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Technical Description
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Page 2 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
Your Ref:
Our Ref: Q17403SY00
Table of content
1 System Introduction - What is Onboard DC Grid...............................3
2 System Benefits – Why Onboard DC Grid .........................................5
2.1 Variable Speed Engines ..............................................................5
2.2 Energy Storage ............................................................................5
2.3 Safety ........................................................................................10
2.4 PEMS - Harmonized Power and Control Platform ......................10
2.5 Other Benefits ............................................................................11
3 System Components .........................................................................12
3.1 Protection Philosophy ................................................................12
3.2 Vessel Control System ...............................................................12
3.3 Power System Components.......................................................13
3.4 Energy Sources .........................................................................13
3.5 Loads.........................................................................................15
3.6 Components ..............................................................................16
3.7 Auxiliary Systems ........................ Error! Bookmark not defined.
3.8 Integrated Operations .................. Error! Bookmark not defined.
Remote Diagnostic Services .......... Error! Bookmark not
defined.
Advisory Systems............ Error! Bookmark not defined.
Page 3 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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1 Abbreviations
= = = =
~ ~
= = =
~ ~
= = = =
~ ~ ~ ~ ~ = ~
= = = = M M M M
~ ~ ~ ~
M M M M
230.00
210.00
190.00
170.00
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Load [%MCR]
The most immediate benefit of this change is reduced fuel consumption, this is
visualized in the graph above. There are also additional benefits to variable speed
operation, these are summarized below:
- Reduced Specific fuel consumption by up ~20% and ~40% for
medium and high speed engines respectively for partial load
operation
- Cleaner combustion process with less build-up of soot when
operating at partial loads
- Reduced GHG emissions due to lower fuel consumption and
reduced particle emissions due to cleaner combustion
- Increased temperature of exhaust gases at lower loads means that
SCRs can be fully operational at all load levels, reducing both NOx
emissions and urea consumption
- Potential reduction in audible noise level by more than 5dB
- Reduced maintenance costs due to reduced wear and tear on the
engine by up to 30%
DC Distribution AC Distribution
Network with or Network with
without converter swbd
Transformer
Converter with
LCL Filter
DC DC with AC with
Direct Conv. Converter
Page 8 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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The DC solutions require less equipment in general (as shown in in the diagram
above) and the converter (if used) also becomes significantly more compact than its
AC counterpart. For basic functions where no selectivity or starting scenarios are
considered, the AC converter solution is almost twice the length of the DC equivalent.
If you also consider selectivity, overvoltage and starting scenarios then this ratio
becomes closer to four.
Required Functions:
Basic Functionality
DC DC DC/AC LCL
... L ... LCU
Conv Converter Filter
800mm* 1400mm**
Solution Solution
+ 800kW Dynamic
Support
+ Overvoltage
Tolerance
+ Selectivity (1500A ...
DC DC
L ... LCU DC/AC
LCL
DC/AC
LCL
Conv Filter Filter
@690Vac) Converter Converter
+ Inrush/Starting
Currents
(1600A@690Vac)
800mm* 2800mm**
* This is added length to existing line-up
** This is a new line-up and may require additional length for cable connection.
The option of connecting the ES directly to the DC link offers a slight reduction in
length compared to the converter option. However, this is at the expense of
controllability of the current in and out of the ES and system voltage level.
From a control perspective this option means that ES power flow is determined by the
sum of the actions of all other sources and consumers in the system. This means that
this method of connection is only suited to a limited number of applications, typically
systems of low complexity where batteries represent a dominant power source.
From a system voltage perspective this option means that the system voltage is
defined by the ES and its state of charge. This can vary significantly and will therefore
require the rest of the system to be over-dimensioned significantly.
Energy Storage & Variable Speed Engines
The combination of ES and variable speed engines offers some additional synergies.
In a system with variable speed engines where energy storage is not included, the
engine needs to be operated in such a way that it always has enough reserves to be
able to absorb load steps. This need to always have some power margins in reserve
means that some optimization potential is left untouched.
Page 9 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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Our Ref: Q17403SY00
When a system is equipped with ES and the Enhanced Dynamic Support function is
activated, the ES can take on the role of absorbing quick load changes and the engine
can now optimize its operation even further.
