Global-PAM’s Engineer Team offers:
Specializes in asset management (ISO 55000) of large-scale power transmission equipment for heavy industry such as mineral processing, cement, and pulp/paper.
We are experts in the engineering, design, manufacture, installation, inspection, and maintenance of power transmissions and structural components for mills, kilns, driers, and crushers.
We conduct annual inspections and risk assessments
for all types of equipment:
Gears, and Grinding
- Bull Gears
- IsaMill and HIGmill Fine Grinding/Stirred Milling Equipment Specialists
- Pump, Crusher, Conveyor, Screen, Scrubber maintenance alignment, condition monitoring
Mobile Equipment
- Shovels
- Drills
- Draglines
- Haul Trucks
- Mobile Equipment
- Lifting Devices
Pipes and Turbines
- Power Turbines
- Tailings Pipes
- Plant Piping
- Pipelines
Advanced NDT Services
- Phase Array Ultrasonics (CSWIP & PCN)
- Eddy Current Array
Annual Bull Gear Inspection Deliverables
- We provide a complete non-destructive examination of the integrity of the mill gear teeth using Eddy Current Array for macro-pitting and cracking and Phased Array UT to map out crack propagation. We analysis the data as we scan the teeth. Data is not reviewed offsite.
- We can clean and inspect a bull gear set in under 10 hours, saving valuable downtime and increasing production revenue.
- Our onsite risk assessment model, as per AGMA 1010 F-14, can provide a comparative measurement of loss probability and consequence. Our extensive database of gear teeth failure modes enables us to provide root cause analysis effectively.
- The final electronic report provides a concise insight for the maintenance team and insurance industry on the level of exposure being presented by any operation relating to girth gear teeth.
- If cracking is detected, we provide remedial repair (excavation) services to slow down or eliminate the crack propagation. The extends the PF curve on affected teeth.
IsaMill and HIGmill Fine Grinding/Stirred Milling Equipment
- We provide a complete Mechanical Mill Inspection of all MIG and UFG grinding applications.
- We provide full installation and commissioning support throughout all stages of the equipment.
- We provide Maintenance and Operational training for All grinding applications
- We provide continuous improvement solutions to allow for improved operations of the fine grinding circuit.
Full Millwright Services and Consultation
- Process Plant/ Underground.
- Pump, Crusher, Conveyor, Screen, Scrubber maintenance Alignment, condition monitoring.
- Preventative maintenance shift and shutdown work.
Advanced NDT Services
Global technicians are experts in advanced non-destructive testing services. Our specialties are Phase Array Ultrasonics (CSWIP & PCN) and Eddy Current Array. We used the most advanced technology to save the asset owner time and money. We are well experienced in lifting device inspections and certification.
Reverse Engineering
We can create “manufacture ready” drawings from our 3D scanning that can be used to obtain various quotes for engineered components. These can be quickly adapted for variations of concepts. The asset owner keeps the drawings.
Types of failures we check for:
Tooth Fracture
- Wear
- Severe Abrasion
- Scuffing
- Indentation
Plastic deformation
- Cold Flow
- Tip-to-Root Interference
- Tight Mesh
Hertzian fatigue
- Severe Progressive Macropitting
- Spalling
Cracking
- Hardening Cracks
- Grinding Damage
- Rim Cracks
- Bending Fatigue Cracks
- Low Cycle Fatigue Cracks
- High Cycle Bending Fatigue Cracks
Case Study
Tooth cracking observation from monthly follow up inspections on a 34′ X 20′ SAG Mill
Signs that you may need an inspection
5 Common Classes of Girth Gear Potential Failure Modes
Common questions
What are the risks of tooth fracture?
- Broken segment wraps around and goes through mesh, the mill or kiln may jump the foundation. This can damage the footing, foundation, trunnion bearings or rollers, the cost of lost production and repairs can easily exceed $50M in mineral processing circuits.
- Load is now concentrated in a smaller area increasing stress resulting in complete tooth loss and loss of torque transmission.
- Load sharing with surrounding teeth decreases resulting in additional fractured teeth and loss of torque transmission.
- Vibrations increase causing damage to the bearing elements.
- Mill head bolts break distorting and damaging the mill shell? which can cause slurry ingres into the gear set.
Do I need annual inspections?
Is the gearing part of a single circuit where failure would bring the line or plant down resulting in lost production. Or is it part of a redundant circuit where failure would cause minimal lost production as material can be processed through the other circuit?
What is the operating schedule of the gearing 24/7, 8 hours a day or once a week? This will help determine the impact of a functional failure
What is the age of the equipment in operating hours, gearing does demonstrate an increase in failure rate with age?
What is the overall condition of the gearing, good, fair, serious, or critical?
