Marine Engine Overhauling and Repair

Diesel Engine Overhaul & Repair | Large Diesel Engine Repair | Marine Engine Repair | Overhauling Services by RA Power Solutions

RA Power Solutions is the leading company extending Diesel Engine maintenance, Repair & overhaul services having experience of 40 years in this field. We have a team of skilled technicians & engineers who have worked in shipyards, Diesel Power Plants & Engine manufacturing companies. RA Power Solutions feel that proper analysis of trouble in Diesel Engine & its solution is of great importance for successful repair. Our technicians are able to quickly analysis in the case of breakdown & undertake the corrective action.

The major overhaul of MAK M453C main engine undertaken by our engineers recently was executed in record time & detail scope of work is as following:

Overhaul of 6 nos cylinder head, replacement of valve seats and valve guides. Replacement of all valve stem guide O-ring seals. Checked cylinder heads warpage and pressure testing of all heads at 5 bar.
Overhaul of jacket water, lubricating oil cooler and charged air coolers.
Dismount and overhaul of VTR 250 turbocharger, renewed the oil slinger, nozzle assembly, and both compressor and turbine side bearings.
Dismount and overhaul of all the air starting valves, relief valves, the piston rings, and seals were changed.
Withdraw all the pistons, cleaned piston ring landing and renewal of piston rings gudgeon pins, and big end bearings.

Took piston ring groove axial and butt clearances.
Clean inspect and measure the cylinder liner internal diameters.
Deglaze the cylinder liners with 120 grit emery cloth.
Measurements of bearing cap gaps (k1-k2).
Polished the crankshaft and took journal measurements.
Renewed all main and locating bearing shells.
Took main bearing top clearances by lead wire.
Took crank web deflection measurements prior and after the renewal of main bearings with spring loaded dial gauge.
Took measurements of both normal and locating bearings k-gap.
Dismount and overhaul all fuel injectors and pressure tested the nozzles.

Overhauling & Repair of Marine Engine is in Process

Dismount and overhaul the fuel pumps and replace the springs, delivery valves, plungers, and barrels.
Setting of valves tappet clearances.
Overhauled both emergency and attached lubricating oil pumps.
Dismount and overhaul of the jacket water pump replaced the bearing and mechanical seal.

The author is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. He has 40 years of experience in working on large crankshafts and Diesel Engines. He is on the board of directors of reputed shipping companies and companies having a large number of Diesel power plants.

For your requirement of diesel engine overhaul and repair, large diesel engine repair, overhauling of diesel engine, overhauling & repair of marine engine please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

CKD Skoda Engine Spares- Piston | Bearings | Cylinder Liners

CKD Skoda 2270/1450 KVA Engine

RA Power Solutions is serving large engineering companies, Shipping organizations, and Diesel Power Plants for the last 40 years. As a company, we believe in the supply of High-Quality spare parts for CKD Skoda Engines and other popular make.

We are the trusted name in the industry and offer the Engine & spare parts strictly as per the international standards.

Every spare part of the engine is audited by our experienced technicians for its quality which includes dimensional inspection & NDT test. The inspection reports in detail are furnished along with the spare parts supplied by RA Power.

**CKD Skoda Engines Available for Sale**

We are maintaining a large stock of CKD Skoda 1450 KVA, 2270 KVA, and all models of Diesel Engines & spare parts. The complete engine of CKD Skoda can be supplied after reconditioning with guaranteed performance. We also supply new and reconditioned spare parts for CKD Skoda Generators’ complete range. Since most CKD Skoda engine spares are 30/40 years old we feel that it makes sense to use the reconditioned spare parts which are available at 25% of the cost of a new one. Thus the company can save a considerable amount on the maintenance of CKD skoda engine spares.

Presently we have available for sale following CKD Skoda Diesel Generating Sets and spare parts. The sets are in working condition & will be supplied after reconditioning. We can also provide you with all major new spare parts for this engine.

List of CKD Skoda Diesel Generating sets available:

S.No.	Make	Type	RPM	No. of Cylinder	Capacity	Base
1	SKODA	638A6S	500	6	2270KVA	HFO/LDO
2	SKODA	638A6S	500	6	2270KVA	HFO/LDO
3	SKODA	9TS35/50-2	375	9	1525KVA	LDO
4	SKODA	9TS35/50-2	375	9	1450KVA	LDO
5	SKODA	638A6S	500	6	2270KVA	HFO/LDO
6	SKODA	638A6S	500	6	2270KVA	HFO/LDO
7	SKODA	638A6S	500	6	2270KVA	HFO/LDO
8	SKODA	638A6S	500	6	2270KVA	HFO/LDO

List of Major reconditioned/New spares available with calibration report and guarantee:

I) Crankshaft
II) Engine Block
III) Connecting Rod
IV) Cylinder Head
V) Piston
VI) Liner
VII) Turbocharger
VIII) Fuel Pump

Note: The writer of this article is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt Ltd.

