MUNIN maintenance storyboard r1 - unmanned-ship. · PDF fileSource: Rødseth & Mo...
Transcript of MUNIN maintenance storyboard r1 - unmanned-ship. · PDF fileSource: Rødseth & Mo...
Maintenance Management and Energy management for Unmanned
Shipping
Harald Rødseth, Master of ScienceMARINTEK
Gudmundur Freyr AtlasonMARORKA
http://www.unmanned‐ship.org
Background
Operation of a ship without personnel on board requires a new maintenance management concept. There exist both hazards and critical functions related to main engine. How serious is poor maintenance?
A structured approach has been developed in order to develop the maintenance concept:
2
Step 1:Requirements
Step 2: System
selection and definition
Step 3: Analysis of existing
concept (AS‐IS)
Step 4: Identify gap
Step 5: Develop new
concept (TO‐BE)
Step 6:Evaluate concept
IDEA:Unmanned shipping Maintenance
concept
Source: Rødseth & Mo (2014): Maintenance Management for Unmanned Shipping, COMPIT
Hypothesis
From a reliability perspective, Failure Modes, Effects, and Criticality Analysis (FMECA) has been performed with 6 steps.
Technical issues such as carry water overflow and leakage through piston rings has been identified as critical events.
Measures have been proposed in order to accept the concept for the design stage.
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Decision logic
Colour code Decision
Not acceptable – risk reducing measures required.
Acceptable – implement risk reducing measures if "reasonably practical".
Acceptable – No further measures are considered necessary
4
Step 4: Critical issuesHypothesis Measures for reducing RPN RPN
Hypothesis no. 1 – Line 2 in FMECA:The MIS ensures that the ship is operational available at an intercontinental voyage for 500 hours without physical intervention with respect to leaking through piston rings.
1. Piston Ring analysis2. Early Warning Indicators &
KPIs
9
Hypothesis no. 2 – Line 3 in FMECA:The MIS ensures that the ship is operational available at an intercontinental voyage for 500 hours without physical intervention with respect to carry water overflow.
1. Piston Ring analysis2. Early Warning Indicators &
KPIs3. New maintenance
programme4. Redesign of engine room
12
Hypothesis no. 3 – Line 5 in FMECA:The MIS ensures that the ship is operational available at an intercontinental voyage for 500 hours without physical intervention with respect to lubrication impurities of crank shaft.
1. Oil analysis for diagnosing and prognosis
12
5
Energy efficient engine room
Very dependent on a effective maintenance system.
Reliable monitoring of key engine parameters to compare to operational benchmarks.
Use algorithms and models with real time data to monitor and identify best practices.
Optimal operational procedures followed under normal conditions.
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Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
TCI
93 %
Availability
92 %
Maint. costs
200 000 $ / vessel
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms for the fleet
Fleet number: 24
Fleet & Map
Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
TCI
93 %
Availability
92 %
Maint. costs
200 000 $ / vessel
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms for the fleet
Fleet number: 24
Fleet & Map Ship name: M/S MUNIN
Ship name : M/S Munin
Status :”Carry water overflow”
Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
233
ActiveEARLY
WARNINGM/S
Munin10.12.2013 11:20:00
High exhaust gas
temperature N/AEARLY WARNING
EWI=60% N/A
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod Maintenance
overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms and Early Warnings
Maintenance Notification
Graphs & Figures Status
Alarm Code 239: Carry Water Overflow
Contact supplier
Contact operation
Submit work order
Sign out
Operational decisions:Sevice speed: 16 knot? with 90 % loadActual speed: 15,5 knot? with x 85 % load
What is the status?Carry water overflow (High probability)Damage of cylinder (Medium probability)
Why?Condensed water pass with scavenging air and water droplets destroys the cylinder oil film by microexploitions
Which failure mecanisms are involved?Scuffing
How do you know?Measurement of humidity and engine room temperature, air pressure at engine roomMeasurement of cylinder liner temerpature
Maintenance historyStatistics of the problemWhat have we learned so far about this problem?
