Portable WE BRING IN INNOVATIONS FOR BETTER

Repair PRODUCTION EFFICIENCY

Workshops
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CONTENTS

3 WORKSHOP IN A RAILROAD CAR

7 PORTABLE REPAIR WORKSHOP FOR HARDWARE

9 PORTABLE REPAIR WORKSHOP FOR MINING EQUIPMENT

11 PORTABLE REPAIR WORKSHOP FOR SHUTOFF AND CONTROL

VALVES AND SPRING-LOADED SAFETY RELIEF VALVES

14 PORTABLE REPAIR WORKSHOP FOR PUMPING EQUIPMENT

16 FIELD MODULE REPAIR STATION MRM/AST 014-01

18 CONTAINER BLOCK FOR REPAIRS MRM/AST 014-01

20 CONTAINER BLOCK FOR WELDING

22 CONTAINER BLOCK FOR CHARGING

23 AN EMPTY CONTAINER BLOCK

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WORKSHOP IN A RAILROAD CAR

T.V. Myakishev managed to meet every customers requirement

Technical Director
VTM Engineering
To d a t e w e k e e p c o n s t r u c t i n g n e w
pipelines, explore new fields, build and develop
infrastructure for high performance production
of hydrocarbons. A big part of this job has to be
conducted in severe weather conditions of tundra
up north of Russia or thick forests of Eastern
Siberia. Great remoteness of construction sites
from regional centers has strong impact on
the quality of equipment maintenance. In tough
operation conditions emergency repair is a top
need, otherwise required spare parts may take
up to several months to be delivered. A portable
repair workshop is a way to adequately solve the
problem with INTRATOOL being Russias pioneer
of the solution.
and offer a solution implementable within one
single railroad car whereas other companies
offered their solution based on two or three
cars. It should be mentioned that the layout
within the car did not affect the broad list of
required tools and equipment specified in the
customers terms. Fully engineered car was
compliant with Russian Railroads norms and
rules and we of course managed to fit in the
schedule and the budget. We were able to select
most space saving yet fully capable and multi-
purpose machines and fit them into a standard
cargo transportation car so that the equipment
is comfortable to use complying with HSE and
fire safety rules.

Below here is an interview with Timofey

Myakishev, Technical Director of VTM Engineering.

Where did it all start? Was it an idea or a

customers order first?

- Our first job in that area was a customized

workshop based on a railroad car, says Timofey.
It was an order for one of Gazprom subsidiaries.
No one had ever undertaken anything similar
in Russia before. Our project won the bid as we

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Were there any challenges during the
implementation of the project? Any bottlenecks
or pitfalls?
- Sure. We had to face some challenges
under way. Still its not an easy task to fit all
the required equipment into one car. I tried
to involve as many experts as possible. We
were consulting equipment manufacturers and
engineering designers at Voytovich car repair
plant. One of the challenges was the width of
the doorways. We didnt really want to cut the
carrying frame and the walls in order to place
the equipment inside the car. Otherwise we would
have had to undergo an expert review of Russian
Railroads. Therefore we were very careful in
selecting the equipment verifying its sizes, hired a
team of professional riggers who had to literally
carry with their hands machines weighing several
tons. We used special supports in order to lock
the equipment in one position in order to ensure
stability and safety of the equipment as the car
is accelerating or braking.
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What kind equipment were you able to place
inside the car?
- We have placed a lathe threading machine,
a vertical drilling machine, milling and grinding
machines, air compressor, a portable plasma
cutting machine, a hydraulic jack, an isolated
welding diesel generator, a heat treatment and
hardening furnace, and even a small hammer mill
have been placed there. Apart from machines,
the configuration had two work benches, a wall
hanging tool cabinet with a full set of professional
and measuring tools. Every machine and piece of
equipment had a set of consumables, spare parts
and various optional devices that occupied an
entire rack cabinet in the car.
 Did operation conditions have any effect on
the cars configuration?
- Yes, due to operation in the conditions of
extreme north where the outside temperature
can get as low as -50C and colder, we had to
fully replace the carriage lining. In its standard
configuration a cargo transportation car
does not imply any heating. We arranged heat
isolation inside, a few compartments were
arranged separated with soundproof shields,
an autonomous heating system was built into
the car so that it can be heated with anything
that burns and radiates heat, Timofey laughs.
Be it wood or coal, it will stay warm anyway. In
some of the locations there are no available
sources of power, for that reason autonomous
heating system was one of the most critical
requirements. We installed a powerful 100kWt
diesel generator with start heating system to
be able to start in the cold and have sufficient
power for all of the equipment. During my trip
to the customers site in Labytnagi for the
acceptance, the temperature outside was -40C,
Inside the car however the workers were okay in
their t-shirts, they said it was the first time they
had ever seen a car had heated so well. The car
has a compartment for the car attendant and a
compartment for a few workers equipped with
everything needed to have rest or take a meal.
The car also had a restroom constructed that
way so that you can even take a shower there.
Do you think there is a good chance for
further development of portable cars in our
country?
- Of course, there is a chance and it is obvious.
Russia is a large country, the territory is
enormous and there are plenty of sites where
equipment is operated at a far distance from
the civilization. It is quite costly to mobilize
equipment for repair and in most cases is not
even possible. Apart from that, equipment is
getting more complex and advanced, therefore
requires qualified timely maintenance and
professional repair. The portable repair workshop
ensures the possibility to provide maintenance
on-site, which largely reduces the duration
of the construction phase in the project
implementation, lower overhead costs. Portable
repair workshops can be configured for a
variety of purposes depending on the customers
requirements and be based on motor vehicles
and other machines. We have accumulated the
experience and at the moment we own a few
generic solutions. We can develop a custom
project with unique specifications as per request.
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Portable Repair Workshops

