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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Action Taken By RA Power Solutions For Repair of Crankshaft Yanmar 8N 330L EV

i) Since the vessel was anchored near Panama Port, RA Power Solutions deputed two technicians having a valid US VISA and Seaman book. Both technicians flew to Panama along with onsite crankshaft grinding machine and measuring instruments and boarded the vessel within 48 hours of the client’s first information of the breakdown of crankshaft of Yanmar 8N 330L EV.

The Details of Engine / Crankpin are as following:

ii) RA Power Solutions technicians inspected all the crankpins (8 Nos) to check the taper & ovality, the dimensions of observed are pasted below.

iii) On going through the readings, it was observed that the crankpin number #02 has developed excessive ovality of 0.43 MM, against the tolerance of 260.00 MM + 0.03 MM. This is considered very much on the higher side. All other crankpins also have ovality ranging from 0.09 MM to 0.10 MM, The bearing line marks and rough surface on the crankpin were observed.

iv) As a Protocol, hardness was checked of eight (8 Nos) Crankpins and was observed within limits.

v) Crack detection was also conducted, and no crack was observed on damaged crankpin number #02 and other crankpins.

vi) It was jointly decided to undertake the grinding of crankpin number #02 and polishing the remaining crankpins to remove the bearing line marks and to improve the surface finish.

vii) Although in the crankpin numbers #01,#03,#04,#05,#06,#07, and #08 the ovality was observed on the higher side as 0.10 MM, however, this was accepted under divation.

viii) The Crankpin number #02 was undersized by 1.5 MM, A Final Dimensional Report after grinding and polishing of crankpins of Yanmar 8N 330L EV is pasted below.

ix) In order to assist ship staff, our technicians undertook the dimensional and MPI Inspection of connecting rods available on the vessel, they were observed within limits.

The engine was commissioned during the presence of our technicians on the vessel.

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 hrs and can be deputed on 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, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

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Insitu Crankshaft Grinding Machine	Onsite Crankshaft Grinder

In Olden times, the crankshaft repair was undertaken in a workshop and on a bench-type crankshaft grinding machine. The customer had no option, but to remove the crankshaft from the engine block and send it to the designated workshop for crankshaft repair purposes. The introduction of an onsite crankshaft grinding machine has made the crankshaft repairs. Simple and less time-consuming. The grinding and polishing of crankshaft is executed onsite and in assembled condition.

RA Power Solutions manufactures the latest design of crankshaft grinding machines, which are capable of undertaking the grinding of crankpin and main journal diameters up to 700 mm. This range of machine covers most of the popular make of engines and their models installed on a vessel or in industries. The onsite crankshaft grinding machine manufactured by RA Power Solutions is designed to maintain all the parameters of the crankshaft strictly, as stipulated in the Engine manufacturer manual. The ovality, Taper, surface finish, and all the major parameters are controlled during the process of repairs.

Onsite Crankshaft Grinding & Polishing Machine	onsite crankshaft grinding machine

The onsite crankshaft grinding machine is designed in such a way that it can be operated even while sailing the vessel. This saves considerable time, as there is no requirement of holding the vessel for repairs. This is of great advantage, especially, In the case of repair of the auxiliary engine crankshaft.

The cost of the machine is very low. It is highly recommended for shipping companies, and heavy industries, having multiple numbers of power generation equipment and engine repair workshops. It is estimated that the investment of an on site crankshaft grinding machine is recovered in the execution of 2-3 jobs.

We extend training to our customers on the operation and maintenance of an onsite crankshaft grinding machine. During the training, the technicians are trained on the job of grinding and polishing of crankshaft.

On-shore and Off-Shore Crankshaft Grinding Machine

For more information regarding onsite crankshaft grinding machine, grinding of crankshaft main journal, main journal crankshaft grinding service, crankshaft journal polishing and grinding, grinding of crankshaft onsite please contact us at rajshahani@rapowersolutions.com, info@rapowersolutions.com or call us at +91 9582647131, +91 9810012383.

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With the introduction of the latest design of onsite compressor crankshaft grinding machines up to 700 mm, we can undertake the repair of compressor crankshafts that get seriously damaged due to the failure of bearings, accidents, or any other reasons. The job of compressor crankshaft repair which other companies from Europe cannot undertake, we execute it successfully only because of our experience of over four decades in this field. This makes us leaders in this field.

