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Onboard DC Grid

Technical Description

Do not distribute this document to third parties.


Please refer to footnote below

Project - 75T BP Hybrid Escort Tug


Owner - Keppel Singmarine Pte Ltd
Yard
ABB ref. No. - Q17403SY00
Shipyard ref. No
Date of first issue - 2017-02-22
Revision - 00
Revision date - 2017-02-22

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.  ABB
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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.
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1 Abbreviations

AVR Automatic Voltage Regulator


BMS Battery Management System
CMS (Super/Ultra) Capacitor Management System
DC Direct Current
DDC Model name for ABBs DC/DC converter
DG Diesel Generator
DSU Diode Supply Unit
ECR Engine Control Room
ES Energy Storage
ESS Energy Storage System
ESIC Energy Storage Input Circuit
GHG Green House Gases
HMI Human-Machine Interface
IC Input Circuit
INU Inverter Unit
ISU Inverter Supply Unit
MCR Maximum Continuous Rating
NOx Nitrogen Oxide
PEMS Power and Energy Management System
PLC Programmable Logic Controler
SCR Selective Catalytic Reducer
SFOC Specific Fuel Oil Consumption
SG Shaft Generator
SWBD Switchboard
VFD Variable Frequency Converter
VMS Vessel Management System
VSD Variable Speed Drive
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Customer: Keppel Singmarine
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2 System Introduction - What is Onboard DC Grid


Onboard DC Grid is a modular DC based system platform tailored to the needs of the
next generation of marine propulsion systems.
Variable frequency converters are widely used in modern marine power systems,
often representing upwards of 80% of the installed load. Recent developments in DC
protection methods has enabled ABB to re-arrange the way these loads are connected
to the main system. This new approach distributes power on DC in order to streamline
system topology and simplify integration of energy sources like variable speed
generators and energy storage.
Onboard DC Grid meets the needs of the next generation of vessels more efficiently
by distributing power on DC instead of AC voltage.
G G G G
G G G G
~ ~ ~ ~
= = = =

= = = =
~ ~
= = =
~ ~
= = = =
~ ~ ~ ~ ~ = ~
= = = = M M M M
~ ~ ~ ~
M M M M

In a DC Grid system, the voltage from AC generators is rectified (AC to DC converter)


immediately at the terminals of the generator and from there the power is transmitted
to consumers on a 1kV DC bus. Inverters (DC to AC converter) are used to convert
the power to:
 variable frequency AC voltage in the case of variable speed motor drives
 fixed frequency AC voltage in the case of normal AC consumers connected to
a scaled down AC distribution.
Energy storage is connected to the system, either via a DC/DC converter or directly
to the DC link.
The Onboard DC Grid platform comprises mainly products with long track-records
from marine AC power systems. The novelty lies with the way these known products
are put together in a system, and the way in which this new system has been purpose
built for the marine propulsion application.
Complementing the power system is an integrated and harmonized control and
communication infrastructure that facilitates a transparent and near-instant
transmission of information between system components. This ensures a holistic
approach to the task of coaching the best performance, be it for safety or efficiency,
out of the DC Grid.
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3 System Benefits – Why Onboard DC Grid


This shift from AC to DC in the form of DC Grid is primarily driven by two main features:
1. Variable Speed Engines
2. The integration of Energy Storage
However the benefits with DC Grid is not limited to these two points. The following
sections will describe some of main benefits in more detail.

3.1 Variable Speed Engines


Unlike AC based distribution systems where connected generators need to match
system voltage and frequency, the DC Grid system only requires the generators to
match system voltage. This means that the generator and engine speed can be
dynamically optimized to the system load situation. When the engine load decreases,
the engine speed is also reduced.

