On-Site Machining of Damaged Intermediate Shaft Journal at Kochi Port
A damaged intermediate shaft journal can affect the proper working of the bearing and may lead to further problems if not repaired correctly. One of them was RA Power Solutions' success in on-site machining of a damaged intermediate shaft journal at Kochi Port, India.
The repair was carried out on a container vessel with portable machining equipment, which avoids the need to remove and transport the entire intermediate shaft to a workshop.
Inspection of the Damaged Intermediate Shaft Journal
A team of three technicians arrived at the vessel with portable on-site grinding and polishing equipment.
Several problems were found on the bearing seating area of the intermediate propeller shaft journal during inspection. Surface cracks were seen and increased hardness and ovality of about 0.38 mm.
The intermediate shaft bearing was also burned out, and the white metal lining had been damaged and taken out. The bearing was immediately packed and sent to the RA Power Solutions factory for white metal rebabbitting to save repair time while the journal repair work continued on the vessel.
Intermediate Shaft Journal On-Site Grinding and Polishing
The damaged journal was machined with portable equipment installed directly on the vessel.
The journal diameter was reduced by 1.00 mm, from the standard 505.00 mm to a final diameter of 504.00 mm. The machining was performed with a diameter tolerance of only 0.02 mm.
The journal was ground to a surface finish of less than 15 Ra.
This on-site machining avoids the complete removal of the shaft for conventional workshop machining and can substantially cut down vessel downtime.
Bearing Machining and Re-babbitting
The damaged intermediate shaft bearing was sent to the factory for rebabbitting while the journal was being machined.
Following the white metal rebabbitting process, the bearing was accurately machined to maintain a bore size of 504.50 mm as required by the equipment manual.
The repaired bearing was then returned for assembly with the machined intermediate shaft journal.
Final Assembly & Testing
After the bearing was installed, blue matching was carried out to verify the contact between the journal and the bearing surface.
The necessary oil gap and other important assembly parameters were also carefully checked.
After the assembly was completed, trials were carried out, and the performance of the intermediate shaft and bearing was found to be satisfactory.
Why Machining the Intermediate Shaft On-Site Is Helpful
Site machining is particularly useful where it is difficult or would cause much downtime to remove and transport a large intermediate shaft.
Portable grinding and polishing equipment permits the damaged journal to be machined directly at the vessel or worksite. Depending on the condition and accessibility of the component, the repair can be carried out without dismantling the entire shaft from the vessel.
For the Kochi Port project, the damaged intermediate shaft journal was successfully repaired from 505.00 mm to 504.00 mm, followed by bearing rebabbitting, machining, blue matching, oil gap checking, and final assembly.
Conclusion
The successful repair at Kochi Port demonstrates that damaged intermediate shaft journals can be successfully restored through accurate on-site machining and polishing. Proper inspection, controlled material removal, accurate bearing machining, and final assembly checks are important to achieving reliable results.
“We also have available engine crankpin bearings in our stock.” For more information, visit now: https://rebabbittingbearing.com/
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, UNITED ARAB EMIRATES, QATAR, KUWAIT, OMAN, and Bahrain.
For information about intermediate shaft grinding, polishing, and on-site machining services, contact RA Power Solutions at rajshahani@rapowersolutions.com or info@rapowersolutions.com.
You can also call +91 9582647131 or +91 9810012383.
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Frequently Asked Questions (FAQs)
1. Can you machine an intermediate shaft journal in the field?
Yes, it is often feasible to machine a damaged intermediate shaft journal on site with portable grinding and polishing equipment.
2. How much material was taken off the journal?
In this project, 1.00 mm was removed from the original 505.00 mm diameter.
3. What was the final size of the journal?
The final machined diameter was 504.00 mm with a tolerance of 0.02 mm.
4. Can worn out white metal bearings be repaired?
"Yes, you can rebabbitt a damaged white metal bearing and then accurately machine it to size.
5. What’s the point of machining shafts on-site?
On-site machining means you can avoid dismantling, transportation, and vessel downtime as the journal is repaired directly at the worksite.
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