A polyester plant in Indonesia was planning a shutdown in four weeks and suspected that the polyester reactor’s 285mm diameter agitator shaft was damaged and would require repair during the maintenance window. The maintenance window was short, and the extent of the repairs required was unknown.
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During periodic maintenance, the crew of a 14-year-old, 122,000 DWT container vessel, noted excessive wear and ovality on five of the six crankpins (#2 through #6) on one of their Wartsila W6L32 auxiliary generators. Crankpin #1 had previously been machined to undersize and did not require repair. The vessel owner contacted Goltens about undertaking the further inspection and rectification of the worn crankpins.
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Goltens received an urgent call from a power plant in the city of Gorontalo in Sulawesi. The plant’s 10MW Shandong Jinan steam turbine suffered a bearing failure resulting in a damaged rotor shaft. The power plant is a vital source of power to the city and minimizing downtime was critical.
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Goltens was contacted by a containership operator to inspect damage on its MAN 9L 48/60 main engine crankshaft. During operation, the main engine’s connecting rod bolts gave away and caused major damage to crankpin number 4. Goltens boarded the vessel at Dubai Maritime City for inspection.
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A mining operation suffered a major bearing seizure on the crankpin of a slurry pump shaft. The pump makers approached Goltens to explore the possibility to repair and restore the crankshaft to original diameter in our workshop.
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A recently built general cargo vessel experienced a bearing failure on its intermediate propeller shaft bearing. Goltens was contacted to perform an inspection on the bearing shell and pedestal and to propose a solution. Upon inspection it was determined that the entire housing would require repair, due to extensive damage on the bearings, sealing areas, and housing mating surfaces.
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PRE-MACHINING Goltens fabricated custom machining rings for installation and machining of the rudder stock. In-Situ specialists mounted carried out an initial removal of 10.00 mm off the diameter to create a reference point for the machining of the running surface. …
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THE INSPECTION Goltens got the call on Sunday and engineers were on site the next day to evaluate the condition of the shaft and identify a repair method for the damage on the EDBG. Goltens undertook an inspection of main …
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WARTSILA 18V32LN ENGINE BLOCK REPAIR Goltens performed laser scanning on the damaged areas to facilitate the casting of precise inserts for the block. Goltens cropped the damaged interior and exterior sections of the engine to ensure clean mating surfaces and …
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TURBINE ROTOR SHAFT REPAIR SCOPE Complete inspection of the rotor shaft including hardness checks, MPI, measurement etc Machining of journal radius/fillets Machining of the shaft journal to undersize 1.00mm Honing and polishing of rotor shaft journal Fabrication of bluing dummy …
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IN-PLACE MACHINING AND ANNEALING After the tender was awarded, Goltens in-place machinists first machined the crankpin to -4.5mm to remove all surface cracks leaving a hard spot 250mm x 120mm. Goltens then performed the annealing process and reduced the crankshaft …
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THE INSPECTION AND THE PROPOSAL During the inspection, Goltens learned that the engine had suffered the same casualty on the same cylinders 30 years earlier. The block had significant damage to the crankcase near the doors, liner landings and the …
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INSPECTION AND REPAIR PLANNING Goltens diesel experts were asked to inspect the damage and determined that the crankshaft could be salvaged within the rated diameter with in-situ machining and annealing. Crankpin journal number 7 (450mm diameter) and main journals number …
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Goltens was called to answer these questions, when this nightmare turned reality aboard a 34-year-old rail vehicles carrier. Goltens specialists surveyed the engine and discovered, in addition to the large hole in the engine block, damage to the lower liner-landing …
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DANGEROUSLY CLOSE TO THE LIMIT The owner opted to go with a competitor and allowed them to machine more than 5.00mm, dangerously close to the 6.00mm limit, from the 600.00mm crankshaft diameter. With less than half a millimeter remaining within …
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PROJECT FACTS Rudderstock Machining Location: Bahamas Vessel Type: Cruise Ship Journal Diameter: 870mm Journal Length: 1,115mm Material Removed: 0.80mm Machining Time: 5 days ON-SITE MACHINING SCOPE Single point cutting/machining of damaged rudderstock removing 0.80mm from the diameter for a finished …
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PROJECT FACTS COLT PIELSTICK PC 2.5V16 Location: San Diego, CA USA Max Hardness Pre-Annealing: 580HB Max Hardness Post-Annealing: 333HB Original Main Journal Diameter: 330.00mm Finished Diameter: 327.00mm (-3.00mm) Thrust Face Machining: -1.00mm (fore/aft) COLT PIELSTICK 2.5 V16 ANNEALING AND MACHINING …
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PROJECT FACTS MV BEAGLE VI Engine Make/Model: Mitsui B&W 5L42MC Engine output: 4983 KW RPM: 176 RMP Original Diameter: 472mm Post Machining Diameter: 466mm Work Location: Kaohsiung – Taiwan IN-PLACE MACHINING SCOPE: Inspection of damaged Engine and Crankshaft including: In …
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PROJECT FACTS PIELSTICK 14PC2.5 V400 Customer: Royal Saudi Naval Forces (RSNF) Engine output: 5,400 kW (13,200 HP) Position: Port Side Main Engine Type of Repair: In Situ Crankshaft Machining, Main Bearing Cap Repair & Engine Overhaul PIELSTICK 14PC2.5 REPAIR SCOPE: …
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PROJECT FACTS COAL/BIOMASS STATION Station Output: 585 MW Shaft Diameter (Pre-Machining): 530 mm Shaft Diameter (Post-Repair): 528.5mm (-1.5mm) Finished surface roughness: 0.2 Ra Repair Time: 4 Days STEAM TURBINE REPAIRS CONSISTED OF: Inspection of the damaged shaft Installation of machining …
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TURBINE SHAFT INSPECTION Once SEC had disassembled the engine and placed the rotor in the stand, Goltens inspected the shaft damage on the compressor and exhaust bearing journals. Goltens visually inspected and calibrated the shaft, performed MPI crack tests and …
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OBSERVATIONS DURING INSPECTION Bearing and sealing area observed to have significant surface scoring Max hardness levels of 334 HB (some areas could not be measured due to deep scoring marks) Magna Flux testing revealed no surface cracks PROJECT FACTS SEC …
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PROJECT FACTS WARTSILA 6L46C CRANKSHAFT Crankpin #2 hardness pre/post: 647HB/380HB Original diameter Crankpin #2: 450.00mm 450.00mm 447.00mm IN-SITU MACHINING REPAIRS Magnaflux and hardness checks on all crankpins Pre-annealing machining of crankpin #1 to 449.0mm to remove surface cracks Local grinding …
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Based on the In-Situ machining experience and expertise gained over the last 60 years in the Goltens group of companies, Goltens made a proposal for repair of the damaged 539mm diameter main journals In-Site. According to the maker, such on-site …
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Demonstration of annealing process Mitsubishi invited Goltens to demonstrate its annealing process on a crankshaft that had been intentionally hardened for the demonstration in its factory in Yokohama, Japan. Goltens technicians traveled to the factory and, following its GL-approved process, …
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