ROMAS Remote Operations of Machinery and Automation Systems

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1 MARITIME ROMAS Remote Operations of Machinery and Automation Systems Haugesundkonferansen 6.februar 2019 Steinar Låg 06 February DNV GL February 2019 SAFER, SMARTER, GREENER

2 Outline The ROMAS Project Some of the work done CONOPS Concept of operations HaziD analysis IAS Data analysis Pilot testing Way forward 2

3 The ROMAS Project 3

4 The ROMAS project ROMAS: Remote Operation of Machinery and Automation Systems NFR application granted Dec 2016 Research project Total budget 9,5 MNOK Partners: Reference partner: 4

5 Remote machinery operation: Background and motivation Shortage of machinery engineers to man ships Increasingly complex ships, new skills needed Increased digitalisation & improved ship-shore connectivity Automation and remote operations is increasingly adopted in other industries Idea: Move the Engine Control Room (ECR) from the ship to a shorebased Engine Control Centre (ECC) Fleet wide control from an on-shore ECC Reduced need for engineers on-board Improved efficiency & safety Not as revolutionary as remote/autonomous navigation 5

6 Some of the work done so far - CONOPS Concept of Operations - HazID analysis - IAS data analysis 7

7 Concept qualification process as per CG-0264 (Class Guideline for Autonomous and remotely operated ships) Submitter s activities Decide on operations and automation High-level design Detailed design Build and integrate Commissioning and test Operations CONOPS Safety philosophy Maintenance philosophy Off-ship systems design Verification and validation strategy Test Reports Configuration management reports Preliminary risk analysis report Design philosophy Detailed vessel design Detailed risk analysis reports Test specifications DNV GL newbuild process Review of overall concepts Plan approval Newbuild survey Test scope approval Test witnessing DNV GL fleet in service process Analyse class operations data FiS surveys 9

8 Fjord1 s ferry route Molde-Vestnes M/F Korsfjord 10

9 Pilot vessel MF Fannefjord Norwegian flagged Ro-ro ferry built for Fjord1 in 2010 Yard: Gdanska Stocznia Remontowa, Gdansk Poland Built to DNV class (Vessel ID 28425/D28424) 1A1 Car ferry B Clean E0 Gas fuelled R4(nor) Double-ended ferry design with battery hybrid gas (and diesel) electric propulsion Highly redundant propulsion system: 2 azimuth thrusters Power: 2x Gas + Battery + Diesel 11

10 Remote operations concept: ECC side ECC located in Fjord1 s office in Molde Manning: 24x7 by 1 operator (chief engineer) Arrangement for additional support (bakvakt) ECC designed to support 3 ferries Similar design & operational profile Pilot tests: Just one ferry (MF Fannefjord) Responsibilities Main responsibility for maintenance & operation Communication with ship and shore-parties Equipment 2 workstations (~ECR-like) Big screen with fleet view 12

11 Remote operations concept: Ferry side Overall manning level (5) remains unchanged to comply with requirements for safety manning Chief engineer replaced by combiman Qualification: Able Seafarer Engine ( Motormann ) Responsibilities: Combination of deck- and machinery- work Emergency/safety duties acc.to safety plan Planned maintenance Assist ECC operator when required Visual inspections and routine work Take local command of technical systems (when required) Receive support and guidance from ECC ECR and Bridge workstations: upgraded 13

12 Remote operations concept: Communications The IAS Network onboard is extended to ECC over a reliable and redundant ship-shore communication link Communications 2 x 4G modems (Telia and Telenor) + ICE Automatic switching Always on 2-way voice ECC-Bridge VHF at ECC Portable communication device to support troubleshooting Example: DAQRI s smart helmet ( 14

13 Remote operations concept: Monitoring & Control IAS (Integrated Automation System) hub for monitoring & control of the machinery and engineering systems IAS functional enhancements Communication system integration: Health monitoring Transfer of Command: Automatic and manual Cyber protection Remote connections from other relevant ship systems such as: Fire alarm / safety systems Shiplog admin and operational data CCTV from engine room 15

14 CONOPS: Mapping of Normal operations 16

15 CONOPS: Identification of abnormal conditions / scenarios 17

16 HazID analysis 19

17 Hazid Analysis DNV GL, Fjord1, Høglund, Rederiforbundet and Sjøfartsdirektoratet Goal: Identify and assess hazards associated with the concept Input: CONOPS Output: Hazid Report + Risk sheets serving as input for further work Two steps Jan 2018 (v1.0): MF Norangsfjord (workshop) Oct-Dec 2018 (v1.1) MF Fannefjord DNV GL) Limitations: Relative exercise, no formal voting, CONOPS completeness Effect on Human Safety Severity Minor Significant Severe Catastrophic Single or minor injuries Multiple or severe injuries Single fatality or multiple severe injuries Multiple fatalities Effect on Ship Local equipment Non-severe ship Severe damage Total loss Frequency F\S 0,01 0, Frequent Likely to occur once per month on one ship 1E+1 6 Probable Likely to occur once per year on one ship 1E+0 5 Reasonably probable Likely to occur once per year in a fleet of 10 ships, i.e. likely 1E-1 to occur a few times during the ship's life 4 Seldom Likely to occur once per 10 years in a fleet of 10 ships 1E-2 3 Remote Likely to occur once per year in a fleet of 1,000 ships, i.e. likely to occur in the total life of several similar ships 1E-3 2 Very remote Likely to occur once per 10 years in a fleet of 1000 ships 1E-4 1 Extremely remote Likely to occur once in the lifetime (20 years) of a world fleet of 5,000 ships 1E-5 20

