Handout MAN Electronic Engines

Operation and Analysis (ME)

E005, Wayne Mller

ME engine
engine control
system
hydraulic power
supply system
filters
pumps
valves
Contents

1 Introduction ............................................................................................................................. 4
1.1 Course Plan ...................................................................................................................... 4
1.2 Abbreviations .................................................................................................................... 5
2 Introduction to the ME engine .................................................................................................. 6
3 ME Concept .......................................................................................................................... 12
3.1 Control System ............................................................................................................... 12
3.1.1 MPC & Control Network ........................................................................................... 12
3.1.2 Control Panels .......................................................................................................... 24
3.2 Tacho System ................................................................................................................. 26
3.3 Performance ................................................................................................................... 30
3.4 Pneumatic Manoeuvring System ..................................................................................... 32
4 Engine Operation .................................................................................................................. 33
4.1 Engine ............................................................................................................................ 33
4.2 Auxiliaries ....................................................................................................................... 37
4.3 Maintenance ................................................................................................................... 39
4.4 Admin ............................................................................................................................. 43
4.5 Alarms ............................................................................................................................ 44
5 Hydraulic Power Supply ........................................................................................................ 47
5.1 System............................................................................................................................ 47
5.2 Filter Unit ........................................................................................................................ 49
5.3 Startup Pumps ................................................................................................................ 52
5.4 Engine Driven Pumps ..................................................................................................... 53
5.5 Valve Block ..................................................................................................................... 68
6 Hydraulic Cylinder Unit .......................................................................................................... 70
6.1 Distribution Block ............................................................................................................ 70
6.2 Components ................................................................................................................... 73
6.2.1 FIVA ......................................................................................................................... 73
6.2.2 Accumulator ............................................................................................................. 74
6.2.3 Cylinder Lubricator ................................................................................................... 76
6.3 Highpressure Pipes......................................................................................................... 83
7 Fuel Oil System ..................................................................................................................... 85
7.1 Fuel Oil Pressure Booster ............................................................................................... 85
7.2 Adjustments .................................................................................................................... 89

2
8 Exhaust Valve System........................................................................................................... 92
8.1 Exhaust Valve Actuator ................................................................................................... 94
8.2 Special running conditions, open exh-valve .................................................................... 98
8.2.1 Small Bore Program (50 ME) .................................................................................... 98
8.2.2 Large Bore Program from 60 and up ........................................................................ 99
9 New displays ECS 0905 ...................................................................................................... 102
9.1 Engine .......................................................................................................................... 102
9.2 Maintenance ................................................................................................................. 105
9.3 Auxiliaries ..................................................................................................................... 111
9.4 Admin. .......................................................................................................................... 111
9.5 Alarms .......................................................................................................................... 112
10 PMI & EDS ........................................................................................................................ 113
10.1 PMI system ................................................................................................................. 113
10.1.1 Ensures ................................................................................................................ 113
10.1.2 Design .................................................................................................................. 115
10.1.3 PMI offline ............................................................................................................ 115
10.1.4 Cylinder Pressure Analyser .................................................................................. 116
10.1.5 Diagrams .............................................................................................................. 118
10.2 CoCoS-EDS................................................................................................................ 128
10.2.1 Features in CoCoS-EDS....................................................................................... 128
10.2.2 Two versions available: ........................................................................................ 128
10.2.3 Online-Service ...................................................................................................... 131
10.2.4 Monitoring Views .................................................................................................. 132
10.2.5 Reporting .............................................................................................................. 134
10.2.6 Line Recorder ....................................................................................................... 136

3
1 Introduction

1.1 Course Plan

Day 1 Day 2 Day 3 Day4

09:00 Welcome Tacho System Hydraulic Power Fuel system

Introduction to Supply
ME engine

10:00 Coffee/Tea Coffee/Tea Coffee/Tea Coffee/Tea

10:20 ME Concept MOP Screens Hydraulic Power Exhaust valve

Supply system
12:00 Lunch Lunch Lunch Lunch

13:00 ME Basic Practical Hydraulic PMI & CoCoS

Overview exercises Cylinder Unit Test
Controller
functions
14:15 Coffee/Tea Coffee/Tea Coffee/Tea Coffee/Tea