For more information on CKD Skoda cylinder liners, CKD Skoda engine spares, and CKD Skoda BEZ bearing please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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.

Crankshaft Grinding | Crankshaft Repair Services

RA Power Solutions undertakes onsite crankshaft grinding and crankshaft repair for the diameter ranging from 30 mm to 700 mm.

The small diameter crankshaft is repaired on site without removing the crankshaft from the block. These services are of great use for the engines which are installed in construction-related equipment, compressors, and diesel-driven equipment operating in remote areas.

Our crankshaft repair services of crankshaft grinding and crankshaft repair are proven as we have been extending these services all over the world for the last forty years.

The main feature of onsite crankshaft grinding, onsite crankshaft repair, crankshaft polishing are as following:

RA Power design and manufactures on site crankshaft grinding equipment as per the site requirement and space constraints Hence there is no compromise with the quality after the repair of the crankshaft.
All the parameters of the crankshaft grinding are maintained strictly as per the manufacturer’s recommendations and tolerances. An inspection report in detail is submitted to the client.
In RA Power Solutions, we give great importance to the calibration of the crankshaft and inspection in detail by experienced technicians which helps us to plan the right strategy and selection of the right equipment for onsite grinding and onsite repair of crankshaft.
We possess the latest breed of inspection instruments including the instruments for the NDT test which helps us to find out the exact fault in the crankshaft resulting in successful repairs.
Replacement of crankshaft in case of breakdown by new crankshaft or reconditioned crankshaft is our expertise. The crankshaft of an auxiliary engine can also be replaced while sailing the vessel.

**Inspection of Crankpin is in Process**

**Grinding of Crankpin by Crankshaft Grinding Machine is in Process**

Our services for crankshaft grinding and repair are available 24*7. Technicians can fly down with portable lightweight crankshaft grinding machine in short notice to all over the world as they carry Indian CDC.

We have been regularly working for various models of engines like Wartsila, Daihatsu, MWM, Caterpillar, MaN, MaK, B&W, Sulzer, Bergen, Detroit Diesel, Stork Werkspoor, Pielstick, Deutz, Yanmar, MTU, Cummins, Nohab Polar, Caterpillar, Mitsubishi, Yanmar, MaK 551, MaK 552, MaK 453, MaK 451 AK, MaK 452 AK, Deutz 540, Deutz 358, Deutz 350, Pielstick PC 2.2 PC 2.5, Wartsila 524, Wartsila 824 TS, Sulzer 6 AL 25/30 and many more.

For more details regarding crankshaft grinding please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

**Crankshaft Grinding Service on Moving Vessel**

Overhauling of Diesel Engine | Engine repair | Marine Engine Overhauling- RA Power Solutions

Engine Overhauling

RA Power Solutions having experience of four decades in on-site repair of major components like crankshaft, connecting rod, cylinder heads and under takes complete overhauling of main and auxiliary diesel engines installed on vessel or on land for power generation and other applications.

Diesel-Engine-Repair-Overhauling-300x225 — **Overhauling of Wartsila Engine**

Following are the main features:

Engine overhauling, engine repair and replacement of crankshaft is undertaken by RA power solutions for last four decades
Engineers and technicians are well experienced to attend any engine breakdown in shortest possible time, most of the engineers and technicians have experience of working in reputed engine manufacturers plant like Wartsila, Caterpillar, Cummins, Mirrlees Blackstone, etc.
All the services pretaining to the repair of Crankshaft and major components of Diesel Engine is available in-house hence in case any component is found damaged at the time of overhauling of the engine the repair is undertaken by our technician on site and downtime is reduced. No need of calling third party for repairs.
RA Power Solutions undertakes one point guarantee for engine overhauling, engine repair and replacement of crankshaft as all parts are calibrated and inspection reports are prepared prior to reassembly of the engine
Crankshaft replacement, correction of crankshaft flange holes, and all repairs of crankshaft is undertaken on-site with a guarantee and in minimum time. The periodic overhauling as per engine manufacturers recomendation is undertaken.
Engineers and technicians undertaking engine overhauling, and engine repair have valid CDC and can sail with the vessel this facilitates overhauling of main engine and auxiliary engine while sailing reducing downtime
RA power solutions undertakes engine overhauling, engine repair and crankshaft replacement of all makes and model of a high capacity diesel engines including : Mirrlees Blackstone, Ruston, Allen, Daiatsu, Yanmar, Caterpillar, Wartsila, SKL, Skoda, Pielstick, Cummins, Deutz, MAN, MAK etc.

