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KNEADER – GAP 2

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KNEADER GEARBOX FAILURE REPORT

PROBLEM DEFINITION:

GAP 2 Kneader Gear Box Failure resulted due to followings:

1. Lube low ow came Kneader sto!!ed as !er interloc".

2. Lubrication unit started in Local and c#ec"ed Found normal.

$. %#en #ig# &ibration came and Kneader sto!!ed for 'ns!ection and found t#e following !arts

damaged.

a. 'n!ut (#aft Pinion and Gear

b. 'ntermediate (#aft Pinion and Gear

c. 'ntermediate Bearing

EFFECT OF PRODUCTION:

1. )ue to failure of Kneader Gearbox t#e Production loss

2. %otal #ours of around 2*+ #rs was ta"en for executing Kneader ,ob.

2

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3

)ate A-%''%/ )0

3.+2.+$ to+4.+2.+$

Kneader of GAP 2 #ad a &er5 6ig# ibration on +3.+2.2+1$ around 2.++ a.m Kneader was sto!!ed

and c#ec"ed. 't was found 'n!ut s#aft Gear intermediate Gear and Pinion got damaged and'ntermediate ) bearing also damaged.

 %#e 'n!ut s#aft Gear intermediate Gear and Pinion along wit# t#e ) Bearing 7$22 -$ ) Bearing22$22 8P 214 9 -$ at ) of 'n!ut (#aft -#anged.

After -#anging Kneader was started on +4.+2.1$ o load %#eir Abnormal rubbing sound wasobser&ed.

Kneader was run at 2$ t!# for 2 s#ifts and found t#e sound was on increasing and we sto! t#e

"neader for c#ec"ing.

13.+2.1$

9es# between 'ntermediate Pinion and $rd stage Gear; mes#ing was one sided. < 13.+2.1$

Gearbox %o! co&er was !ut bac" to increase t#e r!m and c#ec" for abnormal sound 't was found t#atabnormal sound is still on 1+ r!m

 %#e 'ntermediate !inion mes#ing gear of $ rd stage (liding !inion side gear; found damaged.

Gear Box to! co&er 9otor 'n!ut (#aft assembl5 was remo&ed for furt#er c#ec"ing 0il also drainedout.

17.+2.1$

'ntermediate (#aft Assembl5 and its Gear remo&ed.

Kneader slinger #ousing bus# bolts remo&ed

1=.+2.1$

Gear Box Base bolts remo&ed and s#ifted towards t#e dri&e Gearbox cleaning done

Kneader /o"e assembl5 (linger (linger 6ousing and Gimble Pin were remo&ed.

14.+2.1$

Gimble assembl5 was ta"en outside from t#e Gearbox and t#en sliding !inion along wit# t#e bearingsalso remo&ed.

 %#e front bus# >ear bus# >emo&ed 0ld Bearing at (liding Pinion bearing being remo&ed.

Sequence of Acton T!"en

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4

)ate A-%''%/ )0

1*.+2.1$

ew Bearings at bot# t#e ends are installed at t#e sliding !inion and w#ole assembl5

was installed in t#e Gearbox. Gimble assembl5 was also !ut in t#e Gearbox. <1*.+2.1$ da5

nig#t (linger wit# 6ousing front bus# 5o"e assembl5 was ?tted bac"@ Gear Box wass#ifted to its original !lace.

2+.+2.1$

Gearbox installed at its !osition and bolts were tig#tened. Gimble Pin was ?tted atbot# t#e ends

'ntermediate Bus# %o! Pillow bloc" was remo&ed and bolts of 'ntermediate Bus# also

remo&ed.

21.+2.+$

After remo&ing t#e 'ntermediate Bus# Pillow bloc" t#e bus# was rotated at 14+ deg.But clearance not c#anged at to! and at one side it was ero. (o Bottom !illow bloc"bolts were remo&ed and adusted to get t#e clearance at to! and bot# sides. <21.+2.1$

 %#e Gear at (liding Pinion (ide was -#anged 'ntermediate Assembl5 installed 'n!ut(#aft Assembl5 also ?tted Front bus# (linger 6ousing Bolt to! #alf #as beentig#tened. < 21.+2.1$ da5

Kneader 9otor cou!led wit# Gearbox %ermination also done.

22.+2.+$

Bac" las# Gear 9es#ing of all $ stages was done and found o". Gearbox oil ?lledFlus#ed and ta"en out. Gear Box %o! co&er ?tted bac".

