ME Specific Service Experience

March 2014

Compiled and presented by:

Thomas S. Hansen
ME Task Force Group

MAN Diesel & Turbo

<

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

CLO no flow, sensor

Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

>

Multi Purpose Controller (MPC)

History:
2003 ME engine is
introduced

2004 2008 Various design

and production issues
addressed
2008 Burn-in test introduced
2009 Major update of PCB
design

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

>

Manufacturer A
Place of failed MPC

January to September 2011

Customer

Sorting
Delivery Quantity

703

Engine/Shipyard

25

35

Ship owner

19

20

Return rate *)

862

Engine/Shipyard

27

Shipowner

15
4.9%

Delivery Quantity

266

Engine/Shipyard

13

Shipowner
Return rate *)

MAN Diesel & Turbo

6.3%

Delivery Quantity

Return rate *)

Total

45
X

Total production: 1831

Total returned: 100 (produced in 2008-2011)
Return rate:
5.5 %

1
5.3%

THH/dept LDT

ME service experience March 2014

<

>

Manufacturer A

Return rate **)

Customer

X
Y

2008 Year
Production

2009 Year
Production

2010 Year
Production

2011 Year
Production

24.2%

12.7%

4.7%

1.6%

11 (of 44)
14.9%

Z
MAN Diesel & Turbo

THH/dept LDT

4.2%

1.2%

9.1%

2.5%

10 (of 42)

~1.5 %
28 of 1831

7 (of 14)

ME service experience March 2014

<

>

Manufacturer A
Analysis of MPCs
returned in 2011

46

54
Customer
12%

OK
46%

100

FAIL
54%

Part No.

Part Name

PCB

Quantity

49

74HCT245

0340

63

IDT7007S55JI

612

Parts
88%

6 (see next slide...)

48 (see examples in
below table...)

Part No.

Part Name

PCB

Quantity

1450

54V, 400W

0350

0350

1485

33V 1.5kW

0370

3V9

0370

1495

MRF4

0350

617

2AT

0370

1522

TL7705

0350

620

24MHz

0350

1601

20IMX4-1515-8

0350,0360

628

1u 100V

0370

1622

36V . 400W

0350

629

33V 5KW

0370

1662

12A

0370

1167

HCPL0600

0350

3004

10u, 35V

0350

1193

HLMP-4000

0350

3215

XC95144

0340

1370

40R2 0.1%

0350

4291

RELAY, 12V

0370

The failure parts were random and various

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

.
<

>

Manufacturer A
China
shipyard
(Broken)

Shipyard
(Oil)

Shipowner
(Wire: foreign
substance)
MAN Diesel & Turbo

Engine shop
(Crack)

Engine shop
(Damage)

Shipowner
(Burnt: ESD)

Photos of scrapped products returned from the customers

THH/dept LDT

ME service experience March 2014

<

>

Manufacturer B
1. Production of MPCs during the period:

500

2. Number of returned MPCs during the period:

5 (1 pending)

3. Return rate:

1.0 %

4. Failure rate:
- of returned MPCs produced in 2009 and 2010:

0.8 %

- of returned MPCs produced in 2011:

0.0 %

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

>

MPC10 Dedicated CCU

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

10

>

MPC10
Service experience

January 2012:
Introduced for new orders.

Number produced:
~ 3000

Reported claims
Part damaged during
production corrective
action taken
Foreign particle entered
during engine production
BGA burnt due to
component failure
MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

12

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

CLO no flow, sensor

Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

13

>

FIVA with Linear Motor

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

15

>

Linear Motor with Moving Magnet

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

16

>

Old Bearing after approx. 10.000 Hrs.

Bearing very worn

Bearing very worn

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

20

>

New Bearings in Production

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

21

>

Running-in filter, FIVA & Hydr. Pumps

Shop test and sea trial
Many FIVA pilot valves are damaged during shop- and sea trial.
Damage is causes by particles released from the piping system.
In service, ME filter and purifiers gradually makes the oil cleaner.
To prevent this damage, we recommend using of temporary 5 m filter
between the pilot valve and the main body of the FIVA valve, during
shop test and sea trial.
The same filter type is also used before the pilot valves on the
mechanically driven hydraulic pumps.

