What We Do?
In-situ Machining Services
In-situ Crankshaft and Midshaft Grinding
Crankshaft being one of the most critical components in the functioning of an engine requires special attention & care during repair & reconditioning. Journals & Seating areas of mid shafts are important in the functioning of heavy machinery in process plants which require equal attention & care.
Machining and grinding of Crankshafts and Midshafts "In-situ" saves downtime costs and eliminates risk factors involved in transportation, handling dismantling, etc. Crankshaft bend removal can also be carried out In-situ.
- Thorough inspection of crankshafts with appropriate NDT tests. Inspections include Hardness checking with portable hardness tester, Crack detection with MPI.
- Specially designed rotary grinding machine for in-situ application, adaptable for various designs of Crankpins, Main Journals and Shaft Journals.
- Crankshafts and Machine shafts can be ground without dismantling with the range starting from diameter 125mm upwards.
- Trained engineers with good knowledge of procedures and care to be taken during grinding of Crankpin and Journals In-situ.
- Availability of fixtures to suit most of engines enables us to attend to a Job early.
- This machine can also be used with single and multipoint cutters for machining the Journals and then grinding, in cases where higher under-sizing needs to be carried out.
- Dimensional accuracy to meet OEM standards.
In-situ Milling
In-situ milling or portable milling is the process of milling a component or structure at the place of installation. Portable milling is an essential service in machining / re-machining large equipment or equipment base "In-situ" to maintain a flat surface for seating or mounting of structures or components. Large areas, that require to be flat for its functional requirement need to be machined to achieve the required flatness. This requirement can arise after primary construction or during the rehabilitation of the existing area due to wear and damage.
The versatility of our machines helps in adapting them to different field conditions and requirements, not only our machines but our machining teams consist of high specialists of adapting to different situations arising at work site.
The machine we use are designed, manufactured and owned by us, which enable us to redesign and modify them to suit the site requirements any time.
Our strength is in adapting and evolving to unique situations that require specialized machines and fixtures. Turning milling, grinding, boring, dowel-hole machining, gear-train locating bore machining or in other words any machining solution that is required in-situ can be carried out by us to meet and exceed the required level of accuracy.
Our rugged portable milling machines are for on-site machining operations in X Y & Z axes with high accuracy. Typical applications include machining of
- Bed plate
- Base stand
- Corroded guide rail / foundation
- Gear box mounting base
- Range up to 20meters length X 6meters width.
- Hydraulic / Pneumatic drives
- Modular Machine suitable for transport and assembly in confined areas
1. Gearbox Base
2. Machine / Equipment base
3. Missile seating / foundation
Any large flat surfaces requiring machining
In-situ Line Boring
Line Boring is a special type of in-situ boring operation for machining two or more bores in a straight line. The line boring machine is carried out in-situ with our specially designed in-situ line boring machine that is capable of achieving a high degree of accuracy and surface finish.
- In-situ line boring with well-trained and high experienced engineers & technicians.
- Specially designed Hydro-Drive Line Boring machine with accuracies to the tune of around 0.02mm even for large bores.
- A bore of any size and any length can be bored in line.
- Angle boring to a specified angle with respect to the reference axis.
- Specialized fixtures and tools designed to suit different applications.
- Optical and laser alignment of the bores depending on the requirement. Auto aligning fine feed unit for optimum finish.
- The surface finish can be tested with a digital surface roughness gauge.
- All dimensions are maintained as per OEM specifications.
We offer Line boring services from a minimum diameter of 70mm to 3000mm.
Sizes higher than 3000mm can also be machined if the requirements of the customer are presented to us with lead time.
The length of the bore set is not a restriction.
- Diesel Engines
- Main Bearing Housings
- Camshaft housing
- Liner landing area bores
- Compressor Bearing bores
- Sterntube Bores
- Rudder Bushes and bores
- Gas turbines & steams turbine
- Mill stand Coilbox
- Vertical Raw Mill bearing housings
- Rotating shafts lines that require bearing alignment or restoration
In-situ Machining (General)
Repairing a machine at the site of installation saves downtime costs and transportation. This mode of repairing a machine is ideal for machines and components of enormous size and weight that are difficult for conventional machines to work on. Components are brought back to almost new conditions.
- Specialized machines and fixtures with state-of-the-art machining techniques are used.
- Trained and experienced in In-situ machining.
- Creative solutions for every unique problem.
- Checking of machined areas with appropriate testing equipment like laser tracker to meet OEM specifications.
In-situ Repairing are primarily done in
- Horizontal Bores & Journals
- Vertical Bores & Journals
- Flange faces
- Horizontal & Vertical flat surface
- Key way cutting in journal & bores
- On-site milling
We can carry out Turning, Milling, Grinding, Facing and Honing on machines and equipment that cannot be worked upon by conventional machines effectively. Machines of huge size and weight, as well as process equipment (dismantling of which will involve a lot of wasted time), can be worked upon.
From a small keyway of 10mm to a huge area of 20meterX6meter, from a small diameter of 20mm to a diameter of 2meter, from a small hole of 10mm to a bore of 3meter - We can machine "In-situ" or "On-site".
Heavy machinery and structures like those in Cement plants, Steel plants, Ship and other process plants. On-site machining & Grinding of Horizontal and vertical flat surfaces, cylindrical surfaces, deep bores, step bores, blind step bores, and taper or conical machining.
In-situ machining is the ideal solution for any component or part of a machine that is difficult to move to a conventional machine because of size, weight, or assembly complications.
