In Situ Repair Services

Product Details:

We have specialization in rebuilding and repairing the crank shafts, cylindrical shaft, castings and mechanical components, which are damaged and worn out beyond the last permissible limit. We are renowned for repairing manufacturing errors, to repair an obsolete part or a part that has worn excessively. The reclamation of crankshaft (and many other components) can produce considerable saving over the replacement cost, wherein saving of 50% is common and in case of large components, as much as 90% can be saved. Our trained engineers work on site and in the factory to provide highest quality of rebuilding techniques. This helps us to achieve high specification irrespective of all types of components with the assistance of latest equipment.


General Applications:

• Repair and Reconditioning
• Erosion preventing coating
• Anti-Corrosion
• Heat Shield
• Erosion Prevention
• Insulation

Deposit materials mainly used are:

• Steel
• Tungsten Carbide
• Chrome Carbide
• Ceramics and Plastic Composite

Our Techniques are as follows:

• Flame Spraying
• Plasma Spraying
• High Velocity Oxygen Fuel
• Arc Spraying
• Thermal spraying

Advantages:

• Rebuilding provides a smooth, wear - resistant surface with a low co-efficient of friction
• Especially for crankshafts which require a hard surface on the crankpins and main journals, thermal spraying is the best build-up method
• It is a "Cold" process, the risk of heat warp age by welding and the need for subsequent straightening is eliminated
• A prime financial benefit of this application is in saving the replacement cost of the components and in some cases, saving the replacement cost of the engine itself, when new parts are not obtainable
• Depending on the local cost of labour, the cost of repairing of the crankshaft will vary. But having repaired so many crankshafts our experience shows that replacement cost of components is very economical.

Product Details:

We have been into the process of onsite crank shaft grinding over four decades.  It saves down time, cost and knock out the risk factors involved in shipping and handling of Crankshaft.  We have modern crankshaft grinding machines which create minimum vibration. Thus maintaining close tolerance. The onsite crankshaft grinding is undertaken by our experienced technicians.

Product Details:

RA Power Solutions Pvt. Ltd. has more than 37 years of experience of successfully executing on site crankshaft repair irrespective of the type of damage it has. The grinding of a crankshaft in most of cases is done onsite.
We have state of art crankshaft grinding equipment which is portable and lightweight and can be carried to the site. More than 11000 jobs for crankshaft repair up to 700 mm diameter have been executed.

Product Details:

Yanmar S185L crankshaft of the auxiliary engine was reported damaged by a Dubai-based company. The vessel was on its way to Mundra India port.
Ready Availability of Undersize Crank Pin Bearing for Yanmar S185L and other make of engines
Understanding the importance of timely availability of undersize crankpin bearing required after grinding, RA Power Solutions maintains a stock of undersize crankpin Bearings up to 2.0 mm. In most cases, our technicians travel to the site with undersize bearing. This avoids the delay in the commissioning of the engine.
We have been executing the repairs in Laos, Lebanon, Malaysia, Maldives, Mongolia, Nepal, North Korea, Oman, Philippines, Qatar, Russia, Saudi Arabia, Singapore, South Korea, Sri Lanka, Syria, United Arab Emirates, Yemen etc. 

Product Details:

Wartsila Engines are installed in Power plants, vessels, and various offshore installations in large numbers and some of them have crossed 15/20 years of operations.
RA Power Solutions having over 43 years of experience offers in situ machining of all models of Wartsila engine crankshaft including 6R32, 4R32, 8R32, 9R32, W9L20, 12V32LN, 16V32D, 16V32LN, W16V32, W18V32, ZAV 40, R22H, 6ZLA 40,824TS, L20, 7L32, 12V22HF, W9L32.
The in situ machining of Wartsila crankshaft is always beneficial as it does not require a dismantling of crankshaft and transportation for the repairs.
We have been regularly executing the repairs in Argentina, Bahamas, Barbados, Bermuda, Bolivia, Brazil, Canada, Chile, Colombia, Costa Rica, Cuba, Dominican Republic, Ecuador, El Salvador, Guatemala, Guyana, Haiti, Honduras, Jamaica, Mexico, Nicaragua, Malaysia, Nigeria, UAE, Togo, Spain, Madagascar, etc.

Product Details:

The crankpins of the Caterpillar and Cummins engines get worn out and develop ovality after operation for 25000 to 30000 hrs. They need grinding & polishing.

RA Power Solutions undertakes onsite grinding of all models of Diesel Engines including Caterpillar and Cummins.

RA Power Solutions having forty-three years of experience in onsite grinding/ polishing of crankshaft up to 700 mm diameter. After continuous research, we have developed the compact and portable crankshaft grinding machine which can undertake the grinding and polishing of Cummins and caterpillar engine crankshaft without removing it from the engine block

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 on the Caterpillar and Cummins engines. Contact us.

Product Details:

Caterpillar Engine Crankshaft Repair is possible on-site worldwide. We use portable lightweight, the latest design of crankshaft grinding equipment which is carried by technicians all over the world to undertake the grinding of caterpillar engine crankshafts.
The Crankshaft grinding machine undertakes the grinding without removing the crankshaft from the engine block. 
Crankshafts of all models of caterpillars can be polished and grinding can be done without removing them from the Engine.

Additional Information:

• Item Code: 01

Product Details:

RA Power Solutions was informed about the repeated failure of crankpin bearings of MAN B&W 5L 16/24 by one of our client base in Dubai. 

