Manufacturing Capabilities

Principal Products

  • Fixed and Portable Tanks
  • Pressure vessels, heat exchanger units& Fabrications
  • Industrial fire tube boilers
  • Boiler repair and replacement parts, fabricated systems
  • Steel Structure
  • Construction & Modifications

Certifications

Information

ASME S, PP, U and NBNational Board ‘R’ Certification of authorization

Specialty Fields

Equipment for steam generation, heat exchangers, pressure vessels (petrochemical and industrial), heat recovery boilers, generalconstruction services.

Services Available

Engineering

Total Solutions’ engineering department is staffed with experienced engineers and technicians in all areas of design and manufacture, through to final commissioning; employing the latest developments in CAD based technology.

Manufacturing Program Management

Manufacturing Program Management staff coordinates the activities ofthe project team to support manufacturing of contract components.

Manufacturing

A multi-disciplined staff, that support all technical and fabrication requirements. Staff includes manufacturing and welding engineers, programming and tooling designers and all operating support functions. Organized as a structured business unit matrix, allowing focus on individual product fabrication.

Production Control and Manufacturing Services

This department provides support for all project planning, shop planning and shop floor scheduling requirements for manufacturing. They also provide all performance metrics and order status reporting.

Purchasing and Material Control

Material to meet specific project requirements is purchased fromsuppliers qualified in accordance with recognized quality programs.Modern concepts are utilized in the receiving, storing and inter-plantmovement of material. Main stores has two parts carousels, andautomated tool dispensing machines are used in the plant. Aquantity of sheet, plate, tube, pipe, structural steel and pressurevessel fittings

Facilities Engineering

Facilities and Industrial Engineering provide design and projectengineering services for tooling and equipment to supportmanufacturing.

Transportation

Total Solutions’ logistics department is staffed with transportationprofessionals experienced with delivery of our product by rail,barge, multi-axle transporter, heavy lift vessels, flat deck transport,and airfreight. Our department includes a customs specialist, wellversed in international customs documentation and materialclassification.

Quality Assurance

Our fully integrated quality assurance program extends from contract proposal through engineering, to fabrication and site erection of equipment.

Quality Control

Quality control services include a full range of non-destructive testing services, including: calibration of equipment; instruction; certified ASNT level II&III personnel for shop, field or offshore work; gauge calibration laboratory with calibration standards traceable to national standards; full range of physical, visual, metallographic, and dimensional inspection equipment with qualified operators formaintenance of shop and field quality control.

Metallurgical

  • Bend testing machine
  • Charpy impact machine
  • Drop weight ductility testing machine
  • Hardness testers (Rockwell, Brinnell)
  • Microphotography
  • Pyrometers
  • Spectroscope
  • Temperature recorders
  • Tensile strength testing

Non-destructive examination

  • Training level II instructors
  • Helium leak testing
  • Hydrostatic testing
  • Pneumatic testing
  • Liquid penetrate testing
  • Magnetic particle testing
  • NDE equipment calibration services
  • Radiography: Ir92 (Iridium) ray sources,250 kV x-ray equipment
  • Ultrasonic instruments for flaw detection, 3.03 m (10 ft)Immersion Bridge, and digital thickness gauges.

Working Areas & Storage

TS facility was designed and highly equipped to achieve smooth and safe manufacturing processes.

Indoor manufacturing& Office area :7,000 m2

Outdoor working area: 6,000 m2

Storage areas: 2,000 m2

The painting area:1,000 m2

Controlled accessindoor area with controlledatmosphere, maintained tominimize dust anddirt. With overheadradio controlledforklifts bridge.

Total Facility area:

15,500 m2

Indoor manufacturing

7,000 m2

Outdoor working

6,000 m2

Storage area:

2,000 m2


PCD 1100/3B


Material Handling Equipment

Type

Description

Capacity

Overheadcrane

indoor overhead travelling bridge cranes

10 tons

Mobile crane

various mobile

material handling equipment, cranes,

forklifts, etc

25 tons

Forklifts

power rotating units

7 tons

Cutting Equipment

Type

Description

Capacity

Plasma arc cutting

single hand torches, semi-automatic radiograph and circle burners

maximum cutting s.s. capacity 2 in. (5 cm)

Power saws

single hand torches and multiple torch

cold saw

hack saws

16 in. (42 cm) round rectangular

23 x 16.5 in. (58 x 42 cm)

3 in. thick (7.6 cm)

12 x 20 in. (30 x 50 cm)

Cutting Equipment(cont.)

Type

Description

Capacity

Oxy-acetylene

single hand torches and multiple torch machines with photoscopic

and template racing, radiograph, circle burners

Arc-air

manual and automatic

Abrasive

auto back grooveweld seams

automatic belt grinding

Mechanical beveling

general purpose cutoff and bevel of tubing

Hydraulic Shear

4m width and 8 mm Thickness


Forming Equipment

Type

Description

Capacity

Plate rolls

horizontal and Cold

Cold:1 in. thick x

2.5 m wide max.

Tube and pipe benders

rotary benders complete with dies

5 in. dia max. (12.7 cm)

Welding Equipment and Processes

Welding capability in carbon, alloy, ferritic and austenitic stainless steels, aluminum, nickel, inconel and copper alloys. Complete implantfacilities for qualification of procedures and welders. Procedures and welders qualified in accordance with ASME, ASTM Codes

Processes

Equipment

Automatic dual station

fin welding machine

automatic dual tube fin welding station

automatic material handling equipment

tub: 1½ - 3 in. OD; 21.3 mlong

fin: 3/16 in. - ¼ in. thick, ½ in. - 3 in. wide

Flux cored arc

with fume source extraction guns

Gas metal arc

short arc, linear and circular overlay,

Welding Equipment and Processes(cont.)

Processes

Equipment

Shielded metal arc

rotary, transformer

Automatic Dual Station

Boom & Column

Welding 1200A Lincoln

5.5m Column

4m Boom

Submerged arc(single and

tandem wire)

table size: 10 x 300 ft (3 x 91 m)

submerged arc mounted on manipulators

rotary nozzle welders header

end plate welding machine

MIG Welding

Lincoln ESAB Machine

TIG Welding

Lincoln Messer Griesheim Machine

 

Machining Equipment

Type/Description

Capacity/Size

Vertical drill

manual control

centre; single spindle drum drill/mill

mounted on ways

horizontal travel: 6 m

cross travel: 119.3 cm

spindle travel: 119.3 cm

spindle dia: 10 cm

Universal radial drill

portable

Max. height of work: unlimited

drill size: 2 in. (5 cm)

Punch

30 Tons

Peddinghaus

Rotary Saw

Vertical travel: 10 ft (3.05 m).

horizontal travel: 20 ft (6.10 m)

spindle travel: 4 ft 1 in. (1.245 m)

Iron Worker

80 tons

Peddinghaus

Vertical boring mill

Max. height: 100 in. (254 cm)

Max. OD: 84 in. (213 cm)

table Dia.: 72 in. (183 cm)

Vertical milling Machine

manual control

Travel lengthwise: 5 ft 5 in. (1.65 m)

Table travel across: 2 ft 1 in. (63.5 cm)

Lathes swing engine lathe

manual control

Swing over bed: 1.427 m

Dia.71 cm

Distance between centers: 4 m

Painting and Coatings

Painting limited to applying preservative coat of paint to panels andall components. Special coatings applied as required.

General equipment listing

  • Compressors
  • Sand pots
  • Air Sprays