SEMINAR REPORT

SHIP PRODUCTION II
Electrical Shop in a Ship Repair Yard

10-October,2012

Submitted by:
Naseef PK
Nikhil KR
Rashid K
Mohammed Nizar PM
Semester-VII
B.Tech in Naval Architecture
and Shipbuilding
DOST, CUSAT

ELECTRICAL REPAIR SHOP

The electrical shop in a ship repair yard should be equipped and capable of
undertaking repairs and rewinding of full range of motors and generators of ships
and overhaul of electrical apparatus and switch gears. List of major equipments
here are: Electric Coil Winding machines
Industrial Furnaces
Dimmer stats
Quick way Armature winding machine with counter
Coil winding machinery with counter
Testing panel with dimmer stat

The potential for electrical shock hazards is greater in shipbuilding and repair
than in other industries, because workers stand on metal decks and often work in a wet
environment. Work on or around energized electrical equipment can expose workers
to electrocution, burns, or electrical shock. Before work is performed, energized
equipment must be guarded, de-energized, or appropriate PPE used to prevent worker
exposure.

ELECTRICAL SHOP PLAN

MAINTENANCE AND INSPECTION OF ELECTRICAL EQUIPMENT ON

THE SHIP
The electrical switchboards, section boards and their equipment, on board the ship, are
generally subjected to structural, climatic or electrical wear. In order to preserve their
integrity throughout the ship's life, it seemed necessary to develop recommendations
dealing with their maintenance and inspection.

Actions

EVERY

EVERY FIVE

YEAR

YEARS

3.2 Cable penetration devices are still in good condition

3.3 No evidence of overheating, burning or tracking

3.4 Measuring equipment is in order.

3.5 Mechanical ventilation, if fitted, operates as required

3.6 Where a protection device has been replaced, its rating and,

1. Electrical switchboards and section boards are to be visually

examined to assess the good operation and maintenance.
2. Electric equipment is to be examined for cleanliness. Where
deemed necessary, cleaning of electrical equipment.
(dust suction, wiping up oil water deposits)
3. It is to be checked that:
3.1 Cables or other electric equipment are still in the original
position. Any modification should be to the satisfaction
of the Society.

where applicable, settings are to be verified.

4. Contacts and arc screens, if any, of all concerned devices are

to be checked and reconditioned or replaced if necessary in

accordance with manufacturers recommendation.
Movable parts of the said devices are to be tested.
5. Tightening of connections and assemblies which may slacken

is to be checked and tightened, if required, according to the

manufacturers recommendations. Thermograph aids may
be considered to detect hot spots.
6. Where accumulator batteries may be stored, the condition of
connections (salt deposits ...), the fastenings, the ventilation

and the tray tightness are to be checked.

7. Where fitted, computer based systems are to be tested.

Their original functions are to be unchanged.

8. An insulation measurement of any circuit in doubt is to be

carried out. Any large decrease in values is to be

investigated and corrected.
9. All circuits are to be subject to insulation measurements for

comparison with the insulation recordings previously

established. Corrective actions are to be carried out if the
values obtained are under 1k per volt.
10. Circuit interlocks, if any, are to be tested.

11. Protective devices are to be tested. The electronic protective

devices for generators and large consumers are to be tested

12. The operation of all emergency sources of power is to be tested,

including their automatic devices if any.

13. All automatic sequences, e.g. for synchronization, connection,
load shedding if any are to be tested as far as practicable.

PROCESS FLOW FOR GENERATOR/MOTOR REPAIR

Opening meeting between
representatives of yard and owner

Handing over of work to Electric

shop

Identification of physical damage

Insulation check

Dismantling of parts

Re-check for damage

Cleaning of parts. Mainly fresh

water rinsing. If oil present, apply
chemicals.

Baking process done in OVENS

Apply varnish and check the

readings
Once again
Apply coating (eg: BETTOL)

Assemble the parts

Computerized checking of every

parameters
Installation of Machinery

Curing period: Sometimes

need BAKING

Advantage of using
BETTOL
Insulation
Anti-corrosive

MAIN SWITCH BOARD

One more important thing is the main switch board. All the machineries on ship that
consume electrical power should be connected to a main switch board. The system
should be designed in such a way that under all normal conditions of operation, power
should be distributed from main switch board.
The main switch boards are located in the center of the distribution or in engine
control room. They should be installed in such an area that in time of emergency such
as fire or flooding, they should be easily accessible. Thus they should be installed in
spaces away from the main machinery spaces.
In general a MSB should have the following boards,

1. 220V FEEDER PANEL

2. GROUP STARTER PANEL-2
3. 440V FEEDER PANEL-2
4. GEN-3 PANEL
5. TIE BREAKER & ESB BREAKER
6. SYNC PANEL
7. GEN-2 PANEL
8. GEN-1 PANEL
9. 440V FEEDER PNL-1
10. GROUP STARTER PANEL-1

