Ship Design Exercise: 10,000 ton, 100 MW, 20kVDC Surface Combatant ESRDC

Tasking Conduct an extensive design exercise in the S3D environment targeting development of baseline and alternative designs for a 10,000 ton ship featuring a 20 kV dc, 100 MW integrated power system Goals: –Exercise the S3D design environment with a distributed design team and refine S3D tool and procedures –Experiment with various technologies that draw on ESRDC expertise –Identify critical component/technology requirements to achieve the 10,000 ton goal

Technical Approach Define ship requirements – mission, payload, speed, range, etc. Define baseline ship support system concepts Brainstorm variants Run ASSET model of baseline ship –transfer hull, superstructure, volumes, weights, electrical and cooling loads, tankage, etc. to S3D (with permission from NSWCCD). –Get ship hull via Paramarine (hooray for LEAPS Integration!) Lay out baseline ship systems in S3D –Iterate until baseline ship passed S3D simulation level (power/cooling/weight balance). Copy baseline ship in S3D and make changes for variants –Analyze and compare variants

Variants Baseline – 10kV DC, conventional Si, Ring Bus Variant – SiC, 20kV DC Variant – High-Speed Power Generation Variant – Doerry/Amy architecture Variant – Hybrid Electric-Mechanical Drive

DESIGN REQUIREMENTS

Design Requirements ThresholdGoalASSET Installed Power95 MW100 MW99 MW Displacement11,000 mt10,000 mt Maximum Sustained Speed27 kts32 kts30.5 kts Maximum Battle Speed*25 kts30 kts27 kts Cruise Speed14 kts16 kts15 Range3,000 nm6,000 nm49.8 nm Mission equipment delineated in next slide Fit within 10,000 ton hull Meet performance goals and support required mission loads

Speed/Power Conditions Battle condition –Full power to all weapons and vital and select non-vital loads with sufficient power remaining to achieve “battle speed” Surge condition –Max sustained speed –Full power to propulsion, RADAR and InTop –Weapons at reduced power Cruise condition –Operate at most efficient speed (cruise speed), –All weapons off –Radar at reduced power –Subset of vital and non-vital loads operational

Mission Equipment Armament –Railgun (32 MJ, 17 MW) –LASER (1200 kW input / 300 kW radiated) –Active Denial System (600 kW) –Vertical Launch System (VLS), 48 cell Command and Surveillance –Multi-Function Dual-Band Phased-Array Radar (5 MW) –Integrated Topside (InTop), including Surface Electronic Warfare Improvement Program (SEWIP) and communications (2 MW) –Hull Mounted Sonar, Towed-Array Sonar –Total Ship Computing Environment (Integrated weapons, sensor, machinery and navigation control systems) Vehicles –Helicopter/UAV –Small Boats/USV Dimensions, Weights, Power Demand and Cooling Determined from Open Source Data

Mission Load Data For each mission load, the following data is required: –Weight –Volume and principal dimensions –Location constraints –Power Steady-state power required (max connected, battle, surge, cruise) Power interface voltage/frequency –Cooling requirements and temperature limits

Weapons NameWeight (mt) Length (m) Width (m) Height (m) Area Addition (m 2 ) Mission (kW) Cruise (KW) Effy (%) Cooling System Type 30 MJ RAIL GUN MOUNT CHW RAIL GUN PULSE FORMING NETWORK CHW RAIL GUN AMMO20 LASER LASER BELOW DECK EQUIPMENT CHW ACTIVE DENIAL SYSTEM ARRAY ACTIVE DENIAL SYSTEM SUPPORT EQUIPMENT CHW VERTICAL LAUNCH SYSTEM 8 CELL (each) CHW VERTICAL LAUNCH SYSTEM LOADOUT 8 MISSILES92 VERTICAL LAUNCH SYSTEM WEAPONS CONTROL SYSTEM

Sensors and C4I NameWeight (mt) Length (m) Width (m) Height (m) Area Addition (m 2 ) Mission (kW) Cruise (KW) Efficienc y (%) Cooling System Type S BAND RADAR ARRAYS (each) CHW X BAND RADAR ARRAYS CHW S BAND SUPPORT EQUIPMENT CHW X BAND SUPPORT EQUIPMENT14240CHW InTop ARRAY (2 each) CHW InTop BELOW DECK EQUIPMENT CHW BOW SONAR DOME WATER and STRUCTURE72 BOW SONAR SENSOR BOW SONAR ELECTRICAL EQUIPMENT SONAR TOWED ARRAY AND ELEX SONAR TOWING SYSTEM TOTAL SHIP COMPUTING ENVIRONMENT

Loads NameWeight (mt) Length (m) Width (m) Height (m) Area Addition (m 2 ) Mission (kW) Cruise (KW) Mission Cooling Load (KW) Cruise Cooling Load (KW) VEHICLES X HELICOPTERS HANGAR, SUPPORT EQUIPMENT AND SHOPS HELICOPTER FUEL77 RAST MAGAZINE LOADOUT1050 WINCH/CRADLE/SUPPORT BOATS AMALGAMATED LOADS-- vital zone vital zone vital zone vital zone nonvital zone nonvital zone nonvital zone nonvital zone

