Entrust KBK Engineering with service, maintenance, and repairs for decanter centrifuges as well as fabrication of their parts

Specialist in Maintenance and Service for Decanter Centrifuges KBK Engineering Co., Ltd.

40-plus year record of performance for maintenance and service, fabrication, and repairs
  • Hard-facing of flights
  • thermal spray of flights
  • dynamic balance corrections
  • on-site investigations
  • repairs for fitting and sliding parts
  • rewinding of flights
  • hard-facing
  • test runs
  • maintenance and service for planetary gear speed reducers
  • repairs and modifications of casings
  • replacement of consumable parts etc.
Record of performance for maintenance and service.
  • Mitsubishi Heavy Industries
  • Mitsubishi Kakoki Kaisha
  • Saito Separator
  • TOMOE Engineering
  • TANABE WILLTEC
  • IHI
  • Tsukishima Kikai
  • Hiroshima Metal & Machinery
  • ANDRITZ
  • BIRD
  • FLOTTWEG etc.

Maintenance and Service for Decanter Centrifuges

Features of Maintenance and Service for Decanter Centrifuges

Centrifugal force generated by the rotating of a rigid-body bowl and solid-liquid separation due to the difference in velocity of the screw rotating inside, centrifuges are one of the main machines among devices that perform continuous and efficient processing to separate liquids from solids. Since many of the component parts are complex in structure and are manufactured by advanced and precision technology, maintenance and service by experienced engineers is essential. Repairs for fitting parts reduce vibration, and appropriate dimensional and geometric tolerances of bearings and sealing parts maintain the separation performance required for the centrifuge body and in manufacturing processes and, from an equally important standpoint, protect the bearings and external environment from leakage of contents. For such machines having a mechanism in which both the bowl and screw rotate with a slight clearance at high speed, repairs by a company with an experienced team of engineers with a proven record of performance for maintenance and service is a must.

KBK Engineering’s Maintenance and Service
for Decanter Centrifuges

We offer technical strengths backed by manufacturer and user certification and a record of performance in fabrication, maintenance and service for decanter centrifuges with 40-plus years of experience since before our spin off from Kurashiki Boring Kiko Co., Ltd., which is our partner company. KBK Engineering Co., Ltd. is a company that specializes in maintenance and service for rotating machines; specifically, decanter centrifuges. We offer integrated service from advice on diagnosis, condition confirmation and stable production as well as appropriate inspections, hard-facing, thermal spray and plating repairs necessary for maintenance and service, machining and dynamic balance corrections, test runs, and diagnosis. We offer a record of performance for a variety of repairs, including repairs for bowls, screw conveyors and gearboxes, which are main components, as well as bearings and fitting parts, repairs for lip marks of oil seals, welding and hard-facing of screws, fabrication of gears of differential gear units, and hard-facing repairs for spigot joints. We not only conduct simple repairs but also repairs best suited to parts that are needed, for example, high-precision dynamic balance required for stable operation of the entire centrifuge, and extending machine life by fabrication of new parts that can no longer be repaired. After repairs, life-span is extended due to reductions in noise and vibration as a result of smooth rotation, and productivity is also improved due to reductions in moisture content in processed materials and quality stabilization. Indicators for determining the timing of maintenance and service include rising temperatures of bearings, leakage of grease or processed materials, abnormal sounds and vibrations, as well as other process abnormalities, such as increasing liquid side concentration of processed materials and changes in the properties of solid matter.

Bowl
Replacement of strips, inner surface turning, hard-facing repairs for spigot joints, dynamic balance corrections
Screw conveyor
Hard-facing of worn blades, rewinding of blades, dynamic balance corrections
Gearbox
Fabrication of gears, hard-facing repairs for gears, repairs for fitting parts
Casing
Welding repairs for cracks, repairs for chutes, modifications

As shown by the above wide-ranging examples of maintenance and service requested, we are a maintenance and service company specializing in decanter centrifuges that can handle repairs in-house or in conjunction with our partner company.

Practical Examples of Service, Maintenance, and Repairs

Cases of frequently requested service, maintenance, and repairs.

Practical Examples of Service, Maintenance, and Repairs:General maintenance and service for decanter centrifuges

General maintenance and service for decanter centrifuges

We offer all the necessary elements for maintenance and service for decanter centrifuges, including disassembly by grasping the key points, cleaning performed at appropriate levels by judging usage conditions, function-based inspections, repairs and improvements made based on a record of performance and backed by various techniques and methods, assembly performed according to precision work and meticulous procedures, and test runs in order to deliver reliably maintained and serviced products. KBK Engineering offers a record of performance for maintenance and service not only for domestic-made products but also overseas-made products.