We deputed our technicians to Duqm port in Oman to undertake the inspection of the crankshaft and repair. The crankpin diameter and other details are mentioned below. 

Inspection undertaken by RA Power Solutions of Crankshaft of MAN B&W Engine Model no.5L 16/24 

 

i) The connecting rods of all the five crankpins were removed. 

ii) On visual inspection the crankpin bearings were observed damaged with line marks.

iii) All crankpins were checked dimensionally for taper & ovality and to our surprise the ovality ranging from 0.13 mm to 0.20 mm was observed. Considering the standard size of crankpin as 130 mm minus 0.03 mm, It is very much on the higher side. Copy of Inspection report of crankpin is pasted below. 

iv) All the crankpins were subject to checking of hardness by portable hardness tester and it was observed within limits.

 v) As a protocol the crankpins were also subject to crack detection test by MPI. No cracks or abnormality was observed.

 vi) Bearing line marks and rough surface was observed on all crank pins journal. 

 

 Action taken by RA Power Solutions for successful repair of Crankshaft of MAN B&W Engine Model no. 5L 16/24

 i) The five number crankpins were ground to the first step size of 0.5 mm maintaining the tolerances as per the manufacturer specifications. 

 ii) The final diameter was maintained between 129.47 mm and 129.50 mm. 

 iii) The radius and lubricating oil profile was maintained as per the original. 

 iv) Final readings of crankpins after grinding are pasted below. 

 

Supply of undersize Bearing of MAN B&W Engine Model no. 5L 16/24

 RA Power Solutions supplied 0.5 mm undersize bearings to the client. 
The engine was commissioned in the presence of our technicians and performance was observed to be satisfactory.

 

Product Details:

RA Power Solutions was approached by one of largest shipping company based in Athens Greece regarding breakdown of Crankshaft of YANMAR Diesel Generator Model no. 8N280L-EV. Vessel was to take a berth at Mundra port India and the stay of the vessel at port was limited to only 13 hrs.

Following is the details of the crankshaft of Yanmar Diesel Generator Model no. 8N280L-EV 

 

Action taken by RA Power Solutions for successful repair of Crankshaft of Yanmar Diesel Generator Model no. 8N280L-EV.

i) As mentioned above we were given only 13 hrs of time at Mundra Port India to inspect the crankshaft and to execute the repair. In this situation we decided to depute a team of three technicians onboard the vessel instead of two technicians which is our normal practice. 

Following are the main observation:
a) The diameter of crankpin no 4 was checked and following dimensions were observed:

     i) Minimum diameter observed    - 224.15 mm

     ii) Maximum diameter observed   - 225.00 mm

Above shows the ovality of 0.85 mm.

b) The crankpin no. 4 was subject to hardness check and was found within limits except on few scattered points where it was observed in the range of 500 HB.

c) The crankpin was subject to crack detection by high intensity magnaflux torch and no cracks or abnormally was observed. 

d) Due to the seizure of crankpin bearing the radius fillet of both the sides was badly damaged. 

 Successful Repair of Crankshaft of Yanmar Diesel Generator Model no. 8N280L-EV

 a) Our technicians worked non stop and were able to successfully repair the crankpin no. 4 by undersizing and grinding it to 1.0 mm.

b) After grinding & polishing following minimum & maximum crank pin diameter was maintained:

   i) Minimum diameter observed    - 223.98 mm
  ii) Maximum diameter observed   - 224.00 mm

c) The above reading shows the crankpin was undersized by 1.0 mm from 225.00 mm to 224.00 mm thus maintaining the ovality of only 0.02 mm which is far superior than the tolerance stipulated in the manufacturer manual. 

 d) The formation of radius fillet at both ends was a big challenge as it was badly damaged and time available was limited. The radius fillet was also repaired successfully. 

g) It is normal for RA Power Solutions to take such challenging jobs where the damage to the crankshaft due to an accident is very serious and time available is short.   

 h) We have a team of technicians which are experienced to take such challenging assignment. 

 

 

Product Details:

RA Power Solutions was advised about the damage to the crankshaft of MAN B&W 9L27/38 on board the vessel. The vessel was stranded at Lumut Port Malaysia due to non performance of the main engine of MAN. 

We deputed a team of two technicians with necessary onsite crankshaft grinding equipment to undertake the inspection and repair of the crankshaft.  

The details of Engine are mentioned below:


Following are the main observations of the crankshaft of MAN Aux. Engine Model No. 9L 27/38 
i) On visual inspection by our technicians it was observed that crankpin no. 2 have a deep depression mark measuring about 40 x 25 mm. 

 ii) The minimum and maximum dimensions of crankpin no. 2 were observed as following:     a) Standard dimensions of crankpin:  250 mm     b) Minimum size observed :              247.80 mm 
Thus the ovality of more than 2.2 mm was observed. 

iii) Our technicians reported that damage to Crankpin is more as the micrometer is not able to take the reading due to the nature of damage. The crank pin was subject to crack detection by MPI and no cracks were observed. 

Planning for Repair of Crankshaft of MAN Engine Model No. 9L 27/38 

i) During the discussions with the technical staff of the vessel it was informed that a crankshaft repair company from Singapore inspected the damage crankpin no. 2. They observed higher hardness and have undertaken local grinding of the hard spots by a hand grinder.

ii) Our technicians checked the hardness of the crank pin at every step while undersizing it, to our surprise the hardness was coming down as the grinding was done.

iii) Our technicians have undertaken the grinding to the undersize of 4.0 mm and the maximum hardness observed is 328 mm.

iv) The damaged crank pin has been successfully repaired.  

