Table of Contents

Project

Complete 30K Overhaul of EMD 12-645-E8 Main Engine on Jack-Up Drilling Rig in Egypt

Table of Contents

Background

Industry
Oil & Gas
Solution
30K Major Overhaul
(MoH) of Main Engine
Make & Model
EMD 12-645-E8
Main Engine
Asset
Jack-Up
Drilling Rig

Summary About The Project

Neptunus successfully completed a 30K major overhaul of an EMD 12-645-E8 main engine onboard a jack-up drilling rig operating in Egypt. The overhaul was carried out after the engine completed approximately 211,147 running hours to restore engine reliability, improve operational stability, and ensure safe continued operation.

The scope included complete dismantling, inspection, calibration, servicing, and reassembly of major engine systems in accordance with OEM procedures. Critical systems including power packs, connecting rod bearings, fuel injection systems, governor assemblies, blower systems, cooling water pumps, lubrication systems, crankshaft bearings, and safety systems were overhauled, renewed, inspected, and calibrated.

Following completion of the overhaul, successful load trials and safety shutdown tests were carried out. All engine operating parameters including temperatures, pressures, exhaust temperatures, lubrication flow, and safety systems were found within acceptable operating limits, confirming stable engine performance.

Planning

Procedure Carried Out

1. Power Pack Assembly:
2. Rocker Arms and Valve Mechanism:
3. Fuel Injection System:
4. Governor and Linkage System:
5. Crankshaft and Bearing System:
6. Camshaft and Gear Train:
7. Cooling and Lubrication System:
8. Blower and Air System:
9. Engine Block and Structural Inspection:
10. Pre-Commissioning and Load Trials:

Scope for Improvement

Recommendations

Conclusion

Neptunus successfully completed the 30K major overhaul of the EMD 12-645-E8 main engine in Egypt with successful restoration of engine reliability and operational stability. Through systematic inspection, precision calibration, component renewal, safety testing, and strict adherence to OEM procedures, the engine was returned to service with stable operating performance.

This project demonstrates Neptunus expertise in delivering complex offshore main engine overhaul services for jack-up drilling rigs and heavy-duty industrial applications.

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