crankshaft repair services 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.

Onsite Crankshaft Refurbishment | Repair of Main Engine Crankshaft

Portable Crankshaft Grinding Machine is Ready for Dispatch

RA Power Solutions company based in New Delhi, India undertakes crankshaft refurbishment onsite. There is no requirement for disassembly and removal of the crankshaft from the engine block.

We specialize in onsite crankshaft refurbishment, providing a cutting-edge and efficient solution to the challenges faced by industries in need of crank

Our technicians who are well experienced can travel to your site on land or on a vessel with necessary inspection instruments and onsite crankshaft grinding and polishing machine and undertake the necessary onsite repair.

Following is the outline of the inspection and repair of the main engine crankshaft:

I) Inspection of Crankpin/Main Journal: It is important that the surface geometry of the crankpin or main journal is thoroughly checked such as roundness defect, loss of alignment, conicity, barrel form, surface finish, etc.

RA Power Solutions have inspection formats and all the observations of the surface geometry parameters as described above are recorded.

II) Polishing or undersize journals and crankpin:

On the basis of surface geometry reports, the available decision is taken in regard to polishing or grinding of the crankpin and main journal. In the event of minor bearing line marks, pitting, or rough surface it is recommended that these defects are removed only by the process of polishing of crankpin and main journal.

Grinding & Repair of Damaged Crankpin on Board a Vessel

III) RA Power Solutions, the main engine crankshaft repair company uses the latest lightweight and easy-to-operate onsite crankshaft grinding and polishing machine which improves the surface finish without under-sizing of crankpin/main journal diameter.

IV) We recommended the inspection and polishing of crankpins or main journals periodically whenever the engine is taken up for major inspection or overhaul.

If the surface geometry is not within limits specified in the manual by the engine manufacturer and exceeds the tolerance the undersize of journals/crankpins is recommended.

V) Repair of engine crankshaft is recommended in case of severe damage and it becomes necessary to recondition the journal/crankpin by grinding to the next undersize or depending on the availability of undersize bearings.

RA Power Solutions uses high-precision onsite crankshaft grinding machine to undersize the crankpins and tolerance is maintained strictly as per the manufacturer’s specifications. Crankshaft regrinding of large diesel engines up to 700 mm in terms of diameter is undertaken.

We are fully equipped to extend emergency crankshaft repair services through our experienced technicians as they possess valid Indian CDC and can fly all over the world on short notice. The job of crankshaft refurbishment and emergency crankshaft repair is possible even while sailing the vessel. The onsite crankshaft grinding machine is designed to generate minimum vibrations which facilitates maintaining close tolerance.

We specialize in under-size and special-size bearings

The author of this blog is Mr. Raj Shahani (Managing Director of RA Power Solutions). He has forty years of experience in the field of crankshaft repair of high-capacity marine and diesel engines.

For any queries on onsite crankshaft refurbishment, repair of main engine crankshaft, crankshaft inspection onsite, and grinding & repair of damaged crankpin on board a vessel please drop us an 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.

Crankshaft Repair | Crankshaft Grinders | Onsite Crankshaft Machining

RA Power Solutions undertakes the Grinding of Crankshaft of High Capacity Engines used in Shipping companies, Power plants, and in various other sectors. The company has experience of more than forty years in undertaking successful repair of Crankshafts and major components. As we are aware Crankshaft is the heart of the engine and is the most expensive part with limited availability of particular make and model.

Our expertise lies in the repair of crankshafts that meets with a serious accident like a Seizure of a bearing. It is generally observed that due to rubbing of the bearing steel surface with the CR Pin diameter, excessive heat is generated. Thus there is an increase in Hardness. Every manufacturer specifies the maximum limit of Hardness.

Damaged CrankPin of Mirrlees Blackstone Engine

In the case of Mirrlees Blackstone K and KV, major series of engines, the normal hardness at the time of manufacturing of the crankshaft is between 21.5 to 26 on HRC Scale (241 to 268 on the HB scale). It is obvious that after the seizure of the bearing, the hardness increases even to the level of 45 to 50 HRC.

The Mirrlees Blackstone allows the higher hardness under a deviation maximum of up to 32 HRC against the standard of a maximum of 26 HRC. In normal situations as per the manufacturer, the crankshaft stands rejected as it has far higher Hardness than the stipulated in the manual.

Field Instruction for Crankshaft Rehabilitation of Mirrlees Blackstone Engine

RA Power took the following action to save the Crankshaft.

