Kongsberg BWCM 600

Condition Monitoring System

Operator Manual

390250/A
Ferbruary 2014 © Kongsberg Maritime AS
Document history
Document number: 390250 / Revision A
Rev. A February 2014 First version.

The reader
This operator manual is intended as a reference manual for the system operator.

Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.

Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.

Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com

Kongsberg Maritime AS
www.kongsberg.com
 Operator Manual

Table of contents
Glossary..................................................................................................................4
1 SYSTEM DEFINITION ....................................................... 5
1.1 Commissioning.......................................................................................................5
1.2 Learning period ......................................................................................................5
1.2.1 Rough Learning ......................................................................................... 5
1.2.2 500 Hour Learning..................................................................................... 5
1.3 Bearing Check/Overhaul ........................................................................................6
1.4 Sensor replacement.................................................................................................6
2 SYSTEM DESCRIPTION .................................................... 7
2.1 System functionality...............................................................................................7
2.1.1 Engine Monitoring ..................................................................................... 8
2.1.2 Rapid Wear................................................................................................ 9
2.1.3 Slow Wear............................................................................................... 14
3 OPERATIONAL PROCEDURES ......................................... 19
3.1 Alarm test .............................................................................................................19
3.2 Class Report..........................................................................................................20
3.3 Sensor replacement...............................................................................................23
3.3.1 Sensor replacement during Learning Mode ................................................ 23
3.3.2 Sensor replacement during Normal mode .................................................. 24
3.4 Bearing Check/Overhaul ......................................................................................26
3.4.1 Bearing Check/Overhaul during Learning Mode ........................................ 26
3.4.2 Bearing Check/Overhaul during Normal Mode .......................................... 27

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Glossary
BW Bearing Wear
BWCM Bearing Wear Condition Monitoring
BWS Bearing Wear Service
DPU Distributed Processing Unit
LOS Local Operator Station
OS Operator Station
PSS11 Bearing Wear sensor
SCU Segment Controller Unit

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 System definition

1 System definition

The BWCM system is designed to monitor the bearings throughout the lifetime of the
engine; during this long period there will be done maintenance to both engine and system.

1.1 Commissioning
The commissioning is normally done by the supplier or by the part responsible for the
installation. The criterion to start the commissioning is the acceptance of the signed
pre-commissioning check list. This list should be prepared by the installer of the system.
• Acceptance of the pre-commissioning check list
• System set-up (SW)
• Start learning period

1.2 Learning period

Each engine and each measuring point (i.e. sensor) responds differently to the effect of
changing RPM; and the distance measured varies with the RPM. At the start-up of each
installation the system must “learn” this trough a pre-defined “learning period”. The
period consists of 2 separate steps that can/will be conducted by either yard/maker or
the end user:

1.2.1 Rough Learning

The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the first rough compensation
is made to the system the alarms are activated.

1.2.2 500 Hour Learning

During 500 hours the system gathers data and calculates an average compensation value
for every RPM; after this more accurate compensation is activated and the system will
start to use the Normal alarm limit level. After the 500 Hour Learning and activation of
the final and Normal alarm limit level the system is fully operational.

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1.3 Bearing Check/Overhaul

The definition of an Bearing Check/Overhaul is when the sensor (often with brackets) are
removed and later reinstalled. Mostly this happens during bearing open-up inspection
or other work in the crank case that require the removal of sensors and brackets.
During overhaul there is NO running of the engine in the period between removal and
reinstallation. There is no loss of logged measuring data.
The sensor is reinstalled in the presumably same position as it was. However this is
not possible to achieve 100% correctly. The procedures for Bearing Check/Overhaul
during Learning Mode on page 26 and Bearing Check/Overhaul during Normal Mode on
page 27 address this issue.

1.4 Sensor replacement

The definition of “replacement of sensor” is that a sensor has stopped working and is
being replaced by a new sensor. The sensor normally brakes down during operation; and
typical for this situation, and different from “overhaul”, is that the system has missed
data from this sensor for a period of time.
The new sensor is installed in the presumably same position as the old. However this is
not possible to achieve 100% correctly. The procedures for Sensor replacement during
Learning Mode on page 23 and Sensor replacement during Normal mode on page 24
address this issue.

