RA Power Solutions Pvt. Ltd. was called by a leading forging company based in the western part of India, manufacturing open forgings for heavy engineering plants. One of the operations involved the use of a clear space pneumatic hammer, which they imported from Massey of the UK.
Due to constant use of the forging hammer and its age, the pneumatic chamber of the hammer developed a crack measuring 69 inches. The whole plant, due to the non-operation of this critical equipment, was on standstill. The pneumatic chamber is manufactured out of grey cast iron. The company tried to repair the crack by the
Metal Stitching Under Progress on Board the Vessel,
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 through the metal surgery process.
Metal Surgery
RA Power Solutions Pvt. Ltd. initially carried out magnetic particle test (MPI) and dye penetrant test of the 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 the metal locking process.
The keys, master metal locks, and all consumables used for metal surgery were imported from the 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 a crack in cast iron, is cold, no heat is generated, and is a proven method for successful repair of a crack in cast iron casting.
We have more than 45 years of experience of executing crack repair in cast iron by metal surgery, crack repair in cast iron and have experienced technicians available to execute the crack repair onsite in minimum time and cost.
For more information, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
Reduce Cost And Breakdown Time By Onsite Repair Of Crankshaft
The failure of the crankpin and main journal bearing causes serious damage to the crankshaft, which is as follows:
Development of excessive taper and ovality in Crankshaft, Crankpin, and Main Journal.
Development of a crack
Abnormal increase and decrease in hardness
Loss of alignment of the crankshaft, increasing deflection readings.
Development of bearing line marks, pitting, and local depression
Damage to the radius fillet and lube oil profile
The onsite crankshaft grinding equipment developed and manufactured by us is capable of undertaking the grinding and polishing of the crankshaft in one setting. The tolerances after crankshaft repair are strictly maintained as per the manufacturer’s specifications.
Removal of Crankshaft from Engine Block
Repair of Crankshaft is in Process
We have a highly trained and skilled team of technicians who are deployed to the plant site or on a vessel in the shortest possible time. The process we follow for repairing the crankshaft is faster, more cost-effective, and more convenient. It, of course, avoids the removal of the crankshaft and transport to the workshop.
The repair of the crankshaft , onsite repair of crankshaft was executed by RA Power Solutions Pvt. Ltd is approved by leading inspection agencies, including Lloyds, DNV, and many other inspection agencies. For more information, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
RA Power Solutions Pvt. Ltd. extends repair services for main and auxiliary engines, high-capacity compressors, pumps, and rotating equipment. We have the latest design portable equipment, which is carried to the client’s site, whether they are land-based power plants or vessels on the move. The services are offered through trained technicians. Being an Indian company having more than 45 years of experience, we are well known for sincerity, on-time services, and the lowest price in this industry. A few of the services offered to us are as under:
Metal Locking and Metal Stitching
Metal locking and metal stitching is a cold process for the repair of steel casting, which develops cracks or breaks into pieces due to overload, stress, or an accident. RA Power Solutions Pvt. Ltd. has experience of more than 45 years in undertaking the repair of most complex accidental damage to plant and machinery, high capacity marine engines, diesel generating sets, engine blocks, cylinder heads, turbine casing, etc. The repair of casting by metal stitching and metal locking has been executed by trained and experienced engineers having experience of 45 years.
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Engine Block Ready After Metal Stitching Process
Engine Block Ready After Metal Locking Process
Consumables like metal locks and metal keys are procured from reputed companies based in the USA and the UK. We are cost-effective and can depute our team of technicians within 6 6-hour notice.
Material Used in the Metal Locking and Metal Stitching Process
We are experts in the Crankshaft Repair Servicesof high-capacity marine engines up to 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 the white metal rotor shaft bearing, it is necessary to inspect the rotor shaft bearing’s seating diameter. We undertake a complete inspection of the rotor shaft, grinding and polishing onsite. The rotor shaft repair, grinding, and polishing are done without dismantling the rotor shaft from the casing. The rotor shaft grinding and polishing are done onsite.
Rotor shaft white metal Babbitt bearings are manufactured, and rebabbitting of old rotor shaft bearings is also undertaken. We guarantee the satisfactory performance of white metal Babbitt bearings.
Onsite Rotor Shaft Grinding
Rotor Shaft Grinding in Process
Connecting Rod Repair
Connecting rod repair is undertaken with a guarantee, absolutely no need to replace the connecting rod, as in most cases, connecting rods can be repaired and reused.
