wfi - s service division digital ship at posidonia june 2006 in association with ammitec cbm...
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WFI - S Service Division
Digital Ship at Posidonia June 2006 in
Association with AMMITEC
CBMCondition Based Maintenance
and Operationby
Johan Pellas
Ope
ratin
g co
sts
WFI-S Service Division
Fuel cost savings 1 – 4% by optimized operation and maintenance
Maintenance cost savings in a range of 10% to 20% during the life time by optimized operation and maintenance
PresentPresent with CBM
CBM savings
CBM costCBM cost
WFI - S Service Division
CBM - Condition Based Maintenance
To find 80% of the critical cases 7 – 14 days in advance
And
To predict more than 80% of the needed maintenance 1 – 4 months in advance
WFI - S Service Division
CBM - Condition Based Maintenance
Considering the facts that about 60 – 80% of the failure cases
are because of human “misjudgement”
The information was available but
Not understood or not acted correctly
WFI - S Service Division
The Wärtsilä Condition Based Operation and Maintenance The Wärtsilä Condition Based Operation and Maintenance ProgramProgram
CCCC BBBB MMMM
WFI - S Service Division
CBM - Condition Based Maintenance and Operation
The Wärtsilä CBM solution
Is in fact a
Condition Based Operation and
Maintenance solution
WFI - S Service Division
CBM - Condition Based MaintenanceFor
Supporting the owners and usersTo
Achieve the best performance and availabilityBy
Regular analysis and predictions of measured dataAnd
Utilizing the latest technologies
WFI - S Service Division
If we can measure and analyze the application
thenwe have the control !
WFI- S Service Division
CBM
The Wärtsilä CBM concept is basedbased on the use of the installedinstalled and available and available equipmentequipment
On line/ Daily monitoring and analyzing of the measured operation data
- Control and monitoring systems - Pressure measurements
- Temperature measurements - Speed measurements
- Load measure measurement - Vibrations (when available)
- Communications
Mathematical models for calculating the ideal operation parameters for the installations. A dynamic system considering: - Engine specification, installation type and configuration - Ambient conditions - Design criteria - Installation specific data - etc
CBM - Operation - Data - Analyzer
WFI - S Service Division
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 parametersExample-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
CBM - Operation - Data - Analyzer
WFI - S Service Division
WFI- S Service Division
CBMbar 2,4 2,5 2,3°C 56 57 53mbar 0,0 300,0 0,0mbar 0,0 300,0 0,0rpm 18503 18928 17928rpm 18578 18928 17928°C 371 408 328°C 369 408 328°C 377 408 328°C 392 408 328°C 390 418 328°C 410 418 328°C 379 408 328°C 373 408 328°C 378 408 328°C 389 408 328°C 407 418 328°C 394 418 328°C 510 538 458°C 519 538 458°C 352 370 290°C 358 370 290bar 180 181 171bar 180 181 171Max firing pressure A2
Exhaust gas temp. before turbocharger BExhaust gas temp. after turbocharger AExhaust gas temp. after turbocharger BMax firing pressure A1
Exhaust gas temp. B4Exhaust gas temp. B5Exhaust gas temp. B6Exhaust gas temp. before turbocharger A
Exhaust gas temp. A6Exhaust gas temp. B1Exhaust gas temp. B2Exhaust gas temp. B3
Exhaust gas temp. A2Exhaust gas temp. A3Exhaust gas temp. A4Exhaust gas temp. A5
Charge air pressure difference over cooler BTurbocharger speed ATurbocharger speed BExhaust gas temp. A1
Charge air pressure after coolerCharge air temp. after coolerCharge air pressure difference over cooler A
