28 - 09 Dalog Report Shurovo Flender KMPP 601 2012.06.18

REPORT
REPORT NUMBER: HOLCIM SHUROVO-08-339-01.09
Gear Reducer: FLENDER KMPP 601 Line: 361-MD1.M1
Serial No.: 44 36 182 - 0040 -1
Report Period: 2010-09-23 - 2012-06-18
Date of Report: 2012-06-19
Reported by: Dipl.-Ing. Horst Brodherr
Checked by: Dipl.-Ing. (FH) Bernhard Tetzlaff

Plant: SHUROVO Page: 2/25
Type: FLENDER KMPP 601 Date: 2012-06-19
Data: 4334kW / 995rpm / 41.8kNm Name: HoB
Page 002 Contents Report
Page 003 Gearbox Condition and Sensor Positions
Page 004 Condition Summary Comments
Page 005 SENSOR 3 Acceleration - Vibration Diagnostic Indicators: Bevel Gear Stage
Page 006 SENSOR 4 Acceleration - Vibration Diagnostic Indicators: Planetary Gear Stage 1
Page 007 SENSOR 5 Acceleration - Vibration Diagnostic Indicators: Planetary Gear Stage 2
Page 008 SENSOR 6 + 7 Velocity - Vibration Condition Indicators Grinding Bed: X - Y Direction
Page 009 SENSOR 8 - 13 Temperatures Slide Bearing No. 150 - 151 - 451 - 450
Page 010 SENSOR 14 + 15 Displacement Sun Shaft Planetary Gear Stage 1 X ( 0°) - Y (90°) Direction
Page 011 Bevel Gear Stage Faults: Gear Mesh Frequency and Sideband Energy
Page 012 Planetary Gear Faults Stage 1: Planetary Fault Frequencies
Page 013 Planetary Gear Faults Stage 2: Planetary Fault Frequencies
Page 014 Mill Operating Parameter MOP1
Page 015 Mill Operating Parameter MOP2
Page 016 Torque Progress over Measurement Period
Page 017 Torque Alarm - Process Mode - Events I May 2012
Page 018 Torque Alarm - Process Mode - Events II June 2012
Page 019 Torque Alarm - Process Mode - Events III Year 2012
Page 020 Torque Alarm - Start Up Mode - Events I May 2012
Page 021 Torque Alarm - Start Up Mode - Events II June 2012
Page 022 Torque Alarm - Start Up Mode - Events III Year 2012
Page 023 How to read this Report 1
DALOG Diagnosesysteme GmbH

Siemensstrasse 2a
86356 Neusaess
Tel. +49 (0) 821 - 74777-10
Fax +49 (0) 821 - 74777-19
E-Mail:
Horst.Brodherr@dalog.net
Franz.Muschaweck@dalog.net
Bernhard.Tetzlaff@dalog.net
z-dir
x-dir
y-dir
451
150 151
450
150 - 451
See
Sensor Point Flender Sensor No. Measurement Name Bearing No. Condition
comments
Sensor 1 Speed Input Shaft Ok
Sensor 2 Torque Input Shaft Ok
Sensor 3 Acceleration Bevel Gear Stage Ok
Sensor 4 Acceleration Planetary Gear Stage 1 Ok
Sensor 5 Acceleration Planetary Gear Stage 2 Ok
Sensor 6 Vibration Velocity Grinding Bed X - dir Defect Sensor
Sensor 7 Vibration Velocity Grinding Bed Y - dir Ok
Sensor 8 No 823.1 Temperature Slide Bearing Vertical 150 Ok
Sensor 10 No 825.1 Temperature Slide Bearing Horizontal 451 Ok
Sensor 14+15 Displacement Sun Shaft Stage 1 Ok
Sensor 16 Oil Pressure Bearing 150 and 151 Ok
MOP 1 Mill Operating Parameter 1 Ok
MOP 2 Mill Operating Parameter 2 Ok
Legend
Vibration conditions Ok Ok
Remarkable trend or sensor faults Indication
Trend over Alert level ALERT
Trend over Danger level DANGER
Sensor defect or not connected Sensor
CONDITION SUMMARY
Comments :
1.Condition of Bearings:
Notice : No remarkable trend is observed.
2.Condition of the Bevel Gears:

3.Condition of the Planetary Gears:

