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 This is now outdated.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.
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.
RA Power Solutions is engaged in onsite crankshaft grinding, crankshaft machining and crankshaft repair of small and high capacity engines. The crankshafts and all cylindrical shafts of rotatory equipment are repaired onsite without disassembly.
Following are the main features of the services offered related to crankshaft repair:
I) Experience technicians undertake crankshaft inspection which includes dimensional calibration for taper, ovality and hardness testing.
II) In case of failure of bearing or serious damage, it is important to undertake crack check. We recommend magnetic particle inspection and dye penetrant.
III) Checking loss of alignment of crankshaft by deflection gauge or taking the run-out of the main journal.
IV) Straightening of crankshaft is undertaken if required.
V) Radius fillet original profile is maintained in case of damage.
VI) Onsite crankshaft grinding, crankshaft repair is undertaken by using
crankshaft grinding equipment maintaining the crankpin and main journal tolerances as per manufacturers.
VII) Surface finish after crankshaft grinding and polishing is of great importance and is maintained.
Main points related to crankshaft repair services offered by RA Power Solutions:
I) Company having 40 years of experience in repair of crankshaft can easily detect the damage caused to the crankshaft due to accident.
II) We are experts in salvaging the crankshafts which as per the manufacturers are rejected. This is possible due to our vast experience,knowledge and use of latest technological equipment.
III) Large team of experienced technicians having valid passport and seaman book and can travel all over the world in shortest possible notice.
IV) In field of crankshaft repair we are the leaders, most experienced, sincere and trust able.
V) The services provided is on the lowest rates and can be compared with other companies.
VI) Only company having executed more than 11,000 jobs of crankshaft repair and engine overhaul maintenance worldwide.
VII) All the repair services related to high capacity diesel generating sets is offered with guarantee.
Crankshaft needs repair or grinding in case of following defects:
Development of excessive taper and ovality more than the tolerances stipulated.
Loss of alignment of crankshaft.
Seizure of bearing, development of line marks.
Development of pitting and rough surface of crankshaft main journal and crankpin
RA Power Solutions offer crankshaft repair services for last four decades to the land based engine and engines installed on vessels.
The onsite repair services of crankshaft helps in getting the engine back into operation in minimum time. Following crankshaft grinding services are offered by RA Power Solutions at Sea, on land or in shipyard:
Onsite Crankshaft Repair
Onsite Crankshaft journal repair
Onsite Crankshaft polishing
Onsite Main bearing Regrinding
Onsite Crankshaft machining
Orbital crankpin machining/regrinding
Main bearing machining
Insitu Main bearing Main Journal Polishing
RA Power Solutions has technicians who are well trained and have executed successfully more than 11,000 jobs of crankshaft repair. We are also considered to be lowest priced in industry.
RA Power Solutions is the first company to introduce portable, light weight, onsite crankshaft grinding, crankshaft polishing and crankshaft repair machine on the lowest price.
With the introduction of revolutionary onsite crankshaft grinding machine, now it is possible to save the repair cost of crankshaft. The onsite crankshaft grinding repair machine has proven its worth with 70 clients based all over the world.
I) Onsite Crankshaft Grinding Polishing machine can undertake crankshaft grinding and crankshaft polishing up to 700 mm diameter without dismantling of crankshaft.
In terms of taper and ovality tolerance can be maintained within 20 to 30 microns or as per the manufacturer’s requirement.
II) For long life of bearings and crankshaft it is important to have high level of surface finish with Onsite Crankshaft Grinding Polishing Machine it is possible to maintain surface finish 0.15 RA value.
III) Onsite Crankshaft Grinding Polishing Machine is easy to operate and on job training is also provided. IV) Onsite Crankshaft Grinding Polishing Machine can be carried as a accompanied baggage by the technicians all over the world.
V) Onsite Crankshaft Grinding Polishing Machine is ideal for grinding and polishing of main engine and auxiliary engine on board the vessel. All popular make of engine crankshaft can be repaired like MAK, MAN, Wartsila, Daihatsu, Ruston, Yanmar, Mirrless Blackstone, SKODA, etc.
VI) Onsite Crankshaft Grinding Polishing Machine supplied all over the world including Nigeria, Dubai, Singapore, South America, Italy, Maldives, Indonesia, Bangladesh, etc.
