Product Description

Kongsberg K-Chief 600

Vessel Performance System
 Kongsberg K-Chief 600
Vessel Performance System
Product Description

345588/C
May 2011 Kongsberg Maritime AS
Document history
Document number: 345588
Update of specifications and process view in Fuel performance
Rev. C May 2011
monitoring chapter.

Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.

Kongsberg Maritime AS
www.kongsberg.com
 Product Description

Table of contents
Glossary....................................................................................................................4
INTRODUCTION ................................................................ 5
SYSTEM DESCRIPTION...................................................... 7
System modules........................................................................................................7
Fuel performance monitoring ...................................................................................8
Engine performance monitoring............................................................................. 11
Energy management ...............................................................................................15
MAIN BUILDING BLOCKS ................................................ 18
Overview ................................................................................................................18
Vessel Performance System hardware units ...........................................................19
Vessel Performance System sub-systems ...............................................................22
A BRIEF RECAPITULATION ............................................. 27

345588/C 3
Kongsberg K-Chief 600

Glossary

Abbreviations
CAN Controller Area Network
DPU Distributed Processing Unit
LAN Local Area Network
ME Main Engine
OS Operator Station
rpm Revolutions per minute
RTi Remote Torque Interface
SCU Segment Controller Unit
SIU Sensor Interface Unit
VPS Vessel Performance System

Units of measurements
g gram
hrs hours
kg kilogram
kW kilowatt
kWh kilowatt hours
MW megawatt
NM nautical mile

4 345588/C
 Introduction

Introduction

Kongsbergs extensive experience and knowledge in navigation, propulsion and

machinery control systems have made us capable of designing a modular vessel
performance concept, which contributes to improved fuel efficiency and reduced
emissions.
In order to optimize the total energy consumption of the ship, the Kongsberg Vessel
Performance System (VPS) addresses specific areas for improvement, such as engine
optimization, speed profile, optimal trim, speed and rpm/pitch thereby also reducing
operating costs. The system has been installed and proven successful on various types
of ships.
The Kongsberg VPS provides a set of tools that enable ship operators to manage their
vessels in a more economical and environmentally beneficial way, all in compliance
with the present safety regulations.

The Kongsberg VPS can be delivered as an integrated part of the K-Chief 600 automation
system, or as a stand-alone system, with independent operator stations.
The system offers a user-friendly human-machine interface and a practical selection
of process pictures.

345588/C 5
Kongsberg K-Chief 600

Figure 1 K-Chief 600 system architecture

Figure 2 The Vessel Performance main process view

6 345588/C
 System description

System description

System modules
The Kongsberg Vessel Performance System is based on our highly distributed and
modular automation technology. The system concept comprises three main modules:
Fuel performance monitoring
Engine performance monitoring
Energy management

Figure 3 The Vessel Performance System

345588/C 7
Kongsberg K-Chief 600

Fuel performance monitoring

This module is designed to give the operator a tool for monitoring the fuel consumption.
By aiming specifically at the propulsion system, the operator receives invaluable
information on the most economical operation. The module provides an overview of the
propeller, shaft and main engine.

Figure 4 The Fuel performance monitoring module

Based on the acquired measurements, a set of performance parameters is calculated,

including:
Momentary fuel consumption for each engine in kg/hrs
Total momentary fuel consumption in kg/hrs
Hull efficiency in kg/NM
Engine efficiency for each engine in g/kWh
Power efficiency in kWh/NM
Propeller slip in %
Shaft power for each shaft in MW
Shaft torque in kNm
Total shaft power in MW
Duration of voyage in hrs
Distance travelled in NM
Accumulated fuel consumption for each engine in Tons

8 345588/C
 System description

Total accumulated fuel consumption in Tons

Accumulated propeller shaft power for each shaft MWh
Total accumulated propeller shaft power MWh
Fuel oil cost in USD/NM
The Kongsberg MetaPower torque system measures torque on the rotating shaft. The
systems patented optical technology provides high accuracy and long term stability.
Reliable flow (mass) meters, having accuracy better than 0.25 %, shall be installed to
ensure successful consumption measurements of fuel oil and diesel oil. Flow meters
can be supplied by Kongsberg, if required.

