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MAY 2017 Shore-to-ship power Converters ACS6000 SFC & PCS100 SFC Description Roberto Bernacchi, Global Product Manager

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Page 1: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

MAY 2017

Shore-to-ship power ConvertersACS6000 SFC & PCS100 SFC Description

Roberto Bernacchi, Global Product Manager

Page 2: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 2

Agenda

Page 3: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Not all the world’s power is at the same frequency

Static frequency converters for Shore-to-Ship Power

July 31, 2017~80% of ships worldwide are 60Hz

Slide 3

50 Hertz

60 Hertz

50/60 Hertz

Page 4: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

– The world comprises of 50 Hz and 60 Hz power networks and most equipment is designed to operate at the designated frequency

– In developing countries the frequency of the power supply may not be sufficiently regulated to allow correct operation of sensitive equipment

– The majority of ships operate with 60 Hz generators, however when in port they would like to connect to shore side electricity (50 Hz in Europe and Asia)

– Equipment manufactured for 60 Hz utility may be relocated to different parts of the world and required to operate from 50 Hz, or vice versa

– These are the main problems that can be solved with the PCS100 or ACS6000 SFC (Static Frequency Converter)

The problem: 50 Hz or 60 Hz

Static frequency converters for Shore-to-Ship Power

July 31, 2017 Slide 4

Page 5: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Frequency conversion concept

Static frequency converters for Shore-to-Ship Power

July 31, 2017 Slide 5

f1~

~

=

=f2

Page 6: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Applications and segments overview

Static frequency converters for Shore-to-Ship Power

July 31, 2017 Slide 6

Page 7: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

A complete portfolio

Static Frequency Converter for Shore-to-Ship Power

July 31, 2017 Slide 8

PCS100 SFC ACS6000 SFC

5 – 24 MVA / unit0.1 – 2 MVA / unit

Higher power ratings can be achieved by paralleling units

Page 8: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

PCS100 SFC

ACS6000 SFC

Power converter portfolio

Static Frequency Converter for Shore-to-Ship Power

July 31, 2017* Higher power levels can be obtained by paralleling units

Slide 9

0.1 MVA up to 4MVA

– LV IGBT technology

– Forced air cooling

– 0.1 – 2 MVA *

5MVA up to 24 MVA

– MV IGCT technology

– Closed loop liquid cooling

– 5-24 MVA *

Lowest Opex• highest efficiency• highest availability• lowest maintenance costs

Lowest Capex• Smallest weight and footprint• Scalable solution

Lowest project execution & operation risk

• Expert application know how available

• Simulation models available

ABB global footprint• Global Service organization• Global service support

Benefits• Most economic solution

(Opex and Capex) to make frequency fit

Market segments• Green port• Cruise• Container• RORO ferry• Shipyards• FRSU/FSU• Naval ports

Standard Features:• 50 or 60 Hz grid control• Load side transformer

pre-magnetization• Synchronization and

blackstart

Additional Optional Features:• Marine certification• NRTL certificates

Frequency converter Rated power Value proposition Application details

Page 9: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 10

Agenda

Page 10: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Overview

ACS6000

July 31, 2017 Slide 11

– Modular closed-loop water-cooled frequency converter

– Versatile control platform with Optimized Pulse Pattern for special applications (like SFC and S2SP)

– Two Quadrant Operation (Input: 12 or 24 pulse diode bridge) or Four Quadrant Operation (Input: 6, 12 or 18 pulse IGCT Active rectifier)

– Output: IGCT Inverter

– Voltage range : 2.3…3.3 kV, any other voltage available with output transformer

– Power range : 5…24 MVA

– Output frequency range : 50/60 Hz (others available on request)

– Parallelability and scalabilty

Page 11: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Industrial converter for demanding applications

ACS6000 SFC

July 31, 2017 Slide 12

Industries Applications

Cement, Mining and Minerals Mine hoists, conveyors, crushers and mills

Chemical, oil and gasPumps, compressors, extruders, mixers and blowers

MarineMain propulsion, thrusters (pumps and compressors)

Metals Rolling mills, coilers

Pulp and paper Fans, pumps, refiners and chippers

Power generation Fans and pumps

Water Pumps

Special applications

Shore-to-ship power

Static Frequency Conversion / Grid Intertie

Test stands

Wind tunnels

Page 12: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Benefits with modular design

