EcoMarine Propulsion Systems - An Overview

EcoMarine Propulsion Systems Corporation258 Main Street Suite 401Milford, MA 01757http://www.ecomarinepropulsion.com(508) 422-9366

http://www.ecomarinepropulsion.com/

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The EcoMarine Propulsion Systems Corporate Team

Industrial Power Systems, Inc. designs and builds quality electrical controls, switchboards and switchgear. Formed in 1981, they have designed and built over 10,000 control panels covering a broad electrical spectrum. Their strength is in complex and innovative applications, especially where custom design and engineering is a requirement. The company has vast experience in marine switchboards and controls and has built to ABS and USCG specifications for cruise ships, casino boats, workboats, tankers, tugs, barges, dredges, riverboats, ferries, pleasure craft and military vessels.

EcoMarine Propulsion Systems is a joint venture comprised of three world-class businesses whose complementary expertise is the force behind marine electric propulsion and a pioneer for the application of alternative green power sources for the tug/barge marketplace and beyond worldwide. Offering an affordable electric propulsion drive that offers fuel savings, reduced emissions, lower maintenance costs, simplicity of operation and improved vessel environment with regard to noise and onboard sound level reductions.

Comprehensive Power, Inc. is a leading designer and manufacturer of high-performance permanent magnet motors, generators, controls and drives. Based in Marlboro, Massachusetts, the company is an enabling supplier and partner of leading firms in the mobile power, distributed power and renewable energy sectors, helping them produce dynamic energy solutions. Comprehensive Power has supplied power conversion equipment for submarines, self propelled acoustic targets, robots, vehicles, wind turbines, drill rigs, transport systems and industrial equipment manufacturers for over eleven years.

The Force behind Marine Electric Propulsion

Ocean Tug/Barge Engineering has either directly designed, or been a fully participating engineering partner, for 38 operational AT/B’s in the US market over the span of a quarter century. They have engaged in six new build projects in the US as of 2006, and one overseas. The firm has also now entered the international marketplace, with units under design for service in the Far East, and Eastern Europe, and is pioneering the application of alternative "green" power sources for the tug/barge marketplace worldwide. The firm has also expanded its product range with the introduction of new, high technology harbor and offshore tug designs.

EcoMarine Propulsion Systems Corp

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EcoMarine Propulsion PowerRing™ Overview


TCMLoadDemandControl

(1) Inverter/Rectifier Supplies ship service72”H x 18”W x 32”D

DC Bus Tie Switch

(2) TeraTorq® 39120 Motor

(4) CAT C32 Marine Diesel Engine (4) TeraTorq® 2635 Generator

(2) Motor Breaker / Inverter Cabinet 72”H x 48”W x 32”Dwith 8 TIM-270 modules

Shaft speed and direction control

Bridge Control In

(4) Generator Breaker /Rectifier Cabinet 72”H x 36”W x 32”D w/4 TIM-270 modules

Aux Generator/Shore Power in

To Existing Switchboard and Distribution

PowerRing™ Components

Space or spare or braking resistors

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PowerRing™ Benefits

Reduced Downtime and Maintenance Reduced Fuel Consumption Reduced Emissions Reduced Noise Reduced Weight and Smaller Footprint Redundancy & Backup Increased Safety Remote Monitoring of Key Systems Flexible Arrangement Completely Warrantied


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Vessel Design & Operational Benefits

A DC Main Bus Means Reduced Electromagnetic Emissions/Harmonics

Great benefit in running wiring for the system and results in fewer issues for onboard electronics.

Less Complexity In Operation There is no need for complex generator

control/switchgear or complicated generator AC synchronizing equipment.

Generator phase differences and frequency differences are not an issue.

No separate field excitation generator needed and thus no excitation-related failures.

Power management is simplified vs. conventional D/e drives.

Inherent Redundancy and Safety Drive Electronics units can be redeployed within the

system, by anyone, in an emergency. Fault currents are quickly and electronically

eliminated, reducing arc flash hazards.

Voltage from TeraTorq® Inverter Modules (TIMs) into a motor. High frequency “noise” is contained by phase inductors.


