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    15 views55 pages

    029 Systematic and Preventive Maintenance of Gear Units For

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    kING
    cement

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    The International Maintenance Seminar 2002 >MIDTH Institute” Mechanical maintenance of gear units for mills and kilns by Peter Andersen Lecture 06-01 The International Maintenance Seminar - 2002 MIDTH Institute” TABLE OF CONTENTS 1. INTRODUCTION. 2, DESCRIPTION OF DIF PRINCIPLES Spur Gears. Helical Gears. Herringhoné Gears (Double Helical Gear). Bevel Gears Working Principle Gear Boxes Used for Kilns / Mills... Lubrication Systems... Safety Systems 3. ITEMS 10 BE CHECKED 41 4. SYSTEMATIC MAINTENANCE BASED ON CONDITION MONITORING .....21 4.1. Introduction EARS, AND WORKING 4.2 Temperature Monitoring 4.3: Vibration Monitoring 444. Physical Condition Monitoring by Visual Inspection 5. PLANNING OF CONDITION BASED MONITORING 5.1 Standard Procedures / Systematic Monitoring...... 5.2 Systematic Recordings 5.3. Required Resouwes. 5.4. Spare Parts in Stock. 6. ACTIONS BASED ON 6.1 LAMIIS oe ssesnsen 6.2 Action at Next Stop 7, RECOMMENDATIONS FOR PRI 7.1 Temperature... 7.2 Vibration .. 7.3. Visual Inspection . 8. CONCLUSION... ATIC CONDITION MONITORING ‘TIVE MAINTENANCE ACTION a The International Maintenance Seminar - 2002 MmiDTH Institute” INTRODUCTION ‘The term maintenance is a rather diffuse concept. This lecture presents a systematic approach called Condition Based Maintenance. This lecture emphasizes the importance of good maintenance of gear units based on the concept of Condition Based Maintenance. Resides explaining the requirements for implementation of a systematic condition based maintenance, the lectuze lists the most important quantities and concepts for monitoring the gear unit, Finally, examples of actions to be taken ave given based on changes or developments in the recorded findings of the condition monitoring, 2. DESCRIPTION OF DIFFERENT TYPES OF GEARS, AND WORKING PRINCIPLES Before dealing with the condition based maintenance concept, a presentation of the most fundamental gearbox concepts and terminology will be described. Purpose The purpose ofa gearbox in a cement plant is to reduce the speed of the motor and to transmit the power from the motor to the working machine, Types of Gears For large gearboxes (also called Heavy Duty Gearboxes) used for kilns and mills, there are basically four different types of gears which can be identified by looking at the teeth cut: Eiism IDTH The International Maintenance Seminar - 2002 Institute” 2.1 Spur Gears If the tecth are cut straight across the gear blanks, they are called spur gears. See Figure 1 Figure 1. Spur gears. The teeth of these gears are developed on cylindrical pitch surfaces The International Maintenance Seminar - 2002 mMIDTH Institute” 2.2 Helical Gears Instead of cutting the teeth straight across the gear blanks, they can he cut as twisted teeth Such a uniform twist is a true helix and the resulting gears are called helical gears. The angle of bwist is called a helix angle and is normally 20 to 25 degrees. The advantage is that with the same width of a gear rim the tooth flank area is bigger and several teeth are engaged at the same time so the gears can transmit more power and do it more smoothly with less vibrations. See Figure 2 DRIVEN @ Figure 2, Helical gear and pinion MIDTH The International Maintenance Seminar - 2002 Institute” 2.3 Herringbone Gears (Double Helical Gears) Due to the helix angle, the operation of the helical gears produces axial thrusts that must be taken up by the bearings. By using two pairs of opposite helical gears the thrust forces are balanced out, See Figure 3, © @ a S The International Maintenance Seminar - 2002 MIDTH Institute” 2.4 Bevel Gears For this gear. the centerline of the shafts intersect at a right angle. The gears become conical and are therefore called bevel g . In heavy duty gearboxes the bevel gears have logarithmic spiral tecth called Zyclo-Palloid teeth, In these geats, the working flank, and therefore the power transmission, is very large. Because of the curved shape, the teeth are also stronger. See Figure 4, Figure 4. Bevel gears. These gears transmit motion berween nor-interseciing shafts crossing at aright angle 2.5 Working Principle Three different working principles and the attached gear designs will be described in the following: i MIDTH The International Maintenance Seminar - 2002 Institute” 1, Depending on how much the speed should be reduced (ratio) a single, double, triple, or four stage (or step) gear box can be used. Figure 5 shows a single reduction gearbox. Gear Wheel Output shat | casing xi Roller Bearing Drive Shatt BS Pinion , ==) Figure 5. Single reduction gearbox. 