1103089-rro3945140 Gearbox Lufkin

The Energy Flows Through UsTM

Installation, Operation & Maintenance Manual

WARNING: Failure to use this manual for guidance may result in injury to personnel and/or damage to equipment. Lufkin Sales Order Number ................................. 11210762 Lufkin Model ....................................................... NF1619D Lufkin Serial Numbers ......................................... 11210762-01

GE Nuovo Pignone PO Number: ......................................................... Material Code: ..................................................... Job #: .................................................................... Project: ................................................................

439887277 RRO3945140 1103089 Florena Reinjection

April 23, 2014

Phone: 936/634-2211 Fax: 936/637-5774

P O Box 849, Lufkin, TX 75902-0849 www.lufkin.com

Table of Contents TABLE OF CONTENTS------------------------------------------------------ i LIST OF FIGURES ---------------------------------------------------------- iii

1

INTRODUCTION --------------------------------------------------- 1 1.1 1.2 1.3

2

SCOPE .............................................................................. 1 SAFETY PRECAUTIONS ............................................... 1 EQUIPMENT DESCRIPTION ........................................ 1 1.3.1 Factory Testing .......................................................... 1 1.3.2 Gearing ...................................................................... 2 1.3.3 Bearings ..................................................................... 2 1.3.4 Instrumentation .......................................................... 2 1.3.5 Housing...................................................................... 2 1.3.6 Lubrication................................................................. 2

SAFETY SUMMARY----------------------------------------------- 4 2.1 2.2

GENERAL SAFETY PRECAUTIONS ........................... 4 SAFETY EQUIPMENT ................................................... 5 2.2.1 Wear Proper Safety Equipment ................................. 5 2.2.2 Reduce Danger Of Damage To Hearing .................... 5 2.3 REDUCE RISK OF ACCIDENTAL SHOCK .................. 5 2.4 RESUSCITATION ........................................................... 5 2.5 POSSIBLE MISUSES OF EQUIPMENT ........................ 5

3

INSTALLATION ---------------------------------------------------- 6 3.1 3.2 3.3 3.4 3.5 3.6

3.7

4

RECEIPT OF SHIPMENT ............................................... 6 STORAGE ........................................................................ 6 3.2.1 Corrosion Protection During Inoperative Periods...... 6 LIFTING, HANDLING .................................................... 7 FOUNDATION ................................................................ 7 ADDITIONAL REQUIREMENTS .................................. 7 ALIGNMENT................................................................... 8 3.6.1 General ...................................................................... 8 3.6.2 Anticipation of Shaft Operating Positions ................. 8 3.6.3 Alignment Sequence .................................................. 8 3.6.4 Alignment Checking .................................................. 9 TOOTH CONTACT CHECK ........................................ 10

OPERATION -------------------------------------------------------- 11 4.1 4.2 4.3 4.4 4.5. 4.6

LUBRICATION ............................................................. 11 OIL TYPE AND GRADE .............................................. 11 CUSTOMER CHECK BEFORE START-UP ................ 11 START-UP PROCEDURE............................................. 12 CUSTOMER CHECK AFTER START-UP ................... 12 ALARM SWITCHES ..................................................... 13

Installation, Operation, and Maintenance

page i

5

PREVENTIVE MAINTENANCE ------------------------------- 14 5.1 5.2 5.3 5.4

INTRODUCTION .......................................................... 14 DAILY MAINTENANCE .............................................. 15 MONTHLY MAINTENANCE ...................................... 15 QUARTERLY MAINTENANCE .................................. 15 5.4.1 Oil Analysis Guidelines ........................................... 15 5.5 ANNUAL MAINTENANCE .......................................... 16 5.6 OIL CHANGE INTERVALS ......................................... 16

6

DISASSEMBLY ---------------------------------------------------- 17 6.1

6.2 6.3 6.4 6.5 6.6 6.7

7

GENERAL ...................................................................... 17 6.1.1 Lock Out/Tag Out Procedure ................................... 17 6.1.2 Visual Inspection ..................................................... 17 TOOLS REQUIRED ...................................................... 17 SPARE PARTS............................................................... 17 REMOVAL OF GEAR COVER..................................... 18 REMOVAL OF PINION, GEAR, AND BEARINGS .... 18 THRUST BEARING REMOVAL .................................. 19 OIL SAMPLE COLLECTION ....................................... 19

GEAR INSPECTION ---------------------------------------------- 20 7.1

TOOTH CONTACT CHECKING.................................. 20 7.1.1 Introduction.............................................................. 20 7.1.2 Why Check Tooth Contact....................................... 20 7.1.3 When to Check Tooth Contact ................................. 20 7.1.4 How to Check Tooth Contact................................... 20 7.1.5 Soft Blue Method ..................................................... 20 7.1.6 Hard Blue Method ................................................... 21 7.2 INTERPRETATION OF TOOTH CONTACT .............. 21 7.3 GEAR CONDITION ASSESSMENT ............................ 22 7.3.1 Types of Gear Wear or Failure ................................ 23 7.3.2 Definition of Gear Failure ........................................ 23

8

BEARING INSPECTION ----------------------------------------- 24 8.1 8.2

BEARING TYPE ............................................................ 24 BEARING CONDITION ASSESSMENT ..................... 25 8.2.1 Bearing Clearance .................................................... 25 8.2.2 Bearing High Spots .................................................. 26 8.2.3 Flaking of Babbitt .................................................... 26 8.2.4 Scoring ..................................................................... 26 8.2.5 Wiping ..................................................................... 26 8.3 REPLACEMENT BEARINGS ....................................... 26

9

REASSEMBLY ----------------------------------------------------- 27 9.1 9.2

page ii

PREPARATION ............................................................. 27 REASSEMBLY SEQUENCE ........................................ 27 9.2.1 Bearing, Gear, and Pinion Assembly ....................... 27 9.2.2 Gear Cover Assembly .............................................. 28

NF1619D

10

TROUBLESHOOTING ------------------------------------------- 30 10.1 10.2 10.3 10.4 10.5 10.6

11

ABNORMALLY HIGH TEMPERATURE.................... 31 LOW OIL PRESSURE ................................................... 31 UNUSUAL OR EXCESSIVE NOISE ............................ 31 EXCESSIVE VIBRATION ............................................ 32 FOAMING ...................................................................... 32 NO SENSOR READINGS ............................................. 32

NAMEPLATE DATA ---------------------------------------------- 33

List of Figures and Tables Figure 1 Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Lifting provisions....................................................... 7 Expected maximum shaft vibration levels ............... 12 Expected maximum housing vibration levels........... 13 Tooth contact patterns ............................................. 22 Standard N-Unit Bearings ........................................ 24 Pressure Dam Location ............................................ 25

Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7.

Equipment Description Chart .................................... 3 Standard Danger, Warning And Caution Symbols .... 4 Maximum Allowable Run-Out (T.I.R.) ..................... 9 Preliminary Alarm Settings ...................................... 13 Maintenance Schedule Overview............................. 14 Recommended Tightening Torques ......................... 28 Troubleshooting Tips ............................................... 30

Installation, Operation, and Maintenance

page iii

page iv

NF1619D

Introduction

1

QUALITY AND PERFORMANCE ARE PRIMARY CONCERNS AT LUFKIN. The employees of Lufkin Industries 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 has been certified to ISO-9001 with Det Norske Veritas. For further assistance from Lufkin, please call or fax the following numbers: LOCATION Customer Service (Parts, etc.)

PHONE (936) 637-5211

FAX (936) 637-5883

Service Department

(936) 637-5307

(936) 637-5104

Repair Division

(936) 637-5413

(936) 637-5104

Engineering

(936) 637-5266

(936) 637-5774

1.1

SCOPE

The objective of this manual is to give general information on installation, lubrication, operation, maintenance, disassembly and reassembly of Lufkin Industries model NF1619D 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. Table 1 provides an overview of equipment features.

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

These high speed gear units are used for speed increasing service between a gas turbine and a centrifugal compressor. 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. The electrical schematic is shown on the Wiring Diagram.

1.3.1

Factory Testing

Factory testing of Lufkin 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

page 1

1.3.2

Gearing

Lufkin gears are computer designed according to the latest American Petroleum Institute (API) standards. Conservative service factors, based on API recommendations and on Lufkin's experience, are applied to the ratings to ensure long gear life. N-type units have horizontally offset gearing and use double helical design utilizing hobbed and precision ground gear teeth. Gears and pinions are made from high quality, carburizing grade alloy steel forgings. The pinion and gear are made integral with their shafts and are turned, ground and hobbed. The teeth are then CBN ground to ensure accuracy. See the Installation Plan for shaft end details.

1.3.3

Bearings

The high speed radial bearings on this unit are tilt pad journal bearings. The low speed bearings are centrifugally-cast babbitt with a split steel shell and a pressure dam for improved stability. A tilting pad thrust bearing is used on the low speed shaft to locate the gearing and resist any external axial forces.

1.3.4

Instrumentation

This unit has embedded temperature sensors, vibration probes, proximitors, key phasors, and accelerometers.

1.3.5

Housing

Housings are designed for heavy duty service to provide maximum rigidity, assuring precision gear alignment. All housings are precision bored; bore alignment is certified before assembly. Housing design incorporates the necessary oil piping for bearing and gear mesh lubrication. The housing is a fabricated steel structure, with the split line on the horizontal centerlines of the rotating elements. The gear housing is fully stress relieved before machining. 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 freedom from foreign particles. The exterior is painted per customer specifications. Inspection covers are provided for inspection and examination of all gear components.

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 the 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.

