Spectral Analysis of Torsional Vibrations Measured by Optical Sensors, as a Method for Diagnosing Injector Nozzle Coking in Marine Diesel Engines
Abstract
:1. Introduction
- (a)
- Measurement accuracy resulting from a large number of pulses per revolution;
- (b)
- Absolute reference to the accurate identification of the phase and processing in the domain of angles;
- (c)
- Ability to mount on the free ends of the shaft of a generator set.
2. Materials and Methods
- (a)
- Two laser heads;
- (b)
- An electronic block, converting the voltage signal from the measuring heads into digital records;
- (c)
- A Saia Burgess Controls programmable logic controller (PLC) for data recording.
- (a)
- As the load of the generator changes, a phase shift occurs between its electromotive force and the voltage in the mains to which electric energy is generated. Any further increase in the load on the unit elevates the value of the phase shift, which also affects the distribution of torsional moments of the drive shaft;
- (b)
- In order to achieve the run uniformity factor of ≤1/250, the unit was equipped with a heavy flywheel. The rotor of the generator is heavy as well;
- (c)
- The shaft is of the resilient variety.
- (a)
- Counting the pulses (i1i) generated by the first measuring head while the first perforated disc moved by two teeth and two gaps (i.e., by 4 degrees of the crankshaft’s rotation). Because the validation of results is based on indicator charts, a gradual measure of the angle was adopted;
- (b)
- Counting the pulses (i2i) generated by the second measuring head while the second perforated disc moved by two teeth and two gaps (i.e., by 4 degrees of the crankshaft’s rotation);
- (c)
- Calculating the time (t1i) in which two teeth and two gaps of the first disc moved by 4 degrees of the crankshaft’s revolution:
- (d)
- Calculating the time (t2i) in which two teeth and two gaps of the second disc moved by 4 degrees of the crankshaft’s revolution:
- (e)
- Calculating the mean angular velocity (ω1i) for the movement of the first disc by 4° of the crankshaft’s revolution:
- (f)
- Calculating the mean angular velocity (ω2i) for the movement of the second disc by 4° of the crankshaft’s revolution:
- (g)
- Calculating the displacement of the second disc (φ2i), assuming that the displacement of the first disc (φ1i) was increasing every 4° of the crankshaft’s revolution (i.e., it equaled 4; 8; 12; 16°… of the crankshaft’s revolution), meaning that the displacement of the second disc was the product of the second disc’s velocity and the time during which the two teeth and two gaps of the first disc moved by 4° of the crankshaft’s revolution:
- (h)
- Adding all partial displacements of the second disc in order to obtain the total displacement value of the second disc (φ2). The system measures displacements by one section, consisting of two teeth and two gaps, which is equal to 4° of the crankshaft’s revolution. This means that one full rotation is divided into 90 sections. The system measures 10 crankshaft revolutions, so the total number of sections equals 900:
- (i)
- Adding all partial movements of the first disc (φ1):
- (j)
- Calculating torsion fluctuations (φ) by subtracting the sum of the first disc’s displacements from the sum of the second disc’s displacements:
3. Results and Discussion
- (a)
- The use of the method is planned for use as an on-line diagnostic system on autonomous and unmanned ships;
- (b)
- Failures introduced on one cylinder increase the load on other defect-free cylinders, which often results in exceeding the alarm thresholds of permissible exhaust gas temperatures, the most universal level 70% of loading of the diesel–electric unit was adopted.
- stage 1—coked injector nozzle in cylinder one,
- stage 2—coked injector nozzle in cylinder two,
- stage 3—coked injector nozzle in cylinder three.
3.1. Results of Tests of a Diesel–Electric Power Unit with a Defect-Free Ship Engine
3.2. Results of Tests with a Diesel–Electric Power Unit and a Coked Injector Nozzle
- (a)
- An increase in the pressure of fuel injected by the coked nozzle, to approximately 100 MPa (Figure 9, Figure 10 and Figure 11). Injectors in a defect-free engine spray fuel at the pressure of approximately 70 MPa (Figure 5). The difference was 30 MPa and maximum permissible error in this case was 0.8 MPa;
- (b)
- (c)
- A drop of the maximum combustion pressure in the cylinder with the coked injector, to approximately 7 MPa (Figure 9, Figure 10 and Figure 11). The maximum combustion pressures in cylinders of a defect-free engine were almost equal and amounted to approximately 8 MPa (Figure 5). The difference was 1 MPa and the maximum permissible error in this case was 0.075 MPa;
- (d)
- ―
- With the first injector nozzle defective, the largest differences in amplitude values were observed for seven harmonic components of the following orders: (6.25 Hz), 1 (12.5 Hz), (18.75 Hz), 4 (50 Hz), 6 (75 Hz), 6 (81,25 Hz), and 8 (100 Hz);
- ―
- With the second injector nozzle defective, the largest differences in amplitude values were observed for twelve harmonic components of the following orders: (6.25 Hz), 1 (12.5 Hz), (18.75 Hz), 2 (25 Hz), 3 (37.5 Hz), (43.5 Hz), (56.25 Hz), 6 (75 Hz), 6 (81,25 Hz), 7 (87.5 Hz), 7 (93.75), and 8 (100 Hz);
- ―
- With the third injector nozzle defective, the largest differences in amplitude values were observed for nine harmonic components of the following orders: (6.25 Hz), 1 (12.5 Hz), (18.75 Hz), 2 (25 Hz), 3 (43.5 Hz), 4 (56.25 Hz), 6 (75 Hz), 6 (81,25 Hz), 8 (100 Hz).
