Joe FammeMichel Masse

Chang-min LeeTed Raitch

May 26, 2011r4

ASNE Intelligent Ship Symposium

Elevator SummaryDesign and Operate Systems with the Goals in Mind

Objective Models: Achieve Purposes of User Reduce Manning Human Systems Integration Systems Assurance before Production Reduce TOC, or, Increase Return on Investment (ROI)

Object Models used to Create Objective Models Physics based models of each component of the ship’s hull,

mechanical, electrical and DC systems as “objects” modeled in physics equations

Object is: pump, pipe, valve, generator, SB, motor, wire, diesel engine, GT Engine, tank, control element …

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ASNE Intelligent Ship Symposium

“Objective” Modeling: The Adaptive Lenses1994 - 2011

“Objective” Model Designs to support of Navy Priorities1994: Human Risk Mitigation

Reduce Manning [USS Stark, Roberts, Princeton, Tripoli]

2003: Human Systems IntegrationSingle objective model from design to training /

operational decision aids2009: Performance Validation for Affordability

Dynamic V&V of design before release to production2011: Reduce Total Ownership Costs

Use Cost and ROI as object attributes

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Run-TimeData Trend

CAD ………………..“Does it Fit”?Physics ……………“Does it Work”?

Automation

Analysis

Simultaneous Design & Control

www.ITEinc.US 8

Adjust properties

~85% Standard Navy HME Items

www.ITEinc.US

9Integrated Product Data Environment (IPDE

Drill into Firemain by Deck & Section for compartment model, get

www.ITEinc.US

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Click on Pump “Motor” linkClick on Pump “Motor” link and Open the Associated and Open the Associated Electrical Model, then getElectrical Model, then get

www.ITEinc.US

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See Associated Motor (to right)See Associated Motor (to right) then To switchboard (left)then To switchboard (left)

ASNE Intelligent Ship Symposium

ContentTo Invigorate Discussion on TOCAn Affordable Navy

Early Design Decisions Control CostCommercial vs. Naval Control Systems

Example: Mining EnterpriseOMB Design & Control Reduce TOC

Concurrent Design /Control Systems / TOC reduction Commercial Enterprise (Mine): Objective = $ ROIExample Navy TOC SavingsConclusions

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ASNE Intelligent Ship Symposium

Ms. Stiller (DASN): TOC Reduction

“Design for Affordability” - challenge requirementsContract for Affordability - competitionBuild Affordably - Navy and Industry work together Maintenance and Operational Affordability - explore to reduce TOCAffordability Tools - decision tools focus on overall affordability.Affordable Innovation - tell / show decision makers the return on investment (ROI )Affordable Planning - Strategic planning beyond the FYDP allow industry to make stable

investments

Note: This DASN guidance for cost reduction is a continuation of NAVSEA shipbuilding cost reduction conferences conducted 2007 – 2009, summarized in ASNE Technical Paper, “Performance Based Design for Fleet Affordability,” ASNE Day 2009 – Published in Naval Engineers Journal, 2009 | Vol. 221 No. 4, p.117, copy at www.ITEinc.US, Tab Technical Papers.

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ASNE Event, March 15, 2011

Early Design Decisions Drive Cost

FeasibilityStudies

ContractDesign

Detail Designand Construction

Cost Incurred

Cost (and Performance)“Locked-in”

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NAVSEA Ship Design Panel (SD-8) JHU-APL March 2011

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ASNE Intelligent Ship Symposium

Objective ModelsObjective Model refers to the objective purpose of the model Objective Purpose include:

Operate the plantOperate safelyControl costsMake a profitROIenvironmental compliance

Attributes of Supporting Physics Object Models:Physical Attributes: Size, Weight, PositionPerformance Attributes: Physics Volume, Velocity, Thermal, Watts …Control Attributes: Analog / DigitalTOC Attributes: Cost$, LCC$, MTBF to support ROI Analysis

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ASNE Intelligent Ship Symposium

Object Models “Object” model in physics of each component of the plant or ship’s hull, mechanical, and

DC systems as an “object” modeled in physics equations such as a pump, pipe, valve, motor, wire, diesel engine, tank

Object Model Equation Variables / Attributes include:

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Performance Attributes: Physics Models

Volume, Velocity, Thermal, Watts …

Physical Attributes: Integrated CAD – Physics

Size, Weight, Position …

Control Attributes

TOC Attributes Available, but not used:Cost$, LCC$, MTBF(T) to support ROI Analysis

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Green =Bore levels for ore mapping

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333 mCVM = 333 m long

Mine = 2,100 m deep, 40 Levels

Mine is105 years old

2,1

00 m

ete

rs

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Redundant Computing for Life Safety

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8Calculations solve differential equations simulta neously in a matrix with fast convergence

9Systems account for natural ventilation effect

10Standardized Atkinson resistance and standardized friction factors are corrected for density change

11Dynamic transient calculations permit real-time control

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Compute Return on Investment associated with all capitalization and operation control options and actions

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Compute economic cost and environmental implications, and costs for all control options and actions

14Record and account and report environmental emissions

  Air Flow Mass Balance Calculations

1Calculations are dynamic with transient and steady state response

2Calculations use compressible flow physics

3Calculations account for mass and energy accumulation

4Systems perform a mass flow balance

5Density is variable and is a function of pressure and temperature

6CFM calculations are based on calculated density

7The mass conservation law is applied at every point

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Computed Variable Ops Standard Ops

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Table 3. Design and Lifecycle Phases

Projected Savings Reuse PBDC Models 30 Ships in Class over Life Cycle of 30 Years ($M)

Ship Requirements GivenConcept Design CompletePreliminary Design CompleteAutomation Design Updates - Full Reference Model Avail.