The filters are removed after sea trial

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

22

>

Running-in filter, FIVA & Hydr. Pumps

Shop test and sea trial

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

23

>

Running-in filter on FIVA Valves

Shop test and sea trial
Pilot valve
Main valve
Running-in filter

Subplate
5-micron filter cartridge

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

24

>

Running-in filter on Hydraulic pump

Shop test and sea trial

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

25

>

ELVA
Problem and countermeasure
Challenge:
Many failures of the original CWAT ELVA
Always related to the ON/OFF control valve
Action:
Solution with an MOOG ON/OFF control valve installed with
reuse of the main valve body has been service tested with a
successful result
Decision has been made that all existing vessels with ELVA
are being modified to Moog-ELVA

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

26

>

ELVA
Photos
Original version

MAN Diesel & Turbo

New version

THH/dept LDT

ME service experience March 2014

<

27

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

CLO no flow, sensor

Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

28

>

CLO Level Switch

History
History:
Soldering point

2003 The sensor is introduced

on ME engines PLCA-50
2003-7 Many false alarms
2008 The design was modified
and the claim rate much reduced
2010 Many claims of low
insulation due to varistor type/
quality (RBedia# < 2 M & Rcomp < 70.0 K)
2010 Design was changed to
achieve much improved
insulation properties
2011 Only improved type
(CLS-50) is delivered
MAN Diesel & Turbo

THH/dept LDT

Hole in wire

ME service experience March 2014

<

30

>

History of Pepperl & Fuchs Sensor for

Exhaust Valve
History:
2008 Many failures reported
2009 W42 Thorough production
improvements
2010 Jan. Stock is returned to
manufacturer for checking
2010 Temporary introduction of
2 out of 100 HASA testing
(destructive testing) of delivered
sensors
2010 2012 No sensors of
improved version has failed due
to design or quality

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

31

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

CLO no flow, sensor

Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

35

>

ISIC DURA PC Restart MOP Problem

History
March 2012: Reports of DURA
PC MOP reporting restart MOP
event log purge

March 2012: Investigation in

LDT/LDE department is
launched
April 2012: Investigation result
and proposed countermeasure
is agreed with maker (ISIC)

June 2012: Hardware kit is

finalized
August 2012: Software upgrade
is ready

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

37

>

ISIC DURA PC Restart MOP Problem

Problem description
Problem description
During scheduled clean-up of event log data base, a read/write error can

cause the MOP to stop and request restart.

Identified related software issues
Event log database algorithm is intolerant towards any read/write failure.
Identified related hardware issues
1/ Weak connection between harddisk cradle interface pcb and harddisk
2/ Harddisk cradle resonance

Problem is a combination of hardware and software problem

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

38

>

ISIC DURA PC Restart MOP Problem

Countermeasures
Hard disk cradle and interface PCD replaced with direct connection

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

39

>

EC-MOP
Designed by MAN Diesel & Turbo
Advantages:
More robust and reliable
Lower cost

Very low heat dissipation

Only the necessary interfaces
MDT owned design
Simple installation/cabling
MDT look and feel
Only one new type of MOP
Only one new software image

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

40

>

EC MOP
Number delivered: ~900
Number claims: 25

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

41

>

EC MOP
Investigations:

USB port failure:

USB board U4, the IC showed was burned
and cracked. The root cause is believed to
be an Iinternal electrical breakdown in the
touch controller board causing the USB
board to breakdown

Touch screen calibration:

Some cases of incorrect touch screen

calibration where found. The problems were
found to be related to the production
procedues which was corrected.

