condition based monitoring for diesel genset
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WAE Generator Data Center (Green belt certificate project)
Mr. Otgontugs U.
Sales engineer,
Power System Division
Agenda
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
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
Perf
orm
ance
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
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
0.0
%
0.1
%
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%
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%
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%
74
.2%
25
.5%
0 -
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85
0 -
90
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95
0 -
10
00
10
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-1
05
0
Speed
Speed Histogram
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%
0.0
%
0.0
%
0.0
%
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%
0.0
%
0.0
%
0.0
%
0.2
%
19
.6%
59
.9%
19
.0%
0.1
%
0 -
50
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-5
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55
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0
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-6
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90
-9
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95
-1
00
10
0 -
10
5
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5 -
11
0
Percent Rated Torque
Torque Histogram
Reporting
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
Agenda
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
EMCP Monitoring Solution
Netbiter Monitoring Solution
• The Netbiter remote management solution includes communication gateways, secure hosting servers and a web user interface.
Bernini Design Solution
Comparison of Different Solution
Item EMCP / CAT Netbiter Bernini
Cost
Experience
Generator number
Modem
Distance
Server location
Support
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
Agenda
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
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
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
Support Person from CAT
Agenda
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
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
Agenda
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
Project Finance
- Cost Analysis - Pugh Matrix - Project Chart
Agenda
Condition Based Monitoring
Remote monitoring Solution
Six Sigma Approach
Project implementation
Project finance
Conclusion
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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