Due to the lack of knowledge and experience the hand grinder was used to check the hardness which in turn rather damaged the crankpin.   

 

Additional Information:

• Delivery Time: Within 24 Hours

Product Details:

RA Power Solutions is acknowledged all over the world as a leader for grinding of crankshafts onsite without removing them from the engine block. 
The advantage of RA Power Solutions:
Use of a specially designed compact onsite grinding machine capable of undertaking crankshaft grinding without involving the dismantling of the shaft from the entablature.
Crankshaft grinding machines are manufactured in-house and can be designed & modified as per the site requirements. This is of great advantage to our clients from shipping companies, power plants, etc.
In-house trained engineers and mechanics skilled in the art of in situ crankshaft grinding.
It is possible to repair the crankshaft even while sailing the vessel, the ready availability of tools, technical data, and technicians.
All technicians have seaman books and some of them have US visas. They can sail from one port to another.

Product Details:

In-situ crank shaft grinding is the latest process of grinding and polishing of crankshaft, CR pin and main journal without removing crankshaft from the engine block. The in-situ crankshaft grinding and in-situ repair of crankshaft saves time as it does not require removal of crankshaft from the engine block. RA Power Solutions has the facility to undertake crankshaft repair up to the diameter of 700 mm.
Ours is the only company which can do on site crankshaft grinding and on site crankshaft polishing while vessel is sailing having four decades of experience in crankshaft repair.

Additional Information:

• Delivery Time: 5-6 weeks

Product Details:

RA Power Solutions was approached by a company based in Gambia regarding failure of their main engine crankshaft of Allen PVBCS12 F.

RA Power Solutions deputed two technicians along with the necessary portable onsite crankshaft grinding machine to Banjul port Gambia.

The details of main engine and crankshaft dimensions are mentioned below:

After undertaking the inspection of the crankshaft it was observed that 3 number of crankpins were damaged due to bearing seizure and balance 3 number of crankpins had rough surface and bearing line marks. 

Benefits of Allen Engine PVBCS12 F Crankshaft Repair by RA Power Solutions

i) RA Power Solutions is having more than four decades of experience in extending crankshaft repair services for medium & high capacity engines, compressors and all types of rotary equipments. 

ii) It is our constant endeavour to develop and modernise in situ crankshaft grinding machines from time to time.

iii) Presently our grinding machines are capable of undertaking the crankshaft repair from 35 mm to 700 mm in terms of diameter.  

 

Product Details:

Our system holds expertise in Polishing of Crankshaft. The polishing of crankshaft is done to remove the bearing line marks.

Product Details:

RA Power Solutions have been involved in marine diesel engine maintenance over four decades. Our team of qualified engineers uses latest technology for marine engine maintenance. And overhauling. We have executed number of projects of major overhauling of diesel engine in Qatar, Dubai, etc.

Product Details:

Repair of 6 MW cracked engine block has been executed by RA Power Solutions. The crack engine block of Wartsila was successfully repaired by use of special alloy keys to undertake metal locking and metal stitching.

RA Power Solutions was approached by a leading shipping company based in Miami USA regarding a problem faced by them in the crankshaft of Wartsila Vasa Type 6R32 main engine. The vessel was stranded at the Port of Las Calderas in the Dominican Republic. 

In fact due to ongoing COVID-19 and omicron infection the flights were closed and on partial resumption of flights two technicians were deputed. 

 
Wartsila Vasa main engine type 6R32 details

We are giving below the major specifications of the crankshaft of Wartsila Vasa type 6R32.

Inspection of Wartsila Vasa type 6R32 Crankshaft and observations:

i) On arrival of our technicians the visual inspection of the crankshaft was conducted. The crankpin bearing of crankpin no. 5 was observed damaged and all the connecting rods were removed.  

ii) All the crankpins were subject to dimensional inspection for taper & ovality.Our technicians were surprised to see crankpin number 5 which was  found to be badly damaged having following dimensions:  

   a) Minimum dimensions of crankpin no. 5:    269.05 mm

   b) Maximum dimensions of crankpin no. 5 :  270.00 mm

iii) The hardness of all the crankpins was checked by a portable hardness tester. The hardness of all the crankpins was observed within limits except crankpin no. 5 having hardness of 588 on the HB scale was observed.

 iv) The magnetic particle test of all the crankpins was done and no crack was observed. 

 
v) Deflection was observed within limits. 

 vi) On visual inspection deep line marks & rough surface was observed on balance five number crankpin.

Action taken to successfully repair  Crankshaft of Wartsila Vasa type 6R32

i) The grinding of crankpin no. 5 was undertaken initially to the undersize of only 0.5 mm. since the depth of damage was on the higher side. Our technicians had no option but to reduce the diameter by 1.5 mm. This was done in consultation with the chief engineer of the vessel. After final grinding the following dimensions were maintained:

 
 a) Minimum diameter of crankpin no. 5:   268.48 mm

 b) Maximum diameter of crankpin no. 5:  268.50 mm

The ovality of 0.02 mm was  maintained with high surface finish better than the specifications of  Wartsila Engine manufacturer. 

ii) All pins were polished by a special polishing media and surface finish was improved considerably. 

We were approached by our old client who informed about the damage to the crankshaft of Bergen Rolls Royce make of Engine model C 25:33 L9P.

