Vedanta Aluminium Limited, Lanjigarh Work Instruction For Maintenance of ESP Collecting & Emitting gearbox.

Ver No. Department: Power plant WI No. CPP/ ELEC / 18 Page No. Rev No.

Input Output

Spanner set, Screw driver set, Hydraulic jack, Bearing Puller, Brass rod, Hammer, Circlip pliers Daily Maintenance report

Responsibility For Operation / Recording : Electrician / Maintenance report Monitoring / Recording : Electrical engineer / Daily Maintenance report Supervision
Activities Sl.No. Activity

: Electrical Manager.
HIRADEC E-ASPECT LEGAL Ref No.

A 1. 2. 3. 4. 5. 6. 7. 8. 9.

Emitting Gear Box: Drain out the oil from the emitting gearbox and distance piece into a container. Remove the cable of the motor. Remove the bolts from the base of the Gear box Remove the grip coupling by unlocking the Allen screw and with the puller. Remove the Electric motor along with the pinion by unlocking the nuts and the spring washer. Remove the first stage unit (Distance piece) along with the pinion from the second stage (Gear Box) by removing the nuts and the spring washer. Dismantle the first unit from the casing. Remove the intermediate shaft assembly by removing the hex nuts screws and the spring washer. For removing the 2nd stage pinion shaft, remove the external circlip and strike the pinion shaft with a brass hammer from the motor side end till the shaft along with the bearing comes out from the output end leaving the gear in the casing. To remove the 3rd stage pinion shaft, the internal circlip is to be removed by the circlip pliers and strike the shaft from the output end with a brass hammer till the 2 nd stage gear touches the inside wall of the casing. Remove the bearing and the external circlip and now strike the shaft from the motor end side till the shaft comes out from the output end side leaving the gear in the casing. Dismantling of emitting gear (2nd gear unit) Remove the output shaft sub assembly by removing the hex nut head, screws &washer and the oil seals. For removing the 2nd stage pinion shaft, the external circlip is to be removed by the circlip-pier and strike the

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15. 16. B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

pinion shaft with a brass hammer from the motor end side till the shaft along with the bearing comes out from the output end leaving the first stage gear in the casing. To remove the 3rd stage pinion shaft, remove the internal circlip and strike the shaft from output end with a brass hammer till the second stage gear touches the inside of the casing, now strike the shaft from the motor end till the shaft comes out from the output end leaving the gear in the casing. Wash all the components in diesel thoroughly and clean it and store it in a dry place. The bearing condition are checked & replacement done, if required. Examine each component of the gears for cracks or surface defects. Reassemble the gear box Connect the power cables to Motors. COLLECTING GEAR BOX Remove the four nos. of bolts connecting to the flange of the collecting gearbox. Drag the gearbox to detach the coupling with the collecting shaft mechanism. Remove the coupling of the gearbox with help of hydraulic jack. Drain the oil from the distance piece and also in the gearbox. Remove the six nos. hex bolts so that junction ring will be separated from the gear case and remove key from the output shaft. Remove the internal circlip from the gear case and external circlip from the output shaft. Hammer the output shaft from the motor end with brass rod so that the gearwheel, spacer and the collar of the NJ210 bearing come out from the output shaft. Remove the other bearing in the similar fashion. For the distance piece, remove the pinion wheel with the help of the puller from the output shaft and remove the key from the output shaft. Remove the three nos. of the hex bolts and remove the thrust cover and flange from the gearbox, remove the internal &external circlip and the slow speed assembly by hitting the shaft with brass rod. The gear wheel in the output shaft was removed and the spacer and the collar of the NJ204 bearing can be separated. The pinion shaft and the other bearings can be removed in the similar fashion from the gear case. Wash all the components in diesel thoroughly and clean it and store it in a dry place. The bearing conditions are checked & replacement done, if required. Examine each component of the gears/pinions for cracks or surface defects. For re-assembly perform the same operation in the reverse

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order. Reassemble the gear box Connect the power cables to Motors QUALITY: 1. All the parameters, activities are to be maintained within prescribed limit. 2. Any deviation from the norm is to be recorded and corrective action is to be taken accordingly.

Record

: Daily Maintenance Report.

Reference Document : Self prepared

Prepared by: Satrughna Das

Approved & Issued by: Niranjan Das

Date of Issue: 25.10.2008