In December 2024, RA Power Solutions successfully repaired a Himsen Hyundai 6H17/28 crankshaft on a vessel anchored at MIP Mersin, Turkey. The Italian-owned ship experienced a major breakdown in one of its auxiliary engines due to lubricating oil pump failure, which damaged all connecting rod bearings. Upon inspection, technicians found bearing material embedded in all six crankpins, with taper and ovality measurements ranging from 0.22 mm to 0.86 mm. Technicians also detected minor hairline cracks. Using in situ crankshaft grinding equipment, the team reduced the diameters of the crankpins by 1.00 mm to 1.50 mm, restoring them to operational standards.

Therefore, this case clearly highlights why in-situ crankshaft grinding and on-site crankshaft repair services continue to be the preferred choice for shipowners and marine engineers, especially when they are facing unexpected engine breakdowns.

Why This Repair Was Critical

Initially, the auxiliary engine’s lubricating oil pump failed, which consequently caused extensive damage to the connecting rod bearings. As a result, bearing material was found embedded in all six crankpins, ultimately leading to significant taper and ovality beyond acceptable limits.

Without timely intervention, this damage could have led to further engine failure, extended downtime, costly workshop overhauls, or even disassembly of the entire engine block — all of which are highly disruptive and expensive for commercial vessels.

On-Site Crankshaft Grinding: How It Works

Insitu crankshaft grinding uses state-of-the-art portable grinding machines that are brought directly to the vessel. Technicians perform precision grinding and polishing of crankpins and journals without the need to remove the crankshaft.

Key benefits include:

• Fast turnaround and reduced vessel downtime
• No dismantling or transportation of the crankshaft
• Restoration of OEM-compliant dimensional tolerances
• Minimal interruption to vessel operations
• Cost-competitive compared to workshop repairs

These advantages make onsite machining one of the most efficient marine crankshaft repair solutions in the industry.

Before vs After: Dimensional Accuracy Restored

Before repair, crankpin taper and ovality ranged from 0.22 mm up to 0.86 mm, exceeding acceptable engine standards and risking further mechanical issues.

After precise in-situ grinding:

• Three crankpins were ground to a diameter of 174.00 mm
• Three additional crankpins were ground to 173.50 mm
• Final measurements had ovality within 0.02 mm, meeting strict OEM tolerances and ensuring long-term reliability.

This precise dimensional restoration demonstrates the accuracy of insitu crankshaft grinding technology.

Global On-Site Crankshaft Repair Capabilities

RA Power Solutions provides onsite crankshaft grinding and heavy engine repair services worldwide — from Turkey to the Middle East, South Asia, Africa, and beyond. Their teams are ready to respond quickly and efficiently, minimizing operational disruptions for shipping companies everywhere.

For a comprehensive overview of a similar repair, check out our latest blog post: Himsen Hyundai 6H17/28 Crankshaft Repair in Turkey.

For more information regarding crankshaft grinding services, onsite insitu crankshaft repair, crankshaft grinding and repair, grinding of onsite crankshaft repair, insitu crankshaft grinding repair, grinding of crankshaft onsite please contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com or call us at +91 9582647131 or +91 9810012383.

FAQs

What is Onsite Crankshaft Grinding?

Onsite crankshaft grinding is a specialized process of repairing damaged or worn crankshafts without removing them from the engine block. Instead of sending the engine or crankshaft to a distant workshop, technicians bring portable equipment directly to the engine’s location—be it on a ship, power plant, or remote industrial site.

This method uses state-of-the-art orbital grinding tools that ensure the crankshaft journals are repaired with micron-level precision while the crankshaft remains in situ.

Importance of Crankshaft Integrity in Marine and Industrial Engines

Crankshafts are the backbone of large diesel engines. They convert linear piston motion into rotational energy, powering everything from cargo vessels to power plants. When a crankshaft gets damaged, it directly affects engine balance, efficiency, and safety.

Effects of Crankshaft Damage

• Loss of engine power
• Vibration and misalignment
• Increased fuel consumption
• Risk of catastrophic engine failure

Common Causes of Crankshaft Wear

• Oil starvation
• Bearing failure
• Overloading
• Misalignment
• Material fatigue over time

Traditional Workshop Repair vs. Onsite Grinding

Limitations of Workshop Repairs

• Disassembly and reassembly risks
• High logistical costs for large engine parts
• Longer downtime due to transport and scheduling
• Potential exposure to environmental elements during transit

Cost and Time Benefits of Onsite Grinding

• Up to 70% time is saved by avoiding disassembly
• Huge reduction in transportation and crane charges
• Same precision as in controlled workshop environments

Seven Powerful Benefits of Onsite Crankshaft Grinding

1. Minimizes Downtime—Time is money, especially in industries like shipping and power generation. Onsite grinding cuts downtime drastically by eliminating disassembly, transport, and reinstallation.
2. Reduces Transportation Costs—Moving a large marine engine crankshaft can cost thousands of dollars. Onsite services eliminate this cost.
3. High-Precision Repair Onboard—With orbital grinding technology and laser alignment tools, onsite grinding achieves tolerances as low as 10 microns—comparable to workshop standards.
4. Environmentally Friendly Operations—No fuel-intensive transport or waste-producing disassembly means a significantly lower carbon footprint.
5. Restores Original Crankshaft Parameters—Advanced grinding tools restore crankpins and main journals to original diameters and surface finishes.
6. Avoids Risk of Engine Reassembly Errors—Every time an engine is dismantled and reassembled, there’s a risk of human error. Onsite repair eliminates this risk.
7. Enables Emergency Repairs in Remote Locations—Onsite services can be deployed anywhere in the world, including offshore rigs or remote deserts, minimizing mission-critical downtimes.

Technologies and Tools Used in Onsite Grinding

• Portable crankshaft grinding machines
• Non-contact micrometers
• Vibration analyzers
• Hardness testers
• Surface finish comparators
• Alignment lasers

These tools ensure the job meets OEM standards regardless of the location

Step-by-Step Process of Onsite Crankshaft Grinding

1. Initial Inspection
2. Hardness & Crack Detection
3. Journal Alignment Check
4. Setup of Portable Equipment
5. Orbital Grinding Execution
6. Surface Finish Measurement
7. Final Alignment and Calibration

E-E-A-T in Crankshaft Grinding Services

Google’s E-E-A-T (Experience, Expertise, Authoritativeness, and Trustworthiness) applies here too. High-quality crankshaft service providers should demonstrate:

Experience: Decades of fieldwork on varied engines

Expertise: Skilled technicians trained by OEMs

Authoritativeness: ISO/ABS certifications

Trustworthiness: Transparent reports, case studies, and client reviews

Conclusion

Insitu crankshaft grinding isn’t just a convenient service— it’s a game-changer for marine and industrial engines. It combines cost efficiency, precision, and speed, especially when downtime isn’t an option. Choosing the right service provider ensures your engine is back to work with OEM-grade performance, without ever leaving its location.

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