Their planetary machining project involved the repair of a damaged coupling locating taper at the drive end of a 1000 megawatt x 14-metre long x 65,000 kg alternator/generator rotor in a nuclear power station in Ukraine.
The team designed and produced a special taper turning machine that accommodates the dimensions of the alternator shaft drive end taper, which had a small end diameter of Ø816mm, a large end diameter of Ø820mm, and a distance of 760mm. They also ensured the extreme accuracy requirements of the taper by using special gauges produced to check the dimensions at 25mm intervals along the full length of the taper.
At a brand new power station in South America, personnel discovered severe damage to the J Shape Labyrinth Seals of a new 80-tonne LP Turbine Shaft when opening a packing case. The In-Situ Machining design team rose to the occasion, creating special tooling to replace and re-machine the stainless steel J Shape Labyrinth Seals.
Precision was paramount, with the seals being only 0.35mm thick, and In-Situ Machining successfully machined off 5mm from the 900mm diameter within a tolerance of 0.1mm on diameter and a concentricity tolerance of 0.025mm. The OEM and power station personnel inspected and approved the project. By completing the repairs within a limited timeframe, In-Situ Machining Solutions ensured that the build schedule remained intact.