Installation Manual Rev.
S.W. Cooling Pumps & Engine Room Ventilation Fans
Variable Speed Drives Upgrade
Head office
ΑΒΒ SA
Athens
13th km Athens - Lamia National Rd
GR-144 52 Metamorphossi
Tel.: +30 210 2891 500
Fax: +30 210 2891 599
abb@gr.abb.com
Branch office Marine & Turbocharging
Thessaloniki Skaramagkas Cyprus
15th km Thessaloniki - N. Moudania 13th km Athens - Korinth National Rd 1, Alexandrias Str.
National Rd GR-124 62 Skaramagkas Ind. Zone Ag. Sylla, 3rd Phase
GR-570 01 Thermi Τel.: +30 210 4212 600 CY-4180 Limassol
Τel.: +30 2310 460 900 Fax: +30 210 4212 614 Tel.: +357 2534 3428
Fax: +30 2310 460 999 turbo@gr.abb.com Fax: +357 2534 3429
abbng@gr.abb.com turbo@cy.abb.com
www.abb.gr
Contents
1. DEFINITIONS AND ABBREVIATIONS 3
2. GENERAL FUNCTIONAL DESCRIPTION 3
2.1 Background 3
2.2 General design concept 3
3. SITE SURVEY ISSUES 4
4. INSTALLATION ISSUES 15
5. AFTER THE INSTALLATION 22

Installation Manual Rev.4 Page: 2

1. DEFINITIONS AND ABBREVIATIONS

MAS Machinery Automation System

VSD Variable Speed Drive
HMI Human machine Interface
DOL Direct on line
MODBUS RTU Is a register trademark of Modicon

2. GENERAL FUNCTIONAL DESCRIPTION

2.1 Background

The purpose of this document is to provide information regarding the installation of the ABB solution for
energy efficiency upgrade in the Sea Water Pumps and Engine Room Ventilation systems onboard. This
document is based on ABB installation rules and practices adapted to the specific marine project
conditions.

Sea Water circuit supply is implemented with the use of a number of sea water pumps. The number of
pumps depends on equipment particulars but in general consists from one up to three sea water pumps.
Normally one of them is always active and the rest are in standby mode in case the pressure drops below
a certain value or a failure comes up. If this happens then these pumps will start also (one at a time)
automatically.

The Engine Room ventilation system consists of a number of fans which depends on equipment
particulars. In general the number of fans is two (2) up to four (4). Normally these fans are rotating only to
one direction (air supply to engine room) but there are also cases where some of them can be reversible
also and act as exhaust fans in case of i.e. fire.

2.2 General design concept

Number of cabinets

The system consists of a number of cabinets. The number of them depends on the application but the
most common configuration includes 3 cabinets. Each cabinet can include up to two VSD.

The first cabinet accommodates the VSDs for one or two sea water pumps motors and also the PLC, the
touch panel, manual by-pass switches and a number of contactors.
Depending on customer request the touch panel can be installed away from the cabinet (i.e. on the Engine
Control Room).

The rest of the cabinets accommodate the drives/accessories for the fans.

Configuration examples:

· 2 Pumps, 4 Fans
o Total 3 Cabinets. One for the Pumps and two for the Fans
· 2 Pumps, 2 Fans
o Total 2 Cabinets. One for the Pumps and one for the Fans
· 1 Pump, 2 Fans
o Total 2 Cabinets. One for the Pump and one for the Fans

Installation Manual Rev.4 Page: 3

 PLC

The PLC is the communication and control core of the system. In particular the PLC:

· Communicates with all the drives with the use of MODBUS RTU. The PLC is the master of the
bus and controls all the drives regarding start, stop, speed, variables reading, alarm handling,
etc.
· Reads all the sensors values (temperature, pressure, etc.) with the use of analog input I/O cards.
· Communicates with the existing start panels with the use of digital inputs and relay contacts
· Calculates the reference speed values for all the drives depending on sensor measurements and
using PID control.
· Communicates with the touch panel and provides information needed for reporting, system
supervision and alarm/ events recordings.

Drives

· The drives are dimensioned according to the motors which are connected to them. One drive per
one motor model is followed.
· The speed reference and all commands are set to the drive from the PLC with the use of
MODBUS.
· Each drive protects its connected motor (for overvoltage, overcurrent, phase lost, etc…)

Touch Panel, Analog sensors and contactors

· The touch panel presents the current status of the installation in a simple and comprehensive way
and also stores historical data for reporting reasons.
· Alarms and Events, Actual speed readings, Reference point’s readings, PID settings, Sensor
readings and commissioning tools are also provided from the touch panel.
· A number of analog sensors (temperature and pressure) are used for providing all the necessary
data needed for the calculation (by the PLC) of the reference speed of all the drives.
· A number of contactors is used for merging the existing start panel discrete automation logic with
the upgrade. The existing start panels and relative MAS remain operational. Signals exchanged
include: VFD run and stop, VFD Fault, VFD Alarm indication.