270.00 Fixed Speed Speed Range: 60-100%


250.00
SFOC [g/kWh]

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%

3.2 Energy Storage


Energy Storage (ES) and associated technologies have received a dramatic increase
in attention in recent years, not least in the maritime industry. Whilst this can be
attributed to a number of different factors, what is certain is that it has the potential to
improve safety, efficiency and performance of future vessels.
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Energy Storage Functions


ES can be used in a wide range of ways onboard a vessel and most of these can be
broken down into the few basic functions (or combinations thereof) described in the
table below.
Symbol Name Description Purpose
Spinning Unit is connected and running but not • Backup for running gensets
Reserve charging or discharging energy into • Fewer engines needed online
the system. On loss of generating • Improved fuel efficiency
capacity it steps in to take the load for through higher partial load
a predefined period of time. • Reduced engine running hours
If other functions are activated
simultaneously, this function ensures
that sufficient energy is left in battery.
UPS Enhanced Same as spinning reserve, but on a • ES storage solutions can give
Ride Through local level in a sub-system like a UPS like functionality for all or
thruster or drilling drive. portions of power system
• New ways of achieving higher
ERN numbers
• Higher power system
availability
Peak Shaving Unit absorbs load variations in the • Level the power seen by
network so that engines only see the engines
average system power. • Offset the need to start new
engine
• Improved fuel efficiency
• Reduced engine running hours
Enhanced Unit absorbs sudden load changes • Instant power in support of
Dynamic and then ramps the change over on running gensets
Performance running engines. If peak shaving is • Enable use of «slower»
used, then this function is engines;
automatically included. • LNG/Dual Fuel engines
• Fuel Cells
Strategic Unit charges and discharges to • Charging and discharging ES
Loading optimize the operational point of media in such a way that it
running engines, ensuring that energy optimizes the operating point
is produced at the lowest cost, taking of the gensets.
the efficiency of the ES system into • Power is produced at peak
account. efficiency
Zero Unit powers the system so that • Zero emissions in harbour
Emissions engines can be turned off. • Quiet engine room
Operation
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Energy Storage Types


ES media fall into three broad categories; batteries, super capacitors and flywheels
where the first two seem to be gaining ground on the latter. Super capacitors are often
favored in repetitive and power intensive applications. Batteries on the other hand
have typically suited energy-intensive applications. The battery is, however, slowly
encroaching on super capacitor territory with its improving chemistries and cooling
solutions. This rapid development means that it is economically and technically viable
to use ES on an increasingly large scale in marine power systems.

Batteries Super/Ultra Capacitors Flywheel


 Energy intensive  Repetitive power  Repetitive power
Applications Intensive Applications intensive applications
 Moving into Power
applications

Integrating Energy Storage into a Power System


However; the availability of ES only gets you part of the way to improved safety,
efficiency and performance. First; the energy must be made available to consumers.
Since most Energy Storage media are DC based, the integration into a DC distribution
system becomes simpler than doing the same into an AC based distribution system.

DC Distribution AC Distribution
Network with or Network with
without converter swbd

Transformer

Converter with
LCL Filter

Energy Storage Energy Storage


Medium Medium

DC DC with AC with
Direct Conv. Converter
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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

Converter for DC Converter for AC


+ 800kW Dynamic Solution Solution
Support

DC DC DC/AC LCL
... L ... LCU
Conv Converter Filter

800mm* 1400mm**

Required Functions: Converter for DC Converter for AC


Advanced Functionality

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.
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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.

Fuel stop limit

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]

Fixed Speed Curve Propeller Curve MCR/Propeller Curve MCR Curve

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).
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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.

