1) Repair and Maintenance Services
Our company provides a comprehensive range of repair and maintenance services tailored to industrial equipment, ensuring high efficiency and reliability for your operations. Our services cover various aspects, each designed to minimize downtime and extend the lifespan of your equipment.
- Vibration Condition Monitoring (VCM)
We specialize in Vibration Condition Monitoring (VCM), an essential diagnostic tool used to detect early signs of mechanical failure in rotating equipment such as pumps, motors, and fans. By analyzing vibration data, we can predict potential issues like misalignment, imbalance, or bearing wear. This proactive approach allows us to recommend timely interventions, helping clients avoid costly breakdowns and extend equipment service life.
- Temperature Condition Monitoring (TCM)
Temperature Condition Monitoring (TCM) is another critical service we provide, particularly in environments like steel and copper plants where equipment operates under extreme conditions. By tracking temperature variations in critical components such as motors, bearings, and electrical systems, we identify overheating and other thermal anomalies. Early detection of temperature fluctuations prevents equipment failure and reduces the risk of unexpected downtime, ensuring smooth and continuous operations.
- Fan Balancing
Unbalanced fans can cause excessive vibration, leading to premature wear and tear on bearings and structural components. Our fan balancing services ensure that fans operate smoothly, reducing noise levels, increasing efficiency, and preventing damage to the overall system. We bring fans back to optimal condition, prolonging their operational life and improving overall system performance.
- Fault Diagnosis
We provide comprehensive fault diagnosis services for a range of industrial components, including pumps, fans, and conveyor belts. Our team uses advanced diagnostic tools to identify mechanical issues such as wear, misalignment, and fatigue in key equipment. Through a systematic approach, we pinpoint the root causes of faults, providing actionable insights for repairs that restore equipment functionality while preventing future failures. Below are two sample papers showcasing our recent work in condition monitoring (Click on the title to download the full paper).
- Vibration Analysis for Fault Diagnosis in Multi-Stage Centrifugal Pumps: A Case Study at Khatun Abad Copper Complex
- Vibration Analysis for Fault Diagnosis in an Overflow Ball Mill: A Case Study at Sarcheshmeh Copper Complex
2) Relining Process and Equipment Overhaul Services
- Relining Process
The relining process is a crucial part of overhauling mineral processing plants, involving the replacement of worn-out liners in SAG mills and ball mills. Our expert team excels in carrying out this intricate procedure with efficiency and safety as top priorities. From the careful removal of old liners to the precise installation of new ones, our relining specialists manage every step, ensuring your mill quickly returns to optimal operating condition.
By minimizing downtime and maximizing equipment reliability, we help clients maintain production schedules while reducing long-term maintenance costs. Our team’s expertise ensures a smooth, timely relining operation that enhances mill performance and extends the lifespan of your processing equipment.
- Industrial Relining Equipment Overhaul
In addition to the relining process, we offer comprehensive overhaul services for industrial relining equipment, including Liner Bolt Removal Hammers and Liner Handlers. Our skilled technicians address any issues with these critical tools to ensure they function correctly and reliably during the relining process.
Our equipment overhaul services include:
- Inspection and Diagnosis: Thorough examination of Liner Bolt Removal Hammers and Liner Handlers to identify and diagnose any problems.
- Repair and Maintenance: Comprehensive repairs and maintenance to restore equipment to optimal working condition, including part replacements and mechanical adjustments.
- Testing and Calibration: Rigorous testing and calibration to ensure equipment meets performance standards and operates efficiently.
By maintaining and overhauling your relining equipment, we ensure that your relining operations proceed smoothly, with minimal interruptions and maximum effectiveness.
3) Technical Documentation Services
We provide comprehensive technical documentation services that cover both condition monitoring and the full lifecycle of industrial parts. Our documentation ensures that clients have a complete, organized record for effective equipment management and compliance.
