Comprehensive Power Introduction Aug2013

Comprehensive Power Proprietary
Introduction to Comprehensive Power
 Comprehensive Power is a leading
designer and manufacturer of high-
performance permanent magnet (PM)
motors, generators, controls and drives
 We provide enabling technology for
rugged industry applications including
global oilfield, military, marine propulsion
and renewable energy
 We were founded in 1998, and are
located in Marlborough, MA
 We Invent and Produce Unique Solutions
which are Manufactured in the USA

Why PM motors?
 Full torque, even at stall speed.
 Motors can operate with higher speeds and
greater precision than achieved by the
established fluid or electromechanical
drive technologies.
 Direct-drive torque motor modules reduce
the need for power transmission
components such as gear boxes, couplings
and linkages, thereby reducing the
efficiency losses in machinery created by
these components.
 Global market for direct drive torque
motor modules has grown from $98
million in 2008 to $195 million in 2012 and
is forecast to grow to be worth nearly
$300 million in 2016.
Source: http://www.imsresearch.com/press-
release/more_machine_builders_turn_to_direct_drive_torque
_motor_modules&cat_id=201&type=LatestResearch
Example Comprehensive Power TeraTorq® motor
Torque – Speed curve

TeraTorq® motors, in green, on skids with pumps
Top Drive with a TeraTorq® Motor
 Faster setup time
 “Always On” resilient power
electronics
 Reduced Maintenance
 Less space required/lighter weight
 Reduced fuel consumption
 Safer operation for crew
We provide enabling technology to the global oilfield, renewable
energy, marine propulsion, and military industries.

Lightweight with high efficiency,
generators from Comprehensive
Power are deployed on each of the
two wind turbines in the picture.
TeraTorq® generator, yellow, in center
of turbines on right, is sealed for
subsea operation.
ORPC’s TidGen - the first grid connected tidal generation system in the US

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.
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.
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.
The Force behind Marine Electric Propulsion
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.
 Improved
maneuverability
 Full torque at low speed
 Low rotor inertia in motors
enables rapid acceleration,
deceleration, or stopping
 “Always On” / High
Uptime
 Reduced Maintenance
 Reduced Weight and
Smaller Footprint
 Reduced Fuel
Consumption
 Reduced Emissions
 Increased Safety Read about the PowerRing™ Marine Propulsion
System for Workboats at www.ecomarinepropulsion.com

 Custom motors and
power electronics
 Rugged packaging,
including motors and
encapsulated power
electronics for subsea
deployment
 High uptime, long life

 Rollers
 Presses
 Shredders
 Crushers
 Compressors
 Fans
 Pumps…
….and other high torque applications
where precise control is required
energy, marine propulsion, and military industries and…

TeraTorq® High Performance Motors and Generators
 Designed for long life use in harsh environments –
rugged, sealed, and highly shock tolerant
 Patented, propriety designs provide as much as 5X
reductions in size and weight compared to motors
and generators from other vendors
 Low rotor inertia enables unmatched, precise control
 Full torque at stall speed
 High efficiency
 Customizations for your system can include -
mounting, shaft interface, housing material,
pressure compensation for subsea deployment,
cable entries, and more
TeraTorq® motors have been deployed in subsea applications for military use since 2003, and on drill rigs since 2004. TeraTorq® motors and
generators have logged millions of hours of rugged field use.

TeraTorq® High Performance Motors
and Generators
 Compact and rugged high power motors based on a field
proven scalable design
 7 standard diameters with incremental length for added
torque
 13xx series: 13” diameter
 160 to 1,200 ft-lbs
 300 to 2,000 ft-lbs
 1,500 to 6,000 ft-lbs
 3,000 to 24,000 ft-lbs
 6,000 to 54,000 ft-lbs
 12,000 to 96,000 ft-lbs
 26,000 to 214,000 ft-lbs
 Custom motors and generators can be designed and built
 The same machine design functions well as a motor or a
generator
Page 10Comprehensive Power Proprietary

Variable Speed Generator (VSG) Operation
 Reduce fuel consumption and
emissions
 Reduce engine wear and maintenance
 Reduce size and weight
 Eliminate need for synchronization
equipment and the related complex
operational processes
CAT C32 engine with a TeraTorq® generator
About 5 feet shorter and about 8000lb lighter
vs. a ‘standard’ genset

The Most Advanced Modular Drive System
The image on the right
features multiple racks of
TIM-270s, or TIMs
(TeraTorq® Inverter
Modules).

