ACE Presentation Associated Consulting Engineers Consulting Plant Engineering

ACE Presentation

Associated Consulting Engineers Consulting – Plant Engineering, project management Technik – Start up and service support, diagnostic Services – Retainer ship, training, documentation Associated consulting Engineers, 21, Saibaba park New civil road, Valsad 396001 India www. acepolytech. com

The Company �We are group of professionally qualified engineers with more than 9 decades of cumulative experience in industry �We are into providing engineering services and automation solutions for polymer compounding industry for the last 20 years �Authorized service partners for Krauss Maffei Berstorff, Elin motoren, (BKG Under Water Pelletizer, Kreyenborg group, Promixon mixer – currently not active)

Business Philosophy �Quality- Tools & Training are our key investments �Commitment, Transparency & Integrity as basis of business �To deliver our collective skill & knowledge to our customer and society at large �Profit is a by product of hard work & essential to continued hard work �Compete with cooperation

ACE – Current Focus ◦ Consultancy – �Selective projects in india �Strategic tie ups with European experts for services outside india. This is now in initial phase of joint approach to project. ◦ Technik �Acquire More principles from Europe �Offer off site services �Focus on spares / sourcing �While maintaining focus on plastics, expand in �Related area like food & pharma �Develop generic capabilities – mechanical – alignment, precision repairs – gear box ◦ Services – to continue more as sustaining measure to support of development of above plans �Retainership �Training / documentation

Business scope �Inspection, Overhaul & Repair of AC/DC motors & Gear boxes & other key up & downstream equipments for twin screw extruders � On site diagnostic services, inspection and installation of up and down stream equipments for compounding plant following proper SOP’s

Our workshop Approx 10000 Sq ft floor area

Our service approach within 1 day 300 km 200 km 100 km

Instruments Make : SPX Powerteam Hydraulic puller Model : PH 103 C & RPS 1010 • Capacity : 10 T • Spread : 432 mm • Stroke : 381 mm • Pump capacity : 700 bar Make : Enerpac Hydraulic cylinders & pumps Model : RC-102 & P-392 • Capacity : 5 T, 10 T • Pump capacity : 700 bar

Make : SKF vibration meter Model : CMAS 100 SL • Velocity range: 0. 7 to 65 mm/s • Acceleration range: 0. 2 to 50 g. E • Temp range: -20 to 200°C Make : Easy Laser shaft alignment tool Model : XT-440 • Shaft Diameter range: 20 mm to 500 mm • Accuracy: 0. 001 mm

Make : TPI Vibration analyser kit Model : 9080 plus • Frequency range – 2 Hz to 1 K Hz (ISO) 1 k. Hz to 10 k. Hz (BOU) • Max frequency resolution - 1. 25 Hz @ 800 lines FFT setting • Measure – Acceleration in g Velocity in mm/s (or inch/s) Bearing noise in BOU (bearing damage units) Displacement (mm, microns, inch) • Smart trend meter with recording facility • Vib. Trend PC software

Make : Bosch Endoscope with image and video recording facility Model : GOS 10. 8 V-LI • Camera cable length = 1. 2 m • Display size = 2. 7” Make : Megger Insulation Tester 10 KV Model : MIT 1025 • Digital display • Software generated report

Make : Easytherm Bearing Induction Heater Model : 3. 5 • Diameter 15 mm to 420 mm • Max weight: 70 kg • Max temp: 240°C Make : RSK Presicion level guage (accuracy 0. 02 mm /m) Model : 541 -1502 Length : 150 mm & 300 mm

Make : Mitutoyo Bore guage with expansion rodes Model : Series 511 • Range: 18 mm to 250 mm • Length of measurement : 3 m Make : Mitutoyo digital outside micrometer Range: 0 to 300 mm

Make : SKF Thermal camera Model : TKTI 10 Make : Circutor System analyser Model : C-80 • Measure in true RMS • Measurement of harmonic distortion in current & voltage • Automatic data recording in internal memory • Large colour display • Storage upto 1 GB data • Software generated report with thermal & digital image

