09-Sundyne Presentation Fs Improvement

RECENT RECENT UPGRADES/IMPROVEMENTSUPGRADES/IMPROVEMENTS

GEARBOX UPGRADES RESULTING FROM MARKET FEEDBACK

• SHAFT BALANCING NOW STANDARD • TAPERED ALIGNMENT BOLTS• O-RINGS STANDARD IN GEARBOX SPLIT

LINE• LUBE PUMP UPGRADED• EXTENDED SIGHT GLASS• SEAL BUSHINGS • NEW INPUT SHAFT SEAL • TAPERED THRUST WASHERS

..

GEAR DRIVEN PRODUCTS

SHAFT BALANCING

• Need:– Address vibration as an ongoing

end user concern

• Feature: – All shafts in gearbox drivetrain are

balanced (input, idler & output)– ISO 1940 Grade 2.5

• Benefits:

– Address customer feedback– Reduced vibration, noise– Improved reliability & operating life

• Field Eng. Bulletin 40.20.40

SUNDYNE

INPUT SHAFT

SUNDYNE

IDLER SHAFT


•Shaft balancing •Tapered alignment pins•O-rings standard in gearbox •Lube pump upgrade•Extended sight glass•Seal Bushings •New input shaft seal •Tapered thrust washers

TAPERED ALIGNMENT BOLTS

• Need: – Maintain integrity of original gearbox

alignment between overhauls

• Feature: – Lead in chamfer prevents threads

from shaving aluminum housing upon installation

• Benefits: – Maintains true position of close

tolerance holes in gearbox housings– Alignment maintained after multiple

rebuilds– Attaching hardware now consistent

throughout


NEW ½”-13 THREAD

OLD 5/8”-18 THREAD



O-RINGS STANDARD IN GEARBOX SPLIT LINE

• Need:– Address plant EH&S concerns regarding oil

leakage

• Feature: – O-rings replace paper gaskets in gearbox

housings– LMV-322/311 gearboxes upgraded– Viton is standard material throughout

• Benefits: – Eliminates oil leakage at split-line– Less clean-up & contamination– More durable for assembly and rebuild


O-rings



LUBE PUMP UPGRADE

• Need:– Reduce risk of bearing damage

due to inadequate lubrication

• Feature: – Supplier Quality Driven – Lube pump & anti-rotation pin

improved– Apply SPC to manufacturing

process– Improved component tolerances,

testing & packaging

• Benefits: – Eliminate oil pressure fluctuations– Prevent oil pump seizure– Reduce wear at input shaft slot

• Field Eng. Bulletins 40.20.40 & 40.20.43 NEW PIN OLD PIN


INSTALLED PIN


EXTENDED SIGHT GLASS

• Need:– Maintain optimum oil level for

proper lubrication and cooling

• Feature: – Extended tube acts as oil

reservoir allowing entrained air to escape

– Tested low foam sight glass using ISO VG 32 Oil at 140°F, operating at 34,000 rpm

• Benefits: – Accurate oil level reading at all

oil temperatures and speeds– Ensures the correct oil level is

maintained – Prevents overfilling


– GA01AA05 replaces GA01AA01

NEW DESIGN

OLD DESIGN



SEAL BUSHINGS• Need:

– Increase seal life for certain applications

• Feature: – Segmented carbon bushing– Close radial clearance against

hardened shaft sleeve– Available as throat, isolation or

steam bushing

• Benefits: – Regulate seal cavity pressure on

seal flush plan 11 & 21 arrangements

– Maintain sufficient vapor pressure margin to prevent flashing at the seal face.

– Maintain cool liquid in external seal pot for plan 23 arrangements such as boiler feed service

• Sales Alert: March 2008

• See drawings in new Sundyne o-ring kits

Single seal with Isolation bushing

Tandem seal with throat bushing


GEAR/DIRECT DRIVEN PRODUCTS

NEW INPUT SHAFT SEAL

• Need:– Increase lip seal life– Eliminate water contamination of oil

• Feature:

– Inner sleeve rotates with shaft against stationary outer seal

– Tested against high pressure spray, 5500 start/stop cycles

– One design for LMV-322/311/331 gearboxes

• Benefits: – Extended life vs. traditional lip seal

– Target 3 to 5 years

– Prevents water, dust and debris from entering gearbox

– Keeps oil inside gearbox– Inner sleeve eliminates input shaft

grooving

• Field Eng. Bulletin 40.20.XX– Part number 20-378 replaces 20-019



TAPERED THRUST WASHER

• Need:– Higher suction pressure design – Reduce risk of upset condition

bearing failures

• Feature: – Historically a Flat Plate – Now a Tapered Land Thrust

Bearing– Develops oil wedge

– Same part installed in upper and lower position

• Benefits: – Higher thrust capacity– Dimensionally Interchangeable – Dual taper allows bi-directional

rotation


– Part number remains WA01AA01XXX

OLD DESIGN

NEW DESIGN



BEARING BOX

• Need:– Customers require API 610 OH3

compliant bearing bracket

• Feature: – API 610 compliance achieved– Available in sealed for life, pressure

lube, oil mist bearing configurations– Field Interchangeable – Bearing L10 life exceeds 25,000 hours

• Benefits: – 3 to 5 years MTBR– Standard design simplifies

maintenance– Extended application range

– Suction pressures up to 1100 PSI– Upgrade field installations

COUPLING HOUSINGS

• Need:– International standard design for

coupling housings– Improved motor alignment

• Feature: – Fabricated steel upgraded to cast

aluminum– Design consolidation: 3 castings

accommodate all frame sizes – Dimensional optimization of DBSE

• Benefits: – Non-sparking, lightweight

construction– Standard design: 3 castings

accommodate both NEMA and IEC motors

– Ease of assembly – Remove coupling center section with

motor in place– Larger access ports– Improved coupling alignment

SUNDYNE LMV-341 SUNDYNE LMV-341 UPGRADESUPGRADES

Bi-directional LubeOil Pump Provides

Pressure Feel Lubrication

Idler ShaftJournal Bearing

16 Pitch Spur GearHigh-Speed Mesh

Idler ShaftJournal & Taper

Land Thrust

SundGardTM

Oil Filterb3ò200

Mechanical Seal 1-3/4” (44.5mm) HighCapacity Journal Bearings

Integral PinionGear forMinimized Vibration

Split LineO-Ring Seals

Oil Fill Port

Spherical RollerBearings5-Yr L10

16 Pitch Helical GearLow Speed Mesh

LMV-341

Orificed Oil Feedto Input Bearings

Shaft Driven

Bi-DirectionalLube Pump

SundGardTM

Oil Filter

MechanicalGearbox Seal

Internal MainReservoir

Oil Fill Port

Bearing Plate MtdRelief Valve at 100 PSI

Oil Pressure Gage Min. 25 psi to Bearings

LMV-341 INTERNAL LUBE OIL SYSTEM

GEARBOX UPGRADESUMMARY OF THE MAIN CHANGES

– 16 PITCH HELICAL GEARS REPLACED 16 PITCH INPUT SPUR GEARS

– CYLINDRICAL ROLLER BEARINGS CHANGED TO SPHERICAL ROLLER TYPE BEARINGS ON THE INPUT SHAFT

– LOWER IDLER THRUST BEARING CHANGED FROM FLAT TO TAPER LAND TYPE

– INPUT BEARING LUBRICATION CHANGE : LUBE JETS HAVE BEEN REPLACED WITH CIRCULATING OIL LUBRICATION BY SUPPLYING OIL THROUGH ANNULAR GROOVE AND LUBRICATING HOLES

– AUGMENTED BY 50% OIL FLOW TO UPPER AND LOWER IDLER BEARINGS

– A KMC DEFLECTION PAD THRUST BEARING WAS ADOPTED FOR HIGH SUCTION PRESSURE APPLICATIONS

LMV/ BMP-341

GEARBOX UPGRADESUMMARY OF THE MAIN CHANGES (CONTINUED)

– INCREASED THE INTERNAL LUBE PUMP CAPACITY– INCREADED RELIEF VALVE CRACKING PRESSURE,

AND FLOW CAPABILITY– INCREASED OIL FILTER CAPACITY TO 57 L/MN– RECOMMEND OPERATION WITH ISO VG 46 TYP OIL

FOR EXTENTED BEARING LIFE– A PRE LUBRICATION LUBE SYSTEM BECAME

MANDATORY FOR START UP AND COAST DOWN PHASES

ADDITIONAL CHANGES NOT HEREABOVE LISTED HAVE BEEN IMPLEMENTED IN ORDER TO IMPROVE EASE OF MAINTENANCE AND MISTAKE PROOFING

