Metal Stitching and Thread Repair Inserts

RA Power Solutions was informed by one of our client regarding damage of cam case cover of MAN diesel engine on board a vessel sailing near China.

The details including photographs were examined and it was observed while the cam case cover was broken in to pieces the threads on the engine body and the dowel pin were also damaged.

Cracked Housing of Engine Block
Cracked Housing of Engine Block
Broken Area
Broken Area
Damaged Upper Threads
Damaged Upper Threads

 

 

 

 

 

RA Power Solutions deputed their team of technicians on board the vessel and they executed the repair of engine block, cam case cover sitting area by following procedure:

I) The broken bolt which remained  inside the thread hole was drilled out.

II) The damaged threads on cam cover sitting area on entablature was removed by drilling new blind holes, suiting the new M12 Helicoil thread inserts.

III) Re-tap holes for the new M12 Helicoil thread inserts was done carefully.

IV) New M12 Helicoil thread inserts were installed in the engine frame/ entablature.

V) The 2 guide pins for the roller guide housing were removed taking due precaution.

VI) New roller guide housing was installed, with correct M12 hexagon bolts  and including the newly introduced 10 mm washers.

VII) After final alignment of the roller guide housing, the bolts were  tightened with the correct tightening torque.

VIII) Finally the two ø8 mm guide pin holes were drilled in both roller guide housing and engine frame and afterwards newguide pins were installed

repair of Threads on Engine Block Under Process
repair of Threads on Engine Block Under Process
Repair of Thread Hole by Metal Stitching
Repair of Thread Hole by Metal Stitching

 

 

 

 

 

 

 

The repair of threads by thread repair inserts (helicoil inserts) proved to be successful as the engine is performing satisfactory and no oil leakage is observed. The shipping company owners were asked to replace the complete engine block by the manufacturers as per them it was not possible to execute this kind of repairs.

Damaged Thread Hole Under Metal Stitching and Metal Locking
Damaged Thread Hole Under Metal Stitching and Metal Locking
Metal Stitching of Bottom Area of Threaded Hole to Give Extra Strength
Metal Stitching of Bottom Area of Threaded Hole to Give Extra Strength

 

 

 

 

 

 

The above job was successfully executed by a team of experienced and dedicated team of RA Power solutions.

Cam Cover Sitting Area of Engine Block After Repair
Cam Cover Sitting Area of Engine Block After Repair

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 equipments. The company specializes in executing the repairs i.e. metal stitching/metal locking, grinding and repair of crank shafts, rebabbitting of bearings, connecting rod reconditioning, overhauling of Engines which have serious problem  resulting to the immense saving to the owners.

Email Us on rajshahani@rapowersolutions.com, info@rapowersolutions.com

Phone: +91-124-4378292
+91-9213604692

RA Power Solutions was informed by one of our client regarding damage of cam case cover of MAN diesel engine on board a vessel sailing near China. The details including photographs were examined and it was observed while the cam case cover was broken in to pieces the threads on the engine body and the … Continue reading “Metal Stitching and Thread Repair Inserts”

Crankshaft Repair at Low Cost

Crankshaft repair is required in case of following observations:

I) Development of taper and ovality due to continuous running.

II) Seizure of bearing, increase in hardness and development of crack

III) Loss of alignment of crankshaft or change in web deflection of crankshaft and many more reasons

RA Power Solutions Pvt. Ltd. undertakes crankshaft repair. We have team of experienced technicians who undertake crankshaft repair onsite.

These days there is no need of removing the crankshaft from the Engine block and send it to workshop for crankshaft repair.

RA Power Solutions undertakes crankshaft repair, crankshaft grinding and crankshaft polishing onsite without removal of crankshaft from the engine block. The onsite repair of crankshaft not only reduces the downtime but saves considerable cost in terms of removal of crankshaft, packing, transportation etc.The sending of  crankshaft to the workshop now is outdated.

RA Power Solutions have facility to undertake onsite crankshaft repair from 50 mm to 700 mm diameter.

