Lufkin Gear [PDF]

Zitiervorschau

LUFKIN GEAR N1619C 102920-050 REV. 01 Page 1 of 205

9. LUFKIN GEAR

01 Rev.

09.11.2007 Status

Date

Issued for approval

E. Tritsch

A. Brekl

F. Eickelberg

Description

Prepared

Checked

Approved

LUFKIN GEAR N1619C 102920-050 REV. 01 Page 2 of 205

LIST OF CONTENT 1.

GENERAL TECHNICAL MANUAL Table of content List of figures 1. Introduction 2. Safety Summary 3. Installation 4. Operation 5. Preventive Maintenance 6. Disassembly 7. Gear inspection 8. Bearing inspection 9. Reassembly 10. Trouble shooting

2.

DRAWINGS 2.1. Assembly drawing 2.2. Section through shafts 2.3. Mass elastic diagram 2.4. Wiring diagram 2.5. Parts list 2.6. Data Sheet

3.

INSTRUCTIONS FOR ACCESSORIES 3.1. Prosensor - RTD 3.2. BENTLY NEVADA - Proximitor 3.3. YOKOGAWA – Temperature transmitter

Page 1 3 4 7 10 15 18 21 26 31 36 40

LUFKIN GEAR N1619C 102920-050 REV. 01 Page 3 of 205

1. GENERAL TECHNICAL MANUAL Table of content List of figures 1. Introduction 2. Safety Summary 3. Installation 4. Operation 5. Preventive Maintenance 6. Disassembly 7. Gear inspection 8. Bearing inspection 9. Reassembly 10. Trouble shooting

Page 1 3 4 7 10 15 18 21 26 31 36 40

Increaser type N1619C • SULZER PUMPEN’s order No. : 4500092222 – Item no. : 34-P-101 A/B-GB1 • LUFKIN France's order No. : 352531 • Serial No. : 30-6464

Prepared by Catherine BONTEMPI

1

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

LUFKIN France

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

High Speed Gears

S. BAUD A

27.06.03

REV

DATE

R. GUIZZETTI First issue

NAME

CHECKED

QA APPROVED

MODIFICATIONS

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Table of Contents TABLE OF CONTENTS..............................................................................................................1 LIST OF FIGURES AND TABLES ............................................................................................3 1. INTRODUCTION.....................................................................................................................4 1.1. SCOPE ....................................................................................................................................4 1.2. SAFETY PRECAUTIONS ...........................................................................................................4 1.3. EQUIPMENT DESCRIPTION ......................................................................................................4 1.3.1. Factory Testing...............................................................................................................4 1.3.2. Gearing...........................................................................................................................5 1.3.3. Bearings..........................................................................................................................5 1.3.4. Instrumentation...............................................................................................................5 1.3.5. Housing...........................................................................................................................5 1.3.6. Lubrication .....................................................................................................................6 2. SAFETY SUMMARY...............................................................................................................7 2.1. GENERAL SAFETY PRECAUTIONS ...........................................................................................7 2.2. SAFETY EQUIPMENT ...............................................................................................................8 2.2.1. Wear Proper Safety Equipment ......................................................................................8 2.2.2. Reduce Danger Of Damage To Hearing ........................................................................8 2.3. REDUCE RISK OF ACCIDENTAL SHOCK ..................................................................................8 2.4. RESUSCITATION .....................................................................................................................8 2.5. POSSSIBLE MISUSES OF EQUIPMENT.......................................................................................9 3. INSTALLATION ....................................................................................................................10 3.1. RECEIPT OF SHIPMENT .........................................................................................................10 3.2. STORAGE ..............................................................................................................................10 3.2.1. Corrosion Protection During Inoperative Periods ......................................................10 3.3. LIFTING, HANDLING .............................................................................................................11 3.4. FOUNDATION........................................................................................................................11 3.5. ADDITIONAL REQUIREMENTS ...............................................................................................12 3.6. ALIGNMENT .........................................................................................................................12 3.6.1. General .........................................................................................................................12 3.6.2. Anticipation of Shaft Operating Positions....................................................................12 3.6.3. Alignment Sequence......................................................................................................12 3.6.4. Alignment Checking......................................................................................................14 3.7. TOOTH CONTACT CHECK .....................................................................................................14 4. OPERATION...........................................................................................................................15 4.1. LUBRICATION .......................................................................................................................15 4.2. OIL TYPE AND GRADE .........................................................................................................15 4.3. CUSTOMER CHECK BEFORE START-UP ................................................................................15 4.4. START-UP PROCEDURE ........................................................................................................16 4.5. CUSTOMER CHECK AFTER START-UP ..................................................................................16 Installation, Operation, and Maintenance Manual

page 1

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

4.6. ALARM SWITCHES................................................................................................................17 5. PREVENTIVE MAINTENANCE .........................................................................................18 5.1. INTRODUCTION.....................................................................................................................18 5.2. DAILY MAINTENANCE..........................................................................................................18 5.3. MONTHLY MAINTENANCE ...................................................................................................19 5.4. QUARTERLY MAINTENANCE ................................................................................................19 5.4.1. Oil Analysis Guidelines ................................................................................................19 5.5. ANNUAL MAINTENANCE ......................................................................................................20 5.6. OIL CHANGE INTERVALS ......................................................................................................20 6. DISASSEMBLY ......................................................................................................................21 6.1. GENERAL .............................................................................................................................21 6.1.1. Lock Out/Tag Out Procedure .......................................................................................21 6.1.2. Visual Inspection ..........................................................................................................21 6.2. TOOLS REQUIRED .................................................................................................................21 6.3. SPARE PARTS .......................................................................................................................22 6.4. REMOVAL OF GEAR COVER..................................................................................................22 6.5. REMOVAL OF PINION, GEAR, AND BEARINGS .......................................................................23 6.6. THRUST BEARING REMOVAL ...............................................................................................24 6.7. OIL SAMPLE COLLECTION ....................................................................................................25 7. GEAR INSPECTION .............................................................................................................26 7.1. TOOTH CONTACT CHECKING................................................................................................26 7.1.1. Introduction ..................................................................................................................26 7.1.2. Why Check Tooth Contact ............................................................................................26 7.1.3. When to Check Tooth Contact ......................................................................................26 7.1.4. How to Check Tooth Contact........................................................................................26 7.1.5. Soft Blue Method ..........................................................................................................27 7.1.6. Hard Blue Method ........................................................................................................ 27 7.2. INTERPRETATION OF TOOTH CONTACT ................................................................................27 7.3. GEAR CONDITION ASSESSMENT ...........................................................................................29 7.3.1. Types of Gear Wear or Failure ....................................................................................29 7.3.2. Definition of Gear Failure............................................................................................30 8. BEARING INSPECTION ......................................................................................................31 8.1. BEARING TYPE .....................................................................................................................31 8.2. BEARING CONDITION ASSESSMENT......................................................................................32 8.2.1. Bearing Clearance........................................................................................................32 8.2.2. Bearing Contact and Correction ..................................................................................33 8.2.3. Bearing High Spots.......................................................................................................33 8.2.4. Flaking of Babbitt.........................................................................................................34 8.2.5. Scoring..........................................................................................................................34 8.2.6. Wiping...........................................................................................................................34 8.3. REPLACEMENT BEARINGS ....................................................................................................34 9. REASSEMBLY .......................................................................................................................36 9.1. PREPARATION ......................................................................................................................36 9.2. REASSEMBLY SEQUENCE .....................................................................................................36 Installation, Operation, and Maintenance Manual

page 2

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

9.2.1. Bearing, Gear and Pinion Assembly ............................................................................36 9.2.2. Gear Cover Assembly ...................................................................................................37 10. TROUBLESHOOTING........................................................................................................40 10.1. ABNORMALLY HIGH TEMPERATURE ..................................................................................41 10.2. LOW OIL PRESSURE ...........................................................................................................41 10.3. UNUSUAL OR EXCESSIVE NOISE .........................................................................................41 10.4. EXCESSIVE VIBRATION ......................................................................................................42 10.5. FOAMING ...........................................................................................................................42 10.6. NO SENSOR READINGS .......................................................................................................42

List of Figures and Tables FIGURE 1 : EXPECTED MAXIMUM SHAFT VIBRATION LEVELS ..........................................................17 FIGURE 2 : EXPECTED MAXIMUM HOUSING VIBRATION LEVELS ......................................................17 FIGURE 3 : TOOTH CONTACT PATTERNS .........................................................................................28 FIGURE 4 : STANDARD UNIT BEARINGS..........................................................................................31 FIGURE 5 : PRESSURE DAM LOCATION ............................................................................................32 TABLE 1 : STANDARD DANGER, WARNING AND CAUTION SYMBOLS ...............................................7 TABLE 2 : MAXIMUM ALLOWABLE RUN-OUT, (TIR) .....................................................................13 TABLE 3 : MAXIMUM ALLOWABLE RUN-OUT, (TIR) METRIC .....................................................13 TABLE 4 : MAINTENANCE SCHEDULE OVERVIEW ...........................................................................18 TABLE 5 : TROUBLESHOOTING TIPS................................................................................................40

Installation, Operation, and Maintenance Manual

page 3

GENERAL TECHNICAL MANUAL

NTE 19.219

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Rev. A Date : 27.06.03

1. INTRODUCTION QUALITY AND PERFORMANCE ARE PRIMARY CONCERNS AT LUFKIN France. The employees of LUFKIN France have made every effort to provide the customer with high quality, long lasting equipment which will give trouble-free service for many years provided it is operated within its designed capacity and is properly lubricated and maintained. Reflecting its commitment to Quality, LUFKIN France has been certified to ISO-9001 Bureau Véritas International Quality System Certificate, No. 86387. For further assistance from LUFKIN France, please call or fax the following numbers: LOCATION LUFKIN France -

PHONE

FAX

33 (0)3.84.49.64.00

33 (0)3.84.49.54.54

70220 FOUGEROLLES

1.1. SCOPE The objective of this manual is to give general information on installation, lubrication, operation, maintenance, disassembly and reassembly of LUFKIN France high speed gear units. In addition, there is supplementary information on unit storage, coupling alignment, oil characteristics, bearing wear, and gear wear. Any vendor supplied instruction manuals for accessory equipment are appended.

1.2. SAFETY PRECAUTIONS Every effort has been made to place hazard warnings and explanatory or cautionary notes in appropriate parts of this text. It is strongly recommended that this manual be reviewed thoroughly before attempting to install, operate, service, or repair this equipment.

1.3. EQUIPMENT DESCRIPTION Type N, NF and NM high speed gear units are used for both speed reducing and speed increasing service. These high speed units must be used when the pinion speed is higher than 3600 RPM or when the pitch line velocity is higher than 5000 feet per minute (25.4 meters per second). For a cross section view of the gearing see the Parts List; for the general shaft arrangement, shaft ends, and hold down locations see the Installation Plan. The Mass Elastic drawing provides component weights and Wr2 values.

1.3.1. Factory Testing Factory testing of LUFKIN high speed gear units includes a detailed test of the gear at rated speeds with no load or partial load. Data recorded during testing may include bearing temperatures, shaft and housing vibration levels, oil flow and pressure, oil temperature, efficiency, and an analysis of sound level.

Installation, Operation, and Maintenance Manual

page 4

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

1.3.2. Gearing LUFKIN gears are computer designed and rated according to the latest American Petroleum Institute (API) or American Gear Manufacturers Association (AGMA) standards. Conservative service factors, based on API or AGMA recommendations and on LUFKIN's experience, are applied to the ratings to ensure long gear life. High speed units have horizontally offset gearing. Most use double helical design utilizing hobbed and precision ground gear teeth. Gears and pinions are made from high grade or high quality carburizing grade alloy steel forgings. Generaly the gear is shrinking on its shaft and, except for very low ratios which result in large pinion diameters the pinion is made integral with its shaft. The pinion and the gear are turned, ground and hobbed. The teeth are then ground to ensure accuracy. Pinion and gear shaft extensions are ground to nominal dimensions with a tolerance of plus or minus 0.0005 inch (0.0127 mm).

1.3.3. Bearings Type NM Units - The low speed bearings are the self-aligning type mounted in bearing carriers. The high speed bearings are the centrifugally-cast babbit type with a one-piece steel shell. Type N and NF Units - The low speed and high speed bearings are centrifugally-cast babbitt with a split steel shell. A flanged, babbitted thrust bearing is used on the low speed shaft to locate the gearing and resist any external axial forces. When customer-specified thrust exceeds standard thrust capacity, a tilting pad or tapered land thrust bearing can be used. When required by operating conditions, pressure dam or tilt pad journals bearings are furnished to ensure stability at all load conditions.

1.3.4. Instrumentation Depending on customer specifications, a high speed gear unit may have various instrumentation installed or provided for, including embedded resistance temperature detectors, accelerometers, vibration probes, temperature switches, or pressure switches.

