CAss of Gear Boxes
Condition Assessment (CAss) of Gear Boxes includes Visual Inspection, Vibration Analysis, Vibration Assessment, Vibration Probing Study, Ultrasound Assessment, Thermography, Gear Oil Analysis, etc. Vibration Analysis is an expensive Condition Monitoring tool hence it is only suggested for CM of Gearboxes. Since CM of other equipment/ machines can be carried out by other less expensive and easier CM tools while VA being a crucial CM tool for Gearboxes is always suggested to be carried out.
Visual Inspection includes inspecting the ambient conditions – moisture (humidity)/dust/gases, operating conditions – load, number of startings, Oil Leakages, etc.
Vibration Analysis is carried out to inspect the condition of Gears (actually Gear Mesh) for backlashes, teeth Wear & Tear, Gear alignment etc and to monitor the condition of bearings. For this, it is necessary to have data/ details of Gears & Bearings in Gearbox, viz. Gears – Number of teeth in each gear, Bearings- Inner/Outer Diameter of Bearing & Number of Rolling Elements in Bearing. In the absence of this data, vibration analysis of the Gearbox is not at all possible.
Vibration Probing Study is done to learn about the condition of the rigidness of foundation, deformation in base rail, fastening of Gear Box with base rail, bent shaft condition, piping strain (if motor driving pump) & soft foot conditions.
Vibration Assessment, Thermography, Ultrasound Assessment is done to learn the condition of bearings, Misalignment, Bearing Housing, etc.
Ultrasound Assessment is carried out to learn about backlashes & broken teeth of gears.
Gear Oil Analysis/ Gear Lubricant Analysis is done to know the condition of oil. The list of Oil/Lubricant Analysis Tests is suggested, viz. Viscosity Testing, Ferrous Density Testing, Water Contamination in Oil, Oxidation, TAN – Total Acid Number is a titration method designed to indicate the relative acidity in a lubricant, Particle Count testing usually according to ISO 4406 and SAE 4059, Ferrous Particle Count Testing, Wear Debris Analysis, Elemental Spectroscopy, etc.
