312401b k chief 500 operator manual ams pcs pms

Kongsberg K-Chief 500 Alarm and Monitoring System with Process Control and Power ManagementOperator Manual

312401/B March 2009

Document historyDocument number: 312401 Rev. A Rev. B June 2007 March 2009 First edition in Teamcenter. Replaces AD-00534. No changes to contents. Major revision. Refer to P&I BKJ01-2007/1530.

This Operator Manual describes how to use the K-Chief 500 Alarm and Monitoring System with Process Control and Power Management controls and display facilities. It is intended for system operators. He/she should be experienced in the operation of alarm and monitoring systems and have basic knowledge of personal computers or should have attended a Kongsberg Maritime training course.

The reader

NoteThe 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.

WarningThe 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: [email protected]

Kongsberg Maritime ASBekkajordet P.O.Box 1009 N-3194 Horten, NorwayTelephone: +47 33 03 20 00 Telefax: +47 85 02 80 28 www.kongsberg.com

Operator Manual

Table of contentsAdmonitions ........................................................................................................... 11 Glossary..................................................................................................................12 Alarm list terms ......................................................................................................14 1 1.1 1.2 2 2.1 2.2 2.3 INTRODUCTION .............................................................. 15 Purpose ...................................................................................................................15 Safety rules .............................................................................................................17 SYSTEM DESCRIPTION.................................................... 18 System overview ....................................................................................................18 K-Chief 500 system diagrams ................................................................................20 Design principles ....................................................................................................222.3.1 2.3.2 2.3.3 System components .................................................................................... 22 Decentralized system architecture ................................................................ 23 Centralized operation .................................................................................. 25 Alarms ....................................................................................................... 27 Engine exhaust gas temperature monitoring.................................................. 30 Trend monitoring ........................................................................................ 30 Fuel performance system (optional) ............................................................. 30 Running hours and counters......................................................................... 31 Tank display ............................................................................................... 32 Engine monitoring ...................................................................................... 34 About the Bridge Watch Monitoring System................................................. 40 About bridge watch alarms .......................................................................... 40 Stand-by pumps.......................................................................................... 41 Valve control ............................................................................................. 42 PID controllers .......................................................................................... 43 Compressor control .................................................................................... 43 Purier control ........................................................................................... 43 Boiler control ............................................................................................ 44 Introduction................................................................................................ 45 Generator control functions ........................................................................ 46 Power management functions with shaft generator ....................................... 47

2.4 2.5

Alarm system..........................................................................................................272.4.1 2.5.1 2.5.2 2.5.3 2.5.4 2.5.5 2.5.6

System functions, Alarm and Monitoring System .................................................30

2.6

System functions, Bridge Watch Monitoring System ............................................402.6.1 2.6.2

2.7

System functions, Process Control System ............................................................412.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6

2.8

System functions, Power Management System .....................................................452.8.1 2.8.2 2.8.3

3 3.1

UNIT DESCRIPTIONS ...................................................... 50 Overview ................................................................................................................50

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Kongsberg K-Chief 500

3.2

Operator Stations and Operator Panels ..................................................................513.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 Operator Station (OS) ................................................................................. 51 Midi Operator Station (MOS) ...................................................................... 52 Control Room Panel (CRP) ......................................................................... 53 Input Panel (INP)........................................................................................ 54 Alarm & Control Panel (ALC)..................................................................... 55 Touch Control Panel (TCP) ......................................................................... 56 Purpose ...................................................................................................... 58 Watch Calling repeat alarm feature............................................................... 58 Watch Bridge Unit (WBU) .......................................................................... 59 Watch Cabin Unit (WCU) ........................................................................... 60 Main characteristics .................................................................................... 63 Remote Analogue input (RAi-16) ................................................................ 64 Remote Analogue input (RAi-10tc).............................................................. 64 Remote Digital Input (RDi-32, RDi-32a)...................................................... 65 Remote Analogue Output (RAo-8)............................................................... 66 Remote Digital Output (RDo-16) ................................................................. 66 Remote Input/Output (RIO-C1) ................................................................... 67 Remote Input/Output (RIO-C2) ................................................................... 68 Generator Protection (RIO-C3) .................................................................... 69 Generator Monitoring and Control (RIO-C4) ................................................ 70 Digital Governor Unit (DGU) ...................................................................... 71 Multiple Serial Interface Module (MSI 12) ................................................... 71 Process Segment Starcoupler (PSS).............................................................. 72 Voltage Converter Controller (VCC) ............................................................ 73 Gateway types ............................................................................................ 74 The System Gateway (SGW) ....................................................................... 74 Dual Process Segment Controller (dPSC) .................................................... 75

3.3

Watch Calling System ............................................................................................583.3.1 3.3.2 3.3.3 3.3.4

3.4

Distributed Processing Units ..................................................................................633.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.4.13 3.4.14

3.5

Gateways ................................................................................................................743.5.1 3.5.2 3.5.3

4 4.1

USER INTERFACE ............................................................ 77 Overview ................................................................................................................774.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 Operator functions ...................................................................................... 77 Alarm and monitoring display ..................................................................... 77 Process mimics, bar graphs and status displays ............................................. 77 Logging and hard copy ............................................................................... 78 Self-checking and diagnostics...................................................................... 78 Access control ........................................................................................... 78 Display layout ............................................................................................ 79 Image types in the main window.................................................................. 79

4.2

System images ........................................................................................................794.2.1 4.2.2

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4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.2.10

Process image............................................................................................. 80 List image .................................................................................................. 80 Trend image ............................................................................................... 82 Monitoring image ....................................................................................... 83 System conguration image......................................................................... 84 PDF viewer ............................................................................................... 85 Navigator ................................................................................................... 86 How processes are displayed and controlled ................................................. 87

4.3 5 5.1 5.2

ShipViewer .............................................................................................................89 GETTING STARTED.......................................................... 90 Operator stations and panels...................................................................................90 Using the Control Room Panel (CRP) ...................................................................915.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 Understanding the CRP ............................................................................... 91 ALARM group buttons and lamp ................................................................. 91 PANEL group lamps ................................................................................... 92 COMMAND group buttons and lamps ......................................................... 92 INPUT group buttons and lamp(s) ............................................................... 93 Trackball ................................................................................................... 94 Buzzer ....................................................................................................... 94 Temperature sensor ..................................................................................... 94 Understanding the TCP ............................................................................... 95 Alarm Navigator......................................................................................... 95 Graphic Display Navigator .......................................................................... 96 Understanding the ALC............................................................................... 97 ALARM group buttons and lamps ............................................................... 97 PANEL group lamps ................................................................................... 98 COMMAND group buttons and lamps ......................................................... 98 Background light ........................................................................................ 98 Buzzer ....................................................................................................... 98 Temperature sensor ..................................................................................... 99 Understanding the INP .............................................................................. 100 INPUT group buttons and lamp(s) ............................................................. 100 Trackball ................................................................................................. 101 Background light ...................................................................................... 102 Temperature sensor ................................................................................... 102 Range of use ............................................................................................ 103 Understanding the keyboard ...................................................................... 103 Understanding the display ......................................................................... 105

5.3

Using the Touch Control Panel (TCP)....................................................................955.3.1 5.3.2 5.3.3

