NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Designing All Electric Ships

CAPT Norbert Doerry Howard Fireman Naval Sea Systems Command

Ann Arbor, Michigan May 16 - 19, 2006

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

AGENDA
Integrated g Power System y ( (IPS) ) Introduction IPS Design Opportunities IPS Design Considerations IPS Design Watch Items Conclusions
The Integrated Power System provides the naval architect with many opportunities to optimize ship design.
Its important that the Naval Architect take advantage of these opportunities, otherwise a sub-optimized IPS ship design may not outperform an optimized conventional mechanical drive ship design.

Improving the efficiency of prime movers and propulsors (along with drag reduction) can compensate for lower transmission efficiency of electric drive.

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Integrated Power System (IPS)

IPS consists of an architecture and a set of modules which together g p provide the basis for designing, procuring, and supporting marine power systems applicable over a broad range of ship types: yp
Power Generation Module (PGM) Propulsion Motor Module (PMM) Power Distribution Module (PDM) Power Conversion Module (PCM) Power Control (PCON) Energy Storage Module (ESM) Load (PLM)

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS Architecture Integrated I t t d Power P

Propulsion and Ship Service Loads provided power from same prime movers

Zonal Distribution
Longitudinal Distribution buses connect prime movers to loads via zonal distribution nodes (switchboards or load centers).

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS M IPS: Medium di V lt Voltage AC D Design i

PDM - PCM Xformer

4160 V

PDM - PCM Xformer

4160 V

PDM - PCM Xformer

4160 V

PDM - PCM Xformer

4160 V

SP PDM

PGM

PGM PDM

PGM PDM PMM

PMM PDM PGM

PDM

SP

PGM Xformer
4160 V

PGM Xformer
4160 V

Xformer
4160 V

Xformer
4160 V

PDM - PCM Zone 1 Zone 2 Zone 3

PDM - PCM Zone 4

PDM - PCM Zone 5 Zone 6

PDM - PCM Zone 7 SP = Shore Power

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

PDM M

SP

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS with DC Zonal Electrical Distribution: Medium Voltage AC Distribution System

PGM To DC ZEDS To DC ZEDS PGM

PMM Motor Drive Motor

Motor Drive PMM

Motor

To DC ZEDS PGM

PGM

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

DC Z Zonal l El Electrical t i l Di Distribution t ib ti System S t

AN ELECTRICAL ZONE DC PCM-1 DC AN ELECTRICAL ZONE PCM-1 DC DC AN ELECTRICAL ZONE PCM-1 AN ELECTRICAL ZONE PCM-1 DC PCM-4 AC INPUT DC DC DC

AC LOADS

PCM-4 AC INPUT PCM2 DC D AC LOADS DC D

AC LOADS

PCM4

DC LOADS

PCM-2

PCM2

PCM2

DC

PCM-1

PCM-1

DC

PCM-1

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

AC LOADS PCM-1

AC INPUT

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS Design Opportunities Support S t High Hi h P Power Mi Mission i S Systems t Reduce Number of Prime Movers Improve System Efficiency Provide General Arrangements Flexibility Improve Ship Producibility Support Zonal Survivability Facilitate Fuel Cell Integration

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

S Support t Hi High h Power P Mission Mi i Systems S t

Organic Surveillance Drone
High Altitude B Beam Power P to t Aircraft Ai ft Minimal Handling - No Refueling

High Powered Sensor

Combination Sensor and Weapon High Powered Microwave High Powered Laser

Electromagnetic Gun
More than 10 MJ on Target Megawatt Range

High Energy Laser

Enhanced E h d Self S lf Defense D f Precision Engagement No Collateral Damage Megawatt Class Laser

Integrated Power System

Affordable Power for Weapons and Propulsion Power Dense, Fuel Efficient Propulsion All Electric Auxiliaries Reduced Signatures No Hydraulics Power Conversion Flexibility No HP Gas Systems Reduced Sailor Workload May 16-19, 2006

NO ENERGETICS ABOARD SHIP!