4.Torque measurements:
5.Remark :
Findings:
Sensor no.6 - grinding bed - shows faulty signals.
Please check sensor mounting and cable connection.
Fig.1 Sensor 3
Raw Signal
40 1
RMS3 [g]
30
0.8 Basis 0.67
Current 0.64
0.6
20 Alert 1.07
0.4 REF_Corr 0.06
10
0.2
Black Line as Reference Value: Torque Average CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Sensor 3
Raw Signal
40 4
PtoP3 [g]
30 3
Basis 2.64
Current 2.64
20 2 Alert 4.22
REF_Corr 0.53
10 1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Sensor 3
Envelope
40
0.3 RMS_ENV3 [g]
30
Basis 0.19
0.2 Current 0.23
20 Alert 0.34
REF_Corr 0.71
0.1
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Sensor 3
0.8 Envelope
40
PtoP_ENV3 [g]
30 0.6 Basis 0.37

Current 0.40
20 0.4 Alert 0.80
REF_Corr 0.44
10 0.2
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title SENSOR 3 - Vibration Diagnostic Indicators
Current - Range Days 1 2012-06-17 - 2012-06-18 Bevel Gear Stage
Gearbox Hours Date Data conditions Compress 12 hr
Operation Time 2916 2010-09-23 - 2012-06-18 Sample Rate 10 1/hr Standstill Removed
Fig.1 Sensor 4
0.8 Raw Signal
40
RMS4 [g]
0.6 Basis 0.44
30
Current 0.48
0.4
20 Alert 0.77
REF_Corr 0.87
10 0.2
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Sensor 4
6
Raw Signal
40
PtoP4 [g]
30 4
Basis 3.18
Current 3.54
20 Alert 5.57
2 REF_Corr 0.88
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Sensor 4
1.5 Envelope
40
RMS_ENV4 [g]
30
Basis 0.79
1
Current 0.85
20 Alert 1.46
0.5 REF_Corr 0.76
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Sensor 4
2.5
Envelope
40
PtoP_ENV4 [g]
2 Basis 1.50
30
1.5 Current 1.45
20 Alert 2.58
1
REF_Corr -0.50
10
0.5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Gear Stage 1
Fig.1 Sensor 5
0.4
Raw Signal
40
RMS5 [g]
0.3
30
Basis 0.20
Current 0.21
0.2
20 Alert 0.38
REF_Corr 0.65
10 0.1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Sensor 5
3
Raw Signal
40
PtoP5 [g]
30
Basis 1.63
2
Current 1.78
20 Alert 3.05
1 REF_Corr 0.71
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Sensor 5
0.3
Envelope
40 0.25 RMS_ENV5 [g]
30 0.2 Basis 0.14

Current 0.17
0.15
20 Alert 0.27
0.1 REF_Corr 0.93
10
0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Sensor 5
Envelope
40
1.5 PtoP_ENV5 [g]
30
Basis 0.82
1 Current 0.99
20 Alert 1.70
REF_Corr 0.85
0.5
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Gear Stage 2
Fig.1 Sensor6 x-dir

Sensor 6 shows faulty signals
RMS Value
40
20 VEL_AVG1 [mm/s]
30
Basis 2.63
15
Current 0.46
20 10 Alert 9.76
REF_Corr 0.03
10 5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s
Fig.2 Sensor6 x-dir

MAX Value
40
20 VEL_MAX1 [mm/s]
30
Basis 3.72
15
Current 0.71
20 10 Alert 14.14
REF_Corr -0.01
10 5
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s
Fig.3 Sensor7 y-dir

6
RMS Value
40
5 VEL_AVG2 [mm/s]
30 4 Basis 3.01
Current 2.82
3
20 Alert 5.47
2 REF_Corr -0.40
10
1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s
Fig.4 Sensor7 y-dir

MAX Value
40
6 VEL_MAX2 [mm/s]
30
Basis 3.52
4 Current 3.33
20 Alert 6.72
REF_Corr -0.48
2
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm/s
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Vibration Velocity Grinding Bed
Current - Range Days 1 2012-06-17 - 2012-06-18 X - Y Direction
140 100
130
90
120
80
110
Warning Level: 105°C
100
70
90
60
80
70 50
60
40
50
30
40
30
20
20
10
10
0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 hr
°C kNm
Feature Phys.Unit max min mean sdev Rcorr

