9 - PMI & EDS (January 2010) PDF

MAN Diesel PrimeServ Academy
PMI & CoCoS-EDS Applications
e n
a g
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Co
y
d em
c a
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e rv
e S
Prim
ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 <1>
PMI system – purpose
e n
a g
n h
p e
Co
y
d em
c a
- A The purpose is to follow alterations in:
e rv the combustion conditions,
S
the general cylinder condition,
e the general engine condition
rim
in order to discover any operational
P disturbances.
ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

ME PMI
e n
Observations:
a g
n h
e
Engines poorly balanced, often outside recommended deviation limits
o p
Engines operated with low Pmax level
y C
Result:
d em
c a
Increased fuel oil consumption & CO2 emissions
- A
rv
1 bar increase in average Pmax => 0.20 - 0.30 g/kWh decrease in fuel oil consumption
S e
e
rim
Action:
P Adjust engine continuously to best operating conditions

PMI system – ensures
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S To ensures Emissions according
rim
Technical File with:
P specified components
>specified Performance<

PMI system – design
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
Prim
PMI offline
e n
a g
h
Pressure transducer
PMI controller
e n
o p
y C
Power
supply
em
Engine
control
room
c ad
- A
e rv
e S
rim
LED
indicator
P Intermediate
Or frequency
divider box
Crankshaft pickup
mounted at free end
of crankshaft
Two-stroke diesel engine

PMI – Cylinder Pressure Analyser
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
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Prim
PMI
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a g
n h
p e
Co
y
d em
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- A
e rv
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Prim
PT diagram
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a g
n h
p e
Co
y
d em
c a
- A
e rv
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Prim
PT diagram - zoomed
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
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Prim
PV diagram
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
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Balanced plot, Pmax - Pcomp
e n
P,comp tuning is
a g
done by entering
h
a Compression
e n Ratio Offset:
op C,Ratio=P,Comp / P,Scav.
y C C,Ratio Offset =
em
-1,1 / 3,62 = -0,3
d
1,1bar
a
(Reading from
- A c P.scav sensor is
corrected to
rv
Absolute value
S e by adding
e
athmospheric
rim
-2,5bar pressure, 1 bar)
P P,Max. Tuning is
done by entering
an offset
directely in bar

Balanced plot, Pi
e n
a g
n h
p e
Co
y
em
P(i) tuning:
c ad Offset (High)Load
A
(+0,27/19,1)x100%
rv - =1,4%
e
-0,27 bar
e S
rim
19,1 bar
P
Calculated values
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
Prim High Load
(MCR 6S70ME-C7: 18.660 kW)

Fuel index adjustment
e n
a g
n h
Index offset (P,i) at High Load
e
in Percentage.
o p
y C
em
Index offset (P,i) at Low Load in
d
Percentage.
a
A demand for additional
- A c balancing when running low

load is supplied here.
e rv
e S
Prim
Adjustment of maximum pressure
e n
a
Timing of fuel injection
g
n h
(corresponding to VIT adjustment
e
on the MC engine).
o p
y C
d em
a
Tuning of P,comp is made by
- A c adding an offset to the

