Services

Field Machining Support

Successful field machining projects have details. Lots of details. From line boring bucket pin bores to cutting the  hydraulic profile of a 280″ hydro turbine discharge ring, success is in the details. Field Machining Associates is here to serve you and help ensure your field machining project, no matter the scope, is successful. Proper planning prevents poor performance, and we can bring experience to bear in all of the following areas:

  • Boring Bar Operations
  • Circular Milling
  • Linear Milling
  • Custom Drilling
  • Journal Turning
  • Project Planning
  • Procedure Writing
  • Fixture Design & Fab
  • Cavitation Repair
  • Safety Planning
  • Jobsite Assessment
  • Grouting & Anchoring
  • Estimating
  • Vendor Management
  • Training & Staffing

    Project Planning – The First Step To Success in the Field

    Proper Planning Prevents Poor Performance. When you plan a field machining project, you prepare for success by addressing all the details. All of following have details that can make or break a project. Are you prepared?

    • Application & Tool Selection
    • Cutting Tools
    • Fixturing
    • Jobsite Power, Air, Ventilation
    • Rigging & Crane Support
    • Engineering Support
    • Shipping Logistics
    • Scheduling
    • Welding & Heat Treat
    • Precision Measurement Tools
    • Customer Submittals
    • Job Site Leadership
    • Crew Staffing & Training
    • Safety Plans and PPE
    • Known Unknowns & Risk Plans

    Project Experience

    The following lists represent the types of projects in which FMA has direct experience. They represent multiple units in plants all over North America and one in South America. The tools involved Climax BB 5000 & 6100 Boring Bars, CM 6200 Circular Mills, LM 6200 Linear Mills, Climax FF 8000 Flange Facers, Climax milling spindles mounted in all sorts of ways, Bortech Bore Welders, welding and heating equipment, Lamina drills, custom built boring bars 330″+ long, automatic welding, Hilti drills and anchoring systems, Lily grout pumps, Chemgrout grout pumps, and numerous other tools and materials too numerous to mention.  

    • Cavitation & Crack Repair
    • Embedded Component Replacement
    • Stainless Weld Overlays
    • Sole Plate Machining
    • Wicket Gate Line Boring
    • Discharge Ring Anchoring and Grouting
    • Rotor Valve Seal Seat Machining
    • Generator Shaft Keyway Milling
    • Crosshead Keyway Repair
    • Nose Cone O-ring Seal Groove Repair – In Situ
    • Penstock Spool Piece Seal Seat Machining
    • Discharge Ring Repair and Replacement
    • Rotor Coupling Bore Machining
    • Shaft Coupling Bore Machining
    • Stator Split Flange Machining
    • Head Cover Split Flange Seal Repair and Machining

    Particularly Interesting Projects

    Rotary Valve Rotor Seal Seat Repair

    Due to the nature of confidentiality agreements and customer sensitivity, details identifying the customer and plant are omitted. Photos of the work were also unfortunately forbidden so there is nothing to view. In a nutshell, FMA personnel were involved in the restoration of a seal seat on a ~90″ diameter rotor valve. The machining utilized elaborate fixturing to mount a Climax CM6200 Circular Mill in  an “upside down OD mount position”. The milling column Z axis was modified to reach “down” 27″ to the seal seat surface. Following the seal seat surface restoration, a new O-ring groove was also machined.

    Sole Plate Machining

    Due to the nature of confidentiality agreements and customer sensitivity, details identifying the customer and plant are omitted. Photos of the work were also unfortunately forbidden so there is nothing to view. In a nutshell, FMA personnel were involved in the machining of generator sole plates flat and level to within .004″ Multiple Climax LM 6200 mills were employed with custom fixturing and utilized laser alignment to meet a demanding energy plant schedule in a very challenging environment in record time.

    Rotor to Shaft Coupling Alignment Boring

    Due to the nature of confidentiality agreements and customer sensitivity, details identifying the customer and plant are omitted. Photos of the work were also unfortunately forbidden so there is nothing to view. In a nutshell, FMA personnel were involved in the alignment boring of a new generator rotor hub to align to a shaft that was machined overseas. Utilizing a template that was bored during the shaft machining, a Climax BB 5500 boring bar and custom fixturing cut the bores to very close tolerances. A two-man crew completed the job ahead of schedule.

    Gallery Coming Soon!

    Contact Us

    PO Box 125, Hixson, TN 37343-0125

    (423) 762-4134

    contact@fieldmachinetool.com