RA POWER SOLUTIONS PVT. LTD.

South City, Gurugram, Haryana

RA Power Solutions is one of the oldest company based in New Delhi, India, undertaking crack repairs of damaged heavy components, manufactured out of cast iron, bronze,   aluminium and cast steel. by cold process of metal lock and metal stiching.

Metal stitching and metal locking is a simple but proven process of repairing cracks in heavy components without following the wielding method which generates excessive heat.

RA Power Solutions has experienced technicians and a process available by which the damaged portion of the component is completely cut off. The new casting is  made of cast iron, cast steel or aluminium as per the original damaged component is manufactured and taken to the site. The new casting is  properly assembled and is metal stitched  by our experienced technicians using the best quality of metal keys and locks.

The photograph shown  in this blog are of MAN main engine model SMIT MAN R666W (Main Engine Port Side) which met with an serious  accident. In this case, we have successfully repaired the engine block, cylinder liner and piston having multiple cracks, length measuring  from 75mm to 190 mm.

RA Power Solutions was approached by a leading automobile manufacturing company based in North India to execute the repair of a damaged main frame body of 3500 Ton Press, supplied, installed, and maintained by a renowned Japanese company. RA Power Solutions team of engineers visited the plant during the shutdown and following was observed.

• The main frame of the 3500 Ton Press, which developed crack was the backbone of the plant as the complete body of the vehicles including doors/bonnet etc were formed on the press.
• The company was asked to disassemble all the parts, adjacent to the area where the crack was developed.
• The crack area of the press was thoroughly cleaned. Paint and red oxide were completely removed by the chemicals.
• The hardness test of the crack area of the press was undertaken.
• The MPI test was done on the crack area where a crack having a horizontal profile measuring 400 MM was observed.
• The crack was through the complete width of the frame plate having thickness of 40 MM.

All the technical parameters including load characteristics of 3500 Ton Press were studied by the RA Power Solutions engineers and it was decided to go ahead with the repair of crack by metal stitching and metal locking process.

RA Power Solutions is having experience of more than 44 years in the field of extendingCrankshaft and Cylindrical Shaft repair servicesall over the world.

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

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.

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.

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.

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.

MAN B&W STX Engine Model No 5L16/24 crankshaft is repaired by RA Power Solutions successfully, as per the manufacturers the grinding and undersize of crankpin is not allowed.

RA Power Solutions maintains a stock of Undersize Crankpin Bearings up to 4.00 MM for MAN B&W STX Engine Model No 5L16/24 and supplying Undersize Crank Pin Bearings from own stock and most of the undersize ranging from 0.5 M, 1.00 MM, 1.5 MM up to 4.00 MM.

The Main advantage is that we supply you Undersize Crankpin Bearings and the job is done Insitu without the removal of the crankshaft.

RA Power Solutions was approached by a company based in Dubai regarding a problem in crankshaft faced in MAN Diesel Generating set model no. 9L28/32.

Visit us:https://crankshaftgrindingrepair.com/MAN-Diesel-Generator-Model-no-9L28-32.php

Onsite crankshaft grinding machine provides the perfect solution for the repair of a crank pin or main journal of diesel engine. By use of an onsite crankshaft grinding machine, there is no requirement of removing of the crankshaft from the main engine or to dis-assemble the major components of the engine. The in-situ crankshaft grinding machine manufactured by RA Power Solutions

The crankshaft of Naval STORK Werkspoor S.A Engine on board a vessel at the port of Miragoane in Haiti has been successfully repaired by RA Power Solutions Engineers.

We were contacted by a Miami USA-based shipping company regarding the failure of the crankshaft of the main engine. The vessel was stranded at the port of Miragoane in Haiti.

RA Power Solutions is regularly executing repair of a crankshaft in Haiti, Dominican Republic, Santo Domingo, Puerto Rico, Jamaica, Cuba, Bahamas, Virgin Island, Bani, Venezuela, Barahona, USA, and neighboring countries.

RA Power Solutions, with 43 years of presence in the international market, has been successfully repairing heavy cast iron, aluminum, bronze, and cast steel components using the metal locking and metal stitching process. This is a cold process and no heat is generated.

The crack repair developed in high-casting components is executed onsite without dismantling the main equipment. RA Power Solutions has developed special alloy keys and locks that have almost ten times more strength than the original casting. Now it is possible to repair the cracks that develop in large, heavy-duty cylinder liners. The cracks repaired are mainly in the non-operational area of the cylinder liners. The repair of cracks in large cylinder liners has become popular, as in most cases, it is not possible to arrange the replacement of the cracked liners with new ones.

