Repair of Damaged Engine Block

RA Power Solutions was recently approached by a diesel power plant based in South America having Wartsila 12V32 and Wartsila 18V32 diesel generating sets.

Broken Engine Block of Wartsila Diesel Engine
Broken Engine Block of Wartsila Diesel Engine

A serious accident took place due to failure of cylinder liner resulting in to the damage of various parts including lower and upper engine block of Wartsila 18V32 engine. On investigation by RA Power Solutions technicians it was observed that upper and lower engine block suffered severe multiple cracks measuring to total 2900 mm in length and  damage of casting into small pieces measuring 300 X 460 mm.

Casting Piece Given Profile as per Damaged Engine Block
Casting Piece Given Profile as per Damaged Engine Block

Various options were discussed and it was decided to replace the lower and upper crankcase. The cost of replacement of damage lower and upper engine block of Wartsila 18V 32 was exorbitant with a delivery period of 9 months. RA Power Solutions proposed to repair the multiple cracks and damaged portion by metal stitching and metal locking process. This is a cold process of crack repair and has been followed by our technicians in number of installations all over the world during our service to the industry for last four decades

Special Metal Locks and Keys Used in Metal Stitching Process
Special Metal Locks and Keys Used in Metal Stitching Process

The damaged portion of the engine block was given a discipline profile and new piece of casting having similar metallurgical properties as of the parent material was placed and metal stitched using the latest design of metal stitching locks and keys. The multiple cracks were properly marked by our technicians using the latest MPI equipment to identify the cracks. The multiple cracks were also repaired by metal stitching and metal locking process.

Special Keys Used in Metal Stitching
Special Keys Used in Metal Stitching

RA Power Solutions also undertook the onsite grinding of crankshaft which got damaged due to accident and re-assembled the engine in 16 days time. All these repairs were conducted in-house with the onsite portable equipments which were carried to the site by the technicians. Perhaps no other company in the world can offer all repair services under the same roof.

The engine is performing satisfactory.

RA Power Solutions specializes in cast iron repairs, utilizes advance metal stitching and metal locking processes that are ideal and most suited for this type of crack repair.

RA Power Solutions takes the pride to announce that in our four decades of experience, we were able to save millions of dollars of end users by undertaking the onsite repairs of damaged parts avoiding the  expenses towards the cost of new parts which are exorbitantly priced with long delivery.

Meta Stitching Of Engine Block is in Process
Metal Stitching Of Engine Block is in Process

 

Repair of Damaged Engine Block by RA Power Technician
Repair of Damaged Engine Block by RA Power Technician

We have a dedicated team to undertake the repair of crack and damaged engine components. It is possible to undertake metal stitching and metal locking for repairs of crack on a moving vessel.

Repair of Engine Block by Metal Stitching/Metal Locking
Repair of Engine Block by Metal Stitching/Metal Locking While Vessel is Sailing

Technicians can join the vessel in short time as they carry seaman passport. As an Indian company we are respected for our sincerity, experience and lowest cost.

For more information, please email us on info@rapowersolutions.com

Insitu Crankpin Machining

Sulzer model 6RTA Engine was reported damaged in high seas near Mombasa on a transit to Sri Lanka. On investigation, it was observed that the connecting rod bolts got sheared damaging lower and upper engine block and three crankpins of the Crankshaft.

Team of RA Power Solutions technicians having experience of undertaking in-situ crankpin machining and a team undertaking repair of crack and damaged engine block by metal stitching and metal locking process was deputed on board a vessel within a short notice as all of them have a seamen passport.

Repair of Engine Block by Metal Stitching Process
Repair of Engine Block by Metal Stitching Process

On preliminary examination multiple cracks on upper and lower crack case of engine block were observed measuring in totality 2900 mm in terms of length. Three crankpins were damaged developing taper and ovality exceeding more than 1 mm. RA Power Solutions team of technicians worked non-stop and executed the repair of crankpins by onsite crankshaft grinding machine. All pins were undersized to 1.5 mm due to the damage.

