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Project

Breakdown Repair and Seal Replacement of MAN AMG 28 EV Gearbox on Offshore Vessel in Nigeria

Table of Contents

Background

Industry
Marine
Solution
Gearbox Seal
Replacement and Breakdown
Repair Services
Make & Model
MAN AMG 28 EV
Gearbox
Asset
Offshore Supply
Vessel

Summary About The Project

Neptunus carried out inspection, troubleshooting, and overhaul of both Port and Starboard MAN AMG 28 EV gearboxes after severe operational issues were reported. The Port gearbox was found seized, and both gearboxes showed heavy contamination due to water and oil mixing.

A detailed inspection confirmed internal damage including corrosion, rusting, and deterioration of critical components due to water ingress. Based on findings, a complete overhaul along with seal replacement and consumable renewal was executed.

Post overhaul, the gearbox was reassembled, tested, and restored to smooth operational condition. System flushing and oil analysis confirmed negligible water content, ensuring reliability and readiness for vessel operations.

Planning

  • Team Composition: Team of 5 engineers led by experienced team leaders
  • Duration: 27 December 2024 to 08 January 2025 with extended overhaul and assembly phases
  • Work Scope:
    Inspection, fault diagnosis, seal replacement, gearbox dismantling, overhaul, flushing, reassembly, and performance verification

Procedure Carried Out

1. Initial Inspection:
  • Conducted detailed inspection of Port and Starboard gearboxes
  • Identified seized condition of Port gearbox
  • Detected heavy contamination due to water and oil mixture
2. Gearbox Dismantling:
  • Dismantled gearbox components for detailed internal inspection
  • Assessed condition of bearings, shafts, seals, and internal assemblies
3. Internal Component Inspection and Restoration:
  • Identified severe rusting, pitting, and corrosion on internal parts
  • Polished gearbox shaft to remove rust and restore surface condition
  • Verified damage to non-regular consumable components
4. Seal Replacement :
  • Replaced damaged seals to eliminate contamination source
  • Ensured proper sealing integrity to prevent future ingress
5. Consumables and Spare Replacement:
  • Replaced worn and damaged consumables including non-standard items
  • Validated earlier recommendation based on actual component condition
6. Gearbox Reassembly:
  • Reassembled gearbox after overhaul and replacement activities
  • Ensured proper alignment and torque settings
  • Confirmed smooth rotation and free movement
7. System Cleaning and Flushing:
  • Drained contaminated oil from sump
  • Cleaned sump and pipelines thoroughly
  • Performed air blowing to remove water impurities
  • Flushed system using fresh oil
8. Testing and Oil Analysis:
  • Conducted propeller pitch tests to check for seal leakage
  • Increased vessel trim during testing for accurate observation
  • Collected oil samples for laboratory analysis
  • Confirmed negligible water content and stable oil condition

Recommendations

  • Regular monitoring of gearbox oil condition to detect contamination early
  • Periodic inspection and replacement of seals to prevent water ingress
  • Scheduled flushing and cleaning of lubrication systems
  • Immediate inspection if abnormal gearbox behavior is observed

Conclusion

Neptunus successfully completed the gearbox overhaul and seal replacement for the MAN AMG 28 EV system, restoring full functionality and operational reliability. Detailed inspection, accurate diagnosis, and systematic execution ensured elimination of contamination and prevention of future issues. Final testing and oil analysis confirmed stable performance, reinforcing Neptunus’ expertise in delivering reliable marine gearbox repair and breakdown services for offshore vessels.

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