Alarm and Safety Systems

Alarm and Safety Systems

Objectives

Participants completing this course will be able to

recognise and describe the Alarm and Safety System,
it’s unique components and control systems and
have a formal understanding of its operation and
applications for fault finding and troubleshooting.

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 Alarm and Safety Systems

This Presentation will define the equipment that is

included in the alarm and safety system and to detail the
individual components contained within it.

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 Alarm and Safety Systems
Over View

•Installed to meet Marine Society Rules

•Independent of Control system (ECM)

•Alarm System Functions

•Inform operator of a serious condition
•Provide audible and visual alerts
•Safety System Functions
•Safety system can independently shut down the engine
•Safety System shutdown capability can be overridden if the
event that operation of the vessel makes engine shutdown hazardous

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 Alarm and Safety Systems

•The shaded area of this diagram shows the position of the alarm and safety
system in the control system relationship.
•The propulsion and auxiliary options share much of the same basic hardware,
although they are packaged differently.

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 Propulsion System Layout
An example of the architecture required for the separation of the
Monitoring, Alarm, and Safety System.

A. Control B. Alarm C. Safety

1. Control Sensors
2. ED3 Display
3. ECM
4. Fuel System Control Valves
5. Fuel System Shutoff Valve
6. Alarm Sensors 10. Safety Sensor
7. Local Analog Display (LAD) 11. Safety Module
8. Customer Interface Box(CIB)
9. Remote Analog Display

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 Alarm and Safety Systems
•Cummins supplies:
•Local Analog Display provided to monitor 6 sensors
• Up to 35 marine approved sensors
•On-engine wiring harness
•Customer connections available in CIB
•Requires a 3rd party alarm monitoring system for full Class
approval
•Sensor types
•Thermocouple or PT100 for temperature
•4-20mA for pressure

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 Customer Connections

 All alarm and safety sensors are connected

to the CIB for monitoring
 Sensors that require 3rd party monitoring are
available at the terminal strips contained
within the CIB
 Information on these connections can be
found in the CIB Connection Details file

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 Local Analog Display (LAD)
The LAD indicates and alarms the following analog sensor information:
1. Coolant temperature
2. Exhaust stack temperature (LB)
3. Engine speed
4. Exhaust stack temperature (RB)
5. Battery voltage
6. Lube oil pressure
7. Gear oil pressure (if applicable)

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 Local Analog Display (LAD)
• LAD Alarm Indication Sequence
• Alarm setpoint exceeded:
• The associated bar graph will flash red when setpoint exceeded
• The LAD buzzer will sound
• Pressing the Silence Horn button ceases the horn, but the bar
graph will still be flashing red
• Pressing the Acknowledge button will stop the bar graph from
flashing, but will remain orange until the threshold issue has been
resolved
• Sensor fault/broken wire:
• Same as above
• Sensor fault light illuminated

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 Alarm System Sensors
Alarm system sensors that fulfil marine society unmanned engine
room requirements.

Sensor Qty Monitored By

After Cooler Water Inlet Temperature 1 3rd party

Fuel Filter Outlet Pressure 1 3rd party

Fuel Filter Differential Pressure 1 3rd party

Lube Oil Pressure 1 LAD

Lube Oil Filter Differential Pressure 2 3rd party

Sea Water Pump Outlet Pressure 1 3rd party

Cylinder Cooling Water Pressure 1 3rd party

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 Alarm System Sensors
Sensor Qty Monitored By
Cylinder Cooling Water Outlet Temp 1 LAD

Charge Air Receiver Temp (I M Temp) 3 3rd party

Exhaust Gas Temp – Individual Cylinder 16 3rd party

Exhaust Stack Temp – LB & RB 2 LAD

Lube Oil Temperature 1 3rd party

Starter Air Pressure (customer provided) TBD 3rd party

Gear Oil Pressure (customer provided) TBD LAD

Gear Oil Temperature (customer provided) TBD 3rd party

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 Recommended Alarm Sensor Setpoints
Sensor Setpoint

Aftercooler Water Inlet Temperature 71°C [160°F]

Fuel Filter Outlet Pressure 74 kPa [10.7 psi]

Fuel Filter Differential Pressure (service only)* 28 kPa [4 psi]

Lubricating Oil Pressure 24 to 45 psi

Lubricating Oil Filter Differential Pressure 35 psi

Sea Water Pump Outlet Pressure OEM defined

Cylinder Cooling Water Pressure 4-11 psi

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 Recommended Alarm Sensor Setpoints
Sensor Setpoint

Cylinder Cooling Water Outlet Temperature 100°C [212°F]

Intake Manifold Temperature (RB front, RB rear, LB rear) 82°C [180°F]

Exhaust Gas Temperature – Individual Cylinder 732°C [1350°F]

Exhaust Stack Temperature - LB & RB 593°C [1100°F]

Lubricating Oil Temperature 121°C [250°F]

If these set points are exceeded the alarm will operate.

