Man B&W Me Engine1

ME Engine Control System
MAN B&W Di e e s l MAN B&W Di e e s l
Safety philosophy and issues of the control system
for the
The ME-engine: Introduction to computer control of the engine combustion proces The Engine Control System: Principles and safety features Integration of the ME-engine to the ship systems
ele ctronicall y controlled ME-e ngine

by
Life-cycle activities:
Main te nance a nd trou ble sho oting Up date of SW
Jrn S. Andersen
Mana ger Basic Ele ctron ic System Ele ctron ics & Softw are Devel opmen t
The Engine Control System as an off-the-shelf product
MAN B&W Di e e s l
MAN B&W Di e e s l
The ME-engine essentials - Why?

Th e ME eng in e type - the electronically contro lled engin e Engine Control System
Possibility for d ifferent operation mod es Op timal com bustio n at all op eratio n speeds an d loads Redu ced part load fuel consu mptio n Smokeless operatio n at all operatio n speeds Redu ced cylin der lubricating oil comsum ptio n Easy ad aptatio n to different fuel Lo wer dead slow ru nnin g and slow steaming , down to 10% rp m L1 Imp ro ved engine acceleration
First ME-engine in operation: December 2003

ME-engine: ME-engine : Electronic Fuel Injection

Injection pressure
MPC
Fuel oil
ELFI ampl.
Principle diagram for electronic f uel injection
ELFI setpoint
f(x)
ELFI pump pis
TDC
ELFI setpoint
Timing exam of f uel injection ple
ELFI pump piston position
May 2005: 12 engi nes in operatio n

Injection pressure
Fuel Oil Injection

Fuel Oil Injection

Phas e 2
5. Th e ELF I valve is activat ed u pward s, closin g the ret urn flow an d op ening for the flow of pr essur ised h ydra ulic oil. T he o il passe s thr oug h the ELFI valve a nd fills t he h ydrau lic cha mbe r. Th e hig h pr essur e for ces th e pist ons u pward s. Th e fu el oil inlet is closed . Th e pr essur e on the fuel o il rises a nd e xceed s the for ce of the s pring in the cylinde rs fu el inject o n va ve . i l ELF I Valve
Phas e 1
1. 2. The pist ons move t o the bottom position. The f uel inlet is open. Hydraulic oil leaves the hydraulic oil chamber via t he ELFI valve. The accumulat ors are supplied by the Hydraulic Power S upply. The pressuri sed hydraulic oil is held back by t he closed ELFI valve.
ELF I
6. 7. 8.
Un es pr surised fue oil l Pr e ssurised fu oil el Un es pr surised hy draulic oi l Pr e ssurised h ydraulic o il
Un es pr surised fue oil l Pr e ssurised fu oil el Un es pr surised hy draulic oi l Pr e ssurised h ydraulic o il
MAN B&W Di e e s l
MAN B&W Di e e s l
S50ME-C Exhaust Valve System

Hydraulic System on the ME Engine

Hydraulic Cylinder Unit (HCU)
Hyd ra ulic pu sh r od
Fu el Oil Pr essu re Boo st er
Exh aus t va lve Exh aus t va lve Act uat or NC Valv e FI VA
Exh aus t Valv e Act uat or
Me mb ra ne ac cum ul ato r ELVA on -o ff valv e
Acc um ula tor
To d ra in
MAN B&W Di e e s l
7S50 ME-C Hig h p re ssu re hyd r aul ic o il - i nle t

MAN B&W Di e e s l
Lu be o ii l t eng i e l n et o n
Hydraulic System on the ME Engine

Fuel Injection Profiles

7S50ME-C 900 75 % Load Injection Profiles
MAN B&W Diesel A/S 2003-02-14 14:30
Hydraulic Cylinder Unit (HCU)

800
700
Classic Constant Press Double Injection
600
Elect ri cally dr ive n st ar t-u p p um p s Ma in fil ter
Eng ine dr ive n pu m ps
Step -u p ge ar
bar
500
400
300
200
Byp ass fil ter
100
Lu be o ii l t eng i e l n et o n
0 165 170 175 180 185 d 190 195 BDC 200 205 210 215
MAN B&W Di e e s l
MAN B&W Di e e s l
Exhaust valve timing

Engine Control System Control functions

Engine Control System
Ele ctr onica lly profile d inje ction onica Ex haus t v alv e a ctua tion G ov er nor func tion
Early closing Late closing Early open ing Late ope ning Refer enc e
Exhaust valve m ovement

