Lifeboat engines tested without load lose up to 25% power

Over a decade of field collaboration on the Norwegian Continental Shelf has revealed a critical and recurring problem: lifeboat engines tested without load degrade systematically over time, and may fail when you need them most.

What we found

Between 2012 and 2025, Frydenbø and operators on the Norwegian Continental Shelf conducted an extensive collaboration to improve the safety, performance, and reliability of lifeboat engines.

Lack of load during routine testing led to degraded engine performance and increased risk of failure. Testing confirmed that engines must run at a minimum of 50% load for 15 minutes (within a 25-minute test cycle) to maintain condition and performance.

Inspections and tests revealed that routine no-load testing over time, combined with unsuitable fuel, had resulted in engines with power output reduced by up to 25%.

The following faults were documented:

Severe soot accumulation and seized turbochargers
Corrosion on critical components
Stuck injection pumps and injectors (IDID)
Engine power reduced by up to 25%
Seized wastegates — risk of engine damage
Soot buildup in exhaust system — risk of chimney fire

Full technical documentation with field evidence, photographs, and recommended corrective actions.

Why does this happen?

Diesel engines are designed to operate under load. Sufficient loading ensures correct temperature and pressure in the combustion process, minimises the risk of deposits from unburned fuel, and maintains a cleaner internal engine environment.

Operating at low load or no load leads to incomplete combustion. The result is soot deposits, bore glazing, oil retention loss, and progressive weakening of mechanical components — without this necessarily being visible from the outside.

What does the regulation say?

This is not only a technical issue — it is also a compliance issue. NORSOK S-001:2020+AC:2021 is explicit:

NORSOK S-001:2020+AC:2021

"The lifeboat shall be equipped with an engine that can be run at high speed (rpm) and load when stowed in the davit to prevent soot and coke build-up."

Requirement for load-based testing of lifeboat engines.

Routine testing without sufficient load does not satisfy this requirement. If your current maintenance procedure does not include load-based testing, the protocol must be updated.

What to do now

We recommend performing a thorough condition check of the lifeboat engine and exhaust system. Specific actions:

Perform a general system check and service of the engine
Check and/or replace fuel injection components
Check and/or replace the turbocharger (if installed)
Clean the engine for soot buildup — combustion chamber, pistons, valves, manifold and pipes
Check engine compression
Assess the need for overhaul, new engine, and/or engine brake
Update maintenance procedures — routine testing every 14 days with equipment that ensures engine load (approx. 30 min), with logging of engine parameters

Frydenbø Dyno Engine Brake — a new industry standard

The Frydenbø Dyno Engine Brake is a system that provides adjustable load (0–100%) during testing and simulates real operating conditions — without launching the lifeboat. The solution has become the new industry standard for load-based testing of lifeboat engines on the Norwegian Continental Shelf.

Realistic load — simulates actual operating conditions without launching the lifeboat
Cleaner combustion — minimises soot buildup and oil/diesel residues in the exhaust system
Prevents cylinder corrosion through 14-day routine testing
Continuous logging of test parameters for documentation and control
Reduced maintenance costs over time
Ensures compliance with NORSOK S-001:2020+AC:2021