JOB REPORT

MACHINERY MAINTENANCE
Tag # ME-135 C Description Gear Box (P-101 C) Date April 24, 2021

SAP Work Order 11128611 Area 01 (Urea) Job Duration

1. Background

P-101 A, B and C are the three positive displacement motor driven pumps that pressurize liquid

Ammonia from suction pressure 23 kgcm-2 to 240 kgcm-2 discharge pressure individually. Motor

Power is transmitted to pump through torque converter that can adjust the speed of pump

accordingly. Between Torque converter and crankshaft, the Gear Box (ME 135 A/B/C) is

installed in each pump to reduce the speed form 1450 to 114 rpm max.

Before the month of April, foaming was being observed in gear box oil (GARDE: OMALA 220

S2G 220) of all three pumps. Several attempts had been made to eliminate foaming but none

worked out. So, it was decided to change the oil category SHELL OMALA 220 S2 G 220 to

CALTEX MEROPA 220.

This foaming was found severe in Pump P-101 C so it was decided to change its oil first. Pump

P-101 C was handed over in order to replace the oil grade but during practiced visual

investigation from casing windows to gear box ME-135 C shrieking gear tooth damage was

found on 2 out of 3 shafts assemblies. In order to see all the gear tooth, gear box was freed from

both input and output couplings and observed.

2. Scope of Work

Based upon visual investigations made and observations as discussed in below paragraphs it was

decided to dismantle the gear box shafts and shift them to workshop for maintenance that

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increased the maintenance time. Later on, 3 out of 4 gears, two shafts and all the bearings were

replaced.

3. Observations

After visual investigations from window thorough observations was carried out by freeing the

gear box from inboard and outboard couplings with upper-half casing removed. Following

observations were made during field inspection and workshop maintenance,

3.1 Axial Floats at handover

Before dismantling the shaft assemblies, axial floats were recorded for each shaft. These floats

are given in the table 1,

Table 1 (Axial Floats before shifting to workshop for maintenance)

Sr. # Description Axial Float (mm)

1 High Speed Shaft (Input Shaft) 0.05 (0.12-0.15)
0.06 (0.15-0.18)
2 Intermediate Speed Shaft
0.13 (With Force)
3 Slow Speed Shaft (Final Output Shaft) 0.94 (0.3-0.4)

3.1 High Speed Shaft (See Annexure 1)

Sr. # Description State

Both the bearings (Pos. 16 & 17) were found in good condition. No cage
1 Satisfactory
distortion or damage to rolling elements was found.
Both the bearings (Pos. 16 & 17) were found in good condition. No cage
2 Satisfactory
distortion or damage to rolling elements was found.
DPT of High speed shaft pinion was found satisfactory. No tooth damage or
3 Satisfactory
looseness was observed in it.
Input shaft (Pos. 7) was in good health. No fretting or corrosion under the pinion
4 Satisfactory
was observed.
5 The measured axial float was 0.94 mm. (Recommended: 0.12 – 0.15) Not In range

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3.2 Intermediate Speed Shaft (See Annexure 1)

Sr. # Description State

Both bearings (Pos. 18) were in good health. Inner race, outer race, cages and
1 Satisfactory
rolling elements were in satisfactory condition.
ISS bull gear (Pos. 8) in meshing with high speed shaft pinion was also found in
2 Satisfactory
good condition. No looseness on shaft was observed.
Severe pitting, material removal and tooth damage was observed in DPT of ISS
3 pinion (Pos. 9). The observed damage was not localized to single tooth rather Damaged
spread over many tooth. See figure 1, 2 &3.
For intermediate speed shaft: Unevenness, fretting and material absence was
4 Damaged
observed on it under bull gear (Pos. 8) in mesh with input pinion.
5 The measured axial float was 0.13 mm. (Recommended: 0.15-0.18) Not in range

3.3 Slow Speed Shaft (See Annexure 1)

Sr. # Description State

Both Bearings (Pos. 20 & 21) were found operating and in good health. None of
1 Satisfactory
its components was found damage.
Slow speed shaft (Pos. 11) was in good condition. No fretting or damage was
2 Satisfactory
noticed.
DPT of slow speed shaft bull gear (Pos. 10) tooth was carried out. Severe pitting
3 and material absence was found. But this was localized to some of the tooth. See Damaged
Figure 4.
4 The measured axial float was 0.94. (Recommended: 0.03 – 0.04). Not in range

3.4 Filters and Lip Seals

Sr. # Description State

Both the filters were in satisfactory condition. The choking was not found but one
1 Satisfactory
of the filter was found blackish.

2 All the lip seals were in good health and not found leaking or lip-hardened. Satisfactory

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MACHINERY MAINTENANCE
4. Work Done
In order to rectify the gear box damage, following maintenance activities were performed after
carefully examining the damage occurred, material availability and pump down time.

4.1 High Speed Shaft

Since no tooth damage on the pinion gear, shaft fretting or bearing damage was observed so this
high speed input shaft was used as such. All the activities were focused to other two shafts and
meshing gears. See Figure 6.

