Unbenannt-2 1 05.12.

2016 09:19:02

RENK-MAAG Non-Destructive Testing (NDT )

On site, on your system!
 RENK-MAAG On-site non-destructive testing

For the long-term availability,

reliability and security of your system.

For many years, RENK-MAAG has per-

formed non-destructive materials testing of
highly-stressed elements of gear units,
couplings, complete sets of gear teeth and
white metal bearings. These tests have
been performed both in RENK-MAAG’s own
works and on-site on customers’ premises.

Nowadays a production
stoppage means a loss
of millions of euros.

Trained staff using the latest technologies

and working in close cooperation with
the customer perform customer-specific
inspection work and make a valuable
contribution to the operating reliability of
the system.

Magnaflux testing detects changes in the

surface of the material. Using appropriate
test equipment, this type of testing can
be performed on site without problems.
Ultrasonic testing is a valuable instrument
for inspecting the inner structure of the
material. This is the only way by which
internal changes within the material, such
as very small inclusions, can be detected.
Undetected, such inclusions can grow over
the years and in the worst cases lead to
a tooth breaking or a rotor bursting, with
major consequential damage.

RENK-MAAG uses the latest technology.

The Epoch 1000i performs tests using
both the conventional method and also
the Phased Array method.
2
The safety and availability of systems is of
central importance. Nowadays a production
stoppage means a loss of millions of euros.
Lack of proper maintenance can also lead
to injuries to personnel and loss of image.
To guard against these negative variables,
RENK-MAAG offers in addition to the proven
techniques of visual inspection of gear
units “internal inspection” of the gear unit
components, all from a single source.
RENK-MAAG recommends material testing
of components, especially components
of older and heavily stressed gear units and
couplings. The best time for this type of
test is at the scheduled periodic inspection
of the gear unit (major overhaul). The
materials test engineer travels to the site
after the gear unit specialist and can start
work as soon as the gear unit has been
opened. Gear unit inspection and materials
Materials test engineers RENK-MAAG also performs non-destructive
at RENK-MAAG are trained testing on gear units manufactured by
other companies and on other system
to SN EN ISO 9712 and components.
work all over the world.
tests can be performed at the same time
without problems. Neither procedure will
cause delay to the other.
Certified RENK-MAAG materials test
engineers perform the full range of tests
using the most modern test equipment
including special test heads for gear teeth. Play it safe:
Based on their knowledge in the field of
materials testing on gear units, a complete
At the next major
test of the gear set and the bearings can overhaul, include an
generally be completed within 2–3 days – “NDT” inspection.
depending on the size of the gear unit and
the test method.
3
 RENK-MAAG On-site non-destructive testing
How are tests conducted in the field? The fields of application
of the individual test methods.
Test method
Conventional
Gear wheel From approx. gear module 4.5 From gear module 8
Pinion From approx. gear module 4.5 From gear module 8
Bearings Yes
Rotors
(gear wheels / pinions)
• Ultrasound is used to detect cracks within
the internal structure of the material.
Magnetic particle testing renders even the
most minute surface cracks visible.
Ideally therefore the two tests should be
performed in combination on rotors.
• Magnetic particle testing involves the
entrainment / preparation of fluorescent
sprays* with metal particles and the
facility for darkening the workplace on
site so that the gear unit parts can be
illuminated with ultraviolet light.
• Ultrasonic testing can however be
performed only on gear units with gear
modules greater than about 4.5. If the
gear teeth are smaller than this, magnetic
particle testing or dye penetrant testing
* Classed as hazardous goods, therefore prohibited
from carriage on aircraft.
4
Ultrasound Magnetic particle
Phased array – –
Yes
Yes
Yes No
are available. The latter method is more
suitable for small rotors, since for larger
items the quantities of test media (red
spray / white spray) required can quickly
become very large.
• Depending on the size of the gear module
or gear unit, select between the options
of conventional ultrasonic testing and the
phased array method. The phased array
method permits testing with multiple
concurrent sound waves. Accordingly it
permits a wider section to be tested.
The materials test engineer has to apply
the test head to the individual tooth less
often, so he can work more efficiently.
The phased array method is of great inter-
est for testing the larger components
of the gear unit, since the cost saving due
to the reduced test time can be consider-
able.
The phased array method can save up to 50 %
of the testing time!
Dye penetrant
Yes (but uneconomic)
Yes (but uneconomic)
Yes
Bearings
• White metal is non-magnetic. Therefore
bearings can be tested only by means
of ultrasound and dye penetrant methods.
Detailed technical information on the
individual test methods can be found on the
following pages.
All enquiries for materials testing are
reviewed by our Quality Department, which
prepares a recommendation for the tests
that are required, including the time taken
by the test engineer. When we prepare
quotations we are always careful to offer
the customer the best options from the
technical and cost-effectiveness points of
view.
Expertise based on
more than 100 years of
building gear units and
gear wheels contributes
to the measurement data
we collect on site.

