MA N B&W Diesel

Safety philosophy and issues of the control system

for the

electronically controlled ME-engine

by

Jørn S. Andersen
Manager
Basic Electronic System
Electronics & Software Development

© MA N B&W Diesel

ME Engine Control System

MA N B&W Diesel

ƒ The ME-engine: Introduction to computer control of

the engine combustion proces
ƒ The Engine Control System:
Principles and safety features
ƒ Integration of the ME-engine to the ship systems
ƒ Life-cycle activities:
ƒ Maintenance and trouble shooting
ƒ Update of SW

ƒ The Engine Control System as an off-the-shelf product

© MA N B&W Diesel

1
 The ME-engine essentials
- Why?
MA N B&W Diesel

Possibility for different operation modes

Optimal combustion at all operation speeds and loads
Reduced part load fuel consumption
Smokeless operation at all operation speeds
Reduced cylinder lubricating oil comsumption
Easy adaptation to different fuel
Lower dead slow running and slow steaming,
down to 10% rpm L11
Improved engine acceleration

© MA N B&W Diesel

The ME engine type

- the electronically controlled engine
MA N B&W Diesel

Engine Control
System

© MA N B&W Diesel

2
 First ME-engine in operation:
December 2003
MA N B&W Diesel

May 2005: 12 engines in operation

© MA N B&W Diesel

ME-engine:
ME-engine:
Electronic Fuel Injection
MA N B&W Diesel

Injection pressure

Principle diagram for

MPC Fuel oil
electronic fuel injection
ELFI
ELFI f(x) ampl.
setpoint

ELFI pump piston

TDC

ELFI
setpoint

Timing ELFI
pump
example of fuel injection piston
position

Injection
pressure

© MA N B&W Diesel

3
 Fuel Oil Injection
MA N B&W Diesel

Phase 1
1. The pistons move to the bottom position.
2. The fuel inlet is open.
• Hydraulic oil leaves the hydraulic oil chamber
via the ELFI valve.
• The accumulators are supplied by the ELFI
Hydraulic Power Supply. The pressurised
hydraulic oil is held back by the closed ELFI
valve.

Un pressu rised fue l oil

Pressu rised fue l oil
Un pressu rised h ydraul ic oil
Pressu rised h ydrau lic oil

© MA N B&W Diesel

Fuel Oil Injection

MA N B&W Diesel

Phase 2
5. The ELFI valve is activated upwards, closing
the return flow and opening for the flow of
pressurised hydraulic oil. The oil passes
through the ELFI valve and fills the hydraulic
chamber.
6. The high pressure forces the pistons upwards.
ELFI
7. The fuel oil inlet is closed. Valve
8. The pressure on the fuel oil rises and exceeds
the force of the spring in the cylinder’s fuel
injection valve.

Un pressu rised fue l oil

Pressu rised fue l oil
Un pressu rised h ydraul ic oil
Pressu rised h ydrau lic oil

© MA N B&W Diesel

4
 S50ME-C Exhaust Valve System
MA N B&W Diesel

Hydraulic
pu sh ro d

Exhaust valve

Exhaust valve
Actu ator

Membrane
accumulator
ELVA
on -off valve

To d rain 7S50ME-C
High p ressure hydraulic oil - inlet
© MA N B&W Diesel

Hydraulic System on the ME Engine

MA N B&W Diesel

Hydraulic Cylinder Unit (HCU)

Fu el Oil Pressure
Boo ster

Exhaust Valve
NC Valve
Actu ator
FIVA

Accumu lator

Lube oilinl
nletto engine

© MA N B&W Diesel

5
 Hydraulic System on the ME Engine
MA N B&W Diesel

Hydraulic Cylinder Unit (HCU)

Step-u p
Engine driven
driven
pu mps gear
Electrically driven
start-u p pum ps

Main Bypass
filter filter

Lube oilinl
nletto engine

© MA N B&W Diesel

Fuel Injection Profiles

MA N B&W Diesel

15/02/2003
7S50ME-C 75 % Load Injection Profiles
MAN B&W Diesel A/S 2003-02-14 14:30

900

Classic
800 Constant Pressure
Double Injection
700

600

500
bar

400

300

200

100

0
165 170 175 180 185 190 195 200 205 210 215
deg a BDC

© MA N B&W Diesel

6
 Exhaust valve timing
MA N B&W Diesel

Exhaust valve movement

80

70

60
Early closing
50
Late closing
mm

40 Early opening
Late opening
30
Ref erence
20

10

0
90 110 130 150 170 190 210 230 250 270 290
Dg. C. A.

