Services

Services:

1) We are doing refurbishment services for all make (like KOBE, Howden, Gardner Denver, Boge, Sulzer etc) of Screw compressors in any condition, including, seized, worn out, damaged etc. We have almost 50 years of experience in this field.

2) Repairing/ servicing of high-pressure valves (bigger than 6 inchX2500# rating).

3) Development and Manufacturing of mechanical spares/component of any machine in fertilizer, power, plant or refinery etc.

4) We can help in failure analysis of mechanical components through qualified metallurgist and can suggest better alternate material for trouble free service.

5) 3D scanner for development of manufacturing drawings of the parts/components or part machines.

6) Upgradation of material of construction or heat treatment or coating for frequently failing components.

7) System Problem resolving approach with vast experience of services in variety of industries.

 

In-situ services:

1) Flange facing and seat renovation (raised face, flat face, ring Joint groove etc) of vessel without stud opening. We have successfully done in-situ flange facing of 2.5 mtr. diameter within acceptable engineering tolerances. Stud opening of such vessels is a tedious job in itself. In-situ machining job of flange facing and seat renovation was done as per engineering standard having finish level better than 2.5 micron. Job was completed in record time to minimise the production lose.

2) Drilling of through hole for thermo well in 680mm thick ammonia synthesis converter shell cover of alloy steel. Weight of this cover is approx. 13 tons.

3) In-situ in line boring of vertical compressors up to 600 mm diameters. Recently we have completed in-situ in line boring of DCM Hydrogen Compressor cylinder to remove ovality and regain finish to improve compressor performance. Oversize boring was done and the piston and piston rings were replaced suitable to oversize boring.

4) In-situ drilling and tapping of generator foundation frame for 30MW generator replacement job at power plant. Drilling and thread tapping of size M27 X8 pich.

5) We have successfully overhauled 8 inch2500# rating block valve of 1969 vintage in DCM to make valve operation easy and improve valve passing problem. This valve was opened for the first time after operation of more than 40 years.

6) Ammonia plant shutdown related maintenance jobs involving skilled and unskilled manpower for handling pipe lines and vessel flange joints of various size and ratings.

7) Machining and lapping of bridgeman gasket seat of ammoniachiller vessels for holding pressure of 350 bar. Flange size approx. 1600 mm

8) Scratching and lapping of steam chest sealing surface of synthesis compressor 27MW steam turbine for leak sealing.

9) In-situ pattern making is also possible in case sample can not be given to take out.

10) On site 3D scanning for any component within accuracy of 0.02mm for development of manufacturing drawings/CAD model for manufacturing development.

Spare parts development and manufacturing of spares:

All critical components are manufactured following the critical manufacturing protocol. Material is tested and inspected before final machining. End users are involved through out the manufacturing to generate confidence for the quality and dimensional accuracy.

On request and requirement 3rd party inspection can be arranged.

1) KOBE make CO2 gas compressor cylinder liner in cast iron, an import substitute. Complete casting tested ultrasonically and radiography for defect free manufacturing and machining done within acceptable tolerance protocol. ID of the liner is honed to improve the performance.

2) Screw compressor rotors for KOBE make ammonia refrigeration system were repaired to regain the compressor performance for the ammonia manufacturing facility. Theses rotors are required to run with oil film thickness sealing in between the male and female counter parts. As these compressors are running without timing gears, rotor sealing edges gets rub off with time, losing the compressor performance. Lip seals are re-made and fitted on all lobs of the screws and final machining is done to required protocol size to maintain rotary clearances.

3) Development of Gear and screw oil pumps to accommodate in the old machines and match the performance as per requirement for ammonia refrigeration system and other facilities. This is import substitution.

4) Various Stage Diffusers for Multi stage high pressure centrifugal ammonia transfer pump for Ammonia-Urea manufacturing facility. This is import substitution.

5) Poppet and plate valves for Kobe make reciprocating compressors for Urea making facility. These valves are of approx. 12 inch diameter used in CO2 gas compressor. This is import substitution.

6) Development of low opening impeller of highspeed carbamate centrifugal pump for urea plant. This is very critical import substitution. (6.5 mm opening of impeller shroud)

7) Development of lever of the auto recirculation valve of high-pressure multistage boiler feed water pumps. This is import substitution.

8) Development of multi lob oil pump for screw compressors for high pressure lube oil service.

9) Development of timing gear set for imported screw compressor.

10) Development and manufacturing of various size (Dia 3 inch and 4 inches) piston rods of Kobe make reciprocating compressors for CO2 gas and Ammonia Synthesis gas service. These piston rods were supplied in forged steels with proper heat treatment, hard coating and grind finishing. All threads of these piston rods are developed by thread rolling to have better strength and finishing.

11) Successful development of screw compressor end casing.

12) Successful development of reformer tube nipping tool with clamps, which can also be used for other industrial purposes.

13) Manufacturing of fluid end of high-pressure plunger pumps in stainless steel.

14) Manufacturing of FCM rotors

15) Manufacturing of spiral bevel gears for cooling tower gear boxes.

16) Manufacturing of shaft of multistage high pressure boiler feed water pumps and high pressure HPC pumps of using material SS 431 and 17PH4 respectively.

17) Bearing housing of Urea centrifuge machine.

18) Manufacturing of Stud with nuts for Urea Reactor control valve in material specification A193 Gr.B8ML/A194 Gr. B8ML in forged/solution annealing/strain hardening and rolled threads.

19) Pistons for CO2 gas and Ammonia synthesis gas reciprocating compressors in material likeA536Gr.65/45/12

20) Bearing housing for high temperature Benefield solution pumps to fit in pump foundation and accommodate antifriction bearings with cooling water jacket.

21) Suction Valves and cylinder heads for reciprocating compressors of various sizes and makes.

22) Development of nitride coated plunger for reciprocating high pressure ammonia pumps for DCM Urea plant. These plungers are performing better than coated plungers.