1.3.5. Housing Housings are of two-piece construction with parting line between housing and cover accurately machined. Housings are designed for heavy duty service to provide maximum rigidity, assuring precision gear alignment. All housings are precision bored, and bore alignment is certified before assembly. Housing design incorporates the necessary oil piping for bearing and gear mesh lubrification. Type N and NM Units - Housing is of controlled specification high tensile gray iron, carefully stress-relieved before machining for dimensional stability during machining and operating life. Interior surfaces are shot-blasted, cleaned and painted, unless otherwise specified with LUFKIN standard paint, to ensure absolute freedom from foreign particles. Type NF Unit - Housing is a fabricated steel structure, with the split line on the horizontal centerlines of the rotating elements, carefully stress relieved before machining.

Installation, Operation, and Maintenance Manual

page 5

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Fabricated housings provide superior strength and rigidity for accurate shaft bores and for proper gear meshing. Interior surfaces are shot-blasted, cleaned and painted to ensure absolute freedom from foreign particles.Unless otherwise specified, the interior and exterior of this unit have been coated with LUFKIN standard red oxide primer and the exterior is finished with LUFKIN standard finish paint. Inspection covers are provided for inspection and examination of all gear components, with a vent connection provided in the cover to maintain atmospheric pressure inside the gear housing.

1.3.6. Lubrication The lubrication system for this unit is not supplied by LUFKIN. It is to be provided by the customer or others after delivery. Refer to the Installation Plan for gear unit oil supply. The unit is provided with connections for supplying oil to bearings and to the gear mesh sprays. The unit requires an external lubrication system and reservoir. Refer to the Installation Plan for requirements of the lube system.

Installation, Operation, and Maintenance Manual

page 6

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

2. SAFETY SUMMARY DANGER :

WARNING :

DANGER notices are used

WARNING notices are

to indicate an imminently hazardous situation. Failure to comply will result in death or serious injury to personnel.

used to indicate a potentially hazardous situation. Failure to comply could result in death or serious injury to personnel.

CAUTION : CAUTION notices are used to indicate a potentially hazardous situation. Failure to comply may result in minor or moderate injury to personnel and/or damage to equipment.

Table 1 : Standard Danger, Warning and Caution Symbols

2.1. GENERAL SAFETY PRECAUTIONS The following are general precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.

DANGER :

Lock out/tag procedures are fully explained in DISASSEMBLY

Never remove the inspection cover while the machinery is in operation. Always lock out/tag ou all power sources while performing maintenance

DANGER :

WARNING : Never block the gear mesh by inserting material between the gear elements.

Never work on machinery that is still in operation or is still moving.

WARNING : Shaft and coupling guards must be securely in place before operation.

CAUTION : Only persons familiar with and proficient at servicing, installation, maintenance, operation, and assembly of gearing should be involved in those phases of use.

When manuals are supplied by a vendor for auxiliary or accessory equipment installed by LUFKIN, they are included in the appendix to this manual. IMPORTANT : Read and observe all safety warnings and messages in vendor manuals.

Installation, Operation, and Maintenance Manual

page 7

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

LUFKIN does not assume responsibility for proper guarding of shafting and couplings. LUFKIN may in some cases supply the guards; however, because of the position of the gear in the power train, the guards must also be attached to other equipment. The user must ensure adequate guarding is provided and used in the power train.

2.2. SAFETY EQUIPMENT 2.2.1. Wear Proper Safety Equipment Personnel working with or near heavy equipment should wear safety equipment appropriate to the area in which they work: •

Safety glasses with side shields

•

Appropriate hard soled shoes

•

Appropriate head gear (hard hats)

2.2.2. Reduce Danger Of Damage To Hearing Gears and their connecting equipment may produce noise levels that are capable of causing hearing loss with long-term, unprotected exposure.

CAUTION : Use of hearing protection should be considered when working near any noisy equipment.

The use of hearing protection equipment should be considered whenever working in areas containing equipment emitting high noise levels or noise at frequencies that are bothersome.

2.3. REDUCE RISK OF ACCIDENTAL SHOCK Personnel working with or near high voltage should remove watches, rings, or any jewelry that could make physical contact with circuits. Do not replace components or make adjustments inside the equipment with the high voltage supply energized.

DANGER : Keep away from live circuits.

Under certain conditions, dangerous potentials caused by charges retained by the capacitors may exist when power is off. To avoid casualties, always disconnect the power and discharge the circuit before touching it.

Under no circumstance should any person reach into an enclosure to service or adjust equipment when not in the company of someone who is capable of rendering aid in the event of an accident.

2.4. RESUSCITATION Personnel working with or near high voltage should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery or the Red Cross. Installation, Operation, and Maintenance Manual

page 8

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

2.5. POSSSIBLE MISUSES OF EQUIPMENT Following are some possible misuses of gear units that might be encountered. To prevent injury/death of personnel and/or damage to equipment, the operator should avoid : •

Overloading the gear (increasing torque above nameplate conditions.)

•

Running the gear above rated speeds.

•

Reversing rotation.

•

Changing lubricant type or grade.

•

Providing inadequate lubrication.

•

Operating at temperatures above recommended levels.

•

Operating with vibration above recommended levels.

•

Misalignment of the unit.

Installation, Operation, and Maintenance Manual

page 9

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

3. INSTALLATION 3.1. RECEIPT OF SHIPMENT Equipment should be checked against shipping papers on receipt. The gear unit should also undergo a visual inspection to ensure that no damage has occurred during shipment. If you suspect that the unit may be damaged, contact LUFKIN for assistance. Check: •

Gear casing and shafts for signs of damage.

•

Any gauges provided for cracks in the glass.

•

Piping for dents, crimps, cracks or other damage.

A coating of Blancome 37AP1 has been applied to all non-painted surfaces. Before installation, carefully remove the coating, using a safe solvent and a soft rag. Take care not to damage any oil seals or shafting while cleaning. All piping furnished by anyone other than LUFKIN should be carefully cleaned. The Installation Plan drawing for the gear will show all customer piping connections as well as any electrical connections (See Wiring diagram).

3.2. STORAGE The gear is tested at LUFKIN with a break-in oil that contains a rust preventative ARDROX 3961M which will protect the internal parts for at least six months after shipment. Do not store the gear unit outdoors unless covered. If the inoperative period is greater than six months, see "Corrosion Protection During Inoperative Periods".

3.2.1. Corrosion Protection During Inoperative Periods NOTE :

Items 1 through 4 assume normal atmospheric conditions.

1. On new gear units shipped from LUFKIN, the rust inhibitor adhering to exposed surfaces should prevent corrosion of interior parts for at least six months with covered storage. 2. When the unit has been operated for a period of time with a recommended lubricating oil, the oil will protect interior parts for inoperative periods up to 30 days. 3. If additional down time is needed, the customer should hand spray oil on the gear mesh and manually rotate the gear unit shafts every 30 days to redistribute the oil and gain protection for 30 days. 4. If extended down time is expected and it is impractical to turn the shafts, a rust preventive type oil should be brushed or sprayed on the gear teeth and bearings. Any openings such as breathers or labyrinth seals should be sealed with masking tape. A quality rust preventive oil should give 12 months protection against corrosion. This oil should be compatible with the operating oil, and it should be unnecessary to remove the rust preventive oil when the unit is started again.

Installation, Operation, and Maintenance Manual

page 10

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

5. For adverse conditions or long term storage, coat all parts with rust inhibitor compatible with operating oil and seal all openings. 6. A second method of long term storage is to disassemble the unit and coat each part with CosmolineTM or equivalent. Before the unit can be placed in service, special cleaning with solvents will be necessary to remove all preservative from unit and parts.

3.3. LIFTING, HANDLING The gear unit should always be moved by rolling on bars or skates, or lifting it with properly rated slings through lifting lugs or rings found on all LUFKIN gear units.

WARNING : Improper lifting techniques could cause damage to the gears and/or harm to personnel.

CAUTION : Do not lift unit by either input or output shafts. Do not bump the shafts.

LUFKIN provides drilled and tapped holes for lifting. The user must provide properly rated lifting devices. On some fabricated housings, lifting holes are an integral part of the fabrication.

See the Installation Plan for lifting weights. Never lift or sharply strike the shaft extensions. Always exercise extreme caution while lifting any part of a gear unit.

3.4. FOUNDATION To maintain alignment, the gear unit must be securely mounted to a suitable rigid foundation. Two of the more common foundations are the concrete foundation and soleplate combination, and the common baseplate. The concrete foundation and soleplate combination is semi-permanent and allows for the removal of the gear housing at a later date without disturbing the permanent mounting pad. Once a general elevation is established above the concrete foundation, the soleplate is grouted into place, leaving a space of about a 1/8 inch (3 mm) between the top of the soleplate and the bottom of the gear unit feet. This shim space allows room for proper positioning of the gear unit for low speed and high speed coupling alignment. The soleplate has tapped holes already in place so that bolts can be used to clamp down the feet of the gear unit (with the proper shims in place) at all positions. The most common baseplate is a rigid structural steel foundation with the gear mounted with either the driver or driven equipment or the gear and both the driver and driven equipment mounted. LUFKIN often supplies this type of baseplate, with the gear rough aligned to the prime mover or driven equipment. In this case, final alignment is necessary after the baseplate has been grouted in.

Installation, Operation, and Maintenance Manual

page 11

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

CAUTION : Adequate foundation must be provided for proper alignment.

NTE 19.219 Rev. A Date : 27.06.03

The housing must not be twisted or in a bind as this will adversely affect tooth contact and will cause bearing edge loading. Use an adequate area of shims under all tie down bolts. In making up the shim pack, use as few shims as possible so the pack will not be "soft".

3.5. ADDITIONAL REQUIREMENTS Check all studs, capscrews and bolts for proper tightening.

3.6. ALIGNMENT 3.6.1. General Securing proper shaft alignment is one of the most important phases of setting up a gear unit. Even though flexible couplings are used on the shaft extensions, any appreciable amount of misalignment can cause a multitude of gear problems ranging from non-uniform bearing and gear tooth wear to vibration and coupling problems. Uncorrected misalignment can lead to catastrophic failure. Therefore, it is essential that good alignment be maintained, and that thermal growth and shaft operating position in the bearings be anticipated during shaft alignment.

3.6.2. Anticipation of Shaft Operating Positions The final position of the shaft, under operating load and temperature, will differ from its position under no load and ambient temperature. This is due to thermal expansion of the gear housing and the direction of the bearing loading. The driven and driving machines also have thermal movement which must be either added or subtracted from the gear movement, depending upon the direction of the movements. The axial and radial running position of each shaft must be determined and set correctly. The running positions depend on operating load and temperature and will differ from the positions under no load and at ambient temperature because of thermal expansion of the gear housing and the direction of the bearing loading. A temperature rise of 30 - 70 degrees Fahrenheit (15 - 40 degrees Celsius) is within normal range. For expected movement and thermal growth values see the Installation Plan drawing. Couplings should allow the shafts to float axially. The gear may be initially centered in the housing by carefully prying the low speed gear through its full axial travel while measuring the distance with an indicator. The gear should be centered when it is positioned at half the full travel amount.

3.6.3. Alignment Sequence The following sequence assumes that the foundation is level, the driving or driven machine (whichever is more permanently settled) is secured, and any shipping locks and covers are removed from the gear unit. 1. Level and secure the gear unit. Jacking screws holes are provided on the base flange for bringing the gear unit to the same horizontal plane as the connecting shaft.

Installation, Operation, and Maintenance Manual

page 12

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

•

Shim under the low machine to bring it to the proper height.

•

Move one unit until all are in the same plane as the connecting shaft.

NTE 19.219 Rev. A Date : 27.06.03

2. Establish running position of driven and driving shafts, making sure journals are centered axially and vertically. 3. Connect gear unit shafts and coupling flanges. •

Care should be taken in joining the two coupling halves to observe any coupling match marks.

•

Allow for axial thermal growth. Failure to properly align axially can cause cross mesh loading which can lead to premature gear failure.

•

Keep outer diameter runout within recommended maximum allowable runout, total indicator reading (T.I.R.) In a close coupled condition, T.I.R. should not exceed the values in Table 2 and Table 3. When the shafts are not close coupled, contact LUFKIN. Shaft Surface Velocity (fpm) 5000 and up 3000 to 5000 1500 to 3000 500 to 1500 500 and below

Outside Diameter, TIR (inches) 0.002 0.004 0.006 0.008 0.010

Face, TIR per inch of R (inches) 0.0004 0.0005 0.0006 0.0008 0.0010

Table 2 : Maximum Allowable Run-Out, (TIR) Shaft Surface Velocity (m/s) 25.4 and up 15.2 to 25.4 7.6 to 15.2 2.5 to 7.6 2.5 and below

Outside Diameter, TIR (mm) 0.05 0.10 0.15 0.20 0.25

Face, TIR per mm of R (mm) 0.010 0.012 0.015 0.020 0.025

Table 3 : Maximum Allowable Run-Out, (TIR) METRIC 4. Check for free axial movement of the pinion and gear. Do not force shaft movement to the point of damaging the bearing shell. 5. Tighten foundation bolts. •

Before tightening the foundation bolts, be sure that the base of the gear unit sets evenly on all shims so that there will be no distortion after tightening the bolts.

•

After tightening the bolts, check for distortion by placing a dial indicator on the gear housing foot near the bolt to be checked. If the housing foot moves more than 0.002 inch (0.05 mm) when that bolt is loosened, then distortion is present and the housing needs additional shims around that bolt.

