In Situ Crankshaft Repair Archives

In situ Machining of Sulzer Z 40/48 Crankshaft on vessel | Sulzer crankshaft repair

A Sulzer main engine Sulzer Z 40/48 aboard a container vessel faced serious damage to the crankshaft due to failure of the Governor, this resulted in damage to crankpins.

The major technical details of Sulzer Z 40/48 crankshaft are given below:

S. No.	Crankshaft Details
1.	Engine Make	Sulzer
2.	Engine Model	Z 40/48
3.	Crankpin Diameter Standard	330 mm
4.	Crankpin Bearing Width	132 mm
5.	Place of execution of crankshaft repair	Port of Las Calderas Bani in Dominican Republic

**Damaged crankpin of Sulzer Model Z 40/48**

**Repair of Crankshaft of Sulzer Model Z 40/48**

The inspection of the Sulzer crankshaft was done by our technicians and the following main observations were reported.

On removal of the connecting rod from all the six crankpins the crankpin bearings were observed badly damaged. There were deep scoring marks and localized damage on the crankpin.
The hardness and crack detection was done and they were observed to be within limits.
Deflection readings were within the parameters stipulated in the manual.
The crankpins dimensional were checked and ovality as per following table was observed.

**Sulzer Model Z 40/48 crank pin no 04 before grinding**

**Crankpin no. 05 of Sulzer Z 40/48 before grinding**

**Sulzer Model Z 40/48 crank pin no 06 before grinding**

Action taken by RA Power Solutions for successfully repair of crankshaft Sulzer Z 40/48

The ovality, deep scoring marks and local damage was observed on all crankpins, further the ovality ranging from 0.11 mm to 0.43 mm was observed as per the dimensional chart pasted above.
In this situation client’s management was consulted and a presentation was made on the damage to the crankshaft and the remedial action proposed by RA Power Solutions.
All the crankpins were undersized as per the chart below except crankpin no 01 which was only polished:

The radius fillet of two crankpins which were damaged due to the accident was also repaired.
After repair technicians again checked all the parameters and were found within limits.

Sulzer Model Z 40/48 crankpin repair results

RA Power Solutions experienced technicians repaired the crankshaft successfully within the tolerance limits specified in the manual and then re- install the crankshaft to full rated capacity of the load.

By undertaking the repairs of the crankshaft onsite without removing it from the engine block, clients save the down time and also the cost of removing it from the block and sending it to the workshop.

**Crankpin no. 03 after grinding & polishing on board a vessel**

**Sulzer Z 40/48 Crankpin after successful repair**

**Sulzer engine Z 40/48 Crankpin no. 05 after repair**

RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company and extends crankshaft repair services all over the world. We can move our team of technicians and equipment anywhere in the world within 24 hours of first information.

We have been regularly executing on-site crankshaft repairs and crankshaft grinding in Dubai, Oman, Saudi Arabia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, and Fujairah, Bahrain, Kuwait, Iraq, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

For more details of the Repair of engine, Engine Sulzer, please email us on raj.shahani@rapowersolutions.com, info@rapowersolutions.com or Call +91 9582647131, +91 9810012383.

Compressor Crankshaft Grinding and Polishing Onsite

RA Power Solutions was approached by a leading Fertilizer producing company based in north India regarding the requirement of onsite grinding and polishing of compressor crankshaft.

The company has five high-capacity CO2 compressors which have been imported from a leading company based in Europe.

Our team consisting of three technicians along with onsite crankshaft grinding equipment was deputed to the site and following was observed:

Details of CO2 Compressor Crankshaft:

S. NO	Crankshaft Details
1	Engine Make/ Model	CO2 COMPRESSOR
2	Crankpin Diameter Standard	317.30 MM
3	Crankpin Bearing Width	210.00 MM
4	Main Journal diameter	330 mm & 317.30 mm
5	Main Journal Width	370 mm & 225 mm
6	Place of execution of crankshaft repair	Fertilizers & Chemicals Plant in India

On dimensional inspection of crankpin it was observed that crankpin nos. 02 developed excessive ovality. It also had deep line marks due to the failure of bearings which are of babbitt white metal type.
All the remaining crankpins were inspected and rough surfaces including bearing line marks were observed.
The main journal having a standard diameter of 330 mm also had a rough surface and required polishing.

**Damage of crankpin no. 6 of Compressor**

**Onsite repair of damaged crankshaft of CO2 Compressor**

**Picture showing before polishing of Main Journal**

Action taken by RA Power Solutions

Considering the fact that the main journal having a diameter of 330 mm having a rough surface and bearing line marks it was decided to remove the crankshaft from the compressor.

RA Power Solutions technicians submitted a drawing of V-Block which were manufactured in the factory for placement of crankshaft.

The grinding of crankpin no. 02 was undertaken and the final dimensions were maintained between 315.58 mm to 315.60 mm. The ovality of only 0.02 mm was observed.

