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.
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.

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.

2
«
Our dynamic
service team
is ready for takeoff.»

3
 Even the best machines need maintenance

Gearbox maintenance On-site support

You have chosen to put your trust RENK-MAAG offers world-wide services
in a RENK-MAAG gearbox. It is in your for all MAAG turbo and marine gear-
hands to preserve the legendary boxes. Certified service technicians with
longevity and robustness of this quality years of experience inspect and maintain
product by following the corresponding the gearboxes in accordance with the
service and inspection intervals. customized maintenance schedule to suit
your needs. Regular gearbox mainte-
nance ensures safe and reliable system
operation.

« Certified techni-
cians with years
of experience inspect
and maintain the gear-
Gearbox condition and availability with maintenance
New Service life

boxes on site – anywhere

in the world.»
(Visual check)
(Visual check)
Safe range
Operating condition
Critical range

0
1000 oph

8000 oph

20 000 oph

40 000 oph

other
40 000 oph

other
40 000 oph

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

4 Lifetime without service

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

«
 egular gearbox
R
maintenance
ensures safe and reliable
system operation.»

5
 Regular maintenance – long operating life

Maintenance schedule

Depending on the number of years 20 000 operating hours check

of operation or operating hours since The gearbox is opened – but not dis­
commissioning or the last maintenance mantled – to gauge the condition of its
work, we recommend the following interior. This is ideal if you have only
RENK-MAAG standard inspections: a brief shutdown or a limited budget.

1000 operating hours check 40 000 operating hours check

This check is undertaken on gearboxes This large-scale check involves dismant­
when taken into service. ling, cleaning and re-assembling the
gearbox. If necessary, individual compo-
8000 operating hours check/annual check nents or worn parts are replaced.
A brief check through the inspection
cover provides an overview of the
gearbox condition.

Inspection example using a 20 000 operating hours check

Phone:

No. Process name -2 -1 1 2 3 4 6 7

Check spare parts stock

Process Milestone External processes

Project: Interruption Collective process External milestone
Underway Collective process for project Qualifying date

Page 1

6
 Check
1000 oph 8000 oph 20 000 oph 40 000 oph
Installation of installation/
check check check check
Commissioning

Working days 10 1 – 3 1 2 3 – 4 6 –7

Operating
years since – – – 1 2 – 3 5 +
last inspection

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

RENK
Sulze -M
AAG
P.O. r-Allee 46GmbH
B
RENK-MAAG GmbH 8404 ox 3068
Sulzer-Allee 46 Switz Winterth
P.O. Box 3068 Phone +41 52 erland ur Phon
262 89 88 Fax e +41 52
8404 Winterthur Fax +41 52 262 +41 262
info
Switzerland info@renk-maag.c 89 89 @r 52 89
h www enk-m 262 89 88
www.renk-maag.c
h Main .renk aag.ch
-maa
89

tena g.ch

nce
Sche
dule
for R
ENK-
MAA
G Tu
5 years)

rbo G
earb
oxes
(or latest after

«
ars)
(on request)

5 ye
8000 oph

after
oph

Descr
ly

Every 20 000 oph

h
Every 40 000 oph

iption
Daily/Constant

test

t)
After first 1000

0 op
Yearly or every

Gear of
ques
Special service

x work bo
tly

Che
(or la
00 op

ck dr
y 800
stan

Che ive gr
(on re

Description of ck ro oup
Weekly

oph

work
The maintenance
to fo

We recommend
Che
ck an rs visua r noise an
oph
/Con

10
ever

Other couplings Che d re lly d leak

(if applicable) tight
000

ck
first

rvice

Check all bolt all bo en ge s

kly

000

Che
Daily

connections lt co
Remararks
ly or

ck lo box
Maintenance ad co nnec
Wee

anch
y 20

according to manu Che tions

After

oring
ial se

ck ntac
y 40

facturer
Che X no load

schedule is attached
Gear driven pump t pa
Year

carrying out
X ck al X toot ttern
Ever

Check for noise C ignm h co of te X

Ever

and leaks he en ntac et h

Spec

ck al t pa to (red in
Maintenance Che ignm t Xof gear accor ding tte manufactur k orer
according to manu ent
Rotary drive/ Turnin facturer X Dism
ck, cl
ean of ge box – dr rn (blue met
allic) Rem
g Gear/ barring an and arbo iving ink te X arks

