1 ISE3 - HVAC Project Development of ISE Interoperability Modules Final Demonstration Washington, D.C. October 21, 2004

1

ISE3 - HVAC Project

Development of ISE Interoperability Modules

Final Demonstration

Washington, D.C.

October 21, 2004

2

Agenda

• ISE Project Overview

• Interoperability and Integration

• Common Parts Catalog (CPC)

• Navy Vision

• Highlights of ISE2 Demo - April 10, 2003

• Overview of TWR841 Test Ship

• ISE3 - HVAC Demo

• Return on Investment

3

ISE3 Team Participants

Gulf Coast Region University ofMaritime Technology Center New Orleans

4

Other Team Membersfrom ISE2 Project

• American Bureau of Shipping (ABS)

• Altarum

• Anteon Corporation (Proteus)

• Marine Machinery Association (MMA)

• Naptheon

• Northrop Grumman Ship Systems - Avondale Operations

• Northrop Grumman Newport News

• University of Connecticut

5

ISE Builds tools to Support 2nd Generation IPDE

DigitalMOCKUP

CollaborativeDesign-Build

3D DesignElectronic

DRAWING

Virtual Product& Process

Digital Ship Design Process Evolution

• Enhanced Product Model

• Lean Design

• Rule Based Design

• Internet Technologies

• Remote Collaboration

• Intensive Simulations

• High-end Integrated Analysis

• Desktop Visualization

• Business Process Modeling

• Integrated Design/Build

Process

• Sophisticated Eng.Analysis

• Simulation Based Design

• Computer-Aided Drafting

• Data Config. Mgmt.

• 3D Visualization (Polygonal)

• Interactive Walkthrough

• Anthropomorphic Modeling

• 3D Wireframe/Solids

• Rudimentary Data Mgmt

First Generation Integrated Product DevelopmentEnvironment (IPDE)

2nd Generation IPDE

6

ISE Background

• First NSRP major systems technology project• Phase 1: Requirements definition and

architecture for shipbuilding systems interoperability

»March 1999 to December 1999

• Phase 2: Deployment for Structure & Piping »March 2000 to December 2003

• Phase 3: Deployment for HVAC & CPC Interfaces»October 2003 to October 2004

7

ISE Project Approach

• Develop and demonstrate tools that are low cost – can be selectively used by shipyards to support

interoperability– capitalize on XML and related Internet technologies

• Flexibility is critical– allow shipyards to transform their data to/from common

information model

• Drive development of shipbuilding product data standards (e.g. STEP, PLIB)

– Construct a single Shipbuilding Information Model – Demonstrate and educate U.S. shipbuilding community

8

ISE Architecture

• Accessible to large and small shipyards– Only system dependency is Web infrastructure– Utilizes open standards

• Innovative integration of STEP and XML technologies– Supports sharing of geometric & geometric product

models

• Permissive (mediation) architecture– Lets each enterprise choose its own tool set

• Incorporated into CAD platforms used by U.S. shipbuilders

ISE architecture represents an innovative, practical solutionto the information interoperability challenge

9

Levels of Interoperability

INTOP

Inter-businesssystem domain

Shipyard A Shipyard B

Inter-System

Inter-component

IDE

PartsLibrary

PDM/CAD

ERP/CAM

Inter-System

Inter-component

IDE

PartsLibrary

PDM/CAD

ERP/CAM

10

Collaboration among Shipyards is Required in Today’s Environment

• Almost every major recent U.S. Navy ship design and/or construction contract has involved collaboration among multiple shipyards – For example:

• CVNX (NGNN & EB)• DDX (NGSS - Ingalls & Bath)• Initial LPD Award (NGSS - Avondale & Bath)• VIRGINIA (EB & NGNN)

• This trend will continue• Navy views system interoperability as enabling

multiple yards to be viewed as “One Shipyard”

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NAVSEA Vision of “One Shipyard”

11

11

12

Goals of Integration

• Better analysis through simulation• Re-use of data instead of redundant data

– increased accuracy– eliminates unnecessary checking– speed of data entry (already entered)

• Facilitates partnering with other firms• Reduce overhead costs

13

Integration Strategy

• STEP (Standard for Exchange of Product Model Data) – Is a good common language for CAD Product

Models

• XML (Extensible Markup Language) – Is good for CAE applications

• Therefore, combine the two, and embed small strings of STEP into XML, based on industry agreements, such as ISE

