The repair of crack and repair of damaged casting by welding process is now completely outdated and is not recommended for repair of damaged cast metal and cast iron parts. In fact, it is observed that in certain cases repair by welding results in more serious damage due to the generation of heat and stress during the process of welding. RA Power Solutions have been undertaking repairs of the damaged engine block, steel components repair, cast iron repairs and all types of cast components by metal stitching and metal locking process for last four decades.
We have a separate and dedicated team of technicians who have the capability to undertake the onsite repair of crack and damage casting by using portable tools and high-quality consumables (locks and keys ) which are imported by us from UK.
I) It is possible to undertake crack repair and repair of damage casting by metal stitching and metal locking process onsite. Hence there is no requirement of transporting the crack or damage components to the workshop.
II) In most of the cases, there is no requirement of dis assembly of equipment.
III) We possess portable tools to execute the repairs on site.
IV) The time duration for repair of crack and damaged cast components by metal lock and metal stitching is low.
V) Metal Stitching and Metal Locking is a permanent crack repair method as no heat is generated which is associated with welding.
VI) The crack and damaged area after repair by metal locking and metal stitching process are restored to its original profile and are also recommended for gas or watertight repair.
VII) Repairs are undertaken with the guarantee.
The repair by metal stitching and metal locking process can be undertaken of cast iron, aluminum parts including the following :
I) Damaged turbocharger casing.
II) Pump casing and gearboxes.
III) Cracked engine block, cam covers, cylinder liners, turbine casings, and all components.
We always depute our highly experienced team of technicians and engineers for repair of engines which are damaged due to the accident. Technicians travel with calibrated instruments to inspect the major components and also undertake the repair onsite in case possible. This is of great advantage to the customers as they need not engage a third party for inspection and repair of the damage components on site . We also supply genuine spare parts of the engine in collaboration with our partners based in UK. We are giving below the process of engine repair which have been undertaken by us recently:
Complete Overhaul of YANMAR 6T220-ET main Engine
I. Overhaul of 6 nos cylinder head, replacement of valve seats and valve guides. Replacement of all valve stem guide O-ring seals. Checked cylinder heads warpage and pressure testing of all heads at 5 bar.
II. Overhaul of jacket water, lubricating oil cooler and charged air coolers.
III. Dismount and overhaul of VTR 230 turbocharger, renewed the oil slinger, nozzle assembly and both compressor and turbine side bearings.
IV. Dismount and overhaul of all the air starting valves, relief valves , the piston rings and seals were changed
V. Withdraw all the pistons, took piston clearances and check and cleaned piston ring landing and renewal of piston rings gudgeon pins and big end bearings.
VI. De-glaze the cylinder liners.
VII. Took Crank web deflection measurements prior and after renewal of main bearings
VIII. Renewed all main bearings shells.
IX. Dismount and overhaul all fuel injectors and pressure tested the nozzles
X. Dismount and overhaul the fuel pumps and replacement of delivery valves, plunger and barrels .
XI. Setting of valves tappet clearances.
XII. Overhauled both emergency and attached lubricating oil pumps.
XIII. Dismount and overhaul of both sea water and jacket water pumps, replaced the mechanical seals.
Crankshaft is considered to be a heart of the engine. It is important that all the parameters recommended by engine manufacturers are strictly maintained for continuous and satisfactory performance of the engine.
It is observed that crankshaft failure can happen at any time in spite of excellent maintained engine. Secondly, due to continuous running of a diesel engine the wear and tear, development of taper and ovality, pitting and rough surface is developed. This needs to be corrected. By introduction of onsite crankshaft grinding and crankshaft polishing machine, RA Power Solutions has made onsite crankshaft grinding and polishing easy. Now there is no need of removing the crankshaft and sending it to the workshop for repairs.
With our revolutionary onsite crankshaft grinding and onsite polishing machine, it is possible to do the repair of crankshaft onsite.
Crankshaft grinding crankshaft polishing machine has the following features:
I) The crankshaft grinding machine is available in the range of 30 mm to 700 mm which covers crankshafts of small to high capacity engines.
II) The performance of onsite crankshaft grinding machine manufactured by RA Power Solutions is a proven, solution-focused approach with guaranteed results in terms of tolerances. By using onsite crankshaft grinding machine, shipping companies, diesel power plant, drydocks have reduced the downtime considerably and save money which really matters due to competition.
