Westech - UG3 e UG4
Westech - UG3 e UG4
GEAR CORPORATION
GENERAL ELECTRIC
S664A LOAD GEAR
WESTECH GEAR CORPORATION
GENERAL ELECTRIC
S664A LOAD GEAR
SERVICE MANUAL
6810-111?420
MODEL 6810-1361-S664A
PART NO. 6810-1112435-1
1 INTRODUCTION 3
2 DESCRIPTION 3
3 PRECAUTIONS 3
4 STORAGE 4
5 INSTALLATION 4
6 OPERATION 5
7 MAINTENANCE SCHEDULE 5
8 TROUBLESHOOTING 6
9 DISASSEMBLY 6
10 BEARING INSPECTION 7
11 ASSEMBLY 7
FIGURE
TABLE
1 OPERATING CHARACTERISTICS 9
3 TROUBLESHOOTING GUIDE 11
4 PARTS LIST 12
2
SECTION 1
INTRODUCTION
This manual, applicable to the G.E. S664A Load Gear repair information. Load Gear operational time will
manufactured by the WesTech Gear Corporation, be maximized and the need for tear-down and parts
provides safety and handling precautions along with replacement will be minimized if attention is given to
storage, installation, preventive maintenance and understanding and using procedures as recommended.
SECTION 2
DESCRIPTION
The Load Gear, Figure 1, is a single reduction speed of nine probes. To measure casing vibration, two
reducer having double helical gearing and babbitted transducers are mounted toward the turbine end of
bearings with shafts vertically offset to transmit the upper casing and another is mounted toward the
power from a gas turbine to an electrical generator. generator end of the lower casing. Two duplex
A solid-on-shaft pinion is flanged for connection to thermocouples are installed in each bearing and
the turbine and a hollow solid-on-shaft gear is spline another is located to measure oil temperature at the
connected to a quill shaft with flange for connection drain port in the lower casing.
to the generator. The cast iron gear casing, in three
pieces, has horizontal splitlines at the high speed and Pressure lubrication is provided to each bearing and
low speed axes. End covers are of ductile iron with to seven spray nozzles directed at the gear teeth.
aluminum oil seals and sheet steel air seals.
A sheet steel heat shield is mounted at the turbine end
To measure shaft vibration, two probes are installed of the Load Gear. A coupling guard is provided at
near each end of the high speed and low speed shafts the flange connection between the Load Gear and
and a keyphasor is at the generator flange, for a total Generator.
SECTION 3
PRECAUTIONS
The Load Gear has certain features which constitute flammable. Keep flames, sparks and lighted
h~7ards that can result in personal injury or cigarettes away when the gear case is open.
equipment damage. With adequate training, attention
to the Service Manual and emphasis on individual Gear Noise: Noise from the Reduction Gear can
responsibility such injury or damage will be damage hearing. If the Load Gear is operating
minimized. with no sound enclosure, ear protection should
be worn.
Hazards associated with the Load Gear and mitigating
safety measures are as follows: Parts Handling: The Load Gear and components
must be lifted correctly and handled with care.
Rotating Shaft Extensions: Shafting, loose Personal injury can result from sharp edges and
fasteners and foreign material when rotating at heavy parts. Damage to components can be
high speed can be dangerous. Before rotation, avoided by observance of correct installation,
couplings must be properly bolted, parts wiped disassembly and assembly procedures. The
clean and shaft guards secured. assembled unit should be lifted by using lifting
eyes. Do not use shaft extensions to lift the
Meshing Gear Teeth: An exposed gear mesh has unit. Use care to avoid damage to machined
the potential for serious personal injury and can surfaces.
be damaged from foreign objects. When the
gear teeth are exposed, warnings must be posted Leads from the Temperature Detectors can be
and rotation controlled. Measures must be taken damaged during disassembly or assembly. When
to avoid objects falling into the mesh or gear assembling, care must be taken to not pinch or
case. cut the insulation on the lead wires.
DO NOT OPERATE THE UNIT WITH THE It is recommended that printed reminders be
INSPECTION COVER REMOVED. provided and that checks before start-up and
— The oil vapor present in a gear case is scheduled observation during operation be
instituted.
SECTION 4
STORAGE
As shipped from the factory, exterior machined Periodic external and internal inspections should be
surfaces and interior surfaces of the Load Gear will made during the storage period and if necessary the
have been coated with a rust preventive material. rust preventive coating should be replaced where heat
During storage the unit should be sheltered from and time have caused the coating to drain from some
extreme heat, excessive temperature fluctuations and surfaces.
airborne contaminants
SECTION 5
INSTALLATION
Handle and lift the Load Gear with care to avoid Check instrumentation circuits for continuity.
personal injury and damage to the components. The
lifting equipment must have a capacity of at least Flush the Load Gear thoroughly before operation.