14

XML + STEP = Ideal Combo

• XML brings:– Accepted format/schema method– Web-enabled

• STEP brings:– Standards for data expression– Standards for geometric exchange

Leverages development of interfaces

15

XML = Industry StandardContainer for Data

STEP = ISO StandardLanguage for Data*

Data

CompanyA

StandardsVirtualShip

part(s)Company

B

Transactions of Data Packaged in Standards

XSLT - map data to another XML schema

XML and STEP

16

Shipbuilding Product Data in STEP

System Product Definition Analysis / Simulation DeliveryResults and

Cable harness design : AP212HVAC : AP227 ed.2

Shipbuilder Parts : PLIB

Structural Analysis : AP209Structural Analysis : AP209

Ship Structures : AP

Ship Machinery: AP

Process Plant Piping: AP

Ship Structures : AP218

Ship Machinery: AP227 ed.2

Process Plant Piping: AP227

Ship Arrangement : APShip Arrangement : AP215

Ship Moulded Forms : APShip Moulded Forms : AP216

Sys

tem

En

gin

eeri

ng

: A

P23

3

Pro

du

ct C

onfi

gura

tion

: A

P20

3

Tech

nical D

ata Pack

age : AP

232

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DONXML

• The Department of Navy (DON) vision for Extensible Markup Language (XML) is to fully exploit XML as an enabling technology to achieve interoperability in support of maritime superiority

• For cataloging product data in XML format, the DONXML working group has agreed to allow the STEP Schemas developed under the ISE Project to be registered in the DONXML repository

18

Endorsement from Northrop Grumman

"The development and testing of international standards for product data is important to the Shipbuilding industry for interoperablility and data archiving which will enable NAVSEA's "One Shipyard" Concept."

Dave WhiddonVP Research, Development & Design

Northrop Grumman Ship Systems

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Endorsement fromElectric Boat

"Electric Boat endorses the development of interoperability tools and the use of international standards for product model exchange in the shipbuilding industry. We feel that these efforts (undertaken under the NSRP ASE Program) will enhance collaboration among U.S. shipyards and foster the Navy's goal of "One Shipyard".

Millard FirebaughVP-Innovation and Chief Engineer

Electric Boat Corporation

20

The Navy and Shipbuilders Are Using Product Model Data Technology

Product Model Data = 3-D CAD + definitions + other documentation

Continued investment is key indication of value

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ISE Tools

• Tools developed by the ISE Project are made available on the Web at: www.isetools.org

• These include:– Formal information requirements published

• Ship Piping

• Ship Structures

• Ship HVAC

• CPC Interfaces

– Translator generators for custom representations

– XML schema generators• ISO 10303-28 ed 2

– Automated test frameworks for conformance testing

NAVY Ships are a NAVY Ships are a Highly Complex ProductHighly Complex Product

BOEING 777BOEING 777

50,000 HRS50,000 HRS103,000 PARTS103,000 PARTS254 TONS254 TONS

AUTOMOBILESAUTOMOBILES

23 HRS23 HRS3,000 PARTS3,000 PARTS1.9 TONS1.9 TONS

INCREASING INCREASING COMPLEXITYCOMPLEXITY

MANUFACTURING TIME (MONTHS)MANUFACTURING TIME (MONTHS)

MISSILEMISSILE

1,700 HRS1,700 HRS5,000 PARTS5,000 PARTS1.6 TONS1.6 TONS

LAND VEHICLELAND VEHICLE


FIGHTER FIGHTER AIRCRAFTAIRCRAFT


SSBNSSBN

12,000,000 HRS12,000,000 HRS1,000,000 PARTS1,000,000 PARTS18,750 TONS18,750 TONS

Labor Hours WeightParts

SSNSSN

8,000,000 HRS8,000,000 HRS950,000 PARTS950,000 PARTS6,900 TONS6,900 TONS

0 10 20 30 40 50 60 70 80

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Roadmap - Past

Ship Structural Envelope

Distribution Systems Equipment/Subsystems Miscellaneous

Ship ArrangementISO AP 215:2004

Ship Moulded FormsISO AP 216:2003

Ship StructuresISO AP 218:2004

Piping(Plant Spatial Configuration)

ISO AP 227:2001

Cable Trays(Plant Spatial Configuration)ISO AP 227 Edition 2

Parts LibraryISO 13584

Reference Data Libraries

ISO 15926

AP 233 Systems Engineering Data Representation

AP 239 Product Life-cycle Support

Ship Product Model Data ExchangeISO TC 184/SC 4/WG 3

Computational Fluid Dynamics

ISO AP 237

•Ship Structural Envelope (hull form, arrangements, structure)•Distributed Systems (piping, electrical, HVAC, cable trays, mechanical)•Equipment/Subsystems

Mechanical Systems(Plant Spatial Configuration)ISO AP 227 Edition 2

HVAC(Plant Spatial Configuration)ISO AP 227 Edition 2

Logistics/SparesISO AP 232:2002

Electrical(Electrotechnical Design & Install)

