DI-027-02_REV_2_PROPULSION_SYSTEM_REPORT.pdf

ORIGINAL TESTING RESULTS - FOR INFORMATIONAL USE ONLY

DI-027-02 Propulsion System Report Contract 6913G623P800007

Preliminary/Contract Design of Motor Vessel Ranger IV

Submitted by:

Loch Harbour Group

3060 Williams Drive, Suite 510

Fairfax, Virginia 22031

Preliminary/Contract Design of Motor Vessel Ranger IV

Contract No.: 6913G623P800007

CLIN-00100

DI-027-02 Propulsion System Report Revision 2

Date: April 4, 2025

DISTRIBUTION Statement C: Distribution authorized to the U.S. Government agencies and their Contractors.

Other request for this document shall be referred to US Department of Transportation Volpe Center.

TABLE OF CONTENTS

ACRONYMS AND ABBREVIATIONS

REVISION TABLE

REFERENCES

LIST OF SYMBOLS

SUBMISSION SUMMARY

A. REQUIRED EQUIPMENT

B. PERFORMANCE – OPERATING PARAMETERS

C. DESIGN BASIS & ASSUMPTIONS

D. ADDITIONAL PROPULSION INFORMATION

ACRONYMS AND ABBREVIATIONS

ACRONYM DESCRIPTION

CTO Centrum Techniki Okretowej

TAI TAI Engineers, LLC

SOW Statement of Work

LHG Loch Harbour Group

PTO Power Take Off

PTI Power Take In

CPP Controllable Pitch Propellor

FPP Fixed Pitch Propellor

SCR Selective Catalytic Reduction

SS Sea State

REVISION DESCRIPTION DATE AUTHOR

0 Initial submission 05/06/24 LHG 1 Revised submission for Design Review 4 07/11/24 LHG 2 Revised to remove outdated information 04/04/25 VOLPE

REVISION TABLE

REFERENCES

(1) Technical Report No RH-2024/T-003E Ranger IV Passenger Ferry RESULTS OF

MODEL TESTS IN CALM WATER, dated January 2024.

(2) CLIN-0010 DI-023 MODEL TEST REPORT, dated April 12, 2024.

LIST OF SYMBOLS

*See Reference (1).

SUBMISSION SUMMARY

This document is submitted by Loch Harbour Group, 3060 Williams Drive, Suite 510, Fairfax, Virginia 22031, to satisfy CLIN 00100 DI-027-02 Propulsion System Report, of Contract No.

6913G623P800007.

The purpose of this report is to present and document the supporting calculations and identify the design criteria, environmental conditions, margins and parameters used in the design and selection of the propulsion system including diesel generator sets, propulsion motors, propulsion motor drives, passive/active filters, transformers, shafting, propellers, and associated equipment.

The report includes:

• A description of the selected equipment.

• A discussion of alternatives investigated, tradeoff studies performed in arriving at the selected design, and rationale for selection of equipment.

• Diesel-electric solutions include a system harmonic analysis and sub-transient reactance calculations to show how the required power quality characteristics will be achieved under all operating conditions.

• Diagrams and lists which depict the salient features, configuration and components of the propulsion systems. Supporting calculations for each component shall be provided.

Sections (A) through (D) of this report are derived from Reference (1). However, an alternative approach has been provided for the design propeller performance in Appendix – 1. This

Appendix is derived from Reference (2), which reflects the 1500 hp engine that NPS has elected for use on the Ranger IV.

Government REVIEW and COMMENT of this report is REQUIRED.

Review Schedule: Allow 14 days for the Government review and comment before Final Design

Assessment.