3.4 PEMS - Harmonized Power and Control Platform


Onboard DC Grid lowers operating costs and emissions whilst improving on power
system fault tolerance. This is possible because system integration and control is done
in such a way that it plays to the strengths of the various energy sources in the system,
and keeps the reins tight on consumers.
Onboard DC Grid has adopted a new approach to power and energy management in
the form of the Power and Energy Management System – PEMS. PEMS manages
both the balance of power (traditional PMS responsibility) and energy in the power
system. The latter becomes important when adding sources like batteries or super
capacitors with very finite amounts of energy available. The balance of power also
takes on new dimensions in a DC Grid system when sources like variable speed
generators, shaft generators and batteries operate in parallel.
So, what does it mean to “play to the strengths” of a system’s energy sources? For a
simple hybrid system this means that ES will primarily perform an energy buffering
function whilst engines provide the steady-state power.
Some of the functionality to achieve this is implemented at lower levels, closer to the
converters and ES – typically functions requiring fast response. Whilst other functions
have been implemented at a higher level such as the traditional PMS domain –
typically functions that require a level of coordination between sources. Optimal
functionality and performance is achieved through tight horizontal integration between
power sources and consumers, as well as tight vertical integration between fast
embedded control of converters and generators and the system level application.
Onboard DC Grid and PEMS have a harmonized control and communication
infrastructure that allows for a transparent and lightning-fast flow of information
between system components. This ensures a holistic approach to the task of coaching
the best performance, be it for safety or efficiency, out of a power system.
The high level of integration also means that high quality information is available to an
operator should he need it.

1
High speed engines
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3.5 Other Benefits


In addition to the benefits described above, there are numerous other benefits with
DC distribution. Some of these are summarized below:
- Power transmission: Distributing on 1000Vdc instead of 690Vac
reduces cable need by as much as ~40%.
- Voltage distortion: (THD) common in AC systems with
frequency converters is no longer a problem
- Shore connection: if shore connection is done on the DC side
vessel can more easily connect to shore connections in different
ports because network frequency is no longer an issue. Also, by
doing it this way starting currents from motors and transformers
are not drawn from the shore-connection thus allowing more
operational flexibility in ports with low-power feeders. If ES is
available onboard, then this can be operated in parallel to take
peak loads, improving operational flexibility in port even further
- Shaft Generators: variable speed shaft generators can be
integrated in the same simple way as variable speed generators.
Similarly, a PTI/PTO solution can be solved in a very streamlined
fashion, analogous with ES.
- Centralized Drive Lineup: Collecting all the drives in a central
lineup means that the need for ambient conditions (temp and
humidity) and cleanliness is reduced in e.g. thruster rooms. This is
particularly useful during construction and commissioning.
- Centralized vs Distributed: whilst most system will be highly
centralized, the DC Grid platform also supports fully distributed
systems using cables or bus-ducts.
- Space and Weight Reduction: the number of components in the
system has been reduced resulting in a reduced footprint of up to
30% as compared with an AC system.
- Electrical Efficiency: In the process of going from AC to DC
distribution the electrical system has improved by 0.5-1
percentage points.
- Variable Speed Motors: Fans and pumps represent a large
portion of the auxiliary loads on-board modern vessels. Most of
these can be operated at significantly improved efficiency by
fitting variable speed drives. This enables regulation of flow by
means of adjusting fan or pump speed instead of e.g. throttling.
The DC Grid platform is uniquely suited to tapping into this
potential in a cost-efficient way.
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4 System Components

4.1 Protection Philosophy


Onboard DC Grid employs a patented protection scheme that uses a combination of
fuses, isolators and breakers and converter control to effectively protect the system.

4.2 Vessel Control System


Onboard DC Grid uses ABB’s flagship automations platform 800xA to implement
system control functions, including PEMS and VMS.
PEMS coordinates and monitors the operation of the power system with respect to
balance of power and energy. Standard load sharing is done autonomously by the
different energy sources. The picture below shows an example ECR HMI for a simple
DC Grid system.

For vessels with automatic charging from shore, the PEMS coordinates the process
of connecting, charging and disconnecting from charging station.
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4.3 Power System Components


The diagram below shows an example DC Grid system. The following sections will
describe the main components in more detail.

