express agreement that they will not be reproduced,

1 GENERAL
2 Project: Guru Gobind Singh Refineries Project Job No. : 6922
3 Owner : M/s HMEL Site : BHATINDA, INDIA
4 Purchaser : KSB Pumps Ltd., Unit : CPP Motor driven Unit No.: 575
5 Item No. : Service : Gear Box for S.T Driver for BFW Pump (HRSG)
6 No. reqd. : 3 Working: 2 Standby: 1 Driver Type: Electric Motor Driven Eqpt.: BFW Pump
7 Applicable to :  Proposals  Purchase  As Built
8  : Scope, Option & Information specified by Purchaser. : Information required from and options left to vendor. Vendor to cross (x) the selected option.
9 Manufacturer: TRIVENI ENGG. & INDS. LTD., MYSORE Model : HSG 220
10  RATING REQUIREMENTS  BASIC GEAR DATA 2980
11 Driven Eqpt. Power (kW): Nor.: ? Max.: ? kW Mechanical rating : 3603 kW @ 2982/4000 rpm
12 Driver Power (kW): Rated: 910 kW Max.: kW Thermal rating : NA kW @ rpm
13 Gear rated power (kW): (Rem. 1) 1001 Full load power loss (kW): 8.5 Mech. efficiency: 99 %
14 Torque @ Max. Cont. Speed (kg-m): 243.6 @ 2982 rpm 2980 Pitch line velocity (m/s): 39.3
15 Max. Torque : 326.8 kg-m @ 4000 rpm Tooth pitting index, "K" : Actual: 1.58 Allowable : 1.79
copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1645-DS-911 Rev.0 210 X 297

16 Rated speed (rpm) : Tangential load, "Wt" (kg): 2592

They are merely loaned on the borrower's

17 - Input :2980 Specified  Nominal Bending stress number St "Wt" Pinion Gear
18 - Output :4000  Specified  Nominal Actual : 99.61 97.31
19 Allow variation in gear ratio : 2 % Allowable : 265.40 265.40
20 Max continuous speed (rpm): ---- Material index no. : 3.03
21 Trip speed (rpm) : ---- Anticipated SPL : 82 dBA @ 1 m
22 Gear service factor (Min.) : 1.7 Journal static weight loads :
23 Pinion/Gear Hardness : 58 HRC Pinion : 32.5 kg Gear: 51 kg
2
24 Shaft assembly designation : L-R WR referred to LS shaft (kg-mm²): 606.6
25 - HS shaft rot. facing coupling end  CW  CCW Breakaway Torque (kgf -m) @ LS shaft : 2.475
26 - LS shaft rot. facing coupling end  CW  CCW Overhung Load Factor : ----
27 HS shaft end :  Cylindrical  Taper  1-Key  CONSTRUCTION FEATURES
28  2-Keys  Hydraulic taper  Integral flange Type of Gear  Reducer  Increaser
29 LS shaft end :  Cylindrical  Taper  1-Key  Single stage  Double stage
30  2-Keys  Hydraulic taper  Integral flange  Single helical  Double helical
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.

31 External loads : NIL   Other :

32 Other operating conditions : - Teeth
33  INSTALLATION DATA Number of teeth: Pinion: 41 Gear: 55
34  Indoor  Heated  Under roof Gear ratio 1.341 Centre Distance (mm): 220
35  Outdoor  Unheated  Partial sides Pitch Dia: Pinion (mm) 187.91 Gear (mm): 252.1
36  Grade  Mezzanine  Finish (RA): 0.6
37  Winterisation Required  Tropicalization Required AGMA Geometry factor "J" :
38 Electrical Area Class: Grp: Div.: Pinion: 0.5064 Gear : 0.5184
39 Max. allow. SPL : 82 dBA @ 1.0 m Helix angle (°): : 29.22 Normal Pressure angle (°):20
40 Elevation (m): Barometer (kg/cm²A): Net face width, "Fw" (mm) : 140 Pinion L/D: 1.06
41 Range of ambient temperatures: Normal Diametrical Pitch: 6.35 Backlash (mm): 0.14/0.41
42 Dry Bulb Wet Bulb
43 Minimum °C °C
44 Normal °C °C Manufacturing methods: Pinion Gear
45 Maximum °C °C Teeth generating process : Hobbing Hobbing
46 Unusual Conditions  Dust  Fumes  Others: Teeth finishing process : Grinding Grinding
47  ADDITIONAL REQUIREMENTS Teeth hardening method : Case carburising Case carburising
48 MOUNTING PLATES NOT IN SCOPE Pinion to shaft :  Integral  Shrunk-on
49  Gear furnished with : Gear to shaft :  Integral Shrunk-on
50  Baseplate  Soleplate(s)  RADIAL BEARINGS
51  Baseplate suitable for column mounting : Pinion Gear
52  Grout type :  Epoxy  Other: Manufacturer Triveni Triveni
53 Type Plain Journal Plain Journal
54  PAINTING :  Mfr. Std.  EIL Std Diameter mm 90 90
55 APPLICABLE SPECIFICATIONS Length mm 65 65
56  API Std.677 Journal Velocity m/s 18.8 14
57  Other: Loading kg/cm² 26 26
58 1.Design basis for Instrumentation & Painting GT-5-7680 Clearance (min-max) mm 0.13-0.17 0.13-0.17
59 2. Painting Specification EIL-6922-0642-ptBb08r0 Span mm 300 300
60 L10 Life (Roller Elements) hrs --- ---

