The Center for Naval Metal Working presents the Navy ManTech Project - PowerPoint Presentation

1. The Center for Naval Metal Working presents the Navy ManTech ProjectM2854 - Automated Pipe Fitting Scriber (A collaboration effort between ONR,CNM, EWI, BIW and MECCO)POP January 20 – April 21Kyle Green and Nick Evans – General Dynamics Bath Iron WorksLarry Brown and Zane Bogosian – EWITim Macon – CNM For additional information contact: info@navalmetalworking.org2021 NSRP All Panel MeetingDCN 43-7886-21

2. AgendaObjectivesAcknowledgementsBackgroundBenefitsResultsIssues/WorkaroundsNext Steps

3. ObjectiveGDBIW wants to improve reliability and effectiveness of marking pipe fittings prior to welding by developing an automated scribing prototype that will do the following:Reduce the amount of handling time of pipe fittingsReduce the labor required to produce a scribeProduce accurate quality scribes to facilitate ease of weld visual inspection (VT)Reduce the overall time to perform VT weld inspection by the welder, Front Line Supervisor (FLS), and US NavyReduce the number of rejected joint weldsReduce the consumable cost of manual scribing implements, e.g. pencils, sharpeners, gagesIncrease on-job-site and ergonomic safetyPrecise Scribe Line on Copper Fitting

4. AcknowledgementsProject funding provided by the Office of Naval Research (ONR) Navy ManTech ProgramNavy ManTech program oversight provided byNeil Graf – ONR Program OfficerTim Macon – Center for Naval Metalworking Project ManagerPaul Blomquist – Project Technical RepresentativeGeneral Dynamics Bath Iron WorksSarah Glazier – Project ManagerKyle Green – Project ManagerNick Evans – Technical LeadEWILarry Brown – Senior Project ManagerZane Bogosian – Principal InvestigatorLance Cronley – Technical LeadAdditional technical support provided byMECCO

5. BackgroundDDG-51 Class of ships contain several different piping systemsThousands of pipe weld joints are made during ship fabrication; many of these use a filet weld joint designThe Navy requires a reference mark (scribe line) to be made on fittings a specific distance from the end of the fittingThe weld face is consumed during the weld process and it is impossible to verify that the required weld size has been achieved with this scribe markGeneral Dynamic Bath Iron Works’ (GDBIW) current method of applying scribe lines on P-fittings is a manual effortGDBIW has found best success using a Staedtler Omnichrom 108, white heat resistant pencil, along with a BIW designed and fabricated pipe scribe gageSocket Weld Fillet Size, Section View (Typical)GDBIW pipe scribe gauge with Omnichrom 108 heat resistant pencil

6. BackgroundThe pencil-marking method is used in all stages of constructionGDBIW has several issues with this method of scribing: Marks are easily removed by pre- and post-weld cleaning and joints may have to be cut and re-fit if no scribe marks are presentDistribution of pencils, gages, and pencil sharpeners is problematic and dull pencils can cause reference marks to be inaccurateReference marks made shipboard are somewhat cumbersome, especially if the pipe is in a remote, dark, and/or congested areaVT (visual) inspection is difficult because weld size measurement must be done at the location of the scribePipe scribing by vibra-etch tool methodVibra-etch toolGDBIW has previously developed a quasi-mechanized method to produce a permanent scribe (“vibra-etch”) on fittingsDremel tool on platform and tool rotated by handProcess is entirely manual and limited to 2.5 in diameter

7. BenefitsBy developing a prototype that will produce permanent and accurate circumscribed marks for P-1 and P-2 socket welded fittings, GDBIW expects to be able toReduce scribe labor time by 83%Reduce visual (VT) inspection time by 67% which will decrease the number of rejected welds due to inability to locate markSoft savingsErgonomic ease of useReduced repetitive motion impactEstimated 1/3 reduction of lifetime fitting handlingTotal takt time studies from prototype testing have met or exceeded all benchmarks for success with some eclipsing benchmarks by almost three folds. (Benchmarked at 120 secs and coming in at 46 secs)

