Overhauling of Main Engine Repair | Repair of Engine Metal Stitching of Damaged Block- RA Power Solutions

RA Power Solutions received an emergency call from a Steel Company based in Indonesia regarding damage of their Engine SULZER 6RND68.

On arrival of our team of engineers, it was observed that lower engine block of SULZER 6RND68 was damaged badly. Hence it required disassembly of complete engine, overhauling & repair of engine block by metal stitching & metal locking.

Overhauling of Main Engine
Overhauling of Main Engine

Following is the brief of job description executed:

I) Inspection and overhaul of the cylinder covers including the fuel and starting valves located in the covers. The cylinder covers cooling spaces were also inspected, cleaned and fitted back with new O-rings.

II) Dismount, Inspect and overhaul the exhaust valves, renewed the seals and grinding the valve spindles.

III) The cylinder liners were cleaned, calibrated and honed in order to restore the liners running surfaces and remove ovality. This ensured that the piston rings perform better and this will lead to a better overall cylinder condition, compared to if honing had not been done. The cylinder liners cooling spaces were also inspected, cleaned and fitted back with new o-rings.

IV) Replacement of thrust block pads and correction of end play.

V) Metal locking of damaged Engine block by our technicians.

Damaged Engine Block
Damaged Engine Block
Repair of Engine Block by Metal Stitching is in Process
Repair of Engine Block by Metal Stitching is in Process
Special Keys & Locks Used in Metal Stitching Process
Special Keys & Locks Used in Metal Stitching Process

 

 

 

 

 

 

 

VI) Inspected and adjusted the chain drive.

VII) Retightened the stay-bolts, holding down bolts end chocks.

VIII) Took bearing clearances with a telescopic feeler gauge and checked bearing edges by wire gauges.

IX) Crankshaft alignment measurement was taken with dial gauge (autolog method)
Conclusion: The engine was tested on full load for 72 hours & all the parameter were recorded. The engine is performing satisfactorily.

RA Power has experience of more than 40 years in extending services for Overhauling of Main Engine Repair / Repair of Engine Metal Stitching of damaged Block.

Repair & Overhauling of Engine is in Process
Repair & Overhauling of Engine is in Process
Inspection of Engine Spare Parts is in Process
Inspection of Engine Spare Parts is in Process

Metal Stitching and Metal Locking of Engine Block – RA Power Solutions

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