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Preventing Maintenance Contract

Benefits of the Preventing Maintenance Contract(PMC)
Helps you in minimizing the maintenance & operation cost with minimum downtime of your Godrej machine by planned and proper periodic maintenance.
You can avail concessional rate for spares which are required to be ordered and kept in stock.
Concessional service charges compared to one time call.
Attention by skilled and trained technicians who will attend to your Godrej machine, suggest timely remedial measures and recommend suitable spare parts to be procured if any. This will help you in proper maintenance of your machine at minimal cost.
Preventive Maintenance Schedule For Godrej Power Press & Mechanical Press Brake
Lubrication
Flush out and clean the lubricating system and refill with fresh oil
Check the oil lines, oil holes and oil grooves for clogging up.
Drain the oil from the enclosed gear box and fill fresh oil to the specified level.
General
Left-to-right and front-to-back level of the machine and correct, if required.
Clearance in the gib guides if excessive, adjust.
Adjust back gauge driving and indicator chains.
Adjust belts for tightness.
Condition of brake liner and brake adjustment.
Tripping linkage/EPT System.
Counter balance assembly.
Clutch assembly for liner wear and replace liner if required.
Electrical contacts and connections and rectify where required.
P B tooling for condition & recommend.
Productivity improvement necessity and recommend any accessories / upgrading.
Preventive Maintenance Schedule For Godrej Mechanical Shear
Lubrication
Flush out and clean the lubricating system and refill with fresh oil
Check the oil lines, oil holes and oil grooves for clogging up.
Drain the oil from the enclosed gear box and fill fresh oil to the specified level.
Motor bearings (with grease)
Drain and refill oil in hold down box.
General Check
Left-to-right and front-to-back level of the machine and correct, if required.
Clearance in the gib guides if excessive, adjust.
Adjust back gauge driving and indicator chains.
Adjust belts for tightness.
Condition of brake liner and brake adjustment.
Knife clearance and reset, if required.
Tripping linkage.
Counter balance assemblies
Hold down units for leakage
Electrical contacts and connections and rectify where required.
Blade sharpness and recommend grinding / spare blade.
Terms & Conditions For PMC
Duration of this agreement will be ONE YEAR w.e.f. date of receiving full earnest money.
Machines are expected to be in good working condition while accepting the contract. In case there is a breakdown thenthe machine will be attended first at cost and the PMC will be separately discussed.
In order to ensure minimum downtime the customer is advised to order and stock all the required spares for PreventiveMaintenance Contract (PMC) in advance. The list of spares is available on the net for standard models or can be requested. In any case our representative will hand over such list while finalizing the contract.
All recommended lubricants, oils, tools, etc., are in the scope of the customer. In addition, we request the customer to provide basic help to our technician like the material handling equipment and semiskilled labour etc.
In order to get the best results, it is obvious that the customer should carry out the daily maintenance as per the guidelinesgiven in manual.
Preventive maintenance shall be carried out as per the laid down format enclosed. However we will be open to carry outany job over and above the scope of preventive maintenance at an extra cost.
The customer is expected to keep available the said machine / s or other facilities. In case of any difficulty the date should be changed in advance by mutual consent. Alternatively the visit will be treated as completed.
It is possible that machine covered under the plan can breakdown. Our services will in any case be available insuch event at an extra cost.
We can also undertake overhaul of subassemblies / assemblies at an extra cost.
We shall be entitled to terminate the agreement in the event of change of ownership or location of the said machine.
Either party shall entitled to terminate the agreement at any time giving one months advance notice, and the customershall be entitled to refund of the advance on pro-rata basis for the unexpired period of the agreement.
If prior to offering the machine for PMC the machine is offered for overhauling, a lump sum quotation towards service charges will be offered with concessional service charges as above.
Fill the below mentioned form for Preventive Maintenance Contract (PMC)
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Precision Engineering Equipment

