Date: 01/03/2012

FINAL GEARBOX INSPECTION REPORT SITE: BHORUKA POWER CORPORATION LIMITED., Neria Mini Hydel Scheme, Village: Nidle, Taluk: Belthangady, South Canara Dist., KARNATAKA EQUIPMENT: TG Gearbox. Power: 5050 KW. Ratio: 2.885 Oil recommended: ISO-VG-320 Oil Quantity: 147 Lpm Driving Equipment: Hydel Turbine Driven Equipment: Alternator Further to the Preliminary report dated 28.12.2011, the gearbox tooth mesh was inspected at site after decoupling the turbine and following observations made. OBSERVATIONS: a) Static blue teeth condition checked by decoupling both low speed and high speed couplings. Unit Number: 1 Speed: 260 / 750 rpm. Teeth Design: Single Helical Service Factor: 2.00

Mesh Pattern in Both HS & LS Shaft Decoupled Condition

Only 40% contact found towards alternator side.

b) MOP dismantled from pinion NDE side and all gearbox foundation bolts were Loosened and blue contact pattern was rechecked. Mesh pattern found same as above.

MOP Dismantled

Mesh Pattern

c)

Further pinion NDE thrust housing was loosened and blue contact rechecking was done.

Mesh Pattern while foundation bolts & thrust housing in loose condition

Mesh Pattern in Non-active flank

Contact pattern found towards pinion DE side for around 20% length of the total face width. d) Mesh Pattern checked on non-active flank and contact found towards pinion DE for around 30% of the total face width.

After checking mesh contact pattern at different conditions at site, it was decided to take the gearbox for TEIL works repair & rectification. PRE RECEIPT CHECKS. Before receipt of gearbox following in house checks were carried out on gearbox performance data, quality, manufacturing and testing records i. Review of raw material records did not show any deviation as regards to ultrasonic, cleanliness, grain size, inclusions, chemical composition and mechanical properties from standard requirements. Review of manufacturing processes confirmed that the subject pinion shaft has gone through the standard processes and in- process checks. Records of no load full speed test at Mysore also did not reveal any deviations.

ii.

To analyze this problem gearbox was brought back to TEIL works on 30.01.2012 and Gearbox tooth mesh was checked using foundation stools to simulate site foundation condition.

Casing Joint Line

Blue contact checked and found towards pinion DE side for around 35% length of the total face width which was similar to what was found at site. To understand the fragileness of casing the gearbox was then placed on the foundation master using gearbox tank as support and mesh contact was checked.

Oil tray

Teeth Mesh contact found at the Centre for around 75-80% of the total face width as Below.

CONCLUSIONS: From the detailed observations of the pattern of failure of pinion teeth, various tests, checks and studies carried out, following conclusions have been deduced. 1. 2. Raw material of pinion shaft is found to meet the design specifications. The manufacturing processes followed are found in line with design requirements. The tooth quality such as profile, helix, and PCD run out, accumulated pitch error found confirming to the required DIN class of accuracy. The heat treatment processes followed have met the requirements of case depth, microstructure and case hardness. The review of MRT report suggests that the gearbox running parameters such as casing vibration, noise and bearing temperatures were well within the permissible limits during shop testing. The blue contact during open inspection found 80-90% of the face width. The tooth contact of gearbox at site during 2011 off season was observed to be 40% as against 80-90% achieved at TEIL works during shop testing. The tooth contact check carried out at TEIL works on receipt back of the gearbox from site indicated contact pattern similar to that of site. The teeth mesh was found improving from 40% to 80% when gearbox was positioned on oil tray indicating presence of possible fragileness in the casing.

3. 4.

5.

6.

To summarize the tooth contact of the gearbox was found very sensitive to the gearbox positioning. The casing bore coaxiality found varying depending on the method of gearbox positioning. This fragileness of casing is the most probable cause for the tooth contact shift and pitting in the pinion. The gearbox is provided with mesh adjustment mechanism for such eventualities at site and usage of the same at site during installation could have avoided such end loading and teeth damage if commissioning work was entrusted to TEIL. It is a general practice to check the tooth contact pattern after erection of the gearboxes at site. Nevertheless this mesh check will be carried out for this supply. CORRECTIVE ACTION: Teeth contact at site will be ensured to 80-90%(as obtained during testing at TEIL facility) by TEIL service engineer after gearbox erection at site. This check will surely eradicate the root cause of end loading due to which previous failure had occurred.