Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair- RA Power Solutions

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, cast iron or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of Crack or damaged components. In most cases, the repairs are undertaken on site without dismantling the major components. This results in the saving of downtime of the plant & money.

RA Power Solutions is a leader in this field of repair of large damaged casting components by Metal stitching & Metal Locking, we offer Crack repair services 24/7 through our technicians who are well experienced. Our senior most technician executing Crack repair by Metal Locking & Metal Stitching process has 35 years of experience and have the record of executing more than 1500 jobs which are saved from rejection and are performing satisfactorily.

Broken Crankcase Door of Engine
Broken Crankcase Door of Engine
Metal Stitching & Locking of Crankcase Door is under progress
Metal Stitching & Locking of Crankcase Door is Under Progress

 

 

 

 

 

 

 

The repair of Crack and damaged casting by Metal Locking & Metal Stitching process was developed in late 1930 as cold option for repair of Crack or damaged cast iron components & equipment. This process of casting crack repair has proved successful as it is cold and stress-free without generation of any heat. In most of the crack repair jobs undertaken by us, it does not require machining.

Our technicians have Indian CDC / Palau CDC which facilitates them to execute the Crack repair even while sailing of the vessel this again proves to be of great advantage to the ship owners and the industries.

Metal Stitching & Metal Locking of Lobe Blower Casing
Metal Stitching & Metal Locking of Lobe Blower Casing

The author is Mr. Raj Shahani Managing Director of RA Power Solutions having experience of almost four decades of working on high capacity diesel engines, turbines, and rotary equipment. The company specializes in executing the repairs i.e. metal stitching/metal locking, grinding and repair of crankshafts, rebabbitting of bearings, connecting rod reconditioning, overhauling of Engines which have a serious problem resulting to the immense saving to the owners.

For more information, please email us on info@rapowersolutions.com or Call us on +91 – 124 – 437 8292, +91 9213604692

Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump Repairing
Metal Stitching & Metal Locking of Suction Bell Mouth of CW Pump
Broken Suction Bell Mouth of CW Pump
Broken Suction Bell Mouth of CW Pump

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, cast iron or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of Crack or damaged components. In most cases, the repairs are undertaken on site without dismantling the major components. This results in … Continue reading “Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair- RA Power Solutions”

Diesel Engine Overhaul | Diesel Engine Repair | Crankshaft Main Bearing Replacement

RA Power Solutions was informed regarding the failure of three nos Crank pin Bearings of MAN B&W 5L60MC main engine onboard a vessel near South Africa.

RA Power experienced team of technicians boarded the vessel in a short time of 18 hours of receipt of intimation regarding the problem faced by the vessel. Following jobs were executed for overhaul and replacement of crankpin bearings in order to operate the engine satisfactorily after Engine repair and Engine overhaul.

MAN B&W 5L60MC Engine Repair & Overhauling is in Process
MAN B&W 5L60MC Engine Repair & Overhauling is in Process
DESCRIPTION:

I) Inspection and overhaul of the cylinder covers including the fuel and starting valves located in the covers.

II) The cylinder covers cooling spaces were also inspected, cleaned and fitted back with new O-rings.

III) Dismounting, Inspect and overhaul of the exhaust valves, renewed the seats and grinding the valve spindles.

IV) The cylinder liners were cleaned, calibrated and honed in order to restore the liners running surfaces and remove ovality. This ensured that the piston rings perform better and this will lead to a better overall cylinder condition, compared to if honing had not been done. The cylinder liners cooling spaces were also inspected, cleaned and fitted back with new o-rings.

Inspection of Engine Spares is in Process
Inspection of Engine Spares is in Process
Inspection and Repair of Crankshaft
Inspection and Repair of Crankshaft
V) The Crank pin  bearing caps were dismounted, both top and bottom bearing shells renewed

VI) The Crankshaft Crankpin  diameter was checked for the following parameters:

a) Visual inspection to check the presence of any Bearing Line marks or rough surface.

b) All the Crankpins were calibrated for taper & ovality.

c) Hardness was checked and observed within limits.

d) MPI was done to check the presence of any crack.

e) Crankshaft all pins were polished by onsite Crankshaft Grinding Machine removing the bearing line marks and for improving the Crank pin surface finish.

