Major Overhaul of Perkins 3012-TAG2A Engine – Generator No. 1
Client
Eu-Retec Pvt Ltd / Continental AG
Service Provider
Mermaid Solutions Pvt Ltd
Location
Kalutara, Sri Lanka
Project Overview
The Perkins 3012-TAG2A engine (Generator No. 1, Engine No: SGC120229U3333B) originally installed in a 675KVA FG Wilson generator was brought in for a major overhaul by Mermaid Solutions Pvt Ltd under PO No: 4500770170, dated 30.09.2024. Prior to this engagement, the engine had undergone a previous overhaul conducted by an external third-party service provider. During the current dismantling and inspection phase, several critical deficiencies associated with the prior repair were identified, which contributed to premature component failure and overall engine performance degradation. Key Technical Observations from Previous Overhaul: – Substandard Head Gaskets: Locally fabricated head gaskets were used in the prior overhaul, which failed to conform to OEM specifications. This resulted in poor sealing, combustion gas leakage, and coolant-oil cross-contamination risks. – Piston Crown & Skirt Damage Due to Incorrect Assembly: Multiple piston crowns showed impact marks and denting, while skirts had uneven wear. This was due to insufficient piston-to-liner clearance, likely from incorrect measurement.
Tight clearances led to piston seizure, wear, and liner scoring, affecting engine longevity and performance.
Mermaid Solutions Pvt Ltd has provided a comprehensive technical recommendation and overhaul strategy using reconditioned or OEM-standard components, proper precision gauging, and Perkins guidelines for reassembly.
Project Timeline
• Initial Inspection & Dismantling – October 2024
• Overhaul Execution & Reassembly – October–December 2024
• Completion & Testing – January 2025 (expected)
• Final Load Testing & Handover – 31st March 2025
Key Achievements & Outcomes
• Restoration of full engine operational performance.
• Significant cost savings through reconditioning and selective reuse.
• Project delivery aligned with client’s cost and time constraints.
• Long-term reliability ensured through replacement of critical components.
• Generator was duly load tested, installed, commissioned, and formally handed over on 31st March 2025.
Scope of Work
1.Initial Assessment & Defect Identification
• Complete dismantling and inspection of the engine.
• Identification of worn or damaged components including liners, pistons, valves, turbocharger parts, and freshwater system components.
• Submission of an additional parts list and technical recommendations for customer approval.
2.Overhaul Execution
• Engine Block Restoration:
• Reconditioning of cylinder liners and pistons using imported or compatible components.
• Replacement of worn valve collets, tappet screws, and injector bolts.
• Refurbishment or replacement of cylinder heads.
• Turbocharger and Fuel System:
• Replacement of A-bank turbine wheel.
• Servicing of corroded fuel lines and inspection of injector systems.
• Cooling System:
• Reuse of the freshwater pump and manifold plugs where possible.
• Radiator core reconstructed from two damaged units to optimize cooling capacity.
• Starter & Flywheel System:
• Replacement of flywheel ring gear and pinion gear to restore reliable startup.
• Final Assembly & Testing:
• Reassembly with proper torque settings and clearances.
• Dynamic testing and final performance validation under load conditions.
Procurement & Delivery
• Spare parts sourced from OEM and reconditioned suppliers.
• DAP delivery terms to Kalutara Factory, with progressive payment milestones as follows:
– 40% advance.
– 40% after component receipt.
– 20% after final commissioning.
– 5% retention bond for 12 months post-completion.
Contact Details
Mermaid Solutions Pvt Ltd
No. 73, MJC Fernando Mawatha, Idama, Moratuwa, Sri Lanka
Email: info@mermaidsolutions.com | Tel: +94 11 264 5189
Project Contact: Namal Fernando | +94 77 789 7341