Shipboard Power Systems Design and Verification Fundamentals

Mohammed M. Islam (Moni) was R&D Supervisor of Applied Science at Northrop Grumman Ship Systems, served as the IEEE-45 central committee Chair, and was a member of the IEEE 1580 working group. He has forty-three years of diversified shipboard electrical engineering experience and has played significant roles in every part of new shipbuilding and ship modernization engineering. He provides electrical engineering subject matter expert services, specializing in interpretation of rules and regulations.

• Preface xix1. Overview 11.0 Introduction 11.1 Shipboard Power System Design Fundamentals 31.2 Ship Design Requirements 31.3 ETO Certification: MEECE 41.4 Legacy System Design Development and Verification 41.5 Shipboard Electrical System Design Verification and Validation (V&V) 51.5.1 Verification and Validation (V&V) Overview 51.5.2 Verification 51.5.2a Acceptance of Verification 81.5.3 Validation 81.5.4 Differences between Verification and Validation: Shipboard Electrical System Design and Development Process 81.6 IEEE 45 DOT Standards: Recommended Practice for Shipboard Electrical Installation 101.7 Other Rules and Regulations, and Standards in Support of IEEE 45 DOT Standards 111.8 Shipboard Ungrounded Power System 111.9 Shipboard Electrical Design Basics 121.10 Electrical Design Plan Submittal Requirements 141.11 ABS Rules for Building and Classing Steel Vessels 151.12 Shipboard Electrical Safety Considerations 171.13 High-Resistance Grounding Requirements for Shipboard Ungrounded Systems (See Chapter 9 for Details) 181.14 Shipboard Electrical Safety Considerations 191.14.1 Arc Flash Basics (See Section 12 for Details) 191.14.2 Arc Flash Hazard Analysis Procedures 201.14.3 Warning Label Placement 211.15 Propulsion Power Requirements (IEEE Std 45-2002, Clause 7.4.2) 211.16 IMO-Solas Electric Propulsion Power Redundancy Requirements 221.17 Regulatory Requirements for Emergency Generator 231.18 USCG Dynamic Positioning (DP) Guidelines 241.19 IEC/ISO/IEEE 80005-1-2012: Utility Connections in Port—High Voltage Shore Connection (HVSC) Systems—General Requirements 281.20 Mil Standard 1399 Medium Voltage Power System Characteristics 281.21 Shipboard Power Quality and Harmonics (See Chapter 7 for Detail Requirements) 291.21.1 IEEE Std 45-2002, Clause 4.6, Power Quality and Harmonics 291.21.2 Power Conversion Equipment-Related Power Quality 301.21.2a IEEE Std 45-2002, Clause 31.8, Propulsion Power Conversion Equipment (Power Quality) 301.22 USCG Plan Submittal Requirements 311.23 ABS Rules for Building and Classing Steel Vessels (Partial Listing) 321.24 Design Verification and Validation 331.24.1 Design Verification Test Procedure (DVTP) 331.24.2 Qualitative Failure Analysis (QFA) 361.24.3 IEEE 519 Harmonic Standard 361.25 Remarks for VFD Applications Onboard Ship 362. Electrical System Design Fundamentals and Verifications 372.0 Introduction 372.1 Design Basics 392.2 Marine Environmental Condition Requirements for the Shipboard Electrical System Design 402.3 Power System Characteristics: MIL-STD-1399 Power Requirements 412.4 ABS Type Approval Procedure (Taken From ABS Directives) 422.4.1 List of Recognized Laboratories 452.4.2 Nationally Recognized Testing Laboratory Program 452.4.3 Procedure for Becoming Type Approved 472.5 Shipboard Electrical Power System Design Basics 482.5.1 Table 2.4: Explanation for Note 1 of Figure 2.1 (Use of Multiple Options, Step Down Transformer, MG Set,PCU) 492.5.2 Table 2.5: Explanation for Note 2 of Figure 2.1 (Use of Power Conversion Unit to Supply Power from MV SWBD to the Ship Service SWBD) 502.5.3 Table 2.6: Explanation for Note 3 of Figure 2.1 (Use of Motor Generator with MV Input to AC Motor and Driving