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Project

30K Major Overhaul of EMD 12-645 E8 Engine on Jack-up Drilling Rig in DR Congo

Table of Contents

Background

Industry
Oil & Gas
Solution
30K Major Overhaul
of Engine
Make & Model
EMD 12-645 E8,
Engine
Asset
Jack-up
Drilling Rig

Summary About The Project

Neptunus carried out a 30K major overhaul of the EMD 12-645 E8 engine onboard a jack-up drilling rig operating in DR Congo after 35512 running hours. The objective was to restore engine performance, eliminate wear-related risks, and ensure reliable offshore operation.

The scope included complete power pack replacement, crankshaft and bearing inspection, fuel system overhaul, cooling system servicing, and full recalibration as per OEM standards. Critical components such as camshaft bearings, injectors, pumps, gears, and seals were renewed or serviced.

Post overhaul, the engine was successfully tested under no-load and full-load conditions. All operating parameters including pressure, temperature, and load response were stable and within acceptable limits, confirming successful restoration.

Planning

  • Team Composition: Team of 3 technicians led by a team leader
  • Duration: 08 July 2025 to 19 July 2025
  • Work Scope: 30K major overhaul including dismantling, inspection, power pack renewal, calibration, system overhaul, reassembly, and load trial

Procedure Carried Out

1. Power Pack and Cylinder System:
  • All power packs renewed with new baskets and seat rings
  • Cylinder heads dismantled, cleaned, and reassembled
  • Injector sleeves replaced and torque tightened as per OEM
  • Valve timing checked and set to 106 degrees
  • Cylinder block and liners cleaned and calibrated
  • Piston assemblies dismantled, inspected, and reassembled
2. Fuel Injection System:
  • All injectors replaced with unit exchange sets
  • Fuel injection pumps inspected and overhauled
  • Plunger barrels, delivery valves, and seal kits renewed (selective units)
  • Fuel rack and linkages inspected and adjusted
  • Injection timing verified and confirmed
3. Crankshaft and Bearing System :
  • Crank pin inspection and calibration carried out
  • Main bearing and thrust collar replaced
  • Connecting rod bearings fully renewed
  • Crankshaft deflection and alignment checked
4. Camshaft and Gear Train :
  • Camshaft bearings replaced
  • Front and rear gear trains renewed and backlash adjusted
  • Accessory gears, bushings, and drive systems replaced
  • Vibration damper replaced and aligned
5. Cooling and Lubrication System:
  • Lube oil pump, scavenging pump, and water pumps renewed
  • Lube oil cooler unit exchanged due to condition issues
  • Piston cooling lines and LO lines replaced
  • Thermostat housing cleaned and fitted with new elements
  • Cooling system pressure tested and verified
6. Air and Exhaust System:
  • Blower assemblies replaced with unit exchange units
  • Air starting system inspected and confirmed OK
  • Air box cleaned and inspected for leakage
  • Exhaust system condition verified during trials
7. Governor and Control System:
  • Governor reused and drive system inspected
  • Linkages and bearings checked and adjusted
  • Overspeed and safety trip systems inspected and tested
8. Pre-Commissioning and Safety Checks:
  • Lube oil priming and circulation verified
  • Crankcase pressure detector tested
  • Low lube oil pressure trip tested successfully
  • Overspeed trip activated at 990 RPM
  • No load and load trials conducted successfully

Scope for Improvement

  • Improve lifting and special tools availability for heavy components
  • Enhance onboard maintenance tool handling system for major overhaul tasks

Recommendations

  • Monitor engine closely for first 100 hours after overhaul
  • Inspect lube oil filters after initial operation period
  • Conduct lube oil analysis at 100 hours
  • Replace lube oil if contamination is detected
  • Maintain strict monitoring of pressure and temperature parameters
  • Follow OEM guidelines for start and shutdown procedures

Conclusion

Neptunus successfully completed the 30K major overhaul of EMD 12-645 E8 engine onboard a jack-up drilling rig operating in DR Congo. Through systematic execution, full power pack renewal, and precise calibration, the engine was restored to stable and reliable operational condition.

The successful load trial and safety verification confirmed full readiness for continued offshore drilling operations.

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