1103089-RRO3945140 Gearbox Lufkin

The Energy Flows Through UsTM
Installation, Operation &

Maintenance Manual
WARNING:
Failure to use this manual for guidance may result
in injury to personnel and/or damage to equipment.
Lufkin Sales Order Number ................................. 11210762

Lufkin Model ....................................................... NF1619D
Lufkin Serial Numbers ......................................... 11210762-01
GE Nuovo Pignone
PO Number: ......................................................... 439887277
Material Code: ..................................................... RRO3945140
Job #: .................................................................... 1103089
Project: ................................................................ Florena Reinjection
April 23, 2014
Phone: 936/634-2211 P O Box 849, Lufkin, TX 75902-0849

Fax: 936/637-5774 www.lufkin.com
Table of Contents
TABLE OF CONTENTS------------------------------------------------------ i
LIST OF FIGURES ---------------------------------------------------------- iii
1 INTRODUCTION --------------------------------------------------- 1
1.1 SCOPE .............................................................................. 1
1.2 SAFETY PRECAUTIONS ............................................... 1
1.3 EQUIPMENT DESCRIPTION ........................................ 1
1.3.1 Factory Testing .......................................................... 1
1.3.2 Gearing ...................................................................... 2
1.3.3 Bearings ..................................................................... 2
1.3.4 Instrumentation .......................................................... 2
1.3.5 Housing...................................................................... 2
1.3.6 Lubrication................................................................. 2
2 SAFETY SUMMARY----------------------------------------------- 4
2.1 GENERAL SAFETY PRECAUTIONS ........................... 4
2.2 SAFETY EQUIPMENT ................................................... 5
2.2.1 Wear Proper Safety Equipment ................................. 5
2.2.2 Reduce Danger Of Damage To Hearing .................... 5
2.3 REDUCE RISK OF ACCIDENTAL SHOCK .................. 5
2.4 RESUSCITATION ........................................................... 5
2.5 POSSIBLE MISUSES OF EQUIPMENT ........................ 5
3 INSTALLATION ---------------------------------------------------- 6
3.1 RECEIPT OF SHIPMENT ............................................... 6
3.2 STORAGE ........................................................................ 6
3.2.1 Corrosion Protection During Inoperative Periods...... 6
3.3 LIFTING, HANDLING .................................................... 7
3.4 FOUNDATION ................................................................ 7
3.5 ADDITIONAL REQUIREMENTS .................................. 7
3.6 ALIGNMENT................................................................... 8
3.6.1 General ...................................................................... 8
3.6.2 Anticipation of Shaft Operating Positions ................. 8
3.6.3 Alignment Sequence .................................................. 8
3.6.4 Alignment Checking .................................................. 9
3.7 TOOTH CONTACT CHECK ........................................ 10
4 OPERATION -------------------------------------------------------- 11
4.1 LUBRICATION ............................................................. 11
4.2 OIL TYPE AND GRADE .............................................. 11
4.3 CUSTOMER CHECK BEFORE START-UP ................ 11
4.4 START-UP PROCEDURE............................................. 12
4.5. CUSTOMER CHECK AFTER START-UP ................... 12
4.6 ALARM SWITCHES ..................................................... 13
Installation, Operation, and Maintenance page i

5 PREVENTIVE MAINTENANCE ------------------------------- 14
5.1 INTRODUCTION .......................................................... 14
5.2 DAILY MAINTENANCE .............................................. 15
5.3 MONTHLY MAINTENANCE ...................................... 15
5.4 QUARTERLY MAINTENANCE .................................. 15
5.4.1 Oil Analysis Guidelines ........................................... 15
5.5 ANNUAL MAINTENANCE .......................................... 16
5.6 OIL CHANGE INTERVALS ......................................... 16
6 DISASSEMBLY ---------------------------------------------------- 17
6.1 GENERAL ...................................................................... 17
6.1.1 Lock Out/Tag Out Procedure ................................... 17
6.1.2 Visual Inspection ..................................................... 17
6.2 TOOLS REQUIRED ...................................................... 17
6.3 SPARE PARTS............................................................... 17
6.4 REMOVAL OF GEAR COVER..................................... 18
6.5 REMOVAL OF PINION, GEAR, AND BEARINGS .... 18
6.6 THRUST BEARING REMOVAL .................................. 19
6.7 OIL SAMPLE COLLECTION ....................................... 19
7 GEAR INSPECTION ---------------------------------------------- 20

7.1 TOOTH CONTACT CHECKING.................................. 20
7.1.1 Introduction.............................................................. 20
7.1.2 Why Check Tooth Contact....................................... 20
7.1.3 When to Check Tooth Contact ................................. 20
7.1.4 How to Check Tooth Contact................................... 20
7.1.5 Soft Blue Method ..................................................... 20
7.1.6 Hard Blue Method ................................................... 21
7.2 INTERPRETATION OF TOOTH CONTACT .............. 21
7.3 GEAR CONDITION ASSESSMENT ............................ 22
7.3.1 Types of Gear Wear or Failure ................................ 23
7.3.2 Definition of Gear Failure ........................................ 23
8 BEARING INSPECTION ----------------------------------------- 24

8.1 BEARING TYPE ............................................................ 24
8.2 BEARING CONDITION ASSESSMENT ..................... 25
8.2.1 Bearing Clearance .................................................... 25
8.2.2 Bearing High Spots .................................................. 26
8.2.3 Flaking of Babbitt .................................................... 26
8.2.4 Scoring ..................................................................... 26
8.2.5 Wiping ..................................................................... 26
8.3 REPLACEMENT BEARINGS ....................................... 26
9 REASSEMBLY ----------------------------------------------------- 27
9.1 PREPARATION ............................................................. 27
9.2 REASSEMBLY SEQUENCE ........................................ 27
9.2.1 Bearing, Gear, and Pinion Assembly ....................... 27
9.2.2 Gear Cover Assembly .............................................. 28
page ii NF1619D
10 TROUBLESHOOTING ------------------------------------------- 30
10.1 ABNORMALLY HIGH TEMPERATURE.................... 31
10.2 LOW OIL PRESSURE ................................................... 31
10.3 UNUSUAL OR EXCESSIVE NOISE ............................ 31
10.4 EXCESSIVE VIBRATION ............................................ 32
10.5 FOAMING ...................................................................... 32
10.6 NO SENSOR READINGS ............................................. 32
11 NAMEPLATE DATA ---------------------------------------------- 33
List of Figures
and Tables
Figure 1 Lifting provisions....................................................... 7
Figure 2. Expected maximum shaft vibration levels ............... 12
Figure 3. Expected maximum housing vibration levels........... 13
Figure 4. Tooth contact patterns ............................................. 22
Figure 5. Standard N-Unit Bearings ........................................ 24
Figure 6. Pressure Dam Location ............................................ 25
Table 1. Equipment Description Chart .................................... 3

Table 2. Standard Danger, Warning And Caution Symbols .... 4
Table 3. Maximum Allowable Run-Out (T.I.R.) ..................... 9
Table 4. Preliminary Alarm Settings ...................................... 13
Table 5. Maintenance Schedule Overview............................. 14
Table 6. Recommended Tightening Torques ......................... 28
Table 7. Troubleshooting Tips ............................................... 30
Installation, Operation, and Maintenance page iii

page iv NF1619D
Introduction 1
QUALITY AND PERFORMANCE ARE PRIMARY CONCERNS AT LUFKIN.
The employees of Lufkin Industries have made every effort to provide the customer with high
quality, long lasting equipment which will give trouble-free service for many years provided it is
operated within its designed capacity and is properly lubricated and maintained.
Reflecting its commitment to Quality, Lufkin has been certified to ISO-9001 with Det Norske
Veritas.
For further assistance from Lufkin, please call or fax the following numbers:
LOCATION PHONE FAX
Customer Service (Parts, etc.) (936) 637-5211 (936) 637-5883
Service Department (936) 637-5307 (936) 637-5104
Repair Division (936) 637-5413 (936) 637-5104
Engineering (936) 637-5266 (936) 637-5774
1.1 SCOPE
The objective of this manual is to give general information on installation, lubrication, operation,
maintenance, disassembly and reassembly of Lufkin Industries model NF1619D gear units. In
addition, there is supplementary information on unit storage, coupling alignment, oil
characteristics, bearing wear, and gear wear. Any vendor supplied instruction manuals for
accessory equipment are appended. Table 1 provides an overview of equipment features.
1.2 SAFETY PRECAUTIONS

Every effort has been made to place hazard warnings and explanatory or cautionary notes in
appropriate parts of this text. It is strongly recommended that this manual be reviewed
thoroughly before attempting to install, operate, service, or repair this equipment.
1.3 EQUIPMENT DESCRIPTION

These high speed gear units are used for speed increasing service between a gas turbine and a
centrifugal compressor. For a cross section view of the gearing see the Parts List; for the general
shaft arrangement, shaft ends, and hold down locations see the Installation Plan. The Mass
Elastic drawing provides component weights and Wr2 values. The electrical schematic is shown
on the Wiring Diagram.
1.3.1 Factory Testing

Factory testing of Lufkin gear units includes a detailed test of the gear at rated speeds with no
load or partial load. Data recorded during testing may include bearing temperatures, shaft and
housing vibration levels, oil flow and pressure, oil temperature, efficiency, and an analysis of
sound level.
Installation, Operation, and Maintenance page 1

1.3.2 Gearing
Lufkin gears are computer designed according to the latest American Petroleum Institute (API)
standards. Conservative service factors, based on API recommendations and on Lufkin's
experience, are applied to the ratings to ensure long gear life. N-type units have horizontally
offset gearing and use double helical design utilizing hobbed and precision ground gear teeth.
Gears and pinions are made from high quality, carburizing grade alloy steel forgings. The pinion
and gear are made integral with their shafts and are turned, ground and hobbed. The teeth are
then CBN ground to ensure accuracy. See the Installation Plan for shaft end details.
1.3.3 Bearings
The high speed radial bearings on this unit are tilt pad journal bearings. The low speed bearings
are centrifugally-cast babbitt with a split steel shell and a pressure dam for improved stability. A
tilting pad thrust bearing is used on the low speed shaft to locate the gearing and resist any
external axial forces.
1.3.4 Instrumentation
This unit has embedded temperature sensors, vibration probes, proximitors, key phasors, and
accelerometers.
1.3.5 Housing
Housings are designed for heavy duty service to provide maximum rigidity, assuring precision
gear alignment. All housings are precision bored; bore alignment is certified before assembly.
Housing design incorporates the necessary oil piping for bearing and gear mesh lubrication.
The housing is a fabricated steel structure, with the split line on the horizontal centerlines of the
rotating elements. The gear housing is fully stress relieved before machining. Fabricated
housings provide superior strength and rigidity for accurate shaft bores and for proper gear
meshing.
Interior surfaces are shot-blasted, cleaned, and painted to ensure freedom from foreign particles.
The exterior is painted per customer specifications.
Inspection covers are provided for inspection and examination of all gear components.
1.3.6 Lubrication
The lubrication system for this unit is not supplied by Lufkin. It is to be provided by the
customer or others after delivery. Refer to the Installation Plan for gear unit oil supply. The unit
is provided with connections for supplying oil to the bearings and to the gear mesh sprays. The
unit requires an external lubrication system and reservoir. Refer to the Installation Plan for
requirements of the lube system.
page 2 NF1619D
Table 1. EQUIPMENT DESCRIPTION CHART
Specifications Service Factor Service HP
AGMA 6011 AGMA 2.51 43047 HP
API 613, Fifth Edition API 1.63 32100 kW
Gearing Bearings Design Clearance

High Speed Pinion Double Helical HS - tilt pad journal 0.0080 – 0.0100 inch
41 teeth 0.2032 – 0.2540 mm
Low Speed Gear Double Helical LS - hydrodynamic 0.0120 – 0.0140 inch
76 teeth with pressure dam 0.3048 – 0.3556 mm
Thrust Bearing Endplay

Kingsbury 0.014 - 0.018 inch
(0.356 - 0.457 mm)
Reductions Single Lubrication Weight
Parallel shaft Increaser Oil Type: Unit – 17100 lbs.
speed AGMA Lt Turbine (7756 kg)
ISO VG: 32
Offset Horizontal Customer furnished Heaviest Maintenance
lubrication system Lift – 2917 lbs.
(1323 kg)
Heat treatment Carburized Speed Housing
Cutting method Hobbed Input – 6100 RPM fabricated
Tooth finish CBN ground Output – 11307 RPM with inspection covers
Instrumentation and Accessory Equipment
• Embedded • Vibration probes • Proximitors • Accelerometers
temperature sensors • Key Phasors
Additional Information
Center Distance: 16.5" Rotation: CCW
Effective Face: 20.5" Prime Mover: Gas Turbine
NDP: 4 Driven Equipment: Centrifugal Compressor

Safety Summary 2
Table 2. Standard Danger, Warning, and Caution Symbols
DANGER: WARNING: CAUTION:
DANGER notices are used to WARNING notices are used CAUTION notices are used to
indicate an imminently to indicate a potentially indicate a potentially
hazardous situation. Failure hazardous situation. Failure hazardous situation. Failure
to comply will result in to comply could result in to comply may result in
death or serious injury to death or serious injury to minor or moderate injury to
personnel. personnel. personnel and/or damage to
equipment.
2.1 GENERAL SAFETY PRECAUTIONS

The following are general precautions that are not related to any specific procedures and
therefore do not appear elsewhere in this publication. These are recommended precautions that
personnel must understand and apply during many phases of operation and maintenance.
DANGER: Lock out/tag out procedures

Never remove the inspection cover are fully explained in
while the machinery is in operation. DISASSEMBLY
Always lock out/tag out all power
sources while performing maintenance
DANGER:
WARNING: Never work on machinery that is
still in operation or is still moving.
Never block the gear mesh by
inserting material between the CAUTION:
gear elements.
WARNING: Only persons familiar with and proficient at

servicing, installation, maintenance,
Shaft and coupling guards must be operation, and assembly of gearing should
securely in place before operation. be involved in those phases of use.
When manuals are supplied by a vendor for auxiliary or accessory equipment installed by Lufkin,
they are included in the appendix to this manual. IMPORTANT: Read and observe all safety
warnings and messages in vendor manuals.
Lufkin does not assume responsibility for proper guarding of shafting and couplings. Lufkin may
in some cases supply the guards; however, because of the position of the gear in the power train,
the guards must also be attached to other equipment. The user must ensure adequate guarding
is provided and used in the power train.
page 4 NF1619D
2.2 SAFETY EQUIPMENT
2.2.1 Wear Proper Safety Equipment
Personnel working with or near heavy equipment should wear safety equipment appropriate to
the area in which they work:
• Safety glasses with side shields
• Appropriate hard soled shoes
• Appropriate head gear (hard hats)
2.2.2 Reduce Danger Of Damage To Hearing
Gears and their connecting equipment may produce noise levels
CAUTION: that are capable of causing hearing loss with long-term,
unprotected exposure. The use of hearing protection equipment
Use of hearing protection should should be considered whenever working in areas containing
be considered when working near equipment emitting high noise levels or noise at frequencies that
any noisy equipment.
are bothersome.
2.3 REDUCE RISK OF ACCIDENTAL SHOCK

Personnel working with or near high voltage should remove watches, rings, or any jewelry that
could make physical contact with circuits.
Do not replace components or make adjustments inside the
DANGER: equipment with the high voltage supply energized. Under
certain conditions, dangerous potentials caused by charges
Keep away from live circuits. retained by the capacitors may exist when power is off. To
avoid casualties, always disconnect the power and discharge
the circuit before touching it.
Under no circumstance should any person reach into an enclosure to service or adjust equipment
when not in the company of someone who is capable of rendering aid in the event of an accident.
2.4 RESUSCITATION
Personnel working with or near high voltage should be familiar with modern methods of
resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery or the
Red Cross.
2.5 POSSIBLE MISUSES OF EQUIPMENT

Following are some possible misuses of gear units that might be encountered. To prevent
injury/death of personnel and/or damage to equipment, the operator should avoid:
• Overloading the gear (increasing torque above nameplate conditions.)
• Running the gear above rated speeds.
• Reversing rotation.
• Changing lubricant type or grade.
• Providing inadequate lubrication.
• Operating at temperatures above recommended levels.
• Operating with vibration above recommended levels.
• Misalignment of the unit.
• Operating with windage baffles not properly installed.

