Our Services
 
Total Engineering Solutions   Reverse Engineering Spare Parts   Retrofitting Faulty Mechanical Seals   Refurbishment & Supply of Existing/
New Mechanical Seal
 
Condition Monitoring   In Situ Vibration Analysis   Balancing   Laser Alignment
  Total Engineering Solutions
We provide total engineering solutions to resolve root issues in problematic rotating equipment such as pumps, blowers, and compressors that, if left to progress, will lead to catastrophic failures.
 
Causes of Issues
Most underperformance and failures (e.g. seal leaks) in rotating equipment are due to imbalance, misalignment, wear and looseness, leading to excessive vibrations that accelerate wear and lower power efficiency.
Our Solution Process
CFD Flow Simulation
Using computer-assisted Computational Fluid Design (CFD), our teams analyse and understand how interacting components in rotating systems behave. Based on the flow simulation, our team redesigns and modifies the equipment for improve efficiency, reliability and safety.
 
Reinforcement
Certain spare parts for the rotating equipment may be outdated, expensive, or even obsolete. Replacing these parts might not offer a sustainable solution, as the problems could resurface over time. To provide a more permanent solution, we offer total redesign and reinforcement services to strengthen and fine-tune the equipment.
  Reverse Engineering Spare Parts
Reverse engineering offers a workaround for replacing obsolete spare parts in rotating equipment that are:
 
   Expensive
 
   Old & obsolete
 
 
   Difficult to procure
 
   Unsustainable (temporary solution)
 
However, developing accurate blueprints for reversed engineered parts is a highly technical challenge that is prohibitively expensive if carried out manually.
 
Our Solution Process
Computer-Assisted 3D Scanner Design
Using computer-assisted Computational Fluid Design (CFD), our teams analyse and understand how interacting components in rotating systems behave. Based on the flow simulation, our team redesigns and modifies the equipment for improve efficiency, reliability and safety.
  Retrofitting Faulty Mechanical Seals
Retrofitting can be a cost-effective option to upgrade existing systems and simultaneously replace faulty components with improved performance and safety characteristics.
 
To achieve this, a component has to be disassembled, inspected, measured, redesigned, and reassembled
 
   A process that requires a high-level of specialised expertise and equipment.
Our Solution Process
Detailed Analysis
To determine areas for improvement, rotating equipment and its components will be disassembled, cleaned, photographed, and inspected for a detailed analysis.  
 
Fabrication, Assembly & Testing
Once the changes are determined, components that need to be replaced are measured, modelled in CAD, and sent to a third party for fabrication. The component is then collected, reassembled, and tested for optimal function.         
  Refurbishment & Supply of Existing/New Mechanical Seal
 
Replacing worn mechanical seals is a significant cost associated with operating high-performance rotating equipment, with damage often resulting from rotor misalignment, seal incompatibility, excessive heat, improper installation, and poor storage conditions.
 
Our Solution Process
Lapping & Polishing
Using a combination of lapping and polishing, it is possible to smoothen the surfaces of mechanical seals to working order with the exact surface finish and flatness tolerances for optimal functionality. 
 
Leak Test, Elastomer Upgrade & Site Installation
A leak test is performed and the elastomer is upgraded or replaced as necessary before the fully refurbished component is installed on-site.
  Condition Monitoring
Condition monitoring is a preventative maintenance approach that employs specialised sensors, analysers, and software to measure vibrations and other parameters to:
 
 
   Predict the long-term functionality and safety of rotating machines.
 
   Identifying issues that can progress into catastrophic failure or result in long-term inefficiency and productivity loss.
Our Solution Process
Long-Term Analysis
Condition Monitoring sensors and analysers are attached directly to rotating equipment where long-term operating data is collected and sent to our computers for detailed analysis. Customers will receive an alert with the recommended actions if repairs are necessary.
  In Situ Vibration Analysis
For large equipment with vibration issues, we offer on-site services where our team conducts thorough analysis to identify any underlying problems, including potential structural issues. 
 
Depending on the condition of the equipment, we provide recalibration services to ensure optimal performance of the equipment, making necessary adjustments as required.
Our Solution Process
Operational Deflection Shape (ODS) Analysis
ODS combines dimensional and vibration data to create visual simulations of vibration patterns of a machine or structure - thus allowing for easy and accurate analysis to facilitate corrective actions. If issues are detected, a technical team will be sent on-site to assist with repairs.        
  Balancing
 
Over time, even well-built rotating equipment can undergo misalignment, cause imbalances, and produce vibrations that can damage their structure and components. 
 
Our Solution Process
In Situ Balancing
Our teams can carry out balancing while rotating equipment is operating and without dismantling and reassembly - thereby allowing for balancing issues to be resolved within days.
 
Shop Balancing
For more complex balancing issues, rotating equipment will be transferred to our factory where balancing work can be carried out with heavy-duty equipment and specialised tools.
  Laser Alignment
 
When heavy rotating equipment operate at high speeds, any misalignment in the coupling shafts and other moving components can sufficiently damage bearings, seals, and couplings to result in catastrophic failure.
Our Solution Process
Laser Precision Alignment
Our teams utilise precise laser tools when realigning critical components (such as shaft couplings connections) back to correct operating tolerances.
 
Graphical Interface & Computerised Alignment Report
In addition, our laser alignment solution technology is equipped with an intuitive graphical user interface that displays real-time vertical and horizontal alignment data to help minimise errors.
Spark Engineering Sdn. Bhd.
199101017567 (227879-P)