Insitu Crankpin Grinding | Crankpin Repair | Marine and Industrial Engine

RA Power Solutions undertake crankpin polish and crankpin grinding of crankshaft for four stroke and two stroke for marine and industrial diesel engines.

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.

Damage Crankpin of Wartsila 12V32
Damage Crankpin of Wartsila 12V32
Insitu Crankshaft Grinding Machine from Crankcase Window
Insitu Crankshaft Grinding Machine from Crankcase Window

 

 

 

 

 

 

 

 

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.

Inspection and Grinding of Crankpin of Wartsila Engine is in Process
Inspection and Grinding of Crankpin of Wartsila Engine is in Process

 

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.

II) Engine block repair by metal stitching and metal locking, line boring and other process.

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.

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

Grinding of Crankpin Under Process
Grinding of Crankpin Under Process
Finished Crankpin of Wartsila Engine After Onsite Grinding
Finished Crankpin of Wartsila Engine After Onsite Grinding

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

Lock and Stitch Cast Iron Repair by RA Power Solutions Pvt. Ltd.

Repair of cracks developed in commonly used industrial castings and metal is possible to repair by cold method called lock and stitch. It is also known as metal stitching and metal locking. In case of cast iron equipments and parts damaged in to pieces.

Crack Repair by Lock and Stitch Method
Crack Repair by Lock and Stitch Method

RA Power Solutions Pvt. Ltd. undertakes repair by lock and stitch process which is cold method as no heat is generated. Crack repair by lock and stitch method in cast iron is proved to be of great success in comparison to the crack repair by welding.

In case of critical cast iron components like engine block, main journal housings, cylinder heads, turbine casings crack repair by metal stitching is highly recommended as it does not develop any misalignment of the casting or shrinkage. We undertake crack repair of cast iron for last more than 37 years on time, within budget and with experienced technicians.

Cast iron repair by metal stitching and metal locking process have following main advantages

I) Repair of broken casting or crack developed in casting irrespective of its length is possible on site without dismantling the equipment.

II) Saves replacement of parts or equipments in totality and reduces downtime.

III) Cast iron repair by metal stitching and metal locking is the only process which restores strength in cast iron beyond the original casting.

IV) Metal stitching and metal locking is the only method known to be successful in replacing of the large pieces of broken casting with new piece.

V) Metal stitching and metal locking is the process which caters to heavy industry.

RA Power Solutions Pvt. Ltd. is the only company which can undertake crack repair by Lock and stitch method while vessel is sailing.

Complete Piece Replaced by New Casting
Complete Piece Replaced by New Casting
Engine Block of MAN Diesel Engine Broken Ito Pieces
Engine Block of MAN Diesel Engine Broken Ito Pieces

 

Metal Stitching of Forging Press - Crack Measuring 230 inches
Metal Stitching of Forging Press – Crack Measuring 230 inches
Repair of Engine Block of Yanmar Engine on Vessel
Repair of Engine Block of Yanmar Engine on Vessel

Lock and Stitch Cast Iron Repair

Heavy castings like turbine casing, gearboxes, engine block, heads and heavy cast iron parts  need not to be disassembled in case of development of crack in casting or breakage of casting in to pieces due to accident.

Cold metal stitching and metal locking process is used to repair cracks in cast iron. The process of crack repair by metal stitching and metal locking does not require any welding and generation of heat. The time has proved that the crack repaired in casting by metal stitching and metal locking is far stronger and more durable in comparison to the repair of crack by welding process.

Repair of Broken Casting by Metal Stitching Process
Repair of Broken Casting by Metal Stitching Process
Broken Engine Block of Yanmar Engine
Broken Engine Block of Yanmar Engine

In most of the cases crack repair in casting is possible onsite and there is no need of transporting the heavy cast piece to the workshop. RA Power Solutions Pvt. Ltd. undertakes crack repair by metal stitching and metal locking process for last more than 3 decades and have executed number of repairs successfully all over the world.

