CASE STUDY
A unique solution reduces
downtime at a busy
petrochemical plant
A unique, in-situ bearing maintenance programme, devised by David Brown Santasalo (then David
Brown), enabled vital work to be performed while keeping disruption of production at a busy
petrochemical plant to a minimum.
The plant’s high speed gas turbine sets, fitted with main speed reduction units and other associated
equipment, were housed inside an acoustic compartment making routine maintenance difficult.
With operational hours on some of the generator sets approaching the point where main speed
reduction idler bearings were due for service, it was important to find the right solution and the
right service partner to reduce downtime
Continued...
Global Gearing.
Local Support.
CASE STUDY
David Brown Santasalo came up with a unique procedure to raise the lid of the acoustic compartment
rather than use the traditional dismantling solution. This made the maintenance less expensive to perform
and even more importantly, the shorter downtime meant the cost to the customer in terms of lost
production was significantly reduced.
In brief, the procedure involves inserting four high tensile screwed bars into the M20 jacking holes in the
gearbox lid and gradually raising the cover, little by little at each corner ensuring that the cover remains
level at all times.
At an appropriate height, support tubes are positioned between the joints by removing each of the four
corner bars in turn and refitting them through the tubes. Additional safety measures are then taken and in
the space now available the idler gear can be supported by a sling and the cartridge removed to allow the
bearing change to be effected.
Health and safety considerations were paramount and the diligence shown by David Brown Santasalo was
matched by exceptional technical proficiency. The work carried out by the David Brown Santasalo team to
develop the procedure is now paying off and the in-situ bearing change method is being applied to all the
customer’s service contracts.
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