1. Development of ISE Interoperability Modules
ISE3 - HVAC Project
Development of ISE Interoperability Modules
Final Demonstration
Washington, D.C.
October 21, 2004

2. Agenda ISE Project Overview Interoperability and Integration
Common Parts Catalog (CPC)
Navy Vision
Highlights of ISE2 Demo - April 10, 2003
Overview of TWR841 Test Ship
ISE3 - HVAC Demo
Return on Investment

3. ISE3 Team Participants Gulf Coast Region University of
Maritime Technology Center New Orleans

4. Other Team Members from ISE2 Project
American Bureau of Shipping (ABS)
Altarum
Anteon Corporation (Proteus)
Marine Machinery Association (MMA)
Naptheon
Northrop Grumman Ship Systems - Avondale Operations
Northrop Grumman Newport News
University of Connecticut

5. ISE Builds tools to Support 2nd Generation IPDE
Digital
MOCKUP
Collaborative
Design-Build
3D Design
Electronic
DRAWING
Virtual Product
& Process
Digital Ship Design Process Evolution
Enhanced Product Model
Lean Design
Rule Based Design
Internet Technologies
Remote Collaboration
Intensive Simulations
High-end Integrated Analysis
Desktop Visualization
Business Process Modeling
Integrated Design/Build Process
Sophisticated Eng.Analysis
Simulation Based Design
Computer-Aided Drafting
Data Config. Mgmt.
3D Visualization (Polygonal)
Interactive Walkthrough
Anthropomorphic Modeling
3D Wireframe/Solids
Rudimentary Data Mgmt
First Generation Integrated Product Development
Environment (IPDE)
2nd Generation IPDE

6. ISE Background First NSRP major systems technology project
Phase 1: Requirements definition and architecture for shipbuilding systems interoperability
March 1999 to December 1999
Phase 2: Deployment for Structure & Piping
March 2000 to December 2003
Phase 3: Deployment for HVAC & CPC Interfaces
October 2003 to October 2004

7. ISE Project Approach Develop and demonstrate tools that are low cost
can be selectively used by shipyards to support interoperability
capitalize on XML and related Internet technologies
Flexibility is critical
allow shipyards to transform their data to/from common information model
Drive development of shipbuilding product data standards (e.g. STEP, PLIB)
Construct a single Shipbuilding Information Model
Demonstrate and educate U.S. shipbuilding community

8. ISE Architecture Accessible to large and small shipyards
ISE architecture represents an innovative, practical solution
to the information interoperability challenge
Accessible to large and small shipyards
Only system dependency is Web infrastructure
Utilizes open standards
Innovative integration of STEP and XML technologies
Supports sharing of geometric & geometric product models
Permissive (mediation) architecture
Lets each enterprise choose its own tool set
Incorporated into CAD platforms used by U.S. shipbuilders

9. Levels of Interoperability
INTOP
Inter-business
system domain
Shipyard A
Shipyard B
Inter-System
Inter-
component
IDE
Parts
Library
PDM/CAD
ERP/CAM

10. Collaboration among Shipyards is Required in Today’s Environment
Almost every major recent U.S. Navy ship design and/or construction contract has involved collaboration among multiple shipyards
For example:
CVNX (NGNN & EB)
DDX (NGSS - Ingalls & Bath)
Initial LPD Award (NGSS - Avondale & Bath)
VIRGINIA (EB & NGNN)
This trend will continue
Navy views system interoperability as enabling multiple yards to be viewed as “One Shipyard”

11. NAVSEA Vision of “One Shipyard”11
NAVSEA Vision of “One Shipyard” 11

12. Goals of Integration Better analysis through simulation
Re-use of data instead of redundant data
increased accuracy
eliminates unnecessary checking
speed of data entry (already entered)
Facilitates partnering with other firms
Reduce overhead costs

13. Integration Strategy
STEP (Standard for Exchange of Product Model Data)
Is a good common language for CAD Product Models
XML (Extensible Markup Language)
Is good for CAE applications
Therefore, combine the two, and embed small strings of STEP into XML, based on industry agreements, such as ISE