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PORTABLE REPAIR WORKSHOP FOR
HARDWARE

Emergency response teams dealing with hardware

repairs are supposed to operate with tools and
equipment placed inside the car, which allows for
hardware equipment such as:

Any type of heat exchangers

Air coolers
Tanks, separators, filters of various types
and sizes
Rectification columns
Tube furnaces.

Inspection of hardware reliability at oil and gas

treatment and petrochemical plants has shown
that over 40% of hardware failures are related
to reliability of heat exchanging hardware. Among
the most likely reasons of failures is wearing out
as a result of corrosion and erosion as well as
contamination of working surface with various
types of sediments.

Application of professional equipment for

extraction and hydraulic cleaning allows to achieve
high efficiency during maintenance of heat
exchangers, tanks and columns.

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BASIC CONFIGURATION OF MRM/APO 014-01

Service/activity Equipment

Storage for tools and devices Work bench

Disassembly of heat exchangers Hydraulic roller tube extractor

Loading/offloading Two-beam overhead crane

Threading, tapping Tapping machine

Cargo storage Shelf rack

Securing tubes in the tube sheet Portable expanding tool

Tube damage analysis Pipe integrity inspection tool

Dust elimination Dust catching apparatus

Grinding and finishing of metal cutting, wood-working and other types of tools Grinding machine

Connecting hydraulic tools All purpose hydraulic pump

Securing tubes in the tube sheet Hydraulic rolling-in tool

Storage for tools, spare parts, tooling Tool cabinet

* Capacity and configuration of the portable repair workshop depend on

Customers specific requirements and job specifications.

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PORTABLE REPAIR WORKSHOP FOR MINING
EQUIPMENT

Portable workshop for mining equipment is

designed for repair and maintenance of mining,
open-cut and mining processing equipment.

The combination of tools and equipment inside

the car allows for field performance of replacement,
refurbishment and repair with partial workshop
disassembly of:

Worn out excavator components

Heavy caterpillar machines
Components and units of BelAZ and other
types of open-cut equipment
Mechanisms and systems of dumping cars
Worn out components of scrubbers
Parts of mechanical screens (shafts,
bearings, etc.)

As repair of mining equipment and machines is

an effort consuming process, we have designed a
repair module. It allows to timely prevent failures,
maintain and repair all types of mining machines
and equipment. Availability of professional repair
tools and equipment ensures restoration of
functionality in no time.

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BASIC CONFIGURATION OF MRM/GOO 014-01

Service/activity Equipment
Storage for tools, assembly/disassembly spot Work bench
Storage for tools and devices Work bench
Storage for tools and devices Space saving work bench
Pressing parts and components Hydraulic jack
Loading/offloading Two-beam overhead crane
Assembly/disassembly, replacement of worn out parts A set of tools
Finishing parts Bench face grinder
Deflashing, beveling, grinding Grinding machine
Threading, tapping Tapping machine
Cargo storage Shelf rack
Cutting and facing of steel pre-fabricated parts Metal cutting machine
Dust elimination Dust catching apparatus
Shaft boring, threading Lathe threading machine
Shaft boring, milling of parts Lathe milling machine
Cutting of rubber, asbestos and asbestos-free materials, leather, felt, cardboard, plastic and other materials O-ring cutting machine
Storage of tools, spare parts, tooling Tool cabinet

* Capacity and configuration of the portable repair workshop depend on

Customers specific requirements and job specifications.

