Some minor wear was found and refurbished before the original gears were reassembled into the gearbox
With lubrication supplies to the bearings
being critical to the smooth running of
the gearbox, the misalignment of the
oil galleries in the bearings was the next
problem area to resolve. Again, these were
re-machined and positioned in the correct
location so that the new, quality bearings
would now have sufficient lubrication.
Several of the shafts were repaired using
a wire thermal spray process and then
machined back to the design tolerance for
a perfect fit. Two shafts were beyond repair
and so the machine shop manufactured
new components as replacements.
On the positive side, the original gears
were inspected with a penetrating dye and
all were found to be undamaged. Some
minor wear was found and refurbished
before they were reassembled into the
gearbox. The robustness of the gears
appeared in direct contrast to the rest
of the gearbox, leading the engineers
to question if the gearbox had originally
been manufactured in parts, in separate
locations, prior to original assembly.a
Throughout the repair project, the
customer was regularly updated on
progress and despite the considerably
broadened scope, the deadline for
completion was still met. All of the
damage was repaired and all components
were manufactured and assembled to best
engineering practices, which significantly
improves the durability of the gearbox.
Repairs by Sulzer are recognized by the
quality of workmanship which has been
proven to increase the service life of an
asset and maintain long-term reliability.
Aneil Hanafiah concludes: “This particular
example illustrates the potential for a
relatively simple repair to escalate into
something much more complex. It also
shows how the purchase of what could be
imitation products without knowledge can
sometimes lead to additional maintenance
costs that will often far outweigh the
initial low cost benefit. Now termed as
the total cost of ownership (TCO), this
approach takes into account the long term
implications of running and maintenance
costs and gives us a more realistic value to
high quality equipment and repairs.”
About Sulzer
Sulzer is the leading worldwide,
independent service provider for large
rotating equipment. With technically
advanced and innovative service and
maintenance support solutions, Sulzer
provides a turnkey service that provides its
customers with the peace of mind to focus
on their core operations.
Included in this package is a highly
efficient and dependable high-voltage
coil manufacturing and supply service,
delivered from a purpose built facility
within the Birmingham Service Centre, UK.
It is recognized for producing very high
quality coils for high voltage motors and
generators; designed, manufactured and
shipped by a highly skilled and dedicated
team to ensure fast and reliable service.
With an in-house copper rolling mill,
Sulzer customers can benefit from round-
the-clock manufacturing to ensure that
every coil is delivered on schedule. In
conjunction with constant quality control
and full HV on-site testing facilities, Sulzer
can deliver quality, precision and speed,
any time, day or night.
For further information:
Sulzer : Harpreet Suree
Tel: +44 (0)121 766 6161
Web: www.sulzer.com
Email: [email protected]
All of the damage was repaired and all components were manufactured and assembled to best engineering practices,
significantly improving the durability of the gearbox
“Repairs by Sulzer are
recognized by the quality of
workmanship which has been
proven to increase the service
life of an asset and maintain
long-term reliability.”