Damaged Crank Pin of MAN Diesel Engine
Damaged Crank Pin of MAN Diesel Engine
Crack Detection of Crankpin Before Grinding
Crack Detection of Crank-pin Before Grinding

 

 

 

 

 

 

 

Having more than 37 yrs of experience, we have highly skilled in house technicians to execute crankshaft repair.We are most respected and cost effective company in Asian region.  We also manufacturer crankshaft repair machine/crankshaft grinding and polishing machine which is light weight, easy to operate.

Crankshaft Grinding of Damaged Crankpin on Board the Vessel
Crankshaft Grinding of Damaged Crank pin on Board the Vessel
Crankshaft Repair on Board the Vessel
Crankshaft Repair on Board the Vessel

 

 

 

 

 

 

 

The range of machine is from 50 mm to 700 mm which is reasonably priced and we have sold more than 63 machines all over the world.

Crack Detection of Crankpin After Grinding
Crack Detection of Crank pin After Grinding
Crankpin After Grinding
Crank-pin After Grinding

 

 

 

 

 

 

 

Author of this blog is Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having experience of more than 36 years. Company deals in onsite crankshaft grinding, crankshaft repair, rebabbitting of bearings, metal stitching/metal locking of cast iron, connecting rod repair, etc.

Crankshaft repair is required in case of following observations: I) Development of taper and ovality due to continuous running. II) Seizure of bearing, increase in hardness and development of crack III) Loss of alignment of crankshaft or change in web deflection of crankshaft and many more reasons RA Power Solutions Pvt. Ltd. undertakes crankshaft repair. … Continue reading “Crankshaft Repair at Low Cost”

Connecting Rod for Sale

We maintain large stock of reconditioned connecting rods and new connecting rods of following makes of diesel engine:

MAIN & AUX. ENGINES

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

Each connecting rod is passed through stringent quality control procedures by the technicians having more than 40 years of experience. In case of any deviation connecting rods are repaired in-house on latest breed of special purpose machine.

The big end of the connecting rod is re-bored and standard bore  tolerance as specified in the manual  is maintained. In case of small end the bush is replaced by new one and re-bored to the standard size.

Connecting Rod of Daihatsu Diesel Engine
Connecting Rod of Daihatsu Diesel Engine

Each connecting rod is subject to dimensional inspection and passes through the crack detection test by MPI.We don’t recommend repair of bend  connecting rod or the connecting rods which has lost its alignment/straightness.

The connecting rods supplied are 1/3rd the cost of new connecting rod resulting to the huge saving for the owners.

Connecting Rod of MAK Diesel Engine for Sale
Connecting Rod of MAK Diesel Engine for Sale
Connecting Rod Under Reconditioning
Connecting Rod Under Reconditioning
Inspection of Wartsila Connecting Rod
Inspection of Wartsila Connecting Rod

We maintain large stock of reconditioned connecting rods and new connecting rods of following makes of diesel engine: MAIN & AUX. ENGINES MAN-B&W Sulzer Wartsila MAK Deutz Pielstick Mitsubishi Daihatsu Yanmar Bergen Niigata Himsen Fiat Allen Hanshin MWM Caterpillar SKL Ruston Crepelle Stork Paxman Mirrlees Blackstone Alco, ABC, Crepelle, Nohab, etc. Each connecting rod is … Continue reading “Connecting Rod for Sale”

Portable Crankshaft Polishing Machine

In case of bearing failure or continuous running of crankshaft it develops bearing line marks, pitting or rough surface. This requires polishing of crankshaft, crankpin and main journal.

Revolutionary onsite portable crankshaft polishing machine has been introduced by RA Power Solutions Pvt. Ltd. which is portable, light weight, easy to operate and can be taken to the site. The polishing of crankshaft, crankpin is possible without removing the crankshaft from the engine block. The onsite crankshaft polishing machine is manufactured from 50 mm to 700 mm diameter.

The use of crankshaft polishing machine removes the bearing line marks, pitting and improves the surface finish as required by the manufacturer.