GENERAL PURPOSE DATA SHEET NO REV.

ENGINEERS INDIA LIMITED GEAR UNIT 19
6922-575-16-45-DS25 A
NEW DELHI
(Section: C-3.4) Page 1 of 3
  THRUST BEARING(S)

They are merely loaned on the borrower's express agreement that they will not be reproduced,
61 MISCELLANEOUS
62  Torsional analysis by (2.6.1.8) Gear Vendor  Other Pinion Gear
63  Lateral analysis by  Gear Vendor  Other Location NDE
64  Spare set of gear rotors Manufacturer Triveni
65  Orientation of oil inlet and drain connection Type Hydrodynamic Tapered land

66 [REFER TRIVENI GA DRAWING - LATER] Size Dia 90 x 65 lg

67 Area mm² 6685
68 Loading kg/cm² 13.35
69  VIBRATION DETECTORS Rating kg/cm² ---- -----
70 Radial: (If Recommended by GB mfr.) NA L10 Life (Roller Elements) hrs NA
71  Manufacturer Type : Int. thrust load N (")
72  No. at each shaft bearing Total No.: Ext. thrust load N (")
73  Oscillator-Demodulators supplied by
74  Manufacturer NA  COUPLING & GUARDS
75  Monitor supplied by High Speed Low Speed
76  Location Rem. 3 Enclosure Coupling Manufacturer
copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1645-DS-911 Rev.0 210 X 297

77  Manufacturer Coupling Furnished by

78  Alarm  Shutdown Coupling Type
79  Shutdown time delay seconds Coupling Model
80 Axial : (If Recommended by GB mfr.) Provisions only Coupling Rating kW/100 rpm
81  Manufacturer BN or eqv No. Reqd.: 2 Coupling Lubrication
82  Location Rem. 3 At NDE of HSS Taper mm/m
83  Oscillator-Demodulators supplied by Taper guage furnished by
84  Manufacturer BN or eqv Limited end float
85  Shutdown time delay seconds Mount coupling halves
86  Monitor supplied by Cylindrical / 1-key  
87  Location Enclosure Cylindrical / 2-keys  
88  Manufacturer Tapered / 1-key  
89  Alarm  Shutdown Tapered / 2-keys  
90  Shutdown time delay seconds Tapered / keyless  
91 Accelerometer : (Provisions only) Coupling Guard Type
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED.

