Girth Gears: Theory and Technology

Girth Gears: Theory and Technology‎
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fabricated Girth Gear
Forged and electro welded technology
Our choice is Fabricated Girth gear:
• The forged material structure

excludes the risk of inclusions and
request for repair welding of the
body structure and e.g. grinding of
toothed areas.
• The welding procedure exclude the

need of patterns, reducing the lead
time and ensure high quality product
supply with customized design
Titel 9 December 2014 2

Fabricated Steel
Advantages:
 Good physical properties in all directions.

 No micro-porosities such as gas holes, micro-
shrinkage and pinholes.
 Absence of macro defects such as hot tears,
shrinkage and sand inclusions.
 No weld repairs or “blend-outs” required in
critical tooth areas or web.
 Very good metallurgical yield.
 Repeatability of dimensions and orientation.
 Uniform metallurgical chemistry.
Challenges:
 “Give me what I have (cast steel)”
9 December 2014 3
Manufacturing procedure
Forging Packing
Welding QA NDT Machining QA Final
Material and
process inspection process Inspection
process shipping
• Forging Material process

• Welding process
• QA NDT Inspection
• Machining process
• QA Final Inspection
• Packing and shipping

Forging Material process
 Forging
 Final Rolling
 Furnace Cooling
 Control on production
 Water quenching
 Hardness testing
 Rough machining
 Ultrasonic Testing and Measuring
 Final inspection Certification

Certificate and Qualification
 WELDING PROCESS QUALIFIED
Welding Procedure Approval Record – WPAR
Procedure Qualification Record - PQR
Welding Procedure Specification – WPS
Welder Qualification Record – WQR
ACCORDING TO THE STANDARDS

UNI EN ISO – AWS – ASTM – ASME
ITALIAN AND INTERNATIONAL

WELDING INSTITUTE

Welding Procedure
AWS D1.1 2010 ASME CODE IX 2010 UNI EN ISO 15614-1 2008
ITEM Stell Strutural welding Pressure recipint welding Structure - PED
Material ASTM (not A 291) ASTM / Comparison UNI
Request PQR - WPS PQR - WPS PQR - WPS

Welding process
 preparation of all web, ribs and junction plate with cutting
software.
 Bending of external
Rim + Hardness test

Welding process
 Fit-up and welding of complete

internal web
 Preparation of chamfer
 Fitt up and Weld external Rib with

intyernal web plate
 Fit up and welding of joint flanges

Welding process
 NDT control before heat treatment
 PWHT Post weld heat treatment

Welding process
 NDT - QA inspection
 Sand blasting and paint

Certificate and Qualification
 NON DESTRUCTIVE TEST
ASNT - qualification 2° Level SNT-TC-1°

UNI EN 473 - ISO 9712 Qualification 2° Level
Ultrasonic testing
Magnetic particle
Penetrant testing

Machining Process
Mill Split Rougth tourn Plunge and
Assemble Inspection
Joints and gear rougth cut
gear halves splitline
holes fabbrication teeth
Final inspect
Finish
Open joint gear blank Finish hob QA Final
machining,
inspection dimensional teeth inspection
drill
and run out
• Mill Split Joints and holes
• Assemble gear halves

Machining Process

Machining Process
• Plunge and rougth cut teeth

• Open joint inspection
• Finish machining, drill

Machining Process
• Finish hob teeth
• QA Final inspection

Quality Inspection Test Plan
 QT Forged material - Chemical and mechanical properties
 certificate of HT
 Inspect gear rim hardness
 UT reports for rim material
 Welding procedures WPQR – WPS
 Welding map
 Stress relieving PWHT Diagram
 UT and MT 100% welding area before and After PWHT

Quality Inspection Test Plan
 inspect final girth gear run-out on gear cutter
 inspect tooth flank surface finish
 inspect pitch, profile and pitch line pattern
 MT test 100% teeth area
 Inspect joint flange tightness and Open joint
 final document review

Gear Joint Inspection
9 December 2014 19
Mounting Flange
 Layout of bolt holes
 Runout of flange
 Flatness of flange
 Alignment of gear dependent

on accuracy of flange.
 Use of shims should be avoided.
9 December 2014 20
Excessive Gear Runout
 Setup and support in vertical boring mill
 Setup and support in finish gear cutter
 FLSmidth tolerance for as-machined ø6.4m gear

 Roller supported - axial 0.10mm, radial 0.13mm
 Flange mounted – axial 0.08mm, radial 0.13mm
 FLSmidth installation tolerance for same ø6.4 gear

 Roller supported – axial 0.53mm, radial 0.80mm
 Flange mounted – axial 0.27mm, radial 0.40mm
 Why critical?
 Indicator of gear set alignment and ultimately the achievable life
expectancy of the gear set.
9 December 2014 21
AGMA Tooth Quality Requirements
 Flange mounted gear sets:  Spring mounted gear sets:
 Gear  Gear
 Pitch Q10  Pitch Q8
 Profile Q10  Profile Q8
 Lead Q10  Lead Q8
 Runout Q10  Runout Q8
 Case-hardened pinion  Through-hardened pinion

 Pitch Q12  Pitch Q10
 Profile Q12  Profile Q10
 Lead Q12  Lead Q10
 Runout Q12  Runout Q10
9 December 2014 22
Profile quality control
Human hair
70 µm
Balance wheel after cutting Balance wheel after grinding

