Turner MCS performed an upgrade of four 16RK280 diesel engines powering the jet propellers on a 98m fast ferry catamaran sailing in the Canary Islands. Parts’ obsolescence was the main reasons why Turner ECS received the order to replace the existing electronic injection and speed control system for each engine.
Woodward’s new Flex 500 hardware platform was selected as the new main controller performing speed control, I/O management and backup safety features. In addition Woodward’s new LECM hardware platform was selected to perform electronic fuel injection, safety features and backup speed control. The new hardware allows the customer to take complete ownership of the system with unrestricted access to both the application software and all system diagnostics using dedicated software tools.
Engine safety is guaranteed with a new redundant system design. Both the Flex 500 and the LECM monitor all safety channels. In addition a DNV approved electronic overspeed device has been installed. The system also includes three junction boxes containing remote I/O modules which collect measurements from sensors on the engine.
Two CAN networks have been installed to allow all devices to communicate with each other. One network is dedicated to remote I/O data collection and one network is dedicated to the communication between the two main controllers. In addition, the Flex 500 communicates via Modbus to the ship control system. Two communication gateways allow remote access to the main controllers and the HMI for live troubleshooting and system monitoring.
Cylinder exhaust gas temperature balancing was introduced as a new feature by configuring the LECM to increase or decrease injection duration on each cylinder. This guarantees a lower peak temperature and lower cylinder-to-cylinder and bank-to-bank temperature deviation.
Combustion optimization has been achieved by monitoring live cylinder pressure and by using an EFI system for real-time combustion diagnostics and control.
All four engines were started and tested on load and the complete functionality was tested as specified in the site acceptance test document prepared by Turner MCS and signed off by the customer. This included new functionalities with respect to the old system e.g. temperature balancing.