Case Studies
POWER & UTILITIES
Water Circulating Pump
The Problem:
Impeller seriously worn out and cracked.
Dia. 1,200mm /Current material UNS C95300
ATW Solution: REPLICATE
1- Reverse engineering using 3D scanning, profile inspection,
2- CAD modelling and casting using 3D technology to avoid casting defects,
3- Machining of the new impeller,
4- Final Inspection by PMI and radiography testing.
2- CAD modelling and casting using 3D technology to avoid casting defects,
3- Machining of the new impeller,
4- Final Inspection by PMI and radiography testing.
Results & Benefits:
50+% Faster, 60% Cheaper than OEM
REFINERY
Seawater Pump
The Problem:
Stage blower worn out from high usage and brackish water.
Current material Bronze B148
Current material Bronze B148
ATW Solution: REPLICATE / REINFORCE
1) Reverse engineer a new part
2) Upgrade material to Stainless Steel CFM8 (UNS 31600)
Results & Benefits:
60% Faster, 60% Cheaper than OEM. Longevity increased by 30%
60% Faster, 60% Cheaper than OEM. Longevity increased by 30%
PULP & PAPER
Wood Chip Feeder
The Problem:
Plug screw housing internal surface heavily worn out.
ATW Solution: RECONDITION
1) Rebuild the screw,
2) Add Stellite 6 as hard-facing
2) Add Stellite 6 as hard-facing
Results & Benefits:
60% Cheaper than Vendor, Longevity increased by 30%
BIO-INDUSTRY
Water Centrifugal Pump
The Problem:
Bearing failure causing dangerous unbalanced impeller operations.
Dia. 285 x 235 mm / Current material UNS S3220S
Dia. 285 x 235 mm / Current material UNS S3220S
ATW Solution: REPLICATE (URGENT PROJECT)
1) Reverse engineering by dimensional analysis
2) Reconditioning of impeller by TIG welding
3) Machining and final assembly
2) Reconditioning of impeller by TIG welding
3) Machining and final assembly
Results & Benefits:
Faster 30 days vs. 3 months by OEM / 70% Cheaper
PETROCHEMICALS
Steam Turbine
The Problem:
Rotor heavily damaged by corrosion pitting.
Dia. 1,000 x 3,500mm
Dia. 1,000 x 3,500mm
ATW Solution: RECONDITION
Reconditioning of rotor using laser welding
Results & Benefits:
70+% Faster / 80% Cheaper than OEM (no international logistics)
OEM (for Petrochemical Plant)
Reciprocationg Air Compressor
The Problem:
Crank case cracked and seriously damaged. Old model discontinued by Burckhardt. OEM asked by Plant Owner to replace the part.
ATW Solution: 3D MODELLING (URGENT PROJECT)
1) Determine if a more recent model of Burckhardt compressors could replace the old one.
2) Use the damaged crank case to conduct a dimensional analysis and generate a 3D model for Burckhardt headquarters.
Results & Benefits:
2) Use the damaged crank case to conduct a dimensional analysis and generate a 3D model for Burckhardt headquarters.
Results & Benefits:
3D modelling done in 3 days: OEM could respond positively to its Client that a New Machine could replace the old one and fit into the same process "location".
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