Expert assessment and refurbishment of Flender gear units for a company in the energy sector

Striving to produce environmentally clean electricity and heat. Striving to ensure energy security – major overhaul of the power plant coal handling conveyor gear unit.

Industry	Project length
Power plants	2 weeks

Key issues

The FLENDER gear unit required a comprehensive overhaul due to advanced wear on key components.

The expert assessment showed the following:

Wear on bearings and seals, requiring their replacement.
Worn off input shaft at the place where the sealant works.
Damage to the output sleeve at the clamping point of the clamping ring.
Significant contamination of the gear unit with used oil, indicating the need for cleaning and oil change.
Incidence of corrosion on gear elements, although without cracks or mechanical damage.
Soiling of exterior body and minor corrosion marks requiring refinishing of the paint coating.

These problems affected the safety and efficiency of the gear unit and created a risk of failure if service action was not taken.

Customer expectations

The Customer wanted a comprehensive solution to ensure the reliability and long-term operation of the gear unit, which included:

Precise technical expert assessment with documentation of gear unit condition.
Development of a renovation plan taking into account all elements requiring repair or replacement.
Replacement of worn parts and restoration of full functionality of the device.
Conduct of movement tests to confirm the efficiency of the gear unit before it is used again.
Provision of a guarantee for the works carried out and parts supplied.

Solution

STERNET, in accordance with Flender’s manufacturer guidelines, carried out the renovation in several stages:

Expert assessment

Gear unit disassembly and initial external cleaning.
Technical assessment of individual components (bearings, seals, seats, gear elements) and measurements of key parameters.
Photographic documentation and preparation of a report describing wear and tear and overhaul recommendations.

Renovation

Replacement of all gear unit bearings and seals.
Renovation of the input shaft by moving the seal and replacing the output sleeve (except for one component replaced with the customer’s consent for the period of waiting for a replacement part).
Cleaning, lubrication and pouring new oil according to standards.
Alignment and control of gear mesh in order to ensure optimum operation.
Conduct of tests at idle gear for 2 hours, which confirmed lack of abnormalities, a stable operating temperature and no leaks.

Additional work

Renovation of the paint coating and anti-corrosion protection of elements.
Labelling, preparation of boards.
Supervising the assembly of the gear unit on site, including alignment of the system and installation of the coupling.

Remont kapitalny przekładni przenośnika nawęglania elektrowni

Remont przekładni dla firmy z branży energetyki

Summary

Thanks to a comprehensive overhaul, the Flender gear unit has been restored to full working order. The service process included a detailed expert assessment, replacement of key components and testing to confirm the reliability of the device. STERNET met all of the Customer’s expectations by delivering a device ready for further operation, while maintaining the highest quality standards and compliance with the manufacturer’s guidelines.

A 12-month warranty was provided for the work carried out and parts replaced, with the Customer enjoying technical support and full confidence in the performance of the gear unit.

Expert assessment and refurbishment of Flender gear units for a company in the energy sector

Key issues

Customer expectations

Solution

Summary

See also

Optimisation of geared motor drives

Using a Digital Twin in the Modernisation of the Warehouse of a Pharmaceutical Company

Selection of drives for machines at the Waste Disposal Plant