Benefits of fuel performance monitoring

Continuous measurements of fuel consumption and engine power output
Monitoring of parameters for improving the vessels overall performance
The fuel performance process view gives the operator a tool to see the operational
performance of the vessel. The view is customer specific and can be adapted to the need
of the customer. To be able to get maximum performance from this view, Kongsberg
recommends installing:
MetaPower shaft torque meter
High accuracy fuel flow meter
High accuracy cylinder lubrication oil flow meter

Figure 5 Fuel performance monitoring process view

345588/C 9
Kongsberg K-Chief 600

Recommended inputs
The following parameters will be measured and connected to the Fuel performance
monitoring system in order to achieve optimal indications and advice:
Fuel (mass) oil flow for each propulsion engine (both input and output flow to be
measured)
Fuel (mass) oil flow for each auxiliary engine (both input and output flow to be
measured)
Fuel oil temperature for all input and output flows to be measured
Weight of fuel oil types
Running signal for each propulsion engine to be logged
ME rpm
Shaft power for each propeller shaft
Shaft torque for each propeller shaft
Ship speed in water (Log)
Ship speed over ground (GPS)
Trim, List and Draft (optional)
Wind speed (optional)
Wind direction (optional)
Rudder movement indicator (optional)
Manual insertion of fuel specific weight in kg/l
Manual insertion of fuel price at last bunkering
Fuel performance roundtrip monitoring display
Fuel monitoring log
The input signals should be analogue or on a serial interface. A sensor input cabinet will
be delivered together with the required number of Distributed Process Units, if needed.

10 345588/C
 System description

Engine performance monitoring

This module is designed to give the operator instantaneous status of the engines
operational performance. By advanced cylinder pressure measurements, subsequent
analysis of the combustion process offers diagnosis algorithms based on empirical results
and physical models. The module will give engine status and hints based on expert
advices. Changing of fuel quality is a challenge, to which the analysis tool provides a
detailed guide for adjustments and tuning of the engines.
Based on the combustion process analysis, torque measurements, fuel quality and fuel
consumption, the emission of CO2, NOX and SOX can be calculated.

Figure 6 The Engine performance monitoring module

Benefits of engine performance monitoring

Reduction of fuel consumption
Monitoring of cylinder load
Calculation of CO2, NOX and SOX
Reduction of maintenance costs and improved planning of maintenance
Reduced risk for engine damage
Optimization of engine-running conditions
Documentation of engine conditions to class societies and insurance companies
The Engine performance monitoring module consists of instrumentation and
measurement units which supply all necessary data for:
Main engine cylinder performance monitoring

345588/C 11
Kongsberg K-Chief 600

Auxiliary engine cylinder performance monitoring

The main engine will normally be equipped with fixed (on-line) combustion pressure
sensors, whilst one portable (off-line) combustion pressure sensor will be employed
for each auxiliary engine.

Figure 7 Engine performance monitoring process view (for Main Engine)

The system provides the operator with main engine performance status based on the
engine cylinder pressure. The cylinder pressure are monitored by online or offline
cylinder pressure sensors. This will provide the user a tool to optimize the engine to
reduce fuel consumption. The engine analysis is provided by EPOS and integrated
in the K-Chief 600 automation system.

Cylinder pressure measurement

Cylinder pressure measurement can be used both for 2 and 4stroke engines. Data from
cylinder pressure sensors, fuel sensors and other signals that are closely related to the
rotation of the engine are processed in real-time and transferred to the K-Chief 600
automation system using the Sensor Interface Unit (SIU).
The combustion analysis gives the engine status and hints based on a deep expert look
into the engine.
The analysis tool provides support regarding the challenge of variable fuel quality. A
detailed guide for adjustments of the engine tuning is displayed in the K-Chief 600.

12 345588/C
 System description

Figure 8 Engine cylinder performance process view (for Main Engine)

Continuous cylinder pressure measurement

Continuous cylinder pressure measurement is performed by using sensors permanently
mounted on each cylinder. The pressure measurement will be performed continuously.
Acquisition of real-time data for pressure curves can be triggered from the K-Chief
600 automation system.

Manual cylinder pressure measurement

Manual cylinder pressure measurement is performed by using the same measurement
sensor and modules as for continuous measurement. The data sampling will be done
using a mobile sensor. The actual measuring process is performed at one cylinder after
the other under preferably constant engine operation conditions.

Required inputs
The following inputs are required in order to achieve optimal indications and advice:
Scavenger air inlet pressure (bar)
Engine room atmospheric pressure (bar)
Exhaust gas temperature (C)
Fuel index (%, mm)
Shaft power (kW)
Engine speed (rpm)
Engine room temperature (C)
Coolant temperature (C)

345588/C 13
Kongsberg K-Chief 600

The Engine performance system can be further expanded with Kongsbergs Bearing
Wear Condition Monitoring System, Cylinder Liner temperature and Main Bearing
temperature sensors. This will provide the user with a comprehensive overview of the
engine status at all times. The system can be used for condition based maintenance.