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PORTABLE REPAIR WORKSHOP FOR SHUTOFF AND CONTROL VALVES
AND SPRING-LOADED SAFETY RELIEF VALVES

Valves repair workshop is made up of two

modules and is engineered with all necessary tools
and equipment to be used in challenging conditions
where urgent repair of valves is not possible.

Emergency response teams dealing with

inspection, repair and testing of valves are able to
perform and works associated with restoration and
repair of valves.

A set of tools and equipment in the car allows

on-site repairs along with full disassembly inside
the workshop:

Steel and cast iron valves

Check valves
Plug and ball valves, etc.
Reverse valves
Reduction valves
Spring-loaded relief valves

There is a reliable proven solution to carry out

repairs and maintenance in the field, which is a
portable workshop. The concept of portable repair
workshops is especially hot for remote and sparsely
populated areas where urgent equipment repair
or maintenance as well as personnel training is
required.

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BASIC CONFIGURATION OF MRM/ZRA, PPK 014-01-1

Service/activity Equipment

Storage for tools and devices Work bench

Loading/offloading Two-beam underhung crane

Grinding solid surfaces on fittings, cylinders, pumps, turbine bodies, etc. Portable bench

Welding deposition of sealing surfaces Welding unit

Storage of cargos Shelf rack

Testing of safety relief valves and shutoff valves Portable testing rig

* Capacity and configuration of the portable repair workshop depend on

Customers specific requirements and job specifications.

Fully engineered with testing and repair equipment

for on-site maintenance of shutoff valves, safety
relief and block valves. 20 and 40 foot containers
are fully set with necessary equipment for both
a standard maintenance procedure and also can
be equipped as per your specifications and climate
conditions.
If necessary a container can be certified as
per EN/DNV and can be prepared for operation in
hazardous areas.

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BASIC CONFIGURATION OF MRM/ZRA, PPK 014-01-2

Service/activity Equipment
Storage for tools, assembly/disassembly spot Work bench

Loading/offloading Two-beam overhead crane

Water tank Anion tank

Compressed air feed Oil-free scroll compressor

Storage for tools and devices Bench

Finishing sealing surfaces of fittings Vertical grinding machine

Portable power station Diesel generator

Setting up a testing rig with air and nitrogen sources High pressure compressor

Documentation of jobs at rigs PS-T10 and PS 75/1525L-400 Documentation system

Testing fittings on strength and durability Testing rig

Lapping of parts Lapping machine

Disassembly of fittings OD50-250 mm Hydraulic chucking device

* Capacity and configuration of the portable repair workshop depend on

Customers specific requirements and job specifications.

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PORTABLE REPAIR WORKSHOP

FOR PUMPING EQUIPMENT

A portable repair workshop for pumping

equipment is designed for maintenance and all
types of repairs of pumping units.
The set of tools and equipment inside the
container allows for field repairs along with
partial disassembly in the workshop:
Rotary pumps of various types
Semi-submersible pumps
Piston-type, plunger, metering pumps.

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BASIC CONFIGURATION OF MRM NKO 014-01

Service/activity Equipment
Storage for tools, assembly/disassembly spot Work bench

Storage for tools and devices Work bench

Pressing parts Hydraulic jack

Loading/offloading Two-beam overhead crane

Heating bearings up to 55 kg Induction heater

Heating bearings up to 560 kg Induction heater

Disassembly Set of hydraulic pullers

Balancing Dynamic balancing tool

Assembly/disassembly, replacement of worn out parts Set of tools

Debugging, beveling, grinding Grinding machine

Pressing-off, pressing-on, alignment Heavy-duty hydraulic jack

Eliminating dust Dust catching apparatus

Welding deposition of sealing surfaces Welding unit

Threading, tapping Tapping machine

Lapping of parts Lapping machine

Storage of cargos Shelf rack

Shaft boring, threading Lathe threading machine

Shaft boring, milling of parts Lathe grinding machine

Cleaning Ultrasonic washing apparatus

Cutting out O-rings Cutting device

Storage of tools, spare parts, consumables Tool cabinet

* Capacity and configuration of the portable repair workshop depend on

Customers specific requirements and job specifications.

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FIELD MODULE REPAIR STATION MRM/AST 014-01

A field module repair station is designed for

maintenance, reduction of down time, repair of
heavy machines and equipment in the field.

The repair station is made up of four container

blocks:
Welding
Repairs
Charging
Auxiliary.

The configuration of the repair station allows

for performance of a wide range of repair
activities.

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 It also allows an operation of each of the container blocks
as a self-supported module as necessary. Each container
is engineering with lights, electric heating, ventilation, fire
safety alarm sensors, firefighting systems and a panel for
the connection of external power sources.

