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Girth gear crack repair

Success story of the successful Girth gear crack repair

  • This case study deals with a Girth gear crack repair, (Gear with almost 36 cracks), using special welding alloys and process which requires total stoppage of the plant.
  • In order to overcome this situation, plants normally have spare gears in place. But the exorbitant cost of the Girth gear as well as the long lead time of the OEM, compels the management to look for alternative solution at an affordable cost.
  • Repair welding of the cracks, can contribute lots of savings to the industry, as the repair welding would cost only 15 to 20% of the cost of Girth gear. This is ensured by selection of suitable welding alloys and adopting the right procedure for the repair.

 

Mechanical

Properties

Base Material

Weld Material

Tensile Strength N/mm2

690 – 830

670 – 750

Yield Strength N/mm

490

410

Elongation %

21

40 – 45

  • The challenge in the reclamation of the crack is avoiding distortion and maintaining the teeth profile, which was achieved by the special techniques used and the low heat input nature of the alloys selected. The alloy with excellent elongation adapts easily to the thermal expansion difference and stresses.

Key benefits due to successful Girth gear crack repair :

  • Above case study addresses the concern of top management about reclamation of key spares rather then buying new. This approach is economical and technically superior for the society.
  • The solution in terms of repair and reclamation aware society to adapt better metallurgical upgrades and innovative processes to improve the availability of the plant and machinery.
  • Overall, this thereby reduces the downtime losses and operational costs resulting into absolute improvement of the bottom line for the organization.