Cylinder Liner | Cylinder Sleeves | Cylinder Manufacturers

RA Power Solutions manufacture and export cylinder liners and Cylinder sleeves for a wide range of engines, compressors, and all applications. The selection of the right material composition of cylinder liner keeping in view its application is of great importance. RA power solutions strictly maintain the metallurgical composition of the cylinder liner and cylinder sleeve as per the engine manufacturer’s specifications. Liners are cast centrifugally which ensures cylinder liners casting free of any defects like porosity, blowholes any other abnormalities.

We maintain a large stock of cylinder liners of popular make and models of engines the cylinder liner and cylinder sleeves are also developed and manufactured as per drawing or the sample provided by the client.

Cylinder sleeve | Cylinder liner exporters

RA power solutions stands a guarantee the satisfactory performance of the liner for the period of 12 months from the date of dispatch of the cylinder liner from our works. The liners manufactured by RA power solutions are priced considerably low in comparison to the prices offered by the manufacturers of the engines.

We are the OEMs for various manufacturers of the engine.

cylinder liner and cylinder sleeve after phosphating

For more information on SKL engine cylinder liners and cylinder sleeves, engine cylinder liners, Cylinder liner manufacturer, manufacture and export cylinder liners please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Crankshaft Repair Services And Tools

Crankshaft repair is required in case of the following abnormalities observed in the crankshaft

Development of taper and ovality in crankpin and main journal of the crankshaft in access of tolerances stipulated by the manufacturer.
Development of bearing line marks, pitting, and rough surface.
Damage of radius profile due to accident or seizure of bearing of crankpin or main journal.
Development of crack and variation in hardness of the crankpin and main journal of the crankshaft.
Loss of alignment of the crankshaft.

Crankshaft repair is undertaken by RA power solutions of the crankpin and main journal of the crankshaft diameter ranging from 35mm to 700mm. Crankshaft repair is undertaken by experienced technicians who have been specifically trained in our workshop on a dummy crankshaft, the company has experience of more than four decades in crankshaft repair services.

The on-site grinding equipment designed and manufactured by RA power solutions can maintain a close tolerance after crankshaft grinding within 0.02mm and the surface finish which is far superior to international standards. The crankshaft grinding machine has a main frame manufactured out of titanium steel which makes it lighter and vibration-free during operation. The grinding of the crankshaft is possible even while sailing of the vessel and there is no requirement of holding the vessel at anchor or a port for crankshaft repair.

RA Power Solutions is a leading provider of specialized crankshaft repair services and innovative crankshaft repair tools. With a team of highly skilled technicians and engineers, we offer comprehensive solutions for repairing damaged or worn-out crankshafts in various industries. From onsite inspections to comprehensive repairs, we are equipped to handle all aspects of crankshaft maintenance. Our advanced crankshaft repair tools, designed with precision and durability in mind, streamline the process, guaranteeing swift yet reliable service.

All the crankshafts repaired by RA power solutions are guaranteed for a satisfactory performance we have successfully executed more than 10,000 crankshaft repair jobs. The services of crankshaft grinding and crankshaft repair are offered at low cost and our technicians carry CDC of Indian origin, Panama, and Pallav.

Contact numbers for rajshahani@rapowersolutions.com, info@rapowersolutions.com, and +91 9582647131 and +91 9810012383 are available for more information on crankshaft repair services.

Crankshaft Repair | Crankshaft Grinding and Crankshaft Polishing – RA Power Solutions

The concept of onsite repair of crankshaft is getting popular with the introduction of a portable lightweight on-site crankshaft grinding machine. Now it is possible to undertake crankshaft repair, crankshaft grinding and polishing on site without dismantling the crankshaft from the engine.

On-site Crankshaft Repair, Crankshaft Grinding, and Crankshaft Polishing costs low with minimum downtime and inconvenience as it does not require removal of crankshaft from the engine block, packing, and transportation to the designated workshop for repair by grinding or polishing process.

