Condition Monitoring
Wartsila India Ltd
Condition Monitoring Diesel Generators by V Pramodkumar
Condition Monitoring
Why??
Optimum Utilization of DG Set
Maximum availability of Machine
Reliable Operation
Change in Maintenance concept
Improve MTBF
Wartsila India Ltd
Condition Monitoring
Wartsila India Ltd
Effects if DG sets are not monitored Monitory Loss (Fuel Consumption Increase) Diff. Pr. across C A Coolers. +2g/kWh
200-400mm H2O
with increase of every 100mm H2o
C. W. temp temp.. bef befor ore e eng eng.. 45 Deg. Deg.C C at 100% 100% Load Load +3g/kWh Wh +3g/k
with every with every 10 Deg.C rise in in temp. temp.
Exhaust Gas back pr. after the T/c +2g/kWh
300mm H 2o
with increase of every 100mm H2o
Condition Monitoring
Wartsila India Ltd
Effects if DG sets are not monitored
Reliability of Machine Engine Block Blow Off If
excess crankcase pressure unnoticed
Valve Burnin Valve Burningg- Cons Conseque equentia ntiall Damage Damage to Turbochargers If
Exhaust Temperature are not monitored
Crankshaft Seizure If
bearing temperatures are not monitored Or Lube oil pressure/temperature is not monitored
Condition Monitoring Critical Parameters To be Monitored Exhaust Temperature Before
and After Turbochargers
Individual
Cylinder
Bearing Temperature Main Big
Bearing
End Bearing
Cooling Water System Cooling
Water Temperature
Cooling
Water Pressure
Wartsila India Ltd
Condition Monitoring
Wartsila India Ltd
Critical Parameters To be Monitored Fuel System Fuel
Pump Rack Positions ( larger l arger machines)
Fuel
Oil Pressure/Temperature
Differential
Pressure Across Fuel Filters
Charge Air System Charge Safety
Air temperature/ Pressure
Air Pressure
Differential Pressure Across Air Filters/Coolers
Lube Oil System Lube
Oil Pressure/Temperature
Lube
Oil Volume
Crankcase
Pressure
Differential
Pressure across Lube Oil Filters
Condition Monitoring
Wartsila India Ltd
ALARMS AND LIMITS
Just installation of monitoring devices does not ensure safety of equipments
Devices should alert operator
Alarm must appear at trigger point
Should stop the machine on critical values
Condition Monitoring
Wartsila India Ltd
Typical Monitoring devices with safety features • Lube oil Pressure
Alarm/Stop
• Lube Oil Temperature
Alarm/Stop
• Exhaust Temperature
Alarm/Stop
• Cooling water temperature
Alarm/Stop
• Engine Over speed
Alarm/Stop
• Charge Air Temperature
Alarm/Stop
Condition Monitoring
Wartsila India Ltd
Typical Monitoring devices with safety features
Differential Pressure
Alarm
Across air coolers
Turbochargers Over speed
Alarm
Crankcase Pressure
Alarm/Stop
Pre Lube oil Pressure
Alarm
Over current
Stop
Under/Over Frequency
Stop
Condition Monitoring
Wartsila India Ltd
Monitoring devices for Diesel Generator Set • Temperature Sensor/Switch • Pressure Transducer/Switch Transducer/Switch • Cylinder Pressure Indicator • Pressure and Temperature Gauge • Speed Sensors • Power Monitoring Unit • Thermocouples
Condition Monitoring
Wartsila India Ltd
Latest Monitoring devices for Diesel Generator Set •
Continuous Measurement of Water in Lube Oil
•
Crankcase Pressure Monitoring System
•
Continuous Oil Level Monitor
•
Wireless big end bearing temperature
•
monitoring
•
CBM
Condition Monitoring
Water Transducer A Continuous Measurement of Water in Lube Oil
Wartsila India Ltd
Condition Benefits Monitoring
Wartsila India Ltd
Follow up of trends and historitic data
Indicates the margin to water saturation i.e. free water formation.
On-line and continuous measurement.
Easy to install
The measurement remains proportional to the water saturation level of the oil, independent of type, ageing and temperature of the oil.
Work Works s wit with h all all kind kind of oil oil syst system ems s
Condition Monitoring
Wartsila India Ltd
How can can we monit monitor or the cran crankcas kcase e environm environment ent ?
