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 The companies based in Europe have an old design and outdated equipment as they take reference of radius fillet to undertake grinding.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.

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• Development of taper and ovality beyond the specified limits.
• Development of rough surface of crankpin and main journal diameter.
• Line marks, pitting marks due to use of bad quality oil or use of lubricating oil for prolonged hours.
• Development of bearing line marks, pitting marks due to failure of bearings, or removal of bearing top layer.
• Development of cracks due to accident or failure of crankpin and main journal bearing.
• Increase or decrease in hardness more than the limits stipulated in the engine maintenance manual.
• Loss of alignment of crankshaft and variation in deflection reading.
• Damage of radius fillets due to failure of bearings.
• Damage of counterweight and counterweight bolts due to an accident.

RA Power Solutions is the leader in onsite grinding of crankshaft repair of medium and large crankshafts of 2-stroke and 4-stroke engines. We have introduced a revolutionary, easy to operate Insitu crankshaft grinding machine having a range from 35 mm to 700 mm in terms of diameter for undertaking the crankshaft polishing, crankshaft grinding, crankshaft repair, and grinding of crankshaft onsite.

We use the machines developed by RA Power Solutions. This has a great advantage to our clients as we can modify the design of the in situ crankshaft grinding machine as per the space available at the site. There are hundreds of jobs of in situ crankshaft grinding, rotor shaft, alternator shaft, and turbine shaft grinding for which RA Power Solutions has successfully developed dedicated grinding and polishing equipment. The jobs that other companies cannot take even those jobs have been successfully executed by RA Power Solutions.

The comprehensive crankshaft polishing, grinding of crankshaft repair onsite services offer

• Grinding, polishing, and machining of main journals diameter ranging from 35 mm to 700 mm.
• Machining, grinding, and polishing of crank pin journals diameter ranging from 35 mm to 700 mm.
• Machining and grinding of radius fillet maintaining the profile strictly as per original.
• Removal of cracks in crank pin and main journals by grinding and polishing process.
• The in situ crankshaft grinding machine used by us can undertake the repair of the crankpin and main journal by removal of minimum stock.
• Controlling of hardness developed in the crank pin and the main journal by the peening process.
• Straightening of crankshaft and control of deflection.
• Polishing of crankpins, main journal, crank journals, and alternator bearing diameter for removal of bearing line marks, pitting, and increasing the surface finish.

Advantages of RA Power Solutions main journal, crank pin machining, crankshaft polishing, repair and grinding of crankshaft onsite

• Experience of over forty years in the field of maintenance and repair of diesel engines.
• More than 10,000 crankshafts, alternator shafts, rotor shafts, and turbine shafts were repaired successfully all over the world.
• Trained and experienced technicians are available 24/7.
• Training is given in-house training school.
• Tailor-made in situ crankshaft grinding and polishing machines used to work in limited space available on board the vessel or in diesel power plants.
• The Insitu crankshaft grinding machine used is lightweight and can be carried as accompanied baggage by technicians all over the world.
• Quick response time as all our technicians have valid Indian CDC and can reach any destination in the world with the Insitu crankshaft grinding machine on short notice.
• All jobs of crank pin crankshaft polishing crankshaft grinding, crankshaft repair, and grinding of crankshaft repair on site are undertaken with a guarantee.
• We have the most competitive rates in the world.

List of Alternate Location Service Providers by Ra Power

We have been regularly executing the repairs in Madagascar, Oman, Qatar, Philippines, Bahrain, Srilanka, Bangladesh, Myanmar, Turkey, Nigeria, Greece, Saudi Arabia, UK, Dubai, Malta, Cyprus, Singapore, Malaysia, Colombia, Indonesia, Hong Kong, Spain, Netherlands, Dubai, Portugal, Estonia, Morocco, Belgium, Vietnam, Canada, etc.

For more information, grinding of crankshaft repair, grinding of crankshaft onsite, crankshaft grinding and repair, or Crankshaft Polishing, please email us at rajshahani@rapowersolutions.com, or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

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