Installation 3
3.1 RECEIPT OF SHIPMENT
Equipment should be checked against shipping papers on receipt. The gear unit should also
undergo a visual inspection to ensure that no damage has occurred during shipment. If you
suspect that the unit may be damaged, contact Lufkin for assistance. Check:
•Gear casing and shafts for signs of damage.
•Any gauges provided for cracks in the glass.
•Piping for dents, crimps, cracks or other damage.
A black coating of Equipment-Kote™ by Esgard, Inc., has been applied to all non-painted
surfaces. Before installation, carefully remove the coating, using a safe solvent and a soft rag.
Take care not to damage any oil seals or shafting while cleaning. All piping furnished by anyone
other than Lufkin should be carefully cleaned.
The Installation Plan drawing for the gear will show all customer piping connections as well as
any electrical connections.
3.2 STORAGE
The gear is tested at Lufkin with a break-in oil that contains a rust preventative (Interfilm Type
1™ by Esgard, Inc.) which will protect the internal parts for at least six months after shipment.
Do not store the gear unit outdoors unless covered. If the inoperative period is greater than six
months, see "Corrosion Protection During Inoperative Periods."
3.2.1 Corrosion Protection During Inoperative Periods

NOTE: Items 1 through 4 assume normal atmospheric conditions.
1. On new gear units shipped from Lufkin, the rust inhibitor adhering to exposed surfaces
should prevent corrosion of interior parts for at least six months with covered storage.
2. When the unit has been operated for a period of time with a recommended lubricating oil,
the oil will protect interior parts for inoperative periods up to 30 days.
3. If additional down time is needed, the customer should hand spray oil on the gear mesh and
manually rotate the gear unit shafts every 30 days to redistribute the oil and gain protection
for 30 days.
4. If extended down time is expected and it is impractical to turn the shafts, a rust preventive
type oil should be brushed or sprayed on the gear teeth. Any openings should be sealed
with masking tape. A quality rust preventive oil should give 12 months protection against
corrosion. This oil should be compatible with the operating oil, and it should be
unnecessary to remove the rust preventive oil when the unit is started again.
5. For adverse conditions or long term storage, coat all parts with rust inhibitor compatible
with operating oil and seal all openings.
6. A second method of long term storage is to disassemble the unit and coat each part with
Cosmoline™ or equivalent. Before the unit can be placed in service, special cleaning with
solvents will be necessary to remove all preservative from unit and parts.
page 6 NF1619D
3.3 LIFTING, HANDLING
The gear unit should
always be moved by Lifting Provisions
rolling on bars or
WARNING: skates, or by lifting
it with properly
Improper lifting techniques could cause rated slings through
damage to the gears and/or harm to
personnel.
the lifting
provisions on the
top of the unit or the
provisions on the
side of the unit. See
CAUTION: Figure 1 for lifting
Do not lift unit by either input or output provision locations.
shafts. Do not bump the shafts. On fabricated
housings, lifting
holes are an integral
part of the
fabrication. See the Figure 1
Installation Plan or Table 1, “Equipment Description
Chart” for lifting weights.
Never lift or sharply strike the shaft extensions.
Always exercise extreme caution while lifting any part of a gear unit.
3.4 FOUNDATION
The unit must be mounted on a substantial foundation. One
system uses a concrete base, a sole plate on the top of the
CAUTION: concrete, about 1/8-inch (3mm) shim space, then the gear unit.
Adequate foundation must be provided The sole plate has tapped holes already in place so that bolts
for proper alignment. can be used to clamp down the feet of the gear unit (with the
proper shims in place) at all positions.
Once a general elevation is established above the concrete, the sole plate is grouted into place,
leaving a space of about a 1/8-inch (3mm) between the top of the sole plate and the bottom of the
gear unit feet. This shim space allows room for proper positioning of the gear unit for slow speed
and high speed coupling alignment.
The most common system in use is a rigid structural steel baseplate with the gear mounted with
either the driver or driven equipment or the gear and both the driver and driven equipment
mounted. Lufkin often supplies this type of baseplate, with the gear and other equipment rough
aligned, requiring final alignment in the field.
The housing must not be twisted or in a bind as this will adversely affect tooth contact and will
cause bearing edge loading. Use an adequate area of shims under all tie down bolts. In making up
the shim pack, use as few shims as possible so the pack will not be "soft".
3.5 ADDITIONAL REQUIREMENTS

Check all studs, capscrews and bolts for proper tightening.
This unit is supplied with a windage baffle on the shaft extensions. Operation with these baffles
removed or improperly installed may cause shaft leaks.

3.6 ALIGNMENT
3.6.1 General
Securing proper shaft alignment is one of the most important phases of setting up a gear unit.
Any appreciable misalignment can cause a multitude of gear problems from excess bearing and
gear tooth wear to vibration problems. Uncorrected misalignment can lead to catastrophic failure.
Therefore, it is essential that thermal growth and shaft operating position in the bearings be
anticipated during shaft alignment and that good alignment be maintained.
3.6.2 Anticipation of Shaft Operating Positions

The axial and radial running position of each shaft must be determined and set correctly. The
running positions depend on operating load and temperature and will differ from the positions
under no load and at ambient temperature because of thermal expansion of the gear housing and
the direction of the bearing loading. A temperature rise of 30–70 degrees Fahrenheit (15–40
degrees Celsius) is within normal range. For expected movement and thermal growth values see
the Installation Plan drawing. Couplings should allow the shafts to float axially.
The driven and driving machines also have thermal movement which must be either added or
subtracted from the gear movement, depending upon the direction of the movements.
The gear may be initially centered in the housing by carefully prying the low speed gear through
its full axial travel while measuring the distance with an indicator. The gear should be centered
when it is positioned at half the full travel amount. The equivalent high speed pinion position is
attained when it is torqued into its operating position with the gear still centered.
3.6.3 Alignment Sequence

The following sequence assumes that the foundation is level, the driving or driven machine
(whichever is more permanently settled) is secured, and any shipping locks and covers are
removed from the gear unit.
1. Level and secure the gear unit. Jacking screws holes are provided on the base flange for
bringing the gear unit to the same horizontal plane as the connecting shaft.
• Shim under the low machine to bring it to the proper height.
• Move one unit until all are in the same plane as the connecting shaft.
2. Establish running position of driven and driving shafts, making sure journals are centered
axially and vertically.
3. Connect gear unit shafts and coupling flanges.
• Lubricate the couplings.
• Care should be taken in joining the two coupling halves to observe any coupling match
marks.
• Allow for axial thermal growth. Failure to properly align axially can cause cross mesh
loading which can lead to premature gear failure, and/or non-synchronous shaft vibrations.
• Keep outer diameter runout within recommended maximum allowable runout, total
indicator reading (T.I.R.) In a close coupled condition, T.I.R. should not exceed the values
in Table 3. When the shafts are not close coupled, contact Lufkin.
page 8 NF1619D
Table 3a. Maximum Allowable Run-Out, (TIR)
Shaft Surface Outside Diameter, Face, TIR
Velocity TIR per inch of R
(fpm) (inches) (inches)
5000 and up 0.002 0.0004
3000 to 5000 0.004 0.0005
1500 to 3000 0.006 0.0006
500 to 1500 0.008 0.0008
500 and below 0.010 0.0010
Table 3b. Maximum Allowable Run-Out, (TIR) METRIC

Shaft Surface Outside Diameter, Face, TIR
Velocity TIR per mm of R
(m/s) (mm) (mm)
25.4 and up 0.05 0.010
15.2 to 25.4 0.10 0.012
7.6 to 15.2 0.15 0.015
2.5 to 7.6 0.20 0.020
2.5 and below 0.25 0.025
4. Check for free axial movement of the pinion and gear. Do not force shaft movement to the
point of damaging the bearing shell.
5. Tighten foundation bolts.
• Before tightening the foundation bolts, be sure that the base of the gear unit sets evenly on
all shims so that there will be no distortion after tightening the bolts.
• After tightening the bolts, check for distortion by placing a dial indicator on the gear
housing foot near the bolt to be checked. If the housing foot moves more than 0.002 inch
(0.05 mm) when that bolt is loosened, then distortion is present and the housing needs
additional shims around that bolt.
6. Make a soft blue tooth contact check (see GEAR INSPECTION, “Soft Blue Method.”)
3.6.4 Alignment Checking

When the preliminary soft blue contact check is satisfactory, a hot alignment check should be
made by running the gear train until temperatures stabilize, shutting it down and taking indicator
readings while the package is hot (see GEAR INSPECTION, “Hard Blue Method.”)
If optical alignment equipment is available, the hot alignment check should be made with the
package bolted together and running, using the optical alignment flats on the gear unit in
conjunction with any optical alignment flats provided on the driving and driven equipment.
After complete hot alignment is obtained, the gear unit should be doweled to the foundation or
base while the unit is running and temperatures are stabilized. The base flange is drilled for
dowel pins, but they must be reamed at assembly. Locate the dowels under both ends of the most
critical shaft. (usually the high speed pinion). Do not use more than two dowel pins and do not
put dowel pins on both ends of the unit.

WARNING:
After coupling alignment is established, place coupling
Failure to use coupling guards may
result in serious injury to personnel. guards in position and secure.
3.7 TOOTH CONTACT CHECK

After completing the alignment and prior to start-up, the tooth contact pattern should be checked.
See GEAR INSPECTION for instructions on performing a soft blue check and how to interpret
results.
During testing at the plant, layout blue is applied to the
gear teeth so that in the field the contact obtained on the
test stand may be verified. The soft blue check after field
CAUTION: alignment should match the hard blue contact pattern left
Proper tooth contact must be obtained on the gears from the Test Stand.
before the unit is put into operation.
After completing the start-up procedure outlined in
OPERATION, run the unit for two hours under a light
load, shut it down and remove the inspection cover to
observe the areas on the pinion where the blue has worn
off.
If the contact is not satisfactory, the problem is possibly due to gear housing distortion caused by
drawing the housing down to a base that is not square with the housing. Be sure the gear housing
rests evenly on any shims before tightening the foundation bolts.
page 10 NF1619D
Operation 4
4.1 LUBRICATION
At the time of shipment, Lufkin coats interior gear parts with a rust preventative oil. This oil
should be compatible with the operating oil, and it should not be necessary to flush the unit prior
to putting in lubricating oil.
In the gear drive, lubrication serves three basic functions:
1. To separate tooth surfaces and prevent metal-to-metal contact, thereby reducing friction
and wear.
2. To remove heat losses at the gear mesh.
3. To remove heat produced in the bearings.
It is very important to the successful and satisfactory operation of a gear unit that careful
attention be given to proper lubrication, and that the lubricant be kept clean. Every precaution
should be taken to prevent water and foreign particles from entering the gear case. If the oil does
become contaminated by water or foreign particles, it should be analyzed and changed, if
necessary, or cleaned and reconditioned.
4.2 OIL TYPE AND GRADE

The lubricating oil must be high grade, high quality, well
refined petroleum oil. Straight mineral type lubricant should
be used. Consult Lufkin before using any synthetic lubricants.
CAUTION:
Also, it is essential that the oil be clean and non-corrosive to
Do not change grades of oil without gears and bearings. It must be neutral in reaction, possess
approval by Lufkin. good defoaming properties, and also have good resistance to
oxidation.
Lufkin specifies AGMA # Light Turbine (ISO VG 32) oil on the Parts List and Installation Plan
drawings, as well as on the unit nameplate. Also see INTRODUCTION, “Lubrication”. It is
useful to take a baseline analysis of the oil being put into the unit for later comparison.
4.3 CUSTOMER CHECK BEFORE START-UP

1. Check all instrumentation and lubrication connections.
2. Check that all necessary piping and accessory wiring is complete.
3. Check the lubricating system for correct type and quantity of oil.
4. Check for correct shaft alignment. See INSTALLATION.
5. Check for foundation bolt tightness. See INSTALLATION.
6. Check tooth contact. See GEAR INSPECTION.
7. Check that coupling guards and inspection covers are in place.
8. Check that windage baffles are in place.