ACS6000

July 31, 2017 Slide 13

All ACS6000 drives are configured of a combination of standardized modules

The modules can be arranged according to the required output power and application specific needs

Benefits

– Optimal adaptation of converter rating according customer requirements

– Customer specific engineering can be taken into account with the flexible Control, Terminal and Interface units

– Each configuration consists of well-proven industrial components

– Compact, standardized design reduces space requirements

– Reduced installation and commissioning time

ACS6000

Base

Module

Pre-defined

interfaces

for power,

cooling and

control

connections

LSU

COU WCU

CBU

CIU IFU

ARUINU

TEU BCUVLU RBU

Page 13: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Modular design

ACS6000 SFC

July 31, 2017 Slide 14

Terminal and Control Unit Contains the power terminalsand the control swing frame

Inverter UnitSelf-commutated, 6-pulse, 3-level voltage source inverter with IGCT technology

Capacitor Bank Unit DC capacitors for smoothing the intermediate DC voltage

Water Cooling Unit Supplies the closed cooling system with deionized water for the main power components

Active Rectifier Unit (ARU)Self-commutated, 6-pulse,3-level voltage source inverterwith IGCT technology

Page 14: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Model ratings & dimensions

ACS6000 SFC

July 31, 2017 Slide 15

Double Power UnitDouble (filterless)

11 times switching OPPs

Triple Power UnitTripple

HEAT LOSS DIMENSION WEIGHT

ID Configuration Name

Max continuous

output power

[MVA]

Overload

capability

[10 sec]

Short circuit

limit

[1 sec]

GRID SIDE LOAD SIDEInto WATER

[kW]

WxDxH

[mm]kg

Double-ACS6109_L12_2a05 7,5 135% 162% DIODE (12p) 2 UNITS (12p) 93 8830x1069x2162 7645

Double-ACS6107_A06_2a05 7,5 126% 180% ACTIVE (6p) 2 UNITS (12p) 134 9130x1069x2479 8395

Double-ACS6109_L12_2a7 7,5 226% 226% DIODE (12p) 2 UNITS (12p) 85 8830x1069x2162 7885

Double-ACS6114_L12_2a7 13 130% 130% DIODE (12p) 2 UNITS (12p) 149 9030x1069x2162 8015

Double-ACS6207_A12_2a7 14 129% 134% ACTIVE (2*6p) 2 UNITS (12p) 231 11830x1069x2479 10780

Double-ACS6114_L12_2a9 14 127% 135% DIODE (12p) 2 UNITS (12p) 163 9030x1069x2479 8195

Double-ACS6209_A12_2a9 15 126% 151% ACTIVE (2*6p) 2 UNITS (12p) 250 11830x1069x2479 10960

Triple-ACS6209_L24_3a7 18 141% 141% DIODE (24p) 3 UNITS (18p) 201 13530x1069x2162 11940

Triple-ACS6209_A12_3a7 18 157% 157% ACTIVE (2*6p) 3 UNITS (18p) 307 14530x1069x2479 13575

Triple-ACS6214_L24_3a7 21 121% 121% DIODE (24p) 3 UNITS (18p) 242 14930x1069x2479 13185

Triple-ACS6214_L24_3a9 26 125% 125% DIODE (24p) 3 UNITS (18p) 314 14930x1069x2479 13185

Triple-ACS6309_A18_3a9 27 134% 134% ACTIVE (3*6p) 3 UNITS (18p) 469 17030x1069x2479 15970

Triple-A

Triple-B

MODEL INTERFACENOMINAL RATING (c)

Double-A

Double-B

Page 15: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Inverter units (INU)

ACS6000 SFC

July 31, 2017 Slide 16

Double–A INU Double-B INU Triple INU

… up to 7,5 MVA … up to 15 MVA … up to 24 MVA

One power stage is consisting of 3 phase modules in 3-level topology

– Snubberless topology

– Fuseless design

– Discrete GCTs and diodes

Page 16: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Diode rectifier units (LSU)

ACS6000 SFC

July 31, 2017 Slide 17

Passive diode rectifier (named LSU / line supply unit)

Double-A & -B: 12-pulse ( ≤14 MVA)

Triple: 24-pulse ( ≤ 24 MVA)