Compression Ratio here
e rv
e S
Prim
The PMI Online System
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e rv
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Prim
ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 18 >
PMI online – Auto tuning
e n
Reduction in Fuel oil consumption / CO2 emission
a g
n h
e
1 bar increase in average Pmax => 0.20 - 0.25 g/kWh decrease in fuel oil consumption
o p
Limit Pmax
y C
em
Potential
Potential
c ad
- A
e rv
e S
rim
Pure Pmax level increase Balancing & Pmax level increase
Potential 5-10 bar Potential additional 2-5 bar
P At full as well as part loads Gain even with engines already being
operated within recommended limits
ME Engine - (LDE4/TOM)
PMI (January 2010) © MAN Diesel 2010/01/01 < 19 >
Engine tuning process
e n
PMI Online Continuous auto tuning
a g
n h
e
Apply Apply Apply
p
Pmax Pcomp MIP Tuned
o
Semi - auto tuning Engine
Obsrv. Key
Yes
Adjustmen
y C
em
values needed?
No
d
Yes
c a
Extract
- A Identify Identify
rv
Identify
key values Pmax Pcomp MIP
e
Maihak adjust adjust adjust
e S
rim
Adjust Adjust Adjust
Retrieve Pmax Pcomp MIP
P
pressures
Manual offset adjustment
PMI Offline
PMI online 2nd generation
e n
g
Engine Control
a
Engine Room Portable
PMI/CoCoS- Room measuring unit
h
EDS PC Junction box
n
MAN Diesel
e
Junction Box
PMI DAU
p
Data Aqusition Unit
Co
y
24V
MOP B
d em To Tacho System
c a To Pscav sensor
- A
HUB
e rv Connectors
e S AMS PC
rim
*Optional
P Fixed Pressure Sensor

Up to 14 cylinders

ME PMI
Auto-tuning
e n
TCP/IP
a g
h
MOP-B PMI / CoCoS-EDS PC
e n
o p
C
Arcnet TCP/IP
y
em
MPC
d
DAU
c a
- A
Modbus
e rv
Remote I/O
e S with I/P
rim
converters
P Pmax adjustment signals MC Engine
Pmax Feedback signals

Cylinder pressure
Auto tuning: ME & MC engines
e n
a g
h
TCP/IP MOP-S
n
MOP-B (CoCoS-EDS /
e
PMI PC)
o p
Arcnet
y C TCP/IP
MPC
d em PMI DAU
c a
- A
rv
Pmax Feedback signals
e
Cylinder pressures
S
I/P converters
e
(MC only)
rim
PMI sensors
P
Actuators
Pmax adjustment signals (VIT)

MC/ME Engine

PMI online - Auto tuning
e n
g
Prototype field test of auto-tuning function
ha
ME ECS SW AutoTuning on Maersk Wizard 6S60ME-C
Bar
n
Pmax Cyl1
Manual adjust Auto-tuned Auto-tuned Adj Pmax Cyl1
e
150
150
Manual
Pmax Cyl2
p
Adj Pmax Cyl2
Offset
Forced unbalance Pmax Pmax Cyl3
o
Adj Pmax Cyl3
Pmax Cyl4
C
145
145 Adj Pmax Cyl4
AutoTuning Pmax Ballance Pmax Cyl5
y
Adj Pmax Cyl5
Pmax Cyl6
em
Adj Pmax Cyl6
140
140
Pmax
Pcomp Cyl1
Adj Pcomp Cyl1
Pcomp Cyl2
d
Adj Pcomp Cyl2
a
Pcomp Cyl3
135
135 Adj Pcomp Cyl3
c
Pressure in bar
Pcomp Cyl4
Adj Pcomp Cyl4
A
Pcomp Cyl5
-
Adj Pcomp Cyl5
rv
130
130 Pcomp Cyl6
Adj Pcomp Cyl6
Pi Cyl1
Se
Adj Pi Cyl1
Pi Cyl2
125
125 Adj Pi Cyl2
Pcomp
e
Pi Cyl3
Adj Pi Cyl3
rim
Pi Cyl4
Adj Pi Cyl4
120
120 Pi Cyl5
Adj Pi Cyl5
P
Pi Cyl6
Auto tuning applied Adj Pi Cyl6
115
115
1.39 1.4 1.41 1.42 1.43 1.44 1.45

