We recently completed a successful onsite repair of a BERGEN B32:40L8P engine crankshaft onboard a vessel in Jamaica.

The details of the job are as follows:

Onsite Inspection of Crankshaft – BERGEN B32:40L8P

• Two of our experienced technicians, along with our portable onsite crankshaft grinding equipment, traveled from New Delhi, India, to Jamaica.
• Our equipment is lightweight, compact, and portable, allowing it to be transported as accompanied baggage, which eliminates delays associated with cargo shipment and customs clearance.
• Upon boarding, the vessel was found fully loaded with containers, yet our team immediately initiated the crankshaft inspection.
• It was observed that Crankpin No. 5 had suffered severe damage due to a bearing failure.
• The crankpin was thoroughly cleaned, and embedded bearing material was carefully removed.
• Dimensional checks revealed:
  • Minimum Diameter: 269.75 mm
  • Maximum Diameter: 270.00 mm
  • Ovality: 0.25 mm
  • Deep scoring marks were also noted due to the bearing failure.
• A Magnetic Particle Inspection (MPI) using a high-intensity Magnaflux torch was conducted to check for cracks. No cracks or abnormalities were detected.
• Hardness testing was performed, and confirmed that values remained within permissible limits.

Onsite Grinding of BERGEN Crankpin

• The crankpin was calibrated and ground in multiple stages, with ovality strictly controlled during the process.
• Due to deep scoring, the crankpin had to be ground to an undersize of 2 mm.
• The final dimension achieved was 268.00 mm – 0.02 mm, ensuring precision and compliance with engine requirements.

Engine Commissioning

• The vessel had a 2 mm undersize bearing in stock, which was installed immediately after grinding.
• A trial run of the engine was conducted in the presence of our technicians, and performance was found to be fully satisfactory.

About RA Power Solutions

We are a global leader in onsite crankshaft grinding and repair services for crankpins and main journals up to 700 mm. With over four decades of hands-on experience, we are Asia’s most established and trusted company in this field.

We are the original developers and manufacturers of portable onsite crankshaft grinding machines. Our machine design originates from a reputed Italian engineering firm. To date, we have supplied over 80 onsite crankshaft grinding machines across the globe.

In addition to repair services, we also supply the complete range of tools and measuring instruments necessary for crankshaft repairs.

We offer hands-on training programs for client technicians at our in-house training center in New Delhi, India, conducted by our expert engineers. Our training sessions have been successfully delivered to clients from Colombia, Panama, Ecuador, Dubai, Singapore, Bangladesh, Tanzania, and many other countries.

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

The post Crankshaft Repair | Onsite Crankshaft Grinding | BERGEN Engine | 45 Years Experience appeared first on Crankshaft Grinding Repair.

Considering the serious damage to the Auxiliary Engine MAN B&W 6L 16/24, a team of three (3) technicians was deputed, which consisted of a Senior Metal Stitching Engineer and Two (2) technicians to repair the crankshaft.

The vessel was boarded by our technicians in Pasir Gudang. Following are the main details of the engine:

Inspection of Crankshaft:

1. All the crankpins were inspected dimensionally, and line marks and ovality were observed on all the crankpins. The standard diameter of crankpin was 130.00 MM.
2. All other parameters, like hardness, and crack detection by MPI, were found within limits.
3. On visual inspection of the radius fillet of two (2) crankpins was found damaged.

Inspection of Engine Block

1. The Engine Block window seating area of Unit number #04 (Port Side) was found badly damaged.
2. The Cam Case was also found broken.

Few Photographs of the damaged Cam Case are given below:

Broken Camshaft Area of the Window	Damaged Window cover Sittting Area

Action Taken by RA Power Solutions to Repair of Crankshaft and Engine Block of MAN B&W 6L 16/24

i. Considering the damage, all six (6) crankpins diameter was reduced from 130.00 Mm to 129.50 MM, maintaining the tolerance of 0.02 MM.

A copy of the report indicating the final dimensions is pasted below:

ii. The broken engine block was repaired by Metal Stitching Process. The new pieces of casting were metal stitched as shown in the photographs.

Initial Cut Given in Engine Block Window Area	Fitment of New Casting in Damaged Area
MAN B&W Model No.6L 16/24 during metal lock	Metal locking of broken area of MAN B&W Model No.6L 16/24

iii) The Undersize bearings were also supplied by RA Power Solutions.

iv) The Engine was commissioned in the presence of our technicians and performance was found satisfactory.