III) The onsite crankshaft grinding and polishing is undertaken by the same equipment. Every time engine is open for major overhauling, crank pin and main journal of crankshaft can be polished to remove the bearing line marks and to improve the surface finish. This increases the life of bearing and avoids crankshaft from breakdown.
IV) The crankshaft grinding and crankshaft polishing machine is designed to provide workshop quality service onsite, drydock or even while sailing of the vessel. The equipment has minimum vibrations, manufactured of titanium alloy which absorbs the vibrations. This facilitates to maintain close tolerances of crankpin and main journal of the crankshaft even while sailing of the vessel.
V) 24/7 global support services are provided for any guidance for operation and maintenance of the onsite crankshaft grinding machine. A training program is designed and arranged onsite covering all the aspects of the operation and maintenance of the machine.
VI) Machine is priced low and has the capability to generate high revenue in short time. The onsite crankshaft grinding machine is supplied complete in all respect ready to operate with consumables sufficient to repair one crankshaft.
VII) RA Power Solutions maintains a large databank of crankshafts of reputed diesel engine manufacturer and their models.
Author is Mr. Raj Shahani, Managing Director of the company. He is having 40 years of experience in grinding of crankshaft, polishing of crankshaft and all services related to repair of engines and supporting equipment. He has designed and developed the portable crankshaft grinding machine to save time and money.
We will be pleased to share more information regarding onsite crankshaft grinding and polishing machine, please email us on firstname.lastname@example.org
RA Power Solutions is the leading company extending Diesel Engine maintenance, Repair & overhaul services having experience of 40 years in this field. We have a team of skilled technicians & engineers who have worked in shipyards, Diesel Power Plants & Engine manufacturing companies. RA Power Solutions feel that proper analysis of trouble in Diesel Engine & its solution is of great importance for successful repair. Our technicians are able to quickly analysis in the case of breakdown & undertake the corrective action.
The major overhaul of MAK M453C main engine undertaken by our engineers recently was executed in record time & detail scope of work is as following:
I. Overhaul of 6 nos cylinder head, replacement of valve seats and valve guides. Replacement of all valve stem guide O-ring seals. Checked cylinder heads warpage and pressure testing of all heads at 5 bar
II. Overhaul of jacket water, lubricating oil cooler and charged air coolers
III. Dismount and overhaul of VTR 250 turbocharger, renewed the oil slinger, nozzle assembly and both compressor and turbine side bearings.
IV. Dismount and overhaul of all the air starting valves, relief valves, the piston rings, and seals were changed
V. Withdraw all the pistons, cleaned piston ring landing and renewal of piston rings gudgeon pins and big end bearings.
VI. Took piston ring groove axial and butt clearances
VII. Clean inspect and measure the cylinder liner internal diameters
VIII. Deglaze the cylinder liners with 120 grit emery cloth.
IX. Measurements of bearing cap gaps (k1-k2)
X. Polished the crankshaft and took journal measurements
XI. Renewed all main and locating bearing shells.
XII. Took main bearing top clearances by lead wire
XIII. Took crank web deflection measurements prior and after the renewal of main bearings with spring loaded dial gauge.
XIV. Took measurements of both normal and locating bearings k-gap.
XV. Dismount and overhaul all fuel injectors and pressure tested the nozzles.
XVI. Dismount and overhaul the fuel pumps and replace the springs, delivery valves, plungers, and barrels.
XVII. Setting of valves tappet clearances.
XVIII. Overhauled both emergency and attached lubricating oil pumps.
XIX. Dismount and overhaul of the jacket water pump replaced the bearing and mechanical seal.
The author is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. He has 40 years of experience in working on large crankshafts and Diesel Engines. He is on the board of directors of reputed shipping companies and companies having a large number of Diesel power plants.
RA Power Solutions is serving large engineering companies, Shipping organizations, Diesel Power Plants for the last 40 years. As a company, we believe in the supply of High-Quality spare parts of CKD Skoda Engines and other popular make.
We are the trusted name in the industry and offer the Engine & spare parts strictly as per the international standards.
Every spare part of the engine is audited by our experienced technicians for its quality which includes dimensional inspection & NDT test. The inspection reports in detail are furnished along with the spare parts supplied by RA Power.
