01 renk-maag servicebroschuere plan en-1
TRANSCRIPT
RENK-MAAG
Field ServiceAlways Nearby
Innovative Power Transmission
2
RENK-MAAG service team
We are ready for takeoff!
Professional, swift and customer focused – this is our dynamic service team. Our service technicians work tirelessly the world over all year round to install and maintain gearboxes for our customers. Any necessary repairs are undertaken on site wherever possible.
In the event of more complex issues, such as vibrations in the train, we provide professional assistance which could include a vibration measurement and analysis by our testbed specialists.
More information about our services can be found in this brochure.
We maintain contact with our custo- mers before, during and after the sale of a gearbox. Our goal is the satis-faction of our customers. They appre- ciate having a competent and reliable partner – our RENK-MAAG service team.
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Our dynamic service team
is ready for takeoff.»«
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New
Check 1 Check 2 Check 3 Other checks...
Op
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Service life
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Certified techni-cians with years
of experience inspect and maintain the gear-boxes on site – anywhere in the world.»
Gearbox maintenance
You have chosen to put your trust in a RENK-MAAG gearbox. It is in your hands to preserve the legendary longevity and robustness of this quality product by following the corresponding service and inspection intervals.
Service intervals Extend the overall service life through regular maintenance
(see Maintenance Schedule attached).
Gearbox condition and availability with maintenance
Even the best machines need maintenance
On-site support
RENK-MAAG offers world-wide services for all MAAG turbo and marine gear-boxes. Certified service technicians with years of experience inspect and maintain the gearboxes in accordance with the customized maintenance schedule to suit your needs. Regular gearbox mainte-nance ensures safe and reliable system operation.
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Regular gearbox maintenance
ensures safe and reliable system operation.»
After each inspection or overhaul, our service technicians will provide you on the spot with a system report contain-ing the following points of importance to safety and optimum availability:
• General condition of the gearbox • Possible and detected defects • Recommended spare parts • Due date and scope of next inspection
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Phone:
Process name
Project:
Process
Interruption
Underway
Check spare parts stock
Milestone
Collective process
Collective process for project
External processes
External milestone
Qualifying date
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Regular maintenance – long operating life
Maintenance schedule
Depending on the number of years of operation or operating hours since commissioning or the last maintenance work, we recommend the following RENK-MAAG standard inspections:
1000 operating hours checkThis check is undertaken on gearboxes when taken into service.
8000 operating hours check/annual checkA brief check through the inspection cover provides an overview of the gearbox condition.
20 000 operating hours checkThe gearbox is opened – but not dis-mantled – to gauge the condition of its interior. This is ideal if you have only a brief shutdown or a limited budget.
40 000 operating hours checkThis large-scale check involves dismant-ling, cleaning and re-assembling the gearbox. If necessary, individual compo-nents or worn parts are replaced.
Inspection example using a 20 000 operating hours check
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An operating year is considered to be 8000 operating hours in this table.
The maintenance schedule is attached to this brochure.
InstallationCheck
of installation/ Commissioning
1000 oph check
8000 oph check
20 000 oph check
40 000 oph check
Working days 10 1 – 3 1 2 3 – 4 6 –7
Operating years since last inspection
– – – 1 2 – 3 5 +
Spare parts RENK-MAAG recommends holding the following key components in stock:
• 1 spare set of rotors• 1 spare set of bearings• 1 spare set of oil scrapers• 1 spare set of instrumentation
The spare parts can then be replaced immediately, limiting any production downtime to a minimum.
Keep in mind that even under the best conditions, it will take several months for spare bearings and rotors to be delivered.
We recommend carrying out
standard inspections.»«Description of work
Daily
/Con
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y
Afte
r firs
t 100
0 op
hYe
arly
or e
very
800
0 op
hEv
ery
20 0
00 o
phEv
ery
40 0
00 o
ph (o
r lat
est a
fter 5
yea
rs)
Spec
ial s
ervi
ce (o
n re
ques
t)
Remarks
Other couplings (if applicable)Check all bolt connections
X X X X
Maintenance according to manufacturer
X according to manufacturer
Gear driven pumpCheck for noise and leaks
XMaintenance according to manufacturer
X according to manufacturer
Rotary drive/Turning Gear/barring gearCheck drive for noise and leaks
X when operating
Check oil level
X X
Check all bolt connections
X
Maintenance according to manufacturer
X according to manufacturer
Synchronous clutchCheck for noise and leaks
XDismantle, clean, check
X X
Maintenance according to manufacturer
X according to manufacturer
Nondestruvtive testingUltrasonic testing (toothing, bearings)
X recommended every 40 000 oph
Magnetic particle testing (toothing)
X recommended every 40 000 oph
Dye penetrant testing (toothing, bearings)
X recommended every 40 000 oph
Operational vibration measurement and analysis
X
MiscellaneousInspection of special tools for gearbox
X
Inspection of special tools for anchoring
X
Inspection of spare parts / spare gearbox
X
Preservation of spare parts / spare gearbox
X
Inspection of third-party parts
X according to manufacturerImportant:This “Maintenance Schedule” is not plant-specific; it can also be used as a supplement to the instruction manual
but does not take the place of any plant-specific information. The work to be carried out shall be either considered
according should be adapted to the current operating hours of the gearbox and any abnormalities noticed during
operation. We recommend having all work performed by one of our experienced specialists.