Installation, Operation, and Maintenance Manual

page 13

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

•

NTE 19.219 Rev. A Date : 27.06.03

Make a soft blue tooth contact check (see GEAR INSPECTION "Soft Blue Method").

3.6.4. Alignment Checking When the preliminary soft blue contact check is satisfactory, a hot alignment check should be made by running the gear train until temperatures stabilize, shutting it down and taking indicator readings while the package is hot (see GEAR INSPECTION "Hard Blue Method"). If optical alignment equipment is available, the hot alignment check should be made with the package bolted together and running, using the optical alignment flats on the gear unit in conjunction with any optical alignment flats provided on the driving and driven equipment. After complete hot alignment is obtained, the gear unit should be doweled to the foundation or base while the unit is running and temperatures are stabilized. The base flange is drilled for dowel pins, but they must be reamed at assembly. Locate the dowels under both ends of the most critical shaft (usually the high speed pinion). Do not use more than two dowel pins and do not put dowel pins on both ends of the unit.

WARNING :

After coupling alignment is established, place coupling guards in position and secure.

Failure to use coupling guards may result in serious injury to personnel.

3.7. TOOTH CONTACT CHECK After completing the alignment and prior to start-up, the tooth contact pattern should be checked. See GEAR INSPECTION for instructions on performing a soft blue check and how to interpret results.

CAUTION : Proper tooth contact must be obtained before the unit is put into operation.

During testing at the plant, layout blue is applied to the gear teeth so that in the field the contact obtained on the test stand may be verified. The soft blue check after field alignment should match the hard blue contact pattern left on the gears from the Test Stand.

After completing the start-up procedure outlined in OPERATION, run the unit for two hours under a light load, shut it down and remove the inspection cover to observe the areas on the pinion where the blue has worn off. If the contact is not satisfactory, the problem is possibly due to gear housing distortion caused by drawing the housing down to a base that is not square with the housing. Be sure the gear housing rests evenly on any shims before tightening the foundation bolts.

Installation, Operation, and Maintenance Manual

page 14

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

4. OPERATION 4.1. LUBRICATION At the time of shipment, LUFKIN coats interior gear parts with a rust preventative oil. This oil should be compatible with the operating oil, and it should not be necessary to flush the unit prior to putting in lubricating oil. In the gear drive, lubrication serves three basic functions : 1. To separate tooth surfaces and prevent metal-to-metal contact, thereby reducing friction and wear. 2. To remove heat losses at the gear mesh. 3. To remove heat produced in the bearings. It is very important to the successful and satisfactory operation of a gear unit that careful attention be given to proper lubrication, and that the lubricant be kept clean. Every precaution should be taken to prevent water and foreign particles from entering the gear case. If the oil does become contaminated by water or foreign particles, it should be analyzed and changed, if necessary, or cleaned and reconditioned.

4.2. OIL TYPE AND GRADE The lubricating oil must be high grade, high quality, well refined petroleum oil. Also, it is essential that the oil be clean and non-corrosive to gears and bearings. It must be neutral in reaction and possess good defoaming properties and also have good resistance to oxidation. Straight mineral type lubricant should be used under normal operating conditions. Consult LUFKIN before using any synthetic lubricants.

CAUTION : Do not change grades of oil without approval by LUFKIN.

LUFKIN specifies oil grade on the Parts List and Installation Plan drawings, as well as on the unit nameplate.

Also see INTRODUCTION "Lubrication". It is useful to take a baseline analysis of the oil being put into the unit for later comparison.

4.3. CUSTOMER CHECK BEFORE START-UP 1. Check all instrumentation and lubrication connections. 2. Check that all necessary piping and accessory wiring is complete. 3. Check the lubricating system for correct type and quantity of oil. 4. Check for correct shaft alignment (See INSTALLATION). 5. Check for foundation bolt tightness (See INSTALLATION). Installation, Operation, and Maintenance Manual

page 15

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

6. Check tooth contact (See GEAR INSPECTION). 7. Check that coupling guards and inspection covers are in place.

4.4. START-UP PROCEDURE Check oil temperature. The minimum start up temperature for the oil in the gear unit is 70°F (21°C.) It is best to start the unit with an oil temperature as close to operating conditions as possible.

WARNING : Coupling guards and inspection covers must be secured BEFORE start-up.

Gears starting up with oil temperature below 70°F (21°C) may require additional care to ensure oil is flowing to the mesh and bearings. It may be advisable at low temperatures to slowly start-up or run oil through an auxiliary pumping system (if available) to pre-warm it.

Start unit at reduced speed and load if practical. Monitor bearing temperatures, housing and shaft vibrations, and oil pressure to ensure acceptable conditions are maintained.

CAUTION : Operation of the gear unit with no oil will result in damage.

NOTE :

Increase speed gradually until operating values are reached. Continue monitoring to assure acceptable temperatures, pressure and vibration.

There are times that vibration levels will exceed expected limits until temperatures have stabilized and/or loads have approached.

4.5. CUSTOMER CHECK AFTER START-UP 1. Run gear unit at light load while checking for adequate lubrication. 2. Watch the bearings for a sudden high temperature rise which could indicate a bearing problem. 3. Run gear under full load and speed and check for unusual noise and vibration. Expected maximum shaft vibration level for the units may be found in Figure 1, and the expected maximum housing vibration in Figure 2. 4. Also check oil temperature and bearing temperature. See "Alarm Switches" below for starting alarm settings. After temperature stabilization, the oil temperature into the gear unit should generally not exceed the oil inlet temperature stated on the Installation Plan drawing. 5. After unit has run for two hours under load, shut it down, check coupling alignment, check and tighten any bolts that may be loose, and recheck tooth contact.

Installation, Operation, and Maintenance Manual

page 16

GENERAL TECHNICAL MANUAL

NTE 19.219

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

Rev. A Date : 27.06.03

Peak-to-peak displacement (µm)

55 50 45 40 35 30 25 20 15 0

5 000

10 000

15 000

20 000

25 000

30 000

Maximum continuous speed (RPM)

Figure 1 : Expected maximum shaft vibration levels

Peak-to-peak displacement (µm)

20 18 16 14 12 10 8 0

5 000

10 000

15 000

20 000

25 000

30 000

Maximum continuous speed (RPM)

Figure 2 : Expected maximum housing vibration levels

4.6. ALARM SWITCHES The preliminary settings offered in General Arrangement Drawing are above the expected operating level of the gear unit. However, actual field operating levels of the gear unit may be higher or lower than expected values. Therefore, the values in General Arrangement are preliminary and may be decreased or increased to better suit actual field operating levels. When lower values are used LUFKIN need not be consulted; however, when the values are increased over those listed in General Arrangement consult LUFKIN for suitability.

Installation, Operation, and Maintenance Manual

page 17

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

5. PREVENTIVE MAINTENANCE LUFKIN recommends following the detailed maintenance schedule on the next few pages for most operating conditions.

5.1. INTRODUCTION The Scheduled Maintenance instructions in this manual are intended to provide a guide for minimum operations required to ensure years of trouble-free operation. Table 4 gives an overview of scheduled maintenance.

•

DAILY check oil temperature

MONTHLY • check operation of auxiliary equipment

•

check oil pressure

•

check operation of alarms

•

check vibration

•

check tightness of foundation bolts

•

check noise

•

check for oil contamination

•

check for oil leaks

•

QUARTERLY analyze oil sample

•

ANNUALLY check bearing clearance

•

check endplay

•

check tooth contact pattern

•

check coupling

OR

•

check alignment

every six months

•

check pump drive coupling

OIL CHANGE • •

2500 hours of operation

Table 4 : Maintenance Schedule Overview If major repairs should be needed on this gear unit, it is best to return it to the factory. If time is not available for factory repairs, LUFKIN has available capable field servicemen who can perform on site analysis and repair.If the customer desires to repair the equipment, the Parts List furnished with the gear unit and the information in this manual should be studied carefully. Good preventive maintenance habits will prolong the life of the gear unit and will help in detecting trouble spots before they cause serious damage and long down time.

5.2. DAILY MAINTENANCE •

Check the oil temperature and pressure against previously established norms.

•

Check for unusual vibration and noise.

Installation, Operation, and Maintenance Manual

page 18

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

•

NTE 19.219 Rev. A Date : 27.06.03

Check for oil leaks.

5.3. MONTHLY MAINTENANCE •

Check operation of auxiliary equipment and/or instrumentation and alarms.

•

Check tightness of foundation bolts.

•

Check oil for possible contamination. A sample should be obtained from the floor of the gear case.

5.4. QUARTERLY MAINTENANCE The greatest advantage to oil analysis is that it can detect many failures before they are catastrophic. The only way to do this is to take frequent samples and have them evaluated immediately. Monitor the results if a change is noted, respond accordingly. Take oil sample and submit for laboratory analysis. Compare the results to the initial baseline analysis done when oil was first put into the unit.

5.4.1. Oil Analysis Guidelines It is recommended that the oil be changed in the following cases : •

The total acid number increases by 2. For example: new oil might have a total acid number of 0.4. When this number increases to 2.4 or above, the oil should be changed. This acid number increase is associated with oxidation of the oil which results in oil breakdown.

•

A rapid change in viscosity is noted. Gear oil is "sheared" as it lubricates the meshing gear teeth. This shearing eventually causes the oil to thin out and lose its film thickness. A rapid decrease could mean oxidation. A decrease of 10% is excessive.

•

The water content is more than 0.1%. Water in oil causes the oil to lose its film strength and also will cause corrosion to gear elements and bearings.

•

The silicon content is above 50 parts per million. This signifies the oil is dirty.

•

The iron content is above 200 parts per million. This indicates contamination from gear wear particles.

•

A rapid increase is noted in any of the wear elements. As a guide, if rapid increases of any of the following materials are detected, the probable origins of that material are listed : • Alloy Steel - Gear teeth, bearings • Mild Steel - Oil pump, slinger, or baffle rubbing gear case • Cast Iron - Oil pump • Aluminum - Oil seal, seal guards or carriers • Babbitt - Journal bearings

Installation, Operation, and Maintenance Manual

page 19

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

5.5. ANNUAL MAINTENANCE •

Check bearing clearance and endplay.

•

Check tooth contact pattern.

•

Visually inspect couplings and check alignment.

•

Inspect tags and labels showing replacement part numbers. Replace if necessary.

•

Inspect warning signs and labels. Replace if necessary.

5.6. OIL CHANGE INTERVALS Under normal operating conditions, the lubricating oil should be changed every 2500 hours of operation or every six months, whichever occurs first. The unit should be drained by removing the drain plugs (see the Installation Plan for location).

DANGER : When working near rotating elements, be certain that the driving and driven equipment are securely locked out.

Complete oil changes for units with large capacity oil systems are sometimes impractical. In this case, draining the oil system, cleaning the reservoir and/or gear sump, and then recharging the system with the original oil that has been cleaned and reconditioned may be sufficient.

If this approach is taken, LUFKIN strongly recommends routine oil analysis so that any breakdown of the oil being reused can be detected before affecting gear operation.

Installation, Operation, and Maintenance Manual

page 20

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

6. DISASSEMBLY During disassembly, refer to the Installation Plan and Parts List furnished with this manual.

6.1. GENERAL NOTE :

Any work done on equipment during the warranty period without the written approval of an authorized LUFKIN representative could void the warranty.

6.1.1. Lock Out/Tag Out Procedure 1.

Identify the energy sources used and all control devices.

2.

Notify all affected personnel.

3.

Turn OFF all operating controls.

DANGER : When working near rotating elements, be certain prime mover is turned off and locked out/tagged out.

6.

4. Lock out or tag out all switches and energy controls in "OFF" or "SAFE" positions. 5. Test all operating controls to make sure no power is getting to equipment.

Perform required maintenance.

6.1.2. Visual Inspection The following sequence is for complete disassembly. Visual inspection of the gearing through the inspection cover may provide the information necessary to determine the cause of a problem without complete disassembly.

6.2. TOOLS REQUIRED For disassembly and reassembly, several commonly available tools may be required. No special tools or fixtures are required for the housing and gears, and no tools for assembly/disassembly are provided by LUFKIN. Following is a list of some tools that will be helpful : •

Crane or hoist, along with soft slings or chains

•

Eyebolts

•

Dial indicator

Installation, Operation, and Maintenance Manual

page 21

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL •

Pry bar

•

Crocus cloth or fine steel wool

•

Wrenches, screwdrivers, torque-wrench

•

Prussian blue or similar dye for tooth contact check

•

LocTiteTM 510

NTE 19.219 Rev. A Date : 27.06.03

6.3. SPARE PARTS Parts such as gaskets should be replaced when disassembly is performed. Contact LUFKIN Customer Service or a sales office for a list of recommended spare parts for the gear unit. Refer to the Parts List for a complete list of unit part numbers and descriptions.