In-situ Flange Facing
For repairing / re-machining of damaged or rebuilt flanges in the installed condition. Flanges can be machined to the required surface finish from grinding finish to "Phonographic Serrated" finish. The type of flange facing operation can be widely varied with a single point tool or a multi-point cutter or even a grinding wheel.
Machines can be mounted to Internal (Bore mounted) or External (OD mounting) surfaces that are available to suit different counting conditions. Even special mounting requirements can also be met up to 6 meters.
Type of Flange Machining normally attended to with well experienced service personnel
- Raised Face Flanges
- RTJ Flanges
- O-Ring Groves
- Tube Shell Flanges
- Man-ways
- Gun Mountings
- Pipe & Steam Flanges
- Chamfers and weld preparations
- Phonographic - Serrated finishes
- Good Finish and Flatness accuracy
- Flange facing machine suitable for OD, ID, and Special Mountings
From 50mm to 6000mm Flanges can be machined with single-point tools or milling tools or a grinding wheel as per the requirement.
ID mounting, OD mounting, or special mounting can be provided based on site condition and application. Surfaces can be machined to very close tolerances with the required surface finish.
Vertical, Horizontal, Inclined, or Overhead Flange facing can be performed to the required accuracy.
- Pipe line flanges, Equipment to pipe line flanges
- Pressure vessel cover seatings, Man hole cover seatings
- Furnace Crown rings / Lip rings, Slew rings of Cranes / Turrets
- Heat Exchangers
- Gun / Weapon Seatings
- Most flat, circular seating area machining requirement can be fulfilled with this service
In-situ Metal Stitching
The metal stitching also called the meta lock process is a cold repair process for repairing of cracked or broken cast-iron, cast-aluminum components. This process is based on fundamental engineering principles and is an emergency service for the marine and land-based industries.
This process ensures the leak-proof repair of components operating under high pressure and heat. Cracked or broken Cast-iron Gearbox casings, Pump casings, structures, and machine body parts can be metal stitched to almost original operating condition.
- Most repairs can be carried out on-site, resulting in a great saving time and dismantling.
- Maintains alignment and original surface with little or no machining or re-machining required.
- Dampens and absorbs compression stress and spreads the tensile strains.
- Dampens the load away from fatigue points.
- The repair being completely cold does not require the application of heat which often introduces fresh stress and change of material characteristics.
- A pressure tight seal can be achieved.
- Even completely broken off pieces can be rehabilitated with new casting pieces replaced and metal-stitched in place.
In most cases, a minimum wall thickness of 8 mm will be sufficient for metal-stitching operation.
The use of different types of Locks, Pins, Master-Locks, and special locks and techniques ensure the strength of the joint for long, trouble-free service life.
The strength of repaired components is comparable to new ones.
All types of Casings & housings made of Cast-iron or Cast-aluminium components like
- Gearbox housing
- Bedplate frame
- Cylinder heads
- Pump casings
- Engine block
- Turbocharger
- Brake drum
- Flange plate
- Gas inlet casing
- Machine frames, etc.
In-situ Machining in Cement Industries
In-situ machining is an ideal solution for process industry during breakdown repairs as it brings the downtime to bare minimum. The cost involvement for downtime in a Cement industry is huge and equipment replacement is expensive. We provide on-site machining services that drastically reduces the downtime cost and avoids expensive replacements, thereby helping in productivity and profitability. Our in-situ machines are highly specialized, they are conceived and made considering the exacting requirement at work sites
In-situ machining of intermediate shaft bores, slip ring & grooves, etc can be carried out with minimum down time and high degree of accuracy. The versatility of our machines helps in adapting them to different field conditions and requirements, not only our machines but our machining teams consist of highly specialists of adapting to different situations arising at work site.
The machine we use are designed, manufactured, and owned by us, which enable us to redesign and modify them to suit the site requirements any time.
Our strength is in adapting and evolving to unique situations that require specialized machines and fixtures. Turning, milling, grinding, boring, dowel-hole machining, gear-train locating bore machining or in other words any machining solution that is required in-situ can be carried out by us to meet and exceed the required level of accuracy.
Machining & Grinding
Damaged shaft journals can be machined and ground on-site, either after welding build up or downsizing, to restore the shaft to working condition.
Example- Fan shaft , Roller journals, Trunnion machining and grinding
Machining and rehabilitation of fixed shafts like fulcrum shaft of Rocker Arm require specially adapted fixtures and tools. Those tools & fixtures are versatile and are capable of adapting to different types and sizes of applications.
Shafts and journals up to 2000mm can be machined or ground to close dimensional accuracy with excellent surface finish. Shafts & journals of high dimensions can be machined and ground base on customer special requirements.
Line boring In Housing
Line boring of damaged bearing housing to maintain location and concentricity in shortest possible time is of essence in many situations. Line boring can be carried out either after welding built up or to oversize the housing.
Example - Rocker Arm bearing housings, roller bearing housing, line shaft bearing housing, etc.
- Raw Mill - Gearbox, Mill bearing housing, Rocker arm journals, Rocker arm bushes, Taper pin bores
- Cement Mill - Gearbox, Mill bearing housing, Rocker arm
- Ball Mill - Drilling & Tapping on body, Trunnion journal grinding, Thrust face grinding, Gearbox
- Kiln - Support roller, Thrust Roller, Tyre , Alignment, Gearbox
- Coal Mill - Gearboxes, Shafts, stud repair
- Roller Press Journals