1, Another working principle is used in the Planetary Gearbox as shown in Figure 6. Here we have the input shaft with the sun wheel/pinion, the planet wheels are connected to the spider, which again is fixed to the output shaft, and the stationary ring gear The International Maintenance Seminar - 2002 MIDTH Institute” e 7 Ta oRive SHAFT starionany e RING GEAR Figure 6. Planetary gear reduction set 1. The third working principle to be mentioned is the symmetrical gearbox, where the high-speed pinion meshes two gearwheels which sit on each individual pinion C i it Cc shaft. These pinions mesh the same low-speed gearwheel. In this way it is possible to transmit the double amount of power from the motor to the working machine. This type of gear box is called Symetro Gear as shown in Figure 7. € 1B MIDTH The International Maintenance Seminar - 2002 Institute See ®@ Figure 7. Symetro gear. 2.6 Gear Boxes Used for Kilns / Mills For rotating kilns we usually find one or two double or triple stage gearboxes which are used to drive the girth gear fixed around the kiln tube. Helical and/or herringbone gears are > employed, For ball mills a single, or double stage gearbox is used, with helical and/or herringbone gears, Single or double stage gearboxes are often used since they provide a faster rotating speed as required for ball mills. Figure 8 shows a single and a double drive with pinion and gear rim, The Internationa! Maintenance Seminar - 2002 MIDTH Institute” Figure 8. Drive with pinion and gear rim. MIDTH The International Maintenance Seminar - 2002 Institute” Fora center driven ball mill, a Symetro or a Planetary gearbox is often used because they both can be designed to have the same ouiput speed and torque as required for the mill, see 9. Figure 9. Central drive for ball mill. The Symetro operates with helical gears in the high speed gearing and hemingbone gear the low speed gearing, The Planetary gearbox operates with spur gears only. This avoids thrust forces For vertical mills, Fig. 10, a planetary or a double or triple stage Atox gearbox (Fig. 11) is used with some modifications: + Inthe input end, there is a bevel gearing with Zyelo-Palloid teeth. Since the intermediate anid output shaft stand in a vertical position, the input shaftis in a horizontal position so that it can be connected to the horizontal motor shatt. 16 The International Maintenance Seminar - 2002 MIDTH Institute” Figure 10. 4fox mill with gear unit + In the output end, there is a connecting flange standing on a thrust bearing. The mill table stands on this flange. e Main manufactures of heavy duty gearboxes for kilns and mills are: + FLENDER + PEKRUN + PHILADELPHIA + RENK A + TACHE, + MAAG (member of FFE-group) 17 MIDTH The International Maintenance Seminar - 2002 Institute” MAAG manufactures the FLS-designed SYMETRO and ATOX gearboxes for, respectively, ball mills and Atox vertical mills. MAAG also manuftctures planetary gearboxes for both ball and vertical mills. Figure 10 shows the gear unit mounted at the base of the Atox mill, 6 3 Yeast — 2 La 5 { 4 Figure 11. Gear wnit for Ator mill. Key to Figure 11 1, Drive shaft 2. First reduction (bevel gear) | 3. Rollerbearing 4, First intermediate shaft 18 The International Maintenance Seminar - 2002 MIDTH Institute” 5. Second reduction 6. Second intermediate shaft 7. Third reduetion 8. Output shaft 9. Connecting flange (to vertical mill) 10, Thrust bearing for connecting flange 2.7 Lubrication Systems ‘The most simple and most reliable lubrication system is the self lubricated gearbox. The gearwheel or wheels dipping in the oil bath takes up the oil, thus lubricating the gear mesh. Some oil is caught by an oil tench and led 10 the bearings. This pri pls is illustrated in Figure 12. igure 12 Splash lubricated gear set. If the rotational speed of the gear is very low or the gear does not dip in the oil, itis necessary to use an oil circulation pump with pipes to obtain sufficient lubrication. 