0 100 200 300
Time i seconds 400 500 secs 4
x 10

PMI online - Auto tuning
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(ME-MOP: Layout proposal for Auto-tuning screen)
Green Ship of the Future:
Auto-tuning - Potential
e n
a g
h
 Fuel oil consumption
n
Reduction potential: 3 g/kWh
Reduction typical: ½ - 1 g/kWh
p e
Co
y
 Emission
em
potential: 2% C02 reduction
 Operation cost reduction
c ad
A
Reduced engine maintenance costs,
rv -
increased availability/reliability
S e
e
 Simplified operability
rim
Ease workload on crew
Ensures always well adjusted engine
P
e n
CoCoS - EDS
a g
n h
p e
Computer
Co
Controlled
y
Surveillance
d em
c a
Engine
- A
e
Diagnostics rv
e S
rim
System
P
CoCoS-EDS
e n
CoCoS-EDS
a g
n h
p e
Two versions available:
Co
y
 CoCoS-EDS ME Basic: Mandatory for all ME, ME-C and ME-B engines
em
 CoCoS-EDS Full version: Optional for all MAN Diesel 2-stroke engines
d
c a
- A
rv
 Both versions shares the same system software that makes monitoring, adjustment and
e
trouble shooting of the engine much more efficient.
S
e
P rim
 The main difference is the configuration of the software and the interface towards other
systems (e.g. Alarm and monitoring system AMS etc) up to 80 080
kW

CoCoS-EDS
e n
 CoCoS-EDS ME Basic:
a g
 No commissioning needed, plug ‘n’ play.
n h
p e
o
 Interface to the MAN Diesel Systems i.e. ECS and
PMI (PMI On-line or Off-line)
y C
em
 Log and display of data from the ME ECS and PMI
via MOP-B
c ad
A
 Used for condition monitoring, recording, show
rv -
trends, reporting, adjustments and trouble shooting
e
of the ME engine.
S
e
P rim up to 80 080
kW

CoCoS-EDS ME Basic Version
Home office Plant ECR E/R
e n
a g
n h
p e
o
MPC(s)
MOP-A
MOP-B
y C
em
Firewall
d
PMI On-Line or
VPN router
a
Off-Line
- A
CoCoS
c CocoS
DAU
rv
Client PC(s) PMI
S e
e
Firewall
VPN router BWM
rim
LWM
P
Terminal
Boxes / DPU
AMS

CoCoS-EDS
e n
a
 CoCoS-EDS Full version, includes all features of ME Basic version and additionally:
g
n h
 Interface to other system e.g. AMS to log cylinder exhaust gas temperatures, BWM
p e
for bearing wear monitoring, LWM for liner wear monitoring etc
Co
 Reference measurements (Model curves) for enhanced trouble shooting
y
em
performance analysis and diagnostics
c ad
 Requires commissioning by MAN Diesel service engineer
- A
e rv
e S
kW

CoCoS-EDS Full Version
Home office Plant ECR E/R
e n
a g
n h
p e
o
MPC(s)
MOP-A
MOP-B
y C
em
Firewall
d
PMI On-Line or
VPN router
a
Off-Line
- A
CoCoS
c CocoS
DAU
rv
Client PC(s) PMI
S e
e
Firewall
VPN router BWM
rim
LWM
P
Terminal
Boxes / DPU
AMS

CoCoS-EDS
e n
a g
h
Benefits:
• Increased availability and reliability of the diesel engine
e n
o
• Optimise plant performance to gain a reduction of operating costsp
y C
d em
The CoCoS-EDS will:
c a
- A
rv
• Facilitate decision making by the chief/crew/home office/ commissioning engineer to:
S e
• Prevent failures or reduce the risk of failures or allowing for earlier and appropriate
e
rim
corrective actions at earliest possible time
• Specify causes and effects in case of unusual engine behaviour
P • Provide performance analysis and reporting facilities

CoCoS-EDS
e n
a g
h
Features in CoCoS-EDS:
e n
• Data Logging
op
• Monitoring
y C
em
• Performance analysis and diagnostics
• Trend Logging
• Reporting
c ad
- A
e rv
e S
P rim
CoCoS-EDS Online Service
Ships Network (Lan)
e n
Router/Firewall
a g
h
Satellite
Switch
e n
o p
Engine Control Room
C
Satellite dish GeNuA
y
GeNuA Box PC
em
ECR
Box
c ad Converter
v - A
r
AMS ECS
Ship
S e
e
Prim Engine readings,
for the whole day,
received every night!
Office HQ
D/E