5.4

Using the Alarm & Control Panel (ALC) ..............................................................975.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7

5.5

Using the Input Panel (INP) .................................................................................1005.5.1 5.5.2 5.5.3 5.5.4 5.5.5

5.6

Using the Midi Operator Station ..........................................................................1035.6.1 5.6.2 5.6.3

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5.6.4

Menus...................................................................................................... 106 Explanation of controls and indicators........................................................ 107 How to adjust illumination for LCD type panels ......................................... 109 How to adjust illumination for LED type panels...........................................110 How to test the panel..................................................................................110 Explanation of controls and indicators.........................................................110 How to respond to alarms ...........................................................................112 How to adjust illumination for LCD type panels ..........................................113 How to adjust illumination for LED type panels...........................................113 How to test the panel..................................................................................113

5.7

Using the Watch Bridge Unit ...............................................................................1075.7.1 5.7.2 5.7.3 5.7.4

5.8

Using the Watch Cabin Unit................................................................................. 1105.8.1 5.8.2 5.8.3 5.8.4 5.8.5

6 6.1 6.2

OPERATIONAL PROCEDURES, ALARM AND MONITORING SYSTEM......................................................................... 114 Overview .............................................................................................................. 114 OS operational procedures using the Control Room Panel (CRP)....................... 1156.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15 6.2.16 6.2.17 6.2.18 6.2.19 6.2.20 6.2.21 6.2.22 6.2.23 6.2.24 6.2.25 6.2.26 6.2.27 How to handle alarm events........................................................................115 Navigator name denitions ........................................................................115 How alarms are printed after a black-out .....................................................116 How to acknowledge alarms .......................................................................116 How to display Alarm Summary .................................................................117 How to display alarm history ......................................................................119 How to display alarm group information .................................................... 120 How to display counters and reset counters................................................. 121 How to display offscan alarms ................................................................... 121 How to toggle between group and alarm display ......................................... 122 How to set day, dusk or night viewing conditions ....................................... 122 Screen Saver............................................................................................. 124 How to save screen dump .......................................................................... 125 How to customise the Favourites ............................................................... 126 How to print Miscellaneous Logs............................................................... 127 How to congure the Event Log ................................................................ 132 How to congure your own Selected Points group ...................................... 133 How to change the list of tags in the Selected Points group .......................... 134 How to congure the Autolog.................................................................... 135 How to congure the Noonlog ................................................................... 136 Where to nd the Event Log display .......................................................... 137 How to display system information ............................................................ 137 Access control system ............................................................................... 138 How to display Distributed Processing Unit information ............................. 145 How to change time zone .......................................................................... 145 How to change system time ....................................................................... 146 Info eld .................................................................................................. 147

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6.2.28 6.2.29 6.2.30 6.2.31 6.2.32 6.2.33 6.2.34 6.2.35 6.2.36 6.2.37 6.2.38 6.2.39 6.2.40 6.2.41

How to override limitations to acknowledge alarms .................................... 147 How to override limitations to control pumps and valves ............................. 147 How to silence the Control Room Panel buzzer........................................... 148 How to change tag parameters for a channel ............................................... 148 How to change Deviation parameters ......................................................... 152 How to access the Watch Calling Conguration .......................................... 155 How to set the On Duty engineer ............................................................... 155 How to select the Watch Responsible location ............................................ 156 How to call ofcers................................................................................... 157 How to change the engineer qualications .................................................. 159 How to dene watch calling Off-Duty mode............................................... 159 How to change the owner of the Watch Calling panel .................................. 160 How to make your own short trend display ................................................ 162 How to make your own long trend display ................................................. 176 How to lock and unlock the Touch Control Panel ........................................ 180 How to display Alarm Summary ................................................................ 182 How to display alarm history ..................................................................... 183 How to display alarm group information .................................................... 184 How to display counters and reset counters................................................. 184 How to display offscan alarms ................................................................... 185 How to toggle between group and alarm display ......................................... 186 How to set day, dusk or night viewing conditions ....................................... 186 Screen saver ............................................................................................. 188 How to save screen dump .......................................................................... 189 How to customise the Favourites ............................................................... 190 How to print Miscellaneous Logs............................................................... 190 How to congure the Event Log ................................................................ 195 How to congure your own Selected Points group ...................................... 196 How to change the list of tags in the Selected Points group .......................... 197 How to congure the Autolog.................................................................... 199 How to congure the Noonlog ................................................................... 199 Where to nd the Event Log display .......................................................... 200 How to display system information ............................................................ 200 Access control system ............................................................................... 201 How to display Distributed Processing Unit information ............................. 207 How to change time zone .......................................................................... 208 How to change system time ....................................................................... 209 Info eld .................................................................................................. 210 How to override limitations to acknowledge alarms .................................... 210 How to override limitations to control pumps and valves ............................. 210 How to silence the Control Room Panel buzzer............................................211 How to change tag parameters for a channel ................................................211

6.3

OS operational procedures using the Touch Control Panel (TCP).......................1806.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 6.3.15 6.3.16 6.3.17 6.3.18 6.3.19 6.3.20 6.3.21 6.3.22 6.3.23 6.3.24 6.3.25 6.3.26 6.3.27 6.3.28

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6.3.29 6.3.30 6.3.31 6.3.32 6.3.33 6.3.34 6.3.35 6.3.36 6.3.37 6.3.38

How to change Deviation parameters ......................................................... 215 How to access the Watch Calling Conguration .......................................... 218 How to set the On Duty engineer ............................................................... 218 How to select the Watch Responsible location ............................................ 218 How to call ofcers................................................................................... 219 How to change the engineer qualications .................................................. 221 How to dene watch calling Off-Duty mode............................................... 221 How to change the owner of the Watch Calling panel .................................. 222 How to make your own short trend display ................................................ 224 How to make your own long trend display ................................................. 238 How to handle alarm events....................................................................... 242 How to display alarm history ..................................................................... 242 How to display alarm summary.................................................................. 243 How to display alarm group information .................................................... 243 How to set the keyboard and screen conguration ....................................... 244 About password access.............................................................................. 245 How to display information about DPUs, tags and tag details ...................... 246 How to change tag parameters .................................................................. 247 How to change alarm limits ....................................................................... 251 How to change alarm delay ....................................................................... 251 How to receive a call................................................................................. 252 How to respond to alarms .......................................................................... 252 How to call the ON DUTY engineer .......................................................... 252 How to transfer watch responsibility .......................................................... 252 How to accept watch responsibility ............................................................ 253 How to display alarm information when in off duty mode (on WBU) ........... 253 How to display alarm information when in off duty mode (on WCU) ........... 253 Main ShipViewer functions ...................................................................... 255 Understanding the ShipViewer display ....................................................... 255 Explanation of ShipViewer displays ........................................................... 257 How to print displayed information............................................................ 260 How to save ShipViewer images ................................................................ 261 How to view saved mimic diagram les ..................................................... 261 ME monitoring overview mimic ................................................................ 263 Bearing Wear............................................................................................ 263 Cylinder Liner Fluctuating monitoring (scufng) .................................... 271

6.4

MOS operational procedures................................................................................2426.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10

6.5

Watch Calling system operational procedures .....................................................2526.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7