Manual Pressure Measurement
Oil Mist Detector
To enhance the safety, the new product is; Crankcase Pressure Monitoring System
Condition Monitoring
Wartsila India Ltd
Oil level is monitored manually 2 - 4 times times per per day depen depending ding on the the routine routine
The alternative is
Continuous Oil Level Monitor
Condition Monitoring
The system is based reliable strain gauge principle i. e weighting of the cylinder no moving parts
Wartsila India Ltd
Condition Monitoring • High measuring accuracy ± 1mm • No moving parts • Ready calibrated at factory • Easy and fast installation • Can be connected to any existing alarm and monitoring system • Reliable strain gauge principle
Wartsila India Ltd
Condition Monitoring • Standard current and voltage output •To have alarms on any kind of level • Automa Automatic tic fillin filling g of lub lub oil • Detect Detect abnor abnormali malities ties in the the lub oil system • Full control of S. L. O. C
Wartsila India Ltd
Condition Monitoring
Wartsila India Ltd
What is one of the most serious breakdown scenarios ? Big End Bearing Failure and in many cases the consequential damage such as engine block and/ or crankshaft
Condition Monitoring
Faster and more accurate monitoring of the sensitive part i. e measure the bearing temperature
Wartsila India Ltd
Condition Monitoring
WIRELESS BIG END BEARING TEMPERATURE MONITORING
Wartsila India Ltd
Condition Monitoring
Wartsila India Ltd
CBM Condition Based Maintenance Relia Re liabl blee and Econ Econom omic ical al Dies Diesel el En Engi gine ne application operation
Condition Monitoring
Benefits of CBM
CBM Reduced
operating costs - Reduce Reduced d fuel fuel consu consumpt mption ion - Reduce Reduced d maint maintena enance nce cost cost - Increa Increased sed comp compone onent nt life life time time
Reduced
number of unplanned stops
Reduced
number of failure’s
Improved
maintenance planning
Improved
follow up of the installation condition condition
Condition Monitoring
Wartsila India Ltd
If we can measure and analyze the application we have the control !
Communication
Condition Monitoring Owner /Operator office
Local Wärtsilä office
The installation
Wärtsilä Monitoring
CBM Report
Data transfer
Wärtsilä database
Condition Monitoring
Wartsila India Ltd
CBM - Conditio Condition n Based Based Maintena Maintenance nce
The Wärtsilä CBM solution is in fact a combination of Condition Based Operation and Condition Based Maintenance
Condition Monitoring
Wartsila India Ltd
CBM The Wärtsilä CBM solution is based on the use of the installed and available equipment On line or Daily monitoring and analyzing of the measured operation data
- Con Control trol and moni monitori toring ng syste systems ms - Pre Pressu ssure re mea measur sureme ements nts - Tem Temper peratu ature re measur measureme ements nts - Sp Spee eed d measu measure reme ment ntss - Loa Load d measu measure re measu measurem rement ent - Vi Vibra bratio tions ns (when (when availa available ble)) - Comm Communic unicatio ation n techn technolog ologies ies - E tc
Condition Monitoring
Wartsila India Ltd
CBM - Operation - Data - Analyzer Mathematical models for calculating the ideal operation Mathematical parameters for the installations. A dynamic system considering: - Engine Engine specifica specification tion,, installat installation ion type type and configuration - Ambie Ambient nt condit condition ionss - Desi Design gn cr crit iter eria ia - Instal Installat lation ion spec specifi ificc data data - e tc
Condition Monitoring
Wartsila India Ltd