6.4. REMOVAL OF GEAR COVER Throughout the disassembly sequence, observe carefully what may have occurred inside the unit and record the position and condition of any failed parts. Note any parts, bolts, nuts, or holes that are numbered or match marked; they must be reassembled as matched for correct assembly. 1. Remove any deflectors, baffles, or coupling guards. 2. Disconnect the high speed and low speed couplings. 3. Disconnect any piping, conduit, or wiring that joins the housing sections. 4. Remove any bearing temperature sensor service heads, probes, or other auxiliary instruments that could be damaged by removal of the cover. 5. Remove the cap screws in the upper half of the seals, end caps, and thrust bearing housing; if lockwiring is supplied, cut where necessary. 6. Remove end caps, seals, and gaskets. 7. Carefully loosen the thrust bearing housing (Use the jacking screw holes to loosen from gear housing). 8. Remove all cap screws, nuts and dowel pins on the parting line. Take care to remove any dowel pins located under the flush plugs. Leave studs in place to serve as guides for cover removal. 9. Break the parting line seal by using jacking screws in the jacking screw holes located on each end of the gear unit. Some sharp raps with a rawhide hammer at the corner positions and prying with a large screwdriver may be needed to loosen the parting line joint. 10. Attach a crane or hoist to the lifting provisions in the cover and carefully lift the cover by lifting both ends equally about 1/4 inch (6 mm). Check that bearings remain seated and no conduit or wiring that crosses the parting line is still connected. 11. Check the upper bearing halves to see if they are stuck in the cover. If they are, carefully pry them out or push them out with a rod inserted through the bearing thermometer holes.

Installation, Operation, and Maintenance Manual

page 22

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

CAUTION : Do not bump gear assembly with the raised cover.

NTE 19.219 Rev. A Date : 27.06.03

12. Carefully lift the cover straight up until it clears the gearing. The cover will need enough clearance above the gear and studs for the cover to be removed.

13. Place the cover on wood blocks so that the machined split line will not be damaged. Take care that internal lubrication lines are not damaged.

6.5. REMOVAL OF PINION, GEAR, AND BEARINGS NOTE :

The gear and pinion must be removed from housing to inspect or replace NM Type bearings.

Removal of gearing from housing is not required if only bearing or rotating element inspection is needed. Bearings others than tilt pad journals can be removed and replaced by rolling shells out of housing. Do not remove more than one bearing at a time : replace bearing after inspecting it and prior to inspecting other bearings. The thrust bearing is more difficult to remove and reinstall than the radial bearings. If you desire to remove the thrust bearing, refer to the detailed instructions in "Thrust Bearing Removal". 1. Mark the location of each bearing in the housing so that it can be reassembled correctly. 2. One bearing at a time, remove bearing top half. See BEARING INSPECTION for details on assessing bearing condition. NOTE :

Tilt pad journals bearings should be left in position in the housing.

a. Note (and mark if the factory marking has worn off) the exact orientation of the bearing and which face is out so that it will be replaced correctly. b. If necessary, rotate the bearing until its parting line is level with the housing parting line. c. Remove any bearing straps supplied. d. Insert an eye bolt in the top half of the bearing and lift it up. e. If gears are to be removed, either • remove the top halves of the bearings or • wire or strap the top and bottom halves of each bearing together to lift shaft and bearings out as a unit. 3. Remove the pinion by using a soft sling on each side of the mesh. Place the shaft on a soft material such as wood or rubber or a padded V rack, taking care not to damage the gear teeth. NOTE :

Tilt pad journals bearings should be removed with the pinion and may then be disassembled for inspection.

Installation, Operation, and Maintenance Manual

page 23

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

4. Remove the low speed gear and shaft assembly with a chain inserted through a lifting hole or eyebolts inserted into the gear. Be careful to protect the teeth by placing wood blocks between the chain and the sides of the gear. 5. Place the gear on a soft surface such as wood taking care not to damage the teeth. Block each side to prevent the gear from rolling. 6. See GEAR INSPECTION for an analysis of gear problems.

6.6. THRUST BEARING REMOVAL Use the following guidelines to remove the thrust bearing : 1. If the thrust bearing contains temperature sensors, the lead wires exit the bearing housing through an oil seal fitting. 2. Loosen and remove the outer half only of the seal fitting along with the internal sealing elements from the lead wires. 3. Remove the thrust bearing end cap bolts. 4. Remove the end cap and shims from the thrust bearing housing. Be careful to avoid crimping or tearing the plastic shims. 5. Use wide jaw pliers to pull the outer backing ring a short distance out of the thrust bearing housing. 6. Remove the outer backing ring and thrust pads. Mark the position of pads containing embedded temperature sensors so they can be returned to their original location. 7. Remove the axial probe target plate. 8. Loosen the two set screws in the thrust collar lock nut. 9. Remove the lock nut by turning it counterclockwise. Use a spanner wrench or a small punch inserted into the spanner holes to loosen the nut.

CAUTION : Before removing the thrust collar from the bearing housing, tilt the top of the collar forward to see if any bearing pads are stuck to the back side of the collar. Remove any stuck pads before they can fall out of the housing and be damaged.

10. Insert capscrews into the threaded puller holes in the thrust collar. 11. Carefully remove the thrust collar. Do not allow the collar to drop down and damage the lock nut threads as it is being removed. 12. Mark the position of the inner thrust pads containing embedded temperature sensors so they can be returned to their original position. Remove the shoes and inner backing ring.

Installation, Operation, and Maintenance Manual

page 24

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

6.7. OIL SAMPLE COLLECTION If desired, collect a representative full quart (liter) sample of oil from the sump for later analysis. See PREVENTIVE MAINTENANCE "Oil Analysis Guidelines", for a discussion of oil quality and contamination.

Installation, Operation, and Maintenance Manual

page 25

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

7. GEAR INSPECTION 7.1. TOOTH CONTACT CHECKING 7.1.1. Introduction The purpose of this guide is to describe why you should check gear tooth contact, how the actual check is made, and how to interpret the tooth contact check on power transmission gearing with involute double helical teeth and parallel input and output shafts.

7.1.2. Why Check Tooth Contact Gear teeth must have an even load across the entire face width to minimize stress on the teeth. The contact between gear teeth is line contact; therefore, the alignment between the rotating elements (pinion and gear) is critical. Tooth alignment is controlled by the accuracy of the rotating elements, the housing, and the bearings assembly.

7.1.3. When to Check Tooth Contact Tooth contact should be checked on all new installations, after any disassembly of the gear unit, and after any major housing-to-foundation change.

DANGER : When working near rotating elements, be certain prime mover is turned off and locked out/tagged out.

It may also be checked as part of routine annual maintenance or when a problem related to alignment is suspected. Contact must be checked on the job foundation to be sure the unit will operate properly.

7.1.4. How to Check Tooth Contact The contact can be checked two ways : •

Soft blue : Apply soft machinist's bluing or transfer bluing to the teeth of one gear and roll that gear by hand through mesh with its mating gear. (The terms "blue" or "bluing" are used for convenience; the dye is available in other colors.) The transfer of the blue from one gear to the other gear is read as the contact.

•

Hard blue : Paint the gear teeth with hard or layout blue, run the gear unit, and observe the pattern of 'wear-off' of the bluing.

Contact checking may usually be accomplished through the inspection cover port. Occasionally, soft blue checking is done with the housing cover removed, such as during the reassembly process.

Installation, Operation, and Maintenance Manual

page 26

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

7.1.5. Soft Blue Method The soft blue method is usually done first. Since the unit is not running, this check does not give true contact. It does give a good indication of what contact will be. If it indicates inadequate contact, you may choose not to start the unit until contact is corrected. If the unit has been disassembled, then a soft blue check before the housing cover is installed may save a tear-down to correct contact. This is especially important if a new set of rotating elements or bearings is installed. Soft blue is usually applied to three or four teeth on the pinion in two places 180° apart. Clean the teeth thoroughly with solvent, and brush on the blue in a very thin and even layer. With the gear set centered, hold a drag on the low speed shaft and roll the pinion through mesh with the gear. Rotation direction is not important, but the contact must be checked on the loaded flank, not the unloaded tooth flank. Observe the blue that transferred from the pinion to the gear. This is the contact pattern. Cellophane tape can be used to remove this blue pattern from the gear and save it for maintenance records: after the check, firmly place a piece of tape on the gear tooth flank, remove the tape, place it on a clean sheet of white paper, and label it with : •

the date

•

name and number of the part the tape was lifted from

•

the wing and apex

•

which helix (left or right, noting whether wing or apex is leading)

The contact should be checked at three places around the gear (approximately 120° apart); however, the blue must be reapplied and smoothed on the pinion after each meshing.

7.1.6. Hard Blue Method Thoroughly clean the area where hard blue is to be applied. The teeth must be absolutely free of oil, or the blue will not adhere properly and large flakes will chip off, making the contact check inaccurate. Apply the blue to an area three or four teeth wide at four places on the gear and at two on the pinion. Run the unit (usually at full speed). Running conditions may vary from no load to full load. The best way is to run the unit at very light load (up to 20%) for two hours or so, and then shut it down and check the contact. With higher loads the unit should run a shorter time before checking contact. The trick is to run the unit just long enough to wear the blue off the areas of higher contact stress. High loads can mask poor contact and give a false reading.

7.2. INTERPRETATION OF TOOTH CONTACT The following is information to be used only for guidance in deciding if tooth contact is adequate. Contact LUFKIN on how to correct poor contact. Assuming properly manufactured parts, minor corrections can be made to the tooth contact by shimming the gear housing. Installation, Operation, and Maintenance Manual

page 27

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Exactly what contact should be acceptable has to be based on LUFKIN's recommendations and experience. Remember that tip or root relief modifications are designed to improve load distribution when a unit is operating under load, but they can make the contact appear quite bad under no load, as in a soft blue check. Generally, with a soft blue check you are looking for some blue to transfer, usually in a line that covers at least 80% of the face width.

Figure 3 : Tooth Contact Patterns Do not be alarmed by a lack of blue covering the flank of the tooth; flank contact should normally not extend entirely to the tip of the tooth. See Figure 3 for examples of tooth contact patterns. Keep in mind that a soft blue contact will not produce such dark impressions - look for the same pattern in a «sketchy» impression. The hard blue check can be done from no load to full load, and the results will vary with the load condition. If the unit is run at no load the test will usually appear similar to a soft blue check. More blue will wear off the pinion than the gear due to the higher number of cycles the pinion sees. As the load increases, blue will wear off more of the tooth flank. Look for evidence of even load across as much of the gear tooth, both flank and face width, as possible.

Installation, Operation, and Maintenance Manual

page 28

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

7.3. GEAR CONDITION ASSESSMENT During the initial operating period of a set of gears, minor tooth imperfections will be smoothed out, and the working surfaces will polish out under normal operating conditions; however, the life of a gear set may be seriously shortened by the following problems : •

poor coupling alignment

•

dirty lube oil

•

insufficient lubrication

•

poor tooth contact

•

overloading the teeth.

In assessing gear wear, observe carefully and document the condition of the tooth surface and the operating conditions. It is recommended that before a questionable gear set is considered inoperative, periodic examinations be made with photographs or carbon impressions to determine whether or not the observed condition is progressive.

7.3.1. Types of Gear Wear or Failure Listed below are several common types of gear wear or failure, extracted from Appearance of Gear Teeth–Terminology of Wear and Failure, ANSI/AGMA 1010-E95 (revision of ANSI/AGMA 110.04), Dec. 1995 with the permission of the publisher, The American Gear Manufacturers Association, 1550 King Street, Suite 201, Alexandria, Virginia 22314. Additional information with photographs and illustrations may be found in this bulletin. Abrasion - Type of wear :Removal or displacement of material due to the presence of hard particles suspended in the lubricant or embedded in the flanks of the mating teeth (includes scoring). Bending fatigue - Progressive failure through crack initiation, propagation, and fracture. Contact fatigue - Cracks and the detachment of material fragments from the gear tooth surface caused by contact stress (includes pitting, spalling and subcase fatigue). Corrosion - Type of wear : Chemical or electrochemical reaction between the surface of a gear and its environment. Cracks - Splits caused by bending fatigue, mechanical stress, thermal stress, material flaws, or improper processing. Erosion - Type of wear : Loss of material from surface because of relative motion of a high velocity fluid. Fracture - A fatigue failure caused by tooth overloading resulting in gear tooth or portion of tooth breaking off (includes tooth shear). Plastic deformation - Deformation caused by stress exceeding the yield strength of the material (including indentation, cold flow, hot flow, rolling, tooth hammer, rippling, ridging, burring, root fillet yielding, or tip-to-root interference).

Installation, Operation, and Maintenance Manual

page 29

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Scuffing - Severe adhesion that causes transfer of metal from one tooth surface to another due to welding and tearing. Wear - Change to a gear tooth surface involving the removal or displacement of material, caused by mechanical, chemical, or electrical action (includes adhesion, abrasion, polishing, corrosion, fretting corrosion, scaling, cavitation, erosion, electrical discharge, and rippling).

7.3.2. Definition of Gear Failure It should be understood that the above mentioned types of wear do not necessarily constitute complete failure, for failure is a matter of degree or rate of progression.

Installation, Operation, and Maintenance Manual

page 30

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

8. BEARING INSPECTION 8.1. BEARING TYPE LUFKIN's standard journal bearings for gear units are split, steel-backed, babbitt-lined bearings, shown in Figure 4. NOTE :

NM Type unit are furnished with one-piece, steel-backed, babbitt-lined journal bearings on high speed shaft only.

