1. Machinery Systems Arrangement and Integration Process Overview Jeffrey Merlino NSWCCD-SSES 935 05 March 2015 DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.

2. Key Discussion Points Functional Aspects of Machinery Arrangements Design Development Machinery Arrangements Engineering Manager (EM) Roles and Responsibilities Machinery Arrangements Design Process Overview –The 20,000 Foot Level –Equipment Modeling and Cataloging –Machinery Space Arrangements Drawing Development –Concept Development and Visualization Key Machinery Integration Considerations Machinery Arrangements Work Portfolio Machinery Arrangements Capability Next Steps Machinery Arrangements Capabilities Summary NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 2 05 MAR 2015

3. Functional Aspects of Machinery Arrangements Functional aspects of Machinery Arrangements consists of: –Developing the configuration and basic arrangement of machinery spaces –Establishing the orientation of machinery in relation to ship’s geometry, structure and ship protection features –Setting the limiting dimensions for major machinery components –Set dimensions, number and location of machinery spaces –Provisioning for adequate space for operation, maintenance, and repair –Ensuring required separation exists for all vital systems and equipment –Developing initial propulsion shafting and combustion air system concepts NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 3 05 MAR 2015

4. Machinery Arrangements Roles and Responsibilities Functional Responsibility is to SEA 05Z13 –SEA 05Z13 is the Navy’s Technical Authority for shipboard machinery arrangements –Perform life cycle, tech authority, programmatic and engineering support functions on behalf of SEA 05Z13 –SSES 935 is SEA 05Z’s acting Engineering Manager since 2004 Current applicability limited to surface ship non-nuclear –Coverage for subsurface machinery arrangements to be added Principle Role is to develop design products that integrate machinery with other key aspects of a ship’s design NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 4 05 MAR 2015

5. Machinery Arrangements Design Guiding Principles Pre-position arrangements efforts to quickly react to our customer needs Accurately assess the feasibility of machinery systems as part of the Total Ship System Be ready to provide ship integration insight to architecture teams as options are being explored Assess alternatives at the appropriate level of fidelity and substantiate conclusions Provide technical artifacts on time and within budget 05 MAR 2015 NSWCCD-SSES 935 Machinery Systems Arrangements and Integration Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 5

6. Machinery Arrangements Design Process Overview The 20,000 Foot Level View Pre-position our arrangements efforts to be able to quickly react and assess the feasibility of machinery architectures being explored –Requires heavy lifting up front but pays off quickly Be ready to provide ship integration insight to the architecture teams as options are being explored –Arrangements need to be more dog and less tail Assess architecture alternatives at the appropriate level of fidelity and substantiate conclusions –Adequately communicate assumptions and measures Provide technical artifacts on time and within budget –Cost and schedule almost always drive NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 6 05 MAR 2015

7. Machinery Arrangements Design Process Overview Equipment Modeling NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 7 Vendor-Furnished ICDs 3D Model 3D Model Extracts for 2D Ship Fit-up Studies 05 MAR 2015

8. Machinery Arrangements Design Process Overview Equipment Cataloging NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 8 05 MAR 2015

9. Maintain a comprehensive and accurate equipment catalog –About 600 machinery components –Functions as a shopping list during early design & concept development –Extremely valuable asset for a designer to have at his/her disposal –Tailored to support common design and acquisition databases –Linked to critical design attributes Machinery Arrangements Design Process Overview Equipment Cataloging NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 9 05 MAR 2015

10. Machinery Arrangements Design Process Overview Machinery Arrangements Drawing Development Detailed 3-D modeling of machinery spaces –Propulsion and auxiliary system equipment –Ship geometry and structure –Survivability and recoverability –Human Systems Integration NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 10 05 MAR 2015

11. Machinery Arrangements Design Process Overview Machinery Arrangements Drawing Development Provides an affordable substitute to building scale models and mock-ups Equipment access and removal can be demonstrated for all major components Gives the viewer a thorough, interactive vision that can not be obtained in 2-D NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 11 05 MAR 2015

12. Machinery Arrangements Design Process Overview Concept Development and Visualization Provide Concept Development Support to three primary customers –In-house RDT&E Efforts –SEA 05D –Existing Ship Designs Provide quick and accurate assessments based on known equipment configurations Utilizes a “sandbox” assessment approach –Build-up and tear-down options quickly –Global CAD formats that can be easily distributed to stakeholders & collaborators NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 12 05 MAR 2015

13. Machinery Arrangements Design Process Overview Concept Development and Visualization Tools and processes allow us to develop impressive visualizations Visualizations are cut directly from the engineering design drawings Can be used to perform detailed engineering assessments Equipment Visualization of Fuel Cell Technology Alternatives NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 13 05 MAR 2015