ELECTRICAL DIAGRAMS
Different types of diagrams used in the ships and shop involves,

BLOCK DIAGRAM
SYSTEM DIAGRAM
CIRCUIT DIAGRAM
WIRING DIAGRAM
CONNECTION DIAGRAM

Block diagram

The block diagram is typically used for a higher level, less detailed description aimed
more at understanding the overall concepts and less at understanding the details of
implementation. In electrical engineering, a design will often begin as a very high
level block diagram, becoming more and more detailed block diagrams as the design
progresses, finally ending in block diagrams detailed enough that each individual
block can be easily implemented (at which point the block diagram is also a schematic
diagram). This is known as top down design. Geometric shapes are often used in the
diagram to aid interpretation and clarify meaning of the process or model. The
geometric shapes are connected by lines to indicate association and direction/order of
traversal. Each engineering discipline has their own meaning for each shape.
System diagram

The system diagram shows connections between different systems involved. It helps
the engineer to understand different interconnections between the systems. It also
helps to identify the corrections required when the problem is identified.
Circuit diagram

A circuit diagram (also known as an electrical diagram, elementary diagram,

or electronic schematic) is a simplified conventional graphical representation of
an electrical circuit. A pictorial circuit diagram uses simple images of components,
while a schematic diagram shows the components of the circuit as simplified standard
symbols; both types show the connections between the devices,
including power and signal connections. Arrangement of the components
interconnections on the diagram does not correspond to their physical locations in the
finished device. Unlike a block diagram or layout diagram, a circuit diagram shows
the actual wire connections being used. The diagram does not show the physical
arrangement of components.

Wiring diagram

A wiring diagram is a simplified conventional pictorial representation of an electrical

circuit. It shows the components of the circuit as simplified shapes, and the power and
signal connections between the devices. A wiring diagram usually gives more
information about the relative position and arrangement of devices and terminals on
the devices, to help in building the device. This is unlike a schematic diagram where
the arrangement of the components interconnections on the diagram does not
correspond to their physical locations in the finished device. A pictorial diagram
would show more detail of the physical appearance, whereas a wiring diagram uses a
more symbolic notation to emphasize interconnections over physical appearance.

Connection diagram

The detailed connections that have to be made are indicated in this diagram. Each and
every specification must be included in this diagram regarding connections.

TESTING

INSULATION RESISTANCE (MEGGER)

The insulation resistance (IR) test (also commonly known as a Megger) is a spot
insulation test which uses an applied DC voltage (typically either 250Vdc, 500Vdc or
1,000Vdc for low voltage equipment <600V and 2,500Vdc and 5,000Vdc for high
voltage equipment) to measure insulation resistance in either k , M or G . The
measured resistance is intended to indicate the condition of the insulation or dieletric
between two conductive parts, where the higher the resistance, the better the condition
of the insulation. Ideally, the insulation resistance would be infinite, but as no
insulators are perfect, leakage currents through the dielectric will ensure that a finite
(though high) resistance value is measured.
Because IR testers are portable, the IR test is often used in the field as the final check
of equipment insulation and also to confirm the reliability of the circuit and that there
are no leakage currents from unintended faults in the wiring (e.g. a shorted connection
would be obvious from the test results).
One of the advantages of the IR test is its non-destructive nature. DC voltages do not
cause harmful and/or cumulative effects on insulation materials and provided the
voltage is below the breakdown voltage of the insulation, does not deteriorate the
insulation. IR test voltages are all well within the safe test voltage for most (if not all)
insulation materials.

 CURRENT (CLAMP METER)

Clamp meters are a very convenient testing instrument that permits current
measurements on a live conductor without circuit interruption. When making current
measurements with the ordinary multimeter, we need to cut wiring and connect the
instrument to the circuit under test. Using the clamp meter, however, we can measure
current by simply clamping on a conductor as illustrated in Fig.2. One of the
advantages of this method is that we can even measure a large current without shutting
off the circuit being tested.

VOLTAGE (MULTIMETER)
A multimeter is very useful in measuring and testing DC voltage. The
multimeter can be a standard multimeter, a digital multimeter (DMM), or a
auto-ranging digital multimeter. The source of the DC voltage can be from
batteries, circuits, transformers, or any other electronic device that operates on
DC voltage. Troubleshooting of DC electronics is made easier by using a
digital multimeter to test in-circuit DC voltage and compare the results to an
electrical schematic. Faulty components can be identified within the circuit in
order to make repairs.

 RESISTANCE (MULTIMETER)
An ohmmeter can be used to directly measure an unknown resistance R .This is
the simplest way to measure resistance. It is important to realize that an
ohmmeter cannot be used when the resistance is connected in a circuit and a
current is flowing through it .

