WFI - S Service Division Digital Ship at Posidonia June 2006 in Association with AMMITEC CBM Condition Based Maintenance and Operation by Johan Pellas.

WFI - S Service Division

Digital Ship at Posidonia June 2006 in

Association with AMMITEC

CBMCondition Based Maintenance

and Operationby

Johan Pellas

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


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



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


The Wärtsilä Condition Based Operation and Maintenance The Wärtsilä Condition Based Operation and Maintenance ProgramProgram

CCCC BBBB MMMM


CBM - Condition Based Maintenance and Operation

The Wärtsilä CBM solution

Is in fact a

Condition Based Operation and

Maintenance solution


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


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


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



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


CBM


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



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


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

E-mail

ISDN

VPN Virtual Private Network

ISDN Integrated Services Digital Network

LTC Local Telephone Company

ISP Internet Service Provider



Data transfer / Communications:

- Direct satellite connection- On-line real time broad band Internet / VPN- ISDN connection- Automatic e-mail connections- Manual e-mail sending



…as of may 2005

> 85 Installations Connected to the Wärtsilä CBM Solution March 2006

Marine and Power Plants








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


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


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



In addition

Reduced number of unplanned stops Improved maintenance planning Improved spare parts planning

Improved follow up



Thank you for your attention


The Wärtsilä Condition Based Operation and Maintenance The Wärtsilä Condition Based Operation and Maintenance ProgramProgram

CCCC BBBB MMMM

WFI - S Service Division Digital Ship at Posidonia June 2006 in Association with AMMITEC CBM Condition Based Maintenance and Operation by Johan Pellas.

Documents

maintenance slide

cbm service division

maintenance cbm condition

wfi s service division

cbm cbm savings cbm

cbm operation

maintenance solution

ammitec cbm condition