PowerPack Project:

Reverse Engineering & Manufacturing of Coil Tubing PowerPack Unit At the request of Sharif Jihad University for National Iranian Drilling Company.
Fars Manda Toseeh reverse-engineered and redesigned the PowerPack unit for coil tubing operations. The coil tubing unit performs a wide range of well intervention services, including acidizing, well cleaning, cement plug setting, nitrogen well stimulation, E-Line logging, well killing, obstruction removal, and plug installations.
The PowerPack, originally from HYDRA Rig (Canada), was reverse-engineered and manufactured by Sharif Jihad University and deployed in Iran’s oil fields. This unit supplies hydraulic and pneumatic power to Injector, Reel, Hose Reel, Levelwind, Priority BOP, Auxiliary, and the Control Cabin.
The diesel engine transfers power via a three-shaft gearbox to pumps, pressurizing the hydraulic system. The unit also includes essential startup components such as a fuel tank, radiator, and filtration system, along with pressure and flow control mechanisms.

Main Components of the PowerPack Unit:

        • Frame
        • Power Generation Unit (Diesel Engine with over 400 HP)
        • Power Transmission System
        • Hydraulic Power Pump System
        • Control Panel
        • Filtration System
        • Reservoirs
        • Heat Exchangers
        • Hoses and Fittings
POWERPACK1
POWERPACK2
POWERPACK3
Powerpack-new2
Powerpack-new1

Valve Test Machine Project:

Design and Manufacture of a Valve Test Machine for 2 to 24-inch Valves in Class 150 to 1500 Pounds Commissioned by Ardabil Industrial Valves Company.
this machine is a critical tool for evaluating the performance and integrity of industrial valves across various applications, including oil, gas, petrochemical, and water & wastewater industries. It is specifically designed to assess leakage rates, pressure resistance, and operational efficiency of valves.

Applications of the Industrial Valve Test Machine:

    1. Leak Test: Assessing valve leakage under various pressure levels.
    2. Pressure Test: Evaluating the maximum pressure tolerance of valves.
    3. Performance Test: Analyzing valve functionality under different operational conditions.
    4. Calibration: Adjusting and calibrating valves to ensure accuracy and reliability.

Components of the Industrial Valve Test Machine:

    1. Hydraulic or Pneumatic Pump
    2. Pressure Source
    3. Pressure Gauges
    4. Fittings and Hoses
    5. Controllers
    6. Test Chamber
    7. Safety Systems
VALVE-TEAST1
valve-project-picture2
valve-project-picture1

Overshot Project:

Reverse Engineering of Downhole Tool (Overshot) Ordered by National Iranian Drilling Company.
The Overshot is a crucial tool in drilling operations and well services for oil and gas fields. It is specifically designed to recover stuck drilling tools and equipment from within the well.

Structure and Function of Overshot:

The Overshot generally consists of several main components:

    1. Gripper Assembly: Used to grip and lock onto downhole tools.
    2. Locking and Release Mechanism: Allows secure locking and subsequent release of the tool.
    3. Main Body: Houses these assemblies and connects to surface wellhead services, enabling the retrieval of downhole tools to the surface.

Applications of Overshot:

      1. Retrieval of Drilling Tools
      2. Wellbore Cleaning
      3. Enhancing Drilling Operation Safety
Overshot3
Overshot2
Overshot1
Overshot-new2
Overshot-new3
Overshot-new1

Three-Roll Calendar for Thermoforming Machine:

Design and Manufacturing of Three-Roll Calendar for Pishro Plast Ahadi Company.
The calendar is a crucial component in thermoforming machines, used in the production of plastic sheets and films. Its primary function is to convert molten plastic from the extruder into thin sheets and films with uniform thickness and quality.

Role of the Calendar in the Thermoforming Process:

    1. Forming Plastic Materials: Converts molten plastic into thin sheets by passing it through steel rollers.
    2. Thickness and Quality Control: Ensures precise control over the thickness and quality of the produced sheets.
    3. Cooling and Shape Stabilization: Cools and solidifies the formed sheets to achieve their final shape.

Cylinder Components:

    1. Roller and Bearing Assembly
    2. Heating System
    3. Cooling System
    4. Thickness Control System
    5. Motors and Drives
    6. Frame and Body
Calender1
Calender2
Calender3