MARINE HIGH VOLTAGE SYSTEMS

HIGH VOLTAGE SYSTEMS ON SHIPS

 Introduction

•As we all know usually the ship operates with a 3 phase. 60Hz.
440 Volts supply which is being generated and distributed on
board.
• Every day the owners and designers aim for bigger ships for
more profitability.
•As the ship size increases, there is a need to install more
powerful engines and other machinery.
•This increase in size or machinery and other equipment
demands more electrical power and thus it is required to use
higher voltages on board a ship
 Why High Voltage in Ships?
– Higher power requirements onboard vessels is the foremost
reason for the evolution of HV in ships.
– Higher power requirements have been necessitated by
development of larger vessels required for container transort
particularly for reefer containers.
– gas carriers needing extensive cooling electrical propulsion.
– For ships with a large electrical power demand it is necessary to
utilize the benefits of a high voltage HV installation.
– The design benefits relate to the simple ohms law
relationship that current (for a given power)is reduced as the
voltage is increased. Working at high voltage significantly reduces
the relative overall size and weight of electrical power equipment.
 Advantages & Disadvantages of using HV

Advantages
— For a given power, Higher voltage means Lower
current, resulting in
— Reduction in size of generators, motors, cables etc.
— Saving of Space and weight
— Ease of Installation
— Reduction in cost of Installation
— Lower losses — more efficient utilisation of generated
power.
— Reduction in short circuit levels in the system which
decides the design and application of the electrical
equipment used in the power system.
Advantages & Disadvantages of using HV

Disadvantages:
1. Higher Insulation requirements for cables and
equipment used in the system.
2. Higher risk factor and the necessity for strict
adherence to stringent safety procedures.
 Marine HV Systems

What is classed as HIGH VOLTAGE ?

• “ In Marine practice, voltages below 1000 V AC ( 1 kV ) are

considered Low Voltage and High Voltage is any voltage
above 1 kV. Typical marine high voltage system voltages are
3.3 kV, 6.6 kV and 11 kV.”
 Marine HV Systems

• The Major differences in HV and LV supply

• HV systems are more extensive with complex networks and connections
• Isolated equipment MUST BE earthed down
• Access to HV areas should be strictly limited & controlled
• Isolation procedures are more involved & authenticated
• Switching strategies should be formulated and recorded
• Specific test probes and instruments must be used for testing
• Diagnostic IR testing is necessary
• HV systems are usually earthed neutral and use current limiting resistors
• Special HV Circuit Breakers have to be installed for isolation

Operation & Maintenance of HV Systems:

• Only by trained Senior Engineering Staff- STCW-2010 Manila amendments
• HV Check list: Code Of Safe Working Practices ( COSWP ) - 2010
 Marine HV System
Comparison between 6.6 KV & 440 V
6.6 kV High Voltage 440 Volt

Current Low High

Type of Circuit Breaker VCB ACB

ACB/VCB Maintenance Vacuum Checker/Gap gauge Visual Check

Safety Device Location Separate Protection (TSW) Inside ACB built-in

Control circuit voltage DC 110 V DC 24 V

Bus-bar Small – 8mmx50mmx2 bars 8mmx200mmx4 bars

Bus-bar distance Wider Narrow

MSB Protection Fully Compartmental No Compartments

Mech.Key interlock for door No interlock
Internal short circuit Can cause Explosion No explosion

Protection from Explosion Pressure relief flap, Reinforced No such features

panel doors secured with bolts
Earthing Device Earthing Switch provided No earthing switch
Creepage & Clearance for HV Systems:

Nominal Voltage ( KV ) Min. Air Clearance ( mm)

