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: