Overhauling of Diesel Engine | Engine repair | Marine Engine Overhauling

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.

Diesel-Engine-Repair-Overhauling-300x225
Overhauling of Wartsila Engine

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.
Overhauling of Caterpillar
Overhauling of Caterpillar Engine
Inspection of connecting rod
Inspection of connecting rod
Cylinder head overhauling
Cylinder head overhauling

 

 

 

 

 

 

 

 

 

 

Cylinder Liner | Cylinder sleeves | Cylinder manufacturers

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

Cylinder sleeve | Cylinder liner exporters
Cylinder sleeve | Cylinder liner exporters
Cylinder liner | Cylinder sleeve
Cylinder liner | Cylinder sleeve
Cylinder liner manufactures
Cylinder liner manufactures
cylinder liner and cylinder sleeve after phosphating
cylinder liner and cylinder sleeve after phosphating

Crankshaft repair is required in case of following abnormalities observed in the crankshaft

  • 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 crankpin and 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.

Crankshaft repair
Crankshaft repair
On-site crankshaft repair
On-site crankshaft repair
Crankshaft repair machining
Crankshaft repair machining

Crankshaft Repair | Crankshaft Grinding and Crankshaft Polishing

The concept of onsite repair of crankshaft is getting popular with the introduction of a portable lightweight on-site crankshaft grinding machine. Now it is possible to undertake crankshaft repair, crankshaft grinding and polishing on site without dismantling of the crankshaft from the engine.

On-site Crankshaft Repair, Crankshaft Grinding, and Crankshaft Polishing costs low with minimum downtime and inconvenience as it does not require removal of crankshaft from the engine block, packing and transportation to the designated workshop for repair by grinding or polishing process

Advantage of trusting RA power solutions

  • First company based in Asia having experience of four decades in Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing

  • All repairs of crankshaft and process followed for grinding of crankshaft and polishing of crankshaft are approved by class agencies of repute like DNV, Lloyds and various inspecting organisations spread all over the world

  • The repair of crankshaft is executed with a guarantee for the satisfactory performance, the pre and final inspection reports before and after grinding and polishing crankshaft are submitted

  • Technicians executing the repair of crankshaft onsite are highly skilled, trained in our factory on a dummy crankshaft in order to understand the techniques for successful repair of the crankshaft. Some of our technicians have experience of more than 45 years.

  • The onsite inspection and polishing of crankshaft repair is recommended to enhance the life of crankshaft and bearings

  • RA power solutions offers and undertakes inspection and polishing of crankshaft on board a vessel on a nominal cost

  • During our working of four decades on diesel power plant, shipping companies we have undertaken Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing number exceeding more than 10,000

Conclusion:

RA power solutions has team of technicians with valid CDC from Panama, Palau, and India and can travel all over the world within a short notice

On site crankshaft grinding
On-Site Crankshaft Grinding
Crankpin grinding and polishing
Crankpin grinding and Polishing
On-site crankshaft repair
On-site crankshaft repair

On-Site Crankshaft Grinding Machine | Crankshaft Polishing Machine

Crankshaft grinding machines are designed to maintain the accurate tolerances as per the engine manufacturer’s recommendation

Generally, it is observed that even for the higher diameter of crankpin and main journal of the crankshaft the tolerances do not exceed more than 0.05mm in order to achieve such close tolerances of crankpin and main journal of crankshaft RA power designs and manufactures on-site crankshaft grinding machine which has the capability to maintain the close tolerance of even 0.01mm/0.02mm which is far better than the close tolerance specified by the engine manufacturers.

The on-site crankshaft grinding machine and crankshaft polishing machine manufactured by RA power solutions has the following features:

    1. Crankshaft grinding machine is designed in a way that it can be inserted from the inspection window of the engine block thus there is no need of removal of the crankshaft from the engine block.