Grinding of Crankpin on Board a Vessel
Grinding of Crankpin on Board a Vessel
Crankpin After Grinding by Crankshaft Grinding Machine
Crankpin After Grinding by Crankshaft Grinding Machine

 

 

 

 

 

 

 

The engine block cracks were repaired by metal locking and metal stitching process. The complete job was executed within 68 hours. The hard work, knowledge, experience, sincerity of technicians have been very much appreciated by the owners. This achievement was possible due to RA Power Solutions having latest design of equipment, experienced technicians having Indian CDC.

For more information, please email us on info@rapowersolutions.com

Crankshaft Grinding Machine for Small Diameter

Onsite grinding of crankshaft without removing it from the engine block is undertaken by taking the reference of radius fillet.

The onsite crankshaft grinding machine is placed on both side of the radius of the crankpin and tool rotates undertaking grinding and polishing of crankshaft. This process of crankshaft grinding by in-situ crankshaft grinding machine is successful generally for the diameter of the crankpin of 200 mm and above having a bearing width of 125 mm minimum.

Crankshaft Grinding Equipment from 30 mm Diameter
Crankshaft Grinding Equipment from 30 mm Diameter
Insitu Crankshaft Grinder
Insitu Crankshaft Grinder

 

 

 

 

 

For the smaller diameter of the crankpin, it is not possible to undertake the grinding by taking the reference of radius fillet due to the space constraints.

RA Power Solutions has introduced a compact, easy to operate onsite crankshaft grinding machine which is suitable for grinding and polishing of small diameters of the crankpin above 30 mm. The crankpin bearing width can be as small as 30 to 40 mm. With this latest technological advance crankshaft grinding machine, it is easy to grind the smaller diameter of the crankpin having smaller crankpin bearing width.

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

The crankshaft grinding machine has the main features of machining, grinding and polishing of the crankpin. The tolerances in terms of taper, ovality, surface finish are maintained far better than the manufacturer’s recommendation.

RA Power Solutions having 4 decades of experience in in-situ crankshaft grinding have executed successfully repair of more than 11,000 crankshaft all over the world and are leaders in this field.

For your requirement of portable onsite crankshaft machine, you may write us on info@rapowersolutions.com

CKD Skoda Bearings by RA Power Solutions, India

CKD Skoda engines and CKD Skoda diesel generating sets are slow RPM and are installed all over the world. Presently, CKD Skoda plant is closed for last 15 years and due to non availability of spares various problems are faced by the clients having CKD Skoda generating sets or CKD Skoda engines installed for applications like shipping and industries.

CKD SKODA Bearings Ready for Dispatch
CKD SKODA Bearings Ready for Dispatch

RA Power Solutions is associated with CKD Skoda since 1982 . We manufacture and supply Skoda white metal bearing and Skoda tri metal bearings for crankpin and main journals. The CKD Skoda bearings are manufactured under the strict quality norms. We have been regularly exporting these bearings all over the world including Czech Republic. A country where CKD Skoda IV) engines were manufactured.

Parts like Crankshaft, cylinder liners, valves etc for CKD Skoda engines are available.
We have ready stock for following Skoda engines:

I) CKD Skoda 500 KVA
II) CKD Skoda 608 KVA
III) CKD Skoda 860 KVA
IV) CKD Skoda 1450 KVA
V) CKD Skoda 2270 KVA

Inspection of CKD SKODA Bearings is in Process
Inspection of CKD SKODA Bearings is in Process

We maintain inventory for following models of CKD Skoda Diesel Generating Sets:

 OUTPUT (kVA)  FREQUNCY (Hz)  VOLTAGE (V)  DIESEL ENGINE  RPM
 405  50  400/231  6S275III  600
 405  50  400/231  6-27,5 A0S  600
 500  50  400/231  6S275PN  500
 608  50  400/231  6S275IIIPN  600
 608  50  400/231  6-27,5 A2S  600
 825  50  400/231  6S275IIIPV  600
 825  50  400/231  6-27,5 A4S  600
 860  50  400/231  6S350PN  375
 860  50  6300  6S350PN  375
 860  50  11000  6S350PN  375
 1525  50  6300  9S350IIPS  375
 1525  50  11000  9S350IIPS  375
 1525  50  6300  9TS35/50-2  375
 1525  50  11000  9TS35/50-2  375
 1600  50  400/231  6-27,5 B8S  750
 1600  50  6300  6-27,5 B8S  750
 1600  50  11000  6-27,5 B8S  750
 2140  50  6300  6-27,5 B8S  750
 2140  50  11000  6-27,5 B8S  750
 2270  50  6300  6-38 A6S  500
 2270  50  11000  6-38 A6S  500
CKD Skoda Bearings
CKD Skoda Bearings
CKD Skoda for High Capacity Engine
CKD Skoda for High Capacity Engine

Overhauling and Repair of Marine Diesel Engine

Marine diesel engine is to be maintained and overhauled periodically in accordance with the international rules and regulations. The manufacturer’s recommendations for the periodic overhaul of the marine engine as well as that of the class and the administration is to be followed.

Diesel Engine Repair & Overhauling
Diesel Engine Repair & Overhauling

RA Power Solutions undertakes on-board overhaul and repair of marine engines. The auxiliary engines which are used for generation of power are also overhauled as per the scheduled recommended by the manufacturers.

Reconditioning of Cylinder Heads
Reconditioning of Cylinder Heads

RA Power Solutions undertakes the periodic checks of marine engine and auxiliary engines (generators) on board the vessel for 250, 1000, 2000, 4000, 8000 hours of routine inspection and overhaul.

Team of experienced technicians trained to work in a difficult situation are deputed on board the vessel. In case of any accident or technical issues reported by the chief engineer a  separate technician with instruments and portable equipment is deputed to attend the repairs on the spot. This facilitates the repair of damage parts if possible and the assembly of the engine after overhauling work  in short duration reducing the down time

Prior to assembly of the engine all the parts are thoroughly inspected and calibration report in detail is prepared. In case of any discrepancies, it is highlighted and explained to the engineers and plan for corrective action is made in consultation with the owners.

Inspection & Repair of Engine Spares
Inspection & Repair of Engine Spares

Having the in-house facilities for repair of major engine components, RA Power Solutions has an edge over other agencies. Major parts like crankshaft, engine block, connecting rods, and cylinder heads are calibrated and repaired in most of the cases.

In certain situation in case the damage cannot be attended on vessel the parts are sent to our workshop for repairs.

RA Power Solutions with 4 decades of experience stands guarantee for the job of marine engine overhaul and repair executed.

For more information, please email us your inquires on info@rapowersolutions.com or call us on +91-9810012383

Repairs are in Process During Overhauling of Marine Engine
Repairs are in Process During Overhauling of Marine Engine
Inspection After Overhauling of Marine Engine
Inspection After Overhauling of Marine Engine

Diesel Engine Repair and Overhaul by RA Power Solutions, India

Diesel engine repair and maintenance is one of the important services offered by RA Power Solutions through the trained and experienced engineers and technicians. Our engineers are trained with the OEMs, large power station and can handle all the problems related to the maintenance and repair of diesel engine, generators and all auxiliary equipment installed on the vessel or power plant.

 

Repair and Overhaul of Diesel Engine is in Process
             Repair and Overhaul of Diesel Engine is in Process

It is important that while the diesel engine maintenance is under the process, the major parts like crankshaft, connecting rod, engine block, cylinder liner, cylinder head, etc. are calibrated .

RA Power Solutions is one of the leading companies also providing the services for onsite repair of major components in case need arises.

