Appendix 1 - DDG 1000 Power Conversion Cabinets.docx

Appendix 1 Overview: The Power Conversion Cabinets (PCCs) are the interface between the DDG 1000’s Class High Voltage 4160 V, 60Hz AC distribution system, and the electrical Ship Service Distribution System (SSDS). The system PCCs also interface with the emergency diesel generators to provide electrical power recovery in the event of a loss of power. The PPCs shall perform power conversion, power distribution, and system isolation to the SSDS. The PCCs are arranged in multiple electrical zones with electrical inputs that maximize survivability and redundancy. The cabinets shall be cooled as required per operating specifications using air or cooling water available on the ship. The primary cooling water is freshwater. The designed cabinets shall be networked together for cabinet to cabinet communication and have an interface for the ship’s machinery control system.

Additionally, the PCCs shall be modular to support multiple electrical bus interfaces and loading parameters, shall be capable of network communications, with control and monitoring interfaces to a machinery and engineering control system, shall provide ground fault detection and isolation; and lastly, must comply with the American Bureau of Shipbuilding/Naval Vessel Rules (ABS/NVR) as well as the requirements outlined in MIL-STD-1399, with particular focus on input and output power.

The five types of PCCs outlined below are provided for informational purposes. The United States Navy is seeking interest from parties capable of designing and manufacturing them.

PCCs:

1. PCC-1 – Provides transformer isolated power conversion and rectification between the High Voltage Power System 4160V, 60Hz AC, and the 1000V DC longitudinal buses on port and starboard. There shall be a minimum of one PCC-1 in each electrical Zone, and it provides power to both port and starboard.

2. PCC-2 – Provides DC to DC power conversion interfaces from the 1000V DC longitudinal bus and outputs 650VDC, 850VDC, 900VDC, and 375VDC power conversion in each Zone. The PCC-2’s also provides power inputs for in-zone PCC-3’s and PCC-4’s (where applicable). There are a minimum of two PCC-2’s in each Zone.

3. PCC-3 – Provides non-isolated power inversion from port and starboard incoming 850V DC buses and outputs 450V, 60Hz AC in each zone through load centers. There shall be a minimum of two PCC-3’s in each Zone.

4. PCC-4 – Provides non-isolated power inversion from port and starboard incoming 900V DC buses and outputs 450V, 60Hz to a single Air Conditioning (A/C) Plant in each zone. There shall be a minimum of one PCC-4 in each of the four electrical zones.

5. PCC-5 – Provides non-isolated power inversion from port and starboard incoming 650V DC buses and outputs 450V, 60Hz AC to three electric motors for the steering system. There are at total of two PCC-5’s on each ship. PCC-5 is a steering machinery motor variable frequency drive that controls multiple motors.

Amplifying information on Ship Service Distribution System (SDSS) Interfaces:

1. AC Load Center (LC) – Distributes 450VAC power from the output of each PCC 2, 3, or 4 to individual loads or downstream power panels. Each LC interfaces to the SSDS through motorized circuit breakers to provide load shedding, and protection of upstream and downstream equipment from the effects of SSDS overloads and short circuit faults. The LCs also provide some level of coordination with downstream circuit breakers. Some LCs are attached to the PCC-3’s enclosure and some are detached. The load centers have communications with associated PCC’s and provide load shed protection for the system.

2. DC Load Center (DCLC) – Distributes 650VDC and 375VDC power from the outputs of each PCC-2 to individual loads or downstream power panels. Each DCLC interfaces to the SSDS through motorized Circuit Breakers to provide load shedding, and protection of upstream and downstream equipment from the effects of SSDS overloads and short circuit faults. The DCLCs also provide some level of coordination with downstream circuit breakers. All 375V LCs are attached to the PCC-2 enclosure and all 650V LCs are detached. The load centers have communications with associated PCC’s and provide load shed protection for the system.

Responses shall provide design maturity information of the PCC hardware, software, and cabinet, the scope of non-recurring engineering expected to meet development, integration, and qualification requirements with a notional schedule.

Responses shall also include information about the Original Equipment Manufacturers (OEMs) ability to provide development engineering and lab testing, and sustainment capabilities such as repairs at their facility.

A fully designed, qualified, and tested prototype product is expected to be delivered by August of 2028 to support production in early fiscal year 2029.