PCMS

PROPULSION CONDITION MONITORING SERVICE

Total Lifecycle Costing in Shipping

Optimizing Value by (remote) monitoring
December 10th 2010

1 Wrtsil Propulsion Condition Monitoring Service F.J. Velthuis

 Wrtsil Monitoring Facts

Remote monitoring (live or via E-mail):

Wrtsil monitors over 1100 engines in over 300 installations.
Wrtsil is delivering PCMS for 40+ thrusters just 3 months after
product release.

Wrtsils monitoring mission:

Predict 90% of failure cases 2-6 months before they occur.
Predict 90% of critical failures 7-30 days before they occur.

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2 Wrtsil Condition Monitoring System Product Introduction
 Presentation Contents

Benefits Overview Analysis

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3 Wrtsil Propulsion Condition Monitoring Service
 What does it offer?

Propulsion Condition Monitoring Service (PCMS)

Provides the customer with real-time advise and monthly analysis

reports about the condition of his machinery.

PCMS monitors:
Vibrations
Hydraulic pressures
Lubrication oil temperatures
Lubrication oil contamination
Lubrication oil-water saturation
System parameters
Torsion Vibration
Sensory readings
Dynamic behavior Nautical information
System parameters
Nautical information

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4 Wrtsil Propulsion Condition Monitoring Service
 Your Benefits

Benefits of the Propulsion Condition Monitoring Service (PCMS)

Known machinery condition

Better risk assessment and evaluation
Solid base for operational decisions
Enables dynamic maintenance scheduling
Faults detected before breakdown
Reduced risk of consecutive damage
Optimized maintenance logistics and planning
Periodic internal inspection of thrusters no longer required
Total cost of ownership reduced
Analysis by propulsion experts certified in vibration analysis

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5 Wrtsil Propulsion Condition Monitoring Service
6
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 Overview Controllable Pitch Propeller

SATELLITE
COMMUNICATION

TORQUE PCMS
MEASUREMENT ADVISORY
CONTROL SYSTEM MONITOR
SYSTEM
PARAMETERS

PITCHING
PCMS HYDRAULIC
PROCESSING PRESSURES
UNIT

ACCELEROMETERS
NAUTICAL EXTERNAL
INFORMATION LUB. OIL
CONTAMINATION
WATER SATURATION
TEMPERATURE

Also available for STT, WJ, TT, EP and GB.

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7 Wrtsil Propulsion Condition Monitoring Service
 Overview Steerable Thruster
LUB. OIL
CONTAMINATION
WATER SATURATION PITCHING
SATELLITE TEMPERATURE HYDRAULIC
COMMUNICATION PRESSURES

PCMS
ADVISORY STEERING
MONITOR HYDRAULIC
PRESSURES

ACCELEROMETERS
EXTERNAL

PCMS
PROCESSING
UNIT

NAUTICAL
CONTROL INFORMATION
SYSTEM
PARAMETERS ACCELEROMETERS IN
THRUSTER

Also available for CPP, WJ, TT, EP and GB.

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8 Wrtsil Propulsion Condition Monitoring Service
 Real-time feedback

PCMS Advisory Monitor

Operator is immediately informed incase of irregularities and

advised on how to handle these.

Real-time feedback is received from over 200 preprogrammed

states. Custom states can be added upon operators request.

The PCMS Advisory Monitor shows:

real-time values / operating condition
trend values
advisory messages

Any vessels computer connected to ship network can run the

PCMS Advisory Monitor application.

Standard an integrated panel is included on the bridge or in the

engine control room.

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9 Wrtsil Propulsion Condition Monitoring Service
 Analysis by propulsion experts

Data analysis service build on extensive propulsion knowledge

Data is analyzed by corresponding Wrtsil propulsion experts

certified (ISO 18436-3) in vibration analysis.

Automated analysis algorithms systematically process all data to

ensure that no event is missed.

The automated analysis algorithms use:

- Advanced state detection on data from multiple sources
- Spectrum (FFT) peak recognition
- Spectrum pattern recognition
- Cepstrum analysis

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 Is that ok?

Advanced state detection: critical manoeuvres

When the vessel is sailing full speed ahead a large steering

angle is given to the thrusters. At maximum drift angle this leads
to considerable vibrations on the portside thruster.

The PCMS Advisory Monitor reports:

The vibration level of the portside thruster has risen because a
large steering angle was set at high vessel speed. Please reduce
steering angle or vessel speed for this manoeuvre.