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
TEMP_8 [°C] 73.03 54.75 67.02 2.95 0.86
TEMP_9 [°C] 80.29 63.08 73.96 2.70 0.68
TEMP_10 [°C] 73.73 62.33 67.92 1.80 0.49
TEMP_11 [°C] 72.25 59.84 66.33 1.99 0.50
TEMP_12 [°C] 74.36 59.92 67.72 2.40 0.60
TEMP_13 [°C] 78.52 67.27 73.50 1.68 0.63
TRQavg Torque Average as Reference Values

TEMP_8 Temperature Bearing 150 Radial 823.1
TEMP_12 Temperature Bearing 151 Axial 822.1
TEMP_13 Temperature Bearing 451 Axial 826.1
Basis - Range Days 30 Title Slide Bearing Temperatures 821 - 826

Current - Range Days 1 Bearing No.150 - 151 - 451 - 450
Fig.1 Sensor 14
X-dir
40 11
Average [mm]
30 10 Basis 7.46
Current 7.48
20 9 Alert 11.29
REF_Corr 0.64
10 8
CONDITION Ok
0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm
Fig.2 Sensor 14
X-dir
40 0.3 Peak to Peak [mm]
Basis 0.14
30
0.2 Current 0.11
20 Alert 0.33
REF_Corr -0.55
0.1
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm
Fig.3 Sensor 15
12 Y-dir
40
Average [mm]
30
Basis 7.13
10
Current 7.12
20 Alert 10.78
8 REF_Corr -0.48
10
CONDITION Ok
0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm
Fig.4 Sensor 15
0.3
Y-dir
40
Peak to Peak [mm]
30
Basis 0.12
0.2
Current 0.12
20 Alert 0.30
0.1 REF_Corr -0.50
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm mm
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Displacement X ( 0°) - Y (90°) Direction
Current - Range Days 1 2012-06-17 - 2012-06-18 Sun Shaft Planetary Gear Stage 1
Fig.1 Bevel Gear

Gear Mesh
40
1 GMFs_BEV [g]
30
Basis 0.44
Current 0.54
20 0.5 Alert 1.13
REF_Corr 0.27
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Bevel Gear

0.5
Sidebands
40
0.4 SBs_BEV [g]
30
Basis 0.08
0.3
Current 0.02
20 Alert 0.46
0.2
REF_Corr -0.26
10 0.1
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Pinion Shaft
0.03 Amplitude
40
ENVshft1 [g]
30
Basis 0.02
0.02
Current 0.02
20 Alert 0.03
0.01 REF_Corr 0.23
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Wheel Shaft

0.05
Amplitude
40
0.04 ENVshft2 [g]
30
Basis 0.02
0.03 Current 0.02
20 Alert 0.05
0.02
REF_Corr 0.27
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Bevel Gear Stage Faults
Current - Range Days 1 2012-06-17 - 2012-06-18 GMF + SB and Shaft Faults
Fig.1 Planet Stg.1

0.25
Raw Signal
40
0.2 GMF Planet [g]
30
Basis 0.09
0.15
Current 0.14
20 Alert 0.23
0.1
REF_Corr 0.85
10 0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Planet Stg.1

Envelope
40 0.2
Fault Planet [g]
30 0.15 Basis 0.11

Current 0.09
20 0.1 Alert 0.21
REF_Corr -0.82
10 0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Planet Stg.1

Envelope
40
Fault Sun [g]
0.1
30
Basis 0.07
Current 0.07
20 Alert 0.12
0.05
REF_Corr 0.08
10
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Planet Stg.1

0.2 Envelope
40
Fault Ring [g]
0.15 Basis 0.10
30
Current 0.08
20 0.1 Alert 0.20
REF_Corr -0.83
10 0.05
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Planetary Gear Faults Stage 1
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Fault Frequencies
Fig.1 Planet Stg.2

0.05
RAW Signal
40
0.04 GMF Planet [g]
30
Basis 0.02
0.03
Current 0.02
20 0.02 Alert 0.05
REF_Corr 0.03
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.2 Planet Stg.2
0.04 Envelope
40
Fault Planet [g]
30 0.03 Basis 0.02

Current 0.01
20 0.02 Alert 0.04
REF_Corr -0.02
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.3 Planet Stg.2

Envelope
40 0.04 Fault Sun [g]
30
Basis 0.02
0.03
Current 0.02
20 0.02 Alert 0.04
REF_Corr 0.17
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Fig.4 Planet Stg.2

