Caterpillar Engine Model 3616 | Crankshaft Repair Onsite | Crankshaft Grinding | RA Power Solutions

We received an emergency call from one of the diesel power plant installations in South America advising that their caterpillar diesel engine model 3616 has met with an accident and they are not able to operate the diesel generating set. Our two experienced technicians along with onsite crankshaft grinding machine were deputed.

DETAILS OF DIESEL POWER PLANT OF 135 MW IN SOUTH AMERICA:-

• The diesel power plant has a capacity of 135 MW and it generates power by multiple diesel generating sets which are installed on a barge.
• They have number of diesel generating sets of following make and model

1. Wartsila 12V32
2. Wartsila 18V32
3. Caterpillar 3616
4. Stork 280

• All the diesel generating sets are installed on 5 nos. of barges which are placed on a river.
• The diesel power plant caters for critical power requirement of airport, hospitals and emergency services.
• Inspection was conducted by RA Power Solutions technicians of caterpillar 3616 diesel generating set.
• Our technicians on visual inspection, inspection of the crankshaft observed the bearing material in the sump of Engine block.

THE MAJOR DETAILS OF CRANKSHAFT OF CATERPILLAR 3616 ARE AS FOLLOWING:-

• All the connecting rods were removed and inspection of crankpins was conducted by our technicians
• The Caterpillar 3616 DG& set crankpin has a standard diameter of 216.00 mm. The bearing width is of 165.00 mm.
• All the crankpin dimensions were observed within 0.02 mm except the crankpin no. 3 dimensions of which  were observed as following:-

1. Minimum diameter observed of crankpin no. 3 – 215.74 mm
2. Maximum diameter observed of crankpin no. 3 – 216.00 mm
3. Ovality observed – 0.26 mm

• On visual inspection of crankpin no. 3, the sign of bearing seizure was also observed.
• All the crankpins although dimensionally were observed to be within limits but developed rough surface, linemarks and pitting etc.

READINGS OF CRANK PINS OF CATERPILLAR 3616 DG SET BEFORE GRINDING:-

AS A MATTER OF ROUTINE INSPECTION, THE CRANKSHAFT OF CATERPILLAR 3616 WAS ALSO CHECKED FOR FOLLOWING MAJOR TECHNICAL PARAMETERS:-

• All the crankpins were subject to crack detection test by MPI and dye-penetrant test, no cracks were observed on 8 nos. of crankpin.
• The special attention was paid on crank pin no. 3 which was damaged and seized due to bearing failure, no cracks were observed on this crankpin as well.
• This was a sign of relief for our technicians.
• Hardness was checked and was observed within limits.
• Deflection of the crankshaft was checked and was observed within a specified limit.

ACTION TAKEN BY RA POWER SOLUTIONS FOR SUCCESSFUL REPAIR OF CATERPILLAR 3616 CRANKSHAFT:-

The crankpin no. 3 was ground to the undersize of 0.5 mm which is considered to be first undersize.

THE FINAL DIAMETER OF CRANKPIN WAS MAINTAINED AS FOLLOWING:-

1. Minimum diameter of crankpin no. 3 observed after grinding and polishing - 215.48 mm
2. Maximum diameter of crankpin no.3 observed after grinding and polishing - 215.49 mm
3. The maximum ovality was 0.01 mm

• The balance 7 crankpins were polished by onsite crankshaft grinding and polishing machine and their surface finish was maintained to less than 20 RA value which was again far better than international standards.
• All the important parameters were checked and final inspection reports were prepared.

READINGS AFTER GRINDING AND POLISHING ARE PASTED BELOW:-

EXTRA SERVICES EXTENDED BY RA POWER SOLUTIONS FOR SATISFACTORY PERFORMANCE OF CATERPILLAR 3616 DIESEL GENERATING SET:-

The main objective of RA Power Solutions is not only to repair the crankshaft for which we were contracted but to ensure that after repairs the engine performs satisfactory since the diesel generating set was 16 years old and operated for more than 70,000 hours, RA Power Solutions Technicians calibrated connecting rods and bearings of all 8 nos. crank pins, following was checked.

• Big end and small end of the connecting rod were thoroughly checked dimensionally for bore.
• All the connecting rods matching surfaces, bolts were subject to crack detection by MPI. To our surprise, six sets of connecting rods bolts had hairline cracks. The power plant was advised to replace the connecting rod bolts as no crack on connecting rod and bolts were admissible.
• The bearings were used and were subject to visual and bearing thickness inspection.
• All dimensions were observed within limits and it was recommended to use the same crank pin bearings as they were in a good condition.
• In case of crankpin nos 3, since it was undersized to first step size of 0.5 mm, client was requested to arrange for the undersize bearing.
• During the presence of our technicians on vessel, the diesel generating was assembled and put on full load.

We have 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, Jordan, Libya, Kuwait, Egypt, Morocco, Yemen, Bahrain, Tunisia, Sudan, Oman, Algeria, Saudi Arabia, Iraq, UAE  etc.

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 more than 40 years in the field of Power, Heavy and Shipping industry. He is Technical Adviser to many shipping and heavy industries across the globe.

Mr. Shahani is one of the most enthusiastic professional and he has all the brilliance of an exemplary leader. Mr. Shahani is an extremely effective coach and mentor of teams and is adept at providing leadership in a global, cross-cultural environment.

For more information, please email us at rajshahani@rapowersolutions.com, info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.