aph presentation

8/13/2019 APH Presentation

1/36

Air PreheaterGearboxes


2/36

Corporate Organization Chart

Penn Machine Company

Johnstown, PA

Midwest Gear

Twinsburg, OH

Penn Locomotive Gear

Blairsville, PA

Rail Trans Division

Blairsville, PA

The Marmon GroupRailway Equipment & Services Group

The Marmon Group is an international association of more than 100autonomous manufacturing & service companies, based in Chicago, IL


3/36

The Marmon Group 2003Today, The Marmon Group comprises more than 100 member

companies that operate approximately 550 facilities in more than 40 countriesand employ about 35,000 people. Forbesplaces The Marmon Group at 20thon its list of the largest privately held companies in the United States.

In 2003, member companies completed more than 30 acquisitionswith a total investment of about $300 million. In most cases, the acquisitionscomplimented existing businesses, including wire and cable, medical products,water treatment, retail store displays and industrial materials. Membercompanies also built or expanded more than 20 new factories, offices or

distribution centers during the year.

While the member companies operate independently, a smallprofessional organization in Chicago, Illinois - The Marmon Group, Inc. -manages and invests the member companies financial resources and advises

them on accounting, tax, finance, legal, regulatory, real estate and other

matters.


4/36

History1920 - Company founded as the Penn Smokeless Coal Company1960 - Began to diversify

Steel/General Industry

Transportation

1965 - Bought manufacturing rights to PCC Resilient Wheels

1989 - Purchased Midwest Gear Company

1994 - Rail Trans Division (Gearbox Repair) established

1995 - Marmon Group purchases National Mine Service

1998 - Penn Machine purchases Winchester Tool and Machine2002 - Rail Trans Division relocated to new 50,000 sq. ft. facility in

Blairsville, Pennsylvania


5/36

Midwest Gear

Midwest Gear was founded in 1972 in Twinsburg, Ohio. Since then we have beenmanufacturing high quality products for both large and small manufacturers in a widevariety of industries including Steel, Automotive, Agriculture, Forestry, Paper,Construction, Packaging, Transportation and Strip and Underground Mining.

We can produce a wide range of custom gear products including pinions, sprockets,pinion shafts and wheels as well as providing precision gear grinding and cut teethsubcontracting.

Our modern manufacturing plant of 27,000 square feet is conveniently located on Route82 just minutes from the Ohio Turnpike (I-80) and near routes I-271 and I-480.


6/36

Penn Machine Company

Rail Trans Division Industrial Repair

Gear Box Manufacturing and Repair Facility

Opened May 2002


7/36

Gearbox Manufacturing &

Repair


8/36

Penn Machine Gearbox

Customer List

ALSTOM / Air PreheaterCompany

Wellsville, NY

AK Steel

Middletown, OHWashington Metro AreaTransit Authority

Washington, DC

CommonwealthAluminum

Lewisport, KY

Chicago METRO

Chicago, IL

Wise Metals

Muscle Shoals, AL

Melroe Corporation /Bobcat Division

Bismarck, ND

Cotta Transmission

Rockford, IL

Baltimore Mass Transit

Authority Baltimore, MD

Alstom Transportation,Inc.

Hornell, NY


9/36


10/36

Gearbox Manufacturing and Repair

Right angle spiral bevel drive for a steel

mill continuous caster

Overhead crane trolley drive


11/36

OVERHAUL AND REPAIR PROCEDURES AND PRACTICES

FOR SPEED REDUCERS AND ASSEMBLIES

GENERAL MECHANICAL REPAIR SPECIFICATIONS

1. All speed reducers shall be:A. Have housings sandblasted and primed (for purposes of inspecting housing for cracks)B. Dismantled completelyC. Cleaned free of all rust and greaseD. Inspected and / or tested as follows:

(1) Measure all "fits" and compare with original drawing dimensions. Providesketches for assembly.

(2) Cases, housings, etc. - will be visually inspected for cracks and

other signs of wear.(3) Shaft Gearing - visually inspect and dimensionally checked, for

possible reuse.2. A report of work required to recondition the assembly / speed reducer shall be prepared which shall

include:A. Listing of new parts requiredB. Summary of required reconditioning to return reusable parts to print

specificationC. Summary of price for labor and all materials to complete the job

3. Customer is to approve repair prior to any work proceeding.A. Penn Machine Company will give a one-year warranty when we have replaced all parts,

bearings, and seals as recommended in our quote. If the job is not awarded to PennMachine Company, compensation for disassembly labor, cleaning, inspection, and freightwill be made to Penn Machine Company.


12/36

REPAIR SPECIFICATIONSA. Fits

(1) All fits shall be returned to original size and relative centersusing either; plating, sleeving and / or welding as approved by the customer.B. Shafting

(1) Repair may be by plating and grinding or sleeving and machining.(2) Shall be straight and finished in accordance with tolerances and finish

specifications as indicated on appropriate drawings.(3) New shafting provided shall match the specifications and dimensions of the original

part as per customer print.

(4) Exposed threads and shaft ends will be protected with at least one layer of cardboardor similar material, held firmly in place with tape.

C. Gearing(1) Will be dimensionally inspected to customer prints.(2) New gearing provided shall match the specifications and dimensions of the original

parts as per customer print.D. Cases, Housing, etc.

