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Automation Systems Marine

Monitoring and remote control for


MTU ship propulsion systems

Authors: Blue Vision New Generation is an automation system for propulsion plants in yachts and
workboats with MTU Series 2000 or 4000 engines. It is available both in a straightforward, non-
Dr. Stefan Ihmor classifiable version (Blue Vision Basic New Generation) and in an expanded, classifiable version
Project Director Blue Vision New Generation (Blue Vision Advanced New Generation). In a subsequent expansion stage, Blue Vision Premium
Development New Generation will represent the most extensive version. The Basic, Advanced and Premium
versions supersede the current products Smartline, Blueline and Bluevision.
Cornelius Müller
Project Director Blue Vision New Generation
1. Motivation and sometimes even during the course of a
There would appear to be an irreconcilable gulf product’s development.
between the heterogeneity of customers and
markets in the ship automation area and topics Another challenge concerns the use of complex
such as the use of equipment across product state of the art technologies and extensive devel-
lines or an equivalent parts concept at the level opment processes in conjunction with operational
of assemblies or components. Nowadays, elec- availability over many years. There is a clear trend
tronic components are phased out significantly towards increasing requirements imposed by the
in advance of the end of the product life-cycle, classification societies, not just with regard to

www.mtu-online.com

Blue Vision New Generation | MTU | 1


Fig. 1: 8V 2000 M93 Fig. 2: 16V 2000 M94 Fig. 3: 16V 4000 M53/63 Fig. 4: 20V 4000 M73/93

the quality of products but also their associated The equipment developed by MTU in the include the use of standardized interfaces as
development processes. automation platform MCS-6 has in turn been well as adequate performance for expanding the
configured for the respective applications, system. Uniform software interfaces facilitate the
In order to take account of these requirements, with consideration for the customer require- migration of code and accelerate the integration
MTU Friedrichshafen has created a new technol- ments. As far as the ambient conditions such as of bought-in software. Uniform communication
ogy platform for use in MTU automation systems: temperature, electromagnetic compatibility or interfaces make it possible to exchange entire
“MCS-6”— the 6th generation MTU „Monitoring shock are concerned, all key components met components, e.g. in the case of product phase-
and Control System“. the maximum demanded requirements in order outs. Uniform mechanical interfaces make it
to be used across various products. In terms of possible, for example, to carry out an upgrade of
2. Automation platform the selection of components and assemblies, the products in the field.
Today’s MCS-5 automation platform is a modular emphasis was placed on achieving a consistent
system that has been in place for 20 years now. equivalent part and spare parts concept in order The Blue Vision New Generation system de-
With MCS-6, it is being phased out by a new to meet the requirement for long-term opera- scribed below is the first representative of the
generation. The focus here is directed towards tional availability over many years. Application- new MCS-6 technology generation with its focus
highly specialized components developed by specific peripheral components such as on the automation system for ships’ propulsion
MTU that are combined with commercial off- propulsion control levers and instruments are plants. In the medium term, MTU automation
the-shelf (COTS) products to create modular bought in where sensible, and are connected systems in all applications are being converted
and scalable solutions. via standard interfaces. In addition to tried- from MCS-5 to MCS-6.
and-tested CAN bus technology, Ethernet is
MCS-6 defines cross-application characteristics used as the standard for data communication 2.1 System overview
relating in particular to the aspects of interfaces and service activities. Prefabricated plug-and- Blue Vision New Generation (see Figure 5) is an
and software. Efficient reuse of software, includ- play cabling reduces commissioning times and automation system for the propulsion plants in
ing software test cases on the basis of test case minimizes cabling faults. yachts and workboats with MTU Series 2000 or
libraries as a quality assurance measure, also 4000 engines (see Figures 1 to 4). The system
plays just as much of a role as the decentralized MCS-6 has been configured as open architecture is being introduced in several steps. In the first
application engineering in the project system in order to permit adding, upgrading and ex- phase, Blue Vision New Generation replaces the
business. changing components. Key factors in this regard existing Smartline and Blueline products, and of-

Engineering System
· Application Engineering
· Parameter Setting
· Diagnosis

Automation System for the Propulsion Plant


Remote Control System Monitoring Control System
(RCS) (MCS)

