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1 Electronic Soft Starters for Marine & Offshore Applications Container (Hamburg Express) LNG Support Vessel Off-shoreFPSO Navy Passenger Ship.

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Presentation on theme: "1 Electronic Soft Starters for Marine & Offshore Applications Container (Hamburg Express) LNG Support Vessel Off-shoreFPSO Navy Passenger Ship."— Presentation transcript:

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2 1 Electronic Soft Starters for Marine & Offshore Applications Container (Hamburg Express) LNG Support Vessel Off-shoreFPSO Navy Passenger Ship

3 2  Established in 1977, Solcon is designing, manufacturing and marketing soft starters, protection relays and control systems.  Solcon provides the world’s most comprehensive line of Low Voltage (LV) and Medium Voltage (MV) Soft Starters  40,000 installations since 1977 in Industrial, Marine and Offshore Applications. About Solcon

4 3  Assembly plants in Germany, Korea, Taiwan, USA and Canada. Worldwide Service centers.  Supplying to the largest electrical contractors and shipyards, Solcon is the largest supplier of soft starters for the marine industry. About Solcon TOSHIBA Rolls Royce

5 4 Solcon offers the most comprehensive line of soft starters  - LV SST up to 3MW / 1000V  - MV SST up to 50MW / 15KV  We offer:  - Vast experience in Marine & Offshore Applications (see Reference List)  - Special software to reduce inrush current & voltage drop  - Heavy duty products, easy to install, friendly operation  - Marine Approvals  About 40% of our sales are to the Marine & Offshore Industries  Solcon starters are used by major marine companies in Europe & Asia  Service centers in many countries Soft Starters for Marine & Offshore Applications

6 5 The HRVS-DN MV Soft Starters  Comprehensive line A, V  Designed for generator supply (P gen / P motor ≈1.6)  Low initial current ( ≈0.7*In) and voltage drop  Advanced Motor Protection Package  Easy commissioning and maintenance, field testing with a L.V. motor  Patent pending - Wireless SCR Firing System  Patent pending – Electronic Potential Transformer (EPT)  Fiber optic control  Meets “Partial Discharge” test requirements  Friendly operation, Multi Languages LCD - English, German, French, Spanish  Communication: MODBUS, PROFIBUS and others  Chassis or cabinet type, various options are available M.V. Soft Starters HRVS-DN

7 6 Typical starting methods:  Direct On Line (DOL)  Star-Delta  Autotransformer (ATS)  Electronic Soft Starters  Electronic Frequency Drives (VFD) What is the optimum starting method for marine application ? Starting Large Motors on board ships

8 7 Motor Current Inrush current % In Motor Torque Initial Torque % Tn Direct On Line Starting results in High Inrush Current & Mechanical Shock  The high inrush current can result in voltage drops  The high mechanical shock can result in damage to the motor, load and transmission system (gear, belt, etc.). It can also require frequent maintenance. Direct On Line Starting (DOL)

9 8 Two steps starting: Y connected (58% Un), transfer to Delta (100% Un) t U Y = 58% U nY UnUn U Y Transfer point Transfer to Delta by timer - open loop control, which may result in very high inrush current if transfer is done before motor reached close to full speed Step angle of 30° Star-Delta Starting

10 9 The inrush current of the transformer in an Auto-transformer starter may be too quick for the EVR to respond, resulting in a voltage drop 0 Sec. Un 70% 100% 32 Sec. 21% Voltage Drop Auto-transformer starting Autotransformer Starting (ATS)

11 10 M/V Blue Marlin, converted by HHI. Electrical Integrator: Alstom. Application: Starting 2 Thrusters (Lips) 4.5MW, 6.6KV Required: Starting from 2 (out of 3) generators 3.2MW each Customer considered using VFD or Soft Starters. Reduced Voltage Starters (Soft Starters)

12 11 D.O.L Soft-starter Motor Current Motor Torque Comparison Electronic SST vs. DOL

13 12 Supervision of motor and load during acceleration and deceleration Closed current loop motor condition is monitored during starting & running Soft starter M line inputLoad output Safe Starting & Stopping

14 13 Thyristor circuits, Solid state, no moving parts Thyristor Arrangement KV ~ 3 L 1 L 2 L 3 U V W

15 14 Thyristor circuits, Solid state, no moving parts Solcon supplies soft starters for motors up to 50MW at 15KV Thyristor Arrangement KV  3 L 1 L 2 L 3 U V W

16 15 DOL-Direct On Line SST-Soft Starter Voltage Ramp-up Time 2-30 / 90 sec. SSTDOL Un Initial Voltage 10-50/ 80 Un Soft starter – Voltage Ramp-up