The Hardness was taken on various spots, not having a gap of more than 15 mm.
Hardness was recorded and a maximum hardness of 50 HRC was observed.
Since bearing line marks, taper, and ovality on the crank pin were observed, the grinding was undertaken and CR Pin dia was reduced by 3.5 mm approx.
The Hardness was reduced and the maximum Hardness of 42 HRC was observed in a few spots. Although the 42 HRC Hardness was on the higher side than the maximum limit of 32 HRC specified by the manufacturer. The Crankshaft was accepted under deviation due to the following reasons:
1. The higher Hardness was observed in a scattered pattern.
2. The higher hardness was away from the Lubricating Oil Hole and radius fillet of the CR Pin which are considered to be critical Zone.

The versatility of RA Power Solutions crankshaft grinders caters to a wide range of marine and industrial crankshafts, irrespective of their size and design.

The Crankshaft was accepted and his performance is observed as satisfactory from last more than three and half years. The saving of the Crankshaft from rejection was possible only due to the Experience RA Power Solutions has of successful repair of more than ten thousand crankshafts.

RA Power Solutions undertakes Crankshaft Repair, Crankshaft Grinding and offers Onsite Crankshaft Machines to repair companies. We are a leading provider of crankshaft grinding and repair services, specializing in utilizing state-of-the-art crankshaft grinders.

With our state-of-the-art crankshaft grinders and highly skilled technicians, we can accurately recondition damaged or worn-out crankshafts to the original manufacturer’s specifications. By using advanced techniques and precision machinery, RA Power Solutions ensures that the repaired crankshafts regain their perfect alignment, surface finish, and dimensional integrity. Whether it’s a large marine engine or a compact generator, their expertise and commitment to quality make them a reliable choice for any crankshaft-related concerns.

With the use of RA Power Solutions crankshaft grinders, a significant decrease in downtime and repair costs can be achieved, allowing businesses to maintain productivity and efficiency.

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

Grinding & Repair of Crankpin is in Process

Finished Crankpin after Grinding & Repair

For more details on in situ crankshaft grinding and repair, crankshaft grinders, crankshaft grinding repair services, or crankshaft machining contact today by email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Crankshaft Grinding and Crankshaft Repair by Experienced Technicians – RA Power Solutions

Crankshaft grinding and crankshaft repair are important for satisfactory performance of engine. RA Power Solutions Pvt. Ltd. has been undertaking crankshaft repair onsite by portable, light weight crankshaft grinding machine. The crankshaft repair is executed of crankshaft diameter ranging from 60 mm to 700 mm.

We have team of trained and dedicated technicians who are deputed to the site with crankshaft grinding machine along with necessary instruments. The crankshaft repair is undertaken without removing the crankshaft from the entablature.

Crankshaft Grinding of Wartsila Diesel Engine

The crankshaft grinding machine used to undertake crankshaft repair is of latest design having minimum vibrations. This facilitates our technicians to undertake crankshaft repair even while the vessel is sailing. The tolerance after crankshaft grinding and crankshaft repair is maintained within 10 to 20 microns in terms of taper and ovality.

The repair of crankshaft and overhauling of engine while sailing of the vessel between two ports results to the considerable saving to the ship owners as there is no need of holding the vessel at port or anchorage.

The crankshaft repair executed by us is guaranteed for the satisfactory performance. As on date we have executed more than 10,000 repair of crankshaft all over the world.

Crankshaft Grinding of MAN Diesel Engine

For more information on in situ crankshaft grinding machine and grinding of crankshaft please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Crankshaft Repair on Board a Vessel by Experienced Engineers – RA Power Solutions

RA Power Solutions Pvt. Ltd. can easily undertake crankshaft repair on board a vessel while it is sailing by using special equipments.

We can undertake crankshaft repair up to the diameter of 700 mm while the vessel is sailing in high seas in anchorage or at berth. This result to considerable saving for ship repairs as no time is wasted for crankshaft repair as it does not require any anchorage or berth.

RA Power Solutions having 37 years of experience have executed more than 10,000 jobs of repair of crankshaft successfully which is a record.

Damaged Crankpin of MAN Marine Diesel Engine

The crankshafts which have been even rejected by the manufacturers are successfully repaired by us using various process/special equipments which we are learned from our experience. All the repair of crankshaft executed by us is guaranteed for the satisfactory performance. The tolerances as stipulated in the manual are strictly maintained.

Most of our technicians have seaman book and they can sail to any part of the world.

For more details regarding in situ crankshaft grinding, crankshaft repair on board a vessel and onsite crankshaft repair please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Crankshaft Repair in Low Cost – RA Power Solutions

RA Power Solutions Pvt. Ltd. provides crankshaft repair without dismantling of crankshaft from the engine block.

The crankshaft repair on site is cost-effective with minimum downtime.