© MA N B&W Diesel

Engine Control System

Control functions
MA N B&W Diesel

Engine Control Electronically

Electronically profile
profiled
d injection
System Exhaust valve actuation
G overnor function
Turbocharger by-pass
Auxiliary blowers
Starting air valves
Start and Reversing sequences
Cylinder lubrication
Hydraulic power supply

© MA N B&W Diesel

7
 ME Engine Control System
MA N B&W Diesel

ƒ The ME-engine: Introduction to computer control of the

engine combustion proces
ƒ The Engine Control System:
Principles and safety features
ƒ Integration of the ME-engine to the ship systems
ƒ Life-cycle activities:
ƒ Maintenance and trouble shooting
ƒ Update of SW

ƒ The Engine Control System as an off-the-shelf product

© MA N B&W Diesel

ME Engine Control system

Context
MA N B&W Diesel

H MI

Users:
- Operators
- Engineers C on tro l
- Service engineers sys te m
- Performance engineers

© MA N B&W Diesel

8
 ME Engine Control System
Main principles
MA N B&W Diesel

Engine Control System

Main Requirement
to Bridge
HMI HMI
• The engine and thereby the Engine Control
System must have a very high availability.
One failure must not stop the engine.
Engine
Control
Units
ECU
Control
ECU
Central solutions
Network
• The functionality of the control system is
Cylinder
Control CCU CCU CCU CCU
distributed between a number of
Units
autonomous control units.
• Redundancy of functionality is obtained by
duplication and by division on multiple
units working in parallel.
• Communication between control units is
done through a double redundant network.
Crankshaft
measurement • The control system is supplied by two
independent power supplies.
• Essential sensors and actuators are
duplicated (at least).

© MA N B&W Diesel

Engine Control System

Actual configuration
MA N B&W Diesel

BRIDGE PANEL

MAIN O PERAT ION MAIN O PERAT ING

PANEL PANEL
Control Room
MO P A MO P B
Pa nel

EICU A EICU B

LOCAL OPERATI ON PANEL

LOP

ECU A ECU B

CCU CCU
ACU 1 ACU 2 ACU 3 Cylinde r 1 Cylinde r n

Cy l i nd e r Sta rt A ri FIVA
AUXI LIARY L u b ric a to r Va l ve Va l ve
BL OWER 1
M PUMP 1
M PUMP 2

M PUMP 1
M PUMP 2
M PUMP 3

An gle
En co ders

AUXI LIARY Mar ker Se nsor

HY DRAULIC POWE R S UPPLY BL OWER 2

© MA N B&W Diesel

9
 Engine Control System
MA N B&W Diesel

Bridge Br idge
Panel

BACK-UP FOR M OP
Main Control Room
Operatin g Panel PC
Panel Engine Contr ol Room

EI CU A EI CU B

Engine Inter face C ontrol U nit A and B

Local
Operatio n
Panel
Engine Contr ol Unit A a nd B
ECU A ECU B Control Network

Cy linde rs Control Unit 1 per c ylinder

ACU CCU
Engine Room /On Engine
Auxilia ries Control Unit 1 , 2 and 3

© MA N B&W Diesel

Engine Control System

MA N B&W Diesel

Bridge Br idge
Panel

BACK-UP FOR M OP
Main
Control Room
Operatin g PC
Panel Engine Contr ol Room
Panel

LOP
M PC M PC
Mul ti -P urpose Control ler

Local
Operatio n
Panel

Control Network
M PC M PC

M PC M PC

Engine Room /On Engine

© MA N B&W Diesel

10
 Basic Electronic System
Hardware Components
MA N B&W Diesel

Basic Main Operating Panels

Electronic
System
HW
C Control Network
C

Multi Purpose
Controllers MPC MPC MPC MPC
Serial
communication
External
I/O I/O I/O I/O (control)
system

© MA N B&W Diesel

Multi Purpose Controller (MPC)

