hybrid conversions: introduction to hybrid propulsion systems · alcatraz flyer electric propulsion...

Canadian Ferry Association Conference - 2019

Hybrid Conversions: Introduction to Hybrid Propulsion Systems

Larry Machak – American Traction Systems


ATS Milestones

Dual 90kW DC Propulsion Systems32 New Orleans Canal Street Streetcars2008

Dual 300kW AC Propulsion System the Alcatraz Hybrid2008

550kW AC Traction System Venturi Buckeye Bullet 2 302mph Hydrogen Fuel Cell Electric Vehicle

2009

Dual 500kW AC Propulsion Hybrid SystemStatue Cruises 2011

4x 500kW DC Propulsion Battery System Norfolk Southern 999 Locomotive2010


Milestones

Dual 400HP Permanent Magnet Propulsion Spirit of the Low Country2018

2012Two Dual 500kW AC Propulsion Hybrid SystemsAlcatraz ClipperAlcatraz Flyer

Electric Propulsion System and ControlsSAMSA Africana Research Vessel 2015

6MW DC Propulsion System and ControlsUSNS Waters 2013

2019 Quad 150HP AC Propulsion and ControlsGees Bend


Project presently underway

DOT Alabama / HMS - Gees Bend Battery Ferry

The first battery only ferry in North America


Hybrid Propulsion SystemsUS Coast Guard approved

diesel-electric-hybrid passenger ferries

The Alcatraz HybridThe Hornblower Hybrid The Alcatraz FlyerThe Alcatraz Clipper

All powered by ATS propulsion systems


Hybrid Ferry Operational Review

Alcatraz Island, San Francisco CA is only serviced by the Hornblower Hybrid fleet.

Summer5,200

per day

Fall - Spring2,000

per day

1 million passengers/year

since 2012

Over 7 million passengers!!


Multiple Energy Sources

What is a Hybrid Propulsion System?

Propel the Ship



Hybrid Propulsion is not a new idea

Egyptian reed shipc. 4000BC

Phoenician Shipsc. 600BC




Power Conversion

Generators Batteries SuperCaps

SolarPanels

FuelCells

WindTurbines

ShorePower

Propellers Thrusters Ship Services

Multiple Loads




Power Conversion

Generators Batteries ShorePower


Multiple Loads




Power Management



Multiple Loads




Power Conversion



Multiple Loads



Common Bus

Power Conversion

Power Conversion



Two Power Bus Topologies May be Used:

Common DC Bus

Common AC Bus



The two feuding geniuses waged a "War of Currents" in the 1880s over whose electrical system would power the world.

Tesla's alternating-current (AC) system Edison's direct-current (DC) system.

Nikola Tesla Thomas Edison

Amongst science nerds, few debates get more heated than the ones that discuss Nikola Tesla and Thomas Edison.



ATS has deployed propulsion systems using both topologies

Common AC Bus on the USNS Waters and Africanaup to 7 MW Diesel Electric DC Propulsion

Common DC Bus on Hybrid Passenger Vesselsup to 1.5 MW Hybrid Propulsion


Types of Electric Marine Propulsion Systems

Diesel Electric

Series Hybrid

Parallel Hybrid

Plug-in Electric



Diesel-Electric



Diesel-Electric Powertrains consist of a diesel engine connected to a generator which creates electricity to power electric propulsion motors.

Benefits of a Diesel Electric System

• Engine is decoupled from the Propulsion motorseliminates aligning the engine, gearbox and drive shaft

• Allows the diesel engine to mounted in any location



Diesel-Electric Series Hybrid



Diesel-Electric Series Hybrid

Series drivetrains are the simplest hybrid configuration. The propulsion motor(s) receives electric power from either the battery pack or from a generator run by an engine.

Benefits of a Series Hybrid System

• Both the engine/generator and shore power recharge the battery pack• More efficient at low speeds than conventional systems• Smaller engine to obtain the same performance as a conventional

vessel - the battery provides extra power as required



Diesel-Electric Parallel Hybrid



Diesel-Electric Parallel Hybrid

In vessels with parallel hybrid drivetrains, the engine and electric motor work in tandem to generate the power that drives the propeller(s).