Godrej Precision Engineering Division delivers customized solutions meeting exacting quality requirements in the high technology domain.Broadly Godrej Precision Engineering business can be classified as:Equipment for Nuclear Power Generating plants of Nuclear Power Corporation Ltd : Godrej Precision Engineering is qualified for several fuel handling and positioning systems for the Power Plants and competes for orders from NPCIL.Equipment for Indian Defence : Largely contributed for 1st time developmental projects for Indian Defence systems.Customized equipment : Large precision fabricated and machined equipment for Gas & Steam Turbines, Turrets for Ladles in Steel industry for the continuous casting process.Manufacture of Wind Turbine Generator Parts : These are precision fabricated and machined to close tolerances. The present focus is to produce the large parts needed for gearless wind turbines.Precision Engineering Services : Offering lifetime support service for equipment and system supplied by PES
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Workshop Vehicle

Application
Field Work shop cabin on wheels.
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Mobile SAR For Defence Lab

Application
System used for microwave mapping of large objects by Defence Laboratory, Jodhpur.
Key Features :
Product Development from concept.
Positional accuracy and movement, with repeatability in 0.5 mm.
Movement :
X axis 10 meters
Y axis 3.0 meter
Z axis rotation 120 degree.
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Object Laying Equipment

Used to lay, bury, camouflage, Anti-Tank bar mines across the plain, desert and semi-desert terrain. The system is built on a 8x8 TATRA V 815 vehicle
Capacity to carry maximum 507 mines at a time
Key Features :
First time development in India for Army.
Power supply system to produce required power of 138HP.
GPS system having accuracy 20 mm, to record position of each mine layed.
Automatic dispensing arming, trenching and camouflage system.
Designed to work at -15 to +50 Celsius.
Challenges :
Space constraints
  • Accommodating sub-assembliesto store and dispense 507 mines in a fully automated mode, with space for seating for two operators.
  • Accommodation of DG for Power supply.
Making the system highly reliable and robust, to handle ammunitions in a very dusty environment.
Modification of the engine chassis to suit our requirements.
Short deploying time - Retaining the mobility of the system (departure angle, belly angle) even while enabling the system to become mission ready in couple of minutes.
Laying mines at 10 seconds interval, continuously.
Electrical:
  • Harnessing the entire wiring.
  • Junction box of DG
  • Cable laying and ducting.
Designing and development of GPS system with 20 mm accuracy
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Calandria For 700MW PHWR

Calandria is the horizontal axis cylindrical vessel at the core of reactor assembly with two end shields at both ends.
The overall size 8282 x 5282 having shell of dia. 7864 & wall thickness of 32 mm of S.S. 304L.
Challenges:
  • Fabrication of shell in 3 sectors maintaining dimensional stability.
  • Welding of all cirseam, long seams maintaining dimensional stability.
  • Welding, Distortion control & sequencing of 122 nozzles on the shell.
  • Cautious Customer since its a first time development order with GPE.
  • 100 % RT of all weld joints.
  • Alignment of small shell & main shell vertical axis within 1 mm.
  • Handling of Calandria shell.
  • Transportation of Calandria to RAPP site
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Mobile Autonomous Launcher

Application
Vehicle mounted Launcher for 3 BrahMos missiles, for autonomous - self sufficient launch.
Key Features :
Operation in extreme conditions -40 to +55 deg C
Mechanical system with Low alloy high strength material, requiring special welding process, distortion control.
High flow hydraulics
Variable speed Power-Supply.
Electrical controls, Software development for Auto-Launch-cycle.
Complete System integration of subsystemsMechanical, Hydraulic, Electrical Controls, Power Supply, A/C, Thermal conditioning, Equipment shelter with Nuclear-Biological filters.
Prompt Site Support for Launcher for Joint Receipt Inspection of Defence forces for induction.
After sales service / AMC.
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Mobile Replenishment Vehicle

Application
Replenish Mobile Launchers with loaded missile containers and remove spent containers from launchers.
Key Features :
System mounted on TATRA 12x12, used for transporting missile containers.
Autonomous operation with crane mounted on vehicle.
Removes spent containers from launcher, loads launcher with new containers.
Loads spent containers on vehicle and transports back spent containers to depot.
System maintains Missiles at desired temperature during transit
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Rotating Plugs

