TECHNO GEARS INDUSTRIES LLC

Abraj Energy Services SAOC

Method Statement for Repairing of Draw Works Gear Box Housing

QTY: 2 NOS

JOB NO: TGI-24-FXX

DOCUMENT NUMBER: TGIL/ABJ/24/FXXX/MS-01

2 05.11.2024 Revised as per Client comments

1 31.10.2024 Revised as per Client comments

Muthuvel Sanketh Baskaran
0 29.10.2024 Issued for approval
Arumugam Shetty Ponnaiah
REV.
DATE ISSUE DETAILS PREPARED BY REVIEWED BY APPROVED BY
NO.

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 Method Statement for Repairing of Draw Works
Gear Box Housing
DOC. NO: TGIL/ABJ/24/FXXX/MS-01 Rev 2

1. Purpose
The purpose of this method statement is to outline the methodology to repair the Gear Box Housing
as per Scope of Work (SOW) and the purchase order requirements accordance with OEM drawings
provided by client.

2. Reference Documents
• SOW provided by Client
• OEM Drawings
• Purchase Orders

3. Equipment Data
Manufacturer : SEW Euro Drive
Model : 3G590NE-1320
Serial Number : 25.2000536820.0001.14.75
Operating Power : 1000 kw
Running output Torque : 86800 Nm
High speed : 803 rpm
Low Speed : 109 rpm
Lubricating Oil : ISO VG Mineral Oil
Transmission Ratio : 7.35
Year of built : 2014
Type of Gear Box : Reduction Gear Box for Draw works
Drawing Number : 88146898 B

4. INPUT DATA (by Client)

Pre-inspection of Draw works gear box 2 Nos against housing as per below criteria for each Bore
Housing/Shafts.

Input Shaft: (BRG: 23228EJW33)

Shaft OD Tolerance: 140.043 to 140.068 mm
Bore Tolerance: 250.00 to 250.046 mm

Idler Shaft: (BRG: 23228EJW33)

Shaft OD Tolerance: 140.043 to 140.068 mm
Bore Tolerance: 250.00 to 250.046 mm

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 Method Statement for Repairing of Draw Works
Gear Box Housing
DOC. NO: TGIL/ABJ/24/FXXX/MS-01 Rev 2

Compound Shaft: (BRG: 23236EJW33)

Shaft OD Tolerance: 180.050 to 180.079 mm
Bore Tolerance: 320.00 to 320.057 mm
Require OEM Drawing for
dimensional verification
Output Shaft: (BRG: 24048EJW33)
Shaft OD Tolerance: 240.050 to 240.079 mm
Bore Tolerance: 360.00 to 360.057 mm
5. SCOPE OF WORK (by Client)
1. Inspect GB bearing housing, take all initial measurements to be verified with OEM.
2. All measurements to be verified and Approved by Abraj/OEM.
3. Housing Material Grade: Q345B or equivalent ASTM A572 Gr 50. Use equivalent WPS according to
material grade.
4. Set of line boring for each bearing housing, to identify the centre of each bearing prior to start any
turning process. Torque the gearbox bolts (upper with lower Housing): Bolt Size: M42 and to be
torqued 3045 Nm.
5. Rough machining of bearing housing (in rejected out of tolerance) as per attached DWG: Z0056464
B. and above criteria.
6. Filling of bearing housing with welding as per Material grade (equivalent WPS).
7. Final machining of all bearing housing (in rejected out of tolerance). As per the above criteria.
8. Measure the centre distance and verify the distance (X-Axis) between bearings.
9. Verify bore centre distance between each shaft according to DWG: 88146898
10. Perform MPI test after all process.
11. Provide repair plan/ITP.
12. Preserve the machined area with anti-rust oil, pack and keep it ready for delivery
6. Repair Procedure
1. Conduct a visual examination of the Gear Box body before disassembling the machine to identify any
external damages.
2. Completely drain the oil from the Gear Box.
3. Remove the top and bottom covers of the Gear Box, which were partially disassembled at the Client's site.
4. During the disassembly of the Gear Box covers, ensure that the locating dowel pins remain in their original
positions.
5. Clear all debris from the Gear Box.
6. Thoroughly clean the Gear Box body by water jet cleaning

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 Method Statement for Repairing of Draw Works
Gear Box Housing
DOC. NO: TGIL/ABJ/24/FXXX/MS-01 Rev 2

