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Innovative Power Transmission

RENK-MAAG

Field Service
Always Nearby

RENK-MAAG service team

We are ready for takeoff!


Professional, swift and customer focused this is our dynamic service team. Our service technicians work tirelessly the world over all year round to install and maintain gearboxes for our customers. Any necessary repairs are undertaken on site wherever possible. In the event of more complex issues, such as vibrations in the train, we provide professional assistance which could include a vibration measurement and analysis by our testbed specialists. More information about our services can be found in this brochure. We maintain contact with our customers before, during and after the sale of a gearbox. Our goal is the satisfaction of our customers. They appreciate having a competent and reliable partner our RENK-MAAG service team.

Our dynamic service team is ready for takeoff.

Even the best machines need maintenance

Gearbox maintenance
You have chosen to put your trust in a RENK-MAAG gearbox. It is in your hands to preserve the legendary longevity and robustness of this quality product by following the corresponding service and inspection intervals.

On-site support
RENK-MAAG offers world-wide services for all MAAG turbo and marine gearboxes. Certified service technicians with years of experience inspect and maintain the gearboxes in accordance with the customized maintenance schedule to suit your needs. Regular gearbox maintenance ensures safe and reliable system operation.

Certified technicians with years of experience inspect and maintain the gearboxes on site anywhere in the world.

Gearbox condition and availability with maintenance


New

Operating condition

0
Check 1 Check 2 Check 3

Critical range

Safe range

Service life

Other checks...

Service intervals Extend the overall service life through regular maintenance (see Maintenance Schedule attached).

After each inspection or overhaul, our service technicians will provide you on the spot with a system report containing the following points of importance to safety and optimum availability: General condition of the gearbox Possible and detected defects Recommended spare parts Due date and scope of next inspection

Regular gearbox maintenance ensures safe and reliable system operation.

Regular maintenance long operating life

Maintenance schedule
Depending on the number of years of operation or operating hours since commissioning or the last maintenance work, we recommend the following RENK-MAAG standard inspections: 1000 operating hours check This check is undertaken on gearboxes when taken into service. 8000 operating hours check/annual check A brief check through the inspection cover provides an overview of the gearbox condition. 20 000 operating hours check The gearbox is opened but not dismantled to gauge the condition of its interior. This is ideal if you have only a brief shutdown or a limited budget. 40 000 operating hours check This large-scale check involves dismantling, cleaning and re-assembling the gearbox. If necessary, individual components or worn parts are replaced.

Inspection example using a 20 000 operating hours check

Phone:

No.

Process name

-2

-1

Check spare parts stock

Process Project: Interruption Underway

Milestone Collective process Collective process for project Page 1

External processes External milestone Qualifying date

Check 1000 oph 8000 oph 20 000 oph 40 000 oph Installation of installation/ check check check check Commissioning Working days Operating years since last inspection 10 13 1 2 1 34 23 6 7 5+

An operating year is considered to be 8000 operating hours in this table.

Sulzer-Allee 46 P.O. Box 3068 CH-8404 Winte rthur Switzerland

RENK-MAAG GmbH

Phone +41 (0)52 262 89 88 Fax +41 (0)52 262 89 89 info@renk-maag.c h www.renk-maag.c h

AAG Sulze Gm P.O. r-Allee 46 bH B CH-8 ox 3068 Switz 404 Win erland terth ur

RENK

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Phon Fax e +41 (0 +41 )52 26 info 2 (0 @r www enk-m )52 262 89 88 89 89 .renk aag.ch -maa g.ch

Sche

dule

for R

(or latest after 5 years) (on request)

ENK-

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Daily /Con stan Wee tly kly After first 1000 Year oph ly or ever y 800 Ever y 20 0 op 000 h oph Ever y 40 000 oph Spec (or la ial se test rvice after (on re 5 ye ques ars) t)

earb

oxes

Every 20 000 oph Every 40 000 oph

Daily/Constant

After first 1000

Yearly or every

The maintenance schedule is attached to this brochure.

