Offtopic-Portable Miling Machine in 15 Days

[khalid]

As i was making video with mobile so you can see me in reflection of Laptop screen at the end of video.

[khalid]

Here is the actually how the machine will install..some 6mm deep test.. complete depth testing shall be carried out on Monday.

[t_vandemark]

Khalid, it looks great. Are you at all worried about the cutting fluid getting into the electronics?

[khalid]

Khalid, it looks great. Are you at all worried about the cutting fluid getting into the electronics?

We are using compressed air and no cutting fluid

[khalid]

I have 13 years of mechanical maintenance (stationery equipment) experience in fertilizer plant. This year we have had hotspots in our primary reformer and due to innovative technique all were rectified on-line without any downtime.
Innovation,hardworking,commitment,leadership and good management always pays off...I am the ever youngest Section Head at my fertilizer plant.

Tomorrow we shall give presentation and demo of this machine to our GM.

[scottp55]

Congratulations Khalid, Hope all goes well at demo.

[gene]

So you do the repairs without shutting down the plant ?

[khalid]

So you do the repairs without shutting down the plant ?

Yes and No.. Depends upon the situation and risks... For example, leakages can be arrested using box-up clamps, peening welding techniques etc. The hotspots on the walls and roof of induced draft furnace can be taken care online without shutting down the plant.
The repair of critical service cracks like we are talking in this thread we have to shutdown the plant. But if the same cracks appears on coolig water pipings/natural gas lines/steam and other utilities line we do special SOC's/JSA's and do online repair. We did arrested High Pressure Heat exchangers leakages from covers/flanges online and we try to keep the plant in running without compromising on safety. Safety and Quality of the job is 1st priority. At our plants production is our second priority.

[khalid]

Congratulations Khalid, Hope all goes well at demo.

Thanks,
Here in the picture the 65mm deep slot took 6Hrs of time. Previously manual machining with big steps at 30mm took almost 30Hrs of time and the finish was too much pathetic.. The machine was stopped to lengthen the tool with new tool adapter. As it has rough machining with endmill at 1.5mm stepover so we fine not that good finish at the walls but its okay.. We can run another finish machining using ballnose but we no need to....
The cavity walls are at 15degree upto 70mm depth and the remaining 20mm depth is at 37.5degree.Job in progress.

[khalid]

Here is the rough cut at full depth by the machine. 10 degree(in the above posted wrongly written 15 degree) for 70mm and the remaining is 37.5 degree upto next 20mm. Total depth is 90mm. The complete machining took place with one 16mm End Mill..No sharpening/replacement of the tool. The tool was not blunt..No coolant at all. Job took 10Hrs as expected...