RA Power Solutions has saved a number of engines by undertaking the repair of damaged, cracked cylinder liners using the metal locking and metal stitching process. Below, we provide a photograph of MAN engine cylinder liners that have been repaired by us.

We regularly undertake the repair of engine blocks, compressors, and all cast iron, bronze, and aluminum components for the following engine makes:

• Akasaka
• Mitsubishi
• Daihatsu
• Yanmar
• Hanshin
• Kobe Mitsubishi
• Caterpillar
• Wartsila
• Deutz-KHD
• Volvo Penta SKL
• MAK
• Sulzer
• MAN B&W
• SKL
• MTU MAK
• Pielstick

We have been regularly providing metal stitching,  metal locking, metal surgery, and repair services in Iraq, Iran, Dubai, Oman, Saudi Arabia, Singapore, Russia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, Fujairah, Bahrain, Gambia, Kuwait, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Malaysia, Indonesia, Madagascar, Vietnam, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, South Korea, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

RA Power Solutions undertakes the repair of badly damaged cast iron, bronze, and aluminum components through metal locking and metal stitching processes. The main expertise of RA Power Solutions is to repair heavy components that have been badly damaged into pieces due to accidents.

We remove the damaged area of the casting from the equipment and give it with a geometrical discipline sheet. The new casting having superior metalogical properties than the parent casting is replaced and fixed by a metal lock and metal stitching process.

We have introduced the repair of cracked cylinder liners using metal locking and metal stitching processes. This service has become very popular, especially among ship owners, power plants, engineering companies, etc. which have old equipment where the replacement of components is not possible.

The photographs shown here are of cylinder liners that were rejected due to the development of multiple cracks. The cracks were clearly identified by the MPI process and repaired using the metal lock and metal stitching process.

We have been regularly providing metal stitching, metal locking, metal surgery, and repair services in Iraq, Iran, Dubai, Oman, Saudi Arabia, Singapore, Russia, Qatar, Abu Dhabi, Sharjah, Ajman, Umm Al-Quwain, Fujairah, Bahrain, Gambia, Kuwait, Antigua and Barbuda, Belize, Dominica, Dominican Republic, Malaysia, Indonesia, Madagascar, Vietnam, Grenada, Guyana, Haiti, Jamaica, Saint Kitts and Nevis, Saint Lucia, South Korea, Saint Vincent and the Grenadines, Trinidad, and Tobago, etc.

Babbitt White Metal Bearings for all applications are manufactured by RA Power Solutions Pvt Ltd. A company well-known all over the world for its quality, services, and products for over forty-four years.

Manufacturing of New Babbitt White Metal Bearings is undertaken on the basis of a sample or a drawing provided by our client. The old bearings rebabbitting is undertaken maintaining the composition of babbitt white metal superior than the original. This increases the life of Babbitt white metal bearings.

The Bearings have been successfully developed and manufactured. RA Power Solutions Manufactures Babbitt White Metal Bearings up to 1500 MM in terms of diameter.

Intermediate Propeller Shaft Bearing was repaired by RA Power Solutions Pvt Ltd, the detail of repairs are as follows:- 

• The Intermediate Propeller Shaft Bearing having a standard inner diameter of 505.00 MM and width of 400.00 MM was collected by a RA Power Solutions representative from a Cochin Port of a vessel owned by a company having headquarters in Vietnam.
• The bearing was badly damaged and Babbitt white metal from the Intermediate Propeller Shaft Bearing was removed by machining process.
• The bearing was subject to a short blasting process for cleaning, hardness test, and crack check by MPI process.
• A few hardened spots were observed on the inner diameter of the Intermediate Propeller Shaft Bearing. These hardened spots were removed by a process called scooping.
• Rebabbitting by a high grade of Babbitt white metal was done. We undertake the rebabbitting of white metal by centrifugal process, which ensures proper bonding between the Babbitt white metal and the steel casing of the bearing.
• The bearing inner diameter was machined to 504.50 MM keeping the oil gap of 0.50 MM, as prescribed in the manual. The in place machining of the Intermediate Propeller Shaft bearing was also undertaken by RA Power Solutions and the final diameter of the Intermediate Propeller Shaft was maintained, as 504.00 MM.

As mentioned above, the Intermediate Propeller Shaft Bearing inner diameter was maintained at 504.50 with an oil gap of 0.50 MM. 

Considering the damage to the Intermediate Propeller Shaft it was undersized by 1.00 MM and the final size was maintained, as 504.00 MM instead of the standard diameter of 505.00 MM.

