Services

1. INSITU PLANO-MILLING OF MACHINE BEDS/FRAMES
This is a process by which Machine Bases or Beds and Foundation Plates and Seating Bases, can be machined by INSITU PLANO MILLING. This is a process to correct the Worn-out surfaces and thus improve the surface flatness for proper seating. There is no restriction of size, which means any size of any length can be INSITU Machined by us at your site. We use LASER TRACKER ALIGNMENT device to mount our machine and to verify the quality of work after completion of work.

2. INSITU MACHINING OF TRUNNION JOURNALS
This is a process by which Raw Mill/Cement Mill Trunnion Journals can be repaired by INSITU machining at site. The scorings formed over a period of time, can be removed and the Trunnion Journal diameter will be undersized to standard diametrical tolerances as per OEM's specification. The Trunnion Journal will be stationary while our INSITU attachment will rotate around to effect grinding. This will generate true spherical surface. Using this state of art INSITU machine, any shafts upto 3200mm diameter can be INSITU machined/ground

RawMill Trunnion Journal (FLSmidth Make-Dia 1300mm)in a Thermal Power Plant -Before INSITU Grinding	Raw Mill Trunnion Journal (FlSmidth Make)-INSITU Grinding in Progress	RawMill Trunnion Journal (FLSmidth Make) -After INSITU Grinding
RawMill Trunnion Journal (KCP Make-Dia 1450mm)in a Cement Industry -Before INSITU Grinding	RawMill Trunnion Journal (KCP Make) -After INSITU Grinding

3. INSITU Shaft Journal Tooling and Grinding
Any shaft journal from MG Cylinder Journal of Paper Machine to Axles of tracks of Bucket Wheel Excavators, ID fan Shaft Journals to Gear-Box Drive shaft journals to any Pump Shaft journals, can be INSITU Machined and Ground at site to required tolerances without dismantling or removal from position. We are equipped to machine shafts upto 2500mm diameter.

Bucket Wheel Exchavator 1357 Hollow Axle (Dia 700 X 2000mm Length)-After INSITU Grinding in a Mining Industry
MG Cylinder Journal of Paper Machine-During INSITU Machining in a Paper Industry

4. INSITU Boring – Tooling & Grinding
Any Bores or Housings from Vertical Raw Mill Rocker Arm co-axial Housing to Gyratory Crusher Top and Bottom shell Seats can be INSITU machined and ground to required tolerances. Bores upto 4000mm diameter can be INSITU machined/ground.

INSITU Boring of Roller Press Blind Bore of size Diameter 300mm and Length 5000mm. The bore was oversized using a specially designed INSITU Machine which is first of its kind and was never ever carriedout INSITU	INSITU Boring-Vertical Raw Mill Rocker Arm co-axial Housing in a Cement Industry
INSITU Boring & Facing-Slew Drive Gear-box seating bore (Dia 1000mm) of Bucket Wheel Excavators.	INSITU Boring & Facing of Gyratory Crusher Taper Seat (Dia 2000mm)in Mining Industy

 

5. INSITU Flange Facing &Tube Sheet Facing
The Gasket Seating Face of huge Flanges and Tube Sheet Flanges can be INSITU machined in position. INSITU Grinding of faces are also possible with an additional attachment, if required. We can handle flanges upto 7000mm in diameter.

INSITU Flange Facing of Dome End-Cover (Dia 1300mm) in progress at a petrochemical Industry	INSITU Flange Facing of Shell Flange(Dia 1300mm) in Progress in a Petrochemical Industry
INSITU Flange Facing (Dia400mm)-Manway flange-Petrochemical Industry	INSITU Flange Facing of Ammonia Condenser in a Fertilizer Industry

 

6. INSITU Key-way Cutting
Any damaged or new Key-ways or Key-slots can be cut INSITU on any shafts. Key-ways upto 2000mm length can be cut. Internal key slots can also be machined, if required.

INSITU Machining of Key-way in MG cylinder Journal in a Paper Industry

INSITU Machining of Roller shafts in a Steel Industry

 

7. INSITU Grinding of Turbine Rotor Thrust Disc/Collar
This is a specially designed INSITU Grinding Machine for Grinding of Thrust Collar Discs of Turbine Shafts of any size. The Thrust collar in Turbine shafts, if damaged can be corrected in position without dismantling / disturbing the turbine rotor.

INSITU Grinding of 60MW Turbine Rotor Thrust Collar in a Thermal Power Plant of TNEB

INSITU Grinding of 110MW Turbine Rotor Thrust Collar-at a Thermal Power Plant of PSEB

 

8. INSITU Crank-pin Grinding
Any damaged Crank-pins of Diesel Engines can be repaired INSITU without dismantling the crank-shaft from the crank-case. Grinding will be done to the next undersize and suitable undersize bearings may be used further.

INSITU Crank-pin Grinding – Before & After

 

9. INSITU Line Boring of Diesel Engines
Any damaged Main Housing of crack-case in Diesel Engines can be repaired using this equipment. Also, any co-axial bores like VRM Mill Rocker Arm co-axial housings can also be INSITU machined at site. INSITU Line-Boring to any length can be carriedout to standard tolerances.

INSITU Line-Boring of Main Housing of SKL 1100KVA Diesel Engine

 

10. INSITU Liner Honing
Liners of Marine and Land based Diesel engines can be honed INSITU.

INSITU Honning of Marine Main Engine Liner-Before & After

 

11. INSITU Shaft Thread Cutting
The Damaged Threads on Large Shafts of any pitch can be repaired and as well, new threads too can me machined. The shaft will be stationary while our Shaft Turning machine with Threading attachment will be mounted on the shaft to cut new threads. Threads can be cut on shafts upto 2000mm diameter.

INSITU Repair of damaged Threads of Super Heavy Duty Crusher in a Mining Industry

 

12. INSITU Bore Thread Cutting
The Damaged Threads on Bores or large stud holes of any pitch can be repaired INSITU and new threads if required can be cut too.

INSITU Thread Cutting in Stud-hole of Ammonia Reactor in a Fertilizer Industry

 

13. INSITU Kiln Support Rollar/Tyre Grinding
Kiln tyres and support rollers can be ground in position while in operation. The In-let and out-let seal seat areas too can be INSITU machined

INSITU Machining of seal face location areas in a Cement Industry

 

14. INSITU Drilling / Deep Hole drilling
Deep Hole drilling in any plane and any length can be carried out INSITU.

INSITU Deep Drilling/Boring in Progress

INSITU Deep Drilling/Boring in Progress

 

15. METAL-STITCH of cracked cast-iron, cast steel and aluminium bodies
Complete and reliable solution for cracked or broken casings made of cast iron and aluminium casings. 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