Used for aligning fueling arm with fuel channels in Fast Breeder reactor
Material: A48 P2 plates, forgings
Size: 7 meter diameter 2.5 meter height
Weight: 120 tons
Critical Requirement: Position accuracy within 0.5 mm
Challenges :
Procurement of A48 P2 plates, rings and forgings to required dimensions
Large precision fabrication of 7 meter diameter shells, ovality control within 3mm, gap between two shells within 20 mm
VTL machining with temperature correction, flatness 150 microns Thermocouples installation with He-leak test & RT
Thermocouples installation with He-leak test & RT
Development of custom built Gear boxes designed for seismic conditions
Manufacturing of Turntable Slewing bearings, 7 meter and 4.7 meter diameter as per IGCAR design
Teflon coating proving and application on rings prior to finish machining
Assembly and functional testing to prove position accuracy
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Bridge

Used for positioning Fuelling Machine Head in front of fuel channels in the reactor, remotely operated. Two assemblies needed per reactor
Material: SA 515
Size: 9.6 meter wide x 1.1 meter depth x 12.5 meter height
Weight: 70 tons
Critical requirements:
Precise location of fueling head in front of desired fuel channel, every time
Service life of 30 years
Challenges:
300 precision components per assembly
Large size precision fabrication and machining
Machining of 1.6 meter x 8 meter face within 50 microns flatness
Aligning 10 meter long columns
Procurement of special drive mechanism parts precision ball screws, gear boxes
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Drive Mechanisms - 500 MW, 220 MW

Drive Mechanisms move control Rods up and down in reactor core to control nuclear reaction and also act as safety mechanism to shut down reaction
Material: SS 304, 17:4 pH
Size: 500 x 400x 1200 mm height
Weight of assembly 300 kg
Critical requirements:
Rod drop by 6.6 meter using gravity within 2 seconds
Dampening mechanism to stop rod which can attain terminal velocity of 25 cm / sec
Service life of 30 years
Challenges:
Manufacturing of 130 nos. precision machined components
Smooth functioning assembly for gravity drop and dampening
Assembly performance under simulated operating conditions using SCADA
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Nuclear Reactor 500 MW Air Lock Doors

Air Lock Doors (main and for fuel)
Material: SA516GR 70
Size: max 4500 x 5270 (ht) mm
Weight : 16 Ton / 11 ton
Heavy Fabrication, Machining & Assembly with door opening closing mechanisms
Shop testing and demonstration
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Primary Sodium Pump Shaft, PFBR For BHAVINI Through KBL

Main shaft of Primary Circuit Sodium Pump for Prototype Fast Breeder Reactor.
Material: SS
Size: 700 mm diameter x 11 meter long
Critical Requirement: Position accuracy within 0.5 mm
Made from three parts, two solid forgings about 3.5 meters long and one hollow forged pipe about 5 meters long, at the centre
Shaft to be dynamically balanced at 600 rpm
Challenges :
Reconditioning and calibration of lathe to deliver 50 microns over 12 meter length.
Development of line boring 650 mm ID x 5 meter long and honing of centre piece
Optical alignment and welding of 3 pieces together within 2 mm over 12 meter length.
Development of machining process, parameters to deliver accuracy of 50 microns over entire 12 meter length.
Bearing diameter grinding
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New Fuel Magazine (STIB) 220 MW

Used for handling new nuclear fuel bundles from storage area to Transfer magazine, Two units per reactor
Material: SS 304
Size :1.4 meter x 1.2 meter x 3 meter
Weight: 3 Tons / assembly
Critical requirements:
Precision distortion controlled fabrication, precision alignment of all tubes with two fuel ports
Challenges:
400 precision components per assembly
Machining of components with tolerances in the range 5 to 10 microns
Optical alignment of magazine tubes within 100 microns
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Stand Pipe Thimble Assemblies 220 MW

