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

The concept of onsite repair of crankshaft is getting popular with the introduction of a portable lightweight on-site crankshaft grinding machine. Now it is possible to undertake crankshaft repair, crankshaft grinding and polishing on site without dismantling of the crankshaft from the engine.

On-site Crankshaft Repair, Crankshaft Grinding, and Crankshaft Polishing costs low with minimum downtime and inconvenience as it does not require removal of crankshaft from the engine block, packing and transportation to the designated workshop for repair by grinding or polishing process

Advantage of trusting RA power solutions

  • First company based in Asia having experience of four decades in Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing

  • All repairs of crankshaft and process followed for grinding of crankshaft and polishing of crankshaft are approved by class agencies of repute like DNV, Lloyds and various inspecting organisations spread all over the world

  • The repair of crankshaft is executed with a guarantee for the satisfactory performance, the pre and final inspection reports before and after grinding and polishing crankshaft are submitted

  • Technicians executing the repair of crankshaft onsite are highly skilled, trained in our factory on a dummy crankshaft in order to understand the techniques for successful repair of the crankshaft. Some of our technicians have experience of more than 45 years.

  • The onsite inspection and polishing of crankshaft repair is recommended to enhance the life of crankshaft and bearings

  • RA power solutions offers and undertakes inspection and polishing of crankshaft on board a vessel on a nominal cost

  • During our working of four decades on diesel power plant, shipping companies we have undertaken Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing number exceeding more than 10,000

Conclusion:

RA power solutions has team of technicians with valid CDC from Panama, Palau, and India and can travel all over the world within a short notice

On site crankshaft grinding
On-Site Crankshaft Grinding
Crankpin grinding and polishing
Crankpin grinding and Polishing
On-site crankshaft repair
On-site crankshaft repair

On-Site Crankshaft Grinding Machine | Crankshaft Polishing Machine – RA Power Solutions

Crankshaft grinding machines are designed to maintain the accurate tolerances as per the engine manufacturer’s recommendation

Generally, it is observed that even for the higher diameter of crankpin and main journal of the crankshaft the tolerances do not exceed more than 0.05mm in order to achieve such close tolerances of crankpin and main journal of crankshaft RA power designs and manufactures on-site crankshaft grinding machine which has the capability to maintain the close tolerance of even 0.01mm/0.02mm which is far better than the close tolerance specified by the engine manufacturers.

The on-site crankshaft grinding machine and crankshaft polishing machine manufactured by RA power solutions has the following features:

    1. Crankshaft grinding machine is designed in a way that it can be inserted from the inspection window of the engine block thus there is no need of removal of the crankshaft from the engine block.

    2. In case of space restrictions, RA power has the capability to design the equipment according to the space available on site for grinding or polishing of crankshaft/turbine/alternator shaft/rotor shaft etc…

    3. The on-site crankshaft grinding machine is lightweight portable and can be easily carried to the site all over the world. The crankshaft grinding  machine is packed in the suitcase and is carried as accompanied baggage accepted by all international airlines

    4. The main body of crankshaft grinding equipment is manufactured out of titanium alloy which is lightweight and can absorb the vibrations this feature of crankshaft grinding machine facilitates RA power technicians to undertake crankshaft repair on board the vessel while it is sailing, maintaining the close tolerances within 20 microns.

    5. Crankshaft grinding machine designed and manufactured by RA power can presently work up to 700mm diameter which we are in process of extending up to 1000mm.

Conclusion

RA power has sold more than 70 crankshafts grinding machines all over the world which are performing satisfactorily the cost of the machine is low and is affordable for repair workshop, shipping company, power plants etc…

 Crankshaft grinding machine for repair and grinding
Crankshaft grinding machine for repair and grinding
Crankpin grinding on board the vessel
Crankpin grinding on board the vessel
Crankshaft Grinding Machine for Small Diameter
Crankshaft Grinding Machine for Small Diameter

 

Cast Iron Crack Repair By Metal Stitching – RA Power Solutions

Steam turbine casing of Hangzhou make was reported damaged due to accident. The turbine operates at 130 MW peak load.

