Early Fault Detection Extended Major Overhaul Which Otherwise Costs ~$2,50,000 For 7 Vessels

CASE STUDY

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Early Fault Detection Extended Major Overhaul Which Otherwise Costs ~$2,50,000 For 7 Vessels

Background

Equipment

Niigata engines

Vessel

Habour tug

Solution

Engine Condition Monitoring System

Customer

Habour Tug Operator In India

CHALLENGE

  • 7 vessels were due for a major overhaul as per OEM’s maintenance cycle at 24,000 running hours which would have cost the customer $2,50,000
  • Along with the cost this major overhaul would have cost the customer about 18-20 days of downtime for each vessel, resulting in loss of revenue
  • The life-cycle of each vessel is around 20 years, approximately 65,000 running hours, meaning 2 MOH have to be performed for each vessel before it’s scrapped.

SOLUTION

  • The Customer deployed Neptunus’ engine condition monitoring system (part of Neptunus’ Asset Reliability Management solution) on all 14 engines of their 7 tugs for an engine health checkup which was already above 24,000 running hours
  • Neptunus did the engine health check without opening up the engine and with the help of 2 sensors only we submitted a conclusive report which indicated to replacing only 2 injectors on a couple of their tugs and they can run further without a major overhaul
  • This helped the customer make a confident data-backed decision, replace only the required parts and extend the major overhaul
  • With the extension of 1st MOH, the customer is able to eliminate 2nd MOH in life-cycle of these vessels

BENEFITS

  • Customer was able to see in-depth report cylinder-specific, do the necessary scope needed at bare minimum cost
  • With this approach, the customer is able to eliminate 2nd MOH thus resulting in huge savings of $1,00,000 for each vessels