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Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 23 November 2015

Jacob Munk Plum, Electrical Surveyor of LR EMEA, Copenhagen TSO

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Introduction

• Facing the new requirements for sulphur emissions, in the Nordic we see owners looking for different kind of propulsion principles. One of these is hybrid- and battery designs. But what are the challenges, regarding stable functionality and safety?

• In this presentation I will cover basics on battery functionality and safety and how the battery is implemented in the ships electrical grid seen from a class perspective.

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Agenda

• Batteries for propulsion purposes – reason, types and integration• Lloyd’s Register– what does the class do?• Lloyd’s Register ”Unconventional/Novel” Design Process• Lloyd’s Register Risk Assessment (ARBD)• Risk Assessment on batteries

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

What does the class do?

• Beginning of project – before decision on final design and subsuppliers are chosen:LR can provide consulting on Risk AsssessmentAnother LR department can carry out the Risk Assessment for client

• When subsupplier is chosen and design is fixed:LR can carry out the RA/ Hazid Identification and provide a HAZID study reportAt this point also the Plan Approval process commenses.

• When documention for build/rebuild/modification is complete:LR can carry out the HAZOP, i.e. conduct a procedure to identify hazardous operationsFinal drawings for Plan Approval is submitted and Design Appraisal Document is issued

• When build/rebuild/modification is ongoing:Local surveyor follows installations and attend FAT

• When build/rebuild/modication is complete:• Local surveyor attends HAT and Seatrails.

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

LR Novel Design Process – Systems of Unconventional Design

• Prescriptive rules.Known systemsLong experience on operationPrecise rules

• New systems – Systems of Unconventional Design (Rules Pt.7, Ch.15) – Prescriptive rules has not been developedAnother method: Risk Assessment LR use a defined process to identify and evaluate the Risks.

• Assessment of Risk Based Designs - ARBD

START ENDDesign and

Safety Statement

RiskAssessment

CriteriaSatisfied

NO Revision andSupporting

Studies

Final DesignAssessment

YES

Generic Process for the Assessment of Risk Based Designs (ARBD)

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

The Hazards - Total Systems Engineering Concept

Component level – the Cell

Battery Module

(strings of cells)

Battery System

Ship System Level

Functional, performance

and verification

requirements to address the

issues:

a ‘TOTAL SYSTEM’ concept Concept of

operation

Electrical protection

and isolation

Redundancy

Construction – Survey

EmissionsBattery

management

Installation

Special fire safety

Human Factors

Risk Assessment for Failure

Control systems

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Batteries for propulsion purposes - Fuel Savings

Optimized use of the Diesel Generators - Load 85-95% Always be in the Best Point of Specific energy (kWh/g’s). Energy storage = Battery. Surplus power -> Charge battery.Power demand for thrusters > DG power supply -> Discharge battery -battery is a virtual generatorResult: Instead of two DG’s on partial load, one can be run on full load = Fuel savingConventional DE system Hybrid DE system with batteries

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Batteries for propulsion purposes – Installation

• DG replaced by converter AC/DC + battery pack.

• The converter controls the charging/discharging of battery by voltage.

• Existing PMS controls converter --> charge by surplus energy-> discharge by power demand

• Independent Battery Pack Controller for battery safety.

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Batteries for propulsion purposes - Type of Battery

Types of batteries:Mainly Lithium Ion: High energy density, many charge cyclesIssues: Contains lots of energy, what will happen if something goes wrong?

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

LR What does class do?

Safety and stability• Can it burn / cause

a fire?• Can it cause

electrical problems; short circuit, shock hazard, disrupt essential services?

• Can it harm personnel and materials in other ways; toxic, corrosion etc.?

• Is it stable over time?

• Is safety measures in place?

Pack level

Cell level

Electronics Thermal management

Cell design Cell chemistry

Active Passive

Forced cooling

Short circuit Overvoltage Thermal active trip of current

Cell voltage balancing

Pack voltage balancing

Electrode coatings

Shutdown seperators

Safety vents

Safety circuits (current /thermal material trips)

Electrolites Cathode/ anode materials

Additives Positive thermal coefficient devices: i.e. pcm, polymers, ceramics/grafeen

Box construction

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Risk Assessment on Batteries – Scandlines Voglefulg example

• Example: Scandlines Vogelflug line• What kind of battery?• How much energy is installed?• Is it for essential service?• Installations? How and where?• Worst case failure?• Is safety measures in place?

ActivePassiveTo prevent failureAfter failure

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Risk Assessment on Batteries - HAZID example

• Example on Battery HAZID (Safety Actions Register List)

ITEM CAUSE HAZARD POTENTIAL EFFECTS

SAFEGUARDS

RECOMMENDATIOS

1.2 control system failures

1.2.1. Battery monitoring failure

Internal failure No voltage cell or temperature or module measurement

Thermal Runaway

Pack controller will shut down pack, and alarm to PMS

1.2.1 Charger/discharger convertor failure

Internal failure No proper charge/discharge current control and voltage control

Thermal Runaway

Pack controller will shut down pack, and alarm to PMS

1.2.3 Temperature sensor failure

Internal failure Temperature can be high without knowing

Thermal Runaway

Pack controller will shut down pack, and alarm to PMS

1.2.4 voltage sensor failure

Internal failure Voltage can be high without knowing

Thermal Runaway

Pack controller will shut down pack, and alarm to PMS

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Besides the actual identification of hazards, LR also looks on the quality of the risk assessment:• Is there a report ready for review? Is it structured and well explained?

Is there a clear scope of the risk assement study?• Who attended the HAZID and what are their qualifications?

DO they have a satisfactory level of knowledge and experience on the matter?

• Has enough time been used to carry out the HAZID? Is the time recorded?• Which method has been used to identify the hazards and causes?• Where the estimation of consequence and likelihood and hence risk

appropriate?• Has the report been independently revieved prior to presentation for LR?

Risk Assessment on Batteries - ARBD review

START ENDDesign and

Safety Statement

RiskAssessment

CriteriaSatisfied

NO Revision andSupporting

Studies

Final DesignAssessment

YES

Class approval of Systems of Unconventional Design –Hybrid and Battery Designs 07 October 2015

Lloyd’s Register’s approach to Hybrid Power Systems and Battery Energy Storage

Lloyd’s Register and variants of it are trading names of Lloyd’s Register Group Limited, its subsidiaries and affiliates.Copyright © Lloyd’s Register [Entity]. 2013. A member of the Lloyd’s Register group.

Jacob Munk PlumSurveyor, Electrical DepartmentCopenhagen Technical Support OfficeLloyd’s Register EMEAStrandvejen 104 A, 2., DK-2900 Hellerup, DenmarkE jacob.plum@lr.org

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QUESTIONS ?