Gear faults predicted at a major Canada based metal manufacturer

A gearbox installed at a major Canadian steel producer had historically encountered failures due:

  • Gear Fracture
  • Overheating
  • Shaft Fracture
  • Tooth Fracture

Failures on this critical asset caused unplanned downtime and spillage of hazardous substances on the site.

Some of the contributing factors for these failures were as follows:

Gear Fracture – caused by bearing failure, incorrect assembly etc.

Tooth Fracture – caused by process related excessive wear, bearing failure, pitting/spalling

Shaft Fracture – caused by coupling failure, bearing failure

Overheating – caused by Oil line failure, filter bowl failure

As can be seen, bearing failure was responsible for 75% of failures.

Introduction of VibrationLF system:

The VibrationLF system is especially suited for various kinds of bearing failures such as:

  • Bearing Inner Race Failure
  • Bearing outer race failure
  • Bearing Cage failure
  • Bearing ball failure

Based on our vibration analysis, we were able to identify an early stage bearing failure and recommended a bearing replacement ahead of the planned maintenance cycle. This saved our client an unplanned outage that could have resulted in over $1 million dollars in lost revenue.

 

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