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KNEADER GAP 2

KNEADER GEARBOX FAILURE REPORT


PROBLEM DEFINITION:
GAP 2 Kneader Gear Box Failure resulted due to followings:
1. Lube low flow came, Kneader stopped as per interlock.
2. Lubrication unit started in Local and checked, Found normal.
3. Then high vibration came and Kneader stopped for Inspection and found the following parts
damaged.
a. Input Shaft Pinion and Gear
b. Intermediate Shaft Pinion and Gear
c. Intermediate Bearing

EFFECT OF PRODUCTION:
1. Due to failure of Kneader Gearbox the Production loss
2. Total hours of around 290 hrs was taken for executing Kneader Job.

Sequence of Action Taken


Date

ACTIVITY DONE
Kneader of GAP 2 had a very High Vibration on 05.02.2013 around 2.00 a.m, Kneader was stopped
and checked. It was found Input shaft Gear, intermediate Gear and Pinion got damaged and
Intermediate DE bearing also damaged.

The Input shaft Gear, intermediate Gear and Pinion along with the DE Bearing 6322 C3, NDE Bearing
5.02.03 to 22322 , NUP 218 EM C3 at NDE of Input Shaft Changed.
08.02.03
After Changing Kneader was started on 08.02.13 No load, Their Abnormal rubbing sound was
observed.
Kneader was run at 23 tph for 2 shifts and found the sound was on increasing and we stop the
kneader for checking.
Mesh (between Intermediate Pinion and 3rd stage Gear) meshing was one sided. 15.02.13
Gearbox Top cover was put back to increase the rpm and check for abnormal sound, It was found that
abnormal sound is still on 10 rpm
15.02.13

The Intermediate pinion meshing gear of 3 rd stage ( Sliding pinion side gear) found damaged.
Gear Box top cover, Motor, Input Shaft assembly was removed for further checking, Oil also drained
out.
Intermediate Shaft Assembly and its Gear removed.

16.02.13

Kneader slinger housing, bush bolts removed


Gear Box Base bolts removed and shifted towards the drive, Gearbox cleaning done

17.02.13

Kneader Yoke assembly, Slinger, Slinger Housing and Gimble Pin were removed.
Gimble assembly was taken outside from the Gearbox, and then sliding pinion along with the bearings
also removed.

18.02.13

The front bush, Rear bush Removed, Old Bearing at Sliding Pinion bearing being removed.

Sequence of Action Taken


Date
19.02.13

20.02.13

21.02.03

22.02.03

ACTIVITY DONE
New Bearings at both the ends are installed at the sliding pinion and whole assembly
was installed in the Gearbox. Gimble assembly was also put in the Gearbox.
19.02.13 day
night Slinger with Housing, front bush, yoke assembly was fitted back; Gear Box was
shifted to its original place.
Gearbox installed at its position and bolts were tightened. Gimble Pin was fitted at
both the ends
Intermediate Bush Top Pillow block was removed and bolts of Intermediate Bush also
removed.
After removing the Intermediate Bush Pillow block the bush was rotated at 180 deg.
But clearance not changed at top and at one side it was zero. So Bottom pillow block
bolts were removed and adjusted to get the clearance at top and both sides.
21.02.13
The Gear at Sliding Pinion Side was Changed, Intermediate Assembly installed, Input
Shaft Assembly also fitted, Front bush , Slinger Housing Bolt top half has been
tightened. 21.02.13 day
Kneader Motor coupled with Gearbox, Termination also done.
Back lash, Gear Meshing of all 3 stages was done and found ok. Gearbox oil filled,
Flushed and taken out. Gear Box Top cover fitted back.
Kneader Shaft with Gearbox was coupled. Breather, Yoke bolts tightening, Foundation
bolts tightening been done.
Kneader Gear Box Base Bolt tightened, Screw Shaft coupling bolts was tightened, and
Gland Packing was installed. Gear Box fresh oil filled .The Plant started at 23 tph and
vibration readings are taken and found normal , then the TPH increased to 25 and
gradually increased to 31 tph. - 23.02.13
During night the tonnage was increased to 34 tph. And readings were taken and4found

PROBABLE CAUSES FOR FAILURE AND ACTIONS TAKEN


S.N
o

Probable Causes

Action Plan

Statu
s

Remarks

Lubrication Point
Reorientation

Lubrication Points to be
changed

Done
.

Lubrication Points changed with


reference to GAP 1.

Gear meshing,
Backlash, Root
Clearance

Blue match, Backlash


and root clearance
checking

Done

Intermediate Meshing Gear


contact was less, So the Gear
Changed.

Increase in Sliding
Pinion Bearing
Clearance

Bearings to be changed

Done

Bearing clearance was increased


to 0.32 mm and the standard to
be 0.070 to 0.09 mm

Gear box and Screw


shaft Shim and
Coupling bolts
disturbance

Coupling bolts and


shimming checking

Done

Coupling bolts loosened and


tightened for proper seating,
Shimming checked for proper
installation

Screw Shaft Timing


disturbance

Clearances between
flight and Teeth to be
Checked

Done

The distance at forward and


backward stroke measured and
found ok.

Gimble Pivot Pin


Clearance Checking at
both sides

Flange to be removed
for taking out the Gasket

Done

The Pin Flange removed and


gasket was taken out.

Increase in
Intermediate Bush
Clearance.

Shimming about 0.4mm


to be given in Lower
Pillow Block

Done

Shimming was done to reduce


the clearance between bush and
Output Shaft
5

OBSERVATION AFTER ELIMINATING PROBABLE CAUSES:

1. Kneader was started in decoupled condition of around 3 hrs.


2. Kneader Gearbox and Screw Shaft was coupled and trial was taken in No load
Condition and no abnormal sound found.
3. After completion of load of 23 t/hr was taken and run for few hrs , Then tonnage
was increased to 25 t/hr. It was in Normal Condition.
4. As we increase the tonnage and rpm of around 27 t/hr and 34 rpm. The sound
and vibration readings increased.
5. The vibration Readings are daily monitored.
6. The B&P Expert will visit between 25th to 28th March.

ROOT CAUSES FOR FAILURE


S.N
o

Cause

Action Plan

Status

Remarks

Lubrication Point
Reorientation

Lubrication Points to be
changed

Done.

Lubrication Points changed


with reference to GAP 1.

Increase in
Intermediate Bush
Clearance.

Intermediate Bush to be
Changed

To be
Done

Clearance was around 0.4


mm against 0.118 to 0.23
mm

FUTURE ACTIONS:
S.No

ACTION TO BE TAKEN

TARGET
DATE

Shimming at the Outboard


Bearing

15.02.13

Change of Intermediate Bush

31.03.13

Gear Box to Screw Shaft


Alignment

31.03.13

Remarks

As the

GEAR BOX AT OPEN CONDITION

Front
Bush

Gimble
Assembl
y

Pillow Block
with
Intermediate
Bush

Rear
End
bush

FRONT BUSH

REAR BUSH

INTERMEDIATE
BUSH

Gear Box Gears and Lubricating Points

Intermediat
e Shaft
meshing
Gear
Lubricatin
g point
for
Bearing

Input
Shaft
Assembly

Intermediate
Shaft Assembly

10

Intermediate Meshing Gear contact area


BEFORE

AFTER

11

Gear Box Gears and Lubricating Points

12