Gas Engine Repair

With more than 150 natural gas, biogas, landfill gas and specialty gas engines, RS Motor is a competitive company with large-scale contracts that meets the needs of its customers and is a sign of guarantee for production.

Whatever the type of engine of the major brands that RS Motor works on and wherever it is located, RS Motor is able to provide a fast, efficient and quality response. Many years of experience mean that our engineers and technicians are able to deal with any type of repair either on-site or at RS Motor’s premises.

What repairs do we carry out on gas engines at RS Motor?

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Here is a brief summary of the most important parts repair work we usually carry out at RS Motor.

• • Cylinder head reconditioning: Replacement of valves, seats, guides, sleeves (depending on cylinder head model), O-rings, valve guides, repair and/or machining of cylinder head shell (if necessary), planing of cylinder head faces, complete cylinder head assembly and final hydraulic test.
  • Ultrasonic cleaning of intercooler: Complete disassembly of the intercooler, subsequent ultrasonic cleaning, mechanical cleaning of covers and body, replacement of sealing gaskets, complete assembly of the intercooler and final hydraulic test.
  • Lube oil cooler overhaul: Disassembly of the lube oil cooler, replacement of sealing elements, assembly and hydraulic test.
  • Overhaul of lube oil cooler: Disassembly of lube oil cooler, replacement of sealing elements, assembly and hydraulic test.
  • Connecting rod reconditioning: Checking the parallelism of the connecting rod body. If within tolerances, new connecting rod foot bushings and new bolts or studs are fitted.
  • Checking of the connecting rod body parallelism.
  • Repair of water or oil pumps: In this case, the seals, gaskets and sealing rings and/or bushings or pinions are replaced if they cannot be repaired.
  • Water or oil pump repair: In this case, the seals, gaskets and sealing rings and/or bushings or pinions are replaced if they cannot be repaired.
  • Checking of starter motors or starters: In the RS Motor electrical workshop, specialised equipment is available to check whether the starters of the motors are in good condition or not. If a part needs to be replaced, this can also be carried out.
  • Engine block machining: Sometimes it is necessary to carry out some extra work, such as machining the top and/or bottom of the engine block.
  • Check of the crankshaft condition:Dimensional check of all crankshaft dimensions.
  • Renovation of the main engine parts: Pistons, main bearings or main bearings, connecting rod bearings or main bearings, cylinder liners, cylinder head gasket kit, axial bearings, camshaft bushes…
  • Renovation of the main engine parts: Pistons, main bearings or main bearings, connecting rod bearings or main bearings, cylinder liners, cylinder head gasket kit, axial bearings, camshaft bushings…
  • Renovation of secondary engine parts: Seals, bolts, O-rings, rubber silentblocks, spark plugs, coils, ignition cables, air filters, oil filters, UPF filters
  • ….

Gas engine maintenance

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There are several types of maintenance that can be carried out on industrial gas engines. Among them, RS Motor specialises in the following:

• • Preventive maintenance: This is maintenance carried out taking into account the engine’s operating hours. The interval of hours varies according to the engine manufacturer. They range from minor preventive maintenance to major preventive maintenance (usually called overhaul). The work to be carried out in the preventive maintenance of engines is listed in the manufacturer’s maintenance plan.
  • Corrective maintenance: Type of work or maintenance that needs to be carried out as soon as possible after an unscheduled engine shutdown for various reasons (seizure, high temperatures, high pressures, electronic faults, etc.). The work carried out is adapted to the needs of the engine at that moment.

On this occasion we show how RS Motor repairs an industrial gas engine, which develops from 3.5 MW to 4.5 MW of power.

One of the most important jobs is to check the dimensions of the crankshaft. Then, if the crankshaft is OK, the bearings or main bearings are replaced, the connecting rods are reconditioned at RS Motor,…

In any case, it is sometimes necessary to carry out some extra work, such as machining the upper and/or lower part of the engine block. The same applies to cylinder heads if the cylinder head is not in good condition. Apart from the replacement or renewal of components such as valves, seats, valve guides, springs,… sometimes the cylinder head body or shell may be cavitated due to the action of water over time. To try to solve this, RS Motor carries out machining and planing work (only when possible) so that they can be reused.

Other important engine parts that RS Motor has to recondition are: intercoolers, oil coolers, pumps,… Once these elements are repaired or reconditioned, they undergo a hydraulic test in order to verify the absence of leaks.

Finally, when all the work is completed, RS Motor starts to reassemble the engine and then sends it to the customer’s plant.

In short, an appropriate technical service, combined with the quality of the spare parts used, means that the engine can run more regularly.

Service for gas engines

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At RS Motor, we are specialists in carrying out work on the gas engines mentioned below:

Overhaul of gas engines

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On occasions and in plants where downtime makes it unfeasible, RS Motor can carry out Overhaul work using a shortblock exchange or a longblock exchange, thus minimising plant downtime due to preventive/corrective engine maintenance.