S V ENGINEERS, Inc. has been manufacturing, designing, engineering and servicing gas, oil, coal, solid waste, wood, biomass and hybrid fuel-fired steam and hot water boilers, Flower Extraction Plants, Steam Distillation Units and Reactor Kettles, since 1999, for thousands of satisfied customers. In addition to a complete line of steam and hot water boilers, S V ENGINEERS & Welding Company also manufactures a complete line of boiler parts and boiler room peripherals and provides unparalleled turnkey after-market products and services to deliver complete installation and operation to its customers.

Some of Our Clients

S V ENGINEERS, INC.

S V ENGINEERS, Inc. has been designing, engineering and servicing a complete line of solid fuel, solid waste, biomass, gas, coal and oil-fired steam and hot water boilers since 1999, for thousands of satisfied customers. SVE  also manufactures a complete line of boiler room peripherals such as blowdown separator surge tanks, and pressurized feedwater tanks. In addition, SVE also offers expertise and professional consultancy services in the area of Mechanical Engineering, IBR Steam Boilers, Stainless Steel Fabrication and MS Sheet Metal fabrication.

The company since started to date has been involved in Engineering design and sheet metal Fabrication, shop floor inspections for IBR Boilers, its accessories and allied equipments while in key stage of manufacturing. The company specializes in Stainless Steel Fabrication involving manufacture of complete Solvent/Flower Extraction Plant, Herbal Extraction and Steam Distillation Plants. Manufacturing of Stainless Steel/Mild Steel Storage Tanks of capacities up to 100,000 Litres, manufacturing and installing of Lorry Tankers of both MS and SS, manufacturing of SS and MS Reactors are our core areas of expertise.  Other services include annual maintenance service of boilers in process industries, management information system in regards to boiler operation, fuel economy, and increasing of boiler efficiency.

The establishment of S V ENGINEERS was mainly to cater quality and efficient services in the field of engineering/sheet metal fabrication, erection and commissioning and supply and service of spare parts and accessories for process industries. Other services in the firm involves supply and construction of refractory furnaces for boiler plants and kilns, supply and laying of insulation lining both hot and cold for process industries, supply of chemicals and de-scaling of boilers and bullet tanks, conversion of oil fired boilers to solid fuel boiler, supply of conveyors and fuel feeding system, supply of steam boilers and turbines for process industries.

SVE proudly offers major repairs as well as service & preventative maintenance of steel boilers, IBR welding, "R" & "PP" stamps, refractory & tube repairs. SVE stocks a large inventory of boiler parts including pollution control systems & exchangers, controls, forced draft burner parts, feed water tanks, water softeners, chemical feed systems, castables, refractories & insulations. We offer in-stock replacement parts for all major commercial/industrial boilers.

Field Installation & Product Education

Our installation crews are headed by the most knowledgeable people in the boiler industry, backed with solid years of on-site experience. During the installation process, we educate your maintenance staff with the proper use, care and maintenance of your boiler.

24 x 7 Customer Service

Our customer service staff are trained to answer any question you may have regarding your boiler, its proper operation, and maintenance. Our staff is available 24 hours a day, 7 days a week. Questions can be asked either on-line or by telephone, at your convenience, before, during or after the sale.

Repair & Refurbishing Services

Parts and serviceability are the keys to preventive maintenance and peek-operating efficiency of your boiler. We stock replacement parts for our boilers and other major competitors. We ship from our Parts Center in Coolidge, Georgia via Emory, DHL, FedEx and UPS for speedy delivery of critical parts to your facility. We also provide repair and refurbishing services by our trained personnel, either on- or off-site.

Company's History & Core Values

Inspiration

The inspiration behind the company’s manpower is its founder and Managing Director Shri. T.V. Sridhar who is a Mechanical Engineer by profession having more than 35 years of rich experience in the field of Sheet Metal Fabrication, Boiler and Stainless Steel Fabrication.

His inspiration has led S.V.Engineers to the New Millennium which today is capable of fulfilling Engineering Needs for various process industries.

Core Values

• Quality, efficiency and integrity is the first and foremost
• Advice and act for the customer’s benefit
• Conduct the business lawfully, ethically and morally
• Work on time and in a safe manner
• Execute the work in a efficient and right way
• Treat employees as our most important source
• Sustain expansion and growth
• Act to the Golden Words: “Client is King”

Company Policy & Objectives

We shall use out inherent strengths to improve our skills and expertise to ensure Total Customer Satisfaction by adhering to Quality Management system Standards and by providing quality effective and efficient engineering services.

Objectives

• To provide beneficial and efficient consultation
• To increase the tonnage of fabrication by around 10%
• To provide quality and efficient spare products
• To increase the volume of boilers, reactors, storage tanks and distillation unit sales
• To promote co-generation  to all viable process industries
• To promote small and large captive solvent extraction plant generation
• To conduct business in a lawfully, ethically and moral way

Small Industrial Boilers (SIB)

As Per Indian Boiler Regulations, Regulation 619

 “Small Industrial Boiler" means:

a) a shell type boiler generating stream for use external to itself under pressure upto 7 kg/cm2 and having a volumetric capacity exceeding 22.75 litres, but not exceeding 500 litres including the volumetric capacity of all pressure parts being heated from the same heating source and connected to the boiler; or
b) a coil type boiler or a once through boiler or a water tube boiler having the conditions specified in clause (a) above except that –
  (i) the limitation of pressure shall be 12 kg/cm2, and
  (ii) the capacity shall be not exceeding 150 litres.
 
Provided that in case of boilers having combined features of clauses (a) and (b), the working pressure shall be restricted to 7 kg/cm2 and the volumetric capacity of particular pressure parts shall not exceed the limits specified in the respective clauses above subject to an aggregate of 500 litres.

