Wartsila 18V32LN Engine Block Metal Stitching Wartsila 18V32LN engines suffered a connecting rod...

Wartsila 18V32LN Engine Block Metal Stitching Wartsila 18V32LN engines suffered a connecting rod failure
Wartsila 18V32LN Engine Block Metal Stitching Wartsila 18V32LN engines suffered a connecting rod failure
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Transcript of Wartsila 18V32LN Engine Block Metal Stitching Wartsila 18V32LN engines suffered a connecting rod...

  • WORLDWIDE IN-SITU MACHINING SERVICES

    ENGINE BLOCK REPAIR - METAL STITCHING WARTSILA 18V32LN CEMENT PLANT – DOMINICAN REPUBLIC When reciprocating engine parts seize or break free at high speed, the results are never positive. If luck is on your side, emergency shutdown procedures can sometimes limit the damage, but when parts come loose from the engine the result is most often catastrophic.

    Such was the case for a leading cement producer in the Dominican Republic. During routine operation, one of its Wartsila 18V32LN engines suffered a connecting rod failure resulting in major damage to the engine block and the crankshaft. Collisions with the connecting rod knocked large pieces of the block free between the inspection doors and smaller pieces inside the crankcase. The casualty also resulted in significant damage to the lower liner landing surface and the engine’s crankshaft.

    Goltens thoroughly inspected the obvious damage and performed crack testing on other areas to ensure all damage was identified. Goltens assured the customer that the block was not condemned and could be repaired in place with a combination of metal stitching and in-situ machining.

    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 then measured the areas for the fabrication of cast inserts to be stitched into the block. The inserts were carefully positioned and metal stitched into place using Lock-n- Stitch tooling. With metal stitching complete, Goltens machined the stitched surfaces and performed thorough crack testing to ensure the repairs were successful.

    To repair the damage to the liner landing surface, Goltens line bored the damaged bore and installed a sleeve insert and machined it to standard diameter.

    ENGINE BLOCK REPAIR RESULTS What appeared to be a potentially condemned engine was a routine, albeit high precision and challenging, repair for Goltens experts. The block repairs were thoroughly checked and cleared before Goltens moved on to repair the damage to the engine’s crankshaft.

    PROJECT FACTS: ENGINE BLOCK REPAIR Customer: Large Cement Plant Location: Dominican Republic Engine Make/Model: Wartsila 18V32LN Year of Manufacture: 2004 Rated Output: 6,528 KW

    Inspection of exterior block damage

    Damaged section cropped from engine block

    3D Laser scan of the damaged section of the block

  • WORLDWIDE IN-SITU MACHINING SERVICES

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    187.78

    6 0.

    43

    170.71

    40.55 4

    8. 47

    4 8.

    85

    22.89

    UNLESS OTHERWISE SPECIFIED:

    CHECKED

    SIZE

    APPLICATION

    TITLE:

    PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC TOLERANCING PER:

    Q.A.

    FINISH

    DWG. NO.

    DATE

    USED ON A

    DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL

    NEXT ASSY

    MATERIAL

    NAME

    REV

    DO NOT SCALE DRAWING SCALE: 1:5

    REGION 5-1

    ENG APPR.

    THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF . ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF IS PROHIBITED.

    COMMENTS:

    DRAWN

    MFG APPR.

    SHEET 1 OF 1

    2 1

    A

    B

    A

    B

    12

    Center wall stitched in place

    Milling machine mounted for machining

    Stitching of inspection door top insert

    Finish machining of block exterior

    Finish machining of block exterior Fully repaired block exterior

    Center cast insert in place Stitching in progress Cast insert design from laser scan data