Condition Monitoring of Diesel Generators

Condition Monitoring Wartsila India Ltd
Condition Monitoring
Diesel Generators
by V Pramodkumar
Why??
Optimum Utilization of DG Set

Maximum availability of Machine
Reliable Operation
Change in Maintenance concept
Improve MTBF
Effects if DG sets are not monitored
Monitory Loss (Fuel Consumption Increase)
Diff. Pr. across C A Coolers. 200-400mm H2O

" +2g/kWh with increase of every 100mm H2o
C. W. temp. before eng. 45 Deg.C at 100% Load

" +3g/kWh with every 10 Deg.C rise in temp.
Exhaust Gas back pr. after the T/c 300mm H2o

" +2g/kWh with increase of every 100mm H2o
Effects if DG sets are not monitored
Reliability of Machine
Engine Block Blow Off

" If excess crankcase pressure unnoticed
Valve Burning- Consequential Damage to

Turbochargers
" If Exhaust Temperature are not monitored
Crankshaft Seizure
" If bearing temperatures are not monitored
" Or Lube oil pressure/temperature is not monitored
Critical Parameters To be Monitored
Exhaust Temperature
" Before and After Turbochargers
" Individual Cylinder
Bearing Temperature
" Main Bearing
" Big End Bearing
Cooling Water System
" Cooling Water Temperature
" Cooling Water Pressure
Critical Parameters To be Monitored
Fuel System
" Fuel Pump Rack Positions ( larger machines)
" Fuel Oil Pressure/Temperature
" Differential Pressure Across Fuel Filters
Charge Air System
" Charge Air temperature/ Pressure
" Safety Air Pressure
" Differential Pressure Across Air Filters/Coolers
Lube Oil System
" Lube Oil Pressure/Temperature
" Lube Oil Volume
" Crankcase Pressure
" Differential Pressure across Lube Oil Filters
ALARMS AND LIMITS
Just installation of monitoring devices

does not ensure safety of equipments
Devices should alert operator
Alarm must appear at trigger point
Should stop the machine on critical values

Typical Monitoring devices with
safety features
• Lube oil Pressure Alarm/Stop

• Lube Oil Temperature Alarm/Stop
• Exhaust Temperature Alarm/Stop
• Cooling water temperature Alarm/Stop
• Engine Over speed Alarm/Stop
• Charge Air Temperature Alarm/Stop
Typical Monitoring devices with
safety features
Differential Pressure Alarm

Across air coolers
Turbochargers Over speed Alarm
Crankcase Pressure Alarm/Stop
Pre Lube oil Pressure Alarm
Over current Stop
Under/Over Frequency Stop
Monitoring devices for Diesel Generator Set
• Temperature Sensor/Switch
• Pressure Transducer/Switch
• Cylinder Pressure Indicator
• Pressure and Temperature Gauge
• Speed Sensors
• Power Monitoring Unit
• Thermocouples
Latest Monitoring devices for Diesel Generator Set
• Continuous Measurement of Water in Lube Oil

• Crankcase Pressure Monitoring System
• Continuous Oil Level Monitor
• Wireless big end bearing temperature
• monitoring
• CBM
Water Transducer
A Continuous Measurement
of Water in Lube Oil
Condition
Benefits Monitoring Wartsila India Ltd
Follow up of trends and historitic data

Indicates the margin to water saturation i.e. free
water formation.
On-line and continuous measurement.
Easy to install
The measurement remains proportional to the water
saturation level of the oil, independent of type,
ageing and temperature of the oil.
Works with all kind of oil systems
How can we monitor the crankcase environment ?
Manual Pressure Measurement

Oil Mist Detector
To enhance the safety, the new product is;

Crankcase Pressure Monitoring System
Oil level is monitored manually

2 - 4 times per day depending on the routine
The alternative is
Continuous Oil Level Monitor

The system is based reliable

strain gauge principle i. e
weighting of the cylinder no
moving parts
• High measuring accuracy ± 1mm

• No moving parts
• Ready calibrated at factory
• Easy and fast installation
• Can be connected to any existing
alarm and monitoring system
• Reliable strain gauge principle
• Standard current and voltage

output
•To have alarms on any kind of
level
• Automatic filling of lub oil
• Detect abnormalities in the lub oil
system
• Full control of S. L. O. C
What is one of the most serious breakdown scenarios ?
Big End Bearing Failure and in many cases the

consequential damage such as engine block and/ or
crankshaft
Faster and more accurate

monitoring of the sensitive
part i. e measure the
bearing temperature
WIRELESS BIG END

BEARING TEMPERATURE
MONITORING
CBM
Condition Based Maintenance
Reliable and Economical Diesel Engine
application operation
Condition Monitoring Benefits of CBM
CBM
Reduced operating costs
- Reduced fuel consumption
- Reduced maintenance cost
- Increased component life time
Reduced number of unplanned stops
Reduced number of failure’s
Improved maintenance planning
Improved follow up of the installation condition

If we can measure
and analyze the application
we have the control !
Condition Monitoring Communication
Owner /Operator office Local Wärtsilä office
The installation Wärtsilä

