Novexa’s Presentation*: The wear maintenance approach of

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Novexa’s Presentation*: The wear maintenance approach of rotating tubes driveline

This document is the sole property of NOVEXA and must not be copied, issued or reproduced without authorisation 1

Average shutdown period reduction (days)

Strategy Preventive approach development

Business On site machining specialist

Headquarters Valence (26) – Near Lyon (FRANCE)

Experience 15 years of worldwide experience and more than 500 rotating tubes assistance

Life span extension (years) Cost reduction (€)

Cost / efficiency ratio (i.e: Kiln / mill girth gear reprofiling)

Strategy Conditional Preventive maintenance of major rotating equipments (kilns, mills)

Business On site machining specialist (gears, gearboxes, kiln tyres & rollers)

Experience 15 years of worldwide experience and more than 500 rotating tubes assistance

*Headquarters Valence (26) – Near Lyon (France)

This whole document is the sole property of NOVEXA and must not be copied, issued or reproduced without authorisation

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Novexa’s Presentation


1st level: The training program

2nd level: The maintenance and wear monitoring project – NOVEXA toolkit

3rd level: The online wear calculation module


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Conditional Preventive approach - The Training Program – 2 Days


How to transfer our knowledge

Bringing wear analysis awarness

Transferring essential and technical knowledges to follow the wear evolution

Providing high technology methods and a preventive maintenance program to

manage the gear wear

Bringing huge and short term maintenance operations savings

Meshing model (NOVEXA’s development)


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Summary of the Training Program


Introduction 1 Novexa business

Drive analysis

Gears 2

Operational characteristics

12 Key parameters to know

Wear analysis

Wear speed calculation, profile deformation and thickness remaining

Data sheet and meshing modification

Gear damages

Maintenance solutions

Bearings 3 Lubrication

Level, reliefs and clearances

Scrapping method

Bearings damages

Vibration 4

Lubrication 6

Lubrication methods

Lubricants (Specification and selection)

The preventive approach 7 Wear control program of gear

Oil analysis, temperature and print control

Drive alignment

Non destructive testing

Axial/Radial runout

Success story

Gear meshing effect (horizontal, vertical, axial analysis)

Drive analysis

Tyres / rollers 5

Tyres damages

Balance / translation

Maintenance solutions


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Conditional Preventive approach – The NOVEXA toolkit

Providing a high level technique

approach different from usual solutions

Giving access to objective values

to analyze by yourself the wear of gears

Bringing important savings with:

- Wear speed calculation : how to increase significantly the life span

- Remaining thickness calculation : decide between flipping, reprofiling, or changing

- Profile deformation calculation: give us target to avoid and reduce vibration


The wear monitoring project of gears


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Conditional Preventive approach – Online wear calculation module


Your secure access to NOVEXA reports and the gear wear calculation module

Providing a free access and usefull wear

calculation module

Helping to organize your own data base

- Including automatic calculation and analysis

of the wear level of gears

Overall correct condition

Close monitoring recommended

Excessive wear of gears – an intervention

is needed

Important risks of breakage / irreversible

damages

Providing close technical assistance by

phone/ email

Equipments characteristics


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Business

On site reprofiling and welding repair of gears

Defects corrected: high vibrations,

teeth breakage / cracking,

bad load distribution,

shock when meshing or at junction,

profile deformation

On site machining and welding repair of kiln tyres and rollers


To anticipate and solve wear problems on rotating tubes driveline as a whole

tolerance at 0.07mm – on pitch, flatness, profile

Defects corrected: facetting,

scratches,

spalling and all surface deteriorations,

thrust tyre defects,

material discharge and flatness defects,

conicity in rolling components,

runout, humps, cracks


Before After

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Business



All types

mill trunnions bearings,

pinions bearings, kiln rollers

All types of pads

brass, lead sleeve bearings,

others.

Measurement up to 60 meters /

accuracy 0.2mm


Alignment controls of

horizontal kilns, mills

Bearing scraping

in 4/5 hours

Spectral vibration analysis,

ultrasonic testing,

magnetic inspection

Full range of non

destructive testing

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Business



Non exhaustive list

of products’ supply

pinions, kiln rollers, etc.


Full range of products’

supply

Supply of girth gear

and adjustment

Partnership with 3 main gears’

manufacturers in Europe

Supply of lubricants and

centralized system

Lubrication advices

supply of centralized system

large range of lubricants supply

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Business cases among our 500 interventions

OCEANIA New Caledonia – CM 2 gear reprofiling + bearing scraping – January 2011

EUROPE United Kingdom – Mill Girth gear reprofiling – April 2007

MIDDLE EAST Jordan – Kiln tyres cracks repair – April 2010

CARRIBEAN Martinique plant – Mill pinion bearings scraping – October 2008

ASIA South Corea – Kiln 2&3 girth gears reprofiling – August 2008 / Sept 2009

THE GLOBAL PROJECT Brazil - Kiln revamping – August 2010


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Business case – New Caledonia – CM 2 gear reprofiling + bearing scraping


405 mm : input/output clearance

220 000€ + 7 days of production

+ 11 000 € / year of energy saving

Return on investment 3 years (energy saving)