14. Leverages development of interfaces
XML + STEP = Ideal Combo
XML brings:
Accepted format/schema method
Web-enabled
STEP brings:
Standards for data expression
Standards for geometric exchange
Leverages development of interfaces

15. XML and STEP Transactions of Data Packaged in Standards Virtual Ship
part(s)
Standards
XML = Industry Standard
Container for Data
Company A
Company B
STEP = ISO Standard
Language for Data*
Data
XSLT - map data to another XML schema

16. Shipbuilding Product Data in STEP
Shipbuilder Parts : PLIB
Structural Analysis : AP209
Structural
Analysis : AP209
HVAC : AP227 ed.2
Cable harness
design : AP212
Product Configuration : AP203
System Engineering : AP233
Ship Arrangement : AP215
Ship
Arrangement : AP
Technical Data Package : AP232
Ship Moulded Forms : AP216
Ship
Moulded
Forms : AP
Ship Structures : AP218
Ship
Structures : AP
Ship Machinery: AP227 ed.2
Ship Machinery: AP
Process Plant Piping: AP227
Process Plant Piping: AP
Delivery
Results and
System
Product
Definition
Analysis / Simulation

17. DONXML
The Department of Navy (DON) vision for Extensible Markup Language (XML) is to fully exploit XML as an enabling technology to achieve interoperability in support of maritime superiority
For cataloging product data in XML format, the DONXML working group has agreed to allow the STEP Schemas developed under the ISE Project to be registered in the DONXML repository

18. Endorsement from Northrop Grumman
"The development and testing of international standards for product data is important to the Shipbuilding industry for interoperablility and data archiving which will enable NAVSEA's "One Shipyard" Concept."
Dave Whiddon
VP Research, Development & Design
Northrop Grumman Ship Systems

19. Endorsement from Electric Boat
"Electric Boat endorses the development of interoperability tools and the use of international standards for product model exchange in the shipbuilding industry. We feel that these efforts (undertaken under the NSRP ASE Program) will enhance collaboration among U.S. shipyards and foster the Navy's goal of "One Shipyard".
Millard Firebaugh
VP-Innovation and Chief Engineer
Electric Boat Corporation

20. The Navy and Shipbuilders Are Using Product Model Data Technology
When you move from 2-d data to 3d data in assemblies the difference is even more dramatic.
Product Model Data =
3-D CAD +
definitions +
other documentation
Continued investment is key indication of value

21. ISE Tools
Tools developed by the ISE Project are made available on the Web at:
These include:
Formal information requirements published
Ship Piping
Ship Structures
Ship HVAC
CPC Interfaces
Translator generators for custom representations
XML schema generators
ISO ed 2
Automated test frameworks for conformance testing

22. NAVY Ships are a Highly Complex Product
ISE
NAVY Ships are a Highly Complex Product
SSBN
12,000,000 HRS
1,000,000 PARTS
18,750 TONS
SSN
8,000,000 HRS
950,000 PARTS
6,900 TONS
BOEING 777
50,000 HRS
103,000 PARTS
254 TONS
LAND VEHICLE
5,500 HRS
14,000 PARTS
65 TONS
FIGHTER
AIRCRAFT
57,000 HRS
30,000 PARTS
10 TONS
MISSILE
1,700 HRS
5,000 PARTS
1.6 TONS
AUTOMOBILES
23 HRS
3,000 PARTS
1.9 TONS
INCREASING COMPLEXITY
Labor Hours
Parts
Weight 10 20 30 40 50 60 70 80
MANUFACTURING TIME (MONTHS) 22