Monitoring Views - The Main Window
e n
g
Title bar Status
ha
n
Menu bar
p e
Tool bar
Co
y
d em
Engine view
c a
- A
e rv
e S
rim
Display groups
P
Status bar

Engine Overview
e n
Engine overview:
a g
 Quick overview of the data logging
n h
and diagnostic intervals for the
p e
particular engine. Displays also the
Co
availability of serial interface data
y
em
and definition of values measured.
c ad
- A
e rv
e S
kW

Standard report
e n
Standard Report:
a g
 Provides a complete listing of the
n h
latest set of operating parameters.
p e
Co
y
d em
c a
- A
e rv
e S
kW

Customisation of Standard Report
 Standard Report can
e n
a g
h
be customised in the
following way:
e n
op
C
 Tools
y
em
 Customise Display
d
Groups
 Chose desired
c a
- A
rv
fields using mouse
cursor press
S e
e
’Select’, then
rim
’Ready’
P
 A new standard
report nr. will
appear up in right
corner
Reporting, Customised reports
e n
Customized Reports:
a g
 Provides a function to create
n h
entirely new reports or edit existing
p e
report lay-outs.
Co
 Can contain live operating data
y
and/or stored “off-line data
d em
c a
- A
e rv
e S
kW

Reporting, Performance Report
e n
a g
 Example of customised
n h
p e
o
report, Performance report
y C
d em
c a
- A
e rv
e S
P rim
Reporting, Fuel consumption
e n
a g
 Example of customised
n h
p e
o
report, Fuel oil consumption
y C
d em
c a
- A
e rv
e S
P rim
Line Recorder, Data Logging
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
Prim
Line recorder, costumisation of
Display Groups
e n
g
 Line Recorder
ha
e n
 Tools  Customise
op
 Display Groups
y C
d em
c a
- A
rv
 Chose desired
e
fields using ’Shift’
S
e
and ’Ctrl’, press
rim
’Select’, then
P
’Ready’
 New group will be

added on right
Bar Charts
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
Prim
Characteristics Map
e n
a g
n h
p e
 The charts
Co
y
describes the
em
behaviour of the
d
optimal tuned
engine. Cross hear
c a
indicats current
- A
operating value
e rv
e S
P rim
Load Diagram
e n
a g
 The charts
n h
describes power
p e
and speed limits.
Co
y
Cross hear
em
indicates current
d
operating value
c a
- A
e rv
e S
P rim
Performance curves / Tables
e n
a g
h
 The vertical line shows the
current power of the engine
e n
 Use cursor to read the
op
C
corresponding values in the
y
table
em
 Provides easy means of
d
comparing current
a
performance against
c
background curves
- A
showing values when the
rv
engine was new, alternative
e
when CoCoS was installed
e S
P rim
Monitoring
e n
a g
n h
p e
Co
y
d em
c a
- A
e rv
e S
Prim
ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 50

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MAN Diesel PrimeServ Academy

PMI & CoCoS-EDS Applications

e rv the combustion conditions,

e the general engine condition

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 <6>

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01

- A c balancing when running low

- A c adding an offset to the

Manual offset adjustment

P Fixed Pressure Sensor

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 21 >

P Pmax adjustment signals MC Engine

Pmax Feedback signals

Pmax adjustment signals (VIT)

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 23 >

1.39 1.4 1.41 1.42 1.43 1.44 1.45

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 24 >

 Operation cost reduction

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 28 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 29 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 30 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 31 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 32 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 33 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 35 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 36 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 37 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 38 >

ME Engine - PMI (January 2010) © MAN Diesel 2010/01/01 < 40 >

 New group will be

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