FSI Condensed Historical Project List & Experience
- 18000 ton press. New proportional water hydraulic valves & electrical controls.
- Convert 18000 ton press to optional 9000 ton cogging mode. Control system modifications, prefill valve modifications, & extensive field machining rework of the main ram cylinders.
- 35000 ton press forging cell. Specify and install (2) 35 foot diameter rotary forge furnaces, (1) 6000 lb rail-bound manipulator, and the foundation and utilities for the facility.
- 35000 ton press side ram synchronization. Supplied new water hydraulic proportional valves, new piping, new electrical controls, and major resurfacing of the (2) side rams.
- 50000 ton press. Supplied and installed new water hydraulic valves and controls for a 25 foot long slide.
- 50000 ton press main ram repairs. Designed & built new handling equipment and motor driven cart to quickly remove and replace (4) of the (9) main rams & cylinders (42 in diameter), in order to minimize press downtime.
- Integrity inspection of 50000 ton press & 35000 ton press. Determine remaining fatigue life of major components.
- Major rework of an automated heat treat manipulator in order to reduce transfer time and improve the accuracy of the part location in a critical air quench. Main trolley completely redesigned with a parallel arm fork arrangement in order to improve accuracy & reliability.
- Integrity inspection of 8000 ton forging press. Inspected main press frame and components.
- 12000 ton horizontal extrusion press relocated from New York to Texas. Responsible for the management & design of the press foundation, extensive press rework, structural improvements, new water hydraulic operating valves for 13 different functions, new piping, high pressure tie in to existing accumulator system, proportional control of main ram, mandrel ram, & pullback rams, new electrical controls. Resurfaced main & side rams and field machined platens.
- 35000 & 14000 ton vertical extrusion presses. Included replacing (2) (54 & 74 in diameter) main rams & cylinders, Extensive rework to 6000 ton knockout, field machining of main platen, & field installation of forging pot guides.
- 29000 ton press overhaul. Completely disassembled press frame, replaced (3) major platens (~300-600 tons each), reworked top & bottom tool slides, reassembled press frame, installed 28 in diameter hydraulic nuts, & start-up test. Field machining of main platen & main ram gland ring threaded holes. Total project duration reduced from 12 weeks to 5 weeks.
- Large diameter pipe bending machine. Relocate pipe bending machine from South Africa to Texas. Designed machine foundation, utilities, and conversion of electrical systems to US standards.
- Integrity inspection of 40000 gallon accumulator system & 33000 gallon accumulator system. Inspected the vessel walls, end closures, piping, etc.
- 15000 lb rail-bound manipulator. Modifications to improve the accuracy of positioning of the parts in the press.
- 6000 ton press complex. Extensive rework of a 6000 ton press, 2000 ton press & 1000 ton press for closed die forging. Designed and manufacture new press dome/main cylinder for the 6000 ton press. Supplied new water hydraulic valves, piping, accumulator modifications, and electrical controls for all three presses.
- Tool Slides for 6000 ton press. Designed, built, & installed new top and bottom die slides, hydraulic die clamps for quick die change, and piping and controls for the die slides.
- 3000 ton cogging press. Rework of the column seats (stay rods) and installation of hydraulic nuts for pretensioning.
- 3000 ton press. Designed, built, & installed locking clamps for the lower tool slide, supplied operating valves, and piping.
- 8000 ton press. New tie rods/columns. Existing tie rods developed major cracks and were failing. Reworked 1-existing tie rod by removing damaged threads, weld overlaying the surface, and re-machining to original dimensions.
- 4-1000Ton Press production line. Supplied new oil hydraulic control valves, piping, and electrical controls to reduce leaks & improve productivity and reliability.
- Redesigned 8000 ton press main ram/piston connection to increase fatigue life & reliability.
- 5000 Ton Cogging Press. Repaired the 42.25” diameter main ram in place. Main ram could not be removed from press due to interference with the center stalk. Top of ram was cracked ~270 degrees around the circumference. Ram top was cutoff, a new ram cap was manufactured, set & aligned in place, welded (~8” cross-section), & field machined in place.
- 8000 Ton Cogging Press. Repaired circumferential crack in the main ram cylinder. Crack was ~ 180 degrees around the flange radius. Filed installed a series of bolts with hydraulic nuts to close the crack & reinforce the cylinder flange. Field welded the crack where it surfaced on the cylinder ID and field ground to match existing surfaces.
- 7000 Ton Closed Die Press. Field repaired moving crosshead crack ~96” long.
- 8000 Ton Critical Operations Press. Project management & design responsibility for rework & installation of the press, supplying new oil hydraulic system & electrical controls, designing-building-& installing new 5-axis 2000LB capacity automated manipulator, & interfacing all electrical systems together.
- 50000 Ton Rebuild. Replaced five (5) main rams and cylinders, two (2) banjo piping connections, and one (1) piping manifold. Designed and utilized motorized special handling fixtures for ram removal. Manufactured spare pipe manifold.
- 29000 Ton Press Rebuild. Evaluated, disassembled, and repaired forging press after major component failure. Performed extensive rework, repair, and replacement services in order to return the press to service in minimal time.
- 6500 Ton Press Container Rams Replacement. Designed, manufactured and installed two (2) container ram/cylinder assemblies into the existing press.
- 12000 Ton Horizontal Extrusion Press Alignment. Performed extensive realignment of the press rams.
- 6500 Ton Horizontal Extrusion Press Ram-Cylinder Replacement. Installed new rams and cylinders and complete press alignment adjustments.
- Large Tonnage Closed Die Press Installation. Installation of a large tonnage press and hydraulic system. Also performed extensive FEA modeling of the major press components to identify potential failure risks.
- 13000 Ton Press Components. Designed and manufactured the main rams and cylinders for a unique product test press. FSI also supplied the complete water hydraulic system and electrical controls. The hydraulic system and controls are installed in a standard shipping container for ease of shipment anywhere in the world as the press has the potential to be moved as the job requires.
- Water Hydraulic System for 6500T and 3300T Presses. Complete design and supply of an extensive water hydraulic system for operating a 6500 ton and a 330 ton closed die forging press complex. Includes design and specification of the proportional and solenoid valve system, piping, and support systems.
- 3000 Ton Press Hydraulic and Electrical Control System. Design, construction, and installation of a new oil hydraulic system and electrical controls for a critical powder compaction process requiring close tonnage and speed control.
- 175MN Aircraft Isothermal Forging Press Facility Design & Project Management. Complete project management, design, construction, and installation of a new 175MN oil hydraulic press, hydraulic system, electric rotary vacuum furnaces, automated 2T manipulator for vacuum service, electrical control systems, portable vacuum die heating and forging chamber system, building specifications, and all support utility systems.
- 165MN Multipurpose Forging Facility Design & Project Management for Critical Mining and Aircraft Components. Complete project management, design, construction, and installation of a new 165MN oil hydraulic press, hydraulic system, gas fired rotary furnaces, semi automated 6MT manipulator, electrical control systems, billet descale, building specifications, and all support utility systems.