14 345588/C
 System description

Energy management
These modules are designed to give the operator systematic methods to measure, register
and analyze the energy usage of the ship. This approach identifies specific actions that
operators can take in order to reduce energy consumption. The primary objective of the
methodology is to optimize the use of fuel and minimize environmental effects.
Other objects are to increase knowledge regarding energy issues, maintain effective
monitoring and reporting of fuel usage and reduce risk of discontinued service of energy
systems.

Figure 9 The Energy management module

The Energy Management system has the ability to connect to a shore portal. This is a
web based on-shore fleet management system that makes ships operational information
available to stakeholders throughout the shore organization. The portal allows for
on-shore reporting, monitoring and comparison of sister ships or of an entire fleet.

Benefits of energy management

Fuel savings
Reduced emissions
A complete operational overview
Decision support
Reliable and clear reports
Operational history
Voyage tracking

345588/C 15
Kongsberg K-Chief 600

Inventory overview
Calculation of CO2, NOX and SOX

Figure 10 Energy management process view

Kongsberg Maritime provides engine and propulsion optimization with modules for hull
performance calculations. Modules available are:
Hull/resistance calculations (hull/propeller fouling)
Trim optimization
Optimum speed calculations
Economic speed calculations
The associated reporting functions are available on special request.
The Energy management system is using a vessel model to compensate for environmental
effects like wind, waves, sea current, and operational parameters like speed, trim,
rpm/pitch, torque and so on. The vessel model will be improved over time.
Depending on the agreed scope, the system has potential to give guidance for then
following parameters:
Optimal trim
Optimal speed (advanced speed pilot)
Optimal rpm/pitch
Hull/propeller fouling compared to clean hull

16 345588/C
 System description

Other energy consumers can be included and be analyzed for optimal operation. This
can typically be a Power Management system, Boilers, Waste Heat Recovery System
or HVAC.
The Energy management module will also include more advanced reports and route
comparing functionality than what the Fuel performance monitoring system can offer.

345588/C 17
Kongsberg K-Chief 600

Main building blocks

Overview
The following sections describe the main building blocks of the Vessel Performance
System. These building blocks are both hardware and software entities, which combined
constitute the complete system.
Software and system components are common with the K-Chief 600 automation system,
allowing integration and joined support. Data transfer via the CAN bus is the base for
easy communication with other Kongsberg systems.

Typical configuration alternatives

Fuel performance monitoring module
K-Chief 600 Operator Station(s)
Kongsberg MetaPower torque system
Mass flow meters for main and auxiliary engines
Fuel performance software
Engine performance monitoring module
K-Chief 600 Operator Station(s)
Vessel Performance Operator Station(s)
Ship@Web Server
Fixed cylinder pressure sensors for main engine
Portable cylinder pressure sensors for auxiliary engines
Engine performance software (AVL EPOS)
Energy management module
K-Chief 600 Operator Station(s)
Vessel Performance Operator Station(s)
Ship@Web Server
A selection of Energy Management software modules (Marorka Maren)

18 345588/C
 Main building blocks

Vessel Performance System hardware units

Standard K-Chief 600 automation system units
The K-Chief 600 is a modular system that allows us to meet individual ship owners
requirements using standard modules. The main building blocks of the K-Chief 600 are:
Operator Stations (OS)
Their main functions are to receive alarms and to allow monitoring and control of
the system. They can display process views, allow control of the Watch Calling
System and print various logs. They also enable the operator access to Distributed
Processing Units for inspection of variables, remote operation of equipment
adjustment of parameters and so on.
Operator Panels
Their main functions are to act as status and command panels for the Operator
Stations. Each panel also include a keypad for entering numerical values into
the system and/or a trackball for controlling the cursor position on the Operator
Station screen.
Distributed Processing Units (DPU)
The main functions of the Distributed Processing Units are to monitor analogue
or digital sensors, and to provide analogue and digital output to different devices.
All units have the same mechanical construction and are built using the same
electronic design principles.
Refer to the K-Chief 600 Operator Manual [document 338857] for detailed descriptions
of the standard units listed above.
The units specially designed for use with the Vessel Performance System is described in
the following paragraphs.