80 70 60 50 mm 40 30 20 10 0 90 110 130 150 170 190 210 230 250 270 290 Dg. C. A.
Turboc ha rge r by- pas s A uxiliar y blower s Sta r ting a ir v alv es Sta r t and R ev er sing s eque nce s C ylinder lubr ica tion H ydr aulic powe r s upply
MAN B&W Di e e s l
MAN B&W Di e e s l

ME Engine Control system Context
The ME-engine: Introduction to computer control of the engine combustion proces The Engine Control System: Principles and safety features Integration of the ME-engine to the ship systems Life-cycle activities:
Users: - Operat ors - Engi neers - Service engineers - Perf ormance engineers
HMI
Control system
MAN B&W Di e e s l
MAN B&W Di e e s l
ME Engine Control System Main principles

Engine Control System to Bridge
Engine Control System Actual configuration

BR I D E PA N L G E M A I O PE R AT I O N N P AN E L MO P A M A I O PE R AT I N N G P AN E L MO P B
Main Requirement
HMI HMI
The engine and thereby the Engine Cont rol System must have a very high availabilit y. One f ailure must not stop the engine. Central solutions The f unct ionali ty of the control system is distributed bet ween a number of aut onomous control units. Redundancy of functionality is obtained by duplication and by divisi on on multi ple unit s working in parallel. Communication between control units is done through a double redundant network.
C ont r l R om o o Pa nel
Engine Control Units
EU C Control Network
EU C
EI C U A
EI C U B
LO C AL O PER AT I N P AN EL O LO P EC U A EC U B
Cylinder Control Units
CU C
CU C
CU C
CU C
AC U 1
AC U 2
AC U 3
CC U C yl nder 1 i
CC U C yl nder n i
Crankshaft measurement
M PU P1 M
M PU P2 M
PU M P 1
PU M P 2
PU M P 3
The control system is supplied by two independent power supplies. Essential sensors and act uators are duplicated (at least).
AU XI LI AR Y BL O WE R 1
An gl e En coder s
C nde r St ar A r yl i t i Lubr cat or Val ve i
FI VA Val ve
HYDRAUL POWERSUPPL Y IC MAN B&W Di e e s l
AU XI LI AR Y BL O WE R 2
M ar ker Sen sor
MAN B&W Di e e s l

MAN B&W Di e e s l Bridge Pa n l e MAN B&W Di e e s l

Bridge
Bridge Pa n l e
Bridge
Ma in Ope ra ting Pa n l e
BACK -UPFOR M OP Control Room Pa n l e PC
En gine C trol Room on
Ma in Ope ra ting Pa n l e
Control Room Pa n l e
BACK -UPFOR M OP PC
En gine C trol Room on
EICU A
EICU B
LOP Multi-Purpo e C o s ntrolle r

M C P M C P
En gine Interf ac Contr ol U it Aand B e n

Loc l a Ope ra tion Pa n l e ECU B Control Ne twork
M C P
En gine C trol Unit A and B on

ECU A
Loc l a Ope ra tion Pa n l e Control Ne twork
M C P
Cy ders Contro l U 1 p e cylinder lin nit r

ACU CCU
Auxiliaries C trol Unit 1, 2 and 3 on

MAN B&W Di e e s l
En gine R m/On Engin e oo

MAN B&W Di e e s l
M C P
M C P
En gine R m/On Engin e oo
Basic Electronic System Hardware Components

Multi Purpose Controller (MPC)
Basic Electronic System HW

C C
Main Operating Panels
Control Network
Multi Purpose MPC Controllers

I/O
MPC
I/O
MPC
I/O
MPC
I/O
Serial communication External (control) system
MAN B&W Di e e s l
MAN B&W Di e e s l
Multi Purpose Controller

Multi Purpose Controller (MPC) Software Components

A B
Power Power
Hardware develop ed in-h ouse:

Motorola 6 8332 C PU with Time Proces sing U nit
(Automobil e industry CPU wi th faci lities for determinati on of crankshaft posi ti o p n rogram mabl e in Micro Code)
Contro Network l
Oth er Com pu ter Equ ipm en t
Progr am stored in Fla sh-PR OMs
B
Serial Protocole Sys em t Clock Contro l Network pro tocol (ser vices) Service Te rminal
Software:
RTXC pr e-emptiv e real time ope rating syste m Ba sic Electr onic Sys tem Software pla tform
Im p emented i n C++ l
Mu lti Purp ose Co ntr oller Al rm a hand li g n Variable hand li g n Parame ter hand li g n
Application Software
Im p emented i n C++ and Micro Code l
Appl ication Fu ncti onal ity

