FLENDER-GRAFFENSTADEN OPERATING AND MAINTENANCE INSTRUCTIONS Page : 1 ! ASSURANCE OF QUALITY Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee. P.O. BOX N° 84 - 67402 ILLKIRCH GRAFFENSTADEN CEDEX TELEPHONE : +33 (0) 3 88.67.60.84. FAX : +33 (0) 3 88.67.60.85. E - MAIL : [email protected]OPERATING AND MAINTENANCE INSTRUCTIONS GEARBOX WITH PARALLEL SHAFTS TRL65/1C CUSTOMER REFERENCES . NAME : BHEL ORDER N° : B708P027 JOB NAME : West Coast F.G. REFERENCES . OL N° : 30193.01 FILE N° : 34530 MACHINE N° : 10282 E D C B A 06/09 FOURNAISE MARTIN P. KRATZ Révision Date Revisions Written by Checked by Quality assurance
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FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 1
!
ASSURANCE
OF QUALITY
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
CONTENTS
1. TECHNICAL DESCRIPTION OF THE GEARBOX ........................................................................3 1.1. CASING ...........................................................................................................................................3
5.3.2.1. Oil outlet temperature .......................................................................................................6 5.3.2.2. Bearing temperatures ........................................................................................................6
5.3.3. Vibration amplitude .................................................................................................................6 5.4. SPECIFIC RECOMMANDATIONS.............................................................................................6 5.5. SHUTDOWN ...................................................................................................................................6 5.6. RESTART OF THE GEARBOX ...................................................................................................7 5.7. OPERATING INSTRUCTIONS IN CASE OF ANOMALIES...................................................7
5.7.1. Oil pressure fault ......................................................................................................................7 5.7.2. Temperature faults ...................................................................................................................7 5.7.3. Increase in vibration or noise level..........................................................................................7
6. MAINTENANCE AND SERVICING ON GEARBOX ......................................................................7 6.1. GENERAL .......................................................................................................................................7 6.2. EXTERNAL PARAMETERS TO BE MONITORED.................................................................8
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
1. TECHNICAL DESCRIPTION OF THE GEARBOX
The gearbox is reducer. See data sheet in Appendix 01
1.1. CASING
The casing is made of welded sheet steel. It is designed to keep rotating parts as well as journal and thrust bearings in their correct positions under each and every possible load situation. A stabilisation heat treatment is done to reduce residual stress. A horizontal joint is separating the two parts of the casing.
1.1.1. Lower casing
• The lower casing is fixed on an underframe or mounting base plate.
• It includes oil inlet and outlet flange and the oil collector.
• Unit slinging and handling will be done with attachment hooks fitted to the lower casing.
1.1.2. Upper casing
• The upper casing acts as bearing cap by maintaining the high speed and the low speed shaft line bearings.
• It has a visiting door wich can eventually have a filter breather.
The following auxilliaries can be fixed to the casing :
• turning gear, driven pump, LS and HS coupling cover, measurement and control instrumentation.
1.2. GEAR SET
1.2.1. Toothing
The tooth profile is of the single or double helical type, with tip and root relieve to optimize mesh conditions and a supplementary tooth corr
ection for optimzed tooth contact pattern under load.
1.2.2. Material
The pinion and the wheel are of case-hardened alloy steel. The gear teeth are surface hardened by case-hardening followed by tempering to obtain the necessary hardness to transmit the load. Pinion shaft and wheel shaft are forged. The wheel can be hollow to allow the passing of a quill shaft.
1.2.3. Oil seals
Oil tightness of shafts is obtained with two-parts labyrinth seals in aluminium or bronze. Their radial clearance is determined according to bearing clearance.
1.3. RADIAL BEARINGS
Each shaft is fitted with two bearings. The radial bearings are of the hydrodynamic type, and are designed to guarantee satisfactory running. The bearings are in two parts and made of steel with antifriction coating. They can be dismounted easily. Profile choice is done according to running conditions. Possible types are OFFSET, 4 LOBES, LEMON, CYLINDRICAL or TILTING PADS. . The bearings are positioned in the casing with an anti-rotation pin. The majority of our gearboxes are equipped with an adjustable bearing to optimize the tooth contact. This operation has to be carried out by FLENDER GRAFFENSTADEN personnel.
1.4. THRUST BEARINGS
When thrust bearings are needed, they are dimensioned to support the axial thrust from the toothing as well as external thrusts from the couplings. Two types are being used : TAPERED LANDS or TILTING PADS.
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 4
!
ASSURANCE OF QUALITY
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
1.5. LUBRICATION
The unit is lubricated by forced oil circulation. The bearings are lubricated by internal bores between the bearing and the main collector. The teeth are lubricated with calibrated nozzles. When orifices are used, these must be correctly marked before being removed. The oil flow to the tank must be as direct as possible with a slope greater than 5°. The diameter of the drain pipe must be at least equal to the hole designed for it in the unit.
!
1.6. INSTRUMENTATION
For this chapter, please refer to the outline drawing and wiring diagram in Appendix 08.
2. PROTECTION - SHIPMENT
During reassembly after works testing, all internal machined parts are given a coat of « Castrol SAFECOAT DW 33 » or similar. Orifices are plugged or covered. External machined parts are given a coat of « MOLYDAL MULTI TP » or similar and shaft ends are protected against physical damages. For shipment, sprags or shipping clamps may by provided for moving parts. See diagram n° 01 in Appendix 02. On reaching the final destination, the unit shall be carefully inspected to detect any damage caused by transportation. The internal protection oil applied in the factory before dispatch must be kept until start up, and will be eliminated by lube oil flow.
2.1. STORAGE
Short term storage : for 1 to 2 months at the most.
Medium term storage : 6 months
The unit is delivered on a simple wood frame without packaging.
The unit is protected in a sealed watertight case fitted with air drier bags and is delivered inside a wood box packing.
!
For a long term storage (after 6 months), you have to contact FLENDER-GRAFFENSTADEN for more informations.
!
The oil in use has to be conforme to the OIL TABLE in Appendix 04.
The machine should be stored in a dry room without any large temperature variation.
!
FLENDER-GRAFFENSTADEN manufacturer declines any liability for the consequences of inadequate storage if storage rules given here-above are not respected.
3. INSTALLATION ON SITE
! These operations are not included in the services provided by the manufacturer.
