Professional Documents
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08 - High Voltage Equipments & Their Safety Guidelines
08 - High Voltage Equipments & Their Safety Guidelines
© ABB Group
February 26, 2010 | Slide 1
Why HV Systems are Preferred?
Voltage
V lt CB Max.
M R ti
Rating S
Source or Load
L d % IIncrease Vs.
V
(kV) (kA) (MW) 480 V
0 480
0.480 4 27
2.7 -
66
6.6 3 27 4
27.4 10 3X
10.3X
© ABB Group
February 26, 2010 | Slide 2
Possible Alternatives for Distribution Systems
© ABB Group
February 26, 2010 | Slide 3
ABB Electric Power and Propulsion System
Generators
MV and LV
Transformers Switchboards
Azipod®
Propulsion
Propulsion/Thruster
Drives
© ABB Group
February 26, 2010 | Slide 4
Cargo Pump Drives/Motors
Dual Fuel Electric Propulsion
© ABB Group
February 26, 2010 | Slide 5
Electrical Propulsion Systems
© ABB Group
February 26, 2010 | Slide 6
Conventional vs. Podded Propulsion
A direct diesel
driven system
with shaft line
propulsion
Electrical system
with Azipod®
propulsion
© ABB Group
February 26, 2010 | Slide 7
RoPax Ferry – 3 Versions Source: Deltamarin
Propulsion motors
15 % More capacity
on lower deck
25 % More capacity
on lower deck
© ABB Group
February 26, 2010 | Slide 8
A High Degree of Redundancy gives High Safety
and Availability
Electric Electric
Power Power
Distribution Distribution
Electric Electric
Propulsion Propulsion
System System
Propulsion
Shaft Line
© ABB Group
February 26, 2010 | Slide 9
Benefits of Electric Propulsion
Building Cost
Better utilization of space - more efficient ship
designs
Competitiveness in electric propulsion – single
source supply in steam turbine
Operational
Fuel efficient,
efficient >40% for electric propulsion vs
vs.
<30% for steam propulsion
Lack
L k off crew for
f steam
t turbines,
t bi LNG carriers
i are
today the only commercial vessel type where this
concept is used
© ABB Group
February 26, 2010 | Slide 10
Benefits Electric Propulsion
Increased Safety
Safety,
S f redundancy
d d and
d availability
il bili iis iincreased
d
Environmental
No SOx
Minimizing NOx
Clean combustion – reduced particle emission
and maintenance
© ABB Group
February 26, 2010 | Slide 11
Typical Layout
Control Network
Thrusters
Fieldbus Network
Power Generation
Power Distribution Propulsion
Propulsion Drives
© ABB Group
February 26, 2010 | Slide 12
Electrical Propulsion Systems
© ABB Group
February 26, 2010 | Slide 13
Components of Electrical Propulsion System
© ABB Group
February 26, 2010 | Slide 14
Components of Electrical Propulsion System
Voltage Description Max Max Min Ik2 Break /make STW / Peak
Iac Ip
[V] [kA] [kA] [kA] [kA] [kA]
720 Bow
o Thr. Drive
e 9.8 24.6 6.8 56 / 440 NA
(normal operation)
© ABB Group
Example for Ice Breaker Supply Vessel
February 26, 2010 | Slide 17
List of High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives (cyclo-converter, frequency converter)
Azipod®
© ABB Group
February 26, 2010 | Slide 18
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 19
Generators and Motors
© ABB Group
February 26, 2010 | Slide 20
Electrical Power Plant
© ABB Group
February 26, 2010 | Slide 21
Main Components AMG
Transformers Neutral Point Line Terminals
Stator Core
Air Filters
Stator Windings
Shaft
End Shield
D-end Bearing
Exciter
F
Fan
Rotor Poles
© ABB Group
February 26, 2010 | Slide 22
Terminals
The stator line terminals and neutral terminals are situated in the top box
on the top of the generator
Excitation transformers are installed in the terminal box
The terminals for excitation and control equipment are in auxiliary terminal
box
Differential
Protection
Transformers
Current Transformer Short Circuit Current
for Parallel Operation Transformers
© ABB Group
February 26, 2010 | Slide 23
General Safety Instructions
f Hi
for High
h Voltage
V lt Machines
M hi
© ABB Group
February 26, 2010 | Slide 24
Electric Machines – Standards Requirements
© ABB Group
February 26, 2010 | Slide 25
General Safety Instructions – Machines
© ABB Group
February 26, 2010 | Slide 26
General Safety Instructions – Machines
Additional Safety Instructions for Permanent
Magnet Synchronous Machines
© ABB Group
February 26, 2010 | Slide 27
General Safety Instructions – Machines
Electrical Connections - Safety Rules
B f
Before starting
t ti work
k
The following safety rules must be strictly applied:
D
De-energize!
i !