4.4 START-UP PROCEDURE
The minimum start up temperature for the oil in the gear
unit is 70°F (21°C.) It is best to start the unit with an oil
WARNING: temperature as close to operating conditions as possible.
Gears starting up with oil temperature below 70°F (21°C)
Coupling guards and inspection covers may require additional care to ensure oil is flowing to the
must be secured BEFORE start-up.
mesh and bearings. It may be advisable at low temperatures
to slowly start-up or run oil through an auxiliary pumping
system (if available) to pre-warm it.
CAUTION:
Start unit at reduced speed if practical. Monitor bearing
Operation of the gear unit with and oil temperature as well as oil pressure. Gradually
no oil will result in damage. increase speed while continuing to monitor until operating
speed is reached. Gradually load unit if possible.
4.5. CUSTOMER CHECK AFTER START-UP

1. Run gear unit at light load while checking for adequate lubrication.
2. Watch the bearings for a sudden high temperature rise which could indicate a bearing
problem.
3. Run gear under full load and speed and check for unusual noise and vibration. Expected
maximum shaft vibration level for the NF1619D may be found in Figure 2, and the
expected maximum housing vibration in Figure 3.
4. Also check oil temperature and bearing temperature. See “Alarm Switches” below for
starting alarm settings. After temperature stabilization, the oil temperature into the gear unit
should generally not exceed the oil inlet temperature stated on the Installation Plan drawing.
5. After unit has run for two hours under load, shut it down, check coupling alignment, check
and tighten any bolts that may be loose, and recheck tooth contact.
Figure 2
Expected maximum shaft vibration levels for N Units with good alignment and balance.
page 12 NF1619D
Figure 3
Expected maximum housing vibration levels for N Units with good alignment and balance.
4.6 ALARM SWITCHES

The preliminary settings offered in Table 4 below are above the expected operating level of the
gear unit. However, actual field operating levels of the gear unit may be higher or lower than
expected values. Therefore, the values in Table 4 are preliminary and may be decreased or
increased to better suit actual field operating levels. When lower values are used Lufkin need not
be consulted; however, when the values are increased over those listed in Table 4 consult Lufkin
for suitability.
Table 4. Preliminary Alarm Settings

Sensor Alarm Shutdown
Accelerometer
Casing Acceleration 6 G’s peak **must be determined individually**
Vibration Probes
Shaft Vibration
Shaft Speed, RPM
0<N<5000 2.5 mils (0.063 mm) 4.0 mils (0.102 mm)
5000<N<8000 2.0 mils (0.051 mm) 3.0 mils (0.076 mm)
8000<N<14,000 1.75 mils (0.044 mm) 2.5 mils (0.063 mm)
Probe type RTD or thermocouple 200°F (93°C) 215°F (102°C)
in bearing shell
Bi-metal thermometer in bearing 180°F (82°C) 195°F (91°C)
shell
Embedded RTD or thermocouple 225° F 240° F
in bearing shell load zone (107° C) (116° C)
Oil inlet 150°F (66°C) 160°F (71°C)
Unit sump or drain line 175°F (79°C) 190°F (88°C)

Preventive
Maintenance 5
Lufkin recommends following the detailed maintenance schedule on
the next few pages for most operating conditions.
5.1 INTRODUCTION
The Scheduled Maintenance instructions in this manual are intended to provide a guide for
minimum operations required to ensure years of trouble-free operation. Table 5 gives an
overview of scheduled maintenance.
Table 5. Maintenance Schedule Overview

DAILY MONTHLY
• check oil temperature • check operation of auxiliary
equipment
• check oil pressure • check operation of alarms
• check vibration • check tightness of foundation
bolts
• check noise • check for oil contamination
• check for oil leaks
QUARTERLY ANNUALLY
• analyze oil sample • check bearing clearance
• check endplay
OIL CHANGE • check tooth contact pattern

• 2500 hours of operation OR • check coupling
• every six months • check alignment
If major repairs should be needed on this gear unit, it is best to return it to the factory. If time is
not available for factory repairs, Lufkin has available capable field servicemen who can perform
on site analysis and repair.
If the customer desires to repair the equipment, the parts list furnished with the gear unit and the
information in this manual should be studied carefully.
Good preventive maintenance habits will prolong the life of the gear unit and will help in
detecting trouble spots before they cause serious damage and long down time.
page 14 NF1619D
5.2 DAILY MAINTENANCE
• Check the oil temperature and pressure against previously established norms.
• Check for unusual vibration and noise.
• Check for oil leaks.
5.3 MONTHLY MAINTENANCE

• Check operation of auxiliary equipment and/or instrumentation and alarms.
• Check tightness of foundation bolts.
• Check oil for possible contamination. A sample should be obtained from the floor of the gear
case.
5.4 QUARTERLY MAINTENANCE

• The greatest advantage to oil analysis is that it can detect many failures before they are
catastrophic. The only way to do this is to take frequent samples and have them evaluated
immediately. Monitor the results. If a change is noted, respond accordingly.
Take oil sample and submit for laboratory analysis. Compare the results to the initial baseline
analysis done when oil was first put into the unit. It is recommended that the oil be changed in
the following cases:
5.4.1 Oil Analysis Guidelines

• The total acid number increases by 2. For example: new oil might have a total acid
number of 0.4. When this number increases to 2.4 or above, the oil should be changed.
This acid number increase is associated with oxidation of the oil which results in oil
breakdown.
• A rapid change in viscosity is noted. Gear oil is "sheared" as it lubricates the meshing
gear teeth. This shearing eventually causes the oil to thin out and lose its film thickness.
A rapid decrease could mean oxidation. A decrease of 10% is excessive.
• The water content is more than 0.1%. Water in oil causes the oil to lose its film
strength and also will cause corrosion to gear elements and bearings.
• The silicon content is above 50 parts per million. This signifies the oil is dirty.
• The iron content is above 200 parts per million. This indicates contamination from
gear wear particles.
• A rapid increase is noted in any of the wear elements. As a guide, if rapid increases of
any of the following materials are detected, the probable origins of that material are
listed.
• Alloy Steel–Gear teeth, bearings
• Mild Steel–Oil pump, slinger, or baffle rubbing gear case
• Cast Iron–Oil pump
• Aluminum–Oil seal, seal guards or carriers
• Babbitt –Journal bearings

5.5 ANNUAL MAINTENANCE
• Check bearing clearance and endplay.
• Check tooth contact pattern.
• Visually inspect couplings and check alignment.
• Inspect tags and labels showing replacement part numbers. Replace if necessary.
• Inspect warning signs and labels. Replace if necessary.
5.6 OIL CHANGE INTERVALS

Under normal operating conditions, the lubricating oil should be changed every 2500 hours of
operation or every six months, whichever comes first. The unit should be drained by removing
the drain plugs (see the Installation Plan for location.)
Complete oil changes for units with large capacity oil
systems are sometimes impractical. In this case, draining
DANGER: the oil system, cleaning the reservoir and/or gear sump,
and then recharging the system with the original oil that
When working near rotating elements, has been cleaned and reconditioned may be sufficient. If
be certain that the driving and driven this approach is taken, Lufkin strongly recommends
equipment are securely locked out.
routine oil analysis so that any breakdown of the oil being
reused can be detected before affecting gear operation.
page 16 NF1619D
Disassembly 6
During disassembly, refer to the Installation Plan and
Parts List furnished for the gear unit.
6.1 GENERAL
NOTE: Any work done on equipment during the warranty period without the
written approval of an authorized Lufkin representative could void the warranty.
6.1.1 Lock Out/Tag Out Procedure
1. Identify the energy sources used and all control devices.
2. Notify all affected personnel.
DANGER: 3. Turn OFF all operating controls.
4. Lock out or tag out all switches and energy controls in
When working near rotating elements, “off” or “safe” positions.
be certain prime mover is turned off and 5. Test all operating controls to make sure no power is
locked out/tagged out.
getting to equipment.
6. Perform required maintenance.
6.1.2 Visual Inspection
The following sequence is for complete disassembly. Visual inspection of the gearing through
the inspection cover may provide the information necessary to determine the cause of a problem
without complete disassembly.
6.2 TOOLS REQUIRED

For disassembly and reassembly, several commonly available tools may be required. No special
tools or fixtures are required for the housing and gears, and no tools for assembly/disassembly
are provided by Lufkin. Following is a list of some tools that will be helpful.
• Crane or hoist, along with soft slings or chains
• Eyebolts
• Dial indicator
• Pry bar
• Crocus cloth or fine steel wool
• Wrenches, screwdrivers, torque-wrench
• Prussian blue or similar dye for tooth contact check
• LocTite™ No. 549 Plastic Gasket
6.3 SPARE PARTS

Parts such as gaskets should be replaced when disassembly is performed. Contact Lufkin
Customer Service or a sales office for a list of recommended spare parts for the gear unit. Refer
to the Parts List for a complete list of unit part numbers and descriptions.

6.4 REMOVAL OF GEAR COVER
Throughout the disassembly sequence, observe carefully what may have occurred inside
the unit and record the position and condition of any failed parts. Note any parts, bolts, nuts,
or holes that are numbered or match marked; they must be reassembled as matched for correct
assembly.
1. Remove any deflectors, baffles, or coupling guards.
2. Disconnect the high speed and low speed couplings.
3. Disconnect any piping, conduit, or wiring that joins the housing sections.
4. Remove any bearing temperature sensor service heads, probes, or other auxiliary
instruments that could be damaged by removal of the cover.
5. Remove the cap screws in the upper half of the seals, end caps, and thrust bearing housing;
if lockwiring is supplied, cut where necessary.
6. Remove end caps, seals, windage baffles, and gaskets.
7. Carefully loosen the thrust bearing housing. (Use the jacking screw holes to loosen from
gear housing).
8. Remove all cap screws and nuts on the parting line. Leave studs in place to serve as guides
for cover removal.
9. Break the parting line seal by using jacking screws in the jacking screw holes located on
each end of the gear unit. Some sharp raps with a rawhide hammer at the corner positions
and prying with a large screwdriver may be needed to loosen the parting line joint.
10. Attach a crane or hoist to the lifting provisions in the cover and carefully lift the cover by
lifting both ends equally about 1/4 inch (6 mm).
Check that bearings remain seated and no conduit or
CAUTION: wiring that crosses the parting line is still connected.
11. Check the upper bearing halves to see if they are
Do not bump gear assembly with the
raised cover.
stuck in the cover. If they are, carefully pry them out
or push them out.
12. Carefully lift the cover straight up until it clears the
gearing. The cover will need enough clearance above the gear and studs for the cover to be
removed.
13. Place the cover on wood blocks so that the machined split line will not be damaged. Take
care that internal lubrication lines are not damaged.
6.5 REMOVAL OF PINION, GEAR, AND BEARINGS

Removal of gearing from housing is not required if only rotating element inspection is needed.
Radial bearings can be removed and replaced by rolling shells out of housing, one bearing at a
time (replace the bearing after inspecting it and prior to inspecting other bearings.) The thrust
bearing is more difficult to remove and re-install than the radial bearings. If you desire to
remove the thrust bearing, refer to the detailed instructions in Section 6.6.
1. Mark the location of each bearing in the housing so that it can be reassembled correctly,
and remove high speed bearing upper halves.
2. Remove the pinion with its tilt pad journal bearings in place using a soft sling on each side
of the mesh. Place the shaft on a soft material such as wood or rubber or a padded V rack,
taking care not to damage the gear teeth. The tilt pad journal bearings can now be removed
for inspection.
3. Remove the low speed gear and shaft assembly with its bearings in place with a chain
inserted through a lifting hole or eyebolts inserted into the gear. Be careful to protect the
teeth by placing wood blocks between the chain and the sides of the gear.
page 18 NF1619D
4. Place the gear on a soft surface such as wood taking care not to damage the teeth. Block
each side to prevent the gear from rolling.
5. See GEAR INSPECTION for an analysis of gear problems.
6.6 THRUST BEARING REMOVAL

Use the following guidelines to remove the thrust bearing.
1. The thrust bearing contains temperature sensors, the lead wires exit the bearing housing
through an oil seal fitting.
2. Remove the temperature sensors from the thrust bearing shoes with a small hooked probe to
pull out the star washer through the access cover adjacent to the sensor connection heads.
3. Remove the thrust bearing end cap bolts.
4. Remove the end cap and shims from the thrust bearing housing.
5. Use wide jaw pliers to pull the outer backing ring a short distance out of the thrust bearing
housing.
6. Remove the outer backing ring and thrust pads. Mark the position of pads containing
embedded temperature sensors so they can be returned to their original location.
7. Remove the axial probe target plate.
8. Loosen the two set screws in the thrust collar lock nut.
CAUTION:
9. Remove the lock nut by turning it counterclockwise. Use
a spanner wrench or a small punch inserted into the
Before removing the thrust collar from spanner holes to loosen the nut.
the bearing housing, tilt the top of the
collar forward to see if any bearing pads 10. Insert capscrews into the threaded puller holes in the
are stuck to the back side of the collar. thrust collar.
Remove any stuck pads before they can
fall out of the housing and be damaged. 11. Carefully remove the thrust collar. Do not allow the
collar to drop down and damage the lock nut threads as it
is being removed.
12. Mark the position of the inner thrust pads containing embedded temperature sensors so they
can be returned to their original position. Remove the shoes and inner backing ring.
6.7 OIL SAMPLE COLLECTION

If desired, collect a representative full quart (liter) sample of oil from the sump for later analysis.
See PREVENTIVE MAINTENANCE, “Oil Analysis Guidelines,” for a discussion of oil quality
and contamination.

Gear Inspection 7
7.1 TOOTH CONTACT CHECKING
7.1.1 Introduction
The purpose of this guide is to describe why you should check gear tooth contact, how the actual
check is made, and how to interpret the tooth contact check on power transmission gearing with
involute double helical teeth and parallel input and output shafts.
7.1.2 Why Check Tooth Contact

Gear teeth must have an even load across the entire face width to minimize stress on the teeth.
The contact between gear teeth is line contact; therefore, the alignment between the rotating
elements (pinion and gear) is critical. Tooth alignment is controlled by the accuracy of the
rotating elements, the housing, and the bearings assembly.
7.1.3 When to Check Tooth Contact

DANGER: Tooth contact should be checked on all new installations,
after any disassembly of the gear unit, and after any major
When working near rotating elements, housing-to-foundation change. It may also be checked as
be certain prime mover is turned off
and locked out/tagged out. part of routine annual maintenance or when a problem
related to alignment is suspected. Contact must be
checked on the job foundation to be sure the unit will
operate properly.
7.1.4 How to Check Tooth Contact

The contact can be checked two ways.
• Soft blue: Apply soft machinist's bluing or transfer bluing to the teeth of one gear and roll
that gear by hand through mesh with its mating gear. (The terms “blue” or “bluing” are used
for convenience; the dye is available in other colors.) The transfer of the blue from one gear
to the other gear is read as the contact.
• Hard blue: Paint the gear teeth with hard or layout blue, run the gear unit, and observe the
pattern of 'wear-off' of the bluing.
Contact checking may usually be accomplished through the inspection cover port. Occasionally,
soft blue checking is done with the housing cover removed, such as during the reassembly
process.
7.1.5 Soft Blue Method

The soft blue method is usually performed first. Since the unit is not running, this check does not
give true contact. It does give a good indication of what contact will be. If it indicates inadequate
contact, you may choose not to start the unit until contact is corrected. If the unit has been
disassembled, then a soft blue check before the housing cover is installed may save a tear-down
to correct contact. This is especially important if a new set of rotating elements or bearings is
installed.
page 20 NF1619D
Soft blue is usually applied to three or four teeth on the pinion in two places 180° apart. Clean
the teeth thoroughly with solvent, and brush on the blue in a very thin and even layer. With the
gear set centered, hold a drag on the gear and roll the pinion through mesh with the gear.
Rotation direction is not important, but the contact must be checked on the loaded flank, not the
unloaded tooth flank. Observe the blue that transferred from the pinion to the gear. This is the
contact pattern.
Cellophane tape can be used to remove this blue pattern from the gear and save it for
maintenance records: after the check, firmly place a piece of tape on the gear tooth flank, remove
the tape, place it on a clean sheet of white paper, and label it with:
• the date
• name and number of the part the tape was lifted from
• the wing and apex
• which helix (left or right, noting whether wing or apex is leading)
The contact should be checked at three places around the gear (approximately 120˚ apart;)
however, the blue must be reapplied and smoothed on the pinion after each meshing.
7.1.6 Hard Blue Method

Thoroughly clean the area where hard blue is to be applied. The teeth must be absolutely free of
oil, or the blue will not adhere properly and large flakes will chip off, making the contact check
inaccurate.
Apply the blue to an area three or four teeth wide at four places on the gear and at two on the
pinion. Run the unit (usually at full speed.) Running conditions may vary from no load to full
load. The best way is to run the unit at very light load (up to 20%) for two hours or so, and then
shut it down and check the contact. With higher loads the unit should run a shorter time before
checking contact. The trick is to run the unit just long enough to wear the blue off the areas of
higher contact stress. High loads can mask poor contact and give a false reading.
7.2 INTERPRETATION OF TOOTH CONTACT

The following is information to be used only for guidance in deciding if tooth contact is
adequate. Contact Lufkin on how to correct poor contact. Assuming properly manufactured parts,
minor corrections can be made to the tooth contact by shimming the gear housing. Exactly what
contact should be acceptable has to be based on Lufkin's recommendations and experience.
Remember that tip or root relief modifications are designed to improve load distribution when a
unit is operating under load, but they can make the contact appear quite bad under no load, as in
a soft blue check. Generally, with a soft blue check you are looking for some blue to transfer,
usually in a line that covers at least 80% of the face width. Do not be alarmed by a lack of blue
covering the flank of the tooth; flank contact should normally not extend entirely to the tip of the
tooth. See Figure 4 for examples of tooth contact patterns. Keep in mind that a soft blue contact
will not produce such dark impressions–look for the same pattern in a “sketchy” impression.
The hard blue check can be done from no load to full load, and the results will vary with the load
condition. If the unit is run at no load the test will usually appear similar to a soft blue check.
More blue will wear off the pinion than the gear due to the higher number of cycles the pinion
sees. As the load increases, blue will wear off more of the tooth flank. Look for evidence of even
load across as much of the gear tooth, both flank and face width, as possible.

