Download - ME-Specific Service Expirience March 2014
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1 < > MAN Diesel & Turbo
ME Specific Service Experience March 2014
Compiled and presented by:
Thomas S. Hansen
ME Task Force Group
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2 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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4 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Multi Purpose Controller (MPC)
History:
2003 ME engine is introduced
2004 2008 Various design and production issues
addressed
2008 Burn-in test introduced
2009 Major update of PCB design
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5 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Place of failed MPC
Manufacturer A
Customer Sorting Total
X
Delivery Quantity 703
Engine/Shipyard 25
Ship owner 19
Return rate *) 6.3%
Y
Delivery Quantity 862
Engine/Shipyard 27
Shipowner 15
Return rate *) 4.9%
Z
Delivery Quantity 266
Engine/Shipyard 13
Shipowner 1
Return rate *) 5.3%
January to September 2011
Total production: 1831
Total returned: 100 (produced in 2008-2011)
Return rate: 5.5 %
35
20
45 X Y Z
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6 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Customer 2008 Year
Production
2009 Year
Production
2010 Year
Production
2011 Year
Production
X 24.2% 12.7% 4.7% 1.6%
Y 14.9% 4.2% 1.2%
Z 9.1% 2.5%
Re
turn
ra
te *
*)
Manufacturer A
11 (of 44)
10 (of 42)
7 (of 14)
~1.5 %
28 of 1831
X Y Z
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7 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
OK 46%
Customer 12%
Parts 88%
FAIL 54%
Part No. Part Name PCB Quantity Part No. Part Name PCB Quantity
49 74HCT245 0340 1 1450 54V, 400W 0350 3
63 IDT7007S55JI 0350 2 1485 33V 1.5kW 0370 1
612 3V9 0370 3 1495 MRF4 0350 1
617 2AT 0370 1 1522 TL7705 0350 3
620 24MHz 0350 1 1601 20IMX4-1515-8 0350,0360 2
628 1u 100V 0370 2 1622 36V . 400W 0350 2
629 33V 5KW 0370 5 1662 12A 0370 2
1167 HCPL0600 0350 3 3004 10u, 35V 0350 1
1193 HLMP-4000 0350 2 3215 XC95144 0340 1
1370 40R2 0.1% 0350 1 4291 RELAY, 12V 0370 1
Analysis of MPCs
returned in 2011
The failure parts were random and various
Manufacturer A
100
46 54
6 (see next slide...)
48 (see examples in
below table...)
.
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8 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
China
shipyard
(Broken)
Engine shop
(Crack)
Shipowner
(Burnt: ESD)
Shipyard
(Oil)
Engine shop
(Damage)
Shipowner
(Wire: foreign
substance) Photos of scrapped products returned from the customers
Manufacturer A
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9 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
1. Production of MPCs during the period: 500
2. Number of returned MPCs during the period: 5 (1 pending)
3. Return rate: 1.0 %
4. Failure rate:
- of returned MPCs produced in 2009 and 2010: 0.8 %
- of returned MPCs produced in 2011: 0.0 %
Manufacturer B
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10 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
MPC10 Dedicated CCU
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12 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
MPC10 Service experience
January 2012:
Introduced for new orders.
Number produced:
~ 3000
Reported claims
Part damaged during production corrective action taken
Foreign particle entered during engine production
BGA burnt due to component failure
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13 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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15 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
FIVA with Linear Motor
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16 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Linear Motor with Moving Magnet
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20 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Old Bearing after approx. 10.000 Hrs.
Bearing very worn
Bearing very worn
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21 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
New Bearings in Production
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22 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Running-in filter, FIVA & Hydr. Pumps Shop test and sea trial
Many FIVA pilot valves are damaged during shop- and sea trial.
Damage is causes by particles released from the piping system.
In service, ME filter and purifiers gradually makes the oil cleaner.
To prevent this damage, we recommend using of temporary 5 m filter between the pilot valve and the main body of the FIVA valve, during
shop test and sea trial.
The same filter type is also used before the pilot valves on the mechanically driven hydraulic pumps.
The filters are removed after sea trial
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23 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Running-in filter, FIVA & Hydr. Pumps Shop test and sea trial
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24 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Running-in filter on FIVA Valves Shop test and sea trial
Subplate
5-micron filter cartridge
Pilot valve
Main valve
Running-in filter
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25 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Running-in filter on Hydraulic pump Shop test and sea trial
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26 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
ELVA Problem and countermeasure
Challenge:
Many failures of the original CWAT ELVA
Always related to the ON/OFF control valve
Action:
Solution with an MOOG ON/OFF control valve installed with reuse of the main valve body has been service tested with a successful result
Decision has been made that all existing vessels with ELVA are being modified to Moog-ELVA
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27 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ELVA Photos
Original version New version
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28 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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30 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
CLO Level Switch History
History:
2003 The sensor is introduced on ME engines PLCA-50
2003-7 Many false alarms
2008 The design was modified and the claim rate much reduced
2010 Many claims of low insulation due to varistor type/
quality (RBedia# < 2 M & Rcomp < 70.0 K)
2010 Design was changed to achieve much improved
insulation properties
2011 Only improved type
(CLS-50) is delivered
Soldering point
Hole in wire
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31 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
History of Pepperl & Fuchs Sensor for
Exhaust Valve
History:
2008 Many failures reported
2009 W42 Thorough production improvements
2010 Jan. Stock is returned to manufacturer for checking
2010 Temporary introduction of 2 out of 100 HASA testing (destructive testing) of delivered
sensors
2010 2012 No sensors of improved version has failed due
to design or quality
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35 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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37 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
ISIC DURA PC Restart MOP Problem History
March 2012: Reports of DURA
PC MOP reporting restart MOP
event log purge
March 2012: Investigation in
LDT/LDE department is
launched
April 2012: Investigation result
and proposed countermeasure
is agreed with maker (ISIC)
June 2012: Hardware kit is
finalized
August 2012: Software upgrade
is ready
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38 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
ISIC DURA PC Restart MOP Problem Problem description
Problem description
During scheduled clean-up of event log data base, a read/write error can
cause the MOP to stop and request restart.