7. Perform a visual inspection of the body to detect any visible defects.

8. After cleaning, mask all machined surfaces and all lubrication pipes, including the Bearing Housing, and
proceed with blasting. Ensure all lubrication lines positions are not changed or damaged during blasting
and cleaning.
9. Conduct Magnetic Particle Inspection (MPI) on the entire body and the bearing seating area within the
Gear Box.
10. Clean the mating surfaces of both the top and bottom covers.
11. Re-assemble the Gear Box top cover to the bottom cover, aligning with the dowel pin locations, and torque
the gearbox bolts (Bolt Size: M42) to 3045 Nm.
12. Measure the existing bore diameters of the bearing housing at all locations where shaft seating area align
with X axis and document all the dimensions, including taper and ovality.
13. Dimensions shall be measured in 3 locations in each Bore (2x 4 = 8 bores), each location 3 readings (1,2,3)
shall be taken and documented in dimension report.

by which method of measurement inner diameter tool by inside micrometer / bore dial
14. Measure the outer diameter and Inner Diameter of the new bearings intended for installation.
15. Measure the bearing seating diameters of the Shafts in same pattern for client records. by micrometer
15a. measure the center distance between bore by vernier
16. Assess the clearance between the outer diameter of the bearing and the housing bore diameter to evaluate
whether rebuilding through welding and re-boring is necessary.
17. Prepare an initial inspection report and obtain approval for the rebuilding and repair of any bores that are
out of tolerance. If rebuilt by welding is required, the affected bore shall be enlarged at least 5 mm more
than the required diameter using Boring machine.
18. Prepare the Horizontal Boring Machine (M/c No: HB XX) for re-machining of Gear Box Housing and set
the machine in the following sequence.
a. Ensure the job card with complete scope of work and drawings are issued to Operator before
commencing the job.

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 Method Statement for Repairing of Draw Works
Gear Box Housing
DOC. NO: TGIL/ABJ/24/FXXX/MS-01 Rev 2

b. Brief this method statement to the Operator, and explain the drawings for dimensions, tolerance and
alignment requirements.
c. Keep ready the required tools and calibrated instruments for machining and inspection.
d. Clean the table and ensure it is free from any dust or metal particles.
e. Clean the Gear box bottom thoroughly and place it on the machine Table and clamp it with table.
f. Dial all the front & back side bore faces horizontally and vertically and align it within 0.02 mm to 0.04 mm
g. Dial the front and backside bores of output side for their centers and alignments between the bores
within 0.02 mm in all directions. to 0.04 mm
h. Tighten the clamps and stoppers firmly to arrest the movements in all directions.
i. Keep the housing in same position and move the machine table to dial the bores in Input side and
check the alignment in all directions and ensure all the bores of Input and Output sides of housing
are aligned within 0.0007” to 0.0015”
19. Keep the Gear Box body in same position in clamped condition and enlarge all the bores to minimum 4 to
5mm more than the requirements.
20. Conduct MPI and ensure the surfaces are free from defects.
21. Re-built all the bore by welding as required with applicable WPS by qualified welders

Location A: enlarged Bore (+4 to 5 mm of existing Bore)

Location B: After Welding
Location C: After Final machining
The weld deposit on thickness shall be minimum 3.5 mm (It can be achieved by 2 layers)
22. Allow the machine to cool down completely.
23. Re-bore all the bore with min 0.5 to 0.75 mm stock for final machining.

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 Method Statement for Repairing of Draw Works
Gear Box Housing
DOC. NO: TGIL/ABJ/24/FXXX/MS-01 Rev 2

24. Now recheck the alignments in all directions and center distance between the bores
25. Perform final machining within the tolerance as per the drawing dimensions and reference to bearing
dimensions and tolerance. (Keep the bore tolerance in minimum side)
26. Inspect the bore diameter, center distance and bore alignment according to DWG: 88146898 and
dimensions provided by client.
27. Ensure that all acceptance criteria and measurement/tolerance are meeting the OEM requirement
28. Conduct MPI and ensure there is no surface defects in machined area.
29. Apply grease on machined area of bearing housing to prevent rust on surfaces.
30. Apply paint externally for minimum 200microns thickness (Blue colour),
31. Deliver the Gear box body without removing the bolts to avoid damages and distortion.

7. Documentation
• Certificate of Service
• Method Statement
• Inspection and Test Plan
• Initial visual inspection report
• Final Visual Inspection Report
• Dimension Report (initial and final)
• Welding Procedure Specification
• Welder Qualification Certificate
• Batch certificate of Electrodes
• NDT Reports
• NDT Technician Qualification
• Welding Inspector Qualification
• Blasting and Painting report

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