AC Generator) 512.5.4 Table 2.7: Explanation for Note 4 of Figure 2.1 (High-PowerBattery Supplying Power to the 480 V Ship Service Switchboard) 512.5.5 Table 2.8: Explanation for Note 5 of Figure 2.1 (Use of Step Down Service Transformer to Supply Power from MV SWBD to the Ship Service SWBD) 522.5.6 Table 2.9: Explanation for Note 6 of Figure 2.1 (Variable Frequency of Adjustable Drive for Electrical Propulsion Application) 532.6 Shipboard Electrical Standard Voltages 532.6.1 NORSOK Standard 6.1 System Voltage and Frequency 542.7 Voltage and Frequency Range (MIL-STD-1399) 552.8 Ungrounded System Concept (ANSI and IEC) 552.9 Concept Design 562.9.1 Power Generation 562.9.2 Power Distribution 562.10 Design Features Outlined in 562.11 Protective Device–Circuit Breaker Characteristics 572.12 Fault Current Calculation and Analysis Requirement 572.12.1 Fault Current Calculation Fundamentals 592.13 Adjustable Drive Fundamentals 592.13.1 Advantages of ASD for Shipboard Application 592.13.2 Disadvantages of VFD/ASD for Shipboard Application 612.14 Fundamentals of ASD Noise Management 612.15 Electrical Noise Management (See Chapter 7 for Additional Details) 622.16 Motor Protection Solutions: DV/DT Motor Protection Output Filter 643. Power System Design, Development, and Verification 673.0 Introduction: Design, Development, and Verification Process 673.1 Typical Design and Development of Power Generation and Distribution (See Figure 3.1) 673.2 Failure Mode and Effect Analysis (FMEA): Design Fundamentals 683.2.1 Failure Mode and Effect Analysis (FMEA) 683.3 Failure Mode and Effect Analysis (FMEA) Electric Propulsion System Diesel Generator: Design Fundamentals 703.3.1 Diesel Engine Operational Mode Selection 703.3.2 Diesel Generator Safety System Functions 713.3.3 Power Management Overview Mimic (Central Control Station and Switchboard) 723.3.4 Power Distribution Mimic Page 733.4 Design Verification: General 733.4.1 Qualitative Failure Analysis (QFA) 733.4.2 Qualitative Failure Analysis (QFA) Basics 743.4.3 Process Failure Mode and Effect Analysis (FMEA): General 743.4.4 Qualitative Failure Analysis (QFA)-1 753.4.5 Explanation of the Detail Design Using QFA 753.4.6 Design Verification Test Procedure (DVTP): General 753.4.7 Example-1: Propulsion Plant (DVTP) Design Verification Test Procedure 773.5 Ship Service Power System Design: System-Level Fundamentals (Figure 3.2) 783.6 Single Shaft Electric Propulsion (Figure 3.3) 793.7 Electrical Generation and Distribution with Detail Design Information (Figure 3.4) 813.8 Electric Propulsion and Power Conversion Unit for Ship Service Distribution (Figure 3.5) 833.9 6600V and 690V Adjustable Speed Application with High-Resistance Grounding-1 (Figure 3.6) 853.10 MV and 690V Adjustable Speed Application with High-Resistance Grounding (Figure 3.7) 873.11 Fully Integrated Power System Design with Adjustable Speed Drive (Figure 3.8) 893.12 Variable Frequency Drive (VFD) Voltage Ratings and System Protection 913.13 Example 460V, Three-Phase, Full Wave Bridge Circuit Feeding Into a Capacitive Filter to Create a 650 VDC Power Supply 913.14 Special Cable and Cable Termination Requirements for Variable Frequency Drive Application 913.15 Harmonic Management Requirements for Variable Frequency Drive Application 913.16 Switchgear Bus Bar Ampacity, Dimension, and Space Requirements 933.16.1 Bus Bar Rating for English Dimensions (Inches) 933.16.2 Bus Bar Rating for Metric Dimensions (Millimeter:MM) 943.16.3 Nominal Working Space Requirements 953.17 MEECE (Management of Electrical and Electronics Control Equipment) Course Outline Requirements: USCG 964. Power Generation and Distribution 994.0 Introduction 994.1 Generation System Requirements 1014.2 IEEE Std 45-2002, ABS-2002 and IEC