19 MIiIDTH The International Maintenance Seminar - 2002 Institute” In most cases it is also necessary to cool down the oil, if the outside total surface of the gearbox is not large enough to get rid of the produced heat Besides the gearbox there can be @ pipe system with oil pump, filter(s), and cooler. It is called a pump station or pump unit. This applies for ATOX GEAR, SYMETRO GEAR, and all planetary gearboxes to day. Figure 13 shows the lubrication unit for the Symetro gear. Pan 1 Pre filter 2 Pump 3 Filter 4 Oil cooler c= Figure 13, Lubrication unit for the Symetro gear. 2.8 Safety Systems Safety systems are necessary to give a waming in the case of failures. Thus, damage can be avoided. A safety system will also monitor sufficient oil lubrication and in some cases, oil level. If there is a pump station there might be a sensor monitoring the oil flow and pressure, The manufacturer has placed, or made preparations for placement of sensors for meesuring temperatures in oil and bearings. A safety system can also monitor vibrations, For all these instruments, there is one set point ems must be checked at for alam and one for tripping the motor. The function of these regular intervals. > The International Maintenance Seminar - 2002 MIDTH Institute” 3 ITEMS TO BE CHECKED AT A GEAR UNIT A gear unit is made up of a number of individual components. In the following, the most basic elements to be checked or monitored during normal maintenance procedures are mentioned. The working order of these components are vital for satisfactory function and operation of the gear unit as a whole casing; must be tight to prevent oil leakage teeth only undamaged teeth can perform satisfactorily bearings; correct bearing function is important for avoiding tooth wear oil: correct quantity and satisfactory quality are necessary pump station: lubrication can only be satisfactory if there is sufficient oil circulation couplings: non-metallic parts must receive special attention Specific maintenanc 44 {idelines regarding all of these components are listed under Section 4. SYSTEMATIC MAINTENANCE BASED ON CONDITION MONITORING 4.1 Introduction Condition based maintenance is to monitor the condition of @ machine and obtain a precise picture of the state of health of each vital component - gears, bearings, ete. With this data, the maintenance department knows when a shutdown is necessary and the precise nature of the repairs that need to be carried out Through analysis of monitorings of the most critical gearbox components, itis possible to predict \when the equipment will reach a condition, where the achieved production resulis are unacceptable, or in which the mechanical condition is unacceptable. MIDTH The International Maintenance Seminar - 2002 Institute” ‘Thus, itis possible to utilize the monitoring equipment to the maximum and to plan a convenient time for the overhaul of equipment before the unacceptable condition is reached ‘This, in fact, is the principle of Condition Based Maintenance: “A system for prediction of the time for the next inspection or repair/replacement.” or, in other words: "a machine should not be overhauled, until the actual condition of the machine indicates that overhaul is required” Equipment condition can be evaluated by monitoring the following three things + temperature + vibration + physical condition (visual inspection) 4.2 Temperature Monitoring ‘Today it is a must that critical parts and their operational conditions are monitored. An example of this is high-speed bearings and oil temperatures (when coolers are involved). Where this is monitored, there will be an alarm setting and maybe a trip setting to give a wait of sudden inerease in temperature. In many new plants it is also possible to read the temperatures in the Central Control Room and even see the trend for the lust 24 hours or past week, The sensor used is a resistance phial called Pi100, 43 ration Monitoring “The gearbox’s vibrations are monitored by an accelerometer permanently fixed on the gearbox. There is also an alarm and tip setting indicating sudden bearing or tooth failure. ‘This can be done with the instrument “Vibrocontrol” manufactured by Schenck. Figure 14. ‘This instrument