x work Che ck dr ive gr Che ck ro oup fo to Che ck an rs visua r noise an Other couplings lly d re d leak Che (if applicable) tight ck al s Check all bolt en ge l bolt Che connections arbo conn Remarks ck lo x an Maintenance ad ectio Che according to manu chor ns ck no contac ing facturer Gear driven pump t pa X C load X heck tte X X alignm tooth co rn of te Check for noise Che eth and leaks ntac en ck al of according to (red in t pa ignm t X gear Maintenance Che tte manufacturer k or according to manu ent ck, cl met of ge box dr rn (blue facturer X ean allic) Rotary drive/ Turnin Dism ink te iving arbo and an g Gear/ barring x st) mac gear Check drive for Lubr tling and if necess driven hi noise and leaks icatio ary re insp mac ne Xec according Che Check oil level hi pl to manu ne tion ck oi n system of al ace air filtfacturer l leve Che Check all bolt l gear er l ck Dp connections box X Che when operating parts of lu Maintenance X ck X lu be oi according to manu be oi Che l filter facturer Synchronous clutch l X ck lu bricat for water and clea Che Check for noise ion n/re co ck an and leaks d clea system ntent/con place Che X Dismantle, clean, ck, for according m manufactur n ta to check leak er inatio Maint clean an lube oil s X Maintenance n (ana cool enan d if ne according to manu er ce lysis Extra ce facturer Nondestruvtive ) chec of lubricat ssary re testing X X io Che ks fo plac Ultrasonic testing ck va n e lube (toothing, bearin cuum r HET Xsystem Che gs) according to oil filt gear ck in Magnetic partic sy manufacturer er le testing (tooth Instru strumen stem (fu boxes ing) Dye penetrant nctio ts an men testing (toothing, Rec tatio d va X n)recom bearings) ord Operational vibrat lves n (m mended every oper Che 40 000 oph ion measureme onito X (func ating ck op nt and analysis tion) recommended ring Miscellaneous data every 40 000 erat Che of oph ing X shaft mend ck recom Inspection of and ed every 40 000 special tools for Func fit and tig data casi oph gearbox X tio htne Inspection of ng vi Instal n chec ss of special tools for bratio k anchoring latio instru Inspection of n + te n Che men spare parts / spare mp.) X ck fo check tatio gearbox Preservation of r vis n Che spare parts / spare ual da ck pr X gearbox Inspection of mag otec X Che third-party parts e X tive ck tu Verifi passag X bes X es fo catio r leak n of Toot junc s hed X tion according to manu co Che box facturer ck co uplings Important: uplin Che gs fo ck al This Maintenan l bolt r leak Che ce Schedule conn ck lu s is not plant-specifi but does not be ectio Che take the place ns ck of any plant-specifi c; it can also be used as a(re oil pipi according should supplemenng c information. pl Dism be adapted to The work to be ace) lu t to the instruction manu operation. We the antle carrie br recommend having current operating hours al ic shall epla of theRgearbox , clean d out ants be either consid all work perfor ce Oand any abnor on co ered med by one of malities notice -rings and chec uplin d during our experienced service@renk-maa g.ch gs specialists. k X

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work

Weekly

Description of

Special service

Gear

Descr

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X X X X X X X X X X X X X X X X X X X X X X X X X X X

Rem

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ing co nditi on

in op

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8000 oph

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We recommend carrying out standard inspections.

X X X X X X X X X X X X X X

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X X

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X X X X X X X X X X X X X X X

in op er in op ating co nd erat ing co ition nditi on

+ 41 52 262 87

62

RENK-MAAG

GmbH, CH-840

4 Winterthur,

Switzerland We reserve all rights in connec

tion with this docume

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Spare parts
RENK-MAAG recommends holding the following key components in stock: 1 1 1 1 spare spare spare spare set set set set of of of of rotors bearings oil scrapers instrumentation The spare parts can then be replaced immediately, limiting any production downtime to a minimum. Keep in mind that even under the best conditions, it will take several months for spare bearings and rotors to be delivered.

Preparing for deployment and planning

Extensive organisation
Both the RENK-MAAG service technicians and the back office are flexible, quick to respond and reliable. Our service doesnt just cover technical matters, we also organise all administrative aspects of the service, including processing the travel arrangements required, organising travel, special training courses or medical examination and certification. Before they set out, the service technicians are always prepared and instructed by our back office. They are informed of special customer concerns and are provided with details of the gearbox or entire system. Once on site, our service technicians are therefore ready to get started right away.

Coordinating dates
As well as planning deployment, we will happily provide a customised work programme. This provides you with a detailed overview of the work to be undertaken in advance of the service date. You can also plan shutdown times in advance and coordinate them with other work required on your system. This can prevent bottlenecks, such as crane capacities. Once you have opted for a RENK-MAAG service, you can rely on us to take care of everything else. We are a reliable partner for all gearbox maintenance!