18 Hazid Workshop risk matrix Conventional ops Rempote ops Remote ops w/mitigations Risk matrix 21

19 30 mitigations identified 30 mitigations Training (2) Design (13) Procedure (15) 22

20 30 mitigations identified Training(2) Machinery training (Combiman) Safety training (Combiman) Design(13) UPS for IAS & Comms Descriptive Battery Alarm Alarm limits adjusted for remote operations Alarms with priority/criticality Sufficient IAS integration Additional ICE modem Comms outage alarm Walkthrough of all essential sensors Visual surveillance (CCTV) at ECC Redundancy of comms modems VHF at ECC Sufficient UPS, broadband and security at ECC Additional sensors or inspection tools for gas system Procedures(15) Avoid simultaneous overhaul of two engines/generators Procedure for ECC-Bridge communication Procedure for handling comms loss Procedure for spare ferry to be put into operations Procedure for ECC handling for simultaneous problems on two ferries Procedures/criteria for taking the ferry out of service Procedure for transferring command from ECC to Bridge Procedure for ECC support in severe weather conditions Updated procedures for remote/eccoperations Procedure for handling water ingress Procedure for fire handling Procedure for bilge handling CBM (Condition Based Maintenance) Updated procedure for gas system Updated procedure for battery system 23

21 Hazid Results Conventional ops ROMAS ops w/mitigations Increased risk 6.6 Communication failure 6.7 ECR/ECC outage Reduced risk Too many alarms for ECC operator Alarm information not detailed enough 6.4 Unplanned Maintenance & Repair 6.13 Fire incident 6.14 Environmental emissions 24

22 IAS data analysis 25

23 Analysis of historic IAS data why? The IAS (Integrated Automation System) the main user interface for the chief engineer integrates many important ship systems Displays the health status of the machinery logs important measurements, alarms and events Combine with other data sources ALARM Could be automated? Affecting manning levels? Does it trigger work? MF Fannefjord Does it trigger maintenance or repairs? Skills & tools needed? MF Norangsfjord Is safety affected? Analysis Could be done remotely? On-board or in port? Countermeasures? Insights Aim: Build knowledge about the existing operations and practices

24 Data sources IAS logs events and alarms AIS data position, speed, operational mode Historic maintenance logs Chief engineer s log book 27

25 IAS-log: Need for filtering... (Norangsfjord 2016) Alarmer + Eventer [126100] ~ 345 per dag Eventer: ikke behov for håndtering Overgangsalarmer rel til DG start/stop og THR stop Alarmer (alle statuser) [28166] Nye alarmer (status 5) [1773] Ex DG Stop/Start & THR Stop [1555] Pivot System-Alarmer [661] Kun hørbare alarmer Oppfølgingsalarmer for samme system (2 min) Alarmer fra M&R September Ekskludert Maintenance & Repair [540] Ex Other [250] ~ 0,7 per dag Koble på landstrøm Tester og feilsøk REPEAT og FIRE Alarmer 28

26 COMMON alarms 29

27 Handling of routine work (planned maintenance) 2017 : 1434 records Mapped into categories Currently carried out by Service Personell (external) Could be carried out by Service Personell (external) Requires local precence of Chief Engineer Could be carried out by other crew (e.g. Combiman) Could be remotely operated Could be automated/skipped 30

28 IAS data analysis key findings Better and wider integration needed Data collected/presented in fewer systems => operator-focus Alarm improvements are needed Too many «nuisance alarms» need for cleaning up and reduce volume Context/mode awareness and suppression of non-essential alarms Descriptive alarm texts - get rid of COMMON Alarms Categorisation of alarm criticality to enable prioritisation Increase automation minimise manual operations However, automation will call for new alarms.. Sensor quality and self-diagnostics Need for supporting offline analysis Historical IAS logs and digital engine log Standard data/formats Benefit: analysis / trending for CBM Total BILGE BLACKOUT BOILER BUS_ COMMUNICATIO DEAD DG1 DG2 DG3 DG4 FO FW HYD. AGG MBS MSB NODE PUBLIC ADDRES SEWAGE SLUDGE START AIR THR1 THR2 UPS 31

29 Pilot testing campaign 32

30 Pilot test program 1Q 2019 M/F Fannefjord as pilot vessel ECC in Molde (Fjord1 s premises) Based on previous work: CONOPS, Hazid and IAS data analysis In between test phases: Analysis of logs, documenting and assessing experiences. Making adjustment to equipment in ECC and on-board the ship, as well as operational procedures. 33

