HIGH TECHNOLOGY IN THE SERVICE OF THE CEMENT INDUSTRY · PDF fileHIGH TECHNOLOGY IN THE...

HIGH TECHNOLOGYIN THE SERVICE OF

THE CEMENT INDUSTRY

SPECIFIC LUBRICANTS

MAINTENANCE PRODUCTS

FIELD TECHNICAL ASSISTANCE

PERSONAL ATTENTION AND TRAINING

Kra�tPolymers & Fluids

KRAFFT PRESENTATION FOR THECEMENT INDUSTRIES

LUBRICATION OF GEARS


Index1 LUBRICATION OF GEARS

2 TECHNICAL ASSISTANCE PROGRAM FOR GEARS

3 APPENDIX

• Geometry:Thegeargeometrychangeswiththedifferencesbetweenassemblyandworkingtemperature(speciallyinkilns),withloadorunloadequipment.

• Flank roughness:Withvaluesnear50microns,becauseofthecomplicatedmanufacturingprocessesduetothebigsizeofthegears.

• High and changeable slide speed:(From0toseveralmeters/second).Thisgeneratesconsiderabletemperatureincreasesanddoesnotallowahydrodynamiclubricatingfilmformation.

Kiln and mill geared by pinion (single or double) - girth gear system are widely extended due to the advantages they provide.

From the lubrication point of view there are several factors that allow a good operation under low wear and with long duration.

IMPORTANT FACTORS FOR GEAR LUBRICATION :


LUBRICATION OF PINION-GIRTH GEAR FOR KILNS AND MILLS

• High peripheral speed (mills):Itproducescentrifugationeffect.

• Hard working condi-tions:Underimpacts,vibrations,dustyatmos-pheres,etc.

· Kilnandmillgearsarealwaysworkingunder mixed lubri-cationconditionswheretheproportionsoflimitandhydro-dynamiclubricationdependonthedesignandcinematiccharacteristicsofthegear.

· Duringtherunning-inofthesegearsandasaconsequenceofthehighroughnessoftheattackflanks,wecanpracticallyassumethereisnohydrodynamicareacarryinganyload.

· Thequickgears(mills)workwithahydrodynamiccarryingareahigherthantheslowgears(kilns).Thekilnsworkpracticallyinaconstantlimitlubricatingsituation.

· Thethicknessofthefluidlubricatingfilmlocatedatthenonslidingarea(pitchdiameter)canbecalculated.Thisthicknesswillgiveusthemini-mumviscosityrequiredbythelubricanttobeused.

· TominimizetheeffectsofthelimitlubricationasmuchaspossibleisnecessarytoincludeAntiwear, E.P.andsolid(Graphite,MoS2)additivesinordertoreducethewearintoacceptablelevelstoreachasatisfactoryworkinglifeofthegear.

Allthesecharacteristicsandmanyothersmakedifficulttheformationofahydrodynamiclubricatingfilm.

Ifwecouldbeabletoprovidealubricating film thicker than the roughness height,itshouldavoidanymetal-metalcontactinthegears.Inthissituationtheproblemcouldbesolvedbyselectingalubricantwiththeproperviscositysuitableforthedifferentloads,speeds,roughness,etc...

· Averyimportantaspectistofindalubricatingsystemthatreducestheinitialroughnessofthegearcarryingarea.

During the first working hours,thepossibilitiesofhydrodynamiclubricationaresmallerduetothesizeofthesurfaceroughness.Atthismomentitiscriticaltoselecttheadequateproductsandmethodsto improve the carrying areaofthegearsandreduce the irregularitiesofthesurfacetominimumvalues.-

· Forgettingaproblemfreegearduringtheserviceitisnecessarytotakeinmindthefollowingfactors:

*Duringtheconstructionandassemblyofthegears,toreduceasmuchaspossiblethemisalignment,thevibrationsandtheassemblyclearanceserrors.

*Duringthestartingup,togetacorrectcarryingareaformation,tore-duceasmuchaspossibletheroughnessoftheflanksandtoselectalubricantdistributionsystemadequatetothegearrequirements.

