Crankshaft Repair on Board a Vessel by Experienced Engineers

RA Power Solutions Pvt. Ltd. can easily undertake crankshaft repair on board a vessel while it is sailing by using special equipments.

We can undertake crankshaft repair up to the diameter of 700 mm while the vessel is sailing in high seas in anchorage or at berth. This result to considerable saving for ship repairs as no time is wasted for crankshaft repair as it does not require any anchorage or berth.

Damaged Crankpin of MAN Marine Diesel Engine
Damaged Crankpin of MAN Marine Diesel Engine
Crack Detection by MPI Before Grinding
Crack Detection by MPI Before Grinding

 

 

 

 

 

 

RA Power Solutions having 37 years of experience have executed more than 10,000 jobs of repair of crankshaft successfully which is a record.

Crack Detection of Crank Pin
Crack Detection of Crank Pin
Crankshaft Repair Under Process
Crankshaft Repair Under Process

 

 

 

 

 

 

 

The crankshafts which have been even rejected by the manufacturers are successfully repaired by us using various process/special equipments which we are learned from our experience. All the repair of crankshaft executed by us is guaranteed for the satisfactory performance. The tolerances as stipulated in the manual are strictly maintained.

Most of our technicians have seaman book and they can sail to any part of the world.

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

Crankshaft Repair in Low Cost

RA Power Solutions Pvt. Ltd. provides crankshaft repair without dismantling of crankshaft from the engine block.

The crankshaft repair on site is cost effective with minimum downtime.

We are Indian company based in New Delhi with 37 years of experience in repair of crankshaft. We are cost effective and considered to be most experienced organization. The crankshaft repair of large industrial engine, marine engine, compressor and rotatory equipments is executed irrespective of its location. We are equipped with latest design of crankshaft repair machines which are compact and light weight.

Crankshaft Grinder
Crankshaft Grinder

 

Portable Crankshaft Grinder
Portable Crankshaft Grinder

 

 

 

The crankshaft repair grinders have minimum vibrations, thus the close tolerances of crankpin and main journal diameter can be maintained after grinding and polishing

Crankshaft Repair On Land, Anchorage or at Sea

Crankshaft Repair On Land, Anchorage or at Sea
                       Crankshaft Repair On Land, Anchorage or at Sea

Crankshaft repair services up to diameter of 700 mm are extended for land based engine, vessel on anchorage or vessels on move in high seas. Our technicians are trained and experienced to work in any condition with the latest design of crankshaft grinder.

Crankshaft Repair
                        Crankshaft Repair

The onsite repair of crankshaft considerably reduces the cost of repairs, reduces the downtime when every minute of breakdown means a lot of inconvenience and loss of revenue. Crankshaft repair covers following activities:

I) Crankshaft Straightening

II) Main Bearing Journal grinding/ Polishing/Superfinishing

III) Crankshaft Grinding/ correction of lub oil and radius profile

IV) Crankshaft Journal Repair

V) Orbital Crankpin Machining/Regrinding

Crankshaft Repair on Land.
Crankshaft Repair on Land.

VI) Crankshaft Keyway Repair

VII) Main Bearing Machining

VIII) Crankpin inspection ie hardness, crack check etc

IX) Crankshaft Polishing

X) Crankshaft peening

XI) Main Bearing Regrinding

XII) Crankshaft Machining

Crankshaft Repair of Hyundai Diesel Engine
Crankshaft Repair of Hyundai Diesel Engine
Crankshaft Repair on Anchorage
Crankshaft Repair on Anchorage
Crankshaft Repair While Vessel on Move
Crankshaft Repair While Vessel on Move
Before and After Grinding of CR Pin
Before and After Grinding of CR Pin

High Quality Marine Engine Spares

RA Power Solutions Pvt. Ltd. provides engine repair services for last 37 years to shipping industry and diesel engine driven power plants.

Marine Engine Spares
Marine Engine Spares

Our expertise is in repair of high value spare parts onsite like crankshaft, cylinder heads, cylinder liners, connecting rods and other marine engine spares.

