Repair

Repair

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24 hour support and fast gearbox repairs

Gearboxes are used in high-demand market segments (Marine, Industry, Power), where our clients expect a rapid response to minimize downtime costs. That’s why we offer worldwide gearbox support 24 hours a day, always providing our customers the fastest gearbox repair.

We are not tied to any single manufacturer, which means that we can develop customized solutions that are the most effective and efficient for our clients. We are the one-stop-shop for your gearbox repair. We combine over 50 years of experience with modern manufacturing facilities and an extensive inventory to deliver fast and impeccable service.

Our gearbox repair procedure

We are able to deliver high quality gearbox repair services through our standardized repair procedure. The first step is to establish the condition of the gearbox with gear clearances, contact patterns and bearing settings, all being carefully recorded before the gearbox is dismantled. After the investigation is complete, the best available option will be discussed with the client; a standard overhaul or a complete gearbox repair. 

Every service request and repair follows our standardized procedure ensuring an absolute minimum loss of downtime and maximum level of efficiency. This can be done either on site or in our workshops. Below a typical hands-on example of our procedure:

 

Gearbox repair procedure 1
 
Step 1: 24h support for emergency gearbox breakdown
An offshore supply vessel suffers from severe onboard gearbox damage. The delivery time for a new, OEM-built gearbox is 11 months. The customer contacts Stork Gears & Services for emergency gearbox repair. 
Gearbox Repair procedure 2
 
Step 2: On-site inspection and dismantling of the gearbox
An Engineer from Stork Gears & Services visits the site of the customer and determines the condition of the gearbox. He checks relevant operational data such as bearing settings, clearances, contact patterns and gathers manufacturing info such as dimensions and materials, and also performs a crack examination. Stork Gears & Services informs the customer about the estimated scope and costs of the project.
Gearbox repair procedure 3
 
Step 3: Fast transport to our workshop
The damaged parts of the gearbox will be transported by plane, ship or truck (depending on the customer's location and wishes). Our workshop is fully equipped with the modern equipment and innovative tools to offer our customers the fastest gearbox repair worldwide. Instead of sending the parts to Rotterdam, an engineer can also travel to the customer's site to perform a reverse-engineering action to duplicate the parts*.
Gearbox Repair procedure 4 Step 4: 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 to determine the condition of the gearbox. An inspection report and damage analysis will be performed and sent to the customer together with a quotation and full repair advice.
Gearbox Repair procedure 5 Step 5: 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 in-house facilities enable us to offer our customers complete gearbox services, for example:
  • vertical and horizontal turning; (CNC) boring and milling; grinding and slotting of key ways; laser cladding of shafts; 
  • vibration measurements; condition monitoring;
  • hardened gearwheel manufacturing with class approval (Lloyd's Register of Shipping, Rina, Germanische Lloyd's, Det Norske Veritas (DNV), The American Bureau of Shipping, ...).
Gearbox Repair procedure 6 Step 6: Gearbox assembly and advanced test run
The gearbox with new parts is assembled. Bearing, gear clearance and contact patterns are carefully adjusted to guarantee optimum performance of the unit. We perform in-house optimization calculations which outcome is grinded directly into the gears in our own gear-cutting department, optimizing gear efficiency while decreasing wear-, noise- and vibration levels.
Gearbox Repair procedure 7 Step 7: Transportation & onsite assembly of the gearbox and related parts
All results will be comprised 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. The ship will be able to set sail again after just six weeks!

* Reverse Engineering

If in some cases the client does not have the technical data of the gearbox to be overhauled. We therefore use reverse engineering to duplicate and improve the existing parts to be replaced. This means that these new parts comply with the specifications of the original parts. A delivery time of one day is guaranteed for a simple gears and three weeks for carbonized or nitrated internal works.

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