A gearbox installed at a major Canadian steel producer had historically encountered failures due:
- Gear Fracture
- 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.