The repair of crack and repair of damaged casting by welding process is now completely outdated and is not recommended for repair of damaged cast metal and cast iron parts.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.
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.
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.
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.
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 was recently approached by a diesel power plant based in South America having Wartsila 12V32 and Wartsila 18V32 diesel generating sets.
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.
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
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.
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.
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.
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.