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88
P.O. Box 3068 Fax +41 (0)52 262 89 89
CH-8404 Winterthur [email protected]
www.renk-maag.ch
+ 41 52 262 87 62
© RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland
We reserve all rights in connection with this document.
Description of work
Daily
/Con
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tlyW
eekl
yAf
ter fi
rst 1
000
oph
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
Remarks
GearboxCheck drive group for noise and leaks
X
in operating condition
Check rotors visually
XX
XX
Check and retighten gearbox anchoring
XX
XX
Check all bolt connections
XX
XX
Check load contact pattern of teeth (red ink or metallic)
XX
XX
Check no load tooth contact pattern (blue ink test)
X
XX
in uncoupled condition
Check alignment of gearbox – driving machine
X
XX
in uncoupled condition
Check alignment of gearbox – driven machine
X
XX
in uncoupled condition
Check, clean and if necessary replace air filter
X
Dismantling and inspection of all gearbox parts
X
Lubrication systemCheck oil level
X
in operating condition
Check Dp of lube oil filter and clean/replace
X
Check lube oil for water content/contamination (analysis)
XX
XX
Check lubrication system for leaks
X
in operating condition
Check and clean lube oil cooler
X
XX
according to manufacturer
Check, clean and if necessary replace lube oil filter
X
Maintenance of lubrication system
Xaccording to manufacturer
Extra checks for HET® gearboxes
Check vacuum system (function)
XX
XX
Check instruments and valves (function)
XX
XX
Instrumentation (monitoring of shaft and casing vibration + temp.)
Record operating data
X
in operating condition
Check operating data
X
in operating condition
Check fit and tightness of instrumentation
X
Function check
X
Installation check
X
Check for visual damage
X
Check protective tubes
X
Check passages for leaks
X
Verification of junction box
X
Toothed couplingsCheck couplings for leaks
X
Check all bolt connections
XX
XX
Check lube oil piping
X
Check (replace) lubricants on couplings
XX
Xonly for oil-filled couplings
Dismantle, clean and check
X
Replace O-rings
X
Maintenance Schedule for RENK-MAAG Turbo Gearboxes
RENK-MAAG GmbHSulzer-Allee 46
Phone +41 (0)52 262 89 88
P.O. Box 3068
Fax +41 (0)52 262 89 89
CH-8404 Winterthur [email protected]
Switzerland
www.renk-maag.ch
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Preparing for deployment and planning
Extensive organisation
Both the RENK-MAAG service tech-nicians and the back office are flexible, quick to respond and reliable.
Our service doesn’t just cover tech-nical matters, we also organise all administrative aspects of the service, including processing the travel arrange-ments required, organising travel, special training courses or medical examination and certification.
Before they set out, the service technicians are always prepared and instructed by our back office. They are informed of special customer concerns and are provided with details of the gear - box or entire system. Once on site, our service technicians are therefore ready to get started right away.
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Month
T30M29 W31 T01 F02 S03 S04 T06M05 W07 T08 F09 S10 S11 T13M12 W14 T15 F16 S17 S18 T20M19 W21 T22 F23 S24 S25 T27M26 W28 T29 F30 S01 S02 T04M03 W05 T06 F07 S08 S09 T11M10 W12 T13 F14 S15 S16 T18M17 W19 T20 F21 S22 S23 T25M24 W26 T27 F28 S29 S30 T01M31
Monthcalendar week calendar week calendar week calendar week calendar week calendar week calendar week calendar week calendar week
You can rely on us to take care
of everything else.»
