Marine Diesel Engine Overhaul: Engine Service Support Team Beats the Clock

By George Backwell at March 23, 2013 01:04
Filed Under: Engine overhauls, Marine Diesel Engines

Overhaul cylinder heads and liners; pistons and con rods; cam shafts; bearings; vibration dampers and injectors, and two turbocharger units after completely dismantling three of the marine diesel engines that power Dive Support Vessel (DSV) Rockwater 1, and get it all done within 18 days.  That would be a tall order for many firms in the engine service support business, but Royston’s nine-man team of engineers based in Newcastle-on-Tyne, in the North-East of England, worked day-and-night shifts without missing a beat to complete this first stage of the vessel’s 30,000-hour engine overhaul so that the  Subsea 7 offshore vessel was back to work on time after scheduled docking.

Photo courtesy of Royston Ltd.

While the team beavered away aboard the DSV in the Barrow-in-Furness dock, another six engineers machined components in the company’s nearby Newcastle workshop, a job that included servicing 27 cylinder heads and liners; fuel injectors; and a complete overhaul of two turbochargers.

The 98-m LOA, 4,905 gt Rockwater 1, features a single-bell saturation dive system, and is powered by a diesel-electric propulsion system consisting of five 1,700 kW Brons-MAN ASL25/30 diesel engines that each drive a 2125 kVA NEBB WAB 630 generator which produces power for two 1,800 kW azimuth thrusters and three 7,90 kW tunnel thrusters.  Because the diesel engines are used to power generators the Rockwater 1’s engineering staff will be able to vary their running hours and control the service intervals; this way the Royston team will be able to overhaul the remaining two engines during the ship’s next planned maintenance period.

DSV Rockwater 1: Photo courtesy of Subsea 7

P&O Australian Contract
Royston is a firm with a global reach, having facilities in Perth, Western Australia where the ‘Down-Under’ team earlier completed a major three-week 60,000-hour diesel engine overhaul contract with P&O for work on the P&O Southern Supporter while she was berthed not far way in Henderson’s Fremantle dock.

The P&O Southern Supporter has an Ice Class 1A rating and is well-known in the Southern Ocean where she has been operating extensively since launch in 1993.  The 74-m vessel is equipped with an A-frame and crane which enables her to perform a wide variety of survey, maintenance and supply tasks.  Engine performance and reliability are critical for a ship that has been used to take equipment and personnel into Antarctica.

On this job, again time was of the essence, and the project called on the eight-man Royston team to work continuously around the clock to service and re-build the ship’s three Cat 3516 engines. This included a complete strip-down of the engines, replacing the main bearings, overhauling the cylinder heads, upgrading liners with spacer-plate modifications. The work also included camshaft grinding on one of the engines and the overhaul of all ancillary components.

Royston has been in business for thirty years providing fleet maintenance service for all types of seagoing vessels and for diesel engines on offshore platforms or ashore. They say that their technicians come from a variety of OEM backgrounds and maintain their skills at the highest levels to ensure that even discontinued products can remain fully operational.



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