Maintenance & Trouble Shooting: Hyderabad, 02.03.2017

Maintenance & Trouble shooting Hyderabad, 02.03.2017

Presentation name | place or presenter | YYYY-MM-DD | safety classes 0-3

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General Maintenance of Voith Hydraulic couplings Presentation name | place or presenter | YYYY-MM-DD

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Maintenance Measures With Unit Running Daily: •

Check the oil level in coupling

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Temperatures of bearings, lube oil & working oil

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Lube oil and working oil pressures

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Differential pressure on the lube oil filter

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Maintenance Measures With Unit Running Every 1000 hours of operation:

• Check operating oil for contamination or for its reusability. (centrifuge if required)

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Maintenance Measures With Unit Running Every 3 months:

• Check the vent filter for impurities.

• Measure, record and compare smooth running (vibrations) under the same operating conditions.

In case of any problem, please check first the alignment. 8

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Maintenance Measures when the unit at Standstill Every 2 months:

• Clean vent filter. • Check smooth running of actuator. • Visually inspect gear stage. • Check operating oil for contamination. • Check oil level . In case of too high oil level, check for water content in the oil. 10

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Maintenance Measures when the unit at Standstill Every 8000 hrs of operation or atleast annually: • Analyze operating oil for aging and other specifications. • Inspect and maintain connecting couplings. • Check the actuator functioning. • Check alignment and foundation fixing of hydraulic coupling. • Visual inspection (corrosion, general condition etc) of hydraulic coupling internals by removing inspection cover on top housing.

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Maintenance Measures when the unit at Standstill

• Visual inspection of tooth contact pattern. • Inspection of fusible plugs. •Check and maintain A.O.P. motor

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Maintenance Measures when the unit at Standstill General Overhaul:

In the event of a change in operating behaviour or after max. 7 to 8 years operating time, variable speed & geared variable speed turbo coupling should be overhauled.

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Main housing & Sub assemblies:

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Maintenance Schedule for Voith Variable Speed Couplings and Vorecon 1

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Years

Lube oil filter cleaning / change of elements**

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if necessary

Oil analysis

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quarterly

Visual inspection*

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once a year

Alignment check*

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once a year

Connecting coupling check*

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once a year

Cooler inspection*

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once a year

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after approx. 7 to 8 years

Overhaul

Permanently: monitoring of oil pressures, temperatures, vibrations, speed (covered by monitoring system)

* Intervals can be increased as long as operating behaviour doesn't change ** Intervals depend on cleanliness and environmental conditions 18

Trouble shooting Presentation name | place or presenter | YYYY-MM-DD

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Start-up Trouble

Cause(s)

1. Scoop tube in 0% position

Driven machine cannot start after the driving machine has reached its rated speed

Action(s)

Move scoop tube in 100% direction.

2. Oil pump not delivering any oil

Check the oil level in the sump. Check the direction Check oil pump itself.

3. Starting torque too high. Driven machine blocked.

Check the driven machine itself.

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Start-up Trouble

Cause(s)

Action(s)

1. Driven machine is jammed.

Remove obstacles. (Check fusible plugs)

2. Oil flow too low

Check oil flow

Coupling heats up excessively during “start-up”

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Start-up Trouble

Cause(s)

1. Lack of cooling water. Water is too warm Cooler contaminated

Action(s)

Check cooling system. Clean cooler.

Coupling heats up excessively during “operation” 2. Over loading of the coupling

Check design data (Check fusible plugs)

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Output Speed Trouble

Fluctuations of output speed during auto control of coupling

Cause(s)

Action(s)

1. Improper input signal to the actuator.

Check the controller and calibrate.

2. Actuator speed is too high.

Check and control.

(To & fro movement of control lever) 3. Air entering into the oil circuit.

Check and eliminate.

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Output Speed Trouble

Output speed cannot be controlled

Cause(s)

Action(s)

1. Scoop tube is jammed.

Remove obstacles.

2. Actuator defective

Check the actuator.

3. Input signal problem

Check the controller.

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Output Speed Trouble

Cause(s)

Action(s)

1. Scoop tube not in 100% Position.

Check the scoop tube position.

2. Fusible plugs responded

Find and eliminate the cause. Insert new fusible plugs.

Max.Output speed cannot be reached 3. Too high power requirement of driven machine

4. Working oil flow rate too low

Compare the power data with the project data.Check driven machine for smooth running.

Readjust flow rate.

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Pressure Trouble

Lube oil pressure is low

Cause(s)

Action(s)

1. Lube oil filter clogged

Change over lube oil filter and clean the filter element.

2. Leak in the oil circuits

Check the pipe lines,coolers etc.

3. Ext.lube oil supply too high.

4. Pr.relief valve set too low.

Adapt the orifices.

Correct the setting.

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Pressure Trouble

Differential pressure across double oil filter too high

Cause(s)

1. Lube oil filter clogged

Action(s)

Change over lube oil filter and clean the filter elements.

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Pressure Trouble

Cause(s) 1. Lube oil filter clogged

2. NRV of AOP jammed

Lube oil pressure too low during normal operation

3. Ext.lube oil supply too high.

4. Pr.relief valve jammed or setting distrubed.

Action(s) Change over lube oil filter and clean the filter element.

Check Non return valve

Check the sizing of orifices.

Check the valve & Correct setting.

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Pressure Trouble

Cause(s)

Action(s)

1. Oil level too low

Check oil level & top up.

2. Mechanical wear to pump

Check pump parts.

Working oil pump pressure too low 3. Leakages in the oil circuit.

4. Pr.relief valve jammed or setting distrubed.

Check the internal piping.

Check the valve&Correct the setting.

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Temperature Trouble Lube oil temperature too high downstream of lube oil cooler

Lube oil temperature too high upstream of lube oil cooler

Cause(s) Lube oil Cooler Problem 1. Cooling water flow rate too low 2. Cooling water too warm 3. Cooler is contaminated

1.Fusible plugs responded

Action(s) Increase the cooling water flow rate Check and clean the cooling system

Find and eliminate the cause.Insert new fusible plugs.

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Temperature Trouble

Cause(s) 1. W.Oil pump not delivering oil.

Action(s) Check oil level & top up.

-oil level too low -working oil pump pr<1.5bar -working oil flow rate too low

Working oil temperature exceeds 110 deg C during operation.

2. Fusible plugs responded

Check&Eliminate cause.

3. Working oil cooler.

Check&Eliminate cause.

-cooling water flow rate too low -cooling water too warm -cooler contaminated

4.Operation outside the planned characterisitc curves.

Observe the design data.

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Temperature Trouble

Bearing temperature too high

Cause(s)

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Bearing damage

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Lube oil temperature too high

3. Lube oil pressure too low

Action(s)

Check the bearings and replace.

Check the lube oil cooler.

Check the lube oil system and differential pressure.

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Smooth Running Trouble

Uneven running, vibration and noise

Cause(s)

Action(s)

1.Faulty alignment

Check and correct alignment.

2.Foundation bolts are loose, the foundation is defective

Check the foundation and retighten the foundation bolts.

3. Wear or insufficient lubrication of connecting couplings

Check the connecting couplings.

4. Unbalance of rotating parts

Measure the vibration and check the runner parts.

5. Bearing damage

Check and replace bearings.

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Contact: Ch.Eswara Prasad Sr.Manager- Service Sales India ( Industry) Tel: 0091 40 27173561 Mob:0091 9849201753 [email protected]

Presentation name | place or presenter | YYYY-MM-DD | safety classes 0-3

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Gear optimization| Ralf Bratz | 2017-03-02

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