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RENK-MAAG
Field ServiceAlways Nearby
Innovative Power Transmission
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2RENK-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 custo- mers before, during and
after the sale of a gearbox. Our goal is the satis-faction of our
customers. They appre- ciate having a competent and reliable
partner our RENK-MAAG service team.
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3 Our dynamic service team
is ready for takeoff.
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4New
Check 1 Check 2 Check 3 Other checks...
Operating cond
ition
Service life
Critical ra
nge
Safe ra
nge
0
Certified techni-cians with years
of experience inspect and maintain the gear-boxes on site
anywhere in the world.
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.
Service intervals Extend the overall service life through
regular maintenance (see Maintenance Schedule attached).
Lifetime without service
Gearbox condition and availability with maintenance
Even the best machines need maintenance
On-site support
RENK-MAAG offers world-wide services for all MAAG turbo and
marine gear-boxes. 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 mainte-nance ensures safe and reliable system
operation.
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5 Regular gearbox maintenance
ensures safe and reliable system operation.
After each inspection or overhaul, our service technicians will
provide you on the spot with a system report contain-ing 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
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6-2 -1 1 2 3 4 6 7
Phone:
Process name
Project:
Process
Interruption
Underway
Check spare parts stock
Milestone
Collective process
Collective process for project
External processes
External milestone
Qualifying date
Page 1
No.
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 checkThis check is undertaken on gearboxes
when taken into service.
8000 operating hours check/annual checkA brief check through the
inspection cover provides an overview of the gearbox condition.
20 000 operating hours checkThe gearbox is opened but not
dis-mantled 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 checkThis large-scale check involves
dismant-ling, cleaning and re-assembling the gearbox. If necessary,
individual compo-nents or worn parts are replaced.
Inspection example using a 20 000 operating hours check
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7An operating year is considered to be 8000 operating hours in
this table.
InstallationCheck
of installation/ Commissioning
1000 oph check
8000 oph check
20 000 oph check
40 000 oph check
Working days 10 1 3 1 2 3 4 6 7
Operating years since last inspection
1 2 3 5 +
We recommend carrying out
standard inspections.The maintenance schedule is attached
to this brochure.
Insurance spare parts on-site RENK-MAAG recommends holding the
following key components in stock:
1 spare set of rotors 1 spare set of bearings 1 spare set of oil
scrapers 1 spare set of instrumentation
The defective 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 or rotors to be delivered.
Description of work
Daily
/Con
stan
tlyW
eekl
y
Afte
r firs
t 100
0 op
hYe
arly
or e
very
800
0 op
hEv
ery
20 0
00 o
phEv
ery
40 0
00 o
ph (o
r lat
est a
fter 5
yea
rs)
Spec
ial s
ervi
ce (o
n re
ques
t)
Remarks
Other couplings (if applicable)Check all bolt connections
X X X X
Maintenance according to manufacturer
X according to manufacturer
Gear driven pumpCheck for noise and leaks
XMaintenance according to manufacturer
X according to manufacturer
Rotary drive/Turning Gear/barring gearCheck drive for noise and
leaks
X when operating
Check oil level
X X
Check all bolt connections
X
Maintenance according to manufacturer
X according to manufacturer
Synchronous clutchCheck for noise and leaks
XDismantle, clean, check
X X
Maintenance according to manufacturer
X according to manufacturer
Nondestruvtive testingUltrasonic testing (toothing,
bearings)
X recommended every 40 000 oph
Magnetic particle testing (toothing)
X recommended every 40 000 oph
Dye penetrant testing (toothing, bearings)
X recommended every 40 000 oph
Operational vibration measurement and analysis
X
MiscellaneousInspection of special tools for gearbox
X
Inspection of special tools for anchoring
X
Inspection of spare parts / spare gearbox
X
Preservation of spare parts / spare gearbox
X
Inspection of third-party parts
X according to manufacturerImportant: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.
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88
P.O. Box 3068 Fax +41 (0)52 262 89 89
CH-8404 Winterthur [email protected]
www.renk-maag.ch
+ 41 52 262 87 62
[email protected]
RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland
We reserve all rights in connection with this document.
