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LHD 8: a Step Toward the All Electric Warship

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LHD 8: a Step Toward the All Electric Warship Thomas Dalton, Abe Boughner, C. David Mako and Cdr. Norbert Doerry, USN LHD 8: A Step Toward the All Electric Warship ABSTRACT (Figure 1) are designed to support Marine Corps air and amphibious assaults against The recently commissioned Iwo Jima defended positions ashore. The propulsion (LHD 7) is the last ship with plant for the first seven ships of the Wasp conventional steam propulsion that class consists of two independent steam the U.S. Navy plans to build. The boilers and two 35,000 hp steam turbine LHD 8 is the next ship of the class engines capable of driving the ship at over and will be built as a modified repeat 20 knots. This basic steam propulsion design of the LHD 7. The key approach was adopted from the earlier, circa modifications are steam propulsion 1960’s, steam propulsion plant of the being replaced with a hybrid Tarawa (LHA 1) class. In the early 1990s propulsion system of main gas turbine the U.S. Navy made a general decision to engines augmented with auxiliary phase out conventionally powered steam propulsion motors and electric ships due to the high cost of maintenance powered auxiliaries replacing those and manning. During construction of the powered by steam. The LHD 8 will LHD 5, 6 & 7, the Navy conducted a global also be the first USN surface ship to search to replace the steam plant with implement a 4160 VAC Zonal alternative power systems. At that time a Electrical Distribution System (AC General Electric LM2500 gas turbine engine ZEDS) as well as the integrated (25,000 hp) was the only gas turbine engine power system concept for electrical qualified for propulsion of U.S. Navy ships power generation, distribution and and inadequate by itself to replace a 35,000 propulsion. These modifications hp steam turbine plant. embody the intent of the all electric warship concept for the future U.S. Navy. This paper presents the constraints and issues involved in the design process by addressing major design impacts and significant design concerns. This text explores the design options within the available trade space and illustrates specifically how the fleet / mission requirements, LHD 7 hull design and propulsion shafting constraints, schedule and funding drove the propulsion system design. FIGURE 1 - Amphibious Assault Ship (LHD 2 – Essex) INTRODUCTION Because gas turbine engine ducting must be routed through the island structure, gas The 40,500 ton 844 ft ships of the Wasp turbine propulsion for an LHD requires a (LHD 1) class of amphibious assault ships tremendous amount of internal volume that manufacturing lead time needed to support may displace equipment in many existing the ship construction schedule spaces. Studies have shown that although - No Marine Corps missions could be two gas turbine engines per shaft would degraded provide ample power, they would not fit in - Minimize the impact to adjacent non- the existing machinery spaces without major machinery spaces impacts to the surrounding spaces and the - Allow only reasonable machinery engine ducting would severely impact the arrangement changes ship arrangements. With commercial development of the General Electric The amphibious assault ship operating LM2500+ gas turbine engine (35,000 hp), it profile is such that over 75 % of the became conceivable to fit a single gas underway time the ship requires less than turbine engine into a LHD at power levels 10,000 hp for propulsion to travel at speeds comparable to the steam turbine plant it up to twelve knots. Because a single 35,000 would replace. Although conceptual studies hp gas turbine engine is lightly loaded at this were conducted to fit LHD 7 with one power level, the specific fuel consumption LM2500+ gas turbine engine per shaft, the of a gas turbine plant is very unattractive ship was too far into construction to make and well off its most fuel-efficient design such a major change. Accordingly, Iwo point over much of the ship's operating Jima (LHD 7) is the last ship in the U.S. profile. Although these feasibility studies Navy to be built with a conventional steam were not predicated on supplementing the plant and LHD 8 will be the first ship in the gas turbine engines with an electric U.S. Navy to use an LM2500+ gas turbine. propulsion system, their analysis did indicate that significant fuel savings could PROPULSION PLANT be realized by augmenting the gas turbine DESIGN HISTORY propulsion with electric propulsion. As a result, propulsion motors were integrated with the gas turbine engines at a relatively In preparation for the design and modest 1600 hp per shaft, which is capable construction of LHD 8, the U.S. Navy of driving the ship to roughly six knots initiated a series of feasibility studies under ideal wind and sea conditions. (References 1 and 2) aimed at developing a Another recommendation from these