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Table of Contents

Case Study

TOH skipped Successfully with Accurate Health Data for Niigata Engine on board Supply Vessel

Table of Contents

Background

Industry
Oil & Gas
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
Niigata Engines
Asset
Offshore
Supply Vessel

Objective

To minimize unplanned engine downtime and reduce overhaul-related maintenance costs by adopting a data-driven, condition-based monitoring approach.

Challenge / Problem Context

  • Customer needed to eliminate unplanned engine downtime through accurate health diagnostics.
  • OEM recommended a Top Overhaul (TOH) at 12,000 running hours, leading to high maintenance costs.
  • Lack of real-time data limited visibility into actual engine condition.

What Did We Do?

  • Proposed the implementation of a real-time Engine Condition Monitoring System to continuously track engine health parameters.
  • Enabled both onboard and onshore teams to access live engine condition data, ensuring 24/7 visibility and control.
  • Designed a customized real-time dashboard tailored to the customer’s operational needs and preferences.
  • Guided the customer to perform only the necessary cylinder-specific maintenance (injectors, bearings, fuel injection pumps), based on actual engine data.
  • Achieved over 6,000 running hours and 12 months of continuous monitoring without unplanned downtime.

Results That We Achieved

  • Eliminated one complete TOH, saving $60,000 in spares and service costs.
  • Reduced major overhaul (MOH) spare costs to $148,000 from $547,000, resulting in 73% cost savings.
  • Prevented 15 days of vessel downtime, improving revenue generation and asset uptime.
  • Empowered office-based teams to remotely monitor and manage engine health in real time.

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