Ship@Web server
The Ship@Web Server provides K-Chief 600 services on the ships administrative
network. This is based on a secure and safe communication structure.
The server does not require any maintenance or operation by the crew on-board the
vessel, and is fully configured and maintained by Kongsberg.
The core functionality of the Ship@Web server includes:
Integration between K-Chief 600 and all third party software, as AVL EPOS,
Marorka MAREN, Lodic, K-Log and others.
A secure connection between K-Chief 600 and the ships administrative network.
Availability of administrative functionality to the crew and officers on-board the
vessel. Examples are using it as a Ship Viewer on the Chief engineers office or
the use of electronic logbooks.
Ship owner access to the K-Chief 600 system on-shore through a secure web server.
This will give the owner more control over the entire fleets performance through
process views, alarm lists, trends, logbook pages and so on.

345588/C 19
Kongsberg K-Chief 600

Segment Controller Unit (SCU)

The Segment Controller Unit is a Kongsberg Distributed

Processing Unit (DPU). It is a dual four channel CAN
gateway.
The main function of the SCU is to process messages from
the local CAN bus segment and send them to the global
process bus.

Remote Torque Interface (RTi)

The Remote Torque Interface is a Kongsberg Distributed

Processing Unit (DPU). It is used for measuring torque and
RPM on rotating shafts. In addition the unit calculates shaft
power.

Sensor Interface Unit (SIU)

The Sensor Interface Unit is a Kongsberg Distributed

Processing Unit (DPU). It is an intelligent unit where up to
four cylinder pressure sensors may be connected. The SIU
will interpret the signals from the connected sensors and
publish the result to the segment network (CAN bus).
The SIU holds input channels for top dead centre (TDC)
and crank angle.
The SIU is also responsible for the acquirement of raw data for engine performance
analysis.

Cylinder pressure sensor

The Kongsberg GT-26/GT-27 cylinder pressure sensor is

a durable cylinder pressure sensor especially designed for
monitoring of large-bore diesel or gas engines. The sensor
has an integrated amplifier that contains modern drift
compensation and is factory calibrated to a uniform system
output.
The sensor is based on piezoelectric principles. This allows
high lifetime of the sensor also in high performance engines.
Due to its double shell design, the sensor is very insensitive
against deformation of the mounting bore and different mounting torque. No regular
factory calibration is required. Checking against the balancing sensor is sufficient for
practical use.

20 345588/C
 Main building blocks

Fuel flow meter

A flow meter with high accuracy and excellent repeatability is required. The flow meter
will be set up for monitoring flow in kg/h. The flow meter itself is able to provide fuel oil
specific gravity and temperature.
A reliable flow meter is vital in order to achieve correct emission calculations. Accepted
accuracy is 0.25 % or better.
The flow meters are connected to Kongsberg DPUs and update the K-Chief 600
continuously with:
The mass flow measured in kg/h or volume flow in m3/h
The fuel oil specific gravity and the temperature
These values will be transferred to the K-Chief 600 automation system from the flow
meter with the aid of conventional analogue signals or pulses. The results of the
measurements will be presented in a dedicated process view.

345588/C 21
Kongsberg K-Chief 600

Vessel Performance System sub-systems

Kongsberg MetaPower torque and power measurement system for rotating shafts
The MetaPower system allows the ships management to maintain or increase the
speed while saving significant amounts of fuel, reducing CO2 and NOX output levels.
It measures torque and power transferred from the main engines to the propellers.
Comparison between power output and fuel consumption gives valuable information
avoiding over-stressing of the engine.

MetaPower is a digital measuring system using

optical technology for detection of shaft torque,
shaft RPM and consequently the transferred
power. The system offers high accuracy and good
long term stability. By transmitting measured
data via satellite from ship to shore, the shipping
companys operation management is able to
decide the most economical operating modes for
the ships engine and propulsion system.

Figure 11 MetaPower process view

Refer to the MetaPower data sheet [document 355191] for more information.