Sensor- Actuato r API
Con trol Network:

Media a cces s lay ers based on A rcN et s tandar d Transport layer s of pr otocol ba sed on EU: ATOMOS project Application lay ers of protoc ol a re of subs idiary design
MAN B&W Di e e s l MAN B&W Di e e s l V X
Main Operating Panel (MOP)

Main Operating Panel
MAN B&W Di e e s l
MAN B&W Di e e s l
Main Operating Panel

Main Operating Panel (MOP) Software Components
Type approved PC Touch screen operation PCI Control N etwork board In-house developed Includes hardware watchdog Software: Windows 2000 Application software implemented in C++ and graphics in Borland C++ Builder
SW confi ur a g tion disp lay Main Operating Panel System Cl ck o Alarm Handlng i - Al rm list a - Ev lis ent t - Cut-out ists l Det iled alarm nfo a i
Con ol tr Net ork w pr otoco l protocole (servic es)
Input / output chec and test k
Load of Load of MultiPurpose Com plex Con olers Cotr oler ntr ll
Applicati n o SW back up -
Parameter back up -
MAN B&W Di e e s l
MAN B&W Di e e s l
Basic Electronic System System Supervision and Self-test

Basic Electronic System Computer shutdown - fail-safe state

Shutdown / fail-safe state will be entered caused by: Watchdog time-out
HW w atch dog sup ervises SW watchd og SW wa tchd og supe rvi ses time sche dul e o f critical tasks
Th e s ys te m s uper vis ion ch e cks tha t: Ea ch un it is re sp on d in g Ea ch un it ca n b e re ac he d o n b oth Co ntro l N etw o rk li ne s Th e a pp li cati on is e xe cute d i n e ach un it
HW exceptions, e.g. illegal instructions SW exceptions, e.g. failure situations, w hich handling is not implemented in the SW Power failure
Supe rv ision in e a ch c ont rol un it: Te st o f me mo ry an d S W in te g rity d uri ng star t- up of un it Si gn a l an d c ab le sup e rvis io n a s far a s po ssi bl e Su pe rvi si on of ea ch po we r se ctio n o f th e u ni t N on -p rop e r SW ex ecu tio n => Shu tdo w n - fai l sa fe sta te
MAN B&W Di e e s l
All outputs enters a state equal to power-off state.

MAN B&W Di e e s l
Net wo r k
Graphic A ppl icat ion P ict ures
A B
Engin e C ontrol System

environm ent
Power ma nag emen t syste m Engine pe rfor man ce an d diag nosis: CoCoS a nd PMI o nline Rem ote s ervice via sa tellite Vario us info rma tion client s: Ma inten ance etc.
Rem ote ma noe uvring syste m
Ma ster clock
Ship a larm and con trol sy stem
Engine safe ty syste m
Engine Cont rol System
MAN B&W Di e e s l
MAN B&W Di e e s l
Main Operating Panel Alarm System, Alarm List

Alarm Handling - Sub-alarm System

MBD system
HMI A
HMI B
Alarm Channels
Alarm router serial link
Outvar's
Plant Alarm System
Service Terminal
Central Alarm Router A Power failure
(Redundant) Central Alarm Router B
Power failure
MAN B&W Di e e s l
MAN B&W Di e e s l
System interconnection - PC network - the easy way

System interco nnectio n - PC-n etwo rk with safety precaution s
Ch i e o ffi e PC f c
o th r o ff c e PC s e i
Ch i e o ffi e PC f c
o th r o ffi e P C s e c
et he tn Er xxx011 xxx0x2 2 x x C 917891xxx789111 785xxx4xx xx3xxx 0 A 12123A56 12B456 126 x 4 3 x
xxx0112xxx0x2 x x C 467891xxx789111 A 35123A5x 12B456 782 121xxx4x6xxx3xxx 0 1 9 x
et he tn Er
Sh i p a l a a n rm d c o tro l s ys te m n
MOP A
MOP B
Co Co S PM I o n l n e i
Offi ce PC i n ECR
Sh i p a l a a n rm d c o tro l s ys te m n
MOP A
MOP B
Co Co S PM I o n l n e i
Offi ce PC i n ECR
XXX
et he tn Er xxx011 xxx0x2 2 x x C 917891xxx789111 785xxx4xx xx3xxx 0 A 12123A56 12B456 126 x 4 3 x xxx0112xxx0x2 x x C 467891xxx789111 A 35123A5x 12B456 782 121xxx4x6xxx3xxx 0 1 9 x et he tn Er xxx0112xxx0x2 x x C 467891xxx789111 A 35123A5x 12B456 782 121xxx4x6xxx3xxx 0 1 9 x et he tn Er
MAN B&W Di e e s l
MAN B&W Di e e s l

