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Ship Efficiency 2015 - London
Caterpillar Marine Asset Intelligence
The Value of Vessel Monitoring Using Analytics - Case Studies
Mario BacelarDipl. Industrial Mechanical Engineer, MBA
CAT Marine Asset Intelligence
Let me talk about
how technology
and services
enabled by
technology can
help to avoid a
similar disaster…..
“Immediately prior to the position
loss, the OSV had multiple DP
system alarms and failures,
including loss of bow thruster and
engine control.”
Using Analytics help to increase overall performance…
Regression
Corrective
Maintenance
Planned
Maintenance
Condition Based
Maintenance &
Operations
More knowledge, higher visibility, wider perspective, seeking
excellence, improving quality, using remote monitoring
Don’t fix it,
delay the fix
Fix it after it breaks
Fix it before it breaks
Don’t just fix it,
Improve & optimize it
Reactive
Urgency
Overtime
Predict
Plan
Schedule
Cost Focus
Eliminate Defects
Shared Vision
System Performance
Value Focus
Meet short term
budgetBreakdowns Avoid Failures Business Growth
Most companies fall within this range
What are you doing about it?
Marine Asset Intelligence in Action
Data sent off vessel
Asset Intelligence automated analytics &
expert analysis identifies potential issue & develops
advisory
Fleet Advisor communicates maintenance or
operations advisory
Repair conducted when convenient
for customer
Equipment monitored & analyzed automatically +
Crew interface
Dealer
SAFETYEQUIPMENT
MANAGEMENT
SUSTAINABILITYPRODUCTIVITY
Analytics Strategy for Equipment Management
Inputs:
• Electronic Data • Repair History • Fluid Analysis • Site Conditions • Inspections
Equipment
Conditions
Compared
to a
Standard
Equipment
Conditions
Compared
to Similar
Equipment
Equipment
Conditions
Compared
to Itself
CAT CONNECT – PRIMARY MARINE SOLUTIONS
Marine Asset Intelligence
Solution “Value” Offerings
SAFETYEQUIPMENT
MANAGEMENTPRODUCTIVITY SUSTAINABILITY
PROTECT
IMPROVE
OPTIMIZE
Where, if something can go wrong, it will……(list not all inclusive)
• Controllable Pitch Propellers
• Torque meters
• Steering systems
• Main propulsion diesel engines
• Ship’s service diesel generators
• Emergency generators
• Gas turbine main engines
• Gas turbine generators
• Auxiliary gas turbines
• Gas turbine starting systems
Compressors
• High pressure
• Medium pressure
• Low pressure
• De-ballast
compressors
• Air conditioning
• Refrigeration
• Reverse osmosis
• Steam evaporators
• Reduction
gears
• Transmissions
Other auxiliaries
• Waste heat boilers
• Chill water pumps
• Cathodic protection
• Fuel & lube oil
systems
• Purifiers
• Service &
transfer pumps
• Ballast management
systems
• Oily water
separators
• Sewage / gray-water
systems
• Ballast water
treatment systems
• Waterjets
• Fin stabilizers
Fuel flow
meters
• GPS / Navigation systems
• Control systems
• Environmental factors
• Seawater service & fire pumps
Feed & booster pumps
• Deck equipment
Tanks levels
• Fuel oil
• Lube oil
• Cargo
• Ballast
Additional data inputs
• Fluid Analysis / SOS
• Visual (manual) inspections
• Additional / aftermarket sensors
(bearing, oil condition, vibration, …)
• Hull resistance, cleaning,
technologies
• Specialized equipment
• Thrusters
…creating significant value for
the customer
CAT Marine Asset Intelligence provides
technology enabled solutions…
Advanced, automated analytics Based on 30M
hours of machine monitoring, analytics help identify
issues before they become a problem
Expert advisory services Experienced operators,
maintenance and repair technicians and data
analysts provide actionable advisories
Flexible functionality Analytics and advisory
services cover equipment condition, fuel
performance, operations and safety
Broad applicability Can monitor & analyze wide
variety of equipment, both CAT and non-CAT, diesel
engines and auxiliaries
EQUIPMENT
MANAGEMENT
• Avoid failures
• Reduce cost of
maintenance
PRODUCTIVITY
• Reduce downtime
• Increase productivity
SAFETY
• Reduce unsafe
operations &
conditions
SUSTAINABILITY
• Reduce fuel costs
• Ensure environ-
mental compliance
Starting with the Conclusion – Caterpillar Adding Value through Technology
How is our industry evolving?
Awareness
Understanding
Trial Use
Adoption
Internalization
Time
Most marine operators have yet to
integrate technology-based solutions
into their business processes.
15-2
0%
Ado
ptio
n
2015 ?
2014
Where is your
organization on
the adoption
curve?
Caterpillar Case Study – Vessel Monitoring and Analytics
• Large inland river tug
and barge operator
• Trying to improve
maintenance, fuel
efficiency, and
operations using data
analytics
Caterpillar Case Study – Avoiding Equipment Failure
Customer
Objectives
• Provide customer with comprehensive solution
– Equipment: Caterpillar and Non Caterpillar
– Vessel: Fuel performance and operations
Impact
• Identified ways to improve decision making
– Reduced fuel consumption
– Avoided failures and associated downtime
– Reduced operational costs
– Real transparency for senior management
2 Engines 2 Generators
GPS
Tanks &
Bilge
Alarms
Steering
Onboard
viewer
Use Case Impact Applicability
Failing fuel pump and
dirty fuel filters
Avoid failure, downtime, additional repair
costs
Engine overspeed Identify potential heavy wear conditions,
reduce
Engine droop Identify high engine stress events (i.e.,
running over log in river)
Alarm monitoring Ensure onboard alarms receive attention
High exhaust temps Focus troubleshooting on specific equipment
in specific situations
Engine performance
vs. baseline
Focus troubleshooting, improve fuel
efficiency
High stress ops (high
power/rate of turn)
Identify potential heavy wear conditions,
reduce
Daily fuel
consumption
Monitor and benchmark fuel consumption to
help reduce
Long idle periods Monitor fuel consumption and high wear
operations
Duty cycle analysis Monitor fuel consumption and high wear
operations, better plan operational calendar
Maintenance
Fuel &
Productivity
This is one of many “Use Cases” identified for this vessel...
