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Projects and portfolio

Selected work across our disciplines. Each project lists the engineering problem, what VAFTSY did and the result.

Heavy press foundations for the forging industry: project image

Heavy press foundations for the forging industry

Problem
Large forging presses need foundations that carry very high static and dynamic loads without settlement or cracking.
Our contribution
Design and construction of reinforced concrete press foundations, with long-term forging clients in Pune.
Outcome
Press foundations totalling 10,000 tonnes of capacity built to date.
DisciplineCivil
ScopeDesign + build
SectorForging
LocationPune, India
Factory sheds and crane bays: project image

Factory sheds and crane bays

Problem
Industrial buildings must carry overhead cranes and process loads while staying quick to erect.
Our contribution
Pre-fabricated steel structure erection, crane gantries, anti-skid floors and site roads.
Outcome
Turnkey factory buildings delivered from foundation to roof.
DisciplineCivil
ScopeTurnkey
SectorManufacturing
CodesIS codes
Substation and transformer commissioning: project image

Substation and transformer commissioning

Problem
New and expanded plants need power that is designed, installed and approved for audit.
Our contribution
Substation layout, transformer design and commissioning, with documentation for regulatory approval.
Outcome
Industrial power systems commissioned by a Government-approved electrical contractor.
DisciplineElectrical
ScopeDesign + commissioning
SectorIndustrial
ApprovalStatutory
Forging press refurbishment: project image

Forging press refurbishment

Problem
Older forging presses lose reliability and safety as their controls and drives age.
Our contribution
Refurbishment of press electrics, controls and PLC logic, integrated with the existing machine.
Outcome
Presses returned to production with modern control systems.
DisciplineElectrical + mech.
ScopeRefurbishment
SectorForging
SystemsPLC, drives
Assembly line structure under E-stop loads: project image

Assembly line structure under E-stop loads

Problem
A structure carrying robots, stacking racks and conveyors must survive emergency-stop loads and avoid resonance.
Our contribution
Load combination, E-stop and frequency analysis of the full structure.
Outcome
Structure assessed for E-stop conditions, load combinations and natural frequencies.
DisciplineCAE
AnalysisStatic + modal
SectorAutomotive
ToolFEA
Dynamic analysis of a multi-robot structure: project image

Dynamic analysis of a multi-robot structure

Problem
Robots mounted on a shared gantry create vibration, jerk loads and G-forces that drive fatigue.
Our contribution
Dynamic vibration analysis including jerk and G-force loading to establish safety and fatigue life.
Outcome
Safety and fatigue life of the multi-robot structure established.
DisciplineCAE
AnalysisDynamic + fatigue
SectorAutomotive
ToolFEA
ASME Section VIII cyclic-load fatigue: project image

ASME Section VIII cyclic-load fatigue

Problem
Pressure equipment under thermal and pressure cycles needs a code fatigue assessment before certification and stamping.
Our contribution
Design-by-analysis to ASME Sec VIII Div 2, Part 5, for cyclic thermal and pressure loads.
Outcome
Fatigue life evaluated as required by the code for certification and stamping.
DisciplineCAE
CodeASME VIII-2
SectorOil and gas
AnalysisFatigue
Seismic response of a scrubber: project image

Seismic response of a scrubber

Problem
A tall scrubber must remain safe under earthquake loading.
Our contribution
Response spectrum analysis to the IS code, with checks against the system pass criteria.
Outcome
Pass criteria verified for the seismic load case.
DisciplineCAE
CodeIS 1893
SectorProcess
AnalysisSpectrum
Impact analysis of a shock absorber: project image

Impact analysis of a shock absorber

Problem
A rotating machine arm strikes a shock absorber repeatedly, wearing it out.
Our contribution
Transient impact analysis of the cyclic strikes.
Outcome
Damage per strike and replacement life quantified.
DisciplineCAE
AnalysisImpact
SectorMachinery
ToolFEA
Ventilation duct flow optimisation: project image

Ventilation duct flow optimisation

Problem
Each outlet of a ventilation system needed a specific pressure drop.
Our contribution
Steady-state 3D incompressible CFD of the duct network, iterating the geometry.
Outcome
Duct tuned to the required pressure drop at every outlet.
DisciplineCFD
Flow3D, steady
SectorHVAC
ToolCFD
Diesel alternator air intake: project image

Diesel alternator air intake

Problem
Would an intake filter starve the alternator of air?
Our contribution
Flow simulated with and without the filter.
Outcome
Filter effectiveness and its effect on the system quantified.
DisciplineCFD
FlowInternal
SectorPower
ToolCFD
Vane-type mist eliminator: project image

Vane-type mist eliminator

Problem
Natural gas carrying hydrocarbon mist at moderate pressure must be cleaned efficiently.
Our contribution
Multiphase CFD of droplet capture through the vane pack under real operating conditions.
Outcome
Droplet capture efficiency predicted for the operating envelope.
DisciplineCFD
FlowMultiphase
SectorOil and gas
ToolCFD

Project images are from VAFTSY's own work. Client names are not attached to individual projects.

Detailed case studies

Two projects in more depth

Finite element deformation plot of a steel gantry structure, coloured from blue to red
CAD model of a gantry carrying robot arms
Stress contour of a robot cell support frame

Case study · CAE + mechanical

Dynamic analysis of a multi-robot structure

  1. ProblemSeveral industrial robots share one gantry. Their fast moves, jerks and emergency stops shake the structure, which risks fatigue cracking and loss of positioning accuracy.
  2. ContributionWe built a finite element model of the full structure, applied robot reaction loads including jerk and G-forces, and ran dynamic vibration and fatigue analysis.
  3. OutcomeThe safety and fatigue life of the multi-robot structure were established before installation.
Finite element deformation plot of a horizontal pressure vessel with nozzles
The CAE workflow from solid model to mesh to analysis result
Temperature contour along a pipe spool

Case study · CAE

ASME Section VIII cyclic-load fatigue

  1. ProblemPressure equipment that cycles in temperature and pressure must pass a code fatigue assessment before it can be certified and stamped.
  2. ContributionDesign-by-analysis to ASME Sec VIII Div 2, Part 5, combining thermal and pressure cycles in a coupled finite element model.
  3. OutcomeFatigue life was evaluated as the code requires for certification and stamping.

Clients

Who we have worked for

Ford IndiaIndia
KUKA RoboticsGermany
Saudi AramcoSaudi Arabia
Bharat ForgeIndia
EOGTexas, USA
Turkmenistan OilTurkmenistan
Magna ClosuresIndia
LeartikerSpain
Dolphin Heat TransferDubai, UAE

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