Fuel Efficient Power Plant Featuring Variable Speed ... · 16.11.2016 · November 16, 2016 | Slide 10 Motivation & Potentials DC Grid solutions proven on OSV type of vessels. Recorded

DYNAMIC POSITIONING CONFERENCE October 11-12, 2016

OPERATIONS

Fuel Efficient Power Plant Featuring Variable Speed Generation Systems for DP Drilling Units

Jan Fredrik Hansen

Frank Wendt John Olav Lindtjørn

ABB

OPERATIONS SESSIONJan Fredrik Hansen @ MTS Dynamic Positioning Conference Houston October 2016

Fuel-efficient power plant featuring variable speedgeneration system for DP drilling units

© ABB GroupNovember 16, 2016 | Slide 2

Introduction

Growing focus on:SafetyFuel costMaintenance cost

Higher demand for:Optimized power systems

Background

Operators and Charters

Classification Societies

Equipment Suppliers


Introduction

1. Motivation & Potentials2. Examples for drilling vessel3. Case study4. Closing remarks

Agenda

Motivation & Potentials


Motivation & PotentialsEvolution, DP drilling vessels

1997

2016

Thruster drivesPower phase backEngine utilization

Event based protectionClosed bus operationEnergy storage

Variable speed power generation

Safety – Fuel Cost – Maintenance Cost


Motivation & PotentialsVariable speed generation in electric propulsion systems

Variable speed thruster drives – a standard since 80’s (0 to 100%).

Now: variable speed generation on the power plant. Implemented in several vessels, basically LV

systems. Specially successful for DP operation. Typical speed variation from 60% to 100% of nominal. DC or Variable AC

G

M


Motivation & PotentialsEngine performance

Less specific fuel consumption if RPM is adjusted with power consumption.

Savings increase with lower load. Different engine types and sizes, may yield different

curves. Comparing todays engines with tomorrow engines. Fuel saving potential from 10% to 30% on engine

operation below 50%.


Motivation & PotentialsDrilling vessel operation; Speed & thruster profile

DP Transit

DP Transit

DP operation in 85% of time, with thruster loading less than 7%Leads to Generator loading of less than 30% (with some assumptions)


Motivation & PotentialsReference case, LV DC Grid for DP OSV vessel

Az. Main Prop.

2200kW

~

M~

~

M~

~

G~

G#12240kW

1200-1800rpm

~

G~

~

DC Grid Port 1000VDC

Cargo and process system

G#22240kW

1200-1800rpm

3 x 440V – 60Hz

440V Main SwBd Port

M~

~ ~

G~

~

G#3920kW

1200-1800rpm

Az. Bow Thr.850kW

~

M~

~

M~

Tunnel Thr.920kW

2x 1

200k

VA60

0V/4

40V

3 x 440V – 60Hz

440V ROV SwBd Port

~

M~

Tunnel Thr.920kW

~ ~

2x 1

200k

VA60

0V/4

40V

3 x 440V – 60Hz

440V Main SwBd STBD

3 x 440V – 60Hz

440V ROV SwBd STBD

Az. Main Prop.

2200kW

~

M~

M~

~

M~

~


G~

G#42240kW

1200-1800rpm

~

G~

~

G#52240kW

1200-1800rpm

DC Grid STBD 1000VDC


Motivation & Potentials

DC Grid solutions proven on OSV type of vessels. Recorded fuel saving of up to 27%, and average 14%

on total profile measured. High speed (1800 RPM) engines running on medium

speed (1200-1300 RPM) for most of the time. Reduced noise level.

Az. Main Prop.

2200kW

~

M~

~

M~

~

G~

G#12240kW

1200-1800rpm

~

G~

~

DC Grid Port 1000VDC


G#22240kW

1200-1800rpm

3 x 440V – 60Hz

440V Main SwBd Port

M~

~ ~

G~

~

G#3920kW

1200-1800rpm

Az. Bow Thr.850kW

~

M~

~

M~

Tunnel Thr.920kW

2x 1

200k

VA60

0V/4

40V

3 x 440V – 60Hz

440V ROV SwBd Port

~

M~

Tunnel Thr.920kW

~ ~

2x 1

200k

VA60

0V/4

40V

3 x 440V – 60Hz

440V Main SwBd STBD

3 x 440V – 60Hz

440V ROV SwBd STBD

Az. Main Prop.

