Consequences of Hand Polishing of Crankshaft & Benefits of Onsite Polishing Machine- RA Power Solutions

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.

III) The surface finish of the crankpin and main journal is of great importance.

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:

Bearing Line Marks Observed in Crankpin
Bearing Line Marks Observed in Crankpin
Rough Surface Observed in Crankpin of MAN B&W 8L 2330 Engine
Rough Surface Observed in Crankpin of MAN B&W 8L 2330 Engine

 

 

 

 

 

 

 

Inspection of Crankpin before Grinding is in Process
Inspection of Crankpin before Grinding is in Process
Inspection of Crankpin before Grinding by RA Power Solutions
Inspection of Crankpin before Grinding by RA Power Solutions

 

 

 

 

 

 

 

 

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.

Accessories of Crankshaft Grinding Machine
Accessories of Crankshaft Grinding Machine
Portable Onsite Crankshaft Grinding Machine
Portable Onsite Crankshaft Grinding Machine

 

 

 

 

 

 

 

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.

For more information, please email us on info@rapowersolutions.com

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 … Continue reading “Consequences of Hand Polishing of Crankshaft & Benefits of Onsite Polishing Machine- RA Power Solutions”

Crankshaft Reconditioning | Crankpin Reconditioning & Crankpin Machining by Crankshaft Grinder

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.

Grinding of Crankpin by Crankshaft Grinding Machine is in Process
Grinding of Crankpin by Crankshaft Grinding Machine is in Process

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.

Onsite Crankshaft Grinding while Vessel is on Move
Onsite Crankshaft Grinding while Vessel is on Move
Crankpin After Grinding by Onsite Crankshaft Grinder
Crankpin After Grinding by Onsite Crankshaft Grinder

 

 

 

 

 

 

 
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.

Onsite Crankshaft Grinding Machine Offered by RA Power Solutions
Onsite Crankshaft Grinding Machine Offered by RA Power Solutions

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 … Continue reading “Crankshaft Reconditioning | Crankpin Reconditioning & Crankpin Machining by Crankshaft Grinder”

Overhauling of Diesel Engine | Diesel Engine Repair by RA Power Solutions

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.

Inspection & Repair of High Capacity Engine
Inspection & Repair of High Capacity Engine

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.

Repair of MAN Engine is in Process
Repair of MAN Engine is in Process

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.

Inspection of Engine Bearings
Inspection of Engine Bearings
Inspection & Repair of Cylinder Liners
Inspection & Repair of Cylinder Liners

 

 

 

 

 

 

 

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.

Repair of Diesel Engine while Vessel is Sailing
Repair of Diesel Engine while Vessel is Sailing

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”

Crankshaft Machining | Crankshaft Grinding Services | Onsite Crankshaft Repair Services

 

Damaged Crankpin of MAN Engine
Damaged Crankpin of MAN Engine

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.
Onsite Grinding of Crankshaft While Vessel is Sailing
Onsite Grinding of Crankshaft While Vessel is Sailing
Inspection of Crankpin Before Grinding
Inspection of Crankpin Before Grinding

 

 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.
For more information, please email us on info@rapowersolutions.com
Onsite Crankshaft Grinding Repair Machine
Onsite Crankshaft Grinding Repair Machine
Inspection of Crankpin After Grinding
Inspection of Crankpin After Grinding

  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 … Continue reading “Crankshaft Machining | Crankshaft Grinding Services | Onsite Crankshaft Repair Services”

Crankpin Grinding by Crankshaft Grinding Machine

Diesel power plant based in northern India having 10 nos. of 12.3 MW Wartsila diesel generating sets reported severe causality involving one of their Wartsila generator.

RA Power Solutions team of technicians rushed to the power plant with the measuring instruments and onsite crankshaft grinding equipment to access the cause of breakdown.

Wartsila Diesel Generating Sets Installed in Plant
Wartsila Diesel Generating Sets Installed in Plant

On undertaking the detailed inspection of crankshaft including dimensional check, hardness test, MPI for crack and deflection, it was observed that one of the crankpin journal was damaged due to the failure of big end bearing.

Following were the main observations:

I) Taper and ovality in crankpin was observed as 0.70 mm.

II) Due to failure of bearing, deep line marks were visible.

III) Hardness and MPI test was done, no cracks were observed.

Damaged Crankpin of Wartsila Engine
Damaged Crankpin of Wartsila Engine

RA Power Solutions used latest design of onsite crankshaft grinding machine having almost no vibrations. The crankpin was undersized by 1.5 mm maintaining the tolerance within 10 microns. Our technicians took only 18 hours to complete the Crankshaft repair from the time of start of preliminary inspection, grinding and final inspection. The repair of crankpin in such a short time was possible due to the latest technology onsite crankshaft grinding machine used and experience of our technicians. The engine was assembled and is performing satisfactory.

Inpection of Crankpin is in Process
Inpection of Crankpin is in Process
Crankpin Grinding is in Process by RA Power Engineer
Crankpin Grinding is in Process by RA Power Engineer

RA Power Solutions is having four decades of experience in working on crankshaft of high capacity main and auxiliary engines. The technicians are trained in the factory to execute the repair of crankshaft strictly as per the manufacturer’s specifications and tolerances.

We are the leaders in this field and our prices are most competitive.

For more information, please email us on info@rapowersolutions.com

Crankpin After Grinding by Onsite Crankshaft Grinding Machine
Crankpin After Grinding by Onsite Crankshaft Grinding Machine
Grinding of Crankpin by Crankshaft Grinding Machine
Grinding of Crankpin by Crankshaft Grinding Machine

Diesel power plant based in northern India having 10 nos. of 12.3 MW Wartsila diesel generating sets reported severe causality involving one of their Wartsila generator. RA Power Solutions team of technicians rushed to the power plant with the measuring instruments and onsite crankshaft grinding equipment to access the cause of breakdown. On undertaking the detailed inspection of crankshaft including dimensional … Continue reading “Crankpin Grinding by Crankshaft Grinding Machine”

Crankshaft Repair

Crankshaft repair is important for the engines running continuously. It is observed that crankshaft, crankpin and main journal develop taper and ovality after certain hours of operation. This needs crankshaft repair.

Crankshaft Repair

RA Power Solutions Pvt. Ltd. undertakes crankshaft repair by onsite grinding and polishing. The crankshaft repair is done by portable, light weight equipment which can be carried to the site and repair is executed by experienced engineers. In case of seizure of bearing crankshaft, bearing surface becomes rough,develops taper,ovality,bearing line marks and needs repair. This again is done by onsite grinding of crankshaft and main journal.

Crankshaft Deflection and MPI Test Under Process
Crankshaft Deflection and MPI Test Under Process

RA Power Solutions Pvt. Ltd. is associated with leading shipping companies and diesel power plants and undertakes repair of crankshaft for last more than 36 years and have record of executing repair of more than 10000 crankshafts.

Repair of Crankshaft is in Process
Crankshaft Under Repair
Removal of Crankshaft From Engine to Under Repair
Crankshaft Under Repair

Crankshaft repair is important for the engines running continuously. It is observed that crankshaft, crankpin and main journal develop taper and ovality after certain hours of operation. This needs crankshaft repair. RA Power Solutions Pvt. Ltd. undertakes crankshaft repair by onsite grinding and polishing. The crankshaft repair is done by portable, light weight equipment which … Continue reading “Crankshaft Repair”