The Situation
The operator of a major water treatment works in North Somerset was having major issues with failing gearboxes on their primary tanks. The gearboxes were all 40+ years old and spares were no longer available, with the manufacturer having gone out of business. The units were leaking from their output shaft seals, and risked leaking into the tank – something which would cause real problems for the customer.
The Solution
The HAYLEY DEXIS team worked with the customer to source a modern solution capable of fitting in the confined space occupied by the current unit. A modern helical bevel unit was supplied, with a special fabricated output baseplate and shaft to match the original. All modifications were conducted onsite at HAYLEY DEXIS, meaning very little shutdown time was required for the customer. The electric motor meets the latest IE3 specification – saving energy and lowering costs.
"THE CUSTOMER HAS SINCE ORDERED 10 MORE UNITS FOLLOWING THE SUCCESS OF THIS PROJECT."
The Result
The bearings within the unit have been respecified and fitted to carry larger loads and be more resilient. The unit now also has a larger mechanical service factor where, if required, the motor can easily be changed for a larger unit to increase production. Any component spares needed are now readily available, with HAYLEY DEXIS also stocking replacement units and components across the branch network for next-day delivery. Running costs of the future-proofed, modern unit have reduced considerably, with a far more energy efficient gearbox now in-use. The customer was so satisfied with the outcome of the project, that they have since ordered ten more units to be installed across their water treatment works in the South West of England.