30,000 pounds. The external lube oil system should be flushed
separately before connecting to the Load Gear.
Align the load gear on a rigid foundation and bolt Connect the lube oil inlet piping, vent and vent drain,
securely. the drain from the generator, and the drain to the
external sump. Install pressure gage on the flange
Obtain Westech Gear Corporation Loose Parts List opposite the inlet flange.
6810-1112404 from the shipping container and install
the service platforms. Install a heater and auxiliary pump to provide oil
heated to 50 F for start-up and for oil circulation
Mount Platform 6810-1112365-1 on the side of the unit when the Load Gear is not operating. Provide a heat
where the gear mesh inspection and casing drain ports exchange system to maintain inlet oil temperature at
are. Mount Platform 6810-1112365-2 on the side 100 to 120 F during operation. The lubri-
where the junction boxes and generator drain ports cat1g oil for normal operation (viscosity 150 SSU at
are. Use 500-13 by 2.50 long capscrews with lock 100 F) should be supplied at 15 to 25 psig 190210
washers and nuts to fasten the platforms to the lower gpm. Provide a pressure actuated switch to activate
casing. an alarm and auxiliary pump when oil pressure drops
below 15 psig.
Install the heat shield components as shown in the
figure on page 4 of the installation instructions Before start-up remove the gear tooth inspection
6810-111?404. cover, clean and dry the teeth and apply Blue Dykem
layout dye to a band of five teeth on the gear. The
Remove the shipping lock from the high speed flange dye will wear off after a short period of operation
and manually rotate the shafts as a check of condition leaving a readily discernible area of tooth contact.
after shipment.
CAUTION: All articles must be removed from
Remove the low speed centering ring, align the shirt or jacket pocket such as cigarettes, lighters,
generator and turbine and bolt the low speed and high pencils, etc., prior to working around the open
speed flanges. Replace the low speed coupling guard. inspection port.
Mount the nine proximitors remote from the Load Before startup of the Load Gear, circulate oil at
Gear and install conduit from the junction box to the 100 F to 120 F rpm, 15 to 25 psig and a flow rate of
remote proximitors. Thread the cables through the 190 to 210 gpm. Check the coverage from the spray
junction box and conduit to the proximitors. See nozzles, check for leakage and verify drain and vent
Figure 3. functions.
Install conduit from the thermocouple and transducer Replace covers, flanges and gaskets and torque bolts.
junction box to the remote terminal box. Thread the When torquing bolts, see table 2 and apply torque to
thermocouple extension cables and transducer cables bolts in a sequence which will produce complete
through the conduit to the remote terminals. closure of the splitline without gaps or distortion.
4
SECTION 6
OPERATION
At initial start-up verify the following: 6. The tooth contact pattern can be checked after
approximately 12 hours of operation by shutting
L Inlet oil pressure, 15 to 25 prig. the unit down and removing the inspection cover
and observing the areas on the pinion and gear
2. Inlet oil temperature, 100° to 150° F. teeth where the Layout Blue has worn off.
3. Oil flow rate, 190 to 210 gpm. CAUTION: All articles must be removed
from shirt or jacket pocket such as
4. Pressure switch function. cigarettes, lighters, pencils, etc., prior to
working around the open inspection port.
Operate initially at low speed and low load and
increase to rated rpm and load: Ideal contact would be approximately centered
on each helix distributed across 75 to 95% of the
L Verify free rotation. tooth length, from below the tip and above the
root fillet. There should not be contact at either
2. Listen for irregular or cyclic noise. the ends, tip or in the root. Initial contact may
not be as described and may require periodic
3. Observe vibration and temperature inspection to observe the development of the
measurements. If in excess of values in Table 1, pattern. If contact is more prominent on one
shut down, determine cause and make helix investigate the axial alignment and
correction. See Troubleshooting Section 8. allowance for float of either the gear or pinion
to allow mesh centering with consideration given
4. When Load Gear operating with full load has to thermal expansion. If wear or distress is
reached an acceptable stable temperature, record evident on the gear teeth observe the contact
the temperature and vibration values to use as after additional operation. Initially pits may
the normal operating condition not to be develop because of overstressed high spots. As
exceeded. If later operation produces the high spots are removed the load gradually is
temperature or vibration above the normal, distributed over a larger area and the
observe the trend and extent of the change to development of additional pitting stops. If the
determine if shut down is necessary or higher pitting continues or other tooth damage is
values are to be considered normaL observed, a check of operating conditions should
be made. Verify that load, speed and lubrication
5. After reaching normal operating temperature, are within the recommeded limits.
shut down and, as quickly as possible, check the
alignment of the turbine output shaft relative to 7. During the first week of operation maintain
the Load Gear high speed shaft and the sufficient surveillance of the Load Gear to detect
alignment of the generator shaft to the Load abnormal temperatures or vibration, unusual
Gear low speed shaft. Measurements should be noise or oil leakage. After the first week change
made while the components are in the hot the oil filter and check for loose nuts and bolts.