Engine Control Gear Propulsion Auxiliary


System (ECS) System System System

Fig. 5: System overview Blue Vision New Generation


Blue Vision New Generation | MTU | 2
fers the following features: Cylinders 8V 10V 12V 16V
· Monitoring of the propulsion plant on control
stands and locally (engine, gearbox as well as Model
propulsion-specific periphery) 2000 M72 X X X X
· Control of the propulsion plant on control stands
2000 M84 X X X X
and locally (engine and gearbox)
· 1-4 shafts 2000 M84L X -- -- --
· 1-6 control stands 2000 M93 X X X X
· Fixed pitch propeller
2000 M94 X X X X
· Interface for remote control systems from exter-
nal manufacturers
· Classifiable
Cylinders 8V 12V 16V 20V
The automation system for the propulsion plant Model
consists of a Monitoring Control System (MCS) 4000 M53 X X X --
and a Remote Control System (RCS). It is con-
nected to the Engine Control System (ECS), the 4000 M53R X X X --
gearbox system, the propulsion system and the 4000 M63 X X X --
auxiliary systems via interfaces. The application
4000 M63L -- -- X --
engineering is handled by an engineering system.
4000 M73 -- X X X
Monitoring Control System (MCS) 4000 M73L -- X X X
The task of the MCS is to monitor the entire pro-
4000 M93 -- X X X
pulsion plant. For this purpose, sensor signals are
recorded, evaluated and shown on instruments 4000 M93L -- X X X
and displays. The creation, signaling and ac-
knowledgment of alarms represent an important Fig. 6: MTU ship engines which can be connected to Blue Vision New Generation
component of the MCS.
missioning tool has a data tracing function. This CAN bus and a number of I/O signals, e.g. for
The MCS makes it possible for monitoring to take makes it possible, for example, for preset spare safety-relevant functions. The following MTU
place on up to six control stands as well as local parts to be supplied. marine engines can be connected to Blue Vision
monitoring in the engine room. An external voy- New Generation (see Figure 6).
age data recorder (VDR) and a GPS receiver can In addition to configuration, the commissioning
be connected via an NMEA interface (National tool offers extensive diagnostic functions for The following electronic components are mounted
Marine Electronics Association). recording, analysis and storage of process data. directly on the engine in the ECS of an MTU ship
Detailed information about the Blue Vision New engine: Engine Control Unit, Engine Monitoring
Remote Control System (RCS) Generation commissioning tool can be found in Unit and Engine Interface Module.
The RCS is a remote control system for the section 4.
propulsion plant. The RCS is subdivided into Engine Control Unit (ECU)
the local control stand in the engine room, the Automation system interfaces The ECU (see Figure 7) is the electronic engine
RCS components on the control stand and the The first development step of the Blue Vision New governor with integrated engine management.
portable control unit as an optional and mobile Generation automation system only supports pro- The engine governor is a standard component
auxiliary control stand. pulsion systems with reverse-reduction gearboxes from MTU. The main tasks of the ECU include
and fixed pitch propellers. The propulsion-specific controlling the HP injection and the engine speed,
Engineering system periphery that can be connected includes, for as well as various engine protection functions. In
The Blue Vision New Generation engineering sys- example, a shaft brake as well as a fuel prefilter addition, the ECU offers monitoring and diagnostic
tem covers the areas of application engineering, or fuel processing system. functions for the engine.
parameter setting and diagnosis.
By means of the non-MTU RCS interface, as an Engine Monitoring Unit (EMU)
The application engineering of the automation alternative to MTU RCS it is possible to connect The EMU (see Figure 8) acts as a safety system
system is handled by MTU and involves the selec- remote controls for propulsion systems with a for independent monitoring of the various redun-
tion and wiring-up of automation components as water jet or controllable pitch propeller.
well as the definition of parameter values e.g. for
configuration of the alarm signaling in the MCS. In MCS-6, the automation system is separated
As part of project system business, it is possible from the Engine Control System (ECS) by means
for customer-specific adaptations to be carried of a set and defined interface. This makes it
out on the MCS and RCS within the integrated possible to maintain control of the complexity
programmable logic control system. of both systems, to develop the subsystems
independently of one another and to connect
MTU has developed the Blue Vision New Gen- the automation system to the ECS irrespective
eration commissioning tool for local parameter of the series.
setting of the automation system. The tool
provides not only a guided commissioning dialog 2.2 Engine Control System (ECS)
but also an expert mode. In order to meet the The interface between the automation system and
legal requirement for data traceability, the com- the ECS is based on a redundant MTU-specific Fig. 7: Engine Control Unit
Blue Vision New Generation | MTU | 3
Fig. 8: Engine Monitoring Unit Fig. 9: Engine Interface Module Fig. 10: Systembus Processing Unit