Onsite crankshaft grinding is the latest trend in shipping industry. Removing crankshaft from the engine block involves dis assembly of all major parts which require time, efforts and money. The best solution for this is to undertake crankshaft grinding and crankshaft polishing onsite without dis assembly of the crankshaft from the engine block.
RA Power Solutions undertake onsite crankshaft grinding and onsite crankshaft polishing and repairs up to 700 mm diameter.
We have team of experience technicians, they travel all over the world with portable and light weight equipment. It is now possible to execute the crankshaft repair in few hours depending on the diameter and extent of the damage of crankshaft.
RA Power Solutions has executed repairs of more than 10,000 crankshaft all over the world for leading shipping companies, power plants, heavy engineering companies, etc.
We are respected in industry for quality, sincerity and low price.
We have latest design portable equipments which are carried to the client’s site whether they are land based power plants or vessel on move. The services are offered through trained technicians. Being an Indian company having more than 36 years of experience, we are well known for sincerity, on time services and lowest price in this industry. Few of the services offered by us are as under:
Metal Locking and Metal Stitching
Metal locking and metal stitching is a cold process for repair of steel casting which develops crack or gets broken in to pieces due to overload, stress or an accident.
RA Power Solutions Pvt. Ltd. has experience of more than 36 years of undertaking repair of most complexed accidental damage of plant and machinery, high capacity marine engine, diesel generating sets, engine block, cylinder heads,turbine casing etc. the repair of casting by metal stitching and metal locking is executed by trained and experienced engineers having experience of more than 40 to 45 years.
The consumables like metal locks and metal keys are procured from reputed companies based in USA and UK. We are cost effective and can depute our team of technicians within 6 hours notice.
We are experts for repair of crankshaft of high capacity marine engines upto 700 mm diameter, diesel generating sets and other applications. The services are extended all over the world through our experienced technicians.
Rotor Shaft Grinding
In case of failure of white metal rotor shaft bearing it is necessary to inspect the rotor shaft bearing sitting diameter. We undertake complete inspection of rotor shaft, grinding and polishing onsite. The rotor shaft repair, grinding and polishing is done without dismantling of the rotor shaft from casing. The rotor shaft grinding and polishing is done onsite.
Rotor shaft white metal Babbitt bearings are manufactured and rebabbitting of old rotor shaft bearings is also undertaken. We stand guarantee for the satisfactory performance of white metal babbitt bearings.
Connecting Rod Repair
Connecting rod repair is undertaken with guarantee, absolutely no need of replacing the connecting rod as in most of the cases connecting rods can be repaired and re used.
RA Power Solutions Pvt. Ltd. undertakes in-house repair of connecting rods including re-boring of big end and small end, checking of hardness, cracks, etc.
We supply second hand reconditioned connecting
rods for all make and model of diesel 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 etc.
Cylinder Heads are reconditioned at our works. We replace valve seats, valve guides and recondition the cylinder heads which are ready for installation. Repair of cylinder heads is undertaken by our experienced technicians in-house.
The repair of cracks on cylinder heads is done by metal stitching and metal locking process which is cold and proven method of crack repair. Second hand reconditioned cylinder heads are also supplied with guarantee on competitive price.
Rebabbitting of Bearings
Rebabbitting of old white metal bearings of diesel engines, turbines, alternators and all application are undertaken. Rebabbitting of white metal bearings is done by centrifugal process which ensures dense and uniform bonding with the base steel.
We undertake rebabbitting of bearings up to 1500 mm diameter. The white metal used for rebabbitting is imported from Spain. The metallurgical certificate for white metal and dimensional inspection report is submitted after rebabbitting of white metal is done.
The periodic inspection of turbine shaft is necessary. It is common to observe bearing line marks, corrosion, fatigue cracks, taper and ovality on turbine shaft bearing seating area In case these defects are not attended on time it can result to the failure of turbine shaft and damage to other parts.
RA Power Solutions Pvt. Ltd. has successfully executed repair of turbine shafts, crank shaft, rotor shaft, alternator shaft and pump shaft number exceeding 170 up to the diameter of 700 mm.
Special pneumatically driven grinding equipment is used to undertake the grinding of the turbine shaft. The turbine shaft grinding equipment is portable, light weighted and easy to carry to the site. The experienced engineers undertake the grinding of damaged bearing seating area of the turbine shaft and maintain the tolerances within 20-30 microns with high surface finish.