22 345588/C
 Main building blocks

AVL EPOS
AVL EPOS is a software application for monitoring and automatic diagnosis of
large-bore combustion engines and their auxiliaries. The application delivers engine
status and hints based on a deep expert look into the engine.
AVL EPOS displays the engine status via a simple traffic light style indicator. If
integrated fault patterns are identified, the system can provide an output for problems in:
The fuel injection system
The combustion process
Liner/piston behaviour
Exhaust valves

Figure 12 AVL EPOS process view (integrated in K-Chief 600)

The combustion analysis inside AVL EPOS uses verified routines. The subsequent
diagnosis algorithm is based on the results of the combustion analysis using different
state of the art methods and physical models. Data from shop tests, sea trials or real
condition status trials can be used as references for the diagnosis. The human machine
interface contains a representative status - the traffic light - for simple overview. Further
views show measurement data and diagnosis in different detail and depth. Customer
specific reports can be generated.
The customer benefits using AVL EPOS are:
Information about engine condition and possible faults can be received regularly
or on user demand.
The diagnostics will also be viewed on the K-Chief 600 Operator Stations.

345588/C 23
Kongsberg K-Chief 600

Recommendations for optimum engine performance and adjustment are extractable.

Reports can be printed or saved.

Marorka MAREN
Maren is an energy management software application. The integration of Maren in
K-Chief 600 provides a full real-time overview of the vessel status with regards to energy
efficiency, and enables the user to optimize the voyage.
Maren gives the operator energy consumption monitoring and analysis tools to access the
operational economy of the vessels propulsion and voyage. Other on-board systems,
such as WHR and refrigeration systems, can be included in the Maren system.
Maren calculates a set of performance parameters based on the acquired measurements,
as follows:
Fuel consumption for each engine in kg/hrs
Fuel consumption for Main Engine in g/kWh
Total fuel consumption in kg/hrs
Fuel performance in kg/NM
Shaft power for each shaft in MW
Total shaft power in MW
Duration of voyage in hrs
Distance travelled in NM
Accumulated fuel consumption for each engine in tons
Total accumulated fuel consumption in tons
Accumulated propeller shaft power for each shaft MWh
Total accumulated propeller shaft power MWh

24 345588/C
 Main building blocks

Figure 13 Marorka MAREN process view (integrated in K-Chief 600)

All energy management data is made available for post-analysis and printed reports, both
for the crew and fleet management. Each Energy management module is application
specific and emulates a specific energy system, machinery or operation on-board the
ship. A module is defined by measurements, calculated values, displayed information
and module logic, and is based on the ships specifications. The following modules
are available:
Fuel Manager: This module offers an overview over the energy usage of the
propulsion system. It is designed to assist officers in optimizing the ships propulsion
system.
Overview module: This module offers a high level application that easily calculates
and displays an overview of main performance indicators for the energy efficiency of
the vessel. It gives guidance on actions to improve the vessel overall efficiency.
Inventory module: This module enables the operators to keep track of bunker fuel
additions, bunker usage and bunker (storage) remaining on-board as inventories.
Reporting module Bunker intake report: This report is designed for entering
information related to the fuel oil bunkered, such as amount, type, price, batch id,
density, viscosity and sulphur content.
Reporting module Daily report: This report is designed to automatically collect
operational data, such as total fuel, travelled distance, weather conditions and so on.
State Manager module: This module is used to register operational states (such as
manoeuvering and sea passage) of the vessel and allows data to be analyzed with
respect to different operational states.

345588/C 25
Kongsberg K-Chief 600

Trim Optimization module: This module is focused on the seaworthiness of the

ship and provides the operators decision support for improved trim with lowered
hull resistance.
Power Plant module: This module is designed to support the operators to efficiently
manage power production and power usage on-board.
Navigation module: This module presents an overview of the voyage performance
and the effects of the environmental factors on the ship performance. The main
function is therefore Ship Speed and Route Tracking.
Voyages module: This module gives the operators the possibility to simulate a
voyage performance, and it calculates the optimum speed profile for a entire crossing.
The main function is therefore Ship Itinerary Planning and Ship Speed Planning.
History module: This module is an analysis tool that enables ship operators to
graphically compare operational values over a period of time, helping them to target
focus areas for improving energy efficiency and fuel savings.
Analyze module: This module is designed for the post-processing and generation of
reports, summarizing performance, emissions and bunker use, as well as comparing
energy and fuel usage for different voyages and legs.

26 345588/C
 A brief recapitulation

A brief recapitulation

Kongsberg, as a supplier of integrated ship systems, plays an increasingly important role

when optimizing the operation of vessels.
The main contributions of the Kongsberg Vessel Performance System is as follows:
Exhaust emission reduction of CO2, NOX and SOX
Early detection of operational problems and upcoming faults
Predictive maintenance to minimize possible downtime
Fuel consumption reduction

345588/C 27
2011 Kongsberg Maritime