MAINTENANCE OF GB.ppt

PRESENTATION ON MAINTENANCE OF GEARBOX

R K JAIN

MAINTENANCE OF GEARBOX CEMENT PLANT EQUIPMENT ARE EXPECTED TO WORK CONTINUOUSLY WITH DESIRABLE CONDITION.PREVENTIVE MAINTENANCE INSPECTION CONDITION BASED TIME BASED (2000 ,5000 ,10000 HRS)BREAKDOWN MAINTENANCE

INSPECTION CHECK POINTS

FRQCHECK POINTSDAILYOIL PRESSURE,TEMPRATURE,M/C LOADDAILYNOISE,VIBRATION,LOOSENESSDAILY SUMP OIL LEVEL,LEAKAGES.DAILYCLEANINGMONTHLYOIL CONTAMINATION,CONTROLS&ALARM SYSTEMMONTHLYCLEAN FILTER,BREATHER,NOZELS HOLE

MAN-HOLE INSPECTION (MHI) AFTER 2000 HOURS

1Check gears for pitting, visual inspection of gear teeth2Check flow of oil,3Check coupling Bolts alignment,4Clean breathers,5Check foundation bolts for looseness,6Check oil leakage, and force lubrication system7Check any or all points reported by the preventive maintenance personnel

LIFT TOP COVER INSPECTION (LTC) AFTER 5000 HOURS

1All points covered by 2000 hours inspection and in addition2Check backlash, axial float,3Check gear meshing taking cellotape impression,color marking4Check bearing clearance and rollers of bearing,5Check bearing cap bolts,6Check counter weights, rivets and dowels,7Check all tripping circuits fitting,8Check burrs and steps in gears, and9Check all points reported by the preventive maintenance personnel.

COMPLETE REMOVAL OF GEAR INSPECTION >10,000 HOURS

1All points under 5000 hours inspection,2Check bearing housing for ovality, check bearing clearance,3Cleaning of sump oil pathways, oil holes and oil pipeline,4Check shaft level,5Check oil sample,6Check run out,7Clean oil cooler and filter,8Overhaul oil pump,change oil seals9Check shafts for surface and sub surface cracks.

PLANNING OF MAINTENANCE OBJECTIVE SEQUENCE IDENTIFICATION & PROCUREMENT OF TOOLS,MEASURING PARTS AND SPARES.INSPECTION PROCEDURE TOLERANCE LIMITDOCUMENTATION BEFORE & AFTER DISASSEMBLY

GEAR BOX LUBRICATION SYSTEMFORCE LUBRICATION

SEQUENCE OF DISASSEMBLYMEASUREMENT OF CURRENT STATUS OF ALIGNMENT DECOUPLING OF INPUT & OUPUT COUPLINGDISCONNECTION OF INTERLOCKING & POWER SUPPLYDRAIN THE OIL.REMOVAL OF END COVER.REMOVEAL OF DOWELS.DISMENTLING & LIFTING OF TOP COVER

SEQUENCE OF DISMANTLINGREMOVAL OF OIL PIPELINE.INSPECTION OF INTERNAL.REMOVAL OF GEAR SHAFT ASSEMBLY.SELF MADE DRAWING & PHOTOGRAPH OF PART.REMOVAL OF OIL SEALS,BEARING & GEAR.CLEANING & INSPECTION OF PART( BEARING,TEETH,SHAFT,SEAL,PIPELINE ETC.)ARRANGE WORN OUT PARTSA EACH STEP INSPECTION ARE MUST.

ASSEMBLY PROCEDURE OF GEARBOXCLEANING OF OIL SUMP,OIL HOLE & PATH WAS FILLINGCHECKING OF BEARING HOUSING BORE SIZE AND OVALITYINSPECTION OF BEARING BALLS,RACES,CAGESAND CLEARANCECHECKING OF SIZE OF SHAFT,GEAR ID,KEY,CRACKS AND OTHER DEFECTSCHECKING OF GEAR TEETH FITTING OF BEARING ,GEAR ,SHAFT & OIL SEALS.POSITION OF SHAFTCHECKING OF LEVEL AND AXIAL FLOATCHECK GEAR MESH AND BACKLASH.