6.6

ShipViewer operational procedures......................................................................2556.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.6.6

6.7

ME monitoring operational procedures................................................................2636.7.1 6.7.2 6.7.3

7 7.1

OPERATIONAL PROCEDURES, BRIDGE WATCH MONITORING SYSTEM .................................................. 276 Overview ..............................................................................................................276

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7.2

BWMS operational procedures ............................................................................2767.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9 Normal use of the BWMS ......................................................................... 276 How to turn the system on/off ................................................................... 277 How to select backup navigator on duty .................................................... 278 How to turn systems auto mode on/off ...................................................... 278 How to call for backup ............................................................................. 279 How to adjust system timers ..................................................................... 279 How to change between day and night viewing........................................... 280 How to set the keyboard and screen conguration ....................................... 280 How to change access level ....................................................................... 281

8 8.1 8.2 8.3

OPERATIONAL PROCEDURES, PROCESS CONTROL SYSTEM......................................................................... 283 Overview ..............................................................................................................283 About the Process Control System .......................................................................283 OS operational procedures ...................................................................................2838.3.1 8.3.2 8.3.3 8.3.4 8.3.5 How to operate a pump starter ................................................................... 283 How to operate a fan starter ....................................................................... 295 How to operate a compressor..................................................................... 299 How to operate valves ............................................................................... 309 How to operate a PID controller................................................................. 313 How to open Tag overview ........................................................................ 317 How to operate a pump starter ................................................................... 317 How to operate a fan starter ....................................................................... 327 How to operate a compressor..................................................................... 330 How to operate a valve.............................................................................. 340 How to operate a PID controller................................................................. 344

8.4

MOS operational procedures................................................................................3168.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6

9 9.1 9.2 9.3

OPERATIONAL PROCEDURES, POWER MANAGEMENT SYSTEM......................................................................... 347 Overview ..............................................................................................................347 About the Power Management System ................................................................347 OS operational procedures ...................................................................................3489.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 Overview ................................................................................................ 348 How to open the Power Management System display (by using the CRP)........................................................................................................ 349 How to open the Power Management System display (by using the TCP)........................................................................................................ 349 How to operate a generator set with start/stop control ................................. 349 How to operate a generator set without start/stop control ............................ 357 How to operate a generator set without start/stop and with adjustable load setpoint ................................................................................................... 359 How to operate the main switchboard controller ......................................... 360 How to operate a bus-tie breaker ............................................................... 363

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9.3.9

How to operate the one-touch auto sequence .............................................. 364 User interface ........................................................................................... 366 How to operate the main switchboard controller ......................................... 367 How to operate a generator set with start/stop control ................................. 370 How to operate a generator set without start/stop control ............................ 379 How to operate a generator set without start/stop, but with adjustable load setpoint .................................................................................................... 381 How to operate a bus-tie breaker ............................................................... 382

9.4

MOS operational procedures................................................................................3669.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6

10 10.1 10.2 10.3

REFERENCE GUIDE........................................................ 385 Overview ..............................................................................................................385 Tag types...............................................................................................................386 Alarm and monitoring parameters........................................................................38910.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7 10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 Analogue input tag items........................................................................... 389 Counter input tag items ............................................................................. 393 Digital input tag items ............................................................................... 396 Exhaust mean value tag items .................................................................... 397 Exhaust deviation tag items ....................................................................... 400 Common sub-menu items .......................................................................... 401 Alarm sub-menu items .............................................................................. 402 Purpose .................................................................................................... 403 Functions ................................................................................................. 403 Local control ............................................................................................ 403 Operator Station control ............................................................................ 403 Parameters ............................................................................................... 403

10.4 Engineers safety ..................................................................................................403

11 MAINTENANCE .............................................................. 405 11.1 Introduction ..........................................................................................................405 11.2 Preventive maintenance........................................................................................40611.2.1 11.2.2 11.2.3 11.2.4 Maintenance schedule ............................................................................... 406 Weekly maintenance ................................................................................. 406 6monthly maintenance ............................................................................ 407 Yearly maintenance................................................................................... 408

11.3 Corrective maintenance ........................................................................................409 11.4 Built In Self-Test (BIST) ......................................................................................41011.4.1 11.4.2 11.4.3 How to handle DPU error codes................................................................. 410 RIO-C3 7segment display.........................................................................411 How to handle DPU communication errors................................................. 412

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AdmonitionsThe following admonitions found throughout this manual mark special messages to alert the user of specic information concerning of the personnel, the equipment or the process.WARNING Text set off in this manner provides a warning notice that failure to follow the directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment. Caution Text set off in this manner provides a warning notice that failure to follow the directions in this CAUTION can result in damage to equipment. Note

Text set off in this manner presents clarifying information or specic instructions pertinent to the immediate instruction.

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GlossaryACK ALC AMS BIST BWMS CAN CCR CRP DG dPSC DPU ER ECR EMC EMD EMI ESD GND GUI IACS ID IEC IMO INP I/O KM LAN LCD LED MCT MOS NC NO OD OS Acknowledge Alarm & Control Panel Alarm and Monitoring System Built In System Test Bridge Watch Monitoring System Controller Area Network Cargo Control Room Control Room Panel Diesel Generator Dual Process Segment Controller Distributed Processing Unit Engine Room Engine Control Room Electromagnetic Compatibility European union Maritime Directorate Electromagnetic Immunity Electrostatic Discharge Ground (module 0 V reference) Graphic User Interface International Association of Class Societies Inner Diameter International Electrotechnical Commission International Maritime Organisation Input Panel Input/Output Kongsberg Maritime Local Area Network Liquid Crystal Display Light Emitting Diode Multi-cable Transit System Midi Operator Station Normally Closed Normally Open Outer Diameter Operator Station

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PCS PDO PDS PE PEC PLC PMS PS PSO PSS RAi RAi TC RAo RDi RDo RIO SG STP TCP UMS UPS USB UTC UTP VCC WBU WCU

Process Control System Process Data Object Process Data Segment Protective Earth Parallel Earthing Conductor Programmable Logic Controller Power Management System Process Station Power Switch Over Module Process Segment Starcoupler Module Remote Analogue Input Device Remote Analogue Input Device for Thermo Couple Remote Analogue Output Device Remote Digital Input Device Remote Digital Output Device Remote I/O Shaft Generator Shielded Twisted Pair Touch Control Panel Unmanned Machinery Space Uninterruptible Power Supply Universal Serial Bus Universal Time Coordinated Unshielded Twisted Pair Voltage Converter Controller Watch Bridge Unit Watch Cabin Unit

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Alarm list termsAnalogue sensors Grad High Hi-Hi IFH IFL Inhib Low Lo-Lo Offsc Digital sensors Broken Closed Inhib Offsc Open Short The wiring to the sensor has an open-circuit. The switch is closed, such as valve closed. Inhibit. The input signal has been inhibited to avoid unnecessary alarms, such as when the main engine is stopped. Offscan alarm. Indicates that the input signal is not checked for alarm situations. The switch is open, such as valve open. The wiring to the sensor has a short-circuit. Gradient alarm. The input signal is changing rapidly. High alarm. When the input signal is higher than a set limit. High-High alarm. When the input signal is higher than a set limit. Instrument failure high alarm. Used for example when a 4 to 20 mA current loop is giving more than 20 mA. Instrument failure low alarm. Used for example when a 4 to 20 mA current loop is giving less than 4 mA. Inhibit. The input signal has been inhibited to avoid unnecessary alarms, such as when the main engine is stopped. Low alarm. When the input signal is lower than a set limit. Low-Low alarm. When the input signal is lower than a set limit. Offscan alarm. Indicates that the input signal is not checked for alarm situations and is not measured any more.