1] 350 Kg/Hr Horizontal Small Industrial Boiler - Model: SVE-SIB-350

S V ENGINEERS' (Model: SVE-SIB-350) Small Industrial Horizontal Boilers are a perfect solution for small steam users. The unique and innovative design of these boilers solves all the critical problems usually faced by small steam users.
Designed and manufactured conforming to the IBR code, these are the most compact and efficient shell type industrial boilers available in the range.                         S V ENGINEERS' Horizontal Boilers are extremely safe and user friendly. 2-Pass Dry-Back design of this boiler ensures easy flow of flue gases, high efficiency and superior steam quality with dryness fraction over 90%.

Specifications:

                      Model:  SVE-SIB-350

                    Design:  Horizontal 2-Pass Dry-Back

Capacity Of Boiler:  350 Kg/Hr (F & A 100°C)

Working Pressure:  7 kg/cm2 (g)

                         Fuel : Agro-Waste/Fire Wood/ Briquettes
 

2] 200 Kg/Hr Vertical Smoke Tube Small Industrial Boiler - Model: SVE-SVB-200

S V ENGINEERS' (Model: SVE-SVB-200) small industrial Vertical boilers are ideal solution for steam requirement for Small Scale Industries and small processes. The Vertical Smoke Tube Design of this boiler provides continuous steam with low fuel consumption and high efficiency and provides relief for many of the critical problems usually faced by small steam users.
Designed and manufactured conforming to the IBR code, these are the most compact and efficient Vertical Smoke Tube, with Internal Furnace Shell type industrial boilers available in the range.                      

   S V ENGINEERS' Vertical boilers are extremely safe and user friendly. Multi-Tubular Vertical Smoke Tubes, with internal furnace design of this boiler ensures easy flow of flue gases, high efficiency and superior steam quality with dryness fraction over 90%.

Specifications:

                      Model:  SVE-SVB-200

                    Design:  Vertical Smoke Tube Multi-Tubular, Internal Furnace

Capacity Of Boiler:  200 Kg/Hr (F & A 100°C)

Working Pressure:  7 kg/cm2 (g)

                         Fuel : Agro-Waste/Fire Wood/ Briquettes
 

VERTICAL BOILERS

Simple, Reliable & Extremely Efficient

S V ENGINEERS provides startup, installation, commissioning, and servicing for all individual and skid mounted packaged vertical boilers. Our steam plant specialists and field repair/installation crews can work around the clock to ensure your project is completed by or before deadline.

Advantages of Vertical Boilers

Vertical boilers provide for exceptionally high efficiencies, lower fuel costs, and extremely rugged construction. Their compact space saving vertical design is shock proof, with no tubes to loosen or burn out. They offer convenient and trouble free operation. Vertical boilers are also simple and inexpensive to install. Low water pressure drops. Our Vertical Boilers are available from Capacity of 50 Kg/Hr to 1500 Kg/H with working pressure ranging from 5 Kg/cm2 to 10.54 Kg/cm2.

In addition to new and used vertical boilers, S V ENGINEERS' can rebuild your existing boiler in less time than it takes for a manufacturer replacement. Our on-hand inventory of reconditioned vertical boilers have been completely overhauled, inspected, and tested to meet or exceed IBR specifications.

TECHNICAL SPECIFICATIONS

3-Pass Fire Tube Boilers

Water Tube Capacity With Fire Tube Efficiency

Each set of tubes that hot combustion flue gas travels through before making a turn within the boiler, is considered a "pass." A 3-pass firetube boiler design consists of three sets of horizontal tubes (Including Furnace), with the stack outlet located on the rear of the boiler. A downdraft design keeps the cooler water from having an effect on the hot surfaces within the boiler.

Generally speaking, a boiler with more passes provides more opportunities for hot gasses to transfer heat to the water in a boiler and operate more efficiently, however, boiler efficiency is highly affected by tube design, and not simply the number of passes. It is possible for a 3-pass boiler with a tube design (such as XID boiler tubes) that allows more heat transfer time to deliver the same or higher efficiency rating than a 4-pass boiler with standard tubes.

3-Pass Fire Tube Boilers Offer:

• maximized heat transfer
• minimal refractory
• high steam/water storage
• effective handling of wide load demands

Trust the Fire Tube Boiler Experts at S V ENGINEERS

S V ENGINEERS proudly manufactures and sells new 3 pass firetube boilers, and also has the expertise to provide on-site or in-house service and repair for 3 pass boilers from other manufacturers as well.

In addition to an in-stock inventory of used 3 pass boilers, we offer firetube boiler customization to meet any specification. Firetube boilers can be shipped individually, on a packaged skid, or as complete "boiler in a box" solution. And as as a fully licensed General Contractor with divisions dedicated to every aspect of the boiler room inside and out, we are able to provide system design and engineering, concrete work, electrical services, process piping, and more to provide a total steam plant solution.

Our 3-Pass fire tube Boilers are available with capacities ranging from 500 kg/Hr to 6000 Kg/Hr with working pressure ranging from 7 Kg/Cm² to 21.06 Kg/Cm² with firing medium being oil fired burner, agro-waste, fire wood and briquettes in the following different designs :

1] 3-Pass Dry Back

2] 3-Pass Fully Wet Back

3] 3-Pass Semi-Wet Back

4] 3-Pass Reverse Fired Dry Back

Contact S V ENGINEERS today to purchase a new 3-Pass Fire Tube Boiler and to  know about the various models of different capacities.

4-Pass Fire Tube Boilers

Maximized efficiency with lower maintenance cost

Each set of tubes that hot combustion flue gas travels through before making a turn within the boiler, is considered a "pass." A 4-pass boiler design consists of four sets  of horizontal tubes (Including Furnace), with the stack outlet at the front of the vessel. A downdraft design keeps the cooler water from having an effect on the hot surfaces within the boiler. 4-pass boilers leverage natural draft operation which allows cool water to contact the hottest part of the boiler.