A. Standard journal bearing

B. Pressure dam bearing

C. Flat face thrust bearing with radial grooves D. Kingsbury-type equalizing thrust bearing (with tilt pads) Figure 4 : Standard Unit Bearings. When operating speeds or loads make oil-whirl possible, LUFKIN may uses pressure dam journal bearings (Figure 5 B.) or tilt pad journal bearings.

CAUTION : Pressure dam bearings must be positioned correctly to prevent damage to equipment.

The pressure dam journal bearing is designed for a particular direction of rotation; therefore, care should be taken at assembly to assure correct rotation. The pressure dam grooves are positioned on the unloaded side of the bearing journal as shown in Figure 5.

Installation, Operation, and Maintenance Manual

page 31

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Figure 6 Pressure dam location.

Figure 5 : Pressure dam location

To axially locate the gear train and to take any nominal thrust created by external loads, LUFKIN normally uses a flat face thrust bearing with radial grooves (Figure 5 C.) or a Kingsbury-type thrust bearing (six-shoe double bearing with separate collar, Figure 5 D.) located on the low speed shaft or a tapered roller bearings on NM Type units. The unit thrust areas are sized so that the maximum continuous thrust pressure on the flat face bearing is 75 psi (525 kPa), while that for a tapered land is 150 psi.

8.2. BEARING CONDITION ASSESSMENT When the unit is disassembled, the bearings and journal should be carefully inspected for uneven wear or damage. If required, manually polish journals using belt type crocus cloth to remove any high spots. Bearing surfaces should be thoroughly inspected for : •

correct clearance

•

high spots

•

flaking of babbitt

•

scoring

•

wiping

8.2.1. Bearing Clearance The journal bearings used in LUFKIN gears must have clearance between the journal and the bearing. The amount of clearance necessary depends on the oil viscosity, the journal speed and the bearing loading. Each of these parameters is considered in calculating clearance that will provide hydrodynamic lubrication, as well as sufficient oil flow for cooling. Design clearance on the bearings is indicated on the Installation Plan.

Installation, Operation, and Maintenance Manual

page 32

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

Measurement of bearing clearances may be accomplished while the gear is stopped by lifting the shaft and measuring the distance traveled with a dial indicator or by using feeler gauges, carefully sliding a feeler gauge between the top of the bearing bore and the shaft. NOTE :

Tilt pad journals are not easily checked for clearance. These bearings are typically examined for signs of excessive wear or damage, and if they appear to be undamaged are assumed to be acceptable.

Some wear should be expected, especially on a gear that is stopped and started frequently. The bearing may be considered operational as long as the measured clearance does not exceed the design clearance by more than 0.004" (0.1 mm). NOTE :

If shaft vibration is excessive, this clearance increase may not be acceptable contact LUFKIN.

8.2.2. Bearing Contact and Correction High speed and low speed bearings should be checked as they are seated for correct bearing contact using Prussian blue dye. This may be done by rolling out one shell at a time for inspection of transfer of blue dye between shaft and journal. To check the bearing contact, install the lower half of the bearing in each side of the housing with the journal and thrust face clean and dry. Check the outside diameter of the bearing with a 0.0015" (0.035 mm) feeler gauge to be sure the lower half is seated in the housing. In the axial direction, apply a very light line of Prussian blue to the journal and to each thrust face and rotate the shaft 360° by hand. The journal should show blue transfer for a minimum of 80% of the bearing length. After bearing contact is satisfactory, it may be possible to improve gear tooth contact by adjusting the shims under the unit (see INSTALLATION "Alignment" and GEAR INSPECTION "What Good Tooth Contact Is".) Sometimes gear tooth contact may be corrected by scraping and polishing one of the bearings loaded in the bottom section to spread the contact along the face width. If this is necessary, contact LUFKIN. NOTE :

Tilt pad journal bearings should not be modified except for removal of local raised material and polishing.

After correcting bearing and tooth contact and before putting the cover on the gear unit, the bearings should be liberally lubricated with clean oil to provide for initial start-up lubrication.

8.2.3. Bearing High Spots

CAUTION : All bearing journal polishing must be in a circumferential direction to prevent axial scratches.

Location of any high spots in the bearing are indicated by bright spots which should be lightly scraped and polished with fine steel wool or crocus cloth until they blend in with the rest of the bearing.

Installation, Operation, and Maintenance Manual

page 33

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

8.2.4. Flaking of Babbitt Flaking of babbitt in the load area of the bearing is caused by vibration or shock loading of the bearing material, causing the babbitt to fatigue and break loose from the steel shell. The flakes cause scoring as they pass through the bearing and contaminate the lubricating oil. In the advanced stages of flaking, the load carrying area of the bearing is destroyed and the bearing must be replaced.

CAUTION : Do not use sandpaper to polish bearings; damage to equipment may result.

However, if flaking is caught in the early stages, the bearing may be repaired by scraping and polishing. The cause of vibration or hammering should be corrected before the unit is put back in service.

8.2.5. Scoring Scoring, scratching, or marring of the bearing babbitt and/or the journal riding in the bearing is caused by dirt or metal particles in the oil which passes through the bearing. A little scoring is not serious, and the bearing may be polished with fine steel wool to remove any rough edges caused by scoring. Any foreign particles embedded in the babbitt which could score the journal should be carefully picked out, and that area should then be polished smooth. Scoring becomes serious when it significantly reduces the bearing area. In this case, the bearing should be replaced and the gear unit drained and flushed out with a solvent.

8.2.6. Wiping The melting and wiping away of a spot or area of the babbitt is caused by bearing temperatures rising above the pour point of the babbitt. Abnormal bearing temperatures may be caused by : •

insufficient bearing clearances

•

insufficient oil pressure

•

excessively high oil temperature in the bearing

•

a high spot in the bearing

•

extreme bearing loading caused by poor bearing contact

•

gear mesh failure

If wiping is localized in a small spot, the bearing may be repaired by scraping and polishing the spot until it blends in with the remainder of the bearing; otherwise, the bearing must be replaced. Before replacing a wiped bearing, determine and correct the cause of the wipe.

8.3. REPLACEMENT BEARINGS Refer to the Parts List drawing and contact LUFKIN if it is determined that bearings need to be replaced.

Installation, Operation, and Maintenance Manual

page 34

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

If new bearings are used, the following precautions should be taken : 1. Remove all nicks and burrs from the housing and bearing shell. 2. Be sure that journals are free of nicks and high spots. These can be removed using a fine hone and polishing with crocus cloth. 3. Obtain the proper bearing contact as described under "Bearing Contact and Correction". 4. After bearings are fitted and lower halves are installed in housing, check the radial clearance using feeler gauge or plastic gauge material. Check endplay by barring the shaft axially.

Installation, Operation, and Maintenance Manual

page 35

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

9. REASSEMBLY 9.1. PREPARATION NOTE : NOTE :

Any work done on equipment during the warranty period without the written approval of an authorized LUFKIN representative could void the warranty. This procedure assumes that the gear housing is not moved from its foundation/ support and that the original shaft alignment was correct.

1. Carefully clean all the interior surfaces of the housing, the housing cover, and all components that will be reused. Parting line surfaces must be clean and smooth; use a spray-on paint and gasket remover fluid and/or carefully scrape the surfaces if necessary. Corroded spots can be cleaned by using a fine emery cloth, rubbing shafts in a rotary or circumferential direction. Do not rub shafts in a length-wise direction as it may cause seal leaks.

CAUTION : During maintenance of the reduction gear, cleanliness of parts during installation is of utmost importance to assure successful gear operation.

2. Check the bearing shells, the parting line, and the housing bores for any burrs or nicks; remove with a fine file. 3. Put a coat of light oil on all parts to help assembly and to prevent rust during reassembly.

For the discussion that follows, it is assumed that the entire unit must be reassembled. NOTE :

Tighten connectors uniformly: when tightening bolts, studs, or screws on an assembled portion with three or more holes, always partially tighten connectors equally in a «cross» pattern to avoid torquing, binding, or warping the section (for example: 1. top left corner, 2. bottom right corner, 3. top right corner, 4. bottom left corner. Repeat to fully tighten.).

9.2. REASSEMBLY SEQUENCE NOTE :

Although instructions include using sealer between housing sections, this should actually be done on the final assembly, only after checking tooth contact and ascertaining that the unit is aligned properly.

9.2.1. Bearing, Gear and Pinion Assembly 1. Install journal bearings. Before installing journal bearings, note that pressure dam bearings are match marked and are not interchangeable. • Install the lower half of the journal bearings (the half with the slot for the roll pin if there is one) in the housing in the position for which they were marked at disassembly, keeping parting lines on bearing and housing even. Installation, Operation, and Maintenance Manual

page 36

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

• Check with a 0.0015" (0.035 mm) feeler gauge to see that lower halves are seated.

CAUTION : Correct assembly of pressure dam bearings is required to prevent damage.

•

See Figure 5 to seat pressure dam in correct location.

•

Check bearing contact as described in BEARING INSPECTION.

•

Rethread any temperature sensor wires from bearing through housing.

2. Install gear. Lift the low speed gear and carefully place the assembly in its correct location in the gear housing and bearings. Use care to avoid bumping housing or edges of bearings. Check that temperature sensor wires are not pinched.

CAUTION : Do not attempt to install shafts with lower halves of thrust bearing in housing or babbitted thrust faces may be damaged.

3. Set the top of the gear bearings in place and secure (bolts or bearing straps if supplied - see Parts List for requirements). Turn bearings in bore if necessary (see Parts List for requirements).

4. Install pinion. Make sure the pinion is level and line it up in mesh with the gear. With tilt pad journal bearings install the bearings on the pinion, make sure the pinion is level and line it up in mesh with the gear

CAUTION : Do not bump gear assembly into housing.

5. Carefully set the pinion into its bearings and in mesh with the gear. With tilt pad journal bearings, carefully set the pinion and its bearings in mesh with the gear, and roll along gear until bearings are seated in the housing.

6. Set the top of the pinion bearings in place and secure (bolts or bearing straps if supplied see Parts List for requirements).

9.2.2. Gear Cover Assembly 1. Lower the cover over the studs carefully to prevent damage to gearing. Leave suspended high enough to reach RTD holes. 2. Thread the temperature sensor wires from the bearings through the top housing if necessary (for safety place wooden blocks between the middle section and the top while threading wires.)

Installation, Operation, and Maintenance Manual

page 37

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

3. Coat the split line with a small bead of sealer, such as LocTiteTM 510. Circle all studs to assure sealing of oil; avoid feeder groove areas.

CAUTION : Do not block oil passages with sealer.

4. Seat the cover onto the bottom.

5. Torque all cap screws and studs. 6. Perform a soft blue gear tooth contact check. (See GEAR INSPECTION)

WARNING : Do not place hands below suspended housing without blocks for protection.

7. If the contact is not acceptable, check for improperly meshed gears, burrs on shafts or housing bores, or twisted housing. If no satisfactory explanation can be found, contact the LUFKIN Service Department for assistance.

8. Install Kingsbury thrust bearing. • Replace the inner backing ring. It must be firmly seated against the wall of the housing. Note the counter bores on the inside wall of the thrust bearing housing which provide for clearance between the temperature sensor lead wires and the thrust collar. • Thoroughly clean each thrust bearing shoe. • Apply a liberal quantity of thick grease to the back side of each thrust shoe. The grease will serve as a temporary adhesive to keep the shoes positioned in the backing ring as they are installed. • Install the inner thrust shoes taking care to place each shoe having an embedded temperature sensor in its original position.

CAUTION : When installing the leadwire seal fittings, be sure to pull the slack from the leads to prevent them from rubbing against the thrust collar.

•

Feed the lead wires through the wall of the housing and replace the thrust collar.

•

Install and tighten the thrust collar lock nut and tighten the two thrust collar set screws.

•

Install the axial probe target plate.

• Place the outer backing ring on a flat surface. Apply a liberal quantity of grease to the back side of each outer thrust pad and position the thrust shoes on the backing ring. Insure that the shoes with embedded temperature sensors are located in their original position. • Lift the outer backing ring assembly and feed the lead wires through the housing. Install the backing ring while pulling the slack out of the leads. Be sure to pull the leads tight when installing the seal fittings to prevent the leads from rubbing the thrust collar. Installation, Operation, and Maintenance Manual

page 38

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

• Install thrust bearing end cap and tighten securely. Be very careful while handling and installing the shims, since torn or crimped shims can cause incorrect adjustments and oil leaks. When replacing old shims with new ones, use the same color as the old one since the shims are color-coded according to thickness. 9. Measure to ensure low speed shaft has specified axial movement. (Use a pry bar to move gear from side to side if necessary). Also check that the high speed pinion can float axially. 10. Mount the shaft seals, end plates, and other auxiliary equipment which may have been disconnected during disassembly. 11. Reconnect any junction box plate and wiring as necessary (see the Wiring Diagram). 12. Reconnect any instrumentation and lubrication lines necessary (see the Wiring Diagram, Installation Plan, and Lube System Diagram). 13. Couple unit to driver and driven machines (see INSTALLATION). 14. Install inspection covers with gaskets and sealer. 15. Align the unit per INSTALLATION "Alignment" section. 16. Spin the unit slowly with no load, if possible, to verify correct reassembly. Be sure the unit rotates freely and quietly. 17. Confirm proper shaft alignment and tooth contact per INSTALLATION section. 18. Follow the START-UP procedures.

