Mechanical Services

Sulzer Bootham Engineers

Services
Machining
Welding
Surface Engineering
Dynamic Balancing
White Metalling
Unit Reconditioning
Site Services
Mechanical Handling
http://www.sulzerts.com
Mechanical Services
Sulzer Bootham Engineers was originally formed in 1932 and is now
part of Sulzer Turbo Services. Sulzer Turbo Services is the leading,
independent, technically advanced and innovative service and
maintenance provider for all types of rotating mechanical and electro-
mechanical plant worldwide.
Service & Facilities
Sulzer Bootham Engineers operates its Round the Clock service at each
branch and its extensive geographical coverage enables it to meet customer
needs whenever and wherever required. It is supported by a highly skilled
and experienced workforce with well equipped workshops which have adopted
stringent quality management standards. Sulzer Bootham Engineers own
transport fleet will also collect and deliver anywhere in the UK.
Breakdown Service
Mechanical breakdowns cost industry lost production and consequently
lost revenue. They can occur at any time of the day or night and when they
do, Sulzer Bootham Engineers responds quickly to any problem with its
Round the Clock service, bringing savings for the customer in time and
cost.
Market
The customers for Mechanical Services range from small businesses to
large international companies, covering all industries which use machinery.
These include shipping, the major utilities of power generation, mining,
quarrying, water and sewage, and the manufacturing industries, such as
steel, paper, chemicals, food and automotive.
The needs of each customer are varied but usually range from the repair
or re-manufacture of a worn or damaged component, to the overhaul and
rebuild of a complete machine. The Company can, if necessary, manufacture
entirely new components where repair is not possible. Outright
manufacture is also undertaken for new projects and machines, often for
OEMs.
Company Policies
As an international company operating in todays world-wide markets it
has a responsibility to its customers, employees and to the public and, as
such, has formally laid down policies for health and safety, training,
environment and, of course, quality.
The Companys quality objective is to supply products and services which
are fit for purpose and satisfactory in terms of performance, reliability
and safety; in a manner which conforms with the specified requirements
of the Company, its customers and appropriate regulatory authorities;
and which can be verified by documented evidence.
The procedures laid down in the Groups Quality Manual satisfy the
requirements of BS EN ISO 9001: 2008 and, where applicable, material is
sourced and work carried out to recognised national and international
standards.
Machining
Machining is of major importance in any reclamation process, whether it
is turning a shaft to size after welding or metal spraying, grinding a roller
after hard chromium plating or manufacturing a new component such as
a gear, in the refurbishment of a gearbox.
Throughout the network of repair centres, the capability to carry out any
machining process is met by a wide range of facilities which includes :-
Turning
Lathes, capable of accepting work from the smallest components up to
the very largest rollers and equipment, from the heavy industries such as
cement and steel, are available throughout the Mechanical Services division.
Boring
A range of horizontal and vertical borers throughout the division allows a
variety of work to be handled, from small components to large items of
plant. These include the line boring of gearbox and pump casings.
Milling
Universal, Horizontal and Vertical Milling is carried out to meet the
requirements of customers from basic keyway cutting to the machining of
slideways. Each of the companys branches is now equipped with large
Elgamill capacity.
Slotting
Slotting of keyways, serrations and splines is carried out on large capacity
Slotting machines with indexing tables.
Grinding
As a preparation or finishing process, the comprehensive facilities include,
cylindrical, internal, planetary and surface grinding as well as large
crankshaft grinding and camber grinding of rollers.
CNC
For customers with requirements for batch work, the manufacture of
complex components or repeat spares, the division has invested in CNC
turning, milling and machining centres.
Turning facilities enable the production of components from the simplest
pin to shafts requiring up to 8000mm between centres and a swing of
1500mm over the bed. With integral milling and grinding attachments, a
component can be completed in one setting, including the cutting of keyways
and the grinding of journals.
The CNC Machining Centres manufacture components such as cams, dies,
indexing plates, etc and many spare other parts for all types of machinery
and equipment. The recent addition of large CNC Elga Mills further increases
the overall capacity of the division to manufacture parts or carry out sub-
contract machining on larger items.
Inspection
Critical in maintaining the exacting standards our customers have come
to expect are the various stage inspections, to further improve our
inspection and measuring facilities we have invested in the latest technology
for measuring components that are either undergoing manufacture, repair
or re-machining. The investment in portable measurement equipment with
the new 7 axis Platinum Faro Arm allows us to check components not only
in our inspection areas but on machines in the workshop or at our
customers sites.
Welding
Sulzer Bootham Engineers uses a comprehensive range of reclamation
welding processes and the experience of its engineers in determining the
most effective method for a particular application is a major advantage to
customers. Welders at all branches are highly qualified, most have served
recognised apprenticeships and have qualifications to national and
international standards.
The repair to heavy duty bearing housings for steel works, water pump
parts for power stations and acid pump parts for the chemical industry all
demonstrate the different welding techniques that are available from the
extensive range.
The various welding processes are further used to provide our customers
with a comprehensive specialist fabrication service, fabrications to
customers drawings or to replace existing parts can be designed,
fabricated, heat treated and machined dependent on the requirement.
Fabrications can be from mild steel, structural steel, stainless steels,
aluminium alloys and many other specialist materials.
MIG
MIG is used for high deposition rate welding and offers a wide choice of
metals to overlay or match parent material to a high quality. Steel
castings, shafts, fabrications and aluminium pistons can be reclaimed using
this method.
TIG
TIG is used extensively for customers in the plastics industry, where p
erfect coatings of cobalt alloy are required on extrusion screws. However,
it can also be utilised for hard face deposition on gland areas in pumps and
on valve seats.
Hot Wire TIG
Where welding is required with a high degree of control and a smooth weld
profile, such as the reclamation of external diameters of shafts or the
recovery of long small diameter bores, this computerised welding system
produces a very high specification weld deposit. It can also be used for
weld cladding components from the off-shore oil industry, where it was
originally developed, or the chemical industry where it gives corrosion
resistance when using materials such as Inconel 625. Most materials
that are made into welding wire can be deposited by this technique.
Submerged Arc
Submerged Arc is used for heavier deposits onto large items of plant from
industry, such as crane wheels, rollers and shafts. Using rotary welding
of this type ensures that any stress build-up is evenly distributed.
Spiral Welding
Spiral Welding, in either its MIG or TIG form, is a fully automated process
and can be used for small and medium diameter shafts. It is particularly
beneficial in reclaiming acid resistant pump shafts, splined shafts and
impellers. The rotary action also means an even distribution of weld
stresses.
Manual Metal Arc
Manual Metal Arc is used extensively for a wide variety of specialist repairs
to iron castings, such as engine blocks, using ferro nickel consumables.
Because it is very portable, this process is particularly useful for on-site
work.
Surface Engineering
BESCOTE