- Condition Monitoring Documentation
For condition monitoring systems, we produce detailed reports and guidelines that specify the monitoring requirements for each piece of equipment. This includes setting thresholds for alerts, defining maintenance schedules, and recommending necessary interventions. These documents offer a structured approach to maintaining equipment health, contributing to safer and more efficient operations by reducing the risk of unexpected failures.
- Technical Documentation for Industrial Parts
In addition, we prepare technical documents for industrial parts, providing a complete profile of each part’s specifications and production details. This includes detailed information on materials, Inspection Test Plans (ITP), manufacturing processes, technical drawings, painting specifications, welding tables, and photographs. These documents provide a complete overview of the part’s characteristics, from the materials used to the methods of production and quality control. This comprehensive documentation ensures traceability, quality assurance, and compliance with industry standards, while supporting efficient part management throughout its lifecycle.
4) Crack Repair and Wear Restoration of Industrial Parts
One of the main challenges in industrial and mining sectors is the failure of components. Since the failure of any industrial part typically begins with the formation of cracks, repairing these cracks is crucial to prevent further damage or complete failure. Our company specializes in crack repair for industrial parts using two advanced methods: cold bonding and welding.
- Cold Bonding Method
Cold bonding is a unique method, particularly effective for materials with low weldability such as cast iron and certain steel or aluminum alloys. This process is performed using proprietary connectors developed by our company. Unlike traditional hot methods, cold bonding does not alter the material’s structure, preventing the formation of new cracks caused by thermal processes. This method is also known for its rapid implementation on-site and high reliability.
- Specialized Welding
For cases that require welding, we provide a comprehensive and specialized service, including the selection and procurement of specialized electrodes, preparation of Welding Procedure Specifications (WPS), execution of the welding process, and post-weld inspection. Each step is carried out with the utmost expertise to ensure high-quality, durable repairs.
- Wear Restoration
For components that have experienced wear, we restore them by applying specialized coatings tailored to the type of wear damage. This approach ensures that the repaired part can withstand future operational demands and extends its service life.
5) Gear Tooth Restoration and Reconditioning
A common issue faced by industries is the wear, pitting, and tooth breakage in pinions and gears. These defects can lead to increased system vibrations and may necessitate part replacement. Given the high cost of many of these components, repair and reconditioning offer a cost-effective alternative.
We have developed advanced technology for gear tooth restoration and reconditioning. This process is particularly specialized due to the need for precise dimensional quality, strength, and hardness, especially since most of these gears are made from high-strength alloy steels.
- Specialized Restoration Techniques
We address worn or broken gear teeth using expert techniques including welding and coating methods. These specialized processes ensure that the gears are restored to their optimal condition.
- Precision Gear Tooth Finishing
To achieve a high standard of finishing, we have designed and built a fully automatic machine for gear tooth reconditioning. This machine performs the finishing with a tolerance of 0.07 mm and a surface roughness of 1.6 µm, ensuring precision and quality in the final product.
6) 3D Scanning of Industrial Parts
Our 3D scanning service provides precise and detailed digital models of industrial parts, including pinions for SAG mills and worn liners. This cutting-edge technology is essential for accurate analysis, inspection, and restoration of critical components.
Key Features of Our 3D Scanning Service:
- High Precision: Our advanced 3D scanning technology captures detailed measurements and intricate features of industrial parts with exceptional accuracy. This ensures that every aspect of the component is recorded, providing a comprehensive view for evaluation.
- Detailed Analysis: By creating precise digital models, we enable thorough analysis of the part’s condition. This includes assessing wear patterns, identifying damage, and evaluating the overall integrity of components such as pinions and liners.
- Enhanced Restoration: The detailed data obtained from 3D scans facilitates accurate restoration and repair processes. For worn liners or other components, this technology helps in designing and implementing effective solutions that match the original specifications.
- Efficient Documentation: The digital models generated from 3D scans serve as valuable documentation for future reference. This helps in tracking the condition of parts over time and supports maintenance and quality control efforts.