You can rely on us to take care Month Month calendar week calendar week calendar week calendar week calendar week calendar week calendar week else. calendar week of everything M29 T30 W31 T01 F02 S03 S04 M05 T06 W07 T08 F09 S10 S11 M12 T13 W14 T15 F16 S17 S18 M19 T20 W21 T22 F23 S24 S25 M26 T27 W28 T29 F30 S01 S02 M03 T04 W05 T06 F07 S08 S09 M10 T11 W12 T13 F14 S15 S16 M17 T18 W19 T20 F21 S22 S

Planning deployment

RENK-MAAG contacts

Agents
Algeria Australia Belgium Botswana Brunei Canada Chile China Congo Egypt Greece Holland Hong Kong India Indonesia Israel Italy Luxembourg Macau Malaysia Mozambique Namibia New Zealand Nigeria Pakistan Peru Poland Russia Saudi Arabia Singapore South Africa South Korea

10

Taiwan Thailand United Arab Emirates USA Venezuela Zambia Zimbabwe

The current contact details are readily available on our website: www.renk-maag.ch
h

nk-m e@re servic

+ 41 5

7 62 262 8

aag.c

Service job on a modern frigate.

11

And if something does happen?

WHAT CAN BE DANGEROUS FOR A GEARBOX? WHAT DO I NEED TO WATCH OUT FOR? Poor lube oil quality or incorrect oil; ask for our list of recommended lube oils. Uneven or incorrect tooth contact Incorrect train alignment Insufficient oil flow Poor foundations Operation during overload Creepage current on the system This list is for information only and is not exhaustive.

The condition of the gearbox often indicates the condition of the entire system. As the most sensitive component in the train, the gearbox very quickly indicates negative changes. This can be seen from a detailed inspection of the gearbox interior. RENK-MAAG recommends regular gearbox checks. In case of general system inspections the gearbox should be part of the inspection too.

The gearbox is often an indicator of the condition of the entire system.

12

Training and qualification

The RENK-MAAG service technicians have undertaken all standard safety trainings and hold the certificates required to undertake the work. Our service technicians attend training courses on an ongoing basis. These cover all health and safety and environmental protection requirements. For the work on oil platforms we attend special safety training courses and make sure knowledge is regularly refreshed. Our customers appreciate our years of practical experience and the fact that we continuously train our staff.

Some impressions of intense training.

13

Additional on-site services

ULTRASONIC TESTING WITH PHASED-ARRAY METHOD The phased-array method uses several ultrasonic elements and electronic delays to produce sound beams which can be electronically controlled, probed, swivelled and focused. This method allows for rapid testing, storage of all data and testing with several angles. Areas of application Testing complex geometries such as involute teeth, cycloid teeth etc. Testing torsion shafts, thrust collars, couplings, pump rotors Testing welding seams on gearbox housings, pressure pipes, basic frames etc. Testing the corrosion of flanged areas, wall thickness measurement etc. CONVENTIONAL ULTRASONIC TESTING The sound waves are radiated through a contact medium into the test body. The returned or transmitted wave patterns are recorded and analysed. Compared with the considerably faster phased-array method, this method has the advantage that it calculates the position and dimension of inclusions, structural cracks, blow holes etc. in the sub-surface structure of the workpiece. Areas of application Testing white metal bearings, especially the bonding between the bearing body and layer of white metal. Testing teeth or other highly loaded parts. Long-term monitoring of gearbox teeth and rotors.

One unit for two ultrasonic measurement methods


By using the phased-array method, we are able to test the toothing of a gearbox with maximum reliability. The same unit can be used to precisely locate any damage and establish its size using conventional ultrasonic testing. RENK-MAAG can therefore make optimum use of both measurement methods and their respective benefits.

14

Scanning electron microscopy


A tooth replica can be used to examine the surface structure of the tooth using scanning electron microscopy. This test is used to explain the causes of slight to major tooth damage such as grey staining, micropitting, electric erosion resulting from creepage current etc.

Other on-site services


Magnetic powder and dye penetration testing for crack testing of highly loaded gearbox parts. Flow rate and pressure measurements on the lube oil system. Endoscopic examination of gearbox parts. Measuring and aligning shaft trains using laser measuring methods or dial gauges. Casing vibration, airborne noise and shaft vibration measurements on the gearbox including the associated analyses. Other services.

Even the slightest damage to the tooth surface provide clues as to the cause.

Need a more in-depth analysis? We will happily send out one of our specialist to test your gearbox.

