Executive Summary
A large gear drive on an offshore rig was feeding unreliable position data. The root cause was not the drive or the sensor. Its indexing ring had been installed with a warp, so it was not flat and it ran out of true, which made the position sensor misread. ProdSource Solutions mobilized to the rig by boat, removed and reinstalled the wheel flat and round and dead level, fitted a proper indexing bracket and switch, and verified with a dial indicator that it now runs true. The operator regained accurate, reliable operation without replacing the drive.
The Challenge: Bad Data With No Obvious Cause
The gear drive’s position sensor was giving inconsistent readings, right sometimes and wrong other times. Intermittent faults like that are hard to chase, and the operator was looking at the electronics. The real issue was mechanical, and it was hiding in plain sight.
The Root Cause: A Poor Install, Not a Bad Part
On inspection, the drive and sensor were not the issue. The indexing ring had been installed with a warp, so it was not flat and it ran out of true. Every rotation carried that runout, so the sensor was reading against a surface that never sat flat. The data was only as good as the mounting, and the mounting was off.
The Strategy: Fix the Cause, Out on the Rig
Because the rig was offshore, our team went to it by boat rather than pulling the equipment for a shop repair that would have meant far more downtime. The plan was simple and correct: set the ring and wheel true, give the sensor a proper reference, and prove it.
The Execution: Level, Bracket, Switch, and Proof
We took the wheel off and reinstalled it flat and round and dead level, removing the runout that had caused the faults. We fabricated and fitted a proper indexing bracket and switch so the sensor had a clean, true surface to read.
Then we confirmed the work with a dial indicator, watching the wheel run true through a full rotation.
The Result: Accurate Operation, Restored On-Site
The sensor now reads a wheel that runs true, so the position data is dependable again. The operator avoided both a replacement drive and the far larger cost of pulling the equipment. Just as important, the assembly was corrected at the source, so it is no longer a failure waiting to happen.
Do It Right, In the Field
Most vendors either ship a part or tell you to send the equipment in. For offshore and heavy industrial operations, that is time you do not have. ProdSource Solutions diagnoses and corrects the root cause on-site, and proves the work before we leave.
Contact our team about precision field repair.