For training

F
pu
urposes only

PMI & CoCoS-EDS Applications

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

<1>

For training
F
pu
urposes only

PMI system purpose

The purpose is to follow alterations in:

th combustion
the
b ti conditions,
diti
the general cylinder condition,
the general engine condition
in order to discover any operational
disturbances.

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

ME PMI
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
g Pmax => 0.20 - 0.30 g
g/kWh decrease in fuel oil consumption
p

Action:
Adjust engine continuously to best operating conditions

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PMI system ensures

To ensures Emissions according

Technical File with:
specified components
>specified Performance<

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PMI system design

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PMI offline

PMI controller

Engine
control
room

Pressure transducer

Power
supply

LED
indicator
Intermediate
Or frequency
divider box
C k h ft pickup
Crankshaft
i k
mounted at free end
of crankshaft
Two-stroke diesel engine
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

<6>

For training
F
pu
urposes only

PMI Cylinder Pressure Analyser

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PMI

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

<9>

For training
F
pu
urposes only

PT diagram

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PT diagram - zoomed

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

PV diagram

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

Fuel index adjustment

Index offset (P,i) at High Load

in Percentage.

Index offset (P,i) at Low Load in

Percentage.
Percentage
A demand for additional
balancing when running low
load is supplied here.

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

Adjustment of maximum pressure

Timing of fuel injection
(corresponding to VIT adjustment
on the MC engine).

Tuning of P,comp is made by

adding an offset to the
Compression Ratio here

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

The PMI Online System

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 15 >

For training
F
pu
urposes only

PMI online Auto tuning

Reduction in Fuel oil consumption
p
/ CO2 emission
1 bar increase in average Pmax => 0.20 - 0.25 g/kWh decrease in fuel oil consumption

Limit Pmax
Potential
Potential

Pure Pmax level increase

P t ti l 5
Potential
5-10
10 b
bar
At full as well as part loads

PMI & CoCoS

(LDE4/TOM)

Balancing & Pmax level increase

P t ti l additional
Potential
dditi
l2
2-5
5b
bar
Gain even with engines already being
operated within recommended limits

MAN Diesel & Turbo

01/01/2012

< 16 >

For training
F
pu
urposes only

Engine tuning process

PMI Online

Continuous auto tuning

Apply
Pmax

Apply
MIP

Apply
Pcomp

Semi - auto tuning

Tuned
Engine

Yes

Obsrv. Key
values

Adjustmen
needed?

No

Yes

Extract
y values
key
Maihak

Retrieve
pressures

Identify
Pmax
adjust

Identify
p
Pcomp
adjust

Identify
MIP
adjust

Adjust
Pmax

Adjust
Pcomp

Adjust
MIP

Manual offset adjustment

PMI Offline
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 17 >

For training
F
pu
urposes only

PMI online 2nd generation

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 18 >

For training
F
pu
urposes only

ME PMI
Auto-tuning
TCP/IP
MOP-B

PMI / CoCoS-EDS PC

Arcnet
MPC

TCP/IP

DAU

Modbus

Remote
R
t I/O
with I/P
converters

Pmax adjustment signals

Pmax Feedback signals
Cylinder pressure
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

Auto tuning: ME & MC engines

MOP-S

TCP/IP

MOP-B

(CoCoS-EDS /
PMI PC)

Arcnet

TCP/IP

MPC

PMI DAU

Pmax Feedback signals

Cylinder pressures

I/P converters
(MC only)
PMI sensors
Actuators
Pmax adjustment signals (VIT)

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 20 >

Prototype field test of auto-tuning function

ME ECS SW AutoTuning on Maersk Wizard 6S60ME-C

Bar

Auto-tuned

Manual adjust

150

150

Pmax Cyl1
Adj Pmax Cyl1
Pmax Cyl2
Adj Pmax Cyl2
Pmax Cyl3
Adj Pmax Cyl3
Pmax Cyl4
Adj Pmax Cyl4
Pmax Cyl5
Adj Pmax Cyl5
Pmax Cyl6
Adj Pmax Cyl6
Pcomp Cyl1
Adj Pcomp Cyl1
Pcomp Cyl2
Adjj Pcomp Cyl2
y
Pcomp Cyl3
Adj Pcomp Cyl3
Pcomp Cyl4
Adj Pcomp Cyl4
Pcomp Cyl5
Adj Pcomp Cyl5
Pcomp Cyl6
Adj Pcomp Cyl6
Pi Cyl1
Adj Pi Cyl1
Pi Cyl2
Adj Pi Cyl2
Pi Cyl3
Adj Pi Cyl3
Pi Cyl4
Adj Pi Cyl4
Pi Cyl5
Adj Pi Cyl5
Pi Cyl6
Adj Pi Cyl6

Auto-tuned

Manual
Offset

Forced unbalance Pmax

145
145
AutoTuning Pmax Ballance

Pmax

140
140

135
135

Pressure in bar

For training
F
pu
urposes only

PMI online - Auto tuning

130
130

125
125

Pcomp

120
120

Auto tuning applied

115
115

1.39

PMI & CoCoS

1.4

100

1.41

200

1.42

300
Time i seconds

1.43

400

1.44
500

secs

1.45

MAN Diesel & Turbo

x 10

01/01/2012

< 21 >

For training
F
pu
urposes only

PMI online - Auto tuning

(ME-MOP: Layout proposal for Auto-tuning screen)

