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The RAACI Electric Jacking System
2016 Oil and Gas Innovations Conference Minute Maid Park, Houston, TX The RAACI Electric Jacking System Presenter: Dr. Dennis Robichaux Trident Maritime Systems, RAACI Division President Completely Integrated Electrical and Automation Solutions Number of Employees: • 800 Industries Served: • Offshore Marine Industry - OSVs, PSVs, MPSVs, Government, Jack Ups, Cruise ships • Flood Protection Infrastructure • Motor Control Systems for Inland Push boats • Equipment Packages for Mobile Drilling Rigs www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 2 Completely Integrated Electrical and Automation Solutions PRODUCTS ENGINEERED • Vessel One Line Analysis • Responsibility for Integration • Short Circuit Analysis • Responsibility for ABS Approval • Harmonic Analysis • Schematics • Breaker Coordination Study • System Training • Load Flow Summary • Assembly Drawings • Cable Sizing • Outline and Mounting Drawings • Cable Termination Drawings • Network Block Diagrams • Sizing Generators & Motors • Spares Recommendations • 3D Modeling of Equipment • Custom Technical Manual www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 3 Completely Integrated Electrical and Automation Solutions PRODUCTS DELIVERED • 4000 HP Variable Frequency Drives • Remote Monitoring and Control • Medium Voltage Switchboards & MCC’s • Propulsion Motors • 690V/480V Switchboards • Thruster Motors • Emergency Switchboards • Jacking System Motors • Propulsion Control Systems • • Alarm & Monitoring Systems Jacking System Control and Monitoring System • Cargo/Tank Gauging Control Systems • Jacking System MCCs • Damage Control Consoles • Jacking System Variable Frequency Drives • Engine Control Panels • Power Management Systems www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 4 Completely Integrated Electrical and Automation Solutions Bridge Console Workstations Shore Power Engineers Operating Station www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 5 Completely Integrated Electrical and Automation Solutions Montco Offshore Typical Larger Bow Thruster Drive www.TridentLLC.com USCG BP America Typical Main Propulsion Drive 2840 Lausat St. Metairie, LA, 70001 Stone Oil Tel: 504-834-1167 6 Completely Integrated Electrical and Automation Solutions Dennis Robichaux Biography: • President of RAACI Division of Trident Maritime Systems (Office: Metairie, LA) • Experience in the marine automation and control industry for more than 20 years • Led his company from a start up to one of the largest marine system integrators for Siemens in the United States. • Doctorate of Philosophy degree in Electrical Engineering • During his downtime he enjoys coaching his three kid’s soccer, baseball, softball and basketball teams. www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 7 Completely Integrated Electrical and Automation Solutions Types of Electrical Jacking Systems: • Direct On Line (DOL) System with and without autotransformer • Variable Frequency Drive – AFE VFD one per leg with an MCC • Variable Frequency Drive – AFE VFD one per leg without an MCC • Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per leg • Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per leg with a spare • Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per gearbox www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 8 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 9 Completely Integrated Electrical and Automation Solutions Direct On Line (DOL) System Advantages • Very Simple architecture for the system • Easier for vessel operators to service and maintain • Low Cost • Works at 480VAC, 600VAC or 690VAC • One MCC bucket per gearbox motor www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 10 Completely Integrated Electrical and Automation Solutions Disadvantages • Special high slip motor • Re-torqueing system required • Wear and tear on the system is high • Higher wear on the brake system • Overdesign of the gearbox/pinion due to high starting torque. • Limited number of jacking speeds • Extra electrical losses due to use of high slip electric motors • If one braking resistor fails the lift boat may not be able to be lowered www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 11 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 12 Completely Integrated Electrical and Automation Solutions Variable Frequency Drive – AFE one per leg Advantages • Active Front End (AFE) Variable frequency drive (VFD) which limits harmonics • Works at 480VAC, 600 VAC or 690VAC • Continuously variable frequency/speed control from 0 to 100% • One MCC bucket per gearbox motor • No need for Re-torqueing • Simple design but slightly more complex than the basic DOL system • Limits wear and tear on the system because of smooth acceleration and deceleration www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 13 Completely Integrated Electrical and Automation Solutions Disadvantages • System is slightly more complex with AFE VFD technology • If one braking resistor fails the lift boat may not be able to be lowered • If any component of the AFE VFD fails, the lift boat cannot be raised or completely lowered www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 14 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 15 Completely Integrated Electrical and Automation Solutions Variable Frequency Drive – AFE one Motor Module controller per gearbox Advantages • Active Front End (AFE) Variable frequency drive (VFD) which limits harmonics • Works at 480VAC, 600VAC or 690VAC • Continuously variable frequency/speed control from 0 to 100% • One VFD Motor Module per gearbox motor thus providing individual speed control to each motor • No need for Re-torqueing • Simple design but slightly more complex than the basic • Limits wear and tear on the system because of smooth acceleration and deceleration www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 16 Completely Integrated Electrical and Automation Solutions Disadvantages • System is slightly more complex with AFE VFD technology • If one braking resistor fails the lift boat may not be able to be lowered • If the Active Front End module or the Active Line Module fails the lift boat cannot be raised or completely lowered www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 17 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 18 Completely Integrated Electrical and Automation Solutions Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per leg Advantages • Diode Front End Variable frequency drive (VFD) with harmonic cancelling transformers • Works at 480VAC, 600VAC or 690VAC • Continuously variable frequency/speed control from 0 to 100% • One