0.04 Envelope
40
Fault Ring [g]
0.03 Basis 0.02
30
Current 0.01
0.02 Alert 0.04
20
REF_Corr -0.08
10 0.01
CONDITION Ok
0 0
REF: TRQavg
0 500 1000 1500 2000 2500 hr
kNm g
Basis - Range Days 30 2010-10-16 - 2011-07-19 Title Planetary Gear Faults Stage 2
Current - Range Days 1 2012-06-17 - 2012-06-18 Planetary Fault Frequencies
7
140 140
5500 550 550 17 60
6.5
130 130
16
5000 500 500 55
6
120 120 15
50
4500 450 450 14 5.5
110 110
13 45
5
4000 100 400 400 100
12
4.5 40
90 90
3500 350 350 11
4
80 80 10 35
3000 300 300
9 3.5
70 70 30
8
2500 250 250 3
60 60
7 25
2000 50 200 200 50 2.5

6
20
40 40 5 2
1500 150 150
15
4 1.5
30 30
1000 100 100 3 10
20 20 1
2
500 50 50 5
10 10 0.5
1
0 0 0 0 0 0 0 0
0 500 1000 1500 2000 2500 hr

kW mbar t/h °C °C m³/h bar kNm

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
361-MD1_J1_T [kW] 3904.54 1500.00 2897.51 389.63 0.99
361-RM1_PD_T [mbar] 56.21 29.28 46.25 6.33 0.60
361-WF0_Q1_T [t/h] 514.81 212.66 363.52 53.13 0.70
361-RM1_T1_T [°C] 291.17 172.19 218.83 27.12 0.05
361-RM1_T2_T [°C] 94.50 64.81 83.79 4.29 0.19
361-WI1_F1_T [m³/h] 11.00 0.00 3.15 4.14 0.25
Press_T [bar] 1.39 1.00 1.25 0.09 0.21
TRQavg Torque Average Values as Reference

361-MD1_J1_T Mill Main Drive Motor Power Mean Values
361-RM1_PD_T Mill Differential Pressure
361-WF0_Q1_T Mill Feed Rate
361-RM1_T1_T Mill Hot Gas Inlet Temperature
361-RM1_T2_T Mill Hot Gas Outlet Temperature
361-WI1_F1_T Water Injection Rate
Press_T Oil Pressure at Bearings A and B
Basis - Range Days 30 Title Mill Operating Parameter

Current - Range Days 1 MOP1
75 15000 55
1800 1800
70 350 350 14000
50
65 13000
1600 1600
45
60 300 300 12000
1400 1400
55 11000 40
50 250 250 10000

1200 1200 35
45 9000
40 1000 200 1000 200 8000 30
35 7000
25
800 800
30 150 150 6000
20
25 5000
600 600
20 100 100 4000 15
400 400
15 3000
10
10 50 50 2000
200 200
5
5 1000
0 0 0 0 0 0 0
0 500 1000 1500 2000 2500 hr

mm/s 1/min bar 1/min mm m³/h kNm

TRQavg kNm 41.03 15.64 30.54 4.17 1.00
361-RM1_N1_T [mm/s] 2.54 1.49 1.99 0.23 -0.25
361-SR1_S1_T [1/min] 1751.56 1318.83 1613.42 72.69 -0.10
361-HS1_P1_T [bar] 168.73 44.98 124.22 21.22 0.91
361-FN1_S1_T [1/min] 946.76 803.22 875.85 26.04 0.65
361-HS1_L1_T [mm] 86.51 30.89 53.33 11.56 -0.30
361-RM1_F1_T [m³/h] 6253.12 3.97 2589.35 2406.27 -0.27
TRQavg Torque Average Values as Reference

361-RM1_N1_T Mill Vibration
361-SR1_S1_T Seperator Speed
361-HS1_P1_T Hydraulic Pressure
361-FN1_S1_T Mill Fan Speed
361-HS1_L1_T Grinding Bed Depth
361-RM1_F1_T Mill Air Flow
Basis - Range Days 30 Title Mill Operating Parameter