Figure 4 Tooth Contact Patterns
7.3 GEAR CONDITION ASSESSMENT

During the initial operating period of a set of gears, minor tooth imperfections will be smoothed
out, and the working surfaces will polish out under normal operating conditions; however, the
life of a gear set may be seriously shortened by the following problems:
• poor coupling alignment
• dirty lube oil
• insufficient lubrication
• poor tooth contact
• overloading the teeth.
In assessing gear wear, observe carefully and document the condition of the tooth surface and
the operating conditions. It is recommended that before a questionable gear set is considered
inoperative, periodic examinations be made with photographs or carbon impressions to determine
whether or not the observed condition is progressive.
page 22 NF1619D
7.3.1 Types of Gear Wear or Failure
Listed below are several common types of gear wear or failure, extracted from Appearance of
Gear Teeth–Terminology of Wear and Failure, ANSI/AGMA 1010-E95 (revision of
ANSI/AGMA 110.04), Dec. 1995 with the permission of the publisher, The American Gear
Manufacturers Association, 1550 King Street, Suite 201, Alexandria, Virginia 22314. Additional
information with photographs and illustrations may be found in this bulletin.
Abrasion – Type of wear: Removal or displacement of material due to the presence of hard
particles suspended in the lubricant or embedded in the flanks of the mating teeth (includes
scoring).
Bending fatigue– Progressive failure through crack initiation, propagation, and fracture.
Contact fatigue– Cracks and the detachment of material fragments from the gear tooth surface
caused by contact stress (includes pitting, spalling and subcase fatigue.)
Corrosion– Type of wear: Chemical or electrochemical reaction between the surface of a gear
and its environment.
Cracks– Splits caused by bending fatigue, mechanical stress, thermal stress, material flaws, or
improper processing.
Erosion– Type of wear: Loss of material from surface because of relative motion of a high
velocity fluid.
Fracture– A fatigue failure caused by tooth overloading resulting in gear tooth or portion of
tooth breaking off (includes tooth shear.)
Plastic deformation– Deformation caused by stress exceeding the yield strength of the material
(including indentation, cold flow, hot flow, rolling, tooth hammer, rippling, ridging,
burring, root fillet yielding, or tip-to-root interference.)
Scuffing– Severe adhesion that causes transfer of metal from one tooth surface to another due to
welding and tearing.
Wear– Change to a gear tooth surface involving the removal or displacement of material, caused
by mechanical, chemical, or electrical action (includes adhesion, abrasion, polishing,
corrosion, fretting corrosion, scaling, cavitation, erosion, electrical discharge, and
rippling.)
7.3.2 Definition of Gear Failure

It should be understood that the above mentioned types of wear do not necessarily constitute
complete failure, for failure is a matter of degree or rate of progression.

Bearing Inspection 8
8.1 BEARING TYPE
Lufkin's standard journal bearings for N-type gear units are split, steel-backed, babbitt-lined
bearings, shown in Figure 5A.
A. Standard journal B. Pressure dam bearing.

bearing.
D. Kingsbury-type equalizing
C. Tilt Pad Journal Bearing thrust bearing
(with tilt pads.)
Figure 5 N Unit Bearings.
CAUTION:
Pressure dam bearings must be positioned
correctly to prevent damage to equipment. When pressure dam bearings are used (Figure 5B.), ensure
the pressure dams are oriented properly.
The pressure dam bearing is designed for a particular direction of rotation; therefore, care should
be taken at assembly to assure correct rotation. The pressure dam grooves are positioned on the
unloaded side of the bearing journal as shown in Figure 6. Tilt pad journal bearings (Figure 5C)
are used to support the high speed shaft. To axially locate the gear train and to take any nominal
thrust created by external loads, this unit uses a Kingsbury-type bearing (six-shoe double bearing
with separate collar, Figure 5D.), located on the low speed shaft.
page 24 NF1619D
Figure 6 Pressure dam location.
8.2 BEARING CONDITION ASSESSMENT

When the unit is disassembled, the bearings and journal should be carefully inspected for uneven
wear or damage. If required, manually polish journals using belt type crocus cloth to remove any
high spots.
Bearing surfaces should be thoroughly inspected for:
• correct clearance
• high spots
• flaking of babbitt
• scoring
• wiping
8.2.1 Bearing Clearance
The journal bearings used in Lufkin gears must have clearance between the journal and the
bearing. The amount of clearance necessary depends on the oil viscosity, the journal speed and
the bearing loading. Each of these parameters is considered in calculating clearance that will
provide hydrodynamic lubrication, as well as sufficient oil flow for cooling.
Design clearance on the bearings is indicated on the Installation Plan.
Measurement of bearing clearances may be accomplished while the gear is stopped by lifting the
shaft and measuring the distance traveled with a dial indicator or by using feeler gauges,
carefully sliding a feeler gauge between the top of the bearing bore and the shaft.
Some wear should be expected, especially on a gear that is stopped and started frequently. The
bearing may be considered operational as long as the measured clearance does not exceed the
design clearance by more than 0.002" (0.050 mm).
NOTE: If shaft vibration is excessive, this clearance increase may not be acceptable–
contact Lufkin.
NOTE: The clearance on the tilt pad bearings is difficult to check accurately and can normally
be classified as acceptable if the bearings show no signs of distress, damage, or
excessive wear.

CAUTION: 8.2.2 Bearing High Spots
Location of any high spots in the bearing are indicated by
All bearing journal polishing must be in a bright spots which should be lightly scraped and polished
circumferential direction to prevent axial
scratches.
with fine steel wool or crocus cloth until they blend in
with the rest of the bearing.
8.2.3 Flaking of Babbitt

CAUTION: Flaking of babbitt in the load area of the bearing is caused
Do not use sandpaper to polish by vibration or shock loading of the bearing material,
bearings; damage to equipment may causing the babbitt to fatigue and break loose from the
result. steel shell. The flakes cause scoring as they pass through
the bearing and contaminate the lubricating oil. In the
advanced stages of flaking, the load carrying area of the bearing is destroyed and the bearing
must be replaced. However, if flaking is caught in the early stages, the bearing may be repaired
by scraping and polishing. The cause of vibration or hammering should be corrected before the
unit is put back in service.
8.2.4 Scoring
Scoring, scratching, or marring of the bearing babbitt and/or the journal riding in the bearing is
caused by dirt or metal particles in the oil which passes through the bearing. A little scoring is
not serious, and the bearing may be polished with fine steel wool to remove any rough edges
caused by scoring. Any foreign particles embedded in the babbitt which could score the journal
should be carefully picked out, and that area should then be polished smooth. Scoring becomes
serious when it significantly reduces the bearing area. In this case, the bearing should be replaced
and the gear unit drained and flushed out with a solvent.
8.2.5 Wiping
The melting and wiping away of a spot or area of the babbitt is caused by bearing temperatures
rising above the pour point of the babbitt. Abnormal bearing temperatures may be caused by:
• insufficient bearing clearances
• insufficient oil pressure
• excessively high oil temperature in the bearing
• a high spot in the bearing
• extreme bearing loading caused by poor bearing contact
• gear mesh failure
If wiping is localized in a small spot, the bearing may be repaired by scraping and polishing the
spot until it blends in with the remainder of the bearing; otherwise, the bearing must be replaced.
Before replacing a wiped bearing, determine and correct the cause of the wipe.
8.3 REPLACEMENT BEARINGS

Refer to the Parts List drawing and contact Lufkin if it is determined that bearings need to be
replaced. If new bearings are used, the following precautions should be taken:
1. Remove all nicks and burrs from the housing and bearing shell.
2. Be sure that journals are free of nicks and high spots. These can be removed using a fine
hone and polishing with crocus cloth.
3. Obtain the proper bearing contact as described under "Bearing Contact and Correction".
4. After bearings are fitted and lower halves are installed in housing, check the radial
clearance using feeler gauge or plastic gauge material. Check endplay by barring the shaft
axially.
page 26 NF1619D
Reassembly 9
9.1 PREPARATION
NOTE: Any work done on equipment during the warranty period without the written approval of
an authorized Lufkin representative could void the warranty.
NOTE: This procedure assumes that the gear housing is not moved from its foundation/ support
and that the original shaft alignment was correct.
1. Clean all the interior surfaces of the housing, the housing cover, and all components that will
be reused. Parting line surfaces must be clean and smooth; use a spray-on paint and gasket
remover fluid and/or carefully scrape the surfaces if
necessary. Corroded spots can be cleaned by using a fine
emery cloth, rubbing shafts in a rotary or circumferential
CAUTION: direction. Do not rub shafts in a length-wise direction as
During maintenance of the reduction it may cause seal leaks.
gear, cleanliness of parts during
installation is of utmost importance to 2. Check the bearing shells, the parting line, and the
assure successful gear operation. housing bores for any burrs or nicks; remove with a fine
file.
3. Put a coat of light oil on all parts to help assembly and
to prevent rust during reassembly.
For the discussion that follows, it is assumed that the entire unit must be reassembled.
NOTE: Tighten connectors uniformly: when tightening bolts, studs, or screws on an
assembled portion with three or more holes, always partially tighten connectors equally
in a “cross” pattern to avoid torquing, binding, or warping the section (for example: 1. top
left corner, 2. bottom right corner, 3. top right corner, 4. bottom left corner. Repeat to
fully tighten.)
9.2 REASSEMBLY SEQUENCE

Note: Although instructions include using sealer between housing sections, this should
actually be done on the final assembly, only after checking tooth contact and
ascertaining that the unit is aligned properly.
9.2.1 Bearing, Gear, and Pinion Assembly

1. Install journal bearings. Before installing journal bearings, note that the bearings are match
marked and are not interchangeable. Install the bearings in place on their shafts.
2. Install gear. Lift the low speed gear with bearings in
position and carefully place the assembly in its correct
CAUTION: location in the gear housing and bearings. Use care to
Do not bump gear assembly into avoid bumping housing or edges of bearings.
housing.
3. Turn bearings in bore if necessary (see Parts List for
requirements.)
4. Install pinion. Make sure the pinion is level and line it up in mesh with the gear, with its
bearings in place.

CAUTION:
5. Carefully set the pinion in mesh with the gear, and
Do not attempt to install shafts with roll along gear until its bearings are seated the
lower halves of thrust bearing in housing housing bores.
or babbitted thrust faces may be
damaged. 6. Line up the pins in the housing grooves and rotate
bearings until seated.
9.2.2 Gear Cover Assembly

1. Lower the cover over the studs carefully to prevent damage to gearing. Leave suspended high
enough to reach RTD holes.
2. Thread the temperature sensor wires from the bearings as necessary to retain the leads
extending into the housing. Ensure bearing anti-rotation pins are positioned in housing slots.
3. Coat the split line with a small bead of sealer, such
CAUTION: as LocTite™ No. 549 Plastic Gasket. Circle all
studs to assure sealing of oil; avoid feeder groove
Do not block oil passages with sealer. areas.
4. Seat the cover onto the bottom section and install
the cylindrical dowel pins.
5. Torque all cap screws and studs (see Table 6,
WARNING: “Recommended Tightening Torques.”)
Do not place hands below suspended
housing without blocks for protection.
6. Perform a soft blue gear tooth contact check. (See
GEAR INSPECTION.)
Table 6. Recommended Tightening Torques

(for Grade 5 Bolts & Studs)
Tightening Torque Tightening Torque
Nominal Size for BOLTS for STUDS
inches mm Ft. Lbs. N·m Ft. Lbs. N·m
1/2 12.7 75 102 87 117
5/8 15.9 150 203 173 234
3/4 19.0 266 360 307 416
1 25.4 644 873 742 1006
1-1/4 28.8 1120 1519 1484 2012
1-1/2 38.1 1949 2643 2582 3501
1 -3/4 44.5 2286 3100 4073 5522
7. If the contact is not acceptable, check for improperly meshed gears, burrs on shafts or housing
bores, or twisted housing. If no satisfactory explanation can be found, contact the Lufkin
Service Department for assistance.
8. Install Kingsbury thrust bearing.
• Replace the inner backing ring. It must be firmly seated against the wall of the housing.
• Thoroughly clean each thrust bearing shoe.
• Apply a liberal quantity of thick grease to the back side of each thrust shoe. The grease will
serve as a temporary adhesive to keep the shoes positioned in the backing ring as they are
installed.
page 28 NF1619D
• Install the inner thrust shoes taking care to place each shoe having an embedded temperature
sensor in its original position.
• Install and tighten the thrust collar lock nut and tighten the two thrust collar set screws.
• Install the axial probe target plate.
• Place the outer backing ring on a flat surface. Apply a liberal quantity of grease to the back
side of each outer thrust pad and position the thrust shoes on the backing ring. Insure that the
shoes with embedded temperature sensors are located in their original position.
• Lift the outer backing ring assembly and install it into the thrust bearing housing.
• Install the adjusting shims and thrust bearing end cap and tighten securely. Be very careful
while handling and installing the shims, since torn or crimped shims can cause incorrect
adjustments.
• Install temperature sensors in their shoes through the access covers.
9. Measure to ensure low speed shaft has specified axial movement. (Use a pry bar to move gear
from side to side if necessary). Also check that the high speed pinion can float axially.
10. Mount the shaft seals, end plates, windage baffles with spacers, and other auxiliary equipment
which may have been disconnected during disassembly.
11. Reconnect any junction box plate and wiring as necessary (see the Wiring Diagram.)
12. Reconnect any instrumentation and lubrication lines necessary (see the Wiring Diagram,
Installation Plan, and Lube System Diagram.)
13. Couple unit to driver and driven machines (see INSTALLATION.)
14. Install inspection covers with gaskets and sealer.
15. Align the unit per INSTALLATION, “Alignment” section.
16. Spin the unit slowly with no load, if possible, to verify correct reassembly. Be sure the unit
rotates freely and quietly.
17. Confirm proper shaft alignment and tooth contact per INSTALLATION section.
18. Follow the START-UP procedures.