Example of a test recommendation

Gearbox type: G-36 UT 1) UT 1)

MT 2) PT 3)
Module: 6 Phased Array conventional
Gear wheel n.a. 2.6 h 1.8 h n.a.
Pinion n.a. 1.5 h 1h n.a.
Bearings n.a. 0.5 h n.a. 1.5 h
Total time in hours 8.9 h

1)
UT: Ultrasonic testing, 2) MT: Magnetic particle testing, 3) PT: Dye Penetrant Testing

After the test

Prüfbericht Technische Beurteilung
A RENK-MAAG test report is generated for Inspection Certificate Technical Assessment
Seite / Page 1 von / of 1
each set of materials test results. This
report is assessed and evaluated by our Kunde Stichwort Kunden-Best.Nr.
Customer Plant Cust. Order no.

Technical Department before being passed Getriebe-Nr. Typ Auftrags-Nr.

Gearbox no. Type G-65/100 Order no.
to the customer. ZFP Prüfer Rapport-Nr. Rapport-Datum
NDT inspector RENK-MAAG Report no. Report date

If the ultrasonic test results indicate
damage, RENK-MAAG will issue recommen-
dations for future use of the gear unit,
and recommendations for necessary further
actions.
Beurteilung durch die RENK-MAAG Technik
Assessment by RENK-MAAG Technical department
Das Getriebe kann weiterhin innerhalb der Betriebsdaten betrieben werden.
Die Verzahnungs-Anzeigen 1 und 2 sind auf der Registriergrenze und noch als unkritisch eingestuft, da der
Anzeigeort unkritisch ist für einen Zahnbruch. (Die Anzeigen 3-8 sind unkritisch und nicht zwingend zu registrieren,
jedoch hilfreich für spätere Auswertungen)
Die Bindungsfehler auf der unbelasteten Axiallagerseite sind ebenfalls unkritisch, müssen bei der nächsten
Inspektion aber weiter beobachtet werden.
The gearbox can still be operated within the normal operating range.
The indication 1 and 2 in the teeth are exactly on the registration level and classified to be uncritical as the indication
location is uncritical for tooth breakage. (The indications 3-8 are uncritical and below the registration level, but
reported for later analyses). Indication 1 and 2 have to be reviewed at next regular inspection (after 8000 hours).
The bonding errors at the non-loaded axial bearing side are uncritical too, but have to be checked during the next
inspection.

Empfehlungen für den weiteren Betrieb

Recommendation for further operation

Keine Reduktion auf der nominellen Betriebsleistung Getriebe sollte nicht mehr eingesetzt werden
%
None Reduce load to of nominal operation load Gearbox should be taken out of operation

→ Betriebsrisiko in Verantwortung des Kunden!

→ Risk of operation in responsibility of customer

Empfehlungen für zukünftige Inspektionen

Recommendation for further inspections

Extract from a test report with the indications Nächste Prüfung gemäss RENK-MAAG Wartungsplan
Next inspection according to the maintenance schedule
Temporäre Verkürzung der Inspektionsintervalle auf Stunden
Temporary shortened inspection frequency to / hours
that were found. …

Unverbindliche Offertangebote basierend auf obiger Beurteilung 5

Non-binding offer based on above assessment

Rotoren: Inspektion und Reparatur Ersatzteile

Rotors: Inspection and Repair spare parts

Lager: Inspektion und Reparatur

Ersatzteile
 Four test procedures in detail

Specifically aimed at finding defects

in the internal structure of the material.