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NF1619D

Table 1. EQUIPMENT Specifications

Service Factor

AGMA 6011

AGMA API

API 613, Fifth Edition Gearing

Low Speed Gear

Service HP

2.51 1.63

43047 HP 32100 kW

Bearings

Double Helical 41 teeth Double Helical 76 teeth

High Speed Pinion

DESCRIPTION CHART

Design Clearance

HS - tilt pad journal

0.0080 – 0.0100 inch 0.2032 – 0.2540 mm

LS - hydrodynamic with pressure dam

0.0120 – 0.0140 inch 0.3048 – 0.3556 mm

Thrust Bearing

Endplay 0.014 - 0.018 inch (0.356 - 0.457 mm)

Kingsbury Single

Reductions

Lubrication

Increaser

Parallel shaft speed

Weight

Oil Type: AGMA Lt Turbine ISO VG: 32 Customer furnished lubrication system

Offset

Horizontal

Heat treatment

Carburized

Cutting method Tooth finish

Hobbed CBN ground

Unit – 17100 lbs. (7756 kg) Heaviest Maintenance Lift – 2917 lbs. (1323 kg)

Speed

Housing

Input – 6100 RPM Output – 11307 RPM

fabricated with inspection covers

Instrumentation and Accessory Equipment • Embedded temperature sensors

• Vibration probes

• Proximitors • Key Phasors

• Accelerometers

Additional Information Center Distance: 16.5" Effective Face: 20.5" NDP: 4

Installation, Operation, and Maintenance

Rotation: CCW Prime Mover: Gas Turbine Driven Equipment: Centrifugal Compressor

page 3

Safety Summary Table 2.

Standard Danger, Warning, and Caution Symbols DANGER:

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

2.1

2

WARNING: WARNING notices are 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.

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: Never remove the inspection cover

while the machinery is in operation.

Lock out/tag out procedures are fully explained in DISASSEMBLY

Always lock out/tag out all power sources while performing maintenance

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

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

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

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. 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.

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NF1619D

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

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

2.3

Gears and their connecting equipment may produce noise levels that are capable of causing hearing loss with long-term, unprotected exposure. 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.

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. Under DANGER: certain conditions, dangerous potentials caused by charges retained by the capacitors may exist when power is off. To Keep away from live circuits. 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.

2.5

POSSIBLE 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. • Operating with windage baffles not properly installed.

Installation, Operation, and Maintenance

page 5

Installation 3.1

3

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 black coating of Equipment-Kote™ by Esgard, Inc., 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.

3.2

STORAGE

The gear is tested at Lufkin with a break-in oil that contains a rust preventative (Interfilm Type 1™ by Esgard, Inc.) 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. 2. 3.

4.

5. 6.

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. 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. 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. 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. Any openings 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. For adverse conditions or long term storage, coat all parts with rust inhibitor compatible with operating oil and seal all openings. A second method of long term storage is to disassemble the unit and coat each part with Cosmoline™ 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.

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NF1619D

3.3

LIFTING, HANDLING

The gear unit should always be moved by rolling on bars or skates, or by lifting WARNING: it with properly Improper lifting techniques could cause rated slings through damage to the gears and/or harm to the lifting personnel. provisions on the top of the unit or the provisions on the side of the unit. See CAUTION: Figure 1 for lifting provision locations. Do not lift unit by either input or output On fabricated shafts. Do not bump the shafts. housings, lifting holes are an integral part of the fabrication. See the Figure 1 Installation Plan or Table 1, “Equipment Description Chart” 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

Lifting Provisions

FOUNDATION

The unit must be mounted on a substantial foundation. One system uses a concrete base, a sole plate on the top of the CAUTION: concrete, about 1/8-inch (3mm) shim space, then the gear unit. The sole plate has tapped holes already in place so that bolts Adequate foundation must be provided for proper alignment. can be used to clamp down the feet of the gear unit (with the proper shims in place) at all positions. Once a general elevation is established above the concrete, the sole plate is grouted into place, leaving a space of about a 1/8-inch (3mm) between the top of the sole plate and the bottom of the gear unit feet. This shim space allows room for proper positioning of the gear unit for slow speed and high speed coupling alignment. The most common system in use is a rigid structural steel baseplate 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 and other equipment rough aligned, requiring final alignment in the field. 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. This unit is supplied with a windage baffle on the shaft extensions. Operation with these baffles removed or improperly installed may cause shaft leaks. Installation, Operation, and Maintenance

page 7

3.6

ALIGNMENT

3.6.1

General

Securing proper shaft alignment is one of the most important phases of setting up a gear unit. Any appreciable misalignment can cause a multitude of gear problems from excess bearing and gear tooth wear to vibration problems. Uncorrected misalignment can lead to catastrophic failure. Therefore, it is essential that thermal growth and shaft operating position in the bearings be anticipated during shaft alignment and that good alignment be maintained.

3.6.2

Anticipation of Shaft Operating Positions

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 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 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. The equivalent high speed pinion position is attained when it is torqued into its operating position with the gear still centered.

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. • •

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

• •

Lubricate the couplings. 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, and/or non-synchronous shaft vibrations. 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 3. When the shafts are not close coupled, contact Lufkin.

2. 3.

• •

page 8

NF1619D

Table 3a. Maximum Allowable Run-Out, (TIR) Shaft Surface Velocity (fpm)

Outside Diameter, TIR (inches)

Face, TIR per inch of R (inches)

5000 and up

0.002

0.0004

3000 to 5000 1500 to 3000

0.004 0.006

0.0005 0.0006

500 to 1500

0.008

0.0008

500 and below

0.010

0.0010

Table 3b. Maximum Allowable Run-Out, (TIR) METRIC 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 4.

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

Check for free axial movement of the pinion and gear. Do not force shaft movement to the point of damaging the bearing shell. Tighten foundation bolts.

5. • •

6.

Outside Diameter, TIR (mm)

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. 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. Installation, Operation, and Maintenance

page 9

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

3.7

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

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. 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 CAUTION: alignment should match the hard blue contact pattern left on the gears from the Test Stand. Proper tooth contact must be obtained before the unit is put into operation. 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.

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NF1619D

Operation 4.1

4

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. Straight mineral type lubricant should be used. Consult Lufkin before using any synthetic lubricants. CAUTION: Also, it is essential that the oil be clean and non-corrosive to Do not change grades of oil without gears and bearings. It must be neutral in reaction, possess approval by Lufkin. good defoaming properties, and also have good resistance to oxidation. Lufkin specifies AGMA # Light Turbine (ISO VG 32) oil 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 1. 2. 3. 4. 5. 6. 7. 8.

CUSTOMER CHECK BEFORE START-UP Check all instrumentation and lubrication connections. Check that all necessary piping and accessory wiring is complete. Check the lubricating system for correct type and quantity of oil. Check for correct shaft alignment. See INSTALLATION. Check for foundation bolt tightness. See INSTALLATION. Check tooth contact. See GEAR INSPECTION. Check that coupling guards and inspection covers are in place. Check that windage baffles are in place.

Installation, Operation, and Maintenance

page 11

4.4

START-UP PROCEDURE

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

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

4.5.

unit

with

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. 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 if practical. Monitor bearing and oil temperature as well as oil pressure. Gradually increase speed while continuing to monitor until operating speed is reached. Gradually load unit if possible.

CUSTOMER CHECK AFTER START-UP

1. 2.

Run gear unit at light load while checking for adequate lubrication. 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 NF1619D may be found in Figure 2, and the expected maximum housing vibration in Figure 3. 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. Figure 2

Expected maximum shaft vibration levels for N Units with good alignment and balance.

page 12

NF1619D

Figure 3

Expected maximum housing vibration levels for N Units with good alignment and balance.

4.6

ALARM SWITCHES

The preliminary settings offered in Table 4 below 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 Table 4 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 Table 4 consult Lufkin for suitability. Table 4. Preliminary Sensor

Alarm Settings

Alarm

Shutdown

6 G’s peak

**must be determined individually**

2.5 mils (0.063 mm) 2.0 mils (0.051 mm) 1.75 mils (0.044 mm)

4.0 mils (0.102 mm) 3.0 mils (0.076 mm) 2.5 mils (0.063 mm)

Probe type RTD or thermocouple in bearing shell

200°F (93°C)

215°F (102°C)

Bi-metal thermometer in bearing shell

180°F (82°C)

195°F (91°C)

Embedded RTD or thermocouple in bearing shell load zone

225° F (107° C)

240° F (116° C)

Oil inlet

150°F (66°C)

160°F (71°C)

Unit sump or drain line

175°F (79°C)

190°F (88°C)

Accelerometer Casing Acceleration Vibration Probes Shaft Vibration Shaft Speed, RPM 0
Installation, Operation, and Maintenance

page 13

Preventive Maintenance

5

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 5 gives an overview of scheduled maintenance.

Table 5. Maintenance Schedule Overview DAILY • check oil temperature • check oil pressure • check vibration • check noise

MONTHLY • check operation of auxiliary equipment • check operation of alarms • check tightness of foundation bolts • check for oil contamination

• check for oil leaks QUARTERLY • analyze oil sample

ANNUALLY • check bearing clearance • check endplay

OIL CHANGE • 2500 hours of operation OR

• check tooth contact pattern

• every six months

• check alignment

• check coupling

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.

page 14

NF1619D

5.2

DAILY MAINTENANCE

• Check the oil temperature and pressure against previously established norms. • Check for unusual vibration and noise. • 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. It is recommended that the oil be changed in the following cases:

5.4.1

Oil Analysis Guidelines

•

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

page 15

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 comes first. The unit should be drained by removing the drain plugs (see the Installation Plan for location.) Complete oil changes for units with large capacity oil systems are sometimes impractical. In this case, draining DANGER: the oil system, cleaning the reservoir and/or gear sump, and then recharging the system with the original oil that When working near rotating elements, has been cleaned and reconditioned may be sufficient. If be certain that the driving and driven this approach is taken, Lufkin strongly recommends equipment are securely locked out. routine oil analysis so that any breakdown of the oil being reused can be detected before affecting gear operation.

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NF1619D

Disassembly

6

During disassembly, refer to the Installation Plan and Parts List furnished for the gear unit.

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

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

1. 2. 3. 4. 5. 6.

6.1.2

Identify the energy sources used and all control devices. Notify all affected personnel. Turn OFF all operating controls. Lock out or tag out all switches and energy controls in “off” or “safe” positions. Test all operating controls to make sure no power is getting to equipment. Perform required maintenance.