MA N B&W Diesel

© MA N B&W Diesel

11
 Multi Purpose Controller
MA N B&W Diesel

Hardware developed in-house:

Motorola
Motorola 68332
68332 CPU
CPU with
with Time
Time Processing
Processing Unit
Unit
(Automobile
(Automobile industry
industry CPU
CPU with
with facilities
facilities for
for determination
determination of
of
cr
crankshaft
ankshaft position
position –– programmable
programmable in in Micro
Micro Code)
Code)
Program
Program stored
stored in
in Flash-PROMs
Flash-PROMs
Software:
RTXC
RTXC pre-emptive
pre-emptive real
real time
time operating
operating system
system
Basic
Basic Electronic
Electronic System
System Software platform
Implemented
Implemented in
in C++
C++
Application
Application Software
Software
Implemented
Implemented in
in C++
C++ and
and Micro
Micro Code
Code

Control Network:
Media
Media access
access layers
layers based
based on
on ArcNet
ArcNet standard
standard
Transport
Transport layers
layers of
of protocol
protocol based
based on
on EU:
EU: ATOMOS
ATOMOS project
project
Application layers of protocol are of subsidiary design
Application layers of protocol are of subsidiary design
© MA N B&W Diesel

Multi Purpose Controller (MPC)

Software Components
MA N B&W Diesel

A
Control Network
B
Oth er Comp uter
Power Power
Equipm en t

A B
M ult i P urpos e C ontr olle r Sy ste m
Se ri al Pro to co le C on tro l
Al a rm C lo ck N etw o rk
h an d li n g p ro to c ol
(s erv ic es )
Va ri ab l e
h an d li n g Application Se rv ic e
Functionality Te rmi n al
Pa ra me te r
h an d li n g

Se n so r-Ac tua to r API

X
V X

© MA N B&W Diesel

12
 Main Operating Panel (MOP)
MA N B&W Diesel

© MA N B&W Diesel

Main Operating Panel

MA N B&W Diesel

© MA N B&W Diesel

13
 Main Operating Panel
MA N B&W Diesel

• Type approved PC
• Touch screen operation
• PCI Control Network board
• In-house developed
• Includes hardware watchdog
• Software:
• Windows 2000
• Application software implemented in C++
and graphics in Borland C++ Builder

© MA N B&W Diesel

Main Operating Panel (MOP)

Software Components
MA N B&W Diesel

Main Operating Panel

System
Ala rm H and lin g
Cl ock
Graphic - Alarm li st A B
- Event list
Application - Cut-ou t li sts
Netwo rk

Pictures Co ntrol
SW De ta ile d ala rm in fo
con fi gura ti on Ne tw ork
di spla y pro to cole
protocol
(servi ces)

Lo ad of App lica ti on
Inpu t / o utp ut Para meter
Mul
Coti mple
Pu rpose
x SW
che ck a nd test ba ck-up
Co
Controll
ntrollers
er ba ck-up

© MA N B&W Diesel

14
 Basic Electronic System
System Supervision and Self-test
MA N B&W Diesel

The system supervision checks that:

• Each unit is responding
• Each unit can be reached on both Control Network lines
• The application is executed in each unit

Supervision in each control unit:

• Test of memory and SW integrity during start-up of unit
• Signal and cable supervision as far as possible
• Supervision of each power section of the unit
• Non-proper SW execution => Shutdown - fail safe state

© MA N B&W Diesel

Basic Electronic System

Computer shutdown - fail-safe state
MA N B&W Diesel

Shutdown / fail-safe state will be entered caused by:

• Watchdog time-out
• HW watchdog supervises SW watchdog
• SW watchdog supervises time schedule of critical tasks

• HW exceptions, e.g. illegal instructions

• SW exceptions, e.g. failure situations, which
handling is not implemented in the SW
• Power failure

All outputs enters a state equal to

power-off state.
© MA N B&W Diesel

15
 ME Engine Control System
MA N B&W Diesel

ƒ The ME-engine: Introduction to computer control of the

engine combustion proces
ƒ The Engine Control System:
Principles and safety features
ƒ Integration of the ME-engine to the ship systems
ƒ Life-cycle activities:
ƒ Maintenance and trouble shooting
ƒ Update of SW

ƒ The Engine Control System as an off-the-shelf product

© MA N B&W Diesel

Engine Control System

environment
MA N B&W Diesel

Power Engine
management Master clock performance
Remote
system and diagnosis:
manoeuvring
CoCoS and
system
PMI online

Ship alarm and Remote service

control system via satellite

Various
Engine Control information
clients:
Engine safety System Maintenance
system
etc.

