Gearbox Routine CM & PM Options
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| Failure Mode Group | Symptom Group | Strat | Action | Op | Frequency | PFi | Eff | Cost | Skill |
|---|---|---|---|---|---|---|---|---|---|
| Brg/gear fatigue/wear | Brg Temperature | PdM | Bearing casing temperatures higher speed shafts | Op | 2 Months | P | P | L | CM |
| Brg/gear fatigue/wear | Brg Temperature | PdM | Bearing casing temperatures lower speed shafts | Op | 2 Months | P | P | L | CM |
| Brg/gear fatigue/wear | Brg Temperature | PdM | Casing Thermal Image (from all available directions) | Op | 2 Months | P | P | M | CM |
| Brg/gear fatigue/wear | Visual | PdM | Check build-up or debris around input or output shaft | Any | 1 Month | G | P | L | F, Op |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Removable magnetic Chip collector–Quant. analysis | Any | 1 month | Ex | Ex | L | LT, CM |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Online magnetic debris sensor – simple alarm | Any | Ex | Ex | M | LT, CMT | |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Online magnetic debris sensor – quantitative monitoring | Op | Ex | Ex | H | LT, CMT | |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Automatic Ferro-graphic analysis - Laboratory | Op | 1 month | G | G | M | LT |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Removable magnetic Chip collectors – Visual analysis | Any | 1 month | G | G | L | LT, CM |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Oil sampling & lab analysis including PQ | Op | 1 Month | G | G | M | LT |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Patch testing with microscope analysis – Laboratory | Op | 1 Month | G | Ex | M | LT |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Patch testing microscope & XRF spectro analysis – Lab | Op | 1 Month | G | Ex | H | LT |
| Brg/gear fatigue/wear | Lube Wear Debris | PdM | Drain plug magnetic chip collector – Visual analysis | Any | 1 month | P | P | L | LT, CM |
| Brg/gear fatigue/wear | High Friction | PdM | Motor current for no operating load condition | IS | 1 week | OK | OK | M | Op |
| Brg/gear fatigue/wear | High Friction | PdM | Motor current for known operating load | IS | Online | P | P | M | Op |
| Brg/gear fatigue/wear | HS Gear/Brg Prob | PdM | Vibration analysis (VA) high speed shafts (data collector) | Op | 1 Month | Ex | Ex | M | CMT |
| Brg/gear fatigue/wear | HS Gear/Brg Prob | PdM | Online VA high speed shafts | Op | Ex | Ex | X | Op, CMT | |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | VA - demodulated vibration all bearing points (DC) | Op | 1 Month | G | OK | H | CMT |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | Online VA demodulated vibration (including low speed) | Op | G | OK | X | CMT | |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | VA – Time domain analysis all bearing points (DC) | Op | 2 Months | G | G | H | CMT3 |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | Time synchronous averaging TSA time domain (cyclic) | Op | 2 Months | G | G | X | CMT3 |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | Online Time synchronous averaging TSA time domain | Op | G | G | X | CMT3 | |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | Time synchronous averaging TSA (taco input required) | Op | 2 Months | G | G | X | CMT3 |
| Brg/gear fatigue/wear | LS Gear/Brg Prob | PdM | Listening rod (or equivalent) audible noise analysis | Op | 1 month | OK | P | L | L,CM,Op |
| Brg/gear fatigue/wear | Lube Condition | PM | Change oil including flushing out bottom sludge | Isol | 2 years | G | M | F, L, LT | |
| Brg/gear fatigue/wear | Lube Condition | PM | Change out 50% of oil volume | Isol | 2 years | G | L | F, L, LT | |
| Brg/gear fatigue/wear | Lube Condition | PdM | On-site oil mini-lab (oil condition, cleanliness, PQ, etc) | Op | 1 Month | Ex | Ex | H | LT |
| Brg/gear fatigue/wear | Lube Condition | PdM | Oil sampling with lab lube condition assessment | Op | 6 Months | Ex | Ex | M | LT |
| Brg/gear fatigue/wear | Lube Condition | PdM | Portable FTIR monitoring (lube condition) | Any | 1 year | Ex | G | H | LT |
| Brg/gear fatigue/wear | Lube Condition | PdM | Portable oil dialelectric testing (lube condition) | Any | 1 year | G | OK | M | LT |
| Brg/gear fatigue/wear | Lube Condition | PdM | Oil sample on change out with lab oil analysis | Isol | 2 years | P | P | L | F, L, LT |
| Brg/gear fatigue/wear | Lube Contam. | PM | Oil filtration with mobile filter cart | Any | 2 Months | Ex | H | LT | |
| Brg/gear fatigue/wear | Lube Contam. | PM | Strip, inspect and replace seals | Isol | 10 years | P | X | FG | |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Check breather desiccant colour change. Change if req. | Any | 1 Month | Ex | G | L | F |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Patch testing on-site- comparison chart ISO cleanliness | Op | 1 Month | Ex | Ex | L | LT, CMT |
| Brg/gear fatigue/wear | Lube Contam. | PdM | On-site portable sensor ISO cleanliness analysis system | Op | 1 Month | Ex | Ex | L | LT, CMT |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Online particle counting cleanliness analysis system | Op | Ex | Ex | H | LT, CMT | |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Oil sampling with lab particle count-ISO cleanliness code | Op | 2 Months | Ex | G | M | LT |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Test input & output shaft seals (pressure test) | OS | 1 year | G | OK | L | CMT |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Bottom Oil sampling with visual analysis | Any | 2 years | OK | G | L | LT |
| Brg/gear fatigue/wear | Lube Contam. | PdM | Lowest point drain sight glass (Water check) | Any | 1 Month | OK | OK | L | F, Op |
| Brg/gear fatigue/wear | Lube Temp | PdM | Oil Temperature or equivalent (eg. lower casing temp) | Op | 1Month | F, Op | |||
| Brg/gear fatigue/wear | Lube Temp | PdM | Oil Temperature - Online | Op | Op | ||||
| Brg/gear fatigue/wear | Poor Condition | PM | Remove, strip, inspect, NDT gears and replace seals | Isol | 10 years | G | X | FG | |
| Brg/gear fatigue/wear | Poor Condition | PM | Strip, inspect, NDT gears, replace bearing & seals | Isol | 10 years | G | X | FG | |
| Brg/gear fatigue/wear | Poor Condition | PM | Replace with a new gearbox | Isol | 10 years | G | X | FG | |
| Brg/gear seizure | Lube Level | PdM | Oil level check & filtered top up if required | Op | 1 Month | Ex | G | L | F, Op |
| Brg/gear seizure | Lube Level | PdM | Check for visual indications of oil leaks | Op | 1 Month | G | G | L | F, Op |
| Coupling failure | ? | PdM | Coupling checks (depending on coupling type) | Isol | 1 Year | ? | ? | ? | F |
| Coupling Inefficiency | Coupling Temp | PdM | Non-contact temperature of input coupling | Op | 2 Month | Ex | Ex | L | CM |
| Coupling Inefficiency | Coupling Temp | PdM | Non-contact temperature of output coupling | Op | 2 Month | Ex | OK | L | CM |
| Coupling Inefficiency | Coupling Temp | PdM | Thermal Image of input & output coupling | Op | 2 Month | Ex | OK | M | CM |
| Worm wheel wear | Worm Backlash | PdM | Measure worm backlash angle | Isol | 1 year | Ex | G | L | FG |