– Used when higher power is needed

– Used when harmonic requirements cannot be fulfilled with 12-pulse

Maintains power factor at 0.95 in the whole operating range

Page 17: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Active Rectifier Unit (ARU) / Inverter Unit (INU)

ACS6000 SFC

July 31, 2017 Slide 18

Active Rectifier Unit (ARU) rectifies the AC line voltage and charges the DC link capacitors

Inverter Unit (INU) inverts the DC voltage to the AC motor voltage

ARU and INU have identical layout and equipment

– 6-pulse, 3-level voltage source inverters

– IGCT technology

ARU allows four-quadrant operation and controls grid side power factor

Power electronics building block (IGCT)

Page 18: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Capacitor bank and water cooling units

ACS6000 SFC

July 31, 2017 Slide 19

– Centralized unit configured based on the required power

– Automatically dimensioned for both Single and Multi units topology

– Integrated soft charging unit

– Integrated discharging unit

– Separate water cooling unit available in 2 different sizes (800 and 1400 mm wide)

– Equipped with single or redundant pumps

– All needed instrumentation integrated and monitored by the drive control

DC capacitor unit (CBU) Water cooling unit (WCU)

Page 19: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Control and terminal Units

ACS6000 SFC

July 31, 2017 Slide 20

– One control unit per system

– Common cabinet with power cable terminal unit

– Power cable terminal unit

– Can be equipped with various options like motor operated disconnectors etc.

Control unit (COU) Terminal unit (TEU)

Page 20: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Reverse power flow limiting units

ACS6000 SFC

July 31, 2017 Slide 21

– The energy stored in the DC link is dissipated in resistors (1).

– IGCT semiconductors (2) switch the energy to the resistors.

– The energy generated during braking is dissipated in water-cooled resistors (1)

– IGCT semiconductors (2) switch the energy to the resistors

– The energy generated during braking is dissipated through an external resistor

– IGCT semiconductors switch the energy to the resistors

Voltage Limiting Unit (VLU) Resistor Braking Unit (RBU) Braking Chopper Unit (BCU)

Page 21: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Additional benefits

ACS6000 SFC

July 31, 2017 Slide 22

IGCT semiconductors

– An ideal switch for high-powered medium voltage applications

– Low parts count

– High efficiency and reliability

Fuseless design

– Faster and better protection than medium voltage power fuses

Long-life capacitors

– Advanced, environmental friendly, oil-filled foil capacitors

– Lower lifetime costs

Network robustness

– Operation in unbalanced network (up to 25% asymmetry) possible

– Ride through capability for supply voltage dips

– Electric arcs represent a hazard source for people and equipment

– ACS6000 offers the highest possible level of safety thanks to ABB’s Arc Guard SystemTM

– The IAC classified solution assures very fast arc detection and elimination

Reliability Performance Safety

Page 22: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Active Rectifier Unit (ARU) / Inverter Unit (INU)

ACS6000 SFC

July 31, 2017 Slide 23

– Visual and mechanical checks

– Water pressure and insulation tests

– Auxiliary, control and protection devices checks

– Rated current and temperature rise tests

ABB is committed to ensuring the reliability of every drive it delivers

Routine tests

Page 23: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Simple and efficient maintenance

ACS6000 SFC

July 31, 2017 Slide 24

Reliable components

– ABB drive technologies (IGCT semiconductors, multilevel-fuselesstopology) provide low parts count, increasing reliability and availability

Easy access

– The ACS6000 allows easy front access to the drive’s components

Redundant cooling

– The cooling equipment is available with redundant pumps which increases availability

Page 24: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Worldwide service and support

ACS6000 SFC

July 31, 2017 Slide 25

– Supervision of installation and commissioning

– Training

– Remote diagnostics

– Customized maintenance contracts

– Local support

– 24 x 365 support line

– Spare parts and logistics network

– Worldwide service network

Page 25: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 26

Agenda

Page 26: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

The solution

PCS100 SFC – product

July 31, 2017 Slide 27

– The ABB PCS100 SFC is a clean, efficient way to provide the frequency and voltage required

– Complete low voltage product range from 125 kVA to multi MVA

– Modular power electronic architecture

– Parallel capable

– Synchronizing and load limiting functions

Page 27: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Modular construction 125 kVA to 2 MVA

