INV - 2229 Failure of Exciter Gearbox (DF601V) of Sinter Screens at SP4 - 124048

Ref.
Doc No: SSTG/MES-ALL/05

Effective Date: 01.03.2011
Form No: SSTG/FORM/RCFA/18
Rev : 0.04 Dated: 20/01/2020
Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Customer Request Number/ Notification Number: 100001777607
INVESTIGATION REPORT
1. Failure Type (Tick the appropriate option)
SMP Non- Inadequate Poor Assembly/ Spare Operational Poor Design

Compliance Maintenance Repair Quality Malfunction Commissioning Problem
Management Sys
2. The Incidence: Failure of Hearth layer screen 7.009 exciter gearbox (DE) at SP4.
3. Ref-RCFA-SSTG-Archive: MEG/INV/877/08; MEG/INV/1131/11; MEG/INV/1273/13; SSTG/
INV/1812/16 & SSTG/INV/2034/18
4. Keywords: Exciter gearbox
5. Make: Screen – M/s. International Combustion Pvt. Ltd. & Exciter gearbox –M/s. Schenck-Process
6. Equipment ID in SAP-PM*: 10095874
Department : Sinter Plant
Section : SP4
Date/ Time : 10.01.2020/12:00 PM
Location : Hearth layer screen 7.009
Referred by : HoMM SP
7. Investigated By : Ankush Sharma, Aditya Jain and Himanshgu Mandal
8. Discussed With : Rajesh Mishra (Chief, One SSTG), N Rajesh Kumar (CIMMM), Amit Bikram
Sengupta (HOMM-SP), Sourav Paul (SP4)
9. Syndicated With : Amit Bikram Sengupta (HOMM-SP), Sourav Paul (SP4)
10. Repeat Failure (Yes/No): Yes
11. Data Collection & Observations:
• In SP4, the sinter produced is screened through sinter screens E7009 and E7010 before sending it as a
product sinter to Blast Furnaces. Both the screens E7009 and E7010 are M/s. IC make single deck
linear motion type vibro screens (size 3100mm X 8500mm). In each screen for vibration, the excitation
force is generated by two exciter gearboxes connected in series. General arrangement of exciter
gearbox drive components is shown in the below fig.-1.
1 of 25
Ref. Doc No: SSTG/MES-ALL/05
Rev : 0.04 Dated: 20/01/2020
Fig.1- General Layout of Hearth layer screen E 7.009
Fig.2- Drive arrangement of exciter gearbox
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Rev : 0.04 Dated: 20/01/2020
Fig.3
-
Fig.3.a Fig.3.b
• On 10.01.2020, at around 12 PM drive end exciter gearbox of hearth layer screen 7.009 failed. Motor
tripped in overload.
• On observation, DE bearing of long shaft was found jammed. This bearing was showing high
temperatures for last 10 days around 58-600C and was planned to change in next monthly shutdown
but failed before that.
• The failed gearbox was opened in assembly shop and observed, gear teeth of both mating gears of
small & large shaft were severely broken at 4 places and destructive pitting marks along the pitch line
were observed on rest of the teeth as shown in figure 4 & 5.
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Rev : 0.04 Dated: 20/01/2020
Fig. 4 Condition of Failed Gearbox Fig. 5
• Lubrication oil turned to black colour and observed with burnt odour. Heating marks found on internal
surface of gearbox housing as shown in figure 4.
• All the four bearings (22326 CCJAW33 VA405 Make- M/s. SKF) found with severe heating marks
as shown in figure 7.
All 4 nos. bearings of failed

exciter gearbox found with screen
duty class
Fig. 6 Fig. 7
• As per bearing OEM M/s. SKF manual, bearing no 22326 CCJAW33 VA405 is special screen duty
bearing and having internal radial clearance C4.
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• Cage and rollers of the failed exciter gearbox bearing were found damaged and seized. Severe spalling
observed on all the rolling elements of the failed bearing with decolourization (heating marks) as
shown in figure 9 below.
Fig. 9
Fig.8: Damaged bearing
• This failed exciter gearbox was overhauled from M/s. Schenck and installed in the month of Aug’2017.
Thus, exciter gearbox has failed after giving a service life of 2.5 years.
12. Background:
Previous failure history
• Failures in exciter gearboxes of sinter screens (Hearth Layer and Return fines) were a chronic problem
in SP3 and SP4 since commissioning. In 2013, RCFA was carried out having investigation number
MEG/INV/1273/2013 in which the reason of premature failure of exciter gearboxes mainly due to
unwanted high impact loads coming on exciter gearboxes during each start/stop from double cage
motor with frame size 355 S (with higher shaft torque).
• The recommendations of this RCFA i.e., new motor with new frame size(315S) & cardan shaft of
improved design was implemented in SP#3 screens in 2015 whereas in SP4 it was implemented in
2018.
• After implementation of recommendations in SP#3 in 2015, only 1 no failure has been reported in
Aug’2017 after giving service life of 2.5 years.
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Rev : 0.04 Dated: 20/01/2020

