| Woodchucks are Groundhogs, Too, or do You Prefer to Call Them Whistle-Pigs, or Perhaps . . . Land Beavers?
The groundhog (or woodchuck) is actually a rodent of the family Sciuridae, belonging to the group of large ground squirrels known as marmots. We have a groundhog living in our back yard--our forecasted sunny skies did not show up on Ground Hog Day, so our little guy could not have seen his shadow. According to folk lore, this means Spring will come early. Is it possible that our non-winter winter is going to turn directly into Spring?
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| Woodchucks are Groundhogs, Too! |
Back at the ranch, the truly secret sauce of portable machining happens before we leave our shop where we build our portable machine tools and fixtures so please, if you can, continue sending those work scopes, early.
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Please, DON'T WAIT TO SEND YOUR WORK SCOPES . . .
More Job Features coming in the next issue but in the mean time, you can always check our blog out for more recent projects . . .
Tony Piwowarczyk Field System Machining, Inc.Since 1978!www.FieldSystems.com1-800-789-2814 United States+1-847-468-1313 International
Machining Spherical Bearings On-Site? You betcha! Indoors, outdoors, at your plant or ours, Field System Machining repairs both spherical bearing housings and spherical bearings.
Field System Machining pioneered portable spherical bearing machining decades ago. Repairing spherical bearings is challenging enough in a shop and requires custom tooling. In the field repair of spherical bearings and spherical bearing housings requires mad skills and our machinists are just the guys with those mad skills.
Close Up - Custom FSM Manufactured Portable Spherical Boring Bar Setup
On-Site Spherical Bearing Boring Bar-FSM Designed and Manufactured Portable Machine Tools
Portable Bearing Machining - Portable Machine Tools Designed to Solve Any Problem
Filed System Machining Portable Machining Tools and Men are Ready to Rock When Your Machine Ticks but does not Tock.
Journal, Trunion, Spherical Bearing and Collector Ring Portable Machining, Since 1978! Productivity losses and repair costs resulting from shaft or journal scoring or fracturing can be catastrophic. That's why 24/7/365, Field System Machining shaft experts stand ready to provide immediate, expert on-site journal and shaft machining. Field System Machining is a worldwide leader and pioneer in Stationary Journal Machining, Squirrel Cage Machining, Journal Squirrel Machining and Journal Lathe Machining, specializing in cutting, grinding, burnishing and polishing of journals, collector rings, thrust faces, hydrogen seals, spherical bearings, babbitted bearings, trunnion repair, trunnion resurfacing, trunnion machining, as well as repairing turbine journals, shaft journals, shaft bearings, and FD-ID Fan Shafts.
3-D Laser Tracking Metrology Services Division Launched
3-D Laser Tracker Portable Solutions Now Available on Immediate Notice, Throughout the Western Hemisphere
Field System Machining (FSM) has added laser tracker portable on-site three dimensional (3D laser) portable imaging metrology to its arsenal of on-site industrial on-site portable machining and machinery repair weapons. FSM has provided customers with optical and laser metrology solutions for decades, including FSM-supplied optical metrology, and, up until now, third-party laser metrology. More recently, however, obtaining third party laser three dimensional metrology has proved challenging.
While FSM's on-site portable laser metrology partners have provided exemplary service over the years, it was determined that the only way to guarantee that FSM customers received laser tracker alignments, laser tracker surveys, 3-D laser machinery alignments and other on-site laser metrology data services - on time and at reasonable prices - was to vertically integrate those services into the Field System Machining on-site machining offerings.
"We need to provide the solutions our customers need, when they need them, not when our partners are available,” said Tony Piwowarczyk, Field System Machining’s marketing macher. "We can always shoot optics, and we have been doing that ourselves for decades but, on certain projects, three dimensional laser tracking metrology is the fastest measurement method available. We can no longer be dependent upon the availability of third-party metrology services - while some of our three dimensional on-site portable laser tracker metrology partners are outstanding assets to our clients, those partners are not always available. Other laser metrology partners do outstanding work but at twice the price and double or triple the turnaround time, while we are internally capable.”
The time for Field System Machining to provide its own on-site laser alignment, laser three dimensional surveying and laser 3-D machinery imaging portable solutions has arrived. Since each laser tracker costs $120,000 and each laser survey crew requires thousands of dollars of training, in addition to master machinist expertise, FSM determined that the only way to make the investment ROI-reasonable was to offer on-site portable laser tracker solutions to not only its on-site machining clients but to all clients requiring portable, on site or field three dimensional (3D) laser tracker metrology solutions.
During 2012, Field System Machining expects to grow its laser tracker metrology survey fleet from one laser tracker and one two-man survey crew, to two laser trackers and two, two-man survey crews.
Field System Machining was asked to provide machining, welding, and heat treating to repair a leaking boiler water circulation pump body. The pump was first believed to be leaking through the stud holes and rabbit fit--we welded the stud holes, bored them out, tapped them, and machined the gasket fit. Later in the year, it was believed that the rabbit fit was leaking, again; We machined it, again. A third time the pump began leaking and this time it was believed that cracks were forming all the way through the ligaments.