Conditionborder level
Sche
dule
d s
top
Anticipated Anticipated deteriorating deteriorating
raterate
Monitored Monitored deteriorating deteriorating
raterate
Scheduledmaintenance
Optimal time for
maintenance
WFI - S Service Division
CBM
WFI- S Service Division
CBMbar 1,6 2,1 1,9°C 60 57 48Pa 39 44 0Pa 60 44 0rpm 18222 18856 18056rpm 18187 18856 18056°C 406 364 294°C 390 364 294°C 391 364 294°C 397 364 294°C 387 364 294°C 384 364 294°C 388 364 294°C 387 364 294°C 422 364 294°C 396 364 294°C 380 364 294°C 389 364 294°C 364 364 294°C 359 364 294°C 385 364 294°C 402 364 294°C 397 364 294°C 417 364 294°C 514 464 394°C 481 464 394°C 394 354 314°C 383 354 314°C 78 91 73
Exhaust gas temp. after turbocharger BMain bearing temp./Bearing 0
Exhaust gas temp. B9Exhaust gas temp. before turbocharger AExhaust gas temp. before turbocharger BExhaust gas temp. after turbocharger A
Exhaust gas temp. B5Exhaust gas temp. B6Exhaust gas temp. B7Exhaust gas temp. B8
Exhaust gas temp. B1Exhaust gas temp. B2Exhaust gas temp. B3Exhaust gas temp. B4
Exhaust gas temp. A6Exhaust gas temp. A7Exhaust gas temp. A8Exhaust gas temp. A9
Exhaust gas temp. A2Exhaust gas temp. A3Exhaust gas temp. A4Exhaust gas temp. A5
Charge air pressure difference over cooler BTurbocharger speed ATurbocharger speed BExhaust gas temp. A1
Charge air pressure after coolerCharge air temp. after coolerCharge air pressure difference over cooler A
Reduced operating costs - Reduced fuel consumption - Reduced maintenance cost - Increased component life time
Reduced number of unplanned stop
Reduced number of failure
Improved maintenance planning
Improved follow up of the installation condition
CBM
WFI - S Service Division
CBM Service Division
The Inmarsat world copy from Fleet Inmarsat
InternetInternetISP ISP
Customer router
Wärtsilä VPN router
Customer or Wärtsilä automation systems
Wärtsilä Condition Based Maintenance (CBM)
Wärtsilä VPN systems
Condition Based Maintenance General system layout
Automation System
Ethernet
VPN tunnel
CBMDatabase
Customer E-mail server
ISP ISPWärtsiläE-mail server
Wärtsilä ISDN router
LTC LTC
Wärtsilä ISDN router
Unknown
Remote monitoring (read only)
Remote monitoring (read only)
PlantNet
ISDN
VPN Virtual Private Network
ISDN Integrated Services Digital Network
LTC Local Telephone Company
ISP Internet Service Provider
WFI - S Service Division
CBM - Condition Based Maintenance
Data transfer / Communications:
- Direct satellite connection- On-line real time broad band Internet / VPN- ISDN connection- Automatic e-mail connections- Manual e-mail sending
WFI - S Service Division
CBM - Condition Based Maintenance
…as of may 2005
> 85 Installations Connected to the Wärtsilä CBM Solution March 2006
Marine and Power Plants
WFI - S Service Division
CBM - Condition Based Maintenance
WFI - S Service Division
CBM - Condition Based Maintenance
WFI - S Service Division
CBM - Condition Based Maintenance
WFI - S Service Division
When we have the control of the application
thenwe get the best performance from
the installed equipment !
Analyzing / trendsExhaust gas temperature after cylinder A1
250
270
290
310
330
350
370
390
410
430
450
1.3.
2004
3.3.
2004
5.3.
2004
7.3.
2004
9.3.
2004
11.3
.200
4
13.3
.200
4
15.3
.200
4
17.3
.200
4
19.3
.200
4
21.3
.200
4
23.3
.200
4
25.3
.200
4
27.3
.200
4
29.3
.200
4
31.3
.200
4
2.4.
2004
4.4.
2004
6.4.
2004
8.4.
2004
10.4
.200
4
12.4
.200
4
14.4
.200
4
16.4
.200
4
18.4
.200
4
20.4
.200
4
22.4
.200
4
24.4
.200
4
26.4
.200
4
28.4
.200
4
30.4
.200
4
2.5.
2004
4.5.
2004
6.5.
2004
8.5.
