Se hi a= ae — rah ea a 3 A , wa g \ Cooling Tower Gear Box WerShanthi © © Empowered with knowledge to deliver highest quality gears by eee Ca ae ‘Systematic Quality control at every stage of realization, Improved design in line with International standards ees es Reena ‘Computerized Contour / Profile testing, m mye HEAT TREATMEN* Re ee a ee a ee ee et ees cn eet eee eee ‘Madlern casiron foundey an fabrication shop. Prise See eee es ec ee eC eee etterCooling Tower Gear Units ‘SHANTHI GEARS LIMITED Introduction, Design (COIMBATORE - 641 005, INDIA Introduction, Design Features bate:2011/ 12 Introduction. Shanthi new series of Cooling Tower gear units take advantage of our many years of accumulated expertise and experience in designing and manufacturing of transmission products, The end results the series of specific Industry focused solutions, One amongis the series of Cooling Tower Gear Units released with high load carrying capacity, increased efficiency, quietrunning and relibility. These Gear Units are available in both Helical and Bevel Helical versions, The two stage parallel shaft Helical version is with the output shaft protruding downwards and the input side is with motor ‘mounting adaptor, ready to receive the motor of standard frame size, The two stage Bevel Helical version is with the output shaft positioned upwards and the input side horizontal The design of these Gear Units, made with gearing details following addendum modification based on the latest finding of gear design with the help of atest computer software programs has been finalized keeping the most favourable ratio distribution and the no. of teeth, module, helix angle, face width combination inorder to achieve the optimum evenly distributed power rating in various stages and to get the highest diameter forthe shaft extension of the input shaft quite comparable tothat of the prime mover. DESIGN FEATURES: Gears: Single helical gears, profile ground with the latest technique for tip relief and face crowning in the most modern gear grinding, machines are made out of NiCrMo case hardening alloy steel. This ensures high standards of accuracy relevant to ISO! DIN/ AGMA standards o achieve quite running characteristics. Spiral bevel gears are produced in the most modern Bevel generating machines and finished by lapping in dedicated machines, after case hardening. Gear Casing: Gear casings, created using the latest techniques of 3D modeling posses the most modem styling and the rigidity, Both the Helical and Bevel helical gear units are made of close grained Cast Iron to achieve favourable vibration damping properties. Ample space is provided to keep the oil temperature under control and the base design is such that rigidity is ensured with the large diameter fans fitted inthe output shaft running at its fullest capacity. Suitable inspection covers with optimum size are provided, Bearings: Amply proportioned Taper Roller bearings are sed inall the shafts to take arc ofthe radial and thrust loads. ‘Wenormally check the input bearing life for L10 > $0,000 Hours and the output bearing life for L10™1,00,000 Hours. Any additional request can be considered as special if indicated during enquiry stage. Shaft Seals: Spring loaded rubber oil seals are provided inthe shaft extensions, Two such seals are provided witha grease gap inthe output side. A metallic labyrinth sealing arrangement is provided in the top, totake care of the moist atmosphere. Backstops (Holdback