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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.
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
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.
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
Action Plan
Statu
s
Remarks
Lubrication Point
Reorientation
Lubrication Points to be
changed
Done
.
Gear meshing,
Backlash, Root
Clearance
Done
Increase in Sliding
Pinion Bearing
Clearance
Bearings to be changed
Done
Done
Clearances between
flight and Teeth to be
Checked
Done
Flange to be removed
for taking out the Gasket
Done
Increase in
Intermediate Bush
Clearance.
Done
Cause
Action Plan
Status
Remarks
Lubrication Point
Reorientation
Lubrication Points to be
changed
Done.
Increase in
Intermediate Bush
Clearance.
Intermediate Bush to be
Changed
To be
Done
FUTURE ACTIONS:
S.No
ACTION TO BE TAKEN
TARGET
DATE
15.02.13
31.03.13
31.03.13
Remarks
As the
Front
Bush
Gimble
Assembl
y
Pillow Block
with
Intermediate
Bush
Rear
End
bush
FRONT BUSH
REAR BUSH
INTERMEDIATE
BUSH
Intermediat
e Shaft
meshing
Gear
Lubricatin
g point
for
Bearing
Input
Shaft
Assembly
Intermediate
Shaft Assembly
10
AFTER
11
12