Onsite Repair of Crankpin by Crankshaft Grinding Machine
Onsite Repair of Crankpin by Crankshaft Grinding Machine
VII) Adjustment of the variable injection timing (VIT)

VIII) The bearing clearances were taken using lead wire

IX) Crankshaft alignment measurement was taken with a dial gauge.

Conclusion: After replacement of Bearings & Jobs described above undertaken at the time of Engine overhaul & Bearing replacement the engine was tested on the load & performance was observed satisfactory.

Repair of Crankpin is in Process
Repair of Crankpin is in Process
Inspection of Connecting Rod on Moving Vessel
Inspection of Connecting Rod on Moving Vessel

RA Power Solutions was informed regarding the failure of three nos Crank pin Bearings of MAN B&W 5L60MC main engine onboard a vessel near South Africa. RA Power experienced team of technicians boarded the vessel in a short time of 18 hours of receipt of intimation regarding the problem faced by the vessel. Following jobs … Continue reading “Diesel Engine Overhaul | Diesel Engine Repair | Crankshaft Main Bearing Replacement”

Thread repair insert | Crack repair engine block cover

RA power under takes repair of threads and cracks which get damaged due to accident following are advantage

  • Threads of various parts like engine block, turbine casing, cam block get damaged due to the stress or accident
  • Damaged threads are repaired by our engineers onsite without dismantling of the parts
  • The portable lightweight special purpose machines are carried to the site for all the operations required for repair for damaged threads
  • New inserts are fitted in the damaged threads maintaining the same dimensions as of originals. Same size of bolts are used.
  • In case of cracks observed on the threads hole area which is common due to accident it is repaired by the metal lock and metal stitching process.
  • The repairs of damaged threads by using the insert saves the part from rejection and saving to the owners

RA power has experience of more than  40 year in repairing of damaged threads and cracks in mechanical equipments all the repairs undertaken are guaranteed for satisfactory performance.

RA power under takes repair of threads and cracks which get damaged due to accident following are advantage Threads of various parts like engine block, turbine casing, cam block get damaged due to the stress or accident Damaged threads are repaired by our engineers onsite without dismantling of the parts The portable lightweight special purpose … Continue reading “Thread repair insert | Crack repair engine block cover”

Cylinder Liners | Marine Engine Cylinder Liners | Cylinder Liner High Quality

Cylinder Liners have important role in satisfactory performance of the engine. RAP manufactures and exports Cylinder Liners of Cast Iron and Alloy Steel as per the composition described by the manufacturer of the engine.  The Cylinder Liners are manufactured up to length of 1500 mm.
In order to ensure the high quality of liners casting, we use centrifugal process which ensures that there are no blow holes and any abnormalities in casting of Cylinder Liners.
Following quality checks are undertaken during the manufacturing of cylinder liners and cylinder sleeves.

Cylinder Liners and Cylinder Sleeves of MAN Engine
Cylinder Liners and Cylinder Sleeves of MAN Engine

I.) The metallurgical property and composition is maintained strictly as per the recommendation of the original engine manufacturer.

II.) Each Liner is subject to visual inspection for blow hole and for any casting defect.

III.) Cylinder Liners are subject to crack detection by high intensity Magnaflux Equipment for crack detection.

IV.) Important parameters of Cylinder Liners like hardness, honing angle, dimensions are checked and reports are submitted to the clients.

RA Power solutions stands guarantee for the satisfactorily performance of cylinder liners and sleeves.

