MAAG Gear AG August 09 The mill’s gearbox MAAG Gear: A pioneer of modern gear technology.

MAAG Gear AG

August 09

The mill’s gearbox

MAAG Gear: A pioneer of modern gear technology

MAAG Gear AG, CH-8404 Winterthur. We reserve all rights in connection with this document. 2

1913 Foundation of MAAG Zahnräderfabrik in Zurich, Switzerland

1927 Start of internationalisation (MAAG Italy, MAAG France, etc.)

1989 Foundation of MAAG Gear AG, Switzerland

1997 Acquired by FLSmidth

2000 Acquisition of factory in Elblag/ Poland

2003 Move to Winterthur, Switzerland

2007 Sales of marine and turbo business

2009 Move into City of Winterthur

MAAG Gear on the move


MAAG Gear is a leading global player and belongs to FLSmidth since 1997

Engineering, sales, marketing and project management in Winterthur

Production in Poland and Winterthur Quality ISO 9001 certified More than 90 years of grown expertise

Facts


Figures 2008

Turnover: 115 mio CHF Production capacity 80 –100 gear units Employees: 280

Engineers: 105 Technicians: 78 Service: 30 Administrative: 45 External Assistance: 14 Trainees: 8


Engineering experts Gearing technology - parallel gears Gearing technology - bevel gears Metallurgy FEA Antifriction bearings Journal bearings Toothed couplings Acoustics/vibration analysis CAD/PDM Integrated Logistic Support (ILS) /

Reliability Availability Maintenance (RAM)

Supporting tools CAD / Solid Works PDM-Systems / Team Center Ansys for FE-Analysis Various tools for material analysis MAAG Gear-developed program systems

representing the unique experience of generations of gear exports

Collaboration with our customer Cooperation with universities and research

centers

Know-how in engineering and technology


MAAG Gear, a member of FLS since 1997

FLSmidth & Co.

MAAG Gear

FLSmidth Project Division

Cement

FLSmidth

FLSmidth Customer Services

FLSmidth Airtech

Pfister

Ventomatic

Dansk Eternit Holding

Minerals

FLSmidth Minerals

FLSmidth Minerals Division

FLSmidth Dorr-Oliver EIMCO

FLSmidth Krebs

FLSmidth Buffalo

FLSmidth Koch / MVT

FLSmidth Möller

Excel Foundry & Machine

FLSmidth RACHO

FLSmidth ABON


Driving equipment for the cement industry


CPU/CPV/LGDCemet mill

Cement processes driven by MAAG Gear

WPU/WPVRaw mill

PPURoller Press

WPUCoal mill


Driving equipment for the cement industry

Ball mills lateral drive

LGD

Ball mills central drive

CPU/CPV

Roller mills vertical drive

WPU

Roller mills vertical drive

WPV


Benefits to customer High operational reliability Efficiency exceeds 96.5% Customers-specific design of gear units Very high efficiency Planetary stage and thrust

bearing for grinding table with very long service life

Low-cost maintenance

Technical overview Fully developed compact two-stage design

(bevel gear / planetary gear stage) Case hardened or hardened and quenched tooth Bevel gear stage with its own casing Thrust bearing mill table hydro static and hydro

dynamic lubricated Power: 250 to 6,000 kW

Roller mills drive, 2-stage (Type WPU)


Roller mills drive, 3-stage (Type WPV)

Benefits to customer Torque split for compact design Flex pin solution for optimized load distribution Efficiency exceeds approx. 95 % Slide bearing application in bevel and planetary

gear stage Simple mechanism for assembly and adjustment

of bevel gear stage without remove the gear unit

Technical overview 1st stage 3 planets, 2nd stage 5 planets Toothing case hardened or quenched and

tempered Thrust bearing mill table hydro static and hydro

dynamic lubricated Power: 2,500 to 9,000 kW


24/7 Hotline Tel +41 79 619 91 00Troubleshooting

Experienced and skilled service engineers Timely managed

Installation and commissioning

Preventive Monitoring / short reports Assessments Service plan agreementOverhaul Planning and project management Execution and support

Maintenance

Installation / Maintenance


Better performance for longer periods Guaranteed productivity and profitability Continued customer satisfaction Enhanced reliability

Vibration and operating readings Material analysis and monitoring Advisory opinion

Expert reports

During installation and commissioning In house / in MAAG Gear workshop Tailor-made On-site