We are maintaining a large stock of CKD Skoda 1450 KVA, 2270 KVA and all models of Diesel Engines & spare parts. Complete engine of CKD Skoda can be supplied after reconditioning with guaranteed performance. We also supply new & reconditioned spare parts for CKD Skoda Generators complete range. Since most of CKD Skoda engines are 30/40 years old we feel that it makes sense to use the reconditioned spare parts which are available on 25% of the cost of new one. Thus the company can save a considerable amount towards the maintenance of CKD Skoda Engines.
Presently we have available for sale following CKD Skoda Diesel Generating Sets and spare parts.
The sets are in working condition & will be supplied after reconditioning.
We can also provide you with all major new spare parts for this engine.
List of CKD Skoda Diesel Generating sets available:
NO. OF CYL.
List of Major reconditioned/New spares available with calibration report and guarantee:
II) Engine Block
III) Connecting Rod
IV) Cylinder Head
VIII) Fuel Pump
Note: The writer of this article is Mr. Raj Shahani, Managing Director of RA Power solutions Pvt Ltd.
Following is the brief of job description executed:
I) Inspection and overhaul of the cylinder covers including the fuel and starting valves located in the covers. The cylinder covers cooling spaces were also inspected, cleaned and fitted back with new O-rings.
II) Dismount, Inspect and overhaul the exhaust valves, renewed the seals and grinding the valve spindles.
III) The cylinder liners were cleaned, calibrated and honed in order to restore the liners running surfaces and remove ovality. This ensured that the piston rings perform better and this will lead to a better overall cylinder condition, compared to if honing had not been done. The cylinder liners cooling spaces were also inspected, cleaned and fitted back with new o-rings.
IV) Replacement of thrust block pads and correction of end play.
V) Metal locking of damaged Engine block by our technicians.
VI) Inspected and adjusted the chain drive.
VII) Retightened the stay-bolts, holding down bolts end chocks.
VIII) Took bearing clearances with a telescopic feeler gauge and checked bearing edges by wire gauges.
IX) Crankshaft alignment measurement was taken with dial gauge (autolog method)
Conclusion: The engine was tested on full load for 72 hours & all the parameter were recorded. The engine is performing satisfactorily.
RA Power has experience of more than 40 years in extending services for Overhauling of Main Engine Repair / Repair of Engine Metal Stitching of damaged Block.
The small diameter crankshaft is repaired on site without removing the crankshaft from the block. These services are of great use for the engines which are installed in construction-related equipment, compressors and the diesel driven equipment operating in remote areas.
Our services of crankshaft grinding and crankshaft repair are proven as we have been extending these services all over the world for the last forty years. The main feature of onsite crankshaft grinding, onsite crankshaft repair, crankshaft polishing, and onsite machining are as following: I) RA Power design and manufacture on site crankshaft grinding equipments as per the site requirement and the space constrains Hence there is no compromise with the quality after the repair of the crankshaft.
II) All the parameters of the crankshaft grinding are maintained strictly as per the manufacturer’s recommendations and tolerances. Inspection report in detail is submitted to the client.
III) In RA Power Solutions, we give great importance to the calibration of the crankshaft and inspection in detail by the experienced technicians which helps us to plan a right strategy and selection of right equipments for onsite grinding and onsite repair of a crankshaft.
IV) We possess the latest breed of inspection instruments including the instruments for NDT test which helps us to find out the exact fault in the crankshaft resulting to successful repairs.
V) Replacement of crankshaft in case of breakdown by new crankshaft or reconditioned crankshaft is our expertise. The crankshaft of an auxiliary engine can also be replaced while sailing of the vessel.
VI) The crankpin and main journals of the crankshaft having damaged radius fillet or small crank pin bearing width are also repaired by RA Power with the guarantee.
Our services for crankshaft grinding and repair are available 24*7. Technicians can fly down with portable lightweight crankshaft grinding machine in short notice to all over the world as they carry Indian CDC.