to this brochure.
x mac st) X
Lubr tling and if necess – driven

standard inspections.»
Check drive for gear hi X X
noise and leaks
Che
icatio insp Xec accor ary re mac ne X X in op
Check oil level
ck oi n system tion
of
ding to manuhifactur
plac
e air ne er
X
X
X
X
erat
ing co
Check all bolt Che l le al l gear filter X
connections ck Dp vel box X
X
X
nditi
on
Maintenance C he of X when opera pa X
according to manu X ckX lube ting rts
facturer Che lube oil filt X
Synchronous clutch X ck lu oil er X X
Che bricat for water and clea X X
Check for noise ck an ion cont n/ X
and leaks Che d clea system X ent/c replace X in un
Dismantle, clean, ck, n for accor onta to manu
ding
minat facturer
X co
in un upled co
Maintenance
check
X Maint clean an lube oil leak
s ion (a
X
co nd
according to manu enan d if ne cool nalys in un upled co ition
facturer Extra ce cess er X
is) X coup
Nondestruvtive
testing Che chec ofX lubric X atio
ary re
X X
nd
led co ition
Ultrasonic testing ck va ks for plac nditi
(toothing, bearin Che cuum HET ® nXsystem e lube on
Magnetic partic gs) ck in sy gear according to oi l filter
manu
Dye penetrant
le testing (tooth
ing) Instru strumen stem (fu boxes facturer X X
men ts an nc tio X in op
testing (toothing, Rec tatio d va X n)recom X
Operational vibrat bearings) ord n lve mend erat
oper (mon s ed every 40 000 X ing co
ion measureme
nt and analysis
Che
ck op ating itorin X (func tion)mended oph X nditi
Miscellaneous Che erat data g of recom every 40 000 on
Inspection of ck ing X sh aft anmended
recom oph X
special tools for Func fit and tig data d ca every 40 000 oph X in op
er
Inspection of gearbox tio htne X sing acco ating co
special tools for Instal n chec ss of vibrat X rding nd
k
Inspection of
spare parts / spare
anchoring
Che
latio
n ch instru
men
ion +
te X to m ition
gearbox ck ec k X ta mp.) X anuf
Preservation of Che for vis tion X acco actu
spare parts / spare ck pr ual da X X X rding rer
Inspection of gearbox Che otec mag X X X to m
third-party parts ck tive e X X anuf
Verifi passag Xtubes X X actu
catio es fo rer
Toot n of r leak
hed junc s X
Che co tion according to manu
ck co uplings box facturer X
Important: Che uplin in op
ck gs er
This “Maintenan all bo fo X in op ating co
ce Schedule” Che
ck lu lt co r leaks erat nd
but does not
take the place
is not plant-specifi
C be oi nnec ing co ition
according should of any plant-specifi c; it can also be usedheas ck l pipi tions
X
nditi
on
be adapted to c information. Dism a(re
The work
suppl
placemen ng
e) lu t to the instruction manu
X
operation. We the antle
recommend having current operating hours to be, carrie brican
d out al X
of theRgearb
epla cl shall be either consid
all work perfor ceoxOandeaany n ts on ered X
med by one of
our experienced-rings anabnor d ch malitie coup
eck s notice
specialists. lingsd during service@renk-maa
g.ch
X
+ 41 52 262 87 X
62
X
X
X
© RENK-MAAG X X
GmbH, CH-840
4 Winterthur, X
Switzerland
X
X
We reserve all
rights in connec X only
tion with this docume for oi
nt. X l-fille
d co
uplin
gs

Insurance spare parts on-site

RENK-MAAG recommends holding The defective parts can then be replaced

the following key components in stock: immediately, limiting any production
downtime to a minimum.
•1 spare set of rotors
•1 spare set of bearings Keep in mind that even under the best
•1
•1
spare
spare
set
set
of
of
oil scrapers
instrumentation
conditions, it will take several months for
spare bearings or rotors to be delivered. 7
 Preparing for deployment and planning

Extensive organisation

Both the RENK-MAAG service tech­ Before they set out,

nicians and the back office are flexible, the service technicians
quick to respond and reliable. are always prepared
and instructed by our
Our service doesn’t just cover tech- back office. They are
nical matters, we also organise all informed of special
administrative aspects of the service, customer concerns
including processing the travel arrange­ and are provided with
ments required, organising travel, details of the gear­-
special training courses or medical box or entire system.
examination and certification. Once on site, our
service technicians
are therefore ready
to get started right
away.

