NAVYPROM project - Development and implementation of a modern solution to replace the propulsion systems of the Missile Carrier Ships of the Romanian Naval Forces
Project presentation
The main purpose of the "NAVYPROM" project is to strengthen the national defense and raise the national security level through innovative solutions to the technical and technological problems identified at the level of the ships of the Romanian Naval Forces.
The project aims to modernize the propulsion systems with gas turbines used on the rocket-carrying ships of the Romanian Naval Forces by adapting the on board systems to cutting-edge technologies; the development of emerging technologies for the systems related to the propulsion systems, with application in the marine environment and increasing the level of environmental protection by minimizing the impact on marine flora and fauna.
The results of the research carried out within the project will allow exceeding the current stage of the performances achieved by the currently existing engines, allowing the achievement of a higher thermal efficiency with a lower specific fuel consumption, which results in reduced pollution and a reduction of operating costs. It is also important to mention that maintenance will be provided in Romania during the entire life cycle of the product.
Starting from the requirements of the terms of reference of the project, an installation architecture was built that optimally corresponds to all the specific technical and operational requirements and ensures the successful achievement of the project's objectives. From the synthesis of all the available information, the constructive solutions, the performances, the functional limitations and the way of positioning the new technological demonstrators installed on the ship were determined. The determination, design and implementation of the optimal solution are based on the experience and expertise of the technical and scientific teams of the consortium, using techniques and technologies of high performance and reliability. Thus, numerical simulations were carried out in CFD environment of the flow through the newly designed ducts of the new turbo engine, as well as heat transfer and material resistance calculations using the finite element method. Mechanical design of components and SDVs used CAD computer-aided design systems, and manufacturing used CNC machining.
The experimental tests carried out were aimed at determining the global performances of the turbo engine in the new configuration, as well as gathering relevant experimental data for optimization.
Stage I - Establishing the basic configuration of the NPRM-ST40M naval propulsion group and the NPRF-ST40M naval propulsion group
During this stage, activities were carried out to reveal the cruise cells, respectively the booster cells of the NPR type ship (missile carrier ship), research and studies regarding the identification of DT solutions (technological demonstrator) NPRM-ST40M naval cruise propulsion group , respectively, a booster propulsion group for installation on board the NPR type ship and coupling to the propeller shaft and, last but not least, procurement activities for the materials intended for the execution of the exhaust sewer and the equipment that is part of the command and control system of the turbo engine ST40M.
The technological demonstrator configuration of the ST40M naval propulsion group (fig. 1) highlights a trouser-type intake duct design, which bypasses the reversing reducer and couples with a radial-type intake volute to provide air supply to the optimal conditions of the ST40M turbo engine. The evacuation of the combustion gases is carried out by means of the exhaust duct consisting of a diffuser, expansion compensators, elbow with profiled flaps and a pipe that connects to the existing exhaust.
Both the intake sewer and the exhaust sewer represent modular constructions, made of welded sheets.
The reversing reducer is coupled to the ship's reducer and can be supported on the ship's existing supports, with the required adaptations or by means of its own support.
The ST40M turbo engine is coupled by means of the elastic shaft to the reverse gear reducer flange. The ST40M turbo engine rests on its own support by means of two clamping forks connected to height-adjustable support arms.
The main purpose of the "NAVYPROM" project is to strengthen the national defense and raise the national security level through innovative solutions to the technical and technological problems identified at the level of the ships of the Romanian Naval Forces.
The project aims to modernize the propulsion systems with gas turbines used on the rocket-carrying ships of the Romanian Naval Forces by adapting the on board systems to cutting-edge technologies; the development of emerging technologies for the systems related to the propulsion systems, with application in the marine environment and increasing the level of environmental protection by minimizing the impact on marine flora and fauna.
The results of the research carried out within the project will allow exceeding the current stage of the performances achieved by the currently existing engines, allowing the achievement of a higher thermal efficiency with a lower specific fuel consumption, which results in reduced pollution and a reduction of operating costs. It is also important to mention that maintenance will be provided in Romania during the entire life cycle of the product.
Starting from the requirements of the terms of reference of the project, an installation architecture was built that optimally corresponds to all the specific technical and operational requirements and ensures the successful achievement of the project's objectives. From the synthesis of all the available information, the constructive solutions, the performances, the functional limitations and the way of positioning the new technological demonstrators installed on the ship were determined. The determination, design and implementation of the optimal solution are based on the experience and expertise of the technical and scientific teams of the consortium, using techniques and technologies of high performance and reliability. Thus, numerical simulations were carried out in CFD environment of the flow through the newly designed ducts of the new turbo engine, as well as heat transfer and material resistance calculations using the finite element method. Mechanical design of components and SDVs used CAD computer-aided design systems, and manufacturing used CNC machining.
