ENGINE MONITORING UNIQUE ENGINE PROTECTION

ENGINE MONITORING UNIQUE ENGINE PROTECTION

OUR MISSION We shall earn the respect and recognition for our dedication to provide innovative and reliable marine electronics that ensure optimal operation at sea. By utilizing and integrating our technology, experience and competencies in positioning, hydro-acoustics, communication, control, navigation, simulation, and automation, we aim to give our customers The Full Picture. The Full Picture yields professional solutions and global services that make a difference enabling you to stay ahead of the competition. OUR PHILOSOPHY Our success depends on the success of our customers. Actively listening to our customers and truly understanding their needs, and then translating these needs into successful products and solutions is central to achieving our goal. Our people are the key to our success and we empower them to achieve. Working together in a global network of knowledge, guided by our values, engenders innovation and world class performance. Every day we have to think a little differently, because every client is unique. We aspire to translate the imagination and dedication of our staff into successful technologies and solutions. Our commitment is to add value to your operations by providing you with The Full Picture. CONTENTS UNIQUE ENGINE PROTECTION 3 SYSTEM PHILOSOPHY 4 AVODING OPEN-UP INSPECTION 6 UNIQUE TEMPERATURE MONITORING - BEARINGS AND LINERS 8 TORQUE AND POWER MONITORING 10 Kongsberg Maritime August 2014 Design and layout: DEON.NO

UNIQUE ENGINE PROTECTION Engine Monitoring Systems for operational safety KONGSBERG Engine Monitoring Systems are built on KONGSBERG K-Chief hardware and software. They consist of bearing wear and bearing temperature monitoring of crank-train bearings, water in oil, cylinder liner temperature and shaft power monitoring. The Engine Monitoring Systems are fully scalable from standalone to full integration with KONGSBERG K-Chief alarm monitoring system and KONGSBERG AutoChief propulsion control system. All systems are recommended and approved by the major engine designers and are an ideal basis for condition based maintenance. The KONGSBERG Engine Monitoring Systems provide improved operational safety, reduced risk of unforeseeable repair costs and optimized monitoring of the engines. Bearing Wear Conditon Monitoring (BWCM) is required to avoid open-up inspections (MAN B&W 2-stroke engines) Unique protection of the engine by using wireless temperature monitoring of crank and crosshead bearing Can be configured and combined to suit individual needs Approved by MAN Diesel & Turbo for condition based maintenance Engine overview presented in K-Chief 3

SYSTEM PHILOSOPHY Modular and scalable concept Systems may easily be extended by adding additional hardware units such as operator stations, input/output modules and additional measuring points. KONGSBERG System Technology offers signal acquisition and processing units for installation in ER cabinets, ECR consoles or mounted directly on the engine. Processing algorithms are executed within the local acquisition units or in the powerful controller units. By distribution and segregation the consequences of a system fault are reduced and may even be eliminated. The KONGSBERG Engine Monitoring Systems concept yields a modular design, where the various modules can be configured and combined to suit individual needs. The individualised Engine Monitoring systems can then be integrated with KONGSBERG K-Chief and AutoChief system. Each module is fully compatible with each other and therefore provides seamless information sharing and a consistent operation environment. Essential components such as bearing wear sensors and wireless temperature sensors yield the best results that technology has to offer in terms of reliability, accuracy and durability. By utilizing the CAN field bus protocol for engine instrumentation, installation costs are reduced and the quality of data processing enhanced. Utilize open standards for automation systems The engine monitoring functionalities have been developed in close co-operation with maritime professionals, to ensure system functionalities that work effectively and safely in real life operations. The KONGSBERG Engine Monitoring System concept in general and the individual modules utilize open standards, which provide for interfaces to different automation systems. WORKSTATIONS ENGINE MONITORING BRIDGE CARGO AUTOMATION AutoChief engine control Fuel monitoring Cylinder pressure Turbo charger monitoring Torque monitoring Bearing wear and Water in oil Bearing and liner temperature Weather forecast 4

