Cast Iron Repair | Broken Engine Block | Metal Stitching Engine Block - RA Power Solutions

by RA Power Solutions RA power solution

RA Power Solutions was called by a client based in 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-

1) Inspection of engine block/entablature of Wartsila engine model 12V32.
2) On a visual inspection by our technicians, it was observed that the engine block developed multiple cracks near the inspection window.
3) A piece measuring 590 mm X 360 mm was damaged from the entablature casting and came out.
4) Our qualified technicians cleaned the surface area thoroughly, even the paint and the red oxide was removed.
5) The MPI was done for crack detection and all the cracks were clearly identified.
6) The measurement of broken casting was also taken.
The measurement of broken casting was also taken.

The details of crack observed is as following:-

Multiple cracks having length ranging from 20 mm to 430 mm was observed.
The discipline profile to the damaged portion of Wartsila engine block was given by cutting and grinding the final dimensions of which was observed as 660 mm X 396 mm.

Non-availability of Wartsila 12V32 engine block

The 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 defect 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 Solutions 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 repair of the engine block which is manufactured out of cast iron by welding process. Cast iron contains a high level of carbon which burns when the repair of casting is undertaken by 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 significant loss of the centerline of 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/ 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, steel cast components.

Different types of specially designed screws and locks are used in crack and damaged casting repair in metal stitching and metal locking process. The multiple cracks as per the details mentioned above were repaired by 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 satisfactory. This job of repair of Wartsila engine block/ entablature of 12V32 was executed in Year 2013 and since then it is performing satisfactory. The client has not only saved a considerable amount by avoiding the purchase of new engine block but also saved on downtime as they are into the business of power generation for the islands based in Maldives.

RA Power Solutions have a dedicated team of experienced technicians headed by engineer with more than 35 years of experience in 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 within a short notice. The portable, light-weighted pneumatic tools are carried by them as an accompanied baggage. We have been regularly executing the repairs in Madagascar, Oman, Qatar, Philippines, Bahrain, Srilanka, 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.

Content source:

https://metalstitchinglocking.com/blog-details.php?blogname=Cast-Iron-Repair-Broken-Engine-Block-Metal-Stitching-Engine-Block-RA-Power-Solutions