Case Studies

Restored a surge-damaged gearbox to API 613 5th Edition after seven years in service.

Traced a cracked tooth on a 54 MW gearbox to grinding burn, replacing with case-carburised internals.

In-situ repair after catastrophic idler shaft failure - avoided the OEM's 24-month lead time.

Designed a complete new gear set from scratch, restoring plant operation within 20 weeks.

Ended repeated tooth failures on a 54 MW gearbox with an X-shaped helix for even heat dissipation.

A redesigned 1.4 service factor unit in 18 weeks ended failures caused by grid transient loads.

Traced recurring failures to blocked bearing lubrication, resolved with an enlarged oil supply in 18 weeks.

Eliminated premature gear failures by redesigning axial float and casing to balance loading.

Ended two-monthly bearing failures on a 6.7 MW gearbox by enlarging bearings and correcting alignment.

Rebuilt after bull gear fractures shut a fertiliser plant down, with case-hardened gears and tilting pad bearings.

Diagnosed coupling-induced axial loading at a Kenyan plant, resolved with a flexible coupling in 12 weeks.

A single-piece gear wheel replaced a split-type design, ending helix slippage in 18 weeks.

Upgraded to tri-metal pin bearings and balanced planet assemblies after a local repair failed.

Rebuilt complete internals, including the Hirth interface, in about half the OEM lead time.

Traced severe shaft vibration to coupling compression, corrected by removing 2.8 mm of shim.

Ended pitting failures around island-mode transient loads that the OEM's own replacement had repeated.

Pressure dam bearings replaced misalignment-sensitive offset bearings, ending high-speed failures.

Cured vibration with a corrected gear set and reamed coupling bolts, achieving over 90% contact.

Converted ten gearboxes from horizontal to vertical offset, ending tooth failures from rotor pull.

Replaced a critical compressor gearbox under shutdown constraints, delivering a drop-in solution with improved reliability and reduced lead time.

Delivered a high performance steam turbine gearbox upgrade within the existing installation footprint, enabling increased power capacity without any foundation or layout changes.

Identified the root cause of repeated gearbox failures and engineered a long-term reliability solution.

Re-engineered for a replacement engine's reversed rotation - delivered as a drop-in unit in 22 weeks.