Control Rods move within SPTA. Connects Drive Mechanisms to nuclear reactor core
Each reactor requires 81 assemblies
Material: SS 304
Sizes: 150 to 300 mm diameter and 3 meter to 6 meter in length
Weight: 18 tons per reactor
Critical requirements:
Precision machined parts for accurate precise assembly at site
Challenges:
Ovality within 50 to 150 microns
Straightness within 100 microns per 300 mm, maximum 1 mm over 6 meter length
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Shuttle Station (STIB) 220 MW

Used for transferring spent fuel bundles from Transfer Magazine to discharge area. Two assemblies required per reactor
Material: SS 304
Size: 1.2 meter diameter, 4 meter long
Weight: about 3 Tons / assembly
Critical requirements:
Precision distortion controlled SS shell fabrication
Precision alignment of fuel ports
Challenges :
Realization of 150 precision components having tolerances 10-20 microns
Optical alignment of carriage guides with fuel ports
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Shuttle Transfer Stations 500 MW

Used for moving spent nuclear fuel bundles from reactor core to under water storage area
Material: SS 304L
Size:2 meter diameter x 5.5 meter height
Weight: 8 ton
Critical Requirements :
High-pressure leak proof water hydraulic cylinders
Equipment works under heavy water
Service life 30 years
Challenges :
Optical alignment of guide ways to ensure movement within 200 microns over 4.5 meter
Aligning guide rods within 100 microns for 5 meter length
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Transfer Magazine (STIB) 220 MW

Used for transferring new fuel bundles from NFM to Fueling machine & transferring spent fuel back to Shuttle Station
Material : SS 304
Size: 1.2 meter x 600 mm x 3.2 meter
Weight: 5 Tons / assembly
Critical requirements:
Precision distortion controlled fabrication
Very accurate Linear recirculating roller bearing made from AISI 440C
Challenges:
200 precision components per assembly
Machining of components with tolerances in the range 10 to 20 microns
Optical alignment of magazine tubes within 100 microns
Development of Linear recirculating roller bearings
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Ladle Turrets For Steel Industry Concast India Ltd

Used for movement of molten metal filled ladle from furnace to "Continuous Casting Machine" for higher output
Material: carbon steel plates max thickness 130 mm and pipes
Precision fabricated and machined material handling equipment
Manufactured Turrets of both types "with Lower & Lift", "without Lower & Lift", weighing from 15 tons to 75 tons
Delivered more than 20 nos. to Concast India Ltd.
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Gas Turbine Components Manufacturing, For CMN (France)

Exhaust casing of Gas turbines
Material: SA 516 Gr 70, D2M1A2 Casting
Size: 2.5 meter diameter x 2 meter
Weight : 7.5 tons
Critical requirement :
Construction in two halves 100% UT welded joints
Challenges :
Concentricity of cone in fabrication within 4 mm
Distortion control during welding of top and bottom flanges with cone due to thickness variation
Development of fixtures for distortion control done in-house
Deep Hole Drilling through struts and shells
Automation in welding for consistency
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Wind Turbine Parts For Wind World India Ltd

A set has 3 components of Carbon Steel of about 4m diameter weight 7.3 tons
Fabrication of a combination of Prismatic and cylindrical sections to accuracies of +/- 1mm over 4m length
As these structures are prone to heavy distortion during welding, special fixtures are developed to control distortion
Extensive use of automatic welding processes FCAW and SAW
SPM for drilling holes on disc rotor, with multi spindle drilling
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Glove Box

What is Glove Box Glove Box (Qty 91 Nos.) Client DAE, (MRPU)
  • A Glove Box is a sealed container that is designed to allow one to manipulate objects where a separate atmosphere is desired
  • Material of construction
  • Size
  • Weight
Critical Aspect of Glove Box: Generally, there are two types of glove boxes exist
  • One allows a person to work with hazardous substances, such as radioactive materials or infectious disease agents
  • The other allows manipulation of substances that must be contained within a very high purity inert atmosphere such as argon or nitrogen
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Toroidal Vacuum Vessel

What is Toroidal Vacuum Vessel
  • Its High vacuum vessel with vacuum requirement of 1 x 10-9 Torr (Highest ever made in GPE)
  • Material of construction : SS 304L
  • Size
  • Weight