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 • Pry bar • Crocus cloth or fine steel wool • Wrenches, screwdrivers, torque-wrench • Prussian blue or similar dye for tooth contact check • LocTite™ No. 549 Plastic Gasket

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. Installation, Operation, and Maintenance

page 17

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, windage baffles, and gaskets. 7. Carefully loosen the thrust bearing housing. (Use the jacking screw holes to loosen from gear housing). 8. Remove all cap screws and nuts on the parting line. 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. CAUTION: 11. Check the upper bearing halves to see if they are Do not bump gear assembly with the stuck in the cover. If they are, carefully pry them out raised cover. or push them out. 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

Removal of gearing from housing is not required if only rotating element inspection is needed. Radial bearings can be removed and replaced by rolling shells out of housing, one bearing at a time (replace the bearing after inspecting it and prior to inspecting other bearings.) The thrust bearing is more difficult to remove and re-install than the radial bearings. If you desire to remove the thrust bearing, refer to the detailed instructions in Section 6.6. 1. Mark the location of each bearing in the housing so that it can be reassembled correctly, and remove high speed bearing upper halves. 2. Remove the pinion with its tilt pad journal bearings in place 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. The tilt pad journal bearings can now be removed for inspection. 3. Remove the low speed gear and shaft assembly with its bearings in place 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. page 18

NF1619D

4. 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. See GEAR INSPECTION for an analysis of gear problems.

6.6 THRUST BEARING REMOVAL Use the following guidelines to remove the thrust bearing. 1. The thrust bearing contains temperature sensors, the lead wires exit the bearing housing through an oil seal fitting. 2. Remove the temperature sensors from the thrust bearing shoes with a small hooked probe to pull out the star washer through the access cover adjacent to the sensor connection heads. 3. Remove the thrust bearing end cap bolts. 4. Remove the end cap and shims from the thrust bearing housing. 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. CAUTION: 9. Remove the lock nut by turning it counterclockwise. Use a spanner wrench or a small punch inserted into the Before removing the thrust collar from spanner holes to loosen the nut. the bearing housing, tilt the top of the 10. Insert capscrews into the threaded puller holes in the collar forward to see if any bearing pads are stuck to the back side of the collar. thrust collar. Remove any stuck pads before they can 11. Carefully remove the thrust collar. Do not allow the fall out of the housing and be damaged. 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.

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

page 19

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

7.1.4

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. 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.

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.

7.1.5

Soft Blue Method

The soft blue method is usually performed 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.

page 20

NF1619D

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 gear 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. 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. 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 4 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

page 21

Figure 4 Tooth Contact Patterns

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.

page 22

NF1619D

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.) 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

page 23

Bearing Inspection 8.1

8

BEARING TYPE

Lufkin's standard journal bearings for N-type gear units are split, steel-backed, babbitt-lined bearings, shown in Figure 5A.

A. Standard journal bearing.

C. Tilt Pad Journal Bearing

B. Pressure dam bearing.

D. Kingsbury-type equalizing thrust bearing (with tilt pads.)

Figure 5 N Unit Bearings.

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

When pressure dam bearings are used (Figure 5B.), ensure the pressure dams are oriented properly. The pressure dam 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 6. Tilt pad journal bearings (Figure 5C) are used to support the high speed shaft. To axially locate the gear train and to take any nominal thrust created by external loads, this unit uses a Kingsbury-type bearing (six-shoe double bearing with separate collar, Figure 5D.), located on the low speed shaft.

page 24

NF1619D

Figure 6 Pressure dam location.

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: • • • • •

8.2.1

correct clearance high spots flaking of babbitt scoring wiping

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. 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. 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 0.002" (0.050 mm). NOTE:

If shaft vibration is excessive, this clearance increase may not be acceptable– contact Lufkin. NOTE: The clearance on the tilt pad bearings is difficult to check accurately and can normally be classified as acceptable if the bearings show no signs of distress, damage, or excessive wear.

Installation, Operation, and Maintenance

page 25

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

CAUTION:

8.2.2

Bearing High Spots

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.

8.2.3

Flaking of Babbitt

Flaking of babbitt in the load area of the bearing is caused by vibration or shock loading of the bearing material, Do not use sandpaper to polish causing the babbitt to fatigue and break loose from the bearings; damage to equipment may result. 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. 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.

8.2.4

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.

8.2.5

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. 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. page 26

NF1619D

Reassembly 9.1

9

PREPARATION

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

1.

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 CAUTION: direction. Do not rub shafts in a length-wise direction as it may cause seal leaks. 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 1.

Bearing, Gear, and Pinion Assembly

Install journal bearings. Before installing journal bearings, note that the bearings are match marked and are not interchangeable. Install the bearings in place on their shafts. 2.

CAUTION: Do not bump housing.

4.

gear

assembly

into

3.

Install gear. Lift the low speed gear with bearings in position 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. Turn bearings in bore if necessary (see Parts List for requirements.)

Install pinion. Make sure the pinion is level and line it up in mesh with the gear, with its bearings in place.

Installation, Operation, and Maintenance

page 27

CAUTION:

5.

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

9.2.2

6.

Carefully set the pinion in mesh with the gear, and roll along gear until its bearings are seated the housing bores. Line up the pins in the housing grooves and rotate bearings until seated.

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 as necessary to retain the leads extending into the housing. Ensure bearing anti-rotation pins are positioned in housing slots. 3. Coat the split line with a small bead of sealer, such as LocTite™ No. 549 Plastic Gasket. Circle all CAUTION: studs to assure sealing of oil; avoid feeder groove Do not block oil passages with sealer. areas. 4. Seat the cover onto the bottom section and install the cylindrical dowel pins. 5. Torque all cap screws and studs (see Table 6, WARNING: “Recommended Tightening Torques.”) Do not place hands below suspended 6. Perform a soft blue gear tooth contact check. (See housing without blocks for protection. GEAR INSPECTION.) Table 6.

Recommended Tightening Torques (for Grade 5 Bolts & Studs)

Nominal Size

7.

Tightening Torque for BOLTS

Tightening Torque for STUDS

inches

mm

Ft. Lbs.

N·m

Ft. Lbs.

N·m

1/2

12.7

75

102

87

117

5/8

15.9

150

203

173

234

3/4

19.0

266

360

307

416

1

25.4

644

873

742

1006

1-1/4

28.8

1120

1519

1484

2012

1-1/2

38.1

1949

2643

2582

3501

1 -3/4

44.5

2286

3100

4073

5522

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. Install Kingsbury thrust bearing.

8. • • •

Replace the inner backing ring. It must be firmly seated against the wall of the housing. 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.

page 28

NF1619D

• • • •

• •

• 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Install the inner thrust shoes taking care to place each shoe having an embedded temperature sensor in its original position. 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 install it into the thrust bearing housing. Install the adjusting shims and 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. Install temperature sensors in their shoes through the access covers. 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. Mount the shaft seals, end plates, windage baffles with spacers, and other auxiliary equipment which may have been disconnected during disassembly. Reconnect any junction box plate and wiring as necessary (see the Wiring Diagram.) Reconnect any instrumentation and lubrication lines necessary (see the Wiring Diagram, Installation Plan, and Lube System Diagram.) Couple unit to driver and driven machines (see INSTALLATION.) Install inspection covers with gaskets and sealer. Align the unit per INSTALLATION, “Alignment” section. Spin the unit slowly with no load, if possible, to verify correct reassembly. Be sure the unit rotates freely and quietly. Confirm proper shaft alignment and tooth contact per INSTALLATION section. Follow the START-UP procedures.

Installation, Operation, and Maintenance

page 29

Troubleshooting

10

Table 7 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.

Table 7. Troubleshooting Tips Problem Abnormally High Temperature

Low Oil Pressure

Excessive Vibrations

Possible Cause

Remedy

• Housing coated with foreign material, • Clean outside of housing preventing heat dissipation • 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 • Clogged oil filter

• See "Abnormally High Temperature"

• 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 • Determine which parts require balancing and which have been balanced • Tighten bolting

• Unbalanced parts

• Loose foundation bolting

• Coupling misalignment

• Pinpoint noise with mechanic's stethoscope, replace part • Realign couplings

Excessive Noise

• Worn gearing

• Replace worn parts

• Transmission from other equipment

• Add sound blanket or enclosure

Excessive Foaming

• Air in oil

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

No Sensor Readings

• No power

• Check power supply & repair or restore • Test gauge or recording equipment • Replace sensor • Replace lead wire

Unusual Noise

• Worn parts

• Replace filter element

• Faulty gauge or recording device • Failed sensor • Lead wire braid rubbed through; wire contacting metal

page 30

NF1619D

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

Installation, Operation, and Maintenance

page 31

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 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.

10.6

FOAMING

Some foam in a gear unit is generally acceptable and inevitable. If the foam exceeds 2 or 3 inches 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.

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 affected 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.

page 32

NF1619D

Nameplate Data

11

GEARS MODEL NO.

NF1619D

GEAR RATIO

1.854:1

SERIAL NO.

11210762-01

RATED INPUT

6100

ORDER NO.

11210762

RATED OUTPUT

ITEM NO.

ACTUAL K FACTOR

GEAR RATED

API SERVICE FACTOR

269.37

11307 43047 32100

RPM

RPM

HP KW

1.63

UNIT RATED AND BUILT PER: SPEC

API 613 5th Edition

NO. OF TEETH GR/PIN

76 / 41

LUBRICANT AGMA NO.

Lt Turbine

OIL SUMP CAPACITY

---

VISCOSITY SSU @ 100°F

150

ISO GRADE

VG 32

INDUSTRIES, INC. LUFKIN, TEXAS - USA

Installation, Operation, and Maintenance

page 33

GALS

page 34

NF1619D

Power Transmission Div.

