ABB Turbo Gear en HTCT 691 250 VOO01AABB Contents 1.3 Set of Gears.. 1.4 Bearings. 4.5 Built-in Parts. 1.6 Attached Parts.. 4.7 Lubrication .. 4.8 Monitoring (Thermocouple) 2 STORAGE. 3 INSTALLATION 3.1 Erection on baseplate. 3.2 Erection procedure at si 3.3 Alignment 4 COMMISSIONING. 4.1 Preparations 4.4.1 Flushing of lube oil syster 4.1.2 Functional test of the oil system. 4.2 Operation 4.2.1 Start-up, No-Load to nominal speed . 4.2.2 Applying load a 4.2.3 Monitoring 4.3 Gear teeth load contact. 4.3.1 First Check....... 4.3.2 Second Check. 4.4 Shut-down of the unit en HTCT 691 250 VO001A, 3ABS Fig. 4.4 DESCRIPTION General The single stage turbo gear is located between the turbine and the generator, Its main purpose is the reduction of the turbine speed to the synchronuous speed of the generator. Three non-contacting speed sensors (5, Fig. 6.2) pick-up the speed impulses for electrical monitoring of the machine from an impeller wheel attached to the gear shaft. ‘Two vibration sensors (4, 5) located at each side of the turbo gear casing {one at the turbine side and one at the generator side) measure the vibrational level of the turbo gear continuously. ‘Overview en HTCT 691 250 VO001A 5ADB 1.3 Set of Gears The pinion (2, Fig 1.3) and gear wheel (1) of the main drive have case-hard ended and ground single helical gear toothing. in order to assure an even load contact of the gear teeth across the full width the tooth flanks of the pinion are machined with a longitudinal correction (see figure 1.3) which compensates the deformation of the tooth flanks due to load and non-uniform thermal profile along the teeth. Fig. 1.3 Longitudinal correction The pinion shaft is rigidly coupled to the gas turbine / compressor shaft via an intermediate shaft. The axial thrust bearing is installed in the compressor. It guides the rotor in axial direction including the pinion and takes the thrust of the helical gear tooth The gearwheel shaft is rigidly coupled to the generator shaft via an intermediate shaft. A thrust bearing (14, 15, Fig 6.1) installed on the end of the gear wheel shaft takes up the thrust of the helical gear and guides the generator in an axial direction. en HTCT 691 250 VOOO1A 7MBK 13. CT 002 MBK 14 CT 002 MBK 13 CT 001 MBK 14 CT 001 MBK 15 CTO11 MBK 15 CT 001 a ae : = [ ‘ LL == Ti MBK 11 CT 001 MBK 12 CT 001 fe MBK 11 CT 002 MBK 12 CT 002 Fig. 1.4 Thermocouple 2 STORAGE If gearbox is shut down and stored over a longer period of time all parts should be coated with approved VALVOLINE OIL products (TECTYL) after thoroughly cleaning before re-assembly of gearbox: All bright internal surfaces TECTYL 502 or 511 MA (70% 5114 + 30% S06) All bearings surfaces TECTYL 893 or 895 All outside surfaces TECTYL 506, cE If these products are used, it is not necessary to clean the inner gear parts, because the coating is removed by the flushing of the gear prior to commissioning en HTCT 691 250 VOO01A 9ABB 3.3 Alignment The procedure described in chapter 3.2 is carried out previous to alignment if turbine and generator are aligned to gearbox as a fixed point. {f gearbox is aligned to either turbine or generator the procedure of chapter 3.2 is done simultaneously and also after the alignment procedure. The shaft journals of the gear are treated with a conservation product which allows an easy turning of shafts for alignment. en HTCT 691 250 VOOO1A, "1ABB 4.2.2 4.2.3 43 Applying load The gearbox requires no break-in time. It can be fully loaded immediately, if the gear teeth load contact (see chapter 4.3) has been carried out. Make sure that the power value given on the nameplate / f \ isn’t exceeded during start-up and operation, because this will cause damage to the turbo gear. Monitoring The lube oil pressure is monitored by pressure switches at the oil inlet. ‘Thermocouples located in the bearing shells measure the temperature of the bearing. Gear teeth load contact The load tooth contact is to be checked at: - Commissioning - Overhaul - _ Replacement of bearings or gears - Re-alignment The check consists of a visual inspection of the red coated tooth flanks through the