• In SP#4, after implementation of recommendation in 2018, 2 nos. failure happened at hearth layer
screen 7.009 out of which 1 no failure happened at DE gearbox after 28 months & 1 no at NDE after
11 months.
SCREEN 7.009 EXCITER FAILURE DETAILS SP#4
Sl No. EQUIPMENT DATE DE EXCITER DETAILS Type Life given Sl No. DATE NDE EXCITER DETAILS TYPE Life given
1 E7.009 07-11-2016 DE- exciter changed with New New 1 08-06-2016 NDE - exciter changed (New) NEW
DE- exciter changed due to Schenk NDE - exciter (shop Shop

2 E7.009 08-05-2017 13 months 2 18/07/2017 11 months
high temp & oil leakage dr side Overhauled overhauled) changed with new Overhauled
DE - exciter changed due to Schenk
3 E7.009 01-10-2020 28 months 3 20/04/2018 NDE - exciter changed New 9 months
high temp & oil leakage dr side Overhauled
Schenk
4 14/03/2019 NDE - exciter changed 10 months
Overhauled
• However, both these failed gearboxes had also run in the period when recommendations were not
implemented.
14. KPI Impacted & Delay (Loss) information: N/A
15. Protective Devices: Hearth layer screen motor overload current tripping interlock is in service.
16. SMP/ QAP/ Drawings & Sketches: General arrangement drawing of hearth layer screen is attached in
annexure-3.
17. Failure Analysis:
A. Material Defect
• Gear was made of 42CrMo4 steel having tempered martensitic microstructure. Hardness, chemistry
and microstructure are satisfactory.
• This is as per OEM design, hence failure due to material defects can be ruled out. OEM gearbox MoC
datasheet is attached in annexure-4.
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B. Improper Lubrication
Exciter gearbox Oil level
• The lube oil level in the gearbox was maintained at 220 mm (Dip stick level) from port 1 which was
recommended by the OEM based on the gearbox inclination angle w.r.t to horizontal.
Port no1
Fig. 10
Oil changing frequency
• The department has TBM of lube oil changing in the exciter gearbox after every shutdown (30-45
days of service) which is as per OEM catalogue i,e the lubrication oil has to be changed after 1000
hours of continuous to increased service life.
• Oil replacement history is attached in annexure-5.
Type of lubricant
• The lubrication oil ‘Servo mesh plus 220 (Make- IOCL) which is used in exciter gear box is an old
generation oil (only supplied to TSL and rest of other areas it has been stopped). It has less oxidation
stability and EP additives compared to new generation oil/OEM recommended oil (Castrol Opti
gear BM 220).
• Lower EP additives resulted in breakage of Elastohydrodynamic lubrication (EHL) film and less
oxidation stability resulted in faster oxidation of oil (TAN value increases within a short time). This
resulted in faster wear of bearing rolling elements which ultimately leads to increase bearing
clearance.
• It is noticed that Castrol Opti gear BM 220 oil which is given in OEM manual have Microflux trans
(MFT) and Plastic deformation (PD) additive which helps to protect against scuffing and shock
loading and also prevents the progression of pitting in gears. This is also not present in the oil used.
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Oil analysis
• The department sent oil sample after every shutdown (30-45 days) when the oil is changed for oil
analysis as per SAP-PM schedule given below.
Equipment Measurement position Measuring point Description of measuring point Upper range limit Lower range limit Int. meas. Code group Chara
unit ctstcU
nit
10095874 SP4E7009D_GB_1D 2758301 GEAR BOX STATUS
10095874 SP4E7009D_GBL_1D 2758302 OIL LEAKAGE STATUS
10095874 SP4E7009D_GBN_1D 2758303 NOISE FROM GEAR BOX STATUS
10095874 SP4E7009D_GBS_1D 2758304 FUMES AND BURNING SMELL STATUS
10095874 SP4E7009D_GB_1W 2758305 GEAR BOX STATUS
10095874 SP4E7009D_TOB_1W 2758306 TEMPERATURE OF BEARING 70.00 30.00 °C REASON °C
10095874 SP4E7009D_EC_1W 2758307 EXTERNAL CLEANING STATUS
10095874 SP4E7009D_OL_1W 2758308 OIL LEVEL STATUS
10095874 SP4E7009D_GB_2W 2758309 GEAR BOX STATUS
10095874 SP4E7009D_GREASE_2W 2758310 GREASING STATUS
10095874 SP4E7009D_GB_1M 2758311 GEAR BOX STATUS
10095874 SP4E7009D_MM_1M 2758312 MATCH MARK FOUNDATION BOLT STATUS
10095874 SP4E7009D_OB_1M 2758313 BREATHING MATING FACES END COVERS STATUS
10095874 SP4E7009D_VM_1M 2758314 VIBRATION MEASUREMENT 3.00 0.10 MMS REASON mm/s
10095874 SP4E7009D_NM_1M 2758315 NOISE MEASUREMENT 85.00 0.00 dB REASON dB
10095874 SP4E7009D_GBB_1M 2758316 AIR BREATHER STATUS
10095874 SP4E7009D_OHF_1M 2758317 OIL CONDITION STATUS
10095874 SP4E7009D_GB_2M 2758318 GEAR BOX STATUS
10095874 SP4E7009D_FG_2M 2758319 FERROGRAPHY STATUS
10095874 SP4E7009D_OA_2M 2758320 OIL ANALYSIS STATUS
• However only ferrography reports were found available, no oil analysis reports for TAN, viscosity
& water contamination test were found. Last ferrography analysis was done on 04.11.2019 during
shutdown when complete oil was changed. However, ferrography report did not show any
abnormality.
• Lubrication oil of failed gearbox on 10.01.2020 was also sent for ferrography & oil analysis.
Ferrography report was found marginal due to the presence of marginal quantities of abnormal wear
particles and recommending flushing of oil as shown in annexure 2.
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Rev : 0.04 Dated: 20/01/2020