3.1. FOUNDATIONS
The foundations should be built and calculated with appropriate stiffness and damping to prevent resonance phenomena. Take into consideration gearbox data as given on the outline drawing. See outline drawing on Appendix 08. The base plate of the unit is machined flat and parallel to the shafts. Any deformation in the casing due to tightening will affect the teeth contact pattern. It is useful to introduce shims 10 to 20 mm thick between the foundations and the base plate of the unit to facilitate any misalignment correction that may prove necessary.
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 5
!
ASSURANCE OF QUALITY
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
3.2. ALIGNMENT
• Remove transport protections, sprags and shipping clamps before startup.
• If LS shaft is equipped with a quillshaft, leave centering wedges in place during alignment.
!
• If the installation is to operate satisfactorily in service, the different machines must be strictly aligned according to the values given by FG. Faulty alignment will lead to increased vibration and noise levels on the gearbox and on the whole shaft line. The best possible allowance must be made for thermal expansion of the casing and movement of the shafts in the bearings. The design shaft positions for operation under full load are indicated on the outline drawing Appendix 08.
• These positions are given as an illustration, and serve to define the alignment criteria of the different machines. To optimize performance, it is recommended that alignment should be verified with the machines "hot".
! 3.3. HANDLING
Use slinging hooks provided on the lower casing, never attach to any other location such as pipework, components, etc...
3.4. LEVELLING
!
• Levelling of the gearbox is done to obtain a correct tooth contact pattern. The gearbox has to be levelled within an admitted tolerance of ± 0.02 mm/m. Use a precision bubble level on both sides of the gearbox. See diagram n° 02 in Appendix 02.
• It is not necessary to remove upper casing during levelling.
• Control surfaces must be clean and without rust. • If the surfaces are not clean or are damaged,
please contact FLENDER-GRAFFENSTADEN.
!
After each tooth contact control it is necessary to check the levelling.
3.5. TOOTH CONTACT PATTERN Remove these parts before startup. Insert centering wedges again before handling LS shaft. After levelling and alignment but before coupling,
make a first tooth contact pattern check. Open inspection door, and apply prussian blue to a few teeth of the gearwheel. Turn a few times and slow down pinion at the same time. The obtained tooth contact pattern must be conform with Appendix 08. A control of tooth contact pattern after 1-2 hours of running, under full load must be performed. Apply « DYKEN RED »varnish to a few teeth of the pinion (« DYKEN RED » can be obtained from FLENDER-FRAFFENSTADEN customer support department). Clean tooth flanks with a solvent before applying « DYKEN RED » varnish. This method must reveal a contact pattern along the whole length of the tooth.
4. ASSEMBLY & DISMANTLING OF THE GEARBOX
During alignment take into consideration § 3.4. LEVELLING.
! During the warranty period, dismantling of the gearbox requires FLENDER-GRAFFENSTADEN approval.
4.1. DISMANTLING
1. Remove all accessories. 2. Remove upper casing.
The following operations have to be executed by qualified personnel.
3. Remove probes and pipework. 4. Remove upper half-bearings. 5. Sling the shaft and lift it while maintaining it
horizontal, the lower half-bearings must remain in the casing.
6. Protect probe tracks using adhesive paper or equivalente.
7. Remove the lower half-bearings.
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 6
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ASSURANCE OF QUALITY
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4.2. ASSEMBLY
1. The bearings have to be lubricated with clean oil. 2. Two half bearings and their place in the casing
must have the same reference. 3. For thrust bearings, load faces of half bearings
must point in the same section. 4. When lowering a shaft into a thrust bearing, keep
shaft horizontal to avoid damage to thrust surface. 5. Install instrumentation and piping. 6. Internal screws and bots have to be locked. 7. Tighten nuts on the gearbox with the tightening
torque indicated on the Assembly drawing in Appendix 08.
8. If one or more bearings were replaced you have to recheck the tooth contact pattern.
!
5. OPERATION
5.1. OIL SYSTEM PREPARATION AND FLUSHING
Before startup, start the auxiliary oil pump. As soon as the oil circulation is established the oil filter must be cleaned frequently until it is completely clean. Since the bearings and the teeth are connected to the same circuit, it is recommend to provisionally place a metal screen with 0.05 mm mesh at the input to the collector on our unit. This precaution will avoid serious incidents in the bearings due to foreign particles coming from the pipes and carried by the oil.
!
5.2. STARTUP
Before starting rotations, lube oil pressure and temperature must have reached minimum levels.
5.3. CONTROL
5.3.1. Oil pressure
Pressure switch adjustment must be conform to the values given in Appendix 03.
5.3.2. Temperatures
5.3.2.1. Oil outlet temperature
If thermostats are installed on oil return, they must be adjusted as follows :
re, • alarm at 10°C above normal full load temperatu• shutdown at 5°C above alarm temperature.
5.3.2.2. Bearing temperatures
Defined temperature limits must not be exceeded to protect white metal in the bearing. You have to resp Appendix ect the temperature threshold given in 03.
5.3.3. Vibration amplitude
After assembly and dismantling refer to § 3 INSTALATION ON SITE.
Shaft vibration - allowable limits See tables in Appendix 03.
SPECIFIC RECOMMANDATIONS 5.4.
In case of incident on site, repeat all controls mentioned in this manual. !
•
Degradation of lubrication oil : oil in service deteriorates depending on many factors. Laboratory analyses must be carried out
• XTERNAL
•
approximately every 2500 to 3000 hours. Check if oil is conform with § 6.2. EThe metal screen must be removed as soon
as oil circuit flushing is finished. PARAMETERS TO BE MONITORED. Extended shutdown : If a unit is stopped for a longer period, we recommend that the lubrication circuit be operated approximately once a week for one hour. During this operation we recommend that the shafts be turned from time to time.
5.5. SHUTDOWN
There are no special instructions for shutdown. The lubrication system must be operational until the unit is completely stopped.
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 7
!
ASSURANCE OF QUALITY
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
5.6. RESTART OF THE GEARBOX
Generally speaking the gearbox can be started up immediatly after shut down. Respect startup informations descreibed § 5.2. STARTUP.
5.7. OPERATING INSTRUCTIONS IN CASE OF ANOMALIES
!
Instructions to be followed on appearance of alarm :
5.7.1. Oil pressure fault
If the pressure does not rise again and falls below the shutdown pressure for more than 3 seconds the installation must be stopped automatically. However, the unit may operate temporarily provided that temperature limits are very closely monitored. See Appendix 3. Possible causes : • oil level, • filter or cooler dirty, • incorrect pressure setting, • leak, • bearing wear, • oil quality. If the nominal pressure cannot be reached, stop the installation and search for the cause of the incident.
