Data Analysis Inputs:

• Analyzed mill-related data, data sheets, system overviews, drawings, photos, FMEA reports, and O & M Manuals.
• Utilized standard task procedures, including alignment, etc.

Condition Monitoring:

• Analyzed MHM analysis reports & history, lube analysis reports, and external condition monitoring reports.
• Incorporated process and condition monitoring data from OSIPI and SAP-PM history.

Failure History Identification:

Identified failure history, including chipped gear tooth, gear & pinion bearing failures, pipe resonance, etc.

Data Normalization:

Normalized 157 parameters spread across separate flat files for efficient analysis.

Data Analysis Approach:

Applied slice and dice techniques while analyzing failures with contextual links to the condition data across all shared reports.

Root Cause Analysis:

• Utilized Cause & Effect Diagram for comprehensive root cause analysis.
• Conducted engineering analysis of gear & pinion failures, considering factors such as vibration, lubrication, misalignment, etc.

Failure Mode Effects & Criticality Analysis (FMECA):

Identified predictor variables and performed FMECA to enhance understanding of failure modes.

Fatigue Propagation Techniques:

Applied fatigue propagation techniques at the system level, considering root cause, sub-system degradation, and failure propagation.

Prediction Model Building:

Built a robust prediction model to predict gearbox failure based on analyzed data.