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Introduction

1 INTRODUCTION1.1 PurposeThe purpose of this Operator Manual is to present the information required to operate the Kongsberg K-Chief 500 Alarm and Monitoring System. The purpose of this Operator Manual is to present the information required to operate the Kongsberg K-Chief 500 Alarm and Monitoring System with Process Control and Power Management. The manual includes the following main chapters: System description This chapter presents a general introduction to the K-Chief 500 Alarm and Monitoring System. Unit descriptions This chapter presents a technical description of the K-Chief 500 system units. User interface This chapter presents all the elements of the user interface. Getting started This chapter explains how to use the basic control functions of the K-Chief 500 system. Operational procedures, Alarm and Monitoring System This chapter contains step-by-step procedures for operation of the Alarm and Monitoring System for all Operator Station types. Operational procedures, Bridge Watch Monitoring System This chapter contains step-by-step procedures for operation of the Bridge Watch Monitoring System. Operational procedures, Process Control System This chapter contains step-by-step procedures for operation of the Process Control System for all Operator Station types. Operational procedures, Power Management System This chapter contains step-by-step procedures for operation of the Power Management System for all Operator Station types. Reference guide This chapter contains parameter-related information accessible from the various operator locations.

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Maintenance This chapter explains how to keep the system in good working order and what to do if the system fails.Note

The K-Chief 500 is a modular system, consisting of standard main units as Operator Stations, Operator Panels and processing and I/O units. For a specic project conguration, the choice and quantities of items may vary and may depend on ship and class.Important

Windows NT, Windows 2000, Windows XP and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.

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Introduction

1.2 Safety rulesNote

Kongsberg Maritimes health and safety system must be adhered to at all times.WARNING Fire If a re condition arises, emission of toxic fumes can be anticipated from burning insulation, printed circuit boards and similar. WARNING Health hazards Do not inhale dust when cleaning the interior of the system. The dust is a temporary health hazard, depending on individual allergies. Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation, use or maintenance of the equipment. Caution Electrostatic sensitive devices Certain semiconductive devices used in this equipment are liable to damage due to static voltages. Observe all precautions for handling of semiconductive sensitive devices.

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2 SYSTEM DESCRIPTION2.1 System overviewThe K-Chief 500 is an Alarm and Monitoring System with Process Control and Power Management. Modular design allows exibility in conguring the system to individual requirements, covering the whole range from low complexity alarm systems to highly integrated alarm and monitoring systems with advanced process control. Sub-systems can include all or any combination of the following: Alarm and monitoring system Auxiliary control system Power management system Cargo control system Propulsion control Ballast automation system HVAC (air conditioning) Anti-heeling Reefer monitoring Fire system Main Engine monitoring systemNote

This manual only describes the K-Chief 500 used as an Alarm and Monitoring System.Note

This manual describes the K-Chief 500 Alarm and Monitoring System with Process Control and Power Management. The system is based on Kongsberg Maritimes unied automation concept, where each individual ship conguration is built up using standard modules communicating on CAN and LAN networks. The K-Chief 500 is congurable for all ship types, including oil and gas tankers, bulk carriers, passenger vessels, container and Ro-Ro vessels, reefers and other special purpose vessels. The main purpose of the system is to give ships ofcers all the basic alarms and status information they require in order to maintain safe and efcient operation of the machinery and other relevant equipment.

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System description

K-Chief 500 complies with the requirements of IMO, local maritime authorities, IACS, and eleven classication societies. It is designed to meet the classication societies requirements for periodically unmanned engine room operation. The system conforms to all rules and regulations, and all modules are type approved. The system incorporates the latest advances in hardware and software technology. K-Chief 500 is also developed to strict military quality standards. Refer to Typical small K-Chief 500 system (oil tanker) on page 20 and Typical large K-Chief 500 system (gas tanker) on page 21 for a principal overview of the K-Chief 500 system. The K-Chief 500 system can be a stand-alone system, but it may also be interfaced with other systems. Examples of systems are shown in the list underneath. K-Gauge The K-Gauge is a cargo monitoring and control system which is a highly integrated system incorporating level gauging, temperature and pressure monitoring, valve and pump control. K-log The K-Log Electronic Logbooks are designed to replace the traditional paper logbooks. K-Log supports event based recording of data related to navigation, engine watch, port calls and other operational activities. Auto Chief C20 The Auto Chief C20 is a propulsion control system which can be adapted to various engines. Main Engine monitoring system The ME monitoring system monitoring the conditions of Main Engine; Bearing Wear alarm handling, Cylinder Liner temperature and detections of scufng of piston wall, main bearing temperature, x-head bearing and crank bearing temperature, Torque measurements, Water In Oil Detection. The Main Engine monitoring is under constant development to meet the modern requirements of such a system. FleetMaster The FleetMaster enables continuous access to primary vessel data both on board the vessel and from ashore. Voyage data recorder The main purpose of our Voyage Data Recorder (VDR) the Maritime Black Box MBB is to record and store relevant ships data and allow reconstruction of ship incidents at sea. External VDR Serial interface to external systems for instance a re system or a level gauging system.

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2.2 K-Chief 500 system diagramsFigure 1 Typical small K-Chief 500 system (oil tanker)Wheelhouse Engine Control Room

Accommodation

WCU WCU WCU WCU WCU WCU WCU

WBU

Printer OS CRP1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o

OS

OS

Dual LAN Switch MSI12

Instrument driver DPU Dual CAN CEG CEG

Serial line RS-422

dPSC Serial gateway for propulsion control system

DPU

Rotating light and horn

MOS

MOS

MOS

dPSC DPU DPU DPU DPU DPU DPU DPU DPU (vs060222f) DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

dPSC DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

8 DPU Cabinet

16 DPU Cabinet

16 DPU Cabinet with dPSC

PMS modules to be installed in MSB / ESB

Process Area

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Figure 2

Typical large K-Chief 500 system (gas tanker)Wheelhouse Engine Control Room Cargo Control Room

Accommodation

WCU WCU WCU WCU WCU WCU WCU

WBU

Printer OS CRP1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o

Printer OS OS CRP1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o 1 h9 p2 5 A u 1 2 t o

OS

OS

OS

Dual LAN Switch MSI12 MSI12 Switch

Instrument driver DPU Dual CAN

Serial line RS-422 CEG CEG

Serial line RS-422 CEG CEG Dual CAN

dPSC Serial gateway for propulsion control system

DPU

Rotating light and horn

Rotating light and horn Routing of tags between Engine Room and Cargo segments MOS MOS

MOS

MOS

MOS

dPSC

DPU

dPSC DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

dPSC DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

dPSC DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

8 DPU Cabinet

16 DPU Cabinet


PMS modules to be installed in MSB / ESB

(vs060222i)

