5th July 2022 INDUSTRIAL

INSTALLATIONS &
PERKINS 4012 ENGINE FAILURE
MAINTENANCE
The engine does crank but will not start. There were clear signs of no compression, so we opened the inlet manifold for inspection. As
we cranked the engine, we noticed diesel being forced out of the engine onto the inlet manifold (please refer to attached video clip
below). That prompted us to open one of the cylinder heads for inspection. We found out that the exhaust valves were bent (please
refer to attached photos).
Logically, the damage we noticed on one cylinder head is likely to be on the other 11 cylinder heads, since they are subjected to the
same mechanical stresses

The cause of the valves failure was not conclusive, because the genset was serviced prior to our attending. Possible causes of failure
are:

>Low oil in the engine could have caused the valves to get stuck in the valve guides, which could have caused them to get bent,
over time.

>Low oil circulation caused by use of after-market oil filters. Some of the oil filters that are installed on the genset are not from
Perkins, who are the Original Equipment Manufacturers. Physically, the filters are smaller. It is possible that the throughput of
those filters are less than the original filters, and could have resulted in less oil being circulated, causing valves to get stuck in the
valve guides, subsequently bending.

>Incorrect valve clearance settings. This is possible because when we opened the tappet covers, it was clear the valve clearances
were adjusted as the original marks were now off position. It is possible other contractors could have attended and tried to
repair the genset before we were engaged by Water Utilities Corporation.

There were visible signs of rough running on the engine; the protective grill on the radiator had cracks at multiple places caused
by vibration from rough running of the engine.

Unfortunately, we did not find any useful data on the HISTORY log on the Automatic Mains Failure controller. The oldest date
was 18/12/2021, please refer to attached picture (Thune Dam History Log) below:
CONCLUSION AND RECOMMENDATIONS:

1. Generators of the size of Thune Dam (1250KVA) are quite expensive to repair because of the sheer size. It is
recommended to engage companies with proven record of servicing and/or repairing such units.

2. It is also important that OEM spares are used without fail. Use of after-market filters, oils, etc on such expensive
equipment is not recommended.

3. It is advisable to keep your engine’s oil level in check and don’t skip your oil change intervals.

4. Always adhere to service intervals as recommended by the OEM of your gensets, usually set on the controllers. We
recommend 3 levels of MAINTENANCE ALARMS: Maintenance Warning 1 at 250 hours; Maintenance Warning 2 at 270
hours; and Maintenance Shutdown at 300 hours, after which the genset will not start. Reset of maintenance hours should be
done only after servicing the generator.

We have come up with a proposal, based on our findings and experience. The scope of repair includes:
>STRIPPING THE ENGINE
>RECONDTION THE CYLINDER HEADS
>REPLACE INLET AND EXHAUST VALVES
>REPLACE VALVE GUIDES
>REPLACE HEAD GASKETS
>REPLACE RETAINERS
>REPLACE O-RINGS, BANK A
>REPLACE O-RINGS, BANK B
>REPLACE LINERS
>REPLACE LINER O-RINGS
>REPLACE PISTONS, COMPLETE WITH RINGS
>TRANSPORTATION OF CYLINDER HEADS TO AND FROM RE-CONDITIONING

Please feel free to contact the undersigned if further clarification is sought.

Thank you for the business opportunity.

Yours sincerely,

_____________________

GIFT TOBAIWA

PROJECTS AND MAINTENANCE MANAGER

KESINGDON INVESTMENTS (PTY) LTD
PLOT 5051 SOMERSET EXTENSION INDUSTRIAL AREA
FRANCISTOWN
BOTSWANA