condition to note the amount of correction
necessary to prevent misalignment in the hot
condition.
SECTION 7
MAINTENANCE SCHEDULE
2. Check operation of pressure switch, auxiliary oil Check tooth contact pattern and note wear or tooth
pump and/or alarm. distress. See Section on Gear Tooth Contact Pattern.
3. Check operation of temperature switch and oil Check operation of gauges and sensors.
heater and cooler.
SECTION 8
TROUBLESHOOTING
As an aid to the detection and correction of associated with typical problems that may occur at
rnaifunction, Table 3 lists the indications, causes and some time during operation of the load gear.
corrective measures
SECTION 9
DISASSEMBLY
1. See Figure 1 and parts list Table 4 for Remove the vibration probe extension cables and
arrangement and identification of components. conduit as necessary to allow removal of high
Provide hoist capable of lifting 10,000 pounds. speed seal and upper portions of end covers.
The approximate weights of the main
components are: Disconnect the upper two casing vibration
transducers.
Upper casing 1300#, high speed pinion 3900#,
intermediate casing 3000#, and low speed Remove the transducer cables and conduit as
assembly 7400#. Do not disassemble any further necessary to allow removal of the upper casing.
than necessary to effect repair or replacement of
worn or damaged parts. Remove the high speed air shield, shaft seal and
upper portions of the end cover.
Before starting disassembly, clean the exterior of
the casing and remove tools and loose items to Remove the low speed coupling guard and the
avoid their falling into the gear case and causing upper portion of the end cover.
damage to gear teeth, shaft or bearing surfaces
or plugging oil passages. Disconnect the bearing thermocouples, two at
each bearing.
Protect components after removal from casing
by placing on wood or heavy plastic to avoid Remove the screws and dowels from the upper
scratching and nicking mating surfaces and casing. Raise the casing straight up to avoid
probe bands. bumping the pinion teeth.
Use non-metallic slings when lifting and Wire the high speed bearings to the shaft for
handling shafts and gearing. removal as the solid-on-shaft pinion is lifted from
the intermediate casing. To assure correct
2. REMOVAL OF HIGH SPEED PINION AND re-assembly note the position of each bearing and
BEARINGS. locating dowel before removal from casing.
6
Remove the transducer cables and conduit as
3. REMOVAL OF LOW SPEED GEAR ASSEMBLY necessary to allow removal of the intermediate
AND BEARINGS. casing.
NOTE: If only the low speed elements are to be Remove the low speed coupling guard, air
disassembled the high speed pinion, upper casing shields, shaft seals and upper portions of the end
and intermediate casing may be removed as an covers.
assembly.
Disconnect the bearing thermocouples, two at
Remove caps from the four high seed and four each bearing. Remove the thermocouple lead
low speed vibration probe connection heads and wire clamps as necessary to allow removal of the
disconnect the probe leads from the extension intermediate casing.
cables.
Remove the screws and dowels from the lower
Remove the vibration probe extension cables and flange of the intermediate casing. Raise the
conduit as necessary to allow removal of the casing straight up to avoid bumping the gear
shaft seals and upper portions of the end covers. teeth.
Disconnect the upper two casing vibration Wire the high speed bearings to the shaft for
transducers. removal of the low speed rotating elements from
the lower rasing. To assure correct re-assembly
note the position of each bearing and locating
dowel before removal from casing.
SECTION 10
BEARING INSPECTION:
Note the appearance of the babbitt lining. Bearing damage may be a result of oil
contamination, insufficient oil to the bearing,
If temperatures of the bearings and general installation misalignment, excessive load or
operation have been satisfactory minor pitting, system induced vibration. The cause of the
slight scoring or small amounts of metal flow damage must be determined and the necessary
will not require repair or replacement of the corrections made before reassembly to avoid
bearing. damaging the replacement bearings.
SECTION U
ASSEMBLY
1. Clean all parts thoroughly. Remove all 6. Splitlines are to be free of burrs and cleaned
sealant used on splitline surfaces. with acetone or lacquer thinner before
application of sealant.
