The major crankshaft details of the MAN B&W 5L 16/24 are as follows:

In the case of the MAN B&W 5L 16/24 crankshaft, the crankpin diameter is relatively small at 130.00 mm, with a bearing width of only 56.00 mm. To facilitate onsite crankshaft grinding of the crankpin, RA Power Solutions has designed and developed a dedicated onsite crankshaft grinding machine. This machine can be inserted through the inspection window, allowing grinding to be carried out efficiently.

RA Power Solutions deputed technicians, along with equipment, and the following actions were taken:

i) Excessive ovality of 0.97 mm was observed on crankpin No. 03 of the auxiliary engine. Line marks were also noted.
ii) All other parameters, such as hardness, MPI (for crack detection), and visual inspection, were checked and found to be within limits.

iii) Grinding of crankpin No. 03 was carried out, and the diameter was maintained at 128.50 mm (undersized by 1.50 mm).

Advantages of Engaging RA Power Solutions for Repair of Crankshaft – MAN B&W 5L 16/24

i) As a designer and manufacturer of onsite crankshaft grinding machines, we undertake modifications to the equipment, if required, to ensure the successful repair of the crankshaft.

ii) In this case, since the crankpin diameter is only 130.00 mm and the bearing width is 56.00 mm, we developed equipment capable of both grinding and polishing.

iii) We maintain a stock of bearings for popular engine makes and models, including undersized and special sizes. In this case, the required bearings were carried by our technicians, and the engine was commissioned immediately after the crankshaft repair.

Availability of Undersized Crankpin Bearings in Stock of MAN B&W Engine Model No. 5L 16/24

RA Power Solutions has consistently dedicated itself to delivering exceptional and prompt service. With over 46 years of experience, we have successfully repaired more than 10,000 crankshafts worldwide.

We have been regularly providing our services in South Africa, Nigeria, Cambodia, Tanzania, Brazil, Canada, Australia, Bangladesh, Greece, Haiti, Hong Kong, Indonesia, Kenya, Malaysia, Maldives, Kenya, Kuwait, Madagascar, Mexico, Nigeria, Oman, Philippines, Saint Lucia, Saudi Arabia, Singapore, Spain, Sint Maarten, Sri Lanka, Suriname, Thailand, Togo, United Kingdom, United States, Yemen, Zambia, etc.

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

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The non-operation of two auxiliary engines stranded the vessel. Considering the urgency of the situation, RA Power Solutions deputed two technicians along with a specially designed onsite crankshaft grinding machine capable of grinding crankpins with small diameters and narrow widths.

In the case of the MAK 6M20 auxiliary engine, the standard diameter of the crankpin is only 152.00 mm, with a bearing width of 71 mm. The design of our onsite crankshaft grinding machine is such that it can be mounted on the crankpin diameter through the inspection window, and grinding is executed in situ.

The details of the engine are as follows:

Upon arrival on board the vessel, our technicians conducted an initial inspection of all crankpins. They found excessive ovality in all six crankpins of the MAK 6M20 engine.

We have provided a copy of the preliminary dimensional inspection report below.

All other parameters, including hardness, MPI, and deflection, were within acceptable limits. We jointly decided to grind all the crankpins, and RA Power Solutions machined them to a final size of 151.00 mm (1.00 mm undersize) as per the above dimensions.

During the stay of our technicians on board the vessel, the crankshaft of Auxiliary Engine #02 was also inspected. We detected excessive ovality showing the same pattern observed in the crankshaft of Auxiliary Engine 01.

The preliminary dimensional inspection report is provided below:

SIZE OF CR Pins Before Grinding of A/E 02
	A	Aa	C	Cc	B	Bb	Min	STD	Ovality
CR-1	151.73	151.85	151.74	151.84	151.75	151.82	151.73	152.00	0.27 MM
CR-2	151.73	151.85	151.72	151.83	151.70	151.81	151.7	152.00	0.30 MM
CR-3	151.72	151.85	151.71	151.84	151.69	151.83	151.69	152.00	0.31 MM
CR-4	151.75	151.85	151.72	151.84	151.73	151.86	151.72	152.00	0.28 MM
CR-5	151.73	151.84	151.69	151.82	151.70	151.84	151.69	152.00	0.31 MM
CR-6	151.73	151.92	151.72	151.89	151.75	151.84	151.72	152.00	0.28 MM

Our technicians ground this crankshaft and maintained the following dimensions. They successfully commissioned both engines in their presence.