And:
A high vibration level has been detected on the portside thruster.
An increased vibration level can be related to severe operating
conditions and sometimes to mechanical defects. A level
between 4.5 and 11.2 mm/s (10-1000Hz) is still acceptable but
improvement is desirable.

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11 Wrtsil Propulsion Condition Monitoring Service
 Rumble

Vibration Analysis: Example Bearing inner race fault

The automated analysis algorithms that analyze frequency

spectra have detected a fault. There is a peak at the BPFI (Ball
pass frequency inner) of one of the bearings at the propeller
shaft.

Pattern recognition confirms a bearing inner race fault as side

bands are detected at shaft frequency (1X). (In some
configurations BPFO faults are of the same frequency.)

Given the intensity of the vibrations and the near absence of

repetition at higher harmonics bearing inner race fault of stage
2 of 6 is reported to the operator. Propulsion expert will monitor
development of the fault closely. The failure mechanism may
take anywhere from several weeks to several months, small
faults may even disappear wholly.

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 TIFF

Vibration Analysis: Tooth-Interior-Fatigue-Fracture

A Tooth-Interior-Fatigue-Fracture (TIFF) is a
fatigue crack that is initiated at the interior of
the tooth. TIFF is mostly observed at case-
hardened idlers, where teeth are loaded at
both sides during a revolution. For thrusters
TIFF can be related to excessive ventilation or
wind milling.

The picture on the right shows a trend of the

vibration intensity at the frequencies related to
tooth wear.

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13 Wrtsil Propulsion Condition Monitoring Service
 Trends

Vibration Analysis: Frequency Spectrum Matrix (FSM)

To accurately analyze trends in frequency spectra comparison

should only be made between spectra that are measured under
the same operating condition. Single Condition

The operating condition of propulsion equipment is determined

by multiple parameters. For a steerable thruster these are load,
pitch and RPM. PCMS uses a multi-dimensional matrix of
configurable size that defines the operating condition. Thereby
ensuring that a correct comparison is always made.

Note that many condition monitoring systems only measure

Pitch RPM
RPM and vibrations, which can lead to misperceptions, faulty
conclusions and loss of valuable information.

Schematic Frequency Spectrum Matrix

actual size not 4x4x4 but 50x50x20 (configurable)

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 Dirty oil

Continuous oil monitoring

PCMS continuously monitors oil contamination and oil-water

saturation.

A rapid increase in the oil contamination levels indicates that a

mechanical failure has occurred. For example, a progressing
bearing fault will start to give off large quantities of metal particles
from stage 5 of 6.

An increasing oil-water saturation level can indicate leakage in

the oil cooler or the sealing systems.

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 What else can be detected?

ROLLER BEARING WEAR / DAMAGE OIL CONTAMINATION

COCKED ROLLER BEARINGS SEAL LEAKAGE
SLEWING BEARING WEAR / DAMAGE
GEAR WEAR / DAMAGE REDUCED PITCHING PERFORMANCE
BLADE EROSION / DAMAGE REDUCED STEERING PERFORMANCE
REDUCED PUMP PRESSURES
TORSION VIBRATIONS STEERING MOTOR LEAKAGE
RESONANCE COUNTER BALANCE VALVE MALFUNCTION

RAPID LOAD CHANGES REDUCED PROPULSION EFFICIENCY

RAPID TORQUE CHANGES CRITICAL MANOEUVRES

LOOSENESS E-MOTOR ECCENTRIC ROTOR

ANGULAR MISALIGNMENT E-MOTOR ROTOR WARP
PARALLEL MISALIGNMENT E-MOTOR CRACKED ROTOR BARS
COUPLE IMBALANCE E-MOTOR LOOSE ROTOR BARS
STATIC IMBALANCE E-MOTOR LOOSE ROTOR
ECCENTRICITY E-MOTOR LOOSE CONNECTIONS
E-MOTOR LAMINATION PROBLEMS
CAVITATION
FLOW TURBULENCE ETC
WIND MILLING
VENTILATION

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 Applicable to

Applicability of the Propulsion Condition Monitoring Service (PCMS)

PCMS has been developed for:

Steerable thrusters
Transverse thrusters
Controllable pitch propellers
Electric pods
Water jets
Gear boxes

Not restricted to Wrtsil equipment.

Analysis is always carried out by the

corresponding propulsion experts.

For more info contact your Wrtsil

sales representative.

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17 Wrtsil Propulsion Condition Monitoring Service