Question 1.

Power Plant as a Complex System

Emergence: In power plant there are many moving to stationary parts which contribute as whole to generate electricity. Main parts of plant are 1.Coal Conveyor 2.Stoker 3. Pulverizer 4. Boiler 5.Coal Ash 6. Air Preheater 7.Electrostatic precipitator 8.Smoke Stack 9.Turbine 10.Condenser 11. Transformer 12. Cooling tower 13. Generator 14. High voltage power line. None of these individual parts have could generate electricity from coal at high voltage. Most power plants use turbines to produce energy by burning coal or natural gas. The heat produced from combustion is used to heat water in boiler. The liquid water is converted to steam upon heating and is exhausted through a pipe which feeds the steam to the turbine. The pressurized steam flow imparts energy on the blades and shaft of the turbine causing it to rotate. The rotational mechanical energy is then converted to electrical energy using a generator. Generated electrical energy is transmitted through high voltage power lines. None of the single component has the ability to produce energy from coal. The properties of the power plant system would be difficult to predict from looking at the different parts in isolation. The overall system has "emergent properties", or characteristics that appear at a certain level of complexity but do not exist at lower levels. Emergence in this instance derives from the bringing together of different parts in such a way that their dynamic interactions result in properties, capabilities and behaviors of the whole that are not exclusively attributable to either of the rationally separable parts. And it seems that is a fairly general explanation of emergence, i.e., that emergence arises from the dynamic interactions of parts within the whole. Interdisciplinary: Electrical energy generation at power plant involves nearly every field of engineering and many of the natural and even social sciences. Within engineering, mechanical, controls, electrical, materials, and civil engineering are all important to the design and development of turbines and plants. The mathematics, physics, chemistry, and even environmental sciences are important to understanding the science of turbine based electrical energy systems. Within the social sciences, economics, policy, law, and sociology are important to understanding the larger interactions of electrical energy technology with the markets and society. The design of a turbine and plant interlinks almost all of these distinct disciplines together for a holistic and multidisciplinary design that intrinsically integrates the interests of a wide variety of stakeholders for operation over long time periods.

Hierarchy: Hierarchy of a power plant could be defined for any process, like generation of electricity, Safety process of power plant. I have tried to decompose the working aspect of power plant in hierarchal order. As shown in figure power plant is broken in three level hierarchies, even the lowest level of equipment could be broken in sub-parts. Each level offers a different order of capability to manage diverse and complex dynamics with distinctive design and managing implications for how to organize at that particular level. As a hierarchy of value (vs. power), each level has its own richness and value in itself that is subsumed into higher levels as one moves up the hierarchy. In turn, each level provides a value context for lower levels when working down the hierarchy.

Power Plant (A)

Auxiliary System (B3)

Mechanical System (B2)

Electrical System (B1)