Record of performance for maintenance and service
Mitsubishi Heavy Industries, Mitsubishi Kakoki Kaisha, Saito Separator, TOMOE Engineering, TANABE WILLTEC, IHI, Tsukishima Kikai, Hiroshima Metal & Machinery, ANDRITZ, BIRD, FLOTTWEG, etc.

Practical Examples of Service, Maintenance, and Repairs:Repairs for screw conveyors

Repairs for screw conveyors

A screw with a spiral blade wound around a cylindrical shaft has many functions in a decanter centrifuge. It is said to be one of the main structural components of the decanter centrifuge, because of its role of feeding the processed materials into the decanter centrifuge, increasing the speed of the fed processed materials up to the same rotation speed as the bowl, dewatering while passing through the tapered section, and so on, and is the pathway in which processed materials pass where wear occurs frequently due to its high-speed rotation.
By making a correct diagnosis of the processed materials and wear status, KBK Engineering conducts repairs in-house from hard-facing repairs using appropriate materials for worn parts and modifications of blades to improve performance.

Practical Examples of Service, Maintenance, and Repairs:Maintenance and service for differential gear units

Maintenance and service for differential gear units

The differential gear unit mounted on a decanter centrifuge is also called a gearbox, and is broadly divided into a planetary speed reducer, which is a combination of various gears, cyclo speed reducer, and hydraulic motor. These speed reducers produce great differential velocity despite their compact size and are one of the main structural components of the decanter centrifuge. Contents retained in the decanter centrifuge produce large torque in the differential gear unit. As a result, various repairs are required, including diagnosis before disassembly, repairs for and fabrication of gears, and repairs for fitting parts. KBK Engineering offers optimum repair methods and plans based on our record of performance for maintenance and service for decanter centrifuge bodies accompanied by various differential gear units.

Practical Examples of Service, Maintenance, and Repairs:Repairs for bowls

Repairs for bowls

Attention should be paid to wear of the cylindrical part with both ends flange-shaped, which is called a bowl. The wall of the bowl receiving the processed materials fed from the screw conveyor rotating at several thousands of rpm is continually exposed to a heavy load until the processed materials are discharged after dewatering. Wear of the strips mounted on the wall of the bowl to help the conveyance of processed materials influences the separation performance. Repairs with use of appropriate materials as well as knowledge and experience that enable the determination of geometric tolerances and dimensions required for normal vibration-free rotation are necessary to improve the quality of processed materials.

Practical Examples of Service, Maintenance, and Repairs:Dynamic balance corrections

Dynamic balance corrections

Vibration and eccentricity of high-speed rotating machines resulting from an imbalance not only adversely impact fitting parts but also lead to serious accidents. For decanter centrifuges, having a special structure in which the bowl and screw rotate simultaneously, a dynamic balance is required for each part. The most efficient balance corrections suitable for each machine enable low-cost corrections that do not affect the separation efficiency of processed material nor reduce rigidity.

Practical Examples of Service, Maintenance, and Repairs:Test runs

Test runs

Pre-shipment test runs can be made for some models and maintenance and service for a mount set. Conditions after maintenance and service for the decanter centrifuge are checked by monitoring temperatures, vibrations, abnormal sounds of bearings, and other indicators with specified rpm maintained for a certain period of time. By comparing the obtained operating data with actual past results and similar models, it can be confirmed that repairs have been performed successfully and there is no problem with the assembly process of the product subjected to maintenance and service, and only those which have been judged to be normal are delivered.

Practical Examples of Service, Maintenance, and Repairs:On-site work

On-site work

We also perform on-site maintenance and service for and removal and installation of decanter centrifuges as requested. The work period can be shortened without making unwanted repairs by accurately determining parts requiring repairs based on our record of performance for maintenance and service for many different manufacturers’ decanter centrifuges. As repairs for parts are made in cooperation with our partner company Kurashiki Boring Kiko when necessary, speedy thermal spray repairs can be completed with minimal downtime.

Record of performance for maintenance and service

  • Mitsubishi Heavy Industries
  • Mitsubishi Kakoki Kaisha
  • Saito Separator
  • TOMOE Engineering
  • TANABE WILLTEC
  • IHI
  • Tsukishima Kikai
  • Hiroshima Metal & Machinery
  • ANDRITZ
  • BIRD
  • FLOTTWEG etc.

Before & After Maintenance and Service

Examples of before and after service, repairs and maintenance.