We manufacture and supply diesel engine spare parts and supporting equipment for all reputed make of marine engine like MAN-B&W, Sulzer, Wartsila, Mak, Deutz, Pielstick, Mitsubishi, Nohab, Daihatsu, Yanmar, Bergen, Crepelle, Niigata, Himsen, Allen, Stork, MWM, Hanshin, Caterpillar, Ruston, Paxman, Mirrlees, Alco, Fiat, ABC, Crepelle, SKL , etc

Fresh Water Generator
Fresh Water Generator
Cylinder Head
Cylinder Head

 

 

 

 

 

Reconditioned marine engine spare parts are also supplied by us including crankshaft, cylinder heads, cylinder liners, connecting rods, piston rods, camshafts, etc. with guarantee as ours is the only company having 37 years of experience undertaking the reconditioning of spare parts by highly skilled technicians using modern equipments.

Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions
Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions
M453AK Cylinder Head
M453AK Cylinder Head

 

 

 

 

 

 

We also export marine engine spares and supporting equipment like fresh water generator, heat exchanger gaskets, electric motors, etc. to various countries like Qatar, Dubai, South America, Indonesia, Singapore, UK, Germany, Norway, etc.

Cylinder Liners for Wartsila Diesel Engine
Cylinder Liners for Wartsila Diesel Engine
Crankshaft of Wartsila Diesel Engine
Crankshaft of Wartsila Diesel Engine

 

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

Cylinder Liners

 

Cylinder Liners of Ruston Diesel Engine
Cylinder Liners of Ruston Diesel Engine

Cylinder liners are integral part of diesel engine. RA Power Solutions Pvt. Ltd. manufactures cylinder liners having bore size up to 650 mm and length of 1500 mm. The metallurgy of casting is maintained strictly as per the requirement i.e. RPM, load characteristics and design features. The cylinder liners are centrifugally cast in a modern, well equipped foundry. After casting of cylinder liners, each cylinder liner passes through stringent quality control procedures. Presence of hairline cracks is checked by magnetic particle inspection (MPI) and is conducted by a trained and experienced technician.

Cylinder Liners of Marine Diesel Engine
Cylinder Liners of Marine Diesel Engine

The cylinder liner casting is visually checked for the presence of blow holes, porosity or any abnormality during the casting of cylinder liner.

The cylinder liners are initially rough machined in-house by the latest design of machine and tools installed at our works. The final machining is undertaken on DRDO equipped machines which are capable to maintain close tolerances as per the manufacturer’s requirement. The honing operation of cylinder liners is undertaken on world famous Chris Marine machines imported from Sweden.

The cylinder liners are finally checked for all dimensions and reports are prepared. We maintain large stock of cylinder liners for popular makes of diesel engine which includes following: Wartsila, Mak,Deutz, Bergen, Niigata, Himsen, Allen, Stork, Fiat, MWM, Hanshin, Caterpillar, etc.

Cylinder Liners for Wartsila Diesel Engine
Cylinder Liners for Wartsila Diesel Engine
Marine Engine Cylinder Liners
Marine Engine Cylinder Liners

 

 

 

 

 

 

Cylinder Liners of Nohab
Cylinder Liners of Nohab
Cylinder Liners of MAN Diesel Engine
Cylinder Liners of MAN Diesel Engine

 

 

 

 

 

All the cylinder liners supplied by us are guaranteed for satisfactory performance and are priced considerably lower than the cylinder liners manufactured by other manufacturers.

Cylinder Liners of Marine Engine
Cylinder Liners of High Capacity Diesel Engine

RA Power Solutions Pvt. Ltd also supplies reconditioned cylinder liners which are re-honed in house and have minimum wear and tear. We also manufacture cylinder liners as per the customer’s drawing or sample, in case it does not fall in our present range of manufacturing.

You can write us on rajshahani@rapowersolutions or call us on +91-9810012383

Cylinder Liners of Allen Diesel Engine
Cylinder Liners of Allen Diesel Engine

 

Reconditioned Cylinder Liners
Reconditioned Cylinder Liners

Diesel Engine Spare Parts Supplied by RA Power Solutions Pvt. Ltd.

