Home » Case Studies » Cold Stack Engine Inspection for EMD 16-645-E8 After 10 Years of Inactivity onboard offshore rig
Table of Contents
Case Study
Cold Stack Engine Inspection for EMD 16-645-E8 After 10 Years of Inactivity onboard offshore rig
Table of Contents
Background
Industry
Oil & Gas
Solution
Engine Inspection
and Restoration
Planning
Make & Model
EMD
16-645-E8
Asset
Offshore Rig
Objective
To assess the condition of a cold stack engine that has remained inactive for over a decade and prepare a detailed action plan for restoring its operational readiness through inspection, maintenance planning, and overhaul recommendations.
Challenge / Problem Context
1. No Available Maintenance History: The customer had no documented history of engine usage, service records, or part replacements over the past 10 years.
2. Corrosion and Mechanical Degradation: Extended storage led to visible corrosion, rust marks on crankpins, and deterioration of seals and gaskets.
3. Component Integrity Unverified: Internal engine components such as crankshaft, bearings, power packs, and injectors had unknown wear levels due to prolonged inactivity.
4. Major Carbon Deposits and Oil Sludge: Heavy carbon buildup on pistons and cylinder heads, along with oil sludge in blowers and airboxes, was identified.
5. Critical System Inaccessibility: Some components, such as the rear-end gear train and overspeed mechanisms, could not be physically accessed or tested due to engine layout and inactive systems.
What Did We Do?
1. Conducted Full Visual and Boroscopic Inspections: We thoroughly inspected each engine subsystem, including power packs, pistons, liners, crankshaft, fuel linkages, and camshaft components to evaluate wear, corrosion, and deposits.
2. Verified Component Integrity and Identified Failures: All 16 power packs showed carbon buildup, while rocker arm rollers, bearings, and the crankshaft exhibited corrosion and pitting. MPI testing and crankshaft calibration were recommended.
3. Reviewed Engine Safety and Electrical Subsystems: Overspeed mechanisms, governor drive, and alternator systems were assessed visually. While some electrical trip switches worked, the physical and mechanical condition of components required repair or replacement.
4. Developed a Comprehensive Overhaul Work Scope: We recommended replacing all bearings (connecting rod, main, and camshaft), seals, gaskets, and o-rings. In-situ polishing of crankpins and MPI testing of key structural elements were included.
5. Provided Documentation, Evidence & Action Plan: The customer received a comprehensive inspection report with photographic evidence, visual and internal assessments, component-wise action plans, and a timeline for overhaul execution.
Results That We Achieved
1. Defined a Clear Restoration Path for an Engine with No Maintenance History: Our inspection filled the historical data gap with current findings, enabling the customer to plan restoration based on real-time component condition rather than assumptions.
2. Mitigated Risks of Catastrophic Failure from Corrosion and Degradation: By identifying pitting, rust, and component deterioration, we prevented future damage that could arise from using a degraded engine in a critical environment.
3. Validated Component Lifespan and Replacement Needs: Detailed inspection of pistons, liners, bearings, and blowers clarified which components required reconditioning versus full replacement.
4. Restored Clarity Around System Functionality and Safety: Partial functionality of systems like the pre-lubrication pump and electrical trip switch was confirmed, while faulty or inaccessible components were flagged for further service.
5. Delivered a Complete and Actionable Inspection Report: The report included all inspection findings, photographs, service recommendations, and next steps — empowering the customer to proceed confidently with a full EMD Engine Repair Services and reactivation.
