Development of High Temperature Insulated Bus Pipe (HTIBP) for High Energy Naval Systems A Path Forward Plan – Update Rick Worth/NSWCPD, Code 322 May 10, 2016 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Overview/Summary: • High Temperature Insulated Bus Pipe (HTIBP) is a rigid, high voltage distribution product that has been in use in Foreign Navy and Commercial Cruise Ships – Inner solid copper core or aluminum conductor surrounded by an epoxy resin encased by stainless steel shell that is touch safe – Capable of distributing power at greater densities than conventional cable technologies • Initially, in FY 2005, PMS 378 tasked NSWCPD, Code 322 to evaluate HTIBP products for future CVN shipboard use – Samples from 2 vendors failed Navy 3 hour Gas Flame Circuit Integrity (GFCI) testing (FY 2005) – Technical challenges and risk proved too great and project put on hold – Subsequently, RFI, SBIR, NSRP Special Project (FY 2009-2013) further investigated HTIBP • In FY14/15, Tefelen GmbH, developed a 3 and 1 phase HTIBP product (using higher temperature insulation) – 3 phase passed 3 hour GFCI test Nov 2014, Single phase HTIBP sample passed June 2015 ‒ L3 Reps in discussion wiith Tefelen to Set up a plan to build US HTIBP production facility late 2016 – NSWCPD reps in discussion with SEA 05Z TWH to finalize HTIBP Navy cert test program DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
Connecting Methods for 2 or more HTIBP Sections Standard Bolted Connection Flexible Welded Connection Rigid Welded Connection
Electrical Energy Demands of Future Combatants • Established trend of ever increasing electrical power requirements – Hybrid Ship Propulsion utilizes electrical energy as a conversion medium – Directed Energy Weapons utilize electrical power vice explosive propellants – Increased surveillance capability needs result in higher electrical power requirements – EMALS allows for sophisticated launch control, uses electrical power vice steam Increased Electrical Requirements result in challenges to distribute Electrical Power
IBP Benefits vice Cabling • Inherently supports modular construction • Single HTIBP would replace multiple paralleled cables in high current (1000 amps and higher) at medium voltages (4 kV and higher) • Arrangements benefits (less termination space, tighter bend radius, no tangle-box) • Improved reliability/life resulting in lower maintenance costs • Ship ALTS / modification savings (no cable re-pull or splices) • Supports a broad range of applications such as surface ships, submarines and weapons systems • Improved survivability (improved blast/fragmentation, flame integrity and emergency repair) • Size and weight reductions
Space Savings of Cable versus IBP (From Royal Navy CVF Report) 525mm 250 500mm 600 mm 7 – 8 cables per phase for 11 kV at 4000 Amps per phase. Therefore space of saving of 1.12 m² representing a 42 % difference.
Interested Shipyards • GD - Bath Iron Works • HII - Newport News • GD - Electric Boat • HII - Ingalls • Bollinger • GD - NASSCO
Potential Stakeholders for HTIBP • NAVSEA 05Z Technical Warrant • PMS-320 (AC and DC) • HII Ingalls shipbuilding – (7.7 kV AC) • Bath Iron Works – (4160 Vac) • PEO IWS (1000 V DC) • PMS 405 Directed Energy Weapons (1000 V DC) • NSRP Program Manager/Executive Control Board • NSRP Electrical Technology Panel
Background: • In October 2004, PMS-378 tasked NAVSSES Code 982 to evaluate commercial Insulated Buspipe (IBP) products from two foreign vendors. Testing that was performed in FY 2005 provided good results with the exception of flame / heat resistance. The samples failed to pass the Naval 3 hour Gas flame Circuit Integrity (GFCI) test. • An SBIR was funded beginning in FY 2007 to develop IBP using high temperature (HT) insulation (N07-201, UniTech LLC). A polyamide resin developed by NASA called RP-46 was used as the insulation material. RP-46 Insulation curing issues are still unresolved. UniTech LLC completed Phase II without positive results. The SBIR Project has not been extended at this time. • In FY11 a NSRP Panel Project called ‘Insulated Bus Pipe Installation Methods’ was completed. A follow on NSRP Special Project was initiated to identify potential HTIBP vendors. With no vendors ready to produce ‘production’ level parts, this special project was cancelled.