LIST OF PARTS Unit: Unit Rev: Drawing: Serial Numbers:

NF1619D B 1121076201 11210762-01

ITEM 0001 0002 0003

PART NUMBER 22094675 100262065 100261058

0004 0005 0006

100261093 100261092 100261060

0007

100261059

0008 0009 0010 0011 0012 0013 0014 0015 0016 0017 0019 0020

22118000 E7096160 22203300 E7095879 22117300 22200400 19532800 E7090175 E7093975 100262041 22194400 100262005

0021 0023 0024 0025 0026 0027 0028 0029 0030 0031 0032 0033 0034 0035

E7092020 19579200 18918700 E7077733 E7087655 E9063706 N7066745 E9078415 E7085064 E7085524 AP030144 E7083833 E9063710 N7075993

Date: 03/06/2014 Rev: A

Sales Order: 11210762 Customer: NUOVO PIGNONE SRL Customer PO: 439887277 / 43989466

PART DESCRIPTION ASSY HSG/CVR - NF1619D,R-L,KTB GEAR, LSP - NF1619D INCREASER PINION, HS - NF1619D INCR, C'CW ROTATION BEARING, TPJ-RMT, 170MM BORE BEARING, TPJ-RMT, 170MM BORE BEARING, LSP - NF16D, 7.25 BORE, C'CW BEARING, LSP - NF16D, 7.25 BORE, CW SEAL, D-LINE STYLE, 5.50" BORE SCREW,CAP SOC HD,3/4 NCX1-3/4 GUARD, SHAFT - NF1619D INCREAS SCREW, CAP - 1/4-20NC X 5/8 SEAL, D-LINE STYLE, 6.50" BORE ADAPTER,CPLG GRD-N16D,HS,SPLIT BAFFLE HS WINDAGE-NF16D SPACER, 3/4 SCREW, CAP - 3/4 NC X 3 GALV PIPE, SPRAY, 2" TUBE ADAPTER,CPLG GRD-N16D,LS,SPLIT SEAL, D-LINE STYLE, 7.00" BORE, SPLIT SCREW, CAP - 3/4 NC X 3 1/2 COVER, INSPECTION - 18 X 21 GASKET, INSPECTION COVER SCREW CAP ZINC COATED HXHD 3/8 PIPE 2" SCH 40 316L SST FLANGE BLIND 2" STANDARD WT. GSKT FLNG-2" 150# NON-ASBESTOS FLANGE SLIP-ON 2" 316L STL SCREW CAP ZINC COATED HXHD 5/8 NUT HEAVY HEX 5/8"NC NAME PLATE LUFKIN PIPE PLUG 1 1/2 NPT SQUARE FLANGE BLIND 4" STANDARD WT. GSKT FLNG-4" 150# NON-ASBESTOS

Page 1 of 3

QUANTITY 1.000 1.000 1.000

UOM PC PC PC

1.000 1.000 1.000

PC PC PC

1.000

PC

1.000 8.000 1.000 4.000 1.000 1.000 1.000 8.000 8.000 1.000 1.000 1.000

PC PC PC PC PC PC PC PC PC PC PC PC

8.000 1.000 1.000 12.000 4.000 1.000 1.000 1.000 4.000 4.000 2.000 2.000 1.000 1.000

PC PC PC PC IN PC PC PC PC PC PC PC PC PC

Power Transmission Div.

LIST OF PARTS Unit: Unit Rev: Drawing: Serial Numbers:

NF1619D B 1121076201 11210762-01

ITEM 0036 0037 0038 0039 0040 0041 0042 0043 0044 0045 0046 0047 0048 0049 0050 0051 0052

PART NUMBER E7089119 E7089040 22117900 E7086696 E7086697 E7089887 E7095886 E7092430 E9098026 E7094034 E7075919 100262040 E7086421 E7094729 E9067006 E7083277 N7066742

0053 0054 0055 0056 0057 0058 0059 0060 0061 0062

E9078115 E7095882 E7089099 E7079875 E7081946 E7087309 19216500 E7092516 100264245 100264328

0063 0064 0065 0066 0067 0068 0069 0070

100262803 E7090103 E7077732 100262386 E7085065 19206000 21693600 18804200

Date: 03/06/2014 Rev: A

Sales Order: 11210762 Customer: NUOVO PIGNONE SRL Customer PO: 439887277 / 43989466

PART DESCRIPTION STUD, 5/8-11 NC, 3 1/4" SST NUT HVY.HEX HD. - 5/8 NC SST BAFFLE, FALSE BOTTOM NF1619D FLANGE BLIND 16"-150# BLIND GASKET, FLANGE 16"-150# STUD 1"-8 NC X 4 1/2, 316 SST SCREW ADJUSTING-H/H 1"-8NC X4" TUBING 2"ODX120 WALL FITTING, CONNECTOR- 2" 316 SST CONNECTOR, MALE - 316SST BORED NOZZLE SPRAY-VEE JET 1/8 U8030 PIPE, SPRAY, 2" TUBE NOZZLE SPRAY-VEEJET MODEL FLG 1"-3000# SAE KIT 316 SST ELBOW 90 SOCKET WELDING 1" PIPE 1" STAINLESS STEEL T316L GSKT FLNG-1" 150# NON-ASBESTOSGR01 WH FLANGE SLIP-ON 1" T316 SST REDUCER, FLANGE - 1" TO 3/4" STUD, 1/2-13 NC, 2 1/4 SST NUT HVY.HEX HD. - 1/2 ST.STL. PIPE 3/4" 316L SST SEAMLESS STUD W/NUT & WASHERS ADAPTER,MTG-RTD SVC HD-KTB SCREW CAP ZINC COATED HXHD 3/8 BRKT, DBL J/B - SST C-H EXCELL SCREW CAP ZINC COATED HXHD 1/2 NC - 3 NUT HVY.HEX HD. - 3/8" GALV SCREW CAP-DRILLED HEX HEAD SCREW CAP ZINC COATED HXHD 3/8 HOUSING, KTB - JHJ8, NF16D SCREW CAP ZINC COATED HXHD 3/4 BEARING,THRUST JHJ-8 KTB CAP, END - KTB JHJ-8 SHIM, SST JHJ-8 KTB

Page 2 of 3

QUANTITY 8.000 8.000 1.000 2.000 2.000 32.000 4.000 25.130 3.000 3.000 2.000 1.000 10.000 1.000 2.000 15.880 1.000

UOM PC PC PC PC PC PC PC IN PC PC PC PC PC PC PC IN PC

1.000 1.000 4.000 4.000 5.250 2.000 3.000 12.000 1.000 2.000

PC PC PC PC IN PC PC PC PC PC

8.000 12.000 8.000 1.000 8.000 1.000 1.000 1.000

PC PC PC PC PC PC PC PC

Power Transmission Div.

LIST OF PARTS Unit: Unit Rev: Drawing: Serial Numbers:

NF1619D B 1121076201 11210762-01

ITEM 0071 0072 0073 0074 0075 0076 0077 0079 0080 0081 0082 0083 0084 0085 0300 0301 0302 0303

PART NUMBER E7077737 18900101 22248100 E7089480 E7085144 E7087597 100262804 100262007 E7056645 AM086262 22346700 E7056645 21318200 100264327 1121076260 1121076263 E7095878 1121076250

0307 0308 0309 0310 0311

19679100 22194200 22688400 E7085065 22688500

Date: 03/06/2014 Rev: A

Sales Order: 11210762 Customer: NUOVO PIGNONE SRL Customer PO: 439887277 / 43989466

PART DESCRIPTION SCREW CAP ZINC COATED HXHD 5/8 COVER, DRAIN - NF1919D COVER, SIDE ACCESS NF1619D SEAL, RING - FLOATING - 6 1/2" FLANGE 3" SAE 4 BOLT BLIND SCREW, CAP - 5/8 NC X 3 BAFFLE, LSP WIND - NF16D, 7.035 ID BAFFLE, WINDAGE - LSP, NF16D PIPE 3/8" STD, ERW FBN, PER AS SCREW CAP HXHD 3/8X2 1/4 BAFFLE,LSP WIND-NF16D,6.50 ID PIPE 3/8" STD, ERW FBN, PER AS CAPSCREW, HX HD-DR/HD 3/8-16NC SPACER, J-BOX BRACE KIT, ELECTRICAL - NF1619D KIT, ELECTRICAL - NF1619D ORIFICE, PLATE KIT, PAINT - CARBOLINE, RAL 7035, GENP STUD, 1 1/4"-7NCX12 9/16 LONG STUD, 1 1/4"-7NC X 7-9/16 LONG NUT, SELF SEAL 1-1/4-7 NC SCREW CAP ZINC COATED HXHD 3/4 WASHER, SELF SEAL 1-1/4-7 NC

QUANTITY 8.000 2.000 2.000 1.000 1.000 4.000 1.000 1.000 12.000 8.000 1.000 2.000 8.000 1.000 1.000 1.000 1.000 1.000

UOM PC PC PC PC PC PC PC PC IN PC PC IN PC PC PC PC PC PC

14.000 4.000 14.000 10.000 14.000

PC PC PC PC PC

Parts with item numbers of 300 and above are not shown on the drawings. This document and all information thereon is CONFIDENTIAL and is the property of Lufkin Industries, Inc. It shall be used only as authorized. Page 3 of 3

10 4

8

11

19

9

20

21

77

79

80

81

68

7

66

3

67

2 69

5

82 12

13

70

71

SCALE

6

83 14

DETAIL KTB SCALE 0.250

84 15

0.063

16

74

23

SEE DETAIL

24

25

32

26

27

28

29

30

31

KTB

63

65

49 52

53

54

55

50

51

44

45

47

48

56

57

75

LUFKIN GEARS

76

61

62

MODEL NO.

85

SERIAL NO.

NF1619D 11210762-01

ORDER NO.

59

60

ITEM NO. ACTUAL K FACTOR

33 17

44

11210762

45

46

REV.

A

37

73

38

64

72

1

15/64, 2-PLACES DESCRIPTION OF CHANGE

CHANGED TO A LARGER VIBRATION JUNCTION BOX AND MADE NECESSARY ADJUSTMENTS

43

CUSTOMER:

P/O. NO.:

CHGD BY DATE

SPEC.

API 613 5TH ED.

NO OF TEETH

GR/PIN

LUBRICANT AGMA NO.

439887277

PRIME MOVER:

THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND.