16 DPU Cabinet


Engine Room Process Area

Cargo Process Area

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2.3 Design principles2.3.1 System componentsThe K-Chief 500 is a modular system that allows us to meet individual ship owners requirements using standard modules. The main building blocks of the K-Chief 500 are: Operator Stations (OS) Their main functions are to receive alarms and to allow monitoring and control of the system. They can display mimic diagrams, allow control of the Watch Calling System and print various logs. They also enable the operator access to Distributed Processing Units for inspection of variables, remote operation of equipment adjustment of parameters etc. Midi Operator Stations (MOS) Their main functions are to allows alarm indication, process control and power management. The Midi Operator Station is a multipurpose Operator Station designed to be placed anywhere on the ship, even out on deck. For small alarm systems it can be the only Operator Station. Operator Panels (CRP/INP/ALC/TCP) Their main functions are to act as status and command panels for the Operator Stations. They also include a keypad for entering number values into the system and/or a trackball for controlling cursor position on the Operator Station screen. Watch Bridge Units (WBU) Their main functions are to indicate engine room alarms on the bridge while in bridge control and to accept the transfer of machine watch responsibility to and from the bridge. Watch Cabin Units (WCU) Their main functions are to indicate engine room alarms in the engineer on dutys cabin and in the public quarters while in bridge control. Distributed Processing Units (DPU) Their main functions are to monitor analogue or digital sensors and to provide analogue and digital output to different devices. A number of different Distributed Processing Units are available to meet specic control and monitoring applications.

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Dual redundant Local Area Network (LAN) The LAN is used for communication between the Operator Stations and other PC based equipment. Each unit is connected to two completely separate Local Area Networks for maximum redundancy. Dual redundant Controller Area Network (CAN) The CAN is used for communication between the Distributed Processing Units. Each unit is connected to two completely separate CAN-buses for maximum redundancy. Dual Process Segment Controller (dPSC) The dPSC is a dual two channel CAN gateway. In most cases the two channels are working in parallel on redundant CAN lines. The main function of the dPSC is to process messages from the a local CAN-bus segment and send them on the global process bus, where they are available for other dPSCs and System Gateways. Process Segment Starcoupler (PSS) The PSS is used to segment the CAN-bus so that a short circuit or broken line in one segment will not affect the functions in the other segments. System Gateway (SGW) The SGW connects two CAN lines to two Local Area Network lines. The main purpose is to receive messages from the two process buses running CAN, and update the main Operator Station database. Different selections of these units are used to congure each individual system. K-Chief 500 is a fully microprocessor-based system. It is decentralised for safety and ease of installation, but operation is centralised using Operator Stations (OS).

2.3.2 Decentralized system architectureThe heart of the K-Chief 500 system is the small family of different intelligent I/O units called Distributed Processing Units. These communicate with each other on a redundant high capacity process-bus. All monitoring and automation functions are carried out by the Distributed Processing Units, while the centralised Operator Stations provide the Man Machine Interface. Each Distributed Processing Unit type has a specic capacity in number and type of analogue or digital input and output channels. The number of channels varies from 8 to 32. To congure the tasks for a specic Distributed Processing Unit, the appropriate software and parameters are down-loaded to the unit. This allows some Distributed Processing Units to perform

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alarm functions, some control functions, some safety functions or any combination of these. This makes it easy to separate automation system functions. The process-bus used for communication between the Distributed Processing Units in the K-Chief 500 system is the Controller Area Network (CAN) bus. The CAN-bus has a very high reliability. For systems with a high number of Distributed Processing Units or for other design reasons, System Gateways (SGW) may be added to the CAN network. These units provide the necessary segregation of the automation system between for instance the different sections of an alarm and monitoring system. The System Gateways do not lower system performance or limit the possibilities for locating operator stations. The K-Chief 500 is designed to accept both a grounded or a oating earth installation. The latter installation method is required by SOLAS Regulation 45 for some vessels types. Floating earth allows coexistence with other systems and ground leakage detection. The Distributed Processing Units have been designed for immunity against single failures. Each Distributed Processing Unit has an internal three-way galvanic isolation between power, communication and input/output channels. If a unit fails, this will not affect the power source, communication bus or damage the sensors. The Built In System Test (BIST) will detect the error and warn the operator. Failures to the process-bus, cabling or connected sensors will also be detected by the Built In System Test. Exchange of a faulty Distributed Processing Unit can be done without turning the power off the K-Chief 500. The procedure is simply to disconnect and remove the faulty unit, and then mount and reconnect a replacement. The operator then requests the system to replace the module, software is automatically down-loaded and the Distributed Processing Unit starts operating. All Distributed Processing Unit types have been qualied according to the latest revision of the IACS E10 test procedure, satisfying the requirements for placement in the most demanding locations. All Distributed Processing Units can be mounted directly on diesel engines or similar locations without shock absorbers. Only Ingress Protection (IP) may be needed. The Distributed Processing Units are CE marked as required for some European Union agstate vessels. They also meet the requirements to use the Wheel Mark dened by the European Union Maritime Directive (EMD), satisfying all the new Electromagnetic Compatibility (EMC) requirements.

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2.3.3 Centralized operationThe K-Chief 500 system is operated through a number of Operator Stations. These are normally located in the Engine Control Room. Additional stations may be located in the Wheelhouse, Cargo Control Room, Damage Control Room, Ships Ofce or other parts of the vessel. The Operator Stations are normally connected to the Distributed Processing Units trough a Dual Redundant Control Area Network. The Operator Stations are tted with colour graphic displays and are operated through a purpose built Operator Panel. The Operator Stations provides the operator with a number of standard display pictures containing information about the engine and surrounding equipment. Control of any of the Distributed Processing Units can be performed from the Operator Stations. Full monitoring and alarm facilities are provided in both the machinery space and the Engine Control Room. Advanced facilities can also be provided for unmanned machinery space, and the Watch Calling system allows automatic calling of duty engineers. This allows both the machinery space and the Engine Control Room to be safely left unmanned, while the machinery watch is carried out from the Bridge. All Operator Stations are Windows based personal computers, type approved for maritime use. They work in parallel; none of them acts as master. All are interconnected via the dual redundant local area network. Although every Operator Station is identical, access to vital functions may be congured differently. The control availability is dened by extensive use of software password access. Some Operator Stations, such as units located in the Ships Ofce, are normally used for monitoring only. These units will not allow acknowledgement of alarms or execution of control commands. All general information such as monitoring of alarms, trends and graphics are available for inspection. Changing a limit or parameter on one Operator Station will automatically update all other Operator Stations. All operator actions, such as the starting or stopping of a pump or the changing of an alarm limit, are logged and time tagged (optional). Whenever a variable or state changes signicantly the Distributed Processing Units update the database in each of the Operator Stations. This means that data displayed at any Operator Station is always up-to-date. There is no need to request data each time the operator wishes to inspect a variable. As a result of this, the data trafc on the process bus and the Local Area Network is kept to a minimum, giving extremely fast data access. The Operator Station serves as the database host for process data, engineering data and software. Software for Operator Stations and the different Distributed Processing Units are stored

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here. They include functions for automatic down-loading of parameters to the Distributed Processing Units at commissioning time or when a Distributed Processing Unit is replaced. Conguration control of the K-Chief 500 systems is taken care of by an automatic version update at any change of the engineering database or the application software. The system logs all changes made. Version numbers and additional information can at any time be individually inspected for each K-Chief 500, as required by the major classication societies. Our commissioning editor (SeaMate) is used to congure or modify the functionality of the K-Chief 500 and is used to generate as-built documentation. The local area network included as part of K-Chief 500 system can interface with personal computers for remote monitoring and even with other external computer systems.