RA Power Solutions Pvt. Ltd. undertakes in-house repair of connecting rods, including re-boring of the big ends and small ends, checking for hardness, cracks, etc.
Connecting Rod Assembled with Piston After Repair
Liner, Piston, Connecting Rod, and Cylinder Head Under Assembly Supplied by RA Power Solutions
Connecting rods for all makes and models 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, Nohab, etc.
Connecting Rod of the MAN engine
Reconditioning of Connecting Rod
Cylinder Heads
Cylinder Heads are reconditioned at our works. We replace valve seats, valve guides, and recondition the cylinder head, 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 a metal lockingprocess, which is a cold and proven method of crack repair. Second-hand reconditioned cylinder heads are also supplied with a guarantee at a competitive price.
Cylinder Head of Marine Diesel Engine
Cylinder Head
Rebabbitting of Bearings
Rebabbitting of old white metal bearings of diesel engines, turbines, alternators, and all applications is undertaken. Rebabbitting of white metal bearings is done by a centrifugal process, which ensures dense and uniform bonding with the base steel.
We undertake rebabitting of bearings up to 1500 mm in diameter. The white metal used for rebabbitting is imported from Spain. The metallurgical certificate for white metal and the dimensional inspection report are submitted after rebabbitting of white metal is done.
For more information on onsite crankshaft repair services, cylinder liners exporter, cylinder liners, engine cylinder liner, cylinder sleeve manufacturer, metal locking, repair of rotor shaft, and onsite repair services of crankshaft, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
A vessel sailing in the Middle East reported damage to the engine block of Yanmar 6N21L-SN due to RA Power Solutions Pvt. Ltd. deputed a team of technicians with consumables. The broken pieces were assembled, and metal stitching and metal locking were used. The total broken area was 46 inches. The broken pieces were reassembled, and metal stitching was due to a shortage of time and to put on the generator in the minimum possible time. The other alternate option was to use the new piece of casting, which was not done in this case due to a shortage of time constraint.
Yanmar Marine Diesel Engine
RA Power Solutions Pvt. Ltd. deputed a team of technicians with consumables. The broken pieces were assembled and metal stitched/metal locked. The total broken area was 46 inches. The broken pieces were reassembled and metal stitched due to a shortage of time and to put on the generator in the minimum possible time. The other alternate option was to use the new piece of casting, which was not done in this case due to a shortage of time.
Broken Engine Block of Yanmar Engine
Assembly of Broken Pieces of Engine Block
Metal Stitching of Engine Block in Process
Metal Locking of Engine Block in Process
Repair of Engine Block by Metal Locking Process
Engine Block Ready After Metal Locking Process
For further details regarding the metal stitching of engine block, metal stitching service provider, broken engine block of Yanmar, Yanmar marine diesel engine, and broken engine block, etc., contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
Cast iron components can develop cracks and break into pieces due to an accident or overload. Replacing a cracked component is expensive. It is recommended to repair cracks and broken casting by metal stitching and the metal locking process.
Repair Crack and Broken Casting by Metal Stitching / Metal Locking Process
Repair of cracked components is executed by experienced technicians, and we use the consumables comprising of metal locks and metal keys procured from companies based in the UK and the 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 the repair of a crack by welding is not successful. To get more information regarding cracked engine block metal stitching, metal stitching of crack casting, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
RA Power Solutions undertakes the reconditioning of connecting rods irrespective of their size and load factor. We have special-purpose equipment for inspection of connecting rods and repairs. The following steps are taken for the reconditioning of connecting rods.
Connecting rods are disassembled and cleaned with a special chemical.
Dimensional inspection of the large end and the small end bore is done.
The connecting rod is also checked for any loss of alignment on a special-purpose boring machine loaded with DRDO.
Dye penetrant test and MPI are done for crack detection. Special attention is given to detecting the crack in the serration area, connecting rod bolts, and bolt seating area.
Machining and grinding are done to restore the original dimensions of the big end and small end of the connecting rods.
Connecting Rod Reconditioning
Reconditioning of Connecting Rod
Connecting rods are inspected by a senior technician, and reports are maintained.
RA Power Solutions has successfully undertaken the repair of more than 15,000 connecting rods in the last 45 years of operation. RA Power Solutions also exports reconditioned connecting rods at a low price with a guarantee.
