Call Us: 01706 845960
Call Us: 01706 845960
At Saras Process, we’re often called upon to carry out precision metal repairs in unique and challenging environments—and this case was no exception.
A manufacturer of wave generators experienced a problem with scoring on an actuator ram, which occurred during the installation of new seals. The damage threatened the integrity of the hydraulic system, risking oil leakage and operational failure. Our team was brought in to perform a selective electroplating repair to restore the surface and ensure a reliable, leak-proof seal.
What made this job particularly interesting was the setting: the wave machine was stationed on water, tied up to a dock. Despite the unusual location, we were able to carry out the repair using our portable Metal on Metal process, applying metal precisely to the damaged areas without removing the ram or disassembling the machine.
This same approach was also recently used to repair a hydraulic ram operating a road swing bridge spanning the River Hull. Again, the ram had suffered scoring, and we restored the surface using on-site electroplating, sealing the unit and eliminating the need for costly part replacement or downtime.
Our process not only restored the damaged surfaces to full functionality, but also extended the service life of critical hydraulic components in both marine and infrastructure settings. It’s a great example of how Saras Process combines versatility, technical skill, and portability to deliver effective solutions—no matter the location.
A customer working with a leading diesel engine manufacturer encountered a serious issue during routine maintenance. While replacing a set of bearing shells, improper installation led to scoring of the bearing seat—removing excess metal and compromising the engine's ability to achieve a proper ‘bedding’ of the new shell.
To resolve the issue, Saras Process was contacted for a specialised on-site electroplating repair. The job site was the GNPOC oil pipeline, located south of Khartoum, South Sudan—a remote and challenging environment that required both expertise and mobility.
We dispatched one of our trained operators along with a complete Saras Process electroplating kit, including all necessary plating equipment, tools, and solutions. Using our Metal on Metal process, the damaged area was built back up with precision plating, then carefully hand dressed and finished to restore the bearing seat contours to their original dimensions.
This on-site repair allowed the bearing shell to be installed with a proper fit, ensuring full ‘bedding in’ and reliable engine operation going forward. By avoiding part replacement or engine disassembly, the customer achieved significant savings in both time and cost—while restoring full mechanical integrity under demanding field conditions.
This case highlights how Saras Process combines portable electroplating technology and hands-on technical skill to support critical engineering applications in even the most remote industrial locations.
During the refurbishment of a slip ring assembly used to maintain communication between a deep sea diving bell and its surface support vessel, a contractor faced the challenge of re-plating 98 individual slip rings. The original silver plating on the components had deteriorated, with loose and flaking areas compromising the unit’s conductivity and reliability.
Because only the outer diameters of the rings required restoration, Saras Process was chosen to carry out the work using our selective electroplating expertise. Our Metal on Metal plating system allowed us to apply a controlled silver plating finish directly to the required areas—without unnecessary masking or full submersion in a traditional plating bath.
To complete the project, the slip rings were mounted on a custom jig to ensure stability and alignment during processing. All degraded silver was carefully removed, and each ring was pre-treated to ensure strong adhesion of the new plate. We then applied precision silver plating to a pre-determined finished drawing specification, restoring the rings to operational condition.
This project highlights how Saras Process provides accurate, high-quality metal finishing solutions for sensitive, high-performance components—supporting industries such as marine engineering, underwater communication, and specialist electrical applications with speed, precision, and reliability.
Servicing and repairing pipeline inspection equipment—especially components housed in electroless nickel-plated bodies—can be a serious challenge when damage occurs. Even minor surface defects can allow corrosion to creep beneath the plating, particularly around seal faces, putting the entire assembly at risk.
That’s why many companies in the gas and oil industry turn to Saras Process for a trusted repair solution.
When the sealing surfaces become damaged, we remove the compromised nickel plating and any underlying corrosion. Using our selective electroplating process, we restore the affected areas precisely—filling in the damaged zones and then applying fresh nickel plating to meet the original seal diameter or sealing face specifications.
Without this targeted repair service, companies would typically face one of two costly and time-consuming options: either strip the entire electroless nickel coating, re-machine the sealing surfaces, re-manufacture mating components, and re-plate the full body—or source and replace the entire equipment housing.
Our approach eliminates the need for full disassembly or part replacement. With on-site electroplating capabilities and expert surface restoration, Saras Process helps customers extend the life of their equipment, reduce waste, and avoid unnecessary downtime.
This case highlights the value of precision metal finishing in high-stakes sectors where component integrity and sealing performance are critical to operation.