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.
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.
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.
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.
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.
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 firstname.lastname@example.org
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.
A vessel sailing in Middle East reported damage of engine block of Yanmar 6N21L-SN due to accident.
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.
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.
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.
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 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.
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.
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.
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 email@example.com or Call us on +91-9810012383
RA Power Solutions Pvt. Ltd. manufactures gaskets for different equipments like heat exchangers, Fresh Water Generator, purifiers, etc.
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.
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.
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.
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.
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.
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.