On-site machining of the support surface of a "Granulator" for a sugar refining company

Problem:

A sugar refining company in New York had a malfunction with (1) one of its Granulators. In its basic construction, a granulator is an horizontal cylinder about 12 feet in diameter and about 30 feet long, rotating at a low speed while supported on (2) two sets of rollers (one at each end). The surface riding on the rear set of rollers was very badly worn and caused the entire granulator to shake.

Possible Solutions:

• Cut out the damaged back end of the granulator and weld in a new section with a new roller support surface. A very lengthy and costly process that in no way would guarantee a viable outcome.
• Remove the granulator and send it out to have the damaged surface machined true.
  A very costly solution and a long downtime.

Frontline’s Solution:

Machine the damaged area on site while the granulator is actually in service. Frontline welded a support bracket to a steel column located about (2) two feet from the damaged area of the granulator.

A compound bed with a tool post was then mounted on the support bracket and we proceeded to machine the radial and the thrust surfaces while the granulator was in service.

Welding of support bracket to post.	Final set up.
Machining of thrust surface.	Radial surface already machined.

The Results Were:

1. An astonished maintenance manager that could not believe his eyes when he found out that his (2) two month old problem had been resolved while the granulator was actually producing sugar.
2. A very happy plant manger when he realized that the granulator was repaired at a fraction of the cost and without any down time.