Troubleshooting 10
Table 7 provides troubleshooting tips for high speed gears. For more detailed information, refer to
the text following. If the problem cannot be remedied through use of this information, contact
Lufkin.
Table 7. Troubleshooting Tips
Problem Possible Cause Remedy
Abnormally • Housing coated with foreign material, • Clean outside of housing
High preventing heat dissipation
Temperature • High ambient temperature • Provide adequate ventilation
• Lack of oil to bearings and/or mesh • Check lubrication system
(indicated by low oil pressure)
Low Oil • Use of lubricant with lower viscosity • Use correct viscosity lubricant
Pressure than required
• Low lubricant viscosity from high • See "Abnormally High Temperature"
lubricant temperatures
• Clogged oil filter • Replace filter element
• Pump cavitation • Maintain proper oil level in reservoir
• Air leak in suction line • Check and tighten all pipe fittings
• Incorrect relief valve setting • Set relief valve correctly
Excessive • Insufficient foundation rigidity • Reinforce foundation

Vibrations • Dynamic instability (critical speed) • Design to attenuate critical speeds in
operating range
• Unbalanced parts • Determine which parts require
balancing and which have been
balanced
• Loose foundation bolting • Tighten bolting
Unusual Noise • Worn parts • Pinpoint noise with mechanic's

stethoscope, replace part
• Coupling misalignment • Realign couplings
Excessive • Worn gearing • Replace worn parts

Noise • Transmission from other equipment • Add sound blanket or enclosure
Excessive • Air in oil • Add anti-foaming agent (See caution
Foaming in text below.)
No Sensor • No power • Check power supply & repair or

Readings restore
• Faulty gauge or recording device • Test gauge or recording equipment
• Failed sensor • Replace sensor
• Lead wire braid rubbed through; wire • Replace lead wire
contacting metal
page 30 NF1619D
10.1 ABNORMALLY HIGH TEMPERATURE
• Oil level too high. If the oil level in a gear box is so high that the gear runs in the oil, then the
resulting churning action will heat the oil. Check the sight gauge while the unit is running. A
full gauge may indicate inadequate drainage.
• Coated housing. If the gear housing should get coated with a foreign material that will not
permit natural heat removal by convection, high temperature may result. To prevent this, the
unit should be cleaned periodically.
• Hot weather. Obviously, a high ambient temperature will cause abnormally high oil
temperature. To prevent this, provide adequate ventilation around the gear.
• Low oil pressure. If the oil flow to the bearings and gear mesh is below normal (indicated by
below normal oil pressure,) the heat created by friction at the mesh and bearings will cause
abnormally high temperatures. To correct this situation, check the lubrication system for proper
operation (see OPERATION, “Lubrication.”)
10.2 LOW OIL PRESSURE

• Use of a lubricant which has a viscosity less than that for which the lube system was
designed. There are several orifices in the lube system which are sized for lubricants with a
particular viscosity. A lubricant with less than this normal viscosity will pass through the
orifices without building up pressure. This situation can be prevented by using the lubricant
designated on the name plate of the gear unit. Abnormally low viscosity may also result from
high lubricant temperatures. (See above, “Abnormally High Temperatures.”)
• Clogged oil filter. Replacing the filter will allow more oil to flow through it, thus bringing the
oil pressure back to normal.
• Pump cavitation. Should the oil level in the reservoir get so low that the pump suction line
sucks both air and oil, then the oil pressure will drop. This problem may be cured by maintaining
proper oil level in the reservoir.
• Air leak in the suction line to the pump. This situation is similar to pump cavitation in that air
gets in the oil and results in low oil pressure. To remedy this problem, check and tighten all pipe
fittings in the suction line.
• Incorrect relief valve setting. Adjusting the relief valve setting properly will avoid venting the
pump discharge line back to the sump.
10.3 UNUSUAL OR EXCESSIVE NOISE

• Worn parts. One common cause of unusual noise is worn parts. If a part wears enough to cause
slack in the system, the slack may be heard as a rattle or noise of some sort. A mechanic's
stethoscope may be used to pinpoint the worn part which should be replaced.
• Misalignment. A coupling that is out of alignment may also cause noisy operation. The
misaligned coupling causes misalignment in the gear train which then produces noise or
vibrations. The coupling should be immediately realigned before damaging wear occurs.
• Transmitted sound. Occasionally other machinery or equipment may be transmitting excessive
noise. Enclose one or the other or use a sound blanket.

10.4 EXCESSIVE VIBRATION
• Soft foundation. A foundation that is not sufficiently rigid may cause vibration problems. To
correct this, reinforce the foundation.
• Critical speeds. At certain speeds a rotating shaft will become dynamically unstable and the
resulting vibrations and deflections that occur may cause damage to the gear unit. The speeds at
which the shaft becomes unstable are called critical speeds. They are a function of the shaft
geometry and the type and spacing of the supporting bearings. Contact Lufkin if such dynamic
instability is suspected. See OPERATION, “Customer Check After Start-up” for vibration
limits.
10.5 FOAMING
CAUTION: Some foam in a gear unit is generally acceptable and
Measure the anti-foaming agent carefully. inevitable. If the foam exceeds 2 or 3 inches in the sump,
Too much anti-foam agent will stabilize the Lufkin recommends adding an anti-foaming agent such as
foam, destroy the load capacity of the oil, DOW CORNING 200 FLUID™ (1000CS) at
and require a complete oil change.
approximately 0.075 ml per gallon of oil. If excessive
foaming persists, contact Lufkin.
10.6 NO SENSOR READINGS

Various sensing devices for temperature and vibration are installed to provide warnings that can
prevent catastrophic failure. If no readings are being received, before disassembling the unit check
for the following:
• No power. Check that the power supply to the devices is on.
• Failed equipment. Check that the monitoring or recording equipment is functioning.
• Worn wires. If the sensor has failed, partial disassembly may be affected to replace the sensor.
Visual inspection of lead wire overbraids are necessary to ensure that moving parts are not
rubbing through the lead wires and causing shorting out. Replace any worn wires.
page 32 NF1619D
Nameplate Data 11
GEARS
MODEL GEAR
NO. NF1619D RATIO 1.854:1
SERIAL RATED RPM

NO. 11210762-01 INPUT 6100
ORDER RATED RPM

NO. 11210762 OUTPUT 11307
ITEM GEAR
NO. RATED 43047 HP
32100 KW
ACTUAL API SERVICE

K FACTOR 269.37 FACTOR 1.63
UNIT RATED AND BUILT PER:
SPEC
API 613 5th Edition
NO. OF TEETH
GR/PIN 76 / 41
LUBRICANT OIL SUMP GALS
AGMA NO. Lt Turbine CAPACITY ---
VISCOSITY 150 ISO GRADE VG 32

SSU @ 100°F
INDUSTRIES, INC.
LUFKIN, TEXAS - USA

page 34 NF1619D
Power Transmission Div.
LIST OF PARTS
Unit: NF1619D Sales Order: 11210762
Unit Rev: B Date: 03/06/2014 Customer: NUOVO PIGNONE SRL
Drawing: 1121076201 Rev: A Customer PO: 439887277 / 43989466
Serial Numbers: 11210762-01
ITEM PART NUMBER PART DESCRIPTION QUANTITY UOM

0001 22094675 ASSY HSG/CVR - NF1619D,R-L,KTB 1.000 PC
0002 100262065 GEAR, LSP - NF1619D INCREASER 1.000 PC
0003 100261058 PINION, HS - NF1619D INCR, C'CW 1.000 PC
ROTATION
0004 100261093 BEARING, TPJ-RMT, 170MM BORE 1.000 PC
0005 100261092 BEARING, TPJ-RMT, 170MM BORE 1.000 PC
0006 100261060 BEARING, LSP - NF16D, 7.25 BORE, 1.000 PC
C'CW
0007 100261059 BEARING, LSP - NF16D, 7.25 BORE, 1.000 PC
CW
0008 22118000 SEAL, D-LINE STYLE, 5.50" BORE 1.000 PC
0009 E7096160 SCREW,CAP SOC HD,3/4 NCX1-3/4 8.000 PC
0010 22203300 GUARD, SHAFT - NF1619D INCREAS 1.000 PC
0011 E7095879 SCREW, CAP - 1/4-20NC X 5/8 4.000 PC
0012 22117300 SEAL, D-LINE STYLE, 6.50" BORE 1.000 PC
0013 22200400 ADAPTER,CPLG GRD-N16D,HS,SPLIT 1.000 PC
0014 19532800 BAFFLE HS WINDAGE-NF16D 1.000 PC
0015 E7090175 SPACER, 3/4 8.000 PC
0016 E7093975 SCREW, CAP - 3/4 NC X 3 GALV 8.000 PC
0017 100262041 PIPE, SPRAY, 2" TUBE 1.000 PC
0019 22194400 ADAPTER,CPLG GRD-N16D,LS,SPLIT 1.000 PC
0020 100262005 SEAL, D-LINE STYLE, 7.00" BORE, 1.000 PC
SPLIT
0021 E7092020 SCREW, CAP - 3/4 NC X 3 1/2 8.000 PC
0023 19579200 COVER, INSPECTION - 18 X 21 1.000 PC
0024 18918700 GASKET, INSPECTION COVER 1.000 PC
0025 E7077733 SCREW CAP ZINC COATED HXHD 3/8 12.000 PC
0026 E7087655 PIPE 2" SCH 40 316L SST 4.000 IN
0027 E9063706 FLANGE BLIND 2" STANDARD WT. 1.000 PC
0028 N7066745 GSKT FLNG-2" 150# NON-ASBESTOS 1.000 PC
0029 E9078415 FLANGE SLIP-ON 2" 316L STL 1.000 PC
0031 E7085524 NUT HEAVY HEX 5/8"NC 4.000 PC
0032 AP030144 NAME PLATE LUFKIN 2.000 PC
0033 E7083833 PIPE PLUG 1 1/2 NPT SQUARE 2.000 PC
0034 E9063710 FLANGE BLIND 4" STANDARD WT. 1.000 PC
0035 N7075993 GSKT FLNG-4" 150# NON-ASBESTOS 1.000 PC
Page 1 of 3
LIST OF PARTS

0036 E7089119 STUD, 5/8-11 NC, 3 1/4" SST 8.000 PC
0037 E7089040 NUT HVY.HEX HD. - 5/8 NC SST 8.000 PC
0038 22117900 BAFFLE, FALSE BOTTOM NF1619D 1.000 PC
0039 E7086696 FLANGE BLIND 16"-150# BLIND 2.000 PC
0040 E7086697 GASKET, FLANGE 16"-150# 2.000 PC
0041 E7089887 STUD 1"-8 NC X 4 1/2, 316 SST 32.000 PC
0042 E7095886 SCREW ADJUSTING-H/H 1"-8NC X4" 4.000 PC
0043 E7092430 TUBING 2"ODX120 WALL 25.130 IN
0044 E9098026 FITTING, CONNECTOR- 2" 316 SST 3.000 PC
0045 E7094034 CONNECTOR, MALE - 316SST BORED 3.000 PC
0046 E7075919 NOZZLE SPRAY-VEE JET 1/8 U8030 2.000 PC
0047 100262040 PIPE, SPRAY, 2" TUBE 1.000 PC
0048 E7086421 NOZZLE SPRAY-VEEJET MODEL 10.000 PC
0049 E7094729 FLG 1"-3000# SAE KIT 316 SST 1.000 PC
0050 E9067006 ELBOW 90 SOCKET WELDING 1" 2.000 PC
0051 E7083277 PIPE 1" STAINLESS STEEL T316L 15.880 IN
0052 N7066742 GSKT FLNG-1" 150# NON-ASBESTOS- 1.000 PC
GR01 WH
0053 E9078115 FLANGE SLIP-ON 1" T316 SST 1.000 PC
0054 E7095882 REDUCER, FLANGE - 1" TO 3/4" 1.000 PC
0055 E7089099 STUD, 1/2-13 NC, 2 1/4 SST 4.000 PC
0056 E7079875 NUT HVY.HEX HD. - 1/2 ST.STL. 4.000 PC
0057 E7081946 PIPE 3/4" 316L SST SEAMLESS 5.250 IN
0058 E7087309 STUD W/NUT & WASHERS 2.000 PC
0059 19216500 ADAPTER,MTG-RTD SVC HD-KTB 3.000 PC
0061 100264245 BRKT, DBL J/B - SST C-H EXCELL 1.000 PC
0062 100264328 SCREW CAP ZINC COATED HXHD 1/2 2.000 PC
NC - 3
0063 100262803 NUT HVY.HEX HD. - 3/8" GALV 8.000 PC
0064 E7090103 SCREW CAP-DRILLED HEX HEAD 12.000 PC
0066 100262386 HOUSING, KTB - JHJ8, NF16D 1.000 PC
0068 19206000 BEARING,THRUST JHJ-8 KTB 1.000 PC
0069 21693600 CAP, END - KTB JHJ-8 1.000 PC
0070 18804200 SHIM, SST JHJ-8 KTB 1.000 PC
Page 2 of 3
LIST OF PARTS