MCC bucket per gearbox motor • No need for Re-torqueing • Limits wear and tear on the system because of smooth acceleration and deceleration • Braking resistors can be sized to handle a failure and still lower the lift boat • Diode front end modules can be sized to handle a failure and still raise and lower the lift boat www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 19 Completely Integrated Electrical and Automation Solutions Disadvantages • System is more complex with a common DC bus • If a motor module fails, in the VFD, the lift boat cannot raised or completely lowered • Transformers are required www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 20 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 21 Completely Integrated Electrical and Automation Solutions Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per leg with a spare motor module Advantages • Diode Front End Variable frequency drive (VFD) with harmonic cancelling transformers • Works at 480VAC, 600VAC or 690VAC • Continuously variable frequency/speed control from 0 to 100% • One MCC bucket per gearbox motor • No need for Re-torqueing • Limits wear and tear on the system because of smooth acceleration and deceleration • Braking resistors can be sized to handle a failure and still lower the lift boat • Diode front end modules can be sized to handle a failure and still operate the lift boat • A spare motor module is included to handle a failure of one of the motor modules and still operate the lift boat www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 22 Completely Integrated Electrical and Automation Solutions Disadvantages • System is more complex with a common DC bus and a spare motor module • Transformers are required www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 23 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 24 Completely Integrated Electrical and Automation Solutions Variable Frequency Drive – 24 pulse common DC bus with one motor module controller per gearbox Advantages • Diode Front End Variable frequency drive (VFD) with harmonic cancelling transformers • Works at 480VAC, 600VAC or 690VAC • Continuously variable frequency/speed control from 0 to 100% • One Motor module per gearbox motor • No need for Re-torqueing • Limits wear and tear on the system because of smooth acceleration and deceleration • Braking resistors can be sized to handle a failure and still lower the lift boat • Diode front end modules can be sized to handle a failure and still operate the lift boat • A motor module can fail and still operate the lift boat www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 25 Completely Integrated Electrical and Automation Solutions Disadvantages • System is more complex with a common DC bus • Transformers are required www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 26 Completely Integrated Electrical and Automation Solutions Products Chosen • Siemens 1500 series PLC or 414H PLC and Automation • Siemens WinCC HMI graphic software • Siemens 3WL and 3VL IEC circuit breakers • Siemens MCCs • Siemens S120 Variable Frequency Drive Components • Siemens gearboxes • Siemens motors www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 27 Completely Integrated Electrical and Automation Solutions Siemens PLC and Automation • 1500 series or 414H PLCs • Step 7 Engineering Software • TIA- Total Integrated Automation • Redundant IM-153 Interface Modules • Y-Links • Siemens Touch Panels • Ethernet Switches www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 28 Completely Integrated Electrical and Automation Solutions Siemens WinCC HMI Graphics • Remote Access and Monitoring • TIA • Easy to Understand Graphics o Picture of Lift boat with sensor locations o All sensors shown on a mimic for easy of recognition o Visual Alarm Window on each Page o Same Location on each Page • Easy to Navigate Graphics o Pull Down Menu • Disable Nuisance Alarms www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 29 Completely Integrated Electrical and Automation Solutions Siemens 3WL and 3VL Circuit Breakers • 50 Deg C • IEC Approved • ABS Approved • 12KAIC to 130 KAIC Rated • Synchronization o Quick Closing - Spring Operated • Different Electronic Trip to Assist with Coordination • Shunt Trips, UVT Trips, Alarm Contacts, Aux Contacts www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 30 Completely Integrated Electrical and Automation Solutions Siemens Motor Control Centers and Distribution Panels • 50 Deg C • Remote Control from HMI • Remote Monitoring from HMI • MCC Located Centralized Location • Touchscreen for Control www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 31 Completely Integrated Electrical and Automation Solutions Siemens Variable Frequency Drive • 45 Deg C ambient air with no de-rating • Air Cooled • Regeneration • Operator Local Control Panel • Green Control Unit Line Module Motor Modules DRIVE-CLiQ www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 32 FLENDER Jackup Gearboxes Since its introduction in 1997, PLANUREX2 family of Heavy Duty Planetary Gear Units, powers everything that requires high output torques, dependability, and reliability. For the most reliable Jackup Gearboxes where failure is not an option, choose PLANUREX2 from FLENDER Product P2PA.. Sizes 8 Gear stages 7-stages Ratios i = 2500 to 8000 Nominal torques up to 7,000,000 Nm Mounting positions Horizontal www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Made in Germany Tel: 504-834-1167 33 Completely Integrated Electrical and Automation Solutions Siemens Motors • 50 Deg C • Air Cooled • IEC Severe Duty rated IP56 • Brake • Encoder www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 34 Features/Benefits of the Jacking System • Starting of movement of all legs at same time • Accurate speed and torque (pinion load) control even at almost zero speed • Smooth start up (torque increases slowly with brake engaged) • Different speed levels for operation modes • Equal load distribution for each pinion during movement • Failsafe system to protect personnel and equipment • Rack Phase Difference monitoring and correction is standard • Main components are designed to be integrated together • Reliable and easily maintained system • Jacking is possible even after component failures • Accurate load sharing reduces wear • Standard off the shelf components www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 35 Completely Integrated Electrical and Automation Solutions www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 36 The RAACI Electric Jacking System Presented by Dr. Dennis Robichaux President of Trident Maritime Systems, RAACI Division www.TridentLLC.com 2840 Lausat St. Metairie, LA, 70001 Tel: 504-834-1167 37