The bearing after Babbitt white metal was assembled by our technicians on board the vessel. The Oil-gap, blue Matching after thorough inspection of the Intermediate Propeller Shaft and the bearing trials were taken and found to be satisfactory.

RA Power Solutions was approached by a leading shipping company based in Vietnam. The vessel was approaching Kochi Port India and reported serious damage to the Intermediate Shaft and Bearing.

RA Power Solutions three technicians boarded the vessel and their main observations are as following:-

Intermediate Shaft

• On removal of Intermediate Shaft bearing the excessive damage to the bearing seating area was observed.
• The Intermediate Shaft bearing, babbitt white metal was badly stuck on the bearing journal diameter.
• After removal of white metal from the Intermediate Shaft bearing seating area the ovality of 0.38 MM was observed, and the standard diameter of Intermediate Shaft Journal is 505.00 MM.
• Hardness and MPI Tests were undertaken and observed within limits.
• Localized damage, Bearing line marks, and Rough surface were observed on Intermediate Shaft Journal diameter.
• Intermediate Shaft Journal diameter was repaired by in situ grinding and polishing machine and diameter was maintained as 504.00 MM. The intermediate shaft bearing seating diameter was reduced by 1.0 mm.

Repair of Intermediate Shaft Bearing

• After removal of damaged babbitt white metal Intermediate Shaft bearing from the vessel, it was transported to our works based in IMT Manesar near New Delhi by Air, A distance of more than 2600 KM from Kochi Port India.
• The inspection of damaged bearing was undertaken, the bearing was rebabbitted and machining was done maintaining the inner diameter of 504.50 MM, as per the oil gap mentioned in the manual.
• Bearing was again returned to the Kochi Port India and was hand-carried by our representative to save time.

Assembly of Intermediate Bearing and Shaft

• The bearing was Assembled by RA Power Solutions Technicians.
• All the parameters including Oil-gap and Blue Matching of the bearing was done with Intermediate Shaft.
• After assembly trials were taken, the performance of the Intermediate Shaft and bearing was observed satisfactory. The job was executed in a short duration of Eight (8) days.

RA Power Solutions was approached by a company based in Vietnam advising the damage of the crankshaft of MAN B&W STX Engine Model No. 5L16/24.

The ship management advised that in case of MAN B&W STX Engine Model No. 5L16/24 the manufacturer of the engine does not allow the grinding of the crankpin, in case of any accident or damage. They recommended replacement of the crankshaft with a new one.

MAN B&W Engine Model No 6L23/30H crankshaft was reported damaged by a shipping company based in Dubai. Their Vessel was approaching Sikka Port, India, and transit time was less than 18 hours, from Sikka Port the vessel was to cross Suez Canal.

MAN B&W Engine Model No 6L23/30H crankshaft was reported damaged by a shipping company based in Dubai. Their Vessel was approaching Sikka Port, India, and transit time was less than 18 hours, from Sikka Port the vessel was to cross Suez Canal.

RA Power Solutions deputed two technicians with In Situ Crankshaft Grinding/Polishing equipment on board the vessel at Sikka Port, India.

We have been regularly executing on site crankshaft repair and In Situ crankshaft grinding in Dubai, Fujairah, Qatar, Saudi Arabia, Oman, Iraq, Togo, Malta, Freetown, Egypt, Malaysia, Iran, Indonesia, Vietnam, Jordan etc.

RA Power Solutions was approached by a Russian Company based in Yekaterinburg, Russia regarding their urgent requirement of repair of Generator Bearing of Wartsila.

Metal surgery, metal locking and metal stitching is a cold process and no stresses are developed. RA Power Solutions uses high grade of metal keys and metal locks for repair of crack by metal stitching and metal lock process. This is a proven method of crack repair.

Daihatsu 5DK-20 crankshaft repair/ onsite grinding under taken by RA Power Solutions, the crankpin no. 1 was damaged due to failure of bearing, the crankpin was undersized by 1.0 mm. For more information please visit our following link:

RA Power Solutions was approached by one of the largest shipping company based in Athens Greece regarding breakdown of Crankshaft of YANMAR Diesel Generator Model no. 8N280L-EV.

The job of repair of six number of crankpins ofYANMAR Diesel Engine Model 6N18AL-DVwas executed by our technicians during the sailing of the vessel. This was again possible only because our equipment is designed to absorb the vibrations resulting to the maintenance of close tolerances.