ISO AP 212:2001

Finite Element Analysis

ISO AP 209:2001

AutomotiveISO AP 214:2001

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Roadmap - Present







ISO AP 227:2001




ISO 15926





ISO AP 237






ISO AP 212:2001


ISO AP 209:2001


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Roadmap - Future







ISO AP 227:2001




ISO 15926





ISO AP 237






ISO AP 212:2001


ISO AP 209:2001


26

ISE2 Demo Storyboard April 10, 2003

2

LEAPS

3IntelliShip

1FlagShip

Foran

SafeHull

SupplierParts Lib 1012

SIMSMART

CAM(IPT)

16

18

TribonTribon

14

ST-Viewer

Database DeliverablesDatabase Deliverables

4

5

6

11

1315

19

17

CAM

CAE8

9

7a

AutoCAD

PipeStress

CATIACATIA

7b

27

ISE Process - Detail Piping Design Demonstration on April 10, 2003

CATIAV5

TribonM2ISE

28

ISE Process for Feeding Analysis Programs from Structural Design

AtlantecTRIBON

IntergraphISDP

IntergraphIntelliShip

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Common Parts Catalog (CPC) Interfaces

• Developed formal information for– CPC parts data– CPC documents

• Basis for sharing parts data outside the CPC community

• Specification of parts information requirements between Navy and shipbuilders– DONXML repository (in progress)

30

Integrated Shipbuilding Environment

Washington DC • October 21, 2004

HVAC Demonstration

Simsmart

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This ship is used to locate and retrieve torpedoes and missile drones. It has a maximum payload capacity of 42 long tons which includes the deck cargo plus full liquids, full complement, and normal stores.

This ship was selected because it is in-service, has a complete set of drawings available for distribution, and is:

Approved for Public Release: Distribution Unlimited.

The ISE Test Ship - TWR 841

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21 Oct. ‘04

32

• Utilize ship CAD geometry data where possible• Access ship data in multiple systems• Technology leverages ISE XML schemas• Technology will be deployed on LPD 17-20

Selective HVAC STEP Export

TWR Walkthrough

myShipVi

TWRIDE

33

Business Case

Concept Design

Initial Design

Contract Design

Detailed Design

Manufacturing

Teaming Shipyard

Parts

Analysis

34

Analysis(Simsmart ™)


Initial HVACDesign(ISDP)


Detailed DesignTool 1

(TRIBON)


(TRIBON)

Manufacturing (EB Sheet Metal)


Teaming ShipyardDetailed Design

(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)

Legend demonstrated discussed

Order MaterialOrder Material

Parts(CPC)Parts(CPC)

Parts Catalog

CAD Tool

ISE3 Demo Overview

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing

35




(TRIBON)


(TRIBON)

ManufacturingManufacturing


(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

CPCCPC



CPCCPC

Parts Catalog

CAD Tool

Initial Design – Part 1

CPCCPC

Analysis Tool

Manufacturing








(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)



Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing



36

ISDP ISE HVAC Translator


ISE XML

STEP file

Initial Design - Part 1

ISDP



37

Initial Design Analysis






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)



Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing




38

HVAC Design & Performance Analysis

39


Common Parts Catalog






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)



Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


Parts (CPC)

Parts (CPC)

Parts (CPC)

Parts (CPC)

40

Common Parts Catalog

41

Initial Design – Part 2






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing



42

ISDP ISE HVAC Translator


ISE XML

STEP file

Initial Design - Part 2

ISDP

Detailed Design(TRIBON)

Detailed Design(TRIBON)

Updated Plenum

43

Importing into Tribon (Atlantec)






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


(TRIBON)


(TRIBON)

44

Export to Foran (Atlantec)






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


(TRIBON)


(TRIBON)

45

Teaming Yard Detailed DesignAnalysis

(Simsmart ™)Analysis

(Simsmart ™)




(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


(FORAN)


(FORAN)

46

Teaming Shipyard Returns Part

TWR’s HVAC Detailed Design

FORAN HVAC STEP Export Translator


FORAN TWR’s Preliminary Design (ISE2)

FORAN

ISE3

FORAN TWR’s Structural Detailed Design (ISE2)

OUTPUTOUTPUT

ISE3

P21 STEP file

47

Teaming Shipyard Returns Part

HVAC STEP Import Translator

OUTPUTOUTPUT

ISE3

P21 STEP file

FORAN

Database

INPUTINPUT

P21 STEP file FORAN

HVAC STEP Export Translator

ISE3

FORAN

48

Import into Tribon






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


(TRIBON)


(TRIBON)

49

Transfer to Manufacturing






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing


(CATIA)


(CATIA)

50

Manufacturing






(TRIBON)


(TRIBON)




(FORAN)


