Oil & gas · fire water pump drive
Case Studies
Real-world engineering solutions for critical gearbox applications across industries.
Petrochemical & refinery · nitrogen compressor drive
Rebuilt a surge-damaged nitrogen compressor gearbox to API 613 5th Edition, restoring casing integrity and internals after a sudden shutdown seven years into service.
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Petrochemical & refinery · gas turbine generator drive
Traced a cracked tooth on a 54 MW gas turbine generator gearbox to grinding burn during finishing, supplying case-carburised internals validated by roll scan testing.
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Petrochemical & refinery · gas turbine load gearbox
Repaired a 35 MW gas turbine load gearbox in situ after catastrophic idler shaft failure, sparing the customer the OEM's 24-month replacement lead time.
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Petrochemical & refinery · high-speed planetary drive
Designed a complete new gear set for a failed high-speed planetary gearbox when the damaged parts left nothing to reverse-engineer, restoring plant operation within 20 weeks.
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Power generation · gas turbine generator drive
Ended repeated pinion tooth failures on a 54 MW gas turbine generator gearbox by re-engineering the helix to an X-shape for uniform heat dissipation.
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Power generation · steam turbine generator drive
Replaced an under-specified turbine generator gearbox with a redesigned 1.4 service factor unit in 18 weeks, ending gear failures caused by grid transient loads.
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Power generation · steam turbine planetary drive
Traced recurring planetary gearbox failures to blocked pin bearing lubrication, supplying new sun and planet gears with enlarged oil supply within 18 weeks.
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Power generation · booster pump drive
Eliminated premature gear failures in a booster pump gearbox by redesigning axial float and casing dowelling to absorb thermal growth and balance helix loading.
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Chemicals & fertilisers · compressor drive
Ended two-monthly bearing failures on a 6.7 MW compressor gearbox by enlarging bearings and correcting alignment, cutting specific load from 34 to 27 kg/cm2 in 20 weeks.
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Chemicals & fertilisers · compressor drive
Rebuilt an integrally geared air compressor gearbox after bull gear fractures shut a fertiliser plant down, supplying case-hardened gears and serviceable tilting pad bearings.
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Power generation · steam turbine generator drive
Diagnosed repeated turbine generator trips at a Kenyan captive plant as coupling-induced axial loading, resolving it with a flexible coupling in 12 weeks.
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Steel · steam turbine generator drive
Replaced the split-type gear wheel in a 42 MW turbine generator gearbox with a single-piece design, ending helix slippage and one-sided loading in 18 weeks.
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Chemicals & fertilisers · compressor drive
Upgraded a fertiliser compressor gearbox to tri-metal pin bearings and balanced planet assemblies after a local repair failed within six months.
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Chemicals & fertilisers · blower drive
Reverse-engineered complete blower gearbox internals including the Hirth interface, delivering in roughly half the OEM lead time after fatigue failure.
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Cement · steam turbine generator drive
Traced severe shaft vibration on a 25 MW turbine gearbox to coupling compression rather than pre-stretch, correcting it by removing 2.8 mm of shim.
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Cement · steam turbine generator drive
Redesigned turbine generator gear internals around island-mode transient loads, ending pitting failures the OEM's own replacement gear set had repeated.
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Sugar & distillery · steam turbine generator drive
Replaced misalignment-sensitive offset bearings with pressure dam bearings on a 26.9 MW sugar mill turbine gearbox, ending high-speed bearing failures.
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Power generation · steam turbine generator drive
Cured commissioning vibration of 24.6 mm/sec on a biomass turbine gearbox with a corrected gear set and reamed coupling bolts, achieving over 90% contact in 16 weeks.
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Power generation · hydro turbine gearbox