Customer training

Support

Service packages


Mill thrust bearing

Thrust pads Thrust bearings lined with babbitt metal

WPU: The Gear Drive System


Roller Mill

Mill thrusts

Annulus

WPU gear reducer

The WPU Gear System


Schematical Design Concept

Spiral bevel gear set


Set of instrumentation for trend analysis


Set of instrumentation continue

Process signals – directly wired to CS51.1: T1 – Bearing temperature (self-aligning roller bearing bevel pinion, coupling

side)

51.2: T2 – Bearing tempersature (axial self-aligning roller bearing bevel pinion, gearing side)

51.3: T3 – Bearing temperature (self-aligning roller bearing bevel pinion, gearing side)

51.4: T4 – Bearing temperature (roller bearing bevel wheel, below wheel)

51.5: T5 – Bearing temperature (roller bearing bevel wheel, above wheel)

50.1: T11 – Bearing temperature – Segment of axial thrust bearing

46: T12 – Oil temperature at gearbox outlet

Vibration Sensors – directly wired to CS86.1: VS1 – Ring Gear (Annulus) of the planetary stage

86.2: VS2 – Ring Gear (Annulus) of the planetary stage (perpendicular to 86.1)

Note: Wiring between gearbox and centre control room shall be done by the customer


WPV sectional drawing


22 28 3542

5161

7284

97110

125140

155170

191

212

233

254

275

298

320

0

50

100

150

200

250

300

350

26 35 43 54 64 78 92 107 125 142 161 182 200 222 242 274 302 332 360 390 420

Gearbox type

P/n

t

WPU WPV

MaximumP/nt

Selection chart for vertical mill gearbox


Main advantages:

Torque split 30% to 70%, => 2nd stage with smaller dimension

5 Planets on the 2nd PV-Stage, => smaller dimension of the stage

Planets on the 2nd Stage with flex pin, => much better load distribution

No housing integrated Planetary stage => standard components possible => casing optimised to the axial load

Only slide bearings used => unlimited lifetime of bearings

Adjustment of bevel gear=> No need of gearbox disassembly

WPV - Concept


Advantages of the slide bearings:

Short delivery time

Unlimited lifetime => high availability of plant

Higher damping compared to antifriction bearings => less vibration

easy installation and highly service friendly

high know-how basis at MAAG Gear through an enormous amount of deliveries for the Cement, Turbo, and Marine applications

Slide bearings in the bevel gear stage


Advantages of the improved adjustment method:

Tooth contact easy to adjust

Bevel pinion is adjustable from outside

Bevel gear wheel is adjustable through conic shoe

Fast removal of bevel pinion, without need to remove gear

Service friendly through large dimensioned man hole => short maintenance stops=> no pull out of the gearbox

Easy adjustment of bevel gear


WPV 360 – Bevel Gear Stage


Summary

MAAG new developed WPV gearbox show several importantadvantages in investment and operation:

First Test run results and assembly show very encouraging results High potential for optimisation of investment cost Improvement on maintenance and service friendliness increasing

the gearbox availability Lower transport weight and consequently easier erection and

reduced transport costs The independent gearbox modules allow a more flexible and faster

production Lower delivery time for spares due to the smaller gear parts The gearbox is build up with long term approved technologies


Maintenance philosophy

- Permanent surveillance, daily checks (by site personnel)

- Checks after every 1‘000 h of operation (by site personnel)

- Checks after every 6‘000 h – and 12’000 h of operation (annually)(under supervision of MAAG Service personnel)

- Special checks after approx. 80‘000h of operation, or 12 years (under supervision of MAAG personnel)


Daily checks

Permanent surveillance/daily checks (by site personnel)

- Quick check of the whole drive group

- Checking and recording of operating data

- Checking of drive group and accessories for eventual leaks (reducer, couplings, lube oil supply unit, etc.)

- Checking of oil level in lube oil reservoir

- Check p of lube oil filter (if not monitored)


Routine 1’000 h checks

Checks every 1‘000h of operation (by site personnel), (additionally to the aforementioned daily checks)

- Record and check operating data (complete checklist 1 of the instruction manual)

- Check lube oil filter and filter/breather for contamination, cleaning or replacing at need


Regular 6’000 h check

Checks every 6‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned routine checks)

- Check all important bolt connections (reducer, lube oil supply unit, coupling, etc.)

