Overhaul of a steering gear HPU
Full recovery of the hydraulic power unit driving the rudder, with pump replacement and contamination brought back within specification.
Read the case studyParts manufacturing · Industrial
Transmission shaft manufactured by reverse engineering
Manufacture of a transmission shaft for discontinued equipment, worked up from the fractured component with no manufacturer drawing available.
Execution
The sequence applied and the engineering decisions taken
The order below reproduces how the work was actually carried out, including the points where the condition found required a change of scope.
- Full dimensional survey of both fractured halves, including bearing seats, keyways and shoulders.
- Analysis of the fracture zone to identify the root cause, which pointed to stress concentration at an undersized fillet radius.
- Specification of a material with better fatigue performance and definition of the matching heat treatment.
- Detail drawing produced with the fillet radius corrected at the critical section.
- Rough machining, heat treatment and finish machining with in-process dimensional control.
- Final inspection with the critical dimensions and geometric tolerances on record.
- Installation on the equipment with dial indicator alignment and supervised start-up.
Comparison
Condition before and after the intervention
Drag the slider to switch between the two recorded conditions.
- Before
- Equipment stopped by a fractured shaft, with no replacement available from the manufacturer.
- After
- New shaft manufactured with revised material and geometry, equipment back in service.
Result
What the intervention delivered
The equipment was back in service in nine days, against an estimate of more than sixty days by the import route. Correcting the fillet radius at the critical section removed the stress raiser that had caused the fracture.
9
days to return to service
−85%
lead time against importing
1
root cause corrected in the design
Photographic record
Job gallery
The photographic record forms part of the technical report handed to the client and feeds the equipment history.
Portfolio
Other completed projects
Full overhaul of a mooring winch
Complete overhaul of a mooring winch with drum recovery, hydraulic drive overhaul and load testing.
Read the case studyRecovery of a cargo pump losing efficiency
Internal clearances recovered and wear rings manufactured, with the duty curve restored and proven on the test bench.
Read the case studyTechnical support
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