Main Function
Many Heavy Industries use large Helical and Planetary Gearboxes across certain processes. These gearboxes have many internal bearings and gear stages which wear over time. Australian Designed and Manufactured, Surge Developments Magnetic Czek Plug ( pronounced “Check Plug” ) allows the service technician to perform periodic inspections of metal contaminants in the oil, without changing the oil. This is the key function of this design in that oil removal is not necessary and in some case operation of attached systems can remain functional whilst performing the metal particle inspection. Service technicians can identify premature failure of bearings and gears which is crucial for continuous operation of these assets, while reducing maintenance costs.
Heavy Industry Applications
With the large amount of gearboxes and Oil Sumps in all Industries i.e Mining, Marine, Oil and Gas, Paper and Pulp, Port Crane Solutions, Renewable Energy and many more, it is practical to install one or multiple valves onto any installed gearbox or oil sumps with little to no modifications, using the existing threaded ports that are located externally on various gearbox designs. These can also be installed on the main lubrication oil reservoirs to simplify periodic inspections.
The Solution
Magnetic ‘Czek Plug’ Inspection Points
The Magnetic plug (which is removable) collects medium to large metal particles circulating in the oil to allow the technician to send these particles away for analysis, providing specifics of internal component wear. This allows the operator to schedule in potential repairs or exchanges during shutdown periods prior to major failures, avoiding loss of operation and associated detrimental effects on efficiency and profitability.
Available Sizes:
| Nominal Diameter | Major Diameter (Inch) | Major Diameter (mm) | Minor Diameter Nut (mm) | Tapping Drill Size (mm) | TPI | Pitch (mm) |
|---|---|---|---|---|---|---|
| G 1/16" | 0.304 | 7.722 | 6.843 | 6.561 | 28 | 0.907 |
| G 1/8" | 0.383 | 9.728 | 8.849 | 8.565 | 28 | 0.907 |
| G 1/4" | 0.518 | 13.157 | 11.890 | 11.445 | 19 | 1.337 |
| G 3/8" | 0.656 | 16.662 | 15.395 | 14.950 | 19 | 1.337 |
| G 1/2" | 0.825 | 20.955 | 19.172 | 18.633 | 14 | 1.814 |
| G 5/8" | 0.902 | 22.911 | 21.128 | 20.587 | 14 | 1.814 |
| G 3/4" | 1.041 | 26.441 | 24.658 | 24.120 | 14 | 1.814 |
| G 7/8" | 1.189 | 30.201 | 28.418 | 27.877 | 14 | 1.814 |
| G 1" | 1.309 | 33.249 | 30.931 | 30.292 | 11 | 2.309 |
| G 1 1/8" | 1.492 | 37.897 | 35.579 | 34.939 | 11 | 2.309 |
| G 1 1/4" | 1.650 | 41.910 | 39.592 | 38.953 | 11 | 2.309 |
| G 1 3/8" | 1.745 | 44.323 | 42.005 | 41.365 | 11 | 2.309 |
| G 1 1/2" | 1.892 | 47.803 | 45.845 | 44.846 | 11 | 2.309 |
| G 1 5/8" | 2.082 | 52.883 | 50.566 | 49.926 | 11 | 2.309 |
| G 1 3/4" | 2.116 | 53.746 | 51.428 | 50.788 | 11 | 2.309 |
| G 1 7/8" | 2.244 | 56.999 | 54.681 | 54.041 | 11 | 2.309 |
| G 2" | 2.347 | 59.614 | 57.296 | 56.657 | 11 | 2.309 |
| G 2 1/4" | 2.587 | 65.710 | 62.752 | 63.392 | 11 | 2.309 |
| G 2 1/2" | 2.960 | 75.184 | 73.391 | 72.227 | 11 | 2.309 |
| G 2 3/4" | 3.210 | 81.534 | 78.576 | 79.216 | 11 | 2.309 |
| G 3" | 3.460 | 87.884 | 86.289 | 84.927 | 11 | 2.309 |
FAQs
How does the Magnetic Czek Plug help reduce maintenance costs?
By enabling regular metal particle inspections without the need for oil changes, the Magnetic Czek Plug helps service technicians identify potential issues early on. This allows for scheduled repairs or exchanges during planned shutdown periods, reducing the risk of unexpected failures and associated maintenance costs.
What industries can benefit from using the Magnetic Czek Plug?
The Magnetic Czek Plug can be useful in various heavy industries such as Mining, Marine, Oil and Gas, Paper and Pulp, Port Crane Solutions, Renewable Energy, and many more, as these industries use large gearboxes and oil sumps.
How is the Magnetic Czek Plug installed on gearboxes or oil sumps?
The Magnetic Czek Plug can be installed on existing threaded ports located externally on various gearbox designs or main lubrication oil reservoirs with little to no modifications.
What type of metal particles does the Magnetic Czek Plug collect?
The removable magnetic plug collects medium to large metal particles circulating in the oil. These particles can be sent away for analysis to provide specifics of internal component wear.
How does the Magnetic Czek Plug help in maintaining heavy industry assets?
By allowing technicians to identify potential component wear through metal particle analysis, the Magnetic Czek Plug helps operators schedule repairs or exchanges during shutdown periods before major failures occur. This helps avoid loss of operation and associated negative impacts on efficiency and profitability.