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RENK-MAAG at your disposal

New products / spare parts / maintenance / testbed


RENK-MAAG supports you before, during and after the purchase: Our sales team is happy to support you when it comes to new equipment or spare parts for couplings and gearboxes of previous MAAG models. New gearboxes and components can be tested on our modern testbed using the latest technology for monitoring and diagnostics of operating conditions, vibrations, temperatures or noise.

Our manufacturing and other operational activities are implemented in accordance with our internal quality assurance system and in strict compliance with ISO 9001 : 2008 and ISO 14001 : 2004.

10.2012_1 e

RENK-MAAG GmbH P.O. Box 3068 Sulzer-Allee 46 CH-8404 Winterthur Phone +41 (0)52 262 89 88 Fax +41 (0)52 262 89 89 info@renk-maag.ch www.renk-maag.ch

RENK-MAAG GmbH

Sulzer-Allee 46 P.O. Box 3068 CH-8404 Winterthur Switzerland

Phone +41 (0)52 262 89 88 Fax +41 (0)52 262 89 89 info@renk-maag.ch www.renk-maag.ch

Maintenance Schedule for RENK-MAAG Turbo Gearboxes


Every 40 000 oph (or latest after 5 years)

Description of work
Gearbox
Check drive group for noise and leaks Check rotors visually Check and retighten gearbox anchoring Check all bolt connections Check load contact pattern of teeth (red ink or metallic) Check no load tooth contact pattern (blue ink test) Check alignment of gearbox driving machine Check alignment of gearbox driven machine Check, clean and if necessary replace air filter Dismantling and inspection of all gearbox parts

Special service (on request)


X X X

Yearly or every 8000 oph

After first 1000 oph

Every 20 000 oph

Daily/Constantly

Weekly

Remarks
in operating condition

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

in uncoupled condition in uncoupled condition in uncoupled condition

Lubrication system
Check oil level Check Dp of lube oil filter and clean/replace Check lube oil for water content/contamination (analysis) Check lubrication system for leaks Check and clean lube oil cooler Check, clean and if necessary replace lube oil filter Maintenance of lubrication system in operating condition

in operating condition according to manufacturer according to manufacturer

Extra checks for

HET

gearboxes
X X X X X X X X X X X X X X X X X X X X X X only for oil-filled couplings X X X X X X in operating condition in operating condition

Check vacuum system (function) Check instruments and valves (function)

Instrumentation (monitoring of shaft and casing vibration + temp.)


Record operating data Check operating data Check fit and tightness of instrumentation Function check Installation check Check for visual damage Check protective tubes Check passages for leaks Verification of junction box

Toothed couplings
Check couplings for leaks Check all bolt connections Check lube oil piping Check (replace) lubricants on couplings Dismantle, clean and check Replace O-rings

RENK-MAAG GmbH

Sulzer-Allee 46 P.O. Box 3068 CH-8404 Winterthur Switzerland

Phone +41 (0)52 262 89 88 Fax +41 (0)52 262 89 89 info@renk-maag.ch www.renk-maag.ch

Every 40 000 oph (or latest after 5 years)

Description of work
Other couplings (if applicable)
Check all bolt connections Maintenance according to manufacturer

Special service (on request)


X X X X X X X X X X

Yearly or every 8000 oph

After first 1000 oph

Every 20 000 oph

Daily/Constantly

Weekly

Remarks
according to manufacturer

Gear driven pump


Check for noise and leaks Maintenance according to manufacturer X according to manufacturer when operating

Rotary drive/Turning Gear/barring gear


Check drive for noise and leaks Check oil level Check all bolt connections Maintenance according to manufacturer X X X according to manufacturer

Synchronous clutch
Check for noise and leaks Dismantle, clean, check Maintenance according to manufacturer X X X according to manufacturer recommended every 40 000 oph recommended every 40 000 oph recommended every 40 000 oph

Nondestruvtive testing
Ultrasonic testing (toothing, bearings) Magnetic particle testing (toothing) Dye penetrant testing (toothing, bearings) Operational vibration measurement and analysis

Miscellaneous
Inspection of special tools for gearbox Inspection of special tools for anchoring Inspection of spare parts / spare gearbox Preservation of spare parts / spare gearbox Inspection of third-party parts X X X X according to manufacturer

Important:

This Maintenance Schedule is not plant-specific; it can also be used as a supplement to the instruction manual but does not take the place of any plant-specific information. The work to be carried out shall be either considered according should be adapted to the current operating hours of the gearbox and any abnormalities noticed during operation. We recommend having all work performed by one of our experienced specialists.

service@renk-maag.ch

+ 41 52 262 87 62

RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland

We reserve all rights in connection with this document.

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