RELIABLITY CENTERED MAINTENANCCE

FAILURE MODE AND EFFECTS ANALYSIS FOR GEARBOX

S No Components In what ways How will failure affect What is life of What OEM’s What condition monitoring What should be
/ Parts can it fail operation/ function of this part/ defect routines suggest techniques can be applied on the periodicity of
(including equipment? ratio? (including this part and this failure? CM?
degradation)? replacement)?
1. Gears Wear Reduced Load Depends on the Regular oil changes, Vibration analysis, oil analysis, 6 M / 1000 Hr
carrying capacity, high operating proper alignment magnetic particle inspection
pitting noise and vibrations conditions but checks
generally it can
Tooth Total failure of gear operate
breakage Transmission efficiently for 40-
50 years
2. Oil Cooler Corrosion Reduced heat transfer 10-15 years Cleaning and Eddy current testing, visual Annually
efficiency inspection inspection
3. Thrust Wear Reduced heat transfer 20000-30000 Hr Regular lubrication, Vibration analysis, temperature 1000 Hr
bearings misalignment Increased energy proper alignment monitoring, visual inspection
consumption
4. Output shaft Fatigue Reduced power 50 years Calibration and Pressure testing, functional Bi-annually
Wear transmission, vibration cleaning checks, flow monitoring,
pressure monitoring

misalignment

5. Gear Driven Pump Failure Loss of lubrication oil 15- 20 years Regular oil changes, Vibration Analysis, Oil Analysis, Annually
Pump through main gear- filter replacement Temperature Monitoring, Noise
driven pump Analysis, Visual Inspection

6. Control Malfunction System shutdown, loss 15 years Regular Control system monitoring, trend Quarterly
System of temperature control maintenance checks analysis, electrical testing
and software
updates
7. Electrical Motor Failure Loss of stand-by 15-20 years Regular insulation Electrical Signature Analysis, Annually
Motor Pump option for supply of resistance tests Vibration Analysis, Temperature
lubrication oil to Monitoring, Motor Current
Regular oil
gearbox Analysis, visual inspection
changes,
filter
replacement
8. Pressure Electrical Loss of system control 5,000 hours Regular testing and Functional testing Every 1,000 hours
Switch Failure calibration
9. Temperature Sensor drift Inaccurate 8,000 hours Regular calibration Calibration Every 2,000 hours
Sensor temperature
measurements
10. Hydraulic Fatigue Difficulty in gear 20 Years Regular inspection, Visual inspection, hydraulic Anually
Clutch Wear engagement lubrication pressure monitoring
misalignment maintenance