Coordinating dates
As well as planning deployment, we will happily provide a customised work programme. This provides you with a detailed overview of the work to be undertaken in advance of the service date. You can also plan shutdown times in advance and coordinate them with other work required on your system. This can prevent bottlenecks, such as crane capacities.
Once you have opted for a RENK-MAAG service, you can rely on us to take care of everything else. We are a reliable part- ner for all gearbox maintenance!
Planning deployment «
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+
Agents
AlgeriaAustraliaBelgiumBotswanaBruneiCanadaChileChinaCongoEgyptGreeceHollandHong KongIndiaIndonesiaIsrael
ItalyLuxembourgMacauMalaysiaMozambiqueNamibiaNew ZealandNigeriaPakistanPeruPolandRussiaSaudi ArabiaSingaporeSouth AfricaSouth Korea
RENK-MAAG contacts
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+ 41 52 262 87 [email protected]
TaiwanThailandUnited Arab EmiratesUSAVenezuelaZambiaZimbabwe
Service job on a modern
frigate.»
The current contact details are readily available on our website: www.renk-maag.ch
ItalyLuxembourgMacauMalaysiaMozambiqueNamibiaNew ZealandNigeriaPakistanPeruPolandRussiaSaudi ArabiaSingaporeSouth AfricaSouth Korea
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And if something does happen?
The condition of the gearbox often indi-cates the condition of the entire system. As the most sensitive component in the train, the gearbox very quickly indicates negative changes. This can be seen from a detailed inspection of the gearbox interior.
RENK-MAAG recommends regular gear-box checks. In case of general system inspections the gearbox should be part of the inspection too.
WHAT CAN BE DANGEROUS FOR A GEARBOX? WHAT DO I NEED TO WATCH OUT FOR?
• Poor lube oil quality or incorrect oil; ask for our list of recommended lube oils.
• Uneven or incorrect tooth contact• Incorrect train alignment• Insufficient oil flow• Poor foundations• Operation during overload• Creepage current on the system
This list is for information only and is not exhaustive.
The gearbox is often an indi-
cator of the condition of the entire system.»
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Training and qualification
The RENK-MAAG service technicians have undertaken all standard safety trainings and hold the certificates required to undertake the work.
Our service technicians attend training courses on an ongoing basis. These cover all health and safety and environ-mental protection requirements. For the work on oil platforms we attend spe- cial safety training courses and make sure knowledge is regularly refreshed. Our customers appreciate our years of practical experience and the fact that we continuously train our staff.
Some impressionsof intense training.»«
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Additional on-site services
One unit for two ultrasonic measurement methods
By using the phased-array method, we are able to test the toothing of a gearbox with maximum reliability. The same unit can be used to precisely locate any da mage and establish its size using conventional ultrasonic testing. RENK-MAAG can therefore make optimum use of both measurement methods and their respec-tive benefits.
ULTRASONIC TESTING WITH PHASED-ARRAY METHODThe phased-array method uses several ultrasonic elements and electronic delays to produce sound beams which can be electronically controlled, probed, swivelled and focused. This method allows for rapid testing, storage of all data and testing with several angles.
Areas of application• Testing complex geometries such
as involute teeth, cycloid teeth etc.• Testing torsion shafts, thrust collars,
couplings, pump rotors• Testing welding seams on gearbox
housings, pressure pipes, basic frames etc.
• Testing the corrosion of flanged areas, wall thickness measurement etc.
CONVENTIONAL ULTRASONIC TESTINGThe sound waves are radiated through a contact medium into the test body. The returned or transmitted wave patterns are recorded and analysed. Compared with the considerably faster phased-array method, this method has the advantage that it calculates the position and dimension of inclusions, structural cracks, blow holes etc. in the sub-surface structure of the work-piece.
Areas of application• Testing white metal bearings, especially
the bonding between the bearing body and layer of white metal.
• Testing teeth or other highly loaded parts.
• Long-term monitoring of gearbox teeth and rotors.
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Even the slightest damage to the tooth
surface provide clues as to the cause.»
Scanning electron microscopy
A tooth replica can be used to examine the surface structure of the tooth using scanning electron microscopy. This test is used to explain the causes of slight to major tooth damage such as grey staining, micropitting, electric erosion resulting from creepage current etc.
Other on-site services
• Magnetic powder and dye penetration testing for crack testing of highly loaded gearbox parts.
• Flow rate and pressure measurements on the lube oil system.
• Endoscopic examination of gearbox parts.
• Measuring and aligning shaft trains using laser measuring methods or dial gauges.
