New ‘disruptive’ turbocharger maintenance platform aims to cut total ownership costs

How it works

TruCare aims to transform the technical management of oceangoing vessels via an intelligent, centralised predictive monitoring system. It can be fitted onto existing engines without mandatory modifications and will be available as a platform linking all end users and service providers. KBB’s customers and worldwide network of service partners will be the first to benefit from the cutting-edge solution developed for turbochargers.

“TruCare is the most beneficial way to link highly efficient turbocharger technology with decades of turbocharger health and service knowledge,” noted KBB technical director Dr Silvio Risse. “Based on innovative health analysis algorithms and a trendsetting service data management, TruCare will support the vessel operator during the whole turbocharger lifecycle on a new level to keep control of maintenance needs and costs of their equipment,” added Dr Risse.

Progressing from reactive maintenance, as a PdMaaS solution, TruCare will use IoT technologies, edge and cloud-computing, machine learning and digital twins for predictive maintenance of turbochargers, providing improved equipment performance monitoring and technical consultancy.

Key operational parameters will be transmitted from ship-to-shore into a command centre for real-time data analysis, using machine learning algorithms and failure models to monitor turbocharger performance, predict failures and recommend maintenance windows.

By establishing correlations between turbocharger performance and engine parameters, TruCare’s predictive ability in detecting anomalies and complex indications for breakdowns helps pre-empt potential operating issues before there is a crisis, explained Tru-Marine.

TruCare detects the possibility of a fault and recommends service based on the actual operating conditions on board, or whenever the need arises. Furthermore, TruCare differentiates on its capability in predicting the optimal time for refurbishment/overhaul of components, extending the fixed maintenance schedules – moving away from traditional rigid service intervals.

This addresses the commonly occurring, premature turbocharger failures and associated high costs of emergency repairs, vessel downtime, off-hires and delayed port calls.

Tru-Care is designed to improve the total cost of ownership and asset management, by reducing maintenance costs, downtime and extending asset lifetime. Targeting also the challenges of under- and over-maintenance, the digital solution puts control back into the hands of shipowners, managers and operators, to offer peace of mind through a controlled overview of their monitored assets and crew performance.

MRO platform and ecosystem

TruCare will be made available as a platform and ecosystem linking all service providers, vessel owners, managers and operators for the timely dispatch of turbocharger maintenance, repair and overhaul (MRO) service and spares – anytime and anywhere in the world.

Transiting to this ’many-to-many’ business model, all end users of KBB turbochargers will stand to benefit from the synergies among all service providers in terms of their proximity to vessel locations, speed of response as well as advanced planning of service and spares.

Supported by blockchain to track, trace and record

Additionally, blockchain will be used to track, trace and record the service histories and movements of turbochargers and the sub-components from manufacture and repairs to logistics and smart contracts.

Covering every aspect of the MRO chain, blockchain will simplify and expedite tracking while enabling the secure sharing of information between all stakeholders in the value chain that include KBB as the original equipment manufacturer, its global network of authorised service providers, other logistics suppliers, classification bodies, and insurance surveyors.

This addresses the current MRO-related challenges such as a lack of digital records and global database, incomplete and inaccurate data sharing as well as system inconsistencies.

The use of blockchain will bring all stakeholders together towards improving productivity and efficiency, hence significantly reducing MRO costs for both providers and end users.

Savings will be derived from secure data management that ensures privacy and confidentiality, improved insights on service intervals and inventory levels, and even automated workflows with integration to our customers’ internal systems. 

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