Current - Range Days 1 MOP2
80 80 80
75 75 75
8000
70 70 70
7500
65 65 65
7000
60 60 60 6500
55 55 55 6000
50 50 50 5500
200
45 45 45 5000
180
4500
40 40 40 160
4000
35 35 35 140
3500
30 30 30 120
3000
25 25 25 100
2000 2500
20 20 20 80
2000
1500
15 15 15 60 Speed Sensor Fault
1500
1000
10 10 10 40 1000
5 5 5 20 500
500
0 0 0 0 0 0
0 500 1000 1500 2000 2500 hr

kNm kNm kNm kNm 1/min kW

TORQ_MEAN kNm 40.76 15.43 30.19 4.09 1.00
TORQ_MAX1 [kNm] 54.32 25.27 42.13 4.47 0.91
TORQ_PTOP1 [kNm] 28.69 13.54 22.75 3.50 0.03
TORQ_SDV1 [kNm] 6.10 2.74 4.85 0.81 -0.00
361-MD1_J1_T [kW] 3890.09 1469.80 2874.19 387.51 0.99
Speed_mean [1/min] 1445.71 0.00 452.74 511.07 -0.33
TORQ_MEAN Torque Average Values as Reference

TORQ_MAX1 Torque Max Values
TORQ_PTOP1 Torque Peak to Peak Values
TORQ_SDV1 Torque Standard Deviation Values
361-MD1_J1_T Mill Main Drive Motor Power
Speed_mean Input Speed
Basis - Range Days 30 Title Torque Progress

Current - Range Days 1 Over Measurement Period
TORQUE ALARM-EVENTS (Exclude start processing) 05.2012
1 2 3 4 5 6 7 Alarm Production
Month Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Sum Hours
01.05.2012 0 0 0 0 5 0 0 5 18
02.05.2012 0 0 0 0 1 0 0 1 17
03.05.2012 0 0 0 0 0 0 0 0 13
04.05.2012 0 0 0 0 0 0 0 0 3
05.05.2012 1 0 0 0 0 0 0 1 6
06.05.2012 1 0 0 0 3 0 0 4 14
07.05.2012 0 0 0 0 1 0 0 1 4
08.05.2012 0 0 0 0 34 0 0 34 15
09.05.2012 0 0 0 1 10 0 0 11 16
10.05.2012 0 0 0 1 0 0 0 1 4
11.05.2012 0 0 0 0 1 0 0 1 14
12.05.2012 1 0 0 0 4 0 0 5 11
13.05.2012 1 0 1 0 1 0 0 3 17
14.05.2012 1 0 0 0 0 0 0 1 15
15.05.2012 0 0 0 1 1 0 0 2 8
16.05.2012 0 0 0 0 1 0 0 1 18
17.05.2012 1 0 0 0 1 0 0 2 14
18.05.2012 0 0 0 0 0 0 0 0 10
19.05.2012 0 0 0 0 1 0 0 1 1
20.05.2012 1 0 0 0 1 0 0 2 13
21.05.2012 1 0 1 1 3 0 0 6 19
22.05.2012 1 0 0 0 0 0 0 1 14
23.05.2012 0 0 0 0 0 0 0 0 3
24.05.2012 2 0 0 0 10 0 0 12 9
25.05.2012 1 0 1 0 2 0 0 4 8
26.05.2012 0 0 0 0 1 0 0 1 15
27.05.2012 0 0 1 0 1 0 0 2 19
28.05.2012 2 0 1 0 0 0 0 3 13
29.05.2012 1 0 0 0 14 0 0 15 14
30.05.2012 0 0 0 0 0 0 0 0 4
31.05.2012 0 0 0 0 0 0 0 0 0
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2 Total Hours
Sum May 15 0 5 4 96 0 0 120 349
Alarm-Sum and Production Time

