M/s.KAY ARR ENGINEERING SERVICES is a specialized gearbox repair company. As an independent repair company, we overhaul all gearboxes and related drive types. We are active in high-demand market segments (marine, industry, wind), where our customers expect the fastest response in order to minimize downtime costs. We therefore offer gearbox support for 24 hours a day. We work in continuous shifts 7 days a week, always providing our customers the fastest gearbox repair.

when a service request for a gearbox arrives the procedure below is followed. This can be done either on site or in our workshops.

Step 1

Onsite inspection and dismantling of the gearbox

An engineer from M/S.KAY ARR ENGINEERING SERVICES Engineer visits the site of the customer and determines the condition of the gearbox, bearing settings, gear clearance and gearing size and cracks examination. M/S.KAY ARR ENGINEERING Services informs the customers about the estimated scope and cost of the project.

Step 2

Fast transport to our workshop

The damaged parts of the gearbox will be transported by  truck (depending on customer's location and wishes). Our workshop is fully equipped with the most modern equipment and innovative tools to offer our customers the fastest gearbox repair. Instead of sending the parts to Rotterdam, we can also send an engineer to the customer's site to draw or copy the parts*.

Step 3

Disassembly of the gearbox, inspection report and failure analysis

In our workshop the gearbox will be carefully dismantled. Our service department has a wide range of specialized tools in order to determine the condition of the gearbox. An inspection report and damage analysis will be performed and send to the customer together with a quotation and full repair advice.

Step 4

Fast gearbox repair & manufacturing of the supplies

The gearbox will be overhauled in our workshop and the spare parts will be manufactured or purchased. Our extensive facilities enables us to offer our customers complete gearbox services, for example:

• vertical and horizontal turning; (CNC) boring and milling; grinding and slotting of keyways; laser cladding of shafts;
• vibration measurements; condition monitoring;
• Hardened gearwheel manufacturing with class approval.

Step 5

Gearbox assembly and advanced test run

The gearbox with new parts is assembled. Bearing and gear clearance are adjusted and contact patterns are recorded. We can grind the gears in our gear-cutting department, if, due to circumstances, the gear clearance or contact patterns are not in accordance with the specifications. This will result in the gearbox being within the specifications. Once the gearbox has been assembled correctly, it will be tested for 4 hours on our test bed.

Step 6

Transportation & onsite assembly of the gearbox and related parts

All results will be contained within our report, which will be handed over to the client complete with all documents (including any certificates) after the overhaul. The gearbox and related parts will be assembled on board.

Gearbox maintenance - lubrication & vibration analysis

M/s.KAY ARR ENGINEERING SERVICES is well known for her short delivery times and quality of her gearbox repair services. Besides gearbox repair, equally important is discovering the root cause of the gearbox failure in order to avoid unplanned machine downtime in the future. To pinpoint equipment failure we perform oil analysis, vibration measurements and thorough visual inspection, for instance examination of abrasive wear patterns and gear tooth pitting.

Root Cause Failure Analysis
Identifying causes of gearbox failure is a crucial step in preventing future equipment problems. To determine failure root cause we perform both oil analysis and vibration analysis combined with visual inspections. These diagnostic techniques are usually required to monitor the condition of plant machinery and to control the causes of machine failure.

Gearbox lubrication - oil analysis

Proper lubrication is extremely important for the lifetime and condition of the gearbox. In many cases, gear and bearing problems result from contaminated or insufficient oil. Oil filter contamination could cause bearing failure and gear tooth damage. Sometimes insufficient lubrication causes metal-to-metal contact with abrasive wear as a result.

Oil analysis provides important information on wear modes and possible gearbox lubrication problems. On the other hand, visual inspections of wear patterns and gear tooth pitting can reveal lubrication problems e.g. oil leakage or improper lubricants.

Vibration analysis
In addition to oil analysis, vibration analysis is an effective technique for monitoring the condition of the gears and bearings and determing the root cause of machine failure. With our CSI portable spectrum analyzer and vibration measurements detecting various sorts of gearbox problems:

• gear damage (e.g. scoring, abrasive wear)
• bearing defects (cage fractures, inner/outer ring damage)
• alignment errors
• looseness
• imbalance
• resonance areas