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2.4 Alarm system2.4.1 AlarmsAlarm groups

All alarms and monitored values are divided into alarm groups. Each alarm group is displayed on the left side of the Operator Station screen when the Navigator image is displayed. The Navigator is an image which is shown when the HOME button on the Control Room Panel is pushed. The Navigator image makes it easy to navigate to the wanted information in the K-Chief 500 system. For more information on the Navigator please see Navigator on page 86 .Alarm types Alarm detection for analogue signals

The following functions are included: Instrument failure alarms Low-low process alarms with or without action (slow-down) Low process alarms High process alarms High-high process alarms with or without action (slow-down) Return to normal detection with dead-band to avoid alarm uctuations Adjustable lters to remove uctuations in the incoming signals Time delay of alarm triggering and return to normal messagesAlarm detection for on/off (two state) signals

The following functions are included: High process alarms (open or closed) Return to normal detection Time delay of alarm triggering and return to normal messagesAlarm detection for on/off signals with line check

The following functions are included: High process alarms (open or closed) Line broken alarm Line short alarm Return to normal detection Time delay of alarm triggering and return to normal messages

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Inhibit alarm

Some alarms are conditional and will be inhibited when a specied condition is present. This function is accomplished by dening a signal as an inhibit source for a specied alarm or a specied group of alarms. An adjustable time delay is available to extend the inhibit situation for each signal.Alarm state indication

The four last alarms detected by the system will be indicated in the lower right corner of the colour graphics display. The alarm tag, description and state will be displayed. The following states are used by the system: On/off signal open contact alarm: OPEN On/off signal closed contact alarm: CLOSED On/off signal broken alarm: BROKEN On/off signal short alarm: SHORT Analogue signal instrument failure, signal value outside low range: IFL (Instrument Failure Low) Analogue signal instrument failure, signal value outside high range: IFH (Instrument Failure High) Analogue signal high alarm: HIGH Analogue signal low alarm: LOW Analogue signal high-high alarm: HI-HI Analogue signal low-low alarm: LO-LO On/off or analogue sensor taken out of scanning: OFFSC On/off or analogue signal return from alarm: RETURN On/off or analogue signal return from alarm: INHIBITAlarm text colour

Different colours have been used to visually distinguish between the alarm states. The meaning of the different colours is listed below: Normal state: GREEN Alarm state, not acknowledged: RED with asterisk (*) State changed from not acknowledged to normal: RED Alarm state, acknowledged: YELLOW Alarm state, inhibited: BLUE Not updated or invalid values: ORANGE Can be customised for extra critical alarms: MAGENTA

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Alarm and monitoring displays

There are several display pages for presenting alarms and monitored values. The alarm pages comprise: Alarm group display page Alarm summary page, containing a list of all active alarms Alarm history page, containing a consecutive list of time-stamped alarms The monitoring pages include: Group display containing a list of all measuring points within an alarm group Selected points display (and logging facility) Tag details, giving detailed information about each measuring point in the system2.4.1.1 Alarm acknowledge

It is possible to acknowledge alarms while a mimic window, alarm group or alarm summary is displayed. Alarm acknowledgement for separate or group alarms displayed on the screen is done through a single push. It removes the alarm text in the Alarm window (down to the right on the display), and changes the colour on the alarm text in the list views.2.4.1.2 Sound off

It is possible to make the alarm sound silent after it has notied an alarm. This is done by a single push on the sound off button. The alarm text in the Alarm window (down to the right on the display) is not changed by pushing the button.

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2.5 System functions, Alarm and Monitoring System2.5.1 Engine exhaust gas temperature monitoringThe K-Chief 500 exhaust gas monitoring system calculates the deviation between the individual cylinders and the average value of all cylinders. An alarm is given if the deviation exceeds the acceptable limit. Alarm limits are continuously calculated based on the engine load. The dead-band is set narrower as the engine load increases. Individual variations due to different exhaust piping and sensor locations for each cylinder are taken into account. Individual calculations for each cylinder bank are made when relevant. The maximum number of cylinders for each engine or cylinder bank is 16. As the average temperature is used as reference for the deviations, it is necessary to correct the temperature of each cylinder to get the same temperature in all cylinders as reference. This correction is done when running the engine at full load. When the average temperature is below a preset value, the deviation alarm is blocked.

2.5.2 Trend monitoringThe K-Chief 500 automatically records selected measurements, and stores them for use in the trend monitoring system. This system can display recorded and present data for all variables as curves. The trend monitoring system is a part of the Operator Station and consists of two trend displays: Short trend and Long trend. Please see How to make your own short trend display on page 162 and How to make your own long trend display on page 176 for more details.

2.5.3 Fuel performance system (optional)The fuel economising system is a tool to monitor fuel consumption and assess the efciency of the propulsion machinery. To study performance parameters momentary values are available. Accumulated fuel consumption and propeller shaft power such as for a voyage can be displayed and printed for reporting. Calculations are based on the Distributed Processing Units making continuous measurements. The following sensor data are required: Fuel oil ow for each propulsion engine Both input and output ow must be measured Fuel oil temperature for all input and output ows

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Running signal for each propulsion engine Shaft power (torque) for each propeller shaft Ship speed Based on these measurements the following performance parameters are calculated: Momentary fuel consumption for each engine in kg/hrs Total momentary fuel consumption in kg/hrs Hull efciency in kg/nm Engine efciency for each engine in g/kWh Shaft power for each shaft in MW Total shaft power in MW Fuel consumption and power output is calculated over the voyage period. Accumulated data includes: Duration of voyage in hours Distance travelled in nautical miles Accumulated fuel consumption for each main engine in tons Total accumulated fuel consumption in tons Accumulated propeller shaft power in for each shaft in MWh Total accumulated propeller shaft power in MWh Accumulated values can be reset by the operator. When doing so, the accumulated values are printed (a post voyage report). All fuel economising measurements and calculations are available as a display window on any of the Operator Stations.

2.5.4 Running hours and countersTo improve the maintenance plan and to decide which components need overhauling, it is important to know the running hours for each component. The K-Chief 500 running hours function keeps track of the running hours for selected pumps, fans, compressors, puriers, generators etc., and present the result to the operator on demand. Any status signal interfaced to the K-Chief 500 can be used to count running hours. Two separate counter functions are available: Counter for total active running hour Lap counter A table containing all parameters and their running hour values can be printed on demand. Values can be manually reset when units have been overhauled. When required, adjustments can be made to the total running hour or lap counter for any unit. Underneath is a K-Chief 500 display showing a counter image.