All the remaining 05 crankpins were polished, removing the line marks and improving the surface finish. The surface finish after polishing was observed at less than 15 RA value.

All the main journals were also polished onsite removing the ovality to some extent and improving the surface finish again to less than 15 RA value.

**Crack detection test of compressor crankshaft before grinding**

**CO2 Compressor Crankshaft Inspection and Repair on site**

Advantage of getting the crankshaft grinding/ Polishing done by RA Power Solutions

RA Power Solutions is the only company in India having experience of forty-three years in crankshaft repair.
We have ready availability of equipment up to 700 mm diameter. The equipment is portable and lightweight and can be taken to any site all over the world as accompanied baggage. The modification in the onsite crankshaft grinding and polishing equipment is possible as per the site requirement.
In this case since the main journal diameter was to be polished the V-Block was designed and fabricated onsite.
RA Power Solutions as a protocol undertakes all the checks prior to grinding and polishing like cracks by MPI, Hardness test, deflection, etc.
We also manufacture babbitt white metal bearings and do rebabbitting of old bearing up to 1500 mm diameter.

**After Grinding and polishing taken deflection of CO2 Compressor Crankshaft**

**Main Journal of CO2 compressor after polishing**

For more information on crankshaft grinding services, insitu crankshaft grinding and polishing, onsite crankshaft repair, or crankshaft polishing services email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com Call at +91 9582647131,+91 9810012383.

Daihatsu 6 DK-20 Crankshaft Repair | Onsite Grinding of Daihatsu Engine Crankshaft | Crankshaft Machining In Situ

RA Power Solutions was approached by a company based in Greece regarding a problem faced by them in their auxiliary engine of Daihatsu 6 DK-20.

It was reported that the bearing of crankpin no.3 got damaged.

THE ENGINE DETAILS OF DAIHATSU 6 DK-20 ENGINE ARE AS FOLLOWS:-

S. NO	Crankshaft Details
1	Engine Make	Daihatsu
2	Engine Model	6 DK-20
3	Crankpin Diameter Standard	170 mm
4	Crankpin Bearing Width	78 mm
5	Name of Vessel	MV ABBA

ACTION TAKEN BY RA POWER SOLUTIONS TO REPAIR THE CRANKSHAFT OF DAIHATSU 6 DK-20:-

Technicians on boarding the vessel inspected the crankshaft.
The hardness of crankpin no.3 was observed within limits between 210 to 240 HB scale.
After a thorough cleaning of crankpin No. 3, the MPI test was done and no cracks or abnormality was observed.
Crankpin no. 3 was subject to dimensional inspection.

FOLLOWING ARE THE MAIN OBSERVATIONS:-

a) Minimum diameter observed – 169.10 mm

b) Maximum diameter observed – 169.33 mm

c) Total ovality -0.40 mm

The crankshaft was already undersized to 169.50 mm against the standard size of 170.00 mm.

ACTION TAKEN BY RA POWER SOLUTIONS FOR REPAIR OF CRANKSHAFT OF DAIHATSU 6 DK-20:-

The onsite crankshaft grinding machine was set up and grinding of crankpin no.3 was undertaken by reducing the diameter by 1 mm.

a) The minimum diameter observed after grinding – 168.98 mm

b) Maximum diameter observed after grinding – 169.00 mm

c)Total ovality observed after grinding – 0.02 mm

After grinding crankpin no. 3, the engine was assembled and put on trial.
We will be pleased to share the original pre and final machining inspection reports duly signed by the chief engineer of the vessel which has all the technical details required for the successful repair of the crankshaft.

REPAIR OF CRANKSHAFT OF DAIHATSU 6 DK-20 HAVING CRANKPIN BEARING WIDTH OF ONLY 78 MM:-

It was possible for RA Power Solutions to successfully undertake repair of the crankpin having a bearing width of only 78 mm because we have the equipment which can be placed on the crankpin or main journal diameter having a bearing width of as small as 40 mm.

With this advanced technology and process, no other crankshaft repair company has due to which they either reject the crankshaft or recommend getting it repaired from the workshop.

**Crankpin of Daihatsu 6 DK-20 Engine Crankshaft before Repair**

**Magnetic Particle Test of Crankshaft of Daihatsu 6 DK-20 Engine**

**Repair of Crankshaft of Daihatsu 6 DK-20**

**Crankshaft Grinding of Daihatsu 6 DK-20**

We have been regularly executing the repairs in Greece, Moldova, Belarus, Australia, Austria, Belgium, Brazil, Cambodia, Colombia, Denmark, Ethiopia, Ghana, Haiti, etc.

This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.) and a highly experienced business leader with rich experience of more than 40 years in the field of Power, Heavy, and Shipping industry. He is Technical Adviser to many shipping and heavy industries across the globe.

Mr. Shahani is one of the most enthusiastic professionals and he has all the brilliance of an exemplary leader. He is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.

For more information on bearings for Daihatsu engine and Daihatsu crankshaft repair contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.