N-SERIES HIGH SPEED GEAR

LONG-TERM MAINTENANCE PLAN

(INCLUDING N, NF, NV, NQ & NVQ)
 Table of Contents
Inspection Type and Time Intervals . ............................................................................................................. 2

Noise and Vibration Inspection . .................................................................................................................... 3

Visual Inspection ............................................................................................................................................. 3

Major Inspection .............................................................................................................................................. 4

Gear Tooth Detail Inspection . ........................................................................................................................ 5

Spare Parts Classification .............................................................................................................................. 6

Maintenance Plan Summary . ......................................................................................................................... 7

SCOPE OF PROCEDURE:
This maintenance procedure is intended as a guide for end users and operators of LUFKIN INDUSTRIES, Inc. Power
Transmission Division ‘N’ Series High Speed Gearbox products. The procedure includes the latest “best practice” inspection
techniques, with the intent of establishing a cost effective gearbox maintenance plan to maximize reliability.

1. INSPECTION TYPE AND TIME INTERVALS operation (10 years). During this overhaul, any auxiliary
drive rolling element bearings should be replaced
It is recommended that users of LUFKIN ‘N’ Series High along with any spring/locking devices or perishable
Speed Gearboxes plan maintenance intervals in line with seals as detailed in Section 4. A comprehensive Noise
the following operational time periods: and Vibration Inspection should be performed at least
one month prior to and one month after the Major
Noise and Vibration Inspection Inspection.
A comprehensive Noise & Vibration Inspection is
performed, as detailed under Section 2, at 8,000 hours Further examination periods should be established by
of operation (one year) after commissioning. reviewing the operating conditions found during these
initial health checks. If the gearbox is found in poor
Visual Inspection condition, then the inspection interval should be reduced.
A visual inspection is performed at 40,000 hours of If no issues were identified, it may be acceptable to
operation (five years). It is necessary to stop and isolate increase the inspection interval.
the gearbox, remove the guards, acoustic covers,
and inspection covers to allow access to the internal Future Inspections
components of the gear for an inspection as detailed in It is recommended to continue the cycle of inspection
Section 3. A comprehensive Noise & Vibration Survey as:
should be conducted at least one month in advance of
the scheduled inspection. • The Visual Inspection is repeated each additional
40,000 hours (5 years) in service.
Major Inspection
The complete gearbox will be dismantled and • A Major Inspection is conducted each additional 80,000
mechanically inspected for wear or deterioration of hours (10 years) in service.
the bearings, seals, and gear teeth at 80,000 hours of

2 N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN

 Factors Affecting the Suggested Time Intervals It is also advisable to record and view a sample of the
raw input signal. Look for very short duration, high
The above timescales are intended as a guide only; the level peaks. Presence of such peaks can indicate tooth
actual inspection period could be integrated with the failure even when overall levels are relatively low.
Driver and Driven equipment inspection schedules.

The above recommendations assume that the gearbox

is operated continuously. If the gearbox is operated
intermittently, the interval before inspection may be
increased, but it should be limited to a maximum of
125% of the time-based schedule. For example, if a
gearbox is operated for 6 months a year (4,000 hours),
the maximum time recommended before the Major
Inspection is 12.5 years (not 20, as calculated using
actual operating hours).

It is generally recognized that mechanical wear is

most likely to take place during a start-up or shutdown
condition; therefore, the time between inspections for
gearboxes with a high number of start-ups should be
reduced. Our recommendation is that if the gear operates
in excess of 60 start-ups a year, then the inspection
times should be reduced by 20%; in this situation, the 3. VISUAL INSPECTION
maximum time before the Major Inspection is 8 years
for a unit operated on a continuous basis. A visual inspection should be performed every 40,000
hours (5 years) of operation. Prior to the assessment,
2. NOISE AND VIBRATION INSPECTION review the pre-inspection Noise and Vibration Inspection
results. Ensure ‘Consumable’ spare parts are available.
The Noise and Vibration Survey requires the gearbox to At the job site, ensure all permits have been obtained
be operating at typical site load conditions. The units must and isolations have been completed by qualified
be running, so the inspection should result in no downtime personnel. Review the gear for signs of oil leakage or
(subject to site-specific safety requirements). external damage. Include the lubrication system pipe-
work, instrumentation, guards, and paint work in this
Vibration readings should be taken in at least two positions review.
on the gearbox casing in three planes: Horizontal (X),
Vertical (Y), and Axial (Z). It is recommended that as The inspection should include, but is not be limited to:
a minimum, readings are taken over the drive end of
the input and output shafts. Select locations that are Remove the gearcase inspection covers or end covers
directly over the bearings. in accordance with the Instruction Manual for the
specific unit.
If portable monitoring equipment is used, ensure that
the accelerometers are securely fixed. For comparison, Inspect the general appearance of the components and
repeat readings should be taken from the same position the quality of the lubrication oil. Specifically, look for
on each gear; therefore, mark the locations of the signs of wear on mating parts or corrosion inside the
readings and the direction of each. Note the locations on gearcase.
a sketch in the inspection report for future reference.
Record shaft end float (if fitted with thrust bearing) and
Readings should be taken in velocity units (mm/s RMS) gear backlash.
in all three planes at all positions over frequency ranges
of 0–10,000 Hz and 0–500 Hz. These ranges may need Remove the seals. Inspect both ends of all of the
to be adjusted to accommodate the specific gearbox journal bearings (inboard and outboard) for evidence
generated frequencies, such as the tooth meshing of deformation of the babbitt material and signs of
frequency. overheating.