RA Power solutions deputed technician to the site with latest breed of instruments, equipments and consumables in order to undertake inspection of the turbine casing and to execute necessary repair following observation was made.

Observation-

Turbine casing due to accident developed multiple cracks at different locations. Crack of following dimensions were observed

  • Crack having a length of 190mm with indiscipline profile

  • 2 Cracks having length of about 300mm

  • Casting having dimensions of 600mm/450mm with thickness of 45mm was damaged into pieces

Crack repair by Metal lock and Metal stitching.

Crack Repair and damaged casting replacement was under taken by RA power technicians.

    • The damaged casting area was cut and disciplined profile was given measuring 650mm/520mm this area was properly ground

    • The damaged sample piece was sent for metallurgical test to know the composition of material.

  • A wooden pattern was made at site having an exact profile as of damaged area

    • A new casting piece having superior metallurgical properties then the original damage casting was manufactured

  • The new casting piece was fixed in damage area by metal stitching and metal locking process

    • RA power engineers used metal locks, metal keys and all consumables’ imported from UK for repair of cracks and damage casting

  • The polishing of outer and inner surface of damaged area was done and painted

  • The turbine is presently working satisfactory and has completed 3500hr of operation.

RA power under takes repair of crack casting by metal stitching and metal locking process from last 40 years and have executed successfully repair of heavy components used in power plants, industry, ships etc…

The metal stitching and metal locking can also be undertaken while sailing of the vessel.

Turbine casing
Turbine Casing
Damaged turbine casing
Damaged turbine casing
Turbine casing after repairs
Repair of casing by metal lock and metal stitching
Turbine casing after repairs
Turbine casing after repair

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

Onsite Crankshaft Grinding Machine | Insitu Crankshaft Polishing and Grinding Machine | Crankshaft Machining – RA Power Solutions

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.

Portable Crankshaft Grinding Machine
Portable Crankshaft Grinding Machine

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.

III.) The Insitu Crankshaft Grinding and Polishing Machine is user friendly and can be operated by any person having basic machining knowledge.

IV.) The Machine is capable and is designed to maintain the close dimensions and Geometrical tolerances as per the manufacturers requirement.

Onsite Crankshaft Grinding Machine Ready for Dispatch
Onsite Crankshaft Grinding Machine Ready for Dispatch
V.) Presently Onsite Crankshaft Grinding Machine is manufactured for the diameter of the Crank-pin and Main Journal of the Crankshaft ranging from 30 mm to 700 mm.

 

VI.) Crankshaft Grinding Machine is manufactured out of Titanium Alloy which is light Weight and can be easily carried to the Site.

 

VII.) The Machine is capable of working on a Vessel while it is moving.

VIII.) Training forms an Integral part of the Crankshaft Grinding Machine. Training onsite is provided.

 IX) We have sold more than seventy machines all over the world and are priced cheapest in the International Market.

 

Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter
Onsite Grinding Machine for Small Diameter

 

For more details, please email us on info@rapowersolutions.com or visit our website http://www.rapowersolutions.com/onsite-crankshaft-grinding-machine.aspx

Crankshaft Repair | Crankshaft Grinding | Onsite Crankshaft Machining – RA Power Solutions

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.

Damaged CrankPin of Mirrlees Blackstone Engine
Damaged CrankPin of Mirrlees Blackstone Engine
Inspection of Crankpin Under Process
Inspection of Crankpin Under Process

 

 

 

 

 

 

 

 

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.

Field Instruction for Crankshaft Rehabilitation of Mirrlees Blackstone Engine
Field Instruction for Crankshaft Rehabilitation of Mirrlees Blackstone Engine

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.

RA Power Solutions undertakes Crankshaft Repair, Crankshaft Grinding and offer Onsite Crankshaft Machines to the repair companies.

Grinding of Crankpin is in Process
Grinding of Crankpin is in Process by RA Power Solutions

Note: The writer of this article is Mr Raj Shahani, Managing Director of RA Power solutions Pvt Ltd.

Website: http://www.rapowersolutions.com/ and he is instrumental in saving  number of Crankshafts from rejection.

