Maritime Maritime ElectricalElectrical InstallationsInstallations

Diesel Electric Diesel Electric PropulsionPropulsion

NTNUNTNUA. K. A. K. ÅdnanesÅdnanes, ABB Marine, ABB Marine

Integrated Control SystemIntegrated Control System

Control HierarchyControl Hierarchy

User Interface - Operator Stations

System Level Control - Controllers / PLCs

Low Level Control- Governors, AVR, Protection

System Level Control FunctionsSystem Level Control Functions

Energy / Power Energy / Power ManagmenManagmen SystemSystem–– To keep power system running at optimal To keep power system running at optimal

conditions under constraints for the actual conditions under constraints for the actual operationoperation

Vessel Management SystemVessel Management System–– Manual / SemiManual / Semi-- / Automatic remote and / Automatic remote and

local control of vessel systemslocal control of vessel systems

Propulsion and Positioning Control Propulsion and Positioning Control

Sub SystemsSub Systems

Auxilliaries VMS Propulsion PMS

OS

Controllers

Local ControlI/O

Real SystemReal System

Auxilliaries VMS Propulsion PMS

Power PlantPower Plant

Vessel Loads

Propulsion Auxilliaries

Energy Management SystemEnergy Management System

Energy Production

and Distribution

Prime movers

Generators

Switchboards

Transformers

Energy Consumers

Compressors

Separators

Winches

HVAC

Pumps

Thrusters

. . .

Energy Management System

Propulsion Control System

Vessel Management

System

OtherControl Systems

Safety Systems, F&G, ESD, PSD

Power Management SystemPower Management System

PavailablePA,1 - PA,N

LoadReduction/Shedding

t

Auto stop

Tstop

PA,start

Tstart

PA,stop

PA,normalAuto start

Propulsion reduction, critical situation

Propulsion reduction, non-critical

Low Level Control and ProtectionLow Level Control and ProtectionEngine Protection and GoverningEngine Protection and Governing–– Protect diesel engine from damage, Protect diesel engine from damage,

monitoring and shutmonitoring and shut--downdown–– Speed control and load sharingSpeed control and load sharing

Automatic Voltage Regulators (AVR)Automatic Voltage Regulators (AVR)–– Voltage control and reactive load sharingVoltage control and reactive load sharing

Protection RelaysProtection Relays–– Protect el. System from overloads etc.Protect el. System from overloads etc.

Motor Drive ControllersMotor Drive Controllers

Variable Speed Drives (VSD)Variable Speed Drives (VSD)

The most commonly used converters for motor drives are:• Voltage source inverter (VSI) type converters

for AC motors, normally asynchronous motors• Current source inverter type (CSI) converters

for AC motors, normally synchronous motors• Cycloconverters (Cyclo) for AC motors,

normally for synchronous motors• DC converters, or SCR (Silicon Controlled Rectifier)

for DC motors

DOL Asynchronous MotorDOL Asynchronous Motor

Speed

Slip1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

10.90.80.70.60.50.40.30.20.10 snn

s

s

nnn −

Stator current

TorqueLoad curves- full pitch- zero pitch

DOLasynchronousmotor + CPP

SCR DCmotor drive

Cyclo- 1

converterCSI (LCI) 2 VSI PWM 3

Start-up amps Typ. 5 x ratedcurrent

≈ 0(transformer

inrush)

≈ 0(transformer

inrush)

≈ 0(transformer

inrush)

≈ 0(transformer

inrush)Start-up torque transients Typ. 2-3 x

rated torque≈ 0 ≈ 0 Up to 50% of

rated torque≈ 0

Power consumption, lowthrust

≈ 15% ofnominalpower

≈ 0 ≈ 0 ≈ 0 ≈ 0

Amps at low thrust 45-55%of nominal

F(torque) F(torque) F(torque) ≈ 0

Power Factor - full load ≈ 0.85 > 0.9 > 0.76 > 0.9 > 0.95

Power factor variation withload (cosφ)

0.15 .. 0.85(non-linear)

0 .. 0.9(prop. speed)

0 .. 0.76(prop. speed)

0 .. 0.9(prop. speed)

> 0.95(≅ constant)

Dynamic response (power,torque)

3-5 sec(pitch control)

< 100 ms < 100 ms Slower < 50 ms

Torque ripple None Smooth Smooth Pulsating SmoothZero-thrust crossing Smooth if

negative thrustallowed

Discontinuous Smooth Pulsating Smooth

Efficiency at full load High Lower High High HighHarmonic distortion:- at low speed /thrust- at full speed /thrust

NoneNone

F(torque)F(torque)

F(torque)F(torque)

F(torque)F(torque)

≈ 0F(power)

Short circuit contribution Typ. 5 xnominalpower

No No No No

Motor matching required - Some Some Yes No

Commutator No Yes No (sliprings) No (sliprings) No

Schematics of a VSD with DC LinkSchematics of a VSD with DC Link

Rectifier(AC to DC)

Inverter(DC to AC) Motor

Controller

Controls signals Measurements

Interface to control systems, commands and monitoring

Network DC Link Motor supply

3.3kV Motor drive for AM(IM)3.3kV Motor drive for AM(IM)