PCS100 SFC – product

July 31, 2017 Slide 28

– Housed in 800mm cabinets

– 125 kVA power modules

– Minimum spares required

– Fast replacement

Page 28: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Ratings

PCS100 SFC – product

July 31, 2017 Slide 29

Page 29: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Specifications

PCS100 SFC – product

July 31, 2017 Slide 30

Input

Output

Standards

Environment

Interface

Page 30: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Master controller and GDM

PCS100 SFC – How it works

July 31, 2017 Slide 31

– The PCS100 SFC is controlled by a master control module which contains all the firmware for the system and user I/O

– The control I/O is;

– Inputs – Start and Stop / Reset

– Output – Run, warning and fault relays

– The operator controls the SFC via the touch panel LCD display (Graphic Display Module, GDM)

– Event logs, fault information and menus are accessed via the GDM

Page 31: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Rectifier module

PCS100 SFC – How it works

July 31, 2017 Slide 32

– IGBT active rectifier with local controller

– 4 kHz narrow band switching

– Bi-directional power flow

– THDi < 3% Typ. = Unity power factor

– Regulated 750 V DC output

– Air cooled

RFI

Page 32: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Inverter module

PCS100 SFC – How it works

July 31, 2017 Slide 33

– IGBT inverter with local controller

– 4 kHz narrow band switching

– Integrated LCL output PWM filter

– Sinusoidal output voltage < 1.5% THD

– Short circuit proof 200% current limit

– Air cooled

RFI

Page 33: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Sinusoidal PWM modulation

PCS100 SFC – How it works

July 31, 2017 Slide 34

– PWM has no harmonic distortion

– Modulation frequency (4 kHz) is removed by filter

– Inverter creates sinusoidal voltage, rectifier creates sinusoidal current

RFI

Page 34: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Transformer requirements

PCS100 SFC – How it works

July 31, 2017 Slide 35

– An input or output transformer is required to isolate the converters common mode voltage

– An output transformer provides isolated 4 wire output. This configuration is suitable for 380 480 V input supplies

– An input transformer configuration may be preferable if the input is < 380 V or > 480 V, and the output desired is 380-480 V 3 wire

PCS100 SFC Converter

Output Transformer

Load

380-480V Supply

3 3

480V

4

LV or MV

PCS100 SFC Converter

Input Transformer

LoadLV or MV

Supply

3 3

380-480V480V

Note: Neutral must

be left floating (no

connection to SFC

or ground)

Page 35: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Complete system

PCS100 SFC – How it works

July 31, 2017 Slide 36

Rectifier Inverter Transformer50 Hz input

60 Hz output

RFI RFI

Page 36: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Protection and fault handling

PCS100 SFC – How it works

July 31, 2017 Slide 37

– Modules have their own internal controller with synchronized waveform generation

– Power module redundancy means the system can keep going if one module is not working

– Output is short circuit protected with a current limit at 200% for 0.5 sec

– Programmable output over and under frequency and over and under voltage trips

Page 37: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Power module redundancy

PCS100 SFC – How it works

July 31, 2017 Legenda rectifier inverterSlide 38

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module stops only

affected module

pair)

Rectifier

Inverter

Rectifier

Avaliable power 0 kVA/ 0 % (fault with onemodule stops thewhole system)

MTTR 30min

Avaliable power 1875 kVA / 93.7 %

MTTR 30min orcontinue operationuntil scheduledmaintenance

Page 38: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Automatic synchronizing

PCS100 SFC – How it works

July 31, 2017 Slide 39

The PCS10 SFC includes a built in synchronizer

The synchronizer is used to automatically synchronize its output to a live AC bus before starting

Synchronization procedure as follows:

– SFC is given a start command

• SFC measures its output, as it is live it synchronizes the internal control loops to this voltage, frequency and phase.