5.7.2. Temperature faults
If oil inlet temperature increases above the values given in § 5.3.2.1. OIL OUTLET TEMPERATURE, the unit may operate during a short time under constant surveillance of bearing temperatures. If there is a high temperature alarm it is necessary to find out whether this is due to an individual fault (bearing or thrust bearing) or to a general rise at all the monitored points.
• individual rise : monitor the temperature rise
closely. If it stabilizes or returns to normal, the unit can continue operating.
• general rise : check the oil inlet pressure. Check that the heat exchanger is operating properly.
If no fault is found and if one or more temperatures are near the shutdown value, the installation must be stopped in time to avoid serious damage to the unit.
5.7.3. Increase in vibration or noise level The pressure, temperature and vibration should be recorded at all measurment points. If these records are not available, no warranty demands can be brought against F-G.
The main causes of variations in the vibration or noise level are the following : • misalignment, • wear (bearing or thrust bearing), • meshing fault, • loose attached element (protective cover, etc...). In all cases the origin of the change in noise or vibration level must be found and eliminated as soon as possible. In case of warm startup a thermal imbalance can lead to increased shaft vibrations. They will disappear once the gearbox has reached nominal speed.
6. MAINTENANCE AND SERVICING ON GEARBOX
6.1. GÉNÉRAL
The purpose is to describe the frequency and operations necessary for correct maintenance of our machines. See maintenance table in Appendix 07. There is also a table that describes the means to be used to carry out these operations. Finally, the causes of the most frequent incidents due to “auxiliary equipment” are described. Obviously, these are minimum recommendations. Verifications should be made between programmed maintenance work and after any incident that could create abnormal operating conditions and/or any drift in vibration and temperature measurements.
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 8
!
ASSURANCE OF QUALITY
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
6.2. EXTERNAL PARAMETERS TO BE MONITORED
7. SPARE PARTS
When ordering spare parts, please indicate the following : In order to optimize machine lifetime it is necessary to
monitor the following parameters : 1. unit type and number,
6.2.1. Oil 2. the number of parts, their quantity, reference number and designation, 1. flow,
3. the drawing number, if necessary. 2. temperature (inlet and outlet), See spare parts list in APPENDIX 05. 3. pressure,
mentioned otherwise), 8. CORRESPONDENCE 6. water content maxi. 50 ppm, FLENDER-GRAFFENSTADEN BP 84 7. acidity, 67402 8. metal particles content.
ILLKIRCH GRAFFENSTADEN 6.2.2. Stability of foundations/attachments : +33 (0) 3 88 67 60 00 In particular, check that the casing is not twisted (joint plane geometry).
In accordance with the limiting values specified in instructions. See Appendix 03.
6.2.4. Bearing temperatures
In accordance with values specified in the instructions. ee Appendix 03. S
9. APPENDICES
A01 Machine characteristics data sheet A02 Position of blocking parts & planeness of the joint plane A03 Set values A04 Oils table A05 Spare parts list A06 Technical instructions for accessories A07 Maintenance table A08 List of drawings
FLENDER-GRAFFENSTADEN
GUIDE D’EXPLOITATION ET D’ENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS
BETRIEBS UND WARTUNGSVORSCHRIFTEN A 01
ASSURANCE
DE LA QUALITE
FICHE CARACTERISTIQUE DE LA MACHINE MACHINE KENNZEICHEN
GEAR DATA
CARACTERISTIQUES BETRIEBSDATEN GEAR DATA Puissance de calcul Auslegeleistung Gear rated power : 43500 kW Facteur de service Betriebs faktor Service factor : AGMA 421/06 >1.3 Vitesse PV Nenndrehzahl LW Rated speed LS : 3000 RPM Vitesse GV Nenndrehzahl SW Rated speed HS : 5022 RPM Rapport de vitesse PV/GV Uebersetzungsverhaeltnis LW/SW Speed ratio LS/HS : 1.67 CONSTRUCTION KONSTRUKTIONSDATEN CONSTRUCTION FEATURES Entraxe Achsabstand Centerlines distance : 650 mm Masse totale Gesamtgewicht Total weight : 11700 kg Masse carter supérieur Gehäuseoberteilgewicht Upper casing weight : 1050 kg Masse carter inférieur Gehäuseunterteilgewicht Lower casing weight : 10650 kg Masse mobile GV Gewicht Schnelldrehende Welle High speed shaft weight : 1152.3 kg Masse mobile PV Gewicht Langsamdrehende Welle Low speed shaft weight : 2533.6 kg LUBRIFICATION SCHMIERUNG LUBRIFICATION Huile, nature et viscosité Oelviskositaet Lube oil designation : 46 ISO VG Filtration Filtrierung Filtering : 25 µm Pression d’entrée Eintrittsdruck Inlet pressure : 1.5 bar act. Température d’entrée nominale Normale Eintrittstemperatur Normal oil inlet temp. : 45 °C Température d’entrée maximale Maximale Eintrittstemperatur Maximal oil inlet temp. : 55 °C Débit Oelbedarf Oil flow : 860 l/mm Quantité de chaleur à évacuer Abzufuehrende Waermemenge Calories to evacuate : 463860 kCal/h
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
A 02
ASSURANCE
DE LA QUALITE
SKETCH N° 01 :
SKETCH N° 02 :
BOLT
STEEL PLATE
CHECK PLANENESS OF THE JOINT PLANE
SHAFT END
POSITION OF BLOCKING PARTS
PRECISION BUBBLE LEVEL ON STRAIGHT - EDGE + 0.02 mm per meter
SECONDARY MODEL WITH PLATE
OPERATING AND MAINTENANCE INSTRUCTIONS A 03
FLENDER-GRAFFENSTADEN
± ±± ±
Shut down:
1,5 1,2 0,8
JOURNAL BEARING AND THRUST BEARING TEMPERATURE
Alarm:Shut down:
20455560
Nominal inlet temperature range:
HS9273
VALUES OF MONITORING AND PROTECTION SETPOINTS IN OPERATION
SHAFT VIBRATION PTP [µm]
Shaft line Alarm Shut down
0,45
137108
SHAFTS DISPLACEMENT (AXIAL) [mm]
Shaft line Alarm Shut down
During start-up, gears can exhibit a transient spike reading of vibration levels that will exceed shut down settings. Therefore a Trip Multiplier is recommended in the control system.
