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Parker Kittiwake LinerSCAN, Instruction Manual

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Parker Kittiwake LinerSCAN Instruction Manual Download Page 95

Parker Kittiwake

Hydraulic Filter Division Europe
3 - 6 Thorgate Road   Littlehampton
West Sussex   BN17 7LU   United Kingdom
Tel:  +44 (0)1903 731470
Fax: +44 (0)1903 731480
Email: [email protected]
Web: www.kittiwake.com

© 2013 Parker Hannifin Corporation    

MA-K17510-KW

Summary of Contents for Kittiwake LinerSCAN

Page 1: ...LinerSCAN Instruction Manual aerospace climate control electromechanical filtration fluid gas handling hydraulics pneumatics process control sealing shielding...

Page 2: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 1 of 93 5th Generation On Line Wear Metal Debris Sensors Installation and operation User Manual MA K17510 KW...

Page 3: ...icing Do not discard this manual This instruction manual comprises a functional part of the Kittiwake LinerSCAN product The instruction manual must be kept safe for future reference It also provides a...

Page 4: ...nerSCAN Software 34 4 3 Setting Measurement Period 37 4 4 Fault Finding 38 5 Operation 39 5 1 Important 40 5 2 LinerSCAN Software 40 6 Interpreting Results 56 6 1 Introduction 57 6 2 Normal Wear over...

Page 5: ...software reads the output and controls the sensors when monitoring a slow speed diesel engine The software has the following features LinerSCAN data with respect to Engine hours Sensor configuration...

Page 6: ...the halves the result is due to ferrous debris This configuration results in extremely temperature stable and repeatable measurements both coils experience the same environments and external influence...

Page 7: ...alled and operated by qualified persons only Caution The sensors are connected together in this application by waste cylinder lubricant drain pipes the scavenge space and common compressed air and ele...

Page 8: ...ce LinerSCAN uses proven patented Magnetometry combined with internal micro processing to indicate metallic particle contamination The factory calibrated sensors guarantee high reliability with long t...

Page 9: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 8 of 93 3 Installation Installation...

Page 10: ...t Code Description Item Quantity FG K17400 KW LinerSCAN Sensor complete one per cylinder 3 metre cable sensor to sensor Sensor BSP Isolation Valves Weld Boss Hydraulic to BSP fitting 45 Hose fitting S...

Page 11: ...one per engine Terminal Box 1 Terminal Box 2 5 metre cable sensor to sensor PC to Network dongle Software installation disc System computer Connector LinerSCAN terminating connector Airline Pressure S...

Page 12: ...n combined ferrous debris by weight Accuracy 30ppm 3 3 2 Sensor General Zeroing method Air Blast Zeroing synchronisation method Sensor controlled solenoid valve Sensor bore diameter 10mm Permitted Flu...

Page 13: ...d and approved for Shipboard use Min 2 5mm 2 Twisted pair cable shielded Min 0 22 mm Caution LinerSCAN is classified as permanently connected equipment and requires an external isolating switch or cir...

Page 14: ...the LinerSCAN system to the computer A Network to Dongle connector terminates the cable run and a PC to Network dongle connects to a PC Network to Dongle Connector PC to Network Dongle T o L i n e r...

Page 15: ...E R M IN A L B O X O R N E X T S E N S O R E LE C TR IC A L C O N N E C TIO N TE R M IN A TO R O R N E X T S E N S O R A IR IN P U T 1 Connector to Solenoid 5 Air Input Quick Release coupling or ball...

Page 16: ...air pipe 6 10 bar usual working air inch nominal across the main engine at a slight angle to allow draining via drain valve at the lowest point The pipe has to be about 500 1000 mm underneath the sens...

Page 17: ...erSCAN System Schematic Electrical A B L1 L2 1 2 3 4 5 6 N L3 N N N PE PE PE TO TERMINAL BOX 2 CABLE 4 CABLE 5 4 Air Pressure Switch No Pressure Open Contacts TO LINERSCAN SENSORS Plug in LinerSCAN sy...

Page 18: ...3 A B L1 L2 A B N N N PE PE PE 24V TO TERMINAL BOX 1 CABLE 4 TO COMPUTER CABLE 1 TO POWER SUPPLY ENGINE ON OFF SIGNAL CABLE 2 ALARM SIGNAL X 2 CABLE 3 ALARM WARNING NO COM NC ENGINE ON OFF PAIR 2 PAIR...

Page 19: ...stall PC at desired location Ensure the PC is securely mounted and that connections to and from PC are secure and not easy to pull out 3 7 3 Fit LinerSCAN sensor to the mounting bracket This will have...