92 Manufacturer No. Required: 8 Cplg Guard furnished by

93 Location : X and Y Directions on All Bearings Points  PIPING CONNECTIONS
94 Monitor supplied by
No. Size Type
95  INSTRUMENTS Service
96  Low Oil Pressure Alarm Switch: NIL Lube oil inlet 01 1”NB ANSI Flange B16.5 150# RF
97  High Oil Temperature Alarm Switch: NIL Lube oil outlet 01 4” NB ANSI Flange B16.5 150# RF
98  Temperature Measuring Devices: (Rem.2) Casing drain 02 ¾”NB ANSI Flange B16.5 150# RF
99  Thermometers  Thermocouples / RTD's Vent 01 2” BSP Air Breather
100  Liquid Filled Pressure Gauges: NIL Casing purge
101  Thermal Relief Valves: NIL  LUBRICATION REQUIREMENTS
102  CONTRACT DATA  Oil system furnished by:  Gear Vendor  Other:
103  Test data prior to shipment  Oil Visc 46 cSt @ 40°C 7 cSt @ 100°C
104  Progress reports  Lubrication Requirements
105  SHIPMENTS  Main Oil Pump  Shaft Driven  Motor Driven
106 Contract unit Spares  Standby Oil Pump : NA  Yes  No
107 Export boxing    Oil Pump Casing :  Cast Iron  Steel
108 Domestic boxing    Oil Cooler :  Water Cooled  Air Cooled
109 Outdoor strg. over 6 months    Heaters Required :  Yes  No
110 Fit-up & Assy. of mtd. acc. Acc   Type :  Electric with Thermostat  Steam
111 MATERIALS  Duplex Filters :  Yes  No
112 Gear Casing : Casting FG:300 IS:210 Oil Seals: Aluminium System Type :  Self-Contained Splash  Circulating  Pressurised
113 Radial Bearings : White Metal Lined Steel Backed  Filters, Micron Rating : NA
114 Thrust Bearing(s) : White Metal Lined Steel Backed  Minimum Start up Oil Temperature (°C): 21
3
115 HS Shaft : 17CrNiMo6 LS Shaft : 080M40:BS970  Oil Flow (m /hr): 1.8
116 Pinion(s): 17CrNiMo6 Hardness : 58 HRc  Oil Pressure (kg/cm²,A): 1.5 - 2
117 Gear Rim(s): 17CrNiMo6 Hardness : 58 HRc  Unit Power Loss (kW): 8.5
118 Low Temp. Operation : NA Reservoir:  Gear Casing  Separate
119 REMARKS:
120

GENERAL PURPOSE DATA SHEET NO REV.

ENGINEERS INDIA LIMITED GEAR UNIT 19
NEW DELHI
6922-575-16-45-DS25 A
(Section: C-3.4) Page 2 of 3
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced,
121  INSPECTION AND TESTS WEIGHTS & DIMENSIONS
122 Reqd. Observe Witness Test log Net Weight:
123 Shop Inspection  Gear Box : ~ 800 kg Auxiliaries : kg
124 Cleanliness inspection    Max. Maintenance Weight [Identify]: 162 kg
125 Hardness verification Insp.     Total Shipping Weight : ~1000 kg
126 Mag. Particle Inspection    Total Shipping Dimensions: L: 1.2 m W: 1.3 m H: 1.2 m
127 Ultrasonic Inspection   
128 Weld Inspection    BEVEL MOUNTED GEAR BOX DATA (NA)
129 Dismantle-Reassembly Insp.    MOUNTING FLANGES
130 Contact check     Clearance Fit with Jack Register Fit
131 Contact check tape lift (2.5.2.2)     CONSTRUCTION FEATURES:
132 Axial stability check     Transverse Pressure Angle (°):
133 Bearing Visual check   x
  Radial bearings : Pinion Gear
134 Axial stability check     Manufacturer
135 Residual Unbalance Check     Type
136 Mech. run test     Class
137 Extended mech. run test     Cage Speed m/s
copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1645-DS-911 Rev.0 210 X 297

138 Mech. run test (Spare rotors)     B10 L10 Life hrs
139 Part or full load and full speed test    
140 Full torque slow roll test x
  x  Thrust bearings : Pinion Gear
141 Full torque static test     Manufacturer
142 Sound level test   
x  Type
143 Mech. Run Test Couplings: Class
144 - Coupling Installed     Cage Speed m/s
145 - Coupling hubs with Idlers     B10 L10 Life hrs
146 Use shop lube system     Up Thrust Capacity N
147 Use job lube system     Down Thrust Capacity N
148 Use shop vibration probes, etc.   
149 Use job vibration probes, etc.   
150 Final assembly maintenance &    
151 running clearance
152 Oil system cleanliness   
153 Oil system casing joint tightness   
154 Oil system leak test   
155 Warning and protection devices   
156
157
158
159
160
161
162
163
164 REMARKS
nd
165 1. Gear Rated Power shall be min. equal to the max. Installed power of the st. turbine driver as per Cl. 2.4.1.1.1 of API 677-2 Ed.
166 2. In case type of bearings provided are hydrodynamic type , bearing tem. Monitoring devices (As per API 670) including platinum res.
167 temp. detectors, monitors shall be supplied by vendor. Each journal brg. Shall have RTS’s in no less than 50% of the shoes.
168 Each thrust brg. Shall RTD’s in no less that 50% of the active side and min. 2 nos. in the inactive side.
169 3. To be located in control panels (located as per the operation & control philosophy of the plant
170
171
172
173
174
175
176
177

07/02/2008 A ANURAG SM
Date Rev Job Rev. & Approved

GENERAL PURPOSE DATA SHEET NO REV.

ENGINEERS INDIA LIMITED GEAR UNIT 19
NEW DELHI
6922-575-16-45-DS25 A
(Section: C-3.4) Page 3 of 3