is used by FLS. Q The International Maintenance Seminar - 2002 MIDTH Institute” Figure 14 Vibrocontrol by Schenck At regular intervals, vibrations are read and analyzed in order to monitor the condition of gears and bearings. Systematic condition monitoring of the gear through vibration monitoring enables the possibility to interpret the actual and future condition and maintenance requirements. Performance of condition besed monitoring based on vibration measurements requives the following: + equipment for registering the vibrations + hardware and software for quantifying the vibrations + the ability to analyze the results in a systematic manner. + the ability to predict the consequences which will occur in the future. MIDTH The International Maintenance Seminar - 2002 Institute” 4.4 Physical Condition Monitoring by Visual Inspection Systematic visual inspection is important because not everything ean be monitored by sensors, This provides the pos: ty to assess the general physical condition. Such a general assessment cannot be evaluated with any single instrument, Listed below are the guidelines for the components previously listed in Section 3. Casing The casing must he tight to prevent oil leakage. Check for oil leakage at joints and sealings at input and output shafts. Check for cracks in the gear casing. Teeth The most important aspect for proper and long lasting operation is the condition of the tecth. Check for cracks, wear and pittings on each tooth, Bearings Inspect the rollers and raceways to detect any change in the wear patter, pittings or corrosion. The cages should also be inspected for damage. Not all beatings are easily accessible, For those bearings which are not accessible, bearing failure can be detected by vibration analysis, oil The quantity (and that means the oil level) should be correct to ensure the most effective lubrication of bearings and teeth mesh. Check the oil circulation and note the appearance of the oil. Is it dirty? Is there foam on the cil surface? If there are inspection covers, itis, possible to check the teeth, bearings and oil for dirt and foam. Pump Stations ‘The pump station ensures sufficient circulation of oil in the gear unit. In the pump station there are several items to be checked, «© Check to ensure that the function of the pump is operating with the right pressure. Too high pressure indicates that the filter or the cooler has to be cleaned. 24 The International Maintenance Seminar - 2002 MIDTH Institute” + check the filter for dirt and debris + check the oil level Couplings In some couplings, there are rubber parts which should be checked for wear. In membrane couplings, the thin plates should be checked for cracks and corrosion. During a stop it is feasible to check the couplings for wear or corrosion. 3 PLANNING OF CONDITION BASED MONITORING AND MAINTENANCE 5.1 Standard Procedures / Systematic Monitoring + Check the temperature of the oil and bearings and vibration level daily from the displays. (Temax, vibration monitor or soreen ). + Check the filter by taking the filter insert out for visual inspection. + Check the oil level by visually inspecting the dipstick or the oil le jase for oil, The check should be made once a week at a time when the equipment is stopped. + Frequency analyze can be performed monthly with the instruments as mentioned in Section 7. Vibration. + Visually check the condition of tooth, bearing, and oil two to four times a year. 5.2 Systematic Recordings Systematic maintenance efforts, such as monitoring of equipment and collection of condition, data for the equipment/gear unit requires a well organized recording and filing of the information. It is therefore necessary to haye some kind of file on PC as well as record sheets: (hard copy), The data should include temperature and vibration trends as well as frequency MIDTH The International Maintenance Seminar - 2002 Institute” spectrums. Temperature and vibration trends can be graphically illustrated while frequency spectrums can be shown as waterfalls, A record of tooth condition can be kept as a standard sketch, tooth prints or photos, All collected data must have machine identification, date, measuring point and remarks if necessary. The records must be kept in a safe place, though allowing for access by the concerned staff. 