In this competitive world, all the organizations are trying to reduce the cost of operation and maintenance of marine engines  and diesel generating sets.

Marine Engine Spare Parts from OEM
Marine Engine Spare Parts from OEM

It is generally observed that the prices of spare parts are exorbitant and in certain cases the delivery offered is long. RA Power Solutions Pvt. Ltd. supplies spare parts procured directly from OEMs and guarantees the satisfactory performance. Our prices are lowest in the industry

RA Power Solutions Pvt. Ltd. also deals in reconditioned marine engine and diesel generating sets spare parts which are calibrated by our experienced technicians in our state of art, workshop having latest instrumentation and equipments for undertaking repairs. Some of the products offered by us are as under:

Marine Engine Spares

High capacity marine engine spares are supplied for reputed engine manufacturers like Wartsila, Mak,Deutz, Bergen, Niigata, Himsen, Allen, Stork, Fiat, MWM, Hanshin, Caterpillar, etc. The spares parts are procured from the OEM. Each part is subject to calibration and inspection at our works by the experienced technicians. Inspection report is prepared.

Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions
Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions
Marine Engine Spares Supplier
Marine Engine Spares Supplier

RAP also supplies reconditioned spare parts procured from the ship breaking yard and diesel generating power plant which have become abundant due to availability of alternate source of energy. Parts are reconditioned at our works and are supplied with guarantee. We also stand guarantee for lowest price in the industry.

Cylinder Head
Cylinder Head
Cylinder Head Under Assembly
Cylinder Head Under Assembly

 

 

 

 

 

Onsite Crankshaft Grinding Machine

We manufacture latest design of onsite crankshaft grinding machines ranging from 40 mm to 700 mm diameter. Ours is the only company which can execute repair of crankshaft by grinding / polishing on board the vessel  while it is sailing. This is possible only due to the vibration less latest technology crankshaft grinding and polishing equipment designed and manufactured by us and technicians having seaman passport.

Packing in Progress- Insitu Crankshaft Grinding Machine
Packing in Progress- Insitu Crankshaft Grinding Machine
Onsite Crankshaft Grinding Machine Ready for Dispatch
Onsite Crankshaft Grinding Machine Ready for Dispatch

 

 

 

 

 

 

 

We are cost effective and can dispatch our team of technicians with onsite crankshaft grinding equipment within 6 hours notice.

Second Hand Crankshafts

Second hand crankshafts of most of the popular make of engines are available ex-stock. It is a policy of the company to polish all the CR pins and main journals as these facilities are available in house

Marine Engine Crankshaft
Marine Engine Crankshaft

the inspection reports for taper, ovality, hardness, crack detection, alignment, etc. is prepared and submitted with the crankshaft.

We have been selling second hand and reconditioned crankshafts for last 36 years and have sold second hand crankshafts exceeding 160 numbers all over the world. We are priced lowest in the industry.

Reconditioned Wartsila Crankshaft
Reconditioned Wartsila Crankshaft

Fresh Water Generator

Fresh Water Generator, heat exchangers, purifiers are

Fresh Water Generator
Fresh Water Generator

procured from ship breaking yards andabondened diesel power plants. These equipments are fully reconditioned by changing of rubber components, bearings and other spares. All equipments are put on trial and supplied with guarantee on lowest price in the industry.

Gaskets

Gaskets, rubber gaskets for all alpha laval equipments like fresh water generator, heat exchangers, purifiers are available in stock. Gaskets of other make of equipments are also manufactured. We can also develop the gaskets as per the requirement of the client or as per the sample. Performance is guaranteed and gasket are priced nearly half of the OEM price.

Heat Exchanger Gasket
Heat Exchanger Gasket
Gasket
Gasket

 

 

 

 

White Metal Bearing

We manufacture white metal Babbitt bearing for rotor shaft, crankshaft, alternator shaft, turbine shaft and all application.The new white metal Babbitt bearings are manufactured up to 1500 mm diameter. Close tolerances are maintained.

