Sanjay P Valambhiya MD, New Super Engineering Works
In 1995, when we started New Super Engineering works, we had a vision of delivering refrigeration compressor with good quality by remanufacturing the eliminated ones.
Our meticulous effort and commitment have led us to the next level. Our business has grown from smaller scale to larger one. We strongly believe that the remanufacturing and rebuilding businesses provide customer not only with an immediate cost savings, but also help extending life cycles and use materials more efficiently.
We have observed a tremendous growth in refrigeration compressor like Hermetic and Semi hermetic which are widely used by ice cream industries.
The remanufacturing process allows customers maximize the value by
Ensuring maximum productivity, Ensuring cost-effective performance, Increasing reliability Increasing customer’s return on their investment Receiving a like new warranty, Preserving the majority of energy and materials require to make the original component, Same as new performance and reducing the impact on the environment In this era, the intensity of competition in the market is huge. However, our determination is to never compromise with the quality
Our process of operation includes:
Disassembly
All internal and external parts including rods, pistons, crankshafts, bearings, and liners are totally removed from compressor bodies. This also includes fittings, plates, and all electrical components leaving the compressor casting completely stripped.
Parts List
Immediately after disassembly, a complete parts list is made of all internal parts needed for the remanufacturing of the compressor. Compressors bodies and parts are then dispatched to the cleaning department.
Cleaning:
All cast iron components and bodies are burned in an air oven for degreasing. Once all oils and metal particles are burned, the castings are placed in a shot peen machine, charged with specially manufactured soft shot, to clean the castings to its original manufactured appearance. This process is environmentally safe and does not use chemicals that are harmful to the environment. Quality control checks all castings and surfaces to assure no particles remain, and that all surfaces meet the required finish to seal. Surfaces with any marks or scratches are put on a lapping machine or one of our resurfacing machines.
Rewinding:
Varnish
We use the latest material to submerge, dip, and encapsulate stators after windings, then curing in our temperature-controlled ovens.
Vacuum Pressure Impregnation (VPI)
We are the only compressor company that VPI’s stators, 40 HP and above. Our impregnation system ensures full slot penetration of varnish to guarantee no wire flex in the slot to eliminate slot burnouts.
Stator and Rotor Test
All of our semi-hermetic stators and rotors are surge tested to guarantee initial start-up under load. In addition, all stators are tested on a digital watt ohmmeter. This enables us to check our rewinders and make sure all work performed meets E.A.S.A. standards.
The digital ohmmeter measuring is as low as 1/10,000 of an ohm to check for the balance of the coils and conductivity through all soldered connections.
Inspection:
We, at Super Engineering Works, are totally committed to enhance our Customer’s Satisfaction by improvement in quality of all the spares we use and hence we follow small procedure for inspection.
1).We check all the material dimensionally.
2).We also do quality test for spares randomly so we can allow thorough satisfaction to our clients about quality check.
3) We do open head testing to check if any leakage in compressor for 8-12hours continuously.
As we repair old compressors as well, we value our customers money by changing the compressor spares only as per requirement and not blindly changing all the spares because we understand the OEM parts strength and hence we get done grinding, machining, tapping, milling and balancing as per requirement for repairs for old compressor spares. We are also committed to improve organization’s performance by improvement quality management system.
Assembly:
Reciprocating Compressors
Directly from sub-assembly/Quality Control, the compressors are ready for assembly and all internal parts are QC stamped along with the compressor casting. All cylinders are QC approved and recorded on tolerance sheets called Tracer papers, which are with each compressor. The information required for the assemblers is now at their fingertips. Torque specifications, tolerances, and clearances pertaining to each assembly are checked. All The instruments are calibrated, following the ISO Certification program.
Screw Compressors
New Super Engineering Works remanufactures screw compressors for some leading manufacturers. We manufacture Screws of all makes and models. It takes a large amount of specialized tooling that we create in our machine department by our tool and dye maker before we can begin assembly of the Screw line All assemblies meet OEM specifications.
Welding:
Hermetic Compressor Remanufacturing
New Super Engineering Works has a fully equipped welding department which is skilled in submerged arc welding, tig, and argon gas welding. We build Trane, 20 to 30 ton hermetic cans, Dunham-Bush, and Hartford Compressor’s MSC Hermetic compressors. In the near future, we will be building Scrolls.
Testing:
After resurfacing on our Blanchard, the valve plates’ thickness is measured on a true stone using a dial indicator and micrometer. It then goes to our valve plate assembly table.
All pre-qualified internal parts are matched to each compressor casting, and crankshafts are thoroughly checked, going through all tolerances and are laid out with new parts on trays for assembly. The final step for QC is to scrutinize specifications, stamping the parts with the QC approval code. Once completed, the compressor is forwarded to Assembly. Throughout our process in all areas of production, our employees punch in at their department station. The tracer number and employee number is saved in the system. This assures complete tracking of the processes through each department and makes certain that no steps are missed. Detailed reports, including the tracer number, are printed and kept with completed tracer sheets and filed with each compressor.
Compressors are tested with a computerized test program, which monitors test voltages 200, 208, 220, 230, 440, 460, 480, and 575. The entire test procedure begins with a push of a button and goes through a detailed monitoring and recording procedure on amps, vibrations, oil pressures, CFM delivery by stages of unloading to leak back (valve efficiency) test.
Even the oil charge goes through the computer to assure only the correct ounces are charged in the compressor. The computerized test program enables NCE to eliminate human error in testing, and ensures that every compressor is up to only the highest standards of quality. There is no test system in the compressor industry that can perform at this level of quality!