Failure of the remote automatic control of the main engine. Actions of the ETO. Kongsberg Troubleshooting

Greetings! In this article, we will consider the actions of the ETO in case of failure of the remote automatic control of the main engine (real situation).

The vessel is equipped with the AutoChief C20 Propulsion Control System, which is very often used for fixed-pitch MAN MC engines. Produced by Kongsberg Maritime.

AutoChief C20 Control Panel (ACP)

Remote automatic control of the main engine on a merchant vessel involves sophisticated systems that allow for the operation, monitoring, and management of the engine from a distance, typically from the ship's bridge or a centralized control room. This technology enhances operational efficiency, safety, and response times. Here’s a detailed look at the components and functioning of remote automatic control systems for the main engine:

1. Components of Remote Automatic Control Systems

• Engine Control Room (ECR): A centralized area where engine operations are monitored and controlled.
• Bridge Control Console: Allows the bridge team to manage engine operations, particularly useful during navigation and maneuvering.
• Automatic Engine Control Systems: These include electronic control units (ECUs), sensors, and actuators that automate engine functions.
• Monitoring Systems: Sensors and instruments that continuously monitor engine parameters such as temperature, pressure, speed, and fuel consumption.
• Communication Networks: Data transmission systems that relay information between the engine room, ECR, and bridge, often using redundant paths for reliability.

2. Key Features and Functions

• Start and Stop Control: The ability to remotely start and stop the main engine, including sequential start-up procedures.
• Speed Control: Adjusting the engine speed remotely, which is crucial for maintaining optimal cruising speed and fuel efficiency.
• Load Control: Managing engine load to ensure it operates within safe limits, avoiding overloading and ensuring efficient power distribution.
• Alarm and Fault Management: Real-time monitoring systems generate alarms for abnormal conditions such as high temperatures, low oil pressure, and other critical parameters. Automated responses can mitigate risks, and remote diagnostics can help in troubleshooting.
• Data Logging and Analysis: Continuous recording of engine performance data for analysis, which helps in predictive maintenance and operational optimization.
• Safety Interlocks and Protections: Automatic shutdown procedures and protective interlocks are activated in case of critical failures or unsafe conditions.

3. Operation and Control Process

• Normal Operation: Under normal conditions, the engine operates automatically with parameters set and adjusted remotely. The control system manages fuel injection, cooling, lubrication, and exhaust processes to maintain efficient operation.
• Manual Override: In case of system failures or emergencies, manual override controls are available, allowing engineers to take direct control of the engine.
• Emergency Procedures: Automated systems handle emergency shutdowns and engage safety protocols. Manual interventions can be performed from the ECR or bridge if needed.

4. Technological Aspects

• Programmable Logic Controllers (PLCs): Used for automating control processes, executing commands, and ensuring reliable operation.
• Human-Machine Interface (HMI): Graphical interfaces that allow operators to interact with the control systems, view engine parameters, and execute commands.
• Distributed Control Systems (DCS): Integrated systems that manage multiple control processes across the vessel, ensuring coordinated operation of the main engine and auxiliary systems.

5. Advantages

• Increased Efficiency: Automated controls optimize engine performance, reducing fuel consumption and emissions.
• Enhanced Safety: Continuous monitoring and automated emergency responses reduce the risk of accidents and engine failures.
• Improved Reliability: Predictive maintenance and real-time diagnostics help in early detection of potential issues, reducing downtime.
• Operational Flexibility: Remote control allows for better maneuverability and faster response to changing navigational conditions.

6. Challenges and Considerations

• Technical Failures: Dependency on electronic systems means that any failure in these systems can impact engine control.
• Cybersecurity: Protecting the control systems from cyber threats is crucial to prevent unauthorized access or malicious attacks.
• Training and Familiarization: Crew must be adequately trained to operate and manage remote control systems and handle manual overrides when necessary.
• Integration with Legacy Systems: Upgrading older vessels with modern remote control systems can be challenging and require significant investment.

Remote automatic control of the main engine on a merchant vessel leverages advanced technologies to enhance efficiency, safety, and reliability. By automating key processes and enabling remote monitoring and control, these systems allow for optimal engine performance and swift responses to operational demands and emergencies. Proper implementation, maintenance, and crew training are essential to fully realize the benefits of these advanced control systems.

The situation with the failure of the remote automatic control occurred in a maneuvering mode, the vessel was sailing along the river with a pilot.

ACP limits

After the actions of the chief officer when disabling the limits and changing the speed (the exact information is not known exactly what actions were taken), the main engine remote automatic control failed and the ship became uncontrollable in terms of speed.

Propulsion plant

The telegraph control panel on the bridge was full of errors and there was no access to the information on the main screen. At the same time, the main engine worked and kept the revolutions preset before the error.

