Diesel Engine Component Reclamation

Click for Larger Image

Marine Engine Turbocharger – Cast Iron

This marine engine turbocharger casing was brought to us after an attempted weld repair by a third party had failed to seal properly. Our advice was that such a method of repair was incorrect and susceptible to failure. Our customer asked how we could demonstrate the weld and the method of repair was weak and would not hold. We hit it with a hammer and the welded insert fell to the floor.

We effected the new repair by installing a very sturdy insert. This saved the customer several hundreds of thousands of dollars not to mention the downtime costs that would have resulted in catastrophic failure when the weld let go during engine operation.

Click for Larger Image

Marine Diesel Engine – Cast Steel – Cylinder Cover

The 900 mm diameter cylinder covers are off a large, slow speed, marine diesel engine that was developing cracks on the walls near the opening. These cracks were successfully repaired while applying a relative small amount of heat in order not to introduce distortion to the cylinder cover. Furthermore, the cylinder cover was modified to strengthen this recurring problem. Numerous cylinder covers were modified and certified by Lloyds.

Click for Larger Image

Turbocharger Casing – Cast Iron

The turbocharger casing was eroded by the air flow and grit. In assessing a repair method, part of the process often involves understanding the operating environment of that item to make the correct decision in regard to the repair procedure. This casing was welded and machined back to the original dimensions. A more frequent repair for these turbocharger casings is in the labyrinth seal bore where the bore is re-sleeved and re-machined back to original specification.

Exhaust Click for Larger Image

Valve – Marine Diesel Engine

For the large marine engines the exhaust valve and the valve seat insert are refurbished and not replaced due to the high replacement costs. The exhaust valve shown has a 400mm diameter and is approximately 2 metres in length.

The repair material is Stellite No. 6. The old Stellite is removed by machining, then re-placed by weld overlay followed by finish machining. The Stellite achieves a hardness of 47 Rockwell in the workshop and then very quickly work hardens during operation to offer good wear and abrasive properties. Stellite No.6 is commonly used in the marine, petrochemical, marine and pressure valve industries

Click for Larger Image

Marine Diesel Engine – Entablature Damage

The severe damage shown on the entablature was off a marine diesel engine where the con rod failed causing significant damage to one cell but did not damage the crankshaft. The entablature was put back together using metal stitching without introducing heat into the casting to permit any distortion to take place. The entablature was repaired, the engine re-assembled and put back into service without any power limitations.