The utility power plant originally thought the indications of discontinuity developed from metal fatigue occurring over the circ pump's trusty fifty-three years of service. When, for the third time on-site machining excavation of the indications of discontinuity commenced, a surprise was in store for plant personnel.
An undocumented repair was made to the circ pump, involving cutting a large groove into the pump casing and shrinking in a stainless steel ring--this was discovered only after our repairing cracks in the bolt holes twice, passing metallurgy twice, only to have the cracks appear, each time again.
The turbine boiler water circ pump leak reappeared at an inconvenient time--while the 270 MW unit was operating at full base load, 24/7. The plant asked us to make a plug and weld it into place as quickly as possible so that the unit could be put back on line. That plug appears above.
Above you can see that hand excavation a.k.a. crack chasing has commenced on the boiler water circ pump casing. Note that excavation straight through the ligaments was necessary.
Above you can see that not only did we chase cracks, we also machined straight down the rabbit fit and inside the rabbit fit into the circ pump body--that is where the foreign material ring was located. It is unknown when and why the non-ferrous ring was shrink fit into the circ pump body.
This is the boring setup used to machine the rabbit fit and pump casing body. This is also how we machined out the temporary isolation plug.
Excavations are complete.
Heat treating preheat soak is complete and welding is about to start.
Welding up the massive excavations. I love the smell of weld fumes in the morning.
Weld repairs are completed.
Finish machining is under way. The red cage is one of dozens of boring cages FSM has manufactured.
Completed, like new, and ready to go back on line. Field System Machining has been solving power plant outage steam path repair needs since 1978. Field System Machining has performed over 1,000 projects for this one customer, alone.
Steam Turbine Overhaul Major Steam Turbine Diaphragm Repairs - Use an experienced steam turbine diaphragm repair service with a proven track record. Field System Machining's steam turbine diaphragm repair service has stood the test of time with our best customers being repeate steam turbine repair clients.
Turbine on the half shell. In this photograph we see the steam turbine upper shell standing on end and steam turbine nozzle major repair in process. Field System Machining performs major repairs on two to three steam turbine nozzles every year. Our steam turbine nozzle repair clients are all repeat customers.
In this close up we see the major steam turbine nozzle repairs, in progress.
Steam Turbine Diaphragm Major Repairs - BEFORE. Note that partitions are coming apart from the diaphragm body and not tha the previous repair has failed.
How is this for the photograph, AFTER? Beautiful steam turbine diaphragm repaired and ready to go back on line. When you need steam turbine repairs, steam path repair, steam turbine repair and steam turbine diaphragm major overhauls--Contact Field System Machining.
Steam Turbine Nozzle Repair Video
EXPERT PORTABLE STEAM PATH REPAIR SPECIALIZED SERVICES
- Complete Steam Turbine and Gas Turbine Parts and Service. Stationary turbine component repair:
- Refurbishment, repair, manufacture, and installation of turbine nozzles and diaphragms.
- Refurbishment, repair, manufacture, and installation of turbine blade rings.
- Refurbishment, repair, manufacture, and installation of turbine seals, turbine packing gland seals, turbine sensitized packing, and turbine caulking seals.
- Complete shop and on-site NDE, NDT, and metallurgy analysis.
- Computerized Area Checks of turbines generator assemblies.
- Turbine Rotor Component Repair:
- Replacement of blades and buckets.
- Replacement and repair of erosion shields.
- Replacement and repair to tie wires.
- Weld repairs to lashing lugs.
- Complete welding capabilities and refurbishment to tenons -Shroud band/cover replacement.
- Complete welding and heat treating capabilities on:
- Joints.
- Integral Root Radial Seals.
- Partitions & Blade Rings.
- Set-Back Faces.
- Crush Pins.
- Packing and seal Hook Fits.
- All other related components.
- Steam Path Repair Assessments (alternative unnecessary & costly replacement parts).
Steamship? Yes, that's right, there are still non-nuclear fired steam-powered turbine propulsion ships plying the ocean. We recently completed manufacturing an entirely new feedwater turbine as well as overhauling the turbine speed control governor. Field System Machining manufactures turbine parts from examplars as well as overhauls repairable steam turbine parts.
This is the 1 megawatt steam turbine upon arrival. The turbine shaft was beyond repair.
Here we see the major pitting on both the steam turbine wheel and the steam turbine airfoils. Turbine repair is one of Field System Machining's major core competencies.
It wasn't hard to get the two steam turbine wheels off the shaft--they were practically falling off the shaft. The 1965 steamship these wheels came out contains four 11 MW steam propulsion turbines each having two steam turbine driven feedwater pumps. Each turbine can run with only one of its two feedwater pumps so the propulsion turbine was still operable while we manufactured this new shaft, wheels and turbine airfoils.
The feedwater turbine speed trip governor, before we overhauled it.
Forty-five year old governor speed trip ready to go back into service. Steam Turbine Service is a key part of Field System Machining's turbine repair business.
Field System Machining manufactured the shaft, two wheels and installed the two new rows of turbine buckets. This ship is back on its way around the world with one of our turbines running the feedwater pump.