Coal and Fuel Storage and Transporation System

Coal Conveyor

Transmission Line

Fuel Preparation System

Turbine

Step-up Transformer

Ash collection and disposal system

Cooling Tower

Electrical Generator

Lighting and communication system

Super heater

Monitoring and Alarm System

Boiler

Water treatment Plant

Question 2.a
In flight, the airplane is powered by electricity produced by the engine generators The batteries are part of the multiple layers of redundancy that would ensure power in case of power failures. Li-ion batterys unique design provides high power with lower weight and improved charging characteristics. There are many stakeholders for Li-ion battery used in Boeing 787. Stakeholder Need Boeing Company Market share and revenue Employees of Boeing Testing of Li-ion Battery system Thales Avionics Electrical Systems Tier 1 Partner GS Yuasa, Battery Manufacturer Tier 2 Supplier SecuraPlane Tier 2 Supplier Federal Aviation Administration Security and safety of civil aviation Airlines who bought 787 from Boeing More revenue from customers National Transportation Safety Board Safety of people and plane boarding the plane Airline Crew Fly the plane safely Passenger Maximum value of flight and enriched experience Power Distribution Panel Distribute power from battery to equipment Flight Control Electronics System Control the battery malfunctioning Auxiliary Power unit Provide power to auxiliary equipment Battery Design Team Design highly efficient and less weighing battery Battery failure sensing system Sense and report the battery failure Battery temperature sensing system Sense the malfunctioning of battery compartment Over-temperature warning system Monitor and warn battery over temperature Battery Design Team: Key needs of Battery design team are Lightweight Battery for Boeing 787 Design Li-ion battery with improved charging characteristics Design a high power battery which has more storage life Need for lightweight battery originated from better fuel efficiency. In order to provide better fuel efficiency it is mandatory to keep the overall weight of the plane as minimum as possible without risking the safety parameters. Another reason for the needs mentioned above is that battery to discharge a large amount of energy in a very short period of time. And this was required for two different functions at an airplane level. One was for starting the auxiliary power unit and the other was for being able to apply braking to the airplane in the event that all other power sources in the airplane were lost. The 787 braking system is an electrical braking system. It uses electric power to stop the airplane. And we need to be able to stop the airplane, perform a rejected take off on purely battery power without any other power source at all. So those two things, electric braking on the main battery, APU start on the APU battery. Those are the two things that drove Boeing to consider lithium ion batteries as the best power source. Boeing Company: Key needs of Boeing Company are Lower cost by improving fuel efficiency Lower maintenance costs and fewer maintenance tasks.

 Deliver a superior passenger experience All most all airlines follow the spoke and hub model for airport operations. In order to create more revenue Boeing wanted to change the spoke and hub model with nonstop travel between many new "city-pairs" worldwide. It will not only increase the revenue of Airlines which in turn will purchase more 787 from Boeing. More 787 will not only increase Boeings revenue but capture significant share of airline market. Running nonstop flights between distant cities needs more fuel which is getting costlier day by day and it might eat up the profit significantly. Increasing the revenue by reducing the operational cost is another need of Boeing Company. Increase in revenue for commercial Airlines could only be done by flying more passengers and passengers need more value for their money. During the flight enriched experience could lock in the customer and passenger will prefer the same flight in future.

Design and Review Design and Review

Charger Testing

Fig: Boundary and Interaction of different stakeholders of Li-ion battery

Federal Aviation Administration: Key needs of FAA are Li-ion battery should not pose greater risk than other existing battery technology Battery should have least probability of gas emission

Battery should be designed to prevent spilling flammable fluid in case of hazardous event The FAA stated that lithium-ion batteries were a novel or unusual design feature for transportcategory airplanes and that there was limited experience with the use of lithium-ion batteries in applications involving commercial aviation. The FAA pointed out that other users of lithium-ion batteries, including wireless telephone manufacturers and electric vehicle manufacturers, have experienced safety problems, including overcharging, over-discharging, and flammability of cell components. In order to promote safety it was mandatory that this new technology should not pose a greater safety risk than other technologies addressed in existing airworthiness regulations.

References:
http://www.ntsb.gov/news/events/2013/B787_hearing/presentations/GSYuasa_Panel_2.pdf

Question 2.b
The Li-ion battery that is used for the Main and the APU battery contain 8 sealed lithium ion cells that are connected together in series with thermal conductive plates and packaged within an aluminum battery box. The battery also includes the battery monitoring unit (BMU), Hall Effect current sensor (HECS), temperature sensors, internal non-latching contactor, battery failure detection and diode module failure detection (detection of high rate charge current). The BMU, which is installed within the battery, incorporates redundant circuits that generate battery status, balance cell voltages, and makes battery Built In Test Equipment (BITE) and failure annunciation to the battery charger. These protection circuits are designed to protect against overcharge, over-discharge, overheating, and ensure proper cell balancing. Each battery is charged by a dedicated Battery Charger Unit (BCU). All Battery signal and failure information are provided to the aircraft system through the BCU. If an internal battery failure is detected by the BMU, an inhibition signal is relayed to the BCU and it will stop all charging of the battery and shall annunciate the battery failure at the aircraft level. Boing 787 has two sets of Li-ion battery systems known as Main Battery and Auxiliary power unit Battery. Main Battery is located at forward electronics equipment bay; lower fuselage near the front of the airplane. Auxiliary power unit Battery is located at aft electronics equipment bay; lower fuselage; near the back of the airplane. Li-ion battery system in 787 performs many operations. Some of them are listed below.