23. Roadmap - Past Ship Structural Envelope Distribution Systems
Equipment/Subsystems
Miscellaneous
Ship Arrangement
ISO AP 215:2004
Ship Moulded Forms
ISO AP 216:2003
Ship Structures
ISO AP 218:2004
Piping
(Plant Spatial Configuration)
ISO AP 227:2001
Cable Trays
ISO AP 227 Edition 2
Parts Library
ISO 13584
Reference Data Libraries
ISO 15926
AP 233 Systems Engineering Data Representation
AP 239 Product Life-cycle Support
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
Computational Fluid Dynamics
ISO AP 237
Ship Structural Envelope (hull form, arrangements, structure)
Distributed Systems (piping, electrical, HVAC, cable trays, mechanical)
Mechanical Systems
HVAC
Logistics/Spares
ISO AP 232:2002
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Finite Element Analysis
ISO AP 209:2001
Automotive
ISO AP 214:2001

24. Roadmap - Present Ship Structural Envelope Distribution Systems
Equipment/Subsystems
Miscellaneous
Ship Arrangement
ISO AP 215:2004
Ship Moulded Forms
ISO AP 216:2003
Ship Structures
ISO AP 218:2004
Piping
(Plant Spatial Configuration)
ISO AP 227:2001
Cable Trays
ISO AP 227 Edition 2
Parts Library
ISO 13584
Reference Data Libraries
ISO 15926
AP 233 Systems Engineering Data Representation
AP 239 Product Life-cycle Support
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
Computational Fluid Dynamics
ISO AP 237
Ship Structural Envelope (hull form, arrangements, structure)
Distributed Systems (piping, electrical, HVAC, cable trays, mechanical)
Mechanical Systems
HVAC
Logistics/Spares
ISO AP 232:2002
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Finite Element Analysis
ISO AP 209:2001
Automotive
ISO AP 214:2001

25. Roadmap - Future Ship Structural Envelope Distribution Systems
Equipment/Subsystems
Miscellaneous
Ship Arrangement
ISO AP 215:2004
Ship Moulded Forms
ISO AP 216:2003
Ship Structures
ISO AP 218:2004
Piping
(Plant Spatial Configuration)
ISO AP 227:2001
Cable Trays
ISO AP 227 Edition 2
Parts Library
ISO 13584
Reference Data Libraries
ISO 15926
AP 233 Systems Engineering Data Representation
AP 239 Product Life-cycle Support
Ship Product Model Data Exchange
ISO TC 184/SC 4/WG 3
Computational Fluid Dynamics
ISO AP 237
Ship Structural Envelope (hull form, arrangements, structure)
Distributed Systems (piping, electrical, HVAC, cable trays, mechanical)
Mechanical Systems
HVAC
Logistics/Spares
ISO AP 232:2002
Electrical
(Electrotechnical Design & Install)
ISO AP 212:2001
Finite Element Analysis
ISO AP 209:2001
Automotive
ISO AP 214:2001

26. ISE2 Demo Storyboard April 10, 2003
Structural Functional Design
Structural Detailed Design
SafeHull 7a
FlagShip 2 7b 1
IntelliShip 5
Foran 8
CAE 9 3
LEAPS 6
CAM 4
APP
Advanced
Product
Portal
Database Deliverables 19
ST-Viewer 17 15 13
Pipe
Stress
Piping Functional Design
Tribon 16
Tribon
SIMSMART 18 12
Parts Lib
Supplier 14 10 11
Piping Detailed Design
CATIA
CAM
(IPT)
CATIA
AutoCAD

27. ISE Process - Detail Piping Design Demonstration on April 10, 2003
CATIA V5
Tribon M2
ISE

28. ISE Process for Feeding Analysis Programs from Structural Design
Atlantec
TRIBON
Intergraph
ISDP
Intergraph
IntelliShip

29. Common Parts Catalog (CPC) Interfaces
Developed formal information for
CPC parts data
CPC documents
Basis for sharing parts data outside the CPC community
Specification of parts information requirements between Navy and shipbuilders
DONXML repository (in progress)

30. HVAC Demonstration Integrated Shipbuilding Environment Simsmart
Washington DC • October 21, 2004
HVAC Demonstration
Simsmart

