Gearbox Failure: Early Detection Saves Millions

The early identification of a gearbox failure helped Cal Trevo save USD$ 236.114,64. Check out this success story:

Cal Trevo team uses Dynamox technology to monitor the vibration and temperature of their assets. This continuous monitoring enabled the identification of an abnormality in the gearbox vibration levels.

The equipment showed consistent vibration and minimal changes in RMS acceleration data. Additionally, analysts identified a similar behavior in the motor, but with greater amplitude.

Problem Diagnosis

With the trend data from both components, it was reasonable to assume the defect was in the coupling elements between the motor and the gearbox.

The spectra indicated the presence of vibration at 1x RPM and its harmonics, leading to a diagnosis of looseness.

Gearbox and Motor Failure

The maintenance team carried out a scheduled shutdown and confirmed the presence of looseness in the keyway connecting the motor and the gearbox, which corroborated the vibrational behavior of the assembly.

The team estimated the potential cost of an unplanned equipment shutdown and reduced the cost through planned maintenance. In total, Cal Trevo avoided spending USD$ 223.686,29 by preventing a catastrophic failure through predictive maintenance.

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