On Site Machining the 78 Super Calendar - Not for the Faint of Heart
First Ever Ways Repairs to Fifty-Seven Year Old Paper Mill Super Calender--On Site Machining at a Paper Mill
Three companies were asked to bid the field machining repairs to a Wisconsin Paper Mill's 78 Super Calendar. Two of the three on site machining companies declined to bid.
Never one to shy away from difficult work, Field System Machining bid the portable machining work and completed the project in May 2011, completing one half-shift early of our quoted nine shifts completion time.
Since 1978, Field System Machining has performed On Site Machining, mill machinery repair, field machining, and other on site machinery repairs for paper mills, steel mills, aluminum mills, power plants, and industrial facilities and factories of all types.
Here is the Question and Answer session follow up to FSM's repair . . .
FSM: How long was the project contemplated?
Client: Project was scheduled for 9 shifts around the clock, and we successfully completed in 8.5 shifts.
FSM: How many companies bid the work?
Client: FSM was the only bid we entertained, though we did solicit two other companies, they both responded with no-bids.
FSM: Have any of your mills completed this type of Super Calendar repair in the past?
Client: None
FSM: How long has the Super Calendar been in service?
Client: Since 1957, it has had several capital improvements over the years, basically the only area left untouched was the main structure.
FSM: How has the repair improved production volume, reliability and longevity?
Client: Volume? Too early to tell but we are seeing much better runability, sheet draws, windups, tension control and less noise.
Reliability? Our Fiber roll cycle will improve considerably, the sheet runs much straighter and our loading is much more equal. Longevity? It's early but if the improvements are substantial we may consider doing this to our mating Super Calendar.
FSM: What was learned from the project?
Client: Anything can be done!
FSM: What would be done differently?
Client: More documentation up front to confirm each parties involvement. We would have designed the new ways to be thinner if we had understood the machining capabilities a little better to minimize the time required to do the machining.
FSM: Would you recommend us to other paper mills?
Client: Yes
Making a Pass on the New Wear Liners
Close Up of Milling Head Cutter Making a Pass on the Ways Liners