– SFC starts running in parallel with the generator

– Generator can be unloaded and SFC used to supply the switchboard

Loads

Switchboardi.e. Onboarda ship

OutputInput

Page 39: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Parallel load sharing

PCS100 SFC – How it works

July 31, 2017 Slide 40

Two or more PCS100 SFC’s can be paralleled together to supply larger loads

No communication between units or additional hardware is required to allow paralleling. Load sharing is done using droop

– Droop works independently on voltage and frequency and is expresses as a % of nominal, i.e. 1% frequency droop and 5% voltage droop

– Droop means the voltage and frequency will drop slightly when load is increased on the converter, giving a natural balancing effect

– This is like having virtual resistor on the SFC output, therefore allowing the two voltage sources to share

Generators also share powerusing droop, meaning theSFC can also share powerwith other generators

Page 40: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Parallel load sharing – the tandem bicycle analogy

PCS100 SFC – How it works

July 31, 2017 Slide 41

– Imagine a tandem bicycle – both riders are peddling at the same speed (frequency) on the flat road. Their goal is to keep the bicycle speed constant (frequency set point)

– They then go up a hill the front rider (call him SFC1) keeps going at the same speed but the back rider (SFC2) can’t quite maintain the same speed

– Who does the most work (power) ?

– Imagine now the riders are going up the hill again, but this time they have agreed to reduce speed slightly as load increases (use droop)

– Now if one rider is feeling overloaded he reduces speed slightly, which means the load is picked up by the other rider and they balance out

– The exact same mechanism is used by the PCS100 SFC!

Page 41: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Parallel systems

PCS100 SFC – How it works

July 31, 2017 Slide 42

Typical multi MVA system example

Page 42: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Parallel load sharing – the tandem bicycle analogy

PCS100 SFC – How it works

July 31, 2017 Slide 43

– Standard SFC construction is in IP21 cabinets

– IP 23 and IP42 are also possible but additional cost

– PCS100 SFC systems can also be integrated into outdoor enclosures i.e. containers for shore to ship power supply

SFC with louver doors for IP23

Page 43: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Parallel load sharing – the tandem bicycle analogy

PCS100 SFC – How it works

July 31, 2017 Slide 44

Additional I/O is available via the optional CAN I/O Board

– 4 programmable relays

– 7 programmable digital inputs

– RS-485 modbus communications

– Thermal input (PTC or thermostat)

– 2 analog inputs (+/- 10 V or 4-20 mA)

– 2 analog outputs (+/- 10 V or 4-20 mA)

For use with signals such as:

– Overload feedback (relay)

– Synchronised feedback (relay)

– Droop enable (digital input)

– Load power (analog output)

CAN I/O board fits onto the side of the master module

Page 44: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Remote synchronizing

PCS100 SFC – How it works

July 31, 2017 Slide 45

– The PCS10 SFC has an option to perform remote synchronizing

– This synchronizer is used where the SFC is running and it needs to synchronize its output to another bus

– If the SFC and generator are running and the switchboard bus tie is to be closed

– SFC is given a synchronize command

• SFC measures the voltage on the remote synchronizing sensing board and adjusts its output (while running) to match

• Synchronized feedback is given from SFC (via CAN I/O relay or modbus)

– The bus tie can now be closed. Synchronize command is removed from the SFC

Loads

Split Switchboard i.e. Onboard a ship

Bus tie

Loads

Voltage Sensing Board

OutputInput

Page 45: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 46

Agenda

Page 46: ACS6000 SFC & PCS100 SFC Description - · PDF fileShore-to-ship power Converters ... –One control unit per system –Common cabinet with power cable ... – Ride through capability

6 MVA RFC – Typical system

SFC vs RFC – Case study

July 31, 2017 Slide 47

– Air insulated/SF6 MV feeder switchgear

– Feeder transformer: dry type transformer (20 kV / 6 …15 kV)

• Note: Feeder transformer may not be necessary for 15 kV

– Motor: 6 …11 kV brushless excited 10-pole synchronous machine

– Generator: 6 …11 kV brushless excited 12-pole synchronous machine

– Air insulated/SF6 MV load switchgear

Feeder

transformerFeeder Switchgear Load switchgear

Motor

Excitation

unit

Generator

Excitation

unit

Motor GeneratorCoupling

6...11kV

60 Hz

0.4...0.6kV

50 Hz

6.6...11kV/60Hz

Generator

Protection

relaying

Motor

Protection

relaying

Transformer

Protection

relaying

Transformer

Protection

relaying

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– Motor (6MVA):

• Length: 4 m x Width: 1.8 m x Height: 3 … 4.5 m

• Weight: 23.4 tons

– Generator (6MVA):

• Length: 4 m x Width: 1.8 m x Height: 3 …4.5 m

• Weight: 27.3 tons

– System space req. including RFC, Control, Switchgear excluding transformer:

• 9(+3) m x 1.5(+2.0) m x 4.5(+1) m 211 m3

– Overall system weight including RFC, control, switchgear excluding transformers: Approx. 56 tons

6 MVA RFC – Required space for installation

SFC vs RFC – Case study

July 31, 2017 Slide 48

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– Control system:

• Sequences (start/stop/fault); motor/generator & switchgear supervision and voltage control (AVR), 2x excitation supervision and control

– Motor excitation system:

• AC or DC brushless static (thyristor controlled appr. 50 kW) excitation system with crowbar protection circuitry.

