RA Power Solutions has made repair of cracks and damaged engine blocks a simple process. This achievement of repairing engine block, turbine casing, Cylinder heads, and major parts of high-capacity engines is possible because of our experience in undertaking repairs of damage and crack casting by metal lock and metal stitching process.
The cast iron engine block is difficult to weld as it is very brittle. The repair of the cracked engine block by metal lock/metal stitching/metal surgery is proven to be of great success and can result in saving a huge amount as one can avoid buying a new engine block.
Repair of Wartsila 12V32 Engine Block
One of our clients running a Diesel power plant in South America having 47 numbers of Wartsila 12V32 and Wartsila 18V32 engines reported a serious accident in one of their diesel generating sets of Wartsila 12V32 model. The team of engineers of RA Power Solutions conducted the inspection and the following observations were made:-
- The accident took place due to the failure of the connecting rod bearing. The connecting rod hit the engine block from both sides and damaged the block. On undertaking the crack detection test by MPI and die-penetrant test, multiple cracks having lengths measuring from 3 inches to 18 inches were observed.
The following action was taken to repair the Wartsila Engine block:-
- It was decided to cut the damaged and cracked portion of the engine block and give it a discipline profile.
- The portion measuring 24 inches by 39 inches and 13 inches by 26 inches on both sides of the engine block was removed.
- The MPI test was conducted to ensure that no cracked area remains in the crankcase.
- The wooden pattern was prepared onsite as per the damaged and removed casting portion of the engine block. The new casting was manufactured strictly as per the wooden pattern dimensions and profile, and the necessary machining was done in-house.
- The new casting was placed on the engine block and was attached by metal locking and metal stitching process by our technicians.
- The outer surface was ground and was matched with the parent casting.
- The repair of the engine block by replacing the damaged casting and fixing it with a metal lock and metal stitching proved to be successful.
- Our technicians also ensured that no leakage of lubricating oil took place.
RA Power Solutions Pvt. Ltd. has been extending the repair of crack and damage casting services for the last forty-four years and have the technicians and necessary portable tooling available to undertake the onsite repairs. The repairs on board the vessel and while sailing the vessel are also possible. We have the technicians possessing Indian CDC, and it is possible to depute them on short notice.
Follow-up by RA Power Solutions after repair of Wartsila engine 12V32 was done, and it was communicated that the Engine had completed more than 6300 running hours after repair. No leakages and no problems in the operation have been reported.
The company have saved an enormous amount by avoiding the purchase of a new engine block from Wartsila.
This blog is written by Mr. Raj Shahani (Managing Director of RA Power Solutions). He has forty-four years of experience in the field of engine repair and is a technical adviser to various shipping and heavy industries based all over the world.
For all your requirements of crack repair or repair of damage casting of cast iron, aluminium or steel casting, you may contact rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91-9582647131 or +91 9810012383.