TIMs
 200kW / 250Hp power, 9”x9”x25” modules,
typically deployed in arrays
 TIM-270 modules are fully interchangeable with
each other, reducing the number of spare parts
needed to be stocked. Any TIM automatically
performs:
 AC/DC Rectification
 DC/AC Inversion
 DC/DC Power Balancing
 TIMs are used to:
 Drive motors
 Transfer power from a generator or other
source
 Transfer power to/from a switchboard or a
battery bank

Theory of Operation - TIMs
 Each module has 6 power terminals
 DC plus, minus and ground
 3 AC (input / output) phases
 Connected to DC by IGBT switches
 Current can flow in any direction based on switch control
 IGBTs switch rapidly with Pulse Width Modulation (PWM) control
 Output is smoothed by phase inductors
 Harmonics are actively controlled and reduced
 AC voltage is between DC plus and minus
 AC phases provide or draw current on command, at any
frequency from DC to 1,000 Hz
 Modules automatically balance loads when connected in parallel
 Can draw power from lower AC voltages with active power factor
correction
Page 14
08/05/2013Comprehensive Power Proprietary

TIMs
 Designed for continuous “always on” redundant, fail-
safe system operation
 The unlikely event of a failure of a TIM-270 in a
multiple TIM system only decreases the system power
proportionately
 Such a failure will still yield continued system operation
and avoid emergency equipment shutdown
 TIM-270 modules can safely and easily be swapped or
replaced by anyone; no factory certification or special
training is required. Replacing a TIM-270 is a simple
“plug and play” operation.

TFMs (TeraTorq® Frame Modules)
 Modular, expandable drive mounting system
 Power
 Liquid cooling
 Control
 TFMs hold up to 4 TIMs
 About 49” tall, 30.5” deep, 10” wide
 All module connections are blind mate quick
disconnect for safe and foolproof operation

TCM (TeraTorq® Control Module)
 Controls the operation of TIM lineups, which may
be connected to motors, generators, renewable
energy sources, batteries, ultracaps, switchboards,
etc
 Provides information to/from a system controller
via the Modbus Application Protocol (MBAP) over an
Ethernet TCP/IP connection
 Support for web based data collection,
troubleshooting, and preventative maintenance
programs
 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
 Can help work through any unusual situation

Custom Solutions
Custom PM motors and
generators are designed and
manufactured to support power,
speed, size, weight,
operational, and environmental
requirements.
Custom drive and control
electronics can address specific
power management,
transmission, size and
packaging requirements.

08/05/2013Confidential
Example Application – Drill Rig
Feature / Benefit
TeraTorq® Motors,
TIMs
Motors and drives from
other vendors
Reduced size of generators and
drive house

Modular VFD, “always on”, self
service

Support for Variable Speed
Generation (fuel savings)

Support for driving 3rd party
motors
 ?
Safer Operation


Example Application – Direct Drive Motor for Mud Pump
Feature / Benefit
TeraTorq® Motors,
TIMs
other vendors
Reduced size of motors 
service

Direct Drive eliminates gearbox
and gearbox maintenance

Lower Rotor Inertia for more
precise control (fast emergency
stopping if ever required)


Example Application –
High Torque Motor for Active Heave Drawworks
Feature / Benefit
TeraTorq® Motors,
TIMs
AC Induction Motor
Reduced size and weight 
Wider temperature operating
range

