Case Studies

Problem Statement

The client had ordered stators from a local vendor which had longevity issues. The procured stators stopped working within 15-20 days.

The client required good quality stators with long shelf life.

Challenges

The requirement had to be fulfilled during the Covid pandemic.

Solution

The below steps were followed to manufacture stators that were designed to be durable with longer life. The design and manufacturing included the below:

•             Used High Nitrile rubber which is suitable for adhesive applications

• The rubber was molded at 160 degrees for better vulcanization

•             Hardness of 70/75 was maintained for the application

Results Achieved

After installing the rubber stators, the components performed for a longer time, could sustain the pressure and temperature. The order processed included 30 stators.

The client was happy with the delivery and the products supplied were approved without any rework required.

Problem Statement

One of our clients, a valve manufacturer, reported leakage from periphery in the Valve.

Air was passing through the fabric threads causing the leakage in the valve. Bonding issue of rubber with fabric was observed.

The client required diaphragms which could sustain 4.5 barge pressure.

Challenges

The requirement had to be fulfilled during the Covid pandemic.

Solutions like using rubber with different hardness, changing the moulding method and using a different fabric did not work.

Solution

The below steps were followed to design and manufacture diaphragms that would fix the leakage.

•   We increased the thickness in the mould, so the diaphragm thickness also increased. 2-3 samples for trials were given which surpassed leakage testing

•   Used NBR rubber which is suitable for air application

•   Used high tensile fabric and increased the thickness of the fabric for strength of diaphragm

•   We maintained 60/65 hardness for the application

Results Achieved

After installing the diaphragm there were no leakage and diaphragm was able to sustain the pressure. The order processed included 80 NBR rubber diaphragms. The client was satisfied with the modification made and the products supplied were approved without any rejection.

Problem Statement

The client reported leakage from periphery and ID of Gas Turbine.

Diaphragms were installed in the valves, but there were minor leakages from periphery & ID

The client required – Diaphragms which could sustain 10-15 barg gauge pressure

Challenges

The requirement had to be fulfilled during the Covid pandemic.

Solution

The below steps were followed to design and manufacture diaphragms that would prevent the leakage.

•             We developed a new mold

•             Used Viton (FKM) rubber which is suitable for gas application

•             Used high tensile fabric for strength of diaphragm

•             We maintained 70/75 Hardness for the application

Results Achieved

After installing the diaphragm there were no leakages and diaphragm could sustain the pressure. The order processed included 6 Viton rubber diaphragms. The client was satisfied with the development made and the products supplied were approved without any rework.