    2. In case of space restrictions, RA power has the capability to design the equipment according to the space available on site for grinding or polishing of crankshaft/turbine/alternator shaft/rotor shaft etc…

    3. The on-site crankshaft grinding machine is lightweight portable and can be easily carried to the site all over the world. The crankshaft grinding  machine is packed in the suitcase and is carried as accompanied baggage accepted by all international airlines

    4. The main body of crankshaft grinding equipment is manufactured out of titanium alloy which is lightweight and can absorb the vibrations this feature of crankshaft grinding machine facilitates RA power technicians to undertake crankshaft repair on board the vessel while it is sailing, maintaining the close tolerances within 20 microns.

    5. Crankshaft grinding machine designed and manufactured by RA power can presently work up to 700mm diameter which we are in process of extending up to 1000mm.

Conclusion

RA power has sold more than 70 crankshafts grinding machines all over the world which are performing satisfactorily the cost of the machine is low and is affordable for repair workshop, shipping company, power plants etc…

 Crankshaft grinding machine for repair and grinding
Crankshaft grinding machine for repair and grinding
Crankpin grinding on board the vessel
Crankpin grinding on board the vessel
Crankshaft Grinding Machine for Small Diameter
Crankshaft Grinding Machine for Small Diameter

 

Cast Iron Crack Repair By Metal Stitching

Steam turbine casing of Hangzhou make was reported damaged due to accident. The turbine operates at 130 MW peak load.

RA Power solutions deputed technician to the site with latest breed of instruments, equipments and consumables in order to undertake inspection of the turbine casing and to execute necessary repair following observation was made.

Observation-

Turbine casing due to accident developed multiple cracks at different locations. Crack of following dimensions were observed

  • Crack having a length of 190mm with indiscipline profile

  • 2 Cracks having length of about 300mm

  • Casting having dimensions of 600mm/450mm with thickness of 45mm was damaged into pieces

Crack repair by Metal lock and Metal stitching.

Crack Repair and damaged casting replacement was under taken by RA power technicians.

    • The damaged casting area was cut and disciplined profile was given measuring 650mm/520mm this area was properly ground

    • The damaged sample piece was sent for metallurgical test to know the composition of material.

  • A wooden pattern was made at site having an exact profile as of damaged area

    • A new casting piece having superior metallurgical properties then the original damage casting was manufactured

  • The new casting piece was fixed in damage area by metal stitching and metal locking process

    • RA power engineers used metal locks, metal keys and all consumables’ imported from UK for repair of cracks and damage casting

  • The polishing of outer and inner surface of damaged area was done and painted

  • The turbine is presently working satisfactory and has completed 3500hr of operation.

RA power under takes repair of crack casting by metal stitching and metal locking process from last 40 years and have executed successfully repair of heavy components used in power plants, industry, ships etc…

The metal stitching and metal locking can also be undertaken while sailing of the vessel.

Turbine casing
Turbine Casing
Damaged turbine casing
Damaged turbine casing
Turbine casing after repairs
Repair of casing by metal lock and metal stitching
Turbine casing after repairs
Turbine casing after repair

Onsite Crankshaft Grinding | Crankshaft Repair | Crankshaft Polishing and Grinding

RA Power Solutions undertakes Onsite Repair and Grinding of Crankshaft up to diameter of 700 mm. The experience technicians travel with light weight latest design of Onsite Crankshaft Grinding Machine to execute the Crankshaft Repair. The Onsite Crankshaft Grinding Machine has following benefits to the clients.

Crankshaft Grinding Wartsila 18 V32
Crankshaft Grinding Wartsila 18 V32

The Benefits:

I.) You do not need to remove the Cranks shaft from the engine or press.

II.) We save your time: – some of these repairs can be carried out as little as 24 hours.

Insitu Crankshaft Grinding
Insitu Crankshaft Grinding

III.) We save your money: – The engine does not have to be stripped down and transported or reassembled. The savings on this alone are usually very significant.

IV.) We keep your plant running: – Downtime is minimized so that you can be back into operation and earning money sooner.

V.) Machining and polishing of Crankshaft and Crankpin are carried to OEM tolerances and surface finish specifications.

VI.) We cover standard Crankshaft diameter ranging from 30 mm to 700 mm.

VII.) Our patented orbital equipment rotates around damaged crankpin journal using the radius as a datum.