Cylinder Liners Of Allen Diesel Engine
Cylinder Liners Of Allen Diesel Engine

We manufactures and export  Cylinder Liners of the engine- like ABB, ABC, Anglo Belgian Corporation, Akasaka, Alco Diesel Engines, Alfa Laval, Allen, Alpha Diesel, Alstom, B & W, Bergen Diesel Engines, Blackstone, Bosch, Caterpillar, Cegielski, Consilium, Crepelle, Cummins, Daihatsu, Detroit Diesel, Deutz, Deutz Marine Engine, EMD, Fiat, FUJI, Fuji Diesel, Furuno, Hanshin, Headway, HIMSEN, Holset, Hyundai, JRC, Kawasaki, Kelvin Hughes, Kongsberg Maritime, L’Orange Maschinenfabrik, MaK, MAN, MAN B&W, Martek Marine, Mirrlees Blackstone, Mitsubishi, Mitsubishi UE/UEC, MTU, MWM, Napier, NAVTEX, Nigata, Nohab Diesel, Paxman, Pielstick, Ruston & Hornsby, Samsung, Simrad, SKL, Sperry, Stork SW Diesel, Stork Werkspoor, STORK-WARTSILA DIESEL, Sulzer, Volvo Penta, Wartsila, Wartsila Diesel, Westfalia, Wichmann, Woodward, Yanmar etc.

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Cylinder Liners After Honing
Cylinder Liners After Honing
Cylinder Liner after Phosphating
Cylinder Liner after Phosphating

Cylinder Liners have important role in satisfactory performance of the engine. RAP manufactures and exports Cylinder Liners of Cast Iron and Alloy Steel as per the composition described by the manufacturer of the engine.  The Cylinder Liners are manufactured up to length of 1500 mm. In order to ensure the high quality of liners casting, … Continue reading “Cylinder Liners | Marine Engine Cylinder Liners | Cylinder Liner High Quality”

Metal Stitching | Metal Locking | Metal Stitching of Engine Block | Repair of Cast Iron by Metal Stitching

High Capacity Engine and Rotatory Equipments have the components made of Cast Iron and Cast Steel. In case of any damage and development of crack in Olden times, the option was either to replace the component which used to work out very expensive or to repair it by welding process. Which was not always successful.

 

With the improvement in repair technology now, it is possible to repair the crack in  cast iron, steel or aluminium component by metal stitching and metal locking process. The main feature of repair of crack or damaged casting by metal stitching , metal locking and metal surgery is that process does not require disassembly of the equipment and taking the crack or damaged part to the work shop.

New Casting Inserted for Repair of Engine Block
New Casting Inserted for Repair of Engine Block
Damage Area of Engine Block
Damage Area of Engine Block
RA Power Solutions has the team of experience technicians. They can travel to the site with tools and consumables required for metal stitching and metal locking and undertake the repair.  The original profile after crack repair by metal locking and metal stitching is maintained  and in most cases, no machining is required. It is scientifically proved that crack portion of the  component which is repaired by metal locking and metal stitching process has more  tensile strength.

 

RA Power Solutions with the experience of forty years in this field extends metal locking and metal stitching services for repair of damaged casting.  The repair can also be executed while sailing of Vessel. We are considered to be lowest in the cost in comparison to our competitors.

 

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Metal Stitching of Engine Block by Special Keys & Locks
Metal Stitching of Engine Block by Special Keys & Locks
Metal Stitching & Metal Locking of Engine Block Under Process
Metal Stitching & Metal Locking of Engine Block Under Process

High Capacity Engine and Rotatory Equipments have the components made of Cast Iron and Cast Steel. In case of any damage and development of crack in Olden times, the option was either to replace the component which used to work out very expensive or to repair it by welding process. Which was not always successful. … Continue reading “Metal Stitching | Metal Locking | Metal Stitching of Engine Block | Repair of Cast Iron by Metal Stitching”

Connecting Rod Repair | Reconditioning of Connecting Rod

Connecting rods of high capacity main and auxiliary engines are repaired by RA Power Solutions. We have vast knowledge and experience of four decades with the repairs and resizing of connecting rod strictly as per the manufacturer specifications and tolerances.

