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Project

CAT C18 Engine Major Overhaul Services on Offshore Vessel in Mozambique

Table of Contents

Background

Industry
Marine
Solution
Major Overhaul (MoH)
Services
Make & Model
CAT C18 Engine
Asset
Offshore Supply
Vessel

Summary About The Project

Neptunus carried out a complete major overhaul of the CAT C18 engine to restore its performance and reliability after extensive running hours. The overhaul was required to replace critical worn-out components, ensure optimal engine efficiency, and prevent unexpected breakdowns.

The scope included dismantling, inspection, replacement of major assemblies, and reassembly of the engine as per OEM standards. After completion, the engine was successfully tested under no-load and load conditions. All operational parameters remained stable, confirming the engine was restored to optimal working condition and ready for continuous offshore operations.

Planning

  • Team Composition: Team of 6 engineers led by team leader
  • Duration: 11 June 2025 to 14 June 2025
  • Work Scope: Complete major overhaul including dismantling, inspection, replacement of critical components, reassembly, and performance trials

Procedure Carried Out

1. Cylinder Head Assembly:
  • Removed cylinder head and associated components
  • Installed new remanufactured cylinder head with new gaskets and O-rings
  • Reassembled manifolds and accessories
2. Valve Mechanism and Camshaft System:
  • Overhauled rocker arms and valve mechanism
  • Replaced valve bridges and set valve lash as per OEM
  • Installed new camshaft and inspected bushings
3. Power Pack Assembly:
  • Replaced liners, pistons, connecting rods, piston rings, and bearings
  • Installed new assemblies with proper clearances and torque settings
4. Crankshaft and Bearings:
  • Replaced main bearings and thrust bearings
  • Checked crankshaft alignment and end play within limits
  • Replaced front and rear crankshaft seals
5. Fuel System and Injectors:
  • Installed remanufactured unit injectors
  • Replaced fuel transfer pump and fuel lines
  • Performed injector calibration and testing
6. Cooling System and Heat Exchanger :
  • Serviced heat exchanger and replaced hoses
  • Installed new fresh water and auxiliary water pumps
  • Cleaned and reassembled all cooling lines
7. Lubrication System:
  • Installed new oil pump and oil cooler
  • Replaced all filters and strainers
  • Cleaned oil sump and reinstalled
8. Air System and Aftercooler :
  • Replaced aftercooler core and seals
  • Cleaned and reinstalled air inlet and exhaust systems
9. Turbocharger:
  • Replaced turbocharger cartridge
  • Cleaned compressor housing and reinstalled connections
10. Electrical and Control System:
  • Checked ECM parameters and confirmed proper configuration
  • Inspected wiring harness, sensors, and safety systems
  • Verified all safety cut-outs
11. Front and Rear End Assembly:
  • Serviced gear train and verified backlash settings
  • Reinstalled flywheel, housing, and coupling
  • Ensured proper alignment with alternator
12. Pre-Commissioning and Trials:
  • Conducted complete safety and operational checks
  • Ran engine at rated RPM without load for 3 hours
  • Performed load trial for 6 hours with stable parameters
  • Confirmed all readings within OEM limits

Recommendations

  • Monitor engine parameters regularly including temperature, pressure, and vibration
  • Maintain proper lube oil condition and replace when required
  • Follow OEM maintenance schedule strictly to avoid breakdowns
  • Keep critical spare parts available for emergency situations
  • Inspect turbocharger, fuel system, and cooling system periodically

Conclusion

Neptunus successfully executed the major overhaul of the CAT C18 engine, ensuring complete restoration of performance and operational reliability. Through precise execution, adherence to OEM standards, and detailed testing, the engine was returned to service with stable performance under all operating conditions. This project highlights Neptunus’ expertise in delivering dependable marine engine overhaul services for offshore vessels.

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