NEW - DROP IN - Predictive Maintenance
Custom-designed reducer for agitator: Drop-in and predictive monitoring
Design of a smart reducer for real-time monitoring
Agitator for a phosphate producer in Senegal
A major player in the heavy chemical industry, Industries Chimiques du Sénégal (ICS) is facing the challenge of renewing strategic components in its phosphate production line . Merger was therefore approached for a project to optimize an industrial agitator powered by a Hansen gearbox dating from 1981. Due to the site's extreme ambient temperatures and the constraints of the new process, the old equipment was experiencing repeated failures.
The operator needed to secure the agitation process in the tank (the gearbox driving a large vertical shaft equipped with blades) and eliminate any risk of unplanned line stoppages. In phosphate agitators in desert environments, the gearboxes are subjected to mechanical and environmental stresses that can be described as "extreme" because they combine the heavy load of rock processing with the harsh climate. The operator therefore called upon MERGER 's expertise , leveraging the brand's local presence to benefit from an on-site analysis and a customized proposal including the manufacture of a new, special gearbox and monitoring.
From constraints to tailor-made technical and IT solutions
Custom drop-in design
The intervention at a remote industrial site presented specific technical requirements. The 1981 gearbox had to be replaced without altering the upper frame or the structure of the mixing tank. One of the project's unique aspects was the implementation of a comprehensive monitoring system for the mechanical equipment and digital tools to better analyze the line's load increases . MERGER's proposed solution involved using sensors to remotely monitor all fluid- related data (oil and water temperature and pressure). These sensors monitor in real time and generate alerts in case of malfunctions to ensure there are no unexpected shutdowns, particularly of the oil pump.
Reliability and alerts for oil or water level
MERGER worked across the project with the aim of avoiding the lubrication defects and damage (particularly that related to oil pump failures). Oil is an essential component in all mechanical gear transmissions. The speed reducer has need for clean and abundant oil to achieve optimal meshing. The gearbox's lifespan is therefore strongly linked to the proper maintenance of the lubrication system during operation. pressure sensors allow us to confirm proper functioning.
In high-temperature environments, water cooling is a key factor in enabling the mechanical transmission to maintain an acceptable temperature level. Sensors allow for validation of a maintaining the cooling systems in good condition.
Remote predictive maintenance
Having real -time monitoring of fluids and components allows for continuous control of the production line's operation. The original horizontally positioned gearbox suffered from unlubricated areas. 24/7 monitoring allows for tracking machine parameters. This improves diagnostics and enables the early detection of early warning signs of production problems.
Features of the MERGER special reducer
MERGER designed and manufactured a parallel-gear reducer ( 3 gear trains ) arranged horizontally, type UNIPA 695-3 SPECIAL, with a total mass of 10 tons. This system reduces the speed from 1,440 rpm to 32,5 rpm ( reduction ratio of 45). A height stop has been integrated to simplify maintenance and future dismantling. The size of the stop is a key design element: it allows the machine to withstand load changes during loading.
An equipment-integrated monitoring system
Requiring nearly 100 hours of specialized assembly, the solution incorporates an advanced instrumentation system including fluid and temperature monitoring, oil flow sensors, pressure sensors, oil temperature sensors, and gearbox bearing temperature sensors. Design was performed by our in-house engineering department , and assembly validation was conducted by the IFM team.
Sensors and counters installed
– Fluid and temperature control: oil flow, pressure, oil temperature and gearbox bearing temperature sensors.
– Oil quality analysis: Particle counter and moisture sensor to prevent premature wear.
Note that all data is transmitted remotely to personalized dashboards updated in real time, accessible via ICS and MERGER. Alert thresholds (min/max) automatically trigger an email warning to the technical teams, allowing for proactive predictive maintenance.
How to secure an industrial installation remotely?
Whether you operate a chemical unit , a processing site or heavy process equipment , we offer you the know-how and experience of our teams to modernize your mechanical transmissions and avoid unplanned shutdowns.
Like this project, we strive to meet the operational and economic needs of manufacturers in France and around the world :
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Obsolescence management and customized retrofitting ( drop-in ): Many French industrial sites operate older machines (from the 1980s or earlier) whose original components are no longer manufactured. We focus on replacing the gearbox without modifying the infrastructure (chassis, tank, piping, etc.) to avoid civil engineering work and minimize any potential production downtime.
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Shifting towards Industry 4.0 and predictive maintenance: As with the special gearbox designed for an agitator , the integration of connected sensors (flow rate, pressure, temperature, particle counting, humidity) via a platform like IFM Moneo enables a shift from reactive to predictive maintenance . For industrial site operators, this means the near elimination of unplanned shutdowns and interventions scheduled only when metrics indicate that alert thresholds have been reached or exceeded.
To achieve this, we support you at every stage: from the initial site survey to the configuration of the alerts once the equipment is delivered. MERGER can manage the entire project if you prefer a single point of contact.
From on-site analysis to IoT monitoring, the steps of our service
On-site audit and definition of specifications
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Our sales engineers travel to the site: taking measurements, studying the mechanical environment and analyzing installation constraints.
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Data collection and verification: analysis of existing plans, identification of pairs, speeds and points of vigilance.
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Field validation: second confirmation visit on site to validate compliance with the specifications before launch.
Engineering and conceptual improvement
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Custom design ( Drop-in ): 3D study of the reducer for an exact replacement in place of the existing equipment.
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Maintainability optimization: integration of specific features (e.g., height-adjustable dismantling stops) to facilitate future interventions.
Manufacturing and integration of sensors in the workshop
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Machining and assembly: manufacturing of the reducer in our workshops according to industrial robustness requirements.
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Setting up the monitoring solution: installation of the sensor unit (flow, pressure, temperature, humidity and oil particle counter).
Setting up alerts and delivery
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Threshold configuration: programming of dashboards and definition of automatic alerts (sending direct emails in case of anomaly).
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Commissioning and transfer: delivery, on-site installation and provision of remote monitoring access.
PICTURE GALLERY