Grinding & Repair of Crankpin is in Process
Grinding & Repair of Crankpin is in Process
Finished Crankpin after Grinding & Repair
Finished Crankpin after Grinding & Repair

Crankshaft Grinding Machine- Mobile Machining of Crankshaft – RA Power Solutions

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.

Portable Crankshaft Grinding Machine
Portable Crankshaft Grinding Machine
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.

Crankshaft Grinding Machine Packed For Dispatch
Crankshaft Grinding Machine Packed For Dispatch
Crankshaft Grinding Machine Accessories Packed for Dispatch
Crankshaft Grinding Machine Accessories Packed for Dispatch

IV) Customized tooling adapting to all makes of engine and models. Machine available in the range of 60 mm to 700 mm.

V) Onsite grinding of crankpin and main journal is possible with this grinding tool.
VI) Onsite Crankshaft Machine is easy to operate and training is provided.

VII) Machine body is made from titanium which results to the minimum vibration while in operation. Machine can be used on vessel while sailing.

The company has sold more than 70 machines all over the world. It is highly recommended for repair workshops, power plants, shipping and engineering companies.

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

Grinding of Crankshaft on a Moving Vessel
Grinding of Crankshaft on a Moving Vessel
Grinding of Crankshaft in a Power Plant by Crankshaft Grinder
Grinding of Crankshaft in a Power Plant by Crankshaft Grinder
Grinding of Crankshaft on VBlock by Crankshaft Grinding Machine
Grinding of Crankshaft on VBlock by Crankshaft Grinding Machine

CKD Skoda Engine Bearings Manufacturer | Exporter– RA Power Solutions

CKD Skoda engines of different capacities are installed all over the world for various applications. Since last two decades the production of CKD Skoda engines and spare parts is stopped causing inconvenience to the CKD Skoda DG sets installation. RA Power Solutions manufactures white metal and tri metal bearings of crank-pin and main journal for all models of CKD Skoda engines. The bearings are manufactured in a modern workshop having latest breed of equipment following the advance technology and process.

CKD (SKODA) Engine Bearings
CKD (SKODA) Engine Bearings

The experience of four decades in dealing in CKD Skoda generators and spares has helped us in developing and manufacturing CKD Skoda spare parts of a quality which is far superior to the OEMs. This is acknowledged by the companies based in Czech Republic importing container loads of bearings, cylinder liners, and various spare parts from RA Power Solutions.

Inspection of Engine Bearings
Inspection of Engine Bearings
CKD SKODA Bearings
CKD SKODA Bearings

 

 

 

 

 

Each part of CKD Skoda engine exported by RA Power Solutions is subject to stringent quality control norms followed by us. We are priced lowest in the world.

CKD Skoda engine bearings, cylinder liners and various spare parts are readily available in stock and are exported worldwide for following models of CKD SKODA engines:

 OUTPUT (kVA)  FREQUENCY (Hz)  VOLTAGE (V) DIESEL ENGINE  RPM
 405  50  400/231  6S275III  600
 405  50  400/231  6-27,5 A0S  600
 500  50  400/231  6S275PN  500
 608  50  400/231  6S275IIIPN  600
 608  50  400/231  6-27,5 A2S  600
 825  50  400/231  6S275IIIPV  600
 825  50  400/231  6-27,5 A4S  600
 860  50  400/231  6S350PN  375
 860  50  6300  6S350PN  375
 860  50  11000  6S350PN  375
 1525  50  6300  9S350IIPS  375
 1525  50  11000  9S350IIPS  375
 1525  50  6300  9TS35/50-2  375
 1525  50  11000  9TS35/50-2  375
 1600  50  400/231  6-27,5 B8S  750
 1600  50  6300  6-27,5 B8S  750
 1600  50  11000  6-27,5 B8S  750
 2140  50  6300  6-27,5 B8S  750
 2140  50  11000  6-27,5 B8S  750
 2270  50  6300  6-38 A6S  500
 2270  50  11000  6-38 A6S  500

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

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

Insitu Crankpin Grinding | Crankpin Repair | Marine and Industrial Engine – RA Power Solutions

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