Gas Engine Repair

PowerUP inherits a deep expertise and years of experience in gas engine repairs – whether it’s due to an engine damage or for retrofit and upgrade purposes, PowerUP is a partner for repairs that you can count on!

Our remanufactured engines are fitted with new and often upgraded parts where necessary whilst utilizing the remaining lifetime of core components after thorough inspections and testing to provide our customers with the best deals for their needs.

Workflow

We offer repairs of gas engines, generators, turbochargers and peripheral equipment, which can be accomplished on-site or in our repair facilities. Overhauls of OEM gas engines, required at the end of a lifecycle are usually realized in our well-equipped repair workshop by our experienced staff with high-quality spare parts. If required, such an overhaul can also be accomplished on-site, without relocating the engine.

Disassembly & Inspection
Checking the condition of the received engine through a comprehensive and detailed engine inspection during disassembly. Includes inspection of all core-components as well as peripheral equipment.

Cleaning

Thorough internal and external cleaning of all reusable components by means of high temperature pressure cleaning and specialized cleaning concepts for complex parts. (e.g. decoking of cylinder heads & combustion chambers, cleaning of the crankcase’s cooling gallery and peripheral oil- & cooling-water collectors)

Assembly
Performed by our highly trained workshop staff in accordance with our streamlined assembly procedures. Highest standards are applied towards the quality of the single components as well as the workmanship, hence each step is documented in the new-born engine’s assembly report with all required measurements and dry-tests performed.

Final Inspection
Pressure tests on the exhaust line, oil & water circuits and functional testing of the control system follow to provide a full inspection report with details of the condition of all major engine parts.

Painting
Respraying of the entire engine to provide optimal corrosion protection. Custom finishes are subject to availability.

Dispatch
Preparations for dispatch with special packaging / conservation if necessary. Final check of scope fulfilment, sealing of flanges and compensators against humidity and attachment of lifting fixtures and instructions.

Shortblock

Disassembly & cleaning of engine
Measure & realign (if required) crankcase & crankshaft
Reassembly of engine with new or overhauled engine components such as cylinder heads, pistons, cylinder liners, con rods, main bearings, con rod bearings, spar plugs, roller tappets, push rods, rocker arms, etc.
Overhaul of oil pump, oil cooler & jacket water pump
New vibration damper
Change of all elastomer parts (O rings, sealings, rubber rails)
New painting of short block engine

Longblock

Disassembly & cleaning of engine
Measure & realign (if required) crankcase & crankshaft
Reassembly of engine with new or overhauled engine components (same as short block )
Overhaul of turbo charger, intercooler, oil pump, oil cooler, jacket water pump, gas mixer and actuator
New vibration damper and blow by system
Check & change of exhaust manifold
Overhaul of ignition system
Change of all elastomer parts
Check & change all compensators & sensors
New cabling on the engine
New painting of long block engine

Genset

Disassembly, thorough cleaning and checking of the crankcase, crankshaft, turbocharger and intercooler
Complete re-assembly of the engine with new or overhauled parts (same as long block scope)
Alternator – 400 V, 50 Hz, 1500 rpm:
disassembly, thorough cleaning & drying of all winding elements, reassembly replacement of alternator bearings
Genset accessories & assembly: engine, flexible coupling, bell housing & generator mounted on base frame automatic lube refill system, jacket water preheating system air filter, air inlet duct, blow by filter, anti-vibration mounts complete wiring on Genset.
Engine control panel & interface panel
Main gas train for biogas (50-60 % CH4)