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Профессиональный Документы
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Giovanni Benvenuto, Dipartimento di Ingegneria Navale e Tecnologie Marine, Universit di Genova, Italy
Ugo Campora, Dipartimento di Macchine, Sistemi Energetici e Trasporti, Universit di Genova, Italy
ABSTRACT
Various methods are proposed in literature for the engine faults detection, based on the combination of simulation models
with measured engine data. In order to be effective, these methods must be based, in authors opinion, on detailed, reliable
and validated simulation models, able to predict the faulty engine performance, by reproducing its actual work conditions.
This is particularly important in case the simulator is used for the diagnosis of faults or for the engine maintenance staff
training.
The aims of the paper are: firstly, to verify the suitability of the authors diesel engine model to be used for the faults simulation; secondly, to analyse and compare the influence of the engine governor logic on the performance alterations of a
faulty four stroke turbocharged marine diesel engine.
The adopted diesel engine simulation model is based on a two-zone cylinder combustion scheme, which allows a detailed
calculation of the thermodynamic processes inside the cylinders. The thermodynamic study of the in-cylinder phenomena
is combined with a simulation of the behaviour of the turbocharger, of the intake and exhaust systems (intercooler, manifolds, etc.) and of the fuel pump.
The engine faults analysed in the paper, selected on the basis of indications given by the engine maintenance staff and
drawn from bibliography observations, are related to the fuel injection system and to the exhaust manifold behaviour.
The reported analysis and the presented results, relative to the engine performance variation as a consequence of the simulated faults (at different intensity levels), show the validity and the flexibility of the used diesel engine simulator in predicting fault situations. In particular the simulated engine working parameters present a different variation depending on the
adopted engine governor logic.
tion is based on the hypothesis of engine running at constant fuel pump setting and engine speed (condition that
can be verified in an engine test bench). In practical situations, typical of ship propulsion plants, the engine working conditions correspond to the hypothesis of engine
running at constant torque and speed. This last hypothesis
is assumed in [5,13,14] for the prediction of marine diesel
engine faults by means of simulation models.
The aims of the paper are: firstly, to verify the suitability of the authors diesel engine model to be used for the
faults simulation; secondly, to analyse and compare the
influence of the engine governor logic on the performance
alteration of a faulty four stroke turbocharged marine diesel engine. As regards this last aspect, two governor logics
are considered in particular: constant engine torque and
speed (typical of a ship sailing at a constant speed in calm
sea) and constant fuel pump setting and engine speed (that
can be assumed in an engine test bench)
The adopted diesel engine simulation model, already
presented and validated in previous papers [15-21], is
based on a two-zone cylinder combustion scheme, which
allows a detailed calculation of the thermodynamic processes inside the cylinders. The thermodynamic study of
the in-cylinder phenomena is combined with a simulation
of the behaviour of the turbocharger and of the intake and
exhaust systems (intercooler, manifolds, etc.). A filling
and emptying method is adopted in each engine component. The calculation procedure has been validated by
1 INTRODUCTION
The turbocharged diesel engines, thanks to their higher
efficiency, power density, lifetime and lower cost in comparison with other thermal engines, are the most widely
used prime movers in the ship propulsion plants. Therefore it is very important, for the safety and economy of the
navigation, to ensure a perfect efficiency of these engines,
including their auxiliary systems, by means of suitable
techniques directed to the prevention and detection of engine faults. Various methods are proposed in literature for
the diesel engines faults detection and diagnosis. Among
the many available papers and the few considered in this
study [1-14], two basic approaches are substantially used
for marine diesel engine fault diagnosis, the mainly statistical methods [1-4] and those based on diesel engine simulation models [5-14], these last more recent and probably
more useful today.
This second approach, to which also our paper is referred, requires the availability of a detailed, reliable and
validated diesel engine simulation model, including also
the engine auxiliary components (turbocharger, fuel
pump, etc.). In fact the ability of the model to reproduce
the effective engine working conditions is very important
as far as faults prediction and maintenance staff training
are concerned.