45
40 24
35 21
19 19
30 18 17 17
18 18
16
25 15 15 15 15
14 14 14 14 14
13 13 13
20 12
11
10
15 9 9
8 8
10 6 6
4 4 4
5 3 3 3
0 1
0 0
01.05.12
02.05.12
03.05.12
04.05.12
05.05.12
06.05.12
07.05.12
08.05.12
09.05.12
10.05.12
11.05.12
12.05.12
13.05.12
14.05.12
15.05.12
16.05.12
17.05.12
18.05.12
19.05.12
20.05.12
21.05.12
22.05.12
23.05.12
24.05.12
25.05.12
26.05.12
27.05.12
28.05.12
29.05.12
30.05.12
31.05.12
Prodc
Alarm
t.
hrs
TORQUE ALARM-EVENTS (Exclude start processing) 06.2012
01.06.2012 0 0 0 0 0 0 0 0 0
02.06.2012 0 0 0 0 0 0 0 0 0
03.06.2012 2 0 0 0 1 0 0 3 3
04.06.2012 0 0 0 0 0 0 0 0 0
05.06.2012 0 0 0 0 0 0 0 0 0
06.06.2012 0 0 0 0 0 0 0 0 0
07.06.2012 0 0 0 0 0 0 0 0 0
08.06.2012 1 0 0 0 4 0 0 5 17
09.06.2012 1 0 0 0 7 0 0 8 11
10.06.2012 0 0 0 0 0 0 0 0 0
11.06.2012 0 0 0 0 0 0 0 0 0
12.06.2012 0 0 0 0 0 0 0 0 0
13.06.2012 0 0 0 0 1 0 0 1 2
14.06.2012 1 0 0 0 0 0 0 1 19
15.06.2012 0 0 0 0 4 0 0 4 14
16.06.2012 0 0 0 0 0 0 0 0 14
17.06.2012 0 0 0 0 2 0 0 2 21
18.06.2012 1 0 1 0 0 0 0 2 6
19.06.2012 0 0 0 0 0 0 0 0 0
20.06.2012 0 0 0 0 0 0 0 0 0
21.06.2012 0 0 0 0 0 0 0 0 0
22.06.2012 0 0 0 0 0 0 0 0 0
23.06.2012 0 0 0 0 0 0 0 0 0
24.06.2012 0 0 0 0 0 0 0 0 0
25.06.2012 0 0 0 0 0 0 0 0 0
26.06.2012 0 0 0 0 0 0 0 0 0
27.06.2012 0 0 0 0 0 0 0 0 0
28.06.2012 0 0 0 0 0 0 0 0 0
29.06.2012 0 0 0 0 0 0 0 0 0
30.06.2012 0 0 0 0 0 0 0 0 0

Sum Jun 6 0 1 0 19 0 0 26 107

9
8 24
7 21 21
19
6 17 18
5 14 14 15
4 12
11
3 9
2 6 6
1 3 3
2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
01.06.12
02.06.12
03.06.12
04.06.12
05.06.12
06.06.12
07.06.12
08.06.12
09.06.12
10.06.12
11.06.12
12.06.12
13.06.12
14.06.12
15.06.12
16.06.12
17.06.12
18.06.12
19.06.12
20.06.12
21.06.12
22.06.12
23.06.12
24.06.12
25.06.12
26.06.12
27.06.12
28.06.12
29.06.12
30.06.12
Prodc
Alarm
t.
hrs
TORQUE ALARM-EVENTS (Exclude start processing) 2012

Jan 0 0 0 0 0 0 0 0 0
Feb 0 0 0 0 0 0 0 0 0
Mar 0 0 0 0 15 0 0 15 13
Apr 6 0 0 0 156 0 0 162 250
May 15 0 5 4 96 0 0 120 348
Jun 6 0 1 0 19 0 0 26 107
Jul 0 0 0 0 0 0 0 0 0
Aug 0 0 0 0 0 0 0 0 0
Sep 0 0 0 0 0 0 0 0 0
Oct 0 0 0 0 0 0 0 0 0
Nov 0 0 0 0 0 0 0 0 0
Dec 0 0 0 0 0 0 0 0 0
Sum 2012 27 0 6 4 286 0 0 323 718
Annual Sum of Alarms and Production Time

220
400
200
348 350
180
160 300
140 250 250
120
100 200
80 150
60 107 100
40
20 50
13
0 0 0 0 0 0 0 0 0 0
Alarm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecProdct. hrs
Split Up Annual Torque Alarms

