Kneader Analysis
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Transcript of Kneader Analysis
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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'