– Generator excitation system:

• AC or DC brushless excitation (thyristor controlled appr. 50 kW) excitation system with protection crowbar circuitry.

– Load side harmonics (voltage): < 5%

– MTBF: One transformer, two static excitation converters, motor, generator: ~4.4 years

6 MVA RFC – Electrical characteristics

SFC vs RFC – Case study

July 31, 2017 Slide 49

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10 MVA SFC – Typical system

SFC vs RFC – Case study

July 31, 2017 Slide 50

– Air insulated/SF6 MV feeder switchgear

– Feeder transformer: 12 pulse dry type transformer (xx kV/2x~1.7 kV)

– Converter: 3-level NPC MV converter with diode rectifier (at feeder side) and IGCT inverter at load side

– Load side transformer: 2 x 6 pulse dry type transformer (~3 kV / xx kV)

– Air insulated/SF6 MV load switchgear

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– Converter (10MVA):

• Length: 9 m x Width: 1.2 m x Height: 2.2 m

• Weight: 7.5 tons

– System space req. including SFC, control, switchgear, excluding transformers:

• 9 (+3) m x 1.2(+1.2) m x 2.5 m = 72 m3

– System weight including SFC, control, switchgear excluding transformer: Approx. 10 tons

10 MVA SFC – Required space for installation

SFC vs RFC – Case study

July 31, 2017 Slide 51

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– Control:

• Converter control and protection integrated in SFC

– Power factor feeder side: ~0.95

– Power factor load side: variable, 0.8 … 1.0

– Feeder side harmonics (current): according to IEC61000-2-4

– Load side harmonics (voltage): according to IEC/ISO/IEEE 80005-1

10 MVA SFC – Electrical characteristics

SFC vs RFC – Case study

July 31, 2017 Slide 52

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Case study - Comparison table

SFC vs RFC – Case study

July 31, 2017 Slide 53

Item RFC- 6 MVA SFC-10 MVAFeeder and feeder protection components:

Feeder transformer 1 1

Feeder aux. transformer 1 1

Feeder main switchgear 1 1

Feeder aux. Excitation switchgear 2 0

Frequency conversion system:

Length 9m 9m

Width 1.5m 1.2m

Height 4.5m 2.2m

Weight RFC,SFC 56 tons 10 tons

Volume requirement excluding transformer 211m3 72 m3

Load side (V) harmonics <5% <2%

MTBF (estimated) ~4.4 years ~5.7 years

Load side (V) harmonics ~95% ~96.5%

Production time (typical): 10 months 6 months

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Comparison table

SFC vs RFC – Case study

July 31, 2017 Slide 54

SFC RFC

Noise and vibration Low, mainly cooling system (fans-air cooled, pumps-water cooled)

High, especially for large machines

Frequency regulation Precise, electronically controlled Can vary depending on the input frequency

Serviceability/Maintenance Low MTTR due to modular constructionStandard yearly maintenance plan(1/2 days)

Breakdowns can be time consuming (bearing replacement)Critical parts wearing

Efficiency High PCS100 ~95%ACS6000 ~98%

Lower than SFC especially at light/partial loads

Overload capability PCS100 200% x 2 s 150% x 30 s

ACS6000 Depending on the model.