Kneader (#aft wit# Gearbox was cou!led. Breat#er /o"e bolts tig#tening Foundationbolts tig#tening been done.

Kneader Gear Box Base Bolt tig#tened (crew (#aft cou!ling bolts was tig#tened andGland Pac"ing was installed. Gear Box fres# oil ?lled .%#e Plant started at 2$ t!# and

&ibration readings are ta"en and found normal t#en t#e %P6 increased to 23 andgraduall5 increased to $1 t!#. C 2$.+2.1$

)urin ni #t t#e tonna e was increased to $D t #. And readin s were ta"en and found

Sequence of Acton T!"en

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PROBABLE CAUSES FOR FAILURE AND ACTIONS TAKEN

(.o

Probable -auses Action Plan (tatus

>emar"s

1 Lubrication Point>eorientation

Lubrication Points to bec#anged

)one.

Lubrication Points c#anged wit#reference to GAP 1.

2 Gear mes#ingBac"las# >oot-learance

Blue matc# Bac"las#and root clearancec#ec"ing

)one 'ntermediate 9es#ing Gearcontact was less (o t#e Gear-#anged.

$ 'ncrease in (liding

Pinion Bearing-learance

Bearings to be c#anged )one Bearing clearance was increased

to +.$2 mm and t#e standard tobe +.+=+ to +.+* mm

D Gear box and (crews#aft (#im and-ou!ling boltsdisturbance

-ou!ling bolts ands#imming c#ec"ing

)one -ou!ling bolts loosened andtig#tened for !ro!er seating(#imming c#ec"ed for !ro!erinstallation

3 (crew (#aft %imingdisturbance -learances betweenig#t and %eet# to be-#ec"ed

)one %#e distance at forward andbac"ward stro"e measured andfound o".

7 Gimble Pi&ot Pin-learance -#ec"ing atbot# sides

Flange to be remo&edfor ta"ing out t#e Gas"et

)one %#e Pin Flange remo&ed andgas"et was ta"en out.

= 'ncrease in

'ntermediate Bus#-learance.

(#imming about +.Dmm

to be gi&en in LowerPillow Bloc"

)one (#imming was done to reduce

t#e clearance between bus# and0ut!ut (#aft

5

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OBSER#ATION AFTER ELIMINATING PROBABLE CAUSES:

1. Kneader was started in decou!led condition of around $ #rs.

2. Kneader Gearbox and (crew (#aft was cou!led and trial was ta"en in o load-ondition and no abnormal sound found.

$. After com!letion of load of 2$ tE#r was ta"en and run for few #rs %#en tonnagewas increased to 23 tE#r. 't was in ormal -ondition.

D. As we increase t#e tonnage and r!m of around 2= tE#r and $D r!m. %#e soundand &ibration readings increased.

3. %#e &ibration >eadings are dail5 monitored.

7. %#e BP x!ert will &isit between 23t#  to 24t# 9arc#.

6

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ROOT CAUSES FOR FAILURE

(.o

-ause Action Plan (tatus >emar"s

1 Lubrication Point>eorientation

Lubrication Points to bec#anged

)one. Lubrication Points c#angedwit# reference to GAP 1.

2 'ncrease in'ntermediate Bus#-learance.

'ntermediate Bus# to be-#anged

 %o be)one

-learance was around +.Dmm against +.114 to +.2$mm

FUTURE ACTIONS:

(.o A-%'0 %0 B %AK %A>G%)A%

>emar"s

1 (#imming at t#e 0utboardBearing

13.+2.1$

2 -#ange of 'ntermediate Bus# $1.+$.1$ As t#e

$ Gear Box to (crew (#aftAlignment

$1.+$.1$

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>earndbus#

FrontBus#

GimbleAssembl

5

Pillow Bloc"wit#

'ntermediateBus#

GEAR BOX AT OPEN CONDITION

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FRONT BUS$ REAR BUS$

INTERMEDIATEBUS$

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Ge!% Bo& Ge!%' !n( Lu)%c!tn* Pont'

10

Lubricating !oint

forBearing

'n!ut(#aft

Assembl5'ntermediate

(#aft Assembl5

'ntermediate (#aft

mes#ingGear

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Inte%+e(!te Me',n* Ge!% cont!ct !%e!

BEFORE AFTER

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Ge!% Bo& Ge!%' !n( Lu)%c!tn* Pont'