y S. G.

CLARKE
Walkers Limited, Maryborough

Introduction
Problems associated with mill gearing design have previously been
dealt with in Q.S.S.C.T. roceedings by papers from Beale and Fleming
(1964) and Horsburgh (l 59). Some similar material is also available in
proceedings of the I.S.S.C.T. Congresses of 1962 and 1965.
All of these papers are of great value to the gear designer but only
one, that of Scriven (1957), has made reference to the operation of
aring when associated with steam turbine drives and his paper,
although timely, may not have been understood in epth since very few
steam turbines were operated in Queensland 12 years ago.
It is, therefore, the purpose of this paper to make some reference to
gear design, to suggest possible reasons relative to some reported
gearing failures and to set out some advice for the future.

Gear Design
Most, if not all, of our conventional mill gearing is desi
BS436; 1940 and earlier authors have agreed that this
generally acceptable, although some problems do exist in applying this
speed mill gearing.
ecification takes wear and stren
trictly to the formulae are suit
ours on a 12 hour per day basis.
The most satisfact
variation from this
specification is to apply the "expected life factors" set out in
which relates to bevel gearing. This modi
is quite justified when
ed to extreme fatigue
of applying a service
eming have suggested
1.25 as a desirable factor for sugar mill gearing.
Having these specifications to follow, it would then seem to be a
fairly simple task to arrive at a set of mill gears which can transmit the
desired loads for a specified period. Howev the choice of a suitable
material for the wheel and pinion must also
made and this is where
past experience must be applied.
Likewise, past experience is of value to the designer in his final
choice of milling speeds, ower of drive unit, type of drive unit, overall
gear ratio, etc.
All of the above is not necessaril
Society members, so
without going into a complete
et us look at a typical
example associated with the desi
otion mill drive gearing
pinion to which the following conditions apply:-

THIRTY-SIXTH CONFERENCE

1969

Desired cane crushing rate --- 250 tons per hour

- 13.25
Expected fibre % cane
Adopted mill roller speed - 40 ft/min
Type of drive
- steam turbine
H.P. of drive
- 750 rated
- 12
Rev/min of pinion
Number of pinion teeth
- 30
By applying the formulae given in BS436 we may arrive at the
following wear and strength ratings for a pinion made in either of the
following materials :Material 'A' - BS592 Grade C having flame hardened teeth
Material 'B' - BS592 Grade C fully normalised rim
TABLE I-Pinion

tooth loads

It would appear initially that by using material 'A' we have achieved

a very acceptable design assuring long life for both strength and wear
providing we do not exceed our design loading factors. However,
knowing the potential power of steam turbines, let us see what happens
to our life expectancy factors when we progressively increase our tooth
loading.
The graphs in Figures 1 and 2 relate to pinions in material A and B
respectively.
Figure 1 repeats the close relationship between wear and strength
ratings but as a consequence of the distinct curve of this graph, such
ratings fail miserably when overloads occur. Figure 2 likewise repats
the above particular curve but it is obvious that from a strength pornt of
view, material B is capable of accepting the predicted overloads.
On both graphs a series of vertical lines have been drawn and these
indicate the full load torque and overload conditions which can be

Fig. I-Tooth

load and pinion life relation, material "A"

THIRTY-SIXTH CONFERENCE

Fig. 2-Tooth

load and pinion life relation, material "B".

expected from a turbine drive in the event of incorrect speed operation

or operation without due re ard to the correct number of auxiliary hand
nozzles used.
To obtain the full appreciation of this possi
ese torque to rev/min curves are representative
from any steam turbine, but have been
pertaining to a popular type of machine now
3 shows the torque capability of a
used in Queensland. Note that Fig
vernor control only and Figure 4
turbine when it is operated unde
indicates the torque capability of the same machine when all hand valves
are in use in addition to the governor.
Under the latter condition serious overloading can apply, particularly under low speed conditions. Careful relation of nozzle pressure
and turbine speed is constantly necessary to limit full load torque if

Fig. 3---Turbine

torque curves, governor only.

