How Onsite Crankshaft Repair Restored a MAN 8L28/32H Engine at a Power Plant in Sudan
A power plant in Sudan had problems with the crankshaft on its MAN 8L28/32H diesel engine. They needed a safe way to repair it right away to avoid long periods of downtime. After a technical evaluation, the repair was given to RA Power Solutions because it has more than 47 years of experience in onsite crankshaft repair, in situ crankshaft repair, and in situ crankshaft grinding for marine and power plant engines. The goal was to quickly and correctly restore the crankshaft at the installation site while staying within the OEM's recommended tolerances and causing as little trouble as possible to the plant's operations.
After reviewing the client's inspection report and damage assessment, the engineering team at RA Power Solutions designed a customised in situ crankshaft repair plan for the MAN 8L28/32H engine. To ensure the repair could begin without delay, specialized tooling was manufactured specifically for this application before mobilization. A team of two experienced field engineers was then deployed to the power plant in Sudan with a portable onsite crankshaft grinding machine, precision measuring instruments, and inspection equipment. This thorough preparation enabled the complete repair to be performed directly at the installation site, eliminating unnecessary delays and helping the power plant return the engine to service as quickly as possible.
Crankpin Grinding Details—MAN 8L28/32H Engine
Inspection and Assessment Before Repair
Before commencing in situ crankshaft grinding, all crankpins were carefully inspected to measure wear, taper, and ovality. The inspection confirmed that crankpins No. 1, No. 5, and No. 7 had worn beyond the permissible limits, making the grinding of these damaged crankpins necessary.
Pre-Repair Measurements
CR-1: 229.81 mm, Ovality: 0.19 mm
CR-5: 229.90 mm, Ovality: 0.10 mm
CR-7: 229.93 mm, Ovality: 0.07 mm
Based on these measurements, the engineering team finalized the in situ crankshaft repair procedure to restore the crankshaft to OEM-recommended tolerances.
Repair Process Executed on MAN 8L28/32H Crankshaft | Power Plant | Sudan
The following repair procedures were executed onsite with strict adherence to OEM tolerances:
Precision grinding of damaged crankpins #01, #05, and #07 to the recommended undersize
Polishing of crankpin No. #08 to achieve the specified surface finish
Continuous dimensional monitoring during machining to ensure accuracy and consistency
Final inspection to confirm surface integrity and bearing compatibility
Final Dimensions After Repair | MAN 8L28/32H Crankshaft
After completion of grinding and polishing, the crankpins achieved excellent dimensional accuracy and surface finish.
Final Diameter Range: 229.48 mm to 229.50 mm
Achieved Ovality: Within 0.02 mm (well within acceptable limits)
This ensured proper bearing fitment, uniform load distribution, and long-term operational reliability of the engine.
Crankpin Size Measurements After Repair – MAN 8L28/32H Engine
The engine was reassembled and recommissioned without removing the crankshaft from the engine block after the successful onsite crankshaft repair. The project was finished on time, minimizing downtime and repair expenses while returning the engine to dependable operating condition.
RA Power Solutions specializes in onsite crankshaft grinding, repair, crankshaft grinding machines, and refurbishment for marine engines and power plant engines worldwide. Our proven expertise with MAN engines, advanced portable equipment, and highly experienced technicians allows us to deliver reliable and efficient solutions even under challenging site conditions.
We provide crankshaft grinding, in-situ crankshaft grinding, onsite crankpin polishing, damaged engine repair, and worldwide crankpin repair services, covering major industries and engine applications across SAUDI ARABIA, the UNITED ARAB EMIRATES, QATAR, KUWAIT, IRAN, IRAQ, and Turkey.
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For more information on onsite crankshaft repair, grinding of crankshafts, and crankshaft polishing, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.
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