Installation, Operation, and Maintenance Manual

page 39

GENERAL TECHNICAL MANUAL

NTE 19.219 Rev. A Date : 27.06.03

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

10. TROUBLESHOOTING Table 5 provides troubleshooting tips for high speed gears. For more detailed information, refer to the text following. If the problem cannot be remedied through use of this information, contact LUFKIN. Problem

Abnormally High Temperature

Low Oil Pressure

Possible Cause

Remedy

•

Housing coated with foreign material, preventing heat dissipation

•

Clean outside of housing

•

High ambient temperature

•

Provide adequate ventilation

•

Lack of oil to bearings and/or mesh (indicated by low oil pressure)

•

Check lubrication system

•

Use of lubricant with lower viscosity than required

•

Use correct viscosity lubricant

•

Low lubricant viscosity from high lubricant temperatures

•

See "Abnormally High Temperature"

•

Clogged oil filter

•

Replace filter element

•

Pump cavitation

•

Maintain proper oil level in reservoir

•

Air leak in suction line

•

Check and tighten all pipe fittings

•

Incorrect relief valve setting

•

Set relief valve correctly

•

Insufficient foundation rigidity

•

Reinforce foundation

•

Dynamic instability (critical speed)

•

Design to attenuate critical speeds in operating range

•

Unbalanced parts

•

Determine which parts require balancing and which have been balanced

•

Loose foundation bolting

•

Tighten bolting

•

Worn parts

•

Pinpoint noise with mechanic's stethoscope, replace part

•

Coupling misalignment

•

Realign couplings

•

Worn gearing

•

Replace worn parts

•

Transmission from other equipment

•

Add sound blanket or enclosure

•

Air in oil

•

Add anti-foaming agent (See caution in text below.)

•

No power

•

Check power supply & repair or restore

•

Faulty gauge or recording device

•

Test gauge or recording equipment

•

Failed sensor

•

Replace sensor

•

Lead wire braid rubbed through; wire contacting metal

•

Replace lead wire

Excessive Vibrations

Unusual Noise

Excessive Noise

Excessive Foaming

No Sensor Readings

Table 5 : Troubleshooting Tips

Installation, Operation, and Maintenance Manual

page 40

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

NTE 19.219 Rev. A Date : 27.06.03

10.1. ABNORMALLY HIGH TEMPERATURE •

Oil level too high. If the oil level in a gear box is so high that the gear runs in the oil, then the resulting churning action will heat the oil. Check the sight gauge while the unit is running. A full gauge may indicate inadequate drainage.

•

Coated housing. If the gear housing should get coated with a foreign material that will not permit natural heat removal by convection, high temperature may result. To prevent this, the unit should be cleaned periodically.

•

Hot weather. Obviously, a high ambient temperature will cause abnormally high oil temperature. To prevent this, provide adequate ventilation around the gear.

•

Low oil pressure. If the oil flow to the bearings and gear mesh is below normal (indicated by below normal oil pressure,) the heat created by friction at the mesh and bearings will cause abnormally high temperatures. To correct this situation, check the lubrication system for proper operation (see OPERATION "Lubrication").

10.2. LOW OIL PRESSURE •

Use of a lubricant which has a viscosity less than that for which the lube system was designed. There are several orifices in the lube system which are sized for lubricants with a particular viscosity. A lubricant with less than this normal viscosity will pass through the orifices without building up pressure. This situation can be prevented by using the lubricant designated on the name plate of the gear unit. Abnormally low viscosity may also result from high lubricant temperatures. (See above, "Abnormally High Temperatures").

•

Clogged oil filter. Replacing the filter will allow more oil to flow through it, thus bringing the oil pressure back to normal.

•

Pump cavitation. Should the oil level in the reservoir get so low that the pump suction line sucks both air and oil, then the oil pressure will drop. This problem may be cured by maintaining proper oil level in the reservoir.

•

Air leak in the suction line to the pump. This situation is similar to pump cavitation in that air gets in the oil and results in low oil pressure. To remedy this problem, check and tighten all pipe fittings in the suction line.

•

Incorrect relief valve setting. Adjusting the relief valve setting properly will avoid venting the pump discharge line back to the sump.

10.3. UNUSUAL OR EXCESSIVE NOISE •

Worn parts. One common cause of unusual noise is worn parts. If a part wears enough to cause slack in the system, the slack may be heard as a rattle or noise of some sort. A mechanic's stethoscope may be used to pinpoint the worn part which should be replaced.

•

Misalignment. A coupling that is out of alignment may also cause noisy operation. The misaligned coupling causes misalignment in the gear train which then produces noise or vibrations. The coupling should be immediately realigned before damaging wear occurs.

Installation, Operation, and Maintenance Manual

page 41

GENERAL TECHNICAL MANUAL INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

•

NTE 19.219 Rev. A Date : 27.06.03

Transmitted sound. Occasionally other machinery or equipment may be transmitting excessive noise. Enclose one or the other or use a sound blanket.

10.4. EXCESSIVE VIBRATION •

Soft foundation. A foundation that is not sufficiently rigid may cause vibration problems. To correct this, reinforce the foundation.

•

Critical speeds. At certain speeds a rotating shaft will become dynamically unstable and the resulting vibrations and deflections that occur may cause damage to the gear unit. The speeds at which the shaft becomes unstable are called critical speeds. They are a function of the shaft geometry and the type and spacing of the supporting bearings. Contact LUFKIN if such dynamic instability is suspected. See OPERATION "Customer Check After Start-up" for vibration limits.

10.5. FOAMING CAUTION : Measure the anti-foaming agent carefully. Too much anti-foam agent will stabilize the foam, destroy the load capacity of the oil, and require a complete oil change.

Some foam in a gear unit is generally acceptable and inevitable. If the foam exceeds 2 or 3 inches (50 - 70 millimeter) in the sump, LUFKIN recommends adding an anti-foaming agent such as DOW CORNING 200 FLUID™ (1000CS) at approximately 0.075 ml per gallon of oil. If excessive foaming persists, contact LUFKIN.

10.6. NO SENSOR READINGS Various sensing devices for temperature and vibration are installed to provide warnings that can prevent catastrophic failure. If no readings are being received, before disassembling the unit check for the following: •

No power. Check that the power supply to the devices is on.

•

Failed equipment. Check that the monitoring or recording equipment is functioning.

•

Worn wires. If the sensor has failed, partial disassembly may be effected to replace the sensor. Visual inspection of lead wire overbraids are necessary to ensure that moving parts are not rubbing through the lead wires and causing shorting out. Replace any worn wires.

Installation, Operation, and Maintenance Manual

page 42

LUFKIN GEAR N1619C 102920-050 REV. 01 Page 48 of 205

2. DRAWINGS 2.1. 2.2. 2.3. 2.4. 2.5. 2.6.

Assembly drawing Section through shafts Mass elastic diagram Wiring diagram Parts list Data Sheet

Assembly drawing

Prepared by Catherine BONTEMPI

5

Section through shafts

Prepared by Catherine BONTEMPI

6

Mass elastic diagram

Prepared by Catherine BONTEMPI

7

Wiring diagram

Prepared by Catherine BONTEMPI

8

35253100 Parts list

Prepared by Catherine BONTEMPI

9

Date : 17/09/07 [11:40] LUFKIN FRANCE SAS

BILL OF MATERIAL - ENGLISH VERSION

Page : 1 Company : 111 Un. : pcs

Project : 352531 N1619 C GEARBOX (2600 KW) Customer: 3158 SULZER PUMPEN Pos. Item 1 6505017600 2 1683084801 3 8041000100 4 7201921524 5 7201919524 6 7365000024 7 7520004516 8 7330006010 9 7577002100 10 8545003300 10 8656001300 11 6505000700 12 7520006012 15 6505001400 16 6504004300 17 7520001206 20 7577004800 20 8211002408 21 8218000001 22 8012000804 23 7137000000 24 7196000502 25 7503010020 26 7577003300 30 7609016150 30 N9027304 31 7201910020 32 7365000020 33 7998016150 40 8655006000 41 7557004012 42 7075006001 46 7201908016 47 7365000016 48 7998040040 49 7609016040 50 7577003300 55 8679000200 60 6505009900 61 6505001300 62 7817072430 100 6505017200 101 8658001100 105 1610086800 106 7557002008 110 8681061128 111 8681061129 120 8656901300 121 7520106016 122 7459001300 124 7283200016 130 8657000300 131 7520004016 200 6505017300

Manufactured Item: 35253100 N16_1_0078_00 Rev : E N16_1_0077_00 F

Housing, machined Retention device for Mann breather Oil separator MANN LB 11 102/2 Machine-made, threaded rod M24x215 Machine-made, threaded rod M24x195 Nut H, M24 Screw H M16x45 Taper pin 10x60 Taper plug BRIGGS - 1/2" Lifting eye male 33 X 350 Labyrinth Inspection cover, machined Screw H M12x60 Gasket for inspection cover Baffle for breather Screw H M6x12 Taper plug BRIGGS - 1"1/2 Cylindrical pin 8x24 LUFKIN plate Grooved nail 4x8 Plate showing direction of rotation Nail LGC-CTR1 2x5 Jacking screw M20x100 Taper plug BRIGGS - 1" Blind flange DN150 DIN2527 Plug rec Hd 1/8 NPT Machine-made threaded rod M20x100 Nut H, M20 Gasket for flange DIN DN150 Blind flange SAE 2" Screw CHc M12x40 Grade 8.8 O-RING JT.5674.353 2'' Machine-made threaded rod M16x80 Nut H M16 Gasket for flange DIN DN40 Blind flange DN40 DIN 2527 Taper plug BRIGGS - 1" Connect. for internal piping N14 - N16 Oil spray pipe Oil spray pipe Nozzle LECHLER 632.724.30.CC Pinion HS 33 t. mod. 6 Oil slinger 4"1/2 Key with flat end 28x16x134 Screw CHc M 8x20 Grade 8.8 Journal bearing 4"1/4 remachined Journal bearing 4"1/4 remachined Labyrinth assembled Screw SSt H M16x60 Windage baffle Std washer M16, zinc dichromate plated Closed end cover Screw H M16x40 Gear 84 t. mod. 6

Drawing Number N16_2_0176_00 GR_2_3848_01 G34.32_0_0001_00 V21.02_0_0215_24 V21.02_0_0195_24 V10.01_0_0000_24 V01.01_0_0045_16 V15.04_0_0060_10 G15.34_0_0021_00 C30.02_0_0033_00 C80_01_2_0013_00 N16_2_0007_00 V01.01_0_0060_12 N16_2_0014_00 N14_2_0043_00 V01.01_0_0012_06 G15.34_0_0048_00 V15.05_0_0024_08 SPQ01.16 V16.03_0_0008_04 SPE01.01 V16.02_0_0005_02 V01.02_0_100_20 G15.34_0_0033_00

V21.02_0_0100_20 V10.01_0_0000_20 DIN V03.21_0_0040_12 G19.30_0_0060_01 V21.02_0_0080_16 V10.01_0_0000_16 DIN G15.34_0_0033_00 N16_2_0099_00 N16_2_0013_00 G12.49_0_0724_30 N16_2_0172_00 C80_03_2_0011_00 ES12_2_0868_00 V03.21_0_0020_08 C80_05_2_0611_28 C80_05_2_0611_29 C80_01_2_0013_00 7520106016 C80_21_2_0013_00 C80_02_2_0003_00 V01.01_0_0040_16 N16_2_0173_00

Net Quantity 1 pcs 1 pcs 1 pcs 8 pcs 8 pcs 16 pcs 10 pcs 4 pcs 4 pcs 2 pcs 1 pcs 1 pcs 4 pcs 1 pcs 1 pcs 2 pcs 1 pcs 2 pcs 2 pcs 8 pcs 2 pcs 8 pcs 4 pcs 2 pcs 2 pcs 2 pcs 16 pcs 16 pcs 2 pcs 2 pcs 8 pcs 2 pcs 8 pcs 8 pcs 2 pcs 2 pcs 2 pcs 2 pcs 1 pcs 1 pcs 2 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 6 pcs 1 pcs 12 pcs 1 pcs 6 pcs 1 pcs

Date : 17/09/07 [11:40] LUFKIN FRANCE SAS

BILL OF MATERIAL - ENGLISH VERSION

Page : 2 Company : 111 Un. : pcs

Project : 352531 N1619 C GEARBOX (2600 KW) Customer: 3158 SULZER PUMPEN Pos. 201 202 205 210 215 220 221 222 223 230 231 232 233 235 236 240 241 242 243 250 260 261 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 300 301 302 303 304 305 310 311 313 314 315 316 317 318 319 323

