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Job Scope: Welding and machining repair of two simultaneously timed sets of in-body internal valve threads. The new in-body internal valve threads are machined to accept a new standard COPES-VULCAN Cage.

Equipment Overview: CFS replicated an exact "mock-up" to demonstrate and prove all processes before performing the actual on-site repair. CFS designed, engineered, manufactured and tested two state of the art machines for the subject valve. The first, a  "boring and facing" machine, was used to do initial and final machining. The second machine was utilized for "threading" only. CFS also modified a TGAW welding system utilizing a specialty welding front end with oscillator interchange.

Job Overview: After proving the successful "mock-up" demonstrations, CFS mobilized to job site. Site specific training, safety training and in processing was the first order of business. Next, the equipment was staged and readied. The valve was then inspected and "As Found" dimensions taken. The initial machining process, "undercutting to clean metal", was performed by the specialty "boring and facing" machine. Next, the valve was preheated to 400 degrees Fahrenheit and the TGAW welding system set into place. The first area to be welded was 14 inches below valve opening and at a diameter of 12 inches.  The second area was 9 inches below the first and at a diameter of 11.5 inches. After the appropriate amount of weld build up, a post weld heat treatment (PWHT) was performed. The valve then needed to cool before the "boring and facing" machine could be reinstalled. The new weld was then re-machined to specific sizes according to FPL Engineering. The land distance between the new in-body internal valve threads had a tolerance of plus or minus one thousands of an inch (0.001") The final process was to machine the actual threads the new standard COPES-VULCAN Cage would have to screw into. These new threads (12 threads per inch) needed to be in perfect timing. The "threading machine" has a continuous thread spindle to achieve this consistency. After the threads were machined the COPES-VULCAN Cage was successfully installed. In addition to the internal valve threads, CFS re-machined the valve opening surface "flange" and repaired one adjacent stud hole.

Schedule: Continental Field Systems prides itself on being able to engineer solutions quickly for its customers. This should be evident by the time line shown below.

• Monday 03/14/05 began developing thread machining concept for customer
• Thursday 03/31/05 received purchase order
• Thursday 03/31/05 began final design, engineering, manufacturing and testing on threading machine
• Tuesday 04/19/05 finalized on-site procedure and schedule
• Sunday 4/24/05 traveled to site
• Saturday 5/14/05 finished job