Pasting of Casting by Metal Lock Process	Perfect Matching of Casting After Metal Locking

Cam Cover Area Metal Stitched

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.

For more details of the Damaged Engine Block by Metal Stitching Process, Onboard Crankshaft Repair Services, repair of crankshaft onsite, in situ crankshaft grinding and repair of MAN engine, onsite crankshaft grinding repair services, onsite crankshaft grinding and repair please email us at info@rapowersolutions.com or call +91 9582647131, or +91 9810012383.

The post Crankshaft Repair of MAN B&W 6L 16/24 In Malaysia appeared first on Crankshaft Grinding Repair.

Wartsila 8L20 having Damage Crankshaft	Damage CR Pin of Wartsila 8L20 Engine

We have a team of trained technicians available 24/7 hrs.

Inspection of the crankshaft of Wartsila 8L20 and Observation

1. On Initial inspection of the crankshaft it was found that the crankpin number #05 was damaged.
2. On further investigation our technicians were surprised to note that the crankpin having standard diameter of 180 MM was already undersized by 2.00 MM and this job was done by a company based in Greece.
3. The excessive taper was observed on the crankpin and no radius fillet profile was made by the crankshaft repair company.
4. Due to the taper in the crankpin number #05 of the wartsila 8L20 crankshaft, the connecting rod was not moving freely and the bearing was developing line marks.
5. It was a challenging job for RA Power Solutions technicians to rectify the taper, which was developed due to application of wrong equipment and process by a company based in Greece.

Crack Detection of CR Pin with MPI	Deep Scoring Marks on CR Pin

Action Taken By RA Power Solutions to Successfully Repair Wartsila 8L20 Crankshaft and To Save it from Rejection

With our experience of more than 44 Years in repair of the crankshaft, latest design of equipment, and experienced technicians, we were able to successfully repair the crankshaft by under-sizing the crank pin and maintaining the final size of 177.00 MM. The crank pin was undersized by 3.0 mm.

CR Pin Grinding Under Process	Polishing of CR Pin after Onsite Grinding

The radius fillet profile of both the sides was prepared and maintained, as per the Wartsila 8L20 specifications stipulated in the maintenance manual.

The engine was commissioned in presence of our technicians and performance was found satisfactory.

For more information regarding crankshaft grinding services, Wartsila 8L20 crankshaft repair, in situ grinding of crankpin, onsite crankshaft grinding repair, insitu crankshaft inspection, crankpin repair, on site crankshaft repair and onsite crankshaft repair services, please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

Final Polishing of CR Pin	CR Pin after grinding & Polishing

The post Wartsila 8L20 Crankshaft Repair at Togo | RA Power Solutions 44 Years Experience appeared first on Crankshaft Grinding Repair.

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.

The details of the crankshaft of Daihatsu 6DL-16 are as follows:

Inspection Conducted by RA Power Solutions technicians and observations:

• On arrival, the inspection in detail was conducted by our technicians.
• It was informed that a local company based in Dubai was engaged to undertake the repair of two crankpins that were damaged.
• The crankshaft repair company based in Dubai took eight days to repair the two crankpins and the bearings failed twice within engine operation of 10 minutes.
• RA Power Solutions technicians did the dimensional inspection of crankpins. They were surprised to note that the crankpins after grinding by a Dubai-based company had ovality up to 0.12 mm against the maximum permissible limit of 0.03 mm by Daihatsu.
• The readings observed by our technicians before grinding are mentioned below:

                  SIZE OF CR JOURNAL                                     SIZES IN MM

• On further investigation, RA Power Solutions was informed that the company from Dubai had no specialized equipment/ tooling to undertake the grinding of Daihatsu 6DL-16 having a standard diameter of 120 mm and crankpin bearing width of only 64 mm. They did it by hand and were not able to control the ovality.

Action taken by RA Power Solutions Technicians

RA Power Solutions technicians after initial inspection for dimensions, hardness, MPI for crack detection, etc undertook the grinding of crankpins 1 & 4 and undersized both the crankpins by 1.0 mm.

The Final report after grinding is pasted below:

                     SIZE OF CR JOURNAL                           SIZES IN MM

It can be seen from the above readings that the taper & ovality were controlled within 0.02 mm. The engine was commissioned in the presence of our technicians and was operating satisfactorily.