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Figure 3

Counter display

2.5.5 Tank displayThe K-Chief 500 system has an optional tank level monitoring system. It has different types of standard tank displays: Cargo tank density display General tank display Level/ullage correction display Ship displayCargo tank density display

It displays density calculations and different parameters. The following information is provided for each tank: Input number for the tank Name of the actual tank Type of tank content American Petroleum Institute (API) density Density in vacuum at 15C Density in air at 15C Density in air at specied temperature T [C] Temperature T [C] at which the density above is given Change in density (air) for a change in temperature of 1C

Positive value if density is increasing by drop in temperature Density at actual temperature

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General tank display

The purpose of this display is to show the result of tank calculation for ballast-, fuel oil and miscellaneous tanks. The following information is provided for each tank: Input number for the tank Name of the tank Type of tank content Actual level corrected for specic gravity, sensor offset, trim and list Actual volume in percent of full tank Actual volume in cubic meter Specic gravity at actual temperature Weight in metric tonnesLevel correction display

This display shows the parameters used for ullage and level correction calculations for each tank. The purpose of this display is to give the user a possibility to see the parameters used for the correction. Information provided in the display: Input number for the tank Name of the actual tank Type of tank content Measured ullage or level before corrections (this value will be displayed at the corresponding DPU if connected) Specic gravity at actual temperature (left blank if ullage measuring) Sensor height above lowest point of tank (left blank if ullage measuring) Longitudinal correction for level sensor location (left blank if trim tables) Transverse correction for level sensor location Actual ullage or level corrected for specic gravity, sensor offset, trim and listShip display

It displays the following: Display of own ships main data Total tank content display Draught and trim display Enter/change sea specic gravity Trim/list type selection

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2.5.6 Engine monitoringKongsberg Engine Monitoring Systems consist of bearing monitoring components covering Bearing Wear, Water in Oil, Temperature of all bearings and additional measuring points like: Cylinder liner, exhaust gas temperature ,Torque measurement Software and system components are common with K-Chief 500 and AutoChief C20, allowing integration and joined support. Data transfer via CAN bus is the base for easy communication with other Kongsberg systems.

Bearing Monitoring

The Kongsberg Bearing Monitoring Systems consist of the PS-10 Bearing Wear Monitoring, Sentry Wireless Temperature Monitoring and PT100 Main Bearing Temperature

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Sensors. In combination these solutions will give the most optimal monitoring of crosshead, crank and main bearing wear/temperature on 2-stroke engines. In a modern large bore two-stroke diesel engine, the reliability, particularly for critical components are vital. All major engine manufacturers continually work to maintain and improve reliability of existing and future machines in spite of i.e. higher output demands. In this picture bearing monitoring is important. The reason for this is rstly that constant monitoring of operating conditions and performance increases the chance of detecting a developing problem at an early stage. Secondly, experience has showed that some components fail most frequently shortly after an inspection, due to incorrect reassembly, foreign particles being introduced etc. Finally, servicing a part only when necessary reduces the owners maintenance costs. Both the Kongsberg Bearing Wear Monitoring and the Kongsberg Bearing Temperature Solutions have the function of predicting a bearing damage before it becomes critical. The systems will provide the crew with an early warning if any of the crank train bearings (crosshead-, crank- and main bearings) has an unexpected bearing problem during service. By providing advanced warning of impending problems, the consequential damage to crankshafts and connecting rods may be avoided. In addition the following advantages might be obtained by installing Kongsberg Bearing Monitoring Solutions; Extended time between open up intervals of bearings Reduction of insurance costs The above benets will call for individual discussions with the relevant Classication Society / Insurance Company.Bearing Wear Monitoring

The Bearing Wear Monitoring system predicts bearing wear in large two-stroke diesel engines, before it becomes critical. The system will provide an early warning if any of the three crank-train bearings (crosshead-, crank- and mean bearing) experience unexpected problems during ship operation. The Bearing Wear sensor is based on a high quality magnetic sensing element. The measurements take place every time the crosshead passes Bottom Dead Centre (BDC). Engine speed is measured continuously to compensate for engine loads and rpm. The Kongsberg BWM system complies with MAN specications on all points. This includes Alarm log, short and long term trend and data storage over more than 5 years. These functions are also available for other Kongsberg systems that easily can be connected to the BWM computer.

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Sentry; Wireless temperature monitoring

Sentry is designed to monitor the temperature of crank pinand crosshead bearings in diesel engines. These bearings can experience rapid temperature changes during damage development. The sensors are designed to give immediate response to the monitoring system. The measurement system is based on radar technology with passive sensors without need of an external power source. A low energy and high frequency radar pulse is transmitted to the Sentry Wireless Sensor via the Sentry Stationary Antenna. When the sensor passes the antenna, the radar pulse is picked up and reected back to the Sentry Signal Processing Unit. The shape and characteristics of the reected pulse determine the temperature of the sensor, i.e. the bearing temperature. The processing unit software calculates the temperature and transmits this to the engine control and monitoring system. The installation of the stationary antenna related to the sensor is exible and non-critical.

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Main Bearing temperature

Custom designed main bearing temperature sensors can be tted into any type of 2-stroke diesel engines. The sensors are mounted on the main bearing girder with the tip of the sensor in direct contact with the bearing shell. The sensor measures the combined temperatures of the bearing shell and of the lubrication oil that ows from the bearing.Cylinder Liner Temperature

The Cylinder Liner Monitoring system measures temperatures in the upper part of the cylinder liner 5-6 mm from the inner surface, thus monitoring the piston running performance in operation. Increased friction between the piston rings and the cylinder liner creates an elevated temperature level, leading to abnormal wear and eventually to piston breakage.

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Scufng monitoring and alarm

The added Kongsberg software and system components provide detection of cylinder liner scufng. Scufng occurs at sub-alarm level temperatures and is recognized by uctuation temperature readings. When scufng is detected, an alarm is given for the related cylinder.Scufng control

When scufng is detected an alarm is given for the related cylinder. An output is then given to the cylinder lubrication system that will increase the amount of cylinder lubrication oil to normalize the condition of the given liner. This function is only available in combination with the MAN Diesel Alpha lubricator.Water in oil detection

The quality of the lubrication oil is critical. Only a small content of water reduces the oils ability to lubricate the bearings. When the water content is high enough for the water to segregate from

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the oil a rapid corrosive process of the bearings will occur. The life time of a Tin/Aluminium bearing may be reduced to only a few hours. This measuring point has become standard on all new MAN Diesel engines.MetaPower torque monitoring

The intention of MetaPower system is to enable the ship owner to optimize the operation parameters of the ship, i.e. to maintain or increase the speed with less consumption of fuel. This is carried out by measuring exact power transferred to the propeller(s) during the trimming procedure. MetaPower is based on a patented LASER technology. The principle is as follows:

An IR beam is transmitted from the processing unit (8) through optical bre (3). In the optical forks (6) and (7) placed in a distance of around 1 m from each other, the light will be pulse modulated by the coding wheels (1) and (2). The modulation will depend on the shaft speed and torque. The signal is received in the processing unit, processed and displayed as rpm, torque and power on system level. The processing unit may via serial communication, analogue or digital outputs be connected to the automation system.

