condition monitoring of diesel generators

Condition Monitoring Wartsila India Ltd

Condition Monitoring Diesel Generators

by V Pramodkumar


Why??

Optimum Utilization of DG SetMaximum availability of MachineReliable OperationChange in Maintenance conceptImprove MTBF

Condition Monitoring


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 OffIf excess crankcase pressure unnoticed

Valve Burning- Consequential Damage to Turbochargers

If Exhaust Temperature are not monitored

Crankshaft SeizureIf bearing temperatures are not monitoredOr Lube oil pressure/temperature is not monitored



Critical Parameters To be Monitored

Exhaust TemperatureBefore and After TurbochargersIndividual Cylinder

Bearing TemperatureMain BearingBig End Bearing

Cooling Water SystemCooling Water TemperatureCooling Water Pressure



Critical Parameters To be MonitoredFuel System

Fuel Pump Rack Positions ( larger machines)Fuel Oil Pressure/TemperatureDifferential Pressure Across Fuel Filters

Charge Air SystemCharge Air temperature/ PressureSafety Air Pressure

Differential Pressure Across Air Filters/CoolersLube Oil System

Lube Oil Pressure/TemperatureLube Oil VolumeCrankcase PressureDifferential Pressure across Lube Oil Filters



ALARMS AND LIMITS

Just installation of monitoring devicesdoes 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 AlarmAcross air coolersTurbochargers Over speed AlarmCrankcase Pressure Alarm/StopPre Lube oil Pressure AlarmOver current StopUnder/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 Measurementof Water in Lube Oil



Follow up of trends and historitic dataIndicates the margin to water saturation i.e. free water formation.On-line and continuous measurement. Easy to installThe 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

Benefits


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 reliablestrain gauge principle i. eweighting of the cylinder nomoving parts



• High measuring accuracy ± 1mm• No moving parts• Ready calibrated at factory• Easy and fast installation• Can be connected to any existingalarm and monitoring system

• Reliable strain gauge principle



• Standard current and voltageoutput

•To have alarms on any kind oflevel

• Automatic filling of lub oil• Detect abnormalities in the lub oilsystem

• 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 ENDBEARING TEMPERATUREMONITORING



CBMCondition Based Maintenance

Reliable and Economical Diesel Engine application operation


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

CBM

Benefits of CBM


If we can measure and analyze the application

we have the control !

Condition Monitoring Communication

The installation Wärtsilä

Wärtsilädatabase

CBMReport

Moni-toring

Data transfer

Owner /Operator office Local Wärtsilä office


CBM - Condition Based Maintenance

The Wärtsilä CBM solution is in fact a combination of

Condition Based Operation and

Condition Based Maintenance

Condition MonitoringCBM

The Wärtsilä CBM solution is basedbased on the use of the installedinstalled and and available available equipmentequipment

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

Wartsila India Ltd


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- etc

CBM - Operation - Data - Analyzer

Wartsila India Ltd


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 parametersExample-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 - Operation - Data - Analyzer

Wartsila India Ltd


Conditionborder level

Sche

dule

d st

op

Anticipated Anticipated deteriorating deteriorating

raterate

Monitored Monitored deteriorating deteriorating

raterate

Scheduledmaintenance

Optimal time for

maintenance

Wartsila India Ltd

CBM


CBMbar 1 ,6 2 ,1 1 ,9°C 60 57 48P a 39 44 0P a 60 44 0rpm 18222 18856 18056rpm 18187 18856 18056°C 406 364 294°C 390 364 294°C 391 364 294°C 397 364 294°C 387 364 294°C 384 364 294°C 388 364 294°C 387 364 294°C 422 364 294°C 396 364 294°C 380 364 294°C 389 364 294°C 364 364 294°C 359 364 294°C 385 364 294°C 402 364 294°C 397 364 294°C 417 364 294°C 514 464 394°C 481 464 394°C 394 354 314°C 383 354 314°C 78 91 73

E xhaus t gas tem p. a fte r tu rbocharger BM a in bearing tem p./B earing 0

E xhaus t gas tem p. B 9E xhaus t gas tem p. be fo re tu rbocharger AE xhaus t gas tem p. be fo re tu rbocharger BE xhaus t gas tem p. a fte r tu rbocharger A

E xhaus t gas tem p. B 5E xhaus t gas tem p. B 6E xhaus t gas tem p. B 7E xhaus t gas tem p. B 8

E xhaus t gas tem p. B 1E xhaus t gas tem p. B 2E xhaus t gas tem p. B 3E xhaus t gas tem p. B 4

E xhaus t gas tem p. A 6E xhaus t gas tem p. A 7E xhaus t gas tem p. A 8E xhaus t gas tem p. A 9

E xhaus t gas tem p. A 2E xhaus t gas tem p. A 3E xhaus t gas tem p. A 4E xhaus t gas tem p. A 5

C harge a ir p ressure d iffe rence over coo le r BT urbocharger speed AT urbocharger speed BE xhaus t gas tem p. A 1

C harge a ir p ressure a fte r coo le rC harge a ir tem p. a fte r coo le rC harge a ir p ressure d iffe rence over coo le r A


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 !