8. Technical ApproachThis chart lays out the project technical approach and milestone evolutions

9. Technical ApproachThe team iteratively narrowed the selection of candidate fittings, beginning with a relatively wide range of material types, sizes, and number of scribes requiredA fitting diameter range was established for parameter developmentIncluded variety of material types and fitting shapesA smaller range of fittings within the diameter requirements of the overall candidate range will be tested on the prototype in a lab environment at EWIThe same range of fittings tested at EWI will be tested at GDBIW in a shipyard environmentFittings tested for prototype acceptance shown in the table on the next slide

10. Technical ApproachSizeTypeMaterial TypeLab AcceptanceShipyard Acceptance1/2 in.TeeCRES 2/12/21 3/8/211/2 in.90° ElbowCRES1/2 in.Reducer90/10 CuNi 2/12/21 3/8/211/2 in.45° Elbow70/30 CuNi2/12/21 3/8/211/2 in.Coupling90/10 CuNi 2/12/21 3/8/212 in.90° ElbowCRES2/12/21 3/8/212 in.Tee90/10 CuNi2/12/21 3/8/218 in. x 6 in.Reducer2/12/21 3/8/218 in.90° Elbow2/12/21 3/8/2110 in.45° Elbow2/12/21 3/8/2110 in.90° Elbow2/12/21 3/8/2110 in.Tee2/12/21 3/8/21Acceptance testing completed at both EWI and BIW. Results from BIW are pendingTool was able to meet all of the functional requirements during acceptance testing and list of design optimization opportunities created for production unit

11. StatusTaskDescriptionStatus1Project InitiationComplete2Define Application Criteria for Automated Pipe Fitting ScriberComplete3Automated Pipe Fitting Scriber Requirements DefinitionComplete4Prototype Development and Prototype Acceptance Testing at EWIComplete5Physical Demonstrations at GDBIWIn-Process6Final ReportingIn-ProcessCurrent status as of 02 March 2021

12. ResultsTask 1 – Project InitiationProject kicked offTask 2 – Define Application Criteria for Automated Pipe Fitting ScriberGDBIW identified the candidate fittings for automating the scribing process with the prototypeTask 3 – Automated Pipe Fitting Scriber Requirements DefinitionGDBIW and EWI developed functional specifications for the pipe scribing prototypeTask 4 – Prototype Development and Prototype Acceptance Testing at EWIGDBIW and EWI developed a prototype design plan and a Prototype Acceptance and Demonstration Evaluation PlanEWI developed operating variables for the prototype on a MECCO demonstration unitMECCO built the prototypeEWI transferred developed parameters to the prototype and executed Part A of the Prototype Acceptance and Evaluation Plan

13. Prototype DesignRevision 1Revision 0Controller – Programed viaTouchpad or KeyboardInitial system design adjusted to address ergonomic concerns and improve material flow

14. Automated Scribing PrototypePneumatic Chuck JawsMarking ToolControllerOperator Push Button ControlsFoot Pedal for Chuck Jaw OperationMarking Guide WheelKey components of the prototype system

15. Example Scribed Fittings45° Elbow90° ElbowCouplingScribe LinesShows scribe marks pre and post wire brush cleaning

16. Project Status / IssuesIssuesAt the onset of project initiation, nationwide lockdowns due to COVID-19 were initiatedBecause of this, travel and in-person meetings were never held for the entirety of the projectKickoff meeting was unable to be held in person at GDBIWVendor visits to GDBIW scheduled during Task 3 unable to heldPrototype development meeting at EWI was unable to be held in personTraining on prototype use unable to occur in personParts and materials supplied by vendor subcontractors impacted by COVID-19Prototype build time delayed because of this