We have been regularly working for various models of engine like Wartsila , Daihatsu , MWM , Caterpillar , MaN , MaK , B&W , Sulzer , Bergen , Detroit Diesel , Stork Werkspoor , Pielstick , Deutz , Yanmar , MTU , Cummins , Nohab Polar , Caterpillar , Mitsubishi , Yanmar , MaK 551 , MaK 552 , MaK 453 , MaK 451 AK , MaK 452 AK , Deutz 540 , Deutz 358 , Deutz 350, Pielstick PC 2.2 PC 2.5, Wartsila 524 ,Wartsila 824 TS, Sulzer 6 AL 25/30 and many more.
RA power solutions having experience of four decades in on-site repair of major components like crankshaft, connecting rod, cylinder heads and under takes complete overhauling of main and auxiliary diesel engines installed on vessel or on land for a power generation and other applications.
Following are the main features:
Engine overhauling, engine repair and replacement of crankshaft is undertaken by RA power solutions for last four decades
Engineers and technicians are well experienced to attend any engine breakdown in shortest possible time, most of the engineers and technicians have experience of working in reputed engine manufacturers plant like Wartsila, Caterpillar, Cummins, Mirrlees Blackstone etc…
All the services pretaining to the repair of Crankshaft and major components of Diesel Engine is available in-house hence in case any component is found damaged at the time of overhauling of the engine the repair is undertaken by our technician on site and downtime is reduced. No need of calling third party for repairs.
RA power solutions undertakes one point guarantee for engine overhauling, engine repair and replacement of crankshaft as all parts are calibrated and inspection reports are prepared prior to reassembly of the engine
Crankshaft replacement,correction of crankshaft flange holes and all repairs of crankshaft is undertaken on site with a guarantee and in minimum time. The periodic overhauling as per engine manufacturers recomendation is undertaken.
Engineers and technicians undertaking engine overhauling,engine repair have valid CDC and can sail with the vessel this facilitates overhauling of main engine and auxiliary engine while sailing reducing downtime
RA power solutions undertakes engine overhauling, engine repair and crankshaft replacement of all makes and model of a high capacity diesel engines including : Mirrlees Blackstone, Ruston, Allen, Daiatsu, Yanmar, Caterpillar, Wartsila, SKL, Skoda, Pielstick, Cummins, Deutz, MAN, MAK etc.
RA power solutions manufacturers and exports cylinder liner | Cylinder sleeve for a wide range of engines, compressors and for all applications. The selection of the right material composition of cylinder liner keeping in view of its application is of great importance. RA power solutions strictly maintains the metallurgical composition of the cylinder liner and cylinder sleeve as per the engine manufacturer’s specifications. Liners are cast centrifugally which ensures cylinder liners casting free of any defects like porosity, blowholes any other abnormalities.
We maintain large stock of cylinder liner of popular make and model of engines the cylinder liner and cylinder sleeves are also developed and manufactured as per drawing or the sample provided by the client
RA power solutions stands guarantee for the satisfactory performance of liner for the period of 12 months from the date of dispatch of the cylinder liner from our works. The liners manufactured by RA power solutions are priced considerably low in comparison to the prices offered by the manufacturers of the engines.
We are the OEMS for various manufacturers of the engine
Development of taper and ovality in crankpin and main journal of the crankshaft in access of tolerances stipulated by manufacturer
Development of bearing line marks, pitting and rough surface
Damage of radius profile due to accident or seizure of bearing of crankpin or main journal
Development of crack and variation in hardness of the crankpin and main journal of the crankshaft.
Loss of alignment of the crankshaft
Crankshaft repair is undertaken by RA power solutions of the crankpinand main journal of the crankshaft diameter ranging from 35mm to 700mm. Crankshaft repair is undertaken by experienced technicians who have been specifically trained in our workshop on a dummy crankshaft, the company has experience of more than four decades in crankshaft repair.
The on-site grinding equipment designed and manufactured by RA power solutions can maintain the close tolerance after crankshaft grinding within 0.02mm and the surface finish which is far superior to the international standards. Crankshaft grinding machine has a main frame manufactured out of titanium steel which makes it lighter and vibration free during operation. The grinding of crankshaft is possible even while sailing of the vessel and there is no requirement of holding the vessel at anchor or a port for crankshaft repair.
All the crankshafts repaired by RA power solutions are guaranteed for a satisfactory performance we have successfully executed more than 10,000 crankshaft repair jobs. The services of crankshaft grinding and crankshaft repair are offered on low cost and our technicians carry CDC of Indian origin, Panama, and Pallav.