Rolls-Royce to build gensets in US for next-generation frigate

Rolls-Royce’s Power Systems division will supply four of its MTU naval generator sets for the US Navy’s second new-generation guided missile frigate in the Constellation class.

Newly upgraded production facilities in Aiken, South Carolina and Mankato, Minnesota will support the manufacture of these generators, which are based on the company’s well-proven MTU 20V 4000 M53B engine. The four generator sets, each rated at 3000 kWe, will provide a total power output of 12 MW for propulsion and on-board power supply.

Constellation-class frigates have a combined diesel-electric and gas (CODLAG) propulsion plant, which combines a single gas turbine, two electric propulsion motors, four ship service diesel generators and one auxiliary propulsion unit. In this configuration, the MTU diesel generators provide electrical power for on-board electronics and cruising speed. The gas turbine is used when the frigate is travelling at high speeds.

Commenting on the contract, Rolls-Royce Solutions America director, Adam Wood, said Rolls-Royce is “thrilled to bring the manufacturing of our MTU naval gensets to the US.” He added: “The seamless transfer of technology from Germany to our Aiken and Mankato facilities has strengthened our ability to meet the high expectations of this project and better position us to compete for future government programmes.”

“Rolls-Royce is thrilled to bring the manufacturing of our MTU naval gensets to the US”

This contract follows Rolls-Royce’s supply of four MTU gensets for the lead ship in the Constellation-class programme, the frigate USS Constellation (FFG-62), which was supported by its production team in Friedrichshafen, Germany, to fulfil the project.

This latest contract will see the US-manufactured gensets installed in USS Congress (FFG-63), the second ship in the Constellation-class programme (formerly known as the FFG(X) programme). The engines will be delivered to Fincantieri Marinette Marine in Marinette, Wisconsin. Fincantieri Marinette Marine was awarded the contract option to build USS Congress in May 2021 and third in the class, USS Chesapeake (FFG-64) in June 2022.

To support USS Congress and future naval business, Rolls-Royce has transferred advanced technology and detailed manufacturing processes to the US, investing in new facility improvements at its Aiken and Mankato plants. Among the significant investments made at the facilities are new assembly tooling and material handling equipment, upgraded hoist systems, adapted test cells and building expansion.

USS Congress (FFG-63) is a multi-mission warship designed for operation in littoral and blue water environments to conduct air, anti-submarine, surface and electronic warfare, in addition to information operations.

Fincantieri Marinette Marine (FMM) Marinette, Wisconsin, was awarded the build contract for the project. The completed vessel will be powered by a combined diesel-electric and gas turbine, allowing for energy-efficient diesel power generation for propulsion at normal cruising speeds with extended range, while enhancing anti-submarine capability in its extremely quiet diesel-electric configuration. When completed, USS Constellation will have an overall length of 151 m, beam of 19.8 m, capacity to accommodate 200 crew and be capable of speeds in excess of 26 knots, with a range of 6,000 nautical miles at 16 knots.

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