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  • 7500 HP Speed Increaser Gearbox Case History Bearing Problem-1

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    Abdulrahman Alkhowaiter
    24 views4 pages
    A 7500 HP gearbox driving a water injection pump experienced repeated bearing failures since 2005 due to an incorrect bearing part installation by the manufacturer. The anti-rotation pins in the bearings were wrongly located, causing instability and damage from poor lubrication. An in-house investigation in 2020 discovered the error. A consultant reviewed the findings and confirmed the root cause was incorrect manufacturing, not user error. Installing the bearings correctly according to the OEM manual solved the problem and was applied to similar machines.

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    7500 HP Speed Increaser Gearbox Failure Case History

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    A 7500 HP gearbox driving a water injection pump experienced repeated bearing failures since 2005 due to an incorrect bearing part installation by the manufacturer. The anti-rotation pins in the bearings were wrongly located, causing instability and damage from poor lubrication. An in-house investigation in 2020 discovered the error. A consultant reviewed the findings and confirmed the root cause was incorrect manufacturing, not user error. Installing the bearings correctly according to the OEM manual solved the problem and was applied to similar machines.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    24 views4 pages

    7500 HP Speed Increaser Gearbox Case History Bearing Problem-1

    Uploaded by

    Abdulrahman Alkhowaiter
    A 7500 HP gearbox driving a water injection pump experienced repeated bearing failures since 2005 due to an incorrect bearing part installation by the manufacturer. The anti-rotation pins in the bearings were wrongly located, causing instability and damage from poor lubrication. An in-house investigation in 2020 discovered the error. A consultant reviewed the findings and confirmed the root cause was incorrect manufacturing, not user error. Installing the bearings correctly according to the OEM manual solved the problem and was applied to similar machines.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    of 4

    Water Injection Pump 7500 HP Gearbox Low Reliability

    Due to Radial Bearing Dam Incorrect Part Installation

    By Humberto A. Carrillo and Abdulrahman Alkhowaiter

    The 7500 HP Gearbox is a speed increaser with induction motor driver at 1777 rpm, and
    output shaft at 3938 rpm driving a water injection pump which has experienced a history of
    bearing failures since installation in 2005. The bearings supplied as well as the ones removed
    from gearbox at repair shop were discovered to have the anti-rotation pin wrongly located.
    This is a manufacturer error, not user error. Hence the bearings were fitted incorrectly
    previously. The issue was spotted in year 2020 by the inhouse repair technicians in charge of
    the job and undoubtedly caused issues such as instability and bearings damage from poor
    lubrication.

    The gearbox is a R-L as per API 613 which means HSS rotates CCW and LSS rotates CW. As per
    OEM the oil dam should be located as shown below. “The pressure dam grooves are
    positioned on the unloaded side of the bearing.” Note extracted from OEM gear manual.
    Inhouse Consultant reviewed the shop findings to inspect gearbox and bearings and found

    Page 1 of 4
    Water Injection Pump 7500 HP Gearbox Low Reliability
    Due to Radial Bearing Dam Incorrect Part Installation

    By Humberto A. Carrillo and Abdulrahman Alkhowaiter

    the shop engineering to be correct; the gearbox historical failures were due to incorrect
    manufacturing at OEM factory. “Excellent research work, the below drawings clearly show
    how the oil dam orientation is supposed to be, so from now on the case is closed from CSD
    point of view; just install them as shown below.” The new repair solved the root cause of
    problem and has been extended to the sister machines.

    Faulty Bearing Locations were on the Low Speed Shaft

    Page 2 of 4
    Water Injection Pump 7500 HP Gearbox Low Reliability
    Due to Radial Bearing Dam Incorrect Part Installation

    By Humberto A. Carrillo and Abdulrahman Alkhowaiter

    Gearbox data Sheet and Correct Bearing Orientation

    Page 3 of 4
    Water Injection Pump 7500 HP Gearbox Low Reliability
    Due to Radial Bearing Dam Incorrect Part Installation

    By Humberto A. Carrillo and Abdulrahman Alkhowaiter

    Page 4 of 4

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