for Generator Size and Rating Selection 1044.3 ABS-2002 Section 4-8-2-3.1.3 Generator Engine Starting from Dead Ship Condition (Extract) 1064.4 Additional Details of Sizing Ship Service Generators 1094.4.1 Engine Governor Characteristics 1104.4.2 Generator Voltage Regulator Characteristics 1104.4.3 How AVR works: 1114.4.4 Droop Characteristics: Generator Set 1114.5 Typical Generator Prime Mover 1124.6 Generator: Typical Purchase Specification (Typical Electrical Propulsion System) 1135. Emergency Power System Design and Development 1155.0 Introduction 1155.1 USCG 46 CFR Requirements: 112.05 (Extract Only) 1165.2 IEEE STD 45-2002, Clause 6.1, General (Extract) 1175.3 Emergency Source of Electrical Power: ABS 2010, 5.1.1 Requirement 1185.4 ABS Emergency Generator Starting Requirement (ABS Rule for Passenger Vessels) 1185.5 Typical Emergency Generation and Distribution System 1195.6 Emergency Generator and Emergency Transformer Rating: Load Analysis (Sample Calculation) 1205.7 Emergency Power Generation and Distribution with Ship Service Power and Distribution System 1205.8 Emergency Transformer 450 V/120V (Per ABS) 1205.9 Emergency Generator Starting Block Diagram 1205.10 Emergency Generation and Distribution Design Verification 1225.11 No-Break Emergency Power Distribution 1236. Protection and Verification 1246.0 Introduction: Protection System Fundamentals 1246.1 Protective Device: Glossary 1266.2 Power System Protections 1286.3 Power System: Procedure for Protective Device Coordination 1316.4 Fault Current Calculation Guidelines (Per USCG Requirements) 1326.5 Overall Protection Synopsis 1326.6 ANSI Electrical Device Numbering (for Device Number Details Refer to ANSI C.37.2) 1356.7 Fault Current Calculations (Per USCG Requirements CFR 111-52-3(B) & (C)) 1366.7.1 Maximum Asymmetrical Fault Current 1376.7.2 Average Asymmetrical Fault Current 1376.7.3 450 V Switchboard Rating 1386.7.4 450 V Switchboard Circuit Breaker Rating 1386.7.5 Fault Current Calculation for the 120 Voltage System is as follows 1386.7.6 RMS Symmetric Current 1386.7.7 Fault Current Calculation Summary 1386.8 Details for Figure 6.3 Typical EOL for MV Generator Protection System: Split Bus with Two Bustie Breakers 1416.9 Details for Figure 6-4: Typical EOL for MV Generator Protection System: Split Bus with Two Bustie Breakers 1436.10 Details for Figure 6.5 Typical for Transformer Protection Schematic 1446.11 Details for Figure 6.10: Typical EOL for MV VFD Transformer Protection Schematic 1456.11.1 Low Overcurrent Setting: (I>) 1496.11.2 High Overcurrent Setting: (I>>) 1506.11.3 Conclusion of Calculation 1506.12 Power System Dynamic Calculations 1556.13 Protective Relay Coordination and Discrimination Study 1557. Power Quality: Harmonics 1587.0 Introduction 1587.1 Solid-State Devices Carrier Frequency 1607.2 MIL-STD-1399 Requirements 1627.3 IEEE STD 519 Requirements (1992 and 2014 Versions) 1627.3.1 Total Harmonic Distortion (THD) 1647.3.2 Total Demand Distortion (TDD): Current Harmonics 1657.4 Calculate the RMS Harmonic Voltage Due to the Respective Harmonic Current 1657.5 Current Harmonic Matters 1677.6 Harmonic Numbering 1677.7 DNV Regulation: Harmonic Distortion 1687.8 Examples of Typical Shipboard Power System Harmonic Current Calculations 1697.9 Choice of 18-Pulse Drive versus 6-Pulse Drive with Active Harmonic Filter 1717.10 Typical Software to Calculate Total Harmonic Distortion and Filter Applications 1727.11 Harmonic Recommendations (IEEE 45.1 Partial Extract) 1757.12 Harmonic Silencing and ARC Prevention (Curtsey of Applied Energy) 1807.13 Applicable Power Quality Standards Include 1848. Shipboard Cable Application and Verification 1858.0 Introduction: Shipboard Cable Application 1858.1 Cable Size Calculation Fundamentals 