Before & After Maintenance and Service01:Before
Before

The ability to convey processed materials was reduced due to the adhesion of tar and wear of the screw. Many problems as a whole were found, such as wear of fitting parts, corrosion of the base plate, and wear of the main body cover.

Before & After Maintenance and Service01:After
After

The ability to convey the processed materials was restored by rewinding and hard-facing the screw. Repairs to eliminate wear were made to restore the fitting parts as if they were brand new by plating, thermal-spraying, and hard-facing, recoating the base plate, and grinding the cover of the main body.

Before & After Maintenance and Service02:Before
Before

The rigid body hard-faced to the screw blade was worn away due to conveyance of hard processed materials. Urgent maintenance and service were requested because an imbalance had caused considerable vibrations.

Before & After Maintenance and Service02:After
After

Wear was suppressed by rewinding the screw blade and hard-facing a rigid body that was higher in hardness than before, and the conveying performance was improved by outer diameter grinding, which enabled more efficient processing than before maintenance and service.

Before & After Maintenance and Service03:Before
Before

Decanter centrifuge for a chemical plant: The quality of processed materials could be stabilized, and a high yield could be continuously maintained by periodically performing regular inspections, replacement of consumable parts, repairs for fitting parts, gear inspections, etc.

Before & After Maintenance and Service03:After
After

Repairs for fitting parts were made, and the screw and bowl as well as the gears of the differential gear unit were inspected, and consumable parts were replaced. By precisely repairing the tolerances of defective parts, product quality improved through stable operation compared to before maintenance and service.

Before & After Maintenance and Service04:Before
Before

Because appropriate geometric tolerances could not be maintained due to heavily corroded fitting parts with the screw and bowl, vibrations occurred, resulting in unstable rotation. Because ordinary repairs would not prove effective, maintenance and service were requested.

Before & After Maintenance and Service04:After
After

After a detailed disassembly, thorough cleaning of the repair site by descaling was conducted and careful repairs were carried out so as not to distort each part. According to the phase of corrosion, all consumables were replaced after examining the tightened bolts and surface conditions.

Please feel free to contact us for consultations, estimates, etc.
If there is a need for an immediate response, please contact us by phone.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

For consultations, please feel free to contact us.

KBK Engineering makes high-quality parts available based on technical strengths having been acquired in maintenance and service for various decanter centrifuges.

Due to manufacturer discontinuation of production and organization scale-downs, there are a large number of decanter centrifuges without expectations for after-sales service.

Based on our technical strengths in maintenance and service accumulated over 40-plus years with Bird centrifuges manufactured by Mitsubishi Heavy Industries from when we were part of Kurashiki Boring Kiko, our repair and fabrication process offers a system in which even complex-shaped parts can be fabricated for restoration by making full use of materials, heat treatment, surface treatment, welding, and machining, and demonstrates that we can fabricate all parts of high-speed rotating machines that require high accuracy.

Fabrication of Parts:Bowl

Bowl

Since the quality of conveyed materials to be separated is directly affected by its accuracy, many elements are needed for its fabrication. It is necessary to appropriately determine the conical element called a beach and the shape and surface condition of the inner surface that can influence the conveying performance.

Fabrication of Parts:Screw

Screw

Fabrication is conducted based on a review of many conditions, such as the selection of the barrel material and hard-facing material for the screw blade in consideration of wear caused by conveyed materials, the blade element for efficient conveyance, and machining and welding methods necessary for vibration-free rotation.

Fabrication of Parts:Differential gear unit

Differential gear unit

Speed reducers that produce slight differential velocity between the bowl and screw consist of many gears and pinion shafts according to the number of stages. They are fabricated based on a review of appropriate materials and elements that can withstand torque caused by processed materials and differential velocity.

Fabrication of Parts:Rotating body parts

Rotating body parts

There are also many cases where wear caused by the conveyed materials and fitting parts due to high-speed rotation may cause damage beyond the scope of ordinary repair. KBK Engineering can fabricate the same parts with advanced measurement techniques.

Parts are repaired with excellent wear resistance and corrosion resistance added by thermal-spraying and hard-facing Stellite, COLMONOY, EutAlloy, and other rigid bodies.

Through an examination of the causes of breakage and wear, the best choice can be made from various materials, such as hard-facing materials, ceramics, and superhard materials, so that parts with even higher resistance can be fabricated. We perform repairs for the purpose of stable operation and quality improvement of decanter centrifuges, including distortion-free hard-facing and thermal spray repairs necessary to restore geometric tolerances. We can also respond to dynamic balance required for rotating machines, including repairs for frames serving as casings.

