Insulated Bus Pipe (IBP), Revolutionary Alternative to Cables for Shipboard Power Distribution March 12, 2019 NSRP 2019 All Panel Meeting

Background Cables used since the advent of electrical distribution in 1800’s Primary cable advancements are in standardization and insulation materials Skin effect and size precludes the use of large conductors for AC Only option for supplying high current loads is parallel cables Cable bend radius is over twelve times the overall diameter, or 26.4” minimum for typical 400 MCM cable Cables run after a ship is fully assembled, does not support modular construction Cable repulls costly and time-consuming

About IBP Touch-safe power distribution able to be shaped into complex shapes Multiple sizes available AC applications up to 36 kV and 6.5 kA DC applications up to 60 kV and 7 kA Shielding/protection options EM shielding High temperature capability Stainless steel outer layer Prefabricated sections installed similarly to pipes Bend radius limited by mechanical strength of conductor 7.2kV AC/12kV DC at 2kA allows an 8” bend radius Designed for 40+ year life

IBP Construction Copper or aluminum conductor, can be solid or hollow UP to 30’ sections are standard Alternating layers of insulating/semiconducting crepe paper vacuum impregnated with resin Up to IP68 construction High temperature coatings Shielding options Multiple connecting methods to suit application Connecting sleeve constructed similar to IBP

IBP Connection methods

IBP Benefits/Advantages Provides SWAP-C savings for increased endurance and design margin Supports modular ship construction, savings cost, and schedule Significant space and weight savings Manufactured into complex shapes, can be placed in tight spaces Rigid construction ensures accurate model High abrasion resistance, increased survivability Repairs easily accommodated, only the damaged section is replaced

IBP Product tested circa 2005 IBP product tested at NAVSSES Philadelphia circa 2005 in support of early Ford class development IBP not governed by any MIL-STD Product tests based on electric cable tests as agreed between NAVSSES Philadelphia and interested program officers

Status of qualification Category & Site Test Status Shock & Vibration at AeroNav Lab Inc. MIL-STD-901D Shock, Grade A, Medium Weight Approved for unrestricted Navy shipboard installation MIL-STD-167-1 Vibration Vendor Shock/Vibration Fixture Fixture may require qualification Electrical Compliance Testing at KEMA Powertest, Inc. Shield Continuity Pass Insulation Resistance (initial and after AC Voltage Withstand test) Partial Discharge (Corona) Level Conductor Resistance AC Voltage Withstand Basic Insulation Test (BIL) to IEC 60502 Three Phase Bolted Fault to ANSI C37.23 EMI Radiated to MIL-STD-461E (RE 101) Free Air Ampacity

Status of qualification (con’t) Category & Site Test Status Installation Compliance Testing at General Cable Corp Watertight Integrity Pass Centering and Circularity Inconclusive; minor concern as test specific to cable not IBP. Drip Shrinkage Gas Flame Fail; but retested and passed in 2014 and 15 Acid Gas Equivalent Pass except for ground wire, a minor concern Halogen Content Smoke Index Toxicity Ordinance Survivability Testing Aberdeen Proving Ground (APG) Riflemen Improved survivability over medium voltage cable Fragmentation

Advancements US manufactured IBP demonstrated to the Navy in a lab environment 1/24 through 2/1 Incorporated in the power circuit during MVDC grounding testing at FSU CAPS facility

IBP Observations from demo No issues observed during the two (2) week demonstration AC IBP sections were exposed to 4.16 kV AC RMS line-to-line, 250 amps peak DC IBP sections were exposed to as much as 5 kV DC, 200 amps DC IBP is not expected to increase parasitic capacitance: ~5.4 ηF IBP to ground (100 KHz to 20 MHz) ~70 ηF overall DC side (including IBP) to ground Real-time temperature sensing of IBP coupling bolts: Identify coupling bolts that come loose over time

Project Status Land Based Case Study of Insulated Bus Pipe for Ship Design Culminated in lab test demo at FSU CAPS 1/24-2/1 2019 Final Report to issue 3/20 Qualification Testing of Insulated Bus Pipe (IBP) for Shipboard Introduction Conduct electrical characterization, installation compliance, and shock and vibration tests Build a low magnetic signature co-axial IBP for medium voltage direct current (MVDC) shipboard application Generate IBP interface methods for power and loads Generate a roadmap leading to IBP shipboard installation Qualify a section of IBP for US Navy shipboard use

Conclusion Provides numerous benefits to designers, builders, and the Navy Benefits increased with high power loads Increased budget margin for future upgrades IBP has already passed a number of tests, and will work with Tech Warrant Holder community to determine qualification path Once qualified, IBP will be available for shipboard integration

Status of qualification Team Members: Tefelen, AeroNav Laboratories (Lead Test Lab), General Dynamics Bath Iron Works Supportive Shipyards: Newport News Shipbuilding & Ingalls Shipbuilding Certification Authorities: American Bureau of Shipping & Naval Surface Warfare Center Philadelphia Division SEA 05Z approval of final qualification tests is required