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Technical Evaluation

Customer: Engineer / Technician: Date:

NEOMILLE Cleiton Coutinho / Eiky Asso 11/08/2021
Contact / Department: E-mail.: Tel.:
DIEGO CAMELO / SERVICE FOOD&WATER diego.camelo@alfalaval.com 11 5188-
Equipment: Model: Serial Number:
GEARBOX GEARBOX 20 kNm DD 5026567

Rotor Number: PI / NF: Product Number:

0366997 / 21192 61241654-80

1. Photografic record of the equipment.

Receipt

Packaging:
☐ Mounted ☒ Partially disassembled ☐ Loose ☒ Separator disassembled
gearbox
☐ Disassembled ☒ Pallet ☐ Box/Crate

Decanter items:
Lower base ☐ Yes ☒ No ☐ N/A Main engine ☐ Yes ☒ No ☐ N/A
Top base ☐ Yes ☒ No ☐ N/A Auxiliary engine ☐ Yes ☒ No ☐ N/A
Hood ☐ Yes ☒ No ☐ N/A Case protection ☐ Yes ☒ No ☐ N/A
Gearbox ☒ Yes ☐ No ☐ N/A Cylinder ☐ Yes ☒ No ☐ N/A
Bearings ☐ Yes ☒ No ☐ N/A Screw Conveyor ☐ Yes ☒ No ☐ N/A
Feet ☐ Yes ☒ No ☐ N/A Smaller cube ☐ Yes ☒ No ☐ N/A
Adapter / Pulley ☐ Yes ☒ No ☐ N/A Biggest cube ☐ Yes ☒ No ☐ N/A
Feeding Tube ☐ Yes ☒ No ☐ N/A Special tools ☐ Yes ☒ No ☐ N/A
Note:

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Technical Evaluation

2. Gearbox

Disassembly

External visual assessment of the box, initially When the magnetic plugs were removed, there was a
the magnetic plug is worn out, so we request a lack of oil and the presence of filings apparently from
replacement. the gears.

After dismantling the top cover, it was seen that the top bearing had a chipped area, as highlighted in the
images above

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Technical Evaluation

The highlighted smaller shaft has its gear teeth completely damaged. Due to the proportion of the
damage found, we requested the replacement of the components of this set.

The cover is damaged and there is crusted material in the highlighted area, therefore we request
replacement, the gears will also be requested due to contact with the other damaged teeth.

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Technical Evaluation

The initial stage shows signs of overheating, damaged gears and jamming, due to the damage found we
requested this complete set.

Highlighting the condition of the components of the initial gear set.

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Technical Evaluation

After removing this stage, the lower part is undamaged.

The only highlight is the dirt that was crusted on the edges of the box.

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Technical Evaluation

After disassembling the gears, the bushings showed marks and will be sent to metrology to check for
wear. After analyzing our metrology, the bushings are in accordance with the design and do not require
replacement.

The black line indicates that the oil level is too low.

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Technical Evaluation

Parts sent to metrology for checking according to the original project drawing.

3. Final Considerations

The equipment arrived at the service center assembled, without the torque arm.
The gearbox was without oil and the magnetic plugs contained the presence of filings.
During disassembly it was found that the first stage components were excessively damaged, with the
initial gears completely damaged and locked at first.
The wear marks found on the bushings of the internal gears of the box may have been caused by operating
with filings in the oil, which end up spreading throughout the lubrication assembly and passing between these
devices.

 Root Cause Conclusion

The oil level in the box appears to have been low. The level is indicated by the black line in the image below.
Low oil level filled with insufficient lubrication of planetary gear bearings.

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Technical Evaluation

After inspecting and analyzing the equipment design, we recommend replacing the parts indicated in the
quote.

4. Recommendations

Replace parts that show wear beyond their safety limits, as they can cause serious damage or
fatal injuries.
Use original parts and services from Alfa Laval, aiming to guarantee the best performance and adequate
maintenance of the equipment. Alfa Laval assumes no responsibility for the safe operation of equipment
where non-genuine parts have been used.

Check the equipment manual for the type of lubricating oil that should be used, the quantity and
the appropriate interval for change, to avoid premature wear of parts and unexpected equipment stops.

Carry out periodic cleaning according to the needs of the process in which the equipment is used.

Do not exchange parts from one machine to another. Major parts cannot be replaced without balancing the
entire rotor.

Reginaldo Marinho
Supervisor de Serviços - Workshop Repair Telefone:
+55 11 5188-6058
E-mail: reginaldo.marinho@alfalaval.com

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