Inspection of White Metal Bearing
Inspection of White Metal Bearing
White Metal Alternator Bearing of Wartsila
White Metal Alternator Bearing of Wartsila

 

 

 

 

 

 

We regularly export white metal Babbitt bearings for different applications all over the world. We are cost effective and have experience of more than 36 years in this field.

Tri Metal Bearing

After grinding of crankshaft under size and special size

Tri Metal Bearing
Tri Metal Bearing

tri metal bearings for crankpin and main journal are required. RA Power Solutions Pvt. Ltd. manufactures tri metal bearings as per the requirement. We also have facility to develop and manufacture bearings in case the quantity is large.

 

We have new and reconditioned spare parts of following make of engine:

  • MAN-B&W

    Wartsila Marine Diesel Engine
    Wartsila Marine Diesel Engine
  • Sulzer
  • Wartsila
  • Mak
  • Deutz
  • Pielstick
  • Mitsubishi
  • Daihatsu
  • Yanmar
  • Bergen
  • Niigata
  • Himsen
  • Allen

    MAK Marine Diesel Engine
    MAK Marine Diesel Engine
  • Stork
  • Fiat
  • MWM
  • Hanshin
  • Caterpillar
  • SKL
  • Ruston
  • Paxman
  • Crepelle

    MAN Marine Diesel Engine
    MAN Marine Diesel Engine
  • Mirrlees
  • Alco
  • ABC
  • Crepelle
  • Nohab etc

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.

Insitu Grinding of Crankshaft

Insitu grinding of crankshaft and polishing is offered by RA Power Solutions Pvt. Ltd. for last more than 3 decades. Our experienced technicians reach at site in minimum possible time with Insitu crankshaft grinding machine and undertake crankshaft repair without removing of crankshaft from the main engine.

Insitu Crankshaft Grinding in Process
Insitu Crankshaft Grinding in Process
Crankshaft Grinding
Crankshaft Grinding

 

 

 

 

 

 

 

The Insitu crankshaft grinding is undertaken by light weight portable Insitu crankshaft grinding machine which is operated pneumatically. The equipment is of latest design and is capable to maintain the close tolerance within 20 to 30  microns in terms of  taper and ovality. Onsite crankshaft grinding can also be undertaken while the vessel is sailing. This is possible due to continuous research and development done by our engineers to minimize the vibrations while the vessel is sailing.Our technicians hold valid seamen book and can sail if required.

 

Upper View of Crankshaft Grinding Machine
Upper View of Crankshaft Grinding Machine

The time required for repair that involves crank pin grinding and polishing of crankshaft is minimum due to the latest design of our crankshaft grinding equipment executed by experienced technicians.

We can undertake grinding and polishing of crankshaft up to 700 mm diameter and have executed more than 10,000 repairs in our 36 years of experience world wide.

Onsite Crankshaft Grinding Machine Ready for Dispatch
Onsite Crankshaft Grinding Machine Ready for Dispatch

 

Pneumatic Motor Mounted on Machine
Pneumatic Motor Mounted on Machine

 

 

 

 

Author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. He has been working on crankshafts for last more than 36 years. The author had his training with leading crankshaft manufacturers like CKD Skoda in Pilsener Czech Republic , Sidenor in Spain, National Forge in Germany, etc.

Crankshaft Straightening

It is generally observed that in case of failure of crank pin bearing or Main journal bearing, crankshaft loses its alignment. The alignment of crankshaft and its straightness is of great importance. The crankshaft alignment is specified by the manufacturer according to the crankpin diameter,main journal diameter length of crankshaft etc.

Crankshaft Straightening Process of MAN Diesel Engine
Crankshaft Straightening Process of MAN Diesel Engine
Crankshaft Straightening
          Crankshaft Straightening

In case there is a loss of crankshaft alignment, it is observed that main journal bearings fail repeatedly.

RA Power Solutions Pvt. Ltd. undertakes straightening of crankshaft as per the manufacturer’s specifications onsite by peening process. The technicians are experienced and trained to correct the loss of alignment of crankshaft by peening process. The crankshaft is straightened by peening process to the maximum extent and the final correction is done by grinding of main journals incase required.