20 YECIRS W€RATIJG D(P€FUENE W I T H

R. Hamdani
Former Plant Manager
Saudi Kuwaiti Cement Manufacturing Co.
Kursaniyah, Kingdom of Saudi Arabia

Z.K. Zarif
Sales Manager
ABB, Asea Brown Boveri Ltd.
Baden, Switzerland

To be presented at the 32nd IEEE Cement Conference

Tampa, Florida, U.S.A. May 1990

57
1. ABSTRACT

The trend to large grinding mills in the cement, mining

and related industries with the attendant increase in motor
drive horsepower has affected the options for mill drive
equipment.
The development of large adjustable-speed alternating
current drives and especially the introduction of the
gearless synchronous motor drive ( F I G . 1) have created new
possibilities of available mill drives.
This paper reviews the more significant aspects and
characteristics of the gearless drive ( G D ) , also called
wrap-around, and presents some comparisons between the GD
and the Twin AC as well as Twin BC drives.

2. INTRODUCTION

Ideally, a mill drive should:

- Consist of a minimum of mechanical and electrical
components
- Use a minimum of floor space
- Protected from the immediate mill environment
- Allow for mill speed variation
- Mill design concept not affected
- Necessitate little maintenance
- Require a minimum of spare parts inventory
- Allow for a max. degree of operational availability
- Require a low peak start-up load
- Allow the mill to turn in either direction

The only mill drive system presently available which

responds to all of the above conditions is the gearless
synchronous motor.

58
3. DESCRIPTION AND ANALYSIS

3.1 Mounting of a gearless drive

There are two ( 2 ) principle ar gements for the mounting
of a gearless drive.
The first arrangement ( F I G . 2 ) consists of the wrap around
principle where motor rotor is built onto (around) the mill
shell.
Advantage : - Minimum floor space requirements

Disadvantages: - The motor must be designed to fit the

mill; rather than being designed for
maximum motor efficiency and minimum motoi
diameter.
- The motor is directly exposed to the
immediate mill environment.
- Height of motor structure for large mills

The second arrangement ( F I G . 3 ) is the external drive

principle where motor rotor is fixed onto a torque tube
extension of the inlet or outlet mill trunnion.
Advantages : - Optimal motor design
- Maximum accessibility to both mill and
motor
- Reduced height of motor structure
- Easy shifting of motor stator

Disadvantages: - Larger floor space requirement

- Longer outlet or inlet material transfer
paths.

59
3.2 Investment cost

3.2.a General consideration

The gearless motor is a fully integrated drive system.
If compared on a motor to motor basis only, the gearless
motor is considerably more expensive than AC and DC units.
If compared on a system to system basis, the difference
between gearless and other drive systems is far less
important. This is especially true for medium or large
high horsepower mills. This assumes under condition that
the gearless drive manufacturer is not obliged to design
the motor in order to fit the mill rather than look for the
optimal motor design.

3.2.b Investment cost comparison table

ITEMS GEARLESS CONVENTIONAL

wrap
around 1 Twin AC
external Fxd spd
drive /Id. sh. 1 Twin DC

GIRTH GEAR
PINIONS
PINION BEARING
CLUTCHES
LUBRICATION SYSTEM
COMPR. AIR SYSTEM
ENGINEERING
VARIOUS
MOTOR
INCHING SERVICE

MECH. ERECTION I

SRAND TOTAL I I

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3.3 Operating cost/operating experience

3.3.a Operating cost

The gearless motor is a fully integrated mill drive system
practically consisting of a single drive unit without
wearingparts (except brushes and seals) and a minimum
number of auxiliary mechanical and electrical components.
In comparison to the gearless system, the AC and DC twin
drive units consist of a considerable number of components
and wear elements such as motor and pinion bearings, gear
trains, clutches auxiliary drives, compressed air and
lubrication system, etc.
Contrary to the pinion gear drives, the gearless system is
not subject to vibration effects.
It can therefore be deducted that from an operational cost
viewpoint, the gearless drive is more efficient than the
other systems.
According to figures from the industry, the operating cost
does not exceed US$ 15'000.-- per year and motor versus
close to US$ 75'000.-- per year and drive for Twin DC and
Twin AC units.