8
 Coordinating dates

As well as planning deployment, we Once you have opted

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

Planning deployment
Month
calendar week calendar week calendar week calendar week calendar week
Month
calendar week
« You can rely
on us to take care
of everything
calendar weekelse.»calendar week
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

9
 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.
• 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 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.

«
The gearbox
is often an indi-
cator of the condition
of the entire system.»

10
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 impressions
of intense training.»

11
 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 da­mage
and establish its size using conventional
ultrasonic testing. RENK-MAAG can
therefore make optimum use of both
measurement methods and their respec-
tive benefits.
12
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 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.
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.
•M  easuring and aligning shaft trains
using laser measuring methods or dial
gauges.
«
E ven the slightest
damage to the tooth
surface provide clues as
to the cause.»

• Flow rate and pressure measurements • Casing vibration, airborne noise and shaft
on the lube oil system. vibration measurements on the gearbox
• Endoscopic examination of gearbox including the associated analyses.
parts. • Other services.

Need a more in-depth analysis?

We will happily send out one of our
specialist to test your gearbox. 13
 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 PROCEDURE
A 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
A repair is possible efficient testbed for certification purposes.
in the majority
of cases.» REPAIR GOALS
• Quick turnaround time
• Original dimensions are maintained
where possible
• Reusable as new parts

MODIFICATIONS
RENK-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

14
Always nearby

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

«
 e are just
W
next door …
simply have a look
at the contact details
on our website.»

15
 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 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.

Our manufacturing and other operational activities

are implemented in accordance with our internal
quality assurance system and in strict compliance with
ISO 9001 : 2008, ISO 14001 : 2004 and OHSAS 18001.

RENK-MAAG GmbH
P.O. Box 3068 • Sulzer-Allee 46 • CH-8404 Winterthur
Telephone +41 52 262 89 88 • Fax +41 52 262 89 89
03.2013_2 e

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

Maintenance Schedule for RENK-MAAG Turbo Gearboxes

Every 40 000 oph (or latest after 5 years)

Special service (on request)
Yearly or every 8000 oph
After first 1000 oph

Every 20 000 oph

Daily/Constantly

Description of work Weekly Remarks

Gearbox
Check drive group for noise and leaks X in operating condition
Check rotors visually X X X X
Check and retighten gearbox anchoring X X X X
Check all bolt connections X X X X
Check load contact pattern of teeth (red ink or metallic) X X X X
Check no load tooth contact pattern (blue ink test) X X in uncoupled condition
Check alignment of gearbox – driving machine X X X in uncoupled condition
Check alignment of gearbox – driven machine X X X in uncoupled condition
Check, clean and if necessary replace air filter X
Dismantling and inspection of all gearbox parts X
Lubrication system
Check oil level X in operating condition
Check Dp of lube oil filter and clean/replace X
Check lube oil for water content/contamination (analysis) X X X X
Check lubrication system for leaks X in operating condition
Check and clean lube oil cooler X X X according to manufacturer
Check, clean and if necessary replace lube oil filter X
Maintenance of lubrication system X according to manufacturer
Extra checks for HET® gearboxes
Check vacuum system (function) X X X X
Check instruments and valves (function) X X X X
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 couplings
Check couplings for leaks X
Check all bolt connections X X X X
Check lube oil piping X
Check (replace) lubricants on couplings X X X only for oil-filled couplings
Dismantle, clean and check X
Replace O-rings X
RENK-MAAG GmbH
Sulzer-Allee 46 Phone +41 52 262 89 88
P.O. Box 3068 Fax +41 52 262 89 89
8404 Winterthur info@renk-maag.ch
Switzerland www.renk-maag.ch

Every 40 000 oph (or latest after 5 years)

Special service (on request)
Yearly or every 8000 oph
After first 1000 oph

Every 20 000 oph

Daily/Constantly

Description of work Weekly Remarks

Other couplings (if applicable)
Check all bolt connections X X X X
Maintenance according to manufacturer X according to manufacturer
Gear driven pump
Check for noise and leaks X
Maintenance according to manufacturer X according to manufacturer
Rotary drive/Turning Gear/barring gear
Check 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 clutch
Check for noise and leaks X
Dismantle, clean, check X X
Maintenance according to manufacturer X according to manufacturer
Nondestruvtive testing
Ultrasonic 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
Miscellaneous
Inspection 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 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 service@renk-maag.ch
according should be adapted to the current operating hours of the gearbox and any abnormalities noticed during
+ 41 52 262 87 62
operation. We recommend having all work performed by one of our experienced specialists.

© RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland We reserve all rights in connection with this document.