Repairs for Parts:Screw

Screw

Repairing a screw with use of a hard-facing material that improves wear resistance can increase durability, improve separation performance of conveyed materials, and also prevent contamination. The screw can be reused by considering the fabrication or rewinding of the blade according to the repair site.

Repairs for Parts:Hard-facing repairs for solid matter discharge pathways

Hard-facing repairs for solid matter discharge pathways

Pathways for solid matter being discharged while rotating at high speed are always subjected to wear. Hard-facing repairs are made by weld surfacing or thermal spraying in cooperation with Kurashiki Boring Kiko according to the characteristics of conveyed materials, by selecting appropriate materials and repair methods to extend their life-spans.

Repairs for Parts:Thermal spray repairs for fitting parts

Thermal spray repairs for fitting parts

Oil seals serve to prevent leakage of contents in decanter centrifuges and grease and oil necessary for their stable operation, while adjacent bearings are an important region that supports high-speed rotation. We conduct repairs based on a review of thermal spray materials and methods and by using the most appropriate method in consideration of cost and delivery time.

Repairs for Parts:Dynamic balance corrections

Dynamic balance corrections

Our record of performance for maintenance and service for various decanter centrifuges enables us to make balance corrections of screws and bowls that will not resist processed materials. We consider not only balance conditions and correction methods, but also priority of installation and removal of additional materials.

Reasons why KBK Engineering is selected
for service, repairs, and maintenance for decanter centrifuges

We offer the very best in service and solutions to problems based on our reliable technical strengths.

Reasons why KBK Engineering is selected:Maintenance and service technology that you can entrust to us with complete confidence

REASON 01

KBK Engineering was spun off from Kurashiki Boring Kiko as an independent company specializing in maintenance and service for decanter centrifuges. Conventionally, maintenance and service for machines relied on an engineer’s intuition and experience, but nowadays, maintenance and service based on mechanical engineering and material engineering is required. In the maintenance and service industry, handing down of technology and technical strengths is of critical importance, and we, with our core of young engineers, perform maintenance and service for all manufacturers’ decanter centrifuges through maintenance and service supported by our reliable technology.

Reasons why KBK Engineering is selected:Technical Strengths

REASON 02

Older decanter centrifuges that have been used for many years may not have data such as drawings available. KBK Engineering uses its advanced measurement techniques and reverse engineering to fabricate hard-to-procure parts. By setting materials and appropriate dimensional tolerances, and making full use of changes in materials and various surface treatment types and heat treatment, the life-spans of existing parts can be extended. We contribute to future improvement in productivity by making modifications to fit existing parts based on dimensional restoration.

Reasons why KBK Engineering is selected:Proven Record of Performance

REASON 03

We offer our customers the very best in service and solutions to problems with our reliable technical strengths backed by a long record of performance for maintenance and service and manufacturer-certified. Requests for maintenance and service from many users and manufacturers over many years are the fruits of recognition of our technical strengths certified and authorized as well as advanced expertise.

Reasons why KBK Engineering is selected:Proven Record of Performanc:Stringent Controlse

REASON 04

Since July 2009, when we received ISO9001:2008 certification, the international standard for quality management systems, our quality management systems have been reviewed and ISO9001:2015 certified. Our work proceeds based on controlled processes, and the maintenance and service history of each customer is recorded and information including dimensional records and photographs, as well as reports, is carefully preserved for future access. We take on the role of machine manager in support of our customers.

Reasons why KBK Engineering is selected:Flexible Response

REASON 05

We provide one-stop response and support from transportation, overhaul and maintenance, fabrication of parts, repairs, dynamic balance corrections, test runs, to delivery. Through our established network, we perform repairs, fabrications and modifications, aiming at realizing delivery schedules in line with customer requirements. For thermal spray repairs, in particular, including before and after machining, we offer an integrated service with our partner company, Kurashiki Boring Kiko, to provide high-quality repairs suitable for every usage condition.

Reasons why KBK Engineering is selected:Personnel Training

REASON 06

In maintenance and service of machines, maintenance and service based on mechanical engineering and material engineering is required, and transferring technology and technical strengths is of critical importance. By holding regular study sessions with specialized instructors and experts, our core of young engineers actively absorb knowledge and skills in order to perform maintenance and service backed by our reliable technical strengths and technology.

Please feel free to contact us for consultations, estimates, etc.
If there is a need for an immediate response, please contact us by phone.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

For consultations, please feel free to contact us.

We provide high-quality maintenance and service for our customers in accordance with standardized procedures.

