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.
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.
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.
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.
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.
RA Power Solutions have experienced technicians to undertake metal stitching and metal locking process with guarantee.
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.
White metal Babbitt bearing is used in engines, turbines, alternator, pumps and various other Rotating equipments. It is important that the grade and quality of white metal which is used for babbitting of bearing is selected based on the load characteristics, operational condition on the Babbitt bearing.
The white metal babbitting is done by centrifugal system and this ensures that the Babbitt white metal bonds properly with the steel base of the bearing. The quality of Babbitt bearing is checked by ultrasound for bonding.
RA Power Solutions Pvt. Ltd. undertakes babbitting of white metal bearing up to 1500 mm inner diameter. The babbitting is done by the experienced technicians and is done by centrifugal process which ensures that Babbitt white metal forms a uniform layer. The grade and quality of white metal used for babbitting is carefully selected.
The in-house machining facility ensures that all the parameters of bearings are maintained as per the manufacturer’s specifications and tolerances.
The large bench type crankshaft grinding and polishing machines are outdated and are replaced by portable, light weight onsite grinding and polishing machine. The machine is driven either by pneumatic motor or is electrically operated.
The objective of using pneumatic motor is to make machine compact which can be inserted from the inspection window of the engine block for grinding of crankpin and main journal.
Crankshaft Grinding and Polishing Machine is light weight and can be carried to the work site by the technicians. It is easy to assemble and operate. Any technician with machine shop experience can easily operate this machine. The crankshaft grinding and polishing machine is capable of maintaining taper, ovality and high surface finish after grinding operation and all the dimensions of crankpin or main journal can be controlled as per the manufacturer’s requirement.
RA Power Solutions Pvt. Ltd. designs and manufactures the onsite crankshaft grinding and polishing machine as per the customer’s requirement. We have capability of designing and manufacturing the grinding machine up to 700 mm in terms of diameter.
More than 60 crankshaft grinding and polishing machines have been supplied all over the world which are performing satisfactory. The cost of on site crankshaft grinding and polishing machine is very low.