LMV/ BMP-341

HELICAL INPUT GEARS

LOWER VIBRATION

LOWER NOISE

SPHERICAL ROLLER INPUT BEARINGS

INPUT HOUSING & BEARING PLATE

PUMPS ONLY

PREVENTS MIXING UPPER & LOWER HIGH SPEED BEARINGS

PIN IN LOWER GBX HOUSING

LOWER BEARING HAS HOLE FOR PIN

PIN PART NUMBER: 08-013AF, INSTALLED AT ASSEMBLY

MISTAKE PROOFING HIGH SPEED BEARINGS

MISTAKE PROOFING HIGH SPEED BEARINGS

BI-DIRECTIONAL TAPER LAND THRUST WASHER

TAPER LANDS

OIL FEED GROOVES

LMV/ BMP-341

APPLIES TO ALL UNITS

INPUT SEAL IS COMPATIBLE WITH BOTH CONFIGURATIONS

INPUT SEAL

IMPUT SEAL

INPUT SHAFT SEAL

LMV/ BMP-341

KMC TILT-PAD BEARING INCORPORATED FOR HIGH SUCTION PRESSURE APPLICATIONS• 3500# UPTHRUST CAPABILITY

HIGH SPEED SHAFT AND THRUST RUNNERS REDESIGNED TO ACCOMMODATE HIGH AND STANDARD THRUST OPTIONS

INCREASED SIZE OF SHAFT SHOULDERS FOR THRUST RUNNERS• .050” => .190” SHOULDER

NEW STANDARD THRUST SHAFT ASSEMBLY IS INTERCHANGEABLE WITH ORIGINAL DESIGN

NEW HIGH SPEED SHAFT & KMC THRUST BEARING

STANDARD THRUST HIGH THRUST

NEW HIGH SPEED SHAFT ASSEMBLY

KMC THRUST BEARING

NEW STANDARD DESIGNED FOR 15 GPM

FILTER CANISTER IS SAME SIZE AS ORIGINAL

NEW STANDARD USABLE FOR SPARES

3 MICRON @ BETA>200 IS STANDARD

SAME PART NUMBER AS ORIGINAL

OIL FILTER ENHANCEMENT

PRESENT NEW FLOW FILTER FILTER(GPM) (PSI) (PSI)

9.0 5.70 3.9912.5 7.92 5.5415.0 9.50 6.65

GEARBOX MOUNTED FILTER PRESSURE DROP

OLD VALVE

• 65 PSIG CRACKING PRESSURE• RATED FOR 4.1 GPM

NEW VALVE (P/N 71-424)

• 100 PSIG CRACKING PRESSURE• 3/4” VALVE RATED FOR 15 GPM • BEARING PLATE REQUIRES 3/4” TAP

RELIEF VALVE

LUBE SYSTEM CHANGES

AUXILIARY LUBE PUMP REQUIRED

INTERNAL LUBE PUMP SELECTION:

• 50 HZ - 12.5 GPM - PU01AW01B

• 60 HZ - 10.8 GPM - PU01AW03B

• ALL WITH KMC THRUST BEARING:– PU01AW01B - 12.5 GPM@50HZ,15 GPM@60HZ

LUBE SYSTEM SET-UP

CUSTOMER’S AUXILIARY PUMP MAY

BE REQUIRED TO DEVELOP ADEQUATE

PERMISSIVE START PRESSURE

RECOMMENDED OIL

ISO - 46 @ 50 -60 ºC TO BEARINGS

ISO - 32 @ 50 ºC TO BEARINGS

LUBE SYSTEM SET POINTS

TEMPERATURE:• NORMAL OPERATION 50°C – 60°C• ALARM 70°C

PRESSURE:• NORMAL OPERATION > 1.7Barg• ALARM – 1.4Barg• PERMISSIVE START / SHUTDOWN –1Barg

LMV-341 PHOENIX GEARBOX SEAL:

GEARBOX SEALS

GEARBOX SAME AS LMV-341 EXCEPT:

• DIFFERENT SPEED RATIOS

• DIFFERENT HIGH SPEED SHAFT EXTENSION

• KMC THRUST BEARING STANDARD FOR LOWER HIGH SPEED BEARING

HIGH FLOW PUMPS WITH PHOENIX GEARBOX

09-Sundyne Presentation Fs Improvement

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