Make : Lutron Digital anemometer Model : AM-4201 • Accuracy – 99. 9 % • Measure in m/s, km/h, ft/min • Data hold function Make : Allosun Electronic stethoscope Model : EM 410 • Frequency range – 100 Hz to 10 K Hz • Ambient noise permitted – 100 d. B

Model : High pressure pump • Capacity : 0 to 2000 bar

Diagnostic tools �Vibration analysis (TPI) �Industrial endoscope with image recording (Bosch) �Thermal imaging (SKF) �Laser alignment tool (Easy Laser) �Bore measurement (Mitutoyo) �Insulation tester (Megger UK) �Oil analysis (out sourced)

Typical compounding plant

Feeders: Capabilities We have wide experience with different type Loss-In-Weight feeders. We have handled following type of feeders �K-Tron : 100+ �Brabender : 25+ �Sonner : 10+ �Schenck : 10+

Feeders: Services Sr No Services 1 Screw wear measurement 2 Load cell, Card, Cable Integrity check 3 Mechanical ( Gearbox & bearings)

Motors: Capabilities We are handling following types of motor of rating 5 to 1500 KW �Water cooled motor �Air cooled motor Major motors that we have handled till now are of make �Elin motoren �Siemens �Baumuller

Motor: Services Sr No Services Tools used 1 Vibration analysis Vibration analyser kit (TPI – 9080 plus) 2 Bearing change Hydraulic puller (Enerpac), induction heater 3 Water cooling jacket descaling GWK descaling unit PGDU-200 4 Re-winding & Vacuum pressure impregnation 5 Insulation (IR) test 6 Winding resistance measurement (low ohm resistance) 7 Shaft repair- surface rebuilding ESAB consumables 8 Rotor balancing Outsourced 9 Rotor cylindricity correction Outsourced Megger MIT-1025 (UK)

Example Elin motor Tunnel boring machine motor complete overhaul with rewinding

Motor Inspection sample report

Motor IR test sample report

Laser alignment using easy laser alignment kit (XT-440)

Laser alignment sample report

Diagnostic package examples �Vibration analysis by TPI vibration analyser kit

�Gear box thermal image by SKF thermal camera �Electrical parts thermal image by SKF thermal camera

Gear box: Capabilities This is one of the major service we provide. We have attended following makes of gear boxes till now �Siemens/ Flender �Zambello �SEW �PIV �Other German make

Gear Box: Services Sr No Services Tools used 1 Vibration analysis Vibration analyser kit (TPI – 9080 plus) 2 Overhaul: Bearing, seals & gears replacement Hydraulic puller (Enerpac), induction heater 3 Oil analysis Outsourced 4 Thermography SKF thermal camera 5 Shaft repair ESAB consumables 6 Physical inspection Endoscope (Bosch) 7 Gear measurement Outsourced 8 Shaft balancing Outsourced 9 Alignment with motor Laser alignment tool (Easy laser XT-440)

Example Gear box overhaul �Make – German GB �Bearings & seals worn replaced �Replaced in 5 days

Example Gear box overhaul �Make – German GB �Problem: Bearings & seals worn �Replaced in 6 days

Barrel & Screw: Services Sr No Services Tools used 1 Bore measurement of barrels Mitutoyo Bore Guage 2 Barrel cooling channel descaling GWK descaling unit PGDU -200 3 Screw wear measurement 4 Element wear out measurement 5 Control system for barrel cooling unit 6 Barrel liner replacement Hydraulic press, Shrink fitting operation 7 Thermography to check hot spots SKF thermal camera TKTI 10

Melt pump: Services Sr No Services Tools used 1 Cooling jacket Descaling GWK descaling unit PGDU-200 2 GB overhaul Typical as used eariler 3 Shaft, Bearings, Polymer channel bore measurement Mitutoyo 4 Thermography SKF Thermal camera TKTI-10

