CHALLENGE

Through our sales efforts, we successfully convinced a market leader in the shipping industry to implement our VIB360 System to monitor the health of a Post-Panamax size container vessel’s main engine with a power rating of 65,000 kW. Initially, there were no reported pain points from the customer, indicating a perceived smooth operation and efficiency in their vessel’s performance

The main engine of this vessel typically operates between 30 to 95 RPM, with a rated RPM of 102. During the trial period, the VIB360 Smart Efficiency Monitoring and Analytics Tool detected unusual engine behaviour below and above 70 RPM. This behaviour led to a significant issue: an increase in fuel consumption by over 1% above 70 RPM.

Investigation

Investigation revealed that the vibration damper, a large mass fitted at the free end of the crankshaft, would excite whenever the engine RPM would cross 70 RPM. This excitation caused unnecessary twisting of the crankshaft (which is over 18 metres in length). As a result, there was a lag in piston travel, which disturbed the pre-set fuel timing in a couple of cylinder units. 

This led to approximately 1% higher fuel consumption for the same power output, translating to an additional 500 tons of fuel consumption annually.

We shared these findings with the ship owner and advised them to consciously monitor the actual fuel consumption between 30 to 70 RPM and compare it with the consumption at 75 RPM or above. The initial investigations conducted by the owners aligned with our findings.

Impact

• The financial impact of this increased fuel consumption was substantial. With the average cost of marine fuel being around $600 per ton, the additional 500 tons of fuel consumption resulted in an extra annual expenditure of $300,000. 

• Additionally, the environmental impact was considerable. Higher fuel consumption resulting in an  increase in emissions, which could have jeopardised the vessel’s compliance with international emission regulations, has now been fully mitigated.