Moni- CBM
toring
Report
Wärtsilä
Data transfer
database
CBM - Condition Based Maintenance
The Wärtsilä CBM solution is in fact

a combination of
Condition Based Operation
and
Condition Based Maintenance
CBM
The Wärtsilä CBM solution is based on the use of the installed and
available equipment
On line or Daily monitoring and analyzing of the measured operation
data
- Control and monitoring systems

- Pressure measurements
- Temperature measurements
- Speed measurements
- Load measure measurement
- Vibrations (when available)
- Communication technologies
- Etc
CBM - Operation - Data - Analyzer
Mathematical models for calculating the ideal operation

parameters for the installations.
A dynamic system considering:
- Engine specification, installation type and
configuration
- Ambient conditions
- Design criteria
- Installation specific data
- etc
CBM - Operation - Data - Analyzer

Mathematical models for calculating the ideal operation
parameters for the installations and predictions for the
future.
One should know how changing in the operation

conditions are having influence on all other parameters
Example
-Change in air inlet temperature > changed TC speed >
changed receiver pressure > changed peak pressure > changed
exhaust gas temperatures > waste gate / by-pass valve position >
changed fuel consumption > changed emissions etc
CBM Monitored Optimal time
deteriorating for
rate maintenance
Condition
border
level
Anticipated
deteriorating
Scheduled stop
rate
Scheduled
maintenance
CBM C h a rg e a ir p re s s u re a fte r c o o le r bar 1 ,6 2 ,1 1 ,9
C h a rg e a ir te m p . a fte r c o o le r °C 60 57 48
C h a rg e a ir p re s s u re d iffe re n c e o v e r c o o le r A Pa 39 44 0
C h a rg e a ir p re s s u re d iffe re n c e o v e r c o o le r B Pa 60 44 0
T u rb o c h a rg e r s p e e d A rp m 18222 18856 18056
T u rb o c h a rg e r s p e e d B rp m 18187 18856 18056
E xh a u s t g a s te m p . A 1 °C 406 364 294
E xh a u s t g a s te m p . B 1 °C 396 364 294
E xh a u s t g a s te m p . b e fo re tu rb o c h a rg e r A °C 514 464 394
E xh a u s t g a s te m p . b e fo re tu rb o c h a rg e r B °C 481 464 394
E xh a u s t g a s te m p . a fte r tu rb o c h a rg e r A °C 394 354 314
E xh a u s t g a s te m p . a fte r tu rb o c h a rg e r B °C 383 354 314
M a in b e a rin g te m p ./B e a rin g 0 °C 78 91 73
When we have the control of the

application we get the best
performance from the installed
equipment !
When we have the control we can

make the savings !
According to several
Operating
insurance companies
costs
and other investigations,

CBM savings as much as 60% to 80%
of the claims are because
CBM cost
of human mistakes!
The information was
available but the actions
Traditional CBM was not taken
Operating
The biggest savings are

costs
on the reduced fuel

CBM savings
consumption
CBM cost
in average 5 - 10 g / kWh
(2-5%) during the life
time cycle of the
application
Traditional CBM
Operating
Reduced maintenance
costs
cost by making the

CBM savings
correct maintenance
CBM cost at the correct time
in the range of 5 – 20%
saving
Traditional CBM
Operating
Improved reliability by
costs
expert analyzing / follow

CBM savings
up and regular feed
CBM cost back including
predictions and
recommendations
Traditional CBM
Custoimised CBM reports based on your specification
8Different level reports

8Top Management reports
8Middle Management level Report
8Operator level report
8Performance report
8Fuel consumption
8Operation data evaluation
8Heat recovery
8Comments/suggestions
8Environmental report
8Emission-calculations
8Technical report
8Coming maintenance
8Trends / Alarm analyze
8Comments/suggestion
Condition Monitoring Analyzing
Operation data out of limits (engine/month)
4,00
Start statistics
Average amount / running day
3,50
140
3,00 18
16 13
120
2,50
7 1
7
1,92 3,20
Total number of start attempts

2,00 2,00 15
100 7 7
2 4
2,00 16 7
1,50
16
80
1,00 0
1,08 1,00 60 122 117

0,50 116
0,75 109 108
0,50 104
96 96 95 93 95
0,00 0,00 91
0,00 87
1.5.2003 - 31.5.2003 91246 1.6.2003 - 30.6.2003 91246 1.7.2003 - 31.7.2003 91246
40 74 72
1.8.2003 - 31.8.2003 91246 1.9.2003 - 30.9.2003 91246 1.10.2003 - 31.10.2003 91246
days: 24 days: 3 days: 1 days: 25 days: 20 days: 10
Engine and period

