Crankshaft Repairing

In the United States of America/RA Power Solutions has successfully repaired a crankshaft of MAN B&W 7L32/40, having standard diameter of 290.00 MM. The Main achievement is that our technicians flew from New Delhi India Airport to Boston, United States of America, and boarded the vessel, The technicians disembarked at Panama Port after successfully executing the repairs. RA Power Solutions offers specialized crankshaft grinding repair services, ensuring the highest level of precision and reliability. With over 44 years of experience in the industry, our expert technicians utilize state-of-the-art equipment and techniques to restore crankshafts to their optimal performance. We provide in-situ grinding, allowing repairs to be conducted on-site without the need for disassembly, minimizing downtime, and reducing costs. Our services are trusted by clients worldwide, delivering exceptional quality and efficiency. Trust RA Power Solutions for your crankshaft grinding needs and experience unparalleled service and expertise.

In the country of Iran, diesel generating sets are widely used for power generation. One of our clients operates multiple diesel generator sets at various locations across Tehran, Iran. These generators are typically run continuously for several days, except during scheduled preventive maintenance.

Caterpillar G3616 Crankshaft

The Caterpillar G3616 gas engine met with an accident and, upon preliminary inspection, was found to be damaged.

RA Power Solutions’ technicians arrived at the site near Tehran and inspected the crankshaft of the Caterpillar G3616. The following are the main observations:

(i) The crankpin bearing of Number #03 was severely stuck to the crankpin surface. The top layer of the bearing had melted and become embedded in the crankpin diameter.

(ii) The bearing material embedded in the crankpin surface was removed to facilitate inspection for hardness, presence of cracks, and dimensional accuracy.

(iii) The minimum and maximum crankpin diameters observed are as follows:

(a) Minimum diameter: 214.93 mm

(b) Maximum diameter: 216.00 mm

Against the standard diameter of 216.00 mm, an ovality of 1.07 mm was observed

(iv) Minor surface cracks were also observed during the MPI (Magnetic Particle Inspection).

(v) Hardness was found to be within acceptable limits, except at a few spots.

Saving of Caterpillar G3616 Crankshaft From Rejection

Based on the fact that the ovality in crankpin number #03 was observed to be 1.07 mm, an inquiry was sent to the manufacturer. The manufacturer informed us that the maximum allowable undersize for the crankpin is 1.00 mm, meaning the minimum acceptable diameter must be 215.00 mm. In this case, since the damage had already reached 1.07 mm, the crankshaft is considered rejected, as per the manufacturer’s guidelines. In this case, the expected undersize after grinding was 2.00 mm, which is beyond the permissible limit.

RA Power Solutions has undertaken onsite grinding of Crankpin Number #03, reducing its size by 2.00 mm, and the following dimensions were maintained after grinding:

a) Minimum diameter observed: 213.98 mm

b) Maximum diameter observed: 214.00 mm

RA Power Solutions, a company providing services for the past 45 years, arranged a 2.00 mm undersized bearing for the Caterpillar G3616 crankshaft through a leading manufacturer based in Germany.

The engine has been assembled and is performing satisfactorily.

We have been regularly executing the on site crankshaft repairs and crankshaft grinding of different engines, like Caterpillar, Wartsila, Cummins, Yanmar, Daihatsu and MAN and MAK in Iran, Iraq, 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.

The MAN B&W 6L23/30H engine belonging to our client, a leading shipping company based in Dubai, met with an accident near Singapore. The details of the crankshaft damage and engine specifications are as follows:

 

 

The vessel was scheduled to sail from Singapore Anchorage to Taiwan. Our technicians, along with the onsite crankshaft grinding machine, boarded the vessel at Singapore Anchorage and sailed to the Port of Taiwan. During the sailing, an inspection of the MAN B&W 6L23/30H crankshaft was conducted, and the necessary repairs were successfully executed.

 

 

Step Taken to Onsite Repair Of MAN B&W 6L23/30H Crankshaft

i) A pre-inspection of all the crankpins was conducted. Crack detection using MPI and hardness testing were also carried out. The dimensional report is as follows:

 

 

 

RA Power Solutions has recently executed the in place machining and grinding of auxiliary engine model 7L23/30H MAN B&W at Suez Port. The crankshaft of the MAN B&W model 7L23/30H had a major failure, as all the crankpins were damaged due to the use of inadequate lubricating oil. The operation manual appears not to have followed the protocol for changing the lubricating oil.