Generally speaking, a 4-pass boiler provides more opportunities for hot gases to transfer heat to the water in a boiler and operate more efficiently (yielding a higher overall heat-transfer co-efficient).

4-Pass Fire Tube Boilers Offer:

• maximized heat transfer
• minimal refractory
• high steam/water storage
• effective handling of wide load demands

Trust the firetube boiler experts at S V ENGINEERS

S V ENGINEERS proudly manufactures and sells new 4-pass firetube boilers. We are also authorized to serivce and repair 4-pass boilers from other manufacturers as well, both on-site and in-house at our facility in Mysore, Karnataka.

In addition to an in-stock inventory of used 4 pass boilers, we offer firetube boiler customization to meet any specification. Firetube boilers can be shipped individually, on a packaged skid, or as complete "boiler in a box" solution. And as as a fully licensed General Contractor with divisions dedicated to every aspect of the boiler room inside and out, we are able to provide system design and engineering, concrete work, electrical services, process piping, and more to provide a total steam plant solution.

Our 4-Pass fire tube Boilers are available with capacities ranging from 1500 kg/Hr to 6000 Kg/Hr with working pressure ranging from 10.54 Kg/Cm² to 21.06 Kg/Cm² with firing medium being oil fired burner, agro-waste, fire wood and briquettes in the following different designs :

1] 4-Pass Dry Back

2] 4-Pass Fully Wet Back

3] 4-Pass Semi-Wet Back

4] 4-Pass Reverse Fired Dry Back

Contact S V ENGINEERS today to purchase a new 4-Pass Fire Tube Boiler and to  know about the various models of different capacities.

Wet-Back Vs Dry-Back Fire Tube Boilers

Understanding the operational design differences

Firetube boilers are available in either dryback or wetback design. They are identified by the type of reversal (turnaround) chamber, or posterior portion of the combustion chamber, through which flue gasses travel through the furnace to second-pass tubes to heat water within the boiler.

Wet-back Firetube Boilers

The wetback boiler design features a reversal chamber that is jacketed, or completely surrounded by water, which is used to direct flue gasses from the furnace to the tube banks. The surrounding water absorbs burner heat, helping improve operating efficiency as heat from combustion goes directly into evenly heating water instead of refractory. The wet back boiler design uses separate tube sheets between tube passes which can be more forgiving with load changes.

Wetback firetube boilers offer a more optimal functional footprint, with lift off or split-hinged doors that require no cool-down period and can be opened immediately. While there is no expensive refractory to maintain, internal pressure vessel maintenance (i.e. cleaning and tube removal) can be more involved and challenging.

Dry-back Firetube Boilers

The dryback boiler reversal chamber has a rear wall that is lined, or jacketed with refractory, which passes combustion gasses from the furnace to multiple tube sheets and reflects burner heat, resulting in exterior radiation losses. The dry back boiler design uses a common rear tube sheet and features convenient fire-side and water-side access.

Dryback boilers have a larger functional footprint due their heavy, vessel-sized rear door which requires sufficient space to open and a cool-down period prior to opening. Dryback boilers also require regular refractory and tube sheet inspection, which can be costly maintenance items.

Trust the Fire Tube Boiler Experts at S V ENGINEERS

If you need help navigating the design aspects to better understand the pros and cons of wetback and dryback firetube boilers, contact our steam plant experts at S V ENGINEERS today. We can help you make an informed decision based on your unique circumstances and provide the boiler that's just right for you.

SOLVENT EXTRACTION OF ESSENTIAL OILS

Solvent extraction is used to extract Essential Oils from plants that cannot withstand the high heat used in steam distillation. Very delicate aromatics, Jasmine, Linden Blossom, etc can not survive the process of distillation. To capture their magical aromas, a process of solvent extraction is used. For some plants, the intense heat damages them so, that the essential oils are unusable therefore, they must be extracted via other means.

For essential oil solvent extraction methods one might use alcohol, hexane, ethanol, ether, methanol or even petroleum to coax the oils out of the plant. Most people don’t approve of these methods, however, because some of the solvent will end up in the final essential oils that are consumed. This makes for an impure oil, that aromatherapy and healing purists won’t tolerate.

An extracting unit is loaded with perforated trays of blossoms. The blossoms are washed repeatedly with a solvent (usually hexane.) The solvent dissolves all extractable matter from the plant whch includes non-aromatic waxes, pigments and highly volatile aromatic molecules. The solution containing both solvent and dissolvable plant material is filtered and the filterate subjected to low pressure distillation to recover the solvent for further use. The remaining waxy mass is what is called the concrete and it contains in the case of Jasmine grandiflorum as much as 55% of the volatile oil.

The concentrated concretes are processed further to remove the waxy materials which dilute the pure essential oil. To prepare the absolute from the concrete, the waxy concrete is warmed and stirred with alcohol (usually ethanol.). During the heating and stirring process the concrete breaks up into minute globules. Since the aromatic molecules are more soluble in alcohol than is the wax an efficient separation of the two takes place. But along with the aromatic molecules a certain amount of wax also becomes dissolved and this can only be removed by agitating and freezing the solution at very low temperatures (around -30 degrees F) In this way most of the wax precipates out. As a final precaution the purified solution is cold filtered leaving only the wax-free material (the absolute.)

After the solvent extraction process has been completed, the resulting absolute will have an extremely low concentration of solvent residue, approximately 5 to 10ppm (parts per million). The current European Union standards are for less than 10 parts per million solvent residues in a finished absolute.7 However, even with such a potentially small residue (less than .0001%), many aromatherapists disagree with the use of absolutes for individuals with a compromised immune system due to the potential effect of the residual pesticide. Absolutes are highly concentrated aromatic substances and are obtained from delicate flowers by either enfleurage or solvent extraction. Absolutes will most often resemble the natural aroma of the plant and are normally more colored and viscous than essential oils. Absolutes are used extensively in the cosmetic and perfume industries due to their strong aromas. There are also different grades of absolutes. The top grade is the uncut, which can be a thick or semisolid substance, making them difficult to work with. Less expensive grades are diluted with alcohol to make them more user friendly, although often the strength of aroma is slightly diminished.