System
For the optimum performance of a component in a specific environment,
the most suitable surface or coating has to be engineered. This is the
basis of surface engineering. The BESCOTE

system has been

established to facilitate the selection and application of the most suitable
and cost effective surface be it by welding, electro plating or thermal
spraying. BESCOTE

takes full account of the components operating

environment, its base material, working temperature and any corrosive or
erosive conditions as well as life cycles and costs. The BESCOTE

system can then be formulated for the application and fully defined and
documented.
Electro-Plating
Both hard chromium and heavy nickel plating facilities are available from
branches throughout the UK.
Hard Chromium
Hard Chromium produces a metal coating with a low co-efficient of friction
recognised for its hardness, wear resistance and, when used with nickel,
anti-corrosion properties.
Mining equipment, rolls and cylinders all benefit from the reduced wear
rate and anti-corrosion properties, whilst the low co-efficient of friction
makes chromium an ideal coating for bearing journals, crankshafts and
hydraulic rams.
Nickel
Nickel can often be used under chromium for corrosion protection or where
heavy deposits are required. Nickel alone can give an added protection to
components operating in highly corrosive atmospheres or chemical
solutions.
With plating tanks amongst the largest in the country the majority of
industrial plating work can be accommodated.
Super Finishing
By using the latest microfinishing machines, customers can specify
repeatable surface finishes of less than 1 in. CLA.
This process can be used on almost any material including steels, iron,
hard chromium and nickel plating, ceramics, chrome and tungsten carbides
and even paper or rubber.
Customer requirements for super finishing include:- Chrome plated rollers
for the printing and magnetic media industries where mirror-like finishes
are essential, and plungers and rams where seal life and performance
require a specified surface finish.
Thermal Spraying
Sulzer Bootham Engineers offers all forms of Thermal Spraying, currently
available, which can be used to restore component dimensions with similar
materials to the original. However, using todays more suitable engineered
coatings results in increased life without distorting, cracking or inducing
embrittlement into the base material. It is widely used for repair and OEM
applications in gas turbine and aerospace manufacture.
Combustion Wire
This method provides a high quality, cost effective and fast turnaround
process for rebuilding small to medium size components, such as bearing
areas on pump shafts and motor rotors. It uses wire drawn consumables
such as carbon and stainless steels, copper, nickel alloys, zinc and
aluminium.
Electric Arc
The fastest form of thermal spraying uses the same type of consumables
as combustion wire. It is particularly suited to the reclamation of larger
components such as hydraulic rams and printing cylinders. Two wires are
used, usually of the same composition, which are melted in the electric
arc and then projected on to the work piece using compressed air. Dissimilar
metals like carbon steel and copper can be used to form pseudo alloys to
give high resistance to wear with good heat dissipation properties for
clutch plates.
Combustion Powder
This process deposits any type of powder that can be melted in an oxy /
acetylene flame, though materials of similar composition to wires can be
deposited in this way, it is more commonly used for spraying oxide ceramics
and fused hard facing alloys. The most popular applications with Sulzer
Bootham Engineers customers are fused coated pump plungers and steel
work rollers.
Plasma
Generating gun temperatures that are hotter than the surface of the sun
to melt any powdered consumables, plasma coatings are of superior quality
and integrity being extremely dense and well bonded. Ceramic oxides of
chrome, aluminium and titanium give longer life, often fourfold, to seal
areas particularly for centrifugal pump gland sleeves and shafts, as well
as reciprocating pump plungers. Oxides of Zirconia give excellent thermal
barrier properties to power station burner tips and motorsport exhaust
systems.
HVOF
The HVOF principle of operation is similar to that of a rocket motor, using
either propylene gas or kerosene liquid as a fuel. With particle velocities
of four times the speed of sound, the coatings are best described as
superlative for extreme wear and erosion conditions. The systems strength
is in the application of tungsten carbides and chromium carbides to improve
wear life on fan blades, pump casings and tile moulds. Some of Bootham
Engineers latest developments in this field position the company at the
forefront of Surface Engineering technology.
Dynamic Balancing
Following the manufacture or repair of any rotating component it has
become standard practice to dynamically balance. Balancing reduces
bearing load and running noise and increases the life, quality and efficiency
