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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.