4. Conclusions
- (a)
- The assumptions adopted for the proprietary algorithm used for calculating torsional vibration values were correct;
- (b)
- The data, recorded by 16 MHz laser heads, are sufficient to determine torsional vibrations of the diesel–electric unit’s shaft;
- (c)
- The spectra obtained for the defect-free/healthy ship engine are strongly correlated (Table 3). It proves the high repeatability of the results for a given sample;
- (d)
- The spectra obtained for the engine with a particular coked injector are strongly correlated (Table 3), which also proves the high repeatability of the results for a given sample;
- (e)
- The values of harmonic component orders obtained are clearly visible in the spectra (Figure 8);
- (f)
- Torsional vibration spectra of the DEU with a defective injector nozzle were different from those obtained for a defect-free engine (Figure 13);
- (g)
- The distribution of differences in the values of the first sixteen harmonic components depend on the cylinder in which the defective injector nozzle was installed.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Sulzer 3AL25/30 Four-Stroke Engine | ||
Piston diameter | 250 | (mm) |
Piston stroke | 300 | (mm) |
Nominal effective power | 408 | (kW) |
Mean effective pressure | 1.47 | (MPa) |
Injector opening pressure | 25 | (MPa) |
Fuel delivery advance angle | 17 | (deg) |
Nominal rotating speed | 750 | (rpm) |
Number of cylinders | 3 | (-) |
Firing order | 3-2-1 | (-) |
GD8 500-50/3 Synchronous Generator | ||
Power | 500 | (kVA) |
Rotating speed | 750 | (rpm) |
Stator voltage | 400 | (V) |
Stator current | 723 | (A) |
Frequency | 50 | (Hz) |
Order of a Harmonic (k) | Frequency (Hz) |
---|---|
6.25 (one cylinder combustion) | |
1 | 12.5 (basic harmonic component) |
1 | 18.75 (combustion harmonic component) |
2 | 25 |
2 | 31.25 |
3 | 37.5 |
3 | 43.5 |
4 | 50 (polar pulsation for four pairs of poles of a single voltage phase) |
Engine Condition | Sample Pearson’s Correlation Coefficient Full Spectra/First Sixteen Harmonics |
---|---|
Defect-free/healthy engine | 0.84/0.83 |
Coked injector nozzle in the first cylinder | 0.80/0.78 |
Coked injector nozzle in the second cylinder | 0.92/0.93 |
Coked injector nozzle in the third cylinder | 0.82/0.81 |
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Drewing, S.; Witkowski, K. Spectral Analysis of Torsional Vibrations Measured by Optical Sensors, as a Method for Diagnosing Injector Nozzle Coking in Marine Diesel Engines. Sensors 2021, 21, 775. https://doi.org/10.3390/s21030775
Drewing S, Witkowski K. Spectral Analysis of Torsional Vibrations Measured by Optical Sensors, as a Method for Diagnosing Injector Nozzle Coking in Marine Diesel Engines. Sensors. 2021; 21(3):775. https://doi.org/10.3390/s21030775
Chicago/Turabian StyleDrewing, Sebastian, and Kazimierz Witkowski. 2021. "Spectral Analysis of Torsional Vibrations Measured by Optical Sensors, as a Method for Diagnosing Injector Nozzle Coking in Marine Diesel Engines" Sensors 21, no. 3: 775. https://doi.org/10.3390/s21030775
APA StyleDrewing, S., & Witkowski, K. (2021). Spectral Analysis of Torsional Vibrations Measured by Optical Sensors, as a Method for Diagnosing Injector Nozzle Coking in Marine Diesel Engines. Sensors, 21(3), 775. https://doi.org/10.3390/s21030775