Reconditioning of Connecting Rod
Reconditioning of Connecting Rod

The calibration report of major parts of diesel engine is maintained and handed over to the clients after the overhauling and repair of diesel engine is executed.

The diesel engine overhauling and repairs services comprises of following:

I) To undertake shifting of high capacity diesel engines from one location to another.

II) Complete overhaul of diesel engine and generating sets is done as per the engine manufacturer’s instructions and maintenance manual.

III) Major Diesel engine repair and maintenance jobs are executed like replacement of engine block, crankshaft, cylinder heads and cylinder liners, etc. in case of accident or normal wear and tear.

IV) Diesel engine overhaul and repair is supported by team of experience technicians who can also undertake onsite repair of major components if required.

Inspection and Repair of Engine Spares
Inspection and Repair of Engine Spares
Inspection of Crankpin of MAN Engine
Inspection of Crankpin of MAN Engine

 

 

 

 

 

 

 

We are the only company which can provide all the services related to diesel engine repair under one roof involving crankshaft grinding, engine overhauling and commissioning and supplying new and reconditioned engine spares.

The diesel engine repair can also be executed while sailing of vessel as our technicians have valid Indian CDC.

Inspection and Repair is in Process
Inspection and Repair of Heat Exchanger is in Process
Inspection of Diesel Engine
Inspection of Diesel Engine

Turbine, Rotor and Alternator Shaft Grinding and Polishing

Failure of bearing due to over load or accident results to development of taper and ovality on turbine, alternator, rotor shaft. In certain cases the deep bearing line marks are developed and bearing surface becomes rough. This needs to be corrected.

Repair of Turbine and Alternator Shaft
                    Repair of Turbine and Alternator Shaft

RA Power Solutions undertake grinding and polishing of crankshaft, rotor shaft, turbine shaft, alternator from last 4 decades. We are the leaders in extending the grinding and repair services. The main features of turbine, alternator, rotor shaft grinding and polishing are as following:

I) Initial inspection of turbine, alternator, and rotor shaft is undertaken by experienced technicians. They carry all latest instruments to check dimensions, hardness, surface roughness, crack detection, taper and ovality. It is of great importance that proper inspection by Qualified and Experienced Engineer is conducted.

II) Latest breed of turbine, alternator, rotor shaft grinding and polishing equipment is available with us having capacity up to 700 mm diameter.

Grinding & Repair of Crankshaft After Major Accident
Grinding & Repair of Crankshaft After Major Accident

III) Onsite grinding and polishing equipment used by RA Power Solutions is light and compact. Easy to carry to site and can be fitted on the damaged diameter of turbine, alternator and rotor shaft. It is important as minimum dis assembly of the parts is required.

IV) The turbine, alternator, rotor shaft grinding equipment is capable of maintaining close tolerance even up to 20 microns with surface finish of 0.15 Ra value which is far better then the international standard.

V) All the repairs of turbine, alternator, and rotor shaft are executed with guarantee.

RA Power Solutions also manufactures new white metal Babbitt bearing up to 1500 mm and rebabbitting of old bearings which get worn out or damage is done.

Grinding of RotorShaft
Grinding of RotorShaft
Grinding of Main Journal on Board a Vessel
Grinding of Main Journal on Board a Vessel

Crankshaft Grinding Services by Experienced Technicians

RA Power Solutions provides onsite crankshaft grinding services for last four decades. Crankshaft having diameter up to 700 mm is repaired onsite without removing the crankshaft from the engine block.Crankshaft Grinding Services by Ra Power Solutions

The grinding of crankshaft onsite is possible by introduction of onsite crankshaft grinding machine which is portable, light weight and can be inserted from the inspection window of the engine block. RA Power Solutions also manufactures and sells crankshaft grinding machine. The crankshaft grinding services are offered by us through our technicians who are well trained in our workshop and have experience of providing crankshaft grinding services for last 30 to 35 years. After repair of crankshaft, the dimensional tolerances are maintained within 20 to 30 microns and surface finish as per the international standards.