53 Required Resources At many plants today, the size of the mechanical maintenance staff is kept at a minimum; allowing only for the possibility to perform the daily routine. Therefore it is sometimes necessary to have some extemal assistance, for example: + analysis of oil samples. + performance of vibration analysis. + technical help from gear specialists. + if there is any repair or replacement work to be done at the next stop, it may be necessary fo engage external contractors. 5.4 Spare Parts in Stock One of the advantages of the condition based maintenance program is that predictions regarding future maintenance needs can be made. Consequently. itis possible to estimate the future recommended quantity of oil required at a specific time. Make sure that there is always the right quantity and quality of oil in stock, Likewise it is required to have a stock of bearings to compensate for naturally occurring wear. thas to be taken into consideration that some large bearings have a long delivery time, up 10 one year. How many pinions and gears whieh should be kept on hand as spare parts depends on past expetience, records of wear, manufacturers recommendation, etc. Always keep oil pumps, filter inserts, valves, in stock. It may also be advantageous to keep coolers in stock. The International Maintenance Seminar « 2002 MIDTH Institute” ACTIONS BASED ON SYSTEMATIC CONDITION MONITORING Based on the findings concerning the condition of the gear unit as acquired through systematic maintenance and condition monitoring, it is possible to initiate preventive maintenance on the equipment. In other words, future maintenance requirements ean be predicted, The monitoring of the gear unit provides information on the condition through recorded measurements of temperature, vibration and visual inspection, An analysis of the different records of the condition monitored on the gear will either show that the measured data is stabile and constant or developing with a specific tendency. The task of an analysis is to interpret the condition and/or development tendeney over a periad and to provide an explanation for why a specific tencleney is developing. The reason could be just normal wear, or worse, poor maintenance. Also, deteriorating condition can be caused by faulty assembly or adjustment or even poor fabrication ‘The important issue arising from systematic maintenance and analysis of condition records, is that indications are given when it is required fo find the reason fora trend and plan for the. appropriate actions to be taken 6.1 Limits ‘The limits are found in the instructions from the manufacture or in international standards such as ISO. ‘The maintenance staff's experience with the specific equipment will often give the first indication of changed conditions and unacceptable levels or indications. It is not advisable to try and acquire knowledge regarding limits by letting the equipment simply exceed critical point and breakdown. The recorded condition monitoring should indicate changes. The conditions recorded should be compared to the known, estimated, reasonable and acceptable limits. MIDTH The International Maintenance Seminar - 2002 Institute” 62 Action at Next Stop Itis not always necessary to take action when there is an increase in the level oF a certain measurement, An increase could be very small due to inherent tolerances in the measuring procedure or instrument. changes in production or a measurement-affecting condition such as ambient temperature. In the case ofa significant change, adjusiment or replacement though, must be considered. If there is doubt, it can be a good idea to consult the manufacturer, or a gear specialist. If adjustment or replacement is found to be necessary then ‘a contractor should be engaged. te RECOMMENDATIONS FOR PREVENTIVE MAINTENANCE ® ACTIONS We will now focus on the three important areas, which can be monitored (temperature, vibration, visual inspection), For each of these quantities we will list some facts, guidelines and examples for effective preventive maintenance actions, hased on the experience of FLS. 7.1 Temperature Check the temperatures as mentioned in Section 5.1. Normal temp.: 50-60°C. or less. Max.: 85°C for EP-gear oil. If the oil temperature rises the reason can be: + Increased ambient temperature. + Insufficient cooling caused by blockage in pipes or the cooler itself, + Insufficient water supply to the cooler or, if it is cooled by air, dist and dust in the cooling ribs. + Wom oil pump. If the bearing temperature rises or the difference between bearing-and oil temperature rises, the reason can be: The International Maintenance Seminar - 2002 + Insuificient oil flow to the bearing. + Bearing failure + Malfunction of the sensors or display. 