Home » Case Studies » In-Situ Crankshaft Repair Ensures On-Time Deployment of Offshore Rig
Table of Contents
Case Study
In-Situ Crankshaft Repair Ensures On-Time Deployment of Offshore Rig
Table of Contents
Background
Industry
Oil & Gas
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
CAT 35 Series Engine
Asset
Offshore Jack-up Rig
Objective
To ensure the offshore rig could be deployed on schedule for a new contract, while maintaining high engine reliability and avoiding costly downtime.
Challenge / Problem Context
Crankshaft damage during overhaul: During the 2nd Top End Overhaul on a CAT 35 Series engine, damage marks were observed on the crankshaft.
Unavailability of spare parts: A replacement crankshaft was not available within the limited timeframe.
Deployment urgency: The rig was scheduled to be deployed for a new contract in just 10 days, leaving no scope to send the crankshaft for repair and return.
What Did We Do?
Performed in-situ repair of the crankshaft: Leveraging our long-standing partnership with the customer, Neptunus consulted with the rig owner and operations team and carried out an in-situ repair of the damaged crankshaft. This ensured the overhaul could be completed without waiting for a replacement part.
Installed Engine Condition Monitoring System (ECMS): After engine assembly, Neptunus installed a permanent Engine Condition Monitoring System based on torsional vibration monitoring. This system continuously tracked the crankshaft and overall engine health, ensuring the customer was not taking any operational risks.
Enabled predictive maintenance capability: The ECMS provided very early warnings of emerging faults, allowing the maintenance team to plan corrective actions proactively and avoid unplanned breakdowns during operations.
Results That We Achieved
Cost savings: Direct savings of ~$54,000 were realized by avoiding the replacement of the crankshaft.
Revenue protection and cash flow improvement: The rig was deployed on schedule, preventing a potential 1-month delay. This ensured ~$750,000 revenue (30 days × $25,000/day) and improved cash flow management.
Reduced downtime: Downtime of repairs was reduced by ~90%, significantly improving asset availability.
Operational continuity: The Engine Condition Monitoring System operated reliably for the 8-month contract period with zero engine breakdowns.
Penalty avoidance and operational focus: The customer avoided penalty charges for delayed deputation, while automated monitoring allowed the rig and technical teams to focus on core drilling operations without concerns about engine reliability.