17 16 Voltage Ramp-down Time 2-30 / 90 sec. SST dynamic decelerationDOL Un Initial Voltage DOL-Direct On Line SST-Soft Starter Soft starter – Voltage Ramp-up

18 17 Current Ramp-up Time SST – Current limit / 500% I FLA 300% Un DOL I FLA 400% In Un DOL-Direct On Line SST-Soft Starter 500% In Soft starter – Current Limit

19 18 FPSO Fluminense: - Load: Gas Compressor - Generator: 21/28MW - Tested Motor: 3.5MW - Current Limit: 3.7 x In - Starting Time: 4.7 Sec. Special software Limits initial current to 70% In Voltage drop <10%. Current & Voltage during starting (MV)

20 19 Time Torque M start Accel. Torque Motor DOL Voltage Speed Load Speed The fast increase of speed results in fast change of flow & high pressure Pump Starting D.O.L

21 20 Time Torque M start Accel. Torque DOL With soft starter Voltage Slow Accel. Speed Load Speed SST Time Soft starter - Torque Control (Starting)

22 21 Special software for “Pump Control”, reducing hammering problems Time Area of Pump Control Stop Curves Voltage Area of Pump Control Start Curves Time 123 DOL 04 Speed DOL 5 Soft Starters for Pump Starting

23 22 Electronic soft starters eliminate the inrush current & voltage drop  Low initial current ( ≈ 0.7*In) and voltage drop  Smooth voltage Ramp-up to full voltage  Designed for generator supply (P gen / P motor ≈ 1.6) Soft starter M Gen. set Soft Starters = Eliminating Voltage Drops

24 23 Electronic soft starters reduce starting torque & mechanical shock Smooth Acceleration & Deceleration (extending system’s life expectancy) Soft Starters = Reduced Maintenance

25 24 Start Run Soft Stop Stop  Too Many Starts+---  Long Start Time (Stall) +---  O/C Shear pin ++++  Overload -+--  Under Current -+--  Under / No Voltage+++-  Over Voltage +++-  Phase Loss +++-  Phase Sequence +++-  Wrong Con/ Shorted SCR +-+- Continues on next page The Soft starter provides ideal protection for the motor & the load Advanced Motor Protection

26 25 Start Run Soft Stop Stop  Heat-sink Over temp  External Fault 1 &  Unbalance Current+++-  Ground Fault Current.+++-  Power On & no Start---+  By-pass Open-+-- Advanced Motor Protection

27 26 Full remote control - Start, stop, parameter settings and supervision via Communication RS485 with MODBUS or PROFIBUS Protocols Soft Starters = Ease of Communication

28 V 10-15KV MV Soft Starters up to 50MW, 15KV

29 28 Digital Reduced Voltage Starter HRVS-DN Mode StoreReset Select On Start Run S.Stop Stop Test D. Adj. Fault CURRENT LIMIT 400% Easy adjustments for all applications, matching motor - load characteristics Easy Operation

30 29 Summary: When starting current must be reduced to avoid voltage drops, due to the low ratio between motor / Generator power. When starting torque must be reduced (mechanical problems) When starting complicated mechanical loads When starting sensitive loads When starting high inertia loads (long starting time) For frequent starting Preventing over pressure and hammer effect in pump applications When To Use Soft Starters

31 30 Cargo Pumps (LNG), Ballast pumps,Hydraulic pumps (power packs) Large motors Frequent starts Chillers (air-condition & refrigeration)  Gas Compressors (FPSO)  Water injection Pumps (FPSO) Thrusters Fire fighting pumps (LNG, FPSO) Typical Applications on ships

32 31  Heavy duty design for Marine & Off-shore Applications  Easy commissioning and operation, field testing with a L.V. motor  Comprehensive line V up to 50MW  Advanced Motor Protection package  Communication: MODBUS or PROFIBUS Solcon’s MV Soft Starters HRVS-DN

33 32  Patent pending - Wireless SCR Firing System (no wires in the power section)  Patent pending – Electronic Potential Transformer (EPT)  Fiber optic control  Meets “Partial Discharge” test requirements  Chassis or cabinet type, various options are available Solcon’s MV Soft Starters HRVS-DN

34 33 Voltages groups: 2300, 3300, 4160V 5500, 6000, 6600V 10000, 11000V 13,800, 15000V Available Ratings

35 34 Heavy duty hinges Customer Terminals Compartment Motor Protection Relay Door locks MV Cable Connection LV Compartment SST Keys (behind window) IP00 - IP67 Local Operating Buttons Secondary door locks MV Compartment Construction