1858.2 Shipboard Cable for ASD and VFD Applications 1868.3 Cable Requirements Per IEEE Std 45 1868.4 Cable Shielding Guide Per IEEE Std 1143 1878.5 Cable: Physical Characteristics 1928.6 Cable Insulation: Typical 1978.7 Cable Ampacity 1998.8 Commercial Shipboard Cable Circuit Designation 2038.9 Example 1: Low-Voltage 600 V/1000V IEC Cable Details 2058.10 Example 2: MV Voltage 8 KV/10 KV 2068.11 Example 3: VFD Cable LV (600 V/100) and MV VOLTAGE (8 KV/10 KV) 2088.12 Ground Conductor Size 2088.13 Develop Math to Calculate the Ground Conductor for Parallel Run 2098.14 Cable Designation Type (Typical Ship Service Cable Symbol or Designation) 2098.15 Cable Color Code: Shipboard Commercial Cable 2108.16 ASD (VFD) Cable Issues for Shipboard Application 2118.17 ABS Steel Vessel Rule: Part 4, Chapter 8, Section 4: Shipboard Cable Application 2128.18 Grounding Conductor Size: for Cable Rated 2 KV or Less for Single Run 2149. Grounding, Insulation Monitoring Design, and Verification 2169.0 Introduction 2169.1 System Grounding Per IEEE 45 2179.1.1 Shipboard LV Power System Grounding IEEE 45 Recommendations (See Figures 9.1 and 9.2) 2179.2 Selection of High-Resistance Grounding (HRG) System 2199.3 IEEE 142 Ground Detection Requirements 2209.4 IEC Requirements: Insulation Monitoring System 2219.4.1 Insulation Monitoring 2249.4.2 Insulation Monitoring System for Grounded AC Systems with VFD System 2249.5 System Capacitance to Ground Charging Current Calculation (Taken From IEEE 142 Figs. 1.6 and 1.9) 2259.6 Total System Capacitance Calculation 2259.7 Calculate Capacitive Charging Current: (for a Typical Installation) 2269.8 Capacitive Charging Current Calculation: Sample Calculation 2279.8.1 Iccc Calculation for Generators 12,000 kVA, 6600V, 3-Phase, 3-Wire—Total 4 2279.8.2 Iccc Calculation for Transformers 2279.8.3 Cables 8 kV—(4/0 AWG) (T-212) Cable Three Core 2289.8.4 Total Capacitive Charging Current 2289.8.5 Grounding Transformer Size Calculation 2299.8.6 Grounding Resistor Size Calculation 2299.9 Grounding Resistor Selection Guideline Per IEEESTD 32-1972 2309.10 Grounding Resistor Duty Rating 2319.11 Zigzag Grounding Transformers: IEEE STD 142 Section 1.5.2 2329.12 Rating and Testing Neutral Grounding Resistors: IEEE STD 32-1972 2339.13 Voltage Stabilizing Ground Reference (VSGR) Phaseback for Ground Detection (Curtsey of Applied Energy) 2349.13.1 Typical HRG Elementary Diagrams are Very Close to the Voltage Stabilizing Ground Reference (VSGR) Phaseback Unit, Looking Alike Phaseback’s Function is Exactly Opposite to the HRG 2389.13.2 Phaseback Voltage Stabilizing Ground Reference Addresses and Solves the Following Issues 2399.14 HRG Versus VSGR 2409.15 Shipboard Ground Detection System Recommendations 24010. Shore Power LV and MV Systems 24210.0 Introduction 24210.1 LV Shore Power System 24210.2 MV (HV) Shore Power System 24310.3 Low-Voltage Shore Power System 25010.4 Four-Wire Grounded System LV Shore Power Connections 25310.5 Medium-Voltage Shore Power System (MV) 25310.6 Extract from IEC/ISO/IEEE 80005-1 Part 1: High-Voltage Shore nConnection (HVSC) Systems HV Shore Power Requirements (Shore to Ship Power Quality and Protection Requirements) 25611. Smart Ship System Design (S3D) and Verification 26011.0 Introduction 26011.1 Virtual Prototyping for Electrical System Design 26111.2 Electrical Power System Smart Ship System Design FailureMode and Effect Analysis 26411.3 Marine Technology Society (MTS) Guidelines for DP Vessel Design Philosophy: Guidelines for Modu DP System and Commercial Ships 26611.4 Additional Marine Technology Society (MTS) Requirements Applicable for Ship Design: (USCG Recognized MTS Requirements) 26611.5 Condition-based Maintenance 27211.6 FMEA Objectives: S3D Concept 27211.7 