Background (cont): • Subsequently in early 2014, ONR 33 and NSRP provided NSWCPD, Code 322 funding to identify and investigate other vendor’s products and to perform testing on any promising products identified. • A German company (with a manufacturing facility underway in the US) called Tefelen GmbH has a 3 phase IBP product that uses high temperature insulation. They also manufacture a single phase IBP, but at that time was not high temperature rated. • Tefelen shipped a high temperature rated 3 phase IBP to the Navy for 3 hour GFCI testing. It passed the GFCI test on November 18, 2014. Based on the success of that test, Tefelen developed and shipped a single phase high temperature IBP sample for additional GFCI testing • Tefelen shipped the 1 phase sample to Aero Nav labs in College Point, NY on June 4 , 2015. NSWCCD was funded by National Ship Research Program (NSRP) to perform Navy 3 hour GFCI testing on the 3 phase Tefelen provided sample. The 3 hour GFCI test was performed on June 5, 2015. It successfully passed this test.
GFCI Testing: • The Navy 3 Hour GFCI test plan was followed for this testing in June 2015 at AeroNav Lab in College Point, NY. • A 24” ribbon burner was placed across the three phases of the Tefefen sample. A Hi- pot was used to provide the 8 kV to the center terminal, while the outer two terminals were connected to the return ground of the Hi-pot. The leakage current was monitored by the meter on the Hi-pot and cannot exceed 250mA.. • Since the sample was open ended, the only current is a small leakage current that is determined by the capacitance of the sample. The leakage current never Figure 1: Set up showing 1 Phase HTIBP exceeded 10 mA. It Passed sample, Gas piping, and electrical connections.
Summary of FY14/15 Effort: • Owing to the success of this 1 phase Tefelen HTIBP sample in this flame test, Tefelen is presently in discussions with ATK in West Virginia to set up a production facility in early 2016. Two Tefelen Single Phase HTIBP (White) Tefelen HTIBP Connecting Tube rated at 15 kV at 1300 Amps. And one prepared for GFCI Testing 600 V rated at 1300 amps (Black ) • In addition to that testing, a full HTIBP qualification test program will be prepared and presented to the NAVSEA electrical tech warrant holder for concurrence. A NSRP/PEO Ships/PMS-320 effort will be proposed to fund this effort.
Initial Recommended Path to Implementation (Part 1 of proposed NSRP/PEO Ships Program) • Perform Navy 3 Hour Gas Flame Circuit Integrity Test on Telefen HTIBP samples • AeroNav Labs under contract to perform 3 hour GFCI test in June 2015 - 6 Month Effort WAS COMPLETED • Material Qualification – Proposed to PMS-320 • Test requirements proposed by NSWCPD for review and approval by SEA 05Z TWH (G. Blalock) – 1 Year Effort • LBES installation / test • DDG-1000 application proposed between switchboard and harmonic filters of AIM motor. – 6 Month Effort • Final qualification test would be DDG 1002
Parallel Part 2 Effort to HTIBP Qualification Testing • Rigorous Business Case for US Navy applications – Design approach is different – Material cost is likely higher • Connection Techniques need to be investigated and proven Navy Ship Board Ready • Design and build practices need to be established • Specifications and installation methods need to be matured – Develop requirements for DC systems in parallel • Need to establish standard parts approach – Avoid unique parts for each builder / ship class • Need to characterize maintenance requirements • Limited modifications by shipbuilder • Need to mature manufacturing base (Tefelen/ATK marketing product to Power Utilities to harden substations – Navy will not be the only customer)
Backup Slides
Ship Use of IBP Technology Use is becoming common in Military and Commercial ships
Challenges IBP Resolves • Power Cables become large and unwieldy – High Power circuits require multiple conductors – Dangerous and time consuming to install / connect – Bend radii are large, compartments are dedicated to changing direction • Insulated Bus Pipe – Accepted to reduce weight and space claims – Can be installed as part of blocks/modules and then connected – Turns are prefabricated, thus small radii are possible
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