The Detail of Engine,Crankpin diameter and bearing width are mentioned below in the box:

Action taken by RA Power Solutions to Repair Bergen Rolls Royce Crankshaft Model no. C 25:33 L9P

i) Before the arrival of our two technicians and  boarding on a vessel at Mumbai Port India, the ship staff removed all the connecting rods.  

ii) On visual inspection one number of crankpin was observed damaged having standard diameter of 230 mm and crank pin bearing width of 92 mm.

The minimum & maximum reading of crank pin was observed as following: 

  a) Minimum diameter observed-   229.61 mm

   b) Maximum diameter observed-  229.93 mm

Against the standard diameter of 230.00 mm the ovality of 0.32 mm was observed which is considered to be very much on the higher side. Deep bearing line Mark’s and rough surface was observed.

iii) All other crankpins were also subject to dimensional inspection, taper & ovality was observed within limits. Only the Bearing line marks were observed. 

iv) As a routine inspection the hardness of crankpin was inspected and was observed within limits. The crack detection was  also undertaken by MPI and no crack was observed. 

v) The grinding of one number of crank pin was undertaken maintaining the final size of 229.00 mm with undersize of 1.0 mm. 

Successful Repair of Bergen Rolls Royce Crankshaft Model no. C 25:33 L9P

i) RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company having global presence and executing successfully repair of medium & large crankshafts diameter ranging from 30mm to 700 mm. 

ii) We have a team of experienced technicians who are factory trained and ready to fly to  any site all over the world with equipment in a short notice.

iii) All our technicians have valid Indian CDC. 

iv) We are regularly extending our services to Marine, Power Plant and heavy industries all over the world. 

vi) We are perhaps the lowest in cost in comparison to the companies in UK, Europe and other countries. 

 

Product Details:

RA Power Solutions Supply  High Capacity Diesel Engine Spares And Also Repairs The Marine Engine Parts  Like Crankshaft, Engine Block, Cylinder Heads, Bearings Etc.

Product Details:

As an expert of crankshaft repair upto 700 mm diameter for the last 41 years RA Power Solutions is successful In repairing the crankshafts which meet even with serious accidents and are even  rejected by the manufacturer for one reason or another. By using the latest technology, experience and most modern and revolutionary crankshaft grinding machines in most of the cases, we are successful in undertaking the repair of the crankshaft. However, there are cases where the crankshaft is found beyond repair limit.

Crankshaft Replacement undertaken by RA Power Solutions

RA Power Solutions undertakes replacement of crankshafts for engines mounted on vessel and in industry. Our technicians have experience and are expert in replacement of old and damaged crankshaft with new one. Prior to the replacement of the crankshaft in the engine block, it is thoroughly inspected. After assembly of the new crankshaft, the important parameters like taper, ovality, deflection, run out etc are checked.

For your requirement of crankshaft replacement, you may contact RA Power Solutions. We have been working on engines like Wartsila, MAN B&W, MAK, SKL, Caterpillar, Ruston, DEUTZ, Alpha B & W, Bergen, Sulzer, MTU, nohab polar, Pielstick, Hatlapa, Mitsubishi, stork werkspoor, MVM, Yanmar etc

Product Details:

We Have Been In Engine Repairs And Maintenance From Over four Decades. We Offer Engine Repair, Maintenance And Overhaul Services With A Guarantee. We Have Successfully Repaired Marine Engine To Companies Based Qatar, Dubai, Maldives, Sri Lanka Etc.  We Have Team Of Trained Engineers And Technicians Who Can Be Deputed At Site To Undertake For Preventive Maintenance And Overhauling Of The Diesel Generating Sets Respective Of Their Make And Models.

In case of high and medium capacity diesel engines, the crankshaft gets damaged due to continuous running or gets worn out. This requires repair of crankshaft by highly precision equipment. Crankshaft grinding of compressor shaft, diesel engine, pump and all rotatory equipments is possible now onsite without removing the crankshaft from the compressor casing or engine block. RA Power Solutions undertakes onsite crankshaft grinding upto 700 mm diameter.

RA Power Solutions have been executing on site crankshaft grinding and crankshaft repair services for the last more than four decades. We have experienced technicians  and on site grinding equipment available up to 700 mm diameter. 

The Main Advantage Of Appointing RA Power Solutions For Crankshaft Grinding & Crankshaft Repair:

1)Experience of more than 41 years in repair,grinding and polishing of crankshaft,cylindrical shaft,turbine,rotor,alternator shaft etc.

2)All our technicians are well experienced.

3) The crankshaft grinding machine is developed and manufactured by us and in case of limited availability of space the necessary modification in the equipment can be done in short notice. This is of great advantage in case of engine crankshafts where the bearing width is less.We modify the machine according to the bearing width dimensions.    

4) The on site crankshaft grinding machine is lightweight and can be taken to any site in the world as a accompanied baggage there is no need of booking it as cargo involving customs formalities, clearance etc which is expensive and time consuming. 

5) Equipment is Pneumatically operated and the client has to only arrange for the Air. 

6)We have the  instruments for checking hardness, crack detection by latest high intensity magnaflux torch, Mitutoyo instruments to check dimensions, surface finish electronic tester etc to undertake the inspection of crankshaft before and after the grinding is undertaken.. 

7) Our technicians are qualified to undertake non destructive magnetic particles tests and other examinations. Calibrate instruments are used for inspection purposes. 

8) We have in house training school where the technicians are trained and briefed about day to day development in the field of crankshaft repair with the availability of modern equipment.

Use of the latest technology equipment and process, having experienced technicians has made us the leader in the field of crankshaft grinding and crankshaft repair. We are respected for our sincerity and honest approach. 