2. Inspect for cracks and damage.
7. When assembling bearings, shafts and casing,
3. Ensure clean and unobstructed oil passages and oil the babbitt surfaces and position each
nozzles. bearing and locating dowel as noted when load
gear was disassembled. See Table 2 for bolt
4. Check condition of shaft journals and probe torques.
bands. Lightly sand journals to remove high
spots and burrs. Probe bands must have no 8. Replace thermocouple lead wires and clamps
more than .0005 mechanical and electrical and connect as shown in Figure 2.
runout.
9. Replace end covers.
5. Housing bores and bearing outside diameters
must be clean and free of burrs to allow
proper seating of bearings.
14. Replace the transducer conduit and cables. See
10. Replace shaft seals and adjust clearance of seal Figure 2.
bore to shaft. Facing the shaft flange, provide
clearance of .000/.002 at low speed right, high 15. Replace the conduit and vibration probe
speed right, high speed bottom and equal extension cables, connect to the probe leads and
within .003 at low speed top and bottom. replace the caps on the connection heads. See
Figure 3.
11. Rotate gearing manually. Gearing must rotate
freely. Rubbing or scraping must be corrected 16. Check instrumentation circuits.
before operating.
17. Review Installation and Operation Sections
12 Replace the air shields. before start-up.
8
TABLE 1
9
TABLE 2
TORQUE VALUES
DRY THREAD
.250-20 6-8
.375-16 25-30
.500-13 60-75
.625-11 120-150
.750-10 220-260
.875-9 360-430
1.000-8 540-640
1.000-12 950-1050
NOTE:
When ordering replacement parts, list the unit model number and
serial number as shown on the load gear nameplate. Refer to
Figure 1 and list the part number and name of the required part
as shown in Table 4.
Order both upper and lower halves when replacing bearings. Gear
assembly and pinion should be replaced as a set. Coupling hub
and quill shaft if re-used will require balancing in assembly
with the replacement solid-on-shaft gear.
10
TABLE 3
TROUBLESHOOTING GUIDE
Probable Action To
Malfunction Cause Be Taken
U
TABLE 4
PARTS LIST
FIND FIND
LIE NOMENCLATURE PART NO, OTY, LIE NOMENCLATURE PART NO. OTY,
12
TABLE 4 (CONT)
PARTS LIST
FIND FIND
]„I$ NOMENCLATURE PART NO. OTY LIR NOMENCLATURE PART NO, OTY,
H- HEAT SHIELD -
L - SHAFT SEAL ASSEMBLIES -
UPPER 6810-1117566-1 2
HIGH SPEED 6810-1112430-1 1 LOWER 6810-1112567-1 1
LOW SPEED 6810-1112430-2 1 BRACKET 6810-1117565-1 2
.36-16X3.0 SCREW WG209303 16 BRACKET 6810-1]12565-2 2
1.5 NPT PLUG 203150 2 BRACKET 6810-1112565-3 4
BRACKET 6810-1117565-4 2
T- THERMOCOUPLE (TC) SYSTEM - BRACKET 6810-1112565-5 2
BRACE 6810-1117565-6 2
BEARING EMBEDDED TC 208938 8 .38-16X.88 SCREW 104046 6
TC RECEPTACLE 208937 8 .38-16X2.0 SCREW 104051 6
TC CABLE WG209491 8 38-16 HEX NUT 120051 24
PROBE TYPE TC WG209343 1 .38-16x1.0 SCREW 104047 18
ACCESS FLANGE 6810-1112446-1 1
FLANGE GASKET 6810-1112448-1 1 K- COUPLING GUARD
.5-13X1.8 SCREW WG152847 4
TC PROBE HOLDER 202472 1 GUARD 6810-1112367-1 1
ALUMEL SPADE LUG 208943 18 SUPPORT 6810-1112366-1 1
CHROMEL SPADE LUG 208944 18 .5-13X1.3 SCREW 104086 6
.5-13X.88 SCREW 104084 8
13
FIGURE 1
LOAD GEAR ARRANGEMENT
14
FIGURE 2
THERMOCOUPLE AND TRANSDUCER SCHEMATIC
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TURBINE C2 C4 GENERATOR
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15
FIGURE 3
SHAFT VIBRATION PROBE SCHEMATIC
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TURBINE P4 GENERATOR
END I END
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P1 I PS P3
P7 P6 P4
P2 P8
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16
WESTECH GEAR CORPORATION
FIELD OFFICES
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GEAR CORPORATION
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