Benefits of a Parallel Hybrid System

• Uses a smaller battery pack than series hybrids• The engine is connected directly to the propeller(s) eliminating the

inefficiency of converting mechanical power to and from electrical power which increases efficiency

• Smaller engine to obtain the same performance as a conventional vehicle - the battery provides extra power as required



Plug-In Electric



Plug-In Electric

Vessels can be recharged from an external source of electricity (shore power) at lower cost than operating a diesel engine; the electricity is stored in battery packs for vessel propulsion

Benefits of a Plug-in System

• Very quiet and smooth • Suitable for short (< 25 mile) commutes • Recharge from the grid utilizing low off-peak electricity rates• Zero emissions at the vehicle


Battery Interface to the DC Bus

Zero Emission and Hybrid Propulsion Systems



The ideal situation is for the battery voltage to remain stable, this does not occur.

There is a 1:1.5 or more fluctuation in the battery voltage from fully charged to discharged.

As the battery state of charge decreases, the voltage also decreases causing the current drawn from the batteries to increase.



• There are two methods of interfacing batteries to the common DC Bus

1) Batteries are tied directly to the DC bus

The DC bus fluctuates with the battery state of charge(Non-regulated DC Bus)

2) Batteries are isolated via DC/DC converters

The DC remains at a stable voltage(Regulated DC Bus)

There are advantages and disadvantages to both topologies



Non-regulated DC Bus

PROS

CONS

ü Better Efficiencyü Simple Control Loopsü Better for All-Electric Systems

ü More Batteries are Requiredü Expensive Short Circuit Protectionü System is sized for Minimum

Voltage/Maximum Current



Regulated DC Bus

PROS

CONS

ü Less Batteries Requiredü Lower Short Circuit Currentü Better for Longer Voyages

ü More Complex Power Electronics Required


Hybrid Vessel Power Management

Zero Emission and Hybrid Propulsion Systems



• The Energy Management of a hybrid vessel must be a blend of optimal control algorithms and real time performance.

• Vessel Power Management has unique challenges since the operational conditions of a given route is dynamic. The same vessel traveling the same route will never be subject to the same conditions.

• There will be variations of temperature, wind, current, debris, etc. that must be dealt with in real time.


• Never Compromise the Safety of the Vessel

• Maximize the life of the batteries

• Optimize the efficiency of the vessel



• Generators are operated at their optimal performance setting using the batteries to balance the load and to meet peak load requirements.

• Batteries can react to large power demand swings faster and more efficiently than the diesel generators.

• Battery only mode provides a higher quality experience due to quiet running.

• Using Shore Power to charge the batteries is the most economical and efficient means of charging.



ATS Hybrid Propulsion Systems

• Only 1 diesel engine is operating under normal cruise conditions (multiple genset configurations)

• Operating time is balanced between the engines

• Better fuel economy by decoupling the engine speed from the propeller speed

• Minimized pollution due to efficient operation of the diesel engine


ATS Hybrid Propulsion System

• Eliminates the auxiliary generator for house loads

• Engines are decoupled from the propeller

• Eliminates aligning the engine, gearbox and propeller shaft

• Allows the diesel generators to be mounted in any location with complete vibration isolation from the hull

• Quiet and smooth propeller reversal by reversing the rotational direction of the electric propulsion motor


Hybrid Ferry Operational Review

15%• Avg. Fuel Consumption

• Less NOx emissions & particulate matter

10%• Lower decibel (dB) levels than conventional

ships

ZERO• Diesel fuel consumption & exhaust fumes

during boarding and low speed operation

Advantages of the ATS Hybrid Propulsion System


Hybrid Vessel Engine Room

ATS Hybrid Vessel Propulsion System

Typical ATS Hybrid Marine Propulsion System


Port Propulsion Rack Starboard Propulsion RackPower Distribution RackDC Bus Capacitors

GeneratorModule

PropulsionInverter

IsolationPanel

Pre-Charge Panel

PropulsionInverter

GeneratorModule

DC/DC Chopper

DualDC/DC

Chopper

DualDC/DC

Chopper

DualInverter

IsolationPanel

Typical ATS Hybrid Marine Propulsion System

The typical ATS propulsion system is divided into three high-voltage rack assemblies

Two generator and propulsion control assemblies (with DC bus isolation contactor) and one power conversion/distribution rack in the center.

Each assembly measures 4 ft deep x 4 ft wide x 4 ft 2in tall


Electric Propulsion Controls and Accessories

Questions?

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