Generic Control Block DiagramGeneric Control Block Diagram

PI

Speedcontrol

Torquelimitation

Speedlimitation

Speedreference

Torquereference

Motorcontroller Control

signals

FrequencyConverter

Motor

FluxControl

Fluxreference

Measurementand

motor model

Speed

Currents

Fluxestimate

Torqueestimate

Speedfeedback

Torquereference

Simulation and Control DiagramSimulation and Control Diagram

Speedcontrol

PI

Torquelimitation

Speedlimitation

Speedreference

Torquereference

Torquecontrol loop

Speed

Torquereference

1

1 + Ts

Torque

1

J s

Motorinertia

KpTiS

(1 + Tis)

Loadcurve

Real Motor Controller (ABB)Real Motor Controller (ABB)

13.06.2000, ACS 6000SD Hardware Descr iptionPage 35

ABB Automation

ACS 6000 SD/AD Control Configuration

AMC3 /DDCS -OpticLinks

To the AdvantController

PC Link/Remote diag

Door panel

DI/O

PT100

Fieldbus Adapterto other systems

Te mpe rature measurement

Speed feedback (opt)

CDP312

Position feedback (opt)

INTInterface

Application and MotorController, AMC3

GateUnits

GUGateUnits

Gate Units

GU

•WCU supervision•charging/discharging•emergency stop•emergency OFF•MCB Control AI/O

S800

AI/O•Transformer supervision•Motor surervision•ON, RUN, STOP•RDY_ON, RDY_REF

DI/O

S800Option

Real Motor Controller (ABB)Real Motor Controller (ABB)

13.06.2000, ACS 6000SD Hardware Descr iptionPage 34

ABB Automation

ACS 6000 Control UnitAMCApplication andMotor Controller

S800 I/OModules

COU in Swingframe

Control of Power SemiconductorsControl of Power Semiconductors

ON OFF

ConductionLosses

SwitchingLosses

Off-stateLosses

Power SemiconductorsPower Semiconductors• Uncontrolled devices

The diode is an uncontrolled device. It will conduct current if positively biased, and block for currents when negatively biased, depending on the surrounding conditions.

• Turn-on controllable devicesThe thyristor is a device that without a gate firing signal will block currents in both directions. If positively biased and in blocking mode, a gate firing signal (current pulse) is given, the thyristor will conduct until the surrounding circuits force the current to reverse. The thyristor will then enter blocking mode by itself, until positively biased and a new gate firing signal is given.

• Turn-on and turn-off controllable devicesThe transistor is the most known component. If positively biased, the transistor can be turned on from a blocking condition by giving a gate firing signal (continuous current). If removing the gate firing signal, the transistor will re-enter blocking mode, even if positively biased. A transistor is normally not designed to tolerate negative voltage bias, or special concerns must be taken.

Power SemiconductorsPower Semiconductors

IGBT IGCT

Voltage Source Inverters (VSI)Voltage Source Inverters (VSI)

PM

ttt

cosφ = 0.95 (constant)

constant voltage

near sinusoidalcurrents

1212--pulse Rectifierpulse Rectifier

Vdc =2x1.35xVll

Ddytransformer

Vdc =1.35xVll

Series connection Parallel connection

Ddytransformer

Current and Voltage Distortion, VSICurrent and Voltage Distortion, VSI

Harmonic DistortionHarmonic Distortion

,...,,,h,..,,nxnh

1311752116

=⇒=±=

,...25,23,13,11,...2,1,112

=⇒=±=

hnxnh

6-Pulse

12-Pulse

0 %

5 %

10 %

15 %

20 %

25 %

1 2 3 4 5 6 7 8 9 10 11 12

Ih(6-p)Ih(12p)

)1(

2)(

%100i

iTHD h

h∑∞

=×=

Pulse Width Modulation

Generation of ONGeneration of ON--OFF signalsOFF signals

0 5 10 15 2

OnOff

Upper and lower switchingelements are switched in opposite orders:- ON: Upper = on, Lower = off- OFF: Upper = off, Lower = on

0 5 10 15 20 5 10 15 20 5 10 15 2

ThreeThree--level, Zero Voltage Clampedlevel, Zero Voltage Clamped

Vdc/2

Phase 1

+

0

_

Phase 2 Phase 3

Vdc/2

+

0

_

Phase

+

0

_

Phase

+

0

_

Phase

+

0

_

Phase

+

0

_

Phase

+

0

_

Phase

Positive Current:

Negative Current:

a) b)

Motor Voltage, Current, TorqueMotor Voltage, Current, TorqueTorque

Line to line voltage

Current

Control Strategies for AM (IM)Control Strategies for AM (IM)

Scalar ControlScalar ControlRotor Flux Vector ControlRotor Flux Vector ControlStator Flux Vector ControlStator Flux Vector Control

Vs

n : 1

Rs Ls Rr / sLr

LmRm Vs

Rs Ls Lr

LmRm

Rr / s* *

Operation Boundaries VSD IM(AM)Operation Boundaries VSD IM(AM)

