Marine Water Cooled Reactor

Marine propulsion and auxiliary power systems demand reactors that can perform reliably under thermal, electrical, and spatial constraints unique to shipboard environments. The Marine Water Cooled Reactor is engineered to support large current flows, mitigate harmonic distortion, and maintain thermal stability within confined marine enclosures. The design focuses on improving power quality, reducing equipment stress, and extending the operational life of propulsion and distribution systems. 

Rated Voltage

Up to 11 kV (customizable per marine application)

Frequency Range

50 Hz / 60 Hz

Rated Current

Up to 4000 A continuous (forced water-cooled)

Inductance Value

0.1 mH to 50 mH (based on load application)

Harmonic Attenuation

5th, 7th, 11th harmonic suppression; THD reduction up to 35%

Product Description

Confined engine rooms generate excessive ambient heat, often pushing dry-type reactors beyond acceptable temperature rise limits. Direct water cooling through hollow copper conductor paths and jacketed coil surfaces enables precise control over thermal gradients. By rejecting heat directly into closed-loop freshwater or seawater systems, the reactor maintains Class H insulation performance during continuous operation. Heat transfer coefficients are engineered for uniform coolant flow distribution to avoid localized hotspots and premature thermal fatigue. 

Insulation Class

Class H (180°C)

Dielectric Strength

3.0 kV to 5.0 kV for 1 minute (phase-to-ground)

Temperature Rise

≤ 90°C over 40°C ambient (per IEC 60076-6)

Core Material

Low-loss CRGO / High-permeability laminated steel

Cooling Type

Closed-loop freshwater or seawater jacket cooling

Impedance Tolerance

±10% (custom tuning available)

Mounting Type

Base or flange mounted (shock and vibration resistant)

Ambient Temperature Range

-25°C to +55°C (marine engine room rated)

Altitude Rating

Up to 1000 m without derating

Noise Level

< 65 dB(A) at 1 meter distance

Protection Degree

IP55 to IP67 (based on installation location)

Standards Compliance

IEC 60076-6, IEC 60092, DNV, ABS, Lloyd’s Register

Technical Advantages

Variable frequency drives (VFDs), frequently used in marine propulsion and thruster systems, introduce dominant 5th, 7th, and higher-order harmonics. These harmonics increase total harmonic distortion (THD), which leads to overheating of generators and destabilization of sensitive electronic controls. The water-cooled reactor is designed with carefully calculated leakage reactance and core permeability to provide controlled impedance at specific frequencies. This supports selective harmonic filtering and helps maintain voltage waveform integrity across busbars and switchboards. 

Weight and space constraints on vessels require reactors that offer high magnetic performance without excessive bulk. The design integrates low-loss core laminations with compact winding geometries and fluid-embedded cooling paths. Use of rectangular conductors and precision-wound coils enhances the space factor while maintaining required air gaps for thermal insulation. The reactor’s overall footprint is minimized through vertically stacked winding modules and integrated manifold routing, allowing flexible mounting in auxiliary rooms or motor control centers. 

 

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Industry Applications

Propulsion Motor Drives

Installed between VFD and propulsion motor to reduce harmonics, control inrush current, and stabilize drive performance under variable loads. 

Bow and Stern Thruster Systems

Used to dampen voltage spikes and minimize current distortion during rapid directional changes in thruster motor control systems. 

Marine Shaft Generators

Deployed to balance reactive power, suppress harmonic feedback, and improve voltage waveform quality feeding auxiliary shipboard loads. 

Main Switchboards

Connected on feeder circuits to limit fault currents, control power transients, and protect downstream switchgear from electrical disturbances. 

HVAC and Compressor Systems

Supports inductive motor loads by smoothing current waveform, improving power factor, and reducing stress on refrigeration and air systems. 

Ballast Pump Drives

Filters high-frequency switching harmonics from VFD-controlled pump motors to prevent cable heating and interference with navigation electronics. 

 

Reactive Power Balance and Generator Optimization

Electrical propulsion systems on ships often suffer from lagging power factors due to inductive load dominance. The reactor’s designed reactance compensates for leading or lagging reactive power components, improving power factor and reducing generator excitation demand. This lowers fuel consumption per kilowatt and minimizes the need for oversized alternators. The reactor impedance is tuned to the load characteristics of each vessel type—be it cargo, cruise, or offshore support vessel—for optimal reactive load sharing across multiple power sources. 

High motor starting currents and abrupt load variations in marine systems cause voltage spikes and transient oscillations. The reactor incorporates low-saturation, high-flux-density core materials and non-linear permeability profiles to absorb transient energy while maintaining steady-state inductance. This protects insulation systems in transformers, cables, and switchgear from over-voltage stress. Damping behavior is calculated to match shipboard fault response times and prevent sympathetic resonance with capacitor banks or harmonic filters. 

Marine Water Cooled Reactor

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate design marine water cooled reactors for compact engine room integration?

Frigate uses vertical winding layouts and optimized coil stacking to reduce reactor footprint without compromising performance. Cooling manifolds are integrated within the core structure to eliminate external pipe routing. All units are custom-dimensioned based on available mounting space and airflow restrictions. This ensures compliance with shipboard layout constraints and service access requirements. 

What testing protocols does Frigate follow for marine water cooled reactors before delivery?

Each reactor undergoes high-voltage insulation testing, impedance verification, and thermal endurance tests under simulated marine loading. Water-side pressure testing ensures jacket integrity under operational and surge conditions. RTD sensors are calibrated and verified for accuracy against thermal rise limits. Final validation includes harmonic response analysis under load-matched VFD conditions. 

How does Frigate manage corrosion risks in seawater-cooled reactor designs?

Frigate selects titanium or duplex stainless steel for all coolant-exposed components in seawater circuits. Epoxy encapsulation with high tracking index prevents moisture-induced partial discharges within the winding area. Gasket materials are chosen for chloride resistance and long-term sealing stability. Optional sacrificial anode integration helps prevent galvanic activity in mixed-metal systems. 

What fault scenarios are considered in Frigate’s reactor thermal design?

Frigate simulates overload, loss of coolant flow, and rapid load change scenarios using finite element thermal models. The cooling path is engineered to handle short-duration overcurrent without exceeding Class H insulation limits. Embedded thermal switches and RTDs detect threshold violations in real time. This approach ensures protective tripping before insulation damage occurs. 

How does Frigate tune reactor impedance for specific marine applications like thrusters or compressors?

Impedance values are calculated based on connected motor characteristics, switching frequency, and system resonance points. Frigate adjusts core geometry, winding spacing, and conductor size to achieve target reactance. Each unit is simulated using harmonic analysis tools to confirm suppression at dominant frequencies. Final values are validated with prototype testing before production. 

 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Marine Water Cooled Reactor

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