dant engine signals in classified installations, 2.3 Versions allocated to precisely one shaft. The LOP functions
including monitoring of engine speed and lubri- The Blue Vision New Generation product line is as a local control stand in the engine room, and
cating oil pressure, as well as oil mist detection. available in two versions. The Blue Vision Basic comprises the Systembus Processing Unit (SPU,
New Generation (see Figure 11) version offers a see Figure 10) in combination with an operating
In addition, the EMU permits an expansion to the straightforward, non-classifiable system on the basis unit, the Local Operating Station (LOS).
range of signals for monitoring engine measuring of the components listed below, as the successor
points such as individual exhaust monitoring. to the current Smartline product line. The follow- The SPU contains two independent modules for
ing chapters explain the equipment and functions. MCS and RCS. The MCS module monitors the
Engine Interface Module (EIM) engine and gearbox as well as additional drive-
The EIM (see Figure 9) is the central interface The Blue Vision Advanced New Generation (see related signals. The RCS module is the central
between the ECS and the automation system, Figure 12) is the successor to the current Blueline unit for remote control of the propulsion system.
and implements the monitored safety circuit. product line and offers an expanded, classifiable In addition, it monitors the expanded range of
For this purpose, it provides an emergency version of Blue Vision New Generation. signals for classified installations. The LOS is in
stop function for up to eight emergency stop turn connected via the MCS module in order to be
momentary-contact pushbuttons integrated 2.4 Devices and functions independent of the RCS module.
in the hardware. Furthermore, checking and
monitoring of an optional emergency air-shutoff Local Operating Panel (LOP) und Systembus There are two versions of the LOP: the LOP 13 (see
flap are possible. Control functions close to the Processing Unit (SPU) Figure 13, Blue Vision Basic New Generation) for
engine, e.g. for the starting sequence, are also The LOP is the central component in the Blue non-classified applications and the LOP 14 (see
implemented in the EIM. Vision New Generation automation system and Figure 14, Blue Vision Advanced New Generation)
as such is contained in each version. It is always for classified applications. The operating unit of the
Slave Control Stand

Instruments DIS PAN CL PAN DIS Instruments


2nd Control Stand

POU
MCS-CAN-Bus MCS-CAN-Bus
RCS-CAN-Bus RCS-CAN-Bus
Main Control Stand

Instruments DIS PAN CL PAN DIS Instruments RIM


1st Control Stand

MCS-CAN-Bus MCS-CAN-Bus
RCS-CAN-Bus RCS-CAN-Bus

LOP 13 LOP 13
Engine Room

Ethernet
EIM EIM

Fig. 11: System overview Blue Vision Basic New Generation (based on two shafts and two control stands)
Blue Vision New Generation | MTU | 4
Instruments DIS PAN PAN CL PAN PAN PAN DIS Instruments
Slave Control Stand
2nd Control Stand

MCS-CAN-Bus SCU RCS-CAN-Bus SCU MCS-CAN-Bus

Instruments DIS PAN PAN CL PAN PAN PAN DIS Instruments


Main Control Stand
1st Control Stand

MCS-CAN-Bus SCU RCS-CAN-Bus SCU Switch MCS-CAN-Bus

LOP 14 LOP 14

Ethernet Ring
Engine Room

Ethernet
EIM EIM

Fig. 12: System overview Blue Vision Advanced New Generation (based on two shafts and two control stands)