3 (3.3) 55

6 (6.6) 90

10 (11) 120

15 160
 Marine HV Systems
Vacuum Circuit Breakers
• Fixed and moving contacts sealed inside evacuated borosilicate glass.
• The moving contact operates via flexible metal bellows – charged by motorized or
solenoid system.
• High dielectric strength of vacuum allows very short contact separation and rapid
interruption of the arc.
• Arcing period is much shorter < 15 mSec and arc energy is very much lower
compared to ACB.
• Compact & Quiet unit, Minimum wear & tear, minimum maintenance
• Non inflammable and non toxic
• Typical life over 10 years.
• SF-6 Gas Breakers
• Contact separation by Sulphur Hexafluoride gas sealed in the chamber at a
pressure of 500 Kpa ( 5 Bar at 20 degC ).
• Arc quenching is faster than VCB due to gas absorbing the heat energy.
Risk Factor in Low Voltage
System
ELECTRIC SHOCK
 Marine HV Systems

EFFECT OF ELECTRIC CURRENT ON HUMAN BODY

Sr.No. AC 50 Hz mA DC mA AC 10,000 Hz mA EFFECT

1 0 to 1 0 to 5 0 to 9 No sensation

2 1 to 8 6 to 55 10 to 55 Mild shock-tingling sensation

3 9 to 15 60 to 80 60 to 80 Painful shock and surprise

4 16 to 20 80 to 100 80 to 100 Some loss of muscle control

5 20 to 45 100 to 350 --- Severe shock and loss of

muscle control
6 50 to100 400 to 800 --- Possible heart failure

7 Over 100 Over 800 --- Usually fatal

Risk Factor in High Voltage
System
ELECTRIC ARC FLASH
 Marine HV Systems
Arc Flash / Arc Blast -- Typical Consequences
• Arc flash happens between conductors or conductors & earth while
ArcBlast is the energy that spreads to surrounding areas.
• A phase to phase arc flash in a 480 V system can cause 20KA fault current
and would release 1.6 Mega Joules energy. This is equivalent to 380gm of
TNT explosion.
• The IR/UV radiation can cause skin disorders to nearby personnel. Intense
heat radiation can cause severe burns and fire hazard in the area.
• The brilliant light energy can cause partial or total blindness in people.
Safety Measures
> Ideally work on a HV system shall be done after
isolating,disconnecting,proving “System Dead” and earthing/discharging.
> Use of PPE : Graded Rubber gloves, safety goggles, hearing protection
and protective clothing.
> Cat-3 type require clothing rated for Min.25 cal/cm2 energy to damage
( equiv. to 1.05 MJ/M2 )
 Marine HV Systems:

Risk Factors in HV Systems :

Besides the earlier mentioned factors of risks in using HV system
like Arc flash/blast, insulation failure, tracking due to moisture, dust etc.,
Electric shock is a serious danger if not adequate precautions are not taken.
Additionally in this regard, the following points should be given due
consideration in handling HV systems especially during maintenance work.

a)Cable & Interelectrode Capacitance:

High Voltage equipment will store energy even after disconnection. For
example, on a 6.6 KV switch board, a fatal residual capacitance charge may
still be present hours or even days after later. Hence system discharge to
earth & confirming ‘system dead ‘ is essntial before work.

b)HV Inductance:
If during maintenance a high voltage circuit main earth (CME) is removed
from the system, it must not be worked on as the high voltage cabling can
recharge itself to a voltage (say 3 kv) from induced voltages from nearby live
HV cables. Hence due precaution needed.
 Marine HV Systems

Short Circuit : Effects and Protection :

“ A short circuit is an abnormal connection through a negligible impedance made

accidentally or intentionally, between two points of different potentials in a circuit. “

Aftereffects:

1.On rush of enormous current between two potential points.

