Emergency Rebuild for the Power Generation Industry
Product engineers work with our customers to lower life cycle costs by implementing predictive maintenance programs, performing overhauls and upgrades, manufacturing replacement enclosed drives and parts, and by applying over 125 years of design engineering and manufacturing experience.
All of these factors came into play when we received an emergency call from a customer in a major city in the Mid-Atlantic states. They had six gas turbines used to supplement the power grid during peak usage.
- Philadelphia Gear Defies Gravity, Water and Time
- Emergency Rebuild
for the Power Generation Industry
- Creative Engineering Helps Restore Service to Power Plant
Custom Engineering Produces Cost-Effective Solution
for Coal-Fired Power Plant
- On Land Fix for Offshore Problem Gets Platform Back in Production in Record Time
- Quick Turnaround Time
Helps Plant Save Thousands in Energy Costs
- Reverse Engineering of Mission Critical Gearbox Restores
- Onsite Technical Services
Brings Plant Back Online in 10 Days
- Philadelphia Gear Saves Major Chemical Company Hundreds of Thousands of Dollars with Creative Gearbox Solution
- Complete Drivetrain Repair For a Major North American Steel Mill
- Pump Powertrain Project For a Wastewater Treatment Plant
- The End-to-End Service Provider Powering Hydro
- Philadelphia Gear and Standard Machine Work Together to Help Limestone Plant Extend Critical Kiln Life
- Upgraded Lube System for Gearbox at a Critical Pump Station
Though in service for 30 years, the units never had a complete oil change, which led to a bearing failure and an emergency shutdown. When we received the gearbox, the engineers at our Delaware Service Center conducted several diagnostic operations including magnetic particle inspection (MPI) of all rotating elements, measurement and charting of gear tooth geometry, and calculation of stress levels in the damaged components. They determined the unit could be repaired in 8 weeks for $90,000, compared to $300,000 and 26-30 weeks for a new gearbox. Downtime was a major factor, so the decision was clear.
Major elements of the rebuild included: reworking the quill shaft, new split bushings, re-machining of the housing and the manufacture of new gear sets to AGMA 13 accuracy. Stringent quality assurance procedures were performed and documented. Only then was the unit reassembled, tested and shipped to the customer, along with a final report that included before and after photography and test stand data.
Based on this experience, city government, in conjunction with our engineers, developed and implemented a scheduled overhaul program to ensure the future reliability of their other units.