Description of work
Daily
/Con
stan
tlyW
eekl
yAf
ter fi
rst 1
000
oph
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
Remarks
GearboxCheck drive group for noise and leaks
X
in operating condition
Check rotors visually
XX
XX
Check and retighten gearbox anchoring
XX
XX
Check all bolt connections
XX
XX
Check load contact pattern of teeth (red ink or metallic)
XX
XX
Check no load tooth contact pattern (blue ink test)
X
XX
in uncoupled condition
Check alignment of gearbox driving machine
X
XX
in uncoupled condition
Check alignment of gearbox driven machine
X
XX
in uncoupled condition
Check, clean and if necessary replace air filter
X
Dismantling and inspection of all gearbox parts
X
Lubrication systemCheck oil level
X
in operating condition
Check Dp of lube oil filter and clean/replace
X
Check lube oil for water content/contamination (analysis)
XX
XX
Check lubrication system for leaks
X
in operating condition
Check and clean lube oil cooler
X
XX
according to manufacturer
Check, clean and if necessary replace lube oil filter
X
Maintenance of lubrication system
Xaccording to manufacturer
Extra checks for HET gearboxes
Check vacuum system (function)
XX
XX
Check instruments and valves (function)
XX
XX
Instrumentation (monitoring of shaft and casing vibration +
temp.)
Record operating data
X
in operating condition
Check operating data
X
in operating condition
Check fit and tightness of instrumentation
X
Function check
X
Installation check
X
Check for visual damage
X
Check protective tubes
X
Check passages for leaks
X
Verification of junction box
X
Toothed couplingsCheck couplings for leaks
X
Check all bolt connections
XX
XX
Check lube oil piping
X
Check (replace) lubricants on couplings
XX
Xonly for oil-filled couplings
Dismantle, clean and check
X
Replace O-rings
X
Maintenance Schedule for RENK-MAAG Turbo Gearboxes
RENK-MAAG GmbHSulzer-Allee 46
Phone +41 (0)52 262 89 88
P.O. Box 3068
Fax +41 (0)52 262 89 89
CH-8404 Winterthur [email protected]
Switzerland
www.renk-maag.ch
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8Preparing for deployment and planning
Extensive organisation
Both the RENK-MAAG service tech-nicians and the back office are
flexible, quick to respond and reliable.
Our service doesnt just cover tech-nical matters, we also
organise all administrative aspects of the service, including
processing the travel arrange-ments 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 gear - box
or entire system. Once on site, our service technicians are
therefore ready to get started right away.
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9Month
T30M29 W31 T01 F02 S03 S04 T06M05 W07 T08 F09 S10 S11 T13M12 W14
T15 F16 S17 S18 T20M19 W21 T22 F23 S24 S25 T27M26 W28 T29 F30 S01
S02 T04M03 W05 T06 F07 S08 S09 T11M10 W12 T13 F14 S15 S16 T18M17
W19 T20 F21 S22 S23 T25M24 W26 T27 F28 S29 S30 T01M31
Monthcalendar week calendar week calendar week calendar week
calendar week calendar week calendar week calendar week calendar
week
You can rely on us to take care
of everything else.
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 part- ner for
all gearbox maintenance!
Planning deployment
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10
And if something does happen?
The condition of the gearbox often indi-cates 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 gear-box checks. In case of general
system inspections the gearbox should be part of the inspection
too.
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.
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 gearbox is often an indi-
cator of the condition of the entire system.
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11
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 environ-mental
protection requirements. For the work on oil platforms we attend
spe- cial 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 impressionsof intense training.
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12
Additional on-site services
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 da mage and establish its size
using conventional ultrasonic testing. RENK-MAAG can therefore make
optimum use of both measurement methods and their respec-tive
benefits.
ULTRASONIC TESTING WITH PHASED-ARRAY METHODThe 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 TESTINGThe 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 work-piece.
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.
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13
Even the slightest damage to the tooth
surface provide clues as to the cause.
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.
Need a more in-depth analysis? We will happily send out one of
our specialist to test your gearbox.
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14
Modifications and repairs at RENK-MAAG
RENK-MAAG repairs or overhauls all RENK-MAAG products where
necessary. The same applies for all MAAG turbo and marine
gearboxes, couplings and GP pumps for which spare parts are
manufactured according to original drawings. RENK-MAAG also
maintains individual components such as bearings, rotors, turning
gears, etc. and also conducts repairs of third party products.
REPAIR PROCEDUREA detailed inspection is initially made of the
affected parts. This results in an objective report regarding the
condition of the parts and any deviations from the norm, as well as
a repair proposal. The second step is the repair itself. A test run
of each complete gearbox or coupling can be conducted on our
efficient testbed for certification purposes.
REPAIR GOALS Quick turnaround time Original dimensions are
maintained where possible
Reusable as new parts
MODIFICATIONSRENK-MAAG undertakes modifications of gearboxes
after clarification of the technical feasibility. This includes:
Speed alterations Performance modifications Additional
instrumentation Turning gear Mounted pumps Custom modifications
A repair is possible in the majority
of cases.