Step. 01

Maintenance and Service Flow:Inquiry

Step. 01

Let us know your machine condition and the details of the problem. Prepare drawings and instruction manuals, if available. In case of an emergency, contact us by phone at +81-(0)86-450-4577

Step. 02

Maintenance and Service Flow:Submission of an estimate for basic maintenance and service

Step. 02

An estimate for basic maintenance and service will be submitted based on the information provided, discussions, on-site checks, etc.

Step. 03

Maintenance and Service Flow:Carrying-out (some machines)

Step. 03

Decanter centrifuges, etc., requiring measurements at the time of removal, will be removed on-site and carried out by our staff, as necessary.

Step. 04

Maintenance and Service Flow:Carrying-in

Step. 04

The removed machine will be carried in to our factory, where a large truck exceeding 10t can enter.

Step. 05

Maintenance and Service Flow:Disassembly, cleaning and inspection

Step. 05

Disassembly and cleaning are performed according to proper procedures, and each part is measured dimensionally and inspected. A determination is made on the course of repairs and maintenance and service according to the results of an inspection. Various types of non-destructive inspections are also performed as necessary.

Step. 06

Maintenance and Service Flow:Submission of an estimate for repairs and a report

Step. 06

An inspection report and an estimate for additional repairs will be prepared based on the results of inspections and the course of repairs, maintenance and service are submitted, and the course of repairs, maintenance and service is finalized after consultations with the customer.

Step. 07

Maintenance and Service Flow:Repairs for parts and fabrication of parts

Step. 07

Repairs for parts and fabrication of parts are performed by planning appropriate processing methods at each subcontract factory. Various types of hard-facing are performed by our skilled engineers.

Step. 08

Maintenance and Service Flow:Dynamic balance corrections

Step. 08

This process is indispensable to maintenance and service for high-speed rotating machines. Actual running in an unbalanced state will cause a failure, breakage, or an accident.

Step. 09

Maintenance and Service Flow:Inspections before assembly

Step. 09

Repaired and fabricated parts are inspected, and only parts that have been confirmed to meet specifications are used for assembly.

Step. 10

Maintenance and Service Flow:Assembly and adjustments

Step. 10

By tightening each part to the proper torque, assembly is performed while adjusting component parts to the minimum. O-rings, oil seals, bearings, and other parts are handled carefully to prevent damage.

Step. 11

Maintenance and Service Flow:Test runs

Step. 11

After assembly, test runs are performed where possible, and temperature, vibration, and various other data are collected. The results are reflected in a report.

Step. 12

Maintenance and Service Flow:Delivery and submission of a report

Step. 12

After completion of all work, delivery is made to the customer-designated site. Installation of equipment can also be arranged. Based on the submitted report, we can also offer consultations on operation, maintenance and service plans.

Frequently asked questions and answers. Please feel free to contact us if you have any questions that have not been posted.

Q1What are some of the features that KBK Engineering offers?
We provide maintenance and service for high-speed rotating machines, especially for decanter centrifuges. Our group company offers advantages through integrated maintenance and service when it comes to handling all necessary repairs, such as hard-facing and thermal spray.
Q2What kind of a partner company is Kurashiki Boring Kiko?
Our partner company has a 60-year history and is equipped with machining facilities required for repairs of rotating machines, such as pretreatment, thermal spray, and finishing processing.
Q3What kind of information is needed to request an estimate?
Please provide us with assembly drawing(s), machine conditions, past repair status, operating conditions, delivery time, etc., to the extent possible.
Q4What is the difference from manufacturer maintenance and service?
In many instances, when a machine seizes up it is because a component part or parts are damaged. We have the know-how to repair component parts and have an established network for fabrication of component parts, so that short delivery times and low-cost repairs can be guaranteed.
Q5What if the manufacturer of an older machine is no longer in business?
We can provide maintenance and service even for older machines where drawings are no longer available. New parts can be fabricated from existing parts by reverse engineering and restored to their original state.
Q6What is your company’s policy concerning customer information and drawings?
We recognize and understand that machines used for operation and raw materials processed are each customer’s confidential information and proprietary assets.
Q7Can you handle maintenance and service for machines other than decanter centrifuges?
We have a record of performance for maintenance and service for various high-speed rotating machines, and we also offer maintenance and service for diverse machines other than decanter centrifuges. For details, see the section for maintenance and service for various rotating machines including examples of maintenance and service.

Inquires

Please feel free to contact us by phone, fax, or web form.

Inquiries by Phone
+81-(0)86-450-4577
Business Hours
8:30 a.m. to 5:30 p.m. (weekdays)

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