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 System description

2 System description

2.1 System functionality

Purpose of the system
The bearing wear system measures the combined wear of all bearings in each crank train.
The system consists of sensors, processing units and a computer. Its main purposes are:
• Giving alarms in due time before bearing wear down causes a dangerous situation
and/or costly repairs
• Logging data and trough the long term log provide information on when to overhaul
the bearings and when to NOT overhaul the bearings

Learning Mode
Each engine and each measuring point (i.e. sensor) responds differently to the effect
of changing RPM; and the distance measured varies with the RPM. At the start-up of
each installation the system must “learn” this trough a pre-defined “learning period”.
The period consists of 2 separate steps that can/will be conducted by either yard/maker
or the end user with the BWS application
The BWS application is located under Tools and Bearing Wear View menu
Rough Learning
The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the rough compensation is
made to the system the alarms are activated.
500 Hour Learning
During 500 hours the system gathers data and calculates an average compensation value
for every RPM. When 1000 BW values corresponding to 1000 engine revolutions has
been sampled for a compensation level this level is valid and downloaded to the SCU, a
valid compensation level is then updated each 50 hours; the accuracy of the system will
increase until 500 hour of logging is done and the system is in Normal operation

Normal operation
After the Learning Mode the system will monitor the wear down of the bearings and
logging long trend and event data for later retrieval. During maintenance of the engine
and the system itself there are some situations that require the attention of the user.

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2.1.1 Engine Monitoring

Engine Monitoring Overview

Engine Overview gives a quick overview of the engine an will indicate which cylinder
that has an problem and what function that has triggered alarm

Figure 1 Engine Monitoring view

Alarm indication

All bearing shells for a cylinder will indicate alarm and need to be checked for damage
or wear
• Bearing shell — Gray = Normal

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 System description

• Bearing shell — Red = Alarm

Function in alarm indication

• Green dot = Normal

• Red dot = This function is indicating alarm, click button to open view for detailed
information

2.1.2 Rapid Wear

Purpose
The purpose of Rapid Wear is to detect a quickly developing bearing wear down situation
and alarm limits are set low to ensure an early detection. Rapid wear down of the
bearings are normally a clear indication of a bearing seizure. Full damage to the bearing
can occur within minutes of running time and is then followed by consequential damage
to other engine parts due to friction and heat.

Figure 2 Rapid Wear view

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Rapid Wear values

Figure 3 Rapid Wear flow

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 System description

• Single Rapid

Absolute value of Difference value

• Cylinder Rapid

Absolute sum of Fore and Aft Difference values

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• Twin Cylinder Rapid

Absolute sum of Aft and Fore Difference values between cylinders

Note
For the first cylinder, last cylinder and cylinder against the drive there are no Twin
Cylinder Rapid value because there are no neighbor cylinder

Running status
Mimic text BWCM running status Action
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern
Engine stopped BWCM stopped
Engine running direction BWCM stopped BWCM stopped because
unknown engine running direction is
unknown for the system

Mode status
Different modes are used to deactivate/activate alarms
Mimic text State Action
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active
and logging data for 2nd
and 3rd compensation point

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Mimic text State Action

500 Hour Preliminary 500 Hour Learning running Alarms active
Learning
500 Hour Learning 500 Hour Learning running Alarms active
and curve deviation check
started
Normal Learning Mode done Alarms active

Alarm limits
To avoid unnecessary/false Bearing Wear alarms, the Rapid Wear is build up with
dynamics alarm limits. Dependent upon engine speed changes, the alarm system will
increase alarm limits accordingly.
Single Sensor value
TAG name TAG description Basic value Max value
SR_ALIM SINGLE RAPID 0.25 0.375
ALARM LIMIT
Cylinder Sum value
TAG name TAG description Basic value Max value
CR_ALIM CYLINDER 0.18 0.27
RAPID ALARM
LIMIT
Main Bearing Sum value
TAG name TAG description Basic value Max value
TCR_ALIM TWIN CYLINDER 0.25 0.375
ALARM LIMIT