We are Indian company based in New Delhi with 37 years of experience in repair of crankshaft. We are cost-effective and considered to be most experienced organization. The crankshaft repair of large industrial engine, marine engine, compressor, and rotatory equipments is executed irrespective of its location. We are equipped with latest design of crankshaft repair machines which are compact and lightweight.

The crankshaft repair grinders have minimum vibrations, thus the close tolerances of crankpin and main journal diameter can be maintained after grinding and polishing.

Crankshaft Repair On Land, Anchorage or at Sea

Crankshaft repair services up to diameter of 700 mm are extended for land-based engine, vessel on anchorage, or vessels on move in high seas. Our technicians are trained and experienced to work in any condition with the latest design of crankshaft grinder.

Crankshaft Repair on Land. — Crankshaft Repair on Land

The onsite repair of crankshaft considerably reduces the cost of repairs, reduces the downtime when every minute of breakdown means a lot of inconvenience and loss of revenue.

Crankshaft repair covers following activities:

Crankshaft Straightening
Main Bearing Journal grinding/ Polishing/Superfinishing
Crankshaft Grinding/ correction of lub oil and radius profile
Crankshaft Journal Repair
Orbital Crankpin Machining/Regrinding
Crankshaft Keyway Repair
Main Bearing Machining
Crankpin inspection ie hardness, crack check etc
Crankshaft Polishing
Crankshaft peening
Main Bearing Regrinding
Crankshaft Machining

Crankshaft Repair of Hyundai Diesel Engine

If you are in need of crankshaft grinding or repair services, please contact RA Power Solutions today for crankshaft grinder Dial +91 9582647131 or +91 9810012383 and email info@rapowersolutions.com, rajshahani@rapowersolutions.com.

Crankshaft Straightening – RA Power Solutions

It is generally observed that in case of failure of the crankpin bearing or main journal bearing, the crankshaft loses its alignment. The alignment of the crankshaft and its straightness is of great importance. The crankshaft alignment is specified by the manufacturer according to the crankpin diameter, main journal diameter length of the crankshaft, etc.

RA Power Solutions provides efficient and cost-effective services to keep engines running smoothly and reliably. Trust us to deliver top-notch crankshaft repair & straightening solutions, backed by years of expertise in the field.

In case there is a loss of crankshaft alignment, it is observed that the main journal bearings fail repeatedly.

RA Power Solutions undertakes straightening of the crankshaft as per the manufacturer’s specifications onsite by the peening process. The technicians are experienced and trained to correct the loss of alignment of the crankshaft by the peening process. Crankshaft repair & straightening is a crucial procedure employed to rectify crankshafts that have become bent or damaged due to extensive usage or mishaps.

The crankshaft is straightened by the peening process to the maximum extent and the final correction is done by grinding of main journals in case required.

We are a leading provider of crankshaft straightening services, ensuring the optimal performance and longevity of engines in various industries. RA Power Solutions guarantees exceptional results, enhancing the overall efficiency and reliability of engines, and earning the trust of clients worldwide.

RA Power Solutions specializes in expert crankshaft repair & straightening services. The crankshaft is a critical component of any engine, and over time, it can suffer from wear, damage, or misalignment due to various factors. With our state-of-the-art technology and experienced technicians, RA Power Solutions offers reliable solutions to restore crankshafts to their optimal condition.

Get in touch with RA Power Solutions today, and let us help you maintain the performance and longevity of your machinery through expert crankshaft straightening services. We look forward to serving you!

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 Repair in Limited Engine Space – RA Power Solutions

RA Power Solutions Pvt. Ltd. have successfully executed crankshaft repair on board a vessel of Hyundai engine. The crankshaft repair companies based in Norway, Singapore, and UK were invited to execute the grinding operation on crankshaft bearings of which were seized due to lube oil pump failure. These companies were not able to execute the repairs due to non availability of compact portable tool which was required as the space available from the inspection window was less.

Knowing the constraints of space, RA Power Solutions Pvt. Ltd. designed and manufactured a special-purpose crankshaft grinding machine which was inserted from the inspection window, and grinding of 6 nos. pins was successfully executed. The engine is performing satisfactorily.

The repair of crankshaft on site was possible because the crankshaft grinding machine designed by RA Power solutions was compact, lightweight and was manufactured according to the size of the window and space available in the crankcase of the engine. The technicians were able to maintain the tolerance after grinding within 20 microns against the stipulated tolerance of 30 microns in the manufacturers manual.

**Repair of Crankshaft in Limited Space**

We have successfully done more than 10,000 jobs of crankshaft repair all over the world like Qatar, Dubai, Sudan, Indonesia, Singapore, South America, Malaysia, Jordan, Kenya, Maldives, Nigeria, Iran, Iraq, Oman, etc.

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