Metal Stitching Salvages Badly Damaged HP And LP Compressor Casings
A machinery repair specialist contacted Goltens with an urgent request for repair support on badly damaged compressor casings.
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All In-Place Machining Case Studies
MAN 6L35MC Main-Engine Crankshaft Replacement Minimizes Downtime for Chemical Tanker
Goltens was engaged to inspect the main-engine crankshaft on a 23-year-old, 11,700-dwt chemical/product tanker anticipating that the crankshaft could be salvaged with in- situ machining.
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In-Situ Laser Cladding and Machining Restores Chinese Chemical Plant to Operation
A Chinese PTA chemical plant, with 1.5 million tons of annual production, was undergoing an emergency overhaul on a large multi-axis air compressor critical to plant production. Due to the criticality of the compressor, the plant was pressing for the shortest possible completion.
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Remetalling and Machining Restore Agitator Shaft
A polyester plant in Indonesia was planning a shutdown in four weeks and suspected that the polyester reactor’s 285mm diameter agitator shaft was damaged and would require repair during the maintenance window. The maintenance window was short, and the extent of the repairs required was unknown.
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Simultaneous Machining of Crankpins Speeds Repair
During periodic maintenance, the crew of a 14-year-old, 122,000 DWT container vessel, noted excessive wear and ovality on five of the six crankpins (#2 through #6) on one of their Wartsila W6L32 auxiliary generators. Crankpin #1 had previously been machined to undersize and did not require repair. The vessel owner contacted Goltens about undertaking the further inspection and rectification of the worn crankpins.
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Steam Turbine Rotor Shaft Machining – Indonesia
Goltens received an urgent call from a power plant in the city of Gorontalo in Sulawesi. The plant’s 10MW Shandong Jinan steam turbine suffered a bearing failure resulting in a damaged rotor shaft. The power plant is a vital source of power to the city and minimizing downtime was critical.
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In-Place Metal Stitching Salvages Another Badly Damaged Engine Block
An 11-year-old container vessel suffered a major casualty on one of its Yanmar 6EY26L auxiliary engines resulting in pieces of the connecting rod breaking through the crankcase wall causing extensive damage. Knowing how operationally disruptive and exceedingly expensive a block replacement would be, the owner contacted Goltens Dubai to inspect the damage and determine if the block could be salvaged.
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Annealing And Machining Salvages Another Badly Damaged Crankshaft
Goltens was contacted by a containership operator to inspect damage on its MAN 9L 48/60 main engine crankshaft. During operation, the main engine’s connecting rod bolts gave away and caused major damage to crankpin number 4. Goltens boarded the vessel at Dubai Maritime City for inspection.
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In-Place Machining Solution Resolve Shafting Issue
A 12-year-old container ship was undergoing dry docking in China when issues with the main engine shafting were discovered. The coupling bolts for the flywheel and the intermediate shaft had elongated and been worn to an oval shape and there was 0.5mm clearance between the flywheel and intermediate shaft landing surfaces.
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Laser Cladding And Machining Salvages Slurry Pump Shaft For Mine
A mining operation suffered a major bearing seizure on the crankpin of a slurry pump shaft. The pump makers approached Goltens to explore the possibility to repair and restore the crankshaft to original diameter in our workshop.
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Time Wasted – Should Have Waited For Goltens
A recently built general cargo vessel experienced a bearing failure on its intermediate propeller shaft bearing. Goltens was contacted to perform an inspection on the bearing shell and pedestal and to propose a solution. Upon inspection it was determined that the entire housing would require repair, due to extensive damage on the bearings, sealing areas, and housing mating surfaces.
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Shaft Seal Liner Removal for the USNS Red Cloud
INSPECTION AND WORK SCOPE Goltens determined that the shaft seal liner could be removed from the shaft but due to the short space between the shaft and shaft housing, special tooling and brackets would have to be fabricated at Goltens …
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General Electric 7LM6000 Gas Turbine Powerplant Repair in Palembang, Indonesia
Once the gearbox was moved to a safe work area and the gears were secured, Goltens machined the damaged areas on the gear to ready the surface for repair. Technicians then applied selective electroplating to the damaged gear teeth using …
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Welding and On Site Machining Restores Badly Worn Rudder Stock
PRE-MACHINING Goltens fabricated custom machining rings for installation and machining of the rudder stock. In-Situ specialists mounted carried out an initial removal of 10.00 mm off the diameter to create a reference point for the machining of the running surface. …
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High-precision In-place Machining on Stern Tube Housing
After preliminary meetings and discussions on the tolerances of the bush and tube Goltens proposed a combination of on-site and workshop efforts to complete the work. ON-SITE WORKSCOPE Port and Stbd. Bore alignment laser checks In-situ line boring of Port …
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Fast Response and Expert Repair on EDBG Avoids Shutdown for US Nuclear Plant
THE INSPECTION Goltens got the call on Sunday and engineers were on site the next day to evaluate the condition of the shaft and identify a repair method for the damage on the EDBG. Goltens undertook an inspection of main …
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Engine Block Repair – Metal Stitching Wartsila 18V32LN
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 …
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Slip Ring In-Place Machining Returns Coal Fired Steam Turbine To Service
THE RESULT The entire repair was completed inside of 5 days onsite inclusive of waiting and staging. Both sets of slip rings were machined to a surface finish of 1.0Ra in accordance with the manufacturer’s specifications and the turbine generator …
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In-place Machining Minimizes Cost and Downtime for Tanker Engine Repair
PROJECT FACTS Description: MAN B&W HUYNDAI 7L23/30H Location: Portugal – US (under voyage)
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In-place machining of steam turbine rotor shaft in four days
TURBINE ROTOR SHAFT REPAIR SCOPE Complete inspection of the rotor shaft including hardness checks, MPI, measurement etc Machining of journal radius/fillets Machining of the shaft journal to undersize 1.00mm Honing and polishing of rotor shaft journal Fabrication of bluing dummy …
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In-situ laser cladding & machining for Shanghai steam plant
Read about how Goltens executed a detailed solution using its traditional in-place machining coupled with a low surface temperature laser cladding technology. To prove out the viability of the proposed repair, the repair process was tested on a scrap valve in …
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In-place machining and major maintenance service – Wartsila 18V50DF
IN-PLACE MACHINING AND ANNEALING After the tender was awarded, Goltens in-place machinists first machined the crankpin to -4.5mm to remove all surface cracks leaving a hard spot 250mm x 120mm. Goltens then performed the annealing process and reduced the crankshaft …
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Fast response and comprehensive repair for Arizona nuclear power plant
THE INSPECTION AND THE PROPOSAL During the inspection, Goltens learned that the engine had suffered the same casualty on the same cylinders 30 years earlier. The block had significant damage to the crankcase near the doors, liner landings and the …
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Turning up the heat in Cameroon
INSPECTION AND REPAIR PLANNING Goltens diesel experts were asked to inspect the damage and determined that the crankshaft could be salvaged within the rated diameter with in-situ machining and annealing. Crankpin journal number 7 (450mm diameter) and main journals number …
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BioWAVE in-situ machining
THE BIOWAVE™: The bioWAVE™ ( http://www.biopowersystems.com/ ) is being developed for utility-scale power production from ocean waves. Its nature-inspired design (biomimicry) combines high conversion efficiency with the ability to avoid excessive wave forces, enabling supply of grid-connected electricity at a …
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