RA Power Solutions Pvt. Ltd. is the first company which can undertake repair of high capacity engine blocks, turbine casings, cylinder heads and all cast parts installed on the vessel while it is on move.

Assembly of Broken Pieces of Engine Block
Assembly of Broken Pieces of Engine Block
Metal Stitching of Engine Block in Process
Metal Stitching of Engine Block in Process

 

 

 

 

 

 

 

The lock and stitch cast iron repair executed by us is guaranteed for satisfactory performance. We are cost effective and priced lowest in the industry.

Metal Stitching and Metal Locking of Engine Block
Metal Stitching and Metal Locking of Engine Block
Engine Block After Repair
Engine Block After Repair

Metal Locking and Metal Stitching

Metal locking and metal stitching is a process of repair of cast metals having different metallurgy without the necessity of wielding. Metal locking and metal stitching is a cold and proven method of repair of cast iron and cast steel components.

The advantage of crack repair and broken casting by metal locking and metal stitching is that it can be carried out at the site anywhere and it even does not require dismantling of the equipment in most of the cases this results to the considerable saving of time and money. Crack and broken casting repair by metal stitching and metal locking is proven and is old method for crack repair it is widely used for heavy duty plant and equipment, ship engine, heavy duty forging presses, etc.

Metal Stitching of JIBB Plate of 225 Ton
                                            Metal Stitching of JIBB Plate of 225 Ton
Repair by Metal Stitching Process
                                                       Repair by Metal Stitching Process

We regularly execute crack repair by metal locking and metal stitching of following parts:

Engine Block, Cylinder Head, Generators, Turbo Chargers, Turbine Casing, Gear Box Housing, Pump Casings, Compressor Crank Cases ,Forgings Hammer, Lathe / Press/ Milling/Boaring etc .M/c. all Cast Equipments etc.

Metal Stitching and Metal Locking of Engine Block

Engine blocks, casting and most of the parts are manufactured of common material like cast iron. Cracks developed in cast iron parts are most difficult to undertake repair by welding process as it needs pre-heating of the cast iron prior to the welding. In certain cases it can cost additional stresses resulting to the damage of casting.

Material Used in Metal Locking and Metal Stitching Process
                                  Material Used in Metal Locking and Metal Stitching Process

It is proven that metal stitching and metal locking has advantage of repairing cracks in cast iron casting due to cold process using different profile and material of stitching pins and locks without applying any heat as in case of welding.

RA Power Solutions Pvt. Ltd. undertakes metal stitching and metal locking of casting and has successfully repaired various major components of high capacity diesel engine.

Application includes repair of Engine Block, Cylinder Head, Generators. Turbo Chargers, Turbine Casing, Gear Box Housing,     Pump Casings, Compressor Crank Cases ,Forgings Hammer, Lathe / Press/ Milling/Boaring etc .M/c. Other all Casting Equipments etc. 

In last 36 years more then 650 jobs of crack repair have been successfuly   executed.

Stitching Pin Used in Metal Stitching Process
Stitching Pin Used in Metal Stitching Process
Metal Stitching Done in Broken Area of Generator
             Metal Stitching Done in Broken Area of Generator

 

Metal Stitching of Crack Casting

In case of crack developed in casting of mechanical equipments the repair of metal stitching and metal locking is proved to be the best and successful process. In case of engine block and turbine casings, heavy castings is used in mechanical equipments. It is quite difficult to replace them due to cost, time factor and interchangeability issue.

Metal Locking of Wartsila Diesel Engine
Metal Locking of Wartsila Diesel Engine

The repair of cracks by metal stitching and metal locking is a cold process. No heat is generated and the same original profile is maintained. In case of cracks developed in housing of engine block, the crack repaired by metal locking and metal stitching is highly recommended as there is no distortion in the central line of the housing takes place.

Metal Stitching of Jenbacher Engine Block
Metal Stitching of Jenbacher Engine Block
Metal Stitching of Jenbacher Engine Block Under Process
Metal Stitching of Jenbacher Engine Block Under Process

RA Power Solutions have experienced technicians to undertake metal stitching and metal locking process with guarantee.