Screen Changer & PDV: Services (as required) Sr No Service 1 Visual inspection for groove & scratches 2 Control syncing with extruder Tools used

Pelletizer: Services Sr No Service 1 Overhaul 2 Control syncing with extruder

Descaling of cooling channel � � � Why descaling? ? Even when not blocked a relatively thin layer of scale or corrosion can act as an insulator and have a huge impact on the efficiency of your circuit GWK make pump unit with online temp and p. H measurement Capable to remove all types of scales formed inside the cooling channels Equipped with 4 way valve to reverse flow to ensure quick & complete removal of scales Separate tanks for both chemical and water flushing Drain tank for neutralize descalant and then dispose off

Descaling process flow Flushing system with DM water Add descaling agent till p. H goes below 1 Circulate Descaling agent till the p. H is constant about 2 Add Neutralising agent till the p. H is above 12 Flushing system with DM water Reverse the flow of the descaling agent Circulate neutralising agent for 2 hours Flushing system with DM water

Descaling sample report

Thermography �Instrument � – SKF TKTI 10 The SKF TKTI 10 is a digital camera with advanced thermal imaging capabilities. It is ideal for use as a Predictive Maintenance (Pd. M) tool. Thermography is a non-invasive technique and is well suited for mechanical and electrical inspections, energy conservation and plant safety activities.

� It has a large backlight 3 ½” colour screen which gives clear & sharp resolution. � Special features – 1) 2) 3) 4) 5) 6) � It is designed for easy operation Temperature range : -10 deg C to +350 deg C Multiple temperature measurement Difference between temperature measured 20° x 20° field of view and 47 x 47 pixel detector Image storage : radiometric data & digital image Thermography applications: 1) Overheated connections for high & low voltage installations, cable insulation 2) 3) Mechanical issues like hot bearings, overheated motors Mould inspection

Thermography sample report

IT enabled services ( proposed) Mobile application , external to customer ERP, Customer interface Service call login , status update, time sheet , report, critical data logging like vibration enabled. Service engineer Calender with Schedule appointment, movement, Support data base ACE data base Customer / Equipment Additional support like manuals, technical details Updated history cards and repairs log with spares ACE Control Room Assigning jobs, movement support , logistics and hotel, tools

Services ◦ ◦ Looking only for high end services – if and when required. Now have place to offer shop services. Ready to invest in tools and training as required. Can work as front end – make all preparation at site for KMB technician to take over – possibility of a overall saving in time ◦ A joint services has potential of addressing cost sensitive Indian market for services – quote possible that most European share in services in India is disproportionately low compared to population of equipment. ◦ Can actively assist in spares sourcing in India ◦ Can also support in ME / Iran / Far east when required.

ACE focus on services �Mechanical ◦ ◦ ◦ Twin screw gear box Kneader gear box Specialised mixers De scaling barrels / jackets/ moulds Laser alignment Thermography �Electrical ( partly with strategic tie ups) ◦ Thermography ◦ AMC for control system – PLC / FC ◦ Feeders ( Loss in weight systems)

Approach & Schedule �Form a new company with majority shareholding by Kaushik – 3 /4 quarter 2019 – mostly closely held private limited liability company. �Actively search for European partner – This will accelerate growth in multiple ways ◦ Creditability in india and Europe ◦ Acquiring more principles ◦ Additional fund to accelerate tools acquisition �Add staff & train Adequate for present

Our team Mr. Kaushik D Naik Proprietor of the company ME (Prod. ) GDMM, DBM Chartered Engineer Mr. Bharat D Patel Senior associates Mechanical

Mr. Ankit B Fruitwala Project & Service engineer (Electrical & Instrumentation) BE Electrical Mr. Nitant R Vyas Project & Service engineer (Mechanical) BE Mechanical Mr. Manish N Patel D’man Mechanical

Thank you for your attention