DEPARTMENT MAINTENANCE

Mirpur Mathelo SECTION MACHINERY

UTILITY
Tag # Maintenance Report Supervised By:
ME-810 C Title: RMF/ SAG
Date: OVERHAULING OF
JUNE 19, 2014 TP800C GEAR BOX
ME-810C

Problems & Findings:

 One tooth of intermediate gear Output side was found chipped off
throughout the length.
 Corrosion was also observed on all gears.
 Some Bearing clearances exceeded.
 In the presence of all of these faults the gearbox was handed over at 19,
June, 2014 for completely maintenance.

Observations:
 During inspection from inspection window it was observed that
intermediate shaft single helical gear teeth (one complete and at least one
half length) found chipped off along the length.

 Corrosion was found at bull gear teeth and intermediate gear teeth.
 Corrosion on bull gear teeth

Corrosion on Intermediate gear teeth

 Cold alignment reading
Turbine to Gearbox (dial on gearbox)

0.00
0.00

+0.02 A +0.10
0.00

+0.23 0.00 R +0.03

+0.06
+0.03

+0.12
+0.29
Prepared by: Zahid Bashir (APP-MNT-MAC)

Gearbox to pump (dial on gearbox)

.
0.00 0.00

+0.05 R -0.24 -0.11 A 0.00

-0.19 -0.11
  This alignment reading shows that the turbine found 0.29mm up as
compared to gearbox in cold conditions which was not satisfactory.
 Secondly the pump found 0.19mm down as compared to gearbox.
 Turbine to gearbox shim pack coupling found in good condition.
 Gear to pump gear coupling also found good condition.
 Lining and scratches marks were found at babbitting area of some bearings.

  Backlash was measured:

Input ponion to idler gear was 0.34mm.
Idler gear to out put gear was 0.55mm.
Prepared by: Zahid Bashir (APP-MNT-MAC)
Work Done:
 First of all removed the gearbox top cover and checked bearing clearances
(radial/axial) and crush by dial (Details in the attached clearance sheet)
 Rigging activity of both bridges and gears was done. Gears were shifted to
workshop.
 After gears observations it was decided to change output set. However the
bull gear found shrink fitted. For removing it from shaft two heating torches
were used and hydraulic pressure of 8000 PSI was applied by hydraulic jack
but could not be removed. After then reclaimed gears set was issued but it
was observed that issued sets bull gear must be double key fitted, but the
old ones were without key and no other spare output shaft was available.

New gear with double key way Old shrunk fitted gear without key

 Finally it was decided to use old gear set. Cleaning of each gear was carried
out.
 DPT test was performed on all gears and produced satisfactory results.
 Deep groove was observed on lip seal area that caused oil leakage at low
speed shaft so it was decided to install a sleeve and machine it to the
required seal size. For this the coupling hub was removed.Shaft seal area
 size was 144.30mm. Sleeve dimensions are as fallows
Inside diameter= 144.22mm Outside diameter= 160mm

Prepared by: Zahid Bashir (APP-MNT-MAC)

Bearings clearances by measurement

 Output shaft bearings measurements

Shaft axial distance between thrust collar=110.04~11
Bearing width=109.76mm
Axial clearance=0.28~0.30mm

Thrust cum journal bearing Inside diameter=160.08~160.09mm

Shaft O/D at thrust cum journal bearing area=159.84mm
Clearance=0.24~0.25 mm

Journal bearing (turbine side) inside diameter=160.03~160.04mm

Shaft outside diameter at journal bearing area=159.83mm
Clearance=0.20~0.21mm

 Intermediate shaft bearings measurements

Shaft axial distance between thrust collar=110.10mm
Bearing width=109.85mm
Axial Clearance=0.25mm

Thrust cum journal bearing inside diameter=160.02mm

Shaft O/D at thrust cum journal bearing area=159.86mm
Clearance=0.16mm

Journal bearing (pump side) inside diameter=159.96~160.01mm

Shaft outside diameter at journal bearing area=159.86~159.87mm
Clearance=0.10~0.15mm

 Input shaft Bearings measurements

Turbine side journal bearing inside diameter=90.05~90.06mm
Turbine side bearing area shaft outside diameter=89.88mm
 Clearance=0.13~0.14mm

Pump side journal bearing inside diameter=90.15mm

Pump side bearing area shaft outside diameter=89.89mm
Clearance=0.26

 From these measurements the following observations were made.