(FORAN)

AnalysisAnalysis


(CATIA)


(CATIA)

Parts (CPC)

Parts (CPC)




Parts Catalog

CAD Tool

Parts (CPC)

Parts (CPC)

Analysis Tool

Manufacturing



51

Electric Boat HVAC Demo Scenario

STEPFILE

CATIA V5

GenerateManufacturing

Parameters

CATIA V4 / CDMManufacturing

Process

CommonParts

CatalogManufacture Part

52

ELBOWH = 4”W = 6”Rin = 4”Rout = 12”

DUCTH = 4”W = 6”L = 86””

TRANSITIONH1 = 4”W1 = 6”H2 = 3”W2 = 12”L = 12”

Revised Duct for DemoH = 4”W = 6”L =12”

EB ManufacturesTest Case 4

53

Return on Investment (ROI)

• Professor Alley Butler of the Gulf Coast Region Maritime Technology Center (GCRMTC) and the University of New Orleans is conducting a Return on Investment Analysis as part of the ISE3 Project

• Although his study has not yet been completed, the following slides give some early results from his analysis

54

HVAC Data Exchange ROI

• Current estimates point to substantial savings in engineering manhours by employing the AP 227 neutral format for porting information to Simsmart

• Estimates are incomplete, but analysis is in progress– Part 1 : Flow Analysis– Part 2 : Manufacturing

• Additional cost savings are anticipated from manufacturing implementation

55

Estimating Savings from an ISE-3 Implementation

• The ISE-3 deliverables for HVAC permit porting of information from most commonly used CAD systems to the Simsmart analysis tool– This capability should save manhours of

engineering and designer time– It avoids re-entering data to create the Simsmart

models

• Time is money. So, how much time and money is saved?

56


• The Cruiser/Destroyer/Frigate Case– Potential Savings are estimated to be

• 6,903 manhours• $414,162 for one ship design

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• This preliminary analysis can be extended to:– Other classes of ships (e.g. submarines, carriers)– Additional systems

• i.e. for auxiliary systems that are not specifically HVAC, such as engine/generator uptakes

• Additional exchange scenarios (such as Manufacturing) should also be included in calculating ROI

58

NIST: Economic Impact Assessment- Product Data Sharing -

Source : Planning Report 02-05 December 2002

• The Shipbuilding Industry has the opportunity to realize $147.1M in annual benefits by sharing product data :- $76.4M in cost avoidance

◦ Elimination of redundant design, analysis, and manufacturing systems◦ Training◦ IT support◦ Productivity loss

- $70.7M in risk mitigation◦ Model rework◦ Manual data re-entry◦ Delays

• Currently, the Shipbuilding Industry is only realizing $25.7M in annual benefits.

59

Goal : Implement in Production

• The ISE Project has developed tools and demonstrated interoperability between shipyards in the areas of:– Structure

– Piping

– HVAC

– Common Parts Catalog Interfaces

• The goal of current and future efforts is to make these techniques and tools available in production and to all U.S. shipyards– STEP Shipbuilding Translators

– XML Tools

– Common Parts Catalog Interfaces

• A Website has been established to contain the relevant software tools, schemas, etc. as provided by the ISE Project– www.isetools.org

60

Summary

• ISE3 has successfully demonstrated the potential of standards based data exchange to LEAN design and construction processes for HVAC as ISE1 and ISE2 had done for molded forms, structures and piping.

• Two major challenges lie ahead of us:– Commercialization of this technology

– Continuing to prototype standards based data exchange in other application areas such as ships arrangements, ships electrical systems, and system engineering

61

Conclusions

• In order to increase the availability and lower the price of production ready tools:– The ship owner / operator needs to insist that data be

delivered in a system neutral format– The shipbuilder needs to insist that STEP

functionality be an integral part of product

• The next challenge is to move this technology into the mainstream and that the technology is mature enough to transition into commercial CAD and Product Modeling products

62

Endorsements

• The technology works and it is supported by upper management in major U.S. shipyards– "The development and testing of international standards for product data

is important to the Shipbuilding industry for interoperablility and data archiving which will enable NAVSEA's "One Shipyard" Concept.”

Dave Whiddon

VP Research, Development & Design

Northrop Grumman Ship Systems

– "Electric Boat endorses the development of interoperability tools and the use of international standards for product model exchange in the shipbuilding industry. We feel that these efforts (undertaken under the NSRP ASE Program) will enhance collaboration among U.S. shipyards and foster the Navy's goal of "One Shipyard".

Millard Firebaugh

VP-Innovation and Chief Engineer

Electric Boat Corporation

Documents

1 ISE3 - HVAC Project Development of ISE Interoperability Modules Final Demonstration Washington, D.C. October 21, 2004