We extend free training to the customers having duration of 1 week during which the operation of crankshaft polishing machine, maintenance are explained and demonstrated.

The cost of machine is kept low as it is the company’s objective that nobody should spend exorbitant amount on polishing and grinding of crankshaft anymore and sending it to the workshop.More then 60 machines are sold all over the world.

 

Crankshaft Polishing Machine Packed in Steel Box
Crankshaft Polishing Machine Packed in Steel Box
Packing in Progress Insitu Crankshaft Grinding Machine
Packing in Progress Insitu Crankshaft Grinding Machine

 

 

 

 

 

 

 

Close Up View of Crankshaft Polishing Machine After Packing
Close Up View of Crankshaft Polishing Machine After Packing
Crankshaft Grinding Machine Packed in Steel Box
Crankshaft Grinding Machine Packed in Steel Box

 

 

 

 

 

 

 

Author is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. having 37 years of experience in working on large crankshafts. The crankshaft grinding and polishing machine has been developed through a consistent and focused R&D with field trails undertaken in different conditions.

The aim of the company is to reduce the cost of repair of crankshaft and stop the outdated practice of sending crankshaft to the workshops.

In case of bearing failure or continuous running of crankshaft it develops bearing line marks, pitting or rough surface. This requires polishing of crankshaft, crankpin and main journal. Revolutionary onsite portable crankshaft polishing machine has been introduced by RA Power Solutions Pvt. Ltd. which is portable, light weight, easy to operate and can be taken … Continue reading “Portable Crankshaft Polishing Machine”

Connecting Rod Reconditioning

The connecting rods of the engine are under the tremendous pressure. The connecting rod has to bear the extreme load and stress condition. In most of the cases connecting rods are made out of forging and composition of material is selected  to give enough strength to the connecting rod.

The continuous running, stopping and changing of direction combined with the weight of the piston and rpm of the engine put lot of stress on the connecting rod. This results to the development of various defects in connecting rod like excessive taper and ovality in big end and small end of connecting rod, loss of alignment of connecting rod, etc.

RA Power Solutions Pvt. Ltd. undertakes reconditioning of connecting rods for high capacity diesel engine of all make 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 Rods of Mitsubishi Marine Diesel Engine
Connecting Rods of Mitsubishi Marine Diesel Engine

Following steps are followed for reconditioning and resizing of connecting rod

I) Connecting rod is checked for parallelism, alignment and taper and ovality in big end and small end.

II) Connecting rods having bend are not recommended for repair as per RA Power Solutions Pvt. Ltd. experience.

III) Crack detection by MPI is done of connecting rod bolt sitting area and bolts. The connecting rod bolts again are under heavy stress all the time and develop hairline cracks. It is recommended to replace connecting rod bolts after certain hours of operation as specified in manual.

IV) The connecting rod big end is re-bored to the standard size and tolerances are maintained. In case of connecting rod small end it is recommended to replace the bush and re-bore it maintaining the center distance between the big end bore and small end bore as per the manufacturer’s specifications.

Connecting Rod of Yanmar Ready for Dispatch
Connecting Rod of Yanmar Ready for Dispatch
Reconditioning of Connecting Rod
Reconditioning of Connecting Rod

All the reconditioned connecting rods after re-sizing are inspected by experience technicians and calibration report id prepared.

RA Power Solutions Pvt. Ltd. has 37 years of experience of undertaking successfully reconditioning of connecting rods.

RA Power Solutions Pvt. Ltd. also maintains large stock of reconditioned connecting rods which are supplied with guarantee. We have larges stock of connecting rods of 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.

The connecting rods are priced 1/3 of new connecting rods resulting to the considerable saving for the owners.

