Gearing Inspection February 2015: The Lubrication Reliability Source™

The Lubrication Reliability Source™

Gearing Inspection February 2015

World Class Lubrication Reliability for the Mining Industry

1

Ball Mill Inspection

Overview

 The following report provides a brief overview of the Ball mill inspection conducted on 18th February 2015  The gearing terminology is based on the AGMA 1010-E95 standard, “Appearance of Gear Teeth”  Pinion tooth measurements were recorded on both pinions. It should be noted that these measurements have low reproducibility and are for “general reference” only.  Included in the report is information on the various adjustments and improvements carried out while onsite.

2

Pinion # 1 with LE9011

Excellent clear “wet” lubricant film

3

Pinion # 1 March14 – This mark is a contact pattern transferred from the girth gearing, with small pit mark on the pitch line.

Close up of previous contact pattern – DE # 1 pinion tooth February15 – Note contact areas & pit mark unchanged compared to last inspection.

4

Pinion # 1

Close up of previous wear pattern – NDE # 1 pinion tooth

March14 – Indentation on pinion and some minor third party abrasive wear caused by entrained contaminants. Feb15 – No increase in size or severity of Indentation or abrasive wear.

5

Girth Gear with LE9011

Note original machining marks visible on wet lubricated teeth

6

Girth Gear

Inspection in March 2014

March14 – Scoring and adhesive wear plus minor third party abrasive wear caused by entrained contaminants.

February15 – No major change in size or severity of wear pattern.

7

Girth Gear

Note slurry visible in roots and shroud

8

Pinion measurements

Ball Mill Inspection

Measurements taken on both pinions 100mm and 200mm from the discharge side in 5 locations at depths of 10mm.

Tooth Ambient Temp # 1 Tooth Ambient Temp # 2 Pinion # 1 10mm 20mm 30mm 40mm 50mm

100mm 23.7mm 34.8mm 43.1mm 50.0mm 55.2mm

26.3 C 31 C 200mm 24.4mm 34.6mm 43.4mm 49.1mm 55.8mm

Pinion # 2 10mm 20mm 30mm 40mm 50mm

100mm 29.0mm 38.0mm 46.0mm 52.1mm 57.0mm

200mm 28.5mm 39.0mm 43.3mm 53.1mm 57.2mm

9

Ball Mill Inspection

Spray pattern adjustment conducted by Lubrication Engineers

Note spray pattern prior to adjustment shows parts of the girth gear not receiving coverage, following adjustment there is complete gear coverage. Before spray nozzle adjustment

After spray nozzle adjustment

10

Ball Mill Inspection

Spray Nozzle Adjustment

Before spray nozzle adjustment

After spray nozzle adjustment

11

Ball Mill Inspection

Pinion #1 Inspection door

Note gap where incorrect hinges have been welded onto door leaving void for dirt ingress. Urgent attention required! 12

Ball Mill Inspection

LE fitted special PTFE seal tape to inspection doors.

13

Ball Mill Inspection

Pinion #2 Inspection Door

14

Ball Mill Inspection

Summary

 Lubricant film is excellent on both pinions and girth gearing  Previously observed tooth wear is stable  Mild slurry ingress is observed in the roots of the girth gear  Pinion tooth baseline measurements were recorded  Spray nozzles were re-aligned to provide correct spray pattern  Pinion # 1 inspection cover has been refitted in the incorrect location  Special PTFE sealing tape was applied to pinion # 2 inspection covers  Recommendations  Continue to monitor the pinion temperatures weekly  Visually inspect both pinions with a strobe light weekly  Urgently refit pinion # 1 inspection door and reseal  Report completed by Rodney Fitzpatrick ([email protected])

15