ACFM Inspection on Gear Shaft During 24-Hour Shutdown

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