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CASE STUDY

Major Faults Accurately Pinpointed on Naval Ship Engine During its Operation with Engine Condition Monitoring System by Neptunus

Background

The maintenance of a naval ship is of paramount importance for ensuring it is ready for combat, carrying out its duties, and fulfilling its mission. Without a proactive approach to its maintenance, it may be unable to perform its tasks effectively and could even become a liability during a battle.

Industry Segment

Defence

Arm Solution

Engine Condition Monitoring

Equipment

Navy Fleet tanker

Objectives

 To test its ability to provide accurate data as well as pinpoint existing and emerging faults in a naval ship engine.

Highlights Of Our Product

Easy To Install And Operate

Pinpoint emerging defects

Remote monitoring of all assets under a single central command,

Increased uptime of engines

Engine
Agnostic

Scientifically Extend Overhaul Intervals with Significant Cost Savings

Evaluation Process

  • 8 MPU Sensors were installed to monitor health of the Port and Stbd main engine & torque of the individual propeller shafts
  • The diagnosis was done in a dual-cylinder setup due to the absence of provision to mount a TDC sensor on the cam gear.
  • Data stored in Vib360: engine condition monitoring system , can be periodically downloaded for trend analysis.
  • The system was installed and monitored by Naval Command for over six months for the evaluation process.

Discovery/Insights From Our System

  •  Some issues highlighted by the system during the trial period are described below

Port Engine

  • Operating efficiency is high at higher loads as compared to lower loads
  • Power loss at low loads is 2.3% and 0.9% at high loads.

Stbd Engine:

  • Significant torsional twist on the crankshaft is observed during low loads and idling (359 RPM), indicating non-uniform power strokes
  • Compression issues on cylinders observed – due to worn piston rings & fuel leakage

Conclusion

Navy opened the STBD Engine to validate the results provided in real-time offline by Vib360 system and found worn rings in a few cylinders

Provides reliable data that can be used to stop Catastrophes (Failures)

Helps to accurately identify mechanical and operating conditions at different power loads.

Results

The Diesel Testing & Tuning Team (DTTT) in Mumbai and Visakhapatnam have each started the process on Gem to purchase one portable box and added it to their regular tool list. Data from every engine on every war vessel would be obtained once a month for analysis, trending, and alarms for years, and the permanent installation of the tool on all the naval engines would be decided based on its performance.

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Neptunus Power Plant Services Pvt. Ltd.

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Neptunus Main Office

A 554/555, TTC Industrial Area,
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Maharashtra 400710, India.

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