Next Generation Power and Energy

EXPONAVAL 2010
02 December 2010
Valparaiso, Chile
CAPT Lynn Petersen
Deputy Director
PMS 320 (ESO)
(ESO)
(Presented by: Dr. Peter Cho
ONR Global)

Distribution A: Cleared for Public Release

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Outline SHIPS

• Brief History of Navy Electric Drive

• Challenges/Opportunities
• Next Generation Integrated Power System
• Open Architecture Business Model
• Intelligent Ship/Power Dense Technologies
• Hybrid Electric Drive (HED)

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Electric Drive SHIPS

USS Langley
Recommissioned 1922
- First US Aircraft Carrier -

USS Jupiter
Commissioned 1913
- Collier -

Distribution A: Cleared for Public Release 3

 Today’s Integrated Electric Ships

PLATFORM RESULTS
Amphibious Assault (LHD 8)
 The first U.S. Navy amphibious ship built with Gas Turbine
Engines and Hybrid Electric Drive resulting in significant fuel
savings compared with steam driven LHD

Combat Logistics Force (T-AKE)

 T-AKE is powered by a commercial integrated power system,
providing reduced acquisition and life cycle costs

Surface Combatant (DDG 1000)

 ZUMWALT’s Integrated Power System (IPS) combines 78MW
of installed power generation for propulsion and ship service
into a single unified electrical system.

Meeting the Mission with Increased Power and Reduced Costs

ASNE CAPS Brief Oct 2010 Distribution Statement A: Approved for public release
 Other Naval Trends…

UK (23 + IPS/hybrid ships) France

 Type 23 Frigate, in-service –  BPC (LPD) in-service,
hybrid electric/mechanical drive Podded Integrated Power System
 Type 45 Destroyer, in-service –  Future CV in design –
full Integrated Power System full IPS, maybe Pods
 Albion Class LPD, in-service –
full Integrated Power System
 Wave Class Oiler, in-service –
full Integrated Power System
 CV(F) under contract –
full Integrated Power System

Netherlands (2 ships) France, Italy, Greece,

 LPD “Rotterdam” Class, in-service Morrocco
– full Integrated Power System  FREMM Frigate – Hybrid Drive
 IPS declared for future surface (28 planned, 4 under construction)
combatants

Germany Australia (2 ships)

 U-212 Submarines  Canberra Class LPD - Podded IPS
- Diesel Electric w/ PM Motors  Collins Class SSG - diesel-electric
- AIP systems using fuel cells

All diesel submarines are electric drive

…many other Navies interested

ASNE CAPS Brief Oct 2010 Distribution Statement A: Approved for public release
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Our Challenges SHIPS

 Reduce Fuel Dependency

 Greater Demands for Power

 Control Costs

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… Also The Challenge of New
Technology SHIPS

Design and
Begin Technology Deliver
Concept Start Ship Surface Deliver Deliver
Design Selection Construction Ship Sub Carrier

Ship Schedule
8 years
10 years
12 years
Advanced
Development
Models Qualification

Research Engineering or
(Science & Full Scale
Technology) Models

To Reduce Risk and Costs, Engineering Development

Models Must Precede “Design and Technology Selection”
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How Do We Meet Our Challenges SHIPS

 Fleet-wide Analysis of Demand

 Early Investment in Technology

 Integrated System Demonstrations

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Navy Fuel Usage and Trends SHIPS

PRICE TRENDS VS
FY07 DON Fuel Usage NAVY SHIP / AIRCRAFT CONSUMPTION
(38.8 Million Barrels)
1% Shore
Non-Tactical Vehicles
X
7% Price 400

Tactical Vehicles AIRCRAFT

10% Ships

# ships & aircraft (x10)

350

40%
Aviation X
300

42% SHIPS

250

2020
1% AS
5%
5% LPD
1% LCC LSD

Expected FY09 fuel bill: $5.3B

40%
11% DDG
Per bbl cost +400% since FY03
LHD
6% CV • Energy (fuel) demand will increase
9% 18% • Combat / Weapons power
FFG CG • Force Structure changing – Higher fuel consumption
• Operational requirements
• Fuel cost uncertainty – Probably
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Support High Power Mission Systems SHIPS