Low speed shaft thrust cum journal bearing axial was found 0.28 ~ 0.30mm
and radial clearance was found 0.24~0.25mm. Both clearances were across
the limits then it was decided to use new bearing.
 New thrust cum journal bearing axial clearance was measured in workshop
found 0.11mm that it was too low. To bring this clearance in acceptable
range it was decided to apply cut of 0.04mm on each side. After that
activity the final axial clearance was found 0.19mm by measurement in
workshop.
 Pinion gear, pump side bearing radial clearance was found 0.26mm by
measurement which was not satisfactory. After then it was decided to use
new bearing. New bearing clearance was found 0.11mm by measurement.
But at the site during installation its clearance measured by plastic gauge
found 0.07~ 0.09mm which was not acceptable. To increase it a cut of
0.05mm was applied by machine shop. So that it’s radial clearance was set
within 0.10mm (measured by plastic gauge).
 Intermediate pump side bearing was found oval. Its clearance by
measurement was found 0.10~0.15mm meaning ovality of 0.05mm.Its
maximum clearance was in acceptable range so it was decided to use it
again and removed ovality by applying cut of 0.05mm at its inside diameter.
 Others bearings clearances (by measurement) were in acceptable range.
 Cleaning of each part was done.
 All gear sets were shifted in area then measured the crush of each bearing
by using lead wire.
 First measured the crush at Intermediate shaft’s pump side bearing but
found clearance of 0.05mm. Then a shim of 0.06mm was used on bearing
upper half so that its final crush value was set within 0.01mm.
 Secondly measured the crush at low speed shaft’s pump side bearing but
found clearance of 0.30mm. To remove this clearance a shim of 0.20mm
and 0.10mm was used on bearing upper half so that its final crush value
was set at 0.00mm.
Prepared by: Zahid Bashir (APP-MNT-MAC)

 Backlash values:
Input ponion to idler gear was 0.34mm
Idler input gear to out put gear was 0.55mm
Both values were found same as old.
 Gears contact was checked by prusion blue and paper found 80% which
was acceptable.
 Lube oil lines were fitted after cleaned by pressurized air.
 Lube oil circulation test was performed found ok.
 Alignment was carried out after all activities. The final readings are as
follows.

 Cold alignment reading

Turbine to Gearbox (dial on gearbox)

0.00 0.00

0.00 0.00

-0.07 0.00 R +0.03 -0.13 +0.02 0.00 R +0.03

+0.01
+0.03 +0.03

-0.20 +0.03

Gearbox to pump (dial on gearbox)

0.00 0.00

0.00
0.00

+0.01 0.00 R +0.03 +0.02 -0.06 0.00 R +0.03 -0.05

+0.03
+0.03

+0.03 -0.11
Prepared by: Zahid Bashir (APP-MNT-MAC)

 Greased the gear coupling (by hand and by grease gun) then it was coupled.
Check the total float of coupling found 5.30mm further it was centered at
2.65mm.
 Coupled the turbine and gearbox shaft with shim pack coupling.

CLEARANCES OF TP-800C GEAR BOX (ME-810C)

 High Speed Shaft
NO Description Before Final Crush
. By dial By measurement
1 Radial clearance Gov. end 0.10 0.13~0.14 0.12 0.01
2 Radial clearances pump 0.15 0.11 0.10 0.01
side

 Low speed shaft

NO. Description Before Final Crush

By dial By
measurement
1 Radial clearance Gov. end 0.11 0.20 0.11 0.01
2 Radial clearances pump 0.16 0.18 0.00
side
3 Axial end play 0.20 0.19 0.15
 Intermediate Shaft
NO Description Before Final Crush
. By dial By measurement
1 Radial clearance Gov. end 0.16 0.16 0.11 0.00
2 Radial clearances pump 0.10~0.15 0.10~0.15 0.11 0.01
side
3 Axial end play 0.20 0.25 0.18
 Backlash
No Description Before After
.
1 Input Pinion to Idler gear 0.34 0.34
2 Idler gear to output shaft 0.55 0.55

Startup:
At 30, June 2014 the machine was completely ready for startup. Machine
was taken in service and found normal. The following vibration readings
were observed at 6845rpm.

Measurement Horizontal Vertical Axial

Point
- Current Previous Current Previous Current Previous
value value value value value value
Turbine Inboard 6.1 6.2 1.9 1.8 1.6 1.9
Turbine Outboard 3.9 3.9 2.7 2.8 1.5 1.7
Input Pinion 3.3 3.2 3.7 3.9 5.7 6.6
Inboard
Intermediate 4.6 4.0 3.9 4.2 5.8 5.3
Turbine Side
Intermediate 3.7 3.1 4.6 4.5 5.7 5.6
Pump Side
Output Pump 4.2 5.9 7.7 11.0 7.3 11.2
Side
Pump Inboard 2.5 2.7 1.8 1.9 1.3 1.3
Pump Outboard 2.0 2.1 1.8 1.8 1.6 1.5
Spares consumed:
Descriptions Warehouse code Quantity
Lip oil seal 29-2051-1256 03
Pinion bearing 69-7800-4038 01
Output thrust cum bearing 69-7800-4055 01
Team:
Engineers:
Rao Muhammad Faisal Syed Asfandyar Gilani M. Talha Khan
Staff:
Morning Night
Zafarullah Mureed Abbas
Hafiz Riaz Atta Mujtaba
 Attaullah Rasheed Mubbashir Tariq
Shahid Ali
Zahid Bashir
Prepared by: Checked by:
Zahid Bashir (APP-MNT-MAC) Asfandyar Gilani (DE-MNT-MAC)