LS
LSHS
0,40
HOUSING VIBRATION (sensor in radial position)
Overall value in mm/s RMS in the frequency range 10 to 2500
Hz
Alarm Shut down
7 11
Alarm Shut down
OIL PRESSURE at gearbox inlet flange [bar]
Normal Alarm Shut down
Overall value in g peak in the frequency range 2500 to 10000
Hz18
Acceleration not used for protection shut
down. (API670/4th§5.4.5.1)
OIL INLET TEMPERATURES [°C]
Minimum inlet temperature before start-up:
Measurement using rigid removable sensors Measurement using flexible sensorsStabilization temperature +10°C Maximum 125°C
Stabilization temperature +20°C Maximum 130°C
Alarm:
Shut down:
Alarm:
ASSURANCEDE LA QUALITE
OPERATING AND MAINTENANCE INSTRUCTIONS A 04FLENDER-GRAFFENSTADEN
LUBRICATING OIL RECOMMENDATIONS
Mineral oil : classification TSE and TGE (of ISO 6743-5)
Method CaractristicsTest
ISO VG ISO 3448 32 46Viscosity Index, mini ISO 2909 100Viscosity cST 100 °C, mini ISO 3104 5,1 6,5Flash point, °C, mini ISO 2592 210 220Pour point, °C, maxi ISO 3016 -10Air release at 50 °C, minute, maxi DIN 51381 3 4Demulsibility at 54 °C, ISO 6614 5 1040/40/0, minute, maxiFoam, Seq, ml/ml, maxi ISO 6247 I : 10 / 0
II : 20 / 0III : 10 / 0
FZG damage load stage DIN 51354 / 2 min. 7RBOT, minute, mini ASTM D2272 450Tost, hour to IA=2, mini ISO7624 4000Acidity, TAN, mgKOH/g, maxi ISO 6618 0.2
OPERATING CARACTERISTICS
Water content, ppm, maxi in tank 100Start-up temperature, °C, mini oil inlet 20Filtration BETA for 25 µm, mini oil inlet 150
ISO 4572
oil inlet 45 to 55 50 to 60Normal supply temperature for continuous operation °C
ASSURANCEDE LA QUALITE
OPERATING AND MAINTENANCE INSTRUCTIONSA 05
SPARE PARTS LIST FLENDER-GRAFFENSTADEN
Assembly drawing : 02S287Outline drawing : 02N357
Spare partsITEM Number GEARING Type Drawing or Norm
DESIGNATION 1** 2*
A100 1 GEAR WHEEL PV 04AE578 *
A201 1 PINION SHAFT GV 04AE579 *
ASSURANCEDE LA QUALITE
SPARE PARTS LIST A 05
R-GRAFFENSTADEN
Spare partsITEM Number BEARINGS & THRUSTS BEARINGS Type Drawing or Norm
A turning gear device is composed of : • Electrical motor. • Electrical contact preventing starting of the electrical motor when handwheel is in position. • Handwheel for manual turning operations. • Speed reducer. • « SSS Gears » automatic clutch.
2. CARACTERISTICS
2.1. GÉNÉRAL FEATURES : • Turning speed : 150 Rpm on HS shaft. • Breakaway torque : 5714 mN
2.2. ÉLECTRICAL MOTOR : • Type : LS225ST • Voltage : 415 V • Power : 37 kW • Frequency : 50 Hz • Speed : 1470 RPM. • Protection : IP55 • Shape : V1/FF400 • Insulation : Classe F
2.3. SPEED REDUCER FG : • Type : KAF148 • Reduction ratio : 9.77
2.4. « SSS GEARS » COUPLING : • Type : 36T • Assembly drawing : SM 17007
Principles of operationApplicable principlesBasic SSS clutch principleDashpot - double acting
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section7
Section 8
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Preface
This manual and its associated assembly drawing relates to a complete family ofturning gear clutches of the following sizes.
Size - 36T, 44T, 55T, 65T, and 80T.
Two types of size 36T clutch are covered. One for standard installation and one forinstallation where a greater axial expansion is demanded.
The instructions contained in this manual are suitable for all clutches in thisfamily.
The assembly drawing clearly shows all relevant dimensions, weights, torques,and lubrication requirements for each size of clutch.
Use in potentially explosive atmospheres
These SSS clutches are intended only for use in slow speed turning gear drivesand may only be used in accordance with these instructions and the operatinginstructions for the complete turning gear system.
These clutches comply with the requirements of Directive 94/9/EC Group IICategory 2G provided that:
Lubricating oil is supplied to the SSS Clutch continuously when any partof the clutch is rotating.
The limitations on clutch alignment and installed length are strictly observed.
II 2G T4
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Section 1 General description
The function of the clutchThe SSS (synchro-self-shifting) turning gear clutch is installed between a turninggear motor drive and its associated driven machinery.
It is designed to provide a simple, mechanical, means of automatically engagingand disengaging the turning gear motor as and when it is required.
If the driven machinery is stationary, the clutch will automatically engage fromrest at the moment the turning gear motor starts to rotate.
The clutch will automatically disengage as the driven machinery accelerates awayunder its main drive, allowing the turning gear motor to be shut down independ-ently.
The turning gear motor can be independently started while the main drive is stilloperating so that when the main drive is shut down and the driven machinerydecelerates, the clutch will automatically engage to maintain the driven machin-ery at turning gear speed.
LubricationLubricating oil is supplied to the clutch input shaft from the main plant lubricationsystem through the input hub to the input shaft.
From there it is distributed through internal drillings to lubricate the rotating andsliding parts and feed the dashpot.
1.11.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.21.2.1
1.2.2
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Section 1
1.31.3.1
1.3.2
Main clutch componentsThe clutch comprises three main sub-assemblies: An input assembly; A helicalsliding assembly; An output assembly. These are shown in the top half of theillustration in 1.3.2. The main component parts are shown in the bottom half.
General description
A diagrammatic view of the clutch and its component parts
Input assembly
Helical sliding assembly
Output assembly
pawls
Driving teeth
Driven teeth
Helical sliding component Output clutch ring
Dashpot
Ratchet
Helical splines
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Installation of the clutchSection 2
CLUTCH SERIAL No R * * * *
Clutch identificationEach clutch is marked with an individual four figure serial number preceded by theletter ‘R’. The number (illustrated below), is marked on the outside of the clutchand, where possible, each individual sub-assembly.
Direction of rotationThe outside diameter of the input flange is marked with an arrow (illustratedbelow) indicating the direction of rotation.
