Our projects

Client in need of overhaul and OEM price and lead-time not acceptable.

We received the bundle and rotor insider pressurized canister. Dismantled the bundle, created CAD model of rotor, refurbished the rotor (repair of journal bearing lands, NDT, low-speed balance) and manufacture new labyrinths following APS process

CASE STUDY 2

MAIN OIL LINE PUMP RE-RATE

Client requested to replace the Main Oil Line cartridge with re-designed shaft, impellers, diffusers, ring section, balance drum and restriction bush. The impellers and diffusers specifically re-designed to operate at the required lower flow (65%)

Flow Reduced
Head Increased

CASE STUDY 3

SHAFT FAILURE ANALYSIS

As per information obtained from customer, fan shaft and bearings first were replaced in August 2018 and second time in April 2020. In October 2020 high vibration spikes were observed and WO raised for investigation which was scheduled for the 26 Nov 2020. But on the 25th Nov 2020 night the shaft breakdown had occurred. The unit was withdrawn from service as a result of sudden failure in form of fractured shaft.

SHAFT REDESIGN

In the design of the blade hub, a bush was used, due to which the shaft was adhered to the conical shape of the inner diameter of the hub. As per redesign proposal, the conical shape will initially be set on the shaft itself. This will help to reduce the overall number of parts in fan, i.e. complexity, reduce the risk of breakage of individual parts and significantly reduce the amplitude of vibration when using the equipment.
Based on the decision to set the conical shape of the shaft in the blade hub sector, it is necessary to replace the vertical thrust bearings with more suitable for the stable shaft design. The old bearings of part number 505-09660-11 (ZAS 5203) with an inner diameter of 55 mm will be replaced with new ones under the number ZAS 5211 with an inner diameter of 70 mm.
For securing and the pulley it was decided to add two nuts at the ends of the shaft. The nuts themselves will be notched, due to whiсh the blade hub h, under heavy load, there is no risk that they will spin and fly out. The nuts will be secured in-place with 2-3 grub screws.

CASE STUDY 4

3D LASER SCANNING

Power Turbine Ring Pads, Bearing Pads and Thrust Pads were prepared for deviation check and model comparison. Comparison has been performed between new and used parts. Parts had been cleaned and fixed for scanning with ROMER ABSOLUTE ARM 3D scanning equipment. Scanned models in form of point cloud data later had been processed and 3D Solid Models of parts were constructed. Data had been aligned along major axes and deviation check between new and used parts were performed.

CASE STUDY 5

MOTOR RECONDITIONING

The motor completely stripped and the most of components found to be in acceptable condition. The rotor shall be re- worked due to excessive pitting damage on both DE and NDE sides of journal bearing. The stator inside surface and rotor’s body were found in eroded condition.

Concerning erosion initiation on stator’s internal surface and rotor’s body – it is recommended to be coated with special erosion/temperature resistant coating to prevent further development of erosive marks (statistically, once erosion initiates and gets noticed during 2nd overhaul, by the time of 3rd overhaul amount of accumulated erosion damage leads to catastrophic failure and renders equipment completely non-recoverable) and significantly prolong the lifespan of motor.

CASE STUDY 6

GRAHAM VACUUM PUMP RECONDITION PROCESS

Totally failed Mechanical Seal
Cavitation caused erosion on impellers
Eroded and corroded areas on side plates
The severe damages on shaft’s key slot

OEM recommendation was to scrap the unit, SPM Oil and Gas overhauled.

Internal side of casing was accurately polished through pneumatic brush.
Impellers have been restored through
The key groove was repaired and the impeller case was polished
All spares were covered with TC composite coating

CASE STUDY 7

EGGER SAND JETTING PUMP RECONDITION

Wear plate along with Casing inner borders were in eroded condition
Wear plate removed and found deeply eroded condition
Protection caps faced severe erosion
Eroded vanes of the impeller

Machining process of eroded surface of pump casing suction bore
Manufacturing of the specific size of bushing with internal TC surface
The eroded areas, of the impeller vanes were filled via welding.
Newly fabricated erosion plate

CASE STUDY 8

MOL BOOSTER PUMP RECONDITION

Eroded casing shrouder
Eroded impeller and split flange was before
Eroded wearing rings
Bottom bearing found absolutely damaged

The remaining shoulder parts has been machined out
Installation of the special borders on the sides
Final machining after welding. MPI Test performed and no cracks or porosity observed

CASE STUDY 9

MAIN POWER GENERATOR AIR COOLER

Restoration process of damaged ends for plate cooler pipes. Plate cooler seal plates as well as pipe ends were restored and modified. Originally heat exchanger tube ends are sticking up approximately 1.0-1.5mm) from tube sheet, which is allowing to repairing leaking areas by welding.

Reworked seal plate to be installed along with 0.25mm NOVUS SUPRA gasket

CASE STUDY 10

MOL PUMP RECONDITION

Casing eroded place machining sketch
Pump Casing eroded places were welded and carefully machined
Cartridge old holes and new drilled hole sketch. Used cartridge has previously modified and new holes drilled

CASE STUDY 11

MOL PUMP RECONDITION

MOL Pump erosion zones were observed on each impeller vanes ( 7 pcs of vanes on each impeller) with approximately length 25-35 mm and maximal deepest zone (3.5mm) at the end of the vanes
Weld up of damaged vanes and further milling