RA Power Solutions was called by a client based in the Maldives to inspect the engine block of Wartsila 12V32 which got seriously damaged due to an accident.
RA Power Solutions technicians visited the island and undertook the inspection as per the following details:
- Inspection of engine block/entablature of Wartsila engine, model 12V32.
- On a visual inspection by our technicians, it was observed that the engine block developed multiple cracks near the inspection window.
- A piece measuring 590 mm X 360 mm was damaged from the entablature casting and came out.
- Our qualified technicians cleaned the surface area thoroughly, even the paint and the red oxide were removed.
- The MPI was done for crack detection and all the cracks were clearly identified.
- The measurement of broken casting was also taken.
The details of the crack observed are as follows:-
- Multiple cracks having a length ranging from 20 mm to 430 mm were observed.
- The discipline profile of the damaged portion of the Wartsila engine block was given by cutting and grinding the final dimensions which were observed as 660 mm X 396 mm.
Non-availability of Wartsila 12V32 engine block
Diesel engines are in operation all over the world in power plants, ships, heavy engineering industries, etc. The breakdown of the engine happens either due to mishandling, material defects, or poor maintenance of the engine. This results in a major breakdown, which can be devastating.
These types of accidents cause severe damage to the engine component or even injuries to the operator present in the engine room.
Prior to the arrival of RA Power technicians on site, the owners of the Diesel power plant explored various possibilities of repair, including repair by welding process. Our technicians explained the difficulty in repairing the engine block, which is manufactured out of cast iron by the welding process. Cast iron contains a high level of carbon, which burns when the repair of casting is undertaken by a welding process.
The concentrated heat caused by the welding process also results in the expansion and contraction of the casting, developing the stresses in the engine block/entablature.
In some cases, the welding due to the high-temperature process also results in the hardening or rather development of more cracks. We have also experienced that due to stress and contraction, there is a significant loss of the centreline of the main journal housings of the block, which is of great importance.
Repair of Wartsila 12V32 engine block by metal stitching and metal locking process
The repair of engine block and entablature of Wartsila engine model 12V32 was undertaken by metal stitching and metal locking process which is a proven cold repair method of repairing heavy cast iron casting, aluminium casting, and steel cast components.
Different types of specially designed screws and locks are used in crack and damaged casting repair in the metal stitching and metal locking process. The multiple cracks as per the details mentioned above were repaired by the metal stitching process. The damaged area of the engine block was fitted with a new piece of casting and was metal stitched. The engine was put on load after the repairs by metal lock and metal stitching process and performance was observed as satisfactory. This job of repairing of Wartsila engine block/ entablature of 12V32 was executed in the Year 2013 and since then it has been performing satisfactorily. The client has not only saved a considerable amount by avoiding the purchase of a new engine block but also saved on downtime as they are in the business of power generation for the islands based in the Maldives.
RA Power has a dedicated team of experienced technicians headed by an engineer with more than 44 years of experience in the repair of cracks in cast iron, aluminium cast steel, and steel casting by metal stitching and metal locking.
All our technicians have valid CDC and can fly to any destination on short notice. The portable, lightweight pneumatic tools are carried by them as accompanied baggage. We have been regularly executing the repairs in Madagascar, Oman, Qatar, Philippines, Bahrain, Sri Lanka, 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.
This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions India Pvt. Ltd.).
Mr. Shahani is a highly experienced business leader with rich experience of 44 years in the field of Power, Heavy and Shipping industries. He is a Technical Advisor to many shipping and heavy industries across the globe.
Mr. Shahani is one of the most enthusiastic professionals, and he has all the brilliance of an exemplary leader. He is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.
For more information on repair cast iron, cast iron stitching, cast iron engine repair, cast iron crack repair, cold metal stitching, cast iron engine block metal lock, broken engine block, and metal surgery contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.