Because only flat and well aligned carrying surfaces are able to combi-ne big loads and low wear conditions.

-Itisalsonecessaryagoodafter-assemblymaintenanceserviceofthegearanditslubricatingsystem.Theproperselectionandsprayingregulationofthelubricantwillguaranteethelonglifelastingontheseinstallations.

However and because of the special working specifications of these big gears we can conclude the following points:


• Topreparespecial productstofulfilthehere-abovementionedrequirements.

• Todesignwelldefinedrunning-in methodstoreducetheinitialroughnesssurfaceinorder:

· Toprovidetothegearthebiggestpossibleloadcarryingarea.

· Togetthehighesthydrodynamiclubricationareawiththethinnestlubricantfilm.

CONCLUSIONS: All the above mentioned factors led us to the following actions:

V V V

h

Boundary Lubrication

www.substech.com

FMixed Lubrication

FHydrodynamic Lubrication

F

Lubrication regimes

Coe�

cien

t of f

rictio

n Stribeck curve

Bearing parameterŋN/Pav



0 PROCESS PHILOSOPHY

RUNNING-IN OF MILL AND KILN GEARS

It exists different processes to perform a running-in, or in other words, to increase the carrying area. We will speak about 2 processes: one used by most of the lubricant manufacturers, and the other one used by KRAFFT.

FIRST PROCESS

Thefirstideathatcomesinmindisto cut the crestsoftheroughnessandtheprofileimperfection.Soforthatitisnecessarytoincludeabrasiveparticlesintherunninginlubricants.Ineffectthankstotheseabrasive particles,thecontactareaisincreased,butthisprocesspresentdifferentdisadvantages:

• Iftherunningingreaseispulverized,theabrasiveparticleswillcausewearinallthesprayingsystem:thepump,thedistributorvalves,thenozzles…

• Theparticlesarecausingwearonthegearsthemselves.Sotheuseofthiskindoflubricantmustbeverycarefulandlimitedinthetimeinordertonotshortenthegearlife.

• Iftherunningingreaseisusedfordiplubrication,thesumpmustbecleanedverycarefullybeforeusingtheservicegrease:tobesurethatnoabrasiveparticleisleftinit.

• Thelastpointisthattheabrasiveparticlescausesomemicroscratchesonthesurface;thesecancreatelocalstressconcentrationandconse-quentlymetalfatigue.Thisfatigueeventuallycausespitting.

SECOND PROCESS (used by KRAFFT)

ItsphilosophyhasbeendevelopedinthefortieswhenfirsttheMoS2(disulphideofmolybdenum)hasbeendiscoveredandusedassolidlubricant.Thismaterialismoreresistantthanthesteel,soitwillwithstandathigherloadsthanthesteel.Usingthisproperty,wecanprotectthemetallicsurfacewithalayerofsolidlubricant.Sowiththehighloadofthecontactbetweenmatingflanks,thecrests(andotherprofiledeformationcreatingalsoalocalhighload)willbedeformedplasticallytillthecontactsurfaceisincreasedandthecontactpressuredecreased.

Sowecansaythatthisrunninginprocessworksbyplastic deformationofthemetalprotectedbyasolidlubricantlayerthatavoidsanyseizing.

Soobviouslythisrunningingreasedoesnotcontainanyabrasiveparticlesandnotonlythat:itmustprovidelubricantcharacteristicssuperiortothegreaseusingthem.Forexampleatypicalsolutionforthefirstprocesswouldbetouseanotverypuregraphite,i.e.theimpuritiespresentinitwilldotheabrasivejob.Onthecontrary,ourshastocontainahighlypuregraphiteasintheservicegreaseand,furthermore,tohighlyincreasethesurfaceprotection,weaddeddisulfideofmolybdenumwhichhasasynergiceffectwiththegraphite.

Thankstothe lack of abrasive particle,wehavethenfollowingadvantagesusingthisprocess:

• Iftherunningingreaseispulverized,thereisno forced wearonthespraysystem(pump,distributorvalve,nozzles…).

