Repair of Engine Block by Metal Stitching Archives

Overhauling of Main Engine Repair | Repair of Engine Metal Stitching of Damaged Block

RA Power Solutions received an emergency call from a Steel Company based in Indonesia regarding damage of their Engine SULZER 6RND68.

On arrival of our team of engineers, it was observed that lower engine block of SULZER 6RND68 was damaged badly. Hence it required disassembly of complete engine, overhauling and repair of engine block by metal stitching & metal locking.

Following is the brief of job description executed:

Inspection and overhaul of the cylinder covers including the fuel and starting valves located in the covers. The cylinder covers cooling spaces were also inspected, cleaned and fitted back with new O-rings.
Dismount, Inspect and overhaul the exhaust valves, renewed the seals and grinding the valve spindles.
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.
Replacement of thrust block pads and correction of end play.
Metal locking of damaged Engine block by our technicians.

Special Keys & Locks Used in Metal Stitching Process

Repair of Engine Block by Metal Stitching is in Process

Inspected and adjusted the chain drive.
Retightened the stay-bolts, holding down bolts end chocks.
Took bearing clearances with a telescopic feeler gauge and checked bearing edges by wire gauges.
Crankshaft alignment measurement was taken with dial gauge (autolog method)
Conclusion: The engine was tested on full load for 72 hours & all the parameter were recorded. The engine is performing satisfactorily.

Repair & Overhauling of Engine is in Process

Inspection of Engine Spare Parts is in Process

For more details regarding overhauling of engine, repair of engine metal stitching of damaged block, crankshaft grinding, and engine block repair please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Repair of Damaged Engine Block | Engine Block Repair

RA Power Solutions was recently approached by a diesel power plant based in South America having Wartsila 12V32 and Wartsila 18V32 diesel generating sets.

Broken Engine Block of Wartsila Diesel Engine

A serious accident took place due to failure of cylinder liner resulting in to the damage of various parts including lower and upper engine block of Wartsila 18V32 engine. On investigation by RA Power Solutions technicians it was observed that upper and lower engine block suffered severe multiple cracks measuring to total 2900 mm in length and damage of casting into small pieces measuring 300 X 460 mm.

Various options were discussed and it was decided to replace the lower and upper crankcase. The cost of replacement of damage lower and upper engine block of Wartsila 18V 32 was exorbitant with a delivery period of 9 months. RA Power Solutions proposed to repair the multiple cracks and damaged portion by metal stitching and metal locking process. This is a cold process of crack repair and has been followed by our technicians in number of installations all over the world during our service to the industry for last four decades.

Casting Piece Given Profile as per Damaged Engine Block

Special Metal Locks and Keys Used in Metal Stitching Process

The damaged portion of the engine block was given a discipline profile and new piece of casting having similar metallurgical properties as of the parent material was placed and metal stitched using the latest design of metal stitching locks and keys. The multiple cracks were properly marked by our technicians using the latest MPI equipment to identify the cracks. The multiple cracks were also repaired by metal stitching and metal locking process.

RA Power Solutions also undertook the onsite grinding of crankshaft which got damaged due to accident and re-assembled the engine in 16 days time. All these repairs were conducted in-house with the onsite portable equipments which were carried to the site by the technicians. Perhaps no other company in the world can offer all repair services under the same roof.

Metal Stitching Of Engine Block is in Process

The engine is performing satisfactory.

RA Power Solutions specializes in cast iron repairs, utilizes advance metal stitching and metal locking processes that are ideal and most suited for this type of crack repair.

RA Power Solutions takes the pride to announce that in our four decades of experience, we were able to save millions of dollars of end users by undertaking the onsite repairs of damaged parts avoiding the expenses towards the cost of new parts which are exorbitantly priced with long delivery.

We have a dedicated team to undertake the repair of crack and damaged engine components. It is possible to undertake metal stitching and metal locking for repairs of crack on a moving vessel.

Repair of Damaged Engine Block by RA Power Technician

Repair of Engine Block by Metal Stitching/Metal Locking While Vessel is Sailing

Technicians can join the vessel in short time as they carry seaman passport. As an Indian company we are respected for our sincerity, experience and lowest cost.

For more information on engine block repair and damage engine block repair, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal Stitching and Metal Locking of Engine Block – RA Power Solutions

Engine blocks, casting and most of the parts are manufactured of common material like cast iron. Cracks developed in cast iron parts are most difficult to undertake repair by welding process as it needs pre-heating of the cast iron prior to the welding. In certain cases it can cost additional stresses resulting to the damage of casting.

Material Used in Metal Locking and Metal Stitching Process

It is proven that metal stitching and metal locking has advantage of repairing cracks in cast iron casting due to cold process using different profile and material of stitching pins and locks without applying any heat as in case of welding.

RA Power Solutions Pvt. Ltd. undertakes metal stitching and metal locking of casting and has successfully repaired various major components of high capacity diesel engine.

Application includes repair of Engine Block, Cylinder Head, Generators. Turbo Chargers, Turbine Casing, Gear Box Housing, Pump Casings, Compressor Crank Cases, Forgings Hammer, Lathe / Press/ Milling/Boaring etc .M/c. Other all Casting Equipments etc.

In last 36 years more then 650 jobs of crack repair have been successfuly executed.

Stitching Pin Used in Metal Stitching Process

Metal Stitching Done in Broken Area of Generator

For more details regarding crack repair by metal stitching, engine block repair, cold metal lock stitching, and cast iron by metal lock & metal stitching, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.