© MA N B&W Diesel

16
 Main Operating Panel
Alarm System, Alarm List
MA N B&W Diesel

© MA N B&W Diesel

Alarm Handling - Sub-alarm System

MA N B&W Diesel

MBD system
HMI A

HMI B

Alarm Channels Alarm

router Plant
serial link Alarm
Outvar's System

Central
Service Alarm
Terminal Router
A

Power
failure

(Redundant)
Central
Alarm
Router
B

Power
failure

© MA N B&W Diesel

17
 System interconnection
- PC network - the ’easy’ way
MA N B&W Diesel

Chief off ice P C other offi ce PC’s

ern
e x7 8x x910
x1x1x 7x8
2 x x910
x1x1
2x
Eth t
C78
9
31
01
2
A1245
6 1x x2 3x4x
A x5 6
x 1xx2 3x4x
B 5x6
x

S hi p alarm and CoCoS

MOP A MOP B
control syst em P MI online Of fice P C in ECR
ern
e

x7 8x x910
x1x1x 7x8
2 x x910
x1x1
2x
Eth t

C78
9
31
01
2
A1245
6 1x x2 3x4x
A x5 6
x 1xx2 3x4x
B 5x6
x

© MA N B&W Diesel

System interconnection
- PC-network with safety precautions
MA N B&W Diesel

Chief off ice P C other off ice P C’ s

et
ern

7x8x x910
x1x1
2x7x8
x x9 1x11
0 x1
2x
Eth

C78
9
31
01
2
A1245
6 1xx2 3x4x
A 5x6
x 1x2
x 3xBx45x6x

S hip alarm and CoCoS

MOP A MOP B Of fice P C i n E CR
control system P MI online

XXX
et

et
ern

ern

7x8x x910
x1x1
2x7x8
x x9 1x11
0 x1
2x 7x8x x910
x1x1
2x7x8
x x9 1x11
0 x1
2x
Eth

Eth

C78 C78
9
31
01
2 9
31
01
2
A1245
6 1xx2 3x4x
A 5x6
x 1x2
x 3xBx45x6x A1245
6 1xx2 3x4x
A 5x6
x 1x2
x 3xBx45x6x

© MA N B&W Diesel

18
 ME Engine Control System
MA N B&W Diesel

ƒ The ME-engine: Introduction to computer control of

the engine combustion proces
ƒ The Engine Control System:
Principles and safety features
ƒ Integration of the ME-engine to the ship systems
ƒ Life-cycle activities:
ƒ Maintenance and trouble shooting
ƒ Update of SW

ƒ The Engine Control System as an off-the-shelf product

© MA N B&W Diesel

Life-cycle activities:
Trouble-shooting and repair
MA N B&W Diesel

Consequences of the ’single failure principle’:

ƒ In a duplicated system must failures be remedied
rather fast
– in theory within an infinitively short period.
ƒ It must be avoided that trouble-shooting introduces
additional failures.

© MA N B&W Diesel

19
 MOP I/O test
MA N B&W Diesel

© MA N B&W Diesel

MOP I/O test

MA N B&W Diesel

© MA N B&W Diesel

20
 MOP I/O test
MA N B&W Diesel

© MA N B&W Diesel

Repair Philosophy
- ’Repair by replacement’
MA N B&W Diesel

• The function and location of

Multi Purpose Controllers
are identified by an ID-key plug

• Back-up of application SW and

adjustment parameters is stored in the
Main Operating Panel(s), and is loaded
via the Control Network

ID-key on MPC

© MA N B&W Diesel

21
 Exchange of Multi Purpose Controller
MA N B&W Diesel

Turn off the power

from the defective
MPC
Plug-in the network
address ID-key
Remove all plug and restore all
connectors for cabling
external cables
Turn on the power
Remove the to the new MPC
network address
ID-key plug
During startup, the MPC will download the correct application software
(it is ti ed by a wi re to
and the latest parameter data from the MOP units, and automatic start
the bo x o f the MPC) executing the application after the download is finished.
Du ring the p roced ure that will take so me minu te s, the LED o f the MPC wi ll bl ink an d
cha nge co lor seve ral times to indi cate activity.
Remove the
defective MPC and
install a spare MPC Verify that the replaced MPC is
unit indicated as running in the system
overview screen on the MOP