We are serving all over the world and have reputed companies as our reference in more than 103 countries all over the world. 

 

RA Power Solutions was approached by a company based in Dubai regarding a problem in crankshaft faced in MAN Diesel Generating set model no. 9L28/32.

The make,model of Engine and crankshaft details are given below:

Repair of MAN Engine Model no. 9L28/32 Diesel Generating set Crankshaft

RA Power Solutions deputed two technicians along with an onsite crankshaft grinding machine and technicians boarded the vessel at port of Jebel Ali Dubai.

i) It was observed that the crankpin no. 3 of the AE#02 was damaged. The Bearing material was embedded on the crank pin diameter. After removal of the white metal from the crankpin the dimension inspection was done and following was observed:

a) Minimum crankpin diameter observed  :  229.44 mm

b) Maximum crankpin diameter observed :  229.83 mm

The above readings were observed against the standard diameter of 230.00 mm.    

ii)The radius fillet and lubricating oil hole profiles were found acceptable with no damage.

iii) All  other parameters were observed within limits. 

Successful Crankshaft Repair of MAN Engine Model no. 9L28/32

i) The grinding of crankpin no. 3 was initially undertaken to the undersize of 1.0 mm maintaining the crankpin diameter of  229.00 mm.Since the Bearing line marks were still visible it was decided to grind further.The final size maintained after grinding and polishing  was 228.50 mm which is 1.5 mm undersize. 

ii) Considering the rough surface finish and bearing line marks all the remaining crankpins were polished while using the state of art crankshaft grinding & polishing machine using the latest polishing media. 

iii) The surface finish of less than 0.20 RA value was maintained. 

iv) The ship had the 1.5 mm undersize bearing available which was assembled and the engine was put on load.

Product Details:

 

RA Power Solutions was informed by one of our client regarding failure of Crankpin no. 6 of AE#2 of MAN 9 ASL 25/30 Model Engine. 

The Engine details are as following:

 

Our technicians boarded the vessel at Mumbai port and performed an evaluation of the crankshaft. 

Following were the main observations:

Inspection & observation of MAN 9 ASL 25/30 crankshaft of engine no. 2 crank pin no. 6:

i) During the visual inspection of crankpin  it was observed that the crank pin bearing got melted and was badly embadded on the crankpin. 

ii) The crankpin bearing was removed and was found badly damaged. It was a serious accident as the bearing was burnt which shows that temperature exceeded 600°/700° celsius. 

iii) The crank pin was polished and dimensional inspection was conducted. During the dimensional inspection the ovality of 0.66 mm was observed.   

iv) The radius fillet of both the sides was badly damaged. 

v) The crack detection by MPI and high intensity magnaflux torch was conducted by our qualified technician showed the multiple cracks, length ranging from 5 mm to 19 mm.

vi) The hardness was found on a higher side.

Action taken by RA Power Solutions technicians to repair crank pin of MAN 9 ASL 25/30 

i) The crankpin bearing width 77 mm only made the execution of the job very complicated.

ii) We used a specially designed onsite crankshaft grinding tool to be accommodated on the crankpin. 

iii) We could undertake the grinding of crankpin with damaged radius because of the use of the latest technology of crankshaft grinding equipment developed and manufactured by us.  

iv) Initially the grinding was done to undersize 0.5 mm and crank pin diameter was maintained 194.50 mm. On undertaking the MPI test the multiple cracks were still present on a critical location near the radius fillet. 

v) The grinding of crankpin was again resumed and crack detection by MPI method was undertaken at different stages.  

vi) Finally the crankpin diameter was reduced to 193.5 mm as all the cracks got removed.

vii) The engine was assembled, oil gap was checked and everything was obseved within limits. Engine  was commissioned.   

 

 

Wartsila Engine Model 6R32, 4R32, 8R32, 9R32, 12V32LN, 16V32D, 16V32LN, W16V32, W18V32 Crankshafts are repaired by RA Power Solutions on site installed in Power Plants & ships all over the world.
We have been extending crankpin repair and crankshaft grinding services for Wartsila engine Model no. 6R32, 4R32, 8R32, 9R32, 12V32LN, 16V32D, 16V32LN, W16V32, W18V32 and diesel generating sets installed in any part of the world.
RA Power Solutions have been undertaking crankpin repair services for the last 42 years. All our technicians have valid Indian passports, seaman books and can travel short notice.Some of them also have American visa.
We have  executed successfully repair of more then 300  nos of crankshaft of Wartsila Engine Model no. 6R32, 4R32, 8R32, 9R32, 12V32LN, 16V32D, 16V32LN, W16V32, W18V32 for various shipping companies & Power Plants.  

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RA Power Solutions undertakes repair of compressor crankshafts of different types of compressor used in industry. We can undertake onsite repair of crankshaft diameter ranging from 35 mm to 700 mm. The main advantage of getting the compressor crankshaft repair done from RA Power Solutions is that we have experience exceeding four decades in repair of compressor crankshafts and can undertake compressor crankshaft repair on site without removing it from engine block upto the crank pin diameter of  700 mm. 

 REASON FOR FAILURE OF COMPRESSOR CRANKSHAFT:-

• Absence of lube oil on desired pressure is the main cause of failure of compressor crankshaft.
• Use of sub-standard lubrication oil and non-replacement of oil as suggested in the maintenance manual.
• Choking of lubricating oil filters and non-replacement on time.
• High operating oil temperature.
• Non-replacement of connecting rod and main journal bearings of compressor crankshaft as suggested in the manual.