Connecting Rod of Diahatsu Marine Diesel Engine
Connecting Rod of Diahatsu Marine Diesel Engine
Connecting Rod Reconditioning
Connecting Rod Reconditioning
Connecting Rod Assembled with Piston after Repair
Connecting Rod Assembled with Piston after Repair
Connecting Rod of Crepelle
Connecting Rod of Crepelle

The connecting rods of the engine are under the tremendous pressure. The connecting rod has to bear the extreme load and stress condition. In most of the cases connecting rods are made out of forging and composition of material is selected  to give enough strength to the connecting rod. The continuous running, stopping and changing … Continue reading “Connecting Rod Reconditioning”

Heat Exchanger Gaskets

Heat Exchanger Gaskets are important for satisfactory performance of the main equipment. We manufacture gaskets for all makes and equipments where gaskets are used.

Plate Heat Exchanger Gaskets
Plate Heat Exchanger Gaskets

For more than 30 years we have been specializing in manufacturing of precision rubber gaskets as per the manufacturer’s requirement. The rubber gaskets of all types like Neoprene gaskets, silicone gasket, Viton gasket, EPDM gasket , nitrile gasket are manufactured.

RA Power Solutions Pvt. Ltd. manufactures plate heat exchanger gaskets in accordance with a thorough quality control process. We fully inspect gaskets to ensure that they meet international standards with the help of our gaskets testing facilities.

We offer a 12 month warranty for all plate heat exchanger gaskets supplied by us.

Heat Exchanger Gaskets
          Heat Exchanger Gaskets
Gasket
                           Gasket

Heat Exchanger Gaskets are important for satisfactory performance of the main equipment. We manufacture gaskets for all makes and equipments where gaskets are used. For more than 30 years we have been specializing in manufacturing of precision rubber gaskets as per the manufacturer’s requirement. The rubber gaskets of all types like Neoprene gaskets, silicone gasket, … Continue reading “Heat Exchanger Gaskets”

Crankshaft Repair While Sailing

Crankshaft repair by grinding and polishing is now possible while vessel is on move. RA Power Solutions Pvt. Ltd. is the first company to offer crankshaft repair services while vessel is sailing by onsite portable crankshaft grinding equipment which is taken on board the vessel. The crankshaft repair is undertaken by vibration free crankshaft grinding machine without removing the crankshaft from the engine block thus saving time and cost.

MAN B&W STX 6L23/30H
MAN B&W STX 6L23/30H

RA Power Solutions Pvt. Ltd. undertakes onsite crankshaft grinding and polishing on board the vessel while sailing up to 700 mm diameter.

RA Power Solutions Pvt. Ltd. has recently undertaken grinding of all 6 CR pins of MAN B&W STX 6L23/30H while sailing of vessel between ports of Malaysia and Indonesia. The crankpins were damaged due to lack of lubrication oil and all the pins were undersized by 0.5 mm. The tolerances after grinding and polishing have been maintained as per the manufacturer’s requirements.

Repair of Crankshaft in Engine Block
Repair of Crankshaft in Engine Block

RA Power Solutions Pvt. Ltd. has designed vibration free onsite crankshaft grinding and crankshaft polishing equipment by which it is possible to execute crankshaft repair while ship is on move. This saves the time and keeps vessel moving.

Crack repair of engine block, cylinder heads, casing and all broken castings on board a vessel is possible while sailing. We are the first company to introduce these services.

Crankpin Under Test to Check Crack
Crankpin Under Test to Check Crack
Dye Penetrant Test of Crankpin
Dye Penetrant Test of Crankpin

 

Onsite Crankshaft Grinding Machine from Engine Block
Crankshaft Grinding While Sailing
Crankpin Under Grinding Process
Crankpin Under Grinding Process

 

 

 

 

 

 

Crankpin Ready After Grinding and Polishing
Crankpin Ready After Grinding and Polishing

 

 

 

 

 

 

Crankshaft Polishing in Process by Crankshaft Polishing Machine
Crankshaft Polishing in Process by Crankshaft Polishing Machine

Crankshaft repair by grinding and polishing is now possible while vessel is on move. RA Power Solutions Pvt. Ltd. is the first company to offer crankshaft repair services while vessel is sailing by onsite portable crankshaft grinding equipment which is taken on board the vessel. The crankshaft repair is undertaken by vibration free crankshaft grinding … Continue reading “Crankshaft Repair While Sailing”

Cast Iron Crack Repair by Metal Stitching Process

Cast iron crack repair by metal stitching and metal locking process is highly recommended. Metal stitching process for repairing casting is widely use, accepted in the industry and more successful process for repairing cracks in cast iron.

