maintenance in dredging

© Wärtsilä EXTERNAL

MAINTENANCE IN DREDGING

Thema avond:

Onderhoud aan motoren, hoe noodzakelijk is dit kostbare

kwaad?

5 © Wärtsilä 2 May

2016 Eric Kloosterziel -

GM Agreement Sales

Services NE

Eric Kloosterziel – Wärtsilä Netherlands

Breda

June 6th , 2016

© Wärtsilä EXTERNAL 15 June 2016

STELLING:

Onderhoud aan motoren, hoe noodzakelijk is dit kostbare kwaad?

If you think maintenance is expensive,

try to run your equipment without

maintenance.

Geen onderhoud is pas duur……..


WHY?

But equally important…………

First thing that comes into your mind…………


THE CHALLENGE FOR OWNERS, OPERATORS, MANAGERS AND THE O.E.M’S:

• Spending as little as possible, while:

• Not jeopardizing reliability and uptime

• Minimizing unplanned cost

• Maintaining maximum efficiency

We need to find the fine balance between:

Is this hard to achieve?


THE “TRUTH” ABOUT OEM MAINTENANCE SCHEDULES

• Maintenance Intervals are too short.

• Too many parts must be changed while still useful

WHY????????

We don’t want to risk our reputation

We don’t want to risk YOUR reputation


THE RESULT:

• Operators stretch maintenance intervals based on experience and “gut feeling”

• Operators re-use parts that should be changed according to the OEM manual

• Operators search for cheaper sources on the market

So:

• Operators save money on maintenance but take a calculated risk of

• Unscheduled down time

• Increased fuel consumption

• Problems with classification/ insurance


OPEX: DIFFERENT BUDGETHOLDERS, DIFFERENT INTEREST…….

• Typical SFOC vs Maintenance Cost

• 95% Fuel Cost

• 5% Maintenance Cost

2.200

110

Opex

Fuel Cost

Maintenance Expenditure

Case: 3 x 6L46F , 5.000RH/y/eng, HFO, 10y period

• Fuel cost: 7,8 MEUR/ year

• Average Maintenance cost : 300k EUR/year (approx 4%)

• This means: 1% saving on Fuel cost (78KEUR/y) equals almost 25% maintenance cost ……

Or looking at it from another perspective…

What if the fuel consumption would rise by 1% due to saving 10% maintenance cost by postponing

maintenance….


ASSET AVAILABILITY

• Maintenance cost : 300,000 EUR/year

• Lowering the Maintenance cost by 25% (75.000 EUR/y in this example) would be a huge achievement

• What is a typical Day rate in dredging….

USD 100,000? Or m3 price?

• How much risk are we willing to take to lose 1 productive day…….


WHAT CAN WÄRTSILÄ DO TO HELP?

• 24/7 online monitoring of the condition of the equipment, checking actual values and long term

trends

• Compare with design/ sea trial / historical data and check with similar equipment in similar

conditions

• Perform periodical inspections (opening or endoscopic) to check the condition

And based on this:

• Perform maintenance based on the real condition of the equipment

• Predict possible future failures

• Give recommendations for actions and maintenance to bring back or keep the efficiency on the

original level (and save on fuel cost and emissions)

• Give recommendations for extending overhaul intervals

• Provide the customer with a “DMP statement” that is accepted by Class/ insurance


HOW DO WE DO THIS: CONDITION MONITORING


• Engine and propulsion condition monitoring

• Alignment of operational decisions based on the actual condition of the equipment

• Prediction of condition for formulating maintenance strategy

• Maintenance planning makes maintenance costs predictable

• Identification of faults well before they lead to breakdowns

• Class-approved concepts

• Equipment safety and reliability

11

EXTEND TIME

BETWEEN

OVERHAULS

DETECT

POTENTIAL

FAILURES

PROVIDE

PREDICTABILITY

PRESERVE

HEALTH

CBM FOR RELIABLE OPERATIONS


Periodical inspections reveal the actual condition of the equipment, and can allow extended service intervals.

12

*Depending on the operation conditions and results from previous inspection

Max. DMP

major

overhaul

interval

Opening inspection to

determine possible

extension of overhaul

interval

Intermediate inspection

(1/2 of standard

maintenance interval)

*Major overhaul

or Intermediate

and/or opening

inspection

Major overhaul

interval

according to

DMP based

inspections

Standard major

overhaul

according to

maintenance

manual

Intermediate inspection

Opening inspection

Major overhaul

29.1.2016

INSPECTIONS TO DELIVER CONDITION DYNAMIC MAINTENANCE PLANNING


THE POWER OF CBM: EXTENDING MAINTENANCE INTERVALS


THE POWER OF CBM: FUEL SAVINGS


FACTORS THAT AFFECT FUEL COSTS

Where to focus on fuel saving?

Air intake filter

p +50 mm H2O

Air cooler

p +100 mm H2O

Turbocharger

Cleanliness

LT cooling

water temperature

+10°C

Exhaust gas pipe

p + 100 mm H2O

Fuel

Water +1%

Heat value

-500kJ/kg

Nozzle

Injection pump

Fuel flow / visc

+2 g/kWh

+2 g/kWh

+3 g/kWh

+2 g/kWh

+2 g/kWh

+2 g/kWh

+2.5 g/kWh

+5 g/kWh

+5 g/kWh

+2 g/kWh

Totally 27 g/kWh 810.000 kg/year 13.5%

(6.000 h * 5.000 kW / year)

Air intake filter

p +50 mm H2O

Air cooler

p +100 mm H2O

Turbocharger

Cleanliness

LT cooling

water temperature

+10°C

Exhaust gas pipe

p + 100 mm H2O

Fuel

Water +1%

Heat value

-500kJ/kg

Nozzle

Injection pump

Fuel flow / visc


Onderhoud aan motoren, hoe noodzakelijk is dit kostbare

kwaad?

15 June 2016

FINAL ANSWER TO THE QUESTION:

2 - Hoe kostbaar we het maken bepalen we samen

1 - Onderhoud aan motoren is noodzakelijk.

3 - We moeten het niet benaderen als “kwaad” maar als kans

om ons te onderscheiden van de concurrentie.

maintenance in dredging

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