31. The ISE Test Ship - TWR 841
This ship is used to locate and retrieve torpedoes and missile drones. It has a maximum payload capacity of 42 long tons which includes the deck cargo plus full liquids, full complement, and normal stores.
This ship was selected because it is in-service, has a complete set of drawings available for distribution, and is:
Approved for Public Release: Distribution Unlimited.
21 Oct. ‘04
3131

32. TWR Walkthrough myShipVi Selective HVAC STEP Export
Utilize ship CAD geometry data where possible
Access ship data in multiple systems
Technology leverages ISE XML schemas
Technology will be deployed on LPD 17-20
TWR
IDE

33. Business Case Concept Design Analysis Initial Design Parts
Contract Design
Teaming Shipyard
Detailed Design
Manufacturing

34. ISE3 Demo Overview Initial HVAC Design (ISDP) Analysis (Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

35. Initial Design – Part 1 CPC CPC Initial HVAC Design (ISDP)
Analysis
(Simsmart ™)
Analysis
(Simsmart ™)
Parts
(CPC)
CPC
Parts
(CPC)
CPC
Detailed
Design
Tool 2
(CATIA)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Analysis
Order Material
Order Material
CPC
Parts (CPC)
Manufacturing
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Parts Catalog
Analysis Tool
Analysis Tool
CAD Tool
CAD Tool
Manufacturing
Manufacturing

36. Initial Design - Part 1 ISDP Analysis (Simsmart ™)
Selective HVAC STEP Export
STEP file
Analysis
(Simsmart ™)
ISDP ISE HVAC
Translator
ISE
XML

37. Initial Design Analysis
Initial HVAC
Design
(ISDP)
Analysis
(Simsmart ™)
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

38. HVAC Design &
Performance Analysis

39. Common Parts Catalog Initial HVAC Design (ISDP) Analysis (Simsmart ™)
(CPC)
Parts
(CPC)
Parts (CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

40. Common Parts Catalog

41. Initial Design – Part 2 Initial HVAC Design (ISDP) Initial HVAC Design
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

42. Initial Design - Part 2 ISDP Detailed Design (TRIBON)
Selective HVAC STEP Export
Updated
Plenum
STEP file
Detailed Design
(TRIBON)
ISDP ISE HVAC
Translator
ISE
XML

43. Importing into Tribon (Atlantec)
Initial HVAC
Design
(ISDP)
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 1
(TRIBON)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

44. Export to Foran (Atlantec)
Initial HVAC
Design
(ISDP)
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

45. Teaming Yard Detailed Design
Initial HVAC
Design
(ISDP)
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

46. Teaming Shipyard Returns Part
FORAN
FORAN TWR’s Preliminary Design (ISE2)
FORAN TWR’s Structural Detailed Design (ISE2)
TWR’s HVAC Detailed Design
ISE3
Selective HVAC STEP Export
FORAN HVAC STEP Export Translator
P21 STEP file
OUTPUT
ISE3

47. Teaming Shipyard Returns Part
FORAN
Database
FORAN
HVAC STEP
Import Translator
ISE3
FORAN
HVAC STEP
Export Translator
P21 STEP file
INPUT
ISE3
OUTPUT
P21 STEP file

48. Import into Tribon Initial HVAC Design (ISDP) Analysis (Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

49. Transfer to Manufacturing
Initial HVAC
Design
(ISDP)
Analysis
(Simsmart ™)
Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

50. Manufacturing Initial HVAC Design (ISDP) Analysis (Simsmart ™) Parts
(CPC)
Parts
(CPC)
Detailed
Design
Tool 2
(CATIA)
Teaming Shipyard
Detailed
Design
(FORAN)
Detailed
Design
Tool 1
(TRIBON)
Analysis
Manufacturing
(EB Sheet Metal)
Order Material
Parts (CPC)
Manufacturing
(EB Sheet Metal)
Legend
demonstrated
discussed
Parts Catalog
Analysis Tool
CAD Tool
Manufacturing

51. Electric Boat HVAC Demo Scenario
CATIA V5
STEP
FILE
Generate
Manufacturing
Parameters
Common
Parts
Catalog
CATIA V4 / CDM
Manufacturing
Process
Manufacture Part

