Onsite Crankshaft Repair | Crankshaft Grinding | Crankshaft Reconditioning is undertaken by RA Power Solutions Pvt Ltd for last four decades. The company has technicians who are trained to undertake Onsite Crankshaft Repairs strictly as per manufacturers specifications stipulated in the manual.
All technicians have valid CDC and can travel in a short notice anywhere in the world to board the vessel. The Onsite Crankshaft repair and onsite crankshaft grinding equipment used by RA Power Solutions has a main structure manufactured out of Titanium steel which results to absorption of Vibration while the Crankshaft Grinding machine is in operation in high seas with turbulence. The quality after the reconditioning and repair of Crankshaft is of Great Importance and is maintained. Following checks are undertaken.
Quality of a Re-Machined Pin or Journal
The quality of a pin or journal after machining has to meet following requirements:
I) Geometrical tolerance in accordance with manufacturer specifications.
II) A blueing check has to be carried out on the re-machining surface. Blueing Shells: Min. Width equivalent to Journal or Crank-pin dimensions respectively. Min. Length equivalent to 1/5 of Journal or crank-pin circumference.
III) Required contact area: Min. 35% equally distributed over width and circumferences.
IV) Free of hairline cracks: Journal or crank pin to be tested by mean of Magnetic Particle crack detection method.
V) Free of Martensite: The microstructure is to be tested for edged areas of martensite structure will replicas or micro etching with 5% nitric acid in alcohol ( Nital) applied to the pin after polishing.
VI) Maximum admissible hardness of remaining local hardspots : However such local hardspots are not tolerated around the fillets and the bores for lubrication.
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Engine population is rapidly increasing for shipping industry, power plants and various applications. In most of the cases engines are used not only for the emergency purpose but as a base load. The continuous running of diesel engine results to wear and tear of crankpin and main journal of the crankshaft. In certain cases taper and ovality more than the permissible limit is developed in the crankpin and the crankshaft main journal.
The disassembly of the crankshaft from the main engine and to send it to the designated workshop is a lengthy process. This is now outdated. RA Power Solutions having the experience of more than four decades in repair of crankshaft have developed a portable, light weight onsite crankshaft grinding machine which can be taken to the site as an accompanying baggage. The onsite crankshaft grinding machine has following features:
I) Light in weight, can be carried to the site easily.
II) Portable nature of onsite crankshaft grinding machine facilitates it to insert from the inspection window and undertake grinding and polishing of crankpin.
III) Machine is designed and can maintain the taper and ovality within 0.02 mm. This meets with the OEMs tolerances.
IV) Surface finish and other parameters can be maintained as per the international norms.
V) Onsite crankshaft grinding machine is easy to operate
VI) Onsite training is provided for smooth running of crankshaft grinding machine.
VII) More than 70 machines sold all over the world and performing satisfactory.
VIII) Insitu crankshaft grinding machines are low priced and recommend for repair workshops, shipping and engineering companies and power plants.
Crankshaft grinding machines exported to various countries including Dubai, Singapore, Bangladesh, Indonesia, Greece, Qatar, Nigeria, South America, etc.
With the experience of more than four decades, RA Power Solutions has been the leader in providing insitu crankpin, main journal grinding and machining. The removal of crankshaft from the engine block incase of accident or normal wear and tear is not required. The removal of crankshaft from the engine block is a lengthy process and expensive and engine manufacturers are to be contacted for the disassembly and removal of the Crankshaft from engine.
The onsite crankpin, main journal grinding and polishing is undertaken by RA Power Solutions using the state of art equipment which can be taken to any site on ship or land based industry.
The onsite crankshaft grinding machine is placed on the damage crankpin through the inspection window provided in the crankcase. Due to the compact design of the machine, most of the crankshafts can be repaired onsite.
RA Power Solutions undertakes onsite grinding of crankshaft and polishing of diameter ranging from 60 mm to 700 mm.
The jobs of crankpin and main journal repair of crankshaft executed by us have following features:
I) Having latest quality control measuring instruments to check hardness, crack by MPI, taper, ovality , surface finish, etc.
II) All instruments used for measuring the crankpin and main journal diameter are periodically sent to the laboratory for calibration. Valid certificate are kept in record as per the requirement of inspection agencies.
III) Latest design and technology instruments/Equipments are used prior to repair of the crankshaft and after the repair are executed.
Advantage of RA Power Solutions for Crankshaft and Main Journal Repair
I) Crankshafts are repaired onsite up to the diameter of 700 mm. No need of removal of crankshaft.
II) Experienced team of technicians is always ready to leave for sailing all over the world.
The holding of seamen passport by technicians’ facilitates them to fly out to any country in short notice.
III) The robust design, use of titanium for manufacturing the body of crankshaft grinding machine ensures minimum or no vibration while crankshaft grinding machine is in operation. The job of repair of crankshaft can be executed while the vessel is sailing.
All the services required for repair of engine and to put it back to the operation are extended by RA Power Solutions including commissioning and trial part.
IV) The experience of repairing over 10,000 crankshaft makes us leader in this field. Cost of repair of crankshaft and the services offered are the lowest in industry. This is possible due to continuous upgrading of technology and process followed by us.
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Crankpin grinding, crankpin repair by insitu crankshaft grinding machine is offered by RA Power Solutions through highly motivated team of technicians who have the experience of four decades in crankshaft grinding and crankshaft repair. It is important that the crankshaft is initially inspected by the experienced technicians in order to detect the fault after the damage or accident.
Following are the major parameters which are examined before the repair of crankshaft:
I) Minimum and maximum diameter of the crankpin and main journal, taper and ovality is checked.
II) Run out of main journals and deflection readings are taken to verify the loss of alignment.
III) Complete non-destructive test using MPI and ultraviolet lamp for heat cracks is undertaken of crankpins and the main journal of the crankshaft.
IV) Crankshaft is also subject to hardness test.
Based on the preliminary inspection reports prepared by the technicians the repair procedure is planned. The onsite crankshaft grinding machine used for the crankshaft repair is light weight and is placed on the damaged crank pin from the inspection window of the engine block.There is no requirement of removing the crankshaft from the Entablature and send it to the workshop as bench type grinders are now out dated.
The crankshaft grinding and crankshaft polishing is undertaken maintaining taper and ovality, surface finish as per the OEMs requirement. RA Power Solutions have facilities to undertake insitu crankshaft grinding, crankshaft polishing and crankshaft repair up to the diameter of 700 mm without removing the crankshaft from the engine block.
During and after the repairs all the major technical parameters are checked and calibration report is prepared.
It is possible to execute the crankshaft grinding and crankshaft repair on board a vessel while it is sailing. Technicians have seaman passport and can travel to any part of the world in a shortest possible time thus attending to the damaged engine in short time. We are class approved and stand guarantee for the satisfactory performance of crankshaft after repairs.
We are commonly working on following engines:
Wartsila, Daihatsu, Mirrless Blackstone, Yanmar, Allen, MAK, MAN, B&W, Sulzer, Caterpillar, Fiat, Mitsubishi, MTU, Cummins, Deutz, Nohab Polar, Wartsila 12V32, Wartsila 18V32, Pielstick, Bergen , Detroit Diesel, MaK 552 , MaK 453 , MaK 451 AK, Niigata, MaK 452 AK, Ruston, Lister Blackstone K8 Major MK2, Volvo Penta, etc.
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