2.If tripped by protection, loss of power to equipment.
3.If system overloads, generator trips and loss of power to whole system.
4.Possibility of arc flash, fire hazard, damage to parts and/or shock.
5.If Earth fault, effect depends on Neutral earthed or insulated.
Protection:

1. Equipment protection by Short Circuit relay, Earth fault relay etc.,

2. Proper selection of insulation rating/material for application
3. Correct installation methods of cables, joints,glands,terminals etc.,
4. Ingress protection against dust,moiture,foreign particles, water etc.,
 Marine HV System

Design Prevention
• Limiting fault current in the system to minimum by use of grounding
resistors/fuses. Typical current of < 5 A does not create arc flash.
• Arcing time reduction: During maintenance, upstream protective devices
can be set to lower values to isolate system in case of fault.
• Light/Current based detectors of arcing can be employed to activate
protection relays in the system.
• Use of Arc Eliminator ?
• Remote operation/Use of Robots to perform rack in/rack out of CBs !
• Operate from outside “Flash Protection Boundary”
• FPB = “Distance from an arc flash source within which an unprotected
person has a 50% chance of receiving a 2nd degree burns.”
• If operating within this distance, then Cat-3 Protective clothing is a must.
HV / LV Limits :
 Marine HV Systems

HV Work Procedures:
• System safety Requirements:
a) Only trained personnel handle HV systems ( Engineers /Electrical Officer )
- STCW -2010 amendments
b) Risk Assessment by Chief Engineer/Electrical Officer prior to work
- STCW -2010
c) Permit to Work system ( special to HV ) to be in place - EPTW
- STCW -2010 & COSWP-2010
d) Sanction for Test system ( separate from Permit to work ) – COSWP-2010

e) Limited Access Form ( for personnel to work in the vicinity ) - “

f) Earthing Down : Circuit earthing/Bus-bar earthing methods - “

g) Caution notices display at appropriate places

h) Cordon off HV areas to prevent unauthorized access

•
 Marine HV Systems

HV Test Objectives:
• Periodic Testing : To prove Integrity
& Reliability of equipments
• Diagnostic Testing: Comparative measurements
& fault serenity
• Fault Simulation : Verification of Component stability
& endurance
HV Installations to cover: ( 1000 V & above )
• Generators & Motors ( Propulsion, Bow thruster etc., )
• A/C Compressors, Deck machineries
• Switch gears, Transformers, Cables & Accessories
 Marine HV Systems

Suggested HV Tests on Board:

• Insulation Resistance ( IR Test )
• Polarity Index ( PI Test )
• Infrared Imaging ( Hot spot Location )
• Circuit Breaker Test
• Partial Discharge Test
• BIL (Basic Insulation Level ) Test
• Life Test
N.S.: Follow Manufacturer’s guidelines for testing & maintaining HV M/cs.
HV Insulation depends on
Temperature,Humidity,Surface conditions and Operating Voltage
Before IR Test, Power must be OFF, isolated & “confirm DEAD” by
Approved Line Tester, Earthed for safety in accordance with Standards
(EPTW)
*********
 Marine HV System
Infrared Imaging:
 Marine HV Systems

IR Measurement & Polarization Index Check:

* Recommended routine testing and after major repair work.

* Hand cranking or electronic meggar- 1 minute application
* Measured after a run, ie., in warmed up condition.
* As per National Electrical Code, IR = 20 x En / (1000+2P ) MΩ
where En= rated ph to ph voltage & P= rated power in KW.
•International Association of Classification Societies. (IACS) table:
Rated Voltage Min.Test Voltage Min.IR value (MΩ )
1000 to =/< 7200 1000 V KV + 1
7200 to =/< 15 KV 5000 V KV +1
However, for 6.6 KV & above a 5000 V meggar is recommended.
P.S. IR value drops to half for every 10 degC increase.

Polarization Index is measured at regular intervals to assess the

equipment insulation status. It is an extension of IR test and gives an
idea of extendibility of a machine’s working life. Recommended values:

PI = 1.5 & above for class A insulation system

= 2.0 & above for class B & F insulation system
Typical HV Switch gear & Panels:

Std. Ref.: IEC-60298: : Enclosures : IP-23 to IP-65 based on use & location.
Bus bar : Two sections at least, split and isolated by CB or Disconnector.
If two separate Switch Boards are used with cable interconnection, then CB at
each end of cable recommended. In case of Earthed Neutral System, neutral
disconnect Facility for maintenance and IR test must be provided.
 Marine HV System
Typical HV Cable Installation
MARINE HV SYSTEMS