52. EB Manufactures Test Case 4
Revised Duct for Demo
H = 4”
W = 6”
L =12”
ELBOW
H = 4”
W = 6”
Rin = 4”
Rout = 12”
DUCT
H = 4”
W = 6”
L = 86””
TRANSITION
H1 = 4”
W1 = 6”
H2 = 3”
W2 = 12”
L = 12”

53. Return on Investment (ROI)
Professor Alley Butler of the Gulf Coast Region Maritime Technology Center (GCRMTC) and the University of New Orleans is conducting a Return on Investment Analysis as part of the ISE3 Project
Although his study has not yet been completed, the following slides give some early results from his analysis

54. HVAC Data Exchange ROI
Current estimates point to substantial savings in engineering manhours by employing the AP 227 neutral format for porting information to Simsmart
Estimates are incomplete, but analysis is in progress
Part 1 : Flow Analysis
Part 2 : Manufacturing
Additional cost savings are anticipated from manufacturing implementation

55. Estimating Savings from an ISE-3 Implementation
The ISE-3 deliverables for HVAC permit porting of information from most commonly used CAD systems to the Simsmart analysis tool
This capability should save manhours of engineering and designer time
It avoids re-entering data to create the Simsmart models
Time is money. So, how much time and money is saved?

56. HVAC Data Exchange ROI The Cruiser/Destroyer/Frigate Case
Potential Savings are estimated to be
6,903 manhours
$414,162 for one ship design

57. HVAC Data Exchange ROI This preliminary analysis can be extended to:
Other classes of ships (e.g. submarines, carriers)
Additional systems
i.e. for auxiliary systems that are not specifically HVAC, such as engine/generator uptakes
Additional exchange scenarios (such as Manufacturing) should also be included in calculating ROI

58. NIST: Economic Impact Assessment - Product Data Sharing -
The Shipbuilding Industry has the opportunity to realize $147.1M in annual benefits by sharing product data :
$76.4M in cost avoidance
Elimination of redundant design, analysis, and manufacturing systems
Training
IT support
Productivity loss
$70.7M in risk mitigation
Model rework
Manual data re-entry
Delays
Currently, the Shipbuilding Industry is only realizing $25.7M in annual benefits.
Source : Planning Report December 2002

59. Goal : Implement in Production
The ISE Project has developed tools and demonstrated interoperability between shipyards in the areas of:
Structure
Piping
HVAC
Common Parts Catalog Interfaces
The goal of current and future efforts is to make these techniques and tools available in production and to all U.S. shipyards
STEP Shipbuilding Translators
XML Tools
A Website has been established to contain the relevant software tools, schemas, etc. as provided by the ISE Project

60. Summary
ISE3 has successfully demonstrated the potential of standards based data exchange to LEAN design and construction processes for HVAC as ISE1 and ISE2 had done for molded forms, structures and piping.
Two major challenges lie ahead of us:
Commercialization of this technology
Continuing to prototype standards based data exchange in other application areas such as ships arrangements, ships electrical systems, and system engineering

61. Conclusions
In order to increase the availability and lower the price of production ready tools:
The ship owner / operator needs to insist that data be delivered in a system neutral format
The shipbuilder needs to insist that STEP functionality be an integral part of product
The next challenge is to move this technology into the mainstream and that the technology is mature enough to transition into commercial CAD and Product Modeling products

62. Endorsements
The technology works and it is supported by upper management in major U.S. shipyards
"The development and testing of international standards for product data is important to the Shipbuilding industry for interoperablility and data archiving which will enable NAVSEA's "One Shipyard" Concept.”
Dave Whiddon
VP Research, Development & Design
Northrop Grumman Ship Systems
"Electric Boat endorses the development of interoperability tools and the use of international standards for product model exchange in the shipbuilding industry. We feel that these efforts (undertaken under the NSRP ASE Program) will enhance collaboration among U.S. shipyards and foster the Navy's goal of "One Shipyard".
Millard Firebaugh
VP-Innovation and Chief Engineer
Electric Boat Corporation