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

2. 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

3. 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

4. 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

5. DESIGN REQUIREMENTS

6. 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

7. 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

8. 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

9. 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

10. 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 MOUNT8010 1230040CHW RAIL GUN PULSE FORMING NETWORK21017000500CHW RAIL GUN AMMO20 LASER544316 LASER BELOW DECK EQUIPMENT564324120025CHW ACTIVE DENIAL SYSTEM ARRAY120.622.4600 ACTIVE DENIAL SYSTEM SUPPORT EQUIPMENT1111225CHW VERTICAL LAUNCH SYSTEM 8 CELL (each)583.42.547.73548024075CHW VERTICAL LAUNCH SYSTEM LOADOUT 8 MISSILES92 VERTICAL LAUNCH SYSTEM WEAPONS CONTROL SYSTEM1412450050

11. 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)101441612501530CHW X BAND RADAR ARRAYS2.51 6.254001530CHW S BAND SUPPORT EQUIPMENT20 10 2 CHW X BAND SUPPORT EQUIPMENT14240CHW InTop ARRAY (2 each)22112200050025CHW InTop BELOW DECK EQUIPMENT22.5 6.25CHW BOW SONAR DOME WATER and STRUCTURE72 BOW SONAR SENSOR30551.5400 BOW SONAR ELECTRICAL EQUIPMENT 1771228425 SONAR TOWED ARRAY AND ELEX2510075 SONAR TOWING SYSTEM15632705075 TOTAL SHIP COMPUTING ENVIRONMENT4020102200150 60

12. 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-------------- 2X HELICOPTERS2012.53.34.1 HANGAR, SUPPORT EQUIPMENT AND SHOPS2014104.6280 HELICOPTER FUEL77 RAST30144256 MAGAZINE LOADOUT1050 WINCH/CRADLE/SUPPORT301252120 BOATS16113.23 ------------AMALGAMATED LOADS-- vital zone 1788622315249 vital zone 21013761405304 vital zone 31013761405304 vital zone 4916751366300 nonvital zone 116329365117 nonvital zone 219137176148 nonvital zone 319937880151 nonvital zone 416338265153

13. BASELINE SHIP

14. 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

15. Naval Architecture View

18. Electrical View

19. PGM PMM RG Radar ZZZZ PCM

20. Electrical View

24. Thermal View

25. CHW ZZZZ RGRadar PMM

26. Thermal View

27. Mechanical View

29. 20KV SiC VARIANT

30. 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

31. 10kV Baseline

32. 20kV SiC

33. Weight Comparison Value10kV Baseline20kV SiC Cable Weight (kg)175,165.188,394.1 Converter Weight (kg)259,166168,083 Piping/Chiller WeightStill in process

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

35. HIGH SPEED GENERATOR VARIANT

36. 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 23.5 MW @ 6,200 rpm –LM2500+/Vectra40G ISO 31.3 MW @ 6,200 rpm –LM2500+/Vectra40G4 ISO 34.3 MW @ 6,200 rpm –LM500 direct drive ISO rated 4.6 MW @ 7,000 rpm

37. 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: 10.1111/j.1559-3584.2008.00164.x ~ 3 m reduction in length

38. Baseline SWBS 300 Weight

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

40. MVDC CANDIDATE REFERENCE ARCHITECTURE

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

42. MVDC Candidate Reference Architecture

43. Zone 2 PCM-1A Zone 1 PCM-1A Zone 2 ACLC Zone 1 ACLC

44. 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

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

46. MECHANICAL/ELECTRICAL HYBRID VARIANT

47. 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

48. FUTURE CAPABILITIES: INTAKE/UPTAKE SIZING 48

49. 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