Home » Case Studies » Rig Owner Extends EMD Engine Overhaul by 6000 Hours for On-Time Deployment
Table of Contents
Case Study
Rig Owner Extends EMD Engine Overhaul by 6000 Hours for On-Time Deployment
Table of Contents
Background
Industry
Oil & Gas
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
EMD 12V-645E8
Engine
Asset
Offshore
Drilling Rig
Objective
To assess the true health of two EMD engines and optimize overhaul decisions, enabling the customer to deploy their rig on time while reducing unnecessary costs.
Challenge / Problem Context
Two EMD 12V-645-E8 engines were due for a 30,000-hour overhaul, but the rig owner faced budget constraints.
A new drilling contract was finalized, and the rig needed to be commissioned within a short timeframe.
The technical team was uncertain about whether the engines were reliable enough to enter the new contract without an immediate overhaul.
What Did We Do?
For the budget constraint challenge: Neptunus recommended pre-overhaul diagnostics using torsional vibration analysis instead of proceeding with a standard overhaul, with the goal of identifying only the necessary spares and consumables.
For the commissioning deadline challenge: Our expert team boarded the rig and carried out real-time health diagnostics using our proprietary torsional vibration tool to provide immediate insights into engine condition.
For the uncertainty about engine reliability: We analyzed the data and prepared a detailed health inspection report. The results indicated that both engines were in satisfactory condition, and overhauls could safely be extended by at least 2,000 hours.
Results That We Achieved
From addressing the budget constraint: The overhaul interval was ultimately extended to 36,000 hours (6,000 hours beyond the OEM schedule), reducing lifecycle costs by $32,000 per engine and saving a total of $64,000 across both engines.
From meeting the commissioning deadline: The rig was deputed on time without the 2-month delay that an overhaul would have caused. This enabled uninterrupted operations, generating $1.5 million in revenue and improving cash flow.
From resolving uncertainty in reliability: The customer confidently deployed the rig under the new contract, saving an additional $10,000 in offshore logistics and manpower costs. The technical team was able to focus on drilling operations instead of engine overhaul planning.