14:30 Exchange of Practical Hydraulic Evaluation

MPC controller exercises and Cylinder Unit Certification
Introduction to faultfinding Theoretical
Simulator exercises Lub Oil
+/- 16:00 End of Day End of Day End of Day End of Day

4
1.2 Abbreviations

5
2 Introduction to the ME engine

Designations

Same structural parts as MC-Design

The ME engine programme consists of 14 engine types

with outputs ranging from 6,320 80,080 kW.
Variable electronically-controlled timing of fuel
injection and exhaust valves for lower specific fuel
consumption and better performance parameters
Lower rpm possible for manoeuvring
Better astern and crash stop performance
Improved emissions characteristics, such als lower
Nox and smoke values at any load
Equalized thermal load in and between cylinders
minimizing the risk of premature need for overhaul
System incorporating performance monitoring to
promote longer times between overhauls

6
Development of the ME-engine
1991 Start of Intelligent Engine Project
1993 4T50MX equipped with Electronic Engine Control equipment
1997 4T50MX with 2nd generation control equipment
1997/98 Design - Production - Installation of mechanical/hydraulic components for service
test on M/T "Bow Cecil
1997/98 Design and implementation of governor functionality, and service test onboard
Shanghai Express
1998/2000 Design - Production - Test - Installation of Engine Control System on M/T Bow Cecil
2000 Start of service test on M/T Bow Cecil
2003 First production engine

Components Omitted / Redesigned

Chain drive
Chain wheel frame
Chain box on frame box
Camshaft with cams
Roller guides for fuel pump and exhaust valve
Fuel pumps
Exhaust valve
Exhaust actuator
Starting air distributor
Governor
Regulating shaft
Mechanical Lubricator
Local control stand

7
New Components / Redesigned

Hydraulic Power Supply (HPS)

Hydraulic Cylinder Unit (HCU)
Engine Control System (ECS)
Starting air valves
Start and Reversing sequences
Governor function
Auxiliary blowers
Electronically Profiled Injection (EPIC)
Exhaust valve actuation
Cylinder lubrication (ACC)

Exhaust valve
Crankshaft position sensing system
Local Operation Panel (LOP)

ME Engine Hydraulic Oil Loop

8
ME Engine Hydraulic Oil Loop

Hydraulic Cylinder Unit HCU

9
ME Fuel Oil Pressure Booster - MC versus ME

Exhaust valve system - MC versus ME

10
ME Engine Control System

ME Tachosystem

11
3 ME Concept

3.1 Control System

Bridge Ctr System

Engine Ctr System

3.1.1 MPC & Control Network

The Multi Purpose Controllers are identical hardware wise and have different software
configurations. Two redundant control networks are connecting all Multi Purpose Controllers
and both Main Operating Panels. A backup of the application- and setup- software is stored on
both Main Operation Panels. At replacement, the new controller is automatically configured with
correct software via the control networks

12
.

13
14
LED Information Code
The LED gives information, either as a constant light or by flashing. A flashing LED is a coded
message from the controller. The code consists of 2 digits:
1. Digit is given by red flashes on yellow/orange background
2. Digit is given by green flashes on yellow/orange background
The 2 digits are separated by a 1 sec. yellow/orange pulse.

15
Control Network

MPCs Nordic Brasilia 6S70ME-C

16
Engine Interface Control Unit

EICU Interface to External Systems

EICU Speed Setpoint

17
ECU Start Block

ECUI

18
Injection Profiles

Governor

19
Cylinder Control Unit, CCU

20
Starting Air Systems

Starting- and Pilot Air Valve

21
Auxiliary Control Unit, ACU - Blower Control
The blowers are starting one by one, to prevent
overload of electrical system

In AUTO mode:
The blowers are started at Prepare Start
At engine running they are controlled by the
scavenge air pressure, stop at 0.7 bar (time
delay), start at 0.4 bar.
At engine stop they will continue running for
default 20 min.

In MANUAL mode:
Controlled by the operator
An alarm is activated when selecting manual
mode.

Auxiliary Control Unit, ACU Pump Control

Electrically driven pumps 1 & 2 are controlled by
ACU 1 & 2.

Engine driven pumps 1, 2 & 3 are controlled by ACU

1, 2 & 3, The control is modulated, based on the
pressure setpoint and the actual hydraulic pressure.