ONE

ARRANGEMENT:

GAS TURBINE

DRIVEN EQUIPMENT: INSTALLATION PLAN: ASSEMBLY DRAWING:

39

DATED:

R-L

ROTATION, HS:

CENTRIFUGAL COMPRESSOR 11210762IP

LOCATION OF INSTALLATION:

40

41

MASS ELASTIC:

WIRING DIAGRAM:

LA FLORENA, COLUMBIA

11210762ME 11210762WD

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED

PREP. BY:

AJM

9/12/13

CHECKED BY:

RFE

10/31/13

Andrew McKinnon

ENGINEERING RELEASE:

RPM HP

1.63

- - -

ISO GRADE

150

GALS

ISO VG 32

3/6/14

BER O

INDUSTRIES, INC. LUFKIN, TEXAS - USA

DATE

CERTIFIED BY:

43047

EM

07/19/13

INCR/RDCR

GEAR RATED

RPM

76/41

42

C'CW

11307

OIL SUMP CAPACITY

AGMA #0

LUFKIN

NUOVO PIGNONE

NO. OF UNITS:

AJM 3/4/14

45

RATED OUTPUT

UNIT RATED AND BUILT PER:

58

44

6100

M

36

RATED INPUT

F

ORIFICE KTB

35

1.854:1

API SERVICE FACTOR

269.37

VISCOSITY SSU @ 100 F

34

GEAR RATIO

INDUSTRIES, INC. Lufkin, Texas

Parts List No.

(Serial No.)

11210762-01

A

309GPM AT 1170 LPM AT

HEAT REJECTION RATE

25 PSI 172 kPa 2552499 749

& 131 & 55 BTU/HR KW

F C

**************************************** CERTIFIED DATE

9.

Andrew McKinnon

- DENOTES CENTER OF GRAVITY LOCATION.

10. DIMENSIONAL INTERPRETATION = INCHES [MILLIMETERS] UNLESS NOTED OTHERWISE. 11. INSTRUMENTATION LEGEND: VX1 - HS DE HORIZ. V/P TE1A - HS DE RTD VY1 - HS DE VERT. V/P TE1B - HS DE RTD VX2 - HS NDE HORIZ. V/P TE2A - HS NDE RTD VY2 - HS NDE VERT. V/P TE2B - HS NDE RTD VX3 - LSP DE HORIZ. V/P TE3A - LSP DE RTD VY3 - LSP DE VERT. V/P TE3B - LSP DE RTD VX4 - LSP NDE HORIZ. V/P TE4A - LSP NDE RTD VY4 - LSP NDE VERT. V/P TE4B - LSP NDE RTD VA4A - LSP NDE AXIAL V/P TE5A - THRUST BEARING DE RTD VA4B - LSP NDE AXIAL V/P TE5B - THRUST BEARING DE RTD A1 - HS DE ACCLRM TE6A - THRUST BEARING NDE RTD A3 - LSP DE ACCLRM TE6B - THRUST BEARING NDE RTD KP2 - HS NDE K/P TE6C - THRUST BEARING NDE RTD KP4 - LSP NDE K/P "DE" - DRIVE END "NDE" - NON DRIVE END 12. EXPECTED BEARING BABBIT TEMPERATURE AT FULL SPEED, FULL LOAD AND 131 OIL INLET TEMPERATURE HS BEARINGS: 200 F [93 C] LSP BEARINGS: 199 F [93 C] 13. ORIFACE PLATE TO BE INSTALLED ON 4" ANSI FLANGED OIL INLET 0.118" [3.00] INSIDE DIAMETER IS DEFINED AFTER MECHANICAL RUN TEST

3/6/14

****************************************

2.50 [63.5 ] LIFTING PROVISION, 4-PLACES AS SHOWN 73.91 [1877.3 ]

VY3

CL

31.00 [787.4 ] 16.74 [425.1 ] TYP

[

UNIT

]

.79 [20.0 ] TYP

F [55 C]

SECTION

23.81 [604.8 ]

12.50 [317.5 ]

1.50 [38.1 ]

B-B

KP2

13.56 [344.5 ]

13.56 [344.5 ]

39.13 [993.8 ] 1-1/2" NPT UNIT PURGE CONNECTION, EITHER END

6.00 [152.4 ]

UNIT

HS

CL

CL

LSP

1.50 [38.1 ]

1.44 [36.5 ]

24.38 [619.1 ] 28.13 [714.4 ]

TE2A TE2B TE3A TE3B

19.50 [495.3 ] TO OUTLET FLANGE

1.44 [36.5 ]

1.00 [25.4 ]

7.06 [179.2 ]

36.14 [917.9 ]

32.25 [819.2 ] 3.50 [88.9 ]

11.56 [293.7 ]

11.56 [293.7 ]

1.00 [25.4 ]

M10 X 1.5 EARTH GROUNDING BOSS, 1-EACH END

10.50 [266.7 ] OIL INLET

4" X 150 LB ANSI FF STUDDED FLANGE CONNECTION, OIL TO GEAR UNIT, THIS END ONLY. (BLIND FLANGED CLOSURE FOR SHIPPING.) BOLTING PROVIDED BY LUFKIN

19.31 [490.5 ] OIL INLET

A

DESCRIPTION OF CHANGE

CHGD BY DATE

AJM 3/4/14

REV.

DESCRIPTION OF CHANGE

CHGD BY DATE

TE1A TE1B TE4A TE4B

11.49 [291.8 ] 66.88 [1698.6 ]

PLAN, INSTALLATION -

THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND.

CHANGED TO A LARGER VIBRATION JUNCTION BOX; DIMENSION CHANGED TO 57.88 WAS 55.51; DIMENSION CHANGED TO 26.63 WAS 24.63

VX4

TE6C

23.25 [590.6 ]

REV.

54.25 [1378.0 ]

18.00 [457.2 ]

ENGR. CODE NO.

SK20128-8

8.42 [213.8 ]

VX1

HS

.94 [23.8 ]

CUSTOMER DRAIN CONNECTION 4.33 [110.0 ]

26.63 [676.3 ] KP4

CL

UNIT

VX2

CL 6.00 [152.4 ]

16.50 [419.1 ]

17.50 [444.5 ]

7.50 [190.5 ]

VX3 12.00 [304.8 ]

19.25 [489.0 ]

VY4

CL

10.00 [ 254.0 ] TYP

16"-150 LB ANSI FF, STUDDED FLANGE CONN UNIT OIL DRAIN, EITHER END BOLTING PROVIDED BY LUFKIN

A

68.75 [1746.3 ] MINIMUM COVER REMOVAL

4.00 [101.6 ]

7.50 [190.5 ]

2"-150# RF FLANGE CONNECTION FOR BREATHER

VY1

A1

A

LSP

INSPECTION DOOR

VA4B

9.50 [241.3 ]

1"X150# ANSI RF FLANGE KTB CONNECTION. (316L SST PIPE)

VY2

2.50 [63.5] LIFTING PROVISION 4 PLACES AS SHOWN

VA4A

13.940 .015 [ 354.08 .38 ]

10.00 [ 254.0 ] TYP

TE5B TE6B

TE5A TE6A

HS SHAFT END DETAIL SEE SHEET 2 OF 2

23.81 [604.8 ]

3/4 NPT AXIAL V/P PROVISION, 1.13 [28.6] FROM MOUNTING TO SENSING SURFACE

39.72 [1008.8 ]

SEE HS COUPLING GUARD ADAPTER DETAIL SEE SHEET 2 OF 2

]

26.81 [681.0 ]

.63 [15.9 ]

THICK,

A3

57.88 [1470.0 ]

5.00 [127.0 ]

25.94 [658.8 ]

[

34.06 [865.0 ]

.08 [1.9 ]

CL UNIT

33.13 [841.4 ]

.79 [20.0 ] TYP +.0010 1.5748 -.0000 +.025 40.000 -.000 TYP

.79 [20.0 ] TYP

CL

16.56 [420.7 ]

28.43 [722.0 ]

+.0010 1.5748 -.0000 +.025 40.000 -.000 TYP

46.38 [1177.9 ]

17.38 [441.3 ]

27.63 [701.7 ]

15.50 [393.7 ]

TEMPERATURE

MAX OIL FLOW

2.56 [65.1 ] HEX FLAT

28.75 [730.3 ]

VIBRATION

UNITS LESS LUBE SYSTEM

23.25 [590.6 ]

LSP

F MAX TEMP C MAX TEMP

18.13 [460.4 ]

1"-8 NC [25.4] LEVELING SCREWS, 4 PLACES AS SHOWN

CL

---

3.13 [79.4 ] HS

---

57.88 [1470.0 ]

1.63 [41.3 ]

CL

--GPM AT --LPM AT

3.38 [85.7 ]

SEE LSP COUPLING GUARD ADAPTER DETAIL SEE SHEET 2 OF 2

3.937 [100.00] ACROSS FLATS, MANUAL TURNING PROVISION W/ REMOVABLE COVER

LSP

REQ'D WATER FLOW

1.75 [44.5] THRU, 3.75 [95.3] SPOTFACE TO CLEANUP, 4 HOLES FOR FOUNDATION BOLTS, GRADE 5 OR EQUIVALENT.

CL

NUOVO PIGNONE CUSTOMER 439887277 CUSTOMER ORDER NO. 11210762 LUFKIN ORDER NO. 11307 1.854:1 INPUT 6100RPM, OUTPUT RPM, RATIO 108232 HP AGMA MECH. RATING, SF= 1.0, 80709 KW API S.F. = 1.63 2.51 43047 HP SERVICE RATING, SF= , 32100 KW F.) RECOM'D. LUBE OIL LT. TURBINE (150 SSU AT 100 ISO VG 32 (32 CST AT 40 C.)