ASSISTANCE PROVIDED BY RA POWER SOLUTIONS FOR ONSITE REPAIR OF COMPRESSOR CRANKSHAFT

• As mentioned above, we have availability of portable, compact onsite compressor crankshaft grinding tools upto 700 mm diameter.
• Our technicians visit the site with the tools and undertake the grinding of crank pin without removing the crankshaft from the compressor block.
• Our technicians are fully trained for repair of seriously damaged compressor crankshafts due to accidents or normal wear and tear due to continuous running.
• All the technicians are trained in our in house training school.
• Technicians are qualified and carry valid CDC and can reach any site or vessel all over the world in a short time.

WE UNDERTAKE COMPRESSOR CRANKSHAFT REPAIR FOR FOLLOWING TYPE AND MAKE:-

• Reciprocating Compressor
• Rotary Screw Compressor
• SIGMA Control Compressor Controller
• Centrifugal Compressor
• Gas Compressor
• Positive Displacement compressor
• Screw Compressor
• Scroll Compressor
• Dynamic Compressor
• Centrifugal Compressor
• Air compressor
• Hydrogen compressor
• Ammonia compressor
• Turbo Compressor
• Axial Compressor 
• Refrigeration compressor
• Makita
• Senco
• ANEST IWATA
• Gardner Denver
• Graham Sulzer
• Hitachi
• Bostitch
• Rolair Systems
• Brehob
• Lufkin
• Zebra 
• Ingersoll Rand  
• Grasso
• Curtis-Toledo
• Brehob
• General Electric

 

 

We are pleased to advise that we have expanded our operation and extending crankshaft repair & engine overhauling services in Malaysia and neighbouring countries. With the opening of our office in Malaysia the local customers can avail our following services: 

• Straightening, grinding and complete repair of Crankshafts.
• Rebabbitting and Manufacturing of white metal bearings up to 1500 mm diameter. Development & Manufacturing of babbitt white metal bearings as per the drawing or sample. Engineers with CAD-CAM & instruments can be deputed at remote sites for preparation of drawing.  
• Manufacturing & Export of Babbitt white metal of different grades as per client's requirement.

• On site Metal stitching of damaged cast iron, aluminium, Bronze heavy components like engine blocks, cylinder liner, cylinder heads etc.

• Supply of Spare Parts of all make from OEM.  

• Ready stock of bearings Standard and special size.  
• Inspection on site (Calibration, Hardness test, Magnetic Particle Test, Trueness, Deflection, Surface Roughness)
• Supply of reconditioned spare parts and marine equipment like fresh water Generator,Heat exchangers, Compressors. DG sets etc.
• Overhauling & repair of engines.  
• Alternator repairs.

 

 

We were approached by a ship management company based in Athens, Greece having ninety vessels regarding breakdown of the crankshaft of Daihatsu Engine 5DK-20.

 

The engine & crankshaft details are given below:

RA Power Solutions team of two technicians with portable crankshaft repair equipment was immediately deputed to Navlakhi Port in western part of India. On inspection of crankshaft following was observed:

 

Main observations of the crankshaft of Daihatsu Engine 5DK-20 after inspection

 

i) The crankpin no. 3 was badly damaged due to seizure of the bearing. The bearing white metal was badly embedded on the crankpin diameter. 

 

ii) On visual inspection it was observed that the radius fillet of both sides was  damaged and original profile of radius fillet was lost. 

 

iii) After removal of bearing material from the crankpin diameter deep scoring marks and multiple depressions were observed.

vi)The crankpin was subject to MPI test for crack detection, multiple cracks were observed having length ranging from 3.0 mm to 19 mm. All the cracks were hairline cracks.  

v) Hardness was taken and was found on the higher side even up to 515 BHN. This was the scattered hardness. 

vi) Deflection of complete crankshaft was checked and was observed within limits. 

 

 

RA Power Solutions  undertakes crankshaft repair of diesel engine used as generator, marine engine & auxiliary engine, compressor, forging hammers and all heavy rotatory equipment's having crankshaft or cylindrical shafts upto 700 mm diameter.  

Advantages of crankshaft repair services offered by RA Power Solutions. 

We are mentioning below few of the advantages of getting crankshaft repair executed by RA Power Solutions. 

  i) We believe that the crankshaft is a piece of art and even for the heavy crankshafts the tolerance in terms of taper and ovality ranges between 20 to 50 microns which is very less and requires experience, special skill and dedicated latest design of equipment to maintain.  

 ii) RA Power Solutions is the only manufacturer of the onsite crankshaft grinding machine in the world and has supplied over 70 machines which are in operation by leading shipping companies, Power Plants and repair workshops etc.   

 iii) Our designing and manufacturing of onsite crankshaft grinding machines for crankshaft repair can be easily modified according to the site requirement. 

 iv) Difficult and serious damage of crankshaft are successfully repaired as we have in-house capability of modifying our equipment as per the site requirement and condition.
 
v) Most of the companies based in Europe, UK undertaking crankshaft repair cannot successfully execute the repair of crankshaft radius fillet of which is damaged or worn out due to accident. They always recommended to either remove the crankshaft from the engine block and send it to the workshop or to reject it.  

Availability of trained & experienced technicians for crankshaft repair : 

 i) All our technicians are trained in our in-house training school near New Delhi, capital of India.   

 ii) The technicians are trained on dummy crankshafts under the senior supervisions, who has experience of 30 and 40 years in crankshaft repair.  

iii) Our mission is to create awareness and make it understandable to our clients all over the world that it is not a difficult task to repair the crankshaft, which few companies have been propagating and made monopoly by charging exorbitant price. 

