which causative analysis
could not yield a conclusive reasoning. This is the problem definition and a
control challenge. From a shipboard operational perspective, the challenge
can be stated as: Provide continuous mobility, power, and thermal
management for shipboard combat systems despite major disruptions
involving cascading failures. A key aspect of this problem involves controlling
the dynamic interdependence of a hierarchically structured distributed power
and automation infrastructure. The problem is posed in terms of continuity of
service for prototypical future power electronics based shipboard Integrated
Power System (IPS). The case in point is the Automated Power management
System (APMS) specifically and the Integrated Power Management System
(IPMS) in the broader sense. A reference can be drawn out of the Angara
system which is the APMS onboard Talwar Class Ships. The aim of this paper
is to bring out how important it is to incorporate the factors such as fault
tolerance and system integrity as an organic component of the system
architecture, control strategy, algorithms, and technology base. Innovative
research that directly contributes to a more robust automation infrastructure is
indeed the need of the hour. Conceptually, the control system equivalent of an
error correcting code is sought. The desired system must maintain situational
awareness and control authority despite a variety of component failures,
internal errors, and exogenous disturbances. Overall, the paper brings out
requisite criterions that are generally essential for a conclusive analysis of fall
outs of a power supply anomaly that would aid the designers in designing the
thresholds.
1. Introduction.
Future Navy surface combatants will be
commissioned with significantly higher
demands for electric power to support
electric drive propulsion, high-energy
weapon systems, electrical auxiliary
systems, and network centric warfare.
These interdependent and automated
systems require dependable, integrated
control to dynamically and efficiently
manage limited resources. This
requirement is critical during the major
disruptions associated with battle and
damage control operations. An example
of system interdependence involves the
electrical power system, cooling
systems, and combat systems. High
power density electrical power and
energy weapons require cooling. Today
this cooling is provided through a
distributed chilled water system. To chill
the water for cooling, electric power is
required to operate the refrigeration
equipment and circulation pumps. High-
energy weapon systems tend to be
pulsed with large transient demands for
electrical power and cooling. Moreover,
combat sensing and information
management systems’ power quality
and continuity requirements limit
disruptions to hundreds or tens of
milliseconds. The automation system
must rapidly distinguish between normal
and casualty transients, dynamically
reconfiguring interdependent systems
under stressful battle conditions.
Furthermore, continuous, accurate
situational awareness is dependent
upon vulnerable, distributed sensing
and communication systems which also
rely on continuous power delivery.
Because shipboard power components
form tightly coupled finite inertia
systems, faults can readily propagate
into overall system failures. Solid-state
power conversion and switchgear
introduce the capability to quickly
isolate faults avoiding system disruption
or failure. In summary, the electric
power grid presents the most
challenging shipboard support system
control problem.
Life Extension of Missiles.
2. The laid down life of missiles is very
short vis-à-vis the life of missile systems. The
missiles being very expensive cannot be
turned over frequently. Hence, there is a
definite need to carry out life extension
studies on the missiles so that economy can
be achieved without compromising the
effectiveness of a missile system.
State of Maintenance Resources.
3. State of maintenance of any missile
system is one of the key factors in
determining the life of the equipment. The
vital maintenance resources, which have a
bearing on sustenance of the equipment, are
as follows:-
(a) Spares: These are the most
vital resources for sustenance of any
weapon system. The spares of most
of the weapon system are not
forthcoming due to various reasons
viz., closure of production line by
OEMs. Thus, there is a need to
identify alternate sources of supplies.
Better inventory management is also
required to improve the situation.
(b) Technical Manpower: Better
personnel management in terms of
planned rotation of trained manpower
in similar units, longer tenures and
flexibility in posting planning helps in
effective maintenance of complex
missile system resulting in enhanced
sustenance.
(c) Overhaul: Overhaul of
equipment is planned after a laid down
vintage and exploitation to give it a
new lease of life and enhance its
period of sustenance. Timely planning
and execution of overhaul projects is
essential for optimum increase in life
of the equipment.
(d) Reoptimisation:
Reoptimisation may have to be
 resorted to be resorted to in case equipment during the life cycle can be
the required spares and knowhow broadly classified as under:-
do not materialise due to (a) User maintenance Spares: Low
circumstances beyond control. As a cost, low tech, fast moving
scope of reoptimisation is limited vis- expendable items.
à-vis overhaul, the expected life of
reoptomised equipment may be (b) Field Maintenance Spares to
considered as half of that replace damaged functional
overhauled equipment and in such components exhibiting random failure.
cases the equipment may have to (c) Overhaul Spares.
be phased-off earlier.