Reconditioned Connecting Rods of MAK Engine in Stock
Reconditioned Connecting Rods of MAK Engine in Stock

It is our experience that most of the users are not aware of the fact that in case of development of taper and ovality, connecting rods can be repaired and high cost of purchase of new connecting rods can be avoided. We undertake repair of connecting rod in case  following abnormalities observed:

I) Damage of serration to some extent.

II) Damage of small end and replacement of bush.

III) Development of taper and ovality more then the prescribed limit.

We do not recommend repair of connecting rod in case loss of alignment or cracks are observed.

Connecting rods repaired by RA Power Solutions are guaranteed for satisfactory performance. Calibration certificate is issued for each connecting rod after repair.

Reconditioned Connecting Rod of Allen Engine in Stock
Reconditioned Connecting Rod of Allen Engine in Stock

RA Power Solutions also maintain large stock of used connecting rods which are reconditioned in-house and are available ex-stock. All the important parameters of used connecting rods after reconditioning are maintained as new one.

The cost of reconditioned connecting rod is considerable low in comparison to new connecting rods sold by the engine manufacturers. Owners can save substantial cost by using reconditioned connecting rod.

We export connecting rod of  engines like Ruston, Allen, B&W, DAIHATSU, MAN, Mirrlees Blackstone, Niigata, Caterpillar, Deutz, Wartsila, Sulzer, Yanmar, Bergen, Mitsubishi, Cummins etc.

For more information, please email us on info@rapowersolutions.com or call us on +91-9582647131

Reconditioning of Connecting Rod is in Process
Reconditioning of Connecting Rod is in Process
Connecting Rod of Yanmar Engine Ready for Inspection Before Reconditioning
Connecting Rod of Yanmar Engine Ready for Inspection Before Reconditioning
Inspection of Connecting Rod on Board a Vessel
Inspection of Connecting Rod on Board a Vessel

Connecting rods of high capacity main and auxiliary engines are repaired by RA Power Solutions. We have vast knowledge and experience of four decades with the repairs and resizing of connecting rod strictly as per the manufacturer specifications and tolerances. It is our experience that most of the users are not aware of the fact … Continue reading “Connecting Rod Repair | Reconditioning of Connecting Rod”

Cylinder Liners/Cylinder Sleeves of Diesel and Marine Engine

In case of diesel engines, cylinder liners as the name describes forms the cylindrical space in which the piston reciprocates.

The cylinder liners/cylinder sleeves used in high capacity diesel engines, marine engine and other applications have far superior material in comparison to cylindrical block of the diesel engine.

Mirrlees Blackstone Engine Cylinder Liners/Cylinder Sleeves
Mirrlees Blackstone Engine Cylinder Liners/Cylinder Sleeves

RA Power Solutions understands the importance of cylinder liner application and manufactures the cylinder liners having following features:

I) The cylinder liners manufactured are of alloyed cast iron with composition of chromium, vanadium and molybdenum. The percentage varies according to the application of the cylinder liner.

II) Cylinder liner of cast iron manufactured by RA Power Solutions contains graphite which is considered to have good lubricant properties.

III) The alloying elements used at the time of casting of cylinder liner resist corrosion and improves the wear resistance at high temperatures.

IV) The cylinder liners are cast by centrifugal system which ensures dense and blow hole free casting.

V) The cylinder liner manufactured by RA Power Solutions are high wear resistance having good thermal conductivity and internal damping properties.

VI) The cost of the cylinder liners is considerably low in comparison to the cylinder liners supplied by the manufacturers of the engines. All cylinder liners stand guarantee for the satisfactory performance.

Second Hand Cylinder Liner
Second Hand Cylinder Liner

 RA Power Solutions manufactures and exports following cylinder liners.We can develop new range of cylinder liners as per the sample and drawing.

