The pictures on this page detail a case study of a non-typical diamond wire cutting application. This study proves that this technology is very adaptable when coupled with the right engineering and manpower. We continue to provide typical cutting applications as well so feel free to contact us with any of your requirements.
The Location:
Hydro-electric generating facility located on the Susquehanna River in southeastern Pennsylvania. | |  |
The Challenge:
To remove 10 poles from the rotor without damaging the pole windings or the rotor. Process would need to be performed dry, without significant heating and within a 2-week window. | | |
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Problems:
The dovetail keys that are typically removed to release the pole were corroded.
The rotor lay horizontal so drilling of the keys and/or dovetail presented a significant challenge due to the total length (80” each).
Access to the keys and dovetail was limited to a ¾” opening on each side.
Poles had to be removed while positioned at top-dead-center of rotor.
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| | The working platform was 20’ above ground level and only semi-rigid (i.e. scaffolding).
Competition:
3 competitors failed in their attempts to remove the keys by drilling, tapping, pushing, pulling, etc. The delays tightened the completion window significantly. The MLS Solution: To use our Diamond Wire System to part the dovetail at the bottom of each pole. |
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Making it work:
Step 1:
Fabricate a mock-up test in which we could verify proper operation, cutting speeds and wire performance. This was accomplished at our test facility and we informed our customer that we could remove a single pole in 30-36 hours. | | 
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Step 2:
Mobilize on-site, and set up our equipment and attach to the rotor for rigidity.
Step 3:
Begin the removal process while working with the customer for the timing of the pole removal (lifting) and rotor rotation.
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Performance:
From the first pole to the last, we were able to reduce our parting time from the initial 28hrs to just 11hrs. The total job was completed 6 days ahead of schedule and at roughly 65% of the quoted cost. The savings of course, were given back to the customer. | |  |
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 | | Conclusion:
MLS Machine Shop provided a unique solution to a machining problem where others failed, all while working in a harsh environment under severe constraints. |