7.2 Vibration MIDTH Institute” The most simple vibration measurement instrument today is the Integrated Vibration Meter, which measures the total vibration level f ex. from 10 to 2000 Hz(Hertz) and has a visual display. Figure 15 shows the integrated vibration meter from Bruel & Kjecr. To analyze the signal a data collector (SKF named: Mierolog) is used for electronic recording of the signal from the gear box. Figure 15 Typical integrated vibratign meter MIDTH The International Maintenance Seminar - 2002 Institute” C4 | ——= Figure 16. SKF Microlog data collector. 30 @ The International Maintenance Seminar - 2002 MIDTH Institute” . This is a mathematical formulation first formulated by Fourier, which states that any periodic The signal is broken down into its individual frequencies by means of Fourier analysis curve, no matter how complex, may bé looked upon as a combination of a number of pure sinusoidal curves with harmonically related frequencies. When all mea: rement recordings are finished on a route, the data collector is connected to a PC. Thereafter. all data is filed and can be mathematically treated and compared statistically. A readi market today is PRISM 4 from SKF. available program on the Tor ter the vibrations, an accelerome! important always to choose the same measurement points so the measurements are comparable, thus preserving the actual calibration of the accelerometer. Mounting should be as close as possible to the bearing and ona rigid/heavy surface, for example, a bearing house, The measuring point should never be ona thin cover. This is to avoid resonance vibrations arising in the mounting site, Figure 17 illustrates this principle. A and C show correct mounting points. MIDTH The International Maintenance Seminar - 2002 Institute” Mark the measuring point and remove dirt, oil and paint, thus providing a straight clean surface for fixation of the meter. The accelerometer should be fixed with a m: gnel, so the pressure between accckexometer and mounting surface is always the same. If this is not done, the measurement will not be the same everytime. The conventional methods for affixing the accelerometer are shown in Figure 18. T D Magnet A Thin loyer < of wan Steet ‘tug Figure 18. Methods of mounting the accelerometer. Measurement of the Vibrations rations measurements can be measured in: + Displacement, + Velocity or + Acceleration. ‘The main difference is that there is a phase difference between the amplitude-time curves of the three parameters as shown in the drawing. Whether acceleration, velocity or displacement is to be the evaluating parameter depends upon the nature of the vibration, what information ‘you intend to extract and inherent transducer specifications. 32 The International Maintenance Seminar - 2002 MIDTH Institute™ Displacement: can be measured with a transducer having a specified use range from 0 up to Velocity: Acceleration Figure 19 shows the 3 quantitis 500-600 Hz. can be measured with a transducer having a specified use range from 10 up to 2000 Hz. there are no frequency restrictions regarding acceleration measurements Acceleration measurements also have the added adyantage that itis electronically possible to integrate the signal into velocity and displacement measurements, and their distinctions, Attenuation i [ dB FS Velocity (90° phase lead) Displacement Lo, Acceleration (180° phase lead) Acceleration, a a Velocity, v = fee 1 10Hz 100 7 kHz 10 700 Figure 19. Differences. Acceleration, velocity, displacement. 33 miIDTH The International Maintenance Seminar - 2002 Institute @ Characteristic Values Found in Vibrations Peak-to-peak value: indicates the maximum oscillation of the wave Peak value: indicates the level of short duration shocks, no account is taken for time history of the wave, Average value: takes time history into account but has limited practical interest RMS yalue (Root Mean Square): the most relevant when it both takes the time history of the wave into account and gives an amplitude value which is directly related to the energy content, ay ‘These characteristic values are shown in Figure 20. 