Page 20: ...NOT plug into the computer 3 7 8 Install LinerSCAN software Anti Virus software can interfere with the installation Disable Virus checker during installation If the PC is not connected to a network o...

Page 21: ...oc Page 20 of 93 Right Click on the icon for LinerSCAN55 exe and select Properties option Select the Compatibility Tab tick the option Run this program in compatibility mode for selecting Windows XP S...

Page 22: ...ge 21 of 93 Double click on the icon for LinerSCAN55 exe The program will display a welcome window The program will be installed in the displayed folder recommended It can be installed in another fold...

Page 23: ...s Once the data is correct click Next Number of Cylinders Number of cylinders on the engine Initial engine hours Current Main Engine running hours Engine Monitor port Not used on 5th Generation LinerS...

Page 24: ...t Limit Wear rate in ppm First stage warning indicator Recommend 400ppm Red Alert Limit Wear rate in ppm Second stage alarm indicator Recommend 800ppm Blast Time Seconds Time for air blast to clear th...

Page 25: ...until Windows completes the installation Once the LinerSCAN installation is complete it will automatically launch the PC to network converter driver installation Please choose the preferred language...

Page 26: ...25 of 93 Select the I agree to accept to accept the licence agreement option and click the Next button The program will be installed in the displayed folder recommended It can be installed in another...

Page 27: ...l ISSUE P doc Page 26 of 93 Tick all the available options then click Next The driver is now ready to be installed click the Next button Windows security sometimes displays a warning message in that c...

Page 28: ...tion program has finished click the Finish button If required reboot the computer after installation If the window below is still open from the previous LinerScan 5 5 installation click the Finish but...

Page 29: ...ing Microsoft Windows XP Double click on the icon for LinerSCAN55 exe The program will display a welcome window The program will be installed in the displayed folder recommended It can be installed in...

Page 30: ...s Once the data is correct click Next Number of Cylinders Number of cylinders on the engine Initial engine hours Current Main Engine running hours Engine Monitor port Not used on 5th Generation LinerS...

Page 31: ...e in ppm First stage warning indicator Recommend 400ppm Red Alert Limit Wear rate in ppm Second stage alarm indicator Recommend 800ppm Blast Time Seconds Time for air blast to clear the sensor Recomme...

Page 32: ...It may be necessary to restart the computer after installation 3 7 9 Install the Network to PC dongle Plug in the USB lead into a free USB port on the PC Note once a port is selected always use the sa...

Page 33: ...his location in the search and click browse and find c kittiwake drivers Click Next Connect the LinerSCAN network to the CAN dongle 3 7 10 Complete the pre commissioning Checklist MA K17612 KW This is...

Page 34: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 33 of 93 4 Commissioning Commissioning...

Page 35: ...valves are correctly opened for sensor measurement 4 2 Start the LinerSCAN Software Start LinerSCAN software by double clicking on shortcut on the desktop Ensure network to dongle is plugged into the...

Page 36: ...detects the first sensor the following dialogue box appears For this example it will be assumed that the sensor with serial number 14437 has been installed on Cylinder 1 In this case sensor ID and cyl...

Page 37: ...on Cylinder 2 As shown in the picture below using the increment decrement buttons select the appropriate ID number from the New ID field For this case the Sensor ID needs to be reset from 1 to 2 in o...

Page 38: ...t the measure time greater than 1 hour 4 3 1 Test Air and Engine Signals Check function of Air pressure signal Turn the sensor air supply off and allow the pressure in the airline to fall The No Air a...

Page 39: ...leading to no oil getting to the sensors The system does have a blockage alarm however this is usually seen once the engine has been operated If a short voyage is not possible to check adequate fillin...

Page 40: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 39 of 93 5 Operation Operation Manual...

Page 41: ...ate If power or air supply is interrupted it must be re connected as soon as possible LinerSCAN must be powered ON at all times including power and air supply Failure could result in sensor blockages...

Page 42: ...will be recorded e Stopped When the sensors have been stopped f Starting When the sensors have been Started g Off Sensor not connected no power 4 Next test Time time until next measurement is taken 5...

Page 43: ...ors on all cylinders measuring Sensors start automatically when the software is loaded Stop All Cylinders Stops the sensors on all cylinders measuring Any active alarms are also cleared Single Measure...

Page 44: ...ction This function is also useful if the data files become too large An archive folder is created and the program re started It is possible to view this exported data using the LinerSCAN View softwar...

Page 45: ...ted in an Archive Folder as shown Export Data See the section Exporting Data Enter Log Create an entry in the Event History This is useful events which help understand ppm readings For example Cylinde...

Page 46: ...10 KW LinerSCAN manual ISSUE P doc Page 45 of 93 Export Log Export the Event History to a file The software will ask for a location select and Click OK Quit LinerSCAN Stops the sensors and closes the...

