The future of Engine Automation

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1 The future of Engine Automation

2 MAN Diesel & Turbo Leading technology responsibly MAN Diesel & Turbo is the world s leading designer and manufacturer of low- and medium-speed engines our power plants are capable of supplying around 50 percent of the energy needed for all world trade. We develop two-stroke and four-stroke units, auxiliary engines, turbochargers and propulsion packages, manufactured both by the MAN Diesel & Turbo Group and licensed partners. At MAN Diesel & Turbo, we are focusing more attention on the environmental performance of our engines than ever before. By applying our unrivalled understanding of large engine technology, we aim to make our engines progressively cleaner, more powerful, and more efficient. We are committed to cutting emissions while increasing the fuel efficiency and power density of our engines. To this end, we support the introduction of new laws and regulations on ship emissions. Our aim is to deliver power plants that achieve an ideal synthesis of prime mover characteristics. Leveraging MAN Diesel & Turbo s core competencies, we have developed the robust, first-class SaCoS one engine control system taking our commitment to the environment a step further. SaCoS one 3

3 MAN Advanced automation solutions for turbochargers and four-stroke engines Today s engines are constantly evolving, and the latest innovations pose new challenges. Control systems play a crucial role in extracting the best-possible performance from the power plant, so it is vital that they keep up with the pace of engine development. To do this, they must combine sophisticated hardware and first-class software design. SaCoS one (Safety and Control System on engine) from MAN Diesel & Turbo does just that, and is able to withstand even the harshest operating conditions. As technology pushes the boundaries of the physically possible, concepts such as adaptive engine control provide the flexibility required to meet today s performance needs. And a guaranteed, future-proof approach to design helps tackle the problems of tomorrow. SaCoS one was developed with these aspects in mind, while keeping an eye on another key factor: safety. This system meets the highest of safety standards, and this is reflected in the first two letters of the name. Increasing functionality & benefits Variable valve timing Electronic injection Adaptive engine control However, the complexity of engines is not shaped by technology alone. Changing legal requirements and evolving customer demands call for a range of application variants. In response to these imperatives, MAN Diesel & Turbo has developed an intelligent, decentralized system that separates hardware and software levels, and boasts a variety of modular functions Number of engine functions Number of sensors Number of total automation functions VTA control Online data access Emissions control Knock control Fuel sharing Flexible interfaces 4 SaCoS one SaCoS one 5

4 The Family A turnkey system solution Control modules Display module The SaCoS one family is a solution capable of meeting a variety of system requirements: with just a few module types, we cover the whole engine range. Components can be added in line with the specific application. Older, centralized systems can no longer keep pace with rapidly evolving engines and variants. In contrast, SaCoS one is based on a flexible, decentralized system, so it is able to adapt to these challenges quickly and easily. Redundant System Bus A clearly structured system of modular components The challenge was to create a solution that accommodates as many application scenarios as possible. In response, we produced a clear, modular design that forms the basis of our entire four-stroke product portfolio, including all turbochargers from the small five-cylinder auxiliary genset, to the 20-cylinder dualfuel engine. incorporating additional functionality and I/O ranges is easy, regardless of the physical con figuration. The modular design is highly scalable and simple, ensuring that new monitoring functionality can be integrated quickly and efficiently. Compatibilities at a glance Modules with flexible functionality Gateway modules Intelligent system structure Control modules Display module Flexibility and scalability are core elements of the SaCoS one development philosophy. The system architecture connects control modules, display devices, and other modules designed for specialist functions or standard input/output (I/O) ranges. All modules are designed for versatility, communicate seamlessly with one another, and provide system information via an easy-to-use interface. Thanks to redundant engine control, SaCoS one offers maximum reliability and availability. What s more, it also improves monitoring and analysis. All components communicate via a compact bus system, which can be extended using external I/O channels. As a result, GENSET PROPULSION LARGE L16/24 L21/31 L27/38 V28/33D L32/40 V32/40 L+V32/40G L+V32/44CR V35/44G L+V48/60B L+V48/60CR L+V51/60DF L+V51/60G These highly integrated modules have been designed for a variety of uses and feature a number of analog and digital I/O channels. They include the main processing system for use in SaCoS one products. Modules with flexible functionality These modules are designed for specific uses based on particular core functions. With software developed in-house by MAN Diesel & Turbo experts, they can be upgraded via flexible system extensions. This module enables straightforward, user-friendly operation, and boasts a TFT touchscreen display specially designed for harsh operating environments. What s more, it features an integrated programmable logic controller (PLC) and a range of I/O channels. The additional Ethernet port allows system downloads and software backups to take place via EPERT or service programs. Gateway modules These modules provide the main interface-to-customer system functionality, as well as data logging options and a dual-core service module. They enable users to download and back up system software. 6 SaCoS one SaCoS one 7

