Metal Locking and Metal Stitching of Engine Block on Board the Vessel

A vessel sailing in Middle East reported damage of engine block of Yanmar 6N21L-SN due to accident.

Yanmar Marine Diesel Engine
Yanmar Marine Diesel Engine

RA Power Solutions Pvt. Ltd. deputed team of technicians with consumables. The broken pieces were assembled and metal stitched/metal locked. Total broken area was 46 inches. The broken pieces were re-assembled and metal stitched due to shortage of time and to put on the generator in minimum possible time. The other alternate option  was to use the new piece of casting which was not done in this case due to shortage of time.

Broken Engine Block of Yanmar Engine
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Assembly of Broken Pieces of Engine Block

 

 

 

 

 

 

Metal Stitching of Engine Block in Process
Metal Stitching of Engine Block in Process
Metal Locking of Engine Block in Process
Metal Locking of Engine Block in Process
Repair of Engine Block by Metal Locking Process
Repair of Engine Block by Metal Locking Process
Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Stitching Process

Metal Stitching of Crack Casting

Cast iron components develop cracks and break into pieces as a result of accident or overload. The replacement of crack component is expensive. It is recommended to repair crack and broken casting by metal stitching/metal locking process.

Repair Crack and Broken Casting by Metal Stitching Process
       Repair Crack and Broken Casting by Metal Stitching / Metal Locking Process

RA Power Solutions undertakes repair of crack engine block, cylinder heads and cast components onsite by metal stitching and metal locking process which is proved to be successful.

Repair of crack components  is executed by experienced technicians and we use the consumables comprising of metal locks and metal keys procured from companies based in UK and USA. We also stand guarantee for the satisfactory performance after metal stitching/metal locking of the component. Most of the metals can be metal stitched where repair of crack  by welding is not successful.

Metal Stitching of Jenbacher Engine Block
Metal Stitching of Jenbacher Engine Block

 

Metal Stitching Done in Broken Area of Generator
Metal Stitching Done in Broken Area of Generator

Connecting Rod Reconditioning

Connecting Rods
Connecting Rods

RA Power Solutions undertakes reconditioning of connecting rods irrespective of its size and load factor. We have special purpose equipments for inspection of connecting rods and repairs. Following steps are taken for reconditioning of connecting rods.

I) Connecting rods are dis-assembled and cleaned with the special chemical.

II) Dimensional inspection of large end and small end bore is done.

III) Connecting rod is also checked for any loss of alignment on special purpose boring machine loaded with DRDO.

IV) Dye penetrant test and MPI are done for crack detection. Special attention is given to detect the crack on serration area, connecting rod bolts and bolt sitting area.

V) Machining and grinding is done to the restore the original dimension of big end and small end of connecting rods.

Connecting Rod Reconditioning
Connecting Rod Reconditioning
Reconditioning of Connecting Rod
Reconditioning of Connecting Rod

Connecting rods are inspected by senior technician and reports are maintained.

RA Power Solutions has successfully undertaken repair of more than 15,000 connecting rods in last 36 years of operation. RA Power Solutions also exports reconditioned connecting rods on low price with guarantee.

Connecting Rod Assembled with Piston After Repair
Connecting Rod Assembled with Piston After Repair
Connecting Rod of Crepelle
Connecting Rod of Crepelle

 

Cylinder Head Repair

Sulzer Cylinder Head
Sulzer Cylinder Head

RA Power Solutions Pvt. Ltd. undertakes complete reconditioning of cylinder heads. It is observed that cracks are developed due to sudden change of temperature of cylinder heads. We recommend repair of cracks by metal stitching process which is cold and no heat is generated. The valve seat and valve guides should also be replaced of cylinder heads. We have Chris marine equipment for reconditioning of cylinder heads.

Cylinder Head
Cylinder Head

RA Power Solutions Pvt. Ltd. also maintains large stock of reconditioned cylinder heads which are supplied on very low price. All cylinder heads are guaranteed for performance. Cylinder head of following make of engine are available in stock.

  • MAN-B&W

    Cylinder Head of Deutz Engine
    Cylinder Head of Deutz Engine
  • Sulzer
  • Wartsila
  • MAK
  • Deutz
  • Pielstick
  • Mitsubishi
  • Daihatsu
  • Yanmar
  • Bergen
  • Niigata

    MAK Cylinder head
    MAK Cylinder head
  • Himsen
  • Allen
  • Stork
  • Fiat
  • MWM
  • Hanshin
  • Caterpillar
  • SKL
  • Ruston
  • Paxman

    Cylinder Head of Marine Diesel Engine
    Cylinder Head of Marine Diesel Engine
  • Crepelle
  • Mirrlees
  • Alco
  • ABC
  • Crepelle
  • Nohab etc. are available in stock.

Author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having experience of more than 36 years. He is instrumental in executing successfully repairs of crankshaft, engine block, cylinder heads, connecting rods and mechanical equipment replacement cost of which works out in millions of dollars.

You can email us on rajshahani@rapowersolutions.com or Call us on +91-9810012383

Heat Exchanger Gaskets

RA Power Solutions Pvt. Ltd. manufactures gaskets for different equipments like heat exchangers, Fresh Water Generator, purifiers, etc.

Heat Exchanger Gaskets
Heat Exchanger Gaskets

The heat exchanger gaskets manufactured have the profile strictly as per the requirement or the plates on which it is to be fixed. The hardness, quality of the gaskets is maintained in order to ensure that there are no leakages while the equipment is operated on a pressure. Each gasket is subject to in-house quality checks prior to dispatch.

