Early Detection of Fault & Precision in Diagnosis Saves 70% of the Overhaul Cost and Avoids Revenue Loss of ~USD 14,000

CASE STUDY

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Early Detection of Fault & Precision in Diagnosis Saves 70% of the Overhaul Cost and Avoids Revenue Loss of ~USD 14,000

Background

Industry Segment

Marine

Arm Solution

Engine Condition Monitoring System

Equipment

Caterpillar 3516

CHALLENGE

  • Neptunus was assigned a Top Overhaul (ToH) service for a tug boat on its port-side main engine.
  • The job involved the replacement of 3 faulty fuel injectors that were supplied by the customer from their inventory
  • These spares were not as per the OEM recommended model, but the customer took the decision to use these due to the paucity of time & additional cost involved in procuring a new spare

SOLUTION

  • After completion of the ToH as per the customer’s requirement, Neptunus suspected that the customer-supplied injectors may affect the engine performance. Hence recommended the detailed health check of the engine using the engine condition monitoring tool under Neptunus’ Asset Reliability Management solution (ARMs).
  • At 40% load during the test, the engine showed no trouble. However when the load increased to 60%, the engine started encountering fuel injection-related abnormalities. Hence Neptunus offered the customer genuine reman parts to avoid future problems
  • The starboard engine which was due for MoH shortly, was also diagnosed with ARMs at 65% load. Based on the cylinder level detailed diagnosis, it was recommended that only a partial MoH on specific cylinders is required rather than the full MoH as per the running hour schedule.

BENEFITS

  • Timely risk assessment and support on procuring the genuine ReMan spares at lesser cost saved ~USD 14,000 for the customer by avoiding the risk of de-hiring of the vessel and subsequent loss of revenue and repair cost.
  • The bigger saving was realized by the customer on the starboard side engine by not doing the major overhaul when it was not needed. This saved more than 70% of the cost to the customer on the account of spare part replacement, manpower & time