0072 18900101 COVER, DRAIN - NF1919D 2.000 PC
0073 22248100 COVER, SIDE ACCESS NF1619D 2.000 PC
0074 E7089480 SEAL, RING - FLOATING - 6 1/2" 1.000 PC
0075 E7085144 FLANGE 3" SAE 4 BOLT BLIND 1.000 PC
0076 E7087597 SCREW, CAP - 5/8 NC X 3 4.000 PC
0077 100262804 BAFFLE, LSP WIND - NF16D, 7.035 ID 1.000 PC
0079 100262007 BAFFLE, WINDAGE - LSP, NF16D 1.000 PC
0080 E7056645 PIPE 3/8" STD, ERW FBN, PER AS 12.000 IN
0081 AM086262 SCREW CAP HXHD 3/8X2 1/4 8.000 PC
0082 22346700 BAFFLE,LSP WIND-NF16D,6.50 ID 1.000 PC
0083 E7056645 PIPE 3/8" STD, ERW FBN, PER AS 2.000 IN
0084 21318200 CAPSCREW, HX HD-DR/HD 3/8-16NC 8.000 PC
0085 100264327 SPACER, J-BOX BRACE 1.000 PC
0300 1121076260 KIT, ELECTRICAL - NF1619D 1.000 PC
0301 1121076263 KIT, ELECTRICAL - NF1619D 1.000 PC
0302 E7095878 ORIFICE, PLATE 1.000 PC
0303 1121076250 KIT, PAINT - CARBOLINE, RAL 7035, 1.000 PC
GENP
0307 19679100 STUD, 1 1/4"-7NCX12 9/16 LONG 14.000 PC
0308 22194200 STUD, 1 1/4"-7NC X 7-9/16 LONG 4.000 PC
0309 22688400 NUT, SELF SEAL 1-1/4-7 NC 14.000 PC
0311 22688500 WASHER, SELF SEAL 1-1/4-7 NC 14.000 PC
Parts with item numbers of 300 and above are not shown on the drawings.
This document and all information thereon is CONFIDENTIAL and is the property of Lufkin Industries, Inc.
It shall be used only as authorized.
Page 3 of 3
10 11 19 20 21 77
4 8 9 79 80 81
68
66 67
3 2
69 70 71
5 SCALE 0.063
6
DETAIL KTB
82 83 84 SCALE 0.250
12 13 14 15 16 74
SEE DETAIL KTB
23 24 25 32 26 27 28 29 30 31 63 65 49 50 51 44 45 47 48
52 53 54 55 56
57
LUFKIN GEARS
75 76
MODEL GEAR
61 62 85 NO. NF1619D RATIO 1.854:1
SERIAL RATED
NO. 11210762-01 INPUT 6100
RPM
ORDER RATED
NO. 11210762 OUTPUT 11307
RPM
59 60 ITEM GEAR
RATED 43047 HP
NO.
API
ACTUAL
K FACTOR
269.37 SERVICE 1.63
FACTOR
33
UNIT RATED AND BUILT PER:
SPEC. API 613 5TH ED.
17 44 45 46 NO OF
58 TEETH
GR/PIN 76/41
LUBRICANT OIL SUMP
AGMA NO. AGMA #0 CAPACITY - - - GALS
VISCOSITY ISO
SSU @ 100 F 150 GRADE ISO VG 32
BER O
EM
F
34 35 36 37 73 38 64 72 1 43 44 45 39 40 41 42
M
LUFKIN INDUSTRIES, INC.
ORIFICE KTB 15/64, 2-PLACES CUSTOMER: NUOVO PIGNONE LUFKIN, TEXAS - USA
CHGD BY P/O. NO.: 439887277 DATED: 07/19/13
REV. DESCRIPTION OF CHANGE DATE
NO. OF UNITS: ONE ARRANGEMENT: R-L ROTATION, HS: C'CW DATE
CHANGED TO A LARGER VIBRATION JUNCTION BOX AND MADE NECESSARY ADJUSTMENTS AJM
A 3/4/14 PRIME MOVER: GAS TURBINE INDUSTRIES, INC.
INCR/RDCR PREP. BY: AJM 9/12/13 Lufkin, Texas
DRIVEN EQUIPMENT: CENTRIFUGAL COMPRESSOR
INSTALLATION PLAN: 11210762IP MASS ELASTIC: 11210762ME CHECKED BY: RFE 10/31/13
THIS DRAWING AND ALL INFORMATION THEREON
IS CONFIDENTIAL AND IS THE PROPERTY OF
ASSEMBLY DRAWING:
LOCATION OF INSTALLATION:
WIRING DIAGRAM:
LA FLORENA, COLUMBIA
11210762WD
CERTIFIED BY: Andrew McKinnon 3/6/14 Parts
List
(Serial No.)
11210762-01 A
LUFKIN INDUSTRIES, INC. IT SHALL BE USED
ONLY AS AUTHORIZED BY LUFKIN INDUSTRIES,
INC. AND IS SUBJECT TO RETURN ON DEMAND. REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE LATEST REVISION UNLESS INDICATED ENGINEERING RELEASE: No.
NOTES:
**************************************** 1. ESTIMATED NET UNIT WT. = 17,100 LBS. [7756 KG.]
COMPLETE UNIT MAY BE LIFTED FROM EITHER 4-HOLE SET OF LSP SHAFT END DETAIL
LIFTING PROVISIONS. SEE SHEET 2 OF 2
LUFKIN INDUSTRIES, INC. 2. HEAVIEST MAINTENANCE LIFT = 2917 LBS. [1323 KG.] - LSP ASSEMBLY.
3. REFER TO PARTS LIST 11210762-01 FOR FURTHER INFORMATION. 18.307 .020
LUFKIN, TEXAS 4. INTERCONNECTING PIPING MUST BE CLEANED BEFORE UNIT OPERATION. [ 465.00 .50 ]
5. THIS UNIT TO BE BUILT PER API-613 FIFTH EDITION SPECIFICATIONS,
DATED FEB 2003. SEE LSP COUPLING GUARD
NUOVO PIGNONE 6. DESIGN RADIAL BEARING CLEARANCES: ADAPTER DETAIL
CUSTOMER
439887277 HS BRG.: 0.0080 - 0.0100" [0.203 - 0.254] 1.75 [44.5] THRU, 3.75 [95.3] 3.937 [100.00] ACROSS FLATS, SEE SHEET 2 OF 2
CUSTOMER ORDER NO.
LUFKIN ORDER NO. 11210762 LSP BRG.: 0.0120 - 0.0140" [0.305 - 0.368] SPOTFACE TO CLEANUP, 4 HOLES MANUAL TURNING PROVISION
INPUT 6100RPM, OUTPUT 11307
RPM, RATIO 1.854:1 THRUST BEARING ENDPLAY: 0.014 - 0.018" [0.30 - 0.36] FOR FOUNDATION BOLTS, W/ REMOVABLE COVER
GRADE 5 OR EQUIVALENT. 1.63
AGMA MECH. RATING, SF= 1.0, 108232 HP 7. VIBRATION EQUIPMENT SET POINTS:
80709 KW [41.3 ]
API S.F. = 1.63 HS PINION DISPLACEMENT - ALARM 1.75 MILS [44.5 microns] PEAK TO PEAK
SERVICE RATING, SF= 2.51
, 43047 HP SHUTDOWN 2.50 MILS [63.5 microns] PEAK TO PEAK 3.38 57.88 3.13
32100 KW LSP SHAFT DISPLACEMENT - ALARM 2.00 MILS [50.8 microns] PEAK TO PEAK [85.7 ] [1470.0 ] [79.4 ]
RECOM'D. LUBE OIL LT. TURBINE (150 SSU AT 100 F.) SHUTDOWN 3.00 MILS [76.2 microns] PEAK TO PEAK
LSP
ISO VG 32 (32 CST AT 40 C.) 1"-8 NC [25.4] 18.13 23.25 2.56
LSP AXIAL DISPLACEMENT - ALARM 5.00 MILS [127.0 microns] INTO BABBITT 28.75
[460.4 ] [590.6 ]
TEMPERATURE
SHUTDOWN 10.00 MILS [254.0 microns] INTO BABBITT LEVELING SCREWS, [730.3 ] [65.1 ]
CL
REQ'D WATER FLOW ---
GPM AT --- F MAX TEMP
HS
HEX FLAT 34.06
--- --- 2 4 PLACES AS SHOWN
LPM AT C MAX TEMP [865.0 ]
CL
CASING ACCELERATION - ALARM 6g's [58840 mm/s ] PEAK
27.63 26.81
NOTE: THESE VALUES ARE ESTIMATES ONLY. FIELD CONDITIONS WILL DICTATE
UNITS LESS LUBE SYSTEM [701.7 ] [681.0 ]
FINAL ALARM AND SHUTDOWN VALUES WHICH MAY BE HIGHER OR LOWER THAN THESE
309GPM AT 25
STARTING VALUES.
MAX OIL FLOW PSI & 131 F 8. TEMPERATURE MONITORING PROTECTION EQUIPMENT SET POINTS:
1170 172 16.56
LPM AT kPa & 55 C 15.50 .08
2552499 EMBEDDED TEMPERATURE SENSOR IN BEARING SHELL [420.7 ]
[1.9 ]
LSP
HEAT REJECTION RATE BTU/HR [393.7 ]
749 ALARM SETTING 225 F. [107 C.] RISING
KW
SHUTDOWN SETTING 240 F. [116 C.] RISING
CL UNIT
CL
UNIT
****************************************
9. - DENOTES CENTER OF GRAVITY LOCATION. CL 33.13
CERTIFIED Andrew McKinnon 10. DIMENSIONAL INTERPRETATION = INCHES [MILLIMETERS] UNLESS NOTED OTHERWISE.
31.00
[841.4 ]
5.00
HS
DATE 3/6/14 [787.4 ] [127.0 ]
VIBRATION
11. INSTRUMENTATION LEGEND:
CL
VX1 - HS DE HORIZ. V/P TE1A - HS DE RTD 16.74 25.94
****************************************
VY1 - HS DE VERT. V/P TE1B - HS DE RTD [425.1 ] [658.8 ]
VX2 - HS NDE HORIZ. V/P TE2A - HS NDE RTD TYP 28.43
VY2 - HS NDE VERT. V/P TE2B - HS NDE RTD [722.0 ]
VX3 - LSP DE HORIZ. V/P TE3A - LSP DE RTD .63
VY3 - LSP DE VERT. V/P TE3B - LSP DE RTD 39.72
[15.9 ]
VX4 - LSP NDE HORIZ. V/P TE4A - LSP NDE RTD [1008.8 ]
VY4 - LSP NDE VERT. V/P TE4B - LSP NDE RTD .79
VA4A - LSP NDE AXIAL V/P TE5A - THRUST BEARING DE RTD +.0010 .79
1.5748 .79 [20.0 ] [20.0 ]
VA4B - LSP NDE AXIAL V/P TE5B - THRUST BEARING DE RTD -.0000 TYP
[20.0 ] TYP
[ ]
A1 - HS DE ACCLRM TE6A - THRUST BEARING NDE RTD +.025 +.0010
A3 - LSP DE ACCLRM TE6B - THRUST BEARING NDE RTD 40.000 TYP 1.5748 SEE HS COUPLING GUARD
-.000 -.0000 TE5B
[ ]
KP2 - HS NDE K/P TE6C - THRUST BEARING NDE RTD TYP +.025 ADAPTER DETAIL TE6B
KP4 - LSP NDE K/P 40.000 SEE SHEET 2 OF 2 TE5A
-.000
"DE" - DRIVE END TE6A
TYP HS SHAFT END DETAIL
"NDE" - NON DRIVE END
12. EXPECTED BEARING BABBIT TEMPERATURE AT FULL SPEED, FULL LOAD AND 131 F [55 C] SEE SHEET 2 OF 2
OIL INLET TEMPERATURE SECTION B-B VA4A VA4B
HS BEARINGS: 200 F [93 C] 13.940 .015
LSP BEARINGS: 199 F [93 C] [ 354.08 .38 ] 2"-150# RF FLANGE
13. ORIFACE PLATE TO BE INSTALLED ON 4" ANSI FLANGED OIL INLET 0.118" [3.00] THICK, 9.50 CONNECTION FOR BREATHER
INSIDE DIAMETER IS DEFINED AFTER MECHANICAL RUN TEST [241.3 ]
2.50 [63.5 ] LIFTING 1"X150# ANSI RF FLANGE
PROVISION, 4-PLACES 23.81 23.81 KTB CONNECTION.
A
AS SHOWN [604.8 ] [604.8 ] (316L SST PIPE)
46.38
19.25 16.50 26.63 8.42
[1177.9 ]
73.91 [489.0 ] [419.1 ] [676.3 ] [213.8 ]
[1877.3 ] 17.38 12.50 INSPECTION DOOR
[441.3 ] [317.5 ] 10.00
[ 254.0 ] KP4
VY3 3/4 NPT AXIAL
1.50 V/P PROVISION, TYP VY1
[38.1 ] KP2 1.13 [28.6] FROM
MOUNTING
A3 68.75
TO SENSING SURFACE
VY4
[1746.3 ]
VY2 MINIMUM
2.50 [63.5] COVER REMOVAL
LIFTING PROVISION
UNIT
4 PLACES 17.50
AS SHOWN [444.5 ]
CL
A1
4.00 VX1
[101.6 ] 10.00 7.06
57.88
[ 254.0 ] [179.2 ] 54.25
[1470.0 ]
TYP [1378.0 ]
18.00
A 7.50 7.50 [457.2 ]
UNIT
[190.5 ] [190.5 ]
36.14
VX2 32.25 [917.9 ]
CL
.94 [819.2 ]
VX3
[23.8 ]
HS
LSP
HS
LSP
16"-150 LB ANSI FF, 3.50 VX4
CL
STUDDED FLANGE CONN 1.50 [88.9 ]
CL
CL
12.00
CL
UNIT OIL DRAIN, [38.1 ]

[304.8 ] EITHER END CUSTOMER DRAIN
BOLTING PROVIDED BY CONNECTION
LUFKIN
4.33 TE6C
6.00 13.56 13.56 6.00 [110.0 ] 1.00
[152.4 ] [344.5 ] [344.5 ] [152.4 ] [25.4 ]
1.44 24.38 19.50 1.44 M10 X 1.5 EARTH GROUNDING
11.56 1.00 10.50 11.49 TE1A
39.13 [36.5 ] [619.1 ] [495.3 ] [36.5 ] BOSS, 1-EACH END
[293.7 ] [25.4 ] [266.7 ] [291.8 ] TE1B
[993.8 ] TO OUTLET FLANGE
TE2A OIL INLET TE4A
11.56 TE4B
28.13 TE2B 66.88
1-1/2" NPT UNIT PURGE 23.25 [293.7 ]
[714.4 ] TE3A [1698.6 ]
CONNECTION, EITHER END TE3B [590.6 ] 4" X 150 LB ANSI FF
19.31 STUDDED FLANGE CONNECTION,
[490.5 ] OIL TO GEAR UNIT, THIS
OIL INLET END ONLY. (BLIND FLANGED
CLOSURE FOR SHIPPING.)
BOLTING PROVIDED BY LUFKIN
ENGR. CODE NO. PLAN, INSTALLATION - NF1619D

THIS DRAWING AND ALL INFORMATION THEREON MATERIAL SPECIFICATIONS R-L UNIT, C'CW ROTATION, INCREASER
LUFKIN INDUSTRIES, INC. IT SHALL BE USED 1.854:1 RATIO
INC. AND IS SUBJECT TO RETURN ON DEMAND.
DWN AJM CHK RFE APP JWL
N/C-CAM
CHGD BY CHGD BY
REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE DATE 8/6/13 SCALE 0.083 READY
REV. DESCRIPTION OF CHANGE DATE REV. DESCRIPTION OF CHANGE DATE
LATEST REVISION UNLESS INDICATED OTHERWISE
SK20128-8 CHANGED TO A LARGER VIBRATION JUNCTION BOX; DIMENSION CHANGED TO 57.88 WAS AJM
RELEASED FROM DESIGN ENGINEERING:
A PERTAINS TO / ALSO USED ON
INDUSTRIES, INC.
55.51; DIMENSION CHANGED TO 26.63 WAS 24.63 3/4/14
S/O 11210762
LUFKIN, TEXAS
11210762IP
WIRING DIAGRAM 11210762WD
MASS ELASTIC 11210762ME
SUPERSEDED BY: SHEET 1 OF 2
A
DYNAMIC LOAD (OVERTURNING MOMENT) DUE ONLY TO NOTE: DYNAMIC LOAD AT OVERLOAD
TANGENTIAL FORCE AT RATED OPERATING CONDITIONS TORQUE CONDITIONS IS DETERMINED BY .820 .015
MULTIPLYING THE DYNAMIC LOAD [ 20.83 .38 ]
.375/.378 [9.53/9.60] REAMED
DYNAMIC LOAD AT OPERATING CONDITIONS BY THE RATIO
.405 .005 20-HOLES EQUALLY SPACED
684431 IN-LB OF THE TANGENTIAL LOAD AT OVERLOAD
M10 X 1.5 TAP THRU, [ 10.29 .12 ] ON B.C. SHOWN
77330 NM CONDITIONS TO THE TANGENTIAL LOAD AT
NORMAL OPERATING CONDITIONS. 8-HOLES
16.50 EQUALLY SPACED .185 .005
[419.1 ] ON B.C. SHOWN. [ 4.70 .12 ]
B.C.
17.75
[ 450.9 ] 12.875 B.C.
STATIC LOAD DYNAMIC LOAD DUE ONLY TO RESIDUAL UNBALANCE IN ROTATING ELEMENTS O.D. [327.03 ]
INCR 17100 LB OPERATING AT MAXIMUM ALLOWABLE VIBRATION LEVELS 15
22.5
R-L C'CW 7756 KG
13.940 .015
ALARM SETTING LOAD AT SHUTDOWN SETTING LOAD AT [ 354.08 .38 ]
VIBRATION LEVEL ALARM LEVEL VIBRATION LEVEL SHUTDOWN LEVEL
PINION 0.00175 IN. 3273.45 LB 0.0025 IN. 4676.36 LB
44.5 µM 1484.81 KG 63.5 µM 2121.16 KG 13.695 .005
GEAR 0.002 IN. 3080.46 LB 0.003 IN. 4620.7 LB [ 347.85 .12 ]
11.7505 .0005 18.0
50.8 µM 1397.27 KG 76.2 µM 2095.91 KG [ 298.463 .012 ]
HS COUPLING
GUARD ADAPTER
DETAIL 11.690 .015
+ SCALE 0.125 [ 296.93 .38 ] 11.190 .015
F [ 284.23 .38 ]
LSP SHAFT - M10 X 1.5 TAP THRU
16-HOLES
EQUALLY SPACED
- A + ON B.C. SHOWN. 45
CENTERLINE OF 23.75
SHAFTS, UNIT - C + [603.3 ]
COLD, SHAFTS 22.913 BC
O.D.
AT REST [581.99 ]
+.015
.489
-.000
HS PINION
[ ]
+ + +.38
- 12.42
B
-
D
- E
-.00 HS SHAFT END DETAIL
SCALE 0.333
DETAIL- MECHANICAL & THERMAL MOVEMENT
+ 11.25
SECTION C-C
DETAIL- AXIAL THERMAL GROWTH
ALIGNMENT DATA INCHES [MM]
AMBIENT RADIAL MECHANICAL & THERMAL AXIAL THERMAL

TEMP. MOVEMENT GROWTH
HS HORIZ HS VERT LSP HORIZ LSP VERT HS AXIAL LSP AXIAL 1.001/1.003 [25.425-25.476]
"A" "B" "C" "D" "E" "F" REAMED, 18 HOLES EQUALLY
2.520 .020 SPACED ON B.C. SHOWN.
68 F
20 C
-.001
[-.033]
+.029
[+.744]
+.013
[+.329]
+.023
[+.582]
+.022
[+.559]
+.027
[+.681]
LSP COUPLING [ 64.01 .50 ] C'BORE FAR SIDE TO DIMENSIONS
SHOWN
86 F -.001 +.025 +.011 +.019 +.019 +.023 GUARD ADAPTER 1.260 .008
[ 32.00 .20 ]
30 C [-.033] [+.647] [+.279] [+.485] [+.483] [+.579]
DETAIL .138 .020
104 F -.001 +.022 +.009 +.015 +.016 +.019 SCALE 0.125 20 16.142 B.C.
40 C [-.033] [+.551] [+.230] [+.388] [+.398] [+.477] [ 3.51 .50 ] [410.00 ]
+.020
1.850
-.000
[ 47.00
+.50
-.00 ]
TPJ BEARING
18.307 .020
HS
[ 465.00 .50 ]
CL
LSP
30
CL
UNIT
CL
+.0000
12.5999
+.0014
[ 320.037
+.000
+.036 ]
PRESSURE DAM ORIENTATION
UPLOADED PINION, DOWNLOADED GEAR
INCREASER
SECTION A-A
LSP SHAFT END DETAIL

SCALE 0.250
EXPECTED CONTACT ACROSS PINION FACEWIDTH AT NO LOAD:

WING,
NON- WING,
DRIVE ENGR. CODE NO. PLAN, INSTALLATION - NF1619D
APEX DRIVE
END APPROX 80 % OF HELIX WIDTH, MINIMUM APPROX 25% OF HELIX WIDTH, TOWARD APEX END THIS DRAWING AND ALL INFORMATION THEREON MATERIAL SPECIFICATIONS R-L UNIT, C'CW ROTATION, INCREASER
(BLIND) (EXT.)
LUFKIN INDUSTRIES, INC. IT SHALL BE USED 1.854:1 RATIO
N/C-CAM
CHGD BY CHGD BY
REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE DATE 8/6/13 SCALE 0.083 READY
REV. DESCRIPTION OF CHANGE DATE REV. DESCRIPTION OF CHANGE DATE
LATEST REVISION UNLESS INDICATED OTHERWISE
SEE SHEET 1 OF 2
RELEASED FROM DESIGN ENGINEERING:
PERTAINS TO / ALSO USED ON
INDUSTRIES, INC.
LUFKIN, TEXAS
SUPERSEDED BY:
11210762IP SHEET 2 OF 2
A
16.50 PITCH GROOVE 2
[419.1 ] TEETH MATERIAL HARDNESS WR WT
DIA DIA
2
HS PINION 41 11.564 10.698 9310H 58 Rc 13913 IN LBS 1031 LBS
2
18.31 [293.73] [271.73] [4.072 KG*M ] [468 KG]
[465.0 ] LSP GEAR 76 21.436 20.570 9310H 58 Rc 2
2915 LBS
143248 IN LBS
2
12.60 .14 (INTEGRAL) [544.47] [522.48] [41.920 KG*M ] [1322 KG]
[320.0 ] [3.5 ] 2.52
[64.0 ] BEARING BORE BEARING LENGTH PROJECTED AREA
2
HIGH SPEED 6.693 6.693 44.795 IN
2
[170.00] [170.00] [28900.00 MM ]
2
LOW SPEED 7.250 7.250 52.563 IN
HEX TURNING PROVISION 2
[184.15] [184.15] [33911.22 MM ]
3.94
2 2 2
[100.0 ] WR REFERRED TO LSP = 191054 IN LBS [55.910 KG*M ]
ACROSS FLATS
8.04 PRESSURE ANGLE = 20 NORMAL NDP = 4 HELIX ANGLE = 27.580199
2.50 7.00
[204.1 ] .38
[63.5 ] [177.8 ]
[9.5 ] MODULE = 6.35
.38
[9.5 ] 1.75 5.50
[44.5 ] [139.7 ]
8.00
7.75 [203.2 ]
[196.9 ]
NOTE:
VALUES USED FOR CALCULATIONS ARE
6.69 11.63
11.38 [170.0 ] 3 3
[288.9 ]
[295.3 ] 34.06 DENSITY = .283 LBS/IN [7833.4 KG/M ]
[865.0 ] 6 2 3
SHEARING MODULUS OF ELASTICITY = 11.8 X 10 LBS/IN [81.4 X 10 MPa]
.13 DIMENSIONAL INTERPRETATION = INCHES [MILLIMETERS] UNLESS NOTED OTHERWISE.
[3.2 ] 7.24
[183.8 ]
SHAFT STIFFNESS:
8 8
HS PINION: 1.42 X 10 IN LBS/RAD [.16 X 10 N M/RAD] FROM
10.70 MESH CENTERLINE TO FACE OF UPSET FLANGE.
[271.7 ] 19.00 16.75
16.50
[482.6 ] [425.5 ] 8 8
[419.1 ] LSP SHAFT: 1.50 X 10 IN LBS/RAD [.17 X 10 N M/RAD] FROM
BAND OD CL OF
10.25 CL OF
TYP BRG MESH CENTERLINE TO FACE OF UPSET FLANGE.
[260.4 ] BRG
2.50
[63.5 ]
23.00 MINIMUM EXPEDTED SHAFT TENSILE PROPERTIES

[584.2 ]
TENSILE YIELD ULTIMATE TENSILE UNADJUSTED ENDURANCE LIMIT
PSI MPA PSI MPA PSI MPA
10.25 18.38 16.75
[466.7 ]
HS SHAFT 95,000 655 125,000 862 62,500 431
[260.4 ] [425.5 ]
CL OF 18.00 CL OF LSP SHAFT 95,000 655 125,000 862 62,500 431
BRG [457.2 ] BRG
BAND ID
TYP
2.00 10.70
[50.8 ] [271.7 ] .06
28.43 [1.6 ] 7.24
[722.0 ] TYP [183.8 ] 11.00
[279.4 ]
6.69
8.75 [170.0 ]
[222.3 ]
6.50
5.07 3.75
[165.1 ]
[128.9 ] [95.3 ] 5.06
11.69 [128.6 ]
[296.9 ]
.70 11.19
.41 [284.2 ] .82
[17.7 ]
[10.3 ] .19 [20.8 ] 1.38
[4.7 ] 11.75 [34.9 ]
8.13
[298.5 ] [206.4 ]
13.94
[354.1 ]
ENGR. CODE NO. DIAGRAM, MASS ELASTIC - NF1619D,

MATERIAL SPECIFICATIONS INCREASER, R-L UNIT
LUFKIN INDUSTRIES, INC. IT SHALL BE USED RATIO 1.854:1
N/C-CAM
CHGD BY
REFERENCES TO DOCUMENTS AND DRAWINGS IMPLY THE
LATEST REVISION UNLESS INDICATED OTHERWISE DATE 10/1/13 SCALE - - - READY
SK19127-4 RELEASED FROM DESIGN ENGINEERING:
S/O 11210762
INDUSTRIES, INC.
LUFKIN, TEXAS
I/P 11210762IP
SUPERSEDED BY:
11210762ME
TEMPERATURE MONITORING
R-L
JUNCTION BOX
ORDER
*SEE TYPICAL JUNCTION BOX LAYOUT ELECTRICAL AREA IEC ZONE 2, GROUP IIB, T3
A1 CLASSIFICATION
TEMPERATURE JUNCTION BOX
DIN RAIL
CUSTOMER LUFKIN
LOCATION LUFKIN CUSTOMER LUFKIN CUSTOMER
TAG NO. ID NO. LOCATION LOCATION
ID NO. TAG NO. ID NO. TAG NO.
RED RED RED ITEM DESCRIPTION PART NO. DETAILS
1 29 64
WHITE WHITE WHITE SPRING-LOADED EMBEDDED, DUAL ELEMENT (DUPLEX) RTD'S,
2 30 65 6 WIRE, PLATINUM DIN CALIBRATION, 100 ^ AT
TE-341/A WHITE WHITE WHITE 0°C # 0.12% AT 0°C (0.00385 ^ / ^ /°C)
3 31 THRUST TE-345/A 66 TE-350/A 13 DUPLEX
LSP DE SENSOR TYPE E7093567 2 PER HS RADIAL BEARING (4 TOTAL) MINCO S102618PDPD3S144B0
BLUE BLUE BEARING BLUE HS NDE EMBEDDED RTD'S
TE3A RADIAL 2 PER LS RADIAL BEARING (4 TOTAL) MINCO S102618PDPD3S144B0
4 32 INBOARD TE5A 67 RADIAL TE2A
RTD 2 PER THRUST DE (2 TOTAL) MINCO S102618PDPD3S144B0
YELLOW YELLOW (DE) YELLOW RTD
TE-341/B 3 PER THRUST NDE (3 TOTAL) MINCO S102618PDPD3S144B0
5 33 RTD TE-345/B 68 TE-350/B
YELLOW YELLOW YELLOW FLEXIBLE LIQUIDTIGHT FLEXIBLE METALLIC WITH STAINLESS STEEL CORE.
6 34 69 CONDUIT
METALLIC PVC COATING, ANACONDA SEALTITE HCI
7 35 70 CONDUIT SEALTITE LIQUIDTIGHT FITTINGS MATCHED TO ANACONDA SEALTITE CONDUIT
RED RED RED FITTINGS FITTINGS FOR IP67 RATING, STAINLESS STEEL
8 36 71
WHITE WHITE WHITE HOUSING EXIT OIL 1 PER HOUSING EXIT, UP TO 4 EXITS PER FITTING, MINCO FG,
9 37 72
TE-342/A WHITE WHITE WHITE
FITTINGS SEAL STAINLESS STEEL, SILICONE GROMMET
THRUST TE-346/A TE-351/A
LSP DE 10 38 73
BEARING HS NDE
TE3B RADIAL BLUE BLUE BLUE SERVICE HEADS NONE RTD LEADS TERMINATE IN JUNCTION BOX
INBOARD TE5B RADIAL TE2B
RTD 11 39 74
(DE) RTD
TE-342/B YELLOW YELLOW YELLOW
RTD TE-346/B TE-351/B NEMA 4X,
12 40 75 CROUSE-HINDS TYPE Ex-CELL MODEL XLVS, 316L STAINLESS STEEL,
YELLOW YELLOW YELLOW ZONES 1 &2
DUAL RATED, EXTERNAL/INTERNAL GROUNDING STD, 2 SIDE
13 41 76 JUNCTION BOX AEx AND EEx
GLAND PLATES AND 1 BOTTOM GLAND PLATE, IP66 AND NEMA 4X,
'e' 'ia' II T6 WITH GROUNDING BUSBAR AND 16 GROUNDING TERMINALS
14 42 77 ATEX II 1 G
RED RED RED
15 43 78
WHITE WHITE WHITE BREATHER/DRAIN YES MOUNTED IN BOTTOM GLAND PLATE OF JUNCTION BOX
TE-343/A 16 44 79
WHITE WHITE THRUST TE-347/A WHITE TE-352/A
LSP NDE CUSTOMER
17 45 BEARING 80 HS DE NONE LOCATED IN BOTTOM GLAND PLATE BY CUSTOMER
TE4A RADIAL CONNECTIONS
BLUE BLUE OUTBOARD TE6A BLUE RADIAL TE1A
RTD
18 46 (NDE) 81 RTD
TE-343/B
YELLOW YELLOW RTD TE-347/B YELLOW TE-352/B JUNCTION BOX
19 47 82 TERMINAL BLOCKS WEIDMULLER SAK 2.5, BEIGE TERMINALS
CONNECTIONS
YELLOW YELLOW YELLOW
20 48 83
21 49 84 JUNCTION BOX HUB W/GROUNDING SCREW, NO CONDUIT SEALS PROVIDED,
MYERS HUB
RED RED RED ENTRY IP66 SEALING WASHER
22 50 85
WHITE WHITE WHITE
TE-344/A 23 51 86 PLUGS FOR EEx'e' PLUGS
THRUST TE-348/A TE-358/A DOMED HEAD, STAINLESS STEEL
LSP NDE WHITE WHITE WHITE UNUSED HOLES AND LOCKNUTS
BEARING HS DE
TE4B RADIAL 24 52 87
OUTBOARD TE6B RADIAL TE1B
RTD BLUE BLUE BLUE
(NDE) RTD
TE-344/B 25 53 RTD TE-348/B
88 TE-358/B JUNCTION BOX 10 AWG GROUNDING FROM MYERS HUB TO GROUNDING BAR IN JUNCTION BOX
YELLOW YELLOW YELLOW GROUNDING GREEN/YELLOW GROUND BUSBAR TO GROUNDING STUD AND GROUNDING STUD TO HSG
26 54 89
YELLOW YELLOW YELLOW
27 55 90 JUNCTION BOX TRAFFOLYTE
ENGRAVE WITH REQUIRED MARKING. DO NOT DRILL THRU TO ATTACH.
LABELING LABEL
28 56 91
LIQUIDTIGHT FLEXIBLE RED LOW POINT
57 92 NONE NO SERVICE HEADS
METALLIC CONDUIT DRAINS
WHITE
WITH INTEGRAL COPPER 58 THRUST TE-349/A 93
GROUNDING WIRE WHITE BEARING
59 OUTBOARD TE6C 94
BLUE (NDE)
60 RTD TE-349/B 95
YELLOW
61 96
YELLOW * TYPICAL JUNCTION BOX LAYOUT
62 97 SHOWN NOT TO SCALE
63 98 NEMA 4X / IP66
CONDUIT HUB FOR EEx'ia' 'e'
TERMINAL STRIP
TERMINAL STRIP
TERMINAL STRIP
99 STAINLESS STEEL
JUNCTION BOX ENTRY
100 EEx'e' JUNCTION BOX
GROUNDED TO GROUND LUG SHOWN NOT TO SCALE
STAINLESS STEEL
(TYPICAL FOR EACH CONDUIT ENTRY)
EEx'de'/NEMA 4X
PLUG FOR
110 UNUSED HOLES
GLAND PLATE
(TOTAL OF 110 TERMS) GROUNDING
LUG
CUSTOMER CONNECTIONS:
NONE BREATHER/DRAIN
GROUNDING BUSBAR STAINLESS STEEL
WITH 16 TERMINALS
ENGR. CODE NO. DIAGRAM, WIRING - STD V12/W3, MOD T11/W3

MATERIAL SPECIFICATIONS 8 RAD V/P, 2 K/P, 2 AX V/P
LUFKIN INDUSTRIES, INC. IT SHALL BE USED 2 ACCEL, 13 DUPLEX EMB RTDS
DWN PID-RH CHK AJM APP JWL N/C-CAM
CHGD BY
LATEST REVISION UNLESS INDICATED OTHERWISE DATE 09-23-13 SCALE - - - READY
1) REWIRED TEMPERATURE TERMINALS PER CUSTOMER SPECIFICATIONS 2) WIRED PID-LB RELEASED FROM DESIGN ENGINEERING:
A2 PERTAINS TO / ALSO USED ON
INDUSTRIES, INC.
PROXIMITORS TO TERMINALS PER CUSTOMER SPECIFICATIONS 02-26-14
S/O 11210762
LUFKIN, TEXAS
11210762WD A
CUSTOMER LUFKIN
VIBRATION MONITORING
LOCATION DIN RAIL
TAG NO. ID NO.
PROBE:
XE-351/X LSP DE OUTPUT
COMMON
1
R-L
VX3 HORZ. 1 -24VDC
2
A2 ORDER
PROX: V/P
XT-351/X 3 ELECTRICAL AREA IEC ZONE 2, GROUP IIB, T3
CLASSIFICATION
PROBE: 4
XE-351/Y LSP DE OUTPUT
COMMON
VY3 VERT. 2 -24VDC
5 VIBRATION JUNCTION BOX
PROX: V/P
XT-351/Y 6
PROBE: 7
XE-352/X LSP NDE OUTPUT
3
COMMON
8 ITEM DESCRIPTION PART NO. DETAILS
VX4 HORZ. -24VDC
PROX: V/P
XT-352/X 9
0.5 M LEAD LENGTH BENTLY NEVADA MODEL 330105-02-12-05-02-05
PROBE: 10 BENTLY NEVADA 2 X-Y RADIAL PROBES PER HS SHAFT END (4 TOTAL)
VIBRATION
XE-352/Y LSP NDE OUTPUT
COMMON PROBE
3300XL
E7082882
2 X-Y RADIAL PROBES PER LSP SHAFT END (4 TOTAL)
VY4 VERT. 4 11 8MM PROBE 1 HS KEYPHASOR PROBE
-24VDC TYPE
PROX: (QTY 12) 1 LSP KEYPHASOR PROBE
V/P 12
XT-352/Y 2 LSP AXIAL PROBES
PROBE: 13
XE-353/X HS NDE OUTPUT
VIBRATION PROBE BENTLY NEVADA 3300XL 95 OHM UNARMORED 4.5M LENGTH
5
COMMON
14 E7082884
VX2 HORIZ. -24VDC EXTENSION CABLE (QTY 12) BENTLY NEVADA MODEL 330130-045-00-05
PROX: V/P 15 VIBRATION PROBE BENTLY NEVADA
XT-353/X E7087100 3300XL 5M EFFECTIVE LENGTH BENTLY NEVADA MODEL 330180-51-05
PROXIMITOR (QTY 12)
PROBE: 16
OUTPUT
XE-353/Y HS NDE COMMON ONE PER EACH
6 17 VIBRATION PROBE
VY2 VERT. -24VDC
SERVICE HEADS
RADIAL AND LASNEK STAINLESS STEEL, IP66
PROX: V/P 18 AXIAL PROBE
XT-353/Y
19 BENTLY NEVADA
PROBE: ACCELEROMETER E7087499 BENTLY NEVADA MODEL 330400-01-05
OUTPUT (QTY 2)
XE-354/X HS DE COMMON
7 20
VX1 HORIZ. -24VDC
ACCELEROMETER BENTLY NEVADA
PROX: E7086738 BENTLY NEVADA 12' LENGTH, UNARMORED, MODEL 16925-12
V/P 21 EXT. CABLE (QTY 2)
XT-354/X
22 ACCELEROMETER ADAPTER AND ACCELEROMETER HERMETICALLY SEALED. HOUSED IN STAINLESS
PROBE: OUTPUT HOUSING ATEX REDUCER STEEL ADAPTER AND ACCESS PROVIDED BY DUAL RATED REDUCER
XE-354/Y HS DE
8 COMMON
23
VY1 VERT. -24VDC
ACCEL/SPARE TERMINALS IN
PROX: 40 WEIDMULLER SAK 2.5, BEIGE TERMINALS
V/P 24 CONNECTION JUNCTION BOX
XT-354/Y
25 VP AND ACC. MULTI
PROBE: OUTPUT CHAIN CABLES THROUGH 4 PORT HEAD, 7 = MAX CABLES IN 3/4"
CABLE ROUTING CABLE / CONDUIT
ZE-350/A LSP NDE 9
COMMON
26
VA4A AXIAL -24VDC
PROX: V/P 27 FLEXIBLE LIQUIDTIGHT FLEXIBLE METALLIC WITH STAINLESS STEEL CORE.
ZT-350/A CONDUIT
METALLIC PVC COATING, ANACONDA SEALTITE HCI
28
PROBE: OUTPUT
ZE-350/B LSP NDE 10

COMMON
29
VA4B AXIAL
-24VDC CONDUIT SEALTITE LIQUIDTIGHT FITTINGS MATCHED TO ANACONDA SEALTITE CONDUIT
PROX: 30 FITTINGS FITTINGS FOR IP67 RATING, STAINLESS STEEL
V/P
ZT-350/B * TYPICAL JUNCTION BOX LAYOUT
31 NEMA 4X,
PROBE: OUTPUT SHOWN NOT TO SCALE ZONES 1 &2
CROUSE-HINDS TYPE Ex-CELL MODEL XLVS, 316L STAINLESS STEEL,
KE-351 11
COMMON
32 DUAL RATED, EXTERNAL/INTERNAL GROUNDING STD, 2 SIDE
LSP NDE JUNCTION BOX AEx AND EEx
KP4
-24VDC
GLAND PLATES AND 1 BOTTOM GLAND PLATE, IP66 AND NEMA 4X,
K/P 'e' 'ia' II T6
PROX: 33 WITH GROUNDING BUSBAR AND 16 GROUNDING TERMINALS
ATEX II 1 G
KT-351
34
PROBE: OUTPUT BREATHER/DRAIN YES MOUNTED IN BOTTOM GLAND PLATE OF JUNCTION BOX
PROXIMITOR STRIP
COMMON
KE-352 12 35 IP66
HS NDE -24VDC
TERMINAL STRIP
TERMINAL STRIP
KP2 STAINLESS STEEL CUSTOMER
K/P 36 NONE LOCATED IN BOTTOM GLAND PLATE BY CUSTOMER
PROX: JUNCTION BOX CONNECTIONS
KT-352 SHOWN NOT TO SCALE
37
JUNCTION BOX HUB W/GROUNDING SCREW, NO CONDUIT SEALS PROVIDED,
MYERS HUB
38 ENTRY IP66 SEALING WASHER
39 PLUGS FOR EEx'e' PLUGS

DOMED HEAD, STAINLESS STEEL
UNUSED HOLES AND LOCKNUTS
WHITE (C)
(COMMON) 40
JUNCTION BOX 10 AWG GROUNDING FROM MYERS HUB TO GROUNDING BAR IN JUNCTION BOX
BLACK (A)
(SIGNAL) 41 GROUNDING GROUNDING GREEN/YELLOW GROUND BUSBAR TO GROUNDING STUD AND GROUNDING STUD TO HSG
LSP DE LUG
VE-351 A3 RED (B)
42 ACCELEROMETER ACCELEROMETER CABLES CONTAIN A SHIELD THAT IS TERMINATED
ACCLRM (POWER) WIRE SHIELDING
GREEN
CABLES AT THE TERMINAL BLOCK IN THE JUNCTION BLOCK
(SHIELD) 43 BREATHER/DRAIN
JUNCTION BOX TRAFFOLYTE
WHITE (C) ENGRAVE WITH REQUIRED MARKING. DO NOT DRILL THRU TO ATTACH.
(COMMON)
44 GROUNDING BUSBAR LABELING LABEL
HS DE
VE-352 A1 BLACK (A)
45 WITH 16 TERMINALS LOW POINT
ACCLRM (SIGNAL) YES 1 ON EACH LOWEST POINT SERVICE HEAD, SST
RED (B)
DRAINS
46
(POWER) GLAND PLATES
GREEN
(SHIELD)
47
48
49
SERVICE ENTRANCE
50
CONDUIT HEAD
51
52
ENGR. CODE NO. DIAGRAM, WIRING - STD V12/W3, MOD T11/W3

80 THIS DRAWING AND ALL INFORMATION THEREON
MATERIAL SPECIFICATIONS 8 RAD V/P, 2 K/P, 2 AX V/P
LUFKIN INDUSTRIES, INC. IT SHALL BE USED 2 ACCEL, 13 DUPLEX EMB RTDS
(TOTAL OF 80 TERMS) PID-RH AJM APP JWL
DWN CHK N/C-CAM
CHGD BY
LATEST REVISION UNLESS INDICATED OTHERWISE DATE 09-23-13 SCALE - - - READY
SEE SHEET 1 OF 2 RELEASED FROM DESIGN ENGINEERING:
S/O 11210762
INDUSTRIES, INC.
LUFKIN, TEXAS
11210762WD A

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1103089-RRO3945140 Gearbox Lufkin

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The Energy Flows Through UsTM

Installation, Operation &

Lufkin Sales Order Number ................................. 11210762

Phone: 936/634-2211 P O Box 849, Lufkin, TX 75902-0849

Installation, Operation, and Maintenance page i

7 GEAR INSPECTION ---------------------------------------------- 20

8 BEARING INSPECTION ----------------------------------------- 24

11 NAMEPLATE DATA ---------------------------------------------- 33

Table 1. Equipment Description Chart .................................... 3

Installation, Operation, and Maintenance page iii

1.2 SAFETY PRECAUTIONS

1.3 EQUIPMENT DESCRIPTION

1.3.1 Factory Testing

Installation, Operation, and Maintenance page 1

Gearing Bearings Design Clearance

Thrust Bearing Endplay

Installation, Operation, and Maintenance page 3

DANGER: WARNING: CAUTION:

2.1 GENERAL SAFETY PRECAUTIONS

DANGER: Lock out/tag out procedures

WARNING: Only persons familiar with and proficient at

2.3 REDUCE RISK OF ACCIDENTAL SHOCK

2.5 POSSIBLE MISUSES OF EQUIPMENT

Installation, Operation, and Maintenance page 5

3.2.1 Corrosion Protection During Inoperative Periods

3.5 ADDITIONAL REQUIREMENTS

Installation, Operation, and Maintenance page 7

3.6.2 Anticipation of Shaft Operating Positions

3.6.3 Alignment Sequence

Table 3b. Maximum Allowable Run-Out, (TIR) METRIC

3.6.4 Alignment Checking

Installation, Operation, and Maintenance page 9

3.7 TOOTH CONTACT CHECK

4.2 OIL TYPE AND GRADE

4.3 CUSTOMER CHECK BEFORE START-UP

Installation, Operation, and Maintenance page 11

4.5. CUSTOMER CHECK AFTER START-UP

4.6 ALARM SWITCHES

Table 4. Preliminary Alarm Settings

Installation, Operation, and Maintenance page 13

Table 5. Maintenance Schedule Overview

OIL CHANGE • check tooth contact pattern

5.3 MONTHLY MAINTENANCE

5.4 QUARTERLY MAINTENANCE

5.4.1 Oil Analysis Guidelines

Installation, Operation, and Maintenance page 15

5.6 OIL CHANGE INTERVALS

6.2 TOOLS REQUIRED

6.3 SPARE PARTS

Installation, Operation, and Maintenance page 17

6.5 REMOVAL OF PINION, GEAR, AND BEARINGS

6.6 THRUST BEARING REMOVAL

6.7 OIL SAMPLE COLLECTION

Installation, Operation, and Maintenance page 19

7.1.2 Why Check Tooth Contact

7.1.3 When to Check Tooth Contact

7.1.4 How to Check Tooth Contact

7.1.5 Soft Blue Method

7.1.6 Hard Blue Method

7.2 INTERPRETATION OF TOOTH CONTACT

Installation, Operation, and Maintenance page 21

7.3 GEAR CONDITION ASSESSMENT

7.3.2 Definition of Gear Failure

Installation, Operation, and Maintenance page 23