Upgrade of Obsolete Woodward Actuators

An offshore semi-sub drilling rig experienced engine performance issues due to aging and obsolete Woodward EM80 actuators on two HIMSEN 12H32/40V engines. With spare parts no longer available and reliability declining, the operator engaged Heinzmann Automation AS for a modern and future-proof upgrade.

The challenge
The failure of the EM80 actuators led to breakdowns and operational disruptions. A robust, long-term solution was urgently needed to secure engine performance and ensure regulatory compliance.

The solution

Heinzmann Automation AS proposed a full upgrade using:

• Heinzmann 4Q-Drive: For precise, responsive engine control, improved fuel efficiency, and reduced emissions.
• StG 90 Actuator: Designed for harsh marine environments, offering high reliability and low maintenance.
• Seamless Integration: Fully compatible with the existing engine control system.

Phased Implementation
The first upgrade involved two engines and was carried out during a scheduled mobilization off the coast of Ghana. Due to the successful outcome, the remaining six engines were later upgraded with the same system. This brought the total to eight engines now operating with the Heinzmann 4Q-Drive and StG 90 actuator solution.
A specialized Heinzmann team handled equipment delivery, installation, commissioning, and verification within days. The project was executed in close cooperation with the rig owner and class societies, ensuring compliance throughout.

Results

• Restored Performance: All eight engines now benefit from precise and efficient control.
• Increased Reliability: Robust components reduce the risk of failure and unplanned downtime.
• Rapid Deployment: Minimal operational disruption during both phases of the upgrade.
• Future-Ready: A scalable control platform that supports future performance improvements.

Conclusion
By replacing obsolete Woodward actuators with Heinzmann’s advanced system, the rig owner restored full engine performance and reliability across all eight engines. This successful project underlines the importance of proactive upgrades and showcases Heinzmann’s ability to deliver effective engine control solutions in demanding offshore environments.