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
Kra�tPolymers & Fluids
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 GEARS
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:
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• 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
LUBRICATION OF GEARS
Kra�tPolymers & Fluids
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.
RUNNING-IN OF MILL AND KILN GEARS
Before starting the running in process, we recommend some preliminary inspections:
• Towritedowneveryinformationaboutthegears(numberofpinionandgirthgearteeth,module,diameteretc...).
• To markthreegirthgearteethlocatedmoreorlessat120ºandthreeteethofeachpinion. Theseteethwillbeusedasareferenceforthecorrectalignmentandtheevolutionofthe
settlement.
• Toguaranteethelackofabnormalroughnessanddamagesinthepinionandgirthgearsurfacesbyacareful check.
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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.
LUBRICATION OF GEARS
1 PRELIMINARY INSPECTIONS
LUBRICATION OF GEARS
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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
RUNNING-IN OF MILL AND KILN GEARS
Kra�tPolymers & Fluids
LUBRICATION OF GEARS
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
LUBRICATION OF GEARS
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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)
RUNNING-IN OF MILL AND KILN GEARS
Kra�tPolymers & Fluids
LUBRICATION OF GEARS
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
LUBRICATION OF GEARS
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KGP-2/P GREASE CONSUMPTION(Withcontinuoussprayingconditionstartingconditions)
8gr/h.cmforMillwith2pimions
6 gr/h.cm for Millwith1pimionorKilnwith2pinions
4 gr/h.cm for Kilnwith1pimion
TEETH WIDTH (mm)
RUNNING-IN OF MILL AND KILN GEARS
Kra�tPolymers & Fluids
LUBRICATION OF GEARS
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.
LUBRICATION OF GEARS
Kra�tPolymers & Fluids
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
LUBRICATION OF PINION-GIRTH GEAR FOR KILNS AND MILLS
Kra�tPolymers & Fluids
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...
TECHNICAL ASSISTANCE PROGRAM FOR GEARS
Kra�tPolymers & Fluids
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.
TECHNICAL ASSISTANCE PROGRAM FOR GEARS
LUBRICATION OF PINION-GIRTH GEAR FOR KILNS AND MILLS
Kra�tPolymers & Fluids
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.
TECHNICAL ASSISTANCE PROGRAM FOR GEARS
Kra�tPolymers & Fluids
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
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TECHNICAL ASSISTANCE PROGRAM FOR GEARS
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
Kra�tPolymers & Fluids
TECHNICAL ASSISTANCE PROGRAM FOR GEARS
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:____
____ ____ ____
____ ____ ____
Kra�tPolymers & Fluids
TECHNICAL ASSISTANCE PROGRAM FOR GEARS
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: _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
Kra�tPolymers & Fluids
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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
Kra�tPolymers & Fluids
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
an company