28/05/2013

Brammer’s gearbox repair service

revives performance and energy efficiency

Brammer is firmly established as the UK’s number one supplier of maintenance, repair and overhaul (MRO) products for the manufacturing sector, with a customer base including major names such as Nissan, Thames Water and Unilever. All of these customers benefit from competitive pricing through the Brammer Group’s extensive buying power, exceptional local service, and a broad range of independent technical expertise.

However an increasing number of companies are taking advantage of Brammer’s extensive range of value-added technical services aimed at helping companies manage the maintenance of their plant-critical assets – an area which if overlooked can result in additional costs and unplanned downtime.

Among those services is an ISO accredited gearbox repair service which enables companies to completely outsource all aspects of repair to a highly trained, dedicated and responsive service team.

Gearboxes are often a key plant asset, integral to the operation of many processes where unplanned downtime can halt production lines, reduce productivity and throw production schedules into disarray, meaning it is critical that repair and maintenance issues can be quickly and efficiently resolved.

Gearboxes require regular inspection to ensure they continue working optimally. They frequently have to operate in arduous conditions, making the early identification of potential faults all the more important. This is where condition monitoring, in particular the use of vibration analysis equipment, comes into its own.

“Accurate condition monitoring identifies a maintenance problem before it can lead to line stoppage, enabling the manufacturer to organise a suitable replacement at the plant’s convenience,” explains Andy Batey, Brammer’s Repair Centre Manager.

“Furthermore, this method of monitoring gearboxes ensures that rather than being replaced after a specified period - which could mean products with useful life still in them are needlessly discarded - they are replaced on a condition basis,.”

As with many industrial components, contamination is often a reason for failure. Oil contamination can result in reduced operating life in rolling element bearings, which can potentially damage other components and ultimately lead to failure of the gear train. Meanwhile, water contamination of gear oil will cause it to break down, affecting the performance of the oil between the teeth of the running gear train and causing increased wear rates. Corrosion-induced fatigue failure is also a possibility if pitting is allowed to occur. “While this is only a small possibility, the threat still remains”, added Andy Batey.

He continued: “Industrial gearboxes generally have a considerable service life and, if they do fail, can usually be repaired or reconditioned. However, their performance and energy efficiency even after reconditioning may make replacement with a more energy-efficient product advisable.

“Each application should therefore be thoroughly examined and a decision made as to whether replacement is the right way forward. Energy savings of up to 20 per cent are achievable over traditional worm boxes by installing either a helical bevel or planetary gearbox, depending on the application.”

The availability of an authorised partner like Brammer for technical support and advice, product supply and repair is delivering major benefits for many companies, who are enjoying more efficient operation and reduced total cost of ownership from the service and advice they are receiving.

As well as advice on product selection and the ability to supply the latest gearboxes for a range of global manufacturers, Brammer has more than 30 years’ experience in gearbox repair.

Andy Batey explains: “Outsourcing the gearbox management and maintenance function is an increasingly popular option. This provides flexibility and an independent source to consult and discuss on whether it is best practice to repair or replace a gearbox, as well as a one-stop-shop for configuring and supplying all gearbox components.

“Brammer caters for practically every gearbox type in industries such as aggregates, chemicals, food and drink, metals, paper and utilities, supplying custom designed solutions for any application including design and installation. Furthermore, a full guarantee is provided for all work undertaken.”

Brammer can supply and repair products from leading global gearbox manufacturers including Flender, Siemens, Renold, Bonfiglioli, Paravalux, SEW, David Brown, Lenze, Nord, Dodge and Brevini.

Andy added: “Gearbox repairs are quality assured, and completed to original manufacturer specification. Spares are used whenever possible, and for obsolete parts Brammer manufactures and reverse engineers replacement components from a vast library of technical drawings.

“All products are quality control inspected, as well as having a complete service log recorded before being dispatched. Each repair carries a comprehensive warranty too. This service is offered nationwide, covering all aspects of gearbox application design and support.”