In-Situ machining restores El Salvador powerplant diesel generator
Wartsila Vasa 18V32 piston failure
Nejapa Power, a powerplant in El Salvador suffered a major casualty to one of its Wartsila VASA 18V32 generators. As a result of a piston failure, the generator suffered a broken counterweight, sheared counterweight bolts, badly damaged crankpin bearings, a damaged crankpin journal and damaged fillet radii along with damage to other engine components.
Goltens inspected the damage and proposed an in-situ machining process to restore the crankshaft to operational status and get the generator back up operational without removing it from the engine. Goltens mobilized its in-situ specialists and tooling to the powerplant and undertook the multi-phase repair to restore the badly damaged generator.
Damaged crankpin journal
Damaged Bearing shells
Machining fillet radii
Machining of crankpin journal
Machining of counterweight mating surfaces
Completed crankpin journal
IN-SITU MACHINING PROJECT FACTS
| Engine: | Vasa 18V32 |
| Engine Output: | 5,800kW |
| RPM: | 720 RPM |
| Original Crankpin Diameter: | 269.00 mm |
| Finished Crankpin Diameter: | 267.00 mm |
| Distance between Webs: | 210.00mm |
WARTSILA CRANKSHAFT REPAIRS
- Machining new fillet radii
- Machining and superpolishing crankpin journal #6 to – 3.00mm undersize with finish <0.2Ra
- Removal of sheared counterweight bolts
- Fabrication of a custom jig and surface machining of counterweight mating surface on crankshaft
RESULTS
Goltens’ in-situ machining efforts avoided the cost and downtime that would have been required to disassemble and transport the damaged crankshaft to a workshop for repair as well as the cost and downtime associated with the generator rebuild. CUSTOMER TESTIMONIAL: “We would like to remark professionalism shown by Goltens Technical Personnel throughout the repair process complying our safety & technical standards. Engine Crank Pin repair performed by Goltens has exceeded our expectations, positioning your company as a key provider for our business.” -ROBERTO MARTINEZ PERLA Maintenance Manager – Nejapa Power Plant
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