Scribd Logo
Upload

Welcome to Scribd!

  • Caso de Estudio en Caja de Piñones

    Uploaded by

    flacos7022465
    11 views1 page
    This document summarizes a case study of gear failure prediction in a Mullor gearcase used in a foundry. Analytical ferrography of the gearcase oil sample revealed large gear and bearing wear particles, correctly predicting failure of the pinion gear. Replacing just the failed gear cost $1,500, rather than a full unit replacement of $10,000, saving $8,500. Unscheduled downtime of even two weeks would have cost $100,000, so oil analysis prevented much higher costs and production impacts. The customer now performs monthly oil analysis of the gearcase for continued condition monitoring.

    Original Description:

    Se estudia el daño en una caja reductora mullor

    Original Title

    Caso de estudio en caja de piñones

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    This document summarizes a case study of gear failure prediction in a Mullor gearcase used in a foundry. Analytical ferrography of the gearcase oil sample revealed large gear and bearing wear particles, correctly predicting failure of the pinion gear. Replacing just the failed gear cost $1,500, rather than a full unit replacement of $10,000, saving $8,500. Unscheduled downtime of even two weeks would have cost $100,000, so oil analysis prevented much higher costs and production impacts. The customer now performs monthly oil analysis of the gearcase for continued condition monitoring.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    11 views1 page

    Caso de Estudio en Caja de Piñones

    Uploaded by

    flacos7022465
    This document summarizes a case study of gear failure prediction in a Mullor gearcase used in a foundry. Analytical ferrography of the gearcase oil sample revealed large gear and bearing wear particles, correctly predicting failure of the pinion gear. Replacing just the failed gear cost $1,500, rather than a full unit replacement of $10,000, saving $8,500. Unscheduled downtime of even two weeks would have cost $100,000, so oil analysis prevented much higher costs and production impacts. The customer now performs monthly oil analysis of the gearcase for continued condition monitoring.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 1

    For more information, contact your Predict Representative, or call (800) 543-8786

    Or visit our website at www.predictusa.com


    ISO-9001 CERTIFIED
    Mullor Gearcase
    Industry: Foundry
    Case Study No. 81544




    Analytical Ferrography Provides Early Warning
    of Mullor Gearcase Failure
    These are pictures of a failed
    85B Mullor Gearcase.

    The Mullor Gearbox was
    installed in July 2002. After
    approximately 900 hours of
    operation, the unit developed a
    klunking noise.

    An oil sample was sent to
    Predict on October 31, 2002 for
    analysis. This revealed the
    generation of extremely large
    gear and bearing wear
    particles.


    Figure 1. Low Alloy Steel Gear and
    Bearing Wear Particles by
    Analytical Ferrography


    Figure 2. Copper Alloy Metal
    Bearing Wear Particles by
    Analytical Ferrography

    The inspection of the unit
    revealed a pinion gear starting
    to disintegrate.

    Figure 3. Pinion Gear


    Figure 4. Disintegrating Gear


    Figure 5. Close-up of Gear


    Figure 6. Alternate Close-up

    One tooth had completely
    detached from the gear.


    Figure 7. Broken Tooth

    The oil was drained from the
    unit and all the debris was
    thoroughly flushed from the
    gearcase. The unit was then
    filled with new oil. Operation
    resumed under close watch
    until a replacement gearcase
    was secured and installed.

    This timely identification
    prevented the unexpected
    breakdown of the entire unit, by
    requiring the replacement of
    only the single gear. Without
    this analysis, the unit would
    have continued operation until
    total failure.

    The cost of replacing the gear
    was $1,500. If collateral
    damage had occurred, then the
    cost to replace the entire unit
    would have been $10,000.
    Unscheduled down time was
    estimated at $50,000 per day.
    As a result, any down time
    during the two weeks needed
    to schedule repairs would have
    greatly affected production.

    The customer has initiated
    monthly analysis of this unit to
    more closely monitor its
    operation.

    Stephen T. Hierro, J r.
    Machine Condition Analyst
    sthierro@predictusa.com
    CASE STUDY
    $10,000 SAVINGS
    plus elimination of unscheduled
    downtime at $50,000 per day.

    You might also like