20 1
18
Action Alert Advent ure of t he Seas 0
1
0
Successful starts Failed starts Advent ure
Total electrical production
12000
E n g in e 1 s p e c if ic f u e l c o n s u m p tio n a n d lo a d
Electrical Production (MWh)
10000 LLooaaL
dd %
8000 2 1 0 ,0 9 0 ,0
8 0 ,0
Consumption g/kWh
6000
2 0 0 ,0 7 0 ,0
4000 6 0 ,0
5 0 ,0
2000
1 9 0 ,0
4 0 ,0
0
3 0 ,0
1 8 0 ,0
02
02
02
02
03
03
03
03
03
03
03
03
03
2
3
00
00
00
00
2 0 ,0
20
20
20
20
20
20
20
20
20
20
20
20
20
.2
.2
.2
.2
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11
12
10
0.
1.
1.
0.
1.
8.
1.
0.
1.
0.
1.
1.
0.
1.
0.
1.
1.
-3
-3
-3
-3
-3
-2
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
1 0 ,0
2
3
00
00
00
00
00
00
00
00
00
00
00
00
00
2
3
00
00
00
00
2
2
.2
.2
.2
.2
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1 7 0 ,0 0 ,0
10
11
12
10
1.
1.
1.
1.
Date Advent ure

3
3
DG Set 1 DG Set 2 DG Set 3 DG Set 4 DG Set 5 DG Set 6
.0
.0
.0
.0
.0
.0
.0
0
0
.1
.1
.1
.1
.1
.1
.1
25
26
27
28
29
30
31
P e rio d
The installation today
Moni-
toring
Condition Monitoring CBM Marine Solution
Case Study
Piston Liner Seizure

Customer : ABC India Ltd.

Power Source : DG Set
Accident : Seizure in Piston/Liner
Monetary Loss : 10 Lacs (components)
Power Outage : 72 hours
Production Loss: Unknown
Observations:
• All exhaust temperature and bearing

temp were o.k
• Lube Oil temp was o.k.
• Lube oil pressure was o.k
• Operating Parameters were o.k
• However Crankcase Relief valve
operated during Failure
Observations:
• Piston was seized in liner

• Rings were not seized
• Small end Bearing was seized
• Big end Bearings were o.k.
• Gudgeon Pin suffered multiple cracks due to
seizure
• Lube Oil Pump was o.k.
• Connecting Rod was o.k.
Reason :
• Material Investigation indicated no problem

with quality of small end bearing or gudgeon
pin
• Piston was seized in liner due to low lube oil
Flow to piston.
• Seizure has happened gradually
• Low lube oil flow caused overheating of
piston top
• Lube oil flow was reduced due to ingress of
dirt in piston oil drillings
How the accident could have been

avoided
Engine was not equipped with

• Oil Mist detector
• Crankcase Pressure Transducer
Engine Could have been stopped earlier if the

above safety were present.
Condition Monitoring
Thank You!

Condition Monitoring of Diesel Generators

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Condition Monitoring of Diesel Generators

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Condition Monitoring Wartsila India Ltd

 Optimum Utilization of DG Set

Monitory Loss (Fuel Consumption Increase)

Diff. Pr. across C A Coolers. 200-400mm H2O

C. W. temp. before eng. 45 Deg.C at 100% Load

Exhaust Gas back pr. after the T/c 300mm H2o

Engine Block Blow Off

Valve Burning- Consequential Damage to

 Just installation of monitoring devices

 Devices should alert operator

 Alarm must appear at trigger point

 Should stop the machine on critical values

• Lube oil Pressure Alarm/Stop

 Differential Pressure Alarm

• Continuous Measurement of Water in Lube Oil

 Follow up of trends and historitic data

How can we monitor the crankcase environment ?

 Manual Pressure Measurement

To enhance the safety, the new product is;

Oil level is monitored manually

Continuous Oil Level Monitor

The system is based reliable

• High measuring accuracy ± 1mm

• Standard current and voltage

What is one of the most serious breakdown scenarios ?

Big End Bearing Failure and in many cases the

Faster and more accurate

WIRELESS BIG END

Reduced number of unplanned stops

Reduced number of failure’s

Improved maintenance planning

Improved follow up of the installation condition

The installation Wärtsilä

CBM - Condition Based Maintenance

The Wärtsilä CBM solution is in fact

- Control and monitoring systems

CBM - Operation - Data - Analyzer

Mathematical models for calculating the ideal operation

CBM - Operation - Data - Analyzer

One should know how changing in the operation

When we have the control of the

When we have the control we can

and other investigations,

The biggest savings are

on the reduced fuel

cost by making the

expert analyzing / follow

Custoimised CBM reports based on your specification

8Different level reports

Total number of start attempts

1,08 1,00 60 122 117

Engine and period

Successful starts Failed starts Advent ure

Total electrical production

Date Advent ure

Piston Liner Seizure

Customer : ABC India Ltd.

• All exhaust temperature and bearing

• Piston was seized in liner

• Material Investigation indicated no problem

How the accident could have been

Engine was not equipped with

Engine Could have been stopped earlier if the

Optimum Utilization of DG Set

Just installation of monitoring devices

Devices should alert operator

Alarm must appear at trigger point

Should stop the machine on critical values

Differential Pressure Alarm

Follow up of trends and historitic data

Manual Pressure Measurement

Reduced number of unplanned stops

Reduced number of failure’s

Improved maintenance planning

Improved follow up of the installation condition