Critical Aspect of :
  • Its High vacuum vessel with vacuum requirement of 1 x 10-9 Torr (Highest ever made in GPE)
  • Material of construction is SS 304L
  • Total 111 nos. of ports on Toroidal vessel
  • All the weld joints tested for helium leak testing at rate of less than 1 x 10-9 Mbar L/s
  • Vessel is undergone various cleaning procedures like buffing, Degreasing, Electro- polishing and ultrasonic cleaning to achieve the surface finish of 1 micron and achieve highest cleanliness to reduce out gassing effect.
  • ID of vacuum vessel is electro-polished to improve surface finish to less than 1 micron All the weld joints tested for helium leak testing at rate of less than 1 x 10-9 mbar L/s
  • ID of vacuum vessel is electro-polished to improve surface finish to less than 1 micron.
  • Total 111 nos. of ports on Toroidal vessel

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De-Choker

Used for De chocking Rollers of Hot and cold mill during Maintenance

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Catalyst Basket For Nitric Acid Plant

ApplicationUsed in Nitric acid plant. Component consist of Heat shield, containment ring, Basket & gratings.
Special Material
Haynes Alloy 230 for grating
Inconel 800 for containment ring.
Base Material-SS310 , 800
Welding process-GTAW
Wire-Inconel 82(ERNiCr-3)
Critical requirement :
Assembly of Gratings
100% RT of all weld joints
First time developed in India
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Cmm Calibration

CMM Calibration.
NABL Accredited for CMM Calibration with Laser Interferometer.
Calibration as per ISO 10360-2 standards.
Range of Calibration : 0- 10000 mm
Uncertainty of Measurement: 0.6 + L / 1000 here L is the length to be measured.
Types of CMM Can be calibrated
Moving Bridge.
Fixed Bridge.
Cantilever.
Horizontal Arm.
Gantry.
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Cmm Inspection

  • Model GLOBAL/S
  • X 700 mm
  • Y 1000 mm
  • Z 700 mm
Scope of machine calibration:
Critical dimension measurement on CMM machine.
GRANITE SQUARE, TRISQUARE ENGINEERS SQUARE.
Geometrical parameter inspection like Flatness, Parallelism and Cylinder Distance.
GAUGES & FIXTURES.
SINEBAR.
Platesize : 1400 x 1000 mm
Weight carrying capacity : 800 kg
Note actually job dimension and geometry decides the useful working area on CMM considering probe swiveling conditions and features to be measured.
CMM Calibration & Acceptance Standard
Calibration done as per Calibration standardsISO 10360 - 2.
Repeatability: 2 Microns.
2.5 + 4xL / 1000 here L is the length to be measured.
Advance Facility:
DDC Mode & Data pull
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Microtron Magnet Assembly

What is Microtron
  • Microtron Magnet Assembly is used to generate and energize electrons & photons
  • Material of construction : Extra Ferrite Electric Steel (EFE) SS 316 LN
  • Size
  • Weight
Critical Aspect of Microtron:
  • Welding of EFE required manufacturing of electrodes out of the material itself
  • Magnet Pole, Yoke & Vacuum chamber all needed with demanding accuracies.
  • Flatness of 0.03mm was achieved over a span of 1400mm
  • Helium leak testing with leak rate less than 1 x 10-9 Mbar-litre per second 1
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Oil Header Assembly Of Kaplan Turbine

ApplicationSystem through which pressurized oil enters from top end of turbine and rotates the runner.
It includes series of pipe (total size 34m) passing through shaft center
Scope includeRaw material procurement, fabrication, stress relieving, machining, hydro testing with oil
Critical requirement
Precision fabrication
Accurate & Precise machining of pipe
Hydro testing at pressure 240 bars
Developed first time India for customer
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Machine Tool Service