CBM - Operation - Data - Analyzer Mathematical models for calculating the ideal operation parameters for the installations and predictions for the future. One should know how changing in the operation conditions are having influence on all other parameters Example -Change in air inlet temperature > changed TC speed > changed receiver pressure > changed peak pressure > changed exhaust gas temperatures > waste gate / by-pass valve position > changed fuel consumption > changed emissions etc
Condition Monitoring CBM
Wartsila India Ltd Optimal time for maintenance
Monitored deteriorating rate
Condition border level
Anticipated deteriorating rate
p o t s d e l u d e h c S
Scheduled maintenance
Wartsila India Ltd
Condition Monitoring CBM
C h a r g e a i r p r e s s u r e a f t e r c o o le le r C h a r g e a i r te te m p . a f t e r c o o l e r C h a r g e a i r p r e s s u r e d i ff ff e r e n c e o v e r c o o l e r A C h a r g e a i r p r e s s u r e d i ff ff e r e n c e o v e r c o o l e r B Turbocharger speed A Turbocharger speed B E x h a u s t g a s te te m p . A 1 E x h a u s t g a s te te m p . A 2 E x h a u s t g a s te te m p . A 3 E x h a u s t g a s te te m p . A 4 E x h a u s t g a s te te m p . A 5 E x h a u s t g a s te te m p . A 6 E x h a u s t g a s te te m p . A 7 E x h a u s t g a s te te m p . A 8 E x h a u s t g a s te te m p . A 9 E x h a u s t g a s te te m p . B 1 E x h a u s t g a s te te m p . B 2 E x h a u s t g a s te te m p . B 3 E x h a u s t g a s te te m p . B 4 E x h a u s t g a s te te m p . B 5 E x h a u s t g a s te te m p . B 6 E x h a u s t g a s te te m p . B 7 E x h a u s t g a s te te m p . B 8 E x h a u s t g a s te te m p . B 9 E x h a u s t g a s t e m p . b e f o r e tu tu r b o c h a r g e r A E x h a u s t g a s t e m p . b e f o r e tu tu r b o c h a r g e r B E x h a u s t g a s t e m p . a f te te r t u rb rb o c h a r g e r A E x h a u s t g a s t e m p . a f te te r t u rb rb o c h a r g e r B M a i n b e a r in in g t e m p . / B e a r i n g 0
b a r °C Pa Pa rp m rp m °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C
1 ,6 60 39 60 18222 18187 406 390 391 397 387 384 388 387 422 396 380 389 364 359 385 402 397 417 514 481 394 383 78
2 ,1 57 44 44 18856 18856 364 364 364 364 364 364 364 364 364 364 364 364 364 364 364 364 364 364 464 464 354 354 91
1 ,9 48 0 0 18056 18056 294 294 294 294 294 294 294 294 294 294 294 294 294 294 294 294 294 294 394 394 314 314 73
Condition Monitoring
Wartsila India Ltd
When we have the control of the the application we get the best performance from the installed equipment !
Condition Monitoring
Wartsila India Ltd
When we have the control we can make the savings !
Condition Monitoring
g n i t a r s e t p s o O c
CBM savings CBM cost
Traditional
CBM
Wartsila India Ltd
According to several insurance companies and other investigations, as much as 60% to 80% of the claims are because of human mistakes! The information was available but the actions was not taken
Condition Monitoring
g n i t a r s e t p s o O c
CBM savings CBM cost
Traditional
CBM
Wartsila India Ltd
The biggest savings are on the reduced fuel consumption in averag averagee 5 - 10 g / kWh kWh (2-5%) during the life time cycle of the application
Condition Monitoring
g n i t a r s e t p s o O c
CBM savings CBM cost
Wartsila India Ltd
Reduced maintenance cost by making the correct maintenance at the correct time in th thee rang rangee of 5 – 20% 20% saving
Traditional
CBM
Condition Monitoring
g n i t a r s e t p s o O c
Wartsila India Ltd
Improved reliability by CBM savings CBM cost
Traditional
CBM
expert analyzing / follow up and regular feed back including predictions and recommendations
Condition Monitoring
Wartsila India Ltd
Custoimi Custoimised sed CBM reports reports based based on your your specifica specification tion
8
