Instruction Manual

For
SPEED REDUCTION GEARBOX
H2-630
2250 kW, 989 / 119.99 RPM
M/s. DVC MEJIA THERMAL POWER STATION.
Application :- CEMENT MILL DRIVE

Premium Transmission Limited,

Unit I, P.B. No.5, Chinchwad,
Pune-411 019,
India.

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Index:

1. GENERAL DESCRIPTION
01. GENERAL
02. GEAR UNIT

2. INSTRUCTIONS FOR ERECTION, COMMISSIONING AND SERVICING

01. DISPATCH
02. UNPACKING
03. ALIGNMENT OF THE COUPLINGS
04. FIXING OF THE GEARS ON THE FOUNDATION
05. LUBRICATION
06. COMMISSIONING AND MAINTENANCE

ANNEXURE I

For instructions for separate base mounted lubrication oil system

ANNEXURE II

General Information

ANNEXURE III

Check list before starting & while running the gearbox.

DRAWINGS
1.0 General arrangement

: - B 63 H 302

2.0 Sectional arrangement

: - B 63 H 300

3.0 FLS P & I Diagram

:- B 63 H 303

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01.

GENERAL DESCRIPTION

01.01 GENERAL:

The installation consists of two main parts, the main gear unit and
lubrication system.
The main gear unit transmits the drive normally at reduced speed from
prime mover, an electric motor, to the girth gear of the Coal mill through
gear coupling.
Refer General arrangement drawing no.: B 2211-6300-SPCL-S-1119 for
over all dimensions and technical details.
The pipeline network delivers the lubrication oil to the antifriction bearings
and sprays for gear meshing.

01.02 THE GEAR UNIT:

EXTERNAL DETAILS
The gear case consists of two halves, fabricated out of M. S. Plates and
joined. The flanges of the two half casings are secured by bolts. The input
and output shafts extend from one end of the case. Both Input & output
shafts are connected through gear couplings to the motor and equipment
respectively.
The inspection covers are provided on the top side of the top casing for
gear mesh and internal inspection and four lifting lugs are provided on top
casing for lifting of top casing. Four lifting lugs provide on bottom casing are
to be used for lifting total gear unit.

INTERNAL DETAILS:
Two pairs of gears are mounted together in the gear case to form two stage
speed reduction unit.
All gear internals are made out case carburising steel, duly carburised,
hardened and precisely ground on gear grinding machine.
The pinion is integral with shaft and gearwheel is mounted on gear shaft
and are supported on antifriction bearings housed in the casing.

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02.

02.01

INSTRUCTIONS FOR ERECTION, COMMISSIONING AND SERVICING

DISPATCH:
Before dispatch, the complete gears are carefully assembled and submitted
to shop trials and are made ready to be put into service. Therefore, no
alteration should be made to the bearings lubrication system during
erection without our agreement. The gears are thoroughly cleaned and
protected with preservative before they leave our works. All openings are
temporarily closed with covers or plugs to avoid contamination due to
impurities. However they are dispatched without oil filling.

02.02

UNPACKING:
When arrived at destination, the gears have to be unpacked and checked in
order to ascertain that no damage has occurred during the transport. Till
unpacking the gearbox is to be stored in warehouse well protected against
precipitation and excessive temperatures as well as corrosive
environmental conditions. We would decline every responsibility for
damages due to unsuitable storage.
After unpacking, the exterior
machined surfaces coated with Black Japan are to be thoroughly
cleaned with kerosene or benzene.

02.03

ALIGNMENT OF THE COUPLINGS:

During the erection of the gear, special care must be taken for their
accurate alignment with the coupled machines. It is important that the
following points are observed:
i)

The two shaft ends must be concentric to each other.

ii)

