cast iron crack repair Archives - RA Power Solutions

Overhauling of Main Engine Repair | Repair of Engine Metal Stitching of Damaged Block

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 and repair of engine block by metal stitching & metal locking.

Following is the brief of job description executed:

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.
Dismount, Inspect and overhaul the exhaust valves, renewed the seals and grinding the valve spindles.
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.
Replacement of thrust block pads and correction of end play.
Metal locking of damaged Engine block by our technicians.

Special Keys & Locks Used in Metal Stitching Process

Repair of Engine Block by Metal Stitching is in Process

Inspected and adjusted the chain drive.
Retightened the stay-bolts, holding down bolts end chocks.
Took bearing clearances with a telescopic feeler gauge and checked bearing edges by wire gauges.
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.

Repair & Overhauling of Engine is in Process

Inspection of Engine Spare Parts is in Process

For more details regarding Metal Stitching of Damaged Block, overhauling of engine, repair of engine metal stitching of damaged block, crankshaft grinding, and engine block repair please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Cast Iron Crack Repair By Metal Stitching – RA Power Solutions

Cast iron crack repair by metal stitching and metal locking process is highly recommended. Metal stitching process for repairing casting is widely use, and accepted in the industry, and more successful process for repairing cracks in cast iron.

Steam turbine casing of Hangzhou make was reported damaged due to accident. The turbine operates at 130 MW peak load.

RA Power Solutions deputed technician to the site with latest breed of instruments, equipments and consumables in order to undertake inspection of the turbine casing and to execute necessary repair following observation was made.

Observation-

Turbine casing due to accident developed multiple cracks at different locations. Crack of following dimensions were observed

Crack having a length of 190mm with indiscipline profile
2 Cracks having length of about 300mm
Casting having dimensions of 600mm/450mm with thickness of 45mm was damaged into pieces

Crack repair by Metal lock and Metal stitching.

Crack Repair and damaged casting replacement was undertaken by RA power technicians.

The damaged casting area was cut and disciplined profile was given measuring 650mm/520mm this area was properly ground
The damaged sample piece was sent for metallurgical test to know the composition of material.
A wooden pattern was made at site having an exact profile as of damaged area.
A new casting piece having superior metallurgical properties then the original damage casting was manufactured.
The new casting piece was fixed in damage area by metal stitching and metal locking process.
RA power engineers used metal locks, metal keys and all consumables’ imported from UK for repair of cracks and damage casting.
The polishing of outer and inner surface of damaged area was done and painted.
The turbine is presently working satisfactory and has completed 3500hr of operation.

RA power under takes repair of crack casting by metal stitching and metal locking process from last 45 years and have executed successfully repair of heavy components used in power plants, industry, ships etc…

The metal stitching and metal locking can also be undertaken while sailing the vessel.

To know more about cast iron crack repair, metal locking, cast iron stitching, metal surgery, and engine block repair, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Repair of casing by metal lock and metal stitching

Turbine casing after repairs — Turbine casing after repair

Crankshaft Grinding Services By Experienced Technicians – RA Power Solutions

When it comes to maintaining marine engines, one vital aspect that deserves the utmost attention is the crankshaft. The crankshaft plays a crucial role in converting linear motion to rotational motion, and any wear or damage to this component can lead to a significant decrease in engine performance. However, thanks to the expertise of experienced technicians and specialized services like Crankshaft Grinding, marine engine owners can revitalize their crankshafts and restore optimal engine functionality. In this blog, we will delve into the significance of crankshaft grinding services and how they can breathe new life into your marine engines.

RA Power Solutions provides onsite crankshaft grinding services for last four decades. Crankshaft having diameter up to 700 mm is repaired onsite without removing the crankshaft from the engine block.

The grinding of crankshaft onsite is possible by introduction of onsite crankshaft grinding machine which is portable, light weight and can be inserted from the inspection window of the engine block. RA Power Solutions also manufactures and sells crankshaft grinding machine. The crankshaft grinding services are offered by us through our technicians who are well trained in our workshop and have experience of providing crankshaft grinding services . After repair of crankshaft, the dimensional tolerances are maintained within 20 to 30 microns and surface finish as per the international standards.

Prior to undertaking grinding of crankshaft, all the major parameters of crankshaft i.e. dimensional inspection, hardness test, crack detection, deflection, etc. are checked.

In case the basic parameters are found within the repair limits, crankshaft grinding is undertaken. RA Power Solutions can maintain the tolerances strictly as per the manufacturer’s recommendations. With the introduction of latest design of onsite crankshaft grinding machine the vibrations in the crankshaft grinding machine are reduced to minimum. This ensures maintenance of close tolerance and also facilitates grinding of crankshaft on board a vessel while it is sailing in high seas. The grinding of crankshaft while sailing of the vessel results to the considerable saving to the owners.

For more information on crankshaft grinding, repair of crankshaft, and onsite crankshaft grinding services please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.