17. Project Status / Issues Risk MitigationsCollaboration between team members done remotelyKickoff meeting held on schedule via teleconferencePrototype development meeting held on scheduled via teleconferenceMECCO provided training for prototype software to EWI via videoconferenceEWI trained GDBIW on prototype use remotely via videoconferenceFinal Review to be held via teleconferenceMarket survey of automated scribing technology done remotelyVirtual demonstrations held with vendors in lieu of onsite visits

18. Project Status / Issues Risk Mitigations (cont’d)Vendor evaluation and selection done remotelyDecision matrices developed between CNM, GDBIW, and EWICandidate vendors evaluated to these matricesPreferred solution selected based on evaluationPrototype design and build done remotelyDesign telecons held between CNM, GDBIW, EWI, and MECCOMECCO provided periodic updates of build scheduleParameters developed during prototype build on demonstration unitMECCO provided EWI with a unit like the prototype during buildContract modified to extend POP through April 30, 2021

19. Next StepsFor EWIShip prototype to GDBIW for Part B of the Prototype Acceptance and Demonstration EvaluationProvide training to GDBIW personnel on prototype useParticipate and assist in Part B Prototype Acceptance and Demonstration Evaluation via videoconferenceFor GDBIWInstall the prototype at GDBIWExecute Part B of the Prototype Acceptance and Demonstration EvaluationCreate Final Business Case AnalysisCreate Implementation PlanFinal Reporting

20. Questions?

21. Produce accurate quality scribes to facilitate ease of weld visual inspection (VT) and mechanize the socket weld pipe fittings scribe processPerforming Entities:Navy ManTech – Program OversightPMS 400D – Project OversightCNM – Project Management / Technical OversightEWI – Lead Technical DeveloperGDBIW – Facility Technical Support, Implementing OrganizationTechnical Achievements:Mar 20 Application Criteria for Automated Pipe Fitting ScribingJun 20 Pipe Fitting Scriber Functional SpecificationsJul 20 Prototype Design PlanJul 20 Prototype Acceptance and Demo. Evaluation PlanFeb 21 Results from Prototype Acceptance Demonstration Evaluation Plan, Parts A & BMar 21 Imp Plan and Final Business CaseApr 21 Final Report/ReviewProject Number: M2854Title: Automated Pipe Fitting ScriberPerforming Activity: Center for Naval Metalworking (CNM) Objectives: Develop an automated mechanism to produce permanent and accurate circumscribed marks, both efficiently and effectively, for socket weld pipe fittings, and deploy it in advance of joint fabrication and installation. Start / End Dates: Jan 20 – Apr 21Project Cost: ManTech Investment: $645Weapon System: DDG-51Implementation: System: DDG 51 / Shipyard Facilities Site: General Dynamics Electric Boat (GDBIW) – Bath, ME Schedule: Implementation start 2Qrt FY21 on DDG 132Status: On track; full implementation anticipated Cost * Schedule Technical Payoff:Reduce time required to scribe socket weld pipe fittings by 83%Reduce time required to VT inspect socket weld pipe fittings joints 6%Savings:$365K per DDG Hull$2.19M over five yearsROI 1.8*Ceiling increase in process for EWI based on extended PoP

22. Project TeamSarah Glazier – Project ManagerKyle Green – Project ManagerNick Evans – Technical LeadRon Pinard – Pipe Shop POCMark Snider – Deputy DirectorPaul Blomquist – PTRTim Macon – Project ManagerNeil Graf – Program OfficerLarry Brown – Senior Project ManagerZane Bogosian – Principal InvestigatorLance Cronley – Technical LeadLee Fuglestad - PMS 400DDavid Clark – CACI

23. Contact InformationExecutive DirectorMarty Ryan(864) 646-4512marty.ryan@ati.orgDeputy DirectorMark Snider(843) 709-3090mark.snider@ati.org Technical DirectorPaul Blomquist(207) 251-8500pblomquist@ewi.orghttps://www.navalmetalworking.org