© MA N B&W Diesel

ME Engine Control System

MA N B&W Diesel

ƒ The ME-engine: Introduction to computer control of the

engine combustion proces
ƒ The Engine Control System:
Principles and safety features
ƒ Integration of the ME-engine to the ship systems
ƒ Life-cycle activities:
ƒ Maintenance and trouble shooting
ƒ Update of SW

ƒ The Engine Control System as an off-the-shelf product

© MA N B&W Diesel

22
 ME Engine Control System
MA N B&W Diesel

Software update

The Engine Control System

is built as an
off-the-shelf
product

The software and – not least – the test

is under on-going evolutionary development

© MA N B&W Diesel

Development Project
MA N B&W Diesel

© MA N B&W Diesel

23
 UnitTest
MA N B&W Diesel

Software module test

Scope: Software modules executed in test stubs and simulation
environment on PC
Specification: Test stubs defined by the developer. Test stubs and results
are configuration controlled, maintained and used for
regression test
Who: Software developer

© MA N B&W Diesel

Tests
MA N B&W Diesel

Test automation:
Compiler
The compilation of source code must not cause warnings.
In case it is unavoidable in a specific module, the specific
warning is explicitly suppressed in this module

Scripts: Runs the tests stubs and compares the results

with previous stored results

PClint: Static source code analysis: Strict type checking,

syntax checking etc.

Codeguard: Boundary checks, memory leaks

© MA N B&W Diesel

24
 Sub-system Test
MA N B&W Diesel

Network node software test

Scope: Assembled software for the network node executed in
simulation environment on PC
Specification: Simulated environment defined by the developer. Simulated
environment and previous results are configuration controlled,
maintained and used for regression test
Who: Software developer

© MA N B&W Diesel

Position control model

MA N B&W Diesel

Requested
curr ent (table)
Linear
Motor
+
Requested + PD + Current out
position (table) –: control

LVDT
Linear Motor
Actual position

© MA N B&W Diesel

25
 Valve controlsim ulation
MA N B&W Diesel

ELFI pi lot spool position

Requested
Position profile Mea sured e rror
mm

LVD T po s. feed back

Large fuel i ndex

Sm all fuel index

Adap tation contribu ti on

Mea sured e rror

Mea sured e rror give s ch ange s to ea rlie r cu rrent valu e
A

Re que ste d curren t

Actual cu rrent
ELFI Current

Adaptation

msec Time

© MA N B&W Diesel

Sub-system Test
MA N B&W Diesel

Network node test

Scope: Software in Control unit with I/O and network in laboratory
Specification: Network node: Test environment defined by the developer.
Test stubs and results are configuration controlled,
maintained and used for regression test
Who: Software developer

© MA N B&W Diesel

26
 Integration & System Test
MA N B&W Diesel

Integration & System test (step A)

Scope: All control units with network and I/O’s connected to simulator
Specification: System test specification
Who: Software developer(s) and person responsible for test

© MA N B&W Diesel

System Test
MA N B&W Diesel

System test (step B)

Scope: Control system etc. on the research engine
Specification: System test specification & test
t est programs for ‘Type approval
test’ and ‘Engine delivery test’
Who: Software developer(s) and person responsible for test

© MA N B&W Diesel

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 Com m issioning & Delivery Test
MA N B&W Diesel

Delivery of Engine
Scope: Engine
Specification: Engine Delivery Test specification
Who: Engine builder, Owner and Classification Society

© MA N B&W Diesel

Com m issioning & Delivery Test

MA N B&W Diesel

Delivery of Engine
Scope: Actual engine in the ship propulsion plant
Specification: Sea
Sea trial test specification
Who: Engine builder, Owner and Classification Society

© MA N B&W Diesel

28
 MAN B&W Diesel A/S
MA N B&W Diesel

Thank you for

your attention!

© MA N B&W Diesel

29