• However, oil analysis report was found critical and having high TAN value of oil.
• This indicates lubrication oil (Servo mesh plus 220) degrading in 30 to 45 days in terms of
TAN value as shown above.
C. Overloading
• The hearth layer screen 7.009 both in SP3 & 4 has rated capacity of 374 TPH & designed capacity
of 490 TPH.
• Maximum production in SP3 & SP4 in a shift is around 375 TPH which is lower than design
capacity of 490 TPH.
• The feed rate was also checked & found ok with in rated capacity of 375 TPM at screens,
• Hence overloading due to high material flow can be ruled out.
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D. Increase in internal radial clearance of bearings
• It was also noticed that out of 7 gearboxes failed in last four years, 3 nos. are M/s. Schenck over
hauled and one is shop overhauled.
SCREEN 7.009 EXCITER FAILURE DETAILS SP#4

Sl No. EQUIPMENT DATE DE EXCITER DETAILS Type Sl No. DATE NDE EXCITER DETAILS TYPE
1 E7.009 11/7/2016 DE- exciter changed with New New 4 6/8/2016 NDE - exciter changed (New) NEW
DE- exciter changed due to high temp & Schenk NDE - exciter (shop overhauled) changed Shop
2 E7.009 5/8/2017 5 18/07/2017
oil leakage dr side Overhauled with new Overhauled
DE - exciter changed due to high temp & Schenk
3 E7.009 10/1/2020 6 20/04/2018 NDE - exciter changed New
oil leakage dr side Overhauled
Schenk
7 14/03/2019 NDE - exciter changed
Overhauled
• Failed DE gearbox of screen 7.009 on 10/01/2019 was also M/s. Schenck overhauled, however no
overhauling reports are available with department.
• All the four bearings 22326 CCJAW33 VA405 found with severe heating marks on them a shown
below in figure 12.
Fig.12
• Internal clearance of all four bearings of long & short shaft were measured. Radial clearance of
bearings (DE & NDE) found increased more than maximum recommended limit as per bearing
OEM M/s. SKF as shown in the below table.
22326 CC JA W33 VA405 , Cylindrical bore bearing clearance table
Befor mounting RIC After mounting RIC After mounting RIC

Shaft type Side
(As per standard) (As per standard) (Actual)
DE side 0.35
Large shaft
NDE side 0.28
0.19 - 0.24 0.14 - 0.20
DE side 0.22
Short shaft
NDE side 0.21
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Rev : 0.04 Dated: 20/01/2020