• Thereisno forced wearonthegearflanks.

• Thisrunningingreasecanbeusedalong timewithoutdamagingthegearbyexcessivewear.

• Ifthegreaseisusedfordiplubrication,firstthereisnoneedtosubstitutequicklythisgreasebytheservicegreaseandsecondthereisno need for sump cleaning.

• Thelastadvantagecomesfromthesurfacefinish:iftheabrasivesparti-clesarecausingmicroscratchesonthesurface,thisplasticdeformationcreatesasimilareffecttoacoldrollmillingofsteelsheet.Theresomekindofsuperficial hardeningthatincreasesthesurfaceloadresistan-ce.Andconsequentlythesurfacewillhaveanincreasedresistancetofatigue,soan increased resistance to appearance of pitting.Sowiththiskindofprocess,wecanexpectthatthegearlifeislonger.


Before starting the running in process, we recommend some preliminary inspections:

• Towritedowneveryinformationaboutthegears(numberofpinionandgirthgearteeth,module,diameteretc...).

• To markthreegirthgearteethlocatedmoreorlessat120ºandthreeteethofeachpinion. Theseteethwillbeusedasareferenceforthecorrectalignmentandtheevolutionofthe

settlement.

• Toguaranteethelackofabnormalroughnessanddamagesinthepinionandgirthgearsurfacesbyacareful check.


2 PRIMER PASTE APPLICATION (Pre-Treatment)

In order to create a first solid lubricant layer on the flanks to avoid any contact metal-metal, we recommend to apply a paste with a high content of solid lubricants on the teeth.

PRODUCT Lubekrafft® G Paste

Accordingtoourexperience,empirically,thequantityofpastetobeusedis:

Q(in kgs.) = 0.9 x b x m x N x 10-3

b=wideofthegearteeth(incm.).

m=module(incm).

N=Numberofgirthgearteeth+numberofpinionteeth.

QUANTITY

PROCEDURE to APPLY :

1. Tocleananddegreasecarefullythefullgearusingproductswhichdonotleaveoilyresidues.

Ausefulsystemis: · Cleanfirstlywithdieselfuel. · Makeasecondcleaningwithtrichloroethyleneorsimilarto

removeoilyresidues.

2. ToapplyLubekrafft®GPastewithahardbrushtothegearsurface.

3. TosettletheLubekrafft®GPastefilmbyrubbingusingarotatingmachineprovidedwithachamois,leatherorsimilarthatdoesnotleavehairoranyotherresidue.

4. Toturnthegearswiththeauxiliarymotorforsomelaps.

5. Toturnthegearsduring5-10minuteswiththeauxiliaryengine.ApplytheLubekrafft®GPastetoreplacepotentialproductshor-tages.

6. Torepeatthepoints2,3,4and5twice. Thepoint6iscritical,becausewegetafirstroughnesssquas-

hingwithoutoverloadingthegear.Asaconsequencethegearispreparedtocarrybiggerloadingsurfaceinthenextrunning-inoperation.

AnotherimportantaspectofusingLubekrafft®GPasteisthepossibilityofobservingtheessentialpinion-girthgearalignment:lookingtothepatternoftheprintofthecontactonthegirthgear,thealignmentcanbechecked(fig.1).Andaccordingthepattern,someconclusionscanbeobtainedabouttheassemblyproblemifitexists.

Seethefollowingpageforexamples.


1 PRELIMINARY INSPECTIONS



PRINT ON THE GIRTH GEAR REFLECTING THE ASSEMBLY

a) Loadpatternonthegirthgear(perimeter)whenthepinionwarps(twists).

b) Loadpatternduetothegirthgearoscillation.

c) Loadpatternononeend:misparallelismbetweenbothaxles.

d) Circumferentialloadduetoamanufacturingdefectorathermaldeformation.

e) Loadpatterncausedbyapinionenlargedonbothendsduetoapressfitassemblytoostrong.

f) Loadpatternduetoamisalignmentbetweenbothpartsofthegirthgear.

g) Loadpatternduetoamisalignmentofonlyonegirthgearhalf.

h) Loadpatterncausedbyagirthgeareccentricity.Theimageappearmoreorlessstrongdependingontheoutofroundposition.

i) Loadpatterncausedanabnormalfrictionheatingonthecoatingjoints.