We are Pioneers in Manufacturing of Solvent Extraction Equipments

S V ENGINEERS has been manufacturing Solvent Extraction Machinery and Equipments since 1999 for many satisfied customers, mainly from Tamil Nadu in South India. We specialize in complete Design, Fabrication, Erection and commissioning of a Solvent Extraction Plant of capacity up to 50 Tonnes.

A Solvent Extraction Plant typically consists of the following machinery/equipments and we are pioneers in manufacturing these equipments as per the requirement of the design and plan:

• Extractors - Our Extractors are of robust construction made out of SS304 Grade Stainless Steel sheets, with dished bottom and top. The top dish is provided with counter weight to facilitate easy opening for loading and unloading of flowers, and steam distribution coil pipe is provided in the bottom for steam flow inside the Extractor. Our Extractors are available in different capacities and sizes as per the requirement of the customer.

• Rotary Extractor - A relatively new method of initial process of flower extraction is by using a Rotary Extractor. SVE manufactures rotary extractors which are robust in construction and consists of a perforated SS drum inside the shell, which is driven by a Gear Box to rotate at 5 r.p.m. Our Rotary Extractors are designed in such a way that the overall process of loading, unloading, solvent feed and removal of left over flower are performed wihtout any hassels or restrictions, thus enabling you to obtain optimal effectiveness and efficiency.

A Typical Rotary Extractor with Gear Box and Motor

Extractors mounted on platform, receiving tanks in the bottom

An Heat Exchanger consisting of 425 Tubes

• Condensers - SVE specializes in manufacture of Shell and Tube Condensers for flower extraction plants as well as other chemical process plants. Our condensers are designed to  provide optimal heat transfer, with minimum heat losses, and are of counter-flow design, and available in both Vertical orientation and Horizontal orientation.

• Receiving Tanks & Storage Tanks - Our receiving tanks are made out of Stainless Steel SS304 grade and available in various sizes as per the capacity of the Extractor.

• Purification Unit - Purification unit is used to purify the crude solvent to remove any unwanted odour from the solvent, and then fed into the Extractors. The purification Unit consists of a Kettle with column mounted on it, consisting of ceramic raschig rings. The vapour will pass through the raschig rings and then to a condenser, and finally to a receiving tank, where pure solvent is collected.

• Finisher - The Finisher is used to obtain absolute, and consists of a Kettle, Column, Condenser and Receiving tank. Various capacities of finishers are manufactures by us, but the standard capacity of finisher used in majority of flower extraction plants is 100 Litres.

Steam Distillation Units

SVE specializes in design, manufacture and supply of Steam Distillation Units of different sizes and capacities as per the customer's requirement. These units require steam from Boilers and are used for Extraction of Essential Oils. The steam distillation units are more economical for larger areas and for continuous work. We fabricate the range of distillation units and columns in any dimensional specifications using superior quality raw materials. We also facilitate customization of products as per the client's preferences & requirements. Some common attributes of our machinery products are:

• Longer life

• Excellent finishing

• Better production output

• Compact design

• Less maintenance

• Cost effective

• Easy to operate

Steam Distillation Unit Installed at Tirupattur, TN

Field Distillation Units

SVE manufactures  field distillation units (FDU), which are used for the distillation and extraction of essential oils from herbs, shrubs, leaves, roots or other part of plant by passing the saturated steam. Our FDU systems consist of built-in-boiler tubes submerged in water for producing steam.

The FDU can be set up and operated without highly skilled labours as well as it can be run without power. Besides superior quality, our field distillation unit is most cost-effective system in this industry. Some important features of these systems are:

• Operate on low pressure drops
• High numbers of separation stages
• Performance retention is maintained even in high capacity columns
• Durable and less maintenance
• Random packings replacement in a given column enhance capacity by 50% to 20%
• Minimum hold-up & reflux ratios
• Less energy consumption

Contact SVE today to get a detailed information about the various capacities of the above equipments. We provide complete information and also advice as per your requirement and specifications.

MANUFACTURE OF STAINLESS STEEL & MILD STEEL EQUIPMENTS

SVE designs and manufactures a variety of Stainless Steel and Mild Steel equipments and machinery as per the requirements of our clients.We use high quality SS304/310/316 grade Stainless Steel sheets as per the rquirement of design. Following is the list of equipments that we manufacture:

• Stainless Steel Reactors - for manufacture of Resins, Pottasium Nitrate, Circumin Extraction and many other applications. These Reactors are provided with MS Jacket for steam circulation and consists of SS Coils inside the Reactor to facilitate cooling as and when required. Agitator is driven by suitable Gear Box and Motor to mix the product to the desired R.P.M.

• Stainless Steel Kettles - for production of food items like Jams, Sauce, Honey and many others. These kettles are useful for smaller process industries who manufacture food items in small quantities. These kettles are available in Jacketed design or Electrical Coil Type.

• Stainless Steel/Mild Steel Storage Tanks - We manufacture SS and MS  Storage Tanks of capacity upto 100 Tonnes.

• Chimneys - We maufacture Self Supporting Chimneys, with base plate, foundation bolts for all process and chemical industries upto 150 Feet Height. Made out of IS2062 Gr B Sheets, our chimneys are of robust construction and long life is guaranteed.

FORCED CIRCULATION EVAPORATORS

As the name implies, force is used to drive the liquid through the evaporator tubes thus producing high tube velocities. A high efficiency circulating pump, designed for large volume and sufficient head, is used to supply the force. Proper design results in controlled temperature rise, controlled temperature difference and tube velocities that give optimum heat transfer. Forced Circulation Evaporators are recommended for viscous, scaling and salting liquids. As the liquid is only heated in the steamchest with flashing taking place in the separator and no boiling taking place within the tubes, fouling on hot tube walls is reduced.