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 Safety System

Cummins supplies:

•Safety Module installed in CIB

•5 safety switches/sensors read by Safety Module
•On-engine wiring harness
•Customer connections available in CIB for
•Customer supplied emergency stop
•Remote annunciation for engine shutdown

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 Safety Module
Front View

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 Safety Module
Back View

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 Safety Module
• Safety Module Indication Sequence
• Switch setpoint exceeded for pre-defined time:
• Threshold exceeded light illuminates
• FSOV de-energized
• Stop command sent to ECM (secondary)
• Engine shutdown occurs
• Sensor fault/broken wire:
• Sensor fault light illuminates
• Safety Module must be reset after shutdown sequence has occurred by
pushing “Local Reset” button on the back of the Safety Module

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 Safety System Sensors
Safety system sensors that fulfill marine society unmanned
engine room requirements.

Switch/Sensor Qty Monitored By

Lube Oil Press Switch - LSR (Low Speed Range) 1 Safety Module

Lube Oil Press Switch - HSR (High Speed Range) 1 Safety Module

Cylinder Cooling Water Pressure Switch 1 Safety Module

Cylinder Cooling Water Temperature Switch 1 Safety Module

Engine Speed Sensor 1 Safety Module

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 Default Safety Switch/Sensor
Setpoints
Switch/Sensor Set point

Lubricating Oil Pressure Switch (L S Range) 131 kPa [19 psi]

Lubricating Oil Pressure Switch (H S Range) 276 kPa [40 psi]

Coolant Pressure Switch 14 kPa [2 psi]

Coolant Temperature Switch 220°F [104°C]

Engine Speed 2070 rpm for auxiliary

2280 rpm for propulsion

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 Default Safety Switch/Sensor Setting
Test Connector is Self Sealing - To measure actual fluid pressure during
engine operation, connect an adapter to the test connector. It is not
necessary to turn the isolator valve to the OFF position due to the check
valve (check valve is spring loaded (1)). This can cause an alarm.

To test the alarm system sensor, turn the isolator valve to OFF position and
connect an adapter to the test connector with a controlled pressure source.
Raise the pressure above the setpoint for the sensor, the slowly release the
pressure until the alarm sounds.

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 Default Safety Switch/Sensor Setting
Safety Shutdown Test
The safety shutdown test is a procedure to demonstrate the shutdown
functions of the QSK60 marine safety system.

Equipment needed to conduct the tests:

Regulated pressure source providing between 0 and 50 psi, with mating for
Danfoss™ pressure manifold

Variable temperature liquid bath capable of up to 110°C [230F°] for a 6 mm

[0.24 in] diameter probe

Frequency generator to simulate engine speed signal (rpm). Can also set
safety module overspeed setpoint switch to 1475 rpm, start engine, and
verify shutdown.

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 Default Safety Switch/Sensor Setting
Low Coolant Pressure Shutdown
Shut down the engine
Rotate the isolation valve (1) 90 degrees
clockwise to closed position .
Remove the rear-most pressure fitting cap
(2) from the manifold block, and
connect a regulator pressure source.

Adjust the regulated pressure source to 69 kPa [10 psi]

Start the engine

Lower the regulated pressure to 6.9 kPa [1 psi]

Shutdown will occur at approximately 13.8 kPa [2 psi]

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 Default Safety Switch/Sensor Setting
Press the reset button on the back of the safety module
Acknowledge faults on the ECM by first pressing the local analog display stop
button and then the fault acknowledge button on the printed circuit board.
This is for auxiliary application only as the Dominion ECM must be in stop
mode, not Emergency stop mode to acknowledge faults.

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 Alarm System Sensors

Danfoss Pressure Sensor – Connected to Alarm System

4-20 ma analog output used for fluid pressure monitoring

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 Alarm System Sensors

Danfoss PT100 Temperature Sensor

– Connected to Alarm System
Used for gas or fluid temp monitoring

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 Safety System Switch

Danfoss Temperature Switch

– Connected to Safety System
And set to specific temperature
Will shut down engine if set limits
Are exceeded.

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 Safety System Switches

Danfoss Pressure Switch

– Connected to Safety System
And set to specific pressure
Will shut down engine if set limits
Are exceeded.

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 Alarm and Safety Systems

Pressure sensors and switches have

A self sealing test point for testing and
setting purposes, and isolator valve.

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 Alarm and Safety Systems

QSOL contains details on the checking

And setting of these Danfoss sensors
and switches in the
Master Repair Manual QSK60
Marine Alarm and Safety System
System Description. (209-001)

We will be using this document for

The practical exercises in the work shop.

