dynamic positioning conference october 13-14, 2015 … · 4 x schottel stp 200 fp. 128 t bp...
TRANSCRIPT
DYNAMIC POSITIONING CONFERENCEOctober 13-14, 2015
THRUSTERS
Preventative Maintenance Methods for Heavy DutyAzimuth Thrusters
Frank ZellerSchottel
Preventive maintenance methods for heavy duty azimuth thrusters
Frank Zeller October 2015
YOUR PROPULSION EXPERTS 2
DYNAMIC POSITIONING
YOUR PROPULSION EXPERTS 3
CONTENT
General influences
Wear and tear
Preventive actions
Preventive maintenance
Condition monitoring
Typical applications
Example from field
Summary
YOUR PROPULSION EXPERTS 4
GENERAL INFLUENCES
Harsh Weathers Calm Weathers
YOUR PROPULSION EXPERTS 5
GENERAL INFLUENCES
corrosion steering forces
structural fatigue
vibrationhydrodynamic
loads
operational loads
engine loads
thermal cycles
foreign object damage
grounding
YOUR PROPULSION EXPERTS 6
WEAR AND TEARTh
rust
erre
liabi
lity
BREAKDOWN
Life time
Normal wear
Start of minor failures
Start of major failures
Near to Breakdown
New
Simplified Explanation
YOUR PROPULSION EXPERTS 7
WEAR AND TEARTh
rust
erre
liabi
lity
Normal wear
Start of minor failures
Start of major failures
Near to Breakdown
Unnoticeable Condition Change
Measurable Increase of Vibration/Pressure/
Temperature
Perceptible Increase of Vibration/Pressure/
Temperature
New
BREAKDOWN
Years/Month Month/Weeks Weeks/Days
YOUR PROPULSION EXPERTS 8
WEAR AND TEAR
Normal wear
Start of minor failures
Start of major failures
Near to BreakDown
Influence of operation conditions and maintenanceD
egra
datio
n
X ? BREAKDOWN Y ?
YOUR PROPULSION EXPERTS 9
PREVENTIVE ACTIONS
Different Operation Modes (e.g. PSV HAVILA AURORA)
YOUR PROPULSION EXPERTS 10
PREVENTIVE ACTIONS
Thrust
Dislocation
Linear Variation
ExponentialVariation
Operation Modes „Precision“ vs. „Relax“
YOUR PROPULSION EXPERTS
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PREVENTIVE ACTIONS
Depending on the selected operation modes the wear and tear will be influenced:
(High Precision Mode (HP)/Ecomomical Mode (E))
RPM:HP larger range & more cyclesE smaller range & less cycles
Torque:HP larger range & higher torqueE smaller range & lower toque
Steering:HP larger range & more cyclesE smaller range & less cycles
(same period, same sea state)
HP-Mode
E-Mode
11
RPM
Torque
Steering
YOUR PROPULSION EXPERTS 12
PREVENTIVE ACTIONS
Considers the inner geometry of the bearing Bearing clearance Change of clearance through thermal effects Change of clearance due to fits Displacement and tilting of the bearing due to deformation of
shafting/housing Lubrication system Lubricants and impurity
Design of bearing arrangements
Load distributionLoad distribution
Complies with
The bearing service life is determined on the basis of theindividual application load conditions, defined by the servicefactor or an individual load spectra.
