IE A075COMMISSION REPORT ON THE USE OF XADO COMPOUNDS
LPS-ZU rotary gearbox: at work instead of overhaul, parts found serviceable
No new chipping appeared on the teeth and splines, the units were found fit without an overhaul. 0 new chips — chips on the rotor shaft splines and the housing rim teeth, 13 → 13 over 850 m of drilling; 0.10 mm — largest loss of tooth thickness over 850 m of drilling, 3.00 → 2.90 mm (2002).
of the Tishinsky mine, Kazzinc JSC
What the full teardown showed
| UNIT OF THE ASSEMBLY | CONDITION BEFORE TREATMENT | WHAT WAS MEASURED |
|---|---|---|
| Rotary gearbox LPS-ZU No. 16 | 11,000 operating hours, overall wear 70–80%, drive seized, submitted for major overhaul | Operating hours and drilling footage after treatment |
| Gear rims of the upper and lower housing parts | Chipping on 3 and 4 teeth, wear above the maximum permissible | Tooth thickness at a depth of 4.3 mm: 3 teeth × 3 points |
| Splined rotor drive shaft | Chipping on 6 splines, wear of the spline joints above the maximum permissible | Tooth thickness at a depth of 4.5 mm: 3 teeth × 3 points |
| Bearings No. 405, No. 118, No. 1605, No. 407, No. 211 and the loose-ball bearing | Wear of rollers and balls above the maximum permissible | Radial clearances, condition of races and rolling elements |
| Planet gears and planet bearings | Wear of the gearbox gears above the maximum permissible | Chipping and damage found at teardown |
Condition of the units at full teardown after 850 m of drilling
| UNIT | BEFORE TREATMENT | AFTER 850 M OF DRILLING |
|---|---|---|
| Splines of the rotor drive shaft | chipping on 6 splines | chipping on 6 splines, no new ones appeared |
| Gear rim of the lower housing part | chipping on 4 teeth | chipping on 4 teeth, no new ones appeared |
| Gear rim of the upper housing part | chipping on 3 teeth | chipping on 3 teeth, no new ones appeared |
| Bearings No. 405, No. 118, No. 1605, No. 407, No. 211 and the loose-ball bearing | wear of rollers and balls above the maximum permissible | after washing and control measurements of radial clearances, fit for further operation |
| Rolling elements of the housing loose-ball bearing | wear above the maximum permissible | show no one-sided wear, fit for further operation |
| Planet gears and planet bearings | wear of the gearbox gears above the maximum permissible | no additional chipping or damage, in working order |
Chips were counted at the full teardown on 18.05.2002 and compared with the inspection record of 05.12.2001. The friction surfaces show areas of a glossy mineral-ceramic coating.
Tooth thickness of the lower housing part gear rim, mm
| TOOTH | MEASUREMENT POINT | BEFORE TREATMENT | AFTER 850 M OF DRILLING | CHANGE |
|---|---|---|---|---|
| 1 | near end, 10 mm from the edge | 6.05 | 6.10 | +0.05 |
| 1 | middle | 5.95 | 5.90 | −0.05 |
| 1 | far end, 10 mm from the edge | 6.85 | 6.90 | +0.05 |
| 2 | near end, 10 mm from the edge | 5.75 | 5.70 | −0.05 |
| 2 | middle | 5.95 | 5.95 | 0 |
| 2 | far end, 10 mm from the edge | 5.75 | 5.70 | −0.05 |
| 3 | near end, 10 mm from the edge | 5.75 | 5.80 | +0.05 |
| 3 | middle | 5.70 | 5.60 | −0.10 |
| 3 | far end, 10 mm from the edge | 5.65 | 5.65 | 0 |
Measured at a depth of 4.3 mm at three points of the tooth — 10 mm from each edge and at the middle, on three teeth of the rim.
Tooth thickness of the splined part of the rotor drive shaft, mm
| TOOTH | MEASUREMENT POINT | BEFORE TREATMENT | AFTER 850 M OF DRILLING | CHANGE |
|---|---|---|---|---|
| 1 | 20 mm from the shaft | 3.40 | 3.35 | −0.05 |
| 1 | 30 mm from the shaft | 2.85 | 2.80 | −0.05 |
| 1 | 40 mm from the shaft | 2.55 | 2.50 | −0.05 |
| 2 | 20 mm from the shaft | 3.00 | 2.90 | −0.10 |
| 2 | 30 mm from the shaft | 2.90 | 2.85 | −0.05 |
| 2 | 40 mm from the shaft | 2.55 | 2.50 | −0.05 |
| 3 | 20 mm from the shaft | 3.10 | 3.05 | −0.05 |
| 3 | 30 mm from the shaft | 2.95 | 2.95 | 0 |
| 3 | 40 mm from the shaft | 2.85 | 2.80 | −0.05 |
Measured at a depth of 4.5 mm at three points by distance from the shaft — 20, 30 and 40 mm, on three teeth of the splined part.
Conclusion of the commission
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
How such units are treated:
Limits of this report: The results relate to the LPS-ZU rotary gearbox of a drill rig under underground mine conditions; with other units and operating modes the figures may differ. The commission included staff of W.F.G. Corporation LLP, which carried out the treatment.