Test head
Transmitted pulse

s Sound level

Defect echo

Gear tooth Rear wall echo

(or white metal bearing)

1. Conventional
ultrasonic testing (UT)
Ultrasonic testing permits us to localise
and assess defects in the internal structure
of the material. Structural cracks such as
bonding failures in white metal bearings can
reliably be located. Ultrasonic testing is an
acoustic procedure which has the special
advantage that it permits the user to test the
entire volume of a component. The simplest
way to describe the principle of ultrasonic
testing is to consider it as an impulse-echo
procedure. For this purpose the elapsed
Test head position
and test track on
the tooth head.
travel time of the sound wave is measured
and sound waves (start pulse, reflected
sound waves) are visualised on a screen.
Impulse-echo procedure
A test head is placed against the surface
of a plane-parallel workpiece that is to be
tested. This head acts alternately as an
ultrasound transmitter and an ultrasound
receiver (Graphics 1–3). The ultrasound
device to which the test head is connected
measures the time delay of the echo. It then
displays whether an echo was received
after an ultrasound pulse was transmitted,
Test object
Test head
Test object
Sound level
Test head
Sound level
together with the time delay. If the speed
of sound in the material to be tested is
known, the measured time delay gives an
indication of the distance from the test
head of the reflection point of the ultra-
sound pulse. If this distance corresponds
to the thickness of the workpiece, there
was no obstacle within the material that
hindered the propagation of the sound
waves. The test object is thus free of
defects (Graphic 2). If however an earlier
echo is received back, this must originate
from a break in the material or from a
defect within the
SI
workpiece (Graphic 3).
Rear wall echo
SI
Rear wall echo
0 1 2 3 4 5 6 7 8 9 10

Graphic 2
0 1 2 3 4 5 6 7 8 9 10
SI

Test object
SI Defect echo
Test head
Test head positions Rear wall echo
and test tracks on Test object
the tooth flank. Sound level Defect echo
Test head
Rear wall echo
Defect
Graphic 3Sound level
0 1 2 3 4 5 6 7 8 9 10

