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Holcim Guayaquil – Equateur

In-factory repair of a shafted pinion with a broken tooth

Following the discovery of a broken tooth (at 50%) on the cement mill pinion, the Ecuadorian cement manufacturer decided to limit the risks by opting for on-site repair of a pinion in stock that was also cracked. Holcim chose Novexa for repair, in consideration of our expertise and commitments as a guarantee of success.

Replacing the shafted pinion with a new one was an option but with a longer delay of 26 weeks. No risks could be taken, given that the installed pinion as well as the pinion in stock where both concerned by a broken tooth. Novexa provided sustainable repair solutions on the pinion and on the spur girth gear, helicoid and herringbone gears.

Replacing the shafted pinion with a new one was an option but with a longer delay of 26 weeks. No risks could be taken, given that the installed pinion as well as the pinion in stock where both concerned by a broken tooth. Novexa provided sustainable repair solutions on the pinion and on the spur girth gear, helicoid and herringbone gears.

Holcim à découvert une fissure sur le pignon d'entrainement du broyeur Meulage à la fraise carbure et contrôle pénétrant révélateur ( à 50°C ) Quand toutes les phases préliminaires sont validées , le rechargement peut démarrer Après reprofilage Novexa, la tolérance est de 0,1mm max pour les profils , pas et planéité Reconstruction de la dent à 40% Reconstruction de la dent à 90% Le reprofilage Novexa assure une tolérance inférieure à 0,08mm même sur denture hélice Après réparation complète, le pignon est comparable à un neuf Vue générale de la zone cassée après réparation
Holcim à découvert une fissure sur le pignon d'entrainement du broyeur
Meulage à la fraise carbure et contrôle pénétrant révélateur ( à 50°C )
Quand toutes les phases préliminaires sont validées , le rechargement peut démarrer
Après reprofilage Novexa, la tolérance est de 0,1mm max pour les profils , pas et planéité
Reconstruction de la dent à 40%
Reconstruction de la dent à 90%
Le reprofilage Novexa assure une tolérance inférieure à 0,08mm même sur denture hélice
Après réparation complète, le pignon est comparable à un neuf
Vue générale de la zone cassée après réparation

Problems before intervention

  • The installed pinion had a little wear but a broken tooth on over 50% of its surface
  • Profil deformation girth gear 0.3 mm max
  • Provision of a new pinion requires more than 26 weeks
  • Risk of production downtime in case of breakage of the installed pinion and degradation of the girth gear

Novexa Intervention

Novexa proposed an alternative to replacement with a reloading and reconditioning of the pinion:

  • On-site machining of profiles guaranteed to 0.1mm
  • A short intervention time of 3 days
  • Controlled reloading procedure followed by an Ultrasound control

Holcim Guayaquil therefore has pinion in stock, available for immediate replacement of the broken pinion on the mill. The risks are reduced and production continuity is ensured.

Advantages for our client

  • 6 -month delivery time avoided
  • 0,1 mm tolerance for on-site machining (profile, pitches and flatness)
  • 12 -month guaranty, with application of Perma rods
  • Ensuring more reliable production and limitation of risks

Novexa’s offer

Experts in rotative equipment wear management (gears and tires)

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