Home » Case Studies » Successful CAT 3516 C HD TOH and improved Fuel Efficiency with AI-based Technology on Jack-up Rig
Table of Contents
Case Study
Successful CAT 3516 C HD TOH and improved Fuel Efficiency with AI-based Technology on Jack-up Rig
Table of Contents
Background
Industry
Oil & Gas
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
Caterpillar
3516 C HD
Engine
Asset
Offshore Rig
Objective
To check the accuracy of Vib360 in providing actionable insights about the engine’s overall mechanical and operational state and test its ability to pinpoint existing or emerging faults.
Challenge / Problem Context
Difficulty in identifying early-stage issues such as injection timing and compression faults.
Lack of real-time condition monitoring, making it hard to plan maintenance.
Risk of unnecessary overhauls leading to high downtime and costs.
No direct correlation between fuel efficiency and engine health data available for operators.
What Did We Do?
Installed Vib360 condition monitoring system on Engine 4 with two non-invasive MPU sensors mounted on the flywheel to track crank speed and TDC signals.
Conducted a before-and-after overhaul analysis at 65% load to evaluate system accuracy and fault detection capabilities.
Used the system to pinpoint injection timing and compression issues across specific units (R5, L4, R9, R13 before TOH).
Enabled remote monitoring of engine health under a centralized command system for quick access and decision-making.
Scientifically assessed the data to correlate mechanical health, operational conditions, and fuel efficiency improvements post-overhaul.
Results That We Achieved
Pinpointed Hidden Faults: - Before: Identified issues in injection timing (L2, L4, L6, L15, L8) and compression (R5, L4, R9, R13). -After: All injection and compression issues resolved post-TOH.
Improved Mechanical Health: - Mechanical health score improved from 70% to 100% after overhaul. -Operating condition rose from 55% to 99%, confirming system accuracy.
Fuel Efficiency Gains: - Power loss reduced from 1.51% to 0.66%, translating to significant fuel savings. - Compression and injection timing indicators confirmed the engine was running at optimum efficiency.
Reduced Maintenance Costs: Enabled operators to defer unnecessary maintenance, extending overhaul intervals and lowering overall maintenance spend.
Reliability & Correlation: Data correlated with actual engine operating parameters, building trust in Vib360 as a reliable diagnostic tool.
Conclusion
The Vib360 Engine Condition Monitoring System proved to be a reliable, non-invasive, and easy-to-operate tool that not only pinpointed faults at the component level but also demonstrated measurable improvements in fuel efficiency and mechanical health. This case validates its ability to extend overhaul intervals, cut maintenance costs, and maximize operational reliability for offshore oil rigs.