Note
The alarm limits for Rapid Wear values is indicated in the bargraph

How to use Bearing Wear monitoring parameters

State Action
Single Rapid value Alarm/Slowdown Gauge bearings for this
cylinder, check for metal
shavings and abnormal
high temperature

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Cylinder Rapid value Alarm/Slowdown Gauge bearings for this

cylinder, check for metal
shavings and abnormal
high temperature
Twin Cylinder Rapid value Alarm/Slowdown Gauge bearings for this
cylinder, check for metal
shavings and abnormal
high temperature

Note
Follow engine manufacture instruction to check the bearings

2.1.3 Slow Wear

Purpose
Slow Wear is designed to detect slow developing wear as can occur during the life time
of the engine; still the operation can be considered normal. Alarms are a warning that
bearing overhaul is due and logged data and a long term trend log are used to support the
decision to do maintenance or not.

Figure 4 Slow Wear view

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 System description

Slow Wear values

Figure 5 Slow Wear flow

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• Devation

Sensor Deviation Fore and Aft value is Sensor value subtracted average value of all
other sensor values to remove change in engine frame due to temperature changes
Cylinder Deviation value is average of Fore and Aft Sensor value in same cylinder
subtracted average value of all other sensor values to remove change in engine frame
due to temperature changes and load conditions
• Sensor value

Zero adjusted Sensor value

• Prewarning

Prewarning value is the latest average value for Sensor Deviation in the long term log

Running status
Mimic text BWCM running status Action
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern

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 System description

Mimic text BWCM running status Action

Engine stopped BWCM stopped
Engine running direction BWCM stopped BWCM stopped because
unknown engine running direction is
unknown for the system

Mode status
Different modes are used to handle alarm levels
Mimic text State Action
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active, High alarm
and logging data for 2nd limit level
and 3rd compensation point
500 Hour Preliminary 500 Hour Learning running Alarms active, High alarm
Learning limit level
500 Hour Learning 500 Hour Learning running Alarms active, High alarm
and curve deviation check limit level
started
Normal Learning Mode done Alarms active, Normal
alarm limit level

Alarm limits
To avoid unnecessary/false bearing wear alarms the Slow Wear is build up with two set of
alarm limits, dependent upon Mode the alarm limit level is set.
Sensor value
Tag name: CYLxx_BWS-y
State LL L H HH
Normal – 0.7 – 0.5 0.5 0.7
High - 0.9 - 0.8 0.8 0.9
Sensor Deviation value
Tagname: SNSxx_y_DEV
State LL L H HH
Normal - 0.5 - 0.4 0.4 0.5
High - 0.7 - 0.5 0.5 0.7

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Cylinder Deviation value

Tagname: CYLxx_DEV
State LL L H HH
Normal - 0.3 0.3
High - 0.4 0.4
Prewarning value
Tagname: SNSxx_y_PREW
LL L H HH
-0.5 -0.25 0.25 0.5
Engine speed curve deviation value
Tagname:
CYLxx_yCURVE
– 0.2 0.2

Note
The alarm limits for Slow Wear values is indicated in the bargraph

How to use Bearing Wear monitoring parameters

State Action
BWM sensor value Alarm Gauge bearings for this
cylinder at next opportunity
BWM sensor deviation Alarm Gauge bearings for this
value cylinder at next opportunity
BWM cylinder deviation Alarm Gauge bearings for this
value cylinder at next opportunity
BWM Prewarning value Alarm Keep a closer look at the
BWCM system
BWM RPM curve Alarm Indicating possible bearing
deviation wear under 500 hour
learning; gauge bearings
for this cylinder at next
opportunity

Note
Follow engine manufacture instruction to check the bearings

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 Operational procedures

3 Operational procedures

3.1 Alarm test

Alarm Test test is done to verify activation of horn and light when alarm is activated.
Slowdown Test test is done to verify activation of slowdown function on engine