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15
We are just next door
simply have a look at the contact details on our website.
Contact us all over the world
RENK-MAAG is represented by desig-nated agents in over 35
countries around the world. So we can advise and support our
customers on all continents directly whether on new gearboxes or
couplings, modifications, replacements, spare parts, repairs or
field service.
The current contact details are readily available on our
website: www.renk-maag.ch
Always nearby
-
RENK-MAAG GmbHP.O. Box 3068 Sulzer-Allee 46 CH-8404
WinterthurTelephone +41 52 262 89 88 Fax +41 52 262 89 89
[email protected] www.renk-maag.ch
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 gear-boxes of previous
MAAG models.
New gearboxes and components can be tested on our modern testbed
using the latest technology for moni-toring and diagnostics of
operating conditions, vibrations, temperatures or noise.
RENK-MAAGat your disposal
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.
03.2013_2 e
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Description of work Daily
/Con
stan
tly
Wee
kly
Afte
r firs
t 100
0 op
h
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
RemarksGearboxCheck drive group for noise and leaks X in
operating conditionCheck rotors visually X X X XCheck and retighten
gearbox anchoring X X X XCheck all bolt connections X X X XCheck
load contact pattern of teeth (red ink or metallic) X X X XCheck no
load tooth contact pattern (blue ink test) X X X in uncoupled
conditionCheck alignment of gearbox driving machine X X X in
uncoupled conditionCheck alignment of gearbox driven machine X X X
in uncoupled conditionCheck, clean and if necessary replace air
filter XDismantling and inspection of all gearbox parts
XLubrication systemCheck oil level X in operating conditionCheck Dp
of lube oil filter and clean/replace XCheck lube oil for water
content/contamination (analysis) X X X XCheck lubrication system
for leaks X in operating conditionCheck and clean lube oil cooler X
X X according to manufacturerCheck, clean and if necessary replace
lube oil filter XMaintenance of lubrication system X according to
manufacturerExtra checks for HET gearboxesCheck vacuum system
(function) X X X XCheck instruments and valves (function) X X X
XInstrumentation (monitoring of shaft and casing vibration + temp.)
Record operating data X in operating conditionCheck operating data
X in operating conditionCheck fit and tightness of instrumentation
XFunction check XInstallation check XCheck for visual damage XCheck
protective tubes XCheck passages for leaks XVerification of
junction box XToothed couplingsCheck couplings for leaks XCheck all
bolt connections X X X XCheck lube oil piping XCheck (replace)
lubricants on couplings X X X only for oil-filled
couplingsDismantle, clean and check XReplace O-rings X
Maintenance Schedule for RENK-MAAG Turbo Gearboxes
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88P.O. Box
3068 Fax +41 (0)52 262 89 89CH-8404 Winterthur
[email protected] www.renk-maag.ch
-
Description of work Daily
/Con
stan
tly
Wee
kly
Afte
r firs
t 100
0 op
h
Year
ly o
r eve
ry 8
000
oph
Ever
y 20
000
oph
Ever
y 40
000
oph
(or l
ates
t afte
r 5 y
ears
)
Spec
ial s
ervi
ce (o
n re
ques
t)
RemarksOther couplings (if applicable)Check all bolt connections
X X X XMaintenance according to manufacturer X according to
manufacturerGear driven pumpCheck for noise and leaks XMaintenance
according to manufacturer X according to manufacturerRotary
drive/Turning Gear/barring gearCheck drive for noise and leaks X
when operatingCheck oil level X XCheck all bolt connections
XMaintenance according to manufacturer X according to
manufacturerSynchronous clutchCheck for noise and leaks XDismantle,
clean, check X XMaintenance according to manufacturer X according
to manufacturerNondestruvtive testingUltrasonic testing (toothing,
bearings) X recommended every 40 000 ophMagnetic particle testing
(toothing) X recommended every 40 000 ophDye penetrant testing
(toothing, bearings) X recommended every 40 000 ophOperational
vibration measurement and analysis XMiscellaneousInspection of
special tools for gearbox XInspection of special tools for
anchoring XInspection of spare parts / spare gearbox XPreservation
of spare parts / spare gearbox XInspection of third-party parts 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.
RENK-MAAG GmbHSulzer-Allee 46 Phone +41 (0)52 262 89 88P.O. Box
3068 Fax +41 (0)52 262 89 89CH-8404 Winterthur
[email protected] www.renk-maag.ch
+ 41 52 262 87 62
[email protected]
RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland We reserve all
rights in connection with this document.
