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Table of Contents

Project

CAT 3516B Engine Top Overhaul on Jack-Up Drilling Rig in DR Congo

Table of Contents

Background

Industry
Oil & Gas
Solution
Top Overhaul and
Complete Engine
System Restoration
Make & Model
CAT 3516B
Engine
Asset
Jack-up
Drilling Rig

Summary About The Project

Neptunus executed a complete top overhaul of the CAT 3516B engine to restore performance efficiency and reliability. The scope included dismantling of major assemblies, replacement of critical wear components, servicing of fuel, cooling, air, and lubrication systems, and reassembly as per OEM specifications.

Key systems such as cylinder heads, injectors, turbochargers, pumps, oil cooler, and aftercooler were either replaced or refurbished. Electrical systems and ECM were inspected and validated.

After completion, the engine was successfully started, tested under no-load and load conditions, and monitored for performance stability. All parameters including pressure, temperature, and load response were found within acceptable operating limits, confirming successful restoration.

Planning

  • Team Composition: 1 Team Leader + 3 Technicians
  • Duration: 22/08/2025 to 27/08/2025 (6 Days)
  • Work Scope:
    - Complete top-end overhaul of CAT 3516B engine
    - Replacement of major rotating and combustion components
    - Fuel, air, cooling, and lubrication system servicing
    - Reassembly and OEM-standard calibration
    - Safety checks and load trial validation

Procedure Carried Out

1. Cylinder Head and Valve System:
  • Removed existing cylinder heads and installed remanufactured cylinder heads
  • Replaced cylinder head gaskets and sealing components
  • Overhauled valve mechanism including rocker arms, valve bridges, and pushrods
  • Reused selected rocker components after inspection and cleaning
2. Fuel Injection System :
  • Installed new reman unit injectors
  • Replaced injector lifters and seals
  • Renewed injector harness and electrical connectors
  • Serviced fuel lines and fuel manifolds
3. Cooling System:
  • Replaced fresh water pump and auxiliary water pump
  • Installed new thermostat housing and thermostat elements
  • Serviced cooling lines and regulator components
  • Installed new aftercooler cores with sealing kits
4. Lubrication System:
  • Replaced lube oil cooler with reman unit
  • Replaced lube oil pump and scavenging pump components
  • Renewed lubrication lines and filters
  • Cleaned LO strainer and reinstalled
5. Air and Exhaust System:
  • Replaced both bank turbocharger cartridges with reman units
  • Cleaned air inlet and exhaust manifolds
  • Reinstalled air shutoff system and verified functionality
  • Checked air box condition and ensured leak-free operation
6. Engine Block and Mechanical Structure:
  • Decarbonized and cleaned engine block
  • Inspected liner condition and confirmed within OEM limits
  • Performed calibration checks on critical surfaces
  • Replaced seals, gaskets, and O-rings across assemblies
7. Electrical and Control System:
  • Verified ECM configuration and diagnostics
  • Checked all harnesses and sensors for functionality
  • Conducted safety cut-out testing for shutdown systems
  • Validated instrumentation panel performance
8. Testing and Commissioning:
  • Engine started successfully after assembly
  • No-load running performed with stable parameters
  • Load test conducted for extended duration
  • Safety systems tested including:
    - Low lube oil pressure shutdown
    - Over-speed protection
    - Crankcase pressure alarm

Result

The engine was successfully restored to full operational condition after overhaul. Performance parameters including temperature, pressure, and load response remained stable during testing. The unit was safely handed over after successful validation, confirming readiness for continuous offshore drilling operations.

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