220
200
180
160
140
120
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2
TORQUE ALARM-EVENTS (Starting processing) 05.2012
01.05.2012 0 0 0 0 6 0 0 6 18
02.05.2012 1 0 0 0 6 0 0 7 17
03.05.2012 0 0 0 0 2 0 0 2 13
04.05.2012 0 0 0 0 2 0 0 2 3
05.05.2012 0 0 0 0 6 0 0 6 6
06.05.2012 2 0 0 0 8 0 0 10 14
07.05.2012 0 0 0 0 3 0 0 3 4
08.05.2012 0 0 0 0 17 0 0 17 15
09.05.2012 0 0 0 0 14 0 0 14 16
10.05.2012 0 0 0 0 0 0 0 0 4
11.05.2012 0 0 0 0 1 0 0 1 14
12.05.2012 0 0 0 0 8 0 0 8 11
13.05.2012 0 0 2 0 2 0 0 4 17
14.05.2012 0 0 0 0 1 0 0 1 15
15.05.2012 0 0 0 0 0 0 0 0 8
16.05.2012 0 0 0 0 3 0 0 3 18
17.05.2012 0 0 0 0 0 0 0 0 14
18.05.2012 0 0 0 0 3 0 0 3 10
19.05.2012 0 0 0 0 3 0 0 3 1
20.05.2012 0 0 0 0 6 0 0 6 13
21.05.2012 0 0 0 0 4 0 0 4 19
22.05.2012 0 0 0 0 0 0 0 0 14
23.05.2012 0 0 0 0 0 0 0 0 3
24.05.2012 1 0 0 0 7 0 0 8 9
25.05.2012 0 0 0 0 1 0 0 1 8
26.05.2012 0 0 0 0 1 0 0 1 15
27.05.2012 0 0 0 0 1 0 0 1 19
28.05.2012 0 0 0 0 8 0 0 8 13
29.05.2012 1 0 0 0 5 0 0 6 14
30.05.2012 0 0 0 0 0 0 0 0 4
31.05.2012 0 0 0 0 0 0 0 0 0
Sum May 5 0 2 0 118 0 0 125 349

18
16 24
14 21
19 19
12 18 17 17
18 18
16
10 15 15 15 15
14 14 14 14 14
13 13 13
8 12
11
10
6 9 9
8 8
4 6 6
4 4 4
2 3 3 3
0 1
0 0
01.05.12
02.05.12
03.05.12
04.05.12
05.05.12
06.05.12
07.05.12
08.05.12
09.05.12
10.05.12
11.05.12
12.05.12
13.05.12
14.05.12
15.05.12
16.05.12
17.05.12
18.05.12
19.05.12
20.05.12
21.05.12
22.05.12
23.05.12
24.05.12
25.05.12
26.05.12
27.05.12
28.05.12
29.05.12
30.05.12
31.05.12
Prodc
Alarm
t.
hrs
TORQUE ALARM-EVENTS (Starting processing) 06.2012
01.06.2012 0 0 0 0 0 0 0 0 0
02.06.2012 0 0 0 0 0 0 0 0 0
03.06.2012 0 0 0 0 4 0 0 4 3
04.06.2012 0 0 0 0 0 0 0 0 0
05.06.2012 0 0 0 0 0 0 0 0 0
06.06.2012 0 0 0 0 0 0 0 0 0
07.06.2012 0 0 0 0 0 0 0 0 0
08.06.2012 0 0 0 0 4 0 0 4 17
09.06.2012 0 0 0 0 2 0 0 2 11
10.06.2012 0 0 0 0 2 0 0 2 0
11.06.2012 0 0 0 0 0 0 0 0 0
12.06.2012 0 0 0 0 0 0 0 0 0
13.06.2012 0 0 0 0 7 0 0 7 2
14.06.2012 0 0 0 0 2 0 0 2 19
15.06.2012 0 0 0 0 1 0 0 1 14
16.06.2012 0 0 0 0 2 0 0 2 14
17.06.2012 0 0 0 0 1 0 0 1 21
18.06.2012 0 0 0 0 0 0 0 0 6
19.06.2012 0 0 0 0 0 0 0 0 0
20.06.2012 0 0 0 0 0 0 0 0 0
21.06.2012 0 0 0 0 0 0 0 0 0
22.06.2012 0 0 0 0 0 0 0 0 0
23.06.2012 0 0 0 0 0 0 0 0 0
24.06.2012 0 0 0 0 0 0 0 0 0
25.06.2012 0 0 0 0 0 0 0 0 0
26.06.2012 0 0 0 0 0 0 0 0 0
27.06.2012 0 0 0 0 0 0 0 0 0
28.06.2012 0 0 0 0 0 0 0 0 0
29.06.2012 0 0 0 0 0 0 0 0 0
30.06.2012 0 0 0 0 0 0 0 0 0

Sum Jun 0 0 0 0 25 0 0 25 107

9
8 24
7 21 21
19
6 17 18
5 14 14 15
4 12
11
3 9
2 6 6
1 3 3
2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
01.06.12
02.06.12
03.06.12
04.06.12
05.06.12
06.06.12
07.06.12
08.06.12
09.06.12
10.06.12
11.06.12
12.06.12
13.06.12
14.06.12
15.06.12
16.06.12
17.06.12
18.06.12
19.06.12
20.06.12
21.06.12
22.06.12
23.06.12
24.06.12
25.06.12
26.06.12
27.06.12
28.06.12
29.06.12
30.06.12
Prodc
Alarm
t.
hrs
TORQUE ALARM-EVENTS (Starting processing) 2012