VIII.) We can also Hone and Polish your crankpin if the damage is slight or you just want to improve the surface finish up to 0.3 micron Ra Value.

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Onsite Crankshaft Grinding
Onsite Crankshaft Grinding
Repir ofCrankshaft MAN B& W
Repir of Crankshaft MAN B& W

Onsite Crankshaft Grinding Machine | Insitu Crankshaft Polishing and Grinding Machine | Crankshaft Machining

In case of accident of Crankshaft in recent past, it was necessary to disassemble the crankshaft from the engine block or housing, pack it and send it to the designated work shop.

The Introduction of Onsite Crankshaft Grinding Machine, Insitu Crankshaft Polishing and Grinding  Machine, Crankshaft Machining, there is no need of removing the Crankshaft and sending it to the work shop as now it is possible to undertake crankshaft grinding and crankshaft repair with revolutionary design of Onsite Crankshaft Grinding Machines manufactured by RA Power solutions.

Portable Crankshaft Grinding Machine
Portable Crankshaft Grinding Machine

The Onsite Crankshaft Grinding Machine has been developed out of our experience of Crankshaft repair of Forty Years. The Machine is Light Weight and can be taken to the Site. It has following Features.

I.) Onsite Crankshaft Grinding Machine , Insitu Crankshaft Polishing and Grinding Machine is manufactured by RAP after extensive research, development and our experience.

II.) The Machine in the Initial Years was used by our technicians for  In-house applications. Now from last ten years Machine  is sold in open market all over the world.

III.) The Insitu Crankshaft Grinding and Polishing Machine is user friendly and can be operated by any person having basic machining knowledge.

IV.) The Machine is capable and is designed to maintain the close dimensions and Geometrical tolerances as per the manufacturers requirement.

Onsite Crankshaft Grinding Machine Ready for Dispatch
Onsite Crankshaft Grinding Machine Ready for Dispatch
V.) Presently Onsite Crankshaft Grinding Machine is manufactured for the diameter of the Crank-pin and Main Journal of the Crankshaft ranging from 30 mm to 700 mm.

 

VI.) Crankshaft Grinding Machine is manufactured out of Titanium Alloy which is light Weight and can be easily carried to the Site.

 

VII.) The Machine is capable of working on a Vessel while it is moving.

VIII.) Training forms an Integral part of the Crankshaft Grinding Machine. Training onsite is provided.

 IX) We have sold more than seventy machines all over the world and are priced cheapest in the International Market.

 

Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter

 

For more details, please email us on info@rapowersolutions.com or visit our website http://www.rapowersolutions.com/onsite-crankshaft-grinding-machine.aspx

Crankshaft Repair | Crankshaft Grinding | Onsite Crankshaft Machining

RA Power Solutions undertakes Grinding of Crankshaft of High Capacity Engines used in Shipping companies, Power plants and in various other sectors. The company has experience of more than forty years in undertaking successful repairs of Crankshaft and major components. As we are aware Crankshaft is a heart of engine and is most expensive part with limited availability of particular make and model.

Damaged CrankPin of Mirrlees Blackstone Engine
Damaged CrankPin of Mirrlees Blackstone Engine
Inspection of Crankpin Under Process
Inspection of Crankpin Under Process

 

 

 

 

 

 

 

 

RAP expertise lies in repair of crankshaft s which meets with a serious accident like Seizure of bearing. It is generally observed that due to rubbing of bearing steel surface with the CR Pin diameter, excessive heat is generated. Thus there is a increase in Hardness. Every manufacturer specifies the maximum limit of Hardness.

In case of Mirrlees Blackstone K and KV, major series of engine, the normal hardness at the time of manufacturing of crankshaft is between 21.5 to 26 on HRC Scale (241 to 268 on HB scale). It is obvious that after seizure of bearing, the hardness increases even to the level of 45 to 50 HRC.

The Mirrlees Blackstone allows the higher hardness under deviation maximum up to 32 HRC against the standard of maximum  26 HRC. In normal situation as per the manufacturer, the crankshaft  stands rejected as it has far higher Hardness then the stipulated in the manual.