Achievement by RA Power Solutions

The grinding of the crankpin of Daihatsu 6DL-16 needs specially designed, compact onsite crankshaft grinding equipment which RA Power Solutions has developed. This equipment is manufactured in two parts and is inserted from the inspection window of the engine block.

In this case, the crankpin diameter is only 120 mm, and the crankpin bearing width of 64 mm, we have designed the equipment that can undertake grinding/ polishing of the crankpin without removing it from the entablature.

We have been extending our onsite services all over the world for the last forty-three years and regularly work on high RPM engines like Daihatsu, Yanmar, Volvo, MAN B&W,  Caterpillar, Cummins, Deutz Engines, etc.

RA Power Solutions is ISO 9001:2015 (Quality Management System) & ISO 14001:2015 (Environmental Management System) certified approved company.

We have been regularly executing the 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 Repair of the engine and onsite crankshaft replacement, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

The post Daihatsu 6dl 16 Onsite Crankshaft Grinding Dubai appeared first on Crankshaft Grinding Repair.

A crankshaft is a piece of art manufactured with close tolerances; it needs expert services to successfully execute the repair. We have repaired some crankshafts that the small and inexperienced companies damaged due to lack of know-how and experience. Recently, we have saved the crankshaft of MAN Diesel Engine Model no. CME 5L 16/24 from rejection.

Following are the details:

Crankshaft repair of MAN Diesel Engine Model No. CME 5L 16/24. Crankshaft Grinding Engine Details Table

It was reported by Dubai Dubai-based company that one of their vessel which was sailing near Chittagong port had met with an accident and the crankshaft was damaged. RA Power Solutions. deputed two technicians along with necessary tooling to Chittagong. They boarded the vessel in a short time of 12 hours after receiving the first communication of the breakdown. This was possible as all our technicians have valid Indian CDC.

Following the Inspection of the crankshaft was conducted

• All the crankpins were subject to crack detection by MPI and no crack or abnormality was observed on the crankpin.
• Hardness with a portable calibrated hardness tester was checked and was found within limits.
• The deflection of the crankshaft was within limits.

All the crankpins were checked for taper and ovality out of five crankpins, two number crankpins had the following readings

Ongoing through the above dimensions, owners were surprised as the damage to the crankpins was beyond the last limit stipulated by the engine manufacturer i.e. MAN Diesel for Engine Model no. CME 5L 16/24. In other words as per the manufacturer, there was no solution but to reject the crankshaft and replace it with a new one.

RA Power Solutions took the following action to save the crankshaft from rejection

• Based on the above readings of crankpin no. 2 and crankpin no. 4, it was decided to undersize the crankpin to 1.5 mm and 2 mm from the standard diameter of 130 mm.
• The grinding was undertaken by our technicians and the final diameter of 128.50 and 128.00 mm was maintained.
• The undersized crankpin bearings of 1.5 mm and 2 mm were arranged by RA Power Solutions.
• The MAN Diesel Engine Model no. CME 5L 16/24 was commissioned and the engine is performing satisfactorily.

The under-sizing of the crankpin up to 2 mm is of course done under deviation and against the manufacturer’s recommendation but the fact is that the crankshaft has been successfully repaired and is saved from rejection which helped the owners of the vessel to save a considerable amount and downtime. We at RA Power Solutions always believe in saving the crankshaft from rejection. The cost of the crankshaft is exorbitant and has no justification by the engine and crankshaft manufacturer who enjoy the monopoly.

RA Power Solutions suggests not engaging companies with no expertise and specialized equipment for the repair of the crankshaft. We have the knowledge, experience, and necessary equipment to undertake the repair.

Crankpin Repair Services

We observed that companies avoid crankpin repair due to the time taken to repair of crankpin and the high cost. This was true as few companies based in Europe and Singapore enjoyed the monopoly and charged exorbitantly for crankpin repair. With the introduction of onsite crankpin repair and main journal repair machine, it is now possible to undertake the crankpin and main journal grinding and polishing in minimal time.

Secondly, the cost of crankpin repair charged by RA Power Solutions is almost one-fourth of the charges of European and other companies. In simple language, crankpin repair has become easy with a low cost. For more information about crankshaft grinding services, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

The post World Leading Company of Crankshaft Grinding Services | RA Power Solutions appeared first on Crankshaft Grinding Repair.