CONTINUITY (MULTIMETER)
One of the most basic uses of a multimeter is to test for continuity. Testing for
continuity basically means testing to see if there is an electric connection
between two points. If two points are electrically connected they are said to be
continuous. This brief guide explains how to use a digital multimeter to find
out if there is an electric connection between two points.

INSULATION CLASS
Electrical insulation is classified with its maximum allowable temperature. By
adopting an insulation technique of higher thermal endurance, electric instruments can be
downsized. In early times, the temperature classes of electric insulators were simply divided
into natural organics, inorganics, and combinations thereof. In the late 1930s, the types of
synthetic resins became diverse and their production volumes increased, with their
application range being gradually expanded to insulation. In the late 1940s, when silicone
resin became a popular insulator material, the H-class insulator was added to the temperature
classes, and it became increasingly necessary to find applications for heat resistant materials
in electric instruments.

CLASS Y

Withstands a temperature of up to 90C; typically made of cotton, silk, or paper.

e.g.: Cotton, silk and paper.

CLASS A

Withstands a temperature of up to 105C; reinforced Class-Y materials with

impregnated varnish or insulation oil.
e.g.: Cotton silk and paper all suitably impregnated or coated with oil or other
insulating compound.

CLASS E
Withstands a temperature of up to 120C.
e.g.: Mica, asbestos and glass products all organic bounding substances.

CLASS B
Withstands a temperature of up to 130C. This has a form that inorganic
material is hardened with adhesives. This is the first insulator using this structure.
e.g.: Mica, asbestos and glass products all with suitable bonding.

CLASS F
Withstands a temperature of up to 155C; for example, made of Class-B
materials that are upgraded with adhesives, silicone, and alkyd-resin varnish of
higher thermal endurance.
e.g.: Mica asbestos and glass products all with inorganic bonding substances.

CLASS H
Withstands a temperature of up to 180C; for example, made of inorganic
material glued with silicone resin or adhesives of equivalent performance.
e.g.: Mica, glass fibre, asbestos, silicon all with silicone as bonding material.

CLASS C
Withstands a temperature of up to 180C or higher; made of 100% inorganic
material.
e.g.: Mica, porcelain, glass, quartz all with or without inorganic bonding material.

PROTECTION CLASS
DENOTED AS IP XY
Ingress Protection rating is used to specify the environmental protection - electrical enclosure
- of electrical equipment.
Ingress Protection (IP) ratings are developed by the European Committee for Electro
Technical Standardization (CENELEC) (NEMA IEC 60529 Degrees of Protection Provided
by Enclosures - IP Code), specifying the environmental protection the enclosure provides.
The IP rating normally has two (or three) numbers:
1. Protection from solid objects or materials
2. Protection from liquids (water)

Protection against mechanical impacts (commonly omitted, the third

number is not a part of IEC 60529)

MOTOR STARTERS
CAGE MOTOR

DIRECT ON LINE
DOL STARTER CONTROL SCHEMATIC DIAGRAM

STAR/DELTA

 AUTOTRANSFORMER

ELECTRICAL SURVEY REQUIREMENT

Generators
A generator is a simple device to convert mechanical energy into electrical energy. Usually
they generate rotating current 50Hz or 60Hz leaving for direct-driven machines of the
following engine speeds of 500/600 RPM, 6001720 RPM, 750/900 RPM, 100011200 RPM,
1500/1800 RPM and 3000/3600 RPM. The higher figures are mostly for smaller generator
sets or turbine driven machines.

Electric motors
Electric motors are simple devices to convert electrical energy into mechanical energy. AC
squirrel cage motors have the same RPM restriction as AC generators. Motors area available
in different casings for fitting on a foundation or flange for fitting to a pump. Also various
protection classes against the ingress of solid particles and water area available, and for use in
an explosive
Environment increased safety "non sparking types" and flame proof motors are available.

Cables
Cables form the connections between the different parts of the electric installation and are
nowadays available as low-smoke , low toxic and even fire-resistant types. Application of
such more sophisticated cables will reduce the consequences and damage of a fire. The
commercially attractive PVC insulated types are vulnerable in case of fire. The insulation
burns causing short circuits. They generate high quantities of toxic and corrosive gases which
will damage a lot more of the installation than that damaged by the fire only. However, a
disadvantage of the low smoke types of cables is that their mechanical properties are
considerably less.