How-to
1 Go to BWS →Alarm test

2 To activate test:
a Click button for the test that shall start
b Click Yes on warning

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3 Button will turn red for the test that's active

Expected result
• Alarm Test: Horn and light to be activated
• Slowdown Test: Slowdown of engine to be activated
WARNING
Do not activate Slowdown Release test when engine is running
because this will cause the engine to Slowdown

4 Click button for active test to deactivate the test

3.2 Class Report

How-to
1

Generate Report
a Open Home view or Navigation line
b Go to Bearing Wear →Engine Monitoring Log →Class Report
c Select time period for the report in Select time
d Click Generate Report button
e Report is ready when status is Report generated C:\Ros\PdsLog\BWLog\Xml
Reports\.........

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Copy Report to USB drive

a Connect USB drive into USB port on OS
b Go to Top bar Menu →System →Maintenance

c In Maintenance view go to Backup

d Select Bearing Wear Report
e When status is USB drive is ready click Start button

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f When status is Backup completed successfully click Release USB button and
remove USB drive

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 Operational procedures

Class Report file

In the Zip file the Class Report is located in the Xml Reports folder at Ros\PdsLog\BWLog
The Class Report contains:
• Engine information: Contain information on the ship and engine
• Status list: To provide a quick overview of each cylinder
– Normal “N” : Indication that no wear has been detected beyond the Pre-Warning
limit
– Pre-Warning “W”: Indicating that wear has been detected beyond the Pre-Warning
limit
– Alarm “A”: Indicating that an alarm has been released from sensors connected to
this cylinder
– Unknown “U”: Indication that sensors in this cylinder has lost initial reference level
• Trend data list: Long tend log from filtered sensor value
• Logging: Event log of all changes of the system

3.3 Sensor replacement

3.3.1 Sensor replacement during Learning Mode
Sensor replacement during Learning Mode
The new sensor is installed in the presumably same position as the old. However this
is not possible to achieve 100% correctly. The procedures for replacement address
this issue.
This procedure must be followed when a sensor needs to be replaced during the Learning
Mode. Installation distance of the sensor is likely to change when a sensor is exchanged;
zero point need to be adjusted and Learning Mode need to be restarted to avoid offsets on
the compensation data.

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Kongsberg BWCM 600

Scope of work
• Replacement the defect sensor
• Set node id
• Restart of Learning Mode

How-to
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”

4 Safely remove all tools and the broken sensor from the crank case.
5
Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> DPU Replacement and select sensor to be replaced
with new one
c Open Menu —> Tools —> BWS —> Learning Mode
d Click Cancel
e Click Start
f When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
g If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC

3.3.2 Sensor replacement during Normal mode

This procedure must be followed when a sensor needs to be replaced during Normal
Mode. Installation distance of the sensor is likely to change when a sensor is exchanged;
zero point need to be adjusted to avoid offset on measuring value; this is automatically
done by the Readjust function.

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 Operational procedures

Scope of work
• Replacement the defect sensor
• Set node id
• Start of Readjust
Procedure
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”

4 Safely remove all tools and the broken sensor from the crank case.
5 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> DPU Replacement and select sensor to be replaced
with new one
c Open Menu —> Tools —> BWS —> Readjust
d Select the sensors that is replaced
e Click Start
f Click Next in Select data view without setting date
g When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
h If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC

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3.4 Bearing Check/Overhaul

3.4.1 Bearing Check/Overhaul during Learning Mode
This procedure must be followed when overhaul is done during the Learning Mode.
Both installation distance of the sensor and bearing clearance is likely to change when
a bearing is overhauled; zero point need to be adjusted and Learning Mode need to be
restarted to avoid offsets in the compensation data.
Case A: The overhaul does NOT require the removal of Bearing Wear sensors and
brackets (typical crank –and/or cross-head bearing overhaul). There might however be a
change in bearing clearance after the overhaul.
Case B: The overhaul requires the removal of sensors and brackets (typical Main bearing
overhaul); there will be a change in both bearing clearance and sensor position after
the overhaul.