For more information about Connecting Rod Reconditioning, Used Connecting Rod, or Connecting Rod, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
RA Power Solutions Pvt. Ltd.undertakes complete reconditioning of cylinder heads. It is observed that cracks develop due to sudden changes in the temperature of cylinder heads. We recommend the repair of cracks by the metal stitching process, which is cold and no heat is generated. The valve seat and valve guides should also be replaced with cylinder heads. We have Chris’s marine equipment for reconditioning cylinder heads.
Cylinder Head
RA Power Solutions Pvt. Ltd. also maintains a large stock of reconditioned cylinder heads, which are supplied at very low prices. All cylinder heads are guaranteed for performance. The cylinder heads of the following makes of engines are available in stock.
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., are available in stock.
MAK Cylinder head
On-site Diesel Engine Repair is one of the important services provided by RA Power Solutions. We have ex-engineers from engine manufacturers like Wartsila, Caterpillar, Ruston, Cummins, Deutz, etc, who have joined hands with us. Technicians and engineers are experienced and can meet any emergency requirement of diesel engine repair due to accidents for land-based or vessel-mounted main and auxiliary engines.
Cylinder Head of Deutz Engine
Cylinder Head of Marine Diesel Engine
The normal routine overhauling of diesel engines is also undertaken. The main advantage of onsite diesel engine repair services extended by RA Power Solutions is that we have in-house facilities for undertaking the repair of major components like engine block, crankshaft, cylinder head repair, etc, and there is no need to engage a third party. We are world-famous for extending onsite crankshaft grinding repair and all the services related to diesel engines.
The author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd., having experience of more than 45 years. He is instrumental in executing the successful repair of crankshaft, engine block, cylinder heads, connecting rods, and mechanical equipment replacement costs, which work out to millions of dollars.
Sulzer Cylinder Head
For more information regarding cylinder head repair, you can contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +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, and quality of the gaskets are 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
RA Power Solutions is a one-stop shop for all your problems related to crankshaft grinding, insitu crankshaft repair and grinding, whether there is a requirement for repair services, supply of spare parts, or consulting services. We are respected all over the world as the most trusted and cost-effective company. Contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
RA Power Solutions offers the latest technology for onsite machining of crankshafts. The services of onsite crankshaft repair are offered worldwide using a range of specially designed orbital turning equipment to repair damaged crankpins and the main journal of diesel engines, compressors, and reciprocating equipment.
We have factory-trained, highly skilled, and motivated technicians to offer onsite repair of damaged crankshafts, either onboard or offshore. The company has been in the business of offering onsite crankshaft grinding and polishing for the last 45 years and is well-known all over the world for its quality repair.
More than 1000 crankshafts have been repaired successfully all over the world, with diameters ranging from 40-700 mm. Unlock precision and efficiency with RA Power’s crankshaft grinder machine! Boost engine performance, reduce downtime, and ensure top-notch crankshaft quality. Take action now and revolutionize your machining process with our cutting-edge solutions!
Insitu Crankshaft Grinding Machine
RA Power Solutions offers state-of-the-art crankshaft grinder machines, designed for precision and reliability in crankshaft repair and refurbishment. Elevate your engine performance with our cutting-edge technology. Explore our range now!
For any information regarding the crankshaft machining, crankshaft grinder machine and crankshaft machining, email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383
Grinding of the rotor shaft is required due to wear and tear of the rotor shaft diameter, damage to the rotor shaft bearing seating area, or failure of the bearing. RA Power Solutions undertakes onsite grinding and polishing of rotor shafts having diameters up to 700 mm. The initial inspection of the rotor shaft is conducted by experienced technicians, which includes crack detection by MPI, hardness test, and dimensional inspection.
Rotor Shaft Grinding Machine
Onsite grinding of the rotor shaft is performed using the latest design of rotor shaft grinding machine. It was developed and manufactured by RA Power Solutions. The rotor shaft grinding machine has almost zero vibration, which helps to maintain the tolerance of the rotor shaft. Their bearing sitting area up to 20 microns.
RA Power Solutions Pvt. Ltd. has successfully executed more than one thousand jobs of grinding rotor shafts, crankshaft grinding, and rotating equipment.
Onsite Rotor Shaft Grinding Machine
Rotor Shaft Grinder
RA Power Solutions specializes in the comprehensive refurbishment of rotor shafts. Our expert team employs cutting-edge techniques to restore your rotor shafts to their optimal condition. Enhance reliability and efficiency while extending the lifespan of your critical components. Trust us for top-notch rotor shaft refurbishment services. For information on the refurbishment of the rotor shaft, grinding of main journals, and Onsite Rotor Shaft Grinding Machine, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