Symetro Gear - New rotating parts October 2011 23

Why quality is so important
Total Girth Gear installation cost survey
Calculation example:
Kiln size ø5.0 x 90 m

Production: 4500 tpd
Parts 27%
• Estimated cost of parts: EUR 450.000,- (27%)
Girth gear + springs etc.
Mech. 8%
• Est. mech. erection costs: EUR 130.000,- (8%)
Consequential 65%
29% of parts cost
• Estimated consequential loss : EUR 1.080.000,- (65%)

EUR 4500/hour in 10 days
• Total installation costs: EUR 1.660.000,- (100%)

Conclusion:
• The cost of the Girth Gear is only a “piece of the cake” compared with the total substantial
installation cost.
• Long term solution with high FLSmidth quality is the best solution to ensure a beneficial
investment.
Fabricated Girth Gear October 2011 24

Reference List
Mill - Girth Gears

Reference List
Mill - Girth Gears 1975 - 2011

1 POLYSIUS GERMANIA 525 17 KHD 5
2 POLYSIUS FRANCIA 50 18 SCHLENK 10
3 POLYSIUS SPAGNA 27 19 MEERSTETTER 13
4 POLYSIUS INDIA 11 20 FERRY CAPITAIN 1
5 POLYSIUS BRASILE 7 21 CMD 1
6 POLYSIUS USA 7 22 HEIDELBERG 1
7 POLYSIUS AUSTRALIA 3 23 CEMEX 2
8 POLYSIUS SOUTH AFRICA 1 24 TEUTRINE 4
9 THYSSENKRUPP 21 25 ITALCEMENTI 8
10 FLSMIDTH 13 26 I.C.F. 7
11 FLSMIDTH MINERALS 4 27 FEMA 11
12 SIEMENS 10 28 SUEZ CEMENT 5
13 HOLCIM 10 29 YTONG 4
14 FLENDER 9 30 ESSROC USA 2
15 LA FARGE 7 31 ZAMZAM 2
16 CVRD VALE 7 32 COLACEM 5
33 Other 65
Total Mill – Girth Gear 857


Reference List
Kiln - Girth Gears

Reference List
Kiln - Girth Gears 1975 - 2011
1 POLYSIUS GERMANIA 126 12 MEERSTETTER 4

2 POLYSIUS FRANCIA 42 13 HEIDELBERG 1
3 POLYSIUS SPAGNA 4 14 CEMEX 1
4 POLYSIUS INDIA 18 15 ITALCEMENTI 2
5 THYSSENKRUPP 4 16 COLACEM 1
6 FLSMIDTH 3 17 Other 20
7 HOLCIM 2
8 FLENDER 1 Total Kiln – Girth Gear 234
9 LA FARGE 1
10 KHD 2
11 SCHLENK 2

THANK YOU

Girth Gears: Theory and Technology

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Girth Gears: Theory and Technology

Uploaded by

Copyright:

Available Formats

Girth Gears: Theory and Technology‎

Our choice is Fabricated Girth gear:

• The forged material structure

• The welding procedure exclude the

Titel 9 December 2014 2

 Good physical properties in all directions.

 “Give me what I have (cast steel)”

• Forging Material process

Titel 9 December 2014 4

Titel 9 December 2014 5

ACCORDING TO THE STANDARDS

ITALIAN AND INTERNATIONAL

Titel 9 December 2014 6

ITEM Stell Strutural welding Pressure recipint welding Structure - PED

Material ASTM (not A 291) ASTM / Comparison UNI

Request PQR - WPS PQR - WPS PQR - WPS

Titel 9 December 2014 7

Titel 9 December 2014 8

 Fit-up and welding of complete

 Fitt up and Weld external Rib with

 Fit up and welding of joint flanges

Titel 9 December 2014 9

 PWHT Post weld heat treatment

Titel 9 December 2014 10

 Sand blasting and paint

Titel 9 December 2014 11

ASNT - qualification 2° Level SNT-TC-1°

Titel 9 December 2014 12

• Mill Split Joints and holes

• Assemble gear halves

Titel 9 December 2014 13

Titel 9 December 2014 14

• Plunge and rougth cut teeth

Titel 9 December 2014 15

Titel 9 December 2014 16

 QT Forged material - Chemical and mechanical properties

 Inspect gear rim hardness

 UT reports for rim material

 Welding procedures WPQR – WPS

 Stress relieving PWHT Diagram

 UT and MT 100% welding area before and After PWHT

Titel 9 December 2014 17

 inspect final girth gear run-out on gear cutter

 inspect tooth flank surface finish

 inspect pitch, profile and pitch line pattern

 MT test 100% teeth area

 Inspect joint flange tightness and Open joint

 final document review

Titel 9 December 2014 18

 Alignment of gear dependent

 Use of shims should be avoided.

 FLSmidth tolerance for as-machined ø6.4m gear

 FLSmidth installation tolerance for same ø6.4 gear

 Case-hardened pinion  Through-hardened pinion

Balance wheel after cutting Balance wheel after grinding

Symetro Gear - New rotating parts October 2011 23

Kiln size ø5.0 x 90 m

• Estimated consequential loss : EUR 1.080.000,- (65%)

• Total installation costs: EUR 1.660.000,- (100%)

Fabricated Girth Gear October 2011 24

Mill - Girth Gears

Titel 9 December 2014 25

Mill - Girth Gears 1975 - 2011