of rotating machinery.
The Companys balancing service is available at its workshops and on-site,
using the very latest electronic precision balancing equipment. With a
workshop capacity ranging from 0.1 kilograms to 14,000 kilograms and to
a maximum length of 9 metres, most components can be accommodated
and balanced either to a specific tolerance or to ISO 1940-1:2003,
BS6861-1:1987.
Should the component require a mandrel or modification to enable either
mounting in the machine or the attachment of correction weights,
experienced engineers will design and manufacture the necessary parts,
taking into account the tolerance to be achieved.
This service is not limited to in-house manufactured/repaired items, the
Company also carries out dynamic balancing of production batches for
many Blue Chip companies.
White Metalling
White metals of varying grades have long been used as an anti-friction
material for lining bearings. The applications include bearings for turbines,
gearboxes, internal combustion engine crankshafts, stern tubes and fans.
As with other metal replacement processes, white metalling depends on
thorough preparation, top class quality control procedures and a wealth
of experience, not only to carry out the work, but also to select the
appropriate grade metal.
New metal, to a national or international standard, is always used as
premature failure from inclusions and gas induced cavities can occur
through using reclaimed material.
Temperature controlled melting pots ensure the metal properties are
maintained at the highest level and non-destructive testing, such as
ultrasonic, is then used to check the quality of the bearing and its bonding
with the supporting shell.
The Companys extensive machining facilities mean that the finishing of
bearings is equally controlled in respect of quality and delivery.
Unit Reconditioning
Mechanical machinery from all industries has one thing in common it
loses efficiency during normal operation through wear.
Using in-house precision fitting skills, all types of process machinery, pumps,
engines, compressors, crushers and gearboxes can be reconditioned back
to their original, or even an enhanced standard. The components of these
assemblies can be reclaimed using the extensive range of metal replacement
techniques available, thereby improving their service performance and
extending life cycles. The units are then meticulously rebuilt, followed by a
thorough final inspection.
Reconditioning has many benefits over buying new. Firstly, it can be quicker
than waiting for a replacement unit, especially if the original is old. A new
unit may not fit, creating extensive problems during re-installation and
further work may be necessary to ensure satisfactory operation.
Improvements in the wear characteristics of key components can often be
achieved through the use of surface engineering, thereby increasing the
units operational life.
Gearbox Overhaul
All types and size of gearboxes from stirrer and shaft mounted gearboxes
to double reduction and mill gearboxes can be overhauled within the branch
network.
Gearbox overhaul gives the customer a cost effective and in many cases,
faster alternative to the purchase of a new unit. In cases of obsolete
equipment, the client can use the gearbox that fits exactly rather than
adapting a modern near equivalent.
Pump Overhaul
Sulzer Bootham Engineers refurbishes pumps used in all process industries,
from chemical works to food factories, coal mines to paper mills, and
power stations to steel works, as well as water supply and sewerage
treatment.
The range of pump types and sizes is equally diverse and covers single and
multi-stage centrifugal pumps, reciprocating ram pumps and vacuum pumps
including liquid ring, Roots type, rotary vane and reciprocating units.
Again, the complete refurbishment can be carried out at each branch;
from the initial assessment of the work required, by skilled teams of
technicians, through the repair itself, which can include welding and
machining of casings, thermal spaying and regrinding of shaft bearing areas
or the manufacture and re-machining of parts where the component may
be beyond repair; to the final rebuild and thorough inspection.
Of special interest for pump refurbishment are the modern surface coatings
which can be used to increase the life of components, by many times in
some cases, or epoxy-based coatings which reduce the surface friction
inside the casing giving savings in energy costs.
Power Presses
The automotive and white goods industries use Sulzer Bootham Engineers
services for the overhaul of power presses and their components. Sulzer
Bootham Engineers has an exclusive agreement with OEM to provide its
entire off site workshop requirements and spares support service. The
agreement also gives full access to OEMs technical archives.
Site Services
For equipment that cannot be removed from site and where it is less time
consuming or more cost effective, the Company can carry out many of its
wide range of services on site.
These services include: -