6
Defect

0 1 2 3 4 5 6 7 8 9 10
The test head is moved at definite axial
intervals along a test track on the head
of the tooth, over the entire length of the
tooth. This procedure is followed along both
flanks of each tooth. In addition a further
ultrasound emission is performed at the
head of the tooth (Graphic 1).
Location and determination
of the defect (views)
The test device / test head is calibrated and
adjusted using a test body (tooth segment)
in which there is a flat-bottomed hole of
1 mm diameter. If a defect echo is received
from the object being tested, the distance
from the test head to the reflection point
travelled by the sound wave can be read off
on the device. This permits the coordinates
of the location of the defect to be deter-
mined. If the amplitude of the defect echo
exceeds a certain value it is registered
on the display as an indication, and is
documented in the RENK-MAAG test report.
Indications are described in terms of their
echo amplitude and extent.
Individual indication without extent (EE)
An individual indication is present when an
echo from the reflection point decreases
WITHOUT extent (EE)
Graphic 4: Individual view (EE)
evenly from the maximum in all directions
when sampled consistently, see Graphic 4.
Individual indication with extent (EA)
Indications with extent exhibit a decrease
in amplitude that is uneven in at least one
direction. The determination of the extent
is performed using the half-amplitude
method. This allows discrimination only
between individual indications with extent
and individual indications without extent.
Conventional ultrasonic testing is laborious
and, depending on the size of the toothed
2. Ultrasonic testing with
the phased array method
The phased array method is a further
development of ultrasonic testing. Advanced
array heads with many elements emit
bundles of high-frequency sound into the
test body. The echoes returned reproduce
detailed representations of the inner struc-
ture of the test body. This procedure is
supported by a powerful software package.
Multiple emission angles can be achieved
from a single sound injection position. A
tooth can be 100% sampled from a single
WITH extent (EA)
Graphic 5: Extent (mm)
Screen view
Graphic 6: Test head movement
gears, may be expensive. Therefore when­
ever possible RENK-MAAG works with the
new phased array test method, which is
quicker (can be used from gear module 8).
sound injection position. Using high test
sensitivity the entire rotor set can quickly
be tested.
The following advantages of phased array
testing can be emphasised in comparison
to conventional methods:
• The wide angular range from a single
sound injection position (additional
detection of off-centre defects).
• Time saving when testing large
components.
• Easily understandable 3D visual
representation.
7
 Four test procedures in detail
Optical detection of defects
on the surface of the material.
Magnetic particle testing of gear teeth, using a hand-held magnet.
3. Magnetic particle testing
(MT)
Magnetic particle testing (also known
as Magnaflux testing, MP testing or
MT testing) is another method of non-
destructive materials testing. Its purpose
is primarily to detect even very fine
fissures leading to breaks in the material
not visible to the naked eye, both at the
surface (e.g. cracks) and in zones close to
the surface. Ferromagnetic materials can
be tested. For magnetic particle procedures
8
Damage found – crack 1 mm.
Visible cracks on a thrust cone.
the test section of the workpiece must
be magnetised. Optimum detection of
defects is achieved when the magnetic
field is at right angles to the material
defect. The magnetic flux then passes along
a ferromagnetic field in the workpiece.
The primary direction of the field is a line
from one magnetic pole to the other. This
can be achieved by a clamping jig. In this
way the entire workpiece is magnetised.
Hand-held magnets can also be placed
on the workpiece; these have the effect of
magnetising the area between the two Visible cracks on a fitting bolt.
Source for magnetic particle testing: http://www.mr-chemie.de/produkte/magnetpulverpruefung/beschreibung/
Planetary axes – full of cracks.
poles. In order to detect randomly oriented
cracks, two or more types of magnetisation
can be employed concurrently in a com­
bined procedure.
Coloured or fluorescent magnetic particles
are available as test media. Fluorescent
magnetic particles have the greatest sen­
sitivity. A distinction is also made between
wet testing (using water or oil as a carrier
medium) and dry testing. The defect
detection capability is greatest using wet
testing.
4. Dye penetrant
testing (PT)
Dye penetrant testing (also known as
red-white testing, PT or FE testing) can be
used on ferrous and non-ferrous metals,
many plastics, ceramic materials, glass etc.
to detect surface defects on components
and machines. It can be performed quickly
Summary
Regular gearbox maintenance
in combination with NDT package
ensures safe and reliable system
operations.
Indication of a bonding failure in a bearing shell.
and without great cost. The pre-requirement The characteristic of dye penetrant testing
for selecting dye penetrant testing as is that defects such as cracks, pores etc.
a method is that the defects are open become visible and can be detected, even
to the surface. This procedure finds in non-magnetisable materials.
applications in the testing of weld seams,
castings, in shipbuilding, aircraft building,
in the automobile industry, and in the
building of apparatus and containers etc.
A distinction is made between coloured
dye penetrant testing and fluorescent
dye penetrant testing. Fluorescent dye
penetrant testing uses a dye which flu­
oresces when illuminated by UV radiation.
­RENK-MAAG works exclusively with
coloured dye penetrant testing. Bearing shell after application of the developer.
Both dye penetrant testing methods are based on four operations:
1. Preparatory cleaning
2. Application / soaking in of the dye penetrant
3. Intermediary washing / drying
4. Development / assessment
Source for dye penetrant testing: http://www.mr-chemie.de/produkte/eindringpruefung/beschreibung/
Carefree package with RENK-MAAG service technicians
• Offshore training certified for platforms
• Medical certificates and immunisation
• Crane operator certified
• Visa applications with Letter of Invitation
• Other individual information such as requested
online trainings / certificates
9
 RENK-MAAG Complementary services
Everything else you need for maintenance of your gear unit and / or coupling
Additional inspections and analyses
• 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.
• Flow rate and pressure measurements
on the lube oil system.
Field service – Regular maintenance means long operating life
Maintenance schedule
Depending on the number of years of
operation or operating hours since commis-
sioning or the last maintenance work, we
recommend the following RENK-MAAG
standard inspections:
• Run-inInspection
Within first year of operation.
• MinorInspection
A brief check through the inspection cover
provides an overview of the gearbox
condition.
• Major Overhaul
This large-scale check involves dismant­ling,
cleaning and re-assembling the gearbox.
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
10
• 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.
• Oil analyses.
• Other services.
If necessary, individual components or worn
parts are replaced. – This will be the right
time for a non-destructive testing (NDT).
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
Phone +41 52 262 87 62
service@renk-maag.ch
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.
 Buy new, repair or modify?
Although defects in RENK-MAAG gearbox­es
are rare, incorrect storage, improper care,
changing operating conditions, inadequate
oil quality or poor maintenance can
occasionally result in damage. New parts
do not always have to be procured in such
circumstances.
Why preventive control?
Even if no damage is apparent we still
recommend that specific periodic inspec-
tions of major components are conducted
by RENK-MAAG. Such preventive measures
do not necessarily result in repairs. On the
contrary, inspections safeguard long-term,
trouble-free operation, and extend the
service life.
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 g­ ears, 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
Contact us
all over the world
RENK-MAAG is represented by designated
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
report regarding the condition of the parts A repair is possible
and any deviations from the norm, as well as in the majority of cases.
a repair proposal. The second step is the
repair itself. A test run of each complete
gearbox or coupling can be conducted on our
state-of-the-art testbed for certification
purposes.
Repair goals
• Quick turnaround time
• Original dimensions are maintained
where possible
• Reusable as new parts
Damage assessments
RENK-MAAG conducts non-destructive,
and if necessary, destructive damage
assessments together with external
independent experts.
Modifications
RENK-MAAG undertakes modifications
of gearboxes after clarification of
the technical feasibility. This includes:
• Speed alterations
• Performance modifications
e.g. power upgrades
• Additional instrumentation
• Turning gear
• Mounted pumps
• Custom modifications
 RENK-MAAG Maintenance and NDT Schedule

