/ 10 / 5-Jun-08

Diesel engine bearing monitoring

/ 11 / 5-Jun-08

Kongsberg MaritimeWhy Bearing Monitoring?

Facts about 4-stroke diesel engine seizures:• Approx. 30% of all seizures reported to classification societies

relate to bearings• More than 50% of all bearing seizures occur shortly after major

overhauls or maintenance work

Facts about 2-stroke diesel engine seizures:• Approx. 20% of all seizures reported to classification societies

relate to bearings • Approx. 70% of all bearing seizures happen shortly after overhaul

or open-up inspections

Oil Mist Detection does not protect engine components from seizuresAn extension of Bearing Open-Up Intervals is expected

/ 12 / 5-Jun-08

Kongsberg MaritimeDiesel engine seizure statistics

MEDIUM SPEED MAIN ENGINE DAMAGES

0 2 4 6 8 10 12 14 16 18 20

Others

Connecting rod upper bearing

Cylinder cover & valves

Fuel pump, camshaft & drives

Cylinder liner

Cylinderblock, frame & bedplate

Turbo charger

Piston

Crank Bearing & Pin

Main Bearing & Journal

Percentage of all damages

Based on statistics from Det Norske Veritas in the period from 1990 to 1996

/ 13 / 5-Jun-08

Kongsberg MaritimeDiesel engine seizure statistics

Slow speed engines damages

0 5 10 15 20 25

Others

Main Bearing & Journal

Crank Bearing & Pin

Fuel pump, camshaft & drives

Crosshead bearing & guides

Cylinder cover & valves

Cylinder liner

Cylinderblock, frame & bedplate

Piston

Turbo charger

Percentage of all damages

Based on statistics from Det Norske Veritas in the period from 1990 to 1996

/ 14 / 5-Jun-08

Kongsberg MaritimeEngine protection

Crank Case ProtectionBearing Temperature Monitoring:

Monitoring of crank-, main-and crosshead bearingsFeasible for all 2- and 4-stroke enginesReplacing Oil-Mist Detection (OMD)

Extension of Bearing Open-Up Intervals Bearing Wear Monitoring:

Providing wear data from any of the three crank-train bearingsFeasible for all 2-stroke enginesExtending open up inspections

/ 15 / 5-Jun-08

Kongsberg MaritimeOil Mist Detector vs. temperature monitoring

Main BearingTemperature

Oil Mist

Cu

ttin

g t

he o

il s

up

ply

Cu

ttin

g t

he o

il s

up

ply

Alarm limitAlarm limit

Ala

rm f

rom

oil m

ist

Ala

rm f

rom

oil m

ist

Ala

rm f

rom

tem

pera

ture

sen

sor

Ala

rm f

rom

tem

pera

ture

sen

sor

Abstracts from report made by Abstracts from report made by D.ParoD.Paro, G. , G. LiljenfeldtLiljenfeldt, T. , T. BlombergBlomberg, , WârtsiläWârtsilä

1 2 3 4 5 ( Min )

( oC )

400

300

200

100

/ 16 / 5-Jun-08

Kongsberg MaritimeMAN Diesel - Engine design update

MAN Diesel - new monitoring standard• All vessels having ME-C, MC & MC-C engines

(bore 46 cm and above) ordered after 1. March 2008, have bearing wear monitoring system (BWM) as standard

• For engines not covered by BWM, main bearing temperature sensors will be standard

• All MAN Diesel two-stroke engines will have “Water in Oil” (WiO) sensors as standard

/ 17 / 5-Jun-08

Kongsberg MaritimeMAN Diesel - Engine design update

MAN Diesel - new monitoring standard• Intended effect is to prevent damage of

crankshaft and bedplate in case of severe bearing failures

• Over time the intention is to accept fewer open-up inspections during service of engines equipped with BWM (when accepted by class societies)

• Signal processing and alarm handling is specified by MAN Diesel

• BWM system must be connected to alarm-and to safety system

/ 18 / 5-Jun-08

Kongsberg MaritimeBearing monitoring - Summary

Recommended for 4-stroke engines:• Temperature sensors on main-

and crank (big-end) bearing

Recommended for 2-stroke engines:• Temperature sensors on crosshead-, crank-

and main bearings• Bearing Wear Monitoring (BWM)• Combinations of Bearing Wear- and