Pre-installation actionsRead the Preface of this manual.
Ensure that the clutch assembly drawing is available and used throughout theassembly operation.
Ensure that the main plant driving and driven shafts, have been inspected andmeet technical specification and tolerance. Particular attention should be paid toalignment details given in the illustration in 2.3.4 and the distance between flangefaces shown on the assembly drawing.
DIRECTION OF
ROTATION
INPUT
2.12.1.1
2.22.2.1
2.32.3.1
2.3.2
2.3.3
2.3.4
To check concentricity, use the driving shaft flange as a datum and rotate the indicator about the outside diameter of the driven shaft flange.
To check parallelism, use the driving shaft flange as a datum and rotate the indicator
about the face of the driven shaft.
Maximum dial indicator reading to be as specified
by machinery manufacturer.
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Installation of the clutchSection 2
Clutch installation - method 1Axially shorten the clutch by carefully sliding the output clutch ring (3) towardsthe input shaft (1). This ensures that the assembly clears the location spigots onthe driving and the driven shafts.
Position the clutch between the driving and driven shafts and fit the input shaftflange (1) onto the spigot of the turning gear shaft flange. Align the bolt holes andbolt the two flanges together.
Axially extend the clutch by carefully sliding the output clutch ring (3) away fromthe input shaft (1). Fit the output clutch ring flange onto the spigot of the drivenmachine shaft flange. Align the bolt holes and bolt the two flanges together.
Ensure that filtered lubrication oil is supplied to the clutch via the drilled oilwayin the input shaft and refer to the assembly drawing to check the specified flow rateand pressure.
Check that the input and output halves of the clutch are running true on theirrespective driving and driven shafts (see 2.4.7).
Be aware that it is possible to fit the clutch back-to-front. Always re-check that theclutch input shaft has been fitted to the turning gear drive before starting thedrive.
2.42.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
Check that the input half of the clutch is is fitted concentric and parallel.
Check that the output half of the clutch is fitted concentric and parallel.Maximum dial indicator
reading = 0.03 mm TIR
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Clutch installation - method 2Remove the output clutch ring (3) from the clutch assembly.
Fit the output clutch ring flange (3) onto the spigot of the driven machine inputshaft flange. Align the bolt holes and bolt together.
Fit the clutch input shaft flange (1) and the remaining clutch assembly onto thespigot of the turning gear shaft flange. Align the bolt holes and bolt together.
Fit the turning gear drive and clutch assembly into its operating position, carefullyfeeding the clutch mechanism into the, already fitted, output clutch ring.
Accurately position and secure the turning gear drive.
Ensure that filtered lubrication oil is supplied to the clutch via the drilled oilwayin the input shaft and refer to the assembly drawing to check the specified flow rateand pressure.
Check that the input and output halves of the clutch are running true on theirrespective driving and driven shafts (see 2.4.7).
Be aware that it is possible to fit the clutch back-to-front. Always re-check that theclutch input shaft has been fitted to the turning gear drive before starting thedrive.
Section 2 Installation of the clutch
2.52.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.5.8
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Maintenance of the clutchSection 3
Clutch maintenance requirementsThe SSS Clutch requires no routine maintenance and is designed to last thelifetime of the main plant.
During overhaul of the main plant, it is recommended that the SSS clutch shouldbe removed for inspection. SSS Gears should be contacted in this regard.
3.13.1.1
3.1.2
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Section 4 Fault finding
GeneralThe only faults likely to occur are those caused by operational defects - notably alack of lubricating oil during operation and/or misalignment.
A lack of lubricating oil will result in overheating and damage to the clutch teethand the pawl and ratchet mechanism.
Misalignment could result in damage to the pawl and ratchet mechanism such thatthe clutch will not engage.
The clutch fails to engage from rest or at low speedIf the turning gear motor will not rotate the driven machine from standstill or if,when at low speed, the turning gear motor is able to rotate slightly faster than thedriven machinery, then there is damage to the pawl and ratchet mechanism.
Action: Stop the drive immediately to prevent further damage and contact SSSGears.
The clutch fails to disengageIf the speed of the turning gear motor will not reduce below the speed of the drivenmachine when the turning gear motor is turned off, this indicates that the clutchmechanism is damaged and held in the engaged position.
Action: Stop both the driven machine and the turning gear motor immediately toprevent further damage and contact SSS Gears.
4.14.1.1
4.1.2
4.1.3
4.24.2.1
4.2.2
4.34.3.1
4.3.2
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Section 5 Parts List
5.1
Item Description Qty
1 Input shaft 12 Helical sliding component 13 Output clutch ring 14 Stop cap 15 Not used -6 Pawl 27 Pawl spring 28 Pawl pin 29 Pawl stop pin 210 Not used -11 Socket head cap screw 412 Socket set screw 213 Socket set screw 2
Clutch parts list
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Spare partsSection 6
6.16.1.1
6.1.2
6.1.3
6.26.2.1
Ordering spare partsFive items of information are required when ordering spare parts from themanufacturers. (1) The quantity required, (2) The item number, (3) The descrip-tion, (4) The drawing number, (5) The clutch serial number.
The clutch serial number (preceded by the letter R) is marked on the outside of theclutch. The remaining information required is found in Section 5 of this manualand on the assembly drawing.
Order example: Quantity 2, Item 6, Pawl, Drawing number SL.*****, Serialnumber (see clutch).
Recommended sparesIt is advised that the following spares are carried as stock.
Item Description Qty
6 Pawl 27 Pawl spring 28 Pawl pin 29 Pawl stop pin 212 Socket set screw 213 Socket set screw 2
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
7.1 Clutch assembly drawing - SM.17016
The clutch assembly drawing is provided inthis manual as a bound-in insert
Assembly DrawingSection 7
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Principles of operation
Applicable principlesThe SSS clutch incorporates a number of features. As an aid to understandingthese features, the applicable SSS principles of operation are contained in thepages of this section.
These principles are:
Basic SSS clutch principle SSS Principle No. 1a.
Dashpot - double acting SSS Principle No. 4.
The diagrams used to describe these SSS principles are generic and not descriptiveof any individual SSS Clutch. A diagrammatic view of the clutch is contained inSection 1 and assembly drawings can be found at the back of this manual.
Section 8
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Principles of operation
Basic SSS clutch principle (SSS Principle No.1a)The initials SSS denote the 'Synchro-Self-Shifting' action of the clutch, wherebythe clutch driving and driven teeth are phased and then automatically shiftedaxially into engagement when rotating at precisely the same speed. The clutchdisengages as soon as the input speed slows down relative to the output speed.