ASSEMBLY PROCEDURE OF GEARBOXFILLING OF OILCHECKING OF LUBRICATION SYSTEMCLOSING OF TOP COVER WITH SEALANT,DOWELLING & TIGHTING BOLTS DIAGONALLYFIX BEARING COVER WITH SEALANTS & GASKETS WITH RECOMMENDED GAP.ALIGNMENT WITH CONNECTING MACHINE COUPLE THE MOTORFIXING OF VIBRO SWITCH,THERMO SWITH,LEVEL SWITCH

GAP BETWEEN BEARING & COVER TOUNG (COLLER)

DO NOT USE IN ASSEMBLYDO NOT USE WOOD IN PUSHING OF BEARING NEVER USE COTTON WASTEDO NOT KEEP ANY THING LOOSE IN POCKETNEVER USE WRONG TOOLS , SPANNER & MEASURING TOOLSNEVER USE NON RECOMMENDED LUBRICANTS.

SAFETY PRECAUTION DURING DISASSEMBLY & ASSEMBLYUSE PROPER LIFTING CAPACITY TOOLS.AVOID PEOPLE SHOULD NOT COMING UNDER LOAD.GEAR SHOULD NOT COME IN CONTACT STEEL ROPE.KEEP PART ON CLEAN SHEET OR WOOD.SPILLED OIL SHOULD BE REMOVED/SHOAKED.ALL SAFETY GUARD SHOULD INSTALLED.SITE CLEANING BEFORE OPERATION.

PRESENTATION ON DISASSEMBLY AND ASSEMBLY OF GEARBOX

NS RAJPUT

WHAT IS DIS ASSEMBLY ?DISMENTLING OF AN EQUIPMENTINSPECTION OF ALL PARTSTAKE CORRECTIVE ACTION FOR REPAIRING OR REPLACING THE PARTS.

NEED FOR DISASSEMBLY OF GEARBOX CEMENT PLANT EQUIPMENT ARE EXPECTED TO WORK CONTINUOUSLY WITH DESIRABLE CONDITION.PREVENTIVE MAINTENANCE INSPECTION CONDITION BASED TIME BASED (2000 ,5000 ,10000 HRS)BREAKDOWN MAINTENANCE

INSPECTION CHECK POINTS

FRQCHECK POINTSDAILYOIL PRESSURE,TEMPRATURE,M/C LOADDAILYNOISE,VIBRATION,LOOSENESSDAILY SUMP OIL LEVEL,LEAKAGES.DAILYCLEANINGMONTHLYOIL CONTAMINATION,CONTROLS&ALARM SYSTEMMONTHLYCLEAN FILTER,BREATHER,NOZELS HOLE

MAN-HOLE INSPECTION (MHI) AFTER 2000 HOURS

1Check gears for pitting, visual inspection of gear teeth2Check flow of oil,3Check coupling Bolts alignment,4Clean breathers,5Check foundation bolts for looseness,6Check oil leakage, and force lubrication system7Check any or all points reported by the preventive maintenance personnel

LIFT TOP COVER INSPECTION (LTC) AFTER 5000 HOURS

1All points covered by 2000 hours inspection and in addition2Check backlash, axial float,3Check gear meshing taking cellotape impression,color marking4Check bearing clearance and rollers of bearing,5Check bearing cap bolts,6Check counter weights, rivets and dowels,7Check all tripping circuits fitting,8Check burrs and steps in gears, and9Check all points reported by the preventive maintenance personnel.

COMPLETE REMOVAL OF GEAR INSPECTION >10,000 HOURS

1All points under 5000 hours inspection,2Check bearing housing for ovality, check bearing clearance,3Cleaning of sump oil pathways, oil holes and oil pipeline,4Check shaft level,5Check oil sample,6Check run out,7Clean oil cooler and filter,8Overhaul oil pump,change oil seals9Check shafts for surface and sub surface cracks.

PLANNING OF DIS ASSEMBLY OBJECTIVE OF DISASSEMBLY SEQUENCE OF DISASSEMBLY IDENTIFICATION & PROCUREMENT OF TOOLS,MEASURING PARTS AND SPARES.INSPECTION PROCEDURE TOLERANCE LIMITDOCUMENTATION BEFORE & AFTER DISASSEMBLY

GEAR BOX BEARING COVER