Good overload capability

Technology, as perceived by end users

New technology concerns on operation & maintenance

Old, proven technology high reliability

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Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 55

Agenda

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One of the world’s largest S2SP installations

Shore-to-ship power – Rotterdam, The Netherlands

July 31, 2017 Slide 56

Complete electrical infrastructure to simultaneously power several vessels while berthed in the port of Hoek van Holland

– Customer

Stena Line B.V., a subsidiary of Stena AB, one of the world’s largest ferry companies

– Year of commissioning

2012

The entire installation, both onshore and onboard the ships, was accomplished within a year and was activated at the Stena Line ferry terminal at the port of Rotterdam in June 2012

– Turnkey shore-to-ship power installation including design, engineering, project management, installation and commissioning

– Complete substation and automation package based on PCS 6000 static frequency converters rated at 6 MVA

– Mitigation of negative impact of ferry operations on the local community and the environment

– Reduction of fleet’s fuel consumption

– Greenhouse gas emissions reduced by 98%

– Less noise and vibrations

Customer needs ABB response Customer benefits

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Knutsen FSO project

ACS6000 - SFC

July 31, 2017 Slide 57

– ACS6000 SFC in double configuration performing 50 to 60 Hz frequency conversion at 6,6 kV

– Marine / off-shore certified system

– Island mode operation and bumpless switch between grid-to-island and vice versa

Customer needs ABB response Customer benefits

– Martin Linge O&G offshore facility (Norway) uses a floating, storage, and offloading unit (FSO) supplied by Knutsen NYK Offshore Tankers AS

– The Martin Linge field, including the FSO needs to be powered with electricity from shore through the world’s longest high voltage AC subsea cable. (approx. 180 km length)

– Martin Linge FSO represents an environmentally friendly installation with regards to CO2 emissions.

– Operating in parallel with diesel generator sets including active and reactive load management to optimize power consumption

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First 50/60 Hz shore connection in Sweden

Shore-to-ship power – Gothenburg, Sweden

July 31, 2017 Slide 58

Shoreside power supply to a vast number of Stena Line vessels while at berth

– Customer

Processkontroll Elektriska AB Stenungsund

– Year of commissioning

2012

– Turnkey 11kV Grid Integration, including Safe+ GIS switchgear 6 bays 50Hz, 4 bays 60Hz, and 2 transformers type Resibloc

– Two static frequency converters 1250kVA

– PLC system type AC500

– Dependable project execution from design to start-up, and state-of-the-art equipment

– Reliable shoreside power supply to ferries

– Reduced emissions, low-frequency noise and vibrations

– Better environment for passengers, crew, dockworkers and local residents

Customer needs ABB response Customer benefits

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Standard containerized solution for shipyards

Shore-to-ship power – Fincantieri, Italy

July 31, 2017 Slide 59

– Shore power supply for Castellamare shipyard for newly built vessels

– Outdoor solution with minimized civil works

– Short delivery time of 15 weeks

– Customer

Fincantieri

– Year of commissioning

2014

– Standard containerized solution, air-cooled, including frequency converter, isolation transformer, LV switchgear

– One static frequency converter PCS100, 1000kVA, rack-mounted

– Scalable solution suitable for all shipyards

– Lower OPEX costs than 60 Hz diesel genset

– Improved efficiency at partial loads

– High reliability owing to converter redundancy

Customer needs ABB response Customer benefits

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Static Frequency Converters for Shore-to-ship power application

ACS6000 SFC

PCS100 SFC

SFC vs RFC

Success stories

Summary

July 31, 2017 Slide 60

Agenda

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SFC dimensioning: Ask the right questions

Summary

July 31, 2017 Slide 61

1. Voltage and frequency

– Grid side (U1, f1)

– Ship side (U2, f2)

2. Power [MVA]

– Nominal & Peak

– Ship load profile, Single Line Diagram

– Direct online motors

– Transformer inrush

– Overload (protection & selectivity)

3. Installation

– Indoor / Outdoor

4. Environmental data

– Minimum / maximum temperatures

– Pollution levels

U1f1

~~

==

U2f2

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ABB’s SFCs are the ideal solution for providing a different frequency and voltage.

ACS6000 - PCS100 SFC design provides the followings benefits:

– Energy savings compared to dynamic converters.

– High reliability static conversion.

– Rugged ratings and short circuit protection.

– Versatile configurations.

– High efficiency even at partial load ~98.0 % (ACS6000 SFC) ~95.0 % (PCS100 SFC)

Advanced System Integration support

– Pre-engineered packages for fast lead time

– Customized solution for demanding requirements

ABB can deliver these benefits worldwide with performance and support you can trust.

ACS6000 - PCS100 SFC Static Frequency Converter

Summary

July 31, 2017 Slide 62

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