Temperature Monitoring• Water in Oil sensor

/ 28 / 5-Jun-08

Bearing Wear Monitoring System

/ 29 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring

Monitors the actual combined wear of the main-, crank- and crosshead bearings

Can be fitted in both MAN Diesel- and Wärtsilä two-stroke engines

Two sensors installed per cylinder (fore and aft)

Measures how far down the crosshead guide shoe comes in Bottom Dead Center (BDC)

MAN Diesel has recently decided to standardize on Bearing Wear Monitoring on several engine designs

Crank bearing Main bearing

Crossheadbearing

/ 30 / 5-Jun-08 30© KONGSBERG 5. juni 2008

Kongsberg MaritimeBearing Wear Monitoring

Can bus segment A / 24 V DC

CYL.1CYL.2

ENGINE WALL

INSIDE ENGINE CRANKCASE

AFT

FOR

E

FOR

E

Can bus segment B / 24 V DC

AFT

CYL.4

AFT

FOR

E

CYL.7

AFT

FOR

E

CYL.6

AFT

FOR

E

CYL.5

AFT

FOR

E

CYL.3

AFT

FOR

E

CYL.8

AFT

FOR

E

10

2 3 4

7

9

8

7

UX-808

UX-808

UX-788

UX

-788

1

2 sensors one fore and one aft in each cylinder

Measuring at bottom dead center (BDC)

Sensors between cylinders are connectedon same CAN cable

System split into two segment for safety

/ 31 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: Standard features

• Field bus (CAN Open) sensor output• Fully integrated with Kongsberg

automation system (AMS)• Signal processing performed inside

sensor • Measures bearing wear and splash oil

temperature• Individual sensor compensation for

• Engine speed/load• Ambient temperature inside crank

case• External mechanical influences caused

by manoeuvring etc.

785 .0134

1.15

1.65

2.8

/ 32 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: Operator Station Mimic

• Sensor data is collected via the CAN field bus network

• Data viewed and stored in the operator station

• Trend data reports are generated to document the bearing integrity

/ 33 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: Simple Installation

/ 34 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: MAN Diesel 12K98MC

/ 35 / 5-Jun-08

Kongsberg MaritimeBearing Wear data from large container Vessel

• Vessel turns into the Read Sea• Bearing Wear raw data values changes• What happens?

/ 36 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: REFIT – “no problem”

Kongsberg Maritime can do refit installations of complete bearing monitoring packages without interfering with the vessel schedule

/ 37 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring: References (March 2008)

Seapartner AB (Sweden)

1 vessel MAN Diesel 12L45GFMatson Navigation (USA)

3 vessels MAN Diesel 8K80MC-C

1 vessel MAN Diesel 8L80MCDalian Maritime University (China)

1 vessel MAN Diesel 6S35MC-CCosta Mare (Greece)

5 vessels MAN Diesel 12K98MCPasha Hawaii Transport Lines LLC

1 vessels MAN Diesel 7S50MC-C Jean AnnConocoPhillips Company

1 vessels MAN Diesel 7S50MC-C EndeavourMitsui ship yard

4 vessels MAN Diesel 12K98MC-C

/ 38 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring - Stand alone installation

/ 39 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring - K-Chief 500 integration

K-Chief Integration

/ 40 / 5-Jun-08

Kongsberg MaritimeBearing Wear Monitoring - Topology add-on systems

Cylinder Liner

Main Bearing

Crosshead

OperatorStation

E.C. room

Engine room

Crank Bearing

Bearing Wear

/ 41 / 5-Jun-08

Kongsberg MaritimeBenefits of k-Chief integration

• One supplier of all automation equipment onboard, thus:•All existing process data available on one screen •Easy to compare and evaluate data from several process segments/sources (better system overview)

•Higher degree of communication redundancy (dual CAN)•Fewer system components and fewer system layers •Local time stamping follows the data all the way thru•All process data available on the administrative network•Common infrastructure, less spare parts necessary on stock •Single point of contact for service

• All together: Improved decision support