($0.50)

Contract Design CompleteDetail Design CompleteConstruction CompleteTests-Trials - Full reference Model Available as Performance Standard

($1.00)

Training PBD models embedded for Eng.-DC training reduces travel/time lost

($30.00)

Decision Aids PBD models improve efficiency - support CSOSS-EOSS-EOCC

($50.00)

Distance Support PBD models support NAVSEA trouble repair for reduced crews

($60.00)

Modernization Ship-Alts - PBD Ref Models used to pre-validate modernization

($60.00)

Savings per Ship 30 Yr.

($201.50)

Life Cycle Savings: 30 ships in Class ($6,045)

ASNE Intelligent Ship Symposium

ROI estimate for DDG Model

The cost of OMB object and objective design modeling for a class of ships as described in this paper might be in the range of $25M.

The Navy return on investment is in the range of $242 for every $1 of model cost. To be conservative, the estimated cost of building the total ship object model was doubled

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ASNE Intelligent Ship Symposium

Double Equipment Life Reduce TOC 19%

Doubling Equipment “Life” can Reduce TOC 19% A NAVSEA ROI model for the doubling of the life of “parts”

showed a 19% reduction on TOC for the ship program (Strickland, J. at NAVSEA SD-8 Panel, JHU-APL March 2011)

The submarine community seems to have already adopted this strategy to reduce TOC with the Virginia Class.

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Thank You!

Fair Winds and Following Seas!

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Figure 2. OMBC Mining System

PBD =Design

“WORKS”

CAD =Design“FITS”

Common Parts Catalog

Integrate Ship Design Toolswww.NSRP.org (Maritech)

Integrated Shipbuilding Environment

Use the Design Tools

For HSI

SpiralDesign

Process• Conceptual• Preliminary

• Contract• Detail

Achieve HSIobjectives:

•Automation•Reduced Crew•Survivability

•Safety

•Delivera Full Ship

PBD Modelto support

Tests &Trials

Validate ShipSystems & Model

T&Tusing the

PBD model“VirtualShip”BeforeDock& SeaTrials:

All Systems,

Separately&

Together

• Electrical• Fluid• Gas

• HVAC• Controls

T&Tof the

“ActualShip”DuringDock& SeaTrials:

All Systems,

Separately&

Together

• Electrical• Fluid• Gas

• HVAC• Controls

Tests & Trials

Achieving CNO Sea Enterprise ObjectivesTransformational Ship Design Process – Improve Design, Reduce Costs

•The Ship

• Real-timeValidated

PBDModelof theShip

•CADDrawings

• Update allconfiguration

partnumbers

to theERP – TDKM

IPDEPrograms

DeliverTo the Navy

•Shore & Afloat Dynamic Eng/DC

& Total Ship Training

•Real-timeReadiness

Assessmentof ship

& systems

• Engineering &DC Operational

DecisionAids

• DistanceSupport

•Future ShipModernization

Re-use the PBDModel for HSI Objectives of:

Seamless Data ExchangeWith all IPDE Programs

ONR Smart Ship System Design Environment

Physics Based Design (PBD) is a foundation for Navy Sea Enterprise Metrics: verifies systems performance (temp., pres., amps …) and timing.

Will ENSURE that ALL ship systems “work” together and meet ship mission requirements before dock & sea trials.

ITE Inc. 1507A N Colonial Terrace, Arlington,. VA 22209 jfamme@ITEinc.US

Reduce RISK & COST

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Integrated Design•Doctrine•Ship Design•Automation Design•Simulation Based Total Ship-Crew Model•Validate Automation - Reduced Manning

Operational, Threat & Damage Adaptive

•Autonomic (M&S Based) Reconfiguration•Intelligent Agents•Autonomic Response

Security•Access Points•Remote Monitoring

Core Model & SimulationEmbedded M&S Based Training / Decision Aids•Networked BG to Shore•Individual to Total Crew

Simulation Based Acquisition & Operation

•Integrated CAD-Physics Smart Product Model through all design phases, with dock & sea trial model validation, reuse of the validated model that will run in parallel during operations, supporting decision aids, ship wide performance monitoring to support all functions on this slide and future Alts & modernization

Mission Readiness•Local & Network within ship & across Battle Force platforms•Combat Systems•Engineering Systems•Damage Control•Distant Support•EHM & CBM•Electronic Manuals•3D Visualization•Crew Location / Monitoring

Damage Control•Autonomic•Intelligent Agent SW•M&S Based Reconfiguration•Personal On-The Move Displays•Combat Systems•Engineering Systems•Damage Control•Electronic Manuals•3D Visualization

Integrated & Distributed Command Capabilities

•Combat & Engineering Systems•Personal On-Move PDA Communications & Control •Electronic Navigation / M&S Based Decision Aids

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