industrial equipment repair

Today, our customers expect more from us: fast and personalized problem analysis, reliable estimation of the required scope of work, quality implementation of solutions in electrical machinery service and industrial equipment manufacturing. We communicate in the language of the customer and solve problems together. This is how we win together as a team.

OVERVIEW:

• Metal processing and special machine tools, lathes, milling, balancing machines: metal processing up to 3000 mm in diameter and length up to 5000 mm
• Equipment for banding, electric machine manifold penetration, hydraulic presses for various purposes
  
• Machines for winding and body insulation, for manufacturing and forming sections of electrical machines of various sizes
  
• Balancing equipment with lifting capacity up to 12 tons
  
• Laser cutting machines
  
• Welding equipment and devices: welding of products, including submerged-arc and argon-arc welding in automatic mode, diameter up to 4000 mm and dimensions up to 8000 mm
  
• Impregnation-drying complex: vacuum impregnation plant (VPI technology), drying ovens
  
• Pyrolysis furnace (annealing): operating temperature up to +450 °C with afterburning of gases
  
• Availability of fixtures and lifting equipment up to 100 tons
  
• Accredited testing laboratory
  
• Own fleet of trucks and cars
  
•  Washing chamber

VACUUM-PRESSURIZED IMPREGNATION UNITS (VPI)

MAIL COMPONENTS:

• Autoclave
• Impregnation agent storage tank with heating, mixing, degassing unit 
• Compressor, vacuum station
• Vacuum and compressed air lines, heating/cooling circuit and compound transfer lines 
• Impregnation filtration system
• Heating system 
• Cooling system 
• Ventilation system 
• Control system

FUNCTIONALITY:

• Quick-acting bayonet shutter
• Vacuum and air line
• Sensors for continuous monitoring of pressure, temperature, viscosity, impregnation level
• Heating system, cooling system
• Degassing unit
• Programmed blocking of autoclave lid opening in the presence of pressure, vacuum
• Manual or automatic loading conveyor system
• Automated control and dispatching system of autoclave (ACS) - + Remote control and reporting on technological process

AUTOCLAVES FOR POLYMERIZATION OF COMPOSITES

Autoclaves by Volna are designed for heat treatment (autoclave molding) of composite materials in various working solutions in accordance with the technical specifications of the customer for various technological processes

FUNCTIONALITY:

• Quick-acting bayonet shutter Adjustable heating speed Adjustable cooling speed
• Minimal temperature gradient throughout the interior space
• Pass-through bushings with connected t° sensors → Monitoring and control of t° at any location
• Modern thermal insulation materials → Reduction of heat losses and autoclave dimensions
• Vacuum line with high-temperature vacuum hoses
• System for pressurizing the autoclave with air or inert gases
• Fans for forced convection Minimal temperature gradient throughout the interior space
• Manual or automatic loading conveyor system
• Automated control and dispatching system of autoclave (ACS) → Remote
• Сontrol and reporting on technological process

AUTOCLAVES FOR TRIPLEX PRODUCTION

Autoclaves make it possible to produce laminated glass (triplex) of various sizes, based on customers' technical requirements.

ADVANTAGES OF USING AUTOCLAVES FOR THE PRODUCTION OF TRIPLEX:

• Maximum glass transparency
  
• High impact and shear strength
  
• The glass is resistant to significant temperature fluctuations
  
• Increased resistance to humidity
  
• Simultaneous lamination of different product properties
  

FUNCTIONALITY:

• Quick-acting bayonet shutter
• Adjustable heating speed
• Adjustable cooling speed
• Minimal temperature gradient throughout the interior space
• Modern thermal insulation materials -- Reduction of heat losses and autoclave dimensions
• Manual or automatic loading conveyor system
• Fans for forced convection -- Minimal temperature gradient throughout the interior space

VACUUM IMPREGNATION UNITS FOR CASTINGS

Impregnation of castings is performed to seal micropores, shrinkage sinks and microcracks in metal castings, synthetic materials, ceramics, composites and electroplated parts. It allows to increase the ability of products to withstand high pressures (up to 150 kg/cm and more) tenfold

IMPREGNATION PROCESS

• Impregnation of castings using the dry/moist vacuum method 
• Removal of excess compound
• Washing castings with water
• Polymerization of the product in a hot environment

FUNCTIONALITY:

• Autoclave with centrifugation system
• Cold rinse module, warm rinse module
• Polymerization module + 98 °С
• Lifting equipment for moving parts between operations 
• Baskets, cassettes for placing and rotating products 
• Vacuum and pressurization system
• Automated control system

DRYING AND HEAT TREATMENT FURNACES

APPLICATIONS

• Heating and drying of electric machine winding after impregnation Convective/IR drying of paint coating
• Dehydration of various materials
• Metal heating to relieve locked-up welding stress, aging stress, etc.
• Heat treatment of various materials

OPTIONS & EXTRAS

• Chamber vapour concentration monitoring system up to the lower flammability limit
• Additional accessories on demand
• Continuous furnace conveyor design
• Loading system with sliding trays
• Temperature sensors to be placed at the product in the chamber Door domes intended to prevent gas release from the furnace into the environment
• Other options and extras on demand

POLYMERISATION OVENS FOR COMPOSITE MATERIALS

Polymerisation ovens are used to cure binders while producing articles from composite materials by vacuum or injected moulding. Besides, these are commonly used for thermal post-treatment of finished goods, to dry materials, to warm up moulds, for other purposes.