3. SITE SURVEY ISSUES

Before the physical installation of equipment a site survey must take place in the engine room in order to:

· Identify the installation location of all the cabinets

· Identify the installation location of the sea water pressure transmitter
· Identify the installation location of fresh water temperature sensor
· Identify the installation location of the engine room temperature sensor
· Identify the installation location of the engine room differential pressure transmitter

Installation Manual Rev.4 Page: 4

 Cabinets Installation

The cabinet accommodating the VFDs for the PUMPS and the PLC must be installed in a place where:

· It is close to the pump motors controlled by the VFDs. In this way the power cable lengths are
minimized, installation work is simplified and costs and possible mistakes are reduced.
· It is possible to secure the cabinet not only in the floor (with the use of appropriate screws) but
also to the wall for cabinet top support. It is essential that all the cabinets are installed with both
bottom and top support for vibrations reduction.
· The cabinet is not exposed to excessive heat (from neighboring electromechanical machines or
air ducts)

Photos with already installed cabinets:

Picture 1: Cabinet bottom support Picture 2: Cabinet top support

Sea water pressure transmitter installation

The sea water pressure transmitter must be installed in the common sea water outlet of all pumps to
measure the existing sea water pressure.
Usually this transmitter is installed next to already installed measuring equipment with the use of a “T”
connector.

Photos with already installed sea water pressure transmitters:

Picture 3: Sea water transmitter Picture 4: “T” connector closer view

Installation Manual Rev.4 Page: 5

 Picture 5: Installation example on an existing drawing

è It is important to finish all welding works before connecting the pipe and the cable to the sea water
pressure transmitter

Installation Manual Rev.4 Page: 6

 Fresh water temperature sensor

The fresh water temperature sensor will be installed in the F.W. pipeline after the common outlet of the
coolers and before the 3-way valve as illustrated in Picture 6 drawing. The fresh water pipeline will have
to be drilled and prepared for the sensor installation.

Picture 6: Installation example on an existing drawing

Installation Manual Rev.4 Page: 7

 Photos from previous installations follow:

Picture 7: Position before the 3-way Picture 8:Welding of thread

valve clearly marked

Picture 9: Drilling of pipe and installation Picture 10: Electrical connection of temperature
of temperature sensor sensor

è It is important to finish all welding works before installing the sensor and connecting the signal cable

Installation Manual Rev.4 Page: 8

 Engine room temperature sensors

One temperature sensor will be installed in the engine room.

The location selected should not be exposed to air blows (no direct line on sight with air ducts) or excessive
heat (not too close to electromechanical machines producing excessive heat).

In the following photos some already installed engine room temperature sensors are displayed.

Picture 11: Welding the temperature sensor’s base Picture 12: Installing and connecting the sensor

è It is important to finish all welding works before installing the sensor and connecting the signal cable.

Differential pressure transmitter

The differential pressure transmitter is used to provide to the PLC information regarding the pressure
difference between engine room pressure and outdoor environment pressure (sea level pressure).

For that reason the unit has 2 ports for connecting pipes. One is called H (high pressure port, measuring
pressure from inside the E.R) and the other is called L (low pressure port, measuring pressure from
outdoor environment)

The location for installing the differential sensor should allow not too large pipes installed on the pressure
ports (High or Low). A maximum of 7.5 meters length per pipe is advised.

The Low pressure pipe has its end outside the E/R in a position where inspection can be done. The High
pressure pipe has its end inside the E/R in a position which is not affected by pressure fluctuations (not
direct line of sight with any air ducts, not close to doors, etc).
The unit must also be away from any source of excessive heat (away from any electromechanical
machines that produce excessive heat)

Installation Manual Rev.4 Page: 9

 In the following photos some already installed differential pressure transmitters are displayed.

Picture 13: The end of the low pressure pipe Picture 14: Pipe going inside
(outdoor). Note the intentional bend to avoid rain Pipe support example
water entrance

Picture 15: Pipe support example Picture 16: Differential pressure sensor

Installation Manual Rev.4 Page: 10

 Picture 17: Supports should Picture 18: Base should be welded.
be welded for Differential’s piping. You can use a “U Bolt” for supporting the sensor.

Picture 19: Low Pressure must be connected Picture 20: High pressure must be connected to
to pipe going outside Engine Room pipe going inside Engine Room

Installation Manual Rev.4 Page: 11

 Picture 21: Low Pressure pipe going outside Picture 22: Differential sensor low pressure
protection cover. side protection cover.