Units): When required, to avoid the reverse rotation of the fam blade, we can provide backstop units builtin the gearbox, in the first intermediate pinion shaft. The backstops are of centrifugal lift off type, and have the adequate capacity to withstand the full rated torque. Cooling Generally the cooling tower gear units are cooled by convection and radiation from the external surfaces ofthe gear case Lubrication: Lubrication i by the transfer of ol to the mesh points by gear dipping inthe sump of Gear unit. The oil slinger system, through the oil tothe top cover, and by proper design of cover, the ol is directed tothe top bearings, and adequate il supply tothe top bearings is ensured, For grade of oil referto "Guide lines for selection” sheet Direction of Rotation : Both input and outputshatts will rotate clockwise, when viewed from respective shaft ends, For other requirements refer to SGL. aer 3 a —— Shanthi 22073 Cooling Tower Gear U ‘SHANTHI GEARS LIMITED Guidelines for Selection COIMBATORE - 641 005, NDIA bate:2011/12 ate Guidelines For Selection : Determine required transmission ratio nm fiveg required transmission ratio jing in nominal ratio my ny [rpm] input speed Select appropriate nearest nominal ratio. iN ny [rpm] output speed Determine required Mechanical Power Capacity Pang [kW] required Mechanical Power Capacity Prcg = Paxfi Ps [kW] nominal Mechanical Power Capacit Select Gear Unit Size kw] my Size based on type and appropriate nearest nominal ratio from the table Size using P y > or=P seq mechanical service factor normally 2 unless otherwise specified Inputs required for selection 1) Drive motor power and speed 2) Required fan speed (i.e.) output speed of the gear box required 3). Driven fan weight 4) Aerodynamie axial thrust load on ouput shaft 5) _Atinput side floating shaft weight and length 6) Ambient temperature 7) Other service condition 8) Recommended service factor (if known) 9) Any other information EXAMPLE Given Data Power 30 kW Speed nl: 1500 rpm Cooling Fan Speed nd: 173 1pm Axial Thrust Load Ton (1000kg = 9.81kN) Weight of Fan 500kg Gear Unit Design Foot mounted, Bevel Helical Vertical Output Shaft Required Transmission Ratio 1500. L569 17 Nominal ratio Required Mechanical Power Capacity Preq=Pdx f1 =30x2 = 60kW Gear Unit Type and Size Refer Page No.4 & 5 Gear Unit Size 160 with PN=72KW & Load = 13.4kN is selected ‘CONCLUSION Bevel Helical Gear Unit, Foot mounted, Vertical Output Shaft Type BDCT, Size 160, 9:1 nominal ratio is selected.Cooling Tower Gear U Shanth G27. —=—] ‘SHANTHI GEARS LIMITED Nomenclature & Lubricants COIMBATORE - 641 005, INDIA Date : 2011/12 Nomenclature : (B) (©) (cr) (es) | SIZE CT- COOLING TOWER APPLICATION D-DOUBLE STAGE, B - BEVEL HELICAL GEAR UNITS Standard Sizes Available 130,160,185,225,265,320,370,442 Standard Nominal Ratios Available 5,5.6,63, 7.1, 8,9, 10, 11.2, 12.5, 14 & 16 Details Required at the time of enquit Output s Fan Diameter, Fan Weight and Fan Thrust load Ambient Temperature Optional items requirement Other details like conical output shaft ete. if any. Type of Gearbox required Helical / Bevel Helical Power of Drive Motor and Speed weed / Ratio Lubricants : TSO Viscosity Grade (mm at 40°C) #Ambiont Load classifications of Driven machine (from Table 1) ‘Temperature Uniform Moderate Shock Heavy Shock coy Lead () Load (Mt) Load (4) 21050 ves20 vaso vaso Gear Units are supplied without oil. Before putting it in operation, ensure that they are filled to correct