SIZE OF CR Pins After Grinding A/E 02
	A	Aa	C	Cc	B	Bb	Min	Max	Ovality
CR-1	151.00	150.99	150.99	150.98	150.99	151	150.98	151.00	0.02 MM
CR-2	151.00	150.99	150.99	150.98	151.00	150.98	150.98	151.00 0.02 MM	0.02 MM
CR-3	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM
CR-4	151.00	150.99	150.98	150.99	150.99	151.00	150.98	151.00	0.02 MM
CR-5	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM
CR-6	151.00	150.99	150.98	150.98	150.99	151.00	150.98	151.00	0.02 MM

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We have developed a revolutionized tooling which has the capabilities to execute the repairs to close tolerances as stipulated in the engine manufacturer’s manual.

Case Study of Repair of MAK-1 8CM32C Engine Crankshaft In Burkina Faso, West Africa

The major details of the crankshaft of the MAK-1 8CM32C Engine are as follows:

i) Due to the repeated failure of bearings, it was decided by the client to get an audit of the crankshaft for all the major parameters. RA Power Solutions deputed two (2) technicians along with the onsite crankshaft grinding machine from New Delhi to Burkina Faso. During the initial inspection, the following was checked and observed.

a) The dimensional inspection of the crankpins was conducted, and excessive ovality was observed in all the crankpins. The readings for all the crankpins are pasted below:

b) As protocol, all the crankpins were checked for hardness by a portable hardness tester and were found within limits.

c) MPI was also undertaken to check the cracks, and no abnormality was observed.

ii) The grinding of all the eight (8) crankpins was executed onsite by our technicians. The first step size and tolerance of 0.02/0.03 MM were maintained.

In Place Machining of Crankshaft of MAK-1 8CM32C Engine

RA Power Solutions has been successfully executing the repair of high-diameter crankshafts up to 700 mm. We also specialize in onsite grinding of small-diameter crankpins with a bearing width of the crankpin as low as 50 mm to execute onsite such types of complex crankshaft repairs onsite. We have developed special-purpose onsite crankshaft machining equipment by which the repairs can be executed. We execute repairs for Marine, industrial, stationary power, and offshore sectors all over the world.

Our technicians are available to travel worldwide on short notice. Additionally, several of our technicians hold valid US visas, enabling them to travel to South America, the Caribbean, and other destinations as needed.

At RA Power Solutions, we provide specialized crankshaft grinding machines, onsite crankshaft grinding repair, insitu crankshaft grinding, Onsite crankshaft grinding machines,  insitu crankshaft grinding machines, crankpin bearings, metal stitching, metal locking, engine block repair, crack repair by metal stitching, cast iron crack repair, crankpin polishing, inspection of crankshaft, crankshaft inspection, rebabbitting bearing, babbitt white metal, engine overhauling, grinding of crankpin, connecting rod, and turbine shaft bearing services worldwide, including South Africa, Singapore, Greece, Dubai, Iraq, Iran, Malaysia, Colombia, and Brazil.

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

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The Auxiliary engine number #02 of MAN B&W 5L 16/24 was stopped due to low air pressure, two of our technicians boarded the vessel and inspected the crankshaft. All Five (5) crankpins having a standard diameter of 130.00 MM had ovality ranging from 0.10 MM to 0.40 MM, which is considered to be on the higher side. The crankpins also had bearing line marks, rough surfaces, and localized damage, as the engine was operated in spite of the problem in the crankshaft.

The dimensional Report of crankpins is pasted below:

The hardness and MPI for crack detection was conducted and no abnormality was observed. Technicians started onsite grinding of crankpins were ground ranging from 1.0 MM undersize to 1.50 MM.

The main advantage of onsite crankshaft grinding jobs executed by RA Power Solutions is that the technicians and equipment are trained and designed to execute the job even while sailing of the vessel. There was absolutely no requirement of holding of the vessel. RA Power Solutions also supplied the undersized crankpin bearings for this engine and it was commissioned in a short notice.

RA Power Solutions with experience of more than 44 years extends onsite crankshaft grinding services to leading shipping companies, power plants and heavy industries all over the world.

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

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RA Power Solutions was approached and deputed our two technicians along with onsite crankshaft grinding equipment. The vessel was anchored at MIP Mersin, Turkey.