University of Michigan, Dept. NA&ME Designing All Electric Ships

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Reduce Number of Prime Movers Ships Power

Prime P i Mover GEN Prime Mover

Propulsion
Prime Mover

Traditional

Prime Mover Prime Mover

GEN

GEN

Power Conversion and Di t ib ti Distribution

Prime Mover

Reduction Gear

Prime Mover

Reduction Gear

Electric Drive with Integrated Power

May 16-19, 2006

Prime Mover Prime Mover Prime Mover Prime Mover

GEN

GEN

Power Conversion and Distribution

MD MD

Mtr Mtr

GEN

GEN

University of Michigan, Dept. NA&ME Designing All Electric Ships

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NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Improve System Efficiency

A generator, motor drive and motor will generally be less efficient than a reduction gear . But electric drive enables the prime mover and propulsor to be more efficient, as well as reducing drag.
Mechanical Drive Gas Turbine Reduction Gear Generator Drive Motor Propeller Relative Drag Coefficient Total Ratio 70% 100% 21% 30% 99% 96% 95% 98% 75% 97% 24% 116% Electric Drive 35%

Representative values: not universally true

TRADE TRANSMISSION EFFICIENCY TO REDUCE DRAG AND IMPROVE PRIME MOVER AND PROPELLER EFFICIENCY
May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

11

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Improve System S Efficiency: ff Contra-Rotating Propellers

Increased Efficiency y
Recover Swirl Flow 10 15% improvement

R Requires i special i lb bearings i f for inner shaft if using common shaft line Recent examples feature Pod for aft propeller

Anders Backlund and Jukka Kuuskoski, The Contra Rotating Propeller (CRP) Concept with a Podded Drive

http://www.mhi.co.jp/ship/english/htm/crp01.htm

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

12

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

General Arrangements Flexibility Improve Ship Producibility

Vertical Stacking of Propulsion Components Pods Athwart ship Engine M Mounting ti Horizontal Engine Foundation Engines E i i in Superstructure Distributed Propulsion Small Engineering Spaces
12 APR94 G. C DR NH D : S EA 0 3R 2 Re v 1 2 8 MAR 9 5

Di Diesel l Mechanical M h i l System S t

Propulsion / Elec tri cal Power Machin ery Space Intakes/Uptakes Z ones Without Pr opulsi on / Electr ical Power Spaces Shaft Lin e

Integrated Power System

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

13

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Support Zonal Survivability

Zonal Survivability is the y of a distributed ability system, when experiencing internal faults, to ensure loads in undamaged zones p a service do not experience interruption.
Sometimes applied to only Vital Loads. Usua Usually y requires equ es o one e longitudinal bus to survive damage.

Limits damage propagation to the fewest number of zones.

Enables concentration of Damage Control / Recoverability y Efforts.

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

14

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Facilitate Fuel Cell Integration Many Advantages

Highly Efficient (35-60%) No Dedicated intakesuptakes; use ventilation

Challenges g
Reforming Fuel into Hydrogen Onboard Chemical Plant. Eliminating Sulfur from fuels. Slow Dynamic Response Requires Energy storage to b l balance generation ti and d load Slow Startup Best used for base-loads
University of Michigan, Dept. NA&ME Designing All Electric Ships

May 16-19, 2006

15

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS Design Considerations

Selection of High Voltage Bus Voltage Number and Type of Power Generation M d l Modules Propulsion Motor Module Technology Propulsor Architecture AC or DC Zonal Electrical Distribution

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

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NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Selection of High Voltage Bus Voltage

Higher Voltages Desired
Circuit Breaker Rating Reduced Cable Weight Generator Reactance
40 40 7 0 14 0 50 100 150 200 250 80 110

Lower Voltage Desired

Reduce risk for corona Possible elimination of transformer for propulsion motor module Insulation and Thermal design of Generator

Total Generation Power Required (MW) 450 VAC 4 16 kV 4.16 6 9kV 6.9kV 13 8kV 13.8kV

Shore Power
450 V, 4.16 kV or 13.8 kV desired

Selecting the bus voltage is a compromise

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

17

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Number and Type of Power Generation Modules