4.2 Intermediate Speed Shaft

Since serious tooth damage, absence of material and shaft fretting was observed on intermediate
speed shaft so following activities were performed to rectify it, (See figure 7)

 Pinion (Pos. 9) was integral to the shaft so new shaft-pinion assembly was issued from
warehouse.
 Fretting did not allow the old bull gear (Pos. 8) to be used again. So, new bull gear (Pos.
8) was issued.
 This bull gear was heated at 250OC in electric oven and installed to shaft with
interference of 0.06 mm.
 Two new bearings (FAG 23236 & FAG 30236) were heated to 120OC using induction
heater and placed to shaft at 0.08 interference.
 Old bull gear and intermediate shaft-pinion assembly was reclaimed.

4.3 Slow Speed Shaft

Initially it was decided to revert the bull gear (Pos. 10) but later on due to pump down time
limitation and difficulty in retrieving the bull gear from shaft it was decided to use new shaft and
bull gear. (See figure 8)

 New shaft (Pos. 11) was issued from warehouse. Upon measuring the OD of shaft issued
from WH, it was found deviating from original shaft. So it was machined from machine
shop as per original dimension and new key was also machined.
 New bull gear (Pos. 10) was issued from warehouse and heated to 250OC and installed to
the shaft with interference of 0.07 mm.
 Preventively, both bearings were replaced with new bearings (FAB 23048) and installed
with interference of 0.07 mm by heating through induction heater at 150OC.

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 Both bull gear and shafts were reclaimed in normal routine after maintenance activity
completed and pump was in running condition.

4.4 Interferences and Floats

Interferences and floats are very important in shaft assemblies since it has wide effect on
performance of rotary equipment.
4.4.1 Interferences
Table 2 gives the interferences of shaft-bearing and shaft-gears assembly,
Table 2 (Final Installed Interferences)

Sr. # Description Interferences (mm)

1 Intermediate speed shaft-bearing (FAG 23236) 0.08
2 Intermediate speed shaft-bearing (FAG 30236) 0.08
3 Intermediate speed shaft-bull gear (Pos. 8) 0.06
4 Slow speed shaft-bearing (Both 23048) 0.07
5 Slow speed shaft-Bull Gear (Pos. 10) 0.07

4.4.2 Axial Floats

Table 3 describes the recommended range, individual axial float of shaft and float when all
shafts were installed with gear meshing,

Table 3: Axial Floats (In mm)

Shaft Individual Axial Float when Free Axial Float when in Mesh
Value Range Original Value Modified value Range
High Speed Shaft 0.06 0.24-0.30 0.17 0.17* 0.12-0.15
Intermediate speed shaft 0.13 0.31-0.35 0.33 0.21** 0.15-0.18
Slow speed shaft 0.96 - 2.30 0.36*** 0.30-0.40

*** Slow speed shaft axial float was recorded 2.30 mm. This was well beyond the range so motor side
cover plate was machined 1.85~1.90 mm at rear face to bring it within range specified.

** 0.18 mm Gasket added instead of 0.30 mm previous gasket installed.

* 0.30 mm Gasket added to high speed shaft.

Note: See Annexure 2 for comparison of old and new ME-135C shaft assemblies.

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MACHINERY MAINTENANCE
5. Basic Data and Information
Table 4: General Data
GEAR BOX (ME-135 C )

Sr. # Description Value/Data

1 Speed of input shaft (High speed shaft) 1450 rpm max.

2 Speed of output shaft (Slow speed shaft) 114 rpm max.

3 High speed shaft Pinion Tooth 21

4 Intermediate speed shaft bull gear tooth (Pos. 8) 66

5 Intermediate speed shaft pinion tooth (Pos. 9) 19

6 Slow speed shaft bull gear tooth (Pos. 10) 77

7 Old Oil grade SHELL OMALA S2 G 220

8 New Oil Grade CALTEX MEROPA 220

6. Startup
 No abnormality was reported during the startup and handover of P-101 C to the unit.
 Temperature and pressure drop of oil was found satisfactory.
 No noise or vibrational abnormality was reported.

Teams:
Day Shift Night Shift
Muhamad Bilal Hassan Abdul Hamid Shakir
Ahmed Noor Umer Hayat
Khalid Naseer Muhammad Yousaf
Muhammad Murtaza Nazar Hussain
Meer Hassan Abdul Rehaman

Prepared By:
Reviewed By: Noor-Ul-Hassan (DM-MACH 1)

ME-135 C
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MACHINERY MAINTENANCE
ANNEXURE 1

Figure 1 (Intermediate speed shaft pinion) Figure 2 (Intermediate speed shaft pinion)

Figure 3 (Intermediate speed shaft pinion) Figure 4 (Slow speed shaft bull gear)

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MACHINERY MAINTENANCE

Figure 6 (High speed Shaft)

Figure 7 (Intermediate speed Shaft) Figure 8 (Slow Speed Shaft)

Figure (Machining of new output shaft)

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ANNEXURE 2

MACHINED FACE (1.8~1.90mm)

GASKET ( 0.18 mm)

GASKET ( 0.30 mm)

Old Shaft-Gear Assembly (ME-135 C) New Shaft-Gear Assembly (ME-135 C)

ME-135 C