WS09TZ200052

TATA STEEL LIMITED

P.O. Bistupur Jamshedpur

Jharkhand India, 831001

INSPECTION REPORT

Danieli Service job Number WS09TZ200052

Service job Type MSS30I 02G05000 03

Prepared by: Ajay Kumar

Checked by: Karthik R / Mahesh Kumar

Danieli Service ref: DIL-TS- GEARBOX-052-PRE-17

Rev: 00

Date: 18/12/2017
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A. FIRST LOOK INFORMATION

1 Gearbox Type Bevel gearbox

2 Number of Stages 1 stages

3 Distance between I/P to O/P Shaft 380mm

4 Srv No MSS30I 02G05000 03

5 Jet Position WS09TZ200052

6 UMC No 5894A0330

7 Area LD # 2

8 Driven Equipment Fin Fan

9 User Details Mr. Adesh yadav Email: adesh.yadav@tatasteel.com

10 User Contact Details Tel : Mobile: 9204651935

11 Date of receipt 15/12/2017

12 Scope of work Overhauling

13 Problem Reported Sound / leakage

14 How long the problem was 1 month

15 Previous repair Date & Workdone 2006

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B. TECHNICAL INFORMATION

Gearbox type: : Bevel Gear Unit

OEM. : Amarillo

Year of Supply : 2006

Lubrication Type : Splash type

Lubrication Oil : No info available

Gear Ratio : 5.5 : 1

Drive Motor capacity : No info available

Weight without oil : No info available

Operating time (hours/day) : 24 hrs

Ambient Temperature : No info available

Max Oil Sump capacity : No info available

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C. INSPECTION PLAN

SL. AREA OF INSPECTION INSTRUMENTS USED

Bearin
1 Bearing condition Visual, Feeler gauge
2 Seal conditions Visual
3 Housing conditions Visual checks
4 Housing bore dimensions Inside Micrometer, Bore dial
5 Housing Flatness checks Surface plate / feeler gauges
6 Shaft bearing seating, Coupling surface Outside Micrometer
7 Shaft Run out checks V Blocks / Dial indicator
8 Shaft condition checks Die penetrate test (DPT / UT)

9 Gears tooth cordial thickness Disk micrometer

Pin / Ball measurements
10 Gear tooth surface condition Visual checks Die penetrate test / Hardness test
11 Gear Backlash Dial gauge

12 Input / Output Coupling conditions Visual checks / Micrometer

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D. OBSERVATIONS

Gearbox as received condition Top cover removed

Housings condition before cleaning Housings condition after cleaning

Gears are found with Major pitting – NOT ACCEPTABLE

 WS09TZ200052

Bearings found with rusted and dust, rotational mark on the outer race & pitting on rolling elements.

Bore dimension checking carried out on all the bearing bores.

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E. MEASUREMENTS

1. HOUSING

HOUSING TYPE FABRICATION

MEASUREMENTS
Bore No. TOLERANCE VALUE H7 REMARKS
1 2 3
A Ø80 (+0.030, -0) -0.02 -0.01 0.00 Polishing

A1 Ø146 (+0.040, -0) +0.02 +0.01 +0.02 Polishing

B Ø117 (+0.035, -0) +0.03 +0.05 +0.04 Polishing

B1 Ø136 (+0.040, -0) +0.02 +0.01 +0.02 Polishing

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F. SHAFTS

SHAFT DIAMETER
SHAFT POSITION SPECIFIED AREA TOLERANCE p6 REMARKS
1 2 3
INPUT DE SIDE Bearing seating Ø41.2 (+0.026,+0.042) +0.03 +0.04 +0.03 ACCEPTABLE