inspection opening (10, Fig. 6.2) provided in the upper gear case. Three sections of teeth on the wheel (at 120°) and one section on the pinion are coated with an oi-hard red lacquer. (On the original gears this is already done by the manufacturer.) The respective teeth must be cleaned and thoroughly de-greased prior to coating. The lacquer is to be applied in a thin even coat and left to dry for some hours. cE Best product is DYKEM LAYOUT RED DX-296 . en HTCT 691 250 VOOO1A 13a FA Di 44 Shut-down of the unit Except for corrosion protection no special precautions for prolonged shut- downs are necessary. One of the following methods to prevent gear corrosion is recommended: 1. Operate the group every week at normal operating temperature. 2. If the group cannot be started-up, operate the lube oil system only for 5 minutes, if possible with simultaneous turning of the shafting. This has to be done with “cold” oil (at ambient temperature) to prevent condensation (= rust). Under no circumstances should the "cold" gearbox be a flushed with "warm" oil, except immediately before start- up. 3. If the gearbox is shut down for an extended period without possibility of intermittent operation or flushing, then a conservation of the gearbox must be carried out as described in chapter 2. As an alternate possibility the gearbox may be protected by means of a cover gas, such as nitrogen at pressure slightly above ambient, especially if the other units of the group are also protected by this method, This last method may require additional sealing of the gearbox. The decision how to protect the gearbox best during scheduled and un- scheduled shut-downs depends on the operational possibilities at the site, the length of shut-down as well as the climatic conditions. HTCT 691 250 VOOO1A 15,ABB 5.2 5.3 5.3.1 en 6. Check Oi! Pump. CE Refer to separate manufacturer's instruction of the oil pump. Test run After replacing bearings or gears the procedure of re-starting has to follow the same sequence as at commissioning, regarding part load and full load tooth checks etc. Dismantling and Reassembly Removal of gears A eNo Remove shaft speed transducer (5, Fig. 6.2). Remove gear case (4). De-couple gear shafts. Remove thermocouples (301, 302, Fig 6.1) from pinion bearings upper half (wrench 13 mm). Loosen nuts on bearing cap staybolts using adequate accessories and hydraulic tools. Ee Refer to separate manufacturer's instruction of the 10. 11. hydraulic tools, Lift off double bearing caps (4, 5), using two M20 eyebolts. Remove axial thermocouples from the outer thrust bearing. Slide pressure plate (16) by min. 13 mm outward, support on lower screws. Remove two piece outer thrust bearing after turing it until split is horizontal. Lift gear shafts slightly to allow turning of two-piece journal bearings until split is horizontal. Remove thermocouple from inner thrust bearing, turning bearing as required. Remove two-piece inner thrust bearing after tuming it until split is horizontal. HTCT 691 250 VOO01A 7ABS 5.3.4 5.3.5 Replacement of the journal bearings [E> _ Before mounting, inspect the fitted surfaces of the bearing halves for mechanical damage (protruding material to be filed down). Observe the following points when installing the bearing: 1. The bearings are marked for assembly. Bearing numbers 8 and 9 for pinion bearings, 10 and 11 for wheel bearings are marked at bearing split adjacent to the same numbers on lower gear case and cap. A direction of rotation arrow is marked on the bearing cap outside. Also, bearings and caps are designed to prevent faulty assembly. 2. It is recommended to check the bearings alignment by turning the shafts in the lower halves, using "blueing" on the shaft journals. The bearings should show full, even contact across their width, 3. Afterward the no-load gear tooth contact has to be checked (see chapter 5.4). 