The basic operating principle of the SSS clutch can be compared to the action of anut screwed on to a bolt. If the bolt rotates with the nut free, the nut will rotatewith the bolt. If the nut is prevented from rotating while the bolt continues to turn,the nut will move in a straight line along the bolt.
In an SSS clutch the input shafthas helical splines which corre-spond to the thread of the bolt.Mounted on the helical splinesis a sliding component whichsimulates the nut. The slidingcomponent has external clutchteeth at one end, and externalratchet teeth at the other (seeFigure 1).
When the input shaft rotates,the sliding component rotateswith it until a ratchet toothcontacts the tip of a pawl on theoutput clutch ring to preventrotation of the sliding compo-nent relative to the outputclutch ring, and align the driv-ing and driven clutch teeth (seeFigure 1 and Figure 4).
As the input shaft continues torotate, the sliding componentwill move axially along the heli-cal splines of the input shaftmoving the clutch driving anddriven teeth smoothly into en-gagement.
During this movement, the onlyload taken by the pawl is thatrequired to shift the lightweight
Clutch teeth
Input shaft Output clutch ring
Helical sliding component
Pawls
Ratchet
Helical splines
Figure 1: Clutch disengaged
AA
Movement into engagement
Figure 2: Engaging travel (pawls unloaded)
Section 8
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Principles of operation
sliding component along thehelical splines.
As the sliding componentmoves along the input shaft,the pawl passes out of contactwith the ratchet tooth, allow-ing the driving teeth to comeinto flank contact with thedriven teeth and continues theengaging travel (see Figure2).
Driving torque from the inputshaft will only be transmittedwhen the sliding componentcompletes its travel by con-tacting an end stop on theinput shaft, with the clutchteeth fully engaged and thepawls unloaded (see Figure3).
When a nut is screwed againstthe head of a bolt, no externalthrust is produced. Similarlywhen the sliding componentof an SSS clutch reaches itsend stop and the clutch istransmitting driving torque,no external thrust loads areproduced by the helicalsplines.
If the speed of the input shaftis reduced relative to the output shaft, the torque on the helical splines will reverse.This causes the sliding component to return to the disengaged position and theclutch will overrun. At high overrunning speeds, pawl ratcheting is prevented bya combination of centrifugal and hydrodynamic effects acting on the pawls.
The basic SSS clutch can operate continuously engaged or overrunning at maxi-mum speed without wear occurring.
Figure 3: Clutch engaged
SSS Principle No.1a -continued
Section 8
AAAAAAAAAAAAAAAA
AAAAAAAAA AAA
AAAAAA
......and the driving and driven teeth are perfectly aligned for inter-engagement
As the clutch input overtakes the clutch output, the pawls engage with the ratchet.......
Pawl
Ratchet
Clutch output
Clutch input
Figure 4: Clutch teeth alignment.
SSS Gears Turning Gear Clutch: Manual Number IB.545Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Dashpot - double acting type (SSS Principle No.4)The purpose of the double acting dashpot is to cushion clutch engagement at highacceleration and slow down the rate of disengagement.
Principles of operation
Figure 1:
Clutch Disengaged
The dashpot is continuously supplied with low pressure oil - usually from the main machinery lubrication system.
Clutch teeth
Input shaft
Output clutch ring
Helical sliding component
PawlsRatchet
Helical splines
Oilsupply
Free movement
Dashpot filled
with oil
Pawls unloaded
Oilsupply
Cushioned movement
Figure 2:
Clutch Engaging
Strong dashpot action starts after the pawls are unloaded, and then continues to the end of the clutch engaging travel.
Figure 3:
Clutch Engaged
Final clutch engaging travel is cushioned by the dashpot action. The dashpot also slows down the rate of clutch disengagement.
Section 8
FLENDER-GRAFFENSTADEN
GUIDE D’EXPLOITATION ET D’ENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS
BETRIEBS UND WARTUNGSVORSCHRIFTEN LIBRETTO D’USO E MANUTENZIONE
MANUAL DE USO Y DE MANTENIMIENTO
A 06
ASSURANCE DE LA QUALITE
DISPOSITIF DE DEMARRAGE STARTING DEVICE
ANLASSWIEDER STAND DISPOSITIVO DE DARRANQUE DISPOSITIVO DI AVVIAMENTO
I - PUMP IDENTIFICATION PLATE Every SEIM T3C and T3A and PU pumps type is identified by a metal plate riveted to the body of the pump bearing the pump model code number and the serial number of the individual pump. The metal plate looks like this:
I.1 - IDENTIFICATION CRITERIA Tables 1 and 2 illustrate the pump identification criteria in full. The dimensionnal and functional charateristics of each model of pump are indicated in specific tables. I.2 - DIRECTION OF ROTATION The direction of rotation of the motor must conform with the direction indicated by the arrow of the identification plate. II - INSTALLATION T3C and T3A and PU pumps type have cast iron bodies. Pumps may be installed in any position but the delivery flange should be higher than the suction flange to allow air to exit. The pressure at the suction flange can be positive or negative (see the specific tables) Although SEIM screw pumps have excellent self priming characteristics, it is advisable that the suction line and the pump form a siphon system to keep the pump full when it is not in operation and thus avoid damage at start-up. Do not use a non-return valve to ensure that fluid is retained as this would cause loss of head on the suction line to increase. II.1 - SUCTION AND DELIVERY FLANGES
2
The suction flanges are conformed with the UNI 2281-67 PN10 or PN 16 standard. The delivery flanges are designed to take UNI 2284-67 PN40. ANSI flanges can be supplied on request. For the T3C and PUC pump, the suction flange can be fitted at a 90° angles to the delivery fitting: to position the suction flange correctly follow the procedure below (the numbers in brackets refer to the components shown in figure 1): 2.1.1 - Position of the suction flange with hexagonal nuts 1) Loosen the hexagonal nuts (15) and remove the screws (17); 2) Turn the suction flange (21) until the desired position is reached; take care not to damage
the o-ring (16) fitted on the housing on the body of the valve (14); 3) Push the suction flange (21) against the body of the valve (14); 4) Replace the screws (17) and tighten the hexagonal nuts (15). When supplied by SEIM, the openings of the suction and delivery attachments of the pump are protected by plastic covers and the motor shaft is also covered with plastic to respect the pump and ensure that impurities do not get inside. The plastic covers must not be removed until just before the pump is fitted to the hydraulic system line. II.2 - CONNECTION TO ELECTRIC MOTOR The pump is connected to B35 type motors (motors with feet and flanges) by a normalised flexible coupling and spider, and to B3 type motors (motors with feet) by means of a flexible coupling (in this case, the pump will be equipped with feet), or to B5 type motors (motors with flanges) for immersed vertical installations. This system reduces the extent of any alignement errors to values easily compensated by the flexible coupling. When a B5 type motor is used the spider can be fitted with feet. II.3 - FILTER ON THE SUCTION LINE It is advisable to install a 125 micrometer filter on the suction line since particulate contaminants in the fluid can cause wear by abrasion and increase slack and internal blowby, thus reducing the head. The dimensions of the filter can be adequately defined according to the head, operating temperature and difference in pressure across the filter itself.