• Casing vibration, airborne noise and shaft vibration measurements on the gearbox including the associated analyses.
• Other services.
Need a more in-depth analysis? We will happily send out one of our specialist to test your gearbox.
«
RENK-MAAG GmbHP.O. Box 3068 • Sulzer-Allee 46 • CH-8404 WinterthurPhone +41 (0)52 262 89 88 • Fax +41 (0)52 262 89 89
[email protected] • www.renk-maag.ch
New products / spare parts /maintenance / testbed
RENK-MAAG supports you before, during and after the purchase: Our sales team is happy to support you when it comes to new equipment or spare parts for couplings and gear-boxes of previous MAAG models.
New gearboxes and components can be tested on our modern testbed using the latest technology for moni-toring and diagnostics of operating conditions, vibrations, temperatures or noise.
RENK-MAAGat your disposal
Our manufacturing and other operational activities are implemented in accordance with our
internal quality assurance system and in strict compliance with ISO 9001 : 2008 and ISO 14001 : 2004.
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1 e
Description of work Daily
/Con
stan
tly
Wee
kly
Afte
r firs
t 100
0 op
h
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
RemarksGearbox
Check drive group for noise and leaks X in operating conditionCheck rotors visually X X X XCheck and retighten gearbox anchoring X X X XCheck all bolt connections X X X XCheck load contact pattern of teeth (red ink or metallic) X X X XCheck no load tooth contact pattern (blue ink test) X X X in uncoupled conditionCheck alignment of gearbox – driving machine X X X in uncoupled conditionCheck alignment of gearbox – driven machine X X X in uncoupled conditionCheck, clean and if necessary replace air filter XDismantling and inspection of all gearbox parts XLubrication system
Check oil level X in operating conditionCheck Dp of lube oil filter and clean/replace XCheck lube oil for water content/contamination (analysis) X X X XCheck lubrication system for leaks X in operating conditionCheck and clean lube oil cooler X X X according to manufacturerCheck, clean and if necessary replace lube oil filter XMaintenance of lubrication system X according to manufacturerExtra checks for HET® gearboxes
Check vacuum system (function) X X X XCheck instruments and valves (function) X X X XInstrumentation (monitoring of shaft and casing vibration + temp.)
Record operating data X in operating conditionCheck operating data X in operating conditionCheck fit and tightness of instrumentation XFunction check XInstallation check XCheck for visual damage XCheck protective tubes XCheck passages for leaks XVerification of junction box XToothed couplings
Check couplings for leaks XCheck all bolt connections X X X XCheck lube oil piping XCheck (replace) lubricants on couplings X X X only for oil-filled couplingsDismantle, clean and check XReplace O-rings X
Maintenance Schedule for RENK-MAAG Turbo Gearboxes
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88P.O. Box 3068 Fax +41 (0)52 262 89 89CH-8404 Winterthur [email protected] www.renk-maag.ch
Description of work Daily
/Con
stan
tly
Wee
kly
Afte
r firs
t 100
0 op
h
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
RemarksOther couplings (if applicable)
Check all bolt connections X X X XMaintenance according to manufacturer X according to manufacturerGear driven pump
Check for noise and leaks XMaintenance according to manufacturer X according to manufacturerRotary drive/Turning Gear/barring gear
Check drive for noise and leaks X when operatingCheck oil level X XCheck all bolt connections XMaintenance according to manufacturer X according to manufacturerSynchronous clutch
Check for noise and leaks XDismantle, clean, check X XMaintenance according to manufacturer X according to manufacturerNondestruvtive testing
Ultrasonic testing (toothing, bearings) X recommended every 40 000 ophMagnetic particle testing (toothing) X recommended every 40 000 ophDye penetrant testing (toothing, bearings) X recommended every 40 000 ophOperational vibration measurement and analysis XMiscellaneous
Inspection of special tools for gearbox XInspection of special tools for anchoring XInspection of spare parts / spare gearbox XPreservation of spare parts / spare gearbox XInspection of third-party parts X according to manufacturer
Important:This “Maintenance Schedule” is not plant-specific; it can also be used as a supplement to the instruction manual but does not take the place of any plant-specific information. The work to be carried out shall be either considered according should be adapted to the current operating hours of the gearbox and any abnormalities noticed during operation. We recommend having all work performed by one of our experienced specialists.
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88P.O. Box 3068 Fax +41 (0)52 262 89 89CH-8404 Winterthur [email protected] www.renk-maag.ch
+ 41 52 262 87 62
© RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland We reserve all rights in connection with this document.