preventive maintenance and repair

MERGER Gearbox Repair - Steel and Mining Industry

A look back at an industrial overhaul of several speed reducers used in the steel and mining industries.

The interest of preventive maintenance

The sector steel industry is a particularly demanding environment for industrial equipment. Between dust, shocks, vibrations and high temperatures, the continuous stripping lines, rolling cold, from recruit continuous and coating lines must not only be reliable, 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 an overhaul and repair of three reducers. Operations of reparation on Corbas (69), conducted in 3 weeks thanks to precise preparation and determination of the maintenance operations necessary carried out in advance with the customer on its production site.

Discover these operations below Preventive maintenance, and how we previously carried out the visit to the customer for a analysis by endoscope, And a pre-spotting parts to keep and parts to change.

retrofit arcelor maintenance

Customer context: Anticipate mechanical wear to avoid production line shutdowns

on-site reducer maintenance and analysis

Avoid costly production downtime

The client of mergers operates in the sector of steel industry, an area where the mechanical reducers and speed variators are constantly exposed to harsh conditions: The omnipresent dust, vibrations of different frequencies, repeated mechanical shocks on the driven rollers, as well as very significant temperature variations, are factors that accelerate the wear of the equipment. In such an environment, the reducers used for rolling mills, conveyors, roller tables must be particularly robust and reliable. Therefore, their maintenance and preventive maintenance are essential for avoid production shutdowns expensive. 

The need: a precise diagnosis on each reducer and a tailor-made revision

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 (housings, gears, shafts, bearings, seals) and to replace them as needed, to ensure that the reducers retain their original performance after the restoration.
mergers took charge of this project in several stages, using its technical expertise and analytical capacity to offer a solution de Preventive maintenance 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 precisely inspect the interior of the speed reducers, determine the wear level of each of the parts, identify the potentially damaged mechanical elements to establish an initial diagnosticThis analysis made it possible to define the elements to be kept and those to be replaced, ensuring a targeted approach, mechanically and financially efficient.

I would like a technical visit

Complete overhaul at MERGER

Once the repair needs have been determined on the customer site, here are the revision steps in our workshops.
- Cleaning : Each reducer was thoroughly cleaned with a high-pressure cleaner and an ultrasonic machine. Aided by the mechanical effect (high pressure, vibration and hot water) and the chemical effect (specific solvent for reducer oils and greases), all parts were cleaned. The outer casing and then each of the shafts, covers, gears and wheels. This thorough cleaning was essential for a complete assessment. It was also useful to subsequently facilitate perfect reassembly and adjustment.
– In-depth diagnosis: A visual expertise was carried out to validate the initial diagnosis. Each gear, shaft pinion, smooth shafts, keyed-grooved shafts and wheels were carefully observed. The teeth are the subject of particular attention. Each of the observations is noted and photographed during the expertise. They will then feed into the final expert report given to the client.
- Compliance controls and measures : The crankcase bores were checked, and dimensional measurements were taken on all mechanical components to verify their compliance with the original technical specifications.
- Replacement of defective parts : The parts identified as defective during the analysis were replaced with new MERGER certified components. The bearings were replaced with premium brands such as SKF, FAG INA, TIMKEN, NSK. The seals were also systematically replaced as for all our revisions..
- Reassembly and adjustments : The reassembly was carried out respecting the functional clearances. A careful adjustment of the gears, teeth and shafts was carried out in particular using the blue range control.
retro fit maintenance factory gear merger
Arcelor merger reducer repair

Trials, tests and finishing

Before being returned to the customer, the reducers were subjected to a series of 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 finishing work, including a exterior paint specific to protect them against the harsh conditions of the site. production de steel industry.
I need a revision

What other operations can merger perform for your reducers?

MERGER maintains production lines equipped with reducers of all sizes, types, brands and eras for its industrial customers.

We also carry out Retro-fit or Drop-in operations on MERGER reducers and reducers from other brands.

What other operation, besides repair, is best suited to your needs?

Repair, but also Retro-Fit and Drop-IN

RETROFIT

Retrofitting involves modifying or improving an existing system. It retains all or part of the original components while integrating technical improvements (e.g. changing gears, reinforcing bearings, adding modern sensors). Aimed at extending the life of the equipment and improving its performance, it often requires engineering studies and custom adjustments.  

DROP IN

Drop-in involves completely replacing a component or system with a new or equivalent model, designed to fit without major modifications. Often standardized or plug-and-play, it is ready to be installed directly. It 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 not 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.

80 years of expertise in installation AND repair of reducers, we work on many brands 

Examples of reducer brands for which we work

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

Falk Gears
Flender Gears
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
Motovario
Paramount Gears
PHB – Pohlig Heckel Bleichert
Philadelphia
PIV
Posiva
PUGLIA BROTHERS
Power Plant Gears
Push

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

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