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Engine / Generator
Control Upgrades
CCGS Louis S. St-Laurent
MV Caribou
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CCGS Louis S. St-Laurent
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CCGS Louis S. St-Laurent
Flagship of the CCG Fleet
Built at Canadian Vickers, Montreal, PQ
In service 1969 & modernized 1988
Heavy Icebreaker - Ice Class 100A
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CCGS Louis S. St-Laurent
Diesel electric AC/DC
Triple screw – fixed pitch
5 Krupp Mak 16M453C main engines
3 General Electric DC motors
Total propulsive power 20,142 kw
Propulsion bus 6.6Kv and 560A
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CCGS Louis S. St-Laurent
Concerns
Load control and sharing units, synchronizing
units and governors suffering from many age
related dynamic problems
Hunting
Instability - ramping
Operating outside control window
Difficult to set up and retain settings
Units obsolete and parts availability an issue
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CCGS Louis S. St-Laurent
Removed
Speed & phase matching synchronizers provided frequency & phase matching
Automatic generator loading control units to soft load machines in and out of the load sharing
loop
Generator load sensors
Woodward 1000 Series speed controllers Prototype dual dynamics
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CCGS Louis S. St-Laurent
Installed
Woodward EGCP-3 Load Managers
Replaced speed & phase matching units, load
sensing units, and loading control units
Reserve functionality for further modifications
Woodward 828 electronic speed controllers
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Woodward EGCP - 3
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Woodward EGCP 3
In this application it handles:
Load sharing
Power factor
Synchronization
Sequencing
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Before & After
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EGCP-3 Louis St. Laurent
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EGCP-3 Passenger Ship Example
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The EGCP 3 is capable of much more:
Generator/engine protection
bus protection
reverse power
start/stop, etc
see handout
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Woodward 828
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Woodward 828
Designed for controlling load and speed of
engines in generating set service
Has internal circuitry and connections
designed for use in load sharing systems
Two speed inputs
Four analog inputs, three analog outputs
Eight discrete inputs, three discrete outputs
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Two Speed Inputs?
Systems with low frequency oscillatory modes due to engine and driven load inertias and flexible couplings are difficult to control.
In some instances a coupling by itself can produce torsional frequencies. We don’t want the actuator to respond to speed sensor changes it cannot control with the fuel.
The two speed inputs permit dynamic filtering.
Or the two speed inputs can be used for redundancy reasons
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Dual Dynamics?
In a marine application
Main engine clutch: out vs engaged
SS Gen circuit breaker: open vs closed
In other applications
Idle speed vs rated speed
Diesel fuel vs natural gas
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TIME
SP
EE
D
GAINADJUSTMENT
COMPENSATIONADJUSTMENT
RESETADJUSTMENT
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2nd Dynamics
Gain 2
Reset 2
Compensation 2
Gain Ratio 2
Window Width 2
Gain Slope Bk Pnt 2
Gain Slope 2
Speed Filter Freq 2
1st Dynamics
Gain1
Reset 1
Compensation 1
Gain Ratio 1
Window Width 1
Gain Slope Bk Pnt 1
Gain Slope 1
Speed Filter Freq 1
Externally Switchable Dynamics
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CCGS Louis S. St-Laurent
Upon installation of 828’s and EGCP 3’s the units were tuned/calibrated to interact with Siemens. PT’s & CT’s correct, phasing, synchronization, load
control, load sharing etc.
Operational trials alongside & at sea Stability tests and adjustments
100% load, response times, load sharing etc
Sea trials 4 days (in conjunction with Siemens trials)
Arctic trials – conducted several weeks after open water trials (looking for ice for loading purposes)
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CCGS Louis S. St-Laurent
Upgraded system
responsive
stable
reliable
TCMS witnessed test, trials and approved
installation
Crew given formal training on new controls
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CCGS Louis S. St-Laurent
Issues Project done in two main phases
Continuity of staff afloat and ashore
Re-familiarization with project
Documentation and parts
Final adjustments, tuning and trials done
while ship operational en-route Arctic
As Fitted drawings are NEVER “as fitted”
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MV Caribou
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MV Caribou
Flagship of the Marine Atlantic fleet
Built at Versatile Davie Inc, Lauzon PQ
In service in 1986 – (22 years ago!)
Class: Lloyd’s 100A1
Ice class: Northern Baltic 1A Super
15 knot economical cruising, 22 knot max
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MV Caribou
ASEA propulsion system
Twin screw – Kamewa CPP
4 MaK 8M552 main engines – 7000 bhp ea.
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MV Caribou
Concerns
ASEA propulsion controls inputting to DEGO
governor in turn controlling PGTM actuators
Instability - hunting
Frequent over speeds when manoeuvring
Harbour entry a risky proposition
DEGO unit obsolete and superseded
Finger trouble
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MV Caribou
Removed DEGO governors
Removed Kamewa rack feedback transmitters
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MV Caribou
DEGO Governors
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MV Caribou Installed Woodward 828 electronic governors
Installed Woodward PG-EG actuators
Installed PMC rack feedback transmitters
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MV Caribou
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MV Caribou
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MV Caribou
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MV Caribou
Stability tests and adjustments
Individual diesels
response at 25, 50, 75 and 100% load
response with sudden removal of 100% load
crash stops and manoeuvres at 100% load
Paralleled diesels
at 25, 50, 75 and 100% load
sudden load removal
crash stops and manoeuvres at 100% load
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MV Caribou
Upgraded system
responsive
stable
reliable
Lloyds and TCMS approved installation and
witnessed tests and trials
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MV Caribou
Issues
Ship departed port immediately after undocking
and trials carried out while underway and in
service
Blockage at turbo aftercoolers
Finger trouble with original installation
Woodward is programmable via hand held of lap top
No individual pots providing idle temptation
“As Fitted” drawings are NEVER “as fitted”
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Thank you!