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

42

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

Position sensor for hydraulic pump

CLO no flow, sensor
Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

43

>

Agenda
1

ME-ECS installation types historically and present standard

Summary of inspection reports

Countermeasures

Changes in the pipeline

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

45

>

ME-ECS: ME Engine Control System

Installation types

Classic ME-ECS control panel

Engine

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

ECR

<

46

>

ME-ECS: ME Engine Control System

Installation types

ME-ECS control panel for China

Engine

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

ECR

<

47

>

ME-ECS: ME Engine Control System

Installation types

Engine-mounted Control Cabinets (ECC) new standard

Engine

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

ECR

<

48

>

ME-ECS: ME Engine Control System

Installation types

Common Control Cabinets (CCC) - option

Engine

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

ECR

<

49

>

Summary of Inspection Reports

Engine builder installations
Junction box wiring causing isolation errors:

Wires touch the interior faces of the box and rub

against them due to vibrations
Wires get wedged between box and lid
Cause: Wires have not been cut to length and are
insufficiently strapped!

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

50

>

Summary of Inspection Reports

Yard installations
EICU installations in ECR
Excessive wire length
Units installed without cabinet
Insufficient strapping and marking of cables & wires

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

53

>

Summary of inspection reports

Yard installations
Cable routing, marking and screen termination
Insufficient cable marking
Missing or wrong cable glands
Wrong screen termination in cable glands
Resulting in:
More complicated troubleshooting
Great risk of insulation faults or short circuits
EMC problems

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

54

>

Countermeasures
Updated Production Specification
Our Production Specification for Mounting and installation of electrical
equipment has been updated, focusing on:

New installation types (ECC w. MPC10)

New screen terminations in selected locations
Junction box wiring

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

56

>

Countermeasures
Implemented design changes
Introduction of ECC, Engine-mounted Control
Cabinets:
Elimination of PDB and safety system box
on the control panel
EMC cable glands replaced by screen
termination on controllers & grounding bars

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

57

>

Countermeasures
Design changes implemented
EICU cabinet introduced:

One cabinet for both EICU A & B

No cable glands: all cables enter through the bottom of the
cabinet with screen termination on a steel comb

Cables are connected to a terminal row with spring-loaded

push-in terminals, leaving the electronics untouched

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

58

>

Countermeasures
Junction box requirements
To counteract the many insulation faults in junction boxes, a set of requirements
have been defined specifically for the junction box design and wiring.
Important highlights are:

Wires must be cut to correct length excessive wire length is not acceptable
Wires must be tied securely, preferreably to support bars
Wires must under no circumstances touch the interior parts of the box or the
box itself

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

59

>

ME/ME-C Service Experience

Agenda:

Controllers:

MPC, MPC10

Actuators:

FIVA, ELVA

Sensors:

Position sensor for hydraulic pump

CLO no flow, sensor
Inductive sensors

Operating panels: ISIC DURA PC, EC MOP

Installation:

Installation types
Summery of inspections and problems
Countermeasures
Changes in the pipeline

Monitoring

PMI Auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

60

>

PMI Auto-Tuning. Standard on engines

contracted after April 1st 2013

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

62

>

Auto-Tuning
Potential Fuel Reduction
Reduction in fuel oil consumption / CO2 emissions
1 bar increase in average pmax => 0.20-0.25 g/kWh decrease in fuel oil consumption

Reference pmax

Potential

Potential

Pure pmax level increase

Potential 5-10 bar
Potential 1-2.5 g/kWh

Balancing + pmax level increase

Potential additional 2-5 bar

Total potential 1.4 3.75 g/kWh

Will also benefit engines already being
operated within recommended limits
MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

63

>

PMI Auto-Tuning
10K98ME-C

Reference pmax

Average pmax

Continuous auto-tuning activated

Result: 4-bar pmax increase

1-1.2 g/kWh SFOC reduction

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

64

>

PMI Auto-Tuning. Standard on engines

contracted after April 1st 2013
MOP screen for PMI auto-tuning

MAN Diesel & Turbo

THH/dept LDT

ME service experience March 2014

<

65

>

All data provided in this document is non-binding.

This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual 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, especially specific
site and operational conditions.

MAN Diesel & Turbo

<

66

>

Thank you for your attention

Questions?

MAN Diesel & Turbo

<

67

>