INPUT DE SEAL AREA Seal area Ø38 (+0.026,+0.042) +0.03 +0.03 +0.04 ACCEPTABLE

INPUT NDE SIDE Bearing seating Ø62 (+0.032,+0.051) +0.04 +0.03 +0.04 ACCEPTABLE

OUTPUT DE SIDE Bearing seating Ø72 (+0.032,+0.051) +0.04 +0.05 +0.06 ACCEPTABLE

OUTPUT NDE SIDE Bearing seating Ø78 (+0.032,+0.051) +0.05 +0.05 +0.04 ACCEPTABLE

OUTPUT SEAL AREA Seal area Ø76 (+0.032,+0.051) +0.03 +0.04 +0.03 ACCEPTABLE

Run out check

TOLERANCE 0.05 ACTUAL RUN OUT REMARKS

SHAFT POSITION
1 2 3
INPUT PINION 0.03 0.03 0.04 ACCEPTABLE
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2. GEARS
TECHNICAL INFORMATION
S.
No DESCRIPTION INPUT PINION OUTPUT GEAR REMARK
.

1 Gear Type BEVEL BEVEL

2 Number of Teeth 10 55

3 Outside Diameter 65 280

4 Face Width 52 35

NOT ACCEPTABLE NOT ACCEPTABLE NOT ACCEPTABLE

5 Surface condition

Module
6

7 Tooth thickness Not yet measured Not yet measured

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3. BEARINGS

BEARING POSITION BEARING TYPE SPECIFIC NO. CONDITION REMARKS

INPUT DE SIDE TAPER ROLLER TIMKEN 336 - RUSTED AND JAMMED REPLACE
332 USA

INPUT NDE SIDE TAPER ROLLER TIMKEN RUSTED AND JAMMED REPLACE
H913810 –
H913842 USA

OUTPUT DE SIDE TAPER ROLLER TIMKEN RUSTED AND JAMMED REPLACE

H715311 -
H715345 CDI
19 USA

OUTPUT NDE SIDE TAPER ROLLER TIMKEN RUSTED AND JAMMED REPLACE
LM814810 –
LM814849 USA
ZC

G. RECOMMENDATIONS

 Parts need to be replaced / reused as per the BOM.

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H. TECHNICAL REPAIR BILL OF MATERIAL

REPAIR BILL OF MATERIAL
JET POSITION: WS09TZ200033 DATE: 23/10/2017
SL. Description 1 Description 2 Description 3 QTY UM REMARKS CODE
1 BEARING 336 -332 USA TIMKEN/FAG/SKF 1 NR REPLACE P
2 BEARING H913810 – H913842 TIMKEN/FAG/SKF 1 NR REPLACE P
3 BEARING H715311 - H715345 TIMKEN/FAG/SKF 1 NR REPLACE P
4 BEARING LM814810 – LM814849 TIMKEN/FAG/SKF 1 NR REPLACE P
5 LOCK NUT 2 NR REUSABLE P
6 LOCK WASHER 1 NR REUSABLE P
7 HEX HEAD BOLT M10X25-8.8 UNBRAKO 4 NR REPLACE P
8 HEX HEAD BOLT M8X25-8.8 UNBRAKO 6 NR REUSABLE P
9 HEX HEAD BOLT M12X30-8.8 UNBRAKO 10 NR REUSABLE P
10 HEX SOCKET BOLT M12X30-8.8 UNBRAKO 8 NR REUSABLE P
11 GASKET 1MMx 500Mx500M 1 NR REPLACE P
12 EYE BOLT M20 1 NR REUSABLE P
13 KEY 08X10X65 1 NR REUSABLE P
14 OIL SEAL 473228 VITON TYPE 2 NR REPLACE P
15 OIL SEAL 417349 VITON TYPE 2 NR REPLACE P
16 HOUSING 1 CASTING 1 NR REUSABLE M
17 HOUSING 2 CASTING 1 NR REUSABLE M
18 INPUT PINION Ø 65, W-52, 10z 1 NR REPLACE M
19 OUTPUT GEAR Ø280, W-35, 55z 1 NR REPLACE M
NOTE:- P = PURCHASE / STANDARD ITEM
M = MANUFACTURED / MAKE ITEM