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Project

CAT 3306 Engine Fuel Pump Overhauling for Oil Rig in India

Table of Contents

Background

Industry
Oil & Gas
Solution
Fuel Pump Overhauling with Governor
Make & Model
CAT 3306
Main Engine
Asset
Drilling Rig

Summary About The Project

Neptunus carried out fuel pump overhauling with governor servicing for a CAT 3306 Engine installed on an oil rig in India. The fuel pump and governor assembly was received at the Neptunus workshop for repair and was partially dismantled using special tools. The work included dismantling of the governor and fuel transfer pump, extraction of five plunger barrel assemblies, and extraction of a bushing terminal using a welding method. During dismantling, the milling areas of the plunger-barrel nuts were found to be in rusted condition across all units. The fuel pump housing and accessories were cleaned, followed by installation of new fuel rack bearing bushings, fuel pump camshaft thrust bearing, lifters, barrel and plunger assemblies, seal O-rings, holding nuts, gaskets, and other required components. The governor shaft and housing were also cleaned and installed with new gaskets, while the feed pump and other accessories were cleaned and installed with new gaskets and seal O-rings. Holding nuts were torqued according to OEM specifications.

Planning

  • Team Composition: Neptunus team of 2 led by the Team Leader
  • Duration: 05 April 2023 to 10 April 2023
  • Work Scope:
    Partial dismantling of the fuel pump and governor, fuel transfer pump servicing, extraction of plunger barrel assemblies, cleaning of fuel pump components, replacement of fuel rack bearing bushings, camshaft thrust bearing, lifters, barrel and plunger assemblies, seals, O-rings, gaskets, governor shaft and housing servicing, feed pump servicing, and reassembly as per OEM specifications.

Procedure Carried Out

1. Fuel Pump and Governor Dismantling:
  • Partially dismantled the governor and fuel transfer pump using special tools.
  • Dismantled the fuel pump assembly.
  • Extracted five plunger barrel assemblies.
  • Extracted one bushing terminal using a welding method.
2. Fuel Pump Cleaning:
  • Cleaned the fuel pump housing and other accessories.
  • Prepared the components for inspection and reassembly.
3. Fuel Rack Bearing and Bushing:
  • Cleaned the fuel rack bearing area.
  • Installed a new fuel rack bearing bushing.
4. Fuel Pump Camshaft and Thrust Bearing:
  • Cleaned the fuel pump camshaft.
  • Installed the fuel pump camshaft with a new thrust bearing.
5. Lifter Installation:
  • Installed new lifters in the fuel pump assembly.
6. Barrel and Plunger Assembly:
  • Installed new barrel and plunger assemblies.
  • Installed new seal O-rings.
  • Installed new holding nuts.
  • Torqued the holding nuts as per OEM specifications.
7. Governor Servicing:
  • Cleaned and installed the governor shaft.
  • Cleaned and installed the governor housing.
  • Installed new governor housing gaskets.
8. Feed Pump and Accessories:
  • Cleaned and installed the feed pump.
  • Cleaned and installed other fuel pump accessories.
  • Installed new gaskets and seal O-rings as required.
9. Timing and Installation Checks :
  • Engine timing and fuel pump timing are to be matched during installation.
  • The installation requirements were noted for proper engine starting and fuel pump operation.

Recommendations

During engine starting, the engine main air filter should be removed and the intake should be blinded as specified in the Work Completion Report. Engine timing and fuel pump timing should be matched carefully during installation to ensure correct fuel injection timing and engine operation. The old spare parts and remaining new spare parts should be kept in the fuel pump box for proper record and future reference.

Scope for Improvement

The dismantling inspection identified rusted conditions in the milling areas of the plunger-barrel nuts across all units, requiring careful inspection during fuel pump servicing. The bushing terminal also required extraction using a welding method. Continued inspection of fuel pump components, bearings, bushings, barrel and plunger assemblies, seals, O-rings, and related accessories during future maintenance can help identify wear, corrosion, and component condition at an early stage.

Conclusion

Neptunus carried out fuel pump overhauling with governor servicing for a CAT 3306 Engine for an oil rig in India. The work included partial dismantling of the fuel pump and governor, extraction of five plunger barrel assemblies, cleaning of components, replacement of the fuel rack bearing bushing, camshaft thrust bearing, lifters, barrel and plunger assemblies, seals, O-rings, and gaskets. The governor shaft, governor housing, feed pump, and other accessories were also cleaned and installed. Holding nuts were torqued as per OEM specifications, with engine timing and fuel pump timing identified as important installation requirements. The overhaul work restored the fuel pump assembly with the required replacement components and reassembly activities documented in the Work Completion Report.

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