Constant torqueregion

Field weakeningregion

Speed

Magnetic flux level

Maximum torque boundary

Maximum stator current boundary

Stator voltage

Stator frequency

Pitching momentlimitation

Operation Boundaries VSD IM(AM)Operation Boundaries VSD IM(AM)

Constant torqueregion

Field weakeningregion

Speed

Maximum torque boundaryBollard Pull, V=0

Sailing, V>0

Quadrants of OperationQuadrants of Operation

Speed

Torque

P<0 P>0

P>0 P<0

Quadrant IVBreaking

Speed>0, Torque <0

Quadrant IIIMotoring

Speed<0, Torque <0

Quadrant IMotoring

Speed>0, Torque >0

Quadrant IIBreaking

Speed<0, Torque >0

Conceptual Design ConsiderationsConceptual Design ConsiderationsLife Cycle Cost, LCC = CapEx + OpExCapital Expenditures Operational Expenditures

Man-hour cost Man-hour cost is defined as the cost of theneeded man-hours per year to operate andmaintain the facility/equipment:

• Fixed crew.• Workload dependent crew.• Contractors.• Vendors.

Spare partsconsumption cost

The total cost of spare parts andconsumables over the design life of thefacility and systems, necessary to completethe predicted work load for all maintenanceactions (i.e. preventive maintenance,corrective maintenance and servicing).

Logistic supportcost

The total logistic support cost necessary tosupport operation and maintenancerequirements for the facility and system (e.g.supply boat, diving support vessel,helicopters)

Energyconsumption cost

The total energy consumption cost for thefacility and systems. It shall include the costof fuel required to generate the power andassociated CO2 tax.

Insurance cost The total cost related to insurance for theproduction facility.

Onshore supportcost

The total cost of the required onshore supportservices and administration.

Cost of deferredproduction

The total cost of deferred production due toprobability of failure of system andequipment.

Design andadministrationcost

The total engineering and projectadministration cost from the project start tooperation.

Equipment andmaterial purchasecost

The total purchase cost associated with thesystem.

Fabrication cost The total fabrication cost associated with thesystem.

Installation cost The total cost of installing the systems andequipment.

Commissioningcost

The total cost to commission, and whennecessary certify, the installed systems andequipment.

Insurance sparescost

The total purchase cost for the initial sparesholding for the systems and equipment,necessary to obtain the required systemregularity.

Reinvestment cost The total cost to remove, refurbish orpurchase, install and commission systemsand equipment that is predicted to exceed itsdesign life during the life of the facility.

Finance costs Finance costs during construction

Operation ProfileOperation ProfileOPERATION PROFILE

0

500

1000

1500

2000

2500

0 50 100 150 200 250 300 350

DAYS 1990

kW

Fuel ConsumptionFuel Consumption

0

50

100

150

200

250

300

350

0 % 20 % 40 % 60 % 80 % 100 % 120 %

[%MCR]

[g/k

Wh]

100 200 300 400 500

500

1000

1500

2000

2500

3000

100

200

300

Days

Power, kW

Thrust, kN

Cumulativethrust demand

Fixed speedCP propeller

Variable speedFP propeller

Detailed DesignDetailed Design

During the detailed design and engineering phase, several analytical and numerical calculationsmust be performed in order to achieve safe and reliable operation, in common described asnetwork analysis or electrical power system studies:

- Load flow calculation- Short circuit calculations- Ground fault calculations- Relay coordination study- Harmonic analysis- Voltage drop calculation of inrush of transformers and starting of motors

Dependent on system configuration and vessel application the following analysis can also benecessary:

- Transient analysis of network behavior after disturbance, e.g. short circuit- Reliability or failure mode analysis

A thorough and precise work in this phase is essential for safe, reliable, and cost efficientoperations, and flexibility for future upgrades and modifications of the system later during the lifetime of the vessel.

Example Example -- old Shuttle Tankerold Shuttle Tanker

PM

PM

11kV / 60Hz

G G

4000kW

G G

M

3000kW750RPM

f1f211kV/690V

4000kW 4000kW 4000kW

Cycloconverter Cycloconverter

12000kW90RPM

M

1700kW750RPM

f1f2

M

3000kW750RPM

f1f2

M

1700kW750RPM

f1f2

Pumps

f1f2

Pumps

f1f2 11kV/69

Example Example -- new Shuttle Tankernew Shuttle Tanker

SummarySummary

Electric Installations in Electric Installations in all Vesselsall VesselsElectric Propulsion in Electric Propulsion in Cruise, Special and DPCruise, Special and DPOther Applications will Other Applications will followfollowCost, Income, LCCCost, Income, LCCVarying Operating Varying Operating Profile or Other Profile or Other RequirementsRequirements

ConceptsConceptsElectric Power System Electric Power System OverviewOverviewComponentsComponentsPrime Mover to PropellerPrime Mover to PropellerVariable Speed DrivesVariable Speed DrivesControl SystemsControl SystemsHarmonic DistortionHarmonic DistortionClass RequirementsClass RequirementsExample ConfigurationsExample Configurations