Pinion

GirthGear

Fig: 1

π x D




Ingeneraltermsitcanbesaidthat100gr/hourpernozzle(ifthewidthsprayedbyonenozzleisaround150-200mm;ifnot,changethevalueaccordingly)isenoughquantityforkeepingasufficientlubricationintherunning-inperiodandassuretheprogressivepinion-girthgearsettle-ment.Thiswillguaranteealoadcarryingsurfaceof90%approx.

Ifweconsiderthedurationofarunning-inperiodin300hoursaverageandwehavedoublepiniongearswith8-10nozzles,thequantityofKGP-2/PEgreaserequiredshouldbearound:

PRODUCT KRAFFT KGP-2/P E

Accordingtoourexperience,empirically,thequantityofpastetobeusedis:QUANTITY

240 kgs. - 300 kgs.

Inanycasethecriterionofthegearmanufacturerisveryimportanttodetermineboththenecessaryapplyinghoursandtheminimumquantityofrunning-ingreaserequired.

Incaseofmissinginformation,wewouldconsiderthattherunning-inprocessisfinishedwhenweget80-90%ofcarryingareaat100%millload,witharegulardistributionalongthetoothwidthandasatisfactorysurfacefinish.

PROCEDURE to APPLY

1. Cleanthewholelubricationsystem(pump,filters,nozzles,etc.).

2. FillthegreasingsystemwithKGP-2/PEgrease.

3. Checkthatthespraytrace(print)andthenozzleflowagreewiththespecifiedparameters.

4. Turnthegearatleastduring30minutes.Bythiswayweguaranteethetotalimpregnationofthegearwiththerunning-inlubricant.

5. Turnthemillwiththemainengineatnormalworkingspeedduring2hoursandtestthemarkedteethforcheckingtheirevolution.

6. Ifthepreviouspointiscorrectwecanconsiderthatthegearisreadytofinishthefullsettlementprocess.

MILLS LOADING SEQUENCE:

Asanexamplewecanindicateasequenceforloadingmills.Thissequencegivesverygoodresultsaccordingourexperience.Inanycaseisveryimportanttoknowthecriterionofthegearmanufacturer.Note:itisimportanttoloaddirectlyat100%newgears:asthecontactsurfaceissmallatthebegin,itwillcreateanoverloadandconsequentlyitcoulddamagethesurfaceandcauseanearlyappearanceofpitting).

Mill loading Working hours

40-60% 50-60hours

60-80% 100-120hours

80-100% 150-170hours

3 RUNNING PROCESS



INSPECTIONS:

Itisnecessarytomakeadetailedinspectionofthegearteethsituation(speciallythosemarkedasareference)every24millworkinghoursandeverytimetheloadisincreased.

Besidesthesecarefulinspectionsitwillbenecessarytocheckalignment,carryingareaevolutionandteethtemperatureatleastevery:

KGP-2/P-E GREASE CONSUMPTIONFor Running-In (Consideringcontinuousspraying)

FIRSTSIXHOURS: Every2hours

FOLLOWINGTWELVEHOURS: Every4hours

FOLLOWINGTWENTY-FOURHOURS: Every6hours

FOLLOWINGTWENTY-FOURHOURS: Every8hours

RESTOFRUNNING-INPROCESS: Every12hours

10 gr/h.cm for Millwith2pimions

7,5 gr/h.cm for Millwith1pimionorKilnwith2pinions

5 gr/h.cm for Kilnwith1pimion

TEETH WIDTH (mm)




The running-in process could be considered achieved when:

• weget80-90%ofcarryingarea

• at100%millload,

• witharegulardistributionalongthetoothwidthand

• asatisfactorysurfacefinish.

