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Y ...Signature Redacted Modeling Brake Specific Fuel Consumption to Support Exploration of Doubly Fed Electric Machines in Naval Engineering Applications by Michael R. Rowles, Jr. B.E., Electrical Engineering, Naval Architecture, State University of New York, Maritime College, 2006 Submitted to the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degrees of Naval Engineer and Master of Science in Naval Architecture and Marine Engineering at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY June 2016. 2016 Michael R. Rowles, Jr. All rights reserved. The author hereby grants to MIT permission to reproduce and to distribute publicly paper and electronic copies of this thesis document in whole or in part in any medium now known or hereafter c: A uth or ........................................... Signature redacted Department of Mechanical Engineering A may 22,k 2016 C ertified by ............................ Signature redacted .... Weston L. Gray, CDR, USN Associate Professor of the Practice, Naval Construction and Engineering redacted ..Thesis Reader Certified by .......... Signature Ll James L. Kirtley Professor of Electrical Engineering redacted Isis Supervisor Accepted by ............ SSignatu gnatu re ...................... Rohan Abeyaratne MASSACHUSETTS INSTITUTE Chairman, Committee on Graduate Students OF TECHNOLOGY Quentin Berg Professor of Mechanics Department of Mechanical Engineering JUN 02 2016 LIBRARIES ARCHIVES Modeling Brake Specific Fuel Consumption to Support Exploration of Doubly Fed Electric Machines in Naval Engineering Applications by Michael R. Rowles, Jr. Submitted to the Department of Mechanical Engineering on May 12, 2016 in Partial Fulfillment of the Requirements for Degrees of Naval Engineer and Master of Science in Mechanical Engineering Abstract The dynamic operational nature of naval power and propulsion requires Ship Design and Program Managers to design and select prime movers using a much more complex speed profile rather than typical of commercial vessels. The inherently reduces the overall efficiency of the plant as operated in comparison to its potential. The fuel consumption of prime movers is a multi-variable function of power demand and rotational speed. Mechanically coupled power and propulsion arrangements constrain this two degree of freedom relationship by removing the independence of the speed parameter. Fixed frequency power generation requires a constant prime mover speed that has a narrow power band for optimal fuel consumption. Likewise, geared propulsion arrangements restrict the prime mover's speed to a dependence on the combined propulsor thrust-hull resistance performance which generally follows a cubic function. Optimal fuel consumption, however, involves matching the load's efficiency performance to that of the prime mover. This requires the rotational speed of the prime mover to be an independent variable with the freedom to adjust to the lowest specific fuel consumption for the demanded power. Variable frequency drive (VFD) concepts offer relief of this constraint but at a cost in the form of increased power conversion and control support system footprints. The ever increasing and complex demands for electrical power 3 increases the motivation and interest in innovative technologies that improving current design concepts. Incorporating doubly fed electric machines (DFEM) into the power and propulsion design architecture enables the efficiency results of a VFD system but with a smaller conversion and control support footprint. The Navy has invested resources into research and development of several electric power and propulsion technologies enabling deployment of VFD systems on a handful of ship classes. The wind power generation industry has matured many aspects of DFEM technology. Leveraging this experience into naval engineering applications could help facilitate additional platform types and sizes to benefit from the operational advantages of integrated electrical architectures. Applying DFEM concepts to naval engineering requires a horizontal transfer of the body of knowledge. Researchers in the field of DFEM technology need to gain a better understanding of the intricacies of integrating a marine vessel's engineering plant with the vessel's designed purpose. New methods of analysis tailored specifically to marine power and propulsion require development for the technology to be properly assessed. This study outlines the various issues challenging ship designers and explains the manner in which DFEM research can be continued in naval engineering. Finally a method of examining a prime mover's fuel consumption is developed to provide a three-dimensional "fuel map" surface relationship of power-to-speed-to-fuel consumption. This thesis will serve as a building block supporting further DFEM power and propulsion concept analysis. Thesis Supervisor: James L. Kirtley Title: Professor of Electrical Engineering, MIT Thesis Reader: Weston Gray Title: Associate Professor of Practice for Naval Architecture and Marine Engineering, MIT 4 [This page intentionally left blank] 5 Dedication I dedicate this work to those living and those no longer with us whose love and support have made my life an adventure to cherish. To my loving wife Lily who jumped on this roller coaster life ages ago and has been riding the rails with me ever since. To my grandparents, Joyce and Bill, whose passing during this tour left a tremendous hole in my heart. And finally to my boys, John and Jacob, amazing gifts from God whose arrival in my life not only filled the hole but left it overflowing with joy. Your endless love and unquenchable spirits proved to me the existence of the Almighty. 6 Acknowledgements First and foremost I must take to this opportunity and every opportunity to come to give my deepest thanks to God for carrying me through this project, challenging academic tour, and long career. Without His persistent grace in my life I surely would have faltered. I would like to express my thanks to LT Brandon Zoss, USN for the indispensable just-in-time wisdom he provided in the 1 th hour of this thesis. Thank you also to the exceptional MIT faculty members whose wisdom, compassion, and extra- curricular support successfully guided me through this tour: Professors Gilbert Strang, Tomasz Wierzbicki, Themis Sapsis, Nicholas Makris, Michael Triantafyllou, and James Kirtley as well as CAPTs Mark Thomas, "Chip" McCord, Joe Harbour, CDR Weston Gray, and Mary Mullowney. I must also acknowledge the Department of Veteran's Affairs, the medical professionals of US Coast Guard Base Boston, especially Dr. Brian Quint and LT Yarom Eloul, and the congregation of St. Anne's in-the-Fields for tending to the well-being of my mind, body, and soul. And finally and forever I must reiterate my thanks to God with whom it all begins and ends, you have my love and endless gratitude, Sir. 7 Table of Contents Abstract........................................................................................................................................... 3 Dedication ....................................................................................................................................... 6 Acknow ledgem ents......................................................................................................................... 7 Table of Contents ............................................................................................................................ 8 List of Figures ............................................................................................................................... 10 List of Tables ................................................................................................................................ 12 Chapter 1 Introduction ............................................................................................................ 13 1.1 Overview ........................................................................................................................... 13 1.2 M otivation......................................................................................................................... 15 1.4 Scope and Delim itation................................................................................................... 18 1.4.1 Thesis Objectives .............................................................................................. 19 1.4.2 Tasks ..................................................................................................................... 19 1.4.3 A ssum ptions........................................................................................................ 19 1.5 Thesis Outline/Organization ......................................................................................... 20 Chapter 2 Background .................................................................................................................. 22 2.1 Basics of M arine Power and Propulsion...................................................................... 22 2.1.1 Overview .................................................................................................................. 22 2.2.2 Prim e M overs........................................................................................................ 24 2.2 N aval W arships........................................................................................................ 35 2.2.1 Pow er Plant Design...........................................................................................
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