Gearbox Shaft Repair

Complete reconditioning and repair of gearbox input and output shafts for a thermal power plant's coal handling system. The gearbox shafts had undergone severe wear due to prolonged operation without maintenance, resulting in damaged bearing seats and worn keyways.

Our team executed a comprehensive repair plan including bearing seat buildup by metal deposition welding, re-machining to original specifications, keyway restoration, and surface grinding of seal running surfaces.

Work Done:

• Input Shaft Repair: Bearing seat buildup by welding (2 locations), re-machined to k6 fit, keyway recut
• Output Shaft Repair: Damaged thread section cut and re-threaded, bearing journal reground
• Intermediate Shaft: Complete replacement manufacturing as per original drawing
• Testing: Dye penetrant testing for weld integrity, dimensional inspection after machining

Outcome:

The repaired gearbox was reassembled and test run successfully. The plant reported zero issues during commissioning and the gearbox has been operating reliably since the repair, saving the client significant cost compared to replacement.