Past studies have shown that 4 to 6 power generation modules generally provide the most cost effective solutions.
Typically have at least 2 larger Main generators and 2 smaller auxiliary generators

Auxiliary Generators sized to be efficient between the minimum operating conditions (with 2 online) and the point where the main generators are efficient.
Often Diesel Generators Should be self-starting

Main Generators sized to provide maximum power requirements along with auxiliary generator sets
Often Gas Turbine Generators An even number simplifies bus architecture

May also need small emergency generators for dark-ship start

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

18

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Propulsion Motors:
General Observations

Propulsion Motors are typically custom designed for the application based on standard Frame Frame Sizes Sizes.
Frame size determines rotor diameter. Variables are length and shaft speed.

The Motor Drive has a large impact on both the Propulsion M t and Motor d the th High Hi h V Voltage lt Di Distribution t ib ti S System. t
Harmonics and Power Quality Part Load Efficiency Number of Motor Phases Need for Propulsion Transformer

Motor Designs have changed significantly in past 15 years to take advantage of new high voltage and current power electronics. electronics
Permanent Magnet (PM) and Advanced Induction Motors (AIM) have largely displaced DC and Synchronous Motors for high power applications. Homopolar Motors and Superconducting Motors are still being developed.

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

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NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Motors: Basic Scaling Law HP D2 L A B RPM HP D L A Power Rating R t Di Rotor Diameter t Rotor Active Length Surface Current Density (C d t Material (Conductor M t i l & Cooling C li Method) M th d) B Rotor Flux Density (Saturation of Magnetic Material) RPM Shaft Speed

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

20

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Propulsion Motor Thumb Rules

For a given technology, cost is roughly proportional to Torque Torque. Maximum Rotor Diameter is limited by shaft rake considerations, manufacturability and manufacturability, transportability. Motor efficiencies at design power typically fall in range of f 90-98%. 90 98% Below about 15-35% rated power, the efficiency of a p conventional motor drops rapidly.
Can be improved through advanced motor design and g with motor proper integration drive
May 16-19, 2006

Representative Efficiency Curves

http://www.amsuper.com/products/library/HTS_efficiency_advantage.pdf

University of Michigan, Dept. NA&ME Designing All Electric Ships

21

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Propulsor Architecture
Improve Efficiency
Fixed Pitch vs. CPP Contra-rotating Pods Tandem Motors

Maneuverability
Trainable Pods Thrusters

Survivability
Distributed Propulsion

Suppo t innovative Support o at e Hull u Design

SWATH Multi-Hulls

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

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NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

AC or DC Zonal Electrical Distribution AC Z Zonal l El Electrical t i l Di Distribution t ib ti i is preferred f d when h

Power Quality of the high voltage bus is good enough such that ship service loads receive power meeting MIL-STD1399 section 300A Interface standards.
Depends on Motor Drive Technology Depends on Harmonic Filtering on high voltage bus

The number of un-interruptible loads is small.

Otherwise, DC Zonal Electrical Distribution (or Integrated Fight Through Power IFTP) is generally preferred

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

23

NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

IPS Design Watch Items Part P t Load L d Effi Efficiencies i i Dark-Ship Starts Shore Power Power Generation Module Start Time Component Reliability Common Mode Failure Transformer In-Rush Current

May 16-19, 2006

University of Michigan, Dept. NA&ME Designing All Electric Ships

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NINTH INTERNATIONAL MARINE DESIGN CONFERENCE 2006

Conclusions Th The Integrated I t t d Power P System S t provides id the th naval l architect with many opportunities to optimize ship design. g
Its important that the Naval Architect take advantage of these opportunities, otherwise a sub-optimized IPS ship design g may y not outperform p an optimized p conventional mechanical drive ship design.

Improving the efficiency of prime movers and propulsors (along with drag reduction) can compensate for lower transmission efficiency of electric drive.
University of Michigan, Dept. NA&ME Designing All Electric Ships

May 16-19, 2006

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