Cast Iron Repairs | Cracked Engine Block Repair | Damaged Engine Bedplate Repairs | Metal Stitching – RA Power Solutions

The repair of a damaged engine block, turbocharger casing, heavy cast iron parts can be successfully repaired by metal stitching, metal locking, and metal surgery process.

The repair of crack and repair of damaged casting by welding process is now completely outdated and is not recommended for repair of damaged cast metal and cast iron parts. In fact, it is observed that in certain cases repair by welding results in more serious damage due to the generation of heat and stress during the process of welding. RA Power Solutions have been undertaking repairs of the damaged engine block, steel components repair, cast iron repairs and all types of cast components by metal stitching and metal locking process for last four decades.

Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump Repairing
Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump Repairing
Broken Suction Bell Mouth of CW Pump
Broken Suction Bell Mouth of CW Pump

 We have a separate and dedicated team of technicians who have the capability to undertake the onsite repair of crack and damage casting by using portable tools and high-quality consumables (locks and keys ) which are imported by us from UK.
Broken Area of Engine Block
Broken Area of Engine Block

 

Engine Block After Metal Stitching and Metal Locking
Engine Block After Metal Stitching and Metal Locking

 

 

 

I) It is possible to undertake crack repair and repair of damage casting by metal stitching and metal locking process onsite. Hence there is no requirement of transporting the crack or damage components to the workshop.

II) In most of the cases, there is no requirement of dis assembly of equipment.

III) We possess portable tools to execute the repairs on site.

IV) The time duration for repair of crack and damaged cast components by metal lock and metal stitching is low.

V) Metal Stitching and Metal Locking is a permanent crack repair method as no heat is generated which is associated with welding.

VI) The crack and damaged area after repair by metal locking and metal stitching process are restored to its original profile and are also recommended  for gas or watertight repair.

VII) Repairs are undertaken with the guarantee.

Metal Surgery under Process while Vessel is Sailing
Metal Surgery under Process while Vessel is Sailing
The repair by metal stitching and metal locking process can be undertaken of cast iron, aluminum parts including the following :

I) Damaged turbocharger casing.
II) Pump casing and gearboxes.
III) Cracked engine block, cam covers, cylinder liners, turbine casings, and all components.
IV) Heavy industrial and mining equipment.

For detailed repair process of damaged casting by metal locking and metal stitching, email us on info@rapowersolutions.com

Overhauling of Main Engine Repair | Repair of Engine Metal Stitching of Damaged Block- RA Power Solutions

RA Power Solutions received an emergency call from a Steel Company based in Indonesia regarding damage of their Engine SULZER 6RND68.

On arrival of our team of engineers, it was observed that lower engine block of SULZER 6RND68 was damaged badly. Hence it required disassembly of complete engine, overhauling & repair of engine block by metal stitching & metal locking.

Overhauling of Main Engine
Overhauling of Main Engine

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.

Damaged Engine Block
Damaged Engine Block
Repair of Engine Block by Metal Stitching is in Process
Repair of Engine Block by Metal Stitching is in Process
Special Keys & Locks Used in Metal Stitching Process
Special Keys & Locks Used in Metal Stitching Process

 

 

 

 

 

 

 

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.

Repair & Overhauling of Engine is in Process
Repair & Overhauling of Engine is in Process
Inspection of Engine Spare Parts is in Process
Inspection of Engine Spare Parts is in Process

Onsite Crankshaft Grinding | Crankshaft Repair | Crankshaft Polishing and Grinding – RA Power Solutions

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.

Crankshaft Grinding Wartsila 18 V32
Crankshaft Grinding Wartsila 18 V32

The Benefits:

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.

Insitu Crankshaft Grinding
Insitu Crankshaft Grinding

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.

V.) Machining and polishing of Crankshaft and Crankpin are carried to OEM tolerances and surface finish specifications.

VI.) We cover standard Crankshaft diameter ranging from 30 mm to 700 mm.

VII.) Our patented orbital equipment rotates around damaged crankpin journal using the radius as a datum.

VIII.) We can also Hone and Polish your crankpin if the damage is slight or you just want to improve the surface finish up to 0.3 micron Ra Value.

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Onsite Crankshaft Grinding
Onsite Crankshaft Grinding
Repir ofCrankshaft MAN B& W
Repir of Crankshaft MAN B& W

Crankpin Grinding | Crankpin Repair – Get it Executed by Experts – RA Power Solutions

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.

Onsite Crankpin Grinding and Crankpin Polishing
Onsite Crankpin Grinding and Crankpin Polishing

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.

Damaged Crankpin of Marine Engine
Damaged Crankpin of Marine Engine
Onsite Crankshaft Grinding Machine - Grinding Crankpin on Board a Vessel
Crankshaft Grinding Machine – Grinding Crankpin on Board a Vessel

 

 

 

 

 

 

 

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.

For more information, please email info@rapowersolutions.com or call us on +91-9582647131

Finished Crankpin After Grinding
Finished Crankpin After Grinding
Grinding of Crankpin is in Process
Grinding of Crankpin is in Process

Repair of Damaged Engine Block – RA Power Solutions

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