Technologies to Support Zero Technologies to Support Zero MaintenanceMaintenance

CDR Timothy J. McCoy, USNCDR Timothy J. McCoy, USN

Assoc. Prof. Of Naval Construction and EngineeringAssoc. Prof. Of Naval Construction and EngineeringMassachusetts Institute of TechnologyMassachusetts Institute of Technology

Electronic Technologies Support Zero Maintenance

• More Electric Ships

• Modern Control Systems

• Electric Weapons

Propulsion Systems

• Purpose & uses:– Provides mobility for the ship

• Subsystems / Components– Prime Movers– Transmissions– Propulsors

Fuel

Transmission PrimeMover

Propulsor

Thrust

Integrated Power System Architecture

PropulsionMotor

MotorDrive

PowerConversion

Module

ShipServicePower

Main PowerDistribution

Generator PrimeMover

Electric Propulsion Advantages

• Fewer Prime Movers – Less equipment to maintain– Fewer moving parts to wear

• Can optimize loading of engines easier– Under-loading of Diesels causes much of USN's problems– Under-loading GT's causes significantly increased fuel usage

• Best architecture for adopting Fuel Cell Prime Movers• Electric Machines & Solid State power converters require

less preventative maintenance than the components they replace

• More amenable to automation – requires automation

Modern Power Devices

1200volt / 1000 amp IGBT

Modern AC Drives

An incomplete listing of modern integrated electric shipsName Type Year Power Rating System Particulars Builder Displaceme Main Engines SourceFantasy Cruise 1988 2 x 14MW KvaernerEcstacy Cruise 1989 2 x 14MW KvaernerHarmony Cruise 1989 2 x 12MW KvaernerFascination CruiseInspiration CruiseSeili Service 1990 15MWFincantieri Cruise 1991 2 x 12MWSensation Cruise 1992 2 x 14MW Stattendam Cruise 1992 2 x 12MWStellendam Cruise 1993 2 x 12MWHanne Knutsen Shuttle Tkr 1994 19MWJorunn Knutsen Shuttle Tkr 1994 19MWDestiny Cruise 1995 2 x 20 MW KvaernerHeidrun Shuttle Tkr 1995 19 MWRotterdam Dutch LPD 1997 2 x 11 MWElation Cruise 1998 2 x 14 MW Azipod KvaernerHealey USCG Ice Brkr 1999 2 x 11 MW AvondaleSedco Express Drill Rig 1998 4 x 7 MW Synchro PodsSegero Cable Layer 1998 2 x 2.7 MW Pods

Mariella Amoretti Chem Tanker 1998 Shaft gen/mtr.

Articaborg Ice Brk / Supply 1998 2 x 2 MW Azipod Kvaerner

Hornisse Chem Tanker 1998 Shaft gen/mtr.

Pride of Washington Ferry 1998 4 x 4 MWParadise Cruise 1999 2 x 14 MW Azipod KvaernerEuropa Cruise 1999 2 x 10 MW Azipod KvaernerEagle Class (3 ships) Cruise ordered 2 x 21 MW Azipod Kvaerner 140,000 gt

Costa Atlantica, Carnival Cruise 2000 2 x 17.6 MW Azipod Kvaerner 84,000 gt6 x Wartsila 9L46D, 10,395 kW each

Jan 02 Maritime Reporter

Carnival Spirit, Carnival Cruise 2001 2 x 17.6 MW Azipod Kvaerner 84,000 gt6 x Wartsila 9L46D, 10,395 kW each

Jan 02 Maritime Reporter

Carnival Pride, Carnival Cruise 2001 2 x 17.6 MW Azipod Kvaerner 84,000 gt6 x Wartsila 9L46D, 10,395 kW each

Jan 02 Maritime Reporter

Aker Geo Seismic Research ordered Pods Aker FinnyardsSuperstar Virgo Cruise 1999 Meyer Werft 76,880 gt

Tarquin Loch LPG carrier 1999 400 kw Shaft generator

Prospero, Donsotank Chem Tanker 2000 2 x 5.1 MW 127 RPM SSP-5 Pods Shanghai Edward 18,000 dwtun-named, Donsotank Chem Tanker 2002 2 x 5.1 MW 127 RPM SSP-5 Pods Shanghai Edward 18,000 dwt2 ships Heavy Lift Ship ordered 2 x 5.1 MW SSP-5 Pods

Nils Holgersson Ferry 2001 2 x 11 MW 22 ktsSSP-10 Pods Bremerhaven 34,500 gt

5 Caterpillar Motoren Diesel Gensets, total 29.9 MW output

Dec 01 Maritime Reporter

un-named Ferry ordered 2 x 16.8 MW 26.5 kts SSP-14 Pods

Bremerhaven 34,500 gt

Voyager of the Seas, Royal Caribbean

Cruise 1999 3 x 14 MW 22 kts Azipod Kvaerner 137,000 gt 6 x Wartsila Dec 01 Maritime Reporter

Explorer of the Seas, Royal Caribbean

Cruise 2000 3 x 14 MW 22 kts Azipod Kvaerner 137,000 gt 6 x Wartsila Dec 01 Maritime Reporter

Adventurer of the Seas, Royal Caribbean

Cruise 2001 3 x 14 MW 22 kts Azipod Kvaerner 137,000 gt 6 x Wartsila Dec 01 Maritime Reporter