The axes of the two shafts must be aligned properly. The alignment of
the gears is usually performed by means of the coupling flanges, which
must run true with their shafts. The importance of a careful alignment
of the couplings, in order to avoid vibrations, increases with the speed
of the gears. The shafts are first tested for concentricity, either by
means of a straight edge laid across the outside diameter of the two
halves of the coupling or by means of a dial indicator as shown in the
sketch adjoining by moving the shafts and checking the measure e at
various positions, the two shafts can be brought accurately concentric
to each other (Ref. Fig. No. 1)
The next procedure is to bring the two axes in correct alignment. This is
performed by checking the distance between the faces of the coupling
halves. This distance should be equal at various positions when
moving both shafts, see measures a and b of the sketch adjoining
(Ref. Fig. No. 2). For allowable misalignment value refer point 6 of
Annexure No.III

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During adjustment of the two coupling halves it is important that when

checking for concentricity, as well as for alignment, both axes are
turned through the same amount and in the same direction for every
measurement. When proceeding this way, eventual errors of alignment
caused by run out of the coupling halves are practically eliminated.
AXIAL FIXATION OF THE SHAFTS:
If the couplings allow an axial displacement of the shafts coupled
together, as it is the case for elastic or tooth-couplings, the axial thrust
due to the single helical gearing is taken up by adequate bearings fitted
in the gear itself.
When fitting the coupling halves on the gear shafts, care has to be
taken that shafts do not receive any blows, as the roller bearings would
thereby be damaged. The coupling halves must be either shrunk on or
fitted without heating, by means of forcing- on screw and removed with
the aid of forcing-off screws. All gear shaft ends are provided with
tapped holes for the forcing screws and coupling halves should also
have corresponding tapped holes.
When aligning big gears, the expansion of the gear case due to the
heat generated in service has to be considered. This means the
differences from base to axes of the coupled machines should be
considered while aligning the shafts. The temperature of the gear case
in service is generally observed to be 60-70C.

02.04

FIXING OF THE GEARS ON THE FOUNDATION:

The pads of the foundation to which the gear box is screwed down, should
be machined in order to prevent distortions of the casing when tightening
the nuts, which would effect the perfect meshing of pinions and gears.

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02.05

LUBRICATION:
The gears supported with roller bearings are provided with forced
lubrication on teeth and bearings. By separate Forced Lubrication System
motor driven oil pump take the oil from the gear case and deliver it to the
spray pipe for the lubrication of the gear mesh and bearings. The gear case
serves as oil tank. The lubricating oil is filled in through the opening of the
inspecting cover, provided on the top of the casing. The oil level should
reach the upper mark of the oil level indicator / Dipstick. It should never
drop below the lower mark, as the lubrication would then fail to function.
The recommended oil is of viscosity grade ISO VG-320

02.06

COMMISSIONING AND MAINTENANCE:

Horizontal type gearboxes with roller bearings have generally pinions and
gears with case-hardened and ground tooth flanks. Hence they do not
need a running in of the gears. However we recommend to run the
gearbox on no load for 48 hours. During this period it is to be observed that
temp rise of bearings is not excessive and running is smooth. Now the
lubricating oil in the box is to be removed and filtered. The gearbox is to be
rinsed with petrol and refilled with filtered oil.
The loading of gearbox from no-load to full load is to be done gradually.
First change of oil is to be done after 500 to 600 working hours.
Subsequent oil change can be made, if necessary on examination of oil
after every 3 months of running.
The teeth and bearing of gears should be annually checked and inside
parts to be cleaned if necessary.
The sump oil temperature of gearbox in service may rise up to 95C. If the
gear is running with abnormal noise or temperature rise is too high, it is
recommended to have the gearbox checked by a specialist.
When dismantling, gear parts should be match marked properly. We take
no responsibility for premature wear or damage of the gears due to erection
errors. If desired by customer we will be glad to depute our specialist for
erection. Please refer our assembly drawing (Drg. No. B 2211-6300-0008SECT-S-1119). For guidance, which is supplied with the manual.

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2.07

INSTRUCTIONS FOR LONG STORAGE OF GEAR UNITS:

Following instructions for the long time storage of the gear units is of
extreme importance as violation of which can lead to the premature failure.
Long time storage of gear units can be due to:
A) Units is not in action, however, installed in place
Or
B) Unit is kept in store and waiting for its use.