34 a The International Maintenance Seminar - 2002 MIDTH Institute” — — — — 1 Avera: RMS Level. Level Peak Level Peak-to- Peak Level = (per RMS Level = \t$ xit}dt 7 Average Level = 1 J Ixidt | Peak Level oe Soe Average Level | RMS |_¥ Level Figure 20. Characteristic values found in vibrations. Cunt Atel MIDTH The International Maintenance Seminar - 2002 Institute” To give an idea what vibration level is good or bad: a good guideline is obtained which is an empirical German standard adapted as ISO standard, These limits are depicted in Figure 21 ‘Vibration severity Vin mis evaluation grade a7 oa 0128 Group K Group M ‘Group G ‘Group T Small Medium Large Turbo machines machines machines machines Figure 21. Standard for acceptable vibration levels. The International Maintenance Seminar - 2002 MIDTH Institute” Frequency Analysis The breaking down of vibration signals into individual frequency components is called frequency analysis. This illustrates the level of each specific frequency. According to ISO, standard frequencies are measured in Hz (Hertz), cycles per second. In USA they use CPM, Cycles Per Minutes, The frequencies of interest are: + the rotational frequencies of the shafis + tooth mesh frequencies and + bearing frequencies. All these frequencies can be calculated (ref. Encl. 1). Of interest is also the harmonic frequencies which means the double, triple (or more) of the calculated frequency. These are known as 2nd, 3rd, or 4th harmonic. They indicate misalignment and deformation on the teeth or bearings. The bearing defect frequencies which can be detected are: + outer ting + inner ring + rolling element. Because these frequencies could be very difficult to detect in the common “noise” in the spectrum a method called “envelope detection” or “enveloping” hes been developed. This method uses both the very high frequency (2-50kHz) content and the low frequency repetition of the bearing defect signal. The signal is first filtered so that only the high frequencies remain. The pulse’s energy contents then reduced, The intervals at which they ‘occur are still the same because the repetition frequency of the defect signal is not changed by the filuation. The result of the process is a low frequency signal containing the bearing defect frequencies. 37 MIDTH The International Maintenance Seminar - 2002 Institute” 7.3. Visual Inspection Oil Condition Dark oil means that the oil is dirty or too old. Foam on the surface impairs the effect of the EP (Extreme Pressure) additives in the oil. \Water in the oil is also very dangerous because water brakes the oil film between the teeth in the gear mesh, Oil Requirements Oil used for gear units is EP-oil, (Extreme Pressure additives) Viscosity should be: 320 or 460 ¢St Specifications for oil quality are listed in the AGMA 250.04 (American Gear Manufacturer Association), (ref, Enel, 3). A list of product names from the main international oil companies is listed in Encl. 2. Bearings Condition There are different kind of wear pattems. Look especially for abrasive wear and spalling, Check the clearance with a feeler gauge and make a comparison with previous measurements. Tooth Condition A vigilant tooth inspection program must be maintained. Here is a listing of the six most commonly occurring problems + Normal run-in or initial pittings are very small pittings which appear at the pitch circle during the first period of operation, They will disappear after some time + Destructive pittings are more severe and show first on the dedendum (under the pitch circle) of the teeth. The reason is always pressure which is too high, caused b 1, too soft material 2. misalignment 3. Incorrect tooth profile. 