INJEGOV has just concluded a contract with a power utility for the major overhaul of four Wartsila 18V32 gensets.
Due to the critical role of the plant, works were executed under tight deadlines, which were met by our team of experienced engineers. Except for our technical expertise, our project management know-how proved valuable for the project to stay on time and within budget. Although our customers faced significant delays in the supply of spare parts required for the job, our vast experience in the field allowed us to provide guidance on how we could work around them.
Wartsila 18V32 genset major overhaul work done:
PROJECT IN NUMBERS
- 72 Cylinder Heads
- 72 Cylinder Liners
- 72 Pistons
- 72 Fuel Pumps
- 16 Coolers & Heat exchangers
- 4 Speed Governors
- 38 Main Bearings
- Crankshaft inspection
INJEGOV’s technical expertise and project management know-how proved valuable for the project to stay on time and within budget.
Wartsila cylinder liners reconditioning
Cylinder liners must be maintained strictly under manufacturer specifications. Upon receiving the cylinder liners in our workshop, we proceeded with chemical cleaning, optical and dimensional inspection, and honing using our top-quality Chris Marine honing machine. After cylinder honing work completion, final measurements and optical inspections were conducted to ensure proper surface quality and roughness under the makers’ guidelines. Final reports were submitted to the client. Finally, the Wartsila cylinder liners were installed back on the engine.
Cylinder liner honing with Chris Marine
Wartsila cylinder liner honing
Wartsila cylinder liners after honing ready for re-installation
Wartsila 18V32 cylinder liners upon receival to our mechanical workshop
Wartsila Fuel Pumps reconditioning
The excellent condition of the fuel injection system, in general, and the fuel pumps, in particular, is very important for the efficient operation of diesel engines.
We completed disassembling and chemical cleaning upon receiving the fuel injection system components. After cleaning, we inspected the components to identify any signs of wear. Finally, the components were adjusted as per maker’s recommendations. After renewing the worn fuel injection system spare parts with new ones and adjustments per makers’ guidelines, we reinstalled them back on the engine.
Dissmanded Wartsila fuel pump parts after cleaning and inspection
Wartsila complete fuel pump before dismantling and cleaning
Wartsila Fuel pump body ready for assembly
Wartsila fuel pump roller upon receipt
Wartsila Fuel pump rollers upon receival
Wartsila Pistons reconditioning
To begin, we completed the disassembly after receiving the four-stroke pistons in our workshop facilities. After completing chemical cleaning and decarbonization, our experts marked the spares with unique reference numbers to ensure traceability.
Following non-destructive testing, dimensional inspection, and reassembly with new spare parts, as per maker’s guidelines. After that, we assembled following the manufacturer’s procedures and specifications.
Ultimately, our team installed the fully reconditioned pistons on the Wartsila 18V32 engine. A complete inspection report was produced and sent to our customer.
Wartsila piston skirts NDT testing
Wartsila Piston disassembly before cleaning
Wartsila Pistons ready for shipping
Wartsila Pistons after reconditioning
Complete piston with connecting rod and piston skirts upon receival
Coolers & Heat exchangers reconditioning
Upon receiving the components in our workshop, we proceeded with dismantling and chemical cleaning of coolers. According to maker’s guidelines, we completed pressure tests to ensure tight operation after the renewal of spare parts (gaskets, o-rings, packings, etc.).
Air cooler after reconditioning
Air cooler before reconditioning
Air cooler upon receival
Air coolers after reconditioning
Wartsila crankshaft inspection
On-site inspection (optical and dimensional), measurements, on-site cleaning, and polishing.
Crankshaft polishing
Connecting rod assembly on crankshaft
Crankshaft after polishing and Connecting rod assembly on crankshaft
Connecting rod assembled on Wartsila crankshaft
Various Pumps overhauling
Upon receiving the components in our workshop, we dismantled and chemically cleaned the pumps. After the renewal of spare parts as per maker’s guidelines, we completed pressure tests to ensure tight operation.
Oil pump upon receival
Overhauled pumps ready for installation
Overhauled water pumps ready for installation
Water pump disassembly for inspection
Wartsila 18V32 genset major overhaul summary
In conclusion, we offered comprehensive assistance to our clients throughout the entire duration of the Wartsila 18V32 major overhaul project. Our support encompassed various services, ensuring our customers received end-to-end support. It is important to note that our services were tailored to meet each project’s specific needs and requirements.
The feedback we received from the technical staff and top management was outstanding. They expressed their satisfaction with the services we provided. Their positive feedback serves as a testament to our work’s high quality and effectiveness.