Provide safeguard against reclosing!
Verify safe isolation from supply!
Connect to earth and short!
Cover or pprovide barriers against
g neighbouring
g g live
parts!
De-energize auxiliary circuits
(f example,
(for l anti-condensation
ti d ti h heating)!
ti )!
© ABB Group
February 26, 2010 | Slide 28
General Safety Instructions – Machines
Electrical Connections - Safety Rules
© ABB Group
February 26, 2010 | Slide 29
General Safety Instructions – Machines
Electrical Connections - Safety Rules
© ABB Group
February 26, 2010 | Slide 30
General Safety Instructions – Machines
Electrical Connections - Safety Rules
© ABB Group
February 26, 2010 | Slide 31
General Safety Instructions – Machines
Operation - Safety Rules
© ABB Group
February 26, 2010 | Slide 32
General Safety Instructions – Machines
Additional Safety Instructions for Permanent Magnet
Synchronous Machines
© ABB Group
February 26, 2010 | Slide 33
General Safety Instructions – Machines
Additional Safety Instructions for Permanent Magnet
Synchronous Machines
© ABB Group
February 26, 2010 | Slide 34
General Safety Instructions – Machines
Additional Safety Instructions for Permanent Magnet
Synchronous Machines
© ABB Group
February 26, 2010 | Slide 35
General Safety Instructions – Machines
Additional Safety Instructions for Permanent Magnet
Synchronous Machines
© ABB Group
February 26, 2010 | Slide 37
General Safety Instructions – Machines
Rules During any Operations
© ABB Group
February 26, 2010 | Slide 38
General Safety Instructions – Machines
Rules During any Operations
© ABB Group
February 26, 2010 | Slide 39
General Safety Instructions – Machines
Rules During any Operations
© ABB Group
February 26, 2010 | Slide 40
General Safety Instructions – Machines
Rules During any Operations
© ABB Group
February 26, 2010 | Slide 42
General Safety Instructions – Machines
Rules During any Operations
C
Connections
ti iin terminal
t i l boxes
b (Ex
(E motors)
t )
All connections in main terminal boxes must
be made with Ex-approved connectors,
c a
which are
e de
delivered
e ed with
t tthe
e machine
ac e by tthe e
manufacturer.
All co
connections,
ec o s, in auxiliary
au a y terminal
e a bo
boxes,
es,
as marked intrinsically safe circuits (Ex i or
EEx i)) must be connected to p proper
p safety y
barriers.
© ABB Group
February 26, 2010 | Slide 43
General Safety Instructions – Machines
Rules During any Operations
Space heaters
If an anti-condensation heater
heater, without self-
regulation, is turned on immediately after the
motor is shut down,
down take suitable measures
to control the inside motor housing
temperature.
temperature
The anti-condensation heaters can only
operate within a temperature controlled
environment.
© ABB Group
February 26, 2010 | Slide 44
General Safety Instructions – Machines
Rules During any Operations
P
Pre-start
t t ventilation
til ti
Ex nA / EEx nA and Ex e / EEx e machines
may, or in some cases, have to be equipped
with a provision for pre-start ventilation.
Before starting, check the need to purge the
machine enclosure to make sure that the
enclosure is free
f off flammable
f gases. Based
on the risk assessment, make the decision,
whether
hether there is a need to use se the pre
pre-start
start
ventilation or not.
© ABB Group
February 26, 2010 | Slide 45
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 46
Transformers – Function
© ABB Group
February 26, 2010 | Slide 47
Transformer Types
“W t” & “D
“Wet” “Dry”
”TTransformers
f
© ABB Group
February 26, 2010 | Slide 48
Dry Transformers – Enclosures
IP-classification - Enclosures
A dry transformer is normally used for indoor operation with IP00
protection BUT additional IP protection can be supplied
IP00
IP31 IP44
IP23
© ABB Group
February 26, 2010 | Slide 49
Transformers
Transformer Safety
R
Recommendations
d i
© ABB Group
February 26, 2010 | Slide 50
Transformers – Symbols of Danger
Symbols of danger can be found on the Transformer
Warning:
g Prohibition:
Danger - High Voltage Do Not Touch
Surface Area is Live
© ABB Group
February 26, 2010 | Slide 51
Transformers – Safety
© ABB Group
February 26, 2010 | Slide 52
Transformers – Safety
© ABB Group
February 26, 2010 | Slide 53
Transformers – Safety
Verify
y that anyy inductor is de-energized
g before
testing for continuity or resistance
Uncontrolled release of energy may result if the
inductor's current is suddenly interrupted
Electromagnets and superconductive magnets
may produce large external force field that may
affect the proper operation of the protective
instrumentation and controls
© ABB Group
February 26, 2010 | Slide 54
Transformers – Safety
By de
de-energizing
energizing a magnet suddenly can
produce large eddy currents in adjacent
conductive materials that may
y cause excessive
heating and hazardous voltages.
