Thrusters Health Monitoring of Propulsion and Steering Devices Arthur Boogaard Eddy Engels Albert Wesselink Wärtsilä Propulsion The Netherlands Return to Session Directory
Condition based maintenance of Steerable Thrusters Dynamic Positioning Conference 2005 Houston, Texas Arthur Boogaard Eddy Engels Albert Wesselink Wärtsilä Propulsion The Netherlands 1
Contents Introduction Wärtsilä Propulsion Steerable Thrusters design philosophy Failure cases and results of malfunctions Health Measuring of Steerable Thrusters Communication Conclusion 2
Wärtsilä Propulsion Propulsion Products Brand name LIPS 3
Health monitoring Wärtsilä engines saving fuel consumption extend lifetime of components increase maintenance intervals 4
Design philosophy LIPS steerable thrusters Double supported pinion and gear wheels High quality forged steel gearwheels machined after hardening: Klingelnberg cyclo palloid HPG process Separate dedicated bearings for axial and radial loads Triple Viton lip type seals running on liners with ceramic coating Product range 900 kw 7.000 kw 5
What can go wrong Seal damage: water content in lub oil reduces the life time of bearings and gears with 50%. Inadequate lubrication due to late filter / oil change Overloading of the thruster External impacts Eventually this leads to early wear of gears and bearings Wear particles spread through the unit and affect other healthy components THE HEALTH OF THE THRUSTER SLOWLY BUT STEADILY DETERIORATES 6
Results of malfunctions Unplanned maintenance / repairs Replacement parts Loss of redundancy (Class) Docking 7
Where to go today tomorrow future alarms monitoring diagnostics/ prognostics pressure oil temperature level early detection of deteriorating components vibrations moisture particles combine signals, remaining lifetime database result: signals make trend line 8
From alarming temperature alarms lubrication steering pressure alarms pumps steering motors filters level gearboxes header tanks Rely on expertise on board, Wärtsilä s service Alarm: (too?) late, not source related 9
to monitoring Add sensors to system Accelerometers Moisture sensors Particle detector With signals: Detect early changes in behaviour Establish trend lines 10
Sensors (1/2) z Accelerometers: damage to race way / roller element damage to gearing vibration determine frequencies relation to damaged element signal analyzing 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 50 10 0 150 200 2 50 300 fre que nc y [Hz] 11
Sensors (2/2) Moisture sensor: water affects gear and bearings decrease of lifetime Particle sensor: detection wear bearings, gearing cross reference to other sensors 12
Human interface Off-line monitoring Robust software Fit to purpose Easy to use Trend watching 13
Health monitoring local readout of individual signals health gears health bearings 14
to (in future) diagnostic/prognostics Use data from monitoring Add belief rules, expertise from practice Build neural network Self learning system 15
Health diagnostics system GPS DEMANDED PITCH AZIMUTH RPM SHIP NETWORK LOG-FILE DATA FUSION & DECISION SUPPORT Envelope spectra Roller Bearings Envelope Spectra Gears Oil data processing Response identification PRESS. CW PRESS. CCW PITCH AZIMUTH RPM ACTUAL RECEIVER / SIGNAL DEMODULATOR OIL TEMP. AMB. TEMP. GEAR BOX STEM SECTION ELECTRIC POWER GENERATION ELECTRIC POWER GENERATION Accelerometers near Roller Bearings RECEIVER / TRANSMITTER TRANSMITTER SIGNAL MODULATOR Accelerometers near (Bevel) Gears Oil Moisture and Particle sensors Pitch actuating pressures In rotating part 16
Conclusion Today: alarms periodical maintenance / operating hours alarms actions too early / (too) late Tomorrow: monitoring: early detection of deteriorating components less unplanned dry-docking decrease down time decrease stock less surprises, saving money Diagnostics/prognostics: in future 17