EngineTorque
Maximum Cont.
Rating (MCR)
Propeller Curve
SFOC Contour
Fixed Speed
Curve
The effect of this is shown in the diagrams below for an example high speed machine.
360
340
320
SFOC [g/kWh]
300
280
260
240
220
200
180
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Engine load [% of MCR]
Going from fixed speed to variable speed operation, the speed vs. load path is moved
from the vertical 1800rpm axis (red line) to the propeller curve (blue line). When energy
storage is added then this path can be moved even further to the left, sometimes all
the way to the MCR curve (green line). The effect this has on the specific fuel oil
consumption (SFOC) is shown in the graph above. The figure shows the SFOC for
the traditional AC System (blue), DC grid with variable speed (green) and DC grid with
variable speed and energy storage (orange).
Page 10 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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3.3 Safety
DC is inherently simpler than AC. When building up a system platform this means that
it is easier to predict fault scenarios and devise effective protection against them. In
Onboard DC Grid this has translated into:
- Closed bus operation in DP2 without additional equipment because
common mode faults like governor and AVR failures is handled
more effectively
- Generators that can be online in close to 10 seconds1 because they
don’t need to wait for synchronization.
- Engines that are virtually impossible to overload even when
operated at lower speeds. This is because each generator has
inbuilt overload protection that limits output power. The end result
is that the engine does not stall and remains online.
- Clearing of major short-circuit currents in a “soft” way so that the
system recovers quickly and predictably. The system is therefore
not plagued by ugly transients as is often the case in AC systems
when large fault currents are interrupted by protective devices.
1
High speed engines
Page 11 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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4 System Components
For vessels with automatic charging from shore, the PEMS coordinates the process
of connecting, charging and disconnecting from charging station.
Page 13 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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DG DG DG DG DG DG
M M
circuit provides protection and selectivity for equipment downstream and also offers soft
connection to the ship system meaning that mechanical switching devices do not need to
be operated on every connection cycle.
Controls and Functionality
Each system has a dedicated PLC controller fitted in a dedicated control cabinet. This PLC
functions as a local PEMS node and also handles the local control for this energy source.
A touch panel is installed in the door of the control cabinet for local control and display
of status, alarms and events. The controller interfaces directly with the converter, ES and
its respective drive line-up. Wireless communication is provided between shore and ship
for coordination of charging sequence.
Special Features Ratings
Overvoltage limiter System Voltage : 700-1000Vdc
Undervoltage limiter ES Voltage : system voltage
Power : up to 2MW (more on
request)
4.5 Loads
Propulsion Drive – ACS800 INU
Hardware
The thruster/propulsion drive solution connects an asynchronous AC motor to an ACS800
converter that in turn is connected to the dc link, via a fused switch.
Controls and Functionality
Each system has a dedicated PLC controller fitted in a control cabinet. This PLC handles the
local control for this load and interfaces with the PEMS on the process network. A touch
panel is installed in the door of the control cabinet for local control and display of status,
alarms and events. The controller interfaces directly with the converter, motor and its
respective drive line-up.
Special Features Ratings
Under voltage control System Voltage : 1000Vdc
M Power and speed control modes Motor Voltage : 660-690Vac
available Power : up to 5.5MW (more on
Load limitation on under voltage request)
Integrated du/dt filters for reduced
motor cable rating
Page 16 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
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4.6 Components
Switching Devices – Isolator & Circuit Breakers
Hardware
Withdrawable isolators and circuit breakers are both based on ABB’s EMAX DC
family of products that offer spring-charged and motorized operation.
Special Features Ratings
Motorized System Voltage : 1000Vdc
Spring charged Currents
Lockable Isolator:
Withdrawable Isolator : < 7kA
Circuit breaker: < 5kA
Input Circuits
Hardware
Solid-state component that is used to segregate a dc-link from the DC distribution
grid. It allows free flow of load and fault current in the positive direction. In the
<- Inn negative direction it also allows free flow of load current, but will instantly block a
fault current.
Ratings
Out -> System Voltage : 1000Vdc
Iin <7kAdc
Iout < 1kAdc
Page 17 of 17
Customer: Keppel Singmarine
Project: 75T BP Hybrid Escort Tug
Your Ref:
Our Ref: Q17403SY00