Sulzer model 6RTA Engine was reported damaged in high seas near Mombasa on a transit to Sri Lanka. On investigation, it was observed that the connecting rod bolts got sheared damaging lower and upper engine block and three crankpins of the Crankshaft.
On preliminary examination multiple cracks on upper and lower crack case of engine block were observed measuring in totality 2900 mm in terms of length. Three crankpins were damaged developing taper and ovality exceeding more than 1 mm. RA Power Solutions team of technicians worked non-stop and executed the repair of crankpins by onsite crankshaft grinding machine. All pins were undersized to 1.5 mm due to the damage.
The engine block cracks were repaired by metal locking and metal stitching process. The complete job was executed within 68 hours. The hard work, knowledge, experience, sincerity of technicians have been very much appreciated by the owners. This achievement was possible due to RA Power Solutions having latest design of equipment, experienced technicians having Indian CDC.
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The onsite crankshaft grinding machine is placed on both side of the radius of the crankpin and tool rotates undertaking grinding and polishing of crankshaft. This process of crankshaft grinding by in-situ crankshaft grinding machine is successful generally for the diameter of the crankpin of 200 mm and above having a bearing width of 125 mm minimum.
For the smaller diameter of the crankpin, it is not possible to undertake the grinding by taking the reference of radius fillet due to the space constraints.
RA Power Solutions has introduced a compact, easy to operate onsite crankshaft grinding machine which is suitable for grinding and polishing of small diameters of the crankpin above 30 mm. The crankpin bearing width can be as small as 30 to 40 mm. With this latest technological advance crankshaft grinding machine, it is easy to grind the smaller diameter of the crankpin having smaller crankpin bearing width.
The crankshaft grinding machine has the main features of machining, grinding and polishing of the crankpin. The tolerances in terms of taper, ovality, surface finish are maintained far better than the manufacturer’s recommendation.
RA Power Solutions having 4 decades of experience in in-situ crankshaft grinding have executed successfully repair of more than 11,000 crankshaft all over the world and are leaders in this field.
Crankshaft grinding and crankshaft repair are important for satisfactory performance of engine. RA Power Solutions Pvt. Ltd. has been undertaking crankshaft repair onsite by portable, light weight crankshaft grinding machine. The crankshaft repair is executed of crankshaft diameter ranging from 60 mm to 700 mm.
We have team of trained and dedicated technicians who are deputed to the site with crankshaft grinding machine along with necessary instruments. The crankshaft repair is undertaken without removing the crankshaft from the entablature.
The crankshaft grinding machine used to undertake crankshaft repair is of latest design having minimum vibrations. This facilitates our technicians to undertake crankshaft repair even while the vessel is sailing. The tolerance after crankshaft grinding and crankshaft repair is maintained within 10 to 20 microns in terms of taper and ovality.
The repair of crankshaft and overhauling of engine while sailing of the vessel between two ports results to the considerable saving to the ship owners as there is no need of holding the vessel at port or anchorage.
The crankshaft repair executed by us is guaranteed for the satisfactory performance. As on date we have executed more than 10,000 repair of crankshaft all over the world.
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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.
RA Power Solutions having 37 years of experience have executed more than 10,000 jobs of repair of crankshaft successfully which is a record.
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.
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.