We manufacture and export cylinder liners for following engine make:

CKD Skoda (All models of Engine), Ruston, Allen, B&W, DAIHATSU, MAN, Mirrlees Blackstone, Niigata, Caterpillar, Deutz, Wartsila, Sulzer, Yanmar, Bergen, Mitsubishi and Cummins etc.

For more information, please email us on info@rapowersolutions.com

Reconditioned Cylinder Liners Ready for Dispatch
Reconditioned Cylinder Liners Ready for Dispatch

In case of diesel engines, cylinder liners as the name describes forms the cylindrical space in which the piston reciprocates. The cylinder liners/cylinder sleeves used in high capacity diesel engines, marine engine and other applications have far superior material in comparison to cylindrical block of the diesel engine. RA Power Solutions understands the importance of … Continue reading “Cylinder Liners/Cylinder Sleeves of Diesel and Marine Engine”

Grinding of Crankshaft in Oman by RA Power Solutions

A vessel sailing near Oman  reported serious breakdown of auxiliary engine of Yanmar model 6N18AL. RA Power Solutions team which is always ready for emergency response left for Oman and conducted the detailed inspection of the engine. It was observed that crankpin no. 4 bearing seized resulting to the damage of CR pin no. 4. All other crankpins also developed ovality to the extent of maximum 0.20 mm.

Damaged Crankpin of Yanmar Engine
Damaged Crankpin of Yanmar Engine
Crack Detection Test of Crankpin
Crack Detection Test of Crankpin

After checking the hardness, crack and other parameters of the crankpins the grinding was started. The ship was to sail to the next port and it was decided that grinding of crankshaft is to be executed by RA Power Solutions technicians while the sailing of the vessel. RA Power Solutions having portable latest design of crankshaft grinding machine with almost no vibrations started the grinding of crankshaft while the sailing of the vessel. The 6 crankpins grinding to 0.40 mm undersized was completed in a short time of 60 hours. The repair of crankshaft was successful as the engine was put back in to operation and is performing satisfactory.

Onsite Crankpin Grinding is in Process
Onsite Crankpin Grinding is in Process

RA Power Solutions having 40 years of experience in field of crankshaft grinding has achieved many land marks and have performed more than satisfactory for the clients spread all over the world. The expert team of crankshaft grinding technicians can undertake the grinding of crankshafts up to 700 mm.

Crankpin Grinding by Onsite Crankshaft Grinding Machine
Crankpin Grinding by Onsite Crankshaft Grinding Machine

All the parameters like taper, ovality, surface finish etc. after crankshaft grinding are maintained strictly as per the manufacturer’s specifications. RA Power Solutions undertakes all the jobs related to repair, maintenance, overhauling of high capacity of diesel engines and diesel generating sets onsite all over the world.

 Only company which has undertaken repair of more than 11,000 crankshafts and is highly respected for its commitment

For more information, please email us on info@rapowersolutions.com

Onsite Crankpin Grinding is in Process
Onsite Crankpin Repair is in Process
Inspection and Grinding of Crankshaft is in Process
Inspection and Grinding of Crankshaft is in Process

A vessel sailing near Oman  reported serious breakdown of auxiliary engine of Yanmar model 6N18AL. RA Power Solutions team which is always ready for emergency response left for Oman and conducted the detailed inspection of the engine. It was observed that crankpin no. 4 bearing seized resulting to the damage of CR pin no. 4. … Continue reading “Grinding of Crankshaft in Oman by RA Power Solutions”

Reconditioned Connecting Rods and Repair

RA Power Solutions is a leader in undertaking repair and reconditioning of the  connecting rods of high capacity engines installed in diesel engine power plants, ships and for other applications.

Reconditioning of connecting rod and repair methodology have been developed by using latest breed of equipment and our experience of four decades in this field.

Marine Engine Connecting Rods under Reconditioning
Marine Engine Connecting Rods under Reconditioning

We strongly recommend our customers to go for reconditioned connecting rods which are thoroughly checked in our workshop and repair maintaining the tolerances as original.

