Wartsila 6L20 In-Situ Mains Crankshaft Honing & Superfinishing

Client: Confidential
Industry: Marine & Shipping
Location: France
Project Duration: 48 Hours

Overview

A marine vessel operating in France required immediate mains journal restoration to prevent prolonged downtime and maintain engine reliability. Royce Onsite Machining was engaged to perform a complete in-situ crankshaft honing and superfinishing operation directly onboard the vessel, with all work completed within a strict 48-hour timeframe.

The objective was to restore the crankshaft journal surface condition, improve bearing performance, and return the engine to operational service without removing the crankshaft assembly.

Challenge

During inspection, several issues were identified that required urgent corrective action:

• Light scoring, surface wear and journal imperfections
• Deterioration in surface finish impacting bearing efficiency
• Increased risk of further crankshaft and bearing damage
• Limited maintenance window due to vessel operational commitments

Conventional workshop repair methods involving crankshaft removal and transportation would have significantly increased downtime, costs, and logistical complexity.

Solution & Methodology

1. On-Site Inspection & Assessment

• Comprehensive crankshaft inspection and measurement conducted in situ
• Detailed condition assessment confirmed the feasibility of onsite restoration
• Initial dimensional and surface condition readings documented for process control

2. Precision Journal Honing

• Controlled honing operations performed to restore journal geometry and consistency
• Bearing contact conditions improved through precision surface correction
• Surface profile optimised to support effective lubrication retention

3. Superfinishing Operations

• Advanced superfinishing techniques applied to achieve ultra-fine surface quality
• Friction characteristics reduced to improve bearing performance
• Micro-surface integrity enhanced to support long-term operational reliability

4. Final Inspection & Verification

• Final dimensional inspections confirmed compliance with required tolerances
• Surface finish measurements verified against engineering specifications
• Crankshaft approved for immediate operational return following completion

Technical Summary

• Engine Type: Wartsila 6L20
• Service Type: In-situ crankshaft honing and superfinishing
• Location: France
• Duration: 48 Hours
• Methodology: Onsite restoration without dismantling or crankshaft removal
• Result: Restored journal integrity and improved operational performance

Outcome

The crankshaft restoration was completed successfully onsite within the allocated 48-hour schedule, eliminating the need for component removal, workshop machining, and extended vessel downtime.

Following completion, the engine was returned to service with restored surface integrity, improved lubrication performance, reduced friction characteristics, and enhanced operational reliability.

This project highlights Royce Onsite Machining’s capability to deliver rapid-response in-situ crankshaft restoration services for the marine industry, providing efficient and cost-effective solutions in remote and time-sensitive operating environments.