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2.6 System functions, Bridge Watch Monitoring System2.6.1 About the Bridge Watch Monitoring SystemThe Bridge Watch Monitoring System serves the following purposes: Central bridge alarm panel provides visual and audible alarms and warnings. These are initiated by systems and individual navigation equipment serving primary bridge functions. Bridge watch monitoring feature for detection of unattended bridge or operator disability based on interval checking. Alarm transfer to specic locations outside the bridge to alert and call the master and back-up navigator(s), automatically initiated in case the bridge alarms are not attended to or an operator disability is detected. Call back-up navigator for purpose of manual and instant initiation of alarm transfer from bridge for alert and call of master and back-up navigator(s).

2.6.2 About bridge watch alarmsThe Bridge Watch Monitoring Systems generates a prewarning and an alarm when the interval timers have expired. Prewarning: Prewarnings are only given on the bridge. 30 seconds before the alarm timer expires, a prewarning lamp starts ashing. 15 seconds before the alarm timer expires, a prewarning buzzer starts sounding. Alarm: The alarm is congurable to sound between 3 and 12 minutes after the last alarm-timer reset. To reset the alarm timer, push: Any external sound off button Any key on the Bridge Watch Monitoring panel The alarm is given as follows: When the alarm timer has expired in the captains and back-up ofcers quarters. After an additional delay called Last stage delay. The alarm is given in the captains and all navigating ofcers quarters and in public areas. The Last stage delay is congurable between 0 and 3 minutes.

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2.7 System functions, Process Control SystemAll data acquisition, signal conditioning, signal scaling and process control is performed by each individual Distributed Processing Unit. This solution guarantees that local operation is available even if the Operator Stations are not functioning.

2.7.1 Stand-by pumpsGeneral

Pump control is located in the Distributed Processing Units. Remote control is available from the Operator Stations in two ways: Through the stand by pump display (mimic diagrams). Through a (mimic) diagram included in the monitoring and control system.Stand by start at low pressure

When the pressure drops below the set limit the stand by pump automatically starts. The limit may be adjusted if an analogue sensor is used.Inhibit stand by start

Starting of the stand by pump is blocked after a blackout or at a group start, until the pressure has been built up. The stand by logic can also be inhibited by an external condition, such as main engine stopped, aux engine stopped or a similar condition.Restart after blackout

Some units have to be automatically restarted after a blackout. These units are included in a start sequence. The delay time dened in the Distributed Processing Units pump logic determines the start sequence. The operator can adjust the sequence timing.Group start of pumps

Remote controlled pumps can be started in sequence.Alarms from the stand by pump logic

Stand by start alarm Auto start fail or trip Non stand by alarm (indicates that a stopped pump is no longer in stand by mode). Sensors: Pressure switches or analogue sensors may be used for the control functions.

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Limits: All limits are downloaded from the Operator Station as part of its database. The limits may be adjusted at the Operator Station or the Midi Operator Station. Conguration: To maintain redundancy in a two or three pump system, the signals from the motor starters and the process are normally routed to different Distributed Processing Units. This conguration allows the system to work even if one of the Distributed Processing Unit fails. The stand by pump logic is also active when the Operator Station is down.

2.7.2 Valve controlGeneral

Valve control is located in the Distributed Processing Units. Remote control is available through the displays on the Operator Stations.Valve Types

Single Acting Valve: This valve type is controlled by one digital output signal. The valve-position (closed or open) is given by the signals by one or two limit switches. Double-Acting Valve: This valve type is controlled by two digital output and two input signals. The valve is opened or closed by pulsing a relay. Double-Acting Valve with Position Control: This valve type is controlled by two digital outputs; two digital inputs and an analogue input signal. The valve position is set within a dened dead band by pulsing a relay.Additional functions

In addition, the following functions are available as part of the valve control system: Pulsed output. Automatic closing of a set of valves. Automatic opening or closing of valves. Close on an analogue setpoint, using deadband. Low-level Auto CLOSE Valve, remote OPEN/CLOSE function. Close when a low level switch opens. Automatic OPEN/CLOSE of Valve Remote OPEN/CLOSE function. Close when a low level switch opens. Valve Change-Over on Alarm with Reset.

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2.7.3 PID controllersThe PID controller system is a set of software modules located in the appropriate Distributed Processing Unit. All combinations of PID controllers are available. Cascade control is accomplished by connecting two controllers together. The PID controllers can be congured from the Operator Station or the Midi Operator Station. The following parameters are available: Tuning parameters (gain, integration time and derivation time) Controller setpoint Output mode (true control mode, AUTO, or valve position control mode, SEMIAUTO) Controller types (P, PI, PD or PID) Selection of input and output signal type Input and output channel number Sampling time

2.7.4 Compressor controlThe compressor control system is a set of software modules located in the appropriate Distributed Processing Unit. The main purpose is to maintain the air receiver pressure at a constant value. This function includes remote manual and automatic start and stop of compressors, restart after blackout and automatic drain control. The compressor control system communicates with the Operator Station or the Midi Operator Station and can be monitored or controlled from here.

2.7.5 Purier controlThe purier control system is a set of software modules located in the appropriate Distributed Processing Unit. The purier control program is specially written to operate Alfa Lavals self cleaning oil puriers, and includes operation of the following equipment: Crude oil booster pump (optional) Crude oil temperature controller Puriers Sealing valves Discharge valves The equipment may be controlled from the Operator Station or the Midi Operator Station. Purier conguration is selected manually by operating different by-pass valves directly. The purier control program will sense if puriers are running in series or parallel. Mode of operation is indicated in the mimic

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display by showing the oil path as green lines. Purier no. 1 will always run as purier, whereas purier no. 2 may be selected to run as purier or clarier.

2.7.6 Boiler controlThe boiler control system is a set of software modules located in the appropriate Distributed Processing Unit. The program consists of a standard PID controller and is adaptable to different types of boilers. The boiler control system uses fail checking extensively, and employs a program for controlled shut down, and provides visible alarms. Boiler system parameters are available on the Operator Station or the Midi Operator Station. All parameters are found in the steam system display. System information such as alarms and analogue values are part of the normal K-Chief 500 alarm and monitoring system. The boiler control involves total control of the following equipment: Fuel oil stand-by pumps Burner motor Fuel pre-heater Nozzles Ignition unit Air damper Steam release valve These units are connected to and controlled by the appropriate Distributed Processing Unit.

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System description

2.8 System functions, Power Management System2.8.1 IntroductionThe Power Management System controls the power generation and distribution on board the vessel. It includes all the automatic functions necessary for safe and economic operation of the power plant. The basic system consists of one Distributed Processing Unit per connected generator unit. Each performs the power management functions of the connected generator unit. The system is suitable for electrical generators driven by a diesel engine, a steam turbine or by the propeller shaft. The Distributed Processing Units have different congurations and control strategies depending on the type of drive. The Distributed Processing Units are connected to the Operator Station, which allows the operator to initiate the same monitoring and control functions that can be performed locally. For complex Power Management Systems an additional Distributed Processing Unit, the dPSC, is used for mode control etc. This is a unit giving redundancy both in function and communication, and allows separation of local PMS CAN process bus data trafc from other parts of the global CAN-network of the K-Chief 500 system. The Power Management System will be adapted to the specic conguration of power generators and bus bars on the ship. In order to comply with the latest rules of separation of functions for alarm, control and safety, these functions have been addressed to separate Distributed Processing Units like this:

312401b k chief 500 operator manual ams pcs pms

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