Onsite Crankshaft Grinding for Man B&W 7L23/30H Auxiliary Engine at Suez Port

 

In place Crankshaft machining and grinding of Man B&W 7L23/30H  Auxiliary EngineDeputation of RA Power Solution technicians to Suez Port:

RA Power Solutions deputed two technicians, along with an onsite crankshaft grinding machine and necessary measuring instruments, to Suez Port, where they boarded the vessel. The inspection of crankshaft was conducted as per the RA Power Solutions protocol.

 

Damaged Crankpin of MAN B&W 7L23/30H Auxiliary Engine

 

Damaged Bearing of MAN B&W 7L23/30H Crankpin

 

The following are the main observations:

(i) On the visual inspection of the crankpins, it was observed that all seven crankpins were damaged. The bearing material was embedded on a few of the crankpins. The deep bearing line marks and rough surface are also observed.

(ii) The hardness of the crankpin was taken, and no abnormality was observed.

(iii) The crack detection of all seven crankpins was undertaken by the MPI method, and no crack was observed.

(iv) On dimensional inspection of the crankpins, orality in the range of 0.10 mm to 0.26 mm was observed in the case of six crankpins. In the remaining one, a crankpin ovality of 1.40 mm was observed.

 

MAN B&W 7L23/30H Crankpin Inspection

 

MPI Inspection of MAN B&W 7L23/30H Engine

 

The standard details of the crankshaft are as follows:

Action taken by RA Power Solutions for the successful repair of MAN B&W crankshaft:

(i) Six numbers of crankpins were undersized by 0.5 mm.

(ii) One number of crankpins was undersized by 2.0 mm.

 

(iii) We strictly maintained all parameters as per the manufacturer’s requirements and the maintenance manual.

 

Global Onsite Crankshaft Grinding & Crankpin Repair Services

RA Power Solutions is a leading global provider of onsite crankshaft grinding, crankpin repair, and journal machining for marine and industrial engines. 

We have successfully completed repair projects in:

Egypt, UAE, Saudi Arabia, Qatar, Oman, Kuwait, Singapore, Malaysia, Indonesia, Turkey, Greece, Bangladesh, Sri Lanka, Azerbaijan, Nigeria, Ghana, and multiple West African regions.

Product Details:

A Caterpillar 3516 crankshaft met with an accident in a diesel generating set installed in a gold mine in Burkina Faso. In the gold mine, all equipment is operated by power generated through diesel generating sets. The critical operations of the gold mine came to a standstill due to the breakdown of the Caterpillar 3516 diesel generator crankshaft.

RA Power Solutions, having a global presence in the repair of crankshafts of main and auxiliary engines up to 700 mm diameter for the last 46 years, was approached by the client and was asked to explain the need for immediate repair of the crankshaft. Two technicians from RA Power Solutions, along with onsite crankshaft repair equipment, were deputed to Burkina Faso. The details of the engine and crankshaft are as follows:

RA Power Solutions, having a global presence in the repair of crankshafts of main and auxiliary engines up to 700 mm in diameter for the last 46 years, was approached by the client and was asked to explain the need for immediate repair of the crankshaft. RA Power Solutions dispatched two technicians and onsite crankshaft repair equipment to Burkina Faso.

 

The details of the engine and crankshaft are as follows:

 

 

On going through the above details, one can observe that the diameter of the crankpin is very small, i.e., 135.00 mm, and the bearing width is 120.00 mm. 

Inspection of the Caterpillar 3516 Crankshaft

On inspection of the oil sump and Caterpillar crankshaft, it was observed that crankpin number 07 was damaged. The following steps were taken:

a) The connecting rod was opened.

b) Crankpin number 07 was subjected to dimensional inspection for taper, and ovality of 0.80 mm was observed.

The minimum and maximum diameters of crankpin number 07 were as follows:

• Minimum diameter: 134.20 mm

• Maximum diameter: 135.00 mm

c) Visual inspection of the damaged crankpin revealed deep line marks.

d) As per protocol, the crankpin’s hardness and cracks were checked using the MPI method, and no abnormalities were observed.

Action Taken by RA Power Solutions to Save the Crankshaft of Caterpillar 3516 

The various reports and photographs of the damaged crankpin were carefully studied, and considering that all other parameters, such as hardness, crack detection report, deflection, and runout, were within limits as per the manufacturer’s manual, it was decided to save the crankshaft from rejection by grinding it.