SVE's Forced Circulation Evaporators may be equipped with either horizontal or vertical steam chests. The circulating pump withdraws liquid from the lower part of the vapor-liquid separator and circulates it through the tubes at a high velocity.  Boiling is suppressed in the tubes either by liquid head or an orifice plate. The heated liquid is discharged into the separator where the vapor flashes off due to the temperature difference and is removed through the top outlet. The liquid is discharged at a maintained liquid level. 

Characteristics:

• Operates with extremely low temperature differences

• High tube velocity

• Velocity mechanically produced and controlled

• Gives high rate of heat transfer, rapid evaporation and high concentration without requiring high operating temperatures or large heating surface

• Maximum recovery of solids

• Can use horizontal or vertical tubes

• Tubes are readily accessible for cleaning and inspection

• Suitable for single or multiple effects

Product Application:

• Very viscous liquids

• Scaling liquids tending to produce scale

Examples of Forced Circulation Application:

• Organic Jaggery

• Acid Raffinates

• Glycerin

• Irish Moss Extracts

• Sodium Sulphate

• Gelatin

• Heat-sensitive materials
• Crystal producing liquids

• Glue
• Pectin Solutions
• Sugar Esters
• Tomato Paste
• Yeast Cream
• Ammonnium Sulphate

Advantages:

•  In forced circulation evaporator there is a rapid liquid movement due to high heat transfer coefficient.

• Salting, scaling and fouling are not possible due to forced circulation.

• Thess evaporators are suitable for themolabile substances because of rapid evaporation.

• It is suitable for the viscous preparation because pumping mechanism is used.

Disadvantages:

• In forced circulation evaporator the hold up of liquids is high. The equipments is expensive because  power is required for circulating the liquids, and hence pumping costs will be very high.

Contact SVE today to know about the Various Equipments we manufacture of different capacities as per your requirement.

BOILER RETUBING & TUBE REPLACEMENT

Retubing and Tube Replacement for Boilers of all sizes

S V ENGINEERS specializes in the retubing of firetube boilers, watertube boilers, superheaters, pre-heaters, heat exchangers and other pressure vessels. Boiler tubes must be able to endure extremely high temperatures, pressures, and potentially wide fluctuations in demand depending on the application. Boiler re-tubing and tube replacement can extend the life of the boiler, and saves the tubes from deteriorating due to scale build up and cracking. Boiler retubing can be completed by our experts onsite at your facility, or at our Mysore, Karnataka, fabrication and repair shop or as required. S V ENGINEERS also provides a large variety of emergency rental boilers to keep operations running during repairs.

Boilers and auxiliary equipment should be professionally checked every year. Contact S V ENGINEERS for information on our annual equipment service and maintenance contracts. Regularly scheduled inspection and proper boiler maintenance can improve efficiency, and prevent costly and unexpected interruption in production.

S V ENGINEERS can retube boilers by all leading manufacturers of India and abroad, restoring them to factory specifications. We also offer custom bent tubing, cracked tube sheet repair and tube sheet replacement. We provide custom welding in house or on-site, and offer a complete inventory of replacement boiler tubes in all sizes, thicknesses and materials.

S V ENGINEERS' Boiler Retubing process includes:

• Inspection - SVE visually inspects each boiler, and perform NDT testing as needed. We use dye penetrant testing to expose areas of boiler tube sheet cracking.
   
• Boiler Tube Extraction - old boiler tubes are removed along with the tube ends. Any minor tube sheet cracks are then repaired to the IBR code specifications.
   
• Boiler Tube Installation - new boiler tubes (manufactured to meet or exceed specifications) are installed, rolled, beaded and sometimes welded (in the hot pass).
   
• Boiler Testing & QC - SVE hydro-tests the boiler, witnessed by Inspector of Factories and Boilers. The boiler is then closed and prepared to fire using all new gaskets. We visually check scale and fits during this phase. SVE can provide ultrasonic thickness testing, or boroscope the inside of watertube boiler tubes as required. We can also handle code repairs to access points, nozzles and other related equipment.
   
• Documentation - SVE provides all completed repair forms for submission to Inspector of Factories and Boilers & other applicable regulatory agencies.

Whether performed in house or on site, SVE has all the necessary retubing equipment required to handle boiler tube replacement, including:

• Tube expanders
• Tube & pipe cutters
• Tube lubricants
• Extension couplings & universal joints
• Handhole cleaning and seat grinding kits
• Tube end polishing kits

Extend the Life of your Boiler:

Tubes are the heart of any boiler unit. Improper deaeration and water treatment can significantly affect the lifespan of tubes. Additionally, tube replacement can often indicate water quality issues that need to be addressed.

Retubing can increase the life of the unit by many years. If you are experiencing excessive scale or system leaks, SVE can help you determine whether tube replacement is the best option, or if it’s time to replace/upgrade your boiler.

• Excessive scaling adheres to the tubes
• The tubes become pitted (holes caused by oxygenation, overtreatment of water chemicals, stresses or strains, etc.)
• Tubes continue leaking at the tubesheet after several attempts to roll them

Contact SVE today to discuss your boiler retubing and repair needs, or for more information on our re-tubing services, boiler tube replacement and onsite installation. We have experienced crews ready to assist you.

REAR DOOR REPAIR & REPLACEMENT

If you have a Horizontal Boiler and need rear door replacement, trust the experts at SVE to help. Tube leaks and equipment age commonly cause overheating and lead to rear door refractory failure.

SVE has rebuilt/refurbished hundreds of  rear doors of Horizontal Boilers in stock, and can replace doors of any size and design.

All doors are built to OEM specs and include anchors, insulation, high-strength (bottom) castible/refractory handling temperatures up to 3000, baffle tile and complete rear gasket kits for all sizes.