31 Hazid: 30 mitigations identified Training(2) Design(13) Procedures(15) Machinery training (Combiman) Safety training (Combiman) UPS for IAS & Comms Descriptive Battery Alarm Alarm limits adjusted for remote operations Alarms with priority/criticality Sufficient IAS integration Additional ICE modem Comms outage alarm Walkthrough of all essential sensors Visual surveillance (CCTV) at ECC Redundancy of comms modems VHF at ECC Sufficient UPS, broadband and security at ECC Additional sensors or inspection tools for gas system Avoid simultaneous overhaul of two engines/generators Procedure for ECC-Bridge communication Procedure for handling comms loss Procedure for spare ferry to be put into operations Procedure for ECC handling for simultaneous problems on two ferries Procedures/criteria for taking the ferry out of service Procedure for transferring command from ECC to Bridge Procedure for ECC support in severe weather conditions Updated procedures for remote/eccoperations Procedure for handling water ingress Procedure for fire handling Procedure for bilge handling CBM (Condition Based Maintenance) Updated procedure for gas system Updated procedure for battery system 34

32 Mitigations implemented for pilot testing (implemented, partly implemented) Training(2) Machinery training (Combiman) Safety training (Combiman) Design(13) UPS for IAS & Comms Descriptive Battery Alarms Alarm limits adjusted for remote operations Alarms with priority/criticality Sufficient IAS integration Additional ICE modem Comms outage alarm Walkthrough of all essential sensors Visual surveillance (CCTV) at ECC Redundancy of comms modems VHF at ECC Sufficient UPS, broadband and security at ECC Additional sensors or inspection tools for gas system Procedures(15) Avoid simultaneous overhaul of two engines/generators Procedure for ECC-Bridge communication Procedure for handling comms loss Procedure for spare ferry to be put into operations Procedure for ECC handling for simultaneous problems on two ferries Procedures/criteria for taking the ferry out of service Procedure for transferring command from ECC to Bridge Procedure for ECC support in severe weather conditions Updated procedures for remote/eccoperations Procedure for handling water ingress Procedure for fire handling Procedure for bilge handling CBM (Condition Based Maintenance) Updated procedure for gas system Updated procedure for battery system 35

33 + new features identified in pilot planning (implemented, partly implemented) Training(2) Machinery training (Combiman) Safety training (Combiman) 36 Design(13) UPS for IAS & Comms Descriptive Battery Alarms Alarm limits adjusted for remote operations Alarms with priority/criticality Sufficient IAS integration Additional ICE modem Comms outage alarm Walkthrough of all essential sensors Visual surveillance (CCTV) at ECC Redundancy of comms modems VHF at ECC Sufficient UPS, broadband and security at ECC Additional sensors or inspection tools for gas system IAS Command transfer functionality IAS alarm history resynchronisation Shiplog integration (ticket/adm system) Voice communication ECC-Bridge Comms system health monitoring Digital engine log book Big Screen Fleet view in ECC ESS/battery integration Fire system integration Procedures(15) Avoid simultaneous overhaul of two engines/generators Procedure for ECC-Bridge communication Procedure for handling comms loss Procedure for spare ferry to be put into operations Procedure for ECC handling for simultaneous problems on two ferries Procedures/criteria for taking the ferry out of service Procedure for transferring command from ECC to Bridge Procedure for ECC support in severe weather conditions Updated procedures for remote/eccoperations Procedure for handling water ingress Procedure for fire handling Procedure for bilge handling CBM (Condition Based Maintenance) Updated procedure for gas system Updated procedure for battery system

34 Fleet Status ECC implementation by Høglund Big Screen CCTV ECC BIG screen layout AIS

35 ECC Implementation by Høglund Fleet Status Persons On Board: Automatically updated from Shiplog. Can easily be expanded with other info e.g. dangerous cargo Time saver during emergencies

36 Pilot test scope Normal operations Test cases Abnormal cases & failures Functional tests Ship-to-shore comms failures IAS Comms interworking New ECC & IAS functionality Nr Test type Scenario 1 Abormal 2 Abormal 3 Abormal DG auto-stop 4 Abormal 5 Abormal Black-out. 6 Abormal Putting spare ferry into operation Operational problems on two ferries simultaneously Unplanned Maintenance & Repair. Loss of ship-shore communications 7 Abormal ECC unavailable. 8 Abormal Loss of propulsion or manoeuvring capability. 9 Abormal Extreme weather 10 Abormal Evacuation 11 Abormal Mob boat operation 12 Abormal Water ingress / Loss of stability. 13 Abormal Fire alarm / fire incident. 14 Abormal Equipment down for maintenance 39

37 Pilot test program 1Q 2019 Dry-run P0 Tønsberg 5/12 Test P1: Molde 23/1 40

38 Way forward 41

39 Way forward Continue and complete pilot campaign Document and share learnings within the project and externally Use learnings for future operations and development of new products & services Remote Ready IAS system [Høglund] Rules, RPs and TQ/AIP programs [DNV GL] and regulations [NMA] Consider commercial deployment for new ferries [Fjord1] 42

40 Thank you for the attention! Steinar Låg Phone: SAFER, SMARTER, GREENER Read more about ROMAS in DNV GL s Research Review 2018: 43