21 - johan pellas
TRANSCRIPT
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1 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
IMarEST
Condition Based Maintenance ConferenceLondon 28-29 September 2010
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2 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
OEMs, maintenance and emission control-
the solution for li fe time optimising of
installations
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3 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM(Condition Based Maintenance)
and
Dynamic Maintenance Planning
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4 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Today CM (Condition Monitoring) is most common
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5 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Todays CM solution
Failures Marine industry:
Machinery failure ~40% (MAIB)
Only ~1% discovered duringroutine inspections (MAIB)
Operating hours based maintenance
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6 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CM and human factor today
About 60 80% of fai lure cases arebecause of human misjudgement
The information was available
but not understood or incorrect / no
actions
We need a CBM solut ion to support
the operators
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7 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM (Condition Based Maintenance)
CBM is to:
Understand the process
Data analysing
Based on analysis, trendsand knowledge make the
predictions = CBM
Dynamic maintenance
planning / schedules
Cost prediction and follow up
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8 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Wrtsi l CBM
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9 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM and remote monitor ing
Remote support to the
owners and operators:
- To optimise the installation
- To reach the bestperformance of the installed
equipment
- To predict comingmaintenance
- To avoid unplanned stops
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10 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM for the essential equipment
CBM for the essential
equipment and follow up:
Maximized reliabil ity
Maximized availability
Maximized predictabili ty
Maximized life cycleperformance
Optimized operation cost
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11 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Benefits with CBM
Optimized life cycle costs
Reduce the fuel cost /
Emissions with about 2-5%
Reduce the maintenance cost
with about 10-20% / dynamic
maintenance planning andschedules
Minimize the number of
unplanned maintenance/stop
with 60-90%
Increase the total availability
with about 5 20%
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12 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM installations
More than 300 marine and power plant installations / 1170 engines /11.500MW are already connected to the Wrtsil CBM centre
More than 130 installations are on line 24/7
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13 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
flat picture 2254mm x 66mm
(100dpi)
Wrtsi l CBM
CBM targets
To predict more than 90% of the required maintenance 2 6months in advance
To find more than 90% of the critical cases 7 30 days inadvance
Reduce your fuel consumption and emissions with 2 - 5%
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14 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Data transfer & communication
Data transfer &communications
Measuring theimportant equipment
and parametersMonitoring / Expert analysis
and feed back
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15 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Possible CBM set up / si te
Data transfer &communications
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Wrts il 23.09.2010 Dept. 42039
Additional Monitoring Systems
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17 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Wrtsi l CBM
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18 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM operation data analyser
Mathematical models for calculating the ideal operationparameters for the installations.
A dynamic system considering:
Engine specification, installation type and configuration
Ambient conditions
Design criteria Installation specific data
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19 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM operation data analyser
Mathematical models for calculating the ideal operationparameters for the installations and predictions for the future.
Every engine type have there own mathematical model
One should know how changing in the operation conditionsare having influence on all other parameters for the specificengine types and configurations
Example:
Change in air inlet temperature changed TC speedchanged receiver pressure changed peak pressurechanged exhaust gas temperatures waste gate / by-pass valve position changed fuel consumption
changed emissions etc.