APPLICATION:

1. FillthelubricationsystemwiththeKRAFFTregulargearlubricantKGP-2/Pgrease.

2. Turnthegear24hoursminimum,keepingthenozzleflowatthelevelsindicatedfortherunning-ingrease.

3. Reducethenozzleflow,ifthereisnotnegativeevolutionintheteethsurface,to80gr/h.pernozzle(ifthewidthsprayedbyonenozzleisaround150-200mm;ifnot,changethevalueaccordingly).

QUANTITY :

Wecanusefollowing“rule”toestablishtheKGP-2/Pregulargeargreasenecessaryquantity:

• Doublepinionsturningamill 8grs/h-cmoftoothwidth.

• Singlepinionturningamillordoublepinionturningakiln 6 grs/h-cm. of tooth width

• Singlepinionturningakiln 4 grs/h-cm of tooth width.

TheconsumptionofregulargearlubricantKGP-2/Pin24hoursserviceandrelatedtotoothwidthcanbeobservedinthefollowinggraphic.

4 REGULAR GEAR LUBRICATION



KGP-2/P GREASE CONSUMPTION(Withcontinuoussprayingconditionstartingconditions)

8gr/h.cmforMillwith2pimions

6 gr/h.cm for Millwith1pimionorKilnwith2pinions

4 gr/h.cm for Kilnwith1pimion

TEETH WIDTH (mm)




4 REGULAR GEAR LUBRICATION

LUBRICATION WITH INTERVALS

ThelubricationwithintervalsisusedwhenwewanttoreducetheconsumptionofregulargearlubricantKGP-2/P.

Theinstructionstofolloware(IMPORTANTNOTE:assumingthattheinstanta-neousnozzleflowisaround80grperhourandpernozzleifthesprayedwidthisaround150-200mmoraflowadjustedaccordinglytoanotherwidth).

A CYCLE WITH A SPRAYING TIME SHORTER THAN 1/4 OF THE CYCLE TIME WITH A PAUSE TIME LONGER THAN 3/4 IS NOT RECOMMENDED.

(Forexampleshorterthan1’sprayingandlongerthan3’.Note:thisisalwaysassumingtherecommendednozzleflow:80grperhourandpernozzleifthewidthreachedbythenozzleisaround150-200mm)

Attachedagraphwithtypicalconsumption.Thesevaluesarejustforgeneralorientationbecausetheconsumptionshouldbeadjustedforeachmachine.Obviouslygearswithwear,misalignment,vibrations…willrequiremorelubricant.

NOTES:Tochoosethecycletimedependsonthesprayingsystemitself,butitexiststwomainsrecommendedrules:

1. Theidealshouldbetohaveacontinuoussprayingwiththecorrectconsumption,butusuallyitisnotpossibletospraytosuchalownozzleflow.

2. Theminimumrecommendedsprayingtimeshouldbeatleastthetimeforonerevolutionofthemillorkiln(forexampleifthekilnrotatesat1.5rpm,theminimumsprayingtimeshouldbe40”+asafetymargin);formoresafetyasprayingtimecorrespondingtoatleast2to3rotationsissuitable;

3. Itisbettertohaveashortcycletimethanalonginordertoavoidalongtimewithoutlubrication(forexample1’sprayingtimewith2’pauseisbetterthan5’sprayingtimeand10’pause).

1. Keepconstantthepumpandnozzleflow.Starttheintervalprocesswith80%ofthecyclesprayingand20%pause (forexample1’spraying-4’pause).Keepthisprocessforatleast24hoursservice.

2. Ifthereisnonegativeevolution,wecancontinuedecreasingthesprayingtimeand/orincreasingthepausetime. Keepeverynewcycleforatleast24hoursservice.

3. Iftheevolutionispositive,wecancontinuethisprocessuptoto1/3ofthecycletimesprayingand2/3pause (forexample1’spraying-2’pause).

4. Forahigherreductionofthelubricantconsumption,thesameprocedurecanbefollowedbutincreasingthepauseintervalslittlebylittle.