studies gas turbine propulsion concept and reducing was to retain a small auxiliary boiler for Total Ownership Costs (TOC) over the heating and hotel services. This design expected 40 year service life of the ship. feature ensured that the 450 VAC electric Early results of this study showed that TOC plant would essentially be maintained at could be drastically reduced simply through roughly the same size as previous ships in the predicted reduction in crew size of at the class by simply replacing the same least 80 personnel and decreased number of steam turbine generators with maintenance requirements associated with diesel generators of comparable power level the removal of steam turbine engines and and density. Although the TOC savings boilers. To minimize design and were sufficient to justify the conversion to construction costs, a number of constraints gas turbine propulsion in manpower and were placed on the design: maintenance reductions alone without - Maintain the existing shaft line rake and electric propulsion, the addition of an skew of the steam propulsion plant to retain electric propulsion system enhanced those the same Wasp (LHD 1) class hull savings. hydrodynamic characteristics - Limit design changes to the second stage The design concept for the LHD 8 was of the reduction gear to maintain the further refined to totally eliminate all shipboard steam heating for spaces, laundry, cooking and other hotel services, resulting in PROPULSION PLANT a greatly increased electric plant capacity. DESIGN Consequently, the generation and distribution system voltage was increased to The propulsion system for each of the two 4160 VAC to meet the additional load shafts of the LHD 8 consists of a single demand for electric heating on a cold day. main gas turbine engine (LM2500+ at With the removal of the steam auxiliaries, 35,000 hp) and an auxiliary propulsion the worst case load demand changed from a 0 motor (5000 hp) driving a two-stage mission scenario of debarking on a 90 F 0 reduction gear into a controllable pitch day to a cruise condition on a 10 F day. It propeller (CPP) (Figures 3 and 4). The gas was then realized that the ship had as much turbine engines drive the reduction gear as 8 MW of excess generating capacity 0 through an overrunning self-synchronizing under typical climatic conditions of a 70 F clutch. The first stage reduction gear casing day (Figure 2). is modified from the LHD 7 design to accept the single gas turbine engine and propulsion All Conditions Total Load Composite motor input, in lieu of the high and low 17000.0 pressure steam turbine engines. The single 15000.0 gas turbine engine input pinion splits into two locked power train drives. The 13000.0 Anchor propulsion motor drives through a self- Cruise 11000.0 Debark synchronizing clutch into one of the two kW Shore 9000.0 locked train first stage reduction gears. The 7000.0 existing shaft rake and skew were retained and modifications to the second stage 5000.0 reduction gear have been minimized to only 3000.0 that necessary to fit the CPP hydraulic oil 90 Degree 78 Degree 65 Degree 40 Degree 10 Degree distribution box. The length of the gas Temperature turbine engine module in the machinery rooms required moving the reduction gear FIGURE 2 - Predicted LHD 8 ship service several feet aft from the prior ship design power demand loading curves location. This was beneficial since it without anticipated service life load growth eliminated one section of line shafting. margin While the reduction gear ratios for the gas This excess capacity could support electric turbine engines and propulsion motors are propulsion considerably larger than the 1600 identical, the maximum shaft speed of 180 hp propulsion motors originally planned rpm from the gas turbine engine is twice that anytime it was warmer than the extreme from the propulsion motor at 90 rpm. design condition of a 100 F day. Since the Propulsion is provided from either the gas propulsion motors are not mission essential turbine engine or the propulsion motor, but (the ship can fulfill all mission requirements not both simultaneously. Transitioning from using the gas turbine engines alone), larger propulsion motor to gas turbine engine drive propulsion motors could be incorporated and back is allowed over the entire speed / without requiring an increase in the total power range of the propulsion motor. electric plant generating capacity. Accordingly, follow-on study determined the optimal propulsion motor rating to be 5000 hp per shaft, which was subsequently incorporated into the final design. Propulsion Brakes Line Shafting MRG Propulsion Gas Turbine Motor Main Thrust Bearing Propulsion Turning Clutches Gear FIGURE 3 - Conceptual diagram of shaft propulsion power train arrangement for LHD 8 summary (Table 1) for each design condition, the worst case scenario was during a cruise condition on a 100 F day when approximately 19 MW of power was required to operate the ship.
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