Shore Vessel Vessel Shore

DG DG DG DG DG DG

M M

4.4 Energy Sources


Variable Speed Generator – UNIREC & AMG
Hardware
The variable speed generator solution comprises a synchronous generator with an
integrated thyristor rectifier and an automatic voltage regulator tailored to the needs of
a DC system. The rectifier is then connected directly to the grid via a withdrawable
DG isolator that is either located in the drive line-up or alternatively integrated into a bus-
duct.
The generator is dimensioned to deliver constant voltage throughout the full speed
range. Increasing the speed range requires an increase in the size of the generator.
Controls and Functionality
Each generator 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 generator.
A touch panel is installed in the door of the control cabinet for local control and display
of system status, alarms and events.
The controller interfaces directly with the rectifier, AVR and its respective isolator and
forms an autonomous sub-system.
Special Features Ratings
 Overvoltage protection  Voltage : 1000Vdc
 Overvoltage limiter  Speed : engine specific
 Soft-start  Power : up to 4MW (more on
 Engine stall protection request)
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Fixed or Variable Speed Generator – ACS800 DSU & AMG


Hardware
This variable speed generator solution comprises a synchronous generator with a diode
rectifier and an automatic voltage regulator tailored to the needs of a DC system. These
DG are connected to the dc link zone via a withdrawable isolator that is located in the drive
line-up together with the diode rectifier.
In the case of variable speed operation, the generator is dimensioned to deliver constant
voltage throughout the chosen speed range. Increasing the speed range requires an
increase in the size of the generator.
Controls and Functionality
Each generator 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 generator.
A touch panel is installed in the door of the control cabinet for local control and display
of system status, alarms and events.
The controller interfaces directly with the rectifier, AVR and its respective isolator and
forms an autonomous sub-system.
Special Features Ratings
 Overvoltage limiter  Voltage : 1000Vdc
 Soft-start  Speed : engine specific
 Engine stall protection  Power : up to 650kW (more on
request)

Energy Storage System – ACS800 DDC & ES


Hardware
The ESS solution comprises an ES media in the form of a battery or super-capacitor
complete with its own management system (BMS or CMS), protection and isolating
device. This is connected to the DC/DC converter (with inductor) that in turn is connected
to the dc link via a fuse-switch. The converter steps up the ES voltage to system level and
controls the energy flow in and out of the ES.
Controls and Functionality
Each ES 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 ESS. 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.
Special Features Ratings
 Overvoltage limiter  System Voltage : 1000Vdc
 Undervoltage limiter  ES Voltage : < 50% system voltage
 Over and under charge control  Power : up to 6MW (more on
request)
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Buffered Shore Charger – DC Connection with ACS800 ISU & ES Buffer


Hardware
The Buffered Shore Charger solution connects to the national grid via a step-down
transformer. From there an active rectifier controls the flow of energy into a battery that
is connected either directly to the dc link or via a DDC converter (shown to the left
without). Connection to ship is done via an input circuit and isolating device. The input
...to ship

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
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Off-grid Converter – ACS800 Off-grid ISU


Hardware
The Off-grid converter solution connects the AC distribution switchboard to the dc link, via
a transformer and inverter (with LCL filter) that in turn in connected to the dc link via a
fuse.
Controls and Functionality
Each system is controlled by a 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,
switchboard and its respective drive line-up.
Special Features Ratings
 Bi-directional power flow possible  System Voltage : 1000Vdc
 Active harmonic filtering allowing up  Swbd Voltage : project specific
to 50% converter load on swbd  Power : up to 5.0MVA (more on
 Automatic synchronisation and request)
parallel operation with other AC
sources/swbd
 120% overcurrent capability for
transients like inrush, starting currents
and short-circuit

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
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Input Circuits – for Energy Storage (ESIC)


Hardware
Solid-state component that is used to segregate a dc-link from the DC distribution
<- Inn
grid. It allows free flow of load and fault current in the positive direction. In the
negative direction it also allows free flow of load current, but will instantly block a
fault current.
Out -> Ratings
 System Voltage : 1000Vdc
 Iin < 7kAdc
 Iout < 7kAdc

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