3.3.b Operating experience

The first gearless drive of 9000 HP.(FIG. 4 ) was put into
operation in France in 1969. Still operating to this day
without any problems, it represents almost 2 0 years of
industrial experience.
Based on the positive experience in France, three units of
8500 HP were started up in Italy in 1971 and have fully
satisfied needs and expectations ever since.
In the following years such gearless drives were installed
in Canada in 1973, Korea, Germany, Norway, Belgium,
Romania, Switzerland and also in developing countries such
as Algeria, Iran, Indonesia, Saudi Arabia, Taiwan, followed
by a 8500 HP unit in a copper ore grinding facility in
Papua New Guinea.
Some of the latest development in the field of gearless
drives comprise a 15'000 HP unit in Chili and two large
units in the USSR (Soviet Union).

61
 It can also be confirmed that practically none of the
gearless units have ever been subject to unscheduled
stoppages and therefore have never been the source of
unexpected production losses.

3.4 Operation availibility

3.4.a Principle of availability

The availability o f any operational system is determined by
the number o f elements forming the system and the
availability of each individual element.

ELEMENTS DUAL PINION DRIVES GEARLESS

DC DRIVE
fixed spd
I I
GEARLESS MOTOR
MOTOR WITH BEARINGS
CLUTCH (COMPRESSOR)
BEARING PINION SHAFT
PINION
GIRTH GEAR
LUBRICATION SYSTEM
(PUMP + COMPRESSOR
TRANSFORMERS
ELECTRONIC PACKAGE

According to industry sources, the availibility ratio f o r

gearless drives reaches values which are around 99%.
From the above listing it can be deducted that the
operational availability o f dual pinion drives will be less
than 90%.

62
3.5 Weakness analysis
The following table presents a listing of the weak aspects
of the different mill drives.

ITEM GD Twin AC Twin DC

fixed speed

- SYSTEMS EFFICIENCY 93% 91% 88%

(100% TORQUE)
- INITIAL START-UP PROCEDURE Routine Routine Routine
- AUTO-BLOCKAGE OF MILL Portable Inherent Inherent
IN CASE OF LINER CHANGES winch
- LOAD SHARING No problem Affecting Affectin5
gear train gear trair
- START-UP POWER PEAKS Low High Low
- OPER. + MAINTEN. COST Low High High
- AVAILABILITY 99% 89% 89%
- ALIGNMENT TOLERANCES t 600/104 f 1/104 2 1/104
inch inch inch
I

3.6 Maintenance and services

3.6.a Gearless drive

For the gearless drives, the maintenance and service
requirements (FIG. 5) are limited to the checking and
routine exchange of brushes and seals on the main unit and
some routine interventions on the electronics.
Approximate yearly cost: included in US$ 15'000.--.

3.6.b Twin drives

These systems require a frequent checking of the various
elements, a regular control of pinions/gear alignments,
daily grease inspections of the gear lubrication system,
routine service of collectors and brushes.
Approximate yearly cost: included in US$ 75'000.--.

63
3.6.c Comment s
It has been experienced that gearless drives do not require
more maintenance and services than any electrical motor.
One of the positive aspects of the gearless drive is the
absence of motor bearings.

3.7 Production cost / p roduction experience

3.7.a Production cost

Regarding efficiency, there are noticable differences in
production cost between the GD and the Twin AC and the Twin
DC systems.
Electrical power consumption for GD drives are Lower than
for Twin AC and Twin DC drives, if compared on a system
basis.
In addition to the higher power consumption for Twin AC and
Twin DC drives, the additional cost for lubricants for the
latter should also be considered.

3.7.b Production experience

Production experience with GD and Twin AC and Twin DC
system is practically in line with the availability ratios.
Non-stop around the clock runs for extended periods of time
are routinely obtained with GD equiped grinding mills.

4. Training of personnel

Electricians formed in modern day electrical and electronic

systems can be trained on GD systems.
Such training can take place on site during the erection
and commissioning phases of the gearless system.
The gearless system does not require more advanced basic
knowlegde in electricity and electronics than for Twin AC
and Twin DC systems.

