condition & performance monitoring Case study: vibration monitoring via satellite
Two ships operated by United European Car Carriers (UECC) have been fitted with equipment to monitor the vibration behaviour of their engine gearboxes. The systems have been installed in their enginerooms by Schaeffler (UK) which is also providing exception- based remote monitoring services via a VSAT link. Schaeffler told Marine Propulsion that this provides UECC with an early warning system for potential gearbox failures. It also generates useful diagnostics and trend information that the operator can give to class society inspectors during ship audit inspections. These reports, Schaeffler said, eliminate the need for time consuming, one-off gearbox inspections, which cost significant sums and cause costly delays. Each of the ships – Autostar and
Autosun – is fitted with Schaeffler’s eight-channel FAG DTECT X1s vibration monitoring system, set up to monitor four vibration points on each of the two main engine gearboxes. A panel PC displays the vibration data from each gearbox and the systems are connected to the ship’s VSAT communications system. UK-based company Hargreaves Marine, Schaeffler (UK)’s partner for the marine industry, was responsible for specifying and installing the equipment, along with providing the remote
The control box receives information from eight vibration sensors (credit: Schaeffler (UK))
monitoring service. The systems have been in operation for a year, during which vibration data has been sent ashore every 12 hours via satellite link and cloud server. If an alarm is generated, shore staff can see which bearing on which gearbox was responsible, and decide whether action is required by the ship’s engineers. Chief engineers at UECC receive a
monthly report showing the gearbox vibration data and measuring points. This information can be collated into annual reports or five-yearly class audits. Jim Belsham, technical
Infrared fuel sensor checks fuel quality Fuel savings of up to 5 per cent are claimed if a fuel quality sensor is fitted as part of a fuel management strategy, claims the device’s manufacturer, CMR Group. It described its Near Infrared Intelligent Sensor (NIRIS) as the world’s first
commercial high horsepower diesel fuel quality sensor and explained that it detects fuel parameters by applying advanced hydrocarbon profiling that measures the molecular structure of fuel. “This allows real-time optimisation of injection, combustion and post-treatment for all types of fuel, including bio-fuels,” it said in a statement.
When used in conjunction with an engine control unit “NIRIS can help to significantly reduce fuel consumption and engine emission levels,” it said. Further benefits claimed for the unit include lower fuel analysis costs, correct engine performance and the overall alleviation of damage to components due to inferior or low-grade fuels.
The NIRIS unit can be retrofitted anywhere between the low pressure and high pressure fuel pumps (credit: CMR)
94 I Marine Propulsion I April/May 2014
NIRIS is based around an infrared spectrometer that performs continuous analysis of a range of parameters including the cetane index, density and percentage of biodiesel. It provides information that engineers can use for assessing fuel quality.
superintendent at UECC, is responsible for the remote condition monitoring installations. “When a ship’s gearbox reaches 60,000 to 70,000 hours in service the last thing we want to do is to replace all the bearings inside the gearbox that are potentially still in good condition,” he said. “Around two years ago we therefore looked for an alternative solution. “So far, we have not found any unusual problems, but the system constantly reassures us that the gearboxes are not going to suddenly fail and cause costly downtime.”
Data upgrade improves ship performance
An upgrade to part of the automation system on Royal Caribbean International’s Allure of the Seas has given the ship 6,500 more data points and increased its data storage to seven years (up from one year). Kongsberg has installed its Information Management System (K-IMS) to replace the history station within the existing Kongsberg Maritime K-Chief automation system, which now has 76 remote control units controlling over 40,000 data points. The upgrade, Kongsberg said, provides Royal Caribbean with extensive data and statistics with which to improve vessel operational performance. K-IMS has a suite of applications within a web portal that is available both on board and on the Royal Caribbean office network in Florida, USA. K-IMS data can be accessed on board using tablets and is displayed on a large screen in the engine control room. It also provides a report each day showing what is consuming the most power, to help decide which machinery can be shut off to save fuel. MP
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