Case A — Scope of work:

• Overhaul
• Cancel Learning Mode procedure and restart procedure

How-to
1 Do bearing overhaul according to engine makers requirements
2 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> BWS —> Learning Mode
c Click Cancel
d Click Start
e When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
f If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC
Case B — Scope of work:
• Removal of the Bearing Wear Sensor and bracket
• Overhaul
• Reinstallation of sensor and bracket.
• Cancel Learning Mode procedure and restart procedure

How-to
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).

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 Operational procedures

WARNING
DO NOT remove the sensor from the brackets

Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position

3 Do overhaul according to engine makers requirements

4 Reinstall bracket with sensor(s) in it’s former position regarding to marks made
before bracket was removed
Note
Make sure that each bracket with sensors is reinstalled in the SAME POSITION as
before, then further adjustment of sensor position can be avoided

5 Go the K-Chief 600 OS

a Set user access to Chief or higher level
b Open Menu —> Tools —> BWS —> Learning Mode
c Click Cancel
d Click Start
e When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
f If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC

3.4.2 Bearing Check/Overhaul during Normal Mode

This procedure must be followed when overhaul is done when the system is in Normal
Mode. Both installation distance of the sensor and bearing clearance is likely to change
when a bearing is overhauled; zero point need to be adjusted to avoid offset on measuring
value; this is automatically done by the Readjust function in BWS.
Case A: The overhaul does NOT require the removal of Bearing Wear sensors and
brackets (typical crank –and/or cross-head bearing overhaul). There might however be a
change in bearing clearance after the overhaul.
Case B: The overhaul requires the removal of sensors and brackets (typical Main bearing
overhaul); there will be a change in both bearing clearance and sensor position after
the overhaul.

Case A — Scope of work:

• Overhaul
• Start the Readjust procedure
Procedure:

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Kongsberg BWCM 600

1 Do bearing overhaul according to engine makers requirements

2 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> BWS —> Readjust
c Select the sensors that is affected by the overhaul
d Click Start
e Click Next in Select data view without setting date
f When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
g If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC
Case B — Scope of work:
• Removal of the Bearing Wear Sensor and bracket
• Overhaul
• Reinstallation of sensor and bracket
• Start the readjust procedure
Procedure:
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).
WARNING
DO NOT remove the sensor from the brackets

Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position

3 Do overhaul according to engine makers requirements

4 Reinstall bracket with sensor(s) in its former position regarding to marks made
before bracket was removed
Note
Make sure that each bracket with sensors is reinstalled in the SAME POSITION as
before, then further adjustment of sensor position can be avoided

5 Go the K-Chief 600 OS

a Set user access to Chief or higher level
b Open Menu —> Tools —> BWS —> Readjust
c Select the sensors that is affected by the overhaul
d Click Start

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 Operational procedures

e Click Next in Select data view without setting date

f When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
g If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC

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A Slowdown test, 19
System definition, 5
Alarm test, 19
500 Hour Learning, 5
Bearing Check, 6
B Bearing Overhaul, 6
Commissioning, 5
Bearing Check after Learning period, 5
Seatrial, 26 Rough Learning, 5
Bearing Check during Sensor replacement, 6
Learning Mode, 26 System functionality, 7
Bearing Check during Engine Monitoring, 8
Normal Mode, 27 Rapid Wear, 9
Bearing Overhaul during Slow Wear, 14
Learning Mode, 26
Bearing Overhaul during
Normal Mode, 27

C
Class Report, 20

E
Engine Monitoring, 8

H
How-to
Alarm test, 19
Bearing Check after
Seatrial, 26
Bearing Check during
Learning Mode, 26
Bearing Check during
Normal Mode, 27
Bearing Overhaul during
Learning Mode, 26
Bearing Overhaul during
Normal Mode, 27
Class Report, 20
Sensor replacement
during Learning Mode, 23
Sensor replacement
during Normal Mode, 24
Slowdown test, 19

R
Rapid Wear, 9

S
Sensor replacement during
Learning Mode, 23
Sensor replacement during
Normal Mode, 24
Slow Wear, 14

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©2014 Kongsberg Maritime