Following are the major Engine and Crankpin details:

HIMSEN HYUNDAI 6H 17/28 CR Pin Having Hairline Crack

Main Observations of Crankshaft of HIMSEN HYUNDAI 6H 17/28

i) On visual inspection, it was found that it was a case of lubricating oil pump failure, damaging the bearings of all connecting rods.

ii) The bearing material was found embedded on all six (6) crankpins and was carefully removed. After polishing the crankpins, the dimensional inspection was conducted. The taper, ovality ranging from 0.22 MM to 0.86 was observed.

CR Pin Hardness Inspection	CR Pin of HIMSEN HYUNDAI 6H 17/28 Before Repair

The Dimensional Inspection Report of Six (6) Number Crankpins of HIMSEN HYUNDAI 6H 17/28:

iii) The hardness was checked and was found within limits, except for a few spots, which were found not harmful to the crankshaft.

iv) The crankpins were subject to a MPI test for crack detection and minor hairline cracks were observed, All other parameters were found within the limit.

Crank Pin Before Repair	HIMSEN HYUNDAI 6H 17/28 After Grinding And Polishing

Action Taken By RA Power Solutions Technicians For Damaged Crankpins:

i) The grinding of all six (6) crankpins was undertaken by our insitu crankshaft grinding machine.

ii) Three (3) number of crankpins diameter was reduced by 1.00 MM and the final size was maintained as 174.00 MM.

iii) Three (3) number of crankpins diameter was reduced by 1.50 MM and the final size was maintained at 173.50 MM.

Final Report After Grinding is Pasted Below:

The tolerance of all six (6) number crankpins was maintained with 0.02 MM.

We have been regularly executing on site crankshaft repairs and In Situ crankshaft grinding in Dubai, Fujairah, Qatar, Saudi Arabia, Oman, Iraq, Togo, Malta, Freetown, Egypt, Malaysia, Iran, Indonesia, Vietnam, Jordan, etc.

We have a team of trained technicians available 24/7 and can be deputed at short notice. Some of our technicians also have valid US VISA and can fly to South America, Caribbean countries, etc.

For more information regarding crankshaft grinding services, onsite insitu crankshaft repair, crankshaft grinding and repair, grinding of onsite crankshaft repair, insitu crankshaft grinding repair, grinding of crankshaft onsite please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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Crankshaft Failure

• Use of nonstandard lubricating oil or using it for an extended time without changing it.
• Use of bearings beyond the operating hours specified in the maintenance manual of the engine manufacturer.
• Use of substandard lubricating oil filters and using them beyond the specified hours.
• Not maintaining the lubricating oil temperature and oil gap as per the maintenance manual.
• Use of substandard quality bearings.
• Not carrying out the periodical inspection of the crankshaft at the time of undertaking maintenance.
• Non-calibration of crankpin and main journal diameter for taper and ovality.
• Ignoring of crankpin and main journal line marks, pitting, rough surface.
• Increase in deflection readings.
• Non-replacement of connecting rods in case of abnormalities observed.
• Non-calibration of connecting rods big end bore and small end bore.
• Non-inspection of connecting rods, bolts for cracks or distortion, and tightening torque.

As mentioned the crankshaft failure can be caused due to not paying attention to the above.

RA Power Solutions Pvt. Ltd. has been working on the crankshaft of medium and high-capacity engines, 2-stroke and 4-stroke engines for four decades and strongly suggests that all the parameters mentioned in the maintenance manual of the engine manufacturer should be checked. The checks mentioned above are of great importance and we have experienced that most of the crankshaft and engine Get damaged due to ignoring the above points, the user can extend the life of the engine considerably by following the above checks. RA Power Solutions undertakes onsite repair of the crankpin journal and main journal Grinding of the crankshaft.

The following are the main features of crankshaft journal repair

• We undertake crankshaft grinding, and repair of crankshafts having diameters from 35 mm to 700 mm irrespective of the length of the crankshaft.
• The crankshaft repair is undertaken onsite, there is no requirement for the removal of the crankshaft from the engine block.
• All the parameters like taper ovality, and surface finish as mentioned in the maintenance manual are strictly maintained.
• Crankshaft journal repair & Crankshaft journal Grinding are done onsite and by use of the latest crankshaft grinding machine, the repairs are done in minimum time reducing the downtime considerably.
• We can depute technicians on short notice all over the world and our technicians have valid Indian CDC. We also depute our engineers to undertake reinspection of the crankshaft with the calibrated instrument and regrinding of the crank journal if required can be done on the spot.

For more information on crankpin journal repair, grinding of crankshaft main journal, and repair of crankshaft main journal, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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