Home » Case Studies » Early Detection of Injector Faults and Data-Driven MoH Optimization Save Over 70% in Maintenance Costs on Offshore Vessel
Table of Contents
Case Study
Early Detection of Injector Faults and Data-Driven MoH Optimization Save Over 70% in Maintenance Costs on Offshore Vessel
Table of Contents
Background
Industry
Marine
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
Caterpillar 3516
Asset
Tugboat
Objective
To verify the operational reliability of customer-supplied fuel injectors installed during a Top Overhaul on the port engine and to optimize overhaul scope for the starboard engine using real-time condition monitoring.
Challenge / Problem Context
Use of non-OEM injectors during Top Overhaul on the port engine: The customer opted to install 3 fuel injectors from their own inventory, which were not as per OEM specifications, to save time and cost.
Risk of undetected performance issues due to injector incompatibility: Neptunus suspected potential performance issues post-overhaul due to incompatible parts but needed real-time data for validation.
Scheduled Major Overhaul on the starboard engine: The starboard engine was due for a Major Overhaul based on run-hour schedules, posing significant cost and downtime risk if not optimized.
What Did We Do?
Performed a detailed health check on the port engine using our Engine Condition Monitoring System (ARMs): Post-overhaul, Neptunus conducted a real-time vibration-based diagnostic test. While the engine performed well at 40% load, fuel injection issues were detected at 60% load.
Recommended the replacement of incompatible injectors with genuine Reman parts: Based on the ARMs findings, Neptunus advised replacing faulty injectors with OEM Reman spares to prevent future breakdowns and inefficiencies.
Conducted a condition-based diagnostic on the starboard engine: A test was carried out at 65% load using the ARMs system. The diagnosis revealed that only a few cylinders required overhaul, negating the need for a full MoH.
Results That We Achieved
Avoided ~USD 14,000 in revenue loss and repair costs on the port engine: Early detection of injector-related issues prevented operational failures that could have led to vessel de-hiring and costly CAT Engine Repair and Overhaul.
Saved over 70% of overhaul cost on the starboard engine: Condition-based decision-making helped the customer avoid unnecessary spare parts replacement, man-hours, and vessel downtime by performing only a partial MoH.