Additional S3D Process Safety Features 27212. Electrical Safety and Arc Flash Analysis 27412.0 Introduction 27412.1 Injuries Result from Electrical-Current Shorts 27412.2 General Safety Tips for Working with or Near Electricity 27512.3 Arc Flash Basics 27612.4 Fundamentals of Electrical Arc and Arc Flash 27712.5 Definitions Related to Arc Flash (Derived from NFPA 70E NEC, NFPA 70E, and IEEE STD 1580 for Shipboard Electrical Installations) 27812.6 Causes of Electric Arc 27912.7 Incident Energy 27912.8 Incident Energy at Arc Flash Protection Boundary 28012.9 The Flash Protection Boundary 28012.10 Electrical Hazards: Arc Flash with Associated Blast andShock 28012.11 Shock Hazard 28112.12 Hazard/Risk Categories (Derived from NFPE-70E) 28212.12.1 Hazard/Risk Category: Description (HRC-0) 28212.12.2 Hazard/Risk Category: Description (HRC-1) 28212.12.3 Hazard/Risk Category: Description (HRC-2) 28512.12.4 Hazard/Risk Category: Description (HRC-3) 28512.12.5 Hazard/Risk Category: Description (HRC-4) 28512.13 Shipboard Electrical Safety Compliance Chart per NFPA 70E 2012 Table 130.7.C.9 28512.14 Arc Flash: OSHA Requirements (29 CFR 1910.333) 28612.15 Arc Flash: National Electrical Code (NEC) Requirements 28612.16 Arc Flash: NFPA 70E 2012 Requirements 28712.17 Arc Flash Boundary: NFPA 70E 28912.18 Low-Voltage (50 V–1000 V) Protection (NFPA 70E 130.3 (A1)) 29012.19 Medium-Voltage (1000V and Above) (NFPA 70E 130.3 (A2)) 29012.20 Arc Flash: IEEE 1584 Requirements and Guidelines 29112.21 Arc Flash: Circuit Breaker Time Currect Coordination—Overview 29212.22 Arc Flash Calculation Analysis and Spreadsheet Deliverables 29612.22.1 For Shipboard Arc Flash Analysis the Following Should be Included 29612.23 Methods of Developing Analysis 29612.23.1 Coordination Study 29612.24 Fault Current Analysis to Ensure Power System Component Protection Characteristics 29612.25 Fault Current Calculation: Approximation for Arc Flash Analysis 29712.26 Shipboard Fault Current Calculation Guidelines (per USCG Requirements) 29812.27 Example Shipboard Fault Current Calculations (per USCG Requirements CFR 111-52-3(B) & (C)) 29812.28 Shipboard Power System Short-Circuit Current Calculation (Refer to US Navy Design Data Sheet 300-2 for Details) 29912.29 Fault Current and Arc Flash Analysis as Required by NFPA 70E 30012.30 Fault Current and Arc Flash Analysis Guide by IEEE 1584 30112.31 Electrical Safety and Arc Flash Labeling (NFPA 70E) 30212.32 Arc Flash Protection-Boundary 30312.33 Sample Arc Flash Calculations: Spreadsheet—Excel Type 30412.33.1 NFPA 70E 2009 Equation D.5.2 (A) for Arc Flash Calculation 30412.34 Low-Voltage (50 V–1000 V) Protection (NFPA 70E 130.3 (A1)) 30412.35 Medium Voltage (1000V and Above) (NFPA 70E 130.3 (A2)) 30412.36 IEEE 1584-Based Arc Flash Calculations 30512.36.1 IEEE 1584: Incident Energy Exposure 30512.36.2 IEEE 1584: Arcing Current Calculation: Up to 1000V Systems 30512.36.3 IEEE 1584: Arcing Current Calculation for 1 kV to 15 kV 30612.36.4 IEEE 1584: Flash Protection Boundary Calculation (DB) 30612.36.5 IEEE 1584: Flash Protection Boundary 30612.36.6 IEEE 1584: Level of PPE 30612.36.7 IEEE-1584: Equipment Class 30712.36.8 IEEE 1584: Distance Exponent 30712.36.9 IEEE 1584: Arc Duration/Total Arc Clearing Time 30812.36.10 IEEE 1584: Available Three-Phase Bolted Fault Current 30812.36.11 IEEE 1584: Predicted Three-Phase Arcing Current 30812.37 Sample Shipboard Arc Flash Calculation Project 31012.37.1 General 31012.37.2 Short-Circuit Study 31012.37.3 Protective Device Coordination Study 31012.37.4 Arc Flash Hazard Study 31012.37.5 Analysis 31012.37.6 Report 31112.38 Fast-Acting Arc Management System: Arc Flash Mitigating Hardware Driven Time 31112.39 Guidelines for Shipboard Personnel 312Glossary 315Index 325