3
III - PUMP START - UP III.1 - BEFORE START - UP When installing the pump (new or reconditions), fill the pump with the operating fluid and turn the shaft manually in the direction indicated on the identification plate to lubricate the internal components of the pump. It is then ready for start-up. III.2 - DIRECTION OF ROTATION To check the direction of rotation of the pump, switch the electric motor on and off rapidly and observe the rotation of the motor impeller or, if easier, of the shaft by making a suitable opening on the spider. The direction of rotation must match the one indicated by the arrow on the identification plate. III.3 - START-UP The pump can only be started if the suction and delivery lines are fully open. The pump is « primed » when it starts to deliver head. Leave the pump operating for a few minutes to remove air from the fluid then regulate the pressure to the system value. If priming does not occur within 30 seconds stop the motor, wait a few seconds and repeat the start-up operation. If the pump cannot be primed check the conformance of the system. IV - DISMANTLING AND FITTING THE PUMP These instructions assume that the pump has already been disconnected from the spider, or flexible coupling for the fixing feet version, and from the suction and delivery lines, and that it has been completely drained of fluid and the flexible half-coupling removed. IV.1 - DISMANTLING THE PUMP The following procedure should be followed (the numbers in brackets refer to the components shown in figures 1 and 2):
4
1) Block the body of the pump (14) horizontally, ensuring that the data on the identification plate is not obscured;
2) Loosen the nuts (15) and remove the 4 screws (17) which connect the suction flange (21)
to the body of the pump (14); 3) Remove the suction flange (21) taking care not to damage the o-ring (16); 4) Unscrew the 4 screws (20) which hold the support plate (19) to the body of the pump, by
means of the spacing pins (18); 5) Remove the side screws (13) by turning clockwise; 6) Remove the tab (1) from the central screw (12); 7) Unscrew the 4 fixing screws (5); 8) Remove the flexible washer (2) on the central screw; 9) Use an extractor to remove the motor coupling flange (6); the bearing (4), labyrinth (8) and
the fixed part of the mechanical seal (9) remain inside the flange (6); 10)Remove the flexible washer (3) and bearing (4) from the flange; 11)Remove the flexible washer (7) and labyrinth (8) from the flange; 12)If necessary remove the fixed part of the mechanical seal (9) from the coupling flange (6)
following the instructions given in section 5 (« Replacement of the mechanical seal »); if left in place do not let your hands touch the sliding surface of the seal.
13)If necessary remove the fixed part of the mechanical seal (11) from the central screw (12)
following the instructions given in sections 5 (« Replacement of the mechanical seal »); if left in place do not let your hands touch the sliding surface of the seal.
IV.2 - INSPECTION If correctly installed and if start up has been performed correctly, SEIM pumps need very limited inspection. However, if the components of the pump are so worn that pressure is not maintained it is normally preferable to replace the whole pump rather than specific components, as when one of the component is worn the others generally are too. To inspect the pump and determine the state of wear, check the following parts which can be replaced easily: Fixed part of the mechanical seal (9), rotating part of the mechanical seal (11), o-ring (10 and 16), bearing (4), labyrinth (8) and support plate (19).
5
IV.3 - ASSEMBLY To assemble the pump the procedure described for dismantling must be followed in reverse. It is advisable to take the following precautions: 1) Fit the rotating part of the mechanical seal (11) on the central screw (12) following the
instructions given in section 5 (« Replacement of the mechanical seal »); 2) Check that drainage hole on the motor coupling flange (6) is free of any impurities; 3) If previously dismantled, fit the fixed part of the mechanical seal (9) in the motor
coupling flange (6) following the instructions given in section 5; 4) Slide the labyrinth (8) inside the coupling flange (6) and block it with the flexible washer
(7); 5) Clean the sliding surfaces of the rotation part of the mechanical seal (11), fitted on the
central screw (12) with methylated spirit, taking care to leave no residue; 6) Clean the sliding surfaces of the fixed part of the mechanical seal (9), fitted on the motor
coupling flange (6) with methylated spirit. 7) Clean the central screw leaving no residue and fit into the body of the pump. 8) Slide the motor coupling flange (6) on the central screw, centering the screw with the
internal washer of the labyrinth (8); 9) Taking care not to damage the o-ring (10), fit the motor coupling flange (6) correctly to
the body of the pump (14) and tighten the 4 screws (5); 10) From the side of the motor coupling flange (6), use a suitable sized sleeve to push the
internal washer of the labyrinth (8) to the edge screw (2) ‘see enlargement in figures 1 and 2;
11) Insert the bearing (4) on the central screw (2) and the motor coupling flange (6), using
the flexible rings (2) and (3) block the assembly with the flexible washer ; 12) Clean the two side screws (13) leaving no residue and insert them using an anticlockwise
motion into the body of the pump (14) until they reach edge; 13) Clean the support plate (19), lubricate it and then fit to the body (14) using the spacing
pins and fixing screws (20), ensuring that the position of the two slide housings correspond with the position of the two side screws (13);
14) Check that the o-ring (16) is intact and fit the suction flange (21) on the body of the
pump (14). For the T3C, check that the position of the suction hole in relation to the delivery hole coincides with the requirements of the system;
15) Insert the tab (1) in its housing on the central screw (12) using a plastic hammer;
6
16) Lubricate the screws and turn the shaft manually in the direction indicated on the
identification plate so that the internal components of the pump are lubricated. V - REPLACEMENT OF THE MECHANICAL SEAL These instructions suppose that the pump is already disconnected from the spider, suction line and delivery line, and that it has been fully drained and the flexible half-coupling removed. It is advisable to follow the instructions (the numbers in brackets refer to the components listed in figures 1 and 2): 1) Follow the whole procedure described in section 4.1 « Dismantling the pump » from
point 6 to point 10. 2) The internal diameter of the fixed part of the mechanical seal (9) is less than the diameter
of the hole (shaft housing) in the motor coupling flange (6). Remove the fixed part of the mechanical seal (9) by pulling it out with your fingers.