Life-cycle activities: Trouble-shooting and repair

Consequences of the single failure principle: In a duplicated system must failures be remedied rather fast in theory within an infinitively short period. It must be avoided that trouble-shooting introduces additional failures.
MAN B&W Di e e s l
MAN B&W Di e e s l
MOP I/O test

MOP I/O test
MAN B&W Di e e s l
MAN B&W Di e e s l
MOP I/O test

Repair Philosophy - Repair by replacement

The fu ncti on and l ocation of Multi Purpo se Controll ers are id entified b y an ID-key plu g Back-up of appl icatio n SW a nd ad justment p arameters is store d i n the Main Opera ti ng Panel (s), and i s lo ade d via the Con tro l N etwork
ID-key o n M PC
MAN B&W Di e e s l
MAN B&W Di e e s l
Exchange of Multi Purpose Controller


Tu rn off th e po wer fro m th e de fective MPC Rem ove a ll con necto rs fo r exte rna l cable s Rem ove t he ne twork a ddr ess ID-k ey plug (it istied by a w to ire the box o the MPC f )
Plug- n the netwo rk i ad dres s ID-ke y plug and res tore all cab li g n Tu rn on th e po wer to the n ew MPC Dur ing sta rtu p, the MPC will do wnload the corr ect a pplicatio n soft ware an d the latest par ame ter data from the MOP u nits, an d au tom atic sta rt exe cuting the applica tion a fter the d ownloa d is fin s hed. i Du ng the procedure that w tak some minu the LED of the MPCwillblinkand ri ill e tes, changecolor seve altimes to ndicate ac r i tivity. Verify that the r epla ced M PC s i indica ted as ru nning in th e syste m ove rview scr een on t he M OP
Rem ove t he de fective MPC and insta ll a spa re M PC un t i
MAN B&W Di e e s l
MAN B&W Di e e s l

Development Project
Software update The Engine Control System is built as an
off- the -sh elf

product
The softw are and not least the test is under on-going evolutionary development
U ni T est t
Te st s
Software mod ule test

S co pe: S oft ware modules execut ed in test st ubs and simulat ion environm ent on PC S pecificatio n: T est stubs defi ned by the developer. Test st ubs and result s n:T are configuration cont rolled, maint ained and used f or regression t est Who: S oft ware developer
Test automation: Com piler

The com pil ation of so urce cod e m ust no t cause warn ing s. In case it is unavoi dable in a sp eci fic mod ule, the specific warn ing is expli citl y supp ressed i n thi s m odul e
Scrip ts: Runs the PClint:
tests stu bs and com pares the results wi th previ ous stor ed resul ts Static so urce cod e anal ysis: S tr ict type ch ecki ng, syntax checki ng etc. checks, m em ory leaks
Cod eguard: Bo undary
MAN B&W Di e e s l
MAN B&W Di e e s l
S ubsyst Test em
Position control model
Network nod e so ftware test

S cope: A ssembl ed sof tware f or the network node execut ed in simulat ion environment on P C S pecif icat ion: S imulat ed environment defined by the developer. Sim ulated environm ent and previous results are confi gurat ion controlled, mai nt ained and used for regression t est Who: S oft ware developer Requested posi ti o (tabl e) n
+ :
Requested cu rrent (table) Li near Mo to r

+
PD control
Curren out t
Linear Motor Actu po al sition
LV DT
MAN B&W Di e e s l
MAN B&W Di e e s l
V al cont si ul i ve rol m aton

MAN B&W Di e e s l ELFI pilo s po po itio t ol s n MAN B&W Di e e s l
S ubsyst Test em Network nod e test
Req ueste d Position pro file

mm
Measured error
LVDT pos. feed back

L a e fu e n d e rg l i x Sma l l fu e n d e l i x Ada p tion c on ta tributio n
S cope: S oft ware in Control unit wi th I/O and net work in laboratory S pecif icat ion: Net work node: Test environment defi ned by the developer. Test st ubs and resul ts are configurati on cont rolled, mai nt ained and used for regression t est Who: S oft ware developer
Measured error
Measured error giv changesto earlier current val e es u
Re quested current Actual cu rent r