5 The Wide Range of Benefits Offered by Ongoing development of future-proof solutions Optional Extensions End-to-end data management expertise, including online support Plug-and-play philosophy Comprehensive family of modules from a single source Databox Collection of engine operating data Online Service Remote access Retrofit and upgrade solutions Outstanding safety standards (CE) CoCoS EDS Self service on board End-to-end expertise in data management, with online support Guaranteed future-proof Cost optimization Classification societies Toolbox Installation and maintenance First-class quality More than just engine electronics The SaCoS one Toolbox A product of excellent design and failure mode effect analysis (FMEA), SaCoS one meets all environmental testing requirements defined by classification societies. Excellent production and quality management systems help ensure extremely high levels of quality. Plus, all SaCoS one modules must pass rigorous electronic testing, including: Automated optical inspection In-circuit testing Boundary-scan testing Burn-in and run-in testing Functional testing The entire system is then subjected to an automated integration test before ultimately undergoing an onengine system test. Hardware Control system pre-tested in factory Plug-and-play components ensure easy module exchange Reduced cabling Guaranteed long-term supply of spare parts Software Integrated self-diagnostics and data security Sensor monitoring Standardized interfaces Easy operation and maintenance SaCoS one doesn t stop at engine control. This end-toend system combines a variety of solutions, while offering access to online services and a far-reaching network of experts. It meets both customer needs and market demands, and includes features such as safety and alarm systems, auxiliary control, and remote access. SaCoS one is fully engine-mounted, making it an ideal solution for use with conventional or electronic fuel injection engines. The SaCoS one Databox This data logging module works in much the same way as black boxes on aircraft continuously gathering engine operating data and archiving it. Information is compressed and processed, before being made available for further analysis. The SaCoS one Toolbox combines hardware and software elements, enabling the installation and maintenance of products from the SaCoS one range. Specialist software programs are installed on a dedicated laptop and delivered with all the necessary peripheral hardware components, including cables and USB sticks. The CoCoS EDS (on-board unit) CoCoS EDS provides all the tools necessary for monitoring, performance evaluation and fault analysis in diesel engines. Suitable for single- or multipleengine plants, it offers owners and operators an integrated data analysis system. What's more, it streamlines fault analysis helping to minimize the risk of engine failure or damage. 8 SaCoS one SaCoS one 9