18.307 .020 [ 465.00 .50 ]

HS

LUFKIN INDUSTRIES, INC. LUFKIN, TEXAS

LSP SHAFT END DETAIL SEE SHEET 2 OF 2

CL

****************************************

NOTES: 1. ESTIMATED NET UNIT WT. = 17,100 LBS. [7756 KG.] COMPLETE UNIT MAY BE LIFTED FROM EITHER 4-HOLE SET OF LIFTING PROVISIONS. 2. HEAVIEST MAINTENANCE LIFT = 2917 LBS. [1323 KG.] - LSP ASSEMBLY. 3. REFER TO PARTS LIST 11210762-01 FOR FURTHER INFORMATION. 4. INTERCONNECTING PIPING MUST BE CLEANED BEFORE UNIT OPERATION. 5. THIS UNIT TO BE BUILT PER API-613 FIFTH EDITION SPECIFICATIONS, DATED FEB 2003. 6. DESIGN RADIAL BEARING CLEARANCES: HS BRG.: 0.0080 - 0.0100" [0.203 - 0.254] LSP BRG.: 0.0120 - 0.0140" [0.305 - 0.368] THRUST BEARING ENDPLAY: 0.014 - 0.018" [0.30 - 0.36] 7. VIBRATION EQUIPMENT SET POINTS: HS PINION DISPLACEMENT - ALARM 1.75 MILS [44.5 microns] PEAK TO PEAK SHUTDOWN 2.50 MILS [63.5 microns] PEAK TO PEAK LSP SHAFT DISPLACEMENT - ALARM 2.00 MILS [50.8 microns] PEAK TO PEAK SHUTDOWN 3.00 MILS [76.2 microns] PEAK TO PEAK LSP AXIAL DISPLACEMENT - ALARM 5.00 MILS [127.0 microns] INTO BABBITT SHUTDOWN 10.00 MILS [254.0 microns] INTO BABBITT 2 CASING ACCELERATION - ALARM 6g's [58840 mm/s ] PEAK NOTE: THESE VALUES ARE ESTIMATES ONLY. FIELD CONDITIONS WILL DICTATE FINAL ALARM AND SHUTDOWN VALUES WHICH MAY BE HIGHER OR LOWER THAN THESE STARTING VALUES. 8. TEMPERATURE MONITORING PROTECTION EQUIPMENT SET POINTS: EMBEDDED TEMPERATURE SENSOR IN BEARING SHELL ALARM SETTING 225 F. [107 C.] RISING SHUTDOWN SETTING 240 F. [116 C.] RISING

MATERIAL SPECIFICATIONS

DATE

WIRING DIAGRAM

11210762WD

MASS ELASTIC

11210762ME

INCREASER

AJM

8/6/13

CHK

RFE SCALE

APP

JWL

0.083

N/C-CAM READY

RELEASED FROM DESIGN ENGINEERING:

PERTAINS TO / ALSO USED ON 11210762

C'CW ROTATION,

1.854:1 RATIO DWN

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED OTHERWISE

S/O

R-L UNIT,

NF1619D

INDUSTRIES, INC. LUFKIN, TEXAS

SUPERSEDED BY:

11210762IP SHEET 1 OF 2

A

DYNAMIC LOAD (OVERTURNING MOMENT) DUE ONLY TO TANGENTIAL FORCE AT RATED OPERATING CONDITIONS

NOTE: DYNAMIC LOAD AT OVERLOAD TORQUE CONDITIONS IS DETERMINED BY MULTIPLYING THE DYNAMIC LOAD AT OPERATING CONDITIONS BY THE RATIO OF THE TANGENTIAL LOAD AT OVERLOAD CONDITIONS TO THE TANGENTIAL LOAD AT NORMAL OPERATING CONDITIONS.

DYNAMIC LOAD 684431 IN-LB 77330 NM

INCR R-L C'CW

STATIC LOAD

.820 .015 [ 20.83 .38 ]

17.75 [ 450.9 ] O.D.

DYNAMIC LOAD DUE ONLY TO RESIDUAL UNBALANCE IN ROTATING ELEMENTS OPERATING AT MAXIMUM ALLOWABLE VIBRATION LEVELS

17100 LB 7756 KG

ALARM SETTING

PINION GEAR

LOAD AT

SHUTDOWN SETTING

3273.45 LB

0.0025 IN.

VIBRATION LEVEL

ALARM LEVEL

44.5 µM

1484.81 KG

0.00175 IN. 0.002 IN.

3080.46 LB

50.8 µM

1397.27 KG

SHUTDOWN LEVEL

63.5 µM

2121.16 KG

76.2 µM

4620.7 LB

2095.91 KG

HS COUPLING GUARD ADAPTER DETAIL SCALE

+ B -

+ D -

DETAIL- MECHANICAL & THERMAL MOVEMENT

45

22.913 BC [581.99 ] +.015 -.000 +.38 12.42 -.00

.489

HS PINION

E +

18.0

11.190 .015 [ 284.23 .38 ]

M10 X 1.5 TAP THRU 16-HOLES EQUALLY SPACED ON B.C. SHOWN.

23.75 [603.3 ] O.D.

- C +

11.7505 .0005 [ 298.463 .012 ]

11.690 .015 [ 296.93 .38 ]

0.125

B.C.

13.940 .015 [ 354.08 .38 ]

13.695 .005 [ 347.85 .12 ]

- A + CENTERLINE OF SHAFTS, UNIT COLD, SHAFTS AT REST

12.875 [327.03 ]

15

22.5

4676.36 LB

+ F -

LSP SHAFT

.185 .005 [ 4.70 .12 ]

LOAD AT

VIBRATION LEVEL

0.003 IN.

M10 X 1.5 TAP THRU, 8-HOLES EQUALLY SPACED ON B.C. SHOWN.

16.50 [419.1 ] B.C.

.375/.378 [9.53/9.60] REAMED 20-HOLES EQUALLY SPACED ON B.C. SHOWN

.405 .005 [ 10.29 .12 ]

[

SECTION C-C

11.25

DETAIL- AXIAL THERMAL GROWTH

]

HS SHAFT END DETAIL SCALE

0.333

ALIGNMENT DATA INCHES [MM]

-.001 [-.033]

LSP HORIZ "C"

LSP VERT "D"

HS AXIAL "E"

LSP AXIAL "F"

+.025 [+.647]

+.011 [+.279]

+.019 [+.485]

+.019 [+.483]

+.023 [+.579]

+.029 [+.744]

+.022 [+.551]

+.013 [+.329]

+.023 [+.582]

+.009 [+.230]

+.015 [+.388]

+.022 [+.559]

+.016 [+.398]

LSP COUPLING GUARD ADAPTER DETAIL

+.027 [+.681]

+.019 [+.477]

SCALE

1.001/1.003 [25.425-25.476] REAMED, 18 HOLES EQUALLY SPACED ON B.C. SHOWN. C'BORE FAR SIDE TO DIMENSIONS SHOWN

2.520 .020 [ 64.01 .50 ]

1.260 .008 [ 32.00 .20 ]

.138 .020 [ 3.51 .50 ]

0.125

+.020 -.000 +.50 47.00 -.00

1.850

[

16.142 [410.00 ]

20

B.C.

]

TPJ BEARING

18.307 .020 [ 465.00 .50 ] LSP

104 F 40 C

-.001 [-.033]

HS VERT "B"

UNIT

CL

86 F 30 C

-.001 [-.033]

AXIAL THERMAL GROWTH

HS

68 F 20 C

HS HORIZ "A"

RADIAL MECHANICAL & THERMAL MOVEMENT

CL

AMBIENT TEMP.

30

CL

+.0000 +.0014 +.000 320.037 +.036

12.5999

[

PRESSURE DAM ORIENTATION

]

UPLOADED PINION, DOWNLOADED GEAR INCREASER

SECTION A-A LSP SHAFT END DETAIL SCALE 0.250

EXPECTED CONTACT ACROSS PINION FACEWIDTH AT NO LOAD: WING, NONDRIVE END (BLIND)

REV.

APPROX 80 % OF HELIX WIDTH, MINIMUM

DESCRIPTION OF CHANGE SEE SHEET 1 OF 2

APEX

CHGD BY DATE

REV.

APPROX 25% OF HELIX WIDTH, TOWARD APEX

DESCRIPTION OF CHANGE

WING, DRIVE END (EXT.)

PLAN, INSTALLATION - NF1619D

ENGR. CODE NO. THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND. CHGD BY DATE

MATERIAL SPECIFICATIONS

R-L UNIT, C'CW ROTATION, INCREASER 1.854:1 RATIO DWN

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED OTHERWISE

DATE

AJM

8/6/13

CHK

RFE SCALE

APP

JWL

0.083

N/C-CAM READY

RELEASED FROM DESIGN ENGINEERING:

PERTAINS TO / ALSO USED ON

INDUSTRIES, INC. LUFKIN, TEXAS

SUPERSEDED BY:

11210762IP SHEET 2 OF 2

A

16.50 [419.1 ]

HS PINION 18.31 [465.0 ]

LSP GEAR

12.60 [320.0 ]

.14 [3.5 ]

(INTEGRAL)

2.52 [64.0 ]

TEETH

PITCH DIA

GROOVE DIA

41

11.564

10.698

76

3.94 [100.0 ] ACROSS FLATS

WR 8.04 [204.1 ]

7.00 [177.8 ]

2.50 [63.5 ] 5.50 [139.7 ]

6.69 [170.0 ]

10.25 [260.4 ]

16.50 [419.1 ] CL OF BRG

143248 IN

2

2

[468 KG] 2915 LBS

LBS 2

LBS

2

[55.910 KG*M

NORMAL

NDP = 4

[1322 KG]

44.795 IN

2

52.563 IN

2

2

[28900.00 MM ]

[184.15] 2

1031 LBS

LBS

PROJECTED AREA

7.250

REFERRED TO LSP = 191054 IN

2

[41.920 KG*M ]

NOTE: VALUES USED FOR CALCULATIONS ARE 3 3 DENSITY = .283 LBS/IN [7833.4 KG/M ]

34.06 [865.0 ]

2

[33911.22 MM ] ]

HELIX ANGLE = 27.580199

6

SHEARING MODULUS OF ELASTICITY = 11.8 X 10

LBS/IN

2

[81.4 X 10

3

MPa]

DIMENSIONAL INTERPRETATION = INCHES [MILLIMETERS] UNLESS NOTED OTHERWISE.

