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