Fresh Water Generator Gaskets
Fresh Water Generator Gaskets
Heat Exchanger Gasket
Heat Exchanger Gasket

Crankshaft Machining

Crankshaft of Wartsila Engine
                                     Crankshaft of Wartsila Engine

RA Power Solutions offers latest technology for onsite machining of crankshaft. The services of onsite crankshaft repair is offered worldwide using the range of specially designed orbital turning equipment to repair damaged crankpin and main journal of diesel engine, compressors and reciprocating equipments.

Insitu Crankshaft Grinding Machine
Insitu Crankshaft Grinding Machine

We have factory trained, highly skilled and motivated technicians to offer repair onsite of damaged crankshaft either on board or offshore. The company is in to business of offering onsite crankshaft grinding and polishing for last more than 36 years and is well known all over the world for its quality repair.

More than 1000 crankshaft have been repaired successfully all over the world diameter ranging from 40-700 mm.

New Crankshaft
                 New Crankshaft

 

 

Grinding of Rotor Shaft by Rotor Shaft Grinder

Grinding of rotor shaft is required due to wear and tear of the rotor shaft diameter, damage of rotor shaft bearing sitting area or due to failure of bearing.

Rotor Shaft Grinding Machine
                                 Rotor Shaft Grinding Machine

RA Power Solutions undertakes onsite grinding and polishing of rotor shaft having diameter up to 700 mm. The initial inspection of rotor shaft is conducted by experienced technicians which includes crack detection by MPI, hardness test and dimensional inspection.

Rotor Shaft Grinder
Rotor Shaft Grinder

Onsite grinding of rotor shaft is done by a latest design of rotor shaft grinding machine developed and manufactured by RA Power solutions. The rotor shaft grinding machine has almost zero vibration which helps to maintain the tolerance of rotor shaft bearing sitting area up to 20 microns.

RA Power Solutions Pvt. Ltd. has executed successfully more than one thousand jobs of grinding of rotor shaft, crankshaft and rotating equipment.

 

Onsite Rotor Shaft Grinding
Onsite Rotor Shaft Grinding
Rotor Shaft Grinding in Process
Rotor Shaft Grinding in Process

 

 

 

 

Onsite Rotor Shaft Grinding Machine
Onsite Rotor Shaft Grinding Machine
Insitu Rotor Shaft Grinding Machine
Insitu Rotor Shaft Grinding Machine

Crank Pin Repair on Board a Vessel of Hyundai Diesel Engine

RA Power Solutions Pvt. Ltd. was called by a shipping company based in Indonesia reporting the failure of crank pins of Hyundai 1.8 MW diesel engine. Our technicians were deputed with portable crankshaft grinding machine designed and manufactured by us.

Hyundai Diesel Engine for Repair
Hyundai Diesel Engine for Repair

On arrival of our technicians it was observed that all the 6 CR pins of Hyundai engine were badly damaged due to failure of lubricating oil pump. The initial inspection of crank pins was conducted comprising of calibration for taper and ovality. Hardness test, crack detection by MPI and deflection checks were also done and recorded.

RA Power Solutions Pvt. Ltd. was successful in executing the on site crankshaft grinding of 6 nos. CR pins in short time of 72 hours. This achievement was possible because of the excellent design of onsite crankshaft grinding machine was developed and manufactured by RA Power solutions in house engineers. A pneumatic turbine with high capacity and latest design was used which helped technicians to execute the repairs in short duration.

MPI of Crankpin for Crack Detection is in Process Crank Pin Repair of Hyundai Diesel Engine
MPI of Crankpin for Crack Detection is in Process Crank Pin Repair of Hyundai Diesel Engine

RA Power Solutions Pvt. Ltd.  is far ahead of its competitors having more than 36 years of experience and  extending the services of crankshaft repairs all over the world.

CR pins Grinding of Hyundai engine is in Process CR Pin After Grinding
CR pins Grinding of Hyundai engine is in Process CR Pin After Grinding

Crankshaft Grinding Executed on Board a Vessel

RA Power Solutions has executed successfully grinding of 6 pins on board a vessel at Dumai/Lubuk Gaung Port, Indonesia of MAN B&W STX 6L23/30H.Engine

In this case, crankshaft grinding was required because all the CR pins having standard diameter of 185 mm developed taper and ovality. Out of 6 CR pins not even a single pin was seized  or crack was developed.

Crankshaft Deflection and MPI Test Under Process
Crankshaft Deflection and MPI Test Under Process

The above observations shows that the engine users should periodically get the crankshaft calibrated and go for grinding and polishing as crankshaft develops taper and ovality due to continuous running.

Before and After Grinding of CR Pin
Before and After Grinding of CR Pin

To execute above job, RA Power Solutions Pvt. Ltd. used crankshaft grinder which is light weight and crankshaft grinder was taken to the site.RA Power solutions has sold more then 60 crankshaft grinding machines all over the world.

                                                                                                                                    

After Grinding of CR Pin
After Grinding of CR Pin

 

On-shore and Off-shore Crankshaft Grinding Machine

RA Power Solutions Pvt. Ltd. has been successfully executing on-shore and off-shore grinding of crankshafts irrespective of its location. The services of crankshaft grinding are offered to the industries, power plants, shipping companies all over the world.

On-shore and Off-Shore Crankshaft Grinding Machine
On-shore and Off-Shore Crankshaft Grinding Machine

Crankshaft grinding machine is of latest design and can maintain the tolerance within 20 microns. The crankshaft grinding machines are light weight and can be taken on-shore and off-shore.RA Power solutions have sold more then 60 machines all over the world

Offshore Grinding of Crankshaft Under Process On-shore Grinding of Crankshaft Under Process
Offshore Grinding of Crankshaft Under Process On-shore Grinding of Crankshaft Under Process