EL F Cu rre t I n Ad a ta o p ti n ms e c MAN B&W Di e e s l Ti e m MAN B&W Di e e s l
I egraton & S yst T est nt i em

S yst em Test System test (step B)

S cope: Control system etc. on t he research engine S pecif icat ion: S yst em t est specificati on & test program s for T ype approval test test and Engine del ivery t est Who: S oft ware developer(s) and person responsible for t est
Integration & System test (step A)

S cope: A ll cont rol units wi th net work and I/ Os connect ed to si mulator S pecif icat ion: S yst em t est specificati on Who: S oft ware developer(s) and person responsible for t est
MAN B&W Di e e s l
MAN B&W Di e e s l
C om m i oni & D elvery Test ssi ng i

C om m i oni & D elvery Test ssi ng i Delivery o f Engin e

S cope: S pecif icat ion: Who: Actual engine in the ship propulsion plant Sea Sea trial test specifi cat ion Engine builder, O wner and Classif icat ion S oci ety
Delivery o f Engin e
S cope: S pecif icat ion: Who: Engine Engine Del ivery Test specif ication Engine builder, O wner and Classif icat ion S oci ety
MAN B&W Di e e s l
MAN B&W Di e e s l
MAN B&W Diesel A/S

MAN B&W Di e e s l
Thank you for your attention!
MAN B&W Di e e s l
10

Man B&W Me Engine1

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Man B&W Me Engine1

Încărcat de

Drepturi de autor:

Formate disponibile

ME Engine Control System

MAN B&W Di e e s l MAN B&W Di e e s l

Safety philosophy and issues of the control system

ele ctronicall y controlled ME-e ngine

The Engine Control System as an off-the-shelf product

The ME-engine essentials - Why?

First ME-engine in operation: December 2003

ME-engine: ME-engine : Electronic Fuel Injection

Principle diagram for electronic f uel injection

ELFI pump pis

Timing exam of f uel injection ple

ELFI pump piston position

May 2005: 12 engi nes in operatio n

Fuel Oil Injection

Fuel Oil Injection

Un es pr surised fue oil l Pr e ssurised fu oil el Un es pr surised hy draulic oi l Pr e ssurised h ydraulic o il

Un es pr surised fue oil l Pr e ssurised fu oil el Un es pr surised hy draulic oi l Pr e ssurised h ydraulic o il

S50ME-C Exhaust Valve System

Hydraulic System on the ME Engine

Fu el Oil Pr essu re Boo st er

Exh aus t va lve Exh aus t va lve Act uat or NC Valv e FI VA

Exh aus t Valv e Act uat or

Me mb ra ne ac cum ul ato r ELVA on -o ff valv e

Acc um ula tor

7S50 ME-C Hig h p re ssu re hyd r aul ic o il - i nle t

Hydraulic System on the ME Engine

Fuel Injection Profiles

Hydraulic Cylinder Unit (HCU)

Classic Constant Press Double Injection

Elect ri cally dr ive n st ar t-u p p um p s Ma in fil ter

Eng ine dr ive n pu m ps

Byp ass fil ter

Exhaust valve timing

Engine Control System Control functions

Exhaust valve m ovement

ME Engine Control System

ME Engine Control system Context

The Engine Control System as an off-the-shelf product

ME Engine Control System Main principles

Engine Control System Actual configuration

Engine Control Units

Cylinder Control Units

C nde r St ar A r yl i t i Lubr cat or Val ve i

HYDRAUL POWERSUPPL Y IC MAN B&W Di e e s l

M ar ker Sen sor

Engine Control System

Engine Control System

BACK -UPFOR M OP Control Room Pa n l e PC

En gine C trol Room on

En gine C trol Room on

LOP Multi-Purpo e C o s ntrolle r

En gine Interf ac Contr ol U it Aand B e n

En gine C trol Unit A and B on

Loc l a Ope ra tion Pa n l e Control Ne twork

Cy ders Contro l U 1 p e cylinder lin nit r

Auxiliaries C trol Unit 1, 2 and 3 on

En gine R m/On Engin e oo

En gine R m/On Engin e oo

Basic Electronic System Hardware Components

Multi Purpose Controller (MPC)

Basic Electronic System HW

Main Operating Panels

Multi Purpose MPC Controllers