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
Effects if DG sets are not monitored

Wartsila India Ltd

Monitory Loss (Fuel Consumption Increase) Diff. Pr. across C A Coolers. 200-400mm H2O

+2g/kWh with increase of every 100mm H2o

C. W. temp. before eng. 45 Deg.C at 100% Load
+3g/kWh with every 10 Deg.C rise in temp.

Exhaust Gas back pr. after the T/c

300mm H2o

+2g/kWh with increase of every 100mm H2o

Condition Monitoring
Effects if DG sets are not monitored

Wartsila India Ltd

Reliability of Machine
Engine Block Blow Off
If excess crankcase pressure unnoticed

Valve Burning- Consequential 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

Wartsila India Ltd

Bearing Temperature
Main Bearing Big End Bearing

Cooling Water System
Cooling Water Temperature Cooling Water Pressure

Condition Monitoring
Critical Parameters To be Monitored Fuel System

Wartsila India Ltd

Fuel Pump Rack Positions ( larger machines) Fuel Oil Pressure/Temperature Differential Pressure Across Fuel Filters

Charge Air System
Charge Air temperature/ Pressure Safety 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
ALARMS AND LIMITS

Wartsila India Ltd

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
Typical Monitoring devices with safety features • Lube oil Pressure • Lube Oil Temperature • Exhaust Temperature • Cooling water temperature • Engine Over speed • Charge Air Temperature

Wartsila India Ltd

Alarm/Stop Alarm/Stop Alarm/Stop Alarm/Stop Alarm/Stop Alarm/Stop

Condition Monitoring
Typical Monitoring devices with safety features Differential Pressure Across air coolers Turbochargers Over speed Crankcase Pressure Pre Lube oil Pressure Over current Under/Over Frequency

Wartsila India Ltd

Alarm Alarm Alarm/Stop Alarm Stop Stop

Condition Monitoring

Wartsila India Ltd

Monitoring devices for Diesel Generator Set • Temperature Sensor/Switch • Pressure 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

Wartsila India Ltd

Water Transducer
A Continuous Measurement of Water in Lube Oil

Condition Monitoring Benefits

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. Works with all kind of oil systems

Condition Monitoring

Wartsila India Ltd

How can we monitor the crankcase environment ? 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 per day depending on the routine The alternative is

Continuous Oil Level Monitor

Condition Monitoring

Wartsila India Ltd

The system is based reliable strain gauge principle i. e weighting of the cylinder no moving parts

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 • Automatic filling of lub oil • Detect abnormalities in 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

Wartsila India Ltd

Faster and more accurate monitoring of the sensitive part i. e measure the bearing temperature

Condition Monitoring

Wartsila India Ltd

WIRELESS BIG END BEARING TEMPERATURE MONITORING

Condition Monitoring

Wartsila India Ltd

CBM
Condition Based Maintenance Reliable and Economical Diesel Engine application operation

Condition Monitoring
CBM Reduced operating costs - Reduced fuel consumption - Reduced maintenance cost - Increased component life time
Reduced number of unplanned stops Reduced number of failure’s Improved maintenance planning

Benefits of CBM

Improved follow up of the installation condition

Condition Monitoring

Wartsila India Ltd

If we can measure and analyze the application we have the control !

Condition Monitoring
Owner /Operator office

Communication
Local Wärtsilä office

The installation
Monitoring

Wärtsilä
CBM Report

Data transfer

Wärtsilä database

Condition Monitoring
CBM - Condition Based Maintenance

Wartsila India Ltd

The Wärtsilä CBM solution is in fact a combination of Condition Based Operation and Condition Based Maintenance

Condition Monitoring
CBM

Wartsila India Ltd

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

- Control and monitoring systems - Pressure measurements - Temperature measurements - Speed measurements - Load measure measurement - Vibrations (when available) - Communication technologies - Etc

Condition Monitoring

Wartsila India Ltd

CBM - Operation - Data - Analyzer
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

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
Monitored deteriorating rate

Wartsila India Ltd
Optimal time for maintenance

Condition border level

Scheduled maintenance

Scheduled stop

Anticipated deteriorating rate

Condition Monitoring
CBM
C h a rg e a ir p re s s u re a fte r c o o le r C h a rg e a ir te m p . a fte r c o o le r C h a rg e a ir p re s s u re d iffe re n c e o v e r c o o le r A C h a rg e a ir p re s s u re d iffe re n c e o v e r c o o le r B T u rb o c h a rg e r s p e e d A T u rb o c h a rg e r s p e e d B E xh a u s t g a s te m p . A 1 E xh a u s t g a s te m p . A 2 E xh a u s t g a s te m p . A 3 E xh a u s t g a s te m p . A 4 E xh a u s t g a s te m p . A 5 E xh a u s t g a s te m p . A 6 E xh a u s t g a s te m p . A 7 E xh a u s t g a s te m p . A 8 E xh a u s t g a s te m p . A 9 E xh a u s t g a s te m p . B 1 E xh a u s t g a s te m p . B 2 E xh a u s t g a s te m p . B 3 E xh a u s t g a s te m p . B 4 E xh a u s t g a s te m p . B 5 E xh a u s t g a s te m p . B 6 E xh a u s t g a s te m p . B 7 E xh a u s t g a s te m p . B 8 E xh a u s t g a s te m p . B 9 E xh a u s t g a s te m p . b e fo re tu rb o c h a rg e r A E xh a u s t g a s te m p . b e fo re tu rb o c h a rg e r B E xh a u s t g a s te m p . a fte r tu rb o c h a rg e r A E xh a u s t g a s te m p . a fte r tu rb o c h a rg e r B M a in b e a rin g te m p ./B e a rin g 0 bar °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