Engine overview Cylinder Liner Temperature Monitors piston running performance by measuring the temperature of the cylinder liners. Bearing Wear Measures the combined wear of crosshead, crank and main bearing and provides early warning of bearing seizure. It is required to avoid open up inspections. Main Bearing Temperature Mounted on the bearing girder with the tip in direct contact with the bearing shell. Crank and Crosshead Temperature Measures continuously the temperature of the bearings. The sensor communicates wirelessly with a processing unit using a high frequency and low energy radar pulse. Water in Oil The sensor gives continuous measurement of moisture in oil, and oil temperature. Moisture is measured in terms of water activity. Shaft Power Calculates torque and power. The system is 100% digital and measures the twist of a rotating shaft.

AVOIDING OPEN-UP INSPECTION Condition monitoring of crank-train bearings in 2-stroke diesel engines The KONGSBERG Bearing Wear Condition Monitoring (BWCM) system measures and displays the combined physical wear of the crosshead, crank and main bearings, providing early bearing seizure warnings if problems occur during engine operation. The sensors are specifically designed to provide reliable and accurate measurements over years of operation inside the engine. The BWCM system uses two sensors mounted in each cylinder compartment, measuring every time the crosshead passes Bottom Dead Centre. The KONGSBERG BWCM sensors are compensated for engine speed, engine load (cpp) and engine crank case temperature. Main Benefits Approved to avoid open-up inspections Unique long-term measuring accuracy Compact and simple cabling and installation on the engine Full integration with KONGSBERG K-Chief and AutoChief system 6

Water in Oil sensor The KONGSBERG Water in Oil sensor enables fast and reliable detection of moisture in lubrication oil. It can be used in online moisture monitoring and as a control device. The Water in Oil sensor measures moisture in oil in terms of the water activity (aw) and temperature (T). Water activity indicates directly whether there is a risk of free water formation which causes corrosion of the bearings. The measurement is also independent of oil type and age. The sensor incorporates the latest generation of the HUMICAP Sensor, which is the result of ten years of field experience. It was developed for demanding moisture measurement in liquid hydrocarbons. The sensor's excellent chemical tolerance provides accurate and reliable measurement over a wide measurement range. Avoiding open up inspection The KONGSBERG Bearing Wear Conditon Monitoring (BWCM) system is designed according to the specifications of MAN Diesel & Turbo and received a Type Approval according to Germanischer Lloyd s (GL) Guidelines for Machinery. The following systems are part of a class survey arrangement: BWCM system Water in Oil sensor Shaft Earthing Device (owner or yard supply) Computerized Planned Maintenance System (owner or yard supply) Main Benefits According to MAN Diesel & Turbo and GL specifications condition based overhaul of crank-train bearings Dual sensor for continuous measurement of moisture in oil and oil temperature Easy to maintain in the field BEARING WEAR SENSOR WATER IN OIL SENSOR 7

UNIQUE TEMPERATURE MONITORING - BEARINGS AND LINERS SENTRY - For crankpin and crosshead bearing temperature monitoring The SENTRY wireless bearing temperature monitoring system is capable of continuously measuring the temperature of bearings during engine operation. The wireless sensors are individually interrogated from a multiplexed Signal Processing Unit (SPU) using a high frequency and low energy radar pulse. The radar pulse is transmitted to the wireless sensor via a coaxial cable to a stationary antenna positioned inside the crank case. Within the interrogation range of the stationary antenna the sensor responds to the radar pulse by reflecting a pulse pattern back to the SPU. The characteristics of the reflected pulse are uniquely defined by the temperature. Main Benefits Continuously measuring temperature of the bearings for fast response time Passive sensor, no battery required Proven and reliable technology Type Approved to replace Oil Mist Detectors Main components are: Wireless temperature sensor Stationary reading antenna Signal Processing Unit SIGNAL PROCESSING UNIT STATIONARY ANTENNA RADAR PULSE FROM SIGNAL PROCESSING UNIT PULSE RESPONSE FROM SENSOR SENSOR WIRELESS TEMPERATURE SENSOR o C 400 300 200 100 CUTTING THE OIL SUPPLY ALARM FROM TEMPERATURE SENSOR ALARM LIMIT ALARM FROM OIL MIST DETECTION 1 2 3 4 Min 8

