Gearbox Selection, Maintenance and Troubleshooting

Background & About the Course:

Gearbox Selection, Maintenance and Troubleshooting is crucial process for ensuring optimal performance in mechanical power transmission systems across various industries, including manufacturing, energy, mining, and transportation. Gearboxes are vital components that power machinery, and their reliability significantly affects operational efficiency and productivity. However, selecting the appropriate gearbox, maintaining it effectively, and diagnosing issues can be challenging. Inadequate selection, poor maintenance, or delayed troubleshooting can lead to operational disruptions, equipment failures, and costly downtime.

This training course is designed to equip participants with the necessary knowledge and skills to address these challenges. By integrating theoretical knowledge with practical hands-on experience, the course covers essential principles of gearbox selection, preventive maintenance strategies, and advanced troubleshooting techniques. Participants will learn how to optimize gearbox performance, extend its service life, and swiftly address issues to minimize downtime, thereby enhancing overall reliability and operational efficiency.

Course Objectives:

• Understand the standards for setting up a gearbox plan.
• Perform gearbox recalculation and planning.
• Classify and analyse gears.
• Conduct gearbox maintenance.
• Apply measurement techniques and conduct gearbox testing.
• Analyse gearbox failures.

Who Should Attend:

• Maintenance, Operator, Mechanical Technicians
• Engineers/Superintendents/Supervisors
• Rotating Engineers/Superintendents/Supervisors
• Power Plant Engineers/Superintendents/Supervisors

Course Content:

1. Introduction:
   • Application of Gear Systems
   • Gear Classification
   • Gear Nomenclature
   • Power Train
   • Gear Standards
   • Unit Systems
2. Gear Analysis:
   • Power Train
   • Stress and Deflection
   • Strength/Allowable Stress
   • Fatigue
   • Gear Design Life
3. Gear Design:
   • Spur & Helix Gear
   • Gearbox
   • Spur& Helic Gear Design
4. Measurement and Testing:
   • Principles of Measurement
   • Geometry Measurement
   • Vibration Measurement
   • Noise Measurement
   • Gear System Efficiency
   • Gear Testing
5. Maintenance and Lubrication:
   • Maintainability and Maintenance
   • Maintenance in Product Life Cycle
   • Life Cycle Cost
   • Importance of Maintenance
   • Maintenance Categories
   • Gear Maintenance
   • Lubrication
   • Gear Lubrication
   • Power Losses in Gear
   • Types of Gear Lubrication
   • Lubrication for Loaded Gear
   • Influence of Gear Lubrication on Surface Distress
6. Gear Failure:
   • Failure Classification
   • Wear
   • Surface Fatigue
   • Plastic Flow
   • Breakage
   • Hertz Contact

About the Trainer:

Cecep Slamet Abadi, ST., M.T,

Cecep Slamet Abadi, ST., M.T, is an associate instructor at FJM with a background in Mechanical Engineering for both undergraduate and graduate levels. Active as a lecturer since 1996, he also has extensive experience in industry and consultancy, including roles at LAPI ITB, Puslitbang Air, PINDAD, and energy audits at Pertamina EP Pangkalan Susu, Tambung, and Rengasdengklok. He is also part of the competency testing team at IATKI (Ikatan Ahli Ketenagalistrikan Indonesia). For industrial training, Mr. Cecep has conducted over 150 in-house and public training sessions for organizations such as Indonesia Power, PLTA Saguling, Freeport-Papua, Chevron Oil/Gas, Chevron Geothermal, Premier Oil, Pupuk Sriwijaya, Pupuk Kujang, Badak LNG, and others.