Cast Iron Repair | Broken Engine Block by Metal Stitching

A client based in the Maldives contacted RA Power Solutions to inspect a Wärtsilä 12V32 engine block that had suffered severe damage in an accident.

RA Power Solutions technicians visited the island and undertook the inspection as per the following details:

• Our technicians inspected the engine block/entablature of the Wärtsilä 12V32 engine.
• During the visual inspection, they found multiple cracks around the inspection window of the engine block.
• A 590 mm × 360 mm section of the entablature casting had broken away completely.
• Our qualified technicians thoroughly cleaned the affected area and removed all paint and red oxide to expose the damaged casting.
• They performed Magnetic Particle Inspection (MPI) to detect and identify all cracks in the affected area.
• Our technicians also measured the broken casting section to determine the extent of the damage and plan the repair accurately.

The details of the crack observed are as follows: –

• Our technicians identified multiple cracks ranging from 20 mm to 430 mm in length across the damaged area.
• Our technicians restored the profile of the damaged section of the Wärtsilä engine block by cutting and grinding the area to the required final dimensions of 660 mm × 396 mm.

Repairing a Damaged Wärtsilä 12V32 Engine Block When a Replacement Was Unavailable

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.

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.

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 that welding the cast-iron engine block would be difficult. The high carbon content in cast iron can burn during welding, making the repair more challenging and increasing the risk of further damage to the casting.

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 significant loss of the centreline of the main journal housings of the block due to stress and contraction, which is of great importance.

Repair of the Wartsila 12V32 engine block by metal stitching and metal locking process

The repair of engine block and entablature of the Wartsila engine model 12V32 was undertaken by the metal stitching and metal locking process, which is a proven cold repair method for repairing heavy cast iron casting, aluminium casting, broken engine blocks and steel cast components.

Engineers use specially designed screws, keys, and locks to repair cracks and damaged castings through the metal stitching and metal locking process.

Our technicians repaired all the cracks identified in the Wärtsilä 12V32 engine block using the metal stitching process. They also prepared and fitted a new section of casting to replace the broken portion of the engine block and securely metal-stitched it to the existing casting.

After completing the metal locking and metal stitching repairs, the team commissioned the engine and placed it under load. The engine performed satisfactorily during the load test.

RA Power Solutions completed this Wärtsilä 12V32 engine block/entablature repair in 2013, and the engine has continued to perform satisfactorily since the repair.

The repair enabled the client to avoid purchasing a replacement engine block, resulting in substantial cost savings. It also significantly reduced downtime, which was particularly important because the client operates a power-generation facility serving islands in the Maldives.

RA Power has a dedicated team of experienced technicians headed by an engineer with over 47 years of experience in the repair of cracks in cast iron, aluminium cast steel, and steel casting by metal stitching and metal locking.

Global Onsite Cast Iron Crack Repair Services

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.

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.