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20 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Daily measurement / analyze example
bar 2,4 2,5 2,3
C 56 57 53
mbar 42 60,0 25
mbar 35 60,0 25
rpm 18503 18928 17928
rpm 18578 18928 17928
C 371 408 328
C 369 408 328
C 377 408 328
C 392 408 328
C 390 418 328
C 410 418 328C 379 408 328
C 373 408 328
C 378 408 328
C 389 408 328
C 407 418 328
C 394 418 328
C 510 538 458
C 519 538 458
C 352 370 290
C 358 370 290bar 180 181 171
bar 180 181 171Max firing pressure A2
Exhaust gas temp. before turbocharger B
Exhaust gas temp. after turbocharger A
Exhaust gas temp. after turbocharger BMax firing pressure A1
Exhaust gas temp. B4
Exhaust gas temp. B5
Exhaust gas temp. B6
Exhaust gas temp. before turbocharger A
Exhaust gas temp. A6Exhaust gas temp. B1
Exhaust gas temp. B2
Exhaust gas temp. B3
Exhaust gas temp. A2
Exhaust gas temp. A3
Exhaust gas temp. A4
Exhaust gas temp. A5
Charge air pressure difference over cooler B
Turbocharger speed A
Turbocharger speed B
Exhaust gas temp. A1
Charge air pressure after cooler
Charge air temp. after cooler
Charge air pressure difference over cooler A
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21 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM operation data analyser
Tu r b o c h a r g e r s p e e d A
15000
16000
17000
18000
19000
20000
21000
22000
01.09
.2009
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Date
Turbocharge
rspeed
A(
rpm
)
50
55
60
65
70
75
80
85
Lo
ad
%
S ite A lert Action L oad
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CBM calculated fuel consumption
22 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
68
70
72
74
76
78
80
82
84
86
193
193,5
194
194,5
195
195,5
196
196,5
197
197,5
Engine 1 August Engine 2 Engine 3 Engine 4 Engine 5 Engine 6
Load%
Fuelconsum
ptiong/kWh
Average fuel consumption and average load per m onth
C on su mption L oad
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23 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM operation data analyser
61 0
61 5
62 0
62 5
63 0
63 5
64 0
64 5
65 0
65 5
66 0
0,1
1
10
10 0
CO2g/
kWh
A u g u s t 2 0 1 0
NOxCOx,THC,C
O,PMg/kWh
Average ca lcu lat ed em is s io n s p er d ay
NO x SO x T HC C O P M C O 2
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24 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM operation data analyser
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25 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM for the essential equipment
CBM for the essential
equipment and follow up:
Maximized reliabil ity
Maximized availability
Maximized predictabili ty
Maximized life cycleperformance
Optimized operation cost
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26 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Additional benefits with CBM
Optimized life cycle costs
Reduce the fuel cost /
Emissions with about 2-5%
Reduce the maintenance cost
/ dynamic maintenance
schedule with about 10-20%Minimize the number of
unplanned maintenance/stop
with 60-90%
Increase the total availability
with about 5 20%
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27 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Fuel and maintenance cost / total operating costs
The fuel costs are about 50 % - 80% of all operationcosts for vessels/power plants
The total maintenance costs are about 5 - 10% of alloperation costs.
FUEL
Maintenance 5-10%
Fuel 50 80%Other 10 45%
Communication
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28 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM feed back / follow up
Ideal reference values
Remote monitoring
Condition feed back
Predictions
Production reports
Special analysis
Alarm log analysis
Etc.
CBMDatabase
CBM
Analysing and Feed
back
CBMReport
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29 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Maintenance today
The EU industry:
Scheduled maintenance
~55%
Unplanned maintenance
~30%
CBM ~15%
Shipping?
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30 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Data transfer direction today
VPN router 1
VPN router 2
E-mail 1
VPN 1
Company info rmation
Internal use
VPN 2
E-mail 1 CBM
E-mail 2
VPN router 3
VPN router 4
VPN router E-mail 2
E-mail 3
E-mail 4
E-mail
VPN 1
Company i nformation
Internal useVPN 1
Company i nformation
Internal use
Is this the future
concept to accept or is
it a centralised
solution for the
future?
VPN 1
Company i nformation
Internal use
Is this the future
concept
or
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31 Wrtsil 27 September 2010 Presentation name / Author
Wrtsil launches the Wrtsil 3C to fully integrate all ship controls
with a single interface (SMM Hamburg)
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32 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM = > 24/7 Remote Support = > Centralized one supplier solution
Remote on sit e training
Optimisation
Your preferred suppl ier
Wrtsil
Asset management
Bridg e and cargo syst ems
Life cycle support
VPN router
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33 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
CBM = > 24/7 Remote Support = > Centralized one supplier solution
CBM
Remote on sit e training
Maintenance management
Remote commiss ionin g /
update etc
Remote technic al support servi ces /
analysis etc
Online suppo rt 24/7 spare part
ordering and f ollow up/ manuals /
bulletin s / reports etc
Spare part / maintenance prediction / fo llow up
Budget making support / follow up
Remote operation
Optimisation
Total site support
Centralised one supplier
solution
Total site control
Site optimisation
Your preferred suppl ier
Wrtsil
Asset management
Bridg e and cargo syst ems
Operation management
Life cycle support
VPN router1
VPN router
Back up
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34 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Wrtsi l CBM
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35 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
On-line vision for the Wrtsil CBM centre in the future
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36 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Questions?
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37 Wrtsil 27 September 2010 Presentation name / Author, DocumentID:
Thank You!