21 - Johan Pellas

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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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OEMs, maintenance and emission control-

the solution for li fe time optimising of

installations


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CBM(Condition Based Maintenance)

and

Dynamic Maintenance Planning


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Today CM (Condition Monitoring) is most common


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Todays CM solution

Failures Marine industry:

Machinery failure ~40% (MAIB)

Only ~1% discovered duringroutine inspections (MAIB)

Operating hours based maintenance


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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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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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Wrtsi l CBM


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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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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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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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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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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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Data transfer & communication

Data transfer &communications

Measuring theimportant equipment

and parametersMonitoring / Expert analysis

and feed back


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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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Wrtsi l CBM


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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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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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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. before turbocharger A

Exhaust gas temp. A6Exhaust gas temp. B1



Exhaust gas temp. A2




Charge air pressure difference over cooler B

Turbocharger speed A

Turbocharger speed B


Charge air pressure after cooler

Charge air temp. after cooler

Charge air pressure difference over cooler A


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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

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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


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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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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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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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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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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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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Maintenance today

The EU industry:

Scheduled maintenance

~55%

Unplanned maintenance

~30%

CBM ~15%

Shipping?


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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


Internal use

Is this the future

concept to accept or is

it a centralised

solution for the

future?

VPN 1


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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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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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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Wrtsi l CBM


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On-line vision for the Wrtsil CBM centre in the future


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Questions?


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Thank You!

21 - Johan Pellas

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