3) Remove the rotating part of the mechanical seal (11) from the central screw (12),
facilitating the operation by turning the seal clockwise and holding the central screw still. 4) Remove the packaging from the replacement seal without touching its sliding faces with
your hands. Do not leave the parts of the seal with the sliding surfaces on the work bench. 5) The fixed part of the mechanical seal (9) must be introduced into the cavity in the motor
coupling flange (6) by pressing it with your fingers or using a sleeve with suitable internal and external diameters to press its outer ring without touching the sliding surfaces. Lubricate the o-ring with a thin film of oil.
6) Clean the rotating part of the mechanical seal (11) with methylated spirit, taking care not
to touch sliding surface, and slide onto the central screw (12), turning the seal clockwise while holding the central screw still and pressing it against the washer of the central screw (12).
7) Fit the motor coupling flange (6) to the central screw, centring the screw with the internal
washer of the labyrinth (8). 8) Follow the « Assembly » procedure described in section 4-3 from point 9 to point 11.
7
COMPONENT LIST 1) tab 2) shaft retaining ring 3) internal retaining ring 4) self-lubricating bearing 5) hexagonal-slotted flat head screw 6) motor coupling flange 7) internal retaining ring 8) labyrinth 9) fixed part of the mechanical seal 10) o-ring 11) rotating part of the mechanical seal 12) central screw 13) idler screws 14) pump casing 15) hexagonal nuts 16) o-ring 17) hexagonal head fixing screws 18) spacing pins 19) support plate 20) hexagonal-slotted flat head screw 21) suction flange
8
Table 1 - Type T3C - T3A pump identification number 1° Digit: version T = pump for external installation with cast iron body 2° - 4° Digit: external diameter of central screw (mm) 5° Digit: screw length number 3 = number of hydraulic seals on central screw 6° - 8° Digit: screw gauge in mm 9° Digit: internal characteristics O = standard version T = anti-clockwise rotation 10° Digit: external characteristics A = axial suction flange version C = radial suction flange version 11° Digit: special versions O = standard version A = version in accordance with API 676 K = built-in safety valve with internal recirculation L = built-in safety valve with external recirculation 12° Digit: type of gaskets and seals O = Viton gaskets and widia/widia mechanical seal 13° Digit: safety valve characteristics A = gauge pressure 0-7 bar B = gauge pressure 7-15 bar C = gauge pressure 15-40 bar 14° Digit: inlet/outlet flanges characteristics A = ANSI 150 RF norm B = ANSI 300 RF norm D = DIN norm 15° Digit: P = body with fixed feet: horizontal position L = body with fixed feet: vertical position Table 2 - Individual pump serial number 1°-2° Digit: year of production code number (example : 10=1995 ; 11=1996) 3°-4° Digit: month tested 5°-8° Digit: serial number
9
10
11
OPERATING AND MAINTENANCE INSTRUCTIONSA 07
MAINTENANCE BOARD FLENDER-GRAFFENSTADEN
Operations to be done before : years 1 2 3 4 5 6 7 8 9 10HOURS 200 8000 16000 24000 32000 40000 48000 56000 64000 72000 80000
Bearings (See also note A)Visual inspectionWear measurementDye penetration if necessaryReplace if : max clearance is reached
or there are any cracksToothing (See also note B)
Visual inspection (throuth the trap door)Check the contact surface by checkingthe ''Dyken red'' varnishMesure the backlash and check the contact with methylene blueDye penetration or magnetic particle inspectionReplace if : wear to severe
presence of crackspitting, ect...
SealVisual inspectionMesure clearance between shaft/oil sealReplace if : too much clearance
presence of leaksafter installation of new bearing shells
spline for quill shaft / sleeve couplingReplace if : severe wear marks
excessive clearancebreakage and / or deteriorationof toothing profiles
CasingNew compound on joint planeInternal cleanliness checkCheck of internal pipeworkLevelling
AlignmentInspection and any necessary modification
Aucillary equipmentSuch as pumps, turning gear, clutchs etc...in accordance with the specific See Appendix 06instructions included in our manual
Note A : Bearing. In case clearance of bearings exceed maxi recommended 30%, it is absolutely necessary tomount a set of spare bearings. Replacement of bearing may also be necessary in case presence of inlet lubrication oil cannot be maintained. LS and HS thrust bearing pads have to be replaces as soon as half of active area is tarnished.
Note B : Toothing. Control of tooth contact has be carried regulary through visiting door. Unilateral tooth contact means that foundation gave way. Such a tooth contact is highly detrimental to good quality of toothing especially in case of turbomachines which are therefore it is important toidentify the cause and find remedy for it at very short time.
ASSURANCEDE LA QUALITE
FLENDER-GRAFFENSTADEN
GUIDE D’EXPLOITATION ET D’ENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS
BETRIEBS UND WARTUNGSVORSCHRIFTEN LIBRETTO D’USO E MANUTENZIONE
MANUAL DE USO Y DE MANTENIMIENTO
A 08
ASSURANCE DE LA QUALITE
RECAPITULATIF DES PLANS / LIST OF DRAWINGS LISTE DER ZEICHNUNGEN / RECAPITULACION DE LOS PLANOS / REPLOGIO DI PLANI
Plan d’assemblage Assembly drawing Montagezeichnung Plano de ensamblaje Piano d’assemblaggio
N°
02S287
Plan d’encombrement + caractéristiques Outline drawing + characteristics Einbauzeichnung + Technische Angaben Plano di dimensiones + caracteristicas Piano d’ingombrio + caratteristiche
N°
02N357
Schéma de sortie de câble : Température Wiring diagram : Temperature Verkabelungsschema : Temperatur Esquema de montaje del cable : Temperatura Schema di uscita di cavo : Temperatura
N°
27D601
Shéma de montage / câblage : Vibration Wiring diagram : Vibration Verkabelungsschema : Schwingung Esquema de montaje / cableado : Vibracion Schema di montaggio / cablaggio : Vibrazione
N°
Portée dentures Tooth contact pattern Verzahnungstragbild Asiento de los dentados Portata dentura