Another manufacturer's gearbox failure on a drag chain conveyor at Rugby Cement's South Ferriby works gave Flender the opportunity to prove just how effective its fast-track service really is.
Rugby Cement's own vibration monitoring detected an early bearing failure on a primary and main gearbox on the clinker drag chain, five weeks prior to a major kiln shutdown.
On inspection of the gearbox, cracking was discovered at the root of the gear teeth. As Rugby's strategy is to reduce overall life cycle costs, the company decided to look at replacing the two original gearboxes with a single, energy efficient unit with a higher service factor. Due to the time implications, Rugby consulted Flender, one of their preferred suppliers.
As Stuart Blackburn, Mechanical Maintenance Team Leader, commented: "The failure was identified five weeks before we removed the unit, but we discovered more damage upon removal and then were up against the clock, with only two and a half weeks‚ lead time during the shutdown. Flender not only delivered their new unit within two weeks, but it was also a superior design."
Benefits of the new Flender FZG B45H12 gear unit included:
• A torque rating of 75,000Nm
• A single unit combining gearbox and motor flanged on,
replacing the previously separate motor driving the main box
• More efficient design, absorbing two previously separate gear
ratios
• Quieter, more flexible operation
• Longer service intervals
• Flender's fast track service system
• the whole unit was constructed, configured and delivered
within 14 days.
The bedplate was modified for the new unit and everything was up and running a couple of days after delivery to site.
Flender is able to provide continuous monitoring to ensure all plant shutdowns are planned for routine replacement and servicing.
Flender Power Transmission (UK)
FLENDER SERVICE EXCELS FOR RUGBY CEMENT
Another manufacturer's gearbox failure on a drag chain conveyor at Rugby Cement's South Ferriby works gave Flender the opportunity to prove just how effective its fast-track service really is.
Rugby Cement's own vibration monitoring detected an early bearing failure on a primary and main gearbox on the clinker drag chain, five weeks prior to a major kiln shutdown.
On inspection of the gearbox, cracking was discovered at the root of the gear teeth. As Rugby's strategy is to reduce overall life cycle costs, the company decided to look at replacing the two original gearboxes with a single, energy efficient unit with a higher service factor. Due to the time implications, Rugby consulted Flender, one of their preferred suppliers.
As Stuart Blackburn, Mechanical Maintenance Team Leader, commented: "The failure was identified five weeks before we removed the unit, but we discovered more damage upon removal and then were up against the clock, with only two and a half weeks‚ lead time during the shutdown. Flender not only delivered their new unit within two weeks, but it was also a superior design."
Benefits of the new Flender FZG B45H12 gear unit included:
• A torque rating of 75,000Nm
• A single unit combining gearbox and motor flanged on,
replacing the previously separate motor driving the main box
• More efficient design, absorbing two previously separate gear
ratios
• Quieter, more flexible operation
• Longer service intervals
• Flender's fast track service system
• the whole unit was constructed, configured and delivered
within 14 days.
The bedplate was modified for the new unit and everything was up and running a couple of days after delivery to site.
Flender is able to provide continuous monitoring to ensure all plant shutdowns are planned for routine replacement and servicing.
For more information, please visit:
href="https://edir.bulk-online.com/profile/10135-siemens-automation-drive-technologies.htm" target="blank">https://edir.bulk-online.com/profile...chnologies.htm
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