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REAL Services' technically sophisticated clients included establishments that are primarily engaged in the extraction and processing geologic mineral contents for
agriculture & animal, food & food ingredients and industrial applications.

These mineral extraction and mining operations maintenance programs include Ferrography and Oil Analysis; provided by REAL Services along with our exclusive SAVE REPORT that provides Return On Investment and Cost Justification of your PM Program.

Mining - Salt Evaporator - Gearbox

Case Study # 66

F-002 Bottom Capper; Gear Speed Reducer.  The equipment particle concetration (EPC) of 1,175,840 is excessive; this is the FIRST time this equipment was tested and rated CRITICAL September, 1997.

Recommendation: Scheduling this equipment for maintenance action. Specifically to correct bearing failure and resulting abnormal gear wear.

 

   

Analytical results show the presence of 400 micrometer (um) Copper Alloy (including Brass & Bronze) Severe Sliding wear and 200um Rolling Contact (Bearing) wear particles resulting in an alignment problem and abnormal gear wear.

The viscosity of this lubricant is significantly higher than expected. The incorrect lubricant can cause an increase in the coefficient of drag of this equipment, resulting in an increased wear rate.

The size, shape and composition of these particles are of great concern.

   

Upon opening of gear case; the bearing wear found to have failed resulting in an alignment problem with the gear set.  This alignment problem gear tooth wear.

This early notification allowed for the scheduling of equipment out of services.  Lead time to order proprietary components which minimized repairs and downtime.

        

CUSTOMER  ESTIMATED  COST SAVINGS:

Original Component Savings:                                  63,500
Secondary Damage Savings:                                    4,700
Down Time Min./Production hrs. Savings:                2,550
Business Interruption:                                                         0
RUSH Shipping Cost Savings:                                  3,750
Parts & Inventory Warehouse Savings:                            0
Overtime Repair Savings:                                                  0    
                                Total SAVINGS:         $ 74,500

   

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