2200kW

~

M~

M~

~

M~

~


G~

G#42240kW

1200-1800rpm

~

G~

~

G#52240kW

1200-1800rpm

DC Grid STBD 1000VDC

Reference case, LV DC Grid for DP OSV vessel

Example for drilling vessels


Example for drilling vesselsMid size segment with LV DC Grid

G#1/2/31800-3000kW720-1200rpm

G~

~

Busd

uct

DC Grid Lineup A1000VDC

~

T#22500kVA600V/480V

~

M~

~

M~

~

M~

~

1000VDC

M~

~

1000VDC

480V Main SWBD 1

480V, 60Hz

NO

480V, 60Hz

DC Grid Lineup B1000VDC

T#43000kVA600V/480V

T#32500kVA

600V/480V

480V, 60Hz

G~

~

Busd

uct

1x Top Drive a 860 kW; 2x Draw -work a 860kW2x Mud pump a 1660kW; 2x Anker winch a 600kW1x Energy Storage 1500KW/300kWh

M~

~

M~

~

M~

~

M~

~


Azipod-D3000kW

650V

~

~

Az Thr Aux480V MCC

M~

M~

M~

Stee

ring

VSD

&Va

rious

Thr

Aux

.VS

D C

onsu

mer

s

~~~

300kVA0.6/0.48kV

Dyn11

Azipod-D3000kW

650V

~

~

Az Thr Aux480V MCC

M~

M~

M~

Stee

ring

VSD

&Va

rious

Thr

Aux

.VS

D C

onsu

mer

s

~~~

300kVA0.6/0.48kV

Dyn11

G~

~

Busd

uct

T#13000kVA

600V/480V

480V Emerg SWBD 480V Main SWBD 2

Azipod-D3000kW

650V

~

~

Az Thr Aux480V MCC

M~

M~

M~

Stee

ring

VSD

&Va

rious

Thr

Aux

.VS

D C

onsu

mer

s

~~~

300kVA0.6/0.48kV

Dyn11

Azipod-D3000kW

650V

~

~

Az Thr Aux480V MCC

M~

M~

M~

Stee

ring

VSD

&Va

rious

Thr

Aux

.VS

D C

onsu

mer

s

