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.

Crankshaft

Grinding of Crankshaft by Crankshaft Grinder
Grinding of Crankshaft by Crankshaft Grinder

It is observed that due to seizure of bearing in most of the cases, crankshaft loses its alignment and develops bend. The alignment of crankshaft is important and it is maintained at the time of machining/grinding of crankshaft.

RA Power Solutions undertakes straightening of crankshaft onsite irrespective of the length of crankshaft, diameter of CR pin and main journal. The straightening of crankshaft is done by peening procedure for which our technicians are trained. Number of jobs has been successfully executed for straightening and onsite grinding of crankshaft.

Crankshaft Grinding
Crankshaft Grinding in Process

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

 

Inspection and Calibration of Connecting Rod

It is generally observed that due to continuous running of engine, connecting rod big end bore develops taper and ovality. The small end bush also gets worn out. It is important that connecting rods are subject to thorough inspection after certain hours of operation as described in the manual.

Wartsila Connecting Rod Inspection
              Wartsila Connecting Rod Inspection

The crack detection is important of serration area and also of connecting rod bolts. Most of the serious accident happen due to failure of connecting rod bolts that can damage the crankshaft, engine block and other parts resulting to heavy losses.

Connecting Rod Assembled with Piston After Repair
Connecting Rod Assembled with Piston After Repair

RA Power Solutions Pvt. Ltd. engineers are available on call and can visit the vessel or a power plant with necessary instruments to conduct inspection on site of connecting rods. The technicians are experienced and inspection report is submitted with necessary recommendations for successful repair of connecting rods.

Connecting Rod of MAN engine
Connecting Rod of MAN engine
Calibration of Connecting Rod
Calibration of Connecting Rod

 

 

 

 

 

Crankshaft Repair in Limited Engine Space

RA Power Solutions Pvt. Ltd. have successfully executed repair of crankshaft on board a vessel of Hyundai engine. The crankshaft repair companies based in Norway, Singapore and UK were invited to execute the grinding operation on crankshaft bearings of which were seized due to lube oil pump failure.These companies were not able to execute the repairs due to non availability of compact portable tool which was required as the space available from the inspection window was less.

Hyundai Diesel Engine for Repair
                           Hyundai Diesel Engine for Repair

Knowing the constraints of space, RA Power Solutions Pvt. Ltd. designed  and manufactured a special purpose crankshaft grinding machine which was inserted from the inspection window and grinding of 6 nos. pins was successfully executed. The engine is performing satisfactory.

The repair of crankshaft on site was possible because the crankshaft grinding machine designed by RA Power solutions was compact, light weight and was manufactured according to the size of the window and space available in the crankcase of the engine. The technicians were able to maintain the tolerance after grinding within 20 microns against the stipulated tolerance of 30 microns in the manufacturers manual.

Repair of Crankshaft in Limited Space
Repair of Crankshaft in Limited Space
Inspection for Crack Detection
Inspection for Crack Detection
CR Pin After Grinding
                                                    CR Pin After Grinding

New and Reconditioned Cylinder Liners

New and Reconditioned Cylinder Liners
     New and Reconditioned Cylinder Liners

Cylinder liners for popular engines like MAN-B&W, Sulzer, Wartsila, Mak, Deutz, Pielstick, Mitsubishi, Daihatsu, Yanmar, Bergen, Niigata, Himsen, Allen, Stork, Fiat, MWM, Hanshin, Caterpillar, SKL, Ruston, Paxman, Crepelle, Mirrlees, Alco, ABC, Crepelle, Nohab are manufactured by RA Power Solutions Pvt. Ltd.

The cylinder liners are centrifugally cast, machined and honed in-house. RA Power Solutions manufacturers cylinder liners up to 500 mm bore with height of 1500 mm. Cylinder liners are regularly exported.
RA Power Solutions Pvt. Ltd. also supplies second hand and reconditioned cylinder liners. Each cylinder liner is subject to crack detection test by MPI and Dye penetrant inspection. Cylinder liners are honed. We ensure that the remaining life of the cylinder liners is more than 80% and the cost is approximately 1/3rd of the new cylinder liners.

The reconditioned cylinder liners are popular and used in large by the shipping companies, diesel power plants having engines which are old and companies have stopped production.

Revolution in Crankshaft Grinding

revolution in engineering 11

Good News for Shipping Companies, Power Plants and Repair Workshops.

Crankshaft grinding machine up to 700 mm diameter is designed, developed and manufactured by RA Power Solutions. Machine is having following features:

Crankshaft Grinding Machine Design: Machine is portable; light weight and can be carried to the site. Nowadays, there is no need of disassembly of complete engine.

Operation of Crankshaft grinding machine: The machine is operated pneumatically or by electrical motor. The design is so simple and machine can be easily operated by a skilled technician.

Quality: Crankshaft grinding machine is capable of maintaining close tolerance in terms of taper and ovality up to 20 microns and can also achieve the surface finish as per the International standards.

Training: RA Power Solutions Pvt. Ltd. provides training to the clients, technicians for the duration of 3 days. The assembly, operation and maintenance of the machine are explained.

Cost of Machine: Presently, shipping companies, power plants having high capacity diesel generating sets have no option but to call for the technicians from the companies based in Norway, Singapore, UK and various countries by paying exorbitant amount and travel expenses. The Crankshaft grinding machine is manufactured by RA Power Solutions is very reasonably priced and the cost can be recovered in 1 or 2 jobs of repairs.

We have supplied more than 60 Insitu crankshaft grinding machines all over the world which are performing satisfactory.

Disassembly of Crankshaft Grinding Machine with Pneumatic Motor
Disassembly of Crankshaft Grinding Machine with Pneumatic Motor
Disassembly of Crankshaft Grinding Machine
Disassembly of Crankshaft Grinding Machine

 

 

 

 

 

 

Assembly of Crankshaft Grinding Machine in Progress
Assembly of Crankshaft Grinding Machine in Progress
Assembly of Crankshaft Grinding Machine with Pneumatic Motor
Assembly of Crankshaft Grinding Machine with Pneumatic Motor

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

WORKING OF ONSITE CRANKSHAFT GRINDING MACHINE (400-450mm)

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.

New and Reconditioned Marine Engine Spares

RA Power Solutions have been working on high capacity diesel engine for last more than 3 decades. The genuine and high quality spares are very important for satisfactory performance of engine.

RA Power Solutions Pvt. Ltd. deals in spare parts and supporting equipments of following engine: 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.

The spare parts are procured from the OEMs and inspected at our works by the experienced technicians. Generally, these parts are 20 to 30% cheaper than the engine manufacturers.

RA Power Solutions also deals in reconditioned spare parts. The engines which are not in operation are sourced parts are calibrated and reconditioned as per the manufacturers specifications.

We strongly feel that considering the high cost of new spare parts, it is advisable to use the reconditioned parts which are calibrated and are within the manufacturer’s specifications. This again saves the operation cost considerably.

Following new and reconditioned spare parts of high capacity diesel engine are available in stock.

  • PISTON RODS
  • CAMSHAFTS
  • CYLINDER HEADS
  • CONNECTING RODS
  • CYLINDER LINERS
  • CRANKSHAFTS
  • COMPLETE AUXILIARY ENGINES
  • ENGINE FRAME AND BEDPLATES
  • FUEL PUMPS
  • PISTONS

 

PISTON RODS
PISTON RODS
CAMSHAFTS
CAMSHAFTS
CYLINDER HEADS
CYLINDER HEADS
CRANKSHAFT
CRANKSHAFT

 

 

 

 

 

 

 

CYLINDER LINERS
CYLINDER LINERS