7.24 [183.8 ] 10.70 [271.7 ]

58 Rc

[170.00]

[184.15]

WT

[4.072 KG*M ]

6.693

7.250

2

13913 IN

BEARING LENGTH

[170.00]

20

58 Rc

9310H

[522.48]

WR

MODULE = 6.35

11.63 [295.3 ]

.13 [3.2 ]

2

20.570

6.693

PRESSURE ANGLE =

.38 [9.5 ]

8.00 [203.2 ]

7.75 [196.9 ] 11.38 [288.9 ]

[544.47]

LOW SPEED

HEX TURNING PROVISION

1.75 [44.5 ]

21.436

9310H

[271.73]

BEARING BORE

HIGH SPEED

.38 [9.5 ]

[293.73]

MATERIAL HARDNESS

SHAFT STIFFNESS:

19.00 [482.6 ] BAND OD TYP

8 8 HS PINION: 1.42 X 10 IN LBS/RAD [.16 X 10 N M/RAD] FROM MESH CENTERLINE TO FACE OF UPSET FLANGE.

16.75 [425.5 ] CL OF BRG

8 8 LSP SHAFT: 1.50 X 10 IN LBS/RAD [.17 X 10 N M/RAD] FROM MESH CENTERLINE TO FACE OF UPSET FLANGE.

2.50 [63.5 ] 23.00 [584.2 ] 10.25 [260.4 ]

18.38 [466.7 ] CL OF BRG

2.00 [50.8 ]

10.70 [271.7 ]

28.43 [722.0 ]

HS SHAFT

LSP SHAFT

7.24 [183.8 ]

6.50 [165.1 ]

5.07 [128.9 ]

.41 [10.3 ]

.06 [1.6 ] TYP

16.75 [425.5 ] CL OF BRG

3.75 [95.3 ]

11.69 [296.9 ]

.19 [4.7 ]

11.19 [284.2 ]

.82 [20.8 ]

11.75 [298.5 ]

PSI

MPA

95,000

655

95,000

655

ULTIMATE TENSILE PSI

MPA

125,000

862

125,000

UNADJUSTED ENDURANCE LIMIT

862

PSI

MPA

62,500

431

62,500

431

11.00 [279.4 ]

6.69 [170.0 ]

8.75 [222.3 ]

.70 [17.7 ]

18.00 [457.2 ] BAND ID TYP

TENSILE YIELD

MINIMUM EXPEDTED SHAFT TENSILE PROPERTIES

5.06 [128.6 ]

1.38 [34.9 ]

8.13 [206.4 ]

13.94 [354.1 ]

DIAGRAM, MASS ELASTIC - NF1619D,

ENGR. CODE NO. THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND.

SK19127-4

REV.

DESCRIPTION OF CHANGE

CHGD BY DATE

MATERIAL SPECIFICATIONS

DATE

I/P

11210762IP

AJM

10/1/13

CHK

RFE SCALE

APP

- - -

JWL

RELEASED FROM DESIGN ENGINEERING:

PERTAINS TO / ALSO USED ON 11210762

RATIO 1.854:1 DWN

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED OTHERWISE

S/O

INCREASER, R-L UNIT

N/C-CAM READY

INDUSTRIES, INC. LUFKIN, TEXAS

SUPERSEDED BY:

11210762ME

TEMPERATURE MONITORING

R-L JUNCTION BOX *SEE TYPICAL JUNCTION BOX LAYOUT A1

LOCATION

RED WHITE

TE-341/A TE3A TE-341/B

LSP DE RADIAL RTD

WHITE

BLUE YELLOW YELLOW RED WHITE

TE-342/A TE3B TE-342/B

LSP DE RADIAL RTD

WHITE

BLUE YELLOW YELLOW RED WHITE

TE-343/A TE4A TE-343/B

LSP NDE RADIAL RTD

WHITE

BLUE YELLOW YELLOW RED WHITE

TE-344/A TE4B TE-344/B

LSP NDE RADIAL RTD

WHITE

BLUE YELLOW YELLOW

LIQUIDTIGHT FLEXIBLE METALLIC CONDUIT WITH INTEGRAL COPPER GROUNDING WIRE

1

29

2

30

3

31

4

32

5

33

6

34

7

35

8

36

9

37

10

38

11

39

12

40

13

41

14

42

15

43

16

44

17

45

18

46

19

47

20

48

21

49

22

50

23

51

24

52

25

53

26

54

27

55

28

56 57 58 59 60 61 62

LOCATION

RED

LUFKIN ID NO.

CUSTOMER TAG NO.

64

WHITE WHITE

THRUST BEARING INBOARD (DE) RTD

BLUE YELLOW YELLOW

TE-345/A TE5A

65 66 67

TE-345/B

68 69 70

RED

71

WHITE WHITE

THRUST BEARING INBOARD (DE) RTD

BLUE YELLOW YELLOW

TE-346/A TE5B TE-346/B

72 73 74 75 76 77

RED

78

WHITE

THRUST BEARING OUTBOARD (NDE) RTD

WHITE

BLUE YELLOW

TE-347/A TE6A TE-347/B

YELLOW

79 80 81 82 83 84

RED

85

WHITE

THRUST BEARING OUTBOARD (NDE) RTD

WHITE

BLUE YELLOW

TE-348/A

86 87

TE6B TE-348/B

YELLOW

88 89 90

RED

LOCATION

LUFKIN ID NO.

CUSTOMER TAG NO.

WHITE

BLUE YELLOW

HS NDE RADIAL RTD

THRUST BEARING OUTBOARD (NDE) RTD

WHITE

BLUE YELLOW

TE-349/A TE6C

FLEXIBLE METALLIC

LIQUIDTIGHT FLEXIBLE METALLIC WITH STAINLESS STEEL CORE. PVC COATING, ANACONDA SEALTITE HCI

CONDUIT FITTINGS

SEALTITE FITTINGS

LIQUIDTIGHT FITTINGS MATCHED TO ANACONDA SEALTITE CONDUIT FOR IP67 RATING, STAINLESS STEEL

HOUSING EXIT FITTINGS

OIL SEAL

1 PER HOUSING EXIT, UP TO 4 EXITS PER FITTING, MINCO FG, STAINLESS STEEL, SILICONE GROMMET

SERVICE HEADS

NONE

RTD LEADS TERMINATE IN JUNCTION BOX

JUNCTION BOX

NEMA 4X, ZONES 1 &2 AEx AND EEx 'e' 'ia' II T6 ATEX II 1 G

BREATHER/DRAIN

YES

CUSTOMER CONNECTIONS

NONE

JUNCTION BOX CONNECTIONS

TERMINAL BLOCKS

JUNCTION BOX ENTRY

MYERS HUB

TE-358/A

PLUGS FOR UNUSED HOLES

EEx'e' PLUGS AND LOCKNUTS

DOMED HEAD, STAINLESS STEEL

TE-358/B

JUNCTION BOX GROUNDING

10 AWG GREEN/YELLOW

GROUNDING FROM MYERS HUB TO GROUNDING BAR IN JUNCTION BOX GROUND BUSBAR TO GROUNDING STUD AND GROUNDING STUD TO HSG

TE-350/B

RED WHITE WHITE

BLUE YELLOW

HS NDE RADIAL RTD

TE-351/A TE2B TE-351/B

YELLOW RED WHITE WHITE

BLUE YELLOW

HS DE RADIAL RTD

TE-352/A TE1A TE-352/B

YELLOW RED WHITE WHITE

BLUE YELLOW

HS DE RADIAL RTD

TE1B

YELLOW

JUNCTION BOX LABELING LOW POINT DRAINS

E7093567

TRAFFOLYTE LABEL NONE

TE-349/B

LOCATED IN BOTTOM GLAND PLATE BY CUSTOMER WEIDMULLER SAK 2.5, BEIGE TERMINALS HUB W/GROUNDING SCREW, NO CONDUIT SEALS PROVIDED, IP66 SEALING WASHER

ENGRAVE WITH REQUIRED MARKING. DO NOT DRILL THRU TO ATTACH. NO SERVICE HEADS

95

* TYPICAL JUNCTION BOX LAYOUT SHOWN NOT TO SCALE CONDUIT HUB FOR JUNCTION BOX ENTRY EEx'e' GROUNDED TO GROUND LUG STAINLESS STEEL (TYPICAL FOR EACH CONDUIT ENTRY)

99 100

110

CUSTOMER CONNECTIONS: NONE

THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND.

DESCRIPTION OF CHANGE 1) REWIRED TEMPERATURE TERMINALS PER CUSTOMER SPECIFICATIONS 2) WIRED PROXIMITORS TO TERMINALS PER CUSTOMER SPECIFICATIONS

PID-LB 02-26-14

MATERIAL SPECIFICATIONS

GROUNDING LUG BREATHER/DRAIN STAINLESS STEEL

GROUNDING BUSBAR WITH 16 TERMINALS

8 RAD V/P, 2 K/P, 2 AX V/P

2 ACCEL, 13 DUPLEX EMB RTDS DWN

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED OTHERWISE

DATE

PID-RH

CHK

09-23-13

AJM SCALE

APP JWL

- - -

N/C-CAM READY

RELEASED FROM DESIGN ENGINEERING:

PERTAINS TO / ALSO USED ON S/O

EEx'de'/NEMA 4X PLUG FOR UNUSED HOLES

DIAGRAM, WIRING - STD V12/W3, MOD T11/W3

ENGR. CODE NO.

CHGD BY DATE

NEMA 4X / IP66 EEx'ia' 'e' STAINLESS STEEL JUNCTION BOX SHOWN NOT TO SCALE

GLAND PLATE

(TOTAL OF 110 TERMS)

A2

MOUNTED IN BOTTOM GLAND PLATE OF JUNCTION BOX

94

98

REV.