14. Machinery Arrangements Design Process Overview Concept Development and Visualization LHD 1 Class Well Deck Overhead Lifting Capability Study NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 14 05 MAR 2015

15. Key Machinery Integration Considerations Considering the Impact on the Total Ship System Thermal Management –Chilled water, seawater, heat-to-air, or some combination Power Conditioning and Energy Storage –Comes with their own sub-system impacts System Control and Monitoring –Local and remote monitoring considerations Maintenance –Special materials and equipment needs OBRPs and Special Stowage –What you’re taking to sea to keep the system operational Cabling, Wiring, and Distributives –Separation between system components –Crossing watertight boundaries NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 15 –Vital versus Non-Vital –Never underestimate the size insulation 05 MAR 2015

16. Key Machinery Integration Considerations Considering the Impact on the Total Ship System Simple Rankine Recovery Cycle Example NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 16 05 MAR 2015

17. Key Machinery Integration Considerations Integration Considerations We Think About Early Exhaust Temperature and Velocity Impacts to mastborne equipment The ship’s IR Signature Lifecycle upgrade potential Boundary layer entrapment Exhaust gas re-ingestion Intake Trunk Size and Location Often driven by engine removal needs NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 17 05 MAR 2015

18. Key Machinery Integration Considerations Integration Considerations We Think About Early Harsh Environments of Shipboard Machinery Spaces –Steady state machinery compartment and uptake space environmentals are some of the harshest aboard Space temps between 40 and 125°F (4 and 52°C) Non-condensing humidity as high as 100 percent Sea water temps between 35 and 95°F (2 and 35°C) Ship Inclinations during Operation –Ship inclinations vary substantially during operation Machinery expected to function throughout a wide range of list, trim and roll combinations Rotating machinery should always be fore and aft NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 18 05 MAR 2015

19. Key Machinery Integration Considerations Integration Considerations We Think About Early The Right Shock Grade for Machinery Systems –Grade A: equipment is essential to the safety and continued combat capability of the ship –Grade B: operation not essential to the safety and combat capability of the ship but could be a hazard to personnel, Grade A items, or the ship as a whole Machinery Noise and Vibration –Prevention during system design –Controlling the source during operation –Resilients require regular maintenance NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 19 05 MAR 2015

20. Key Machinery Integration Considerations Integration Considerations We Think About Early Enclaving or De-centralizing Systems –Thinking in terms of spreading the architecture out into multiple spaces and when that’s appropriate ‘Hatchability’ –Final location of components are often chosen opportunistically –Could be Machinery Spaces, Chimney Spaces, or other compartments –Avoid unnecessary cost and complexity by making something hatchable that doesn’t need to be Leveraging Onboard Systems as much as Possible –The less you bring with you, the better off we all are NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 20 05 MAR 2015

21. Key Machinery Integration Considerations Integration Considerations We Think About Early Integrated Logistics –Never too early to think about good logistics Operational Procedures Technical Manuals Maintenance Planning Alteration and System Drawings Supply Support and Testing Special Purpose Tools and Test Equipment Calibration Onboard Repair Parts School Houses NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 21 05 MAR 2015

22. Machinery Arrangements FY-15 Work Portfolio Workload Summary 05 MAR 2015 NSWCCD-SSES 935 Machinery Systems Arrangements and Integration Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE FY 15 Arrangements Workload Summary –5.0 FTEs of labor in-house in FY 15 4 FTEs supporting arrangements-related workload –0.5 FTE issued to contracted support FY 15 work portfolio breakdown –RDT&E31 % –New Acquisition Support42 % –In-Service Support20 % –Concept Development 5 % –Other 2 % FYA 15 Workload Cornerstones –USMC AAV GTE Filter Prototyping –DDG 51 Production HED Integration –DDG 51 FLT III Preliminary Design –ORP Electrical Arrangements 22

23. Machinery Arrangements Capability Next Steps Arrangements MIL-STD Authorship Machinery Arrangements MIL-STD Authorship –Provides Machinery Arrangements Development Guidance for new ship design efforts Establishes standard design practice for machinery arrangements design Standard’s Emphasis is on design development occurring between Concept Study and Contract Design –Scope limited to Surface Ship Non-Nuclear Designs –Published in Q3 of FY 2014 NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 23 05 MAR 2015

24. Machinery Arrangements Capability Next Steps Automating the Process Explore the development and use of a mathematical method for machinery arrangements design –Standardize and estimate machinery systems equipment interactions –Automate the development of early stage machinery arrangements –Build in maintainability and operability rules –Apply cross product design standards uniformly –Configuration manage the machinery parts catalog 05 MAR 2015 NSWCCD-SSES 935 Machinery Systems Arrangement Design Capabilities INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO THE RESTRICTIONS ON THE COVER PAGE 24