Engine driven pumps 4 & 5 are the same type as 1,

2 & 3 but are controlled digitally by ECU A & B,
either maximum AHEAD or maximum ASTERN.

If the engine is equipped with 4 or 5 engine

driven pumps, ECU A & B are not 100 %
redundant.

22
Multi Purpose Controller, MPC Summary

The MPCs are software wise configured to 4 different controller functions:

1) Engine Interface Conrol Unit EICU

2 completely redundant units
Handles the interface to external systems

2) Engine Control Unit ECU

2 completely redundant units (except with more than 3 engine driven pumps)
Handles the engine specific control functions (the govenor)

3) Cylinder Control Unit CCU

1 for each cylinder unit, redundancy by multiplicity with reduced power.
Handles the cylinder specific functions (fuel injection, exh. valve, cylinder lubrication and
starting air valves)

4) Auxilliary Control Unit ACU

3 units, redundancy by multiplicity
Handles the auxilliary systems (hydraulic power supply, aux blowers)

23
3.1.2 Control Panels

Main Operating Panel

24
Main Operating Panel, MOP

Local Operating Panel (LOP) - FPP

Local Operating Panel (LOP) - CPP

25
3.2 Tacho System

There are 2 redundant tacho systems:

System A
System B
Standard is:
Angle encoders with one
Reference sensor on the turning wheel (A-system)
Option is sensors at the turning wheel

26
Angle Encoders

27
Amplifier Boxes

Semicircular Ring

Master Slave A, MSA, on AFT end of Engine

28
Trigger Rings + Sensors (option)
Triggersegment with a sine-curved tooth-profile. The total trigger ring is built by 8 equal
segments.

2 redundant set of sensors.

Each set measure engine speed and crankshaft position for synchronization of the control
events. Also checks the direction.
Each set consist of four sensors. Two quadrature sensors measure on a trigger ring with
360 teeth and two marker sensors measures on a semicircular ring.

29
3.3 Performance

By changing the exh. valve closing timing, the Pcomp can be adjusted, and then the Pmax can
be kept constant in a bigger range. The maximum pressure rise (Pmax Pcomp) has the the
same limits as for MC engine because the combustion chambers are identical (i.e. 35 bar).

30
Pscav, Pcomp & Pmax

31
3.4 Pneumatic Manoeuvring System

32
4 Engine Operation
4.1 Engine

Operation

Access Level

33
Status Start blocked

Status

34
Process Information -Running Mode

Process Information - Speed Control

35
Cylinder Load

Cylinder Pressure

36
4.2 Auxiliaries

Hydraulic System

Scavenge Air

37
Cylinder Lubricators

38
4.3 Maintenance

System View, I/O Test

System View, I/O Test - ECU-A

39
System View, I/O Test - ECU-A, Channel-32

System View, I/O Test - ECU-A, Channel-35, Invalidated

40
Invalidated Inputs

Network Status

41
Network Status ECU A Net A Failure

Network Status ECU A Net A + B Failure

42
4.4 Admin

Version

Set Time

43
4.5 Alarms

Alarm List

Event Log

44
Event Log - Filter

Manual Cut-Out List

45
Channel List

46
5 Hydraulic Power Supply

5.1 System

Lubricating and Cooling Oil System

47
Hydraulic Power Supply HPS

Separate Hydraulic System

48
5.2 Filter Unit

Filter Unit, Schematic

Filter and pumps

49
Filter Single filter cartridge

10 m filter cartridge: 6 m filter cartridge:

08/06 = production month/year 09/06 = production month/year
1340006 = filter cartridge ID 1341446 = filter cartridge ID
25 = manufacturer's filter mesh code Sintered filter material

Automatic Filter

50
Automatic Filter, Type 6.64

Backflushing, initated at interval of every 60 minutes

Pressure dependent backflushing, initated at dP=0,6 bar.
Pressure dependent alarm, initated at dP=0,8 bar.

