Line boring Flames Tube 183mm
Ø170mm to Ø183mm Flame Tube Line Boring Repair
Client: Electric Welding
Industry: Power Generation
Location: UK
Duration: Completed within 2 days
Service: Onsite Line Boring & Precision Machining
Overview
Royce Onsite Machining was engaged by Electric Welding to carry out a precision onsite line boring repair on two flame tubes within a power generation application.
The existing Ø170 mm bores required machining to Ø183 mm to restore the components to the required engineering specification. Due to the size, configuration and location of the flame tubes, removing the components for conventional workshop machining would have created additional logistical requirements and increased downtime.
To complete the repair onsite, Royce Onsite Machining utilised a Climax BB5000 line boring system, combined with a bespoke machining setup designed and manufactured by Royce engineers specifically for the application.
The bespoke setup provided the required rigidity, stability and control to accurately machine both flame tubes. Controlled cuts of approximately 3 mm on diameter per machining pass were taken to progressively open the existing Ø170 mm bores to the required Ø183 mm finished diameter.
The complete machining operation was successfully completed onsite within two days, helping the client minimise downtime and avoid the need to remove the components for workshop repair.
Work Carried Out
Initial Inspection and Assessment
- The two flame tubes were inspected to establish the condition and dimensions of the existing Ø170 mm bores.
- The required finished bore diameter of Ø183 mm was established.
- The component configuration and available access were assessed to determine the most suitable onsite machining method.
- A bespoke machining arrangement was developed to provide secure and accurate support for the line boring equipment.
Bespoke Line Boring Setup
- Royce Onsite Machining utilised a Climax BB5000 line boring system for the machining operation.
- A bespoke setup was designed and manufactured by Royce engineers to suit the specific geometry and access requirements of the flame tubes.
- The setup provided the necessary rigidity and stability to maintain machining accuracy throughout the operation.
- The machining system was aligned and secured before commencing the boring operation.
Controlled Bore Enlargement
- The existing Ø170 mm bores were progressively opened up to the required Ø183 mm diameter.
- Controlled machining passes of approximately 3 mm on diameter at a time were used to manage the material removal rate and maintain control of the machining process.
- The two flame tubes were machined accurately using the onsite line boring equipment.
- Measurements were taken throughout the operation to monitor bore size and ensure the required final dimensions were achieved.
Final Machining and Verification
- Both flame tube bores were machined to the required Ø183 mm finished diameter.
- Final dimensional checks were carried out following machining.
- The completed bores were inspected to verify dimensional accuracy and consistency.
- The components were confirmed ready for their intended power generation application.
Why Was the Climax BB5000 Used?
The Climax BB5000 was selected because it provides a versatile and robust onsite line boring solution suitable for precision machining applications where access, alignment and controlled material removal are critical.
For this project, the BB5000 was combined with a bespoke Royce Onsite Machining setup specifically engineered around the flame tube configuration.
This combination allowed Royce engineers to establish a stable machining arrangement while working directly on the equipment onsite. The ability to control the machining operation and progressively remove material in approximately 3 mm diameter increments helped maintain stability and dimensional control throughout the repair.
Using onsite line boring equipment also avoided the need to remove the flame tubes and transport them to an external machining facility, helping reduce both logistical requirements and equipment downtime.
Technical Highlights
- Client: Electric Welding
- Industry: Power Generation
- Components: Two flame tubes
- Original Bore: Ø170 mm
- Final Bore: Ø183 mm
- Material Removal: 13 mm on diameter overall
- Machining Passes: Approximately 3 mm on diameter per pass
- Equipment: Climax BB5000 line boring system
- Setup: Bespoke Royce-engineered machining setup
- Repair Method: Onsite line boring and precision machining
- Completion Time: 2 days
- Verification: Final dimensional inspection and measurement
Outcome
Royce Onsite Machining successfully machined two flame tube bores from Ø170 mm to Ø183 mm onsite within two days.
The use of the Climax BB5000, combined with a bespoke Royce-engineered setup, provided a stable and controlled machining arrangement suited to the component configuration.
By progressively removing material in controlled 3 mm diameter machining passes, Royce engineers were able to accurately enlarge the existing bores to the required finished diameter while maintaining control throughout the operation.
Completing the work onsite eliminated the need to transport the components to a workshop and helped the client minimise downtime and disruption to their power generation operations.
This project demonstrates Royce Onsite Machining’s capability to deliver bespoke onsite line boring solutions for power generation equipment, including precision machining of difficult-to-access components where conventional workshop machining may not be practical.
Why Choose Royce Onsite Machining?
Royce Onsite Machining provides specialist onsite line boring and precision machining services for critical industrial equipment.
Our engineers can design and manufacture bespoke machining setups to overcome challenging access, geometry and installation requirements. By bringing the machining equipment directly to the component, repairs can often be completed without extensive dismantling or transportation.
This approach can help reduce downtime, minimise logistical costs and allow critical equipment to be returned to service more quickly.
Royce’s onsite machining capabilities are suitable for demanding applications across power generation, marine, heavy engineering and other industrial sectors.
What Is Onsite Line Boring?
Onsite line boring is a precision machining process used to enlarge, restore or correct the alignment of existing bores without removing the component from its installed location.
A line boring machine uses a precision boring bar supported through the component. The cutting tool removes controlled amounts of material as the bar rotates, allowing the bore to be progressively machined to the required diameter and specification.
Onsite line boring is particularly useful for large, heavy or difficult-to-remove components where transportation to a conventional workshop would result in significant cost or downtime.
For this project, the existing Ø170 mm flame tube bores were progressively machined to Ø183 mm using a Climax BB5000 and a bespoke Royce setup.
Is Line Boring an Expensive Repair Method?
Line boring can provide a cost-effective alternative to removing and replacing components or transporting large equipment to a workshop.
The cost depends on factors such as the component size, bore dimensions, material condition, required tolerances, accessibility and the amount of machining required.
Because the work can be completed onsite, customers can potentially reduce costs associated with dismantling, transportation, workshop machining, reassembly and extended downtime.
For critical power generation equipment, the cost of onsite machining should therefore be considered alongside the potential operational cost of taking equipment out of service for longer periods.
Does Royce Onsite Machining Have Experience in Power Generation?
Yes. Royce Onsite Machining provides onsite line boring and precision machining services for demanding industrial applications, including power generation.
Our engineers have experience developing bespoke machining solutions for components where access, accuracy and minimal downtime are critical.
Where standard machining equipment cannot be directly applied, Royce can develop bespoke fixtures, supports and machining arrangements to suit the component and working environment.
Each project is assessed individually to determine the most appropriate machining method, equipment and setup, with dimensional checks carried out throughout the operation and following completion.
Need Onsite Line Boring for Power Generation Equipment?
If you have a damaged, undersized or incorrectly dimensioned bore that requires precision machining without removing the component from site, Royce Onsite Machining can assess the application and develop a suitable onsite machining solution.
Contact Royce Onsite Machining to discuss your onsite line boring and precision machining requirements.