N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN 3

 Obtain an oil sample and send to a specialized laboratory inspection Noise and Vibration Inspection results. Ensure
for analysis. Monitor levels of iron, water, acidity, and ‘Consumable’ and ‘Recommended’ spare parts are available.
foreign debris. LUFKIN’s recommended cleanliness At the job site, ensure all permits have been obtained and
level based on ISO 4406:1999 is 18/16/13. Inspect the isolations have been completed by qualified personnel.
lubrication system filter. Review the gear for signs of oil leakage or external damage.
Include the lubrication system pipe-work, instrumentation,
If sludge is evident, remove the oilway plugs and clean guards, and paint work in this review.
as necessary.
The Major Inspection should include all steps discussed
Check to ensure instrumentation is operating in Section 3 in addition to the following, but should not be
satisfactorily. limited to:

Inspect as many gear teeth as possible using a Remove the guards and disconnect couplings. Check
Borescope, mirrors, and lights. A good reference is coupling bolt shanks for steps and bolt holes for
AGMA 1010 Publication “Appearance of Gear Teeth– distortion or signs of overload.
Terminology of Wear and Failure”.
Disconnect and remove instrumentation as required.
Check auxiliary drives, if applicable, for bearing or seal Drain the oil system if required. It is preferable to
damage or overheating. Ensure clutches and brake dismantle the gear unit without disturbing the bottom half
pads are serviceable. of the gearcase. Doing so will ensure that the coupling
alignment will not be changed. However, if access is
Inspect the couplings on the drive and driven shaft restricted or dangerous, the unit must be returned to a
of the gear. Check disc packs for cracks and signs of suitable workshop for the complete inspection.
deterioration. Check gear-type couplings for excessive
tooth fretting. Remove the top half of the gearcase and any auxiliary
casing.
Check the foundation bolts for corrosion and confirm
the bolts are tight. Check that any internal instrumentation cable runs are
securely fastened and have not been rubbing against a
Report any abnormalities to LUFKIN INDUSTRIES. rotating shaft.

Remove bearing caps and bearings.

Remove the Pinion and Gearwheel to a safe area

(preferably on a suitable stand). Clean and inspect
all the gear teeth, instrumentation bands, and radial
and thrust bearing surfaces. Conduct a 100% crack
detection process of the gear teeth by magnetic particle
or dye penetrant methods.

Remove the quill from the Torque Shaft (if included).

Check the condition of the coupling drive teeth, the
diametrical fits at the ends of the splined coupling teeth,
and the retaining plate for fretting.

Inspect Babbitt Bearings for scoring, embedded debris,

or overheating. Remove minor embedded debris from
the babbitt material by scraping and polishing. Use a dye
penetrant crack test on the babbitt surface. Ultrasonically
4. MAJOR INSPECTION examine the bearing to test for delamination of the
babbitt material. Measure the Babbitt Bearing diameters
A Major Inspection should be carried out every 80,000 hours and Shaft Journal sizes in three areas to establish the
(10 years) of operation. It is strongly recommended that bearing clearances. Compare the values to the required
LUFKIN’s field service personnel perform this inspection. clearances.
Prior to the commencement of work, review the pre-

4 N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN

 Inspect the labyrinth seal and baffle plates for signs of
rubbing and wear. Replace if worn.

Ensure all oil holes and oilways are clear, and remove
any sludge or dirt deposits.

