Singapore Port Emergency Repair – Diesel Engine Replacement & Gas System Recovery

Project Title: Emergency Engine & System Repair – Salwico SW2020 + Diesel Unit
Date: Dec 1 – Dec 15, 2024
Location: Singapore International Port
Client: Confidential (Bulk Carrier)
Repair Focus: Diesel engine replacement, gas detection unit failure, vacuum pump leak
Team: HENLICO Ship Maintenance Division

Background

On the morning of December 1st, 2024, HENLICO received an urgent message from a returning client at Singapore Port. The vessel had been scheduled to sail out within three weeks, but now suffered a dual fault:

• The Salwico gas detection system was stuck in looped self-test mode;

• One of the primary diesel generator engines failed to start up, despite multiple ignition attempts.

Our response was immediate. Within 6 hours, our maintenance division dispatched a team of engineers and logistics coordinators. Spare parts and diagnostic tools were simultaneously arranged for international freight.

Day 1–3: Onboard Arrival & Fault Investigation

Upon boarding, our team split into two units:

1. System Diagnostics Team focused on the SW2020 gas unit;

2. Engine Team opened up the failed generator housing.

Findings revealed:

• The vacuum switch (VS1) of the Salwico unit wasn’t triggering under expected pressure;

• Diesel generator #2 suffered from a cracked cylinder liner, likely due to a recent overheat.

A full cylinder head + liner replacement was proposed and approved within 24 hours.

Day 4–10: Repair Execution

During this phase:

• We removed and replaced the faulty diesel engine liner and piston assembly;

• Precision laser alignment was carried out for the new shaft coupling;

• Salwico's unit was recalibrated, and VS1 and FS (flow switch) were replaced;

• Saltwater ingress damage near the pump was cleaned and sealed.

Despite one delay due to missing O-rings stuck in customs, our advance-planned logistics ensured alternative supply via a local partner.

Day 11–13: Final Testing & QA

With both systems restored, our engineers ran:

• A 48-hour burn-in test for the diesel generator under full load;

• Recalibration of the Salwico unit including all ballast tank sampling points;

• Leak check under high-pressure vacuum and discharge.

System logs were verified, and internal redundancy controls were tested.

Day 14–15: Delivery & Client Feedback

On December 15, we delivered a full technical report to the client:

• Scope of replaced components and system changes;

• Calibration data log and backup procedures;

• Maintenance advice for both engine and gas system teams.

The client was highly impressed, stating:

"Your team has not only solved the problem but made our vessel more reliable than before. You’ve earned our long-term trust."

Summary

This project combined mechanical overhaul, electrical diagnostics, and rapid global sourcing—demonstrating HENLICO’s core strength:
speed, precision, and on-time delivery under pressure.