Steel mill bed rail portable machining is one of FSM's many steel mill on-site machining competencies. Field System Machining has performed steel mill machinery repair, steel mill turnaround and steel mill outage work since 1978, and we are getting pretty good at it.
If the above isn't a rigid setup, I've never seen one. The milling involved machining from the top faces 9/16” and from the vertical inside faces, 1/2" material on all three pinion stands, for installation of new pre fabricated “L” liners. In total 3 sets of bed rails were machined. Note the ubiquitous beverage container on top of the milling machine--It has become an unspoken FSM machinist tradition to capture a beverage container in a job progress photo.
Here you can see that we are preparing to set our equipment. Some of our men prefer working in power plants because there are no deep greasy pits to wade around in while machining and setting up, as there are in steel mills. Some of our men don't care for power plant work, due to the ever present but invisible particulates on the turbine deck. They each have their strengths and drawbacks. Whichever you prefer, in place machining gets into your blood. Your aural and olfactory sensstions spike your adrenaline when you walk into a steel mill and hear the noise and smell the mixture of grease and steel power.
Drill baby, drill; Drill those liners! In addition to machining the horizontal and angled rail beds for acceptance of the liners, we also drilled, tapped and installed the liners into our newly machined rail beds.
The machine has been set on the new rail liners, and it is time for Field System Machining to return to beautiful downtown South Elgin, Illinois, after another successful steel mill outage.
Field System Machining recently completed two additional portable machining work scopes at the same mill where we completed the 25,000 horsepower motor pedestal field machining project (see blog post "Motor Pedestal On-Site Machining Steel Mill Outage").
The first project required over boring seventy-five existing flange holes to 1-5/8" OD,
approximately 6" deep. FSM provided four men working continuously for fifteen hours to complete the scope on time.
Drill Baby, Drill! We were allowed up to one fifteen hour day to oversize these holes using portable boring machines.
After oversizing the holes we were required to machine the 97" OD x 90" ID flange, removing enough stock to true up the surface.
Field System Machining completed these two small on-site machining projects on time and on budget, making for a very happy customer. Regardless of whether your project requires six machines and twelve men per shift, around the clock, or one machine and two men working twelve hour weekdays only, Field System Machining can handle your portable machining, on-site machining, field machining, in-place machining or in-situ machining project.
Field System Machining has exceed outage manager expectations for over thirty-three years. Send us your work scope, drawings and photographs and we will quote your project. Don't know where to begin? Download "The Top Ten Things to Know Before Calling the Field Machining Company."
Cold Cast Iron Welding is a specialty of Field System Machining. We were tapped twice this year by hydroelectric maintenance repair organizations to perform cast iron weld repairs for hydroelectric plant repair projects.
The great thing about working at Hydroelectric plants is that the view is typically better than at steel mills, nuclear power plants or fossil fueled power plants.
Above is one of six excavated areas in the cast iron draft tube. Cracks and corrosion formed in these six areas, requiring excavation and cold cast iron welding.
DC Reverse Polarity FSM O 1-625 Superior Advantages are:
- High Strength Factor.
- High frictional wear resistance.
- All position welding ease.
- Safe, solid weld on most ferrous, nonferrous and dissimilar metals in all combinations
- Tough, crack free, easily machineable.
- Easy arc control, little or no preheat or post heat required.
- Tensile strength: 110,000 PSI.
- Hardness: Rc 20-23.
Complete welding and heat treating capabilities on:
- Joints.
- Integral Root Radial Seals.
- Partitions & Blade Rings.
- Set-Back Faces.
- Crush Pins.
- Packing and seal Hook Fits.
Welding and heat treating joints, root radial seals, partitions, blade rings, crush pins, packing hook and seal fits, qualified welding procedures, certified welders, metallurgist, metallurgical testing solutions.
Hydroelectric Machinery Repaired On-Site: Turbine runner machining | Turbine runner welding | Wear ring machining | Head cover machining | Wicket gate line boring | Wicket gate machining | Shaft journal machining | Shaft journal welding | Shaft journal sleeving | Shaft thrust collar machining | Collector ring machining | Any other hydroelectric field machining project you can dream up—if you the budget and the time, it can be field machined by Field System Machining . . .
Having a keyway cutter is handy, but what do you do when all of your machines are out and/or your keyway cutter is too small to fit around the shaft, and you get the call for an emergency keyway cut at 180 degrees to the existing keyway? Use a portable X-Y milling table, of course. 
Above you can see that we manufactured a quick and dirty (this was an emergency job) pedestal (gray) and V-horse (rust), welded the two fixtures together, and then tack welded the combined fixture to the floor. Next, we leveled out and bolted our portable milling machine to the fixture.
Above you can see that we are ready to start milling the keyway. In the foreground you see the rigid drive hooked up to the X-Y table, or "feed table" as we call them, to control the X travel of the table. The Y travel is controlled by an electric drive on the back end of the cross slide. The Z travel on this project is a fixed height, so we do not have a Z drive in place. The gray bucket adorned with duct tape is the coolant mister, which keeps the end mill cool while it mills the keyway.
Above you can see that the keyway milling is in progress, well on its way to being complete. The secret sauce in field machining is all in the setup.