186

THIRTY-SIXTH CONFERENCE

1969

Fig. 4--Turbine torque curves, governor plus hand valves.

overloading of the gearing is to be avoided. Likewise, any proposed

increase in steam line pressure should be carefully considered, since such
an increase will automatically increase the turbine steam ring pressure
and allow additional torque to be applied to the gearing.
Returning now to Figure 1, observe the immediate reduction in
expected gearing life which occurs when overload conditions are applied.
In fact, continued operation under 50 per cent overload conditions can
reduce the strength life expectancy from 6,200,000 hours to 12,500 hours
or a 98 per cent reduction in the life expectancy. A similar effect can be
observed from Figure 2 but here, due to the greater strength life expectancy, the effect will not be as disastrous, seriously affecting only the wear
life expectancy which will of course be indicated by gear tooth wear
rather than a tooth strength failure.
What of the Future?
As mentioned earlier, the paper by Scriven has already made clear
the serious overloads which can be experienced with steam turbine drive
units if adequate care and attention is not applied. Experience gained in
more recent times has proved these statements to be painfully true, so
what can be done to overcome these problems in the future? Let us
commence with a few suggestions:(l) Operate the prime mover and its gearing within its full load
capacity range at all times and restrict the use of auxiliary power boosting
devices to periods of low steam pressure only.
(2) Provide lock-up devices on all auxiliary power devices and hand
nozzles so that their use can only be directed by senior staff personnel.

1969

-SIXTH CONFERENC

187

unit at roller speeds commensurate with

(3) Operate the mi
This feature can, of course, be related to (1)
normal torque requirem
above and constant reference to speedltorque curves will assure this safe
operation.
(4) Keep a daily log of turbine nozzle steam pressures or install
steam flow recorders so that reasonably accurate data is available to
immediately indicate plant operation at above normal torque ratings.
designed to give a high strength life expectancy
life rating may be lower than desired. Wear can
periodic inspection and partially overcome by
ith high viscosity oils. Wear rates can be measured
ment steps taken in adequate time.
(6) Install gearing of heavier design, even incorporating one
additional reduction stage. rger and heavier gears will incur higher
initial costs but these may be more acceptable than later breakdowns.
peak load torques
(7) Install prime movers designed only t
this output torque
within the capacity of the associated gearing
by astute operation of auxiliary power boo
(8) Seriously consider the implications involved before increasing
steam pressure to any existing prime mover installation as such an increase will automatically increase the torque output of the turbine and
this may be beyond the peak designed torque capacity of associated
gearing.
ms of prime mover drives and
(9) Consider the use
ategory will fall high speed
their likely effect on coup
In the case of the last, the
engines, electric motors,
to drive the hydraulic pump
conventional steam turbin
units without fear of ov
hydraulic circuit will auto) and Wright (1969)l.
matically limit the peak

Conclusion
It has been shown that there is no mystery about mill gearing design
nor the reasons for premature gearing failures. It is realized that minor
overloading of milling plant is not entirely unavoidable nor is it to be
completely discouraged if high eficiency is to be maintained at increased
crushing rates. However, care is needed to determine the absolute limit
of overloads permitted with mill gearing particularly when turbine drives
are used and some suggestions ave been made of steps considered
worthwhile for future consideration.
REFERENCES
Fleming, J. C., (1964), Specification and design of mill gearing. Proc.

Q.S.S.C.T., thirty-first Conf., 133.

Hill, J. W., (1968), Proposal for a direct hydraulic mill drive. Proc. Q.S.S.C.T.,thirty-fifth
Conf., 101.
, G. E., (1959), Some problems associated with mill gearing design. Proc.
Q.S.S.C.T., twenty-sixth Conf., 163.
McNee, A. W. P., (1962), Mill gearing. Proc. I.S.S.C.T., eleventh Cong., 1125.
Scrivea, H. E. B., (1957), Some considerations in the use of turbine drives. Proc. Q.S.S.C.T.,
twenty-fourth Conf., 165.
Linden, S., (1965), The application of steam turbines to the cane sugar industry.
Proc. I.S.S.C.T., twelfth Congr., 1584.
D. J., (1969), The application of hydraulics to sugar mill drives. Proc. Q.S.S.C.T.,
thirty-sixth Conf.