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 22 >

For training
F
pu
urposes only

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

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

For training
F
pu
urposes only

CoCoS - EDS
Computer
p
Controlled
Surveillance
Engine
Diagnostics
System

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 24 >

For training
F
pu
urposes only

CoCoS-EDS
CoCoS
EDS

CoCoS-EDS
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)
up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 25 >

For training
F
pu
urposes only

CoCoS-EDS
CoCoS
EDS

CoCoS-EDS ME Basic:
No commissioning needed, plug n play.
Interface to the MAN Diesel Systems i.e. ECS and
PMI (PMI On-line
O li or Off
Off-line)
li )
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.

up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 26 >

For training
F
pu
urposes only

CoCoS-EDS ME Basic Version

Home office

ECR

Plant

E/R

MPC(s)

MOP-A
MOP-B
Firewall
VPN router

CoCoS
Client PC(s)

CocoS
PMI

PMI On-Line or
Off-Line

DAU

Firewall
VPN router

BWM
LWM
Terminal
Boxes / DPU
AMS

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 27 >

For training
F
pu
urposes only

CoCoS-EDS
CoCoS
EDS

CoCoS-EDS Full version

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
R f
measurements
t (M
(Model
d l curves)) for
f enhanced
h
d trouble
t bl shooting
h ti
performance analysis and diagnostics
Requires commissioning by MAN Diesel service engineer

up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 28 >

For training
F
pu
urposes only

CoCoS-EDS Full Version

Home office

ECR

Plant

E/R

MPC(s)

MOP-A
MOP-B
Firewall
VPN router

CoCoS
Client PC(s)

CocoS
PMI

PMI On-Line or
Off-Line

DAU

Firewall
VPN router

BWM
LWM
Terminal
Boxes / DPU
AMS

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 29 >

For training
F
pu
urposes only

CoCoS-EDS

Benefits:
Increased availability and reliability of the diesel engine
Optimise
O ti i plant
l t performance
f
to
t gain
i a reduction
d ti off operating
ti costs
t

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

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 30 >

For training
F
pu
urposes only

CoCoS-EDS

Features in CoCoS-EDS:
Data Logging
gg g
Monitoring
Performance analysis and diagnostics
Trend Logging
Reporting

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 31 >

For training
F
pu
urposes only

CoCoS-EDS

PMI & CoCoS

Online Service

MAN Diesel & Turbo

01/01/2012

< 32 >

For training
F
pu
urposes only

Monitoring Views - The Main Window

Title bar

Status

Menu bar
Tool bar

Engine view

Di l groups
Display

Status bar
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 33 >

For training
F
pu
urposes only

Engine Overview

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

up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 34 >

For training
F
pu
urposes only

Standard report

Standard Report:
Provides a complete listing of the
latest set of operating parameters.

up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 35 >

For training
F
pu
urposes only

Customisation of Standard Report

Standard Report can

be customised in the
following way:

Tools
Customise Display
Groups

Chose desired
fields using
g mouse
cursor press
Select, then
Ready
Ready

A new standard
report nr. will
appear up in right
corner
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 36 >

For training
F
pu
urposes only

Reporting Customised reports

Reporting,

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

up to 80 080
kW

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 37 >

For training
F
pu
urposes only

Reporting Performance Report

Reporting,

Example of customised
report, Performance report

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 38 >

For training
F
pu
urposes only

Reporting Fuel consumption

Reporting,

Example of customised
report, Fuel oil consumption

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 39 >

For training
F
pu
urposes only

Line Recorder,
Recorder Data Logging

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 40 >

For training
F
pu
urposes only

Line recorder, costumisation of

Display Groups

Line Recorder

Tools Customise
Display Groups

Chose desired
fields using Shift
and Ctrl, press
Select,
Select , then
Ready

New group will be

added on right
PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 41 >

For training
F
pu
urposes only

Bar Charts

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 43 >

For training
F
pu
urposes only

Characteristics Map

The charts
describes the
behaviour of the
optimal tuned
engine. Cross hear
indicats current
operating
ti value
l

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 44 >

For training
F
pu
urposes only

Load Diagram

The charts
describes power
and speed limits
limits.
Cross hear
indicates current
operating value

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 45 >

For training
F
pu
urposes only

Performance curves / Tables

The vertical line shows the

current power of the engine

Use cursor to read the

corresponding
di values
l
in
i the
th
table

Provides easy means of

comparing
p
g current
performance against
background curves
showing values when the
engine was new, alternative
when CoCoS was installed

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 46 >

For training
F
pu
urposes only

Monitoring

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

47

For training
F
pu
urposes only

Disclaimer
All data provided in these training materials is non-binding.
non binding.
This data serves informational purposes only and is especially not
guaranteed in any way.
Depending on the subsequent specific individual projects
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
project, especially specific site and
operational conditions.

PMI & CoCoS

MAN Diesel & Turbo

01/01/2012

< 48 >