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 KEY:
= BASE ENGINE SENSOR
QSK60-Marine Sensor Configuration (Propulsion)
TIMING PRESS AMBIENT AIR PRESS
= ALARM SENSOR (for Class)
= ALARM SENSOR (local panel) OIL TEMP FUEL TEMP RAIL PRESS Fuel Leakage Detector (for 3 hi press hoses)
(in oil pan)
= ALARM SENSOR
= SAFETY SENSOR (for Class) BLOWBY PRESS INTAKE AIR TEMP (base & alarm for class)
CM500 ECM BOOST PRESSURE
Fuel Filter Outlet Press
Aftercooler Water Inlet
Fuel Filter Delta Press Temperature
(across all filter elements) ECVA FUEL PUMP PRESS
FUEL FILTER ENGINE COOLANT
INTAKE AIR TEMP PRESSURE & TEMP

CUSTOMER INSTALLED INTAKE MANIFOLDS (4) (Sea water

Pressure
Gearbox Oil Pressure
Cooling
Left Bank System)
LB8 LB 1
FLYWHEEL HSG

FRONT

THERMOSTAT HSG
ENGINE SPEED

Stack EGT
OIL PRESSURE
(RIFLE) (Cylinder
TURBO TURBO Cooling
REAR S S Water
Stack EGT Level)

Lube oil Cylinder

Pressure Water
RB8 RB 1 Outlet
Temp
EGT x 16 Right Bank
Engine Speed
Oil Pressure Oil Pressure
(Post Filter - (Pre Filter - Lube
Lube Filter Head) Filter Head) Cylinder water
CUSTOMER PROVIDED inlet pressure
Start Air Pressure
Gearbox Oil Temp
INTAKE AIR TEMP INTAKE AIR TEMP
 KEY:
= BASE ENGINE SENSOR (ECM)
QSK60-Marine Sensor Configuration (Auxiliary)
= ALARM SENSOR (for Class)
TIMING PRESS AMBIENT AIR PRESS Dominion ECM
OIL TEMP FUEL TEMP RAIL PRESS
Fuel Leakage Detector
= ALARM SENSOR (local panel) (for 3 hi press hoses)
(in oil pan)
= ALARM SENSOR
= SAFETY SENSOR (for Class) BLOWBY PRESS COOLANT PRESSURE
INTAKE AIR TEMP (base engine &
Fuel Filter Outlet Press alarm for class)
Fuel Filter Delta Press BOOST PRESSURE
(across all filter elements) ECVA FUEL PUMP PRESS
FUEL FILTER ENGINE COOLANT
INTAKE AIR TEMP PRESSURE & TEMP

INTAKE MANIFOLDS (4) Aftercooler (Sea water

Water Inlet Temp Pressure
Cooling
Left Bank System)
LB8 LB 1
FLYWHEEL HSG

FRONT

THERMOSTAT HSG
ENGINE SPEED

Stack EGT
OIL PRESSURE
(RIFLE) (Cylinder
TURBO TURBO Cooling
REAR S S Water
Stack EGT Level)

Lube oil
Pressure Cylinder
RB8 RB 1 Water
Outlet
EGT x 16 Right Bank Temp
Engine Speed Oil Pressure Oil Pressure
(Post Filter - (Pre Filter - Lube
Lube Filter Head) Filter Head) Cylinder water
CUSTOMER PROVIDED inlet pressure
Start Air Pressure

INTAKE AIR TEMP INTAKE AIR TEMP

 Sensor Locations

After Cooler Water Inlet Temperature Sensor

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 Sensor Locations

Fuel Filter Outlet Pressure and Differential pressure sensors

Sensor mounting location on three way manifold block

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 Sensor Locations
Lube Oil Pressure Sensors
Sensors mounted on the Danfoss manifold block are:
1. Lube Oil Pressure Sensor - Connected to ECM
2. Low lube oil pressure LSR (low speed range) switch – Safety System
3. Low lube oil pressure HSR (high speed range) switch – Safety System
4. Lube oil pressure sensor – Alarm System

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 Sensor Locations

Lube Oil Filter Differential Pressure Sensors

Connected to the Alarm System

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 Sensor Locations
Cylinder Cooling Water Sensors
1. Pressure Sensor –Alarm System
2. Pressure Switch – Safety System
3. Temperature Switch – Safety System
4. Temperature Sensor – Alarm System

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 Sensor Locations
Intake Manifold Temperature Sensors
One sensor mounted in each intake manifold as follows:
• Left Front - ECM
• Left Rear, Right Front, and Right Rear - Alarm System

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 Sensor Locations
16 Individual Cylinder Exhaust Gas Temperature sensors
– Connected to Alarm System

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 Sensor Locations
Exhaust Gas Stack Temperature – Alarm System
Two exhaust gas temperature sensors one for each bank.

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 Sensor Locations
Three Engine Speed Sensors
One sensor provided for each system:
E – ECM
A – Alarm
S – Safety

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 Sensor Locations
Starter Air Pressure (Customer Provided)
Starter air line comes to engine as shown below, but shipyard likely will
have a sensor mounted near air bottles and will need to provide a feedback
signal (Assumed to be a switch contact or 4-20 mA signal).

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 Alarm and Safety Systems
Practical exercise in workshop

• Locating and identifying Safety System components

• Tracing wiring harness

• Visual inspection of system

• Fault finding and Diagnosis of System

• Settings and validation of

Safety system switches.

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Alarm and Safety Systems