From the literature analysis it is observed that in a few
cases (for instance [11]) the diesel engine faults simula-
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d ( U ) 1
= mi H i - mo H o + m f H f + - P
dt
V
id =
40
( )-0.388 CN
K id n pcy
0.69
4.644
exp
Tcy
(5)
When the combustion process starts, the cylinder volume is split into two parts, a burning zone and a non burning one. At each calculation step (d), the heat released
(dQf) by the combustion process is given by:
(6)
dQf = Mf dxb Hf
ign m
(7)
dxb = 1 exp K a
pin pcy
m f = K in f 2
f
) 0.5 d 2
(8)
(1)
Session C
(4)
where the convective heat transfer coefficient (h) is obtained as indicated in [24] and the heat transfer area (Aw)
is expressed as function of the piston position (x) defined
in equation (1).
The ignition delay angle (id) is given by [25]:
Ma = i V v
(3)
where the inlet and outlet masses (mi and mo) are in this
application put equal to zero.
In order to evaluate the heat flow term in the previous
equation, the convective gas-cylinder wall heat transfer, in
the calculation step (d), is determined as follows:
1/2
1 l2
2
x = r 1 + - 2 - sen - cos
r r
(2)
36
2.3
dQw = Ab [Kcon k/B ReKre (Tg - Tw) + Kra (Tg4 - Tw4)] dt (10)
which includes the effect of both convection and radiation. In the non burning zone only the convective heat
transfer between fluid and cylinder wall is considered.
The heat transfer between wall and coolant fluid is computed, therefore the cylinder wall temperature is determined.
The work done onto the piston in the energy equation
(3), for each calculation step (d), is evaluated as:
dW = pcy dV
(11)
V'Cc = V' C
nCc = nTC
(17)
Ta
Tref
(18)
Ta
2.5
TURBINE MODULE
The turbine block is very similar to that used for the
compressor.
A turbine steady state map is also in this case given in
2D matrix form, flow rate and efficiency being functions
of the expansion ratio (T = pi/po) and of the kinematic ratio (ut/co). By the dynamic equation:
(12)
d
1
= Q
dt
J
(19)
(13)
QE = (b.m.e.p.) V
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Tref
(16)
37
1
4
(20)
pcy
0.8
0.6
p ref
p calc
Q ref
Q calc
Qbr = Kp np2
TDC
0.8
0.6
0.4
0.2
270
0.2
360
450
0
540
crank angle []
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(21)
0.4
0
180
The figure shows the layout of the connections between the main blocks of the simulator. The DIESEL ENGINE module, already described, calculates the engine
torque(QE). The engine speed (nE) is determined by solving equation (19) in the SHAFT DYNAMIC module, where
the input variable brake torque (Qbr in the figure) comes
from the BRAKE block, whose output (ship propeller
torque) is determined by the simple equation:
Fig. 3 Constant fuel pump setting and engine speed governor logic.
38
gine simulator the correct value of this parameter is determined, by means of a SIMULINK 2D table, as function
of engine speed and load. For the fault simulation an error
in the fuel injection start crank angle has been assumed,
ranging in a -6 to +6 degrees shifting interval.
Figure 4 shows the results of the considered fault simulation in case of constant engine torque and speed governor logic, while figure 5 shows the analogous results in
case of constant fuel pump setting and engine speed governor logic.
By comparing the cylinder pressure versus crank angle
variations (figures 4a and 5a) it can be deduced that the
difference in the assumed engine governor logic produces
an appreciable effect on the results only in case of start injection error of +6 degrees. The analysis of the analogous
data obtained for the cylinder temperatures (figures 4b
and 5b), does not show any appreciable difference between the two cases.
On the contrary, the results obtained for some engine
parameters (figures 4c and 5c), show interesting differences according to the adopted engine governor logic. As
example the engine Brake Specific Fuel Consumption
(BSFC), when the error in the start injection crank angle is
negative, increases more in the case of constant engine
torque and speed governor logic, than in the other case.
Instead, when the error in the start injection crank angle is
positive, the behaviour is about the same in the two cases.
