This can be particularly useful where parts have become obsolete and cannot be obtained from manufacturers or suppliers. In these cases QCNC can reverse engineer the parts and store drawings/machining codes to reproduce the part in the future with short lead times. The same can be applied to parts with long supplier delivery times, we have been able to cut quoted delivery times from 20 weeks to 3 days!

During the blasting cycle, the deposits, which have been dislodged by the action of the glass beads, are removed by filtration of the glass beads and debris together. The glass beads which have been broken during the operation are also removed at this stage of the filtration, thus assuring that only perfectly round beads are recycled, reducing any possible abrasion to the job by the use of broken beads. This also ensures a zero emission into the environment.

Our Grit Blasting Facility uses steel grit for the removal of heavy rust and corrosion. This also prepares the components with the correct surface profile for painting or other protective coatings.

Before welding any type of material, we use our Material Analyzing equipment to analyze the material composition down to its component elements. From this breakdown we can then select a welding procedure and electrode which will be able to successfully weld the metal. If required, preheat and post-heat procedures are also employed as part of the procedure. Non-destructive testing can also be carried out on critical components.

Our range of fabrication covers Silos, Tanks, Rollers, Drums, Special Storage Containers, Pump Skids, Spools and a vast range of other items. Small fabricated items can also be Sand Blasted down to SSPC-SP10 surface finish and coated with Epoxies or other painting systems specified.

Equipment balanced include, but are not limited to: Turbine Rotors, Pump Impellers, Pump Elements, ID & FD fans, Compressor Rotors, Electrical Rotors, Centrifuges and virtually any type of rotating component or assembly. A comprehensive balance report is provided with any balancing carried out. This report details all input parameters, ‘as found’ condition, tolerances used and ‘final’ balance tolerances achieved. In addition, we have Portable Field Balancing equipment. This equipment is a multi-plane balancing instrument which can dynamically balance jobs on site, without the need to remove the job. It also serves as a predictive maintenance instrument. For example we can take normal vibration readings of your equipment at regular fixed intervals, and plot them on a graph.

Over a period of time, subsequent plots may show an increase in vibration levels on a particular piece of equipment. This is an early indicator that the equipment may fail if not attended to earlier. This type of predictive maintenance saves cost by reducing fixed interval servicing such as bearing changes, which may not be necessary at this point in time. It can also indicate in a timely manner bearing failure, thus saving unexpected down time.

Qualitech has recently installed an indoor Glass Bead Blasting facility. This allows us to clean a Turbine Rotor or any other piece of equipment by using Glass Beads exclusively. The use of Glass Beads ensures there is no damage to the component being blasted. The results are astounding, the cleaned part looks like the “as new” condition. In fact many customers ask to see the facility for themselves after looking at the finished product. The process cleans grime, varnish, rust and any other deposits from the original material. This helps to restore the original balanced condition of the Rotor.

Qualitech undertakes comprehensive repairs to complete pump assemblies or components as required. These include the manufacture of shafts, wear rings, bushings, wear sleeves, spacer sleeves, balance sleeves, throttle bushings etc.

Pumps can be repaired on a turn-key basis. Disassembly of the pump is carried out, followed by a comprehensive report which is discussed with the customer. Component repairs then proceed. We are able to source any type of materials worldwide for manufacture of shafts, wear rings, sleeves, bushings or anything else that is required.

Qualitech has been able to locate special synthetic wear ring and bushing materials which can run dry, temporarily, at temperatures of 500F without seizing. Weld repair procedures are used for specialist welding of all components. Our inspection department can also analyze the original materials used in the pump to verify their composition, using x-ray technology.

Pump casings can be rebuilt and line-bored to original manufacturer’s specifications and even internally coated with abrasion resistant coatings, for longer life. The pump impellers are balanced individually, followed by a progressive balance of the complete rotating element. Final assembly and pressure testing is carried out by experienced in house technicians.

Our In-House overhaul service includes all types of pump assemblies including Vertical, Horizontal Split, and Boiler feed, Turbine, Reciprocating, Vane type, Submersible, Diaphragm and many others.

Turbine Repairs

Turbine repairs is an area which has been rapidly developing, mainly due to customer demand. We have, for a number of years, been in the business of shaft repairs, namely de-stacking Rotor assemblies, repairing/manufacturing new shafts, re-assembling and balancing the complete Rotor. Rotor assemblies can also be Glass Bead Blasted in our indoor facility to look like the “as new” condition.

In addition to this, we now carry out Gas/Steam path repairs, in which Diaphragm vanes and Nozzle blocks etc. are welded and machined back to original specifications. Labyrinth seals can also be fitted, peened and machined on both Rotors and casings. Turbine and Compressor casings are also rebuilt, repaired, re-dowelled, line bored etc. along with any other reconditioning work required to be carried out. Casing faces can be hand scraped and “blued” for gas sealing.

We also manufacture a wide range of spare parts for Turbines using specified materials. These include, among others, Rotor Shafts, Labyrinths, Nozzle Blocks, Speed Pickups, Shafts, Gears, Couplings, Dowels, etc. Rotor shaft repairs can be carried out using a variety of materials including, but not limited to, Ceramics, Stainless Steel or Tungsten Carbide, using the HVOF metal spraying system. Diaphragms are also ‘pad welded’ and machined for a better radial fit in the casing.

Modifications and upgrades are carried out regularly in our workshop under the supervision of OEM representatives, which have included many of the world’s top manufacturers of Turbines, Compressors and other Rotating equipment.

The department is staffed by experienced mechanics that will disassemble the equipment, provide inspection reports, with a recommendation for repairs. The customer may supply the parts required, or they can be repaired or manufactured by Qualitech if the estimated costs are acceptable to the customer. A final inspection report is presented with the completed job, documenting all the work carried out, with all the assembled running clearances etc.

In cases where the customer requests that an original equipment supplier representative oversees the overhaul/ repair, this can be accommodated, as we have had representatives of most of the major equipment suppliers from around the world in our workshop working alongside us. Overhauls carried out include, but are not limited to: Single and Multistage Pumps of all descriptions including Horizontal split, Vertical etc., Gearboxes, Winches, Compressors and a large variety of other industrial equipment used in the different industries.