2.07.01

THE UNIT IS INSTALLED; BUT NOT IN ACTION:

When the gear unit is installed in the system but is out of action, a quantity
of oil must be added to exceed maximum level by 30 mm to 50 mm. Special
attentions should be given to the condition of the oil. Old oil which may form
a deposit or be acidic should be removed. The gears should be turned
slowly by hand at intervals, in order to ensure the oil is distributed over all
parts in contact. Wherever grease nipples are provided, add grease through
grease nipples.

2.07.02

THE UNIT IS TO BE STORED FOR A LONG TIME:

When the unit is required to store for a long time, it should be run for 5
minutes after filling with rust protective oil. The level of the oil should be
about 30 mm to 50 mm higher than the normal oil level. After all the parts
are thoroughly coated with oil , the protective fluid can be drained and kept
for other similar oprations. This is to be done once in every month. The
inspection cover and the drain plugs should be completely sealed. On
starting up the speed reducer, no special precaution need to be taken other
than filling the oil bath according to the recommended quantity and quality
of lubricating oil. To prevent corrosion during storage, Silica Gel bags
should be kept in the vicinity of the gear unit, not inside gear case. Silica
Gel should be periodically checked for moisture absorption and be changed
in an interval.

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2.08

TRANSPORT
Transport of the complete gear unit should be undertaken by using wire
ropes / cable strips of required strength.
While lifting the complete gear unit, please do not use the lifting lugs
provided on the top cover. Use the lifting lugs provided on bottom part of
the gear cases.

ANNEXURE I
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LUBRICATION OIL SYSTEM:

001.

GENERAL DESCRIPTION:
Lubrication oil system consists of two motor driven lubrication oil pumps,
which pump the lubricating oil to the gearbox through basket filters and the
oil cooler. Refer P & I diagram of the FLS.

002.

PREPARATION FOR STARTING OF THE SYSTEM:

1. The FLS is to be started first and should run for one hour before starting
the gearbox. Then start the gearbox. The built on pump will develop
more pressure on the delivery line and the delivery pressure will
increase and reach upto 3.8 Kg/ cm2 (approx.). At this stage the FLS will
stop automatically. Now the gearbox will be lubricated by only built-on
pump and the delivery pressure will be about 1.2 1.8 kg /cm2. Once
the pressure comes down below 1.0 kg /cm2. The FLS system will start
automatically.
This phenomenon is dependent on the actual settings of the instruments on
the FLS.
2. GENERAL PRECAUTION:
Check the oil level. If the oil level is low, fill gearbox oil sump to correct
level with the approved oil. Ensure the filtering elements in the filters are
clean and cooler is not choked. Check the flow of the cooling water and
ensure that it is adequate.
3. Start the lubrication oil pump and check the oil pressure indicated on
the pressure gauges, which shows the system is functioning correctly.
Start the system at least one hour before starting of mill gearbox

003.

WEEKLY INSPECTION:
Check the oil level and top up if necessary. Clean the filter element if
pressure drop across filter is 1bar. Ensure the oil breather is breathing
properly and not choked.

004.

INSPECTION AND MAINTENANCE:

To ensure a long life of the gear unit a periodical inspection and
maintenance procedure must be followed as listed below:
1.

After 200 to 500 operation hours

A.

Oil
Oil must be drained and filtered.
- Drain the oil while unit is still warm.

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The oil can be reused after filtering through a 25 micron

filter.
or
Filter the oil through a 25 micron filter while the unit is
operating, the total volume of the oil must pass 10 times
through the filter.
B.

Check following items

- Oil level.
- Oil tightness of gear unit.
- Tightening of the bolts of the reaction arms.
- Alignment of high speed and generator shafts.
- Air breather not clogged.
- Anti-corrosion protection of gearbox and out coming
shafts

2.

After 8000 operating hours or after 1 year and every year after
A.

Oil
Take oil sample 0.25 litre form drain cock while oil is still
warm. Oil sample must be analysed by a qualified
laboratory. The parameters listed below must be checked :
-

presence of extreme pressure additives (%).

absence of water (%).

viscosity at 40oC and 100oC.

TAN-value (mg KOH/g.).

metal particles (ppm).

