Projects

Issues

• Incompatible material of internal components subjected to high temperatures.
• Design issues with stresses higher than material yield point.
• Impact loading of components had not been considered as part of the design.

Solution Provided

• Re-designed the components, accounting for impact loading.
• Changed material of components to suit high temperature application.

Issues

• Existing valve was welded inline and replacement of nozzle and seat was not possible.
• Outlet of the new valve was located 45mm lower existing valve therefore outlet pipe required modification.

Solution Provided

• New valve was RTJ flanged which allow future replacement of the seat.
• Developed detailed installation plan including drawings for the installation of the new flanged valve.

Issues

• Some valves were obsolete hence spares were not available.
• High OEM cost to manufacture and supply obsolete valve parts.
• Material incompatibility due to change in process conditions resulting in shortened service life and increased maintenance costs.

Solution Provided

• Reverse engineered components using the CMM. Using the CMM both simple and complex geometries were measured to an accuracy of 0.05mm.
• Prepared engineering drawings and proposed change of material including the necessary surface/heat treatment to suit the current process conditions, thus, improving service life and reduced maintenance costs.
• Sourced and organised manufacturing of the components locally to reduce lead time and cost.

The CMM was also used to carry out quality inspections on in-situ machining work to ensure the work had been carried out within tolerances and specifications.

Efficiency

With the number of valves used in the plant, a software system was required for an efficient management of the technical data and maintenance history of the valves.

Identify bad actors

Software system would help in efficient maintenance planning and identification of bad actors through their maintenance history. This would further help in planning corrective actions to avoid repeated failures.

Document Management

Pro-Mech developed an efficient database that allowed for storing and retrieving of various documents such as data sheets, drawings, overhaul reports, previous modifications, maintenance procedures etc.

Reports

The software also provided a capability to generate reports based on various parameters for technical analysis and future improvements such as system, operating conditions, valve type, size or pressure class.

Detailed Scope of Works

• Prepared detailed scope of work, for the valves scope, with identification of contingency requirements.
• Identified the requirement for specialized services i.e. welding, in-situ machining etc.
• Prepared detailed RFQ’s for engaging service providers.

Safe Work Procedures

• Prepared safe work procedures and ITP’s.

Spare Parts Management

• Prepared spare part lists for each equipment and obtained quotations.
• Placed orders and carried out regular follow-ups to ensure the parts were supplied on time.
• Performed quality inspections of spares on receipt.

Onsite technical support and Quality assurance

• Provided onsite technical and engineering support during the execution phase of maintenance works.
• Carried out quality inspections on the work carried out by the service providers to ensure the work has been carried out as per the defined scope, procedures and specifications.

Detailed Scope of Works

• The existing safety valve installed on the slurry pumps onsite was found to be unstable and leaking during the pump operation. To correct the issue, a design modification was carried out on the valve bonnet
• Post modification, trials were successfully completed, and the design change was implemented on the valves.