(1) Fits - See 4-a. above.(2) All bolts, studs, pipe plugs, and other fittings shall be removed and theholes re-tapped as necessary.

(3) Bolts, studs, and pipefittings may be reused if in good condition.(4) Replacement bolts, studs, and pipe fittings shall be of equivalent grade

and material unless otherwise specified.E. All print modifications must be approved by customer prior to implementation.


13/36

ASSEMBLY AND TEST SPECIFICATIONS

A. All seals and gaskets will be replaced.B. All bearings will be replaced.C. All speed reducer overhauls and repairs shall be run tested to check freedom of movement

clearances, contact patterns, and backlash.D. Where pressure lubricated units are involved, the assembly shall be pressure tested where

applicable.E. Painting and Identification

1. All speed reducers will have:(a) Exterior surfaces cleaned of all loose scale and rust.(b) Exterior surfaces will have one coat of Red Oxide Primer appliedfollowed by one coat of industrial Grey enamel unless otherwisespecified by the customer.

(c) A new identification tag will be installed to each overhauled speedreducer with the following information:

1. Date overhauled

2. Serial number3. Ratio

F. Shipment1. All openings are to be properly protected with plugs or covers.

G. The unit shall be marked to indicate that lubricant must be added prior to operation.


14/36

PENN MACHINE COMPANY RUN TEST PROCEDURE

1. Firmly mount gearbox to be tested to run test stand.

2. Fill the unit with Penn Machine Company run test lubricant.

3. Attach the oil pumping station to the unit if required.

4. Hook up all run test equipment including vibration analysis monitor.

5. Check plant noise level with decibel meter.

6. Start test motor and set variable RPM to the gearbox requirements.

7. Check test motor noise level with decibel meter.

8. Attach gearbox to test motor and record decibel reading during run test.

9. Check all gearbox sealed areas for any oil leakage.

10. Record vibration analysis data and gearbox bearing temperature after onehour of testing.


15/36

Overhaul Procedures

The overhaul processbegins with a visualinspection of the exterior

of the unit (noting anyabnormalities)

If equipped with anoverrunning clutch, therotation of the input shaft

is checked and noted forreassembly purposes


16/36

Sandblasting

All Air Preheatergearbox housings aresandblasted in order

to visually check forcracks andabnormalities.


17/36

Disassembly

The next step is the disassembly of the gearbox.


18/36


19/36


20/36

Inspection

A visual inspection ofthe gearing is done at

this time to determineif it is suitable to besubjected to the NDTto qualify it for reuse


21/36

Cleaning

The next process is to clean the housingand all components so they are free from

dirt, grease, and oil residueSeveral different measures are employedto achieve this result


22/36

Cleaning

In cases where thereis an abundance ofgrease and oil, the

gear case is firstcleaned in a solventparts washer toremove the majority

of the contamination


23/36

Cleaning

From the solventparts washer, the unitis then placed in a

water based, heated,high pressurecleaning tank toremove the remainder

of the residue


24/36

Cleaning

The result of this processis a clean housing bothinside and out

Additional cleaning is

also done to componentswith a wire wheel, surfaceconditioning pad andother hand tools toachieve the desired

results


25/36

Mag Particle Testing

All shafts and gearingthat have passedvisual inspection are

now checked forcracks with a Magna-Flux tester


26/36

Dimensional Testing

All shaft fits and gearand housing boresare dimensionally

checked againstmanufacturersspecifications


27/36

Quotation

Determinations have been made to allcomponents. A quotation and report issent to the customer for approval to

proceed with the repair.


28/36

Assembly

All overhauls include new bearings, seals,shims, gaskets, fasteners and whereapplicable overrunning clutch


29/36

Setting Pinion Depth

The first step in theassembly process is toset the spiral bevel piniondepth to the

specifications for theparticular gear set

This setting achieves theproper contact pattern on

the gear setPinion depth is set toOEM specification


30/36

Backlash Setting

Next the proper shimsare determined toachieve the correct

backlash for the spiralbevel gear set

Measurements aretaken at the pitch line

diameter


31/36

Assembly

The remainder of thegearing is installed intothe housing and coversare installed

A special fixture is usedto ensure the changegear cover is properlypositioned for sealalignment

This cover is then drilledand doweled in place soalignment can bemaintained during futurerepairs


32/36

Run Test

Upon completion ofassembly, thegearbox is then takento the run test area

It is subjected to aone hour run test tocheck for noise, heat,vibration and leaks


33/36

Painting

After a successful runtest the unit is takento the paint booth

It is then sprayed withan industrial gradeepoxy primer


34/36

Identification

An AGMA name plate isinstalled on the gearboxwith all pertinentinformation regarding

ratio, horsepower,capacities, serial number,date of manufacture,speed and lubrication


35/36

Shipping

The unit is thencarefully prepared forshipping


36/36

Quality Assurance

The quality of a gearbox begins with engineering.Although the majority of our business has beenengineered by our customer we do have our ownengineering capabilities and experienced gear engineers

that review all drawings before manufacturing.All inspection records are maintained and can be

provided to the customer upon request. In addition, thecalibration of machines, checking, testing and measuring

equipment is performed on a strict schedule and fullydocumented.

aph presentation

Documents