oil levels, as per the ‘markings of dipsticks, with proper garde of lubricants, given in the tables, Examples of Lubricants +#For other Ambient temperatures and load classifications, please refer to SHANTHI. Viscosity 80: Bhat Hindustan] idan oil ‘AtA0°C in me” Petroleum | Casto! Esso | potroleum | corporation | Mebil Sh ves20 Mak amacam |Castol Aha] SPARTAN | Parhan | Servomash | Mobigear |shell Macoma 320 ‘sP320 | ep320 | eps | spa20 eae 220 IMAK amacam |Gastol Alpha | SPARTAN | Parhan | Servomesh | Mobigear Shel Macoma ve 460 460 ‘sP450| EPas0 | EPs | SPs 538 4860 03SSS ——— Shanthi Cooling Tower Gear Units Power Ratings ‘SHANTHI GEARS LIMITED COIMBATORE - 641 005, INDIA Date : 2011 Mechanical Power Capacities in kW Nominal Speedttpm) ‘Gear Unit Size Ratioiy ["wotorn; | Fann | 130 | 160 | 15 | 225 | 265 | 320 | 370 | a2 1800 360 [0 | 123 | a1 | oat | 625 | 1000 | vos? | 2165 5 1500 300 [71 | 108 | 212 | 300 | 560 | 907 | 1459 | 1908 we 1800 sar [vet | 205 | 303 | s77 | 979 | 1007 | 2128 1500 268 [67 | 98 | 198 | 204 | soe | ae | 1415 | 1879 we 1800 206 | e7 | 102 | 213 | 205 | sea | ae | v4o7 | 1940 1500 238 | sa | 90 | 188 | 260 | 496 | 776 | 1239 | 1708 "4 "800 25a | o4 | 95 | 194 | 275 | 510 | 090 | 1052 | 1760 1500 an | se | es | 171 | 242 | 457 | 738 | 1190 | 1558 3 1800 2a5_| so | 60 | 178 | 24a | a66 | ras | azxa | 1620 1500 tes] se _| ve | 157 | 218 | 410 | 57 | 1068 | 1453 3 "800 200 | 4 | 62 | 150 | zor | aoe | ror | an | 1491 1500 1s7_| 48 | 72 | 140 | 200 | 56 | o17 | 96 | 1319 1800 120 [48 | 72 | 143 | 204 | 368 | 639 | toz8 | 1371 1500 150 [41 | 63 | 126 | 180 | 24 [sea | 903 | 1207 v2 1800 11 | 43_| or | 128 | 104 | 30 | ses | oze | 1250 1500 194 [38 [59 [118 [102 | 298 [497 [817 | 1102 we 1800) 144 [38 [62 [114 [105 | 308 [sea [esr | 1150 1500 720 | 35 | 85 | 100 | 145 | 271 | 460] 754 | 1010 a 1800 129 [32 | 87 | 100 [145 | 273 | 453 | 753 | 1050 1500 vor | 28 | so | ea | 120 | 240 | aoe | 60a | ozs "800 “19 [28 [se | et | 127 | 247 | 420 | 682 | 067 "6 1500) [23 [4s [80 [2 | ar [avo [600 | est This is the rated capacity of the gear box. Please refer selection procedure on Page No. 2 for selecting suitable units. For ratings above 1800 Rpm and below 1500 RPM input speed, refer Intermediate ratios are also possible, for details refer to SHANTHI. 2SSS — Shanthi 6a ———— Cooling Tower Gear Units ‘SHANTHI GEARS LIMITED f COIMBATORE - 641 005, INDIA Thrust Load & Actual Ratios Date : 2011/12 Allowable Thrust Load in (KN) on Slow speed Shaft for a limiting value of output bearing life as 100,000 Hours. Ly Nominal ‘Speed (rem) Gear Unit Size Ration [~Motorn, | Fann, | 130 | 160 | 185 | 225 | 265 | 920 | 370 | 482 : 7800 360 os | oa | 2 | 7 | ws | 32 | 2s | aor 7500 so fo | | | | ws | ms | 27 6 se 1800 sx | | we [7 [as [see [ 32 | 36 428 7500 28 fos | us | 155 | es | 20 | m5 | 37 45 200) zee [to | na [9 [7 | aoa [oar [oss | sao 7500 ze | 0s | n75|1575| 1 | 2s | 2 | ars | «7s 7A 3200) zea to | 121 | ses | 19 | ara [ 265 | a0 | 407 7500 an [| ws pw | aos | zs | | ais | sis : 800 as [ua | 2s | ws | 26 | 22 [20 [ass | ot +500) ses [| ris | 13 | aras[ ars | 235 | 305 | 48 54 : +800 20 | ne | asa [vs | 21a | 2x2 [oz | asa | sao 7500 wer [2s | | 1s | 26 | 5 | sas | 49 58 o 200 seo [za | | 12 [ 2s | es | us | ors | sor 7500 iso [13 | 7s 12 | 208 | 20 | aos | sare | oa2 na +200 ser [saa_| v2 [| re7 [203 | ora | a5 | sar | oo 7500 v4 [ ise | 15 | 175 | 266 | 29 | a8 | sere | a7 tas 3800) va [ias | a5 | wo | 209 | 203 | o9a | a7 ar 500 vo [ 43 | 158 | a | 2s | 1 | «1s | ooze | 75 a 7800 wo [sai | t56 | ae | |e | ze | os | ria +500 wor [ae [wes [2 | as [ssa | as | os9 [76 e 7200 we [iar | 2 [a | aa |e | | ee | vs 7500 [iss | 71 | 220 | zee | aes | «ss | os7e | ers Actual Ratios : Nominal Unit Size Ratio [130 160 185 225 | 268 320 370 [442 8 aeee [soos | soo | 4665 | sory | eer | sosr | soar 56 sess | _sese | sass | sa53 | sees | ssaa | soo | S002 63 a0 | asec | asee | e200 | sara | 6208 | ara | oats 72 705s | 7086 | ross | eases | rte | roar | vase | 7238 3 7esi_| rest | esr | reso | 0222 | ros | az | azz ° aero | sew | air | asco | ao | sass | aon | aaa 0 voooe | iaors [ iors | e623 | 0250 | aes | 0260 | 10.280 s12_| tos | 10923 | 10028 | toss | sor | so7eo | stor | n077 v5 | 1240 | 1240 | 2aao | 12000 | 12ers | iazes | iors | i208 % wears | ia00s | tooo | vase | tarez | tavee | vata | tae 16 15406 | 154i [| sao | 490s | 15600 | 15202 | 15600 | 15036es 5, lh 3 Cooling Tower Gear Units ‘SHANTHI GEARS LIMITED COIMBATORE - 641 005, INDIA Date : 2011/12 PRINCIPAL DIMENSIONS (mm) fe ao ["[e[u—[o[e[s;@leyelel lel e(s[ els [sfelalaye a a ots | as Be | we] we) weal Te ea sw [Tome] HO | wo [ame Pree we | we | wae] He | Be [ae Poo fae | | w ae |W |] |S] THR] ew |S | | BY Yer | | BSS ae - wa : wer 7 mL a | m| ve| | oe[ [wel « [we (wefwsfa | =| [mle] pw © t ws [eof mo] a] wo] [wml 6 [em [wml [ole lm) wl wl ae @ wo | wo] | oo] woo] a6 | wool « [um [wee veo | o| fall rir 28 z———— Shanthi &: LL Fear Cooling Tower Gear Units ‘SHANTHI GEARS LIMITED COIMBATORE - 641 005, INDIA Date : 2011/12 1. _ Dip stick assembly with Drain plug 2. Magnetic float switch with temperature sensor (optional) Pump Lubrication (optional) Fan Cooling (optional) Backstop arrangement (optional) Regreasable Labyrinth Arrangement Extended output shaft (optional) Breather cum oil filing plug 7———— Shanthi Gas73 LL Cooling Tower Gear Units Bevel input shalt Input extension keyway Oil linger Input brealing =A Input bearing - B Lock - washer Lock nut Adjustable plate Intermediate bearing -A Intermediate pinion shaft Bevel wheel seat key ‘SHANTHI GEARS LIMITED COIMBATORE - 641 005, INDIA Date : 2011/12 Bevel wheel Oil retainer plate Intermediates bearing - B ‘Output shaft bearing - A Spacer for distance reduction Output gear wheel Output gear wheel seat key Output sbaft (taper straight extension) Output shaft extension key Output shaft bearing - B Output oil sealShanthi Geo, 5) REGIONAL OFFICES & BRANCHES Creed No, 24/3, 1st Floor, 1st Block, SNe meee Td CEE TE eer eer UP cr wioceel eee a EAN 337-340, 3" Floor, neo ae Sayajigunj, Baroda - 390 005 ne et Eee) Pee teeter) Ba E-mail: bar.br@shanthigears.com Ue che ieee Pea rN Tecra S Tr Ree ae eC ea) eee ee Cee Mere rr On A ae erry td RM. Colony, Dindigul- 624 001 E-mail: che.br@shanthigears.com aera Pore ee aaa Near South City Mal, Pore emeia DPOREEDCar eros EPO en ee Tretel\ PO No. 11, Pandiyan Nagar, Thirunagar, Madurai - 625 006 rn Cerrrs) eR Cerro a ee RUT 222, Creative Industries Building, Sundar Nagar, Road No. 2, Kalina, eee) eee rs ear pres or) Fax :491 22 26662349 Sa Reet) Plot No. 72, Ground Floor, ea ny kharkhana, Secunderabad - 500 015 PR reacrOrer) eRe er ay SHANTHI GEARS LIMITED - C Unit Avinashi Road, Muthugounden Pudur Post, Coimbatore-641 406, Tamil Nadu, India Cees ier oar ete eee oASHANTHI GEARS LIMITED 304-A, Shanthi Gears Road, Singanallur, Coimbatore - 641 005. Tamil Nadu, India. Ey ey eye een eee TEL Pee ee ees re Sea ee