INSTALLATION REPORT SO No.

550969

By Sébastien RIONDEL Date: 04/08/11 to 17/08/11

Direct customer: GE AERO
User: BURGO PAPER MILL SORA
Kind of plant: LM2500-NFVQ2019D-GENERATOR BRUSH
People met: Mr Paul Walker and Mr Ruben Chica (GE AERO)

Purpose of visit: Replacement gearset option B

SUMMARY OF SERVICE VISIT

1. EQUIPMENT IDENTIFICATION

Equipment type Original order no. Serial no. No. hours Observations
NFVQ2019D 203768 119654 13440 Option A last January

2. EQUIPMENT LOCATION

Fig.1: Lufkin gearbox NFVQ2019D condition on site

The reason of my visit in BURGO paper mill in Sora was the replacement of the gearset option B
after 3580 hrs running since last replacement of last January (option A). On my arrival on the site, I met
Mr Ruben Chica (GE Spain) and Mr Paul Walker (Field service representative in England. We noted no
damage on the teeth when I opened the inspection plate and disassembly. We did not check the
alignment before disassembly.

Signature Sébastien RIONDEL Page 1 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

3. INSPECTION / CHECKS :
3.1. Bearing condition:

Fig.2: LS DE bearing

Fig.3: LS NDE bearing

Signature Sébastien RIONDEL Page 2 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

Fig.4: HS DE bearing

Fig.5 HS NDE bearing

Fig.6: Condition of old gear set option A

Signature Sébastien RIONDEL Page 3 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

4. FINDINGS DURING REASSEMBLY :

4.1. Record of clearances, backlashes, and tooth contact patterns:

Internal Dimensions of the HS bearings (This Diagram is for Illustration Purposes Only)

HS NDE HS DE

11,751 ’’ 11,750”

Internal Dimensions of the LS bearings (This Diagram is for Illustration Purposes Only)

LS NDE LS DE

12,251 ’’ 12,250”

Outside Dimension of the Bearing Journals of the High Speed Pinion (This Diagram is for
Illustration Purposes Only):

11,733’’ 11,732’’

Signature Sébastien RIONDEL Page 4 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

 INSTALLATION REPORT SO No. 550969

SUMMARY OF SERVICE VISIT

Outside Dimension of the Bearing Journals of the Low Speed Gear (This Diagram is for Illustration
Purposes Only):

12,235’’ 12,235’’

Calculated Bearing Clearance New gear set:

Bearing Location Designed Clearance Actual Clearance

High Speed DE .016”- .0195” 0,018"
High Speed NDE .016”- .0195” 0,018”
Low Speed DE .014”- .0175” 0,015”
Low Speed NDE .014”- .0175” 0,016”

We removed the River Hawk coupling and reinstalled on new gear with 0,395” set in place on
shaft. We checked the run out 0,02mm on coupling and 0,05mm on LS flange with new bushing plate
installed. We had reset the pressure in the coupling with the pins in good place.
We put back reassembly of the unit; we had 0,041’’ backlash and 0,096’’end play HS pinion. The
soft blue contact was correct and we had not clearance between the bearings and casing.

Fig.7: New bushing plate installed on LS shaft

Signature Sébastien RIONDEL Page 5 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

4.2. Blue contact bearings casing bores:

LS bores

HS bores

Fig.8: Blue contact bearings with the bores casing

4.3. Blue contact journal bearings:

LS bearings

Signature Sébastien RIONDEL Page 6 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

HS bearings

Fig.9: Blue contact journal bearings with the shafts

4.4. Levelling gearbox casing checking:

I checked the level of the gearbox and found 1 graduation difference between a
both sides 0,02 mm.

Fig.10: Checking of levelling gearbox

Signature Sébastien RIONDEL Page 7 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

4.5. Soft blue contact checking:

Fig.11: Soft blue contact after reassembly

The tape of the tooth contact show 90% contact on left helix and 40% on right helix GT side on
LS gear. After reassembly I made the new RTD connections in the terminal heads and in the junction
box.
4.6. Alignment between the generator and the gearbox :

RIM FACE
0.00 6,25mm

- 0.002’’ -0,008’’ 6,31mm 6,34mm

-0.009’’ 6,37mm

Fig.12: Alignment after reassembly generator side

Signature Sébastien RIONDEL Page 8 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

4.7. Alignment between the turbine and the gearbox

VERTICAL HORIZONTAL

GAP OFFSET GAP OFFSET

-0,24 mm -5,09mm 0,17mm 0,55mm

Fig.13: Alignment after reassembly turbine side

TARGET VALUES (Specifications GE)

VERTICAL HORIZONTAL

GAP OFFSET GAP OFFSET

-0,33 mm -4.90mm 0,00mm 0,00mm

We centred the rotating elements in the housing unit for GE check the Pre stretch and also
checked the distance of the LS flange end 1216mm +/- 1,5mm. We had 7,43 mm of pre-stretch on
Ameridrice coupling LS shaft after realignment in the tolerance required from GE.
5. REPLACED PARTS:

PARTS TRACEABILITY NO. ORDER NO. ITEM NO.

LS Gear 336955-01 328581 21953400
HS Pinion 336853-02 328581 21953500
4 RTD probes E7086922 GE provision

6. TESTS :
We started up the unit at 10.12 o’clock on 16th Tuesday. First starting we checked the hard blue
contact with 20% load during 2 hours (6,5Mw). We synchronised 1 Mw at 10.30. Everything was
correct, the temperatures of the bearings were stabilized and the vibrations were acceptable.

Ge decided no install the complete set vibrations probes on the gearbox, only 2 accelerometers
on top casing.

Signature Sébastien RIONDEL Page 9 of 13

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SUMMARY OF SERVICE VISIT

Overall view

90% 55%- 60%

Fig.14: Hard blue contact with 20% in load on active flank LS gear

The contact with 20% in load shows 90% on Active helix gene side and 55%-60% on
active helix GT side. The hard blue contact was correct in the specification of Lufkin Ind.

After hard blue contact in 20% in load, we restarted the units for the full test in 28 Mw (we
limited the load because the climatic conditions is very hot). After 2 hours in full power, we stopped
the units to check the hard blue contact in 100% in load. We had 100% of contact on both active
helices appear to confirm the design. The condition of the gears was perfect, no abnormal marks and
wear, no vibrations and noise.

Signature Sébastien RIONDEL Page 10 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

Overall view

100% 100%

Fig.15: Hard blue contact with 100% in load on active flank LS gear

Signature Sébastien RIONDEL Page 11 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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Fig.16: Hard blue contact with 100% in load on no active flank LS gear

Fig.17: Temperature and vibrations stabilized with 27,2 MW.

See attached in appendix the report of vibrations for the full test.

Signature Sébastien RIONDEL Page 12 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A

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SUMMARY OF SERVICE VISIT

Fig18: Trend plot acceleration – Gearbox

7. CONCLUSIONS

The service job which consisted has to replace the gears option A installed last January by option
B was passed very well. The full tests were conclusive and show that the gearbox can be running in
good condition.
Mr Paul Walker released me on August 17, 2011 and the end customer had the units for running
in normal condition.

Signature Sébastien RIONDEL Page 13 of 13

LUFKIN FRANCE - 70220 FOUGEROLLES LKF 19.030 A