RA Power Solutions undertakes rebabbitting of bearings and manufacturing of new white metal, tri metal bearings by centrifugal casting process up to 1500 mm diameter. This process of rebabbitting is highly recommended for diesel engines, steam and hydro turbines and equipment which operate on heavy load. The rebabbitting by centrifugal casting is the process by which maximum bond strength is obtained. We undertake manufacturing of new white metal babbitt bearings and rebabbitting of old damaged or worn out bearings.
We manufacture new white metal babbitt bearings and repair old babbitt bearings for following applications.
I) Fan bearing, bearings for alternator, turbine, and all applications
II) Motor bearing
III) Engine bearing
IV) Tilt pad bearings
V) Pillow blocks
New Babbitt Bearing and Rebabbitting services by RA Power Solutions :
I) We have experienced technicians and production staff controlling the process of rebabbitting. Latest design of centrifugal equipment is used.
II) High, dense bonding of white metal with steel lining enhancing performance and service life of the bearing.
III) Excellent machining facilities to maintain original tolerances as per OEMs
IV) All the bearings after rebabbitting are thoroughly inspected and reports are prepared and submitted to the clients.
We have a pre-design process for rebabbitting of bearing designed by special experts. Highlights of the process is as follows:
I) Complete inspection of bearing and preparation of the report
II) Remove worn babbitt material.
III) Clean, & repair surfaces
IV) Re-babbitting of bearing by a centrifugal process
V) We will provide proof of bond for client’s satisfaction
Diesel Engine maintenance, overhaul, repair & replacement of Crankshaft is undertaken by RA Power Solutions through the experienced technicians. We leaders in providing Engine maintenance & overhaul services for the last 4 decades.
The main advantage of assigning a job of Diesel Engine Overhaul & Repair, Engine maintenance to RA Power Solutions is that we are experts in undertaking the onsite repair of Crankshaft, Engine block and all major services including repair of damaged casting. Metal locking & Metal Stitching, Rebabbitting of white metal bearing, alternator services are offered in house this reduces the downtime of the engine.
All our technicians carry valid Indian CDC & can execute the Diesel Engine Overhaul & Repair, Marine & Power Plant Diesel Engine Repair & maintenance while sailing.
We are giving below details of an overhaul of Wartsila 12V32 Engines executed in Panama, South America in November 2015.
I) Dismount and overhaul all cylinder heads, grind the valves and replacement all valve guide O ring seals. Checked cylinder heads leakage and pressure testing of all heads at 5 bar
II) Overhaul the charged air coolers, Jacket water, and lubricating oil Alfa Laval plate heat exchangers.
III) Dismount and overhaul all ABB turbochargers, renewed the compressor and turbine side bearings.
IV) Withdraw all the pistons, took piston clearances and check and cleaned piston ring landing and renewal of piston rings gudgeon pins and big end bearings.
It is experienced that Diesel Power Plants & Shipping companies award the repair companies job of Crankshaft Grinding, repair & overhaul of the engine without checking their credentials. This results in to the major break down & heavy losses to the clients. RA Power Solutions has experience of 40 years in this field of repair of Crankshaft, Overhauling of high capacity Diesel & major engine repair. The services extended by us are far better then the International standard and our service charges are lowest in the world.
We have 24/7 availability of technicians with necessary credentials & valid Indian CDC. They can travel to any destination in the world in short notice. We are the only company in the world which manufactures onsite crankshaft grinding equipment up to 700 mm & provide Crankshaft repair services as well. We have sold 70 onsite Crankshaft Grinding machines & have trained more than 150 technicians to undertake the repair of Crankshaft.
Stop availing the Crankshaft repair and Engine overhaul services from the local companies & avail the benefit of our experienced & low-cost services provided with the guarantee.
We provide all the services related to repair of Crankshaft which includes following:
I) Complete Calibration of Crankshaft diameter ranging from 30 mm to 700 mm. Inspection includes dimensional inspection of Crankpin & main journal, checking of hardness, Crack detection test with MPI, surface roughness test. Inspection report in detail on our formats are prepared and submitted to our client.
II) On-site Grinding & Polishing of Crankshaft maintaining the tolerances as mentioned in the maintenance manual of the engine manufacturer.
III) Straightening and Peening of Crankshaft.