Ukku tanker 1993 2 x 11.4 MW Azipod 16,000 dwtLunni tanker 1995 2 x 11.4 MW Azipod 16,000 dwtRadiance of the Seas Cruise 2001 2 x 19.5 MW Azipod Meyer Werft 88,000 gt GE GT EnginesBrilliance of the Seas Cruise 2002 2 x 19.5 MW Azipod Meyer Werft 88,000 gt GE GT EnginesRoyal Caribbean Cruise ordered 2 x 19.5 MW Azipod Meyer Werft 88,000 gt GE GT EnginesRoyal Caribbean Cruise ordered 2 x 19.5 MW Azipod Meyer Werft 88,000 gt GE GT EnginesMillennium, Celebrity Cruise Lines

Cruise 2000 2 x 19.5 MW Mermaid Chantlers de l'Atlantique

91,000 gt GT Engines Jul 01 Maritime Reporter

Infinity, Celebrity Cruise Lines Cruise 2001 2 x 19.5 MW Mermaid Chantlers de l'Atlantique

91,000 gt GT Engines Jul 01 Maritime Reporter

un-named, Celebrity Cruise Lines

Cruise ordered 2 x 19.5 MW Mermaid Chantlers de l'Atlantique

91,000 gt GT Engines Jul 01 Maritime Reporter

Commercial Marine

Integrated Electric Ships

(68 ships listed on a

VERY incomplete list)

Foreign Navy Trends

• UK– Type 23 Frigate in Service -- hybrid electric / mechanical drive– Type 45 under contract -- full integrated power system– LPD replacement, under construction -- full IPS– Oiler replacement, under construction -- full IPS

• Netherlands– LPD "Rotterdam" in service -- full IPS– IPS declared for future surface combatants

• Spain– Developing IPS for combatants & auxiliaries

• France, Canada, Brazil, Japan, Russia ...– Investigating IPS for future ships

• Many other Navies interested

Over 27 countries represented at the last All Electric Ship Conference

Technologies to Support Zero Maintenance (cont.)

• Electric Auxiliaries– VSD fed motors for fluid pumping applications

• Eliminate dampers, unloading valves• Reduce pump wear and pipe erosion• Eliminate electromechanical motor controllers,

gearboxes & clutches on winches– Solid state ABT's – Need I say more!– Eliminate central hydraulics on Subs

Technologies to Support Zero Maintenance

• More Electric Ships

Modern Control Systems

• Electric Weapons

Technologies to support Zero Maintenance (cont.)

• Intelligent and "Sensorless" controls– "automatic controls" vice "remote manual controls"– Robust, "trustworthy" automation– MEMS sensors– Current signature analysis (ORNL)– Non-intrusive Load Monitoring, NILM (MIT)

• Wireless Networking– Wi-Fi– Bluetooth– Others

Technologies to support Zero Maintenance (cont.)

• "Reach-back" technologies– Examples:

• Caterpillar – Online satellite access to their engines & equipment

• Alstom – USCGC Healey propulsion system

NILM Diagnostics Example: Fouled Heat Exchanger

Motor Startup transient

Motor

Pump

450 vac

NILM developed by Prof. Steven B. Leeb at MIT

NILM Hardware Test Setup

Successful Fault Prediction

Technologies to Support Zero Maintenance

• Integrated Electric Power Systems

• Modern Control Systems

Electric Weapons

EMALS / EARS

• EMALS– Baseline for CVN-78– Uses linear motors to launch aircraft vs. steam catapults– Rotating electric machines for energy storage– Ongoing competition – Large-scale prototypes under

construction & test, downselect scheduled next year– Primary reasons for going electric:

• Lower maintenance & manning requirements• Less stressful for airframes

• EARS– Uses electric machines to dissipate energy from arresting wires

vs. hydraulic motors– Not as far along as EMALS but development is ongoing

Rail Gun

Rails

DrivingCurrent Magnetic Field (B)

ArmatureCurrent (J)

Armature(Projectile)

Current Flowing in the Rails Creates a Magnetic Field Which InteCurrent Flowing in the Rails Creates a Magnetic Field Which Interacts with the Current in racts with the Current in the Armature to Generate a the Armature to Generate a LorentzLorentz ((JxBJxB) Force) Force

Disadvantages:• Barrel wear / Rail

Gouging

• High Current Switching

• Reg. Volume behind proj. is filled with Magnetic flux

Advantages:• Mature Technology• Simplest Power

Systems• Relatively Constant

Force• Simple EML (Linear DC

Motor)• Demonstrated – 4.2

km/s for 700 g projectile

• Efficiency getting better

Notional Navy EM GunRequirements:• Flt. Mass – 15 kg• Launch Mass – 20 kg• Launch Velocity – 2.5 km/s• Muzzle Energy – 63 MJ• Breech Energy – ~150 MJ• Barrel Length – 10 m• Peak Accel. – 45 kgee• Firing Rate – 6 to 12 RPM

BJFrrr

×=

Free Electron Laser (FEL)& Solid State Laser

A Free Electron Laser is a device that includes an accelerator, a magnetic undulatoror wiggler, and an optical cavity to produce a beam of coherent radiation.

LoopPCM

Amplifiers

Master Oscillator

• Some of the SS Lasers are Operating in the Correct Atmospheric Windows for Maritime Propagation (~1.0 Micron)

• Other Services are Pursuing SS Lasers due to Perceived Smaller Size & Ruggedness

• Primary Technology Hurdle is Removing Excess Heat from the Solid Material

Electrons wiggling in the undulatormagnet emit light.Bunching of the electrons creates coherent laser light.

Summary

• Electronic Technologies are available today

• Electronic Technologies are more reliable and require less maintenance than mechanical technologies, in general

• Many Electronic Technologies bring warfighting benefits as well as reduced maintenance.

The technologies are out there. The US Navy needs a paradigm shift!