VRM reliability and protection concept -

Dalog as a preventive maintenance tool

© Holcim Group Support Limited 2010

 Objectives

 Everybody understands the basics of the concept

 Everybody understands the difference between

installation and integration of the monitoring system
 Everybody knows the purpose of a protection loop

 Everybody knows how to react on an anomaly reported

in a DALOG report

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 Agenda

 VRM reliability and protection concept

 Installation vs integration

 Protection loops

 Typical DALOG report (all )

 Typical DALOG reports (containing remarks)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 Protection loops 1/3

 Protection loops control critical parameters (e.g. the

torque at the input shaft of the reducer or vibration
levels) in such way that the mill can continue operation
as long as possible.
 Reduced throughput will be brought back to nominal by
either the operator (e.g. hydraulic pressure) or the HLC
(e.g. feed rate)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 Protection loops 2/3
General Protection Loop Actions - Loesche
PLC- DALOG
No. HAC Alarm criteria of output signal Value PCS Action
Input Settings
Torque Max (P01 Tmax) alarm if:
1 IX 106.2 xxx-2N1.10 2 < X1 < 3 X1 = 2.5 Reduce hydraulic Pressure setpoint by 10%
Torque peaks > Tnom * X1 for more than 2 seconds

Torque Average (P02 Tavg) alarm if:

2 IX 109.2 xxx-2N1.11 1.05 < X2 < 1.15 X2 = 1.1 Reduce hydraulic Pressure setpoint by 5%
Tav g > Tnom * X2

Torque Impact (P03 Timpact) alarm if:

3 IX 109.3 xxx-2N1.12 Torque peaks > Tnom * X3 more than 10 times per minute 1.6 < X3 < 1.8 X3 = 1.7 Lift rollers and stop feed
Indication for heavy vibrations
Torque Negative (P04 Tneg) alarm if:
4 IX 110.1 xxx-2N1.13 Reduce hydraulic Pressure setpoint by 10%
Torque peaks < -5 kNm more than 10 times per minute

Torque Dynamic (P05 Tdyn) alarm if:

5 IX 112.1 xxx-2N1.14 Reduce hydraulic Pressure setpoint by 10%
Torque fluctuations (PtP) > Tav g

Torque Average 2 (P06 Tavg2) alarm if:

6 IX 113.1 xxx-2N1.15 1.15 < X4 < 1.3 X4 = 1.2 Reduce hydraulic pressure setpoint by 7%
Tav g > Tnom * X4

Torque Impact 2 (P07 Timpact2) alarm if:

7 IX 113.2 xxx-2N1.16 Torque peaks > Tnom * X5 more than 10 times per minute 1.8.< X5 < 2.0 X5 = 1.9 Lift rollers and stop feed
Indication for heavy vibrations

8 IX 113.3 xxx-2N1.17 Watchdog

Tnom = nominal torque at reducer inlet

Tav g = average torque over one minute at reducer inlet

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 Protection loops 3/3

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG Report (all )

 The following pages show a typical DALOG report,

Condition Flags in “Gearbox Condition Display” all
green.
 Points to observe:
 Gearbox Condition Display
shows a section of the gearbox and gives a summary in colors
 Condition Summary Comments
gives clear statements on the condition of the gearbox. Any
anomaly observed is described under “6. Remark”.
 Sensor Readings
 Mill Operation Parameters
 Torque Alarm Events

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG Report (containing remarks)

 The following pages show a typical DALOG report,

some Condition Flags in “Gearbox Condition Display”
are in other colors than .

 Points to observe
 Condition Summary Comments
gives clear statements on the condition of the gearbox. Any
anomaly observed is described under “6. Remark” and refers to
specific pages in report.
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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept
 DALOG report (all green)

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© Holcim Group Support Limited 2010 VRM reliability and protection concept