KGP-2/P-E GREASE MINIMUM CONSUMPTIONConsidering1/3sprayingtimeand2/3pausetime

2,7 gr/h.cm for Millwith2pimions

2,0 gr/h.cm for Millwith1pimionorKilnwith2pinions

1,3 gr/h.cm for Kilnwith1pimion

TEETH WIDTH (mm)

TECHNICAL ASSISTANCE PROGRAM FOR GEARS



TECHNICAL MEANS

The program is different according the gear life phase:

Running-in:

• PresenceatthelocalandworkingroupwithCementIndustryMaintenanceTeamandtheEngineeringassemblyTeam.

• Running-inprocesswhenitisrequiredbythecustomer.

Follow-up:

• Unlessitisagreedwiththecustomer,thegeneralinspectionwillbedoneonceperyear.Thisinspectionwillcoverthegearsandthegrea-singsystems(seeattacheddocument).

Repair:

• KRAFFTTechnicalAssistanceTeamisreadytocollaborate,ifitisnecessaryandifthecustomerrequestsit,inthecorrectionofanyinciden-cehappenedonthegear.

Thistechnicalserviceisofferedfree of chargetoourcustomers.

KRAFFT, S.L. owns the necessary technical means for giving an adequate Technical assistance for gears, as follow:

• Stroboscope4911(BRÜEL&KJÆR).

• Portablestroboscope4912(BRÜEL&KJÆR).

• Vibrometer2513(BRÜEL&KJÆR).

• Photoelectricprobe(BRÜEL&KJÆR).

• HeadphonesandamplifierWQ0623(BRÜEL&KJÆR).

• DigitalthermometerTMDT-1andProbeTMDT1-30(SKF).

• InfraredthermometerRAYTEK,RayngerPM30type.

a) Dynamicinspection:whentheequipmentisrunning

1. Vibrations:wemeasurethevibrationsonthepinion’sbearings,inthethreedirec-tions:axial,horizontalandvertical.

ThemeasurementismadeinagreementwiththeISO3945:Mechanicalvibrationoflargerotatingmachineswithspeedrangefrom10to200r/s–Measurementandevaluationofvibrationseverityinsitu.

ThisstandardisspecifyingtheseverityforglobalvalueofRms,takenintotherangeof10and1000Hz.Wemeasurealsothepeakvaluesinordertocheckwhetherthereareshocksornot.

TheseveritytableofthestandardisgivingthefollowinglimitsfortheRmsvalues

Upto1.8mm/s:good From1.8upto4.6mm/s:satisfactory From4.6upto11.2mm/s:unsatisfactory Above11.2mm/s:unacceptable

Ateveryvisit,wemakethemeasurementwhatallowsafollowupoftheevolutionwhatisatleastasimportantasthevalueitself.Anincreaseisshowingapossibleproblem.

Here below a graph’s example.

2. Temperature:wemeasurethetemperatureallalongtheteethtocheckthealignmentbetweenthepinionandthegirthgear.

Ahighertemperatureindicatesahigherload.Thereforewemeasurethetemperatureon3or5pointsalongtheteeth:pinionandgirthgear.

Tohaveagoodalignmentthetemperaturesshouldbesimilarallalongoralittlebithigheronthemiddleastheheatexchangeislessonthisareathanontheends.

Foranacceptablealignment,theΔTbetweentheendsshouldbe≤3ºC.AΔTbet-weentheends≥7ºCrequirerealignment.Withavalueinbetween,itwilldependonthefacilitytorealign.

Herebelowsomeexamplesofacceptableandnonacceptabletemperaturepattern:

3. Visual inspection:withastroboscopewecheckthecontactbetweenthematingteethandalsothestateoftheflank:pitting,scoring....

Thankstothemarksoftheimpregnatedgraphite,indicatingahighload,itispossi-bletoverifythealignmentandconfirmthetemperaturepattern.Onthegirthgear,itallowsustocheckwhetherthereisalsoanaxialorradialmisalignment.

