On-site services solve tricky problems

Manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team.
Overcoming extremely limited clearances while manoeuvring a 3m-diameter 23t gear for Blue Circle Southern in Australia is just one example of the resourcefulness regularly shown by David Brown's on-site services team. In this case a special cradle was constructed under David Brown's guidance and the gear was transferred into place on rails. The cement mill gearbox operated by Australia's major cement producer had suffered a bearing failure and the resulting debris caused significant damage to the slow speed dual drive double helical pinions and gear teeth.

Engineers from David Brown attended the site to make repairs and allow continued production, at a reduced rate of 75% of full capacity, while the replacement gear and pinions could be manufactured by David Brown Australia.

In the interim there was close liaison with the client to plan the gear set replacement method and keep downtime to a minimum.

Production resumed at 100% following installation of the new gear set in 2004.

An inspection carried out in 2005, following 12 months of full production, showed exceptional tooth contact patterns and an absence of tooth wear, giving the overall refurbishment project a double 'thumbs up'.

The contract underlines the scope of David Brown's on-site services in a market which is increasingly driven by service as well as product excellence.

The team that worked on the project is just part of David Brown's fully qualified field service engineer resource which is available in most key geographies to provide a number of key services from performance testing, fault diagnostics through to installation/commissioning, alignment checks and emergency repairs.

Recognising the importance of preventative maintenance, the company also boasts a range of applications knowledge, gained through close long-term customer partnerships in many heavy process industries, to offer performance improvements to transmissions and other rotating equipment.

Using appropriate condition monitoring and analysis techniques, David Brown is able to pin point critical process issues and recommend courses of action to substantially reduce the associated risks.

David Brown's deep knowledge of transmissions and other rotating equipment, combined with its close geographic proximity, means it is well positioned to respond rapidly to its customers' needs, seeking to identify and predict issues, and offering solutions to improve their process performance.

Service engineers are also available to install and inspect transmissions and other rotating equipment throughout the world and David Brown provides installation services and alignment checks that cover everything from a simple equipment installation to a complete drive system installation.

To ensure a proper startup of the equipment, David Brown service engineers can also provide its customers with inspection services and advice on project managing installations.

Finally, experienced service engineers, using modern equipment and leading technology, provide repair services at the site to restore or enhance performance of transmissions or other rotating equipment.

The services range from emergency repairs, as in Australia, to repairs of equipment during planned shutdowns.

Repair services cover all transmissions used in a variety of heavy process industries, from metals processing through to mining and cement manufacture.