Identified related software issues
Event log database algorithm is intolerant towards any read/write failure.
Identified related hardware issues
1/ Weak connection between harddisk cradle interface pcb and harddisk
2/ Harddisk cradle resonance
Problem is a combination of hardware and software problem
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39 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
Hard disk cradle and interface PCD replaced with direct connection
ISIC DURA PC Restart MOP Problem Countermeasures
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40 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
EC-MOP Designed by MAN Diesel & Turbo
Advantages:
More robust and reliable
Lower cost
Very low heat dissipation
Only the necessary interfaces
MDT owned design
Simple installation/cabling
MDT look and feel
Only one new type of MOP
Only one new software image
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41 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
EC MOP
Number delivered: ~900
Number claims: 25
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42 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
EC MOP
Investigations:
USB port failure:
USB board U4, the IC showed was burned
and cracked. The root cause is believed to
be an Iinternal electrical breakdown in the
touch controller board causing the USB
board to breakdown
Touch screen calibration:
Some cases of incorrect touch screen
calibration where found. The problems were
found to be related to the production
procedues which was corrected.
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43 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: Position sensor for hydraulic pump
CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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45 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Agenda
1 ME-ECS installation types historically and present standard
2 Summary of inspection reports
3 Countermeasures
4 Changes in the pipeline
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46 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME-ECS: ME Engine Control System Installation types
Engine ECR
Classic ME-ECS control panel
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47 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME-ECS: ME Engine Control System Installation types
Engine ECR
ME-ECS control panel for China
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48 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME-ECS: ME Engine Control System Installation types
Engine ECR
Engine-mounted Control Cabinets (ECC) new standard
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49 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME-ECS: ME Engine Control System Installation types
Engine ECR
Common Control Cabinets (CCC) - option
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50 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Summary of Inspection Reports Engine builder installations
Junction box wiring causing isolation errors:
Wires touch the interior faces of the box and rub against them due to vibrations
Wires get wedged between box and lid
Cause: Wires have not been cut to length and are
insufficiently strapped!
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53 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Summary of Inspection Reports Yard installations
EICU installations in ECR
Excessive wire length
Units installed without cabinet
Insufficient strapping and marking of cables & wires
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54 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Summary of inspection reports Yard installations
Cable routing, marking and screen termination
Insufficient cable marking
Missing or wrong cable glands
Wrong screen termination in cable glands
Resulting in:
More complicated troubleshooting
Great risk of insulation faults or short circuits
EMC problems
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56 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Countermeasures Updated Production Specification
Our Production Specification for Mounting and installation of electrical
equipment has been updated, focusing on:
New installation types (ECC w. MPC10)
New screen terminations in selected locations
Junction box wiring
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57 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Countermeasures Implemented design changes
Introduction of ECC, Engine-mounted Control
Cabinets:
Elimination of PDB and safety system box on the control panel
EMC cable glands replaced by screen termination on controllers & grounding bars
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58 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Countermeasures Design changes implemented
EICU cabinet introduced:
One cabinet for both EICU A & B
No cable glands: all cables enter through the bottom of the
cabinet with screen termination on a steel comb
Cables are connected to a terminal row with spring-loaded
push-in terminals, leaving the electronics untouched
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59 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Countermeasures Junction box requirements
To counteract the many insulation faults in junction boxes, a set of requirements
have been defined specifically for the junction box design and wiring.
Important highlights are:
Wires must be cut to correct length excessive wire length is not acceptable
Wires must be tied securely, preferreably to support bars
Wires must under no circumstances touch the interior parts of the box or the box itself
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60 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
ME/ME-C Service Experience Agenda:
Controllers: MPC, MPC10
Actuators: FIVA, ELVA
Sensors: Position sensor for hydraulic pump
CLO no flow, sensor
Inductive sensors
Operating panels: ISIC DURA PC, EC MOP
Installation: Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline
Monitoring PMI Auto-tuning
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62 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
PMI Auto-Tuning. Standard on engines
contracted after April 1st 2013
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63 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Auto-Tuning
Potential Fuel Reduction
Pure pmax level increase
Potential 5-10 bar
Potential 1-2.5 g/kWh
Reduction in fuel oil consumption / CO2 emissions
1 bar increase in average pmax => 0.20-0.25 g/kWh decrease in fuel oil consumption
Reference pmax
Potential
Potential
Balancing + pmax level increase
Potential additional 2-5 bar
Total potential 1.4 3.75 g/kWh
Will also benefit engines already being
operated within recommended limits
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64 < > MAN Diesel & Turbo ME service experience March 2014 THH/dept LDT
Continuous auto-tuning activated
Reference pmax
Average pmax
Result: 4-bar pmax increase
1-1.2 g/kWh SFOC reduction
PMI Auto-Tuning
10K98ME-C
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65 < > MAN Diesel & Turbo THH/dept LDT ME service experience March 2014
MOP screen for PMI auto-tuning
PMI Auto-Tuning. Standard on engines
contracted after April 1st 2013
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66 < > MAN Diesel & Turbo
All data provided in this document is non-binding.
This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject
to changes and will be assessed and determined individually
for each project. This will depend on the particular
characteristics of each individual project, especially specific
site and operational conditions.
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67 < > MAN Diesel & Turbo
Thank you for your attention
Questions?