His equipment provides such a major advantage as uniform temperature distribution within the chamber ensured by the effective air recirculation system of our own design, which significantly reduces the time required to reach the desired temperature in the furnace. Therefore, the chamber gets warmed up sooner and heat is evenly distributed throughout the internal chamber space, thus precluding formation of hot and cold areas.

OPTIONS

• High-performance forced recirculation system for uniform temperature distribution within the chamber
• Adjustable heating and cooling rates
• Vacuum bags with inlets for binder and vacuum – for vacuum forming/vacuum injected moulding (VARTM) processes
• Possibility to place any number of temperature sensors at the product with easy connection in the chamber and readings displayed at the operator’s touch screen
• Easy-to-use loading system based on a rail track mounted inside and outside the chamber, or a flat-bed chamber with a material handling trolley
• Adaptive control system tailored to the customer’s needs respecting its functions and interface. The control system supports integration with the infusion module under common control
• SCADA-based control system for remote condition monitoring with the possibility to generate process charts and protocols as required

PYROLYSIS/ANNEALING FURNACES

The pyrolysis/annealing furnaces are designed for controlled thermal decomposition of organic insulation of electric machine winding in low-oxygen atmosphere (pyrolysis process).

FEATURES:

• These are used to remove winding during overhauling at electric machine repair and service facilities
• Pyrolysis process (controlled thermal destruction of insulation materials under anaerobic conditions)
• Monitoring of oxygen (O2) concentration in the furnace
• Internal furnace
• pressure monitoring and keeping below the ambient
• Safety valve to protect the furnace against internal overpressure 

ADVANTAGES

• Less efforts to remove electric machine winding
• Advanced production technology, better repair quality Personnel safety – no harmful exposure during destruction of windings
• Eco-friendly – three-stage afterburner to burn organic matter pyrolysis products at high temperatures
• Safety – multilevel accident prevention and monitoring system Control system that allows assigning annealing conditions to certain types of insulation materials and loaded weights; pre-set annealing programmes created by Volna company based on its expertise in using such type of furnaces

INDUCTION DRYING FURNACES

Induction drying furnaces are intended to dry and pre-heat various items, including electric machine winding, in the air at up to +280 °C in stationary conditions, through energy loss on internal wall magnetization.

These are most efficient for post-impregnation drying of electric machine winding, having no red-hot electric heating elements or NiCr (FeCrAl) coils that can ignite solvent vapours extracted from the impregnating compound by drying.

FEATURES

• Minimum heating circuits with process chamber surface itself being the heating surface which ensures uniform and gradual heating
• Fire safety with the wall (being the heating element) temperature not much above the process temperature in the chamber
• Modern heat insulation and intelligent heating control system energy saving, energy consumption lower by 20 % to 40 %
• Safety: as flammable gas concentration reaches the explosive limit, heating stops and the furnace turns into the ventilation mode to remove the flammable gas flammable gas concentration monitor

VACUUM DRYING OVENS FOR TRANSFORMER WINDING

Vacuum drying ovens for transformer winding are mainly used to dry active parts (winding) of oil-immersed transformers with oil-paper insulation, may be used for deep drying of electric machine windings, as well as for drying wood, powders and other materials subject to quick and efficient removal of water or any other vaporizing fluid.

Vacuum drying is the most efficient method to dry active parts (winding) of electric machines. It involves active part preheating up to 100-110 °C with subsequent vacuumisation of the furnace chamber. Thereupon moist comes out of the deep insulation layers to be vaporised and removed from the furnace chamber. Thus the drying process takes 3-4 times less time.

ADVANTAGES

• More intensive evaporation than by hot air drying or natural drying
• Applicability of several winding drying quality assessment techniques: by the end of water extraction, by winding insulation resistance, or by the chamber vacuum drop test
• Transformers may be oil-immersed under vacuum, so that oil would fill the insulation pores before they are exposed to damp air

INDUCTION MELTING FURNACES

Induction melting furnaces are intended to melt, superheat and refine molten steel, cast iron and non-ferrous metals. Such devices are used in metallurgy, engineering, agriculture, railways, shipbuilding, aircraft building, etc.

ADVANTAGES

• Uniform and gradual heating thanks to the minimum number of heat transfer circuits, metal itself being heated by eddy currents
• Multilevel protection and monitoring system to maintain minimum cooling water pressure, nominal power supply voltage, desired shutdown time
• Control cabinet with an operator’s panel in immediate proximity to the furnace to control the power of the furnace elements and program the heating process
• Control system (PCS) for automated control of the melting process according to the preset programme
• Automatic dumping actuator of the melting block with a control panel and manual dumping option in case of power shutoff