36 35 Line Connection (in the back) Ground Bus Customer Terminals Soft Starter Power Section Bypass Contactor Electronic Potential Transformer (Transmitter) Motor Connection Door Switch Space Heater Line Contacrtor Medium Voltage Section

37 36 EPT Transmiter (Tx) Fiber optic Line Contactor M L2L2 L1L1 Starter Temp. Feedback Firing Trafo.. / 24V Fiber optic C/T Power Supply EPT Receiver (Rx) L3L3 By-pass Contactor Control Module Firing Cntrol Power block Medium Voltage Block Diagram

38 37 Low Voltage Section Control C/Bs Fiber-optic Connections Selector switches: * SST-DOL * Local-Remote Firing Transformer Aux. Relays Connecting Plug

39 38 1. Analogue board (Analogue output related to motor’s current) 2. Relay Card, installed for synchronous motors and optional communication option. Power Supply Board µPµP Fiber optic board Option cards: 3. Communication Board, RS 485 Control Module

40 39 Mechanical Construction 6600V <600A

41 40 LED & LCD  LEDs for quick status display  LCD Illuminated, with 2 lines, 16 characters each, Language selection: English, French, German & Spanish  Six keys, factory default parameters Medium Voltage Digital Reduced Voltage Starter HRVS-DN Mode Store Reset Select On Start Run S.Stop Stop Test D.Adj Fault CURRENT LIMIT 400% Medium Voltage Soft Starters HRVS-DN

42 Stop Soft Stop Start Input 3 (Ext. Fault - 1) Input 4 (Ext. Fault - 2) Common - B Aux. Contact “Immediate” L1 N Fault Contact (Fault / Fail Safe) Aux. Contact End Of Accel.” Input 1 - Test / Reset Common - A Input 2 - D. Adjust / Reset Firing Transformer Control Control Commands Control Supply Ext. Faults Output Relays Control Wiring

43 42 Vessel: Fluminense Operator: Shell Electrical contractor: Siemens Marine Location: Bijupira oil field near Brazilian coast 3 x 6.6KV, 400A Soft Starters for Compressors 3 x 6.6KV, 400A Soft Starters for Water Injection Pumps 1 x 6.6KV, 400A Soft Starter for Emergency Fire Pump Ship Owner: Shell Courtesy: Jurong Shipyard FPSO

44 43 FPSO - Fluminense Seawater Injection Pump Gas Compressor MV Motor Control Center

45 44 Vessel: Modec venture 11 Customer: SANTOS (Australia) Main Contractor: MODEC (Japan) Electrical contractor: Terasaki (Japan) Shipyard: Jurong (Singapore) Soft-Starters: 3 x Water Injection Pumps (11KV/250A) 3 x Gas Compressors (6.6KV/250A) 1 x Hot Oil Pump (6.6KV/140A) Ship Owner: Modec FPSO

46 45 Vessel: Berge-helena Customer: Bergessen, Norway Soft-Starters: 3 x Water Injection Pumps (11KV/250A) Ship Owner: Bergessen FPSO

47 46 Vessel: “Petrojarl 1” First FPSO concept for “PGS” Electrical system: Stadt Norway (ABB) Water Injection Pump: 6600V, 1.8 MW Ship Owner: PGS (Petroleum Geo Services) FPSO

48 47 FPSO “Petrojarl II - Foinhaven” Electrical Contractor : Siemens Norway Water Injection Pumps (11KV/350A) Ship Owner: PGS (Petroleum Geo Services) FPSO

49 48 Vessel: Bunga Kerta Electrical contractor: Terasaki Shipyards: MISC, Malaysia Nishishiba Pumps 2 speed motor at 6.6KV, 35A and 140A FPSO

50 49 Main Contractor: Samsung Heavy Industries, Supplied through ABB Marine, Norway (Similar supplied to Daewoo & Hyundai shipyards through Terasaki and C&A). LNG Cargo Pumps & Compressor, 6.6KV, 70A and 140A Multi-start - 2 soft starters, each starting 5 motors Ship Owner: Woodside FPSO

51 50 Main Contractor: SBM Monaco Application – KUITO FPSO (Angola) - Water Injection Pump ABB Motor - 6.6KV, 144A, 1.5MW FPSO

52 51 M1M1 Motor Protection Relay L 1 (Line) LB 1 (Bypass) M2M2 L 2 (Line) LB 2 (Bypass) M3M3 L 3 (Line) LB 3 (Bypass) Configurations: 2-4 (5) motors, with/without bypass, PLC or Relays, etc. SST Multi-Start (Solcon, first to introduce Multi-start method)

