ACFM Inspection on Gear Shaft During 24-Hour Shutdown Service Line

Overview

Gecric Integrity carried out an Alternating Current Field Measurement (ACFM) inspection on a critical gear shaft at a mining operation during a scheduled 24-hour shutdown. The objective was to detect surface-breaking defects and assess the integrity of the shaft within a limited timeframe to support safe and efficient restart of operations.

Planning

Pre-shutdown engagement with client maintenance and engineering teams
Identification of critical inspection zones on the gear shaft
Selection of ACFM technology for rapid, high-sensitivity crack detection without surface coating removal
Development of a detailed execution schedule to fit within the 24-hour shutdown window
Mobilization of certified NDT personnel and specialized ACFM equipment

Execution

Surface preparation (minimal, as required for ACFM application)
Deployment of ACFM probes across designated inspection areas
Real-time detection and sizing of surface-breaking cracks
Immediate data interpretation and validation by certified technicians
Continuous coordination with client teams to optimize shutdown time

Operational Challenge

Strict 24-hour shutdown window with no allowance for delays
Critical nature of the gear shaft to plant operations
Need for accurate defect detection without extensive surface preparation
High-pressure environment requiring rapid decision-making

Outcome

Completed full inspection within the 24-hour shutdown period
Successfully identified and characterized surface defects
Enabled informed maintenance decisions prior to restart
Prevented potential equipment failure and unplanned downtime
Supported safe and timely resumption of mining operations