Failure of Steel Car / Hot Metal Car Gearbox

at LD#2 & LD#3

Case for Horizontal Deployment

1
Brief Background:

Incident
• On 08.01.2019 , LD2 Steel Car Gearbox failed within one month of Service.
• In a similar incident, LD#3 Hot Metal Gearbox failed within one week of
service.
• In both cases, lubrication was not done.
• It shall also be noted that a similar failure had happened in past and
RCFA (INV_0731) was released which suggested that all gearboxes shall
be tagged and modification of Input shaft & Intermediate shaft shall be
done by incorporating grease nipple in end cover and grease retaining
ring shall be provided as per Drg Number as per drawing no. 1-3804-13-
005 and 1-3804-13-012. (Refer Annexure 2 for Drg).

Shared Services Division Slide 2 TATA Steel

Analysis :-
Old Drg. New Drg.

 Steel Car gearbox earlier had a oil lubrication system and oil pump (driven by output shaft) was provided
to lubricate all stages of gearbox.

 Later provision for grease lubrication in gearbox was provided for Input shaft, first & second intermediate.
 Out of 8 gearboxes used in Steel Car, it was found that only 4 Gearboxes has provision for greasing thru
end cover, in 3 gearboxes, greasing is done thru inspection cover and One gearbox (which failed) had
provision of greasing thru top housing.
Shared Services Division Slide 3 TATA Steel
Analysis

Sl No. Recommendations Responsibility

1. LD Mech
All gearboxes used in LD Shop Steel cars/ HM Car shall be mapped &
numbering shall be done.
2. Provision for lubrication of all greasing points shall be inspected in all LD Mech

mapped gearboxes and lubrication port to be provided thru end cover

as per drawing no. 1-3804-13-005 and 1-3804-13-012.

3. LD Mech
Checklist of Lubrication shall be numbered and shall clearly specify the point
of lubrication.

Shared Services Division Slide 4 TATA Steel

Shared Services Division Slide 5 TATA Steel