53 52 M1M1 Motor Protection Relay L 1 (Line) Motor Fuses M2M2 M3M3 Configurations: 2-4 (5) motors, with/without bypass, PLC or Relays, etc. SST L 2 (Line) LB 2 (Bypass) L 3 (Line) LB 3 (Bypass) LB 1 (Bypass) Disconnect Motor Fuses Disconnect Motor Fuses Disconnect Multi-Start (Solcon, first to introduce Multi-start method)

54 53 M/S Blue Marlin WARTSILA / LIPS extendable thruster Electrical Contractor: HHI 2 x 6600V, 4.5MW Retractable Thruster Ship Owner: Dockwise Shipping B.V., Netherlands Support Vessels

55 ‘Helder A” Platform, North Sea, six MV SST are installed and operating Customer: UNOCAL 76 (United Oil of California) Special requirements: Dual voltage at 2.3 & 3.3KV and Max. cabinet height meter Platform Owner: Shell (Previously UNOCAL 76) Offshore Platform

56 55 Place: ONGC MPS INDIA (Oil & Natural Gas Corporation of India, Mumbai South Platform) Location: 160Km from Bombay Main Contractor : Hyundai Heavy Industries Electrical Contractor : C&A Motor : TEMIC (Toshiba&Mitsubishi) 11,000V, 232A, 3.8MW, 1480RPM, 50Hz Load : Centrifugal Booster Gas Compressor with "Step Up" gear 9300RPM. Generators: Two 11000V,630A,12000KVA, 9600KW generators One 11000V,252A,5000KVA,4000KW generator Current signal phase 1 while starting the compressor (5 sec) ONGC MPS INDIA – before the expansion Offshore Platform

57 56 Dredger Ship - picture shown for reference only Main Contractor – A Dutch Shipyard Electrical Contractor - Siemens Holland 2 x HRVS-DN 6600V, 300A (Dredge Pumps) Ship Owner: IADC Penta-Ocean Construction Co., Ltd Dredger Ship

58 57 Driving a hydraulic pump motor for Oil and Gas fields, development Unmanned Underwater Crawler Application – Underwater Crawler Hydraulic drilling pump motor Starter Supplier – Emko Kimo India 1 x HRVS-DN 3000V, 23A, 80KW (hydraulic Power Pack) Starting Conditions x In (175A), 3000 RPM Motor, 255NM Crawler Manufacturer – THEIS Brandschutztechnik Gmbh, Siegen, Germany

59 58 Main Contractor: Shanghai Zhenhua Port Machinery CO.,LTD. Customer: Shanghai Salvage Bureau of The Ministry of Communication PRC 7000T Floating crane of ZPMC, Thruster Multi-start - 2 soft starters, 6.3KV, 250A Floating crane of ZPMC 7000 Tons

60 59 Main Contractor: 711 Institute of Shanghai Customer: Guangzhou Salvage Bureau of The Ministry of Communication PRC supplied to JingJiang Eastern Shipyard 4000T Floating crane of ZPMC, Thruster Multi-start - 3 soft starters 6.0KV, 250A Floating crane of ZPMC 4000 Tons

61 60 Passenger Vessel – BC Ferries C-Class type ferries Project Contractor – Flensburger Schiffbau, Germany Integrator - SAM Germany Motor type - 6 x 11MW at 6.6KV, Main Propulsion, 2 per Ferry Ship Owner: BC Ferries Largest in the world – 11MW Main Propulsion soft-starters Main Propulsion

62 61 Passenger Ship – Genesis with 6,400 Passengers capacity Project Contractor – Motor type - 11KV at 5MW, Bow Thruster Ship Owner: Royal Caribbean Passenger Ship - Bow Thruster

63 A A A A A A LV Soft Starters up to 3MW, 1000V

64 63 Lloyd’s Approved (ENV 1 & ENV 2) : A 1800A and above are designed to meet Lloyd’s specifications for ENV1 & 2 requirements cUL cUL Approved : 8-820A 1100A and above are designed to meet cUL requirements Canada CE Approved (EMC & Safety) : A 1800A and above are designed to meet CE requirements European UL UL Approved : 8-820A, 1100A and above are designed to meet UL requirements USA Germaniche Lloyd’s Approved: A 1800A and above are designed to meet Germaniche Lloyd’s specifications GL CCC Chinese Market CCC Approved : 8-820A Italian RINA: A 1800A and above are designed to meet RINA specifications RINA GOST-R Russian Market Russian Approved : 8-820A Det Norsk Veritas: A 1800A and above are designed to meet DNV specifications DNV Marine & Offshore EX Approval : In Process RVS-DN Approvals

