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© 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
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© 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……..
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© Wärtsilä EXTERNAL 15 June 2016
WHY?
But equally important…………
First thing that comes into your mind…………
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© Wärtsilä EXTERNAL 15 June 2016
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?
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© Wärtsilä EXTERNAL 15 June 2016
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
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© Wärtsilä EXTERNAL 15 June 2016
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
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© Wärtsilä EXTERNAL 15 June 2016
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….
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© Wärtsilä EXTERNAL 15 June 2016
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…….
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© Wärtsilä EXTERNAL 15 June 2016
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
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© Wärtsilä EXTERNAL 15 June 2016
HOW DO WE DO THIS: CONDITION MONITORING
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© Wärtsilä EXTERNAL
• 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
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EXTEND TIME
BETWEEN
OVERHAULS
DETECT
POTENTIAL
FAILURES
PROVIDE
PREDICTABILITY
PRESERVE
HEALTH
CBM FOR RELIABLE OPERATIONS
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© Wärtsilä EXTERNAL
Periodical inspections reveal the actual condition of the equipment, and can allow extended service intervals.
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*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
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© Wärtsilä EXTERNAL 15 June 2016
THE POWER OF CBM: EXTENDING MAINTENANCE INTERVALS
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© Wärtsilä EXTERNAL 15 June 2016 14
DYNAMIC MAINTENANCE PLANNING DATA
Engine types
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© Wärtsilä EXTERNAL 15 June 2016
THE POWER OF CBM: FUEL SAVINGS
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© Wärtsilä EXTERNAL 15 June 2016
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
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© Wärtsilä EXTERNAL
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.
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5 © Wärtsilä 2 May
2016 Eric Kloosterziel -
GM Agreement Sales
Services NE
Hartelijk dank voor uw aandacht.