Crankshaft grinder manufactured by RA Power Solutions is used for grinding and polishing of crank pin and main journal of crankshaft. Crankshaft grinder is  capable of maintaining all the parameters and tolerances in terms of ovality and taper strictly as per the manufacturer’s requirement. Portable onsite crankshaft grinder is recommended for heavy engineering companies, diesel power plants, shipping companies, repair workshops, etc.

Main journal grinding and machining is undertaken by RA Power Solutions by onsite journal grinding and polishing machine. The machine is compact in size and the main journal grinding and machining is undertaken without removing it from the main equipment.

Crankshaft is an important part of the engine. In case of High Capacity Marine, Industrial and Power Plant engines, the cost of crankshaft is very high. In fact worldwide there are limited manufacturers of heavy-duty crankshafts, which are used in high-capacity Engines, Compressors, Pumps and Rotary equipment. It is important that crankshafts are properly maintained in order to increase the operation hours and save the cost.

RA Power Solutions with more than 44 years of experience in crankshaft repairs have saved more then ten thousand (10, 000) crankshafts from rejection. This was possible only because of bringing the awareness to ship owners staff, power plants, and users in general during the conferences held all over the world and the various blogs written, publications, etc.

The Crankshaft maintenance is easy and the life can be increased many folds by taking following steps.

i) Visual Inspection Of Crankshaft:- We Suggest that crankshaft should be subject to Visual Inspection periodically. The Crankpin Cap and Main Journal Cap can be opened for Visual Inspection, the focus should be on radius fillet of both sides, and lubrication oil hole, and Crankpin /Main Journal dia should be free of any Scratch marks or Rough Surface.

ii) Periodic Polishing of Crank Pin and Main Journal of Crankshaft:- Regular Polishing of Crankpin and Main Journal can extend the life of crankshaft and bearings. With the latest technology of onsite crankshaft polishing machines, It is simple to polish the crankpins in a few hours.

iii) Crankshaft Grinding:- We strongly recommend that incase of development of taper, ovality, and rough surface the grinding should be done in accordance with the manufacturer's standards.

With the crankshaft grinding we can easily restore the original dimensions. The grinding of the crankshaft is done onsite and there is no need for removal of the crankshaft from the entablature.

iv) Change of Oil and Oil Filters of Engines:- In order to increase the life of crankshaft and bearings, It is recommended to follow the manufacturer guidelines for change of Oil and Oil Filters.

Engine cylinder liner and sleeves are manufactured by us up to 1500 mm length of the liner. Liners are centrifugally cast and are machined in-house. Cylinder liners and cylinder sleeves for all popular makes and models of diesel engine are available in stock.

RA Power Solutions is the leading cylinder liner and cylinder sleeves manufacturer of all makes of diesel engine with four decades of experience and expertise.

Replacement and rebabbitting services for white metal bearings is offered by us. We ensure that white metal of higher grade is used for rebabbitting of the bearing. After the removal of white metal from the old bearing, the bearing inner casing is thoroughly inspected for any cracks or abnormalities. In case of any hard spots, they are removed by scooping process.

Crankshaft grinding services are extended for the engines installed in diesel power plants and on vessel. The crankshaft grinding services are provided through our technicians who have experience of working with engine manufacturers. All crankshaft grinding services extended by RA Power Solutions are guaranteed for satisfactory performance.

Our highly skilled and trained supervisors and technicians offer crank pin grinding services on-site, on-board and off-shore. We are known as one of the respected leading companies in this field of crank pin grinding and crankpin polishing. Our technicians travels all over the world without any hassle in shortest possible time.

RA Power Solutions repair crankcase by metal stitching and metal locking process. It is a cold and Class approved process of repairing engine components. No heat is generated in this process. We have a team of technicians having years of experience in repairing engine components by metal locking and metal stitching process.

Metal stitching is a cold process of repairing cracks in cast metals without the need of welding. No heat is generated in this effective metal stitching process. Metal stitching is a reasonable repair method when some cracks appear or major pieces break from any cast iron component.

Metal locking is a well-proven process to repair cast iron components such as engine blocks or turbine casings safely and permanently. RA Power Solutions having more than four decades of experience in the field of metal locking and metal stitching.

RA Power Solutions repair cracked engine block by metal stitching and metal locking process while vessel is sailing. We have four decades of experience in repairing engine components by cold process i.e. metal locking and metal stitching.

CKD Skoda Engine Liner and cylinder sleeves are manufactured and exported by us all over the world. The cylinder liners for CKD skoda are exported by us for the last 30 years and the performance is proved. The cylinder liners are available with us in stock.