Repair of seriously damaged compressor crankshaft was successfully repaired by RA Power Solutions technicians

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 a 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 crankshaft repair company.

• Due to the breakdown of the compressor, 60% of the operation comes to a standstill incurring heavy losses on per per-day basis.
• The crank pin of the compressor crankshaft having a 290 mm diameter was badly damaged due to the failure of the 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 the crank pin diameter was polished to undertake the inspection.
• The multiple cracks on the crank pin diameter were observed, there was higher hardness than specified, and taper and ovality of around 0.90 mm were also observed due to the failure of the bearing.
• In fact, due to the presence of multiple cracks lengths 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 the order and on exorbitant price.
• After the planning of the repair strategy, the grinding of the 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.
• Despite undersizing the diameter by 6mm, 3 cracks measuring 10-25 mm were still present on the crank pin. The cracks on the crank pin are not acceptable as per the class and international standards.
• It was decided to remove the crack in the scooping technology.
• The cracks were fully removed by the Scooping Process and sharp edges were polished.
• The white metal Babbitt bearing was sent to our works for Rebabbitting and was sent back to the site after repairs.
• The compressor was assembled and for the last 18 months, it has been running continuously and giving satisfactory performance.

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

Save your Compressor Crankshaft Repair from rejection, and contact RA Power Solutions.

About the author of Compressor Crankshaft Repair

This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.).

Mr. Shahani is a highly experienced business leader with rich experience of more than 40 years in the field of Power, Heavy and Shipping industry. He is a Technical Adviser to many shipping and heavy industries across the globe.

Mr. Shahani is one of the most enthusiastic professionals and he has all the brilliance of an exemplary leader. Mr. Shahani is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.

For more information, Compressor Crankshaft Repair, in situ crankshaft grinding, and crankpin repair services please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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On crankshaft inspection after the accident, we have observed following

Observation of crankpin and main journal of crankshaft after bearing failure

• Due to failure of crank pin or main journal bearings, on visual inspection the crankpin and main journal diameter develops line marks, pitting, and rough surface.
• In case after failure of crank pin, the main journal bearing, the engine is not stopped on time, and the radius fillet of both sides gets damaged. In some cases, we have noticed that the lubricating oil hole profile also gets lost.
• In most of cases, bearing failure results in the sticking of bearing material on the crankshaft surface. The main reason is that the bearing steel shell rubs with the crankpin and main journal diameter, temperature abnormally increases due to friction, and bearing material melts.
• Overheating due to failure of bearing shell on the crankshaft also results in black/ blue discoloration.
• The hardness increases due to abnormal heating.
• Cracks on crank pin and main journal in some of the cases are also observed.
• In case the accident is serious, it can also cause the loss of alignment of the crankshaft which becomes a serious issue for onsite repair.
• In case of above observation, certainly it is not possible to assemble the new bearings and operate the engine.
• The crankpin and main journal of the crankshaft after thorough examination requires grinding.
• We have observed that in some cases ship owners and maintenance engineers try to do the polishing of crankpin and main journal by hand which results in the repetitive failure of bearing and crankshaft.
• As a repair company with forty years of experience, we have observed that generally the crank pin and main journal diameter has to be maintained between 0.03 and 0.05 mm which is impossible to maintain by hand.
• Hence, RA Power Solutions does not recommend polishing the crankshaft by hand.

Specialization of RA Power Solutions in Crankshaft Machining and Polishing on Site

RA Power Solutions specializes in repair of crankshaft onsite without removing it from the engine block. Our technicians with onsite portable crankshaft machining equipment visit your plant or board the vessel all over the world to undertake the repairs.

With more than 10, 000 crankshaft repair jobs undertaken by us, our success rate of repair of seriously damaged crankshaft is almost 100%. We agree that there are cases where due to failure of bearing, generation of abnormal heat, multiple cracks are developed or the taper and ovality developed after the accident are higher than the last limits specified by the manufacturer. In that case there is no point in attending to the repairs.

Following steps are taken for successful repair of crankshafts of main and auxiliary engines

We give great importance to the pre-inspection of the damaged crankshaft. This is done by our experienced technicians using the state of art measuring instruments which are calibrated and certified by the agency of repute.