64
 ABSTRACT

Saudi Kuwaiti Cement Company (SKC), a new Company in the

Cement field has gone through a unique experience by
putting into process the biggest plant of the country in
the middle of the dessert. The challenge is completed by
the implementation of 6 Gearless Drives whereas only
approximately 20 similar drives are installed in the world.
The challenge was a sign of confidence on the Engineering
Group and the support given by the manufacturer to provide
the most reliable equipment. After three years of operatior
the targets are achieved and the future could be forecastec
confidently.
During the first 3 years of operation, SKC's operation
personnel has met and attended the various failures which
may happen for gearless drive operation. They also erected
2 motors. This unique experience led to conclude that
Gearless drive is simple as any synchronous motor and it i s
the equipment of high reliability.

65
4.2 Data of Equipment driven by Gearless drives

13.8
RAW MILL 1 420 9,700 5,200 --e- OCT. 1985
15.2
13.8
RAW MILL 2 420 9,700 5,200 ---e OCT. 1985
15.2
CEMENT 14.5
MILL 1 100-135 9 ,700 5,300 OCT. 1985
15.8
CEMENT 14.5
MILL 2 100-135 9,700 5,300 ---- OCT. 1985
15.8
CEMENT 14.5
MILL 3 100-135 9,700 5,300 ---- SEPT. '87
15.8
CEMENT 14.5
MILL 4 100-135 9,900 5,300 ---- SEPT. '87
15.8

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4.3 Data of Gearless drive
Three-phase Svnchronous Motor

Type : WAZ 730-80-40

Quantity : 6
Installation : Indoor

Monitorinu Elements
- 4 Airgap Probes (Alarm at 2 M M / Trip at 3 MM) both
adjustable;
- Dust Seal Monitor; C

- 6 Pt 100 in the Stator Windings.

4.4 Description of the Drive System

The main components of the Drive are:
- Motor
- Power Pack (electronics)
- Transformers

67
5. Behaving of the Gearless drives during 3 years of operation

Hereunder, the problems encountered during 3 years of

operation (till end of August, 1988) with Gearless drives
are reported. The table below shows the operation time of
the various Gearless drives from their induction into
operation.

EQUIPMENT I START-UP
TOTAL
RUNNING HOURS

RAW MILL 1 Oct., 1985 11 ,425 4 I 571,290 403

RAW MILL 2 Oct. , 1985 12 371 4,932,534 278

CEMENT MILL 1 Oct., 1985 14,182 1,581,125 65

CEMENT MILL 2 Oct., 1985 12 ,785 1,430 ,525 33

CEMENT MILL 3 Sept. 1987 3,107 317,599 495

CEMENT MILL 4 Sept. 1987 2,528 248 ,566 10

We have tabulated the details of each failure encountered

and the corresponding time to undertake the repair.

68
5.1 Summary of non-availability of Raw Mill 1 Gearless Drives
(From: October, 1985 to: August, 1988,
Total running h o u r s : 1 1 , 4 2 5 )

TYPE OF PROBLEM DOWNTIME

DATE BRIEF DESCRIPTION HOURS MANHOURS
NOV. '86 CONTACTOR FOR PRIMARY FAN-LTD 2 2

NOV. '86 AIRGAP VARIATION 336 970

JAN. '87 CARBON BRUSH ALIGNMENT 8 16.5

MAR. '87 FAILURE OF PRIMARY FAN 8 20

APR. '87 FAILURE OF 2 4 VOLTS POWER SUPPLY 3 6

MAY '87 FAILURE OF CONTACTORS - LTD 3 3

MAY '87 FAILURE OF POWERSUPPLY GATE CONTROL 3 3

MAY '87 THYRISTOR FUSE DUE TO CHILLER TEMP. 2 4

NOV. '87 FAILURE OF PRIMARY FAN 8 24

FEB. '88 DUST SEALING 8 24

APR. ' 8 8 IUST SEALING 8 10

APR. '88 SECONDARY FAN DUE TO CHILLER TEMP. 2 4 .