The dimensions of portable workshops are based on

standard 1S 20 containers, which ensures their smooth
transportation with any transportation means. Since each
module is equipped with fittings on each of their corners, it
allows transportation and moving of container blocks with
trailers and port loading units.

All modules have customized configuration that allows

operation in tough working conditions and sever weather
conditions at temperatures from -40 to +40C.

Repairs Welding Auxiliary Charging

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CONTAINER BLOCK FOR REPAIRS MRM/AST 014-01
The set of equipment and tools in the repairs
container block allows for repairs and maintenance
with full disassembly inside the workshop:
Engines of heavy trucks: KAMAZ, MAZ, GAZ
series YMZ 236, 238
Engines of tractors: series D-240, D-245
Gear boxes
Producing simple components of units
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Repair and maintenance of any vehicles in the
field becomes a challenging task: unavailability
of tools and devices and, most importantly,
comfortable conditions e.g. during winter time. For
that reason a portable repair and maintenance
station is irreplaceable and is able to ensure
everything is in place for a timely or urgent repair
of machines and units.
BASIC CONFIGURATION OF MRM/AST BR 014-01

Service/activity Equipment

Storage for tools, assembly/disassembly spot Work bench

Assembly/disassembly of components, units of vehicles Garage hydraulic crane

Removing oil from components and units Oil collector tank 3194, 70 l

Maintenance of power equipment Power equipment maintenance and repair kit

Cleaning, purging Compressor, Remeza SB 4/S-100 LB 30 A

Loading/offloading Compressor, Remeza SB 4/S-100 LB 30 A

Measurement of electrical and mechanical performance of diesel engines Multi-purpose stroboscope

Washing of components and units under pressure with heated water Washing apparatus

Tapping and milling Portable tapping and milling machine

Workshop heating Heating unit

Pressing of parts Garage jack

Testing and adjustment of diesel engine nozzles Machine for testing spray cones of diesel injectors

Storage for tools, assembly/disassembly spot Work bench

Assembly/disassembly of YMZ and KAMAZ engines Combustion engine assembly/disassembly bench

Pressing-off and pressing-on of pivots Hydraulic pivot puller

Shaft boring, milling of parts High accuracy lathe threading machine

Sharpening of metal tools Grindstone

Storage of tools Storage rack for tools

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CONTAINER BLOCK FOR WELDING
The set of equipment inside of the welding
container block allows for performance of welding
jobs both inside and outside of the workshop:
Flame cutting operations outside of the
workshop
Electric welding on a customized table
Preparation of electrodes (hardening, drying)
before use
Preparation of elements for welding.
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Inverter welding is applied as one of the key
methods of welding, which has a number of
advantages:
High quality welding
Easy arc striking
Low scattering of metal
Work in confined spaces and various positions
Easy set up welding parameters, as a result
lower welder qualification requirements.
BASIC CONFIGURATION OF MRM/AST BS 014-01

Service/activity Equipment

Assembly/disassembly spot Work bench w/o drawers

Loading/offloading Jib crane

Workshop heating Heating unit

Drying and baking of electrodes Furnace for drying and baking of electrodes

Welding Welders table with filter

Welding Welding unit

Sharpening of metal tools Grindstone

Flame cutting Gas manifold (propane)

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CONTAINER BLOCK FOR CHARGING

The set of equipment inside of the charging
container block allows for charging batteries of
exploration equipment and other:
Encapsulated gel cell lead acid batteries
Ion lithium gel cell batteries
Car batteries for custom vehicles
Monitoring of charging batteries.
The benefit of the container is an easy and simple
charging of car batteries of various purposes,
monitoring of batteries set up parameters, charging
of up to 140 special batteries and the safety of
both the model and the equipment inside built in
explosion-proof configuration.

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BASIC CONFIGURATION OF MRM/AST BZ 014-01
Service/activity Equipment

Charging of vehicles batteries Charging unit for charging car batteries

Charging, maintenance and monitoring of batteries of seismic exploration

Charger
equipment

Placing car batteries for charging Racks for storage and charging of batteries

Room hydrogen concentration analysis Gas detector

AN EMPTY CONTAINER BLOCK

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Headquarters
195027, - 3, Shosse Revolutsii
, 3, St Petersburg, 195027
. (): +7 (812) 313-50-92 tel. (multichannel): +7 (812) 313-50-92
: +7 (812) 313-50-93 fax: +7 (812) 313-50-93
e-mail: intratool@intratool.ru e-mail: intratool@intratool.ru

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