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We utilize IT in new ways
October 22nd 2012
Intelligent maintenance
with vibration measuring
by Hans Beyer
Innovate Software

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We utilize IT in new ways
October 22nd 2012
Agenda
• Presentation
• The situation as is
• Project overview
• Economy

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We utilize IT in new ways
October 22nd 2012
Our Purpose
• Promote knowledge of DTU SDC.
• To be the glue between the customer and DTU.
• To ensure a valid business case.
• To uncover other possible benefits.

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We utilize IT in new ways
October 22nd 2012
DTU collaboration
• Customers sign contracts directly with DTU SDC.
• Projects based in SDC, who coordinates internally on DTU.
• DTU is handles development and project management.
• We ensure that projects are PRINCE2 compliant.

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We utilize IT in new ways
October 22nd 2012
Agenda
• Presentation
• The situation as is
• Project overview
• Economy

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We utilize IT in new ways
October 22nd 2012
History
• Shipping companies want to optimize maintenance.
• I wanted to transfer my knowledge from planes to ships.
• My intention was Scheduled Maintenance on ships.
• Shipping companies want Conditional Maintenance.
• Shipping companies want to monitor hidden machinery.

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We utilize IT in new ways
October 22nd 2012
Maintenance
• Breakdown Maintenance
All components used to their full extend. Seemingly efficient but
makes planning impossible and can become very expensive.
… is unfortunately predominant.
• Scheduled Maintenance
Intervals by usage or calendar. Safe but causes unnecessary
maintenance and often changing of functioning parts.
… is safe but often unnecessary expensive.
• Conditional Maintenance
Continual monitoring of components. Safe but requires a lot of
man hours and knowledge of the parts in question.
… optimizes use of equipment but takes a lot of time.

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We utilize IT in new ways
October 22nd 2012
Agenda
• Presentation
• The situation as is
• Project overview
• Economy

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We utilize IT in new ways
October 22nd 2012
Draft
• Continuous monitoring of vibrations in equipment.
• Maintenance is transferred from Breakdown to Conditional.
• This eliminated damages caused by break downs.
• This minimizes time on sea lost on break downs.
• Planned maintenance is cheaper than acute help.
• The crew’s time spend on maintenance is minimized.
• Planned maintenance can be coordinated across the fleet.

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We utilize IT in new ways
October 22nd 2012
Equipment
• Diesel engines, 2 Hz, complex measuring (every 8th degree).
• Turbines, 200 Hz, simple measuring.
• Turbos, 1.500 Hz, simple measuring.
• Gearboxes, 100 Hz, relatively simple measuring.
• Propelling, 50 Hz, relatively simple measuring.
• Compressors, 50 Hz, simple measuring.
• Generators, 50 Hz, simple measuring.
Complex measuring: Several processes and frequencies, short intervals, external factors.
Relatively simple measuring: Similar frequencies, long intervals, external factors.
Simple measuring: Similar frequencies, long intervals.

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We utilize IT in new ways
October 22nd 2012
Overview
Shipping
Company
Filtering on frequencies
Cleansing signals with
algorithms

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We utilize IT in new ways
October 22nd 2012
Integration
Sertica
Intelligent Layer
Vibration Data Engine Data
DTU
DTU
Presentation Layer
MAN B&W
Fleet Management
Presentation Layer
Sertica DTU S.I.S.
DTU - Vibration Measurement Project

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We utilize IT in new ways
October 22nd 2012
Schedule
• Establish simple measuring of vibrations and/or noise.
 Test environment on DANA: selecting sensors and points of measuring.
 Collecting reference data and threshold limits.
 Filtering signals by frequency and possibly algorithms.
• Integrate to existing PMS systems pr. ship.
 Integrating to threshold-alarms on PMS-system.
 Transmitting data to land based PMS-system.
• Establish maintenance database on shore.
 Collecting historical data for analysis.
 Developing algorithms for predicting decomposition on equipment.
• Communicate directly with equipment vendors.
 Equipment vendors will be able to advise on running equipment.

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We utilize IT in new ways
October 22nd 2012
Agenda
• Presentation
• The situation as is
• Project overview
• Economy

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We utilize IT in new ways
October 22nd 2012
Business Case
• Maintenance on 100 ships cost 20 mill. USD yearly.
• 5% of the 20 mill. USD is Breakdown Maintenance.
• Breakdown Maintenance can be almost eliminated.
• That is a yearly saving of 1 mill. USD on maintenance.
• On top of that comes:
 Increased reliability and increased sailing (earning).
 Savings on equipment because it can be used closer to break down.
 Savings on staff costs for maintenance.

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We utilize IT in new ways
October 22nd 2012
Financing
• The Danish Maritime Foundation is interested.
• We will apply for 50% funding on October 26th.
• We are looking for the remaining 50% elsewhere.
• Are you interested in collaborating with one or two others?
• Innovate Software is paid by DTU.
• Total project budget is estimated 700-750.000 USD.