BQ_028_PPT_HED_Informational_Brief_for_DDG_102.pptx

DDG 51 Hybrid Electric Drive (HED) Backfit Program Informational Brief

DDG 101, 50% IPTD

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

DDG 51 HED Solution

(2) Active Front End Drives HED Switchboard

2550 HP Induction Motor

Reduces fuel consumption in DDG 51 FLT IIA by 4,739 – 5,822 bbls/ship/year

Increases mission effectiveness through longer time on station, fuel efficiency and longer ship range

Improves engineering plant efficiency for DDG 51 class

Significantly reduced GTMs operating hours

Operational Benefits Provides propulsion at 10kts or less without the need for LM2500 main engines

Design is based upon fielded/mature technologies

Technical Details

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Major Components

Motor Motor Drive

SSS Type 120T automatic operating clutch at motor non-drive-end with servo actuated lock-out feature Kop-Flex drive-end flexible disc pack/ quill shaft/shear pin assembly Output shaft speed sensor assembly Grounding brush assembly at drive end

Rugged Enclosure with door mounted HMI Chilled Water Cooled Each of the two (2) frequency converter(s) offered comprises the following assembled modules:

IGBT rectifier (active front end) EMI filter on drive input DC link, pre-charge and braking chopper IGBT inverter Cooling System Control unit(s)

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Drive Cabinet dimensions

6,834 LBS Dry (Each)

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor dimensions 28,500 LBS Dry

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Switchboard dimensions

4,000 LBS

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Ship Location

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Structural – 3 Hull & 1 Interior Blkhd Access Cuts, Removes/Modifies 20 existing foundations, Installs 15 each new Foundations Assemblies, 305SqFt of new Steel Plate, 16Ft of new T-Beams, 320Ft of new Angle Bar & Flat Steel, 94Ft of new Wide Flange Steel Beam

Electrical - Installs 6,391 feet of New Cable (130ft of Fiber) with 76 Electrical Connection points on 38 Cable Assemblies

Piping – Installs new and Modifies existing piping system with 650ft of Cres PPG, 1,147ft of Gage Tubing and 38 valve assemblies. Impacts & Modifies the following Piping Systems: FW & CONT AIR, CHW, FDE. MDW, LP AIR, SW & HYD, FWC & MDW, HYD & HWTR, PROP CONT, LUBO, HALON, BLEED AIR & DRAIN, CCS & DCC WASTE DRAIN, SWC, VCHT, FUEL OIL, FIRE MAIN, AFFF & MDS, PDW, GFA & HYD, GFH & CWD, CAL & CAE, VENT & GAGE BOARD.

HVAC – Removes Existing Vent Duct, Manufactures & Installs 23 New Vent Duck Assemblies

Mechanical – Critical alignment of the HED Motor to the MRG SID Scope of Work

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Material HED Hardware T400 Cables Remaining HED Cables Foundations Max PreFab Kits

LLTM

Balance of Incidental Material for Installation Supplier

HSC

HSC

HSC and/or BIW PY

BIW PY

BIW PY

BIW PY

Installing Yard Material Responsibility

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

1st Plat Highlight

Motor Drive A Install Path Motor Drive A Location

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

2nd Plat Highlight

Motor Drive B and 2SC Switchboard Install Path HED Motor Location Motor Drive B Location 2SC SWBD Location

Motor Install Path

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

2 Shell Cuts on Starboard Side

1st Plan and 2nd Plat

Between Frame 292 and Frame 300

Motor Drive A through 1st Plat Cut

Motor Drive B and Switchboard through 2nd Plat Cut Starboard Shell Cut

FWD

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Starboard Shell Cut

Structural SID 8670349

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

1 Shell Cut on Port Side into SD Storeroom #1

2nd Plat

Between Frame 234 and Frame 245

Motor and Foundations through Shell Cut Port Shell Cut

FWD

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Port Side Rip Out List HED Motor Installation has the following impacts to existing equipment:

Hydraulic Oil Line

Lubricating Oil Line

Oil Motor Controller

Decking around FWD corner of MRG

Terminal Box

Ltg Distro Box

Flow Meter

FWD Bulkhead boxes

2/1/2018 **List is highlights, not exhaustive list of impacts, which are contained in the SIDs

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Structural SID 8670349

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

FIREMAIN

FWD CL

BULKHEAD CUT LOCATION

ANTICIPATED SHELL CUT LOCATION

VIEW ORIENTATION

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Technical Highlights : MRG Spool Piece One time-saving suggestion Install the MRG adapter spool piece at beginning of Avail

HED Motor connects to the MRG through a spool piece

MRG

Spool Piece

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Lubricating oil is required to install PTO

Work isolated to Inboard Lower Intermediate Shaft Forward MRG End Cover. Akin to protecting the gear for an inspection

Once the spool piece is installed, MRG may be buttoned up, and lube oil system secured

HED Motor connects to MRG through a spool piece 2/1/2018

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Installation Side View of Mechanical Interface Post Installation Cut-Shot of Complete Mechanical Interface

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Piping will go under, through, and around new HED Motor foundation

Work must be phased between laying some LO piping, installing the HED Motor foundation, and finishing the remaining LO lines

After spool piece is installed, HED does not require LO during installation

Recommend securing LO, blanking off and flanging existing piping after spool piece installation

Will ensure both MRG and LO systems are secured for remainder of Avail 2/1/2018

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Technical Highlight : MRG Spool Piece Spool Piece gets installed in MRG, and then the Motor is installed

Once Spool Piece is installed, the MRG can remain sealed

Recommend to install at the start of the Avail

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor Foundation

Foundation Prefabricated by BIW Installed on MRG sub-base Machined in place Bolt holes sighted off of MRG reference and drilled Motor installed and aligned Eccentric bushings inserted to allow for tolerance NSWCPD Alignment Procedure by Code 422

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor Foundation

Eccentric Bushings – BIW PreFab

Superbolt – HSC Thick washer – BIW PreFab

Foundation – BIW PreFab Surface Machining - MSR Holes Drilled – MSR

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Electrical Portion

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Electrical Cabling Highlight

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Electrical Cabling Highlight Roll back and reuse New T400 8 new T400 4 each Drive 5 new 2kv Cables 5 new 2kv Cables

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor Drives have

4 x T400 cable inputs (each drive has 4)

5 x LS2KV cable outputs (each drive has 5)

Motor Drive – Roxtec Interface

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor Drive – Roxtec Interface

Roxtec parts are provided by HSC

Each Motor Drive has 4 input and 5 output cables

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor Drive – Electrical Connections

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Major Cables

10 x LS2KV power cables

Minor Cables

Aux power

Serial interface

Encoder signal Motor – Electrical Connections

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Motor – Electrical Connections

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Electrical Switchboard Cabling

2SC HED SWBD

Retain existing cables 12 new T400 cables 2/1/2018

Remove and replace short end of existing 2SA-3SA Bus Tie cables from the 2SA SWBD.

NSWCPD Switchboard Installation Procedure by Code 429

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Pre-Availability

Configuration checks

Establish baseline

Dockside

Validate installation

At-Sea

Post Avail performance measures Hybrid Electric Drive – Testing Plan

3 Phases of Testing

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

HED – Availability Dockside Testing

HED Test POC – (Gianfranco) John Buonamici

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Extra Slides - Backup

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

LS2KVTSGSG-400 Cable Spec

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Concern:

Potential damage to MRG isolators due to the preheat mounting surface of the MRG subbase adjacent to existing Inbd/Fwd Isolator to prepare HY-80 plating for rip-out of existing adjacent items & weldment of HED-EPS foundation.

It is not recommended to remove a vertical isolator from the MRG as a welding heat prevention. Removing the isolator will impact MRG, shaft bearing alignment, and MRG snubber installation. Reestablishing isolator compression values, thermal offsets, and snubber clearances, can turn into a long tedious process. It is expected that weld pre-heat and in-process welding temperature can be managed to avoid removing an isolator.

MRG Work Concern

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative Use) (01/07/2016). Other requests shall be referred to SEA21 PMS 407

Acronyms

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