Rear door installation can be completed in as little as one day. No installation is too challenging - SVE can deliver & change out on site. We even have a custom rolling cart to replace doors on boilers in highly confined spaces.

Contact SVE today  for more information on rear door replacement and installation for Horizontal boilers.

BOILER RECONDITIONING

We Make Your Old Boiler New

SVE's boiler reconditioning services manage the entire reconditioning process from the outside-in, including tube replacements, new casing and insulation, new refractory, level control replacements, new wiring, all new gaskets, updated control systems and design modifications as well as burner retrofits and even fresh new paint.

SVE will help you find the most efficient, economical and effective solutions to get the most out of the life of your boiler systems. We ensure that all reconditioned boilers receive the latest technology in boiler control upgrades.

Contact our boiler experts for more information on our reconditioning services, equipment upgrades and in-stock inventory of reconditioned boilers.

INDUSTRIAL BOILER TUNING

Tuning Industrial Boilers for optimal efficiency

Boiler tuning is an important maintenance item used to adjust the air to fuel ratio in the boiler and achieve maximum combustion efficiency - the measure of how effectively the heat content of a fuel is transferred into usable heat.

Beyond ensuring long term equipment life and operational reliability, highly efficient boiler systems can mean significant bottom-line cost reduction, NOx reduction and fuel savings. Boiler tuning should be performed each year to maintain peak efficiency.

A regular boiler tune-up provides an opportunity to verify current boiler operating performance and establish a baseline for optimization adjustments, such as fine-tuning the amount of excess air available to completely burn the fuel. Using the optimal amount of excess air minimizes heat loss up the stack and improves combustion efficiency. It is not uncommon for boilers to operate at greater than desired excess air levels, resulting in in heat lost due to the increased flue gas flow, which lowers the overall boiler fuel-to-steam efficiency.

Two primary indicators used to measure combustion efficiency are flue gas oxygen (or carbon dioxide) composition and stack temperatures.

• Flue gas composition indicates whether the fuel is being burned as efficiently as possible.
• Flue gas temperature indicates how effectively combustion heat is being transferred to the boiler water.

We Tune to Perfection

Our combustion experts at S V ENGINEERS are factory trained technicians, qualified to inspect and tune industrial boilers and burner equipment, according to manufacturer specifications, IBR guidelines, and requirements of Inspector of Boilers. We service all major brands of industrial boilers and burners, including equipment from all manufacturers from India and all over world.

• Boiler Tuning
• Boiler Inspection
• Boiler Efficiency Optimization
• Boiler Safety Shut-Off Verifications
• Low Water Control Test
• Positive Gas Valve Shut Off Testing

Tuning your boiler and burner equipment can help you identify and address elevated NOx and CO levels, steam and stack temperature variance, boiler control issues, and even tube failure. Don't wait for your industrial boiler and burner to cause emergency shutdown.

Contact SVE today and learn more about our boiler tuning services. We provide annual maintenance contracts to keep your entire system running smoothly.

BOILER INSPECTION & SERVICE

Protect your Boiler and equipment investment

Just like the car you drive every day, industrial or commercial boilers and auxiliary boiler equipment need to be properly maintained at recommended intervals for peak performance and long service life. Additionally, a certification of inspection is needed to operate from year to year. S V ENGINEERS is your one-stop-shop for boiler inspection, planned outage maintenance, emergency service, and on-site equipment assessments.

Annual Boiler Inspection

Every boiler and pressure vessel in the United States above 15 lb requires an annual inspection, generally led by a licensed inspector from a commercial insurance provider. Annual inspection is typically geared toward a specific piece or set of equipment and involves a planned outage to open the boiler(s) and inspect the fire and water side.

A qualified service company like S V ENGINEERS works side by side with inspectors to record any problems and identify and make repairs that may be required such as tubing, refractory, gaskets, controls, etc.

Specifically, an annual boiler inspection addresses the labor, material, equipment and supervision to:

• remove all safety relief valves, and replace them with valves provided by customer
• open the boiler(s), inspect tubes, tube sheets, level controls
• close the boiler(s), clean outside area and prepare for firing
• perform calibration service and performance testing on the boiler safety interlocks, controls and valves
• inspect related equipment including deaerators, feedwater systems, economizers, blowdown systems, etc. as applicable

Boilers and equipment which pass inspection receive a new annual certificate of operation. Keep your steam plant operating at its best – ask about our annual maintenance contracts!

Planned Outage Maintenence

Planned outages are used to conduct annual equipment inspections, install new equipment and make upgrades, and address routine maintenance items and repairs to industrial boilers and auxiliary equipment within a designated window of time. A successful plant or process outage requires a qualified service provider with sufficient manpower availability and experience to expect the unexpected, with a contingency plan in place to meet project deadlines. It also requires proper planning to order new or used equipment, or check the availability of rental equipment as needed with sufficient lead time to secure for any pieces taken out of service.
 

With planned outage maintenance through S V ENGINEERS, you can expect:

• service tech crew scheduling
• project management & client communication
• equipment rental & purchase management
• safety oversight
• inspector coordination
• service/maintenance reporting
• system testing & restoration
• contingency planning

Emergency outage service and repairs

Unplanned outages happen when you least expect them, and somehow it’s always at the worst time. Equipment failure and emergency shutdowns can be extremely stressful and costly as well due to lost production time. SVE’s Field Service & Repair division and Parts divisions are both available 24/7 for emergency help. Additionally, our Rental Boiler division has a wide variety of trailer mounted or skid mounted rental boiler units in stock ready to ship and have you up and running in as little as 24-48 hours. Regardless of the type of emergency service you need, SVE has depth of experience and manpower to handle your toughest challenges and limit down time to bring your operation back online quickly.