Switchboards and switchgear assemblies

Switchboards and other switchgear assemblies basically serve to connect and disconnect
generators and consumers to the main power supplysystem. They contain also the protection
devices of the generators, the cables and the consumers against overload and short-circuits.
Switchboardsand other control-gear assembliescan be operated by engineers, but servicing
and maintenance and repairs should be carried out byspecialists.Laws in most countries issue
a clearinstruction of how to power a part of an installation safely, to carry out
repairsand power up safely afterwards. It also defines skills andresponsibilities of the
operators andmaintenance people. The main differencesbetween an industrial switchboard
and a marine switchboard areprotection class IP23 with closed doors. In case of open doors,
protection class lP20, handrails, door catchersin open position, measuring and
indicationinstruments to be able to
synchronise and for load sharingof both power and current etc.
When electric power is required for propulsion of the ship, the source of
power is to be duplicated and the main bus basin the main switchboard
is to be divided in two parts connected by a removable link for small
installations up to full-size circuit breakers with selective protection devices for large
installations. Duplicated essential consumers shallbe supplied each from a side of the switch
board,or when supplied from distribution-boards from separate
distribution-boards, each supplied from a side of the main switchboard.All of this with the
same target that a single fault does neither impair thepropulsion system nor impair
thehabitability for the crew. This single failure also includes a fire or other damage to a cable
tray. Therefore thepower cables and control cables toessential duplicated consumers shall be
separated.

Circuit breakers and contactors

A circuit breaker is designed to close and interrupt a short-circuit current a few times only
without maintenance.A contactor is designed to withstand thousands of times the starting
currents of electric motors. A circuit breaker is therefore not suitable tostart a large motor.
Switching capabilitiesare given under different conditions. Some manufacturers give a
capacity only once possible.
Moulded case circuit breakers, especially the current limiting types can be replaced as a
complete unit only.

Emergency generator
An emergency generator is a generator with the same characteristics as a main generator but
located in a space separated from the main generators and independent of any equipment
outside this space. So starting equipment such as an air bottle with a non-return valve of the
engine room starting air system, a
separate fuel tank, an emergency switchboard in the same space as the generator set to limit
the possibility of failure of the emergency system in case of failure of a space, This all to
ensure continuity of emergency power as much as possible

Starting devices
Starting devices are used to limit the in-rush current of a consumer when connected to the
main power supply to an acceptable value. That is to a value that does not disturb the proper
functioning of the other devices in the installation. Starting devices are also used to limit the
starting torque of an electric motor.

HAZARDOUS AREAS
Dangerous areas are those areas where due to the continuous or part time
presence of gases or flammable liquids or even explosive dust, the risk of explosion exists.
Dangerous areas are, for example, the tanks of a tanker and the deck above, the cargohandling area, pump room etc..but also the car-deck of a ferry where cars are stowed with
fuel in their tanks, a helicopter refilling station on a yacht and a paint store or the hold of a
dry-cargo ship certified for the carriage of dangerous goods.
Cost-effective solution number one is not to install any electrical equipment
In dangerous areas. The dangerous areas are divided into the following
zones:

Zone 0
Areas where an explosive-gas atmosphere is continuously present or Can be present. For
example, a cargo tank of a crude oil tanker, oil products
tanker or chemical tanker carrying flammable liquids other than liquefiedgases having a nash
point not exceeding 60C and for liquefied gases the cargo tank and the secondary barrier
spaces.

Zone 1
Areas where an explosive-gas atmosphere will be periodically present during normal
operation. For example, spaces adjacent to and below the top of the cargo tanks carrying
crude oil, oil products etc. with a flash point not
Exceeding 60C.Spaces separated by a single deck or bulkhead from zone 0 areas, also cargo
pump rooms and enclosed and semi-enclosed spaces in which pipes containing above cargoes
are located. Also areas on open deck within 3 metres of any cargo tank outlet, cargo valve,
cargo-pipe flange, cargo-pump room outlets, 6 metres radius from high pressure discharge
valves and 2.4 metres above deck

.Zone 2
Areas where an explosive gas atmosphere is not present during normal operation and. if
present, for a short period of time for tankerscarrying products with a flash point above
60C.This is the only zone defined for the dry-cargo ships and for Ro/Ro spaces of ferries if
sufficiently ventilated. The explosive-gas atmosphere is considered not to be present during
normal operation.
Caution: Liquified natural gas (LNG) and the vapours from kerosine are heavier than air and
any opening to a deck or lower space shall be subject to further study with respect to the
zoning. The gases are divided into the following groups:
- Group I: methane such as expected in coal mines
- Group II: General industrial gases and gases from combustible liquids and combustible
solids
- Group IIA: Propane
- Group IIB: Ethylene
- Group IIC: Hydrogen
Apart from the gas group, certified safe equipment shall also be selected on the basis of the
maximum surface temperature during operation. This surface temperature shall be below the
ignition temperature of the gas emitted by the cargo as is stated in the cargo lists.
Temperature classes and maximum surface temperatures are as follows:

TI below 450C

T2 300C

T3 200C

T4 135C

T5 100C

T6 85C