Wartsila India Ltd
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 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

Wartsila India Ltd

CBM savings
CBM cost

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

Operating costs Traditional

CBM

Condition Monitoring

Wartsila India Ltd

Operating costs

The biggest savings are on the reduced fuel CBM savings consumption
CBM cost

in average 5 - 10 g / kWh (2-5%) during the life time cycle of the application

Traditional

CBM

Condition Monitoring

Wartsila India Ltd

Operating costs

Reduced maintenance cost by making the CBM savings correct maintenance CBM cost at the correct time
in the range of 5 – 20% saving
Traditional CBM

Condition Monitoring

Wartsila India Ltd

Operating costs

Improved reliability by
CBM savings
CBM cost

expert analyzing / follow up and regular feed back including predictions and recommendations

Traditional

CBM

Condition Monitoring

Wartsila India Ltd

Custoimised CBM reports based on your specification

8Different level reports 8Top Management reports 8Middle Management level Report 8Operator level report 8Performance report 8Fuel consumption 8Operation data evaluation 8Heat recovery 8Comments/suggestions 8Environmental report 8Emission-calculations 8Technical report 8Coming maintenance 8Trends / Alarm analyze 8Comments/suggestion

Condition Monitoring
Operation data out of limits (engine/month)
4,00

Analyzing
Start statistics
140

Average amount / running day

3,50

3,00

18 120 7 3,20 2,00 7 100 16 1 16 80 7 2 7 4 16 0 60 104 40 109 96 122 108 87 91 96 95 93 74 95 72 117 7 13

2,50

Total number of start attempts

2,00

1,92

2,00

15

1,50

1,00

0,50

1,08

1,00 0,00 0,00
1.7.2003 - 31.7.2003 91246 days: 1 1.8.2003 - 31.8.2003 91246 days: 25

0,75

116

0,50

0,00 1.5.2003 - 31.5.2003 91246 days: 24

1.6.2003 - 30.6.2003 91246 days: 3

1.9.2003 - 30.9.2003 91246 days: 20

1.10.2003 - 31.10.2003 91246 days: 10

Engine and period Action Alert

20

1 18

Advent ure of t he Seas

0

0 1

Successful starts

Failed starts

Advent ure

Total electrical production
12000

E n g in e 1 s p e c if ic f u e l c o n s u m p tio n a n d lo a d
L o ad d L o aL % 2 1 0 ,0 Consumption g/kWh 2 0 0 ,0 1 9 0 ,0 1 8 0 ,0 1 7 0 ,0
.0 3 .0 3 .0 3 .0 3 .0 3 .1 0 .0 3 .1 0 .1 0 .1 0 .1 0 .1 0 .1 0 .0 3
Advent ure

Electrical Production (MWh)

10000

8000

6000

4000

2000

0
20 02 20 02 20 03 20 03 20 03 20 03 20 03 20 03 20 03 20 02 20 02 20 03 20 03 00 2 00 2 00 2 -3 1. 10 .2 -3 0. 11 .2 -3 1. 12 .2 -3 1. 10 .2 00 3

9 0 ,0 8 0 ,0 7 0 ,0 6 0 ,0 5 0 ,0 4 0 ,0 3 0 ,0 2 0 ,0 1 0 ,0 0 ,0

-3 0. 4.

-3 1. 8.

-3 0. 9.

-3 1. 5.

-3 1. 1.

-2 8. 2.

-3 0. 6.

-3 1. 7.

-3 1. 8. 00 3 1. 9. 2

-3 0. 6.

-3 1. 7.

00 2

00 2

00 3

00 2

00 2

00 3

-3 1. 3.

00 3

00 3

00 3

00 3

1. 10 .2 00 2

1. 11 .2 00 2

1. 12 .2 00 2

00 3

00 3

Date
DG Set 1 DG Set 2 DG Set 3 DG Set 4 DG Set 5 DG Set 6

1. 10 .2 00 3

1. 6. 2

1. 7. 2

1. 8. 2

1. 9. 2

1. 3. 2

1. 4. 2

1. 1. 2

1. 2. 2

1. 5. 2

1. 6. 2

1. 7. 2

1. 8. 2

-3 0. 9.

26

28

25

27

30

29

P e rio d

31

Condition Monitoring
The installation today

Wartsila India Ltd

Monitoring

Condition Monitoring

CBM Marine Solution

Condition Monitoring

Wartsila India Ltd

Case Study Piston Liner Seizure

Condition Monitoring
Customer : Power Source : Accident : Monetary Loss : Power Outage : ABC India Ltd. DG Set

Wartsila India Ltd

Seizure in Piston/Liner 10 Lacs (components) 72 hours

Production Loss: Unknown

Condition Monitoring Observations:

Wartsila India Ltd

• 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 Observations:
• Piston was seized in liner • Rings were not seized • Small end Bearing was seized • Big end Bearings were o.k.

Wartsila India Ltd

• 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 Reason :

Wartsila India Ltd

• 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!

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