Main bearing temperature sensors Custom designed main bearing temperature sensors can be fitted into any type of 2-stroke and 4-stroke diesel engines. On 2-stroke engines the sensors are mounted on the main bearing girder with the tip of the sensor in direct contact with the bearing shell. The sensor measures the combined temperatures of the bearing shell and of the lubrication oil that flows from the bearing. On 4-stroke engines the sensors are inserted in the main bearing cap. Monitoring cylinder liner temperature The KONGSBERG cylinder liner monitoring system monitors the piston running performance by measuring the temperature of the upper part of the cylinder liners. Increased friction between the piston rings and the cylinder liner creates an elevated temperature level leading to abnormal liner wear and potential piston ring breakage. Temperature alarm limits can be individually set on the PC work station to give early warning about high thermal load and potential cylinder liner scuffing. The KONGSBERG cylinder liner monitoring system consists of high quality temperature sensors and one field-bus signal converter on each cylinder and one common Operator Station. Additionally, individual relay output alarms can be provided directly to the cylinder lubrication units in order to temporarily increase the cylinder lubrication. Main Benefits Tailor made to the Wärtsilä MAPEX PR condition monitoring system Also used to send scuffing alarms to the MAN Diesel & Turbo Alpha Lubricator Easy to refit on MAN Diesel & Turbo and Wärtsilä engines Field-bus signal converters (CAN Open) installed directly on engine block BEARING TEMPERATURE SENSOR LINER TEMPERATURE SENSORS CONVERTER 9

TORQUE AND POWER MONITORING MetaPower is 100% digital and based on optical measurement The MetaPower System measures the twist of a rotating shaft. Two slotted wheels are mounted on the shaft. Light is transmitted by LEDs through the slots in each wheel, converted to a digital electronic signal and sent back to the processing unit for calculation of the corresponding torque. The system displays RPM, torque and power for both shafts. High accuracy torque measurement No need for strain gauges or any type of delicate electronics glued to, or mounted on the rotating shafts. The system is a digital measuring system using LED switches for the detection of the shaft twist, the shaft RPM and consequently the transferred power. PROCESSING UNIT CONNECTION BOX ROTATING SHAFT Main Benefits Service free operation The maintenance (cleaning lenses and code wheels) is conducted by the crew No sensitive electronics No mechanical wear No zero point drifting over time Not affected by ambient temperature variations Integrated K-Chief and standalone installation 10

GLOBAL CUSTOMER SUPPORT We are always there, wherever you need us. K ONGSBERG customer services organisation is designed to provide high-quality, global support, whenever and wherever it is needed. We are committed to providing easy access to support and service, and to responding promptly to your needs. Support and service activities are supervised from our headquarters in Norway, with service and support centres at strategic locations around the globe where you are and the action is. As part of our commitment to total customer satisfaction, we offer a wide variety of services to meet individual customers operational needs. KONGSBERG support 24 is a solution designed to give round-the-clock support. For mission-critical operations, KONGSBERG support 24 can be extended to include remote monitoring. We can adapt the level of support needs by offering service agreements, on-site spare part stocks and quick on-site response arrangements. Svalbard Canada (5) USA (14) Mexico (2) Norway (35) Finland Russia UK (11) Denmark Ireland Poland (2) Germany Netherlands Hungary France Spain Italy (2) Greece South Korea (6) UAE (3) China (4) Saudi Arabia India (4) Venezuela Brazil (3) Nigeria Malaysia Singapore (4) South Africa Australia (2) Antarctica Global and local support We provide global support from local service and support facilities at strategic locations worldwide. Service and support work is carried out under the supervision of your personal account manager, who will ensure that you receive high-quality service and support where and when you need it. Your account manager will ensure continuity and work closely with your personnel to improve and optimize system availability and performance. Under the direction of your account manager, and with a local inventory of spare parts, our well qualified field service engineers will be able to help you quickly and effectively. SUPPORT 24 Call +47 815 35 355 E-mail: km.support@kongsberg.com

kongsberg.com