To enable the customer to avoid an unnecessary major overhaul (MOH) at 24,000 running hours by implementing a real-time engine condition monitoring solution and ensure vessel uptime above 98% throughout its life cycle.
Challenge / Problem Context
High Overhaul Cost: The OEM recommended a major overhaul at 24,000 running hours, costing over $100,000.
Multiple Overhauls in Asset Lifecycle: With a total expected life of ~65,000 running hours, the vessel was scheduled for 2 MOHs, significantly increasing lifecycle costs.
Uptime Target Pressure: The customer had a contractual requirement to maintain vessel uptime above 98%.
Engine Health Concerns: Initial health check showed injection-related anomalies, creating uncertainty about deferring MOH.
What Did We Do?
Implemented Real-Time Engine Monitoring: Deployed Neptunus’ Engine Condition Monitoring System (ECMS) on board to monitor engine health continuously, including cylinder-specific parameters.
Diagnosed Issues Early: Identified injector-related concerns through the first health check and recommended targeted intervention instead of a full overhaul.
Advised Data-Driven Decision-Making: Guided the customer to replace only the 2 affected injectors (approx. $5,000), allowing them to safely postpone the MOH without compromising reliability.
Enabled Remote Engine Visibility: Equipped both onboard and office teams with access to real-time engine condition data for improved operational decision-making.
Redefined Overhaul Strategy: Advised the customer to rely on condition-based data to schedule overhauls, eliminating unnecessary service events while maintaining reliability.
Results That We Achieved
$100,000+ Cost Savings: Helped the customer defer the 24,000-hour MOH, saving over $100,000 through targeted intervention.
Avoided Second MOH Entirely: By pushing the overhaul strategically, the customer avoided the need for a second MOH during the vessel's life cycle.
98%+ Uptime Maintained: Achieved the customer’s uptime target by ensuring real-time visibility and proactive maintenance decisions.
Zero Reliability Compromise: The vessel continued operating reliably with real-time condition data backing all decisions.
Optimized Maintenance Strategy: Shifted from time-based to condition-based maintenance, resulting in long-term operational and financial gains.