Backflushing Line to
Lube Oil Tank

51
5.3 Startup Pumps

Start up Pumps, fixed

Start up Pumps

Electrically Driven Startup Pumps

52
5.4 Engine Driven Pumps

Electrically Driven Start-up Pumps

Axial Piston Pump - A4VSO xxx HS3xxx. (Bosch-Rexroth)

Axial Piston Pump - Rotating Parts

53
Axial Piston Pump - Valve Plate

Swash Plate Principle

Pump sizes:

125 ccm/rev - 3 pumps

180 ccm/rev - 3 pumps
250 ccm/rev - 3 pumps
355 ccm/rev - 3 pumps
500 ccm/rev - 3 to 5 pumps

54
7S50ME-C
Design features for K+S80ME-C9, K98ME-C7:
210 Bar -> 300 Bar
Working pressure increased from 210 bar to 300 bar resulting in: HPS:
Necessary pump size reduced from 355 cc to 250 cc.
Only 3 pumps needed.
Same pipe and hose dimensions.

This is because of the relation between Q (flow) and pressure (p) shown by the equation:
N=Qx p, where N is the power generated by the pump, the power output is the same; therefore
a higher pressure will result in a lower flow.

Gear Box for HPS

Hydraulic Power Supply

55
Pump Drive and Moment Compensator

Chain Tensioner

56
Pump Drive

Pump Shaft Principle

Hydraulic Power Supply 7S60ME-C

57
Access to Chain Tightener

Access to Hydraulic Power Supply

Mounting of HPS
Structure of HPS and Framebox
Design of components

Design of Hydraulic Power Supply

58
Hydraulic Power Supply

HPS access on older models

12K98ME Engine driven Hydraulic Power Supply

59
10-12K98ME/ME-C

Engine Driven Pumps

60
Automatic mode:
The pressure set point is depending on the engine load.
The pumps have two running modes, 1 in pressure control mode [Ctrl] (selected via the
MOP screen), 2 in follow mode [Folw].
The [Ctrl] pump is running 50% and compensates immediately for deviations between
actual pressure and set point. Over time the [Folw] pumps will take over the compensation
while the [Ctrl] pump goes back to 50 %.
In case the pressure controlling pump faces a failure, one of the other pumps will take
over pressure control.

Manual mode:
The pressure set point is set by the operator

Summary
In case of control failure of a pump, the swash plate will be forced to maximum capacity in
AHEAD direction.
Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.
Pump Nos. 1, 2, and 3 have their own sensor for system pressure, connected to their
controlling ACU
Pump Nos. 4 and 5 are controlled by a binary signal, either max capacity AHEAD or
ASTERN. No. 4 is controlled from ECU A, and No. 5 from ECU B.
All pumps have sensors for suction pressure. If the pressure is too low, or all sensors are
failing, a SHUT DOWN will be activated.

61
Leak Detection

62
Leak Connections

Pump Drive with Accumulator Block - Located on aft end of the engine (7S50ME-C).

Sensors for Suction Pressure

63
Engine Driven Pumps, Nordic Brasilia 6S70ME-C

12K98ME - Different Mark Versions

64
12K98ME - ME-Mark 4 (updated version). New H.P connection between acc. block and safety block
based on service experience

12K98ME - ME-Mark 4

65
12K98ME - Mark 4, Complete HPS with Accumulator Blocks

Galleries and Shielding

12K98ME - ME-Mark 4

66
HPS unit ready for installation on the engine.

Pumps and Valve Block, K98ME/-C Mark 3 (Modulated valve block)

67
5.5 Valve Block

K98ME/-C, Mark 3, Modulated valve Block

68
Fore Section, Mark 3

Aft Section, Mark 3

69
6 Hydraulic Cylinder Unit

1) Distribution Block

2) Components:
FIVA
Accumulators
Cylinder Lubricator

3) Highpressure Pipes

6.1 Distribution Block

70
L70ME

Valve Operation

71
 Valves

CAUTION
HCU OVERHAULING
1. CLOSE VALVE NO. 420, 531
2. OPEN VALVE NO. 421, 405, 406
3. CHECK PRESSURE AT MEASURING POINT 455.
WARNING NEVER OPEN VALVE 420 WHEN SYSTEM PRESSURE IS ON

CAUTION
LUBRICATION OVERHAULING
1. CLOSE VALVE NO. 560
2. CHECK PRESSURE AT MEASURING POINT 565
3. IF PRESSURE IS PRESENT, PRESS THE PRE-LUB BUTTON AT THE HMI PANEL.
Cautions