IV) Replacement of Crankshaft in case of rejection
The author is Mr. Raj Shahani Managing Director of RA Power Solutions having experience of almost four decades of working on high capacity diesel engines, turbines, and rotary equipment. The company specializes in executing the repairs i.e. metal stitching/metal locking, grinding and repair of crankshafts, crankshaft machining, rebabbitting of bearings, connecting rod reconditioning, overhauling of Engines which have a serious problem resulting to the immense saving to the owners.
RA Power Solutions is providing major overhauling & repair of high capacity engines installed on the ship & in industries. Our technicians are experienced & they have worked with reputed engine manufacturers like Wartsila, Caterpillar, Mirrlees Blackstone,Cummins etc.
The following jobs are undertaken pertaining to major Overhauling, Engine Repair & Engine Services offered by RA Power solutions.
I) Inspection of all parts after disassembly of the Engine.
II) Preparation of report in details of parts inspected & overhaul of Engine.
III) Most of the parts are repaired or reconditioned by RA Power solutions on site with portable equipment & dedicated team of technicians.
IV) Assembly of parts maintaining clearance strictly as specified in the manual.
V) Complete assembly of the Engine.
VI) Load trial of the Engine.
Following is the description of activities of major overhaul of MAN B&W L23/30H auxiliary engine undertaken recently.
I. Dismantled all units of cylinder heads
II. Removal of all inlet valve, exhaust valve and valve guides III. Renewal of all valve spindles, inlet valves, exhaust valves, valve guides, guide O rings, valve rotators and valve springs. IV. Reconditioning of all valve spindle seats and valve seat rings V. Dismounting, cleaning and Inspection of all cylinder heads cooling water space and replacement of all O rings. VI. Inspection and cleaning of all fuel injector sleeves VII. Lapping of all cylinder liner and cylinder head sealing face VIII. Pressure testing of all cylinder heads at 6 bar IX. Inspect and check clearances of all valve gears, valve bridges and push rods X. Renewal of all cylinder liner sealing joints XI. Dismounted all units pistons and connecting rods, replacement of all connecting rod big-end bearing shells. Cleaning of all pistons and replacement of all piston rings. XII. Inspection and de-glazing of cylinder liners. Measurement of all units cylinder liner piston ring butt clearances and all pistons vertical groove clearances. XIII. Measurement of camshaft bearing clearances with filler gauge XIV. Dismount ,overhaul and remount all 7 nos fuel injection valves and renewal of the nozzles XV. Dismount and clean the lub oil filter and renew all four filter elements with original new XVI. Dismount and clean lub oil cooler XVII. Dismount the charge air cooler, cleaned the cooler element by immersion in detergent and compressed air XVIII. Dismount and clean both turbine and compressor sides of turbocharger XIX. Took crankshaft deflection measurement with spring loaded dial gauge XX. Adjusted the inlet and exhaust valve clearances.
RA Power Solutions have a large team of engineers & technicians available 24/7 all of them have valid Indian CDC & Palau CDC & can travel to any destination in a short notice.
The author is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. He has 40 years of experience in working on large crankshafts and Diesel Engines. He is on the board of directors of reputed shipping companies and companies having a large number of Diesel power plants.
Manufacturers of high capacity diesel engines are maintaining close tolerances in terms of taper and ovality of crankpin and main journal diameter of the crankshaft. The maintenance of close tolerances and high surface finish results in the generation of more power, longer life of crankshaft and bearing, less noise level, low vibration, friction, and better fuel efficiency. RA Power solutions have been working on crankshafts of marine engines and engines used for various applications with the diameter ranging from 30 mm to 700 mm.
In general following close tolerance of crankpin and main journal are observed:
I) Taper and ovality of crankpin and the main journal are maintained between 0.02 mm to 0.05 mm depending on the diameter of crankpin and main journal.
II) The surface finish of less than 0.25 RA value is maintained.
RA Power solutions have observed that sometimes due to an emergency, to put back the engine into operation, the crankshaft crankpin and main journal are hand polished by emery paper, nylon rope and other means. This has serious consequences on CR pin and main journal. Few of them are as follows:
I) Bearing line marks, pitting marks are observed on crankpin and main journal of crankshaft cannot be removed by hand polishing.
II) It is our experience that in case of development of taper and ovality, it can never be reduced and controlled by hand polishing. On the contrary ovality and taper increases.
