Remote marine lube oil diagnosis using intelligent sensor systems Dr. M Knowles and Dr. D Baglee Institute for Automotive and Manufacturing Advanced Practice (AMAP), University of Sunderland Marine Maintenance Technology Conference 2014 14th – 16th October 2014: Brussels, Belgium

Presentation Outline Background to project POSSEIDON project RCM for guiding future development Potential further research directions

Marine Lubricating Oil Condition Monitoring The primary purposes of oil are to reduce friction in moving components and to prevent metal to metal contact. Oil can also be used as a means of transporting and removing wear particles and heat and transmitting power in hydraulic systems. Analysing oil not only allows the condition of the oil to be managed but also allows other faults in mechanical systems to be detected.

Onboard Test Kits Advantages: Disadvantages: Immediate Results Risk of Contamination

Onshore Laboratory Testing Advantages: Wide range of tests available High accuracy Disadvantages: Long lead time

Posseidon The Posseidon projects seeks to address these problems by providing a means to monitor the condition of engine lubricating oil

Partnership Fundacion Tekniker IB Krates OÜ Martechnic GmbH Fundacion Tekniker IB Krates OÜ Institut für Mikrotechnik Mainz GmbH (IMM) BP Marine Limited RINA SPA Wearcheck GmbH Sunderland University

Sensor selection Sensor Output IR sensor Water concentration Soot concentration TBN Viscosity sensor Viscosity FTIR sensor Water content Insoluble content Optical particle detector Particles

Prototype

Intelligent Diagnostics The use of condition monitoring through a set of novel sensors has enabled condition based maintenance to be performed. Data from sensors is used to inform maintenance decisions using a repository of predetermined actions for particular combinations of sensor readings. In order to fully realise the potential of the sensor system, however, an intelligent solution is required which can autonomously and automatically interpret the data. In this way information can be provided to the operators on the likelihood of faults occurring in each component.

Bayesian Network Screenshot

Main Interface Screenshot

Posseidon Acheivements The need for the product has been demonstrated The viability of the system has been proved by the development of the prototype system More work to be done

Need for Strategic Development Ship engine rooms are hostile environments Heat Vibration Equipment is on a large scale Condition Monitoring is Expensive Development needs to be guided by a strategy

Reliability Centred Maintenance RCM is a maintenance methodology based upon the collection and analysis of basic equipment data. The primary reason for the development of RCM is to implement a preventive maintenance strategy that could adequately address system availability.

RCM Methodology What is the function of the equipment? What causes each functional failure? What causes each failure and identify failure modes? What is the failure effect? What is the consequence of each failure? What proactive task(s) should be done to predict or prevent each failure? What default action should be done to if a suitable proactive task cannot be found?

RCM Benefits An RCM analysis will enable the correct sensor configuration to be determined for the application. Different combinations of engine and lubricant mean the criticality of the parameters various in each application. The application of such technology may be seen as unproven in this context. A detailed RCM analysis will form the basis of a business case since it ties any investment to where it is most needed.

RCM Benefits Greater safety and environmental protection, due to improved maintenance Improved operating performance, due to more emphasis on the maintenance requirements of critical components Greater maintenance cost-effectiveness, due to less unnecessary maintenance A comprehensive maintenance database, which reduces the effects of staff turnover with its attendant loss of experience and expertise

Hardware and miniaturisation Progress has already been made on miniaturising the individual sensors. Bespoke design is now required to produce a reliable and robust unit

Display Technologies Robust display technologies exist which support marine communication standards and which offer the desired level of robustness.

Extensibility Future Sensor additions – beyond oil Vibration Temperature Thermal Imaging Exhaust Emissions

Onboard/Offboard Connectivity NMEA 2000 – Supported by proposed display units Inter-sensor connectivity – WSNs? Ground to shore connectivity Cost Update rate

Design issues What info is displayed? Resilience Use of software ‘mock-ups’ to obtain feedback from engineering personnel Resilience Use of bespoke test rigs to simulate vibration, thermal conditions etc.

Conclusion A sensor system has been developed to support online condition monitoring Future development to realise the prototype is needed A structured data-based approach should be used to prioritise development activities.

Thank you for your attention