Page 47: ...be exported to a specified location on the computer or a USB memory stick Create a new folder for exported data this is easiest on the desktop Right Click and go New Switch to Overview tab f2 Press th...

Page 48: ...E P doc Page 47 of 93 Click No to Transmit all The software then asks where to export the data to Browse to the folder and click OK The below message will show If data export is cancelled by clicking...

Page 49: ...can reduce the size of files sent for email or if only certain engine hours are needed Click Yes this gives two options Only export new data collected since the last time the data was exported select...

Page 50: ...l ISSUE P doc Page 49 of 93 Press Export The software then asks where to export the data to Browse to the folder and click OK The below message will show If data export is cancelled by clicking Cancel...

Page 51: ...ble to 5 th Generation LinerSCAN 3 LinerSCAN software 5 3 is backward compatible with older versions of LinerSCAN sensors and hardware This is not applicable to 5th Generation LinerSCAN 4 IMO number r...

Page 52: ...onds d Consecutive Alarm Trigger Number of consecutive readings above the Alarm ppm threshold before an alarm is sounded This can be changed between 3 and 9 e Measurement Interval Time between reading...

Page 53: ...1 Cylinder Select the cylinder which requires alteration 2 New Liner Engine hours when a new liner was fitted 3 New Piston Fitted Engine hours when new piston was fitted 4 New Piston Rings Engine hou...

Page 54: ...reen displays the historical data from the sensors This view is useful to monitor trends in the sensor wear metal debris ppm parts per million View Sensor outputs by ticking the boxes on the right han...

Page 55: ...t1 Ext2 Ext3 Ext4 Values only change with optional extra input modules Values are 0 100 4 Displays Engine On Off changes 5 Alters the scale of the Engine hours axis 6 Allows the scale of the Engine ho...

Page 56: ...Red Alert Cylinder x Red Alarm Sensor ppm has exceeded the warning level The presence of all alarms is logged in the event history the Dashboard and the cylinder colour Press Confirm Alarm to accept t...

Page 57: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 56 of 93 6 Interpreting Results Interpreting Results...

Page 58: ...problems This feedback can currently be made available in the field using on board oil analysis equipment or sample based oil analysis from a laboratory This has proved time and time again to be a su...

Page 59: ...esses low wear in normal operation adequate lubrication and high wear again as the component eventually fails This is often called a classic bath tub curve With this knowledge specific warning limits...

Page 60: ...ime is too long oil is wasted if the time is too short then there is possibility for damage This bedding in period is also dependent on various parameters such as engine load and fuel sulphur so havin...

Page 61: ...ain showing textbook bedding in curve During this bedding in period the effect of reducing the cylinder lubricant by 10 was demonstrated As expected it increased the wear on the liner and showed how s...

Page 62: ...the damage of an engine After normal operating conditions the fuel was switched to that which was recently bunkered This fuel was with in specification but had a higher than average catalyst fines con...

Page 63: ...high levels lasted for many days At the time the crew took no actions to prevent further damage The engine manufacturer decided to carry out an inspection at the next available port It was found that...

Page 64: ...than in normal conditions This could have lead to the hard ceramic catalyst fines being forced into the metal surface and cause the scuffing Figure 7 Damage to rings and liner caused by catalyst fines...

Page 65: ...1 and 5 had their exhaust valves lifted and bore measurements were taken Results showed both were in good condition and had low wear rates During the next short voyage after maintenance all cylinders...

Page 66: ...d improved Subsequent wear debris levels only went as high as 450ppm a considerable improvement Figure 9 Damaged caused by routine maintenance Below shows the levels of wear occurring after maintenanc...

Page 67: ...ofile 6 8 Feedrate optimisation Optimising cylinder lubricant usage is a way to reduce one of an engines largest overhead but there is a point where these savings can be eroded by increased maintenanc...

Page 68: ...s such as fuel with high catalyst fines Trending of cylinder wear is very important Trending after damage events can show if permanent damage has occurred or if the situation is improving When liners...

Page 69: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 68 of 93 7 Troubleshooting and Fault Finding Troubleshooting and Fault Finding...

Page 70: ...ring Software firmware problem Restart software on PC and re boot sensor Fuse blown Check lights on bottom of sensor inside box Is the fuse OK Sensor not communicating Check the LinerSCAN software net...

Page 71: ...K17510 KW LinerSCAN manual ISSUE P doc Page 70 of 93 7 1 1 LinerSCAN software Network Tab The Network tab F6 should look as below Red data lines denote network traffic errors Contact Kittiwake for adv...