Deployed
Increasing Power Demands
Mission 2014 2014 2016 2020 2020+
Capability

0.4 MW 0.4 MW 2 MW 30 MW 20 MW
Weapon
System
Development
TRL=6 Active
Denial
System

Weapon Laser Weapon System

Development Solid State
TRL=4/5 Laser
System

Technology Electro-
Development Magnetic Free Electron
TRL=3/4 Power
Power Demands
Demands per
per Mount
Mount Launch Laser System
Multiple
Multiple Mounts
Mounts per
per ship
ship Rail Gun

Sensor and Weapons Power Demands will

Rival Propulsion Power Demands

April 2009
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 Integrated, Large Scale System PEO

Demonstrations: Electric Ship INP SHIPS

POWER SYSTEM ELECTRIC WEAPONS

NGIPS
Technology High Power Weapons
Development & Sensors
Roadmap Integrated Support
Systems

Operating and Acquisition Cost

Support Cost Game Changer
Game Changer

Electric Ship Prototype

Innovation Naval Prototype

NEXT GENERATION INTEGRATED POWER IS KEY ENABLER OF FUEL

EFFICIENCY AND ADVANCED WEAPON SYSTEMS
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Outline SHIPS

• Brief History of Navy Electric Drive

• Challenges/Opportunities
• Next Generation Integrated Power System
• Open Architecture Business Model
• Intelligent Ship/Power Dense Technologies
• Hybrid Electric Drive (HED)

Distribution A: Cleared for Public Release 12

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ASN(RD&A) Letter
Establishing the Electric Ships Office / 13 Nov 2007 SHIPS

“I direct the Program Executive

Officer (PEO) Ships to establish an
Electric Ships Office to assume
responsibility for developing and
executing an integrated power
system (IPS) technology
development and transition plan.”

Message: Develop and Execute NGIPS Technology

Development Roadmap

Distribution A: Cleared for Public Release 13

 Next Generation Integrated Power System (NGIPS)
Technology Development Roadmap (TDR)
Roadmap defines path for NGIPS
development, provides guidance to Navy
and industry developing organizations and
forms the basis for coordinated planning
and future Navy investments Med. Voltage DC
(MVDC) Systems

Medium Voltage, Medium

Frequency (MVMF) Systems
Power Density

Medium Voltage AC FSC ?

(MVAC) Systems DDG(X)?
Submarines? LCS(X)?
JHSV?
Low Voltage AC T-AGOS(X)?
(LVAC) Systems DDG 51 Flt III?

T-AKE 1 CVN 78
DDG 1000 LHD(8)
LHA(R) MLP
DDG 51 Flt III?
DDG 51 Flt IIA
Virginia

Navy Now Next Navy Navy After Next

“Directing the Future of Ship’s Power”
ASNE CAPS Brief Oct 2010 Distribution Statement A: Approved for public release
 Shipboard Power &
Propulsion Systems

Steam
Older ships were Reduction Steam Generator
Gear Turbine
Turbine Boiler(s) Fuel
‘integrated’ on the To Ship
Service
steam side Loads
Feed
Condenser Pump

Prime
Generator Mover
‘Integration’ was lost
To Ship
when we transitioned to Reduction Prime Service
internal combustion Gear Mover Loads
Prime
engines Generator Mover

IPS brings back ‘integration’ on

Main Power
the electrical side, enabled by:
Propulsion Motor Distribution Prime
 Solid State Power Electronics Motor Drive
Generator
Mover
 Multi-Megawatt Motor Drives
 Automated Controls
Power Ship
Conversion Service
Module Power
ASNE CAPS Brief Oct 2010 Distribution Statement A: Approved for public release
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Open Architecture Business Model

SHIPS

Navy Controls NGIPS Architecture and Interfaces;

‘What Pieces Will Be Needed and How They Fit Together’

Integrated Power
Architecture (IPA)
Power Distribution Power Conversion
Power Generation
Mission Systems
Ship’s Power Sources

System Control Power Load Energy Storage Propulsion

Industry Competes for

Components;
‘Submit Proposals for Their Piece
of the Puzzle’