Boiler and equipment assessment

Do you have a non-emergency issue with an industrial or commercial boiler or auxiliary equipment that you’d like a second opinion on from a qualified service expert? Each and every day we work with plant engineers, supervisors and boiler operators who face technical issues beyond their expertise, and need a hands-on assessment. We have service technicians who identify problems, validate suspicions, and give accurate scope to problems like leaks, operation inefficiencies, hot spots, vibrations, etc. Don’t guess – call S V ENGINEERS today to schedule an on-site boiler and equipment assessment and get the answers you need.

S V ENGINEERS is the only partner you need

S V ENGINEERS has the depth of experience, the manpower, successful history of past projects and safety record to handle your boiler inspection and service needs. Contact SVE today and learn more or schedule your planned outage work today.

BOILER INSTALLATION & START UP

Complete Boiler Solutions from A to Z

We are experts in all aspects of a boiler system’s lifecycle as well as everything inside the 4 walls of the boiler room. We are a one-source boiler service provider that coordinates delivery and installation, removal and disposal of your old boiler and start-up of your new system.

SVE understands the costly effects of downtime.  Whether you make your boiler purchase through SVE or another company, our large staff of boiler installers and service technicians will get you up and running faster than anyone in the industry. SVE’s industrial boiler installation services include:

• Consultation and boiler sales
• Plant & system design
• Boiler transportation & removal
• 24/7 boiler system installation & support
• Boiler startup and equipment training
• Unlimited license for Mechanical, General, and Electrical Contracting
• Commissioning
• Servicing and maintenance

Boiler Installation anywhere in India

SVE provides thorough planning and implementation of all types of boiler systems. Our skilled and experienced technicians keep downtime to a minimum. We handle and guide you through installation for basic Boiler in a Box systems to complex, multi-phase boiler installations.  Our teams are there from start to finish and provide continued boiler maintenance services for the life of your boiler. Our approach addresses all areas of the installation process:

• Building and piping high lines
• Fuel storage & handling
• Boiler rentals
• Master control rooms
• Steam distribution header systems
• Chemical feed systems
• Plant lighting
• Concrete and electrical work

Contact our boiler experts today to learn more about our full service boiler installation and startup capabilities.

PRESSURE VESSEL REPAIR

Taking the Pressure Off Pressure Vessels

SVE can quickly repair pressure vessels that have deteriorated over time due to corrosion or regular mechanical wear. By combining the efforts of our quality control management team, we ensure proper procedures, quality welding, and testing are all applied for the best in quality repairs.

Types of pressure vessels & equipment we repair:

• High Pressure Steam Drums    
• Super Heaters
•  Air Tanks
•  Heat Exchangers
•  Heat Set Tunnels
•  Chemical Reactor Vessels
•  Bioreactor Vessels
•  Reactor Pressure Vessels

•   Dimple Jacket Tanks

•   Tube Sheets

•   Ligament Repairs

•   Latex Storage Tanks

•   Tube Dutchmans

•   Autoclaves

•   Heat Exchangers

PROJECT PLANNING & DESIGN

Planned for Success

SVE’s Engineering & Design division boasts of decades of experience in steam plant project work. Our experience means that each and every mechanical contracting project is meticulously planned by industry experts, from small commercial or industrial steam plants to large industrial power plants generating multiple MegaWatts of power for cities and communities. We can work with side by side as subcontracted steam plant specialists for General Contractors or engineering firms, or manage the entire project from A-Z, with planning and design to equipment delivery and installation.

New steam plant project? Here’s what you can expect:

• Our team of specialists (engineers, estimators, project managers, and field craftsmen) who are experts in building mechanical construction, plumbing and electrical codes, etc. will build a new plan from an idea, work from provided specs or survey a physical site to determine the details required to assess the full scope of a project. We look at key components like existing piping and utilities available (or those needed), and identify equipment needed to install, modify or repair.

• Our engineers design for planned output requirements (size, pressure, flow, etc) and account for possible growth projections to build a solution that can factor additional capacity.

• This team builds an estimate for each project along with a detailed design and building project plan including delivery dates, equipment requirements and installation dates.

• We work with any and all state regulatory entities to ensure that all steam and hot water project requirements are up to code and meet regulatory standards.

• Management! It’s not over just because our project is complete. We provide regular inspections and tune ups to make sure our project work.

Equipment repair, modification, or steam plant expansion? Here’s our process:

• Our engineering staff performs a careful evaluation of the need first, and will walk through your plan or put together a project requirements to meet your need.

• SVE provides engineering for repairs and equipment alterations. We have full R,S & U stamps to work with fired (steam boilers and hot water heaters) and unfired vessels (DA systems and feedwater tanks).

• Once we establish a project scope (design & calculate, equipment or system modifications, custom application development, etc.) we will work with you to determine a timeline and budget for your project.

• Have other general contractors or even sub contractors? Great! We work well with other teams and can become a part of the team or lead it depending on your needs.

• Whether it’s boiler installation, process piping or building a mezzanine - we have the mechanical and electrical contracting expertise to meet your complete steam plant needs. You can count on SVE, remove, replace, relocate or install any piece of equipment or machinery.

Mechanical contracting projects require expert coordination of multiple resources and schedules. SVE is uniquely positioned to leverage our multiple internal divisions to provide a total steam solution, and work cross functionally with other teams that may already be in place to make sure that design and engineering plans take into account all of the moving pieces for your project.

Contact our Mechanical Services group to learn more about our steam plant engineering and design services. We can take your project from idea to successful completion.

EQUIPMENT INSTALLATION & SET UP

Planned for Success

When steam plant equipment is delivered or moved as part of a project, our experienced installers can prepare it for operation, including placement and assembly, on-site welding, alignment, pressure testing and commissioning. At SVE we have the necessary expertise, tools and people to offload and install one piece of equipment, to relocate an entire steam plant or build one from the ground up.

Steam generation equipment installation takes precision

We pride ourselves in the level of technical expertise we have in our organization when it comes to mechanical contracting projects like steam generation and hot water heating systems, hot oil for circulation, vaporized systems, preheating treated water supplies, blowdown systems, economizers and more.