Root Cause Analysis
Cylinder liner
Shaft
Piston
Ship name: M/S MUNIN
Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
233
ActiveEARLY
WARNINGM/S
Munin10.12.2013 11:20:00
High exhaust gas
temperature N/AEARLY WARNING
EWI=60% N/A
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod Maintenance
overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms and Early Warnings
Maintenance Notification
Graphs & Figures Status
Early warning code 233: Piston condition
Contact supplier
Contact operation
Submit work order
Sign out
Analysis object: Blow-by in combustion chamber
Cylinder liner
Shaft
Piston
399,9
400
400,1
400,2
400,3
400,4
400,5
400,6
400,7
400,8
0 2000 4000 6000 8000 10000 12000
Cylinder1
Cylinder3
Cylinder2
Cylinder4
Cylinder5
threshold
Cylder6
Max
Lin
er D
iam
eter
(mm
)
Ship name: M/S DRAUPNER
Main Engine Diesel Generators WHRS
TCI TCI TCI
83 % 94 % 97 %
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
Maintenance planning and scheuduling
Reliability analysis
Back
Ship name: M/S DRAUPNER
Main Engine KPI‘s
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
Back
TCI
83%
Ship name: M/S DRAUPNER
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
TCI
83%
Main Engine KPI‘s
Back
KPI/Cyl. 1 2 3 4 5 6
Texh[°C] 404.4 403.5 410.6 412.9 413.0 405.8
Texh rel [°C] ‐4.0 ‐4.9 2.2 4.5 4.6 ‐2.6
Close window
Last automatic update: 4.7.2014 8:00
Update values
Texh
Ship name: M/S DRAUPNER
Main Engine KPI‘s
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
Back
TCI
83%
Ship name: M/S DRAUPNER
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
TCI
83%
Main Engine KPI‘s
Back
Close window
Last automatic update: 4.7.2014 8:00
Update values
Tcyl,liner
KPI/Cyl. 1 2 3 4 5 6
Texh[°C] 125 128,4 130.2 131.4 131.6 126.6
Texh rel [°C] ‐3.9 ‐0.5 1.3 2.5 2.7 ‐2.3
Ship name: M/S DRAUPNER
Main Engine KPI‘s
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
Back
TCI
83%
Ship name: M/S DRAUPNER
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
TCI
83%
Main Engine KPI‘s
Back
KPI/Cyl. 1 2 3 4 5 6
Pmax [bar] 110.0 111.1 109.4 109.2 108.9 111.3
Pmax rel 0.02 1.12 ‐0.58 ‐0.78 ‐1.08 1.3
Close window
Last automatic update: 4.7.2014 8:00
Update values
Pmax
Ship name: M/S DRAUPNER
Main Engine KPI‘s
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
Back
TCI
83%
Ship name: M/S DRAUPNER
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
TCI
83%
Main Engine KPI‘s
Back
Liner wear
399,9
400
400,1
400,2
400,3
400,4
400,5
400,6
400,7
400,8
0 2000 4000 6000 8000 10000 12000
Cylinder1
Cylinder3
Cylinder2
Cylinder4
Cylinder5
threshold
Cylder6
Max
Lin
er D
iam
eter
(mm
)
Last manual update: 4.6.2014 15:10
Close window
Ship name: M/S DRAUPNER
Main Engine KPI‘s
KPI Description TCI Status View details
TC ΔT Temperature differencebetween inlet and outlet of ME turbochargers
95%
Texh Cylinder Exhaust gas temperature 88%
Tcyl,liner Cylinder liner temperature 70%
Pcomp Cylinder compression pressure in ME 84%
Pmax Maximum cylinder pressure in ME 85%
MIP Mean indicated pressure for eaxh cylinder 88%
Ignition Ignintion point in eaxh cylinder 90%
ΔPscav.cooler Pressure drop over scavengeair cooler 93%
Liner wear Maximum liner diameter in each cylinder 82%
Back
TCI
83%
Ship name: M/S DRAUPNER
Main Engine Diesel Generators WHRS
TCI TCI TCI
83 % 94 % 97 %
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
Maintenance planning and scheuduling
Reliability analysis
Back
Ship name: M/S DRAUPNER
Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
TCI
93 %
Availability
92 %
Maint. costs
200 000 $ / month
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms for the fleet
Fleet number: 24
Fleet & Map
Event id StatusShip name
Event initiated Event name Failure mode Value RPN
235ActiveALARM
M/S Munin
11.12.2013 13:54:00
Carry water overflow
Unable to provide power to
propulsion system with 100 % efficiency /power
ALARMEstimated remaining oil film40% 12
234ActiveALARM
M/S Munin
230
ALARM under
progress by harod
M/S Munin
231Signed out by harod
232Signed out by brmo
229Signed out by harod
228Signed out by harod
Maintenance overview
Preventive maintenance program
Analyse selected event
Maintenance KPIs
Maintenance status & history
Status reports
Maintenance planning and scheuduling
Reliability analysis
Status: Alarms for the fleetMaintenance KPI
Source: Partly based on NS‐EN 15341 "Maintenance Key Performance Indicators", 2007