- Check and if necessary re-tighten gearbox anchoring

- Check lube oil for water content/contamination, Analysis of lube oil by the supplier (replacement according to recommendation)

- Visual check of lube oil-sample from axial bearing casing


Regular 12’000 h check

Checks every 12‘000h of operation (under supervision of MAAG service personnel), (additionally to the aforementioned regular checks)

- Checking of alignment to driving- and driven machine

- Inspection of central bearing no. 1 (input shaft)

- Check of instruments and interlocks, record setting points (complete checklist no. 2)

- Inspect and clean lube oil cooler (if required)

- Partial disassembly and inspection of in- and output coupling, replacing of lubricants and seals

- Functional and alignment check of auxiliary drive

- Inspection of spare parts (if available), special tools


Special checks - Overhaul

Special checks, overhaul after approx. 80‘000 h of operation, or 12 years (under supervision of MAAG personnel)

- Disassembly of the entire reducer, inspection of all parts. Ultrasonic bonding test of all bearings. (replacement of parts if required)

- Maintenance of components (motors, instruments, etc.) (according to the individual supplier)

Estimated shutdown time 2 weeks, depending upon accessibility, availability of facilities as well as findings and results of the inspection.


Customer Service Products

Overview Customer Service Products

Service & Spare Parts Contracts Easy – Training Concept Performance – Gear Box upgrade Prevention – Security thanks obviating Speed – Security thanks fast information flow


Customer Service Products

Easy – Training Concept

- training of customers service personnel

Challenge – Gear Box upgrade

- exchange of an existing gear box, incl. gear boxes from

competitors

Prevention – Security thanks obviating

- checks via vibration measuring, incl. gear boxes from competitors

Speed – Security thanks fast information flow

- 24 h/day vibration measurement thanks direct access of

customers data’s via internet.

33

MAAG Gear AG

August 09

Gearbox Damage

How to handle material availability


Source of information and procedures

Emergency situation: a) Customer contacts Field Service Dept: Emergency

description, detailed information b) Customer contacts Sales: availability of spare parts,

delivery schedules Service report at customer Sales travel report at MAAG Gear Customer / Agency request once procedure defined Monitoring system


Material planning for repair (1)

1. Emergency case: Damage assessment and evaluation Material selection (parts, spares) Availability at customer site

2. Service report: History of the gearbox Detect background of failure Recommendations for repair

3. Sales travel report: Spare parts already delivered Identification of spares required Contact persons Express delivery Quotes


Material planning for repair (2)

4. Customer / Agency request: Contact Field Service Dept. for details / history Proceed standard spare parts quotation

5. Monitoring system Data exchange Analysis Recommendations Follow up after repair


Information flow

Customer address

Contact name; e-mail; phone No.

Plant code name

Gearbox type & ex. Order No.

Parts description

Drawing No.

SAP No. (If available)

Quantity

Reason for material request

Time frame

ServiceReport Basic Info

Material Info

Gen. Info


Repair options (1)

1. On site repair by MAAG Gear Field Service Engineers Field Service Dept. to contact customer & make proposal for

service intervention (material inspection on site) If damage material is already specified, then standard part

quotation is issued If defective material is already inspected, then procedure

according to inspection report recommendations


Repair options (2)

2. In house repair at MAAG Gear production site Delivery of damaged parts Quote for damage assessment and inspection Quote for repair

3. Repair by 3rd. Party Cooperation under customer responsability


MAAG Gear locations for development, production and sales Winterthur, Switzerland / Elblag, Poland Bethlehem, North America / sales office Beijing, China / sales office

Service Centers including agents and FLS partner offices world wide(MAAG Gear service centers in USA, Mexico, Poland and Denmark)

MAAG Gear locations and service centers


MAAG Gears in operation around the world

Algeria Angola Argentina Austria Bangladesh Belgium Bolivia Brazil Bulgaria Canada China Colombia Costa Rica Croatia Denmark Ecuador Egypt El Salvador France Germany Greece Honduras

India Indonesia Iran Ireland Israel Italia Japan Jordan South Korea Kuwait Lebanon Malaysia Mexico Nigeria Pakistan Peru Philippines Poland Russia Saudi Arabia Senegal South Africa

Spain Sudan Sweden Switzerland Syria Taiwan Thailand Togo Turkey UAE Ukraine Uruguay USA Vietnam Yemen


Core Elements of our Corporate Strategy Sustainable sales growth Dynamic, relevant innovation pipeline Operational excellence Winning organization Ensure we have the right people and the right

working environment to deliver our vision Constant willingness to innovate and close

collaboration with our customer

MAAG Gear‘s vision

MAAG Gear AG August 09 The mill’s gearbox MAAG Gear: A pioneer of modern gear technology.

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Transcript of MAAG Gear AG August 09 The mill’s gearbox MAAG Gear: A pioneer of modern gear technology.