 Low cost of crankshaft repair offered by RA Power Solutions  

 We are the cheapest in the world executing crankshaft repair at minimum cost.  

 We don't charge separately for NDT test, cost for repair of radius fillet, out of station allowance etc. 

 We have successfully executed damaged crankshaft repair of MAN B&W, Yanmar, Daihatsu, Wartsila, Ruston & Hornsby Engine etc.  

We have been regularly executing the repairs in Argentina, Bahamas, Barbados, Bermuda, Bolivia, Brazil, Canada, Chile, Colombia, Costa Rica, Cuba, Dominican Republic, Ecuador, El Salvador, Guatemala, Guyana, Haiti, Honduras, Jamaica, Mexico, Nicaragua etc. 

 

Product Details:

RA Power Solutions have been successfully undertaking onsite repair of crankpin/ Main Journal for the last 41 years. We have the facilities to undertake repair of crankshaft diameter ranging from 30 mm to 700 mm. 

We have observed that due to accident the radius fillet of the crankpin and main journal gets damaged or worn out, In which condition it becomes difficult to undertake the grinding of the crankshaft as most of companies have the grinding tool which is placed on the radius fillet and undertakes the grinding by taking the reference of fillet radius. 

In this situation the crankshaft repair companies either reject the crankshaft or recommend sending the crankshaft to a designated workshop for the repair.   

We are the only company in the world which can undertake the grinding of crankpin having damaged radius fillet. We have the credit and experience of successfully undertaking the repair of crankshaft radius fillet of which is damaged or worn out.   

 

Successful Repair of Crankshaft with damaged Fillet radius:

i) It is generally noticed that in case of seizure of bearing the bearing material gets embedded on the crankpin and the radius fillet of both the sides. 

ii) Radius fillet gets damaged either during the failure of bearing as the bearing steel shell rubs with the radius fillet or the bearing material gets embedded on the radius fillet which while removing damages the radius fillet.

iii) Crankshaft repair companies take the reference of radius fillet for grinding purpose and are not able to undertake repair due to damage radius fillet.   

iv) RA Power Solutions has the necessary tools, equipment and expertise for repair of crankshaft having damage radius fillet. 

v) Don't reject or and send it to the workshop contact RA Power Power Solutions who will undertake the repair of damage radius fillet crankshaft onsite whether on vessel or for land base engines.    

vi) Our technology and equipment is so advanced that the damaged  radius fillet crankshaft repair is possible even while the vessel is sailing in a disturbed condition. 

We have successfully executed damage radius crankshaft repair of MAN B&W, Yanmar, Daihatsu, Wartsila, Ruston & Hornsby Engine etc. 

RA Power Solutions is a leader in repairing of compressor crankshafts onsite which can be seriously damaged due to an accident. The installation of compressor may be on a oil rig in high seas, vessels or oil and gas refineries or any industry.

With the introduction of the latest design of onsite compressor crankshaft grinding machines upto 700 mm, we are able to undertake the repair of compressor crankshaft which gets seriously damaged due to the failure of bearings, accidents or any other reasons.

REPAIR OF SERIOUSLY DAMAGED COMPRESSOR CRANKSHAFT SUCCESSFULLY BY RA POWER SOLUTIONS TECHNICIANS WHICH WAS REJECTED BY THE REPUTED CRANK SHAFT REPAIR COMPANY BASED IN EUROPE:-

We were approached by a company having various oil rigs in Saudi Arabia for repair of their compressor crankshaft of reputed make of compressor having standard crank pin diameter of 290 mm and main journal diameter of 320 mm.

Our team of senior technicians boarded the oil rig and the following action was taken for successful repair of the compressor crankshaft which was otherwise rejected by the compressor manufacturer and compressor crank shaft repair company.

• Due to breakdown of the compressor, 60% of the operation come to the stand still incurring heavy losses on per day basis.
• The crank pin of the compressor crankshaft having 290 mm diameter was badly damaged due to failure of bearing. The bearing material was badly stuck on the crank pin.
• The damaged crank pin bearing was removed from the crank pin with great difficulty and crank pin diameter was polished to undertake the inspection.
• The multiple cracks on crank pin diameter were observed, there was higher hardness than specified, taper and ovality of around 0.90 mm was also observed due to the failure of bearing.
• In fact, due to presence of multiple cracks length ranging from 12 mm to 119 mm, the reputed world renowned compressor manufacturer rejected the crankshaft and advised to replace it with a new one offering delivery of 8 months from the date of placement of order and on exorbitant price.
• After the planning of the repair strategy, the grinding of crank pin was started.
• The number and intensity of cracks started vanishing during the process of grinding. The last under size crank pin permissible by the compressor manufacturer was 4 mm but RA Power Solutions technicians based on their experience and expertise decided to reduce the diameter of the crank pin by 6 mm and it was maintained as 284 mm against the standard crank pin diameter of 290 mm to save the compressor crankshaft from rejection and to resume the production.
• In spite of under sizing the diameter by 6mm, 3 cracks measuring 10-25 mm were still present on the crank pin. The cracks on crank pin are not acceptable as per the class and international standards.
• It was decided to remove the crack by the scooping technology.

 

For inspection of compressor crankshaft and on site repair of compressor crankshaft, please feel free to write to us or contact us for repairs with guarantee.