Operation Concept 1: Stores energy and to provide power to critical equipment for finite
amount of time until electrical generation system is up during unlikely events.

Operation Concept 2: Deliver more energy more quickly and recharge faster Operation Concept 3: Provides energy during ground operations such as refueling and
powering the braking system while towing.

Operation Concept 4: Provides energy during ground operations such as refueling and
powering the braking system while towing.

Operation Concept 5: Provides energy to start Auxiliary power unit to start airplane engines. Operation Concept 6: Provide circuit protection against overcharging. Operation Concept 7: Provides the status of batterys voltage and temperature to aircraft
control system.

References:

http://787updates.newairplane.com/787-Electrical-Systems/Batteries-and-Advanced-Airplanes http://www.boeing.com/787-media-resource/docs/Sinnett-TOS-Deck.pdf http://www.ntsb.gov/investigations/2013/boeing_787/interim_report_B787_3-7-13.pdf

Question 2.c
System Requirements (1) Safe cell temperatures and pressure must be maintained during any foreseeable charging or discharging condition and during any failure of the charging or battery monitoring system not shown to be extremely remote. The lithium ion battery installation must preclude explosion in the event of those failures. (2)Design of the lithium ion batteries must preclude the occurrence of self-sustaining, uncontrolled increases in temperature or pressure. (3) No explosive or toxic gases emitted by any lithium ion battery in normal operation, or as the result of any failure of the battery charging system, monitoring system, or battery installation not shown to be extremely remote, may accumulate in hazardous quantities within the airplane. (5) No corrosive fluids or gases that may escape from any lithium-ion battery may damage surrounding structure or any adjacent systems, equipment, or electrical wiring of the airplane in such a way as to cause a major or more severe failure condition (6) Each lithium ion battery installation must have provisions to prevent any hazardous effect on structure or essential systems caused by the maximum amount of heat the battery can generate during a short circuit of the battery or of its individual cells. (7) Lithium ion battery installations must have a system to control the charging rate of the battery automatically, so as to prevent battery overheating or overcharging. (8) Any lithium ion battery installation whose function is required for safe operation of the airplane must incorporate a monitoring and warning feature that will provide an indication to the appropriate flight crewmembers whenever the state-of-charge of the batteries has fallen below levels considered acceptable for dispatch of the airplane. (9) Battery must pass mechanical tests including Random Vibration test High power vibration test Electrolyte test Shipping container shock (10) Battery must pass abuse tests including High rate charging Overcharge to 36V Nail penetration test High impedance external short circuit test (11) Battery must pass climate tests including High temperature test Low temperature test Altitude test Overpressure test

Design Trades Weights Not heat up Cooling above TBD degree mechanism of battery 9 9 Energy provided to equipment in critical need 1 Proper Fire extinguisher shall be identified to douse battery fire 3

Stakeholders Needs Battey should not overheat Battery should not emit smoke under hazardous condition Battery should not emit gas under hazardous condition Weight of battery should be minimum Cost of battery should be less Battery should not overcharge Battery should pass all mechanical tests Battery should pass all abuse tests No corossive liquid should escape in case of damage Total

8 35

9 45

9 30

9 35

Question 2.d
Requirements: 1: Lithium ion batteries on the Boeing Model 787-8 airplane must be designed and installed in such a way so that no explosive or toxic gases emitted by any lithium ion battery in normal operation, or as the result of any failure of the battery charging system, monitoring system, or battery installation not shown to be extremely remote, may accumulate in hazardous quantities within the airplane. In case of vents smoke/fire, which is classified as catastrophic and battery vent and/or smoke (without fire), which is classified as hazardous battery must fulfill three requirements 1.1 The battery shall have a probability of less than 1 x 10-7 for smoke emission. 1.2 The battery shall have a probability of less than 1 x 10-7 for gas emission. 1.3 The battery shall have probability of less 1 x 10-9 for spilling flammable fluid. 2: Lithium ion battery installations must have a system to control the charging rate of the battery automatically, so as to prevent battery overheating or overcharging, and, 2.1 A battery temperature sensing and over-temperature warning system with a means for automatically disconnecting the battery from its charging source in the event of an overtemperature condition, or, 2.2 A battery failure sensing and warning system with a means for automatically disconnecting the battery from its charging source in the event of battery failure. 2.3 The nominal voltage of battery should be 29.6 V while operation voltage range must be within 20-32.2 V 2.4 Maximum discharge capacity should not exceed 1000 A (though typically 450 A for ~45 seconds, when being used for APU start -up ,and no greater than three attempts at start up)

References:
http://www.ntsb.gov/investigations/2013/boeing_787/interim_report_B787_3-7-13.pdf http://www.prba.org/wp-content/uploads/NTSB-Lab-Report-Marchh-2013-Dreamliner.pdf http://www.ntsb.gov/news/events/2013/B787_hearing/presentations.html

Optional bonus question:

The 787 Program covers many areas of interest, from the market, customers, and airplane technology to manufacturing enhancements and an extensive partner team, among others. Boeing

vision with 787 is to sell 3,300 units over 20 years (2011-2030). During design and development Boeing targeted following things. 20 percent more fuel efficient than similarly sized airplanes 20 percent fewer emissions than similarly sized airplanes 30% savings on maintenance Extracts as much as 35 percent less power from the engines than traditional pneumatic systems on today's airplanes Boeing used electrical systems extensively on the 787 instead of traditional hydraulic equipment - a change that reduced the 787's weight but added to its complexity. Change to more electric system saves money which is main need of Boeing. Boeing and its battery supplier team proposed the Liion battery because of its better performance characteristics over other battery used in aviation industry. It is well known fact that Lithium-ion batteries can catch fire if they are overcharged, and once alight, they are difficult to extinguish because the chemicals produce oxygen. It is quiet understood that even safety is a major concern for Boeing but cost of safety measures conflicted with saving cost. It shows that even for one stake holder there is a conflicting requirement. FAA, which is governing body of civil aviation maintains and creates safety standards, stated that lithium-ion batteries were a novel or unusual design feature for transport category airplanes and that there was limited experience with the use of lithium-ion batteries in applications involving commercial aviation. The FAA pointed out that other users of lithium-ion batteries, including wireless telephone manufacturers and electric vehicle manufacturers, have experienced safety problems ,including overcharging, over discharging, and flammability of cell components. The FAA indicated that lithium-ion batteries have certain failure, operational, and maintenance characteristics that differ significantly from those...batteries currently approved for installation on large transport-category airplanes. In particular, the FAA noted that lithium-ion batteries are significantly more susceptible to internal failures that can result in self - sustaining increases in temperature and pressure (thermal runaway) than nickel - cadmium or lead - acid batteries. Requirements of Boeing and FAA have conflicted with each other on the grounds of profit vs. safety. Primary need of Boeing is to provide great value to its investors by saving more on 787 design and operation. While need of FAA is safety not the profit for Boeing investors. Conflicting requirements could be resolved or balanced by hierarchy and control concept. Hierarchical level Name Example Mission Need + Objective + Operation to meet the need = Airlines Market capture + Cost savings + production of 787 System System = Airplane + Ground support + Communication System Element Airplane = Structure + Power + Thermal Subsystem Power = Li-ion Battery + Electronics + Fuses Component Li-ion Battery = Li-ion cells + Interconnects + Battery cover Part Li-ion cells Requirements could balance if a responsibility of each level is handled by respective owners.