~~~

300kVA0.6/0.48kV

Dyn11

G~

~

Busd

uct

G~

~

Busd

uct

G~

~

Busd

uct

~ ~

NONO NO

G#475/61800-3000kW720-1200rpm

Thruster #1 Thruster #2 Thruster #3 Thruster #4

~

T#41500kVA

600V/480V

~

480V, 60Hz

480V Drill SWBD 2

NO

480V, 60Hz

480V Drill SWBD 1

NO

T#51500kVA

600V/480V


G#1/2/31800-3000kW720-1200rpm

G~

~

Busd

uct

DC Grid Lineup A1000VDC

~

T#22500kVA600V/480V

~

M~

~

M~

~

M~

~

1000VDC

M~

~

G~

~

Busd

uct


G~

~

Busd

uct

T#13000kVA

600V/480V

~

T#1500

600V/

T#1500

600V/


Island converters Energy StorageIndividual Rectifiers


Azipod-D3000kW

650V

~

~

Az Thr Aux480V MCC

M~

M~

M~

Stee

ring

VSD

&Va

rious

Thr

Aux

.VS

D C

onsu

mer

s

~~~

300kVA0.6/0.48kV

Dyn11

Thruster #1


Thruster side DC Link

Thruster Auxilliaries



Fuel saving potential from 12% to 18%


Example for drilling vesselsLarge size segment with MV Variable AC

Main SWBD

G~

Thruster

Thr. Transformer11kV/690V50-62Hz

Generator11kV, 3ph, 52-62Hz(624-750rpm)

LV Main Distribution

M~

~ ~

DC Distr.Transformer11kV/690V50-62Hz

Thr. VSD

G~


Thruster

~~


11kV 3ph, 50-62Hz

~ ~

LV Main DC Distribution

Thr. VSD

~ ~

M~

M~

LV Sub DC Distribution

Various VSD e.g Drilling Drive

Energy Strorage

Main SWBD

G~

Thruster




~~

Thr. VSD

G~


Thruster

~~


11kV 3ph, 50-62Hz

Thr. VSD

Main SWBD

G~

Thruster




~~

Thr. VSD

G~


Thruster

~~


11kV 3ph, 50-62Hz

Thr. VSD

1000Vdc

Constant AC voltage/variable frequency Distribution

High power consumers suitable for variable frequency power supply

Constant DC Voltage Distribution

High power consumers suitable for DC power supply

Constant AC Low Voltage/constant frequency Distribution

Low power consumers requiring constant voltage/ constant frequency power supply

Various low power consumers

~ ~ ~Various VSD e.g. Vessel Auxiliary



M~

~ ~

~ ~


~ ~

M~

M~



Energy Strorage

1000Vdc





M~

~ ~

~ ~


~ ~

M~

M~



Energy Strorage

1000Vdc




LV DistributionConstant AC voltage Voltage/variable frequency Distribution

Low power consumers suitable for variable frequency power supply

AC Distr.Transformer11kV/440V50-62Hz



LV Distribution LV Distribution

Constant AC voltage/variable frequency power generation

~~



Main SWBD

G~

Thruster




Thr. VSD

G~


Thruster

~~


11kV 3ph, 50-62Hz

Thr. VSD

Constant AC voltage/variable frequency Distribution

High power consumers suitable for variable frequency power supply

AC Distr.Transforme11kV/440V50-62Hz

Constant AC voltage/variable frequency power generation

~~



Thruster

M~

~ ~

Thruster

~ ~


~ ~

M~

M~


Various VSD e.g

Energy Strorage

1000Vdc

frequency power supply

Constant DC Voltage Distribution

High power consumers suitable for DC power

l


LV DistributionConstant AC voltage Voltage/variable frequency Distribution

Low power consumers suitable for variable frequency power supply




M~

~ ~

~ ~

M~

M~

LV Sub DC


Energy Strorage

High power consumers suitable for DC power supply

Constant AC Low Voltage/constant frequency Distribution

Low power consumers requiring constant voltage/ constant frequency power supply


~ ~Various Vessel A


Island converters



Fuel saving potential from 14% to 33%

Case Study



Power plant data; one week recording from a drillship

Baseload around 6 MW (MW in periods); Thrusters, auxiliaries, hotel load etc.

Additional power variations of 6MW on top of the baseload; Drilling operation.



Engine/operation type Q’ty Gen sets Fuel consumption [t]

Fixed speed operated typical medium speed marine engine

3 318,8

2 294,7

Variable speed operated common rail engine

3 257,6

2 254,9

20% fuel saving going from fixed speed 3 engines to variable speed 3 engines. Max potential in this case about 63t fuel per week saved => Annually 3200t fuel savings With variable speed engines, there difference between 2 and 3 generators online is

relative small, operation with open bus?

Closing Remarks


Closing RemarksPros & Cons

Variable speed power generation increases fuel efficiency in DP operation. Applicable for most types of DP vessels. For LV DC Grid applications each generator is can be individually

controlled. No synchronization Free load sharing No system harmonic distortion on main distribution.

Some additional equipment and modifications: Generators need to be dimensioned for full voltage at reduced RPM. Generators need to be dimensioned for individual rectifier operation (LV DC Grid) Island converters needed for fixed frequency distribution. Modification of SWBD protection (frequency range) for MV variable AC networks. Energy storage for dynamic support, however already today highly discussed for

standard AC systems.

High speed vs medium speed engines?


Closing Remarks

Variable Speed

Energy Storage

Improved System• Operational Costs• Dynamic

Performance• Safety &

Availability

Documents

Fuel Efficient Power Plant Featuring Variable Speed ... · 16.11.2016 · November 16, 2016 | Slide 10 Motivation & Potentials DC Grid solutions proven on OSV type of vessels. Recorded