Onsite Rotor Thrust Face Machining
Client: Electrical Energy Manufacturer
Industry: Power Generation
Location: Offshore – Segenal
Duration: Completed within Days
Service: Onsite Rotor Thrust Face Machining
Overview
Royce Onsite Machining was engaged to carry out an urgent in-situ machining operation on a critical power generation rotor. The rotor’s thrust face had scored and hardened surfaces and required precision machining to restore its operational geometry. Any delays could have resulted in extended downtime or the need for rotor replacement.
Using Royce Onsite’s orbital machining technology, the team removed the hardened layer and machined the rotor thrust face to OEM tolerances, under their supervision, all without removing the rotor from its assembly. This advanced technology allowed precise material removal and high-efficiency machining in-situ, ensuring the rotor returned to full operational status quickly, avoiding costly downtime.
Work Carried Out
Damage Assessment
- Inspected the rotor thrust face to identify surface hardening and wear.
- Verified that the rotor material was suitable for machining without compromising integrity.
Rotor Thrust Face Machining
- Removed hardened layers from the rotor thrust face using orbital machining, restoring it to acceptable working condition.
- Machined the rotor thrust face with precision in-situ methods, achieving OEM-specified tolerances under OEM oversight.
- Ensured alignment and surface geometry met OEM operational standards.
Finishing and Verification
- Carried out measurements and non-destructive testing to confirm dimensional accuracy, surface finish, crack free condition.
Technical Highlights
- Repair Method: Onsite rotor thrust face machining using orbital machining technology
- Tolerances Achieved: OEM-specified tolerances under OEM supervision
- Surface Hardness: Hardened layer removed to enable accurate machining
- Downtime Avoided: Completed in hours
- Surface Finish: Smooth, precise, and fully aligned with OEM specification
Verification: Non-destructive testing confirmed full restoration
