Spiral welder rescues food processor

Liverpool, UK – Rewinds & J Windsor (RJW) of Liverpool has carried out a repair contract for a large oil seed food processing company in the north of England. The work on a rotary diverter lock assembly – from a conveyor handling system – was made of 316L stainless steel and measured 2.5m long and 500mm diameter.

The food processor opted for the repair route as a new unit would have cost over £20,000. Moreover, delivery would have taken up to 22 weeks from receipt of manufacturer’s drawings; no drawings were available so redrawing would add further cost and time penalty.

Instead RJW collected the rotor lock shaft assembly from site, cleaned and inspected it and made detailed measurements. Its materials’ analysis confirmed the assembly to be of 316L stainless steel, while an ultrasonic test found the shaft was structurally sound with no inherent flaws or cracks. 

A detailed inspection, however, found that the drive end bearing diameter to be bent and worn, with the non-drive end showing signs of wear – so effecting its serviceability and indicating an immediate risk of catastrophic failure. This would have led to huge downtime costs and production problems affecting not only the site but their key downstream customers.

RJW’s repair work included the use of a new £100,000 spiral welding machine, which was specially designed for shaft and other rotating machinery repairs. Welding was carried out using 316L welding wire and externally approved welding procedures. A dye penetrant inspection was completed and found to be satisfactory following machining, with the shafts restored to manufacturer’s standard.

According to RJW, all work was carried during normal working hours and the unit was returned within seven working days – and could have been completed in 30 hours using its round-the-clock service.