The experimental tests carried out were aimed at determining the global performances of the turbo engine in the new configuration, as well as gathering relevant experimental data for optimization.
Stage I - Establishing the basic configuration of the NPRM-ST40M naval propulsion group and the NPRF-ST40M naval propulsion group
During this stage, activities were carried out to reveal the cruise cells, respectively the booster cells of the NPR type ship (missile carrier ship), research and studies regarding the identification of DT solutions (technological demonstrator) NPRM-ST40M naval cruise propulsion group , respectively, a booster propulsion group for installation on board the NPR type ship and coupling to the propeller shaft and, last but not least, procurement activities for the materials intended for the execution of the exhaust sewer and the equipment that is part of the command and control system of the turbo engine ST40M.
The technological demonstrator configuration of the ST40M naval propulsion group (fig. 1) highlights a trouser-type intake duct design, which bypasses the reversing reducer and couples with a radial-type intake volute to provide air supply to the optimal conditions of the ST40M turbo engine. The evacuation of the combustion gases is carried out by means of the exhaust duct consisting of a diffuser, expansion compensators, elbow with profiled flaps and a pipe that connects to the existing exhaust.
Both the intake sewer and the exhaust sewer represent modular constructions, made of welded sheets.
The reversing reducer is coupled to the ship's reducer and can be supported on the ship's existing supports, with the required adaptations or by means of its own support.
The ST40M turbo engine is coupled by means of the elastic shaft to the reverse gear reducer flange. The ST40M turbo engine rests on its own support by means of two clamping forks connected to height-adjustable support arms.
Fig. 2 shows the technological demonstrator configuration of the ST40M naval propulsion group. The ST40M turbo engine has the power shaft in the front, which is an advantage over the existing configuration, because there is no need to reverse the flows in the force cell, which is better from a constructive point of view.
The intake ducting consists of a profiled pipe that connects to the existing intake manifold, and at the other end to a radial air intake volute in the turbo engine.
The evacuation of combustion gases is carried out through the exhaust duct consisting of a diffuser, expansion compensators, elbow with profiled flaps and a pipe that reaches the existing exhaust, using the same route as in the existing configuration. Both the intake sewer and the exhaust sewer represent modular constructions, made of welded sheets.
The booster transmission assembly connects to the existing booster reducer and is supported by a front wall that is placed on the hull of the ship, forming a firm grip.
The ST40M turbo engine is supported by a support assembly consisting of adjustment rods provided at the ends with clamping forks. The turbo engine mount is connected to a front bulkhead that connects to the hull of the ship to ensure a firm grip.
The intake ducting consists of a profiled pipe that connects to the existing intake manifold, and at the other end to a radial air intake volute in the turbo engine.
The evacuation of combustion gases is carried out through the exhaust duct consisting of a diffuser, expansion compensators, elbow with profiled flaps and a pipe that reaches the existing exhaust, using the same route as in the existing configuration. Both the intake sewer and the exhaust sewer represent modular constructions, made of welded sheets.
The booster transmission assembly connects to the existing booster reducer and is supported by a front wall that is placed on the hull of the ship, forming a firm grip.
The ST40M turbo engine is supported by a support assembly consisting of adjustment rods provided at the ends with clamping forks. The turbo engine mount is connected to a front bulkhead that connects to the hull of the ship to ensure a firm grip.
The numerical analyzes developed on the air intake and combustion gas exhaust ducts also contributed to the design of the solutions. They highlight minimal pressure losses, below the values indicated by the turbo engine manufacturer.
Stage II Research and development for the DT NPRM/NPRF-ST40M cruise and booster naval propulsion group on the stand
As part of the activities carried out in Stage 2, a test stand layout study was developed for testing a DT NPRM-ST40M cruise naval propulsion group, respectively NPRF-ST40M booster, in which the test configurations were defined. Execution documentation was also developed for the components required for testing. The components for the stand testing of the DT naval propulsion group have all been completed, the configuration of the assembly is shown in Fig.1.
Stage II Research and development for the DT NPRM/NPRF-ST40M cruise and booster naval propulsion group on the stand
As part of the activities carried out in Stage 2, a test stand layout study was developed for testing a DT NPRM-ST40M cruise naval propulsion group, respectively NPRF-ST40M booster, in which the test configurations were defined. Execution documentation was also developed for the components required for testing. The components for the stand testing of the DT naval propulsion group have all been completed, the configuration of the assembly is shown in Fig.1.
For the stand testing of the DT booster naval propulsion group, based on the execution documentation, the components required for testing were manufactured, in the configuration of Fig.2.
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