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 PEO

Outline SHIPS

• Brief History of Navy Electric Drive

• Challenges/Opportunities
• Next Generation Integrated Power System
• Open Architecture Business Model
• Intelligent Ship/Power Dense Technologies
• Hybrid Electric Drive (HED)

Distribution A: Cleared for Public Release 17

 Technology Development Overview PEO

( ONR Advanced Naval Power ) SHIPS

Motors & Heat Transfer,

Actuators Energy Storage
Thermal Mgmt
Motors Batteries
High Waste Heat
Actuators Flux Removal Capacitors
Electro-Mechanical Adv. Chiller Flywheels
Devices Technologies / HVAC
Power
Generation
Fuel Cells Power Distribution Power
Conversion
Distribution
Advanced
Power Generation
& Control
Generators Architecture
Direct Conversion System Control Power Load Energy Storage Switching &
Photovoltaics Conditioning
Future Fuels

ONR Maintaining Robust S&T Investment

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Intelligent Ship/Power Dense Technologies: Compact Power Conversion
Power Conversion Module/ Power Control Module
SHIPS

Objectives
 Develop motor drive topology and
[EPE – 08-07] components that lead to a 2-3X increase
in power density (to 2-3 MVA/m3), a
reduction in harmonic distortion from ~9%
to <1%, and an increase in efficiency from
94% to 98%, i.e., a 2X reduction in thermal
Power In losses.
Power
Power Sensors
Sensors
AAtotoDD  Develop a high power density bi-
directional PCM that interfaces to energy
Filter Conv. .
Conv
Filter
0.01..0.1 s 1..10 s 10..1000 s 1 . . . 1000 ms
System

storage modules, enabling wider system

Power Gate Inner Load System
Power Gate Modulator Inner Load Level
Driver Modulator Controller Level
Module
Module Driver Loop
Loop Controller Controller
Controller

Power
Power
Filter
Filter
Sensors
Sensors
AAtotoDD
Conv.
Conv. usage of installed energy storage with an
Sensors
Sensors
AAtotoDD
Conv.
Conv. Integrated Power System.
System Action

analog digital  Develop a power management controller

S&T Products that will provide ~2x increase in whole
• Large scale demonstration of multifunction system dynamic reaction time and power
converter in FY 2011 partitioning from propulsion to ship
• Large scale demonstration of bi-directional service & weapons loads in <x ms.
power converter in FY 2011
• Large scale demonstration of power
management controller in FY 2012

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Intelligent Ship/Power Dense Technologies: Solid State Power
Substation: SHIPS
Power Conversion Module

Solid State Power Substation (SSPS) Program

• DARPA, ONR, PEO-Carriers, ESO
• Phase III in progress (6/2007- 6/2010)
• Team: GE, Cree, Powerex, LANL, IAP, GD-EB
Goal
• Compact, light-weight replacement for 2.7 MVA,
13.8 kV/ 465 Vac, 60 Hz iron-core transformers
• ~3X improvement in weight
• Demonstrate high voltage, high frequency
electronic power conversion (10 kV @ 20 kHz)

Status
• SSPS building block tested to full power at GE
• Navy testing completed at NSWC (Phila. LBES)
from October 2010
Enabling technology for other applications: radar power, MVDC circuit breakers
Reduction in SiC prices will open up large commercial markets!
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Intelligent Ship/Power Dense Technologies:
Adaptive Automation for Control SHIPS

Requirement Capability
• Battlespace Situational Awareness • Faster Time to Optimal Decision
• Ship Capability Awareness • Cognitive Decision Aids
• Ship Systems Situational Awareness • Situational Awareness
• Resident Instantiated Modeling • Faster Time to Optimal Action
• Shipboard to enable Real Time Analysis • Autonomous/Reflexive Operations
• Predictive Performance based on Condition
and Context (mission)
• Increased Survivability
• Pre-Hit Reconfiguration
System Of Systems • Increased Recoverability
Functional • Service Restoration
Models • Damage Mitigation
Total Ship Software Model • Reduced Cost
• Reduced Watchstanding
Physics Based Models
• Reduced Maintenance

Enables Enables
Predictive and Adaptive
Machinery Monitoring and Control
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Intelligent Ship/Power Dense Technologies:
Diagnostics, Prognostics and Self Healing SHIPS
Control