Fitting and Servicing

Hydraulic Services

On-Site Machining

Thermal Spraying

Welding

Electro-Plating

Predictive Maintenance

On Site Balancing

Laser Alignment

Labour Supply
Fitting and Servicing
The removal and installation of mechanical or electrical plant will often
require professional skills and specialist handling equipment. At Sulzer
Bootham Engineers we are well equipped to undertake this work,
experienced fitters can attend your Works to repair equipment on site or
are able to remove the equipment, refit and re-commission on completion
of repairs. The type of plant and equipment can be virtually anything including
power presses, production machinery, machine tools etc.
Hydraulic Services
Specialist Hydraulic Services are available including, Condition Monitoring,
Flow Testing, Fault Finding and Diagnostics, Planned Maintenance, upgrading
of Existing Machines, Component Repair, Supply of New Equipment and
Spare Parts.
All these services are available to cover industries such as Mining, Shipping,
Waterways, Railways, Automobile Industry and for all types of Production
Machinery including Power Presses, Injection Moulding Machinery, Winches,
Scissor Lifts, and Mobile Plant etc.
Hydraulic Cylinders are manufactured complete as replacements or to
customer design, design and manufacture services are also available to
suit your requirements, all services include full test and certification on
completion.
On-Site Machining
We provide a comprehensive, in-situ machining service. Our portable
equipment can be adapted for a wide range of machining applications,
purpose built equipment can be manufactured to suit any application
regardless of size.
On Site Machining Services Include:

Flange Facing

Line Boring

In-Situ Milling

Pipe Cutting

Shaft Turning

Stud Removal

Drilling

Commutater & Slip Ring Machining
We manufacture site machining equipment for specialist applications not
only for ourselves but for customers, this service is especially useful when
customers require a quick turn around to meet production demands, this
can also include repair of old or worn out machines.
Thermal Spraying
Integral to the On-Site machining process is the full range of thermal
spraying processes; these services can also be made available at your
site.
Welding
Welding for the overlay of worn components such as shafts, weld repairs
to machinery and associated parts or for fabrication of new parts. Engineers
equipped with portable welding equipment and generators when power
supplies are not available.
Electro-Plating
Selective plating of scored shafts, rams or bearings with metallic coatings
such as hard chromium and nickel.
Predictive Maintenance
Our Condition Monitoring programme tracks the change in a machines
condition and reduces the chance of any catastrophic failures and loss of
production, allowing routine maintenance to be carried out when it is
convenient rather than when it is an emergency.
Vibration Analysis Measuring vibration is an excellent, non-intrusive tool
for detection of mechanical and electrical problems such as: - mechanical
imbalance, misalignment or defective bearings and gears as well as electrical
problems.
Thermography is a non-intrusive tool used to detect temperature values
which can be analysed to identify many potentially expensive faults before
failure occurs.
Problems in, for example, bearings, hydraulics, fuses, control boards and
overhead power lines, can be identified using our top of the range Thermal
Imaging cameras and the latest software.
On Site Balancing
Imbalance is probably the most common cause of excessive vibration, so
we have invested in the latest portable, in-situ balancing equipment. The
balancing procedure can be performed with minimum disruption and saving
unnecessary downtime and costs. As normal practise our operators will
always carryout vibration analysis on the equipment prior to balancing to
ensure that imbalance is the problem.
Laser Alignment
Drive shaft alignment is one parameter that is critical to the life of bearings,
seals and couplings in rotating equipment. Even the smallest amount of
misalignment can cause abnormal stresses in rotating machines, quickly
leading to excessive wear in components.
Re-alignment of the machines, using the very latest electronic laser
equipment, can be quickly carried out by our engineers. The laser system
is easily fitted to the shaft or coupling of horizontal or vertical mounted
machines.
Labour Supply
Alternatively we can supply necessary manpower to supplement your own
workforce, even at supervisory level if necessary. Whenever you need
additional labour, be it due to illness, holidays or during periods of scheduled
maintenance, we can help out for as long as is required for a single day or
for several weeks or more.
Mechanical Handling
The lifting division offers a comprehensive service to industry for all lifting
and mechanical handling needs covering the following services.
Design, Manufacture and Installation
This service covers the design, manufacture and installation of mechanical
handling equipment from simple supported runway beams to complete
factory handling systems, overhead cranes, gantry structures, jib cranes,
portable gantries and spreader beams.
Supply of New Equipment
Sulzer Bootham Engineers has distributorships which cover the supply of
chain slings, wire slings, belt slings, round slings, load restraints, shackles,
eyebolts, plate clamps, electric hoists, chain blocks, pull-lifts, winches,
hydraulic lift tables and jacks.
Repair, Test and Re-Certification
All the equipment we manufacture and supply can also be repaired, tested
and re-certified to its original specification to meet with the current
regulations. This service can be extended to cover any mechanical handling
equipment, including other items such as fork truck tines.
On-Site Testing
A fleet of vehicles is equipped with Hiab cranes and test weights to carry
out on-site testing and certification at the customers works.
Lifting Equipment Hire
For those unforeseen or infrequent requirements, a comprehensive range
of equipment is available for hire.
Infra-Red and Radio Control Systems
