Customer's Challenge
A feedstock process company in Singapore encountered severe wear on a critical drive shaft in one of its production ovens. The drive shaft, which connects to a motor and is supported by a bearing, had deteriorated due to constant abrasion from the bearing contact area. Shutting down the oven for repair would reduce the plant’s productivity, making the repair timeline essential for minimizing downtime.
Solution
Metal Machines was engaged to deliver a cost-efficient, time-sensitive on-site engineering solution to restore the drive shaft and return the oven to operation quickly.
After receiving the enquiry, Metal Machines immediately sent a team to assess the site and better understand the situation and the client’s requirements. In collaboration with the client, it was determined that the best course of action was to conduct in-situ machining to reduce the shaft’s diameter and insert a new sleeve to fit the bearing.
To expedite the process, Metal Machines customized an existing machine to suit the specific machining area. While the machine was being modified, the engineering team worked on risk assessments, machining procedures, drawings, and sleeve fitting calculations. This preparation took just a day and a half before the team was activated for the actual repair.
The drive shaft was machined on-site to the required size, while the new sleeve was machined in Metal Machines’ workshop with precise inner diameter interference. The sleeve was shrink-fitted into the shaft without the need for final machining. The entire job was completed within 4 days, meeting the client’s schedule and achieving high satisfaction.
Benefit
Conventional shaft repair methods involve welding overlay, Post-Weld Heat Treatment (PWHT), and Non-Destructive Testing (NDT), which can be time-consuming and costly. Metal Machines’ solution bypassed these lengthy steps, significantly reducing the repair time and ensuring the shaft was back in operation quickly. This not only minimized the plant’s downtime but also helped avoid potential profit loss and additional repair costs.