Page 72: ...are 7 1 3 LinerSCAN software errors CAN Bus dongle not installed Action Check the USB to CAN converter is correctly plugged in Error win CAN close error 5120 Action Check the USB to CAN converter is c...

Page 73: ...fitted LinerSCAN software not receiving data measurement from one sensor Sensor not connected to network Check all connecting plugs leads Software firmware problem Restart software on laptop and re bo...

Page 74: ...to that sensor and see if it fills with oil Overhaul air solenoid There is no air blast Check for noise and feel vibrations from the air blast Check for air pressure Is the no air alarm activated Pipe...

Page 75: ...ur for several hours This is seen as flat lines on data charts The progress of filling can be seen by observing the level sensor within the sensor box When the sensor is full the LED will switch on wh...

Page 76: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 75 of 93 The time for the sensor to fill can be monitored by the Level sensor status lights Level Sensor LED indicator...

Page 77: ...be on an even keel otherwise oil may flow away from the scavenge space exit pipe 1 Turn power to the sensor off 2 Turn air supply to the sensors off 3 In port engine off open the scavenge inspection...

Page 78: ...w any oil to flow into the container and then empty the container for the test 6 Slowly pour 500ml of new cylinder oil over the edge of the cylinder as shown The objective is to mimic oil flowing from...

Page 79: ...anual ISSUE P doc Page 78 of 93 10 Reconnect the oil in hose to the sensor 11 Keep the air and power supplies OFF 7 4 1 Oil flow checklist Cylinder 300ml Oil collected in 60 minutes OK Not OK 1 2 3 4...

Page 80: ...e your hand or metallic object wrapped round the level sensor to simulate a full sensor the green and Yellow lights must be on to read full 4 The sensor will now air blast regularly this can be felt b...

Page 81: ...ncentration in ppm based on a simple calibration procedure Both ICP and RDE instruments suffer from size limitation effects For ICP only particles smaller than approximately 3 microns can be measured...

Page 82: ...n one half of the instrument and the other is the measurement coil into which the sample flows When the instrument has been on for some time the temperatures of these two coils are the same This has t...

Page 83: ...es are processed not deleted the some messages may be delayed for 30seconds This issue grows with the number of sensors there are 14 on some vessels The sensor values are still recorded but briefly sh...

Page 84: ...in pipes the scavenge space and common compressed air and electrical power supplies Therefore when maintenance is undertaken all common supplies power air oil and drain need turning off disconnecting...

Page 85: ...ckages Cleaning the sensor Checking calibration System functionality 8 1 1 Checking the Readings Sensor Confidence Test A measure check can be made by inserting the calibration rod into the sensor as...

Page 86: ...e LinerSCAN software to be closed or the Network Dongle to be removed Follow the steps below Step 1 Step 2 Step3 Step 4 Remove the oil pipes Press x in HyperTerminal Press c and follow on screen instr...

Page 87: ...RS232 allows direct connection to the sensor via HyperTerminal on a laptop The serial settings are 9600 baud 8 data bits no parity and 1 stop bit No handshaking Remove the 4 screws on the terminal box...

Page 88: ...noid Valves Caution Turn the oil valves OFF disconnect the air supply and disconnect the Power supply Remove the electrical connection M4 nuts and solenoid clamp Remove the nylon tube by pushing the c...

Page 89: ...MA K17510 KW LinerSCAN manual ISSUE P doc Page 88 of 93...

Page 90: ...e as this may scratch and damage the plastic Before dismantling the sensor perform a blockage test as detailed in the Troubleshooting and Fault Finding section The sensor is best serviced when removed...

Page 91: ...manual ISSUE P doc Page 90 of 93 Remove the 4 screws holding the gland plate Use 18mm and 22mm spanners to remove the U pipe IMPORTANT The 18mm spanner is used to prevent damage to the sensor especial...

Page 92: ...ean the sensor bores and U tube Should the sensor bore be completely blocked the air blast solenoid will need removal inspection and possible cleaning In addition the sensor will need removal from the...

Page 93: ...doc Page 92 of 93 Remove two BSP nuts 27mm Spanner and 5 x M8 bolts 8mm Hex The sensor can be removed whilst attached to the chassis plate Remove the oil inlet fitting 4 x M4 bolts 3mm hex key Remove...

Page 94: ...e work and re assemble the sensor Assembly is the opposite of disassembly Ensure O Rings are re fitted correctly Pipe work to the sensor must also be clear of debris before re mounting sensor 8 5 Chan...

Page 95: ...ter Division Europe 3 6 Thorgate Road Littlehampton West Sussex BN17 7LU United Kingdom Tel 44 0 1903 731470 Fax 44 0 1903 731480 Email kittiwakesales parker com Web www kittiwake com 2013 Parker Hann...

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