Offering improved efficiency and safety, these state-of-the-art systems
can be installed within a day to give the added benefits of reduced
maintenance and breakdowns.
Operator Training - Health & Safety
Todays Health & Safety legislation means it is essential that operators
are trained in the safe use of lifting equipment. Safety training courses,
organised by Sulzer Dowding and Mills at its own works or on site, enable
customers to meet this important requirement.
Lifting Equipment Engineers Association
So that customers can have complete confidence in all services, the
Companys engineers are trained and examined to standards laid down by
the LEEA, and audited at regular intervals.
Avonmouth Tel: 0117 938 1188
Third Way,
Avonmouth,
Bristol BS11 9HL
Fax: 0117 938 0066
Email: bootham.avonmouth@sulzer.com
Daventry Tel: 01327 877410
Unit 12C,
Daimler Close,
Royal Oak Industrial Estate,
Daventry,
Northants NN11 8QJ
Fax: 01327 877411
Email: bootham.daventry@sulzer.com
Scarborough Tel: 01723 582621
Cayton Low Road,
Eastfield,
Scarborough YO11 3BZ
Fax: 01723 583455
Email: bootham.scarborough@sulzer.com
Southampton Tel: 023 8023 4999
William Street,
Southampton SO14 5QH
Fax: 023 8023 4312
Email: bootham.southampton@sulzer.com
York Tel: 01904 477670
Amy Johnson Way,
Clifton Moor,
York YO30 4WT
Fax: 01904 691826 Engineering
Fax: 01904 690641 Mechanical Handling
Email: bootham.york@sulzer.com
Sulzer Bootham Engineers
Sulzer Bootham Engineers 2011
Useful Conversions
Length
1 millimetre................ = 1000 micrometres................. = 0.0394 inch
1 centimetre...............= 10 millimetres........................ = 0.3937 inch
1 metre...................... = 100 centimetres.....................= 1.0936 yards
1 kilometre................. = 1000 metres..........................=.0.6214 mile
1 inch.........................................................................= 2.54 centimetres
1 foot.........................= 12 inches...............................= 30.48 centimetres
1 yard.........................= 36 inches.............................. = 0.9144 metre
1 mile.........................= 1760 yards...........................= 1.6093 kilometres
Area
1 sq metre..................= 10,000 sq centimetres........... = 1.196 sq yards
1 hectare...................= 10,000 sq metres..................= 2.47U acres
1 sq kilometre............ = 100 hectares.........................= 0.3861 sq mile
1 sq foot.....................= 144 sq inches.........................= 0.0929 sq metre
1 sq yard.................... = 9 sq feet................................= 0.8361 sq metre
1 acre....................... = 4840 sq yards.......................= 4046.9 sq metres
Capacity
1 cu decimetre............= 1000 cu centimetres..............= 0.0353 cu foot
1 cu metre..................= 1000 cu decimetres................= 1.308 cu yards
1 litre........................ = 1 cu decimetre...................... = 0.22 gallon
1 cu yard.................... = 27 cu feet..............................= 0.7646 cu metre
1 pint........................ = 4 gills................................... = 0.5683 titre
1 gallon......................= 8 pints..................................= 4.5461 litres
Weight
1 gram........................= 1000 milligrams......................= 0.0353 ounce
1 kilogram.................. = 1000 grams.......................... = 2.2046 pounds
1 tonne.......................= 1000 kilograms.......................= 0.9842 ton
1 ounce.......................= 437.5 grains..........................= 28.35 grams
1 pound.......................= 16 ounces..............................= 0.4536 kilogram
1 stone......................= 14 pounds.............................= 6.35 kilograms
1 ton......................... = 2240 pounds.........................= 1.016 tonnes
USA Dry Measure Equivalents
1 pint......................... = 0.9689 UK pint.......................= 0.5506 litre
1 bushel.....................= 0.9689 UK bushel.................. = 35.239 litres
USA Liquid Measure Equivalents
1 pint (16 fl oz)...........= 0.8327 UK pint......................= 0.4732 litre
1 gallon = 0.8327 UK gallon = 3.7854 litres
Temperature Conversion
C = (F - 32) x
5
9
F = + 32
9 x C
5
............................................
Celsius -18 -10 0 10 20 30 40
Farenheit 0 10 20 30 40 50 60 70 80 90 100 110
http://www.sulzerts.com
Camp Hill, Birmingham B12 0JJ
Tel: 0121 766 6161 Fax: 0121 766 6098
Sulzer Bootham Engineers