Liquid cooled (no external blower
fan needed; no noise from fan)

Lower Rotor Inertia for more
precise control


Electric Motor Upgrade to Hydraulic Tongs
Feature / Benefit
TeraTorq® Motors,
TIMs
other vendors
Size and weight that is small
enough to fit within space of
existing hydraulics

service


Example Application – Electric HPU
Feature / Benefit
TeraTorq® Motors,
TIMs
other vendors
Reduced size and weight 
Direct Drive
 ?
Liquid cooled (no external blower
fan needed; no noise from fan)

service


Tug Boat Propulsion System
Feature / Benefit
TeraTorq® Motors,
TIMs
Motors and drives from other
vendors
Reduced size of motors, generators AND drive
cabinets

Direct drive, including full torque even at low
speed

Modular VFD, “always on”, self service, includes
built-in filtering

Variable Speed Generation – fuel savings with
advanced intelligent energy management,
reduced emissions

Support for driving 3rd party motors, such as
pumps or other equipment
 ?
Safer Operation 

Refurb of Research Vessel Propulsion System
Feature / Benefit
TeraTorq® Motors,
TIMs
Motors and drives from other
vendors
Small footprint of motors, generators AND drive
cabinets – need to fit within existing space


FAQs
 Can I use TIM drive lineups with motors or generators
that are not manufactured by Comprehensive Power?
 Yes you can (although we would like you to consider all
of our equipment, including our motors and generators,
our drives are compatible with products from other
manufacturers).
 Can a TIM really be replaced by non-factory personnel?
 Yes. After following your defined safe procedure to open
the circuit breaker for the drive line, just push a button
and pull the handle to remove a TIM, and then slide a
replacement in.
 Can I use my own housing for my TIMs, TFMs, and TCMs?
 Yes. we will assist your design efforts and support the
deployment of the equipment within your own housing.
 Also we sell rack systems and cabinets, and we can also
recommend partners who also sell racks and cabinets for
our power electronics.

FAQs (con’d)
 If a TIM fails, does my system stop operating?
 No. In the unlikely event of a TIM failure, the
remaining TIMs will continue to operate, and the drive
lineup will have proportional power available.
 Does a TIM need to be programmed or require a hardware
modification to perform an AC/DC conversion or another
function?
 No. Any TIM can perform any function, and any TIM
can be placed in any TFM slot. The TIM’s function is
controlled by a TCM which is part of the drive lineup.
 Can this drive and power electronics system function as a
Microgrid?
 Yes. TIM systems support power being supplied from
one or multiple sources, including transformers,
switchboards, grid connections, generators and battery
banks. Power can be distributed to multiple loads,
including hotel loads, MCCs, motors and battery banks.

TIMs vs. Other Power Electronics Solution
Feature / Benefit
TeraTorq® Motors,
TIMs
other vendors
1 Spare Component for any
AC/DC, DC-DC, DC/AC function

service

Truly parallel for the lifetime of
your equipment – TIMs from any
manufactured lot today, or in the
future, can automatically be
paralleled with any other TIM

Self Service

Safer Operation

Lower cost of operation – reduced
maintenance, fewer parts


Summary
 TeraTorq® Motors and generators are available up to 214,400ft-lb
 Customizations include selectable mounting, shaft interface, housing material,
pressure compensation, and cable entries
 Custom designed motors, generators, and power electronics are also available
 Our high performance equipment provides significant advantages around
 Size, Weight, Control, Efficiency
 Up time, Reliability, Ruggedness
 TIMs/TFMs/TCMs
 Power and control Comprehensive Power motors or 3rd party motors
 “Always on”
 Web based monitoring, control
 Support for heterogeneous system design - TIMs can drive TeraTorq® and 3rd
party motors

Comprehensive Power
Let us power your system.
Jeff Sable, Director Sales and Marketing
(508) 460-0010 x706
jsable@comprehensivepower.com
@jeffsable on Twitter

Comprehensive Power Introduction Aug2013

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