Field Instruction for Crankshaft Rehabilitation of Mirrlees Blackstone Engine
Field Instruction for Crankshaft Rehabilitation of Mirrlees Blackstone Engine

RA Power took the following action to save the Crankshaft.

I.) The Hardness was taken on various spots, not having gap of more than 15 mm.

II.) Hardness was recorded and maximum hardness of 50 HRC was observed.

III.) Since  bearing line marks, taper and ovality on the crank-pin was observed, the grinding was undertaken and CR Pin dia was reduced by 3.5 mm approx.

IV.) The Hardness was reduced and the maximum Hardness of 42 HRC was observed on few spots. Although the 42 HRC Hardness was on higher side, then the maximum limit of 32 HRC specified by the manufacturer. The Crankshaft was accepted under deviation due to following reasons

a)  The higher Hardness was observed in a scattered pattern.

b) The higher hardness was away from the Lubricating Oil Hole and radius fillet of the CR Pin which are considered to be critical Zone

The Crankshaft was accepted and his performance is observed as satisfactory from last more than three and half years.

The saving of Crankshaft from rejection was possible only due to the Experience RA Power solutions has of successful repair of  more than ten thousand crankshaft.

RA Power Solutions undertakes Crankshaft Repair, Crankshaft Grinding and offer Onsite Crankshaft Machines to the repair companies.

Grinding of Crankpin is in Process
Grinding of Crankpin is in Process by RA Power Solutions

Note: The writer of this article is Mr Raj Shahani, Managing Director of RA Power solutions Pvt Ltd.

Website: http://www.rapowersolutions.com/ and he is instrumental in saving  number of Crankshafts from rejection.

Grinding & Repair of Crankpin is in Process
Grinding & Repair of Crankpin is in Process
Finished Crankpin after Grinding & Repair
Finished Crankpin after Grinding & Repair

Crankshaft Grinding Machine- Mobile Machining of Crankshaft

In case of failure of crankshaft or bearing on a vessel/stationary power plant it results to extremely high cost for repairs and with long downtime. RA Power Solutions manufactures and exports onsite and insitu crankshaft grinding, crankshaft machining equipment which saves considerable cost of repair and save time as disassembly of the crankshaft and transport to the workshop is not required.

Portable Crankshaft Grinding Machine
Portable Crankshaft Grinding Machine
The insitu crankshaft grinding machine performs and delivers the same quality standards which are achieved by old designed, conventional bench type crankshaft grinding machine.

Advantage of using RA Power Solutions onsite crankshaft grinding machine and mobile machine:

I) Company having more than 40 years of experience in grinding and repair of crankshafts of high capacity marine and industrial engines and understands the importance of maintaining tolerances as per OEMs.

II) It is a highly advanced technology grinding machine which is designed to take the stress while machining and polishing of crankshaft, crankpin and main journal.

III) Crankshaft Grinding Machine is light weight and compact and can be easily taken to the site all over the world as accompanied baggage.

Crankshaft Grinding Machine Packed For Dispatch
Crankshaft Grinding Machine Packed For Dispatch
Crankshaft Grinding Machine Accessories Packed for Dispatch
Crankshaft Grinding Machine Accessories Packed for Dispatch

IV) Customized tooling adapting to all makes of engine and models. Machine available in the range of 60 mm to 700 mm.

V) Onsite grinding of crankpin and main journal is possible with this grinding tool.
VI) Onsite Crankshaft Machine is easy to operate and training is provided.

VII) Machine body is made from titanium which results to the minimum vibration while in operation. Machine can be used on vessel while sailing.

The company has sold more than 70 machines all over the world. It is highly recommended for repair workshops, power plants, shipping and engineering companies.

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Grinding of Crankshaft on a Moving Vessel
Grinding of Crankshaft on a Moving Vessel
Grinding of Crankshaft in a Power Plant by Crankshaft Grinder
Grinding of Crankshaft in a Power Plant by Crankshaft Grinder
Grinding of Crankshaft on VBlock by Crankshaft Grinding Machine
Grinding of Crankshaft on VBlock by Crankshaft Grinding Machine