Similar considerations can be expressed also for the
variables displayed in figures 4c and 5c, that is for cylinder air mass flow variation and turbocharger (TC) speed.
The effects of the considered fault and of the engine governor logic adopted are confirmed in the analysis of the
working point shift shown in the turbocharger compressor
map (figures 4d and 5d).
The analysis of pressure and temperature variations in
different engine components, as a consequence of the considered fault and governor logic, is reported in figures 4c
and 5c, showing a similar behaviour even if with some
differences in the calculated values. Only in the case of
exhaust gas receiver temperature a substantial difference
is observed between the two different engine governor logics, when the start injection error assumes a negative
value (shifting of different sign in the two cases of figures
4c and 5c).
The results shown in figure 4 are in agreement with the
qualitative indications given by the engine maintenance
staff.
5.2 EXHAUST MANIFOLD FAULT
This damage, considered of particular concern by the
engine maintenance staff, consists in a pressure loss increase in the pipes connecting the exhaust manifold with
the turbine of the turbocharger, loss caused by dirt or
breakdowns in the pipes. As a consequence, the inlet turbine pressure has a reduction, proportional to the damage
intensity.
In the developed model this fault is simulated by an increase of the exhaust manifold-turbine pipe pressure loss
coefficient (Kpia) in equation (14). This coefficient assumes increasing values until the turbine inlet pressure is
the 70% of its value without fault. The analysis of the
(22)
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Session C
40
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41
AKNOWLEDGMENTS
The authors wish to gratefully aknowledge Eng. Giulio
Capezzuoli and Mr. Alessandro Morgia of the Wrtsil
Navim Diesel srl (Italy) for the support and the information received.
NOMENCLATURE
A
co
CN
d
e
h
H
Hf
kg
K
J
l
m
M
n
p
P
Q
Q
r
Re
t
T
ut
U
V
V
W
6 CONCLUSIONS
In the paper a complex and reliable simulation model
describing a four stroke turbocharged marine diesel engine, developed by the authors and already presented in
previous publications, is applied to the simulation of two
typical engine faults: fuel injection start crank angle error
and exhaust manifold damage.
The main goals of the study, that is to verify the suitability of the authors diesel engine model to be used for
the faults simulation and to analyse and compare the influence of the engine governor logic on the performance
alterations of a faulty marine diesel engine, appear to be
reached.
The presented simulation results, concerning the considered faults, are in good agreement with the (qualitative)
indications given by the diesel engine maintenance staff,
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42
cylinder area
isentropic expansion velocity
cetane number
injector hole diameter
error
thermal conductivity
specific enthalpy
fuel lower heating value
ratio of specific heats
constant
inertia of rotor
connecting rod length
mass flow rate
mass
rotational speed
pressure
power
torque
heat
crank radius
Reynolds number
time
temperature
turbine rotor tip speed
specific internal energy
volume, displaced volume
volumetric flow rate
work
x
xb
[5] N. P. Kyartos: A Microcomputer Based Diesel Engine Simulator for Advanced Ship Propulsion Monitoring and Control Systems Naval Engineers Journal, January 1989, pp 66-72.
[6] A. N. Perakis, B. Inz: Reliability Analysis of
Great Marine Diesels: State of the Art and Current
Modeling Marine Technology, July 1990, pp 237249.
[7] D. A. Kouremenos, C. D. Rakopoulos, D. T. Hountalas: Developed and Validation of a Diagnosis
Method for Diesel Engines Proceedings of the
ASME Advance Energy Systems Division, AESVol. 36, 1996, pp 527-539.
[8] D. A. Kouremenos, D. T. Hountalas, P. N. Kotsiopoulos: Developed of a Thermodynamic Method for
Diagnosis and Tuning of Diesel Engines and its Application on marine Engines Proc. Instn Mech
Engrs Vol. 209, Part. A: Journal of Power and Energy, 1995, pp 125-139.
