SERVICES
1)
INSITU crank-shaft grinding and polishing of upto 700mm diameter.
2)
INSITU Journal machining of upto 1000mm diameter.
3)
INSITU Journal Squirrel machining of upto 1000mm diameter.
4)
INSITU Flange facing of upto 7000mm diameter.
5)
INSITU External & Internal honning upto 2000mm diameter.
6)
INSITU Boring of any diameter and length.
7)
INSITU Line boring of any diameter.
8)
INSITU VERSA Milling in any place.
9)
INSITU grinding/machining of rotary kiln tyres, support rollers and its process seal location areas.
10)
INSITU drilling/deep drilling to any diameter and depth.
11) INSITU Thread cutting/forming on shafts/bores of any size
12) INSITU repair of torched cylinder heads of Mirleus Blackstone engines
13) INSITU Buffing and superfinishing
14) METAL-STITCH of cracked/broken casings/housings made of cast iron, cast steel and aluminium equipments.
15) INSITU KEY-WAY cutting on shafts of any diameter and length

Some of our important and complex projects executed are given with photographs:

(1)INSITU crank-pin grinding-without dismantling

Suitable for undersizing and polishing of crank-pins of large crank-shafts of diameter 76mm to 1500mm to a high degree of surface finish
Press Crank-pin of dia 460 mm before grinding

 
 Press Crank-pin after grinding INSITU

 
Skoda 500 KVA Crank-pin of dia 170 mm before grinding

 
Skoda 500 KVA Crank-pin after INSITU grinding

 
Skoda 860 KVA Crank-pin of dia 225 mm before grinding

 
Skoda 860 KVA Crank-pin of dia 225 mm after grinding

 
INSITU Crank-pin grinding of skoda 500KVA in progress

 
INSITU Crank-pin grinding of skoda 860 KVA in progress.  However, dismantling of Engine block is not necessary.

 
Calibration of Crank-pin is done after completion of grinding on Daihatsu Aux engine of crank-pin dia 195 mm.

 
Dye-penetration test being done after grinding to identify cracks, if any on a crank-pin of oxygen compressor.

 
(2)INSITU machining of journal:
Any journal from I.D. fan shaft to M.G.cylinder journal of paper machine can be machined using our portable tooling equipment, without disturbing the shaft from its position to standard tolerance, irrespective of its size and weight.
INSITU machining of drive-end journal of M.G.Cylinder of Paper Machine of dia 450 mm X 450 mm width made of Cast-Iron is shown.

(3) INSITU machining of Flange faces, Spigots and counter bores:
Large flanges of any diameter in any plane can be machined to standard tolerances.


INSITU machining and flange facing of taper seating area being done on Iron-Ore Crusher of dia 2 m.

 
INSITU flange facing being done on hydroset seating area of dia 1.2 m

 

INSITU flange facing of Man-way hole being carried out.

 
(4)INSITU drilling or enlarging of existing holes:
Our INSITU drilling attachment powered by pneumatic motor, can drill any diameter of holes in any plane or angle to any depth.
The photograph illustrates INSITU drilling and enlarging of 2 inches stud holes to 2/12 inches.  A total of 30 holes were enlarged in a span of 2 days.

(5) INSITU machining of Rotary kiln tyres, support rollers and seal location areas:
Onsite machining of kiln tyres, support rollers and process seal location areas can be executed, without dismantling or disturbing from its position. Problems such as uneven concave and convex wear on tyres and support rollers can be corrected on-site using our portable INSITU machining equipment.

Front Seal Location area.

 

 Rear Seal location area

 
The Photograph shows INSITU machining of Front and Rear process seal location areas of Rotary Kils. 

 
(6) INSITU Boring- Repair of Mirrlees Blackstone 6MW cylinder Heads:
A very unique and special type of repair was carried out by us for repairs of flame torched 6MW cylinder heads. With this repair we can boost that we are the only company offering such types of repair services in India.

The flame torched area in MB 6MW cylinder head is clearly visible after enlarging the exhaust port by INSITU boring.

 
The enlarging of exhaust value port is done accurately by our INSITU boring attachment.

The photograph shows the torched cylinder head after fixing of C.I.Sleeve and completion of machining.

 
(7) INSITU boring & honing- Repair of Liner Seating area:
INSITU boring and honing of Liner seating area of Cummins 1000KVA, 'V' type engine was carried-out. The damage was due to connecting-rod failure.
The Photograph shows INSITU machining and honing of bottom liner seating area of cummins 1000KVA, 'V' type Engine block being done.  The damage was due to Con-rod failure.

(8) METAL-STITCH of cracked cast-iron, cast steel and aluminium bodies:
METAL-STITCH is an innovative and highly skilled process of repair for cracked or broken cast-iron, cast-steel and aluminium bodies and housings.
Cracked Cummins 380 KVA Engine block, damaged due to Con-rod failure, before repairs.
Cracked Cummins Engine block after repairs by METAL-STITCH

 
Skoda 2270 KVA Inlet casings repaired by METALSTITCH

 
DP Crack test Shows crack in liver collar seating area in SKL 1100 KVA Engine Block The liver collar seating area of SKL 1100 KVA Engine Block after METAL-STITCH.

The METAL-STITCHED areas are being machined finally to facilitate perfect seating of Liner Collar
Crack in SKL 1100 KVA

 
Cylinder heads repaired by METAL-STITCH

 
Cummins 380 KVA Engine block damaged due to con-rod failure shown.

 
The damage was repaid by fixing a new C.I. plate,followed by METAL-STITCH and D.P.Test

 
A marine Aux. Engine of Daihatsu 625 KVA Crank-Case was damaged due to con-rod failure,is shown.

 
The damage is rectified by METAL-STITCH.

 
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