IV) It is observed that by hand polishing the marks can never be removed fully. Thus the desired surface finish as per the manual cannot be maintained.
RA Power solutions, during their work on high capacity engines installed with clients spread all over the world, have observed that in most of the cases hand polishing rather deteriorates the condition of crank pin and main journal and in some cases results in the rejection of crankshaft.
Recently one of our client having 3 generators of MAN B&W 8L 23/30 had a problem in all crankpins having a standard diameter of 185mm. Bearing line marks and the rough surface was observed. All the crankpins were hand polished by nylon wire and new bearings were used. The crankshaft failed within 20 minutes of the operation of the engines. Few photographs are given below:
Introduction of Portable Crankshaft Grinding Machine by RA Power Solutions
RA Power solutions have introduced portable, lightweight onsite crankshaft grinding and polishing machine which is capable of grinding and polishing the diameter ranging from 30 mm to 700mm. The onsite crankshaft grinding machine is revolutionary portable equipment which can be inserted from the inspection window of the engine block. There is no requirement of removal of crankshaft from the engine block.
On site crankshaft grinding and polishing machine is easy to operate and we also extend training to the buyer’s technicians. Inviting companies for polishing of crankshaft is no more required as it can be undertaken by your technicians with the portable onsite crankshaft grinding machine. You can save on the exorbitant amounts charged by European companies, which was their monopoly till the last few years.
More than 70 machines have been sold all over the world and are operating successfully.
The author is Mr. Raj Shahani, Managing Director of RA Power Solutions Pvt. Ltd. He has 40 years of experience in working on large crankshafts and Diesel Engines.He is on the board of directors of reputed shipping companies and companies having a large number of Diesel power plants.
The crankshaft grinding and polishing machine has been developed through a consistent and focused R&D with field trials undertaken in different conditions.
To avoid crankshaft from rejection or to reduce the minimum diameter of Crankpin and Main journal after grinding companies all over the world are approaching RA Power solutions for onsite repair of the crankshaft.
Ra Power solutions is having the expertise of successfully repairing more than 10,000 crankshafts for different applications and diameter ranging from 30 mm to 700 mm. There are companies based in Europe who had the monopoly in onsite grinding and repair of crankshaft and were charging exorbitantly. By introduction of onsite repair of the crankshaft, RA Power Solutions has bought a revolution by executing onsite crankshaft repair far better than the international standards and with the lowest price. In this time of recession when the shipping companies and large industries are passing through difficult times repair of crankshaft, maintenance and overhauling of diesel engine and all services related to engine room offered by RA Power has resulted to considerable savings for the shipping companies and heavy Engineering organizations having Diesel power plants.
We follow the below mentioned procedure for successful onsite repair of crankshaft:
I) Thorough cleaning of Crankshaft/Main Journal which is damaged.
II) Visual inspection of radius fillet, lubrication oil hole, surface finish, and other parameters of Crankpin and Main journal.
III) Conducting of NDT test by qualified technicians with latest instruments for crack repair, hardness test, surface finish, dimensional inspection, etc.
IV) Selection of correct onsite tooling to execute the grinding and polishing.
V) Final inspection by senior technicians of crankshaft and preparation of reports.
All the crankshaft reconditioning jobs undertaken by RA Power Solutions are guaranteed for the satisfactory performance.
RA Power Solutions is the only company in the world which apart from providing onsite repair services also sells onsite crankshaft grinding machine capacity ranging from 30 mm to 700 mm. More than seventy crankshaft grinder machine have been sold worldwide. Hundreds of technicians have been trained to execute successful repairs of crankshaft onsite.
Overhauling and Maintenance of Diesel Engine undertaken as per the manufacturer’s recommendations is of great importance for the satisfactory performance of the main engine and auxiliary engines on board a vessel and installed in power plants.
RA Power Solutions undertakes complete overhaul, maintenance, and repair of engine and have experience of more than 40 years in this field. We have a team of technicians and engineers who have experience and have worked with the reputed engine manufacturers.
We follow the guidelines mentioned in the maintenance manual of the engine manufacturer’s religiously which enhances the life of the engine and results to the satisfactory performance.
The main advantage of engine overhaul and engine maintenance services extended by RA Power Solutions is that we have in-house facilities for reconditioning of major components like crankshaft, engine block, connecting rods, cylinder heads, cylinder liners, etc. We also undertake rebabbitting of white metal bearings, crack repair of cast iron and Aluminium components by metal locking and metal stitching process.