BASELINE SHIP

Baseline Ship Assumptions –Main bus carries full 100 MW –20kVDC is equivalent to 13.8 kVAC Electrical Design –Si Power Electronics –10kVDC, or 6.9 kVAC –DC Disconnects, not circuit breakers –Regular (not high-speed) generators –Ring Bus electrical distribution Thermal Design –Parallel supply and header loops –Branches for each zone and major loads –Rail gun barrel cooling not provided by CHW Naval Architecture Design –Electrical and thermal loops separated longitudinally, vertically and transversely –Separation between enginerooms and motors –Balance achieved in ASSET

Naval Architecture View

Electrical View

PGM PMM RG Radar ZZZZ PCM

Electrical View

Thermal View

CHW ZZZZ RGRadar PMM

Thermal View

Mechanical View

20KV SiC VARIANT

20kV SiC Variant Change weight/volume of power electronics to coincide with SiC Change bus voltage to 20kVdc Change generator voltage to 13.8kVac Higher temperature allowed

10kV Baseline

20kV SiC

Weight Comparison Value10kV Baseline20kV SiC Cable Weight (kg)175, ,394.1 Converter Weight (kg)259,166168,083 Piping/Chiller WeightStill in process

Thermal View Note: SiC Power Electronics are now FW cooled instead of CHW, operate at a higher temperature.

HIGH SPEED GENERATOR VARIANT

High Speed Generator Variant 36 High speed electric machines enable significant reduction in size/weight of GTG’s –Power = torque x speed; more speed = less torque –Electric machines scale with torque –Size/weight reduction enhances design flexibility Most effective with dc distribution –Eliminates gearbox needed to synchronize SSGTG’s Notional gas turbine generator set models –Water-cooled generators to maximize power density –LM2500/Vectra30G ISO ,200 rpm –LM2500+/Vectra40G ISO ,200 rpm –LM2500+/Vectra40G4 ISO ,200 rpm –LM500 direct drive ISO rated 4.6 7,000 rpm

Turbine Generators Machinery designs based on realistic equipment designs –Curtiss Wright HS Generator* Generator analysis / package design Fully water-cooled machine –GE LM2500/Vectra 40 family of engines Industrial equipment designed by Dresser Rand for marine service Some Navy experience, not fully qualified –LM500 Generator Sets Eliminated gearbox Scaled generator for 7,000 rpm 37 *Raymond M. Calfo, Gregory E. Poole, and John E. Tessaro “High frequency ac Power Systems”, ASNE DOI: /j x ~ 3 m reduction in length

Baseline SWBS 300 Weight

HS Generator SWBS 300 Weight Weight savings added ~ 500 nm to the endurance range Further savings potential with elimination of one SSGTG

MVDC CANDIDATE REFERENCE ARCHITECTURE

MVDC Architecture Baseline 41 Bus Node PCM 1A PGM IPNC PMM EMRG AC LC PCM SP MVDC Candidate Reference Architecture “Doerry/Amy Variant”

MVDC Candidate Reference Architecture

Zone 2 PCM-1A Zone 1 PCM-1A Zone 2 ACLC Zone 1 ACLC

Doerry/Amy Architecture Required development of new component models –Bus Node –PCM1A –IPNC –ACLC (with multiple inputs) Demonstrate ability to effective implementation of component blocks for new or notional equipment –Goes beyond component attribute characteristics –Capture functionality in simulation framework 44 Reduced SWBS 300 weight by XXX tons

New Component Blocks 45 New component-specific models plus enhanced port flexibility

MECHANICAL/ELECTRICAL HYBRID VARIANT

Mechanical/Electrical Hybrid Mechanical Propulsion with two Main Reduction Gearboxes –Two LM2500+G4 gas turbines –Two 10 MW PM Electric Machines (M/G) + PCM –Increased ship service power generation –Trading baseline mission systems (e.g. VLS, ADS) for EMRG –Trading gearbox size/weight against 40 MW low speed motor and variable frequency drive Electric drive via gearbox motors up to ~ 20 kts –High efficiency PM motor and improved SFC turbine operation Mechanical/hybrid drive above 20 kts Pulsed Alternator system in place of capacitor banks and energy storage 47 More extensive exercise for mechanical design discipline

FUTURE CAPABILITIES: INTAKE/UPTAKE SIZING 48

Future Capability: Intake/Uptake Sizing Motivation: –Intakes/Uptakes occupy critical volume across multiple decks and compartments –Poor design impacts GT performance –Enhance routing flexibility Distributed Systems Capability –Create Intake/Uptake components in HVAC workspace Track geometry of assembled duct Use equivalent length for elbows/transitions –Connect with selected GT/GTG Expanding attributes to include exhaust mass flow rate, temperature, flange areas, collector/duct pressure drop allocations –Algorithm estimates pressure drop and/or guidance on equivalent diameter Foundation analytical work done, need to implement across multiple design disciplines 49