CROUSE-HINDS TYPE Ex-CELL MODEL XLVS, 316L STAINLESS STEEL, DUAL RATED, EXTERNAL/INTERNAL GROUNDING STD, 2 SIDE GLAND PLATES AND 1 BOTTOM GLAND PLATE, IP66 AND NEMA 4X, WITH GROUNDING BUSBAR AND 16 GROUNDING TERMINALS

93

97

63

SPRING-LOADED EMBEDDED, DUAL ELEMENT (DUPLEX) RTD'S, 6 WIRE, PLATINUM DIN CALIBRATION, 100 ^ AT 0°C # 0.12% AT 0°C (0.00385 ^ / ^ /°C) 2 PER HS RADIAL BEARING (4 TOTAL) MINCO S102618PDPD3S144B0 2 PER LS RADIAL BEARING (4 TOTAL) MINCO S102618PDPD3S144B0 2 PER THRUST DE (2 TOTAL) MINCO S102618PDPD3S144B0 3 PER THRUST NDE (3 TOTAL) MINCO S102618PDPD3S144B0

CONDUIT

TE2A

YELLOW

DETAILS

13 DUPLEX EMBEDDED RTD'S

96

YELLOW

PART NO.

SENSOR TYPE

TE-350/A

92

WHITE

DESCRIPTION

WHITE

91

RED

ITEM

TERMINAL STRIP

DIN RAIL

ZONE 2, GROUP IIB, T3

TERMINAL STRIP

LUFKIN ID NO.

IEC

TERMINAL STRIP

CUSTOMER TAG NO.

TEMPERATURE JUNCTION BOX

ORDER ELECTRICAL AREA CLASSIFICATION

INDUSTRIES, INC.

11210762

LUFKIN, TEXAS

SUPERSEDED BY:

11210762WD SHEET 1 OF 2

A

PROBE: XE-351/Y PROX: XT-351/Y PROBE: XE-352/X PROX: XT-352/X PROBE: XE-352/Y PROX: XT-352/Y PROBE: XE-353/X PROX: XT-353/X PROBE: XE-353/Y PROX: XT-353/Y PROBE: XE-354/X PROX: XT-354/X PROBE: XE-354/Y PROX: XT-354/Y PROBE: ZE-350/A PROX: ZT-350/A PROBE: ZE-350/B PROX: ZT-350/B PROBE: KE-351 PROX: KT-351 PROBE: KE-352 PROX: KT-352

VX3

LSP DE HORZ. V/P

VY3

VX4

LSP DE VERT. V/P LSP NDE HORZ. V/P

VY4

LSP NDE VERT. V/P

VX2

HS NDE HORIZ. V/P

VY2

HS NDE VERT. V/P

VX1

HS DE HORIZ. V/P

VY1

HS DE VERT. V/P

VA4A

LSP NDE AXIAL V/P

VA4B

LSP NDE AXIAL V/P

VIBRATION MONITORING

DIN RAIL 1

OUTPUT

1

-24VDC

2

COMMON

3 2

OUTPUT

4

-24VDC

5

COMMON

LSP NDE K/P

3

OUTPUT

7

-24VDC

8

COMMON

HS NDE K/P

4

OUTPUT

10

-24VDC

11

COMMON

5

OUTPUT

13

-24VDC

14

COMMON

15 6

OUTPUT

16

-24VDC

17

COMMON

18 19

OUTPUT

7

COMMON

20

-24VDC

21 8

22

OUTPUT

23

COMMON -24VDC

24 9

OUTPUT

25

-24VDC

26

COMMON

10

OUTPUT

28

-24VDC

29

COMMON

30 31

11

COMMON

32

-24VDC

VE-352

A1

HS DE ACCLRM

DESCRIPTION

VIBRATION PROBE TYPE

BENTLY NEVADA 3300XL 8MM PROBE (QTY 12)

E7082882

0.5 M LEAD LENGTH BENTLY NEVADA MODEL 330105-02-12-05-02-05 2 X-Y RADIAL PROBES PER HS SHAFT END (4 TOTAL) 2 X-Y RADIAL PROBES PER LSP SHAFT END (4 TOTAL) 1 HS KEYPHASOR PROBE 1 LSP KEYPHASOR PROBE 2 LSP AXIAL PROBES

VIBRATION PROBE EXTENSION CABLE

BENTLY NEVADA (QTY 12)

E7082884

3300XL 95 OHM UNARMORED 4.5M LENGTH BENTLY NEVADA MODEL 330130-045-00-05

VIBRATION PROBE PROXIMITOR

BENTLY NEVADA (QTY 12)

E7087100

3300XL 5M EFFECTIVE LENGTH BENTLY NEVADA MODEL 330180-51-05

VIBRATION PROBE SERVICE HEADS

ONE PER EACH RADIAL AND AXIAL PROBE

ACCELEROMETER

BENTLY NEVADA (QTY 2)

E7087499

BENTLY NEVADA MODEL 330400-01-05

ACCELEROMETER EXT. CABLE

BENTLY NEVADA (QTY 2)

E7086738

BENTLY NEVADA 12' LENGTH, UNARMORED, MODEL 16925-12

PART NO.

* TYPICAL JUNCTION BOX LAYOUT SHOWN NOT TO SCALE

34

12

COMMON

35

-24VDC

36

WHITE (C) (COMMON)

40

BLACK (A) (SIGNAL)

41

RED (B) (POWER)

42

GREEN (SHIELD)

43

WHITE (C) (COMMON)

44

BLACK (A) (SIGNAL)

45

RED (B) (POWER)

46

GREEN (SHIELD)

47

IP66 STAINLESS STEEL JUNCTION BOX SHOWN NOT TO SCALE

ACCELEROMETER HERMETICALLY SEALED. HOUSED IN STAINLESS STEEL ADAPTER AND ACCESS PROVIDED BY DUAL RATED REDUCER

ACCEL/SPARE CONNECTION

TERMINALS IN JUNCTION BOX

40 WEIDMULLER SAK 2.5, BEIGE TERMINALS

VP AND ACC. CABLE ROUTING

MULTI CABLE / CONDUIT

CHAIN CABLES THROUGH 4 PORT HEAD, 7 = MAX CABLES IN 3/4"

CONDUIT

FLEXIBLE METALLIC

LIQUIDTIGHT FLEXIBLE METALLIC WITH STAINLESS STEEL CORE. PVC COATING, ANACONDA SEALTITE HCI

CONDUIT FITTINGS

SEALTITE FITTINGS

LIQUIDTIGHT FITTINGS MATCHED TO ANACONDA SEALTITE CONDUIT FOR IP67 RATING, STAINLESS STEEL

JUNCTION BOX

NEMA 4X, ZONES 1 &2 AEx AND EEx 'e' 'ia' II T6 ATEX II 1 G

BREATHER/DRAIN

YES

MOUNTED IN BOTTOM GLAND PLATE OF JUNCTION BOX

CUSTOMER CONNECTIONS

NONE

LOCATED IN BOTTOM GLAND PLATE BY CUSTOMER

MYERS HUB

PLUGS FOR UNUSED HOLES JUNCTION BOX GROUNDING

BREATHER/DRAIN GROUNDING BUSBAR WITH 16 TERMINALS

CROUSE-HINDS TYPE Ex-CELL MODEL XLVS, 316L STAINLESS STEEL, DUAL RATED, EXTERNAL/INTERNAL GROUNDING STD, 2 SIDE GLAND PLATES AND 1 BOTTOM GLAND PLATE, IP66 AND NEMA 4X, WITH GROUNDING BUSBAR AND 16 GROUNDING TERMINALS

HUB W/GROUNDING SCREW, NO CONDUIT SEALS PROVIDED, IP66 SEALING WASHER

EEx'e' PLUGS AND LOCKNUTS

DOMED HEAD, STAINLESS STEEL

10 AWG GREEN/YELLOW

GROUNDING FROM MYERS HUB TO GROUNDING BAR IN JUNCTION BOX GROUND BUSBAR TO GROUNDING STUD AND GROUNDING STUD TO HSG

WIRE SHIELDING

ACCELEROMETER CABLES

JUNCTION BOX LABELING

TRAFFOLYTE LABEL

LOW POINT DRAINS

GLAND PLATES

LASNEK STAINLESS STEEL, IP66

ADAPTER AND ATEX REDUCER

JUNCTION BOX ENTRY

GROUNDING LUG

DETAILS

ACCELEROMETER HOUSING

33

39

LSP DE ACCLRM

ZONE 2, GROUP IIB, T3

ITEM

27

37

A3

IEC

VIBRATION JUNCTION BOX

12

38

VE-351

ORDER ELECTRICAL AREA CLASSIFICATION

9

OUTPUT

KP2

A2

6

OUTPUT

KP4

R-L

TERMINAL STRIP

PROX: XT-351/X

LOCATION

TERMINAL STRIP

PROBE: XE-351/X

LUFKIN ID NO.

PROXIMITOR STRIP

CUSTOMER TAG NO.

YES

ACCELEROMETER CABLES CONTAIN A SHIELD THAT IS TERMINATED AT THE TERMINAL BLOCK IN THE JUNCTION BLOCK ENGRAVE WITH REQUIRED MARKING. DO NOT DRILL THRU TO ATTACH. 1 ON EACH LOWEST POINT SERVICE HEAD, SST

48 49

SERVICE ENTRANCE CONDUIT HEAD

50 51 52

DIAGRAM, WIRING - STD V12/W3, MOD T11/W3

ENGR. CODE NO. THIS DRAWING AND ALL INFORMATION THEREON IS CONFIDENTIAL AND IS THE PROPERTY OF LUFKIN INDUSTRIES, INC. IT SHALL BE USED ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES, INC. AND IS SUBJECT TO RETURN ON DEMAND.

80

(TOTAL OF 80 TERMS) REV.

DESCRIPTION OF CHANGE SEE SHEET 1 OF 2

CHGD BY DATE

MATERIAL SPECIFICATIONS

2 ACCEL, 13 DUPLEX EMB RTDS DWN

REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED OTHERWISE

DATE

PID-RH

CHK

09-23-13

AJM SCALE

APP JWL

- - -

N/C-CAM READY

RELEASED FROM DESIGN ENGINEERING:

PERTAINS TO / ALSO USED ON S/O

8 RAD V/P, 2 K/P, 2 AX V/P

INDUSTRIES, INC.

11210762

LUFKIN, TEXAS

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11210762WD SHEET 2 OF 2

A