LOP 13 only provides basic functions (ready for MCS and RCS modules of the LOPs in the engine Prefabricated plug-and-play cabling is used to
operation, start, stop, combined alarm/horn off, room. In Blue Vision Basic New Generation, MCS connect the engine and gearbox as well as the
test overspeed, emergency stop, turn engine); the and RCS control stand components installed MTU RCS and MCS components on the LOP. A
LOP 14, on the other hand, offers a classifiable throughout the ship are connected to the associ- non-MTU RCS and selected shipyard signals can
local operating unit (in addition to the LOP 13: con- ated LOP via CAN bus. In Blue Vision Advanced be connected by the customer in a shipyard duct
trol of engine and gearbox as well as a display with New Generation, this task is carried out by the employing standard terminal technology.
operating keys for local monitoring). The LOP 14 is Systembus developed for the propulsion system.
also available in Blue Vision Basic New Generation. The operational availability of Systembus communi- Standard TCP/IP packages are used for carrying
cation is ensured by a ring topology in combination service and process data via the Systembus. CAN
Communication between the individual LOPs with the Media Redundancy Protocol. A managed bus data can also be transported via the System-
of the power train (in multi-shaft installations) Ethernet switch functions as the media redundancy bus (CAN over Ethernet, CoE).
and the connected automation components is manager. This divides up the ring so that it can be
explained below. closed immediately in case of a loss of communi- Systembus Coupling Unit (SCU)
cation. The cross-shaft ring structure connects all Only CAN-based units are employed on the control
Systembus and cabling Systembus stations by means of 3-port switches stands in Blue Vision New Generation. The SCU
The Systembus is an Ethernet-based field bus for inside the unit, applying Ethernet cables, thus (see Figure 15) was developed for connecting
carrying process and service data between the minimizing the cabling complexity. the CAN bus stations to the Systembus (only Blue

Fig. 13: Local Operating Panel 13 Fig. 14: Local Operating Panel 14 Fig. 15: Systembus Coupling Unit

Blue Vision New Generation | MTU | 5


Fig. 16: Display Basic DIS Fig. 17: MTU Multi Function Display Fig. 18: Operating Panel

Vision Advanced New Generation). It has a redun- Operating Panel (PAN) Portable Operation Unit (POU)
dant electrical power supply and two independent The operating panel PAN 9 (see Figure 18) was For Blue Vision Basic New Generation, an optional
microcontroller systems including two times two developed for operating the propulsion plant. It Portable Operation Unit (POU, see Figure 22)
CAN interfaces and emergency stop signals. Thus, makes it possible to input and display up to six is available as a mobile auxiliary control stand.
all MCS and RCS components for one shaft are con- functions. The PAN 9 uses the SAE J1939 CAN Alternatively, the POU can be connected at up to
nected to one control stand via only one SCU on transmission protocol, and is used in the following four different locations via the Remote Interface
the Systembus in a classifiable way. confi­gurations: Module (RIM), thereby facilitating maneuvering.
· Start/stop PAN (control stands) The following actuators can also be connected via
Displays (DIS) · Control active, start, stop, combined alarm/ the RIM, and activated by the POU:
The following displays are available: horn off, override, emergency stop · Windlass
· Basic DIS (see Fig. 16) · LOP-PAN (operating unit of the LOP 13) · Bow thruster
· Version: Blue Vision Basic New Generation · Version: Blue Vision Basic New Generation · Stern thruster
· CAN transmission protocol: SAE J1939 · Ready for operation, start, stop, com­­­
· MTU Multi Function Display (MFD, see Fig. 17) bined alarm/horn off, test overspeed, The RIM interacts with the LOP 13 using the CAN
· Version: Blue Vision Basic New Generation and emergency stop, turn engine transmission protocol CANopen.
Advanced New Generation · RCS-PAN + control stand PAN (classified
· CAN transmission protocol: PCS-5 control stands) 3. Development according to the specifica-
· Type-approved · Version: Blue Vision Advanced New Generation tions of the classification societies
· 1x RCS-control-stand-PAN: Display “com- The shipyard must present extensive verification
Instruments manding control stand” and “control stand records for registering a ship with a classifica-
Instruments (see Figures 19 and 20) are available transfer” tion society. This also includes verification of the
for the following functions: · 1x RCS-info-PAN per shaft: Display of automation system for the propulsion plant. If
· Blue Vision Basic New Generation “clutch position” and “synchronization for these verification documents are already avail-
· Engine speed (combination instrument with control stand acceptance”. able, this simplifies the classification process
LCD, up to eight additional measuring points) significantly. At MTU Friedrichshafen, therefore,
· Gear oil pressure Optionally, an external horn can be con- all components for use in classified systems are
· Gear oil temperature nected to the PAN 9. provided with a type approval for the relevant
· Engine cooling water temperature classification societies, for example:
· Engine lubricating oil pressure Propulsion Control Lever (CL) · ABS (American Bureau of Shipping)
· CAN transmission protocol: SAE J1939 The following propulsion control levers (CL, see · BV (Bureau Veritas)
· Blue Vision Advanced New Generation Figure 21) are available for the propulsion plant · DNV (Det Norske Veritas)
· Engine speed remote control: · GL (Germanischer Lloyd)
· Rotational speed · Blue Vision Basic New Generation and Ad- · LRS (Lloyd’s Register)
· Gear oil pressure vanced New Generation · RINA (Registro Italiano Navale)
· Gear oil temperature · RCS UNO/6k (for 1 shaft)
· Engine cooling water temperature · RCS DUO/6k (for 2 shafts) Development according to V-Model
· Engine lubricating oil pressure · RCS TRIO/6k (for 3 shafts) One important aspect in the development of
· CAN transmission protocol: SAE J1939 · CAN transmission protocol: CANopen Blue Vision New Generation was to ensure early
· Type-approved · Type-approved involvement of the classification societies in the

