DYNAMIC POSITIONING CONFERENCE

October 13-14, 2015

THRUSTERS

Preventative Maintenance Methods for Heavy Duty

Azimuth Thrusters

Frank Zeller
Schottel
Preventive maintenance methods for
heavy duty azimuth thrusters

Frank Zeller October 2015

DYNAMIC POSITIONING

YOUR PROPULSION EXPERTS 2

CONTENT

 General influences
 Wear and tear
 Preventive actions
 Preventive maintenance
 Condition monitoring
 Typical applications
 Example from field
 Summary

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GENERAL INFLUENCES

Harsh Weathers Calm Weathers

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GENERAL INFLUENCES

steering forces
corrosion

structural fatigue
hydrodynamic
loads vibration

foreign object operational loads

damage
engine loads

grounding thermal cycles

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WEAR AND TEAR
Simplified Explanation
New
Normal wear

Start of minor failures

reliability
Thruster

Start of major failures

Near to Breakdown

Life time

BREAKDOWN

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WEAR AND TEAR

Unnoticeable
Condition Change
New
Normal wear
Measurable Increase
of Vibration/Pressure/ Start of minor failures
Temperature
reliability
Thruster

Perceptible Increase
of Vibration/Pressure/
Temperature Start of major failures

Near to Breakdown

BREAKDOWN
Years/Month  Month/Weeks  Weeks/Days

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WEAR AND TEAR
Influence of operation conditions and maintenance

Normal wear

Start of minor failures

Degradation

Start of major failures

Near to BreakDown

X? BREAKDOWN Y?

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PREVENTIVE ACTIONS
Different Operation Modes (e.g. PSV HAVILA AURORA)

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PREVENTIVE ACTIONS

Operation Modes „Precision“ vs. „Relax“

Linear
Thrust Variation

Exponential
Variation

Dislocation

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PREVENTIVE ACTIONS
Depending on the selected operation
modes the wear and tear will be influenced: RPM
HP-Mode
(High Precision Mode (HP)/Ecomomical Mode (E))
Torque
RPM:
HP larger range & more cycles Steering
E smaller range & less cycles
(same period, same sea state)
Torque:
HP larger range & higher torque
E smaller range & lower toque 11

Steering:
HP larger range & more cycles
E smaller range & less cycles E-Mode

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PREVENTIVE ACTIONS

M
Design of bearing arrangements
Ma
ML2 Servicefactor (SF) Load distribution Load distribution
Mn
ML3

The bearing service life is determined on the basis of the

individual application load conditions, defined by the service
factor or an individual load spectra.

 Considers the inner geometry of the bearing Complies with

 Bearing clearance
 Change of clearance through thermal effects ISO 281 / 16281 Dynamic load ratings and rating life
 Change of clearance due to fits
 Displacement and tilting of the bearing due to deformation of ISO 15312 Thermal speed rating
shafting/housing
 Lubrication system DIN 732 Thermally safe operating speed
 Lubricants and impurity

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PREVENTIVE MAINTENANCE

Scheduled Maintenances

Normal wear
Proactive
Maintenance Start of minor failures
Degradation

Minor
Repairs

Major
Repairs Start of major failures

Near to BreakDown

Thruster Lifetime

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PREVENTIVE MAINTENANCE
Preventive Maintenance
Measure and analyze vibration, SCHOTTEL Data
pressure, temperature, signals, compare New
Normal wear
alarms and liquids Service Data
Start of minor failures

+ Experience
reliability
Thruster

Unnoticeable
Condition Change
Start of major failures
Real Condition
Prognosis
Optimized
Near to BreakDown
Planning

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CONDITION MONITORING

Diagnostic System „S-COM“

S-COM
SRP 9000 LSU Parameters (SCHOTTEL Condition Monitoring)

 Temperature
 Vibration
 Saturation of water in oil
 Particle in oil
 Thruster speed
 Thruster steering angles

Independent system
No connection and influence
at thruster control

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CONDITION MONITORING

Necessary components of an underwater mountable unit

SRP 9000 LSU

water saturation
lubrication
monitoring display
speed pick-up

particle sensor

acceleration sensor

S-COM switch box

power train hydraulic temperature sensor

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CONDITION MONITORING

Schematic of system:

Firewall
galvanic isolated
Internet
switch box
S-COM
steering
switch box

Control parameters

S-COM
switch box terminal
prime mover box

Temperature, water saturation, particle count,

speed sensors Acceleration sensors

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CONDITION MONITORING

Examples for monitored parameters e.g. water saturation in oil:

SRP 9000 LSU

water saturation

speed pick-up

e.g. time signal acceleration at specific rpm:

particle sensor x,y,z-axis z-axis

acceleration sensor

temperature sensor
power train

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CONDITION MONITORING

Detection of bearing defects:

Each roller bearing has specific defect frequencies depending on the geometry

race
frequency

signal preparation in S-COM Identification

of typical
defect
frequencies
(outer race frequency)

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CONDITION MONITORING

Development of bearing defects

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CONDITION MONITORING

Vessel Data Connection Data Transfer SCHOTTEL

S-COM V-SAT Server
on board E-Mail
(Satellite) S-COM
Ship Server,…
FTP
Analysis
3G E-Mail Automatic 24/7 event
(Cell-Phone) support
UMTS, HSDPA,… FTP
Periodic Report
Manually E-Mail
USB-Stick

Operator
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CONDITION MONITORING

Monitoring Report:
Content:

General project data

Status overview
Summary
Log Book
Maintenance proposal

Issued:

Periodical reports
(e.g. every 3, 6, 12 months)
On request by customer
Automatic event reporting when
the “alarm” level was reached

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TYPICAL APPLICATIONS

RIVERCRUISER VIKING DOUBLE-ENDED FERRY BERGENSFJORD

4 x SCHOTTEL STP 200 FP 4 x SCHOTTEL Combi Drive Type SCD 2020

128 T BP OFFSHORE TUG LUZ DE MAR PSV BOURBON MISTRAL

2 x SCHOTTEL Rudder Propeller Type SRP 3040 CP 2 x SCHOTTEL Combi Drive Type SCD 2020

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EXAMPLE FROM THE FIELD
PSV vessel with S-COM operating in
the Gulf of Guinea, next Benin
 S-COM detected bearing failure at
upper gear box
 Customer contacted and repair
solution agreed
 Service engineer sent with spares
for the exchange of the failed
bearing S-COM
 Job done within few days Monitoring
Center

Google Maps - © 2013 Google

© George Saunders

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SUMMARY

Current situation:

 Maintenance in regular
 Dismantling even if not required
fixed intervals

 Short-term planning of docking times

 Unexpected repair and
downtime in case of damage  Short-term, unexpected staff assignment
 Loss of job or business

unexpected

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SUMMARY

Situation with S-COM:

 Condition based maintenance  Dismantling in case of indication of

wear / damages
 Early detection of damages
 Running systems are not touched
 improved planning of dockings, better
coordination
earlier degradation
 short ‘off hire’ period for customers

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SUMMARY
Situation with S-COM:
 advance warning to avoid
emergencies
 specific maintenance
recommendation or repair advices
 scheduled docking
YOUR PROPULSION EXPERTS
 Increased knowledge of operating
conditions due to data recording
(speed, load, steering angle, etc.)
 Increase of maintenance intervals
possible
less degradation longer intervals
27
THANKS !

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