Item 6505017400 6230023540 8658001500 8681062006 8681062007 8656901200 7459001200 7520106018 7283000018 6505017700 7520004518 6505017900 7520004516 6505017800 7464000700 8680000301 LFN9009042 8452000103 LFAM113882 8508000024 6505018800 7520002012 8508003901 8508003701 8508001002 8508001202 8508001002 8508001202 8508000025 8508000025 7020000037 7020000038 7020000012 7520102508 7365100008 8508000914 8508000814 LFE7087100 E7087499 8678000600 8678000700 8508003612 6535009800 7557001206 E7082882 8678000800 18638100 18647900 8508000122 8508000318 8508003712 8508003712 8508001718 7585350512

Manufactured Item: 35253100 N16_1_0078_00 Rev : E N16_1_0077_00 F

Shaft LS KEY 36 X20 X160 Oil slinger D:6" Journal bearing LS 6"1/4, remachined Journal bearing LS 6"1/4, remachined Labyrinth assembled Windage baffle Screw SSt H M18x60 Washer M18, u Housing for thrust bearing, machined Screw H M18x45 End cover for KTB Screw H M16x45 Thrust bearing JHJ7 Key for KINGSBURRY thrust bearing 7 Nut for thrust bearing JHJ7 Screw 1/4 NCx1/2 Target, probe jhj7 Cap screw, hex.soc.hd 1/4-20NC Earth stud N Junction box holder Screw H M12x20 Electric connection box Inox AR-8/FR:366x5 Electric connection box SSt AR-6/FR:350x2 Terminal block Phoenix Blue Terminal block end Phoenix Blue Terminal block Phoenix Blue Terminal block end Phoenix Blue Rail omega Rail omega TAG: TEMPERATURE Junction Box TAG: VIBRATION Junction Box Identification plate, SI Screw SSt H M8x25 Nut SSt H, M08 Spacer ∅8.2/14 x 3 Spacer M5x30 for junction box Proximitor Accelerometer BN Cable 6 ft for accelerometer 330400 Cable 9 ft for accelerometer 330400 Cable gland HAWKE 501/421 Protection for accelerometer Screw CHc M 6x12 Grade 8.8 Bently Nevada probe 330105 Screened cable 4.5m BN (3300XL8mm) Assembly, vib. probe radial Assembly, vib. probe axial Connection head EEx-d / IIC-T6 IP65 Reducer EExd, 1" NPT - 1/2" Cable gland HAWKE 501/421 Cable gland HAWKE 501/421 Reducer EExd 1"NPT/M-M20/F RTD PT100 duplex L=145

Drawing Number N16_2_0174_00 SR_2_0235_40 C80_03_2_0015_00 C80_05_2_0620_06 C80_05_2_0620_07 C80_01_2_0012_00 C80_21_2_0012_00 V11.01_0_0000_18 N16_2_0177_00 V01.01_0_0045_18 N16_2_0179_00 V01.01_0_0045_16 N16_2_0178_00 C80_07_2_0007_00 C80_04_2_0003_01 C80_06_2_0001_03

N16_2_0188_00 V01.01_0_0020_12

LFE7087100 E7087499

NF16_2_0098_00 V03.21_0_0012_06

Net Quantity 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 8 pcs 16 pcs 1 pcs 8 pcs 1 pcs 6 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 4 pcs 2 pcs 2 pcs 4 pcs 1 pcs 1 pcs 55 pcs 2 pcs 12 pcs 2 pcs 0.5 m 0.5 m 1 pcs 1 pcs 2 pcs 8 pcs 8 pcs 8 pcs 4 pcs 10 pcs 2 pcs 1 pcs 1 pcs 2 pcs 2 pcs 4 pcs 10 pcs 10 pcs 8 pcs 2 pcs 10 pcs 10 pcs 10 pcs 10 pcs 10 pcs 1 pcs

Date : 17/09/07 [11:40] LUFKIN FRANCE SAS

BILL OF MATERIAL - ENGLISH VERSION

Page : 3 Company : 111 Un. : pcs

Project : 352531 N1619 C GEARBOX (2600 KW) Customer: 3158 SULZER PUMPEN Pos. Item 324 7585350511 325 7585350510 326 7589400450 327 8508001804 328 8508003812 329 8508003812 340 8508800412 341 7020000097 342 7020000098 343 7020000099 344 7020000100

Manufactured Item: 35253100 N16_1_0078_00 Rev : E N16_1_0077_00 F Drawing Number

RTD PT100 duplex L=70 RTD PT100 duplex L=1000 Temperature transmitter, YOKOGAWA Cable BATT BS5308 (black) Cable gland HAWKE 501/453 Cable gland HAWKE 501/453 Cable gland HAWKE 501/453 TAG JB RTD TAG JB RTD TAG JB VIB TAG JB VIB

Net Quantity 1 pcs 4 pcs 6 pcs 50 m 6 pcs 6 pcs 3 pcs 1 pcs 1 pcs 1 pcs 1 pcs

Data sheet

Prepared by Catherine BONTEMPI

10

LUFKIN GEAR N1619C 102920-050 REV. 01 Page 66 of 205

3. INSTRUCTIONS FOR ACCESSORIES 3.1. 3.2. 3.3.

Prosensor - RTD BENTLY NEVADA - Proximitor YOKOGAWA – Temperature transmitter

3.1. PROSENSOR – RTD's

Prepared by Catherine BONTEMPI

12

OPERATING INSTRUCTIONS Operating Instruction n° ATEX Ex 01/ 2003 Temperature sensor type PROSENSORex 1. MARKING Marking must comprise the following indications : PROSENSOR 15 rue de Montvaux 57 865 AMANVILLERS - FRANCE CE PROSENSORex INERIS 03ATEX0120 (Year of construction) II 2 G EEx d IIC T amb. = -40°C à +40°C

2. OPERATING INSTRUCTIONS Following instructions must be read with 1. NF C 15 100 norm (french rule of electric installations) 2. NF EN 60 079-14 norm (electric installations in gas explosive atmospheres), 3. NF EN 60 079-17 norm (inspection and maintenance in the dangerous sites), 4. decrees, laws, directives, circulars of applications, standards, the code of practice and any other document concerning its place of installation. Non respect of those could not engage our responsablility. Our equipment are CE marked according to ATEX 94/9/CE directive. They are planned for use in the gas explosive atmospheres : IIA ou IIB ou IIC group - 2G category - zones 1 and 2.

Make sure of compatibility between the indications being reproduced on the maker badge, the explosive atmosphere present, the zone of use and the ambient and surface temperatures. The installation of the material must be carried out by qualified personnel and ability.

Until the 30/06/2003, marketed equipments can be equipped with accessories or (and) components certified according to the CENELEC rules relating to the electric materials usable in explosive atmospheres of group II. From this date, accessories or (and) components assembled equipping the equipment must have a certificate of examination EC-Type. This note is a complement with the descriptive note of the Prosensorex temperature sensor. Marking according to 1.0.5 from ATEX directive : - PROSENSOR 15 rue de Montvaux 57 865 AMANVILLERS - type Prosensorex - INERIS 03ATEX***** - (serial number) - (Year of construction) peut être inclus dans le type -

II 2 G EEx d IIC T6

DO NOT OPEN WHEN ENERGIZED

2.1 Use Material is under the user’s responsibility.

2.2 Mounting & dismounting The fixation of the probe is ensured with either the threaded, fixed or sliding connection, located under the head or with a flange, according to the mechanical configuration of the probe. After electric connection and before the powering, take care to close the lid by the system of fast closing clips or to screw the lid then to block it via present CHC screw using a six sides key # 4.

2.3 Maintenance and breakdown service In the event of failure of the electric material, this one will be turned over to: PROSENSOR 15 rue de Montvaux 57 865 AMANVILLERS - FRANCE The instrument is envisaged to be installed in the state, the responsibility of the manufacturer in the event of failure cannot be committed for any possible modification which has occurred after the delivery. Any repair or modification can be carried out only by the manufacturer of the instrument.

Thermocouple probes - Wiring must be done with a tinned copper braid cable. WIRING DIAGRAM : (example with K thermocouple - Other thermocouple : respect the polarities according to the colors defined according to international coding)

2.4 Installation The installation of the instrument is carried out by a personnel qualified and informed about standard ATEX and the provisions which it implies. It is managed by the owner of the factory site or any approved fitter. This one must make sure that the instrumentation of the whole of the measuring equipment is compatible for a use in explosive atmosphere. It is necessary in order to make safe the system, to connect the apparatus to the mass using the provided screws contained inside the explosion-proof case. These screws must be installed in the openings envisaged for this purpose, inside and outside the box.It is appropriate then, according to the type of element of measurement, to follow the plan of adapted wiring presented below.

Transmitters - Do not to apply a current higher than 1 mA in the resistive element in order to avoid overheating. - The converter must be assembled in a metal head connected to the ground. - Electric connection must be carried out with a shielded cable whose two ends are connected to the ground. - Power supply must be CEM certified. - Respect the polarities of the thermocouple according to the colors defined according to international coding. WIRING DIAGRAM :

Platinium RTD probe - The measurement current accross a RTD component must not exceed 1mA in order to avoid overheating. - It is recommended to use a cable with tinned copper braid WIRING DIAGRAM :

The transmitter delivers an 4-20 mA analogical signal and functions on the principle of the 2 wires loop of temperature signal transmission.

2.5 ADJUSTMENT : The initial adjustment of the transmitter is carried out in factory by our services according to the range of temperature requested in the purchase order and the required output signal. This one can be modified, via the optional data-processing interface in the case of programmable transmitters, and by adjustment of the external span in the case of the configurable transmitters.

The user engages however with being equipped with the material necessary to these operations with adjustment

2.6 ELECTRIC SPECIFICATIONS : Supply voltage : Absorbed current : Dissipated power :

U max. = 30 V I max. = 50 mA P max. < 1 W

2.7 PARTICULAR CONDITIONS : The maximum temperature of gas or fluid to be measured should not exceed 150°C.

WARNING !!! Make sure that the device is not under tension for any maintenance action

DO NOT OPEN WHEN ENERGIZED.

3. WARNING The manufacturer cannot be held responsible for failure if the electric material has to support particular constraints in service (brutal handling, effects of moisture, variations in ambient temperature, effects of chemical agents, corrosion, for example).

POLARITY

COUPLE

+

TJEK-

+

CODING COLOR THERMOCOUPLE ACCORING TO THE INTERNATIONAL STANDARDS France

France

NFC 42-323

NFC 42-323

Yellow

U.K.

USA

Japon

IEC 584-3

DIN 43714

BS 1843

ANSI 96-1

JISC 1610

Yellow

Marron

Marron

Red

White

Blue

Red

Blue

Blue

White

White

Marron

Blue

Red

White

Yellow

Yellow

Black

Black

Red

Yellow

White

Red

Black

Black

White

White

Blue

Blue

Red

White

Yellow

Purple

Purple

Red

Marron

Purple

Red

Orange

Blanc

Blanc

Black

Blue

Red

White

Yellow

Yellow

Green

Green

Rouge

Marron

Yellow

Red

Purple

Purple

White

White

Green

Blue

Red

White

Pink

Pink

Orange

Orange

White

White

Blue

Red

+

N-

+

Interna. Germany

NFC 42-324

+

+

Interna. IEC 584-3

R-

Yellow

Yellow

Orange

Orange

Red

White

Black

Red

Green

Green

Blanc

Blanc

White

Blue

Red

White

+

Yellow

Yellow

Orange

Orange

Red

White

Black

Red

Green

Green

White

Blanc

White

Blue

Red

White

Yellow

Black

Black

Red

Red

Red

Black

White

White

Black

Black

Black

SB-

+

3.2. BENTLY NEVADA – Proximitor – Accelerometer

Prepared by Catherine BONTEMPI

13

BENTLY NEVADA – Proximitor

Prepared by Catherine BONTEMPI

14

Part Number 141078-01 Revision E, July 2003

3300 XL 8mm Proximity Transducer System Manual

3300 XL 8mm Proximity Transducer System Manual

Copyright © 2003 Bently Nevada, LLC All Rights Reserved. The information contained in this document is subject to change without notice. The following are trademarks or registered trademarks of Bently Nevada, LLC in the United States and Other Countries: ACM™, Actionable Information®, Actionable Information to the Right People at the Right Time®, ADRE, ™, Asset Condition Management™, Asset Condition Monitoring™, Bently ALIGN™, Bently BALANCE®, Bently DOCUVIEW™, Bently LUBE™, Bently Nevada, Bently PERFORMANCE™, Bently RELIABILITY™, CableLoc™, ClickLoc™, Data Manager, Decision SupportSM, DemoNet™, Dynamic Data Manager, Engineer Assist™, FieldMonitor™, flexiTIM™, FluidLoc, Helping You Protect and Manage All Your Machinery, HydroScan, HydroView™, Key ∅, Keyphasor, Machine Condition Manager™ 2000, MachineLibrary™, Machine Manager™, MicroPROX, Move Data, Not People, Move Information, Not Data™, NSv™, Prime Spike™, PROXPAC, Proximitor, REBAM, RuleDesk™, SE™, Seismoprobe, Smart Monitor, Snapshot™, System 1™, System Extender™, TDXnet™, TDIXconnX™, The Plant Asset Management CompanySM, TipLoc™, TorXimitor, Transient Data Manager, Trendmaster, TrimLoc™, Velomitor Bently Nevada’s orbit logo and other logos associated with the trademarks in bold above, are also all trademarks or registered trademarks of Bently Nevada in the United States and other countries. The following ways of contacting Bently Nevada are provided for those times when you cannot contact your local Bently Nevada representative: Mailing Address Telephone Fax Internet

ii

1631 Bently Parkway South Minden, NV 89423 USA 1 775 782 3611 1 800 227 5514 1 775 215 2876 www.bently.com

Related Documents The following documents contain additional information that you may find helpful when you install the transducer. Installing the Transducer Best Practices Document - Proximity Probes and Related Accessories: The Installation and Application of Eddy Current Proximity Transducers (AN028). Guidelines for Grounding (Earthing) Bently Nevada Rotating Machinery Information Systems (AN013). Installation of Electrical Equipment in Hazardous Areas (AN015). Considerations when using Eddy Current Proximity Probes for Overspeed Protection Applications (AN085) Transducer Installation Accessories 31000/32000 Proximity Probe Housing Manual (124200-01). 31000/32000 Proximity Probe Housing Data Sheet (141610-01) 3300 XL Proximitor Housing Data Sheet (141195-01) 3300 XL Monitor and Transducer Verification Kits Data Sheet (141196-01) Electrical and Mechanical Runout “Glitch”: Definition of and Methods for Correction, Including Shaft Burnishing to Remove Electrical Runout (AN002). API 670, Fourth Edition, Sections 6.1.1 (Location and Orientation – Radial Shaft Vibration Probes) and 6.1.2 (Location and Orientation – Axial Position Probes. Available from the American Petroleum Institute, Publications and Distribution, 1220 L Street NW, Washington DC, 20005, USA. Reference Performance Specifications for the 3300 XL 8 mm Transducer System (159484). Bently Nevada Glossary (133055-01). Symbols Procedures in this manual use the following symbols:

Connect

Disconnect

Observe

Record Value

iii

3300 XL 8mm Proximity Transducer System Manual

European CE mark for the Bently Nevada 3300 XL Transducer System In this Document is a list of the 3300 XL Transducer Assemblies that have the CE mark, applicable standards used for certification, and installation instructions required for compliance. Proximity Transducer Systems are electronic devices typically used in industrial applications. The 3300 XL Transducer System has been certified using the same Technical Construction File (TCF) and Declaration of Conformity as the 3300 8mm Transducer System because they are similar in design and application. The 3300 XL Proximity Transducer System consists of a Proximitor® Sensor, Proximity Probe, and Extension Cable. TCF through TUV Rheinland of North America A Technical Construction File has been prepared through TUV Rheinland of North America (TUV Rheinland File Number: P9472350.07). The Certificate of Compliance is for Directive 89/336/EEC (EMC Directive). The applicable Generic Norms are: EN50081-2 and EN50082-2. Installation Instructions These instructions are an addition to the Installation Instructions in Section 2. Proximity Probes All probe cases must have a solid connection to earth ground. Compliant Systems and Component Part Numbers #

Model

1

3300 XL

Model Numbers 330180, 330101*, 330102*, 330103*, 330104*, 330105*, 330106*, 330140, 330141, 330145, 330171, 330172, 330173, 330174, 330191, 330192, 330193, 330194, 330195, 330196, 330197, 330198, 330255, 330130, and 330190**

Includes all options and all approval versions of the base model numbers listed *--Pre XL probes and cables may be used as part of a CE XL system. **--any proximity probe, or extension cable which works correctly with the listed module.

iv

Testing and Test Levels Title

EN

EN

ENV

ENV

EN

ENV

ENV

EN

55011

61000-4-2

50140

50204

61000-4-4

50142

50141

61000-4-8

(EN 61000-4-3)

Rad. RFI

(EN 61000-4-5)

(61000-46)

Mag. Fields

Surge

Cond. RFI

Emission

ESD

EFT

Rad. RFI Test Levels

Emission Class A

4kV; 8kVc

Criteria †

N/A

A

10V/md

10V/me

2kVf

0.5kVf

10Vg

30A/m, 50Hz

A

A

B

A

B

A

These notes listed below apply only to the table “Testing and Test Levels” c discharge method: Contact; Air d 80-1000 MHz sweep with 80% 1 kHz sine wave amplitude modulation e 900 MHz dwell with 100% 200 Hz square wave modulation f lines tested: I/O g 150 kHz-80 MHz sweep with 80% 1 kHz sine wave amplitude modulation † For the purposes of the 5/8mm 3300 XL System CE certification, the following criteria are defined as follows: -

Criteria A: Transducer system will output less than one third of a 3mil p-p meter scale (less than 1 mil p-p) and will return to steady state after test completion.

-

Criteria B: Transducer system may react in any manner during test, but must self recover after test completion.

-

Criteria C: N/A

v

3300 XL 8mm Proximity Transducer System Manual

Contents Related Documents ...........................................................................................................................iii European CE mark for the Bently Nevada 3300 XL Transducer System......................................... iv

Section 1 — System Description ......................................................... 1 Transducer System ............................................................................................................................. 1 Proximitor® Sensor ........................................................................................................................... 1 Proximity Probe and Extension Cable ............................................................................................... 1 Connectors ......................................................................................................................................... 2 Extended Temperature Range Applications....................................................................................... 2 Receiving, Inspecting, Handling and Disposing of the System ......................................................... 3 Customer Service ............................................................................................................................... 3

Section 2 — Installation........................................................................ 5 Installing the Probe ............................................................................................................................ 5 Mounting the Proximitor® Sensor..................................................................................................... 7 Interchangeable Mounting Feet.......................................................................................................... 8 Mounting the Proximitor® Sensor with DIN Mount Part.................................................................. 9 Removing the Proximitor® Sensor from the DIN Rail.................................................................... 10 Termination of Field Wiring in the Terminal Block ........................................................................ 10 Routing the Extension Cable and Field Wiring ............................................................................... 11

Section 3 — Maintenance and Troubleshooting .............................. 13 Scale Factor Verification.................................................................................................................. 14 Troubleshooting ............................................................................................................................... 17 Fault Type 1: VXDCR > -17.5 Vdc or VXDCR < -26 Vdc.................................................................... 19 Fault Type 2: VSIG = O Vdc ............................................................................................................ 20 Fault Type 3: -1 Vdc < VSIG < 0 Vdc .............................................................................................. 20 Fault Type 4: VXDCR >

2

0.50

20

>>

>>

>>

3

0.75

30

>>

>>

>>

4

1.00

40

>>

>>

>>

5

1.25

50

>>

>>

>>

6

1.50

60

>>

>>

>>

7

1.75

70

>>

>>

>>

8

2.00

80

>>

>>

>>

9

2.25

90

>>

>>

>>

>> = Enter values into these cells

>>

ASF (Average Scale Factor)

>>

Vdc n - 1 − Vdc n 0.25 Vdc 0.25 mm − Vdc 2.25 mm ASF(V/mm) = 2 ISFn (V/mm) =

ISFn (mV / mil) = 16

Vdc n - 1 − Vdc n 0.01

ASF(mV / mil) =

Vdc 10 mil − Vdc 90 mil 0.08

Section 3 — Maintenance and Troubleshooting

Vdiffn = Vdc n + (mmn • 7.87)

Vdiffn = Vdc n + (miln • 0.2)

5. Use the following formula to determine maximum Deviation from Straight Line (DSL):

DSL(mm) =

Vdif

DSL(mil) =

Vdif

(max)

− Vdif

(min)

= ______ mm

(min)

= ______ mil

15.74 (max)

− Vdif

0.4

If the ISF or DSL of the system is out of tolerance, contact Bently Nevada, LLC for further information on possible calibration problems. The preceding pages indicate scale factor verification using a TK-3. This is suitable for rough verification. For API 670 system verification a more precise micrometer and target must be used. There are two different 3300 XL Micrometer Kits that can be used to verify the calibration of our transducer systems or to check the scale factor of specific shafts. Both micrometer kits will work with Bently Nevada eddy current transducers ranging in size from the 3300 XL NSv™ and 3300 RAM Transducer Systems up to the 3300 XL 11 mm and the 7200 14 mm Transducer Systems. Both micrometers also have options for either a metric or English micrometer. The 3300 XL Precision Micrometer (part number 330185) is a highly accurate verification device. It should be used when performing acceptance testing on our transducer systems. All of our transducer systems have a specified linear range and average scale factor (ASF). The transducer systems also have a maximum deviation from straight line (DSL) and ISF tolerances for ambient and extended temperatures. The 3300 XL Precision Micrometer comes with a high precision 4140 steel target and is used to make precise measurements and verify whether the transducer system is working properly and within published specifications. The 3300 XL Shaft Micrometer (part number 330186) is used to check the scale factor of the transducer system directly on your shaft. You can compare the scale factor of your transducer system with that of a Bently Nevada supplied 4140 steel target to check whether errors in the measurement are due to runout, target material or a problem in the transducer system.

Troubleshooting This section shows how to interpret a fault indication and isolate faults in an installed transducer system. Before beginning this procedure, be sure the system has been installed correctly and all connectors have been secured properly in the correct locations. When a malfunction occurs, locate the appropriate fault, check the probable causes for the fault indication and follow the procedure to isolate and correct the fault. Use a digital voltmeter to measure voltage. If you find faulty transducers, contact your local Bently Nevada, LLC office for assistance. The troubleshooting procedures use measured voltages as shown in the following figure and tables:

17 •

3300 XL 8mm Proximity Transducer System Manual

Vps

Vxdcr

MADE IN U.S.A.

Vsig

Table 3-1. Symbols for Measured Voltages Symbol

Meaning

Voltage measured between...

VSIG

Signal voltage from the transducer

OUT and COM

VPS

Power supply voltage

Power Source and Common

VXDCR

Supply voltage at transducer

-VT and COM

Note: VSIG, VPS, and VXDCR are all negative voltage values.

Table 3-2 Definitions

18

Symbol

Definition

Example

A>B

"A" value is more positive than "B"

-21 > -23

A -17.5 Vdc or VXDCR < -26 Vdc Possible causes: •

Faulty power source

•

Faulty field wiring

•

Faulty Proximitor Sensor

MADE IN U .S.A.

Vps Measure VPS: Is VPS > -23 Vdc or VPS < -26 Vdc? Yes:

Faulty power supply.

No:

Go to next step.

MADE IN U.S.A.

Vxdcr Measure VXDCR: Is VXDCR > -23 Vdc or VXDCR < -26 Vdc? Yes: Faulty Field wiring. No: Faulty Proximitor® Sensor.

19

3300 XL 8mm Proximity Transducer System Manual

Fault Type 2: VSIG = O Vdc Possible causes: •

Incorrect power source voltage

•

Short circuit in field wiring

•

Short circuit at Proximitor Sensor terminal connection

•

Faulty Proximitor® Sensor

Does fault condition type 1 exist? Yes:

Use the procedure for fault type 1

No:

Go to the next step

MADE IN U.S.A.

Vsig Measure VSIG: Is VSIG = 0 Vdc? No:

Incorrect power source voltage or short in field wiring or short at Proximitor® sensor terminal connection.

Yes:

Faulty Proximitor® Sensor.

Fault Type 3: -1 Vdc < VSIG < 0 Vdc Possible causes:

20

•

Probe is incorrectly gapped (too close to target)

•

Incorrect power source voltage

•

Faulty Proximitor Sensor

•

Probe is detecting other material than target (counterbore or machine case)

•

Short or open circuit in a connector (dirty or wet) or loose connectors

•

Short or open circuit in the probe

•

Short or open circuit in extension cable

Section 3 — Maintenance and Troubleshooting

Does fault condition type 1 exist? Yes:

Use the procedure for fault type 1

No:

Go to the next step

Is the probe gapped correctly? Are counterbore dimensions correct? (See Installing the Probe on page 5.) No:

Regap the probe or check counterbore. Retest system.

Yes

Go to the next step.

Step 2

Original probe/ extension cable MADE IN U.S.A.

Known good probe with correct length cable (open gap with probe held away from conductive material)

Vsig

Measure VSIG: Is VSIG < VXDCR + 1 Vdc? No:

Faulty Proximitor® Sensor

Yes:

Go to next step

Inspect for clean connection: Is the connection dirty, rusty, or a poor connection? Yes:

Clean the connector using isopropyl alcohol or electronic terminal cleaner, reassemble and retest the system.

21

3300 XL 8mm Proximity Transducer System Manual

No:

Go to the next step.

Measure resistance RTOTAL: Is RTOTAL within specifications? 5 m system: 8.75 ± 0.70 Ω 9 m System: 9.87 ± 0.90 Ω Yes:

Retest original system

No:

Go to the next step

Measure resistance, RPROBE: Is RPROBE with specifications (see “Probe dc resistance (nominal) (RPROBE table” on page 29)?

22

No:

Faulty probe.

Yes:

Go to next step.

Section 3 — Maintenance and Troubleshooting

Measure the resistance, RJACKET and RCORE: Is the resistance within specifications (see Extension cable dc resistance [nominal] table on 29)? No:

Faulty extension cable

Yes:

Retest the original system

Fault Type 4: VXDCR