Equipment Condition Assessment for Gearboxes

We conduct gearbox assessments in two phases: external assessment (non-intrusive) and internal assessment (where justified by findings or planned outage access). External assessment includes vibration measurement with spectral analysis focused on gear mesh frequencies and bearing defect frequencies, temperature measurement and thermal imaging, external leak and seal condition evaluation, oil analysis review (spectrometric metals, ferrography, viscosity, moisture, particle count), and backlash measurement where external access permits. Internal assessment (when performed) includes gear tooth surface condition grading per ANSI/AGMA 1010 with photographic documentation, contact pattern evaluation using marking compound, bearing condition assessment (raceway inspection, cage condition, clearance measurement), seal condition from internal side, housing bore measurement for bearing fit verification, and shaft inspection at seal and bearing locations. Oil system components (pump, filter, cooler) are assessed for condition and capacity adequacy. Each gearbox receives a condition grade per component (gears, bearings, seals, housing, oil system) with remaining useful life estimation based on wear progression rate, and prioritized recommendations with cost estimates for monitoring, repair, or replacement actions.