Full Auxiliary Generator Replacement Onboard: Zero Vessel Downtime
Replacing a vessel’s entire auxiliary power plant is one of the heaviest engineering scopes a ship can undergo, and normally, it means the vessel goes off-hire. At MI Solutions, our onboard mechanical and electrical team recently completed a full auxiliary generator replacement, removing and replacing all three auxiliary generators, rebuilding foundations to Class-approved design, and re-commissioning the entire power system, all without immobilising the vessel. This article breaks down the scope of that project and the standard our marine mechanical engineering team applies to every major machinery replacement.
From rigging generators through deck to engine room, to foundation rebuilds, pipework renewal, and full electrical re-commissioning, this is what a zero-downtime auxiliary generator replacement looks like from start to finish.
Project Scope at a Glance
The full auxiliary generator replacement covered all three units in a 16/24 configuration, delivered end-to-end by MI Solutions’ in-house onboard team:
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3x Weichai Generator Removal & Replacement
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Foundation Demolition & Class-Approved Rebuild
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Anti-Vibration Mounting & Precision Alignment
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Fuel, Water & Exhaust Pipeline Renewal
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Exhaust Insulation & Cladding
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Full Electrical Wiring & Commissioning
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The Replacement Scope: Phase by Phase
MI Solutions executed the auxiliary generator replacement in four coordinated phases, each managed by MI Solutions’ in-house team as one point of contact from mobilisation to commissioning, with no subcontracting and no interruption to trading.
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Phase 1
Removal & Rigging: Deck to Engine RoomAll three existing auxiliary generators in the 16/24 configuration were disconnected, disassembled where required, and rigged out of the engine room. The new Weichai generator sets were then rigged in, moved from deck level, through hatch openings, and lowered into position in the engine room under controlled lifting conditions. Every lift and rigging sequence was planned in advance to protect the surrounding machinery space and maintain safe access throughout, carried out entirely by MI Solutions’ in-house onboard team. |
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Phase 2
Foundation Rebuild & Anti-Vibration MountingThe old generator foundations were gouged out completely and rebuilt to a Class-approved design suited to the new Weichai units. This step is critical, as foundation geometry and material specification directly affect long-term vibration behaviour and alignment stability. New anti-vibration mounts were installed and each generator set precision-aligned to manufacturer tolerances, ensuring smooth running and minimal transmitted vibration to the hull structure. |
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Phase 3
Pipeline, Exhaust & Insulation WorkFull pipeline renewal was carried out across fuel, cooling water, and exhaust systems to match the new generator specification: routed, fitted, and pressure tested to ensure a clean, reliable connection into the vessel’s existing systems. New exhaust insulation and cladding were fitted along the full exhaust run, protecting crew and surrounding equipment from surface heat while meeting fire safety and insulation requirements. Fabrication and welding for pipe runs and supports were completed in-house by MI Solutions’ welding and fabrication team. |
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Phase 4
Electrical Wiring & CommissioningComplete electrical wiring was carried out for all three generator sets, including power cabling, control wiring, and integration with the vessel’s switchboard and monitoring systems, executed entirely by MI Solutions’ in-house electrical technicians. Each generator was started, load tested, and verified for correct synchronisation and parallel operation before being handed back to the vessel’s crew for service. |
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The Result
Zero Vessel DowntimeThe standout result of this project isn’t just the scope. It’s that the vessel continued trading throughout. Foundation rebuilds, rigging, pipework, and electrical commissioning were sequenced so that the ship’s operational schedule was never interrupted. Delivered with 100% in-house skills, no subcontracting, and no delays waiting for third-party support, this is the standard MI Solutions applies to every major machinery replacement project across Africa and the Middle East. |
Related Services from MI Solutions
Major machinery replacement work like this frequently draws on several disciplines at once. MI Solutions provides all of the following under one roof, with one point of contact and no subcontracting delays:
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Marine Mechanical
Main & Auxiliary Engine OverhaulFrom full generator replacement to main engine overhaul, MI Solutions’ marine mechanical engineers cover auxiliary machinery, pump overhaul, and general mechanical service across all vessel types. |
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Marine Hydraulics
Hydraulic System Repair & OverhaulGenerator replacement projects often run alongside hydraulic scope elsewhere onboard. MI Solutions’ marine hydraulic repair team covers deck machinery, steering gear, and cargo system hydraulics across all major manufacturers. |
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Welding & Fabrication
Marine Welding & Steel FabricationFoundation rebuilds, pipe runs, and support structures require precision fabrication. MI Solutions’ welding and fabrication team handles structural steel, pipe fabrication, and Class-approved welding, onboard or in-house. |
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Docking & Layup
Docking, Drydock Support & Layup ServicesWhere a generator replacement is planned around a docking window, MI Solutions’ docking and layup team supports full drydock planning, repair execution, and return-to-service preparation. |
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Marine Spare Parts
Generators, OEM Parts & Marine Spares: Fast Supply to PortNeed auxiliary generators, spares, or OEM components delivered to your vessel? As one of the most reliable marine spare parts suppliers in the UAE, MI Solutions sources and delivers class-approved components direct to port alongside the installation team, across Africa and the Middle East. |
Planning a Generator Replacement? Contact MI Solutions
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