Replace rolling element bearings, spring devices,

fasteners with locking devices, grommets, and
seals. Only use parts recommended by LUFKIN
INDUSTRIES.

If an overrunning clutch is included, the pawls, pins

and springs should be replaced. The unit should be
thoroughly cleaned to ensure free movement of the
pawls.

On reassembly, ensure that all locking devices are in

good, working condition.
Heavy contact marking on the gear tooth profile. This
Check the foundation bolts for corrosion and confirm may indicate pinion-to-gear or coupling misalignment.
the bolts are tight.
Surface deterioration on the flanks of the gear teeth.
Check the drive and driven coupling alignment. This can range from micro-pitting to portions of teeth
missing.
Report any abnormalities to LUFKIN INDUSTRIES.
Evidence of overheating by a brownish discoloration
on the flanks of the gear teeth. This may indicate a
lubrication oil problem.

Evidence of excessive wear on coupling teeth, such

as wear steps visible on ends of teeth. A small wear
step is generally not critical. If unsure, measure the
wear step and the size of the tooth and refer to LUFKIN
INDUSTRIES.

GEAR TOOTH DRESSING PROCESS AT SITE

Small areas of debris should be removed and the

damage dressed out with a fine oil stone. This is a
skilled operation and should be performed by a LUFKIN
representative.

If significant tooth failures are found, discuss in detail

with LUFKIN Industries before commencing any
dressing of the gear teeth.

5. GEAR TOOTH DETAIL INSPECTION

When performing gear tooth inspections, LUFKIN strongly

recommends that an experienced technician, familiar with
such inspection, is employed. A good reference standard
for gear tooth inspection is AGMA 1010 Publication. When
inspecting gear teeth, it is particularly important to look for:

N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN 5

6. SPARE PARTS CLASSIFICATION

Gearbox spares can be classified into three groups.

Spare Part Classification

Consumable (Inspection) Recommended (Start-Up) Strategic (Insurance)

Gaskets Bearings Gearwheel & Pinion set
Locking Washers & Nuts Labyrinth Seals Torque (Quill) Shaft
Springs Temperature Sensors Torque Limiting Coupling
Filter Element Oil Pump and Drive Coupling Clutch
Rolling Element Bearings
Sealant

When establishing a suitable cost effective spare part inventory strategy, many factors should
be taken into consideration by the operator. These factors include the criticality of the plant, the
delivery time of the spare parts, the operating environment, the age and future duty of the plant,
and the design life of the gearset. A graphical presentation of a possible decision making process
is shown in Figure 1. Spare parts for these units typically are not stock items and have relatively
long manufacturing lead times.

Figure 1 - Spare Part Strategic Inventory Recommendation

300,000

• Strategic
• Recommended
• Consumable
200,000
Operating Hours

• Recommended
• Consumable

• Recommended
100,000

• Consumable
• Consider Raw Material
for Strategic parts*

Purchase spares
as required
0

Low High
Criticality of Plant

* Gear forgings may be procured as an option to minimize manufacturing lead-time and minimize
investment in spare part inventory on less critical applications.

6 N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN

7. MAINTENANCE PLAN SUMMARY

A summary of the suggested maintenance plan is shown in the table below.

For further advice, on any maintenance related gearbox issue, LUFKIN or Non-LUFKIN, contact your local LUFKIN Sales
Office, or visit our website at www.LUFKIN.com

Noise & Vibration

Hours (YRS) Survey Visual Inspection Major Inspection

8,000 ( 1 ) •
40,000 ( 5 ) • •
80,000 ( 10 ) • •
120,000 ( 15 ) • •
160,000 ( 20 ) • •
200,000 ( 25 ) • •

N-SERIES HIGH SPEED GEAR LONG-TERM MAINTENANCE PLAN 7

 The Standard of Excellence
For more information about quality Lufkin products and services,
please contact the Lufkin sales, service and support office.

Corporate Headquarters European Headquarters

LUFKIN Industries, Inc. LUFKIN FRANCE, S.A.
Lufkin, Texas, USA Fougerolles, France
(936) 637.5224 (phone) (33) 3 84.49.64.00 (phone)
(936) 633.3916 (fax) (33) 3 84.49.64.41 (fax)

gearsales@lufkin.com
www.lufkin.com

Source:O1SD 3010
Printed 3/09
N-SERIES HIGH SPEED GEAR LONG TERM MAINTENANACE PLAN 7