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Vessel Design & Operational Benefits Small and Lightweight Drive Package

PowerRing components are more compact and lighter than conventional AC or other DC drive systems.

Reduced sizes for new vessel machinery and ease of refit into existing vessel designs.

Simplicity of Troubleshooting & Repair Interchangeable drive line components. Drive components can safely be handled by

individuals and small work crews. Unit exchange with the factory allows for a quick

and cost-effective turnaround for replacement of many drive line items.

Worldwide service for the propulsion system is planned.

The TD800 rack shown is 800mm wide and holds up to 12 TIMs


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Vessel Design & Operational Benefits Fuel Monitoring and Management

The system accommodates a fuel management system (FMS) to monitor fuel use in both real-time and trend line formats.

FMS can be configured to interface with GPS to provide matching speed, location, power and fuel use information.

Wheelhouse Configuration The wheelhouse displays and controls can be customized for

the particular vessel and service. Integrated bridge controls are available.

Direct drive means no reverse reduction gear nor associated maintenance.

ABS The system will be delivered with full ABS certification. ABS Certificate of Product Design (TIM-270,TFM-521)

awarded 7/12/12. Total Ship System Approach

Single-source, warrantied, full vessel electrical solution, including ship service switchboards and distribution panels.

Example FMS screen.


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Vessel Propulsion & Operational Benefits

Engines can be taken off-line, reducing wear and maintenance.

Engines can operate at varying speeds; there is no need to synchronize system components.

Propellers can turn slowly (at full rated torque, forward or reverse) with no clutches.

Interfaces with Z-drives and controls, reduction gears, VSP units, CP propeller systems, and bow thrusters.

Power module failure in a drive electronics component yields proportional loss of capacity, not a complete propulsion line power failure.

Engine failure still permits balanced thrust from both propellers.

6 millisecond response to prop jamming reduces impact damage and enables jam clearing.

Faster shaft reversing time provides faster stops as well as better maneuverability.

CAT® C32


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Remote Monitoring, Predictive Maintenance System status is continuously logged locally

and can be viewed over the internet Mode, power, status information Voltages, speeds , currents, temperatures Battery health (in hybrid systems) Fault reporting and identification

Remote support personnel can spot many problems before they interfere with operation

Can help work through any unusual situation

Example web monitoring system.


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PowerRing™ Benefits

System is “future-proof” due to the ability to easily adopt to new technologies and control them from the DC bus.


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PowerRing™ Systems are built upon TeraTorq® Components

Modular, configurable systems, with industry leading performance, built upon a proven Permanent Magnet (PM) architecture


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TeraTorq® Motors and Generators

Designed for use on oil rigs and other harsh environments – rugged, sealed, and highly shock tolerant

Optional hollow shaft facilitates compact coaxial deployment

Propriety design provides as much as 5X reductions in size and weight compared to other motors and generators

Direct liquid cooling eliminates the need for a dedicated heat exchanger and blower

Scalable platform design with dozens of different motor and power sizes, up to 20,000 Hp, up to 214,400 ft-lb

TeraTorq® motors have been deployed in subsea applications for military use since 2003, and on drill rigs since 2004. A TeraTorq® generator is being used subsea as part of the first US grid connected ocean tidal generation system announced in September 2012, and TeraTorq® generators were used on related subsea prototype projects since 2010.

TeraTorq® motors and generators have logged more than 4,000,000 hours of rugged field use.


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Variable Speed Generator (VSG) Operation

Reduce fuel consumption Reduce emissions Reduce noise Reduce engine wear and engine

maintenance requirements Increased engine life

VSG can be utilized in Diesel Electric, Hybrid Diesel Electric, and Dual Fuel configurations

CAT® C32 engine with a TeraTorq® generator


Example - CAT® 3512 engine with a Conventional Generator (top) and a 3512 with a TeraTorq® generator

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Space savings of 4’ 37/8” (or a reduction in length of 26.3%)

Weight reduction approximately 6,150lb (4,100lb vs. approximately 10,250lb)


Example CAT® C32 engine with a Conventional Generator (top) and a C32 with a TeraTorq® generator

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Space savings of 4’ 111/2” (or a reduction in length of 35.2%)

Weight reduction approximately 7,800lb (1,200lb vs. approximately 9,000lb)


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VSG operation can typically reduce fuel usage by 5% - 15% for a boat.