Maintenance - Avoiding Fuel Pump Failure
Week 1 Week 2 Week 3
Fuel pump
failure & repair
2σ
Baseline
Low Fuel Pressure (2σ from ‘like-new’)
Like
New
7 days
before
failure
4 days
before
failure
2 days before
failure
Potential Impact: $20k/day rev loss + $15k add’l for offsite repair
(vs. preventative) = $35,000 per failure
Fault New -7 days -4 days -2 days
Exhaust
FuelCoolingOil TurboAux
Real Operational Transparency for Management
Recent operations including
position, course, speed, rpm,
power, fuel burn, etc.
Duty cycle analysis shows long periods
at idle, with short period of time at high
power; enables comparison across the
fleet as well as trend throughout time
Fuel and
productivity
analysis
enables
comparison
of boats
and
trending
over time
Caterpillar Case Study – Vessel Monitoring and Analytics
Customer
Objectives
• Trying to improve maintenance, uptime, and reliability
• Customer asking for increased focus on fuel efficiency
OSV: ~3500 DWT, CAT 3516 engines
Impact
• Identified ways to improve decision making
– Identified fuel injector problem prior to equipment
failure and increased fuel efficiency
Use Case Impact Applicability
Equipment failure Avoid failure, downtime, additional repair
costs
Engine overspeed Identify potential heavy wear conditions,
reduce
Over-cooling Improve engine performance, health and
remaining life
Faulty fuel injectors Avoid failure & associated downtime/repair,
improve fuel efficiency
High exhaust temps Focus troubleshooting on specific equipment
in specific situations
Engine performance
vs. baseline
Focus troubleshooting, improve fuel
efficiency
Daily fuel
consumption
Monitor and benchmark fuel consumption to
help reduce
Long idle periods Monitor fuel consumption and high wear
operations
Duty cycle analysis Monitor fuel consumption and high wear
operations, better plan operational calendar
Maintenance
Fuel &
Productivity
Range of Application – Specific Value Propositions
Caterpillar Case Study – Faulty Fuel Injector
• Automated analytics
identified fuel injector
issue
• High right exhaust
bank temperatures
• Erratic low speed
RPM
• Higher fuel
consumption
compared to other
engine
Impact
Issue
• Replaced faulty fuel injectors:
• Avoided potential catastrophic failure
• Improved fuel efficiency, resulting in $175/day in fuel
savings (>$50,000 per year) - fuel savings based on
observed operational duty cycle
Caterpillar Case Study – Vessel Monitoring and Analytics
Customer
Objectives
• Trying to improve maintenance, fuel efficiency, and
operations using data analytics
• New vessel – Cat® C175 engines and C9 generators
Impact
• Identified ways to improve decision making
– Optimized vessel speed and operations to reduce
fuel consumption
– Tune equipment to increase performance &
reliability
– Reduce risk of failure by identifying and resolving
issues early
Large harbor tug operator
Use Case Impact Applicability
Identifying potential
problems before
failure
Avoid failure, downtime, additional repair
costs
Engine overspeed Identify potential heavy wear conditions,
reduce
Engine droop Identify high engine stress events (i.e.,
running over log in river)
Alarm monitoring Ensure onboard alarms receive attention
Identifying faulty
sensors prior to failure
Focus troubleshooting on specific equipment
in specific situations
Engine performance
vs. baseline
Focus troubleshooting, improve fuel
efficiency
High stress ops (high
power/rate of turn)
Identify potential heavy wear conditions,
reduce
Daily fuel
consumption
Monitor and benchmark fuel consumption to
help reduce
Long idle periods Monitor fuel consumption and high wear
operations
Optimizing transit
speed
Decrease fuel consumption with optimal
transit speed
Maintenance
Fuel &
Productivity
Range of Application – Specific Use Cases
Sensor issue Potential impact if not resolved
Port engine coolant sensor spikes • Mask of pending failures
• Prevented control system logics from
protecting engine
Sustained high pressure differential for
#2 air filter
• Masked reduced air flow
• Decreased fuel efficiency
• Engine stall
• Crew bypass with unfiltered air
Cylinder exhaust temperature spikes of
over 400 degrees per second caused
by failed thermocouple
• No true monitoring of cylinder
• Unforeseen & unprotected failure
• None of these issues would have been readily apparent to onboard crew
• Likely first indication would be actual equipment issue or failure
• Resolving could help avoid catastrophic failure during operations
Tug Case Study: Resolving Undetected Sensor Issues
• Port engine fuel pressure is 3 PSIG lower than starboard
• Similar operating situation & conditions
Port Engine
rpm vs. Fuel Pressure
Starboard Engine
rpm vs. Fuel Pressure
Impact
Issue
Tug Case Study: Detailed Engine Optimization
• Identify potential filter or fuel pump issues earlier, before failure
• Fine tune for optimal performance and increased fuel efficiency
What is going
through your head
at this exact
moment?
“I am so happy that I am using technology and Caterpillar services to give me confidence that my equipment will not fail me now”……right?
CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow” and the “Power Edge” trade dress, as well
as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
©2015 Caterpillar
All rights reserved.
THANK YOU FOR YOUR ATTENTION!
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