72
6.2 Components

6.2.1 FIVA

Valves

Fuel Injection Valve Actuation

MAN Diesel FIVA

73
FIVA Spool Positions

6.2.2 Accumulator

Diaphragm, Working Principle

Nitrogen Check, SL06-469

The accumulator charge pressure should be checked within
the first week of service. Next check should be made around 4
months later, followed by checking every 6 months. A minor
leakage from the accumulators is unavoidable, and service
experience shows that a pressure drop in the range of 2-5
bar/month is to be expected. The charge pressure is
dependent on working servo oil pressure as well as the
accumulator temperature. For the 200 bar HPS accumulator
charging pressures are:

95 bar +0/-5 @ 20C

105 bar + 0/-5 @ 50C

74
 Fractured Disc
Accumulator Diaphragm, Sl06-469

Accumulator dismantling

Accumulator assembling

75
6.2.3 Cylinder Lubricator

Cylinder Lubrication System

Cylinder Liners

76
ME Cylinder Lubricator

The purposes of cylinder lubrication are as follows:

1. To create a hydrodynamic oil film separating the piston rings from the liner
The optimum is kept safely down to a feedrate of 0.60 g/kWh.
2. To clean the piston rings, lands and ring grooves
All approved cylinder oils fullfils the requirements due to the detergency properties of the
cylinder luboil, even at a feed rate as low as 0.60 g/kWh.
3. To control corrosion, i.e. control the neutralisation af sulphuric acid
According to latest Service Letter (SL09-507) Feedrate Factor and Minimum Feedrate have
to be adjusted to 0.20 g/kWhxS% and 0.60 g/kWh

77
Optimising the Cylinder Condition Lubrication versus Maintenance

ACC Dosages calculated from different Feedrate Factors (SL09-507, Normal Running)

Operation on fuel oil with around 1.5% sulphur should preferably be done in combination with a
low-BN cylinder oil. However, continuing on BN70 cylinder oil is possible for a limited period of
7-14 days without any serious risks of over alkalinity. We recommend using a lower-BN cylinder
oil, when operating on low-sulphur fuels for extended periods (more than 14 days).

78
Running in New liner and rings, SL09-507

ACC Cylinder Lubrication

79
Correction Tables

When operating the Lubrication from MOP without updated software, the system will not allow
the Feed Rate Factor to be adjusted below 0.25g/kWhxS%. To ensure correct lubrication oil
dossage correspondig to Feed Rate Factor settings 0,20 or 0,23g/kWhxS, the factor has to be
adjusted to 0.26g/kWhxS% in the MOP and correction on the sulphur content in the fuel oil (S%)
has to be done according to the Correction Tables.

In case of CCU failure, where the CCU cannot be changed immediately, the cylinder lubrication
can be achieved by a temporary cable from one of the ECU units, plug 52, to the solenoid valve
on the lubricator on the unit in question.The lubrication will be with random timing.

80
Cylinder Lubrication Back-up

81
HCUs Mounted on a Common Base Plate

Hydraulic Cylinder Units

HCU Line, 300 Bar

82
6.3 Highpressure Pipes

Double Wall Piping, Sealings

ME Engines Double wall pipe Original design

Tool for dismantling HP Double walled pipe

83
Double Walled pipe New design Double wall Pipe

Leak Detection

1. CLOSE the valve 430 at the last but one Hydraulic Cylinder Unit.
2. OPEN the valve 431 at the last HCU to decrease the pressure in the space between the
inner and outer pipe.
3. CLOSE the valve 431 at the last HCU again.
4. Check the pressure increase in the space between at pos. 435, at the last HCU
5. If the pressure increases to system pressure level, the leakage has been found.
6. When the leakage has been eliminated, bring all the valves to their normal position

84
7 Fuel Oil System

1) Fuel oil pressure booster

2) Adjustments

7.1 Fuel Oil Pressure Booster

85
Slide type Fuel Valve

Fuel Oil Injection working principle

86
Fuel Oil Injection working principle

Fuel Oil Booster Pipe Connections

Fuel Oil Pressure Booster, K98ME

87
Fuel Oil Pressure Booster Item description K98 ME

88
7.2 Adjustments

FIVA Valve Position Control

Supervision of FIVA Feedback Signal & Plunger Position

The FIVA is immediately set to exhaust valve open position: (Safe position) if:

1 The FIVA valve feedback signal is not valid, i.e. outside 4-20 mA
The FIVA valve feedback signal indicates a too high (not physical possible) speed
The FIVA valve feedback signal indicates a position not allowed outside a window around
TDC

2 The fuel booster position feedback signal indicates that the fuel booster is moving during
the compression stroke.

Reset by resetting CCU in question, or invalid / valid these 2 inputs Ch. 30 & 31

Feedback Supervision

89
Fuel Index Adjustment

Adjustment of Maximum Pressure

90
Suction Valve, K98ME

Fuel Oil Pressure Booster, Technical Data, K98ME

Hydraulic pressure mounting: 2200 bar
Hydraulic pressure dismantling: 2000 2400 bar
Booster housing, weight: 260 kg
Booster complete, weight: 700 kg
Hydraulic plunger, weight: 70 kg
Fuel plunger weight: 35 kg
Top cover, weight: 260 kg
Suction valve, tightening torque: 1165 Nm

91
8 Exhaust Valve System

1) Exhaust valve actuator

2) Exhaust valve

3) Special running conditions

Exhaust Valve Actuation -MC versus ME

92
Exhaust Valve - Pipe Connections

93
8.1 Exhaust Valve Actuator

Working Principle

94
Design Features - MC versus ME

Design Details

95
8.2 Exhaust valve

ME Exhaust valve

Exhaust Valve Assembly

96
Exhaust Valve

Sealing Oil Control Unit

MOP Exhaust Valve Adjustments

97
8.2 Special running conditions, open exh-valve

8.2.1 Small Bore Program (50 ME)

98
8.2.2 Large Bore Program from 60 and up

99
100
101
9 New displays ECS 0905

9.1 Engine

Process Adjustment Auto Tuning

Cylinder Load

102
Cylinder Pressure

Fuel Quality

103
Chief Limiters

104
9.2 Maintenance

System View, I/O Test

Network Status

105
Function Test HCU

Function Test HCU

106
Function Test HCU

Function Test Tacho

107
Function Test Tacho

Function Test HPS

108
Troubleshooting HCU

Troubleshooting HPS

109
Troubleshooting HPS Events

Troubleshooting HCU Events

110
9.3 Auxiliaries

Cylinder Lubricators

9.4 Admin.

Version

111
9.5 Alarms

Alarm List

Alarm List

112
10 PMI & EDS

10.1 PMI system

The purpose is to follow alterations in:

The combustion conditions

The general cylinder condition
The general engine condition
In order to discover any operational disturbances

Observations:
Engines poorly balanced, often outside recommended deviation limits
Engines operated with low Pmax level

Result:
Increased fuel oil consumption & CO2 emissions
1 bar increase in average Pmax => 0.20 - 0.30 g/kWh decrease in fuel oil consumption

Action:
Adjust engine continuously to best operating conditions

10.1.1 Ensures
To ensures Emissions according Technical File with:
specified components
>specified Performance<

113
114
10.1.2 Design

10.1.3 PMI offline

115
 Engine Control Engine Room
PMI/CoCoS-
EDS PC Room

Converter box
MAN B&W Diesel A/S

Converter BOX

Controller with
Junction box Transducer
MOP B MAN B&W Diesel A/S

JUNCTION BOX

24V
HUB

Intermediate Box
PMI
MAN B&W Diesel A/S

Angle Encoder
TDC BOX

AMS PC
Intermediate Box
*) Optional Alphalub
MAN B&W Diesel A/S

TDC BOX

10.1.4 Cylinder Pressure Analyser

116
PMI

117
10.1.5 Diagrams

PT diagram

PT diagram zoomed

PV diagram

118
Balanced plot, Pmax - Pcomp

P,comp tuning is done by entering a Compression Ratio Offset:

C,Ratio=P,Comp / P,Scav.
C,Ratio Offset = -1,1 / 3,62 = -0,3
Reading from P.scav sensor is corrected to Absolute value by adding athmospheric pressure, 1
bar. P,Max. Tuning is done by entering an offset directely in bar.

