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Location:
Kleinsteinbach/Germany
Sector:
Sewage treatment plant technology
Application:
Screw pump drive
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Location: Kleinsteinbach/Germany
Sector: Sewage treatment plant technology
Application: Screw pump drive
The inspection involved using a flexible video-endoscope to assess the condition of the gearing components and bearings in the installed gear unit without dismantling any of the drive technology.
The diagnostic report prompted the operator to replace the existing gear unit (manufactured by a third-party) with a three-stage X.e series helical gear unit. The industrial gear unit from SEW-EURODRIVE was supplied as part of a complete package including an energy-efficient motor, motor adapter with torsionally flexible claw coupling and a pin coupling for attaching it to the worm shaft.
Retrofit – servicing a screw pump drive
Retrofit is an offer within our Life Cycle Services.
The Kleinsteinbach sewage treatment plant operated by the Mittleres Pfinztal and Bocksbachtal Sewage Board reliably removes solids, fecal matter and all kinds of organic compounds from the community's wastewater on a daily basis. With the capacity to serve 32 000 inhabitants, it is one of Germany's medium-sized sewage treatment plants.
In November 2014, the operator of the sewage treatment plant decided to arrange a preventive diagnostic check of its drive technology to ensure continued system availability. We used a flexible video endoscope to assess the condition of gearing components and bearings. The gear unit does not need to be disassembled for this purpose. The endoscope probe is introduced into the gear unit through small openings and the high-resolution camera provides razor-sharp images of the interior. A visual inspection of the bearings and gear teeth, combined with video footage of the tooth flanks, ultimately enables a conclusion to be drawn about the condition of the drives. Signs of damage such as micro-pitting, pitting and fretting can be identified at an early stage and appropriate measures decided on.
We offer further analysis options as part of a "Quick Check", during which one of our specialists records and assesses condition-related variables such as the overall condition of the exterior, running noise, oil level/quality etc. This is a quick and reliable way of obtaining important information about the drive technology's condition – the basis for optimizing in-house maintenance.
Based on the overall condition of the gearing components and the state of the gear unit lubricant, recommendations can be made for the drives inspected. The gear unit of the screw pump on the interim lift system already exhibited significant signs of wear. The gear and pinion of the output stage in particular had large pitted areas, which could develop into larger flank ruptures and ultimately result in the total failure of the drive unit. Further drives with only minimal damage, such as the ones on the intake pumping station and the scraper, were classified as not critical.
In addition to retrofits for existing drive technology, we offer other services to help operators of sewage treatment plants prevent unscheduled stoppages. From inspection and maintenance to repair, everything is provided from a single source – for our own equipment and also products of other manufacturers. The sample-based production of spare parts (gearing components, shafts etc.) and the reconditioning of existing gear unit housings round off the service portfolio for industrial gear units. Customers using our maintenance service benefit from a 24-month warranty that also applies to third-party components. In addition, our tight-knit network of service centers and technical offices ensures customers are supported throughout the entire operational phase.
The findings ultimately prompted the user to replace the existing gearbox (from another manufacturer) with an industrial gearbox from us. The original bevel spur gearbox with belt drive was replaced with a three-stage spur gearbox. The connection to our DRN energy-efficient motor was achieved using a motor adapter with an integrated, torsionally flexible jaw-type coupling. The connection to the worm shaft was realized using a pin coupling, which compensates for oscillations and drive shocks through its elastomer elements. The reverse acceleration caused by the backflow of water during the switch-off of the motor is additionally absorbed by a backstop on the gear unit. With a gear ratio of 36, the rated output torque of the X-series gear unit is 8,500 Nm. This standalone industrial gearbox platform is available as a spur gear and bevel spur gear unit. With a wide range of optional equipment and options, as well as the ability to make customer-specific adaptations, it is ideally suited to meet the requirements of the water and wastewater management sectors.