CONDITION MONITORING AND CBM SERVICES - Wärtsilä

CONDITION MONITORING AND CBM SERVICES

MAXIMIZE AVAILABILITY AND
PERFORMANCE TARGETS
Wärtsilä’s condition monitoring and
CBM services assist in meeting
the technical, economical and
environmental performance targets
of an installation.
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BE FUEL EFFICIENT
Changes in operating parameters may increase the
fuel consumption, which in turn has a direct impact
on the economical and environmental performance of
the installation. With condition monitoring equipment
operation parameters can be fine-tuned, maintaining
the best possible fuel efficiency. Fuel savings of up to
3–5% can be achieved.

LIFECYCLE PERFORMANCE
Power plants and marine installations are
increasingly focusing their attention on
equipment performance and advanced
maintenance programmes as a way to optimize
the lifecycle performance. However, this
requires an effective new approach which is
why many industries today employ systems for
real-time condition monitoring and predictive
maintenance such as Condition Based
Maintenance (CBM).
Wärtsilä’s CBM is well established
within the industry. The use of the latest
communications technology makes it
possible to fine-tune equipment operation
parameters, taking into account the operating
profile, ambient conditions, type of fuel and
other factors that can affect the lifecycle
performance.
CBM has become an integral part of
maintenance planning for many power plants
and marine applications around the world.
Trends and changes in operating parameters
can be identified well before they might
compromise the performance of the
6000 MW AND GROWING
The first installation was brought online in early
2001. Today, around 200 installations – almost
700 engines or 6.0 GW – are monitored from
our CBM centres. The cost savings achieved and
increased equipment availability are making these
services attractive to an ever broader spectrum
of customers. Our customers range from cruise,
ferry, cargo and tanker vessels to dredgers,
offshore rigs and navy vessels. We were the first
engine manufacturer in the world to sign CBM
contracts within the cruise and offshore drilling
industries.
installation. Maintenance is then only
performed when needed, which optimizes plant
safety, operational availability and productivity.
The trend towards automated, minimally
manned or even unmanned plants constantly
emphasizes the need for reliable condition
monitoring and maintenance programmes.
And this is not limited simply to the engine and
engine room equipment; Wärtsilä has recently
introduced CBM systems for propulsion
equipment and steerable thrusters.
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CBM REPORTS/ENGINE CONDITION OVERVIEW
The convenient traffic light system used in the reports
indicates the level of maintenance required: When the
engine operating data is within the ideal window, the
engine symbol is green. When the operating data falls
slightly outside the ideal window, the data will be yellow.
When the operating data is outside the yellow range, the
symbol turns red.
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Typical systems and operating data included in the CBM report
Fuel system l Lube oil system l Cooling water system l Turbocharger
speed l Charge air pressure / temperature l Exhaust gas temperatures
l Main bearing temperatures l Cylinder liner temperatures l Crankcase
pressure
DYNAMIC MAINTENANCE SCHEDULE
Conventional equipment maintenance means
scheduled preventive maintenance routines strictly
based on equipment running hours. So it is not
always possible to match various schedules in
the best way, which in turn can affect operational
availability.
In contrast, predicting the actual condition
of the equipment makes it possible to regroup
the maintenance of equipment and systems in a
maintenance window so that it also fits in with other
business factors.

MAINTENANCE ONLY WHEN NEEDED
A number of smart electronic technologies
have opened up new engine maintenance
opportunities over the last decade, and plug-in
diagnostics systems are now part of modern
engine maintenance.
However, this tends to happen only on
scheduled service dates. Wärtsilä’s condition
monitoring and CBM services take the concept
several steps further.
By networking equipment sensors and
automatically monitoring the equipment
condition and logging the data, installation
performance information is collected
continuously and transmitted regularly back to
our CBM centre. Feeding the information into
the CBM system accurately determines the
actual overall condition of the installation and
ultimately the maintenance it needs.
Our specially developed software analyses
the installation’s operation data by comparing
it against the engine’s ideal design values
and other parameters. A Wärtsilä engine
expert then provides predictions on engine
performance and recommendations for
optimizing the operation and maintenance
profile. Detailed CBM reports are provided on a
PLAN AHEAD – STAY AHEAD
With the possibility it gives to balance the time
between overhauls, minimize downtime and optimize
the installation performance, CBM is becoming an
industry standard. The aim is to find more than 90%
of the critical cases 7 – 30 days in advance and to
predict more than 90% of the required maintenance
2 – 6 months in advance.
regular basis to the technical staff, owner and
operator of the installation.
If required, a sensor-based network
can also be used to monitor environmental
emissions, which are usually closely related
to engine operating efficiency. It is clear that
more regulations will come into force, with a
continuous drive for higher efficiency and lower
emission levels. Tighter NO X, CO X and SO X
standards mean condition monitoring and CBM
technology will play a key role.
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COMMUNICATIONS SETUP
Installations are linked to the Wärtsilä CBM centres via secure
Internet connections. Satellite communication, along with
automatic transfer of data from the installations to the CBM
centres, enables online monitoring of, for instance, engines
onboard vessels. There is also a manual solution for collecting
operating data and sending e-mail using specialised Wärtsilä
software. If operation data trends show that operating
parameters will go outside the ideal window, the CBM centre
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analysis and prognostics will predict the operating condition of
the engine. Recommendations to adjust operating parameters
together with maintenance recommendations are sent to
owners and operators. Any required spare parts/consumables
can then be made available in the next harbour.
With an optimum solution available for every need, both
old and new installations can be connected to our condition
monitoring and CBM services.

Wärtsilä is a global leader in complete lifecycle power solutions for the
marine and energy markets. By emphasising technological innovation
and total efficiency, Wärtsilä maximises the environmental and economic
performance of the vessels and power plants of its customers. Wärtsilä
is listed on the NASDAQ OMX Helsinki, Finland.
WÄRTSILÄ ® is a registered trademark. Copyright © 2009 Wärtsilä Corporation.