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Case Study

45-Day MOH Job of Four CAT 35 Engines Completed in 40 Days, Securing Millions for Rig Owner

Table of Contents

Background

Industry
Oil & Gas
Solution
Major Overhaul
(MOH) of
Four Engines
Make & Model
Caterpillar
(CAT) 35
Series Engines
Asset
Offshore
Drilling Rig
(at Dubai Dry Dock)

Objective

To complete a major overhaul (MOH) of four CAT 35 engines, including the supply of critical spares, within a strict 45-day deadline at Dubai Dry Dock for a global offshore drilling company.

Challenge / Problem Context

  • Engine room had limited space, allowing work on only two engines at a time.
  • Strict 45-day deadline where any delay meant a 90-day rig deployment loss and millions in missed revenue.
  • Low vendor confidence due to previous delays caused by a local service provider.
  • Labour shortage and challenges in handling heavy components like crankshafts and alternators in tight spaces.
  • Labour shortage and challenges in handling heavy components like crankshafts and alternators in tight spaces.

What Did We Do?

  • Planned staggered execution with parallel workstreams to optimize available space and reduce idle time.
  • Deployed two service teams working in coordinated shifts for up to 17 hours per day under strict project management.
  • Assigned a highly experienced crew with a proven track record and provided on-site supervision to ensure quality.
  • Rotated skilled teams and used specialized tools to safely move and reassemble heavy components.

Results That We Achieved

  • Completed the overhaul in 40 days, followed by load trials and handover in 2 days, totaling 42 days and finishing ahead of the deadline.
  • Rig was deployed on time, helping the customer avoid a $4 million loss due to delay.
  • Achieved seamless coordination with no idle time or handling damage despite the constraints.
  • Strengthened customer trust and confidence in Neptunus as a reliable service partner.

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