Pitch control after reprofiling Scraping operation

CM situation

-Bad lubrication + high temperature

on trunnion

-High vibration level on pinion/gear

Engineering proposal

-250 000€ for 1 new girth gear

investment

-14 days of shutdown including 2

bearings scraping

NOVEXA operation

-2 bearings scraping in 3 days (including dismantling + reassembling)

-10 years of life span extension

after reprofiling

-5% energy consumption saving

SAVINGS


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Business case – Europe UK - Mill 2 girth gear reprofiling


Before

150 000€ / year for maintenance operations

3 000 000€ / year due to non production

(150 000€/days saved during 20 days)

After NOVEXA reprofiling

Mill situation

-mill reliability 86%

-150 000€ / year for maintenance

operations


-900 000€ for 1 new girth gear

investment

-14 days of shutdown

NOVEXA operation

-mill reliability 95%

-10 years of life span extension

after reprofiling

SAVINGS


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Business case - Middle East Jordan - Kiln tyre cracks repair


Blanket + flamme installation Situation after 6 days of welding

405 000€ + 4 days of production (compared to investment)

Tyre situation

-cracks: 55% of the tyres width

-risk of cracks extension +

unexpected shut-down


-1 new shell under tyre and the

corresponding tyre investment

-12 days of shutdown

-investment cost 500 000€

NOVEXA operation

-strict respect of the customer

welding procedure

-welding operation in 8 days

-operation cost 95 000€

SAVINGS


Diameter adjustment after welding operation

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Business case - Caribbean Martinique plant – Bearings scraping


Bearings dismantling During scraping, a line is traced

each 35/40 mm

Scraping in 4 hours – diam 1400 mm, width 350 mm

entry clearance 3 mm

900 000€ + 6 days of production (compared to the engineering proposal)

Bearings situation

-bad lubrication + high

temperature

-risk of damages + unexpected

shut-down


-2 bearings scraping in 9 days

(including dismantling and

reassembling)

Novexa operation

-2 Bearings scraping in 3 days (including dismantling + reassembling)

-22 000€ for scraping + mill

alignment + logistics

SAVINGS


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Business case – Sth Corea - 2 kilns girth gear reprofiling


Before (kiln#2) After (kiln#2)

860 000 € (2 girth gears)

+ 5 days of production / kiln (compared to the engineering proposal)

NOVEXA reprofiling

In 2008, the company decision

was to invest on 5 new girth

gears: Malaysia (kiln), Corea (2

kilns), Philippines (2 girth gears)


-1 000 000€ for 2 new girth gears

investment

-14 days of shutdown / kiln

Mr X (technical center in Asia in

2008) drove inspections in each

plants with NOVEXA. Conclusion:

no need to replace any of these 5

girth gears

SAVINGS


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The saving program 1/3


NOVEXA global project Kiln revamping - Brazil - August 2010

2.25 millions € (compared to investment)

20 000 € / year (energy consumption)



35 days of shutdown

- 2 new shells under tyres and the 2

corresponding tyres investment

- 1 new girth gear investment

- Supply of a new pinion

-Supply of new pinion bearings

Costs 2.5 millions €

NOVEXA solution

8 days of shutdown

- On site machining of 3 tyres

- On site machining of 6 rollers

- Girth gear reprofiling

- Supply of a new pinion

- Pinion bearings scraping

-Kiln Alignment

NOVEXA costs 250 000€

Return on investment 4 years

SAVINGS +

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Before intervention

- Most of suppliers recommendation was to

invest on a new kiln installation

- Gear profile deformation : 1.6 mm

- Shocks when meshing

- 3/4 flats on tyres (1 meter each)

- Runout at 15 mm on 2 tyres

- Flatness distorsion up to 2 mm on rollers

- Intensity variation –

from 230 to

400 Amp

After intervention

- Gears accuracy tolerance

0.15mm (pitch, flatness, profile) – same

tolerance as a new gear

after girth gear

reprofiling

- Tyres/rollers cutting tolerance: 0.07mm

flatness, ovality below 1mm, diam dif R/L below

0.3mm

- Intensity variation

falls down –

from 235 to 260

Amp

10 years of life

span extension

(on average)


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Gears

0.15mm accuracy tolerance

After girth gear reprofiling

Pinion supply by NOVEXA

Tyres / rollers

Tyre grinding Bearing scraping

by NOVEXA

Bearing scraping

Blue print contact

after scraping Roller diameter control


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This document is the sole property of NOVEXA and must not be copied, issued or reproduced without authorisation

Conclusion


Customized saving strategy

High level technique solutions

Rotating tubes global wear

monitoring approach

NOVEXA’S STRENGHTS

Worldwide references

Unique wear monitoring method

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Office

7 rue Arturo Toscanini

26 000 Valence

FRANCE

Tel: +33 (0)4 75 25 14 18

Fax: +33 (0)4 75 25 16 14

[email protected]

www.novexa.com

Fabrice ZIEGLER Managing director


26 000 Valence

FRANCE

Tel: +33 (0)4 75 25 14 18

Mob: +33 (0)6 75 08 11 26

Fax: +33 (0)4 75 25 16 14

[email protected]

Gaylor CHAPUT Account manager


26 000 Valence

FRANCE

Tel: +33 (0)4 75 25 14 18

Fax: +33 (0)4 75 25 16 14

[email protected]

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Novexa’s Presentation*: The wear maintenance approach of