Advantage of trusting RA Power solutions

First company based in Asia having experience of four decades in Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing.
All repairs of crankshaft and process followed for grinding of crankshaft and polishing of crankshaft are approved by class agencies of repute like DNV, Lloyds and various inspecting organisations spread all over the world.
The repair of crankshaft is executed with a guarantee for the satisfactory performance, the pre and final inspection reports before and after grinding and polishing crankshaft are submitted.
Technicians executing the repair of crankshaft onsite are highly skilled, trained in our factory on a dummy crankshaft in order to understand the techniques for successful repair of the crankshaft. Some of our technicians have experience of more than 45 years.
The onsite inspection and polishing of crankshaft repair is recommended to enhance the life of crankshaft and bearings.
RA power solutions offer and undertake inspection and polishing of crankshaft on board a vessel at a nominal cost.
During our working of four decades on diesel power plant, shipping companies we have undertaken Crankshaft Repair, Crankshaft Grinding and Crankshaft Polishing number exceeding more than 10,000.

Conclusion:

RA power solutions has team of technicians with valid CDC from Panama, Palau, and India and can travel all over the world with short notice.

For more details regarding crankshaft grinding, on site crankshaft repair, onsite crankshaft grinding and polishing please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

On-Site Crankshaft Grinding Machine | Crankshaft Polishing Machine

Crankshaft grinding machines are designed to maintain the accurate tolerances as per the engine manufacturer’s recommendation.

Generally, it is observed that even for the higher diameter of crankpin and main journal of the crankshaft the tolerances do not exceed more than 0.05mm in order to achieve such close tolerances of crankpin and main journal of crankshaft RA power designs and manufactures on-site crankshaft grinding machine which has the capability to maintain the close tolerance of even 0.01mm/0.02mm which is far better than the close tolerance specified by the engine manufacturers.

The on-site crankshaft grinding machine and crankshaft polishing machine manufactured by RA power solutions has the following features:

Crankshaft grinding machine is designed in a way that it can be inserted from the inspection window of the engine block thus there is no need of removal of the crankshaft from the engine block.
In case of space restrictions, RA power has the capability to design the equipment according to the space available on site for grinding or polishing of crankshaft/turbine/alternator shaft/rotor shaft etc…
The on-site crankshaft grinding machine is lightweight portable and can be easily carried to the site all over the world. The crankshaft grinding machine is packed in the suitcase and is carried as accompanied baggage accepted by all international airlines.
The main body of crankshaft grinding equipment is manufactured out of titanium alloy which is lightweight and can absorb the vibrations this feature of crankshaft grinding machine facilitates RA power technicians to undertake crankshaft repair on board the vessel while it is sailing, maintaining the close tolerances within 20 microns.
Crankshaft grinding machine designed and manufactured by RA power can presently work up to 700mm diameter which we are in process of extending up to 1000mm.

Crankshaft grinding machine for repair and grinding

Conclusion

RA Power has sold more than 70 crankshafts grinding machines all over the world which are performing satisfactorily the cost of the machine is low and is affordable for repair workshop, shipping company, power plants, etc…

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

Cast Iron Crack Repair By Metal Stitching – RA Power Solutions

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

Steam turbine casing of Hangzhou make was reported damaged due to accident. The turbine operates at 130 MW peak load.

RA Power Solutions deputed technician to the site with latest breed of instruments, equipments and consumables in order to undertake inspection of the turbine casing and to execute necessary repair following observation was made.

Observation-

Turbine casing due to accident developed multiple cracks at different locations. Crack of following dimensions were observed

Crack having a length of 190mm with indiscipline profile
2 Cracks having length of about 300mm
Casting having dimensions of 600mm/450mm with thickness of 45mm was damaged into pieces

Crack repair by Metal lock and Metal stitching.

Crack Repair and damaged casting replacement was undertaken by RA power technicians.

The damaged casting area was cut and disciplined profile was given measuring 650mm/520mm this area was properly ground
The damaged sample piece was sent for metallurgical test to know the composition of material.
A wooden pattern was made at site having an exact profile as of damaged area.
A new casting piece having superior metallurgical properties then the original damage casting was manufactured.
The new casting piece was fixed in damage area by metal stitching and metal locking process.
RA power engineers used metal locks, metal keys and all consumables’ imported from UK for repair of cracks and damage casting.
The polishing of outer and inner surface of damaged area was done and painted.
The turbine is presently working satisfactory and has completed 3500hr of operation.

RA power under takes repair of crack casting by metal stitching and metal locking process from last 40 years and have executed successfully repair of heavy components used in power plants, industry, ships etc…

The metal stitching and metal locking can also be undertaken while sailing the vessel.

To know more about cast iron crack repair, metal locking, cast iron stitching, metal surgery, 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 casing by metal lock and metal stitching

Turbine casing after repairs — Turbine casing after repair