A magnetic field could attract nearby magnetic
material, including tools, that could cause injury
or damage on impact
impact.
© ABB Group
February 26, 2010 | Slide 55
Transformers – Safety
Protection against
g touch
Transformers supplied as only IP00 must be
l k d away under
locked d use, guaranteeingt i when h
energised they can never be touched.
Th transformer
The t f castt resin
i coilil surface
f is
i
NOT touch safe. Accidental touch protection
co ld be pro
could provided
ided thro
through
gh the installation of
safety barriers, gates or similar.
© ABB Group
February 26, 2010 | Slide 56
Transformers – Safety
Earth Connections
The joint
Th j i t resistance
i t off the
th protective
t ti earthing
thi
must be dimensioned in such a way that
protective systems (e(e.g.
g fusible cut
cut-out,
out
overload switch, breaker, etc.) are in
operation at all times and trigger as the case
may be.
The cross section of the earthing connections
must comply with the regulations and on-site
conditions
diti - mustt be
b maintained
i t i dd during
i
repair/maintenance operations.
© ABB Group
February 26, 2010 | Slide 57
Transformers – Safety
Electrical and Mechanical Connections
The minimum distance (see table supplied by
manufacturer) between live parts as well as between
live p
parts and earthed pparts must not be fallen short of.
This relates to the distances between cables and high
voltage windings in particular.
All retaining elements of the screw connections are to
be checked and replaced as the case may be before re-
connecting.
connecting
All connections must fit tightly and be mechanically
secure The bolts for the electrical connections are to be
secure.
tightened using a torque wrench.
© ABB Group
February 26, 2010 | Slide 58
Transformers – Safety
Min. Distance/Space Requirements
The transformers outline drawing g can best be used for
dimensions of the units. The installation cell should be
designed so that the rating plate and all monitoring
equipment can be read without entering the cell.
Minimum distances must be maintained between all live
parts
t and
db between
t live
li parts
t tto earth.
th
To ensure non-restricted circulation of air on all sides of
th transformer,
the t f a 0.3
0 3 m minimum
i i distance
di t tto any wallll
must be maintained and in addition, distance must be
allowed for installation and maintenance requirements
requirements. A
distance greater than 0.5 m must be maintained
between two transformers.
© ABB Group
February 26, 2010 | Slide 59
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 60
Types of Switchboards
Unimotor
UniSwitch
UniSafe
U iS f
UniGear
SafePlus
SafeRing
etc.
t
© ABB Group
February 26, 2010 | Slide 61
Switchboard Functions
Different
e e t types o
of cub
cubicles:
c es
Protection
Distribution
Generation
G ti
Measuring
g
etc
© ABB Group
February 26, 2010 | Slide 62
Metal Clad Design
Pressure relief
Circuit breaker 12 kV,
kV 25 kA
Air insulated
A Busbar compartment
B Breaker compartment
C Cable compartment
D Control compartment
1 Busbars
2 Tulip
p contacts
3 Vacuum circuit breaker
4 Earthing switch
5 C
Current
t ttransformer
f
6 Voltage transformer
7 Control unit
© ABB Group
February 26, 2010 | Slide 63
Metal Enclosed Design
KV)
Byy H/1600 = 400 mm (12 kkV)
Byy H/1850 = 650 mm (24 K
Pressure relief
200
© ABB Group
February 26, 2010 | Slide 64
LV Switchgear
© ABB Group
February 26, 2010 | Slide 65
HV Switchgear
© ABB Group
February 26, 2010 | Slide 66
High Voltage (Main) Switchboard
© ABB Group
February 26, 2010 | Slide 67
HV Switchgear
Frequency:
y 50 Hz or 60 Hz. 60 Hz is a more
common frequency in ship networks
Higher
Hi h ffrequency Æ smaller
ll transformers
t f
and generators
Typical voltage levels: 440V, 690V, 3300V,
and 6600V
6600V.