Technical Objectives: S&T Challenges

Develop technologies to address incipient fault detection,
fault accommodation and self-healing of electric drive • Identification of practical and cost effective
systems failure precursor features and methods
Provide automated integration between the PHM • Determination of failure precursors directly linked
technologies and fault accommodation / self healing
approaches to failure progression
Demonstrate the developed technologies in a realistic • Development of dynamic fault accommodation
hardware-in-the-loop test bed and with actual component strategies
faults/data
• Development of physics-based failure
Provide a logical path for technology transition in a ship
systems application in Phase II and Phase III progression modeling
commercialization

Deliverables and Schedule

Distribution A: Cleared for Public Release

When is an IGBT Going to Fail?
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Power Generation: Fuel Cells
(Power Generation Module) SHIPS

 Many Advantages
– Highly Efficient (35-60%)
– No Dedicated intakes-
uptakes; use ventilation
 Challenges
– Reforming Fuel into
Hydrogen – Onboard
Chemical Plant.
– Eliminating Sulfur from
fuels.
– Slow Dynamic Response –
Requires Energy storage to
balance generation and
load
– Slow Startup – Best used
for base-loads
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Motors and Actuators:
( Propulsion Motor Module) SHIPS

 Permanent Magnetic Motor (PMM)

– Load testing completed June 08
 Full power on one stator ring (18MW)
– No plans for additional testing

 High Temperature
Superconducting Motor (HTS)
– Full Power Testing Complete
(December 08)
– Motor Achieved Design Rated
Torque @ Rated Speed for 36.5
MW!

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Outline SHIPS

• Brief History of Navy Electric Drive

• Challenges/Opportunities
• Next Generation Integrated Power System
• Open Architecture Business Model
• Intelligent Ship/Power Dense Technologies
• Hybrid Electric Drive (HED)

Distribution A: Cleared for Public Release 25

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Hybrid Electric Drive (HED)
(for DDG-51 Flt IIA )Background SHIPS

 NAVSEA 21 sponsored HED industry studies and Navy

Trade Space Analysis for DDG 51 Class fuel economy

 NAVSEA Congressional Adds to design, build & test a

HED proof of concept system to be demonstrated at
Navy Land Based Engineering Site
Hybrid Electric Drive (HED) ERM
attached to Main Reduction Gear
 Leveraging ONR investments in shipboard energy
storage and dynamic controls to be demonstrated at
LBES (NSWC Philadelphia)

 Hybrid Electric Drive established as a top-priority

for the Navy's energy task force to demonstrate the
capability at the Navy's Land Based Engineering
Site (Philadelphia, PA) in 2011 and at-sea in a DDG- Shipboard Energy Storage

51 Class ship in 2012.

for Single Generator Operations

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Fuel Efficiency Technology Enablers SHIPS

Increased Risk & Fuel Economy Payoff

Hybrid Electric Drive & Energy Storage improves energy efficiency of

in service surface combatant power plants
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ONR SWAMPWORKS: Enabler For Hybrid Electric Drive

SHIPS

ONR investigated feasibility and conducted technical assessment of energy

saving alternatives through BAA 07-029
Shipboard Energy Storage Hybrid Drive Dynamic Controls

Gearbox
Main

PTO
Energy
M/G Storage
Connection to
Ship Service
Bus
Connection to
Electric Drive / Ship Service
PDSS / Bus
Energy M/G

PTO
Storage Energy
Storage

Gearbox
Systems

Main
• Energy storage enhances hybrid drive
• Hybrid drive dynamic analysis ensures
savings & enables single generator ops
power quality capability and control
• Eliminates “Dark Ship” condition
• Develop and de-risk control approaches
• De-Risks future Next Generation
to address DDG-51 Machinery Control
Integrated Power System Energy Storage
System requirements
Modules

ENERGY STORAGE INTEGRATED INTO THE HYBRID ELECTRIC DRIVE SYSTEM

PROVIDES THE GREATEST FUEL SAVINGS For NAVY SHIPS
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Conclusion SHIPS

“Valley of Death”

Power Distribution Power

Power Generation Conversion

System Control Power Load Energy Storage

Questions?
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