2004
Date
Ex
ha
us
t g
as
te
mp
era
ture
A1
(°C
)
50
55
60
65
70
75
80
85
90
Lo
ad
%
Site Alert Action Load
Analyzing
Total electrical production
0
2000
4000
6000
8000
10000
12000
1.6.
2002
- 30.
6.20
02
1.7.
2002
- 31.
7.20
02
1.8.
2002
- 31.
8.20
02
1.9.
2002
- 30.
9.20
02
1.10
.200
2 - 3
1.10
.200
2
1.11
.200
2 - 3
0.11
.200
2
1.12
.200
2 - 3
1.12
.200
2
1.1.
2003
- 31.
1.20
03
1.2.
2003
- 28.
2.20
03
1.3.
2003
- 31.
3.20
03
1.4.
2003
- 30.
4.20
03
1.5.
2003
- 31.
5.20
03
1.6.
2003
- 30.
6.20
03
1.7.
2003
- 31.
7.20
03
1.8.
2003
- 31.
8.20
03
1.9.
2003
- 30.
9.20
03
1.10
.200
3 - 3
1.10
.200
3
Date
Ele
ctri
cal P
rod
uct
ion
(M
Wh
)
DG Set 1 DG Set 2 DG Set 3 DG Set 4 DG Set 5 DG Set 6Adventure of the Seas
1.5.2003 - 31.5.2003 91246
days: 241.6.2003 - 30.6.2003 91246
days: 31.7.2003 - 31.7.2003 91246
days: 11.8.2003 - 31.8.2003 91246
days: 251.9.2003 - 30.9.2003 91246
days: 201.10.2003 - 31.10.2003 91246
days: 10
1,08
1,92
0,000,00
1,00
2,00
0,000,00
0,50
3,20
0,75
2,00
0,00
0,50
1,00
1,50
2,00
2,50
3,00
3,50
4,00
Av
era
ge
am
ou
nt
/ ru
nn
ing
da
y
Engine and period
Operation data out of limits (engine/month)
Action AlertAdventure of the Seas
104
7
96
15
109
7
116
16
87
16
91
7
122
18
96
2
95
7
93
4
74
16
95
7
18
1
10
108
1
72
0
117
13
0
20
40
60
80
100
120
140
To
tal
nu
mb
er o
f st
art
atte
mp
ts
Start statistics
Successful starts Failed starts Adventure of the Seas
Engine1 specific fuel consumption and load
170,0
180,0
190,0
200,0
210,0
Period
Co
ns
um
pti
on
g/k
Wh
0,010,020,0
30,040,050,060,0
70,080,090,0
Lo
Load % Load
Condition Based Maintenance (CBM)
Condition Based Maintenance General reporting layout
Ethernet
VPN tunnel
VPN Virtual Private Network
PDF Portable Document Format
RPA Reference Performance Analyser
RPADatabase
CBM reporting tools
Remote monitoring servers
Ideal reference valuesRemote monitoringPredictionsProduction reportsStart failuresAlarm log analysis…
CBM report
CBMDatabase
WFI- S Service Division
Different level reports Top Management reports Middle Management level Report Operator level report
Performance report Fuel consumption Operation data evaluation Heat recovery Comments/suggestions
Environmental report Emission-calculations
Technical report Coming maintenance Trends / Alarm analyze Comments/suggestion
Custoimised CBM reports based on your specification
WFI - S Service Division
When we have the control then
we can make the savings !
Op
erat
ing
co
sts
WFI-S Service Division
Savings:
10 - 20% in the maintenance costs
1-4% fuel savings during the life time of the installation
Traditional CBM
CBM savings
CBM costCBM cost
WFI - S Service Division
CBM - Condition Based Maintenance
In addition
Reduced number of unplanned stops Improved maintenance planning Improved spare parts planning
Improved follow up
WFI - S Service Division
CBM - Condition Based Maintenance
Thank you for your attention
WFI - S Service Division
The Wärtsilä Condition Based Operation and Maintenance The Wärtsilä Condition Based Operation and Maintenance ProgramProgram
CCCC BBBB MMMM
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