[9] D. A. Kouremenos, D. T. Hountalas: Diagnosis and
Condition Monitoring of Medium-Speed Marine
Diesel Engines Tribotest Journal, September
1997, pp 63-91.
[10] D. T. Hountalas, D. A. Kouremenos: Development
and Application of a Fully Automatic Troubleshooting Mehod for Large Marine Diesel Engines Applied Thermal Engineering 19, 1999, pp 299-324.
[11] D. T. Hountalas: Prediction of Marine Diesel Engine Performance Under Fault Conditions Applied
Thermal Engineering 20, 2000, pp 1753-1783.
[12] N. B. Jones, Yu-Hua Li: A Review of Condition
Monitoring and Fault Diagnosis for Diesel Engines
Tribotest Journal, March, 2000, pp 267-291.
[13] K. Logan, B. Inozu, P. Roy, J. F. Hetet, P. Chesse,
X. Tauzia: Real-Time Marine Diesel Engine Simulation for Fault Diagnosis Marine Technology,
January 2002, pp 21-28.
[14] P. Chesse, D. Chalet, X. Tauzia, J. F. Hetet, B.
Inozu: Real-Time Performance Simulation of Marine Diesel Engines for the Training of Navy Crews
Marine Technology, July 2004, pp 95-101.
[15] G. Benvenuto, U. Campora, G. Carrera, P. Casoli: A
Two-Zone Diesel Engine Model for the Simulation
of Marine Propulsion Plant Transients MARIND
98, Second International Conference on Marine Industry, Varna, Bulgaria, September 28 October 2,
1998.
[16] G. Benvenuto, U. Campora, M. Figari. Reduction of
NOx Emissions from Marine Diesel Engine by
Means of Exhaust Gas Recirculation Technique: a
Numerical Approach IMAM 2000 Conference,
Ischia, Italy, April 2-6, 2000.
[17] G. Benvenuto, U. Campora: Modelling of Sequentially Turbocharged Marine Diesel Engines
Subscripts
a
b
c
con
coo
cy
C
E
ex
exc
f
fo
i
id
ign
in
o
p
Q
ra
ref
T
ub
v
w
ambient, advance
burned, burning zone
corrected
convective
coolant
cylinder
compressor
engine
exhaust gas receiver
excess
fuel
formation
inlet
ignition delay
ignition
injector
outlet
propeller
torque
radiation
reference
turbine
unburning zone
volumetric
wall
REFERENCES
[1] T. Terano: Trouble Diagnosis System of Marine
Engine-its System Analysis Ship Operation
Automation, 1976.
[2] P. S. Fredriksen: Advanced Condition Monitoring
System Based on Microprocessor Components
Ship Operation Automation, 1976.
[3] J. Holtrop, G. J. Menner: A Statistical Power Prediction Method International Shipbuilding Progress 25 (290), 1978.
[4] B. Inz, A. N. Perakis: Statistical Analysis of Failure Time Distributions for Great Lakes Marine Diesels Using Censored Data Journal of Ship Research, March 1991, pp 73-82.
Session C
43
[18]
[19]
[20]
[21]
[22]
100
100
90
96.6
-0.1
0.7
1.8
0.15
1.0
-.05
-0.8
0.3
-0.08
0.3
-1.4
-2.7
0.15
0.6
0.01
-0.4
1.9
-2.2
mismatches [%]
mismatches [%]
mismatches [%]
pc-pexp [bar]
mismatches [%]
pc-pexp [bar]
mismatches [%]
mismatches [%]
pc-pexp [bar]
ENGINE LOADS
85
75
94.8
90.8
MISMATCHES
0.3
0.7
-1.3
-2.7
-2.9
-3.3
0.21
0.23
0.7
0.1
0.11
0.22
-0.9
1.9
2.9
3.1
-3.1
-3.4
50
79.4
25
66
1.9
-4.6
-4.9
0.32
-1.1
0.32
2.2
3.4
-4.6
-3.1
-6.4
-3.7
.41
-2.5
0.39
-1.4
2.4
-3.6
Tab. 1 Steady state engine conditions, comparison between reference and simulation results.
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