MAY '88 SECONDARY FAN DUE TO CHILLER TEMP. 2

JUNE '88 ZONTACTOR FOR PRIMARY FAN-LTD 2

JUNE '88 PRIMARY FAN FAILURE 8 24

OTAL: 103 1173.5

Availabilty of the Gearless Drive = 96 %

69
From the table above, it can be seen that the major failure
happened after one year of operation as a result of air gap
variation.

Reasons for Air Gap Variation

It was impossible to determine exactly the reasons for
misalignment whether due to soil settlement or relative
movement between Mill & Stator foundations. Also, it was
discovered that co-ordinates of civil foundation and
reference axis of Mill/Motor are different so that was
impossible to retrace the original conditions. Such
investigation took a long time before concluding to go
ahead with new alignment.

70
5.2 Summary of Non-Availability of Raw Mill 2 Ring Motor

From: Oct. 1985 to: August 1988

Total Running Hours: 12,371.9 hours

DATE ITYPE OF PROBLEM, BRIEF DESCRIPTIONIDOWNTIME H R S . ~ MANHOUR!

OCT. ‘85 IAIRGAP VARIATION I 120 I 400
JUL. ‘86 IFLAPS I 2 I 20
DEC. ‘86 ]GATE CONTROL UNIT I 40 I 150
JAN. ‘87 ITHYRISTOR FUSE - CHILLER TEMPERAT.] 4 I 8
JAN. ‘87 !MIN. DUE CARBON BRUSHES 48 48
I I
FEB. ‘87 ]DUST SEALING 16 33
I
FEB. ‘87 (SLIP RINGS - SMOOTHENING I 24 1 65
MAY ‘87 IDUST SEALING I 4 I 8
MAY ‘87 COOLING SYSTEM - PRESSURE SWITCHES! 4 I 8
DEC. ‘87 (L.T.D. DUE TO CHILLER TEMPERATURE I 2 I 6
JAN. ‘88 1L.T.D. DUE TO CHILLER TEMPERARURE I 2 6
FEB. ‘88 IDUST SEALING I a 1 24
JUNE ‘88 1L.T.D. / PANEL SUPPLY I 2 I 2
JUNE ‘88 ICONTACTORS - PRIMARY FAN I 2 7

I TOTAL I 278 1 785

Availability of the ring motor: = 98 %

71
5.3 Summary of Non-Availability of C. Mill 1 Ring Motor
From: Oct. 1985 to: Aug. 1988
Total Running Hours: 14,182 Hours

8 48

2 10

Availability of the gearless drive = 100% practically.

72
5.4 Summary of Non-Availability of Cement Mill 2 Gearless
Drives
From: Oct. 1985 to: August 1988
Total Running Hours: 12,785 Hours

JUN. ‘88 ICONTACTORS L.T.D. I 2 8

I TOTAL I 33 153

From Sept. 1987 to: August 1988

Total Running Hours: 3,107.8 Hours

TYPE I
INOV. DATE
‘87 AIR
OF PROBLEM, BRIEF DESCRIPTION~DOWNTIHE HRS.

GAP 90 I
MANHOURS

480
DEC. ‘87 ]ALIGNMENT OF CARBON BRUSHES 4 9
NOV. ‘87 ~H.T. BREAKER 8 30
APR. ‘88 IAUXILLIARY DRIVES L.T.D. 1 4

73
6. Conclusion

Experience of SKC is showing that availability of gearless

drive is almost 100% except in case of accidental major
failure which may take one week for repairs.

The objectives set by SKC to select reliable equipment for

the most important equipment of its process have been
achieved after the first year's operation. This achievment
brings to SKC Management a real comfort € o r planning their
production schedule safely and believing that the equipment
will perform the target.

As an user, we believe in gearless drives because we can

run safely and continously at any time in the middle of the
dessert.

74
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78
 PLANT "LE HAVRE"
(Ciment Lambert-L-afarge)

First G e a r l e s s Milldrive - M o t o r in t h e World

Type WAZ 800-95-44

Rated o u t p u t 8600 Hp (6420 ltW)
1 5 r p m - 5,5cycles - p.f.=l,O
Operation duty: c o n s t torque from 13,5- 15 rpm

FIG. 4 FIRST CEXILESS DRIVE

79
 b t t

m o o

cv G

-
,aI I I I

80