ISO 281 / 16281 Dynamic load ratings and rating life
ISO 15312 Thermal speed rating
DIN 732 Thermally safe operating speed
M
Ma
ML2
ML3
t
Mn
Servicefactor (SF)
YOUR PROPULSION EXPERTS 13
Scheduled MaintenancesD
egra
datio
n
Normal wear
Start of minor failures
Start of major failures
Near to BreakDown
Proactive Maintenance
Minor Repairs
Major Repairs
Thruster Lifetime
PREVENTIVE MAINTENANCE
YOUR PROPULSION EXPERTS
Unnoticeable Condition Change
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Thru
ster
re
liabi
lity
BREAKDOWN
Preventive MaintenanceMeasure and analyze vibration, pressure, temperature, signals, alarms and liquids
compareNormal wear
Start of minor failures
Start of major failures
Near to BreakDown
New
SCHOTTEL Data
Service Data
+ Experience
OptimizedPlanning
Real ConditionPrognosis
PREVENTIVE MAINTENANCE
YOUR PROPULSION EXPERTS 15
CONDITION MONITORING
Diagnostic System „S-COM“
SRP 9000 LSU
Temperature Vibration Saturation of water in oil Particle in oil Thruster speed Thruster steering angles
ParametersS-COM
(SCHOTTEL Condition Monitoring)
Independent systemNo connection and influence
at thruster control
YOUR PROPULSION EXPERTS 16
CONDITION MONITORING
lubrication
hydraulic
Necessary components of an underwater mountable unit
water saturation
speed pick-up
particle sensor
acceleration sensor
temperature sensorpower train
SRP 9000 LSU
monitoring display
S-COM switch box
YOUR PROPULSION EXPERTS 17
CONDITION MONITORING
Control parameters
switch box steering S-COM
switch box
switch box prime mover
S-COM terminal box
galv
anic
isol
ated
Schematic of system:
Fire
wal
l
Internet
Temperature, water saturation, particle count, speed sensors Acceleration sensors
YOUR PROPULSION EXPERTS
CONDITION MONITORING
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e.g. water saturation in oil:
e.g. time signal acceleration at specific rpm:
Examples for monitored parameters
x,y,z-axis z-axis
water saturation
speed pick-up
particle sensor
acceleration sensor
temperature sensorpower train
SRP 9000 LSU
YOUR PROPULSION EXPERTS 19
CONDITION MONITORING
Detection of bearing defects:
signal preparation in S-COM
Each roller bearing has specific defect frequencies depending on the geometry
Identification of typical defect frequencies
(outer race frequency)
racefrequency
YOUR PROPULSION EXPERTS 20
CONDITION MONITORING
Development of bearing defects
YOUR PROPULSION EXPERTS 21
CONDITION MONITORING
S-COMon board
Vessel
Operator
Data Transfer
E-MailFTP
E-MailFTP
E-MailUSB-Stick
S-COMAnalysis
Automatic 24/7 event support
Periodic Report
SCHOTTELServer
Data Connection
V-SAT(Satellite)Ship Server,…
3 G(Cell-Phone)UMTS, HSDPA,…
Manually
YOUR PROPULSION EXPERTS 22
CONDITION MONITORING
Content:
General project dataStatus overview SummaryLog BookMaintenance proposal
Monitoring Report:
Issued:
Periodical reports (e.g. every 3, 6, 12 months)On request by customerAutomatic event reporting when the “alarm” level was reached
YOUR PROPULSION EXPERTS 23
TYPICAL APPLICATIONS
RIVERCRUISER VIKING4 x SCHOTTEL STP 200 FP
128 T BP OFFSHORE TUG LUZ DE MAR2 x SCHOTTEL Rudder Propeller Type SRP 3040 CP
PSV BOURBON MISTRAL2 x SCHOTTEL Combi Drive Type SCD 2020
DOUBLE-ENDED FERRY BERGENSFJORD4 x SCHOTTEL Combi Drive Type SCD 2020
YOUR PROPULSION EXPERTS 24
EXAMPLE FROM THE FIELD
Google Maps - © 2013 Google
PSV vessel with S-COM operating in the Gulf of Guinea, next Benin
S-COMMonitoring
Center
S-COM detected bearing failure at upper gear box
Customer contacted and repair solution agreed
Service engineer sent with spares for the exchange of the failed bearing
Job done within few days
© George Saunders
YOUR PROPULSION EXPERTS 25
SUMMARY
Current situation:
Maintenance in regular
fixed intervals
Short-term planning of docking times
Short-term, unexpected staff assignment
Loss of job or business
Unexpected repair and downtime in case of damage
unexpected
Dismantling even if not required
YOUR PROPULSION EXPERTS 26
SUMMARY
Situation with S-COM:
Dismantling in case of indication of wear / damages
Running systems are not touched
improved planning of dockings, better coordination
short ‘off hire’ period for customers
Condition based maintenance
Early detection of damages
earlier degradation
YOUR PROPULSION EXPERTS 27
SUMMARY
Situation with S-COM:
advance warning to avoid emergencies
specific maintenance recommendation or repair advices
scheduled docking
Increased knowledge of operating conditions due to data recording (speed, load, steering angle, etc.)
Increase of maintenance intervals possible
less degradation longer intervals
YOUR PROPULSION EXPERTS
THANKS !
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