Pre-inspection includes the following

• Dimensional inspection of crankpin and main journal.
• Checking deflection/run-out to know the loss of alignment of crankshaft if any.
• Checking of hardness.
• Crack detection by MPI, Dye–penetrant test.
• Visual inspection
• The pre-inspection report of crankshaft is thoroughly studied by our technicians on site and strategy and successful repair is planned.
• The grinding of crankpin and main journal is undertaken removing the minimum stock possible. This helps in enhancing the life of the crankshaft.
• The removal of minimum stock from crank pin and main journal is possible only because of the use of the latest generation of onsite crankshaft grinding machine by us.
• The final inspection is undertaken and reports are prepared.

RA Power Solutions regularly undertake on site grinding of crankshaft, rotating shafts, alternator shafts, rotor shafts, turbine shafts, electric motor shafts, crankshaft machining and polishing.

We provide crankshaft grinding services in countries like Australia, Bangladesh, Cambodia, Chinese Mainland, Hong Kong, Indonesia, Japan, Malaysia, Maldives, Myanmar, New Caledonia, New Zealand, Philippines, Singapore, South Korea, Sri Lanka, Thailand, Vietnam, Afghanistan, Bahrain, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman, Qatar, Saudi Arabia, Syria, United Arab Emirates, Yemen, etc.

For more information, in place crankshaft machining and polishing, polishing crankshaft please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

The post Crankshaft Machining and Polishing | Insitu Cutting of Crankpin | RA Power Solutions appeared first on Crankshaft Grinding Repair.

We work on all types of Compressor Crankshafts including the following

• Axial Compressor
• Screw Compressor
• Centrifugal Compressor
• Turbo Compressor
• Reciprocating Compressor

The above compressors are in operation all over the world for a wide range of applications in industries, oil and gas sector, textiles, chemical companies, etc.

We extend services related to the Polishing and Grinding of Compressor Crankshaft maintaining the following major parameters and tolerances.

• On site compressor crankshafts are repaired by RA Power Solutions of diameter ranging from 30 mm to 700 mm.
• No requirement of removing the crankshaft from the compressor casing or body.
• The grinding of the compressor crankshaft and repair are undertaken without the disassembly of the main equipment.
• The use of modern, state of art compressor crankshaft grinding machines can deliver tolerances in terms of taper and ovality within 0.02 mm with a surface finish of 0.20 Ra value or even less depending on the compressor manufacturer’s requirement.
• Any length of compressor crankshafts can be repaired on-site.
• Stop sending the crankshaft of the compressor to the workshop for repairs which requires tremendous efforts to remove of compressor shaft from the main body, pack it, and send it to the workshop.
• Accidental repairs are undertaken on priority by senior engineers and technicians employed by us on a 24/7 basis.

Compressor shaft requires service with passion

• Our team of technicians is dedicated and works with all sincerity only with one motto of putting the compressors and main equipment in operation in the minimum possible time.
• The team is geared up to work non-stop, 24 x 7 hours to deliver the desired quality and results.

Specialized Compressor Crankshaft Repair equipment Used by RA Power Solutions

• We design and manufacture the on site compressor crankshaft grinding and repair equipment in technical collaboration with the world’s leading crankshaft grinding machine manufacturer based in Italy and undertake modifications in our compressor crankshaft grinding equipment in case of availability of limited space or any other restriction.
• Our technicians are trained in our in-house training school where we undertake serious damage jobs and extend the job training to our technicians.

Availability of Compressor White Metal Babbitt Bearing and Tri Metal Bearing

Knowing the difficulty faced by our clients, we undertake regularly the Rebabbitting of metal bearings used in high-capacity compressors. We also manufacture new white metal Babbitt bearings for compressors as per the drawing or sample.

The Rebabbitting of old damaged bearings and manufacturing of new bearings is done with a great speed to reduce downtime. We also supply tri metal bearings used these days on compressor crankshafts with high RPM.

The undersize, special size, crank pin, and main journal bearings for most of the popular compressor models are available in stock or they are sourced through our principles based in Japan, Korea, and Europe.

We have been working on all models of compressors including Ariel, Cummins, Kirloskar, Samson, Porter-Cable, Stanley Bostitch, Campbell Hausfeld, DeWalt, Makita, Senco, ANEST IWATA, Gardner Denver, Graham Sulzer, Hitachi, Rolair Systems, Brehob, Lufkin, Zebra, Ingersoll Rand, etc

For more information on compressor shafts, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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