65 64 Actual Voltage drop oscillogram Autotransformer Starting – Voltage Drop

66 65 Soft Starter for the Moby-Wonder Bow Thruster Ship Owner: Moby Lines Passenger Ship – Bow Thruster

67 66 Passenger Ship – Cilja Lines, 20 different installations Project Contractor - York Sweden Electrical Contractor - Electromontage Motor type - 450KW Chillers Ship Owner: Cilja Lines Passenger Ship - Refrigeration Compressors

68 67 Blue Star Paros, 2 starters 690V, 1800A - Thrusters 4 starters 690V, 820A - AC Chillers Ship Owner: Blue Star Maritime S.A. Passenger Ferry – Bow Thruster

69 68 M/S Hamburg Express Ballast pumps 9 x 580A RVS-DN starters, 440V Ship Owner: Hapag Lloyd Container Carrier

70 69 BGP-Pioneer Bow Thruster at 0.5MW / 440V Ship Owner: TGS Seismic Research Vessels

71 70 MV Lochnagar Ulstein for Petro Bras Croatian Shipyard Bow Thruster at 1.8MW / 690V Support Vessels

72 71 Ship Name - Navion Hispania Ship Type - Buoy tanker platform with storage tank for loading and offloading Application - bow Thruster 690V, 2400A Electrical Contractor - Aker Norway Power section in the rear part Control module in the front part Buoy Tanker Platform & Storage

73 72 Coal Carrier – Caribbean Islands Ship Name – Gdansk Nassau Ship Type – Coal Carrier Application - bow Thruster 690V, 2150A Electrical Contractor - ABB RVS-DN 2150 bow thruster

74 73 Vessel Name - MV Botnica Main Contractor – Aker Finnyards Sub Contractor – Ulstein Norway Motor type - 4 x Hydraulic Power Packs, each 450KW (for crane) Support Vessels

75 74 MV Northern Eagle Sabroe Refrigeration Compressors, 440V, 220KW Support Vessels

76 75 MS Syklus Hydraulic Stern Thrusters 220KW Support Vessels

77 76 MS Leinebris Ulstein Bow Thruster 110KW Private Yachts

78 77 WMO shipyard (Jotland - Denmark) 3 Vessels at 3 x 220KW LNG Pumps per vessel Three Italian LNG Carriers

79 78 CGG FOHN Shipyard: La-Spezia (Italy) Schottel 360° Azimuth Main Propulsion 2 x 1.1MW Seismic Research – Main Propulsion

80 79 Pemex (Petroleum of Mexico) Pol-Chuc platform, Dos-Bocas 6 water injection pumps 480V, 300HP Platform Owner: PEMEX Offshore Platform

81 80 AKAL-J Mexico 6 x Crude oil and Gas pumps (480V/390A)

82 81 Pemex (Petroleum of Mexico) Abkatun-A platform, Dos-Bocas location, 3 air-compressors 480, 200HP Platform Owner: PEMEX Oil & Gas

83 82 1 x RVS-DX Driving a hydraulic power pack for the “Explorer 4” robotic arm Unmanned Underwater ROV (Remote Operated Vehicle)

84 83 12 x RVS-DN Driving a medium voltage transformer V 3300V 2000 Meters underwater 440V M RVS-DN Seaway Kingfisher Seaway Kingfisher Seaway Kestrel Seaway Kestrel Seaway Discovery Seaway Discovery Seaway Harrier Seaway Harrier Seaway Invincible Seaway Invincible Seaway Hawk Seaway Hawk Seaway Falcon Seaway Falcon Seaway Eagle Seaway Eagle Seaway Commander Seaway Commander Seaway Condor Seaway Condor 12 Units for special Application to Stolt M/S Seaway Commander Seaway Kingfisher Seaway Kestrel Seaway Discovery Seaway Harrier Seaway Invincible Seaway Hawk Seaway Falcon Seaway Eagle Seaway Commander Seaway Condor

85 84 Italian Aircraft Carrier “Cavour” All auxiliary motors of the gas turbines Shock tested for 100G Naval Application

86 85 Italian / French Navies 4 x AAW class “Horizon” Frigates 16 Auxiliary motors of the gas turbines KW / 440V Tested For 200G MILC 2210 specificatiuon Test Certificates Naval Application

87 86 MIL-Spec tests included: - Temperature cycle - Mechanical shock - Vibration - Humidity & condensation - Salt mist SEM-N for Naval Applications

88 87 MPR-6 DGF (Directional Ground Fault) MCC by Terasaki (Japan) Motor Protection – Marine and Offshore - DGF

89 88 Motor Protection – Marine and Offshore LNG FINIMA – 8 Protection Relays

90 89 Thank you


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