Babbitt Bearings play a very important role in operation of heavy industrial machinery, Diesel Engine, Turbine, Alternator etc. It is important that the quality of babbitt Bearing used is proven and meets with all International standard and technical specifications. 

RA Power Solutions having 41 year of experience in undertaking onsite repair of shafts understand the importance of high quality and reliability of babbitt Bearing. 

We undertake onsite grinding, polishing and repair of shafts up to 700 mm diameter. We  manufacture new babbitt bearings or undertake rebabbitting of old bearings. The shafts on which we regularly work are as following:

i) Crankpin and main journal of crankshaft of main engine,auxilary engine, compressor etc.

ii) Electrical Motor shafts diameter ranging from 35 mm onwards. 

iii)Turbine shaft, Rotor shaft and Alternator shaft used in Power sector.

iv) Compressor, Crankpin and main journal. 

RA Power Solutions manufactures and supplies all over the world babbitt bearing of different grades of white metal.All white metal babbitt bearings supplied by us stand guarantee for satisfactory performance. 

In order to maintain the high quality and international standard of babbitt bearing we follow the lattest manufacturing process gist of which is given below:

Manufacturing steps for babbitt bearing:

i) Selection of outer casing of bearing is done keeping in view of the application of the bearing load, the characteristic of designing and various other factors.The outer bearing casing can be of forged steel,casting of MS pipe.  

ii) After machining the bearing steel shell is subject to grit blasting. 

iii) The bearing shell at this stage is subject to NDT which includes crack detection, hardness test, ultrasound.

iv) The babbitt white metal casting is done on the centrifugal machine where the babbitt white metal temperature is controlled.

This procedure of centrifugal casting of babbitt white metal ensures uniform and strong bonding with the steel shell. After final machining  all the bearings are subject to ultrasound test to check the bonding of the babbitt white metal. 

Cylinder Liner manufacturer and exporter

RA Power Solutions has emerged as a leading manufacturer and exporter of cylinder liner. The Cylinder liners are manufactured by us for all popular make & model of main engine, auxiliary engine,compressor. 

The Cylinder Liners up to 1500 mm length are manufactured by centrifugal casting process. 

The machining of the liner is undertaken in house maintaining all the dimensions strictly as per the OEM standard.

We regularly develop and manufacture cylinder liners for Diesel Engine, compressor, rotating equipment manufacturing of which is discontinued.We develop and manufacture cylinder liners as per drawing or sample provided by our client.

For development & manufacturing of heavy weight cylinder liners we have a team of engineers who visit the plant or vessel with all necessary instruments and CAD/CAM. They prepare the drawing of heavy cylinder liners on the spot and cylinder liners are manufactured according to the drawing prepared by our engineer. 

We have been regularly exporting the bearings/ cylinder liners to Bahrain, Bangladesh, Bhutan, Brunei, Burma, Cambodia, East Timor, Georgia, Hong Kong, India, Indonesia, Iran, Iraq, Israel, Japan, Jordan, Kazakhstan, Kuwait, Kyrgyzstan, Laos, Lebanon, Malaysia, Mongolia, Nepal, North Korea, Oman, Papua New Guinea, Philippines, Qatar etc.

Product Details:

Turbine shaft polishing up to diameter of 1500 mm is done. The turbine shaft polishing is undertaken onsite without removing the turbine shaft from the main equipment. Tolerances as per the manufacturer are strictly maintained.
White metal Babbitt turbine bearings are manufactured and rebabbitting of old white metal bearings is done.

Product Details:

Whenever there is an accident of engine, it is necessary to undertake crankshaft inspection. We suggest that all the crankshafts after 10 000to 15000 hours of operation should be subject to inspection. It is generally observed that crankpin and main journal diameter of the crankshaft develop taper and ovality or rough surface, bearing line marks.

 In case, the crankpin and main journal diameter are periodically inspected and polished, one can expect a long life of the crankshaft and bearings.

RA Power Solutions extends following services for insitu inspection of crankshaft:-

·  Dimensional inspection of crankshaft, main journal and crankpin.

·  MPI test for crack detection.

·  Hardness test.

·  Deflection

·  Run out

·  Visual inspection

We also undertake crankshaft inspection while sailing of the vessel. All our technicians have valid Indian CDC.

Product Details:

The quality control is an operation as much heavy as many are the Phases necessary for its execution. For this reason, carrying out all Measurements with a single tool means saving time, manpower and Improving the accuracy of control.

RA Power Solutions is pleased to announce that we have successfully undertaken repair of one number of crankpin of gas engine Deutz MWM TBG632V16 in Iran. The crank pin has been undersized 0.5 mm. 
RA Power Solutions also manufacture standard & undersize crankpin & main journal bearings. 
RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company having 41 years of experience in undertaking crankshaft repair up to 700 mm diameter.
We are considered to be the most respected and low cost company for repairs.
 

RA Power was invited by a Power house based in Iran having gas engine Deutz MWM TBG632V16. The crankpin having standard diameter of 205.00 mm and bearing width of 160 mm was damaged. RA Power Solutions deputed two technicians and has successfully undertaken crankshaft repair of Gas engine Deutz MWM TBG632V16. RA Power technicians have valid passports, Seaman books and can travel to all over the world in a short time. We extend services for onsite crankshaft grinding upto 700 mm diameter.
We have been regularly executing the on site crankshaft repairs and crankshaft grinding in Greece, Singapore, Dubai, Oman, Qatar, Malaysia, Kuwait, Hong Kong, Iran, Bangladesh, Philippines, Indonesia, Egypt, Sri Lanka etc.