225MW COMBINED

CYCLE GAS BASED

POWER PLA
Files exported on
11/19/2012
Main Table Of Contents
Files exported on 11/19/2012
Couplings 1.7
1.7
Couplings
Load Coupling
Table of Contents OMML_LC_TOC
Load Coupling OMML_LC_01
GE Energy
OPERATION AND MAINTENANCE MANUAL
COMPONENT LITERATURE
________________________________________________________________________
All rights reserved Copyright Droits de reproduction rservs ________________________________________________________________________
OMML_LC_TOC_6FA_E1018_A_EN Revision : A Date : 07/2011
LOAD COUPLING
TABLE OF CONTENTS
Designation GE device File name
Load coupling OMML_LC_01_Coupling_A_EN
Rev. : A
Page : 1/1
GE Energy
OPERATION AND MAINTENANCE MANUAL
COMPONENT LITERATURE
________________________________________________________________________
All rights reserved Copyright Droits de reproduction rservs ________________________________________________________________________
OMML_LC_01_Coupling_A_EN Revision : A Date : 03/2011
EQUIPMENT DEFINITION
GE DEVICE :
DESIGNATION : LOAD COUPLING
SUPPLIER : RENK
TYPE : MC6-565
LITERATURE REFERENCE : B00006500-2 + 0770909_8 (13 PAGES)
Rev: A
Page: 1/14
Operation ManuaI
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B000065-02-en/04.2006
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Contents
0 DecIaration by the Manufacturer 2
1 GeneraI 3
1.1 ntroduction 3
1.2 Copyright and Patent Rights 3
1.3 mportant Notes for the User 3
1.4 nstruction/Training 4
2 Safety 4
2.1 Symbols and Signs 4
2.2 ntended Application 5
2.3 Remaining Risk 5
2.4 Safety nstructions 5
2.5 nstructions with respect to particular
hazards
7
3 TechnicaI Description 7
4 Transport and Storage 8
4.1 Scope of Delivery 8
4.2 Transport 8
4.3 Storage 8
5 AssembIy 9
5.1 Component Marking 9
5.2 Cleaning 9
5.3 Alignment 9
5.4 nstallation of the Coupling 10
6 Dismounting the CoupIing 11
7 Maintenance and Repair 11
8 DisposaI/RecycIing 12
9 TroubIeshooting 12
10 Spare Parts 12
B000065-02
2
Declaration by the Manufacturer
as defined by Machinery Directive 98/37EC, articIe 4 paragraph 2 and annex II B
We hereby declare that the product described below is to be incorporated in a machine or to be combined
with other machines to make a complete machine or a complete unit. t must not be put into service until it
has been confirmed that the complete machine or complete system into which this product is to be incor-
porated satisfies the requirements of the EC directives, in particular the EC Machinery Directive.
Product: Diaphragm CoupIings
Turbo Series
Type: MC6-565
Reference: The couplings described in this operation manual.
Place, Date : Rheine, 03.04.2006
nformation on signatory: Manager Product Development
- legally binding signatures, at least p.p.
B103300
B000065-02-en/04.2006
3
1 GeneraI
1.1 Introduction
This operation manual accompanies the
delivery of a diaphragm coupling by RENK
AG, Plant Rheine. The abbreviated term
'coupling' is used throughout the following
text.
The operation manual is an essential guide
to ensure the successful and reliable
operation of the coupling. t contains
important instructions how to operate the
coupling in a safe, appropriate and
economic manner. Observing the manual
helps avoiding hazards, reduces repair
costs and downtimes and increases the
reliability and lifetime of the coupling.
t is of utmost importance to always have
the operation manual available in the direct
vicinity of the coupling. The manual has to
be read and followed by all persons being
charged to work at or on the coupling, e.g.
Operation, including remedy of faults
during service, as well as disposal of
greases and other products required for
the operation, and/or
Maintenance (servicing, repair)

Note:
Copies of the dimension drawing and of the
order acknowledge have to be attached to
the operation manual.
These documents furnish important spe-
cific coupling data.
1.2 Copyright and Patent Rights
This operation manual shall be treated con-
fidentially. t shall only be made available to
authorised persons.
t is not allowed to transfer this operation
manual to any third party without having
received the written permission from RENK
AG beforehand.
All the documents are protected according
to the copyright law. t is not permitted to
copy or reproduce any documents as a
whole or in part, or to use them or make
them available to others, unless explicitly
approved in writing.
Contravention is punishable and subject to
claims for compensation. We reserve all
rights to exercise commercial trademarks.
1.3 Important Notes for the User
The operation manual is an essential com-
ponent of the coupling. The operator of the
plant is responsible to take care that the
operating staff takes due note of these
instructions.
The operator has to complete and supple-
ment this operation manual by additional
instructions and regulations regarding the
prevention of accidents and the protection
of the environment, including relevant pro-
visions for supervising and reporting obliga-
tions with respect to operational features,
e.g. as far as the organisation of work,
working sequences and personnel are con-
cerned.
n addition, carefully observe:
valid regulations and laws concerning
safety at work being in force in the
country and site of installation, and
the recognised subject-specific and tech-
nical rules and standards regarding the
safe and proficient execution of work.
The operator of the coupling is not allowed
to carry out any modifications, conversions
B000065-02
4
or retrofits on the coupling which may affect
the safety, without prior written approval
from RENK AG.
This also applies to the installation and the
adjustment of safety equipment as well as to
welding operations on parts of the coupling.
All spare parts which are put into service
have to comply with the technical require-
ments set forth by RENK AG.
This is only ensured if original spare parts
are used.
Skilled and trained personnel shall be em-
ployed only. Responsibilities and
competencies of the personnel with
respect to operation, maintenance and
repair have to be clearly defined.
For warranty reasons, RENK AG is to be
informed in writing about the date of the
first start-up of the equipment.
1.4 Instruction/ Training
As the operator of the equipment you are
obliged to advise and instruct the operating
staff of valid legal provisions and regula-
tions regarding the prevention of accidents
and on existing safety equipment at or
around the coupling. The different qualifica-
tions of the employees have to be taken
into account.
The operating personnel must have under-
stood the instructions and it has to be safe-
guarded that the instructions are strictly
observed. This way only will promote the
personnel's awareness of hazards and
safety at work. This should be verified at
regular intervals. t is strongly recom-
mended that the operator of the plant re-
quests the operating staff to confirm in writ-
ing the participation in such training/ instruc-
tion courses.
2 Safety
The coupling has been designed and con-
structed according to the latest state of
technology and in compliance with recog-
nised safety regulations.
Nevertheless, the use of the coupling may
cause risks for the operator or other per-
sons, or may deteriorate the function of the
coupling or other equipment, if it is:
operated by unskilled and non-instructed
personnel,
not used for the purpose and application
as intended,
improperly serviced and maintained.
2.1 SymboIs and Signs
The following signs and symbols are used
in this operation manual in order to high-
light important details:
Danger!
This is to be understood as a warning that
personal injuries can occur if the given
instruction is not followed exactly.
AII WARNINGS must be strictIy ob-
served!
Attention!
This means that damages can occur at the
product and/or accessory equipment due
to false and inaccurate observance of the
specified measure/ instruction.
AII the PRECAUTIONARY MEASURES
resuIting therefrom have to be strictIy
observed!
B000065-02-en/04.2006
5

Note:
This refers to a procedure or circumstance
of special interest or importance. Within the
interest of the proper application of the cou-
pling as intended, all the stated measures
and notes have to be observed carefully!
x This eye-catching point denotes working
sequences and/or operating steps. The
steps are to be followed in the order from
up to down!
This dash identifies enumerations.
2.2 Intended AppIication
This coupling exclusively serves for the
transmission of torque between two ma-
chines. The coupling compensates mis-
alignments and displacements.
The technical details of the coupling have
to be observed and complied with. These
data are stated on the dimension drawing.
Any other use or operation of the coupling
beyond the above mentioned application
purpose is not regarded as the intended
application. The operator / user of the cou-
pling is solely responsible for all damages
resulting therefrom. This also applies to
unauthorised modifications, which are car-
ried out on the coupling.
The intended application also includes the
observance of instructions relating to:
safety and security,
operation,
maintenance/ repair,
as described in this operation manual.
2.3 Remaining Risk
Even if all the safety regulations and in-
structions are strictly observed, there re-
mains a risk when operating the coupling.
Danger!
Injuries due to touching the rotating
coupIing.
The coupling has to be secured with suit-
able protective devices against uninten-
tional physical contact (finger-safe).
Danger!
Injuries due to energy reIease in case of
faiIure.
The IeveI of the remaining risk is pro-
portionate to the transmitted power.
The coupling has been designed/ devel-
oped taking into account respective safety
factors.
2.4 Safety Instructions
Every person being involved or charged
with the assembly or maintenance of the
coupling is obliged to have read and un-
derstood this operation manual.
The operation manual shall always be kept
ready to hand in the direct vicinity of the
coupling.
The coupling must only be used in a tech-
nically unobjectionable state and in accor-
dance with the intended purpose as agreed
while carefully complying with this manual.
n particular, circumstances or distur-
bances, which affect the safety, have to be
eliminated immediately.
No responsibility will be assumed for any
damages and accidents, which result from
the non-observance of this operation man-
ual.
The relevant regulations and provisions
regarding the prevention of accidents and
other generally recognised rules on safety
B000065-02
6
at work and occupational medicine and
health care have to be strictly observed.
The instructions with respect to maintenance
work have to be observed when inspecting,
servicing or repairing the coupling!
Should operation fluids (such as oils) leak
out while working on the coupling, these
fluids have to be immediately and com-
pletely removed with a cloth from the floor
and working area.
The responsibilities and competencies as
regards the various activities to be carried
out in conjunction with the operation, main-
tenance and repair of the coupling have to
be clearly defined. Only in this way, mis-
takes or false handling can be avoided, in
particular in danger situations.
f safety-affecting changes in the operational
behaviour or irregularities are observed, the
coupling has to be put out of operation im-
mediately. The responsible post/ person has
to be notified without delay.
As far as necessary or required by legal
regulations, the personnel must put on
protective equipment (protective clothing
and gloves, ear plugs, protective goggles)!
Skilled and reliable personnel only are
allowed to perform work on the coupling.
The minimum age as permitted by law has
to be observed!
Do not stay under suspended loads!
2.4.1 Operating the CoupIing
The coupling must only be put into service
in assembled state, ready for use.
The coupling shall only be operated after all
the protecting equipment and safety devices,
e.g. detachable protective devices, have
been mounted and are ready to operate.
2.4.2 Servicing/ Remedy of FauIts
Prescribed time periods or intervals being
specified in this operation manual with
respect to routine and recurring checks/
inspections have to be observed.
f the machinery branch into which the cou-
pling is mounted has to be disconnected
for servicing or repair work, it has to be
secured against unexpected re-
engagement:
Main control devices such as switches
and valves have to be locked away and
the key has to be taken out,
and/or
attach warning signboards to the main
control devices.
t is of importance that the workshop se-
lected to perform necessary servicing and
repair work is appropriately equipped.
Screwed connections that have been
loosened for maintenance or repair works
have to re-tightened. f specified, the
screws have to be tightened with a torque
wrench.
f safety equipment has to be removed in
order to carry out installation, maintenance
and repair works, these devices have to be
re-mounted and checked immediately upon
completion of the maintenance or repair
work!
f individual components or larger assem-
blies have to be replaced, these have to be
carefully attached and secured to the lifting
appliance, so a to minimise all risks. Only
use suitable and technically unobjection-
able lifting appliances and load lifting ele-
ments of sufficient lifting capacity.
B000065-02-en/04.2006
7
Take care for the safe and environment-
friendly disposal of spare parts, greases,
oils and other agents used for operation.
2.5 Instructions with respect to
particuIar hazards
2.5.1 OiIs, greases and other chemicaI
substances
The safety data sheets of the substances
used have to be attached to the operation
manual.
When handling with oils, greases and other
chemical substances, the applicable regu-
lations and safety data sheets supplied by
the manufacturers of such products with
respect to storage, handling, application
and disposal have to be strictly observed
and complied with!
Put on protective equipment made of suit-
able material (protective goggles, rubber
gloves, rubber boots, protective clothing)
when working with etching products!
n case of contact with eyes or skin, the
affected part has to be washed over with
ample water. Suitable equipment (eye
washing bottle, hand basin, shower) has to
be available near the workplace!
Skin that is strained by the use of cleaning
or disinfecting products should be treated
with care products. The preventive use of
skin protection products and appropriate
skin care can avoid damages to the skin.
2.5.2 Noise
The A-weighted permanent noise pressure
level of the coupling is below 83 dB(A).
t is therefore not necessary to wear ear-
plugs.
t may happen that the coupling amplifies
existing noises originating from the con-
nected machines. n such a case, and in
particular in the neighbourhood of loud
machines, it is recommended to wear ear
protectors.
3 TechnicaI Description
The coupling is divided into two coupling
halves.
Both coupling halves consist of the flanged
shaft [9260 and 9261 resp.] with the pro-
filed diaphragms, the adapter [9120 and
9121 resp.] and the guard ring [9352].
The guard rings mechanically protect the
diaphragms. They also serve for guiding
the spacer in case of damage due to over-
load.
The torsional stiff, backlash-free and flexi-
ble coupling allows shaft misalignments,
such as axial, angular and parallel mis-
alignment.
The occurring restoring forces remain low
within the permissible misalignment range.
All the coupling components are finish-
machined, balanced and prepared to be
assembled/ installed.
B000065-02
8
4 Transport and Storage
4.1 Scope of DeIivery
The coupling is supplied in partly assem-
bled state. The individual components
shown on the dimension drawing belong to
the scope of delivery.
On receipt of the coupling, check whether all
the parts have been supplied and that they
are not damaged. Complaints regarding the
delivery have to be immediately addressed to
RENK AG in writing.
The Standard General Terms and Condi-
tions of RENK AG are applicable.
4.2 Transport
Danger!
Injuries are possibIe due to coupIing
parts faIIing down!
Select appropriate lifting tools in depend-
ence of weight and size of the components,
or packaging resp.
The coupling is packed in a robust wooden
crate.
x During transport, the coupling has to be
secured against slipping or falling down.
x Observe the relevant provisions for the
prevention of accidents!
Attention!
Damages to the coupIing due to defor-
mation of the diaphragms.
The transportation of the equipment/
equipment components may cause defor-
mations of the base frame, which may
overload the diaphragms. Dismount the
coupling in case of uncertainty as regards
eventual deformations.
4.3 Storage
The coupling is supplied with anti-corrosion
protection. This protection is suitable for
normal transport and storage conditions.
The corrosion protection is effective for six
months, provided the parts are stored in a
dry and protected place.
Attention!
Corrosion damages on the coupIing
parts!
When the storage period of 6 months has
been exceeded, the corrosion protection
has to be regularly checked on all coupling
components
x f required, the coupling parts have to
be protected with a long-term preserva-
tion agent (consult RENK AG before-
hand!).
x The coupling parts have to be stored in
a dry place under roof and have to be
protected against mechanical damages.
x Do not expose the coupling parts to a
saliferous or acidiferous environment.

Note:
RENK AG does not assume any responsi-
bility for damages due to improper corro-
sion protection!
B000065-02-en/04.2006
9
5 AssembIy
Attention!
The coupIing or the machines to be
connected can be damaged due to the
use of faIse tooIs!
The coupling must only be assembled by
instructed and skilled personnel.
t is of utmost importance to acquaint one-
self with all the markings on the coupling
and to assemble the coupling in accor-
dance with these markings.
Suitable tools/ devices have to be used to
assemble the coupling.
Never use striking tools and/or sharp tools
for the installation/ assembly!

Note:
The necessary details for the installation
are stated on the dimension drawing.
5.1 Component Marking
The main parts of the coupling (i.e. the
flanged shaft, adapter and guard ring) are
marked with the RENK order number
(Com. No.).
Care has to be taken that the correct cou-
pling and the appertaining parts are used
for the specified application.
The main parts are marked with their as-
sembly positions. n addition, observe the
identification of the coupling halves (A and
B).
5.2 CIeaning
Attention!
Damages to the surfaces of the cou-
pIing due to the use of cIeaning prod-
ucts containing soIvents.
The use of cleaning products containing
solvents is not permitted.

Note:
All the coupling parts have to be cleaned of
anti-corrosion agents.
x Use wax solvents, cleaning gasoline (no
petroleum!) or an alkali industrial cleaner
to clean the coupling parts.
5.3 AIignment
Due to the high coupling speed, it is essen-
tial to align the flanges to be coupled with
utmost precision.
Thermal expansions of the machines to be
coupled should, as far as known, be con-
sidered for the alignment.

Note:
Carefully observe the alignment instruc-
tions as specified by the gearbox and tur-
bine manufacturer.
The following alignment values are given
as recommendation only:
Parallel offset:
0.35 mm with a coupling length of 1245,2
mm.
Angular offset:
0.02 mm referred to a measuring radius of
200 mm.
B000065-02
10
Axial offset:
Turbine and gearbox have to be aligned to
the dimension 1245,2 mm (as stated on the
dimension drawing), with a tolerance of
max. 0.1 mm.
5.4 InstaIIation of the CoupIing
Attention!
Incorrect assembIy of the parts causes
damages to the coupIing components.
The coupling parts have to be assembled
according to their markings (A-A, B-B, Or-
der Com. No.). Observe the instructions
furnished by the machinery suppliers!
Attention!
Improper instaIIation may cause dam-
ages to the contoured diaphragm.
The coupling halves have to be mounted
with utmost care and caution. The thin
diaphragm surface can easily be damaged
due to improper handling. Take care that
the exposed diaphragm surfaces are not
dented or scratched during assembly.
x Make sure that the driving machine is shut
off and secured against re-engagement.
x The flanged shaft, guard ring and the
adapter are marked so that their position
to each other can easily be checked.
Carefully observe the identification mark-
ings of the sides A and B.
x Remove the adapter.
x Use a suitable lifting device to mount the
turbine-side coupling half (long half) into
the turbine inlet air chamber.
x Place the adapter on the centering of the
turbine flange.
x Turn the coupling parts until the markings
are located side by side.
x Slide the guard ring over the flange shaft
and the adapter.
x Screw down the coupling half with the
fitted bolts.

Note:
The way how to bolt the coupling half to the
turbine or gearbox flange resp. is de-
scribed in the fitted bolt instructions.
x Do not remove the lifting device!
x Shift the gearbox shafts by 25 mm to-
wards the gearbox.
x The coupling half on the gearbox side
has to be mounted correspondingly.
x Turn the coupling halves in such a way
that the markings on the flange of the
flanged shafts are located side by side.
x Join the coupling halves by moving the
gearbox shaft.
x nsert the fitted bolts 9140 from the gear-
box side into the bores and tighten them
crosswise with the nuts. Observe the
tightening torque mentioned on the di-
mension drawing.
Attention!
Broken coupIing boIts cause damages
to the coupIing.
The tightening torques stated in the dimen-
sion drawing applies to dry or slightly oiled
bolts.
Never use pastes that reduce the friction
(such as products containing MoS
2
).
B000065-02-en/04.2006
11
6 Dismounting the CoupIing
Attention!
Injuries of the Iimbs when touching the
rotating coupIing!
After having disconnected the drive
motor, the coupIing may stiII continue to
turn for a Ionger time period untiI it
comes to a compIete standstiII.
For this reason, wait until the coupling has
come to a complete stop before opening
the protective cover.
Attention!
Burns of the Iimbs when touching the
coupIing!
After Ionger operation periods, the sur-
faces of the coupIing may stiII be very
hot.
For this reason, wait until the coupling has
cooled down before opening the protective
cover.
t is recommended to wear heat-resisting
gloves.
Attention!
Take care not to damage the dia-
phragms.
Take utmost care when dismounting the
coupling. Avoid damaging the diaphragms.
Dismount the coupling as described below:
x Secure the coupling halves by placing a
support underneath, or by means of a lift-
ing device!
x Loosen the nuts and remove them from
the fitted bolts.
x Remove the fitted bolts from the bores.
x Screw the puller screws (thread M12) into
the pulling-off threads of the flanges of
the flanged shaft and separate the halves
from each other. At the same time, slowly
move the gearbox shaft toward the gear-
box.
x Remove the fitted bolts that connect the
coupling with turbine or gearbox flange,
resp.. See instructions for the fitted bolts.
x Pull off the coupling half from the center-
ings of the turbine or gearbox flange
resp., and remove coupling half.
Further operations can now be performed,
such as e.g. inspection, cleaning, etc..
7 Maintenance and Repair
Danger!
CriticaI injuries due to fIying around
coupIing pieces or tooIs in case of un-
expected rotationaI movement of the
shaft.
f the coupled machinery train has been
switched off for repair or maintenance op-
erations, the same has to be secured
against unexpected re-engagement:
x Main control devices such as switches
and valves have to be locked, and the
key has to be taken out, and/or
x attach warning signboards to the main
control devices.
B000065-02
12
Attention!
Severe injuries are possibIe due to fIy-
ing around coupIing pieces if the cou-
pIing has not been assembIed correctIy.
Once the coupling has been disassembled,
it must only be taken into operation again
after having re-assembled it completely
and when it is ready to operate.
Replace the self-locking nuts [9370] after
they have been removed for five times at
latest, because they will then lose their
self-locking feature.
The coupling does not require regular
maintenance. Any changes of the running
behaviour of the coupling have to be veri-
fied immediately.
When disassembling the coupling, the
contoured diaphragms have to be exam-
ined for deformations, damages of the pro-
tective layer and corrosion.
8 DisposaI/ RecycIing
The operation of the coupling does not re-
quire any substances or liquids, which are
subject of particular disposal regulations.
Any cleaning products or greases, which
are used for the maintenance of the cou-
pling, have to be disposed of in accordance
with valid laws and provisions.
f the coupling is replaced by a new one, the
laws and provisions concerning waste dis-
posal being in force at the point of time
have to be carefully observed.
9 TroubIeshooting
t is essential to also consider the coupled
machines when determining the causes for
any problems or troubles with the coupling.
During all the operation modes, the cou-
pling has to run at low noise and low vibra-
tions. Any deviation from the above must
be considered as an operation fault, which
has to be corrected immediately.
10 Spare Parts
Please address spare part orders to RENK
AG, Rheine Works. The following informa-
tion is required:
RENK-order number (Com.-No.,
marked on the largest external diameter
of the coupling)
Denomination of the part
Part number (see dimension drawing)
Size or dimensions of the part (if known)
Required quantity
RENK Aktiengesellschaft
Rheine Plant
Rodder Damm 170
48432 Rheine
Germany
Phone: +49 5971 790 0
Fax: +49 5971 790 208
E-Mail: info.rheine@renk.biz
http: // www.renk.biz
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