38 The International Maintenance Seminar - 2002 MIDTH Institute” + Abrasive wear is more than normal wear caused by abrasive particles in the oil. More advanced wear shows up first as scuffing, + Galling or scoring is an advanced state of scuffing. Scoring is progressive because the roughness in the ditection of sliding tends to cut through the oil film. It can be caused by misalignment, incorrect tooth profile, thin oil, low oil level orhigh operating temperature + Spalling is when pivees fall out of a fatigue ease hardened or nitrated tooth surface because of a load which is too heavy, + Broken-down profile appears when pittings have developed over a long period. This is the terminated stage (tooth profile damaged beyond limits for normal use). Those (as well as some other) types of tooth damage are shown in Figure 22 Nowa runin Destructive pitting ‘isatignmant | Abrasive wear Aawanessgatiog Spaling Figure 22. The different types of tooth damage. MIDTH The International Maintenance Seminar - 2002 Institute” CONCLUSION When choosing a maintenance strategy, the maintenance team must chose between whether the employed system is to be: + “run to breakdown” (corrective maintenance) + time based preventive + condition based maintenance This paper has concentrated on condition based maintenance, which is generally regarded to be the most modern method and within the economic range of most maintenance budgets. A condition based program can be initiated simply by monitoring temperature and vibrations as well as a vigilant, disciplined practice of visual observations. Temperature monitoring can easily be performed by using simple, commercially available resistant thermometers with different kinds of displays. Vibration monitoring requires slightly more sophisticated equipment, Besides the transducer (accelerometer), some data-logging equipment and frequency analysis equipment will be necessary. Measurement aggregates are available from many suppliers and at a reasonable price, As an altemative, a firm specializing in vibration measurements and interpretation of the results ean be engaged, Besides these wo aspec ual inspection program must be maintained in accorance with the guidelines as presented here. 40 The International Maintenance Seminar - 2002 MIDTH ee Institute” € Formulas Rotational frequency of shatt/pinion in Hz f=f kz Tooth mesh frequency in Hz 1, = RPM of shaft/pinion Z = Number of teeth on pinion é Formulas for bearing defects Zi R zxnxl,, f,, ==x—| 1-— «cose |= ———— 2° 60D, 60(1_, +0,) Defect on outer ring frequency in Hz n R zxnxO, {, == x= | 1+ -xcosa@ |= 2 60\ D, 60(I,, +O,) Defect on inner ring frequency in Hz _nx(,, +R) 60xR Defect on one roller frequency in Hz 2= number of rollers per row n= Innerring RPM 1, Inner ring outer diameter in mm. = — Outer ring inner diameter in mm. D,= Pitch circle diameter in mm. Roller diameter in mm. = Contact angle in degrees Q 73 a MmIDTH The International Maintenance Seminar - 2002 Institute” EP Gear Oil Oil Company Product Name BP BP Energol GR-XP 320 Caltex Meropa 320 Castrol Alpha SP 320 ® Chevron Gear Compound EP 320 Esso/Exxon Spartan EP 320 Mobil Oil Mobilgear 632 Optimol Olwerke Optio! Optigear BM 320 Shell Shell Omata Gil 320 ) Texaco Meropa 320 Tribol Tribol 1100/320 The oils mentioned above have the normally used viscecity 320 cSt. If a heavier oil is recommended the product name changes to 460 instead of 320 except for Mobil Qil which changes from the listed product name to Mobilgear 634. 2 Systematic and Preventive Maintenance of Gear Units for Mills and Kilns Mr. Peter Andersen INTRODUCTION “TYPE OF GEARS AND WORKING PRINCIPLE, + SYSTEMATIC MAINTENANCE. * PLANNING OF CONDITION MONITORING INTRODUCTION sACTIONS, *RECOMMENDATIONS. *PRACTICAL EXAMPLES. “DISCUSSION. *CONCLUSION. fen TYPE OF GEARS SPUR GEARS. HELICAL GEARS. HERRING-BONE GEARS. BEVEL GEARS. Hikers SPUR GEAR 27 a lL. HELICAL GEAR |. @ é HERRINGBONE GEAR. [Berens BEVEL GEAR WORKING PRINCIPLE SINGLE / DOUBLE / TRIPLE STAGE GEARBOXES. SIDE DRIVE GEARBOXES SYMETRO GEARBOXES PLANETARY GEARBOXES. mom GEARBOXES FOR KILN AND MILLS = i KILN: “MILLS: DOUBLE OR s E EEE TRIPLE STAGE, DOBBLE STAGE. SIDE DRIVE, SS uEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEel SYMETRO. PLANETARY, SIDE DRIVE Herons MAAG|PLANETAR’ GEARBOX “| FOR VERTICAL MILL [enon MAAG PLANETARY GEARBOX FOR BALL MILL [Emo ATOX GEARBOX FOR VERTICAL MILL eer i) LUBRICATION SYSTEM SELF LUBRICATING. CIRCULATION OIL PUMP. PUMP UNIT. lemons PUMP UNIT WITH. FILTER AND COOLER SAFETY SYSTEMS (1 OTL LEVEL. (® TEMPERATURE. Himon (5 )VIBRATION. - VIBRATION MONITOR: om fene SYSTEMATIC MAINTENANCE LOOK =VISUAL INSPECTION LISTEN =VIBRATION FEEL PERATURE Baw PLANNING OF CONDITION MONITORING +SYSTEMATIC MONITORING. “DAIL A “WEEKLY. ©

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