EcoMarine Propulsion Systems - An Overview

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

The EcoMarine Propulsion Systems Corporate Team

The Force behind Marine Electric Propulsion
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.

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.

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.

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.

Page 2
EcoMarine Propulsion Systems Corp 10/6/2012

EcoMarine Propulsion PowerRing™ Overview

Page 3

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

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

DC Bus Tie Switch

To Existing Switchboard
Bridge Control In and Distribution

(2) Motor Breaker /
Inverter Cabinet
72”H x 48”W x 32”D Space or
with 8 TIM-270 spare or
modules braking
resistors

(1) Inverter/Rectifier
Shaft speed and direction control Supplies ship service
72”H x 18”W x 32”D

Aux Generator/Shore Power in

(2) TeraTorq® 39120 Motor
Page 4
EcoMarine Propulsion Systems Corp
10/6/2012

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
Page 5

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 Voltage from TeraTorq® Inverter Modules (TIMs)
system, by anyone, in an emergency. into a motor. High frequency “noise” is contained
 Fault currents are quickly and electronically by phase inductors.
eliminated, reducing arc flash hazards.

Page 6

 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

Page 7

 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) Example FMS screen.
awarded 7/12/12.
 Total Ship System Approach
 Single-source, warrantied, full vessel electrical solution,
including ship service switchboards and distribution panels.

Page 8

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 CAT® C32

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.

Page 9

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 Example web monitoring system.

 Can help work through any unusual situation

Page 10

PowerRing™ Benefits

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

Page 11

PowerRing™ Systems are built upon TeraTorq® Components

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

Page 12

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.

Page 13

Variable Speed Generator (VSG) Operation

 Reduce fuel consumption
 Reduce emissions
 Reduce noise
 Reduce engine wear and engine
maintenance requirements
 Increased engine life

CAT® C32 engine with a TeraTorq® generator

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

Page 14

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

 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)

EcoMarine Propulsion Systems Corp Page 15
10/6/2012

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

 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)

10/6/2012


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.

Page 17


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

Page 18

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

Page 19

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

Page 20

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).

10/6/2012

TeraTorq® Control Module (TCM)

TCMs

 control the operation of
TIMs and TeraTorq® motors
 communicate via Modbus
TCP protocol

Page 22

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

Page 23

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

Page 24

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.

Page 25

High Power/High Safety Battery

Page 26

EcoMarine Propulsion
Bob Hill, Founder and V.P. Naval Architecture & Marine Engineering
(508) 422-9366
rhill@ecomarinepropulsion.com

Glenn Beaupre, President
(508)-422-9366
904-325-5565 (m)
gbeaupre@ecomarinepropulsion.com

Frank Jones, CTO
fjones@ecomarinepropulsion.com

Jeff Sable, Director Sales and Marketing
(508) 422-9366
(508) 259-2989 (m)
jsable@ecomarinepropulsion.com

www.ecomarinepropulsion.com

Page 27

EcoMarine Propulsion Systems - An Overview

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