Fig. 19: Engine Speed Fig. 20: Engine Speed


Blue Vision Basic New Generation Blue Vision Advanced New Generation Fig. 21: Control Lever Fig. 22: Portable Operation
Portable Unit Unit (POU)
Operation
Blue Vision New Generation | MTU | 6
development process. Due to their demanding The right-hand branch of the V-model starts with 4. Commissioning
requirements and specifications, the classifica- the software module test of safety-related func- Blue Vision New Generation is equipped with
tion societies GL, DNV and LRS were selected tions. This is followed by the software integration configurable software. The system can have its
as contacts for developing the Blue Vision New and the device test. When all components have parameters set locally by an innovative, configura-
Generation system. passed the test at device level, this is followed by tion tool which is independent of the platform,
the system integration and system test. After- namely the Blue Vision New Generation commis-
MTU develops all hardware and software com- wards the system is verified in a realistic field test. sioning tool. For this purpose, the tool firstly has a
ponents according to the familiar V-model The development process for certification of Blue structured commissioning dialog which automati-
(see Figure 23). This procedure contributes Vision New Generation Advanced components is cally writes all necessary parameters at the end
to avoiding systematic faults during product completed by type approval. of the procedure. Secondly, the tool offers an
development. The development process was expert mode for reading and writing individual
specially tailored to the specifications of the The quality assurance plan contains verification parameters. The commissioning tool has a set
three classification societies, and was presen­­­- activities (e.g. reviews) and quality assurance mea- of diagnostic functions for complex commission-
ted to them at an early stage of development. sures for project milestones and products defined ing procedures. Process data can be recorded
This society recognized it as state of the art. at the start of the project (devices as well as docu- and analyzed. The service application engineer
Continuous quality assurance in the project ments). Validation for all devices also takes place can temporarily set selected parameters once a
provides verification of development in accor- at different development phases in order to check release procedure has been performed, and can
dance with the process, to ISO 9001. and thus ensure market acceptance regularly. stimulate process variables. The tool has user and
rights management on the basis of license files.
A requirements specification is the input pa- Failure mode and effect analysis (FMEA)
rameter for the left-hand branch of the V-model. An extensive failure mode and effect analysis Selected information, e.g. the GPS position of
For this purpose, there is a system require- (FMEA) of the entire propulsion plant has been the ship, can be logged over a long period on an
ments analysis on the basis of which a system performed for the Blue Vision New Generation SD card. All changes made using the Blue Vision
design is carried out. Starting from this, the system; it has been presented to the three clas- New Generation commissioning tool within the
requirements on the device-level for hardware sification societies, which have recognized it as LOP are stored on the SD card, including infor-
and software are analyzed and transferred into state of the art. The system FMEA evaluates the mation about what was changed and which user
device design documents. Afterwards the device probability and criticality of (individual) faults at made the change.
designs are converted into a detailed software system level, with the result that Blue Vision New
design, which in turn serves as the basis for Generation provides adequate compensation for A data tracing function makes it possible to track
implementation. all considered faults. system data, thereby permitting subsequent