A. REQUIRED EQUIPMENT

Dual Hybrid Propulsion System

• Two CAT 3512E Diesel Engines w/ Tier 4 Support Equipment

• Two Reintjes WAF 675 PTO/PTI Gearbox Assemblies

• Two VEM IE4-W61R Propulsion Motors

• Two 534 eKW Corvus Orca Battery Strings

• Two Diesel Gensets

2nd Deck Equipment Layout/Configuration

Item # Equipment Description Remarks/Miscellaneous Notes

1 Main Diesel Engines #1 & #2

#1 STBD

#2 PORT

2 Reduction Gear Box

3 Reduction Gear Box Motor

4 Diesel Generator Sets

1 2 3 4

Item # Equipment Description Remarks/Miscellaneous Notes

1 Main Diesel Engines #1 & #2

2 Reduction Gear Box

6 Diesel Generator Set

27 Propulsion Engine Selective

Catalytic Reduction (SCR)

1 2

B. PERFORMANCE – OPERATING PARAMETERS

I. Propulsion System

a. Main Propulsion Engine Options & Associated Shafting Systems

i. Diesel Engines with two shafted CPP propellors

ii. Diesel-electric with two shafted CPP or FPP propellors

b. Azipods are not allowed due to maintenance locations

II. Diesel Engines – Medium Speed Diesel

III. EPA Criterion – Must meet current EPA Requirements – Tier III or Tier IV depending on engine characteristics.

IV. Fuel – Diesel

Centrum Techniki Okretowej Calm Water Testing (See Reference (1))

CTO conducted calm water tank tests on a model Ranger IV Passenger Ferry. While CTO conducted four specific tests as laid out in the Contract/SOW, this report will focus on the self-propulsion characteristic testing & corresponding results.

Independent Variables

I. CTO provided the hull model equipped with stock propulsion system (tested at two loading conditions).

II. Computational Fluid Analysis was conducted by CTO at a speed of 15 knots.

III. Tests were executed in a deep-water towing tank sized ~ 270 meters (l) x 12 meters (w) x 6 meters (h).

a. Tank was outfitted with a towing carriage (maximum speed of 12 m/s).

b. Full scale propulsion predictions were modeled for freshwater

c. Temperature: 15°C

IV. Self-propulsion Model Tests were executed with stock propeller models CP767A and

CP768A.

V. Two Draughts of 2.515 meters and 2.743 meters.

VI. Eleven different speeds were utilized in testing: 4, 5, 6, 7, 8, 10, 12, 13, 14, 15, and 16 knots.

VII. Model Attributes

a. Scale 1:8.269

b. Material Composition: Wood

c. Outer surface of model was hydrodynamically smooth

d. Turbulisation: 1.0 mm diameter wire at station 19

e. Appendages: Shafts with brackets, rudders with headboxes, bilge keels, thruster tunnel with grids

f. Hull Version/Model: M1143 was used (see Reference (1) for Hull Data)

Propeller Proficiency Testing (see Reference (1))

CTO Test Results / Conclusions (see Reference (1))

Sketches of Model Features (see Reference (1))

Electrical Load Analysis

See DI-030 Electric Power Load Analysis

C. DESIGN BASIS & ASSUMPTIONS

CTO Propulsion Test Characteristics (see Reference (1))

Self-Propulsion Test Results (see Reference (1))

Trips/Transit Profile

Sea State Conditions

Calculations/Measurements Performed by TAI Engineering

Desired Fuel Features

Fuels must be readily available in Houghton, MI but cannot limit the operation of the ship.

Calculations/Measurements Performed by TAI Engineering

Propulsion System Trade-Offs

Propulsor Assembly

Dual Direct

Drive Propulsors

Dual Hybrid

Propulsors

Dual Disel

Electric

Propulsors

Dual Diesel

Electric Hybrid

Propulsors

2 Diesel Engines w/ Tier 4

Support Eqpt

X X

2 Direct Drive

Gearbox Assy’s X

2 Ship Service

Diesel Gensets X X

2 Sets Elec Eqpt

(swbds, xfmrs, etc.)

X X

2 PTO/PTI

Gearbox Assy’s X

2 Motors /

Generators X

2 Battery Strings w/ Assc Elec

Eqpt

X X

2-4 Diesel

Gensets w/ Tier

4 Supp Eqpt

X X

2 Propulsion

Motors X X

2-4 Sets Elec

Propulsion Eqpt

(swbds, xmfrs, etc.)

X X

Propulsion Business Evaluation

Business Case/Risk Assessment performed by TAI Engineering

D. ADDITIONAL PROPULSION INFORMATION

CTO Experiment / Test Assumptions (see Reference (1))

Lightship Weight Breakdown

Calculations Performed by TAI Engineering