Wartsila India Ltd

Condition MonitoringO

pera

ting

cost

s

According to several insurance companies and other investigations, as much as 60% to 80% of the claims are because of human mistakes!

The information was available but the actions was not takenTraditional CBM

CBM savings

CBM costCBM cost

Wartsila India Ltd


pera

ting

cost

s

The biggest savings are on the reduced fuelconsumption

in average 5 - 10 g / kWh (2-5%) during the life time cycle of the application

Traditional CBM

CBM savings

CBM costCBM cost

Wartsila India Ltd


pera

ting

cost

s

Reduced maintenance cost by making the correct maintenance at the correct time

in the range of 5 – 20% saving

Traditional CBM

CBM savings

CBM costCBM cost

Wartsila India Ltd


pera

ting

cost

s

Improved reliability byexpert analyzing / follow

up and regular feed back including predictions and recommendations

Traditional CBM

CBM savings

CBM costCBM cost

Wartsila India Ltd


8Different level reports8Top Management reports8Middle Management level Report8Operator level report

8Performance report8Fuel consumption8Operation data evaluation8Heat recovery8Comments/suggestions

8Environmental report8Emission-calculations

8Technical report8Coming maintenance8Trends / Alarm analyze8Comments/suggestion

Custoimised CBM reports based on your specification

Wartsila India Ltd

Condition Monitoring Analyzing

Total electrical production

0

2000

4000

6000

8000

10000

12000

1.6.200

2 - 30

.6.20

021.7

.2002 -

31.7.

2002

1.8.200

2 - 31

.8.20

021.9

.2002 -

30.9.

2002

1.10.2

002 -

31.10

.2002

1.11.2

002 -

30.11

.2002

1.12.2

002 -

31.12

.2002

1.1.200

3 - 31

.1.20

031.2

.2003 -

28.2.

2003

1.3.200

3 - 31

.3.20

031.4

.2003 -

30.4.

2003

1.5.200

3 - 31

.5.20

03

1.6.200

3 - 30

.6.20

031.7

.2003 -

31.7.

2003

1.8.200

3 - 31

.8.20

03

1.9.200

3 - 30

.9.20

03

1.10.2

003 -

31.10

.2003

Date

Elec

tric

al P

rodu

ctio

n (M

Wh)

DG Set 1 DG Set 2 DG Set 3 DG Set 4 DG Set 5 DG Set 6Advent ure

1.5.2003 - 31.5.2003 91246days: 24

1.6.2003 - 30.6.2003 91246days: 3

1.7.2003 - 31.7.2003 91246days: 1

1.8.2003 - 31.8.2003 91246days: 25

1.9.2003 - 30.9.2003 91246days: 20

1.10.2003 - 31.10.2003 91246days: 10

1,08

1,92

0,000,00

1,00

2,00

0,000,000,50

3,20

0,75

2,00

0,00

0,50

1,00

1,50

2,00

2,50

3,00

3,50

4,00

Ave

rage

am

ount

/ ru

nnin

g da

y

Engine and period

Operation data out of limits (engine/month)

Action AlertAdvent ure of t he Seas

104

7

96

15

109

7

116

16

87

16

91

7

122

18

96

2

95

7

93

4

74

16

95

7

18

1

10

108

1

72

0

117

13

0

20

40

60

80

100

120

140

Tota

l num

ber o

f sta

rt at

tem

pts

Start statistics

Successful starts Failed starts Advent ure

E ngine1 spec if ic fue l consum ption and load

1 7 0 ,0

1 8 0 ,0

1 9 0 ,0

2 0 0 ,0

2 1 0 ,0

25.10.03

26.10.03

27.10.03

28.10.03

29.10.03

30.10.03

31.10.03

P e rio d

Con

sum

ptio

n g/

kWh

0 ,01 0 ,02 0 ,03 0 ,04 0 ,05 0 ,06 0 ,07 0 ,08 0 ,09 0 ,0

LL o a d % L o a d

Condition MonitoringThe installation today

Moni-toring

Wartsila India Ltd

Condition Monitoring CBM Marine Solution


Case StudyCase Study

Piston Liner SeizurePiston Liner Seizure

Wartsila India Ltd


Customer : ABC India Ltd.Power Source : DG SetAccident : Seizure in Piston/LinerMonetary Loss : 10 Lacs (components)Power Outage : 72 hoursProduction 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 oilFlow 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 MonitoringThank You!

condition monitoring of diesel generators

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