Success Stories

December 2014

HORSBURGH & SCOTT RETURNED SUGAR MILL TO PROFITABILITY BY PROVIDING A NEW MAIN MILL PLANETARY GEARBOX IN 4 WEEKS

Horsburgh & Scott (H&S) was contacted by a sugar mill in Central America due to a catastrophic failure on a competitor's gearbox that was driving one of their main mills. The failure threatened to reduce their profits by over 10% for the 2014/2015 grinding season. H&S was able to provide the customer with a new, 1000 HP planetary gearbox, delivered and operating within 4 weeks of order placement and the mill was returned to profitability.

November 2014

HORSBURGH & SCOTT AWARDED $1.95M ORDER FROM LARGE SUGAR MILL FOR UPGRADE OF MAIN MILL AND HIGH SPEED GEARBOX

The customer needed a drop-in replacement with a 2.0 service factor upgrade for seven of their large DRB mill drives. The competition was not able to provide the required power in the same design space and within time constraints. With their in-house capability, Horsburgh & Scott engineered and developed the upgraded gearboxes using an induction hardened, low-speed gear and included two-part housing for easier assembly, service and inspection.

The customer now enjoys improved mill productivity and reliability, while enabling easier and more thorough inspection capability.

October 2014

HORSBURGH & SCOTT GETS LARGE TECHNOLOGY STEEL PROCESSING PLANT BACK IN OPERATION AFTER CRITICAL GEARBOX FAILURE

Horsburgh & Scott received a production line down, emergency call from a large technology steel processing plant. Horsburgh & Scott inspected and identified a catastrophic failure of a broken shaft in a critical gearbox drive in their metal processing plant.

Horsburgh & Scott engineered a unique, cost saving solution by saw cutting the shaft near the gear. They machined out the gear bore, supplied a new shaft, key fit into the existing gear, and then attached a new bearing, seal and the original coupling. This critical rush job took only 19 days from initial call for support to analysis, engineering, development and repair. Horsburgh & Scott is now able to support other plants within the same company across the USA.

Horsburgh & Scott received an email from the customer after the repair was complete. "I want to thank you and your team. Even though this could have been a real show stopper, you and your team stayed on top of it. You executed the plan in a detailed and precise manner. Please forward my thanks to all of your team and others involved."

September 2014

HORSBURGH & SCOTT AWARDED $1.2M ORDER FROM A WESTERN MINING LEADER FOR SAG MILL REPLACEMENT GEAR

The mining company needed someone they could trust with manufacturing a precision, 40 ft. diameter gear for a large CAPEX project. They had planned and called an incumbent parts supplier. Even though the gear was for a competitor's gearbox drive, they requested a quote from Horsburgh & Scott, a brand they could trust with such a large job. The process of analyzing, engineering and quoting required multiple visits to the mining site.

Horsburgh & Scott reverse engineered and manufactured a like-and-kind, drop-in 40 ft. steel fabrication, a recommended design improvement from the original incumbent casting design. The customer now enjoys improved confidence with a stronger, more reliable SAG mill replacement gear. The customer has indicated that Horsburgh & Scott is now their direct supplier of choice for open gearing and gearbox drives.

September 2014

HORSBURGH & SCOTT REPAIRED PLANETARY DRIVE FAILURE AT LARGE POWER UTILITY COMPANY

Horsburgh & Scott identified an input worm gear pinion and worm gear that were out of alignment during operation. Horsburgh & Scott's Field Service Team performed a tear down of the input pinion to identify the root cause of failure. They determined the root cause was the bearing orientation allowing for shaft movement. They installed new bearings in the original arrangement to provide proper bearing alignment, eliminating radial and axial movement. Horsburgh & Scott also provided cross training, and consideration of a spare unit is under review for future repair.

July 2014

HORSBURGH & SCOTT WINS BOF ORDER FROM THE LARGEST INTEGRATED STEEL PLANT IN MEXICO

Steel plant staff were searching for a proven supplier to repair, engineer and manufacture components for a spare BOF unit for a critical CAPEX project. After the customer researched gearing companies including touring Horsburgh & Scott's repair and manufacturing facilities in Cleveland, they awarded H&S the order. The customer felt Horsburgh & Scott had a distinct advantage with large / heavy gear and gearbox experience, in-house heat treat carburizing, proven product quality, and all around complex project capability.

July 2014

HORSBURGH & SCOTT SHIPS FIRST WIND GEARBOX TO KOREA AND BECOMES THE ONLY AMERICAN OWNED GEAR MANUFACTURER TO BUILD OEM WIND TURBINE GEARBOXES

A large alternative energy company asked Horsburgh & Scott (H&S) to manufacture an advanced wind turbine gearbox. The company develops wind parks and manufactures wind turbines. It offers 750KW, 2.0MW, and 2.3MW wind turbines that convert wind energy into electricity using kinetic energy.

The 2.0MW gearbox H&S manufactures is one of the most advanced wind turbine gearboxes in the world. It has been engineered and manufactured to exacting tolerances. It is a dry sump gearbox with full pressure lubrication and includes the use of engineered surface treatments on gears and bearings to increase efficiency and improve wear resistance over the operating temperature range. The gearboxes are assembled at H&S in Cleveland and are made of components manufactured in the USA and from global partners. With the award of this order, H&S has become the only American owned gear manufacturer to build OEM wind turbine gearboxes.

