Retrofit

Repair of MERGER reducers - steel industry - mining industry

Looking back at a speed reducer retrofit: industrial overhaul for the steel industry

The interest of preventive maintenance

The sector steel industry is a particularly demanding environment for industrial equipment. Between dust, shocks, vibrations and high temperatures, machines must not only be efficient, but also able to withstand extreme conditions. It is in this context that MERGER, maker but also a revision specialist, drop in et retrofit of industrial reducers, was requested by a customer to carry out a complete overhaul of its reducers. A retrofit on Corbas (69), carried out in 3 weeks, which illustrates the expertise of MERGER in managing complex projects under tight deadlines.

As part of an operation of Preventive maintenance, we had previously visited the customer for a analysis by endoscope, we have thus carried out a pre-spotting parts to keep and parts to change.

retrofit arcelor maintenance

80 years of expertise in installation AND repair of reducers: many brands in heritage

Need maintenance? Check out all our brands:

Brands

AEI (Associated Electric Industries)
ASEA
Baacke Gearbox
BCSA
Benoni Engineering Works
Bonfiglioli
Bostock and Bramley
bour
Brevini Gears
BTH (British Thomson Houston)
Catep
CHANDIOUX
CMD – Citroen Messian Durand
CORDM
DAVID BROWN SANTASALO
Desch
EICKHOFF
ELLI
ERSTEIN Gears
ESENPRO
Falk Gears
Flender Gears
Fleuder
FOC Transmission
GEC Alstom Gears
GUIBE
Hamworthy Transmissions
HANSEN SUMITOMO
Hansen Transmissions
Hygate Transmissions
Jackson Gears
Jahnel Kestermann
John welsh
Kissling
The Stéphanoise
LUFKIN COMELOR
Maag Italy
mergers
Metropolitan Vickers
Metso Drives
Modern Wheel Drive
morisse nayrat
motorized variator
Paramount Gears
PHB – Pohlig Heckel Bleichert
Philadelphia
PIV
Posiva
PUGLIA BROTHERS
Power Plant Gears
PROMEA SGM
Push
Rauma Repola
Sadi Sala
Sauerwald
Sawa
SEGOR
Sonnerdale Richardson
Sumitomo Gears
Thovet
Turbine Gears
Valmet Power Transmissions
Vosgel
WECO
WIKOV
Worm Gears
ZF Gears

Customer context: Anticipating mechanical wear to maintain production

on-site reducer maintenance and analysis

Avoid costly production downtime

The client of mergers operated in the sector of steel industry, a field where machines are constantly exposed to harsh conditions. The omnipresent dust, incessant vibrations, frequent mechanical shocks, as well as very high temperatures, are factors that accelerate the wear of equipment. In such an environment, the reducers must be particularly robust and reliable, but their maintenance is essential for avoid production shutdowns expensive. 

The need: a precise diagnosis and a tailor-made retrofit

Faced with the gradual wear of its reducers IDENTITY mergers, the customer requested a thorough overhaul. The objective was to identify worn or defective parts and replace them, while ensuring that the reducers maintain their performance after the overhaul.
mergers took charge of this project in several stages, using its technical expertise and analytical capacity to offer a solution de retrofit tailored.

On-site visit and endoscopy analysis

Before the intervention, the technicians of mergers carried out an on-site visit. Using a analysis by endoscope, they were able to thoroughly inspect the reducers, identify potentially damaged parts and establish an initial diagnosticThis analysis made it possible to define the elements to be kept and those to be replaced, ensuring a targeted and effective approach.

Complete overhaul at MERGER

- Cleaning and diagnosis in-depth: Each reducer was carefully cleaned, and a complete assessment was carried out to validate the initial diagnosis concerning the shafts and wheels.
- Compliance controls and measures : The housing bores were checked, and measurements were taken on all components to verify their compliance with technical specifications.
- Replacement of defective parts : Parts identified as defective during the analysis were replaced with new, high-quality components in accordance with customer requirements.
- Reassembly and fine adjustments : The reassembly was carried out with particular care, including the replacement of bearings and seals, as well as careful adjustment of the parts using the blueprint range control.
retro fit maintenance factory gear merger
Arcelor merger reducer repair

Trials, tests and finishing

Before being returned to the customer, the reducers have been subjected to a series of rigorous tests. These testing made it possible to verify the proper functioning of each device in real conditions: vibration control, temperature measurement, assessment acoustic and verification of thesealing.
Adding accessories and finishing:
Finally, the reducers were equipped with the accessoiries identified and have undergone careful finishing work, including a protective paint in order to protect them from the harsh conditions of the site. PRODUCTIVITY (steel industry).

Current and Defunct Brands: Retrofit or Drop-in?

MERGER maintains production lines equipped with reducers from disappeared brands for its industrial customers.

Which application is best suited to your needs and for which brands?

General approach

  • Retrofit:

Involves the modification or improvement of an existing system.
Retains all or part of the original components while incorporating technical improvements (e.g. changing gears, reinforcing bearings, adding modern sensors).
Aims to extend the life of the equipment and improve its performance.
Often requires engineering studies and custom adjustments.

  • Drop-in:

Consists of completely replacing a component or system with a new or equivalent model, designed to fit without significant modifications.
Often standardized or plug-and-play, it is ready to be installed directly.
Does not require complex studies or specific modifications to existing equipment.

Cost and complexity

  • Retrofit:

    More complex and often more expensive in initial engineering, because it involves detailed analysis, custom design, and modifications to the existing system.
    Ideal when existing equipment is still in good overall condition or difficult to replace completely.

 

  • Drop-in:

    Typically less expensive in terms of engineering, because the component is designed to be directly compatible.
    The overall cost, however, can be high if the component being replaced is standardized or expensive.

What needs or objectives?

  • Retrofit:

    Allows the existing structure to be maintained while adapting it to new technologies or requirements (e.g. compliance with environmental standards such as ATEX).
    Ideal for modernizing critical or specific equipment that cannot be easily replaced.
    Helps optimize performance and improve energy efficiency or reliability.

 

  • Drop-in:

    Aim for quick and easy replacement.
    Preferred solution when the existing system is irreparable, obsolete or when downtime must be minimal.
    Does not necessarily change overall performance, but ensures continued operation.

For which brand of speed reducers?

AEI (Associated Electric Industries)
ASEA
Baacke Gearbox
BCSA
Benoni Engineering Works
Bonfiglioli
Bostock and Bramley
bour
Brevini Gears
BTH (British Thomson Houston)
Catep
CHANDIOUX
CMD – Citroen Messian Durand
CORDM
DAVID BROWN SANTASALO
Desch
EICKHOFF
ELLI
ERSTEIN Gears
ESENPRO

Falk Gears
Flender Gears
Fleuder
FOC Transmission
GEC Alstom Gears
GUIBE
Hamworthy Transmissions
HANSEN SUMITOMO
Hansen Transmissions
Hygate Transmissions
Jackson Gears
Jahnel Kestermann
John welsh
Kissling
The Stéphanoise
LUFKIN COMELOR

Maag Italy
mergers
Metropolitan Vickers
Metso Drives
Modern Wheel Drive
morisse nayrat
motorized variator
Paramount Gears
PHB – Pohlig Heckel Bleichert
Philadelphia
PIV
Posiva
PUGLIA BROTHERS
Power Plant Gears
PROMEA SGM
Push

Rauma Repola
Sadi Sala
Sauerwald
Sawa
SEGOR
Sonnerdale Richardson
Sumitomo Gears
Thovet
Turbine Gears
Valmet Power Transmissions
Vosgel
WECO
WIKOV
Worm Gears
ZF Gears

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