Excerpt from an email from the attending Superintendent of the customer to his office, after completion of the work:
Project Overview
QuantiServ recently undertook a challenging and comprehensive repair project on a 46-bore main engine installed on a 12,000 DWT container vessel. The ten-year-old vessel had sustained significant damage to both the crankshaft and engine block. Our team of three highly skilled specialists carried out the repair work in the Caribbean, ensuring the engine was restored to optimal condition and performance.
The entire repair took eight weeks, from start to finish.
Inspection and Proposal
Upon arrival, our team conducted a thorough inspection of the damaged engine components. The inspection revealed extensive damage, necessitating a detailed and precise repair plan. We promptly submitted a comprehensive repair proposal to the vessel’s owner and the classification society. Once the proposal received approval, we commenced the repair work, which included several critical tasks to address the damage.
Whenever we face larger damages, we usually use a 3D scanner to scan the components to be repaired. The highly detailed and accurate geometrical data thus acquired offers numerous advantages. Not only does it accelerate the repair process because it eliminates time consuming manual measurements, it also helps to create very detailed and precise repair castings.
Engine Block Repair
Damage Sustained:
- Crankcase door damage on both starboard (SB) and port side (PS)
- Cam floors damaged on both sides
- Various additional cracks in the crankcase
Repair Details:
- Total length of cracks/junctions stitched: approximately 6 meters
- Number of stitching pins installed: Approximately 1’000 pieces
- Number of tailor-made repair inserts installed: 8 (with the larger inserts casted in a classification-approved foundry and shipped to the vessel prior to commencement of the on-site repair)
- Pre-fabricated sleeve installed in the lower cylinder liner guide
- In-situ line boring and installation of sleeves in two camshaft pockets that were found out of line due to the accident
Our specialists meticulously stitched the cracks and installed the necessary inserts, ensuring the structural integrity of the engine block was fully restored. The use of about 1’000 Castmaster C3 stitching pins and eight custom-cast inserts highlights the extent and complexity required for this repair.
Crankshaft Repair
Damage Sustained:
- Extensive mechanical damage to one crank pin
- Connecting rod, big end bearing housing thrown out of the engine block
- Both counter weights thrown out of the engine block, studs sheared off
- Deep indents in the crankpin surface
- Long cracks, easily visible by naked eye
Repair Details:
- Damaged crankpin machined to undersize
- Landing surfaces of counterweights milled
- Counterweight fastening bolt stubs removed
The crankshaft repair involved machining one crankpin to an undersize diameter and installing a pre-fabricated sleeve in the lower liner guide. These steps were crucial in restoring the crankshaft’s functionality and ensuring the engine’s smooth operation.
Customer Feedback
The customer expressed immense satisfaction with the repair results. The attending superintendent conveyed his positive feedback to his management, highlighting the professionalism and expertise demonstrated by the QuantiServ team. He recommended QuantiServ for future repairs on the company’s vessels, underscoring the trust and confidence our services have earned.
At QuantiServ, we pride ourselves on delivering high-quality, reliable repair services that meet and exceed our customers’ expectations. This project is a testament to our commitment to excellence, precision, and customer satisfaction. We look forward to continuing to provide top-tier repair solutions for the maritime industry.
Follow these links for more information about our in-situ and metal stitching services.
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How can realignment wartsila engine W18V38B
That can of course be done, plesae send an email to info@quantiserv.com