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

What if we don’t keep innovating?

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!