• From above data it can be concluded that clearance of bearings of large shaft increased much more
than recommended limit and led to spalling on DE end bearing and heating marks on both side
bearings.
DE bearing of large shaft found with NDE bearing of large shaft found with
severe spalling & heating marks heating marks
Fig.13 Fig.14
• Clearance of short shaft were also found increased from recommended residual clearance but less
than large shaft bearings.
• Thus, it can be concluded that, clearance of exciter gearbox bearings increased due to degradation
of lubrication oil within 30 to 45 days in terms of high TAN value. This degradation of oil
aggravates wear inside rolling elements and increase in radial clearance.
• Thus, increase in residual clearance of bearing after running in service for 2.5 years caused
sliding motion of rolling elements instead of rolling which results in temperature rise and
spalling of bearing which ultimately led to bearing failure & jamming. Jamming in DE
bearing also caused gear teeth breakage in service.
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18. Reasons of failure:
• Increase in internal clearance of bearing after running in service for 2.5 years caused sliding of
rolling elements which results in temperature rise and spalling of bearing.
• Further fast degradation of Servo mesh plus 220 (old generation oil) in exciter application resulting
is accelerated increase in bearing clearance.
19. Recommendations (Corrective):
Sl No. Recommendations Responsibility Target Recommendation.

Date No.
1. Failed exciter gearbox to be SP4-Mech Done
N/A
changed.
20. Recommendations (Preventive):

Date No.
2. OEM recommended oil (Castrol SP4-Mech,
Opti gear BM 220) to be used in
30.04.2020 400001782078
place of Servo mesh plus 220 (old
generation oil).
3. Running oil replacement of exciter
to be done in 30-45 days. SP4-Mech
It is to be ensured that oil

replacement is done with complete
30.04.2020 400001782079
flushing of old oil (as per SOP).
The job of oil replacement to be

cross checked by competent agency
(SSTG & MED)
4. Unique numbering of all (in-service SP4-Mech
& Spare) the exciter gear boxes to be
30.04.2020 400001782227
done and history of exciters to be
maintained.
5. SMP for exciter gearbox to be SSTG
30.06.2020 400001782081
developed and training to be given.
6. . Overhauled exciter gear box to be
accepted only after verification of
QA reports as per the QAP SP4 Mech
(SSTG/QAP/MEC/0828) Attached as 30.04.2020 400001782228
annexure. - Same to incorporated
in Overhauling Contract
specification.
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21. Recommendations (Predictive):

Date No.
7. Oil analysis along with ferrography
to be done in every oil replacement
(30-45 days) and same to be
incorporated in SAP-PM schedule. SP4-Mech 15.03.2020 400001782080
In case of critical reports for oil
analysis or ferrography, exciter
gearbox to be replaced.
22. Potential Savings:
Chief
One Shared Services Technology Group
Prepared By : Ankush Sharma & Aditya Jain
23. Comments of Chief Electrical Maintenance/ Mechanical Maintenance:
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Annexure 1:- E7.009 failed DE exciter gearbox oil ferrography analysis report
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Annexure 2:- Oil analysis report
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Annexure 3:- General arrangement drawing of hearth layer screen E7.009
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Annexure 4:- Exciter gearbox MoC datasheet
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Annexure 5:- Exciter gearbox (DE/NDE side) oil replacement history
Oil replacement history of DE side / NDE side exciter gearbox
Date of replacement Oil changing interval (no. of days)
22-Jan-19 51
14-Mar-19 24
07-Apr-19 30
07-May-19 31
07-Jun-19 29
06-Jul-19 49
24-Aug-19 30
23-09-2019 32
25-Oct-19 40
04-Dec-19 37
10-01-2020
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Annexure 6:- QAP of gearbox
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INV - 2229 Failure of Exciter Gearbox (DF601V) of Sinter Screens at SP4 - 124048

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Ref.

Doc No: SSTG/MES-ALL/05

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

SMP Non- Inadequate Poor Assembly/ Spare Operational Poor Design

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Fig.1- General Layout of Hearth layer screen E 7.009

Fig.2- Drive arrangement of exciter gearbox

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Fig. 4 Condition of Failed Gearbox Fig. 5

All 4 nos. bearings of failed

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

DE- exciter changed due to Schenk NDE - exciter (shop Shop

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

SCREEN 7.009 EXCITER FAILURE DETAILS SP#4

22326 CC JA W33 VA405 , Cylindrical bore bearing clearance table

Befor mounting RIC After mounting RIC After mounting RIC

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

19. Recommendations (Corrective):

Sl No. Recommendations Responsibility Target Recommendation.

20. Recommendations (Preventive):

Sl No. Recommendations Responsibility Target Recommendation.

It is to be ensured that oil

The job of oil replacement to be

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Sl No. Recommendations Responsibility Target Recommendation.

One Shared Services Technology Group

Prepared By : Ankush Sharma & Aditya Jain

23. Comments of Chief Electrical Maintenance/ Mechanical Maintenance:

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Oil replacement history of DE side / NDE side exciter gearbox

Date of replacement Oil changing interval (no. of days)

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

Investigation Report: SSTG/INV/2229/20 Date: 04.03.2020

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