Crankshaft Repair

Crankshaft repair is recommended in case of following:

I) Development of excessive taper and ovality in crank pin journal and crank main journal.

II) Development of crack and increase in hardness due to failure of bearing.

III) Loss of Alignment of crankshaft

IV) Development of deep bearing line marks, rough surface, pitting, etc.

Crankshaft repair is undertaken by rap by grinding of crankshaft onsite. Crank pin journal and main journal of crankshaft grinding is done of diameter ranging from 60 mm to 700 mm.

We are cost effective and have four decades of experience in Crankshaft repair and crankshaft grinding.

Crankshaft Repair
Crankshaft Repair

 

Crankshaft Grinding on Board a Vessel
Crankshaft Grinding on Board a Vessel

Marine Engine Bearings

Engine bearings for crankpin and main journal are manufactured by RA Power Solutions Pvt. Ltd. We also maintain stock of standard and undersized bearing in trimetal and bimetal of popular make and model of engines.

Alternator Bearing of Wartsila 12V32
Alternator Bearing of Wartsila 12V32
White Metal Bearing of Deutz Engine
White Metal Bearing of Deutz Engine

 

 

 

 

 

After grinding of crankpin and main journal of crankshafts undersize crankpin bearings and main journal bearings are required. It is observed that engine manufacturers in most of the times do not have inventory of undersized bearings, thus delaying the assembly and commissioning of engine.

Ruston Engine Bearing
Ruston Engine Bearing
Engine Bearing of Daihatsu DS 26
Engine Bearing of Daihatsu DS 26

 

 

 

 

 

 

 

 

RA Power Solutions undertake onsite grinding of crankshafts for last more than 37 years.We understand the importance of ready availability of standard bearing, undersized bearings of trimetal and bimetal and bearings for popular engines and models are available in stock. Following is the list of engine for which engine bearings are available.

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.

Engine Bearings for MAN Diesel Engine
Engine Bearings for MAN Diesel Engine
Engine Bearing of Yanmar Diesel Engine
Engine Bearing of Yanmar Diesel Engine

 

 

 

 

 

 

RA Power Solutions stands guarantee for satisfactory performance of engine bearings. The main journal bearings and crank pin bearings are priced lower than the industry with immediate delivery.

Bearings for Diesel Engine
Bearings for Marine Diesel Engine

Author is Mr. Raj Shahani, Managing Director of the company. He is having more than 36 years of experience in rebabbitting of bearings, metal locking/metal stitching of crack steel casting, grinding and repair of all shafts and all services related to repair of engines and supporting equipments.

Company has in-house trained technicians, equipments, marine engine spares for all make and model of engine and serves all over the world.

For more information, please free to call us on +91-9810012383 and email us on info@rapowersolutions.com

 

Crack Repair of Cast Iron by Metal Stitching/Metal Locking Process

RA Power Solutions Pvt. Ltd. has recently undertaken crack repair of cast iron engine block by metal stitching and metal locking process. Engine block which is made of cast iron was broken from the window cover sitting area. The engine block was broken in to pieces measuring approximate 330 x 420 mm.

RA Power Solutions Pvt. Ltd. after getting the dimensions got the casting made of cast iron and it was metal locked and metal stitched on board a vessel. The engine after repairs is performing satisfactory.

Broken Engine Block
Broken Engine Block
Cast Iron Casting Prepared by RA Power Solutions Pvt. Ltd.
Cast Iron Casting Prepared by RA Power Solutions Pvt. Ltd.

 

 

 

 

 

 

In 37 years of experience we have executed more than 1000 jobs of crack repair by metal stitching and metal lock surgery not only for shipping but for all sectors of industry.

Perhaps we are the only company in the world to execute crack repair of engine components or any crack in metal on board a vessel while sailing.

Metal stitching and metal locking process on board the vessel:

Keys and Locks Used in Metal Locking and Metal Stitching Process
Keys and Locks Used in Metal Locking and Metal Stitching Process
Metal Stitching Under Progress on Board the Vessel
Metal Stitching Under Progress on Board the Vessel

 

 

 

 

 

 

 

Metal Stitching Under Process
Metal Stitching Under Process
Casting Piece Stitched in Broken Area of Engine Block
Casting Piece Stitched in Broken Area of Engine Block
Metal Stitching and Metal Locking Under Progress
Metal Stitching and Metal Locking Under Progress

 

 

 

 

 

 

 

Final finish given to Damaged Area of Engine Block
Final finish given to Damaged Area of Engine Block

 

 

 

 

 

 

 

 

 

Author is Mr. Raj Shahani, Managing Director of the company. He is having 37 years of experience in metal stitching and metal locking of crack repair, grinding of crankshaft and all services related to repair of engines and supporting equipments.

Company has in-house trained technicians,equipments and serves all over the world.

Crack Repair by Metal Surgery

RA Power Solutions Pvt. Ltd. was called by a leading forging company based in western part of India manufacturing open forgings for heavy engineering plants. One of the operation involved use of clear space pneumatic hammer which they imported from massey of UK.