Althoughthegreaseisblack,itallowsalsotoseesomedefectsontheflanklikepitting,scoring,seizing...



WHAT IS THE INSPECTION?

Acceptablealignment

Misalignmenttobecorrected50ºC 51ºC 53ºC 52ºC 50ºC 50ºC 52ºC 55ºC 54ºC 53ºC 50ºC 51ºC 53ºC 55ºC 57ºC

VIBRATIONS: CEMENT MILL Nº2RightPinion-Millside

mm/s RMS

b) Staticinspection:afterstoppingtheequipment

1. Defects:Itisagoodpracticetoturnslowlytheequipmentwiththeauxiliarymotorinordertohavealookonalltheteeth.Wecanthenstopwherethedefectsarethebiggest.

Afterstopping,weclean(withsolvent)afewteethandwecheckthemfordifferentpointsofview:

Defects:pitting,definingthesizeanddepth,thescoringorseizing...

Flow of material:wecheckthepresenceofcrestontheheadoratbothendsindi-catingaflowofmaterial.

Surface finish:whetheritisroughornot.

Wear:innormalconditionstheweariscreatingastepneartheroot.

Contact line:ithelpstoseethecontactbetweenthematingteeth.Anyotherdefectshouldbealsoreportedandanalysed.

2. Spray pattern:thespraypatternshouldbecontinue,withoverlappingbetweeneachnozzle. Inorder tohavea truepattern, theplateorpapershouldbeplacedat thesamedistancefromthenozzlesthattheactualdistancebetweenthemandthetoothflank.Examplewith4nozzles:

3. Position of the nozzles: thedistancebetween thenozzlesand the toothflank isusually 200mm (this distance can adjustedby having a good spray patternwithcorrectoverlapping).Anywaywerecommendtofollowtheinstructionsofthesprayingsystemmanufacturerforthedistance.Buttheanglewearerecommendingshouldbealwaystrue,independentlyofthemanufacturer.Iftheangleisbiggerthan30º,thegreasewillbesprayedonthetopoftheflankorevenabovetheflank;iftheangleissmaller,thegreasewillbesprayedatthebottomoftheteeth.




WHAT IS THE INSPECTION?

4 nozzles

Tooth flank completely cobered by grease

Sheet of carton or

steel

4. Nozzles orientation:thenozzlesshouldbeorienteddownwardsormaximumhori-zontally,butneverupwards.Itisnotrecommendedatalltoworkagainstthegravity:thegreasewillhavemoredifficultiestoreachtheteethflank,andeventhegreasecanfallbackonthenozzles,cloggingthem.

5. What gear to lubricate:althoughtolubricateonlythegirthgearisnotforbidden,itisstronglyrecommendedtolubricatethepinioninsteadofthegirthgear.Ifthereare2pinions,itismuchbettertolubricatebothpinions.

6. Grease consumption:althoughtheconsumptioncouldbeeasilyknownbythetimeto use a drum, it is a good practice to check sometimes to time the flow at thenozzles:itcouldbedonenozzlebynozzlebyputtingaglassinfrontofeachnozzleandweightingthegrease(to increasetheprecision, it isbetter tomeasureduringafewcycles).Theotherwayistotakethespraypattern,duringafewcyclesalso,measuringtheweightofthegreaseonthecarton.



Not recommended nozzle orientation

Recommended nozzle orientation

DRIVE

Manufacturer: Starting Date:

Machine: Raw Mill, Cement Mill, Kiln

Pinion Single Double

Gear Spur GearHelical Gear

Power kW

Production



CEMENT INDUSTRY REPORT

DATACOMPANY NAME:

DATE:

GENERAL INFORMATION:

CHARACTERISTICS:

MECHANISMS

Ring Gear Primitive Diameter mm

Ring Gear Teeth Number (Zc)

Module (M) mm

Pinion Primitive Diameter mm

Pinion Teeth Number (Zp)

Pinion Width (bp) mm

Ring Gear Width (bc) mm

Pressure Angle (α)

Starting Date:

Girth Gear - Turned? YES NO DATE:

Pinion 1 - Turned? YES NO DATE:

Pinion 2 - Turned? YES NO DATE:

LUBRICATION SYSTEM

Type Spray Dip

Grease Manufacturer

Grease Name

Nozzle Number

Pump Manufacturer

Spraying Time

Pause Time

Approximate Consumption



INSPECTION

1. Vibrations

WiththemillrunningandwiththevibrometerBRÜEL&KJÆR2513,wehavethefollowingvibrations,inmm/swithapassingbandbetween10Hzand1000HzasrecommendedbytheISOStandard3945forLargeRotatingMachines.Themeasurementsaremadeinthe2pinionbearings.

VERTICAL HORIZONTAL AXIAL

Peak Rms Peak Rms Peak Rms

Pinion 1EngineSide

Pinion 1MillSide

Pinion 2EngineSide

Pinion 2MillSide

2. Contact line

RunningandwiththestroboscopeBRÜEL&KJÆR,weexaminethecontactline:

Pinion1 __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

Pinion2: _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

GirthGear: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

___ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

3. Teeth Temperature

Withtheinfra-redthermometer,wetakethefollowingtemperatures:

Pinion 1

Pinion 2

RoomTemperature:____

____ ____ ____

____ ____ ____



STATIC INSPECTION

1. Reference tooth

Withthemill/kilndrivenwiththeauxiliaryengine,weinspecttheteethtolocatetheworsttooth.Oncelocatedandstopped,wemarkthepinionshaft,onthefreeend,withnumber......inthetopverticalpositionandalsothetoothheadwiththesamenumber,inordertobeabletolocatethetoothforthefollowinginspections.Takepictures.

2. Spray pattern

Withapaperwiththesamewidthoftheteeth,wetaketheprintofthepulverizationsystemduring......minutes.Takeapictureafter.

3. Grease consumption

Wetake.......plasticglassesandidentifythemwithnumber1to....Weputeachglassinfrontthecorrespondingnozzleandwerunthepulverizationsystemduring15minu-tes.

4. Visual inspection:

Cleantheteethwithragandsolventandinspect:

Pinion 1 and 2

Mesh trace:

Teeth aspect (Pitting,Scoring,Galling,Cracks...)

Flank:_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _RootStep: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _HeadCrest: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _EndsCrests: _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

Girth Gear

Mesh trace:

Teeth aspect (Pitting,Scoring,Galling,Cracks...)

Flank:_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _RootStep: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _HeadCrest: __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _EndsCrests: _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _


CORRECTIVE ACTIONS __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

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• LUBRICANTSforBIG OPEN GEARS of COAL, RAW and CEMENT MILLS and for ROTATING KILNS

WITH GRAPHITE

• Lubekrafft® G Paste:primingpasteforrunning-inand/orrepair

• KGP-2/P-E:sprayablerunning-ingrease

• KGP-2/P:sprayableservicegrease(baseoilofISOVG1000)

• KGP-2/PLEX 1500:sprayableservicegrease(baseoilofISOVG2500)

• KGP-2/F:servicegreasefordiplubrication

• KGP-2/M:servicegreaseformanuallubrication

GRAPHITE FREE

• KGP OIL 6:servicelubricant:highlyviscoustransparentoil

• LUBRICANTforKILN LOOSE TYRES

• KROIL SPECIAL RING: graphite suspension in water

• LUBRICANTforROLLER PRESS BEARINGS (also for vibrating screen bearings, splined shaft coupling…)

• KL COMPLEX 2000

Theselubricantsareonlypartofourextendedrangeoflubricants,buttheyarethemostspecializedandsuitableonestocementplants.

ANNEXES

SPECIALTY LIST OF THE PRODUCTS


KRAFFT S.L.U.Carretera de Urnieta s/n20140 Andoain · SPAINTél.: (34)943 410 400 - Fax: (34)943 410 430Email: [email protected]

CERTIFICADO Nº. 1937983/12 CERTIFICADO Nº. 1937983

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