Balanced plot, Pi

P(i) tuning: Offset (High)Load (+0,27/19,1)x100% =1,4%

119
Calculated values

Fuel index adjustment

120
Adjustment of maximum pressure

10.1.5 PMI online

The PMI Online System

121
The PMI Online System

PMI online Auto tuning

122
Engine tuning process

PMI online 2nd generation

123
Sensor Type and Mounting

Option of Sensors

124
ME PMI Auto-tuning

Auto tuning: ME & MC

125
Prototype field test of auto-tuning function

ME-MOP: Layout proposal for Auto-tuning screen

126
Green Ship of the Future: Auto-tuning - Potential

Fuel oil consumption

Reduction potential: 3 g/kWh
Reduction typical: - 1 g/kWh

Emission
Potential: 2% C02 reduction

Operation cost reduction

Reduced engine maintenance costs, increased availability/reliability

Simplified operability
Ease workload on crew
Ensures always well adjusted engine

127
10.2 CoCoS-EDS

Computer
Controlled
Surveillance

Engine
Diagnostics
System

10.2.1 Features in CoCoS-EDS

Data Logging
Monitoring
Performance analysis and diagnostics
Trend Logging
Reporting

10.2.2 Two versions available:

CoCoS-EDS ME Basic: Mandatory for all ME, ME-C and ME-B engines
CoCoS-EDS Full version: Optional for all MAN Diesel 2-stroke engines

Both versions shares the same system software that makes monitoring, adjustment and trouble
shooting of the engine much more efficient. The main difference is the configuration of the
software and the interface towards other systems (e.g. Alarm and monitoring system AMS etc).

128
CoCoS-EDS ME Basic
No commissioning needed, plug n play.
Interface to the MAN Diesel Systems i.e. ECS and PMI (PMI On-line or Off-line)
Log and display of data from the ME ECS and PMI via MOP-B
Used for condition monitoring, recording, show trends, reporting, adjustments and trouble
shooting of the ME engine.

129
Full Version
Includes all features of ME Basic version and additionally:

Interface to other system e.g. AMS to log cylinder exhaust gas temperatures, BWM for
bearing wear monitoring, LWM for liner wear monitoring etc
Reference measurements (Model curves) for enhanced trouble shooting performance
analysisand diagnostics
Requires commissioning by MAN Diesel service engineer

130
10.2.3 Summary

Benefits:
Increased availability and reliability of the diesel engine
Optimise plant performance to gain a reduction of operating costs

The CoCoS-EDS will:

Facilitate decision making by the chief/crew/home office/ commissioning engineer to:
Prevent failures or reduce the risk of failures or allowing for earlier and appropriate
corrective actions at earliest possible time
Specify causes and effects in case of unusual engine behaviour
Provide performance analysis and reporting facilities

10.2.3 Online-Service

Ships Network (Lan)

Router/Firewall
Satellite

Switch
Engine Control Room

Satellite dish GeNuA

GeNuA Box PC
ECR
Box

Converter

AMS ECS
Ship

Engine readings,
for the whole day,
received every night!
Office HQ
D/E

131
10.2.4 Monitoring Views

Main Window

Engine Overview

Quick overview of the data logging and diagnostic intervals for the particular engine. Displays
also the availability of serial interface data and definition of values measured.

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Engine Overview

Provides a complete listing of the latest set of operating parameters.

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10.2.5 Reporting

Customisation of Standard Report

Customised reports

Provide a function to create entirely new reports or edit existing report lay-outs. Can contain live
operating data and/or stored off-line data.

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Example of customised report, Performance report

Example of customised report, Fuel oil consumption

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10.2.6 Line Recorder

Data Logging

Costumisation of Display Groups

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Data Logging/Trends
Typical 100 400 analogue channel / installation
Stored in EDS format data bases
Cycle memory: Each sec /6 hours
Short trend: Each 5 min / 3 weeks
Long Trend: 1-24 times a day/ lifetime
Measurement trend: Manually triggered
Diagnosis trend: Diagnosis triggered
Data export to ASCII format / Excel

Bar Charts

Characteristics Map

The charts describes the behaviour of the optimal tuned engine. Cross hear indicates current
operating value.

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Load Diagram

The chart describes power and speed limits. Cross hair indicates current operating value.

Performance curves / Tables

The vertical line shows the current power of the engine. Use cursor to read the corresponding
values in the table. Provides easy means of comparing current performance against
background curves showing values when the engine was new, alternative when CoCoS was
installed.

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Monitoring

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