Due to constant use of forging hammer and its age the pneumatic chamber of the hammer developed a crack measuring 69 inches. The whole plant due to non operation of this critical equipment was on stand still. The pneumatic chamber is manufactured out of grey cast iron. The company tried to repair the crack by welding process and engaged a leading company to execute the repairs. The crack repair of the cast iron pneumatic chamber was not successful. RA Power Solutions Pvt. Ltd. was called to repair the crack by metal surgery process.

Materials Used in Metal Stitching/Metal Locking Process
                       Materials Used in Metal Stitching/Metal Locking Process

RA Power Solutions Pvt. Ltd. initially carried out magnetic particle test (MPI) and dye penetrant test of cast iron pneumatic chamber to check the exact length and the profile of the crack developed. The paint including red oxide applied on the cast iron pneumatic chamber was removed completely. The crack of 69 inches was repaired by our technicians by metal stitching and metal locking process.

The keys, master metal locks and all consumables used for metal surgery were imported from UK. After the completion of metal stitching and metal locking operations, the chemicals were applied to stop the air leakage from the pneumatic chamber.

Metal Stitching/Metal Locking Procedure
                                 Metal Stitching/Metal Locking Procedure

This process of metal surgery followed by us for repair of crack in cast iron is cold process, no heat is generated and is proven method for successful repair of crack in cast iron casting.

We have more than 37 years of experience of executing crack repair in cast iron by metal surgery and have experienced technicians available to execute the crack repair onsite in minimum time and cost.

Crack Repair by Metal Surgery
                            Crack Repair by Metal Surgery

 

Repair of Crankshaft

Reduce cost and breakdown time by Onsite Repair of Crankshaft

The failure of crankpin and main journal bearing causes serious damage to the crankshaft which are as following:

I) Development of excessive taper and ovality in Crankshaft, Crankpin and Main Journal.

II) Development of crack

III) Abnormal increase and decrease of hardness

IV) Loss of alignment of crankshaft resulting to the increase in deflection readings.

V) Development of bearing line marks, pitting, local depression

VI) Damage of radius fillet and lube oil profile

The removal of crankshaft from the engine block inevitably means high cost and disruption due to transportation and repair in the designated workshop. Removing and sending the crankshaft for repair to the workshop is now outdated.

Removal of Crankshaft from Engine Block
Removal of Crankshaft from Engine Block
Repair of Crankshaft is in Process
Repair of Crankshaft is in Process

 

 

 

 

RA Power Solutions Pvt. Ltd undertakes crankshaft repair onsite without removing it from engine block. The onsite crankshaft repair equipment is placed on the damaged crankpin through the inspection window of the engine block and the grinding is undertaken.

The onsite crankshaft grinding equipment developed and manufactured by us is capable to undertake grinding and polishing of crankshaft in one setting. The tolerances after crankshaft repair are strictly maintained as per the manufacturer’s specifications.

Onsite Crankshaft Grinding amd Polishing Machine
Onsite Crankshaft Grinding amd Polishing Machine
Repair of Crankshaft
Grinding of Crankshaft

 

 

 

 

 

 

We have highly trained skilled team of technicians who are deputed to the plant site or on a vessel in a minimum possible time. The process followed by us for repair of crankshaft is faster, more cost effective and convenient. It ofcourse avoids removal of crankshaft and transport to the workshop.

The repair of crankshaft executed by RA Power Solutions Pvt. Ltd is approved by leading inspection agencies including Lloyds, DNV and many other inspecting agencies.

For more information, please write us on rajshahani@rapowersolutions.com

Crank Pin After Grinding and Polishing
                       Crank Pin After Grinding and Polishing

Repair Services Offered by RA Power Solutions Pvt. Ltd.

Ra Power Solutions Pvt. Ltd. extends repair services for main and auxiliary engines, high capacity compressors, pumps and rotating equipments.

Repair Services for Main and Auxiliary Engines
Repair Services for Main and Auxiliary Engines

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.

Repair crack and broken casting by metal stitching process
Repair Crack and Broken Casting by Metal Stitching Process
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

 

 

 

 

 

 

Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Locking Process
Engine Block Ready After Metal Locking Process

 

 

 

 

 

 

 

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.

Material Used in Metal Locking and Metal Stitching Process
Material Used in Metal Locking and Metal Stitching Process

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.

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

 

 

 

 

 

 

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.

Connecting Rod Assembled with Piston After Repair
Connecting Rod Assembled with Piston After Repair

We supply second hand reconditioned connecting

Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions
Liner, Piston, Connecting Rod, Cylinder Head Under Assembly Supplied by RA Power Solutions

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.

 

Connecting Rod of MAN engine
Connecting Rod of MAN engine
Reconditioning of Connecting Rod
Reconditioning of Connecting Rod

 

 

 

 

 

 

Cylinder Heads

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.

Cylinder Head of Marine Diesel Engine
Cylinder Head of Marine Diesel Engine
Cylinder Head
Cylinder Head

 

 

 

 

 

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.

Crankshaft White Metal Babbitt Bearing
Crankshaft White Metal Babbitt Bearing
Crankshaft Bearings
Crankshaft Bearings

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