Engine Repair Rapid Response for UK Shipping Company

At In-Situ Machining Solutions, we have expertise in machine repair solutions, and we are well-equipped with both the knowledge and equipment to respond to emergency situations like the one detailed in this case study.

The Client's Challenge

In late November 2016, our Managing Director received an urgent call from a prominent UK shipping company. The company in question faced a critical issue: a damaged cam housing location on a main engine, which required immediate attention to avoid significant operational downtime.

In response, two of our engineers, highly skilled in marine repair solutions, were assigned to the task. With the vessel scheduled to depart on Monday morning, the technicians would have to work around the clock, implementing a day and night shift schedule to ensure the repair was completed on time.

Mobile Equipment for Quick Response

By early Sunday morning, the technicians made the journey from our base of operations to the client's location in Sunderland, where the vessel was docked. The urgency of the situation demanded an efficient and timely response, and our team was well-prepared for the challenge thanks to the mobile equipment we have developed that enables us to conduct onsite machining.

Our Successful Solution

Upon arrival at the site, the technicians conducted a thorough assessment of the damage to the cam housing location. The main engine's camshaft is vital for the vessel's operation as it controls the timing of the intake and exhaust valves. Any malfunction generally leads to severe operational failures. The technicians identified that the cam housing had suffered significant wear and deformation, which needed precise and careful machining to restore it to its original specifications.

The repair process was complex and required meticulous planning and execution. The steps involved in the machining repair of the cam housing included:

1. Setup and Alignment: The technicians began by setting up the milling machine onsite. Precision alignment was critical, as any deviation could result in improper machining and further damage. They used laser alignment tools to ensure the milling machine was perfectly aligned with the cam housing.
2. Surface Cleaning and Preparation: Before any machining could begin, the surface of the cam housing was thoroughly cleaned to remove any debris, oil, or residue that could interfere with the milling process. This step ensured that the milling tools could operate smoothly and accurately.
3. Onsite Milling Machine Operations: The primary milling operation involved removing the damaged material from the cam housing. This was done in multiple passes to gradually restore the housing to its original dimensions. The technicians employed high-precision milling cutters, which were selected based on the material and the extent of the damage. We carefully monitored each pass to ensure we removed the correct amount of material without causing further stress to the housing.
4. Dimensional Verification: After the milling process, the technicians conducted dimensional verification using micrometres and dial indicators to ensure that the cam housing met the required tolerances. We then corrected any deviations through additional milling passes or surface finishing techniques.
5. Final Inspection and Assembly: The final step involved a comprehensive inspection of the machined cam housing. The Technical Director personally inspected the work, verifying that all dimensions and tolerances were within specification. Once approved, we reassembled the cam housing into the main engine and tested the engine for operational integrity.

Onsite Marine Cam Repair from In-Situ Machining Solutions

The repair was completed, and the vessel was ready to resume its operations within the required time period. The Technical Director's inspection confirmed the high quality of the workmanship, and he expressed his gratitude for the quick response and professional execution of the repair.

This successful repair not only highlighted our team's technical capabilities but also underscored our commitment to providing rapid and reliable machine repair solutions. We are proud of our team's ability to adapt to emergency circumstances. Here are some other case study examples of successful repair work we have conducted.

• Complete Crankshaft Repair for Stena Estrid
• Crankpin and Main Bearing Journal on a Bergen BRG/M8 Crankshaft
• Machining all Crankpins on a Commodore Clipper MAK 9m 32

Contact us to discover how we will assist your next project with our tailored, efficient solutions. We are reachable 24 hours a day, 7 days a week, for emergency response services and can be scheduled for any regular maintenance your assets need.