We undertake onsite crankshaft grinding and crankshaft engine repair, maintenance and overhauling of diesel engine and various other services with a guarantee and have been providing services to companies based in Qatar, Singapore, Maldives, South America, Greece, Indonesia, Dubai, Maldives, Sri Lanka etc.
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.
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.
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
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
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.
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.
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…
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
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.
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.
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…
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
IV) Customized tooling adapting to all makes of engine and models. Machine available in the range of 60 mm to 700 mm.