Preventing Catastrophic Engine Failure at an Office Property

Upon receipt of a coolant sample report indicating elevated copper and iron levels within the cooling system, the client requested a thorough investigation be performed to determine the root cause.  Our team conducted hydrocarbon and pressure tests on the cooling system, revealing a positive result for hydrocarbons, indicating a critical issue.

What Did We Do?

• Diagnostic Assessment: Swiftly identifying the presence of hydrocarbons in the cooling system leading to an issue with the head gasket. 
• Methodical Disassembly: The removal of heads in preparation for the head gasket replacement, revealed that one of the heads was severely warped. Measurement of the liner protrusion and engine block were conducted and revealed to be outside of tolerable specs indicating a significant issue.  
• Customer Collaboration: It was recommended that the engine block be removed from site to have a thorough evaluation and pressure test performed at our machine shop. An additional option was presented to the customer to simply replace the engine with new.  With Weld Power’s guidance, the customer elected for full engine replacement rather than repair. 
• Expert Handling: Utilizing advanced lifting equipment and with very little room to maneuver, we safely rigged the existing engine off premises.
• Precise Installation: Adhering to industry standards and safety protocols, the new engine was meticulously installed utilizing the same method as used in the removal.
• Thorough Testing: A comprehensive four-hour load bank test evaluated the new engine’s performance under simulated operational conditions, ensuring reliability and efficiency.

This case highlights not only the importance fluid sampling in helping to avoid a critical failure, but also Weld Power’s adeptness in collaborating with clients to devise optimal solutions which fit within their budgets & needs, efficiently addressing intricate challenges, all while maintaining the critical infrastructure of the site.