(e) Sustenance with Reduced
Availability: In case the spares 5. A multi discipline missile system is
position does not improve in the made up to a thousand components and it is
future, it may be worth considering not possible to undertake indigenisation of all
the idea of using predetermined items at one time. In view of the fact that the
quantity of equipment (only where requirements of spares vary during the
the total quantity of equipment is service life of equipment, indigenisation may
reasonably high) as the spares be phased out over the first service life i.e.
bank. It may be resorted to as the prior to equipment becoming due for
last option. overhaul. The major factors dictating factors
dictating indigenisation of spares of imported
(f) Commonality Studies: Most equipment are:-
of the missile systems have
common spare parts, especially for (a) Population of equipment in
the mechanical portion of the service.
equipment. This fact is of great help (b) Retention policy or period of
in maintaining the missile systems of retention.
varying vintages. Special efforts are
required to be put in by specialised (c) Repair policy.
units concerned to identify and (d) The lead time required for the
document the common items development and manufacture of
amongst various equipment. items.
(f) Indigenisation and
Alternate Source of Supply
6. Bulk of the missile systems presently
Indigenisation offers one of
in service have been used extensively over
the most economical and feasible
the years. The requirement of maintenance
option when the spares ex OEM are
spares have gone up due to usage. Large
not forthcoming. Various agencies,
numbers of equipment are reaching its mid
Research organisations and private
life or have crossed their mid life and are due
industries should be fully utilised to
for base repairs. In certain cases, the
achieve the aim of maximum
overhaul is over-due, but it is being
possible indigenisation.
postponed due to non availability of spares.
Spares for maintenance and overhaul are not
Indigenisation. forthcoming in required range and quantity
from overseas sources inspite of high level
4. Indigenisation process is linked with progress actions. Indigenisation of critical
the requirement of spares during the and fast moving items required for
service life of equipment. The requirement maintenance and overhaul still lags
of spares to sustain / maintain the requirement. A gigantic effort is required
towards indigenisation to keep the present
equipment going during its service life. A it with a suitable weapon system. Although
firm line of action has to be spelt out for the creation of overhaul facilities may be
indigenisation of spares for:- cheaper, the overall cost effectiveness of
(a) Equipment that is in the overhaul should be studied in light of
process of induction or the newly equipment efficacy during enhanced life
period and post overhaul reliability.
inducted equipment.
(b) The equipment which is in
service and has reached or crossed Equipment Life Conservation.
its mid life. 10. This is one of the most important
factors affecting the sustainability of a
weapon system. It can be achieved to a great
Phases of Indigenisation.
extent by resorting to the following:-
(a) Providing Adequate
7. The indigenisation of spares can be Technical Accommodation:
phased as under, keeping in view the Prolonged exposure to extreme
usage of spares during the life cycle of an atmospheric conditions has adverse
equipment:- effect on equipment. Items like rubber
(a) Phase I: Spares and parts, insulation, oil seals, lubricants
stores required for servicing and etcetera, perish at an accelerated rate
periodic maintenance. These are under such circumstances, as a result
particularly the items required for of which, items like motors, servos
user maintenance. and electro vacuum devices are more
seriously affected. Thus, provision of
(b) Phase II: Fast moving proper technical accommodation for
spares required for providing field weapon system is absolutely
maintenance and repairs. necessary.
(c) Phase III: Spares required (b) Preventive Maintenance (PM)
for overhaul of equipment and its : All missile systems invariably
mid life. have detailed procedures for PM.
(d) Phase IV: Slow moving Carrying out PM religiously will go a
spares. long way in increasing the life of the
equipment. PM is a vital function in a
unit. The management at all levels
8. Keeping in view, the requirements of must be fully aware of its positive role.
spares during the life cycle of equipment, Creating appropriate temperature and
endeavour should be made to complete the climate for effective PM is a command
indigenisation by the time the equipment function. Evaluation and analysis of
reaches its mid life or the stage of first results obtained should be carried out
overhaul. This will permit a lead time of 8 to through periodic checks. Some points
10 years for completing the indigenisation that need to be diligently merged with
for new equipment. the process are as follows:-
(i) Personnel responsible
for preventive maintenance
Cost Effectiveness.
must be well trained. Longer
9. The cost effectiveness of weapon the association of an individual
system depends not only on the cost of with equipment, greater will be
sustenance but also on the efficacy of the his sensitivity to detect
system vis-a-vis the present and future behavioural symptoms, and
threat perception and the cost of replacing thus can take timely action to
rectify the defects / must be actively progressed.
malfunctions. In this direction, These must be available to the
employing civilian staff and personnel responsible for
training them on the preventive maintenance.
maintenance of these
systems could be considered
as more often than not, Conclusion.
longer employability of 11. Continuing budgetary
service personnel may not be constraints and delays in development
feasible. of indigenous replacements to missile
(ii) The ability to perform systems have forced us to sustain
maintenance activities such systems beyond their intended
depends on the availability of life. With assets of these missile
the repair / maintenance systems being limited and response
stores, tools and test period of their replenishment being
equipment. In case of tools extremely long, total maintenance
and test equipment, their management is the key to sustenance
completeness and of these equipment. Concerted effort
serviceability must be is required at all levels by agencies
periodically checked. concerned to successfully maintain
such equipment in battle worthy
(iii) A regular check should condition at all times.
be kept on the holding of
authorised publications,
including amendments.
Where not held, the issue