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.
 
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
 
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%
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

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
 
ATW Solution: REPLICATE (URGENT PROJECT)
1) Reverse engineering by dimensional analysis
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
 
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:
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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