In the engine room ECR, also on the main computer AMS, a lot of system failure errors were displayed on the bridge. The machine telegraph gave errors, but remained in working order, unlike the telegraph on the bridge.

Alarm monitoring system in the ECR

AutoChief Errors (ACP)

Actions of the ETO

In this situation, the only thing that comes to mind is to restart the telegraph on the bridge. In this case, you first need to give control to the engine room (ECR), after setting the desired number of revolutions of the main engine.

After pressing the corresponding buttons (ECR) and confirming the operation, the control of the main engine was transferred to the ER.

As usual, in such situation there is not enough time for thinking and should to act with radical methods. Therefore, on the telegraph of the bridge, it was necessary to take out the supply terminal and thereby de-energize the unit and reboot it.

Reboot ACP

After the reboot, control was transferred to the bridge and the normal operation of the remote automatic control of the main engine was restored.

Remote automatic control of the main engine (drawing)

In the future, the drawing was investigated and work on the mistakes was done. In this case, it was necessary to go to the UPS cabinet of the main engine, where the main breakers and backup batteries are located. Select the desired breakers, according to the drawing presented above and restart the telegraph.

Breaker F1A

Breaker F1B

Unfortunately, this method of reloading would affect all the components of the main engine automation on the bridge and it is not known how safe it would be.

In this situation, a simple reboot helped, but not with simple actions. From this article we can conclude that when getting on a new vessel, it is very important for ETO to study the circuits and ask yourself a question "how to properly reset (restart) different control systems on a vessel".

The AutoChief C20 is a sophisticated propulsion control system developed by Kongsberg Maritime, designed to provide advanced control and monitoring of the main engine on a variety of vessels. It integrates various subsystems to ensure optimal performance, safety, and efficiency of marine propulsion.

Key Features of the AutoChief C20 Propulsion Control System

1. Comprehensive Control Functions

• Remote Control: Allows for remote operation of the main engine from the bridge or Engine Control Room (ECR).
• Engine Start and Stop: Automated sequences for starting and stopping the engine, including safety checks and interlocks.
• Speed Control: Precise control of engine speed for various operational conditions, including maneuvering and cruising.

2. Monitoring and Diagnostics

• Real-Time Monitoring: Continuous monitoring of engine parameters such as RPM, temperatures, pressures, and fuel consumption.
• Alarm Management: Advanced alarm system that notifies operators of any abnormal conditions or faults.
• Diagnostic Tools: Built-in diagnostic functions to facilitate troubleshooting and maintenance.

3. Safety and Reliability

• Safety Interlocks: Prevent unauthorized or unsafe operations, ensuring that all procedures are followed correctly.
• Emergency Shutdown: Automated emergency shutdown procedures in case of critical failures.
• Redundancy: Redundant components and systems to enhance reliability and minimize the risk of failure.

4. User Interface and Controls

• Human-Machine Interface (HMI): Intuitive graphical user interface that provides operators with easy access to control and monitoring functions.
• Touchscreen Panels: Modern touchscreen panels for efficient interaction and control.
• Manual Override: Capability for manual control in case of system failure or specific operational requirements.

5. Integration and Compatibility

• Integration with Ship Systems: Seamlessly integrates with other onboard systems such as power management, navigation, and automation systems.
• Compatibility: Compatible with a wide range of engines and propulsion systems, making it suitable for various vessel types.

6. Advanced Control Algorithms

• Fuel Optimization: Algorithms designed to optimize fuel consumption and reduce emissions.
• Load Sharing: Efficient management of load distribution among multiple engines if applicable.

7. Data Logging and Analysis

• Data Logging: Continuous recording of operational data for performance analysis and historical record keeping.
• Performance Analysis: Tools to analyze engine performance, identify trends, and predict maintenance needs.

Benefits of the AutoChief C20 System

• Improved Efficiency: Enhances fuel efficiency and overall engine performance through precise control and optimization algorithms.
• Enhanced Safety: Robust safety features and interlocks ensure safe operation under all conditions.
• Operational Flexibility: Provides flexibility in engine operation and control, accommodating various navigational and operational scenarios.
• Ease of Use: User-friendly interface and controls make it easy for operators to manage and monitor the engine.
• Reduced Downtime: Advanced diagnostics and predictive maintenance capabilities help in reducing unexpected downtime and improving reliability.

The AutoChief C20 Propulsion Control System represents a state-of-the-art solution for managing the main engine of merchant vessels. Its comprehensive control functions, advanced monitoring capabilities, and robust safety features make it an essential tool for modern maritime operations. By integrating seamlessly with other ship systems and providing user-friendly interfaces, the AutoChief C20 enhances the efficiency, safety, and reliability of marine propulsion.