This oil analysis will define further lifetime of the oil bath.
A copy of the results of the analysis must be available in the
logbook.
B.

Check items as under 1.B. above.

Notes:
1. The lubrication system has been adjusted by the manufacturer and the
setting must not be disturbed. Care must be taken to observe the absolute
cleanliness during servicing operations on the gearbox and lubrication
system.

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2.
Drain the oil from the sump by opening the drain plug / valve provided
at the bottom most level of the oil sump of gearbox. Run the gearbox for
one hour before oil is drained.
3.
Fill the sump with approved oil, which can be done by removing one
of the inspection covers from the top part of the gear casing and pouring
the oil through exposed aperture. Replace the inspection cover. The sump
capacity is as mentioned on GA drawing

WARNING:
THE OIL LEVEL MUST NOT EXCEED THE FULL LEVEL INDICATED ON
THE OIL LEVEL INDICATOR AS OVERFILLING CAUSES LEAKAGE
THROUGH INPUT SHAFT OIL SEAL.

4. Carry out Normal Running routine.

5. Inspect the oil strainer and filters and ensure the elements are in good
working condition. Before removal of the element cover, mark the cover
to ensure replacement in same position. The element should be rinsed
in a suitable cleaning liquid to remove accumulated dirt. If at all
damaged or worn or it seizes due to negligence resulting in overloading
with dirt, the old element should be replaced by new one.

005.

GENERAL SERVICING FOR COOLER :

OIL SIDE:
Under abnormal conditions oil can reach temperatures sufficient to cause
carbonation and sludge. This condition is shown by a falling off in
performance and indicates the need for cleaning. There are many degreasants available for cleaning the oil side of coolers. We suggest
immersing the complete tube stack in solvent or de-gresant.

WATER SIDE:
Very little guidance is necessary since this side of unit should not become
fouled. If felt necessary to carry out a cleaning operation, wire brushes can
be used for removal of soft deposits. Several solvents are available from
any of the manufacturers for removal of hard deposits and scales from the
inside of the tubes.

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ANNEXURE II
GENERAL INFORMATION

1.0 Recommended quality of oil

ISO VG-320 or Equivalent.

2.0 Recommended oil level

210 MM below from joint face in

running condition of the gearbox and
FLS, i.e all the lube pipes should be
filled with oil.

3.0 Net weight of the gearbox

base

7800 kg . ( Approx. ) , without oil,

plate and FLS skid.

4.0 Recommended back lash in MM -

1st st :- 0.33 to 0.54 mm ( Max.0.66 )

2nd st :- 0.37 to 0.62 mm ( Max. 0.74)

NOTE: The actual backlash values may slightly vary from the values mentioned
above, however that does not effect the performance of the unit.

5.0 For change of antifriction

bearings eject the bearings
by oil injection.
Recommended suppliers for oil injection unit.

SKF INDIA BRG. CO. LTD.

M. G. M. Building
Netaji Subhash Road,
BOMBAY - 400 002.

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ANNEXURE III

CHECK LIST BEFORE STARTING AND WHILE RUNNING THE GEAR BOX.

1. Check whether Oil Level is correct.

2. Ensure that all measuring and controlling instruments are calibrated & working
properly.

3. Ensure that each and every bearing as well as sprays for gear meshing are
getting adequate supply of oil.

4. Ensure that all nuts of the top inspection cover and lubrication oil pipe flanges
are tight.

5. Ensure that the pressure indicator just before the inlet to the gearbox is
showing the pressure as 1.8 Kg / cm2 (Min). It may be adjusted by screwing
high-pressure relief valve provided in the lubrication oil system or by closing the
by-pass valve.

6. Guide Lines for Alignment:-

6.1 Radial or Lateral Alignment Limits :

Up

to

100 R.P.M.

0.15 to 0.30 TIR

100

to

400 R.P.M.

0.08 to 0.15 TIR

400

to 1000 R.P.M.

0.03 to 0.08 TIR

1000

to 1500 R.P.M.

Up

to 0.03 TIR

6.2 Facial or Angular Alignment Limits : 0.01 TIR / 100 mm. of diameter where
alignment reading is taken.

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