4. Prepare gear teeth for load contact check (see chapter 4.3) and check load tooth contact. Replacement of the thrust bearings (see Fig. 6.1) Both thrust bearing units are supplied with adjustment shims to allow Positioning the axial location of each bearing and adjust clearances. The thrust bearings are marked with number 7A for inner bearing and 7B for outer bearing. To install the outer bearing 7B it is necessary to remove first the pressure plate (16) because of the axially oriented positioning pin. After installation of thrust bearing the axial bearing clearance has to be measured and protocolled. HTCT 691 250 VOO01A, 19AB 5.4 5.41 5.4.2 Gear tooth contact at no-load General ‘The check of the tooth contact at no-load has to be carried out after replacement of bearings or gears in the same way as originally done at the manufacturers shop. For this check the gearbox aligned and bolted-down but still de-coupled and the upper gear case removed. A correct no-load tooth contact guarantees a later load contact which Tequires none or only minor correction. Checking procedure For the no-load check a section of gear teeth chosen at random is manually rotated through the mesh whereby blue coating transfers from the wheel teeth to the pinion teeth leaving a tooth contact pattern corresponding to the tooth corrections. The chosen section of teeth on wheel and pinion must be thoroughly cleaned and de-greased. Coating of 3 to 5 adjacent teeth on the gearwheel with “Engineers Blue". Using a piece of foam rubber the "Blueing" is spread to a thin even layer across both flanks of each tooth, Breaking the pinion shaft manually the wheel is then rotated several times back and forth through the mesh until a clear pattern is transferred to the pinion flanks. The pattern thus obtained is protocolled by transferring it to scotch tape which is then stuck on white paper and marked as to driving tooth flank, non- driving tooth flank, coupling side pinion etc. to prevent later mis- interpretation. en HTCT 691 250 VOO01A 24ADB 6 TROUBLE SHOOTING Fault Possible cause Remedy Increased bearing temperatures on main bearings Inadequate oil supply Increased lube oil temperature Damaged white metal on a contact surface Alignment errors Correct oil pressure Adjust oil cooling Replace bearings and inform ABB. Realign (done by ABB staff) Increased bearing temperatures on thrust, bearing Inadequate oil supply Increased lube oil temperature Spray nozzles to tilting pads clogged Inadequate thrust bearing clearance Damaged bearing Correct oil pressure Adjust oil cooling Clean nozzles (done by ABB staff) Correct thrust bearing clearance Install new thrust bearing segment Marginal, one-sided tooth-load pattern; One- sided removal of red lacquer. Signs of wear on ends of loaded tooth flanks Distortion on gear housing Alignment errors. Uneven wear of pinion and/or gear bearings Realign gear housing. Realign the rotor train Replace the pinion and/or the gear bearing en HTCT 691 250 VOOO1A 23ABB Key to Figure 6.1 : Pos. Description 4 Double bearing cap 5 Double bearing cap 14 Glacier double thrust bearing 15 Glacier double thrust bearing 16 Pressure plate 28 Expansion bolt 41 Cover 42 Plate 43° Plate 101 Pinion 104 Auxiliary pinion 105 Wheel 201 Journal Bearing 202 Journal bearing 203 Journal bearing 204 Journal bearing 205 Locating screw 206 Locating sorew 301 Double thermometer 302 Double thermometer 303 Spacer tube 304 Spacertube . en HTCT 691 250 VOO01A 25Fig.6.1 Sectional drawing turbo gear complete ATCT e5T 250 VERO |RABB Pos, Description 1 Geer case, bottom halt 2 3 Ol 4G alt 5 Speed sensors ‘Support surface Fig.6.2 Turbo gear KS MBA30 CSOO1 MBA3O C5002 MBA30 C003 aver APOot MBK10 CY002 MBKi0 C¥O0 HITCT 687 250 VOOOTA 28ABB Data Sheet TURBO GEAR jo | 6 T eg | ma 0 : Type: Gi2s Manufacturer: MAAG 4 Technical Data Distance between centres: 720 mm Speeds: 6209.3 / 3000 rpm Bearing clearances - Pinion bearing: 0.585 to 0.640 mm - Gear bearing: 0.515 to 0.570 mm - Thrust bearing: 0.50 to 0.60 mm Tooth backlash - Main gear set: min. 0.74 mm - Pump gear: min. 0.36 mm ~Max. bearing temperature: 130°C oil ~ Quality: Iso ve4s - Flow (gears): 1360 limin at 2 bar inlet pressure Max. inlet temperature: 65°C Norm. operating pressure: 2 bar en HTCT 691 250 DOOO1A 113Data Sheet ABB Connection Diagram 2 Bly oT [ef Ey PEPE CTER SRT ETE TT 91 HTCT 691 250 DO001A en