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Condition based monitoring for Diesel genset

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Remote monitoring service for CAT diesel genset

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Condition based monitoring for Diesel genset

  1. 1. WAE Generator Data Center (Green belt certificate project) Mr. Otgontugs U. Sales engineer, Power System Division
  2. 2. Agenda  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion
  3. 3.  Pressure to increase productivity  Limited resources  Assets are dispersed and not easily monitored  Experts are not next to equipment  Equipment is more complex “Proactive analysis process using equipment and application data from multiple sources to make informed maintenance, component replacement, and repair decisions.” Why Condition Based Monitoring
  4. 4. Performance Weeks Days Hours Customer Value  Increased Planned Maintenance  Lower Labor and Parts Cost  Increased Availability Failure Machine Alarm Reactive  Extensive Damage  High Cost  Most Downtime Planned Some Damage Moderate Cost Moderate Downtime Predictive Minimum Damage Minimum Cost Planned Downtime Physical Indicator Wear material Operational Change Prognostic deviation Condition Monitoring Equipment Management Health Monitoring Asset Management Why Condition Based Monitoring
  5. 5. How it works Data logging and routing Wired, cell or satellite transmission (can be disabled) CAT secure server Continuous data archiving Customer & Dealer contacts for emergencies CAT dealer Condition Monitoring Specialists 24/7 support Reports : - Fleet analysis - Issues - Recommended actions User network User site CAT Dealer Control center CAT Data Centre Non-CAT data can be acquired
  6. 6. 0.0% 0.1% 0.1% 0.0% 0.1% 74.2% 25.5% 0-750 750-800 800-850 850-900 900-950 950-1000 1000-1050 Speed Speed Histogram 1.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.2% 19.6% 59.9% 19.0% 0.1% 0-50 50-55 55-60 60-65 65-70 70-75 75-80 80-85 85-90 90-95 95-100 100-105 105-110 PercentRated Torque Torque Histogram Reporting
  7. 7. User Benefits  Reduce unscheduled repairs  Increase productivity  Utilize data proactively – Not after failure  Direct maintenance to high value work  Provide visibility of asset performance & health across the enterprise Condition Based Monitoring Summary
  8. 8. Agenda  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion
  9. 9. EMCP Monitoring Solution
  10. 10. Netbiter Monitoring Solution • The Netbiter remote management solution includes communication gateways, secure hosting servers and a web user interface.
  11. 11. Bernini Design Solution
  12. 12. Comparison of Different Solution Item EMCP / CAT Netbiter Bernini Cost Experience Generator number Modem Distance Server location Support
  13. 13.  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion Agenda
  14. 14. What is Our Goal and Strategy Our Goal: to build Mongolian first and only Diesel Generator Data Center, to provide Remote Monitoring service for Diesel Generator Owner Our Strategy: not to lose Our customer to competitor, increase our customers by Remote Monitoring Service
  15. 15. Turning Remote Control Solution into $$$ DEFINE – set the stage Validate/Identify the remote control business opportunity Establish scope of the project Determine the goals of for this business development MEASURE – collect Information Quantify the remote control opportunity Collect the voice of customer Collect the voice of dealer ANALYZE – determine the areas requiring improvement Define customer critical requirement Understand dealer capabilities Identify the gap in performance and their causes IMPROVE – move forward with a customer focused business strategy Generate new solutions or improve processes to close performance gap Develop Implementation plan CONTROL – sustain the strategic improvement Develop Control plan A WELL PROVEN 5-STEP APPROACH
  16. 16. Team Selection No Dept/Div Person responsibility 1 Black Belt Otgon SME 2 PowerSys Otgontugs Project leader 3 Tserenchunt Team member 4 Gantsetseg Team member 5 Janchiv Project Owner 8 Service Sergelenbat SME 9 Khishigbayar Team member 10 IT Bayarmagnai SME 11 Munkh-Orgil SME 12 RUN Batkhishig SME 13 Ariunbold / Andy Project Sponsor 14 Finance ? SME
  17. 17. Support Person from CAT
  18. 18. Agenda  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion
  19. 19. To do list Date (estimated) Project kick-off meeting Feb 27 , 2015 Generator Data Center solution May 25, 2015 Introducing to Project Sponsor (RUN) June 15, 2015 Procurement of Hardware & Software July 31, 2015 Installation Generator Data Center Nov 30,2015 Training operator, technician Dec 2015 Pilot test Dec 2015 Official launch of Generator Data Center Jan 2016 Marketing campaign Jan – Mar, 2016 Providing remote monitoring service to End user Jan 2016 - Project Implementation Schedule Project team meeting held every Friday
  20. 20. Agenda  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion
  21. 21. Project Finance - Cost Analysis - Pugh Matrix - Project Chart
  22. 22. Agenda  Condition Based Monitoring  Remote monitoring Solution  Six Sigma Approach  Project implementation  Project finance  Conclusion
  23. 23. Conclusion - Project team meet every Friday - Target customer: Diesel generator owner, specially who bought from WAE - Coverage area: UB - Should have propose cost effective solution. - In pilot stage better use WAE server, it need to upgrade and add HDD. - Need study Productlink solution from WAT.

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