There are extreme examples where VSG has reduced fuel consumption by 40%.

•Preliminary estimated savings can be provided as part of our proposal based on predicted operation of a vessel.

•Detailed fuel consumption analysis, based on predicted operational parameters and known equipment selections, is available for a fee, either pre- or post-sale.


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While operating efficiently, the PowerRing™ control system can provide preset modes of operation to suit your needs and simplify bridge operation, such as -

FULL POWER HIGH CRUISE LOW CRUISE LOITERING


TeraTorq® Liquid Cooled Inverter Modules (TIMs)

Power Conversion, Motor Drive and Control TIM-270 modules are:

Small - 9” x 9” x 24” deep Powerful - 200 KW, 600 VAC, 900 VDC, 250 HP Flexible - AC/DC, DC/AC, and DC/DC functionality Smart and aware – any module can be replaced without requiring an

electrician – modules are self-configuring. Resilient – parallel, load-balancing by design Modular – Up to 64 TIMs can be networked for a specific function Communicative -

CAN bus communication between TIM modules RS485 network communication, control, data logging

TFM-521 Expandable frame system Each holds up to 4 TIMs; multiple TFMS are typically housed in the

same cabinet All module connections are blind-mate quick-disconnect for safe and

foolproof support

EcoMarine Propulsion Systems CorpPage 19 04/07/23

TeraTorq® Frame Module (TFM),TD800 Modular Drive System

TFM-521 Racks hold up to 4 TIMs All module connections

are blind mate quick disconnect for safe and foolproof support

An 800 mm wide TD800 rack holds 1, 2 or 3 TFMs

A TFM holds 1, 2, 3, or 4 TIMs

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TD800 Modular Drive System

The image on the right features 3 TD800 racks –

The left and right racks are each housing 3 TFMs (and a total of 12 TIMs each).

The middle rack has only 1 TFM (and a total of 4 TIMs).

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TeraTorq® Control Module (TCM)

TCMs

control the operation of TIMs and TeraTorq® motors

communicate via Modbus TCP protocol



Battery Cell Voltage Manager

A circuit board is mounted on each 2V battery cell

Monitors cell voltage Monitors cell temperature Shifts charge from cell to cell to

balance SOC Circuit boards are connected from cell

to cell in daisy chain Jumpers are short and see only 2 volts

Minimizes danger of high voltage wiring Data is passed from module to module

by “Bucket Brigade” Central controller coordinates actions

Gather, analyze, record, report data Identify strong and weak cells Issue commands for charge balancing Flag cells needing maintenance


Battery Life Basics Long strings of batteries have historically poor

deep cycle life 12 volt battery is good for ~300 cycles 300 volt strings in electric vehicles lasted <50

cycles Problem is in maintaining equal State-of-

Charge (SOC) on all cells Strong get stronger and weak get weaker

Strong cells overcharge Weak cells short out

Passive equalization can be a very long process for 700 volt strings

Active equalization levels the playing field Robs the rich and gives to the poor Extends cycle life to > 700 cycles

Problem has been complexity of implementation and safety of low voltage control circuitry in high voltage strings


Battery Management Test - Ongoing

Battery Life demonstration system placed in service in Houston in June 2008

Initial tests were for system characterization

Shallow discharge cycles Equalization Medium discharge cycles Equalization Deep discharge cycles

Next tests implemented continuous equalization and endurance discharge testing

System has been moved to our plant for continued testing

Incredibly fewer cell failures than occur with conventional management methods.


High Power/High Safety Battery

EcoMarine Propulsion

Bob Hill, Founder and V.P. Naval Architecture & Marine Engineering(508) [email protected]

Glenn Beaupre, President(508)-422-9366904-325-5565 (m)[email protected]

Frank Jones, [email protected]

Jeff Sable, Director Sales and Marketing(508) 422-9366(508) 259-2989 (m)[email protected]

www.ecomarinepropulsion.com

EcoMarine Propulsion Systems CorpPage 27 04/07/23

Date post:	19-Oct-2014
Category:	Technology
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EcoMarine Propulsion Systems - An Overview

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