Broken cast iron pieces can also be replaced by new piece of casting undertaking metal locking. This technology is as old as introduction of cast iron casting in industry.

Insertion of Casting Piece in Engine Block
Insertion of Casting Piece in Engine Block
Metal Stitching of Jenbacher Engine Block in Process
Metal Stitching of Jenbacher Engine Block in Process

 

 

 

 

 

 

 

Metal keys and metal locks are used to undertake crack repair in cast iron casting.

Metal keys and Metal Locks are used in Metal Stitching/Locking Process
  Metal keys and Metal Locks used in Metal Stitching/Locking Process

RA Power solutions Pvt. Ltd. has team of trained technicians who undertake metal stitching of broken and crack casting onsite. Necessary tools, consumables and new piece of casting if required are taken to the site and crack repair is executed. There is no requirement for disassembly of the equipment or transporting it to the repair workshop as crack repair is done onsite.

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

It is proved that repair of crack casting by metal stitching process rather enhances the strength of the area after crack repair by the metal stitching is done. We execute crack repairs on board the vessel, power plants all over the world.

Cast iron crack repair by metal stitching and metal locking process is highly recommended. Metal stitching process for repairing casting is widely use, accepted in the industry and more successful process for repairing cracks in cast iron. Broken cast iron pieces can also be replaced by new piece of casting undertaking metal locking. This technology … Continue reading “Cast Iron Crack Repair by Metal Stitching Process”

Connecting Rod Reconditioning

High capacity diesel engines running continuously require periodic check of connecting rods. It is commonly observed that big end of connecting rods develops taper and ovality due to continuous operation of engines. Small end bushes also need replacement.

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

 

 

 

 

Connecting rod bolts are under heavy stress and are required to be inspected periodically for their elongation and in some cases also develop cracks which can prove to be dangerous for the engine. RA Power Solutions Pvt. Ltd. strongly recommends replacing connecting rod bolts after running hours as specified in manufacturers manual.

RA Power Solutions undertakes connecting rod repairs. The big end taper and ovality is corrected and small end bush is changed with the new one. The repair of connecting rod saves the replacement cost which is very high.

Reconditioning of Connecting Rod
Reconditioning of Connecting Rod
Mirrlees Blackstone k Major Connecting Rod
Mirrlees Blackstone k Major Connecting Rod

 

 

 

 

 

RA Power Solutions Pvt. Ltd. undertakes connecting rod repair with guarantee and have executed repair of connecting rods of leading manufacturers of engine.

High capacity diesel engines running continuously require periodic check of connecting rods. It is commonly observed that big end of connecting rods develops taper and ovality due to continuous operation of engines. Small end bushes also need replacement.         Connecting rod bolts are under heavy stress and are required to be inspected … Continue reading “Connecting Rod Reconditioning”

Connecting Rod Inspection

It is very important that connecting rods are inspected periodically. The process of inspection includes following:

  • Connecting rods are required to be cleaned properly.
  • Crack detection is undertaken preferably by Magnetic particle inspection (MPI). Attention has to be paid on joining surface/serration of the connecting rods.
  • Bore size big end and small end is checked.
  • Straightness of Connecting Rods: In case any deviation is observed in connecting rod, RA Power Solutions Pvt. Ltd. undertakes repairs onsite or in our workshop. All the repair of connecting rods undertaken is guaranteed and calibrations certificate is provided.

It is very important that connecting rods are inspected periodically. The process of inspection includes following: Connecting rods are required to be cleaned properly. Crack detection is undertaken preferably by Magnetic particle inspection (MPI). Attention has to be paid on joining surface/serration of the connecting rods. Bore size big end and small end is checked. … Continue reading “Connecting Rod Inspection”