Prior to undertaking grinding of crankshaft, all the major parameters of crankshaft i.e. dimensional inspection, hardness test, crack detection, deflection, etc. are checked.

In case the basic parameters are found within the repair limits, crankshaft grinding is undertaken. RA Power Solutions can maintain the tolerances strictly as per the manufacturer’s recommendations. With the introduction of latest design of onsite crankshaft grinding machine the vibrations in the crankshaft grinding machine are reduced to minimum. This ensures maintenance of close tolerance and also facilitates grinding of crankshaft on board a vessel while it is sailing in high seas. The grinding of crankshaft while sailing of the vessel results to the considerable saving to the owners.
Crankshaft Grinding Machine Undertaking Grinding on Vessel   Repair of Crankpin is in Process by RA Power Solutions   Repair of Crankshaft on Board a Vessel

Cylinder Liners and Cylinder Sleeves

Cylinder liner and cylinder sleeve is a critical component of diesel engine.

Cylinder Liner of Wartsila 12V32
Cylinder Liner of Wartsila 12V32

The selection of material composition of cylinder liner and cylinder sleeve is done based on the capacity of the engine, load characteristics, RPM, type of lubrication used and various other technical aspects.

We manufacture and export cylinder liners for all popular make and model of diesel engines, compressors, hammers and mechanical equipments. We have the facility to manufacture the cylinder liner and cylinder sleeve up to the length of 1500 mm.

The cylinder liner and cylinder sleeves is developed and manufactured based on the drawing or sample of the cylinder liner provided by the user. We also maintain large stock of cylinder liners.

Cyliner Liners After Honing Process
Cyliner Liners After Honing Process

The cylinder liners manufactures by us are cast by centrifugal process. We have developed comprehensive machining facilities which include use of CNC and centerless grinding machines. The final honing operation of cylinder liner and cylinder sleeve is done by Chris Marine Honing Machines which provide accurate cross hatch angle, correct taper, plateau honing.

We stand guarantee for the satisfactory performance of the liners and are priced lowest in the industry.

Cylinder Liner of MAK Engine
Cylinder Liner of MAK Engine
Cylinder Liners Ready for Reconditioning
Cylinder Liners Ready for Reconditioning

Crankshaft Grinding and Crankshaft Repair by Experienced Technicians

Crankshaft grinding and crankshaft repair are important for satisfactory performance of engine. RA Power Solutions Pvt. Ltd. has been undertaking crankshaft repair onsite by portable, light weight crankshaft grinding machine. The crankshaft repair is executed of crankshaft diameter ranging from 60 mm to 700 mm.

We have team of trained and dedicated technicians who are deputed to the site with crankshaft grinding machine along with necessary instruments. The crankshaft repair is undertaken without removing the crankshaft from the entablature.

The crankshaft grinding machine used to undertake crankshaft repair is of latest design having minimum vibrations. This facilitates our technicians to undertake crankshaft repair even while the vessel is sailing. The tolerance after crankshaft grinding and crankshaft repair is maintained within 10 to 20 microns in terms of taper and ovality.

Crankshaft Repair is in Process
          Crankshaft Repair is in Process

The repair of crankshaft and overhauling of engine while sailing of the vessel between two ports results to the considerable saving to the ship owners as there is no need of holding the vessel at port or anchorage.

The crankshaft repair executed by us is guaranteed for the satisfactory performance. As on date we have executed more than 10,000 repair of crankshaft all over the world.

Crankshaft Grinding of MAN Diesel Engine
Crankshaft Grinding of MAN Diesel Engine
Crankshaft Grinding of Wartsila Diesel Engine
Crankshaft Grinding of Wartsila Diesel Engine

 

 

 

 

 

 

 

For more information, please email us on info@rapowersolutions.com or call us on +91 – 124 – 437 8292 , +91 9213604692