Larger
g Vessels: 11 kV
© ABB Group
February 26, 2010 | Slide 68
Compartments in Metal-Clad Switchgear
Compartments:
r
1 Circuit breaker
q
2 Busbar
o
3 Cable
4 Auxiliary
n 5 Interconnection
wiring
ii d ductt
p 6 Voltage transformers
s
© ABB Group
February 26, 2010 | Slide 69
Operation and Protection – Components
REF/REM
Main features:
Protection
Measurement
M
Control
Signaling
Interlock
Automation
Communication
© ABB Group
February 26, 2010 | Slide 70
Internal Arc Safety
Arc-proof tested
Tested according to IEC 298 standards, appendix AA, class A,
criteria 1 to 6.
Criteria:
1 Correctly secured doors
doors, covers do
Testiing setup
p
not open.
2 Parts which may cause a hazard do
not fly off.
3 No holes in the freely accessible
external parts of the enclosure.
enclosure
4 Vertically arranged indicators do not
Infrared
mera
ignite.
cam
Arc Guard
G - fiber
f optic light
detectors
© ABB Group
February 26, 2010 | Slide 72
Before Opening the Door
© ABB Group
February 26, 2010 | Slide 73
Check for Position Indication
© ABB Group
February 26, 2010 | Slide 74
Checking for Energized Busbars
Voltage Indicators
© ABB Group
February 26, 2010 | Slide 75
Safety Interlocks
© ABB Group
February 26, 2010 | Slide 76
Safety Locks
© ABB Group
February 26, 2010 | Slide 77
Safety Locks
© ABB Group
February 26, 2010 | Slide 78
UniSafe – Safety
Instruction
Manual
© ABB Group
February 26, 2010 | Slide 79
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers & contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 80
Power System Protection
Purpose:
To increase safety
To
T avoid
id bl
black-outs
k t
To prevent machinery damage
To detect and minimize further damage
g
The extent
Th t t off the
th protection
t ti system
t depends
d d on
what is to be protected
© ABB Group
February 26, 2010 | Slide 81
High Voltage Disconnecting Equipments
Circuit Breaker
Disconnector
Switch
Fuse
Contactor
etc.
etc
© ABB Group
February 26, 2010 | Slide 82
Circuit Breakers
© ABB Group
February 26, 2010 | Slide 83
Circuit Breakers
Short-circuit currents
Manual/Automatic operation
Local/Remote
L l/R t C
Control
t l
© ABB Group
February 26, 2010 | Slide 84
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 85
Protection Relays
© ABB Group
February 26, 2010 | Slide 86
Relays Installed On-board
© ABB Group
February 26, 2010 | Slide 87
Relays – Machine Protection
© ABB Group
February 26, 2010 | Slide 89
Relays – Machine Protection
REM 543/545 Machine Terminal
© ABB Group
February 26, 2010 | Slide 90
Relays – Feeder Protection
© ABB Group
February 26, 2010 | Slide 91
Relays – Feeder Protection
REF 54_ – Feeder Terminal
© ABB Group
February 26, 2010 | Slide 92
Relays – Feeder Protection
REF 54_ – Feeder Terminal
Features:
- multi protections
- control
- measurement
- condition
monitoring
- supervision
i i
- communication
© ABB Group
February 26, 2010 | Slide 93
Relays – Feeder Protection
REF 54_ – Feeder Terminal Front Panel
© ABB Group
February 26, 2010 | Slide 94
Relays – Feeder Protection
REF 54_ – Feeder Terminal Front Panel
© ABB Group
February 26, 2010 | Slide 95
Relays – Feeder Protection
REF 54_ – Feeder Terminal Rear Plate
© ABB Group
February 26, 2010 | Slide 96
Relays – Feeder Protection
Conventional CT´s and VT´s or/and sensors
Current sensor 2 16
15
X7.2 X6.2 X5.2 X4.2 X3.2 14
X2.5 13
Current transformer
1 1 1
1 1
2
2 2 2 2 12
3 3
3 3
4
4 4 4 X2.6 11
5 5
6
5
6
5
X3.3 1 10
6 6 2
7
8
7 7 7 9
8 8 8
9
10
9 9 9 8
10 10 10
11
11 11 11 7
12
12 12 12 X2.7
13
13 13 13
1
6
14 14
14 14 2
15
15 15 15 5
18
17
18
17
18
17
18
17
X2.8 4
18 18 1
18
18
2
3
2
1
Voltage sensor
Voltage transformer
© ABB Group
February 26, 2010 | Slide 97
High Voltage Equipments On-board
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 98
Motor Drives
© ABB Group
February 26, 2010 | Slide 99
Cyclo-converter
© ABB Group
February 26, 2010 | Slide 100
Frequency Converter
© ABB Group
February 26, 2010 | Slide 101
AC Drive – Applications
D
Dynamic
i Positioning
P iti i off Floating
Fl ti Vessels
V l
Distributed Concept
This dynamically positioned
offshore drilling rig is
equipped with four ACS 6000
single drives.
