MECHANICAL SECTION – ME UNIT
REPORT OF OVERHAULING THE MAIN FERMENTER A AGITATOR
Machine No: AV 2501 A
Machine name: Main Fermenter A agitator
Repairing time: From 25 May 2020 to 03 July 2020
1 – The current state of the machine.
- The overhaul follows the maintenance schedule.
- The activation time was 05 years.
2 – Maintenance description.
2.1 – Motor.
Current state:
- The motor’s coil was still good to be reused.
- Dimension of the bearing housing: +0.00 mm ~ +0.02 mm It’s ok.
Countermeasure:
- Long-term: Replacing bearings 6322 x01pc, 6222 x01pc.
Bearing position Bearing housing at
at position A position A Ø240+0.01
Ø110+0.01
Page 1 of 10
Bearing housing at
position B Bearing position at position B
Ø200+0.02 Ø110+0.02
2.2 – The reducer and the couplings.
Current state:
- The ring gear and the planet gear had some marks on the surface.
- The bearings & the reducer were worn out.
- The outside parts are still good to be reused.
Countermeasure:
- Replacing the couplings RS16020 x01set.
Page 2 of 10
- Replacing the coupling’s chain RS1602RP x01set.
- Replacing the oil seal 210x240x15 x01pcs.
- Long-term: Replacing some bearings 23044 x01pc, 23040 x01pc, PNBYK60-90-105 x05pc, PNBYK45-
75-40 x04pc.
- Reusing the old reducer.
Position of replacing the
bearing PNBYK45-75-40
x04pcs.
Replacing the
couplings RS160-
2RP x01set.
Position of replacing the
bearing PNBYK60-90-
105 x05pcs.
Replacing the bearings PNBYK60-90-105
x05pcs.
Bearing housing Bearing housing Bearing at
at position A at position B Bearing at position
position A
Ø310+0.04 Ø340+0.06 B Ø220+0.02
Ø200+0.01
Page 3 of 10
2.3 – Extended base.
Current state:
- Dimension of the bearing housing: standard: +0.01 mm ~ +0.07 mm.
Upper bearing housing Ø310+0.01
Lower bearing housing Ø340+0.03
The dimensions of the bearing housings are still good.
- Dimension of the bearing position on shaft: standard +0.02 mm ~ +0.05 mm.
Position of installing bearing
Bearing position at the Bearing position at the lower
upper shaft Ø220+0.01 shaft Ø220+0.03
All bearing positions on shafts were still good.
- Upper and lower bearings were worn out after 05 years of running.
- Lantern ring packing was still good.
Page 4 of 10
Lantern ring packing
- Labyrinth packing was still good.
Labyrinth packing
Countermeasure:
- Singly replacing some bearing housings: Bearing 200KBE-030Lx01pc, bearing 23044 x01pcs, oil seal
220x260x15x 06pcs, oil seal 190x230x15 x 02pcs, upper o-ring ID1480xOD1720x3t x01pc, and Gland
packing 25mm x01set.
- Reusing Lantern ring and Labyrinth packing.
Page 5 of 10
2.4 – The shaft of the extended base.
Current state:
- The upper and lower bearing positions on shaft were still good.
Position to install the bearing
-The oil seal caused damages at the bearing position on the shaft.
Position of oil seal
causing damages
on shaft
- The position of Gland on the shaft was worn out.
Page 6 of 10
Countermeasure:
- The shaft was recovered by the metal coating process.
- Replacing all damaged oil seals.
- We detected cracking lines by applying penetrant testing on welding lines No cracks found Result
is OK.
Page 7 of 10
2.5 – The lower shaft (Mixing shaft).
Current state:
- The mixing shaft was out of alignment: it’s shaking 7.7mm (standard: 2.3 mm)
Countermeasure:
- The mixing shaft was aligned by TRUNG ANH DUNG Company Unit The maximum vibration
amplitude (shaking) was 0.8 mm afterwards (standard: 2.3 mm). To know more detail information, please
have a look at the following report.
- Replacing the sleeve.
The sleeve
ID146xOD181.5xL240.5
- Replacing the rubber bushing.
Page 8 of 10
The rubber bushing
ID183xOD223xL265
- The gap between the sleeve and the rubber bushing was currently 1.5mm.
- Singly replacing: Inox sleeve ID146xOD181.5xL240.5 x01pcs, rubber bushing ID183xOD223xL265
x01pcs.
- Replacing the new support for the new sleeve. ID223xOD620xL180 x01pc
- Examining all bolts and nuts on shaft and tighten them by the air tool.
2.6 – Check the declination of the flange at the top.
Current state:
- The declination of the flange at the top was checked: The error = 1.2 mm.
Countermeasure:
- Adjusting the declination of the top flange: the error = 1.2 mm failed to adjust the top flange.
(standard: 0.7 mm).
Page 9 of 10
3 – Lubricant system.
Current state:
- The oil cooler and the oil filter were dirty.
Countermeasure:
- Cleaning the oil box, the oil cooler, and then filtering it.
- Replacing the old dirty oil and lubricant
4 – Running data test.
- Activating a trial operation at tank volume 100Kl: 42 ampe.
- Temperature after running 01 hours: 430C.
- Vibration index on deducer: 47µm.
- Noise: no abnormal noise & smoothly running.
5 – Planning – suggestion.
- Annually examining all welding positions on the shaft to detect cracks is necessary.
- Annually examining and replacing couplings is necessary.
Report date: 21 July 2020.
AVN representation TAD representation
Page 10 of 10
