Crankshaft Repairing Services Providers in India. We have experience of about four decades in crankshaft grinding, engine repairs, and maintenance. While in operations we have repaired over 10,000 crankshafts of Main and Auxiliary engines.
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 email@example.com
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.
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.
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.
Crankshaft is the heart of every engine. It is estimated that the cost of crankshaft is almost 30 to 35% of the total cost of engine. RA Power Solutions considers and treats every crankshaft with the greatest attention. The inexpertly ground crankshaft can lead to the failure of bearing and crankshaft in totality causing considerable damage and loses to the owners.
RA Power Solutions undertakes onsite crankpin grinding and crankpin polishing in one setting. The portable, light weight onsite crankshaft grinding machine is taken to the site. The crankshaft grinding machine is designed in such a way that it can undertake the crankshaft machining, crankshaft grinding and crankshaft polishing in one setting.
The forty years experience of our company and staff guarantees machining, grinding and polishing of crankshaft to the highest professional standards strictly in accordance to the tolerances stipulated by the manufacturers. Our experience of working on crankshaft and the trust of our clients have resulted to successfully repair of more than 10,000 crankshafts Worldwide
The services of crankshaft grinding and crankshaft polishing are extended for all the applications including forging hammers, marine and industrial.Our location in India gives us an opportunity to serve our clients in Middle East Asia and European countries.
Technician’s having Indian CDC can sail on the vessel and can execute the repairs. The main advantage of availing RA Power Solutions services is not only limited to the availability of experienced technicians but all the repairs like metal stitching, repair of major parts, dismantling and overhauling of DG sets is also offered.
We stand guarantee for all the jobs executed by us for successful repair of the engine in totality.
We work on medium and high capacity diesel engines having capacity of more than 400 KW. In terms of diameter we can undertake crankpin polish and crankpingrinding onsite for the diameters ranging from 60 mm to 700 mm.
Crankshaft Grinding and Polishing with Highest Precision
The crankpin grinding and crankpin polishing for marine and industrial application is undertaken by onsite crankshaft grinding machine. The diameter, surface finish and all parameters are maintained strictly as per the manufacturer’s specifications. Each job of crankpin polishing and crankpin grinding is executed with the greatest care because inexpertly repair of crankshaft can lead to the premature failure of the bearing causing considerable consequential damage. In fact with four decades of experience in the field of crankshaft grinding and crankshaft repair our experts technicians guarantee machining of crankshaft to the highest professional standards.
Cost Effective Crankshaft Grinding Services
In spite of constantly executing the repairs as per the OEMs standards with the highest quality demand we as an Indian company are considered to be the lowest price wise in comparison to the companies based in Europe, Singapore and other countries. We have executed successfully repair of over 10,000 crankshafts which is a testimony of confidence on us by clients based all over the world.
Services Related to Repair and Overhauling of Engine
RA Power Solutions offers all the services related to repair and overhauling of medium and high speed engines which includes following:
I)Insitu crankshaft repair, crankshaft grinding and crankshaft polishing up to 700 mm diameter.
III) Repair of major parts like cylinder heads, connecting rods, cylinder liners, etc.
IV) Repair and overhauling of diesel engines
All the repairs and services offered by RA Power Solutions are supported with guarantee.
We extend services all over the world including Nigeria, Singapore, Indonesia, Germany, Taiwan, Belgium, Korea, Ecuador, Brazil, Mexico, Myanmar, Greece, Spain, Finland, Netherlands, Oman, Dubai, Iran, Egypt, Russia, Philippines etc.