Our expert millwrights can set up and align machinery to tolerances within a thousandth of an inch. Look to SVE for expert installation of:

• Firetube Boilers
• Watertube Boilers
• Package Boilers
• Heat Exchangers
• Fans – Forced and Induced Draft
• Blowdown equipment
• Economizers
• Pressure Vessels
• Gear Boxes
• Generators
• Tanks
• Process piping
• ...and much more

Steam Equipment Installation also takes Precision

All of our craftsmen are licensed and certified to manage and operate all heavy equipment to ensure a smooth installation. Our experience team of welders, pipe fitters and millwrights work with in a program plan and use whatever equipment may be needed like cranes, forklifts, scissor lifts, equipment dollies to name a few -  to complete projects on time, safely and efficiently so you can get your steam needs met quickly. We also have the in-house capability to manage custom system controls and provide critical equipment monitoring.

We can lead or we will Partner

Our job is to make sure your mechanical contracting needs are met. IB&M can handle the entire steam plant equipment installation or we can work with the teams you already have in place. Knowing you had a successful install, setup and alignment means the right goal was achieved.

To learn more about our boiler and steam plant equipment installation, setup and alignment services, contact us today.

PROCESS PIPING

Single source Design, Fabrication and Installation

SVE is the only partner you need for your industrial process piping projects. We handle all stages of process piping development, including planning, fabrication, distribution and installation all under one roof – we’re on of the few single-source boiler process piping solution providers in Karnataka.

Our teams design and engineer projects to fit your exact needs, collaborating with you to develop detailed drawings for piping fabrication and installation. Piping, flanged and threaded fittings, welded and brazed fittings, valves, and all accessories are fabricated in our shop and assembled on-site. ISVE supplies all your industrial process piping needs with diameters from ½” to 30”.

We also offer in-house insulation and jacketing services for process piping and tanks.

Process Piping Materials Include:

• Carbon Steel      

• 304 Stainless Steel

• 316 Stainless Steel

• Food Grade Piping
•  Inconels
• Galvanized

• Ductile Iron
•  Copper
• PVC

Above: Process Piping Installation at a Flower Extraction plant at Tirupattur, Tamil Nadu

SVE can create a custom process piping solution built to handle an array of fluids under varied pressure, flowrate and temperature condition including steam, oil, gas, water, condensate return, starch lines, compressed air, chemcials and heat transfer fluids (Dow and Therminal).

Contact our Services division today for more information on our industrial process piping solutions.

BOILER INSULATION

Boiler and Boiler equipment insulation by steam plant experts

Thermal insulation and jacketing is used to keep boilers and pressure vessel units hot, prevent radiant heat loss, and provide safety protection for equipment operators and employees.  Surface temperatures of boiler doors and covers can reach in the hundreds of degrees Farenheit, and present a safety hazard for workers who could come in contact with these surfaces. SVE can help you select the right insulation materials like mineral wool, fiberglass, rubber, foam glass, and calcium silicate for steam plant equipment and boiler systems operating at various temperatures.

SVE offers insulation & jacketing solutions for:

• Boiler equipment
• Boiler doors
• Mud drum covers
• Valves & flanges
• Steam lines

• Condensate lines
• Fuel lines
• Water lines
• Pulled orcompressed air lines
• Refractory

Protect your people and energy savings

Proper insulation on boilers, valves, piping and boiler equipment not only provides a safe operating environment, but also translates to a cost savings by keeping heat from radiating away from your equipment and reducing the fuel required to function. SVE works with you to determine the right kind of boiler insulation and jacketing your plant needs to maximize cost savings and keep operations running smoothly and safely.

Industrial Equipment Insulation experts

SVE helps you reduce fuel costs and keep employees safe. We can create custom boiler insulation solution for your industrial equipment that ensures efficient operation without radiant heat loss and won't interfere with equipment maintenance and repairs.

To learn more about our boiler room equipment insulation services, contact our Mechanical Services team.

PLANT EXPANSION & RE-LOCATION

Taking Industrial Businesses to the next level

Moving or expanding an industrial facility is a considerable undertaking. Depending on the process, production lines can require the square footage of warehouses and buildings in the hundreds of thousands. Steam plant and boiler room equipment associated with these production lines involves the installation or movement of boilers, controls, feedwater systems, fuel systems, process piping, electrical lines, structural supports, access equipment and much more. That’s why so many leading brands trust the experts at S V ENGINEERS to sweat the details of their plant relocation and expansion projects.

We take into account all important logistics in a plant relocation. Our engineers work with you to determine the entire scope of what you need and then build a plan. This includes things like noting equipment conditions before disassembly, packing and shipping, reassembly and management of the entire project.

We provide support in all phases of the process including:

• Rental equipment planning
• Growth output projections & consulting
• Dismantling & assembly
• Packing, shipping & logistics
• Coordination to continue production

SVE has the right people, resources, and expertise to manage your entire move from the pre-planning stages through completion, allowing your staff to focus on their regular duties with minimal disruption.

• Heavy equipment rigging
• Boiler equipment installation
• Erecting services
• Fabrication & welding

• Equipment setup & alignment

SVE is with you every step of the way

You can move across the street or around India. Either way, S V ENGINEERS will ensure your relocation or facility expansion project is a complete success, getting business up and running as usual. Contact us today for more information.

GALLERY

Contact S V ENGINEERS

To contact us directly, please use form provided below

S V ENGINEERS, Inc.

D-158/159, Industrial Estate,

Yadavagiri, Mysore - 570 020

Karnataka State, INDIA

Local          0821-2517118

          info@svengineers.co.in

Chief Executive

Mr. T V Sridhar

           98455 93907

Manufacturing Engineer

Mr. Rakesh V S

          99458 63907

rakeshvs@svengineers.co.in

tvsridhar@svengineers.co.in