June 2014

HORSBURGH & SCOTT RECEIVES FRAC PUMP GEARING ORDER FROM LARGE OIL & GAS DRILLING COMPANY AND SIGNED LONG TERM AGREEMENT

This leading frac pump manufacturer was experiencing a strong peak in demand, straining the existing supplier's lead time, forecast accuracy, quality and inventory management. Horsburgh & Scott rapidly produced and qualified product samples using customer dimensional drawings and improved design recommendations. Horsburgh & Scott developed and is achieving goals of a comprehensive supply chain including: improved lead time, on-time-delivery and Vendor Managed Inventory (VMI). Horsburgh & Scott is now their primary supplier.

May 2014

HORSBURGH & SCOTT DIAGNOSED AND REPAIRED CRACKED HOUSING OF LARGE STEEL MILL

Horsburgh & Scott (H&S) received a call from large steel mill with journal bearings burning up on their mill back up roles.

The H&S Sentry® team collected vibration data and developed a dynamic model while simultaneously monitoring the problematic unit and a good unit with analog sensor for oil pressure. They found that the impact of the slab entering the mill caused a problem with the screw down assembly. After further inspection they found a cracked housing on the primary pinion stand. It was also discovered that the situation was compounded by in-house maintenance personnel having previously reduced the oil pressure because of leaks. This caused instability of the roll neck in the journal bearing and it could not stay in position. H&S repaired the cracked housing, corrected the oil pressure, and the steel mill is now up and running without issue.

February 2014

HORSBURGH & SCOTT MANUFACTURED NEW BULL GEAR TO REPAIR LARGE GEARBOX FOR STEEL FASTENER DIVISION

After analysis and tear down, Horsburgh & Scott identified a large bull gear with custom pinion that had excessive wear in one location of gear mesh. Shock load requirement in conjunction with gear accessory called for frequent maintenance and downtime. Horsburgh & Scott manufactured a new bull gear with the ability to rotate the outer gear ring without having to remove the assembly off of the shaft. Horsburgh & Scott plans to incorporate the improved design in more than 20 machines in the plant.

August 2013

HORSBURGH & SCOTT DIAGNOSED AND REPAIRED VIBRATION ISSUE WITH LARGE MINING COMPANY SMELTER FAN

Horsburgh & Scott (H&S) received a call from a large mining company in Canada due to a large fan in their smelter exhibiting bad vibration and periodic shut downs. The mine’s staff engineers had been studying and analyzing the problem, but were struggling to determine the root cause. H&S sent in their Sentry® condition monitoring team to analyze the problem.

The Sentry® team hooked-up sensors to the in-house PI system and added two instruments to the fan output including a pedo tube and a magnahelic sensor, then loaded the fan. They could see discharge duct velocity in the gas stream went down, while the static pressure was going up, and the vibration was peaking at the same time. This correlated to the fan vibration causing it to stall. They opened the duct work for inspection and found a main intersection was 40% blocked. The blockage was removed and the fan has been operating correctly.

January 2012

HORSBURGH & SCOTT USES SENTRY® TECHNOLOGY TO DIAGNOSE LARGE MINING COMPANY CRANE MALFUNCTION AND REPAIR IN 24 HOURS

A large mining company contacted Horsburgh & Scott (H&S) due to a chattering noise coming from their 90 ft. crane. Their concern was if the crane failed, it would shut down the entire smelter, costing thousands of dollars per minute.

H&S immediately sent out their Sentry® field service team to analyze, determine and validate a root cause and provide a recommendation. After using their Sentry® condition monitoring system, H&S determined the root cause included bearing brinelling, a bent drive shaft, a pinion fit incorrectly to the motor, and an additional bearing not seated properly.

H&S, in a joint effort with mining company personnel, repaired the problems and the mine was up and running, error and noise free in 24 hours.

September 2010

HORSBURGH & SCOTT REPAIRED LARGE MINING COMPANY PULVERIZER WHICH HAS BEEN RUNNING FLAWLESSLY NOW FOR 4 YEARS

A large mining company in Canada had a critical pulverizer suddenly shut down. A neighboring company suggested they call Horsburgh & Scott (H&S) for emergency evaluation and repair. Every day the pulverizer was not up and running, three transportation trains sat idle, costing millions of dollars per day.

H&S was called in and performed a Sentry® system modeling evaluation and found the following causes of failure:

  • A nearby furnace had the heat shield permanently removed, making the pulverizer run at higher than allowed operating temperatures.
  • The company had a pinion alignment maintenance procedure in place involving the use of shims. The shims actually aggravated the pinion mis-alignment.
  • The pulverizer foundation was not stable. The customer thought they cured this issue years ago by encapsulating the entire foundation to repair damages, but Sentry® system sensors showed ¾” gap between the foundation and mating surfaces. The original intended capsulation fix did not work.
  • Anchor bolts could not be tightened, because of the deteriorating foundation.
  • All the system's instrumentation was not providing accurate monitoring.

Over the course of a 12 day outage, H&S repaired the foundation and pulverizer which has since been running flawlessly for four years.

November 2009

HORSBURGH & SCOTT SAVES IRON ORE MINING COMPANY THOUSANDS BY CORRECTLY DIAGNOSING MILL VIBRATION CAUSE WITH SENTRY® TECHNOLOGY AND REPAIRING

An iron ore mining company called Horsburgh & Scott (H&S) because they had severe vibration of a mill drive and were concerned that it would shut down the mill if not addressed. H&S rushed to the scene where the mining company management provided their root cause hypothesis. H&S then offered a dynamic modeling health assessment before spending money for repairs and the company agreed to Horsburgh and Scott's secondary assessment.

H&S Sentry® dynamic modeling uncovered the real root causes, which were different than the customer suspected. The health assessment determined the sole plat, concrete base and mounting under the drive were deteriorating. H&S performed the repairs, while optimizing gearing design and performance. H&S saved the mining company tens of thousands of dollars, relative to the money they were about to spend on a hypothetical cause.

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