Requirements Automation &


Specification Engineering System

Requirements Analysis Type Approval


System
Field Test
System

System Design System Integration & 


(System FMEA) System Test

Development
Engineering
Requirements Analysis System
Device
Software Integration
Device &
Device Test
Device Design
(HW/ SW Architecture)

Development
Hardware
Detailed Design
Software Module Test
Software

Module

Software Implementation

Fig. 23: Electronic development process according to V-model


Blue Vision New Generation | MTU | 7
As a reliable business partner, MTU
also offers customers comprehen-
sive and reliable support services,
including customized service con-
tracts, original MTU spare parts or
consumables such as coolants,
engine oil and engine filters.

delivery of preconfigured spare parts or restoring · Quicker and easier commissioning via struc- 8. Conclusion

Photo credits: pages 1 to 9, MTU Friedrichshafen GmbH.


backed-up configuration statuses locally. tured user dialog The components developed on the basis of
· Type-approved components MCS-6 can be used not only in series production
5. Global service — throughout operational life · Development in accordance with current stan- system business but also in customer-specific
During and after commissioning, the customer is dards project system business. The high degree of
able to rely on the global MTU Service Network · Optimized operation and visualization of the scalability makes it possible for the same com-
which offers rapid, expert support as well as fast propulsion plant ponents to be used for achieving a cost-effective
spare parts provision and logistics. · Uniform spare part concept across all MTU series non-classifiable version (Blue Vision Basic New
· Global sales and service network Generation) as well as an comprehensive clas-
It is necessary to ensure the availability of spare sified system solution (Blue Vision Advanced
parts throughout the entire operational life of 7. Outlook & Trends New Generation). The expansion into Blue Vision
a ship. MTU guarantees that the operator can Development of Blue Vision Basic New Generation Premium New Generation and the updating of Cal-
receive spare parts for up to 30 years. To guaran- and Advanced New Generation will be followed losum will round off the changeover from MCS-5
tee this, the central electronic components are by expansion into Blue Vision Premium New Gen- to MCS-6 in the marine application.
developed, tested and produced in-house at MTU. eration, the successor of the current Bluevision
In the event that a manufacturer phases out parts system. This will implement the following points,
or electronic components during the guarantee for example:
phase, the Development department within MTU · Provision of screen monitoring systems (incl.
will redevelop all affected devices compatibly with keyboard, trackball, …)
the “form-fit-function”, adapting them to all compo- · Expansion of propulsion types to the control-
nents currently available on the market. In order to lable pitch propeller, waterjet, Voith-Schneider,
react to such changes at short notice, MTU Quality POD and combined systems
Management continuously monitors the opera- · Provision of RCS-6 propulsion control lever
tional availability of all components used. (phase-out ROS2 for waterjet, etc.)
· Development of emergency propulsion panel
6. Customer Benefits (e.g. for classified single-shaft installations)
Blue Vision New Generation offers customers the · Expanded RCS functions, e.g. autopilot
following advantages: · Fuel saving functions
· High operational availability and reliability of the · Provision of remote service/remote diagnosis
propulsion plant
· Coordinated range from drive and automation In parallel with the development of the Blue Vision
· High flexibility thanks to modular system struc- Premium New Generation product line for series
ture and open architecture production system business, project system busi-
· Simple, classifiable system in line with current di- ness will be converted to MCS-6 technology on
rectives the basis of “Callosum MC”.

MTU Friedrichshafen GmbH


A Rolls-Royce Power Systems Company

www.mtu-online.com January 2014

MTU is a brand of Rolls-Royce Power Systems AG. MTU high-speed


engines and propulsion systems provide power for marine, rail,
power generation, oil and gas, agriculture, mining, construction and
industrial, and defense applications. The portfolio is comprised of
diesel engines with up to 10,000 kilowatts (kW) power output, gas
engines up to 2,150 kW and gas turbines up to 35,320 kW. MTU also
offers customized electronic monitoring and control systems for its
engines and propulsion systems.

3100701

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