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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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.

The post ON-SITE CRANKSHAFT GRINDING MACHINE | PORTABLE | EASY TO OPERATE appeared first on Crankshaft Grinding Repair.

We also design, manufacture and supply In-Situ Crankshaft and cylindrical shaft repair machines up to 700 MM diameter.

Accessories used in Crankshaft grinding machine	Onsite Crankshaft Grinding and Polishing Machine

The main advantage of In-Situ Crankshaft/Cylindrical Shaft repair machine is that there is no requirement for removal of Crankshaft, Intermediate shaft, Pump Shaft, or any type of Cylindrical Shaft from the casing. The grinding and repairs of damage shaft is possible On-Site.

Major Highlights In-Situ Crankshaft Grinding Machine

1. The In-Situ Crankshaft grinding machine is portable and light in weight can be easily carried by technicians to the site to undertake the Crankshaft Repair.
2. Onsite Grinding and Polishing of Crankshaft is done by a single Crankshaft Grinding Machine, which is easy to operate.
3. The In situ Crankshaft Grinding Machine is capable of grinding the Crankshaft on site within close dimensional tolerance.
4. The In-Situ Crankshaft grinding Machine is of latest technology and is user-friendly.
5. We can supply the Insitu Crankshaft Grinding Machine range starting from 60 mm to 700 mm in terms of diameter

Portable Crankshaft Grinding Machine

Save Cost Of Repair By Small Investment On In-Situ Crankshaft Grinding Machine

1. Portable, lightweight crankshaft grinding machine can be taken to the site.
2. Save cost and downtime, as dismantling of crankshaft is not required.
3. Machine easy to operate, onsite training is provided.
4. Latest technology, new invention, low cost. Reduce cost of maintenance.
5. More than 77 equipment supplied worldwide.

Crankshaft Repair & Crankshaft Grinding by In-Situ Crankshaft Grinding Machine

Crankshaft Repair does not require the crankshaft to be removed from entablature. In the recent past due to seizure of bearing or development of taper, ovality, or loss of alignment of crankshaft, it was necessary to remove the crankshaft from the engine block and send it to the designated workshop for crankshaft grinding and crankshaft repair.

Manufacturer of Crankshaft Grinding Machine	Crankshaft Grinding Equipment

The introduction of a lightweight, vibration-free crankshaft grinding equipment facilitates grinding of crankshaft, crank pin, and crank main journal on the spot while the crankshaft is assembled in the engine block. There is no necessity of even decoupling the alternator and other accessories from the diesel engine.

Training In Situ Crankshaft Grinding Machine

We offer training to customer technicians in their workshop. The technicians should have basic knowledge and experience of handling common instruments like micrometer, bore gauge, and vernier caliper. The following areas are covered during the training of working on crankshaft grinding machine.

Crankshaft Grinding Machine Ready for Dispatch	Crankshaft Grinding and Polishing Machine

1. Opening, and assembly of the machine on the crankpin is shown on a dummy or actual crankshaft.
2. Operations like grinding, polishing, and giving the feed are taught.
3. Inspection of crankshaft in different stages of repair of polishing and grinding is shown to the technician.
4. Upkeep, cleaning, and maintenance of the crankshaft grinding machine is explained.

The suggested duration of training is 1 week.

Portable Crankshaft Grinding and Polishing Machine

For more information regarding Onsite Crankshaft and Cylindrical Shaft Repair Machine, in situ crankshaft grinding and repair, insitu crankshaft grinding machine, portable onsite crankshaft grinding equipment, Onsite Crankshaft Grinding and Polishing Machine, onsite crankshaft polishing machine, grinding and repair of onsite crankshaft, Cylindrical Shaft Repair 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 major technical details of the Intermediate shaft are as follows:

Inspection of Intermediate shaft and repair planning:

• The intermediate shaft having a standard diameter of 280 mm and bearing width of 275 mm was inspected for dimensions, taper & ovality. Excessive ovality ranging from 0.36 mm to 0.72 mm was observed.
• Due to the failure of Babbitt’s white metal bearing the white metal was badly stuck on the diameter. It was removed by our technicians.
• As a routine inspection, the crack detection test by the MPI method was undertaken. Surface cracks on an entire diameter and bearing width were observed. The cracks were minor.
• The hardness was in general observed within limits and in the range of 182 HB scale (minimum) to 343 HB scale (maximum). Few hardened spots were observed.
• Due to the failure of Babbitt white metal bearing, deep scoring marks were observed on the intermediate shaft diameter.
• The intermediate shaft bearing area was observed to be rough with a surface finish of 0.90 RA value which is observed to be poor.

Action taken by RA Power Solutions for successful repair of the Intermediate Shaft

• The grinding of the intermediate shaft bearing sitting area was undertaken in different steps, as the objective was to remove the ovality and bearing line marks by reducing the intermediate shaft diameter to the minimum.
• After undersizing the diameter by 1.0 mm i.e. 279.00 mm the ovality and damage were still observed. It was decided to undertake further grinding.
• Finally, the diameter was reduced by 1.40 mm, maintaining a final diameter of 278.60 mm.
• The intermediate shaft bearing sitting diameter was polished after grinding.
• The following tolerance was maintained:
  • Taper & ovality was maintained within 0.02 mm.
  • The surface finish was improved & maintained less than the 0.15 mm RA value.

Grinding of Intermediate Shaft Bearing sitting diameter having no radius:

The onsite repair of the damaged intermediate shaft diameter was a challenge as it didn’t have any radius fillet. The companies based in Europe have an old design and outdated equipment as they take reference of radius fillet to undertake grinding. In this case, RA Power Solutions used equipment that doesn’t take any reference of radius fillet as the machine designed and owned by RA Power Solutions is a replica of a bench-type crankshaft grinding machine. By using this special-purpose machine, the repairs were executed successfully.

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 crankshaft polishing machine, and main journal polishing please email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131, +91 9810012383.

The post Intermediate Shaft Onsite Grinding and Polishing appeared first on Crankshaft Grinding Repair.

On site crankshaft polishing and crankshaft grinding machines have the following advantages:

• In case of the development of line marks, pitting, watermarks, etc. it is advisable to undertake the polishing.
• The introduction of the crankshaft polishing machine by RA Power Solutions has made it very easy and simple to polish the crankpin and main journal.
• The polishing enhances the surface finish, removes line marks, and pitting marks, and makes the crankpin and main journal diameter as smooth as the original.
• It is a known fact that in case the crank pin and main journal diameter have line marks and poor surface finish the bearing life is reduced. There is also a chance of serious damage to the crankpin and main journal of the crankshaft and corresponding bearings. To increase the life of the crankshaft of a diesel engine, compressor, rotor, or alternator it is advisable to undertake the polishing periodically.
• The cost of a machine manufactured by RA Power Solutions is very low and can be owned by shipping companies, heavy engineering plants, repair workshops, etc.
• The machine is lightweight, portable, and can be taken to the site all over the world.
• With the polishing machine, you can also undertake the grinding of crankpins and main journals.

RA Power Solutions manufactures crankshaft polishing machines and onsite crankshaft grinding machines up to 700 mm in diameter and has sold more than 70 machines all over the world for the last 43 years. For more details, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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