6 MAN PrimeServ Online Service Greater protection for your engines Comprehensive services and solutions are complemented by our Online Service now available for all plants. Customers benefit from an end-to-end data manage- Power plant / vessel MAN Diesel & Turbo ment concept, with MAN Diesel & Turbo ideally located to provide outstanding support, anywhere in the world. This is possible due to rapid access to operating data, long-term trend information, insight into event triggers, and production Data logging Firewall Secure VPN tunnel Firewall Online Service server Information Real-time data variant data. Internet Trend PrimeServ Online Service transmits key engine data via secure connections to PrimeServ experts, from anywhere in the world. They then analyze the information and make recommendations for engine maintenance or repair. What s more, they can access real-time engine data, and use it to offer troubleshooting support. MAN PrimeServ Online Service comprises the following modules: Diagram of PrimeServ Online Service for power plant and marine engines Analysis results Condition monitoring Remote support Performance curves Benefits Continuously collects and monitors engine operating data. Carries out regular evaluation (using both automated and manual methods) and analysis. Condition reporting Delivers regular status reports on key operating conditions. Provides a long-term overview of the condition of your engine and a customized view of operating data, combined with recommendations for future operation. Should a fault develop, online service experts can remotely access the plant and view all relevant data. In many cases, the problem can be resolved quickly by working together with personnel on-site. Quick information In the event of unexpected changes or irregularities in engine operation, you will receive a telephone call or a brief report highlighting and outlining the issue. We compare the current state of your engine with its peak condition (engine fingerprint). By utilizing performance data in combination with additional onsite measurements (e.g. combustion pressure), we can provide advice on restoring your engine to its best-possible condition. Trend analysis This feature evaluates long-term patterns in operating data, making it possible to anticipate potential irregularities (e.g. lube oil degradation) before faults occur. Optimized reliability Higher level of availability Reduce cost Predictive maintenance Faster troubleshooting and fault elimination Advanced functions Secure communication channel Graphical display of operating conditions and trends Lifetime trend storage and backup of operating data Guided fault analysis 10 SaCoS one SaCoS one 11

7 A Global Network of Automation Expertise Your gateway to the technology of the future Automation services Innovative technology is only half of the equation. Even the most advanced systems can only achieve their true potential if supported by professional service. Our systems automation sites enable us to ensure that our technology works for you. Our teams include over 300 highly skilled and motivated automation systems specialists. Once the system is up and running, operation and maintenance is both simple and safe. Customers always have a skilled point of contact, guaranteeing peace of mind. And with sites located conveniently throughout Europe and Asia, help is always close at hand wherever it is needed. Automation sites Europe Automation sites Asia Frederikshavn Busan Copenhagen Changzhou Holeby Shanghai Hamburg Aurangabad Berlin Oberhausen Augsburg Zurich Saint-Nazaire Ready to meet future challenges MAN Diesel & Turbo has over 15 years of experience in engine control software and electronics, and SaCoS one is the product of this knowledge. The system features a combination of established, well-structured software and the latest embedded, microcontroller-based hardware. The software has been tested extensively using standardized PLC technology. The new hardware is based on standard components widely used in the automotive industry, and is robust enough to withstand even the harshest environments. With SaCoS one, all engines are well-prepared for future challenges. 12 SaCoS one SaCoS one 13

8 World-Class Service Marine propulsion, gensets and stationary plants The PrimeServ offering The MAN Diesel & Turbo Group offers worldwide, round-the-clock service, 365 days a year. In addition to MAN Diesel & Turbo s service headquarters in Augsburg, Copenhagen, Frederikshavn, Saint-Nazaire, Hamburg and Stockport, service centers on all continents provide comprehensive and continuous support. MAN Diesel & Turbo engines are renowned for their quality and durability. We are a global organization with a strong local presence, delivering exceptional field service management, tailor-made solutions, and first-class technical support. PrimeServ s aim is to provide: Prompt delivery of high demand OEM spare parts within 24 hours Fast, reliable and competent customer support Individually tailored O&M contracts Ongoing training and qualification of operators and maintainers Global service, open 24 hours-a-day, 365 days-a-year Diagnosis and troubleshooting with our high performance Online Service PrimeServ provides advice and assistance to customers throughout the product lifecycle, from delivery to resale. With our far-reaching network of Service centers, we respond rapidly to customer needs. What s more, we offer outstanding service and unrivalled technical expertise. Plus, we only use genuine spare parts safeguarding the longevity of your engine. 14 SaCoS one SaCoS one 15

9 All data provided in this document is non-binding. This data serves informational purposes only and is 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. Copyright MAN Diesel & Turbo. D EN-N1 Printed in Germany GGKM-0515 MAN Diesel & Turbo Augsburg, Germany Phone Fax MAN Diesel & Turbo a member of the MAN Group