RENK-MAAG’s recommended NDT inspection schedule

Maintenance and NDT Schedule

Run-in Inspection Minor Inspection Major Overhaul

Within first year of operation Every 20 000 oph Every 40 000 oph

NDT packages

NDT Extended
Recommended after the following
NDT Standard numbers of operating hours:
120 000 oph
160 000 oph
200 000 oph
Recommended after the following
240 000 oph
numbers of operating hours:
NDT Basic 80 000 oph
Tests
• Ultrasonic testing of gear teeth
Recommended after the following • Magnetic particle testing of gear teeth
numbers of operating hours: Tests • Magnetic particle testing of thrust cones,
40 000 oph • Ultrasonic testing of gear teeth torsion shafts, fitting pins
• Magnetic particle testing of gear teeth • Bearing inspection, dye penetrant testing
Tests • Magnetic particle testing of thrust cones and bonding checking
• Magnetic particle testing of gear teeth • Bearing inspection, dye penetrant testing • Volume testing on rotors, thrust cones,
• Magnetic particle testing of thrust cones and bonding checking torsion shafts

8 000 oph 20 000 oph 40 000 oph 60 000 oph 80 000 oph 100 000 oph 120 000 oph 140 000 oph 160 000 oph

0 Run-in Insp. Minor Insp. Major Overhaul Minor Insp. Major Overhaul Minor Insp. Major Overhaul Minor Insp. Major Overhaul
+ + + +
NDT Basic NDT Standard NDT Extended NDT Extended

RENK-MAAG service technicians attend training courses on an ongoing basis. They have undertaken all standard safety trainings and hold the certificates required
to undertake the work. These cover all health and safety and environmental protection requirements. For the work on oil platforms they attend special safety
training courses and make sure knowledge is regularly refreshed. 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.

RENK-MAAG GmbH Our manufacturing and other operational activities

P. O. Box 3068 • Sulzer-Allee 46 • 8404 Winterthur • Switzerland are implemented in accordance with our internal quality
Telephone +41 52 262 89 88 • Fax +41 52 262 89 89 assurance system and in strict compliance with
info@renk-maag.ch • www.renk-maag.ch ISO 9001: 2015, ISO 14001: 2015 and OHSAS 18001: 2007.
Ed_1 d