Clark Engine Repair at Laughf’s Gas Terminals, Hambantota
Client
Clark Fire Pump USA
Location: Laughf’s Gas Terminals, Hambantota, Sri Lanka
Service Provider: Mermaid Solutions Pvt Ltd
Project Timeline
• 2020 – Initial diagnostics and failed repair attempts by a reputed company in Sri Lanka.
• 2021 – Mermaid Solutions Pvt Ltd officially took over engine repairs.
• 2022 – Completion of repair works and successful testing
Project Description
Mermaid Solutions Pvt Ltd was entrusted with diagnosing and repairing four fire pump engines at the Laughf’s Gas Terminals in Hambantota, Sri Lanka. Initially, Clark Fire Pump USA identified critical issues with the engines and planned to send their service engineers from the USA. However, due to the COVID-19 pandemic, international travel restrictions made it challenging to deploy overseas personnel. Consequently, Clark USA authorized Mermaid Solutions Pvt Ltd’s local engineers in Sri Lanka to proceed with the repair work.
Initial Diagnosis & Issues Identified
Upon conducting a detailed forensic analysis, the following major issues were identified in the four John Deere diesel engines (Tag Numbers: 4201A, 4201B, 4201C, 4201D):
- Excessive Noise, Vibration, and Overheating: High cooling temperatures, abnormal noise, charge air cooler condensation, cracked JX coupling rubber dampers.
- Unsuccessful Previous Repair Attempts: Repairs by a reputed company in Sri Lanka were ineffective. Vibration dampers failed multiple times.
- Mechanical & Structural Failures: Crank oil seal damage, water accumulation in engine cylinders, excessive crankcase pressure.
- Electrical & Control System Faults: Engine control module malfunctions, digital monitor faults, turbocharger and thermostat issues.
Key Achievements & Outcomes
- Successfully diagnosed and resolved long-standing engine defects.
- Enhanced engine stability and reduced excessive vibration issues.
- Eliminated overheating and optimized cooling system performance.
- Extended engine lifespan through proper oil management and filtration.
- Restored the fire pump engines to full operational efficiency.
- Reduced downtime and future maintenance costs.
Scope of Repairs Undertaken
1. Mechanical & Engine Overhaul
• Complete dismantling and reassembly of engine components.
• Replacement of all vibration dampers with OEM-approved viscoelastic dampers.
• Overhaul of turbochargers, oil pumps, and coolant pumps.
• Cylinder head inspection and replacement of damaged components.
2. Cooling & Lubrication System Restoration
• Lube oil analysis.
• Cleaning and pressure testing of charge air coolers.
• Checking engine valve tappet clearances.
• Installation of a condensation drainage system.
3. Electrical & Control System Upgrades
• Testing, calibration, and programming of the engine control module (ECM).
• Inspection and servicing of the electronic governor card functions.
• Verification of exhaust gas parameters.
4. Final Testing & Certification
• Extensive load tests under operational conditions.
• Verified compliance with OEM specifications.
• Ensured all engines operated within acceptable temperature and vibration limits.
• Received final approval from Clark Fire Pump USA.
Completion Status
The project was successfully completed with the engines restored to optimal performance levels. Mermaid Solutions Pvt Ltd continues to provide maintenance support.
Contact Details
Mermaid Solutions Pvt Ltd
No. 73, MJC Fernando Mawatha, Idama, Moratuwa, Sri Lanka
Email: info@mermaidsolution.com
Tel: +94 11 264 5189