è Important:
First you must finish with welding and then install the Differential sensor.
If the sensor is installed during welding it might heat up and burn!

è Thread of sensor: Female 1/8" BSP and 1/8” NPT fittings.

Recommended tube material: Copper (Cu).

Installation Manual Rev.4 Page: 12

 Picture 23: Differential’s pipe ending in E/R
for measuring pressure inside Engine room

Installation Manual Rev.4 Page: 13

 Touch Panel in ECR

One touch panel will be installed in ECR for monitoring the proper function of the system and the energy savings.

Picture 24: Touch Panel in ECR

Make sure there is enough space for inserting a USB Stick on the back of the Touch panel.

Picture 25 Picture 26

Installation Manual Rev.4 Page: 14

4. INSTALLATION ISSUES

Transporting the equipment

The equipment (cabinets) is delivered to the customer inside robust wooden boxes designed for
transportation.

The following photo is an example:

Picture 27: Cabinet inside the transportation wooden box.

Cabinet installation

The movement of the cabinet to the installation point should be done with safety, care and properly in
order to avoid accidents and damage.

The following photos demonstrate suggested practices:

Installation Manual Rev.4 Page: 15

 Picture 28: Transport of cabinet safely. Secure during movement, avoid inclination conditions

Installation Manual Rev.4 Page: 16

 Picture 29: Hoisting of cabinet using eye bolts

Installation Manual Rev.4 Page: 17

 Cabinet Installation

As previously mentioned each cabinet should be secured to the floor (with the use of appropriate screws)
but also to a wall for cabinet top support. Bottom and top support is essential for vibrations reduction.

Power cables termination

The power cables are connected to the cabinet to the appropriate terminals according to the drawings.
Special care should be given to the termination of the grounding cable in order to minimize radio frequency
interference.
Relevant drawing follows:

Picture 30: Example of cable ground Picture 29: Example of cable ground termination
termination

Grounding the motor cable shield at the motor end

Always ground the motor cable shield at the motor end. For minimum radio frequency interference, ground
the motor cable shield 360 degrees at the lead-through of the motor terminal box.

Picture 31: Grounding at motor site

Installation Manual Rev.4 Page: 18

 Control cables termination

For the termination of the control cables pay attention to the following:

· Ground the outer shields of all control cables 360 degrees at a grounding clamp in the cable
entry box
· Keep the shields continuous as close to the terminals of the control unit as possible.
· Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with
its return wire reduces disturbances caused by inductive coupling

Relevant drawing follows:

Picture 32: Control cables termination example

Installation Manual Rev.4 Page: 19

 Control Cables installation

The installation of the control cables which namely are: Modbus Communications cables, cables from
cabinets to start panels, cables from cabinet to cabinet and sensors cables, need special attention.

It has to be avoided to be installed next to power cables. They should be installed next to other control
cables.
When control cables are to be installed inside cable trays, then cable trays which accommodate control
cables should be preferred.

Electromagnetic noise/ interference could cause errors in Modbus communication and therefore
degradation of communication quality which affects system performance.

Start panels modifications

The modifications on start panels are taking place in order to integrate the drives to the existing automation
system of the vessel.

The existing functionality is not touched.

Motor run and stop and motor faults towards the MAS system remain the same and take account of the
drives (VFDs) when in VFD mode.

ABB provides drawings for the modifications which are necessary for each start panel together with the
drawings of the cabinets.

Installation Manual Rev.4 Page: 20

 An example is illustrated below:

Picture 33: Example of Start Panel drawing (before the modification)

Picture 34: Same start panel modification drawing. Changes required are illustrated in grey.

Installation Manual Rev.4 Page: 21

5. AFTER THE INSTALLATION

After the completion of the installation make sure that the cabinet is clear and any tool or remaining of the
installation works has been removed.

Caution
Do not supply ABB’s cabinet with auxiliary 230VAC without the written approval of ABB.

1. Check that ABB's Cabinet Circuit Breaker F01 is in “off” position.

2. Turn the manual by-pass switch of Left side VFD in ABB Cabinet to position “DOL”.
3. Power up the relevant Start Panel.
4. Start relevant motor from the Start Button of the Start Panel in order to verify the correctness of
the motor’s rotation.
5. Turn the manual by-pass switch of Right side VFD in ABB Cabinet to position “DOL”.
6. Power up the relevant Start Panel.
7. Start relevant motor from the Start Button of the Start Panel in order to verify the correctness of
the motor’s rotation.

Upon successful electrification of both motors, you may continue to operate Direct On Line (manual by-
pass switch of both motors to position “DOL”), controlling the motors from the existing Start Panels, as
necessary.

Installation Manual Rev.4 Page: 22