Different level reports 8Top Management reports 8Middle Management level Report 8Operator level report Performance report 8Performance consumption 8Fuel consumption 8Operation data evaluation 8Heat recovery 8Comments/suggestions 8Environmental report 8Emission-calculations 8Technical report maintenance e 8Coming maintenanc 8Trends / Alarm analyze 8Comments/suggestion
Analyzing
Condition Monitoring Operation data out of limits (engine/month) 4,00
y 3,50 a d g 3,00 n i n n 2,50 u r / t n 2,00 u o m a 1,50 e g 1,00 a r e v A 0,50
Start statistics 140 18 13
16
120 7 1,92
3,20
2,00 2,00
1,08
1,00 0,75 0,00
0,00 1.5.2003-31.5.200391246
1.6.2003 - 30.6.2003 91246
days: 24
days: 3
0,50
0,00 1.7.2003- 31.7.200391246
1.8.2003-31.8.200391246
1.9.2003 - 30.9.2003 91246
days: 1
1.10.2003- 31.10.200391246
days: 25
days: 20
days:10
s t p 100 m e t t a t r a 80 t s f o r e b 60 m u n l a 40 t o T
Engine and period A ct cti on on
7
1
15 16
2
7
7
7
4 16
0
104
109
122
116
96
117 108
87
91
96
95
95
93 74
72
20
1 18
A lert
Adventure of the Seas
0 1
0
Success Successful ful starts starts
Failed Failed starts starts
Adventure
Total electrical production 12000
) h W M ( n o i t c u d o r P l a c i r t c e l E
E n g i n e 1 s p e c i f ic ic f u e l c o n s u m p t i o n a n d l o a d LLooaaL dd %
10000
210,0
8000
6000
4000
2000
0 2 2 2 2 3 3 3 3 3 3 3 3 3 0 2 0 2 0 2 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 0 2 2 2 2 2 2 2 0 2 2 2 2 2 2 2 . . . . . . 6 7 8 . 9 . 1 2 3 . 4 5 6 . 7 . 8 . 9 . 0 . 1 . 2 . 0 . . . . . . . 1 1 1 1 1 . 0 . 1 . 0 . 1 . 1 . 0 . . 3 0 3 1 3 3 3 1 2 8 3 3 0 3 1 3 3 3 3 0 . 1 . 1 . 3 1 3 3 3 2 2 2 2 3 3 3 3 3 3 3 3 3 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 3 2 2 2 2 0 0 2 2 2 2 2 2 2 2 2 2 0 2 0 2 0 6 . 7 . 8 . 9 . 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . . 2 0 . 2 . 0 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 . 1 1 1 1 1 1 . 1 . 1 . 1 .
Date DG Se t 1
DG Se t 2
DG Se t 3
DG Se t 4
DG Se t 6
60,0 50,0 40,0 30,0 20,0 10,0 0 ,0
170,0 Adventure
DG Se t 5
90,0 80,0 70,0
h W k 2 0 0 , 0 / g n o i t 1 9 0 , 0 p m u s n 1 8 0 , 0 o C 3 0 . 0 1 . 5 2
3 0 . 0 1 . 6 2
3 0 . 0 1 . 7 2
3 0 . 0 1 . 8 2
3 0 . 0 . 1 9 2
Period
3 0 . 0 1 . 0 3
3 0 . 0 1 . 1 3
Condition Monitoring
Wartsila India Ltd
The installation today
Monitoring
Condition Monitoring
CBM Marine Solution
Condition Monitoring
Wartsila India Ltd
Case Study Piston Liner Seizure
Condition Monitoring
Wartsila India Ltd
Customer :
ABC India Ltd.
Power Source :
DG Set
Accident :
Seizure in Piston/Lin Piston/Liner er
Monetary Loss :
10 Lacs (components)
Power Outage :
72 hours
Production Loss: Unknown
Condition Monitoring
Wartsila India Ltd
Observations: • All exhaust temperature and bearing temp were o.k • Lube Oil temp was o.k. • Lube oil pressure was o.k • Operating Parameters were o.k • However Crankcase Relief valve operated during Failure
Condition Monitoring
Wartsila India Ltd
Observations: • Piston was seized in liner • Rings were not seized • Small end Bearing was seized • Big end Bearings were o.k. • Gudgeon Pin suffered multiple cracks due to seizure • Lube Oil Pump was o.k. • Connecting Rod was o.k.
Condition Monitoring
Wartsila India Ltd
Condition Monitoring
Wartsila India Ltd
Reason : • Material Investigation indicated no problem with quality of small end bearing or gudgeon pin • Piston was seized in liner due to low lube oil Flow to piston. • Seizure has happened gradually • Low lube oil flow caused overheating of piston top • Lube oil flow was reduced due to ingress of dirt in piston oil drillings
Condition Monitoring
Wartsila India Ltd
How the accident could have been avoided Engine was not equipped with • Oil Mist detector • Crankcase Pressure Transducer Engine Could have been stopped earlier if the above safety were present.
Condition Monitoring Thank You!