The reconditioning of the parts and overhaul of the engine remains the responsibility of RA Power for which we stand guarantee. We promise following for engine overhaul and engine repair services:
I) The highest quality of engine overhaul and engine repair services.
II) Expertise in calibration and replacement of crankshaft
III) The fastest possible turnaround time due to the experience of our technicians.
IV) Constant improvement in the overhaul of the diesel engine and diesel engine repair services.
V) Dedicated customer service staff available 24X7 with valid CDC.
VI) We have a record of repair, overhaul, and maintenance of over 10000 Engines.
Overhauling and Maintenance of Diesel Engine undertaken as per the manufacturer’s recommendations is of great importance for the satisfactory performance of the main engine and auxiliary engines on board a vessel and installed in power plants. RA Power Solutions undertakes complete overhaul, maintenance, and repair of engine and have experience of more than 40 years … Continue reading “Overhauling of Diesel Engine | Diesel Engine Repair by RA Power Solutions”
White metal babbitt bearings are manufactured by RA Power Solutions for all applications like engine, pumps, turbine, alternator and rotatory equipments.
The white metal babbitt bearings are manufactured as per the drawing or as per the sample of the bearings of the equipments which are no more produced by the original manufacturer. Stringent quality control norms are followed at the time of manufacturing of white metal bearings. The centrifugal system followed for rebabbitting of white metal is used which ensures a excellent bonding between the base metal and white metal.
The white metal after centrifugal casting has a dense surface without any pin holes or blow holes which results to the satisfactory performance and long life of the white metal babbitt bearing.
The rough and final machining and maintenance of various critical dimensions are maintained by using in-house latest design of equipment.
White metal babbitt bearings are manufactured as per the international standards maintaining the close tolerances. We have the facility to manufacture white metal babbitt bearing up to the outer diameter of 1500 mm.
Rebabbitting of old white metal bearings is undertaken which develop taper and ovality or get damaged
We are exporting bearings regularly to Singapore, Indonesia, Nigeria, UK, South America, Sri Lanka, Greece, Dubai, Qatar, etc.
RA Power Solutions having more than forty years of experience in field of repair and maintenance of high capacity engines, understands the importance of the parts.
In case of damage of engine components or crack, RA Power Solutions undertakes repair onsite by metal stitching or metal locking process. We are considered to be the leaders in this field as we use the master lock, master piece, keys and consumable of high quality imported from UK. Our technicians are highly experienced. Crack repair and repair of damaged casting components can also be executed while sailing of the Vessel.
Following is the process of metal locking, metal stitching and advantages.
The Stitching Process
1. At first visible and invisible cracks are identified.
2. The parts are clamped together to bring the parts in original position.
3. A rectangular hole is made across the fractured portion.
4. This hole is made by drilling and chipping.
5. The Master lock, large rectangular key of special metal is inserted into the hole.
6. Locking Pins are inserted alongside the master lock to provide a tight and secured master lock.
7. A length of metal stitching keys are inserted on the sides of the master lock to prevent the locking pins to fall out when the casting is subjected to high vibrations.
Advantage of Metal Stitching
1. No heat stress are induced
2. No Distortion occurs
3. In many Instances machining is not required
4. Invaluable in emergency situations
5. Reduces downtime
6. Gas/ Liquid proof repair
Development of Taper and Ovality is common in Crankshaft which gets developed due to continuous running of the engine.
RA Power Solutions is having experience of forty years in onsite Grinding and polishing of Crankshaft diameter ranging from 30 mm to 700 mm. The Onsite Grinding and repair is executed by experienced technicians. We use portable crankshaft grinding machine which is specially developed to undertake Crankshaft grinding and Crankshaft polishing within the tolerances stipulated by the manufacturer.
It is possible to undertake Crankshaft grinding and Crankshaft polishing while the Vessel is sailing.
The Crankshaft grinding machine used for Crankshaft repair is manufactured of Titanium alloy which absorbs the vibrations and facilitates to maintain the close tolerance within 20-30 microns. We are the world leaders in Onsite Repair and offer Crankshaft Grinding Services on the lowest price with international standard. All the Crankshaft repairs undertaken by us are guaranteed for satisfactory performance of Crankshaft and engine.