  • Before Reconditioning After Remanufacturing
  • Noise in the gear box Noise level reduced by app 15 to 20 %
  • Noise in clutch system Abnormal noise eliminated
  • Alignment getting disturbed Alignment restored as per test chart
  • Liners worn out New liner provided
  • Play in the bushes Tooling life improved as expected and increased by 5 times
  • Tooling life has reduced Breakdowns have reduced to 0.5%
  • No. of breakdowns was more approx. 30% Component accuracy found excellent
  • Machine was overloaded Frame repaired
  • Frame cracked Replaced with a new shaft
  • Main shaft bent Piston type clutch fitted
  • Clutch malfunctioning Alignment restored
  • Slide alignment setting disturbed Bushes replaced
  • Clearances developed in bushes Job performance improved
  • Job performance below acceptable limit. Tool life improved and grinding interval improved to 3 months.
  • Tooling getting damaged & needed grinding every 7-8 days Grindlife increased by almost 8 times
Aging machines lead to increasing maintenance cost, unpredictable breakdowns and hence, a drop in performance. Instead of buying a new machine, reconditioning the old one provides almost original performance, is much faster and cost effective, and existing manpower can be utilised. We undertake complete reconditioning of old machines of local and imported makes, providing a 6 months warranty and the Godrej Preventive Maintenance Contract facility. Reconditioning involves complete re-building of the entire machine in order to restore complete functionality and accuracies of the equipment. Based on the scope of contract and your budget, the extent of re-furbishing can include the following:
Complete strip down of the machine with a thorough inspection and replacement, if required, of all worn-out and failed parts with genuine parts.
Machining, grinding, scraping of guides, tables and bearing bushes.
Rewiring of the entire electricals.
Retrofitting of modern hydraulic & CNC systems, if required
Replacement of old lubrication system with a central, motorized, automatic, metered lubrication system with an electronic controller.
Reassembly of the machine.
Realignment of the machine to ensure the original accuracy.
Final inspection, trials & painting of the machine.
Inspection by customer & customer trials.
Re-erection, re-commissioning, trials, training at site.
Satisfied Customers
M/s BEML, Bangalore
M/s Balmer Lawrie, Sylvassa
M/s BHEL, Bhopal
M/s Kerala Electricals, Kerala
M/s S.M.Rolling, Pune
HAL, Bangalore
M/s Supangita Engineers, Bangalore
M/s Northern Railway, Amritsar
M/s Vibha Enterprises, Mumbai
M/s P.M. Techno Bangalore
M/s Remi Motors, Mumbai
Case 1. Imported Machine
Customer Name: MICO, Nashik Make: Krupp 250 T Yr. of Mfg.: 1973 Type of M/c: Forging (H Frame) No. of Yrs used: 25 years Year of Reconditioning: 2000
Customer Name: Supangita Engineers, Bangalore Make: Godrej 100 T Press Type of Press: Forming / Blanking (C frame) Yr. of Mfg.: 1980 Type of M/c: Forging (H Frame) No. of Yrs used: 16 years Year of Reconditioning: 1996
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Bridge And Carriage-700MW Nuclear Reactor For NPCIL

Used for positioning fuelling machine head in front of fuel channels in the reactor, remote operation. Two assemblies needed per reactor
Material: SA 515 Gr70
Size: 11 meter wide x 1.9 meter depth x 14 meter height
Weight:110 tons
Critical requirements:
  • Precise location of fueling head in front of desired fuel channel, every time
  • Service life of 40 years
Challenges:
  • More than 400 precision components per assembly
  • Large size precision fabrication and machining
  • Machining of 1.9 meter x 11 meter face within 50 microns flatness
  • Aligning 14 meter long columns
  • Procurement of special drive mechanism parts precision ball screws, gear boxes and rotary actuators.
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Cryo Arm Second Launch Pad At SHAR - ISRO

Used for carrying fueling pipes to Satellite Launch vehicle
Mounted on launch pad
Material: Structural pipe (API-LX-Gr65)
Precision fabrication of pipes to make boom type structure size 17 meter long , maximum cross section 5 meter x 5 meter, weight 38 tons
Distortion control during welding
Mechanical assembly enabling smooth movement of Arms
Used for fueling Cryogenic fuel just before takeoff on Launch pad
Hydraulic & Electric controls to enable retraction of Arms from Launch vehicle within seconds
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