Power generation and
propulsion can be separated
and distributed to the most
convenient locations resulting
in cost-effective construction.
© ABB Group
February 26, 2010 | Slide 102
AC Drive – Applications
Main Propulsion with Thrusters
Transformerless Multi-Motor-
Drive Concept
This service vessel with two
main propulsion Azimuth
thrusters is assisted by two
smaller (tunnel) thrusters.
This type of configuration is
used for smaller power
requirements.
The mostt economic
Th i solution
l ti
is an arrangement with two
ACS 6000 multi-drives and
li reactances
line t iinstead
t d off
transformers.
© ABB Group
February 26, 2010 | Slide 103
© ABB Group
February 26, 2010 | Slide 104
ACS6000sd – Danger Zones
© ABB Group
February 26, 2010 | Slide 105
Thyristor Power Converters (DC Drives)
S f
Safety S
Symbols
b l
© ABB Group
February 26, 2010 | Slide 106
Thyristor Power Converters (DC Drives)
Safety
y Instructions
All electrical installation and maintenance
work on the thyristor power converter must be
carried out by properly qualified staff who
have been thoroughly
g y trained in electrical
engineering.
The thyristor power converter and its adjacent
units must be properly earthed by qualified
p
professionals.
© ABB Group
February 26, 2010 | Slide 107
Thyristor Power Converters (DC Drives)
Safety
y Instructions
You must NEVER perform any work on the
thyristor power converter while it is still
switched on.
Always,
Always first switch the unit off and use a
measuring instrument to make absolutely sure
that the power converter has really been de- de
energized, and only then you may start with
the work concerned.
© ABB Group
February 26, 2010 | Slide 108
Thyristor Power Converters (DC Drives)
Safety Instructions
Due to external control circuits, there may be
g
dangerously y high
g voltages
g p present at the
thyristor power converter even after the line
voltage has been switched off.
Always work at the unit with appropriate
caution!
Non-compliance with these instructions may
result in injury (or even death!).
© ABB Group
February 26, 2010 | Slide 109
Thyristor Power Converters (DC Drives)
Safety
y Instructions
When thyristor power converters are in use,
the electric motors, power transmission
elements and the driven machines are
working in an extended operating range,
which
hi h means they
h h have to cope with
iha
relatively high loading.
You should have made sure that all units,
devices and appliances used are actually
suitable
it bl for
f this
thi higher
hi h lloading.
di
© ABB Group
February 26, 2010 | Slide 110
Thyristor Power Converters (DC Drives)
Safety
y Instructions
For insulation testing, you must disconnect
all cables from the thyristor power
converter.
You should avoid operating your unit at
values other than the rated data.
Non-compliance with these instructions
may cause lasting damage to the thyristor
power converter.
© ABB Group
February 26, 2010 | Slide 111
Thyristor Power Converters (DC Drives)
Safety Instructions
The
Th thyristor
h i power converter possesses a
number of automatic reset functions.
When these functions are executed, the
unit will be reset after an error and will then
resume operation.
These functions should not be used if other
units and devices are not suitable for an
operating mode of this kind,
kind or if their use
might entail dangerous situations.
© ABB Group
February 26, 2010 | Slide 112
Thyristor Power Converters (DC Drives)
Generators
Motors, Pumps
Transformers
Distribution switchboards
Auxiliaryy and Emergency
g y swgr.
g
Circuit breakers, contactors
Protection relays
Motor Drives
Azipod®
© ABB Group
February 26, 2010 | Slide 114
Azipod® – A Fully Podded Propulsion System
The Azipod® is a podded propulsion system, azimuthing through 360° about its
steering axis. The structure of Azipod® unit itself is shown below.
© ABB Group
February 26, 2010 | Slide 115
Azipod® – A Fully Podded Propulsion System
© ABB Group
February 26, 2010 | Slide 116
Azipod® – A Fully Podded Propulsion System
© ABB Group
February 26, 2010 | Slide 117