The reconditioned connecting rods for most of the popular diesel engines are available in stock or can be supplied in a short duration. Details of few engines for which reconditioned connecting rods are readly available is mentioned below.

MAN-B&W, Sulzer, Wartsila, Mak, Deutz, Pielstick, Mitsubishi, Nohab, Daihatsu, Yanmar, Bergen, Crepelle, Niigata, Himsen, Allen, Stork, MWM, Hanshin, Caterpillar, Ruston, Paxman, Mirrlees, Alco, Fiat, ABC, Crepelle, SKL , etc.

Second Hand Connecting Rod of Wartsila Engine
Second Hand Connecting Rod of Wartsila Engine
Second Hand Connecting Rod of CAT Engine
Second Hand Connecting Rod of CAT Engine

The   availability of reconditioned connecting rod gives ship operators and diesel power plant owners  access to low cost. Reconditioned connecting rods which are equivalent to new one in terms of tolerances, performance and life cycle.

RA Power Solutions as an experienced and most respected company in the field of diesel engines strongly recommends use of reconditioned connecting rods quality of which is guaranteed by our controlled, approved process of repair and technology and through the metallurgical examination during and after reconditioning.

Generally prices of reconditioned connecting rods is 1/4th of the new connecting rod resulting to the enormous saving to the owners.

For more information regarding new connecting rods and reconditioned connecting rods of all make and model of diesel engine, please free to write us on info@rapowersolutions.com

Connecting Rod of MAK Diesel Engine
Connecting Rod of MAK Diesel Engine
Inspection of Wartsila Engine Connecting Rod
Inspection of Wartsila Engine Connecting Rod

RA Power Solutions is a leader in undertaking repair and reconditioning of the  connecting rods of high capacity engines installed in diesel engine power plants, ships and for other applications. Reconditioning of connecting rod and repair methodology have been developed by using latest breed of equipment and our experience of four decades in this field. … Continue reading “Reconditioned Connecting Rods and Repair”

Onsite Crankshaft Grinding Machine for Crankshaft Repair

RA Power Solutions  with 4 decades of experience have now introduced onsite crankshaft grinding machine which is portable and can undertake crankshaft machining, crankshaft grinding, crankshaft repair onsite.

Now there is no need to remove the crankshaft from engine block and sending it to the workshop. Crankshaft grinding machine has following features:

I) The crankshaft grinding machine is introduced by RA Power Solutions having experience of 4 decades in crankshaft repair

II) After extensive trials and experience, the machine is now introduced in the open market for the benefit of shipping companies, engine repair workshops, power plants, etc.

III) The onsite crankshaft grinding and polishing machine is of latest design having minimum vibrations during operation. Onsite crankshaft grinding machine can be used while sailing of the vessel.

Grinding of Crankpin using Onsite Crankshaft Grinding Machine
Grinding of Crankpin using Onsite Crankshaft Grinding Machine

IV) Tolerances achieved after crankshaft grinding and crankshaft polishing are far better than the manufacturer’s specifications. This is proven as repairs executed are class approved.

In case of emergency, this onsite crankshaft grinding and polishing can be operated round the clock. Onsite crankshaft grinding and polishing machine is easy to operate and on job training is provided.

This machine is supplied ready to use and complete in all respect. More than 70 machines supplied all over the world.

For more information, please drop en email at info@rapowersolutions.com

Crankshaft Grinding Machine Packed in Steel Box for Dispatch
Crankshaft Grinding Machine Packed in Steel Box for Dispatch
Onsite Crankshaft Grinding Machine
Onsite Crankshaft Grinding Machine

RA Power Solutions  with 4 decades of experience have now introduced onsite crankshaft grinding machine which is portable and can undertake crankshaft machining, crankshaft grinding, crankshaft repair onsite. Now there is no need to remove the crankshaft from engine block and sending it to the workshop. Crankshaft grinding machine has following features: I) The crankshaft grinding … Continue reading “Onsite Crankshaft Grinding Machine for Crankshaft Repair”