Jan 0 0 0 0 0 0 0 0 0
Feb 0 0 0 0 0 0 0 0 0
Mar 1 0 0 0 30 0 0 31 13
Apr 3 0 0 0 125 0 0 128 250
May 5 0 2 0 118 0 0 125 348
Jun 0 0 0 0 25 0 0 25 107
Jul 0 0 0 0 0 0 0 0 0
Aug 0 0 0 0 0 0 0 0 0
Sep 0 0 0 0 0 0 0 0 0
Oct 0 0 0 0 0 0 0 0 0
Nov 0 0 0 0 0 0 0 0 0
Dec 0 0 0 0 0 0 0 0 0
Sum 2012 9 0 2 0 298 0 0 309 718
Annual Sum of Alarms and Production Time
160 400
348 350
140
120 300
250 250
100
80 200
60 150
107 100
40
20 50
13
0 0 0 0 0 0 0 0 0 0
Alarm Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecProdct. hrs
Split Up Annual Torque Alarms
160
140
120
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Tmax Tavg Timpact Tneg Tdyn Tavg2 Timpact2

28 - 09 Dalog Report Shurovo Flender KMPP 601 2012.06.18

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28 - 09 Dalog Report Shurovo Flender KMPP 601 2012.06.18

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REPORT

REPORT NUMBER: HOLCIM SHUROVO-08-339-01.09

Gear Reducer: FLENDER KMPP 601 Line: 361-MD1.M1

Serial No.: 44 36 182 - 0040 -1

Report Period: 2010-09-23 - 2012-06-18

Date of Report: 2012-06-19

Reported by: Dipl.-Ing. Horst Brodherr

Checked by: Dipl.-Ing. (FH) Bernhard Tetzlaff

Page 002 Contents Report

Page 003 Gearbox Condition and Sensor Positions

Page 004 Condition Summary Comments

Page 012 Planetary Gear Faults Stage 1: Planetary Fault Frequencies

Page 013 Planetary Gear Faults Stage 2: Planetary Fault Frequencies

Page 014 Mill Operating Parameter MOP1

Page 015 Mill Operating Parameter MOP2

Page 016 Torque Progress over Measurement Period

Page 017 Torque Alarm - Process Mode - Events I May 2012

Page 018 Torque Alarm - Process Mode - Events II June 2012

Page 020 Torque Alarm - Start Up Mode - Events I May 2012

Page 021 Torque Alarm - Start Up Mode - Events II June 2012

Page 023 How to read this Report 1

Page 024 How to read this Report 2

Page 025 How to read this Report 3

DALOG Diagnosesysteme GmbH

2.Condition of the Bevel Gears:

3.Condition of the Planetary Gears:

30 0.6 Basis 0.37

30 0.2 Basis 0.14

Fig.1 Sensor6 x-dir

Fig.2 Sensor6 x-dir

Fig.3 Sensor7 y-dir

Fig.4 Sensor7 y-dir

Feature Phys.Unit max min mean sdev Rcorr

TRQavg Torque Average as Reference Values

Basis - Range Days 30 Title Slide Bearing Temperatures 821 - 826

Fig.1 Bevel Gear

Fig.2 Bevel Gear

Fig.3 Pinion Shaft

Fig.4 Wheel Shaft

Fig.1 Planet Stg.1

Fig.2 Planet Stg.1

30 0.15 Basis 0.11

Fig.3 Planet Stg.1

Fig.4 Planet Stg.1

Fig.1 Planet Stg.2

Fig.2 Planet Stg.2

30 0.03 Basis 0.02

Fig.3 Planet Stg.2

Fig.4 Planet Stg.2

2000 50 200 200 50 2.5

0 500 1000 1500 2000 2500 hr

Feature Phys.Unit max min mean sdev Rcorr

TRQavg Torque Average Values as Reference

Basis - Range Days 30 Title Mill Operating Parameter

50 250 250 10000

40 1000 200 1000 200 8000 30

20 100 100 4000 15

0 500 1000 1500 2000 2500 hr

Feature Phys.Unit max min mean sdev Rcorr

TRQavg Torque Average Values as Reference

Basis - Range Days 30 Title Mill Operating Parameter

0 500 1000 1500 2000 2500 hr

Feature Phys.Unit max min mean sdev Rcorr